Maintenance Manual: Series

Maintenance Manual
WP2300S Series
Printed in Germany ● Revision Level B
Order Number: 812529-006
This master manual is subject to continual updates.
It is meant exclusively for businesses authorized by CROWN.
It is not permitted to pass on the contents or copies thereof to third parties.
CROWN Gabelstapler GmbH & Co. KG

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

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

Copyright 2002
CROWN Equipment Corporation
REVISION
Overview of Revisions:
Page A Rev.1 04/00 General corrections and additions to the text.
Reference to authorised service personnel added.
Page 63 Rev.2 05/05 General corrections and additions to text.

Additions to Safety Reverse Switch (SAS)
Used from serial no. 5A336576, except for 5A337937.
Additions to Brake Switch (BRS)
Page 64 Rev.2 05/05 Additions to Platform Control Switches (GCSR, GCSL, PLS)
Page 64_A Rev.2 05/05 Additions to Platform Logic (PLM)

Page 65_A Rev.2 05/05 Updated diagram, addition to PLM.
Page 66_A Rev.2 05/05 WP2340S diagram included.
Page 80_A Rev.2 05/05 Parameter setting for trucks with folded platform.
Parameter setting for trucks with fixed platform.
Page 88_A Rev.2 05/05 Troubleshooting addition.
from page 102 Rev.2 05/05 General text corrections. Updates and additions: Control handle grip,
up to page 112 Switch unit, fast/slow toggle switch, hydraulic PCB, main PCB removal/
installation, potentiometer, safety reverse switch, horn switch, hand grip.
from page 131 Rev.2 05/05 Corrections to diagrams and WP2340S addition.
from page 136 Rev.2 05/05 Wiring diagram updates. WP2340S addition.
WP2300S 05/2005 • Printed in Germany MS-REV-1723
A
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Printed in Germany
B
TABLE OF CONTENT
Printed in Germany
I
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Printed in Germany
M1.0-0000-000II
II M1.0-0000-000II
TABLE OF CONTENT
Table of Content
REV– OVERVIEW OF REVISIONS PAGE SER-NR. CUT REV.

Overview of Revisions: ....................................................... A .......................................................... Rev.2 05/2005
ITD – INTRODUCTION PAGE SER-NR. CUT REV.

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

Jacking up the Truck ........................................................... 11
Raising the Truck with a Crane ........................................... 11
Fixed Platform .................................................................. 11
Folding Platform ............................................................... 12
Both Platforms .................................................................. 13
Raising with a Forklift Truck ............................................... 14
Component Access and Components .............................. 15
Maintenance ........................................................................ 18
Recommended Lubricants and Oils ................................. 18
Lubricants ................................................................... 18
Cold Store Trucks ........................................................ 18
Truck Decommissioning ................................................... 18
Restoring the Truck to Service ........................................... 18
Check and Maintenance Schedule .................................. 20
Safety Reverse Switch –
Functional Test ................................................................... 22
Grease items and grease intervals .................................. 30
Adjusting the Contact Pressure of the Castors
and the Drive Wheel ............................................................ 32
Torques ................................................................................ 33
M2 – HYDRAULICS PAGE SER-NR. CUT REV.

Hydraulic Symbols .............................................................. 37
Hydraulic System ................................................................ 41
Operation ......................................................................... 41
Removing the Hydraulic Unit ............................................ 42
Replacing the Hydraulic Pump ......................................... 43
Removal ...................................................................... 43
Installation ................................................................... 43
Commissioning and Bleeding the System ........................ 43
Filters ............................................................................... 45
Replacing the Pressure Filter ...................................... 45
Replacing the Suction and Return Filters .................... 45
Oil Change ....................................................................... 45
Replacing the Safety Valve ............................................... 46
Safety Valve Setting ......................................................... 46
Safety Valve Test and Setting ...................................... 46
WP2300S 05/2005 • Printed in Germany
III
TABLE OF CONTENT
Testing and Setting the Load-
Dependent Pressure Switch ............................................. 47
M3 – DRIVE UNIT PAGE SER-NR. CUT REV.

Gear Unit .............................................................................. 51
Preparatory Measures ..................................................... 51
Removal ........................................................................... 51
Maintenance .................................................................... 51
General ....................................................................... 51
Gear Unit Disassembly / Assembly .................................. 53
Disassembly ................................................................ 53
Assembly .................................................................... 53
Preparing the Gear Unit .............................................. 53
Flange Shaft Assembly ............................................... 53
Pinion Shaft Assembly ................................................ 54
Adjusting the Bevel Gear Assembly ............................ 54
Final Assembly ............................................................ 54
Assembly .................................................................... 55
M4 – ELECTRICS PAGE SER-NR. CUT REV.

Electrics - General ............................................................... 59
Wire Colour Codes ........................................................... 59
Abbreviations ................................................................... 60
Electrical Symbols ............................................................ 62
Electrical Components ....................................................... 63
Travel Switch (POT, FS, RS) ............................................. 63
Fast/Slow Switch (HSS) ................................................... 63
Safety Reverse Switch (SAS) ........................................... 63
Safety Reverse Switch (SAS) ........................................... 63 .................. Used from serial no. 5A336576,
................................................................................................................. except for 5A337937. ..........................
........................................................................................................................................................ Rev.2 05/2005
Brake Switch (BRS).......................................................... 63
Brake Switch (BRS).......................................................... 63 .................. Used from serial no. 5A336576,
................................................................................................................. except for 5A337937. ..........................
........................................................................................................................................................ Rev.2 05/2005
Raise/Lower Switch (RAS, LOS) ...................................... 64
Pressure Switch (PS) ....................................................... 64
Platform Control Switches (GCSR, GCSL, PLS) .............. 64
Platform Control Switches (GCSR, GCSL, PLS) .............. 64 .................. Used from serial no. 5A336576,
................................................................................................................. except for 5A337937. ..........................
........................................................................................................................................................ Rev.2 05/2005
Lift Limit Switch (LMS) ..................................................... 64
Horn Switch (HNS) ........................................................... 64
Foot Switch (FTS) ............................................................ 64
Key Switch (KYS) ............................................................. 64
Emergency Disconnect (BD) ............................................ 64
Fuses (FU) ....................................................................... 64
OPTION
Thermal Switch (THS) ........................................... 64
Filter (WP2340S only) ...................................................... 64 ......................................................... Rev.2 05/2005
Diode D4 .......................................................................... 64 ......................................................... Rev.2 05/2005
Diode block (DB) .............................................................. 64 ......................................................... Rev.2 05/2005
Platform Logic (PLM) ....................................................... 64_A .............. Used from serial no. 5A336576,
................................................................................................................. except for 5A337937. ..........................
........................................................................................................................................................ Rev.2 05/2005
WP2330S ......................................................................... 65
WP2330S ......................................................................... 65_A ..................................................... Rev.2 05/2005
WP2335S ......................................................................... 66_A ..................................................... Rev.2 05/2005
WP2340S ......................................................................... 66_A ..................................................... Rev.2 05/2005
Battery .................................................................................. 67
IV
TABLE OF CONTENT
General ............................................................................ 67
Replacing the battery ....................................................... 67
Battery Discharge Indicator (BDI) ...................................... 67
General ............................................................................ 67
Battery Discharge Indicator Setting (BDI) ........................ 68
Calibration ................................................................... 68
SEM1 Traction Controller .................................................... 69
General ................................................................................. 69
Precautionary Measures ............................................. 69
Operational Features ....................................................... 69
Speed Control ............................................................. 69
Reduced Speed Ranges ............................................. 69
Downhill Speed Control ............................................... 69
Regenerative Braking .................................................. 69
Anti - Roll Down Function ............................................ 69
Hourmeter ................................................................... 70
Self Test ...................................................................... 70
Monitored Circuits ....................................................... 70
Protective Devices ............................................................ 70
Polarity Protection ....................................................... 70
Wiring Errors ............................................................... 70
Temperature ................................................................ 70
Start Sequence ........................................................... 71
Safety Class ................................................................ 71
Maintenance .................................................................... 71
Replacing the SEM1 Traction Controller ........................... 72
Parameter Setting after Replacing the Traction Controller 72
Preparatory Measures ................................................ 72
Setting ......................................................................... 72
Status LED .................................................................. 74
Programmer ......................................................................... 75
General ............................................................................ 75
Operating SEM1 Controller Menu .................................... 76
General ....................................................................... 76
Menu Functions .......................................................... 76
PARAMETER CHANGE .............................................. 76
Menu Structure for Folded Platform ............................ 77
Menu Structure for Fixed Platform .............................. 78
Parameter Setting, Folded Platform ................................... 79
Parameter Setting, Folded Platform ................................... 80
Parameter Setting, Folded or Fixed Platform .................... 80_A .................................................... Rev.2 05/2005
Parameter Setting, Fixed Platform ..................................... 80
TESTER Menu ................................................................. 82
ALARMS Menu ................................................................ 83
Calibrating the Traction Pod Potentiometer,
PROGRAM VACC menu .................................................. 86
Preparatory Measures ................................................ 86
Calibration ................................................................... 86
CONFIG Menu ...................................................................... 87
SET MODEL .................................................................... 87
SET OPTIONS ................................................................. 87
Adjustments ..................................................................... 87
Traction Controller Safety Test .......................................... 88
Troubleshooting Platform Logic, Controller PN 815144 .... 88_A ..................................................... Rev.2 05/2005
Electric Motors .................................................................... 89
General Maintenance Instructions ................................... 89
Preparation ................................................................. 89
Important Maintenance Instructions ............................ 89
Traction Motor Maintenance ............................................... 90
Access to Brushes ........................................................... 90
V
TABLE OF CONTENT
Maintenance .................................................................... 90
Armature ..................................................................... 90
Bearings ...................................................................... 90
Pump Motor Maintenance ................................................... 91
Access to brushes ............................................................ 91
Maintenance .................................................................... 91
Armature ..................................................................... 91
M5 – BRAKE PAGE SER-NR. CUT REV.

Brake .................................................................................... 95
Removal ........................................................................... 95
Disassembly ................................................................ 96
Test and Inspection ..................................................... 96
Assembly .................................................................... 96
Assembly .......................................................................... 97
Air Gap Setting ................................................................. 97
Brake Moment Setting ...................................................... 98
Testing the Brakes ....................................................... 98
M6 – STEERING PAGE SER-NR. CUT REV.

Multitask Handle - Springs for
Return Function .................................................................. 101
Adjustment ....................................................................... 101
Removal ........................................................................... 101
Assembly .......................................................................... 101
Tiller Handle ......................................................................... 103
Main Components ............................................................ 103
Tiller Handle Component
Removal / Installation ......................................................... 104
Tiller Handle Shells .......................................................... 104
Removing the Upper and Lower Shells ....................... 104
Fitting the Upper and Lower Shells ............................. 105
Switch Unit ....................................................................... 106
Removal ...................................................................... 106
Switch Unit Installation ................................................ 106
"Fast/Slow" Toggle Switch ................................................ 107
Removal ...................................................................... 107
Installation ................................................................... 107
Hydraulic Board ................................................................ 107
Removal ...................................................................... 107
Installation ................................................................... 107
Main PC Board Removal/Installation ................................ 107_B ................................................... Rev.2 05/2005
Potentiometer ................................................................... 108
Removal ...................................................................... 108
Installation ................................................................... 108
Safety Reverse Switch ..................................................... 109
Removal ...................................................................... 109
Installation ................................................................... 109
Horn Switch ...................................................................... 110
Removal ...................................................................... 110
Installation ................................................................... 110
Handle .............................................................................. 111
Removal ...................................................................... 111
Installation ................................................................... 111
M7 – LIFTING MECHANISM PAGE SER-NR. CUT REV.

Lift Linkage .......................................................................... 115
Fork Height Setting .......................................................... 115
Lift Limit Cutout ................................................................... 117
Lift Limit Cutout Setting .................................................... 117
VI
TABLE OF CONTENT
M8 – CYLINDERS PAGE SER-NR. CUT REV.
Lift Cylinders ....................................................................... 121
Operation ......................................................................... 121
Removal ........................................................................... 121
Inspection ......................................................................... 123
Replacing the Piston Seal ................................................ 123
M9 – PLATFORM PAGE SER-NR. CUT REV.

Folding Platform .................................................................. 127
Mechanical Setting ........................................................... 127
Platform Switch Setting (PLS) .......................................... 128
Platform Suspension ........................................................ 129
Plate Spring Layers ..................................................... 129
Side Gates, Mechanical Setting ....................................... 130
Fixed Platform WP2335S ..................................................... 131
Replacing the Savety Switch ............................................ 131
Fixed Platform WP2340S ..................................................... 131_A .................................................. Rev.2 05/2005
Replacing the Savety Switch ............................................ 131_A ................................................... Rev.2 05/2005
Fixed Platform WP2340S ..................................................... 132_A .................................................. Rev.2 05/2005
Replacing Switches below the Entry Bars (FPS 1 & FPS 2)132_A ................................................... Rev.2 05/2005
DIA – ELECTRICAL DIAGRAMS PAGE SER-NR. CUT REV.

Notes to overall wiring diagram, standard version, folded
platform, WP2330S .............................................................. 136 ....................................................... Rev.2 05/2005
Overall Wiring Diagram, Standard, Folded Platform,
WP2330S .............................................................................. 137 ....................................................... Rev.2 05/2005
SCHEMATIC DIAGRAM ................................................... 138 ....................................................... Rev.2 05/2005
TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT ..... 138 ....................................................... Rev.2 05/2005
TRACTION CONTROLLER - SEM1 POWER CIRCUIT ... 139 ....................................................... Rev.2 05/2005
PLATFORM CIRCUIT ...................................................... 139 ....................................................... Rev.2 05/2005
POWER UNIT CIRCUIT ................................................... 140 ....................................................... Rev.2 05/2005
CONTROL HANDLE CIRCUIT ......................................... 140 ....................................................... Rev.2 05/2005
PLATFORM LOGIC .......................................................... 141 ....................................................... Rev.2 05/2005
Notes to overall wiring diagram, with Options, folded
platform, WP2330S .............................................................. 142 ....................................................... Rev.2 05/2005
Overall Wiring Diagram, with Options, Folded Platform,
WP2330S .............................................................................. 143 ....................................................... Rev.2 05/2005
TRACTION CONTROLLER - SEM1 POWER CIRCUIT ... 145 ....................................................... Rev.2 05/2005
PLATFORM LOGIC .......................................................... 147 ....................................................... Rev.2 05/2005
Notes to overall wiring diagram, standard version,
fixed platform, WP2335S ..................................................... 148 ....................................................... Rev.2 05/2005
Overall Wiring Diagram, Standard Version,
Fixed Platform, WP2335S .................................................... 149 ....................................................... Rev.2 05/2005
Notes to overall wiring diagram, with Options,
fixed platform, WP2335S ..................................................... 150 ....................................................... Rev.2 05/2005
Overall Wiring Diagram, with Options, Fixed Platform,
WP2335S .............................................................................. 151 ....................................................... Rev.2 05/2005
Diagrams, Standard Version, Fixed Platform, WP2340S ... 152 ....................................................... Rev.2 05/2005
POWER CIRCUIT - TRACTION & PUMP MOTOR ......... 153 ....................................................... Rev.2 05/2005
Diagrams, with Options, Fixed Platform, WP2340S .......... 155 ....................................................... Rev.2 05/2005
VII
TABLE OF CONTENT
POWER CIRCUIT - TRACTION & PUMP MOTOR ......... 156 ....................................................... Rev.2 05/2005
Wire harness overview, folded platform,
WP2330S all versions ......................................................... 158 ....................................................... Rev.2 05/2005
Main Harness, Folded Platform, WP2330S, All Versions .. 159 ....................................................... Rev.2 05/2005
Control Handle - Wire Harness Folded Platform,
WP2330S, All Versions ........................................................ 160 ....................................................... Rev.2 05/2005
Horn Switch - Wire Harness, Folded Platform,
Wire harness overview, Fixed Platform,
WP2340S, All Versions ....................................................... 162 ....................................................... Rev.2 05/2005
Wire harness overview, Fixed Platform,
WP2340S, All Versions ....................................................... 163 ....................................................... Rev.2 05/2005
Control Handle - Wire Harness FFixed Platform,
Horn Switch - Wire Harness Fixed Platform,
Cables, Platform, Fixed Platform, WP2340S,
All Versions .......................................................................... 166 ....................................................... Rev.2 05/2005
Power Cables ....................................................................... 167
HYD – HYDRAULIC SCHEMATIC PAGE SER-NR. CUT REV.

Hydraulic Schematic ........................................................... 171
VIII
SAFETY
Printed in Germany
1
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Printed in Germany
2 M1.0-0000-0002
SAFETY
Safety Symbols used in the General Maintenance and Repair

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

OPTION cleaning solution which is groundwater-neutral.
Only carry out cleaning with an oil separator.
OPTION
These items relate to optional features not Protect the electrical system from dampness.
supplied with the standard version.
5. Keep the service area clean, dry and well-venti-
lated.
6. Do not allow oil to penetrate the ground or enter

the draining system. Used oil must be recycled.
Oil filters and desiccants must be treated as
special waste products. Relevant applicable
regulations must be followed.
7. Neutralise and thoroughly rinse any spilled

battery fluid immediately.
MS-WP2300S-GB 05/03 • Printed in Germany MS-0000-MA

REV. 1 4/00
33
SAFETY
8. Keep the truck clean. This will facilitate the loca- Warnings and Labels on the Truck
tion of loose or faulty components.
During regular maintenance check that the warnings
9. Make sure that capacity and data plates, warn- and labels on the truck are complete and legible.
ings and labels are legible at all times.
● Clean any illegible labels.
10. Alterations or modifications by the owner or
operator are not permitted without the express ● Replace any faulty or missing labels.
written authorisation from Crown.
The order and meaning of the warnings and labels on
11. Only use original Crown spare parts to ensure the the truck are described in section 10.9 of the parts
reliability, safety and suitability of the Crown truck. manual.
Before Leaving the Truck

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

surface.
Before Carrying out Work on the Truck

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

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

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

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

direction switch, speed control, steering, warning
devices and brakes.
MS-0000-MA MS-WP2300-GB 05/03 • Printed in Germany

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

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

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

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

M8 Cylinder
DIA Electrical Diagrams
HYD Hydraulic Schematic
A01M-gb
MS-WP2300S-GB 05/03 • Printed in Germany MS-ITD-1723
M1.0-0000-0007
7
INTRODUCTION
Model-Number
This manual describes the maintenance and repairs for the following truck versions:
2.0 WP 2335S – 3 – 2 – S
Capacity Load Wheels
2.0 = 2000 kg S = Single

T = Tandem
Model Description
Fork Length
WP = Electric Pedestrian Pallet Truck
Dash mm inch
1 36
2 995
Platform Type
3 42
2335 = Fixed Platform
4 1125
2330 = Folded Platform
5 46
6 1210 48
7 54
8 60
I02a-gb
Fork Spread
Dash mm inch
1 18
2 520 20
3 540 22
4 670 27
I03a-gb
MS-ITD-1723 MS-WP2300S-GB 05/03 • Printed in Germany
88
M1.0-0000-0008
LUBRICATION AND ADJUSTMENT
Printed in Germany
9
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Printed in Germany
10M1.0-0000-00010
Jacking up the Truck Raising the Truck with a Crane

CAUTION Fixed Platform
Always support a raised truck with wooden
Fit the chains or lifting slings as shown in the diagram:
blocks or other suitable means to relieve
the jack.
● to each fork tip with a lifting sling tied around the
platform,
The term "jacking up the truck" always implies that the
raised truck is lowered onto a secure base. or
● with one hook on each side of the platform.
Capacity required: 600 kg for the WP 2300 S less

battery.
Jack up Points
MS1723-100
M1458-a
MS-WP2300S-GB 05/03 • Printed in Germany MS-1.0-1723
M-1.0-0000-00011
11
Folding Platform
Fit the chains or lifting slings as shown in the diagram:
● to each fork tip with a lifting sling tied around the

platform.
Prevent the lifting sling from sliding off: connect it
to the forks, see dashed line S.
or
● Attach a hook to points R and L respectively on

the truck frame.
Prevent accidental sliding off: connect the two
chains or lifting slings, see dashed line H,
between the truck and the gates.
Capacity required: 570 kg for the WP 2300 S less

battery.
S
H
R L
L R
MS-1723-101
MS-1.0-1723 MS-WP2300-GB 05/03 • Printed in Germany
12M-1.0-0000-00012
Both Platforms
It is also possible to raise the truck (with either folding
or fixed platform, after removing the panel) as shown in
the following illustration.
MS-1723-102
M-1.0-0000-00013
13
Raising with a Forklift Truck

DANGER
Use a truck with sufficient capacity and
prevent the truck on the forks from sliding
off.
The WP 2300 S can be raised at an angle using a
forklift truck - see illustration.
Required capacity: 600 kg for the WP 2300S less

battery.
● The forks must be fully raised.
● Position the forks of the lifting truck as shown in

the illustration.
● Place a wooden block approx. 90 mm thick

between the forks of the WP 2300S and the forks
of the lifting truck.
● Secure the WP 2300S on the forks of the lifting

truck (e.g. with an elastic strap).
90
600
> 800
WP
2300
MS-1723-103
14M-1.0-0000-00014
Component Access and

Components
Removing the panel provides access to the drive unit,
hydraulic system, contactors, traction controller etc.
The panel is fixed to the frame by two screws.
Removing the screws allows you to slightly lift the
panel up out of the lower retaining lug, tilt it away and
remove it via the tiller.
Battery connector
(EMERGENCY
DISCONNECT)
FU1
FU2 - FU3 F/C
Fan
Magnetic brake
Traction
controller
Main contactor Horn
Pump contactor
Lift cylinder (LH)
Pump motor
Pressure switch
PS
Lowering
MS-1723-120
valve SV
Hydraulic tank and Traction motor

pump Drive wheel
M-1.0-0000-00015
15
Fast / Slow Travel Switch
Button, Horn
Travel Switch
Reverse Safety Switch MS1723-004

Lift / Lower Switch
16M-1.0-0000-00016
Blank Page
MS-WP2300S-GB 05/03 • Printed in Germany
M-1.0-0000-00017
17
Maintenance ● Every 3 months connect the battery, carry out a

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

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

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

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

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

wooden blocks in order to clear the wheels from
the ground (this prevents the wheels from
flattening under constant pressure).
MS-1.1-1723 MS-WP2300S-GB 05/03 • Printed in Germany
18M-1.0-0000-00018
Lubricant Type Product Description Manufacturer CROWN-Part-No. Type
Aralube HLP2 Aral

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

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

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

Anti-corrosive agent Tectyl 805236-004
cold store trucks.
Acid resistant transparent
coating for traction
Transparent coating 2K Klarlack 805236-003
controllers for cold store
applications.
L01_adjuvants_WPS-GB
M-1.0-0000-00019
19
Check and Maintenance Schedule
The following check and maintenance schedule as- When performing maintenance work always check for
sumes single-shift operation under normal operating wear, corrosion and damage and ensure that the parts
conditions. The length of maintenance intervals will are operating correctly and are secure. If in doubt,
however depend on the particular operating conditions. replace them.
In dusty or otherwise extreme environments, including

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

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

7 Brake
multi-task handle and inverse braking)
8 Steering Check play
9 Fork Check for visible signs of cracks and deformation
10 Wheels / Load wheels Check tyres for wear, nails, metal splints etc.
11 Hydraulic lines and connections Check for leaks, tighten connections if necessary
12 Platform safety switch Check operation (platform up and platform down).
L02-S-GB
20M-1.0-0000-00020
2
7
1
10
11
12 MS1723-200 9
3
10 6
5, 8
7
MS1723-004
M-1.0-0000-00021
21
Safety Reverse Switch –

Functional Test
DANGER
The safety reversing switch must only be

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

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

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

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

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

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

rectified before the truck can be operated again.
WP
2000
22M-1.0-0000-00022
Blank Page
M-1.0-0000-00023
23
Monthly or every 100 service hours
No. Item Action
Check acid density, if necessary replenish with destilled

1 Battery water. Check voltage of all cells, if necessary compensate;
clean and grease battery terminals.
2 Contactors Clean; check, replace if necessary
3 Lift limit switch Check operation
Check wires, switches and connections are secure, check

4 Electrical system
insulation for damage
5 Impulse control Check operation
6 Brake Blast off corrosion; check air gap
7 Lift cylinder Ensure seal is tight
8 Hydraulic oil tank Check oil level, replenish if necessary
9 Load wheels and castor bearings Check for play, replace bearings if necessary
10 Drive wheel Ensure wheel nuts are correctly torqued.
11 Drive unit guide Check for play, replace rails if necessary. Lubricate.
L03-S-GB
24M-1.0-0000-00024
6 5
7
3
11
MS1723-200
10
MS1723-013
9
9
MS1723-011
M-1.0-0000-00025
25
Every 3 months or 250 service hours
No. Item Action
Truck, battery and charger

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

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

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

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

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

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

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

11 Hydraulic system
hours, thereafter every 2000 service hours.
L05-gb
26M-1.0-0000-00026
1
7
11
9
10 9 3
4
MS1723-011
MS1723-011
M-1.0-0000-00027
27
Annually or every 1000 service hours
No Item Action
1 Pump and drive motor Check commutator for damage and wear; blast dust with air
2 Gear unit Check gear oil level, replenish if necessary
Check brake lining and contact surfaces for wear, replace

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

(initial replacement after 500 hours);
5 Hydraulic system
Clean lines and connections,
check tightness and sealing, tighten if necessary
6 Gear unit Change gear oil
L07-gb
28M-1.0-0000-00028
MS1723-200
M-1.0-0000-00029
29
Grease items and grease intervals
Grease Items / Grease Intervals
100 250 500 1000 2000

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

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

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

6 B A/R X
all lifting mechanism joints
7 Lift cylinder attachment B A/R X
8 Piston rod attachment B A/R X
9 Change gearbox oil A A/R Initial change after 250 hoursof operation X
L08-S-gb
A/R = As required
30M-1.0-0000-00030
4
3
1,2
MS1723-011
M-1.0-0000-00031
31
Adjusting the Contact Pressure of Example:

You record a current drive wheel diameter of 220 mm.
the Castors and the Drive Wheel The average for the castor wheels is 120 mm.
The castor wheels are on the left and right hand sides 230 mm - 220 mm = 10 mm (A)
below the truck. They prevent the truck from tipping 125 mm - 120 mm = 5 mm (B)
over when travelling around bends. 10 mm - 5 mm = 5 mm (Adjustment)
The castors apply a certain supporting force to the Therefore, the screws (B) in Fig. M1519 should be
ground over long periods of time, as the drive unit on tightened by 5 mm.
the slide generally compensates the drive wheel and
castor wheel wear. However, the greater the tyre wear, ● Loosen both jam nuts (A) and turn them upward
the less the drive wheel contact pressure. This by at least the calculated adjusting measurement.
increases the braking distance and when travelling with
heavy loads the truck can skid on smooth surfaces. ● Tighten screws (A) in turn until the calculated
adjusting measurement is obtained for both
New drive wheels have a 230 mm diameter. screws.
If the diameter is only 220 mm, the drive unit spring ● Check dimension C: nominal measurement
pre-tension must be increased. Otherwise the drive = 33 mm (with wheels)
wheel will skid excessively, thereby also increasing
the wear. The castor wheels will also wear out ● Jam the screws (B) with nuts (A).
prematurely due to excess contact pressure.
Procedure:
● Park the unladen truck on a level surface.
● Remove the battery connector and the key.

