Model WL-3020 Service Manual - Wolfliftwolflift.ca/assets/docs/Woflift-Service-Manual-R3.3.pdf · Revision 3.3 WolfLift WL3020 Service Manual Printed in Canada Page 4 base tower,

WolfLift WL3020 Service Manual 230104AB 7/2018

Model WL-3020 Service Manual

Revision 3.3

WolfLift WL3020 Service Manual Printed in Canada Page 1

1 General Safety ....................................................................................................................................... 2 1.1 Safety Messages/Signal Words ..................................................................................................... 2

2 WL-3020 System Overview ................................................................................................................... 3 2.1 Subassembly Overview ................................................................................................................. 3

2.2 General Description ...................................................................................................................... 3

2.3 WL-3020 Specifications ................................................................................................................. 4

3 Messages and Error Codes .................................................................................................................... 5 3.1 Software Messages ....................................................................................................................... 5

3.2 AC Drive/Lift Motor Controller Errors ......................................................................................... 21

3.3 DC Steering Controller Errors ...................................................................................................... 38

4 Service Tools ....................................................................................................................................... 39 4.1 Service Mode Input ..................................................................................................................... 39

5 Service Guides ..................................................................................................................................... 61 5.1 Machine is Reporting Tilt Errors When Stowed .......................................................................... 61

5.2 Machine will not turn on ............................................................................................................. 62

5.3 Only display turns on .................................................................................................................. 63

5.4 Drive overload when stowed ...................................................................................................... 64

5.5 Overload when lowering ............................................................................................................. 65

5.6 Overload when raising ................................................................................................................ 66

5.7 Overload when driving elevated ................................................................................................. 67

5.8 Height Calibration ....................................................................................................................... 68

5.9 Weight Calibration ...................................................................................................................... 69

5.10 Tilt Sensor Zeroing ...................................................................................................................... 70

5.11 Communication Problems ........................................................................................................... 71

5.12 PHP errors when deployed ......................................................................................................... 73

5.13 Stall Detected .............................................................................................................................. 74

5.14 Steering Not Functioning, No Errors Reported ........................................................................... 75

5.15 Motion Alarm Settings ................................................................................................................ 76

5.16 Enabling User Password Entry .................................................................................................... 77

5.17 Only Right Drive Controller Powering On ................................................................................... 78

5.18 Manual Raising ............................................................................................................................ 79

5.19 Accessing the Odometer ............................................................................................................. 80

6 Inspection & Maintenance Checklists ................................................................................................. 81 6.1 Inspection Schedule .................................................................................................................... 81

7 Maintenance ....................................................................................................................................... 86 7.1 Scheduled Maintenance Summary ............................................................................................. 86

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1 General Safety

1.1 Safety Messages/Signal Words

This Safety Alert Symbol Means Attention! Become Alert! Your Safety Is Involved!

The Safety Alert Symbol identifies important safety messages on machines, in manuals, or elsewhere.

When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions

in the safety message.

“DANGER” indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

“WARNING” indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

“CAUTION” indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or damage to

equipment.

BEFORE ANY WORK IS PERFORMED ON THE INTERIOR OF THE WL-3020 IT IS IMPERATIVE THAT THE

MACHINE IS PROPERLY LOCKED OUT AT THE MAIN DISCONNECT AND RACKS ARE LOCKED OUT USING

A PROPERLY INSTALLED SAFETY STOP

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2 WL-3020 System Overview

2.1 Subassembly Overview

The following is a general overview of main subassemblies – Front panels taken out to see inside

machine

2.2 General Description

The WL-3020 mobile elevating work platform has two main sections, the base (chassis) assembly and

lifting assembly. The chassis is made up of wheel drives, electrical box, battery box, rear controls,

pothole protection, steering assembly and all supporting structures. The lifting assembly consists of the

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base tower, stage 1, tower 1, stage 2, tower 2, stage 3 and the platform/tower3 assembly. Each stage

moves within the tower below it, moving the platform from its stowed to elevated position.

2.3 WL-3020 Specifications

Dimensions

Elevated Platform Height 19 ft. 7 in. 5.97 m

Stowed Length (add 5.5 in. for removable steps 60 in. 1.53 m

Overall Width 30 in. 0.76 m

Overall Stowed Height 79 in. 2.0 m

Stowed Platform Entry Height 39 in. 0.99 m

Ground Clearance (with platform lowered) 1.75 in. 44.45 mm

Platform Length (with extension platform retracted) 60 in. 1.52 m

Extension Platform Length 30 in. 0.76 m

Tire Size 12x4x8

Overall Machine Weight 2950 lbs. 1338 kg

Floor Loading (with rated load) 149 lbs/sq in. 10.5 kg/sq cm

Performance

Total Platform Lift Capacity (2 persons) 650 lbs. 295 kg

Extension Platform Capacity 250 lbs. 113 kg

Drive Speed - Stowed 3.9 mph 6.3 km/hr

Drive Speed - Elevated 0.75 mph 1.2 km/hr

Selectable 3 Speed Ranges *New Feature*

Gradability 25 % 25 %

Lift Time (with rated load) 22 seconds 22 seconds

Lower Time (with rated load) 22 seconds 22 seconds

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3 Messages and Error Codes The WL-3020 has a number of messages and error codes that will show up on the control box screen.

There are two categories of messages - software messages and motor controller errors.

When the control box is plugged in to the platform, the messages are limited to certain software

messages. It is our recommendation that when troubleshooting a problem to always plug the control

box into the base.

3.1 Software Messages

Software messages are programmed into the machine to show the user normal operating messages as

well as any errors in the machine logic. The following table shows each message and quick description.

Additional information is on the referenced page.

Message Description Page

SEQUENCE Action was attempted with improper trigger sequence Page 8

__._ LH Lift hour Odometer Page 8

__._ DH Drive hour Odometer Page 8

SLEEP The machine is in sleep mode Page 8

******** Display has no information to show Page 9

WL-DRIVE Normal drive mode Page 9

WL-LIFT Normal lift mode Page 9

MODE An action is attempted when the machine is in the wrong mode Page 10

LD-ERR Improper state of the Lift/Drive select switch Page 10

TRIGGER The trigger must be released before another action is attempted Page 10

TILT-L The machine is tilted to the left Page 11

TILT-R The machine is tilted to the right Page 11

TILT-F The machine is tilted to the front Page 11

TILT-B The machine is tilted to the back Page 11

TILT-ERR Tilt sensor is not detected on the CANBus Page 11

STR-ERR Steering controller is displaying an error code or is not detected on startup Page 11

STR-1 The steering controller is not detected on startup Page 12

STR-2 The steering controller has a connection issue or intermittent fault Page 12

STR-4 The steering controller has reported an overtemp fault Page 12

STARTING The machine is powering up Page 12

BASE-LFT The rear control panel raise/lower switch is in the raise position Page 13

BASE-LWR The rear control panel raise/lower switch is in the lower position Page 13

CBOX-ERR A control box is detected in both platform and base locations Page 13

CHARGER The machine is charging and operation is disabled Page 13

OVERLOAD Too much current draw is detected performing the present action Page 13

OVL-S1 Stage 1 has detected too much current draw while lifting or lowering Page 13


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OVL-DRVE A current spike has been detected while in elevated drive Page 13

TILTSTOP The machine is tilted but not critically Page 11

SERVICE The machine is in service mode Page 14

CAN-ERR Communication has been lost with one of the motor controllers Page 15

S1-CAN Communication has been lost with stage 1 Page 15



LD-CAN Communication has been lost with the left drive Page 15

PDOTIME The CANBus has experienced a general failure Page 15

PHP-ERR An error has been detected in the pothole protection system Page 15

PHP-SW The pothole protection limit switch is reporting an improper state Page 15

PHP-WARN Pothole protection has not deployed but is still low enough to allow drive Page 15

PHP-DEPL Pothole protection has not deployed and is too high to allow drive Page 15

OVRDRIVE The machine is in overdrive mode - maximum speed is 3.9mph Page 16

CONTACT The main contactor did not pull in or has experience a failure Page 16

LS1-ERR Stage 1 has experienced a limit switch error Page 17



LS1-1 Stage 1 top and bottom limit switches are active at the same time Page 17



LS1-2 Sate 1 top limit switch is pressed and the slowdown switch is not Page 17



LS1-3 Stage 1 bottom limit switch is pressed and the slowdown switch is not Page 17



LS1-4 Stage 1 top limit switch is showing a state that is not allowed Page 17



LS1-12 Stage 1 slowdown limit switch has not been activated when expected Page 17



LS1-13 Stage 1 top limit switch has not been activated when expected Page 17



S-OFF A stage is turned off Page 18

LS-OFF A limit switch bank is turned off Page 18

EM-WELD A welded EM relay has been detected Page 19

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SSTOP The machine has detected an unexpected movement Page 19

FOOTC The Curtis dual drive system has detected an error Page 19

EM-ERR An error has been detected in the EM Relay Page 19

WOLFLIFT The display screen is not receiving a proper message Page 20

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3.1.1 SEQUENCE

SEQUENCE Category: Normal Operation Location: Platform & Base

User control box input is not following the proper order of operations. The trigger must be pressed

while in neutral before any action is attempted.

3.1.2 __._ LH

__._ LH Category: Normal Operation Location: Base

Lift hour (LH) odometer - this is displayed when the control box is plugged in to the base and in lift

mode.

3.1.3 __._ DH

__._ DH Category: Normal Operation Location: Base

Drive hour (DH) odometer - This is displayed when the control box is plugged into the base and in

drive mode.

3.1.4 SLEEP

SLEEP Category: Normal Operation Location: Base

The machine is in sleep mode. Moving the control stick or pressing the trigger will wake the machine

up. The machine will return to sleep mode after 10 minutes of no action.

Sleep mode is used to preserve battery life in the event that the machine is left turned on. The Right

Drive Controller controls a relay that gives power to the other 4 motor controllers. When in sleep

mode the Right Drive Controller turns off this relay and remains the only controller powered on.

Coming out of sleep mode, the Right Drive Controller turns this relay on and follows normal startup

procedure.

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3.1.5 ********

******** Category: Potential Error Location: Platform & Base

This means that the display is not receiving a signal telling it what to display. If the machine is

functioning normally other than showing this message, this could have a number of causes:

1. The machine is in sleep mode or charging – Message is seen when plugged into the platform.

Both sleep mode and charging only leaves the right drive controller powered on (see 3.1.4

SLEEP for more information). When plugged into the platform, the display gets its serial signal

from the Stage 3 Motor Controller. With this controller powered off, it will have no

information to display. This condition is normal with machine operation.

2. The machine is NOT in sleep mode or charging – Message is seen when plugged into

specifically the base or platform. There is likely a problem with the harness where the control

box is plugged in. From the platform, check wiring of 3rd stage harness. From the base, check

wiring of right drive controller. This condition is not normal with machine operation and

considered an error.

3. The machine is NOT in sleep mode or charging – Message is seen when plugged into the base

as well as platform. There is likely a problem with the display or control box wiring.

Troubleshooting should start with swapping the display with a known good display. If the

error persists, check wiring of the control box and control cable. This condition is not normal

with machine operation and considered an error.

If the machine is showing this message and does not operate normally, see 5.2 Page 62

3.1.6 WL-DRIVE

WL-DRIVE Category: Normal Operation Location: Platform

The machine is currently in drive mode and ready for an action.

3.1.7 WL-LIFT

WL-LIFT Category: Normal Operation Location: Platform

The machine is currently in lift mode and ready for an action.

