812591-006 (Service DT3000)

DT 3000 SERIES
MAINTENANCE MANUAL
Order Number: 812591-006

Revision: A • 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 –
Moosacher Str. 52
80809 Munich
Germany
Phone +49 (0)89 93 00 2 – 0

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

Copyright 2010
Crown Equipment Corporation
TABLE OF CONTENTS
I
Notes:
II
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
Brief description of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Truck Data Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Truck modifications and additions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Personal safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Protecting the hazardous area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hazards from stored energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Restoring the truck to service after repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warning and instruction decals on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lifting gear and slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LUBRICATION & ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifting the truck by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifting the truck with a forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Towing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Jacking up the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Transporting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Securing the truck for transport on a truck bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Storing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Placing the truck in storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Periodically starting a truck that has been in storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Restoring the Truck to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cleaning the Truck and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Effects of incorrect cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Roller and slide bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Corrosion-protected surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cleaning the entire truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cleaning removed components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cleaning other mechanical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Recommended Lubricants and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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TABLE OF CONTENTS
Cold store truck requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Abbreviations used in the table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Annual inspection in accordance with FEM 4.004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Terms and abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lift mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Drive system, steering and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Safety mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Finger Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Testing the finger guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Checking the finger guard mechanism for freedom of movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Repairing the finger guard mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Finger guard mechanism disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Attaching the finger guard mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Adjusting the finger guard mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Battery Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Testing the bar monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Adjusting the BLS sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Adjusting the Outrigger Lift Limit Switch (LMS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Castor Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Replacing single castor wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Replacing the single castor wheel pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Replacing the single castor wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Replacing tandem castor wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Replacing the tandem castor wheel pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Replacing the tandem castor wheel bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Replacing the tandem castor wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Standard torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Replacing the Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Repairing the Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Replacing the hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Hydraulic pump removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Hydraulic pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Hydraulic unit reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Torques and references, without traction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Torques and references, with traction control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Changing the Hydraulic Oil and Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Replacing the Relief Valve RV1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Relief valve test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Flushing the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Preconditions for all drift tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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TABLE OF CONTENTS
Outrigger lift drift test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Fork lift drift test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Trucks with mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Trucks with electrical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Replacing the Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Drive wheel disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Changing the Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DT 3040 -MW and -MF Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
DT 3040 -EF Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Accessing the Service Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Operator and Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Analyzer Menu, A1 – A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Analyzer Menu, A3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Analyzer Menu, A4 Test Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Calibration Menu, C2 Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Calibration, C3 Lift/Lower Rotary Encoder menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Analyzer Menu, A2.2.1 – A2.2.19, Access 2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Analyzer, A2.3.1 – A2.3.15, Access 3 Inputs Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Analyzer, A2.2.1 – A2.2.19, Access 8.1 Inputs Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Analyzer Menu, A2.5.1 – A2.5.8, Access 5 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Features F6 – F7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Features F4 Menu, Truck Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Features Menu, F7.1 – F 7.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Features Menu, F10 – F13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Hour Menu, H1 –– H5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Events Menu, E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Events Menu, E2 – E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Performance Menu, P1 (DT 3040 MW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Performance Menu, P1 (DT 3040 -MF -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Performance Menu, P21 (DT 3040 -MF -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Performance Menu, P4 – P11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Performance Menu, P12 – P16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Utilities Menu, U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Initial truck status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SAS and BRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Operating mode definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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Pedestrian mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Comfort mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Rider mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Brief description of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Platform and Side Restraint Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Brief description of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Folding platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Side restraint and platform setting definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
DT 3040 -MW Software Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Operation modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
DT 3040 -MF Software Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
DT 3040 -EF Software Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Selecting the CALIBRATION Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Calibrating the traction potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Travel direction definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Electric steering calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Proportional lift and lower calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Malfunctions with event code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Locating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Digit convention for event codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Event Code 100 (DT 3040 -MW, -MF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Event Code 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Event Code 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Event Codes 203 - 204 (DT 3040 -MW, -MF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Event Code 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Event Code 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Event Code 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Event code 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Event code 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Event code 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Event code 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Event code 231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Event code 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Event code 233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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Event Code 234 (DT 3040 -MW, -MF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Event code 234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Event code 236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Event code 239 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Event code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Event code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Event code 302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Event code 303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Event code 304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Event code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Event code 306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Event code 307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Event code 308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Event code 309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Event code 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Event code 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Event code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Event code 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Event code 317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Event code 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Event code 321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Event code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Event code 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Event code 328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Event code 329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Event code 333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Event code 334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Event code 337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Event code 338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Event code 341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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Event code 342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Event code 343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Event code 348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event code 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event code 352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Event code 353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Event code 354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Event code 355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Event code 356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event code 357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Event code 358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Event code 359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Event code 361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Event code 362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Event Code 364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Event code 365 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Event Code 100 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Event Code 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Event Code 202 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Event Code 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Event Codes 203 - 204 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Event Code 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Event Code 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Event Code 205 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Event Code 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Event Code 208 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Event code 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Event Code 228 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event code 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event Code 229 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Event code 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Event Code 230 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Event code 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Event Code 231 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Event code 231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Event Codes 232 - 233 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Event code 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Event code 233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Event Code 234 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Event code 234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Event Code 235 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
DT 3000 Series
VIII
TABLE OF CONTENTS
Event code 235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Event Code 236 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Event code 236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Event Code 237 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Event code 237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Event Codes 238 - 239 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Event code 238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Event Code 239 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Event code 239 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Event Code 300 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Event code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Event Codes 301 - 302 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Event code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Event Code 302 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Event code 302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Event Code 303 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Event code 303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Event Code 304 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event code 304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event Codes 305 - 306 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Event code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Event code 306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Event Codes 307 - 308 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Event code 307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Event Code 308 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Event code 308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Event Codes 309 - 310 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Event code 309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Event code 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Event Code 314 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Event code 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Event Code 315 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Event code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Event Code 316 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Event code 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Event Code 317 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Event code 317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Event Code 320 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Event code 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Event Code 321 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Event code 321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Event Codes 322 - 324 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Event code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Event code 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Event Code 326 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Event code 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Event Codes 328 - 329 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Event code 328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Event code 329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Event Codes 333 - 334 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Event code 333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Event code 334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Event Code 335 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Event code 335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
DT 3000 Series
IX
TABLE OF CONTENTS
Event Code 337 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Event code 337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Event Code 338 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Event code 338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Event Code 341 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Event code 341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Event Code 342 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Event code 342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Event Code 343 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Event code 343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Event Codes 348 - 351 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Event code 348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Event code 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Event Code 352 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Event code 352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Event Code 353 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event code 353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event Codes 354 - 355 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Event code 354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Event code 355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Event Code 356 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Event code 356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Event Code 357 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Event code 357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Event Code 358 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Event code 358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Event Code 359 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Event code 359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Event Code 361 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Event code 361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Event Code 362 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Event code 362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Event Code 364 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Event Code 364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Event Code 365 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Event code 365 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Event Code 368 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Event code 368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Event Codes 500 - 501 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Event Code 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Event Code 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Event Codes 502 - 504 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Event Code 502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Event Code 503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Event Code 504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Event Codes 505 - 506 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Event Code 505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Event Code 506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Event code 508 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Event Code 509 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Event code 509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Event Code 510 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Event code 510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Event Code 511 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
DT 3000 Series
X
TABLE OF CONTENTS
Event code 511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Event Codes 512 - 513 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Event code 512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Event code 513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Event Code 514 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Event code 514 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Event Codes 515 - 516 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Event code 515 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Event code 516 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Event Code 517 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Event Code 517 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Event Code 518 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Event code 518 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Event Code 519 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Event code 519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Event Code 520 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Event code 520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Event Code 521 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Event code 521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Event Code 522 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Event code 522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Event Code 523 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Event code 523 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Event Code 524 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Event code 524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Event Code 525 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Event code 525 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Event Code 526 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Event code 526 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Event Code 527 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Event code 527 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Event Codes 528 - 529 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Event code 528 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Event code 529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Event Code 530 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Event code 530 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Event Code 532 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Event code 532 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Event Code 533 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Event code 533 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Event Codes 535 - 536 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event code 535 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event code 536 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event Code 537 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Event code 537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Event Code 538 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Event code 538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Event Code 539 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Event code 539 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Event Code 540 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Event code 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Event Codes 541 - 542 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Event code 541 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Event code 542 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
DT 3000 Series
XI
TABLE OF CONTENTS
Event Code 543 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Event code 543 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Event Code 544 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Event code 544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Event Codes 545, 800 to 905 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Event code 545 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Event code 8xx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Event code 9xx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Events with Text Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Platform Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Truck Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Hightemp TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Hightemp traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Release control handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Release travel control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Hightemp steering controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Hightemp steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
General DC Motor Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Traction Motor (M1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Traction motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Traction motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Repairing the traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Dismantling the rotor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Assembling the rotor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Pump motor (M2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Steer motor (M3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Special tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Steer motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Steer motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Repairing the steer motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Steer motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Steer motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Servicing and Replacing the Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Power fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Discharging the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Servicing the control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Replacing control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Removing the control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Assembling the control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Control Module PMT Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
PMT Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Testing Access 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
DT 3000 Series
XII
TABLE OF CONTENTS
Testing Access 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Testing Access 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Battery Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Battery Discharge Indicator (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Load profile and discharge curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Adapting the BDI setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Repairing Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Wear test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Checking the contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Checking the coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Checking the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Converting the truck from Enter key to key switch power-up function . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Mechanical conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Changing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Converting the truck from key switch to Enter key power-up function . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Mechanical conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Changing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Components and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Servicing the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Measuring the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Replacing the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Parking brake disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Parking brake assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Testing the Braking Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Performing the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Braking distance tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Max. braking distances DT 3040 -MW, with or without max. rated load . . . . . . . . . . . . . . . . . . . . . . 329
Max. braking distances DT 3040 -MF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Max. braking distances DT 3040 -EF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Repairing the Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Replacing the control handle shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Shell removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Shell assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Replacing the switch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Switch unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Switch unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Replacing the “rabbit/turtle” toggle module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Toggle module removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Toggle module assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Replacing the control handle grip PC boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Hydraulic PC board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
DT 3000 Series
XIII
TABLE OF CONTENTS
Hydraulic PC board assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Main PC board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Main PC board assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Replacing the traction potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Traction potentiometer removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Traction potentiometer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Replacing the safety reverse switch (SAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Removing the safety reverse switch (SAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
SAS / BRS switch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Replacing the grips and horn switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Replacing the outrigger lift switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Removing the outrigger lift switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Assembling the outrigger lift switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Repairing Control Handle Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Return spring pre-tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Replacing the return springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Return spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Return spring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Checking forks for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Chain Supports and Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Periodic inspection of chain supports and lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Periodic replacement of chain supports and lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Cleaning lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Inspecting Chain Supports and Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Checking the service hours for the lift chains and anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Checking the lift chain for elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Freedom of movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Worn or missing plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Turned pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Chain lateral wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Checking chain supports and anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Checking the chain pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Checking and adjusting the chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Checking the lifting components for misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Lubricating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Lubrication intervals and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Separating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Tools and equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Replacing Mast Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Replacing mast guards on the TL mast with 1700 mm lift height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Removing mast guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Assembling mast guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
DT 3000 Series
XIV
TABLE OF CONTENTS
Replacing the mast guard on the TL mast with 2100 mm lift height . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Removing mast guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Replacing the mast guard on the TF mast with 2600 mm lift height . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Removing mast guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Hydraulic system repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Replacing the rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Small hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Producing extractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Groove aligning arbor for small rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Assembly devices for large rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Protective mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Rod Seal Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Removing a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Removing a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Inserting a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Fitting a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Rod seal assembly, sealing lip first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Replacing the Lift Cylinder on the TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Removing the lift cylinder (TL mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Lift cylinder (TL mast) assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Repairing the Lift Cylinder for the TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Replacing the Lift Cylinder on the TF Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
Lift cylinder (TF mast) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
Lift cylinder (TF mast) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
Lift cylinder (TF mast) assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Repairing the Lift Cylinder for the TF Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
Replacing the Free Lift Cylinder on the TF Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Free lift cylinder (TF mast) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Free lift cylinder (TF mast) assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
Repairing the Free Lift Cylinder for the TF Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Replacing the Outrigger Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Removing the outrigger lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Outrigger lift cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Repairing the Outrigger Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Replacing the Traction Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Removing the traction cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Traction cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Repairing the Traction Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Adjusting the Folding Platform Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Pre-tensioning the spring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Checking and adjusting switch PLS1 for rider mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
DT 3000 Series
XV
TABLE OF CONTENTS
Adjusting switch PLS2 for pedestrian mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

Replacing the Folding Platform Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Spring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

Wire Colour Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
General contact symbol abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Electrical wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
Wire Harness List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
DT 3040 -MW and DT 3040 -MF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
DT 3040 -EF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
DT 3040-EF Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Spline list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
DT 3040-MF Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Spline list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
DT 3040-MW Main Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Spline list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
DT 3040-EF, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
DT 3040-EF, with Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
DT 3040-MF, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
DT 3040-MF with Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
DT 3040-MW, Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
DT 3040-MW with Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
CAN Connections, DT 3040-MF, -MW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
CAN Connections, DT 3040-EF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
DT 3040 without Traction Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
DT 3040 with Traction Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
DT 3000 Series
XVI
INTRODUCTION
1
Notes:
2
INTRODUCTION
Important Information
Important Information Manual structure

This maintenance manual applies to the DT The manual is divided into the following sections:
3000 Series trucks in the following models(1):
:
Section
DT 3040 -MW
Index
DT 3040 -MF
DT 3040 -EF Introduction
Safety
Service personnel qualification
Lubrication & Adjustment
To maintain the safety and functionality of the
truck, maintenance and repair work must only be Hydraulic System
performed by service engineers who have been Drive Unit
authorised by Crown.
Electrical System
Contact Crown if you wish to have your engineers
trained. Brake System
Steering
Ordering spare parts
To order spare parts, use the spare parts catalog Lifting Mechanism
supplied separately. Always quote the following Cylinders
numbers when ordering spare parts:
Schematic Diagrams
• Truck data number
• Serial number Hydraulic Schematic
These numbers can be found on the truck data plate.
For details of your truck's technical specifications refer
Conventions
to the Technical Specifications chapter in the operator Text mark-ups in the manual
manual.
The following symbols and mark-ups are used in the
Note: Always use original Crown spare parts. manual:
Ordering documentation 1., 2., 3. denote work steps to be taken.
 This arrow indicates the consequences of an
Parts manuals, operator manuals, specification sheets
action.
etc. can be obtained from:
 This arrow indicates action to be taken to avoid
hazards contained in a warnings.
Crown Gabelstapler GmbH & Co. KG
Moosacher Str. 52 (1), (2), (3) etc. indicate text references to item
80809 Munich numbers in illustrations.
Germany • Indicates the first level in a list.
– Indicates the second level in a list.
Tel.: +49 (0)89 / 93 002 -0
Note: Where the word "Note" appears before text, this
Fax: +49 (0)89 / 93 002 -175 or 133
indicates important additional information.
www.crown.com
Brief description of equipment
The components of the truck data number (items 3, 4
and 9, Fig. 1) are used in the manual to refer to
different features.
For example, “3040 -EF” refers to a truck with electric
steering and a folding platform. “3040 -MW” refers to a
truck with mechanical steering and no folding platform.
See page 4 for details of the truck data number.
(1).See truck data number, page 4.
DT 3000 Series Rev.3 07/2009
3
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 DT 3040 -M 2 1 1 S F
Fig. 1 Sample truck data number
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)
6 Straddle width:
S = Special straddle
1 = 560 mm
7 Fork length:
S = Special length
1 = 1150 mm
8 Load wheel version:
S = Single load wheels
T = Tandem load wheels
9 Operator position type:
W = Without platform
F = Folding platform
(a). The capacity plate on the truck is binding.
The truck data number given in the example therefore

shows a DT 3040 with a 2 t capacity. The truck is
equipped with mechanical steering, single load wheels
and a folding platform. The battery tray can
accommodate 315 - 375 Ah batteries. The straddle
width is 560 mm, the fork length is 1150 mm.
DT 3000 Series
4
SAFETY
5
Notes:
6
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.
DT 3000 Series Rev.2 08/2010
7
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 serv- • When handling batteries wear acid protective cloth-
ice 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 repair work that could be hazard-
• The legal minimum age for performing repair work ous to yourself and other people, seal off a large
must be observed. part of the hazardous area with suitable marker
• Service personnel must be trained and authorised tape.
to operate industrial trucks and must be able to • Before carrying out repair work, service personnel
demonstrate their competence. must ensure that there is no one in the hazardous
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 DT 3000 Series
8
SAFETY
Repair work Cleaning work

• Always carry out repair work in accordance with the Particular care is required when cleaning the truck and
test and maintenance schedule contained in this components that have been removed. See page 19.
manual and any applicable service bulletins.
• Before carrying out repair work prepare the truck as Handling batteries
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
hand when carrying out work. suitable insulation (such as a plywood board) if you
• Keep the truck clean; this makes it easier to find have to work 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.
repair work
Warning and instruction decals on
• After carrying out repairs refit any safety mecha-
nisms that have been removed and make sure they the truck
are working correctly. • In accordance with the test and maintenance inter-
• The truck may only be restored to service after re- vals check that the warning and instruction decals
pair work once all the truck functions have been on the truck are complete and legible.
successfully tested, in particular on the following • Clean any dirty decals and replace any damaged or
components: missing ones.
– Brakes 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.
DT 3000 Series Rev.1 04/2009
9
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 DT 3000 Series
10
LUBRICATION & ADJUSTMENT
11
Notes:
12
Transport and Storage
CAUTION
Battery acid can burn
Battery acid will spill if a filled battery tips over during
transport. This can cause injury to bystanders and
damage the truck and transportation equipment.
 Always remove the battery before transporting the
truck.
Lifting the truck

Fig. 2 Lifting gear stop
WARNING Attaching lifting slings (see Fig. 2)
Falling loads are hazardous 4. Attach 4 lifting slings as shown in the illustration:
Fatal injuries can result if the truck or crane tip over or – Strap one lifting sling around each of the forks.
if a load falls. – Strap one lifting sling around either side of the
 Make sure the crane, the lifting truck and the load folded-down side restraint.
handling equipment have the required capacity. 5. Prevent the lifting slings from slipping.
Information on the required capacity can be found 6. Position the crane hook directly above the truck's
on the truck data plate under “Truck Weight Less centre of gravity.
Battery” and “Battery Weight”.  This will ensure there is virtually no swinging
 Refer to the manufacturer's operating instructions when the truck is lifted.
when using load handling attachments. Pay partic-
ular attention to the load handling attachment's ca- Lifting the truck
pacity and static coefficients (safety factor). 7. Raise the truck carefully.
Lifting the truck by crane
WARNING
A falling truck can result in fatal accidents
If components acting as strap points are insufficiently
secured, they can loosen when the truck is lifted. The
truck or components of the truck could fall.
 Before lifting the truck make sure that the compo-
nents used as strap points are securely attached to
the entire truck.
Preparing the truck

1. Fully raise the outriggers.
2. Switch off the truck and remove the key if neces-
sary.
3. Press the Emergency Disconnect.
DT 3000 Series
13
Lifting the truck with a forklift truck

Preparing the truck
2. Switch off the truck and remove the key if neces-
sary.
2 3
Fig. 3 Lifting a truck between its castor wheels

1 Forks of the lifting truck
2 Beam
3 Tensioning belt
Lifting the truck

4. Secure the truck onto the forks of the truck doing
the lifting using a tensioning belt (3).
CAUTION
Take care not to damage the castor wheels and side
restraints when positioning the forks
5. Position a fork (1) at least 1000 mm long of the

truck that is doing the lifting underneath the chas-
sis of the truck (see Fig. 3).
6. Compensate for the difference in height between
the chassis and the outriggers: to do this, lay a suf-
ficiently thick beam (2) across the forks of the truck
that is doing the lifting.
Securing the truck
7. Secure the truck as shown in the illustration with a
tensioning belt (3) on the forks of the truck that is
doing the lifting.
Lifting the truck
8. Raise the truck carefully.
DT 3000 Series
14
Towing the truck
Towing the truck 12. 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
the brakes. Towing the truck
13. Pull the truck slowly and only in a forward direction
(see arrow in Fig. 4).
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 truck
in need of repair do not get damaged by the forks of
the towing truck.
 Make sure the truck in need of repair 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 the drive wheel drags along the
ground while the truck is being towed, the drive system
will get damaged.
 Make sure the drive wheel does not touch the
ground as the truck is being towed.
Fig. 4 Tow direction

Preparing the truck
9. Switch off the truck and remove the key.
11. Position the forks (1) of the towing truck under-
neath the truck. Take care not to damage the drive
and castor wheels or the risers.
DT 3000 Series
15
Jacking up the Truck
Jacking up the Truck Preparing the truck

WARNING 3. Press the Emergency Disconnect.
4. Place wedges (1) behind both of the load wheels.
Tipovers can result in fatal accidents
5. Place the jack under the centre of the truck's chas-
You can be fatally injured by a truck tipover.
sis at the contact point (2).
 Make sure the jack has sufficient capacity. Informa-
tion on the capacity required can be found on the Jacking up the truck
truck data plate under “Truck Weight Less Battery” 6. Jack up the truck until the drive wheel is approx.
and “Battery Weight”. 20 mm clear of the ground.
7. Place hard wooden blocks (3) underneath the
chassis and lower the truck onto them.
8. Place a jack underneath the forks at the contact
WARNING point (4) and raise the truck until it is horizontal.
Incorrect jacking procedures can cause fatal acci- 9. Place a hard wooden block (5) underneath and
dents lower the outriggers onto it.
Improper handling of the truck or the tools can result in Checking the drive wheel freedom of movement
fatal accidents. 10. Check the drive wheel can move freely.
 Never place your hands or other parts of your body  If the drive wheel contacts the ground, repeat
under the truck before it has been supported. steps 5 to 10 and use thicker hard wooden
 Always support a raised truck with wooden blocks blocks.
or other suitable equipment to relieve the jack.  The truck is jacked up correctly when the drive
 Only jack up the truck so far as to raise the wheels wheel is clear of the ground.
off the ground. Any further lifting will increase the
risk of tipover.
1 5 3
4
Fig. 5 Jacking up the truck

1 Wedge
2 Contact point
3 Hard wooden block
4 Contact point
5 Hard wooden block
DT 3000 Series
16
Transporting the Truck
Transporting the Truck 5. On either side strap a tensioning belt (1) around
the outer mast tie bar, as shown in Fig. 6, attach it
The truck must be adequately protected against slip- to fastening eyes (3) and pull it taut.
ping and tipping over when being transported on a
truck bed. Chocking the truck with wedges
Chock the truck with 6 wedges on the load floor (see
Securing the truck for transport on a Fig. 6):
truck bed 1. Push two wedges (5) under the outriggers on the
left and right-hand sides behind the load wheels.
2. Push two wedges (4) at the front under the outrig-
gers.
CAUTION
3. Push two wedges (2) on the left and right-hand
An incorrectly secured truck can cause accidents sides underneath the chassis.
Trucks that are not adequately protected from slipping 4. Secure all wedges to the load surface (e.g. by nail-
and tipping over during transport can damage the load ing them).
and cause accidents.
 The truck is now adequately secured for transport-
 You must be trained and authorised to load the ing on the truck bed.
truck.
 Note that load securing measures must be applied
and assessed correctly in each individual case.
 Ensure the tensioning belts used are taut.
 Prevent the tensioning belts from becoming slack
or loosening on their own.
1
4 5
3 2
Fig. 6 Lorry loading

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

1. Park the truck on the truck bed.
2. Lower the forks and outriggers fully.
DT 3000 Series
17
Storing the Truck
Storing the Truck Periodically starting a truck that has

been in storage
Placing the truck in storage The interval is 3 months.
Trucks that have not been used for more than 3 months
must be placed in storage.
CAUTION
Placing the truck in storage
1. Disconnect the battery. Long periods of inactivity can result in damage to
the hydraulic system
2. De-commission the battery in accordance with the
If the hydraulic system is unused for too long, the hy-
manufacturer‘s instructions.
draulic cylinders may suffer corrosion damage.
3. Clean the truck (see page 19).
 Test the hydraulic system on trucks placed in stor-
age every 3 months.
CAUTION
Incorrect cleaning procedures can cause damage Testing trucks in storage
Improper cleaning can damage truck components 1. Connect the battery.
 Clean the truck in accordance with the instructions 2. Check the battery charge. Charge the battery if
on page 19 necessary.
3. Apply all hydraulic functions. Approach all limit po-
4. Wipe down the truck. sitions at least once to coat the whole of the cylin-
Note: Do not park the truck in the open air or in a humid der surfaces with oil.
environment. 4. Check the hydraulic system and gear unit for leaks.
5. The surfaces of trucks subjected to hostile ambient 5. Check the anti-corrosion agent and replace if nec-
conditions such as saline atmosphere must be essary.
treated with suitable preservatives to prevent cor- 6. After carrying out the checks disconnect the bat-
rosion. tery.
6. Cover the truck with an air-permeable material to 7. De-commission the battery in accordance with the
protect against dust. Do not use plastic sheets as manufacturer‘s instructions.
condensation could form.
7. Jack up the truck (see page 16) to prevent the Restoring the Truck to Service
wheels from flattening. Carry out the following steps to restore the truck to
8. Store the truck in a dry room with constant temper- service after a period of storage:
ature and air humidity. 1. Remove the anti-corrosion agent where neces-
sary.
2. Lift up the truck, remove the hard wooden blocks,
lower the truck - in the reverse order of page 16.
3. Charge the battery according to the manufacturer's
instructions or install a charged battery (see
page 315).
4. Connect the battery.
5. Carry out the daily safety inspection (see operator
manual).
DT 3000 Series
18
Cleaning the Truck and Components
Cleaning the Truck and Compo- CAUTION

nents Incorrect cleaning procedures can damage the
truck
Incorrect cleaning can damage electric components as
CAUTION well as bearings and lift chains.
 When wet-cleaning the truck, do not aim the water
Health risk hose or high pressure cleaner at electrical compo-
Cleaning agents, lubricants and consumables can nents, bearings or lift chains.
damage your health.
 Make sure that no water can penetrate electrical
 Observe the manufacturer’s safety instructions components.
when handling solvents and lubricants.
 Use cleaning petroleum and cleaning petrol only to
clean lift chains, and then apply new type H chain
Effects of incorrect cleaning oil (see page 346).
Electrical components Cleaning the truck surface

Electrical components such as connectors, contacts, 3. It is preferable to dry clean the truck using a cloth,
distributor boards, controllers and wiring can be dam- soft brushes or weak, dry compressed air.
aged by water, cleaning agents and solvents.
4. If you have to wet-clean the truck, do not aim the
Mineral and chemical residue that automatically re- water hose or high pressure cleaner at electrical
main on or in components after cleaning, are a cause components, bearings or lift chains. Avoid using
of corrosion. This corrosion results in malfunctions and cleaning agents where possible. If grease needs to
premature failure. be removed, use a mild neutral cleaning agent.
Roller and slide bearings Note: High pressure cleaning can remove anti-corro-
sion agent and paint from surfaces.
Steam cleaning and solvents damage the lubricant film
on bearing surfaces. This results in dry running and 5. If a neutral cleaning agent has been used, rinse the
rapid damage to the bearing elements. components thoroughly with clear water.
6. Leave the cleaned truck to dry thoroughly.
Corrosion-protected surfaces
Cleaning electrical components
The brake lines, screw connections and shiny metal
surfaces in particular on cold store trucks are factory- 7. Clean electrical components only with weak, dry
treated with an anti-corrosive agent compressed air and a dry cloth.
®
(Anticorit BW 366 ). This protection can be washed off Interior cleaning
by solvents and steam cleaning. The above-mentioned 8. Clean detachable rubber mats with water and a
components will corrode as a result. neutral cleaning agent.
Environmental protection 9. Allow the rubber mats to dry out fully before return-
ing them to the truck.
Cleaning must only be performed in specially desig-
10. Damp-wipe plastic parts with a neutral cleaner.
nated areas to enable hazardous chemicals and oils to
be separated. Note: If necessary use a standard commercial plastic
cleaning agent to remove obstinate dirt.
Collect any waste (such as oily cleaning cloths) and
dispose of them in accordance with local regulations. After cleaning the truck
11. Wipe down the truck.
Cleaning the entire truck 12. Remove any paint damage.
1. Park the truck in an area with an oil separator. 13. Add anti-corrosion agent if necessary.
2. Switch off the truck, disconnect and remove the
Returning the truck to operation after cleaning
battery.
Normally no special measures are required.
DT 3000 Series Rev.2 08/2010
19
Cleaning the Truck and Components
If however there is a possibility that damp may have 5. Re-lubricate, paint or apply anti-corrosion agent to
penetrated electrical components, proceed as follows: the components as required.
1. Clean the truck with weak, dry compressed air and 6. Refit the components.
a cloth.
7. For cold store trucks apply Anticorit BW 366® as
2. Leave the truck to stand for at least 30 minutes in an anti-corrosion agent for screw connections and
a dry environment. shiny metal surfaces.
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 16).
6. Switch on 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.
 Is 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.
Note: Cleaned components must be dry and free of
cleaning agent residue before being refitted, lubricated
or painted.
Rev.2 08/2010 DT 3000 Series
20
Recommended Lubricants and Consumables
Recommended Lubricants and Carefully protect all electrical connections and compo-
nents against corrosion. For detailed information, refer
Consumables to the Electrical System chapter.
The following tables list lubricants and consumables Service intervals (see page 23) must be adapted to the
that Crown uses in its factory. However, you can use conditions of use.
any lubricants provided they meet the same technical
criteria. Abbreviations used in the table
The lubricant type is indicated by letters. Individual let-
Cold store truck requirements ters (A, B, ...) denote lubricants for normal temperature
Special hydraulic oils, lubricants and grease must be ranges, double letters (AA, BB, ...) for low temperature
used for cold store applications (cold store trucks). ranges.
An anti-corrosion fluid (Crown no. 805236-004)
must be applied to all machine parts such as screws,
washers, nuts, pins, retaining rings etc.
Model Lubricant Type Product Manufacturer Part No.
A and AA Transmission oil Degol PAS 150 Aral

Renolin UNISYN Fuchs Mineralöl- ---
CLP 150 werke GmbH
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
ALGWMI SKF
Low temperature grease Aralube SKL2 Aral
BB 053002-005
Unirex Lotemp EP Mobil
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
DT 3000 Series
21
Recommended Lubricants and Consumables
Model Lubricant Type Product Manufacturer Part No.
Low temperature lubrication Mobil SHC 626 Mobil

GG ---
oil
M Special grease Molycote® BR-2 Plus Dow Corning ---
H Lubrication oil (chain) Rexoil Rexnord Kette
824805
GmbH
Lubricants Produkt Application Part no.
Anti-corrosive agent Anticorit BW 366® Corrosion inhibitor for cold store

805236-004
trucks
Rubber & Vinyl Dress- Commercial Rubber Components, Plastic Pan-
-------------
ing els
Rev.1 07/2010 DT 3000 Series
22
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 DT 3000 Series
are those listed in the maintenance schedule
(see page 24)
DT 3000 Series Rev.1 08/2010
23
Maintenance Schedule
To identify the components listed in the following tables
see also:
• Components (page 65)
Electrical System
Lubricant type
Assembly Component Action
Item no.
1000 h
3000 h
12 M
36 M
Electrics Contactor (EDS) Check for wear (see page 318). I-1
Lift limit switch Check operation of LMS1. Test LMS4 if I-2
present (DT 3040 -MF and -EF only).
All switches, wires and Clean if necessary (see page 19). C/X
connections Check for corrosion and damaged insula-
tion. ---
All controls should revert to the neutral po-
sition automatically.
Pump motor (M2) Check motor condition (see page 303). I-3 C/X
Control modules Check and analyse error log.
(Access 2&3, ---
Perform the PMT test (see page 312).
Access 5)
Parking brake (BRK) Check the air gap (see page 326). I-4 C/X
Battery (BATT) Check the battery connector and cables for

I-5
damage, check contacts for burning.
Check battery compartment for spilled acid. I-6
DT 3000 Series
24
I-5
I-1
I-2
I-3
I-4
I-6
Fig. 7 Electrical system inspection points
DT 3000 Series
25
Electrical system
Lubricant type
Item no.
1000 h
3000 h
12 M
36 M
Electrics Display (Access 1) Switch on the truck and test all the displays
I-7
and alarms.
Horn (HN) Check operation. I-8
Emergency Discon- Check operation.
I-9
nect switch (EDS) C/X
Safety Reverse Check operation.
I-10
Switch (SAS)
Side restraints and Check the side restraints and platform logic
I-11
platform logic (see page 111).
DT 3000 Series
26
I-7
I-9
I-8
I-11
I-11
I-8
I-10
I-8
Fig. 8 Electrical system inspection points
DT 3000 Series
27
Lift mechanism
Lubricant type
Item no.
1000 h
3000 h
12 M
36 M
Lift Lift cylinder Check for leaks. I-12
mechanism C/X
Hydraulic oil reservoir Check the hydraulic oil level (see Fig. 27,
I-13
page 51).
D/DD
Replace the hydraulic oil and hydraulic filter L-1
C/X
(see page 51).
Lift linkage (outrigger Lubricate and check for wear.
B/BB L-2
lift)
Outriggers Check for cracks and wear (see page 345). I-14
Lift chain, chain sup- Check the lift chain, chain supports and
ports and chain bolts - chain bolts as outlined in Chain Supports I-15
plurals and Lift Chains, page 347.
Lubricate the lift chain H L-3
Guide pulleys Check for damage and ensure they run
I-16
freely (see page 350). C/X
Tracks in mast sec- Clean and lubricate.
B/BB L-4
tions
Mast rollers Check for wear, faulty bearings and exces-
I-17
sive slack.
Fork carriage Check for cracks and wear (see page 345). I-18
Mast cables Check for damage. I-19
Mast Torque mast attachment screws to
I-20
(320 Nm).
DT 3000 Series
28
I-17
I-15
L-2
I-14
I-16
L-4 I-19
L-2
L-3 I-12
I-12
L-2
L-2
I-20
I-15
I-12
I-20 I-18
I-13
L-1
Fig. 9 Lift mechanism inspection and lubrication points Fig. 10 Lift mechanism inspection and lubrication points
DT 3000 Series
29
Drive system, steering and wheels
Lubricant type
Item no.
1000 h
3000 h
12 M
36 M
Drive system Load and castor Check bearings. Check tyres for wear.
I-21
and wheels wheels
Drive wheel Check the torque (see page 60). Check
I-22 C/X
tyres for wear.
Drive gear unit 1. Change the oil on trucks with mechani-
A/AA
cal steering (see page 61).
2. Change the oil and carry out all other oil L-4
A/AA
changes on trucks with mechanical steer-
ing (see page 61). C/X
Drive gear unit Change the oil on trucks with electrical
E L-5
steering (see page 61).
Folding control handle Check operation (see page 333). ---
Electric steering Check the automatic reset and ensure there
---
is zero backlash.
Steering transmission Check the output pinion of the steer motor
I-23 C/X
for wear (see page 308).
Lubricate the output pinion of the steer mo-
B/BB L-6
tor (see page 308).
Live ring bearing Lubricate B/BB L-7
DT 3000 Series
30
L-7
I-23
L-6
L-7
I-22
L-4
L-5
Fig. 11 Drive system and wheel inspection and lubrication

points
Fig. 13 Drive unit lubrication points
I-21
Fig. 12 Load wheel inspection points
DT 3000 Series
31
Safety mechanisms
Lubricant type
Item no.
1000 h
3000 h
12 M
36 M
Panels Finger guard Check operation (see page 34). I-24
Clean and lubricate guides (see page 34). B/BB L-8
Lift mechanism Mast guards Check they are present, complete, dam-
age-free and securely attached (see I-25
page 353).
Load backrest Check operation and ensure it is securely C/X
I-26
fitted.
Chassis Battery retainer Check battery retainer for damage and en-
I-27
sure it is working correctly.
Test battery retainer sensor (BLS) (see
I-28
page 36.
DT 3000 Series
32
I-25
L-8
I-24
I-26
I-27
I-27
I-28
Fig. 15 Finger guard, mast guard and load backrest
Fig. 14 Battery retainer
DT 3000 Series
33
Finger Guard
Finger Guard 1. Lower and raise the forks several times while mon-
itoring the gap between the finger guard and the
The finger guard is a safety mechanism. Do not oper- back wall of the battery compartment (1, Fig. 16).
ate the truck if the finger guard is not in place or is not
 The finger guard is ok if it rests against the back
working.
wall of the battery tray for all fork positions during
lifting.
Testing the finger guard
 If the gap between the finger guard and the back
wall of the battery compartment increases, the fin-
ger guard is faulty. Check the finger guard mecha-
WARNING nism for freedom of movement and adjust it before
using the truck.
Finger trapping hazard
If the finger guard is not working correctly, a gap be- Checking the finger guard mecha-
tween the battery tray and chassis will open during lift-
ing and lowering operations. You can trap your fingers nism for freedom of movement
if you reach into this gap while activating lifting or low- The finger guard mechanism is located on the left and
ering right hand sides underneath the top cover.
 Proceed with particular caution when the finger
guard is removed.
 Always test the finger guard after servicing it. 1
 Do not authorise the truck to be used until the finger
3 4
guard has been fitted and is working correctly.
2 5
Test
Fig. 17 Finger guard mechanism, right-hand side of the truck

1 Finger guard
2 Washer
3 Spring
4 Bracket
1 5 Bolt
6 Screw
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.
4. Remove the covers.
Fig. 16 Testing the finger guard
DT 3000 Series
34
Finger Guard
Checking the finger guard mechanism 3. Pull out the bolt (5) so that it is released from the
bushing in the bracket (4).
4. Tilt the bolt up slightly and push it out slowly over
CAUTION the bracket. This will relieve the spring (3) fully.
5. Remove the bolt in full from the bracket.
Health risk
6. Remove the spring (3) and washer (4).
Cleaning agents, lubricants and consumables can
damage your health. 7. Clean all components thoroughly and check for
damage.
 Observe the manufacturer’s safety instructions
when handling solvents and lubricants. Attaching the finger guard mechanism
1. Lubricate the bushing in the bracket and the bolt.
5. Clean the finger guard mechanism. 2. Assemble the components in the reverse order of
6. Remove the screw (6, Fig. 17). disassembly.
7. Check the bolt (5) can move freely in the bracket's 3. Check the finger guard mechanism for freedom of
bearing. movement and adjust if necessary.
 If there are signs of running-in, replace the
bushing or repair the finger guard mechanism. Adjusting the finger guard
 If the spring (3) is damaged or the tension too mechanism
weak, replace the spring or repair the finger
guard mechanism. Preparing the truck
 If there are hardly any signs of running-in, no 1. Power down the truck.
parts are faulty or damaged, adjust the finger 2. Disconnect the battery and prevent the truck from
guard mechanism. being switched on again.
Repairing the finger guard 3. Remove the covers.
mechanism Adjusting the finger guard mechanism
Preparing the truck

being switched on again. 1
3. Remove the covers.
Finger guard mechanism disassembly

The following item numbers refer to Fig. 17.
CAUTION
2
Health risk
damage your health.
Fig. 18 Adjusting the finger guard mechanism
1. Clean the finger guard mechanism. 1. Loosen the screws (2) slightly.
2. Remove the screw (6). 2. Align the mechanism while checking the freedom
of movement.
Note: The spring (3) is largely relieved when the
screw (6) is removed. The remaining pre-tension is 3. Tighten the screws (2) if the mechanism works
minor and does not pose a hazard. without getting caught.
4. Test the finger guard (see page 34).
DT 3000 Series
35
Battery Retainer
Battery Retainer  If no message is shown in the display and the

truck can travel, the monitoring system is not
The battery retainer is a safety mechanism. Do not working. Take the truck out of service immedi-
operate the truck if the battery retainer is not in place or ately and repair the monitoring system (see
is not working. troubleshooting).
The battery retainer consists of the following:  If the message "Battery Retainer" is shown in the
• Bar (3) display and the truck cannot travel, the monitoring
• Locking screw (4) system is working.
• Sensor BLS (2) Troubleshooting
Checking the BLS sensor
WARNING 1. Power up the truck.
2. Loosen the locking screw (4) and lift up the bar (3).
A falling battery can cause accidents
 If no message is displayed, proceed to step 3.
If the BLS sensor is incorrect set, the truck can be op-
erated even if the battery is not latched  If the message "Battery Retainer" is shown in the
display, the BLS sensor is working.
 After working on the battery retainer test the re-
tainer and the sensor.
 Do not authorise the truck to be used until the bar
has been fitted and the BLS sensor is working cor-
rectly.
1
1
2
3 Fig. 20 BLS sensor pushbutton
4 3. Hold a flat metal object against the pushbutton (1,

Fig. 20) of the BLS sensor.
 If no message is displayed, the wiring or the
sensor itself is faulty. Check the wiring (see wir-
ing diagram) and repair it; if necessary replace
Fig. 19 Battery retainer the BLS sensor.
1 Screws
2 Sensor (BLS)
Adjusting the BLS sensor
3 Bar Adjusting the BLS sensor
4 Locking screw 1. Remove the battery.
2. Close the battery retainer.
Testing the bar monitoring system
3. Loosen the screws (1, Fig. 19).
Test 4. Set the distance between the BLS sensor and the
1. Power up the truck. bar to 1 mm.
2. Loosen the locking screw (4) and lift up the bar (3). 5. Tighten the screws.
6. Test the monitoring system (see page 36).
DT 3000 Series
36
Adjusting the Outrigger Lift Limit Switch (LMS1)
Adjusting the Outrigger Lift

Limit Switch (LMS1)
This limit switch determines the correct outrigger lift
height when the outriggers are raised. Adjusting this
switch is part of the outrigger height adjustment. See
Adjusting the Outrigger Heights, page 361.
DT 3000 Series
37
Castor Wheel Replacement
Castor Wheel Replacement Pivot bearing assembly