A B B A
● Make sure the truck cannot be switched on.
● Remove the panel.
● Measure and record the drive wheel diameter.
● Measure the diameter of the castor wheels, C C

calculate the average diameter and record.
Calculating the Adjustment Required:
New drive wheel Ø 230 mm minus current drive wheel

Ø=A
New castor wheel Ø 125 mm minus current castor

wheel Ø = B
A - B = Adjustment required
M1519
32M-1.0-0000-00032
Torques
The screw and nut strengths shown below are used in
the manufacture of Crown trucks. The information on
the page is designed to help determine the correct
torque for maintenance work.
NOTE
The torques listed in the maintenance

section always supersede those shown
on next page.
Screw grade marking Nut grade marking
8 .8
8 .8 8
1 2 .9
1 2 .9
graphics: m0340_1...5 T01-gb
M-1.0-0000-00033
33
Standard Screws and Nuts
Grade 8 and 8.8 10 and 10.9 12 and 12.9
Thread Size Torque (Nm)
M5 x 0.8 5-6 7-8 8 - 10
M6 x 1 8 - 10 12 - 14 14 - 16
M8 x 1.25 20 - 25 30 - 35 34 - 40
M10 x 1.5 40 - 45 60 - 65 70 - 75
M12 x 1.75 70 - 80 100 - 110 115 - 130
M16 x 2 170 - 190 240 - 270 280 - 320
M20 x 2.5 340 - 380 450 - 500 550 - 600
M24 x 3 580 - 650 800 - 900 900 - 1050
M30 x 3.5 1150 - 1300 1600 - 1800 1850 - 2100
T02-gb
Umbrako Screws and Nuts
Grade 10 and 10.8 12 and 12.9
Thread Size Torque (Nm)
M5 x 0.8 8 11
M6 x 1 14 19
M8 x 1.25 33 45
M10 x 1.5 63 86
M12 x 1.75 111 152
M16 x 2 270 372
M20 x 2.5 521 717
T03-gb
34M-1.0-0000-00034
HYDRAULICS
Printed in Germany
35
Blank Page
Printed in Germany
36M1.0-0000-00036
HYDRAULICS
Hydraulic Symbols
Vented reservoir
with lines above the fluid level Electric motor
M
with unidirectional turn and speed
Vented reservoir
with lines below the fluid level
Electric motor
M with unidirectional turn
and variable speed
Filter or strainer
Hydraulic pump
with fixed displacement
Hydraulic line with full flow
and single direction of turn
(tubing or hose)
Pilot or drain line or drainage

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

diaphragm type
Flow meter
M3559
M-1.0-0000-00037
M1.0-0000-00037
37
HYDRAULICS
Pressure switch Manual actuator
Double-acting cylinder; Spring, (bias to normal de-

unequal area energised position)
Double-acting cylinder;
equal area
Solenoid single coil or winding
Single-acting cylinder
with spring returned
(rod end vented)
Hydraulic pilot operated
Single-acting cylinder
ram type
Solenoid valve, pilot operated
Single-acting cylinder,
with cushion
Dual solenoid
Assembly housing,
manifold block
Proportional solenoid
Manual lever actuator Pilot check valve (pilot to open)
M3560
38M1.0-0000-00038
M-1.0-0000-00038
HYDRAULICS
Throttle, fixed Shuttle valve
Throttle, adjustable
Single counterbalance valve

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

Check valve
P R
M3561
M-1.0-0000-00039
M1.0-0000-00039
39
HYDRAULICS
2/2 way valve

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

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

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

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

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

(three way, two switch positions);
Spring bias solenoid control
M3562
40M1.0-0000-00040
M-1.0-0000-00040
HYDRAULICS
Hydraulic System
Operation Lifting: The pump delivers oil from the reservoir to

the two lift cylinders.
The hydraulic unit is installed next to the left hand lift The lowering valve and the check valve
cylinder and comprises the motor, pump, reservoir and remain closed.
all filters and valves.
Lowering: The lowering valve opens. The oil flow
returns from the two lift cylinders to the
reservoir.
Lift cylinder
Pressure-Switch
Lowering valve
Filter
Filter
Non-return valve
Pressure relief valve Flow reducer
150 bar
to 170 bar*
Motor
Vent cap
Pump
Filter Filter
Reservoir
M1457-2
* depending on truck model and setting of the pressure relef walve
M-1.0-0000-00041
M1.0-0000-00041
41
HYDRAULICS
Removing the Hydraulic Unit
WARNING ● Unplug the battery connector
(= Emergency Disconnect).
De-pressurise all components before
carrying out maintenance work on the ● Secure the truck from rolling away.
hydraulic system.
● High pressure hydraulic oil can cause ● Before commencing maintenance work place a
serious injuries. flat container or (if necessary) a large cardboard
box underneath the work surface.
● Whenever a high pressure fluid penetrates
the skin it must be treated as an ● Disconnect the wire connections (see Fig.
emergency, even if the skin shows no M1522).
initial reaction. Physical effects set in later.
● Secure all connections before re-applying ● Unscrew the power connections to the pump
system pressure. Keep hands and body motor (see Fig. M1522).
away from any ports as high pressure
hydraulic oil can emerge. ● Unscrew the pressure connection.
● Use absorbent paper to track leaks, never ● Obtain a suitable support on which to rest the
use your hands! hydraulic unit, e.g. a heavy iron ring.
● Remove the hydraulic unit by removing the two

fastening screws (see Fig. M11522) from the
chassis.
Pressure relief valve

(rear view)
Connecting
Cable
Pressure switch (load-

sensitive travel speed
Pump motor reduction)
Screws fastening
hydraulic unit to
chassis
Reservoir flange
M1522
42M1.0-0000-00042
M-1.0-0000-00042
HYDRAULICS
Replacing the Hydraulic Pump ● To refit the hydraulic unit proceed in the reverse
order of Removal. Note torques!
NOTE Both motor connecting cables: 4±0.5 Nm.
The hydraulic pump should not be
replaced on site. Commissioning and Bleeding the
The pump is replaced as a complete as- System
sembly.
The seals of any disassembled parts and ● Check that the system is clean and properly
filters must always be replaced! assembled. In particular, the pressure ports must
be tightly secured.
Removal
● Initially, fill the hydraulic oil only up to half
● Remove the hydraulic unit as described in the the reservoir height (see lubricant table) using
previous section. a filter with a 10 µm minimum retention rate.
In the following instructions all item numbers refer ● Never operate the pump without oil.
to Figure M1442 on next page:
● All components, in particular the hydraulic ports,
● Drain the oil via the filler neck. must be completely clean and dry prior to
commissioning. Otherwise it is impossible to
● Loosen the four screws (item 1). check whether the system is sealed.
● Lift up the motor while ensuring that it does not ● Operate the lifting functions for approx. 30
fall apart. seconds to bleed the system. The oil in the
reservoir will foam considerably.
● Remove the four screws (item 26) from the
reservoir flange and remove the reservoir. ● Check the pressure port and surrounding
hydraulic components for leaks.
● Loosen the four screws (M6 x 50, hex. head) from
the engine side of the hydraulic unit and remove ● Park the truck and leave it to stand for approx. 20
the pump. minutes. During this interval the air will separate
from the oil in the container.
● Loosen the filter clamps (25) and (22) and
remove the filter. ● When there is no more foam in the reservoir
replenish with oil up to half the max. filling height
● Clean all components (except the motor) with a and bleed again until no more foam is visible.
clean degreasing agent; remove the old seals
and blow dry. ● Lower the forks fully.
Installation ● Now fill with hydraulic oil up to the lower mark of

the filler neck.
● Attach the new filter parts to the pump.
● Apply a thin coat of oil to the seal (24) and insert

seal.
● Fit pump (note alignment! See Figure M1442)

and fix with 4 M6 x 50 screws. Torque crossways
to 18 ±2.5 Nm.
● Fit the reservoir with a new lightly oiled seal (26)

and torque the flange ring with four hex. head
screws (M6 x 10) to 8 ±1.2 Nm.
● Fit the motor on the hydraulic block so that the

drive shaft carrier fits into the pump shaft recess.
Align the motor and torque with the four screws
(1) to 8 ±1.2 Nm.
M-1.0-0000-00043
M1.0-0000-00043
43
HYDRAULICS
M1442
44M1.0-0000-00044
M-1.0-0000-00044
HYDRAULICS
Pump Motor
For maintenance and repair work to the pump motor see
chapter 4.
Filters
Replacing the Pressure Filter

● The pressure filter (150 µ) is integrated within the
pressure connection (20). When unscrewing the
pressure port make sure that the ball of the non-
return valve (21) is not lost.
Replacing the Suction and Return Filters

● To access the suction (25) and return filter (22),
the reservoir (26) must be disconnected from the
pump connection plate (14). To do this, remove
the 4 screws (26) from the flange (26).
● The filters (450 µ) are integrated within the

hopper-shaped end piece (nozzle) of the suction
(25) and return (22) lines. To disassemble,
release the clamps.
Oil Change
The oil reservoir (capacity 0.75 litres) does not have an
oil drain plug. The used oil must therefore be
suctionned off or drained from the oil reservoir.
Dispose of used oil via approved disposal methods

only.
M-1.0-0000-00045
M1.0-0000-00045
45
HYDRAULICS
Replacing the Safety Valve ● Now raise a test load which corresponds to
110% of the rated capacity + 100 kg (=
● Remove the hydraulic unit as described in the maximum load). It should not be possible to raise
previous section "Removing the Hydraulic Unit". this load (safety valve opens).
● Remove the locking mechanism (4, Fig. MS1723- lf necessary adjust the safety valve so that it opens
007) and unscrew the safety valve (3), within the above-mentioned tolerance range:
● Remove the O-ring and the filter from the valve ● Remove the hydraulic unit as described in the
seat if they are still located there. previous section "Removing the Hydraulic Unit".
● Apply a thin coat of hydraulic oil to the new O- ● Using a large screwdriver hold the setscrew
ring and position it together with the filter in the securely (1, Fig. MS1723-007) and with a fork
valve seat. wrench undo the jam nut (2, Fig. MS1723-007):
Turn the setscrew clockwise to increase the limit
● Apply a thin coat of hydraulic oil to the safety at which the valve opens, turn it anticlockwise to
valve and screw it in securely to the valve seat. reduce the limit.
Insert the new locking mechanism.
Note: 1/8 turn ~ 200 kg
● Re-fit the hydraulic unit and adjust the safety
valve. ● Fix the setscrew (1) again using the nut (2).
Safety Valve Setting ● Refit the hydraulic unit and repeat the test.
Repeat the setting until the safety valve opens
The safety valve (15, Fig. M1542 previous page and 1 within the tolerance range.
to 3, Fig. MS1723-007 ) protects the hydraulic system
and the lifting mechanisms against overloading.
WARNING
Do not run the pump unit unless it is fixed
to the chassis
● The torque is so great that the unit will
twist. This may result in short circuits and
cause damage.
The safety valve is not accessible when the pump unit
is installed. First remove the pump unit before making
3
adjustments.
2
Safety Valve Test and Setting
MS1723-007
● With the truck at operating temperature raise a 1
test load positioned in the centre of the forks 4
which corresponds to 110% of the rated capacity
(= minimum load). See capacity data plate for this
value. It should be possible to raise this load
safely.
Rated Minimum Maximum

Model
Capacity Load Load
WP2330S 2.000 kg 2.200 kg 2.300 kg
WP2335S 2.000 kg 2.200 kg 2.300 kg
H01-GB
46M1.0-0000-00046
M-1.0-0000-00046
HYDRAULICS
Testing and Setting the Load-
Dependent Pressure Switch
The output signal of the load-dependent pressure
switch (1, Fig. MS-1723-400) is applied to an input of
the traction controller. Only when the load on the forks
is greater than 900 - 1,000 kg does the controller
release the 2nd brake stage and the 2nd brake stage
2
is then also used for braking.
The correct operation of the pressure switch is there-

fore essential for braking with a load. It also affects the 1
maximum travel speed of the truck (see Chapter 4,
Speed Reduction).
● Place a test load of 900 to 1,000 kg on the forks.

Fully lower the forks so that the test load rests on
the ground.
● Switch off the truck.
● Remove the panel.
● Remove the connector from the connecting lugs

of the load-dependent pressure switch.
MS-1723-400
● Connect the programmer (see CHAPTER 4, PRO-
GRAMMER, TEST MENU, PRESSURE SWITCH). Alterna-
tively, connect an ohmmeter or a continuity tester
to the connecting lugs of the load-dependent
pressure switch.
● Switch on the truck.
● Raise the test load while at the same time

observing the test item in the test menu or the
ohmmeter / continuity tester. Continuity should
be indicated if the pressure switch is correctly
set.
● If this is not the case, adjust the pressure switch.

There is a setscrew (2, Fig. MS-1723-400)
between the connecting lugs of the pressure
switch. Turn the setscrew until continuity is
indicated.
● If it is not possible to adjust, this means that the

pressure switch is faulty and must be replaced.
Lower the load before removing the switch
and depressurise the hydraulic system.
MS-WP2300S-GB 05/03 • Printed in Germany
M-1.0-0000-00047
M1.0-0000-00047
47
Blank Page
Printed in Germany
48
DRIVE UNIT
Printed in Germany
49
Blank Page
Printed in Germany
50M1.0-0000-00050
DRIVE UNIT
Gear Unit
Preparatory Measures B
For removal purposes the truck must be raised approx.
500 mm. A
Required Tools:
● Fork lift truck with sufficient capacity, lift height

and fork length to lift the truck.
● Safety mechanism to keep the forks of the lifting

truck holding the raised truck.
● Sufficient quantity of wooden blocks (250 x 250

mm surface area) or suitable supports to hold the
raised truck.
● Device to support the gear unit on a jack or lift

truck. M1564
Removal Lower the mechanism with the gear unit and remove it
from underneath the truck.
Remove the battery connector and key.
Maintenance
Make sure that the truck cannot be switched on.
WARNING
Support the truck with a second fork lift truck and
prevent it from slipping. THE GEAR UNIT MUST ONLY BE REPAIRED
BY PERSONNEL WHO HAVE BEEN TRAINED
DANGER AND AUTHORISED BY CROWN. FAILURE TO
COMPLY WILL INVALIDATE THE
NEVER WORK UNDERNEATH A SUSPENDED MANUFACTURER'S WARRANTY.
LOAD.
SEVERE INJURIES CAN RESULT IF THE To adjust the flank tooth bearing and pre-
TRUCK SUDDENLY FALLS. tension the shaft bearing requires years of
experience in gear units. Faulty settings will
Raise the truck until a jack / lift truck with a support for result in the premature failure of the gear unit.
the gear unit can be pushed underneath the truck. Therefore it is generally preferable to replace
Lift the truck by approximately another 50 mm to the gear in full.
release the gear unit from the gear teeth. New gear units are always supplied without oil!
Lower the truck onto the wooden blocks / supports. Prior to commissioning fill with oil in
accordance with the "Lubricant table".
Raise the mechanism onto the jack / lift truck until it
contacts the gear unit.
General
● All bearings and seals must be replaced.
Remove the electrical connections from the motor.
● Prior to disassembly thoroughly clean the gear
Loosen the six gear unit fastening screws (A) and the unit with a cold-cleaning solution and blast dry
three motor fastening screws (B) in Fig. M1564. with weak compressed air.
● Use assembly equipment and a clean

workbench.
WP2300S 05/2005 • Printed in Germany MS-3.1-1723
M-1.0-0000-00051
M1.0-0000-00051
51
DRIVE UNIT
70
M1530A
MS-3.1-1723 WP2300S 05/2005 • Printed in Germany
52M1.0-0000-00052
M-1.0-0000-00052
DRIVE UNIT
Gear Unit Disassembly / Assembly ● Remove the bearing inner ring (240) from the
bevel pinion shaft.
All item numbers refer to Figure M1530A unless
otherwise stated. ● Thoroughly clean all components and remove
any sealant and adhesive residue.
Disassembly
Assembly
● Drain the oil.
NOTE
● Place the gear unit with the wheel studs in a
device which prevents it from twisting. ALL SEALS AND BEARINGS MUST BE
REPLACED.
● Remove the screws (390), lock washers (330)
and O ring (290) and lift off the cover (30). Preparing the Gear Unit
● Remove the Allen screws (350) and spring lock ● Fit the outer rings of the conical roller bearings
washers (190). (230, 240, 250 and (260) in the respective
grooves of the clean gearbox. Make sure they sit
● Remove live ring bearing (130). evenly in the gearbox. Fit the lock washer (310).
● Remove screw (360) and spacer (190). ● Push the inner ring (260) of the conical roller
bearing (260) onto the bevel wheel (65).
● Loosen bevel wheel nut (140).
● Screw the wheel stud (150) into the flange using
● Remove the gear unit from the device. a dynametric key.
NOTE ● Place the gearbox in its eventual assembly

position.
WHEN REMOVING THE GEAR UNIT, LABEL
THE SHIMS (420, 430,440) IN ACCORDANCE ● Insert the conical roller bearing inner ring (250) in
WITH THEIR LOCATION. THEY WILL HAVE the pre-assembled outer ring (trail wheel side).
TO BE TEMPORARILY RE-FITTED IN THE
SAME POSITION AT A LATER STAGE. ● Press the shaft seal (270) into the gearbox using
● Remove the pinion (65), spacer ring (160) and if a suitable tool.
necessary shim(s) (420,430) from the housing.
Flange Shaft Assembly
● Remove the bearing inner ring (260) from the
bevel wheel (65). ● Lightly grease the flange shaft (50) and carefully
place it in the shaft seal (270) and the conical
● Force out the flange shaft (50) using suitable roller bearing (250).
tools.
● Place the shim (430), spacer (160) and pre-
● Remove the bearing inner ring (250) from the assembled bevel wheel (65, 260) on the flange
flange shaft. shaft.
● Pull out the bearing outer rings (250, 260) from NOTE
their seats in the gearbox.
THE FLANGE SHAFT ASSEMBLY MUST BE
● Remove the rotary shaft seal and the lock washer TENSIONED WITH A TORQUE WRENCH.
(310) from its gearbox seat.
● Arrange the shim (190) and screw (360) and
torque the flange shaft assembly to max. 77 Nm.
● Press the bevel pinion shaft (70) down and out of
the drive pinion (110) and the bearing (230). ● Check freedom of movement and play of the
shaft. If necessary, reduce the torque.
● Remove the bearing (230) and shim(s) (440) if Record the final reading. It will be required during
necessary. calibration.
● Remove the bearing outer ring (240). ● Insert the gear unit with wheel studs in a device
which prevents it from twisting.
M-1.0-0000-00053
M1.0-0000-00053
53
DRIVE UNIT
Pinion Shaft Assembly Checking the Flank Tooth Bearing
● Push the bearing inner ring (240) up onto the

bevel pinion shaft (70).
Bevel pinion inner tooth end
Correct tooth bearings
● Insert the pre-assembled bevel pinion shaft from
the inside of the gearbox into the pre-assembled
bearing outer rings (230, 240).
High
● Push the bearing inner ring (230) via the shank of
the bevel pinion shaft (70) into the bearing outer
ring.
Low
NOTE
THE SPUR PINION NUT MUST BE High Low

TIGHTENED WITH A TORQUE WRENCH.
● Fit the spur pinion (110) and torque new nut
(140) to max. 100 Nm.
Bevel wheel inner tooth end
Correct tooth bearings
● Check freedom of movement and play.
M1565-1
If necessary, reduce the torque.
Record the final reading. It will be required during
calibration. ● Colour the bevel wheel (70) tooth bearings with
touch-up paint (marker colour).
Adjusting the Bevel Gear Assembly
● Remove the gear unit from the device.
NOTE
● Turn the bevel wheel several times in one direction.
CARRY OUT ADJUSTMENT WITH CARE. The tooth bearing will appear as a bright point
BEARING AND SHIM PRE-TENSIONING (shown black in Fig. 1565-1) on the tooth flanks.
AFFECT THE TOOTH BEARING. DO NOT SET
THE PRE-TENSION TOO LOW AS IT ● Check the tooth bearing. Set the tooth bearing to
AUTOMATICALLY REDUCES DURING NOR- within the tolerance limits by adding and/or
MAL OPERATION. removing shims (420,430,440) - Fig. M1565-1.
The correct setting can be determined by the flank Note: Torque screw (360) and nut (140) again
tooth bearing. to their previous values.
Repeat the process until the tooth bearing lies
Basic Rules: within the tolerance limits.
● Always set the bevel gear assembly in Final Assembly

accordance with the correct flank position. The
tooth ends must not form a straight line. ● Remove the bevel pinion shaft and flange shaft.
● The tooth bearing must always rest on the inner ● Clean the components.
tooth end.
● Coat the inside of the bearing inner rings with a
● The tooth bearing must lead from high (tooth thin layer of Loctite 307.
upper edge) to low (tooth lower edge).
● Apply medium strength nut locking solution
To adjust, add and/or remove compensating spacers Loctite 242 (Crown part no. 053050-006) to the
(420, 430, 440), and/or change the bearing pre- threads of the nut (140) and screw (360).
tension.
● To assemble, proceed as described previously.
Figure M1565-1 shows the permissible tooth bearing
limits on the bevel pinion and bevel gear. ● Manually turn the gear unit while checking for
freedom of movement and the absence of play
during operation.
54M1.0-0000-00054
M-1.0-0000-00054
DRIVE UNIT
● Coat the surfaces of the gearbox cover with a thin
layer of Loctite 307 surface sealant , insert the
O ring (290) and fit the lid.
Evenly tighten the screws (390) and spring
washers (330) crossways.
● Coat the gearbox cover - live ring bearing contact

surface with a thin layer of Loctite 307 surface
sealant . Assemble the live ring bearing.
NOTE
ALLOW THE CONTACT SURFACE AND
THREAD SEALANT TO DRY FOR AT LEAST
2 HOURS AT ROOM TEMPERATURE
BEFORE FILLING WITH OIL.
● Place gear unit in assembly position.
● Fill the oil up to the lower mark of the filler plug in

accordance with the application temperature (see
Lubrication and Adjustment chapter).
Assembly
● Assembly is the reverse procedure of removal.
Do not damage the toothing of the motor pinion
(100) or the drive pinion (110).
Drive Motor
For maintenance and repairs to the drive motor see the
end of chapter 4, page M4.35-1720-001.
M-1.0-0000-00055
M1.0-0000-00055
55
Blank Page
Printed in Germany
56
ELECTRICS
Printed in Germany
57
Blank Page
Printed in Germany
58M1.0-0000-00058
M1.0-0000-00058
ELECTRICS
Electrics - General
Wire Colour Codes