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3.1.8 MODE

MODE Category: Normal Operation Location: Platform & Base

An action is attempted when the machine is in the wrong mode. An example would be if steering is

pressed while in lift mode.

3.1.9 LD-ERR

LD-ERR Category: Potential Error Location: Platform & Base

The machine is seeing an improper movement or state of the Lift/Drive Select switch. There are two

conditions that can cause this:

1. The Lift/Drive switch changes states while another action is being performed. An example

would be if the machine is switched to lift mode while driving. This is intended to prevent any

accidental movement from unintended switch movement. Releasing the trigger will clear this

error and allow operation again.

2. The Lift/Drive switch is in an improper state. Both sides of the switch are monitored in

software - If Lift and Drive are both seen as on or off at the same time, LD-ERR will be

displayed and operation will not be allowed. Troubleshooting should start with checking that

the switch is functioning properly, followed by control box wiring. If the problem persists, the

joystick could have a damaged I/O board.

3.1.10 TRIGGER

TRIGGER Category: Normal Operation Location: Platform & Base

The trigger must be released before another action is attempted. This could be displayed because the

trigger has been held down too long in the neutral position or the machine starts with the trigger

pressed. This is intended as a safety feature to prevent any unintentional movement or tying down of

the trigger.

If this message does not clear by releasing the trigger, there could be damage to the joystick.

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3.1.11 Tilt Warnings

TILT-L

TILT-F

TILT-R

TILT-B

Category: Normal Operation Location: Platform & Base

The machine is tilted too far in the specified direction (Left, Right, Front, Back). The machine will only

be allowed to lower. Once lowered, driving is allowed.

As the machine is rated as an indoor slab machine, tilt is limited to 1.5 degrees side to side and 3

degrees front to back. Tilt errors should only be seen when the machine is elevated or stowed in lift

mode. If the machine is showing tilt warnings when stowed or on flat ground, see the following

guides:

5.1 Tilt When Stowed Page 61

5.10 Tilt Sensor Zeroing Page 70

TILTSTOP Category: Normal Operation Location: Platform & Base

TILTSTOP is a tilt warning that limits the maximum height of the machine if tilted very close to the

limits of what is allowed.

If TILTSTOP is seen, the machine must be lowered slightly to an allowable height, and drive/lift

functions will be allowed.

3.1.12 TILT-ERR

TILT-ERR Category: Error Location: Platform & Base

Tilt sensor is not detected on the CANBus. This could mean the sensor is unplugged or damaged. The

machine will only be allowed to lower. Once lowered, driving is allowed in a slow state.

Troubleshooting should start with checking relevant connectors. If all connectors are good, swap the

tilt sensor with a known good. If the problem persists, check for damage to the base wiring harness.

3.1.13 STR-ERR

STR-ERR Category: Error Location: Platform

Steering controller is displaying an error code or is not detected on startup.

For troubleshooting, connect the control box to the Base to see Motor Controller Errors.

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3.1.14 STR-1

STR-1 Category: Error Location: Base

This error indicates that the steering controller is not seen on startup. During startup, the Right Drive

Controller monitors the LED fault line on the steering controller. If no signal is detected, it is assumed

disconnected.

For troubleshooting, check all relevant connectors. If the problem persists, check the steering harness

and steering controller against known goods. If the error is not related to the harness or controller,

check the base harness to right drive controller.

3.1.15 STR-2


This error indicates that the steering controller has a connection issue or intermittent fault.

The Right Drive Controller monitors the LED fault line on the steering controller. If a flash code is

detected on the fault line, but the right drive controller is not able to detect the specific flash code, it

is displayed as STR-2.

Troubleshooting should start by visually checking if there is an LED flash code on the steering

controller. If there is no flash code, there is likely a suspect connection. It is recommended to follow

troubleshooting steps of 3.1.14 STR-1.

If there is a flash code present, visually determine what the code is and see Motor Controller Errors.

3.1.16 STR-4


This error indicates that the steering controller has experienced an overtemp fault. This is a sensor

internal to the controller. If it does not clear with sufficient cooldown time, it could be an indicator of

controller failure.

3.1.17 STARTING

STARTING Category: Normal Operation Location: Platform & Base

The machine is powering up.

This message is only ever seen when transitioning out of sleep mode for a second or two while checks

are being performed.

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3.1.18 BASE-LFT

BASE-LFT Category: Normal Operation Location: Platform & Base

The rear control panel raise/lower switch is in the raise position. This is intended to show the

operator that the base controls are taking priority over the platform controls.

3.1.19 BASE-LWR

BASE-LWR Category: Normal Operation Location: Platform & Base

The rear control panel raise/lower switch is in the lower position. This is intended to show the

operator that the base controls are taking priority over the platform controls.

3.1.20 CBOX-ERR

CBOX-ERR Category: Normal Operation Location: Platform & Base

A control box is detected in both platform and base locations. The machine will not be allowed to

perform any action until one of the control boxes is unplugged and the machine is restarted.

3.1.21 CHARGER

CHARGER Category: Normal Operation Location: Base

The machine is charging and operation is disabled.

3.1.22 OVERLOAD ERRORS

OVERLOAD Category: Normal Operation Location: Platform

Overload is a general message indicating that too much current draw has been seen while performing

the current action. If any overload error is triggered, the machine will stop operation for 5 seconds.

After 5 seconds the error will clear and operation will be allowed again. When plugged into the base,

the screen will display the specific cause of the overload error. See OVL-S1, OVL-S2, OVL-S3, OVL-

DRVE for more information. Plugged into the platform, all overload related errors will show up as

OVERLOAD.

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OVL-S1

OVL-S2

OVL-S3 Category: Normal Operation Location: Base

Overload has been detected on a lifting stage while lifting or lowering:

1. While lifting – In the factory each machine is calibrated with 650lbs. The Amp draw required

for each stage to lift 650lbs is saved locally in the stage controller. If the stage draws more

current than what is saved, operation is stopped for 5 seconds.

2. While Lowering – If the machine sees a spike in current draw while lowering, operation is

stopped for 5 seconds. This is intended as a safety feature to prevent the machine from

lowering onto something below it as well as to prevent any possible debris inside the machine

from causing damage.

If a stage is overloading undeserved while lowering see 5.5 Page 65

If a stage is overloading undeserved while raising see 5.6 Page 66

If a stage controller has been swapped or replaced and needs to be calibrated see 5.9 Page 69

OVL-DRVE Category: Normal Operation Location: Base

Overload has been detected on a drive controller while in elevated drive.

If either drive controller sees a spike in current draw while driving elevated, operation is stopped for 5

seconds. This is intended as a safety feature to prevent the user from driving onto an object that

could be a stability hazard.

If a drive overload is seen while stowed see 5.3 Page 63

If a drive overload is seen undeserved see 5.7 page 67

3.1.23 SERVICE

SERVICE Category: Normal Operation Location: Platform & Base

SERVICE will be displayed at the platform or base for two reasons:

1. The machine is currently in service mode (powered on with the horn pressed).

2. A service feature was left turned on.

A power cycle should clear SERVICE if it currently in service mode. If it is not in service mode, and a

service feature was left turned on, a factory reset should be performed.

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3.1.24 CANBus Errors

CAN-ERR Category: Error Location: Platform

The right drive controller acts as the master on the CANBus. If the right drive controller loses contact

with any of the other controllers, CAN-ERR is displayed from the platform. To see specifically what

controller contact was lost with, the control box should be plugged into the base.

S1-CAN

S2-CAN

S3-CAN

LD-CAN

Category: Error Location: Base

Messages have not been seen on the CANBus from a specific controller.

For troubleshooting, see 5.11 Page 71

PDOTIME Category: Error Location: Platform & Base

PDOTIME is displayed when either drive controller reports a PDO timeout. A PDO is a message sent on

the CANBus (Process Data Object). A PDO timeout is reported when the left and right drive controllers

are not communicating properly.

For troubleshooting, see 5.11 Page 71

3.1.25 Pothole Protection Errors

PHP-ERR Category: Potential Error Location: Platform

PHP-ERR is displayed from the platform if the pothole protection system has not deployed properly or

has experienced an error.

PHP-SW Category: Error Location: Base

PHP-SW is reported if the pothole protection limit switch is reporting a state that is not allowed. Both

contacts on this switch are monitored. PHP-SW is reported if both contacts are on or both contacts

are off.

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PHP-WARN Category: Normal Operation Location: Base

PHP-WARN is displayed if the pothole protection system has not deployed when it should of, but the

height of the machine is still low enough to safely allow drive function. This is intended to give the

user an opportunity to drive to an area where the pothole can deploy without having to lower fully.

If PHP-WARN is displayed even if pothole appears to be deployed, see 5.12 Page 73

PHP-DEPL Category: Normal Operation Location: Base

PHP-DEPL is displayed if the pothole protection system has not deployed when it should of and the

height of the machine is too high to safely allow drive. The machine must be lowered before drive

function is allowed.

If PHP-DEPL is displayed even if pothole appears to be deployed, see 5.12 Page 73

3.1.26 OVRDRIVE

OVRDRIVE Category: Normal Operation Location: Platform & Base

The machine is in overdrive mode. Maximum speed is 3.9mph. Overdrive is a feature that changes the

drive speed from 3mph to 3.9mph when the machine has been going full speed for 5 seconds without

steering input over 1 second.

3.1.27 CONTACT

CONTACT Category: Error Location: Platform & Base

CONTACT is displayed when the main contactor has not functioned as intended. This could mean one

of two things:

1. The contactor has experienced a failure. Failures could include it is welded, or shorted.

2. The Left Drive controller has experienced an error and is not pulling in the main contactor to

protect the system.

In either case, troubleshooting should begin by plugging the control box into the base and seeing

what motor controller errors are present. In the case of a CONTACT error, the Left Drive Controller

will always have a motor controller error.

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3.1.28 Limit Switch Errors

LS1-ERR

LS2-ERR

LS3-ERR Category: Error Location: Platform

LS_-ERR is displayed from the platform indicating that an error has been seen in a limit switch bank.

Plugging the control box into the base will give more detailed error codes.

LS1-1

LS2-1

LS3-1 Category: Error Location: Base

Both top and bottom limit switches are active at the same time. This could indicate that a switch is

sticking, debris, moisture is in connectors, wiring damage or missing flag.

LS1-2

LS2-2


The top limit switch is pressed and the slowdown switch is not. This could indicate that a switch is


LS1-3

LS2-3


The bottom limit switch is pressed and the slowdown switch is not. This could indicate that a switch is


LS1-4

LS2-4


The top limit switch is showing a state that is not allowed. This switch is a dual action switch with a NC

and NO contact. This error indicates that both are off or both are on. This could indicate moisture in

connectors or wiring damage.

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LS1-12

LS2-12


The slowdown limit switch has not been activated and the stage is at a height where it should of seen

the switch. This could indicate moisture is in connectors, wiring damage or missing flag.

This error could also be caused if the machine has been emergency lowered. If emergency lowered,

the height count of the machine will be off. In order to go to full height again, the machine must be

driven fully down first.

Another cause of this error is if this controller has been replaced or swapped and has never been

height calibrated. See 5.8 Page 68

LS1-13

LS2-13


The top limit switch has not been activated and the stage is at a height where it should of seen the

switch. This could indicate moisture is in connectors, wiring damage or missing flag.

This error could also be caused if the machine has been emergency lowered. If emergency lowered,

the height count of the machine will be off. In order to go to full height again, the machine must be

driven fully down first.

Another cause of this error is if this controller has been replaced or swapped and has never been

height calibrated. See 5.8 Page 68

3.1.29 S-OFF

S-OFF Category: Normal Operation Location: Platform & Base

A stage is turned off – drive and steer are disabled. This is intended as a safety feature to prevent a

machine from moving with critical features turned off. This can be fixed with a factory reset.