1. Assemble the new pivot bearing in the reverse or-
The following castor wheel versions are available:
der of disassembly.
• Single castor wheels
• Tandem castor wheels Replacing the single castor wheel
Replacing single castor wheels
Wheel removal
1. Hold on to the screw (6) and remove the nut (10).
WARNING 2. Pull the wheel (9) and the components (7, 8) from
off the wheel bracket (5).
Accidental truck movement can cause injury
Wheel disassembly
A powered up truck with a connected battery can move
suddenly when you are working on it. 1. Remove the bushing (7) and debris guard (8).
You should therefore carry out the following safety pro- 2. Check the bushing (7) and debris guard (8) for
cedures before starting any operations on the truck: damage. Dispose of any damaged components.
 Lower the forks to the ground. Wheel re-assembly
 Switch the truck off. 1. Place the debris guard (8) and bushing (7) into the
 Disconnect the battery. bearings of the wheel (9).
 Prevent the truck from being switched on again. 2. Insert the wheel into the wheel bracket (5) and se-
cure it with the screw (6) and nut (10).
The following item numbers refer to Fig. 21. 3. Tighten the nut until you cannot feel any more axial
play but the wheel is still free to turn.
Preparation
1. Switch off the truck and disconnect the battery.
2. Prevent the truck from being switched on again
and rolling away.
Single castor wheel disassembly
1. Hold on to the screws (11) and remove the
nuts (13).
2. Take the castor wheel and spacer ring (12) down
from out of the chassis.
Single castor wheel assembly
1. Assemble the castor wheel in the reverse order of
disassembly.
Replacing the single castor wheel pivot

bearing
Pivot bearing disassembly
1. Remove the retaining ring (2).
2. Pull the wheel bracket (5) and everything attached
to it from off the disk (1).
3. Remove the retaining ring (4) from the disk (1).
4. Remove and dispose of the pivot bearing (3).
DT 3000 Series
38
13
Frame
12
7
8 10
2
9
8
3
11
Fig. 21 Single castor wheel
DT 3000 Series
39
Replacing tandem castor wheels Replacing the tandem castor wheel bear-
ings
WARNING
Wheel bearing removal
Accidental truck movement can cause injury 1. Remove the screws (9) and the cotter pins (8).
A powered up truck with a connected battery can move 2. Press out the axle (10).
suddenly when you are working on it.
3. Pull the wheels (13) and everything belonging to
You should therefore carry out the following safety pro-
them from off the wheel bracket (7).
cedures before starting any operations on the truck:
4. Remove the bearings (12) from the wheels (13)
 Lower the forks to the ground.
and dispose of them.
 Switch the truck off.
Wheel bearing assembly
 Disconnect the battery.
1. Press the new wheel bearings (12) into the
 Prevent the truck from being switched on again.
wheels (13).
2. Insert the wheels and their corresponding washers
The following item numbers refer to Fig. 22. (11) into the wheel bracket (7) and secure them
Preparation with the axle (10).
1. Switch off the truck and disconnect the battery. 3. Insert the cotter pins (8) and secure them with the
screws (9).
2. Prevent the truck from being switched on again
and rolling away. Replacing the tandem castor wheels
Wheel removal
Tandem castor wheel disassembly
1. Remove the screws (9) and the cotter pins (8).
1. Remove the screws (14).
2. Press out the axle (10).
2. Remove the ring (1).
3. Pull the wheels (13) and everything belonging to
3. Take the castor wheel and spacer ring (2) down
them from off the wheel bracket (7).
from out of the chassis.
4. Dispose of the wheels (13) and the bearings (12).
Tandem castor wheel assembly
Wheel bearing assembly
4. Assemble the castor wheel in the reverse order of
disassembly. 1. Press the new wheel bearings (12) into the new
wheels (13).
Replacing the tandem castor wheel pivot 2. Insert the wheels and their corresponding
bearing washers (11) into the wheel bracket (7) and secure
The following item numbers refer to Fig. 21. them with the axle (10).
3. Insert the cotter pins (8) and secure them with the
Pivot bearing disassembly screws (9).
2. Pull the wheel bracket (7) and everything belong-
ing to it from off the disk (4).
3. Remove the retaining ring (6) from the disk (4).
4. Remove and dispose of the pivot bearing (5).
Pivot bearing assembly
1. Assemble the new pivot bearing in the reverse or-
der of disassembly.
DT 3000 Series
40
Fig. 22 Tandem castor wheel
DT 3000 Series
41
Torques
Torques
Standard torques
Note: The torques listed in the manual always take
precedence over standard torques.
Standard screws and nuts
Grade: 8 and 8.87 10 and 10.9 12 and 12.9
Thread size Torque (Nm)
M5 x 0.8 5-6 7-8 8 - 10

M6 x 1 8 - 10 12 - 14 14 - 16
M8 x 1.25 20 - 25 30 - 35 34 - 40
M10 x 1.5 40 - 45 60 - 65 70 - 75
M12 x 1.75 70 - 80 100 - 110 115 - 130
M16 x 2 170 - 190 240 - 270 280 - 320
M20 x 2.5 340 - 380 450 - 500 550 - 600
M24 x 3 580 - 650 800 - 900 900 - 1050
M30 x 3.5 1150 - 1300 1600 - 1800 1850 - 2100
Umbrako screws and nuts
Grade 10 and 10.9 12 and 12.9
Thread size Torque (Nm)
M5 x 0.8 8 11
M6 x 1 14 19
M8 x 1.25 33 45
M10 x 1.5 63 86
M12 x 1.75 111 152
M16 x 2 270 372
M20 x 2.5 521 717
DT 3000 Series
42
HYDRAULIC SYSTEM
43
Notes:
44
HYDRAULIC SYSTEM
Replacing the Hydraulic Unit
Replacing the Hydraulic Unit
WARNING
High pressure hydraulic system
Risk of injury from escaping hydraulic oil. 1
To avoid accidents:
 Depressurise the hydraulic system before opening
any sections of it.
 Tighten all connections before pressurising the sys-
tem. 3
 Keep hands and body away from pressurized fluid.
 Always use a piece of paper or cardboard to trace
leaks.
Whenever a high pressure fluid enters the skin it must
be treated as a medical emergency.
Seek medical assistance even if the skin appears nor-
mal at first.
CAUTION 2
Health risk
damage your health. Fig. 23 Hydraulic unit attachment
 Observe the manufacturer’s safety instructions 1 Hydraulic unit (motor M2, pump with manifold, container)
when handling solvents and lubricants. 2 Oil level markings (min / max)
2 Hydraulic unit mounting screws
Hydraulic unit removal 6. Loosen the two screws (3) slightly. Push the hy-
Preparation draulic unit (1) slightly up into the slotted holes and
lift it out of the truck.
1. Activate lowering for approx. 20 s.
 The hydraulic system is depressurised. Hydraulic unit assembly
2. Disconnect the battery and jack up the truck (see
1. Assemble the hydraulic unit in the reverse order of
page 16).
removal.
Hydraulic unit disassembly 2. Add hydraulic oil grade D/DD (for grades see
3. Loosen all electrical connections from the hydrau- page 21) as far as the max. marking.
lic unit. 3. Bleed the hydraulic system (see page 52).
4. Loosen all hydraulic lines from the manifold. 4. Flush the hydraulic system (see page 54).
5. Seal any open ports immediately with dummy 5. Perform the drift test (see page 55).
plugs.
DT 3000 Series
45
HYDRAULIC SYSTEM
Repairing the Hydraulic Unit
Repairing the Hydraulic Unit Hydraulic pump removal

Hydraulic pump removal
1. Remove and dispose of the suction filter (5).
CAUTION 2. Unscrew the suction pipe (6) from the pump.
Health risk 3. Remove the screws from the pump (7), take off the
Cleaning agents, lubricants and consumables can pump and dispose of it.
damage your health. Note: The pump cannot be repaired.
 Observe the manufacturer’s safety instructions 4. Unscrew and dispose of the return filter (24).
Hydraulic pump assembly
Hydraulic pump assembly
Note: Use only new seals and filters.
WARNING 1. Thoroughly clean all components, apply a thin
Accidental truck movement can cause injury layer of hydraulic oil and deposit them so that they
are dust and lint-free.
suddenly when you are working on it. 2. Insert a new pump (7) into the valve manifold and
You should therefore carry out the following safety pro- fix it with the two screws.
cedures before starting any operations on the truck: 3. Torque the screws to 25 Nm.
 Lower the forks to the ground. 4. Screw the suction pipe (6) into the pump and hand-
 Switch the truck off. tighten it.
 Disconnect the battery. 5. Attach a new suction filter (5) so that it is hand-
tight.
6. Attach a new return filter (24) so that it is hand-
 Jack up the truck until the drive wheel is clear of the
tight.
ground (see page 16).
Hydraulic unit reassembly
Replacing the hydraulic pump Hydraulic unit reassembly
Note: The following item numbers refer to Fig. 24. For 1. Attach a new O ring (25).
valve descriptions and torques see Fig. 25 and Fig. 26. 2. Connect the valve manifold to the hydraulic reser-
voir (1).
Preparation 3. Connect the reservoir to the valve manifold using
Hydraulic unit disassembly the four screws and re-tighten the clamp.
1. Disassemble the hydraulic unit (see page 45). Assembling the hydraulic unit without the pump
2. Place the hydraulic unit on a workbench. motor
Hydraulic unit disassembly 1. Assemble the hydraulic unit (see page 45).
1. Remove the pump motor (12) and take off the cou- Pump motor assembly
pling (11). 2. Thoroughly clean the coupling (11) and apply
2. Undo the clamp on the reservoir mount (4) slightly grease type B/BB to the slots (for grease grades
and remove the 4 screws from the reservoir mount. see page 21).
3. Pull the manifold and all its attachments off the res- 3. Insert the coupling (11) into the pump (7)
ervoir (1). 4. Align the motor with the coupling and place it on
4. Remove and dispose of the O-ring (25). the valve manifold.
5. Pour out the used oil and dispose of it in accord- Note: Take care not to damage the coupling in the
ance with environmental regulations. process.
6. Clean the reservoir (1). 5. Align the motor on the valve manifold.
DT 3000 Series
46
HYDRAULIC SYSTEM
6. Assemble the pump motor (12) and fasten it with

the two screws. Torque the screws to 10 Nm.
7. Final tasks
8. Add hydraulic oil grade D/DD (for grades see
page 21) as far as the max. marking (2, Fig. 23).
Note: The reservoir capacity is approx. 3.5 litres.
9. Bleed the hydraulic system (see page 52).
10. Check the oil level and replenish as required.
11. Flush the hydraulic system (see page 54).
12. Perform the drift test (see page 55).
DT 3000 Series
47
HYDRAULIC SYSTEM
Fig. 24 Hydraulic unit component parts
DT 3000 Series
48
HYDRAULIC SYSTEM
Torques and references, without traction control
Torques and references, without traction control
10 Nm
45 Nm
20 Nm
B/BB RV1
25 Nm
25 Nm 55 Nm
PCV
PS1
45 Nm PS2
SV1
45 Nm
PV 25 Nm
10 Nm
SV2
25 Nm
Fig. 25 Torques and references - hydraulic system without traction control
DT 3000 Series
49
HYDRAULIC SYSTEM
Torques and references, with traction control
Torques and references, with traction control
10 Nm
45 Nm
20 Nm
B/BB RV1
25 Nm 55 Nm 25 Nm
PCV
PS2
45 Nm
PS1
SV1 PS3
PV 25 Nm 45 Nm
SV3
10 Nm
25 Nm
SV2
Fig. 26 Torques and references - hydraulic system with traction control
DT 3000 Series
50
HYDRAULIC SYSTEM
Changing the Hydraulic Oil and Return Filter
Changing the Hydraulic Oil and 2. Attach the reservoir, taking care not to damage the
O-ring (25, Fig. 24).
Return Filter
WARNING
Risk of injury from escaping hydraulic oil. 1
To avoid accidents:
any sections of it.
tem.
3
leaks.
mal at first.
CAUTION 2
Health risk
damage your health. Fig. 27 Min. and max. oil levels
 Observe the manufacturer’s safety instructions Adding oil
3. Add hydraulic oil via a filter with a minimum reten-
tion rate of 10 µm up to the maximum mark (2) on
Hydraulic unit disassembly the reservoir. For the hydraulic oil grade see the
1. Disassemble the hydraulic unit (see page 45). table on page 21.
2. Place the hydraulic unit on a workbench. Note: The reservoir capacity is approx. 3 litres.
Removing the reservoir and disposing of the used
oil 5. Flush the hydraulic system (see page 54).
1. Remove the screws from the mounting ring (4, 6. Perform the drift test (see page 55).
Fig. 24) and take off the reservoir.
2. Pour out the used oil and dispose of it in accord-
ance with environmental regulations.
3. Clean the reservoir.
Removing and disposing of the suction filter
4. Remove the suction filter (5, Fig. 24) and dispose
of it in accordance with environmental regulations.
Note: Replace the return filter (24) only on request.
Filter and reservoir assembly
1. Assemble the new suction filter
DT 3000 Series
51
HYDRAULIC SYSTEM
Bleeding the Hydraulic System
Bleeding the Hydraulic System 3. Check the pressure port and hydraulic compo-
nents for leaks.
4. Switch off the truck and leave it to stand for approx-
imately 10 minutes.
WARNING
Note: During this time the air will separate from the oil
High pressure hydraulic system in the container.
Risk of injury from escaping hydraulic oil. 5. When there is no more foam, add hydraulic oil via
To avoid accidents: a filter with a minimum retention rate of 10 µm up
 Depressurise the hydraulic system before opening to the maximum mark (2) on the reservoir. For the
any sections of it. hydraulic oil grade see the table on page 21.
tem.
leaks.
mal at first.
CAUTION
Health risk
damage your health.
WARNING
Lowering forks can cause injury
The forks can automatically lower when the hydraulic
system is being depressurised and during the drift test.
 Never stand underneath a raised fork.
 Seal off the hazardous area to prevent other people
from entering and standing under a raised fork.
Bleeding the hydraulic system

1. Activate lifting (initial lift and fork lift) several times
to bleed the system.
 The oil in the reservoir will foam.
Note: After removing the free lift or a lift cylinder it may
be necessary to bleed the system directly from the cyl-
inder, via the bleed screw.
2. Fully lower the forks.
DT 3000 Series
52
HYDRAULIC SYSTEM
Replacing the Relief Valve RV1
Replacing the Relief Valve RV1

The relief valve protects the lifting mechanism against
overload.
Note: The relief valve is preset. It does not need to be
adjusted after replacement.
WARNING
Relief valve disassembly

The relief valve is located on the back of the hydraulic
unit (see Fig. 26).
1. Disassemble the hydraulic unit (see page 53).
2. Place the screwdriver on the hex. bolt and unscrew
the relief valve RV1 (see Fig. 26).
Relief valve assembly
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 torque to
45 Nm.
2. Test the hydraulics.
Relief valve test

1. Place the maximum rated load (see capacity plate
on truck) on the forks and raise it.
 If the load cannot be raised, replace RV1.
 If the load is raised, proceed to step 2.
2. Place the maximum rated load +10% (see capac-
ity plate on truck) on the forks and raise it.
 If the load is raised, replace RV1.
 If the load cannot be raised, RV1 is ok.
DT 3000 Series
53
HYDRAULIC SYSTEM
Flushing the Hydraulic System
Flushing the Hydraulic System

The hydraulic system must be flushed after carrying
out repairs to the system. Before flushing, check all hy-
draulic ports for leaks. In addition, check that all filters
are fitted and that there is sufficient hydraulic oil in the
reservoir (see page 51). Now carry out a drift test as
described on page 55.
WARNING
Lowering outriggers or forks can cause injury
The outriggers or the forks can automatically lower
when the hydraulic system is being bled or during the
drift test.
 Never stand underneath the raised components.
 Seal off the hazardous area to prevent other people
from entering and standing underneath the raised
components.
Flushing the hydraulic system

Note: All cylinders must be bled.
1. Fully raise the outriggers and forks.
2. Visually check for leaky cylinders.
 Repair any leaky cylinders.
3. Extend and retract the outriggers and forks at max-
imum speed to the maximum lift height at least 10
times in order to flush the entire hydraulic system.
DT 3000 Series
54
HYDRAULIC SYSTEM
Drift Test
Drift Test 3. Measure the height of one fork tip above the
ground.
After carrying out repairs to the hydraulic system per-
form a drift test. This is the only way of identifying inter-
nal leakage. 5. Wait for 10 minutes.
Note: Test the fork lift and outrigger lift separately. Measuring the drift
6. After 10 minutes measure the fork tip height again.
Preconditions for all drift tests 7. Calculate the difference between the previously re-
Prepare test loads and bring the truck up to operat- corded measurement and the new measurement
ing temperature to establish the drift.
• The test load must be evenly distributed.  If the drift ≥ 100 mm, the internal leakage is too
great. First flush the hydraulic system again and
• The load centre of gravity must be centrally located,
then repeat the drift test. If the drift is still exces-
600 mm in front of the fork shanks, and must not
sive, establish which components are leaking
exceed the capacity plate specification.
and repair them.
Note: Whenever you carry out a drift test the hydraulic
oil temperature must be 50°C.  If the drift < 100 mm, it has passed the drift test.
1. Measure the temperature in the hydraulic reservoir
before carrying out the drift test.
 If the temperature is 50°C you can start the drift
test.
 If the temperature is too low, proceed to step 2.
2. Raise the forks several times with maximum load
until the temperature is 50°C.
Outrigger lift drift test

Lifting a test load
1. Insert the outriggers under the maximum capacity
load.
2. Raise the outriggers fully.
3. Place a bar across the outriggers, measure and
record the height above the ground.
5. Wait for 10 minutes.
Measuring the drift
6. After 10 minutes measure the bar 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 380) and
repeat the drift test.
 If the drift < 100 mm, it has passed the drift test.
Fork lift drift test

Lifting a test load
1. Insert the forks under the maximum capacity load.
2. Fully raise the forks.
DT 3000 Series
55
HYDRAULIC SYSTEM
Hydraulic System Troubleshooting
Hydraulic System
Troubleshooting
Symptom Probable Cause Remedy
Noisy pump - Oil level too low. - Check oil level.

- Incorrect oil viscosity (e.g. standard oil - Use correct hydraulic oil (see page 21).
used in cold store environment). - Check suction pipe connection to pump.
- Leak in suction pipe union (pump suc- - Replace suction 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
- Relief valve permanently open fill with clean oil.
- Check oil level.
- Check suction pipe / pump connection
(see “Foaming hydraulic oil” symptom).
- Test relief valve (see page 53).
Low flow rate - Air in system - See “Foaming hydraulic oil” remedy.
- Relief valve faulty - See “Pump or oil overheating” remedy.
- Oil too hot - Test relief valve (see page 53).
No build up of pressure - Faulty relief valve - Test relief valve (see page 53), replace if
- Oil level low faulty.
- Add hydraulic oil.
Lifting delay - Air in manifold - Bleed the hydraulic system(see
page 52).
Rev. 1 06/2010 DT 3000 Series
56
DRIVE UNIT
57
Notes:
58
DRIVE UNIT
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. 28 Drive unit - mechanical steering Fig. 29 Drive unit - electric steering
1 Brake 1 Brake
2 Drive 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 Drive motor
DT 3000 Series
59
DRIVE UNIT
Replacing the Drive Wheel
Replacing the Drive Wheel
WARNING
Drive wheel disassembly

Preparation
1. Remove the panels so that the drive wheel can be
accessed.
2. Jack up the truck (see page 16) until 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.
Drive wheel assembly

Assembly is the reverse of disassembly. Torque the
wheel nuts to 130 Nm (M14) or 100 Nm (M12).
DT 3000 Series
60
DRIVE UNIT
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.  Before working underneath a raised truck:
 Observe the manufacturer’s safety instructions – Support the truck raised with a crane in such a
when handling solvents and lubricants. way that it cannot fall down even if the lifting gear
cracks or the crane fails.
The oil should have reached operating temperature be- – If the truck is raised with a forklift truck, it must be
fore changing. This will ensure that it flows away secured on the forks of the truck doing the lifting,
quickly and any contamination is kept in suspension. to prevent it from slipping and falling off. The lift
mechanism of the truck doing the lifting must be
physically chocked before you can work under
the raised load.
Preparing to change the oil

1. Raise the truck with a crane or forklift truck only as
far as is absolutely necessary (see “Lifting the
truck”, page 13). 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.
1 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
8. Clean the drain plug (2), screw it on and tighten.
Note: Make sure you use the correct oil grade. Cold
store trucks require a different type of oil than standard
2 trucks.
9. Add a suitable gear oil (see Recommended Lubri-
Fig. 30 Oil refill and drain plug positions cants and Consumables on page 21) (capacity ap-
Note: The refill plug can only be accessed when the prox. 0.9 L).
truck is raised. Therefore a crane or another truck with 10. Clean the refill plug (1), screw it on and tighten.
sufficient capacity must be used to raise the truck. The 11. Remove the jack from the truck and the device to
truck must not be jacked up for safety reasons. If the prevent it from being switched on.
truck can only be raised by a certain amount, the trac-
tion motor can be disassembled (see page 304) in or- 12. Test the truck.
der to add oil via the open gear unit cover.
DT 3000 Series
61
Notes:
62
ELECTRICAL SYSTEM
63
Notes:
64
ELECTRICAL SYSTEM
Components
Components
ACCESS 8.2 (OCM1)

(hidden)
HSS R/T
ILIS
ILOS
ILIS
HNS1
ILOS
SAS / BRS2
LOS ENC
FS (PF) & RS (FF)
HNS2 RAS ENC
Fig. 31 Components in the control handle
DT 3000 Series
65
ELECTRICAL SYSTEM
DT 3040 -MW and -MF Components
DT 3040 -MW and -MF

Components
Access 1
(Display)
LMS4 (TL 2100mm)
CA205 & BRS SR1

KYS
SR2
HN
CA213
CA212
CA205
LMS1 Line/EDS
FU1
FU2
FU3
FU4
BRK
CA204 M1
CA201
M2
SV1
ACCESS 2/3
SV2 TCM / HCM
CA202
PV
CA206
PLS2
CA221
Note: PLS1, PLS2, SR1 and SR2 are not present on the DT 3040 -MW. PLS1
CA220
Fig. 32 DT 3040 -MW and -MF Components, part 1
DT 3000 Series
66
ELECTRICAL SYSTEM
DT 3040 -MW and -MF Components
CA208 & BRS1 CA200
CA209
(1)
CA208 & ORS
CA211 & ALM
CA218 & SR1 CA210 & FLS
CA217 & PWS
CA219 & SR2
LMS4 (TF 2600mm)
CA207
CA216
(1) ORS is only present on the DT 3040 -MW

BLS BLS CA207.1
Fig. 33 DT 3040 -MW and -MF Components, part 2
DT 3000 Series
67
ELECTRICAL SYSTEM
DT 3040 -EF Components
Access 8.2
Fig. 34 DT 3040 -EF components, part 1
DT 3000 Series
68
ELECTRICAL SYSTEM
CA225
Fig. 35 DT 3040 -EF components, part 2
DT 3000 Series
69
ELECTRICAL SYSTEM
Fig. 36 DT 3040 -EF electrical components, part 3
DT 3000 Series
70
ELECTRICAL SYSTEM
Accessing the Service Levels
Accessing the Service Levels 3. Press the key.

 “LEVEL 3” is displayed.
You can navigate through the menu structures using
4. Press the key.
the cursor keys ( , , , , ) on the display. An
 “PASSWORD” is displayed.
overview of the menu structure can be found in Menu
Structure starting on page 74. 5. Enter password (PIN).
6. Confirm by pressing .
 The "ANALYZER" menu is displayed.
Fig. 37 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.
Accessing service level 2
Note: When you enter the password (PIN) for service
level 2 the display automatically changes to the “ANA-
LYZER” menu.
1. Use the key to select the “SERVICE” menu.
 “SERVICE” is displayed.
2. Press the key.
3. Press the key.
4. Enter password (PIN).
Note: When you enter the PIN for service level 3 the
display automatically changes to the “ANALYZER”
menu.
2. Press the key.
DT 3000 Series
71
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 part number Software version Used in:

(truck data number)(a)
825777-020 010 DT 3040 -MW

DT 3040 -MF
825777-020 010 DT 3040 -EF
(a). A breakdown of the truck data number can be found on page 4.
Access 2&3 (TCM/HCM) software versions
ACCESS 2&3 part number Software version Used in:

827395 041 DT 3040 -MW

DT 3040 -MF
823569-020 041 DT 3040 -EF
Access 5 (SCM) software versions
Access 5 part number Software version Software version Used in:

(master) (slave) (truck data number)(a)
816301-200 313 203 DT 3040 -EF

Access 8.1 software versions
Access 8.1 part number Software version Used in:

825705 024 DT 3040 -MW

DT 3040 -MF
DT 3040 -EF
825706 (F/C version) 024 DT 3040 -MW
DT 3040 -MF
DT 3040 -EF
DT 3000 Series
72
ELECTRICAL SYSTEM
Software Versions
Access 8.2 software versions
Access 8.2 part number Software version Used in:

827531 018 DT 3040 -EF

DT 3000 Series
73
ELECTRICAL SYSTEM
Menu Structure
Menu Structure
OPERATOR MENU SERVICE MENU
Enter Password
Message Mode
All
Speed Analyzer
Hours Status
BDI Inputs (Access 2, 3, 5, 8.1)
Outputs
Test outputs
Hour
Runtime1
Runtime2 Calibration
FF / PF Rocker
Lift/Lower Rotary Encoder
Events Steer System
Last
…
Last-15
Features
Language
Service Travel Alarm ALM
Level 2 Beacon FLS
Level 3 Truck Type
Message Mode
Performance
User Codes
Performance EEPROM Clear
P1 TFD Torque
P2 Hour Meter
P3 Belly Button
Keyless
Infolink
Hour
Runtime 1
Runtime 2
Access 2&3
Performance Access 5
P1, P2, P3
BDI Setting
MAX EVP
MIN EVP Events
EVP Open Delay Chron History (last 15)
EVP Close Delay Accum History
Pump Acceleration Clear History
Pump Deceleration
Adjust Battery
Rider Turtle Speed
Utilities
Walkie Turtle Speed Part Numbers
Turtle Mode Brake (Hard- & Software:
BB Acceleration Access 1, 2, 3, 5,
BB Deceleration 8.1 & 8.2)
Fig. 38 Menu structure
DT 3000 Series
74
ELECTRICAL SYSTEM
Operator and Service Menu
MODEL # PIN PASSWORD
BDI = Value
HOURS = Value
SPEED = Value
RUNTIME # =
Hour H# Value
Value
EVENTS, page 76
Fig. 39 Operator menu and entry to the service menu, part 1
DT 3000 Series
75
ELECTRICAL SYSTEM
HOUR
page 75
Events Last Ev = Value Value
Last-1 Ev = Value Value
Last-4…-15 Ev = Value Value
ANALYZER, page 75
Service Level 2 Password
Level 3 Password
Performance SET P1
Note: The Performance menu is only

displayed if F6 in the FEATURES
menu is set to ENABLE. SET P2
SET P3
Fig. 40 Operator menu and entry to the service menu, part 2
DT 3000 Series
76
ELECTRICAL SYSTEM
Analyzer Menu, A1 – A2
Analyzer Menu, A1 – A2
UTILITIES, page 104
ANALYZER A1 STATUS A1.1 ACCESS 1 Value
A1.2 ACCESS 2&3 Value
A1.4 ACCESS 8.1 Value
(1)
A1.5 ACCESS 5 Value
C2 CALIBRATION,
page 80 A1.6 MAIN C Value
(1)
A1.7 ACCESS 8.2 Value
A2 INPUTS A2.1 ACCESS 1
A2.2 ACCESS 2 A2.2.1, page 82
A3 OUTPUTS, page 78 A2.4 ACCESS 8.1 A2.4.1, page 84
(1)
(1)
A2.8 ACCESS 8.2
(1) Displayed only on the DT 3040 -EF
Fig. 41 Analyzer menu, A1 – A2
DT 3000 Series
77
ELECTRICAL SYSTEM
Analyzer Menu, A3 Outputs
Analyzer Menu, A3 Outputs
A2 Inputs, page 77
A3 OUTPUTS A3.1 BATTERY % Value % Unit %
A3.2 BATTERY VOLTAGE Value V Unit V
A3.3 BATTERY CURRENT Value A Unit A
A3.4 TRACTION SPEED Value kmh Unit km/h
RPM TRACTION
A3.5 Value RPM Unit min-1
MOTOR
(1)
RPM STEER
A3.6 Value RPM Unit min-1
MOTOR
Value 0 = OFF
A3.7 BRAKE Value
Value 1 = ON
A3.8 PV % Value % Unit %
Value 0 = OFF
A3.9 HORN Value
Value 1 = ON
Value 0 = OFF
A3.10 FAN Value
Value 1 = ON
Value 0 = OFF
A3.11 FLS Value
Value 1 = ON
Value 0 = OFF
A3.12 ALM Value
Value 1 = ON
A4 Test Outputs, page 79
Note: Only available in
Value 0 = OFF
service level 3 A3.13 SV1 Value
Value 1 = ON
Value 0 = OFF
A3.14 SV2 Value
Value 1 = ON
Value 0 = OFF
A3.15 SV3 Value
Value 1 = ON
(1) Displayed only on the DT 3040 -EF
Fig. 42 Analyzer menu, A3 Outputs
DT 3000 Series
78
ELECTRICAL SYSTEM
Analyzer Menu, A4 Test Outputs
Analyzer Menu, A4 Test Outputs
A3, page 78 A4 Test Outputs A4.1 FAN Enter to Cancel
Note: Only available in service level 3

A4.2 HORN Enter to Cancel
A4.3 FLS Enter to Cancel
A4.4 ALM Enter to Cancel
Fig. 43 Analyzer menu, A4 Test Outputs
DT 3000 Series
79
ELECTRICAL SYSTEM
Calibration Menu, C2 Steer System
Calibration Menu, C2 Steer System
ANALYZER, page 77
(1)
CALIBRATION STEER
C2 Sure? N Sure? Y
SYSTEM
C2.1 AQUIRE TILLER CENTER CONFIRM
C2.2 ADJ FULL LEFT COARSE Value
FEATURES, page 86
C2.3 ADJ FULL LEFT FINE Value
C2.4 ADJ FULL RIGHT COARSE Value

C3 LIFT/LOWER ROTARY
ENCODER, page 81
C2.5 ADJ FULL RIGHT FINE Value
C2.6 ADJ DRIVE TIRE CENTER Value
C2.7 2ND ENCODER 0
(1) Displayed only on the DT 3040 -EF. For other Save? N 1

models the display changes from CALIBRATION
directly to C3 LIFT/LOWER ROTARY ENCODER
(see page 81).
Save? Y
Fig. 44 Calibration menu, C2 Steer System
DT 3000 Series
80
ELECTRICAL SYSTEM
Calibration, C3 Lift/Lower Rotary Encoder menu
Calibration, C3 Lift/Lower Rotary Encoder menu
C2 STEER SYSTEM, page 80
LIFT/LOWER
CALIBRATION, page 80 C3 ROTARY Sure? N Sure? Y
ENCODER
PRESS LIFT MAX &

C3.1 LOWER MAX, THEN
ENTER
Save? N
Save? Y
Fig. 45 Calibration menu, C3 Lift/Lower Rotary Encoder
DT 3000 Series
81
ELECTRICAL SYSTEM
Analyzer Menu, A2.2.1 – A2.2.19, Access 2 Inputs
Unit Digits
A2.2 ACCESS 2, A2.2.1 RAS ENC = Value Value
(0 – 255)
page 77
Unit Digits
A2.2.2 LOS ENC = Value Value
(0 – 255)
PRESSURE TRANSDUCER Unit Digits

A2.2.3 Value
PS1 = Value (0 – 255)
PUMP MOTOR CURRENT

A2.2.4 Value A Unit A
= Value
PUMP MOTOR ON
A2.2.5 Value % Unit %
= Value
Value 0 = OFF
A2.2.7 BLS = Value Value
Value 1 = ON
Value 0 = OFF
A2.2.8 LMS1 = Value Value
Value 1 = ON
Value 0 = OFF
A2.2.9 LMS4 = Value Value
Value 1 = ON
Value 0 = OFF
A2.2.12 INITIAL LIFT = Value Value
Value 1 = ON
A2.2.13 INITIAL LOWER = Value Value Value 0 = OFF

Value 1 = ON

A2.2.18 Value
PS2 = Value (0 – 255)

A2.2.19 Value
PS3 = Value (0 – 255)
Fig. 46 Analyzer menu, A2.2.1 – A2.2.19, Access 2 Inputs
DT 3000 Series
82
ELECTRICAL SYSTEM
Analyzer, A2.3.1 – A2.3.15, Access 3 Inputs Menu
Analyzer, A2.3.1 – A2.3.15, Access 3 Inputs Menu
A2.3 ACCESS 3, A2.3.1 TEMP ACCESS 2&3 = Value Value C Unit °C

page 77
A2.3.2 TS1 SENSOR = Value Value C Unit °C
Value 0 = OFF
A2.3.3 FF SWITCH = Value Value
Value 1 = ON
Value 0 = OFF
A2.3.4 PF SWITCH = Value Value
Value 1 = ON
Unit Digits
A2.3.5 DRIVE POT = Value Value
(0 – 255)
Value 0 = OFF
A2.3.6 HSS = Value Value
Value 1 = ON
HNS1+2 = Value Value Value 0 = OFF

A2.3.7
Value 1 = ON
Value 0 = OFF
A2.3.8 BRS1+2 = Value Value
Value 1 = ON
(1) Value 0 = OFF

A2.3.9 PLS1 SENSOR = Value Value
Value 1 = ON
(1)
Value 0 = OFF
A2.3.10 PLS2 SENSOR = Value Value
Value 1 = ON
(1) Value 0 = OFF

A2.3.11 SR1 SENSOR = Value Value
Value 1 = ON
(1) Value 0 = OFF

A2.3.12 SR2 SENSOR = Value Value
Value 1 = ON
Value 0 = OFF
A2.3.13 SAS = Value Value
Value 1 = ON
TRACTION MOTOR CURRENT

= Value
A2.3.15 ECR = Value Value Unit Pulses
(2)
Value 0 = OFF
A2.3.16 ORS SWITCH = Value Value
Value 1 = ON
(1) Displayed only on the DT 3040 -MF, -EF

(2) Displayed only on the DT 3040 -MW
DT 3000 Series
83
ELECTRICAL SYSTEM
Analyzer, A2.2.1 – A2.2.19, Access 8.1 Inputs Menu
Analyzer, A2.2.1 – A2.2.19, Access 8.1 Inputs Menu
A2.4 ACCESS 8.1, A2.4.1 RAS ENC = Value Value Unit Digits
(0 – 255)
page 77
Unit Digits
A2.4.2 LOS ENC = Value Value
(0 – 255)
A2.4.3 INITIAL LIFT = Value Value Value 0 = OFF

Value 1 = ON
Value 0 = OFF
A2.4.4 INITIAL LOWER = Value Value
Value 1 = ON
A2.4.5 PF SWITCH = Value Value Value 0 = OFF

Value 1 = ON
Value 0 = OFF
A2.4.6 FF SWITCH = Value Value
Value 1 = ON
Value Unit Digits

A2.4.7 DRIVE POT = Value
(0 – 255)
Value 0 = OFF
A2.4.8 HNS1+2 = Value Value
Value 1 = ON
Value 0 = Rabbit
A2.4.9 HSS = Value Value
Value 1 = Turtle
Value 0 = OFF
A2.4.10 SAS = Value Value
Value 1 = ON
Fig. 48 Analyzer menu, A2.4.1 – A2.4.10, Access 8.1 Inputs
DT 3000 Series
84
ELECTRICAL SYSTEM
(1)
A2.5 ACCESS 5, A2.5.1 TEMP ACCESS 5 = Value Value C Unit °C
page 77
TS3 (TEMP MOTOR) =
A2.5.2 Value C Unit °C
Value
STEER MOTOR CURRENT

= Value
A2.5.4 STEER POT1 = Value Value V Unit V
A2.5.5 STEER POT2 = Value Value V Unit V
ECR2 (ENCODER 48P)

A2.5.6 Value Unit Pulses
= Value
ECR3 (ENCODER 32P)

A2.5.7 Value Unit Pulses
= Value
Value 0 = OFF
A2.5.8 SAHS SENSOR = Value Value
Value 1 = ON
(1)A2.5.1 – A2.5.8 is displayed only on the DT 3040 -EF.
DT 3000 Series
85
ELECTRICAL SYSTEM
Features F6 – F7
Features F6 – F7
CALIBRATION, page 80
FEATURES F1 LANGUAGE = Value ENGLISH
GERMAN
Save? N
FRENCH
HOUR, page 90
SPANISH
Save? Y
DUTCH
TRAVEL ALARM
F2 OFF
ALM
RE-KEY
REQUIRED
ITALIAN
BOTH
POLISH
FF
CZECH
PF
DANISH
F3 BEACON FLS OFF

PORTUGESE
KEY
HUNGARIAN
BOTH
FINISH
FF
NORWEGIAN
PF
SWEDISH
F4 TRUCK TYPE, page 87
RUSSIAN
TURKISH
GREEK
SLOVENIAN
Fig. 50 Features menu, F1 – F3
DT 3000 Series
86
ELECTRICAL SYSTEM
Features F4 Menu, Truck Type
Features F4 Menu, Truck Type
F3 BEACON FLS, page 86
F4 TRUCK TYPE 3040MW
F5 MESSAGE MODE, page 104 3040ES
3040ER
3040EF
3040MS
3040MR
3040MF
Fig. 51 Features F4 menu, Truck Type
DT 3000 Series
87
ELECTRICAL SYSTEM
Features Menu, F7.1 – F 7.4
Features Menu, F7.1 – F 7.4
F7 USER CODES, page 104
F7.1 VIEW CODES ENTRY 1 1000 P1
ENTRY 2 2000 P2
ENTRY 25 xxxx Px
F7.2 ADD CODES PIN 0001
PERFORMANCE
P1
LEVEL
P2
P3
F7.3 MODIFY CODES ENTRY 1 PIN 0001
ENTRY 2
PERFORMANCE
P1
LEVEL
ENTRY 25
P2
F7.4 DELETE CODES ENTRY 1 1000 P1

P3
ENTRY 2 2000 P2
ENTRY 25 xxxx Px
Fig. 52 Features menu, F7.1 – F7.4
DT 3000 Series
88
ELECTRICAL SYSTEM
Features Menu, F10 – F13
Features Menu, F10 – F13
F9 TFD TORQUE, page 88
HOUR METER
F10 H1
= Value
H2
BELLY BUTTON
F11 COASTING
= Value
ON
F12 KEYLESS = Value DISABLE
OFF
KEYLESS Value
ENABLE F12.1
TIMEOUT (10-30 min)
Infolink
F 13 DISABLE
= Value
ENABLE
F1 LANGUAGE, page 86
Fig. 53 Features menu, F10 – F13
DT 3000 Series
89
ELECTRICAL SYSTEM
Hour Menu, H1 –– H5
Hour Menu, H1 –– H5
FEATURES, page 86
Level2: View only

Level3: Increase only
HOUR H1 RUNTIME 1 = Value Value h Unit h
Unit h
H2 Runtime 2 LEVEL = Value H2.1 Runtime2 = Value = level 1 - 9
NOTE 1:
RUNTIME 2 = RUNTIME 1 + additional fixed time delay (Timeout),
EVENTS, page 91 [0 – 11 min.] -> Setting LEVEL: 1 2 3 4 5 6 7 8 9
Value: 0 1 2 3 5 5 7 9 11
Level2: View only

H3 Access 2 = Value Value Unit h
Level2: View only

H4 Access 3 = Value Value Unit h
Level2: View only

(1)
H5 Access 5=Value Value h Unit h
(1) Displayed only on the DT 3040 -EF.
Fig. 54 Hour menu, H1 – H5
DT 3000 Series
90
ELECTRICAL SYSTEM
Events Menu, E1
Events Menu, E1
HOUR, page 90
CHRON
EVENTS E1 E1.1 LAST CODE = Value Value
HISTORY
HOUR = Value Value
TEMP = Value Value
PERFORMANCE E1.2 LAST-1 CODE = Value Value

(DT 3040 MW), page 94
PERFORMANCE
(DT 3040 -MF -EF), HOUR = Value Value
page 96
E2 ACCUM HISTORY, page 91

TEMP = Value Value
E1.16 LAST-15 CODE = Value Value
HOUR = Value Value
TEMP = Value Value
Fig. 55 Events menu, E1
DT 3000 Series
91
ELECTRICAL SYSTEM
Events Menu, E2 – E3
Events Menu, E2 – E3
E1 CHRON HISTORY, page 91
ACCUM EVENT X
E2 Value
HISTORY OCCURENCES = Value
EVENT Y
Value
OCCURENCES = Value
EVENT Z
Value
OCCURENCES = Value
CLEAR CLEAR
E3 E3.1 NO
HISTORY CHRONOLOGICAL
YES
E3.2 CLEAR ALL NO
YES
Fig. 56 Events menu, E2 – E3
DT 3000 Series
92
ELECTRICAL SYSTEM
Performance Menu, P1 (DT 3040 MW)
P16 BB DECELERATION, page 103

EVENTS, page 91
WALKIE TRAVEL
PERFORMANCE P1 SET P1 P1.1 SPEED PF Edit 1 - 9
= Value
WALKIE TRAVEL
P1.2 SPEED FF Edit 1 - 9
Save? N P2 SET P2, page 94 = Value
WALKIE
P1.3 ACCELERATION Edit 1 - 5
= Value
Save? Y
UTILITIES, WALKIE
page 104 P1.4 PLUGGING Edit 1 - 9
RE-KEY = Value
REQUIRED
WALKIE
P1.5 COASTING Edit 1 - 9
= Value
Fig. 57 Performance menu, P1 (DT 3040 MW)
DT 3000 Series
93
ELECTRICAL SYSTEM
P1 SET P1, page 93

EVENTS, page 91
WALKIE TRAVEL
= Value
WALKIE TRAVEL
WALKIE
= Value
Save? Y
UTILITIES,
WALKIE
RE-KEY = Value
REQUIRED
WALKIE
= Value
DT 3000 Series
94
ELECTRICAL SYSTEM
P2 SET P2, page 94

EVENTS, page 91
WALKIE TRAVEL
= Value
WALKIE TRAVEL
WALKIE
= Value
Save? Y
UTILITIES, WALKIE
RE-KEY = Value
REQUIRED
WALKIE
= Value
DT 3000 Series
95
ELECTRICAL SYSTEM
Performance Menu, P1 (DT 3040 -MF -EF)

EVENTS, page 91
RIDER TRAVEL
= Value
RIDER TRAVEL
RIDER
= Value
Save? Y
UTILITIES, RIDER
RE-KEY = Value
REQUIRED
RIDER
= Value
PLT UP
P1.6 SPEED PF Edit 1 - 9
= Value
PLT UP
= Value
PLT DOWN
= Value
PLT DOWN
= Value
P1.10 WALKIE ACCELERATION, page 97
Fig. 60 Performance menu, P1(DT 3040 -MF -EF), Part 1
DT 3000 Series
96
ELECTRICAL SYSTEM
P1.9 PLT DOWN SPEED FF, page 96
WALKIE
= Value
WALKIE
P1.11 PLUGGING Edit 1 - 9
= Value
WALKIE
= Value
SPEED
REDUCTION ON
P1.13 Edit 1 - 3
TURNS
= Value
PANIC STEERING
P1.14 Edit 1 - 9
= Value
Fig. 61 Performance menu, P1(DT 3040 -MF -EF), Part 2
DT 3000 Series
97
ELECTRICAL SYSTEM

EVENTS, page 91
RIDER TRAVEL
= Value
RIDER TRAVEL
RIDER
= Value
Save? Y
UTILITIES, RIDER
RE-KEY = Value
REQUIRED
RIDER
= Value
PLT UP
= Value
PLT UP
= Value
PLT DOWN
= Value
PLT DOWN
= Value
Fig. 62 Performance menu, P2 (DT 3040 -MF -EF), Part 1
DT 3000 Series
98
ELECTRICAL SYSTEM
WALKIE
= Value
WALKIE
= Value
WALKIE
= Value
SPEED
REDUCTION ON
P2.13 Edit 1 - 3
TURNS
= Value
PANIC STEERING
P2.14 Edit 1 - 9
= Value
DT 3000 Series
99
ELECTRICAL SYSTEM

EVENTS, page 91
RIDER TRAVEL
= Value
RIDER TRAVEL
Save? N P4 BDI SETTING, = Value
page 104
RIDER
= Value
Save? Y
UTILITIES, RIDER
RE-KEY = Value
REQUIRED
RIDER
= Value
PLT UP
= Value
PLT UP
= Value
PLT DOWN
= Value
PLT DOWN
= Value
DT 3000 Series
100
ELECTRICAL SYSTEM
WALKIE
= Value
WALKIE
= Value
WALKIE
= Value
SPEED
REDUCTION ON
P3.13 Edit 1 - 3
TURNS
= Value
PANIC STEERING
P3.14 Edit 1 - 9
= Value
DT 3000 Series
101
ELECTRICAL SYSTEM
Performance Menu, P4 – P11
P3 SET P3, page 100
P4 BDI SETTING = Value MAINTENANCE FREE
HEAVY DUTY
P5 MAX EVP = Value EDIT 1 - 20
MEDIUM DUTY
P6 MIN EVP = Value EDIT 1 - 20
STANDARD DUTY
EVP OPEN DELAY
P7 EDIT 1 - 9
= Value
LIGHT DUTY
EVP CLOSE DELAY

P8 EDIT 1 - 9
= Value
PUMP ACCELERATION
P9 EDIT 1 - 9
= Value
PUMP DECELERATION
P10 EDIT 1 - 9
= Value
ADJUST BATTERY
P11 EDIT 1 - 255
= Value
P12 RIDER TURTLE SPEED, page 103
Fig. 66 Performance menu, P4 – P11
DT 3000 Series
102
ELECTRICAL SYSTEM
P11 ADJUST BATTERY, page 102
RIDER TURTLE SPEED

P12 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
P1 SET P1, page 93
Fig. 67 Performance menu, P12 – P16
DT 3000 Series
103
ELECTRICAL SYSTEM
Utilities Menu, U1
Utilities Menu, U1
PERFORMANCE, pages 93, 94, 95, 96, 98, 100
U1.1.1 Module
UTILITIES U1 Part Numbers U1.1 Access 1 Value
PN = Value
U1.1.2 Software
Value
PN = Value
U1.2.1 Module
U1.2 Access 2&3 Value
PN = Value
ANALYZER, page 77
U1.2.2 Software
Value
PN = Value
(1) U1.4.1 Module

U1.4 Access 5 Value
PN = Value
U1.4.2 Software
Value
PN = Value
U1.4.3 Slave
Software Value
PN = Value
U1.5.1 Module
U1.5 Access 8.1 Value
PN = Value
U1.5.2 Software
Value
PN = Value
(1) U1.6.1 Module

U1.6 Access 8.2 Value
PN = Value
(1) Displayed only on the DT 3040 -EF.

