Crown WT 3000 2311

WT 3000 SERIES
MAINTENANCE MANUAL
Order Number: 812588-006

Revision: B • Printed in Germany
This master manual is subject to continual updates.
It is intended solely for companies authorized by Crown.
The transfer of the content or copies thereof to third parties is prohibited.
Crown Gabelstapler GmbH & Co. KG

– European Headquarters –
Philipp-Hauck-Str. 12
85622 Feldkirchen
Germany
Phone +49 (0)89 93 00 2 – 0

Fax +49 (0)89 93 00 2 – 312
www.crown.com
All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2014
Crown Equipment Corporation
TABLE OF CONTENTS
III
Notes:
IV
TABLE OF CONTENTS
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Text mark-ups in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Truck Data Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Model Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Truck modifications and additions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Personal safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Protecting the hazardous area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hazards from stored energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Restoring the truck to service after maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Warning and instruction decals on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifting gear and slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safety Mechanisms and Protective Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Truck safety mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Truck protective guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Lifting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lifting a fixed platform truck with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lifting a rear entry truck with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lifting a side entry truck with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lifting a folding platform truck with a crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lifting a WT 3020 with folding platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Raising a WT 3060 with folding platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lifting the truck with a forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Lifting a truck between its castor wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Lifting the truck beyond its castor wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Towing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Jacking up the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Transporting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Securing the truck for transport on a truck bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Storing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Placing the Truck in Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Periodically starting a truck that has been in storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Restoring the Truck to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cleaning the Truck and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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TABLE OF CONTENTS
Effects of incorrect cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Roller and slide bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Corrosion-protected surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cleaning the entire truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cleaning removed components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cleaning other mechanical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lubricants and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cold store truck requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Annual inspection in accordance with FEM 4.004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Terms and abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Finger Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Testing the finger guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Checking the finger guard mechanism for freedom of movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Repairing the finger guard mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
finger guard mechanism disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Attaching the finger guard mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Adjusting the finger guard mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Metric screws and nuts without flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Metric hex. bolts and nuts with flange (Unbrako® type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Replacing the Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Hydraulic Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Hydraulic unit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Replacing the Hydraulic Oil and Bleeding the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Relief valve replacement and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removing the relief valve on the 1.2 kW hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assembling the relief valve on the 1.2 kW hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Checking the relief valve on the 1.2 kW hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Setting the relief valve on the 1.2 kW hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removing the relief valve on the 2.2 kW hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Assembling the relief valve on the 2.2 kW hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Trucks with mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Trucks with electrical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Replacing the Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Replacing the drive wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Drive wheel disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Drive wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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TABLE OF CONTENTS
Changing the gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Replacing the dust shield ring (from serial no. 5A605126) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Analyzer Menu A1 - A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Analyzer Menu A3 and A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Analyzer menu A3 - A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Analyzer Menu A1 & A2, Access 1 & Access 2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Analyzer Menu A2.3, Access 3 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Analyzer Menu A2.5, Access 5 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Calibration C1 - C2 (C2 - mechanical steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Calibration C3 - C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Calibration C2 (C2 - electric steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Features F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Features F2 - F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Features F5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Features F6 - F7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Features F8 - F15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Hour menu H1 - H59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Events Menu, E1 - E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Performance P1 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Performance P2 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Performance P3 menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Performance P4-P9 menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Performance P10 - P18 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Utilities Menu U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Malfunctions with event code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Locating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Numbering scheme for event codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Event Code 100 (WT 3020 -M, WT 3040 -M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Event Code 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Event Code 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Event Codes 203 - 204 (WT 3020 -M, WT 3040 -M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Event Code 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Event Code 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Event Code 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Event Code 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Event Code 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Event Code 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Event Code 230 (WT 3020 -M, WT 3040 -M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Event Code 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Event Code 231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Event Code 232 - 233 (WT 3020 -M, WT 3040 -M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Event Code 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Event Code 233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
WT 3000 Series
Rev. B
VII
TABLE OF CONTENTS

Event Code 234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Event Code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Event Code 301 - 302 (WT 3020 -M, WT 3040 -M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Event Code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Event Code 302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Event Code 303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Event Code 304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Event Code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Event Code 306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Event Code 307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Event Code 308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Event Code 309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Event Code 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Event Code 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Event Code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Event Code 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Event Code 317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Event Code 319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Event Code 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Event Code 321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Event Code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Event Code 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Event Code 328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Event Code 329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Event Code 333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Event Code 334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Event Code 337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Event Code 338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Event Code 341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Event Code 342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Event Code 343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
WT 3000 Series
Rev. B
VIII
TABLE OF CONTENTS
Event Code 348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Event Code 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Event Code 352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Event Code 353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Event Code 354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Event Code 355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Event Code 356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Event Code 357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Event Code 358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Event Code 359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Event Code 361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Event Code 362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Event Code 364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Event Code 365 -368 (WT 3020 -M, WT 3040 -M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Event Code 365 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Event Code 368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Event Code 370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Event Code 371 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Events displayed as text (WT 3020 -M, WT 3040 -M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Platform Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Entry bar &/or FDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Traction control module hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Traction motor hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Release control handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Travel switch applied too soon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Event Code 100 (WT 3040 -E, WT 3060 -E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Event Code 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Event Codes 200 - 201 (WT 3040 -E, WT 3060 -E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Event Code 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Event Code 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Event Code 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Event Code 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Event Code 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Event Code 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Event Code 206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Event Code 207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Event Code 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
WT 3000 Series
Rev. B
IX
TABLE OF CONTENTS
Event Code 209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Event Code 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Event Code 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Event Code 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Event Code 213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Event Code 214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Event Code 215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Event Code 218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Event Code 219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Event Code 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Event Code 221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Event Code 223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Event Code 224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Event Code 225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Event Code 226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Event Code 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Event Code 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Event Code 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Event Code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Event Code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Event Code 302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Event Code 303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Event Code 304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Event Code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event Code 306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event Code 307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Event Code 308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Event Code 309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Event Code 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Event Code 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event Code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Event Code 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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Rev. B
X
TABLE OF CONTENTS
Event Code 317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Event Code 319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Event Code 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Event Code 321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Event Code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Event Code 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Event Code 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Event Code 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Event Code 328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Event Code 329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Event Code 332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Event Code 333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Event Code 334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Event Code 335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Event Code 337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Event Code 338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Event Code 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Event Code 341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Event Code 342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Event Code 343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Event Code 344 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Event Code 345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Event Code 346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Event Code 347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event Code 348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Event Code 349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Event Code 353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Event Code 370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Event Code 371 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Events displayed as text (WT 3040 -E, WT 3060 -E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
One hyd. function at a time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Platform Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Entry bar &/or FDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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Rev. B
XI
TABLE OF CONTENTS
Traction control module hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Traction motor hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Release control handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Travel switch applied too soon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Event Code 500 - 501 (WT 3040 -E, WT 3060 -E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event Code 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event Code 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event Code 502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Event Code 503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Event Code 504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Event Code 505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Event Code 506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Event Code 507 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Event Code 508 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Event Code 509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Event Code 510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Event Code 511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Event Code 512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Event Code 513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Event Code 514 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Event Code 515 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Event Code 516 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Event Code 517 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Event Code 518 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Event Code 519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Event Code 520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Event Code 522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Event Code 523 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Event Code 524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Event Code 525 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Event Code 526 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Event Code 527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Event Code 528 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Event Code 529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Event Code 530 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Event Code 531 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
WT 3000 Series
Rev. B
XII
TABLE OF CONTENTS
Event Code 532 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Event Code 533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Event Code 535 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Event Code 536 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Event Code 537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Event Code 538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Event Code 539 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Event Code 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event Code 541 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event Code 542 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event Code 543 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Event Code 544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Event Code 545 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Event Code 547 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Events displayed as text (WT 3040 -E, WT 3060 -E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Steering controller hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Steer motor hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Initial truck status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
SAS and BRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Folding platform trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Fixed platform trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Platform and Side Restraint Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Brief description of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Folding platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Side restraint and platform setting definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Fixed platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Analyzer Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Selecting the ANALYZER menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Testing the fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Selecting the ANALYZER menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Selecting the CALIBRATION Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Traction potentiometer calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Travel direction definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Electric steering calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Calibrating the SRT option for mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Load sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Software - Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Brief description of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Parameters that can be set separately in performance settings P1 - P3 . . . . . . . . . . . . . . . . . . . . . . . . 261
Trucks with electric steering and fixed platform in rider mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
WT 3000 Series
Rev. B
XIII
TABLE OF CONTENTS
Trucks with mechanical steering and fixed platform in rider mode . . . . . . . . . . . . . . . . . . . . . . . . . 261
Folding platform trucks in pedestrian mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Trucks with folding platform in rider mode (except for WT3020 MO) . . . . . . . . . . . . . . . . . . . . . . . . 262
Folding platform trucks in pedestrian mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Parameters with the same setting for all performance profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
All trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Trucks with electrical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Trucks with mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
All trucks in rider mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
All trucks in pedestrian mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
All trucks with fixed platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Servicing and Replacing the Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Power fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Discharging the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Servicing the control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Replacing control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Removing the control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Assembling the control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Control Module PMT Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
PMT Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Testing Access 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Testing Access 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Testing Access 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
General DC Motor Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
ABM Traction Motor
(up to Ser. No. 5A604759) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Traction motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Traction motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Repairing the Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Dismantling the rotor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Assembling the rotor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Crown traction motor
(from Ser. No. 5A603324) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Traction motor installation and removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Traction motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Traction motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Repairing the Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Rotor and bearing disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Rotor and bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Pump Motor (M2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Pump motor 1.2 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Pump motor 2.2 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
WT 3000 Series
Rev. B
XIV
TABLE OF CONTENTS
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Steer motor (M3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Special tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Steer motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Steer motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Repairing the steer motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Steer motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Steer motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Checking and Adjusting the BDI Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Checking the BDI Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Adjusting the BDI setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Setting the Load Profile for the Battery Discharge Indicator (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Load profile and discharge curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Assigning a load profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Battery Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Modifying “power up with Enter key” to “power up with key switch” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Modifying “power up with key switch” to “power up with Enter” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Repairing Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Wear test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Checking the contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Checking the coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Checking the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Trucks with mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Trucks with electric steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Components and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Servicing the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Measuring the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Replacing the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Parking brake disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Parking brake assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Testing the Braking Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Performing the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Braking distance tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Max. braking distances WT 3020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Max. braking distances WT 3040 with mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Max. braking distances WT 3040 with electric steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Max. braking distances WT 3060 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
WT 3000 Series
Rev. B
XV
TABLE OF CONTENTS
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Repairing the Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Steering assembly components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Steering assembly removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Repairing the steering transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Steering Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Replacing the SAHS Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
SAHS removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Adjusting the SAHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
SAHS assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Repairing Control Handle Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Removing the covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Return spring pre-tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Replacing the return springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Return spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Return spring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Repairing the Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Replacing the tiller handle shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Shell removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Shell assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Replacing the switch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Switch unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Switch unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Replacing the “rabbit/turtle” toggle module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Toggle module removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Toggle module assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Replacing the tiller handle PC boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Hydraulic PC board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Hydraulic PC board assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Main PC board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Main PC board assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Replacing the traction potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Traction potentiometer removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Traction potentiometer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Replacing the brake switch (BRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Remove the brake switch (BRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
BRS switch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Replacing the grips and horn switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Checking and Adjusting the Fork Height (Lowered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Checking the stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Adjusting the stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Adjusting the Lift Limit Cutout and Fork Height (Raised) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Adjusting the lift limit cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Checking the fork lift height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
WT 3000 Series
Rev. B
XVI
TABLE OF CONTENTS
Checking forks for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Repair Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Small hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Producing extractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Groove aligning arbor for small rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Assembly devices for large rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Protective mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Rod Seal Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Removing a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Removing a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Inserting a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Fitting a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Rod seal assembly, sealing lip first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Cylinders and Cylinder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Hydraulic system with lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Hydraulic system with lift cylinders and traction cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Replacing the Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Lift cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Installing the lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Repairing Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Replacing the Traction Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Removing the traction cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Traction cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Repairing the Traction Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Adjusting the Folding Platform Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Pre-tensioning the spring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Checking and adjusting switch PLS1 for rider mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Adjusting switch PLS2 for pedestrian mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Replacing the Folding Platform Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Spring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

Wire Colour Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
General Contact Symbol Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Electrical wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
WT -M, without CAN Tiller, ABM Motor, Keyless Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
WT -M, without CAN Tiller, ABM Motor, with Key Switch or Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . 360
WT -M, without CAN Tiller, ABM Motor, Access 2/3 Power and Logic Side . . . . . . . . . . . . . . . . . . . . 361
WT -M, without CAN Tiller, ABM Motor, Sensors and Platform Switch . . . . . . . . . . . . . . . . . . . . . . . . 362
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Platform switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
WT -M, without CAN Tiller, ABM Motor, Tiller and Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Tiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Tiller handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
WT -M, without CAN Tiller, ABM Motor, Power-Up Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
WT -E, with CAN Tiller, ABM Motor, Keyless Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
WT -E, with CAN Tiller, ABM Motor, with Key Switch or Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
WT 3000 Series
Rev. B
XVII
TABLE OF CONTENTS
WT -E, with CAN Tiller, ABM Motor,

Power Side Access 3/2 and Access 5, Logic Side Access 3/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Logic Side Access 5 and Interface Access 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
WT -E, with CAN Tiller, ABM Motor:
Platform, Side Restraint and Entry Bar Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Assemblies in Tiller Handle and Power Up Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
WT -E, with CAN Tiller, ABM Motor, CAN-Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
WT -M, without CAN Tiller, ABM Motor,
InfoLink™, Keyless Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
InfoLink™, Keyless Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
InfoLink™, Access 2/3 Power and Logic Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
InfoLink™, Sensors and Platform Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Platform switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
WT -M, without CAN Tiller, ABM Motor, InfoLink™, Tiller and Tiller Handle . . . . . . . . . . . . . . . . . . . 376
Tiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Tiller handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
WT -M, without CAN Tiller, ABM Motor, InfoLink™, Power-Up Variants and InfoLink Wiring . . . . . 377
WT -E, with CAN Tiller, ABM Motor, InfoLink™, Keyless Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . 378
WT -E, with CAN Tiller, ABM Motor, InfoLink™, with Key Switch or Keypad . . . . . . . . . . . . . . . . . . . 379
Power Side Access 3/2 and Access 5, Logic Side Access 3/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
InfoLink™, Logic Side Access 5 and Interface Access 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
WT -E, with CAN Tiller, ABM Motor.
InfoLink™: Platform, Side Restraint and Entry Bar Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
InfoLink™, Assemblies in Tiller Handle and Power Up Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
WT -E, with CAN Tiller, ABM Motor, InfoLink™, CAN-Bus Circuit Diagram . . . . . . . . . . . . . . . . . . . . 384
WT -M, with CAN Tiller, Crown Motor, Keyless Power-Up, Combined EDS/Line Contactor . . . . . . . 385
WT -M, with CAN Tiller, Crown Motor, with Options, Combined EDS/Line Contactor . . . . . . . . . . . 386
WT -M, with CAN Tiller, Crown Motor, Keyless Power-Up, Separate EDS/Line Contactors . . . . . . . 387
WT -M, with CAN Tiller, Crown Motor, with Options, Separate EDS/Line Contactors . . . . . . . . . . . . 388
WT -M, with CAN Tiller, Crown Motor, Platform Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
WT -M, Crown Motor, InfoLink™ Circuit Diagram based on CAN-Bus . . . . . . . . . . . . . . . . . . . . . . . . 390
WT -E, with CAN Tiller, Crown Motor, Keyless Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
WT -M, with CAN Tiller, Crown Motor, with Key Switch or Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
WT -E, with CAN Tiller, Crown Motor, Platform Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
WT -E, Crown Motor, InfoLink™ Circuit Diagram based on CAN-Bus . . . . . . . . . . . . . . . . . . . . . . . . 394
WT -M with InfoLink®, CAN-Bus, Crown Motor,
Standard Equipment, Separate EDS and Line Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
WT -M with InfoLink®, CAN-Bus, Crown Motor,
with Options, Separate EDS and Line Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
WT -M with InfoLink® Retrofit, CAN-Bus, Crown Motor,
with Options, Separate EDS and Line Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
WT -M, Platform Switch and InfoLink® Retrofit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
WT -E with InfoLink®, CAN-Bus, Crown Motor,
Standard Equipment, Separate EDS and Line Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
WT -E with InfoLink®, CAN-Bus, Crown Motor,
WT 3000 Series
Rev. B
XVIII
TABLE OF CONTENTS
with Options, Separate EDS and Line Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

WT -E with InfoLink® Retrofit, CAN-Bus, Crown Motor,
with Options, Separate EDS and Line Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
WT -E, Platform Switch and InfoLink® Retrofit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
Main Wire Harness WT -M to 03/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Main Wire Harness WT -M to 03/2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Main Wire Harness WT -M from 04/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Main Wire Harness WT -E to 06/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Main Wire Harness WT -E from 07/09 to 03/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Main Wire Harness WT -E from 04/2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413

Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Hydraulic Diagram, Trucks without Traction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Hydraulic Diagram, Trucks with Traction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
WT 3000 Series
Rev. B
XIX
Notes:
XVIII
INTRODUCTION
1
Notes:
2
INTRODUCTION
IMPORTANT INFORMATION
Important Information Ordering documentation

This maintenance manual outlines the maintenance Parts manuals, operator manuals, specification sheets
work necessary for the following models of the etc. can be obtained from:
WT 3000 Series truck:
:
Crown Gabelstapler GmbH & Co. KG

WT 3020 – European Headquarter –
WT 3040 Philipp-Hauck-Str. 12
WT 3060 85622 Feldkirchen
Germany
Service personnel qualification
Tel: +49 (0)89 93 00 2 – 0
To maintain the safety and functionality of the Fax: +49 (0)89 93 00 002 – 312
truck, maintenance and repair work must only be
performed by service engineers who have been au- www.crown.com
thorised by Crown.
Contact Crown if you wish to have your engineers Manual structure
trained. The manual is divided into the following sections:
Ordering spare parts
To order spare parts, use the spare parts catalog sup- Section
plied separately. Always quote the following numbers
when ordering spare parts: Index
• Truck data number Introduction
• Serial number Safety
These numbers can be found on the truck data plate.
Inspection and Lubrication
For details of your truck's technical specifications refer
to the Technical Specifications chapter in the operator Hydraulic System
manual.
Drive Unit
Note: Always use original Crown spare parts.
Electrical System
Brake System
Steering
Lifting Mechanism
Cylinders
Schematic Diagrams
Hydraulic Schematic
Conventions
Text mark-ups in the manual
The following symbols and mark-ups are used in the
manual:
1., 2., 3. etc. denote work steps to be taken.
 This arrow indicates the consequences of an ac-
tion.
WT 3000 Series
Rev. B
3
INTRODUCTION
IMPORTANT INFORMATION
 This arrow indicates action to be taken to avoid haz-

ards contained in a warnings.
(1), (2), (3) etc. indicate text references to item num-
bers in illustrations.
• Indicates the first level in a list.
– Indicates the second level in a list.
Note: Where the word "Note" appears before text, this
indicates important additional information.
Rev.3 07/2009 WT 3000 Series

Rev. B
4
INTRODUCTION
TRUCK DATA NUMBER
Truck Data Number

The truck data number is located on the data plate.
It contains important information concerning the truck's
features at the time of delivery.
1 2 3 4 5 6 7 8 9
2.0 WT 3040 -M 2 3 1 S F
Fig. 1 Specification number example
1 Maximum capacity (in tonnes)(a)
2 Model name
3 Model number
4 Steering type
M = Mechanical
E = Electric
5 Battery tray size:
1 = 200 - 240 Ah (212 x 624 x 627 mm)
2 = 315 - 375 Ah (284 x 624 x 627 mm)
3 = 420 - 465 Ah (288 x 628 x 784 mm)
6 Straddle width:
S = Special straddle width
1 = 520 mm
2 = 540 mm
3 = 560 mm
4 = 670/680 mm
7 Fork length:
S = Special length
1 = 1000 mm
2 = 1150 mm
3 = 1200 mm
4 = 1400 mm
5 = 1600 mm
6 = 1800 mm
7 = 2000 mm
8 = 2150 mm
9 = 2400 mm
8 Load wheel version:
S = Single load wheels
T = Tandem load wheels
9 Operator position version:
O = Without side restraints
F = Folding platform
R = Rear entry
S = Side entry
a. The capacity plate on the truck is binding.
The specification number in the example therefore de-

notes a WT 3040 with a 2 tonne capacity. The truck is
equipped with mechanical steering, single load wheels
and a folding platform. The battery tray can hold 315 -
375 Ah batteries. The straddle width is 560 mm, the
fork length is 1000 mm.
WT 3000 Series
Rev. B
5
Notes:
6
INTRODUCTION
MODEL COMPARISON
Model Comparison
WT3020 Standard Optional

2.0 t WT3040 WT3060
2.0 t Work
Assist
2.5 t
F/C
Travelalarm
Quick Exit
12 V Power Supply
Shock Absorb Fixed Single Caster

Caster
Fixed Dual Caster
Standard Optional Load Backrest
No KeySwitch Key Or Keypad
DIN 160 A SBE160 / SB175red / SB175gray
Work
Assist Single
Loadwheels
Tandem
Loadwheels
240 Ah Battery Travelalarm

Battery Liftout Battery Rollout
Battery Liftout 12 V Power Supply
375 Ah Low 465 Ah High
Fixed Single Caster Loadbackrest
Single
Tandem Loadwheels
Loadwheels
Key Switch or Keypad

No Key Switch 2.5 kW Traction Motor 2.5kW Traction Motor
DIN 160A SBE160 / SB175 red / SB175 gray
Foldable Side Restraints

Standard Mech. Steer. Optional Electr. Steer. Standard Electr. Steer.
Kordel 230 Gearbox ABM 250 Gearbox ABM 250 Gearbox

2.0 kW Traction Motor
Combi AC0 Traction Control Combi AC1 Traction Control Combi AC1 Traction Control
Mech. Steer. 300A Traction 350A Traction 350A Traction
250A Hydraulic 270A Hydraulic 270A Hydraulic
ActiveTraction ActiveTraction
Kordel 230 Gearbox
2.2 kW Hydraulic Unit if fork
1.2 kW Hydr. Unit is longer or equal 1600 mm 1.2kW Hydr. Unit 2.2kW Hydr. Unit
Combi AC0 Traction

300A Traction
250A Hydraulic
Optional Rear Entry Optional

1.1kW Hydr. Unit Rear Entry Optional Rear Entry
Optional
Weight Adjustable FlexRide
Optional Side Entry

Weight Adjustable FlexRide
Note: A grey background indicates options.

Optional
Fold Down Step
Fig. 2 Comparison between Models with Standard Equipment and Options
WT 3000 Series
Rev. B
7
Notes:
8
SAFETY
9
Notes:
10
SAFETY
SAFETY NOTICES
Safety Notices
The following symbols will help you to assess the risk
to yourself, other people and materials should you fail
to comply with a safety notice:
DANGER
This symbol warns of immediate danger to the life
and health of personnel.
Severe injury or death will result.
 Follow all instructions indicated by this symbol in or-
der to avoid injury or death.
WARNING
This symbol warns of potential danger to the life
and health of personnel.
Severe injury or death may result.
der to avoid injury or death.
CAUTION
This symbol warns of possible danger to the health
of personnel.
Injury may result.
der to avoid injury.
CAUTION
This signal word without a symbol warns of mate-
rial damage.
Damage to the truck, tools and mechanisms may re-
sult.
 Follow all instructions indicated by this signal word
in order to avoid damage.
WT 3000 Series Rev.2 08/2010

Rev. B
11
SAFETY
BASIC SAFETY NOTICES
Basic Safety Notices • When carrying out work on the hydraulic system,
e.g. bleeding the system, wear suitable protective
clothing such as safety gloves, goggles or a face
Organisational measures mask.
• Maintenance work must only be carried out by ser- • When handling batteries wear acid protective cloth-
vice engineers approved by Crown. ing such as safety gloves, goggles and an apron.
• Work on electrical equipment must only be carried • Long hair, loose clothing and jewellery are prohib-
out by specialist electricians in accordance with ited. They could get caught or drawn in, resulting in
electrical regulations. injury. Do not wear jewellery especially when work-
• Note the basic and action-specific safety notices in ing on electrical systems, as a short circuit could
the respective chapters of this manual. Refer also cause burning.
to the truck operator manual, in particular the Safety • Always use insulated tools when working on electri-
chapter. cal systems.
• Service personnel must also observe statutory and
other binding accident and environmental protec- Protecting the hazardous area
tion regulations.
• When carrying out maintenance work that could be
• The minimum legal age for performing mainte- hazardous to yourself and other people, seal off a
nance work must be observed. large part of the hazardous area with suitable
• Service personnel must be trained and authorised marker tape.
to operate industrial trucks and must be able to • Before carrying out maintenance work, service per-
demonstrate their competence. sonnel must ensure that there is no one in the haz-
ardous area.
Truck modifications and additions • Service personnel must stop work immediately if
• Modifications or additions to the truck may only be any unauthorised persons enter the hazardous
performed with Crown’s prior written approval. In area. These persons must be removed immedi-
such cases the data plate must be changed if nec- ately.
essary.
• If at a later time Crown is no longer in business or is Hazards from stored energy
not operating your country and there is no succes- • High pressure hydraulic oil can cause severe inju-
sor in the interest to the business, modifications and ries. Depressurise the hydraulic system before
alterations may only be performed if the following opening any sections of it.
conditions are met: • A 15 minute discharge time must be observed for
– Design, test(s) and implementation to be carried the electrical energy stored in the capacitors and
out only by an expert in industrial trucks and their coils. Alternatively, these components can undergo
safety a controlled discharge through an electrical resistor.
– Permanent records of the design, test(s) and im- • When carrying out work near the battery, always
plementation to be maintained cover the battery terminals with a suitable insulating
– Modifications must be incorporated into the truck material (e.g. plywood board) to prevent short cir-
labelling and documentation (operator, service cuits.
and parts manuals) • Before carrying out work underneath and on raised
– A permanent and readily visible label to be af- components (e.g. fork carriages, extended mast
fixed to the truck stating the manner in which the stages, the truck itself), attach suitable safety de-
truck has been modified or altered, the date and vices and supports with sufficient capacity.
name and address of the organisation responsi- • Springs and gas pressure dampers must be
ble checked and slowly discharged before removing
them.
Personal safety equipment
• Always wear safety equipment such as safety
shoes and goggles when carrying out maintenance
and repairs. Depending on requirements you may
also need to wear safety gloves and ear muffs.
Rev.1 04/2009 WT 3000 Series

Rev. B
12
SAFETY
Maintenance work Cleaning work

• Always carry out maintenance work in accordance Particular care is required when cleaning the truck and
with the test and maintenance schedule contained components that have been removed. See page 26.
in this manual and any applicable service bulletins.
• Before carrying out maintenance work prepare the Handling batteries
truck as follows: • Batteries may only be charged, serviced or re-
– Park the truck on a level surface placed by trained personnel. Observe the instruc-
– Lower the forks to the ground tions contained in the operator manual, as well as
the instructions of the battery and charger manufac-
– Switch off the truck and prevent it from being turers.
switched on again
• The charger must be appropriate to the battery volt-
– Disconnect the battery and prevent the connector age and capacity. First connect the battery, then
from being attached by unauthorised personnel. switch the charger on.
• When carrying out work that requires battery sup- • When handling batteries wear acid protective cloth-
ply, jack up the truck until the drive wheel is clear of ing such as safety gloves, goggles and an apron.
the ground.
• Do not use a naked flame and do not smoke when
• Do not use a naked flame near the truck or to check handling batteries.
fluid levels or for leaks.
• Do not touch battery terminals with metal objects.
• Always have suitable fire protection equipment to Cover the battery terminals with a suitable insula-
hand when carrying out work. tion (such as a plywood board) if you have to work
• Keep the truck clean; this makes it easier to find in this area.
loose or missing components. • Always charge batteries in designated charging ar-
• Welding work must only be carried out after prior eas and make sure the area is well ventilated.
consultation with Crown. • Remove battery acid stained clothing immediately.
• Keep the work area clean and well lit. An untidy or • If acid comes into contact with the skin, rinse imme-
poorly lit work area can lead to accidents. diately with plenty of clean water. If it comes into
• Only use original Crown spare parts and accesso- contact with the eyes, rinse immediately with clean
ries. water for several minutes and then seek medical at-
• Never install or commission damaged components. tention.
• Immediately neutralize and thoroughly rinse any
Restoring the truck to service after spilled battery fluid.
maintenance work
Warning and instruction decals on
• After carrying out maintenance refit any safety
mechanisms that have been removed and make the truck
sure they are working correctly. • In accordance with the test and service intervals
• The truck may only be restored to service after check that the warning and instruction decals on the
maintenance work once all the truck functions have truck are complete and legible.
been successfully tested, in particular on the follow- • Clean any dirty decals and replace any damaged or
ing components: missing ones.
– Brake Note: The spare parts manual gives details of the la-
– Speed control belling and position of the warning and instruction de-
– Direction switches cals on the truck.
– Steering Lifting gear and slings
– Lifting mechanism
• Always use suitable hoist devices and lifting gear
– Warning devices (horn, warning indicator) with sufficient capacity.
• To avoid endangering other people, always test the • Attach lifting gear to the designated strap points
truck in an open area where there are no other peo- and prevent it from slipping. Make sure the lifting
ple or obstacles. gear cannot touch other components during lifting.
WT 3000 Series Rev.1 04/2009

Rev. B
13
SAFETY
• Do not stand under a swinging load.

• Repair work can only be performed under a raised
truck if the truck has been protected against acci-
dental lowering.
• Work may only be performed on the chassis, fork
carriage or mast if they have also been protected
against accidental lowering.
• Lifting gear such as load slings routed around sharp
edges must be protected from cuts.
Environmental protection
• Any work that involves environmentally hazardous
substances being released must only be performed
in designated areas, to allow hazardous chemicals
and oils to be separated.
• All substances released during maintenance and
repair work must be collected in the proper manner
and disposed of in accordance with national regula-
tions. Oil filters and dehumidifying inserts must be
treated as special waste.
• Always act responsibly when carrying out repairs to
avoid damaging the environment.
Rev.1 04/2009 WT 3000 Series

Rev. B
14
SAFETY
SAFETY MECHANISMS AND PROTECTIVE GUARDS
Safety Mechanisms and Protec- The entry bar stops the truck when you place your foot
on it. This prevents your feet from extending beyond
tive Guards the perimeter of the truck accidentally.
Safety mechanisms and protective guards must only
be removed from service for maintenance and repair
work if absolutely necessary.
The safety mechanisms and protective guards must be
fully operational before the truck is restored to normal
service.
Note: As the service engineer, you are responsible for
ensuring that the safety mechanisms and protective
guards removed from service for maintenance and re-
pair work are restored to full operational order.
WARNING
Damaged safety mechanisms or protective guards
can cause accidents
Accidents with severe or fatal injuries can result if a
safety mechanism or protective guard is not working
properly.
 After working on the truck make certain that the
safety mechanisms and protective guards are in
good working order.
 Do not modify or bypass any safety mechanisms or
protective guards.
 Do not operate the truck if one of the safety mech-
anisms or protective guards is faulty or is missing.
 Repair any faulty safety mechanisms or protective
guards before allowing the truck to be used again.
Truck safety mechanisms

The safety mechanisms are:
• The Emergency Disconnect
• The safety reverse switch (in pedestrian mode) or
the brake switch (in rider and comfort modes).
Truck protective guards

The protective guards are:
• The finger guard
• The entry bar (fixed platform trucks only)
The finger guard prevents fingers from being trapped.
It covers the gap that arises between the battery tray
and chassis during lifting and lowering operations.
For maintenance, inspection and adjustment see
page 38.
WT 3000 Series
Rev. B
15
Notes:
16
INSPECTION AND LUBRICATION
17
Notes:
18
LIFTING THE TRUCK
Lifting the Truck 5. Prevent the lifting slings from slipping.

6. Place the crane hook directly above the truck's
There are various options for lifting the truck securely,
centre of gravity and connect the lifting slings to it.
depending on the truck model.
 This will ensure there is virtually no oscillation
• All trucks can be lifted by crane except for the when the truck is lifted.
WT 3020.
Raising the truck
• Only trucks with a folding platform can be lifted se-
curely with a forklift truck. 7. Raise the truck carefully.
Lifting a side entry truck with a crane

Preparing the truck
WARNING
1. Switch off the truck and remove the key.
Falling loads are hazardous 2. Disconnect the battery.
Fatal injuries can result if the truck or crane crash or if
a load falls.
 Make sure the crane, the lifting truck and the load
handling equipment have the required capacity.
Information on the capacity required can be found
on the truck data plate under “Truck Weight Less
Battery” and “Battery Weight”.
 Attach the load handling equipment correctly.
 Make sure the load cannot slip.
Lifting a fixed platform truck with a

crane
Lifting a rear entry truck with a crane Fig. 4 Raising a truck with side restraints
Preparing the truck Attaching lifting slings (see Fig. 4)

1. Switch off the truck and remove the key. 3. Strap one lifting sling around each of the forks.
2. Disconnect the battery. 4. Strap one lifting sling around the platform directly
in front of the backrest.
5. Attach another lifting sling to the lifting sling at-
tached in step 4.
6. Prevent the lifting slings from slipping.
7. Place the crane hook directly above the truck's
centre of gravity and connect the lifting slings to it.
 This will ensure there is no oscillation when the
truck is lifted.
Raising the truck
8. Raise the truck carefully.
Fig. 3 Lifting a rear entry truck

Attaching lifting slings (see Fig. 3)
3. Strap one lifting sling around each of the forks.
4. Strap one lifting sling around the retaining bracket
on either side of the truck.
WT 3000 Series
Rev. B
19
LIFTING THE TRUCK
Lifting a folding platform truck with

a crane
Lifting a WT 3020 with folding platform
WARNING
Risk of fatal accidents when lifting a WT 3020 with
the crane
The WT 3020 does not have strapping options and
cannot be raised securely with a crane.
 Use a forklift truck to raise a WT 3020.
Raising a WT 3060 with folding platform

Preparing the truck
2. Disconnect the battery.
Fig. 5 Fahrzeug mit klappbarer Plattform heben

Attaching lifting slings (see Fig. 5)
1. Fully raise the forks.
2. Strap one lifting sling around each of the forks.
3. Strap one lifting sling around either side of the
folded-down side restraint.
4. Prevent the lifting slings from slipping.
Raising the truck
5. Raise the truck carefully.
WT 3000 Series
Rev. B
20
LIFTING THE TRUCK
Lifting the truck with a forklift truck pensate for the difference in height between the
forks and the chassis.
Only trucks with a 670 mm width across forks can be
raised beyond the castor wheels. Securing the truck
For all other widths across forks the truck must be 6. Secure the truck on the forks of the truck doing the
raised within the geometry of the castor wheels. lifting with a tensioning belt (3).
Lifting the truck beyond its castor wheels

WARNING
CAUTION
Inadequate fastening can cause accidents
Fixed platform trucks are not suitable for lifting with a Only trucks with a 670 mm width across forks can be
forklift truck. raised beyond the castor wheels.
 Only folding platform trucks can be lifted with a fork-  Trucks with a different width across forks dimension
lift truck. must be raised within the castor wheels.
 Use a crane to lift fixed platform trucks.
Preparing the truck
Lifting a truck between its castor wheels 1. Fully raise the forks.
Preparing the truck 2. Switch off the truck and remove the key.
1. Fully raise the forks. 3. Disconnect the battery.
3
2 1 2
Fig. 7 Lifting the truck within the castor wheels

1 Forks of the lifting truck
Fig. 6 Lifting the truck within the castor wheels 2 Tensioning belt
1 Forks of the lifting truck
Lifting the truck
2 Beam
3 Tensioning belt
4. Place the forks (1) of the truck doing the lifting un-
derneath the chassis of the truck (see Fig. 7). Take
Lifting the truck care not to damage the castor wheels or the side
restraints.
4. Place the forks (1) of the truck doing the lifting un-
derneath the chassis of the truck (see Fig. 6). Take Securing the truck
care not to damage the castor wheels or the side 5. Secure the truck on the forks of the truck doing the
restraints. lifting with a tensioning belt (3).
5. Lay a sufficiently thick beam (2) diagonally over the
forks of the truck that is doing the lifting, to com-
WT 3000 Series
Rev. B
21
TOWING THE TRUCK
Towing the truck 2. Jack up the motor compartment side of the truck
until the drive wheel is approx. 20 mm clear of the
A de-energised truck can be towed over short dis- ground.
tances using a second truck without having to release
3. Pull the truck slowly and only in a forward direc-
the brakes.
tion (see arrow in Fig. 8).
WARNING
Tipovers can result in fatal accidents
A truck tipover can result in fatal injuries.
 Make sure the tow truck has sufficient capacity. In-
formation on the capacity required can be found on
the truck data plate under “Truck Weight Less Bat-
tery” and “Battery Weight”.
 Make sure the drive and castor wheels of the bro-
ken down truck do not get damaged by the forks of
the towing truck.
 Make sure the broken down truck does not slide off
the forks of the towing truck.
CAUTION
Avoid damaging the drive system
When the truck is de-energised the brakes are applied
to the drive wheel. If it drags along the ground while the
truck is being towed, the drive system will get dam-
aged.
 Make sure the drive wheel does not touch the
ground as the truck is being towed.
Fig. 8 Towing the truck

Towing the truck
1. Position the forks of the towing truck underneath
the truck. Take care not to damage the castor
wheels.
WT 3000 Series
Rev. B
22
JACKING UP THE TRUCK
Jacking up the truck Jacking up the truck
WARNING
Tipovers can result in fatal accidents
You can be fatally injured by a truck tipover.
 Make sure the jack has sufficient capacity. Informa-
tion on the capacity required can be found on the
truck data plate under “Truck Weight Less Battery” 1 3
4 5
and “Battery Weight”.
WARNING
Fig. 9 Jacking up the truck
Incorrect jacking procedures can cause fatal acci- 1 Wedge
dents
2 Contact point
Improper handling of the truck or the tools can result in
fatal accidents. 3 Hard wooden block
4 Contact point
 Never place your hands or other parts of your body
under the truck before it has been supported.
 Always support a raised truck with wooden blocks
2. Place wedges (1) behind both of the load wheels.
or other suitable equipment to relieve the jack.
3. Place the jack under the centre of the truck's chas-
 Only jack up the truck so far as to raise the wheels
sis at the contact point (2).
off the ground. Any further lifting will increase the
risk of tipover. 4. Jack up the truck until the drive wheel is clear of the
ground.
5. Place hard wooden blocks (3) underneath the
chassis and lower the truck onto them.
Note: After lowering, the drive wheel should not touch
the ground.
6. Place a jack underneath the forks at the contact
point (4) and raise the truck until it is horizontal.
7. Place a hard wooden block (5) underneath and
lower the forks onto it.
WT 3000 Series
Rev. B
23
TRANSPORTING THE TRUCK
Transporting the Truck 3. Switch off the truck and remove the key.
The truck must be adequately protected against slip-
ping and tipping over when being transported on a 5. Place at least one 100 mm high wooden block (1)
truck bed. across the forks.
6. Attach the tensioning belt (2) to the fastening eyes
Securing the truck for transport on a (5), place it over the wooden block (1) and pull it
taut.
truck bed
Chocking the truck with wedges
Chock the truck with 6 wedges on the truck bed (see
CAUTION Fig. 10):
1. Push two wedges (3) under the forks on the left
An incorrectly secured truck can cause accidents and right-hand sides behind the load wheels.
Trucks that are not adequately protected from slipping
2. Push two wedges (4) at the front under the two fork
and tipping over during transport can damage the load
tips.
and cause accidents.
3. Push two wedges (6) under the chassis on the left
 You must be trained and authorised to load the
and right-hand sides in front of the castor wheels.
truck.
4. Secure all wedges to the truck bed (e.g. by nailing
 Note that load securing measures must be applied
them).
and assessed correctly in each individual case.
 The truck is now adequately secured for transport-
 Ensure the tensioning belts used are taut.
ing on the truck bed.
 Prevent the tensioning belts from becoming slack
or loosening on their own.
2
6 1
3
5
4
Fig. 10 Lorry loading

1 Wooden wedge
2 Tensioning belt
3 Wedge
4 Wedge
5 Fastening eye
6 Wedge
Clamping the truck

1. Park the truck on the truck bed.
2. Fully lower the forks.
WT 3000 Series
Rev. B
24
STORING THE TRUCK
Storing the Truck Testing trucks in storage

1. Connect the battery.
Placing the Truck in Storage 2. Check the battery charge. Charge the battery if
necessary.
Trucks that will not be used for more than 3 months
must be placed in storage. 3. Apply all hydraulic functions. Approach all limit po-
sitions at least once to coat the whole of the cylin-
Placing the Truck in Storage der surfaces with oil.
1. Disconnect the battery. 4. Check the hydraulic system and gear unit for leaks.
2. De-commission the battery in accordance with the 5. Check the anti-corrosion agent and replace if nec-
manufacturer's instructions. essary.
3. Clean the truck (see page 26). 6. After carrying out the checks disconnect the bat-
tery.
CAUTION 7. De-commission the battery in accordance with the
manufacturer's instructions.
Incorrect cleaning procedures can cause damage!
Improper cleaning can damage truck components. Restoring the Truck to Service
 Clean the truck in accordance with the instructions
Carry out the following steps to restore the truck to ser-
on page 26
vice after a period of storage:
1. Remove the anti-corrosion agent where neces-
4. Wipe down the truck.
sary.
Note: Do not park the truck in the open air or in a humid
2. Lift up the truck, remove the hard wooden blocks,
environment.
lower the truck - in the reverse order of page 23.
5. The surfaces of trucks subjected to harsh ambient
3. Charge the battery in accordance with the manu-
conditions such as saline atmosphere must be
facturer's instructions or install a charged battery
treated with suitable preservatives to prevent cor-
(see page 285).
rosion.
6. Cover the truck with an air-permeable material to
protect against dust. Do not use plastic sheets as 5. Carry out the daily safety inspection (see operator
condensation could form. manual).
7. Jack up the truck (see page 23) to prevent the
wheels from flattening.
8. Store the truck in a dry room with constant temper-
ature and air humidity.
Periodically starting a truck that has

been in storage
The interval is 3 months.
CAUTION
Long periods of inactivity can result in damage to
the hydraulic system
If the hydraulic system is unused for too long, the hy-
draulic cylinders may suffer corrosion damage.
 Every 3 months test the hydraulic system on trucks
placed in storage.
WT 3000 Series
Rev. B
25
CLEANING THE TRUCK AND COMPONENTS
Cleaning the Truck and Compo- Cleaning the entire truck

nents 1. Park the truck in an area with an oil separator.
2. Switch off the truck, disconnect and remove the
battery.
CAUTION
CAUTION
Health risk
Cleaning agents, lubricants and consumables can Incorrect cleaning procedures can damage the
damage your health. truck
 Observe the manufacturer’s safety instructions Incorrect cleaning can damage electrical components
when handling solvents and lubricants. as well as bearings and lift chains.
 When wet-cleaning the truck, do not aim the water
hose or high pressure cleaner at electrical compo-
Effects of incorrect cleaning nents, bearings or lift chains.
 Make sure that no water can penetrate electrical
Electrical components components.
Electrical components such as connectors, contacts,  Use only cleaning petroleum and cleaning petrol to
distributor boards, controllers and wiring can be dam- clean lift chains, and then apply new type H chain
aged by water, cleaning agents and solvents. oil (see page 28).
Mineral and chemical residue that automatically re-
main on or in components after cleaning, are a cause
of corrosion. This corrosion results in malfunctions and Cleaning the truck surface
premature failure. 3. It is preferable to dry clean the truck using a cloth,
soft brushes or weak, dry compressed air.
Roller and slide bearings 4. If you have to wet-clean the truck, do not aim the
Steam cleaning and solvents damage the lubricant film water hose or high pressure cleaner at electrical
on bearing surfaces. This results in dry running and components, bearings or lift chains. Avoid using
rapid damage to the bearing elements. cleaning agents where possible. If grease needs to
be removed, use a mild neutral cleaning agent.
Corrosion-protected surfaces
Note: High pressure cleaning can remove anti-corro-
The brake lines, screw connections and shiny metal sion agent and paint from surfaces.
surfaces in particular on cold store trucks are factory-
treated with an anti-corrosive agent (Anticorit BW 5. If a neutral cleaning agent has been used, rinse the
components thoroughly with clear water.
366®). This protection can be washed off by solvents
and steam cleaning. The above-mentioned compo- 6. Leave the cleaned truck to dry thoroughly.
nents will corrode as a result. Cleaning electrical components
7. Clean electrical components only with weak, dry
Environmental protection compressed air and a dry cloth.
Cleaning must only be performed in specially desig-
nated areas to enable hazardous chemicals and oils to Interior cleaning
be separated. 8. Clean detachable rubber mats with water and a
Collect any waste (such as oily cleaning cloths) and neutral cleaning agent.
dispose of them in accordance with local regulations. 9. Allow the rubber mats to dry out fully before return-
ing them to the truck.
10. Damp-wipe plastic parts with a neutral cleaner.
Note: If necessary use a standard commercial plastic
cleaning agent to remove obstinate dirt.
After cleaning the truck
11. Wipe down the truck.
12. Remove any paint damage.
Rev.2 08/2010 WT 3000 Series

Rev: B
26
CLEANING THE TRUCK AND COMPONENTS
13. Add anti-corrosion agent if necessary. Note: Cleaned components must be dry and free of
cleaning agent residue before being refitted, lubricated
Returning the truck to operation after cleaning
or painted.
Normally no special measures are required.
5. Re-lubricate, paint or apply anti-corrosion agent to
If however there is a possibility that damp may have the components as required.
penetrated electrical components, proceed as follows:
6. Refit the components.
1. Clean the truck with weak, dry compressed air and
a cloth. 7. For cold store trucks apply Anticorit BW 366® as an
anti-corrosion agent for screw connections and
2. Leave the truck to stand for at least 30 minutes in
shiny metal surfaces.
a dry environment.
3. Insert the battery but do not connect it yet.
4. Jack up the truck so that the drive wheel is clear of
the ground (see page 23).
6. Power up the truck.
 If a function automatically starts, apply the
Emergency Disconnect immediately.
Note: If possible, apply compressed air to the respec-
tive switch or connector. Repeat steps 1 to 6.
 If the starting pattern is normal, proceed to step
7.
7. Check all functions.
Cleaning removed components

Cleaning other mechanical components
With the exception of lift chains, components that have
been removed can be pressure- or wet-cleaned under
certain conditions.
CAUTION
Steam-cleaning can damage electrical compo-
nents and bearings.
 Mechanical components may only be pressure- or
wet-cleaned if no electrical components or bearings
are affected.
1. Components that have been removed should be

cleaned by hand, ideally with warm water and a
mild neutral cleaning agent.
2. If high pressure cleaning cannot be avoided, it
should be done without a cleaning agent. If grease
needs to be removed, use a mild neutral cleaning
agent.
Note: High pressure cleaning can remove anti-corro-
sion agent and paint from surfaces.
3. If a neutral cleaning agent has been used, rinse the
components thoroughly with clear water.
4. Leave the cleaned components to dry thoroughly.
WT 3000 Series Rev.2 08/2010

Rev: B
27
LUBRICANTS AND CONSUMABLES
Lubricants and Consumables An anti-corrosion fluid (Crown no. 805236-004) must

be applied to all machine parts such as screws, wash-
ers, nuts, pins, retaining rings etc.
CAUTION Carefully protect all electrical connections and compo-
nents against corrosion. For detailed information, refer
The use of non-approved lubricants can damage to the Electrical System chapter.
the truck
Service intervals (see page 31) must be adapted to the
Non-approved lubricants and consumables – even of
application conditions.
the same standard – can lead to damage. This is due
to different additives in the products, which for example
can attack seals or lead to the de-oiling of fats.
Abbreviations used
 Use only the products specified in this manual. The product is indicated by letters. Individual letters (A,
B, ...) denote lubricants for normal temperature ranges
or multiple application lubricants.
Cold store truck requirements Double letters (AA, BB, ...) denote lubricants specifi-
cally for the low temperature range.
Special hydraulic oils, lubricants and grease must be
used for cold store applications (cold store trucks). These abbreviations are used in the maintenance
schedules to describe the product to be used.
Model Lubricant Type Product Manufacturer Part no.
A Transmission oil(a) GX-D 85W-90 Esso

Mobilube HD 85/90 Mobil
---
HYP 85W-90 Aral
Spirax MB 90 Shell
AA Low temperature transmis- Mobil SHC 624 Mobil
---
sion oil(a)
E Transmission oil (normal and Renolin Unisyn Fuchs
---
low temperature)(b) CLP220
B Grease (Multi-Purpose) Aralube HLP2 Aral

LM Grease Castrol
Regulus A2 Century
Beacon EP2 Esso
F806118
EP2 Maxol
Mobiluxe EP2 Mobil
Retinax LX Shell
LGWMI SKF
BB Low temperature grease Aralube SKL2 Aral
053002-005
Unirex Lotemp EP Mobil
WT 3000 Series
Rev. B
28
LUBRICANTS AND CONSUMABLES
Model Lubricant Type Product Manufacturer Part no.
D Hydraulic oil Vitam GF 32 Aral

Hyspin AWS-32 Castrol
Nuto H32 Esso
DTE 24 Mobil
---
Tellus 32 Shell
Hydran LZ 32 Finol
B110 Fuchs Mineralöl-
werke GmbH
DD Hydraulic oil (low temp) Deutz Oel HVI 32 Klockner 053001-009
G Lubrication oil Essolube HDX+40 Esso
Kowal M 40 Aral ---
Delvac 1240 Mobil
Low temperature lubrication Mobil SHC 626 Mobil
GG oil ---
M Special grease Molycote® BR-2 Plus Dow Corning ---

a. Mechanical steering trucks only.
b. Electric steering trucks only.
Lubricants Product Application Part no.
Anti-corrosive agent Anticorit BW 366® Anti-corrosive agent for cold store

805236-004
trucks
Rubber & Vinyl Dress- Commercial Rubber Components, Plastic Pan-
-------------
ing els
WT 3000 Series
Rev. B
29
PLANNED MAINTENANCE
Planned Maintenance Terms and abbreviations used

The following terms and abbreviations are used in the
Maintenance schedule subsequent tables:
This maintenance schedule assumes single shift oper- M Months
ation under normal conditions.
h Service hours
The maintenance intervals must however always be
adapted to the prevailing operating conditions. In ex- X Perform on standard trucks
treme conditions (dust, dirt, humidity etc.) and in C Perform on cold store trucks
cold stores the maintenance intervals should be re- I Inspection item
duced. Exact details should be discussed with a
Crown service engineer. L Lubrication item
Routinely check for wear, corrosion, damage, and test The lubricant type is indicated by letters. Individual let-
component operation and safety when carrying out ters (A, B, ...) denote lubricants for normal temperature
maintenance work. If in doubt, replace components. ranges, double letters (AA, BB, ...) for low temperature
Planned maintenance must be performed either after a ranges.
certain number of service hours or a certain period of
time (whichever is reached first).
The next higher inspection interval includes the
previous intervals.
For example: Let's assume the maintenance schedule
specifies intervals(1) of 500 h, 1000 h and 2000 h. The
maintenance schedule items listed under 500 h and
1000 h would then be included in the 2000 h service.
Annual inspection in accordance

with FEM 4.004
Guideline FEM 4.004 “Regular Inspection of Industrial
Trucks” requires the truck to be inspected by an expert.
This inspection must be carried out annually or in
intervals as specified by the owner's risk analysis.
National regulations must be taken into account.
Exact details of intervals should be discussed with a
Crown service engineer.
1). These intervals are only used as examples.

The binding intervals for the WT 3000 Series
are those listed in the maintenance schedule
(see page 31).
Rev.1 08/2010 WT 3000 Series

Rev. B
30
MAINTENANCE SCHEDULE
Maintenance Schedule
To locate the components listed in the following tables
refer also to:
• Electrical Components (page 291)
Electrical system
Lubricant type
12 M
36 M
Assembly Component Action
Item no.
1000 h
3000 h
Electrics EDS switch-on con- Check for wear (see page 288).
I-1
tactor
Lift limit switch Check operation. I-2
All switches, wires and Clean if necessary (see page 26).
connections Check for corrosion and damaged insula- ---
tion.
C/X
Pump motor Check motor condition (see page 272) and
I-3
carbon brushes for wear (see page 273).
Control modules Check and analyse error log. I-4
Perform a PMT test (see page 269). ---
Parking brake Check air gap (see page 298). I-5
WT 3000 Series
Rev. B
31
I-2
I-1
I-3
I-5
I-4
Fig. 11 Electrical system inspection points
WT 3000 Series
Rev. B
32
Lifting Mechanism
Lubricant type
12 M
36 M
Item no.
1000 h
3000 h
Lifting Mech- Lift cylinder Check for leaks. I-6 C/X
anism
Hydraulic oil reservoir Replace hydraulic oil. D/DD L-1 C/X
Lift linkage Lubricate and check for wear. B/BB L-2 C/X
WT 3000 Series
Rev. B
33
L-2
I-6 I-6
L-2
L-1
Fig. 12 Lifting mechanism inspection and lubrication points

L-2
L-2
Fig. 13 Lifting mechanism lubrication points
WT 3000 Series
Rev. B
34
Drive System and Wheels
Lubricant type
12 M
36 M
Item no.
1000 h
3000 h
Drive System Load and castor Check bearings. Check tyres for wear.
I-7
and Wheels wheels
Drive wheel Check torque. Check tyres for wear.
Note: Once after 50 h for new trucks or I-8 C/X
when replacing the drive wheel.
Drive gear unit 1st Replace oil on trucks with mechanical
A/AA L-3
steering (see page 55).
2. Carry out oil change and all other oil
A/AA
changes on trucks with mechanical steer- L-3
ing (see page 55). C/X
Drive gear unit Replace oil on trucks with electric steering
E L-3
(see page 55).
Dust shield ring before Replace dust shield ring (see page 57).
the live ring bearing C/X
Tiller Check operation. I-9
WT 3000 Series Rev.1 08/2010

Rev. B
35
I-9
I-7
I-7 I-8
L-3
L-3
Fig. 14 Drive system and wheel inspection and lubrication

points
Fig. 16 Drive unit lubrication points
I-7
Fig. 15 Load wheel inspection points
WT 3000 Series
Rev. B
36
Safety Mechanisms
Lubricant type
12 M
36 M
Item no.
1000 h
3000 h
Covers Finger guard Test operation (see page 38). I-8 C/X
Clean and lubricate guides L-5 C/X
Switch elements Entry bar Test freedom of movement and operation
I-9 C/X
(see truck operator manual).
I-8
L-5
L-5
Fig. 17 Finger guard
I-9
Fig. 18 Entry bar
WT 3000 Series
Rev. B
37
FINGER GUARD
Finger Guard Checking the finger guard mecha-

The finger guard is a protective mechanism. The truck nism for freedom of movement
must not be operated if the finger guard is not in place The finger guard mechanism is located on the left and
or is not working. right hand sides underneath the top cover.
Testing the finger guard

1
WARNING 3 4
2 5
Trapping hazard
If the finger guard is not working correctly, a gap be-
tween the battery tray and chassis will open during lift-
ing and lowering operations. You can trap your fingers
if you reach into this gap while activating lifting or low-
ering 6
 Proceed with particular caution when the finger
guard is removed.
 Always test the finger guard after servicing it.
 Only approve the truck for use when the finger Fig. 20 Finger guard mechanism, right-hand truck side
guard has been fitted and is working correctly. 1 Finger guard
2 Washer
Test 3 Spring
4 Bracket
5 Bolt
6 Screw
1 Preparing the truck

1. Power down the truck.
2. Disconnect the battery and prevent the truck from
being switched on again.
3. Remove the side restraints or rear entry platform if
applicable.
Fig. 19 Testing the finger guard 4. Remove the panels.
1. Lower and raise the forks several times while mon- Checking the finger guard mechanism
itoring the gap between the finger guard and the
back wall of the battery compartment (1, Fig. 19).
 The finger guard is ok if it rests against the back
wall of the battery tray for all fork positions during
CAUTION
lifting. Health risk
 If the gap between the finger guard and the back Cleaning agents, lubricants and consumables can
wall of the battery compartment increases, the fin- damage your health.
ger guard is faulty. Check the finger guard mecha-  Observe the manufacturer’s safety instructions
nism for freedom of movement and adjust it before when handling solvents and lubricants.
using the truck.
5. Clean the finger guard mechanism.
6. Remove the screw (6, Fig. 20).
WT 3000 Series
Rev. B
38
FINGER GUARD
7. Check the bolt (5) for freedom of movement in the 2. Assemble the components in the reverse order of
bracket bearing. disassembly.
 If any grooves are present, replace the bushings 3. Check the finger guard mechanism for freedom of
or repair the finger guard mechanism. movement and adjust if necessary.
 If the spring (3) is damaged or the tension too
weak, replace the spring or repair the finger Adjusting the finger guard mecha-
guard mechanism.
 If there are hardly any grooves, no parts are nism
faulty or damaged, adjust the finger guard Preparing the truck
mechanism.
Repairing the finger guard mecha- 2. Disconnect the battery and prevent the truck from
nism
Preparing the truck applicable.
1. Power down the truck. 4. Remove the panels.
2. Disconnect the battery and prevent the truck from Adjusting the finger guard mechanism
applicable.
4. Remove the panels.
1
finger guard mechanism disassembly
The following item numbers refer to Fig. 20.
CAUTION
Health risk
Cleaning agents, lubricants and consumables can
damage your health. 2
 Observe the manufacturer’s safety instructions
when handling solvents and lubricants.
1. Clean the finger guard mechanism.

2. Remove the screw (6). Fig. 21 Adjusting the finger guard mechanism
Note: The spring (3) is largely relieved when the screw 1. Loosen the screws (2) slightly.
(6) is removed. The remaining pre-tension is minor and
2. Align the mechanism while checking the freedom
does not pose a hazard.
of movement.
3. Pull out the bolt (5) so that it is released from the
3. Tighten the screws (2) if the mechanism works
bushing in the bracket (4).
without getting caught.
4. Tilt the bolt up slightly and push it out slowly over
4. Check finger guard operation (see page 38).
the bracket. This will relieve the spring (3) fully.
5. Remove the bolt fully out of the bracket.
6. Remove the spring (3) and washer (4).
7. Clean all components thoroughly and check for
damage.
Attaching the finger guard mechanism

1. Lubricate the bushing in the bracket and the bolt.
WT 3000 Series
Rev. B
39
STANDARD TORQUES
Standard Torques
Metric screws and nuts without flange
Torque table - Metric screws and nuts without flange
Thread diameter Torque (Nm)

and pitch
Grade 8 and 8.8 Grade 10 and 10.9 Grade 12 and 12.9
M5 x 0.80 5-6 7-8 8 - 10

M6 x 1.00 8 - 10 12 - 14 14 - 16
M8 x 1.25 20 - 25 20 - 35 34 - 40
M10 x 1.50 40 - 45 60 - 65 70 - 75
M12 x 1.75 70 - 80 100 - 110 115 - 130
M16 x 2.00 170 - 190 240 - 270 280 - 320
M20 x 2.50 340 - 380 450- 500 550 - 600
M24 x 3.00 580 - 650 800 - 900 900 - 1050
M30 x 3.50 1150 - 1300 1600 - 1800 1850 - 2100
Note: The torques listed in the service manual take precedence over the standard torques.
Metric hex. bolts and nuts with flange (Un-

brako® type)
Torque table - Metric hex. bolts and nuts with flange (Unbrako® type)
Thread diameter Torque (Nm)

and pitch
Grade 10 and 10.9 Grade 12 and 12.9
M5 x 0.80 8 11
M6 x 1.00 14 19
M8 x 1.25 33 45
M10 x 1.50 63 86
M12 x 1.75 111 152
M16 x 2.00 270 372
M20 x 2.50 521 717
Note: The torques listed in the service manual take precedence over the standard torques.
WT 3000 Series
Rev. B
40
HYDRAULIC SYSTEM
41
Notes:
42
HYDRAULIC SYSTEM
REPLACING THE HYDRAULIC UNIT
Replacing the Hydraulic Unit
WARNING 1
High pressure hydraulic system

Risk of injury from escaping hydraulic oil.
To avoid accidents:
 Depressurise the hydraulic system before opening
any sections of it.
 Tighten all connections before pressurising the sys-
tem.
 Keep hands and body away from pressurized fluid.
 Only trace leaks with a piece of paper or cardboard.
Whenever a high pressure fluid enters the skin it must Fig. 22 Mounting the 1.2 kW hydraulic unit
be treated as a medical emergency.
Seek medical assistance even if the skin appears nor-
mal at first.
Hydraulic Unit Removal
CAUTION
Health risk
1
damage your health.
1. Activate lowering for approx. 20 seconds.

 The hydraulic system is depressurised.
2. Disconnect the battery and jack up the truck (see
page 23).
3. Remove all electrical connections from the pump
motor.
4. Disconnect hydraulic lines from manifold. Fig. 23 Mounting the 2.2 kW hydraulic unit
5. Seal any open ports immediately with dummy
6. Loosen the two screws (1) and lift the hydraulic unit
plugs.
out of the truck.
Hydraulic unit installation

1. Assemble the hydraulic unit in the reverse order of
removal.
2. Add hydraulic oil if required.
3. Bleed the hydraulic system.
WT 3000 Series
43
HYDRAULIC SYSTEM
REPLACING THE HYDRAULIC OIL AND BLEEDING THE SYSTEM
Replacing the Hydraulic Oil and 28.

Note: The capacity is approx. 0.75 litres.
Bleeding the System
Bleeding the hydraulic system
Preparing the truck 3. Activate lifting several times to bleed the system.
1. Activate lowering for approx. 20 seconds.  The oil in the reservoir will foam.
 The hydraulic system is depressurised. 4. Fully lower the forks.
2. Switch off the truck, disconnect the battery and 5. Check the pressure port and surrounding hydraulic
prevent the truck from being switched on again. components for leaks.
3. Place a flat tray with a minimum 1 litre capacity un- 6. Switch off the truck and leave it to stand for approx-
derneath. imately 10 minutes.
Remove the reservoir and dispose of the used oil  During this time the air will separate from the oil
1. Loosen the hydraulic reservoir mounting and care- in the container.
fully remove the reservoir from the truck. 7. When there is no more foam in the reservoir add
2. Dispose of the oil in accordance with environmen- hydraulic oil up to the bottom mark of the filler neck.
tal regulations.
3. Clean the reservoir.
Installing the reservoir and adding oil
1. Fit the reservoir and seal.
10 mm
Max.
Min.
Fig. 24 Min. and max. oil levels

2. Add hydraulic oil via a filter with a minimum reten-
tion rate of 10 µm up to the bottom edge of the filler
neck. For the hydraulic oil grade see table on page
WT 3000 Series
44
HYDRAULIC SYSTEM
RELIEF VALVE REPLACEMENT AND ADJUSTMENT
Relief valve replacement and Removing the relief valve on the

adjustment 1.2 kW hydraulic unit
Relief valve (RV1) protects the lifting mechanism Relief valve RV1 is located on the rear of the hydraulic
against overload. unit.
The relief valve must be set accordingly after replace-
ment.
Note: In order to set the relief valve, there must be suf-
ficient hydraulic oil in the reservoir.
WARNING
Accidental truck movement can cause injury
A powered up truck with a connected battery can move
suddenly when you are working on it.
You should therefore carry out the following safety pro- 2 3
cedures before starting any operations on the truck:
 Lower the forks to the ground. 1
 Switch the truck off.
 Disconnect the battery.
 Prevent the truck from being switched on again.
 Jack up the truck until the drive wheel is clear of the
ground (see page 23).
Fig. 25 Relief valve 1.2 kW hydraulic unit

1. Disassemble the hydraulic unit (see page 45).
2. Place the screwdriver on the hex. bolt (3) and un-
screw the relief valve.
Assembling the relief valve on the

1.2 kW hydraulic unit
Note: Assembly is the reverse of disassembly. Note
the following:
1. Apply a thin coat of hydraulic oil to the new relief
valve, insert it into the valve seat and tighten.
2. Check the relief valve setting and adjust if neces-
sary.
Checking the relief valve on the

Checking the relief valve setting
1. With the truck at operating temperature place a
test load of 110% of the rated capacity on the forks.
 The load should lift easily. If not, adjust the relief
valve.
WT 3000 Series
45
HYDRAULIC SYSTEM
2. Now place a test load of 110% of the rated capacity

+100 kg on the forks.
 It should not be possible to raise this load as the
relief valve should open. If it can be raised, ad-
just the relief valve.
Note: The rated capacity can be found on the truck's
capacity data plate. Make sure that the relief valve set-
ting is within the tolerance range. Reset the relief valve
in the event of deviations.
Setting the relief valve on the 1.2 kW

hydraulic unit
Preparation
1. Using a spanner wrench hold nut (3) tight and
loosen nut (2).
2. Unscrew nuts (2) and (3) slightly and gently coun-
ter-fix both nuts.
Relief valve adjustment
3. Using the countered nuts turn the setscrew (1) and
then test the setting (see previous section).
Note: Adjust in small increments, a quarter turn of the
setscrew (1) will reduce or increase the pressure by ap-
prox. 15 bar.
4. Repeat step 3 until the relief valve setting is within
tolerance.
Completing the adjustment
5. Carefully loosen nuts (2) and (3), taking care not to
turn the setscrew (1).
6. Insert nut (3) until it contacts the housing and coun-
ter-fix with nut (2). Take care not to turn the set-
screw (1).
7. Check the relief valve setting again.
 If the setting is within tolerance, secure the nuts
and setscrew with locking varnish.
 If the setting is out of range, repeat the adjustment.
WT 3000 Series
46
HYDRAULIC SYSTEM
Removing the relief valve on the Setting the relief valve on the 2.2 kW
2.2 kW hydraulic unit hydraulic unit
Relief valve RV1 is located on the rear of the hydraulic
unit.
1
2

1. Remove the hydraulic unit (see page 43).
2. Position the screwdriver on the hex. bolt (3) and
unscrew the relief valve (2).
3. Remove the filter (1).
Assembling the relief valve on the

the following:
1. Apply a thin coat of hydraulic oil to the new O ring Fig. 27 Relief valve RV1 position
and position it with the strainer (1) in the valve seat.
Checking the relief valve setting
2. Apply hydraulic oil to the new relief valve (2), insert
it into the valve seat and tighten. 1. With the truck at operating temperature place a
test load of 110% of the rated capacity on the forks.
 The load should lift easily. If not, adjust the relief
valve.
2. Now place a test load of 110% of the rated capacity
+100 kg on the forks.
 It should not be possible to raise this load as the
relief valve should open. If it can be raised, ad-
just the relief valve.
Note: The rated capacity can be found on the truck's
capacity data plate. Make sure that the relief valve set-
ting is within the tolerance range. Reset the relief valve
in the event of deviations.
WT 3000 Series
47
HYDRAULIC SYSTEM
Setting the relief valve on the 2.2 kW

hydraulic unit
Note: Cut the short leg of a 6 mm Allen wrench to ap-
proximately 8 mm leg length. This enables the set-
screw of the relief valve to be adjusted in position.
Preparation
1
2

1. Using a spanner wrench hold the pressure valve
by the hex. bolt (3) tight and loosen the nut (2). Do
not turn the pressure valve in the process!
2. Unscrew the nut (2) approx. one quarter turn.
Relief valve adjustment
3. Using the shortened 6 mm Allen wrench nuts apply
the setscrew (1) and then test the setting (see pre-
vious section).
Note: Adjust in small increments. A quarter turn of the
setscrew (1) will reduce or increase the pressure by ap-
prox. 15 bar.
4. Repeat until the relief valve setting is within the tol-
erance range.
Completing the adjustment
5. Using the shortened 6 mm Allen wrench hold the
setscrew (1) firmly and manually tighten the nut
(2).
6. Check the relief valve setting again.
 If the setting is within tolerance, secure the nuts
and setscrew with locking varnish.
 If the setting is out of range, repeat the adjustment.
WT 3000 Series
48
HYDRAULIC SYSTEM
DRIFT TEST
Drift Test
After carrying out repairs to the hydraulic system per-
form a drift test. This is the only way of identifying inter-
nal leakage.
Requirements
Prepare the test load and bring the truck up to op-
erating temperature
• Place a weight corresponding to the maximum ca-
pacity on the forks.
• The test load must be evenly distributed.
• The load centre of gravity must be centrally located,
600 mm in front of the fork shanks, and must not
exceed the capacity plate specification.
Note: The temperature of the hydraulic oil must be
50°C during the test.
1. Measure the temperature in the hydraulic reservoir
before carrying out the drift test.
 When the temperature is 50°C you can start with
the drift test.
 If the temperature is too low, proceed to step 2.
2. Raise the forks with maximum load several times
until the hydraulic oil temperature is 50°C.
Lifting a test load
1. Insert the forks under the test load.
3. Place a bar across the forks, measure and record
the height above the ground.
4. Switch off the truck and disconnect the battery.
5. Wait for 10 minutes.
Measuring the drift
6. After 10 minutes measure the rail height again.
7. Calculate the difference between the previously re-
corded measurement and the new measurement
to establish the drift.
 If the drift ≥ 100 mm, the internal leakage is too
great. Repair the cylinder (see page 335) and
repeat the drift test.
 If the drift < 100 mm, it has passed the drift test.
WT 3000 Series
49
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM TROUBLESHOOTING
Hydraulic System Trouble-

shooting
Symptom Probable Cause Remedy
Noisy pump - Oil level too low. - Check oil level.