3.1.30 LS-OFF

LS-OFF Category: Normal Operation Location: Platform & Base

A limit switch bank is turned off – drive and steer are disabled. This is intended as a safety feature to

prevent a machine from moving with critical features turned off. This can be fixed with a factory

reset.

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3.1.31 EM-WELD

EM-WELD Category: Error Location: Platform & Base

EM-WELD indicates that the EM relay is welded. Due to the nature of this error, this error will latch

through a power cycle. Booting with the horn pressed in will clear this error.

EM-WELD is shown if a controller is seen powered on when the EM relay should be off.

3.1.32 EM-ERR

EM-ERR Category: Error Location: Platform & Base

EM-ERR is reported if an open or short is detected across the driver that controls the EM relay on the

right drive controller. This error will always be accompanied by a motor controller error, so

troubleshooting should begin with plugging the control box into the base and looking at any motor

controller errors reported.

3.1.33 SSTOP

SSTOP Category: Error Location: Platform & Base

SSTOP displayed if any unexpected movement is detected. Brakes are applied and all functions are

disabled for 5 seconds.

3.1.34 FOOTC

FOOTC Category: Error Location: Platform & Base

FOOTC stands for fault on other traction controller. This means that the Curtis Dual Drive system is

not happy. Troubleshooting should start by plugging into the base and looking at motor controller

errors reported.

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3.1.35 WOLFLIFT WOLFLIFT Category: Error Location: Platform

The display screen is not receiving a proper message. This could mean one of two things:

1. The 3rd stage motor controller has an older software version than the right drive controller

and does not know how to interpret the message that it is being told to display.

2. The platform is not receiving CAN messages from the right drive controller. Troubleshooting

should start by plugging into the base and seeing what other messages are present.

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3.2 AC Drive/Lift Motor Controller Errors

Curtis 1232 AC Motor Controller

Each motor controller has error checks within its operating system, independent of the software that

runs the logic of the WolfLift.

Each error code has a fault code and flash code associated with it. If all communication is working

properly, any error codes will be shown on the control box display in the format of __OS__. The first two

characters specify where the error is coming from while the second two characters specify the fault

code.

Code Meaning Example: S2OS31 would mean stage 2 has a Motor Open fault.

RD Right Drive

LD Left Drive

S1 Stage 1

S2 Stage 2

S3 Stage 3

In the event that there is a communication failure, motor controller error codes can be determined by the flash codes displayed by the LED. Each code consists of two digits. The red LED flashes once to indicate that the first digit of the code will follow; the yellow LED then flashes the appropriate number of times for the first digit. The red LED flashes twice to indicate that the second digit of the code will follow; the yellow LED flashed the appropriate number of times for the second digit. Example: A flash code of RYYYYYYYRRYY = 72 on the left drive controller would indicate that the left drive controller is experiencing a PDO timeout. The following table shows each error message and its respective fault code, flash code, and reference page.

Fault Code Flash Code Error Page

00 38 Main Welded Page 24

01 39 Main Not Closed Page 24

02 45 Pot Over Current Page 24

03 42 Throttle Wiper Low Page 25

04 41 Throttle Wiper High Page 25

05 44 Brake Wiper Low Page 25

06 43 Brake Wiper High Page 25

07 46 EEPROM Failure Page 26

08 47 HPD / Sequence Page 26

09 17 Severe Low Voltage Page 26

10 18 Severe High Voltage Page 26

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11 23 Low Voltage Cutback Page 27

12 24 High Voltage Cutback Page 27

13 21 FLASH21 N/A

14 22 Controller High Temp Page 27

15 15 Severe Low Temp Page 27

16 16 Severe High Temp Page 28

17 31 Driver 1 Open / Short Page 28




21 35 PD Open / Short Page 29

22 31 Main Open / Short Page 30

23 32 EM Brake Open / Short Page 30

24 14 Precharge Failed Page 30

25 26 Digital Out 6 Open / Short Page 31

26 27 Digital Out 7 Open / Short Page 31

27 12 Controller Overcurrent Page 31

28 13 Current Sensor Fault Page 32

29 28 Motor Temp Hot Cutback Page 32

30 49 Parameter Change Fault Page 32

31 37 Motor Open Page 32

32 51 FLASH51 N/A

33 52 FLASH52 N/A

34 53 FLASH53 N/A

35 54 FLASH54 N/A

36 55 FLASH55 N/A

37 56 FLASH56 N/A

38 57 FLASH57 N/A

39 58 FLASH58 N/A

40 59 FLASH59 N/A

41 61 FLASH61 N/A

42 62 FLASH62 N/A

43 63 FLASH63 N/A

44 64 FLASH64 N/A

45 65 FLASH65 N/A

46 66 FLASH66 N/A

47 67 FLASH67 N/A

48 69 External Supply Out of Range Page 33

49 29 Motor Temp Sensor Fault Page 33

50 68 VCL Run Time Error Page 33

51 25 5V Supply Error Page 33

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52 71 OS General Page 34

53 72 PDO Timeout Page 34

54 36 Encoder Failure Page 34

55 73 Stall Detected Page 35

56 N/A FAULT56 N/A

57 N/A FAULT57 N/A

58 47 Emergency Reverse HPD Page 35

59 N/A FAULT59 N/A

60 89 Motor Type Fault Page 35

61 N/A FAULT61 N/A

62 87 Motor Characterization Fault Page 36

63 83 Driver Supply Fault Page 36

64 N/A FAULT64 N/A

65 91 VCL / OS Mismatch Page 36

66 92 EM Brake Failed to Set Page 36

67 93 Encoder LOS N/A

68 94 Emergency Reverse Timeout N/A

69 75 Dual Drive Severe Fault Page 37

70 74 Fault on Other Traction Controller Page 37

71 98 Illegal Model Number N/A

72 95 1298 CONTROLLER ONLY N/A



75 99 Dual Motor Parameter Mismatch N/A

76 N/A FAULT76 N/A

77 - Supervisor Fault Page 37

78 N/A FAULT78 N/A

79 N/A FAULT79 N/A

Revision 3.3


3.2.1 Main Welded

Main Welded Fault: 00 Flash: 38

Description: Prior to the main contactor closing, the capacitor bank voltage was loaded and did not

discharge.

Relevance: Applicable to the left drive controller only

Left Drive (Drive Controller #1) – The contactor is powered by the main contactor driver. Main welded

on left drive would indicate a problem with the contactor.

This error could have the following causes:

1. Main contactor tips are welded closed

2. Motor phase U or V is disconnected or open

3.2.2 Main Not Closed

Main Contactor Did Not Close Fault: 01 Flash: 39

Description: With the main contactor commanded closed, the capacitor bank voltage did not charge

to B+

Relevance: Applicable to the left drive controller only

Left Drive (Drive Controller #1) – The contactor is powered by the main contactor driver. Main

Contactor Did Not Close on left drive would indicate a problem with the contactor.

This error could have the following causes:

1. Main contactor did not close

2. Main contactor tips are oxidized, burned or not making good contact

3.2.3 Pot Overcurrent

Pot Low Overcurrent Fault: 02 Flash: 45

Description: Pot low (pin18) current exceeds 10mA

Relevance: This error should not be applicable. Pin 18 is not used on any controller.

Revision 3.3


3.2.4 Throttle Wiper Low

Throttle Wiper Low Fault: 03 Flash: 42

Description: Throttle pot wiper (pin16) voltage is lower than the low fault threshold.


3.2.5 Throttle Wiper High

Throttle Wiper High Fault: 04 Flash: 41

Description: Throttle wiper (pin16) voltage is higher than the fault threshold.


3.2.6 Brake Wiper Low

Pot2 Wiper Low Fault: 05 Flash: 44

Description: Pot2 wiper (pin17) voltage is lower than the low fault threshold.


3.2.7 Brake Wiper High

Pot2 Wiper High Fault: 06 Flash: 43

Description: Pot2 wiper (pin17) voltage is higher than the high fault threshold.


Revision 3.3


3.2.8 EEPROM Failure

EEPROM Failure Fault: 07 Flash: 46

Description: Controller operating system tried to write to EEPROM memory and failed.

Relevance: This could indicate a controller failure. If this is a new controller, or an existing controller

that has just had its software updated, this could indicate a failure while flashing.

3.2.9 HPD / Sequence

HPD/Sequencing Fault Fault: 08 Flash: 47

Description: HPD or sequencing fault caused by incorrect sequence of KSI, interlock, direction, and

throttle inputs.

Relevance: This error should not be applicable. Direction, throttle and interlock are controlled

through software not inputs on the WL-3020. This error will only appear if a controller is installed that

has not been flashed.

3.2.10 Severe Low Voltage

Severe B+ Undervoltage Fault: 09 Flash: 17

Description: Capacitor bank voltage dropped below the severe undervoltage limit.

Relevance: This error will show up when the machine has an extremely low battery level. It will not

affect lifting, but the user will experience a slow/struggling lift. While driving, Severe B+ Undervoltage

will cause drive to stop. This is a safety feature built in to the back end of the Curtis Dual Drive system

to ensure it has enough battery power to maintain anti rollback.

3.2.11 Severe High Voltage

Severe B+ Overvoltage Fault: 10 Flash: 18

Description: Capacitor bank voltage exceeded the severe overvoltage limit.

Relevance: There is a chance that this error will show up just after charging or while charging.

Depending on what charger is used, the charging voltage could exceed the overvoltage limit for the

controllers.

Revision 3.3


3.2.12 Low Voltage Cutback

Undervoltage Cutback Fault: 11 Flash: 23

Description: Capacitor bank voltage dropped below the undervoltage limit

Relevance: This error will show up when the machine has an extremely low battery level. It will not

affect lifting, but the user will experience a slow/struggling lift. While driving, Severe B+ Undervoltage

will cause drive to stop. This is a safety feature built in to the back end of the Curtis Dual Drive system

to ensure it has enough battery power to maintain anti rollback.

3.2.13 High Voltage Cutback

Overvoltage Cutback Fault: 11 Flash: 24

Description: Capacitor bank voltage exceeded the overvoltage limit.

Relevance: There is a chance that this error will show up just after charging or while charging.

Depending on what charger is used, the charging voltage could exceed the overvoltage limit for the

controllers.

3.2.14 Controller High Temp

Controller Overtemp Cutback Fault: 14 Flash: 22

Description: Heatsink temperature exceeded 85oC

Relevance: This is a sensor internal to the motor controller. If the error does not clear with sufficient

cooldown time, it could indicate a controller failure.

3.2.15 Severe Low Temp

Controller Severe Undertemp Fault: 15 Flash: 15

Description: Heatsink temperature below -40oC


time above -40oC, it could indicate a controller failure.

Revision 3.3


3.2.16 Severe High Temp

Controller Severe Overtemp Fault: 16 Flash: 16

Description: Heatsink temperature above 95oC


cooldown time, it could indicate a controller failure.

3.2.17 Driver 1 Open / Short

Coil1 Driver Open/Short Fault: 17 Flash: 31

Description: Driver 1 (pin 6) is either open or shorted.

Relevance: Pin 6 is used on the left drive and right drive controller only. This error is not applicable to

all lifting controllers.

Left Drive (Drive Controller #1) – Main Contactor 106

Right Drive (Drive Controller #2) – EM Relay 206




Relevance: Pin 5 is used on all controllers to power the brake.