U1.6.2 Software
Value
PN = Value
Fig. 68 Utilities Menu, U1
DT 3000 Series
104
ELECTRICAL SYSTEM
Input Signals
Input Signals Comfort mode

• Platform down
Initial truck status • Side restraint down
The following tables show the status of the most impor- In comfort mode the operator can ride on the platform,
tant inputs required to operate the truck. but only at walking pace (max. 6 km/h).
These inputs can be checked in the Analyzer menu.
Rider mode
It is assumed that the truck is in standby mode, i.e.:
• Platform down
• Truck is switched on and not in idle ( symbol is
• Side restraint closed
not displayed)
In rider mode the operator can ride on the platform. The
• The operator is standing on the platform
maximum speed is approx. 12 km/h.
• The “Rabbit/Turtle” toggle switch is set to "Rabbit"
• The forks and outriggers are fully lowered Conventions
• The temperature of the electronic system and mo-
tors does not exceed 45°C Brief description of equipment
Three components of the truck data number are used
SAS and BRS to assign the truck's equipment to the parameters.
On all trucks with a non-folding control handle and • Model number
electric steering the SAS assumes the function of the • Steering type
BRS electrically. • Operator position type
Operating mode definition The reference 3040 MW for example designates the
DT 3040 model with mechanical steering and without a
The various operating modes of the truck are deter- platform.
mined by the position of the side restraints and the plat-
form:
In the following tables this part of the truck data number
describes the truck model.
1
2
3
4
Fig. 69 Side restraint and platform position definition

1 Side restraint up (Quick Exit)
1 Side restraint closed
3c Side restraint down
4 Platform down
Pedestrian mode
• Platform up
• Side restraint down
In pedestrian mode the maximum speed is 6 km/h.
DT 3000 Series
105
Notes:
106
ELECTRICAL SYSTEM
Input Signals
,
(Sheet 1 of 3) DT 3040 -MW DT 3040 -MF DT 3040 -EF

Control module
Display name in Function & comment Assembly location Pedestrian mode(a) Comfort mode Rider mode Comfort mode Rider mode
Analyzer menu (platform down, side (platform down, side (platform down, side (platform down, side
restraint down) restraint closed) restraint down) restraint closed)
RAS ENC Fork lift limit switch Control handle grip 0 0 0 0 0

LOS ENC Fork lift lower switch Control handle grip 0 0 0 0 0
INITIAL LIFT Outrigger lift switch Control handle grip OFF OFF OFF OFF OFF
INITIAL LOWER Outrigger lower switch Control handle grip OFF OFF OFF OFF OFF
PS1 Outrigger lift pressure sensor. Used for In manifold block on the hydraulic unit.
0 0 0 0 0
load-dependent speed reduction.
Access 2
PS2 Fork lift pressure sensor. Used for load- In manifold block on the hydraulic unit.
0 0 0 21 21
dependent speed reduction.
PS3 Traction cylinder pressure sensor. Used In manifold block on the hydraulic unit.
for load-dependent control of the drive N/A(b) N/A(b) N/A(b) 31 31
wheel contact pressure.
LMS1 switch Outrigger lift limit switch. Motor compartment OFF OFF OFF OFF OFF
LMS4 switch Lift limit in rider mode. Mast OFF OFF OFF OFF OFF
BLS Battery retainer monitoring. Battery compartment OFF OFF OFF OFF OFF
DT 3000 Series
107
ELECTRICAL SYSTEM

Control module
TEMP ACCESS 2&3 Temperature monitoring In the control module(c) ≤ 45°C ≤ 45°C ≤ 45°C ≤ 45°C ≤ 45°C
TS1 Thermal sensor In the drive motor(c) ≤ 45°C ≤ 45°C ≤ 45°C ≤ 45°C ≤ 45°C
PF switch Forward travel switch Control handle grip OFF OFF OFF OFF OFF
FF switch Reverse travel switch Control handle grip OFF OFF OFF OFF OFF
DRIVE POT Traction potentiometer wiper Control handle grip 0 0 0 0 0
HSS “Rabbit/Turtle” toggle switch (R/T) Control handle grip ON ON ON ON ON
HNS1 + 2 Lift switches 1 + 2 Control handle grip OFF OFF OFF OFF OFF
Access 3
BRS1 + 2 Brake switch Below the control handle knuckle OFF OFF OFF OFF OFF
PLS1 sensor Platform sensor 1 On platform hinge N/A(b) ON ON ON ON
PLS2 Sensor Platform sensor 2 On platform hinge N/A(b) OFF OFF OFF OFF
SR1 Sensor Side restraint sensor 1 On side restraint hinge N/A(b) OFF ON OFF ON
SR2 sensor Side restraint sensor 2 On side restraint hinge N/A(b) OFF ON OFF ON
SAS Safety reverse switch Control handle grip OFF OFF OFF OFF OFF
ECR1 Drive motor “B side” encoder, 64 pulses Drive motor “B side”(c) 0 0 0 0 0
FAN Electrical system cooling, switches on at Electrical panel
OFF OFF OFF OFF OFF
temperatures ≥ 45° C
TEMP ACCESS 5 Thermal sensor; switches off all truck In the control module(c) ≤ 45°C ≤ 45°C
functions in event of overtemperature
TS3 (TEMP MOTOR) Thermal sensor; switches off all truck In the steer motor(c) ≤ 45°C ≤ 45°C
functions in event of overtemperature
STEER POT1 Steering potentiometer, slider 1 In the TFD module(c) 2.5 V (±0.2 V) 2.5 V (±0.2 V)
Access 5
STEER POT 2 Steering potentiometer, slider 2 In the TFD module(c) N/A(b) 2.5 V (±0.2 V) 2.5 V (±0.2 V)
ECR2 (ENCODER 48P) Steer motor encoder, 32 pulses Steer motor, "A side" of electric steer-
146 pulses (±20) 146 pulses (±20)
ing(c)
ECR3 (ENCODER 32P) Steer motor encoder, 48 pulses Steer motor, "B side" of electric steer-
107 pulses (±20) 107 pulses (±20)
ing(c)
SAHS SENSOR Straight Ahead Sensor Front of drive unit ON ON
DT 3000 Series
108
ELECTRICAL SYSTEM

Control module
RAS ENC Fork lift limit switch Control handle grip 0 0 0 0 0

LOS ENC Fork lift lower switch Control handle grip 0 0 0 0 0
INITIAL LIFT Outrigger lift switch Control handle grip OFF OFF OFF OFF OFF
INITIAL LOWER Outrigger lower switch Control handle grip OFF OFF OFF OFF OFF
Access 8.1
PF switch Forward travel switch Control handle grip OFF OFF OFF OFF OFF
FF switch Reverse travel switch Control handle grip OFF OFF OFF OFF OFF
DRIVE POT Traction potentiometer slider Control handle grip 0 0 0 0 0
HSS “Rabbit/Turtle” toggle switch (R/T) Control handle grip ON ON ON ON ON
HNS1 + 2 Horn switches 1 + 2 Control handle grip OFF OFF OFF OFF OFF
SAS Safety reverse switch Control handle grip ON ON ON ON ON
(a). The truck does not have a platform. Only pedestrian mode is available.
(b). not available
(c). Not accessible
DT 3000 Series
109
Notes:
110
ELECTRICAL SYSTEM
Platform and Side Restraint Logic
Platform and Side Restraint Folding platform

Logic Side restraint and platform setting defini-
tion
Three components of the truck data number are used
to assign the truck's equipment to the parameters:
• Model number
• Steering type
1
• Operator position type 2
The reference DT 3040 -MW for example designates
the DT 3040 model with mechanical steering and with-
out a platform.
3
4
In the following table this part of the truck data number
describes the truck model.
Fig. 70 Side restraint and platform setting definition

1 Side restraint up (Quick Exit)
1 Side restraint closed
3c Side restraint down
4 Platform down
Note: The platform sensors only connect when the

platform has been folded down as far as the stop.
Someone must be standing on the platform.
,
Platform and side restraint logic, folding platform Platform sensors Side restraint
sensors
Truck model Operating mode Platform and side V max. PLS1 PLS2 SR1 SR2
restraint positions (km/h)
DT 3040 -MW Pedestrian mode Platform up

6 OFF ON OFF OFF
and Side restraint down
DT 3040 -EF Comfort mode Platform down
6 ON OFF OFF OFF
Side restraint down
Rider mode Platform down
12,5 ON OFF OFF OFF
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
DT 3000 Series
111
Notes:
112
ELECTRICAL SYSTEM
DT 3040 -MW Software Parameter Settings

Three components of the truck data number are used to assign the truck's equipment to the parameters.
• Model number
• Steering type
• Platform type
The reference DT 3040 -MF for example designates the DT 3040 model with mechanical steering and a folding platform.
In the following tables this part of the truck data number describes the truck model.
Operation modes
The position of the platform and side restraints determines the rider, pedestrian and comfort operating modes. See page 111.
Markings
X = Relevant
— = Not relevant
DT 3040 -MW (Sheet 1 of 2) Factory Settings
Display Description Range Perfor- Perfor- Perfor-

mance mance mance
setting P1 setting P2 setting P3
Walkie Travel Speed PF Maximum travel speed of unladen truck in direction of control handle. Settings from 1 - 9 in increments of 0.5 km/h.
Setting 1 = 2 km/h, setting 3 = 3 km/h, setting 5 = 4 km/h, setting 7 = 5 km/h, setting 9 = 7 5 3
6 km/h
Walkie Travel Speed FF Maximum travel speed of unladen truck in direction of forks. Settings from 1 - 9 in increments of 0.5 km/h.
6 km/h
Walkie Acceleration Time required(a) for the drive motor to accelerate in pedestrian mode from 0 rpm to a Settings from 1 - 9 in increments of 0.2 s.
speed corresponding to 6 km/h of the unladen truck in performance setting P1. Setting 1 is maximum acceleration, setting 9 minimum acceleration. 4 5 7
Setting 1 = 0.3 s, setting 4 = 1.0 s, setting 9 = 1.9 s
Walkie Plugging Time required(b) for the drive motor to decelerate from a speed corresponding to 6 km/h Settings from 1 - 9 in increments of 0.2 s.
of the unladen truck to 0 rpm by changing direction. Setting 1 is maximum deceleration, setting 9 minimum deceleration. 3 3 4
Walkie Coasting Time required(b) for the drive motor to decelerate from a speed corresponding to 6 km/h Settings from 1 - 9 in increments of 0.2 s.
of the unladen truck to 0 rpm by coasting. Setting 1 is maximum deceleration, setting 9 minimum deceleration. 4 4 4
Speed Reduction On Resulting maximum speed on turns for a 90° control handle lock Settings from 1 - 3 in rider mode:
Turns Setting 1 = 8.8 km/h for 90° control handle lock.
Setting 2 = 7.5 km/h for 90° control handle lock.
Setting 3 = 6.3 km/h for 90° control handle lock. 2 2 3
Settings from 1 - 3 in pedestrian and comfort modes:

Settings 1 to 3 = 4.8 km/h for 90° control handle lock.
All performance settings
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ELECTRICAL SYSTEM
DT 3040 -MW (Sheet 2 of 2) Factory Settings
Display Description Range Perfor- Perfor- Perfor-

mance mance mance
setting P1 setting P2 setting P3
BDI Setting BDI display settings for different application profiles. Light Duty, Standard Duty, Heavy Duty, Maintenance Free (Heavy Duty Plus) Standard Duty
Max EVP Limit for maximum current through the lowering valve PV. This determines the maximum Settings from 1 - 20 in increments of 0.4%
lowering speed. This parameter should only be changed after consultation with the Crown Setting 1 = 44.7 %, setting 19 = 51.8 %, setting 20 = 52.2 % 5
service department.
Min EVP Limit for minimum current through the lowering valve PV. This determines the minimum Settings from 1 - 20 in increments of 0.4%
lowering speed. This parameter should only be changed after consultation with the Crown Setting 1 = 11 %, setting 18 = 17.7 %, setting 20 = 18.5 % 1
service department.
EVP Open Delay PV lowering valve opening delay. Time taken to reach Min EVP. This setting determines Settings from 1 - 9 in increments of 0.05 s.
how softly or abruptly lifting takes place. This parameter should only be changed after Setting 1 = 0.0 s, setting 5 = 0.2 s, setting 9 = 0.4 s 2
consultation with the Crown service department.
EVP Close Delay PV lowering valve closing delay. This setting determines how softly or abruptly lifting stops Settings from 1 - 9 in increments of 0.05 s.
when the lowering switch is released. This parameter should only be changed after con- Setting 1 = 0.0 s, setting 4 = 0.15 s, setting 9 = 0.4 s 2
sultation with the Crown service department.
Pump Acceleration Time taken(b) for the pump motor to accelerate from 0 rpm to maximum speed. Settings from 1 - 9 in increments of 0.1 s.
1
Pump Deceleration Time taken(b) for the pump motor to decelerate from the maximum speed to 0 rpm. Settings from 1 - 9 in increments of 0.2 s.
1
Adjust Batt Option for comparing the battery voltage measured by the control module with the voltage — —
actually measured on the battery. This parameter should only be changed after consulta-
tion with the Crown service department.
Rider Turtle Speed Setting can be changed but has no effect. (The platform switches are overridden as the — 7
truck does not have a platform.)
Walkie Turtle Speed Speed setting when the HSS switch is set to “Turtle”. Settings from 1 - 9 in increments of 0.3 km/h
3
Setting 1 = 2.1 km/h, setting 3 = 2.7 km/h, setting 9 = 4.5 km/h
Turtle Mode Brake Time(b) taken by the drive motor to decelerate from max. speed to 0 rpm, after the BRS Settings from 1 - 9 in increments of 0.2 s.
4
switch has been activated. Setting 1 = 2.2 s, setting 4 = 2.8 s, setting 9 = 3.8 s
BB Acceleration Time(a) taken by the drive motor to accelerate from 0 rpm to max. speed, after the safety Settings from 1 - 9 in increments of 0.1 s. 4
reverse switch SAS has been activated. Setting 1 = 0.9 s, setting 4 = 1.2 s, setting 9 = 1.7 s
BB Deceleration Time(b) taken by the drive motor to decelerate from max. speed to 0 rpm, after the safety Settings from 1 - 9 in increments of 0.2 s.
2
reverse switch SAS has been released. Setting 1 = 0.3 s, setting 4 = 0.9 s, setting 9 = 1.9 s
(a). This is the time the electronic system needs to accelerate the motor on a test bench from 0 rpm to the specified speed. In practice, inertia, friction and other resistances will extend this time.
(b). This is the time the electronic system needs to decelerate the motor on a test bench from the starting speed to 0 rpm. In practice, inertia, friction and other resistances will extend this time.
DT 3000 Series
114
ELECTRICAL SYSTEM
DT 3040 -MF Software Parameter Settings

Three components of the truck data number are used to assign the truck's equipment to the parameters:
• Model number
• Steering type
• Platform type
Operating modes
Markings
X = Relevant
— = Not relevant
DT 3040 -MF (Sheet 1 of 3) Factory Settings
Display Description Range Perform- Perform- Perform-

ance set- ance set- ance set-
ting P1 ting P2 ting P3
Rider Travel Speed PF Maximum travel speed of unladen truck in direction of control handle. Settings from 1 - 9 in increments of 0.5 km/h.
Setting 1 = 7.5 km/h, setting 3 = 8.5 km/h, setting 5 = 9.5 km/h, setting 7 = 10.5 km/h, 7 5 3
setting 9 = 11.5 km/h
Rider Travel Speed FF Maximum travel speed of unladen truck in direction of forks. Settings from 1 - 9 in increments of 0.5 km/h.
Setting 1 = 7.5 km/h, setting 3 = 8.5 km/h, setting 5 = 9.5 km/h, setting 7 = 10.5 km/h, 7 5 3
setting 9 = 11.5 km/h
Rider Acceleration Time required(a) for the drive motor to accelerate in rider mode from 0 rpm to a speed Settings from 1 - 5.
2 3 4
corresponding to 8 km/h of the unladen truck in performance setting P1. Setting 1 is maximum acceleration, setting 5 minimum acceleration.
Rider Plugging Time required(b) for the drive motor to decelerate from a speed corresponding to 8 km/h Settings from 1 - 9 in increments of 0.2 s.
Setting 1 = 0.6 s, setting 3 = 1 s, setting 9 = 2.2 s
Rider Coasting Time required(b) for the drive motor to decelerate from a speed corresponding to 8 km/h Settings from 1 - 9 in increments of 0.2 s.
PLT Up Speed PF Maximum travel speed in pedestrian mode in direction of control handle. Settings from 1 - 9 in increments of 0.5 km/h.
6 km/h
PLT Up Speed FF Maximum travel speed in pedestrian mode in direction of forks. Settings from 1 - 9 in increments of 0.5 km/h.
6 km/h
PLT Down Speed PF Maximum travel speed in comfort mode in direction of control handle. Settings from 1 - 9 in increments of 0.5 km/h.
6 km/h
DT 3000 Series
115
ELECTRICAL SYSTEM

PLT Down Speed FF Maximum travel speed in comfort mode in direction of forks. Settings from 1 - 9 in increments of 0.5 km/h.
6 km/h
Walkie Acceleration Time required(a) for the drive motor to accelerate in pedestrian and comfort modes from Settings from 1 - 9 in increments of 0.2 s.
0 rpm to a speed corresponding to 6 km/h of the unladen truck in performance setting P1. Setting 1 is maximum acceleration, setting 9 minimum acceleration. 4 5 7
of the unladen truck to 0 rpm by changing direction in pedestrian and comfort modes. Setting 1 is maximum deceleration, setting 9 minimum deceleration. 3 3 4

Max EVP Limit for maximum current through the lowering valve PV. This determines the maximum Settings from 1 - 20 in increments of 0.4%
lowering speed. This parameter should only be changed after consultation with the Crown Setting 1 = 44.7 %, setting 19 = 51.8 %, setting 20 = 52.2 % 19
service department.
Min EVP Limit for minimum current through the lowering valve PV. This determines the minimum Settings from 1 - 20 in increments of 0.4%
lowering speed. This parameter should only be changed after consultation with the Crown Setting 1 = 11 %, setting 18 = 17.7 %, setting 20 = 18.5 % 18
service department.
EVP Open Delay PV lowering valve opening delay. Time taken to reach Min EVP. This setting determines Settings from 1 - 9 in increments of 0.05 s.
how softly or abruptly lifting takes place. This parameter should only be changed after Setting 1 = 0.0 s, setting 5 = 0.2 s, setting 9 = 0.4 s 5
consultation with the Crown service department.
EVP Close Delay PV lowering valve closing delay. This setting determines how softly or abruptly lifting stops Settings from 1 - 9 in increments of 0.05 s.
when the lowering switch is released. This parameter should only be changed after con- Setting 1 = 0.0 s, setting 4 = 0.15 s, setting 9 = 0.4 s 3
sultation with the Crown service department.
Pump Acceleration Time taken(b) for the pump motor to accelerate from 0 rpm to maximum speed. Settings from 1 - 9 in increments of 0.1 s.
4
Pump Deceleration Time taken(b) for the pump motor to decelerate from the maximum speed to 0 rpm. Settings from 1 - 9 in increments of 0.1 s.
1
DT 3000 Series
116
ELECTRICAL SYSTEM

Rider Turtle Speed Speed setting in rider mode when the HSS switch is set to “Turtle”. Settings from 1 - 9 in increments of 0.4 km/h
6
Setting 1 = 5 km/h, setting 7 = 7.2 km/h, setting 9 = 8 km/h
Walkie Turtle Speed Speed setting in pedestrian and comfort modes when the HSS switch is set to “Turtle”. Settings from 1 - 9 in increments of 0.3 km/h
4
Turtle Mode Brake Time(b) taken by the drive motor, after the BRS switch has been activated, to decelerate Settings from 1 - 9 in increments of 0.2 s.
4
from max. speed to 0 rpm. Setting 1 = 2.2 s, setting 4 = 2.8 s, setting 9 = 3.8 s
BB Acceleration Time(a) taken by the drive motor, after the safety reverse switch SAS has been activated, Settings from 1 - 9 in increments of 0.1 s. 4
to accelerate from 0 rpm to max. speed. Setting 1 = 0.9 s, setting 4 = 1.2 s, setting 9 = 1.7 s
BB Deceleration Time(b) taken by the drive motor, after the safety reverse switch SAS has been released, Settings from 1 - 9 in increments of 0.2 s.
2
to decelerate from max. speed to 0 rpm. Setting 1 = 0.3 s, setting 4 = 0.9 s, setting 9 = 1.9 s
DT 3000 Series
117
ELECTRICAL SYSTEM
DT 3040 -EF Software Parameter Settings

Three components of the truck data number are used to assign the truck's equipment to the parameters:
• Model number
• Steering type
• Platform type
Operating modes
Markings
X = Relevant
— = Not relevant
DT 3040 -EF (Sheet 1 of 3) Factory Settings

Rider Travel Speed PF Maximum travel speed of unladen truck in direction of control handle. Settings from 1 - 9 in increments of 0.5 km/h.
9 7 5
Setting 1 = 8.5 km/h, setting 5 = 10.5 km/h, setting 7 = 11.5 km/h, setting 9 = 12.5 km/h
Rider Travel Speed FF Maximum travel speed of unladen truck in direction of forks. Settings from 1 - 9 in increments of 0.5 km/h.
9 7 5
Setting 1 = 8.5 km/h, setting 5 = 10.5 km/h, setting 7 = 11.5 km/h, setting 9 = 12.5 km/h
Rider Acceleration Time required(a) for the drive motor to accelerate in rider mode from 0 rpm to a speed Settings from 1 - 5.
2 3 4
corresponding to 8 km/h of the unladen truck in performance setting P1. Setting 1 is maximum acceleration, setting 5 minimum acceleration.
Rider Plugging Time required(b) for the drive motor to decelerate from a speed corresponding to 8 km/h Settings from 1 - 9 in increments of 0.2 s.
Rider Coasting Time required(b) for the drive motor to decelerate from a speed corresponding to 8 km/h Settings from 1 - 9 in increments of 0.2 s.
PLT Up Speed PF Maximum travel speed in pedestrian mode in direction of control handle. Settings from 1 - 9 in increments of 0.5 km/h.
6 km/h
PLT Up Speed FF Maximum travel speed in pedestrian mode in direction of forks. Settings from 1 - 9 in increments of 0.5 km/h.
6 km/h
PLT Down Speed PF Maximum travel speed in comfort mode in direction of control handle. Settings from 1 - 9 in increments of 0.5 km/h.
6 km/h
DT 3000 Series
118
ELECTRICAL SYSTEM

PLT Down Speed FF Maximum travel speed in comfort mode in direction of forks. Settings from 1 - 9 in increments of 0.5 km/h.
6 km/h
Walkie Acceleration Time required(a) for the drive motor to accelerate in pedestrian and comfort modes from Settings from 1 - 9 in increments of 0.2 s.
0 rpm to a speed corresponding to 6 km/h of the unladen truck in performance setting P1. Setting 1 is maximum acceleration, setting 9 minimum acceleration. 4 5 7
of the unladen truck to 0 rpm by changing direction in pedestrian and comfort modes. Setting 1 is maximum deceleration, setting 9 minimum deceleration. 3 3 4

Panic Steering Setting to which the travel speed is reduced for a sudden steering angle. The travel speed Level 1 - 9
reduction takes effect when the difference in angle between the control handle and drive Setting 1 = 4.0 km/h, setting 4 = 7 km/h, setting 6 = 9 km/h, setting 9 = no travel speed 9 9 9
wheel > 25°. reduction
Max EVP Limit for maximum current through the TFD module. This parameter should only be Settings from 1 - 20 in increments of 0.4%
19
changed after consultation with the Crown service department. Setting 1 = 44.7 %, setting 19 = 51.8 %, setting 20 = 52.2 %
Min EVP Limit for minimum current through the TFD module. This parameter should only be Settings from 1 - 20 in increments of 0.4%
18
changed after consultation with the Crown service department. Setting 1 = 11 %, setting 18 = 17.7 %, setting 20 = 18.5 %
EVP Open Delay Delay from Min EVP to Max EVP. This parameter should only be changed after consulta- Settings from 1 - 9 in increments of 0.05 s.
5
tion with the Crown service department. Setting 1 = 0.0 s, setting 5 = 0.2 s, setting 9 = 0.4 s
EVP Close Delay Delay from Max EVP to Min EVP. This parameter should only be changed after consulta- Settings from 1 - 9 in increments of 0.05 s.
3
tion with the Crown service department. Setting 1 = 0.0 s, setting 4 = 0.15 s, setting 9 = 0.4 s
Pump Acceleration Time taken for pump motor to accelerate from 0 rpm to maximum speed. Settings from 1 - 9 in increments of 0.1 s.
4
Pump Deceleration Time taken for pump motor to decelerate from maximum speed to 0 rpm. Settings from 1 - 9 in increments of 0.1 s.
1
DT 3000 Series
119
ELECTRICAL SYSTEM

Rider Turtle Speed Speed setting in rider mode when the HSS switch is set to “Turtle”. Settings from 1 - 9 in increments of 0.4 km/h
6
Setting 1 = 5 km/h, setting 7 = 7.2 km/h, setting 9 = 8 km/h
Walkie Turtle Speed Speed setting in pedestrian and comfort modes when the HSS switch is set to “Turtle”. Settings from 1 - 9 in increments of 0.3 km/h
4
Turtle Mode Brake Time(b) taken by the drive motor to decelerate from max. speed to 0 rpm, after the BRS Settings from 1 - 9 in increments of 0.2 s.
4
switch has been activated. Setting 1 = 2.2 s, setting 4 = 2.8 s, setting 9 = 3.8 s
BB Acceleration Time(a) taken by the drive motor to accelerate from 0 rpm to max. speed, after the safety Settings from 1 - 9 in increments of 0.1 s. 4
reverse switch SAS has been activated. Setting 1 = 0.9 s, setting 4 = 1.2 s, setting 9 = 1.7 s
BB Deceleration Time(b) taken by the drive motor to decelerate from max. speed to 0 rpm, after the safety Settings from 1 - 9 in increments of 0.2 s.
2
reverse switch SAS has been released. Setting 1 = 0.3 s, setting 4 = 0.9 s, setting 9 = 1.9 s
DT 3000 Series
120
ELECTRICAL SYSTEM
Calibration
Calibration Calibrating the traction

Calibration is performed in the “SERVICE” menu under potentiometer
the “CALIBRATION” menu item on the display. To se-
lect the “CALIBRATION” menu proceed as follows: Travel direction definition
Selecting the CALIBRATION Menu
You can navigate through the menu structures using 1 2
the cursor keys ( , , , , ) on the display. An
overview of the menu structure can be found in Menu
Structure starting on page 75.
Fig. 72 Travel direction definition

1 Forward (FF)
2 Reverse (PF)
Requirements
• The truck is jacked up (see Transport and Storage,
page 13).
• The “CALIBRATION” menu is selected (see “Se-
Fig. 71 Display panel lecting the CALIBRATION Menu” on page 121).
Switching the truck on Selecting traction potentiometer calibration
1. Press the key for 1 second. 1. For trucks with a folding control handle set the con-
 The display screen is activated. trol handle to the travel zone. For trucks with a non-
Note: For trucks with a key switch, turn the key switch folding control handle stand on the platform.
right to the "On" position.  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 security 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
your PIN. 4. Press the key.
 The security prompt “SURE? Y” is displayed.
5. Enter the service PIN using the and keys and
Confirming the security prompt
press .
 The "ANALYZER" menu is displayed. 5. Press to confirm the security prompt.
 The prompt “C1.1 TURN ROCKER MAX FF &
6. Press the key until the “CALIBRATION” menu
MAX PF THEN ENTER” appears.
appears.
Traction potentiometer calibration
6. Press the key.
 The current voltage on the potentiometer slider
is displayed.
Note: In steps 7 and 8 move the travel switch very
slowly from the zero position to the stop. This should
take more than 3 seconds.
DT 3000 Series
121
ELECTRICAL SYSTEM
Calibration
7. Move the travel switch from the zero position as far Electric steering calibration
as the stop in the forks direction (FF), then slowly
back to the zero position. Calibration takes place in the following stages:
8. Move the travel switch from the zero position as far • Calibrate the control handle centre position
as the stop in the direction opposite to the forks • Calibrate the drive wheel forward travel
(PF), then slowly back to the zero position. • Calibrate the right steering lock
Note: If you move the control handle too quickly “Cali- • Calibrate the left steering lock
bration Failure” is displayed and you will have to repeat
steps 8 and 7. Requirements
• The front cover to the drive compartment is re-
9. Confirm with .
moved so that the drive wheel position can be seen.
 The security prompt “SAVE? N” is displayed.
Note: If you wish to cancel the calibration, press the lecting the CALIBRATION Menu” on page 121).
key now.
Selecting steering calibration
Saving the calibration
1. Using the key scroll through to the “C1 PF/FF
10. Press the key. ROCKER” menu.
 The security prompt “SAVE? Y” is displayed. 2. Using the key scroll through to the “C2 STEER
11. Confirm with . SYS” menu.
Activating the new setting and carrying out a test 3. Press the key.
run  The security prompt “SURE? N” is displayed.
12. Switch the truck off and on again. Note: If you wish to cancel the calibration, press the
 The new settings are activated. key now.
13. Carry out a test run. 4. Press the key.
5. Press the key.
 The “C2.1 ACQUIRE TILLER CENTER” menu
for calibrating the control handle centre position
is selected.
Calibrating the control handle centre position
1. Set the control handle to the centre position.
2. To confirm the centre position press the key to
select “CONFIRM” and press .
3. By pressing several times on the key, 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.
DT 3000 Series
122
ELECTRICAL SYSTEM
Calibration
Note: The drive wheel position only changes when you 3. Press the key to view the setting (1 to 9) (factory
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 drive wheel an-
Repeat the calibration as required. gle.
4. Press the key.  Press the key to decrease the drive wheel an-
gle.
 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 exactly at the 90° posi-
Calibrating the right steering lock
tion, use the key to select the “C2.5 ADJ FULL
Settings can be made from 1 to 9 for approximate and
RIGHT FINE” menu and fine-tune the setting again.
fine calibration tuning. For fine calibration the 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.
Fine-tuning the right steering lock Saving and activating all settings
1. Using the key select the “C2.5 ADJ FULL 1. Press the key.
RIGHT FINE” menu  The security prompt “SAVE? N” is displayed.
2. Move the control handle anti-clockwise as far as  If you do not wish to accept the settings, cancel
the stop and hold it in that position. the calibration with .
3. Press the key to view the setting. 2. To save the settings, press “SAVE? Y”.
4. Using the and keys change the display read- 3. To confirm the settings press .
ing by just one unit. This will indicate how far the  The display changes to the “C2 STEER SYS”
drive wheel position changes. menu.
 Press the key to increase the drive wheel an- 4. Wait approximately 5 seconds until the new set-
gle. tings are stored.
 Press the key to decrease the drive wheel an- 5. Switch the truck off and on again.
gle.  The new settings are now activated.
5. Confirm the drive wheel position with and posi- 6. Carry out a test run.
tion the control handle in the centre.  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
Proportional lift and lower calibra-
lock should only be given an approximate pre-setting. tion
To do this, proceed as follows:
Requirements
Right steering lock rough calibration
1. Using the key select the “C2.4 ADJ FULL lecting the CALIBRATION Menu” on page 121).
RIGHT COARSE” menu.
Selecting the calibration
2. Move the control handle anti-clockwise as far as
the stop and hold it in that position. 1. Using the key scroll through to the “C3 LIFT/
LOWER ROTARY ENCODER” menu.
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Calibration
2. Press the key.

 The security prompt “SURE? N” is displayed.
3. To continue press .
4. Press the key.
 “C3.1 PRESS LIFT MAX & LOWER MAX THEN
ENTER” is displayed.
Calibration
5. Press the "fork lift" switch and fully extend the
mast.
6. Press the "fork lower" switch and fully lower the
mast.
Saving the calibration and quitting the calibration
menu
7. Press the key.
 The new settings are stored.
 The display changes back to the “C3 LIFT/
LOWER ROTARY ENCODER” menu.
8. Wait for 5 seconds.
 After 5 seconds the new settings are stored.
Activating the new setting
9. Switch the truck off and on again.
 The new settings are activated.
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Event Codes
Event Codes Digit convention for event codes

The DT 3000 is fitted with an electronic control system
Starting Module concerned
for the key operating functions.
digit
Malfunctions with event code 6 Not used
display 7 Not used
Event codes are produced from tests carried out on the 8 Access 8.1 (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.
Digit convention 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).
Digit convention 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)
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Event Code 100 (DT 3040 -MW, -MF)

Event Code 100
Display: EV 100
Service LED: Off
Operator LED: Off
Explanation: Access 1 (display) has not received a reply from Access 3 (TCM) in 7 seconds.
Possible Causes: • Power supply to Access 3 disconnected
• CAN Bus connections faulty
• Software version of Access 1 does not match software version of
Access 2&3
Remedy: Check basic functionality of the display and communication with
Access 2&3
1. Select service level 2 (see page 71).
2. Press the key twice.
 A1.1 ACCESS 1 is displayed.
3. Press the key.
 A1.2 ACCESS 2&3 is displayed.
4. Press the key.
 If the status displayed is ON, proceed to step 5.
 If the status is OFF, proceed to step 9.
 If the display can no longer be operated, proceed to step 21.
Check the Access 1 software version
5. Press to scroll to the ANALYZER menu.
6. Press to scroll to the UTILITIES menu.
7. Press 3x.
 U1.1.1 MODULE PN/SOFTWARE PN is displayed.
 Compare the software version of Access 1 with the list on page 72.
8. If the software version displayed is not on the list, contact the Crown serv-
ice 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 10.
 If the software version is incorrect, proceed to step 21.
Check the power supply to Access 2&3
9. Measure the voltage on Access 2&3 from pin CA209-10 to BATT NEG.
 If the voltage is approximately the same as +BV, the power supply is ok.
Proceed to step 10.
 If there is no voltage, proceed to step 17.
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Check CAN Bus wiring and termination between Access 2&3 and
Access 1
10. Disconnect PC202 from the display.
11. Disconnect PC201 from Access 2&3.
12. Disconnect CA209.
13. Measure the load resistance between PC213-1 and PC213-2 (CAN con-
nection).
 If the resistance is 120 Ω, proceed to step 14.
 If the resistance is not 120 Ω, replace the resistor in connector PC214.
14. Measure the load resistance between JC2002-8 and JC200-9 (connector
on Access 1).
15. If the resistance is not 120 Ω, proceed to step 21.
16. Using a ohmmeter measure the resistance between PC200-8 and PC200-
28 and between PC200-9 and PC200-27.
 If the resistance < 2 Ω, the wires are ok. Proceed to step 18.
 If the resistance > 2 Ω, there is a fault in the wiring. Proceed to step 19.
Repair the power supply to Access 2&3
17. Locate and repair error in wiring between PC200-10 and FU2.
Check CAN Bus terminations
18. Restart the truck.
 If the fault persists, proceed to step 20.
Repair wiring
19. Repair the wiring.
Replace Access 2&3
20. Replace Access 2&3.
Replace Access 1
21. Replace Access 1.
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Event Code 202
Display: EV 202
Service LED: On
Operator LED: Off
Explanation: Voltage on 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 connections on pump motor M2
• Insulation resistances from the power cables or the winding of pump motor
M2 to the truck frame are too low
If the event is displayed during lifting:
• 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 connections
1. Check the power cables to pump motor M2 and its connections are secure
and check for damage.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and connections 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.
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ELECTRICAL SYSTEM
4. Using an ohmmeter measure the resistance from terminal −P on Access 2

to BATT NEG.
 If the resistance < 3 kΩ, the output stage is faulty. Replace Access 2&3.
 If the resistance > 100 kΩ, the output stage is ok. In this case the error
lies in the wiring of -P to pump motor M2 or the terminal on pump motor
M2.
has applied:
 If any cables are loose or damaged, rectify the cause.
6. Measure the insulation resistances from the motor winding 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 steps 3
to 4.
to the truck frame.
ponent.
Check the main contactor ED
10. Check the contacts of the main contactor for wear (see page 318).
 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 2&3.
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ELECTRICAL SYSTEM
Event Codes 203 - 204 (DT 3040 -MW, -MF)

Event Code 203
Display: EV 203
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 the power cables and connections
to the truck frame.
ponent.
 If the insulation resistance is ok, replace Access 2&3.
Event Code 204

Display: EV 204
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. Press the key.
 A1 Status is displayed.
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ELECTRICAL SYSTEM
3. Press the key.

 A2 Inputs is displayed.
4. Press the key.
5. Press the key.
6. Press the key.
 A2.2.1 RAS ENC is displayed.
7. Press the key 3 times.
 A2.2.4 PUMP MOTOR CURRENT is displayed.
8. Press the key.
 The current reading is displayed in Amps.
9. Activate lifting and check the reading.
 If the reading remains at 0 A as the motor is running, proceed to
step 10.
 If > 0 A is displayed while the motor is running, there is no error. Restart
the truck and check the event log.
Delete the EEPROM in Access 1
12. Using the key scroll through to the FEATURES menu.
13. Press the key,
 F1 LANGUAGE is displayed.
14. Using the key scroll through to the F8 EEPROM CLEAR menu.
15. Press the key.
 NO is displayed.
Note: This is a safety prompt. Press the key to cancel.
16. Press to scroll on.
 YES is displayed.
17. Press the key to scroll on.
 ACCESS 1 is displayed.
21. Press the key.
 The EEPROM in Access 1 is deleted.
 The display returns to ACCESS 1.
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ELECTRICAL SYSTEM

23. Re-calibrate the truck completely (see page 121).
 If the event code persists, proceed to step 24.
to the truck frame.
ponent.
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ELECTRICAL SYSTEM

Event Code 205
Display: EV 205
Service LED: On
Operator LED: Off
Explanation: While the pump motor is idle the current measured by Access 2 is > 0 A.
• Access 2 faulty
3. Press the key.
4. Press the key.
5. Press the key.
6. Press the key.
7. Press the key.
9. Press the key.
 If the reading remains at 0 A while the pump motor is idle, there is no
error. Restart the truck and check the event log.
 If a current of > 0 A is displayed while the pump motor is idle, proceed
to step 10.
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ELECTRICAL SYSTEM

13. Press the key,
15. Press the key.
20. Press the key.
to the truck frame.
ponent.
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ELECTRICAL SYSTEM

Event code 208
Display: EV 208
Service LED: On
Operator LED: Off
Explanation: As the truck is powered up, the voltage on the power part of Access 2 is not
0 V.
are shorted with respect to each other
• Access 2&3 is 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.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 228
Display: EV 228
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
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
3. Activate the connected components SV, HN, ALM and FLS in turn and
individually. In the process check if event 228 is displayed for one of these
components.
 If the event is displayed on one of the components, replace the compo-
nent or repair its wiring.
 If no short circuit is found in SV, HN, ALM or FLS, proceed to step 9.
Switch on the fan
5. Press the key.
6. Using the key scroll through to the A4 TEST OUTPUTS menu.
7. Press the key.
 A4.1 FAN is displayed.
8. Press the key.
 ENTER TO CANCEL is displayed and the fan runs for 5 seconds.
Note: Press to cancel the test prematurely.
 If event 228 is displayed, repair the wiring to the fan or replace the fan.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 229
Display: EV 229
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 short cir-
cuits or open connections.
 If there is a short or an open connection, repair the wiring.
 If the wiring is ok, proceed to step 3.
Activate the travel alarm driver output
Note: All drivers are internally monitored even if some options are not in-
stalled. All drivers must therefore be activated in order to test.
4. Press the key.
6. Press the key.
7. Using the key scroll through to the F2 TRAVEL ALARM ALM menu.
 The current setting OFF, BOTH, FF or PF is displayed.
8. If BOTH is not set, press .
 OFF is displayed.
9. Using the key, select BOTH.
10. Press the key.
 The travel alarm driver ALM is activated for both travel directions.
Activate the beacon driver output
11. Press the key.
 F2 TRAVEL ALARM ALM is displayed.
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ELECTRICAL SYSTEM
12. Using the key scroll through to the F3 BEACON FLS menu.
15. Press the key.
 The beacon driver FLS is activated for both travel directions.
16. Disconnect the + wires (red/white) from all the components connected to
the drivers. Make wires to the unused driver outputs accessible.
17. Using an ohmmeter measure in turn each driver output of the - wires
(green/white) to BATT NEG.
 If the resistance is at least 10 kΩ, the respective driver output is ok.
 If less than 10 kΩ is measured on a driver output, proceed to step 18.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 230
Display: EV 230
Service LED: On
Operator LED: Off
Explanation: One or more of the following components have an internal short circuit: FAN,
SV1, SV2, 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 8.
 If the truck starts normally, proceed to step 2.
Isolate the error in the power circuits of the connected components
2. Activate the connected components BR, SV1, SV2, HN, ALM and FS in
turn and individually. In the process check for which component event
EV 230 is displayed.
Note: If both options ALM and FS are installed, adjust them before the test so
that they do not switch simultaneously. (In the FEATURES menu set the op-
tions F2 TRAVEL ALARM ALM to FF and F3 BEACON FLS to PF.)
 If event 230 is displayed for one of these components, proceed to
step 9.
 If event 230 is not displayed, switch on the fan (FAN). Proceed to
step 3.
Note: The fan (FAN) must be switched on via level 3:
Switch on the fan
4. Press the key.
6. Press the key.
7. Press the key.
 If event 230 is not displayed, proceed to step 10.
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ELECTRICAL SYSTEM
Measure the affected component

8. Disconnect the + wire (red/white) and the - wire (green/white) from the re-
spective component.
Note: If ALM or FLS are affected, disconnect the + wire (red/white) and the -
wire (green/white) from both components.
9. Using an ohmmeter measure the resistance of the triggering component.
– Line = 30 Ω
– BR = 13 Ω
– FAN > 100 kΩ
– PV, SV1, SV2 = 21 Ω
– HN > 100 kΩ
– ALM > 100 kΩ
– FLS > 100 kΩ
 If the resistance at ALM and FLS is at least 6 MΩ these components are
ok. Proceed to step 10.
 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 10.
 If for resistance for one component (except for ALM and FLS) does not
match the above values, replace the component.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 231
Display: EV 231
Service LED: On
Operator LED: Off
Explanation: The control module has detected an open circuit on the lowering valve (PV)
Possible Causes: • Faulty coil on lowering valve
• Disconnected circuit to lowering valve
• Access 2 faulty
Remedy: Test the lower command
2. Press the key.
3. Press the key.
4. Press the key.
5. Press the key.
6. Press the key.
7. Press the key.
 A2.2.1 LOS ENC is displayed.
8. Press the key.
 The current reading (0 if not activated) is displayed.
9. Apply the fork lower switch (LOS ENC) and check the display.
 If a reading > 0 is displayed, there is no error. Restart the truck and
check the event log.
 If the reading remains at 0, proceed to step 10.
Check wiring and lowering valve for physical damage
10. Check wiring and lowering valve (PV) for physical damage.
 If there is no physical damage, proceed to step 11.
 If there is physical damage present, repair the damaged parts.
Check the coil of the lowering valve (PV)
11. Open both wires on PV and measure the valve coil resistance.
 If the resistance is > 100 Ω, replace the valve coil.
 If the resistance < 100 Ω, proceed to step 12.
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ELECTRICAL SYSTEM
Check the lowering valve power supply