- Incorrect oil viscosity (e.g. standard oil - Use correct hydraulic oil.
used in cold store environment). - Check suction pipe connection to pump.
- Leak in suction pipe union (pump suc- - Replace filter.
tions air).
- Filter in suction pipe partly clogged.
Foaming hydraulic oil - Air in system - Check oil level.
- Water in oil - Check suction pipe connection to pump.
- Clean reservoir and replace hydraulic
oil.
Pump or oil overheating - Incorrect oil viscosity (e.g. cold store oil - Drain oil completely and add oil depend-
used at normal temperature). ing on the application conditions.
- Oil contaminated with water. - Drain oil completely, clean reservoir and
- Pressure relief valve permanently open fill with clean oil.
- Check oil level.
- Check suction pipe / pump connection
(see “Foaming hydraulic oil” symptom).
- Check setting and operation of relief
valve (see page 45).
Low flow rate - Air in system. - See “Foaming hydraulic oil” remedy.
- Pressure relief valve leaky or set too low. - See “Pump or oil overheating” remedy.
- Oil too hot. - Check setting and operation of relief
valve (see page 45).
No build up of pressure - Faulty relief valve - Test the relief valve (see page 45), re-
- Oil level low place if faulty.
- Add hydraulic oil.
Lifting delay - Air in manifold - Flush the lift cylinders (see page 44).
Rev.\x11 1 06/2010 WT 3000 Series
50
DRIVE UNIT
51
Notes:
52
ENGINE AND TRANSAXLE
COMPONENTS
Components Trucks with electrical steering

A steering assembly with a steering gearbox and steer
Trucks with mechanical steering motor is incorporated via an intermediate flange.
The drive unit components comprise the following: The drive unit components comprise the following:
2
2
3
3
5 4
4
5
Fig. 29 Drive unit - mechanical steering Fig. 30 Drive unit - electric steering
1 Brake 1 Brake
2 Traction motor 2 Steer motor
3 Live ring bearing 3 Steering assembly
4 Drive gear unit 4 Drive gear unit
5 Drive wheel 5 Drive wheel
6 Traction motor
WT 3000 Series
Rev. B
53
REPLACING THE DRIVE WHEEL
Replacing the Drive Wheel
WARNING
You should therefore carry out the following safety pro-
 Lower the forks to the ground.
Replacing the drive wheel

Drive wheel disassembly
Preparation
1. Remove the panels so that the drive wheel can be
accessed.
2. Jack up the truck (see page 23) so that the drive
wheel is clear of the ground.
Drive wheel disassembly
1. Unscrew the wheel nuts.
2. Remove the wheel nuts.
3. Pull the drive wheel off the bolts.
4. Fit the new drive wheel.
Drive wheel assembly
CAUTION
Wheel nuts can cause material damage if they come
loose
 Re-tighten the wheel nuts approx. 50 hours after
assembling the drive wheel.
Assembly is the reverse of disassembly. Torque the

wheel nuts to 130 Nm (M14) / 100 Nm (M12).
Rev.1 08/2020 WT 3000 Series

Rev. B
54
CHANGING THE GEAR OIL
Changing the gear oil

WARNING
A falling truck can cause fatal injuries
CAUTION You can be fatally injured by a falling truck.
Health risk  Use only lifting gear, slings and blocks with suffi-
Cleaning agents, lubricants and consumables can cient capacity.
damage your health.  Support the truck raised with a crane in such a way
 Observe the manufacturer’s safety instructions that it cannot fall even if the lifting gear or crane fail.
Preparing to change the oil
The oil should have reached operating temperature be- 1. Raise the truck with a crane or forklift truck only as
fore changing. This will ensure that it flows away far as is absolutely necessary (see “Lifting the
quickly and any contamination is kept in suspension. Truck”, page 19). The drive wheel must however
be clear of the ground.
2. Secure the truck to prevent it from lowering acci-
dentally.
3. Apply the steering to turn the drive wheel so that
the refill plug (1) and the drain plug (2) on the gear
unit are accessible.
4. Place a flat tray with a minimum capacity of 1.5 li-
tres underneath to collect the used oil.
Draining the oil
5. Unscrew the refill plug.
6. Unscrew the oil drain plug (2) and collect the oil.
7. Dispose of used oil in accordance with environ-
mental and local regulations.
Adding oil
1 8. Clean the drain plug (2), screw it on and tighten.
CAUTION
Risk of gear unit damage
Mixing mineral oil with synthetic oil can damage the
gear unit.
 For trucks with electric steering use type E trans-
mission oil only.
 For trucks with mechanical steering use type A
transmission oil only.
2
9. Add a suitable transmission oil (see Lubricants and

Fig. 31 Oil refill and drain plug positions
Consumables, on page 28)
Note: The refill plug can only be accessed when the Note: The capacity for trucks with mechanical steering
truck is raised. Therefore a crane or another truck with is approx. 0.9 litres, for trucks with electric steering ap-
sufficient capacity must be used to raise the truck. The prox. 1.6 litres).
truck must not be jacked up for safety reasons. If the
10. Clean the refill plug (1), screw it on and tighten.
truck can only be raised a certain amount, the drive
motor can be removed (see page 273) in order to add 11. Remove the jack from the truck and the device to
oil via the open gear unit cover. prevent it from being switched on.
WT 3000 Series
Rev. B
55
CHANGING THE GEAR OIL
12. Test the truck.
WT 3000 Series
Rev. B
56
REPLACING THE DUST SHIELD RING (FROM SERIAL NO. 5A605126)
Replacing the dust shield ring

(from serial no. 5A605126)
The dust shield ring (felt ring) in front of the live ring
bearing protects the bearing from contamination. The
live ring bearing itself is maintenance-free. It cannot
and must not be lubricated.
Preparation
2. Prevent the truck from being switched on again
and rolling away.
3. Disassemble the traction motor (see page 275).
Dust shield ring removal
1. Remove three screws (1). 1
2. Take off the adapter ring (2).
3. Remove plates (3 and 4). In the process pull up
2
and remove the dust shield cover (5).
Note: If the dust shield cover (5) jams when being
pulled out, remove the two screws (8) and washers (7).
Then remove the plate (4). 3
8
4. Remove the dust shield ring (6) from the gap. 7
4
CAUTION 5
6
Risk of damage to the live ring bearing
If compressed air is applied with excess pressure, dirt
can be pressed into the bearing, or the grease filling
can be driven out.
 Apply compressed air of max. 0.5 bar overpres-
sure.
5. Blast out any contamination with weak com-

pressed air.
Dust shield ring assembly
1. Press a new dust shield ring all the way round the
gap.
Note: The dust shield ring must be flush with the top of
the receptacle all the way around.
2. Assemble the previously removed components in
the reverse order of disassembly.
3. Carry out an functional test. Fig. 32 Dust shield ring removal
WT 3000 Series
Rev. B
57
Notes:
58
ELECTRICAL SYSTEM
59
Notes:
60
ELECTRICAL SYSTEM
SOFTWARE VERSIONS
Software Versions
The following menu structure and the flow chart apply
to the following software versions:
Access 1 (display) software versions
Access 1 item number Software version Used in:

(truck data number)(a)
825777-001 600 WT 3040 -M

WT 3040 -E
WT 3060 -E
825777-001 600 WT 3020 -M
a. A breakdown of the truck data number can be found on page 5.
Access 2 (HCM) Software Versions
Access 2&3 item number Software version Used in:

823569-001 600 WT 3020 -M

WT 3040 -M
816300-100 011 WT 3040 -E
WT 3060 -E
Access 3 (TCM) software versions
Access 2&3 item number Software version Used in:

823569-001 600 WT 3020 -M

WT 3040 -M
816300-100 033 WT 3040 -E
WT 3060 -E
WT 3000 Series
Rev. B
61
ELECTRICAL SYSTEM
SOFTWARE VERSIONS
Access 5 (SCM) software versions
Access 5 item number Software version Software version Used in:

(Master) (Slave) (truck data number)(a)
816301-100 308 202 WT 3040 -E

WT 3060 -E
Access 8 (CAN interface) software versions
Access 8 item number Software version Used in:

818767 100 WT 3040 -ER

WT 3040 -ES
WT 3060 ER
824391 100 WT 3040 -EF
WT 3060 -EF
WT 3000 Series
Rev. B
62
ELECTRICAL SYSTEM
MENU STRUCTURE
Menu Structure
OPERATOR MENU SERVICE MENU
Message Mode: Analyzer:

WT 3000 Status
BDI Inputs
Hour Outputs
Speed Test Outputs
Hour: Calibration:
Runtime 1 PF & FF Rocker
Runtime 2 Steering System
Enter Password: Load Sensor
(from Operator Menu, TFD Calibration
enter the 4 digit code)
Events:
Last
… Features:
Last - 15 Languages
Travel Alarm
Beacon
Truck Type
Service: Message Mode
Levle 2 Performance
Level 3 User Codes
EEPROM Clear
TFD Torque
Hour Meter
Performance: Belly Button Rider
P1 Key Less
P2 InfoLink
P3
Hour:
Runtime 1
Runtime 2
Access 2
Access 3
Access 5
Events:
Chron History (last 15)
Accum History
Clear History
Performance:
P1
...
P18
Utilities:
Hardware Part Number
Software Part Number
TI 600-01_2B-2
Fig. 33 Overview
WT 3000 Series
Rev. B
63
ELECTRICAL SYSTEM
MENU STRUCTURE
WT 3000 BDI = Value
HOURS = Value
SPEED = Value
HOUR H1/H2 Runtime 1 = Value Value
EVENTS Last Ev = Value Value
Last-1…-15 Ev = Value Value
SERVICE Level 2 Password

Continued on page
65
Test fans, see

Level 3 Password
page 254
PERFORMANCE SET P1
SET P2
SET P3
TI 600-01_2B-3
Fig. 34 Operator menu and entering the Service menu
WT 3000 Series
Rev. B
64
ELECTRICAL SYSTEM
ANALYZER MENU A1 - A2
Analyzer Menu A1 - A2
From page 64
ANALYZER A1 STATUS A1.1 ACCESS 1 ON
A1.2 ACCESS 2 ON
A1.3 ACCESS 3 ON
A1.4 ACCESS 5 ON
A1.5 ACCESS 8 ON
A1.6 MAIN C ON
A2 INPUTS A2.1 ACCESS 1 Page 68
A2.2 ACCESS 2
Page 68
A2.3 ACCESS 3 Page 69
CALIBRATION To A3 A2.5 ACCESS 5 Page 71
Page 72 Page 66
Fig. 35 Analyzer Menu, Part 1
WT 3000 Series
Rev. B
65
ELECTRICAL SYSTEM
ANALYZER MENU A3 AND A4
Analyzer Menu A3 and A4
A2, page 65
A2
A3 OUTPUTS A3.1 BATTERY % Value
A3.2 BATTERY VOLTAGE Value

=VALUE
BATTERY
A3.3 CURRENT = VALUE
Value
TRACTION
A3.4 Value
SPEED = VALUE
RPM TRACTION
A3.5 MOTOR = VALUE
Value
1
RPM STEER
A3.6 MOTOR = VALUE
Value
A3.7 BRAKE = VALUE Value
A3.8 SVL = VALUE Value
A3.9 HORN = VALUE Value
A3.10 FAN = VALUE Value
A3.11 FLS = VALUE Value
A3.12 ALM = VALUE Value
A4 TEST
CLOSE ED A4.1 FAN Enter to Cancel
OUTPUTS
(5 second timeout)
Escape
TI 600-01_2B-5
WT 3000 Series
Rev. B
66
ELECTRICAL SYSTEM
ANALYZER MENU A3 - A4
Analyzer menu A3 - A4
From A3, page 66

From A3.6, page 66
A3.7 BRAKE = VALUE Value
A3.8 SVL = VALUE Value
A3.9 HORN = VALUE Value
A3.10 FAN = VALUE Value
A3.11 FLS = VALUE Value
A3.12 ALM = VALUE Value
A4 TEST
CLOSE ED A4.1 FAN Enter to Cancel
OUTPUTS
(5 second timeout)
Fan test can only be carried out in service
level 3
Escape
WT 3000 Series
Rev. B
67
ELECTRICAL SYSTEM
ANALYZER MENU A1 & A2, ACCESS 1 & ACCESS 2 INPUTS
Analyzer Menu A1 & A2, Access 1 & Access 2 Inputs
From A2.1, page 65
(1)
ACCESS 1 INPUTS A2.1.1 POT 4 Value
(2)
ACCESS 2 INPUTS A2.2.1 RAS + LMS1 SWITCH = VALUE Value
A2.2.1
A2.2.2 RAS
LOS SWITCH = VALUE Value
A2.2.3 PRESSURE TRANSDUCER = VALUE Value
A2.2.4 PUMP MOTOR CURRENT = VALUE Value
A2.2.5 PUMP ON = VALUE Value
(3)
A2.2.6 LMS 1 SWITCH = VALUE Value
(1) Only available with mechanical steering.

(2) “RAS + LMS1” display only with mechanical steering. For electric steering only “RAS” is displayed.
(3) A2.2.6 is only displayed with electric steering.
Fig. 38 Access 1 and Access 2 Inputs
WT 3000 Series
Rev. B
68
ELECTRICAL SYSTEM
ANALYZER MENU A2.3, ACCESS 3 INPUTS
Analyzer Menu A2.3, Access 3 Inputs
From A2.3, page 65
ACCESS 3 INPUTS A2.3.1 TEMP ACCESS 3 = VALUE Value
A2.3.2 TS1 = VALUE Value
A2.3.3 PF SWITCH = VALUE Value
A2.3.4 FF SWITCH = VALUE Value
A2.3.5 POT WPR = VALUE Value
A2.3.6 HSS1 SWITCH = VALUE Value
A2.3.7 HNS 1 + 2 SWITCH = VALUE Value
A2.3.8 BRS SWITCH = VALUE Value
A2.3.9 PLS1 SENSOR = VALUE Value
A2.3.10 PLS2 SENSOR = VALUE Value
Continued with A2.3.11, page 70
Fig. 39 Access 3 Inputs, part 1
WT 3000 Series
Rev. B
69
ELECTRICAL SYSTEM
From A2.3.10, page 69
A2.3.11 SR1 SENSOR = VALUE Value
A2.3.12 SR2 SENSOR = VALUE Value
A2.3.13 SAS SWITCH = VALUE Value
TRACTION MOTOR CURRENT

A2.3.14 Value
= VALUE
ECR1 ENCODER 64P

A2.3.15 Value
= VALUE (pulses)
Fig. 40 Access 3 Inputs, part 2
WT 3000 Series
Rev. B
70
ELECTRICAL SYSTEM
Analyzer Menu A2.5, Access 5 Inputs
From A2.5, page 65
(1)
ACCESS 5 INPUTS A2.5.1 TEMP ACCESS 5 = VALUE Value
A2.5.2 TS3 (TEMP MOTOR) = VALUE Value
A2.5.3 STEER MOT CURRENT = VALUE Value
A2.5.4 STEER POT1= VALUE Value
A2.5.5 STEER POT 2 = VALUE Value
A2.5.6 ECR2 (ENCODER32P) = VALUE Value
A2.5.7 ECR3 (ENCODER48P) = VALUE Value
A2.5.8 STRAIGHT AHEAD SENSOR = VALUE Value
(1) Only on trucks with electric steering.
Fig. 41 Access 5 Inputs
WT 3000 Series
Rev. B
71
ELECTRICAL SYSTEM
CALIBRATION C1 - C2 (C2 - MECHANICAL STEERING)
Calibration C1 - C2 (C2 - mechanical steering)
From Analyser, page 65
PF / FF
CALIBRATION C1 ROCKER Sure? N Sure? Y
TURN ROCKER MAX PF &

C1.1 Value
MAX FF THEN ENTER
SAVED
Save? N
WAIT
Save? Y
(1)
C2 STEER SYS Sure? N Sure? Y
ACQUIRE TILLER
C2.1 CONFIRM
CENTER
ACQUIRE FULL
C2.2 CONFIRM
LEFT
ACQUIRE FULL
C2.3 CONFIRM
RIGHT
Save? N
To C3, page 72
Save? Y
To page 73
(1) Calibration of SRT option (Speed Reduction on Turns) for trucks with mechanical steering. For electric steering calibration
see page 256.
Fig. 42 Calibration Menu, Part 1
WT 3000 Series
Rev. B
72
ELECTRICAL SYSTEM
CALIBRATION C3 - C4
Calibration C3 - C4
From page 72
From C2, page 72
C3 LOAD SENSOR Sure? N Sure? Y
C3.1 AQUIRE MIN LOAD CONFIRM
C3.2 AQUIRE MAX LOAD CONFIRM
Save? N
To Features, page 75
Save? Y
(1)
C4 TFD CALIBR. Sure? N Sure? Y
TFD CURRENT =
C4.1 VALUE
VALUE
Save? N
Save? Y
(1) Electric steering only
WT 3000 Series
Rev. B
73
ELECTRICAL SYSTEM
CALIBRATION C2 (C2 - ELECTRIC STEERING)
Calibration C2 (C2 - electric steering)
From C1, page 72
(1)
C2 STEER SYS Sure? N Sure? Y
C2.1 ACQUIRE TILLER CENTER CONFIRM
C2.2 ADJ FULL LEFT COARSE VALUE
C2.3 ADJ FULL LEFT FINE VALUE
C2.4 ADJ FULL RIGHT COARSE VALUE
C2.5 ADJ FULL RIGHT FINE VALUE
C2.6 ADJ DRIVE TIRE CENTER VALUE
C2.7 2ND ENCORDER ON/ OFF
Save? N
Save? Y
(1) Electric steering only. For electric steering calibration see page 256.
WT 3000 Series
Rev. B
74
ELECTRICAL SYSTEM
FEATURES F1
Features F1
From Calibration, page 73
FEATURES F1 LANGUAGE = VALUE ENGLISH
GERMAN
Save? N FRENCH
SPANISH
Save? Y
DUTCH
(1)
Re-Key ITALIAN
Required
POLISH
CZECH
DANISH
Continued with Fig. 46 Continued with Fig. 46
(1) After changing the Features menu the truck must always be restarted.
Fig. 45 Features Menu, Part 1
WT 3000 Series
Rev. B
75
ELECTRICAL SYSTEM
FEATURES F1
From Fig. 45 From Fig. 45
PORTUGESE
HUNGARIAN
FINISH
NORWEGIAN
SWEDISH
RUSSIAN
TURKISH
GREEK
To Hour menu, page 82 To F2, page 77 SLOVENIAN
WT 3000 Series
Rev. B
76
ELECTRICAL SYSTEM
FEATURES F2 - F4
Features F2 - F4
From F1, page 76
F2 TRAVEL ALARM OFF
BOTH
F3 BEACON OFF
FF
KEY
PF
BOTH
FF
PF
F4 TRUCK TYPE 3020 MO
3040 MF
3040 MR
3040 EF
3040 ER
3040 ES
3060 EF
To F5, page 78
3060 ER
WT 3000 Series
Rev. B
77
ELECTRICAL SYSTEM
FEATURES F5
Features F5
From F4, page 77
MESSAGE
F5 BDI
MODE
HOURS
SPEED
ALL
To F6, page 79
WT 3000 Series
Rev. B
78
From F5, page 78
Features F6 - F7
PERFORMANCE
F6 ENABLE
=VALUE
DISABLE
F7 USER CODES DISABLE

= VALUE
From / to F7.4, page 80
(1)
ENABLE F7.1 VIEW CODES ENTRY 1 1000 P1
ENTRY 2 2000 P2
ENTRY 3 3000 P3
ENTRY 25 xxxx Px
WT 3000 Series
F7.2 ADD CODES PIN 0001
PERFORMANCE LEVEL P1
P2
To F8, page 81 To F7.3, page 80
P3
(1) The current entry number is displayed for 0.5 seconds. The user code and performance level are then displayed.
79
FEATURES F6 - F7
ELECTRICAL SYSTEM
Rev. B
80
Rev. B
From F7.2, page 79
(1)
FEATURES F6 - F7
F7.3 MODIFY CODES ENTRY 1 PIN 0001

ELECTRICAL SYSTEM
ENTRY 2 PERFORMANCE LEVEL P1
ENTRY 25 P2
WT 3000 Series
(1)
F7.4 DELETE CODES ENTRY 1 1000 P1
P3
From / to F7.1,
page 79
ENTRY 2 2000 P2
ENTRY 25 3000 P3
(1) The current entry number is displayed for 0.5 seconds. The user code and performance level are then displayed.
From F7, page 79
(1)
F8 EEPROM CLEAR NO
Features F8 - F15
YES ACCESS 1 NO
(2)
F9 TFD TORQUE
CONSTANT
= VALUE YES

HOUR METER LOW TO HIGH CLEARED
F10 H1
= VALUE
H2 LOW TO HIGH ACCESS 2 NO

2
(3)
FREE YES
BELLY BUTTON RIDER

F12 OFF
= VALUE
CLEARED
2
ON
ACCESS 3 NO
F13 KEYLESS = VALUE DISABLE
COASTING
WT 3000 Series
YES
KEYLESS VALUE
ENABLE F13.1
TIMEOUT = VALUE (10-30min)
(4)
CLEARED
F14 SRT =VALUE DISABLE
2
ACCESS 5 NO
F15 INFOLINK
DISABLED ENABLE
= VALUE
YES
F15 ENTRY BAR CAN

ON
= VALUE
CLEARED
IO
OFF
(5)
CODE XX
(1) Resets all parameters to default. (4) Option for trucks with mechanical steering.
(2) For trucks with electric steering. (5) Change only with approval of Crown Engineering.
(3) Do not use "FREE" setting!
FEATURES F8 - F15
81
ELECTRICAL SYSTEM
Rev. B
ELECTRICAL SYSTEM
HOUR MENU H1 - H59
Hour menu H1 - H59
From Features, page 76
(2)
HOUR H1 Runtime 1 = Value Value
(2)
H2 Runtime 2 = Value Value
Runtime 2 = Runtime 1 + a fixed value in seconds:
Setting: 1 2 3 4 5 6 7 8 9
Factor: 0 1 2 3 4 5 6 7 8
(1) (3)
H3 Access 2 = Value Value
(1) (3)
To Events, page 83
(1) (3)
(1) H4/H5 only for trucks with electric steering. For trucks with mechanical steering the service hours of Access 2 & 3 are displayed
combined under H3.
(2) In Service Level 2 only the reading is displayed. In Service Level 3 the value can be changed.
Runtime 2 = Runtime 1 + a fixed value in seconds. For example: Setting 1 corresponds to factor 0. Setting 9 corresponds to factor 8.
(3) Display only, reading cannot be changed.
Fig. 52 Hour menu
WT 3000 Series
Rev. B
82
ELECTRICAL SYSTEM
EVENTS MENU, E1 - E3
Events Menu, E1 - E3
From Hour, page 82
CHRON
EVENTS E1 E1.1 LAST CODE = VALUE VALUE
HISTORY
HOUR = VALUE VALUE
TEMP = VALUE VALUE
E1.2 LAST-1 CODE = VALUE VALUE
HOUR = VALUE VALUE
TEMP = VALUE VALUE
E1.16 LAST-15 CODE = VALUE VALUE
HOUR = VALUE VALUE
TEMP = VALUE VALUE
ACCUM EVENT X OCCURENCES =

E2 VALUE
HISTORY VALUE
EVENT Y OCCURENCES = VALUE

VALUE
EVENT Z OCCURENCES = VALUE

VALUE
CLEAR
E3 E3.1 CLEAR CHRONOLOGICAL NO
HISTORY
To Performance, page 84 YES
E3.2 CLEAR ALL NO
YES
Fig. 53 Events menu
WT 3000 Series
Rev. B
83
ELECTRICAL SYSTEM
PERFORMANCE P1 MENU
Performance P1 Menu
From Events, page 81
PERFORMANCE P1 SET P1 P1.1 RIDER TRAVEL SPEED EDIT 1 - 9

PF = VALUE
RIDER TRAVEL SPEED

P1.2 EDIT 1 - 9
FF = VALUE
Save? N
RIDER ACCELERATION
P1.3 EDIT 0 - 4
= VALUE
RIDER PLUGGING
Save? Y P1.4 EDIT 1 - 9
= VALUE
RIDER COASTING
P1.5 EDIT 1 - 9
= VALUE
Re-Key
Required
P1.6 PL UP SPEED EDIT 1 - 9

PF = VALUE

FF = VALUE
P1.8 PL DOWN SPEED EDIT 1 - 9

PF = VALUE

FF = VALUE
WALKIE
P1.10 ACCELERATION EDIT 1 - 9
= VALUE
P1.11 WALKIE PLUGGING EDIT 1 - 9

= VALUE
To Utilities, To P2, page 85 P1.12

WALKIE COASTING
= VALUE
EDIT 1 - 9
page 89
(1)
P1.13 SPEED REDUCTION EDIT 0 - 3
ON TURNS = VALUE
(2)
PANIC STEERING
P1.14 EDIT 1 - 9
= VALUE
(1) Do not change Default setting can only be changed by Crown Engineering
(2) Electric steering trucks only.
Fig. 54 Performance Menu, Part 1
WT 3000 Series
Rev. B
84
ELECTRICAL SYSTEM
PERFORMANCE P2 MENU
Performance P2 Menu
From Events, page 81 From P1, page 84

PF = VALUE
RIDER TRAVEL SPEED

P2.2 EDIT 1 - 9
FF = VALUE
Save? N
RIDER ACCELERATION
P2.3 EDIT 0 - 4
= VALUE
RIDER PLUGGING
= VALUE
RIDER COASTING
P2.5 EDIT 1 - 9
= VALUE
Re-Key
Required

PF = VALUE

FF = VALUE

PF = VALUE

FF = VALUE
WALKIE
= VALUE
P2.11 WALKIE PLUGGING EDIT 1 - 9

= VALUE
To Utilities, To P3, page 86 P2.12

WALKIE COASTING
= VALUE
EDIT 1 - 9
page 89
(1)
ON TURNS = VALUE
(2)
PANIC STEERING
P2.14 EDIT 1 - 9
= VALUE
WT 3000 Series
Rev. B
85
ELECTRICAL SYSTEM
PERFORMANCE P3 MENU
Performance P3 menu
From Events, page 81 From P2, page 85

PF = VALUE
RIDER TRAVEL SPEED

P3.2 EDIT 1 - 9
FF = VALUE
Save? N
RIDER ACCELERATION
P3.3 EDIT 0 - 4
= VALUE
RIDER PLUGGING
= VALUE
RIDER COASTING
P3.5 EDIT 1 - 9
= VALUE
Re-Key
Required

PF = VALUE
P3.7 PL UP SPEED FF EDIT 1 - 9

= VALUE

PF = VALUE

FF = VALUE
WALKIE
= VALUE
To Utilities, To P4, page 87 P3.11 WALKIE PLUGGING

= VALUE
EDIT 1 - 9
page 89
P3.12 WALKIE COASTING EDIT 1 - 9

= VALUE
(1)
ON TURNS = VALUE
(2)
PANIC STEERING
P3.14 EDIT 1 - 9
= VALUE
WT 3000 Series
Rev. B
86
ELECTRICAL SYSTEM
PERFORMANCE P4-P9 MENU
Performance P4-P9 menu
From Events, page 81 From P3, page 86 LIGHT DUTY
PERFORMANCE BDI SETTING

P4 STANDARD DUTY
= VALUE
MEDIUM DUTY
(1)
Save? N
HEAVY DUTY
MAINTENANCE FREE
Save? Y
Re-Key
Required
(2)
P5 MAX EVP = VALUE EDIT 1 - 9
P6 MIN EVP = VALUE EDIT 1 - 9
EVP OPEN DELAY

P7 EDIT 1 - 9
= VALUE
EVP CLOSE DELAY

P8 EDIT 1 - 9
= VALUE
P9 PUMP ACCELERATION EDIT 1 - 9

= VALUE
To Utilities, page 89 To P10, page 88
(1) The procedure for changing and saving parameters is the same for items P4 - P18.
(2) If a TFD module is fitted, parameters P5 - P8 are used to set the pattern of the TFD module. On trucks with mechanical steering
P5 - P8 determine the pattern of the lowering valve. P5 - P8 change only after consultation with Crown Engineering.
WT 3000 Series
Rev. B
87
ELECTRICAL SYSTEM
PERFORMANCE P10 - P18 MENU
Performance P10 - P18 Menu
From P3, page 86
(1)
PUMP DECELERATION
P10 EDIT 1 - 9
= VALUE
ADJUST BATT
P11 VALUE
= VALUE
P12 RIDER TURTLE SPEED = EDIT 1 - 9

VALUE
WALKIE TURTLE SPEED

P13 EDIT 1 - 9
= VALUE
TURTLE MODE BRAKE =

P14 EDIT 1 - 9
VALUE
BB ACCELERATION
P15 EDIT 1 - 9
= VALUE
BB DECELERATION
P16 EDIT 1 - 9
= VALUE
P17 ENTRY BAR BRAKE EDIT 1 - 9

= VALUE
P18 UNLOAD THRESHOLD EDIT 1 - 9

= VALUE
To P1, page 84
(1) The procedure for changing and saving parameters is the same for items P4 - P18.
WT 3000 Series
Rev. B
88
ELECTRICAL SYSTEM
UTILITIES MENU U1
Utilities Menu U1
From Events, page 81
U1 PART
UTILITIES U1.1 ACCESS 1 U1.1.1 Module PN=Value Value
NUMBERS
U1.1.2 Software PN=Value Value
(1),(2)
U1.2 ACCESS 2 U1.2.1 Module PN=Value Value
(1),(2)
(2)
U1.4.3 Slave Software =Value Value
To Analyser, page 65 (2)

TILLER
(1) With mechanical steering Access 2 and Access 3 are not shown separately but as “Access 3 & 2”.
Fig. 59 Utilities Menu
WT 3000 Series
Rev. B
89
ELECTRICAL SYSTEM
EVENT CODES
Event Codes Numbering scheme for event codes

The WT 3000 is fitted with an electronic control system
Starting Module concerned
for the key operating functions.
digit
Malfunctions with event code dis- 6 Not used
play 7 Not used
Event codes are produced from tests carried out on the 8 Access 8 (CAN Interface)
inputs and outputs of control signals. For most faults
the system generates an event code and stores it in the
log book. The last 15 events are displayed in the
Events menu.
Locating malfunctions
Malfunctions occur primarily on external components
such as fuses, solenoids, contactors, motors etc.
These components are necessarily subject to a certain
degree of wear.
The next possible causes include connectors, wiring
and input devices such as switches, potentiometers or
encoders. These are subject above all to ambient con-
ditions.
Experience shows that control modules are very sel-
dom the cause of the problem.
The easiest way of locating a fault is to start trouble-
shooting on the component (the external component).
The following sections list the event code numbers in
ascending order. In addition to each event code they
also list the possible causes, the effect on the truck and
troubleshooting notes.
Numbering scheme for event codes

The first digit of an event code is assigned to a module.
For example, if an event code starts with the digit 2,
then the event has occurred in the Access 2 module,
the hydraulic control module (HCM).
Numbering scheme for event codes
Starting Module concerned

digit
1 Access 1 (Display)
2 Access 2 (Hydraulic control module)
(HCM)
3 Access 3 (Traction control module)
(TCM)
4 Not used
5 Access 5 (Steering control module)
(SCM)
WT 3000 Series
Rev. B
90
ELECTRICAL SYSTEM
EVENT CODE 100 (WT 3020 -M, WT 3040 -M)
Event Code 100 (WT 3020 -M, WT 3040 -M)

Event Code 100
Display: EV100
Service LED: Off
Operator LED: Off
Explanation: Access 1 (display) does not receive a response from Access 3 (TCM) within 7
seconds.
Possible causes: • Access 3 power supply disconnected
• CAN Bus terminations faulty
• Software version of Access 1 does not match software version of Access 3
Remedy: Check basic functionality of display and communication with Access 3
1. Select SERVICE MENU > ANALYZER > A1Status > A1.3 STATUS
ACCESS 3.
 If the status is ON, proceed to step 2.
 If the status is OFF, proceed to step 3.
 If the display cannot be operated, proceed to step 14.
Check Access 2 software version
2. Select SERVICE MENU > UTILITIES > U1 PART NUMBERS > U1.2
ACCESS 2 > MODULE PN/SOFTWARE PN.
 Compare the software version of Access 1 with the list on page 61. If
the software version displayed is not on the list, contact the Crown ser-
vice department.
Note: It is possible that the software version displayed is compatible with the
software version of the display, but had not yet been released at the time of
going to print.
 If the software version is correct, proceed to step 4.
Check Access 2 power supply
3. Measure the voltage on Access 3 & 2 between pin CA209-10 and −Batt.
 If the voltage is approximately the same as +BV, the power supply is ok.
Proceed to step 4.
 If there is no voltage, proceed to step 10.
Check CAN Bus wiring and termination between Access 2 and Access 1
4. Disconnect PC202 from the display.
5. Remove PC209 from Access 3 & 2.
6. Measure the load resistance between PC214-1 and PC214-2 (CAN con-
nection plug).
 If the resistance is 120 Ω, proceed to step 7.
 If the resistance is not 120 Ω, replace the resistor in connector PC214.
7. Measure the load resistance between JC202-8 and JC202-9 (socket on
Access 1).
8. If the resistance is not 120 Ω, proceed to step 14.
WT 3000 Series
Rev. B
91
ELECTRICAL SYSTEM
9. Using an ohmmeter measure the resistance between PC202-8 and

PC209-28 and between PC202-9 and PC209-27.
 If the resistance < 2 Ω the wires are ok. Proceed to step 11.
 If the resistance > 2 Ω, the error lies in the wiring. Proceed to step 12.
Repair Access 2 power supply
10. Locate and repair error in wiring between PC209-10 and FU2.
Check CAN bus termination
11. Restart the truck.
 If the fault persists, proceed to step 13.
Repair wiring
12. Repair the wiring.
Replace Access 3 & 2
13. Replace Access 3 & 2
Replace Access 1
14. Replace Access 1.
WT 3000 Series
Rev. B
92
ELECTRICAL SYSTEM

Event Code 202
Display: EV202
Service LED: On
Operator LED: Off
Explanation: Voltage at terminal −P of Access 2 (HCM) too low.
Possible causes: If the event is displayed during power up, but before the main contactor
applies:
• The power cables to pump motor M2 have a poor contact, are damaged or
connected incorrectly
• Access 2 output stage is faulty
If the event is displayed during power up, but after the main contactor
has applied:
• Check the power cable terminals on pump motor M2
• Insulation resistances of the power cables or the winding of pump motor M2
to the truck frame are too low
If the event is displayed during lifting:
• Insulation resistances of the power cables or the winding of pump motor M2
to the truck frame are too low
• Contacts of main contactor ED are worn
Remedy: If the event is displayed during power up, but before the main contactor
applies:
Check the power cables and terminals
1. Check the power cables to pump motor M2 and its terminals are secure
and check for damage.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the terminals are ok, proceed to step 2.
Check the insulation resistance
2. Measure the insulation resistances from the motor coil and power cables
to the truck frame.
 If the insulation resistance is ok, proceed to step 3.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
Check the output stage of Access 2 for internal short circuits
3. Disconnect the power cable from terminal -P on Access 2.
WT 3000 Series
Rev. B
93
ELECTRICAL SYSTEM
4. Using an ohmmeter measure the resistance between terminal −P on Ac-

cess 2 and -Batt.
 If the resistance < 3 kΩ the output stage is faulty. Replace Access 3 & 2.
 If the resistance > 100 kΩ, the output stage is ok. In this case the error
lies in the wiring from −P to pump motor M2 or in the terminal on pump
motor M2.
has applied:
 If any cables are loose or damaged, rectify the cause.
6. Measure the insulation resistances between the motor coil and power ca-
bles to the truck frame.
ponent.
7. Switch the truck off and on while checking if the error now occurs when the
truck is switched on.
 If the error now occurs when the truck is switched on, carry out steps3
to 4.
bles and the truck frame.
ponent.
Check the main contactor ED
10. Check the main contactor contacts for wear and damage (see page 288).
 If the contacts are worn, repair the contactor.
 If all the above measures have been carried out and the event code per-
sists, replace Access 3 & 2.
WT 3000 Series
Rev. B
94
ELECTRICAL SYSTEM
EVENT CODES 203 - 204 (WT 3020 -M, WT 3040 -M)
Event Codes 203 - 204 (WT 3020 -M, WT 3040 -M)

Event Code 203
Display: EV203
Service LED: On
Operator LED: Off
Explanation: Voltage on terminal −P of Access 2 (HCM) is higher than the battery voltage
Possible causes: • The power cables to pump motor M2 have a poor contact, are damaged or
• Access 2 faulty
Remedy: Check power cables and terminals
to the truck frame.
ponent.
 If the insulation resistance is ok, replace Access 3 & 2.
Event Code 204

Display: EV204
Service LED: On
Operator LED: Off
Explanation: As the pump motor starts up the current measured by Access 2 is either zero
or out of range.
• Access 2 faulty
Test the current sensor in Access 2
2. Select SERVICE MENU > ACCESS 2 INPUTS > A2.2.4 > PUMP MOTOR
CURRENT, activate lifting and check the reading.
 If the reading remains at 0 A as the motor is running, proceed to step 3.
 If a current > 0 A is displayed while the motor is running, there is no
error. Restart the truck and check the event log.
WT 3000 Series
Rev. B
95
ELECTRICAL SYSTEM
Clear the EEPROM in Access 1

3. Open SERVICE MENU > FEATURES > F8 > EEPROM CLEAR >
ACCESS 1 and clear EEPROM.
4. Fully re-calibrate the truck (see page 255).
 If the event code persists, proceed to step 5.
to the truck frame.
ponent.

Event Code 205
Display: EV205
Service LED: On
Operator LED: Off
Explanation: While the pump motor is idle the current measured by Access 2 is > 0A.
• Access 2 faulty
CURRENT and check the reading with the pump motor stationary.
 If the reading remains at 0 A while the pump motor is stationary there is
no error. Restart the truck and check the event log.
 If a current > 0 A is displayed while the pump motor is stationary, pro-
ceed to step 3.
Clear EEPROM in Access 1 and Access 2
ACCESS 2 and clear EEPROM of Access 2.
WT 3000 Series
Rev. B
96
ELECTRICAL SYSTEM

to the truck frame.
ponent.

Event Code 208
Display: EV208
Service LED: On
Operator LED: Off
Explanation: As the truck is powered the voltage on the power part of Access 2 is not 0V.
are shorted with respect to each other
• Access 2 faulty
to the truck frame.
ponent.
Check power cables for short circuits with respect to each other
3. Unscrew both power cables from the motor (+/-) and Access 2 (+Batt/–P).
4. Measure the resistance of the cables with respect to each other.
 If there is a short replace the power cables.
 If the resistance is endless (> 1 MΩ), there is no short circuit. Proceed
to step 5.
WT 3000 Series
Rev. B
97
ELECTRICAL SYSTEM

Event Code 228
Display: EV228
Service LED: On
Operator LED: Off
Explanation: One or more drivers for FAN, SV, HN, ALM or FLS are damaged.
Possible causes: • Physical damage to one of the attached components
• Short circuit in one of the attached components
• Access 2 faulty
Remedy: Check the components connected to the drivers for physical damage
1. Check FAN, SV, HN, ALM and FLS for physical damage.
 If one component is damaged, replace the faulty component.
 If the components are ok, proceed to step 2.
Locate the affected driver
2. Switch the truck off and on again.
3. Activate the connected components FAN, SV, HN, ALM and FLS in turn
and individually. In the process check the component for which event
EV228 is displayed.
Note: The fan (FAN) can be activated via the service menu: SERVICE LEVEL
3 > ANALYZER MENU > A4 > TEST OUTPUTS > CLOSE ED > A4.1 > FN.
 If the alarm is displayed on one of the components, replace the compo-
nent or repair its wiring.
 If no short is found proceed to step 4.
WT 3000 Series
Rev. B
98
ELECTRICAL SYSTEM

Event Code 229
Display: EV229
Service LED: On
Operator LED: Off
Explanation: One or more drivers for FAN, SV, HN, ALM or FLS have a short.
• Short circuit in the feed wire to one of the attached components
• Access 2 faulty
Check terminals for short circuits or open connections
2. Check connections and wiring for FAN, SV, HN, ALM and FLS for shorts
or open connections.
 If there is a short or an open connection, repair the wiring.
 If the wiring is ok, proceed to step 3.
Check drivers in the control module
3. Open SERVICE MENU > FEATURES > F2 & F3 > TRAVEL ALARM &
BEACON and set to “BOTH”.
Note: All drivers are internally monitored even if some options are not in-
stalled. Therefore all drivers must be activated in order to measure.
4. Disconnect the + wires (red/white) from all the components connected to
the drivers. Make wires to the unused driver outputs accessible.
5. Using an ohmmeter measure in turn each driver output between the - wires
(green/white) and −Batt.
 If the resistance is at least 10kΩ, the respective driver output is ok.
 If less than 10kΩ is measured on a driver output, proceed to step6.
WT 3000 Series
Rev. B
99
ELECTRICAL SYSTEM

Event Code 230
Display: EV230
Service LED: On
Operator LED: Off
Explanation: One or more of the following components have an internal short circuit: FAN,
SV, HN, ALM or FLS
Possible causes: • Short circuit in one of the attached components
• Access 2 faulty
Remedy: Rule out the main contactor circuit
 If the error occurs when the truck is switched on, the main contactor
circuit is affected. Proceed to step 3.
 If the truck starts normally, proceed to step 2.
Isolate the error within the FAN, SV and HN circuits
2. Activate the connected components BR, FAN, SV, HN, ALM and FS in turn
EV230 is displayed.
 If the alarm is displayed for one of these components, proceed to step.
4.
 If no component is activating the event code and it persists, proceed to
step 3.
Measure the affected component
3. Disconnect the + wire (red/white) and the - wire (green/white) from the
respective component.
Note: If ALM or FLS are affected, disconnect the + wire (red/white) and the -
wire (green/white) from both components.
4. Using an ohmmeter measure the resistance of the actuating components:
– Line Contactor = 30 Ω
– BR = 13 Ω
– FAN > 100 kΩ
– SV ≈ 31 Ω
– HN > 100 kΩ
– ALM > 100 kΩ
– FLS > 100 kΩ
WT 3000 Series
Rev. B
100
ELECTRICAL SYSTEM
 If the resistance at ALM and FLS is at least 6 MΩ these components are

ok. Proceed to step 5.
 If the resistance at FLS or ALM is still only approx. 10 Ω, replace the
component.
 If the resistances for all other components match the above values, the
triggering component is ok. Proceed to step 5.
 If the reading of one component (apart from ALM and FLS) does not
match the above readings, replace the component.

Event Code 231
Display: EV231
Service LED: On
Operator LED: Off
Explanation: The control module detects an open circuit on the lowering valve (SV)
Possible causes: • Faulty coil in lowering valve
• Disconnected circuit to lowering valve
• Access 2 faulty
Remedy: Test the lowering command
1. Open SERVICE MENU > ANALYZER > A2 INPUTS > ACCESS 2 IN-
PUTS > A2.2.2 > LOS SWITCH.
2. Press the lowering switch LOS and monitor the display.
 If the display remains OFF, the circuit is disconnected. Proceed to step
3.
 If the display changes from OFF to ON when the LOS is applied, pro-
ceed to step 4.
Check the wiring and lowering valve for physical damage
3. Check the wiring and lowering valve for physical damage
 If there is no physical damage, proceed to step 4.
 If there is physical damage, repair the damaged parts.
Check the lowering valve coil
4. Open both wires on the lowering valve and measure the resistance of the
valve coils.
 If the resistance > 100 Ω, replace the valve coil.
 If the resistance < 100 Ω, proceed to step 5.
Check the lowering valve power supply
5. Using an voltmeter measure between the + wire (red/white) on SV and
−Batt.
 If the voltage is not the same as +Batt, check fuse FU3 and the wiring
to the lowering valve.
 If the voltage is the same as +Batt, proceed to step 6.
WT 3000 Series
Rev. B
101
ELECTRICAL SYSTEM
EVENT CODE 232 - 233 (WT 3020 -M, WT 3040 -M)

Event Code 232 - 233 (WT 3020 -M, WT 3040 -M)

Event Code 232
Display: EV232
Service LED: On
Operator LED: Off
Explanation: The control module has detected an open circuit leading to EVP2.
Note: Output EVP2 is not used on the WT 3020 -M or WT 3040-M, pin CA209-
23 is therefore not used.
Possible causes: • Incorrect wiring of pin CA209-23 on Access 3 & 2, or a short circuit to this
pin.
• Access 2 faulty
Remedy: Check pin CA209-23 for shorts and incorrect wiring
1. Check pin CA209-23 for connected wires or a short to the surrounding
pins.
 Remove any connected wires. Repair any shorts discovered.
 If there is no error, proceed to step 2.
Event Code 233

Display: EV233
Service LED: On
Operator LED: Off
Explanation: The control module has detected a fault in the coil of EVP2.
Note: Output EVP2 is not used on the WT 3020 -M or WT 3040-M, pin CA209-
23 is therefore not used.
Possible causes: • Incorrect wiring of pin CA209-23 on Access 3 & 2, or a short circuit to this
pin.
• Access 2 faulty
Remedy: Check pin CA209-23 for shorts and incorrect wiring
1. Check pin CA209-23 for connected wires or a short to the surrounding
pins.
 Remove any connected wires. Repair any shorts discovered.
 If there is no error, proceed to step 2.
2. Replace Access 3 & 2.
WT 3000 Series
Rev. B
102
ELECTRICAL SYSTEM

Event Code 234
Display: EV234
Service LED: On
Operator LED: Off
Explanation: The control module detects an open circuit on the lowering valve (SV)
Possible causes: • Faulty coil in lowering valve
• Disconnected circuit to lowering valve
• Access 2 faulty
Remedy: Test the lowering command
1. Open SERVICE MENU > ANALYZER > A2 INPUTS > ACCESS 2 IN-
PUTS > A2.2.2 > LOS SWITCH.
2. Press the lowering switch LOS and monitor the display.
 If the display remains OFF, the circuit is disconnected. Proceed to step
3.
 If the display changes from OFF to ON when the LOS is applied, pro-
ceed to step 4.
Check the wiring and lowering valve for physical damage
3. Check wiring and lowering valve for physical damage.
 If there is no physical damage, proceed to step 4.
 If there is physical damage, repair the damaged parts.
Check the coil resistance of the lowering valve
4. Open both wires on the lowering valve and measure the valve coil resist-
ance.
 If the resistance is ≈ 30 Ω, the coil is ok. Proceed to step 6
 If the resistance < 25 Ω or > 35 Ω, replace the coil.
WT 3000 Series
Rev. B
103
ELECTRICAL SYSTEM

Event Code 300
Display: EV300
Service LED: On
Operator LED: Off
Explanation: Watchdog error
Effect: • The traction current is cut out and the main contactor ED drops.
Possible causes: • Communication error on the CAN bus
• Access 1 faulty
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Open SERVICE MENU > EVENTS > CHRON HISTORY.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is recorded, proceed to step 3.
Check CAN Bus wiring and terminations between Access 3 and Access
1.
nection plug).
Access 1).
Check CAN bus termination
 If the fault persists, proceed to step 11.
Repair wiring
WT 3000 Series
Rev. B
104
ELECTRICAL SYSTEM

Replace Access 1

Event Code 301
Display: EV301
Service LED: On
Operator LED: Off
Explanation: EEPROM memory error in Access 3
Possible causes: • Intermittent internal error in Access 3
• Access 3 faulty

Event Code 302
Display: EV302
Service LED: On
Operator LED: Off
Explanation: As the truck is switched on, before the main contactor closes, a current > 0 A
is detected in the output stage.
Possible causes: • +Batt and −Batt terminals on Access 3
• Access 3 faulty
Remedy: Check power cable terminals
1. Check power cable terminals on Access 3, in particular +Batt and −Batt.
 Repair the terminals if faulty.
 If the terminals are ok, proceed to step 2.
WT 3000 Series
Rev. B
105
ELECTRICAL SYSTEM

Event Code 303
Display: EV303
Service LED: On
Operator LED: Off
Explanation: Phase voltage out of range
• Access 3 faulty
1. Check power cable terminals, in particular on +Batt and −Batt of Access 3.
Check terminals for corrosion and overheating.

Event Code 304
Display: EV304
Service LED: On
Operator LED: Off
Explanation: Low voltage or overvoltage(a) detected.
The event occurs if the voltage at pin PC201-10 drops below 9 V or the voltage
at the +Batt terminal of Access 3 & 2 exceeds 35 V.
Possible causes: • Battery voltage drop
• Voltage drop via fuse FU2 or relay K1 (or key switch)
• Transitional resistance in terminal of a power cable
• Access 3 faulty
• Battery used with excessive voltage
Remedy: Compare internally measured battery voltage with actual battery voltage
1. Open SERVICE MENU > ANALYZER > A3 OUTPUTS > A3.2 BATTERY
VOLTAGE and record the reading. It should be ≈ 24 V.
Note: Do not use 48 V batteries.
2. Using a voltmeter measure the battery voltage at the battery connector
and compare it with the previous reading from the Analyzer menu.
 If the two readings are identical, proceed to step 5.
 If there is a difference, proceed to step 3.
WT 3000 Series
Rev. B
106
ELECTRICAL SYSTEM
Compare internally measured battery voltage with actual battery voltage

3. Open SERVICE MENU > PERFORMANCE > P11 > ADJUST BATTERY
and enter the actual battery voltage reading with the cursor keys and save
it.
4. Proceed to step 5.
Check for battery voltage drop
VOLTAGE.
6. Raise a load of approx.1000 kg up to the lift limit cutout while monitoring
the battery voltage in the display.
 If the battery voltage drops below 22 V, repair the battery or replace it
with a new one.
 If the battery voltage remains above 22 V during the lift test, the battery
is ok. Proceed to step 7.
Measure the voltage drop on the signal line from Access 3 & 2
7. Measure the voltage between CA201-3 and battery negative.
 If the voltage is approximately the same as the battery voltage (≈ 24 V),
the signal line is ok. Proceed to step 12.
Note: The voltage at CA209-10 is always slightly less than the battery voltage.
This is due to the voltage drop via the signal switch in the main contactor, fuse
FU2, relay K1 or the key switch. However, this is only a few tenths of a volt.
 If the voltage is less than 22V, proceed to step 8.
Establish the cause of the voltage drop on the signal wire
8. Measure the input and output voltage of the signal switch on the main
contactor.
 If there is no significant voltage drop, proceed to step 9.
 If the voltage drops extremely, replace main contactor ED.
9. Measure the input and output voltage of fuse FU2.
 If the voltage drops extremely, replace FU2.
10. Measure the voltage at pin30 (input) and pin 87 (output) of relay K1. If the
truck has a key switch, measure the key switch input and output voltages.
 If the voltage drops extremely, replace relay K1 or the key switch.
11. Measure the voltage drop over the wires:
– Between the signal switch on the main contactor and fuse FU2
– Between FU2 and pin 30 on relay K1
– Pin 87 on relay K1 and pin CA209-10
 If the voltage drops extremely on one wire, repair the wire or connec-
tions.
a. Theoretically, this event code could be displayed for an overvoltage if there had been a conversion to a 48 volt battery connector
and someone had installed a 48 volt battery.
WT 3000 Series
Rev. B
107
ELECTRICAL SYSTEM

Event Code 305
Display: EV305
Service LED: On
Operator LED: Off
Explanation: Voltage on one of the phases U, V or W too low.
Possible causes: • The power cables to traction motor M1 have a poor contact or transition
resistances on the terminals.
• Access 3 faulty
1. Check motor power cable terminals. Check terminals for corrosion and
overheating.
2. Check the internal terminals of the motor and the insulation resistance of
the motor housing to +BV/−Batt.
 If there is a short to +BV/−Batt, replace the motor.
Event Code 306

Display: EV306
Service LED: On
Operator LED: Off
Explanation: Voltage on one of the phases U, V or W too high.
Possible causes: • Power cables to traction motor M1 have a short or the motor itself has a
short.
• Access 3 faulty
1. Check terminals and motor power cables for short circuits.
 If there is a short, repair the wiring.
 If the cables are ok, proceed to step 2.
WT 3000 Series
Rev. B
108
ELECTRICAL SYSTEM


Event Code 307
Display: EV307
Service LED: On
Operator LED: Off
Explanation: On power up there is a test to see if the main contactor contacts are open. If
the circuit which the main contactor contacts close is already closed, this event
code will be issued.
Possible causes: • Main contactor power contacts are welded
• Short circuit in the power routing on main contactor
• Access 3 faulty
1. Check if power cable terminals on the main contactor have shorted.
Check main contactor contacts
2. Check the main contactor contacts (see page 288).
 If the contacts are welded, replace the contacts or the main contactor.
 If the main contactor is ok, proceed to step 3.
WT 3000 Series
Rev. B
109
ELECTRICAL SYSTEM

Event Code 308
Display: EV308
Service LED: On
Operator LED: Off
Explanation: Main contactor contacts do not close.
Possible causes: • Main contactor contacts jamming
• Fuse FU1 faulty
• Coil routing disconnected
• Main contactor coil faulty
• Access 3 faulty
Remedy: Check fuse FU1
1. Measure the voltage at +Batt of Access 3 & 2.
 If there is no voltage, replace fuse FU1.
 If FU1 is ok, proceed to step 2.
Check the contactor coil power supply
2. Connect the positive lead of a voltmeter to the +terminal of the coil (white/
red). Connect the negative lead of the voltmeter to -Batt and switch on the
truck.
 If the voltage ≈ 24 V , the positive power supply to the coil is ok. Proceed
to step 2.
3. Measure the positive power supply over the following components and
wires:
– From the signal switch input on the main contactor to fuse FU2
– From the output of fuse FU2 over pin 30 to pin 87 on relay K1
– From pin 87 on relay K1 to the +pin of the main contactor coil
 If the voltage on one wire drops extremely or if there is no voltage, repair
the wire or connections.
Check the signal wire and coil terminals
4. Check the negative wire (green/white) leading to the coil on the main con-
tactor for continuity to pin PC209-12.
 If it is disconnected, repair the wiring.
Check the main contactor coil
5. Remove both signal cables from the coil.
6. Measure the coil resistance with an ohmmeter.
 If the coil resistance is less than ≈ 30 Ω, replace the main contactor or
coil.
 If the coil is ok, proceed to step 7.
WT 3000 Series
Rev. B
110
ELECTRICAL SYSTEM


Event Code 309
Display: EV309
Service LED: On
Operator LED: Off
Explanation: Current flows to output stage when truck is idle
Possible causes: • Access 3 faulty
Event Code 310

Display: EV310
Service LED: On
Operator LED: Off
Explanation: Internal capacitor bank charge time exceeded
Possible causes: • Additional unauthorised consumers installed
• Access 3 faulty
Remedy: Check for additional consumers
1. Using the circuit diagram and Crown's list of options, check if non-ap-
proved consumers are connected along with the capacitor bank of +Batt
at Access 3 to –Batt.
 Disconnect any non-approved consumers. Proceed to step 2.
 If no non-approved consumers are installed, proceed to step 3.
WT 3000 Series
Rev. B
111
ELECTRICAL SYSTEM

Event Code 314
Display: EV314
Service LED: On
Operator LED: Off
Explanation: Main contactor driver shorted
Possible causes: • Short circuit or disconnection in the wire from CA209-12 to the main con-
tactor coil
• Access 3 faulty
Remedy: Check the wiring for short circuits
1. With the truck switched off, use an ohmmeter to measure from CA209-12
to −Batt on Access 3.
 If the resistance is < 5 kΩ, repair the short in the wiring.
 If the resistance > 5 kΩ, proceed to step 2.
3. With the main contactor open, measure the voltage on the main contactor
coil for both signal wire terminals.
 If the voltage ≈ 24 V, the coil is ok. Proceed to step 4.
 If the voltage is not ≈ 24 V, the coil is faulty. Replace the main contactor
or coil.
WT 3000 Series
Rev. B
112
ELECTRICAL SYSTEM

Event Code 315
Display: EV315
Service LED: On
Operator LED: Off
Explanation: Driver cannot close the main contactor.
Possible causes: • Main contactor coil routing disconnected
• Access 3 faulty
Remedy: Check the contactor coil power supply
truck.
to step 2.
wires:
coil.
WT 3000 Series
Rev. B
113
ELECTRICAL SYSTEM

Event Code 316
Display: EV316
Service LED: On
Operator LED: Off
Explanation: Excessive current through the driver for the main contactor or brake coil
Possible causes: • Short circuit in the brake coil power circuit or the brake coil
• Short circuit in the main contactor coil power circuit or the main contactor
coil
• Access 3 faulty
Remedy: Check the wiring to the main contactor coil and the brake for short cir-
cuits
1. Check the wiring to the main contactor coil and the brake for short circuits.
2. Check if the terminals on the main contactor have been shorted by a for-
eign body.
 Remove any short circuits found.
 If there is no short, proceed to step 3.
Check the coils of the main contactor coil and the of brake for short cir-
cuits
Note: A short is detected at a resistance of < 2 Ω.
3. Remove both signal cables from the main contactor coil.
coil.
5. Remove the cable from the brake.
6. Measure the brake coil resistance with an ohmmeter.
 If the coil resistance is less than ≈ 13 Ω ±10 %, replace the main con-
tactor or coil.
WT 3000 Series
Rev. B
114
ELECTRICAL SYSTEM

Event Code 317
Display: EV317
Service LED: On
Operator LED: Off
Explanation: The zero point of the traction potentiometer deviates from the calibrated value
by more than 1 V and the travel switch is open.
Possible causes: • Physical defect on the traction potentiometer
• Traction potentiometer replaced but not calibrated
Remedy: Check the traction potentiometer for physical damage
1. Open SERVICE MENU > ANALYZER > ACCESS 3 INPUTS > A2.3.5 >
POT WPR.
2. Activate the travel switch in both directions and then restore it to neutral
while observing the display.
 If the display always reverts to the same reading in neutral, the traction
potentiometer is ok. Calibrate the traction potentiometer (see page
255).
 If the display does not revert to the same reading in neutral, the traction
potentiometer is faulty. Replace the traction potentiometer (see page
316).
Event Code 319

Display: EV319
Service LED: On
Operator LED: Off
Explanation: The reading supplied by the pressure sensor is out of the normal range.
Possible causes: • Pressure sensor faulty
• Pressure sensor replaced but not calibrated
Remedy: Check reading supplied by the pressure sensor
PRESSURE TRANSDUCER.
2. Fully lower the unladen forks and check the reading. It should be ≈ 1 V.
3. Raise a load of 2000 kg and check the reading. It should be > 8 V.
 If the readings stated in steps 2 and 3 are displayed, the pressure sen-
sor and wiring are ok. Calibrate the pressure sensor (see page 259).
 If different readings from those stated in steps 2 and 3 are displayed,
proceed to step 4.
WT 3000 Series
Rev. B
115
ELECTRICAL SYSTEM
Check 12 volt supply

4. Measure the voltage (+12 V) between CA204-2 (on the pressure sensor)
and −Batt. It should be ≈ +12 V.
5. Measure the voltage (GND) from CA204-1 to BATT NEG. It should be
≈ 0 V.
 If the voltages measured in steps2 and 3 are correct, the 12 V supply is
 If there is no +12 V supply, repair the disconnection in the wiring be-
tween CA204-2 and CA209-25.
 If a higher reading than +12V is measured at CA204-2, the control mod-
ule is faulty. Replace controller.
 If a reading higher than 1 V is measured at CA204-1, the control module
is faulty. Replace controller.
Measure the pressure sensor output signal
6. Fully lower the unladen forks and measure the voltage between CA209-30
and −Batt. It should be ≈ 1 V.
7. Raise a load of 2000 kg and measure the voltage between CA209-30 and
−Batt. It should be ≈ 8 V.
the pressure sensor is faulty. Replace and recalibrate the pressure sen-
sor.

Event Code 320
Display: EV320
Service LED: On
Operator LED: Off
Explanation: CAN Bus communication failure between Access 3 and Access 1.
Possible causes: • Wiring damaged
• Load resistor faulty
Remedy: Test Access 1
1.
WT 3000 Series
Rev. B
116
ELECTRICAL SYSTEM
nection plug).
Access 1).
Repair wiring
Replace Access 1

Event Code 321
Display: EV321
Service LED: On
Operator LED: Off
Explanation: Incorrect truck model selected.
Possible causes: • Control module replaced and not set
Remedy: Set the truck model
1. Open SERVICE MENU > FEATURES MENU > F4 > TRUCK TYPE and
set the correct truck type.
WT 3000 Series
Rev. B
117
ELECTRICAL SYSTEM

Event Code 322
Display: EV322
Service LED: On
Operator LED: Off
Explanation: Short circuit in the brake positive wire
Possible causes: • Wiring short circuit
Remedy: Check the wiring
1. Measure the voltage between CA209-2 and −Batt. It should be ≈ +BV.
 If the voltage ≈ +BV, proceed to step 2.
 If the voltage is not ≈ +BV, remove the short circuit between the positive
cable (red/white) on the brake and PC209-2.
2. Remove the negative terminal from the brake.
Event Code 326

Display: EV326
Service LED: On
Operator LED: Off
Explanation: Power output stage short circuit
Possible causes: • Short circuit in the power cables
• Control module faulty
2. Check the power cable to the traction motor M1 and its terminals for short
circuits.
3. Check power cable terminals on the control module for short circuits with
terminals +Batt and −Batt.
 If any cables or terminals are shorted, rectify the cause.
to the truck frame.
ponent.
WT 3000 Series
Rev. B
118
ELECTRICAL SYSTEM
Check control module

5. On the control module unscrew the wires from terminals U, V and W.
6. Using an ohmmeter measure the resistance from terminal U on the control
module to +Batt and then to −Batt.
7. Repeat step 6 with phase V and phase W.
 If the resistance at one of the phases is < 100 Ω, the output stage is
faulty. Proceed to step 8.
 If no error is found, restart the truck. Check the event log.

Event Code 328
Display: EV328
Service LED: On
Operator LED: Off
Explanation: Control module faulty
Possible causes: • Control module faulty
Remedy: Replace Access 3 & 2
Event Code 329

Display: EV329
Service LED: On
Operator LED: Off
WT 3000 Series
Rev. B
119
ELECTRICAL SYSTEM

Event Code 333
Display: EV333
Service LED: On
Operator LED: Off
Explanation: The driver cannot activate the brake
Possible causes: • Wiring disconnected
• Open brake coil
 If the voltage is not ≈ +BV, repair the wire (red/white) between the brake
and PC209-2.
Check the brake coil
 If the resistance is not ≈ 13 Ω ±10 %, replace the brake.
Event Code 334

Display: EV334
Service LED: On
Operator LED: Off
Explanation: Occurs only in connection with EV328
Possible causes: • None
Remedy: 1. No action required, the alarm goes out automatically.
WT 3000 Series
Rev. B
120
ELECTRICAL SYSTEM

Event Code 337
Display: EV337
Service LED: On
Operator LED: Off
Explanation: Thermal sensor in the control module returns values beyond the measuring
range of -80°C to +120°C.
Possible causes: • Display faulty
• Access 3 faulty
Test Access 1
Event Code 338

Display: EV338
Service LED: On
Operator LED: Off
Explanation: Battery voltage out of range.
• Access 3 faulty
Remedy: Check the battery condition
1. Check the battery for physical damage.
2. Check the battery terminals for corrosion.
3. Ensure the battery cable is attached securely.
 If the items in steps 1 to 3 are ok, proceed to step 4.
WT 3000 Series
Rev. B
121
ELECTRICAL SYSTEM
Check the condition of the battery cells

4. Measure the individual voltages of the battery cells.
 Replace any faulty cells.
 If all the cells are ok and the sum of the cell voltages is ≈ 24 V, proceed
to step 5.
VOLTAGE.
6. Using a voltmeter measure the battery voltage and compare it with the
reading from the Analyzer menu.
 If the readings are identical, the error has been resolved.
it.

Event Code 341
Display: EV341
Service LED: On
Operator LED: Off
Explanation: Short circuit on the negative side of the brake driver
Possible causes: • Open connection in the brake positive wire
• Short circuit between the brake positive wire and -Batt
• Short circuit on the negative side of the driver in Access 3
Remedy: Check wiring and power supply
1. Disconnect CA209 from the control module and the negative wire (green/
white) from the brake.
2. Check wire (pin PC209-4) for continuity.
 If the wire is ok, proceed to step 3.
 If the wire is disconnected, repair the wire.
3. Connect PC209 and the wire (green/white) to the brake. Measure the volt-
age from both brake terminals to BATT NEG.
 If the voltage is ≈ 24 V, proceed to step 4.
 If there is no 24 volt supply, replace the brake.
4. Measure the resistance between PC209-4 and -Batt.
 If the resistance < 5 kΩ, proceed to step 5.
 If the resistance > 5 kΩ, repair the wiring.
WT 3000 Series
Rev. B
122
ELECTRICAL SYSTEM

Event Code 342
Display: EV342
Service LED: On
Operator LED: Off
Explanation: Forward and reverse travel commands applied simultaneously.
Possible causes: • Open connection, corrosion or short circuit
• Access 3 faulty
Remedy: Check switch status in Analyzer menu
1. Open SERVICE MENU > ANALYZER > ACCESS 3 INPUTS > A2.3.3
AND A2.3.4 and check the switch status.
 If one switch is OFF and the other ON when the travel switch is applied,
there is no error. Restart the truck and check the event log.
 If both switches are ON, proceed to step 2.
Check wiring
2. Check travel direction switch connections from CA410-3 and CA410-4
(Main PCB in the tiller handle) to CA209-31 and CA209-32 on the control
module for shorts.
 If the connections are ok, proceed to step 3.
 Repair the connections if they are not ok.
3. Using a voltmeter measure the voltage from CA209-31 and CA209-32 to
−Batt.
 If the reading is not 0 V, proceed to step 4.
 If the reading is 0 V, proceed to step 6.
4. Temporarily remove the wires of PC209-31 and -32 from the connector.
5. Measure the voltage at the open wire ends to BATT NEG.
6. Check the connector contact for corrosion and check the wiring for shorts
and discontinuity.
 If corrosion or a wiring fault is found, repair the wiring.
 If no error is found in the wiring, the error is probably in the Main PCB
(in the tiller handle). Replace the Main PCB (see page 312). If the error
persists, proceed to step 7.
7. Using the wires from PC209-31 and -32 removed from the connector open
SERVICE MENU > ANALYZER > ACCESS 3 INPUTS > A2.3.3 AND
A2.3.4 and check the switch status.
 If the switch status is ON, the controller is faulty. Proceed to step 8.
WT 3000 Series
Rev. B
123
ELECTRICAL SYSTEM

Event Code 343
Display: EV343
Service LED: On
Operator LED: Off
Explanation: Encoder ECR1 in the traction motor has a fault. The event code is issued if the
encoder detects a change of more than 40 Hz in less than 16 ms.
Possible causes: • Slip in encoder drive
• Wiring error
• Access 3 faulty
Remedy: Check encoder pulses in Analyzer menu
ECR1 ENCODER 64 PULSE.
2. Check the display at first with the truck idle, then at full travel speed.
 If 0 pulses are shown when truck is idle and ±12000 pulses are shown
at full speed, the encoder is ok. Restart the truck and check the event
log.
 If 0 pulses are not displayed when the truck is stationary and/or ±12000
pulses are not displayed at full speed, proceed to step 3.
Check wiring
3. Check the encoder wiring, including connector CA212, for:
– Corrosion
– Loose connections
– Faulty crimp connections on the pins
– Trapped wires
 Repair the wiring if faulty.
 If there is no damage, proceed to step 4
4. Measure the voltage (+12 V) between CA212-1 (on ECR1) and −Batt. It
should be ≈ +12 V.
5. Measure voltage (GND) between CA202-2 and −Batt. It should be ≈ 0 V.
 If there is no +12 V supply, repair the discontinuity in the wiring between
CA212-1 and CA209-25.
ule is faulty. Proceed to step 7.
 If more than 1 V is measured at CA212-2, the control module is faulty.
Proceed to step 7.
WT 3000 Series
Rev. B
124
ELECTRICAL SYSTEM
Check the sensor bearing for physical damage

6. Monitor the running noise of the traction motor.
 If the motor “rattles”, the encoder (sensor bearing) is probably dam-
aged. Repair or replace the motor (see page 273).
 If no physical damage is found, restart the truck and check the event
log.

Event Code 348
Display: EV348
Service LED: On
Operator LED: Off
Explanation: Parking brake does not hold.
When the truck is idle, the control module checks if the traction motor is turn-
ing. The event code is displayed if a rotary movement with at least 0.75 Hz is
detected for more than 2 s.
Possible causes: • Brake faulty
Remedy: Check the parking brake
1. Check the parking brake for damage (see page 298).
Event Code 351

Display: EV351
Service LED: On
Operator LED: Off
Explanation: RAM copy error.
Possible causes: • Static charge
• Insulation resistance too low
Check for static charge
2. Operate the truck for a while, then leave the truck and touch the panel.
 If you feel an electrostatic charge, proceed to step 3.
 If you do notfeel an electrostatic charge, proceed to step 6.
WT 3000 Series
Rev. B
125
ELECTRICAL SYSTEM
Fit the anti-static strap

3. Fit a commercial anti-static strap to the bottom of the truck.
Note: The connection point on the truck must be bare metal prior to assembly.
4. Protect the connection point on the truck against corrosion.
5. Travel again for a short time.
Test the truck's insulation resistance
6. Test the truck's insulation resistance.
 If the insulation resistance is too short, locate and replace the faulty
component.