Left Drive (Drive Controller #1) – Brake 105

Right Drive (Drive Controller #2) – Brake 205

Stage 1 Lift Controller – Brake 305



Revision 3.3





Relevance: Pin 4 is used on both drive controllers and stage 3.

Left Drive (Drive Controller #1) – Beacon 104

Right Drive (Drive Controller #2) – Hold off 204 (to steering controller harness)

Stage 3 Lift Controller – Beacon 604




Relevance: Pin 3 is used on both drive controllers and stage 3.

Left Drive (Drive Controller #1) – Horn 103

Right Drive (Drive Controller #2) – Fault 203 (to steering controller harness)

Stage 3 Lift Controller – Inverter 603

3.2.21 PD Open / Short

PD Open/Short Fault: 21 Flash: 35

Description: Proportional driver (pin 2) is either open or shorted.


Revision 3.3


3.2.22 Main Open / Short

Main Open/Short Fault: 22 Flash: 31

Description: Main contactor driver (pin 6) is either open or shorted.

Relevance: Pin 6 is used on both driver controllers.

Left Drive (Drive Controller #1) – The contactor is powered by the main contactor driver. Main

Contactor Did Not Close on left drive would indicate a problem with the contactor.

Right Drive (Drive Controller #2) – The EM relay is powered by the main contactor driver. Main

Contactor Did Not Close on the right drive would indicate a problem with the EM relay.

3.2.23 EM Brake Open / Short

EMBrake Open/Short Fault: 23 Flash: 32

Description: Electromagnetic brake driver (pin 5) is either open or shorted.

Relevance: Pin 5 is used on all controllers to power the brake.

Left Drive (Drive Controller #1) – Brake 105

Right Drive (Drive Controller #2) – Brake 205




3.2.24 Precharge Failed

Precharge Failed Fault: 24 Flash: 14

Description: Precharge failed to charge the capacitor bank to the KSI voltage.

Relevance: Capacitor precharge is a necessary step before function is allowed. Failed precharge will

be accompanied by an error indicative of a power loss. Examples would be contactor errors,

undervoltage etc.

Revision 3.3


3.2.25 Digital Out 6 Open / Short

Digital Out 6 Open/Short Fault: 25 Flash: 26

Description: Digital Output 6 (pin 19) current exceeded 15mA.

Relevance: Pin 19 is used on the right drive controller only.

Right Drive (Drive Controller #2) – Reverse 219 (to steering controller harness)

3.2.26 Digital Out 7 Open / Short

Digital Out 7 Open/Short Fault: 26 Flash: 27

Description: Digital Output 7 (pin 20) current exceeded 15mA.

Relevance: Pin 19 is used on the right drive controller only.

Right Drive (Drive Controller #2) – Mode 220 (to steering controller harness)

3.2.27 Controller Overcurrent

Controller Overcurrent Fault: 27 Flash: 12

Description: Phase current exceeded the current measurement limit.

Relevance: This error could have the following causes:

1. External short of phase U,V, or W wires

2. Seized brake if accompanied by a Stall Detected error

3. Damaged lift or drive components if accompanied by a Stall Detected error

4. Controller failure

5. Encoder failure

Revision 3.3


3.2.28 Current Sensor Fault

Current Sensor Fault Fault: 28 Flash: 13

Description: Controller current sensors have invalid offset reading


1. Intermittent or dead short to the machine from phase U,V, or W

2. Controller failure

3.2.29 Motor Temp Hot Cutback

Motor Temp Hot Cutback Fault: 29 Flash: 28

Description: Motor temperature is at or above the Temperature Hot parameter setting

Relevance: This is a sensor internal to the motor windings. If the error does not clear with sufficient

cooldown time, it could indicate a motor failure.

3.2.30 Parameter Change Fault

Parameter Change Fault Fault: 30 Flash: 49

Description: A parameter has been changed that requires a power cycle

Relevance: This error should never appear as all critical parameters are set in software. If this error

appears, it is indicative that a user has access to Curtis motor controller tools and has been changing

settings. This controller should be re flashed.

3.2.31 Motor Open

Motor Open Fault: 31 Flash: 37

Description: Motor phase U,V, or W detected open


1. Motor phase is open

2. Bad crimps or faulty wiring

Revision 3.3


3.2.32 External Supply Out of Range

External Supply Out of Range Fault: 48 Flash: 69

Description: External load on the 5V supply (pin 26) or the 12V supply (pin25) draws too much or too

little current

Relevance: Pin 25 and Pin 26 are used on all 5 controllers in multiple locations. See specific wiring

diagrams for further details.

3.2.33 Motor Temp Sensor Fault

Motor Temp Sensor Fault Fault: 49 Flash: 29

Description: Motor thermistor input (pin 8) is at the voltage rail (0 or 10V)

Relevance: Applicable to all 5 motor controllers. This error indicates wiring problems to the

temperature sensor or damage to the sensor itself.

3.2.34 VCL Run Time Error

VCL Run Time Error Fault: 50 Flash: 68

Description: Software has encountered a runtime error.

Relevance: This error should not be applicable. If it appears, it could be indicative of a controller

failure.

3.2.35 5V Supply Error

+5V Supply Failure Fault: 51 Flash: 25

Description: +5V supply (pin26) is outside of +5V±10%.

Relevance: Applicable to all 5 motor controllers. This error could be caused by a very low impedance

on the +5V supply

Revision 3.3


3.2.36 OS General

OS General Fault: 52 Flash: 71

Description: Internal controller fault detected

Relevance: This error is indicative of controller failure

3.2.37 PDO Timeout

PDO Timeout Fault: 53 Flash: 72

Description: Time between CAN PDO messages received exceeded the timeout period. This could

mean there are messages lost intermittently on the CANBus or that there is a complete

communication failure.

Relevance: This error means that there is a failure of the CAN system. This could be due to noise,

moisture, damage, or intermittent connections.

See 5.11 page 71 for further troubleshooting information

3.2.38 Encoder Failure

Encoder Fault Fault: 54 Flash: 36

Description: Motor encoder phase failure detected

Relevance: This error is applicable to all 5 motor controllers. This could be caused by damage to the

encoder, a faulty encoder or faulty wiring.

Revision 3.3


3.2.39 Stall Detected

Stall Detected Fault: 55 Flash: 73

Description: Stall Detected is reported when no motor encoder movement is detected when

commanded to move.

Relevance: This error is relevant to all 5 motor controllers and can be triggered by the following

causes:

1. Seized brake or lift/drive components

2. Faulty motor encoder or motor encoder failure

3. Motor encoder wiring problems

See 5.13 page 74 for further troubleshooting information

3.2.40 Emergency Reverse HPD

Emergency Reverse HPD Fault: 58 Flash: 47

Description: HPD or sequencing fault caused by incorrect sequence of KSI, interlock, direction and

throttle inputs.

Relevance: This error should not be applicable. Direction, throttle and interlock are controlled

through software not inputs on the WL-3020. This error will only appear if a controller is installed that

has not been flashed.

3.2.41 Motor Type Fault

Motor Type Fault Fault: 60 Flash: 89

Description: Unknown

Relevance: This error should not be applicable. If it appears, it could be indicative of a controller or

motor failure.

Revision 3.3


3.2.42 Motor Characterization Fault

Motor Characterization Fault Fault: 62 Flash: 87

Description: Unknown

Relevance: This error should not be applicable. If it appears, it could be indicative of a controller or

motor failure.

3.2.43 Driver Supply Fault

Driver Supply Fault Fault: 63 Flash: 83

Description: Internal controller fault detected. Internal controller fault in the voltage supply for the

driver circuits.

Relevance: This error is indicative of controller failure

3.2.44 VCL / OS Mismatch

VCL/OS Mismatch Fault: 65 Flash: 91

Description: VCL and OS software do not match.

Relevance: This could indicate a controller failure. If this is a new controller, or an existing controller

that has just had its software updated, this could indicate a failure while flashing

3.2.45 EM Brake Failed to Set

EM Brake Failed to Set Fault: 66 Flash: 92

Description: After the EM brake was commanded to set, vehicle movement has been sensed.

Relevance: This error is caused by an EM brake failure. The brake associated with this controller

should be replaced.

Revision 3.3


3.2.46 Dual Drive Severe Fault

Dual Drive Severe Fault Fault: 69 Flash: 75

Description: Curtis dual drive system has experienced a failure. Check other error messages to

determine what is causing the fault.

Relevance: All drive functions are prevented.

3.2.47 Fault on Other Traction Controller

Fault on Other Traction Controller Fault: 70 Flash: 74

Description: This error code will be reported by a drive controller if the other drive controller is

experiencing an error.

Relevance: This error is extremely common when any kind of failure occurs. It does not tell us

anything about the kind of failure that occurred, but is an indicator to check what error has occurred

with the other drive controller.

3.2.48 Supervisor Fault

Supervisor Fault Fault: 77 Flash: Unknown

Description: A supervisor fault has several causes. The most common cause is when one of the digital

inputs is stuck in the range between the guaranteed high threshold (4.4V) and the guaranteed low

threshold (1.5V) for more than 100ms.

Other possible causes include:

1. Analog inputs out of range

2. Internal 5V or 3.3V power supply out of range

Relevance: This fault is very unlikely to occur in the WL3020. However, it can apply to all controllers.

It is likely caused by a short or moisture in the respective controller harness.

Revision 3.3


3.3 DC Steering Controller Errors

Curtis 1212p DC Motor Controller

The steering controller, similar to the AC motor controllers, has error checks within its operating system

independent of the software that runs the logic of the WolfLift.

The steering controller LED fault line is monitored by the right drive controller. If all other systems are

functioning properly, any error codes experienced by the steering controller will be shown on the

control box display when plugged into the base. These error codes will show up as STR-C__.

Each error has a flash code associated with it. If a steering failure occurs and there is a flash code

present but no errors being reported on the display, the flash code can be read on the red LED present

on the steering harness.

The status LED flashes a 2 digit code where the first series of pulses is the first number, and second series of pulses is the second number. For example: RR RRR would be error message STR-C23 – Main fault. The following table shows each error message and its respective flash code.

Code Error Information

STR-C11 Thermal Fault Temperature is greater than 80oC or less than -10oC

STR-C12 Throttle Fault Throttle input wire open or shorted

STR-C13 Speed Pot Fault N/A

STR-C14 Undervoltage Fault Battery voltage is less than 17 Volts

STR-C15 Overvoltage Fault Battery voltage is above 31 Volts

STR-C21 Main Off Fault Internal contactor driver failed open

STR-C22 EMR Seq. Fault N/A

STR-C23 Main Fault Internal contactor welded, stuck open, or driver fault

STR-C24 Main On Fault Internal contactor driver failed closed

STR-C25 Pump SRO Fault N/A

STR-C31 Wiring Fault Short in steering harness

STR-C32 Brake On Fault EM Brake driver shorted

STR-C33 Precharge Fault Brake driver shorted, precharge circuit damaged, or MOSFET failure

STR-C34 Brake Off Fault EM brake driver open

STR-C35 HPD Fault Short in steering harness

STR-C41 Current Sense Fault Short in motor, motor wiring, or controller failure

STR-C42 Hardware Failsafe Short in motor, motor wiring, or controller failure

STR-C43 EEPROM Checksum EEPROM failure or fault

STR-C44 Motor Open Motor wiring is open

STR-C45 Battery Disconnect Battery not connected

Revision 3.3


4 Service Tools

4.1 Service Mode Input

The WL-3020 features a service mode accessible from the control box when plugged into the base.

Service mode allows a technician to turn features on or off that assist in assembly, disassembly,

maintenance and troubleshooting.