12. Using a voltmeter measure between the + wire (red/white) on PV and
BATT NEG.
 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 13.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 232
Display: EV 232
Service LED: On
Operator LED: Off
Explanation: The control module has detected an open circuit leading to EVP2.
Note: Output EVP2 is not used. Pin CA201-23 is therefore not occupied.
Possible Causes: • Faulty wiring from pin CA201-23 on Access 2&3, or a short to this pin.
• Access 2 faulty
Remedy: Check pin CA201-23 for shorts and faulty wiring
1. Check pin CA201-23 for attached conductors or a short to the neighbour-
ing pins.
 Remove any conductors attached. Rectify any shorts.
 If there is no fault, proceed to step .2.
Replace Access 2&3
Event code 233

Display: EV 233
Service LED: On
Operator LED: Off
Explanation: The control module has detected a fault in the coil of EVP2.
• Access 2 faulty
ing pins.
 If there is no fault, proceed to step 2.
Replace Access 2&3

Event code 234
Display: EV 234
Service LED: On
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ELECTRICAL SYSTEM
Operator LED: Off

Explanation: The control module has detected a fault on the coil of the lowering valve (PV).
Possible Causes: • Faulty coil on lowering valve (PV)
• Disconnected circuit to lowering valve (PV)
• Access 2 faulty
2. Press the key.
3. Press the key.
4. Press the key.
5. Press the key.
6. Press the key.
7. Press the key.
8. Press the key.
 If a value > 0 is displayed, proceed to step 11.
10. LOS ENC, check wiring and lowering valve for physical damage.
Check the coil resistance of the lowering valve
11. Open both wires on the lowering valve and measure the valve coil resist-
ance.
 If the resistance ≈ 30 Ω, the coil is ok. Proceed to step 13
 If the resistance < 25 Ω or > 35 Ω, replace the coil.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 236
Display: EV 236
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 the basic function of the pressure transducer
2. Press the key.
3. Using the key scroll through to the A2 INPUTS menu.
4. Press the key.
5. Press the key.
 A2.2 RAS ENC is displayed.
6. Press the key.
 A2.2.1 TEMP ACCESS 2&3 is displayed.
7. Using the key scroll through to the
A2.2.3 PRESSURE TRANSDUCER PS1 menu.
8. Press the key.
 The current reading (0 - 255) is displayed.
9. Place the load on the forks, raise it and lower it again fully. Monitor the
display in the process.
 If the reading changes while the load is being raised and is restored
when the load is deposited, the wiring and transducer are ok.
 If the display does not change, proceed to step 10.
Check the power supply
10. Measure the voltage from CA214-2 (on the pressure transducer) to BATT
NEG. It should be ≈ +13 V.
11. Measure the voltage (GND) from CA204-1 to BATT NEG. It should be
≈ 0 V.
 If the voltages measured are correct, the 13 V power supply is ok. Re-
place the pressure transducer.
 If there is no +13 V supply, repair the disconnection in the wiring be-
tween CA214-2 and CA201-25.
 If a higher reading than +13V is measured at CA204-2, the control mod-
ule is faulty. Replace controller.
 If a higher reading than 1 V is measured at CA204-1, the control module
is faulty. Replace controller.
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ELECTRICAL SYSTEM

Event code 239
Display: EV 239
Service LED: On
Operator LED: Off
Explanation: Readings of pressure transducer PS2 are out of range
Possible Causes: • Wiring error
• Power supply faulty
• Pressure transducer faulty
• Access 2&3 faulty
Remedy: Check the wiring and transducer PS2
1. Place the load on the outriggers but do not raise it.
3. Press the key.
4. Press the key.
5. Press the key.
6. Press the key.
7. Press the key.
9. Activate outrigger lift.
 If the reading changes as the outriggers lift and lower, the wiring and
transducer are ok. Restart the truck. If the event occurs again, proceed
to step 10.
 If the reading does not change, proceed to step 10.
Check positive power supply for transducer PS2
10. Measure the voltage from CA223-2 to BATT NEG.
 If the voltage is approx. 13 V, the positive power supply is ok.
 If there is no power supply, proceed to step 11.
11. Measure the voltage at CA201-25 (Access 2&3).
 If the voltage is approx. 13 V, the positive power supply is available.
Probable error in wiring, proceed to step 13.
 If there is no voltage, the control module is faulty. Proceed to step 16.
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ELECTRICAL SYSTEM
Check negative power supply for transducer PS2

 If the voltage is approx. 0 V, the negative power supply is probably ok.
Proceed to step 14.
 If the voltage is > 0.5 V, proceed to step 16.
Repair wiring
13. Repair the wiring between CA201-25 and CA223-2.
14. Check the wiring between CA201-5 and CA223-1.
 Repair the wiring if faulty.
Replace the PS2 transducer
15. Replace the PS2 transducer.
 If the fault still persists, proceed to step 16.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 300
Display: EV 300
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
3. Press the key.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Check the time and temperature for the last recorded event.
 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 7.
Replace Access 2&3
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Event code 301
Display: EV 301
Service LED: On
Operator LED: Off
Explanation: EEPROM storage error in Access 3
Possible Causes: • Intermittent internal error in Access 3
• Access 3 faulty
Replace Access 2&3

Event code 302
Display: EV 302
Service LED: On
Operator LED: Off
Explanation: As the truck is switched on, before the main contactor closes, a current of >
0 A is detected in the output stage.
Possible Causes: • +Batt and BATT NEG 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
NEG.
 Repair the terminals if faulty.
 If the terminals are ok, proceed to step 2.
Replace Access 2&3
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Event code 303
Display: EV 303
Service LED: On
Operator LED: Off
Explanation: Phase voltage out of range
• Access 3 faulty
1. Check power cable terminals, in particular +Batt and BATT NEG on
Access 3. Check terminals for corrosion or overheating.
Replace Access 2&3
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Event code 304
Display: EV 304
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 2&3 exceeds 35 V.
Possible Causes: • Battery voltage drop
• Voltage drop via fuse FU2, relay K 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
2. Press the key.
3. Press the key.
 P1 SET P1 is displayed.
4. Using the key scroll through to the P11 ADJUST BATTERY menu.
5. Press the key.
6. Using keys and , set the voltage measured on the battery.
9. Proceed to step 22.
10. Using the key scroll through to the A3 OUTPUTS menu.
11. Press the key.
 A3.1 BATTERY % is displayed.
12. Press the key.
 A3.2 BATTERY VOLTAGE is displayed.
13. Press the key.
 The current battery voltage reading is displayed.
14. Record the reading (it should be ≈ 24 V).
Note: Do not use 48 V batteries.
15. 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 22.
 If there is a difference, proceed to step 16.
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Compare internally measured battery voltage with actual battery voltage

16. Press to scroll back to the ANALYZER menu.
17. Press to scroll to the PERFORMANCE menu.
18. Press the key.
20. Press the key.
 The current reading is displayed.
21. Using keys and , set the previously measured reading and enter it
with .
Check for battery voltage drop
22. Press to scroll back to the PERFORMANCE menu.
24. Press the key.
 A1 STATUS is displayed.
26. Press the key.
27. Press the key.
28. Press the key.
29. 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 30.
Measure the voltage drop on the signal line from Access 2&3
 If the voltage is approximately the same as the battery voltage (≈ 24 V),
the signal line is ok. Proceed to step 35.
Note: The voltage at CA201-10 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 K or the key switch. However, this is only a few tenths of a volt.
 If the voltage is less than 22 V, proceed to step 31.
Establish the cause of the voltage drop on the signal wire
31. Measure the input and output voltage of the signal switch on the main
contactor.
 If there is no significant voltage drop, proceed to step 32.
 If the voltage drops extremely, replace main contactor ED.
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32. Measure the input and output voltage of fuse FU2.

 If the voltage drops extremely, replace FU2.
33. Measure the voltage at pin 30 (input) and pin 87 (output) of relay K. If the
truck has a key switch, measure the key switch input and output voltages.
 If the voltage drops extremely, replace relay K or the key switch.
34. 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 K
– Pin 87 on relay K and pin CA201-10
 If the voltage drops extremely on one wire, repair the wire or connec-
tions.
Replace Access 2&3
(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.
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Event code 305
Display: EV 305
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 NEG.
 If there is a short to +BV/BATT NEG, replace the motor.
Replace Access 2&3
Event code 306

Display: EV 306
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.
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Replace Access 2&3


Event code 307
Display: EV 307
Service LED: On
Operator LED: Off
Explanation: On power up a test is performed to check 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 contacts of the main contactor (see page 318).
 If the contacts are welded, replace the contacts or the main contactor.
 If the main contactor is ok, proceed to step 3.
Replace Access 2&3
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Event code 308
Display: EV 308
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 2&3.
 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 1
– From pin 87 on relay K to the +pin of the main contactor coil (LINE)
 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 lead (green/white) to the coil on the main contactor for
continuity to pin PC201-12.
 If it is disconnected, repair the wiring.
Check the main contactor coil
5. Disconnect both signal cables from the coil.
6. Measure the coil resistance with an ohmmeter.
 If the coil resistance is significantly less or more than ≈ 30 Ω, replace
the main contactor or coil.
 If the coil is ok, proceed to step 7.
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Replace Access 2&3


Event code 309
Display: EV 309
Service LED: On
Operator LED: Off
Explanation: Current flows to output stage when truck is idle
Possible Causes: • Access 3 faulty
Replace Access 2&3
Event code 310

Display: EV 310
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 wiring diagram and Crown's options list, check if any unauthor-
ised consumers are connected parallel to the capacitor bank from +Batt on
Access 3 to BATT NEG.
 If an unauthorised consumer is installed, disconnect it. Proceed to
step 2.
 If no unauthorised consumers are installed, proceed to step 3.
Replace Access 2&3
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Event code 314
Display: EV 314
Service LED: On
Operator LED: Off
Explanation: Main contactor driver shorted or wiring disconnected
Possible Causes: • Short circuit or disconnection in the wire from CA201-12 to the main con-
tactor coil
• Access 3 faulty
Remedy: Check the wiring for short circuits
1. Using an ohmmeter with the truck switched off measure from CA201-12 to
BATT NEG on Access 2&3.
 If the resistance < 5 kΩ, remove the short circuit 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. Proceed to step 5.
Replace Access 2&3
Repair the main contactor
5. Replace the coil.
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Event code 315
Display: EV 315
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 FU2 over pin 30 to pin 87 on relay K
– From pin 87 on relay K to the +pin of the main contactor coil
Check the signal line and coil terminals
 If the coil resistance is less than ≈ 30 Ω, replace the main contactor or
coil.
Replace Access 2&3
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Event code 316
Display: EV 316
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 no short circuit is found, 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. Disconnect 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 contac-
tor or coil.
Replace Access 2&3
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Event code 317
Display: EV 317
Service LED: On
Operator LED: Off
Explanation: The zero point of the traction potentiometer deviates by more than 1 V from the
calibrated value 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
2. Press the key.
4. Press the key.
6. Press the key.
7. Using the key scroll through to the A2.3.5 > DRIVE POT menu.
8. 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 121).
 If the display does not revert to the same reading in neutral, the traction
potentiometer is faulty. Replace the traction potentiometer (see
page 338). Now calibrate the traction potentiometer (see page 121).
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Event code 320
Display: EV 320
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
2. Press the key.
4. Press the key.
event, Access 1 is ok. Proceed to step 6.
Check CAN Bus wiring and terminations between Access 3 and
Access 1.
7. Measure the resistance between CA213-1 and CA213-2.
 If the resistance is 60 Ω, the CAN Bus termination is ok. Proceed to
step 14.
 If the resistance is not 60 Ω, proceed to step 8.
8. Disconnect PC202 from Access 1.
 If the resistance is 0 Ω, the CAN Bus wiring is ok. Proceed to step 11.
11. Measure the load resistance between JC200-8 and JC200-9 (bushing on
Access 1).
12. Measure the resistance between PC201-27 and PC201-28.
 If the resistance is 120 Ω, Access 2&3 is ok. Restart the truck and check
the event log.
Repair wiring
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Replace Access 2&3

Replace Access 1

Event code 321
Display: EV 321
Service LED: On
Operator LED: Off
Explanation: Incorrect truck model selected.
Possible Causes: • Control module replaced and not set
Remedy: Set the truck model
2. Press the key.
4. Press the key,
5. Using the key scroll through to the F4 TRUCK TYPE menu.
6. Press the key.
 3040MW is displayed.
7. Use the key to select the correct model. (Refer to the data plate on the
truck and page 4, Truck Data Number).
8. Press the key.
 The selected model is stored.
9. Set the parameters (see page 113) and calibrate the truck (see page 121).
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Event code 322
Display: EV 322
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 from CA201-2 to BATT NEG. It should be ≈ +BV.
 If the voltage ≈ +BV, proceed to step 2.
 If the voltage is not ≈ +BV, remove the short between the positive cable
(red/white) on the brake and PC201-2.
2. Undo the brake negative terminal (green/white) from CA201-4.
Replace Access 2&3
Event code 326

Display: EV 326
Service LED: On
Operator LED: Off
Explanation: Power output stage short circuit
Possible Causes: • Short circuit in the power cables
• Controller 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 NEG.
 If any cables or terminals are shorted, rectify the cause.
to the truck frame.
ponent.
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Check control module

5. Unscrew the cables to terminals U, V and W on the control module.
6. Using an ohmmeter measure the resistance from terminal U on the control
module to +Batt and then to BATT NEG.
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.
Replace Access 2&3

Event code 328
Display: EV 328
Service LED: On
Operator LED: Off
Explanation: Controller faulty
Possible Causes: • Controller faulty
Remedy: Replace Access 2&3
Event code 329

Display: EV 329
Service LED: On
Operator LED: Off
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Event code 333
Display: EV 333
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 PC201-1.
Check the brake coil
 If the resistance is not ≈ 13 Ω ±10%, replace the brake.
Event code 334

Display: EV 334
Service LED: On
Operator LED: Off
Explanation: Occurs only in connection with EV 328
Possible Causes: • None
Remedy: 1. No action required, the alarm goes out automatically.
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Event code 337
Display: EV 337
Service LED: On
Operator LED: Off
Explanation: Temperature gauge in the control module returns values beyond the measur-
ing range of -80°C to +120°C.
Possible Causes: • Display faulty
• Access 3 faulty
Test Access 1
3. Press the key.
5. Press the key.
 If no event is recorded, replace Access 1.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 338
Display: EV 338
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. Make sure the battery cables are 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 voltage 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 1.
2. Press the key.
4. Press the key.
5. Press the key.
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.
9. Press the key.
11. Press the key.
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Event code 341
Display: EV 341
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 PC201 from Access 3 and the negative wire (green/white)
from the brake.
2. Check wire (pin PC201-4) for continuity.
 If the wire is ok, proceed to step 3.
 If the wire is disconnected, repair the wire.
3. Connect PC201 and the cable (green/white) to the brake. Measure the
voltage 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 PC201-4 and BATT NEG.
 If the resistance < 5 kΩ, proceed to step 5.
 If the resistance is > 5 kΩ, repair the wiring.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 342
Display: EV 342
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 travel switch zero position
2. Press the key.
3. Press the key.
4. Press the key.
6. Press the key.
7. Using the key scroll through to A2.3.3 FF SWITCH.
8. Press the key.
 If OFF is displayed, the switch is ok. Proceed to step 9.
 If ON is displayed, the error either lies with connector CA411 or the
control module is faulty. Proceed to step 12.
9. Using the key scroll back to A2.2.3 TEMP ACCESS 2&3.
10. Press the key.
 A2.3.4 PF SWITCH is displayed.
11. Press the key.
Check wiring
12. Check connector CA411 in the control handle for corrosion and short cir-
cuits.
 If the connector is ok, proceed to step 14.
 If the connector is not ok, proceed to step 13.
Replace potentiometer and main PC board
13. Replace potentiometer and main PC board in the control handle.
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Replace Access 2&3

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Event code 343
Display: EV 343
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
2. Press the key.
3. Press the key.
4. Press the key.
6. Press the key.
7. Using the key scroll through to A2.3.15 ECR1.
8. Press the key.
 The encoder pulses are displayed (0 pulses when system idle).
9. Accelerate the truck and monitor the display.
 If 0 pulses are displayed when idle and ± 15000 pulses at full travel
speed, the encoder is ok. Restart the truck and check the event log.
 If 0 pulses are not displayed in idle and/or ± 15000 pulses are not dis-
played at full speed, proceed to step 10.
Check wiring
10. Check the encoder wiring, including connector CA202, for:
– Corrosion
– Loose connections
– Faulty crimp connections on the pins
– Trapped wires
 If no damage is discovered, proceed to step 11
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Check the 12 volt supply

11. Measure the voltage (+13 V) at CA202-1 (on ECR1) to BATT NEG. It
should be ≈ +13 V.
≈ 0 V.
 If the voltages measured in steps 11 and 12 are correct, the 13 V power
supply is ok. Proceed to step 13.
ule is faulty. Proceed to step 14.
is faulty. Proceed to step 14.
Check the sensor bearing for physical damage
13. Monitor the operating noise of the traction motor.
 If the motor rattles, the encoder (sensor bearing) is probably damaged.
Repair or replace the motor (see page 304).
 If no physical damage is found, restart the truck and check the event
log.
Replace Access 2&3
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Event code 348
Display: EV 348
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: Test the parking brake
1. Check the parking brake for damage (see page 325).
Event code 351

Display: EV 351
Service LED: On
Operator LED: Off
Explanation: RAM copy error.
Possible Causes: • Static charge
• Insulation resistance too low
Check for static charge
2. Travel for a short time then exit the truck and touch the panel.
 If an electrostatic discharge occurs, proceed to step 3.
 If no electrostatic discharge occurs, proceed to step 6.
Fit anti-static tape
3. Fit a standard commercial anti-static tape to the bottom of the truck.
Note: The connection point on the truck should be metallic bright before as-
sembly
4. Protect the connection point on the truck from corrosion.
5. Travel again for a short time.
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Test the insulation resistance of the truck

6. Test the insulation resistance of the truck.
 If the insulation resistance is too short, locate and replace the faulty
component.

Event code 352
Display: EV 352
Service LED: On
Operator LED: Off
Explanation: Wrong software version.
Possible Causes: • Wrong software version
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Event code 353
Display: EV 353
Service LED: On
Operator LED: Off
Explanation: Thermal sensor TS1 in the traction motor returns values beyond the measuring
range of -40°C to +200°C.
• Thermal sensor faulty
2. Press the key.
4. Press the key.
6. Press the key.
7. Check the temperature display.
8. Measure the temperature on the motor housing.
 If the temperature on the motor housing is approx. 10°C lower, the ther-
mal sensor TS1 is ok. Proceed to step 13.
 If the difference in temperature is greater than approx. 10°C, proceed to
step 9.
Test thermal sensor
Note: For the following test the internal motor temperature should be approx.
20°C.
9. Disconnect CA203 and measure the resistance of thermal sensor TS1 be-
tween pins JC203-5 and JC203-6.
 If the resistance ≈ 600 Ω (at 20°C internal motor temperature), proceed
to step 10.
 If the resistance differs from this value, the thermal sensor is faulty.
Replace traction motor M1 (see page 304).
Check wiring
10. Check wires from PC203-5 to PC201-5 and PC203-6 to PC201-22 with an
ohmmeter.
 If the resistance in a wire is ≈ 0 Ω, the wiring is ok. Proceed to step 11.
 If the resistance differs from this value, repair the wiring.
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Check the thermal sensor voltage readings

11. Connect PC212, switch on the truck.
12. Measure the voltage between CA201-5 and CA201-22 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 13.
 If the voltage is not correct, replace traction motor M1 (see page 278).
Replace Access 2&3

Event code 354
Display: EV 354
Service LED: On
Operator LED: Off
Explanation: No positive supply for the SMART driver within Access 2&3.
Possible Causes: • FU3 faulty
• Faulty wiring
Remedy: Check fuse
1. Check fuse FU3.
 If FU3 has blown, replace it with a new 4 A/32 V fuse.
 If the fuse is ok, proceed to step 2.
Check wiring
 If the supply is not ≈ 24 V, repair the wire between FU3 and CA201-3.
 If the supply is ≈ 24 V , the wiring is ok. Proceed to step 3.
Replace Access 2&3
Event code 355

Display: EV 355
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
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Event code 356
Display: EV 356
Service LED: On
Operator LED: Off
Explanation: Error in FLASH memory of Access 2&3
Fit anti-static tape
2. Fit a standard commercial anti-static tape to the bottom of the truck.
sembly
4. Switch the truck on and off again.
5. Disconnect the battery, wait for 6 seconds and then connect the battery.
6. Power up the truck.
Import the software
7. If possible and applicable, download the software for Access 3.
8. Delete the EEPROM and reset and calibrate the truck.
Note: If you cannot re-install the software, replace Access 2&3.
Replace Access 2&3
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Event code 357
Display: EV 357
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 CA201-2, the brake and CA201-4 for disconti-
nuity and shorts.
Test 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.
Replace Access 2&3
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Event code 358
Display: EV 358
Service LED: On
Operator LED: Off
Explanation: Current sensor in Access 3 out of range.
Possible Causes: • Access 2&3 faulty
Replace Access 2&3
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Event code 359
Display: EV 359
Service LED: On
Operator LED: Off
Explanation: Traction potentiometer voltage exceeds the limit set during calibration by more
than 0.4 V.
Possible Causes: • Potentiometer drift
• Direction switch drift
• Faulty calibration
• Sluggish or jammed moving parts
• Wiring error
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 mechanism is ok, proceed to step 2.
Calibrate traction potentiometer
2. Calibrate the traction potentiometer (see page 121).
 If the error no longer occurs, the problem is resolved.
 If the error re-occurs, proceed to step 3.
Test direction switch
2. Press the key.
3. Press the key.
4. Press the key.
6. Press the key.
8. Press the key.
 The current status is displayed.
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9. Apply the travel switch in the forks direction (FF) while monitoring the dis-
play.
 If the travel switch changes from OFF to ON, proceed to step 10.
 If the switch is not working, replace the traction potentiometer (see
page 338). Then calibrate the traction potentiometer.
11. Press the key.
12. Press the key.
13. Apply the travel switch in the opposite direction to the forks (PF) while
monitoring the display.
page 338). Now calibrate the traction potentiometer.
Check traction potentiometer for disconnections
16. Press the key.
 The current voltage is displayed.
17. Slowly apply the travel switch in both directions while observing the dis-
play.
 If the reading increases from 0 - 10 V ±10% without interruptions and
also returns to 0 in the same manner, the traction potentiometer is ok.
Restart the truck and check the event log.
 If there is a disconnection or fluctuations in the signal, replace the trac-
tion potentiometer (see page 338). Now calibrate the traction potenti-
ometer.
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Event code 361
Display: EV 361
Service LED: On
Operator LED: Off
Explanation: Voltage reference for ACCESS 2&3 differs from the voltage +BV(AK)
• Main contactor faulty
• Faulty wiring
1. Check condition of fuse FU3.
 Replace the fuse if faulty.
Check wiring
2. Check the wiring between FU3 and CA201-3 for discontinuity and shorts
to BATT NEG.
 Repair the wiring if damaged.
3. Check the condition of the main contactor contacts (see page 318).
 If the contacts are ok, proceed to step 4.
Check the main contactor power cable connections
4. Check the main contactor power cable connections for loose cables, cor-
rosion and burning.
 If there is physical damage present, repair the affected parts.
Replace Access 1
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Event code 362
Display: EV 362
Service LED: On
Operator LED: Off
Effect: • The traction current cuts out and the main contactor ED drops.
• Access 1 faulty
• Access 3 faulty
Test Access 1
3. Press the key.
5. Press the key.
Replace Access 2&3
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Event Code 364
Display: EV 364
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 condition of side restraint sensors SR1 and SR2
2. Press the key.
3. Press the key.
4. Press the key.
6. Press the key.
7. Using the key scroll through to A2.3.11 SR1 SENSOR.
8. Press and check the reading of the SR1 sensor (ON or OFF).
9. Press the key.
12. Compare the switch status of SR1 and SR2 with the Input Signals table on
page 105.
 If the statuses match, proceed to step 25.
 If the statuses do not match, proceed to step 13.
Check connection and attachment
13. Check sensor connection and attachment.
 Repair the connection or attachments if these are not ok.
 If the connection and attachments are ok, proceed to step 14.
Test the sensors
14. Using a suitable piece of metal connect SR1 and SR2 directly while mon-
itoring the display and the LEDs on the sensors.
 If the sensors are ok, proceed to step 15.
 Replace the sensors if faulty.
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Check the truck model setting

17. Press the key,
19. Press the key.
 The truck setting is displayed.
 If the correct model is set, proceed to step 20.
 If the wrong model is set, correct it accordingly.
Check the software version number
 Press the key twice.
FEATURES is displayed.
20. Using the key scroll through to the UTILITIES menu.
 U1.1 Access 1 is displayed.
22. Press to scroll to the U1.2 ACCESS 2&3 menu.
 The software version is displayed.
24. Compare the version number with the table on page 72.
 If the correct software version is being used, proceed to step 25.
 If the software version is incorrect, install the correct version or proceed
to step 25.
Replace Access 2&3
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Event code 365
Display: EV 365
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 from Access 2&3 to traction motor M1 for dam-
age.
 Replace any physically damaged cables.
2. Unscrew the power cables from the traction motor and Access 2&3.
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.
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Event Code 100 (DT 3040 -EF)
Event Code 100

Display: EV 100
Service LED: Off
Operator LED: Off
Explanation: Access 1 (display) has not received a reply from Access 3 (TCM) in 7 seconds.
Possible Causes: • Power supply to Access 3 disconnected
• CAN Bus connections faulty
• Software version of Access 1 does not match software version of
Access 2&3
Remedy: Check basic functionality of the display and communication with
Access 2&3
3. Press the key.
 A1.2 ACCESS 2&3 is displayed.
4. Press the key.
 If the status displayed is ON, proceed to step 5.
 If the status is OFF, proceed to step 9.
 If the display can no longer be operated, proceed to step 21.
Check the Access 1 software version
6. Press to scroll to the UTILITIES menu.
7. Press 3x.
 U1.1.1 MODULE PN/SOFTWARE PN is displayed.
 Compare the software version of Access 1 with the list on page 72.
8. If the software version displayed is not on the list, contact the Crown serv-
ice 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 10.
 If the software version is incorrect, proceed to step 21.
Check the power supply to Access 2&3
9. Measure the voltage on Access 2&3 from pin CA209-10 to BATT NEG.
 If the voltage is approximately the same as +BV, the power supply is ok.
Proceed to step 10.
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Check CAN Bus wiring and termination between Access 2&3 and
Access 1.
10. Disconnect PC202 from the display.
nection).
 If the resistance is not 120 Ω, replace the resistor in connector PC214.
Access 1).
15. If the resistance is not 120 Ω, proceed to step 21.
16. Using a ohmmeter measure the resistance between PC200-8 and PC200-
28 and between PC200-9 and PC200-27.
 If the resistance < 2 Ω, the wires are ok. Proceed to step 18.
 If the resistance > 2 Ω, there is a fault in the wiring. Proceed to step 19.
Repair the power supply to Access 2&3
17. Locate and repair error in wiring between PC200-10 and FU2.
Check CAN Bus terminations
 If the fault persists, proceed to step 20.
Repair wiring
Replace Access 2&3
Replace Access 1
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ELECTRICAL SYSTEM

Event Code 202
Display: EV 202
Service LED: On
Operator LED: Off
Explanation: Voltage on 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 connections on pump motor M2
• Contacts of main contactor ED are worn
Remedy: If the event is displayed during power up, but before the main contactor
applies:
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.
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4. Using an ohmmeter measure the resistance from terminal −P on Access 2

to BATT NEG.
 If the resistance < 3 kΩ, the output stage is faulty. Replace Access 2&3.
 If the resistance > 100 kΩ, the output stage is ok. In this case the error
lies in the wiring of -P to pump motor M2 or the terminal on pump motor
M2.
has applied:
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 steps 3
to 4.
to the truck frame.
ponent.
Check the main contactor ED
10. Check the contacts of the main contactor for wear (see page 318).
 If all the above measures have been carried out and the event code per-
sists, replace Access 2&3.
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Event Codes 203 - 204 (DT 3040 -EF)

Event Code 203
Display: EV 203
Service LED: On
Operator LED: Off
Explanation: Voltage on terminal −P of Access 2 (HCM) is higher than the battery voltage
• Access 2 faulty
to the truck frame.
ponent.
Event Code 204

Display: EV 204
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
2. Press the key.
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3. Press the key.

4. Press the key.
5. Press the key.
6. Press the key.
8. Press the key.
 The current reading is displayed in Amps.
9. Activate lifting and check the reading.
 If the reading remains at 0 A as the motor is running, proceed to
step 10.
 If > 0 A is displayed while the motor is running, there is no error. Restart
the truck and check the event log.
13. Press the key,
15. Press the key.
21. Press the key.
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to the truck frame.
ponent.

Event Code 205
Display: EV 205
Service LED: On
Operator LED: Off
Explanation: While the pump motor is idle the current measured by Access 2 is > 0 A.
• Access 2 faulty
3. Press the key.
4. Press the key.
5. Press the key.
6. Press the key.
7. Press the key.
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9. Press the key.

 If the reading remains at 0 A while the pump motor is idle, there is no
error. Restart the truck and check the event log.
 If a current of > 0 A is displayed while the pump motor is idle, proceed
to step 10.
13. Press the key,
15. Press the key.
20. Press the key.
to the truck frame.
ponent.
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Event code 208
Display: EV 208
Service LED: On
Operator LED: Off
Explanation: As the truck is powered the voltage on the power part of Access 2 is not 0 V.
are shorted with respect to each other
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.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 228
Display: EV 228
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
Locate the affected driver
3. Activate the connected components SV, HN, ALM and FLS in turn and
individually. In the process check if event 228 is displayed for one of these
components.
 If the event is displayed on one of the components, replace the compo-
nent or repair its wiring.
Switch on the fan
5. Press the key.
7. Press the key.
8. Press the key.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 229
Display: EV 229
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 line 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 short cir-
cuits or open connections.
 If there is a short or an open connection, repair the wiring.
Activate the travel alarm driver output
Note: All drivers are internally monitored even if some options are not in-
stalled. All drivers must therefore be activated in order to test.
4. Press the key.
6. Press the key.
7. Using the key scroll through to the F2 TRAVEL ALARM ALM menu.
10. Press the key.
 The travel alarm driver ALM is activated for both travel directions.
Activate the beacon driver output
11. Press the key.
 F2 TRAVEL ALARM ALM is displayed.
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12. Using the key scroll through to the F3 BEACON FLS menu.
15. Press the key.
 The beacon driver FLS is activated for both travel directions.
16. Disconnect the + wires (red/white) from all the components connected to
the drivers. Make wires to the unused driver outputs accessible.
17. Using an ohmmeter measure in turn each driver output of the - wires
(green/white) to BATT NEG.
 If the resistance is at least 10 kΩ, the respective driver output is ok.
 If less than 10 kΩ is measured on a driver output, proceed to step 18.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 230
Display: EV 230
Service LED: On
Operator LED: Off
Explanation: One or more of the following components have an internal short circuit: FAN,
SV1, SV2, 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 8.
 If the truck starts normally, proceed to step 2.
Isolate the error in the power circuits of the connected components
2. Activate the connected components BR, SV1, SV2, HN, ALM and FS in
turn and individually. In the process check for which component event
EV 230 is displayed.
Note: If both options ALM and FS are installed, adjust them before the test so
that they do not switch simultaneously. (In the FEATURES menu set the op-
tions F2 TRAVEL ALARM ALM to FF and F3 BEACON FLS to PF.)
 If event 230 is displayed for one of these components, proceed to
step 9.
 If event 230 is not displayed, switch on the fan (FAN). Proceed to
step 3.
Note: The fan (FAN) must be switched on via level 3:
Switch on the fan
4. Press the key.
6. Press the key.
7. Press the key.
 If event 230 is not displayed, proceed to step 10.
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Measure the affected component

8. Disconnect the + wire (red/white) and the - wire (green/white) from the re-
spective component.
Note: If ALM or FLS are affected, disconnect the + wire (red/white) and the -
wire (green/white) from both components.
9. Using an ohmmeter measure the resistance of the triggering component.
– Line = 30 Ω
– BR = 13 Ω
– FAN > 100 kΩ
– PV, SV1, SV2 = 21 Ω
– HN > 100 kΩ
– ALM > 100 kΩ
– FLS > 100 kΩ
 If the resistance at ALM and FLS is at least 6 MΩ these components are
ok. Proceed to step 10.
 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 10.
 If for resistance for one component (except for ALM and FLS) does not
match the above values, replace the component.
Replace Access 2&3

Event code 231
Display: EV 231
Service LED: On
Operator LED: Off
Explanation: The control module has detected an open circuit on the lowering valve (PV)
Possible Causes: • Faulty coil on lowering valve
• Disconnected circuit to lowering valve
• Access 2 faulty
2. Press the key.
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3. Press the key.

4. Press the key.
5. Press the key.
6. Press the key.
7. Press the key.
8. Press the key.
9. Apply the fork lift switch (RAS ENC) and check the display.
 If a reading > 0 is displayed, there is no error. Restart the truck and
check the event log.
10. Check wiring and lowering valve (PV) for physical damage.
Check the coil of the lowering valve (PV)
11. Open both wires on PV and measure the valve coil resistance.
 If the resistance is > 100 Ω, replace the valve coil.
 If the resistance < 100 Ω, proceed to step 12.
Check the lowering valve power supply
12. Using a voltmeter measure between the + wire (red/white) on PV and
BATT NEG.
 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 13.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 232
Display: EV 232
Service LED: On
Operator LED: Off
Explanation: The control module has detected an open circuit leading to EVP2.
• Access 2 faulty
ing pins.
 If there is no fault, proceed to step .2.
Replace Access 2&3
Event code 233

Display: EV 233
Service LED: On
Operator LED: Off
Explanation: The control module has detected a fault in the coil of EVP2.
• Access 2 faulty
ing pins.
 If there is no fault, proceed to step 2.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 234
Display: EV 234
Service LED: On
Operator LED: Off
Explanation: The control module has detected a fault on the coil of the lowering valve (PV).
Possible Causes: • Faulty coil on lowering valve (PV)
• Disconnected circuit to lowering valve (PV)
• Access 2 faulty
2. Press the key.
3. Press the key.
4. Press the key.
5. Press the key.
6. Press the key.
7. Press the key.
8. Press the key.
 If a value > 0 is displayed, proceed to step 11.
10. LOS ENC, check wiring and lowering valve for physical damage.
Check the coil resistance of the lowering valve
11. Open both wires on the lowering valve and measure the valve coil resist-
ance.
 If the resistance ≈ 30 Ω, the coil is ok. Proceed to step 12.
 If the resistance < 25 Ω or > 35 Ω, replace the coil.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 235
Display: EV 235
Service LED: On
Operator LED: Off
Explanation: Lift / lower encoder signal out of range.
Possible Causes: • Proportional lift and lower not calibrated
• Lift / lower encoder faulty
• Access 2 faulty
Remedy: Calibrate proportional lift and lower
1. Calibrate proportional lift and lower calibration (see page 121).
 If the event code is then still displayed, proceed to step 2.
Check the hydraulic PC board
3. Press the key.
4. Press the key.
5. Press the key.
6. Using the key scroll through to A2.4 Access 8.1.
7. Press the key.
8. Press the key.
 If an output value (0 - 255 digits) is displayed, proceed to step 9.
 If nothing is displayed, replace the hydraulic PC board (see page 337).
9. Press the key.
10. Press the key.
11. Press the key.
 If an output value (0 - 255 digits) is displayed, proceed to step 12.
 If nothing is displayed, replace the hydraulic PC board (see page 337).
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 236
Display: EV 319
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 the basic function of the pressure transducer
2. Press the key.
4. Press the key.
5. Press the key.
 A2.2 RAS ENC is displayed.
6. Press the key.
8. Press the key.
 The current reading (0 - 255) is displayed.
9. Place the load on the forks, raise it and lower it again fully. Monitor the
display in the process.
 If the reading changes while the load is being raised and is restored
when the load is deposited, the wiring and transducer are ok.
 If the display does not change, proceed to step 10.
10. Measure the voltage from CA214-2 (on the pressure transducer) to BATT
NEG. It should be ≈ +13 V.
≈ 0 V.
 If the voltages measured are correct, the 13 V power supply is ok. Re-
place the pressure transducer.
ule is faulty. Replace the control module.
is faulty. Replace controller.
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Event code 237
Display: EV 237
Service LED: On
Operator LED: Off
Explanation: This event is displayed if the truck speed > 6.3 km/h for more than 3 seconds
and there is still pressure in the traction cylinder.
• PV or SV3 valves faulty
Remedy: Lower the load and re-start the truck
1. Fully lower the raised load.
 If the event code no longer occurs, check the event log.
 If the event occurs again, proceed to step 3.
Check lowering valve PV
 If the voltage ≈24 V, the wiring and valve coil are ok. Proceed to step 7.
 If there is no supply, proceed to step 4.
Check valve coil on PV for continuity
4. Disconnect both wires from PV.
5. Using an ohmmeter check the valve coil for continuity.
 If the coil is continuous, proceed to step 6.
 If the coil is not continuous, replace the valve coil.
Repair wiring to PV
6. Remove disconnection from wire 5907 or 2903.
Check SV3 valve
 If the voltage ≈24 V, the wiring and valve coil are ok. Replace
ACCESS 2&3.
 If there is no supply, proceed to step 8.
Check valve coil on SV3 for continuity
8. Disconnect both wires from SV3.
9. Using an ohmmeter check the valve coil for continuity.
 If the coil is continuous, proceed to step 10.
 If the coil is not continuous, replace the valve coil.
Repair wiring to SV3
10. Remove disconnection from wire 5912 or 2943.
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Event code 238
Display: EV 238
Service LED: On
Operator LED: Off
Explanation: Pressure correction for traction cylinder exceeds the permissible timeframe of
6 - 8 s.
Possible Causes: • Leak in hydraulic system
• Sluggish power unit cage
Remedy: Check the hydraulic system for leaks
1. Visually inspect the hydraulic system for leaks, perform drift tests (see
page 55).
 If there is a leak, repair the hydraulic system.
 If the hydraulic system is not leaky, proceed to step 2.
Check power unit cage for freedom of movement
2. Check power cage for freedom of movement.
 If the cage is sluggish, repair the cage suspension.
 If it is not sluggish, contact the Crown service department.

Event code 239
Display: EV 239
Service LED: On
Operator LED: Off
Explanation: Readings of pressure transducer PS2 are out of range
• Power supply faulty
• Pressure transducer faulty
Remedy: Check the wiring and transducer PS2
1. Place the load on the outriggers but do not raise it.
3. Press the key.
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4. Press the key.

5. Press the key.
6. Press the key.
7. Press the key.
9. Activate outrigger lift.
 If the reading changes as the outriggers lift and lower, the wiring and
transducer are ok. Restart the truck. If the event occurs again, proceed
to step 10.
 If the reading does not change, proceed to step 10.
Check positive power supply for transducer PS2
 If the voltage is approx. 13 V, the positive power supply is ok.
 If there is no power supply, proceed to step 11.
11. Measure the voltage at CA201-25 (Access 2&3).
 If the voltage is approx. 13 V, the positive power supply is available.
Probable error in wiring, proceed to step 13.
 If there is no voltage, the control module is faulty. Proceed to step 16.
Check negative power supply for transducer PS2
 If the voltage is approx. 0 V, the negative power supply is probably ok.
Proceed to step 14.
 If the voltage is > 0.5 V, proceed to step 16.
Repair wiring
13. Repair the wiring between CA201-25 and CA223-2.
14. Check the wiring between CA201-5 and CA223-1.
Replace the PS2 transducer
15. Replace the PS2 transducer.
 If the fault still persists, proceed to step 16.
Replace Access 2&3
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Event code 300
Display: EV 300
Service LED: On
Operator LED: Off
• Access 1 is faulty
• Access 3 faulty
1. Switch off the truck, disconnect the battery, wait for 6 seconds , connect
Test Access 1
3. Press the key.
5. Press the key.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 301
Display: EV 301
Service LED: On
Operator LED: Off
Explanation: EEPROM storage error in Access 3
Possible Causes: • Intermittent internal error in Access 3
• Access 3 faulty
Replace Access 2&3

Event code 302
Display: EV 302
Service LED: On
Operator LED: Off
Explanation: As the truck is switched on, before the main contactor closes, a current of >
0 A is detected in the output stage.
• Access 3 faulty
NEG.
Replace Access 2&3
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Event code 303
Display: EV303
Service LED: On
Operator LED: Off
Explanation: Phase voltage out of range
• Access 3 faulty
NEG. Check terminals for corrosion or overheating.
Replace Access 2&3
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Event code 304
Display: EV 304
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 2&3 exceeds 35 V.
Possible Causes: • Battery voltage drop
• Voltage drop via fuse FU2, relay K 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
2. Press the key.
3. Press the key.
5. Press the key.
9. Proceed to step 10.
11. Press the key.
12. Press the key.
13. Press the key.
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18. Press the key.
20. Press the key.
with .
24. Press the key.
26. Press the key.
27. Press the key.
28. Press the key.
with a new one.
Measure the voltage drop on the signal line from Access 2&3
 If the voltage is approximately the same as the battery voltage (≈ 24 V),
the signal line is ok. Proceed to step 35.
Note: The voltage at CA201-10 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 K or the key switch. However, this is only a few tenths of a volt.
 If the voltage is less than 22 V, proceed to step 31.
Establish the cause of the voltage drop on the signal line
31. Measure the input and output voltage of the signal switch on the main
contactor.
 If the voltage drops extremely, replace main contactor ED.
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32. Measure the input and output voltage of fuse FU2.