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

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

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

Used from serial no. 5A336576,
DANGER except for 5A337937.
Jack up the truck before carrying out
The safety reverse switch (SAS) is activated via the
repairs or troubleshooting the electrical
switch cap at the end of the control handle head. The
system.
PLM changes the traction controller immediately from
forward to reverse travel when the SAS is activated.
Travel Switch (POT, FS, RS) The signal for normal travel to the traction controller is
simultaneously interrupted. Depending on the traction
The travel switch is manually activated via the butterfly controller setting, the truck reverses either for a certain
switch on the control handle cap. The travel switch period of time or for as long as the switch is pressed.
consists of a switch (FS) for forward travel, another
switch (RS) for reverse travel, and a potentiometer Brake Switch (BRS)
(POT) to control the travel speed.
The brake switch (BRS) is located directly below the
Fast/Slow Switch (HSS) control handle suspension. As soon as the control
handle reaches the upper or lower brake zone (see
A rotary button (rabbit//turtle & rabbit symbol) activates Fig. M1559-2), the brake switch is activated. The power
the Slow/Fast switch (HSS) on the control handle cap. supply to the traction motor (TM) and the brakes (BR)
The switch signal to the traction controller operates the is cut off via the traction controller. The brake magnet
change between the fast and slow speed zones. releases the armature plate which causes the truck to
brake through spring tension.
Safety Reverse Switch (SAS)
Brake Switch (BRS)
The safety reverse switch (SAS) is activated via the
switch cap at the end of the control handle head. The Used from serial no. 5A336576,
traction controller immediately changes from forward to except for 5A337937.
reverse travel when the SAS is activated. The signal for
normal travel to the traction controller is simultaneously The brake switch (BRS) is located directly below the
interrupted. Depending on the traction controller control handle suspension. As soon as the control
setting, the truck reverses either for a certain period of handle reaches the upper or lower brake zone (see
time or for as long as the switch is pressed. Fig. M1559-2), the brake switch is activated. The power
supply to the traction motor (TM) and the brakes (BR) is
cut off by the traction controller via the PLM. The brake
magnet releases the armature plate which causes the
truck to brake through spring tension.
Upper brake zone
Neutral / Idle Position

Travel zone C
B
Lower brake zone A
M1559-2
WP2300 05/2005 • Printed in Germany MS-4.2-1723
63
ELECTRICS
Raise/Lower Switch (RAS, LOS) Key Switch (KYS)
The raise (RAS) and lower (LOS) switches are activated The key switch activates the power supply to the traction
by cams in the control handle cap. The cams act on controller and the battery discharge indicator (BDI).
switches mounted on the hydraulic PCB of the control
handle. The switches are mutually and mechanically Emergency Disconnect (BD)
locked so that they cannot be pressed at the same time.
Pull the battery connector on the red handle at the top
The raise (RAS) switch activates the pump contactor of the truck to fully disconnect the truck's power supply.
(P), causing the pump to start.
Fuses (FU)
The lower (LOS) switch supplies the solenoid (SV) with
current, causing the solenoid to open. The entire truck circuit is protected by the FU1 fuse
and the control circuit is protected by FU2. Cold store
Pressure Switch (PS) trucks have an additional fuse, FU3, for control
OPTION
handle heating.
The pressure switch is applied if the load raised is
more than 900 kg to 1,000 kg and causes the pressure
to rise in the hydraulic system. This reduces the maxi-
OPTION
Thermal Switch (THS)
mum travel speed in rider mode to a safe level. This is an electronic thermostat for cold store trucks. It
is located on the main PCB of the control handle and
Platform Control Switches applies the heating units when the temperature falls
below 0°C.
(GCSR, GCSL, PLS)
Filter (WP2340S only)
Folded platform only. These three switches are ar-
ranged in series. The chain controls the position of the When jolts are caused by travelling on uneven sur-
gate and the platform. When all the switches are faces, switches FPS1 & FPS2 – actuated by the side
closed, the traction controllers changes to the higher entry bars – can briefly open and inhibit travel. The
platform speed. filter delays the signal to inhibit travel by approx. 1s.
This avoids accidental travel cut-out.
Platform Control Switches
(GCSR, GCSL, PLS) Diode D4
Used from serial no. 5A336576, This freewheel diode on the large brake coil (BR) protects
except for 5A337937. the input on the controller against peak voltages caused
when the large brake coil is switched off.
Folded platform only. These three switches are signal
transmitters for the platform logic and enable slow / fast Diode block (DB)
travel. When all the switches are closed, the traction
controller changes to the higher platform speed. The diode block comprises diodes D1 to D3 in a single
component. It acts as a freewheel diode for the small
Lift Limit Switch (LMS) brake coil (BR) and guides the pressure switch (PS)
signal to connect the 2nd brake level.
The limit switch (LMS) cuts out the pump contactor
circuit when the preset maximum height is reached.
The limit switch is located under the front panel next to
the knuckle.
This switch must be adjusted, see Chapter 7, LIFTING
MECHANISM.
Horn Switch (HNS)

The horn is sounded when the horn switch (horn
symbol) is pressed.
Foot Switch (FTS)

Only available with fixed platforms. When pressed it
releases the travel signal via the traction controller.
MS-4.2-MS-1723 WP2300 05/2005 • Printed in Germany
02 Rev. 05/05
64
ELECTRICS
Platform Logic (PLM)
Used from serial no. 5A336576,
except for 5A337937.
This module detects and analyses the connection
status of the platform switch (PLS) and the side gate
switch (GCSR & GCSL).
Depending on the connection status an output signal is

sent to the traction controller which either enables the
higher travel speed or only permits the lower walkie
speed.
The SAS and BRS signals are also connected via this
module, depending on the platform switch and the side
gate switch, as well as the respective function switch.
64_A
ELECTRICS
WP2330S PC/JC 415
PC/JC 414
PC/JC 413
PC/JC 412
BATTERY TRAY PC/JC 411 HSS (R/T)
PC/JC 410
FU3 (Option F/C) RAS/LOS
HNS
POT,FS,RS
BD
BB (SAS)
LMS
PC/JC 203
813507
P
LINE CA 419 (HNS2)
HANDLE HARNESS
BUSBAR
PC/JC 101 CA 417 (HNS1) PC/JC 406
GCSL BRS
PC/JC 407
BR
INSTRUMENT
PC/JC 404
KYS
MAIN HARNESS
FU2
DB
FU1 PC/JC 202
A,B,C,D AND E
PM
TCM
SV
PS HN
PLS
PC/JC 102
TM
PC/JC 103
GCSR
65
ELECTRICS
WP2330S PC / JC 415
PC / JC 414
PC / JC 413
PC / JC 412
BATT PC / JC 411 HSS (R/ T)
PC / JC 410
FU3 AND RAS / LOS
FU3 HOLDER
OPT. HNS
POT, FS, RS
BD
BB (SAS)
PLM
PC / JC 200
PC / JC 416
PLM Used from S/No. 5A336576 on,

but not on S/No. 5A337937
LMS
LINE
813507_2B
BUSBAR
PC / JC 101
GCSL
FAN
CA 419 (RHS)
HANDLE HARNESS
CA 417 (LHS) PC / JC 4065
BRS
PC / JC 407
BR
INSTRUMENT
PC / JC 404
KYS
MAIN HARNESS
FU2 AND FU2
HOLDER DB
FU1 AND FU1
PC / JC 202
HOLDER
A, B, C, D AND E
PM
SV TCM
PS HN
PLS
PC / JC 102
TM
PC / JC 103
GCSR

02 Rev. 05/05
65_A
ELECTRICS
WP2335S CA 419 (HNS2) HANDLE HARNESS

CA 417 (HNS1)
PC/JC 406
BRS
PC/JC 407
BR
INSTRUMENT
PC/JC 404
KYS
DB
MAIN HARNESS
PC/JC 202
A,B,C,D AND E
FU2 TCM
FU1 HN
PM
SV
PS
TM
PC/JC 415
PC/JC 414 813508
PC/JC 413
PC/JC 412
PC/JC 411 HSS (R/T)
BATTERY TRAY PC/JC 410
RAS/LOS
HNS
POT,FS,RS
FU3 (Option F/C) BB (SAS)
BD
LMS
P
LINE
BUSBAR
FTS
PC/JC 101
66
ELECTRICS
WP2340S
CA 419 (RHS)
CA 417 (LHS) HANDLE HARNESS
PC/JC 406
FU2 AND
BRS
FU2 HOLDER
PC/JC 407
BR
INSTRUMENT
PC/JC 404
KYS
DB
PM MAIN HARNESS
PC/JC 202
FU1 AND A, B, C, D AND E
FU1
TCM
HOLDER
SV HN
PS
TM
FPS
FILTER 813509
PC/JC 415 HSS (R/T)

PC/JC 414
PC/JC 413 RAS/LOS
PC/JC 412
PC/JC 411 HNS
BATTERY TRAY PC/JC 410
FU3 AND
FU3 HOLDER
OPT.
BD
POT,
FS, RS
BB (SAS)
LMS
P
LINE
BUSBAR
PC / JC 101 FTS

02 Rev. 05/05
66_A
Blank Page
66_B
ELECTRICS
Battery Battery Discharge Indicator (BDI)

WARNING
General The following setting and calibration
The battery condition has a considerable impact on the instructions for the BDI apply only to wet
performance of the truck. Effective maintenance will batteries.
maintain the performance levels and lifespan of the ● For maintenance-free batteries follow the
battery. manufacturer's instructions regarding the
discharge terminal voltage.
WARNING
General
The battery must be serviced solely in
accordance with the battery A battery from the factory will require approx. 5 - 10
manufacturer's instructions. charge and discharge cycles to reach its full capacity.
● Incorrect or inadequate maintenance will
initially reduce the performance of the A battery is considered to be technically discharged
truck and ultimately result in premature when it has reached 20% residual capacity. For
failure of the battery. example, a battery with a 500 amp hour capacity has
an actual available output of 400 amp hours.
It is essential to adjust the battery discharge indicator
(BDI) correctly to ensure on the one hand that the In addition, the effective output will depend on the
battery is not fully discharged and on the other that discharge speed, which in turn is affected by the
there is maximum battery capacity available for the particular truck application.
task in hand.
The battery discharge indicator must therefore be set
Replacing the battery in accordance with the truck's particular application
conditions.
WARNING
The battery discharge indicator controls the lift cutout
Only use batteries of the permitted size, system. The lift cutout system is designed to prevent
weight and specifications for this truck. the battery from being operated to the point where is
● An incorrect battery type can cause fully discharged.
damage to the truck.
If the battery is constantly discharged to below 20% of
● An incorrect weight and size will alter the residual capacity it will be damaged.
centre of gravity of the truck, potentially
resulting in accidents. If the lift cutout system is activated above 20% of the
battery's residual capacity the battery will not be
There are several different battery compartment damaged, but the truck's maximum operating time
versions. Refer to the truck operator manual to under a single battery charge will not be attained.
battery replacement instructions.
The operator manual contains the latest safety The lift cutout system should therefore be activated as
instructions and information. close to 20% of the battery's residual capacity as
possible. If at all, it may be slightly above 20%, but
never below.
NOTE
For new trucks the battery discharge
indicator should be set at the latest after
ten discharge and charge cycles.
67
ELECTRICS
Battery Discharge Indicator Setting to check if the battery is actually 100% charged.
Faulty battery cells will make calibration impos-
(BDI) sible.
The acid density is a very reliable indicator of the ● Operate the truck as usual under normal
charge status of a lead acid battery. However, since it operating conditions until the battery is empty:
is unrealistic to continually measure the acid density of both LEDs of the BDI will flash and the lift cutout
a truck battery to an industrial standard, the battery system will be triggered.
voltage is used to determine the charge status over
longer journeys. ● Leave the battery for at least 10 to12 hours (one
hour at the very minimum!).
To adapt the BDI to the battery used and the truck's
specific application profile, you need the battery ● After this interval measure the acid density on at
manufacturer's data sheet. The values you require are least three different battery cells. The smallest
the density of the electrolyte for an 80% discharged recorded value is the one you need.
battery (20% battery residual capacity) and for a fully
charged battery (100% battery capacity). ● Compare the recorded density with the density
specified by the manufacturer for an 80%
Finally, via the potentiometer on the back of the BDI discharged battery (20% residual capacity).
the display is set to the actual discharge terminal
voltage of the battery at 20% residual capacity. ● If the battery is more than 80% discharged (less
than 20% residual capacity), set the
The factory default setting of the battery discharge potentiometer on the back of the BDI to direction
indicator is "N" (any setting from K to U is possible). K.
Calibration ● If the battery is less than 80% discharged (more

than 20% residual capacity), set the
● Fully charge the battery as indicated by the potentiometer on the back of the BDI to direction
battery manufacturer in the operating instructions. U.
Measure the acid density in accordance with the
battery manufacturer's maintenance instructions ● Charge the battery again and then check the
calibration.
Discharge Terminal Voltage Setting in Volts/Cell
K L M N O P Q R S T U
1.57 1.63 1.68 1.73 1.78 1.82 1.84 1.86 1.89 1.91 1.93
E20-GB
MS-4.25-1723 MS-WP2300S-GB 05/03 •Printed in Germany
68
ELECTRICS
SEM1 Traction Controller Operational Features

Speed Control
DANGER
Infinately variable handset programmable speed control
Jack up the truck before carrying out any
in both directions.
repair work or troubleshooting the electrical
system.
Reduced Speed Ranges
There are several interdependent travel ranges with
General reduced speed available: slow travel (via a rotary switch
contained in the tiller handle HSS), slow travel when the
platform is not folded out (via the GCSR, GCSL and
PLS switches) in walkie mode and an automatically
reduced travel speed for loads in excess of 1,000 kg.
Downhill Speed Control

When travelling downhill the controller monitors the
motor anchor speed via the drive signal from the
traction potentiometer. When the set speed is exceeded,
electrical braking with energy retention is introduced.
Regenerative Braking
M1531
Three forms of regenerative braking are available:
The programmable SEM1 impulse controller provides
effective control over the driving behaviour of the truck. ● Release braking (travel switch or multitask handle
return to neutral)
The truck is powered by a separate excited motor
(SEM). This version has two variables for governing the ● Inversion braking (travel switch set in opposite
motor output: field and armature current. direction)
Precautionary Measures ● Braking by reducing speed on a slope: the

controller constantly regulates the engine speed
● Do not attach the controller to a battery with a according to the set value prescribed by the travel
different rated voltage to that of the controller switch. Braking is automatically activated when
(24 - 36 VDC). the set value is exceeded.
A higher battery voltage may destroy the
MOSFETs, while a lower power supply will result Anti - Roll Down Function
in system failure.
This function prevents the truck from accidentally rolling
● Only operate the controller with special traction down a slope. When the key switch is on the controller
batteries. Do not connect to a rectifier or mains monitors the engine speed. If it detects a turning
components. movement without a travel command, braking is
automatically activated.
● When commissioning jack up the truck to prevent
it from starting suddenly if there is a wiring error. If the truck automatically starts to move on a slope, it
therefore brakes after a short period. When the truck
● When the key switch has been turned off the filter stops braking is released causing the truck to move
capacitors in the controller remain charged for a again, followed by further braking. If the brake is not
few minutes. If work is performed on the controller applied the truck will therefore move down the slope
during this time it must be disconnected from the very slowly.
battery (disconnect battery). Finally, to discharge
the capacitors short-circuit the positive and
negative terminals of the power part together over
a resistance (10 - 100 Ohm, min. 5 W) for a few
seconds.
MS-WP2300S 05/05 • Printed in Germany MS-4.3-1723
69
ELECTRICS
Hourmeter Temperature
An hourmeter is integrated within the traction controller From a power part temperature of 70°C upwards the
which can be set via the programmer either to "KEY maximum current is limited in proportion to the rise in
ON" (hourmeter activated when key switch on) or temperature. At 80°C the traction controller automati-
"RUNNING" (hourmeter activated only during travel). cally cuts out.
Self Test At temperatures below -10°C the maximum current is

reduced in proportion to the ongoing battery discharge.
The traction controller self-diagnostic system lists the
five most recent error messages. These error messages Start Sequence
can be called up via the programmer. As well as the
error, the system stores and displays the error fre- To start the truck there is a specific start sequence
quency, the respective number of service hours and the which must be observed. Otherwise the general protec-
temperature of the traction controller at the time the tion will not be activated and the truck will not function.
error was recorded.
Safety Class
In addition a red LED on the traction controller indicates
the last recorded error via a flashing code. The display The traction controller is protected against dust and
is deleted when the controller is switched off and on spray water (IP54).
again, and if the error was only temporary.
Monitored Circuits
The following functions are monitored by the traction
controller microprocessor depending on the operating
mode:
● Starting the truck: control logic system (hardware)

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

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

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

temperature, battery voltage.
Protective Devices
Polarity Protection
A general protection controlled by the logic system
separates the traction controller from the battery and
thus protects the power part from incorrect polarity.
Wiring Errors
All outputs are protected against wiring errors. The
outputs for the general protection and the magnetic
brake can be charged with max. 3 A and are fitted with
both an overload and a short circuit protection.
MS-4.3-1723 MS-WP2300S 05/05 • Printed in Germany
70
ELECTRICS
Maintenance ● Wipe the traction controller with a clean, damp
cloth.
Maintenance of the SEM1 controller is confined to
external cleaning. When carrying out maintenance work, ● When everything is dry, re-connect the power
check the listed errors using the programmer. cable as indicated in Fig. MS-1723-100.
WARNING ● Torque the mounting nut (1, Fig. MS-1723-100)

to 5.5 - 8 Nm.
The SEM1controller operates with high
current. Special safety measures are there- Important: An incorrect torque can damage the
fore required. board and the controller housing.
● Only properly trained personnel must carry ● Re-connect the control lines.
out maintenance work.
● Wear safety glasses. ● For cold store versions: coat the control line
connectors with Dow Corning® 4 Compound, part
● Do not wear any loose clothing. no. 053051-006. Apply an acid-resistant transpa-
rent lacquer, part no. 805236-003, to the controller.
● Do not wear any jewelry.
● Use insulated tools only.
● Disconnect the battery (= emergency disconnect).
● Jack up the truck.
● Discharge the controller capacitors by connecting for

a short time BATT- and BATT+ of the controller via a
cable including a resistor of about 10 Ohm, 5 W.
● Remove the power cable: mark the cable if

necessary. Undo the lower nut (1, Fig. MS-1723-
100).
MS-1723-100
71
ELECTRICS
Replacing the SEM1 Traction ● If necessary clean the contact surfaces and refit
the power cable (you must follow the
Controller instructions in the Maintenance section on the
previous page) and refit the connectors for the
WARNING control lines.
A WP2300S must only be operated with a ● For cold store versions: coat the control line
SEM1 traction controller, part no 81309x- connectors with Dow Corning® 4 Compound, part
xxx. no. 053051-006. Paint the controller with an acid-
resistant clearseal paint.
● Using the SEM1 traction controllers from
the WP2000S series (with different part Important: After replacing the controller check and
numbers) can change the operating adjust the settings. You can adjust the settings to
characteristics and hence result in suit the customer’s requirements. Follow the order
accidents. described as follows.
When you fit a new SEM1 traction controller with part
no. 81309x-xxx in a WP2300S the controller identifies Parameter Setting after Replacing the
the truck model and automatically loads the correct Traction Controller
settings when the truck is switched on.
If you have changed and stored the standard configura- Preparatory Measures
tion with the programmer, the stored parameters will be
loaded the next time the controller is started. ● Power down the truck and jack it up so that the
drive wheel is free (see Chapter 1).
● Prepare to remove the traction controller as
previously described in the Maintenance section. ● When the truck is powered down connect the
programmer to the traction controller.
● Remove the 4 mounting screws and remove the
traction controller. ● Power up the truck.
● When installing a new traction controller: Setting

Check the part no. to make sure the new traction
controller is the right one for this truck. 1. If required, change the options for the safety
reverse switch and the internal service hourmeter
813195-001 WP2300S, fixed platform of the controller. The standard setting is contained
813195-002 WP2300S, fixed platform, F/C in Table E11-GB. When you have made the
813196-001 WP2300S, folding platform changes, switch the truck off and on again to
813196-002 WP2300S, folding platform, F/C activate the changes.
● Check the contact pattern left behind by the 2. Measure the battery voltage directly at the battery
controller back plate on the heat dissipation sheet. and adjust the reading measured and displayed by
The controller must lie fully flat on the heat the traction controller (see CONFIG MENU
dissipation sheet. section).
If there are large areas with no contact to the
controller, replace the heat dissipation sheet to 3. Using the TEST menu check the wiring and
avoid thermal problems. operation of the switches (see TEST menu
section).
● Clean the contact surface of the traction controller
on the truck chassis with a lint-free cloth and use 4. Re-calibrate the traction potentiometer (see
an industry-standard silicon removal agent to “Traction pod – calibrate potentiometer, PRO-
remove the residue of the heat conducting paste. GRAM VACC menu).
● Apply a thin and even layer of Dow Corning® 340 5. Test the traction pod starting point at creep speed.
heat conducting paste, part no. 053051-008 to the The drive wheel should start when the travel
floorboard (= contact surface of the traction switch closes. If necessary increase the value
controller on the truck chassis). accordingly. Repeat the test for both travel
directions (see PARAMETER CHANGE menu
● Secure the traction controller again with the 4 section).
screws.
72
ELECTRICS
WARNING Both parameters, INVERSION BRAKING and
AUX TIME DELAY affect the “feel” of the delay
Do not exceed the maximum permissible when changing direction.
speeds when carrying out the following
adjustments as described below. Important: Power down the truck before
disconnecting the programmer. Now reconnect the
LEDs.
7. With the truck unladen, set the maximum slow
travel speed in walkie mode (CUTBACK SPEED)
(folded platform only). Now set the maximum slow
travel speed for rider mode (CUTBACK SPEED 1).
8. With the truck unladen, set the maximum "For-

ward" (MAX SPEED FRW W ) and "Reverse"
(MAX SPEED BCK W) speeds in walkie mode
(folding platform only).
Note: The maximum permissible speed is 6
km/h unladen.
9. With the truck unladen, set the maximum "For-

ward" (MAX SPEED FRW RU) and "Reverse"
(MAX SPEED BCK RU) speeds for rider mode.
Note: The maximum permissible speed is 10
km/h unladen.
10. Apply the maximum load to the truck. Now record

the maximum speed in walkie mode again (folding
platform only) and then in rider mode. The
maximum permissible speed with the
maximum load in walkie mode is 6 km/h, in
rider mode max. 7 km/h.
11. Release Brake Pattern Setting:

Drive the unladen truck at maximum speed and
release the travel switch. Repeat the test with the
maximum permissible load.
If necessary adjust the braking pattern (RELEASE
BRAKING).
12. Adjusting the braking pattern when reversing

direction:
Carry out this setting first in walkie mode and then
in rider mode.
Drive the unladen truck at approx. 25% of
maximum speed and apply the travel switch in the
opposite travel direction until it reaches the stop.
Adjust the braking pattern so that the delay effect
is gentle (INVERSION BRAKING).
Now repeat the test at maximum speed. Adjust
the setting until the delay effect is gentle in both
speed ranges and the optimum effect is achieved.
Repeat the process in both operating modes with
the maximum permissible load.
Preference should be given to the optimum setting
with the truck unladen.
13. Adjust, where necessary, the time taken to

change direction. To do this change the AUX TIME
DELAY parameter.
73
ELECTRICS
Status LED The status LED is off during normal travel. When an
error occurs it flashes the respective code (see follow-
When the truck is powered up the status LED connected ing table) until the error is rectified.
to terminal strip E briefly flashes. This indicates that the
test program is being booted up by the controller. The programmer can be used to define the error more
exactly.
No of Flashes Console Display Notes
1 Logic failure #1: Line contactor voltage control error
1 Watch dog: Logic or software error
1 EEPROM KO: EEPROM error
2 INCORRECT STARTS: Star ting sequence for travel not correct
2 FORW + BACK: Forward and backward simultaneously requested
3 CAPACITOR CHARGE Problem with power block
3 VMN NOT OK Problem with chopper; armature voltage not correct
3 VFIELD NOT OK Field voltage not correct
4 VACC NOT OK Signal from traction potentiometer not correct
4 PEDAL WIRE KO Traction pod wiring not correct
No field current: Field wiring not correct