To access service mode

1. Unplug control box from platform

2. Plug control box into base

3. Power the machine on with the horn pressed

4. Screen will display SERVICE – ENTER – PASSWORD

5. Now the user will be able to enter a password. To allow the entry of service codes, 837 must be

entered. A factory reset and restart are also allowed at this level.

The following codes can be entered before entering the service mode password 837:

Number Message Description Page

1 EXIT Restarts Machine Page 42

2 RESET Factory Reset Page 42

837 SERVICE Allows service code entry N/A

After entering 837, the following codes are available:

Number Message Description Page

1 EXIT Restarts Machine Page 42

2 RESET Factory Reset Page 42

10 S1-OFF S1 OFF Page 43

11 S1-ON S1 ON Page 43

12 LS1-OFF S1 Limit Switches Off Page 44

13 LS1-ON S1 Limit Switches On Page 44



22 LS2-ON S2 Limit Switches Off Page 44

23 LS2-OFF S2 Limit Switches On Page 44



32 LS3-ON S3 Limit Switches Off Page 44

33 LS3-OFF S3 Limit Switches On Page 44

40 HCAL-OFF Height Counter Calibrating Off Page 45

41 HCAL-ON Height Counter Calibrating On Page 45

42 OVL-OFF Overload Off Page 46

Revision 3.3


43 OVL-ON Overload On Page 46

44 TILT-OFF Tilt Sense Off Page 48

45 TILT-ON Tilt Sense On Page 48

46 STR-OFF Steering Error Check Off Page 49

47 STR-ON Steering Error Check On Page 49

48 CBOX-OFF Multiple Control Box Checking Off Page 51

49 CBOX-ON Multiple Control Box Checking On Page 51

50 LSTP-OFF Lowering Current Limit Off Page 46

51 LSTP-ON Lowering Current Limit On Page 46

52 TBP-OFF Travel Beep Off Page 52

53 TBP-ON Travel Beep On Page 52

54 OVD-OFF OverDrive Off Page 57

55 OVD-ON OverDrive On Page 57

56 PRXY-OFF Steer Proxy Off Page 49

57 PRXY-ON Steer Proxy On Page 49

58 CAN-OFF CAN Check Off Page 53

59 CAN-ON CAN Check On Page 53

60 PHPL-OFF Pothole Error Lift Off Page 54

61 PHPL-ON Pothole Error Lift On Page 54

62 BEEP-OFF Lift & Drive Beep Disable Page 52

63 BEEP-ON Lift & Drive Beep Enable Page 52

64 RESP-OFF Reset Proxy on Startup Disable Page 49

65 RESP-ON Reset Proxy on Startup Enable Page 49

66 SBR-OFF Steering Brake Release Disable Page 49

67 SBR-ON Steering Brake Release Enable Page 49

68 PASS-OFF Turns login off Page 55

69 PASS-ON Turns login on Page 55

70 P-CHANGE Enter new user login password Page 55

71 PHP-ON Pothole switch ignore on Page 54

72 PHP-OFF Pothole switch ignore off Page 54

73 SF-OFF Stage light off Page 56

74 SF-ON Stage light on Page 56

75 SF-1 Stage light constant Page 56

76 SF-2 Stage light flash Page 56

77 VCL180 VCL 180 features enabled Page 60

78 VCL171 VCL 180 features disabled Page 60

79 FS-SET Fast speed percentage change Page 57

80 SS-SET Slow speed percentage change Page 57

81 CI-OFF Charge interlock off Page 58

82 CI-ON Charge interlock on Page 58

Revision 3.3


83 BEEP-SET Change beep volume Page 52

84 CBHW-OFF New control box sensing off Page 51

85 CBHW-ON New control box sensing on Page 51

86 CWA-ON Cold weather overload adjustment on Page 59

87 CWA-OFF Cold weather overload adjustment off Page 59

88 AOVL-ON Advanced overload on Page 46

89 AOVL-OFF Advanced overload off Page 46

90 OVL-R Overload reset Page 46

91 OVLS-ON Overload set on Page 46

92 OVLS-OFF Overload set off Page 46

93 5AC-ON 5A cold boost on Page 59

94 5AC-OFF 5A cold boost off Page 59

Revision 3.3


4.1.1 Exit

Function: Exit Code: 1 EXIT

In any menu, exit can be used as a way to re start the machine. This cycles the power in the right drive

controller, forcing the entire machine to restart. Functionally this is the same as a power cycle.

4.1.2 Reset

Function: Reset Code: 2 RESET

Factory reset can be used in any menu. This will reset most service features to their default settings.

Stage 1 on Stage 2 on Stage 3 on Stage 1 Limit Switches on Stage 2 Limit Switches on Stage 3 Limit Switches on Height Calibration off Overload on Tilt Sensor on Multiple Control Box Checking on

Steering Controller Checks on Steering Proxy Sensors on CAN Checks on Pothole Limit Switch Checks on User Password Required off Charger Interlock on Stage 3 Flash off Overload Set off Cold Weather Adjust on Slow Speed 100% Fast Speed 100%

Revision 3.3


4.1.3 Stage On/Off

Function: Stage 1 Off Code: 10 S1-OFF

Stage 1 function disabled

Function: Stage 1 On Code: 11 S1-ON

Stage 1 function enabled









Revision 3.3


4.1.4 Limit Switches On/Off

Function: Stage 1 Limit Switches Off Code: 12 LS1-OFF

Stage 1 limit switches are ignored

Function: Stage 1 Limit Switches On Code: 13 LS1-ON

Stage 1 limit switches are monitored









TURNING LIMIT SWITCHES OFF CAN RESULT IN DAMAGE TO THE MACHINE IF DRIVEN TOO FAR IN

EITHER DIRECTION

Revision 3.3


4.1.5 Height Calibration

Function: Height Calibration Off Code: 40 HCAL-OFF

Height calibration is turned off

Function: Height Calibration On Code: 41 HCAL-ON

Height calibration is turned on

For instructions on how to properly height calibrate the machine, see 5.8 Page 68

IMPROPER HEIGHT CALIBRATION CAN RENDER THIS SAFETY FEATURE USELESS

Revision 3.3


4.1.6 Current Limits (Overload Settings)

Function: Overload Off Code: 42 OVL-OFF

Overload sensing is turned off when raising and lowering. Current is limited by the controllers at 200

Amps.

Function: Overload On Code: 43 OVL-ON

Overload sensing is enabled. Current limiting when raising is set by AOVL (Advanced Overload)

settings. Current limiting when lowering is set by LSTP (Lowering Current Limit) settings.

Function: Lowering Current Limit Off Code: 50 LSTP-OFF

Specific lowering current limits turned off. Lowering current limit will be the same as raising current

limit.

Function: Lowering Current Limit On Code: 51 LSTP-ON

Specific lowering current limits turned on. Lowering current will be set to 40 Amps.

TURNING OVERLOAD OFF WILL ALLOW THE MACHINE TO RAISE OR LOWER AGAINST AN OBSTACLE AT

FULL POWER. THIS CAN CAUSE DAMAGE TO LIFTING COMPONENTS.

Revision 3.3


Function: Advanced Overload On Code: 88 AOVL-ON

Advanced overload settings are turned on. When enabled, lifting overload is set to a calibrated value.

Function: Advanced Overload Off Code: 89 AOVL-OFF

Advanced overload settings are turned off. Lifting overload is set to 100A. This is not recommended

as it will not be an accurate limit.

Function: Overload Limit Reset Code: 90 OVL-R

When enabled, overload limit will be reset to 0A. This function should only be used when re

calibrating advanced overload.

Function: Overload Limit Set On Code: 91 OVLS-ON

When enabled, the overload limit for each stage will be set to the highest current experienced by the

stage. This function should only be used when re-calibrating advanced overload.

Function: Overload Limit Set Off Code: 92 OVLS-OFF

When disabled, the overload limit for each stage will remain what it was last calibrated to.

Related troubleshooting/instructional guides:

Overload Calibration: 5.9 Page 69

Overload When Lowering: 5.5 Page 65

Overload When Raising: 5.6 Page 66

WHEN USED IMPROPERLY, ADVANCED OVERLOAD SETTINGS, INCLUDING CALIBRATION COULD LEAD

TO THE MACHINE OVERLOADING BELOW CAPACITY OR OVER CAPACITY – THESE FUNCTIONS SHOULD

ONLY BE USED BY AN EXPERIENCED TECHNICIAN

Revision 3.3


4.1.7 Tilt Settings

Function: Tilt Sensor Off Code: 44 TILT-OFF

The tilt sensor is completely ignored. This is a useful feature in the event of sensor failure or wiring

damage to allow the machine to be operated for repair purposes.

Function: Tilt Sensor On Code: 45 TILT-ON

Tilt sensor is enabled.

DISABLING THE TILT SENSOR WILL ALLOW THE MACHINE TO BE USED IN A TILTED STATE. THIS IS

EXTREMELY DANGEROUS – TILT SETTINGS SHOULD ONLY BE USED BY AN EXPEREICED TECHNICIAN

Revision 3.3


4.1.8 Steering

Function: Steering Error Checks Off Code: 46 STR-OFF

All steering controller error codes are ignored. This will allow the machine to function normally even if

the steering controller is missing or has an error.

Function: Steering Error Checks On Code: 47 STR-ON

Steering controller error codes are not ignored.

Function: Steering Proxy Sensors Off Code: 56 PRXY-OFF

Steering proxy sensors are ignored. This is a useful function when servicing the steering mechanism,

allowing the steering to be driven in either direction when not assembled fully.

Function: Steering Proxy Sensors On Code: 57 PRXY-ON

Steering proxy sensors are not ignored.

WHEN USED IMPROPERLY, IGNORING STEERING PROXY SENSORS COULD LEAD TO DAMAGE OF THE

STEERING MECHANISM AS IT WILL DRIVE PAST THE END OF STROKE

Revision 3.3


Function: Proxy Reset Disable Code: 64 RESP-OFF

This is a function used in older machines for troubleshooting purposes. It should not be used.

Function: Proxy Reset Enable Code: 65 RESP-ON


Function: Brake Release Steering Off Code: 66 SBR-OFF


Function: Brake Release Steering On Code: 67 SBR-ON


Revision 3.3


4.1.9 Multiple Control Box Checks

Function: Voltage Multiple Control Box Checks Off Code: 48 CBOX-OFF

This is an older style of multiple control box checking that should be left off.

Function: Voltage Multiple Control Box Checks On Code: 49 CBOX-ON

This is an older style of multiple control box checking that should be left off. It works by monitoring

the voltage on the CANBus. If it moves to a threshold representative of two control boxes present,

function is disabled. This system was subjective to noise and machine voltage, and gave occasional

false errors. It has been replaced by control box hardware code checking in all machines 1.9.0 and

older.

Function: CBHW Multiple Control Box Checks Off Code: 84 CBHW-OFF

Control box hardware code checks disabled.

Function: CBHW Multiple Control Box Checks On Code: 85 CBHW-ON

Control box hardware code checks enabled. This how every machine 1.9.0 and older checks to see if

multiple control boxes are plugged in. Each joystick reports a unique hardware code on the CANBus. If

multiple codes are received, function is disabled.

CBHW SHOULD ALWAYS BE LEFT ON – HAVING MULTIPLE CONTROL BOXES PLUGGED IN WILL

PREVENT THE E-STOP FROM WORKING UNLESS BOTH ARE PRESSED

Revision 3.3


4.1.10 Beep Settings

Function: All Motion Alarms Disabled Code: 62 BEEP-OFF

All motion alarms are turned off

Function: Motion Alarms Enabled Code: 63 BEEP-ON

BEEP-ON will allow the use of motion alarms. With this function entered, by default the lowering

alarm will be enabled. The travel alarm is decided by TBP below.