 If the voltage drops extremely, replace FU2.
33. Measure the voltage at pin 30 (input) and pin 87 (output) of relay K. If the
truck has a key switch, measure the key switch input and output voltages.
 If the voltage drops extremely, replace relay K or the key switch.
34. 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 K
– Pin 87 on relay K and pin CA201-10
 If the voltage drops extremely on one wire, repair the wire or connec-
tions.
Replace Access 2&3
(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.
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Event code 305
Display: EV 305
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.
Replace Access 2&3
Event code 306

Display: EV 306
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.
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Replace Access 2&3


Event code 307
Display: EV 307
Service LED: On
Operator LED: Off
Explanation: On power up a test is performed to check 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.
2. Check the contacts of the main contactor (see page 318).
 If the contacts are welded, replace the contacts or the main contactor.
 If the main contactor is ok, proceed to step 3.
Replace Access 2&3
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Event code 308
Display: EV 308
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 2&3.
 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 5.
wires:
– From pin 87 on relay K to the +pin of the main contactor coil (LINE)
 If the coil resistance is significantly less or more than ≈ 30 Ω, replace
the main contactor or coil.
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Replace Access 2&3


Event code 309
Display: EV 309
Service LED: On
Operator LED: Off
Explanation: Current flows to output stage when truck is idle
Replace Access 2&3
Event code 310

Display: EV 310
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 wiring diagram and Crown's options list, check if any unauthor-
ised consumers are connected parallel to the capacitor bank from +Batt on
Access 3 to BATT NEG.
 If an unauthorised consumer is installed, disconnect it. Proceed to
step 2.
 If no unauthorised consumers are installed, proceed to step 2.
Replace Access 2&3
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Event code 314
Display: EV 314
Service LED: On
Operator LED: Off
Explanation: Main contactor driver shorted or wiring disconnected
Possible Causes: • Short circuit or disconnection in the wire from CA201-12 to the main con-
tactor coil
• Access 3 faulty
Remedy: Check the wiring for short circuits
1. Using an ohmmeter with the truck switched off measure from CA201-12 to
BATT NEG on Access 2&3.
 If the resistance < 5 kΩ, remove the short circuit 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 line 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. Proceed to step 5.
Replace Access 2&3
Repair the main contactor
5. Replace the coil.
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Event code 315
Display: EV 315
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 pin 87 on relay K to the +pin of the main contactor coil
 If the voltage on one line drops extremely or if there is no voltage, repair
coil.
Replace Access 2&3
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Event code 316
Display: EV 316
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 no short circuit is found, 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. Disconnect both signal cables from the main contactor coil.
coil.
 If the coil resistance is less than ≈ 13 Ω ±10%, replace the main contac-
tor or coil.
Replace Access 2&3
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Event code 317
Display: EV 317
Service LED: On
Operator LED: Off
Explanation: The zero point of the traction potentiometer deviates by more than 1 V from the
calibrated value and the travel switch is open.
Possible Causes: • Physical defect on the traction potentiometer
• Traction potentiometer replaced but not calibrated
2. Press the key.
4. Press the key.
6. Press the key.
8. 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 121).
 If the display does not revert to the same reading in neutral, the traction
potentiometer is faulty. Replace the traction potentiometer (see
page 338). Now calibrate the traction potentiometer (see page 121).
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Event code 320
Display: EV 320
Service LED: On
Operator LED: Off
Explanation: CAN Bus communication failure between Access 3 and Access 1.
2. Press the key.
4. Press the key.
Check CAN Bus wiring and terminations between Access 3 and
Access 1.
 If the resistance is 60 Ω, the CAN Bus termination is ok. Proceed to
step 14.
8. Disconnect PC202 from Access 1.
 If the resistance is 0 Ω, the CAN Bus wiring is ok. Proceed to step 11.
Access 1).
 If the resistance is 120 Ω, Access 2&3 is ok. Restart the truck and check
the event log.
Repair wiring
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Replace Access 2&3

Replace Access 1

Event code 321
Display: EV 321
Service LED: On
Operator LED: Off
Explanation: Incorrect truck model selected.
Possible Causes: • Control module replaced and not set
Remedy: Set the truck model
2. Press the key.
4. Press the key,
6. Press the key.
7. Use the key to select the correct model. (Refer to the data plate on the
truck and page 4, Truck Data Number).
8. Press the key.
 The selected model is stored.
9. Set the parameters (see page 113) and calibrate the truck (see page 121).
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Event code 322
Display: EV 322
Service LED: On
Operator LED: Off
Explanation: Short circuit in the brake positive wire
 If the voltage is not ≈ +BV, remove the short between the positive cable
(red/white) on the brake and PC201-2.
2. Undo the brake negative terminal (green/white) from CA201-4.
Replace Access 2&3
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 wires 2925 and 5906 from the coil.
 If the 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. Disconnect wires 2908 and 5900 from the brake coil.
 If the 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 short circuits.
 If there is a short, repair the wire.
 If the wires are ok, proceed to step 6.
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Replace Access 2&3


Event code 326
Display: EV 326
Service LED: On
Operator LED: Off
Explanation: Power output stage short circuit
• 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 NEG.
 If any cables or terminals are shorted, rectify the cause.
to the truck frame.
ponent.
Check control module
5. Unscrew the cables to terminals U, V and W on the control module.
6. Using an ohmmeter measure the resistance from terminal U on the control
module to +Batt and then to BATT NEG.
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.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 328
Display: EV 328
Service LED: On
Operator LED: Off
Event code 329

Display: EV 329
Service LED: On
Operator LED: Off
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Event code 333
Display: EV 333
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 PC201-1.
Check the brake coil
 If the resistance is not ≈ 13 Ω ±10%, replace the brake.
Event code 334

Display: EV 334
Service LED: On
Operator LED: Off
Explanation: Occurs only in connection with EV 328
Possible Causes: • None
Remedy: 1. No action required, the alarm goes out automatically.
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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.
3. Press the key.
Check CAN Bus
 If the resistance is 60 Ω, the CAN Bus is ok. Proceed to step 10.
 If the resistance is not 60 Ω, proceed to step 4.
Check the wiring
4. Remove CA228 from Access 5 and CA200 from Access 1.
 If the resistance is very high (∞), the wiring is ok. Proceed to step 6.
 If the resistance is not ∞, repair the wiring.
Measure the load resistance in Access 1 and Access 5
6. Measure the resistance between JC200-8 and -9 on Access 1.
 If the resistance is 120 Ω, Access 1 is ok. Proceed to step 7.
7. Measure the resistance between JC228-14 and -96 on Access 5.
 If the resistance is 120 Ω, Access 5 is ok. Proceed to step 10.
Replace Access 5
Replace Access 1
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ELECTRICAL SYSTEM
Replace Access 2&3


Event code 337
Display: EV 337
Service LED: On
Operator LED: Off
Explanation: Temperature gauge in the control module returns values beyond the measur-
ing range of -80°C to +120°C.
• Access 3 faulty
Test Access 1
3. Press the key.
5. Press the key.
 If no event is recorded, replace Access 1.
Replace Access 2&3
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Event code 338
Display: EV 338
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. Make sure the battery cables are 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 voltage 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 1.
2. Press the key.
4. Press the key.
5. Press the key.
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.
9. Press the key.
11. Press the key.
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Event code 341
Display: EV 341
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 PC201 from Access 3 and the negative wire (green/white)
from the brake.
2. Check wire (pin PC201-4) for continuity.
 If the wire is ok, proceed to step 3.
 If the wire is disconnected, repair the wire.
3. Connect PC201 and the cable (green/white) to the brake. Measure the
voltage at both brake terminals to BATT NEG.
 If there is no 24 volt supply, replace the brake.
4. Measure the resistance between PC201-4 and BATT NEG.
 If the resistance < 5 kΩ, proceed to step 5.
 If the resistance is > 5 kΩ, repair the wiring.
Replace Access 2&3
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Event code 342
Display: EV 342
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 travel switch zero position
2. Press the key.
3. Press the key.
4. Press the key.
6. Press the key.
8. Press the key.
10. Press the key.
11. Press the key.
Check wiring
12. Check connector CA411 in the control handle for corrosion and short cir-
cuits.
 If the connector is ok, proceed to step 14.
 If the connector is not ok, proceed to step 13.
Replace potentiometer and main PC board
13. Replace potentiometer and main PC board in the control handle.
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Replace Access 2&3


Event code 343
Display: EV 343
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
2. Press the key.
3. Press the key.
4. Press the key.
6. Press the key.
7. Using the key scroll through to A2.3.15 ECR1.
8. Press the key.
 The encoder pulses are displayed (0 pulses when system idle).
9. Accelerate the truck and monitor the display.
 If 0 pulses are displayed when idle and ± 15000 pulses at full travel
speed, the encoder is ok. Restart the truck and check the event log.
 If 0 pulses are not displayed in idle and/or ± 15000 pulses are not dis-
played at full speed, proceed to step 10.
Check wiring
10. Check the encoder wiring, including connector CA202, for:
– Corrosion
– Loose connections
– Faulty crimp connections on the pins
– Trapped wires
 If no damage is discovered, proceed to step 11
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Check 12 V supply
11. Measure the voltage (+13 V) at CA202-1 (on ECR1) to BATT NEG. It
should be ≈ +13 V.
≈ 0 V.
 If the voltages measured in steps 11 and 12 are correct, the 13 V power
supply is ok. Proceed to step 13.
ule is faulty. Proceed to step 14.
is faulty. Proceed to step 14.
Check the sensor bearing for physical damage
13. Monitor the operating noise of the traction motor.
 If the motor rattles, the encoder (sensor bearing) is probably damaged.
Repair or replace the motor (see page 304).
 If no physical damage is found, restart the truck and check the event
log.
Replace Access 2&3
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Event code 348
Display: EV 348
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: Test the parking brake
1. Check the parking brake for damage (see page 325).
Event code 351

Display: EV 351
Service LED: On
Operator LED: Off
Explanation: RAM copy error.
Check for static charge
2. Travel for a short time then exit the truck and touch the panel.
 If an electrostatic discharge occurs, proceed to step 3.
 If no electrostatic discharge occurs, proceed to step 6.
Fit anti-static strap
3. Fit a standard commercial anti-static strap to the bottom of the truck.
sembly
5. Travel again for a short time.
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Test the insulation resistance of the truck

6. Test the insulation resistance of the truck.
 If the insulation resistance is too short, locate and replace the faulty
component.

Event code 352
Display: EV 352
Service LED: On
Operator LED: Off
Explanation: Wrong software version.
Possible Causes: • Wrong software version
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Event code 353
Display: EV 353
Service LED: On
Operator LED: Off
Explanation: Thermal sensor TS1 in the traction motor returns values beyond the measuring
range of -40°C to +200°C.
2. Press the key.
4. Press the key.
6. Press the key.
7. Check the temperature display.
 If the temperature on the motor housing is approx. 10°C lower, the ther-
mal sensor TS1 is ok. Proceed to step 13.
 If the difference in temperature is greater than approx. 10°C, proceed to
step 9.
Test thermal sensor
20°C.
 If the resistance ≈ 600 Ω (at 20 °C internal motor temperature), proceed
to step 10.
Replace traction motor M1 (see page 304).
Check wiring
10. Check wires from PC203-5 to PC201-5 and PC203-6 to PC201-22 with an
ohmmeter.
 If the resistance in a wire is ≈ 0 Ω, the wiring is ok. Proceed to step 11.
 If the resistance differs from this value, repair the wiring.
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Check the thermal sensor voltage readings

11. Connect PC212, switch on the truck.
12. Measure the voltage between CA201-5 and CA201-22 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 13.
 If the voltage is not correct, replace traction motor M1 (see page 304).
Replace Access 2&3

Event code 354
Display: EV 354
Service LED: On
Operator LED: Off
Explanation: No positive supply for the SMART driver within Access 2&3.
• Faulty wiring
Remedy: Check fuse
1. Check fuse FU3.
 If FU3 has blown, replace it with a new 4 A/32 V fuse.
Check wiring
Replace Access 2&3
Event code 355

Display: EV 355
Service LED: On
Operator LED: Off
Explanation: Excessive or low voltage when the truck is switched on
Possible Causes: • See event code 304
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ELECTRICAL SYSTEM

Event code 356
Display: EV 356
Service LED: On
Operator LED: Off
Explanation: Error in FLASH memory of Access 2&3
Fit anti-static strap
2. Fit a standard commercial anti-static strap to the bottom of the truck.
sembly
4. Switch the truck on and off again.
5. Disconnect the battery, wait for 6 seconds and then connect the battery.
Importing the software
7. If possible and applicable, download the software for Access 3.
8. Delete the EEPROM and reset and calibrate the truck.
Note: If you cannot re-install the software, replace Access 2&3.
Replace Access 2&3
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Event code 357
Display: EV 357
Service LED: On
Operator LED: Off
Explanation: Brake driver (SMART driver) does not supply an output signal
• Brake coil faulty
1. Check the wiring between CA201-2, the brake and CA201-4 for disconti-
nuity and shorts.
Test 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.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 358
Display: EV 358
Service LED: On
Operator LED: Off
Explanation: Current sensor in Access 3 out of range.
Possible Causes: • Access 2&3 faulty
Replace Access 2&3
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ELECTRICAL SYSTEM

Event code 359
Display: EV 359
Service LED: On
Operator LED: Off
Explanation: Traction potentiometer voltage exceeds the limit set during calibration by more
than 0.4 V.
Possible Causes: • Potentiometer drift
• Direction switch drift
• Faulty calibration
• Sluggish or jammed moving parts
• Wiring error
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 mechanism is ok, proceed to step 2.
Calibrate traction potentiometer
2. Calibrate the traction potentiometer (see page 121).
 If the error no longer occurs, the problem is resolved.
 If the error re-occurs, proceed to step 3.
Test direction switch
2. Press the key.
3. Press the key.
4. Press the key.
6. Press the key.
8. Press the key.
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9. Apply the travel switch in the forks direction (FF) while monitoring the dis-
play.
11. Press the key.
12. Press the key.
13. Apply the travel switch in the opposite direction to the forks (PF) while
Check traction potentiometer for disconnections
16. Press the key.
 The current voltage is displayed.
17. Slowly apply the travel switch in both directions while observing the dis-
play.
 If the reading increases from 0 - 10 V ±10% without interruptions and
also returns to 0 in the same manner, the traction potentiometer is ok.
Restart the truck and check the event log.
 If there is a disconnection or fluctuations in the signal, replace the trac-
tion potentiometer (see page 338). Now calibrate the traction potenti-
ometer.
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Event code 361
Display: EV 361
Service LED: On
Operator LED: Off
Explanation: Voltage reference for ACCESS 2&3 differs from the voltage +BV(AK)
• Faulty wiring
1. Check condition of fuse FU3.
Check wiring
2. Check the wiring between FU3 and CA201-3 for discontinuity and shorts
to BATT NEG.
3. Check the condition of the main contactor contacts (see page 318).
 If the contacts are ok, proceed to step 4.
Check the main contactor power cable connections
4. Check the main contactor power cable connections for loose cables, cor-
rosion and burning.
 If there is physical damage present, repair the affected parts.
Replace Access 1
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ELECTRICAL SYSTEM

Event code 362
Display: EV 362
Service LED: On
Operator LED: Off
• Access 1 faulty
• Access 3 faulty
Test Access 1
3. Press the key.
5. Press the key.
Replace Access 2&3
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ELECTRICAL SYSTEM

Event Code 364
Display: EV 364
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
2. Press the key.
3. Press the key.
4. Press the key.
6. Press the key.
9. Press the key.
12. Compare the switch status of SR1 and SR2 with the Input Signals table on
page 107.
Check connection and attachment
13. Check sensor connection and attachment.
 Repair the connection or attachments if these are not ok.
 If the connection and attachments are ok, proceed to step 14.
Test the sensors
14. Using a suitable piece of metal connect SR1 and SR2 directly while mon-
itoring the display and the LEDs on the sensors.
 If the sensors are ok, proceed to step 15.
 Replace the sensors if faulty.
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Check the truck model setting

17. Press the key,
19. Press the key.
 The truck setting is displayed.
Checking the software version number
 Press the key twice.
FEATURES is displayed.
20. Using the key scroll through to the UTILITIES menu.
 U1.1 Access 1 is displayed.
22. Press to scroll to the U1.2 ACCESS 2&3 menu.
 The software version is displayed.
24. Compare the version number with the table on page 72.
 If the correct software version is being used, proceed to step 25.
 If the software version is incorrect, install the correct version or proceed
to step 25.
Replace Access 2&3
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Event code 365
Display: EV 365
Service LED: On
Operator LED: Off
Explanation: Short in one of the phases U, V or W
• Traction motor M1 faulty
1. Check the power cables from Access 2&3 to traction motor M1 for dam-
age.
 Replace any physically damaged cables.
2. Unscrew the power cables from the traction motor and Access 2&3.
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.

Event code 368
Display: EV 368
Service LED: On
Operator LED: Off
Explanation:
Possible Causes: • Temporary fault due to high vertical acceleration
• TFD module faulty
Replace TFD module
2. Replace TFD module.
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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
 If the event code occurs, proceed to step 2.
Test Access 1
3. Press the key.
5. Press the key.
Replace Access 5
Event Code 501

Display: EV501
Service LED: On
Operator LED: Off
Explanation: EEPROM error in Access 5.
Replace Access 5
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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
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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 cables to steer motor M3 and its connections are secure
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.
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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 > 0 A.
Possible Causes: • Error in output stage of Access 5
• Error in current sensor of Access 5
Replace Access 5
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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
4. Press the key.
5. Using the key scroll through to the A2 5 ACCESS 5 menu.
6. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
7. Using the key scroll through to the A2.5.3 STEER MOTOR CURRENT
menu.
8. Press the key.
 The current flowing through the output stage of Access 5 is displayed.
 If the reading is 0 A, restart the truck. Check the event log.
 If the resistance with the steer motor idle is > 15 Ω, proceed to step 9.
10. Press to scroll to the FEATURES menu.
11. Press the key.
13. Press the key.
14. Press the key.
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15. Press the key.

16. Press to scroll to the ACCESS 5 menu.
17. Press the key.
18. Press the key.
19. Confirm with .
 The EEPROM is deleted.
21. Test the insulation resistance on the motor windings and the power cables.
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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
• Access 5 faulty
Remedy: Check power fuse FU2
1. Check power fuse FU2 (30 A) on Access 5.
3. Press the key.
5. Press the key.
6. Press the key.
7. Press the key.
12. Press the key.
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14. Press the key.

with .
18. Press the key.
20. Press the key.
21. Press the key.
22. Press the key.
with a new one.
Check Access 5 for possible input voltage drop
24. Measure the voltage from CA228-A7 (on Access 5) to Batt NEG.
 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 25.
Check for voltage drop over fuse F2
26. Measure the input and output voltage from fuse FU2 to Batt NEG.
 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 27.
Check the signal switch in the main contactor
27. 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 28.
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Check the power part of the main contactor

28. Check the power cables on the main contactor and its connections are
secure and check for damage.
 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, connections and main contactor are ok, proceed to
step 29.
Replace Access 5

Event code 511
Display: EV511
Service LED: On
Operator LED: Off
Explanation: No current at phase U
• Access 5 faulty
Remedy: See event code 510.
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Event code 512
Display: EV512
Service LED: On
Operator LED: Off
Explanation: No current at phase W
• Access 5 faulty
Remedy: See event code 510.
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.
 If the wiring is not damaged, proceed to step 2.
Check the ECR2 encoder connector is wired correctly
2. Using the circuit diagram on page 411 (Fig. 156) and the cable numbers
indicated, check if wires to CA226 or CA234 have been connected incor-
rectly.
 If CA226 has been wired incorrectly, replace PC226-2 with PC226-3
(see page 411, Fig. 156).
 If CA234 has been wired incorrectly, replace PC227-B7 with PC227-B8
(see page 411, Fig. 156).
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Event code 514
Display: EV514
Service LED: On
Operator LED: Off
Explanation: An error in one of the 2 redundant steering potentiometer curves has occurred.
• Excessive impact on truck
• Steering potentiometer 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 potentiometer
2. Set the steering to the centre position.
4. Press the key.
6. Press the key.
8. Press the key.
9. Press to scroll to the A2.5.4 STEER POT1 menu.
10. Press the key.
 The output voltage of STEER POT1 is displayed.
11. Slowly change the steering from the left stop to the right while monitoring
the display.
 The readings should increase or decrease without interruption and be
approximately the same (approx. 2.5 V).
13. Press the key.
 A2.5.5 STEER POT2 is displayed.
14. Press the key.
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 If both potentiometers are working correctly, re-calibrate the steering

(see page 122). Proceed to step 15.
 If there is a disconnection in one of the two potentiometers, proceed to
step 16.
Check the TFD module wiring
16. Check the connections from CA224 (TFD module) to CA227 (Access 5)
and CA201-15 (Access 2&3). For wiring diagram see page 411 (Fig. 156).
 If there is a wiring error, repair the wiring.
 If the wiring is ok, replace the TFD module.
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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
3. Remove wire 2936 and pin from PC228-A4.
4. Reconnect PC228.
5. Measure the voltage directly on wire 2936 to BATT NEG.
 If the voltage is 0 VDC, proceed to step 6.
Check wire 2916 for a short
6. Measure the resistance between wire 2936 and Batt NEG.
 If there is a short to Batt NEG, proceed to step 7.
 If the resistance ∞ (> MΩ), proceed to step 9.
7. Remove the short to Batt NEG in wire 2936 from PC228-A4 to connector
CA200-6 on Access 2&3.
8. Remove the short to +Batt in wire 2936 from PC228-A4 to connector
CA201-6 on Access 2&3.
Replace Access 5
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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
2. Press the key.
4. Press the key.
6. Press the key.
7. Using the key scroll through to the A2.5.6 ECR2 menu.
8. Press the key.
 The output pulses for ECR2 are displayed.
9. Leave the steering in neutral and check the reading.
10. Slowly move the steering to the left stop while monitoring the display for
fluctuations and recording the final reading.
11. Slowly move the steering to the right stop while monitoring the display for
12. Repeat steps 9 to 11 and compare the readings with the previous read-
ings.
 If the display fluctuates significantly during steering or if there are major
discrepancies in the pulses counted in the limit positions, replace steer
motor M3.
 If encoder ECR2 is ok, proceed to step 13.
Check the SAHS sensor
13. Monitor 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 permanently lit or not at all, proceed to step 14.
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14. Check the gap between SAHS and the cam for foreign bodies and check
for any accumulation of dirt.
 Remove any foreign bodies or accumulation of dirt.
 If there are no foreign bodies or accumulation of dirt, proceed to
step 15.
15. Check the distance from the SAHS sensor to the cam.
 If the distance ≠ 2.5 mm, set the distance to 2.5 mm. Repeat step 13.
 If the distance = 2.5 mm, proceed to step 16.
 If the problem persists, proceed to step 17.
Replace the SAHS sensor
16. Replace the SAHS sensor and adjust the switch distance.
Replace Access 5
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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
steering potentiometer.
Test Access 1
3. Press the key.
5. Press the key.
Replace Access 5
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Event code 519
Display: EV519
Service LED: On
Operator LED: Off
Explanation: The processors in Access 5 detect different direction messages from the steer-
ing potentiometer.
• Access 1 faulty
Test Access 1
3. Press the key.
5. Press the key.
Replace Access 5
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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
3. Press the key.
5. Press the key.
Replace Access 5

Event code 521
Display: EV521
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.
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Test Access 1
3. Press the key.
5. Press the key.
Replace Access 5

Event code 522
Display: EV522
Service LED: On
Operator LED: Off
Explanation: Internal error in Access 5.
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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
4. Press the key.
6. Press the key.
7. Using the key scroll through to the A2.5.3 STEER MOTOR CURRENT
menu.
8. Press the key.
 The current flowing through the output stage of Access 5 is displayed.
 If the reading is 0 A, restart the truck. Check the event log.
 If the resistance with the steer motor idle is > 15 Ω, proceed to step 9.
10. Press to scroll to the FEATURES menu.
11. Press the key.
13. Press the key.
14. Press the key.
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15. Press the key.

16. Press to scroll to the ACCESS 5 menu.
17. Press the key.
18. Press the key.
19. Confirm with .
 The EEPROM is deleted.
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Event code 524
Display: EV524
Service LED: On
Operator LED: Off
Test Access 1
3. Press the key.
5. Press the key.
 If no event is logged, proceed to step 7.
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
• Access 5 faulty
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Remedy: Check encoder ECR2

2. Press the key.
4. Press the key.
6. Press the key.
8. Press the key.
12. Repeat steps 9 to 11 and compare the readings with the previous read-
ings.
 If the display fluctuates significantly during steering or if there are major
discrepancies in the pulses counted in the limit positions, replace steer
motor M3.
 If encoder ECR2 is ok, proceed to step 13.
14. If the power cables and connections are ok, proceed to step 15.
Replace Access 5
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Event code 526
Display: EV526
Service LED: On
Operator LED: Off
Explanation: The output signal of the steering potentiometer has increased 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.
 Secure the TFD module if it is loose.
 If the attachment is ok, proceed to step 2.
Test the steering potentiometer
4. Press the key.
6. Press the key.
7. Press to scroll to the A2.5 ACCESS 5 menu.
8. Press the key.
10. Press the key.
11. Slowly change the steering from the left stop to the right while monitoring
the display.
 The readings should increase or decrease without interruption and be
approximately the same (approx. 2.5 V).
13. Press the key.
14. Press the key.
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 If both potentiometers are working correctly, re-calibrate the steering

(see page 122). Proceed to step 15.
 If there is a disconnection in one of the two potentiometers, proceed to
step 16.

Event code 527
Display: EV527
Service LED: On
Operator LED: Off
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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
3. Press the key.
5. Press the key.
 If no event is logged, proceed to step 7.
Replace Access 5
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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 in steer motor M3 faulty
1. Check wiring on encoders ECR2 and ECR3 from CA226 and CA234 to
CA227 and CA228 for shorts and damage.
Check encoder ECR2
3. Press the key.
5. Press the key.
7. Press the key.
9. Press the key.
Check encoder ECR3
13. Press the key.
 A2.5.6 ECR2 is displayed.
14. Press the key.
 A2.5.7 ECR3 is displayed.
15. Press the key.
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 If there are no fluctuations in the displays, re-start the truck and monitor
the event.
 If there are significant fluctuations, replace steer motor M3.
Note: With the steering in the centre position, the reading should be 120 ±10
pulses. At the end stops there should be a minimum of 15±10, a maximum of
220±10. ECR2 and ECR3 work opposite to each other: if the number of pulses
on ECR2 increase, they decrease on ECR3.
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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.
Check if SAHS switches
3. Press the key.
5. Press the key.
7. Press the key.
8. Press to scroll to the A2.5.8 SAHS SENSOR menu.
9. Press the key.
 The switch status of sensor SAHS is displayed (0 = OFF, 1 = ON).
10. Move the control handle to the left and right while monitoring if the switch
status in the display and on the LED of SAHS change at the same time.
 If the switch conditions change at the same time, SAHS and communi-
cation with Access 5 are ok. Restart the truck. Check the event log.
 If the switch status does not change, or not simultaneously, proceed to
step 11.
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Check the cam for contamination

11. Check the gap between SAHS and the cam for foreign bodies and check
for any accumulation of dirt.
 Remove any foreign bodies or accumulation of dirt.
 If there are no foreign bodies or accumulation of dirt, proceed to
step 12.
Check the screw-in depth of SAHS
12. Check the distance from the SAHS sensor to the cam.
 If the distance is set incorrectly, adjust the distance and repeat step 10.
 If the distance is within tolerance and the sensor still does not switch,
proceed to step 13.
Replace the SAHS sensor
13. Replace the SAHS sensor and adjust the switch distance. Repeat step 10.
14. If the problem still persists, replace Access 5.

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.
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Event code 535
Display: EV535
Service LED: On
Operator LED: Off
Test Access 1
3. Press the key.
5. Press the key.
 If an event is recorded and the service hours and temperature match
the event, Access 1 is ok.
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: • Transient error
Remedy: Restart the truck
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Event code 537
Display: EV537
Service LED: On
Operator LED: Off
Test Access 1
3. Press the key.
5. Press the key.
Replace Access 5
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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
2. Press the key.
3. Press the key.
4. Press the key.
 The status of the module (ON or OFF) is displayed.
 If a module is OFF, proceed to step 6.
5. Scroll through from A1.2 to A1.7 (see menu structure, page 41) and check
the status of the modules.
 If one of the modules is OFF, proceed to step 6.
 If all modules are ON, restart the truck. Check the event log.
Note: To view the next module, press the key twice. Now press the key,
followed by the key twice.
Check the CAN Bus wiring
6. Check CAN Bus wiring between Access 3 and Access 5 for shorts and
damage.
nection).
 If the resistance is 60 Ω, restart the truck and check the event log.
Test terminal resistance in Access 5
9. Disconnect CA228 from Access 5.
10. Measure the resistance between JC228-6 and JC228-14.
 If the resistance is 120 Ω, the load resistance in Access 5 is ok. Pro-
ceed to step 11.
 If the resistance is not 120 Ω, replace Access 1.
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Test terminal resistance in Access 1

11. Disconnect CA200 from Access 1
 If the resistance is 120 Ω, the terminal resistance is ok. Restart the truck
and check the event log.
 If the resistance is not 120 Ω, replace Access 1.
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Event code 539
Display: EV539
Service LED: On
Operator LED: Off
Explanation: The sum of the voltages of the two steering potentiometers is out of range.
• TFD module faulty
Remedy: Show the voltages of the steering potentiometers in the display
3. Press the key.
5. Press the key.
7. Press the key.
9. Press the key.
10. Note the reading.
12. Press the key.
13. Press the key.
14. Note the reading.
15. Add the readings to obtain the overall voltage.
 If the sum of the two voltages is 4.5 -5.5 V, the steering potentiometers
are ok. Restart the truck. Check the event log.
 If the sum of the two voltages is beyond the 4.5 -5.5 V range, proceed
to step 16.
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Measure the voltage of the steering potentiometers at the connectors

16. Measure the voltage from PC227-6 to PC227-1
17. Measure the voltage from PC201-15 to PC227-6.
 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 in the display, proceed to
step 18.

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 264.
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Event code 541
Display: EV541
Service LED: On
Operator LED: Off
Test Access 1
3. Press the key.
5. Press the key.
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
Remedy: Check status of Access 5
2. Press the key.
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3. Press the key.

4. Press to scroll to A1.4 ACCESS 5.
 The status (ON or OFF) of Access 5 is displayed.
 If the status is ON, proceed to step 6.
 If the status is OFF, restart the truck. Check the event log.
Check the TFD module power supply
6. Disconnect CA228 and remove the wire from PC228-4.
7. Reconnect PC228.
8. Measure the voltage from CA228-4 (cable number 2936) to BATT NEG.
 If the voltage is 0 VDC, locate the error in the power supply.
Check entries in event log
9. Using the key scroll back to A1 STATUS.
11. Press the key.
 If another event is recorded in addition to event code 542 with an iden-
tical time and temperature, rectify this other fault first.
 If no other event is recorded with an identical time and temperature,
proceed to step 12.
Replace Access 5
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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

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
2. Press the key.
3. Press the key.
4. Press to scroll to A1.4 ACCESS 5.
 The status (ON or OFF) of Access 5 is displayed.
 If the status is ON, proceed to step 6.
 If the status is OFF, restart the truck. Check the event log.
Check the TFD module power supply
6. Disconnect CA228 and remove the wire from PC228-4.
7. Reconnect PC228.
8. Measure the voltage from CA228-4 (cable number 2936) to BATT NEG.
 If the voltage is 0 VDC, locate the error in the power supply.
9. Check the wire between CA228-4 and CA228-5 for shorts.
10. Disconnect PC228 and measure the resistance between JC228-4 and
JC228-5.
 If the resistance is ∞ (> MΩ), proceed to step 11.
 If the resistance is less, proceed to step 14.
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Check entries in event log

11. Using the key scroll back to A1 STATUS.
13. Press the key.
 If another event is recorded in addition to event code 542 with an iden-
tical time and temperature, rectify this other fault first.
 If no other event is recorded with an identical time and temperature,
proceed to step 14.
Replace Access 5
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ELECTRICAL SYSTEM
Event Codes 545, 800 to 905 (DT 3040 -EF)
Event Codes 545, 800 to 905 (DT 3040 -EF)

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
Event code 8xx

Display: EV8XX
Service LED: On
Operator LED: Off
Explanation: Error in Access 8.1
Possible Causes: • Access 8.1 faulty
Remedy: Replace Access 8.1 (in control handle grip)
Event code 9xx

Display: EV9XX
Service LED: On
Operator LED: Off
Explanation: Error in Access 8.2
Possible Causes: • Access 8.2 faulty
Remedy: Replace Access 8.2 (for position see DT 3040 -EF Components, page 68)
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ELECTRICAL SYSTEM
Events with Text Messages
Events with Text Messages In some cases the fault may be due to an incorrect
choice of option, truck model or a component malfunc-
These events are normally caused by operator error. tion. This will require the intervention of a service engi-
The text message in the display informs the operator. neer.
The remedial measures the operator can perform are
detailed in the operating instructions.
Platform Failure
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 the truck model setting
3. Press the key,
5. Press , the truck setting is displayed.
Check switch status of side restraint sensors SR1 and SR2
7. Press the key.
8. Press the key.
9. Press the key.
11. Press the key.
14. Press the key.
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ELECTRICAL SYSTEM
Check switch status of platform sensors PLS1 and PLS2

17. Press the key.
18. Using the key scroll through to A2.3.10 PLS2 SENSOR.
19. Press and check the reading of the PLS2 sensor (ON or OFF).
20. Press the key.
21. Using the key scroll through to A2.3.9 PLS1 SENSOR.
22. Press and check the reading of the PLS1 sensor (ON or OFF).
23. Compare the switch status of PLS1, PLS2, SR1 and SR2 with the table
Input Signals on page 107.
Check wiring of the affected sensor
24. Check wiring of the sensor identified as potentially faulty in step 23.
Test the sensors
25. Using a suitable piece of metal connect the dubious sensor directly while
 If the sensor is ok, proceed to step 26.
 Replace the sensor if faulty.
Test the sensor actuators
26. Activate the affected sensor with the platform or side restraints. Monitor
the display in the process.
 If the sensor is not connected, adjust the actuator or sensor.
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ELECTRICAL SYSTEM
Truck 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 1.
Check load profile in the BDI setting
2. Press the key.
3. Press the key.
4. Press the to scroll to the P4 BDI SETTING menu.
5. Check that the setting matches the actual load profile of the truck (see BDI
parameter table on page 316).
 If the setting matches the actual load profile, proceed to step 6.
 If the setting does not match the actual load profile, adjust the load pro-
file (see page 316).
6. Measure the battery voltage directly on the battery connector.
8. Press the key.
9. Press the key.
11. Press the key.
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ELECTRICAL SYSTEM
Hightemp TCM
Display: HIGHTEMP TCM
Service LED: Off
Operator LED: On
Explanation: Traction control module Access 3 temperature too high
Possible Causes: • Fan faulty
• Thermal sensor in Access 3 faulty
• Wiring error
Remedy: Test the fan
2. Press the key.
3. Wait until the temperature in Access 3 has dropped.
5. Press the key.
6. Press the key.
 ENTER TO CANCEL is displayed.
 If the fan is working, proceed to step 7.
 If the fan is not working, proceed to step 12.
Note: The fan cuts out after 5 s. Press to cancel the test prematurely.
Check the fan status in the display
8. Press the key.
10. Press the key.
11. Using the key scroll through to the A3.10 FAN menu.
 If the status is ON but the fan does not start up, proceed to step 12.
 If the status is OFF and the fan does not start up, proceed to step 14.
Check the fan wiring
12. Using a voltmeter measure the battery voltage between −Batt and CA212-
1 (fan).
 If the voltage ≈ 24 V the positive power supply is ok, proceed to step 14.
 If no voltage is measured, check fuse FU4 and the wire to CA213-1 for
continuity.
13. Disconnect JC201 from Access 2&3 and check the wire between JC201-
9 and CA212-2 (fan) for continuity.
 If the wire is continuous, proceed to step 14.
 If the wire is disconnected, repair the wiring.
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ELECTRICAL SYSTEM
Compare the actual temperature with the temperature displayed

15. Press the key.
17. Press the key.
19. Press the key.
 A2.3 TEMP ACCESS 2&3 is displayed.
20. Press the key.
 The temperature of Access 2&3 is displayed.
21. Measure the temperature on the assembly plate and compare the temper-
ature readings.
 If the temperature on the assembly plate is approx. 10 °C lower than the
temperature displayed, the thermal sensor is ok.
 If the temperatures differ by more than 10 °C, replace Access 2&3.
Hightemp traction motor

Display: HIGHTEMP TRACTION MOTOR
Service LED: Off
Operator LED: On
Explanation: Temperature in traction motor M1 too high
• Wiring error
2. Press the key.
5. Press the key.
6. Press the key.
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296
ELECTRICAL SYSTEM

8. Press the key.
10. Press the key.
1 (fan).
continuity.
Measure and check temperature
15. Press the key.
17. Press the key.
19. Press the key.
20. Press to scroll to the A2.3.2 TS1 SENSOR menu.
21. Press the key.
 The drive motor temperature is displayed.
 If the temperature on the motor housing is approx. 10 °C lower that the
temperature displayed, thermal sensor TS1 is ok. Proceed to step 24.
 If the difference in temperature is greater than approx. 10 °C, proceed
to step 23.
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ELECTRICAL SYSTEM
Test thermal sensor

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 24.
Proceed to step 25.
Replace Access 2&3
Replace traction motor M1
25. Replace traction motor M1 (see page 304).
Release control handle

Display: RELEASE CONTROL HANDLE
Service LED: Off
Operator LED: On
Explanation: Incorrect starting sequence.
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 and then start the truck.
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298
ELECTRICAL SYSTEM
Release travel control

Display: RELEASE TRAVEL CONTROL
Service LED: Off
Operator LED: On
Explanation: Incorrect starting sequence.
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.
Hightemp steering controller

Display: HIGHTEMP STEERING CONTROLLER
Service LED: Off
Operator LED: On
Explanation: Steer control module Access 5 temperature too high
• Thermal sensor in Access 5 faulty
• Wiring error
2. Press the key.
5. Press the key.
6. Press the key.
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ELECTRICAL SYSTEM

8. Press the key.
10. Press the key.
1 (fan).
continuity.
Compare the actual temperature with the temperature displayed
15. Press the key.
17. Press the key.
19. Press the key.
20. Press the key.
 The temperature of Access 5 is displayed.
21. Measure the temperature on the assembly plate and compare the temper-
ature readings.
 If the temperature on the assembly plate is approx. 10 °C lower than the
temperature displayed, the thermal sensor is ok.
 If the temperatures differ by more than 10 °C, replace Access 2&3.
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300
ELECTRICAL SYSTEM
Hightemp steering motor

Display: HIGHTEMP STEERING MOTOR
Service LED: Off
Operator LED: On
Explanation: Temperature in steer motor M1 too high
• Wiring error
• Access 5 faulty
2. Press the key.
5. Press the key.
6. Press the key.
8. Press the key.
10. Press the key.
1 (fan).
continuity.
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ELECTRICAL SYSTEM
Measure and check temperature
15. Press the key.
17. Press the key.
19. Press the key.
20. Press to scroll to the A2.5.2 TS3 (TEMP MOTOR) menu.
21. Press the key.
 The steer motor temperature is displayed.
 If the temperature on the motor housing is approx. 10 °C lower that the
temperature displayed, thermal sensor TS3 is ok. Proceed to step 24.
 If the difference in temperature is greater than approx. 10 °C, proceed
to step 23.
Test thermal sensor
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 24.
Proceed to step 25.
Replace Access 5
Replace steer motor M3
25. Replace steer motor M3 (see page 308).
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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 willprobably 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.
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ELECTRICAL SYSTEM
Traction Motor (M1)
Traction Motor (M1) Note: An eye bolt can be fitted to the thread at the rotor
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.
Risk of serious injury 11. Lift out the frame and field (65).
Avoid accidents by:
 Switching the truck off
Traction motor assembly
 Disconnecting the battery. The following item numbers refer to Fig. 75.
 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
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. 73. ion (68) with the drive pinion in the gear unit.
Preparation 4. Fit the tie rod (79) and torque it to 16 Nm.
1. Switch off the truck and disconnect the battery. 5. Attach the retaining ring (82), supporting ring (81),
2. Prevent the truck from being switched on again brake carrier and key (73) of the rotor (72).
and rolling away. Brake assembly
3. Jack up the truck so that the drive wheel is clear of 6. Assemble the brake (see page 327)
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 drive motor and
8. Fit the terminal board and torque the screws to
the brake.
10 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 drive motor).
10. Connect the motor to the brake.
Brake removal
Functional test
6. Disassemble the brake (see page 327).
11. Check operation.
Traction motor disassembly
7. Remove the retaining ring (82), supporting ring Repairing the traction motor
(81), brake carrier and key (73) from the rotor (72). Note: Repairing the motor requires special tools such
8. Unscrew the retaining plate (85) from the bearing as a hydraulic press, suitable extractors and in-house
plate and remove it. produced assembly aids. If you do not have these tools
9. Remove the tie rod (79). then use pre-assembled assemblies (see Parts Man-
ual).
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ELECTRICAL SYSTEM
Traction Motor (M1)
Note: Replace all bearings and seals when repairing. 6. Slide on the shim (67) and insert the retaining ring
(41).
Preparation
1. Disassemble the traction motor (see page 304). Final tasks
2. Place the rotor assembly and B bearing plate on a 1. Assemble the traction motor (see page 304).
workbench.
Dismantling the rotor assembly

Note: The following item numbers refer to Fig. 73.
On the A side (gear unit side):
1. Remove the retaining ring (66) and shim (67).
2. Remove the pinion (68) using a suitable extractor.
3. Remove the key (71).
4. Pull off the centrifugal disc (86) and remove the re-
taining ring (69).
5. Remove the ball bearing (70) using a suitable ex-
tractor.
On the B side (brake side):
2. Press the rotor shaft (72) off the sensor bearing
(75).
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).
Assembling the rotor assembly

On the B side (brake side):
1. Place the shims (77) and a new O ring (76) into the
bearing plate (78).
2. Fit a new sensor bearing (75) into the bearing plate
(78) while noting the orientation of the connector.
3. Insert shims (87) and the retaining ring (74).
4. Press the rotor shaft (72) into the sensor bearing
while supporting the inner ring of the sensor bear-
ing.
5. Insert the retaining ring (80).
On the A side (gear unit side):
1. Press the ball bearing (70) onto the rotor while sup-
porting the rotor.
2. Insert the retaining ring (69).
3. Press on the centrifugal disc (86) while supporting
the rotor.
4. Insert the key (71).
5. Press the pinion (68) onto the rotor while support-
ing the rotor.
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ELECTRICAL SYSTEM
Traction Motor (M1)
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. 73 Drive unit complete
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306
ELECTRICAL SYSTEM
Pump motor (M2)
Pump motor (M2)
Fig. 74 Pump motor

1 Pump motor, complete
2 Clamp
3 Screw
Brushes
2. Prevent the truck from rolling away.
3. Loosen the screw (1) from the clamp (2) and re-
move the clamp.
4. Apply dry compressed air to the motor.
Rotor
1. Check the rotor (see page 303).
Note: Do not overwind the rotor. Replace the motor (1)
if the rotor appears worn or damaged.
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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. 75 Drive unit complete
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308
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 drive 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. Apply grease type B or BB to the pinion (17) (see
6. Position the frame and field (6).
page 21).
7. Press on a new sensor bearing (8) with a suitable
2. Fit the steer motor, complete with B bearing plate
bushing while supporting the rotor (7).
and frame and field, onto the end cap (14).
8. Fit a new O ring (9) into the groove of the sensor
3. Attach the tie rod (1) and using the special tool
bearing (8).
(item no. 822672) torque it to 1.8 Nm.
4. Attach the drive system connector to the retaining Final tasks
plate (85). 9. Assemble the steer motor.
5. Screw on the strain relief firmly.
6. Connect the steer motor.
7. 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).
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ELECTRICAL SYSTEM
Servicing and Replacing the Control Modules
Servicing and Replacing the

WARNING
Control Modules
The number of control modules and assembly loca- Risk of serious injury
tions will vary depending on the truck’s specific equip- Avoid accidents by:
ment and features. See Components, page 65 for  Switching the truck off
more information.  Disconnecting the battery.
 Preventing the truck from being switched on again.
General
 Jacking up the truck and preventing it from rolling
Travel, lifting and power steering are controlled by away
modules which communicate with each other via a
common CAN-Bus:
• Access 1 (Display panel) (Display) Discharging the capacitors
• Access 2 (Traction control module) (TCM) The truck must be de-energised and secured, see
• Access 3 (Hydraulic control module) (HCM) safety notices. Once this has been done:
• Access 5 (Steering control module) (SCM) 1. Short the positive and negative connections of the
• Access 8.1 (CAN interface) (CAN-Interface) control module over a resistor (10 - 100 Ω,
min. 5 W) for a few seconds.
• Access 8.2 (CCD)
 The stored energy has been discharged safely via
Access 2 and Access 3 are located in the same hous-
the resistor.
ing. Access 8.1 in the grip of the control handle.
Access 8.2 at the top left of the chassis, above the hy-
draulic unit.
Servicing the control modules
The truck must be de-energised and secured, see
Power fuses safety notices.
The power fuse FU1 is fitted on a plate above the con- 1. Discharge the capacitors.
trol module. 2. Dry clean the outside of the control module (see
Cleaning the Truck and Components, page 19).
3. Check that the nuts attaching the power cables are
WARNING tight.
4. Check the logged events.
Short circuits can cause fires
Control modules operate at high currents. Please note: Replacing control modules
 You must be trained to carry out this work.
 Use non-fatigue eye protection. Removing the control module
 Wear close-fitting clothing. Securing the truck
 Do not wear jewellery. The truck must be de-energised and secured, see
 Always use insulated tools. safety notices. Once this has been done:
1. Discharge the capacitors.
Removing the control module
2. Remove / disconnect all wires (mark the wires if
necessary).
Note: Note the number and assembly position of the
shims and retaining elements on the power cable con-
nections. They must be fitted in exactly the same posi-
tion during assembly.
3. Remove the bus bars if present.
4. Remove the control module mounting screws.
5. Remove the control module.
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ELECTRICAL SYSTEM
Servicing and Replacing the Control Modules
Checking the assembly plate tooth pattern 7. Connect the battery and remove the immobilizer.
6. Check the tooth pattern left by the back plate of the Setting the truck model
control module on the assembly plate. The full sur-
1. Open SERVICE MENU > FEATURES MENU > F4
face area of the control module must be in contact
> TRUCK TYPE and set the right truck type.
with the plate.
 If there are large areas with no contact to the 1. Select service level 2 (see page 71).
control module, replace the assembly plate to 2. Press the key.
avoid thermal problems. 3. A1 Status is displayed.
4. Using the key scroll through to the FEATURES
menu.
CAUTION
5. Press the key,
Health risk  F1 LANGUAGE is displayed.
damage your health.
F4 TRUCK TYPE menu.
when handling solvents and lubricants. 7. Press the key.
7. Remove the heat conducting paste remains on the 8. Use the key to select the correct model. (Refer
assembly plate with a lint-free cloth and a commer- to the data plate on the truck and page 4, Truck
cial silicon removing agent. Data Number).
9. Press the key.
Assembling the control module  The selected model is stored.
Note: Use a control module with the right software ver- 10. Restart the truck.
sion (see page 72).
Setting the control module parameters
Assembling the control module
11. Set the parameters (starting on page 113) and cal-
1. Apply heat conducting paste (Dow Corning® 340, ibrate the truck (see page 121).
item no. 053051-008) thin and evenly to the base
plate of the new control module. Functional test
2. Attach the control module to the assembly plate. 12. Carry out a functional test.
3. If necessary clean the power cable connections.
CAUTION
Control modules become damaged if the power cable
attachment is tightened too firmly or too loosely.
 Tighten the power cable attachment to the correct
torque. See the "Power Cable Torques" table.
4. Refit / connect all wires. Attach the bus bars if ap-

plicable.
5. Tighten the power cable attachment to the correct
torque. See following table.
Power Cable Torques
Access 2&3 5.6 - 8.4 Nm

Access 5 5 Nm (standard torque)
6. Leave the truck jacked up.
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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
EN 1175-1 requires regular testing of the safety circuits Access 2 is shorted against the -B connection of the
for the controllers used. controller.
The test is a "Pulse Monitor Trip Test”, or PMT for short.
Trucks whose controllers fail the PMT must not be
operated. They must be repaired immediately.
Required tools
• A test wire, approx. 500 mm long with a 1 mm2 Access 2 / Access 3
cross section. The wire must have a 10 A fuse and
10
-B
A
testing terminals at both ends.
PMT Test
-P
WARNING
+ BF FU 7 +
You or other people could be fatally injured + + M2
400A
The truck or moving parts can start accidentally during
the test.
 Jack up the truck until the drive wheel is clear of the Fig. 76 Test setup for Access 2
ground. Test preparation
 Before connecting the test wire, disconnect the bat- 1. Disconnect the battery if it is still connected.
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.
2. Jack up the truck (see page 16) so that the drive  The test is successful if:
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.
6. Disconnect the battery.
Completing the test
7. Remove the test wire.
9. Test the truck's functions.
 If the truck is functioning normally, test Access 3.
DT 3000 Series
312
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 against the
 If the truck is working normally, now test the steer-
BATT NEG. terminal on the controller.
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. 77 Access 3 test setup

Test preparation
1. Disconnect the battery if it is still connected.
2. Connect the test wire to -B and U.
Performing the test
 The test is successful if:
– The traction motor does not start up
6. Disconnect the battery.
Completing the test
7. Remove the test wire.
DT 3000 Series
313
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 against the
BATT NEG. terminal on the controller.
Access 5
W
W
V
V M3
U 3
U AC
-B
-
A
10
Fig. 78 Access 5 test setup

Test preparation
1. Disconnect the battery if it is still connected.
2. Connect the test wire to -B and U.
Performing the test
 The test is successful if:
– 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.
DT 3000 Series
314
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
fatal 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.
DT 3000 Series
315
ELECTRICAL SYSTEM
Battery Discharge Indicator (BDI)
Battery Discharge Indicator Adapting the BDI setting

(BDI) You can navigate through the menu structure using the
cursor keys ( , , , , ) on the display. An over-
Load profile and discharge curve view of the menu structure can be found in Menu Struc-
ture starting on page 74.
Depending on the average load the truck has to carry,
the discharge curve set for the battery discharge indi-
cator will match the actual discharge curve to a greater
or lesser extent.
To adapt the curve better, the interval to the next
charge can be extended if necessary. The factory set-
ting is “Standard Duty”. This setting is suitable if the av-
erage load is 650 kg to max. 800 kg.
The discharge curve the BDI assumes can be better
adapted to the actual discharge curve in the “Perform-
ance P4” menu.
The following table shows the relationship between the
discharge curve selected and the average load moved:
Fig. 79 Display panel

BDI parameter
Load profile Max. ø load (kg) 1. Press the key for 1 second.
Light Duty 500
Note: For trucks with a key switch, turn the key switch
Standard Duty 800 right to the "On" position.
Medium Duty 1200 Selecting the PEFORMANCE menu
Heavy Duty 1600 2. Press the key 3 times
 The "SERVICE" menu is displayed.
Maintenance Free 2000
3. Press the key until “LEVEL 2” appears.
4. Press the key until you are requested to enter
your PIN.
5. Enter the service PIN using the and keys and
confirm with .
6. Press the key until the “PERFORMANCE” menu
appears.
7. Press the key.
 “P 1” appears.
8. Press the key until the “P4” menu appears.
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 parameter table, page 316).
(1).The current setting is displayed. (= Value)
DT 3000 Series
316
ELECTRICAL SYSTEM
Battery Discharge Indicator (BDI)
12. Press the key to confirm.