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

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

7 TH. PROTECTION
or too low (< -10°C)
32 BATTERY LOW Battery voltage too low
E04-gb
74
ELECTRICS
Programmer The programmer is connected to the controller by a

cable, thus powered by the controller.
General
CAUTION
The optional programmer enables programming, testing
and diagnostics for the controller. Only connect / disconnect the programmer
to the controller when the truck is switched
off.
M0271-neu
Display Window
● Alpha-numeric LCD display
● 2 lines @ 16 characters
1 P A R A M . I M A X B .R E V E R S E
B R A K IN G C O M P E N S :
A C C E L . R .B R A K E
2 T E S T E R
M A X S P . S P E E D I
S .P .I S P E E D II
3 S A V E S .P .II S P E E D III
B Y P A S S F IE L D W E A K ..
4 R E S T O R E
I M O T V .P O T .
T E M P . V .B A T T .
5 A L A R M S V . M O T V M N .M O T .
M .S W .T E S T
6 A C C E L E R A T O R
7 M O T O R D A T A
1 3 5
R O L L E N T E R P A R A M
R O L L O U T S E T Operating Keys
2 4 6
M0274d
75
ELECTRICS
Description of Keys
Key Designation Explanation
1 ROLL up Selects the next sub-menu or an option.
2 ROLL down Selects the previous sub-menu or an option.
3 ENTER Enters the main menu. Stores the pin configuration.
4 OUT * Quits a sub-menu or an option. Step by step return to the main menu.
5 PARAM SET UP Increases setting values or selects configuration.
6 PARAM SET DOWN Decreases setting values or selects configuration.
* You can undo a change by switching the truck off and on again. The controller will be reset to the output values,
as long as you have not safed the settings before.
E05-GB
Operating SEM1 Controller Menu ALARMS
General In the ALARMS menu error messages generated

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

used.
76
ELECTRICS
Menu Structure for Folded 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
CUTBACK SPEED VMN
MAX SPEED FORW W TEMPERATURE
MAX SPEED BACK W ACCELERATOR
CUT BACK SPEED 1 FORWARD SWITCH
MAX SPEED FRW RU BACKWARD SWITCH
MAX SPEED BCK RU HANDLE/SEAT SWITCH
CREEP SPEED QUICK INVERSION
PRESSURE SWITCH
CUTBACK SWITCH
WALKIE SWITCH
BATTERY CHARGE
BATTERY ON/OFF SET MODEL SET OPTIONS ADJUSTMENTS
NOT AVAILABLE HOURS: RUNNING / KEY ON ADJUST BATTERY

QUICK INVERSION: BELLY /
TIMED
QUICK INVERSION ON/OFF
77
ELECTRICS
Menu Structure for Fixed 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
FTS BRAKING VMN
CUT BACK SPEED 1 TEMPERATURE
MAX SPEED FRW RU ACCELERATOR
MAX SPEED BCK RU FORWARD SWITCH
CREEP SPEED BACKWARD SWITCH
HANDLE/SEAT SWITCH
QUICK INVERSION
PRESSURE SWITCH
CUTBACK SWITCH
WALKIE SWITCH
BATTERY CHARGE
BATTERY ON/OFF SET MODEL SET OPTIONS ADJUSTMENTS
NOT AVAILABLE HOURS: RUNNING / KEY ON ADJUST BATTERY

QUICK INVERSION: BELLY /
TIMED
QUICK INVERSION ON/OFF
78
ELECTRICS
Parameter Setting, Folded Platform

The settings in this table apply only to traction controllers with part nos. 813196-xxx and software version SW#006B.
PARAMETER CHANGE Menu, folded platform, SW#006B
Recom-
Setting
Menu item mended Description
range
setting
Acceleration delay. The time taken for the traction controller to

1.15 - 3.00
ACCELER DELAY 2 increase the output supply to the traction motors from 0 to 100%
sec
(when transmitter (butterfly switch) suddenly set to limit).
Time taken to reach the new set value when the set value on the
DECELER DELAY 9-0 0 transmitter is changed. Corresponds to the braking intensity when
the transmitter is returned.
Release braking. Activated when the accelerator pedal is released

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

INVERSE BRAKING 0-9 6 set to the opposite direction. Time taken for the motor current to
fall to zero.
Maximum current (= speed) for the low speed range selected by the
fast / slow speed switch (HSS) (in % of max. current ACC for fast
30 - 100 %
CUTBACK SPEED 2 speed (= normal)) in walkie mode. Again, the entire mechanical
ACC
control range of the transmitter is available. Enables more sensitive
travelling at reduced speed.
Max. forward speedin walkie mode: this value determines the

maximum traction motor current during forward travel.
When the armature voltage has been fully absorbed by the
100 - 75 %
MAX SPEED FRW W 6 controller, the speed is increased by weakening the field current.
FCN
If the value is set to 0 the field current will not fall below the
nominal value (FCN = field current nominal) when the armature
voltage is fully absorbed.
Max. reverse speedin walkie mode: this value determines the

maximum traction motor current during reverse travel.
100 - 75
MAX SPEED BCK W 6 controller, the speed is increased by weakening the field current.
% FCN
30 - 100 %
CUTBACK SPEED 1 8 speed (= normal)) in rider mode. Again, the entire mechanical
ACC
control range of the transmitter is available. Enables more sensitive
travelling at reduced speed.
E06-1-GB
79
ELECTRICS
Parameter Setting, Folded Platform

Recom-
Setting
range
setting
Creep speed. Setting for the minimum voltage applied to the

traction motor when the travel switch is closed.
6.5 - 11 % This function should be set to one level below the value at which
CREEP SPEED 3
V Batt. the truck begins to travel.
This ensures that the empty run of the transmitter (butterfly switch)
is kept to a minimum.
Max. forward speedin rider mode: this value determines the

100 - 30 %
MAX SPEED FRW RU 8 controller, the speed is increased by weakening the field current.
FCN
Max. reverse speed in rider mode: this value determines the

100 - 30 %
MAX SPEED BCK RU 8 controller, the speed is increased by weakening the field current.
FCN
E06-2-GB
Parameter Setting, Fixed Platform

The settings in this table apply only to traction controllers with part nos. 813195-xxx and software version SW#105
PARAMETER CHANGE Menu, fixed platform, SW#0105
Recom-
Setting
range
setting

1.15 - 3.00
sec

fall to zero.
E06-3-GB
80
ELECTRICS
Parameter Setting, for Trucks with a Folded Platform

Valid for WP2335S and WP2340S.
Recom-
Setting
range
setting
Creep speed. Setting for the minimum voltage applied to the

traction motor when the travel switch is closed.
6.5 - 11 % This function should be set to one level below the value at which
CREEP SPEED 3
V Batt. the truck begins to travel.
Max. forward speedin rider mode: this value determines the

100 - 30 %
FCN
Max. reverse speed in rider mode: this value determines the

100 - 30 %
FCN
E06-2-GB
Parameter Setting, for Trucks with a Fixed Platform

The settings in this table apply only to traction controllers with part nos. 813195-xxx and software version SW#105
Valid for WP2335S and WP2340S.
Recom-
Setting
range
setting

1.15 - 3.00
sec

fall to zero.
E06-3-GB

02 Rev. 05/05
M1.0-0000-00083
80_A
Blank Page
Printed in Germany
80_B
ELECTRICS
Recom-
Setting
range
setting
Inversion braking. Activated when transmitter (butterfly switch) is set

INVERSE BRAKING 0-9 6 to the opposite direction. Time taken for the motor current to fall to
zero.
Release braking with foot safety switch: activated when the foot
safety switch is released. Time taken for the motor voltage to drop to
FTS BRAKING 0-9 8
zero. A setting of 9 achieves the maximum motor braking effect and
the mechanical brake is also applied with a shorter time delay.
30 - 100 %
CUTBACK SPEED 1 8 speed (= normal)). Again, the entire mechanical control range of the
ACC
transmitter is available. Enables more sensitive travelling at reduced
speed.
Max. forward speed: this value determines the maximum traction

motor current during forward travel.
100 - 75 %
FCN
If the value is set to 0 the field current will not fall below the nominal
value (FCN = field current nominal) when the armature voltage is
fully absorbed.
Max. reverse speed: this value determines the maximum traction

motor current during reverse travel.
100 - 75 %
FCN
If the value is set to 0 the field current will not fall below the nominal
value (FCN = field current nominal) when the armature voltage is
fully absorbed.
Creep speed. Setting for the minimum voltage applied to the traction
motor when the travel switch is closed.
6.7 - 11 %V This function should be set to one level below the value at which the
CREEP SPEED 3
Batt. truck begins to travel.
E06-4-GB
81
ELECTRICS
TESTER Menu
The following table describes the various truck param-
eters which can be selected and checked in the
TESTER menu.
TESTER Menu
Menu Item Description
BATTERY VOLTAGE Battery voltage measured at key switch input.
MOTOR VOLTAGE Current applied to armature, measured between +BATT and VMN.
MOTOR CURRENT Current received by motor armature.
FIELD CURRENT Current received by field coil.
Measures the current between VMN (Volt Motor Negativ) and -BATT.
VMN
The reading indicates the potential difference over the controller power par t.
TEMPERATURE Controller temperature, measured at the aluminium base plate next to the MOSFETs.
Displays the nominal signal of the traction potentiometer. The left hand side displays
ACCELERATOR the voltage reading, the right-hand side the percentage relating to the maximum
operating signal calibrated via PROGRAM VACC.
Tests the operation of the "Forward" (FS) switch.

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

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

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

QUICK INVERSION
Tests the operation of the load dependent "Pressure" (PS) switch). Displays the open
PRESSURE SWITCH
(OFF, load < 1.2to) and closed (ON, load > 1.2to).
Tests the operation of the "Fast / Slow" (FS) switch.

CUTBACK SWITCH
Tests the operation of the "series connection" of (GCSR, GCSL, PLS) switches.
WALKIE SWITCH Displays the open (OFF) and closed (ON) status of this circuit. Only available with
folded platform!
BATTERY CHARGE Displays the battery charge status as a percentage.
E07-GB
82
ELECTRICS
ALARMS Menu
The traction controller can collect and store operational
faults during operation. The last 5 error messages are
stored together with the following information:
● Type of error
● Error frequency
● Hourmeter status
● Power part temperature
The ALARMS menu can be used to call up and read the

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

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

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

the capacitors have not star ted to charge 500
- Armature power cable wiring error
CAPACITOR CHARGE metres after turning the key switch, an error
- Faulty controller.
message appears and the main contactor does not
close.
E08-GB
83
ELECTRICS
ALARMS Menu (Contd.)
Test performed in idle mode with the main

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

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

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

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

carbon brushes).
Test performed during travelling. The error - Faulty current sensor
I = 0 EV ER message appears if the traction current does (replace controller).
not exceed a given minimum value. - Back coupling, logic system or power
par t error (replace component or entire
controller).
E09-GB
84
ELECTRICS
ALARMS Menu (contd.)
- Main contactor jammed (check

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

temperatue exceeds 70°C. The maximum current
- Excessive ambient temperature.
is reduced in propor tion to the rise in
- Temperature sensor faulty (replace
temperature. At 80°C the system automatically
controller).
cuts out.
TH PROTECTION - Faulty logic (replace logic system.)
- If the temperature falls below -10°C, the
- Insufficient heat transfer (check
maximum current is reduced to 80%.
mounting bolts and the rest of the
- If the error message appears in the normal
system).
temperature range, this indicates an error in the
controller.
- Less than 63 % of the battery

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

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

connected or incorrectly connected
CONTACTOR DRIVER; - Contactor drive opened or shor t-
Tests the main contactor circuit.
COIL SHORTED circuited (replace logic system).
- Voltage feedback error to contactor
driver (replace logic system).
E10-GB
85
ELECTRICS
Calibrating the Traction Pod ● The display shows the new minimum and
maximum value and an arrow for the selected
Potentiometer, PROGRAM VACC travel direction.
menu
● Press OUT when you are ready.
It is always necessary to calibrate the traction pod
potentiometer when: ● The display asks “Are you sure?” If you wish to
store the new readings, press ENTER. If not,
● the traction pod potentiometer has been replaced press OUT.
or,
● Press OUT to quit the VACC menu.
● the traction controller has been replaced.
With the WP2300S there is no need to physically adjust

the potentiometer and the travel switch as is the case
with the WP2000S.
Preparatory Measures
● Power down the truck and jack it up so that the
drive wheel is free (see Chapter 1).
● Connect the programmer to the traction controller.
● Power up the truck.
Calibration
● Press ENTER on the programmer.
● Using the ROLL UP and ROLL DOWN keys scroll

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

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

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

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

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

and press the travel switch slowly in the reverse
direction until it reaches the stop.
M1610
86
ELECTRICS
CONFIG Menu ADJUSTMENTS

The CONFIG menu provides access to the SET OP- In the menu item ADJUST BATTERY you can adjust the
TIONS, ADJUSTMENTS and SET MODEL sub-menus. battery voltage measured by the controller to give the
actual battery voltage.
SET MODEL
Using a digital voltmeter measure the battery voltage
This parameter is reserved for future use. directly at the battery. Adjust the voltage shown in this
menu until it matches the voltage measured directly at
SET OPTIONS the battery.
See Table E11-GB for a description of the parameters.

The standard setting for HOUR COUNTER is “RUN-
NING”. For QUICK INVERSION the “BELLY” setting.
CONFIG Menu
Sub-Menu Option Description
SET MODEL NOT AVAILABLE This parameter is reserved for future use.
Determines the operation of the hourmeter in the traction

HOUR COUNTER: controller. The following options are available:
KEY ON / RUNNING - KEY ON: Counts the hours while the truck is switched on
- RUNNING: Counts the hours while the traction motor is applied
Determines the operation of the reverse safety switch (belly

SET OPTIONS switch):
QUICK INVERSION: - BELLY: Truck travels in opposite direction while the safety
BELLY / TIMED reverse switch is applied.
- TIMED: Truck travels in opposite direction while the safety
reverse switch is applied, however, only for 2 seconds.
QUICK INVERSION
Safety reverse switch in platform mode switched on or off.
ON/OFF
Battery voltage recorded by the controller is adjusted to the

ADJUSTMENTS ADJUST BATTERY actual battery voltage. Compensates the voltage drop via the
wiring and the key switch.
Must be set to OFF if a Cur tis BDI (standard for all trucks) is
BATTERY CHECK ON/OFF
used.
E11-GB
87
ELECTRICS
Traction Controller Safety Test ● Power up the truck.

The programmer should display VFIELD NOT OK.
The traction controller safety test takes the form of a Activating the transmitter should have no effect.
Pulse Monitor Trip Test (PMT).
● Switch off the truck and remove the test lead from
In accordance with EU Norm PREN 1175-1 the follow- F1 (the other end remains connected to -BATT).
ing test must be carried out to check the fuse circuit.
● Attach test lead to F2 (item 3).
The test requires a test lead of approx. 1 mm2 diameter
and a 10A fuse. ● Power up the truck.
The programmer should display VFIELD NOT OK.
● Switch off the truck and jack it up. Activating the transmitter should have no effect.
● Connect one end of the test lead to -BATT. ● Switch off the truck, remove the test lead com-
pletely, remove the programmer.
● Connect the other end of the test lead to VMN
(item 1 in Fig. 805980_6). ● When the truck is switched on again and the
transmitter activated, the traction motor should
● Connect the programmer to the traction controller. start.
● Power up the truck. ● If the test proves unsuccessful, replace the

The programmer should display CAPACITOR traction controller.
CHARGE. Activating the transmitter should have
no effect.
● Switch off the truck and disconnect the test lead

from VMN (the other end remains connected to
-BATT).
● Attach test lead to F1 (item 2).
Test lead
1
FU 10A
2
3
Traction Controller
+BATT VMN F1 F2 -BATT
A2 F2 F1
A1
TM
Line
+ -
P
PM
FU1
125A
BD:1 24V BATT. BD:2
805980_6
88
ELECTRICS
Troubleshooting CA 200
PLATFORM LOGIC
2901 +BV 1 +BV(AK)
Platform Logic Controller PN 815144 2925 GCSR 2 GCSR INPUT
2929 GCSL 3 GCSL INPUT

WP2300S Platform Logic Box, M502 2928 PLS 4 PLS INPUT
2933 BRS 5 BRS INPUT

Total Pins: 20 2912 DIODE BLOCK-2
UNUSED 6 UNUSED
Used Pins: 11
UNUSED 7 UNUSED
The Truck has THREE modes of operation: uC
2922 SAS 8 SAS INPUT
1 – Walkie Mode
2 – Rider Mode UNUSED 9 UNUSED
3 – No Drive Mode 503 DIODE BLOCK-1 10 BATT NEG
UNUSED 11 UNUSED
Walkie Mode: 2920 CONTROLLER A-8 12 RIDER OUTPUT

1 – All three Inputs are low 2932 CONTROLLER B-5 13 SAS OUTPUT
a – Input Pin 2, GCSR is low AND UNUSED 14 UNUSED
b – Input Pin 3, GCSL is low AND UNUSED 15 UNUSED
c – Input Pin4, PLS is low
UNUSED 16 UNUSED
2919 CONTROLLER A-5 17 BRS OUTPUT

2 – Side restrains are low and PLS is high
UNUSED 18 PS1 INPUT
a – Input Pin 2, GCSR is low AND
UNUSED 19 UNUSED
b – Input Pin 3, GCSL is low AND
c – Input Pin4, PLS is high 2903 +BV (CONTROL) 20 CODE: +BV
814990-7_2A
Rider Mode:
1 – Pin 12 is high when:
a – Input Pin 2, GCSR is high AND
b – Input Pin 3, GCSL is high AND
c – Input Pin4, PLS is high
No Drive Mode:
If the truck is not in Walkie or in rider mode, then it is
NO DRIVE MODE:
a – Pin 12, Rider mode, is low
b – Pin 17, BRS output (A5) is low
SAS output:
Pin 13 is only high when:
a – SAS Input Pin 8 is high AND
b – Input Pin 2, GCSR is low AND
c – Input Pin 3, GCSL is low AND
d – Input Pin4, PLS is low
BRS output (A5):

Pin 17 is high when BRS Input Pin 5 high
AND
The truck is in Walkie / Rider Mode
Code:
Pin 20 is connected to BATT NEG
+BV (AK)
Pin 1 is connected to +BV (AK)
BATT NEG
Pin 10 is connected to BATT NEG

02 Rev. 05/05
M1.0-0000-00093
88_A
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Printed in Germany
M1.0-0000-00094
88_B
ELECTRICS
probably have been thermally overloaded. Ther-
Electric Motors mal overloading (temperatures >160 ºC) causes
the brushes to swell up.
General Maintenance Instructions Brushes which jam in the brush support produce
intense sparking and destroy the collector.
The following instructions apply to all motors. Details
relating to specific models and designs are provided in ● The brush edges must not be cracked. Brushes
the sub-sections (traction motor, pump motor etc.). with cracking along the long edge of the surface
will have been damaged by a worn collector.
Preparation If information is provided in the manual, restore
the collector to the specified limits. Otherwise,
● Disconnect the battery (= EMERGENCY replace the armature in full.
DISCONNECT).
● Loose brush connections are a clear sign of
● Secure the truck from rolling away. motor overload. In this case inspect the collector
for burning and repair or replace as necessary.
Important Maintenance Instructions
● When fitting the brush take care to place the
● Remove all carbon brushes and check for wear.
spring gently on the brush. If the contact is too
If one or more carbon brushes need to be
hard the brush will be damaged.
replaced, replace all brushes. In addition to the
carbon brushes the pressure springs must also
● Make sure that all brushes contact the armature
be replaced to ensure the correct pressure.
at the same pressure.
The length of the shortest brush determines
whether the brush set needs to be replaced. ● New brushes must be run in with a medium load
in the first hours. Never fully charge the motor
Even if the minimum length has not been straight away.
reached the brushes should be replaced as the
remaining useful life could be much shorter than
the time until the next inspection:
If a brush is too short the spring will lie on the

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

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

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

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

brush support (without spring tension) without
tilting. Never modify brushes if one or more
brushes cannot move freely.
In this case replace all brushes as they will
89
ELECTRICS
Traction Motor Maintenance
M1570
Carbon brush
Armature
● A new armature has a max. diameter of 64.5 mm.
● The armature can be overwound provided the
remaining diameter is no less than 61.5mm.
● The armature must be replaced if the diameter is

60.5mm or less.
● After overwinding cut the mica down to a depth of

0.5 mm without changing the gap width between
the multi-plates.
● The multi-plate edges must be carefully de-

burred.
Bearings
M1569 ● The ball bearings are maintenance-free. They
must always be replaced if removed for repair
Access to Brushes work.
● Disconnect the battery
● Remove the tensioning belt from the motor.
Maintenance
● Apply dry compressed air to the motor.
● Remove all carbon brushes and check them with

the armature in accordance with the instructions
in "Key Maintenance Instructions".
● A new carbon brush is 28 mm long
● Carbon brush wear limit: 15 mm
● Refit the tensioning belt.
90
ELECTRICS
Pump Motor Maintenance Maintenance

● Apply dry compressed air to the motor.
Access to brushes
● Remove all carbon brushes and check them with
the armature in accordance with the instructions
in "Key Maintenance Instructions".
● A new carbon brush is 20 mm long
● Carbon brush wear limit: 10 mm
Armature
● A new armature has a diameter of 40 mm. The
wear limit is 38.3 mm.
● The armature must not be overwound. Instead it
must be replaced when the wear limit is reached.
Refit the hydraulic unit as described in CHAPTER 2.
M1522
● Disconnect the battery
● Remove the hydraulic unit as described in

CHAPTER 2.
● Unscrew the commutator bearing lid and remove

the insulating protective cap.
91
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Printed in Germany
92
BRAKE
Printed in Germany
93
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Printed in Germany
M1.0-0000-000100
94M1.0-0000-000100
BRAKE
Brake
Brake fastening screws on the drive motor
(3 off)
M1462
Removal
CAUTION
Do not bring brake components into con-
tact with oil or grease.
17 Reference numbers in brackets refer to Figure M0195-

17
1.
● Disconnect the battery (EMERGENCY DISCON-

NECT).
● Jack up the truck until the drive wheel is free.

Support the truck and prevent it from rolling
away.
● Remove the front panel.