Function: Travel Beep Off Code: 52 TBP-OFF

This function turns off the travel alarm while leaving the lowering alarm enabled.

Function: Travel Beep On Code: 53 TBP-ON

This function turns on the travel alarm in addition to the lowering alarm.

Function: Motion Alarm Volume Code: 83 BEEP-SET

This function is used to adjust the volume of the motion alarm from 10% to 100%

For detailed instructions on enabling and tuning the travel alarm, see: 5.15 page 76

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4.1.11 CAN Checks

Function: CAN Check Off Code: 58 CAN-OFF

This function will ignore any CAN errors present in software error codes. This will not ignore motor

controller CAN errors such as PDO TIMEOUT. This is useful for allowing machine function with

components missing for assembly/disassembly/repair.

Function: CAN Check On Code: 59 CAN-ON

CAN errors present in software error codes will not be ignored.

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4.1.12 Pothole

Function: Pothole Error Lift Off Code: 60 PHPL-OFF

Lifting is not allowed if pothole does not deploy properly.

Function: Pothole Error Lift On Code: 61 PHPL-ON

Lifting is allowed if pothole does not deploy properly. By default this is turned on.

Function: Pothole Error Checks Off Code: 71 PHP-ON

This function turns off PHP limit switch checks. If the limit switch is unplugged and error checks are

turned off, the machine will function as if pothole is working properly.

Function: Pothole Error Checks On Code: 72 PHP-OFF

This function enables PHP limit switch checks.

POTHOLE ERROR CHECKS SHOULD ALWAYS BE LEFT ON UNLESS TURNED OFF FOR REPAIR OR

TROUBLESHOOTING PURPOSES. IGNORING POTHOLE WILL ALLOW ELEVATED DRIVE EVEN IF POTHOLE

IS NOT DEPLOYED, POTENTIALLY CREATING A VERY DANGEROUS SITUATION.

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4.1.13 User Login

Function: User Login Disabled Code: 68 PASS-OFF

This function disables the requirement for a user password. By default this is turned off.

Function: User Login Enabled Code: 69 PASS-ON

This function enables the requirement for a user password. This is a feature that requires a user to

enter a password from the platform before operation is allowed.

Function: User Password Change Code: 70 P-CHANGE

This function allows a technician to change the required user password if enabled. The default

password is 1234.

For detailed instructions on enabling and setting the user password, see: 5.16 page 77

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4.1.14 Stage 3 Light

Function: Stage Light Off Code: 73 SF-OFF

Optional stage 3 light output is off

Function: Stage Light On Code: 74 SF-ON

Optional stage 3 light output is on

Function: Stage Light Constant Code: 75 SF-1

Light output is steady on, to be used with an LED with a built in flasher.

Function: Stage Light Flash Code: 76 SF-2

Light output is flashing, to be used with a regular LED light.

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4.1.15 Drive Speed

Function: Overdrive Off Code: 54 OVD-OFF

Overdrive disabled

Function: Overdrive On Code: 55 OVD-ON

Overdrive enabled. Overdrive is a feature that changes the drive speed from 3mph to 3.9mph when

the machine has been going full speed for 5 seconds without steering input over 1 second.

Function: Fast Speed Percentage Change Code: 79 FS-SET

Allows a technician to set the maximum drive speed when stowed from 25%-100% of 3mph.

Function: Slow Speed Percentage Change Code: 80 SS-SET

Allows a technician to set the maximum drive speed when elevated from 50%-100% of 0.75mph.

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4.1.16 Charge Interlock

Function: Charge Interlock off Code: 81 CI-OFF

Disables charge interlock – drive and lift functions will be allowed while the machine is charging. This

is intended for technicians to have the ability to service a machine while it is charging.

Function: Charge Interlock on Code: 82 CI-ON

Enables charge interlock – drive and lift functions will not be allowed while the machine is charging.

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4.1.17 Cold Weather

Function: Cold Weather Adjustment On Code: 86 CWA-ON

This feature monitors the temperature sensor of the motor and gives it a current boost depending on

the temperature. By default this feature is turned on. It is necessary for proper functionality in

extreme temperatures.

Function: Cold Weather Adjustment Off Code: 87 CWA-OFF

This turns off cold weather adjustment.

Function: 5A Cold Boost On Code: 93 5AC-ON

This function gives each stage an extra 5 Amps when turned on. It is meant to be a boost for extreme

temperatures if overloads are seen undeserved. By default this is turned off.

Function: 5A Cold Boost Off Code: 94 5AC-OFF

Turns 5A cold boost off.

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4.1.18 VCL Versions

Function: VCL 1.8.0 Features Enabled Code: 77 VCL180

This enables features that require all controllers to be 1.8.0 or newer. If all controllers are 1.8.0 or

newer, this should be enabled.

Function: VCL 1.8.0 Features Disabled Code: 78 VCL171

This disables features that require all controllers to be 1.8.0 or newer. If all controllers are 1.8.0 or

older, this should be disabled.

Note: There are very few machines in the field that have old software in them. If a machine has older

than 1.9.2 software, please contact Haessler Inc. as these machines should be upgraded at some point.

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5 Service Guides

5.1 Machine is Reporting Tilt Errors When Stowed

Condition:

While stowed, the machine randomly reports tilt errors.

Likely Causes:

1. Machine is not fully stowed such that a limit switch is barely activated

2. Loose limit switch bank or faulty limit switch

3. Clevis block interference causing item #1

4. Debris between frame stages causing item #1

Description:

The WL-3020 will only ever display a tilt error when it is elevated. If a tilt error appears while stowed,

it means that the machine is in an elevated state. For safety reasons, the machine must see a number

of conditions satisfied before it is considered stowed. This means that if any of these conditions are

not satisfied, even for a split second, the machine believes it is elevated.

Stowed conditions:

- Stage 1 bottom limit switch activated



This ensures that the machine is completely lowered, and continually monitored to ensure it is

lowered.

If tilt errors appear while driving stowed, it is more than likely a limit switch not fully engaged. In most

cases, if the operator puts the machine in lift mode, it should lower a little further and the error will

go away. This is usually only encountered on extremely uneven terrain where the machine is

bouncing enough for a switch to come off of its flag.

If the error keeps coming back, it could be an indicator of a loose limit switch, and all three banks

should be inspected.

Older machines are especially susceptible as some suffered from a slight interference between the

clevis blocks on stage 2 and stage 3, meaning stage 3 did not always stow entirely. If tilt errors appear

on a machine manufactured before December 2017, please reach out to Haessler Inc for specific

instructions on how to grind the blocks to eliminate this problem.

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5.2 Machine will not turn on

Condition:

Disconnect switch activated, control box e-stop activated, base e-stop activated and nothing happens.

Likely Causes:

1. Extremely low batteries or dead batteries

2. Blown battery fuse

3. Base breaker(s) tripped

4. Loose or damaged e-stop contact

5. Wiring damage

Troubleshooting:

In order to power on the WL-3020, both e-stops must be pulled out and the disconnect switch must

be in the on position. If the machine does not power on at all, the following steps should be followed:

1. Ensure the control box cable is fully plugged in

2. Check all breakers at the back of the machine and the main battery fuse. If a breaker is

tripped, try to reset it. If it continues to trip, there is more than likely a short in the machine.

Attempt to find the short by isolating the harness that the short it in. It may be useful to

disconnect the 8 pin connector at the front of the machine to disconnect the lifting stack,

determining if the short is in the stack or base. If this is the case, it may need to be raised

manually for inspection. See 5.18 page 79 for further instructions.

3. Check that the batteries are not dead.

4. Check that the e-stops in the base and control box are functioning properly.

5. Check that the main disconnect is functioning properly.

6. If no breakers are tripped, base fuse is intact, e-stops are functioning and main disconnect is

functioning, there is likely a loose wire or wiring damage to the e-stop circuit. This should be

traced out to find where it is losing continuity.

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5.3 Only display turns on

Condition:

Machine powers on to the extent that the display turns on however no controllers have power and

the machine will not function.

Likely Causes:

1. Extremely low batteries

2. Base breaker(s) tripped

3. Wiring damage or loose connectors

Troubleshooting:

This error indicates that the e-stop circuit is complete; however the right drive controller is not

getting 24V on KSI (pin 1). The following steps should be followed for troubleshooting:

1. Check battery voltage. It is possible that the batteries are so low that the display will power

on, but there is not enough power to turn on a controller.

2. Although very unlikely to be a cause, the breakers should be quickly checked.

3. Wiring damage or loose connectors could cause this. The damage or loose connector will be

in the base of the machine. It is likely due to a loose emergency lowering harness or right

drive controller connector.

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5.4 Drive overload when stowed

Condition:

While stowed, the machine randomly reports drive overload warning.

Likely Causes:

1. Machine is not fully stowed such that a limit switch is barely activated

2. Loose limit switch bank or faulty limit switch

3. Clevis block interference causing item #1

4. Debris between frame stages causing item #1

Description:

The WL-3020 will only overload in drive when it is elevated. This error is meant to protect the

machine from driving over an obstacle into an unsafe tilted condition. If a drive overload appears

while stowed, it means that the machine is in an elevated state. For safety reasons, the machine must

see a number of conditions satisfied before it is considered stowed. This means that if any of these

conditions are not satisfied, even for a split second, the machine believes it is elevated.

Stowed conditions:




This ensures that the machine is completely lowered, and continually monitored to ensure it is

lowered.

If drive overload is reported while driving stowed, it is more than likely a limit switch not fully

engaged. In most cases, if the operator puts the machine in lift mode, it should lower a little further

and the error will go away. This is usually only encountered on extremely uneven terrain where the

machine is bouncing enough for a switch to come off of its flag.

If the error keeps coming back, it could be an indicator of a loose limit switch, and all three banks

should be inspected.

Older machines are especially susceptible as some suffered from a slight interference between the

clevis blocks on stage 2 and stage 3, meaning stage 3 did not always stow entirely. If tilt errors appear

on a machine manufactured before December 2017, please reach out to Haessler Inc for specific

instructions on how to grind the blocks to eliminate this problem.

Revision 3.3


5.5 Overload when lowering

Condition:

Machine displays overload when lowering.

Likely Causes:

1. E-stop was pressed while in motion and the torque preload is out of sync

2. Debris or physical damage

3. Wiring damage, encoder damage

Troubleshooting:

If the WL-3020 is experiencing overloads lowering, this could be caused by the following conditions:

1. The machine has a function programmed in to eliminate any sag when it begins to lift or

lower. It does this by remembering the torque used to hold its position at shutdown and

applying this torque before the brakes are allowed off. If the machine is powered off while in

motion, it is likely that the first action performed will show up as an overload. This is because

it will not apply the proper amount of current to hold its position and will overcompensate,

applying current that is likely above the allowed threshold. After this initial overload, the

machine should function properly.

2. There are debris or physical damage stopping the lift from operating smoothly. It is

recommended that the control box be plugged into the base to see what specific stage is

causing the overload. Then a full internal inspection should be conducted of that stage and its

respective rack. Greasing the racks at this time would also help reduce current draw.

3. The stage causing the overload has damage to the wiring or encoder, causing it to draw

irregular amounts of current. This would likely be accompanied with a motor controller error

code.

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5.6 Overload when raising

Condition:

Machine displays overload when raising.