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.
 The security prompt “SAVE? Y” is displayed.
15. To confirm, press .
16. Wait for 5 seconds.
 After 5 seconds the new settings are stored.
Activating the new setting
 The new settings are activated.
DT 3000 Series
317
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. 80 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 DT 3000 Series
318
ELECTRICAL SYSTEM
Modifications
Modifications Accessing service level 2

Converting the truck from Enter key level 2 the display automatically changes to the “ANA-
LYZER” menu.
to key switch power-up function
2. Press the key.
WARNING
Accidental truck movement can cause injury 3. Press the key.
A powered up truck with a connected battery can move  “PASSWORD” is displayed.
cedures before starting any operations on the truck: 5. Confirm by pressing .
 Lower the forks to the ground.  The "ANALYZER" menu is displayed.
 Switch the truck off. Selecting the “FEATURES” sub-menu
 Disconnect the battery. 6. Press the key until the “FEATURES” sub-menu
 Prevent the truck from being switched on again. appears.
7. Press the key.
Mechanical conversion  F1 LANGUAGE is displayed.
Note: These conversion instructions apply only to main 8. Otherwise press to scroll to F12 KEYLESS.
wire harnesses with item numbers 825765 and  F12 KEYLESS = ENABLE is displayed.
826923. 9. Press the key.
1. Switch off the truck and disconnect the battery.  DISABLE is displayed.
2. Prevent the truck from being switched on again 10. Press the key.
and rolling away.  The key switch is now enabled for power-up.
Relay K1 removal 11. Restart the truck.
4. Remove relay K from its socket and replace it with
the key switch adapter (item no. 820143).
Assembling and wiring the key switch
5. Assemble the key switch.
6. Connect the wiring of the key switch adapter with
the key switch.
7. Cut through wire 203 on terminal 30 of the relay
socket insulate the ends.
Changing the software

 The Enter sign (↵) appears on the display.
DT 3000 Series
319
ELECTRICAL SYSTEM
Modifications
Converting the truck from key 3. Press the key.

switch to Enter key power-up func-
tion
WARNING Selecting the “FEATURES” sub-menu
Accidental truck movement can cause injury 6. Press the key until the “FEATURES” sub-menu
A powered up truck with a connected battery can move appears.
suddenly when you are working on it. 7. Press the key.
You should therefore carry out the following safety pro-  F1 LANGUAGE is displayed.
cedures before starting any operations on the truck: 8. Otherwise press to scroll to F12 KEYLESS.
9. Press the key.
 Switch the truck off.  DISABLE is displayed.
10. Press the key.
 Prevent the truck from being switched on again.  ENABLE is displayed.
11. Press the key.
Mechanical conversion  F12.1 KEYLESS TIMEOUT is displayed.
Note: These conversion instructions apply only to main 12. Press the key.
wire harnesses with item numbers 825765 and  VALUE XX min is displayed.
826923.  Use the and keys to enter the time re-
1. Switch off the truck and disconnect the battery. quired (10 – 30 min) for the truck to shut down.
2. Prevent the truck from being switched on again 13. Confirm by pressing .
and rolling away. 14. Restart the truck.
Key switch removal
3. Remove the key switch adapter (item no. 820143).
4. Remove the key switch.
Relay K assembly and wiring
5. Strip wire 203 and connect it to terminal 30 of the
relay socket.
6. Insert relay K (item no. 811995-006) into the
socket.
Changing the software

level 2 the display automatically changes to the “ANA-
LYZER” menu.
2. Press the key.
DT 3000 Series
320
ELECTRICAL SYSTEM
Glossary
Glossary
ACCESS 2&3 Hydraulic and traction controllers (contained in the same housing).
Access 2 communicates with Access 3 via the CAN-Bus.
Access 8.1 PC board in the control handle.
Provides a CAN interface.
Access 8.2 Converts analog input signals into digital signals.
AxEDS Auxiliary switch in Emergency Disconnect contactor (EDS).
BD Battery connector.
BLS Battery retainer monitoring sensor.
BRK Electromechanical parking brake.
The brake applies during normal operation only when the truck is stationary. It is therefore
practically wear-free. BRK is applied when the Emergency Disconnect is activated.
BRS Brake switch
BRS2 Brake switch 2.
CAN Refers to the CAN protocol or bus system
CCD Synonym for Access 8.2
Display Display screen
ECR Encoder
EDS Emergency Disconnect contactor
FAN Fan
FS (PF) Forward travel switch (in battery direction)
FU1 Main fuse
FU2 Control circuit fuse
HN Horn
HS Horn switch
HSS “Rabbit/Turtle” toggle switch
InfoLink Truck information system module
K Relay K
Keypad Keypad
KYS Key switch
LMS1 Limit switch 1
LMS4 Limit switch 4
LOS ENC Lowering switch (version with Hall encoder instead of a potentiometer)
M1 Traction motor
DT 3000 Series
321
ELECTRICAL SYSTEM
Glossary
M2 Pump motor
ORS Override switch
PLS1 Platform switch 1
PLS2 Platform switch 2
POT1 Potentiometer 1
PS1 Pressure transducer 1
PS2 Pressure transducer 2
PWS Transformer (DC/DC)
RAS ENC Lift switch (version with Hall encoder)
RS (FF) Reverse travel switch (in forks direction)
SAS Safety reverse switch
Shock Sensor Acceleration sensor. Part of the InfoLink system. Detects the impact of a truck collision.
SR1 Side restraint switch 1
SR2 Side restraint switch 2
TS1 Thermal sensor 1
DT 3000 Series
322
BRAKE SYSTEM
323
Notes:
324
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 is not used as a service brake and is therefore virtu-
ally wear-free.
DT 3000 Series
325
BRAKE SYSTEM
Servicing the Parking Brake
Servicing the Parking Brake Troubleshooting

Servicing is limited to checking the air gap every Symptom: Parking brake does not release.
1000 service hours.
Measuring the air gap 1. Jack up the truck so that the drive wheel is free
(see page 16).
 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 are supplied to the brake's
electrical connector.
 If there is no voltage supply, check the electrical
3 system.
 If at least 16 V 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. 81 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. DT 3040 -MW DT 3040 -EF
3. Remove the dust shield ring (3). DT 3040 -MF
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 is > 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.
DT 3000 Series
326
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. 82 Brake attached to the motor
Parking brake disassembly

Preparation B
prevent the truck from being switched on again.
2. Jack up the truck so that the drive wheel is free
(see page 16).
 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. 82). Fig. 83 Brake transport safety mechanism
6. Remove the retaining ring (3). 2. Remove the elastic band (B, Fig. 83) 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).
DT 3000 Series
327
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. 84 Brake assembly

3. Remove the friction plate (7, Fig. 84), 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. 85 Transport safety mechanism screws
retaining ring (3). 13. Remove the two screws (A, Fig. 85).
6. Place the friction plate (7) in the correct position on 14. Attach the dust shield ring (9, Fig. 84).
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. 83) are
pushed up. Pull the elastic band (B, Fig. 83) 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 (1) to 10 Nm.
DT 3000 Series
328
BRAKE SYSTEM
Testing the Braking Distance
Testing the Braking Distance Braking distance tables

Requirements Max. braking distances DT 3040 -MW, with
or without max. rated load
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)
5 1.
Performing the test
4 1.5
Preparing the truck
3 1.1
1. Place the maximum rated load on the forks and
prevent it from slipping. Max. braking distances DT 3040 -MF
Note: If the maximum rated load is not available, the
test can also be performed without load. With max. rated load in rider mode
2. Lay down a marker to act as the measurement
starting point for the test route. Speed Maximum braking distance
(km/h) (m)
Calculating the braking distance
6.8 2.5
6 2.2
WARNING
5 1.8
Risk of injury to third parties
The brake test requires you to concentrate fully on the Without load in rider mode
truck. As a result, persons running into the travel zone
could be easily hit and fatally injured. Speed Maximum braking distance
 Use marker tape over a large area to block off the (km/h) (m)
test route.
10.5 3.8
 If necessary use assistants to secure critical points
along the route. 9.5 3.4
 Do not perform the test unless you have full control 8.5 3.1
over the test route.
With or without max. rated load in pedestrian mode
1. Accelerate within the test route up to one of the
speeds listed in the table. Speed Maximum braking distance
2. At the marker point (measurement starting point) (km/h) (m)
brake by changing direction.
5 1.8
3. Measure the braking distance.
4 1.5
Analysing the result
1. Calculate the maximum braking distance for the 3 1.1
speed travelled in the corresponding table.
Note: Always select the speed in the table that is near-
est to the speed travelled.
 The braking distance recorded should always be
less than the figure in the table.
 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.).
DT 3000 Series
329
BRAKE SYSTEM
Testing the Braking Distance
Max. braking distances DT 3040 -EF

With max. rated load in rider mode
Speed Maximum braking distance

(km/h) (m)
9.5 3.4
8.5 3.1
7.5 2.7
Without load in rider mode

(km/h) (m)
12.5 4.5
11.5 4.2
10.5 3.8
With or without max. rated load in pedestrian mode

(km/h) (m)
5 1.8
4 1.5
3 1.1
DT 3000 Series
330
STEERING
331
Notes:
332
STEERING
Repairing the Control Handle
Fig. 86 Main control handle components
1 Switch unit 4 Control handle tube

2 Hand grip 5 Upper shell
3 Lower shell
DT 3000 Series
333
STEERING
Replacing the control handle shells

2 2
WARNING
 Lower the forks to the ground. 3
 Switch the truck off. 3
Shell removal
Fig. 88 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 control handle wire harness plug con-
nections and the horn buttons from the PC boards.
1
5
Fig. 87 Shell removal

Fig. 89 Cover removal

4. Lever off the covers (5) on each hand grip.
DT 3000 Series
334
STEERING
5 7
8
7
Fig. 90 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.
Fig. 92 Shell removal

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 control handle.
6
Replacing the switch unit
The switch unit contains the:
Fig. 91 Grip removal
• Safety reverse switch or 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)
• Outrigger lift switch
Note: Replacing any of these components requires the
entire switch unit to be replaced.
DT 3000 Series
335
STEERING
Switch unit removal Switch unit assembly

the following:
1. Re-connect the control handle 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
1 be repaired. It must be replaced as a complete unit.
CAUTION
Use of the wrong toggle module can damage the
1 truck
The module is available as either a standard or a cold
Fig. 93 Shell removal store version.
 Make sure you use the right module.
2 2
Toggle module removal
3
1
Fig. 95 “Rabbit/turtle” toggle module
Fig. 94 Switch unit removal 1. Remove the switch unit (see page 336).
2. Press the thumb markings (3) or pull on the thumb- 2. Remove the screws (2) and take off the toggle
wheels (2). module (1).
 The switch unit will slide up out of the bottom shell.
3. Remove the control handle wire harness plug con-
nections and the horn buttons from the PC boards.
DT 3000 Series
336
STEERING
Toggle module assembly Hydraulic PC board assembly

Note: Assembly is the reverse of disassembly. Note Note: Assembly is the reverse of disassembly. Note
the following: the following:
1. Re-fit the switch unit (see page 336). 1. Assemble the switch unit (see page 336).
2. After assembly, connect the battery and test all the 2. After assembly, connect the battery and test all the
functions of the control handle. functions of the control handle.
Replacing the control handle grip Main PC board removal

PC boards
The main PC board (Main PCB) and the hydraulic PC
board (HYD PCB) are located in the control handle
grip. The main PC board is the larger of the two. Nei-
ther 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. 97 Main PC board removal

1. Remove the switch unit (see page 336).
2. Remove the connector of the potentiometer from
the main PC board.
4. Remove the connector of the safety reverse switch
from the main PC board (2).
1 5. Remove the main PC board.
Note: If you cannot reach the connector on the main
2 PC board, remove the thumbwheels, the bottom cover
and the upper shell cover (see "Replacing the traction
Fig. 96 Hydraulic PC board removal potentiometer" on page 338).
1. Remove the switch unit (see page 336). Main PC board assembly
2. Remove the screws (2) from the hydraulic PC Note: Assembly is the reverse of disassembly. Note
board. the following:
3. Remove the hydraulic PC board (1). 1. Re-fit the switch unit (see page 336).
DT 3000 Series
337
STEERING
Replacing the traction

potentiometer 6
There are no parts of the traction potentiometer (POT
travel switch) that can be repaired. It must be replaced
as a complete unit.
CAUTION
Use of the wrong potentiometer can damage the
truck
The traction potentiometer is available as either a 7
standard or a cold store version.
 Make sure you use the right potentiometer.
Traction potentiometer removal
1 1
2 7

7. Remove the cover (6).
3
5 11
8
4
10
Fig. 98 Thumbwheel removal
Note: Take care not to lose the slide bearings (2) when
removing the thumbwheels (1).
3. Extract the thumbwheels (1).
4. Remove the screws (4) while holding on to the low- 9
ering switch cap (5).
Fig. 100 Traction potentiometer removal
5. Remove the lowering switch cap (5).
9. Remove the connectors from the PC boards.
10. Remove the traction potentiometer (8) from the
square axle.
DT 3000 Series
338
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 336).
functions of the control handle. 7
Replacing the safety reverse switch

(SAS)
Removing the safety reverse switch (SAS)
1 1 7
2
7. Remove the cover (6).
3
5 9
10
4
8
Fig. 101 Thumbwheel removal

11
Note: Take care not to lose the slide bearings (2) when
removing the thumbwheels (1). 12
3. Extract the thumbwheels (1).
4. Remove the screws (4) while holding on to the low-
ering switch cap (5).
Fig. 103 Safety reverse switch disassembly
5. Remove the lowering switch cap (5).
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 safety reverse switch (10).
DT 3000 Series
339
STEERING
SAS / BRS switch assembly 1. Remove the switch unit (see page 336).
Note: Depending on the use of the control handle, this 2. Remove the screws (2).
switch acts either as a safety reverse switch or a brake 3. Remove the electrical connectors.
switch. 4. Remove the screws (4) and take off the switch
Note: Assembly is the reverse of disassembly. Note block.
the following: 5. Remove the screws (3) and take off the outrigger
1. Fill the socket of the micro switch cable (9) with lift switch (1).
grease (part no. 053002-005).
Note: The socket should only be filled with grease (part
Assembling the outrigger lift switch
no. 053002-005). Do not use any other type of grease. Note: Assembly is the reverse of disassembly. Make
sure the gap between the switch cap and the shell is
uniformly even. The switch cap must not jam when ap-
3. After assembly, connect the battery and test all the plied.
Replacing the grips and horn switch 2. After assembly, connect the battery and test all the
Note: Refer to page 334 for the removal and assembly
of the grips and horn switch.
Replacing the outrigger lift switch

Removing the outrigger lift switch
1 3
4
4
2
Fig. 104 Replacing the outrigger lift switch

1 Outrigger lift switch
2 Screw
3 Screw
4 Screw
DT 3000 Series
340
STEERING
Repairing Control Handle Return Springs
Repairing Control Handle

Return 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. 106 Pre-tension adjustment
4 Return spring
5 Spacer ring
Panel removal 6 Axle
7 Dowel pin
2. Set the control handle upright.

1
3. Fix the axle (6) using a fork wrench.
 This prevents the return springs (4) from discharg-
ing when the dowel pin (7) is deflected.
4. Remove the dowel pin (7).
5. Turn the axle (6) 90 degrees with the fork wrench.
2  This will tension the springs.
6. Strike the dowel pin (7) in.
 This increases the pre-tension of the return
springs (4).
7. Make sure the return springs have sufficient pre-
Fig. 105 Panel removal tension. The control handle should move automat-
1. Loosen two screws (1) and push the panel (2) up. ically to the horizontal position.
 The control handle springs are now accessible. 8. If necessary increase the pre-tension of the return
Note: Assembly is the reverse of disassembly. springs further.
9. After adjusting, grease the return springs (for lubri-
Return spring pre-tension adjust- cant see page 21).
ment 10. Assemble all the panels.
Note: The axle (6) contains 2 holes for the dowel pin 11. Test the truck's brakes.
which are offset by 90 degrees. This allows you to ad-
just the pre-tension of the return springs by 90 degrees
respectively by turning the axle.
DT 3000 Series
341
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. 107).
Return spring assembly
Return spring removal
2. Insert the pre-assembled return springs (4) with
1. Remove the cover (see page 341).
the control handle into the control handle knuckle
2. Set the control handle upright. (9).
3. Remove the dowel pin (7). 3. Insert the axle (6) from the left hand side and make
 The axle (6) turns and the return springs (4) are sure that the position of the groove corresponds to
discharged. the groove of the shortened axle (8).
4. Set the control handle all the way down to fully dis- 4. Strike in the axle (6) carefully and drive out the
charge the return springs (4). shortened axle (8).
Note: If the axle is jammed, turn it approx. 20 degrees  The return springs are pushed onto the axle (6) in
clockwise with a fork wrench in order to discharge the the process.
return springs.
Return spring pre-tension adjustment
5. Drive out the axle (6) from the right hand side.
5. Set the control handle upright.
6. Remove the return springs (4).
6. Starting from the neutral position of the return
Return spring assembly springs, turn the axle (6) 90 degrees using a fork
wrench and increase the pre-tension of the return
springs.
7 4 7. Strike the dowel pin (7) in.
8. Make sure the return springs have sufficient pre-
tension.
 The control handle should move automatically to
6 8 the upright position.
9. If necessary increase the pre-tension of the return
springs further.
10. After adjusting, grease the return springs (4) (for
lubricant see page 21).
11. Assemble all the panels.
12. Test the truck's brakes.
9
Fig. 107 Return spring assembly
8 Shortened axle
9 Control handle 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 control handle in the
control handle knuckle (9).
DT 3000 Series
342
LIFTING MECHANISM
343
Notes:
344
LIFTING MECHANISM
Forks
Forks
General
The fork tines and forks must be checked by trained 1
personnel under the maintenance schedule (see
page 28) for cracks, damage and wear.
If the forks are used to transport abrasive loads the in-
spection 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 surface cracks,
damaged or worn parts around the heel of the fork.
 Forks must only be repaired by the fork manufac- Fig. 108 Welding seams between forks and fork carriage
turer.
Checking forks for cracks

Visually inspect all fork surfaces for cracks. Particular
attention should be paid to the weld seams. If in doubt
carry out a non-rupturing crack test (paint penetration
process or Magnaflux®).
Checking forks for cracks
1. Check the welding seams between the forks, fork
carriage and fork shank for cracks (1, Fig. 108).
 Replace the forks if any cracks are detected.
DT 3000 Series Rev.2 10/2010
345
LIFTING MECHANISM
Chain Supports and Lift Chains
Chain Supports and Lift Chains Cleaning lift chains

General
Lift chains are safety components. Careful mainte- WARNING
nance and repairs are a prerequisite for safe truck op-
Improper cleaning can cause chains to crack
eration and long uptime.
A cracked chain can result in fatal injuries.
Never clean lift chains with steam cleaners, cold clean-
ing agents or corrosive, acid-based agents. This can
CAUTION cause direct chain damage through hydrogen embrit-
tlement.
Health risk
Cleaning agents, lubricants and consumables can  Clean the chain surfaces only with paraffin deriva-
damage your health. tives such as cleaning petroleum or cleaning petrol.
Apply a thin layer of the cleaning agent with a hard
bristle brush and wipe with a lint-free cloth.
 Apply an approved type H chain oil immediately af-
ter cleaning or inspection (see Recommended Lu-
Periodic inspection of chain sup- bricants and Consumables table, page 21). The oil
acts as an anti-corrosion agent.
ports and lift chains
CAUTION
Lift chains and chain supports must be periodically
cleaned, inspected and lubricated (see Maintenance
Schedule, page 24).
The interval must be adapted for corrosive or dusty en-
vironments, i.e. reduced accordingly so that safety is
not affected.
Periodic replacement of chain sup-

ports and lift chains
For safety reasons chain supports, lift chains, anchor
bolts and attachments must be replaced periodically ir-
respective of their external condition.
Irrespective of the condition and inspection results
you must replace the following components after
every 6000 service hours or 3 calendar years at the
latest:
• Lift chains
• Chain supports and their attachments
• Anchor bolts and their attachments
Note: Chain supports are marked with the date of man-
ufacture / assembly (week/year).
Rev.2 07/2010 DT 3000 Series
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LIFTING MECHANISM
Inspecting Chain Supports and Lift Chains
Inspecting Chain Supports and Checking the lift chain for elonga-
Lift Chains tion
General
The chain bends as it passes over the chain rollers.
WARNING This gradually causes the chain links and the chain
plate eyelets to wear. The chain therefore elongates
Crashing loads can cause injury
over time.
Lift chains, chain supports, chain bolts and their attach-
ments are safety components. Their failure can Preparatory measures
cause the load to crash, resulting in fatal injuries.
1. Remove the lift chain if it cannot be fully inspected
 Replace damaged lift chains and their chain sup- when installed.
ports, chain bolts and connecting items with original
2. Clean the lift chain (see page 19).
spare parts before restoring the truck to service. If
2 chains are used paired, replace in pair. Tools required:
• Wear gauge (see Fig. 109) or steel ruler
The inspection covers the following points:
• Checking the service hours for the chain supports
and lift chains.
• Checking the lift chain for elongation.
• Checking for wear on the edges of the chain con-
nection plates.
• Checking for pitting due to corrosion, in particular
on the outer surfaces of the connection plates.
CHAIN WEAR SCALE
• Check for twisted and protruding pins.

ROLLER AND LEAF
• Check for loss of freedom in the chain links.

• Checking for damage to the anchor bolts and their
attachments.
• Checking for wear and corrosion of the chain sup-
ports and anchor bolts.
Checking the service hours for the

lift chains and anchor bolts
1. Check the chain support date of manufacture (see
engraving on chain support):
If the chain supports are 3 years or older, replace
the chain supports, anchor bolts and lift chains to-
gether with all their attachments. Fig. 109 Crown wear gauge
2. Check the number of service hours since the chain
support and lift chains were last replaced: Chain wear can be measured with a wear gauge (part
If the chain supports or lift chains have been in no. 106440) or a steel tape measure.
service for 6000 hours or more, replace the chain The Crown wear gauge (see Fig. 109) has two scales:
supports, anchor bolts and lift chains together with • Scale “A” is used for 19.05 mm (0.75 inch) and
all their attachments. 25.4 mm (1 inch) pitch chains.
• Scale “B” is used for 15.88 mm (0.625 inch) pitch
chains.
DT 3000 Series Rev.2 07/2010
347
LIFTING MECHANISM
Checking the chain for elongation Note: For twin chains always replace the second lift
1. Raise the fork carriage to tension the lift chain. chain with the chain support and anchor bolts.
(Pull removed lift chains taut in order to measure Checking the lift chains
them.)
This section lists the inspection items that can be per-
formed in one step:
• Check for loss of freedom in the chain links.
• Check for worn or missing plates.
• Check for twisted and protruding pins.
• Check for lift chain lateral wear.
• Check for lift chain corrosion.
Freedom of movement
Each individual chain link must flex freely. Tight joints
(see Fig. 111) increase friction and the chain tension
during lifting. Excessive chain tension in turn acceler-
ates material wear.
Fig. 111 Tight joints

Possible causes of stiff chain links are as follows:
• Bent pins or plates
Fig. 110 Measurement section (A) on the lift chain
• Rusty chain links
Make sure you measure a part of the chain that passes
over a pulley. • Peened plate edges.
Plate edge distortion is caused by:
2. With taut lift chain check section (A) either in front
or rear of pulley for elongation. – Ruptured chain pinion.
3. Repeat the measurement on 3 parts of the chain – Constant overloading of the chain.
that always pass over a pulley during operation. – Chain striking the mast components.
Note: If you are using a steel ruler, the measurement Worn or missing plates
must include at least 10 links. See following table:
Generally speaking, material wear is the cause of worn
or missing connection plates. The plates near the chain
Pitch No. of Length Wear limit pin hole (see Fig. 112) can crack after a high number of
chain links new lifting cycles with heavy loads.
25.4 mm 12 305 mm 314 mm

1 inch 12 inch 12.375 inch
19.05 mm 16 305 mm 314 mm
0.75 inch 12 inch 12.375 inch
15,88 mm 20 318 mm 327 mm
0.625 inch 12.5 inch 12.875 inch
Fig. 112 Worn connection plate
Replace lift chains, chain supports, anchor bolts
and attachments if the chain has elongated by
more than 3%!
Rev.2 07/2010 DT 3000 Series
348
LIFTING MECHANISM
Turned pins nizing process is an excellent protection and fully pen-

Considerable frictional forces between the connection etrates the joints. Do not remove this layer of grease!
plates and the pins occur when lifting heavy loads with Checking lift chains for rust, rust marks and crack-
an insufficient or non-existent film of oil. ing caused by corrosion
In extreme cases the frictional torque in the joints can 1. If you have not already done so, with the mast fully
be such that the pins turn and gradually work out of the lowered undo the lift chain bolts from the top chain
chain (see Fig. 113). The chain can break as a result. supports (remove the anchor bolts) and thread
Turned pins can be rapidly identified if the flat ends are them out so that they can accessed along their
not all pointing in the same direction. whole length.
2. Check the chain links for corrosion and corrosion
damage (marks, pitting).
3. Rust film on lift chains can be removed with chain
oil. Now check again for rust marks.
4. Immediately replace any chains with rust marks or
pitting along with the chain supports, anchor bolts
and attachments. Chains used in pairs must also
be replaced in pairs.
Chain lateral wear

Wear traces along a stretch of the chain on the pin
heads and the outer plates indicate misalignment. This
can have the following cause:
Fig. 113 Turned pin • Misalignment between the pulley and the chain
Checking chain links for freedom of movement, support (see Checking the lifting components for
worn connection plates and turned pins misalignment, page 350).
1. With the mast fully lowered, undo the lift chain bolts
from the top chain supports (remove the anchor
Checking chain supports and an-
bolts) and thread them out far enough that they can chor bolts
accessed along their whole length.
Checking chain supports
2. Check the chain links for freedom of movement,
worn connection plates and turned pins. 1. Check the chain supports for:
Immediately replace any damaged chains along – Assembly period expiry
with the chain supports, anchor bolts and attach- (max. 6000 hours or 3 years, see date on chain
ments. Chains used in pairs must also be replaced support head)
in pairs. – Cracks
– Corrosion
Corrosion
– Finger wear
Corrosion considerably reduces the capacity of a lift
2. Replace any damaged or worn chain supports.
chain. It results in cracking in the side plates.
Checking the anchor bolts
– Check the anchor bolts for:
– Cracks
– Corrosion,
– Wear
3. Replace any damaged anchor bolts.
Fig. 114 Cracking caused by corrosion 4. Check the condition of the anchor bolt retaining el-
ement.
Lift chains must therefore be protected from corrosion.
Replace any corroded or missing retaining ele-
The layer of grease applied in the factory hot dip galva-
ments.
DT 3000 Series Rev.2 07/2010
349
LIFTING MECHANISM
Checking the chain pulleys 4. Tension the chain with the nut (3).
1. Check the chain pulleys for: 5. Repeat steps 2 and 4 until the chain tension is cor-
rect.
– Wear in the flange area
6. Hold the nut (3) and torque the counternut (2) to
– Running surface wear 170 - 190 Nm.
Worn flanges are due to misalignment. If the pulleys
are worn: Checking the lifting components for
2. Check or adjust the chain tension and mast roller misalignment
setting.
Misalignment of the chain pinion and the chain due to
Checking and adjusting the chain the wrong number of washers on the mast or a dam-
aged mast or cylinder components can also contribute
tension to wearing of the chain sides.
To test whether this is the case, proceed as follows:
1. Park the truck on a level surface.
2. Support the fork carriage and disassemble the an-
chor bolts on both ends of the lift chains.
3. Visually inspect the alignment with the anchor
1 slots.
If the chain ends are not aligned with the chain sup-
port slots:
– Check the mast, cylinder and piston rams for
4 damage.
– Check the alignment of the mast stages (see Re-
placing the mast rollers and adjusting the slack,
page 357).
3
2
Fig. 115 Lift chain and chain support with attachment
1 Lift chain
2 Counternut
3 Nut
4 Chain support
Checking the chain tension

1. Fully lower the fork carriage.
2. Using your thumbs check the lift chain tension (1,
Fig. 115) in the centre.
 The chain tension is correct if the chain cannot
be pushed through by more than 1 mm.
 If the chain can be pushed through further, pro-
ceed to Setting the chain tension.
Setting the chain tension
3. Loosen counternut (2, Fig. 115).
Rev.2 07/2010 DT 3000 Series
350
LIFTING MECHANISM
Lubricating Lift Chains
Lubricating Lift Chains CAUTION

General information A lift chain must never be allowed to dry.
Lubrication is the most important factor in lift chain
maintenance. It considerably affects the chain's useful In dusty operating conditions the multi-plate chains can
life. be more efficiently lubricated than roller chains. Multi-
plate chains consist of several plates. Therefore they
Highly stressed chains under constant use cannot last
provide several paths for the lubricant to reach the
sufficiently long if they are not regularly lubricated.
chain bolt (see Fig. 116) and allow the oil to penetrate
As with all contact surfaces, the tensiled steel precision to the bearing surface on the chain bolt, even when the
moving parts require a durable lubricant film between chain is dirty.
the contact surfaces to avoid excessive wear.
The key thing is that the lubricant oil can penetrate into
the chain bolts. This is impossible if the chains are cov- 1
ered in grease and dirt.
Maintaining a lubricant film on all the chain surfaces
provides the following benefits:
• Restricts joint wear to a minimum (chain elonga-
tion).
• Avoids corrosion.
• Reduces the risk of chain bolts turning.
• Restricts the danger of chain links turning in to a
minimum.
• Ensures an even movement of the chains and thus
reduces noise levels. Fig. 116 Oil film (1) in a multi-plate chain
• Reduces the chain tension due to less friction in the
Lubrication intervals and lubricants
chain system.
Under normal operating conditions the chains should
Key factors when considering which lubricant to use
be cleaned according to the intervals specified in the
are as follows:
maintenance schedule (see page 24), and then lubri-
• High degree of penetration in the narrowest of gaps cated with an approved type H chain lubricant (see
• Maximum tolerance of pressure and shearing page 22). In extreme conditions this interval must be
forces before the lubricant film comes off. reduced accordingly.
• Suitability to the operating temperature range, es-
pecially important for cold store trucks.
Lubrication intervals depend on the operating condi-
tions and the environment. Trucks parked outdoors, in
cold stores or which are subjected to extreme weather
conditions must be lubricated more frequently.
Dust will gather on oiled chains in dusty environments.
However, even in these conditions, regular lubrication
can considerably reduce wear.
A paste mixture of oil and dirt will gather on the chain
links, but they will not wear as fast as they would if they
were left to dry, leaving a metal to metal contact be-
tween the pins and plates.
DT 3000 Series Rev.2 07/2010
351
LIFTING MECHANISM
Separating Lift Chains
Separating Lift Chains Cutting the lift chain
Lift chains are supplied by the meter and must be cut

to the required length.
WARNING
Tools and equipment required Risk of eye damage
• A secure working plate with a hole slightly larger Splinters can fly off during grinding operations.
than the head diameter of a chain bolt. The hole  Wear goggles to avoid eye injuries.
must be deeper than the chain bolt length.
• A backring (washer) with a hole slightly larger than 1. Carefully grind the head of the chain bolt, taking
the head diameter of a chain bolt. The backring care not to damage the chain plate eyelet.
thickness must be slightly larger than the height of
2. Place the backring onto the hole in the working
the head of a chain bolt. The backring prevents the
plate.
inner plate surface from being damaged when you
drive out the chain bolt. 3. Insert the head of the chain bolt to be driven out
into the backring.
• A grinder.
 Align the chain bolt, backring and hole in the
• A hammer and hole with a diameter slightly shorter working plate.
than the chain bolt. Or a press with a suitable man-
4. Drive out the chain bolt.
drel. 1
4
1
3 2
1 Chain plate eyelet 3 Backring
2 Hole in working plate 4 Grinder
Rev.2 07/2010 DT 3000 Series
352
LIFTING MECHANISM
Replacing Mast Guards

Mast guards made of transparent plastic or metal grill
WARNING
prevent people reaching through a raised mast. Risk of trapping and severing limbs from moving
They protect against the risk of severing from lowering machine parts
machine parts. When working on an extended mast, body parts can be
Note: In this manual the term mast guard is used syn- trapped or severed by machine parts lowering auto-
onymously for metal mast grill. matically or accidentally.
 Secure the raised mast stages and forks with suita-
Mast guards / metal mast grills are a safety mecha-
ble, adequately sized supporting equipment to pre-
nism. The truck must not be operated without mast
vent them from lowering.
guards.
The guards are fitted differently depending on the lift
height and model: Preparation
• TL mast with 1700 mm lift height Preparing the truck
• TL mast with 2100 mm lift height (see page 354) 1. Power down the truck.
• TF mast with 2600 mm lift height (see page 356) 2. Disconnect the battery and prevent the truck from
Replacing mast guards on the
TL mast with 1700 mm lift height Removing mast guards
Remove the mast guard for the outer mast
1. Remove the four domed cap nuts (4) and the chas-
1
sis washers (3).
2. Pull the washer (2) off the stay bolts.
3 Removing the mast guard for the inner mast
2
3. Remove the six bolts (5) and the washer (1) from
the inner mast.
4 Assembling mast guards
Assembling the mast guard for the inner mast
1. Position the washer (1) on the brackets in the inner
mast.
Note: The canted surfaces must be facing towards the
control handle.
2. Secure washer (1) with six bolts (5) and torque the
bolts to 8 - 10 Nm.
Note: Insert the bolts and the shaft in the direction of
the forks.
5
Assembling the mast guard for the outer mast
1. Place the washer (2) on the stay bolts.
Fig. 117 Mast guards for TL mast with 1700 mm lift height Note: The canted surfaces must be facing towards the
1 Mast guard for inner mast (window or grill) control handle.
2 Mast guard for outer mast (window or grill) 2. Attach the chassis washers (3).
3 Chassis washer (4 x) 3. Attach the domed nuts (4) and torque them to 40 -
4 Domed cap nut (4 x) 45 Nm.
5 Bolts (6 x)
DT 3000 Series
353
LIFTING MECHANISM
Replacing the mast guard on the TL

mast with 2100 mm lift height
2
2 3
4
Fig. 119 Metal grill for TL mast with 2100 mm lift height
WARNING
Risk of trapping and severing limbs from moving
5 machine parts
When working on an extended mast, body parts can be
trapped or severed by machine parts lowering auto-
Fig. 118 Mast guard for TL mast with 2100 mm lift height matically or accidentally.
1 Mast guard for inner mast (window or grill)  Secure the raised mast stages and forks with suita-
2 Mast guard for outer mast (window or grill)
vent them from lowering.
3 Chassis washer (4 x)
4 Domed cap nut (4 x)
5 Bolts (6 x) Preparation
Preparing the truck
Removing mast guards

sis washers (3).
DT 3000 Series
354
LIFTING MECHANISM
Removing the mast guard for the inner mast

3. Remove the six bolts (5) and the washer (1) from
the inner mast.
Assembling mast guards

Assembling the mast guard for the inner mast
1. Position the washer (1) in the inner mast.
control handle.
2. Secure washer (1) with six bolts (5) and torque the
bolts to 8 - 10 Nm.
Note: Insert the bolts and the shaft in the direction of
the forks.
Note: When assembling a grill (2, Fig. 119), chassis
bolts (3) must first be placed on the stay bolts (RH side
only). Then attach the grill. The rest of the assembly is
then as follows:
control handle.
2. Attach the chassis washers (3).
3. Attach the domed nuts (4) and torque them to 40 -
45 Nm.
DT 3000 Series
355
LIFTING MECHANISM
Replacing the mast guard on the TF

mast with 2600 mm lift height WARNING
Risk of trapping and severing limbs from moving
machine parts
1 When working on an extended mast, body parts can be
trapped or severed by machine parts lowering auto-
matically or accidentally.
2
 Secure the raised mast stages and forks with suita-
3 vent them from lowering.
4
Preparation
Preparing the truck
Removing mast guards

sis washers (5).
5
Removing the top mast guard for the inner mast
1. Remove the two nuts (2) and remove the washer
(1).
6 Removing the bottom mast guard for the inner
mast
2. Remove the two screws (7) and remove the
washer (6).
7 Assembling mast guards
Assembling the top mast guard for the inner mast
1. Position the washer (1) in the inner mast.
Fig. 120 Mast guards for TF mast with 2600 mm lift height
1 Top mast guard for inner mast (window or grill)
control handle.
2 Nut (2 x)
2. Secure the washer (1) with two nuts (2) and torque
3 Mast guard for outer mast (window or grill)
the nuts to 20 - 25 Nm.
4 Domed cap nut (4 x)
5 Chassis washer (4 x)
Assembling the bottom mast guard for the inner
mast
6 Bottom mast guard for inner mast (window or grill)
1. Position the washer (6) on the brackets in the inner
7 Bolts (2 x)
mast.
control handle.
2. Secure the washer (6) with two bolts (7) and torque
the bolts to 8 - 10 Nm.
Note: Fit the bolts from the control handle side.
DT 3000 Series
356
LIFTING MECHANISM

control handle.
2. Attach the chassis washers (5).
3. Attach the domed nuts (4) and torque them to 40 -
45 Nm.
DT 3000 Series
357
Notes:
358
CYLINDERS
359
Notes:
360
CYLINDERS
General
General • Always replace all the seals on the assembly. Used

seals can cause leaks.
Safety notices Replacing the rod seals
CAUTION CAUTION
Health risk Damaged or contaminated seal seats and piston
Cleaning agents, lubricants and consumables can rams will result in immediate leaks, even with new
damage your health. seals. The same applies to the use of unsuitable
tools for seal removal and fitting.
when handling solvents and lubricants.  Before fitting a new seal check the seal seats and
piston rams for damage and make sure they are
clean.
 When replacing rod seals use assembly equipment
and tools made of soft metal or plastic without sharp
WARNING edges. Suitable tools and assembly procedures are
High-pressure hydraulic oil can cause severe in- described starting on page 362.
jury
Whenever a high pressure hydraulic oil enters the skin
it must be treated as a medical emergency.
mal at first.
To avoid accidents:
any sections of it.
tem.
leaks.
Hydraulic system repair instructions

• Hydraulic systems are sensitive to dirt.
• Thoroughly clean disassembled hydraulic compo-
nents before dismantling them.
• Always repair hydraulic components at a clean
workstation.
• Immediately protect cleaned and de-greased com-
ponents with a thin coating of hydraulic oil.
• Protect components against re-contamination be-
fore assembling them.
• Immediately seal open hydraulic ports on repaired
assemblies with dummy plugs. This also applies to
open ports and lines on the truck.
• Do not refinish any cylinder surfaces. Replace any
damaged parts.
DT 3000 Series
361
CYLINDERS
Tools
Tools Producing extractors

1. Hard solder a self-tapping 4 mm screw (3) onto the
shaft (min. 150 mm, long, max. Ø 4 mm) of a
CAUTION screwdriver (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. 121).
1
2
Fig. 123 Groove aligning arbor in a cylinder cap

1 Cylinder cap
Fig. 121 Hook 2 Seal seat
Extractor 3 Groove aligning arbor
Two extractors to remove rod seals (see Fig. 122)