Event Code 352
Display: EV352
Service LED: On
Operator LED: Off
Explanation: Wrong software version.
Possible causes: • Wrong software version
1. Replace Access 3 & 2 with a control module with the correct software ver-
sion.
WT 3000 Series
Rev. B
126
ELECTRICAL SYSTEM

Event Code 353
Display: EV353
Service LED: On
Operator LED: Off
Explanation: Thermal sensor TS1 in the drive motor returns values beyond the measuring
range of -40 °C to +200 °C.
Possible causes: • Wiring error
• Thermal sensor faulty
• Access 3 & 2 faulty.
Remedy: Measure and check the temperature
TS and check the temperature display.
2. Measure the temperature on the motor housing.
 If the temperature on the motor housing is approx. 10°C lower, thermal
sensor TS1 is ok. Proceed to step 7.
 If the temperature difference is greater than approx. 10°C, proceed to
step 3.
Check thermal sensor
Note: For the following test the internal motor temperature should be approx.
20°C.
3. Disconnect CA212 and measure the resistance of thermal sensor TS1 be-
tween pins JC212-5 and JC212-6.
 If the resistance ≈ 600 Ω (at 20 °C internal motor temperature), proceed
to step 4.
 If the resistance differs significantly from this value, the thermal sensor
is faulty. Replace traction motor M1 (see page 273).
Check wiring
4. Check wires from PC212-5 to CA209-5 and PC212-6 to CA209-22 using
an ohmmeter.
 If the resistance in a line ≈ 0 Ω, the wiring is ok. Proceed to step 5.
 If the resistance differs from this value, repair the wiring.
Check the temperature sensor voltage readings
5. Connect PC212 and switch on the truck.
6. Measure the voltage between CA209-5 and CA209-22 to BATT NEG. The
readings should be: ≈ 3 V for tM1 ≈ 150°C and > 0.7 V for tM1 ≈ -25°C
 If the voltage is ok, proceed to step 7.
 If the voltage is incorrect, replace traction motor M1 (see page 273).
WT 3000 Series
Rev. B
127
ELECTRICAL SYSTEM

Event Code 354
Display: EV354
Service LED: On
Operator LED: Off
Explanation: No positive power supply for the SMART driver within Access 3 & 2.
Possible causes: • FU3 faulty
• Faulty wiring
Remedy: Check fuse
1. Check fuse FU3.
 If FU3 has blown, replace with a new 4A / 32V fuse.
 If the fuse is ok, proceed to step 2.
Check wiring
2. Measure the voltage from CA209-3 to −Batt.
 If there is no ≈ 24 V supply, repair the wire between FU3 and CA209-3.
 If there is a ≈ 24 V supply, the wiring is ok. Proceed to step 3.
Event Code 355

Display: EV355
Service LED: On
Operator LED: Off
Explanation: Excessive or low voltage when the truck is switched on
Possible causes: • See event code 304.
Remedy: See event code 304.
WT 3000 Series
Rev. B
128
ELECTRICAL SYSTEM

Event Code 356
Display: EV356
Service LED: On
Operator LED: Off
Explanation: Error in FLASH memory of Access 3 & 2
Possible causes: • Static charge
Fit the anti-static strap
2. Fit a commercial anti-static strap to the bottom of the truck.
Note: The connection point on the truck must be bare metal prior to assembly.
3. Protect the connection point on the truck against corrosion.
4. Switch the truck on and off again.
5. Disconnect the battery, wait for 6 seconds, then connect the battery.
Import the software
7. If possible and applicable, download software for Access 3.
8. Delete the EEPROM and reset and calibrate the truck.
Note: If you cannot re-install the software, replace Access 3 & 2.
WT 3000 Series
Rev. B
129
ELECTRICAL SYSTEM

Event Code 357
Display: EV357
Service LED: On
Operator LED: Off
Explanation: Brake driver (SMART driver) does not supply an output signal
Possible causes: • Faulty wiring
• Brake coil faulty
1. Check the wiring between CA209-2, the brake and CA209-4 for disconti-
nuity and shorts.
Check the parking brake
2. Check the parking brake for signs of overheating and physical damage.
 Repair the brake if damaged or overheated.
 If the brake is ok, proceed to step 3.
3. Remove both wires from the brake.
4. Measure the brake coil resistance.
 If the resistance is 13 Ω ±10%, the brake coil is ok. Proceed to step 5.
 If the resistance is more or less than 13 Ω ±10%, repair the brake.
5. Measure the voltage from CA209-3 to −Batt.
WT 3000 Series
Rev. B
130
ELECTRICAL SYSTEM

Event Code 358
Display: EV358
Service LED: On
Operator LED: Off
Explanation: Current sensor measuring range limits in Access 3 exceeded.
Possible causes: • Access 3 & 2 faulty.
Event Code 359

Display: EV359
Service LED: On
Operator LED: Off
Explanation: Traction potentiometer voltage exceeds the limits set during calibration by
more than 0.4V.
Possible causes: • Potentiometer drift
• Direction switch drift
• Faulty calibration
• Sluggish or jammed moving parts
• Wiring error
• Access 3 & 2 faulty
Remedy: Check mechanism
1. Check the travel switch mechanism for excess friction and check the free-
dom of movement.
 Repair the mechanism if faulty.
 If the mechanical system is ok, proceed to step 2.
Traction potentiometer calibration
2. Calibrate the traction potentiometer (see page 255).
 If the event no longer occurs, the problem is resolved.
 If the event occurs again, proceed to step 3.
WT 3000 Series
Rev. B
131
ELECTRICAL SYSTEM
Check travel direction switch

3. Open SERVICE MENU > ANALYZER > INPUTS > ACCESS 3 INPUTS >
A2.3.3 > PF SWITCH.
4. Apply the travel switch in the drive direction and monitor the operation of
the PF travel direction switch in the display.
 If the switch works correctly, proceed to step 5.
 If the switch does not work correctly, replace the traction potentiometer
(see page 316).
A2.3.4 > FF SWITCH.
6. Apply the travel switch in the forks direction and monitor its operation in the
display.
(see page 316).
Check traction potentiometer for disconnections
A2.3.5 > POT WIPER.
8. Apply the travel switch slowly in both directions while monitoring the dis-
play.
 If the reading increases without discontinuity from 0 - 12 V ±10% and
returns to 0 in the same way, the traction potentiometer is ok. Restart
the truck and check the event log.
 If there is discontinuity or jumps in the signal, replace the traction poten-
tiometer. (see page 316).
WT 3000 Series
Rev. B
132
ELECTRICAL SYSTEM

Event Code 361
Display: EV361
Service LED: On
Operator LED: Off
• Access 3 faulty
Test Access 1
 If the event is logged and the service hours and temperature match the
event, Access 1 is ok. Proceed to step 4.
Replace Access 1
Event Code 362

Display: EV362
Service LED: On
Operator LED: Off
Explanation: +BV at CA209-3 is lower than +BV(AK) at CA209-10
Possible causes: • FU3 faulty
• Wiring error
• Main contactor contacts worn
• Power cable on the main contactor loose or corroded terminals
• Access 3 faulty
Remedy: Check fuse
1. Check fuse FU3.
 If FU3 has blown, replace with a new 4A / 32V fuse.
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133
ELECTRICAL SYSTEM
Check wiring
2. Measure the voltage at CA209-3 to BATT NEG.
Check main contactor and its wiring
3. Check the main contactor contacts (see page 288) and the power cable
terminals.
 If the contacts and the power cable terminals are ok, proceed to step 4.
 Repair the main contactor or power cable terminals if faulty.

Event Code 364
Display: EV364
Service LED: On
Operator LED: Off
Explanation: Side restraint logic and truck type do not match
Possible causes: • Incorrect truck type set
• Side restraint sensor faulty
• Wiring error
• Wrong software installed
Remedy: Check switch status of side restraint sensors SR1 and SR2
1. Open SERVICE MENU > ANALYZER > A2 INPUTS > ACCESS 3 INPUTS
> A2.3.11 and check the switch status of sensor SR1.
3. Compare the switch status of SR1 and SR2 with the Input Signals table on
page 247.
 If the statuses match, proceed to step 10.
 If the statuses do not match, proceed to step 4.
Check connection and attachment
Note: The WT320-MO uses jumper part no. 825877 instead of sensors SR1
and SR2 on connectors PC207 and PC208. On the WT3040-MR and WT3040-
MS the connectors are open.
4. Check the connection and attachment of the sensors.
 Repair the connection or attachments if these are not ok.
 If the connection and attachment are ok, proceed to step 5 or 6.
WT 3000 Series
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134
ELECTRICAL SYSTEM
EVENT CODE 365 -368 (WT 3020 -M, WT 3040 -M)
Test sensors (all except WT320-MO, WT340-MR and MS)

5. Using a suitable piece of metal switch SR1 and SR2 directly while moni-
toring the display and the sensor LEDs.
 If the sensors are ok, proceed to step 7.
 Replace the sensors if faulty.
WT320-MO only: check wire bridges are present
6. Check if the bridges (BRIDGE) part no. 825877 are fitted on jumpers
PC207 and PC208.
 If the bridges are present, proceed to step 4.
 If a bridge is missing, attach the bridge.
Check the truck model setting
7. Open SERVICE MENU > FEATURES > F4 > TRUCK TYPE and compare
the setting with the actual model.
 If the correct model is set, proceed to step8.
 If the wrong model is set, correct it accordingly.
Check the software version number
8. Open SERVICE MENU > UTILITIES > ACCESS 3 & 2 > SOFTWARE PN.
9. Compare the version number with the table on page 61.
 If the software version is incorrect, install the correct version or proceed
to step 10.
Event Code 365 -368 (WT 3020 -M, WT 3040 -M)

Event Code 365
Display: EV365
Service LED: On
Operator LED: Off
Explanation: Short in one of the phases U, V or W
• Traction motor M1 faulty
Remedy: Check wiring
1. Check the power cables of Access 3 & 2 to traction motor M1 for damage.
 Replace any physically damaged cables.
2. Unscrew the power cables from the traction motor and Access 3 & 2.
3. Using an ohmmeter check the power cables for shorts.
 Replace any power cables affected by shorts.
 If there is no short circuit, replace traction motor M1.
WT 3000 Series
Rev. B
135
ELECTRICAL SYSTEM
EVENT CODE 365 -368 (WT 3020 -M, WT 3040 -M)
Event Code 368

Display: EV368
Service LED: On
Operator LED: Off
Explanation: Potentiometer for SRT beyond range
Possible causes: • Incorrect setting
Remedy: Traction potentiometer calibration
Check traction potentiometer output voltage
A2.3.5 > POT WIPER.
3. Apply the travel switch slowly in both directions while monitoring the dis-
play.
 If the reading increases from 0 - 10 V ±10% and returns to 0 in the same
way, the traction potentiometer (POT1) is ok. Restart the truck and
check the event log.
 If the reading does not increase from 0 - 10 V ±10%, or does not return
to 0, replace the traction potentiometer (see page 316).
A2.3.3 > PF SWITCH.
(see page 316).
A2.3.4 > FF SWITCH.
display.
(see page 316).
Check traction potentiometer wiring
8. Check the potentiometer wiring
 If the wiring is ok, replace the traction potentiometer (see page 316).
WT 3000 Series
Rev. B
136
ELECTRICAL SYSTEM

Event Code 370
Display: EV370
Service LED: On
Operator LED: Off
Possible causes: • Setting is ENABLED despite the SRT option not being installed.
Remedy: Check SRT option status
1. Open SERVICE MENU > FEATURES > F14 > SRT and check setting.
 If the option is set to ENABLED, set it to DISABLED.
 If the function is already DISABLED, proceed to step 2.
Test Access 1
2. Measure the voltage between CA202-13 and −Batt.
 If 0 V is displayed, restart the truck and check the event log.
3. Remove pin 13 from CA202 and measure the voltage directly between pin
13 and −Batt.
 If the event code does not disappear and the reading is not 0 V, Access
1 is faulty. Replace Access 1.
 If the reading is 0 V and the event code is no longer displayed, restart
Event Code 371

Display: EV371
Service LED: On
Operator LED: Off
Explanation: Travel direction switch not applied for 1 second but more than 3 V applied to
the traction potentiometer slider.
Possible causes: • Traction potentiometer incorrectly calibrated
• Direction switch faulty
• Wiring error
• Traction potentiometer faulty
Remedy: Traction potentiometer calibration
Check traction potentiometer wiper voltage
POT WPR.
WT 3000 Series
Rev. B
137
ELECTRICAL SYSTEM
 If the display does not revert to 0 V in neutral, the traction potentiometer

is faulty. Replace the traction potentiometer (see page 316).
 If the display always reverts to 0 V in neutral, the traction potentiometer
A2.3.3 > PF SWITCH.
(see page 316).
A2.3.4 > FF SWITCH.
display.
(see page 316).
7. Check mechanical parts and wiring of traction potentiometer.
 If the traction potentiometer or wiring are faulty, replace the damaged
parts.
 If no errors are found, replace the traction potentiometer (see
page 316).
WT 3000 Series
Rev. B
138
ELECTRICAL SYSTEM
EVENTS DISPLAYED AS TEXT (WT 3020 -M, WT 3040 -M)
Events displayed as text In some cases the fault may be due to an incorrect
choice of option, truck model or a component malfunc-
(WT 3020 -M, WT 3040 -M) tion. This will require the intervention of a service engi-
These events are normally caused by operator error. neer.
The text message in the display informs the operator.
The remedial measures the operator can perform are
detailed in the operating instructions.
Platform Error
Display: PLATFORM FAILURE
Service LED: Off
Operator LED: On
Explanation: Discrepancy in the platform side restraint logic.
Possible causes: • Platform or side restraint sensors faulty
• Incorrect truck model set
• Wiring error
Remedy: Check truck model setting
1. Open SERVICE MENU > FEATURES > TRUCK TYPE and compare with
the actual truck model
 If the truck model is set incorrectly, set the correct truck model.
 If the setting is correct, proceed to step 2.
Check switch status of side restraint sensors SR1 and SR2 and platform
sensors PLS1 and PLS2
> A2.3.9 and check the switch status of sensor PLS1.
5. Compare the switch status of PLS1, PLS2, SR1 and SR2 with the Input
Signals table on page 247.
 If the statuses do not match, proceed to step 6 (for WT 30220) or
step 7.
WT320-MO only: check wire bridges are present
PC207 and PC208.
WT 3000 Series
Rev. B
139
ELECTRICAL SYSTEM
Check wiring of affected sensor

7. Check wiring of sensor considered to be questionable in step 5.
8. Using a suitable piece of metal switch the questionable sensor directly
while monitoring the display.
 If the sensor is ok, proceed to step 9.
 Replace the sensor if faulty.
Test sensor actuator
9. Activate the affected sensor with the platform or side restraints. Monitor
the display in the process.
 If the sensor does not switch, adjust the actuator or sensor.
Entry bar &/or FDS

Display: ENTRY BAR &/OR FDS
Service LED: Off
Operator LED: On
Explanation: On fixed platform trucks a logical error was caused by the entry bar or the step.
Possible causes: • Entry bar sensor or step sensor faulty
• Wiring error
Check the option setting
Note: For fixed platform trucks, PLS1 is the presence sensor. PLS2 is the entry
bar sensor.
2. Check switch status of side restraint sensors SR1 and SR2 and platform
sensors PLS1 and PLS2.
WT 3000 Series
Rev. B
140
ELECTRICAL SYSTEM
WT3020-MO only: check wire jumper is present
PC207 and PC208.
10. Using a suitable piece of metal connect the dubious sensor directly while
monitoring the display.
Stopped
Display: TRUCK STOPPED
Service LED: Off
Operator LED: On
Explanation: Battery residual capacity below the permissible level.
Possible causes: • Battery faulty
• BDI setting does not match the performance setting
• Battery voltage set incorrectly
Remedy: Charge the battery or install a charged battery
1. Charge the battery fully or replace it with a fully charged battery.
 If this resolves the error, return the truck to service.
 If the BDI still does not show a fully charged battery, proceed to step 2.
WT 3000 Series
Rev. B
141
ELECTRICAL SYSTEM
Check load profile in the BDI setting

2. Open SERVICE MENU > PERFORMANCE > P11 > ADJUST BATT and
check that the setting matches the actual load profile of the truck. (see BDI
parameters table, page 283).
 If the setting and the actual load profile match, proceed to step 3.
 If the setting does not match the actual load profile, adjust the load pro-
file (see page 283).
VOLTAGE and record the reading.
it. Proceed to step 5.
VOLTAGE.
with a new one.
is ok.
VOLTAGE.
9. Raise a load of approx. 1000 kg up to the lift limit cutout while monitoring
with a new one.
WT 3000 Series
Rev. B
142
ELECTRICAL SYSTEM
Traction control module hot

Display: HIGHTEMP TCM
Service LED: Off
Operator LED: On
Explanation: Temperature of traction control module Access 3 too high
Possible causes: • Fan faulty
• Thermal sensor in Access 3 faulty
• Wiring error
Remedy: Test fan
1. Wait until the temperature in Access 3 has dropped.
2. Open SERVICE LEVEL 3 > ANALYZER MENU > A4 > TEST OUTPUTS
> CLOSE ED > A4.1 > FN. The fan should start up (press ENTER to end
the test).
 If the fan is working, proceed to step 6.
 If the fan is not working, proceed to step 3.
Check the fan status in the display
3. Open SERVICE LEVEL 2 > ANALYZER MENU > A3 > OUTPUTS and
check the status.
 If the status is ON but the fan does not start up, proceed to step 4.
 If the status is OFF and the fan does not start up, proceed to step 6.
Check the fan wiring
4. Using a voltmeter measure the battery voltage between battery negative
and CA213-1 (fan).
 If the reading ≈ 24 V, the positive power supply is ok, proceed to step 5.
 If no voltage is measured, check fuse FU4 and the wire to CA213-1 for
continuity.
5. Disconnect JC209 from Access 3 and check the wire between JC209-9
and CA213-2 (fan) for continuity.
 If the wire is continuous, proceed to step 6.
 If the wire is disconnected, repair the wiring.
Compare the actual temperature with the temperature displayed
6. Open SERVICE LEVEL 2 > ANALYZER MENU > A2 > INPUTS > A2.3.1
TEMP ACCESS 3 and check the reading.
7. Measure the temperature on the assembly plate and compare the temper-
ature readings.
 If the temperature on the assembly board is approx. 10°C lower than the
temperature display, the thermal sensor is ok.
 If the temperature readings differ by more than 10°C, replace Access 3.
WT 3000 Series
Rev. B
143
ELECTRICAL SYSTEM

VOLTAGE.
with a new one.
is ok.
VOLTAGE.
with a new one.
Traction motor hot

Display: HIGHTEMP TRACTION MOTOR
Service LED: Off
Operator LED: On
Explanation: Temperature in traction motor M1 too high
• Wiring error
Remedy: Test fan
the test).
check the status.
WT 3000 Series
Rev. B
144
ELECTRICAL SYSTEM

and CA213-1 (fan).
continuity.
Measure and check the temperature
TS1 and check the temperature display.
step 8.
20°C.
 If the resistance ≈ 600 Ω (at 20°C internal motor temperature), the ther-
mal sensor in the motor is ok. Proceed to step 9.
is faulty. Proceed to step 10.
Replace traction motor M1
10. Replace traction motor M1 (see page 273).
Release control handle

Display: RELEASE CONTROL HANDLE
Service LED: Off
Operator LED: On
Explanation: Incorrect starting sequence.
Possible causes: • The tiller is in the travel position when the truck is switched on
Remedy: Release the tiller, then start the truck
1. Release the tiller, then switch on the truck.
WT 3000 Series
Rev. B
145
ELECTRICAL SYSTEM
Travel switch applied too soon

Display: RELEASE TRAVEL CONTROL
Service LED: Off
Operator LED: On
Possible causes: • Traction potentiometer applied while the tiller was still in the travel position,
or before the truck was switched on.
Remedy: Release the travel switch and tiller, then start the truck
1. Release the travel switch, power up the truck, set the tiller to the travel
position and then apply the traction potentiometer.
WT 3000 Series
Rev. B
146
ELECTRICAL SYSTEM
EVENT CODE 100 (WT 3040 -E, WT 3060 -E)
Event Code 100 (WT 3040 -E, WT 3060 -E)

Event Code 100
Display: EV100
Service LED: Off
Operator LED: Off
Explanation: Access 1 (display) does not receive a response from Access 3 (TCM) within 7
seconds.
Possible causes: • Access 3 power supply disconnected
• CAN Bus terminations faulty
• Software version of Access 1 does not match software version of Access 3
Remedy: Check basic functionality of display and communication with Access 3
1. Select SERVICE MENU > ANALYZER > A1Status > A1.3 STATUS
ACCESS 3.
Check the wiring
2. Check connector CA200 for damage.
4. Disconnect CA200 from Access 3 & 2 and CA201 from Access 1.
5. Measure the resistance between PC201-8 and PC200-27.
 If the resistance in a wire is more than 2 Ω, repair the wire.
 If the resistance of each wire is less than 2 Ω, the wires are ok. Proceed
to step 7.
Check the power supply
7. Connect CA200 to Access 3 & 2 and CA201 to Access 1.
8. When the truck is powered up measure the voltage between CA200-13
and BATT NEG.
 If the voltage is approximately the same as +BV, the power supply is ok.
Proceed to step 9.
Check the CAN Bus termination
9. Switch off the truck and measure the resistance between PC211-1 and
PC211-2.
 If the resistance is not 60 Ω, proceed to step 10.
 If the resistance is 120Ω, the terminal resistance is ok.
11. Disconnect CA201 from Access 1.
12. Measure the resistance between JC201-8 and JC201-9 on Access 1.
 If the resistance is 120 Ω, Access 1 is ok.
WT 3000 Series
Rev. B
147
ELECTRICAL SYSTEM
EVENT CODES 200 - 201 (WT 3040 -E, WT 3060 -E)
Check Access 1 software version

13. Select SERVICE MENU > UTILITIES > U1 PART NUMBERS > U1.1
ACCESS 1 > MODULE PN/SOFTWARE PN.
 Compare the software version of Access 1 with the list on page 61. If
the software version displayed is not on the list, contact the Crown ser-
vice department.
Note: It is possible that the software version displayed is compatible with the
software version of the display, but had not yet been released at the time of
going to print.
Replace Access 1
Event Codes 200 - 201 (WT 3040 -E, WT 3060 -E)

Event Code 200
Display: EV200
Service LED: On
Operator LED: Off
Explanation: Watchdog error in Access 2
• Access 2 faulty
Event Code 201

Display: EV201
Service LED: On
Operator LED: Off
Explanation: EEPROM error in Access 2
• Access 2 faulty
WT 3000 Series
Rev. B
148
ELECTRICAL SYSTEM


Event Code 202
Display: EV202
Service LED: On
Operator LED: Off
Explanation: Voltage at terminal −P of Access 2 (HCM) too low.
Possible causes: If the event is displayed during power up, but before the main contactor
applies:
• Access 2 output stage is faulty
has applied:
• Check the power cable terminals on pump motor M2
• Insulation resistances from the power cables or the winding of pump motor
M2 to the truck frame are too low
• Insulation resistances from the power cables or the winding of pump motor
M2 to the truck frame are too low
• Contacts of main contactor ED are worn
Remedy: If the event is displayed during power up, but before the main contactor
applies:
WT 3000 Series
Rev. B
149
ELECTRICAL SYSTEM

to the truck frame.
ponent.
Check the output stage of Access 2 for internal short circuits
3. Disconnect the power cable from terminal -P on Access 2.
4. Using an ohmmeter measure the resistance between terminal −P on Ac-
cess 2 and -Batt.
 If the resistance < 3 kΩ the output stage is faulty. Replace Access 3 & 2.
 If the resistance > 100 kΩ, the output stage is ok. In this case the error
lies in the wiring from −P to pump motor M2 or in the terminal on pump
motor M2.
has applied:
bles to the truck frame.
ponent.
7. Switch the truck off and on while checking if the error now occurs when the
truck is switched on.
 If the error now occurs when the truck is switched on, carry out steps3
to 4.
bles and the truck frame.
ponent.
Check the main contactor ED
10. Check the contacts of the main contactor for wear (see page 288).
 If the contacts are worn, repair the contactor.
 If all the above measures have been carried out and the event code per-
sists, replace Access 3 & 2.
WT 3000 Series
Rev. B
150
ELECTRICAL SYSTEM

Event Code 203
Display: EV203
Service LED: On
Operator LED: Off
Explanation: Voltage at terminal −P of Access 2 (HCM) is higher than the battery voltage.
• Access 2 faulty
Remedy: Check the power cables and terminals
to the truck frame.
ponent.
Event Code 204

Display: EV204
Service LED: On
Operator LED: Off
Explanation: As the pump motor starts up the current measured by Access 2 is either zero
or out of range.
• Access 2 faulty
CURRENT, activate lifting and check the reading.
 If the reading remains at 0 A as the motor is running, proceed to step 3.
 If a current > 0 A is displayed while the motor is running, there is no
error. Restart the truck and check the event log.
WT 3000 Series
Rev. B
151
ELECTRICAL SYSTEM

to the truck frame.
ponent.

Event Code 205
Display: EV205
Service LED: On
Operator LED: Off
Explanation: While the pump motor is idle the current measured by Access 2 is > 0A.
• Access 2 faulty
CURRENT and check the reading with the pump motor stationary.
 If the reading remains at 0 A while the pump motor is stationary there is
no error. Restart the truck and check the event log.
 If a current > 0 A is displayed while the pump motor is stationary, pro-
ceed to step 3.
Clear EEPROM in Access 1 and Access 2
WT 3000 Series
Rev. B
152
ELECTRICAL SYSTEM

to the truck frame.
ponent.

Event Code 206
Display: EV206
Service LED: On
Operator LED: Off
Explanation: Heatsink temperature in Access 2 & 3 > 85 °C
Possible causes: • Truck overloaded
• Fan faulty
• Wiring error
• Truck overloaded
Remedy: Test fan
the test).
 If the fan starts up, wait until the controller has cooled down. If the event
occurs frequently, check the operating conditions with the operator.
 If the fan does not start up and the control module temperature exceeds
45°C, proceed to step 2.
check the status.
3. Using a voltmeter measure the battery voltage between -Batt and CA204-
1 (fan).
continuity.
WT 3000 Series
Rev. B
153
ELECTRICAL SYSTEM

Event Code 207
Display: EV207
Service LED: On
Operator LED: Off
Explanation: The pump motor draws the maximum current for more than 10 seconds.
connected incorrectly.
• The motor is faulty
• Access 2 faulty
Remedy: Repeat the lift operation
1. Release the "Lift" button and press it again.
 If lifting now functions correctly, check the event log.
Check current consumption of pump motor (M2)
2. Select SERVICE MENÜ > INPUTS > ACCESS 2 INPUTS > A2.2.4 >
PUMP MOTOR CURRENT.
3. Raise the maximum load and activate lifting.
 If the reading remains below 100 A while the reading in A2.2.5 = 100%,
 If a current > 100 A is displayed while the reading in A2.2.5 = 100%,
proceed to step 4.
4. Check the power cables to pump motor M2 and its connections are secure
to the truck frame.
ponent.
WT 3000 Series
Rev. B
154
ELECTRICAL SYSTEM

Event Code 208
Display: EV208
Service LED: On
Operator LED: Off
Explanation: As the truck is powered the voltage on the power part of Access 2 is not 0V.
are shorted with respect to each other
• Access 2 faulty
to the truck frame.
ponent.
Check power cables for short circuits with respect to each other
3. Unscrew both power cables from the motor (+/-) and Access 2 (+Batt/–P).
4. Measure the resistance of the cables with respect to each other.
 If there is a short replace the power cables.
 If the resistance is endless (> 1 MΩ), there is no short circuit. Proceed
to step 5.
WT 3000 Series
Rev. B
155
ELECTRICAL SYSTEM

Event Code 209
Display: EV209
Service LED: On
Operator LED: Off
Explanation: Control module error
Possible causes: • Transient error
• Access 2 faulty
Event Code 210

Display: EV210
Service LED: On
Operator LED: Off
• Access 2 faulty
WT 3000 Series
Rev. B
156
ELECTRICAL SYSTEM

Event Code 211
Display: EV211
Service LED: On
Operator LED: Off
• Access 2 faulty
Event Code 212

Display: EV212
Service LED: On
Operator LED: Off
• Access 2 faulty
WT 3000 Series
Rev. B
157
ELECTRICAL SYSTEM

Event Code 213
Display: EV213
Service LED: On
Operator LED: Off
• Access 2 faulty
Event Code 214

Display: EV214
Service LED: On
Operator LED: Off
• Access 2 faulty
WT 3000 Series
Rev. B
158
ELECTRICAL SYSTEM

Event Code 215
Display: EV215
Service LED: On
Operator LED: Off
• Access 2 faulty
Event Code 218

Display: EV218
Service LED: On
Operator LED: Off
Explanation: Communication error on the CAN bus
• Short circuit
• Access 8 faulty
Test Access 1
WT 3000 Series
Rev. B
159
ELECTRICAL SYSTEM
Test the CAN Bus

3. Select SERVICE MENÜ > ANALYZER > A1Status menu> A1.1 STATUS
ACCESS 1 to Access 8.
 If the status of Access 1 to Access 5 is ON and Access 8 is OFF, the
CAN Bus connection is ok.
 If either the status of Access 1 to Access 5 is not ON and Access 8 is
ON, there is a communication error between Access 3 & 2 and Access
Access 8 prüfen
4. Check Access 8 (in the tiller handle) for obvious signs of damage.
 If the card is damaged, replace Access 8.
 Ist die
 If the card is ok, proceed to step 5.
Check the wiring between Access 2 & 3 and Access 8
6. Check the wiring between Access 8 (CA205) and Access 2 & 3 (CA200).
 If the wiring is ok, replace Access 8.

Event Code 219
Display: EV219
Service LED: On
Operator LED: Off
• Access 2 faulty
WT 3000 Series
Rev. B
160
ELECTRICAL SYSTEM

Event Code 220
Display: EV220
Service LED: On
Operator LED: Off
• Access 2 faulty
Test Access 1
Note: All customer-specific settings are cleared and the default values loaded.
WT 3000 Series
Rev. B
161
ELECTRICAL SYSTEM

Event Code 221
Display: EV221
Service LED: On
Operator LED: Off
• Access 2 faulty
Event Code 223

Display: EV223
Service LED: On
Operator LED: Off
Explanation: Error in driver of lowering valve SV.
• Access 2 faulty
1. Open SERVICE MENU > ANALYZER > A3 OUTPUTS > A3.8 SVL.
2. Activate lowering.
 If the display switches from 0% (function not activated) to 100% (func-
tion activated), the lowering valve is faulty. Replace the lowering valve.
 If the display remains at 0%, there is a wiring error. Proceed to step 3.
Check wiring
3. Check wiring from lowering valve to CA200-39 on Access 3 & 2 for dam-
age and shorts.
 If the wiring is damaged or if there is a short, repair the wiring.
WT 3000 Series
Rev. B
162
ELECTRICAL SYSTEM
4. Remove wire 5901 from connector PC200-39.

5. Connect the voltmeter to JC200-39 and activate lowering.
 If the reading is 0 V, Access 3 & 2 are ok.
 If the reading is more than 0 V, proceed to step 6.

Event Code 224
Display: EV224
Service LED: On
Operator LED: Off
Explanation: Short circuit in driver of lowering valve SV.
• Access 2 faulty
Remedy: Check control status
1. Open SERVICE MENU > ANALYZER > A3 OUTPUTS > A3.8 SVL.
 If lowering is not activated and the display shows 100% (function acti-
vated) proceed to step 2.
 If lowering is not activated and the display is 0%, restart the truck and
monitor the event log.
Check wiring
2. Check wiring from lowering valve to CA200-39 on Access 3 & 2 for dam-
age and shorts.
 If the wiring is damaged or if there is a short, repair the wiring.
3. Measure the voltage between CA200-39 and −Batt, do not activate lower-
ing.
 If the reading is 24 V, Access 3 & 2 and the wiring are ok.
 If the reading is significantly less than 24 V or 0 V, there is a short circuit.
Proceed to step 4.
4. Remove wire 5901 from connector PC200-39.
5. Measure the voltage at JC200-39 to BATT NEG.
Note: Do not activate lowering!
 If the reading is 24 V, Access 3 & 2 are ok.
 If the reading is significantly less than 24 V or 0 V, proceed with step 6.
WT 3000 Series
Rev. B
163
ELECTRICAL SYSTEM
Event Code 225

Display: EV225
Service LED: On
Operator LED: Off
Explanation: Error in internal A/D converter.
• Access 2 faulty
1. Disconnect all external devices (barcode readers etc.).
WT 3000 Series
Rev. B
164
ELECTRICAL SYSTEM

Event Code 226
Display: EV226
Service LED: On
Operator LED: Off
Explanation: Communication error within the control module.
• Access 2 faulty
1. Disconnect all external devices (barcode readers etc.).
Checking the software version number
4. Open SERVICE MENU > UTILITIES > U1 PART NUMBER > U1.3
ACCESS 3 > U1.3.2 SOFTWARE NO.
5. Compare the version number with the table on page 61.
 If the software version is incorrect, install the correct version or proceed
to step 9.
Test the CAN Bus
6. Select SERVICE MENÜ > ANALYZER > A1STATUS MENU > A1.1 STA-
TUS ACCESS 1 to Access 8.
 If the status of Access 1 to Access 8 is ON and Access 3 is OFF, the
external CAN Bus connection is ok. However, the internal CAN bus
communication is interrupted. Proceed to step 9.
 If either the status of Access 1 to Access 5 is not ON and Access 3 is
ON, there is a communication error on the CAN Bus. Isolate and rectify
the error on the CAN bus.
Importing the software
7. If possible and applicable, download software for Access 3.
8. Delete the EEPROM and reset and calibrate the truck.
Note: If you cannot re-install the software, replace Access 3 & 2.
WT 3000 Series
Rev. B
165
ELECTRICAL SYSTEM

Event Code 228
Display: EV228
Service LED: On
Operator LED: Off
Explanation: One or more drivers for FAN, SV, HN, ALM or FLS are damaged.
• Short circuit in one of the attached components
• Access 2 faulty
Locate the affected driver
3. Activate the connected components FAN, SV, HN, ALM and FLS in turn
EV228 is displayed.
 If the alarm is displayed on one of the components, replace the compo-
nent or repair its wiring.
 If no short is found proceed to step 4.
WT 3000 Series
Rev. B
166
ELECTRICAL SYSTEM

Event Code 229
Display: EV229
Service LED: On
Operator LED: Off
Explanation: One or more drivers for FAN, SV, HN, ALM or FLS have a short.
• Short circuit in the feed wire to one of the attached components
• Access 2 faulty
Check terminals for short circuits or open connections
2. Check terminals and wiring for FAN, SV, HN, ALM and FLS for shorts or
open connections.
 If there is a short or an open connection, repair the wiring.
Check drivers in the control module
3. Open SERVICE MENU > FEATURES > F2 & F3 > TRAVEL ALARM &
BEACON and set to “BOTH”.
Note: All drivers are internally monitored even if some options are not in-
stalled. Therefore all drivers must be activated in order to measure.
4. Disconnect the + wires (red/white) from all the components connected to
the drivers. Make wires to the unused driver outputs accessible.
5. Using an ohmmeter measure in turn each driver output between the - wires
(green/white) and −Batt.
 If the resistance is at least 10kΩ, the respective driver output is ok.
 If less than 10kΩ is measured on a driver output, proceed to step6.
WT 3000 Series
Rev. B
167
ELECTRICAL SYSTEM

Event Code 230
Display: EV230
Service LED: On
Operator LED: Off
Explanation: One or more of the following components have an internal short circuit: FAN,
SV, HN, ALM or FLS
Possible causes: • Short circuit in one of the attached components
• Access 2 faulty
Remedy: Rule out the main contactor circuit
 If the error occurs when the truck is switched on, the main contactor
circuit is affected. Proceed to step 3.
 If the truck starts normally, proceed to step 2.
Isolate the error within the FAN, SV and HN circuits
2. Activate the connected components BR, FAN, SV, HN, ALM and FS in turn
EV230 is displayed.
 If the alarm is displayed for one of these components, proceed to step 4.
 If no component is activating the event code and it persists, proceed to
step 3.
Measure the affected component
3. Disconnect the + wire (red/white) and the - wire (green/white) from the
respective component.
Note: If ALM or FLS are affected, disconnect the + wire (red/white) and the -
wire (green/white) from both components.
4. Using an ohmmeter measure the resistance of the actuating components:
– Line Contactor = 30 Ω
– BR = 13 Ω
– FAN > 100 kΩ
– SV ≈ 31 Ω
– HN > 100 kΩ
– ALM > 100 kΩ
– FLS > 100 kΩ
WT 3000 Series
Rev. B
168
ELECTRICAL SYSTEM
 If the resistance at ALM and FLS is at least 6 MΩ these components are

 If the resistance at FLS or ALM is still only approx. 10 Ω, replace the
component.
 If the resistances for all other components match the above values, the
triggering component is ok. Proceed to step 5.
 If the reading of one component (apart from ALM and FLS) does not
match the above readings, replace the component.
WT 3000 Series
Rev. B
169
ELECTRICAL SYSTEM

Event Code 300
Display: EV300
Service LED: On
Operator LED: Off
Possible causes: • Communication error on the CAN bus
• Access 1 faulty
• Access 3 faulty
Event Code 301

Display: EV301
Service LED: On
Operator LED: Off
• Access 3 faulty
WT 3000 Series
Rev. B
170
ELECTRICAL SYSTEM

Event Code 302
Display: EV302
Service LED: On
Operator LED: Off
Explanation: As the truck is switched on, before the main contactor closes, a current > 0 A
is detected in the output stage.
• Access 3 faulty
1. Check power cable terminals on Access 3, in particular +Batt and −Batt.
Event Code 303

Display: EV303
Service LED: On
Operator LED: Off
Explanation: Phase voltage out of range
• Access 3 faulty
1. Check power cable terminals, in particular on +Batt and −Batt of Access 3.
Check terminals for corrosion and overheating.
WT 3000 Series
Rev. B
171
ELECTRICAL SYSTEM

Event Code 304
Display: EV304
Service LED: On
Operator LED: Off
Explanation: Low voltage or overvoltage(a) detected.
The event occurs if the voltage at pin PC201-10 drops below 9 V or the voltage
at the +Batt terminal of Access 3 & 2 exceeds 35 V.
Possible causes: • Batterie bricht ein
• Voltage drop via fuse FU2 or relay K1 (or key switch)
• Faulty contact in power supply
• Transitional resistance in terminal of a power cable
• Access 3 faulty
• Battery used with excessive voltage
Remedy: Compare internally measured battery voltage with actual battery voltage
VOLTAGE and record the reading. It should be ≈ 24 V.
Note: Do not use 48 V batteries.
it.
VOLTAGE.
with a new one.
Measure the voltage drop on the signal line from Access 3 & 2
7. Measure the voltage between CA209-10 and −Batt while shaking connec-
tor CA209.
 If the reading is roughly the same as the battery voltage (≈ 24 V), and if
there is no discontinuity on shaking, the connector and signal line are
WT 3000 Series
Rev. B
172
ELECTRICAL SYSTEM
 If the voltage is disconnected on shaking the connector, remove the

connector and check that the contacts are secure. Repair any loose
contacts.
Note: The voltage at CA209-10 is always slightly less than the battery voltage.
This is due to the voltage drop via the signal switch in the main contactor, fuse
FU2, relay K1 or the key switch. However, this is only a few tenths of a volt.
 If the voltage is less than 22V, proceed to step 8.
Determine the cause of the voltage drop on the signal line
8. Measure the input and output voltage of the signal switch on the main
contactor.
 If the voltage drops extremely, replace main contactor ED.
9. Measure the input and output voltage of fuse FU2.
 If the voltage drops extremely, replace FU2.
10. Measure the voltage at pin30 (input) and pin 87 (output) of relay K1. If the
truck has a key switch, measure the key switch input and output voltages.
 If the voltage drops extremely, replace relay K1 or the key switch.
11. Measure the voltage drop over the wires:
– Between the signal switch on the main contactor and fuse FU2
– Between FU2 and pin 30 on relay K1
– Pin 87 on relay K1 and pin CA209-10
 If the voltage drops extremely on one wire, repair the wire or connec-
tions.
a. Theoretically, this event code could be displayed for an overvoltage if there had been a conversion to a 48 volt battery connector
and someone had installed a 48 volt battery.
WT 3000 Series
Rev. B
173
ELECTRICAL SYSTEM

Event Code 305
Display: EV305
Service LED: On
Operator LED: Off
Explanation: Voltage on one of the phases U, V or W too low.
Possible causes: • The power cables to traction motor M1 have a poor contact or transition
resistances on the terminals.
• Access 3 faulty
1. Check motor power cable terminals. Check terminals for corrosion and
overheating.
Event Code 306

Display: EV306
Service LED: On
Operator LED: Off
Explanation: Voltage on one of the phases U, V or W too high.
Possible causes: • Power cables to traction motor M1 have a short or the motor itself has a
short.
• Access 3 faulty
1. Check terminals and motor power cables for short circuits.
WT 3000 Series
Rev. B
174
ELECTRICAL SYSTEM


Event Code 307
Display: EV307
Service LED: On
Operator LED: Off
Explanation: On power up there is a test to see if the main contactor contacts are open. If
the circuit which the main contactor contacts close is already closed, this event
code will be issued.
Possible causes: • Main contactor power contacts are welded
• Short circuit in the power routing on main contactor
• Access 3 faulty
1. Check if power cable terminals on the main contactor have shorted.
Check main contactor contacts
2. Check the main contactor contacts (see page 288).
 If the contacts are welded, replace the contacts or the main contactor.
 If the main contactor is ok, proceed to step 3.
WT 3000 Series
Rev. B
175
ELECTRICAL SYSTEM

Event Code 308
Display: EV308
Service LED: On
Operator LED: Off
Explanation: Main contactor contacts do not close.
Possible causes: • Main contactor contacts jamming
• Fuse FU1 faulty
• Coil routing disconnected
• Access 3 faulty
1. Measure the voltage at +Batt of Access 3 & 2.
 If there is no voltage, replace fuse FU1.
 If FU1 is ok, proceed to step 2.
Check the contactor coil power supply
truck.
to step 2.
wires:
coil.
WT 3000 Series
Rev. B
176
ELECTRICAL SYSTEM


Event Code 309
Display: EV309
Service LED: On
Operator LED: Off
Explanation: Current flows to output stage when truck is idle
Event Code 310

Display: EV310
Service LED: On
Operator LED: Off
Explanation: Internal capacitor bank charge time exceeded
Possible causes: • Additional unauthorised consumers installed
• Access 3 faulty
Remedy: Check for additional consumers
1. Using the circuit diagram and Crown's list of options, check if non-ap-
proved consumers are connected along with the capacitor bank of +Batt
at Access 3 to –Batt.
 If an unauthorised consumer is installed, disconnect it. Proceed to step
2.
 If no non-approved consumers are installed, proceed to step 3.
WT 3000 Series
Rev. B
177
ELECTRICAL SYSTEM

Event Code 314
Display: EV314
Service LED: On
Operator LED: Off
Explanation: Main contactor driver shorted
Possible causes: • Short circuit or disconnection in the line from CA209-12 to the main contac-
tor coil
• Access 3 faulty
Remedy: Check the wiring for short circuits
1. With the truck switched off, use an ohmmeter to measure from CA209-12
to −Batt on Access 3.
 If the resistance is < 5 kΩ, repair the short in the wiring.
 If the resistance > 5 kΩ, proceed to step 2.
3. With the main contactor open, measure the voltage on the main contactor
coil on both terminals for the signal lines.
 If the voltage ≈ 24 V, the coil is ok. Proceed to step 4.
 If the voltage is not ≈ 24 V, the coil is faulty. Replace the main contactor
or coil.
WT 3000 Series
Rev. B
178
ELECTRICAL SYSTEM

Event Code 315
Display: EV315
Service LED: On
Operator LED: Off
Explanation: Driver cannot close the main contactor.
Possible causes: • Main contactor coil routing disconnected
• Access 3 faulty
Remedy: Check the contactor coil power supply
truck.
to step 2.
wires:
– From the output of fuse FU5 over CA225-4 and -5 to pin 30 and pin 87
on relay K1
coil.
WT 3000 Series
Rev. B
179
ELECTRICAL SYSTEM

Event Code 316
Display: EV316
Service LED: On
Operator LED: Off
Explanation: Excessive current through the driver for the main contactor or brake coil
Possible causes: • Short circuit in the brake coil power circuit or the brake coil
• Short circuit in the main contactor coil power circuit or the main contactor
coil
• Access 3 faulty
Remedy: Check the wiring to the main contactor coil and the brake for short cir-
cuits
1. Check the wiring to the main contactor coil and the brake for short circuits.
2. Check if the terminals on the main contactor have been shorted by a for-
eign body.
 Remove any short circuits found.
 If there is no short, proceed to step 3.
Check the coils of the main contactor coil and the of brake for short cir-
cuits
Note: A short is detected at a resistance of < 2 Ω.
3. Remove both signal cables from the main contactor coil.
coil.
 If the coil resistance is less than ≈ 13 Ω ±10 %, replace the main con-
tactor or coil.
WT 3000 Series
Rev. B
180
ELECTRICAL SYSTEM

Event Code 317
Display: EV317
Service LED: On
Operator LED: Off
Explanation: The zero point of the traction potentiometer deviates from the calibrated value
by more than 1 V and the travel switch is open.
Possible causes: • Physical defect on the traction potentiometer
• Traction potentiometer replaced but not calibrated
Remedy: Check the traction potentiometer for physical damage
POT WPR.
2. Activate the travel switch in both directions and then restore it to neutral
while observing the display.
 If the display always reverts to the same reading in neutral, the traction
potentiometer is ok. Calibrate the traction potentiometer (see page
255).
 If the display does not revert to the same reading in neutral, the traction
potentiometer is faulty. Replace the traction potentiometer (see page
316).
Event Code 319

Display: EV319
Service LED: On
Operator LED: Off
Explanation: The reading supplied by the pressure sensor is out of the normal range.
Possible causes: • Pressure sensor faulty
• Pressure sensor replaced but not calibrated
Remedy: Check reading supplied by the pressure sensor
PRESSURE TRANSDUCER.
2. Fully lower the unladen forks and check the reading. It should be ≈ 1 V.
3. Raise a load of 2000 kg and check the reading. It should be > 8 V.
proceed to step 4.
WT 3000 Series
Rev. B
181
ELECTRICAL SYSTEM

4. Measure the voltage (+12 V) between CA210-2 (on the pressure sensor)
and −Batt. It should be ≈ +12 V.
5. Measure the voltage (GND) from CA210-1 to BATT NEG. It should be
≈ 0 V.
ule is faulty. Replace the control module.
is faulty. Replace the control module.
Measure the pressure sensor output signal
6. Fully lower the unladen forks and measure the voltage between CA209-23
and −Batt. It should be ≈ 1 V.
7. Raise a load of 2000 kg and measure the voltage between CA209-23 and
−Batt. It should be ≈ 8 V.
the pressure sensor is faulty. Replace and recalibrate the pressure sen-
sor.

Event Code 320
Display: EV320
Service LED: On
Operator LED: Off
Explanation: CAN Bus communication failure between Access 3 and Access 1.
1.
3. Measure the resistance between CA211-1 and CA211-2.
 If the resistance is 60 Ω, restart the truck and monitor the event log.
WT 3000 Series
Rev. B
182
ELECTRICAL SYSTEM
4. Measure the terminal resistance between CA211-1 and CA211-2.

5. Disconnect CA222 from Access 5 and CA201 from Access 1.
6. Measure the terminal resistance between CA211-1 and CA211-2 again.
 If the resistance is endless (> 1 MΩ), the wiring is ok.
 If there is a short, the error is caused by the wiring. Proceed to step 9.
Test Access 1
7. With the connectors still removed, measure the resistance between
JC201-8 and JC201-9 on Access 1.
Testing Access 3
Repair wiring
Replace Access 1

Event Code 321
Display: EV321
Service LED: On
Operator LED: Off
Explanation: Incorrect truck model selected.
Possible causes: • Control module replaced and not set
Remedy: Set the truck model
1. Open SERVICE MENU > FEATURES MENU > F4 > TRUCK TYPE and
set the correct truck type.

Event Code 322
Display: EV322
WT 3000 Series
Rev. B
183
ELECTRICAL SYSTEM
Service LED: On
Operator LED: Off
Explanation: Short circuit in the brake positive wire
1. Measure the voltage at CA200-30 to BATT NEG. It should be ≈ +BV.
 If the voltage is not ≈ +BV, remove the short circuit between the positive
cable (red/white) on the brake and PC200-30.
2. Remove the negative terminal from the brake.
Event Code 324

Display: EV324
Service LED: On
Operator LED: Off
Explanation: The short circuit protection on the control module for the main contactor coil is
faulty.
Remedy: Check the main contactor coil
1. Disconnect lines 2925 and 5906 from the coil.
 If the coil resistance is less than 25 Ω, replace the main contactor or
coil.
 If the resistance is approx. 30 Ω, proceed to step 3.
. Check the brake coil
3. Remove wires 2908 and 5900 from the brake coil.
 If the coil resistance is less than 8 Ω, replace the brake coil.
 If the resistance is approx. 10 Ω, , proceed to step 5.
Check the wiring for short circuits
5. Check wires 2925, 5906, 2908 and 5900 for shorts.
 If there is a short, repair the line.
 If the wires are ok, proceed to step 6.
Event Code 325
WT 3000 Series
Rev. B
184
ELECTRICAL SYSTEM
Display: EV325
Service LED: On
Operator LED: Off
• Access 2 faulty

Event Code 326
Display: EV326
Service LED: On
Operator LED: Off
Explanation: Power output stage short circuit
2. Check the power cable to the traction motor M1 and its terminals for short
circuits.
3. Check power cable terminals on the control module for short circuits with
terminals +Batt and −Batt.
 If any cables or terminals are shorted, rectify the cause.
to the truck frame.
ponent.
WT 3000 Series
Rev. B
185
ELECTRICAL SYSTEM
Check control module

5. On the control module unscrew the wires from terminals U, V and W.
6. Using an ohmmeter measure the resistance from terminal U on the control
module to +Batt and then to −Batt.
7. Repeat step 6 with phase V and phase W.
 If the resistance at one of the phases is < 100 Ω, the output stage is
faulty. Proceed to step 8.
 If no error is found, restart the truck. Monitor the event log.

Event Code 328
Display: EV328
Service LED: On
Operator LED: Off
Event Code 329

Display: EV329
Service LED: On
Operator LED: Off
• Access 2 faulty
WT 3000 Series
Rev. B
186
ELECTRICAL SYSTEM

Event Code 332
Display: EV332
Service LED: On
Operator LED: Off
• Access 2 faulty
Event Code 333

Display: EV333
Service LED: On
Operator LED: Off
Explanation: The driver cannot activate the brake
Possible causes: • Wiring disconnected
• Open brake coil
 If the voltage is not ≈ +BV, repair the wire (red/white) between the brake
and PC200-30.
Check the brake coil
 If the resistance is not ≈ 13 Ω ±10 %, replace the brake.
WT 3000 Series
Rev. B
187
ELECTRICAL SYSTEM


Event Code 334
Display: EV334
Service LED: On
Operator LED: Off
Explanation: Occurs only in connection with EV328
Possible causes: • None
Remedy: 1. No action required, the alarm goes out automatically.
WT 3000 Series
Rev. B
188
ELECTRICAL SYSTEM

Event Code 335
Display: EV335
Service LED: On
Operator LED: Off
Explanation: CAN Bus communication failure between Access 1 and one of the other con-
trol modules.
1.
4. Measure the terminal resistance between CA211-1 and CA211-2.
5. Disconnect CA222 from Access 5 and CA201 from Access 1.
6. Measure the terminal resistance between CA211-1 and CA211-2 again.
 If the resistance is endless (> 1 MΩ), the wiring is ok.
 If there is a short, the error is caused by the wiring. Proceed to step 9.
Test Access 1
Testing Access 3
Repair wiring
WT 3000 Series
Rev. B
189
ELECTRICAL SYSTEM
Replace Access 1

Event Code 337
Display: EV337
Service LED: On
Operator LED: Off
Explanation: Thermal sensor in the control module returns values beyond the measuring
range of -80°C to +120°C.
• Access 3 faulty
Test Access 1
WT 3000 Series
Rev. B
190
ELECTRICAL SYSTEM

Event Code 338
Display: EV338
Service LED: On
Operator LED: Off
• Access 3 faulty
Remedy: Check the battery condition
1. Check the battery for physical damage.
2. Check the battery terminals for corrosion.
3. Ensure the battery cable is attached securely.
 If the items in steps 1 to 3 are ok, proceed to step 4.
Check the condition of the battery cells

4. Measure the individual voltages of the battery cells.
 Replace any faulty cells.
 If all the cells are ok and the sum of the cell voltages is ≈ 24 V, proceed
to step 5.
VOLTAGE.
it.
WT 3000 Series
Rev. B
191
ELECTRICAL SYSTEM

Event Code 340
Display: EV340
Service LED: On
Operator LED: Off
• Access 3 faulty
Remedy: Clear the EEPROM in Access 1
Note: All customer-specific settings are cleared and the default values loaded.
Event Code 341

Display: EV341
Service LED: On
Operator LED: Off
Explanation: Short circuit on the negative side of the brake driver
Possible causes: • Open connection in the brake positive wire
• Short circuit between positive wire leading to brake and −Batt.
• Short circuit on the negative side of the driver in Access 3
Remedy: Check wiring and power supply
1. Disconnect CA200 from the control module and the negative line (green/
white) from the brake.
2. Check line (pin PC200-31) for continuity.
 If the wire is ok, proceed to step 3.
 Ist die Leitung unterbrochen, Leitung reparieren.
3. Connect PC200 and the wire (green/white) to the brake. Measure the volt-
age from both brake terminals to BATT NEG.
 If the voltage is ≈ 24 V, proceed to step 4.
 If there is no 24 volt supply, replace the brake coil.
4. Measure the resistance between PC200-31 and −Batt.
 If the resistance < 5 kΩ, proceed to step 5.
 If the resistance > 5 kΩ, repair the wiring.
WT 3000 Series
Rev. B
192
ELECTRICAL SYSTEM


Event Code 342
Display: EV342
Service LED: On
Operator LED: Off
Explanation: Forward and reverse travel commands applied simultaneously.
• Access 3 faulty
Remedy: Check switch statuses in Analyzer menu
AND A2.3.4 and check the switch status.
 If one switch is OFF and the other ON when the travel switch is applied,
 If both switches are ON, proceed to step 2.
Check wiring
2. Check travel direction switch connections from CA410-3 and CA410-4
(Main PCB in the tiller handle) to Access 8 CA204-5 and CA204-4.
3. Check CA200-31 and CA209-32 on the control module for short circuits.
 If the connections are ok, proceed to step 4.
 Repair the connections if they are not ok.
4. Using a voltmeter measure the voltage from CA204-5 and CA204-4 to
−Batt.
5. Temporarily remove wires 2980 of PC204-5 and 2981 of PC204-4 from the
connector.
6. Measure the voltage at the open wire ends to BATT NEG.
7. Check the connector contact for corrosion and check the wiring for shorts
and discontinuity.
 If corrosion or a wiring fault is found, repair the wiring.
 If no error is found in the wiring, the error is probably in Access 8 (in the
tiller handle).
Replace Access 8
WT 3000 Series
Rev. B
193
ELECTRICAL SYSTEM

Event Code 343
Display: EV343
Service LED: On
Operator LED: Off
Explanation: Encoder ECR1 in the traction motor has a fault. The event code is issued if the
encoder detects a change of more than 40 Hz in less than 16 ms.
Possible causes: • Slip in encoder drive
• Wiring error
• Access 3 faulty
Remedy: Check encoder pulses in Analyzer menu
ECR1 ENCODER 64 PULSE.
2. Check the display at first with the truck idle, then at full travel speed.
 If 0 pulses are shown when truck is idle and ±14000 pulses are shown
at full speed, the encoder is ok. Restart the truck and check the event
log.
 If 0 pulses are not displayed when the truck is stationary and/or ±12000
pulses are not displayed at full speed, proceed to step 3.
Check wiring
3. Check the encoder wiring for:
– Corrosion
– Loose connections
– Faulty crimp connections on the pins
– Trapped wires
 If there is no damage, proceed to step 4.
4. Measure the voltage (+12 V) between CA217-1 (on ECR1) and −Batt. It
should be ≈ +12 V.
5. Measure voltage (GND) from CA217-4 to −Batt. It should be ≈ 0 V.
ule is faulty. Proceed to step 7.
WT 3000 Series
Rev. B
194
ELECTRICAL SYSTEM
Check the sensor bearing for physical damage

 If no physical damage is found, restart the truck and check the event
log.

Event Code 344
Display: EV344
Service LED: On
Operator LED: Off
Explanation: The status of the safety reverse switch (SAS) or brake switch (BRS) is moni-
tored via the CAN bus and additionally via a hard wired line. If different sta-
tuses are detected by the line and the CAN bus, this event code is displayed.
• Access 3 faulty
Remedy: Check switch status
1. For fixed platform trucks, proceed to step 2. For folding platform trucks,
proceed to step 5.
BRS SWITCH.
3. Do not apply BRS and check the status.
 If the status is OFF, proceed to step 4.
4. Apply BRS and monitor the display.
 If the switch status changes, proceed to step 13.
 If the switch status does not change, proceed to step 8.
SAS SWITCH.
6. Do not apply SAS and check the status.
 If the status is OFF or ON, proceed to step 7.
7. Apply SAS and monitor the display.
 If the switch status changes, proceed to step 13.
 If the switch status does not change, proceed to step 8.
Check wiring
8. Remove wire 2915 from connector CA200-33 on Access 3 & 2.
9. Measure the voltage directly between the wire and −Batt.
 If the voltage corresponds to +Batt, the wire is ok.
 If the voltage does not correspond to +Batt, proceed to step 10.
WT 3000 Series
Rev. B
195
ELECTRICAL SYSTEM
10. Remove wire 2982 from connector CA204-1 on Access 8.

11. Measure the voltage directly between the wire and −Batt.
 If the voltage corresponds to +Batt, the wire is ok.
 If the voltage does not correspond to +Batt, proceed to step 12.
12. Check the wire between CA410-2 and CA204-1 for continuity.
 If the line is continuous, replace switch BRS or SAS.
 If the line is disconnected, repair the wiring.
Replace Access 8

Event Code 345
Display: EV345
Service LED: On
Operator LED: Off
Explanation: See EV344
Possible causes: See EV344
Remedy: See EV344
Event Code 346

Display: EV346
Service LED: On
Operator LED: Off
Explanation: Error in feedback from TFD module proportional driver
• Access 3 faulty
WT 3000 Series
Rev. B
196
ELECTRICAL SYSTEM

Event Code 347
Display: EV347
Service LED: On
Operator LED: Off
Explanation: The travel command frequency for more than 15 s > 20 kHz and the frequency
of encoder ECR1 in the traction motor is < 0.6 Hz.
• Motor blocked
• Faulty wiring
• ECR1 faulty
• Access 3 faulty
Remedy: Note: This event also occurs when the traction motor is blocked. For example,
if the drive wheel is stuck in a hole or pallets have been pushed in an unauthor-
ised manner. Check this first!
The first time the event code appears
Check wiring of ECR1
> A2.3.14.
4. Accelerate the unladen truck up to maximum speed and check the current.
 If the current is approx. 35A, the wiring and encoder are ok. Proceed to
step 6.
 If the current is considerably greater than 35 A and the truck still only
travels at creep speed, the wiring or the encoder in M1 are faulty. Pro-
ceed to step 5.
5. Check wiring of encoder ECR1 for damage.
 If the wiring is ok, repair or replace the motor.
 If neither the encoder nor the wiring is faulty, proceed to step 7.
Check ECR1 (sensor bearing) for physical damage
 If no physical damage is found, proceed to step 7
WT 3000 Series
Rev. B
197
ELECTRICAL SYSTEM

WT 3000 Series
Rev. B
198
ELECTRICAL SYSTEM

Event Code 348
Display: EV348
Service LED: On
Operator LED: Off
Explanation: Parking brake does not hold.
When the truck is idle, the control module checks if the traction motor is turn-
ing. The event code is displayed if a rotary movement with at least 0.75 Hz is
detected for more than 2 s.
Possible causes: • Brake faulty
Remedy: Check parking brake
1. Check the parking brake for damage (see page 298).
Event Code 349

Display: EV349
Service LED: On
Operator LED: Off
Explanation: Travel command frequency > 20 kHz for more than 15 seconds and frequency
of encoder ECR1 in the traction motor < 0.6 Hz.
Possible causes: • FU5 blown
• Faulty wiring
• Access 3 faulty
1. Check fuse FU5 for continuity.
 Replace the fuse if faulty (10 A/32 V).
2. Select SERVICE MENÜ > ANALYZER > A1 STATUS > A1.3 STATUS
ACCESS 3.
 If the ON status is displayed, repair line 209 to connector CA200-20.
 If the OFF status is displayed, repair line from FU5 to connector CA200-
20.
 If the event code persists although neither FU5 nor the wiring are faulty,
proceed to step 3.
WT 3000 Series
Rev. B
199
ELECTRICAL SYSTEM

Event Code 353
Display: EV353
Service LED: On
Operator LED: Off
Explanation: Thermal sensor TS1 in the drive motor returns values beyond the measuring
range of -40 °C to +200 °C.
Remedy: Measure and check the temperature
TEMP ACCESS 3 and check the temperature display.
step 3.
20°C.
 If the resistance ≈ 600 Ω (at 20 °C internal motor temperature), proceed
to step 4.
is faulty. Replace traction motor M1 (see page 273).
Check wiring
4. Check wires from PC215-1 to PC200-12 and PC215-2 to PC200-10 using
an ohmmeter.
 If the resistance in a line ≈ 0 Ω, the wiring is ok. Proceed to step 5.
 If the resistance differs from this value, repair the wiring.
Check the temperature sensor voltage readings
5. Connect PC215 and switch on the truck.
6. Measure the voltage between CA200-12 and CA200-10 and BATT NEG.
The readings should be: ≈ 3 V for tM1 ≈ 150°C and > 0.7 V for tM1 ≈ -25°C
 If the voltage is ok, proceed to step 7.
 If the voltage is incorrect, replace traction motor M1 (see page 273).
WT 3000 Series
Rev. B
200
ELECTRICAL SYSTEM

Event Code 370
Display: EV370
Service LED: On
Operator LED: Off
Possible causes: • Setting is ENABLED despite the SRT option not being installed.
Remedy: Check SRT option status
1. Open SERVICE MENU > FEATURES > F14 > SRT and check setting.
 If the option is set to ENABLED, set it to DISABLED.
 If the function is already DISABLED, proceed to step 2.
Test Access 1
2. Measure the voltage between CA202-13 and −Batt.
 If 0 V is displayed, restart the truck and check the event log.
3. Remove pin 13 from CA202 and measure the voltage directly between pin
13 and −Batt.
 If the event code does not disappear and the reading is not 0 V, Access
1 is faulty. Replace Access 1.
 If the reading is 0 V and the event code is no longer displayed, restart
Event Code 371

Display: EV371
Service LED: On
Operator LED: Off
Explanation: Travel direction switch not applied for 1 second but more than 3 V applied to
the traction potentiometer slider.
Possible causes: • Traction potentiometer incorrectly calibrated
• Direction switch faulty
• Wiring error
• Traction potentiometer faulty
Remedy: Calibrate traction potentiometer
Check traction potentiometer wiper voltage
POT WPR.
WT 3000 Series
Rev. B
201
ELECTRICAL SYSTEM
 If the display does not revert to 0 V in neutral, the traction potentiometer

is faulty. Replace the traction potentiometer (see page 316).
 If the display always reverts to 0 V in neutral, the traction potentiometer
A2.3.3 > PF SWITCH.
(see page 316).
A2.3.4 > FF SWITCH.
display.
(see page 316).
7. Check mechanical parts and wiring of traction potentiometer.
 If the traction potentiometer or wiring are faulty, replace the damaged
parts.
 If no errors are found, replace the traction potentiometer (see
page 316).
WT 3000 Series
Rev. B
202
ELECTRICAL SYSTEM
EVENTS DISPLAYED AS TEXT (WT 3040 -E, WT 3060 -E)
(WT 3040 -E, WT 3060 -E) tion. This will require the intervention of a service engi-
One hyd. function at a time

Display: ONE HYD. FUNCTION AT A TIME
Service LED: Off
Operator LED: On
Explanation: Discrepancy in the lift switch logic.
Explanation: Lift and lower commands applied simultaneously.
• Access 2 faulty
Remedy: Check switch statuses in Analyzer menu
RAS SWITCH and A2.3.4 LOS SWITCH and check the switch statuses.
Note: Do not activate any operation!
 If both switches are OFF, there is no fault. Restart the truck and check
the event log.
 If one of the switches is ON, proceed to step 2.
Check wiring
2. Measure the voltage between CA415-4 and CA415-5 (Main PCB in tiller
handle) and −Batt.
3. Temporarily remove wires 2988 and 2989 of PC415 from the connector.
4. Measure the voltage at pins JC415-4 and JC415-5 to BATT NEG.
 If the voltage is not 0 V, replace Main PCB (see page 316). If the error
persists, proceed to step 6.
5. Measure the voltage directly between wires 2988 and 2989 and −Batt
 If the readings are 0 V, the wiring is ok, proceed to step 6.
 If one of the wires is conducting a voltage > 0 V, there is a short to +Batt.
Locate and clear the short.
Platform Error
Display: PLATFORM FAILURE
Service LED: Off
WT 3000 Series
Rev. B
203
ELECTRICAL SYSTEM
Operator LED: On
Explanation: Discrepancy in the platform side restraint logic.
Possible causes: • Platform or side restraint sensors faulty
• Wiring error
Check switch status of side restraint sensors SR1 and SR2 and platform
sensors PLS1 and PLS2
PC207 and PC208.
Test sensors
Entry bar &/or FDS

Display: ENTRY BAR &/OR FDS
WT 3000 Series
Rev. B
204
ELECTRICAL SYSTEM
Service LED: Off

Operator LED: On
Explanation: On fixed platform trucks a logical error was caused by the entry bar or the step.
Possible causes: • Entry bar sensor or step sensor faulty
• Wiring error
Check the option setting
Note: For fixed platform trucks, PLS1 is the presence sensor. PLS2 is the entry
bar sensor.
2. Check switch statuses of side restraint sensors SR1 and SR2 and platform
sensors PLS1 and PLS2.
PC207 and PC208.
Test sensors
WT 3000 Series
Rev. B
205
ELECTRICAL SYSTEM
Stopped
Display: TRUCK STOPPED
Service LED: Off
Operator LED: On
Explanation: Battery residual capacity below the permissible level.
Possible causes: • Battery faulty
• BDI setting does not match the performance setting
• Battery voltage set incorrectly
Remedy: Charge the battery or install a charged battery
1. Charge the battery fully or replace it with a fully charged battery.
 If this resolves the error, return the truck to service.
 If the BDI still does not show a fully charged battery, proceed to step 2.
Check load profile in the BDI setting
2. Open SERVICE MENU > PERFORMANCE > P11 > ADJUST BATT and
check that the setting matches the actual load profile of the truck. (see
Checking and Adjusting the BDI Setting table, page 281).
 If the setting and the actual load profile match, proceed to step 3.
 If the setting does not match the actual load profile, adjust the load pro-
file (see page 281).
VOLTAGE and record the reading.
it. Proceed to step 5.
VOLTAGE.
with a new one.
is ok.
WT 3000 Series
Rev. B
206
ELECTRICAL SYSTEM

VOLTAGE.
with a new one.
WT 3000 Series
Rev. B
207
ELECTRICAL SYSTEM
Traction control module hot

Display: HIGHTEMP TCM
Service LED: Off
Operator LED: On
Explanation: Temperature of traction control module Access 3 too high
• Wiring error
Remedy: Test fan
the test).
check the status.
and CA213-1 (fan).
continuity.
Compare the actual temperature with the temperature display
6. Open SERVICE LEVEL 2 > ANALYZER MENU > A2 > INPUTS > A2.3.1
TEMP ACCESS 3 and check the reading.
ature readings.
WT 3000 Series
Rev. B
208
ELECTRICAL SYSTEM

VOLTAGE.
with a new one.
is ok.
VOLTAGE.
with a new one.
Traction motor hot

Display: HIGHTEMP TRACTION MOTOR
Service LED: Off
Operator LED: On
Explanation: Temperature in traction motor M1 too high
• Wiring error
Remedy: Test fan
the test).
check the status.
WT 3000 Series
Rev. B
209
ELECTRICAL SYSTEM

4. Using a voltmeter measure the voltage between −Batt and CA204-1 (fan).
continuity.
Measure and check the temperature
TS1 and check the temperature display.
step 8.
20°C.
Replace traction motor M1
10. Replace traction motor M1 (see page 273).
Release control handle

Display: RELEASE CONTROL HANDLE
Service LED: Off
Operator LED: On
Possible causes: • The control handle is in the travel position when the truck is switched on
Remedy: Release the control handle, then start the truck
1. Release the control handle, then switch on the truck.
WT 3000 Series
Rev. B
210
ELECTRICAL SYSTEM
Travel switch applied too soon

Display: RELEASE TRAVEL CONTROL
Service LED: Off
Operator LED: On
Possible causes: • Traction potentiometer applied while the control handle was still in the
travel position, or before the truck was switched on
Remedy: Release the travel switch and control handle, then start the truck
1. Release the travel switch, power up the truck, set the control handle to the
travel position and then apply the traction potentiometer.
WT 3000 Series
Rev. B
211
ELECTRICAL SYSTEM
WT 3000 Series
Rev. B
212
ELECTRICAL SYSTEM
EVENT CODE 500 - 501 (WT 3040 -E, WT 3060 -E)
Event Code 500 - 501 (WT 3040 -E, WT 3060 -E)

Event Code 500
Display: EV500
Service LED: On
Operator LED: Off
Explanation: Serial communication error in Access 5
Possible causes: • CAN bus communication with Access 1 faulty
• Access 5 faulty
Test Access 1
Replace Access 5
Event Code 501

Display: EV501
Service LED: On
Operator LED: Off
Explanation: EEPROM error in Access 5.
Replace Access 5
WT 3000 Series
Rev. B
213
ELECTRICAL SYSTEM

Event Code 502
Display: EV502
Service LED: On
Operator LED: Off
Explanation: Access 5 faulty
Remedy: Replace Access 5
Event Code 503

Display: EV503
Service LED: On
Operator LED: Off
Event Code 504

Display: EV504
Service LED: On
Operator LED: Off
WT 3000 Series
Rev. B
214
ELECTRICAL SYSTEM

Event Code 505
Display: EV505
Service LED: On
Operator LED: Off
Event Code 506

Display: EV506
Service LED: On
Operator LED: Off
Explanation: When the truck is switched on there is an incorrect voltage on the outputs of
the amplifiers in Access 5.
Possible causes: • The power cables to steer motor M3 have a poor contact, are damaged or
• Access 5 faulty
1. Check the power cable leading to steer motor M3 and its terminals to en-
sure they are securely attached and not damaged.
2. Check the insulation resistance of the motor housing to Batt NEG/POS.
 If there is a short, locate and replace the faulty component.
 If the insulation resistance is ok, replace Access 5.
WT 3000 Series
Rev. B
215
ELECTRICAL SYSTEM

Event Code 507
Display: EV507
Service LED: On
Operator LED: Off
Explanation: Access 3 has not closed the main contactor within 1.5 seconds of the truck
switching on.
Possible causes: • See the 300 group of event codes relating to the main contactor
 Read and evaluate events relating to Access 3 (see 300 event codes).
Event Code 508

Display: EV508
Service LED: On
Operator LED: Off
Explanation: While the steering is idle the current at steer motor M3 measured by Access 5
is > 0A.
Possible causes: • Error in output stage of Access 5
• Error in current sensor of Access 5
Replace Access 5
WT 3000 Series
Rev. B
216
ELECTRICAL SYSTEM
Event Code 509

Display: EV509
Service LED: On
Operator LED: Off
Explanation: The current at steer motor M3 measured by Access 5 is too high.
• Access 5 faulty
Check current sensor
2. Select SERVICE MENU > ACCESS 5 INPUTS > A2.5.3 > STEER MOT
CURRENT and check the reading with the steer motor stationary.
 If the reading is 0A, restart the truck. Monitor the event log.
 If the reading with the steer motor idle > 15 A, proceed to step 3.
If the event code persists, proceed to step 5.
5. Check the insulation resistance on the motor coils and the power cables.
WT 3000 Series
Rev. B
217
ELECTRICAL SYSTEM

Event Code 510
Display: EV510
Service LED: On
Operator LED: Off
Explanation: No current at phase V
Possible causes: • Wiring voltage drop
• Battery voltage drop
• Main contactor faulty
• Access 5 faulty
Remedy: Check power fuse FU2
1. Check power fuse FU2 (30A) on Access 5.
 Replace the fuse if faulty.
VOLTAGE.
it.
VOLTAGE.
with a new one.
Check Access 5 for possible input voltage drop
7. Measure the voltage from CA222-7 (on Access 5) to −Batt
 If the voltage is considerably less than Batt POS, locate and remove the
transitional resistance in the wiring.
 If the voltage ≈ 24 V, the wiring is ok. Proceed to step 8.
WT 3000 Series
Rev. B
218
ELECTRICAL SYSTEM