Likely Causes:

1. The machine has too much weight on the platform

2. E-stop was pressed while in motion and the torque preload is out of sync

3. Debris or physical damage

4. Wiring damage, encoder damage

Troubleshooting:

If the WL-3020 is experiencing overloads when raising without 650lbs on the platform, this could be

caused by the following conditions:

1. The machine has a function programmed in to eliminate any sag when it begins to lift or

lower. It does this by remembering the torque used to hold its position at shutdown and

applying this torque before the brakes are allowed off. If the machine is powered off while in

motion, it is likely that the first action performed will show up as an overload. This is because

it will not apply the proper amount of current to hold its position and will overcompensate,

applying current that is likely above the allowed threshold. After this initial overload, the

machine should function properly.

2. There are debris or physical damage stopping the lift from operating smoothly. It is

recommended that the control box be plugged into the base to see what specific stage is

causing the overload. Then a full internal inspection should be conducted of that stage and its

respective rack. Greasing the racks at this time would also help reduce current draw.

3. The stage causing the overload has damage to the wiring or encoder, causing it to draw

irregular amounts of current. This would likely be accompanied with a motor controller error

code.

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5.7 Overload when driving elevated

Condition:

Machine displays overload when driving elevated.

Likely Causes:

1. The machine has experienced a current spike from hitting an obstacle

2. There is damage to the motor encoder or motor wiring

3. There is physical damage to the wheel drive assembly causing abnormal current requirements

Troubleshooting:

If the WL-3020 is experiencing overloads while driving elevated, it could be caused by the following

conditions:

1. The machine has hit an obstacle. This is a safety feature to prevent it from attempting to drive

over the obstacle into an unsafe tilted state. After hitting the obstacle it will likely take

multiple attempts to back off of it, as the drive torque preload will be out of sync. If the

machine does not drive off of the obstacle after multiple attempts, it is recommended to

lower the machine and move it off of the obstacle.

2. One of the drive motors has damage to its wiring or encoder. This will likely be accompanied

by a motor controller error message.

3. Physical damage is causing one of the drives to bind or have trouble moving. This will likely be

obvious and should be replaced.

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5.8 Height Calibration

Description:

Height calibration of the machine is an important safety feature. The encoder on each motor is

tracked, allowing the machine to know the height of each stage. The height of each stage is compared

against what it was calibrated to. If a frame stage travels past the maximum saved height and does

not see a slowdown or top limit switch the machine is stopped with a limit switch error.

If a frame stage is swapped, or a controller is swapped, it is mandatory that the machine is

recalibrated.

Instructions:

To calibrate the maximum height of the machine:

1. Fully lower the machine

2. Start the machine in service mode and enter 837

3. Enter 41 to enable calibration

4. Raise the machine to full height

5. Enter 40 or factory reset to disable height calibration

6. Restart the machine with a power cycle or exit command

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5.9 Weight Calibration

Description:

In order for overload to work properly while lifting, the machine is must be calibrated for 650lbs

capacity. This must be done if a frame stage is swapped out or controller is swapped out.

Instructions:

To calibrate the machine for 650lbs:

1. Fully lower the machine

2. Load 650lbs centered on the platform

3. Raise machine up slightly and lower it fully to ensure torque preload will not spike

4. Start the machine in service mode and enter 837

5. Enter 90 to reset the saved overload calibration

6. Restart the machine and allow to power up fully

7. Restart the machine in service mode and enter 837

8. Enter 91 to turn overload calibration on

9. Raise the machine fully

10. Enter 92 or factory reset to turn weight calibration off

11. Lower the machine fully

12. Remove weights

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5.10 Tilt Sensor Zeroing

Description:

If the tilt sensor is swapped out, or removed and reinstalled for any reason, it must be zeroed in order

for the machine to function properly.

Instructions:

To zero the tile sensor:

1. Power the machine on and position it on level ground

2. Use a small screw driver or pick to push the button on the bottom of the tilt sensor until the

LEDs flash (approximately 5 seconds). Do not press the button after the first set of flashes. If

the LEDs flash a second time (approximately 10 seconds) it will zero to the factory setting of

the sensor, not to the machine and should be re done.

If you do not know where this is located, removing the sensor and looking at the bottom

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5.11 Communication Problems

Condition:

Machine powers up and encounters communication problems. The following error codes will always

be seen with a communication failure:

RDOS53 – PDO Timeout

LDOS53 – PDO Timeout

RDOS70 – Fault on Other Traction Controller

LDOS70 – Fault on Other Traction Controller

Any combination of the following can also accompany a communication failure:

PDOTIME

FOOTC

S1-CAN

S2-CAN

S3-CAN

LD-CAN

CONTACT

Likely Causes:

If the failure is reported immediately on startup it is likely caused by the following:

1. A short across the CAN high and CAN low wires

2. A short of a CAN wire to 24V

3. A short of a CAN wire to ground

4. Moisture in a connector

If the failure is reported intermittently or sporadically it is likely caused by the following:

1. Electrical noise induced on a CAN wire

2. Intermittent short of a CAN wire

3. Short of a U,V,W wire to the machine

4. Moisture in a connector

Troubleshooting:

Due to the nature of CANbus, it is impossible to detect exactly where the cause of the communication

failure is. However, it can be easily pinpointed through process of elimination:

1. Quickly check around the machine for obvious signs of wiring damage or moisture, specifically

the platform control cables and drive motor U,V,W wires

2. Remove the front shroud from the machine and unplug the 8 pin connector. This removes the

lifting stack from the base of the machine. Restart the machine. If the error is reduced to S1-

CAN, S2-CAN or S3-CAN, eliminating OS53 and OS70, it is safe to assume that the cause is

somewhere in the lifting stack. If all errors remain, it is safe to assume that the cause is

somewhere in the base.

3. If the cause is isolated to the base, inspect all connectors and wires in the base.

4. If the cause is isolated to the lifting stack, turn off CAN checks (service mode 837 – 58) so the

machine can drive. The machine needs to be raised manually and should be moved to an area

with a crane or forklift. If it is on a jobsite, the machine should be removed and taken to a

properly equipped shop.

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5. Plug the 8 pin connector back in and raise the machine manually – see 5.18 page 79

6. Once raised, quickly inspect the inside of the machine for any obvious damage to control

cables, cable tracks and power wires.

7. Starting at stage 3, unplug each control cable connector. After each control cable is

unplugged, restart the machine. Eventually the error will be eliminated, isolating that harness

as the cause.

a. Harnesses should be isolated in the following order: 6 pin control cable to platform –

8 pin connector to stage 3 harness – 8 pin connector to stage 2 cable track – 8 pin

connector to stage 2 harness – 8 pin connector to stage 1 cable track – 8 pin

connector to stage 1 harness

8. Once isolated, the harness should be inspected for any damage or moisture. If it is isolated to

a short from a power wire, this wire should be insulated or replaced.

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5.12 PHP errors when deployed

Condition:

Machine displays a PHP warn or PHP deploy error when it appears to be deployed properly

Likely Causes:

1. Emergency lowering was used and the machine was not fully lowered with the control box

2. Pothole limit switch is not being engaged fully by pothole linkage

3. Pothole limit switch is damaged, wet or harness is damaged

Troubleshooting:

If a PHP-ERR is detected while lifting and the mechanism appears to be working properly, the joystick

box should be plugged into the base to see the specific error code.

If a PHP-SW is reported:

1. The switch is reporting a state that is not allowed (ON-ON or OFF-OFF) and should be

inspected for damage.

If a PHP-DEPL or PHP-WARN is reported:

1. If the machine was emergency lowered and not lowered completely with the control box, the

height calibration will be out and the machine will be reporting a false height. If the machine

has a height saved where it should of seen the pothole deployed, it will report one of the

above errors. Lowering the machine fully will reset the count and operation should return to

normal.

2. The linkage responsible for activating the PHP limit switch could be binding or not making

complete contact. This linkage should be lubricated and checked to make sure it is fully

activating the limit switch.

3. Check PHP limit switch and wiring. Swap with known good if necessary.

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5.13 Stall Detected

Condition:

A motor controller is reporting a stall in the motor. This is set by 5 seconds of throttle applied with no

encoder movement.

Likely Causes:

1. Damaged encoder

2. Seized or damaged brake

Troubleshooting:

A stall is reported when a throttle is applied with no encoder movement. If mechanical components

are damaged, this will not show up as a stall as backlash in gears and general slop will still allow SOME

movement of the motor and the encoder will see this. A failure of this nature will show as an

overload. If a stall is detected it is local to the motor and brake assembly.

1. Verify that the brake is clicking off when energized and the motor is free to move. This can be

done on lifting assemblies with emergency lowering. On drive assemblies it can be done by

raising the front of the machine, applying 24v to the brake and moving the affected wheel by

hand.

2. Verify that the encoder is plugged in and not damaged. If there is an encoder failure, this will

likely be displayed by slow, sporadic movement of the motor, followed by a stall detected.

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5.14 Steering Not Functioning, No Errors Reported

Condition:

The steering motor controller is not reporting any errors, when steering is applied nothing happens

Likely Causes:

1. Loose B+ or B- wire to motor

2. Mechanical damage to steering assembly

Troubleshooting:

1. Verify that the motor controller is not displaying a flash code

2. Check all wiring from controller to steering motor

3. Remove steering assembly and inspect the rack, pinion and motor spindle

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5.15 Motion Alarm Settings

Description: The WL-3020 is shipped by default to have audible motion alarms turned off. If the

owner or operator desires, the following settings can be enabled:

1. No audible motion alarms

2. Lowering motion alarm

3. Lowering and driving motion alarms

Instructions:

For all alarms to be turned off, enter 62 BEEP-OFF

For only lowering alarms, enter 63 BEEP-ON and 52 TBP-OFF

For all alarms, enter 63 BEEP-ON and 53 TBP-ON

To adjust the volume of the motion alarm, enter 83 BEEP-SET. This will allow the volume to be set

from 10% to 100% of horn volume. Default setting is 35%.

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5.16 Enabling User Password Entry

Description:

The WL-3020 is equipped with a feature that requires a user to enter a password before operation is

allowed. This is useful to keep unauthorized users from operating the machine without needing

individual keys etc.

Instructions:

In order to disable user password entry, enter 68 PASS-OFF

In order to enable user password entry, enter 69 PASS-ON

In order to set the user password, enter 70 P-CHANGE.

By default the password is 1234. This can be changed to any 4 digit number from 0001 to 9999.

Revision 3.3


5.17 Only Right Drive Controller Powering On

Condition: Machine powers on and only the right drive controller has power.

This will always be accompanied by:

RDOS53 – PDO TIMEOUT

LDCAN or PDOTIME

In certain cases the following errors will also be reported:

RDOS errors to do with Driver 1 or Main: did not close, open, shorted, welded

Likely Causes:

1. Damaged or faulty EM Relay

2. Tripped EM breaker

3. Damaged or shorted rear end wiring

4. Damaged or loose left drive harness

Troubleshooting:

The right drive controller is responsible for powering on the EM relay which gives power to the other

4 AC motor controllers. This is a feature used to accomplish the sleep mode of the WL-3020.

When the left drive controller is not detected, PDO timeout errors will be reported as well as general

software CAN errors. If a problem is detected in the EM relay, motor controller error codes will

provide more information with the nature of the failure.

1. The most likely cause for this error is that the EM relay is not functioning properly. If motor

controller errors are provided pointing to a failure of the EM relay, this should be investigated

further.

2. If errors are not provided pointing to a failure of the EM relay, it should first be checked to

ensure it is working properly. The easiest way to do this is put the machine on charge, forcing

it into sleep mode. There should be no continuity across the EM relay. Out of sleep mode

there should be continuity.

3. Once it is determined that the EM relay is functioning properly, continuity between the EM

circuit and KSI on the left drive controller should be checked. This is likely contained within

the harness on the left drive controller.