.
Fig. 122 Extractor
DT 3000 Series
362
CYLINDERS
Tools
Assembly devices for large rod

seals
Produce a tool body (12, Fig. 124) with a diameter to
match the internal diameter of the cylinder caps.
3
4
Fig. 124 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.
DT 3000 Series
363
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. 122) 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. 121) 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. 126 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. 125).
(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. 127).
can be moved into the loop.  One segment of the rod seal jumps into the seal
seat.
Fig. 125 Threading the rod seal
Fig. 127 The first rod seal segment is located in the seal seat.
7. Retract the pin (2, Fig. 127).
 The rod seal is now fully located in the seal seat
(see Fig. 128)
DT 3000 Series
364
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. 130) 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. 128 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. 130 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. 129 Small rod seal assembly

• Apply a thin coating of hydraulic oil to the rod seal
(2, Fig. 129) and the seal seat (3) in the cylinder cap
(1).
• Place the cylinder cap on the groove aligning arbor
(4).
• Gently bend the rod seal (2) together.
• Place one part of the rod seal into the seal seat (3).
• Press the rod seal into the seal seat using a burr-
free aluminium or plastic arbor (1).
DT 3000 Series
365
CYLINDERS
Replacing the Lift Cylinder on the TL Mast
Replacing the Lift Cylinder on Removing the lift cylinder (TL mast)
the TL Mast
WARNING
WARNING Accidental truck movement can cause injury
High pressure hydraulic system suddenly when you are working on it.
Risk of injury from escaping hydraulic oil. You should therefore carry out the following safety pro-
To avoid accidents: cedures before starting any operations on the truck:
 Depressurise the hydraulic system before opening  Lower the forks to the ground.
any sections of it.
tem.
leaks.
be treated as a medical emergency. WARNING
Seek medical assistance even if the skin appears nor- Risk of trapping and severing limbs
mal at first. Unsecured mast stages and attachments can sever
limbs or even cause fatal injuries.
 Before starting assembly always block and secure
the relevant components with equipment with suffi-
CAUTION cient strength and stability.
Health risk
Cleaning agents, lubricants and consumables can Note: The following item numbers refer to Fig. 131.
damage your health. Preparation
 Observe the manufacturer’s safety instructions 1. Fully lower the outriggers.
2. Place two wooden blocks on the outriggers.
1. Lower the fork carriage onto the wooden blocks.
2. Continue to activate lowering for approx. 20 s.
WARNING  The hydraulic system is depressurised.
Lifting gear failure can cause accidents being switched on again.
 Note the minimum capacity for the lifting gear 4. Disassemble the mast guards (see page 353).
whenever carrying out work on the mast.
Lift chain removal
1. Remove the cotter pin (15) from the top chain bolt
and pull out the chain bolt (14).
2. Take the lift chain (16) out of the pulley and store it
so that it is out of the way.
Chain support removal
Note: If the lift cylinder is removed for repairs and not
replaced, the chain support can remain in place on the
truck.
1. Remove the cotter pin (13) from the chain support
(12).
DT 3000 Series
366
CYLINDERS
2. Remove the jam nuts (11) from the chain support

(12).
3. Remove the chain support (12).
Removing the pulley
1. Remove the retaining ring (18) and remove the pul-
ley (20) and shims (19).
 The piston ram of the lift cylinder is released.
Fork carriage removal
1. Raise the 2nd mast stage (2) with a crane (mini-
mum capacity 600 kg) until the fork carriage can be
pulled out.
2. Pull the fork carriage out to the front and using a
crane or a forklift truck lower it onto a suitable base.
3. Prevent the 2nd mast stage (2) from lowering using
square wooden blocks in the sections of the
1st mast stage (1).
Lift cylinder removal
1. Push a flat tray underneath the hydraulic cylinder
(10).
2. Disconnect the hydraulic port from the lift cylinder.
Note: Seal the lines and port immediately with dummy
plugs.
3. Remove the lift cylinder (10) from its socket in the
1st mast stage (1).
 The lift cylinder is removed.
Lift cylinder (TL mast) assembly

Lift cylinder assembly
1. Assemble the lift cylinder in the reverse order of
disassembly.
2. Counter fix the nuts (11) on the chain support to
170 - 190 Nm.
Note: Make sure the lift cylinder is centred in its socket
on the mast base.
Note: When assembling a new lift cylinder, remove the
angle cleat from the old cylinder. Fit the angle cleat to
the new lift cylinder and torque to 50 - 60 Nm.
DT 3000 Series
367
CYLINDERS
18
21
19
2
17
6
7 18
14
15
16
12 13
4
5
11
3
1
2
10
8
9
15 14
Fig. 131 TL mast
DT 3000 Series
368
CYLINDERS
Repairing the Lift Cylinder for the TL Mast
Repairing the Lift Cylinder for Checking the cylinder tube and piston ram
1. Check the seats for the seal and guide items in the
the TL Mast cylinder tube (12) and the cylinder cap (3) for dam-
Note: The following item numbers refer to Fig. 132. age. Make sure they are clean. If a seat is dam-
aged, dispose of the affected part.
2. Check the piston ram for damage. If there are signs
CAUTION of pitting, corrosion marks or scratches, dispose of
Damaged or contaminated seal seats and piston the piston ram.
rams will result in immediate leaks, even with new 3. Apply a thin coat of hydraulic oil to the piston ram
seals. The same applies to the use of unsuitable and the shiny surfaces of the cylinder tube.
tools for seal removal and fitting.  The cylinder tube and piston ram are protected
 Before fitting a new seal check the seal seats and against corrosion and are ready for assembly.
Fitting the lift cylinder
clean.
and tools made of soft metal or plastic without sharp CAUTION
edges. Suitable tools and assembly procedures are
Used sealing elements can cause leaks
described starting on page 361.
 Always use new parts from the seal kit for assem-
 Do not re-use sealing elements that have been re-
bly, never fit used parts.
moved.
1. Apply a thin coat of hydraulic oil to the new dirt de-

Note: Refer to the Safety notices and Hydraulic system
flector (1), rod seal (2), guide ring (5) and seals (6,
repair instructions on page 361.
7).
Preparation 2. Carefully assembly the above-mentioned parts. Fit
1. Disassemble the lift cylinder (see page 366). the rod seal (2) with the sealing lip first.
Lift cylinder disassembly 3. Fit the new piston (10).
1. Pull the piston ram (8) off the cylinder tube (12). Note: Refer to the rod seal assembly instructions on
2. Unscrew the cylinder cap (3). page 364.
3. Using suitable tools (see page 362) remove the fol- 4. Apply a coat of hydraulic oil to the piston ram and
lowing parts from the seats in the cylinder cap (3) insert it in the cylinder tube without twisting. Take
or cylinder tube (6): care not to damage the seals in the process.
– Dirt deflector (1) 5. Carefully screw on the cylinder cap and torque it to
120 - 140 Nm.
– Rod seal (2)
 The lift cylinder is repaired and ready for assembly.
– Backring (4)
– Guide ring (5) Final tasks
– Seals (6,7) 1. Assemble the lift cylinder (see page 367).
Note: Refer to the rod seal disassembly instructions on

page 364.
4. Dispose of parts 1,2 and 4 - 7.
5. Remove the piston (10) from the piston ram and
dispose of it.
6. Clean all components thoroughly and apply dry
compressed air to them.
 The cylinder is dismantled and can be checked
for damage.
DT 3000 Series
369
CYLINDERS
Repairing the Lift Cylinder for the TL Mast
3
2
5 1
4
2
6 5 - 6 Nm
7
4 8
3
120 - 140 Nm
5 12
6
8
7
12
10
11 13
13
9
8 - 9 Nm
10
11
Fig. 132 TL mast lift cylinder
DT 3000 Series
370
CYLINDERS
Replacing the Lift Cylinder on the TF Mast
Replacing the Lift Cylinder on Lift cylinder (TF mast) removal

the TF Mast
WARNING
WARNING Accidental truck movement can cause injury
High pressure hydraulic system suddenly when you are working on it.
Risk of injury from escaping hydraulic oil. You should therefore carry out the following safety pro-
To avoid accidents: cedures before starting any operations on the truck:
 Depressurise the hydraulic system before opening  Lower the forks to the ground.
any sections of it.
tem.
leaks.
be treated as a medical emergency. WARNING
Seek medical assistance even if the skin appears nor- Risk of trapping and severing limbs
mal at first. Unsecured mast stages and attachments can sever
limbs or even cause fatal injuries.
 Before starting assembly always block and secure
the relevant components with equipment with suffi-
CAUTION cient strength and stability.
Health risk
Cleaning agents, lubricants and consumables can Note: The following item numbers refer to Fig. 133.
damage your health.
Lift cylinder (TF mast) removal
when handling solvents and lubricants. Preparation
1. Fully lower the outriggers and forks.
 The hydraulic system is depressurised.
WARNING 3. Disconnect the battery and prevent the truck from
Lifting gear failure can cause accidents being switched on again.
 Note the minimum capacity for the lifting gear Lift cylinder removal
whenever carrying out work on the mast. 1. Push a flat tray underneath the hydraulic cylinder
(10).
2. Disconnect the top and bottom hydraulic ports from
the respective lift cylinder.
Note: Seal the lines and ports immediately with dummy
plugs.
3. Remove the retaining ring (14) and shims (13).
4. Secure the lift cylinder (12, 15) to the 1st mast
stage (1) so that it does not fall over when the
2nd mast stage (2) is raised.
DT 3000 Series
371
CYLINDERS

mum capacity 600 kg) until the lift cylinder is clear
of the 2nd mast stage.
6. Prevent the 2nd mast stage (2) from lowering using
square wooden blocks in the sections of the
1st mast stage (1).
7. Using lifting equipment, raise the lift cylinder (10)
out of the 1st mast stage and place it down on a
suitable support.
 The lift cylinder is removed.
Lift cylinder (TF mast) assembly

Lift cylinder assembly
disassembly.
Note: Make sure the cylinder is centred in its socket on
the mast base.
Note: Choose the number of shims (13) so that the lift
cylinder has as little slack as possible when installed
vertically.
Note: Torque the hydraulic ports to 70 - 75 Nm.
DT 3000 Series
372
CYLINDERS
10
9 5
6
14
8 13
7
14
13
15
8
11
28
27
23
3 25
26
22
4 21
20
16 24
2
1 19
29
18
12 17
23
22
Fig. 133 TF mast
DT 3000 Series
373
CYLINDERS
Repairing the Lift Cylinder for the TF Mast
Repairing the Lift Cylinder for Checking the cylinder tube and piston ram
the TF Mast cylinder tube (17) and the cylinder cap (6) for dam-
Note: The following item numbers refer to Fig. 134. age. Make sure they are clean. If a seat is dam-
2. Check the piston ram for damage. If there are signs
CAUTION of pitting, corrosion marks or scratches, dispose of
Damaged or contaminated seal seats and piston the piston ram.
rams will result in immediate leaks, even with new 3. Apply a thin coat of hydraulic oil to the piston ram
seals. The same applies to the use of unsuitable and the shiny surfaces of the cylinder tube and
tools for seal removal and fitting. cap.
 Before fitting a new seal check the seal seats and  The cylinder tube and piston ram are protected
piston rams for damage and make sure they are against corrosion and are ready for assembly.
clean.
Fitting the lift cylinder
edges. Suitable tools and assembly procedures are CAUTION
 Do not re-use sealing elements that have been re-
moved.

1. Apply a thin coat of hydraulic oil to the new dirt de-
flector (4), rod seal (5), guide ring (9) and seals (10,
Preparation 11).
1. Disassemble the lift cylinder (see page 371). 2. Carefully assembly the above-mentioned parts. Fit
Lift cylinder disassembly the rod seal (5) with the sealing lip first.
1. Remove the screw (2) and take off the piston ram 3. Fit the new piston (14).
head (1). Note: Refer to the rod seal assembly instructions on
2. Remove the buffer (3). page 364.
1. Pull the piston ram (12) off the cylinder tube (16). 4. Apply a coat of hydraulic oil to the piston ram and
insert it in the cylinder tube without twisting. Take
2. Unscrew the cylinder cap (6). care not to damage the seals in the process.
3. Using suitable tools (see page 362) remove the fol- 5. Carefully screw on the cylinder cap and torque it to
lowing parts from the seats in the cylinder cap (6) 120 - 140 Nm.
or cylinder tube (16):
 The lift cylinder is repaired and ready for assembly.
4. Dirt deflector (4)
5. Rod seal (5) Final tasks
6. Guide ring (9) 1. Assemble the lift cylinder (see page 372).
7. Seals (10, 11)

page 364.
8. Dispose of parts 4, 5 and 9 - 11.
dispose of it.
for damage.
DT 3000 Series
374
CYLINDERS
Repairing the Lift Cylinder for the TF Mast
2
1
3
1
4
5
3 120 - 140 Nm
4 6
5
6 8
9 5 - 6 Nm 7
9
10 16
10
8
11
11 7
12
12
16
13
14
15
13
17
14
8 - 9 Nm 15
17
Fig. 134 TF mast lift cylinder
DT 3000 Series
375
CYLINDERS
Replacing the Free Lift Cylinder on the TF Mast
Replacing the Free Lift Cylinder 1. Remove one retaining ring (5, Fig. 135) and re-
move the axle (4) along with the pulley (2) and
on the TF Mast washers (3).
2. Remove the retaining ring (6, Fig. 135).
Free lift cylinder (TF mast) removal  The piston ram of the lift cylinder is released.
Note: Unless otherwise indicated, the following item Fork carriage removal
numbers refer to Fig. 136.
Preparation mum capacity 600 kg) until the fork carriage can be
1. Fully lower the outriggers. pulled out.
2. Place two wooden blocks on the outriggers. 2. Pull the fork carriage out to the front and using a
crane or a forklift truck lower it onto a suitable base.
1. Lower the fork carriage onto the wooden blocks.
3. Prevent the 2nd mast stage (11) from lowering us-
ing square wooden blocks in the sections of the
1st mast stage (1).
being switched on again. Free lift cylinder removal
4. Disassemble the mast guards (see page 353). 1. Push a flat tray underneath the free lift cylinder
(18).
Lift chain removal
2. Disconnect the hydraulic port from the free lift cyl-
1. Remove the cotter pin (23) from the top chain bolt inder (18).
(22) and pull out the chain bolt.
Note: Seal the line and port immediately with dummy
2. Take the lift chain (26) out of the pulley (24) and plugs.
store it so that it is out of the way.
3. Secure the free lift cylinder (18) so that it cannot fall
Chain support removal over on removal.
Note: If the lift cylinder is removed for repairs and not 4. Loosen the screws (16) from the tie bar, take out
replaced, the chain support can remain in place on the the shims (17) and remove the screws.
truck. 5. Remove the free lift cylinder (18) from its socket in
1. Remove the cotter pin (21) from the chain support the 1st mast stage (1).
(20).  The lift cylinder is removed.
2. Remove the jam nuts (19) from the chain support.
3. Remove the chain support (20). Free lift cylinder (TF mast) assembly
Removing the pulley Lift cylinder assembly
disassembly.
5 2. Counter fix the nuts (19) on the chain support to
1
170 - 190 Nm.
Note: Make sure the lift cylinder is centred in its socket
on the mast base.
6
4 Note: When assembling a new lift cylinder, remove the
angle cleat from the old cylinder. Fit the angle cleat to
5
the new lift cylinder and torque to 50 - 60 Nm.
3
2 5. Perform the drift test (see page 55).
3
Fig. 135 Yoke assembly
DT 3000 Series
376
CYLINDERS
Replacing the Free Lift Cylinder on the TF Mast
10
9 5
6
14
8 13
7
14
13
15
8
11
28
27
23
3 25
26
22
4 21
20
16 24
2
1 19
29
18
12 17
23
22
Fig. 136 TF mast
DT 3000 Series
377
CYLINDERS
Repairing the Free Lift Cylinder for the TF Mast
Repairing the Free Lift Cylinder age. Make sure they are clean. If a seat is dam-
for the TF Mast 2. Check the piston ram for damage. If there are signs
Note: The following item numbers refer to Fig. 137. of pitting, corrosion marks or scratches, dispose of
the piston ram.
3. Apply a thin coat of hydraulic oil to the piston ram
CAUTION and the shiny surfaces of the cylinder tube.
Damaged or contaminated seal seats and piston  The cylinder tube and piston ram are protected
rams will result in immediate leaks, even with new against corrosion and are ready for assembly.
seals. The same applies to the use of unsuitable
Free lift cylinder assembly
tools for seal removal and fitting.
 Before fitting a new seal check the seal seats and
piston rams for damage and make sure they are CAUTION
clean.
edges. Suitable tools and assembly procedures are
 Do not re-use sealing elements that have been re- 1. Apply a thin coat of hydraulic oil to the new dirt de-
moved. flector (1), rod seal (2), guide ring (5) and seals (6,
7).
2. Carefully assembly the above-mentioned parts. Fit
the rod seal (2) with the sealing lip first.
3. Fit the new piston (10).
Preparation
Note: Refer to the rod seal assembly instructions on
1. Disassemble the free lift cylinder (see page 376). page 364.
Free lift cylinder disassembly 4. Apply a coat of hydraulic oil to the piston ram and
1. Pull the piston ram (8) off the cylinder tube (12). insert it in the cylinder tube without twisting. Take
2. Unscrew the cylinder cap (3). care not to damage the seals in the process.
3. Using suitable tools (see page 362) remove the fol- 5. Carefully screw on the cylinder cap and torque it to
lowing parts from the seats in the cylinder cap (3) 120 - 140 Nm.
or cylinder tube (12):  The free lift cylinder is repaired and ready for as-
– Dirt deflector (1) sembly.
– Rod seal (2) Final tasks

– Guide ring (5) 1. Assemble the free lift cylinder (see page 367).
– Seals (6, 7)
page 364.
4. Dispose of parts 1, 2 and 5 - 7.
dispose of it.
for damage.
Checking the cylinder tube and piston ram
cylinder tube (12) and the cylinder cap (3) for dam-
DT 3000 Series
378
CYLINDERS
Repairing the Free Lift Cylinder for the TF Mast
1 2
5 - 6 Nm
3
3 4
2
120 - 140 Nm
5
5
4
6
6
7
7
8
~
12
12
10
11
13
9
8 - 9 Nm
10
13
11
Fig. 137 TF mast free lift cylinder
DT 3000 Series
379
CYLINDERS
Replacing the Outrigger Lift Cylinders
Replacing the Outrigger Lift Removing the outrigger lift cylin-

Cylinders ders
WARNING
Risk of injury from escaping hydraulic oil.
To avoid accidents:
1
any sections of it.
2 tem.
leaks.
3
mal at first.
Note: The procedure is identical for the left and right

4
outrigger lift cylinders.
Preparation and loosening the top mounting
1. Take off the motor compartment panel.
2. Fully lower the forks and outriggers.
3. Pull the clamp (1) off the top mounting.
4. Keep the outrigger lowering switch pressed down.
Fig. 138 LH outrigger lift cylinder  The weight of the piston ram moves it down and
1 Top clamp it is released from the top mounting.
2 Outrigger lift cylinder
3 Hydraulic connection 5. Switch off the truck, jack it up and prevent it from
4 Bottom cleat
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.
DT 3000 Series
380
CYLINDERS
Replacing the Outrigger Lift Cylinders
Outrigger lift cylinder assembly

1. Lubricate the receptacle of the piston ram and the
cylinder base in the truck.
2. Assemble the outrigger lift cylinders in the reverse
order of disassembly.
3. Remove the jack from the truck and start up the
truck.
Fig. 139 Min. and max. oil levels

page 21) as far as the max. marking (2, Fig. 139).
6. Visually inspect the hydraulic system for leaks.
7. Check the oil level and replenish as required.
DT 3000 Series
381
CYLINDERS
Repairing the Outrigger Lift Cylinders
Repairing the Outrigger Lift Cyl- 2. Check the piston ram for damage. If there are signs
of pitting, corrosion marks or scratches, dispose of
inders the piston ram.
Note: The following item numbers refer to Fig. 140. 3. Apply a thin coat of hydraulic oil to the piston ram
and the shiny surfaces of the cylinder tube.
 The cylinder tube and piston ram are protected
CAUTION against corrosion and are ready for assembly.
Damaged or contaminated seal seats and piston Fitting the outrigger lift cylinder
rams will result in immediate leaks, even with new
tools for seal removal and fitting. CAUTION
 Before fitting a new seal check the seal seats and Used sealing elements can cause leaks
piston rams for damage and make sure they are  Always use new parts from the seal kit for assem-
clean. bly, never fit used parts.
and tools made of soft metal or plastic without sharp 1. Apply a thin coat of hydraulic oil to the new guide
edges. Suitable tools and assembly procedures are rings (3), new backring (4) and a new rod seal (5).
2. Insert the above-mentioned parts carefully in the
 Do not re-use sealing elements that have been re- cylinder tube, starting with the bottom bearing ring
moved. (3). Fit the rod seal (5) with the sealing lip first.
Then place a bearing ring (4) on it, if one was fitted
Note: Refer to the Safety notices and Hydraulic system previously.
repair instructions on page 361. Note: Refer to the rod seal assembly instructions on
Preparation page 364.
1. Disassemble the outrigger lift cylinder (see 3. Apply a coat of hydraulic oil to the piston ram and
page 380). insert it in the cylinder tube without twisting. Take
care not to damage the seals in the process.
Dismantling the outrigger lift cylinder
4. Push a well oiled deflector ring (2) over the piston
1. Pull the piston ram (1) off the cylinder tube (6). ram and push it into the seat in the cylinder tube.
2. Using suitable tools (see page 362) remove the fol-  The outrigger lift cylinder is repaired and ready for
lowing parts from the seats in the cylinder tube (6): assembly.
– Dirt deflector (2)
Final tasks
– Guide ring (3)
1. Assemble the outrigger lift cylinder (see page 381).
– Backring (4)
– Rod seal (5)
page 364.
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.
for damage.
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.
DT 3000 Series
382
CYLINDERS
Repairing the Outrigger Lift Cylinders
Fig. 140 Outrigger lift cylinder
DT 3000 Series
383
CYLINDERS
Replacing the Traction Cylinder

Removing the traction cylinder 2
WARNING 1

Risk of injury from escaping hydraulic oil.
To avoid accidents:
any sections of it.
tem.
 Keep hands and body away from pressurized fluid. Fig. 141 Connector plate
 Always use a piece of paper or cardboard to trace 6. Remove the screws (1) and push the connector
leaks. plate (2) and connectors slightly to the side.
be treated as a medical emergency. Discharging the drive cage springs
mal at first.
WARNING
Preparation Risk of injury from pre-tensioned springs
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. 142 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. 143).
DT 3000 Series
384
CYLINDERS
Adjusting the cylinder
1 2
3
4
5 2
1
0 mm
6
Fig. 144 Adjusting the traction cylinder

Fig. 143 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. 144).
3 Hex. bolt on cylinder tube (SW 32) 5. Screw in and tighten the fitting (2, Fig. 143).
4 Square nut, M42 6. Connect the hydraulic line and tighten the union
5 Cylinder tube with external thread, M42 nut (1, Fig. 143).
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. Risk of injury from pre-tensioned springs
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. 142).
side in a recess in the back wall to prevent it from twist- 9. Insert the grease nipple (2, Fig. 142).
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).
Traction cylinder assembly page 21) as far as the max. marking (see 2,
Fig. 139).
Traction cylinder assembly 12. Bleed the hydraulic system (see page 52).
1. Grease the end of the piston ram. 13. Visually inspect the hydraulic system for leaks.
2. Push the square nut into the recess in the back 14. Check the oil level and replenish as required.
wall, narrow side first, and hold it securely.
3. Insert the cylinder into the square nut from the top.
DT 3000 Series
385
CYLINDERS
Repairing the Traction Cylinder
Repairing the Traction Cylinder Fitting the traction cylinder

1. Apply a thin coat of hydraulic oil to the new guide
rings (2) and a new rod seal (3).
2. Insert the above-mentioned parts carefully in the
CAUTION cylinder tube, starting with the bottom guide ring
(2). Fit the rod seal (3) with the sealing lip first.
Damaged or contaminated seal seats and piston
Note: Refer to the rod seal assembly instructions on
rams will result in immediate leaks, even with new
page 364.
tools for seal removal and fitting. 3. Apply a coat of hydraulic oil to the piston ram and
insert it in the cylinder tube without twisting. Take
 Before fitting a new seal check the seal seats and
care not to damage the seals in the process.
clean. 4. Push a well oiled deflector ring (4) over the piston
ram and push it into the seat in the cylinder tube.
and tools made of soft metal or plastic without sharp  The traction cylinder is repaired and ready for as-
edges. Suitable tools and assembly procedures are sembly.
described starting on page 362. Final tasks
1. Assemble the traction cylinder (see page 385).
Preparation
1. Disassemble the traction cylinder (see page 384).
Disassembling the traction cylinder
1. Pull the piston ram (5) off the cylinder tube (1).
2. Using suitable tools (see page 362) remove the fol-
lowing parts from the seats in the cylinder tube (1):
– Dirt deflector (4)
– Rod seal (3)
– Guide ring (2)
page 364.
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.
for damage.
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 coat of hydraulic oil to the piston ram
and the shiny surfaces of the cylinder tube.
 The cylinder tube and piston ram are protected
against corrosion and are ready for assembly.
DT 3000 Series
386
CYLINDERS
Repairing the Traction Cylinder
Fig. 145 Traction cylinder
DT 3000 Series
387
Notes:
388
PLATFORM
389
Notes:
390
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. 147 Panel removal

1 Screws
2 Panel
Testing switch PLS1

3 1. Remove the four screws (1) and take off the panel
(2).
Fig. 146 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°.
5
3. Adjust the spindle (3) with the screw (1) to produce
a gap of 1.5 mm to 2.0 mm from the top of the spin-
dle to the block (see Fig. 146).
Fig. 148 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: Adjust the switch if this functionality is not pro-
vided.
Adjusting switch PLS1
1. Loosen the two M10 screws (4, 5) on the inside
and outside of the chassis.
DT 3000 Series
391
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 panel from the platform (see Fig. 147).
3
1
Fig. 149 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: Adjust the switch if this functionality is not pro-
vided.
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 screws (3) on switch PLS2 (2) to 1 to
2 Nm.
DT 3000 Series
392
PLATFORM
Replacing the Folding Platform Springs
Replacing the Folding Platform

Springs
Spring removal 5
6
8 7 6
1
Fig. 152 Spring removal
5 Dowel pin
6 Screw
7 Bracket
Fig. 150 Panel removal 8 Axle (located on the inside) and pipe
1 Screws
2 Panel
1. Remove the four screws (1) and take off the panel
CAUTION
(2). Risk of injury from heavy component
The platform weighs approximately 31 kg.
 Use suitable lifting gear to remove and assemble
the platform.
4 3. Loosen the screws (6) of the bracket (7) and re-

move the complete platform. Note the wiring.
4. Remove the dowel pin (5).
3 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
Fig. 151 Discharging the springs
the following:
3 Spring
1. If necessary replace the two flanged sleeves sup-
4 Screw
porting the axle (8).
2. After assembly, tension the spring (3) with the
WARNING screw (4).
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).
DT 3000 Series
393
Notes:
394
SCHEMATIC DIAGRAMS
395
Notes:
396
SCHEMATIC DIAGRAMS
Wire Colour Code
Wire Colour Code • The last two digits are a sequence number.
Note: Third party component wires may pose an
The wires used in the truck are colour-coded and
exception to this rule:
numbered 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 connected
ORG Orange 3 ** +12 VDC - transformer
YEL Yellow 4 ** Third DC - transformer
GRN Green 5 ** Negative not connected
BLU Blue 6 ** Negative, insulated
VIO Violet 7 ** +5 VDC - transformer
GREY Grey 8 ** Fourth DC - transformer
WHT White 9 ** Miscellaneous
RED / WHT Red / White 29 ** Positive connected
GRN / WHT Green / White 59 ** Negative connected
** Numbers 01 to 99
DT 3000 Series Rev.1 02/2009
397
SCHEMATIC DIAGRAMS
General contact symbol abbreviations
General contact symbol

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

on
K Relay LMS Limit switch

ACS Travel switch LOS Lower button
AXS Accessories switch ORS Override switch
BRS Brake switch POT Potentiometer
DIS Direction switch RA Raise potentiometer
DRS Door switch RAS Lift button
EDS Emergency Disconnect REA Reach potentiometer
EM Encoder module RS Reverse switch
ENC Encoder SAS Safety Reverse Switch
FS Forward switch SDS Start switch
HBS Handbrake switch SES Seat switch
HNS Horn switch SSS 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.1 02/2009 DT 3000 Series
398
SCHEMATIC DIAGRAMS
General contact symbol abbreviations
Abbreviati Description Abbreviation Description (Sheet 2 of 2)

on
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 --- ---
DT 3000 Series Rev.1 02/2009
399
SCHEMATIC DIAGRAMS
Electrical wiring diagrams
Europe USA Description Europe USA Description
Wires joining Switch applied manually
Wires crossing Solenoid valve
Wire connection Throttle / coil
Plug / socket Resistor
Wire strap Capacitor
Terminal board Potentiometer
Fuse Varistor
V
Assembly Thermal protector
Contact, normally Lamp

open
Contact, normally Horn

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

contactor / relay
Time delay contactor LED

/ relay
Switch, normally Transistor

open
Rev.1 02/2009 DT 3000 Series
400
SCHEMATIC DIAGRAMS
Europe USA Description Europe USA Description
Push button, MOSFET

mechanically
actuated
Pushbutton, Thyristor
hydraulically
actuated
Emergency Comparator
Disconnect
Motor armature
---
DT 3000 Series Rev.1 02/2009
401
SCHEMATIC DIAGRAMS
Wire Harness List
Wire Harness List

DT 3040 -MW and DT 3040 -MF
Item number Description Wire harness Connected component

connectors
825765 Main Harness JC206 SRT

JC208 BRS1
JC215 PC215 (jumper)
PC200 Access 1 (Display)
PC201 Access 2&3
PC202 ECR1
PC204 BLS, LMS2, LMS4, B+(AK), –B
PC205 LMS1
PC209 Access 8.1
PC210 FLS(a)
PC211 ALM(a)
PC212 FAN
PC213 CAN connection
PC214 PS1
PC215 JC215
PC217 PWS
PC218 SR1
PC219 SR2
PC220 PLS1
PC221 PLS2
PC223 PS2
825767 CAN control handle cable JC209 Main harness,
PC410 Access 8.1
825768 Mast cable JC204 LMS1
PC216 BLS
PC207 LMS4
826119 Horn cable PC413, PC417, PC419 Control handle
826120 CAN analog PCB wiring PC418, PC415, PC414 Module wiring within
Access 8.1
827421 Wire harness BLS JC207, PC207.1 BLS
DT 3000 Series
402
SCHEMATIC DIAGRAMS
Wire Harness List
DT 3040 -EF
Item number Description Connector Component
826923 Main harness JC209 Control handle

PC200 Display screen
PC201 Access 2&3
PC202 ECR1
PC203 TS1
PC204 BLS, LMS2, LMS4, B+(AK),
–B
PC208 BRS1
PC210 FLS(a)
PC211 ALM(a)
PC212 FAN
PC213 CAN connection
PC214 PS1
PC217 PWS
PC218 SR1
PC219 SR2
PC220 PLS1
PC221 PLS2
PC223 PS2
PC224 TFD
PC225 Jumper JC225
PC226 ECR3
PC227 Access 5
PC228 Access 5
PC229 SAHS
PC230 Access 8.2
PC231 PS3
PC234 ECR2
827422 CAN control handle cable PC209, PC410 Main harness, control
handle
825768 Mast cable JC204 LMS1
PC216 BLS
PC207 LMS4
DT 3000 Series
403
SCHEMATIC DIAGRAMS
Wire Harness List
Item number Description Connector Component
826119 Horn cable PC413, PC417, PC419 Control handle

826120 CAN analog PCB wiring PC418, PC415, PC414 Module wiring within
Access 8.1
827421 Wire harness BLS JC207, PC207.1 BLS
(a). Option
DT 3000 Series
404
SCHEMATIC DIAGRAMS
DT 3040-EF Main Wire Harness
Detail B PC217
I TFD K HANDLE D BRS1 B DISPLAY
209
KEYPAD 1 2 3 4 5 6 PC224 1 2 3 4 5 6 JC209 A B C PC208 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PC200
3 1 PWS
Adapter 507
3 2 C
KYS 30 204 Detail A 14+15 4 4 4 4 4 4 5 5 5 5 5 5 3 19 3 18 2 2 2 18 18 18 2 2 18 18 18 18 18
2982
5900
204
503
902
907
504
2910
205
2917
700
611
104
103
2938
5913
2920
2981
908
903
2913
203
506
2910
2983
87
2911 204 PC210
Coil Contact
30 12
PC230 2910 2906
911 232 86 206 87 12 2911 3 1 FLS (Opt.)
CCD 1 7 232
Socket 5900
5904
3 2 C
5904 85 11
2 7 206
003 Use Adapter PN820143 for Key Switch 86 12
3 7 R 203
4 7
015 PC211
2907
5 20 3 1 ALM (Opt.)
5905
6 20 3 2 C
7 20
511
8 7
SP1 PC212
905
9 7 2905
3 1 FAN
10 20 5906
PC219 3 2 C
11 20
SP7
306
12 20
SR2 A 3
607
B 3 5903
13 20 24+25
007
14 20
D C 3 2904 24+25
HN (Horn)
15 20
PC234
SP6
CONTACTS
O 16 7
2916 PC218 WHT IN 14+15+16
200
SR1 A 3 305 ECR2 1 9 LINE OUT 14+15+16 2900 PC213

BRN
606 2 9 SP9 901
PC205 B 3 GRN 14+15
2926
SP2 SP3
3 1 CAN CONN.
3 9 906
LMS1 A 3
2942 D C 3
006
YEL
LINE COIL 14+15
5908
201
3 2
510 P 4 9 14+15 OUT 19 3
B 3 150 200
D C 3
2937 PC225 14+15 IN 19 4
GRAY
TS 2 1 9 19 5
PINK
Q 2 9 19 6 G
PC204 150 16 core Cable 813294
2930
B+ (AK) 1 3
2918 6 core Cable 818046
BLS 2 3
PC202 Outlet direction LHS Outlet direction RHS
2922
LMS4 3 3
ECR1 1 9
BRN/GRN Abgangsrichtung links Abgangsrichtung rechts
2923
4 3 YEL
2919 2 9
5 3 GRAY WHT
3 9 21+22
508
B- 6 3 BRN BRK
SP5
BLU 21+22
PC231 P 4 9
605 G 150
Traction 1 3
PS 3 2 304 PC203
3
PINK PC226
M3 top 3 19 TS 1 1 9 RED/BLU
RED 9 1 ECR3 PC227
F 4 3
015 Q 2 9 WHT/GRN 611
9 2 7 1
EPS ACO (B)

WHT/YEL 700
9 3 7 2
YEL/BRN
9 4 P GRAY
7 3
SP4
WHT
7 4
PC229 RED /BLU
7 5
BLK 104
SAHS 1 4 7 6
4
VIO BRN
2 7 7
GRAY/ PINK GRN
E 3 4
B- 14+15+23
500
7 8 M
207
14+15 FU3
202
14+15 4A
PC228
2903
5907
603
302
003
604
303
000
2908
5910
2909
5911
1
2943
5912
20
2900
SP8
14+15 FU4 20 2
3 3 19 3 3 3 19 3 13 13 2901 GRAY /PINK
Pin 1 Pin 2
13 13 13 13 13 13 14+15 10A 7 3
Pin 1 Pin 2 Pin 1 Pin 2
1 2 3 4 PC223 1 2 3 4 PC214 H-Block top H-Block bottom
Pin 1
H-Block middle
Pin 2 2936
7 4
EPS ACO (A)

M1 middle 2940
F PS 2 M2 bottom F PS 1 S PV S SV1 S SV2 S SV3 208
7 5
Initial Lift Mast Lift 14+15 FU5 909
7 6
Mast / Initial Lift Mast Lift Initial LiftTraction 209
14+15 4A 2941
Lowering Cylinder 7 7
WHT /GRN
7 8
WHT /YEL
7 9
YEL /BRN
7 10
YEL
7 11
GRAY
WHT
PINK
2920
2902
2936
2917
5905
5906
2912
5912
5908
2928
2918
2922
5907
5903
2923
2937
2919
5911
5910
2927
BRN
2914
2927
2915
2928
5913
YEL
20 12
006
007
300
910
900
000
501
502
600
103
PINK
7 13
3 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 904
7 14 N
PC220 A B C A PC221
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 PC201
Platform down D PLS 1 D PLS 2 Platform up A CONTROLLER COMBI AC0 826923-2H_1
Fig. 153
DT 3000 Series
405
SCHEMATIC DIAGRAMS
Spline list Wire number Connector / PIN Wire number Connector / PIN
Terminal Terminal
Wire number Connector / PIN
Terminal Spline 4 2901 FU4 OUT Spline 7 2911 Socket B+ (AK) 87
2902 PC201 3 2912 PC201 10
Spline 1 500 B-
2903 PV 2913 PC208 A
501 PC220 B
2904 HN 2914 PC220 A
502 PC221 B
2905 PC212 1 2915 PC221 A
503 PC200 4
2906 PC210 1 2926 Line Coil
504 JC209 2
2907 PC211 1 2930 PC204 1
506 Keypad
2908 SV A1 BLK PC229 1
507 PC217 2
2909 SV A2 2940 PC228 5
508 PC204 6
2916 PC230 16 2941 PC228 7
VIO PC229 2
2938 PC224 5 2942 PC205 A
510 PC205 B
2943 SV A3 Spline 8 202 FU3 OUT
511 PC230 8
Spline 5 300 PC201 25 205 JC209 5
Spline 2 900 PC201 28
BRN/GRN PC202 1 206 Socket 86
901 PC213 1
302 PC223 2 Spline 9 201 EDS OUT
902 PC200 8
303 PC214 2 207 FU3 IN
903 JC209 4
304 PC231 2 208 FU5 IN
904 PC228 14
305 PC218 A
905 PC230 9
306 PC219 A
Spline 3 906 PC213 2
Spline 6 600 PC201 5
907 PC200 9
BLU PC202 4
908 JC209 1
RED PC203 5
909 PC228 6
603 PC223 1
910 PC201 27
604 PC214 1
911 PC230 1
605 PC231 1
606 PC218 B
607 PC219 B
DT 3000 Series
406
SCHEMATIC DIAGRAMS
DT 3040-MF Main Wire Harness
F HANDLE B DISPLAY
Detail B PC200
KEYPAD 1 2 3 4 5 6 PC209 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Detail A 9+10 2 2 2 2 2 2 12 1 1 1 1 12 12 1 1 12 12 12 1 1
Adapter
5900
204
503
902
907
BLK
YEL
PINK
2910
2917
504
205
908
903
203
KYS 2982
30 204 204
2981 30 7
Coil Contact
2910 2910
87
2983 2911 87 7 2911
232
85
206
Socket 85 6
5900
86
232 86 7
206 PC217
K 203 209
Use Adapter PN820143 for Key Switch
2 1 PWS
507
2 2 C Power Supply
PC205
2931
PC210
LMS1 A 2 2906
2 1 FLS (Opt.)
505
B 2 SP1 5904
2918 2 2 C
D C 2
PC219
304 PC211
SR2 A 2
2907
B 2
605 2 1 ALM (Opt.)
5905
SP7
D C 2
001 2 2 C
CONTACTS 200 see Note 13
LINE IN
9+10+16
PC218 2926
SP5
9+10 901
SR1 A 2
305 LINE COIL
9+10
5908
606 120R
B 2
SP9 906
002
D C 2
IN 9+10
200
PC213
EDS 201 901
SP6
OUT 9+10
PC204 VIO SP2 SP3
2 1 CAN CONN.
13+14 906
2 2
B+ (AK) 1 2930 BRK CONTACTS 9+10+16 2900
2 13+14
WHT/GRN LINE OUT 11 3
2921
BLS 2 2
11 4
LMS4 3 2
2922 JC208 11 5
2923
4 2 BRS1 1 11 6 F
2919 RED/BLU
5 2 2 5 JC206
508 GRAY/PINK see Note 14
B- 6 2 3 5 BLK 17 1 SRT
J 4 PINK
PC212
F 17 2
Contact 2905
PC202 YEL 17 3 PINK
1K1 2 1 FAN
5906
ECR1 1 3
GRAY Type 3 2 2 C
11 4 N
JC215 PC215 2 3
BLU
2929 WHT
5 1 1 4 3 3
2916 BRN
5 2 2 4 4 3
RED 500
I H B- 207
SP4
5 3 9+10+15
GRN
9+10 FU2
G 202
2904
5903
6 3
9+10 4A
9+10 9+10
HN 2900
9+10 FU3
(Horn) SP8 2901
9+10 4A
WHT /GRN
GRAY/PINK
208
9+10 FU4
WHT
209
5911
2902
2916
2917
5905
5906
2912
5904
5908
2928
2921
2922
5907
5903
2923
2918
2919
5910
2927
GRN
BRN
VIO
4A
600
003
002
001
300
905
900
000
9+10
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 12 1 1 12 1 1 1 1 1 1 1 1 1 1 11
2903
5907
2914
2927
2915
2928
603
302
003
604
303
000
2908
5910
2909
5911
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 PC201
501
502
2 2 11 2 2 2 11 2 8 8 8 8 8 8 2 2 2 2 2 2 A CONTROLLER COMBI AC0

Pin 1 Pin 2 Pin 1 Pin 2 Pin 1 Pin 2
1 2 3 4 PC223 1 2 3 4 PC214 A B PC220
C A B C PC221
E PS 2 E PS 1 L PV L SV 1 L SV 2 D PLS 1 D PLS 2
Initial Lift Mast Lift Mast / Initial Lift Mast Lift Initial Lift Platform down Platform up
Lowering
825765-2I_1
Fig. 154
DT 3000 Series
407
SCHEMATIC DIAGRAMS
Spline list Wire number Connector / PIN

Terminal
Wire number Connector / PIN
Terminal Spline 6 600 PC201 5
BLU PC202 2
Spline 1 500 B-
RED PC202 5
501 PC220 B
603 PC223 1
502 PC221 B
604 PC214 1
503 PC200 4
605 PC219 B
504 PC209 2
606 PC218 B
505 PC205 B
Spline 7 2911 Socket 87
506 Keypad
2912 PC201 10
507 PC217 2
RED/BLU JC208 2
508 PC204 6
2914 PC220 A
Spline 2 900 PC201 28
2915 PC221 A
901 PC213 1
2926 Line Coil
902 PC200 8
2929 JC215 1
903 PC209 4
2930 PC204 1
Spline 3 905 PC201 27
2931 PC205 A
906 PC213 2
Spline 8 202 FU2 OUT
907 PC200 9
205 PC209 5
908 PC209 1
206 Socket 85
Spline 9 201 EDS OUT
2902 PC201 3
207 FU2 IN
2903 PV 1
208 FU4 IN
2904 HN
2905 PC212 1
2906 PC210 1
2907 PC211 1
2908 SV A1 1
2909 SV A2 1
Spline 5 300 PC201 25
GRAY PC202 1
302 PC223 2
303 PC214 2
304 PC219 A
305 PC218 A
DT 3000 Series
408
SCHEMATIC DIAGRAMS
DT 3040-MW Main Wire Harness
F HANDLE B DISPLAY
Detail B PC200
KEYPAD 1 2 3 4 5 6 PC209 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Detail A 9+10 2 2 2 2 2 2 12 1 1 1 1 12 12 1 1 12 12 12 1 1
Adapter
BLK
5900
204
503
902
907
YEL
PINK
2910
2917
504
205
908
903
203
KYS 2982
30 204 204
Coil Contact
2981 30 7
2910 2910
87
2983 2911 87 7 2911
232
85
206
Socket 85 6
5900
86
232 86 7
206 PC217
K 203 209
Use Adapter PN820143 for Key Switch
2 1 PWS
507
2 2 C Power Supply
PC205
2931
PC210
LMS1 A 2 2906
2 1 FLS (Opt.)
505
B 2 SP1 5904
2918 2 2 C
D C 2
PC211
2907
2 1 ALM (Opt.)
5905
SP7
2 2 C
603 CONTACTS 200 see Note 13
302
003
604
303
000
LINE IN
9+10+16
2926
SP5
9+10 901
2 2 11 2 2 2 11 2 LINE COIL 9+10 5908
1 2 3 4 PC223 1 2 3 4 PC214 120R
SP9 906
E PS 2 E PS 1 200
IN 9+10 PC213
Initial Lift Mast Lift EDS 201 901
SP6
OUT 9+10
PC204 VIO SP2 SP3
2 1 CAN CONN.
13+14 906
2 2
B+ (AK) 1 2930 BRK CONTACTS 9+10+16 2900
2 13+14
WHT/GRN LINE OUT 11 3
2921
BLS 2 2
11 4
2922
LMS4 3 2
11 5
4 2
2923 JC208
2919 RED/BLU
11 6 F
5 2 BRS1 1 5 JC206
508 GRAY/PINK see Note 14
B- 6 2 2 5 BLK
17 1 SRT
ORS 3 5
BRN/GRN 500 PINK PC212
F 17 2
Contact 2905
J 4 5 WHT/YEL PC202 YEL
17 3 PINK
1K1 2 1 FAN
5906
ECR1 1 3
GRAY Type 3 2 2 C
11 4 N
JC215 PC215 2 3
BLU
2929 WHT
5 1 1 4 3 3
2916 BRN
5 2 2 4 4 3
RED
I H B- 207
SP4
5 3 9+10+15
GRN
9+10 FU2
G 202
2904
5903
6 3
9+10 4A
9+10 9+10
HN 2900
9+10 FU3
(Horn) SP8 2901
WHT /GRN 9+10 4A
WHT /YEL
GRAY/PINK
208
9+10 FU4
WHT
5911
209
2902
2916
2917
5905
5906
2912
5904
5908
2921
2922
5907
5903
2923
2918
2919
5910
GRN
BRN
4A
VIO
600
003
300
905
900
000
9+10
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 12 1 12 1 1 12 1 12 1 1 1 1 1 1 1 1 1 1 1 12
2903
5907
2908
5910
2909
5911
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 PC201
8 8 8 8 8 8 A CONTROLLER COMBI AC0
Pin 1 Pin 2 Pin 1 Pin 2 Pin 1 Pin 2
L PV L SV 1 L SV 2
Mast / Initial Lift Mast Lift Initial Lift
Lowering
826420-2D_1
Fig. 155
DT 3000 Series
409
SCHEMATIC DIAGRAMS
Spline list Wire number Connector / PIN