M0195-1
● Blow away any brake dust.
● Undo the electrical connection (CA407) for the

brake wiring (20).
● Unscrew the three Allen screws (3).
MS-WP2300 04/03 • Printed in Germany MS-5.0-1723
95
BRAKE
● Measure the thickness of the rotor (16). Replace
the rotor if it is less than the minimum permissible
thickness of 6.0 mm (new rotors are 10 mm
thick).
● Unscrew the friction plate (18) from the motor

flange.
New friction plates are 1.0 mm thick. Replace if
necessary.
● Unscrew the screws (8) from their respective

nuts.
● Remove the banjo bolts (17) from the magnetic

body (3 off).
● Remove the armature plate (14).
● Thoroughly clean and de-grease the parts.
Test and Inspection

● Check the armature plate (14), friction plate (18)
and rotor (16) for signs of even wear, deep
grooving, cracking and burning. Replace any
worn or damaged components.
● Check the crimp connections of the brake wiring

in connector CA407 for loose or broken wires.
Replace any damaged crimp connections.
● Check the coils of the magnetic body (7) with an

ohmmeter. To do this, on connector CA407
measure between ...
CA407-1 and CA407-2 (BR/1): 10,5 ± 1 Ohm
CA407-3 and CA407-4 (BR/2): 33 ± 3 Ohm
Replace the magnetic body if the resistance
17 17 recordings of a coil lie outside the tolerance
range.
● Check the sealing compound (insulating com-

pound) which secure the coils in the magnetic
body for cracks.
Replace the magnetic body in the event of
cracking.
M0195-1
Assembly
● If the pressure parts (11) and springs (12) have
fallen out of the magnetic body (7), insert them
again: first the springs, then the pressure parts.
● Remove the magnetic body (7) from the motor
(including everything connected to it). ● Insert the spring (10) and bushing (13) into the
magnetic body (7).
Disassembly
● Position the armature plate (14) correctly on the
● Remove the rotor (16) from the hub (15). magnetic body, while noting carefully the hole
Take care not to damage the gear teeth. pattern.
MS-5.0-1723 MS-WP2300 04/03 • Printed in Germany
96
BRAKE
● Using a medium strength screw sealant screw Air Gap Setting
the banjo bolts (17) into the magnetic body (7) as
far as the stop. The operating air gap is measured between the mag-
netic body and the armature plate when the truck is
● Insert the screws (8) into the armature plate so braked. Set the air gap to 0.25 mm (see Fig. M1467).
far that a gap of at least 1mm remains all around
between the armature plate and the magnetic ● Unscrew the banjo bolts (3) as far as the fixed
body. stop on the friction plate (18).
● Screw the friction plate (18) onto the motor. ● Torque the Allen screws (3) evenly to 9.5 Nm.
● Push the rotor (16) onto the hub (15). Ensure that ● Test the working air gap at several points around
the gear teeth are not damaged in the process. the circumference using a feeler gauge.
The air gap must be the same all the way around.
● Fasten the pre-assembled magnetic body (7) to
the motor with the Allen screws (3). ● To increase the air gap slightly unscrew the banjo
bolts (17). To reduce the air gap screw the banjo
● Re-fit the electrical connector (20). bolts (17) into the magnetic body (7). Then re-
measure as described above.
Assembly
● When the air gap has been correctly set, torque
Re-assemble the brake in the reverse order of re- the Allen screws (3) again to 9.5 Nm.
moval.
CAUTION
After assembly it is essential to set the air

gap correctly, test the braking distance
(see following page) and if necessary set
the brake moment.
Fastening screw
Banjo bolt
Operating air gap
Rotor thickness
M1467 De-energised brake
97
BRAKE
Brake Moment Setting If necessary turn up the nose of the retaining sheet
and change the brake moment using the outer ring
until the braking distance is within tolerance when the
Inner ring truck is empty (see Table B0 1S-GB) .Now fix the outer
Outer ring ring again using the retaining sheet.
NOTE
If the max. travel speed is the same with or

without nominal load, the load-dependent
Retaining Sheet pressure switch is either faulty or incor-
rectly set. The braking distance will also be
M1535
much too long. In this case check the
load-dependent pressure switch before
adjusting the 2nd brake stage (See Chapter
The brake moment can be set separately for the first 2, HYDRAULICS)
and second stages. Screw the outer ring into the
magnetic body to increase the moment of the first After setting the 1st stage test the brakes with maxi-
stage (BR/1). Screw in the inner ring to increase that of mum load.
the second stage. If necessary, remove the retaining screw (4, Fig.
M0195-1) from the inner ring and using the threaded
The settings are pre-set, determined by the retaining ring (6) change the brake moment until the braking
elements (retaining sheet for first stage and retaining distance (see Table B0 1S-GB) is within the tolerance
screw for the second stage). Intermediate settings are range with maximum load. Now secure the inner ring
not possible, as the retaining elements must remain again using the screw (4) and washer (5).
effective.
The default settings can be found in table B0 1S-GB

(screw depth A).
Testing the Brakes

● On a level, dry concrete surface with sufficient
grip accelerate the unladen truck, at operating
temperature with a fully charged battery, up to
maximum speed.
● Set the control handle to the lower brake zone.
● Record the braking distance from the point of

brake activation to the time when the truck M0195-1
comes to rest.
WP2300S Nominal Braking Distances and Screw Depth
Braking Distance Braking Distance

Model Capacity Screw Depth A
(new brake) (used brake)
Laden Laden
(nominal Unladen (nominal Unladen
load) load)
2330 Inner ring = 6.6 mm

2.000 kg 1.95 - 2.05 m 1.85 - 1.95 m 1.85 - 1.95 m 1.75 - 1.85 m
2335 Outer ring = 6.4 mm
B01-S-GB
MS-5.0-1723 MS-WP2300 04/03 • Printed in Germany
98
STEERING
Printed in Germany
99
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Printed in Germany
100
STEERING
Multitask Handle - Springs for

Return Function
1
CAUTION
Pre-tensioned springs!
8
When removing, take care to avoid injury.
Before carrying out any work on the tiller:

2
● Remove the battery connector (EMERGENCY 3

STOP).
● Block the truck.

7 4
Adjustment
5
The axle (4) is fitted as standard on the left hand side
with a tensioning pin (5). If the spring pressure reduces 6
over time the spring pre-tension (2) can be increased
as follows:
● Unscrew the panel (1) and push it up.
● Leave the tiller (8) in the rest position (up).
● Drive out the tensioning pin (2) on the left-hand

side.
● Using a face spanner (3) turn the axle (3) as far

as necessary. Drive in the tensioning pin (2) on M1562
the right-hand side.
● If the spring tension is still not sufficient to keep

the tiller up, replace the springs.
Removal ● Drive the axle (3) as far out to the right hand side
so that the 2 springs (4) can be removed.
● Unscrew the panel (1) and push it up.
● Bring the tiller (8) to its highest position and keep Assembly
it there.
● Push the springs (4) onto the axle (3). The inner,
offset end must insert into the axle (3) groove. A
● Mark the position of the axle (3).
strap wrapped around the inner end of the first
spring to be inserted can prove useful when
● Drive out the tensioning pin (2).
inserting the other springs.
The relieved springs should now turn the axle.
● Drive the axle (3) into position.
● Tilt the tiller down to its lowest position.
● Set the tiller (8) to the upper limit.
● If the axle (3) has still not turned, it is clearly fixed
in its position and must be moved with the aid of
● Drive in the tensioning pin on the left-hand side
a face spanner. To fully relieve the springs, rotate
(if necessary on the right). Turn the axle as far as
the axle (3), seen from the left hand side, approx.
necessary. Grease the springs. Fasten the panel.
20° anticlockwise from the fixed position.
Check the brakes.
M1.0-0000-000107
101
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102
STEERING
Control Handle Grip
Main Components
This section contains an overview of the main compo-
nents and associated terms:
Upper shell
Control handle tube
Switch unit
Grip
MS518
Lower shell

02 Rev. 05/05
103
STEERING
Hand grip component removal and Hand Grip Shells
assembly
Upper and lower shell removal
To access the individual components of the hand grip
you will require:
Torx® screwdriver set and a small flat bladed screwdriver.
CAUTION
Short circuit danger!
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. A
MS513
● Remove the four Torx® screws (A, Fig. MS513).
MS514
● 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 lower shell.
● Disconnect the plug connections from the control

handle wire harness and the horn switches from
the switch unit printed circuit boards.

02 Rev. 05/05
104
STEERING
A
MS501
● Remove the inner Torx® screws (A) and pull off
the grips (see Fig. MS501).
MS502
● Using a small flat bladed screwdriver lever off the

cover on each hand grip (see Fig. MS502).
MS503
● Gently press in the horn switch until pull it out of

the grip (see Fig. MS503). Disconnect the plug
connection from the switch.
MS517
B
● Remove the two Torx® screws (B) and the six

Torx® screws (C) (see Fig. MS517). Lift out the
shells.
Upper and lower shell assembly
Assembly is the reverse of disassembly. When assem-

bling, take care not to damage the wiring.

02 Rev. 05/05
105
STEERING
Switch Unit ● Disconnect the plug connections of the control
handle wire harness and the horn from the switch
unit PC boards.
Disassembly
The switch unit contains the safety reverse switch, the

Switch unit assembly
travel switch, the “rabbit/turtle” switch, the main PC board
and the pump controller PC board. Assembly is always the reverse of disassembly.
Replacing any of these components requires the switch Make sure you re-connect the control handle wire har-
unit to be replaced. ness and the horn wiring. The connectors cannot be in-
terchanged and are protected against incorrect polarity.
Guide the switch unit over the two side parts (C, Fig.
MS514) and push the switch unit down and forward.
Tighten the mounting screws (A, Fig. MS513).
Test all the functions once the battery has been re-con-
nected.
A
MS513
● Remove the 4 Torx® screws (A, Fig. MS513).
MS514
● Press the thumb markings (B, Fig. MS514) on the

switch unit or pull on the thumbwheels (B). The
switch unit will slide up out of the bottom shell.

02 Rev. 05/05
106
STEERING
“Rabbit/Turtle” toggle switch Assembly
There are no parts on this switch module that can be ● Insert a new toggle module and fix it with 2 Torx®
repaired. It must be replaced in full. screws.
This switch module is available in two versions: a ● Refit the switch unit (see SWITCH UNIT section in
standard and a cold store version. Make sure you use this chapter). Test the operation.
the right module!
MS504
Hydraulic PC board
A
There are no parts on this PC board that can be repaired.
MS511 It must be replaced in full.
This PC board is available in two versions: a stand-

Disassembly ard and a cold store version. Make sure you use the
right circuit board!
● Remove the switch unit (see SWITCH UNIT section
in this chapter).
Disassembly
● Remove the two Torx® screws (A) (see Fig.
MS511) and remove the toggle module.
in this chapter).
● 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
hydraulic PC board.
Assembly
● 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).
● Refit the switch unit (see SWITCH UNIT section in

this chapter). Test the operation.

02 Rev. 05/05
107
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107_A
STEERING
Main PC Board Removal/Installation ● Remove the two (A) Torx® screws from the
larger, main PC board (the smaller one is the
This PC board is available in two versions: a standard hydraulic PC board). Disconnect safety reversing
and a cold store version. Make sure you use the right PC switch lead connector from main PC board and
board! remove board.
INFORMATION To install, reverse removal procedures.
Because of the compact design, it may

be somewhat difficult to access the
connector on the main PC board through
this process. If you experience difficulties
replacing the board using above procedures,
remove thumb wheels, lower cover and
control handle cap cover (see Traction
Potentiometer Assembly in this section).
There are no parts on this board that can be repaired. It

must be replaced in full.
● Remove control handle cap (see Control Handle

Cap in this section).
● Disconnect potentiometer connector from main

PC board.
Main A
PC Board
10682

02 Rev. 05/05
107_B
STEERING
Potentiometer C
There are no parts on the potentiometer that can be re-

paired. It must be replaced in full. The potentiometer is
available in two versions: a standard and a cold store
version. Make sure you use the right potentiometer!
A MS509
● Remove the four Torx® screws (C) shown in Fig.

MS509. Remove the switch unit cover.
B MS508
Disassembly

in this chapter).

MS508) from the thumbwheels and disconnect
the thumbwheels. Take care not to lose the
plastic slide bearings (washers). MS510
● Remove the two Torx® screws (B) holding the ● Remove the two Torx® screws (D) shown in Fig.
orange lowering switch cap. Lift out the switch MS510. Remove the connectors from the PC
cap. boards. Pull the potentiometer off the square
axis.
Assembly
● Before connecting the cable to the potentio-

meter: Fill the potentiometer bushing with
grease part no. 053002-005. Do not use any
other grease.
Potentiometer assembly is the reverse of disassembly.

02 Rev. 05/05
108
STEERING
Safety Reverse Switch ● Remove the two Torx® screws (B) holding the
orange lowering switch cap. Lift out the switch
cap.
Disassembly
E
F
MS500
B MS508
● Remove the four Torx® screws shown in Fig.
● Remove the switch unit (see SWITCH UNIT section MS509. Remove the switch unit cover.
in this chapter).
INFORMATION
MS508) from the thumbwheels and disconnect The thumbwheels cannot be incorrectly
the thumbwheels. Take care not to lose the positioned. They will only fit correctly in
plastic slide bearings (washers). one position.
● Remove the Torx® screw (item D, Fig. MS500)

and pull out the switch bypass (item E).
C
● Remove the two Torx® screws item F). Discon-
nect the microswitch from the main PC board.
Assembly
● 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 grease.

this chapter) and test the operation.
MS509

02 Rev. 05/05
109
STEERING
INFORMATION Assembly
The thumbwheels cannot be incorrectly INFORMATION
positioned. They will only fit correctly in
one position. 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 disas-

sembly.

MS502
Horn switch
Disassembly
MS503
● Remove the switch unit (see SWITCH UNIT

section in this chapter).

hand grip cover (see Fig. MS502).

the grip (see Fig. MS503). Disconnect the plug
connection from the switch.

02 Rev. 05/05
110
STEERING
Hand Grip
Disassembly

in this chapter).
MS501
Assembly
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 hand grip in the reverse order of disas-

sembly.

MS502
MS503

hand grip cover (see Fig. MS502).

the grip. Disconnect the plug connection from the
switch (see Fig. MS503).
● Unscrew the inner Torx® screw (see Fig. MS501)

and pull the hand grip off.

02 Rev. 05/05
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112
LIFTING MECHANISM
Printed in Germany
113
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114
LIFTING MECHANISM
Lift Linkage ● Repeat procedure on second fork tine.
● Measure the fork height above the lift joint pivot

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

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

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

right when the fork is lowered.
Lift joint stop Stop points
● Tighten counternuts (14). (both sides)
Lift 130 mm ± 5 mm
+3
85-3 mm 85 -3 mm
MS1723-701
M1.0-0000-000123
115
LIFTING MECHANISM
Loadwheel, tandem
M1438
116
LIFTING MECHANISM
Lift Limit Cutout
Lift Limit Cutout Setting

● Fully lower the forks.
● Raise the forks from this postion without rated

load.
● Check the lift height at the fork tip (see previous

page). If the lift height lies outside the tolerance
range, check the mechanical setting of the lift
linkage and adjust if necessary.
● If the mechanical setting of the lift linkage is

correct and the lift height is still outside the
tolerance range, move the lift limit switch (LMS)
into the elongated holes until the lift limit cutout
(pump no longer operates) takes place at a lift
height of 130 mm ± 5 mm.
Limit switch fitted for lift Upper hole: Limit switch location for
cut-out at 130 mm max. lift = 150 mm
Trip cam
Track
M1473
Elongated hole for fine adjustment of lift cut-out point
M1.0-0000-000125
117
Blank Page
118
CYLINDERS
Printed in Germany
119
Blank Page
Printed in Germany
M1.0-0000-000128
120
M1.0-0000-000128
CYLINDERS
Lift Cylinders
Operation
The two lift cylinders are single-acting. The piston rods
are raised by the hydraulic oil pressure and lowered by
the weight of the raised load. Fig. M1475 shows a
cylinder cross-section. Piston Rod
Removal Scraper
● Remove the front panel.
Guide Ring
● Extend the piston rods until the left piston rod
attachment comes to rest next to the contactors
and controller so that the dowel pin can be driven Seal
out.
● Support the fork carriage with wooden blocks or Guide Ring

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

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

rising the system. Keep hands and feet
away from screw holes as high-pressure
fluids can emerge at these points.
● Use paper or cardboard to trace leaks.
Do not use your hands.
M1.0-0000-000129
121
CYLINDERS
● First drive out the dowel from the left-hand piston
rod attachment between the contactors and
controller so far as to be able to check whether
the pin collides with the contactor or controller
when it is fully driven out.
● De-energise the pump motor and prevent it from

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

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

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

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

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

cylinders.
● Lift out the lift cylinders from the chassis.
M1474
Bracket
M1.0-0000-000130
122
CYLINDERS
Inspection Replacing the Piston Seal
Carefully examine the cylinder unit prior to carrying out NOTE
repair work. To do this, extend and retract the cylinder
several times. Check the seal groove and piston rod
(critical seal location) for damage before
● Check the piston rods for signs of nicks, fitting a new seal.
scratches or other damage to the surface. Failure to do so will otherwise result in
repeated leakage.
● Check the scraper rings for wear and unusual
leakage.
Use burr-free assembly tools and equipment made of
● If any excess hydraulic oil is leaking from the soft metal or a suitable plastic without sharp edges to
piston rod this may be due to a damaged rod replace piston seals. Do not use a screw driver or
seal. Replace the rod seal and make sure that similar tools as these could damage the seal edges.
the seal seat is clean and intact.
If a new seal must be inserted over sharp edges, slots
● When repairing the cylinder check the condition or corners, take appropriate protective measures.
of the guide rings. Ideally, all seal components
should be replaced, not just worn or damaged
seals.
● Minor irregularities on the cylinder tube surface

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

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

with hydraulic oil before fitting them.
M1.0-0000-000131
123
Blank Page
124
PLATFORM
Printed in Germany
125
Blank Page
Printed in Germany
126
M1.0-0000-000134
M1.0-0000-000134
PLATFORM
Folding Platform ● Remove the panel (23).
● The brake arm (11) and the brake lining (12)

Mechanical Setting brake the platform (1) when it swings up. Turn in
the screw (14) to increase the friction, turn it out
WARNING to reduce it.
This is a critical setting. The platform must ● Adjust the braking effect so that the platform can
always swing up whenever the driver swing up by itself, with the damping effect, from
leaves the truck. The platform switch is any position. The critical point is a platform angle
actuated and the maximum travel speed of approx. 45 degrees above the horizontal
reduced. position.
M1550
M1.0-0000-000135
127
PLATFORM
Platform Switch Setting (PLS) ● Remove the panel (23).
The switch sends a signal to the traction controller. This ● Loosen the screw (4).
causes the traction controller to switch to a higher max.
travel speed for platform mode when the platform folds ● With the platform lowered twist the adjusting ring
down. (3) so that the switch is activated. Actuation must
occur between 0 degrees (fully lowered platform)
The switch lever for the platform switch (21) is activated and max. 10 degrees for the raised platform. The
via the adjusting ring (3). A screw (4) on the shaft (10) switch must not be activated above 10 degrees.
prevents the adjusting ring from twisting. Now tighten the screw (4) again and check the
setting.
WARNING
This is a critical setting. The platform must
always swing up whenever the driver
leaves the truck. The PLS must then be
actuated within 10 degrees.
M1550
M1.0-0000-000136
128
PLATFORM
Platform Suspension
Plate Spring Layers
To achieve optimal lifespan and spring quality of the
platform, layer the plate springs with 6 sets of 3 springs
and one set of 2 springs.
MS1720-101
M1.0-0000-000137
129
PLATFORM
Side Gates, Mechanical Setting
● Remove the panel (10)
● The setting of the brake (5) determines the

manual force required to fold the side gates in or
out. Turn in the screw (12) to increase the force,
turn out to reduce it.
● Adjust the brake so that the gates can be

handled with medium manual force.
M1546
M1.0-0000-000138
130
PLATFORM
Fixed Platform WP2335S
Replacing the Safety Switch

● Remove screw (A).
● Raise the upper section of the platform (B) and

remove the safety switch plug connection.
● Remove the upper section of the platform.

Remove the safety switch (C).
C
MS-1723-901
B
MS-1723-900

02 Rev. 05/05
M1.0-0000-000139
131
PLATFORM
Replacing the Safety Switch

● Remove screw (A=15).
● Raise the upper section of the platform (B) and

remove the Safety Switch plug connection.
3
4
● Remove the upper section of the platform.
7 Remove the Safety Switch (29).
2
6
8
5
3
4 6 4
3
7
8
9
1
10
12
18
17 B
11 19
15 =A C
35
14 34
36
35
38
13
24
24 24 43
26 24
34 39
C 16 27 45
35 25 44
43 40 41 31
44 23 28
45 42
38 24 24 20
31
26
24 27 21 22
25
41 28
37 42 30
24 23 33 FPS 1 & FPS 2 (29)
20
31 32
Entry Bar (34) 21 29 MS-1723-003
22

02 Rev. 05/05
M1.0-0000-000140
131_A
PLATFORM
Replacing Switches below the Entry

Bars (FPS 1 & FPS 2)
● Remove screws (A=15).
● Raise upper platform section (B) and disconnect

the plug connection to the platform switches.
● Remove the upper platform section. Remove the

switch (44).
3
4 When assembling, ensure that the switch is not dam-
aged by the mechanical elements.
7
2
6
8
5
3
4 6 4
3
7
8
9
1
10
12
18
17 B
11 19
15 =A C
35
14 34
36
35
38
13
24
24 24 43
26 24
34 39
16 27 45
C 35 25 44
43 40 41 31
44 23 28
45 42
38 24 24 20
31
26
24 27 21 22
25
41 28
37 42 30
33
24 23
20
FPS 1 & FPS 2 (29)
31 32
21 29 MS-1723-003
Entry Bar (34) 22

02 Rev. 05/05
M1.0-0000-000141
132_A
Blank Page
132_B
ELECTRICAL DIAGRAMS
Printed in Germany
133
Blank Page
Printed in Germany
134
Blank Page
Printed in Germany
135
DIAGRAMS
Notes to overall wiring diagram,
standard version, folded platform,
WP2330S
Key:
1 Walkie mode
GCSR &/ or PLS &/or GCSL open
2 Forks above 130 mm; LMS open
3 Load < 1000 kg; PS closed, 2/3 brake force
4 Reduce speed: HSS open
5 Active: RAS, BRS, SAS, HNS & LOS closed
6 An SAS signal is required to produce a travel

signal from the FS and RS drivers.
7 Diagnostic LED. Remove to connect programmer.
8 Voltage between B1 and B2 (traction controller)

10 v = Full speed
0 v = No command
MS-DIA-1723 WP2300S 05/2005 • Printed in Germany

02 Rev. 05/05
136 146
DIAGRAMS
Overall Wiring Diagram, Standard, Folded Platform, WP2330S ( ) Colours in brackets correspond to the old revision pre-August 2003
202 KYS COMM +BV 203 JC404-7 BDI +BV
FU2 2901 PC404-2 BDI +BV (AK)
10A TCM SEM1
201
KYS
202 KYS COMM +BV 2 CA 202
c LMS
A 2916 PC404-3 RAS SIG
2917 1 002 PC415-4 RAS SIG
1 5900 PC404-1 TT
2 2902 +BV (AK) 2927 D4 5905 2919 LOS SIG 2 003 PC415-5 LOS SIG
160A
3 5903 BATT NEG

FU1
2908 C1 +BV (AK) 3 001 PC415-2 +BV(AK)

4 5904 BATT NEG
5902 PC407-2 BATT NEG 2913 HNS SIG 4 004 PC410-10 HNS SIG
5 2923 PC407-1 BRS SIG
+BATT 001 JC 406-3 BRS SIG 2928 PC407-1 BRS SIG
A1 6 2 2922 NOT USED 5 012 PC415-7 NOT USED
500 PC 404-5 BATT NEG
BD:1 7 2904 JC103-2 +BV (AK) 2921 4 D2
D1 504 P- BATT NEG 6 013 PC410-1 BATT NEG
002 PC 406-2 +BV (AK) BRS D3 506 PC 407-4 BATT NEG
8 2920 JC102-2 PL SIG 2911 1
3 5
5
2924 PC407-3 BRS / PS SIG CA 404
CURTIS 803 "COMBI"

B 8
5900 A1 TT 1 TT
2911 PS SIG
BRN (010) PC410-7 POT SIG
5903
A2 1
VMN POT CIRCUIT
505 P-
2 BLU (011) PC410-8 POT LOW 2901 BDI +BV (AK) 2 KYS
& DRIVER
BATTERY
3 RED/BLU (009) PC410-5 POT HIGH