8. Check the power cables to steer motor M3 and its terminals are secure
Check for voltage drop over fuse F2
9. Measure the input and output voltage from FU2 to −Batt.
 If the input and output voltages are different, replace FU2 and check the
contacts for corrosion.
 If the input and output voltages are identical, proceed to step 10.
Check the signal switch in the main contactor
10. Measure the input and output voltage of the signal switch in the main con-
tactor to Batt NEG.
 If the input and output voltages are different, replace the main contactor.
 If the input and output voltages are identical, proceed to step 11.
Check the power part of the main contactor
11. Check the power cables on the main contactor and its terminals are secure
 If any cables are loose, damaged or swapped, rectify the cause. If the
main contactor is overheated (recognisable from blue colouring), re-
place the main contactor.
 If the power cables, terminals and main contactor are ok, proceed to
step 12.
Replace Access 5

Event Code 511
Display: EV511
Service LED: On
Operator LED: Off
Explanation: No current at phase U
• Access 5 faulty
WT 3000 Series
Rev. B
219
ELECTRICAL SYSTEM

Event Code 512
Display: EV512
Service LED: On
Operator LED: Off
Explanation: No current at phase W
• Access 5 faulty
Event Code 513

Display: EV513
Service LED: On
Operator LED: Off
Explanation: Channels A and B of encoder ECR2 were swapped when connected.
1. Check wiring for damage.
 Repair the wiring if damaged.
 If the wiring is not damaged, proceed to step 2.
Check the ECR2 encoder connector is wired correctly
2. Using the circuit diagram and the cable numbers indicated, check if wires
to CA218 or PC221 have been connected incorrectly.
 If PC221 is wired incorrectly, replace PC221-7 with PC221-8.
 If CA218 is wired incorrectly, replace PC218-2 with PC218-3.
WT 3000 Series
Rev. B
220
ELECTRICAL SYSTEM

Event Code 514
Display: EV514
Service LED: On
Operator LED: Off
Explanation: An error in one of the 2 redundant steer sensor curves has occurred.
• Excessive impact on truck
• Steer sensors faulty
Remedy: Has the truck travelled over a pothole?
1. Ask the operator if the error occurred after the truck had received a hefty
impact.
 If so, restart the truck. Check the event log.
 If not, proceed to step 2.
Test the steering sensors
2. Set the steering to the centre position.
STEER POT1 and A2.5.4 > STEER POT2 and check the readings.
 The two readings should be approximately the same (approx. 2.5 V).
4. Scroll to A2.5.4 > STEER POT1 and move the steering slowly from the left
end position to the right.
 The reading should increase and decrease without interruption.
 If both sensors are working correctly, re-calibrate the steering (see
page 256).
Check the TFD module wiring
7. Check connections from CA214 (TFD module) to CA221 (Access 5) and
CA200-25 (Access 3 & 2).
 If there is a wiring error, repair the wiring.
 If the wiring is ok, replace the TFD module.
WT 3000 Series
Rev. B
221
ELECTRICAL SYSTEM

Event Code 515
Display: EV515
Service LED: Off
Operator LED: On
Explanation: Maximum angle reached on steered wheel
Possible causes: • LIMIT DEVICE is set to ON
Remedy: The event deletes itself after the steering has been set to neutral.
Event Code 516

Display: EV516
Service LED: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 does not close.
Remedy: Check if the Access 5 wiring has shorted
1. Check if the Access 5 wiring has shorted.
Check for other shorts
2. Disconnect CA222 and remove the wire from PC222-4.
3. Reconnect PC222.
4. Measure the voltage from CA222-4 (cable number 2916) to −Batt.
 If the reading is 0 VDC, proceed to step 5.
 If the reading ≈ 24 V, proceed to step 7.
Check wire 2916 for a short
5. Measure the resistance between wire 2916 and −Batt.
 If there is a short to −Batt, proceed to step 6.
 If the resistance is ∞ (> MΩ), proceed to step 8.
6. Remove the short to −Batt in wire 2916 from PC222-4 to connector
CA200-7 on Access 3 & 2.
7. Remove the short to +Batt in wire 2916 from PC222-4 to connector
CA200-7 on Access 3 & 2.
Replace Access 5
WT 3000 Series
Rev. B
222
ELECTRICAL SYSTEM

Event Code 517
Display: EV517
Service LED: On
Operator LED: Off
Explanation: When the steering is in neutral the SAHS sensor switches around.
• Access 5 faulty
Remedy: Check encoder ECR2
1. Open SERVICE MENU > ANALYZER MENU > ACCESS 5 INPUTS >
A2.5.6 > ECR2.
2. Leave the steering in neutral and make a note of the reading.
3. Slowly move the steering to the left stop while monitoring the display for
fluctuations and recording the final reading.
4. Slowly bring the steering to the right-hand stop, check the display for sud-
den jumps and check the final reading.
5. Repeat steps 2 to 4 and compare the readings with the ones previously
recorded.
 If the display jumps significantly as you steer, or if there are large devi-
ations in the number of pulses counted at the end stops, replace steer
motor M3.
 If encoder ECR2 is ok, proceed to step 6.
Check the SAHS sensor
6. Check the LED on the sensor while moving the steering to the left and
right.
 If the LED lights up when you steer to the left and goes out when you
steer to the right, sensor SAHS is ok.
 If the LED is lit either steadily or not at all, proceed to step 7.
7. Check the gap between SAHS and the cam on the gear unit for foreign
bodies and accumulation of dirt.
 Remove any foreign bodies or accumulation of dirt.
 If there are no foreign bodies or accumulation of dirt, proceed to step 8.
8. Check the distance between the SAHS sensor and the cam.
 If the distance ≠ 2.5 mm, set it to 2.5 mm. Repeat step 6.
 If the distance = 2.5 mm, proceed to step 9.
 If the problem persists, proceed to step 10.
Replace the SAHS sensor
9. Replace SAHS sensor and set the switch distance.
Replace Access 5
WT 3000 Series
Rev. B
223
ELECTRICAL SYSTEM

Event Code 518
Display: EV518
Service LED: On
Operator LED: Off
Explanation: The processors in Access 5 measure a difference of more than 0.7 V in the
steer sensor.
Test Access 1
Replace Access 5
Event Code 519

Display: EV519
Service LED: On
Operator LED: Off
Explanation: The processors in Access 5 detect different direction messages from the steer
sensor.
Test Access 1
Replace Access 5
WT 3000 Series
Rev. B
224
ELECTRICAL SYSTEM

Event Code 520
Display: EV520
Service LED: On
Operator LED: Off
Explanation: The processors in Access 5 detect different signals from channel A or B, or
from A and B of steering encoder ECR3.
Test Access 1
Replace Access 5
Event Code 522

Display: EV522
Service LED: On
Operator LED: Off
Explanation: Internal error in Access 5.
WT 3000 Series
Rev. B
225
ELECTRICAL SYSTEM

Event Code 523
Display: EV523
Service LED: On
Operator LED: Off
Explanation: The steer motor draws the maximum current for more than 1 second.
• Access 5 faulty
Check current sensor
2. Select SERVICE MENU > ACCESS 5 INPUTS > A2.5.3 > STEER MOT
CURRENT and check the reading with the steer motor stationary.
 If the reading is 0A, restart the truck. Monitor the event log.
 If the reading with the steer motor stationary > 15 A, proceed to step 3.
Check steering transmission
5. Disconnect the battery and jack up the truck (see page 23).
6. Turn the drive wheel manually while checking for sluggishness and bear-
ing noise.
 Replace the transmission if it is sluggish or too rough.
 If the transmission is ok, proceed to step 5.
Replace Access 5
WT 3000 Series
Rev. B
226
ELECTRICAL SYSTEM

Event Code 524
Display: EV524
Service LED: On
Operator LED: Off
Test Access 1
Replace Access 5
Event Code 525

Display: EV525
Service LED: On
Operator LED: Off
Explanation: This event only occurs when the steering is applied very quickly: Access 5 has
tried to drive the steer motor but encoder ECR2 does not provide an output
signal.
Possible causes: • Encoder ECR2 faulty
• Insulation resistance too low
• Access 5 faulty
Remedy: Check encoder ECR2
A2.5.6 > ECR2.
2. Leave the steering in neutral and check the reading.
4. Slowly move the steering to the right stop while monitoring the display for
WT 3000 Series
Rev. B
227
ELECTRICAL SYSTEM
recorded.
motor M3.
7. If the power cables and the terminals are ok, proceed to step 8.
Replace Access 5

Event Code 526
Display: EV526
Service LED: On
Operator LED: Off
Explanation: The output signal of the steer sensor has risen by more than 0.3 VDC in less
than 16 ms.
Possible causes: • Encoder ECR3 faulty
• Access 5 faulty
Remedy: Check the TFD module attachment
1. Check the TFD module attachment.
Note: The sensor is located in the TFD module. Do not open the TFD module;
it should only be replaced in full.
 If the TFD module is loose, attach it securely.
 If it is attached securely, proceed to step 2.
Test the steer sensors
WT 3000 Series
Rev. B
228
ELECTRICAL SYSTEM
 If both sensors are working correctly, re-calibrate the steering (see
page 256).
CA200-25 (Access 3 & 2).
Test the steer sensors

Event Code 527
Display: EV527
Service LED: On
Operator LED: Off
WT 3000 Series
Rev. B
229
ELECTRICAL SYSTEM

Event Code 528
Display: EV528
Service LED: On
Operator LED: Off
Event Code 529

Display: EV529
Service LED: On
Operator LED: Off
Test Access 1
Replace Access 5
WT 3000 Series
Rev. B
230
ELECTRICAL SYSTEM

Event Code 530
Display: EV530
Service LED: On
Operator LED: Off
Explanation: Output signals of encoders ECR2 and ECR3 do not match.
• ECR3 or ECR2 faulty
• Access 5 faulty
1. Check wiring on encoders ECR2 and ECR3 from CA218 and CA219 to
CA222 and CA221 for shorts and damage.
Check encoder ECR2
A2.5.6 > ECR2.
3. Leave the steering in neutral and check the reading.
5. Slowly move the steering to the right stop while monitoring the display for
recorded.
motor M3.
Check encoder ECR3
A2.5.7 > ECR3.
8. Repeat steps 3 to 6.
motor M3.
Replace Access 5
WT 3000 Series
Rev. B
231
ELECTRICAL SYSTEM

Event Code 531
Display: EV531
Service LED: On
Operator LED: Off
Explanation: When the truck is powered up the data required by Access 5 was not received
from Access 3.
• Access 1 faulty
• Access 5 faulty
Remedy: Check module status
1. Open SERVICE MENU > ANALYZER > A1 Status >.
2. Scroll through from A1.1 to A1.6 and check the status of the modules.
 If one of the modules is OFF, proceed to step 3.
 If all modules are ON, restart the truck. Monitor the event log.
Check the CAN Bus wiring
3. Check CAN Bus wiring between Access 3 and Access 5 for shorts and
damage.
Check terminal resistance on PC211
4. With the truck switched off, measure the resistance between PC211-1 and
PC211-2
 If the resistance is 60 Ω, the terminal resistance is ok, proceed to step 5.
 If the resistance is not 60 Ω, replace the resistor.
Test terminal resistance in Access 5
5. Disconnect JC222 from Access 5
6. Measure the resistance between JC222-6 and JC222-14.
 If the resistance is 120 Ω, the terminal resistance is ok, proceed to step
7.
 If the resistance is not 120Ω, replace Access 1.
 If the resistance is 120 Ω, the terminal resistance is ok, restart the truck.
Check the event log.
WT 3000 Series
Rev. B
232
ELECTRICAL SYSTEM

Event Code 532
Display: EV532
Service LED: On
Operator LED: Off
Explanation: On power up SAHS cannot find the cam within a 270° rotation.
• Contamination
• Faulty sensor adjustment
• Sensor faulty
• Access 1 faulty
• Access 5 faulty
Remedy: Check communication of SAHS with Access 5
1. Check wiring of sensor SAHS and connector CA213 for shorts and dam-
age.
2. Open SERVICE MENU > ANALYZER > ACCESS 5 INPUTS >
A2.5.8 STRAIGHT AHEAD SENSOR and check the switch status of the
SAHS.
Check if SAHS switches
3. Move the tiller to the left and right while checking if the switch status in the
display and on the LED of the SAHS change at the same time.
 If the switch statuses change at the same time, SAHS and communica-
tion with Access 5 are ok. Restart the truck. Monitor the event log.
 If the switch status does not change, or not at the same time, proceed
to step 4.
Check the cam for contamination
4. Check the gap between SAHS and the cam on the gear unit for foreign
bodies and accumulation of dirt.
 Remove any foreign bodies or accumulation of dirt.
 If there are no foreign bodies or accumulation of dirt, proceed to step 5.
Check the screw-in depth of SAHS
5. Check the distance between the SAHS sensor and the cam (see page
309).
 If the distance is incorrectly set, adjust it and repeat step 3.
 If the distance is within range and the sensor still does not switch, pro-
ceed to step 6.
Replace the SAHS sensor
6. Replace SAHS sensor and set the switch distance (see page 309). Repeat
step 3.
7. If the problem still persists, replace Access 5.
WT 3000 Series
Rev. B
233
ELECTRICAL SYSTEM
Event Code 533

Display: EV533
Service LED: On
Operator LED: Off
Explanation: Due to an error in Access 3, Access 5 closes both the internal safety relays.
Remedy: Check Access 3 event codes
1. Open SERVICE MENU > EVENTS > E1 > CHRON HISTORY.
2. Check entries for Access 3 events (3xx).
 If there are no 300 event codes, restart the truck. Check the event log.
 If there are 300 event codes, locate the cause using the 300 event
codes in this manual.
WT 3000 Series
Rev. B
234
ELECTRICAL SYSTEM

Event Code 535
Display: EV535
Service LED: On
Operator LED: Off
Test Access 1
Replace Access 5
Event Code 536

Display: EV536
Service LED: On
Operator LED: Off
Explanation: Access 5 needs time to calculate the motor resistance and adapt the current
gain accordingly.
Possible causes: •
Remedy: Restart the truck
WT 3000 Series
Rev. B
235
ELECTRICAL SYSTEM

Event Code 537
Display: EV537
Service LED: On
Operator LED: Off
Test Access 1
Replace Access 5
WT 3000 Series
Rev. B
236
ELECTRICAL SYSTEM

Event Code 538
Display: EV538
Service LED: On
Operator LED: Off
Explanation: CAN-Bus error.
• Access 1 faulty
• Access 5 faulty
Remedy: Check module status
1. Open SERVICE MENU > ANALYZER > A1 Status >.
2. Scroll through from A1.1 to A1.6 and check the status of the modules.
 If one of the modules is OFF, proceed to step 3.
 If all modules are ON, restart the truck. Monitor the event log.
Check the CAN Bus wiring
3. Check CAN Bus wiring between Access 3 and Access 5 for shorts and
damage.
Check terminal resistance on PC211
4. Switch off the truck and measure the resistance between PC211-1 and
PC211-2
 If the resistance is 60 Ω, the terminal resistance is ok, proceed to step 5.
 If the resistance is not 60 Ω, replace the resistor.
7.
5.
WT 3000 Series
Rev. B
237
ELECTRICAL SYSTEM

Event Code 539
Display: EV539
Service LED: On
Operator LED: Off
Explanation: The sum of the voltages of the two steer sensors is out of tolerance
Possible causes: • Resistor in intermediate connector 827774 faulty
• Wiring error
• TFD module faulty
Remedy: Show the voltages of the steer sensors in the display
 If the sum of both voltages is 4.5 - 5.5 V, the steer sensors are ok. Re-
start the truck. Monitor the event log.
 If the sum of the two voltages is not within the 4.5 - 5.5 V range, proceed
to step 2.
Measure the voltage of the steer sensors at the connectors
2. Measure the voltage from PC221-6 to PC221-1
3. Measure the voltage from PC200-25 to PC221-6.
 If the readings match those shown in the display, the wiring is ok. Re-
start the truck. Check the event log.
 If the readings differ from those shown on the display, proceed to step 8.
Check resistance in intermediate connector
4. Disconnect CA214 and CA232.
6. If the resistance is approx. 680 , refit the connector and proceed to
step 8.
7. If the resistance is significantly greater (> 750 ), replace the intermediate
connector 827774.
CA200-25 (Access 3 & 2).
WT 3000 Series
Rev. B
238
ELECTRICAL SYSTEM
Event Code 540

Display: EV540
Service LED: On
Operator LED: Off
Explanation: Switch status of SAHS does not match the output of ECR3.
• Access 5 faulty
Remedy: See event code 517, page 223.

Event Code 541
Display: EV541
Service LED: On
Operator LED: Off
Test Access 1
Replace Access 5
Event Code 542

Display: EV542
Service LED: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 is open.
• Access 5 faulty
WT 3000 Series
Rev. B
239
ELECTRICAL SYSTEM
Remedy: Check status of Access 5

1. Open SERVICE MENU > ANALYZER > A1 Status > A1.4 Access 5
 If the status is OFF, restart the truck. Check the event log.
Check entries in event log
4. Reconnect PC222.
 If the voltage is 0 VDC, locate the error in the power supply.
Check event log
7. Check event log for any other events recorded.
 If the time of another event matches the time of the event code (542),
resolve the cause of the other event first.
 If there is no other event or if the time does not match, proceed to step 8
Replace Access 5

Event Code 543
Display: EV543
Service LED: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 is open.
• Access 5 faulty
Remedy: See event code 542
WT 3000 Series
Rev. B
240
ELECTRICAL SYSTEM

Event Code 544
Display: EV544
Service LED: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 is closed.
Remedy: Check status of Access 5
1. Open SERVICE MENU > ANALYZER > A1 Status > A1.4 Access 5
 If the status is OFF, restart the truck. Check the event log.
3. Reconnect PC222.
 If the voltage is 0 VDC, proceed to step 5.
Check wiring
5. Check the wires between CA222-4 and CA222-5 for shorts and damage.
 Repair any shorted or damaged wires.
 If the wires are ok, proceed to step 6.
Check the wires for discontinuity
6. Disconnect CA222-4 and CA222-5.
7. Measure the resistance of the wires from PC222-4 and PC222-5 to BATT
NEG.
 If there is a short to −Batt, proceed to step 8.
 If the resistance is ∞ (> MΩ), proceed to step 6.
Check event log
9. Check event log for any other events recorded.
 If the time of another event matches the time of the event code (544),
resolve the cause of the other event first.
 If there is no other event or if the time does not match, proceed to step 8
Replace Access 5
WT 3000 Series
Rev. B
241
ELECTRICAL SYSTEM

Event Code 545
Display: EV545
Service LED: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 is closed.
• Access 5 faulty
Remedy: See event code 544
Event Code 547

Display: EV547
Service LED: On
Operator LED: Off
Explanation: Overvoltage in one of the phases U, V or W.
2. Check the insulation resistance of the motor housing to Batt NEG/POS.
WT 3000 Series
Rev. B
242
ELECTRICAL SYSTEM
(WT 3040 -E, WT 3060 -E) tion. This will require the intervention of a service engi-
Steering controller hot

Display: HIGHTEMP STEERING CONTROLLER
Service LED: Off
Operator LED: On
Explanation: Temperature of steering control module Access 5 too high
• Wiring error
Remedy: Test fan
the test).
check the status.
4. Using a voltmeter measure the battery voltage between -Batt and CA204-
1 (fan).
continuity.
WT 3000 Series
Rev. B
243
ELECTRICAL SYSTEM

6. Open SERVICE LEVEL 2 > ANALYZER MENU > A2 > INPUTS > AC-
CESS 5 INPUTS > A2.5.1 TEMP ACCESS 5 and check the reading.
ature readings.
Steer motor hot

Display: HIGHTEMP STEERING MOTOR
Service LED: Off
Operator LED: On
Explanation: Temperature in steer motor M1 too high
• Wiring error
• Temperature sensor faulty
• Access 5 faulty
Remedy: Test fan
1. Wait until the temperature in steer motor M3 has dropped.
the test).
check the status.
4. Using a voltmeter measure the voltage between −Batt and CA213-1 (fan).
continuity.
WT 3000 Series
Rev. B
244
ELECTRICAL SYSTEM

6. Open SERVICE LEVEL 2 > ANALYZER MENU > A2 > INPUTS > AC-
CESS 5 INPUTS > A2.5.2 TS2 (TEMP MOTOR) and check the reading.
step 8.
Test temperature sensor
20°C.
 If the resistance differs from this value, the temperature sensor is faulty.
Proceed to step 10.
Replace steer motor M3
10. 10Replace steer motor M3 (see page 279).
WT 3000 Series
Rev. B
245
Notes:
246
ELECTRICAL SYSTEM
INPUT SIGNALS
Input Signals It is assumed that the truck is in standby mode: SAS and BRS
• The key switch is "On"
On all trucks with a non-folding tiller and electric steering the SAS assumes the
Initial truck status • The operator is standing on the platform electrical function of the BRS.
The following tables show the status of the most important inputs required to • The “Rabbit/Turtle” toggle switch is set to "Rabbit"
operate the truck. • The forks are fully lowered Folding platform trucks
,
These inputs can be checked in the Analyzer menu. • The temperature of the electronic system and motors is ≤ 45°C
Folding platform trucks WT3020MO WT3040MF WT3040EF & WT3060EF
Display name in Ana- Function & comment Assembly location Comfort mode Comfort mode Rider mode Comfort mode Rider mode
lyzer menu (platform down) (platform down, side (platform up) (platform down, side (platform up)
restraint down) restraint down)
Control module
RAS & LMS1 Switches Mechanical steering: lift switch and lift limit switch Tiller handle & motor compart-
OFF OFF OFF N/AV(b) N/A(b)
are connected in series. ment
RAS Electric steering: Lift switch Tiller grip N/A(b) N/A(b) N/A(b) OFF OFF
LOS Switch Electric steering: Lowering switch Tiller grip OFF OFF OFF OFF OFF
Pressure Sensor "PS" Load-dependent speed reduction. A linear func- In manifold block on the hydrau-
Access 2
1.0 V (0.1 V) 1.0 V (0.1 V) 1.0 V (0.1 V) 1.0 V (0.1 V) 1.0 V (0.1 V)
tion depending on the hydraulic pressure. lic unit.
LMS1 Switch Electric steering only: Motor compartment
N/A(b) N/A(b) N/A(b) ON ON
Lift limit switch
WT 3000 Series
Rev. B
247
ELECTRICAL SYSTEM
INPUT SIGNALS
,
Folding platform trucks WT3020MO WT3040MF WT3040EF & WT3060EF
Display name in Ana- Function & comment Assembly location Comfort mode Comfort mode Rider mode Comfort mode Rider mode
lyzer menu (platform down) (platform down, side (platform up) (platform down, side (platform up)
restraint down) restraint down)
Control module
TEMP ACCESS 3 Temperature monitoring In the control module(a) ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C
TS1 Temperature sensor In the drive motor(a) ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C
PF switch Forward travel switch Tiller grip OFF OFF OFF OFF OFF
FF switch Reverse travel switch Tiller grip OFF OFF OFF OFF OFF
POT Wiper Traction potentiometer slider Tiller grip 0 V (+0.25 V) 0 V (+0.25 V) 0 V (+0.25 V) 0 V (+0.25 V) 0 V (+0.25 V)
HSS1 Switch “Rabbit/Turtle” toggle switch Tiller grip OFF OFF OFF ON ON
HNS1 + 2 Switch Horn switches 1 + 2 Tiller grip OFF OFF OFF OFF OFF
BRS Switch Brake switch Under the tiller knuckle ON ON ON ON ON
PLS1 Sensor Platform sensor 1 On platform hinge ON ON ON ON ON
Access 3
PLS2 Sensor Platform sensor 2 On platform hinge OFF OFF OFF OFF OFF
SR1 Sensor Side restraint sensor 1 On side restraint hinge OFF OFF ON OFF ON
SR2 Sensor Side restraint sensor 2 On side restraint hinge OFF OFF ON OFF ON
SAS Switch Safety reverse switch Tiller grip ON ON OFF ON OFF
ECR1 Encoder Drive motor “B side” encoder, 64 pulses “B side” of drive motor(a) 0 impulses 0 impulses 0 impulses 0 impulses 0 impulses
FAN Electrical system cooling, switches on at temper- Electrical Panel
OFF OFF OFF OFF OFF
atures ≥ 45°C
TEMP ACCESS 5 Temperature sensor; switches off all truck func- In the control module(a) ≤ 45° C ≤ 45° C
tions in event of overtemperature
TS3 Temperature sensor; switches off all truck func- In the steer motor(a) ≤ 45° C ≤ 45° C
tions in event of overtemperature
STEER POT1 (W1) Hall sensor, output 1 In the TFD module(a) 2.5 V (0.2 V) 2.5 V (0.2 V)
STEER POT 2 (W2) Hall sensor, output 2 In the TFD module(a) N/A(b) 2.5 V (0.2 V) 2.5 V (0.2 V)
Access 5
ECR2 Steer motor encoder, 32 pulses Steer motor, “A side” of the elec-
146 (variable) 146 (variable)
tric steering(a)
ECR3 Steer motor encoder, 48 pulses Steer motor, “B side” of the elec-
109 (variable) 109 (variable)
tric steering(a)
SAHS Straight Ahead Sensor Front of drive unit ON ON
a. Not accessible
b. Not available
WT 3000 Series
Rev. B
248
ELECTRICAL SYSTEM
INPUT SIGNALS
Fixed platform trucks

,
Fixed platform trucks WT3040MR WT3040MS WT3040ER WT3060ES WT3060ER
Display name in Ana- Function & comment Assembly location

lyzer menu
Control module
RAS & LMS1 Switches Mechanical steering: lift switch and lift limit switch are connected in Tiller handle & motor compart-
OFF OFF N/A N/A N/A
series. ment
RAS Electric steering: Lift switch Tiller grip N/A(b) N/A(b) OFF OFF OFF
LOS Switch Electric steering: Lowering switch Tiller grip OFF OFF OFF OFF OFF
Pressure Sensor "PS" Load-dependent speed reduction. A linear function depending on the In manifold block on the hydrau-
Access 2
1.0 V (0.1 V) 1.0 V (0.1 V) 1.0 V (0.1 V) 1.0 V (0.1 V) 1.0 V (0.1 V)
hydraulic pressure. lic unit.
LMS1 Switch Electric steering only: Motor compartment
N/A(b) N/A(b) ON ON ON
Lift limit switch
TEMP ACCESS 3 Temperature monitoring In the control module(a) ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C
TS1 Temperature sensor In the drive motor(a) ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C
PF switch Forward travel switch Tiller grip OFF OFF OFF OFF OFF
FF switch Reverse travel switch Tiller grip OFF OFF OFF OFF OFF
POT Wiper Traction potentiometer slider Tiller grip 0 V (+0.25 V) 0 V (+0.25 V) 0 V (+0.25 V) 0 V (+0.25 V) 0 V (+0.25 V)
HSS1 Switch “Rabbit/Turtle” toggle switch Tiller grip OFF OFF OFF ON ON
HNS1 + 2 Switch Horn switches 1 + 2 Tiller grip OFF OFF OFF OFF OFF
BRS Switch Brake switch Under the tiller knuckle ON ON ON ON ON
Access 3
PLS1 Sensor Platform sensor 1 On platform hinge ON ON ON ON ON
PLS2 Sensor Platform sensor 2 On platform hinge OFF OFF OFF OFF OFF
SR1 Sensor (N/A) Side restraint sensor 1 On side restraint hinge ON ON ON ON ON
SR2 Sensor (N/A) Side restraint sensor 2 On side restraint hinge ON ON ON ON ON
SAS Switch (N/A) Safety reverse switch Tiller grip OFF OFF OFF OFF OFF
ECR1 Encoder Drive motor “B side” encoder, 64 pulses “B side” of drive motor(a) 0 impulses 0 impulses 0 impulses 0 impulses 0 impulses
FAN Electrical system cooling, switches on at temperatures ≥ 45°C Electrical Panel OFF OFF OFF OFF OFF
WT 3000 Series
Rev. B
249
ELECTRICAL SYSTEM
INPUT SIGNALS
Fixed platform trucks (Continued) WT3040MR WT3040MS WT3040ER WT3060ES WT3060ER
Display name in Ana- Function & comment Assembly location

lyzer menu
Control module
TEMP ACCESS 5 Temperature sensor; switches off all truck functions in event of over- In the control module(a) ≤ 45° C ≤ 45° C ≤ 45° C
temperature
TS3 Temperature sensor; switches off all truck functions in event of over- In the steer motor(a) ≤ 45° C ≤ 45° C ≤ 45° C
temperature
STEER POT1 (W1) Hall sensor, output 1 In the TFD module(a) 2.5 V (0.2 V) 2.5 V (0.2 V) 2.5 V (0.2 V)
STEER POT 2 (W2) Hall sensor, output 2 In the TFD module(a) N/A(b) 2.5 V (0.2 V) 2.5 V (0.2 V) 2.5 V (0.2 V)
Access 5
ECR2 Steer motor encoder, 32 pulses Steer motor, “A side” of the elec-
146 (variable) 146 (variable) 146 (variable)
tric steering(a)
ECR3 Steer motor encoder, 48 pulses Steer motor, “B side” of the elec-
109 (variable) 109 (variable) 109 (variable)
tric steering(a)
SAHS Straight Ahead Sensor Front of drive unit OFF OFF OFF
a. Not accessible
b. Not applicable
WT 3000 Series
Rev. B
250
ELECTRICAL SYSTEM
PLATFORM AND SIDE RESTRAINT LOGIC
Platform and Side Restraint Folding platform

Logic Side restraint and platform setting defini-
tion
Conventions
Brief description of equipment
Three components of the truck data number are used
to assign the truck's equipment to the parameters.
• Model number 1a
1b
• Steering type
• Operator position type
The number 3040MF for example denotes a WT 3040
with mechanical steering and a folding platform. 1c
See page 5 details of the truck data number. 2
In the following tables this part of the truck data number
describes the truck model.
Fig. 60 Side restraint and platform setting definition

1a Side restraint up (Quick Exit)
1b Side restraint closed
1c Side restraint down
2 Platform down
Note: The platform sensors only connect when the

platform has been folded down as far as the stop.
There must be somebody standing on the platform.
,
Platform and Side Restraint Logic, Folding Platform Platform Sensors Side restraint sen-
sors
Truck Operating mode Platform and side re- V max. PLS1 PLS2 SR1 SR2
model straint positions (km/h)
WT3020MO Pedestrian mode Platform up

6 OFF ON
OFF OFF
(bridged) (bridged)
Comfort mode Platform down OFF OFF
6 ON OFF
(bridged) (bridged)
WT3040EF Pedestrian mode Platform up

6 ON OFF OFF OFF
Side restraint down
Comfort mode Platform down
6 OFF ON OFF OFF
Side restraint down
Rider mode Platform down
12.5 ON OFF ON ON
Side restraint closed
Quick Exit Platform up
0 OFF ON OFF ON
Side restraint up
Platform down
0 ON OFF OFF ON
Side restraint up
WT 3000 Series
Rev. B
251
ELECTRICAL SYSTEM
PLATFORM AND SIDE RESTRAINT LOGIC
Platform and Side Restraint Logic, Folding Platform (Continued) Platform Sensors Side restraint sen-
sors
WT3060EF Pedestrian mode Platform up

6 ON OFF OFF OFF
Side restraint down
Comfort mode Platform down
6 OFF ON OFF OFF
Side restraint down
Rider mode Platform down
12.5 ON OFF ON ON
Side restraint closed
Quick Exit Platform up
0 OFF ON OFF ON
Side restraint up
Platform down
0 ON OFF OFF ON
Side restraint up
Fixed platform
,
Note: The platform sensors only connect when the

platform is occupied. There must be somebody stand-
ing on the platform.
Platform and Side Restraint Logic, Fixed Platform Platform Sensors Side restraint sen-
sors
WT3040MR
WT3040MS ON ON
Rider mode N/A 12.5 ON ON
WT3040ER (bridged) (bridged)
WT3060ER
WT 3000 Series
Rev. B
252
ELECTRICAL SYSTEM
ANALYZER MENU
Analyzer Menu
Selecting the ANALYZER menu
You can navigate through the menu structures using
the cursor keys ( , , , , ) on the display panel.
An overview of the menu structure can be found in
Menu Structure, starting on page 63.
Fig. 61 Display panel

Switching the truck on
1. Press the key for 1 second.
 The display screen is activated.
Note: For trucks with a key switch, turn the key switch
right to the "On" position.
Selecting the "SERVICE" menu
2. Press the key 3 times.
 The "SERVICE" menu is displayed.
3. Press the key until “LEVEL 1” appears.
4. Press the key until you are requested to enter
your PIN.
WT 3000 Series
Rev. B
253
ELECTRICAL SYSTEM
ANALYZER MENU
Testing the fans Testing the fans
The fan on the Access 2/3 control module (TCM/HCM) 9. Press the key.
can be tested using a function in the Analyzer menu.  The fan should start up and switch off after 5 sec-
onds.
Selecting the ANALYZER menu

Switching the truck on
Note: For trucks with a key switch, turn the key switch
your PIN.
5. Enter the service PIN with the and keys and
confirm with .
 The "ANALYZER" menu is displayed.
Selecting the “A4.1 FAN” sub-menu
6. Press the key until the “A1 STATUS” sub-menu
appears.
7. Using the key scroll through to the
“A4 TEST OUTPUTS” menu.
8. Using the key scroll through to the “A4.1 FAN”
menu.
WT 3000 Series
Rev. B
254
ELECTRICAL SYSTEM
CALIBRATION
Calibration Traction potentiometer calibration

Calibration is performed in the “SERVICE” menu under
the “CALIBRATION” menu item on the display. To se-
Travel direction definition
lect the “CALIBRATION” menu proceed as follows:
Selecting the CALIBRATION Menu 1 2

Fig. 64 Travel direction definition

1 Reverse travel (FF)
2 Forward travel (PF)
Requirements
• The truck is jacked up (see Lifting the Truck, page
19).
• The “CALIBRATION” menu is selected (see “Se-
lecting the CALIBRATION Menu” on page 255).
Fig. 63 Display panel Selecting traction potentiometer calibration
Switching the truck on 1. For trucks with a vertically moving tiller (e.g.
WT3020, WT3040) set the tiller to the travel zone.
For trucks with a non-vertically moving tiller (e.g.
WT3060) stand on the platform.
Note: For trucks with a key switch, turn the key switch  The main contactor applies.
2. Press the key until the
Selecting the Calibration menu “C1 PF/FF ROCKER” menu appears.
2. Press the key 3 times. 3. Press the key.
 The "SERVICE" menu is displayed.  The safety prompt “SURE? N” is displayed.
3. Press the key until “LEVEL 2” appears. Note: To cancel the calibration, press the key.
4. Press the key until you are requested to enter 4. Press the key.
your PIN.  The safety prompt “SURE? Y” appears.
5. Enter the service PIN with the and keys and Confirming the security prompt
confirm with .
5. Press to confirm the security prompt.
 The prompt
6. Press the key until the “CALIBRATION” menu “TURN ROCKER MAX PF & MAX FF THEN E
appears. NTER” appears.
Traction potentiometer calibration
6. Move the travel switch from the zero position as far
as the stop in the forks direction, then slowly back
to the zero position.
WT 3000 Series
Rev. B
255
ELECTRICAL SYSTEM
CALIBRATION
7. Move the travel switch from the zero position as far Electric steering calibration
as the stop in the direction opposite to the forks,
then slowly back to the zero position. Calibration takes place in the following stages:
• Calibrating the tiller centre position
8. Confirm with .
• Calibrating the drive wheel forward travel
 "Save? N” is displayed.
• Calibrating the right steering lock
Note: If you wish to cancel calibration, press the key
now. • Left steering lock calibration
Note: Refer also to the menu list on page 74.
Saving the calibration
Requirements
9. Press the key.
• The front cover to the drive compartment is re-
 "Save? Y” appears. moved so that the drive wheel position can be seen.
10. Confirm with . • The “CALIBRATION” menu is selected (see “Se-
 “WAIT” is displayed until the changes are lecting the CALIBRATION Menu” on page 255).
stored.
Selecting steering calibration
 When the changes are stored, “SAVE” is dis-
played. 1. Using the key, select the “C1 PF/FF ROCKER”
menu.
Activating the new setting and carrying out a test
run 2. Press the key until the “C2 STEER SYS” menu
11. Switch the truck off and on again. appears.
 The new settings are activated. 3. Press the key.
 The safety prompt “SURE? N” is displayed.
12. Carry out a test run.
Note: If you wish to cancel calibration, press the key
now.
4. Press the key.
 The safety prompt “SURE? Y” appears.
5. Press the key.
 The “C2.1 ACQUIRE TILLER CENTER” menu
for calibrating the tiller centre position is se-
lected.
Calibrating the tiller centre position
1. Set the tiller to the centre position.
2. To confirm the centre position press the key to
select “CONFIRM” and press .
3. Press the key several times to select the “C2.6
ADJ DRIVE TIRE CENTER” menu.
Calibrating the drive wheel forward travel
The “C2.6 ADJ DRIVE TIRE CENTER” menu is se-
lected.
1. Press the key.
 The setting is displayed (factory setting = 200).
2. Using the and keys, set the drive wheel to
forward travel.
 Press the key to turn the drive wheel clock-
wise.
 Press the key to turn the drive wheel anti-
clockwise.
WT 3000 Series
Rev. B
256
ELECTRICAL SYSTEM
CALIBRATION
Note: The position of the drive wheel only changes 3. Press the key to view the setting (1 to 9) (factory
when you confirm with the key. setting = 3).
3. Confirm the drive wheel position with . 4. Using the and keys, set the drive wheel ex-
 The drive wheel position changes. actly to the 90 degree position.
Note: Check forward travel by carrying out a test run.  Press the key to increase the angle of the
Repeat the calibration as required. drive wheel.
4. Press the key.  Press the key to decrease the angle of the
drive wheel.
 The “C2.7 2ND ENCODER” menu is selected.
5. Confirm the drive wheel position with .
Note: The “C2.7 2ND ENCODER” menu must not be
changed. The encoder setting must be “ON”. 6. Check the drive wheel position again.
Note: If the drive wheel is not set exactly to the 90°
Calibrating the right steering lock
position, press to select the “C2.5 ADJ FULL RIGHT
Settings can be made from 1 to 9 for approximate and
FINE” menu and perform fine-tuning again.
fine calibration tuning. For fine calibration settings 1 to
9 correspond to an approximate calibration tuning. Left steering lock calibration
There are therefore 9 x 9 settings available. Note: The left steering lock is calibrated in the same
The steering lock must be set so that for a full lock the way as for the right steering lock via the “C2.3 ADJ
drive wheel is set 90° to the right. If not, proceed as FULL LEFT FINE” and “C2.2 ADJ FULL LEFT
follows: COARSE” menus. The fine-tuning factory setting is 3,
the approximate factory setting is 4.
Fine-tuning the right steering lock
Saving and activating all settings
1. Press to select the “C2.5 ADJ FULL RIGHT
FINE” menu 1. Press the key.
2. Move the tiller anti-clockwise as far as the stop and  The saving prompt "SAVE? N” is displayed.
hold it in this position.  If you do not wish to accept the settings, press
to cancel the calibration.
3. Press the key to view the setting (1 to 9) (factory
setting = 5). 2. To save the settings, press “SAVE? Y”.
4. Use the and keys to change the reading by 3. To confirm the settings, press .
just one unit. This will indicate how far the drive  The display changes to the “C2 STEER SYS”
wheel position changes. menu.
 Press the key to increase the angle of the 4. Wait approximately 5 seconds until the new set-
drive wheel. tings are stored.
 Press the key to decrease the angle of the 5. Switch the truck off and on again.
drive wheel.  The new settings are now activated.
5. Confirm the drive wheel position with and posi- 6. Carry out a test run.
tion the tiller centrally.  If the steering lock has been set correctly, the load
6. Check the drive wheel again to see if the 90 degree wheels should turn in the opposite direction for a
position is reached for a full steering lock. full steering lock when the truck is travelling very
 If not, carry out the fine calibration tuning again. slowly. Check this for both directions.
Note: If the setting is 9 and the drive wheel is still not
in the 90° position for a full steering lock, the steering
lock should only be given an approximate pre-setting.
To do this, proceed as follows:
Right steering lock approximate calibration
1. Press to select the “C2.4 ADJ FULL RIGHT
COARSE” menu.
2. Move the tiller anti-clockwise as far as the stop and
hold it in this position.
WT 3000 Series
Rev. B
257
ELECTRICAL SYSTEM
CALIBRATION
Calibrating the SRT option for me- Note: To quit without saving, press . The display then
returns to “C3 LOAD SENSOR”.
chanical steering
18. Press the key.
SRT (Speed Reduction on Turns) is optionally availa-
 The saving prompt "SAVE? Y” appears.
ble, including on trucks with mechanical steering.
Requirements 19. To confirm, press .
 The display returns to the “C3 LOAD SENSOR”
• The “CALIBRATION” menu is selected (see “Se- menu.
20. Wait for 5 seconds.
Selecting steering calibration  After 5 seconds the new settings are stored.
1. Using the key, select the “C1 PF/FF ROCKER” Activating the new setting and carrying out a test
menu. run
2. Press to scroll to the “C2 STEER SYS” menu. 21. To activate the new settings, switch the truck off
3. Press the key. and on again and then carry out a test run.
Note: To cancel the calibration, press the key.
Confirming the security prompt
4. Press the key.
5. Press the key.
 The “C2.1 ACQUIRE TILLER CENTER” menu
for calibrating the tiller centre position is se-
lected.
Calibrating the tiller centre position
6. Leave the tiller in the centre position.
7. Use the key to select “CONFIRM”.
8. To confirm the centre position, press .
Calibrating the left tiller lock
9. Press the key.
 “C2.2 AQUIRE FULL LEFT” is displayed.
10. Turn the tiller as far as the left stop and hold it in
position.
12. To confirm the left end position, press .
Calibrating the right tiller lock
13. Press the key.
 “C2.3 AQUIRE FULL RIGHT” is displayed.
14. Turn the tiller as far as the right stop and hold it in
position.
16. To confirm the right end position, press .
Saving new settings
17. Press the key.
 The prompt for saving N” is displayed.
WT 3000 Series
Rev. B
258
ELECTRICAL SYSTEM
CALIBRATION
Load sensor calibration

Requirements
• The “CALIBRATION” menu is selected (see “Se-
Selecting load sensor calibration
1. Press the key.
 The “C1 PF/FF ROCKER" menu is selected.
2. Press to scroll to the “C3 LOAD SENSOR”
menu.
3. Press the key.
4. To continue press the key.
5. Press the key.
 “C3.1 AQUIRE MIN LOAD” is displayed.
Calibrating the zero point
6. Lower the forks of the truck without load.
7. To confirm, press .
8. Press the key.
 “C3.2 AQUIRE MAX LOAD” is displayed.
Calibrating the maximum load
9. Raise the forks with maximum load (see data
plate).
11. Press the key.
 The prompt “SAVE? N” to cancel the procedure
is displayed.
12. Press the key.
 The prompt “SAVE? Y” to save the settings is
displayed.
Saving the calibration and quitting the calibration
menu
13. Press the key.
 The new settings are stored.
 The display returns to the “C3 LOAD SENSOR”
menu.
 After 5 seconds the new settings are stored.
Activating the new setting
 The load sensor is now calibrated
WT 3000 Series Rev.\x11 1 06/2010

Rev. B
259
Notes:
260
ELECTRICAL SYSTEM
SOFTWARE - PARAMETER SETTINGS
Software - Parameter Settings • Steering type Markings

• Platform type X = Relevant
Conventions The number 3040MF for example denotes a WT 3040 with mechanical steering — = Not relevant
and a folding platform.
Brief description of equipment See page 5 for details of the truck data number. Parameters that can be set separately in performance
Three components of the truck data number are used to assign the truck's equip- In the following tables this part of the truck data number describes the truck settings P1 - P3
ment to the parameters. model.
• Model number Trucks with electric steering and fixed platform in rider mode
Factory Settings Applies to trucks with the following specification numbers:
Display Description Range Perfor- Perfor- Perfor- 3040EF 3040ER 3040ES 3060EF 3060ER 3040MF 3040MR 3040MF 3020MO
mance mance mance
setting P1 setting P2 setting P3
Rider Travel Speed FF Max. reverse speed of unladen truck in rider Values range from 1 - 9 in 0.5 km/h incre-
mode(a) (forks first). ments per value.
9 7 5 — X X — X — — — —
Value 1 = 8.5 km/h, value 5 = 10.5 km/h,
value 7 = 11.5 km/h, value 9 = 12.5 km/h,
Rider Travel Speed PF Max. forward speed of unladen truck in rider Values range from 1 - 9 in 0.5 km/h incre-
mode (battery first). ments per value.
9 7 5 — X X — X — — — —
a. Rider mode: The operator rides on the platform.
Trucks with mechanical steering and fixed platform in rider

mode
mance mance mance
Rider Travel Speed FF Max. reverse speed of unladen truck in rider Values range from 1 - 9 in 0.5 km/h incre-
mode(a) (forks first). ments.
9 7 5 — — — — — — X — —
Rider Travel Speed PF Max. forward speed of unladen truck in rider Values range from 1 - 9 in 0.5 km/h incre-
mode (battery first). ments.
9 7 5 — — — — — — X — —
a. Rider mode: The operator rides on the platform.
WT 3000 Series
Rev. B
261
ELECTRICAL SYSTEM
Folding platform trucks in pedestrian mode
mance mance mance
PL Up Speed FF Max. reverse speed of unladen truck in pe- Values range from 1 - 9 in 0.5 km/h incre-
destrian mode(a) (forks first) with platform ments.
folded up. Value 1 = 2 km/h, value 3 = 3 km/h, 7 5 3 X — — X — X — X —
value 5 = 4 km/h, value 7 = 5 km/h,
Value 9 = 6 km/h,
PL Up Speed PF Max. forward speed of the unladen truck in Values range from 1 - 9 in 0.5 km/h incre-
pedestrian mode (battery first) and platform ments.
7 5 3 X — — X — X — X —
up. Value 1 = 8.5 km/h, value 5 = 10.5 km/h,
PL Down Speed FF Max. reverse speed of unladen truck in rider Values range from 1 - 9 in 0.5 km/h incre-
mode (forks first) with platform folded down. ments.
Value 1 = 2 km/h, value 3 = 3 km/h, 9 7 5 X — — X — X — X —
value 5 = 4 km/h, value 7 = 5 km/h,
Value 9 = 6 km/h,
PL Down Speed PF Max. forward speed of the unladen truck in Values range from 1 - 9 in 0.5 km/h incre-
rider mode (battery first) and platform down. ments.
9 7 5 X — — X — X — X —
a. Pedestrian mode: The operator walks alongside or behind the truck.
Trucks with folding platform in rider mode (except for

WT3020 MO)
mance mance mance
Rider Acceleration Acceleration of unladen truck in rider mode Settings from 0 - 4.

from 0 km/h to 8 km/h. 0 corresponds to maximum acceleration, 4 1 2 3 X X X X X X X X —
corresponds to minimum acceleration.
Rider Plugging Deceleration through changing direction (re- Values range from 1 - 9 in 0.2 s incre-
generative braking) from 8 km/h to 0 km/h in ments(a).
rider mode. 1 corresponds to maximum deceleration, 9
3 5 7 X X X X X X X X —
corresponds to minimum deceleration.
Value 1 = 0.6 s, value 4 = 1.2 s,
Value 9 = 2.2 s
WT 3000 Series
Rev. B
262
ELECTRICAL SYSTEM
mance mance mance
Rider Coasting Deceleration through coasting from 8 km/h Values range from 1 - 9 in 0.2 s incre-
to 0 km/h in rider mode. ments(a).
1 corresponds to maximum deceleration, 9 3 4 5 X X X X X X X X —
Value 1 = 0.6 s, value 4 = 1.8 s,
Value 9 = 2.8 s
Speed Reduction On Cornering speed reduction in rider mode Values range from 1 - 3.
Turns Value 1 = 8.8 km/h for 90° drive wheel an-
gle.
Value 2 = 7.5 km/h for 90° drive wheel an- 2 2 3 X X X X X X X X —
gle.
Value 3 = 6.3 km/h for 90° drive wheel an-
gle.
a. This is the theoretical time the electronic system requires to decelerate a traction motor on the test bench from a speed corresponding to 8 km/h in the truck to 0 rpm. In practice, more time is required due to the inertia of the truck.
Folding platform trucks in pedestrian mode
mance mance mance
Speed Reduction On Cornering speed reduction in pedestrian Values range from 1 - 3.

Turns mode. Values 1 - 3 = 4.8 km/h for 90° drive wheel 2 2 3 X X X X X X X X X
angle.(a)
Walkie Acceleration Acceleration of unladen truck in pedestrian Values range from 1 - 9 in 0.2 s incre-
mode from 0 km/h to 6 km/h. ments(b).
1 corresponds to maximum acceleration, 9
3 5 7 X X X X X X X X X
corresponds to minimum acceleration.
Value 1 = 0.4 s, value 4 = 1.0 s,
Value 9 = 2.0 s
Walkie Plugging Deceleration through changing direction (re- Values range from 1 - 9 in 0.2 s incre-
generative braking) from 6 km/h to 0 km/h in ments(c).
pedestrian mode. 1 corresponds to maximum deceleration, 9
3 5 7 X X X X X X X X X
Value 1 = 0.6 s, value 4 = 1.2 s,
Value 9 = 2.2 s
Walkie Coasting Deceleration through coasting from 6 km/h Values range from 1 - 9 in 0.2 s incre-
to 0 km/h in pedestrian mode. ments(c).
1 corresponds to maximum deceleration, 9
4 5 6 X X X X X X X X X
Value 1 = 1.0 s, value 4 = 1.6 s,
Value 9 = 2.6 s
WT 3000 Series
Rev. B
263
ELECTRICAL SYSTEM
a. Irrespective of the setting, the cornering speed in pedestrian mode is always reduced to 4.8 km/h.
b. This is only the time the electronic system requires to accelerate a traction motor on the test bench from 0 rpm to a speed corresponding to 6 km/h in the truck. In practice, more time is required due to the inertia of the truck.
c. This is the theoretical time the electronic system requires to decelerate a traction motor on the test bench from a speed corresponding to 6 km/h in the truck to 0 rpm. In practice, more time is required due to the inertia of the truck.
Parameters with the same setting for all performance

profiles
All trucks
Display Description Range All performance profiles 3040EF 3040ER 3040ES 3060EF 3060ER 3040MF 3040MR 3040MF 3020MO
BDI Setting BDI display settings for different application Light Duty, Standard Duty, Heavy Duty,
Standard Duty X X X X X X X X X
profiles. Maintenance Free (Heavy Duty Plus)
Pump Acceleration Acceleration time of pump motor from 0 rpm Values range from 1 - 9 in 0.2 s incre-
to maximum speed. ments(a).
1 X X X X X X X X X
Value 1 = 0.4 s, value 4 = 0.8 s,
Value 9 = 2.0 s
Pump Deceleration Deceleration time of pump motor from max- Values range from 1 - 9 in 0.2 s incre-
imum speed to 0 rpm. ments(b). 1 X X X X X X X X X
Value 1 = 0.4 s, value 4 = 0.8 s,
Value 9 = 2.0 s
Adjust Battery Displays the battery voltage measured by — Change only after consultation
X X X X X X X X X
the controller. with Crown service department.
Turtle Mode Brake Sets the electric braking moment when the Values range from 1 - 9 in 0.2 s incre-
“Rabbit/Turtle” toggle switch is set to "turtle". ments.
4 X X X X X X X X X
Value 1 = 2.2 s, value 4 = 2.8 s,
Value 9 = 3.8 s
BB Acceleration Time required by the traction motor to accel- Values range from 1 - 9 in 0.2 s incre-
erate from 0 rpm to maximum speed when ments.
4 X X X X X X X X X
the SAS safety reverse switch is applied. Value 1 = 0.8 s, value 4 = 1.4 s,
Value 9 = 2.4 s
BB Deceleration Time required by the traction motor to decel- Values range from 1 - 9 in 0.2 s incre-
erate from maximum speed to 0 rpm when ments.
2 X X X X X X X X X
the SAS safety reverse switch is released. Value 1 = 0.1 s, value 4 = 0.7 s,
Value 9 = 1.7 s
Unload Threshold(c) Threshold beyond which point the load-de- Values range from 1 - 9 in 5% increments.
pendent travel speed reduction applies. De- Value 1 = 5%, value 4 = 20%, 4 X X X X X X X X X
fault setting is 20% of maximum payload. Value 9 = 45%
a. This is only the time required by the electronic system to accelerate a pump motor on the test bench from 0 rpm to maximum speed. In practice, the pump resistance and the payload will increase this time.
b. This is only the time required by the electronic system to decelerate a pump motor on the test bench from maximum speed to 0 rpm. In practice, the ramps of the lowering valve, throttles and resistors in the hydraulic system will increase this time.
c. This parameter must only be changed after consultation with the Crown service department.
WT 3000 Series
Rev. B
264
ELECTRICAL SYSTEM
Trucks with electrical steering
Max EVP(a) Restricts the maximum EVD torque. Values range from 1 - 9 in 5% increments.
Value 1 = 60%, value 5 = 80%, 5 X X X X X — — — —
Value 9 = 100%
Min EVP(a) Restricts the minimum EVD torque. Values range from 1 - 9 in 2% increments.
Value 1 = 0%, value 5 = 8%, 1 X X X X X — — — —
Value 9 = 16%
EVP Open Delay(a) Time delay setting from minimum to maxi- Values range from 1 - 9 in 0.1 s incre-
mum EVP torque. ments.
2 X X X X X — — — —
Value 1 = 0 s, value 5 = 0.4 s,
Value 9 = 0.8 s
EVP Close Delay(a) Time delay setting from maximum to mini- Values range from 1 - 9 in 0.1 s incre-
mum EVP torque. ments.
2 X X X X X — — — —
Value 1 = 0 s, value 5 = 0.4 s,
Value 9 = 0.8 s
a. This parameter must only be changed after consultation with the Crown service department.
Trucks with mechanical steering
Max EVP(a) Restricts the maximum power supply to the Values range from 1 - 9 in 5% increments.
On/Off lowering valve. Value 1 = 60%, value 5 = 80%, 5 — — — — — X X X
Value 9 = 100%
Min EVP(a) Limits the minimum power supply of the On/ Values range from 1 - 9 in 2% increments.
Off lowering valve. Value 1 = 0 %, value 5 = 8%, 1 — — — — — X X X
Value 9 = 16%
EVP Open Delay(a) Time delay setting from minimum to maxi- Values range from 1 - 9 in 0.1 s incre-
mum lowering speed. ments.
2 — — — — — X X X
Value 1 = 0 s, value 5 = 0.4 s,
Value 9 = 0.8 s
EVP Close Delay(a) Time delay setting from maximum to mini- Values range from 1 - 9 in 0.1 s incre-
mum lowering speed. ments.
2 — — — — — X X X
Value 1 = 0 s, value 5 = 0.4 s,
Value 9 = 0.8 s
a. This parameter must only be changed after consultation with the Crown service department.
WT 3000 Series
Rev. B
265
ELECTRICAL SYSTEM
All trucks in rider mode
Rider Turtle Speed Reduced travel speed setting in rider mode Values range from 1 - 9 in 0.5 km/h incre-
("rabbit/turtle" toggle switch) ments. 7 X X X X X X X X —
1 = 4 km/h, 7 = 7 km/h, 9 = 8 km/h
All trucks in pedestrian mode
Walkie Turtle Speed Reduced travel speed setting in pedestrian Values range from 1 - 9 in 0.5 km/h incre-
mode ("rabbit/turtle" toggle switch) ments. 3 X X X X X X X X X
1 = 2 km/h, 3 = 3 km/h, 9 = 6 km/h
All trucks with fixed platform
Entry Bar Brake Changes the brake moment caused by ap- Values range from 1 - 9 in 0.2 s incre-
plying the entry bar. ments.
2 — X X — X — X — —
Value 1 = 0.2 s, value 4 = 0.8 s,
Value 9 = 1.8 s
WT 3000 Series
Rev. B
266
ELECTRICAL SYSTEM
SERVICING AND REPLACING THE CONTROL MODULES
Servicing and Replacing the Discharging the capacitors

Control Modules The truck must be de-energised and secured, see
safety notices. Once this has been done:
The number of control modules and assembly loca-
1. Short the positive and negative connections of the
tions will vary depending on the truck’s specific equip-
control module over a resistor (10 - 100 Ohm,
ment and features. See Electrical Components,
min. 5 W) for a few seconds.
page 291 for detailed information.
 The stored energy has been discharged safely via
General the resistor.
Travel, lifting and power steering are controlled by Servicing the control modules
modules which communicate with each other via a
common CAN-Bus: The truck must be de-energised and secured, see
safety notices.
• Access 1 (Display panel) (Display)
1. Discharge the capacitors.
• Access 2 (Traction control module) (TCM)
2. Dry clean the outside of the control module (see
• Access 3 (Hydraulic control module) (HCM)
Cleaning the Truck and Components, page 26).
• Access 5 (Steering control module) (SCM)
3. Check that the nuts attaching the power cables are
• Access 8 (CAN interface) (CAN-Interface) tight.
Access 2 and Access 3 are located in the same hous- 4. Check the logged events.
ing. Access 8 in the tiller handle.
Replacing control modules
Power fuses
On the WT 3020 model power fuse FU1 is fitted above Removing the control module
the control module on a plate. For all other models FU1 Securing the truck
is located directly above the control modules.
The truck must be de-energised and secured, see
safety notices. Once this has been done:
1. Discharge the capacitors.
WARNING
Removing the control module
Short circuits can cause fires 2. Remove / disconnect all wires (mark the wires if
Control modules operate at high currents. Please note: necessary).
 You must be trained to carry out this work. 3. Remove the bus bars if present.
 Use non-fatigue eye protection. 4. Remove the control module mounting screws.
 Wear close-fitting clothing. 5. Remove the control module.
 Do not wear jewellery.
Checking the assembly plate tooth pattern
 Always use insulated tools.
6. Check the tooth pattern left by the back plate of the
control module on the assembly plate. The full sur-
face area of the control module must be in contact
with the plate.
WARNING  Are there any large areas without direct contact
to the controller? If so, replace the assembly
Risk of serious injury!
plate to avoid thermal problems.
Avoid accidents by:
 Switching the truck off
 Disconnecting the battery.
 Preventing the truck from being switched on again.
 Jacking up the truck and preventing it from rolling
away
WT 3000 Series
Rev. B
267
ELECTRICAL SYSTEM
SERVICING AND REPLACING THE CONTROL MODULES
CAUTION
Health risk
damage your health.
7. Remove the heat conducting paste remains on the

assembly plate with a lint-free cloth and a commer-
cial silicon removing agent.
Assembling the control module

Note: Use a control module with the right software ver-
sion (see page 61).
Assembling the control module
1. Apply heat conducting paste (Dow Corning® 340,
part no. 053051-008) thin and evenly to the base
plate of the new control module.
2. Attach the control module to the assembly plate.
3. If necessary clean the power cable connections.
4. Refit / connect all wires. Attach the bus bars if ap-
plicable.
Setting the control module parameters
5. Leave the truck jacked up.
6. Connect the battery and remove the immobilizer.
7. Set the parameters (see page 261) and calibrate
the truck (see page 255).
Functional test
8. Carry out a functional test.
WT 3000 Series
Rev. B
268
ELECTRICAL SYSTEM
CONTROL MODULE PMT TEST
Control Module PMT Test Testing Access 2

(HCM) (hydraulic control module)
General
Note: In the following test the power output -P of Ac-
EN 1175-1 requires regular testing of the safety circuits cess 2 is shorted to the -B connection of the control
for the control modules used. module.
The test is a "Pulse Monitor Trip Test”, or PMT for short.
Trucks whose control modules fail the PMT must
not be operated. They must be repaired immedi-
ately.
Required tools
Access 2 / Access 3
• A test wire, approx. 500 mm long with a 1 mm2
10
-B
A
cross section. The wire must have a 10 A fuse and
testing terminals at both ends.
PMT Test
-P
WARNING + BF FU 7 +
+ + M2
You or other people could be fatally injured. 400A
The truck or moving parts can start accidentally during

the test. Fig. 65 Test setup for Access 2
Test preparation
ground.
1. Disconnect the battery if it is still connected.
 Before connecting the test wire, disconnect the bat-
tery from the truck. 2. Connect the test wire to -B and -P.
Preparing the truck Performing the test
1. Switch off the truck and disconnect the battery. 4. Power up the truck.
 The test is successful if:
2. Jack up the truck (see page 23) so that the drive
wheel is clear of the ground. – The traction motor does not start up
– The display shows EV = 310.
 If one of the above conditions is not met, take the
truck out of service and replace the control module.
Completing the test
7. Remove the test wire.
9. Test the truck's functions.
 If the truck is functioning normally, test Access 3.
WT 3000 Series
Rev. B
269
ELECTRICAL SYSTEM
Testing Access 3 9. Test the truck's functions.

 If the truck is functioning normally, repeat steps 1
(TCM) (traction control module)
to 9 with the test wire between -B and terminal V
Note: In the following test phases U, V and W of the and then W respectively.
Access 3 power part are shorted in turn to the BATT
 If the truck is working normally, now test the steer-
NEG. terminal on the control module.
ing control module Access 5 if applicable.
Performing the test
Access 2 / Access 3
W
W
V
V M1
U 3
U AC
-B
-
A
10
Fig. 66 Access 3 test setup

Test preparation
2. Connect the test wire to -B and U.
Performing the test
– The traction motor does not start up
Completing the test
7. Remove the test wire.
WT 3000 Series
Rev. B
270
ELECTRICAL SYSTEM
Testing Access 5
(SCM) (Steering control module)
Note: In the following test phases U, V and W of the
Access 5 power part are shorted in turn to the BATT
NEG. terminal on the control module.
Access 5
W
W
V
V M3
U 3
U AC
-B
-
A
10
Fig. 67 Access 5 test setup

Test preparation
2. Connect the test wire to -B and U.
Performing the test
– The steering and traction motors do not start
– Lifting operations can be performed.
6. Disconnect the battery and remove the test wire.
8. Test the truck's functions.
If the truck is functioning normally, repeat the test with
the test wire between -B and V and W respectively.
WT 3000 Series
Rev. B
271
ELECTRICAL SYSTEM
GENERAL DC MOTOR MAINTENANCE INSTRUCTIONS
General DC Motor Maintenance CAUTION

Instructions Place the pressure springs carefully on the brush be-
fore fitting the brush. Otherwise the brush could be
damaged.
WARNING
Note: Make sure that all brushes contact the commu-
tator at the same pressure.
suddenly when you are working on it. • New brushes must be run in with a medium load in
You should therefore carry out the following safety pro- the first hours. Never fully charge the motor straight
cedures before starting any operations on the truck: away.
 Lower the forks to the ground. Motor
• Blast the motor with dry compressed air.
 Jack up the truck until the drive wheel is clear of the CAUTION
Health risk
Brushes damage your health.
• Remove all brushes and check for wear. The length  Observe the manufacturer’s safety instructions
of the shortest brush determines whether the brush when handling solvents and lubricants.
set needs to be replaced.
• If one or more brushes need to be replaced, replace • If oil or grease is found in the motor commutator
all brushes and their pressure springs at the same compartment (usually a paste consisting of oil, oil
time. This will ensure the correct contact pressure. vapour, dust and carbon particles), immediately re-
move the cause and clean the motor thoroughly:
Note: If the minimum brush length has not been
reached, the brushes should still be replaced as they Note: Oil or grease burns in the brush sparks and
could wear fully before the time of the next inspection. leaves behind a highly abrasive oil ash which can very
quickly destroy the commutator and the brushes.
• The brushes must be able to move freely in the
brush support, without spring tension and without
twisting. Never modify the brushes if one or more
Rotor
cannot move freely. In this case replace all brushes • Check the commutator for unevenness, burning,
as they will probably have been thermally over- grooves and cracking of the multi-plate edges. Turn
loaded. the rotor if necessary.
Note: Thermal overloading causes the brushes to Note: A non-oily, evenly distributed layer on the brush
swell up. Brushes which jam in the brush support pro- surfaces is normal.
duce intense sparking and destroy the commutator.
• The brush edges must not be cracked. Brushes
with cracking along the long edge of the surface will
have been damaged by a worn commutator.
Note: If information is provided in the manual, restore
the commutator to the specified limits. Otherwise, re-
place the rotor or the motor.
• Loose brush connections are a clear sign of motor
overload. In this case inspect the commutator for
burning and repair or replace as necessary.
Rev.1 07/2010 WT 3000 Series

Rev. B
272
ELECTRICAL SYSTEM
ABM TRACTION MOTOR (UP TO SER. NO. 5A604759)
ABM Traction Motor 9. Remove the tie rod (79).

Note: An eye bolt can be fitted to the thread at the rotor
(up to Ser. No. 5A604759) end to lift out the rotor assembly.
10. Lift out the entire rotor assembly with the B bearing
plate while removing the sensor bearing wire from
WARNING the rubber socket.
11. Lift out the frame and field (65).
Risk of serious injury!
Avoid accidents by:
Traction motor assembly
 Disconnecting the battery. The following item numbers refer to Fig. 70.
 Preventing the truck from being switched on again. Traction motor assembly
 Jacking up the truck and preventing it from rolling 1. Assemble the frame and field (65) in the correct
away position.
Note: An eye bolt can be fitted to the thread at the rotor
end to position the rotor assembly.
2. Fit a new or repaired rotor assembly complete with
CAUTION the B bearing plate. To do this, place the sensor
bearing wire in the rubber socket and fit the rubber
Health risk socket into the opening of the B bearing plate.
damage your health.
 Observe the manufacturer’s safety instructions CAUTION
when handling solvents and lubricants. Take care not to damage the toothing of the pinion (68)
in the process.
Traction motor disassembly

3. When positioning, engage the toothing of the pin-
The following item numbers refer to Fig. 70. ion (68) with the drive pinion in the gear unit.
Preparation 4. Attach the tie rod (79) and torque to 16 Nm.
1. Switch off the truck and disconnect the battery. 5. Attach the retaining ring (82), supporting ring (81),
brake carrier and key (73) of the rotor (72).
2. Prevent the truck from being switched on again
and rolling away. Brake assembly
3. Jack up the truck so that the drive wheel is clear of 6. Assemble the brake (see page 299)
the ground.
Restoring the electrical connections
Disconnecting the wiring 7. Fit the retaining plate (85) to the bearing plate (78).
4. Undo all the connections on the traction motor and 8. Fit the terminal board and torque the screws to 10
the brake. Nm.
5. Open the strain relief to remove the steering trans- 9. Fit the drive system connector to the retaining plate
mission connector from the retaining plate (85) (on (85) and screw on the strain relief.
the traction motor).
10. Connect the motor to the brake.
Brake removal
Functional test
6. Disassemble the brake (see page 299).
11. Check operation.
7. Remove the retaining ring (82), supporting ring
(81), brake carrier and key (73) of the rotor (72).
8. Unscrew the retaining plate (85) from the bearing
plate and remove it.
WT 3000 Series
Rev. B
273
ELECTRICAL SYSTEM
ABM TRACTION MOTOR (UP TO SER. NO. 5A604759)
Repairing the Traction Motor Assembling the rotor assembly

Note: Repairing the motor requires special tools such On the B side (brake side):
as a hydraulic press, suitable extractors and in-house 1. Place the shims (77) and a new O ring (76) into the
produced assembly aids. If you do not have these tools bearing plate (78).
then use pre-assembled assemblies (see parts man-
2. Fit a new sensor bearing (75) into the bearing plate
ual).
(78) while noting the orientation of the connector.
Note: Replace all bearings and seals when repairing.
3. Insert shims (87) and the retaining ring (74).
Preparation 4. Press the rotor shaft (72) into the sensor bearing
1. Disassemble the traction motor (see page 273). while supporting the inner ring of the sensor bear-
ing.
2.
5. Insert the retaining ring (80).
Dismantling the rotor assembly
On the A side (gear unit side):
On the A side (gear unit side): 1. Press the ball bearing (70) onto the rotor while sup-
1. Remove the retaining ring (66) and shim (67). porting the rotor.
2. Remove the pinion (68) using a suitable extractor. 2. Insert the retaining ring (69).
3. Remove the key (71). 3. Press on the centrifugal disc (86) while supporting
4. Pull off the centrifugal disc (86) and remove the re- the rotor.
taining ring (69). 4. Insert the key (71).
5. Remove the ball bearing (70) using a suitable ex- 5. Press the pinion (68) onto the rotor while support-
tractor. ing the rotor.
On the B side (brake side): 6. Slide on the shim (67) and insert the retaining ring
(41).
1. Remove the retaining ring (80).
2. Press the rotor shaft (72) off the sensor bearing Final tasks
(75). 1. Assemble the traction motor (see page 273).
3. Remove the retaining ring (74) and shims (87).
4. Remove the sensor bearing (75) from the bearing
plate (78).
5. Remove the shims (77) and O ring (76).
WT 3000 Series
Rev. B
274
ELECTRICAL SYSTEM
CROWN TRACTION MOTOR (FROM SER. NO. 5A603324)
Crown traction motor Traction motor disassembly

(from Ser. No. 5A603324)
Traction motor installation and re- 1
moval
WARNING
Risk of serious injury! 2
Avoid accidents by:
 Disconnecting the battery.
 Preventing the truck from being switched on again.
3
 Jacking up the truck and preventing it from rolling
away
CAUTION
4
Health risk
damage your health.
Fig. 68 Traction motor (M1)

Preparation
WT 3000 Series
Rev. B
275
ELECTRICAL SYSTEM
2. Prevent the truck from being switched on again Functional test

and rolling away. 7. Check operation.
3. Jack up the truck until the drive wheel is clear of the
Disconnecting the wiring
4. Undo all the connections on the traction motor (3,
Fig. 68) and the brake (2).
Brake removal
5. Remove the brake (2).
6. Remove the tie rod (1).
7. Lift off of traction motor.
CAUTION
The splined shaft and motor bearing may be dam-
aged.
Lack of care when depositing the motor on the splined
shaft can damage the shaft or destroy the motor bear-
ing.
 Deposit the motor in such a way that it does not ex-
ert any load on the splined shaft.