Terminal
Wire number Connector / PIN Spline 6 600 PC201 5
Terminal
BLU PC202 2
Spline 1 500 B-
RED PC202 5
503 PC200 4
603 PC223 1
504 PC209 2
604 PC214 1
505 PC205 B
Spline 7 2911 Socket 87
506 Keypad
2912 PC201 10
507 PC217 2
RED/BLU JC208 1
508 PC204 6
BRN/GRN JC208 3
Spline 2 900 PC201 28
2926 Line Coil
901 PC213 1
2929 JC215 1
902 PC200 8
2930 PC204 1
903 PC209 4
2931 PC205 A
Spline 3 905 PC201 27
906 PC213 2
205 PC209 5
907 PC200 9
206 Socket 85
908 PC209 1
Spline 9 201 EDS OUT
207 FU2 IN
2902 PC201 3
208 FU4 IN
2903 PV 1
2904 HN
2905 PC212 1
2906 PC210 1
2907 PC211 1
2908 SV A1 1
2909 SV A2 1
Spline 5 300 PC201 25
GRAY PC202 1
302 PC223 2
303 PC214 2
DT 3000 Series
410
FS (PF)
ACCESS 8.1
GRY
RS (FF)
SAS
HNS 1
HNS 2
Fig. 156
(OCM 1)
BLU
ACC
CA417
CA419
BLK
POT
held closed
1 2 1 2
CA411
CA412
BLK BLK
5 6 1 2 3 4 7 3 1 2 3 1 4 2
nu
GND B-
DT 3040-EF, Standard
LHS
(left) ILIS BLU
BLK BLK
CA420
B+ NTC B- R/T PCB HYDR. PCB
1 B- + - MAGNETIC ROTARY ENCODER & IC
ILOS 2 IC
U+ 360°
BLU HALL DSP
3 T U- B+ Out
BLK ARRAY
BLK TX OTP VDD
4 X ABSOLUTE
+ - - + - +
5 IC INTERFACE SSI
U+ U+ U+
6 U- U- U- +BV_F Out
FS RS ACC RAS ENC VSS
CLK
CSn
DO
1
7 DC CONVERTER
B- 10 V
8 IC IC UB in +5V
BLU U out
9 GND U Reg.
B+ Out B+ Out
BLU
R/T
10
HSS
11 FS RS BB ACC
12 HNS MAGNETIC ROTARY ENCODER & IC
µ-PROCESSOR +10 V
360°
(µP) DC CONVERTER DSP
HALL
UB in ARRAY
U out U Reg. OTP VDD
GND +10 V
TX X
B+ (FU3) ABSOLUTE
INTERFACE SSI
B+
CAN-L
CAN-H
B-
CS1
CS2
CLK
DATA
R/T
B+ (AK)
LOS ENC VSS
CLK
CSn
DO
MAIN PCB
SAS Signal
B+ (AK)
B+ (AK)
B-
204
203 203
3
206 204 GND
10 V
CS1
CLK
DATA
R/T
CS2
ACCESS 1
CA410
CA414
CA415
5 3 1 4 2 6 4 3 1 4 3 2 1 5 6 7 8
CA418
86 + 30 1 3 7 5 8 6 4 11 12 10 2 9
(DISPLAY DCM) BLK10
K
120 Ohm BLK11
YEL
GRY
WHT
BRN
GRN
PINK
BLK5
10 V
CLK
CS2
CS1
GND
85 - 87 BLK4
DATA
2911 B+ (AK) CA200 BLK3

5 3 1 4 2 6
CA209
B+ (FU3)
K BLK2
5900 2 4 9 8 BLK1
205
908
903
504
BLK7
2910
2917
SAHS CA 229 BLK8
B+ (Heating sw)
BLK6
503
907
902
+ 2939
1 B+(AK) B- BLK12
Signal CAN CONNECTION B+ (AK)
3 B+ (AK) B-
CA213 CAN-L
CAN-L
CAN-H
- 509 B-
NPN 2 6 5 4 3 2 1 CAN-H
012
904
909
906 CAN-L
2941
2940
2936
901 CAN-H 4
2913
+13V
2914
2915
2930
PLS1 /
A3
A4
A2
A1
A6
A7
A5
A
A12
A14
+
CA223 INITIAL B+ (AK) FPS
- PS2
4 4 A
B- CA228 = A +13V 4 CA204
P 1 BRS1
305
306
FU 2 SR1 SR2
CAN-L
CAN-H
603 1 C PNP
CAN-L
CA220
302
CAN-H
30 A 2 U A A
ACCESS 5 120 Ohm 1 2 B
GND
2942
2902
2901
CA227 = B 2906 NPN C C NPN

CA218
(SCM)
CA219
CA210
TRACT. CYL.
501
5904
911
905
003
015
2916
+
B+ LMS1 B B
PS3
16 2 1 9 3 4 A B-
CA208
+12 V
GND
W1
High
Low
+12 V
CHNL A
CHNL B
CHNL A
CHNL B
606
607
GND 4
TS M3
P
C C PNP
U
V
CCD CA230
W
U 2 4
B6
B2
B3
B4
B8
B7
B5
A9
B1
GND
CA205
GND
A8
304
8 B
A11
A13
A10
ACCESS 8.2 1 PLS2 /
Initial Lift Stop
A
CA207
6 FTS1&2
510
011
701
611
612
613
105
702
010
014
013
614
104
700
511
605
LMS4 2 A
U
V
W
CA231
BLK
B- GND +13V B- A
BLS PNP C
CA221
2926
+ C PNP A B
M3
3 B C PNP
Battery Latch
LINE
502
CA207.1
Rider Lift Stop
AC
- B
502
GRY
GRY
1
B-
CA216
2943 2908 2909 2903
+
C
T
TS 3
BRN
STEERING MOTOR
CA207
CA207
B
GRN
_
+
SAS
CA204
501
2
SV3 SV1 SV2 PV
ECR2
4 6 5 6 3 6 2 6
4 GND
2 CHNL B
3 CHNL A
1 +12 V
SV MAST LIFT
-
SV TRACT. CYL.
SV INITIAL LIFT
508
508
508
508
PROP. V LOWER
2923
2919
2922
2918
HN
5907
2927
2928
5913
5908
2912
910
900
2920
2917
2937
006
007
103
5912 5910 5911 B- B- B- B-
CA225
CA234
2904 5903
26 15 23 11 34 33 12 10 27 28 1 24 20 CA201 7 31 29 32 19 17 18 21 35 16
2902 AN. A/D DO DO DO DI0 A/D DI1 DI6 DI4 DI9 DI3 DI5 DI8 DI11 DI12 DI7 DI10
3 (EVP2) (EV2) (EV4) (EV5) B+ (EVP1)
FAN B+ B+
2905
5906
ECR3
1 2 9 B+ ACCESS 2/3 + IN
4 GND
2 CHNL B
3 CHNL A
1 +12 V
SMART
CA226
(HCM / TCM COMBI AC0)
5905
1 2
+ OUT
8
CONTROL LOGIC
B-
2907
CA211 CA212
CONTROL LOGIC
2936 B-
DI2
+13 V
TS1
6
GND
CHNL A
CHNL B
CA224 SMART +IN (from EPS - Safety Relais) U V W B- AN.

TFD UNIT BLU 2938
5 5
+ B+ -P CA201 22 5 25 13 14 30 4 2
Coil
WHT 5913
6 6
100
600
300
005
004
000
5909
2935
GRN 104 U V W
3 3 PWS TRACTION
W1 BLK 611 PUMP MOTOR
2 2
1 2 CA217 - MOTOR
+
507
M1
209
BRK
FU1 M2
DT 3000 Series
W2 680 Ohm B- 3
202
2901
ORN 4 4 103 355A

+
T
RED 1 1 700
AC
TS1 MAST
FU5 FU3 FU4 ECR1 PS1
4A 4A 10A 4 +13V
P
U 2 303
2900
GND
+13 V
CHNL B
CHNL A
+13V
208
207
1 CA214
CA202
CA203
2 3 1 4 2 1
201 Ax 604
301
601
602
100
004
005
EDS
EDS GND
5
GND
200 24V BATT
BD:1 BD:2
826774-2D_1
Drawing shows truck in idle state

1 HSS is open in the "Slow" position
2 BLS is open when the battery latch is closed
3 LMS1 is closed when outrigger lift stop is activated
4 See Platform and Side Restraint Logic, page 111
6 LMS4 is applied when fork lift stop is activated in rider mode??
SCHEMATIC DIAGRAMS
411
DT 3040-EF, Standard
412
FS (PF)
Fig. 157
ACCESS 8.1
GRY
RS (FF)
HNS 1
HNS 2
(OCM 1)
BLU
ACC
SAS /BRS2
CA417
CA419
10
BLK
POT
held closed
1 2 1 2
CA411
CA412
BLK BLK
5 6 1 2 3 4 7 3 1 2 3 1 4 2
nu
LHS GND B-
DT 3040-EF, with Options
(left) ILIS BLU CA416

BLK BLK 1 1
CA420
1 B- + - MAGNETIC ROTARY ENCODER & IC 2 2
ILOS 2 IC
U+ 360°
BLU HALL DSP
3 T U- B+ Out
BLK ARRAY
BLK TX OTP VDD
4 X ABSOLUTE
+ - - + - +
5 IC INTERFACE SSI
U+ U+ U+
CLK
CSn
DO
1
7 DC CONVERTER
B- 10 V
8 IC IC UB in +5V
BLU U out
9 GND U Reg.
B+ Out B+ Out
BLU
R/T
10
HSS
11 FS RS BB ACC 9
µ-PROCESSOR +10 V
360°
DT 3040-EF, with Options
(µP) DC CONVERTER DSP

HALL
UB in ARRAY
GND +10 V
TX X
B+ (FU3) ABSOLUTE 9
INTERFACE SSI
B+
CAN-L
CAN-H
B-
CS1
CS2
CLK
DATA
R/T
B+ (AK) 9
LOS ENC VSS
CLK
CSn
DO
MAIN PCB
SAS Signal
B+ (FU3)
B+ (AK)
B+ (AK)
B-
206 204 204
3
GND
10 V
SCHEMATIC DIAGRAMS
CS1
CLK
DATA
R/T
CS2
2xx 86 30 ACCESS 1
POT PCB F/C
5 3 1 4 2 6 4 3 1 4 3 2 1 5 6 7 8
CA410
CA414
CA415
CA418
232 1 3 7 5 8 6 4 11 12 10 2 9
232
(DISPLAY DCM) BLK10
120 Ohm BLK11
YEL
GRY
WHT
BRN
GRN
PINK
BLK5
10 V
CLK
CS2
CS1
KYS 2982
GND
KEYPAD
ADAPTER
BLK4
DATA
506 2981 2983 87 2911 B+ (AK) CA200 BLK3

5 3 1 4 2 6
CA209
B+ (FU3)
29xx BLK2
5900 BLK1
85 2 4 9 8 BLK7
205
908
903
504
B-
2910
2917
SAHS CA 229 BLK8
B+ (Heating sw)
BLK6
503
907
902
+ 2939
1 B+(AK) B- BLK12
Signal CAN CONNECTION B+ (AK)
3 B+ (AK) B-
CA213 CAN-L
CAN-L
CAN-H
- 509 B-
NPN 2 6 5 4 3 2 1 CAN-H
012
904
909
906 CAN-L
2941
2940
2936
901 CAN-H
2913
FLS 4
2914
2915
2930
A3
A4
A2
A1
A6
A7
A5
A
A12
A14
PLS1
+
CA223 INITIAL B+ (AK)
- PS2 +13V
1 2 +13V 4 A
FU 2 B- CA228 = A P 1 BRS1 CA204
CAN-L
CAN-H
FILTER 603 1 C PNP
CAN-L
CA220
302
CAN-H
30 A 2 U 4 4
ACCESS 5 120 Ohm 1 2 B
GND
2942
2902
2901
305
306
CA227 = B 2906 SR1 SR2

(SCM) 3
CA210
TRACT. CYL. A A
501
5904
911
905
003
015
2916
+
B+ PS3 LMS1
16 2 1 9 3 4 A NPN C C NPN
CA218
CA219
B-
CA208
+12 V
GND
W1
High
Low
+12 V
CHNL A
CHNL B
CHNL A
CHNL B
GND 4
TS M3
P B B
C C PNP
U
V
CCD CA230
W
U 2
B6
B2
B3
B4
B8
B7
B5
A9
B1
CA205
A8
606
607
304
8 B 4
A11
A13
A10
ACCESS 8.2 1
Initial Lift Stop
A PLS2
CA207
6
510
011
701
611
612
613
105
702
010
014
013
614
104
700
511
605
GND GND
LMS4 A
U
V
W
2
CA231
BLK
B- GND +13V A
BLS PNP C
CA221
2926
+ C PNP A B
M3
3 B
LINE C PNP
502
Battery Latch
Rider Lift Stop

CA207.1
AC
-
502
B
GRY
1
B-
GRY
CA216
2943 2908 2909 2903
+
TS 3
T
C
BRN
CA207
CA207
B
GRN
_
SAS
501
2
SV3 SV1 SV2 PV
ECR2 STEERING MOTOR

4 6 5 6 3 6 2 6
CA204
4 GND
2 CHNL B
3 CHNL A
1 +12 V
-
SV MAST LIFT
SV TRACT. CYL.
SV INITIAL LIFT
508
508
508
508
PROP. V LOWER
HN
2923
2919
2922
2918
5907
2927
2928
5913
5908
2912
910
900
2920
2917
2937
006
007
103
5912 5910 5911 B- B- B- B-
CA225
CA234
2904 5903
26 15 23 11 34 33 12 10 27 28 1 24 20 CA201 7 31 29 32 19 17 18 21 35 16
2902 AN. A/D DO DO DO DI0 A/D DI1 DI6 DI4 DI9 DI3 DI5 DI8 DI11 DI12 DI7 DI10
3 (EVP2) (EV2) (EV4) (EV5) B+ (EVP1)
FAN B+ B+
2905
5906
ECR3
1 2 9 B+ ACCESS 2/3 + IN
4 GND
2 CHNL B
3 CHNL A
1 +12 V
SMART
CA226
5905
(HCM / TCM COMBI AC0)
1 ALM 2
+ OUT
8
CONTROL LOGIC
B-
2907
CA211 CA212
CONTROL LOGIC
2936 B-
DI2
+13 V
6
TS1
GND
CHNL A
CHNL B
CA224 SMART +IN (from EPS - Safety Relais) U V W B- AN.

TFD UNIT BLU 2938
5 5
+ B+ -P CA201 22 5 25 13 14 30 4 2
Coil
WHT 5913
6 6
100
600
300
005
004
000
5909
2935
GRN 104 U V W
3 3 PWS TRACTION
W1 BLK 611 PUMP MOTOR
2 2
1 2 CA217 - MOTOR
+
DT 3000 Series
M1
507
209
BRK
W2 680 Ohm B- FU1 M2 3

202
2901
ORN 4 4 103 355A

+
T
RED 1 1 700
AC
TS1 MAST
FU5 FU3 FU4 ECR1 PS1
4A 4A 10A 4 +13V
P
U 2 303
2900
GND
+13 V
CHNL B
CHNL A
+13V
208
207
1 CA214
CA202
CA203
2 3 1 4 2 1
201 Ax 604
301
601
602
100
004
005
EDS
EDS GND
5
GND
200 24V BATT
BD:1 BD:2
826774-2D_2

6 LMS4 is applied when fork lift stop is activated in rider mode
9 Freezer conditioning: heating resistors are activated when ambient temperatures are below
5°C.
FS (PF)
ACCESS 8.1
GRY
Fig. 158
RS (FF)
HNS 1
HNS 2
(OCM 1)
BLU
ACC
SAS/BRS2
CA417
CA419
7
POT
BLK
held closed
1 2 1 2
CA411
CA412
BLK BLK
5 6 1 2 3 4 7 3 1 2 3 1 4 2
DT 3040-MF, Standard
nu
LHS GND B-
(left) ILIS BLU
BLK BLK
CA420
ILOS 2 IC
U+ 360°
BLU HALL DSP
3 T U- B+ Out
BLK ARRAY
BLK TX OTP VDD
4 X ABSOLUTE
+ - - + + -
5 IC INTERFACE SSI
U+ U+ U+
CLK
CSn
DO
1
7 DC CONVERTER
B- 10 V
8 IC IC UB in +5V
BLU U out
9 GND U Reg.
B+ Out B+ Out
BLU
R/T
10
HSS
11 FS RS BB ACC
µ-PROCESSOR +10 V
DC CONVERTER 360°
(µP) HALL DSP
UB in ARRAY
B+ (FU2) GND +10 V
TX X ABSOLUTE
INTERFACE SSI
B+
CAN-L
CAN-H
B-
CS1
CS2
CLK
DATA
R/T
B+ (AK)
LOS ENC VSS
CLK
CSn
DO
MAIN PCB
SAS Signal
B+ (AK)
B+ (AK)
B-
204
203 203
3 5 13 14
206 204 GND
10 V
CS1
CLK
DATA
R/T
CS2
ACCESS 1
CA410
CA414
CA415
5 3 1 4 2 6 4 3 1 4 3 2 1 5 6 7 8
CA418
86 + 30 (DISPLAY DCM) 1 3 7 5 8 6 4 11 12 10 2 9
K
120 Ohm
YEL
GRY
WHT
BRN
GRN
PINK
10 V
CLK
CS2
CS1
BLK10
GND
85 - 87
DATA
2911 B+ (AK) CA200 5 3 1 4 2 6 BLK11
CA209
B+ (FU2)
K 5900 2 4 9 8 BLK5
205
908
903
504
2910
2917
BLK4
B- (Heating sw)
907
902
503
BLK3
B+ (AK) B-
BLK2
B- CAN-L
SAS
CAN-H BLK1
BLK7
BLK8
BLK6
120 Ohm
BLK12
2930
4
2913
CA204 CA207 CA207.1
2914
1 2901 BLK PLS1 /

B+ (AK) 1 A A BLS
906
901
FPS
CAN-L
CAN-H
Battery Latch
GRY A
CA213 6 5 4 3 2 1 C C PNP
2931
2902
BRS1 2
3 BRN
CAN CONNECTION B B C PNP
CA220
LMS1 +13V B
A
501
GRN
501
2926
C PNP
4 4
CA205
Initial Lift Stop
+ B B-
305
304
CA208
SR1 SR2
2915
LINE 2 6 A A
505
2901
- LMS4 4
NPN C C NPN
CA218
CA219
B- A PLS2 /
Initial B B FTS1&2
+13V
CA216
CA222
PS2 C PNP A
606
605
302
CA216
2903 2908 2909 2 B

P PNP C
Rider Lift Stop
GRY
CA221
4 U GND GND B
502
1
502
CA223
PV SV1 SV2 603 CA204 4 6 5 6 3 6 2 6

B-
SV MAST LIFT
508
508
508
508
SV INITIAL LIFT
GND
PROP. V LOWER
2923
2919
2922
2921
HN
2927
5908
2912
905
900
2920
003
2917
2918
B- B- B- B-
002
001
2928
5907 5910 5911

2904 5903
26 24 34 23 33 12 10 27 28 1 20 15 CA201 7 31 29 32 19 17 18 21 35 16
2902
3 B+ A/D DO A/D DO DI0 DI1 AN. DI6 DI4 DI9 DI3 DI5 DI8 DI11 DI12 DI7 DI10
FAN (EVP1) (EV4) (EVP2)(EV5) B+ B+
2905
5906
1 2 9
CA212
B+ ACCESS 2/3
+ IN SMART
1 2 8 (HCM / TCM COMBI AC0)
2907
5905
+ OUT
CA211
CA217
CONTROL LOGIC B-
CONTROL LOGIC
PWS
TS1
GND
+13 V
CHNL A
CHNL B
DI2 AN.
1 2 B- U V W B-
2906 5904 6
1 2 11 B+ -P 30 4 2
209
507
CA201 22 5 25 13 14
B- CA210
100
600
300
005
004
000
DT 3000 Series
2916
5909
2935
202
2901
U V W
TRACTION
PUMP MOTOR - B+ (AK) MOTOR
FU4 FU2 FU3 + M1
BRK
4A 4A 4A FU1 M2 3
2929
355A
+
T
AC
CA215 1 2
Mast
207
TS1
208
2900
ECR PS1
4 +13V
P
U 2 303
GND
+13 V
CHNL B
CHNL A
201 Ax +13V
1 CA214
CA202
CA203
EDS 3 1 2 4 5 6
EDS 604
301
601
005
004
602
100
GND
200
GND
BD:1 24V BATT BD:2
825766-2G_2

SCHEMATIC DIAGRAMS
413
DT 3040-MF, Standard
FS (PF)
ACCESS 8.1
GRY
414
RS (FF)
HNS 1
HNS 2
(OCM 1)
BLU
Fig. 159
ACC
SAS/BRS2
CA417
CA419
POT
BLK
held closed
1 2 1 2
CA411
CA412
BLK BLK
5 6 1 2 3 4 7 3 1 2 3 1 4 2
nu
LHS GND B-
BLK BLK
CA420
B+ NTC B- R/T PCB HYDR. PCB 1 1
DT 3040-MF with Options

ILOS 2 IC
U+ 360°
BLU HALL DSP
3 T U- B+ Out
BLK ARRAY
BLK TX OTP VDD
4 X ABSOLUTE
+ - - + + -
5 IC INTERFACE SSI
U+ U+ U+
CLK
CSn
DO
1
7 DC CONVERTER
B- 10 V
8 IC IC UB in +5V
BLU U out
9 GND U Reg.
B+ Out B+ Out
BLU
R/T
10 9
HSS
11 FS RS BB ACC 9
µ-PROCESSOR +10 V
360°
(µP) DC CONVERTER
*
HALL DSP
UB in ARRAY
DT 3040-MF with Options
B+ (FU2) GND +10 V 9 TX X ABSOLUTE 9

INTERFACE SSI
B+
CAN-L
CAN-H
B-
CS1
CS2
CLK
DATA
R/T
B+ (AK)
LOS ENC VSS
CLK
CSn
DO
MAIN PCB
SAS Signal
B+ (FU2)
B+ (AK)
B+ (AK)
B-
204
3 5 13 14
GND
10 V
CS1
CLK
DATA
R/T
CS2
206
204
ACCESS 1
SCHEMATIC DIAGRAMS
POT PCB F/C
CA410
CA414
CA415
5 3 1 4 2 6 4 3 1 4 3 2 1 5 6 7 8
CA418
(DISPLAY DCM) 1 3 7 5 8 6 4 11 12 10 2 9
86 30
120 Ohm
YEL
GRY
WHT
BRN
GRN
PINK
10 V
CLK
CS2
CS1
BLK10
GND
DATA
87 2911 B+ (AK) CA200 5 3 1 4 6 2 BLK11
CA209
B+ (FU2)
5900 2 4 9 8 BLK5
85
232
2982
2983
205
908
903
504
2910
2917
BLK4
B+ (Heating sw)
907
902
503
ADAPTER
BLK3
B+ (AK) B-
BLK2
B- CAN-L
SAS
232
2981
CAN-H BLK1
BLK7
KYS
BLK8
BLK6
29xx
2xx
120 Ohm
BLK12
2930
4
2913
CA204
2914
KEYPAD 2901
506 1 B+ (AK) PLS1
1
906
901
CAN-L
CAN-H
CA213 6 5 4 3 2 1 A CA207 A
2931
2902
BRS1
B- 3 2 C PNP
CAN CONNECTION
BLK
CA220
LMS1 BLS +13V B

A A
501
2926
C PNP C PNP
Battery Latch
CA207.1
4 4
CA205
+ Initial Lift Stop B B B-
305
304
CA208
SR1 SR2
2915
GRY
LINE 2 6 A A
505
BRN
- LMS4 4
C B NPN C C NPN
CA218
CA219
B- A
Initial Lift B B PLS2
+13V
501
CA216
CA222
GRN
PS2 C PNP A
CA207
606
605
CA207
302
CA216
2903 2908 2909 2 B

P PNP C
Rider Lift Stop
GRY
CA221
4 U GND GND B
502
1
502
CA223
PV SV1 SV2 603 CA204 4 6 5 6 3 6 2 6
B-
SV MAST LIFT
508
508
508
508
SV INITIAL LIFT
GND
PROP. V LOWER
2923
2919
2922
2921
HN
2927
5908
2912
905
900
2920
003
2917
2918
B- B- B- B-
002
001
2928
5907 5910 5911

2904 5903
26 24 34 23 33 12 10 27 28 1 20 15 CA201 7 31 29 32 19 17 18 21 35 16
2902
2905
5906
1 2 9
CA212
B+ ACCESS 2/3
+ IN SMART
1 ALM 2 8 (HCM / TCM COMBI AC0)
2907
5905
+ OUT
CA211
CA217 FLS
CONTROL LOGIC
B-
CONTROL LOGIC
PWS
1 2
TS1
GND
+13 V
CHNL A
CHNL B
DI2 AN.
1 2 FILTER B- U V W B-
2906 5904 6
1 2 11 B+ -P 30 4 2
209
507
CA201 22 5 25 13 14
B- CA210
100
600
300
005
004
000
2916
5909
2935
202
2901
U V W
DT 3000 Series
TRACTION
FU4 FU2 FU3 + M1
BRK
4A 4A 4A FU1 M2 3
2929
355A
+
T
AC
CA215 1 2
Mast
207
TS1
208
2900
ECR PS1
4 +13V
P
U 2 303
GND
+13 V
CHNL B
CHNL A
201 Ax +13V
1 CA214
CA202
CA203
EDS 3 1 2 4 5 6
EDS 604
301
601
005
004
602
100
GND
200
GND
BD:1 24V BATT BD:2
825766-2G_4

6 LMS4 is applied when fork lift stop is activated in rider mode??
9 Freezer conditioning: heating resistors are activated when ambient temperatures are below
5°C.
FS (PF)
ACCESS 8.1
GRY
RS (FF)
Fig. 160
HNS 1
HNS 2
(OCM 1)
BLU
ACC
SAS/BRS2
CA417
CA419
POT
BLK
held closed
1 2 1 2
CA411
CA412
BLK BLK
5 6 1 2 3 4 7 3 1 2 3 1 4 2
nu
DT 3040-MW, Standard
LHS GND B-
(left) ILIS BLU
BLK BLK
CA420
ILOS 2 IC
U+ 360°
BLU HALL DSP
3 T U- B+ Out
BLK ARRAY
BLK TX OTP VDD
4 X ABSOLUTE
+ - - + - +
5 IC INTERFACE SSI
U+ U+ U+
CLK
CSn
DO
1
7 DC CONVERTER
B- 10 V
8 IC IC UB in +5V
BLU U out
9 GND U Reg.
B+ Out B+ Out
BLU
R/T
10
HSS
11 FS RS BB ACC
µ-PROCESSOR +10 V
360°
(µP) DC CONVERTER
HALL DSP
UB in ARRAY
B+ (FU2) GND +10 V
TX X ABSOLUTE
INTERFACE SSI
B+
CAN-L
CAN-H
B-
CS1
CS2
CLK
DATA
R/T
B+ (AK)
LOS ENC VSS
CLK
CSn
DO
MAIN PCB
SAS Signal
B+ (AK)
B+ (AK)
B-
204
203 203
3 5 13 14
206 204 GND
10 V
CS1
CLK
DATA
R/T
CS2
ACCESS 1
CA410
CA414
CA415
5 3 1 4 2 6 4 3 1 4 3 2 1 5 6 7 8
CA418
86 + 30 (DISPLAY DCM) 1 3 7 5 8 6 4 11 12 10 2 9
K
120 Ohm
YEL
GRY
WHT
BRN
GRN
PINK
10 V
CLK
CS2
CS1
BLK10
GND
85 - 87
DATA
2911 B+ (AK) CA200 5 3 1 4 2 6 BLK11
CA209
B+ (FU2)
K 5900 2 4 9 8 BLK5
205
908
903
504
2910
2917
BLK4
B- (Heating sw)
907
902
503
BLK3
B+ (AK) B-
BLK2
B- CAN-L
SAS
CAN-H BLK1
BLK7
BLK8
BLK6
120 Ohm
BLK12
2930
2913
2914
CA204 CA207 CA207.1
1 3 BLK BLS
B+ (AK) 1 A A
906
901
CAN-L
CAN-H
Battery Latch
GRY
CA213 6 5 4 3 2 1 C C PNP
2931
BRS1 ORS 2
3 BRN
CAN CONNECTION B B
LMS1
A
501
GRN
2926
C PNP
CA205
Initial Lift Stop
+ B
CA208
CA208
Lift Limit Override
LINE 2 4
505
-
B-
Initial
+13V
CA216
CA222
PS2
2903 2908 2909 302 2 P
4 U
1
CA223
PV SV1 SV2 603 CA204 4 6 5 6 3 6 2 6
SV MAST LIFT
508
508
508
508
SV INITIAL LIFT
GND
PROP. V LOWER
2923
2919
2922
2921
HN
B- B- B- B-
5908
2912
905
900
2920
2924
003
2917
2918
5907 5910 5911

2904 5903
26 24 34 23 33 12 10 27 28 1 20 15 CA201 7 31 29 32 19 17 18 21 35 16
2902
2905
5906
1 2 9
CA212
B+ ACCESS 2/3
+ IN SMART
1 2 8 (HCM / TCM COMBI AC0)
2907
5905
+ OUT
CA211
CA217
CONTROL LOGIC
B-
CONTROL LOGIC
PWS
DT 3000 Series
TS1
GND
+13 V
CHNL A
CHNL B
DI2 AN.
1 2 B- U V W B-
2906 5904 6
1 2 11 B+ -P 30 4 2
209
507
CA201 22 5 25 13 14
B- CA210
100
600
300
005
004
000
2916
5909
2935
2901
202
U V W
TRACTION
FU4 FU2 FU3 + M1
BRK
4A 4A 4A FU1 M2 3
2929
355A
+
T
AC
CA215 1 2
Mast
207
TS1
208
2900
ECR PS1
4 +13V
P
U 2 303
GND
+13 V
CHNL B
CHNL A
201 Ax +13V
1 CA214
CA202
CA203
EDS 3 4 1 2 5 6
EDS 604
301
601
005
004
602
100
GND
200
GND
BD:1 24V BATT BD:2
825766-2G_1

DT 3040-MW, Standard
SCHEMATIC DIAGRAMS
415
416
FS (PF)
ACCESS 8.1
Fig. 161
GRY
RS (FF)
HNS 1
HNS 2
(OCM 1)
BLU
ACC
SAS/BRS2
CA417
CA419
POT
BLK
held closed
1 2 1 2
CA411
CA412
BLK BLK
5 6 1 2 3 4 7 3 1 2 3 1 4 2
nu
LHS GND B-
DT 3040-MW with Options

BLK BLK
CA420
B+ NTC R/T PCB HYDR. PCB 1 1
B-
ILOS 2 IC
U+ 360°
BLU HALL DSP
3 T U- B+ Out
BLK ARRAY
BLK TX OTP VDD
4 X ABSOLUTE
+ - - + + -
5 IC INTERFACE SSI
U+ U+ U+
CLK
CSn
DO
1
7 DC CONVERTER
B- 10 V
8 IC IC UB in +5V
BLU U out
9 GND U Reg.
B+ Out B+ Out
BLU
R/T
10 9
HSS
11 FS RS BB ACC 9
12 MAGNETIC ROTARY ENCODER & IC
DT 3040-MW with Options
µ-PROCESSOR HNS +10 V

360°
(µP) DC CONVERTER
HALL DSP
UB in ARRAY
B+ (FU2) GND +10 V 9 TX X ABSOLUTE 9
INTERFACE SSI
B+
CAN-L
CAN-H
B-
CS1
CS2
CLK
DATA
R/T
B+ (AK)
LOS ENC VSS
CLK
CSn
DO
MAIN PCB
SAS Signal
B+ (FU2)
B+ (AK)
B+ (AK)
B-
204
SCHEMATIC DIAGRAMS
3 5 13 14
GND
10 V
CS1
CLK
DATA
R/T
CS2
206
204
ACCESS 1
POT PCB F/C
CA410
CA414
5 3 1 4 2 6 4 3 1 CA415 4 3 2 1 5 6 7 8
CA418
(DISPLAY DCM) 1 3 7 5 8 6 4 11 12 10 2 9
86 30
120 Ohm
YEL
GRY
WHT
BRN
GRN
PINK
10 V
CLK
CS2
CS1
BLK10
GND
DATA
87 2911 B+ (AK) CA200 5 3 1 4 2 6 BLK11
CA209
B+ (FU2)
5900 2 4 9 8 BLK5
85
232
2982
2983
205
908
903
504
2910
2917
BLK4
B+ (Heating sw)
907
902
503
ADAPTER
BLK3
B+ (AK) B-
BLK2
B- CAN-L
SAS
232
2981
CAN-H BLK1
BLK7
KYS
BLK8
29xx
2xx
BLK6
120 Ohm
BLK12
2930
2913
2914
KEYPAD CA204 CA207 CA207.1
506 1 3 BLK BLS
B+ (AK) 1 A A
906
901
CAN-L
CAN-H
Battery Latch
GRY
CA213 6 5 4 3 2 1 2931 C C PNP
B- BRS1 ORS 2
3 BRN
CAN CONNECTION B B
LMS1
A
501
GRN
2926
C PNP
CA205
Initial Lift Stop
+ B
CA208
CA208
LINE 2 4
505
-
B-
Initial
+13V
CA216
CA222
PS2
2903 2908 2909 302 2 P
4 U
1
CA223
PV SV1 SV2 603 CA204 4 6 5 6 3 6 2 6
SV MAST LIFT
508
508
508
508
SV INITIAL LIFT
GND
PROP. V LOWER
2923
2919
2922
2921
HN
5908
2912
905
900
2920
2924
003
2917
2918
5907 5910 5911 B- B- B- B-

2904 5903
26 24 34 23 33 12 10 27 28 1 20 15 CA201 7 31 29 32 19 17 18 21 35 16
2902
FAN (EVP1) (EV4)(EVP2)(EV5) B+ B+
2905
5906
1 2 9
CA212
B+ ACCESS 2/3
+ IN SMART
1 ALM 2 8 (HCM / TCM COMBI AC0)
2907
5905
+ OUT
CA211
CA217 FLS
CONTROL LOGIC
B-
CONTROL LOGIC
PWS
1 2
TS1
GND
+13 V
CHNL A
CHNL B
DI2 AN.
1 2 FILTER B- U V W B-
DT 3000 Series
2906 5904 6
1 2 11 B+ -P 30 4 2
209
507
CA201 22 5 25 13 14
B- CA210
100
600
300
005
004
000
2916
5909
2935
202
2901
U V W
TRACTION
FU4 FU2 FU3 + M1
BRK
4A 4A 4A FU1 M2 3
2929
355A
+
T
AC
CA215 1 2
Mast
207
TS1
208
2900
ECR PS1
4 +13V
P
U 2 303
GND
+13 V
CHNL B
CHNL A
201 Ax +13V
1 CA214
CA202
CA203
EDS 3 1 2 4 5 6
EDS 604
301
601
005
004
602
100
GND
200
GND
BD:1 24V BATT BD:2
825766-2G_3

9 Freezer conditioning: heating resistors are activated when ambient temperatures are
below 5°C.
SCHEMATIC DIAGRAMS
CAN Connections, DT 3040-MF, -MW
CAN Connections, DT 3040-MF, -MW
ACCESS 2/3 CAN HIGH CA213

900 CAN-H 901
(HCM / TCM) 28 1 CAN
906
2 CONNECTION
CA201
120 Ohm 3
4
905 CAN-L 5
27 6
CAN LOW
ACCESS 1 CAN HIGH

902 903
(DISPLAY) 8
120 Ohm
CA200
907 908
9
CAN LOW
ACCESS 8.1 CAN LOW CA209

(INTERFACE) WHT 1
1
2
CA410
3
5
BRN 6
4 4
CAN HIGH 825766-2G_5
Fig. 162
DT 3000 Series
417
SCHEMATIC DIAGRAMS
CAN Connections, DT 3040-EF
CAN Connections, DT 3040-EF
ACCESS 2/3 CAN HIGH CA213

900 CAN-H 901
(HCM / TCM) 28
906
1 CAN CONNECTION
2
CA201 3
4
910 CAN-L 5
27 6
CAN LOW
ACCESS 5 CAN HIGH

904
(SCM) 14
120 Ohm
CA228
909
6
CAN LOW
ACCESS 1 CAN HIGH

902
(DISPLAY) 8
120 Ohm
CA200
907
9
CAN LOW
CA209
ACCESS 8.1 CAN LOW
WHT 908
(INTERFACE) 1 1
2
CA410
3
5
BRN 6
4
903
4
CAN HIGH
ACCESS 8.2 CAN LOW

911
(INTERFACE) 1
CA230
905
9
CAN HIGH 826774-2D_3
Fig. 163
DT 3000 Series
418
HYDRAULIC SCHEMATIC
419
Notes:
420
HYDRAULIC SCHEMATIC
Hydraulic Symbols
Hydraulic Symbols
Icon Meaning Icon Meaning
Vented reservoir with Electric motor

lines above the fluid unidirectional single
level speed
Vented reservoir with Hydraulic pump fixed

lines above the fluid displacement
level unidirectional
Filter or strainer Spring, (bias to normal

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

flow winding
Control line or drainage Component enclosure

withrestricted flow manifold block
Lines crossing; not Resistor orifice throttle

connected (adjustable)
Lines crossing and Throttle, fixed

connected
Plugged port Relief valve,

adjustable
Accumulator gas Check valve

charged diaphragm
type
DT 3000 Series Rev.2 08/2010
421
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

unidirectional variable
speed
Rev.2 08/2010 DT 3000 Series
422
HYDRAULIC SCHEMATIC
Hydraulic Symbols
Valve block with 3 Proportional solenoid

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

operated solenoid
valve
Velocity fuse Hydraulic pilot

operated hydraulic
valve
Pressure-compensated Manual actuator

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

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

open) ram type
Manual lever actuator Single-acting cylinder

with spring returned
(rod end vented)
DT 3000 Series Rev.2 08/2010
423
HYDRAULIC SCHEMATIC
Hydraulic Symbols
Double-acting cylinder; Thermometer

equal area
Double-acting cylinder; Pressure gauge

unequal area
Pressure switch Hydraulic motor,

bi-directional
Rev.2 08/2010 DT 3000 Series
424
HYDRAULIC SCHEMATIC
DT 3040 without Traction Cylinder
DT 3040 without Traction Cylinder
I
SV2 M2
2
10
3
F M1
SV1
PV
11 4
PCV
8
CV 12
RV1
7
M
5
6
Fig. 164 Hydraulic system without traction cylinder

1 Outrigger lift cylinder 7 Pump
2 Velocity fuse 8 Check valve CV
3 Lift cylinder (fork lift) 9 Valve SV1 (fork lift)
4 Compensation valve PCV 10 Valve SV2 (outrigger lift)
5 Return line filter 11 Proportional valve PV (lowering valve for initial and fork lift)
6 Suction filter 12 Relief valve (opening pressure > 19 MPa)
DT 3000 Series
425
HYDRAULIC SCHEMATIC
DT 3040 with Traction Cylinder
DT 3040 with Traction Cylinder
I
10
M3
T SV2 11 M2
9 F 3
SV3
12 M1
SV1
PV
13 4
PCV
CV 14
RV1
7
M
5
6
Fig. 165 Hydraulic system with traction cylinder

1 Outrigger lift cylinder 8 Check valve CV
2 Velocity fuse 9 Traction cylinder
3 Lift cylinder (fork lift) 10 Valve SV3 (traction cylinder)
4 Compensation valve PCV 11 Valve SV2 (outrigger lift)
5 Return line filter 12 Valve SV1 (fork lift)
6 Suction filter 13 Proportional valve PV (lowering valve for initial and fork lift)
7 Pump 14 Relief valve RV1 (opening pressure > 19 MPa)
DT 3000 Series
426

812591-006 (Service DT3000)

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812591-006 (Service DT3000)

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DT 3000 SERIES

Order Number: 812591-006

Crown Gabelstapler GmbH & Co. KG

Phone +49 (0)89 93 00 2 – 0

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

LUBRICATION & ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Cold store truck requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Outrigger lift drift test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Pedestrian mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Event Code 234 (DT 3040 -MW, -MF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Event code 342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Event code 235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Event Code 337 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Event code 511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Event Code 543 (DT 3040 -EF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Testing Access 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Hydraulic PC board assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Adjusting switch PLS2 for pedestrian mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

Important Information Manual structure

DT 3000 Series Rev.3 07/2009

Truck Data Number

The truck data number given in the example therefore

DT 3000 Series Rev.2 08/2010

Rev.1 04/2009 DT 3000 Series

Repair work Cleaning work

DT 3000 Series Rev.1 04/2009

• Do not stand under a swinging load.

Rev.1 04/2009 DT 3000 Series

Transport and Storage

Lifting the truck

Lifting the truck by crane

Preparing the truck

Lifting the truck with a forklift truck

Fig. 3 Lifting a truck between its castor wheels

Lifting the truck

5. Position a fork (1) at least 1000 mm long of the

Fig. 4 Tow direction

Jacking up the Truck Preparing the truck

Fig. 5 Jacking up the truck

Fig. 6 Lorry loading

Clamping the truck

Storing the Truck Periodically starting a truck that has

Cleaning the Truck and Compo- CAUTION

Electrical components Cleaning the truck surface

DT 3000 Series Rev.2 08/2010

Cleaning removed components

1. Components that have been removed should be

Rev.2 08/2010 DT 3000 Series

Model Lubricant Type Product Manufacturer Part No.

A and AA Transmission oil Degol PAS 150 Aral

Model Lubricant Type Product Manufacturer Part No.

Low temperature lubrication Mobil SHC 626 Mobil

Lubricants Produkt Application Part no.

Anti-corrosive agent Anticorit BW 366® Corrosion inhibitor for cold store

Rev.1 07/2010 DT 3000 Series

Planned Maintenance Terms and abbreviations used

Annual inspection in accordance

(1).These intervals are only used as examples.

DT 3000 Series Rev.1 08/2010