- 2916 RAS SIG 3
24V
TM 4 BLK (007) PC410-4 RS SIG LINE 2915 RAS SIG 4

5 GREY/PINK (005) PC410-2 SAS SIG
YEL (008) PC410-3 FS SIG
3 + 500 A6 BATT NEG 5 BATT NEG
F1 6 PS
+ F1
2909
UNUSED 6 UNUSED
2910
203 KYS COMM 7 BDI
C 2908 JC202-3 +BV (AK)
1 2909 UNUSED 8 UNUSED
RED
PM - 2 2921 PS SIG
3 WHT/GRN (006) PC414-3 R/T (HSS) SIG
FAN +
BD:2
2913 JC 202-4 HNS SIG CA 406
D
1 UNUSED HN
F2 + - - UNUSED 1 RED
F2 2 2912 HNS SIG 2927 D4
002 A7 +BV (AK) 2 BLK BRS
3 501 BATT NEG
5
4 2914 RAS SIG 001 A5 BRS SIG 3 WHT
2915 PC404-4 RAS SIG
BLK
5 502 BATT NEG UNUSED UNUSED
4
6 2918 LOS SIG
E + -
-BATT P CA 407
1 + RXD
+ BR/1
504 JC202-6 2928 DIODE BLOCK (2) BRS SIG 1 BLK
2 RXD NEG + -
505 DB(1) SV 503 -
3 + TXD 5902 DIODE BLOCK (4) BATT NEG 2 BLU
4 TXD NEG - + 2919 JC202-2 LOS SIG BR
+ BR/2
2924 DIODE BLOCK (5) BRS / PS SIG 3 BLK
5 BATT NEG
-
6 + BV (AK) 7 506 DIODE BLOCK (1) BATT NEG 4 BLK
7 UNUSED
8 UNUSED CA 101
CA 411 UNUSED 1 RED
CA 415 CA 410 1
POT 2906 2 BLK GCSL
2
2961 PC410-9 +BV(AK) 1 GRN (013) PC202-6 BATT NEG 1 1
3 2903 3 WHT
WHT (001) PC202-3 +BV(AK) 2 GREY/PINK (005) B-5 SAS SIG 2 4
ACS
UNUSED 4 UNUSED
FS
2961 PC414-1 +BV(AK) 3 YEL (008) B-6 FS SIG 3 5
6
RS
VIO (002) PC202-1 RAS SIG 4 BLK (007) B-4 RS SIG 4 CA 102
RAS 5 LOS 7
PINK (003) PC202-2 LOS SIG 5 RED/BLU (009) B-3 POT HIGH 5 UNUSED 1 RED
6 CA 412
BLK
261 PC410-11 NOT USED 6 5961 PC415-8 NOT USED 6 3 2920 A8 PL SIG 2 BLK PLS
GRAY 1
1 SAS
RED (012) PC202-5 NOT USED 7 BRN (010) B-1 POT SIG 7 SAS 2906 PL SIG 3 WHT
2
BLU 5
1
5961 PC410-6 NOT USED 8 BLU (011) B-2 POT LOW 8 UNUSED 4 UNUSED
CA 413
2962 PC415-1 +BV(AK) 9 1
CA 417
HYDRAULIC PCB CA 103
2 5
1
2 HNS1
GRAY (004) PC202-4 HNS SIG 10 1 UNUSED 1 RED
3
2904
CA 414 261 PC415-6 NOT USED 11 2903 HNS1
4 2904 A7 +BV (AK) 2 BLK GCSR
CA 419
2902 1
2961 PC415-3 +BV(AK) 1 5962 PC414-4 NOT USED 12 5 2 2903 PL SIG 3 WHT
HNS2 5
1
6
2901 1
UNUSED 2 4 UNUSED 4
HNS2 UNUSED
HSS MAIN PCB
WHT/GRN (006) C-3 R/T (HSS) SIG 3
5962 PC410-12 NOT USED 4

813202-Standard_Folded_Rev2B
R/T SWITCH
WP2300S 05/2005 • Printed in Germany MS-DIA-1723

02 Rev. 05/05
137
DIAGRAMS
WP2330S STANDARD, FOLDED PLATFORM WP2330S STANDARD, FOLDED PLATFORM
SCHEMATIC DIAGRAM TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT
TCM SEM1 2903 PC200-20

PS 3 FS
RS
2901 PC200-1 BDI
A 2900 PC404-2 BDI
POT
D4
c
9
DIODE BLOCK BRS 5 5
3
1 5900 PC404-1 BDI KYS 200 PC404-7 BDI
5
HNS 1
HNS 2
SAS
2
2 2902 203 FU2 OUT +BV
BR SMALL COIL 5
5 3 5904
BR LARGE COIL
1
RAS LOS
4 4 5902 DIODE BLOCK (4)
HYDR. PCB
HSS
8 5 2918 PC200-17
LINE
R/T PCB
MAIN PCB
6 UNUSED
INSTRUMENT 2932 JC406-2 BRS
CURTIS 803 "COMBI" 2 7
c
LINE
2919 JC103-2 GCSR
TT 1 LMS
2920 PC200-12
8
2921
2930
KYS 2 8
3
4
BATT NEG 5 8
GCSR
UNUSED 6
7
BDI 1
B PS
UNUSED 8
GCSL
FAN 1 BRN (010) PC410-7 POT WIPER

1
POT CIRCUIT
2 BLU (011) PC410-8 POT LOW
& DRIVER
2910 DIODE BLOCK (3)

PLS
HN
1
4 BLK (007) PC410-4 RS
5 2933 PC210-2
10 5 2 3 4
20 6 YEL (008) PC410-3 FS
1 8 P SV
10
17 13
12
9
C 2914 JC202-3 +BV (AK)
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
1 2921
C
D
A
TCM (SEM 1)
2 2909 DIODE BLOCK (3)

3 WHT/GRN (006) PC414-3 HSS
FAN
+BATT
-BATT
VMN
E
F1
F2
2
3
4
5
6
7
8
1
2906 PC404-4 +BV

HN
A2 F2 F1
7 D 2915 JC 202-4
KYS
1 UNUSED
A1
2 2916
TM
8 505
NOTE: 3
FU2 LINE
10A
1- Walkie Mode: GCSR&/or PLS &/or GCSL open. 4 2907 P
+ - 2- Forks lower than 130mm: LMS closed. 5 506
P
3- Load is less than 1000kg: PS closed, 2/3 brake. 6 2917 SV 507
FU1 PM 4- Reduce speed: HSS is open.
160A 2913 JC202-2
BD:1 24V BATT BD:2
5- Active: RAS, BRS, SAS, HNS & LOS are closed.
8- Diode Block Pin 1, BDI (BATT NEG), Main PCB
(Earth contact), connected to Pump Contactor Contacts.
9- Diode Block Pin 3 connected to Controller C-2.
814990-1_2A.pdf 814990-2_2A.pdf
Used from S/No. 5A336576 on, but not on S/No. 5A337937

02 Rev. 05/05
138 148
DIAGRAMS
TRACTION CONTROLLER - SEM1 POWER CIRCUIT PLATFORM CIRCUIT
CA 101
204 JC202-5 NOT USED 203 KYS IN
TCM SEM1
2926 1 RED
FU3 FU2 GCSL
not mounted 10A A 2927 2 BLK
202 HOUR METER OUTPUT
201
1
FU1 LINE 2929 PC200-3 3 WHT
160A KYS +BV IN TO THE LOGIC 2
LINE CONTACTOR LOW 3 4 UNUSED
BRAKE LOW (large coil) 4
BRS INPUT 5 CA 102
BATTERY NEG 6
1 RED
BATTERY POS (AK) 7 PLS
WALKIE/RIDER MODE 8 2927 2 BLK
A1 +BATT WHT
B 2928 PC200-4 3
BD:1 POT WIPER 1
4 UNUSED
POT LOW 2
POT HIGH 3 CA 103
RS - REVERSE SWITCH IN 4
SAS SAFETY SWITCH IN 5 2926 1 RED
GCSR
FS - FORWARD SWITCH IN 6
2919 CONTROLLER A7 +BV (AK) 2 BLK
A2
VMN
C 2925 PC200-2 3 WHT
BATTERY POS (AK) 1
24V PERF.CUT 2
4 UNUSED
BATTERY TM
PERF. 1/2,HSS (R/T) INPUT 3 NOTE:
GCSL, PLS & GCSR are shown in walkie mode.
F2
+ F1
D DIODE BLOCK
UNUSED 1
HN - HORN HIGH 2
HN - HORN LOW 3 501 PC407-4 BR LOW D1
502 P CONTACTOR CONTACTS 1
P - PUMP CONTACTOR HIGH 4
503 PC200-10
BD:2
- P&SV-P CONTACTOR LOW 5
D2
PM SV - LOWERING VALVE HIGH 6 2911 PC407-1 BRAKE
2
2912 PC200-5
F1
F2 E
2909 CONTROLLER C-2 D3
POSITIVE SERIAL RECEPTION 1 3
2910 PS
NEGATIVE SERIAL RECEPTION 2
P 5902 CONTROLLER A-4
POSITIVE SERIAL TRANSMISSION 3
5903 PC407-2 4
NEGATIVE SERIAL TRANSMISSION 4
5901
BATT NEG 5
BATTERY POS (AK) 6 2908 PC 407-3 5
D4
UNUSED 7
UNUSED 8
-BATT 2904 JC406-3 BRS-5
502 DIODE BLOCK (1) 504 JC202-6
500 PC404-5 814990-3_2A.pdf 814990-4_2A.pdf
NOTE:
1- Voltage between B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND Used from S/No. 5A336576 on, but not on S/No. 5A337937

02 Rev. 05/05
139
DIAGRAMS
POWER UNIT CIRCUIT CONTROL HANDLE CIRCUIT
CA 202 CA 411
CA 410 1
2905 PC404-3 BDI 2934 1 VIO (002) PC415-4 RAS POT
2
LMS GRN (013) PC202-6 1
2913 SV HIGH 2 PINK (003) PC415-5 LOS 3
GRAY/PINK (005) B-5 SAS 2 4
POT
2914 CONTROLLER C1 3 WHT (001) PC415-2 +BV(AK) FS
YEL (008) B-6 FORWARD 3 5
2915 HN HIGH GRAY (004) PC410-10 HN RS

4 6
BLK (007)B-4 REVERSE 4
7
204 +BV FU3 OUT 5 RED (012) CA415-7 +BV F/C RED/BLU (009) B-3 POT HIGH 5
CA 412
504 P CONTACTOR CONTACTS 6 GRN (013) CA410-1 BATT NEG BLK
5961 PC415-8 NOT USED 6 3
GRAY
1 SAS
BRN (010) B- POT SIGN 7 SAS
2
BLU
CA 404 BLU (011) B-2 POT LOW 8

INSTRUMENT CA 413
CA 417
2962 PC415-1 +BV(AK) 9 1
2
CURTIS 803 "COMBI" 2 HNS1
GRAY (004) PC202-4 HN 10 1
5900 CONTROLLER A1 TT 1 TT 3 2904 HNS

261 PC415-6 NOT USED 11 4 2903
CA 419
2900 KYS NO + BV(AK) 2 KYS 5962 PC414-4 NOT USED 12 5 2902 2
HNS2
2905 LMS OUT NC +BV 3 6 2901 1
HNS
MAIN PCB
2906 P CONTACTOR COIL 4
500 P CONTACTOR CONTACTS 5 BATT NEG CA 415
UNUSED 6 UNUSED 2962 PC410-9 +BV(AK) 1
200 KYS +BV 7 BDI WHT (001) PC202-3 +BV(AK) 2
2961 PC414-1 +BV(AK) 3

UNUSED 8 UNUSED
VIO (002) PC202-1 LMS 4
RAS LOS
PINK (003) PC202-2 SV HIGH 5
CA 406 261 CA410-11 NOT USED 6
RED (012) CA202-5 NOT USED 7

UNUSED 1 RED
5961 PC410-6 NOT USED 8
2904 DIODE D4
2 BLK BRS
2932 CONTROLLER A-7
HYDRAULIC PCB
2931 PC200-5 3 WHT
UNUSED 4 UNUSED CA 414
2961 PC415-3 +BV(AK) 1
CA 407 UNUSED 2
HSS
LARGE COIL WHT/GRN (006) CONTROLLER C-3 3
2911 DIODE BLOCK (2) 1 BLK
5962 PC410-12 NOT USED 4
5903 DIODE BLOCK (4) 2 BLU
SMALL COIL BR R/T PCB
501 DIODE BLOCK (1) BLK 814990-5_2A.pdf 814990-6_2A.pdf

4

02 Rev. 05/05
140 150
DIAGRAMS
WP2330S STANDARD, FOLDED PLATFORM
PLATFORM LOGIC
PLATFORM LOGIC
CA 200
2901 +BV 1 +BV(AK)
2925 GCSR 2 GCSR INPUT
2928 PLS 4 PLS INPUT

2912 DIODE BLOCK-2
UNUSED 6 UNUSED
UNUSED 7 UNUSED
uC
UNUSED 9 UNUSED
503 DIODE BLOCK-1 10 BATT NEG
UNUSED 11 UNUSED
2920 CONTROLLER A-8 12 RIDER OUTPUT
2932 CONTROLLER B-5 13 SAS OUTPUT
UNUSED 14 UNUSED
UNUSED 15 UNUSED
UNUSED 16 UNUSED
UNUSED 18 PS1 INPUT
UNUSED 19 UNUSED
2903 +BV (CONTROL) 20 CODE: +BV
814990-7_2A.pdf

02 Rev. 05/05
141
DIAGRAMS
standard version, fixed platform
WP2330S
Key:
1 Walkie-mode
GCSR &/ or PLS &/or GCSL open
2 Forks above 130 mm, LMS open
3 Load < 1000 kg PS closed, 2/3 brake
6 Electronic thermal switch, applies earth for F/C

HR when temperature < +5°C.
7 An SAS signal is required for a travel signal from

the FS and RS drivers.
8 Diagnostic LED. Remove to connect the program-

mer.

10 v = Full speed
0 v = No command
10 Heating for travel switch module

02 Rev. 05/05
142 152
DIAGRAMS
Overall Wiring Diagram, Folded Platform with Options WP2330S ( ) Colours in brackets correspond to the old revision pre-August 2003
205 +BV F/C HR
FU3 202 KYS COMM +BV 203 JC404-7 BDI +BV
2A FU2 2
2901 PC404-2 BDI +BV (AK)
204
LMS
10A TCM SEM1
201
KYS
2926
2925
202 KYS COMM +BV CA 202
c
A 2916 PC404-3 RAS SIG 2917 1 002 PC415-4 RAS SIG
1 5900 PC404-1 TT
160A
FU1
3 5903 BATT NEG

2908 C1 +BV (AK) 3 001 PC415-2 +BV(AK)
4 5904 BATT NEG
5 2923 PC407-1 BRS SIG
A1 +BATT 001 JC 406-3 BRS SIG 2928 PC407-1 BRS SIG
6 2 205 +BV F/C HR 5 012 PC415-7 +BV F/C HR
BD:1 7 2904 JC103-2 +BV (AK) 2921 4 D2
504 P- BATT NEG 6 013 PC410-1 BATT NEG
002 PC 406-2 +BV (AK) BRS D3 D1 506 PC 407-4 BATT NEG
8 2920 JC102-2 PL SIG 2911 1
3 5
5
2924 PC407-3 BRS / PS SIG CA 404
CURTIS 803 "COMBI"

B 9
5900 A1 TT 1 TT
2911 PS SIG
A2 BRN (010) PC410-7 POT SIG
5903
VMN 1
POT CIRCUIT
505 P-
BATTERY
& DRIVER
24V
- 2916 RAS SIG 3

5 GRAY/PINK (005) PC410-2 SAS SIG
F1 6 PS
+ F1
2909
UNUSED 6 UNUSED
2910
203 KYS COMM 7 BDI
C 2908 JC202-3 +BV (AK)
RED
PM - 2 2921 PS SIG
BD:2 FAN +
2913 JC 202-4 HNS SIG
D CA 406
1 UNUSED HN
F2 + - UNUSED 1 RED
F2
2912 HNS SIG
- 2927 D4
2
P 3 501 BATT NEG
5
BLK
4
6 2918 LOS SIG
E + -
-BATT P
1 + RXD CA 407
+ BR/1
504 JC202-6
2 RXD NEG + 2928 DIODE BLOCK (2) BRS SIG 1 BLK
-
505 DB(1) SV 503 -
5
+ BR/2
5 BATT NEG
-
7 UNUSED
8 UNUSED CA 101
CA 411 UNUSED 1 RED
CA 415 CA 410 1
POT 2906 2 BLK GCSL
2
2962 PC410-9 +BV(AK) 1 GRN (013) PC202-6 BATT NEG 1 1
3 2903 3 WHT
16 x //R
WHT (001) PC202-3 +BV(AK) 10 GRAY/PINK (005) B-5 SAS SIG ACS
HR POT F/C
2 2 4
UNUSED 4 UNUSED
FS
6
RS
RAS 5 LOS 7
7
RED
CA 412
BLK
BLK 2920 A8 PL SIG

261 PC410-11 +BV F/C HR 6 CA 416 5961 PC415-8 LOW HR 6 3 2 BLK PLS
GRAY 1 1
1 SAS WHT
RED (012) PC202-5 +BV F/C HR 7 15 x //R 1 BRN (010) B-1 POT SIG 7 SAS 2906 PL SIG 3
2
BLU 5
5961 PC410-6 COMM F/C HR 8 2 BLU (011) B-2 POT LOW 8 UNUSED 4 UNUSED
CA 413
2962 PC415-1 +BV(AK) 9 1
CA 417
HYDRAULIC PCB F/C 2 5 CA 103
2 HNS1
GRAY (004) PC202-4 HNS SIG 10 1 UNUSED 1 RED
3
2904
CA 414 261 PC415-6 +BV HR 11 2903 HNS
4 2904 A7 +BV (AK) 2 BLK GCSR
15 x //R CA 419 1
2902
2961 PC415-3 +BV(AK) 1 5962 PC414-4 COMM F/C HR 12 5 2
5 2903 PL SIG 3 WHT 1
2901 HNS2
6 1
UNUSED 2 4
HNS UNUSED 4 UNUSED
HSS MAIN PCB F/C
WHT/GRN (006) C-3 R/T (HSS) SIG 3 6
5962 PC410-12 COMM F/C HR 4

2 x //R 813202-Options_Folded_Rev2B
R/T PCB F/C

02 Rev. 05/05
143
DIAGRAMS
WP2330S OPTIONS, FOLDED PLATFORM WP2330S STANDARD, FOLDED PLATFORM
11
POT PCB F/C
TCM SEM1 2903 PC200-20
PS 3 FS 2901 PC200-1 BDI
RS
A 2900 PC404-2 BDI
POT
D4
c
9
DIODE BLOCK BRS
1 5900 PC404-1 BDI KYS 200 PC404-7 BDI
5 5
5 2 2902 203 FU2 OUT +BV
HNS 1
HNS 2
SAS
BR SMALL COIL
3 5904
5
BR LARGE COIL
4
RAS LOS
4
HYDR. PCB
F/C 5 2918 PC200-17
8
HSS 11 LINE
F/C
11
F/C
11
6 UNUSED
MAIN PCB
2932 JC406-2 BRS
R/T PCB
INSTRUMENT 7
2919 JC103-2 GCSR
CURTIS 803 "COMBI" 2
c
LINE
8 2920 PC200-12
2921
2930
TT 1 LMS
KYS 2 8
3
4
BATT 5 8
GCSR
6
UNUSED PS
BDI 7
1
B
UNUSED 8 1 BRN (010) PC410-7 POT WIPER
GCSL
FAN POT CIRCUIT

& DRIVER

1
PLS
HN
4 BLK (007) PC410-4 RS
1
5 2933 PC210-2
10 5 2 3 4 6 YEL (008) PC410-3 FS
20
1 8 P SV
10
17 13
12
9 C 2914 JC202-3 +BV (AK)
1 2921
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3

C
D
A
TCM (SEM 1)
3 WHT/GRN (006) PC414-3 HSS
FAN
+BATT
-BATT
VMN
E
F1
F2
2906 PC404-4 +BV

2
3
4
5
6
7
8
1
HN
D 2915 JC 202-4
7
KYS A2 F2 F1 1 UNUSED
A1 2 2916
TM NOTE: 3 505
8
FU2 FU2 LINE
1- Walkie Mode: GCSR + GCSL + PLS open. 4 2907 P
2A 10A
or GCSR + GCSL open + PLS closed.
5 506
+ - 2- Forks lower than 130mm: LMS closed.
6 2917 SV 507
P
3- Load is less than 1000kg: PS closed, 2/3 brake.
FU1 PM 4- Reduce speed: HSS is open. 2913 JC202-2
160A
BD:1 24V BATT BD:2
8- Diode Block Pin 1, BDI (BATT NEG), Main PCB (Earth contact),
connected to Pump Contactor Contacts.
9- Diode Block Pin 3 connected to Controller C-2.
11- F/C Package: Below 5°C active.
814991-1_2A.pdf 814991-2_2A.pdf

02 Rev. 05/05
144 154
DIAGRAMS
TRACTION CONTROLLER - SEM1 LOGIC CIRCUIT PLATFORM CIRCUIT
204 JC202-5 +BV F/C 203 KYS IN

TCM SEM1 CA 101
FU3 FU2
F/C 2A 10A A 2926 1 RED
GCSL
202
201
HOUR METER OUTPUT 1
FU1 LINE 2927 2 BLK
LINE CONTACTOR LOW 3 2929 PC200-3 3 WHT
4 UNUSED
BRS INPUT 5
BATTERY NEG 6
CA 102
BATTERY POS (AK) 7
WALKIE/RIDER MODE 8 1 RED
PLS
A1 +BATT
B 2927 2 BLK
BD:1 POT WIPER 1
2928 PC200-4 3 WHT
POT LOW 2
POT HIGH 3 4 UNUSED
CA 103
SAS SAFETY SWITCH IN 5
2926 1 RED
A2 GCSR
VMN
C 2919 CONTROLLER A7 +BV (AK) 2 BLK
BATTERY POS (AK) 1
24V PERF.CUT 2925 PC200-2 3 WHT
2
BATTERY TM
PERF. 1/2,HSS (R/T) INPUT 3 4 UNUSED
F2 NOTE:
+ F1 GCSL, PLS & GCSR are shown in walkie mode.
D
UNUSED 1
HN - HORN HIGH 2 DIODE BLOCK
HN - HORN LOW 3
P - PUMP CONTACTOR HIGH 4 501 PC407-4 BR LOW D1
BD:2
- P&SV-P CONTACTOR LOW 5 502 P CONTACTOR CONTACTS 1
PM SV - LOWERING VALVE HIGH 6 503 PC200-10
2911 PC407-1 BRAKE D2
F1 2
F2 E
2912 PC200-5
POSITIVE SERIAL RECEPTION 1
NEGATIVE SERIAL RECEPTION 2 2909 CONTROLLER C-2 D3
3
P POSITIVE SERIAL TRANSMISSION 3 2910 PS
NEGATIVE SERIAL TRANSMISSION 4 5902 CONTROLLER A-4
BATT NEG 5 5903 PC407-2 4
BATTERY POS (AK) 6 5901
UNUSED 7
UNUSED 8 2908 PC 407-3 5
D4
-BATT
502 DIODE BLOCK (1) 504 JC202-6
500 PC404-5 814991-3_2A.pdf 2904 JC406-3 BRS-5 814991-4_2A.pdf
NOTE:
1) VOLTAGE BETWEEN B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND. Used from S/No. 5A336576 on, but not on S/No. 5A337937

02 Rev. 05/05
145
DIAGRAMS
WP2330S OPTIONS, FOLDED PLATFORM WP2330S STANDARD, FOLDED PLATFORM
CA 202
CA 411
2905 PC404-3 BDI 2934 1 VIO (002) PC415-4 RAS CA 410 1
LMS POT
2
2913 SV HIGH 2 PINK (003) PC415-5 LOS GRN (013) PC202-6 1
3
2914 CONTROLLER C1 3 WHT (001) PC415-2 +BV(AK) GRAY/PINK (005) B-5 SAS 2 4
POT P
FS
2915 HN HIGH 4 GRAY (004) PC410-10 HN RS
6
BLK (007)B-4 REVERSE 4
204 +BV FU3 OUT 5 RED (012) CA415-7 +BV F/C 7
RED/BLU (009) B-3 POT HIGH 5
CA 412
504 P CONTACTOR CONTACTS 6 GRN (013) CA410-1 BATT NEG BLK
5961 PC415-8 GND F/C 6 3
GRAY
1 SAS
BRN (010) B- POT SIGN 7 SAS
2
BLU
CA 404 INSTRUMENT BLU (011) B-2 POT LOW 8
CA 413
CA 417
2962 PC415-1 +BV(AK) 9 1
CURTIS 803 "COMBI" 2
2 HNS1
GRAY (004) PC202-4 HN 10 1
5900 CONTROLLER A1 TT 1 TT 3 2904 HNS
261 PC415-6 +BV F/C 11 4 2903
2900 KYS NO + BV(AK) 2 KYS 15 x //R CA 419
5962 PC414-4 GND F/C 12 5 2902 2
HNS2
2905 LMS OUT NC +BV 3 6 2901 1
HNS
2906 P CONTACTOR COIL 4 MAIN PCB
500 P CONTACTOR CONTACTS 5 BATT NEG

CA 415
200 KYS +BV 7 BDI WHT (001) PC202-3 +BV(AK) 2
VIO (002) PC202-1 LMS 4

RAS LOS
PINK (003) PC202-2 SV HIGH 5 CA416
CA 406 RED
261 CA410-11 +BV F/C 6 1
0R 16 x //R
BLK
RED (012) CA202-5 +BV F/C 7 2
UNUSED 1 RED
15 x //R
2904 DIODE D4 5961 PC410-6 GND F/C 8 POT PCB F/C
2 BLK BRS
2932 CONTROLLER A-7
HYDRAULIC PCB F/C
2931 PC200-5 3 WHT
UNUSED 4 UNUSED
CA 414
2961 PC415-3 +BV(AK) 1
CA 407 UNUSED 2
HSS
LARGE COIL WHT/GRN (006) CONTROLLER C-3 3
5962 PC410-12 GND F/C 4
5903 DIODE BLOCK (4) 2 BLU 2 x //R
SMALL COIL BR R/T PCB F/C
501 DIODE BLOCK (1) 4 BLK 814991-5_2A.pdf 814991-6_2A.pdf

02 Rev. 05/05
146 156
DIAGRAMS
WP2330S STANDARD, FOLDED PLATFORM
PLATFORM LOGIC
PLATFORM LOGIC
CA 200
2901 +BV 1 +BV(AK)
2925 GCSR 2 GCSR INPUT
2928 PLS 4 PLS INPUT

2912 DIODE BLOCK-2
UNUSED 6 UNUSED
UNUSED 7 UNUSED
uC
UNUSED 9 UNUSED
503 DIODE BLOCK-1 10 BATT NEG
UNUSED 11 UNUSED
2920 CONTROLLER A-8 12 RIDER OUTPUT
2932 CONTROLLER B-5 13 SAS OUTPUT
UNUSED 14 UNUSED
UNUSED 15 UNUSED
UNUSED 16 UNUSED
UNUSED 18 PS1 INPUT
UNUSED 19 UNUSED
2903 +BV (CONTROL) 20 CODE: +BV
814990-5_2A.pdf

02 Rev. 05/05
147
DIAGRAMS

Standard Version,
Fixed platform WP2335S
Key:
1 No drive:
FTS open

7 Diagnostic LED. Remove to connect the

programmer.