1. Apply grease type B or BB to the splined shaft (4,
Fig. 68) (see page 28).
CAUTION
Take care not to damage the gearing when fitting the
motor.
2. Place the motor in the correct position on the trans-

mission while ensuring that the splined shaft en-
gages with the gearing on the transmission.
3. Apply Loctite® 243 to the tie rod, bolt it on and
torque to 20 - 25Nm.
4. If the gearing with the brake has been removed,
attach it again.
Brake assembly
5. Assemble the brake (see page 299)
Restoring the electrical connections
6. Connect the motor to the brake. Torque the power
cable nuts on the traction motor to 7.5 Nm.
WT 3000 Series
Rev. B
276
ELECTRICAL SYSTEM
Repairing the Traction Motor Preparation

1. Disassemble the traction motor (see page 273).
Rotor and bearing disassembly

Rotor disassembly
1. Remove the retaining ring (13) and gear (12).
2. Remove the key (17).
4. Lift out the rotor (4) from the bottom.
Bearing disassembly
6. Pull or push the bearing (15) out of the bearing
plate (9).
Rotor and bearing assembly

Bearing assembly
7. Insert the bearing (15) into the bearing shield (9).
Rotor assembly
1. Insert the rotor (4) into the bearing.
3. Insert the gear (12).
Final tasks
1. Assemble the traction motor (see page 273).
Fig. 69 Traction motor
WT 3000 Series
Rev. B
277
ELECTRICAL SYSTEM
PUMP MOTOR (M2)
Pump Motor (M2)

Pump motor 1.2 kW
Brushes
2. Prevent the truck from rolling away.
3. Unscrew the commutator bearing lid and remove
the insulating protective cap.
4. Apply dry compressed air to the motor.
5. Remove and check the carbon brushes (see
page 272):
– Length of a new carbon brush: 20 mm
– Carbon brush wear limit: 10 mm
Armature
1. Check the armature (see page 272).
A new armature has a diameter of 40 mm. The wear
limit is 38.3 mm.
Note: Do not over tighten the armature. Replace it if
the wear limit has been reached.
Pump motor 2.2 kW

Brushes
2. Prevent the truck from rolling away.
3. Remove the tensioning belt from the pump motor.
4. Apply dry compressed air to the motor.
5. Remove and check the carbon brushes (see
page 272):
– Length of a new carbon brush: 23 mm
– Carbon brush wear limit: 15 mm
Armature
1. Check the armature (see page 272).
A new armature has a diameter of 45 mm. The wear
limit is 4 mm.
Note: Do not over tighten the armature. Replace it if
the wear limit has been reached.
WT 3000 Series
Rev. B
278
ELECTRICAL SYSTEM
STEER MOTOR (M3)
Steer motor (M3)
84
83 52 1
85 18 2
53
82 19
81 3
80 54 20 4
57
79 55 21
5
22
78 56
6
77 23
24
76
75 7
58
87 25
59
74 26
73 27
28 8
60 9
61 10
12 13
72 64 62 11
63 29
30
88 14
31
32 15
71
16
33
70
17
69 34 35
86 36
37 38 39
68 40 41
67
66
45
44
46
65 42
47
43
48
49 51
50
Fig. 70 Steering transmission and steer motor M3
WT 3000 Series
Rev. B
279
ELECTRICAL SYSTEM
STEER MOTOR (M3)
Special tools required CAUTION

To remove and assemble the steer motor:
The pinion (17) and rotor (7) must not be used again
• Tool for the tie rod (part no. 822672).
after disassembly.
• Hydraulic press and suitable supporting equipment
for pressing on components.
5. Pull the pinion (17) off the rotor (7) and dispose of
Steer motor disassembly both parts.
7. Remove the sensor bearing (4) from the bearing
1. Undo all connections from the steer motor. plate (2).
2. Open the strain relief to remove the steering trans-
mission connector from the retaining plate (85) (on Steer motor assembly
the traction motor). 1. Press a new sensor bearing (4) into the bearing
3. Disassemble the tie rod (1) using the special tool plate (2).
(part no. 822672). 2. Fit the retaining ring (5).
4. Lift the steer motor, complete with B bearing plate 3. Press a new pinion (17) into the new rotor (7).
and frame and field, from off the end cap (24). 4. Press the rotor (7) into the sensor bearing (4) while
supporting the inner ring of the sensor bearing.
Steer motor assembly
5. Fit the retaining ring (3).
1. Fit the steer motor, complete with B bearing plate
6. Position the frame and field (6).
and frame and field, onto the end cap (14).
7. Press on a new sensor bearing (8) with a suitable
2. Attach the tie rod (1) and using the special tool
bushing while supporting the rotor (7).
(part no. 822672) torque it to 1.8 Nm.
8. Fit a new O ring (9) into the groove of the sensor
3. Attach the drive system connector to the retaining
bearing (8).
plate (85).
4. Screw on the strain relief firmly. Final tasks
5. Connect the steer motor. 9. Assemble the steer motor.
6. Test the steering.
Repairing the steer motor

Note: Repairing the motor requires special tools such
as a hydraulic press, suitable extractors and in-house
produced assembly aids. If you do not have these tools
then use pre-assembled assemblies (see parts man-
ual).
Note: Replace all bearings and seals when repairing.
Preparation
1. Disassemble the steer motor.
Steer motor disassembly

1. Remove the sensor bearing (8) using a suitable ex-
tractor.
2. Remove the frame and field (6).
4. Press the rotor (7) off the sensor bearing (4).
WT 3000 Series
Rev. B
280
ELECTRICAL SYSTEM
CHECKING AND ADJUSTING THE BDI SETTING
Checking and Adjusting the BDI

Setting
The calibration of the BDI must be checked in the fol-
lowing cases:
• When the truck is used for the first time
• After replacing Access 2/3
Calibrating the BDI ensures that the load profile used
(see page 283) makes optimum use of the battery ca-
pacity.
Requirements
• The battery must have at least 30% residual capac-
ity.
• A calibrated multimeter must be used. Selecting service level 2
Checking the BDI Setting  The “SERVICE” menu is displayed.
Preparing the truck 6. Press the key until “LEVEL 2” appears.
1. Operate the truck for 5 - 10 minutes with load. 7. Press the key until you are requested to enter
2. Park the truck (do not switch it off) and wait for 10 your PIN.
- 15 minutes. 8. Enter the service PIN with the and keys and
Note: Wait for at least 10 minutes. Otherwise you can- confirm with .
not measure the battery resting voltage required for the  The "ANALYZER" menu is displayed.
calibration.
Selecting the Performance menu
9. Press the key until the “PERFORMANCE” menu
CAUTION appears.
Risk of battery damage through incorrect voltage 10. Press the key.
measurement  “P1” appears.
An incorrect battery voltage measurement caused by a
11. Press the key until the “P11” menu appears.
non-calibrated multimeter can result in fully discharged
batteries. 12. Press the key.
 Make sure the multimeter used is calibrated.  “ADJUST BATT= (Value)(1)” is displayed.
13. Press the key and check the reading.
3. Using a calibrated digital voltmeter measure the  If the reading displayed is 0.2 V greater than the
voltage directly at the battery terminals. rounded up value displayed on the battery, the
Note: Do not use under any circumstances the battery setting is ok.
voltage displayed in the “ANALYZER” menu, A3.2. This  If the reading displayed is greater or less than
is the value to be corrected. the rounded up value displayed on the battery +
0.2 V (see following example) continue with
4. Round up the reading to one decimal place and re- step 14.
cord it.
Example: 23.656 volts are measured on the battery.
Navigating in the menus Rounded up to a decimal place this gives 23.7 V. Add
You can navigate through the menus using the cursor 0.2 V. The result is 23.9 V.
keys ( , , , , ) on the display panel. An over-
view of the menu structure can be found in Menu Struc-
ture, starting on page 63.
1). The current reading (= value) is displayed
WT 3000 Series
281
ELECTRICAL SYSTEM
CHECKING AND ADJUSTING THE BDI SETTING
Adjusting the BDI setting

Adjusting the BDI setting
14. Set the rounded up and recorded reading + 0.2 V.
15. Press the key to confirm the selection.
16. Press the key.
 The prompt for saving the new value “SAVE?N”
is displayed.
Note: To cancel the setting, press the key.
17. Press the key.
Activating the new setting and checking accept-
ance
 The new settings are activated.
21. Check that the previous setting has actually been
accepted in the “Performance P11” menu.
WT 3000 Series
282
ELECTRICAL SYSTEM
SETTING THE LOAD PROFILE FOR THE BATTERY DISCHARGE INDICATOR (BDI)
Setting the Load Profile for the Assigning a load profile

Battery Discharge Indicator You can navigate through the menu structure using the
cursor keys ( , , , , ) on the display panel. An
(BDI) overview of the menu structure can be found in Menu
Note: Before changing the load profile calibrate the Structure, starting on page 63.
BDI (see page 281).
A non-calibrated BDI will feed back incorrect values for
the actual battery voltage. The software will then inter-
pret the discharge curves incorrectly and the battery
capacity will either be only partially used or the battery
even fully discharged.
Load profile and discharge curve

Depending on the load weight that is predominantly
moved, the load profile setting for the BDI will match
more or less the actual battery discharge curve.
A better adaptation of the load profile to the application
therefore has the potential to extend the battery runt-
ime significantly. Fig. 72 Display panel
The factory setting is “Standard Duty”. This setting cov- Switching the truck on
ers applications with loads predominantly ranging from
> 650 kg to max.  950 kg. 1. Press the key for 1 second.
The following table shows the corresponding load pro-
files for the loads predominantly moved: Note: For trucks with a key switch, turn the key switch
BDI parameters Selecting the PEFORMANCE menu

Load profile Load predominantly  The "SERVICE" menu is displayed.
moved (kg)
Light Duty 0 kg to < 650 kg 4. Press the key until you are requested to enter
Standard Duty > 650 kg to  950 kg your PIN.
Medium Duty > 950 kg to  1450 kg 5. Enter the service PIN with the and keys and
confirm with .
Heavy Duty > 1450 kg to  1750 kg
Maintenance Free Do not use(a) 6. Press the key until the “PERFORMANCE” menu
a. This load profile is only suitable for lead-acid batteries.
appears.
This battery type is not approved for this truck. 7. Press the key.
The discharge curve assumed by the BDI can be  “P1” appears.
adapted to the actual discharge curve in the “Perfor- 8. Press the key until the “P4” menu appears.
mance P4” menu. 9. Press the key.
 “BDI SETTING = (Value)(1)” appears.
10. Press the key.
11. Press the key until the required setting is dis-
played (see BDI parameters table on page 283).
1). The current setting is displayed. (= Value)
WT 3000 Series Rev. 1 04/2014

Rev. B
283
ELECTRICAL SYSTEM
SETTING THE LOAD PROFILE FOR THE BATTERY DISCHARGE INDICATOR (BDI)
12. Press the key to confirm the selection.

13. Press the key.
 The prompt for saving the new value “SAVE?N”
is displayed.
Note: To cancel the setting, press the key.
14. Press the key.
Activating the new setting and checking accept-
ance
18. In the P4 BDI SETTING menu check that the load
profile has been accepted. If not, repeat the set-
ting.
Rev. 1 04/2014 WT 3000 Series

Rev. B
284
ELECTRICAL SYSTEM
BATTERY INFORMATION
Battery Information
The condition of the battery has a considerable impact
on the performance of the truck. Optimum mainte-
nance is key to maintaining the performance and useful
life of the battery.
Note: Note that only wet cell batteries can be used for
this truck.
Charging the battery
CAUTION
The battery must be serviced and charged strictly
in accordance with the battery and charger manu-
facturers' instructions.
Unsuitable chargers and incorrect maintenance will re-
sult in reduced truck performance in the short term. In
the medium term it will lead to premature battery fail-
ure.
Replacing the battery
WARNING
Incorrect battery sizes and weights can result in fa-
tal accidents.
An incorrect battery weight and size will affect the
truck’s centre of gravity which can result in accidents.
 Only use batteries with the right dimensions, weight
and capacity requirements for this truck.
1. Replace the battery as outlined in the truck opera-

tor manual.
WT 3000 Series
Rev. B
285
ELECTRICAL SYSTEM
MODIFICATIONS
Modifications 12. Enter the service PIN with the and keys and
confirm with .
Modifying “power up with Enter  The "ANALYZER" menu is displayed.
key” to “power up with key switch” Select the “FEATURES” sub-menu
Note: The following description applies only to the 13. Press the key until the “FEATURES” sub-menu
main wire harness, item no. 824533. appears.
14. Use the key to scroll to the ”Key Less Entry”
sub-menu.
WARNING 15. Set “Key Less Entry” in the Features menu, sub-
item F13 to DISABLE.
A powered up truck with a connected battery can move 16. Save the changes and restart the truck.
Modifying “power up with key
cedures before starting any operations on the truck: switch” to “power up with Enter”
 Lower the forks to the ground. Note: The following description applies only to the
 Switch the truck off. main wire harness, item no. 824533.
WARNING
Relay K1 removal Accidental truck movement can cause injury
1. Disconnect the battery and prevent the truck from A powered up truck with a connected battery can move
being switched on again. suddenly when you are working on it.
2. Remove relay K1 from its socket and replace it with
the key switch adapter (part no. 820143).
Assembling and wiring the key switch
3. Assemble the key switch.
4. Connect the wiring of the key switch adapter with
the key switch.
5. Cut wire 203 at terminal 30 of the relay socket and
Key switch removal
insulate the ends.
1. Remove the adapter key switch (part no. 820143).
6. Replace jumper (part no. 826405-001) with jumper
(part no. 826405-002). 2. Remove the key switch.
Relay K1 assembly and wiring
Changing the software
3. Insert relay K1 (part no. 811995-006) in the socket.
 The Enter sign () appears on the display 4. Connect wire 203 to wire 204 on terminal 30 of the
panel. relay socket.
5. Replace jumper (part no. 826405-002) with jumper
(part no. 826405-001).
Changing the software
9. Press the key 3 times.   appears on the display panel.
your PIN.
WT 3000 Series
Rev. B
286
ELECTRICAL SYSTEM
MODIFICATIONS

your PIN.
11. Enter the service PIN with the and keys and
confirm with .
Select the “FEATURES” sub-menu
12. Press the key until the “FEATURES” sub-menu
appears.
13. Use the key to scroll to the ”Key Less Entry”
sub-menu.
14. Set “Key Less Entry” in the Features menu, sub-
item F13 to ENABLE.
15. Save the changes and restart the truck.
WT 3000 Series
Rev. B
287
ELECTRICAL SYSTEM
REPAIRING CONTACTORS
Repairing Contactors contacts must not be treated, as this would cause them
to wear even faster.
Checking the coils

CAUTION
1. Using an ohmmeter measure the resistance be-
The use of other manufacturers' contactors can tween the connections on the coil (2).
damage the truck Note: If there is a freewheel diode between the con-
The original contactors are designed for Crown trucks. nections, desolder it on one side and then test the coil.
 Only use original Crown contactors as replace- Otherwise the results will be false.
ments.  If either an endless resistance or no resistance are
 Do not change the place or the angle where they recorded, the coil (2) is faulty and must be re-
are positioned and do not change the wiring. placed.
Checking the springs

Wear test 1. Check the spring (1) for corrosion or discolouring
caused by heat.
 Replace any corroded or discoloured springs (1).
4
1
Fig. 73 Example of a contactor

1 Spring
2 Coil
3 Contact (moving)
4 Contact (fixed)
Checking the contacts

1. Check the silver coating of the contacts (3,4).
 If the silver coating has worn to the extent that the
support material is visible, both contacts (3, 4)
must be replaced.
Note: The contacts (3, 4) are subject to natural wear
during operation. Blackened, tarnished or scarified
Rev.1 04/2009 WT 3000 Series

Rev. B
288
ELECTRICAL COMPONENTS
289
Notes:
290
Electrical Components
Trucks with mechanical steering
Access 1
(Display)
Horn
SR2
SR1
CA214
KYS (CAN CONN)
CA213
FAN
Line / EDS
FU1
FU2
FU3
FU4
LMS1
CA209
Access 2/3
CA203
(TCM/HCM)
(LMS)
Access 2/3
(TCM / HCM)
CA212 (ECR)
BRK
JC205
M2
M1
PLS2
SV
CA204 CA211 (PLS2)

(PS)
PLS1
CA210 (PLS1)
Fig. 74 Electrical components - Trucks with mechanical steering, part 1
WT 3000 Series
Rev. B
291
CA206
(BRS)
CA215
(ALM)
CA216
(FLS)
CA224
(PWS)
CA207
(SR1)
CA208
(SR2)
CA201
(Handle)
CA200
(Handle)
CA202
HORN Access 1 (Display)
FAN
Fig. 75 Electrical components - Trucks with mechanical steering, part 2
WT 3000 Series
Rev. B
292
Trucks with electric steering
CA214 TFD
CA205 BRS
Display
Horn
SR2
SR1
KYS
Line
CA211
CAN CONN.
CA219 ECR3
M3
FU1
FU2
FU3
FU4
LMS 1 FAN
CA213
CA223 SAHS
LMS1
TCM / HCM
CA216 TS2
CA218 ECR2
CA215 TS1
CA217 ECR1
BRK
M2
M1
PLS2
SV
CA207 PLS2 (Electr.)
CA210
PS PLS1
CA206 PLS1 (Electr.)
Fig. 76 Electrical components - Trucks with electric steering, part 1
WT 3000 Series
Rev. B
293
CA205
BRS
CA225 BRIDGE (POSITION IS SHOWN)
CA203
ALM
CA202
FLS
CA224
PWS
CA208 CA220 HANDLE
SR1
CA209
SR2
CA204 FAN (HIDED) CA201 Display

CA 212
CA221 CONN.
SCM HANDSET
CA222
SCM
SCM
FU2
FU1
FU3
CA200 FU4
TCM / HCM FU5
FU6
FU7
Fig. 77 Electrical components - Trucks with electric steering, part 2
WT 3000 Series
Rev. B
294
BRAKE SYSTEM
295
Notes:
296
BRAKE SYSTEM
COMPONENTS AND OPERATION
Components and Operation

The brake system on this truck consists of two compo-
nents:
• Service brake
• Parking brake
Service brake
The service brake is wear-free as the drive motor in
regenerative mode (EGen®) provides all the brake
power. The brake power is controlled by the traction
controller software.
Parking brake
The parking brake (electromechanical brake) is applied
only when:
• The truck is idle (automatically through the traction
controller).
• The Emergency Disconnect is pulled.
It acts as a parking brake and becomes an emergency
brake as soon as the Emergency Disconnect is pulled.
It is not used as a service brake and is therefore virtu-
ally wear-free.
WT 3000 Series
Rev. B
297
BRAKE SYSTEM
SERVICING THE PARKING BRAKE
Servicing the Parking Brake Troubleshooting

Servicing is limited to checking the air gap every 1000 Symptom: Parking brake does not release.
service hours.
Measuring the air gap 1. Jack up the truck until the drive wheel is clear (see
page 23).
 The drive system in the cage will slip down. The
parking brake on the drive motor becomes ac-
cessible.
2. Attach a digital voltmeter to the brake connections
(measuring range >30 VDC).
1
Note: Do not pull the connections off the brake, the coil
must remain in the circuit.
3. Switch on the truck and apply the travel switch.
Check that 16 to 24 V is applied to the brake's elec-
trical connector.
 If there is no voltage supply, check the electrical
3 system (see page 253).
 If at least 16V is displayed, proceed to step 4.
Checking the coil resistance
4. Switch off the truck, disconnect the battery and
2 prevent it from being switched on again.
5. Remove the electrical connection from the brake.
Fig. 78 Parking brake
6. Using a precise digital ohmmeter measure the coil
Preparation resistance in the magnetic body and compare it
1. Switch off the truck, disconnect the battery and with the figures in the following table.
prevent the truck from being switched on again.
2. Take off motor compartment panel. WT 3020 WT 3040E
3. Remove the dust shield ring (3). WT 3040M WT 3060
4. Apply weak pressurized air to the abrasion.
Rrated(a) 13.3 Ω 10 Ω
5. Use a feeler gauge to measure the air gap between
the brake lining (2) and the armature disk (1). Rmin(a) 12.7 Ω 9.56 Ω
Repair the brake if the air gap > 0.5 mm. The air gap is
not adjustable. A wear part kit is available (see parts Rmax(a) 14 Ω 10.45 Ω
catalog).
a. At 20°C
The wear part kit consists of the following:
– Friction plate  If the coil resistance is within range, the mag-
netic coil is ok.
– Brake disk
 If the coil resistance is out of range, the mag-
– Elastic band and 2 screws to aid installation and netic body is faulty. Replace the brake.
to secure during transport.
WT 3000 Series
Rev. B
298
BRAKE SYSTEM
REPLACING THE PARKING BRAKE
Replacing the Parking Brake Parking brake assembly

Preparation
1 The brake is supplied pre-assembled. Two screws and
2 one elastic band serve as a transport safety mecha-
3 nism and assembly aid.
4
CAUTION
1
Do not remove the elastic band or the screws. The
1 brake will come apart without this transport safety
mechanism.
10
1. Place the brake on a work surface so that the elas-
tic band is facing up.
9
8 6 5
7
Fig. 79 Brake attached to motor
Parking brake disassembly

Preparation B
2. Jack up the truck until the drive wheel is clear (see
page 23).
 The drive system in the cage will slip down. The
parking brake becomes accessible. 5
Parking brake disassembly
3. Remove the panel.
4. Remove the connector from the brake.
5. Remove the dust shield ring (9, Fig. 79). Fig. 80 Brake transport safety mechanism
6. Remove the retaining ring (3). 2. Remove the elastic band (B, Fig. 80) and put it to
7. Remove the three brake mounting screws (1). one side. Do not throw it away!
8. Remove and dispose of the magnetic body (2),
carrier (4), brake disk (6), spacer sleeves (5) and
friction plate (7).
WT 3000 Series
Rev. B
299
BRAKE SYSTEM
REPLACING THE PARKING BRAKE
Removing the transport safety mechanism
1
2
3 WARNING
4
Fatal accidents can result from brake failure when
starting the truck for the first time
1 The brake will not work if the transport safety mecha-
nism is not removed.
1
 Remove the two transport safety mechanism
screws before operating the truck for the first time.
10
8 6 5
7
Fig. 81 Brake assembly

3. Remove the friction plate (7, Fig. 81), taking care
not to lose the spacer sleeves (5).
A
Fitting the carrier, brake disk and friction plate to
the motor
4. Remove the carrier (4) and push it onto the drive
shaft of the motor (8).
5. Secure the carrier (4) onto the drive shaft with the Fig. 82 Transport safety mechanism screws
retaining ring (3). 13. Remove the two screws (A, Fig. 82).
6. Place the friction plate (7) in the correct position on 14. Attach the dust shield ring (9, Fig. 81).
the bearing plate of the motor.
15. Restore the electrical connections.
7. Take out the brake disk (6) and remove the paper.
Operational check
8. Place the brake disk (6) on the carrier (4) on the
motor. 16. Test the parking brake.
Fitting the brake body

9. Make sure the spacer bushings (5, Fig. 80) are
pushed up. Pull the elastic band (B, Fig. 80) pro-
vided over the three brake mounting screws to se-
cure them.
10. Position the brake so that it is correctly aligned with
the motor (8).
Note: The connector socket (10) for the power supply
must be back at the wire.
11. Insert the mounting screws (1), then cut through
the elastic band and dispose of it.
12. Torque the mounting screws to 10 Nm.
WT 3000 Series
Rev. B
300
BRAKE SYSTEM
TESTING THE BRAKING DISTANCE
Testing the Braking Distance Braking distance tables

Requirements Max. braking distances WT 3020
In rider mode:
Carry out the test only on an uncoated, dry, level and
clean concrete surface.
The test route must be sealed off over a large area to SPEED Maximum braking distance
prevent unauthorised access. (km/h) (m)
6 2.2
Performing the test
5.5 2.0
Preparing the truck
5 1.8
1. Place the rated load on the forks and prevent it
from slipping. In pedestrian mode:
2. Lay down a marker to act as the measurement
starting point for the test route.
SPEED Maximum braking distance
Calculating the braking distance (km/h) (m)
6 2.2
WARNING 5.5 2.0
Risk of injury to third parties 5 1.8

The brake test requires you to concentrate fully on the 4.5 1.6
truck. As a result, persons running into the travel zone
could be easily hit and fatally injured. Max. braking distances WT 3040 with me-
 Use marker tape over a large area to block off the chanical steering
test route. In rider mode:
 If necessary use assistants to secure critical points
along the route.
 Do not perform the test unless you have full control (km/h) (m)
over the test route.
7.5 2.7
1. Accelerate within the test route up to one of the 7 2.5
speeds listed in the table.
6.5 2.4
2. At the marker point (measurement starting point)
brake by changing direction. In pedestrian mode:
3. Measure the braking distance.
Analysing the result SPEED Maximum braking distance
1. Calculate the maximum braking distance for the (km/h) (m)
speed travelled in the corresponding table. 6 2.2
Note: Always select the speed in the table that is near-
est to the speed travelled. 5.5 2.0
 The braking distance recorded should always be 5 1.8
less than the figure in the table. 4.5 1.6
 If the braking distance is too long, faulty motor wir-
ing or a faulty motor may be the cause (loose
power cables on the motor and controller, transi-
tion resistances etc.).
WT 3000 Series
Rev. B
301
BRAKE SYSTEM
TESTING THE BRAKING DISTANCE
Max. braking distances WT 3040 with elec-

tric steering
In rider mode:

(km/h) (m)
10 3.6
9.5 3.4
9 3.3
In pedestrian mode:

(km/h) (m)
6 2.2
5.5 2.0
5 1.8
4.5 1.6
Max. braking distances WT 3060

In rider mode:

(km/h) (m)
9 3.3
8.5 3.1
8 2.9
In pedestrian mode:

(km/h) (m)
6 2.2
5.5 2.0
5 1.8
4.5 1.6
WT 3000 Series
Rev. B
302
STEERING
303
Notes:
304
STEERING
REPAIRING THE STEERING ASSEMBLY
Repairing the Steering Assembly
34
23
22
33
21 35
1 32
20 3
31
2
3 8
19
4 9
5 18
10
6
11 30
29
12
7
13 28
27
Intermediate flange 26
14 25
15 24
16
17
Fig. 83 Steering assembly
WT 3000 Series
Rev. B
305
STEERING
REPAIRING THE STEERING ASSEMBLY
Steering assembly components

The steering assembly consists of the following:
• Steer motor
• Steering transmission and intermediate flange
Steering assembly removal and in-

stallation
Removing the steering assembly
3. Remove the drive motor.
4. Undo all connections from the steer motor.
5. Remove the SAHS steer sensor.
6. Remove the screws (7, Fig. 83).
7. Lift out the steering assembly and place it on a
workbench with the steer motor facing up.
Installing the steering assembly
1. Install the steering assembly in the reverse order of
disassembly.
2. Lubricate steering gear teeth with type B lubricant
(see Lubricants and Consumables, page 28).
WT 3000 Series
Rev. B
306
STEERING
REPAIRING THE STEERING TRANSMISSION
Repairing the steering trans- CAUTION

mission If you are using a new intermediate flange, the cylinder
See Fig. 83, page 305. pins (13) must be removed and preserved.
CAUTION Drive and output disassembly

Transmission repair requires special expertise, experi- 11. Pull the pinion shaft with the gear wheel (3), pinion
ence and tools such as presses, extractors, measuring (5) and bearing (1) out of the intermediate flange.
equipment and assembly aids.
If you cannot meet these particular requirements, use 12. Pull the bearing (1), supporting ring (2), gear wheel
a new drive transmission unit. (3) and key (4) off the pinion (5).
13. Extract the gear wheel (9).
14. Remove the supporting ring (10).
CAUTION
15. Press the output shaft (17) and the bearing (15) out
Replace all bearings and seals when repairing. of the intermediate flange.
Output shaft disassembly
Preparation 16. Remove the key (16).
1. Remove the steering assembly (see page 306). 17. Remove the bearing (15) from the output shaft
(17).
2. Remove the steer motor.
18. Press the bearing (11) out of the intermediate
Steering Transmission Disassembly flange.
End cap disassembly
20. Pull the bearing (6) out of the intermediate flange.
3. Remove the screws (23) and take off the clamping
21. Press the shaft seal ring (14) out of the intermedi-
joint (22).
ate flange.
4. Lift off the end cap (21).
Assembly
To pre-assemble the output shaft
CAUTION
1. Press the bearing (15) onto the output shaft (17).
Health risk 2. Assemble the key (16).
damage your health. To pre-assemble the pinion shaft and the interme-
diate flange
when handling solvents and lubricants. 3. Insert the key (4) into the pinion shaft (5).
4. Press on the gear wheel (3).
5. Pour oil out of the steering transmission and dis- 5. Insert the washer (2).
pose of it in accordance with environmental regu- 6. Press on the bearing (1).
lations.
7. Lubricate the sealing lip of the shaft seal ring (14).
6. Remove the O ring (26) from the sensor bearing
8. Press the shaft seal ring (14) into the intermediate
(27).
flange.
7. Take the shim (25) and ring (24) out of the end cap
9. Fit the retaining ring (12) in the intermediate flange.
(21).
10. Press in the bearings (6) and (11).
8. Press the shaft seal ring (19) out of the end cap
(21). Output shaft assembly
9. Remove the seal (20). 11. Press in the pre-assembled output shaft while sup-
porting the inner ring of the bearing (11).
12. Place the washer (10) on the output shaft (17).
WT 3000 Series
Rev. B
307
STEERING
REPAIRING THE STEERING TRANSMISSION
13. Press the gear wheel (9) onto the output shaft (17)
while supporting the output shaft.
14. Fit the retaining ring (8).
Pinion shaft assembly
15. Press the pre-assembled pinion shaft into the
bearing (6).
CAUTION
If you are using a new intermediate flange, tap the pre-
viously removed cylinder pins (13) into the intermedi-
ate flange.
16. Lubricate the sealing lip of the shaft seal ring (19).
17. Press the shaft seal ring (19) into the end cap (21).
CAUTION
Make sure you use the correct oil grade. Cold store
trucks require a different type of oil than standard
trucks.
18. Add a suitable transmission oil (see Lubricants and

Consumables, on page 28)
– Capacity: approx. 0.25 litres
19. Place the seal (20) onto the intermediate flange.
20. Position the end cap (21) onto the intermediate
flange and attach it with the screws (23). Do not
forget the clamping joint (22).
21. Torque the screws (23) to 10 Nm.
22. Fit the ring (24) and spacer (25) in the end cap
(21).
Final tasks
1. Assemble the steer motor.
2. Assemble the steering assembly (see page 306).
3. Lubricate steering gear teeth with type B lubricant
(see Lubricants and Consumables, page 28).
4. Assemble the SAHS steer sensor.
WT 3000 Series
Rev. B
308
STEERING
REPLACING THE SAHS SENSOR
Replacing the SAHS Sensor
2
35,5 +/- 0,5 mm
Fig. 84 SAHS setting dimension
SAHS removal
Sensor removal
1. Remove the plug connection and remove the cable
ties if necessary.
2. Remove the mounting screw of the sensor in the
truck from the retaining plate (2).
3. Pull the sensor out of the hole.
Adjusting the SAHS

Adjusting the screw depth
4. Using a calliper gauge set the distance from the
sensor button to the retaining plate to
35.5 ± 0.5 mm.
SAHS assembly
Sensor assembly
5. Fasten the sensor and the retaining plate back in
the truck.
WT 3000 Series
Rev. B
309
STEERING
REPAIRING CONTROL HANDLE RETURN SPRINGS
Repairing Control Handle Re-

turn Springs 7
If the return spring bias spring force reduces over time,
the pre-tension can be adjusted in several stages. Re-
turn springs whose pre-tension cannot be increased
any further must be replaced.
6
WARNING
A powered up truck with a connected battery can move 4
 Prevent the truck from being switched on again. 5
 Jack up the truck until the drive wheel is clear of the Fig. 85 Pre-tension adjustment
4 Return spring
5 Spacer ring
Removing the covers 6 Axle
1. Remove the covers so that the tiller springs can be 7 Dowel pin
accessed.
2. Set the tiller upright.
Return spring pre-tension adjust- 3. Fix the axle (6) using a fork wrench.
ment  This prevents the return springs (4) from discharg-
ing when the dowel pin (7) is deflected.
Note: The axle (6) contains 2 holes for the dowel pin
4. Remove the dowel pin (7).
which are offset by 90 degrees. This allows you to ad-
just the pre-tension of the return springs by 90 degrees 5. Turn the axle (6) 90 degrees with the fork wrench.
respectively by turning the axle.  This will tension the springs.
6. Strike the dowel pin (7) in.
 This increases the pre-tension of the return springs
(6).
7. Make sure the return springs have sufficient pre-
tension. The tiller should move automatically to the
horizontal position.
8. If necessary increase the pre-tension of the return
springs further.
9. After adjusting, grease the return springs (4) (for
lubricant see page 28).
10. Assemble all the panels.
11. Test the truck's brakes.
WT 3000 Series
Rev. B
310
STEERING
REPAIRING CONTROL HANDLE RETURN SPRINGS
Replacing the return springs Pre-assembling the return springs

1. Push the return springs (4) with the spacer ring (5)
onto the shortened axle (8). The inner, angled end
of the return springs should enter the groove of the
WARNING shortened axle (8) in the process.
Risk of injury from pre-tensioned springs. Note: Note that the shortened axle (8) moves with the
Pre-tensioned springs can snap off with extreme force. axle (6). The return springs are pushed onto the axle
 Be particularly careful when handling springs and (6) at the same time. When inserting the axles make
wear protective goggles. sure the grooves are positioned accordingly (see Fig.
86).
Return spring assembly
Return spring removal
2. Insert the pre-assembled return springs (4) with
1. Remove the covers (see page310).
the tiller into the tiller knuckle (9).
3. Insert the axle (6) from the left hand side and make
3. Remove the dowel pin (7). sure that the position of the groove corresponds to
 The axle (6) turns and the return springs (4) are the groove of the shortened axle (8).
discharged. 4. Strike in the axle (6) carefully and drive out the axle
4. Set the tiller all the way down to fully discharge the (8).
return springs (4).  The return springs are pushed onto the axle (6) in
Note: If the axle is jammed, turn it approx. 20 degrees the process.
clockwise with a fork wrench in order to discharge the
Return spring pre-tension adjustment
return springs.
5. Drive out the axle (6) from the right hand side.
6. Starting from the neutral position of the return
6. Remove the return springs (4).
springs, turn the axle (6) 90 degrees using a fork
Return spring assembly wrench and increase the pre-tension of the return
springs.
7. Strike the dowel pin (7) in.
7 4 8. Make sure the return springs have sufficient pre-
tension.
 The tiller should move automatically to the upright
position.
6 8 9. If necessary increase the pre-tension of the return
springs further.
10. After adjusting, grease the return springs (4) (for
lubricant see page 28).
11. Assemble all the panels.
12. Test the truck's brakes.
9
Fig. 86 Return spring assembly
8 Shortened axle
9 Tiller knuckle
Tools required:
Shortened axle (8) on which the return springs can be
pre-assembled. The axle must be shorter than 119 mm
so that it can be inserted with the tiller in the tiller
knuckle (9).
WT 3000 Series
Rev. B
311
STEERING
REPAIRING THE TILLER HANDLE
Repairing the Tiller Handle
Fig. 87 Main tiller handle components
1 Switch unit 4 Tiller tube

2 Hand grip 5 Upper shell
3 Lower shell
WT 3000 Series
Rev. B
312
STEERING
Replacing the tiller handle shells

2 2
WARNING
 Lower the forks to the ground. 3
 Switch the truck off. 3
Shell removal
Fig. 89 Switch unit removal

2. Press the thumb markings (3) or pull on the thumb-
wheels (2).
 The switch unit will slide up out of the bottom shell.
3. Remove the tiller wire harness plug connections
and the horn buttons from the PC boards.
1 4
Fig. 88 Shell removal

1. Remove the screws (1).
Fig. 90 Cover removal

4. Lever off the covers (5) on each hand grip.
WT 3000 Series
Rev. B
313
STEERING
5 7
8
7
Fig. 91 Horn switch disassembly
5. Carefully push the horn switch (5) in and pull it off 9
the grip.
6. Remove the connector (5) from the horn switch.

8. Remove the screws (7) and (9).
9. Remove the shells (8).
Shell assembly
Note: Assembly of the shells is the reverse order of
disassembly. Take care not to damage the wiring.
1. After assembly, connect the battery and test all the
functions of the tiller handle.
6
Replacing the switch unit
The switch unit contains the:
Fig. 92 Grip removal
• Brake switch
7. Remove the screws (6) and pull off the grips. • Travel switch / traction potentiometer
• “Rabbit/turtle” toggle module
• Main PC board
Hydraulic PC board (lift / lower switches)
• Initial lift switch
Note: Replacing any of these components requires the
entire switch unit to be replaced.
WT 3000 Series
Rev. B
314
STEERING
Switch unit removal Switch unit assembly

the following:
1. Re-connect the tiller wire harness and horn wiring
to the PC boards.
Replacing the “rabbit/turtle” toggle

module
There are no parts of the toggle module (HSS) that can
be repaired. It must be replaced as a complete unit.
1
CAUTION
Use of the wrong toggle module can damage the
truck
1 The module is available as either a standard or a cold
store version.
 Make sure you use the right module.

Toggle module removal
2 2
3
1
3
Fig. 96 “Rabbit/turtle” toggle module

1. Remove the switch unit (see page 315).
Fig. 95 Switch unit removal 2. Remove the screws (2) and take off the toggle
module (1).
2. Press the thumb markings (3) or pull on the thumb-
wheels (2). Toggle module assembly
 The switch unit will slide up out of the bottom shell. Note: Assembly is the reverse of disassembly. Note
3. Remove the tiller wire harness plug connections the following:
and the horn buttons from the PC boards. 1. Re-fit the switch unit (see page 315).
WT 3000 Series
Rev. B
315
STEERING
2. After assembly, connect the battery and test all the Main PC board removal
Replacing the tiller handle PC

boards
The main PC board (Main PCB) and the hydraulic PC
board (HYD PCB) are located in the tiller handle. The
main PC board is the larger of the two. Neither of the
PC boards contains components that can be repaired;
they must be replaced as complete units.
CAUTION
Use of the wrong PC board can damage the truck
This hydraulic and main PC boards are available as ei-
ther standard or cold store versions.
 Make sure you use the right PC boards.
Hydraulic PC board removal 2 1
Fig. 98 Main PC board removal

2. Remove the connector of the potentiometer from
the main PC board.
4. Remove the brake switch connector from the main
PC board (2).
5. Remove the main PC board.
Note: If you cannot reach the connector on the main
1 PC board, remove the thumbwheels, the bottom cover
and the upper shell cover (see "Replacing the Traction
Potentiometer" on page 316).
2
Main PC board assembly
Fig. 97 Hydraulic PC board removal Note: Assembly is the reverse of disassembly. Note
1. Remove the switch unit (see page 315). the following:
2. Remove the screws (2) from the hydraulic PC 1. Re-fit the switch unit (see page 315).
board. 2. After assembly, connect the battery and test all the
3. Remove the hydraulic PC board (1). functions of the tiller handle.
Hydraulic PC board assembly Replacing the traction potentiome-

Note: Assembly is the reverse of disassembly. Note ter
the following:
There are no parts of the traction potentiometer (POT
1. Re-fit the switch unit (see page 315). travel switch) that can be repaired. It must be replaced
2. After assembly, connect the battery and test all the as a complete unit.
WT 3000 Series
Rev. B
316
STEERING
CAUTION
6
Use of the wrong potentiometer can damage the
truck
The traction potentiometer is available as either a
standard or a cold store version.
 Make sure you use the right potentiometer.
Traction potentiometer removal
7
1 1
2
3
7
5
7. Remove the cover (6).
4
Fig. 99 Thumbwheel removal

11
8
Note: Take care not to lose the slide bearings (2) when
removing the thumbwheels (1).
10
3. Extract the thumbwheels (1).
4. Remove the screws (4) while holding on to the low-
ering switch cap (5).
5. Remove the lowering switch cap (5).
Fig. 101 Traction potentiometer removal

9. Remove the connectors from the PC boards.
10. Remove the traction potentiometer (8) from the
square axle.
WT 3000 Series
Rev. B
317
STEERING
Traction potentiometer assembly

Note: Assembly is the reverse of disassembly. Note 6
the following:
1. Fill the socket (10) with grease (part no. 053002-
005).
Note: The socket (10) must only be filled with grease
(part no. 053002-005). Do not use any other type of
grease.
2. Re-fit the switch unit (see page 315).
functions of the tiller handle. 7
Replacing the brake switch (BRS)

Remove the brake switch (BRS)
1 1
2
7

3 7. Remove the cover (6).
5
9
10
4
8
Fig. 102 Thumbwheel removal
Note: Take care not to lose the slide bearings (2) when 11
removing the thumbwheels (1).
3. Extract the thumbwheels (1). 12
4. Remove the screws (4) while holding on to the low-
ering switch cap (5).
5. Remove the lowering switch cap (5).
Fig. 104 Removing the brake switch
8. Remove the screw (8).
9. Remove the switch bypass (12).
11. Disconnect the micro switch (9) from the main PC
board.
12. Take off the brake switch (10).
WT 3000 Series
Rev. B
318
STEERING
BRS switch assembly

the following:
1. Fill the socket of the micro switch cable (9) with
grease (part no. 053002-005).
Note: The socket should only be filled with grease (part
no. 053002-005). Do not use any other type of grease.
2. Re-fit the switch unit (see page 315).
Replacing the grips and horn switch

Note: Refer to page 313 for the removal and assembly
of the grips and horn switch.
WT 3000 Series
Rev. B
319
Notes:
320
LIFTING MECHANISM
321
Notes:
322
LIFTING MECHANISM
CHECKING AND ADJUSTING THE FORK HEIGHT (LOWERED)
Checking and Adjusting the

WARNING
Fork Height (Lowered)
This adjustment sets the fork height so that the lowered Risk of trapping and severing of limbs from acci-
forks can be easily inserted in a pallet. dental fork lowering
The forks can accidentally lower when working on a
Requirements powered up truck with a connected battery.
Note: To check and adjust the fork height the truck cedures before starting any operations underneath
must be parked unladen on an even surface (evenness raised forks:
≤1 mm).
 Lower the forks onto a wooden wedge before
Checking the stop reaching underneath them.
2. Push the wooden block under the forks to prevent

them from lowering.
3. Loosen the nuts (2) on the tie rods (1).
4. Turn the hex. bolt on the tie rods (1) to adjust them
so that when the forks are fully lowered the stop
points of the riser (1, Fig. 105) make slight contact
with the stop points of the forks (2, Fig. 105).
2
Fig. 105 Adjusting the stops

1 Riser stop point
2 Fork stop point
1. Fully lower the forks. 89

-4
mm 85 ±2mm
 The stop points of the riser (1) should just make
contact with the stop points (2) on either side. If
not, then adjust the stop.
Adjusting the stop Fig. 106 Permissible fork heights

Note: Unless otherwise specified, the following item 5. Tighten the nuts (2) on the tie rods (1).
numbers refer to Figure 107, page 324.
Measuring the fork height
1. Raise the forks so that the tie rods (1) can be
reached. 1. Fully lower the forks.
2. Measure the fork height directly above the load
wheels.
 The height should measure 85±2 mm.
3. Measure the fork height at the back wall.
 The fork height on the fork shank may be 85 -4
mm, but no less than the fork height above the
load wheels.
If both measurements are within range, the fork height
is set correctly.
WT 3000 Series
Rev. B
323
LIFTING MECHANISM
CHECKING AND ADJUSTING THE FORK HEIGHT (LOWERED)
Fig. 107 Lifting mechanism
WT 3000 Series
Rev. B
324
LIFTING MECHANISM
ADJUSTING THE LIFT LIMIT CUTOUT AND FORK HEIGHT (RAISED)
Adjusting the Lift Limit Cutout

and Fork Height (Raised)
If the lift limit cutout is set correctly, the fork lift height
will automatically adjust to the correct height.
With this adjustment the lift limit switch LMS1 is set so
that:
1
• The lift is not mechanically restricted by the stop of
the lifting mechanism
• A fork lift height of 125 ±5 mm is achieved 2
Adjusting the lift limit cutout

Note: To check and adjust the lift limit cutout the truck
must be parked unladen on an even surface (evenness
≤1 mm). 4
Preparing the truck
3
2. Disconnect the battery and prevent the truck from
3. Remove the side restraint or rear entry platform if
applicable.
4. Remove the covers and the right side section.
 The lift limit switch becomes accessible.
Fig. 108 Lift limit switch LMS1 and associated components

WARNING 1 Angle
2 Casting on lift mechanism
Risk of trapping and severing of limbs from acci-
dental lift activation 3 Cam switch
Lifting can be activated accidentally when working on a 4 Lift limit switch (LMS1)
powered up truck with a connected battery.
cedures before working on or near the lift limit switch:
 Be particularly careful if you need to carry out a
work step with the truck switched on. In this case
switch the truck off again as soon as you are fin-
ished.
WT 3000 Series
Rev. B
325
LIFTING MECHANISM
ADJUSTING THE LIFT LIMIT CUTOUT AND FORK HEIGHT (RAISED)
Adjusting the lift limit cutout 6. Move the bracket with the lift limit switch until the
status of the LMS1 switch in the Analyzer menu
just changes from ON to OFF.
Note: If the distance in the elongated holes is insuffi-
cient, the cam switch (3, Fig. 110) can be moved down
B
slightly.
7. Screw on the angle making sure you do not move
it.
8. Lower the forks and lift them up again as far as the
stop. Check gap A again.
Note: The casting (2, Fig. 110) must not touch the
4
chassis (1).
3
9. Repeat steps 6 to 8 until gap A is achieved. Now
check the fork lift height.
Checking the fork lift height

Note: To check the fork lift height the truck must be
parked unladen on an even surface (evenness ≤1 mm).
Fig. 109 Gap B between LMS1 and cam switch Checking the height of the raised forks
1. Using a feeler gauge set the gap B between the lift 1. When the lift limit cutout has been set correctly,
limit switch LMS1 (4) and the cam switch (3) to measure the height of the raised forks. It should be
1 mm. 125 ±5 mm.
1
A
125±5 mm
Fig. 111 Fork height raised

Fig. 110 Gap A
2. Push the bracket (1, Fig. 108) up and fasten it tem-
porarily.
3. Activate lifting until the casting (2, Fig. 110) con-
tacts the chassis (1).
4. Lower the forks until the gap A ~ 5 mm (see
Fig. 110).
5. Select the Analyzer menu in the display and scroll
through to item A2.2.6 (LMS1 SWITCH) (see
page 253).
WT 3000 Series
Rev. B
326
LIFTING MECHANISM
FORKS
Forks
General
The forks must be checked by trained personnel for 1
cracks, damage and wear in accordance with the main-
tenance schedule.
Note: If the forks are used to transport abrasive loads
the inspection must be carried out at shorter intervals.
Fork inspection
WARNING
Falling loads can cause injury
If a fork breaks under load it can fatally injure you or
other people.
 Never carry out repair welding to cracks, damaged
or worn parts around the heel of the fork.
 Forks must only be repaired by the fork manu- Fig. 112 Welding seams between forks and fork carriage
facturer.
Checking forks for cracks

Checking forks for cracks
1. Visually inspect all fork surfaces for cracks.
2. Check the welding seams (1, Fig. 112) between
the forks, fork carriage and fork shank for cracks.
Note: Use a non-destructive crack test procedure (dye
penetrant or Magnaflux ® process), if you are unsure
whether there are any cracks.
 Replace the forks if any cracks are detected.
WT 3000 Series Rev.2 05/2012

Rev. B
327
Notes:
328
CYLINDERS
329
Notes:
330
CYLINDERS
REPAIR TOOLS
Repair Tools Producing extractors

1. Hard solder a self-tapping 4mm screw (3) onto the
shaft (min.150 mm, long, max. Ø 4 mm) of a screw-
CAUTION driver (1).
Cylinder surfaces can be damaged through the use 2. Sand the soldering joint.
of unsuitable tools. 3. Wrap insulating tape (1) around the shaft and sol-
 Do not use a screwdriver or similar tools. dering joint of the screwdriver.
 Use burr-free tools made of soft metal (brass, alu- Groove aligning arbor for small rod
minium) without sharp edges or a suitable plastic.
seals
You must produce the following tools yourself: The outer diameter of the groove aligning arbor must fit
the internal diameter of the cylinder cap.
Small hook The arbor should end flush with the bottom of the seal
seat.
Use small hooks to remove small seals (see Fig. 113).
1
2
Fig. 115 Groove aligning arbor in a cylinder cap

1 Cylinder cap
Fig. 113 Hanger 2 Seal seat
Extractor 3 Groove aligning arbor
Two extractors to remove rod seals (see Fig. 114)

.
Fig. 114 Extractor
WT 3000 Series Rev.\x11 1 03/2013

Rev. B
331
CYLINDERS
REPAIR TOOLS
Assembly devices for large rod

seals
Produce a tool body (12, Fig. 116) with a diameter to
match the internal diameter of the cylinder caps.
3
4
Fig. 116 Assembly device for large rod seals

1 Tool body
2 Fixed pin
3 Rod seal (shown for illustration purposes only)
4 Axial moving pins
Protective mechanisms
If the seal has to be pushed over sharp edges, cracks
or nicks, use appropriate plastic protective mecha-
nisms.
Rev.\x11 1 03/2013 WT 3000 Series

Rev. B
332
CYLINDERS
ROD SEAL REMOVAL AND ASSEMBLY
Rod Seal Removal and Assem-

bly 1 2
Removing a large rod seal 3

1. Turn one extractor (see Fig. 114) respectively into
the opposite parts of the rod seal. 4
2. Pull the seal out of its seat using the grips of the
tools.
3. Dispose of the rod seal.
Removing a small rod seal 5

1. Using a small hook (see Fig. 113) pull the rod seal 6
out of the seal seat.
2. Dispose of the rod seal.
Inserting a large rod seal

1. Apply a thin coating of hydraulic oil to the rod seal Fig. 118 Wound rod seal
and the seal seat in the cylinder cap.
5. Push the tool body (1, Fig. 5) into the cylinder cap
2. Place the rod seal over the fixed pin (1, Fig. 117).
(2) until the rod seal (6) is aligned with the seal seat
3. Bend the rod seal under the pin (2). in the cylinder cap.
4. Now bend the resultant loop up so that the pin (3) 6. Retract the pin (1, Fig. 119).
can be moved into the loop.  One segment of the rod seal jumps into the seal
seat.
Fig. 117 Threading the rod seal
Fig. 119 The first rod seal segment is located in the seal seat.
7. Retract the pin (2, Fig. 119).
 The rod seal is now fully located in the seal seat
(see Fig. 120)
WT 3000 Series Rev.\x11 1 03/2013

Rev. B
333
CYLINDERS
ROD SEAL REMOVAL AND ASSEMBLY
Rod seal assembly, sealing lip first

The sealing lip is sensitive and must not be damaged.
Special protective sleeves (1) are required when push-
ing the seal (2, Fig. 122) over the thread and holes.
CAUTION
Incorrectly assembled rod seals will leak
 Fit the rod seal with the sealing lip facing the pres-
sure side.
3
1 2
Fig. 120 Rod seal fully inserted in seal seat
4
8. Pull the tool body out of the cylinder cap.
Fitting a small rod seal

6
1
5
2
3
Fig. 122 Sealing lip facing the pressure side
4 1 Cylinder tube
2 Inner thread
3 Protective sleeve for assembly
4 Rod seal
5 Sealing lip
6 Backring
Fig. 121 Small rod seal assembly

1. Apply a thin coating of hydraulic oil to the rod seal
(2, Fig. 121) and the seal seat (3) in the cylinder
cap.
2. Place the cylinder cap on the groove aligning arbor
(4).
3. Gently bend the rod seal (2) together.
4. Place one part of the rod seal into the seal seat (3).
5. Press the rod seal into the seal seat using a burr-
free aluminium or plastic arbor (5).
Rev.\x11 1 03/2013 WT 3000 Series

Rev. B
334
CYLINDERS
CYLINDERS AND CYLINDER OPERATION
Cylinders and Cylinder Opera- Hydraulic system with lift cylinders

tion and traction cylinder
All trucks offer 2 lift cylinders as standard. These come
in two versions, depending on the fork length (see parts
manual).
Trucks with the Traction Control® System also have a
hydraulic cylinder (traction cylinder) to control the con-
tact pressure of the drive wheel. 1
Hydraulic system with lift cylinders
1 2
3
20 - 24 Nm
20 - 24 Nm
Fig. 124 System with Traction Control System

1 Traction cylinder
2 RH lift cylinder
Fig. 123 Standard system with 2 lift cylinders
3 LH lift cylinder
1 LH lift cylinder
2 RH lift cylinder
WT 3000 Series
Rev. B
335
CYLINDERS
REPLACING THE LIFT CYLINDERS
Replacing the Lift Cylinders Lift cylinder removal
WARNING
High pressure hydraulic oil can cause severe in-
jury
1 Whenever a high pressure hydraulic oil enters the skin
it must be treated as a medical emergency.
mal at first.
2 To avoid accidents:
• Depressurise the hydraulic system before opening
any sections of it.
• Tighten all connections before pressurising the sys-
3 tem.
• Keep hands and body away from pressurised fluid.
• Always trace leaks with a piece of paper or card-
board.
4 Note: The procedure is identical for the left and right lift
cylinders.
Preparation and loosening the top mounting
1. Take off the motor compartment panel.
2. Fully lower the forks.
3. Pull the clamp (1) off the top mounting.
4. Keep the lowering switch pressed down.
Fig. 125 LH lift cylinder  The weight of the piston ram moves it down and
1 Clamp (top mounting) it is released from the top mounting.
2 Lift cylinder  The hydraulic system is depressurised.
3 Hydraulic connection 5. Switch off the truck, jack it up and prevent it from
4 Clamp (bottom mounting) being switched on again.
6. Place a flat tray underneath the truck to collect any
spilled hydraulic oil.
Removing the lower mounting and the hydraulic
connection, taking off the cylinders
7. Undo the hydraulic connections on the cylinders.
Collect any escaping oil.
8. Seal the ports on the connections (cylinder and
hoses) with filler plugs.
9. Remove the bottom cylinder mounting clamp.
10. Lift the cylinders out of the truck.
11. Clean the receptacle of the piston ram and the cyl-
inder base in the truck.
Installing the lift cylinder

1. Lubricate the receptacle of the piston ram and the
cylinder base in the truck.
WT 3000 Series
Rev. B
336
CYLINDERS
REPLACING THE LIFT CYLINDERS
2. Assemble the lift cylinder in the reverse order of

disassembly.
3. Remove the jack from the truck and start up the
truck.
4. To discharge the cylinder raise and lower the forks
until oil flows back to the hydraulic reservoir with-
out any bubbles.
5. Check connections and cylinder for leaks.
6. Check the hydraulic oil level. Add oil if necessary
(for grade see page 28).
WT 3000 Series
Rev. B
337
CYLINDERS
REPAIRING LIFT CYLINDERS
Repairing Lift Cylinders Fitting the lift cylinder

CAUTION
CAUTION Used sealing components can result in leaks

 Always use new components from the seal kit,
Damaged or contaminated seal seats and piston never used ones, for assembly purposes.
rods will result in immediate leaks, even with new
seals. The same applies to the use of unsuitable
1. Apply a thin coat of hydraulic oil to the new guide
tools for seal removal and fitting.
rings (3), new backring (4)(1) and a new rod seal
 Before fitting a new seal check the seal seats and
(5).
piston rods for damage and make sure they are
clean. 2. Insert the above-mentioned parts carefully in the
cylinder tube, starting with the bottom bearing ring
 When replacing rod seals use assembly equipment
(3). Fit the rod seal (5) with the sealing lip first.
and tools made of soft metal or plastic without sharp
Then place a bearing ring (4) on it, if one was fitted
edges. Suitable tools and assembly procedures are
previously.
described starting on page 331.
3. Apply a generous amount of hydraulic oil to the pis-
 Do not re-use sealing elements that have been re-
ton rod and carefully insert it into the cylinder tube
moved.
without twisting. Take care not to damage the
seals in the process.
Preparation 4. Push a well oiled deflector ring (2) over the piston
1. Remove the lift cylinder (see page 336). rod and push it into the seat in the cylinder tube.
Lift cylinder disassembly  The lift cylinder is repaired and ready for assembly.
1. Pull the piston ram (1) off the cylinder tube (6). Final tasks
2. Using suitable tools (see page 331) remove the 1. Assemble the lift cylinder (see page 336).
wiper ring (2), the guide rings (3), the backring
(4)(1) and the rod seal (5) from their seats in the
cylinder tube (6).
3. Dispose of parts 2 to 5.
4. Thoroughly clean the cylinder tube (6) and piston
ram (1) and apply dry compressed air to them.
 The cylinder is now dismantled and can be
checked for damage.
Checking the cylinder tube and piston rod
1. Check the seats for the seal and guide elements in
the cylinder tube (6) for damage. Make sure they
are clean. If a seat is damaged, dispose of the cyl-
inder tube.
2. Check the piston rod for damage. Dispose of the
rod if you find any grooves, corrosion pitting or
scoring.
3. Apply a thin layer of hydraulic oil to the piston rod
and bare surfaces on the cylinder tube.
 The cylinder tube and piston rod are protected
against corrosion and are prepared for assem-
bly.
1). Not available on all models.
WT 3000 Series
Rev. B
338
CYLINDERS
REPAIRING LIFT CYLINDERS
Fig. 126 Lift cylinder
WT 3000 Series
Rev. B
339
CYLINDERS
REPLACING THE TRACTION CYLINDER
Replacing the Traction Cylinder

Removing the traction cylinder 2
WARNING 1
High pressure hydraulic oil can cause severe in-

jury
Whenever a high pressure hydraulic oil enters the skin
it must be treated as a medical emergency.
mal at first.
To avoid accidents:
• Depressurise the hydraulic system before opening
Fig. 127 Connector plate
any sections of it.
• Tighten all connections before pressurising the sys- 6. Remove the screws (1) and push the connector
tem. plate (2) and connectors slightly to the side.
• Keep hands and body away from pressurised fluid. Discharging the drive cage springs
• Always trace leaks with a piece of paper or card-
board.
WARNING
Preparation Pre-tensioned springs can cause injury
1. Fully lower the forks and hold down the lower Pre-tensioned springs can snap off with extreme force.
switch for another 5 seconds.  Be particularly careful when handling springs and
 The hydraulic system is depressurised. wear protective goggles.
prevent it from being switched on again.
3. Jack up the truck and prevent it from being
switched on again.
1 2
4. Place a flat tray underneath the truck to collect any
spilled hydraulic oil.
Removing the panel and connector plate
5. Remove the panel and instrument cover.
Fig. 128 Bushing bracket

7. Remove the grease nipple (2) and the 4 mounting
screws (1) from the top bushing bracket.
 The spring will push the bushing bracket up and
discharge itself in the process.
 The traction cylinder can now be removed (see
Fig. 129).
WT 3000 Series
Rev. B
340
CYLINDERS
REPLACING THE TRACTION CYLINDER
Adjusting the cylinder
1 2
3
4
5 2
1
0 mm
6
Fig. 130 Adjusting the traction cylinder

Fig. 129 Traction cylinder
4. Insert the cylinder so that the collar on the cylinder
1 Hydraulic connection union nut (1) is at the same level as the top of the base plate
2 Fitting (2) (see Fig. 130).
3 Hex. bolt on cylinder tube (SW 32) 5. Screw in and tighten the fitting (2, Fig. 129).
4 Square nut, M42 6. Connect the hydraulic line and tighten the union
5 Cylinder tube with external thread, M42 nut (1, Fig. 129).
6 Piston ram
Pre-tensioning the drive cage
7 Receptacle
Removing the traction cylinder

WARNING
1. Remove the union nut (1) from the fitting (2) and
turn the hydraulic line slightly to the side. Pre-tensioned springs can cause injury
2. Seal the line with filler plugs. Pre-tensioned springs can snap off with extreme force.
3. Unscrew the fitting (2) and seal the bore in the cyl-  Be particularly careful when handling springs and
inder with filler plugs. wear protective goggles.
4. Place a wrench (SW 32) on the hex. bolt and screw
the cylinder up out of the square nut. 7. Push the bushing bracket down while pre-tension-
Note: Hold the square nut tight to prevent the cylinder ing the springs.
from being removed in full. The nut lies loosely with one 8. Fix the bushing bracket with 4 screws (1, Fig. 128).
side in a recess in the back wall to prevent it from twist- 9. Insert the grease nipple (2, Fig. 128).
ing.
Final tasks and cylinder discharge
5. Remove the square nut and cylinder from the
truck. 10. Remove the jack from the truck and start up the
truck.
6. Clean the bore of the receptacle (7).
11. To discharge the cylinder open the union nut (1,
Traction cylinder assembly Fig. 129) carefully until oil emerges without bub-
bles, then tighten it.
Cylinder assembly 12. Check connections and cylinder for leaks.
1. Grease the end of the piston ram. 13. Attach the connector plate and connectors.
2. Push the square nut into the recess in the back 14. Check the hydraulic oil level. Add oil if necessary
wall, narrow side first, and hold it securely. (for grade see page 28).
3. Insert the cylinder into the square nut from the top. 15. Fit the panel and instrument cover.
WT 3000 Series
Rev. B
341
CYLINDERS
REPAIRING THE TRACTION CYLINDER
Repairing the Traction Cylinder 2. Insert the above-mentioned parts carefully in the
cylinder tube, starting with the bottom guide ring
The following item numbers refer to Fig. 131. (2). Fit the rod seal (3) with the sealing lip first.
3. Apply a generous amount of hydraulic oil to the pis-
ton rod and carefully insert it into the cylinder tube
CAUTION without twisting. Take care not to damage the
Damaged or contaminated seal seats and piston seals in the process.
rods will result in immediate leaks, even with new 4. Push a well oiled deflector ring (4) over the piston
seals. The same applies to the use of unsuitable ram and push it into the seat in the cylinder tube.
tools for seal removal and fitting.  The traction cylinder is repaired and ready for as-
 Before fitting a new seal check the seal seats and sembly.
piston rods for damage and make sure they are
Final tasks
clean.
1. Assemble the traction cylinder (see page 341).
 When replacing rod seals use assembly equipment
and tools made of soft metal or plastic without sharp
edges. Suitable tools and assembly procedures are
described starting on page 331.
Preparation
1. Disassemble the traction cylinder (see page 340).
Disassembling the traction cylinder
1. Pull the piston ram (5) off the cylinder tube (1).
2. Using suitable tools (see page 331) remove the
wiper (4), the rod seal (3) and the guide rings (2)
from their seats in the cylinder tube (1).
3. Dispose of parts 2 to 4.
4. Thoroughly clean the cylinder tube (61) and piston
ram (5) and apply dry compressed air to them.
 The cylinder is now dismantled and can be
checked for damage.
Checking the cylinder tube and piston rod
1. Check the seats for the seal and guide elements in
the cylinder tube (1) for damage. Make sure they
are clean. If a seat is damaged, dispose of the cyl-
inder tube.
2. Check the piston ram (5) for damage. If there are
signs of pitting, corrosion marks or scratches, dis-
pose of the piston ram.
3. Apply a thin layer of hydraulic oil to the piston rod
and bare surfaces on the cylinder tube.
 The cylinder tube and piston rod are protected
against corrosion and are prepared for assem-
bly.
Fitting the traction cylinder
1. Apply a thin coat of hydraulic oil to the new guide
rings (2) and a new rod seal (3).
WT 3000 Series
Rev. B
342
CYLINDERS
REPAIRING THE TRACTION CYLINDER
Fig. 131 Traction cylinder
WT 3000 Series
Rev. B
343
Notes:
344
PLATFORM
345
Notes:
346
PLATFORM
ADJUSTING THE FOLDING PLATFORM SWITCH
Adjusting the Folding Platform Checking and adjusting switch

Switch PLS1 for rider mode
Pre-tensioning the spring assembly

2
1
2
1
Fig. 133 Panel removal

1 Bolts
2 Panel
Testing switch PLS1

3 1. Remove the four bolts (1) and take off the panel
(2).
Fig. 132 Pre-tensioning the spring assembly 3 4

1 Screw
2 Counternut
3 Spindle (located on the inside)
1. Remove the front cover from the motor compart-

ment.
2. Fold the platform out approx. 45 degrees.
5
3. Adjust the spindle (3) with the bolt (1) to produce a
distance of 1.5 mm to 2.0 mm from the top of the
spindle to the block (see Fig. 132).
Fig. 134 Checking switch PLS1
4. Using a flat iron (t = 15 mm) jam the bottom end of
3 Switch PLS1
the spindle (3) and fix the position with the counter-
4 Screw
nut, applying a torque of 20 - 25 Nm.
5 Screw
2. Fold the platform down and apply gentle pressure

to it.
 The LED on switch PLS1 (3) should light up.
 When the platform is discharged the LED on the
switch (3) should go out.
Note: If not, the switch must be adjusted.
Adjusting switch PLS1
1. Loosen the two M10 screws (4, 5) on the inside
and outside of the chassis.
WT 3000 Series
Rev. B
347
PLATFORM
ADJUSTING THE FOLDING PLATFORM SWITCH
2. Move the bracket of the switch so that the LED of

switch PLS1 lights up when gentle pressure is ap-
plied to the platform.
3. Torque the screws (4,5) to 20 - 25 Nm.
Adjusting switch PLS2 for pedes-

trian mode
Testing switch PLS2
1. Remove the cover from the platform (see Fig. 133).
3
1
Fig. 135 Checking switch PLS2

1 Lever arm
2 Switch PLS2
3 Screw
1. Raise the platform to full extension.

 The LED on switch PLS2 (2) should light up.
Note: If not, the switch must be adjusted.
Adjusting switch PLS2
1. Raise the platform to full extension.
2. Loosen both screws (3).
3. Using a feeler gauge, adjust switch PLS2 (2) to
produce a 2 mm gap from the lever arm (1).
 The LED on switch PLS2 should light up.
4. Torque the two bolts (3) on switch PLS2 (2) to 1 to
2 Nm.
WT 3000 Series
Rev. B
348
PLATFORM
REPLACING THE FOLDING PLATFORM SPRINGS
Replacing the Folding Platform

Springs
Spring removal 5
6
8 7 6
1
Fig. 138 Spring removal
5 Dowel pin
6 Screw
7 Bracket
Fig. 136 Panel removal 8 Axle (located on the inside) and pipe
1 Bolts
3. Loosen the screws (6) of the bracket (7) and re-
2 Panel
move the complete platform. Note the wiring.
1. Remove the four bolts (1) and take off the panel 4. Remove the dowel pin (5).
(2).
5. Take out the axle (6) from the right.
Note: Make sure that the two flanged sleeves support-
ing the axle (8) do not get lost.
Spring assembly
4
the following:
1. If necessary replace the two flanged sleeves sup-
3 porting the axle (8).
2. After assembly, tension the spring (3) with the
screw (4).
Fig. 137 Discharging the springs

3 Spring
4 Screw
WARNING
Risk of injury from pre-tensioned springs
Pre-tensioned springs can snap off with extreme force.
 Be particularly careful when handling springs and
wear protective goggles.
2. Remove the screw (4) to discharge the spring (3).
WT 3000 Series
Rev. B
349
Notes:
350
SCHEMATIC DIAGRAMS
351
Notes:
352
SCHEMATIC DIAGRAMS
WIRE COLOUR CODE
Wire Colour Code • The last two digits are a sequence number.
Note: Third party component wires may pose an ex-
The wires used in the truck are colour-coded and num-
ception to this rule:
bered according to their function:
• The first or first two digits designate the wire colour.
Abbreviation Colour Colour number Function
BLK Black 0 ** Digital signal

BRN Brown 1 ** Analog signal
RED Red 2 ** Positive not switched
ORG Orange 3 ** +12 VDC transformer
YEL Yellow 4 ** Third DC transformer
GRN Green 5 ** Negative not switched
BLU Blue 6 ** Negative, insulated
VIO Violet 7 ** +5 VDC transformer
GREY Gray 8 ** Fourth DC transformer
WHT White 9 ** Miscellaneous
RED/WHT Red/White 29 ** Positive switched
GRN/WHT Green/White 59 ** Negative switched
** Numbers 01 to 99
WT 3000 Series Rev.3 05/2014

Rev. B
353
SCHEMATIC DIAGRAMS
GENERAL CONTACT SYMBOL ABBREVIATIONS
General Contact Symbol Abbre-

viations
Note: If one of the above abbreviations is used more
than once, a number extension will be used, e.g. SV1,
SV2 etc.
Abbrevia- Description Abbreviation Description (Sheet 1 of 2)

tion
K Relay LMS Limit switch

ACS Travel switch LOS Lower switch
AXS Accessories switch ORS Override switch
BRS Brake switch POT Potentiometer
DIS Direction switch RA Raise potentiometer
DRS Door switch RAS Raise switch
EDS Emergency power disconnect REA Reach potentiometer
EM Encoder module RS Reverse switch
ENC Encoder SAS Safety Reverse Switch
FS Forward switch SDS Start switch
HBS Handbrake switch SES Seat switch
HNS Horn switch SSS Sideshifter switch
HSS Rabbit/Turtle toggle switch THS Thermal switch
KYS Key switch TLT Tilt switch
LGS Light switch WAS Walk-along / pedestrian mode switch
BV (AK) Battery voltage after the key switch M2 (PM) Pump motor
BDI Battery Discharge Indicator MRC Control module
BR Brake OHGD Overhead guard display
BWI Brush wear display P Pump contactor
CA Cable connection PC Plug connection
F Field coil connection PCB Printed circuit board
FAN Fan SF Shunt field
FU Fuse STI Steering wheel indicator
HN Horn SV Solenoid valve
IFD Information display TB Terminal block
JC Socket = counterpart to PC TMM Truck management module
LINE Main contactor TT Hourmeter
M1 (TM) Traction motor VMN Motor driver (volt motor negative)
GPCSR Safety switch - RH side restraint GCSL Safety switch - LH side restraint
Rev.3 05/2014 WT 3000 Series

Rev. B
354
SCHEMATIC DIAGRAMS
GENERAL CONTACT SYMBOL ABBREVIATIONS
Abbrevia- Description Abbreviation Description (Sheet 2 of 2)

tion
PLS Platform switch TCM Traction motor

PS Pressure switch HR Heating
HCM Hydraulic control module ALM Travel Alarm
RECEIVER Receiver TRANSMITTER Transmitter
BDI Combination instrument CHARGER On-board charger
BRK Electromagnetic brake DR Driver
SLS Sideshift left switch SRS Sideshift right switch
ECS Lift control switch --- ---
WT 3000 Series Rev.3 05/2014