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5.18 Manual Raising

Description: The machine has experienced a failure preventing it from lifting. The failure is isolated to

be within the lifting stack and must be raised for further troubleshooting

Instructions: In order to manually raise the machine frame stage brakes must be energized and the

platform lifted, stretching the machine out.

1. Bring the machine to an area with an overhead crane or forklift access.

2. Attach all 4 fall arrest tie off points to the crane using straps or chains. If a crane is not

available, position a forklift beside the machine, with the forks spread underneath the main

yellow platform supports.

3. Jumper out the two terminals on the emergency lowering flasher. This will eliminate the

pulsing action of the brakes.

4. Press the emergency lowering button or jumper normally open contacts and disconnect

normally closed contacts.

5. Raise the machine slowly using the forklift or overhead crane.

If in a low ceiling area, raise the machine until it is possible to reach in and disconnect a brake.

Doing this will ‘freeze’ the desired frame stage when the emergency lowering button is pressed.

If the emergency lowering does not energize the brakes, there is likely damage to the main control

cable. In this situation it is recommended that the floor be removed from the platform and 24V

applied to the desired stage brake to be lifted. It is likely that only the stage 2 and 3 brakes will be

accessible from above. If the floor is removed, it is recommended to lift from the main platform

supports rather than the tie off points.

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5.19 Accessing the Odometer

Description:

The WL-3020 displays individual odometers for lift and drive hours and has separate service intervals

for each.

Instructions:

To see the odometer the control box must be plugged into the base port.

When the lift/drive select switch is on lift, lift hours will be displayed as __._ LH.

When the lift/drive select switch is on drive, drive hours will be displayed as __._ DH.

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6 Inspection & Maintenance Checklists The WL-3020 must be inspected and maintained to the schedule provided below. Inspection and maintenance records should be documented by the owner or dealer. The owner or dealer shall retain the following records for at least 4 years as per ANSI A92.6-2006 section 5.11. Records of repairs, malfunctions and problems, etc. In accordance with CSA B354.2-01, the following inspections must take place:

- Daily Inspection& Maintenance

- Bi-Monthly Inspection& Maintenance

- Annual Inspection& Maintenance

- Structural Inspection& Maintenance

6.1 Inspection Schedule

6.1.1 Daily Inspection

Frequency: Daily or every 8 hours, whichever comes first.

Before use each day, at the beginning of each shift, or eight hours of use, a pre-start and functional test,

as applicable, should be completed. This inspection should include but not be limited to the following as

shown in Table 1: Daily Inspection & Maintenance Checklist. The daily inspection should be completed

and in compliance with the WL-3020 Operator’s Manual. For any reason the machine is not in

compliance with the WL-3020 Operator’s Manual, the machine should be removed from service and

repaired.

6.1.2 Bi-Monthly Inspection

Frequency: Once every 2 months or every 100 operating hours, whichever comes first.

The WL-3020 must always be kept in good working order. In addition to the pre-start/eight-hour

inspections, the user or employer is required to perform a bi-monthly inspection of the WL3020 and

maintain records of this inspection. The bi-monthly inspection and any required maintenance needs to

be performed by a competent service person who understands the mechanics of WL-3020. The

following section is an inspection that should be completed at least once every 2 months in addition to

regular service specified by Haessler Inc. This inspection, which should be completed at least once every

2 months in addition to any regular maintenance and should include but not be limited to the following

as shown in Table 2: Bi-Monthly Inspection & Maintenance ChecklistTable 2: Bi-Monthly Inspection &

Maintenance Checklist. For any reason the machine is not in compliance with the WL-3020 Service

Manual, the machine should be removed from service and repaired.

6.1.3 Annual Inspection

Frequency: Once a year or every 700 operating hours, whichever comes first.

The WL-3020 must always be kept in good working order. In addition to the pre-start/eight-hour

inspections and bi-monthly inspections, the user or employer is required to perform an annual

inspection of the WL-3020 and maintain records of this inspection. This annual inspection and any

required maintenance needs to be performed by a competent service person who understands the

Revision 3.3


mechanics of WL-3020. This inspection, which should be completed at least once per year in addition to

any regular maintenance and should include but not be limited to the following as shown in Table 3:

Annual Inspection& Maintenance Checklist. For any reason the machine is not in compliance with the

WL-3020 Service Manual, the machine should be removed from service and repaired.

6.1.4 Structural Inspection

A complete structural inspection must be performed 10 years after manufacturing date and every 5

years following. If the machine is badly damaged or any event occurs that could reduce structural

integrity a structural inspection must take place. If ownership changes and service history is not

provided, a structural inspection must take place.

Structural inspections must be conducted under the direction of a professional engineer. Any required

maintenance needs to be performed by a competent service person who understands the mechanics of

WL-3020.

In accordance with CSA B354.2-01, the competent service person must:

- Consider the history of the machine in terms of operating hours, operating environment,

number of users, types of users.

- Review all inspection, service and repair records

- Verify all controls and functions

- Conduct a complete visual inspection

Revision 3.3


Table 1: Daily Inspection & Maintenance Checklist

Serial Number: __________________________ Operator’s Name (Printed):

Model:________________________________ ________________________________________

Lift Hourmeter Reading: __________________ Operator’s Name Signature:

Drive Hourmeter Reading: _________________ ________________________________________

Date: __________________________________

Before use each day, at the beginning of each shift, or eight hours of use, a pre-start and functional test,

as applicable, should be completed. This inspection should include but not be limited to the following as

shown in Table 1: Daily Inspection & Maintenance Checklist. The daily inspection should be completed

and in compliance with the WL-3020 Operating Manual. The owner or dealer shall retain the following

for at least 4 years as per ANSI A92.6-2006 section 5.11. Records of repairs, malfunctions and problems,

etc.

Mechanical Electrical

Check Tires and Wheels Battery Fluid Level

Racks & Pinion greased Battery Terminals

All Bolts & Fasteners Platform Controls

Platform Railings Emergency Controls

Platform Chain Base Controls

Fall Protection Anchors Charging Cable

Extension Deck& Safety Stop Plugs

Work Platform Frame Stage Wiring

No Excessive Rust Base Controls

No Internal Panel Wear Cable Track Wiring For Wear Or Damage

No External Panel Wear Limit Switches

Cable Track Function Tilt Switch

Sliding Panel Track Beacon

Sliding Panels Horn

Ladder Secured Miscellaneous

Brakes Cleanliness

Gearboxes (No leaks) Manual

Frame Stages (No excessive wear) Labels & Control Markings

Wheel Drives (No leaks) No General Signs Of Damage

Wheel Bolts (Visually Tight)

Steering Assembly

Pothole Protection Device

Revision 3.3


Table 2: Bi-Monthly Inspection & Maintenance Checklist

Serial Number: __________________________ Technician’s Name (Printed):

Model: ________________________________ ________________________________________

Lift Hourmeter Reading: __________________ Technician’s Name Signature:


Date: __________________________________

The bi-monthly inspection and any required maintenance needs to be performed by a competent

service person who understands the mechanics of WL-3020. This inspection should include but not be

limited to the following as shown in Table 2: Bi-Monthly Inspection & Maintenance Checklist. The bi-

monthly inspection should be completed and in compliance with the WL-3020 Service Manual. The

owner or dealer shall retain the following for at least 4 years as per ANSI A92.6-2006 section 5.11.

Records of repairs, malfunctions and problems, etc.




All Bolts & Fasteners& Mechanical Stops Platform Controls











Sliding Panels Horn

Ladder Secured Miscellaneous

Brakes Cleanliness

Gearboxes (No leaks) Manual

Frame Stages (No excessive wear) Labels & Control Markings

Wheel Drives (No leaks) No General Signs Of Damage

Wheel Bolts (Torqued)

Steering Assembly

Pothole Protection Device

Revision 3.3


Table 3: Annual Inspection& Maintenance Checklist

Serial Number: __________________________ Technician’s Name (Printed):

Model: ________________________________ ________________________________________

Lift Hourmeter Reading: __________________ Technician’s Name Signature:


Date: __________________________________

The annual inspection and any required maintenance needs to be performed by a competent service

person who understands the mechanics of WL-3020. This inspection should include but not be limited to

the following as shown in Table 2: Bi-Monthly Inspection & Maintenance Checklist. The annual

inspection should be completed and in compliance with the WL-3020 Service Manual. The owner or

dealer shall retain the following for at least 4 years as per ANSI A92.6-2006 section 5.11. Records of

repairs, malfunctions and problems, etc.




All Bolts & Fasteners& Mechanical Stops Platform Controls











Sliding Panels Horn

Ladder Secured Switch Wiring & Connections

Brakes Miscellaneous

Gearboxes (No leaks) Cleanliness

Frame Stages (No excessive wear) Manual

Wheel Drives (No leaks) Labels & Control Markings

Wheel Bolts (Torqued) No General Signs Of Damage

Pothole Protection Device All Welds (No Cracks)

Steering Assembly

Revision 3.3


7 Maintenance

7.1 Scheduled Maintenance Summary Table 4: Scheduled Maintenance Interval

Electrical

Battery Fluid Level Daily

Mechanical

Wheel Bolts (Torqued) Bi-monthly or as required

Check Rack and Pinion for wear Bi-monthly or as required

Grease Rack and Pinions Bi-monthly or as required

Grease Steering Rack Bi-monthly or as required

Tighten All Gearbox Bolts Bi-monthly or as required

Tighten Rack Bolts Bi-monthly or as required

Tighten Frame Stage Bolts Bi-monthly or as required

Tighten Wheel Drive Bolts Bi-monthly or as required

Bevel Gearbox Oil Change After initial 40 hours, then every 200 hours or annually thereafter

Spur Gearbox Oil Change After initial 40 hours, then every 200 hours or annually thereafter

Lower Wheel Drive Oil Change After initial 40 hours, then every 200 hours or annually thereafter

Grease Middle Wheel Drive Annually or as required

Grease Upper Wheel Drive Annually or as required

Grease Battery Box Track Annually or as required

Grease Steering Axle Tubes Annually or as required

Lubricate Pothole Protection Annually or as required

Lubricate Steering Linkages Annually or as required

Lubricate Battery Box Latches Annually or as required

Lubricate Battery Box Hinge Annually or as required

Revision 3.3


7.2 Fluids and Lubricants Levels

Assembly Specification Quantity

10 DP Bevel Gear Box 75W90 Full Synthetic with extreme pressure friction modifier 100ml

8 DP Bevel Gear Box 75W90 Full Synthetic with extreme pressure friction modifier 125ml

1st Spur Gear Box 75W90 Full Synthetic with extreme pressure friction modifier 300ml

2nd Spur Gear Box 75W90 Full Synthetic with extreme pressure friction modifier 400ml

3rd Spur Gear Box 75W90 Full Synthetic with extreme pressure friction modifier 300ml

Lower Wheel Drive 75W90 Full Synthetic with extreme pressure friction modifier 610ml

Gear Racks #2 Lithium Grease with 5% Moly N/A

Axel Tube #2 Lithium Grease Fill

Steering Casting #2 Lithium Grease Fill

Middle Wheel Drive #2 Lithium Grease Fill

Upper Wheel Drive #2 Lithium Grease Fill

Note: Rack grease should be applied as a ¼” bead along the length of the racks. Ensure grooves in the

side of the racks are also greased.

Documents

Model WL-3020 Service Manual - Wolfliftwolflift.ca/assets/docs/Woflift-Service-Manual-R3.3.pdf · Revision 3.3 WolfLift WL3020 Service Manual Printed in Canada Page 4 base tower,