10 v = Full speed
0 v = No command

02 Rev. 05/05
148 158
DIAGRAMS
Overall Wiring Diagram, Standard, Fixed Platform WP2335S ( ) Colours in brackets correspond to the old revision pre-August 2003
202 KYS COMM +BV 203 JC404-7 BDI +BV
FU2 2901 PC404-2 BDI +BV (AK)
10A TCM SEM1
201
KYS
202 KYS COMM +BV 2 CA 202
c LMS
A 2916 PC404-3 RAS SIG
2917 1 002 PC415-4 RAS SIG
1 5900 PC404-1 TT
160A
3 5903 BATT NEG

FU1
2908 C1 +BV (AK) 3 001 PC415-2 +BV(AK)

4 5904 BATT NEG
5 2923 PC407-1 BRS SIG
+BATT 001 JC 406-3 BRS SIG 2928 PC407-1 BRS SIG
A1 6 2 2922 NOT USED 5 012 PC415-7 NOT USED
BD:1 7 2904 JC103-2 +BV (AK) 2921 4 D2
8 2903 JC102-2 FTS SIG 2911 1
3 5
5
2924 PC407-3 BRS / PS SIG CA 404
CURTIS 803 "COMBI"

B 8
5900 A1 TT 1 TT
2911 PS SIG
5903
A2 1 BRN (010) PC410-7 POT SIG
VMN POT CIRCUIT
505 P-
& DRIVER
BATTERY

- 2916 RAS SIG 3
24V

F1 6 PS
+ F1
2909
UNUSED 6 UNUSED
2910
203 KYS COMM 7 BDI
C 2908 JC202-3 +BV (AK)
RED
PM - 2 2921 PS SIG
3 WHT/GRN (006) PC414-3 R/T
FAN +
BD:2
2913 JC 202-4 HNS SIG CA 406
D
1 UNUSED HN
F2 + - - UNUSED 1 RED
F2 2 2912 HNS SIG 2927 D4
3 501 BATT NEG
5
BLK
4
6 2918 LOS SIG
E + -
-BATT P CA 407
1 + RXD
+ BR/1
504 JC202-6 2928 DIODE BLOCK (2) BRS SIG 1 BLK
2 RXD NEG + -
505 DB(1) SV 503 -
+ BR/2
5 BATT NEG
-
7 UNUSED
8 UNUSED
CA 411
CA 415 CA 410 1
POT
2
2962 PC410-9 +BV(AK) 1 GRN (013) PC202-6 BATT NEG 1
3
WHT (001) PC202-3 +BV(AK) 2 GRAY/PINK (005) B-5 SAS SIG 2 4
ACS
FS
6
RS
RAS 5 LOS 7
6 CA 412
BLK
261 PC410-11 NOT USED 6 5961 PC415-8 NOT USE 6 3 2903 A8 FTS SIG 2 BLK FTS
GRAY 1
1 SAS 2904 A7 +BV (AK)
RED (012) PC202-5 +BV F/C HR 7 BRN (010) B-1 POT SIG 7 SAS 3 WHT
2
BLU 5
5961 PC410-6 NOT USED 8 BLU (011) B-2 POT LOW 8 UNUSED 4 UNUSED
CA 413
2962 PC415-1 +BV(AK) 9 1
CA 417
HYDRAULIC PCB 2
2 HNS1 5
GRAY (004) PC202-4 HNS SIG 10 1
3
2904
CA 414 261 PC415-6 NOT USED 11 2903 HNS1
4
CA 419
2902
2961 PC415-3 +BV(AK) 1 5962 PC414-4 NOT USED 12 5 2 5
2901 HNS2
UNUSED 2 4 6 1
HNS2
HSS MAIN PCB
WHT/GRN (006) C-3 R/T (HSS) SIG 3
5962 PC410-12 NOT USED 4

813202-Standard_Fixed_Rev2B
R/T SWITCH

02 Rev. 05/05
149
DIAGRAMS
with options, fixed platform
WP2335S
Key:
1 No drive:
FTS open
6 Electronic thermal switch, applies earth for F/C

HR when temperature < +5°C

8 Diagnostic LED. Remove to connect the program-

mer.

10 v = Full speed
0 v = No command
10 Heating for travel switch module

02 Rev. 05/05
150 160
DIAGRAMS
Overall Wiring Diagram, Fixed Platform with Options WP2335S ( ) Colours in brackets correspond to the old revision pre-August 2003
205 +BV F/C HR
FU3 202 KYS COMM +BV 203 JC404-7 BDI +BV
2A FU2 2
2901 PC404-2 BDI +BV (AK)
204
LMS
10A TCM SEM1
201
KYS
2926
2925
202 KYS COMM +BV CA 202
c
A 2916 PC404-3 RAS SIG 2917 1 002 PC415-4 RAS SIG
1 5900 PC404-1 TT
160A
FU1
3 5903 BATT NEG

2908 C1 +BV (AK) 3 001 PC415-2 +BV(AK)
4 5904 BATT NEG
5 2923 PC407-1 BRS SIG
A1 +BATT 001 JC 406-3 BRS SIG 2928 PC407-1 BRS SIG
6 2 205 +BV F/C HR 5 012 PC415-7 +BV F/C HR
BD:1 7 2904 JC103-2 +BV (AK) 2921 4 D2
8 2903 JC102-2 FTS SIG 2911 1
3 5
5
2924 PC407-3 BRS / PS SIG CA 404
CURTIS 803 "COMBI"

B 9
5900 A1 TT 1 TT
2911 PS SIG
A2 BRN (010) PC410-7 POT SIG
5903
VMN 1
POT CIRCUIT
505 P-
BATTERY
& DRIVER
24V
- 2916 RAS SIG 3

F1 6 PS
+ F1
2909
UNUSED 6 UNUSED
2910
203 KYS COMM 7 BDI
C 2908 JC202-3 +BV (AK)
RED
PM - 2 2921 PS SIG
BD:2 FAN +
2913 JC 202-4 HNS SIG
D CA 406
1 UNUSED HN
F2 + - UNUSED 1 RED
F2
2912 HNS SIG
- 2927 D4
2
P 3 501 BATT NEG
5
BLK
4
6 2918 LOS SIG
E + -
-BATT P
1 + RXD CA 407
+ BR/1
504 JC202-6
2 RXD NEG + 2928 DIODE BLOCK (2) BRS SIG 1 BLK
-
505 DB(1) SV 503 -
+ BR/2
5 BATT NEG
-
7 UNUSED
8 UNUSED
CA 411
CA 415 CA 410 1
POT
2
2962 PC410-9 +BV(AK) 1 GRN (013) PC202-6 BATT NEG 1
3
16 x //R
WHT (001) PC202-3 +BV(AK) 10 GRAY/PINK (005) B-5 SAS SIG ACS
HR POT F/C
2 2 4
FS
6
RS
RAS 5 LOS 7
RED
CA 412
BLK
7
BLK 2903 A8 PL SIG
201 PC410-11 +BV F/C HR 6 CA 416 5961 PC415-8 LOW HR 6 3 2 BLK FTS
GRAY 1
1 SAS WHT
RED (012) PC202-5 +BV F/C HR 7 15 x //R 1 BRN (010) B-1 POT SIG 7 SAS 2904 A7 +BV (AK) 3
2
BLU 5
5961 PC410-6 COMM F/C HR 8 2 BLU (011) B-2 POT LOW 8 UNUSED 4 UNUSED
CA 413
2962 PC415-1 +BV(AK) 9 1
CA 417
HYDRAULIC PCB F/C 2
2 HNS1 5
GRAY (004) PC202-4 HNS SIG 10 1
3
2904
CA 414 261 PC415-6 +BV HR 11 2903 HNS
4
15 x //R CA 419
2902
2961 PC415-3 +BV(AK) 1 5962 PC414-4 COMM F/C HR 12 5 2 5
2901 HNS2
6 1
UNUSED 2 4
HNS
HSS MAIN PCB F/C
WHT/GRN (006) C-3 R/T (HSS) SIG 3 6
5962 PC410-12 COMM F/C HR 4

2 x //R 813202-Options_Fixed_Rev2B
R/T PCB F/C

02 Rev. 05/05
151
DIAGRAMS
WP 2340S STANDARD, FIXED PLATFORM WP 2340S STANDARD
TCM SEM1
PS 3 FS
5
RS
A 2901 PC404-2 BDI
BRS FPS1
To C-2 1 5 5
1 5900 PC404-1 BDI KYS 203 JC404-7 BDI
DIODE BLOCK
D4 SAS
2 2902 202 FU2 OUT +BV
HNS 1
HNS 2
3
2
BR SMALL COIL 5 4 5 3 5903
RAS LOS
HSS
1 4 5904 DIODE BLOCK (4)
BR LARGE COIL 5
10 9 001 BLK (2 core) JC 406-3 BRS LINE
INSTRUMENT R/T PCB HYDR. PCB 6 500 PC 404-5 BATT NEG
CURTIS 803 "COMBI" 2903 JC101-2 +BV (AK) FTS
1
LMS
7
LINE MAIN PCB 2
002 BLK (2 core) PC 406-2 BRS
2
8 2904 JC103-1 FPS2
3
2909
2910
4
5 1
6
FAN
7
FPS2
8 HN
PS
8 P SV
B
INPUT FILTER
+BV
+BV (AK) 1 BRN (010) PC410-7 POT WIPER
OUT NO
POT CIRCUIT
To DB 3
BATT
NEG & DRIVER
RED/BLU (009) PC410-5 POT HIGH

FTS 3
10
1
4 BLK (007) PC410-4 RS
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
5 GRAY/PINK (005) PC410-2 SAS

C
D
A
TCM (SEM 1)
6 YEL (008) PC410-3 FS

+BATT
-BATT
C 2908 JC202-3 +BV (AK)

VMN
E
F1
F2
1 2909
2
3
4
5
6
7
8
1

KYS A2 F2 F1 7
3 WHT/GRN (006) CA414-3 HSS
A1
FAN
LINE
FU2
10A
+ - 2915 PC404-4 +BV
9 NOTE:
HN
FU1 PM
P
1- No Drive: FTS, FPS1 & FPS2 open. D 2913 JC 202-4
160A
2- Forks lower than 130mm: LMS closed. 1 UNUSED
BD:1 24V BATT BD:2
3- Load is less than 1000kg: PS closed, 2/3 brake. 2 2912
Speed Unladen 10Km/h.
3 501
4- Reduce speed: HSS is open.
5- Active: RAS, BRS, SAS, HNS & LOS are closed. 4 2914 P
9- Diode Block Pin 1 connected to P (contactor contacts). 5 502
10- Input Filter Batt Neg connected to Diode Block Pin 1 6 2918 SV 503
2919 JC202-2
815513-1_2B.pdf 815513-2_2B.pdf

02 Rev. 05/05
152 162
DIAGRAMS
WP 2340S STANDARD WP 2340S STANDARD, FIXED PLATFORM
POWER CIRCUIT - TRACTION & PUMP MOTOR PLATFORM CIRCUIT
205 CA202-5 NOT USED 202 KYS COMM
TCM SEM1
CA 101
FU3 FU2
2A 10A A UNUSED 1 RED
(not mounted) 204
201
HOUR METER OUTPUT 1
FU1 LINE 2972 2 BLK FTS
LINE CONTACTOR LOW 3 2904 CONTROLLER A8 3 WHT
UNUSED 4 UNUSED
BRS INPUT 5
BATTERY NEG 6
BATTERY POS (AK) 7
CA 102
WALKIE/RIDER MODE 8 2971 1 RED
A1 +BATT FPS1
B 2970 2 BLK
BD:1 POT WIPER 1
UNUSED 3 WHT
POT LOW 2
POT HIGH 3 UNUSED 4 UNUSED
SAS SAFETY SWITCH IN 5 CA 103
2970 1 RED
A2
VMN
C FPS2
2903 CONTROLLER A7 2 BLK
BATTERY POS (AK) 1
24V PERF.CUT 2 UNUSED 3 WHT
BATTERY
TM PERF. 1/2,HSS (R/T) INPUT 3
UNUSED 4 UNUSED
F2 +BV(AK)
INPUT FILTER
+ F1
D
OUT NO
UNUSED 1
HN - HORN HIGH 2 BATT NEG
HN - HORN LOW 3
570 D1 +BV
506 PC 407-4 BRK SMALL 1
BD:2 - P&SV-P CONTACTOR LOW 5

505 P CONTACTOR CONTACTS
PM SV - LOWERING VALVE HIGH 6
D2
2928 PC407-1 BRK LARGE
2
F1
F2 E 2923 CONTROLLER A5
POSITIVE SERIAL RECEPTION 1 D3
2911 PS NO
NEGATIVE SERIAL RECEPTION 2 3
2921 CONTROLLER C2
P POSITIVE SERIAL TRANSMISSION 3
NEGATIVE SERIAL TRANSMISSION 4 5904 CONTROLLER A4
BATT NEG 5 5902 PC407-2 BRK LARGE 4
5905
BATTERY POS (AK) 6
UNUSED 7
UNUSED 8 D4
-BATT
505 Diode Block (1) 504 JC202-6 2974 2927 JC406-2
DIODE BLOCK
2973
NOTE:
1) VOLTAGE BETWEEN B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND. 815513-3_2B.pdf 815513-4_2B.pdf

02 Rev. 05/05
153
DIAGRAMS
WP 2340S STANDARD, FIXED PLATFORM WP 2340S STANDARD, FIXED PLATFORM
2925 LMS1 Opt. CA 411
2926 LMS1 Opt. CA 410 1
CA 202 POT
2
2916 PC404-3 BDI 2917 1 VIO (002) PC415-4 RAS GRN (013) CA202-6 BATT NEG 1
3
LMS
2919 SV HIGH 2 PINK (003) PC415-5 LOS GRAY/PINK (005) B-5 SAS 2 4
POT
FS
2908 CONTROLLER C1 3 WHT (001) PC415-2 +BV(AK) YEL (008) B-6 FORWARD 3 5
6
RS
2913 HN HIGH 4 GRAY (004) PC410-10 HN DRIVER BLK (007) B-4 REVERSE 4
7
205 FU3 OUT NOT USED 5 RED (012) CA415-7 NOT USED RED/BLU (009) B-3 POT HIGH 5
CA 412
BLK
504 P CONTACTOR 6 GRN (013) CA410-1 BATT NEG 5961 PC415-8 NOT USED 6 3
GRAY
1 SAS
BRN (010) B-1 POT WIPER 7 SAS
2
BLU
BLU (011) B-2 POT LOW 8
CA 404 INSTRUMENT CA 413
CA 417
2962 PC415-1 +BV(AK) 9 1
2
CURTIS 803 "COMBI" HNS1
2
GRAY (004) PC202-4 HN 10 1
5900 CONTROLLER A1 1 TT 3
2904
HNS
261 PC415-6 NOT USED 11 4
2903
2901 KYS OUT 2 KYS CA 419
2902
5962 PC414-4 NOT USED 12 5 2
2916 LMS 3 2901 HNS2
6 1
2915 P HIGH 4 HNS

MAIN PCB
500 CONTROLLER A6 5 BATT NEG
203 KYS IN 7 BDI 2962 PC410-9 +BV(AK) 1
UNUSED 8 UNUSED WHT (001) PC202-3 +BV(AK) 2
2961 PC414-1 +BV(AK) 3
VIO (002) PC202-1 LMS COMM 4

RAS LOS
CA 406
PINK (003) PC202-2 SV HIGH 5
UNUSED 1 RED 261 CA410-11 NOT USED 6

2927 D4 BRS
002 BLK(2) CONTROLLER A7 2 BLK RED (012) CA202-5 NOT USED 7
001 BLK(2) CONTROLLER A5 3 WHT 5961 PC410-6 NOT USED 8
UNUSED 4 UNUSED
HYDRAULIC PCB
CA 407 CA 414
LARGE COIL
2928 DIODE BLOCK (2) 1 BLK 2961 PC415-3 +BV(AK) 1
5902 DIODE BLOCK (4) 2 UNUSED 2

BLU
SMALL COIL BR HSS
2924 DIODE BLOCK (5) 3 BLK WHT/GRN (006) CONTROLLER C-3 3
506 DIODE BLOCK (1) 4 BLK 5962 PC410-12 NOT USED 4
815513-5_2B.pdf R/T PCB 815513-6_2B.pdf

02 Rev. 05/05
154 164
DIAGRAMS
WP 2340S OPTIONS, FIXED PLATFORM WP 2340S OPTIONS, FIXED PLATFORM
6 TCM SEM1
POT PCB F/C
PS 3 FS
RS
5 1
A 2901 PC404-2 BDI
POT
To C-2 BRS FPS1
5 5 1 5900 PC404-1 BDI KYS 203 JC404-7 BDI
DIODE BLOCK
SAS
3
2 2902 202 FU2 OUT +BV
HNS 1
HNS 2
D4
2
BR SMALL COIL 5903
5 3
1
4 RAS
5
LOS 4 5904 DIODE BLOCK (4)
F/C F/C
HSS
BR LARGE COIL 6 5
11 10 F/C
001 BLK (2 core) JC 406-3 BRS LINE
6 HYDR. PCB
INSTRUMENT R/T PCB 6 500 PC 404-5 BATT NEG
CURTIS 803 "COMBI"
MAIN PCB LMS 2903 JC101-2 +BV (AK) FTS
TT 1 7
LINE
2 002 BLK (2 core) PC 406-2 BRS
KYS 2
3
8 2904 JC103-1 FPS2
2909
2909
4
BATT NEG 5 1
UNUSED 6
FPS2 FAN
BDI 7
UNUSED 8 9 HN
PS
P SV
B
INPUT FILTER
+BV
+BV (AK)
OUT NO 1 BRN (010) PC410-7 POT WIPER
BATT POT CIRCUIT
NEG
To DB 3
& DRIVER

FTS 11 3 RED/BLU (009) PC410-5 POT HIGH
1
4 BLK (007) PC410-4 RS
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
1
2
3
5 GRAY/PINK (005) PC410-2 SAS
D
A
TCM (SEM 1)
6 YEL (008) PC410-3 FS
+BATT
-BATT
C 2908 JC202-3 +BV (AK)

VMN
E
F1
F2
2909
2
3
4
5
6
7
8
1
1
KYS A2F2F1 8
3 WHT/GRN (006) CA414-3 PERF. 1/2 (R/T)
A1
TM FAN
LINE
FU2 FU2
10A 10A
+-
10 2915 PC404-4 +BV
P HN
FU1 PM D 2913 JC 202-4
160A
1 UNUSED
24V BATT
BD:1 BD:2
2 2912
3 501
NOTE: 4 2914 P
1- No Drive: FTS, FPS1 & FPS2 open.
5 502
2- Forks lower than 130mm: LMS closed.
3- Load is less than 1000kg: PS closed, 2/3 brake, Speed Unladen 10Km/h. 6 2918 SV 503
4- Reduce speed: HSS is open. 2919 JC202-2
6- F/C Package: Below 5°C active.
10- Diode Block Pin 1 connected to P (contactor contacts).
11- Input Filter Batt Neg connected to Diode Block Pin 1 815514-1_2B.pdf 815514-2_2B.pdf

02 Rev. 05/05
155
DIAGRAMS
POWER CIRCUIT - TRACTION & PUMP MOTOR PLATFORM CIRCUIT
205 CA202-5 +BV F/C 202 KYS COMM CA 101
TCM SEM1
FU3 FU2
UNUSED 1 RED
2A 10A A
2972 2 BLK FTS
HOUR METER OUTPUT 1
204
201
FU1 LINE
160A KYS +BV IN TO THE LOGIC 2 2904 CONTROLLER A8 3 WHT
LINE CONTACTOR LOW 3
UNUSED 4 UNUSED
BRS INPUT 5
BATTERY NEG
CA 102
6
BATTERY POS (AK) 7 2971 1 RED
WALKIE/RIDER MODE 8 FPS1
2970 2 BLK
A1 +BATT
B
UNUSED 3 WHT
BD:1 POT WIPER 1
POT LOW 2 UNUSED 4 UNUSED
POT HIGH 3
RS - REVERSE SWITCH IN 4 CA 103
SAS SAFETY SWITCH IN 5
2970 1 RED
A2 2903 CONTROLLER A7 2 BLK FPS2
VMN
C
BATTERY POS (AK) 1 UNUSED 3 WHT
24V PERF.CUT 2
BATTERY TM UNUSED 4 UNUSED
PERF. 1/2,HSS (R/T) INPUT 3
+BV(AK)
INPUT FILTER
F2
+ F1 OUT NO
D
UNUSED 1 BATT NEG
HN - HORN HIGH 2
570 D1 +BV
HN - HORN LOW 3
505 P- CONTACTOR CONTACTS
BD:2 - P&SV-P CONTACTOR LOW 5
2928 PC407-1 BRK LARGE D2
PM SV - LOWERING VALVE HIGH 6 2
2923 CONTROLLER A5
F1 F2 E D3
2911 PS NO
POSITIVE SERIAL RECEPTION 1 3
2921 CONTROLLER C2
NEGATIVE SERIAL RECEPTION 2
P POSITIVE SERIAL TRANSMISSION 3 5904 CONTROLLER A4
NEGATIVE SERIAL TRANSMISSION 4
5902 PC407-2 BRK LARGE 4
5905
BATT NEG 5
BATTERY POS (AK) 6
UNUSED 7 D4
UNUSED 8
-BATT 2974 2927 JC406-2
DIODE BLOCK
505 DIODE BLOCK (1) 504 JC202-6 2973
NOTE:
1) Voltage between B1 & B2: 10V = FULL SPEED, 0V = NO COMMAND 815514-3_2B.pdf 815514-4_2B.pdf

02 Rev. 05/05
156 166
DIAGRAMS
2926 2925
UNUSED CA 411
LMS1 CA 202
CA 410 1
2916 PC404-3 BDI Not Mounted 2917 1 002 BLK PC415-4 RAS POT
2
GRN (013) CA202-6 BATT NEG 1
2919 SV HIGH 2 003 BLK PC415-5 LOS 3
GRAY/PINK (005) B-5 SAS 2 4
POT
2908 CONTROLLER C1 3 001 BLK PC415-2 +BV(AK)
FS
2913 HN HIGH 4 004 BLK PC410-10 HN DRIVER RS
6
BLK (007) B-4 REVERSE 4
205 FU3 OUT 5 012 BLK CA415-7 +BV F/C 7
RED/BLU (009) B-3 POT HIGH 5
504 P CONTACTOR CONTACTS 6 013 BLK CA410-1 BATT NEG CA 412
BLK
5961 PC415-8 GND F/C 6 3
GRAY
1 SAS
BRN (010) B-1 POT WIPER 7 SAS
2
BLU
CA 404 INSTRUMENT BLU (011) B-2 POT LOW 8
CA 413
2962 PC415-1 +BV(AK) 9 1
CA 417
CURTIS 803 "COMBI"
2
2 HNS1
5900 CONTROLLER A1 1 TT GRAY (004) PC202-4 HN 10 1
3
2904
261 PC415-6 +BV 11 2903 HNS
2901 KYS OUT 2 KYS 4
15 x //R CA 419
2902
2916 LMS 3 5962 PC414-4 GND F/C 12 5 2
2901 HNS2
6 1
2915 P HIGH 4 HNS
MAIN PCB F/C
500 CONTROLLER A6 5 BATT NEG
203 KYS IN 7 BDI 2962 PC410-9 +BV(AK) 1
UNUSED 8 UNUSED WHT (001) PC202-3 +BV(AK) 2
2961 PC414-1 +BV(AK) 3
VIO (002) PC202-1 LMS COMM 4