Rev. B
355
SCHEMATIC DIAGRAMS
ELECTRICAL WIRING DIAGRAMS
Electrical wiring diagrams
Europe USA Description Europe USA Description
Cable connection Switch applied manually
Wires crossing Solenoid valve
Wire connection Throttle / coil
Plug / socket Resistor
Wire strap Capacitor
Terminal board Potentiometer
Fuse Varistor
V
Assembly Thermal protector
Contact, normally Lamp

open
Contact, normally Horn

closed
Selective switch Battery
Contactors/relays Diode
Slow release contac- Breakdown diode

tor / relay
Time delay contactor LED

/ relay
Switch, normally Transistor

open
Rev.3 05/2014 WT 3000 Series

Rev. B
356
SCHEMATIC DIAGRAMS
ELECTRICAL WIRING DIAGRAMS
Europe USA Description Europe USA Description
Push button, me- MOSFET

chanically actuated
Pushbutton, hydrau- Thyristor

lically actuated
Emergency power Comparator

disconnect
Motor armature Hall sensor
WT 3000 Series Rev.3 05/2014

Rev. B
357
Notes:
358
+BV
Fig. 139
+BV (AK)
F/C 4 6
TILLER
WT -M, without CAN Tiller, ABM Motor, Keyless Power-Up
16x //R HANDLE

PF
FF
POT1
9 3 3
SAS/
BRS1
HNS 1
HNS 2
+BV
3 2 3
CA 202 F/C F/C HSS1 F/C
K1 RAS LOS
2x //R
86 + 30
15x //R
4 4 4
15x //R
K1 ACCESS 1 120 Ohm 6 6 6

1
+ BV (AK)
85 - 87 (DISPLAY) MAIN HYDR.
-K1 PCB R/T PCB PCB
2 4 9 8 CA 410 CA 414 CA 415
CAN-L
CAN-H
-B -B
+13,8V
CA 214 GND
PLS1/
1 FPS1
A 1 GND
2 CA 208 B
C PNP 10
3 B CA 210
1
4 C 1
NPN
A LMS1
5 -B A
SR2
+13,8V
CAN CONNECTION
6 PNP C
PLS2/
FTS1&2 CA 203 B
3 SR1
1 A
6 8 FLS BRS 1 A
NPN
11 PNP C C -B
CA 211 B
CA 222 1 2
CA 207 B
6 7
-B
GND
UNUSED
UNUSED
UNUSED
CA 216 1 2
6
1
7
11
10
23
34
33
27
28
35
16
15
31
32
17
20
19
29
18
21
CA 209 CA 209
6
ALM 8
HN
26 ACCESS 3/2
SV 24 (TCM/HCM)
CA 217
FAN
PWS
TS1
9
GND
+13,8V
CHNL A
CHNL B
+B -P U V W -B
1 2
3 CA 209
4
2
5
12
30
22
25
13
14
-B
U V W
TRACTION
FU1 + - MOTOR
FU4 FU2 FU3
355A
WT 3000 Series
4A 4A 4A M2
BRK
M1 -B
+
6
T
PUMP MOTOR
TS1
-
+ ECR1
+13,8V
GND
+13,8V
CHNL B
CHNL A
3
LINE
3 4 1 2 CA 212 5 6
PS
1 P 4
GND
1
+13,8V
2
3 CA 204
EDS
Ax
GND
EDS
BD:1 24V BATT BD:2
1 Shown with truck in standby:

- K1 = Closed
- Without load on forks
- Forks fully lowered
- Platform not occupied
- Side restraints down
- Tiller = upright and centred.
2 Reduced travel speed: HSS open
3 LINE, EDS, RAS, LOS, BRS, SAS and HNS are activated when the
switches are closed.
4 F/C option is activated below 5°C.
5 Index number not used
6 Option
7 Filter for strobe (item no. 822569)
8 Strobe (item no. 127651)
9 SAS for folding platform, BRS1 for fixed platform.
10 PLS1 for folding platform, FPS1 for fixed platform.
11 PLS2 for folding platform, FTS1 & 2 for fixed platform.
824302_2J-1
WT -M, WITHOUT CAN TILLER, ABM MOTOR, KEYLESS POWER-UP
Rev. B
SCHEMATIC DIAGRAMS
359
360
Rev. B
Fig. 140
+BV
+BV (AK)
F/C 4 6
TILLER
16x //R HANDLE
PF
FF
5 SRT
6 POT4
POT1
9 3 3
SAS/
BRS1
HNS 1
HNS 2
SCHEMATIC DIAGRAMS
+BV
3 5 13 14 2 3
RAS LOS
2x //R
15x //R
4 4 4
15x //R
WT -M, without CAN Tiller, ABM Motor, with Key Switch or Keypad
ACCESS 1 120 Ohm 6 6 6

(DISPLAY) MAIN HYDR.
KEYPAD 1 6 PCB R/T PCB PCB
2 4 9 8 CA 410 CA 414 CA 415
CAN-L
CAN-H
-B -B
+13,8V
CA 214 GND
PLS1/
1 FPS1
A 1 GND
2 CA 208 B
C PNP 10
3 B CA 210
1
4 C 1
1 6 NPN
A LMS1
KYS 5 -B A
SR2
+13,8V
CAN CONNECTION
6 PNP C
PLS2/
FTS1&2 SR1 CA 203 B
3
1 A
6 8 FLS BRS 1 A
NPN
11 PNP C C -B
CA 211 B
CA 222 1 2
CA 207 B
6 7
-B
GND
UNUSED
UNUSED
UNUSED
CA 216 1 2
6
1
7
11
10
23
34
33
27
28
35
16
15
31
32
17
20
WT -M, WITHOUT CAN TILLER, ABM MOTOR, WITH KEY SWITCH OR KEYPAD
19
29
18
21
CA 209 CA 209
6
ALM 8
HN
26 ACCESS 3/2
SV 24 (TCM/HCM)
CA 217 FAN
PWS
TS1
9
+13,8V
GND
CHNL A
CHNL B
+B -P U V W -B
1 2
3 CA 209
4
2
5
12
30
22
25
13
14
-B
U V W
TRACTION
FU1
WT 3000 Series
FU4 FU2 FU3 + - MOTOR
355A M2
4A 4A 4A
BRK
M1 -B
+
6
T
PUMP MOTOR
TS1
-
+ ECR1
+13,8V
GND
+13,8V
CHNL B
CHNL A
3
LINE
3 4 1 2 CA 212 5 6
PS
1 P 4
GND
1
+13,8V
2
3 CA 204
EDS
Ax
GND
EDS
BD:1 24V BATT BD:2

- K1 = Closed
3 LINE, EDS, RAS, LOS, BRS, SAS and HNS are activated when the
switches are closed.
5 Index number not used
6 Option
9 SAS for folding platform, BRS1 for fixed platform.
10 PLS1 for folding platform, FPS1 for fixed platform.
824302_2J-2
SCHEMATIC DIAGRAMS
WT -M, WITHOUT CAN TILLER, ABM MOTOR, ACCESS 2/3 POWER AND LOGIC SIDE
WT -M, without CAN Tiller, ABM Motor, Access 2/3 Power and Logic Side
FU4 ACCESS 3/2 (TCM/HCM) 824302_2J-3-4

208 209 CA217-1 PWS 2915 CA211-A PLS2
4A ACCESS 3/2 (TCM/HCM)
201
FU2 206 SOCKET 86 10 2912 2911 RELAY SOCKET PIN 87
207 202 205 CA201-1 CA 209 2913 CA206-2 BRS
4A CA 209 - +
12 5908 LINE 2926 2914 CA210-A PLS1
200.1
201.1
FU3 BRS INPUT 1
2901 2902 CA209-3 + OUT
4A
SMART 2 5909 (WHT/GRN) 302 CA200-5 HANDLE
2903 SV +BV (AK) 3
2900
+ IN + - 303 CA204-2 PS
2904 HN 4 2908 (VIO)
HSS1 INPUT 6 BRK 304 CA208-A SR2
AxEDS 2905 CA213-1
2906 CA216-1 SAS INPUT 7 305 CA207-A SR1
200
2907 CA215-1
unused 33
FU1 25 300 301 (GRAY) 1 RED +13,8V ECR1
+B FAN 9 14 004 (WHT) 3 BLU CHNL B
355A +BV (AK) 10 13 005 (BRN) 4 WHT CHNL A
EDS LINE
FLASHING LIGHT (FLS) 11 5 600 601 (BLU) 2 BLK GND
T
LINE CONTACTOR (LINE/EDS) 12 19 UNUSED 602 (RED) 5 BLK TS1
POT WIPER 15 22 100 (GRN) 6 WHT
+
PLATFORM SENSOR 2 (PLS2) 16 6 2916 CA200-1 HSS1 CA212

BD:1
LIFT SWITCH (RAS) 17 7 2917 CA200-2 SAS/BRS1 603 CA200-4 HANDLE
SIDE RESTRAINT SENSOR 1 (SR1) 18 15 003 CA200-3 HANDLE 604 CA204-1 PS1
605 CA208-B SRS2
UNUSED 19 31 2918 CA200-6 FF
606 CA207-B SRS1
M2 LOWER SWITCH (LOS) 20 32 2919 CA200-7 PF
SIDE RESTRAINT 2 SENSOR (SR2) 21 20 2922 CA200-9 LOS
unused 23 29 2923 CA200-11 HNS1&2
* -
SV 24 17 2921 CA203-1 LMS1
-P HORN (HN) 26 1 2909 (GRAY/PINK) CA206-3 BRS
24V
BATTERY CAN LOW 27 18 002 CA207-C SR1
CAN HIGH 28 21 001 CA208-C SR2
HORN SWITCH 1&2 (HNS1&2) 29 35 2924 CA210-C PLS1
U
ECR1 U FORKS FIRST (FF) 31 16 2925 CA211-C PLS2 902 CA202-8 ACCESS 1 CA214
3 CHNL B
V POWER UNIT FIRST (PF) CAN HIGH 28 900 901 1 CAN
4 CHNL A
1 +13,8V
2 GND
M1 W
V
ALARM (ALM)
32
8 CAN LOW 27 905 906

INLINE CAN
TERMINATION
120 Ohm
2
CONNECTION
W unused 34 30 000 CA204-4 PS 907 CA202-9 ACCESS 1 3

CA 212
FAN 4
TS1 +
PLATFORM SENSOR 1 (PLS1) 35
5
T
9 5906 2 1 2905 5
6
CA213 CA213
6
BD:2 CA 209 8 5905 2 ALM 1 2907
CA215 CA215
+12V
22 TS1
5 GND
34 UNUSED
25 +13,8V
13 CHNL A
14 CHNL B 11 5904
HN
GND 33 UNUSED
FLS
BRN
BLU
26 5903 2904
-B
23 UNUSED 2 1 CA222
PLS2 CA211-B 502 Filter
PN822569
PLS1 CA210-B 501 24 5907 SV 2903 2901 FU3
ACCESS1 CA202-4 503 500 2 1 CA216
HANDLE CA200-12 504 506 KEYPAD 3 2902 2906

LMS CA203-B 505 507 CA217-2 PWS
Fig. 141
WT 3000 Series
Rev. B
361
SCHEMATIC DIAGRAMS
WT -M, WITHOUT CAN TILLER, ABM MOTOR, SENSORS AND PLATFORM SWITCH
WT -M, without CAN Tiller, ABM Motor, Sensors and Platform Switch
Sensors CA 207
Platform switch CA 210 FIXED PLATFORM REAR ENTRY
305 A BRN +13,8V SR1 2914 A WIRE 1 FPS1

Side Foot Presence
606 B BLU GND
Restraint Switch 1
Sensor 1
501 -B ACCESS 2/3 B
(Floor Mat Switch)
Signal NPN 1 2
002 CA209-18 ACCESS 2/3 C BLK 2924 CA209-35 ACCESS 2/3 C WIRE 2
300 CA209-25 ACCESS 2/3 2911 RELAY SOCKET PIN 87
301 CA212-1 ECR
CA 208 2912 CA209-10 ACCESS 2/3
302 CA200-5 HANDLE
304 A BRN +13,8V SR2 2913 CA206-2 BRS1
Side
605 B BLU GND
Restraint 2924 CA205-2 SRT
Sensor 2 CA 211
NPN
2926 LINE COIL
Signal
001 CA209-21 ACCESS 2/3 C BLK 1 2
2915 A BRN +BV(AK) FTS 1
600 CA209-5 ACESS 2/3 Foot Guard
601 CA212-4 ECR 502 B BLU -B Switch 1
602 CA212-5 ECR (Entry Bar Sensor)
603 CA200-4 HANDLE CA 203 Signal PNP
2925 C BLK
2920 CA200-8 RAS A BRN +BV(AK) LMS1 2925 CA209-16 ACCESS 2/3
Lift Limit
505 B BLU -B
Switch 502 -B ACCESS 2/3
Signal PNP
2921 CA209-17 ACCESS 2/3 C BLK
CA 210 FIXED PLATFORM SIDE ENTRY
CA 217 1 SR1 and SR2 are not present on trucks without 2914 A WIRE 1 FPS1
PWS side restraints Foot Presence
209 FU4 OUT 1 Switch 1
501 -B ACCESS 2/3 B
2 Pedestrian mode: SR1 and SR2 are OFF (0 V) (Floor Mat Switch)
507 2 Rider mode: SR1 and SR2 are ON (13.8 V) 2924 CA209-35 ACCESS 2/3 C WIRE 2
500 ACCESS 2/3 3 Fixed platform: SR1 and SR2 replaced by
503 CA202-4 ACCESS1
bridge 825877 on CA207 and CA208. CA 207.1
504 CA200-12 HANDLE 2912 CA209-10 ACCESS 2/3
CA 204
506 KEYPAD
2913 CA206-2 BRS1 2970 A BRN +BV(AK) FTS 1
GND PS Foot Guard
604 1 P
2924 CA205-2 SRT 581 B BLU -B Switch 1
303 2 +13,8V (Entry Bar Sensor)
2926 LINE COIL Signal PNP
2971 C BLK
UNUSED 3
CA 207.2 CA 207.2
Signal STANDARD OPTION
000 CA209-30 ACCESS 2/3 4
2971 A Bridge A BRN +BV(AK) FDS 1
1 Fold Down Step
PC211/JC207 582 B B BLU -B
Sensor 1
CA 210 FOLDABLE PLATFORM
2915 A 2970 Signal PNP
2972 C C BLK
2914 A BRN +BV(AK) PLS1
Platform 502 B 580 CA 207.3 CA 207.3
501 -B ACCESS 2/3 B BLU -B
Sensor 1 STANDARD OPTION
2925 C 2974 2972 A Bridge A BRN +BV(AK) FDS 2
Signal PNP
2924 CA209-35 ACCESS 2/3 C BLK 1 Fold Down Step
583 B B BLU -B
Sensor 2
2911 RELAY SOCKET PIN 87 2925 CA209-16 ACCESS 2/3
CA 211 PNP
2912 CA209-10 ACCESS 2/3 502 -B ACCESS 2/3 2973 C C BLK Signal
2915 A BRN +BV(AK) PLS2

Platform
CA 207.4
Sensor 2
Signal PNP Foot Guard
2925 CA209-16 ACCESS 2/3 C BLK -B Switch 2
583 B BLU
(Entry Bar Sensor)
2913 CA206-2 BRS1
Signal PNP
2924 CA205-2 SRT
2974 C BLK
2926 LINE COIL 1 Fixed platform: FDS1 and FDS2 are replaced by bridge.
824302_2J-5-6
Fig. 142
WT 3000 Series
Rev. B
362
SCHEMATIC DIAGRAMS
WT -M, WITHOUT CAN TILLER, ABM MOTOR, TILLER AND TILLER HANDLE
WT -M, without CAN Tiller, ABM Motor, Tiller and Tiller Handle
Tiller CA 200 Tiller handle CA 411

CA 410 1
2916 CA209-6 HSS1 1 WHT/GRN CA414-3 HSS1 POT
CA207-B 606 2
GRN CA200-12 -BATT 1
CA208-B 605 2917 CA209-7 SAS/BRS1 2 GRAY/PINK CA410-2 SAS/BRS1 3
CA204-1 604 GRAY/PINK CA200-2 SAS/BRS 2 POT PN 812885
CA212-5 602 003 CA209-15 POT WIPER 3 BRN CA410-7 POT WIPER 4
CA212-4 601 PF
YEL CA200-7 PF 3 5
CA209-5 600 603 4 BLU CA410-8 POT LOW FF
6
BLK CA200-6 FF 4
CA209-25 300 302 5 RED/BLU CA410-5 POT HIGH 7
CA212-1 301 RED/BLU CA200-5 POT HIGH 5
+13,8V
CA204-2 303 2918 CA209-31 FF 6 BLK CA410-4 FF CA 412
CA208-A 304 BLU
5961 F/C OPTION 6 3 PN 818731
CA207-A 305 2919 CA209-32 PF 7 YEL CA410-3 PF
1
BRN CA200-3 POT WIPER 7 SAS/BRS1
2920 CA203-A LMS1 8 VIO CA415-4 RAS BLK
2 3
BLU CA200-4 POT LOW 8

2922 CA209-20 LOS 9 PINK CA415-5 LOS CA 413
CA 417
2962 CA415-1 +BV(AK) 9 1
2910 RELAY SOCKET PIN 87 10 WHT CA415-2 +BV(AK) 2
2 HNS1
GRAY CA200-11 HNS 10 1
2923 CA209-29 HNS 11 GRAY CA410-10 HNS 3 2904 HNS PN 811933
1 2
261 F/C OPTION 11
-B 500 504 12 GRN CA410-1 -B 15 x //R 4 2903
CA 419
CA202-4 503 5962 F/C OPTION 12 5 2902 2
CA203-B 505 HNS2
KEYPAD 506 6 2901 1
CA217-2 507 HNS PN 811933

MAIN PCB F/C
CA 201
FU2 OUT 202 205 1 RED CA415-7 +BV F/C CA 415

SOCKET 86 206
UNUSED 2 UNUSED 2962 CA410-9 +BV(AK) 1
UNUSED 3 UNUSED WHT CA200-10 +BV(AK) 2
LINE COIL 2926 UNUSED 4 UNUSED 2961 CA414-1 +BV(AK) 3

CA211-A 2915
VIO CA200-8 RAS 4
CA210-A 2914 RAS LOS
CA209-10 2912 CA 206 PINK CA200-9 LOS 5
SOCKET 87 2911
UNUSED 1 RED 261 F/C OPTION 6 CA 416
2913 (RED/BLU) 2 BLK BRS RED 1 2
RED CA201-1 7 1
15 x //R 1
2
16 x //R
2909 (GRAY/PINK) CA209-1 ACCESS 2/3 3 WHT BLK
5961 F/C OPTION 8 2
UNUSED 4 UNUSED
HYDRAULIC PCB F/C POT PCB F/C
CA 205 CA 414
607 (BLK) CA202-5 DISPLAY 1 2961 CA415-3 +BV(AK) 1 1 F/C option activated below 5°C
1.1 kOhm 2 Option
306 ( PINK) CA202-14 DISPLAY 2 UNUSED 2
HSS1 3 For folding platform SAS, for fixed platform
101 (YEL) CA202-13 DISPLAY 3 WHT/GRN CA200-1 HSS1 3 BRS1
1 2
UNUSED 4 5962 F/C OPTION 4
2 x //R
R/T PCB F/C 824302_2J-7-8
Fig. 143
WT 3000 Series
Rev. B
363
SCHEMATIC DIAGRAMS
WT -M, WITHOUT CAN TILLER, ABM MOTOR, POWER-UP VARIANTS
WT -M, without CAN Tiller, ABM Motor, Power-Up Variants
500 ACCESS 2/3 -B

CA202 504 CA200-12 HANDLE
ACCESS 1 1 UNUSED 505 CA203-B LMS1
(DISPLAY) 507 CA217-2 PWS
2 5900
3 204
4 503
5 607 (BLK) CA205-1
506
GND
6 UNUSED
7 UNUSED
900 CA209-28 ACCESS 2/3
CAN HIGH
8 902 901 CA214-1 CAN CON.
120 Ohm
9 907 906 CA214-2 CAN CON.
CAN LOW
905 CA209-27 ACCESS 2/3
10 UNUSED
11 UNUSED
12 UNUSED
13 101 (YEL) CA205-3 SRT

GND
+10V 14 306 (PINK) CA205-2 SRT
STD 1
KEYLESS ENTRY K1 30
30
203
204 1 Bridge 203 is only present when relay K1 is in-
85
85 5900 stalled.
203 205 CA201-1
86
86
206 202 FU2 OUT Note: Remove bridge 203 when converting to
87
87 2910 CA200-10 HANDLE key switch or keypad.
87a 87a
2911 2912 CA209-10 ACCESS 2/3
OPTION 1 2913 CA206-2 BRS
KEYSWITCH
2914 CA210-A PLS1
KYS ADAPTER 2915 CA211-A PLS2
30
KYS 2982 2924 CA205-2 SRT
85
2981 87
2926 LINE CONTACTOR COIL
2983
87a
86
232 232
OPTION 2
KEYPAD
KEYPAD KYS ADAPTER
30
RED/WHT 2982
85
2981 87
BLK 2983
87a
86
RED 232 232
GRN 506
824302_2J-9
Fig. 144
WT 3000 Series
Rev. B
364
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR, KEYLESS POWER-UP
WT -E, with CAN Tiller, ABM Motor, Keyless Power-Up
TILLER HANDLE
+BV +BV
B5 ACCESS 8 MAIN PCB 5
CA411
- K1 = Closed
+BV (AK) (INTERFACE) 6
FU 3
4A
+BV (AK)
B3 CA410 1 - Without load on forks
CA204 FF PF
CA205
A5 3
Drive
A4 4
3
POT1 - Platform not occupied
K1 3 ACCESS 1 FU 6 4
CA212
(DISPLAY) 4A B2 A16 1 7 - Side restraints down
ACCESS 3/2 2
86 + 30
K1
CA201 +12V A9 5 3 - Tiller = upright and centred.
CAN-L
CA201
120 Ohm
-B CA412
CA210 CA200 (TCM / HCM) CA200 3 6 5 4 2 3 1 CA225 9 A13 7
1
PS 85 - 87 1
8
CAN-H 2 9 2 SR1 and SR2 only with folding
1 2 26 +13,8V BOOTSTRAP 40 1 A1 2 SAS/BRS1
P -K1
2 4 platform, otherwise bridge 824907
1 41 GND NCL TXD 1 4 6
CA206 C2 1 CA413 present.
4 23 Signal PCL TXD 2 5 -B C3 8 2 CA417 HNS 1
+ BV (AK)
NCL RXD 29 6 A3 10
3 1
4 2 3 BRS only with fixed platform, oth-
20 SAS 33 B6 9 erwise bridge present on PC205
+ OUT + IN CA419 HNS 2
30 SMART 7 5 1
CA208 SR1 1 2
11
4 8 6 2 4 F/C option is activated below 5°C.
unused 11 12
A
35 C 5 Filter for strobe (item no. 822569)
-
31 B PNP
CA204 4
BRK unused 18 4 8 R/T PCB 6 Strobe (item no. 127651)
A2 3
CA209 SR2 1 2 CA414 HSS1
unused 19 +
A 1
7 Travel alarm (item no. 115565)
SV 39 5 C
-
B PNP 8 Option
unused 20 1
HYDR. PCB
CA223 LMS1 1 CAN-H A15 2 9 SAS for folding platform, BRS1 for
unused 36
HN
32
+
A B4 3 fixed platform.
21 C
B1 CA415
FAN CA204
-
B PNP
4
RAS LOS 10 PLS1 for folding platform, FPS1 for
CA204 unused 38 CAN-L A6
1 2 28 A7 5 fixed platform.
CA206 PLS1/FPS1 HR POT PCB
+
CA203
8 7
CA203
A 1 10 A14 7
4 8 CA416
1 4 8 11 PLS2 for folding platform, FTS1 &
34 C
1 ALM 2 16 -
B PNP 8 2 2 for fixed platform.
FLS 6 8
CA207 PLS2/FTS1&2
+
14 A 1 11
37 -
C
CA 222 1 2 PNP
B
5 8
-B
15 6
CA214 CA232 TFD UNIT
5 5 BLU
+
CA202 1 2 BRS (TILLER)
CA 200 3 Coil
3 6 6 WHT
680 Ohm
25 4 4 ORN
+BV (AK)
4 CAN-H
27 ACCESS 5
13 CAN-L CA221=B
42 (SCM)
17 CHNL B 8 Low B1 2 2 BLK
CA222=A
CHNL A 22 1 2 3 4 5 6 CA211 A4 +5V B2 1 1 RED
+13,8V 9 CAN CONNECTION A5
+B W1 B6 3 3 GRN
PWS ECR1 A7
W CA217
CA224 2 1 W
+12V 1
GND A10
V CAN-L
A6 A8
V
M1 CHNL A CHNL B
120 Ohm
3
FU 7 FU 5 FU 4 CHNL B
-B U 2
4A 10A 10A U GND
CHNL A A9
4
8
CA213
A14 CAN-H +13,8V B5
CA200 CA215 TS1
_
TS1 12 1
+ TRACTION SAHS 1
+
T Signal W
2 MOTOR 3 A3
NPN 2
- V
GND 10 A1
+ U
Ax
EDS -
-P A2 CA218 ECR2 ECR3 CA219
U V W
+BF - A12 +13,8V B4 1 +13,8V +13,8V 1
FU 1 +
M2 CHNL A B8 3 CHNL A CHNL A 3
EDS LINE
355A
PUMP MOTOR +B FU 2
CHNL B B7 2 CHNL B M3 CHNL B 2
GND A11 4 GND GND 4

30 A FEEDBACK TOP
CA216
-B _
-B TS2 B3 1
+ STEERING
T TS2
BD:1 BD:2 A13 2 MOTOR
-
+
24V BATT
824303_2K-1
Fig. 145
WT 3000 Series
Rev. B
365
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR, WITH KEY SWITCH OR KEYPAD
WT -E, with CAN Tiller, ABM Motor, with Key Switch or Keypad
+BV
TILLER HANDLE 1 Shown with truck in standby:
FU 3
KYS 4A +BV ACCESS 8 CA411 - K1 = Closed
B5 MAIN PCB 5
+BV (AK) +BV (AK)
B3
(INTERFACE) 6 - Without load on forks
CA410 1
CA205
CA204 Drive FF PF - Forks fully lowered
A5 3
3 - Platform not occupied
8
KEYPAD 3 ACCESS 1 A4 4 POT1
CA212
FU 6 4 - Side restraints down
(DISPLAY) 4A B2 A16 1 7
ACCESS 3/2 CA201
2 CAN-L
+12V A9 5 3
CA412
CA201
120 Ohm
(TCM / HCM) -B 1
PS CA210 CA200 CA200 3 6 5 4 2 3 1 CA225 9 A13 7 2 SR1 and SR2 only with folding
CAN-H 2
1 2 26 +13,8V BOOTSTRAP 40 1 8 A1 2 SAS/BRS1
9
platform, otherwise bridge 824907
P
1 41 GND NCL TXD 1 4 2 4 6 present.
CA 206 C2 1 CA413
4 23 Signal PCL TXD 2 5 C3 8 2 CA417 HNS 1
3 1 3 BRS only with fixed platform, oth-
NCL RXD 29 6 A3 10 4 2
20 SAS
-B erwise bridge present on PC205
33 B6 9
+ OUT + IN CA419 HNS 2
30 SMART 7 11 5 1 4 F/C option is activated below 5°C.
CA208 SR1 1 2 4 8 6 2
unused 11 12
A 5 Filter for strobe (item no. 822569)
35 -
C
31 B PNP
CA204 4 R/T PCB
BRK unused 18 4 8
A2 3
unused 19 CA209 SR2 1 2 CA414 HSS1 7 Travel alarm (item no. 115565)
+
A 1
SV 39 5 -
C 8 Option
B PNP
unused 20 1 9 SAS for folding platform, BRS1 for
HYDR. PCB
A15 2
HN
unused 36 CA223
+
LMS1 1 CAN-H
fixed platform.
32 A B4 3
21 -
C
PNP B1 CA415
RAS LOS
10 PLS1 for folding platform, FPS1 for
B
CA204 FAN CA204
unused 38 CAN-L A6 4 fixed platform.
1 2 28 A7 5
CA206 PLS1/FPS1
+
HR POT PCB 11 PLS2 for folding platform, FTS1 &
8 7 A 1 10 A14 7 1
CA203 CA203 34 -
C
8
4 8 CA416
2
4 8
2 for fixed platform.
1 ALM 2 16 B PNP
FLS 6 8
CA207 PLS2/FTS1&2
+
14 A 1 11
1 2
37 -
C
CA 222 B PNP
5 8
-B
15 CA214 CA232 TFD UNIT
6
5 5 BLU
+
CA202 1 2 BRS (TILLER)
CA200 3 Coil
3 6 6 WHT
680 Ohm
25 4 4 ORN
+BV (AK)
4 CAN-H
27 ACCESS 5
13 CAN-L CA221=B
42 (SCM)
17 CHNL B 8 Low B1 2 2 BLK
CA222=A
CHNL A 22 A4 +5V B2 1 1 RED
1 2 3CA211
4 5 6
+13,8V 9 CAN CONNECTION A5
+B W1 B6 3 3 GRN
PWS ECR1 A7
2 1 W CA217
CA224 W +13,8V 1
GND A10
V CAN-L
A6 A8
120 Ohm
-B
FU 7
4A
FU 5
10A
FU 4
10A
V
U
U M1 CHNL A
CHNL B
GND
3
2
4
CHNL B
CHNL A A9
8
CA213
A14 CAN-H +13,8V B5
CA200 CA215 TS1
TS1 12 1
+ _ TRACTION SAHS 1
+
Signal W
2 T MOTOR 3 A3
NPN 2
- V
GND 10 A1
+ U
Ax
EDS -
-P A2 CA218 ECR2 ECR3 CA219
U V W
+BF - A12 +13,8V B4 1 +13,8V +13,8V 1
FU 1 +
EDS LINE
355A
PUMP MOTOR +B FU 2
CHNL B B7 2 CHNL B M3 CHNL B 2
GND A11 4 GND GND 4

30 A FEEDBACK TOP
CA216
-B + _
-B TS2 B3 1 STEERING
T TS2
BD:1 BD:2 A13 2 MOTOR
824303_2K-2
-
+
24V BATT
Fig. 146
WT 3000 Series
Rev. B
366
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR, POWER SIDE ACCESS 3/2 AND ACCESS 5, LOGIC SIDE ACCESS 3/2
WT -E, with CAN Tiller, ABM Motor, Power Side Access 3/2 and Access 5, Logic Side Access 3/2
FU7 PWS 1 2 CA224 2929 CA206-A

210 211 511 -B 2930 CA207-A
4A 13 2931 2928
201
FU5 208 CA220-5 ACCESS 3/2 17 5906 WHT LINE BLK 2925 2928
207 205 209 CA200-20 (TCM / HCM) + Batt
SMART
+ OUT
7 2916 CA222-4 ACCESS 5 (SCM)
2924 CA213-1
10A 213 SOCKET 86 2926 CA222-5
°
FU3 + OUT
35 2909 CA208-C SR1 2927 CA222-7
206 202 CA225-2 901 CA211-1
2923
4A 27 900 902 CA222-14
FU4 903 CA201-8 2923
5 2910 PC209-C SR2
2900 2901 2902 CA200-4 904 CA220-4 2918 SOCKET 87
10A 2903 SV UNUSED 11 2920 CA205-1
908 CA211-2
2904 HN 2921 CA209-A
42 909 910 CA222-6
AxEDS 2905 CA204-1 2922 CA208-A
911 CA201-9
2906 CA202-1 37 2914 PC207-C PLS2 2932 CA214-5
912 CA220-1
GRN
2907 CA203-1 2919 CA223-A

30 WHT
2934 CA214-5 BRK
200
31 BRN
21 2911 CA223-C LMS1
EDS LINE 33 2915 CA220-6 HANDLE
4 2902
+BF 25 101 CA214-4 TFD
205 FU5 OUT
FLS
+B ACCESS 5 20 209 208 CA220-5
206 FU3 IN
BD:1 (SCM) FU1 UNUSED 18
RED
BLK
213 SOCKET 86
FU2 U 355A
U 3 5908 CA214-6 TFD
30A
ACCESS 3/2
TCM / HCM
1 2 CA222
UNUSED 19 Filter
V
V M3 14 UNUSED
PN822569
W UNUSED 24 1 2 CA202
W 2906
-B 15 5904
16 5905 2 ALM 1 2907 2934 CA214-5 TFD
CA203 CA203
24V UNUSED 36 2901 FU4 OUT
BATTERY FAN
28 5903 2 1 2905 2904
CA204 CA204
UNUSED 38
HN
39 5901 SV 2903
32 5902
CA210
+ SIGNAL 23 100 4 Signal
P
PS
U GND
U GND 41 600 601 1
+13,8V
V +13,8V 26 300 301 2
BD:2 M2 M1 V
34 2912 CA206-C PLS1 CA212
W 602 2 CONSOLE
W UNUSED 36
302 3
NCL TXD 1 003 4
- PCL TXD 2 002 5
NCL RXD 29 001 6

-P
40 004 1
CA217
+13,8V 9 GRN 1 RED +13,8V ECR1
-B CHNL B 8 YEL 2 BLU CHNL B
CA201-4 505 504 CHNL A 22 GRAY 3 WHT CHNL A
CA220-2 506 VIO CA213-2 UNUSED 38 BLU 4 BLK GND
CA209-B 507 500 GND 10 604 RED 2 WHT TS1
CA208-B 508 501 CA206-B PLS1
TS M1 12 PINK 1 BLK
KEYPAD 509 502 CA207-B PLS2 T
6 2913 CA205-C BRS CA215

CA223-B 510 511 CA224-2 PWS 824303_2K-3-4
Fig. 147
WT 3000 Series
Rev. B
367
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR, LOGIC SIDE ACCESS 5 AND INTERFACE ACCESS 8
WT -E, with CAN Tiller, ABM Motor, Logic Side Access 5 and Interface Access 8
CA222 CA213 CA204

ACCESS 5 1 2982 PC410-2 SAS/BRS1
A1 GRAY/PINK 3 BLU SAHS
(SCM) Signal
-BATT 2 2985 PC414-3 HSS1

A2 VIO -B ACCESS 3/2 2 RED
+BV(AK) NPN 3 2983 PC410-10 HNS
A3 BLK 1 BLK
4 2981 PC410-4 FF
A4 2916 PC200-7 ACCESS 3/2 2918 SOCKET 87 213 SOCKET 86
2925 LINE CONTACTOR 2919 CA223-A 5 2980 PC410-3 PF
206 FU3 IN
A5 2926 2923 2920 CA205-A
2928 2929 CA206-A 2921 CA209-A 6 2988 PC415-4 RAS 209 CA200-20
A7 2927 2930 CA207-A 2922 CA208-A 205 FU5 OUT
2931 CA200-13 7 2989 PC415-5 LOS
A6 910 CAN LOW 900 CA200-27
CA219 8 UNUSED
901 CA211-1
A8 ECR3
CHNL B WHT/GRN 2 BLU CHNL B 9 380 PC410-5 POT HIGH 902 CA222-14
(INTERFACE)
903 CA201-8
ACCESS 8
CHNL A A9 WHT/YEL 3 WHT CHNL A 10 UNUSED
510 CA223-B
GND A10 YEL/BRN 4 BLK GND 11 UNUSED
509 KEYPAD
A12 UNUSED 1 RED +13,8V 12 UNUSED 508 CA208-B
507 CA209-B
A14 902 CAN HIGH 13 180 PC410-7 POT WIPER
CA216 505 CA201-4
TS2 PINK 2 WHT 14 2990 PC415-7
A13 TS2 504 Batt-
15 2987 PC415-2 +BV(AK) 908 CA211-2
GND A11 YEL 1 BLK T
909 CA200-42
16 580 PC410-1 GND
910 CA222-6
CA205 CA220 911 CA201-9
CA221 1 WHT 1 912
TS2 B3 GRAY CA218 2 YEL 2 506
+13,8V B5 RED/BLU 4 BLK GND ECR2 3 PINK 3 2933 FU6 OUT
+13,8V B4 WHT 1 RED +13,8V 4 BRN 4 904
CHNL B B7 BRN 2 BLU CHNL B 5 GRN 5 208
CHNL A B8 GRN 3 WHT CHNL A 6 GRAY 6 2915 CA200-33 ACCESS 3/2

CA214
LOW B1 603 2 2 BLK CA206
1 UNUSED
+5V B2 700 1 1 RED
2 UNUSED
OUTPUT 1 B6 102 3 3 GRN
680 Ohm 3 680 PC410-8 POT LOW
101 4 4 YEL
TFD UNIT 4 UNUSED
2934 5 5 BLU + 5 UNUSED
Coil
6 6 WHT
6 UNUSED
CA232
5908 PC200-3 ACCESS 3/2 7 UNUSED
2934 FU4 OUT 8 UNUSED
101 PC200-25 ACCESS 3/2 824303_2K-5-6
Fig. 148
WT 3000 Series
Rev. B
368
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR: PLATFORM, SIDE RESTRAINT AND ENTRY BAR SWITCHES
WT -E, with CAN Tiller, ABM Motor: Platform, Side Restraint and Entry Bar Switches
CA208 CA206 FIXED PLATFORM REAR ENTRY
2922 A BRN +BV(AK) SR1 1

2929 A WIRE 1 FPS1
Side Foot Presence
-B
508 B BLU Restraint Switch 1
501 B
Sensor 1 (Floor Mat Switch)
Signal PNP
2912 CA200-34 ACCESS 3/2 C WIRE 2
504 -B ACCESS 3/2
505 CA201-4 DISPLAY CA209 500 -B ACCESS 3/2
CA207
Side 2930 A BRN +BV(AK) FTS 1

-B
507 B BLU Restraint Foot Guard
Sensor 2 502 B BLU -B Switch 1
Signal PNP (Entry Bar Sensor)
2910 PC200-5 ACCESS 3/2 C BLK
Signal PNP
506 CA220-2 HANDLE
509 KEYPAD CA223
2919 A BRN +BV(AK) LMS1

Lift Limit
510 B BLU -B
Switch
CA206 FIXED PLATFORM SIDE ENTRY
Signal PNP
2929 A WIRE 1 FPS1
2918 SOCKET 87 Foot Presence
501 B Switch 1
CA205 (Floor Mat Switch)
2920 A RED
2912 CA200-34 ACCESS 3/2 C WIRE 2
500 -B ACCESS 3/2
UNUSED B BLK BRS 2
502 CA207-2
CA207.1
2913 PC200-6 ACCESS 3/2 C WHT
2923 2924 CA213-1 SAHS Foot Guard
581 B BLU -B Switch 1
2925 LINE CONTACTOR (Entry Bar Sensor)
2926 CA222-5 ACCESS 5 Signal PNP
2971 C BLK
2927 CA222-7 ACCESS 5 CA207.2 CA 207.2
STANDARD OPTION
2928 2931 CA200-13 ACCESS 3/2 2971 A Bridge A BRN FDS 1
+BV(AK)
1 Fold Down Step

CA207 582 B B BLU -B
Sensor 1
2930 A 2970 2972 C C BLK Signal PNP
CA206 Foldable Plattform 502 B 580 CA207.3 CA 207.3

STANDARD OPTION
2929 A BRN +BV(AK) PLS 1 2914 C 2974 2972 A Bridge A BRN +BV(AK) FDS 2
Platform 1 Fold Down Step
501 B BLU -B
Switch 1 -B
Sensor 2
583 B B BLU
Signal PNP
2912 CA200-34 ACCESS 3/2 C BLK 2973 C C BLK Signal PNP
500 -B ACCESS 3/2 CA207 CA207.4
2930 A BRN PLS 2 2973 A BRN +BV(AK) FTS 2

+BV(AK)
Foot Guard
Platform
502 B BLU -B
Switch 2
(Entry Bar Sensor)
PNP Signal PNP
2914 CA200-37 ACCESS 3/2 C BLK Signal
2974 C BLK
824303_2K-7-8
Fig. 149
WT 3000 Series
Rev. B
369
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR, ASSEMBLIES IN TILLER HANDLE AND POWER UP VARIANTS
WT -E, with CAN Tiller, ABM Motor, Assemblies in Tiller Handle and Power Up Variants
CA411 CA201
CA410 1
POT1
ACCESS 1 1 UNUSED
580 PC204-16 GND 1
2
(DISPLAY)
3 2 5907
2982 PC204-1 SAS/BRS1 2 4 POT PN812885
3 204
PF 504 -B
2980 PC204-5 PF 3 5
FF 4 505 506 CA220-2
6
2981 PC204-4 FF 4 507 CA209-B
7 5 UNUSED
+13,8V
508 CA208-B
380 PC204-9 POT HIGH 5 GND 509 KEYPAD
CA412 6 UNUSED
BLU 510 CA223-B
581 PC415-8 GND F/C 6 3 PN818731
7 UNUSED
1 CAN HIGH 900 CA200-27
180 PC204-13 POT WIPER 7 SAS/BRS1
BLK 8 903 901 CA211-1
120 Ohm
2 3
680 PC206-3 POT LOW 8 902 CA222-14

CA413 9 911
904 CA220-4
CA417 CAN LOW
2984 PC415-1 +BV(AK) 9 1 10 UNUSED
2 908 CA211-2
2 HNS1 909 CA200-42
2983 PC204-3 HORN 10 1 11 UNUSED
1 2
3 2904 HNS 910 CA222-6
2991 +BV(AK) F/C 11 12 UNUSED 912 CA220-1
15 x //R 4 2903 CA419
582 PC414-4 GND F/C 12 5 2902 2 13 UNUSED OPTION 1 & 2 STD CA225
HNS2 1 204
6 2901 1
GND 2 202 FU3 OUT
HNS +10V 14 UNUSED
MAIN PCB F/C 3 2935
4 203
5 212
CA415 1 6
STD
2984 PC410-9 +BV/AK) 1 KEYLESS ENTRY K1 30
30 212
85
2987 PC204-15 +BV(AK) 2 85 5907
2986 PC414-1 +BV(AK) 3 86

203
86
213 FU5 OUT FU6 CA220-3 2933
87
2988 PC204-6 4
87 2917 2932
RAS LOS 87a 2918 4A
87a
2989 PC204-7 OPTION 1 2919 CA223-2

5
KEYSWITCH 2920 CA205-1
2921 CA209-A
NOT USED 6 CA416 KYS ADAPTER
2922 CA208-A
30
2991 PC410-11 +BV (AK) RED 1 2
KYS 2982 2932 CA214-5 TFD
7 1
15 x //R 1 85
2923 2924 CA213-1 SAHS
2990 PC204-14 +BV (AK) 2 2981
16 x //R 2983 87
CA222-5 2926 2925 LINE CONTACTOR
BLK
581 PC410-6 GND F/C 8 2 87a
CA222-7 2927 2928
86
232 232 CA206-A 2929
HYDRAULIC PCB F/C POT PCB F/C CA207-A 2930
CA200-13 2931
OPTION 2
CA414 KEYPAD 1 For “keyless power-up” (STD with relay K1) use bridge
2986 PC415-3 +BV(AK) 1 KEYPAD KYS ADAPTER 826405-001.
30
For options 1 and 2, remove K1 and use bridge 826405-
RED/WHT 2982 002.
UNUSED 2 85
2981
HSS1 BLK 2983 87
2985 PC204-2 3 87a
86
582 PC410-12 GND F/C
1 2 RED 232 232
4
2 x //R GRN 509
R/T PCB F/C 824303_2K-9-10
Fig. 150
WT 3000 Series
Rev. B
370
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR, CAN-BUS
WT -E, with CAN Tiller, ABM Motor, CAN-Bus
ACCESS 3/2 CAN HIGH CA211

900 901
(TCM / HCM) 27
908
1 CAN CONNECTION
2
CA200 3
4
909 5
42
6
CAN LOW
ACCESS 5 CAN HIGH

902
(SCM) 14
120 Ohm
CA222
910
6
CAN LOW
CA220
ACCESS 1 CAN HIGH
903
(DISPLAY) 8 6 HANDLE
120 Ohm
5
904
4
CA201 3
2
911 912
9 1
CAN LOW
ACCESS 8 CAN LOW

WHT
(INTERFACE) 1
CA205
BRN
4
CAN HIGH 824303_2K-11
Fig. 151
WT 3000 Series
Rev. B
371
SCHEMATIC DIAGRAMS
WT -M, WITHOUT CAN TILLER, ABM MOTOR, INFOLINK™, KEYLESS POWER-UP
WT -M, without CAN Tiller, ABM Motor, InfoLink™, Keyless Power-Up
+BV
+BV (AK)
F/C 4 6
TILLER
16x //R HANDLE
PF
FF
- K1 = Closed
POT1
9 3 3 - Forks fully lowered
SAS/
BRS1 - Platform not occupied
HNS 1
HNS 2
+BV 2 Reduced travel speed: HSS open
3 5 13 14 2 3
3 LINE, EDS, RAS, LOS, BRS, SAS and HNS are activated when the switches are closed.
15x //R
15x //R
2x //R
+ BV (AK)
K1 RAS LOS
86 + 30 4 4 4
K1 ACCESS 1 6 6 6
120 Ohm
85 - 87 1
(DISPLAY) MAIN HYDR. 5 Index number not used
-K1 PCB R/T PCB PCB
2 4 9 8 CA 410 CA 414 CA 415 6 Option
24
PROX. READER
1 1
INFOLINK CAN-L
CAN-H
3 2
4 3 7 Filter for strobe (item no. 822569)
+13,8V
2 14 15
CA250 -B -B
120 Ohm 8 Strobe (item no. 127651)
CA250
4 1 9 SAS for folding platform, BRS1 for fixed platform.
5 2 PLS1/ GND
3
4CAN
FPS1
GND 10 PLS1 for folding platform, FPS1 for fixed platform.
5 A 1
CONNECTION
SHOCK SENSOR

6 CA 208 B
C PNP 10
CA 214 1
B CA 210
CA250 C 1
CA 211.1 NPN
+13,8V
1 6 A LMS1
1
2 7 -B A
3 8
2 SR2
3
4 9 CA250 4 PLS2/ PNP C
25 13 5 FTS1&2 SR1 CA 203 B
6 3
1 A 1
6 8 FLS BRS A
NPN
11 PNP C C
-B
CA 211 B
CA 222 1 2
CA 207 B
6 7
UNUSED
UNUSED
UNUSED
-B
GND
CA 216 1 2
10
23
34
33
27
28
35
16
15
31
32
17
20
19
29
18
21
11
6
1
CA 209 CA 209
6
ALM 8
HN
26
ACCESS 3/2
SV 24 (TCM/HCM) CHNL A
CHNL B
+13,8V
FAN
GND
TS1
9 +B -P U V W -B
CA 224 1 2
3 CA 209
12
30
22
25
13
14
4
2
-B
U V W
TRACTION
FU4 FU2 FU3
FU1 + - MOTOR
355A M2 M1
BRK
4A 4A 4A
-B
6
+
PUMP MOTOR
T
TS1
-
+13,8V
CHNL B
CHNL A
LINE
+13,8V
+ ECR1
GND
3
3 4 1 2 CA 212 5 6
PS
1 P 4
GND
1
EDS
+13,8V
2
EDS
3 CA 204
Ax
GND
BD:1 24V BATT BD:2
827191_2D-1
Fig. 152
WT 3000 Series
Rev. B
372
SCHEMATIC DIAGRAMS
WT -M, WITHOUT CAN TILLER, ABM MOTOR, INFOLINK™, KEYLESS POWER-UP
WT -M, without CAN Tiller, ABM Motor, InfoLink™, Keyless Power-Up
+BV
+BV (AK)
F/C 4 6
TILLER
16x //R HANDLE
PF 1 Shown with truck in standby:
FF - K1 = Closed
POT1
9 3 3
SAS/
BRS1
HNS 1
HNS 2
+BV
3 5 13 14 2 3 3 LINE, EDS, RAS, LOS, BRS, SAS and HNS are activated when the switches are closed.
15x //R
15x //R
CA 202
2x //R
F/C F/C HSS1 F/C
4 4
RAS LOS
4
ACCESS 1 120 Ohm 6 6 6 5 Index number not used
KEYPAD 1 6 (DISPLAY) MAIN HYDR.
PCB R/T PCB PCB 6 Option
2 4 9 8 CA 410 CA 414 CA 415
CAN-L
CAN-H
PROX. READER
1 1
3 2 INFOLINK
+13,8V
4 3 -B -B
2 14 120 Ohm
CA250
CA250 9 SAS for folding platform, BRS1 for fixed platform.
4 1
5 2 PLS1/ GND 10 PLS1 for folding platform, FPS1 for fixed platform.
3 FPS1
4CAN
5 A 1 GND
6CONNECTION CA 208 B
C PNP 10
SHOCK SENSOR
CA250 CA 214 1
B CA 210
15
C 1
1 6 CA 211.1 NPN
+13,8V
CA250 A LMS1
1
1 6
KYS 2 -B SR2 A
2 7 24
3
3 8 4 PLS2/ PNP C
4 9 CA250 5 FTS1&2 SR1 CA 203 B
25 13 6 3
1 A 1
6 8 FLS BRS A
NPN
11 PNP C C -B
CA 211 B
CA 222 1 2
CA 207 B
6 7
UNUSED
UNUSED
UNUSED
-B
GND
CA 216 1 2
10
23
34
33
27
28
35
16
15
31
32
17
20
19
29
18
21
11
6
1
CA 209 CA 209
6
ALM 8
HN
26 ACCESS 3/2
SV 24 (TCM/HCM)
CHNL A
CHNL B
+13,8V
FAN
GND
TS1
9 +B -P U V W -B
CA 224 1 2
3 CA 209
12
30
22
25
13
14
4
2
- BATT
U V W
TRACTION
FU4 FU2 FU3
FU1 + - MOTOR
355A M2 M1
BRK
4A 4A 4A
-B
6
+
PUMP MOTOR
T
TS1
-
+13,8V
CHNL B
CHNL A
LINE
+13,8V
+ ECR1
GND
3
3 4 1 2 5 6
PS
1 P 4
GND
1
EDS
+13,8V
2
EDS
3 CA 204
Ax
GND
BD:1 24V BATT BD:2
827191_2D-2
Fig. 153
WT 3000 Series
Rev. B
373
SCHEMATIC DIAGRAMS
WT -M, WITHOUT CAN TILLER, ABM MOTOR, INFOLINK™, ACCESS 2/3 POWER AND LOGIC SIDE
WT -M, without CAN Tiller, ABM Motor, InfoLink™, Access 2/3 Power and Logic Side
FU4
208 209 CA217-1 PWS ACCESS 3/2 (TCM/HCM)
2915 CA211-A PLS2
4A ACCESS 3/2 (TCM/HCM)
201
FU2 206 SOCKET 86 10 2912 2911 RELAY SOCKET PIN 87

207 202 205 CA201-1
4A CA 209 CA 209 2913 CA206-2 BRS
+ -
200.1
201.1
FU3 BRS INPUT 1 12 5908 LINE 2926 2914 CA210-A PLS1

2901 2902 CA209-3 + OUT
4A 2903 SV +BV (AK) 3 SMART 2 5909 (WHT/GRN) 302 CA200-5 HANDLE
2900
2904 HN + IN + - 303 CA204-2 PS

HSS1 INPUT 6 4 2908 (VIO)
AxEDS 2905 CA213-1 BRK 304 CA208-A SR2
2906 CA216-1 SAS INPUT 7
305 CA207-A SR1
200
2907 CA215-1
unused 33
FU1 25 300 301 (GRAY) 1 RED +13,8V ECR1
+B (+BATT) FAN 9
14 004 (WHT) 3 BLU CHNL B
355A +BV (AK) 10 13 005 (BRN) 4 WHT CHNL A
EDS LINE
FLASHING LIGHT (FLS) 11
5 600 601 (BLU) 2 BLK GND
T
LINE CONTACTOR (LINE/EDS) 12 19 UNUSED 602 (RED) 5 BLK TS1
POT WIPER 15 22 100 (GRN) 6 WHT
+
PLATFORM SENSOR 2 (PLS2) 16 6 2916 CA200-1 HSS1 CA212

BD:1
LIFT SWITCH (RAS) 17 7 2917 CA200-2 SAS/BRS1 603 CA200-4 HANDLE
SIDE RESTRAINT SENSOR 1 (SR1) 18 15 003 CA200-3 HANDLE 604 CA204-1 PS1
UNUSED 19 605 CA208-B SRS2
31 2918 CA200-6 FF
606 CA207-B SRS1
M2 LOWER SWITCH (LOS) 20 32 2919 CA200-7 PF
SIDE RESTRAINT 2 SENSOR (SR2) 21 20 2922 CA200-9 LOS
- unused 23 29 2923 CA200-11 HNS1&2
SV 24 17 2921 CA203-1 LMS1
-P HORN (HN) 26 1 2909 (GRAY/PINK) CA206-3 BRS
24V
BATTERY CAN LOW 27 18 002 CA207-C SR1
CAN HIGH 28 21 001 CA208-C SR2
HORN SWITCH 1&2 (HNS1&2) 29 35 2924 CA210-C PLS1
U
ECR1 U FORKS FIRST (FF) 31 16 2925 CA211-C PLS2 902 CA202-8 ACCESS 1 CA214
3 CHNL B
V POWER UNIT FIRST (PF) 32 CAN HIGH 28 900 901 1 CAN
4 CHNL A
1 +13,8V
2 GND
M1 W
V
ALARM (ALM) 8
CAN LOW 27 905 906
INLINE CAN
TERMINATION
120 Ohm
2
CONNECTION
CA 212 W unused 34 30 000 CA204-4 PS 907 CA202-9 ACCESS 1 3
CA 212 4
5
TS1 +
PLATFORM SENSOR 1 (PLS1) 35 FAN
T
9 5906 2 1 2905 5
6 CA213 CA213
6
BD:2 CA 209 8 5905 2 ALM 1 2907
CA215 CA215
+12V
22 TS1
5 GND
34 UNUSED
25 +13,8V
13 CHNL A
14 CHNL B 11 5904
HN
GND 33 UNUSED
FLS
BRN
BLU
26 5903 2904
-B (-BATT)
23 UNUSED 2 1 CA222
PLS2 CA211-B 502 Filter
PN822569
PLS1 CA210-B 501 24 5907 SV 2903 2901 FU3
ACCESS1 CA202-4 503 500 2 1 CA216
HANDLE CA200-12 504 506 KEYPAD 3 2902 2906

LMS CA203-B 505 507 CA217-2 PWS 827191_2D-3-4
Fig. 154
WT 3000 Series
Rev. B
374
SCHEMATIC DIAGRAMS
WT -M, WITHOUT CAN TILLER, ABM MOTOR, INFOLINK™, SENSORS AND PLATFORM SWITCH
WT -M, without CAN Tiller, ABM Motor, InfoLink™, Sensors and Platform Switch
Sensors CA 207 Platform switch CA 210 FIXED PLATFORM REAR ENTRY
305 A BRN +13,8V SR1 2914 A WIRE 1 FPS1

Side Foot Presence
606 B BLU GND
Restraint Switch 1
Sensor 1 501 -B ACCESS 2/3 B
(Floor Mat Switch)
Signal NPN 1 2
2924 CA209-35 ACCESS 2/3 C WIRE 2
300 CA209-25 ACCESS 2/3
301 CA212-1 ECR 2911 RELAY SOCKET PIN 87
CA 208
302 CA200-5 HANDLE 2912 CA209-10 ACCESS 2/3
304 A BRN +13,8V SR2 2913 CA206-2 BRS1
Side
605 B BLU GND
Restraint 2924 CA205-2 SRT
Sensor 2
Signal NPN 2926 LINE COIL CA 211
001 CA209-21 ACCESS 2/3 C BLK 1 2
600 CA209-5 ACESS 2/3

Foot Guard
601 CA212-4 ECR -B Switch 1
602 CA212-5 ECR 502 B BLU
(Entry Bar Sensor)
603 CA200-4 HANDLE CA 203 Signal PNP
2925 C BLK
2920 CA200-8 RAS A BRN +BV(AK) LMS1
Lift Limit 2925 CA209-16 ACCESS 2/3
505 B BLU -B
Switch
502 -B ACCESS 2/3
Signal PNP
CA 210 FIXED PLATFORM SIDE ENTRY
CA 224
2914 A WIRE 1 FPS1
209 FU4 OUT 1 280 CA250-25 Infolink Foot Presence
Switch 1
501 -B ACCESS 2/3 B
507 2 580 CA250-13 Infolink (Floor Mat Switch)
500 ACCESS 2/3 2924 CA209-35 ACCESS 2/3 C WIRE 2

1 SR1 and SR2 are not present on trucks without
503 CA202-4 ACCESS1
side restraints
504 CA200-12 HANDLE
CA 204 CA 207.1
506 KEYPAD 2 Pedestrian mode: SR1 and SR2 are OFF (0 V) 2912 CA209-10 ACCESS 2/3
604 1 GND
P
PS Rider mode: SR1 and SR2 are ON (13,8 V) 2913 CA206-2 BRS1 2970 A BRN +BV(AK) FTS 1
Foot Guard
3 Fixed platform: SR1 and SR2 replaced by
303 2 +13,8V 2924 CA205-2 SRT 581 B BLU -B Switch 1
bridge 825877 on CA207 and CA208. (Entry Bar Sensor)
2926 LINE COIL Signal PNP
UNUSED 3 2971 C BLK
000 CA209-30 ACCESS 2/3 4 Signal

CA 207.2
2971 A BRN +BV(AK) FDS 1 (OPTION)
Fold Down Step
CA 210 FOLDABLE PLATFORM
PC211/JC207 582 B BLU -B
Sensor 1
1
2914 A BRN +BV(AK) PLS1 2915 A 2970 Signal PNP
Platform
2972 C BLK
Sensor 1
502 B 580 CA 207.3
Signal PNP
2924 CA209-35 ACCESS 2/3 C BLK 2972 A BRN FDS 2 (OPTION)
2925 C 2974 +BV(AK)
2911 RELAY SOCKET PIN 87 Fold Down Step

CA 211 583 B BLU -B
Sensor 2
2912 CA209-10 ACCESS 2/3 2925 CA209-16 ACCESS 2/3
1
502 -B ACCESS 2/3 Signal PNP
2915 A BRN +BV(AK) PLS2 2973 C BLK
Platform
Sensor 2 CA 207.4
1 Trucks without folding steps: FDS1 and
2925 CA209-16 ACCESS 2/3 C BLK Signal PNP FDS2 are replaced by bridge 824907. 2973 A BRN +BV(AK) FTS 2
Foot Guard
2913 CA206-2 BRS1 583 B BLU -B Switch 2
(Entry Bar Sensor)
2924 CA205-2 SRT
Signal PNP
2974 C BLK
2926 LINE COIL 827191_2D-5-6
Fig. 155
WT 3000 Series
Rev. B
375
SCHEMATIC DIAGRAMS
WT -M, WITHOUT CAN TILLER, ABM MOTOR, INFOLINK™, TILLER AND TILLER HANDLE
WT -M, without CAN Tiller, ABM Motor, InfoLink™, Tiller and Tiller Handle
Tiller CA 200 Tiller handle CA 411

CA 410 1
POT
2916 CA209-6 HSS1 1 WHT/GRN CA414-3 HSS1 2
CA207-B 606 GRN CA200-12 -BATT 1
3
CA208-B 605 2917 CA209-7 SAS/BRS1 2 GRAY/PINK CA410-2 SAS/BRS1
CA204-1 604 GRAY/PINK CA200-2 SAS/BRS 2 4
POT PN 812885
CA212-5 602 003 CA209-15 POT WIPER 3 BRN CA410-7 POT WIPER PF
CA212-4 601 YEL CA200-7 PF 3 5
CA209-5 600 603 4 BLU CA410-8 POT LOW 6

FF
BLK CA200-6 FF 4
7
CA209-25 300 302 5 RED/BLU CA410-5 POT HIGH +13,8V
CA212-1 301 RED/BLU CA200-5 POT HIGH 5
CA 412
CA204-2 303 2918 CA209-31 FF 6 BLK CA410-4 FF BLU
CA208-A 304 5961 F/C OPTION 6 3 PN 818731
CA207-A 305 2919 CA209-32 PF 7 YEL CA410-3 PF 1
BRN CA200-3 POT WIPER 7 SAS/BRS1
BLK
2 3
2920 CA203-A LMS1 8 VIO CA415-4 RAS
BLU CA200-4 POT LOW 8
CA 413
2922 CA209-20 LOS 9 PINK CA415-5 LOS CA 417
2962 CA415-1 +BV(AK) 9 1
2
2910 RELAY SOCKET PIN 87 10 WHT CA415-2 +BV(AK) 2 HNS1
GRAY CA200-11 HNS 10 1
2923 CA209-29 HNS 11 GRAY CA410-10 HNS 1 2

3 2904 HNS PN 811933
261 F/C OPTION 11 15 x //R 4 2903
-B 500 504 12 GRN CA410-1 -B CA 419
CA202-4 503 5962 F/C OPTION 12 5 2902 2
HNS2
CA203-B 505 6 2901 1
KEYPAD 506 HNS PN 811933
CA217-2 507 MAIN PCB F/C
CA 201
CA 415 1 F/C option activated below 5°C
FU2 OUT 202 205 1 RED CA415-7 +BV F/C
SOCKET 86 206 2 Option
2962 CA410-9 +BV(AK) 1
UNUSED 2 UNUSED 3 For folding platform SAS, for fixed
WHT CA200-10 +BV(AK) 2 platform BRS1
UNUSED 3 UNUSED
2961 CA414-1 +BV(AK) 3
LINE COIL 2926 UNUSED 4 UNUSED
CA211-A 2915 VIO CA200-8 RAS 4
RAS LOS
CA210-A 2914
CA209-10 2912 CA 206 PINK CA200-9 LOS 5
SOCKET 87 2911
UNUSED 1 RED 261 F/C OPTION 6 CA 416
RED 1 2
2913 (RED/BLU) 2 BLK BRS RED CA201-1 7 1

15 x //R 1
2
16 x //R
BLK
2909 (GRAY/PINK) CA209-1 ACCESS 2/3 3 WHT 5961 F/C OPTION 8 2
UNUSED 4 UNUSED HYDRAULIC PCB F/C POT PCB F/C
CA 414
CA 205
2961 CA415-3 +BV(AK) 1
607 (BLK) CA202-5 DISPLAY 1
1,1KOhm UNUSED 2
306 ( PINK) CA202-14 DISPLAY 2 HSS1
WHT/GRN CA200-1 HSS1 3
101 (YEL) CA202-13 DISPLAY 3
1 2
5962 F/C OPTION 4
UNUSED 4 2 x //R
R/T PCB F/C 827191_2D-7-8
Fig. 156
WT 3000 Series
Rev. B
376
SCHEMATIC DIAGRAMS
WT -M, WITHOUT CAN TILLER, ABM MOTOR, INFOLINK™, POWER-UP VARIANTS AND INFOLINK WIRING
WT -M, without CAN Tiller, ABM Motor, InfoLink™, Power-Up Variants and InfoLink Wiring
500 ACCESS 2/3 -B

CA202 504 CA200-12 HANDLE
ACCESS 1 1 UNUSED 505 CA203-B LMS1
(DISPLAY) 507 CA217-2 PWS
2 5900
3 204
4 503 INFOLINK
CA250
5 607 (BLK) CA205-1
FU2 OUT 2980
506
15
CA250
GND
6 UNUSED Used with InfoLink Box -> K1 Pin 86 2981 24 UNUSED 10
7 UNUSED Used without InfoLink Box -> K1 Pin 86 281 UNUSED 11
900 CA209-28 ACCESS 2/3
CAN HIGH CA224 CA250 UNUSED 12
8 902 901 CA214-1 CAN CON. FU4 OUT 209 1 280 282 25 UNUSED 16
120 Ohm
9 907 906 CA214-2 CAN CON. -B 507 2 580 13 UNUSED 17

CAN LOW UNUSED 18
905 CA209-27 ACCESS 2/3
10 UNUSED UNUSED 19
UNUSED 20
11 UNUSED CA211
6
UNUSED 21
12 UNUSED
5
UNUSED 22
4
UNUSED 23
13 101 (YEL) CA205-3 SRT
3
UNUSED 26
CAN CONNECTION
CA250
GND
+10V 14 306 (PINK) CA205-2 SRT UNUSED 27
2 985 987 5
UNUSED 28
1 980 982 4
UNUSED 29
UNUSED 30
STD 1 CA211.1
203 *281 CA224-1 UNUSED 31
KEYLESS ENTRY K1 30
30 1 981
204 UNUSED 32
85
5900 2 986
KEYSWITCH
2
85
2981 CA250-24 KEYLESS ENTRY 3

UNUSED 33
CA250-15 2980
203 2980 CA250-15 KEYLESS ENTRY 4
UNUSED 34
86
CA224-1 281 86
206 205 CA201-1
5
UNUSED 35
87
87 2910 CA200-10 HANDLE 202 FU2 OUT
CA250-24 2981 6
87a 87a
2911 2912 CA209-10 ACCESS 2/3
OPTION 1 2913 CA206-2 BRS
KEYSWITCH
2914 CA210-A PLS1
CA255 CA250
KYS ADAPTER 2915 CA211-A PLS2
30
SHOCK 1 VIO 1 780 6
KYS 2982 2924 CA205-2 SRT SENSOR 2
85 GRN 2 680 7
2981 2926 LINE CONTACTOR COIL
2983 87
3 BRN 3 080 8
87a
4 WHT 4 081 9
232 232 86
1 Bridge 203 is only present when relay K1 is in-
stalled.
CA251 CA250
OPTION 2 2 Wire 281 used without InfoLink box.
Wire 2981 used with InfoLink box. PROX. 1 RED 1 781 1
KEYPAD READER 3 GRN 3 082 2
KEYPAD KYS ADAPTER 4 WHT 4 083 3
30
Note: Remove bridge 203 when converting
2982 2 BLK 2 681 14
RED/WHT 85 to key switch or keypad.
2981 87
BLK 2983
87a
86
RED 232 232
GRN 506
827191_2D-9-10
Fig. 157
WT 3000 Series
Rev. B
377
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR, INFOLINK™, KEYLESS POWER-UP
WT -E, with CAN Tiller, ABM Motor, InfoLink™, Keyless Power-Up
TILLER HANDLE
+BV +BV CA411 1 Shown with truck in standby:
B5 ACCESS 8 MAIN PCB 5
+BV (AK) FU 3 +BV (AK) (INTERFACE) 6 - K1 = Closed
B3 CA410
4A
CA205
CA204 1
Drive FF PF - Without load on forks
A5 3
3
K1 3 ACCESS 1 A4 4 4
POT1
FU 6
CA212 B2 A16 1
ACCESS 3/2 86 + 30
(DISPLAY) 4A 7
2 CA201 +12V A9 5 3
- Tiller = upright and cen-
CA201
K1 CAN-L CA412
120 Ohm
(TCM / HCM) 9 -B 1
PS CA210 CA200 CA200 3 6 5 4 2 3 1 CA225 A13 7
85 - 87
8
CAN-H 2 9
tred.
1
P 2 26 +13,8V BOOTSTRAP 40 1 -K1 A1 2 SAS/BRS1
1 41 GND NCL TXD 1 4 2 4
C2 6 2 SR1 and SR2 only with fold-
CA206 1 CA413
4 23 Signal PCL TXD 2 5 -B C3 8 2 CA417 HNS 1 ing platform, otherwise
+ BV (AK) 3 1
NCL RXD 29 6 A3 10 4 2 bridge 824907 present.
20 SAS 33 B6
+ OUT + IN
9 CA419 HNS 2 3 BRS only with fixed plat-
30 SMART 7 11 5 1
CA208 SR1 1 2 4 8 6 2 form, otherwise bridge pre-
unused 11 12
PROX. READER
A 24 INFOLINK
1
2
1
3 sent on PC205
35 -
C 3 4
31 B PNP 15 14 2
CA204 4 4 F/C option is activated be-
BRK unused 18 4 8 R/T PCB
CA209 SR2 1 2
CA250 A2 3
HSS1
low 5°C.
unused 19 16 UNUSED UNUSED 10 CA414
+
A 17 UNUSED UNUSED 11 1 5 Filter for strobe (item no.
19 UNUSED UNUSED 12
SV 39 5 C
22 UNUSED UNUSED 18
-
B PNP 23 UNUSED UNUSED 20
1
822569)
unused 20 28 UNUSED UNUSED 21
HYDR. PCB
SHOCK SENSOR
29 UNUSED UNUSED 26
CA223 LMS1 1 32 UNUSED UNUSED 27 CAN-H A15 2
HN
unused 36 + 33 UNUSED UNUSED 30
32 A B4 3
7 Travel alarm (item no.
34 UNUSED UNUSED 31
21 -
C 35 UNUSED
B1 CA415
PNP 6 1 RAS LOS
CA204 FAN CA204 unused 38
B
7 2 CAN-L A6 4 115565)
8 3
1 2 28 A7 5 8 Option
CA206 PLS1/FPS1 4 9 4
5 13 25
HR POT PCB
+
8 7 A 1 A14 7 1 4 8
CA203 CA203 CA416
16
34 -
C 10
8
4 8
2 9 SAS for folding platform,
1 ALM 2 B PNP CA211 CA211.1
1 2 3 4 5 6 1 2 3 4 5 6 BRS1 for fixed platform.
CA207 PLS2/FTS1&2
FLS 6 8
14 +
A 1
CAN CONNECTION 10 PLS1 for folding platform,
CA 222 1 2
37 -
C 11 FPS1 for fixed platform.
B PNP
5 8 11 PLS2 for folding platform,

-B
15 6 CA214 TFD UNIT FTS1 & 2 for fixed platform.
5 BLU
CA202
+
1 2 BRS (TILLER)
CA 200 3 Coil
+BV (AK)
3 6 WHT
25 4 ORN
4 CAN-H
27 ACCESS 5
13 CAN-L CA221=B
42 (SCM)
17 CHNL B 8 Low B1 2 BLK
CA222=A
CHNL A 22 A4 +5V B2 1 RED
+13,8V 9 A5
+B W1 B6 3 GRN
W
ECR1
CA217
A7
CA224 2 1 W +13,8V 1
GND A10
V CAN-L
A6 A8
V
M1 CHNL A 3 CHNL B
120 Ohm
FU 7 FU 5 FU 4 CHNL B 2
-B U
4A 10A 10A U GND 4
CHNL A A9
8
CA200 CA213
A14 CAN-H +13,8V B5
CA215 TS1
TS1 12 1
+ _ TRACTION SAHS 1
+
W
T MOTOR Signal
2 3 A3 V
-
NPN 2
GND 10 A1 U
+
Ax
EDS -
-P A2 CA218 ECR2 U V W ECR3 CA219
+BF A12 +13,8V B4 1 +13,8V +13,8V 1
FU 1 + -
355A CHNL B B7 2 CHNL B M3 CHNL B 2

EDS LINE PUMP MOTOR +B FU 2 GND A11 4 GND GND 4
FEEDBACK TOP
30 A CA216
_
-B TS2 B3 1
+
STEERING
-B T TS2
A13 2 MOTOR
BD:1 BD:2
-
+
24V BATT
827193_2C-1
Fig. 158
WT 3000 Series
Rev. B
378
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR, INFOLINK™, WITH KEY SWITCH OR KEYPAD
WT -E, with CAN Tiller, ABM Motor, InfoLink™, with Key Switch or Keypad
+BV
TILLER HANDLE 1 Shown with truck in standby:
KYS
FU 3
4A +BV ACCESS 8 CA411 - K1 = Closed
B5 MAIN PCB 5
+BV (AK) +BV (AK) (INTERFACE) 6 - Without load on forks
B3 1
CA205
CA204 CA410
Drive FF PF - Forks fully lowered
A5 3
3 - Platform not occupied
8 A4 4 POT1
KEYPAD 3 ACCESS 1 FU 6 4 - Side restraints down
CA212 B2 A16 1 7
(DISPLAY) 4A
ACCESS 3/2 2 CA201 +12V A9 5 3
CA201
CAN-L CA412
120 Ohm
(TCM / HCM) -B
PS CA210 CA200 CA200 3 6 5 4 2 3 1 CA225 9
CAN-H
A13 7
1
2 SR1 and SR2 only with fold-
8 2
1
P 2 26 +13,8V BOOTSTRAP 40 1 A1 2 SAS/BRS1
9
ing platform, otherwise
_ 2 4
1 41 GND NCL TXD 1 4 CA 206 C2 6
1 CA413
bridge 824907 present.
4 23 Signal PCL TXD 2 5 C3 8 2 CA417 HNS 1
NCL RXD 29 6
3 1 3 BRS only with fixed platform,
A3 10 4 2
20 SAS 33
-B
B6 otherwise bridge present on
9
30
+ OUT
SMART + IN
7 5
CA419
1
HNS 2 PC205
11
CA208 SR1 1 2 4 8 6 2
unused 11 12 4 F/C option is activated below
PROX. READER
1 1
A 24 INFOLINK 2 3
35 -
C 3 4 5°C.
31 B PNP 15 14 2
CA204 4
18 R/T PCB
BRK unused
CA250 A2 3
4 8
5 Filter for strobe (item no.
CA209 SR2 1 2
unused 19 +
16 UNUSED UNUSED 10 CA414 HSS1
822569)
A 17 UNUSED UNUSED 11 1
19 UNUSED UNUSED 12
SV 39 5 -
C
22 UNUSED UNUSED 18
B PNP 23 UNUSED UNUSED 20
unused 20 28 UNUSED UNUSED 21 1
HYDR. PCB 7 Travel alarm (item no.
SHOCK SENSOR
29 UNUSED UNUSED 26
CA223 LMS1 1 32 UNUSED UNUSED 27 CAN-H A15 2
unused 36
HN
32
+
A
33 UNUSED
34 UNUSED
UNUSED 30
UNUSED 31 B4 3 115565)
21 C 35 UNUSED
B1 CA415
CA204 FAN CA204
-
B PNP 6 1
4
RAS LOS 8 Option
unused 38 7 2 CAN-L A6
8 3
1 2 28 4 9 4 A7 5 9 SAS for folding platform,
CA206 PLS1/FPS1 5 HR POT PCB
+ 13 25
CA203
8 7
CA203
A 1 A14 7
4 8 CA416
1 4 8 BRS1 for fixed platform.
34 -
C 10
8 2
1 ALM 2 16 PNP CA211 CA211.1
B
1 2 3 4 5 6 1 2 3 4 5 6
10 PLS1 for folding platform,
CA207 PLS2/FTS1&2 CAN CONNECTION
FPS1 for fixed platform.
FLS 6 8
+
14 A 1
37 C 11 11 PLS2 for folding platform,
CA 222 1 2 -
B PNP
FTS1 & 2 for fixed platform.
5 8
-B
15 6 CA214 TFD UNIT
5 BLU
CA202
+
1 2 BRS (TILLER)
CA200 3 Coil
+BV (AK)
3 6 WHT
25 4 ORN
4 CAN-H
27 ACCESS 5
13 CAN-L CA221=B
42 (SCM)
17 CHNL B 8 Low B1 2 BLK
CA222=A
CHNL A 22 A4 +5V B2 1 RED
+13,8V 9 A5
+B W1 B6 3 GRN
W
ECR1
CA217
A7
CA224 2 1 W +13,8V 1
GND A10
V CAN-L
A6 A8
V
M1 CHNL A 3 CHNL B
120 Ohm
FU 7 FU 5 FU 4 CHNL B 2
-B U
4A 10A 10A U GND 4
CHNL A A9
8
CA200 CA213
A14 CAN-H +13,8V B5
CA215 TS1
TS1 12 1
+ _ TRACTION SAHS 1
+
W
T MOTOR Signal
2 3 A3 V
-
NPN 2
GND 10 A1 U
+
Ax
EDS -
-P A2 CA218 ECR2 U V W ECR3 CA219
+BF A12 +13,8V B4 1 +13,8V +13,8V 1
FU 1 + -
355A CHNL B B7 2 CHNL B M3 CHNL B 2

EDS LINE PUMP MOTOR +B FU 2 GND A11 4 GND GND 4
FEEDBACK TOP
30 A CA216
_
-B TS2 B3 1
+
STEERING
-B T TS2
A13 2 MOTOR
BD:1 BD:2
-
+
24V BATT
827193_2C-2
Fig. 159
WT 3000 Series
Rev. B
379
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR, POWER SIDE ACCESS 3/2 AND ACCESS 5, LOGIC SIDE ACCESS 3/2
WT -E, with CAN Tiller, ABM Motor, Power Side Access 3/2 and Access 5, Logic Side Access 3/2
CA224
2929 CA206-A
FU7 511 -B 2 580 CA205-13 INFOLINK 2930 CA207-A
210 211 1 280 CA250-25 INFOLINK 13 2931 2928
4A 3 3
201 17 5906 WHT LINE BLK 2925 2928

FU5 208 CA220-5 ACCESS 3/2 + Batt
SMART
+ OUT
7 2916 CA222-4 ACCESS 5 (SCM)
2924 CA213-1
°
2926 CA222-5
207 205 209 CA200-20 (TCM / HCM) + OUT
35 2909 CA208-C SR1 2927 CA222-7
10A 213 SOCKET 86 901 CA211-1
FU3 2923
27 900 902 CA222-14
206 202 CA225-2 903 CA201-8 2923
4A 5 2910 PC209-C SR2
904 CA220-4 2918 SOCKET 87
FU4
2900 2901 2902 CA200-4 UNUSED 11 2920 CA205-1
908 CA211-2
10A 2903 SV 2921 CA209-A
42 909 910 CA222-6
2904 HN 2922 CA208-A
AxEDS 911 CA201-9
37 2914 PC207-C PLS2 2932 CA214-5
GRN
2905 CA204-1 912 CA220-1

2 2919 CA223-A
2906 CA202-1 30 WHT
200
2907 CA203-1 2 BRK

31 BRN
2934 CA214-5
21 2911 CA223-C LMS1
33 2915 CA220-6 HANDLE
EDS LINE
4 2902
+BF 25 101 CA214-4 TFD
205 FU5 OUT
FLS
20 209 208 CA220-5
RED
ACCESS 5
BLK
+B 206 FU3 IN
UNUSED 18
213 SOCKET 86
BD:1 (SCM) FU1
3 5908 CA214-6 TFD
FU2 U 355A
U 1 2 CA222
30A UNUSED 19 Filter
PN822569
B+ V 14 UNUSED
V M3 2 CA202
1
UNUSED 24
W 2906
W 15 5904
-B
16 5905 2 ALM 1 2907 2934 CA214-5 TFD
CA203 CA203
24V UNUSED 36 2901 FU4 OUT
FAN
BATTERY 28 5903 2 1 2905 2904
CA204 CA204
UNUSED 38
HN
39 5901 SV 2903
32 5902
ACCESS 3/2
CA210
TCM / HCM
+ SIGNAL 23 100 4 Signal
P
PS
U GND 41 600 601 1
GND
U
+13,8V
+13,8V 26 300 301 2
V
BD:2 M2 M1 V 34 2912 CA206-C PLS1 CA212
W 602 2 CONSOLE
UNUSED 36
W 302 3
NCL TXD 1 003 4
- PCL TXD 2 002 5
NCL RXD 29 001 6

-P
40 004 1
2
CA217
+13,8V 9 GRN 1 RED +13,8V ECR1
2
-B CHNL B 8 YEL 2 BLU CHNL B
2
CA201-4 505 504 CHNL A 22 GRAY 3 WHT CHNL A
1
CA220-2 506 VIO CA213-2 UNUSED 38 BLU
1
4 BLK GND
CA209-B 507 500 1
GND 10 604 RED 2 WHT TS1
CA208-B 508 501 CA206-B PLS1 2
KEYPAD 509 502 CA207-B PLS2 TS M1 12 PINK 1 BLK T
CA223-B 510 511 CA224-2 PWS 6 2913 CA205-C BRS CA215

82713_2C-3-4
Fig. 160
WT 3000 Series
Rev. B
380
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR, INFOLINK™, LOGIC SIDE ACCESS 5 AND INTERFACE ACCESS 8
WT -E, with CAN Tiller, ABM Motor, InfoLink™, Logic Side Access 5 and Interface Access 8
CA222 CA213 CA204

ACCESS 5 1
A1 GRAY/PINK 3 BLU SAHS 1 2982 PC410-2 SAS/BRS1
(SCM) Signal
1 -B
A2 VIO -B ACCESS 3/2 2 RED 2 2985 PC414-3 HSS1
1 NPN
A3 BLK 1 BLK +BV(AK)
3 2983 PC410-10 HNS
A4 2916 PC200-7 ACCESS 3/2 2918 SOCKET 87 4 2981 PC410-4 FF

2925 LINE CONTACTOR 2919 CA223-A 213 SOCKET 86
5 2980 PC410-3 PF
(INTERFACE)
A5 2926 2923 2920 CA205-A 206 FU3 IN
ACCESS 8
2928 2929 CA206-A 2921 CA209-A 6 2988 PC415-4 RAS 209 CA200-20
A7 2927 2930 CA207-A 2922 CA208-A
2931 CA200-13 205 FU5 OUT
7 2989 PC415-5 LOS
A6 910 CAN LOW CA219 900 CA200-27
8 UNUSED
1 ECR3 901 CA211-1
CHNL B A8 WHT/GRN 2 BLU CHNL B
9 380 PC410-5 POT HIGH 902 CA222-14
1
CHNL A A9 WHT/YEL 3 WHT CHNL A 903 CA201-8
10 UNUSED
1
GND A10 YEL/BRN 4 BLK GND 510 CA223-B
11 UNUSED
509 KEYPAD
A12 UNUSED 1 RED +13,8V
12 UNUSED 508 CA208-B
A14 902 CAN HIGH CA216 507 CA209-B
13 180 PC410-7 POT WIPER
1 505 CA201-4
TS2 A13 PINK 2 WHT TS2 14 2990 PC415-7
504 Batt-
1
GND A11 YEL 1 BLK T
15 2987 PC415-2 +BV(AK) 908 CA211-2
909 CA200-42
16 580 PC410-1 GND
910 CA222-6
CA221 CA205 CA220 911 CA201-9
1
1 WHT 1 912
TS2 B3 GRAY CA218
2 YEL 2 506
1
+13,8V B5 RED/BLU 4 BLK GND ECR2
3 PINK 3 2933 FU6 OUT
1
+13,8V B4 WHT 1 RED +13,8V
4 BRN 4 904
1
CHNL B B7 BRN 2 BLU CHNL B 5 GRN 5 208
1
CHNL A B8 GRN 3 WHT CHNL A 6 GRAY 6 2915 CA200-33 ACCESS 3/2
PC214/JC232
LOW B1 603 2 BLK CA206
+5V B2 700 1 RED 1 UNUSED
OUTPUT 1 B6 102 3 GRN 2 UNUSED
101 4 YEL 3 680 PC410-8 POT LOW

TFD UNIT
4 UNUSED
2934 5 BLU +
Coil 5 UNUSED
6 WHT
6 UNUSED
5908 PC200-3 ACCESS 3/2
7 UNUSED
2934 FU4 OUT
8 UNUSED
101 PC200-25 ACCESS 3/2 82713_2C-5-6
Fig. 161
WT 3000 Series
Rev. B
381
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR. INFOLINK™: PLATFORM, SIDE RESTRAINT AND ENTRY BAR SWITCHES
WT -E, with CAN Tiller, ABM Motor. InfoLink™: Platform, Side Restraint and Entry Bar Switches
CA208 CA206 FIXED PLATFORM REAR ENTRY

2929 A WIRE 1 FPS1
Side Foot Presence
-B
508 B BLU Restraint 501 B Switch 1
Sensor 1 (Floor Mat Switch)
Signal PNP
2912 CA200-34 ACCESS 3/2 C WIRE 2
504 -B ACCESS 3/2
505 CA201-4 DISPLAY CA209 500 -B ACCESS 3/2
CA207
Side 2930 A BRN +BV(AK) FTS 1

507 B BLU -B
Restraint Foot Guard
-B Switch 1
Sensor 2 502 B BLU
Signal PNP (Entry Bar Sensor)
2910 PC200-5 ACCESS 3/2 C BLK
Signal PNP
506 CA220-2 HANDLE
509 KEYPAD CA223
2919 A BRN +BV(AK) LMS1

Lift Limit
510 B BLU -B
Switch
CA206 FIXED PLATFORM SIDE ENTRY
Signal PNP
2929 A WIRE 1 FPS1
2918 SOCKET 87 Foot Presence
501 B Switch 1
CA205 (Floor Mat Switch)
2912 CA200-34 ACCESS 3/2 C WIRE 2
2920 A RED
500 -B ACCESS 3/2
UNUSED B BLK BRS 2
502 CA207-2
CA207.1
2913 PC200-6 ACCESS 3/2 C WHT
2923 2924 CA213-1 SAHS Foot Guard
1 Fixed platform: SR1 and SR2 replaced by bridge 581 B BLU -B Switch 1
2925 LINE CONTACTOR 825877 on CA207 and CA208. (Entry Bar Sensor)
PNP
2926 CA222-5 ACCESS 5 2 BRS only with fixed platform, otherwise bridge present 2971 C BLK Signal
on PC205
2927 CA222-7 ACCESS 5 CA207.2
2928 2931 CA200-13 ACCESS 3/2 2971 A BRN FDS 1 (OPTION) 1
+BV(AK)
Fold Down
CA207 582 B BLU -B
Step 1

2972 C BLK
CA206 FOLDABLE PLATFORM 502 B 580 CA207.3
2929 A BRN +BV(AK) PLS 1 2914 C 2974 2972 A BRN +BV(AK) FDS 2 (OPTION) 1
Platform Fold Down

501 B BLU -B
Switch 1 -B
Step 2
583 B BLU
Signal PNP
2912 CA200-34 ACCESS 3/2 C BLK 2973 C BLK Signal PNP
1 Trucks without folding steps:
500 -B ACCESS 3/2 CA207 FDS1 and FDS2 are replaced by CA207.4
bridge 824907.
2930 A BRN PLS 2 2973 A BRN +BV(AK) FTS 2
+BV(AK)
Foot Guard
Platform -B Switch 2
502 B BLU -B
Switch 2 583 B BLU
(Entry Bar Sensor)
PNP Signal PNP
2974 C BLK
82713_2C-7-8
Fig. 162
WT 3000 Series
Rev. B
382
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, ABM MOTOR, INFOLINK™, ASSEMBLIES IN TILLER HANDLE AND POWER UP VARIANTS
WT -E, with CAN Tiller, ABM Motor, InfoLink™, Assemblies in Tiller Handle and Power Up Variants
CA 411 CA201
CA 410 1
POT
ACCESS 1 1 UNUSED
580 PC204-16 GND 1
2
(DISPLAY)
3 2 5907
2982 PC204-1 SAS IN 2 4 POT
3 204
PF 504 -B
2980 PC204-5 PF 3 5
FF 4 505 506 CA220-2
6
2981 PC204-4 FF 4 507 CA209-B
7 5 UNUSED
+13,8V
508 CA208-B
380 PC204-9 POT HIGH 5 GND 509 KEYPAD
CA 412 6 UNUSED
BLU 510 CA223-B
581 PC415-8 GND F/C 6 3 PN818731
7 UNUSED
1 CAN HIGH 900 CA200-27
180 PC204-13 POT WIPER 7 SAS/BRS1
BLK 8 903 901 CA211-1
120 Ohm
2 3
680 PC206-3 POT LOW 8 902 CA222-14

CA 413 9 911
904 CA220-4
CA 417 CAN LOW
2984 PC415-1 +BV(AK) 9 1 10 UNUSED
2 908 CA211-2
2 HNS1 909 CA200-42
2983 PC204-3 HORN 10 1 11 UNUSED
1 2
3 2904 HNS 910 CA222-6
2991 +BV(AK) F/C 11 12 UNUSED 912 CA220-1
15 x //R 4 2903
CA 419
582 PC414-4 GND F/C 12 5 2902 2 13 UNUSED OPTION 1 & 2 STD CA225
HNS2 1 204
6 2901 1
GND
+10V 14 UNUSED 2 202 FU3 OUT
MAIN PCB F/C HNS 3 2935
KEYLESS ENTRY CA250-15 2980 4 203
CA250-24 2981 5 212
CA 415 CA224-1 281 2 6
STD
2984 PC410-9 +BV/AK) 1 KEYLESS ENTRY K1 30
30 212
85
2987 PC204-15 +BV(AK) 2 85 5907
CA250-15 2980
2986 PC414-1 +BV(AK) 3 86
203
CA224-1 281 2 86
213 FU5 OUT FU6 CA220-3 2933
87
2988 PC204-6 4
87 2917 2932
RAS LOS1 CA250-24 2981 4A
87a 87a
2918
2989 PC204-7 5 OPTION 1 2919 CA223-2
KEYSWITCH 2920 CA205-1
NOT USED CA 416 2921 CA209-A
6 KYS ADAPTER
2922 CA208-A
30
2991 PC410-11 +BV (AK) RED 1 2
KYS 2982 2932 CA214-5 TFD
7 1
15 x //R 1 85
2990 PC204-14 +BV (AK) 2
2981 2923 2924 CA213-1 SAHS
16 x //R 87
BLK 2983 CA222-5 2926 2925 LINE CONTACTOR
581 PC410-6 GND F/C 8 2 87a
CA222-7 2927 2928
86
232 232 CA206-A 2929
HYDRAULIC PCB F/C POT PCB F/C CA207-A 2930
CA200-13 2931
OPTION 2
CA 414 KEYPAD 1 Bridge 203 is only present when relay K1 is installed.
2986 PC415-3 +BV(AK) 1 KEYPAD KYS ADAPTER 2 Wire 281 used without InfoLink box.
30 Wire 2981 used with InfoLink box.
RED/WHT 2982
UNUSED 2 85
2981
HSS 2983 87
2985 PC204-2 3 BLK 87a
86
582 PC410-12 GND F/C 4
1 2
RED 232 232
2 x //R GRN 509
R/T PCB F/C 82713_2C-9-10
Fig. 163
WT 3000 Series
Rev. B
383
384
Rev. B
Fig. 164
CA211 CAN CONNECTION
ACCESS 3/2 CAN HIGH
900 901 981
(TCM / HCM) 27 2
908 986
3
SCHEMATIC DIAGRAMS
4
5
CA200
909 6
42 7
CAN LOW
CA211.1
WT -E, with CAN Tiller, ABM Motor, InfoLink™, CAN-Bus Circuit Diagram
982
ACCESS 5 CAN HIGH 2
902 987
(SCM) 14 3
4
5
6
CA222
120 Ohm
910 7
6
CAN LOW
CAN HIGH
CA220
ACCESS 1 903
8 6 HANDLE
(DISPLAY) 5
904 4
3
CA201
120 Ohm
2
911 912
9 1
CAN LOW
ACCESS 8 CAN LOW

WHT
1
WT -E, WITH CAN TILLER, ABM MOTOR, INFOLINK™, CAN-BUS CIRCUIT DIAGRAM
(INTERFACE)
CA205
BRN
4
CAN HIGH
WT 3000 Series
988
983
CAN L 6 5 CAN H
2991 CA225-1 CA250 CA250
2992 CA225-4 2990 CA225-2 2980 15

2991 CA225-1 Used with InfoLink Box
2993 CA225-5 2994 2981 24 INFOLINK
2992 CA225-4
Only used without InfoLink Box
2993 CA225-5 2994 281
CA224 CA250
CA211 FU7 OUT 211 1 280 282 25
6 BATT NEG 511 2 580 13
5
4
3 CA250
2 985 987 5
1 980 982 4
CA255 CA250
CA211.1
SHOCK 1 VIO 1 780 6
1 981 SENSOR 2 GRN 2 680 7
CAN CONNECTION
2 986 3 BRN 3 080 8

3
4 WHT 4 081 9
4
5
CA251 CA250
6
PROX. 1 RED 1 781 1
READER 3 GRN 3 082 2
4 WHT 4 083 3
2 BLK 2 681 14
82713_2C-11
SCHEMATIC DIAGRAMS
WT -M, WITH CAN TILLER, CROWN MOTOR, KEYLESS POWER-UP, COMBINED EDS/LINE CONTACTOR
WT -M, with CAN Tiller, Crown Motor, Keyless Power-Up, Combined EDS/Line Contactor

- K1 = Closed
- Platform up
2 Reduced travel speed: HSS1 = Open
3 Folding platform = SAS
Fixed platform = BRS1
4 Folding platform = PLS1
Fixed platform = FPS1
Fixed platform = FTS1 and FTS2
831975_2B-1
Fig. 165
WT 3000 Series
Rev. B
385
SCHEMATIC DIAGRAMS
WT -M, WITH CAN TILLER, CROWN MOTOR, WITH OPTIONS, COMBINED EDS/LINE CONTACTOR
WT -M, with CAN Tiller, Crown Motor, with Options, Combined EDS/Line Contactor

- K1 = Closed
- Platform up
831975_2B-2
Fig. 166
WT 3000 Series
Rev. B
386
SCHEMATIC DIAGRAMS
WT -M, WITH CAN TILLER, CROWN MOTOR, KEYLESS POWER-UP, SEPARATE EDS/LINE CONTACTORS
WT -M, with CAN Tiller, Crown Motor, Keyless Power-Up, Separate EDS/Line Contactors
CA201
B+ (FU2) 205 RED CA410 CA411
IC
FS
B+
+
1 5
RS (FF)
FS (PF)
YEL 6
B+ (AK)
Out
3
U+
-
U-
2 1
ACC
IC
RS
Ou t B+
-
BLK nu 2
905 CAN-L 3 4
ACCESS 2/3 CAN-L 27
U-
U+
+
BLU 3
(HCM / TCM) CAN-H 900 CAN-H 4 RED/BLU
8
POT
28 5 4
+13V
CA204 GRN
1 7
303
PS1 2 CA209
-
P CA209 GRAY/PINK CA412 BLU
000 2 3
4 30 1 3 SAS
-B
U+
U-
BLK
U 203 204 BRN
3
2927
1 ACCESS 1 7
903
908
210
ACC
BLK
206
508
2
B+
(Display DCM)
BLK
-
210 204 5961 held closed GRY
604 6
1 2 3 4 5 6
NTC
261
Out +BV_F
IC
GND 11
+
+ OUT CA500 86 + 30 CA214
T
2908 CAN-H HNS 1
4 SMART + IN 1 2 3 4 5 6 5962 4 1
U-
U+
K 902 901 12 CA417
120 Ohm
ICM Conn. 8 1 3 2
IC
CAN CONNECTION
B+
85 - 87 907 906
B-
B-
RED 2911 CA200 9 2 GRAY
Out
see page 4 K 120 Ohm
10 HNS 2
BRK 5900
5909
2 2 4 CAN-L 3 6 1
2962
5 2
CA419
9
503
CA211 4 MAIN PCB
2925 2915
DI10 16 C A 5 5962
4
CA209 PLS2 B- WHT/GRN ACCESS 8.1
B+ (AK)
HSS
502
B PNP PLS1 6 3 (OCM 1)
34 5
501
B 4 CA414
CA209 B-
PNP
CA206 2961
2924 B- 2914 1 R/T PCB
33 DI7 35 A C 1
CA209 CA210 4 BRS CA415
2903 5907 2913 VIO HYDR. PCB
1 SV 2 24 2 4
2909 2909 261
DI0 1 3 6
5961
CA203 8 RAS LOS1
RED
HN 2921 2921 7
CA209
DI8 17 C LMS 2961
2920 PNP 3
2904 5903
26 CA208 SR2
+13V
A 2962
1
605 B WHT
GND B
304 2
505
2902 001 A PINK
3 B+ DI12 21 C NPN 5
CA213 FAN
DI11
002 305 CA200
2905 5906 18 C A B-
1 2 9 GND
606
B 2910 WHT
DI5 19 NPN 10
CA215 CA207 SR1 2920
8
VIO
2907 5905
1 2 8 DI1 20
2922 2922
9
PINK
2923 2923 GRAY

DI9 29 11 1 Shown with truck in standby:
2919 2919 YEL
DI3 32 7 - K1 = Closed
2918 2918 BLK
DI4 31
300 302
6
RED/BLU
CA216 CA209 +13 V 25 5 - Forks fully lowered
2906 5904 600 603 BLU
1 2 11
B+
GND 5 4 - Platform up
2912 004 2916 WHT/GRN
10 CHNL A 14 1 - Side restraints down
5908 005 2917 GRAY/PINK
12 CHNL B 13 2 - Tiller = upright and centred.
100 003 BRN
TS1 22 3
CA224 2 1 A/D 504 GRN 2 Reduced travel speed: HSS1 = Open
(EVP2) 23 12
TRACTION CA 205
PWS MOTOR TS1 + BRN 100
1
507
209
T WHT / BRN
2
602
B-
2901
CONTROL LOGIC
B+
202
B- U ECR1 CA 212
U AC CHNL B
BLU
4
005
GND 4 Folding platform = PLS1
V 3 CHNL A WHT 3 004
FU4 FU2 FU3 V GND
BLK
2
601 Fixed platform = FPS1
4A 4A 4A W M1 +13V
RED
1
301
W 5 Folding platform = PLS2
B-
2900
208
207
2916
DI2 6
2917
B+
DI6 7
CONTROL LOGIC
2926
201
003
5908
200 AN. 15
+
-P
B-
Ax -
EDS
FU1 B+ + -
M2
355A
PUMP MOTOR
EDS LINE
BD:1 BD:2
B-
24V BATT
500
B- 831975_2C-1
Fig. 167
WT 3000 Series
Rev. B
387
SCHEMATIC DIAGRAMS
WT -M, WITH CAN TILLER, CROWN MOTOR, WITH OPTIONS, SEPARATE EDS/LINE CONTACTORS
WT -M, with CAN Tiller, Crown Motor, with Options, Separate EDS/Line Contactors
RED
see page 4 ICM Conn.
1 2 3 4 5 6
CA500
1 2 3 4 5 6
-B 508
210
206
908
903
2927
CA201
B+ (FU2) 205 RED CA410 CA411
IC
FS
B+
+
1 5
RS (FF)
FS (PF)
YEL 6
Out
B+ (AK) 3
-
U-
U+
2 1
ACC
IC
RS
Ou t B+
-
BLK nu 2
905 CAN-L 3 4
CAN-L 27
U-
U+
ACCESS 2/3
+
BLU 3
8
POT
28 5 4
+13V
CA204 GRN
1 7
303
PS1 2 CA209 CA412
-
P CA209 GRAY/PINK
2 3
BLU
000
4 30 1 3 SAS
U+
U-
BLK
U 204 BRN
1 3 ACCESS 1 7
ACC
KEYPAD 2
BLK
B+
(Display DCM)
BLK
-
604 6
6
NTC
86 30 261
Out +BV_F
IC
GND 11
+
+ OUT CA214
T
232 HNS 1
232
2982
2908 CAN-H
4 SMART + IN RED/WHT 5962 4 1
U+
12
U-
902 901 CA417
120 Ohm
BLK 8 1 3 2
IC
CAN CONNECTION
B+
B-
RED KYS 2983 2911 CA200 907 906 GRAY
B-
9 2
Out
10 HNS 2
BRK 87 120 Ohm
5909
2
GRN
2981 2 4 CAN-L 3 6 1
2962
5 2
CA419
9
506
503
CA211 4 MAIN PCB
2925 2915 B-
DI10 16 C A 5 5962
4
B+ (AK)
502 6 3 HSS
B PNP PLS1 (OCM 1)
34 5
501
B 4 CA414 6
CA209 B-
PNP
CA206 2961
2924 B- 2914 1 R/T PCB
33 DI7 35 A C 1
CA209 CA210 4 BRS CA415
2903 5907 2913 VIO HYDR. PCB
1 SV 2 24 2 4
2909 2909 261
DI0 1 3 6
5961
CA203 8 RAS LOS1
RED
HN 2921 2921 7
CA209
DI8 17 C LMS 2961
2920 PNP 3
2904 5903
26 CA208 SR2
+13V
A 2962
1
605 B
2
GND B WHT
304 2 6
505
2902 001 A PINK
1
3 B+ DI12 21 C NPN 5
CA213 FAN
DI11 18
002 305 CA200
2905 5906 C A B-
1
1 2 9 GND
606
B 2910 WHT POT PCB F/C 6 CA416
DI5 19 NPN 10
2
CA215 CA207 SR1 2920
8
VIO
2907 5905
1 ALM 2 8 DI1 20
2922 2922
9
PINK
2923 2923 GRAY

CA 222 DI9 29 11
2 2919 2919 YEL
FLS DI3 32 7
1
2918 2918 BLK
DI4 31 6
CA216 CA209 +13 V 25
300 302
5
RED/BLU 1 Shown with truck in standby:
2906
1 2
5904
11 GND 5
600 603
4
BLU - K1 = Closed
2912
10
B+
CHNL A 14
004 2916
1
WHT/GRN - Without load on forks
2926
5908
12 CHNL B 13
005 2917
2
GRAY/PINK
TS1 22
100 003
3
BRN
- Platform up
A/D 504 GRN
CA224 2 1 (EVP2) 23
TRACTION CA 205 12
1
507
209
T WHT / BRN
2
602
B-
2901
CONTROL LOGIC
B+
202
B-
U
U ECR1 CA 212
005
BLU 2 Reduced travel speed: HSS1 = Open
AC CHNL B 4 GND
WHT
V 3 3 004
FU4 FU2 FU3 V
CHNL A
GND
BLK
2
601 3 Folding platform = SAS
4A 4A 4A W M1 +13V
RED
1
301
W
B-
2900
208
207
2916
DI2 6 Fixed platform = FPS1
2917
DI6 7
B+
CONTROL LOGIC
2926
201
003
5908
200 AN. 15
+
-P
B- 6 F/C option is activated below 5°C.
Ax -
EDS
FU1 B+ + -
M2
355A
PUMP MOTOR
EDS LINE
BD:1 BD:2
B-
24V BATT
500
B-
831975_2C-2
Fig. 168
WT 3000 Series
Rev. B
388
SCHEMATIC DIAGRAMS
WT -M, WITH CAN TILLER, CROWN MOTOR, PLATFORM SWITCH
WT -M, with CAN Tiller, Crown Motor, Platform Switch
CA 210 FIXED PLATFORM REAR ENTRY CA 210 FIXED PLATFORM SIDE ENTRY
2914 A WIRE 1 FPS1 2914 A WIRE 1 FPS1

Foot Presence Foot Presence
501 -B ACCESS 2/3 B Switch 1 501 -B ACCESS 2/3 B Switch 1
(Floor Mat Switch) (Floor Mat Switch)
2924 CA209-35 ACCESS 2/3 C WIRE 2 2924 CA209-35 ACCESS 2/3 C WIRE 2
2911 RELAY SOCKET PIN 87
CA 207.1
2912 CA209-10 ACCESS 2/3 2912 CA209-10 ACCESS 2/3
2913 CA206-2 BRS1 2913 CA206-2 BRS1 2970 A BRN +BV(AK) FTS 1
Foot Guard
2924 CA205-2 SRT 2924 CA205-2 SRT 581 B BLU -B Switch 1
(Entry Bar Sensor)
2926 LINE COIL CA 211 2926 LINE COIL Signal PNP
2971 C BLK
Foot Guard CA 207.2 CA 207.2
-B Switch 1 STANDARD OPTION
502 B BLU
(Entry Bar Sensor) 2971 A Bridge A BRN +BV(AK) FDS 1
Signal PNP 1 Fold Down Step
2925 C BLK
PC211/JC207 582 B B BLU -B
Sensor 1
2925 CA209-16 ACCESS 2/3 PNP

2915 A 2970 2972 C C BLK Signal
502 -B ACCESS 2/3

502 B 580 CA 207.3 CA 207.3
STANDARD OPTION
1 Fold Down Step
583 B B BLU -B
Sensor 2
2925 CA209-16 ACCESS 2/3
502 -B ACCESS 2/3 Signal PNP
2973 C C BLK
CA 207.4
Foot Guard
(Entry Bar Sensor)
Signal PNP
2974 C BLK

FDS1 and FDS2 are replaced by
bridge 824907.
831975_2B / C-3
Fig. 169
WT 3000 Series
Rev. B
389
SCHEMATIC DIAGRAMS
WT -M, CROWN MOTOR, INFOLINK™ CIRCUIT DIAGRAM BASED ON CAN-BUS
WT -M, Crown Motor, InfoLink™ Circuit Diagram based on CAN-Bus
ICM INFOLINK CONNECTION CAN BASED

PC-502 JC-502
Connect_to Pin Pin I/O-Usage
Free 32 32 Free
Free 33 33 Free
PC500 JC500 Free 16 16 Free

Free 17 17 Free
210
(PC405-5) 6 6
+BV (AK) 2927 5 5 PWR_TO_KYS 24 24 PWR_TO_KYS
206 4 4 PWR_after_KYS 15 15 PWR_after_KYS
+BV ( FU1)
508 Free 23 23 Free
-B 3 3
908 2 2 nu 22 22 nu
CANL
903 1 1
CANH 25 BV 25 25 25 BV
Ferrite-Core
13 GN 13 13 13 GN
CA507 Free 21 21 Free
1 14GND3 30 30 14GND3
2 FREE 31 31 FREE
RS232
3 Free 10 10 Free
11 TX 11 11 11 TX
CA508
12 RX 12 12 12 RX
CA505 1 1
6_5V 6 6 6_5V
4 2 2
SHOCK 7_GN 7 7 7_GN
2 SENSOR 3 3 8_XIN 8 8 8_XIN
LOAD 3_YIN 9 9 3_YIN
3 4 4
1 14_GN2 18 18 14_GN2
19_CS 19 19 19_CS
20_LS 20 20 20_LS
1_10V 1 1 1_10V
14_GN 14 14 14_GN
2_PRDO 2 2 2_PRDO
3_PRD1 3 3 3_PRD1
CA503
1 26_AL 26 26 26_AL
Switch 2 27_AL- 27 27 27_AL-
Proximity- 3 CAN_L 5 5 CAN_L

Ferrite-Core
CAN_H 4 4 CAN_H
4
Free 28 28 Free
Free 29 29 Free
Free 34 34 Free
A
CURRENT C 7_GN
B
CA506
1 2
ALARM
1 2 3 4 5 6
PC 501 CAN 831975_2B / C-4
Fig. 170
WT 3000 Series
Rev. B
390
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, CROWN MOTOR, KEYLESS POWER-UP
WT -E, with CAN Tiller, Crown Motor, Keyless Power-Up
214
+BV
206
+BV (AK)
215
2935
- K1 = Closed CA212
FU 3
4A CA420 12 11 10 9 8 7 6 5 4 3 2 1 +10 V
CA411
- Without load on forks 602
2 204
CA410 +5 V
5
202
YEL
RS (FF)
FS (PF)
K1 3 ACCESS 1 5 FWD
6
- Forks fully lowered 302
3
203
GRY 3 1
ACC
(DISPLAY) B+ FS FILTER1 GND
- Platform up BOOTSTRAP 40
004
1
86 + 30 212 H
CA201
WHT 1
RS
REV FILTER1 nu 2
CA201
K1 +5 V FILTER2
602
302
CAN-L
903 CAN-H
120 Ohm
- Side restraints down PS CA210 CA200 NCL TXD 1
003
4 1 6 5 4 2 3 1 8 BRN 4
CS1 ACC
POT
GND
3
POT
85 - 87 911 CAN-L CAN-H
4
- Tiller = upright and centred. 1
P 2
301 300
26 +13V PCL TXD 2
002
5 -K1
CA225 9 PINK 6
CS2
CLK
GND
Belly_3
+5 V
7
601 600 001 5907 L 505 DATA Belly_3 GND
1 41 GND NCL RXD 29 6 2 4 R/T Belly_1

2 SR1 and SR2: Fixed platform trucks 100
GRN 2 B- µ-PROCESSOR
(µP)
FILTER3 GND
3
CA412 BLU
HNS
10V
have a bridge 824907 on PC208 and
4 23 Signal ACCESS 3/2 2917 FU 6 2932
5V
Belly_1 FILTER3
2918 + BV (AK) -B CA418 1 SAS
B+
BLK
B-
-
3 CLK SAS Signal
PC209. 209 (TCM / HCM) 900 CAN-H 4A

7 2
BLK
20 H 27 DATA
BLK
NTC
GRY
B+ (AK) held closed
Out +BV_F
IC
1
+
CS1
909 CAN-L
T
L 42
3 BRS: Fixed platform trucks have a 2 CS2
U-
U+
WHT + OUT + IN 2916 6 HNS 1
30 SMART 7
bridge 824907 on PC205. 208 YEL 9 B- +5 V FILTER4
B-
3 1
CA417
2915 2915
5 PINK
12 Horn 1 2
GND
SAS 33
4 Folding platform = SAS BRN CA208 SR1 2933
6 GRY
8
4 +24 V
IC Voltage REG.
+10 V
+10 V
GND
31 1 2 3 10 V
U out U Reg.
U Reg. +5 V
HNS 2
Fixed platform = BRS1 BRK
2922 A 904
4
BRN CAN-H 5
11 R/T
UB in
GND
MAIN PCB
4
2
1
2
CA419
2909 912 WHT CAN-L B+ (AK) GND
35 1
BLK12
BLK11
BLK10
C 10
BLK3
BLK7
BLK1
BLK2
BLK6
BLK8
BLK4
BLK5
508 PNP 506 GRN
B 2
unused 11
Fixed platform = FPS1 2903
SV
5901
39
-B
CA209 SR2 1 2 CA220
4
HSS ACCESS 8.1
unused 18 2921 A -B 3
6 Folding platform = PLS2 5
2910
C
CA414
1 (OCM 1)
507 see page 4 1 R/T PCB
Fixed platform = FTS1 and FTS2 unused 19
B PNP
2904 HN 5902 -B 214 6
32 CA223 LMS1 1 6
unused 20
10 V
MAGNETIC ROTARY ENCODER & IC DC CONVERTER MAGNETIC ROTARY ENCODER & IC
RED
2919 A 2936 5 5 10 V UB in
2911 4 DSP HALL

360°
GND U out DSP HALL
360°
CA204 FAN CA204 GND

21 510
C 213
4 4 6 OTP
ARRAY
X TX +5V OTP
ARRAY
X TX
2905 1 5903 PNP B+ (Heating sw) ABSOLUTE U Reg. ABSOLUTE
28 B
ICM Conn.
2 8
unused 36 -B -B 512 3 3 B+ (FU3) GND
INTERFACE SSI
VDD VDD
INTERFACE SSI
CSn
CSn
CLK
CLK
CA206 PLS1/FPS1 7 LOS ENC RAS ENC
DO
DO
VSS VSS
CA203 CA203
unused 38 2929 A
913 2 2 CS2
2 GND
1 10
2907 5905 2912 CS1
1 2 16 34 C 905 1 1 1
501 PNP DATA
B 5
CA200 CA500 CLK
-B CA207 PLS2/FTS1&2 3
CA415 HYDR. PCB
2930 A
14 2914
1 11
37 502
C
B PNP
-B
CA205
5904 2913
15 6 2920
C 3
CA214 CA232
TFD UNIT
A BRS (TILLER) 2934
CA202 1 2 B 5 5 BLU
+
2906 CA 200 Coil
+BV (AK)
5908 5908
3 6 6 WHT
101 101 680 Ohm
2902
25 4 4 ORN
4
2931 +13V 9
GRN ACCESS 5 CA221=B
13
5906 GND 10
604 (SCM) 603
17 Low B1 2 2 BLK
GRAY CA222=A
CHNL B 22 CAN-H 902 700
CAN-H
+B CHNL A 8
YEL A14 +5V B2 1 1 RED
120 Ohm
PWS PINK 102
TS1 12 CAN-L 910 W1 B6 3 3 GRN
901
908
CA224 2 1 A6
2901
TRACTION CA 215 CAN-L YEL/BRN

205
TS1 PINK 2916 A10

511
211
MOTOR + BRN GND

1
RED
1 2 3CA211
4 5 6 A4 WHT/GRN
T WHT / BRN
2 2926
A5 CHNL B A8
-B FU 7 FU 5 FU 4 CAN CONNECTION WHT/YEL
CONTROL LOGIC
B+ ECR1 CA 217
4A 10A 10A U
YEL
2927
A7 CHNL A A9
U AC CHNL A 3
WHT
RED/BLU
210
201 207
BLU GRAY CA213 +13V B5

V
V 3 CHNL B
BLK
4
BLU BLK BRN
CHNL B B7
2925
5906
GND 2 SAHS 1
M1
2900
W RED GRN GRAY/PINK GRN

W +13V 1 3
VIO
A3 CHNL A B8
NPN 2 WHT
B- A1 +13V B4
+
Ax -B ECR3 CA 224
200 EDS -
-P A2 RED WHT
ECR2 CA 216
W +12V 1 RED RED/BLU
+BF W +12V 1
FU 1 + - A12 V M3 CHNL A
WHT
3
GRN WHT WHT/YEL
V CHNL A 3
M2 3 CHNL B
BLU
2
BRN BLU WHT/GRN
U AC BLK YEL
CHNL B 2
355A U GND 4 BLK YEL/BRN
GND 4
EDS LINE PUMP MOTOR +B FU 2 CA 225
TS2 + _ BLK GRAY FEEDBACK
1
T WHT PINK STEERING MOTOR
30 A 2
-B -B PINK
A13
BD:1 BD:2 GRAY
TS2 B3
VIO
500
504
YEL
-
A11
+ 24V BATT -B -B -B
831976_2C-1
Fig. 171
WT 3000 Series
Rev. B
391
SCHEMATIC DIAGRAMS
WT -M, WITH CAN TILLER, CROWN MOTOR, WITH KEY SWITCH OR KEYPAD
WT -M, with CAN Tiller, Crown Motor, with Key Switch or Keypad
CA500
214
6 6
RED
1 Shown with truck in standby: 2936 5 5
- K1 = Closed +BV
213
4 4
CA410 CA420 12 11 10 9 8 7 6 5 4 3 2 1 +5 V
+10 V
5
CA411
YEL
RS (FF)
FS (PF)
FWD
5 6
-B 512 3
206
2932
3
ICM Conn.
+BV (AK) 2918 GRY 1
ACC
- Forks fully lowered 913 2 3 B+ FS FILTER1 GND
2918
2917
213
2 REV FILTER1 nu 2
RS
FU 3 FU 6 WHT
- Platform up CA212 4A 4A 905 1
1 CAN-L
POT
+5 V FILTER2
3
1 CS1 ACC
602 BRN GND POT
4
- Side restraints down 87 86 204 CAN-H
2
202
2935
4
KEYPAD 3 ACCESS 1 PINK
CS2 GND +5 V
7
2982
302
2983
CLK
3 6 Belly_3

Belly_3
004 212 (DISPLAY) CA201 GRN

DATA
R/T Belly_1
GND
2 B- µ-PROCESSOR CA412
BOOTSTRAP 40 1 30 H FILTER3 GND BLU
CA201
3
602
302
(µP)
HNS
903 CAN-H
2 SR1 and SR2: Fixed platform trucks
10V
120 Ohm
003
5V
CA200 1 4 9 CA418 Belly_1 FILTER3
1 SAS
RED/WHT
PS CA210 NCL TXD
BLK
B+
B-
GRN
BLK
RED
-
5 6 2 4 3 1 911 CAN-L 3 CLK
have a bridge 824907 on PC208 and

SAS Signal
301 300 002 8 2
BLK
26 2 5
2981
232
1 2 +13V PCL TXD CA225 7 DATA
BLK
P
NTC
GRY
held closed
KYS 505 B+ (AK)
Out +BV_F
IC
L
PC209.
1
+
CS1
601 600 001 2 4
T
1 41 GND NCL RXD 29 6 2 CS2
7 *
509
U-
U+
100 6 HNS 1
4 23 Signal ACCESS 3/2
3 BRS: Fixed platform trucks have a -B
-B 9 B- +5 V FILTER4
B-
3
1
1
2
CA417
bridge 824907 on PC205. 209 (TCM / HCM) 900 CAN-H
12 Horn
20 H 27 8
GND
IC Voltage REG.
+10 V
909 CAN-L 4 10 V +24 V +10 V U Reg. +5 V GND

HNS 2
L 42 U out U Reg.
4 F/C option is activated below 5°C. WHT + OUT + IN 2916

5 UB in
GND
MAIN PCB
4 1
CA419
30 SMART 7 11 R/T
B+ (AK) GND 2 2
BLK12
208 YEL 10
BLK3
BLK7
BLK1
BLK2
BLK6
BLK8
BLK4
BLK5
BLK11
BLK10
2915 2915
5 PINK
SAS 33 6
Fixed platform = BRS1 BRN
31 CA208 SR1 1 2
2933
3
GRY 4 7
2922 A 904 BRN CAN-H 3 * HSS ACCESS 8.1
BRK 4
6 Folding platform = PLS1 35
2909
C
912
1
WHT CAN-L CA414
1 (OCM 1)
508 R/T PCB
Fixed platform = FPS1 unused 11
B PNP 506
2
GRN 1
2903 5901 -B CA220
SV 39 CA209 SR2 1 2
7 Folding platform = PLS2 unused 18 CA415
10 V
MAGNETIC ROTARY ENCODER & IC MAGNETIC ROTARY ENCODER & IC
2921 A -B DC CONVERTER
10 V UB in
2910 4 DSP 360°
DSP 360°

HALL GND U out HALL
5 507
C GND
6 OTP
ARRAY
TX +5 V OTP
ARRAY
TX
B PNP B+ (Heating sw) ABSOLUTE X U Reg. ABSOLUTE X
2904 HN 5902
unused 19 -B B+ (FU3)
8 GND INTERFACE SSI
VDD VDD
INTERFACE SSI
CA223 LMS1
CSn
CSn
CLK
CLK
32 1 7 LOS ENC RAS ENC
DO
DO
VSS VSS
unused 20 2919 A CS2
2 GND
CA204 FAN CA204 2911 CS1

21 510
C 1
2905 1 5903 PNP DATA
2 28 unused 36
B 5
-B CLK
CA206 PLS1/FPS1 3
8 7 unused 38 2929 A
HYDR. PCB
CA203 CA203 1 10
2907 1 5905 2912
ALM 2 16 34 C 7 CA416
501
B PNP * 1 2
CA 236 1 2 CA200 -B CA207 PLS2/FTS1&2 1 2
GRN
BLK
FLS 6 8
2930 A
14 POT PCB F/C 7
2914
1 11
* CA416
CA 222 1 2
37 502
C
DC / DC B PNP
CONVERTER 5 8 -B
CA205
5904 2913
15 6 TFD UNIT
BLU
RED
C 3
2920 CA214 CA232
A BRS (TILLER) 2934
CA202 1 2 B 5 5 BLU
CA 240 1 2 +
2906 CA 200 Coil
+BV (AK)
5908 5908
3 6 6 WHT
101 101 680 Ohm
2902
25 4 4 ORN
4
2931 +13V 9
GRN ACCESS 5
13 CA221=B
5906 GND 10
604 (SCM) 603
17 Low B1 2 2 BLK
GRAY CA222=A
CHNL B 22 CAN-H 902 700
CAN-H
+B YEL A14 +5V B2 1 1 RED
BRN
8
BLK
CHNL A
120 Ohm
PINK 102
TS1 12 CAN-L 910 W1 B6 3 3 GRN
901
908
CA224 2 1 A6
2901
TRACTION CA 215 CAN-L YEL/BRN

205
TS1 PINK 2916 A10

511
211
MOTOR + BRN GND

1
RED
1 2 3CA211
4 5 6 A4 WHT/GRN
T WHT / BRN
2 2926
A5 CHNL B A8
-B FU 7 FU 5 FU 4 B+ CAN CONNECTION WHT/YEL
CONTROL LOGIC
4A 10A 10A U ECR1 CA 217 2927 CHNL A A9

U AC CHNL A
WHT 3 YEL A7 RED/BLU
210
201 207
GRAY CA213 +13V B5

V 3 CHNL B BLU 4
V BLK BLU BLK BRN
CHNL B B7
2925
5906
SAHS 1
M1 GND 2
2900

W +13V 1 3
VIO
A3 CHNL A B8
NPN 2 WHT
B- A1 +13V B4
+
Ax -B ECR3 CA 224
200 EDS -
-P A2 RED WHT
ECR2 CA 216
W 1 RED RED/BLU
W +12V 1
+BF FU 1 + - A12 V M3 CHNL A
WHT
3
GRN +12V
WHT WHT/YEL
V CHNL A 3
M2 3 CHNL B
BLU
2
BRN BLU WHT/GRN
U AC BLK YEL
CHNL B 2
GND 4
EDS LINE PUMP MOTOR +B FU 2 _
CA 225
FEEDBACK
TS2 + BLK GRAY
1
30 A 2
-B -B PINK
A13
BD:1 BD:2 GRAY
TS2 B3
VIO
500
504
YEL
A11
+ 24V BATT - -B -B -B 831976_2C-2
Fig. 172
WT 3000 Series
Rev. B
392
SCHEMATIC DIAGRAMS
WT -E, WITH CAN TILLER, CROWN MOTOR, PLATFORM SWITCH
WT -E, with CAN Tiller, Crown Motor, Platform Switch
CA206 FIXED PLATFORM REAR ENTRY CA206 FIXED PLATFORM SIDE ENTRY
2929 A WIRE 1 FPS1 2929 A WIRE 1 FPS1

Foot Presence Foot Presence
501 B Switch 1 501 B Switch 1
(Floor Mat Switch) (Floor Mat Switch)
2912 CA200-34 ACCESS 3/2 C WIRE 2 2912 CA200-34 ACCESS 3/2 C WIRE 2
500 -B ACCESS 3/2
500 -B ACCESS 3/2 502 CA207-2
CA207 CA207.1
2930 A BRN +BV(AK) FTS 1 2970 A BRN +BV(AK) FTS 1

Foot Guard Foot Guard
-B Switch 1 581 B BLU -B Switch 1
502 B BLU (Entry Bar Sensor)
(Entry Bar Sensor)
PNP Signal PNP
2971 C BLK
CA207.2 CA 207.2
STANDARD OPTION
1 Fold Down Step
Sensor 1

2972 C C BLK
502 B 580 CA207.3 CA 207.3
STANDARD OPTION
1 Fold Down Step
583 B B BLU -B
Sensor 2
Signal PNP
2973 C C BLK
CA207.4
Foot Guard
(Entry Bar Sensor)
Signal PNP
2974 C BLK
bridge 824907.
831976_2C-3
Fig. 173
WT 3000 Series
Rev. B
393
SCHEMATIC DIAGRAMS
WT -E, CROWN MOTOR, INFOLINK™ CIRCUIT DIAGRAM BASED ON CAN-BUS
WT -E, Crown Motor, InfoLink™ Circuit Diagram based on CAN-Bus
ICM INFOLINK CONNECTION CAN BASED

PC-502 JC-502
Connect_to Pin Pin I/O-Usage
Free 32 32 Free
Free 33 33 Free
PC500 JC500 Free 16 16 Free

Free 17 17 Free
214
(PC405-5) 6 6
+BV (AK) 2936 5 5 PWR_TO_KYS 24 24 PWR_TO_KYS
213 4 4 PWR_after_KYS 15 15 PWR_after_KYS
+BV ( FU1)
512 Free 23 23 Free
-B 3 3
913 2 2 nu 22 22 nu
CANL
905
CANH 1 1 25 BV 25 25 25 BV
Ferrite-Core
13 GN 13 13 13 GN
1 14GND3 30 30 14GND3
2 FREE 31 31 FREE
RS232
3 Free 10 10 Free
11 TX 11 11 11 TX
CA508
12 RX 12 12 12 RX
CA505 1 1
6_5V 6 6 6_5V
4 2 2
SHOCK 7_GN 7 7 7_GN
2 SENSOR 3 3 8_XIN 8 8 8_XIN
LOAD 3_YIN 9 9 3_YIN
3 4 4
1 14_GN2 18 18 14_GN2
19_CS 19 19 19_CS
20_LS 20 20 20_LS
1_10V 1 1 1_10V
14_GN 14 14 14_GN
2_PRDO 2 2 2_PRDO
3_PRD1 3 3 3_PRD1
CA503
1 26_AL 26 26 26_AL
Switch 2 27_AL- 27 27 27_AL-
Proximity- 3 CAN_L 5 5 CAN_L

Ferrite-Core
CAN_H 4 4 CAN_H
4
Free 28 28 Free
Free 29 29 Free
Free 34 34 Free
A
CURRENT C 7_GN
B
CA506
1 2
ALARM
1 2 3 4 5 6
PC 501 CAN 831976_2C-4
Fig. 174
WT 3000 Series
Rev. B
394
SCHEMATIC DIAGRAMS
WT -M WITH INFOLINK®, CAN-BUS, CROWN MOTOR, STANDARD EQUIPMENT, SEPARATE EDS AND LINE CONTACTORS
WT -M with InfoLink®, CAN-Bus, Crown Motor, Standard Equipment, Separate EDS and Line Contactors
5_CANL
4_CANH
CA201
B+ (FU2) 205 RED CA410 CA411
IC
FS
B+
+
1 5
RS (FF)
FS (PF)
PROX. READER
5 4 1 1 YEL 6
Out
B+ (AK) 3
-
U-
U+
2 3 2 1
ACC
3 4
IC
RS
Out B+
-
BLK nu 2
14 2 905 CAN-L 3 4
CAN-L 27
U-
U+
ACCESS 2/3
+
CA250 BLU 3
8
POT
INFOLINK 28 5 4
+13V
CA204 GRN
1 7
303
PS1 2 CA209 CA412
-
P CA209 GRAY/PINK
2 3
BLU
000
4 30 1 3 SAS
U+
U-
BLK
203 204 BRN
SHOCK SENSOR
U 3 ACCESS 1 7
1
ACC
BLK
2
B+
(Display DCM)
BLK
-
604 6
NTC
CA250 261
Out +BV_F
IC
11
+
GND + OUT 86 + 30 CA214
T
6 1 2908 CAN-H HNS 1
7 2 4 SMART + IN 5962 4 1
U+
K 12
U-
902 901 4_CANH CA417
120 Ohm
8 3 8 1 3 2
IC
B+
9 4 85 - 87 907 906 5_CANL
B-
B-
2911 CA200
202
9 2 GRAY
Out
13 25 15 24
K 120 Ohm
10 HNS 2
BRK 5900
5909
2 2 4 CAN-L 3 6 1
24_KEY1
13_GND
25_+BV
2962 CA419
15_IGN
9 5 2
24_KEY
503
CA211 4 MAIN PCB
2925 2915
DI10 16 C A 5 5962
4
B+ (AK)
502 6 3 HSS
B PNP PLS1 (OCM 1)
34 5
501
B 4 CA414
CA446 CA209 B-
PNP
CA206 CAN CONNECTION 2961
24_KEY 2924 B- 2914 1 R/T PCB
2 33 DI7 35 A C 1 CA211.1
24_KEY1
1 CA209 CA210 4 BRS 4_CANH CA415
2903 5907 2913 1 VIO HYDR. PCB
1 SV 2 24 2 4
CA445 5_CANL 261
24_KEY
2 DI0 1
2909 2909
3 2 6
5961
25_+BV 1 CA203 3 8 RAS LOS1
RED
HN 2921 2921 7
CA209
DI8 17 C LMS
4 2961
2920 PNP 3
2904 5903
26 CA208 SR2
+13V
A
5 2962
1
605 B WHT
GND B
2
304 6
505
2902 001 A PINK
3 B+ DI12 21 C NPN 5
CA213 FAN
DI11
002 305 CA200
2905 5906 18 C A B-
1 2 9 GND
606
B 2910 WHT
DI5 19 NPN 10
CA215 CA207 SR1 2920
8
VIO
2907 5905
1 2 8 DI1 20
2922 2922
9
PINK
2923 2923 GRAY

DI9 29 11
2919 2919 YEL 1 Shown with truck in standby:
DI3 32 7
2918 2918 BLK - Key switch, keypad or K1 = closed
DI4 31 6
300 302 RED/BLU - Without load on forks
CA216 CA209 +13 V 25 5
2906 5904 600 603 BLU - Forks fully lowered
1 2 11 GND 5 4
2912 B+ 005 2916 WHT/GRN - Platform up
10 CHNL B 13 1
5908
12 CHNL A 14
004 2917
2
GRAY/PINK - Side restraints down
TS1 22
100 003
3
BRN - Tiller = upright and centred.
CA224 2 1 A/D 504 GRN - LMS = Closed
(EVP2) 23 12
TRACTION CA 205
1
25_+BV
507
209
T WHT / BRN
2
602
B-
2901
CONTROL LOGIC
B+
B- U ECR1 CA 212
U AC CHNL A
BLU
4
004
GND
V 3 CHNL B
WHT
3
005 Fixed platform = BRS1
FU4 FU2 FU3 V GND
BLK
2
601
4A 4A 4A W M1 +13V
RED
1
301 4 Folding platform = PLS1
W
B- Fixed platform = FPS1
2900
208
207
DI2 6
2916
15_IGN B+
DI6 7
2917
CONTROL LOGIC
2926
201
003
5908
200 AN. 15 6 Heating resistors activated below 5°C

+
-P
B-
Ax -
EDS
FU1 B+ + -
M2
355A
PUMP MOTOR
EDS LINE
BD:1 BD:2
B-
24V BATT
_
500
13_GND
B-
831979_2B-1
Fig. 175
WT 3000 Series
Rev. B
395
SCHEMATIC DIAGRAMS
WT -M WITH INFOLINK®, CAN-BUS, CROWN MOTOR, WITH OPTIONS, SEPARATE EDS AND LINE CONTACTORS
WT -M with InfoLink®, CAN-Bus, Crown Motor, with Options, Separate EDS and Line Contactors
5_CANL
4_CANH
CA201
B+ (FU2) 205 RED CA410 CA411
IC
FS
B+
+
5 4 1 5
RS (FF)
PROX. READER
FS (PF)
1 1 YEL 6
B+ (AK)
Out
3
U+
-
U-
2 3 2 1
ACC
3 4
IC
RS
Ou t B+
-
BLK nu 2
14 2
905 CAN-L 3 4
ACCESS 2/3 CAN-L 27
U-
U+
+
CA250 BLU 3
8
POT
INFOLINK 28 5 4
+13V
CA204 GRN
1 7
303
PS1 2 CA209
-
P CA209 GRAY/PINK CA412 BLU
000 2 3
4 30 1 3 SAS
U+
U-
BLK
SHOCK SENSOR
U 204 BRN
1 3 ACCESS 1 7
ACC
KEYPAD 2
BLK
B+
(Display DCM)
BLK
-
604 6
6
NTC
CA250 86 30 261
Out +BV_F
IC
GND 11
+
+ OUT CA214
T
232 HNS 1
232
2982
6 1 2908 CAN-H
7 2 4 SMART + IN RED/WHT 5962 4 1
U-
12
U+
902 901 4_CANH CA417
120 Ohm
8 3 BLK 8 1 3 2
IC
B+
9 4 KYS 2983 2911
B-
B-
RED CA200 907 906 5_CANL
202
9 2 GRAY
Out
13 25 15 24 10
BRK 87 120 Ohm HNS 2
5909
2
GRN 2 4 CAN-L 3 6 1
24_KEY1
13_GND
2981
25_+BV
CA419
15_IGN
2962
9 5 2
24_KEY
506
503
CA211 4 MAIN PCB
2925 2915 B-
DI10 16 C A 5 5962
4
B+ (AK)
502 6 3 HSS
B PNP PLS1 (OCM 1)
34 5
501
B 4 CA414 6
CA446 CA209 B-
PNP
24_KEY 2924 B- 2914 1 R/T PCB
2 33 DI7 35 A C 1 CA211.1
24_KEY1 CA209 CA415
1 CA210 4 BRS 4_CANH HYDR. PCB
2903 5907 2913 1 VIO
4
CA445 1 SV 2 24 2
5_CANL 261
24_KEY
2 DI0 1
2909 2909
3 2 6
5961
25_+BV
1 CA203 3 8 RAS LOS1
RED
HN 2921 2921 7
CA209
DI8 17 C LMS
4 2961
2920 PNP 3
2904 5903
26 CA208 SR2
+13V
A
5 2962
1
605 B
2
GND B WHT
304 6 2 6
505
2902 001 A PINK
1
3 B+ DI12 21 C NPN 5
CA213 FAN
DI11 18
002
C 305 CA200
2905 5906 A B-
1
1 2 9 GND
606
B 2910 WHT POT PCB F/C 6 CA416
DI5 19 NPN 10
2
CA215 CA207 SR1 2920
8
VIO
2907 5905
1 ALM 2 8 DI1 20
2922 2922
9
PINK
2923 2923 GRAY

CA 222 DI9 29 11
FLS
2
1
DI3 32
2919 2919
7
YEL
DI4 31
2918 2918
6
BLK
- Key switch, keypad or K1 = closed
CA216 CA209 +13 V 25
300 302
5
RED/BLU
2906
1 2
5904
11 GND 5
600 603
4
BLU
2912 B+ 005 2916 WHT/GRN
10 CHNL B 13 1 - Platform up
004 2917 GRAY/PINK
12 CHNL A 14 2 - Side restraints down
100 003 BRN
TS1 22 3 - Tiller = upright and centred.
A/D 504 GRN
CA224 2 1 (EVP2) 23
TRACTION CA 205 12 - LMS = Closed
25_+BV
1
507
209
T 602
WHT / BRN
2 B-
2901
CONTROL LOGIC
B- B+ ECR1 CA 212
U
U AC CHNL A
BLU
WHT
4
004
005
GND 3 Folding platform = SAS
FU4 FU2 FU3 V
V 3 CHNL B
BLK
3
GND 2
4A 4A 4A W M1 RED 301
W +13V 1
B-
2900
208
207
2916
DI2 6 5 Folding platform = PLS2
2917
15_IGN DI6 7
B+ Fixed platform = FTS1 and FTS2
CONTROL LOGIC
5908
2926
201
003
200 AN. 15
+
-P
B-
Ax -
EDS
FU1 B+ + -
M2
355A
PUMP MOTOR
EDS LINE
BD:1 BD:2
B-
24V BATT
500
13_GND
B-
831979_2B-2
Fig. 176
WT 3000 Series
Rev. B
396
SCHEMATIC DIAGRAMS
WT -M WITH INFOLINK® RETROFIT, CAN-BUS, CROWN MOTOR, WITH OPTIONS, SEPARATE EDS AND LINE CONTACTORS
WT -M with InfoLink® Retrofit, CAN-Bus, Crown Motor, with Options, Separate EDS and Line Contactors
CA201
B+ (FU2) 205 RED CA410 CA411
IC
FS
B+
+
1 5
RS (FF)
FS (PF)
YEL
PROX. READER B+ (AK) 6
Out
1 1 3
-
U-
U+
2 3 2 1
ACC
IC
RS
Ou t B+
-
3 4 BLK nu 2
14 2 905 CAN-L 3 4
CAN-L 27
U-
U+
ACCESS 2/3
+
BLU 3
CA250 (HCM / TCM) 900 CAN-H 4 8
CAN-H 28 RED/BLU POT
5 4
INFOLINK +13V
CA204 GRN
1 7
303
PS1 2 CA209 CA412
-
P CA209 GRAY/PINK
2 3
BLU
000
4 30 1 3 SAS
U+
U-
BLK
U 203 204 BRN
3
SHOCK SENSOR
1 ACCESS 1 7
ACC
BLK
2
B+
(Display DCM)
BLK
-
604 6
NTC
261
Out +BV_F
CA250
IC
GND 11
+
+ OUT 86 + 30 CA214
T
2908 CAN-H HNS 1
6 1 4 SMART + IN 5962 4 1
U+
K 12
U-
7 2 902 901 902 CA417
120 Ohm
8 1 3 2
IC
8 3
B+
9 4
85 - 87 907 906 912 B-
B-
2911 CA200 9 2 GRAY
Out
4 5 13 25 15 24 K 120 Ohm
10 HNS 2
BRK 5900
5909
2 2 4 CAN-L 3 6 1
25_+BV
5_CANL
13_GND
15_IGN
4_CANH
CA419
24_KEY1
2962
9 5 2
202
503
CA211 4 MAIN PCB
2925 2915
DI10 16 C A 5 5962
4
CA209 B- ACCESS 8.1
2900
PLS2 WHT/GRN
B+ (AK)
502 6 3 HSS
B PNP PLS1 (OCM 1)
34 5
501
B 4 CA414
CA209 B-
PNP
2924 B- 2914 1 R/T PCB
33 DI7 35 A C 1 CA211.1
CA209 CA210 4 BRS 903 CA415
1 2 3 4 5 6 CA500 2903 5907 2913 1 VIO HYDR. PCB
1 SV 2 24 2 4
913 261
2
901
911
500
200
2990
2900
2909 2909 6
DI0 1 3
5961
CA203 3 8 RAS LOS1
RED
HN 2921 2921 7
CA209
DI8 17 C LMS 4 2961
2920 PNP 3
2904 5903
26 CA208 SR2
+13V
A
5 2962
1
605 B WHT
GND B
2
304 6
505
2902 001 A PINK
3 B+ DI12 21 C NPN 5
CA213 FAN
DI11 18
002 305 CA200
2905 5906 C A B-
1 2 9 GND
606
B 2910 WHT
DI5 19 NPN 10
CA215 CA207 SR1 2920
8
VIO
2907 5905
1 2 8 DI1 20
2922 2922
9
PINK
2923 2923 GRAY

DI9 29 11
DI3 32
2919 2919
7
YEL
DI4 31
2918 2918
6
BLK
- Key switch, keypad or K1 = closed
CA216 CA209 +13 V 25
300 302
5
RED/BLU
2906
1 2
5904
11 GND 5
600 603
4
BLU
2912 B+ 005 2916 WHT/GRN
10 CHNL B 13 1 - Platform up
5908 004 2917 GRAY/PINK
CA224 12 CHNL A 14 2 - Side restraints down
100 003 BRN
PWS TS1 22 3 - Tiller = upright and centred.
A/D 504 GRN
2 1 (EVP2) 23
TRACTION
MOTOR TS1 +
CA 205
BRN 100
12 - LMS = Closed
1
507
209
T 602
WHT / BRN
2 B-
2901
200
CONTROL LOGIC
B- B+ ECR1 CA 212
U
U AC CHNL A
BLU
4
004
GND 3 Folding platform = SAS
WHT 005
FU4 FU2 FU3 V
V 3 CHNL B
BLK
3
GND 2
4A 4A 4A W M1 RED 301
W +13V 1
B-
2900
208
207
2916
DI2 6 5 Folding platform = PLS2
2917
B+
DI6 7 Fixed platform = FTS1 and FTS2
CONTROL LOGIC
2926
201
003
2990
5908
200 AN. 15
+
-P
B-
Ax -
EDS
FU1 B+ + -
M2
355A
PUMP MOTOR
EDS LINE
BD:1 BD:2
B-
24V BATT
500
500
B-
831979_2B-3
Fig. 177
WT 3000 Series
Rev. B
397
SCHEMATIC DIAGRAMS
WT -M, PLATFORM SWITCH AND INFOLINK® RETROFIT
WT -M, Platform Switch and InfoLink® Retrofit
PLATFORM SWITCHES INFOLINK LEGACY
CA 210 FIXED PLATFORM REAR ENTRY

CA250 INFOLINK
Normal Mode: CA446 LC Coil + 15_IGN 15
2914 A WIRE 1 FPS1 with InfoLink Box
Foot Presence 1 24_KEY1 24
connect bridge to PC446 2 24_KEY
Switch 1
501 -B ACCESS 2/3 B
(Floor Mat Switch)
Bypass Mode: CA445 CA250
2924 CA209-35 ACCESS 2/3 C WIRE 2 without InfoLink Box 1 25_BV+ 25_BV+ 25
connect bridge to PC445 2 24_KEY
2911 RELAY SOCKET PIN 87
2912 CA209-10 ACCESS 2/3 CA250
202 24_KEY BV - 13_GND 13
2913 CA206-2 BRS1
FU 2 25_BV+
2924 CA205-2 SRT
2926 LINE COIL CA 211 CA214
6
2915 A BRN +BV(AK) FTS 1 5
Foot Guard
-B Switch 1 4
502 B BLU 3
CAN CONNECTION
(Entry Bar Sensor) CA250
Signal PNP 2 5_CANL 5_CANL 5
2925 C BLK 1 4_CANH 4_CANH 4
2925 CA209-16 ACCESS 2/3 CA211.1

502 -B ACCESS 2/3 1 4_CANH
2 5_CANL
3
CA 210 FIXED PLATFORM SIDE ENTRY 4
5
2914 A WIRE 1 FPS1 6
Foot Presence
CA255 CA250
Switch 1
501 -B ACCESS 2/3 B SHOCK 1 VIO 1 6_5V 6
(Floor Mat Switch)
SENSOR 2 GRN 2 7_GND 7
2924 CA209-35 ACCESS 2/3 C WIRE 2 3 BRN 3 8_XIN 8
4 WHT 4 9_YIN 9
CA 207.1
2912 CA209-10 ACCESS 2/3 CA251 CA250
2913 CA206-2 BRS1 2970 A BRN +BV(AK) FTS 1 PROX. 1 RED 1 1_PR5V 1
Foot Guard READER 3 GRN 3 2_PRD0 2
2924 CA205-2 SRT 581 B BLU -B Switch 1 4 WHT 4 3_PRD1 3
(Entry Bar Sensor)
2926 LINE COIL 2 BLK 2 14_PRG 14
Signal PNP
2971 C BLK
CA 207.2 CA 207.2
STANDARD OPTION
1 Fold Down Step
PC211/JC207 582 B B BLU -B
Sensor 1