RAS LOS
CA 406
PINK (003) PC202-2 SV HIGH 5 CA 416
UNUSED 1 RED RED
261 CA410-11 +BV 6 1
2927 D4 BRS 0R 16 x //R
002 BLK(2) CONTROLLER A7 2 BLK BLK
RED (012) CA202-5 FU3 OUT 7 2
001 BLK(2) CONTROLLER A5 3 WHT 15 x //R
5961 PC410-6 GND F/C 8
POT PCB F/C
UNUSED 4 UNUSED
HYDRAULIC PCB F/C
CA 407
CA 414
LARGE COIL
2928 DIODE BLOCK (2) 1 BLK 2961 PC415-3 +BV(AK) 1
5902 DIODE BLOCK (4) 2 BLU UNUSED 2

SMALL COIL BRK HSS
2924 DIODE BLOCK (5) 3 BLK WHT/GRN (006) CONTROLLER C-3 3
506 DIODE BLOCK (1) 4 BLK 5962 PC410-12 GND F/C 4

815514-5_2B.pdf 2 x //R 815514-6_2B.pdf
R/T PCB F/C

02 Rev. 05/05
157
DIAGRAMS
KYS
Wire harness overview,
[7+8] 6+4
[7+8] 6+4
BDI
folded platform, PC404 1 2 3 4 5 6 7 8
P- P FU3 FU2 LMS
5+4
6+4
6+4
6+4
6+4
6+4
6+4
7+8
7+8
2 2 2 2 2 2
WP2330S all versions
9
2902
2901
203
202
HANDLE MAIN PCB
5900
2901
2916
2915
500
203
2915
2914
205
204
202
201
2917
2925
2916
2926
2925
2926
505
504
503
502
6+4 2927 1 2 3 4 5 6
5 1010 1010
12+11 5905 PC413
2904
2903
2902
2901
(pin 5)
2924
10
5905 1
(pin 4) 10
5904
5902
2921
4 (pin 3) 10 2911
2928
(pin 2) 10 2923 2909 201
506 2927 6+4 2910
(pin 1) 10 505
1 LINE 5+4 FU1
002BLK 1 5903 204
2 6+4
001BLK 1 3
JC406 3
PC202 JC202 4
(002) VIO 2 1 1 1 2917 6+4
2910
PS
2928
5902
2924
BRS
506
(003) PINK 2 2 2 1 2919 6+4
2911
(001) WHT 2 3 3 1 2908
(004) GREY 2 4 4 1 2913 2 2 2 2 2918
(012) RED 2 5 5 1 205 1 2 3 4 PC407 6+4 2919
(013) GRN 504
SV
2 6 6 1 BR 6+4
503
1 Main wire harness 813258
2 Control handle - wire harness 812960

501 1
6+4 2904
2912 1 2
HN 2903 GCSR 3 Horn switch - wire harness 811931
6+4 2913 1 3
2906
2903
2904
2903
2902
2901
4
4 Diode block 131011
JC103 1 1
11 11 11 11
1 2 3 4 JC101
2920
2906
5 Diode (D4) 813368 PC417 2 1 2 1 PC419
D GCSL
1 Terminal Type Part No. 1 1
2 1 2 1
2 3 2912
4 062007-021 1 2 3 4 JC102
3 3 501 HNS HNS
PLS
4 3 2914 5 803678-006
5 3 502 PC410
2918
6 803448-003 (013) GRN Housing Par t No. Contact Type Par t No.
6 3 2 1
7 062007-043 (005) GRAY / PINK
2 2
JC101 803450-002 1 803450-010
(008) YEL
A 2 3
1 3 5900 8 803448-002 (007) BLK JC102 803450-002 1 803450-010
2 4
MAIN PCB
2902 9 062007-068 (009) RED / BLU
HANDLE
2 3 2 5
5903 5961 JC103 803450-002 1 803450-010
3 3 2 6
5904 10 062007-005 (010) BRN JC202 803450-003 1 803450-010
4 3 2 7
001BLK
11 813409-003 (011) BLU
TCM SEM1
5 3 2 8
2923
2962 PC202 803450-007 2 116858
6 3 2 9
500 12 813409-001 (004) GRAY PC404 803450-008 2 116858
7 3 002BLK 2 10
2904 E100_Rev2B-GB 261
8 3 2 11
2920 5962 JC406 803450-002 1 803450-010
2 12
B 2 PC407 803450-006 2 116858
1 3 (010) BRN
2 3 (011) BLU
PC415 P C4 1 0 803450-015 2 116858
2962
HYDRAULIC PCB
2 1
3 3 (009) RED/BLU (001) WHT PC413 803450-021 10 803450-022
(007) BLK 2 2
4 3 Key:
HANDLE
2961
5 3 (005) GREY/PINK
2 3 P C4 1 4 803450-020 2 116858
(002) VIO 4
(008)YEL 2
6 3 (003) PINK PC415 803450-008 2 116858
R/T PCB = “Fast/Slow” changeover 261
2 5
module 2 6 PC417 803450-023 11 803450-024

(012) RED
2 7
(All PCBs/modules located in control 5961
2 8
PC419 803450-023 11 803450-024
C handle) A 803450-018 3 803450-019
(006) WHT GRN
3 3 B 803450-017 3 803450-019
2 3 2921 PC414
2961 C 803450-016 3 803450-019
HANDLE
2908
R/T PCB
1 3 2 1
2909
(006) WHT/GRN
2 D 803450-017 3 803450-019
2 3
E99-GB
( ) Colours correspond to old revision pre-August 2003 5962
2 4
Connections by April 2005 Harness_Complete-WPS-Folded_Rev2B

02 Rev. 05/05
158 168
DIAGRAMS
Main Harness, Folded Platform, WP2330S, All Versions
P CONTACTOR COMBI INSTRUMENT KYS
IN OUT
LMS FU2 FU3 CONTACTS COIL 1 2 3 4 5 6 7 8 PC404
6+4 6+4 14
7+8 7+8 6+4 6+4 6+4 6+4 5+4 9 9 2 2 2 2 2 2 *7+8 *7+8 *7+8+13
2900
2900
2902
2901
2903
200
2934
2905
2906
2907
5900
2905
2906
203
201
204
202
500
502
504
506
507
500
203
200
5901 2904
11+12 6+4
DIODE BLOCK
(pin 1) (pin 2) (pin 3) (pin 4) (pin 5)
10 10 10 10 10
JC406
501
502
503
2911
2912
2909
2910
5901
5902
5903
2908
2904
1
BRAKE 2 1
2932
2921 SWITCH 3 1
2931
201
6+4
JC 202
2930 4 2934
FU1 5+4 202 LINE 1 1
5904
6+4 2913 HANDLE
2911
5903
2908
1 2
HARNESS
501
2914
1 3
PC200 2 2 2 2
2915
1 4
2901 204
2 1 +BV 1 2 3 4 PC407 1 5
2925 504
2 2 GCSR 1 6
2929 JC103 BRAKE
2 3 GCSL 505
2928 1 2919 6+4
2930
6+4
2 4 PLS GCSR 2 1 2926 2915 HN
2931
2910 6+4
PS 2 5 BRS
3 1
2925 2916 6+4
2912
6
4 D
7
2913 2922 PC210 JC210 1
2917 6+4 2 8 SAS GRAY/PINK (005)
2922 2916
3 2
TCM
from Handle Harness 1 1 1
507 SV 9
2933 2923 505
3 3
6+4 503 to Controller B-5 3 2 2 2 1
2 10 Batt Neg 2907
3 4
11 815179_2C, 506
2920 3 5
2 12 Rider (A8) C 2914 see Note 4 2917
2923 3 6
2 13 SAS (OUT) (B5) 2921
1 3
14 TCM 2 3
2909
5900
2902
5904
5902
2918
2932
2919
2920
15 3
16
2918 BRS (A-5) 3 3 3 3 3 3 3
2 17
18
1 2 3 4 5 6 7 8 A
815179-1_2C
19 TCM
2903
2 20 +BV (Control)
HOUSING Part No. TYPE Part No.

2927
2926
2929
2927
2928
PC 200 1 803450-010
1 1 1 1
JC 202 803450-003 2 116858
1 2 3 4 JC101 1 2 3 4 JC102
PC 210 803450-005 3 803450-013
GCSL PLS
JC 210 803450-001 4 62007-021
PC 404 803450-008 5 803678-006
JC 406 803450-002 6 803448-003
PC 407 803450-006 7 62007-043
JC 101 803450-002 8 803448-002
JC 102 803450-002 9 62007-068
JC 103 803450-002 10 62007-005
A 803450-018 11 813409-003
C 803450-016 12 813409-001
D 803450-017 13 803678-012 Used from serial no. 5A336576, except for 5A337937
C 803450-016 815179_2-GB
815179_1-GB Connections by April 2005

02 Rev. 05/05
159
DIAGRAMS
Control Handle - Wire Harness Note: Only for use on trucks with PLM
Folded Platform, WP2330S

All Versions
PC 410
GRN (013)
2 1
WHT/GRN (006)
TCM C-3 3 GRAY/PINK (005)
2 2
YEL (008)
2 3
BLK (007)
GRAY/PINK (005) 2 4
TCM B-5 2
RED/BLU (009)
2 5
B 5961
2 6
BRN (010) BRN (010)
1 3 2 7
BLU (011) BLU (011)
2 3 2 8
RED/BLU (009) 2962
3 3 2 9
BLK (007) GRAY (004)
4 3 2 10
261
5 2 11
YEL (008) 5962
6 3 2 12
PC 202 PC 415
VIO (002) 2962
1 2 2 1
PINK (003) WHT (001)
2 2 2 2
WHT (001) 2961
3 2 2 3
GRAY (004) VIO (002)
4 2 2 4
RED (012) PINK (003)
5 2 2 5
GRN (013) 261
6 2 2 6
RED (012)
2 7
5961
2 8
PC 414
2961
2 1
2
WHT/GRN (006)
2 3
5962
2 4
815180_2B
PC 202 803450-007 2 116858
PC 410 803450-015 3 803450-190
PC 414 803450-020 815180_2-GB
PC 415 803450-008
B 803450-017
815180_1-GB
Used from serial number 5A336576, except for 5A337937
( ) Colours correspond to old revision pre-August 2003

02 Rev. 05/05
160 170
DIAGRAMS
Horn Switch - Wire Harness
Folded Platform, WP2330S
All Versions
PC419
2901
PC413 2 1
2902
6 1 2901 2 2
2902
5 1
2903
4 1 PC417
2904
3 1 2903
2 1
2 2904
2 2
1
811931-1_2C

PC 413 803450-021 1 803450-022
PC 417 803450-023 2 803450-024
PC 419 803450-023 811931_2-GB
811931_1-GB
Used from serial number 5A336576, except for 5A337937

02 Rev. 05/05
161
DIAGRAMS
Wire Harness Overview, KYS
[7+8] 6+4
[7+8] 6+4
BDI
Fixed platform, PC404 1 2 3 4 5 6 7 8
P- P FU3 FU2 LMS
5+4
6+4
6+4
6+4
6+4
6+4
6+4
7+8
7+8
All versions 2 2 2 2 2 2
9
2902
2901
203
202
HANDLE MAIN PCB
5900
2901
2916
2915
500
203
2915
2914
205
204
202
201
2917
2925
2916
2926
2925
2926
505
504
503
502
6+4 2927 1 2 3 4 5 6
5 1010 1010
12+11 5905 PC413
2924
2904
2903
2902
2901
(pin 5) 10
5905 1
(pin 4) 10
5902
5904
2921
(pin 3) 10 2911
4
2928
(pin 2) 10 2923 2909 201
506 6+4 2910
2927 1 FU1
(pin 1) 10 505 LINE 5+4
002 BLK 1 5903 204
2 6+4
001 BLK 1 3
JC406
3
PC202 JC202 4
(002) VIO 2 1 1 1 2917 6+4
2910
PS
2928
5902
2924
BRS
506
(003) PINK 2 2 2 1 2919 6+4
2911
(001) WHT 2 3 3 1 2908
(004) GREY 2 4 4 1 2913 2 2 2 2 2918
(012) RED 2 5 5 1 205 1 2 3 4 PC407 6+4 2919
(013) GRN 504
SV
2 6 6 1 BR 6+4
503
1 Main wire harness 813258
501
2 Tiller wire harness 812960
6+4
HN 2912
6+4 2913 3 Horn switch wire harness 811931
2904
2903
2902
2901
4 Diode Block 102232
11 11 11 11
2903
2904
5 Diode Assembly (D4) 813368 PC417 2 1 2 1 PC419
D 2 1 2 1
1 1 1
2912
2 3 Terminal Type Part No. 1 2 3 4 JC101
3 3 501 HNS HNS
2914 4 062007-021 FTS
4 3
502 PC410
5 3 5 803678-006 (013) GRN
6 3 2918 2 1
6 803448-003 (005) GRAY / PINK
2 2
(008) YEL Housing Par t No. Contact Type Par t No.
A 7 062007-043 2 3
1 3 5900 (007) BLK 4
2
8 803448-002 JC101 803450-002 1 803450-010
MAIN PCB
2902 (009) RED / BLU
HANDLE
2 3 2 5
9 062007-068 5961
3 3 5903
2 6 JC202 803450-003 1 803450-010
4 3 5904 (010) BRN 7
2
001 BLK 10 062007-005 (011) BLU PC202 803450-007 2 116858
TCM SEM1
5 3 2923 2 8
6 3 500
11 813409-003 2962
2 9 PC404 803450-008 2 116858
(004) GRAY
7 3 002 BLK
2903
12 813409-001 261
2 10
JC406 803450-002 1 803450-010
8 3 2 11
E100_Rev2B-GB 5962
2904
2 12 P C4 0 7 803450-006 2 116858
B 22
1 3 (010) BRN PC410 803450-015 2 116858
2 3 (011) BLU
PC415
2962 PC413 803450-021 10 803450-022
HYDRAULIC PCB
2 1
3 3 (009) RED/BLU (001) WHT
4 3 (007) BLK Key: 2 2 PC414 803450-020 2 11685 8
HANDLE
2961 3
(005) GREY/PINK 2
5 3
(002) VIO 2 4 PC415 803450-008 2 116858
6 3 (008)YEL
R/T PCB = "Fast/Slow" changeover (003) PINK 2 5 P C4 1 7 803450-023 11 803450-024
261 6
module (012) RED
2
P C4 1 9 803450-023 11 803450-024
2 7
(all PCBs/modules are located in the 5961
2 8 A 803450-018 3 803450-019
C tiller)
(006) WHT GRN
B 803450-017 3 803450-019
3 3
2 3 2921 PC414 C 803450-016 3 803450-019
2961
HANDLE
2908
R/T PCB
1 3 2 1
2909
D 803450-017 3 803450-019
2
(006) WHT/GRN
2 3
E101-GB
( ) Colours correspond to old revision pre-August 2003 5962
2 4
Connections by April 2005 Harness_Complete-WPS-Fixed_Rev2B

02 Rev. 05/05
162 172
DIAGRAMS
Wire Harness Overview,
Fixed Platform, WP2340S,
All Versions
KYS COMBI INSTRUMENT

6+4
6+4
P- P LMS
PC404 1 2 3 4 5 6 7 8
6+4
6+4
6+4
6+4
5+4
6+4
6+4
7+8
7+8
2 2 2 2 2 2
9
2902
2901
203
202
5900
2901
2916
2915
500
203
2915
2914
205
204
202
201
2917
2925
2916
2926
2925
2926
505
504
503
502
2927
6+4
2924 HOUSING Part No. TYPE Part No.

(pin 5)10
5905 JC 202 803450-003 1 803450-010
5902 5905
DIODE BLOCK
(pin 4)10
5904
11+12 PC 404 803450-008 2 116858
2921 JC 406 803450-002 3 803450-013
(pin 3)10 2911
2928
PC 407 803450-006 4 62007-021
(pin 2)10 2923 2909
JC 101 803450-002 5 803678-006
201
506
(pin 1)10
2927 1 LINE
6+4 2910
5+4 FU1 A 803450-018 6 803448-003
505 002BLK(2) 5903 204
1 2
001BLK(2) JC406
6+4 D 803450-017 7 62007-043
1 3
4 C 803450-016 8 803448-002
HANDLE HARNESS
1 1 2917 2910
PS 6+4 E103_1-GB 9 62007-068
2928
5902
2924
2919 506 BRAKE SWITCH 2911
2 1 6+4
3 1 2908 10 62007-005
2913 2 2 2 2
4 1 2918 11 813409-003
5 1 205 1 2 3 4 PC407 6+4 2919
504 BRAKE SV 12 813409-001
6 1 6+4
503
E103_2-GB
JC202
6+4
501
HN 2912
6+4 2913
2903
2904
2908
D C
1 2909 3 1 1 1
2 3 2912 2921 3 2 TCM 1 2 3 4 JC101
3 3 501 3
TCM 2914 FTS
4 3
5 3 502
6 3 2918
001BLK(2)
002BLK(2)
5900
2902
5903
5904
2923
2903
2904
500
3 3 3 3 3 3 3 3
1 2 3 4 5 6 7 8 A
TCM 813258-1_2D

02 Rev. 05/05
163
DIAGRAMS
Control Handle - Wire Harness
All Versions
PC 410
GRN (013)
2 1
GRAY/PINK (005)
2 2
YEL (008)
WHT/GRN (006) 2 3
TCM C-3 3
BLK (007)
2 4
RED/BLU (009)
2 5
5961
2 6
BRN (010)
2 7
B BLU (011)
BRN (010) 2 8
1 3 2962
BLU (011) 2 9
2 3 GRAY (004)
RED/BLU (009) 2 10
3 3 261
BLK (007) 2 11
4 3 5962
GRAY/PINK (005) 2 12
5 3
YEL (008)
6 3
PC 415
2962
2 1
WHT (001)
PC 202 2 2
VIO (002) 2963 (2961)
1 2 2 3
PINK (003) VIO (002)
2 2 2 4
WHT (001) PINK (003)
3 2 2 5
GRAY (004) 261
4 2 2 6
RED (012) RED (012)
5 2 2 7
GRN (013) 5961
6 2 2 8
PC 414
2963 (2961)
2 1
2
WHT/GRN (006)
2 3
5962 4
2
812960-1_2G
HOUSING Part No. Pos. Nr. Teile-Nr.

PC 202 803450-007 2 116858
PC 410 803450-015 3 803450-019
PC 414 803450-020 812960_2-DE
PC 415 803450-007
B 803450-017
812960_1-GB
( ) Colours correspond to old revision pre-August 2003

02 Rev. 05/05
164 174
DIAGRAMS
Horn Switch - Wire Harness
All Versions
PC419
2901
PC413 2 1
2902
6 1 2901 2 2
2902
5 1
2903
4 1 PC417
2904
3 1 2903
2 1
2 2904
2 2
1
811931-1_2C

PC 413 803450-021 1 803450-022
PC 417 803450-023 2 803450-024
PC 419 803450-023 811931_2-GB
811931_1-GB

02 Rev. 05/05
165
DIAGRAMS
Cables, Platform
All Versions
Connect to Input Filter
Batt Neg
+BV(AK)
OUT NO
+BV
DISCONNECT 2903 / 2904 6+4 6+4 6+4 6+4
FROM JC101 MAIN HARNESS
2972
2971
2973
570
JC 103 JC 101
4 3 2 1 1 2 3 4
1 1
2903
2970
2972
2904
Connect with Wire 2927 14+15 2974 JC 102
2974 4
Connect with Diode Inline Wire 2927 4 2973 3
2970
1 2
2971
1
570
Connect with Diode Block Pin1 10

JC 101 803450-002 1 803450-010
JC 102 803450-002 4 062007-021
JC 103 803450-002 6 803448-003
815281_1-GB 10 062007-005
14 803448-004
15 803448-005
815281_2-GB

02 Rev. 05/05
166 176
DIAGRAMS
Power Cables
Index Part No. (mm2) Index Part No. (mm2)

1 052051-010 25 8 052065-039 16
2 052065-040 16 9 807636-002 4
3 052065-031 16 10 807636-001 4
+ 24V -
4 045250 * 11 052065-001 16
5 052051-008 25
6 052065-023 16
BD:1
BD:2
7 052065-024 16
A * Busbar
E102-GB
1
5
160 A
FU1
6 7 P
+ PM -
4
2
Line
11 8
A1 A2
TM
3
10 F1 F2 9
+ BATT F1 F2 VMN
TCM SEM1
807473-2C
A = Battery disconnect
M1.0-0000-000177
167
Blank Page
Printed in Germany
168
HYDRAULIC SCHEMATIC
Printed in Germany
169
Blank Page
Printed in Germany
M1.0-0000-000180
170
M1.0-0000-000180
HYDRAULIC CIRCUIT
Lift cylinder
Pressure-Switch
Lowering valve
Filter
Filter
Non-return valve
Pressure relief valve Flow reducer
150 bar
to 170 bar*
Motor
Vent cap
Pump
Filter Filter
Reservoir
* depending on model and setting of the pressure relef walve M1457-2
WP2300S 05/2005 • Printed in Germany MS-HYD-1723
171
Blank Page
172

Maintenance Manual: Series

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Maintenance Manual

CROWN Gabelstapler GmbH & Co. KG

Phone +49 (0) 89 93 00 2 - 0

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

Page 63 Rev.2 05/05 General corrections and additions to text.

Page 64_A Rev.2 05/05 Additions to Platform Logic (PLM)

Page 65_A Rev.2 05/05 Updated diagram, addition to PLM.

Page 66_A Rev.2 05/05 WP2340S diagram included.

Page 88_A Rev.2 05/05 Troubleshooting addition.

WP2300S 05/2005 • Printed in Germany MS-REV-1723

REV– OVERVIEW OF REVISIONS PAGE SER-NR. CUT REV.

ITD – INTRODUCTION PAGE SER-NR. CUT REV.

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

M2 – HYDRAULICS PAGE SER-NR. CUT REV.

WP2300S 05/2005 • Printed in Germany

M3 – DRIVE UNIT PAGE SER-NR. CUT REV.

M4 – ELECTRICS PAGE SER-NR. CUT REV.

WP2300S 05/2005 • Printed in Germany

M5 – BRAKE PAGE SER-NR. CUT REV.

M6 – STEERING PAGE SER-NR. CUT REV.

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

WP2300S 05/2005 • Printed in Germany

M9 – PLATFORM PAGE SER-NR. CUT REV.

DIA – ELECTRICAL DIAGRAMS PAGE SER-NR. CUT REV.

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

WP2300S 05/2005 • Printed in Germany

Safety Symbols used in the General Maintenance and Repair

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

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

7. Neutralise and thoroughly rinse any spilled

MS-WP2300S-GB 05/03 • Printed in Germany MS-0000-MA

Before Leaving the Truck

● Lower the fork carriage fully.

● Apply the parking brake.

● Turn off the truck and remove the key.

● Block all wheels when parking on an uneven

Before Carrying out Work on the Truck

● Prevent the truck from rolling away.

● Before carrying out work on the hoist frame, the

● Only carry out operational testing when there is

Before Operating the Truck

● Get into the driver's seat.

● Check the operation of the lifting device, travel

MS-0000-MA MS-WP2300-GB 05/03 • Printed in Germany

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

INFORMATION CROWN Gabelstapler GmbH & Co.KG

Service Training M1 Lubrication and Adjustment

CROWN offers the appropriate vehicle related training

● The truck model number M7 Mast / Lifting Mechanism

● The truck serial number

DIA Electrical Diagrams

HYD Hydraulic Schematic

MS-WP2300S-GB 05/03 • Printed in Germany MS-ITD-1723

Capacity Load Wheels

2.0 = 2000 kg S = Single

MS-ITD-1723 MS-WP2300S-GB 05/03 • Printed in Germany

Jacking up the Truck Raising the Truck with a Crane

● with one hook on each side of the platform.

Capacity required: 600 kg for the WP 2300 S less

MS-WP2300S-GB 05/03 • Printed in Germany MS-1.0-1723

● to each fork tip with a lifting sling tied around the

● Attach a hook to points R and L respectively on

Capacity required: 570 kg for the WP 2300 S less