2972 C C BLK
502 B 580 CA 207.3 CA 207.3
STANDARD OPTION
1 Fold Down Step
583 B B BLU -B
Sensor 2
2925 CA209-16 ACCESS 2/3
502 -B ACCESS 2/3 PNP
2973 C C BLK Signal
bridge 824907.
CA 207.4
Foot Guard
-B Switch 2
583 B BLU
(Entry Bar Sensor)
Signal PNP
2974 C BLK 831979_2B-4
Fig. 178
WT 3000 Series
Rev. B
398
SCHEMATIC DIAGRAMS
WT -E WITH INFOLINK®, CAN-BUS, CROWN MOTOR, STANDARD EQUIPMENT, SEPARATE EDS AND LINE CONTACTORS
WT -E with InfoLink®, CAN-Bus, Crown Motor, Standard Equipment, Separate EDS and Line Contactors
+BV
1 Shown with truck
213
206
+BV (AK)
in standby: FU 3
2935
CA212
- Key switch, key- 602
4A
CA410 CA420 12 11 10 9 8 7 6 5 4 3 2 1 +5 V
+10 V
5
CA411
2 204
202
YEL
pad or
RS (FF)
FS (PF)
302
K1 203
3 ACCESS 1 5 FWD
6
3 GRY 1
ACC
K1 = closed 004 86 + 30
(DISPLAY)
CA201
3 B+ FS
RS
REV FILTER1
FILTER1 GND
nu 2
BOOTSTRAP 40 1 212 WHT
- Without load on
CA201
K1 1 +5 V FILTER2
602
302
CAN-L
903 CAN-H
CA225
120 Ohm
003 3
PS CA210 CA200 NCL TXD 1 4 1 6 5 4 2 3 1 9 BRN
CS1 ACC
POT
GND POT
4
forks 301 300 002
85 - 87
8
911 CAN-L CAN-H
CS2 +5 V
4
1
P 2 26 +13V PCL TXD 2 5 -K1
PINK
6 CLK
GND
7
- Forks fully low-
Belly_3
601 600 001 5907 505 DATA Belly_3 GND
1 41 GND NCL RXD 29 6 2 4 GRN R/T Belly_1

CA412
2 B- µ-PROCESSOR
ered 100 (µP)
FILTER3 GND
3
BLU
HNS
10V
4 23 Signal ACCESS 3/2 2917 FU 6 2932
5V
2918 + BV (AK) -B CA418 Belly_1 FILTER3
1 SAS
- Platform up
B+
BLK
B-
-
3 CLK SAS Signal
209 (TCM / HCM) 900 4A
7 2
BLK
- Side restraints 20 27 DATA
BLK
NTC
GRY
B+ (AK) held closed
Out +BV_F
IC
1
+
CS1
909
T
PROX. READER
down 1 1 42 2 CS2
U-
U+
2 3 WHT + OUT + IN 2916 6 HNS 1
3 4 30 SMART 7
- Tiller = upright 14 2 208
5
YEL 9
12
B-
Horn
+5 V FILTER4
B-
3
1
1
2
CA417
and centred. CA250
BRN
SAS 33
2915 2915
6
PINK 8
GND
IC Voltage REG.
+10 V
CA208 SR1 2933 GRY 4 +24 V +10 V GND
- LMS = Closed 31 HNS 2

10 V U Reg. +5 V
INFOLINK 1 2 3 U out U Reg.
2922 A 904 BRN CAN-H 5 UB in 4 1

BRK 4 11 R/T
GND
MAIN PCB 2 2
CA419
2909 912 WHT CAN-L B+ (AK) GND
2 Fixed platform: 35 1
BLK12
BLK11
BLK10
C 10
BLK3
BLK7
BLK1
BLK2
BLK6
BLK8
BLK4
BLK5
508 PNP 506 GRN
B 2
PC208 and 2903 5901
unused 11 -B CA220
4
CA209 SR2 ACCESS 8.1
SHOCK SENSOR
SV 39 unused 18
1 2
3 HSS
PC209 have a 2921 A -B
2910 CA414
1 (OCM 1)
bridge 824907 CA250 5 507
C
PNP
1 R/T PCB
B
6 1 unused 19
3 Fixed platform: 7 2 2904 HN 5902
32 unused 20
-B
CA223 LMS1 1
10 V
8 3 MAGNETIC ROTARY ENCODER & IC DC CONVERTER MAGNETIC ROTARY ENCODER & IC
2919 A 10 V
BRS (tiller) has a 9 4
CA204 FAN CA204 2911 GND
4 DSP HALL
360°
UB in
GND outU DSP HALL
360°
205
5 4 13 25 15 24
21 C ARRAY ARRAY
bridge 824907 on 6 TX TX
OTP +5V OTP
2905 1 5903 510 PNP B+ (Heating sw) ABSOLUTE X U Reg. ABSOLUTE X
28 B
4_CANH
24_KEY1
2
13_GND
5_CANL
36 8
25_+BV
unused INTERFACE SSI INTERFACE SSI

15_IGN
PC205 B+ (FU3) GND VDD VDD

-B
CSn
CSn
CLK
CLK
CA206 PLS1/FPS1 7 LOS ENC RAS ENC
DO
DO
VSS VSS
24_KEY
CA203 CA203
unused 38 2929 A CS2
2 GND
1 10
4 Folding platform = 2907
1 2
5905
16 34
2912
C
CS1
1
501 DATA
SAS CA200
B PNP
CLK
5
-B 3
Fixed platform = 24_KEY CA446
CA207 PLS2/FTS1&2
2930 A
CA415 HYDR. PCB
2 14 1 11
BRS1 24_KEY1
1 37
2914
C
502 PNP
B
5 Folding platform = 24_KEY
CA445
-B
2 CA205
PLS1 25_+BV
1
5904
15 6
2913
C 3 TFD UNIT
2920 CA214 CA232
Fixed platform = A BRS (TILLER) 2934
5 5 BLU
CA202 1 2 B
FPS1 2906 CA 200
+
Coil
+BV (AK)
5908 5908
6 Folding platform = 3 6 6 WHT
101 101 680 Ohm
25 4 4 ORN
PLS2 2902
4 1 2 3 4 5 6 CA211.1 ACCESS 5
Fixed platform = 2931
13 +13V 9
GRN
CA221=B
4_CANH
CAN CONNECTION
5_CANL
FTS1 and FTS2 5906 GND 10
604 (SCM) 603
17 YEL CA211 CA222=A Low B1 2 2 BLK
CHNL B 8 4_CANH 901 CAN-H 902 CAN-L 700
+B GRAY 1 A6 +5V B2 1 1 RED
CHNL A 22
120 Ohm
3
PINK
25_+BV
TS1 12 4 102
CA224 2 1
5_CANL 908 CAN-L 910 W1 B6 3 3 GRN
2 A14
2901
TRACTION CA 215 CAN-H YEL/BRN

TS1 PINK 2916 A10
511
211
MOTOR + BRN 5 GND

1
RED
A4 WHT/GRN
T WHT / BRN 6
2 2926
A5 CHNL B A8
-B FU 7 FU 5 FU 4 WHT/YEL
CONTROL LOGIC
B+ ECR1 CA 217
4A 10A 10A U
BLU GRAY
2927
A7 CHNL A A9
U AC CHNL A 4 RED/BLU
210
201 207
YEL +13V B5
15_IGN
WHT CA213
V
V 3 CHNL B
BLK
3
BLU BLK BRN
CHNL B B7
2925
5906
GND 2 SAHS 1
M1
2900

W +13V 1 3
VIO
A3 CHNL A B8
NPN 2 WHT
B- A1 +13V B4
+
Ax -B ECR3 CA 224
200 EDS -
-P A2 RED WHT
ECR2 CA 216
+BF W +12V 1
WHT
3
GRN WHT WHT/YEL
V CHNL A 3
M2 3 CHNL B
BLU
2
BRN BLU WHT/GRN
U AC BLK YEL
CHNL B 2
GND 4
1
30 A 2
-B -B PINK
A13
BD:1 BD:2 GRAY
TS2 B3
VIO
500
504
13_GND
YEL
A11
+ 24V BATT - -B -B -B
831980_2B-1
Fig. 179
WT 3000 Series
Rev. B
399
SCHEMATIC DIAGRAMS
WT -E WITH INFOLINK®, CAN-BUS, CROWN MOTOR, WITH OPTIONS, SEPARATE EDS AND LINE CONTACTORS
WT -E with InfoLink®, CAN-Bus, Crown Motor, with Options, Separate EDS and Line Contactors
CA410 CA420 12 11 10 9 8 7 6 5 4 3 2 1 +5 V
+10 V
CA411
5
1 Shown with truck in
YEL
RS (FF)
FS (PF)
FWD
5 6
+BV GRY 1
standby:
ACC
3 B+ FS FILTER1 GND
REV FILTER1 nu 2
206
2932
RS
+BV (AK) 2918 WHT
- Key switch, key- 1 CAN-L +5 V FILTER2
2918
2917
213
CS1 ACC
POT 3
FU 3 FU 6 BRN GND POT
4
pad or K1 = closed CA212 CAN-H 4
4A 4A PINK
CS2 GND +5 V
602 CLK 7
6 Belly_3
- Without load on 87 86 204 Belly_3

2
202
2935
DATA GND
KEYPAD 3 ACCESS 1 GRN R/T Belly_1
302 CA412
2983
2982
2 B- µ-PROCESSOR
forks 3 FILTER3 GND BLU
(DISPLAY) (µP) 3
HNS
10V
212
5V
Belly_1 FILTER3
004 CA418 1 SAS
BOOTSTRAP 40 1 CA201
BLK
- Forks fully low-
B-
B+
30
-
CA201
3
602
302
CLK SAS Signal
903 CAN-H
120 Ohm
PROX. READER
BLK
1 1 003
CA200 1 4 9 7 2
RED/WHT
DATA
NCL TXD
BLK
PS CA210
ered
NTC
GRY
2 3
GRN
BLK
RED
5 6 2 4 3 1 B+ (AK) held closed
Out +BV_F
911 CAN-L
IC
1
+
CS1
3 4 301 300 002 8
T
26 2 5
2981
232
1 2 +13V PCL TXD CA225
- Platform up
14 2 P KYS 505
2 CS2
7 *
U-
U+
CA250 601 600 001 2 4 6 HNS 1
1 41 GND NCL RXD 29 6 3 1
- Side restraints
9 B- +5 V FILTER4
509
100 Horn
B-
1 2
CA417
INFOLINK 12
4 23 Signal ACCESS 3/2 -B
down
GND
8 +10 V
-B IC Voltage REG.
209 (TCM / HCM) 900 4 10 V +24 V +10 V

U out U Reg.
U Reg. +5 V GND
HNS 2
- Tiller = upright 20 27 5 UB in 4 1
909 11 R/T
GND
MAIN PCB 2 2
CA419
and centred. 42 B+ (AK) GND
BLK12
10
SHOCK SENSOR
BLK3
BLK7
BLK1
BLK2
BLK6
BLK8
BLK4
BLK5
+ OUT + IN
BLK11
BLK10
WHT 2916
30 SMART 7
- LMS = Closed 208
5
YEL
4 7
2915 2915 PINK ACCESS 8.1
CA250 SAS 33 6 3 * HSS
2 Fixed platform: BRN 2933 GRY
205
6 1
31 CA208 SR1 3
7 2
1 2
904 BRN CAN-H
CA414
1 (OCM 1)
PC208 and PC209 8 3 BRK
2909
2922 A
912
4
WHT CAN-L
1 R/T PCB
9 4
24_KEY
35 C 1
have a bridge 5 4 13 25 15 24 508
B PNP 506
2 GRN
CA415
unused 11
10 V
MAGNETIC ROTARY ENCODER & IC DC CONVERTER MAGNETIC ROTARY ENCODER & IC
824907 -B
4_CANH
24_KEY1
13_GND
2903 5901 10 V
5_CANL
CA220
25_+BV
UB in
CA209 SR2
15_IGN
SV 39 unused 18
1 2
GND
4 DSP HALL
360°
GND U out DSP HALL
360°
2921 A -B 6 OTP
ARRAY
TX +5V OTP
ARRAY
TX
X X
3 Fixed platform: 24_KEY CA446 5
2910
C
B+ (Heating sw)
8 GND
ABSOLUTE
INTERFACE SSI
U Reg. ABSOLUTE
INTERFACE SSI
507 B+ (FU3) VDD VDD
BRS (tiller) has a 2 PNP
CSn
CSn
CLK
CLK
7 LOS ENC RAS ENC
DO
DO
24_KEY1 B VSS VSS
1 2904 HN 5902
unused 19 -B CS2
2 GND
bridge 824907 on CA445

32 unused 20
CA223 LMS1
2919 A
1 CS1
1
24_KEY DATA
PC205 25_+BV
2 CA204 FAN CA204 21
2911
C CLK
5
1 2905 1 5903 510 PNP 3
2 28 36
B HYDR. PCB
4 Option FC/: heat- unused
-B
CA206 PLS1/FPS1
unused 38
ing activated below CA203 8 7
CA203 2929 A 1 10 7
*
CA416
2907 5905 2912 1 2
5°C 1 ALM 2 16 34 501
C
B PNP 1 2
CA 236 1 2 CA200 7
-B POT PCB F/C *
5 Folding platform = CA207 PLS2/FTS1&2 CA416
GRN
BLK
FLS 6 8
2930 A
SAS 14 2914
1 11
37 502
C
Fixed platform = DC / DC CA 222 1 2
B PNP
CONVERTER -B
BRS1 5 8
5904 2913
CA205
15 6 TFD UNIT
BLU
RED
C 3
2920 CA214 CA232
6 Folding platform = A BRS (TILLER) 2934
5 5 BLU
CA202 1 2 B
PLS1 CA 240 1 2
2906 CA 200
+
Coil
+BV (AK)
Fixed platform = 3
5908 5908
6
680 Ohm
6 WHT
101 101
FPS1 2902
25 4 4 ORN
4 1 2 3 4 5 6 CA211.1
7 Folding platform = 2931 +13V 9
13
4_CANH
CAN CONNECTION
5_CANL
604 (SCM)
PLS2 5906
17 GND 10
YEL CA211 CA222=A Low B1
603
2 2 BLK
Fixed platform = CHNL B 8 4_CANH

1
901 CAN-H 902
A6
CAN-L 700
BRN
GRAY
BLK
+B CHNL A 22 +5V B2 1 1 RED

FTS1 and FTS2
120 Ohm
3
PINK
25_+BV
TS1 12 4 102
CA224 2 1
5_CANL 908 CAN-L 910 W1 B6 3 3 GRN
2 A14
2901

TS1 PINK 2916 A10
511
211
MOTOR + BRN 5 GND

1
RED
A4 WHT/GRN
T WHT / BRN 6
2 2926
A5 CHNL B A8
CONTROL LOGIC
B+ ECR1 CA 217
4A 10A 10A U
BLU GRAY
2927
A7 CHNL A A9
210
201 207
WHT YEL CA213 +13V B5

V 3 CHNL B 3
BLK BRN
15_IGN
V BLK BLU CHNL B B7

2925
5906
GND 2 SAHS 1
M1
2900

W +13V 1 3
VIO
A3 CHNL A B8
NPN 2 WHT
B- A1 +13V B4
+
Ax -B ECR3 CA 224
200 EDS -
-P A2 RED WHT
ECR2 CA 216
+BF W +12V 1
WHT
3
GRN WHT WHT/YEL
V CHNL A 3
M2 3 CHNL B
BLU
2
BRN BLU WHT/GRN
U AC BLK YEL
CHNL B 2
GND 4
1
30 A 2
-B -B PINK
A13
BD:1 BD:2 GRAY
TS2 B3
13_GND
VIO
500
504
YEL
A11
+ 24V BATT - -B -B -B
831980_2B-2
Fig. 180
WT 3000 Series
Rev. B
400
SCHEMATIC DIAGRAMS
WT -E WITH INFOLINK® RETROFIT, CAN-BUS, CROWN MOTOR, WITH OPTIONS, SEPARATE EDS AND LINE CONTACTORS
WT -E with InfoLink® Retrofit, CAN-Bus, Crown Motor, with Options, Separate EDS and Line Contactors
+BV
1 Shown with truck in
213
206
+BV (AK)
standby: FU 3
2935
CA212
- Key switch, keypad or 602
4A CA205 CA410 CA420 12 11 10 9 8 7 6 5 4 3 2 1
5
CA411
2 204 GRN
202
K1 = closed K1
RS (FF)
FS (PF)
302 203
3 ACCESS 1 5 5 6
IC
FS
B+
+
3 PINK 1
(DISPLAY)
ACC
- Without load on forks 004 86 + 30
3 3 B+
nu 2
Out
U-
U+
CA201
-
212 WHT FS
BOOTSTRAP 40 1
- Forks fully lowered 1
CA201
K1 1
602
302
903 CAN-H CAN-L
CA225
120 Ohm
IC
RS
3
B+
003 9
-
BRN CS1
PS CA210 CA200 NCL TXD 1 4 1 6 5 4 2 3 1 B- GND POT
- Platform up 85 - 87 911 CAN-L 4 4 CAN-H
Out
4
U+
U-
301 300 002 RS
8
+
CS2
1 2 26 +13V PCL TXD 2 5 GRAY CLK 7
P -K1 6 6
- Side restraints down 1
601 600
41 GND NCL RXD 29
001
6
5907
2 4
505
YEL
DATA
R/T
BB B-
2 2 B- µ-PROCESSOR CA412
- Tiller = upright and
ACC
BLU
100 3
-
(µP)
HNS
ACC
4 23 Signal ACCESS 3/2 2918 + BV (AK) 2917 FU 6 2932 -B CA418 1 SAS
centred.
B+
BLK
B-
U-
U+
-
3 CLK
209 (TCM / HCM) 900 4A
7
SAS Signal
2
BLK
- LMS = Closed 20 27 DATA
BLK
NTC
GRY
B+ (AK) held closed
Out +BV_F
IC
1
+
CS1
909
T
42 5
2 Fixed platform: PC208
U+
+ OUT
U-
PROX. READER
1 1 WHT + IN 2916 6 HNS 1
2 3 30 SMART 7 9 4 1
IC
B+
208 GRN B-
CA417
and PC209 have a
B-
3 4
14 2 2915 2915
5 GRAY
12 2 2
Out
SAS 33 6 2
bridge 824907
CS2
CA250 BRN CA208 SR1 2933 PINK 8
GND
DC CONVERTER
+10 V
+10 V
31 1 2
904
3
BRN CAN-H 4 UB in
U out U Reg.
3 1
HNS 2
INFOLINK 2922 A 10 V
BRK 4 GND
CA419
3 Fixed platform: BRS 35
2909
C
912
1
WHT CAN-L 11 R/T
B+ (AK)
MAIN PCB 1 2
BLK12
BLK11
BLK10
10
508
(tiller) has a bridge
BLK7
BLK5
BLK9
BLK2
B PNP 506 YEL
unused 11 2
2903 5901 -B 4
824907 on PC205 SV 39 unused 18
CA209 SR2 1 2
-B
CA220
3 HSS
SHOCK SENSOR
2921 A
CA414
ACCESS 8.1
4 Folding platform = SAS 5
2910
C 1
R/T PCB
507 PNP 1 (OCM 1)
BLK13
B
CA250 HN
unused 19
2904 5902 -B CA415
6 1
32 CA223 LMS1 1 HYDR. PCB
7 2 unused 20 4
5 Folding platform = 8 3
2911
2919 A
6
CA204 FAN CA204
205
9 4
PLS1 21 510
C
8 RAS LOS1
4 5 13 25 15 24 2905 1 5903 PNP
2 28 unused 36
B
Fixed platform = FPS1 7
13_GND
-B
5_CANL
25_+BV
4_CANH
15_IGN
24_KEY1
CA206 PLS1/FPS1 1
CA203 CA203
unused 38 2929 A
2900
6 Folding platform = 2907

1 2
5905
16 34
2912
C
1 10 2
3
PLS2 CA200
501
B PNP
5
-B
Fixed platform = FTS1 CA207 PLS2/FTS1&2
2930 A
and FTS2 14 2914
1 11
37 502
C
PNP
1 2 3 4 5 6 CA500 B
-B
901
911
500
200
2990
2900
CA205
5904 2913
15 6 2920
C 3
CA214 CA232
TFD UNIT
A BRS (TILLER) 2934
CA202 1 2 B 5 5 BLU
+
2906 CA 200 Coil
+BV (AK)
5908 5908
3 6 6 WHT
101 101 680 Ohm
2902
25 4 4 ORN
W2
4 1 2 3 4 5 6 CA211.1
2931 +13V 9
13 CAN CONNECTION
903
913
5906 GND 10
604 (SCM) 603
17 YEL CA211 CA222=A Low B1 2 2 BLK
CHNL B 8 902 901 CAN-H 902 CAN-L 700
+B GRAY 1 A6 +5V B2 1 1 RED
CHNL A 22
120 Ohm
3
PINK
200
TS1 12 4 102 W1
CA224 2 1
912 908 CAN-L 910 W1 B6 3 3 GRN
2 A14
2901

TS1 PINK 2916 A10
511
211
MOTOR + BRN 5 GND

1
RED
A4 WHT/GRN
T WHT / BRN 6
2 2926
A5 CHNL B A8
CONTROL LOGIC
B+ ECR1 CA 217
4A 10A 10A U
BLU GRAY
2927
A7 CHNL A A9
210
201 207
WHT YEL CA213 +13V B5

V
V 3 CHNL B 3
BLU BLK BRN
2990
BLK CHNL B B7
2925
5906
GND 2 SAHS 1
M1
2900

W +13V 1 3
VIO
A3 CHNL A B8
NPN 2 WHT
B- A1 +13V B4
+
Ax -B ECR3 CA 224
200 EDS -
-P A2 RED WHT
ECR2 CA 216
+BF W +12V 1
WHT
3
GRN WHT WHT/YEL
V CHNL A 3
M2 3 CHNL B
BLU
2
BRN BLU WHT/GRN
U AC BLK YEL
CHNL B 2
GND 4
1
30 A 2
-B -B PINK
A13
BD:1 BD:2 GRAY
TS2 B3
VIO
500
504
500
YEL
A11
+ 24V BATT - -B -B -B
831980_2B-3
Fig. 181
WT 3000 Series
Rev. B
401
SCHEMATIC DIAGRAMS
WT -E, PLATFORM SWITCH AND INFOLINK® RETROFIT
WT -E, Platform Switch and InfoLink® Retrofit
PLATFORM SWITCHES INFOLINK LEGACY
CA206 FIXED PLATFORM REAR ENTRY
2929 A WIRE 1 FPS1

Foot Presence
501 B Switch 1
(Floor Mat Switch)
2912 CA200-34 ACCESS 3/2 C WIRE 2
CA250 INFOLINK
Normal Mode: CA446 LC Coil + 15_IGN 15
500 -B ACCESS 3/2 with InfoLink Box 1 24_KEY1 24
CA207 connect bridge to PC446 2 24_KEY
2930 A BRN +BV(AK) FTS 1 Bypass Mode: CA445 CA250
Foot Guard without InfoLink Box 1 25_BV+ 25_BV+ 25
502 B BLU -B Switch 1 connect bridge to PC445 2 24_KEY
(Entry Bar Sensor)
Signal PNP CA250
2914 CA200-37 ACCESS 3/2 C BLK 205 24_KEY BV - 13_GND 13
FU 5 25_BV+
CA211
CA206 FIXED PLATFORM SIDE ENTRY 6
5
2929 A WIRE 1 FPS1 4
Foot Presence 3 CA250
CAN CONNECTION
501 B Switch 1
2 5_CANL 5_CANL 5
(Floor Mat Switch)
1 4_CANH 4_CANH 4
2912 CA200-34 ACCESS 3/2 C WIRE 2
500 -B ACCESS 3/2 CA211.1
1 4_CANH
502 CA207-2 2 5_CANL
CA207.1
3
2970 A BRN +BV(AK) FTS 1 4
Foot Guard 5
581 B BLU -B Switch 1 6
(Entry Bar Sensor)
Signal PNP CA255 CA250
2971 C BLK SHOCK 1 VIO 1 6_5V 6
SENSOR 2 GRN 2 7_GND 7
CA207.2 CA 207.2
STANDARD OPTION 3 BRN 3 8_XIN 8
2971 A Bridge A BRN +BV(AK) FDS 1 4 WHT 4 9_YIN 9
1 Fold Down Step
Sensor 1 CA251 CA250
PROX. 1 RED 1 1_PR5V 1
2930 A 2970 Signal PNP READER 3 GRN 3 2_PRD0 2
2972 C C BLK
4 WHT 4 3_PRD1 3
502 B 580 CA207.3 CA 207.3 2 BLK 2 14_PRG 14
STANDARD OPTION
1 Fold Down Step
583 B B BLU -B
Sensor 2 1 Trucks without folding steps:
PNP
2973 C C BLK Signal
bridge 824907.
CA207.4
Foot Guard
(Entry Bar Sensor)
Signal PNP
2974 C BLK
831980_2B-4
Fig. 182
WT 3000 Series
Rev. B
402
SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS WT -M TO 03/2012
Main Wire Harness WT -M to 03/2012
Detail B HANDLE HANDLE PWS FLS (Opt.) ALM (Opt.)

Detail A KEYPAD 1 2 3 4 5 6 7 8 9 10 11 12 PC200 1 2 3 4 PC201 1 2 PC224 1 2 PC216 1 2 PC215
Truck with Display w/o KYS Adapter
209
507
2906
5904
2907
5905
2916
2917
003
603
302
2918
2919
2920
2922
2910
2923
504
205
see Detail A 203
KYS
506
30 204 204
2982 30
2981
Coil Contact
2910 2910
Truck with Display w/ KYS 87
see Detail B
2983 2911 87 2911 PC202
Socket 85
5900
1) Cut off and isolate Wire 203 232
232
86 206 206 1 DISPLAY
86 5900
2) Use Adapter PN820143 for KYS 203 2
204
3
503
4
(BLK) 607
5
PC203
2920 6
LMS A 7
505
B SP9 SP8 SP4 SP1 CROWN PN 902
8
2921
C 907
9
PC208 10
304
SR2 A 11
605
B 12
001 (YEL) 101
C 13
CONTACTS 200 (PINK) 306
LINE IN
14
PC207 2926
901
305 LINE COIL 5908
SR1 A
606 120R
B
906
002 200
C IN PC214
EDS OUT
201 901
2908 (VIO) SP2 SP3
1 CAN CONN.
906
2
BRK CONTACTS 2900
5909 (WHT/GRN)
LINE OUT 3
4
JC206 5
6
BRS 1
2
2913 (RED/BLU) JC205
(BLK) 607
1 SRT
3
2909 (GRAY/PINK) (PINK) 306
PC213
4 2 2905
Contact
PC212 (YEL) 101
3 306
1K1 1 FAN
301 (GRAY) 5906
2
ECR 1 4
Type 3
SP7
601 (BLU)
2
004 (WHT)
3
005 (BRN)
4
SP6
602 (RED) 500
5 BATT - 9+10+15
207
100 (GRN) FU2
2904
5903
6
SP5
202
4A
9+10 9+10
HN
2900
FU3
2901
4A
2909 (GRAY/PINK)
5909 (WHT/GRN)
208
FU4
209
4A
2908 (VIO)
004 (WHT)
100 (GRN)
005 (BRN)
2903
5907
2914
2924
2915
2925
604
303
000
2902
2916
2917
5905
5906
2912
5904
5908
2925
2921
2922
5907
5903
2923
2918
2919
2924
501
502
600
003
002
001
300
905
900
000
1 2 3 4 PC204 8
Pin 1
8
Pin 2
A B C PC210 A B C PC211 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
PS SV PLS 1 PLS 2
Access 3/2 (TCM/HCM) PC209
824334_2O-1
Fig. 183
WT 3000 Series
Rev. B
403
SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS WT -M TO 03/2010
Main Wire Harness WT -M to 03/2010
Connection Table
Spline Table
W ire No. Connection W ire No. Connection SPLINE 1 SPLINE 2 SPLINE 3 SPLINE 4 SPLINE 5
2900 Line Contacts FU3 IN 100 (GRN) PC212 6 PC209 22 500 BATT- 900 PC209-28 905 PC209-27 2901 FU3 300 PC209-25
2901 SPLINE 4 FU3 OUT 101 (YEL) JC205 3 PC202 13 501 PC210-B 901 PC214-1 906 PC214-2 2902 PC209-3 301 (GRAY) PC212-1
2902 SPLINE 4 PC209 3 502 PC211-B 902 PC202-8 907 PC202-9 2903 SV 302 PC200-5
503 PC202-4 2904 Horn 303 PC204-2
2903 SPLINE 4 SV 200 Line Contacts EDS
504 PC200-12 2905 PC213-1 304 PC208-A
2904 SPLINE 4 Ho r n 201 SPLINE 9 EDS 505 PC203-B 2906 PC216-1 305 PC207-A
2905 SPLINE 4 PC213 1 202 FU2 OUT SPLINE 8 506 Keypad 2907 PC215-1
2906 SPLINE 4 PC216 1 203 SOCKET 30 SOCKET 86 507 PC224-2
2907 SPLINE 4 PC215 1 204 SOCKET 30 PC202 3 SPLINE 6 SPLINE 7 SPLINE 8 SPLINE 9
2908 (VIO) BRK PC209 4 205 PC201 1 SPLINE 8 600 PC209-5 2911 Socket 87 202 FU2 OUT 201 EDS
601 (BLU) PC212-2 2912 PC209-10 205 PC201-1 207 FU2 IN
2909 (GRAY/PINK) JC206 3 PC209 1 206 SOCKET 86 SPLINE 8
602 (RED) PC212-5 2913 (RED/BLU) JC206-2 206 Socket 86 208 FU4 IN
2910 SOCKET 87 PC200 10 207 SPLINE 9 FU2 IN 603 PC200-4 2914 PC210-A
2911 SPLINE 7 SOCKET 87 208 SPLINE 9 FU4 OUT 604 PC204-1 2915 PC211-A
2912 SPLINE 7 PC209 10 209 PC224 1 FU4 OUT 605 PC208-B 2926 Line Coil
2913 (RED/BLU) SPLINE 7 JC206 2 606 PC207-B
2914 SPLINE 7 PC210 A 300 SPLINE 5 PC209 25
2915 SPLINE 7 PC211 A 301 (GRAY) SPLINE 5 PC212 1
2916 PC200 1 PC209 6 302 SPLINE 5 PC200 5
2917 PC200 2 PC209 7 303 SPLINE 5 PC204 2
2918 PC200 6 PC209 31 304 SPLINE 5 PC208 A
2919 PC200 7 PC209 32 305 SPLINE 5 PC207 A
2920 PC203 A PC200 8 306 (PINK) JC205 2 PC202 14
2921 PC203 C PC209 17
2922 PC200 9 PC209 20 500 BATT NEG SPLINE 1
2923 PC200 11 PC209 29 501 PC210 B SPLINE 1
2924 PC210 C PC209 35 502 PC211 B SPLINE 1
2925 PC211 C PC209 16 503 PC202 4 SPLINE 1
2926 SPLINE 7 Line Coil 504 PC200 12 SPLINE 1
505 PC203 B SPLINE 1
506 Keypad SPLINE 1
507 PC224 2 SPLINE 1
5900 SOCKET 85 PC202 2
5903 Horn PC209 26 600 SPLINE 6 PC209 5
5904 PC216 2 PC209 11 601 (BLU) SPLINE 6 PC212 2
5905 PC215 2 PC209 8 602 (RED) SPLINE 6 PC212 5
5906 PC213 2 PC209 9 603 SPLINE 6 PC200 4
5907 SV PC209 24 604 SPLINE 6 PC204 1
5908 Line Coil PC209 12 605 SPLINE 6 PC208 B
5909 BRK PC209 2 606 SPLINE 6 PC207 B
607 (BLK) PC202 5 JC205 1
000 PC204 4 PC209 30
001 PC208 C PC209 21 900 SPLINE 2 PC209 28
002 PC207 C PC209 18 901 SPLINE 2 PC214 1
003 PC200 3 PC209 15 902 SPLINE 2 PC202 8
004 (WHT) PC212 3 PC209 14
005 (BRN) PC212 4 PC209 13 905 SPLINE 3 PC209 27
906 SPLINE 3 PC214 2
907 SPLINE 3 PC202 9
824334-2O-3
Fig. 184
WT 3000 Series
Rev. B
404
SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS WT -M FROM 04/2012
Main Wire Harness WT -M from 04/2012
Detail B HANDLE HANDLE PWS FLS (Opt.) ALM (Opt.)

Truck with Display w/o KYS Detail A KEYPAD 1 2 3 4 5 6 7 8 9 10 11 12 PC200 1 2 3 4 PC201 1 2 PC224 1 2 PC216 1 2 PC215
see Detail A
Adapter
209
507
2916
2917
2918
2919
2920
2922
2910
2923
2906
5904
2907
5905
003
603
302
504
205
203
KYS
506
30 204 204
2982 30
2981
Coil Contact
Truck with Display w/ KYS 2910 2910
87
see Detail B 2983 2911 87 2911 PC202
1) Cut off and isolate Wire 203 Socket 85
5900
232
232
86 206 206 1 DISPLAY
2) Use Adapter PN820143 for KYS 86 5900
203 2
204
3
503
4
5
PC203
2920 6
LMS A 7
505
B SP9 SP8 SP4 SP1 CROWN PN 902
8
2921
C 907
9
PC208 10
304
SR2 A 11
605
B
12
001
C
13
CONTACTS 200
LINE IN 14
PC207 2926
901
305 LINE COIL 5908
SR1 A
606 120 Ohm
B
906
002 200
C IN PC214
EDS OUT
201 901
2908 (VIO) SP2 SP3
1 CAN CONN.
906
2
BRK CONTACTS 2900
5909 (WHT/GRN)
LINE OUT 3
4
JC206 5
6
BRS 1
2913 (RED/BLU)
2
3
2909 (GRAY/PINK)
PC213
4 2905
1 FAN
301 (GRAY)
5906
004 (WHT)
100 (GRN)
005 (BRN)
602 (RED)
601 (BLU)
SP7
1 2 3 4 PC212 1 2 PC205
SP6
500
ECR1 TS1 BATT - 207
FU2
2904
5903
SP5
202
4A
600
HN
2900
FU3
2901
4A
2909 (GRAY/PINK)
5909 (WHT/GRN)
208
FU4
209
4A
2908 (VIO)
004 (WHT)
100 (GRN)
005 (BRN)
2903
5907
2914
2924
2915
2925
604
303
000
2902
2916
2917
5905
5906
2912
5904
5908
2925
2921
2922
5907
5903
2923
2918
2919
2924
501
502
600
003
002
001
300
905
900
000
1 2 3 4 PC204 Pin 1 Pin 2 A B PC210
C A PC211
B C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 PC209
PS SV PLS 1 PLS 2
Access 3/2 (TCM/HCM)
831971_3C-1
Fig. 185
WT 3000 Series
Rev. B
405
SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS WT -M FROM 04/2012
Connection Table
Spline Table
Wire No. Connection Wire No. Connection SPLINE 1 SPLINE 2 SPLINE 3 SPLINE 4 SPLINE 5
500 BATT- 900 PC209-28 905 PC209-27 2901 FU3 300 PC209-25
2900 Line Contacts FU3 IN 100 (GRN) PC205 2 PC209 22 501 PC210-B 901 PC214-1 906 PC214-2 2902 PC209-3 301 (GRAY) PC212-1
502 PC211-B 902 PC202-8 907 PC202-9 2903 SV 302 PC200-5
2901 SPLINE 4 FU3 OUT 503 PC202-4 2904 Horn 303 PC204-2
2902 SPLINE 4 PC209 3 200 Line Contacts EDS 504 PC200-12 2905 PC213-1 304 PC208-A
505 PC203-B 2906 PC216-1 305 PC207-A
2903 SPLINE 4 SV 201 SPLINE 9 EDS 506 Keypad 2907 PC215-1
507 PC224-2
2904 SPLINE 4 Horn 202 FU2 OUT SPLINE 8 SPLINE 6 SPLINE 7 SPLINE 8 SPLINE 9
2905 SPLINE 4 PC213 1 203 SOCKET 30 SOCKET 86 600 PC209-5 2911 Socket 87 202 FU2 OUT 201 EDS
601 (BLU) PC212-2 2912 PC209-10 205 PC201-1 207 FU2 IN
2906 SPLINE 4 PC216 1 204 SOCKET 30 PC202 3 602 (RED) PC212-5 2913 (RED/BLU) JC206-2 206 Socket 86 208 FU4 IN
603 PC200-4 2914 PC210-A
2907 SPLINE 4 PC215 1 205 PC201 1 SPLINE 8 604 PC204-1 2915 PC211-A
2908 (VIO) BRK PC209 4 206 SOCKET 86 SPLINE 8 605 PC208-B 2926 Line Coil
606 PC207-B
2909 (GRAY/PINK) JC206 3 PC209 1 207 SPLINE 9 FU2 IN
2910 SOCKET 87 PC200 10 208 SPLINE 9 FU4 OUT
2911 SPLINE 7 SOCKET 87 209 PC224 1 FU4 OUT
2912 SPLINE 7 PC209 10 300 SPLINE 5 PC209 25
2913 (RED/BLU) SPLINE 7 JC206 2 301 (GRAY) SPLINE 5 PC212 1
2916 PC200 1 PC209 6 304 SPLINE 5 PC208 A
2917 PC200 2 PC209 7 305 SPLINE 5 PC207 A
2918 PC200 6 PC209 31
2920 PC203 A PC200 8 501 PC210 B SPLINE 1
2921 PC203 C PC209 17 502 PC211 B SPLINE 1
2922 PC200 9 PC209 20 503 PC202 4 SPLINE 1
2923 PC200 11 PC209 29 504 PC200 12 SPLINE 1
2924 PC210 C PC209 35 505 PC203 B SPLINE 1
2925 PC211 C PC209 16 506 Keypad SPLINE 1
2926 SPLINE 7 Line Coil 507 PC224 2 SPLINE 1
5900 SOCKET 85 PC202 2 600 SPLINE 6 PC209 5
5903 Horn PC209 26 601 (BLU) SPLINE 6 PC212 2
5904 PC216 2 PC209 11 602 (RED) SPLINE 6 PC205 1
5905 PC215 2 PC209 8 603 SPLINE 6 PC200 4
5906 PC213 2 PC209 9 604 SPLINE 6 PC204 1
5907 SV PC209 24 605 SPLINE 6 PC208 B
5908 Line Coil PC209 12 606 SPLINE 6 PC207 B
5909 BRK PC209 2
000 PC204 4 PC209 30 900 SPLINE 2 PC209 28
001 PC208 C PC209 21 901 SPLINE 2 PC214 1
002 PC207 C PC209 18 902 SPLINE 2 PC202 8
003 PC200 3 PC209 15 905 SPLINE 3 PC209 27
004 (WHT) PC212 3 PC209 14 906 SPLINE 3 PC214 2
005 (BRN) PC212 4 PC209 13 907 SPLINE 3 PC202 9 831971_3C-3
Fig. 186
WT 3000 Series
Rev. B
406
SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS WT -E TO 06/2009
Main Wire Harness WT -E to 06/2009
PC224
Truck with Display w/o KYS
see Detail A Detail B KYS / KEYLESS 211
4 1 PWS
511
Use Bridge 826405-001 BRIDGE TFD HANDLE BRS DISPLAY 4 2 C
for Connector JC225 Adapter KEYPAD 1 2 3 4 5 6 JC225 1 2 3 4 5 6 PC214 1 2 3 4 5 6 JC220 A B C PC205 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PC201
Truck with Display w/ KYS KYS 212 PC202
204
202
30
2935
203
212
700
603
102
101
2934
5908
912
506
2933
904
208
2915
2920
2913
5907
204
505
903
911
see Detail B 2982 Detail A
509
2981
2917 212 2906
1) Use Bridge 826405-002 30 1 FLS (Opt.)
Coil Contact
87
2983 2918 2917 5904
for Connector JC225 87 2918 2
2) Use Adapter PN820143 232
232
86 213/203
Socket 5907
85
for Keyswitch 213
86
203 PC203
2907
SP14 1 ALM (Opt.)
5905
2
PC223
2919
LMS1 A SP7
B
510 PC204
2911 2905
C PC209 1 FAN
2921 5903
2
SR2 A
507
B SP3
2910 2904
C
IN
200 5902 HN
CONTACTS 2900
OUT
PC208
2922
LINE 2925
SR1 A COIL
PC211
508 5906 200 901
B 1 CAN CONN.
C
2909 201 EDS 908
SP4
2
SP6
3
4
702 5
PC218 1
008 6
ECR1 2
SP5
009
M3 3
SP1
4
608 JC212
004
1 CONN.
602
PC216 1
104 2 HAND SET
607 302
3
TS M3 2 SP8 SP9 003
4
2908 002
5
PC217 1
303 SP12 5900 BRK 001
6
006
ECR M1 2
007
3 701
1 PC219 PC221
SP10
605
4 010 603
2 ECR2 1
011 700
3 M3 2
SP13
103 609 104
PC215 1 4 206
FU3 3
Access 5
606 702
TS M1 2 202
4A 4
701
500 5
102
2924 503 6
PC213 1 BATT - CROWN 2900
FU4 008
7
503 504
SAHS 2 2901
10A 009
8
005
3
207
FU5 PC222
205
10A 1
2
2917 005
SP2 SP11
FU6 3
2932 2916
4A 4
2926
5
910
6
Access 5
210
FU7 2927
7
211
4A 010
8
011
9
5901
2929
2912
2930
2914
5901
2914
2909
2912
2915
5902
5900
2908
5903
2911
5906
5905
5904
2931
2916
2913
2910
2902
5908
601
301
100
501
502
909
600
004
001
900
300
101
100
007
209
103
604
303
006
002
003
609
10
608
1 2 3 4 PC210 A B C PC206 A B C PC207 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 PC200 11
12
PS SV PLS 1 PLS 2 Access 3/2 (TCM/HCM) 607
13
902
14
824533_2J-1
Fig. 187
WT 3000 Series
Rev. B
407
SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS WT -E TO 06/2009
W ire No. Connection W ire No. Connection

2900 Line Contactor Contacts FU3 IN 100 PC210 4 PC200 23 Spline Table
2901 FU4 OUT SPLINE 4 101 PC214 4 PC200 25
2902 PC200 4 SPLINE 4 102 PC214 3 PC221 6
SPLINE 5 SPLINE 6 SPLINE 7 SPLINE 8 SPLINE 9 SPLINE 10
2903 SV SPLINE 4 103 PC215 1 PC200 12
2904 HORN SPLINE 4 104 PC221 3 PC216 1 900 PC200-27 908 PC211-2 2918 Socket 87 300 PC200-26 600 PC200-41 2923 SPLINE 7
2905 PC204 1 SPLINE 4 901 PC211-1 909 PC200-42 2919 PC223-A 301 PC210-2 601 PC210-1 2924 PC213-1
2906 PC202 1 SPLINE 4 200 Line Contacto Contacts EDS 902 PC222-14 910 PC222-6 2920 PC205-A 302 JC212-3 602 JC212-2 2925 LINE COIL
2907 PC203 1 SPLINE 4 201 EDS SPLINE 1 90 3 PC201-8 911 PC201-9 2921 PC209-A 2926 PC222-5
2908 PC200 30 BRK 202 FU3 OUT JC225 2 904 JC220-4 912 JC220-1 2922 PC208-A 2927 PC222-7
2909 PC208 C PC200 35 203 JC225 4 SOCKET 86
2923 SPLINE10 2928 SPLINE 11
2910 PC209 C PC200 5 204 JC225 1 PC201 3
2911 PC223 C PC200 21 205 FU5 OUT SPLINE 13 SPLINE 11 SPLINE 12 SPLINE 13 SPLINE 14
2912 PC206 C PC200 34 206 FU3 IN SPLINE 13 2928 SPLINE 10 604 PC200-10 205 FU5 OUT 2932 FU6 OUT
2913 PC205 C PC200 6 207 FU5 IN SPLINE 1 2929 PC206-A 605 PC217-4 208 JC220-5 2933 JC220-3 Spline Table
2914 PC207 C PC200 37 208 JC220 5 SPLINE 13 2930 PC207-A 606 PC215-2 209 PC200-20 2935 JC225-3
2915 JC220 6 PC200 33 209 PC200 20 SPLINE 13
2931 PC200-13 213 SOCKET 86 SPLINE 1 SPLINE 2
2916 PC222 4 PC200 7 210 FU7 IN SPLINE 1
2917 SOCKET 87 FU6 IN 211 FU7 OUT PC224 1
206 FU3 IN 201 EDS 500 BATT-
2918 SOCKET 87 SPLINE 7 212 JC225 5 SOCKET 30 207 FU5 IN 501 PC206-B
2919 PC223 A SPLINE 7 213 SOCKET 86 SPLINE 13 210 FU7 IN 502 PC207-B
2920 PC205 A SPLINE 7 511 PC224-2
2921 PC209 A SPLINE 7 300 PC200 26 SPLINE 8
2922 PC208 A SPLINE 7 301 PC210 2 SPLINE 8 SPLINE 3 SPLINE 4
2923 SPLINE 10 SPLINE 7 302 JC212 3 SPLINE 8 504 BATT- 2901 FU4 OUT
2924 PC213 1 SPLINE 10 303 PC217 1 PC200 9 505 PC201-4 2902 PC200-4
2925 Line Contactor Coil SPLINE 10 506 JC220-2 2903 SV
2926 PC222 5 SPLINE 10 500 BATT NEG SPLINE 2 507 PC209-B 2904 HORN
2927 PC222 7 SPLINE 10 501 PC206 B SPLINE 2
508 PC208-B 2905 PC204-1
2928 SPLINE 11 SPLINE 10 502 PC207 B SPLINE 2
2929 PC206 A SPLINE 11 503 BATT NEG PC213 2 509 KEYPAD 2906 PC202-1
2930 PC207 A SPLINE 11 504 BATT NEG SPLINE 3 510 PC223-B 2907 PC203-1
2931 PC200 13 SPLINE 11 505 PC201 4 SPLINE 3 2934 PC214-5
2932 FU6 OUT SPLINE 14 506 JC220 2 SPLINE 3
2933 JC220 3 SPLINE 14 507 PC209 B SPLINE 3
2935 JC225 3 SPLINE 14 509 KEYPAD SPLINE 3
510 PC223 B SPLINE 3
5900 BRK PC200 31 511 PC224 2 SPLINE 2
59 0 1 SV PC200 39
5902 HORN PC200 32 600 PC200 41 SPLINE 9
5903 PC204 2 PC200 28 601 PC210 1 SPLINE 9
5904 PC202 2 PC200 15 602 JC212 2 SPLINE 9
5905 PC203 2 PC200 16 603 PC221 1 PC214 2
5906 Line Contactor Coil PC200 17 604 PC200 10 SPLINE 12
5907 PC201 2 SOCKET 85 605 PC217 4 SPLINE 12
5908 PC214 6 PC200 3 606 PC215 2 SPLINE 12
607 PC222 13 PC216 2
000 PC209 30 PC204 4 608 PC222 11 PC218 4
001 JC212 6 PC200 29 609 PC222 10 PC219 4
002 JC212 5 PC200 2
003 JC212 4 PC200 1 700 PC221 2 PC214 1
004 JC212 1 PC200 40 701 PC221 5 PC219 1
005 PC222 3 PC213 3 702 PC221 4 PC218 1
006 PC217 2 PC200 8
007 PC217 3 PC200 22 900 PC200 27 SPLINE 5
008 PC221 7 PC218
PC200
2 901 PC211 1 SPLINE 5
009 PC221 8 PC218 3 902 PC222 14 SPLINE 5
010 PC222 8 PC219 2 903 PC201 8 SPLINE 5
011 PC222 9 PC219 3 904 JC220 4 SPLINE 5

909 PC200 42 SPLINE 6
912 JC220 1 SPLINE 6 824533_2J-3
Fig. 188
WT 3000 Series
Rev. B
408
SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS WT -E FROM 07/09 TO 03/2012
Main Wire Harness WT -E from 07/09 to 03/2012
Detail B
PC224
Truck with Display w/o KYS KYS / KEYLESS 211
1 PWS
see Detail A Adapter 511
Use Bridge 826405-001 KYS 30 212
BRIDGE TFD HANDLE BRS DISPLAY 2
2982
for Connector JC225 2981
2917 Detail A KEYPAD 1 2 3 4 5 6 JC225 1 2 3 4 5 6 PC214 1 2 3 4 5 6 JC220 A B C PC205 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PC201
87
Truck with Display w/ KYS 2983 2918 PC202
204
202
2935
203
212
700
603
102
101
2934
5908
912
506
2933
904
208
2915
2920
2913
5907
204
505
903
911
509
see Detail B 212 2906
232 86 213/203 30 1 FLS (Opt.)
Coil Contact
1) Use Bridge 826405-002 232 2917 5904
for Connector JC225 87 2918 2
2) Use Adapter PN820143 Socket 85
5907
213
for Keyswitch 86
203 PC203
2907
SP14 1 ALM (Opt.)
5905
2
PC223
2919
LMS1 A SP7
B
510 PC204
2911 2905
C PC209 1 FAN
2921 5903
2
SR2 A
507
B SP3
2910 2904
C
IN
200 5902 HN
CONTACTS 2900
OUT
PC208
2922
LINE 2925
SR1 A COIL
PC211
508 5906 200 901
B 1 CAN CONN.
C
2909 201 EDS 908
SP4
2
SP6
3
4
WHT 5
PC218 1
BRN 6
ECR2 2
SP5
GRN
3
SP1
4
YEL JC212
16 core Cable 004
1 CONN.
GRAY 6 core Cable 602
2 HAND SET
PC216 1
302
PINK 3
TS2 2 SP8 SP9 003
4
WHT 002
5
PC217 1
GRN SP12 BRN BRK 001
100
6
YEL
ECR1 2
GRAY
3 RED/BLU
1 PC219 PC221
SP10
BLU
4 WHT/GRN 603
2 ECR3 1
Access 5 (SCM)
WHT/YEL 700
3 2
SP13
PINK YEL/BRN GRAY
PC215 1 4 206
FU3 3
RED WHT
TS1 2 202
4A 4
RED/BLU
500 5
102
BLK VIO 6
FU4 BRN
7
VIO 504
SAHS 2 2901
10A GRN
8
GRAY/PINK
3
207
FU5 PC222
205
10A 1
2
2917 GRAY/PINK
SP2 SP11
FU6 3
2932 2916
4A 4
2926
5
Access 5 (SCM)
910
210 6
FU7 2927
7
211
4A WHT/GRN
8
WHT/YEL
GRAY
9
WHT
PINK
GRN
2903
5901
2929
2912
2930
2914
5901
2914
2909
2912
2915
5902
5903
2911
5906
5905
5904
2931
2916
2913
2910
2902
5908
BRN
601
301
100
YEL
501
502
909
600
004
001
900
300
101
100
209
604
002
003
YEL/BRN
10
YEL
1 2 3 4 PC210 A B C PC206 A B C PC207 2 441 40 39 38 37 6 35 334 33 32 31 30 9 28 227 26 25 24 23 22 21 20 19 18 17 6 15
1 4 113 12 11 10 9 8 7 6 5 4 3 2 1 PC200 11
PS SV PLS 1 PLS 2 Access 3/2 (TCM/HCM)

12
PINK
13
902
14 824533_2K-1
Fig. 189
WT 3000 Series
Rev. B
409
SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS WT -E FROM 07/09 TO 03/2012
Connections Spline Table
W ire No. Connection W ire No. Connection SPLINE 1 SPLINE 3 SPLINE 4 SPLINE 5 SPLINE 6 SPLINE 7 SPLINE 8
2900 Line Contactor Contacts FU3 IN PINK PC215 1 PC200 12 201 EDS 504 BATT- 2901 FU4 OUT 900 PC200-27 908 PC211-2 2918 Socket 87 300 PC200-26
2901 FU4 OUT SPLINE 4 GRN PC217 1 PC200 9 207 FU5 IN 505 PC201-4 2902 PC200-4 901 PC211-1 909 PC200-42 2919 PC223-A 301 PC210-2
2902 PC200 4 SPLINE 4 BRN BRK PC200 31 210 FU7 IN 506 JC220-2 2903 SV 902 PC222-14 910 PC222-6 2920 PC205-A 302 JC212-3
29 03 SV SPLINE 4 WHT PC200 30 BRK 507 PC209-B 2904 HORN 903 PC201-8 911 PC201-9 2921 PC209-A
2904 HORN SPLINE 4 YEL PC217 2 PC200 8 SPLINE 2 508 PC208-B 2905 PC204-1 904 JC220-4 912 JC220-1 2922 PC208-A
2905 PC204 1 SPLINE 4 GRAY PC217 3 PC200 22 500 BATT- 509 KEYPAD 2906 PC202-1 2923 SPLINE10
2906 PC202 1 SPLINE 4 501 PC206-B 510 PC223-B 2907 PC203-1
2907 PC203 1 SPLINE 4 BLK PC213 1 SPLINE 10 502 PC207-B 2934 PC214-5
2909 PC208 C PC200 35 GRAY PC221 3 PC216 1 511 PC224-2
2910 PC209 C PC200 5 VIO BATT NEG PC213 2 SPLINE 9 SPLINE 10 SPLINE 11 SPLINE 12 SPLINE 13 SPLINE 14
2911 PC223 C PC200 21 GRAY/PINK PC222 3 PC213 3 600 PC200-41 2923 SPLINE 7 2928 SPLINE 10 604 PC200-10 205 FU5 OUT 2932 FU6 OUT
601 PC210-1 BLK PC213-1 2929 PC206-A BLU PC217-4 208 JC220-5 2933 JC220-3
2912 PC206 C PC200 34 BRN PC221 7 PC218 2
602 JC212-2 2925 LINE COIL 2930 PC207-A RED PC215-2 209 PC200-20 2935 JC225-3
2913 PC205 C PC200 6 GRN PC221 8 PC218 3
2926 PC222-5 2931 PC200-13 213 SOCKET 86
2914 PC207 C PC200 37 WHT/GRN PC222 8 PC219 2
2927 PC222-7 206 FU3 IN
2915 JC220 6 PC200 33 WHT/YEL PC222 9 PC219 3
2928 SPLINE 11
2916 PC222 4 PC200 7 RED/BLU PC221 5 PC219 1
2917 SOCKET 87 FU6 IN WHT PC221 4 PC218 1
2918 SOCKET 87 SPLINE 7 BLU PC217 4 SPLINE 12
2919 PC223 A SPLINE 7 RED PC215 2 SPLINE 12
2920 PC205 A SPLINE 7 PINK PC222 13 PC216 2
2921 PC209 A SPLINE 7 YEL PC222 11 PC218 4
2922 PC208 A SPLINE 7 YEL/BRN PC222 10 PC219 4
2923 SPLINE 10 SPLINE 7
2925 Line Contactor Coil SPLINE 10
2926 PC222 5 SPLINE 10 200 Line Contacto Contacts EDS
2927 PC222 7 SPLINE 10 201 EDS SPLINE 1
2928 SPLINE 11 SPLINE 10 202 FU3 OUT JC225 2
2929 PC206 A SPLINE 11 203 JC225 4 SOCKET 86
2930 PC207 A SPLINE 11 204 JC225 1 PC201 3
2931 PC200 13 SPLINE 11 205 FU5 OUT SPLINE 13
2932 FU6 OUT SPLINE 14 206 FU3 IN SPLINE 13
2933 JC220 3 SPLINE 14 207 FU5 IN SPLINE 1
2934 PC214 5 SPLINE 4 208 JC220 5 SPLINE 13
2935 JC225 3 SPLINE 14 209 PC200 20 SPLINE 13
210 FU7 IN SPLINE 1
5901 SV PC200 39 211 FU7 OUT PC224 1
5902 HORN PC200 32 212 JC225 5 SOCKET 30
5903 PC204 2 PC200 28 213 SOCKET 86 SPLINE 13
5904 PC202 2 PC200 15
5905 PC203 2 PC200 16
5907 PC201 2 SOCKET 85 301 PC210 2 SPLINE 8
5908 PC214 6 PC200 3 302 JC212 3 SPLINE 8
000 PC209 30 PC204 4

001 JC212 6 PC200 29 500 BATT NEG SPLINE 2
002 JC212 5 PC200 2 501 PC206 B SPLINE 2
003 JC212 4 PC200 1 502 PC207 B SPLINE 2
100 PC210 4 PC200 23 506 JC220 2 SPLINE 3
101 PC214 4 PC200 25 507 PC209 B SPLINE 3
102 PC214 3 PC221 6 508 PC208 B SPLINE 3
509 KEYPAD SPLINE 3
900 PC200 27 SPLINE PC200
5 510 PC223 B SPLINE 3
901 PC211 1 SPLINE 5 511 PC224 2 SPLINE 2
902 PC222 14 SPLINE 5
909 PC200 42 SPLINE 6 603 PC221 1 PC214 2
912 JC220 1 SPLINE 6 700 PC221 2 PC214 1 824533_2K-3
Fig. 190
WT 3000 Series
Rev. B
410
SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS WT -E FROM 04/2012
Main Wire Harness WT -E from 04/2012
PC224
211
Truck with Display w/o KYS KYS / KEYLESS 1 PWS
511
see Detail A BRIDGE TFD HANDLE BRS DISPLAY 2
Use Bridge 826405-001
for Connector JC225 KEYPAD 1 2 3 4 5 6 JC225 1 2 3 4 5 6 PC214 1 2 3 4 5 6 JC220 A B C PC205 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PC201
Detail B Detail A
204
202
203
212
700
603
102
101
912
506
904
208
204
505
903
911
2935
2934
5908
2933
2915
2920
2913
5907
Truck with Display w/ KYS PC202
509
see Detail B 212 2906
30 1 FLS (Opt.)
Coil Contact
1) Use Bridge 826405-002 Adapter 2917 5904
87 2918 2
for Connector JC225 KYS 2982
30 212 5907
2) Use Adapter PN820143 2981 85
2917 213
for Keyswitch 87 86
2983 2918 203 PC203
2907
232 86 213/203 Socket SP14 1 ALM (Opt.)
232 5905
PC223 2
2919
LMS1 A SP7
510
B PC204
2911 2905
C PC209 1 FAN
2921 5903
SR2 A 2
507
B SP3
2910 2904
C
200 5902 HN
IN
2900
PC208 OUT
LINE
2922 2925
SR1 A COIL
PC211
508 5906 200 901
B 1 CAN CONN.
C
2909 201 EDS 908
2
SP4
257_Crown
SP6
3
4
WHT 5
PC218 1
BRN 6
ECR2 2
SP5
GRN
3
SP1
4
YEL JC212
16 core Cable 004
1
GRAY 6 core Cable 602
2 CONN.
PC216 1
302 HAND SET
PINK 3
TS2 2 SP8 SP9 003
4
WHT 002
5
PC217 1
GRN SP12 BRN BRK 001
6
100
BLU
ECR1 2
YEL
3 RED/BLU
1 PC219 PC221
SP10
GRAY
4 WHT/GRN 603
2 ECR3 1
Access 5 (SCM)
WHT/YEL 700
3 2
SP13
PINK YEL/BRN GRAY
PC215 1 4 206
FU3 3
RED WHT
TS1 2 202
4A 4
RED/BLU
500 5
102
BLK VIO 6
FU4 BRN
7
VIO 504
SAHS 2 2901
10A GRN
8
GRAY/PINK
3
207
FU5 PC222
205
10A 1
2
2917 GRAY/PINK
FU6 3
Access 5 (SCM)
SP2 SP11 2932 2916
4A 4
2926
5
910
210 6
FU7 2927
7
211
4A WHT/GRN
8
WHT/YEL
GRAY
PINK
WHT
GRN
2903
5901
2929
2912
2930
2914
5901
2914
2909
2912
2915
5902
5903
2911
5906
5905
5904
2931
2916
2913
2910
2902
5908
BRN
601
301
100
YEL
501
502
909
600
004
001
900
300
101
100
209
604
002
003
YEL/BRN
10
YEL
1 2 3 4 PC210 A B C PC206 A B C PC207 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 PC200 11
SV 12
E PS P CONN. PLS 1 PLS 2 Access 2/3 (TCM/HCM) PINK
13
902 14
831972_3B-1
Fig. 191
WT 3000 Series
Rev. B
411
SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS WT -E FROM 04/2012
W ire No. Connec t ion W ire No. Connect ion Spline Table
2900 Line Contactor Contacts FU3 IN PINK PC215 1 PC200 12
2901 FU4 OUT SPLINE 4 GRN PC217 1 PC200 9 SPLINE 1 SPLINE 3 SPLINE 4 SPLINE 5 SPLINE 6 SPLINE 7 SPLINE 8
2902 PC200 4 SPLINE 4 BRN BRK PC200 31 201 EDS 504 BATT- 2901 FU4 OUT 900 PC200-27 908 PC211-2 2918 Socket 87 300 PC200-26
2903 SV SP LINE 4 WHT PC200 30 BRK 207 FU5 IN 505 PC201-4 2902 PC200-4 901 PC211-1 909 PC200-42 2919 PC223-A 301 PC210-2
2904 HORN SPLINE 4 YEL PC217 3 PC200 8 210 FU7 IN 506 JC220-2 2903 SV 902 PC222-14 910 PC222-6 2920 PC205-A 302 JC212-3
2905 PC204 1 SPLINE 4 GRAY PC217 4 PC200 22 507 PC209-B 2904 HORN 903 PC201-8 911 PC201-9 2921 PC209-A
2906 PC202 1 SPLINE 4 BLK PC213 1 SPLINE 10 SPLINE 2 508 PC208-B 2905 PC204-1 904 JC220-4 912 JC220-1 2922 PC208-A
500 BATT- 509 KEYPAD 2906 PC202-1 2923 SPLINE10
2907 PC203 1 SPLINE 4 GRAY PC221 3 PC216 1
501 PC206-B 510 PC223-B 2907 PC203-1
2909 PC208 C PC200 35 VIO BATT NEG PC213 2
502 PC207-B 2934 PC214-5
2910 PC209 C PC200 5 GRAY/PINK PC222 3 PC213 3
511 PC224-2
2911 PC223 C PC200 21 BRN PC221 7 PC218 2
SPLINE 9 SPLINE 10 SPLINE 11 SPLINE 12 SPLINE 13 SPLINE 14
2912 PC206 C PC200 34 GRN PC221 8 PC218 3
600 PC200-41 2923 SPLINE 7 2928 SPLINE 10 604 PC200-10 205 FU5 OUT 2932 FU6 OUT
2913 PC205 C PC200 6 WHT/GRN PC222 8 PC219 2 601 PC210-1 BLK PC213-1 2929 PC206-A BLU PC217-2 208 JC220-5 2933 JC220-3
2914 PC207 C PC200 37 WHT/YEL PC222 9 PC219 3 602 JC212-2 2925 LINE COIL 2930 PC207-A RED PC215-2 209 PC200-20 2935 JC225-3
2915 JC220 6 PC200 33 RED/BLU PC221 5 PC219 1 2926 PC222-5 2931 PC200-13 213 SOCKET 86
2916 PC222 4 PC200 7 WHT PC221 4 PC218 1 2927 PC222-7 206 FU3 IN
2917 SOCKET 87 FU6 IN BLU PC217 2 SPLINE 12 2928 SPLINE 11
2918 SOCKET 87 SPLINE 7 RED PC215 2 SPLINE 12
2919 PC223 A SPLINE 7 PINK PC222 13 PC216 2
2920 PC205 A SPLINE 7 YEL PC222 11 PC218 4
2921 PC209 A SPLINE 7 YEL/BRN PC222 10 PC219 4
2922 PC208 A SPLINE 7 100 PC210 4 PC200 23
2923 SPLINE 10 SPLINE 7 101 PC214 4 PC200 25
2925 Line Contactor Coil SPLINE 10 102 PC214 3 PC221 6
2926 PC222 5 SPLINE 10 200 Line Contacto Contacts EDS
2927 PC222 7 SPLINE 10 201 EDS SPLINE 1
2928 SPLINE 11 SPLINE 10 202 FU3 OUT JC225 2
2929 PC206 A SPLINE 11 203 JC225 4 SOCKET 86
2930 PC207 A SPLINE 11 204 JC225 1 PC201 3
2931 PC200 13 SPLINE 11 205 FU5 OUT SPLINE 13
2932 FU6 OUT SPLINE 14 206 FU3 IN SPLINE 13
2933 JC220 3 SPLINE 14 207 FU5 IN SPLINE 1
5901 SV PC200 39 210 FU7 IN SP LINE 1
5902 HORN PC200 32 211 FU7 OUT PC224 1
5903 PC204 2 PC200 28 212 JC225 5 SOCKET 30
5904 PC202 2 PC200 15 213 SOCKET 86 SPLINE 13
5905 PC203 2 PC200 16 300 PC200 26 SPLINE 8
5907 PC201 2 SOCKET 85 302 JC212 3 SPLINE 8
000 PC209 30 PC204 4 501 PC206 B SPLINE 2
001 JC212 6 PC200 29 502 PC207 B SPLINE 2
003 JC212 4 PC200 1 505 PC201 4 SPLINE 3
004 JC212 1 PC200 40 506 JC220 2 SPLINE 3
901 PC211 1 SPLINE PC200
5 508 PC208 B SPLINE 3
902 PC222 14 SPLINE 5 509 KEYPAD SPLINE 3
911 PC201 9 SPLINE 6 603 PC221 1 PC214 2
700 PC221 2 PC214 1 831972_3B-3
Fig. 192
WT 3000 Series
Rev. B
412
HYDRAULIC SCHEMATIC
413
Notes:
414
HYDRAULIC SCHEMATIC
HYDRAULIC SYMBOLS
Hydraulic Symbols
Icon Meaning Icon Meaning
Vented reservoir with Electric motor unidi-

lines above fluid level rectional single speed
M
Vented reservoir with Hydraulic pump fixed

lines below fluid level displacement unidirec-
tional
Filter or strainer Spring, (bias to normal

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

flow winding
Pilot or drain line, lim- Component enclosure

ited flow manifold block
Lines crossing; not con- Resistor orifice throttle

nected (adjustable)
Lines crossing and con- Throttle, fixed

nected
Closed line port Relief valve, adjusta-

ble
Accumulator, gas Check valve

charged, diaphragm
type
WT 3000 Series Rev.2 08/2010

Rev. B
415
HYDRAULIC SCHEMATIC
HYDRAULIC SYMBOLS
2/2 way valve Hydraulic steer unit

(2 ways, 2 connections)
T L
P R
3/2 way valve Torque generator

P
T
3/2 way valve Shut-off valve, manual

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

(4 ways, 2 connections) with controlled flow,
pressure-regulated
4/3 way valve Flow divider/combiner

4/3 way valve Single pre-tension

(4 ways, 3 connections; valve assembly in
manual activation and manifold
spring centred
Flow meter Electric motor unidi-

rectional variable
M speed
Rev.2 08/2010 WT 3000 Series

Rev. B
416
HYDRAULIC SCHEMATIC
HYDRAULIC SYMBOLS
Valve block with 3 oper- Proportional solenoid

ating units
Shuttle valve Dual solenoid
Relief valve, fixed Solenoid valve, hy-

draulic pilot operated
Velocity fuse Hydraulic pilot oper-

ated hydraulic valve
Pressure-compensated Manual actuator

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

flow control, fixed with cushion
Pilot check valve (pilot Single-acting cylinder

to open) ram type
Manual lever actuator Single-acting cylinder

with spring returned
(rod end vented)
WT 3000 Series Rev.2 08/2010

Rev. B
417
HYDRAULIC SCHEMATIC
HYDRAULIC SYMBOLS
Double-acting cylinder; Thermometer

equal area
Double-acting cylinder; Pressure gauge

unequal area
Pressure switch Hydraulic motor, bi-di-

rectional
Rev.2 08/2010 WT 3000 Series

Rev. B
418
HYDRAULIC SCHEMATIC
HYDRAULIC DIAGRAM, TRUCKS WITHOUT TRACTION CONTROL
Hydraulic Diagram, Trucks without Traction Control
8
7 4
6
M
Fig. 193
1 Lift cylinder 5 Filter

2 Pressure sensor PS 6 Hydraulic pump
3 Lowering valve SV 7 Relief valve RV1
4 Resistor orifice throttle 8 Check valve CV
WT 3000 Series
Rev. B
419
HYDRAULIC SCHEMATIC
HYDRAULIC DIAGRAM, TRUCKS WITH TRACTION CONTROL
Hydraulic Diagram, Trucks with Traction Control
1
9
8
7
4
6
M
Fig. 194
1 Lift cylinder 6 Hydraulic pump

2 Pressure sensor PS 7 Relief valve RV1
3 Lowering valve SV 8 Check valve CV
4 Resistor orifice throttle 9 Traction cylinder
5 Filter
WT 3000 Series
Rev. B
420

Crown WT 3000 2311

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Crown WT 3000 2311

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Available Formats

WT 3000 SERIES

Order Number: 812588-006

Crown Gabelstapler GmbH & Co. KG

Phone +49 (0)89 93 00 2 – 0

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

INSPECTION AND LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Effects of incorrect cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Changing the gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Event Code 234 (WT 3020 -M, WT 3040 -M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Event Code 348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Event Code 209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Traction control module hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Checking forks for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

WT -E, with CAN Tiller, ABM Motor,

with Options, Separate EDS and Line Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413

Important Information Ordering documentation

Crown Gabelstapler GmbH & Co. KG

 This arrow indicates action to be taken to avoid haz-

Rev.3 07/2009 WT 3000 Series

Truck Data Number

The specification number in the example therefore de-

WT3020 Standard Optional

Shock Absorb Fixed Single Caster

No KeySwitch Key Or Keypad

DIN 160 A SBE160 / SB175red / SB175gray

240 Ah Battery Travelalarm

Key Switch or Keypad

Foldable Side Restraints

Kordel 230 Gearbox ABM 250 Gearbox ABM 250 Gearbox

Combi AC0 Traction

Optional Rear Entry Optional

Optional Side Entry

Note: A grey background indicates options.

Fig. 2 Comparison between Models with Standard Equipment and Options

WT 3000 Series Rev.2 08/2010

Rev.1 04/2009 WT 3000 Series

Maintenance work Cleaning work

WT 3000 Series Rev.1 04/2009

• Do not stand under a swinging load.

Rev.1 04/2009 WT 3000 Series

Truck safety mechanisms

Truck protective guards

Lifting the Truck 5. Prevent the lifting slings from slipping.

Lifting a side entry truck with a crane

Lifting a fixed platform truck with a

Preparing the truck Attaching lifting slings (see Fig. 4)

Fig. 3 Lifting a rear entry truck

Lifting a folding platform truck with

Raising a WT 3060 with folding platform

Fig. 5 Fahrzeug mit klappbarer Plattform heben

Lifting the truck beyond its castor wheels

Fig. 7 Lifting the truck within the castor wheels

Fig. 8 Towing the truck

Jacking up the truck Jacking up the truck

Fig. 10 Lorry loading

Clamping the truck

Storing the Truck Testing trucks in storage

Periodically starting a truck that has