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ESR 5000 SERIES

MAINTENANCE MANUAL

Order Number: 812577-006


Revision: A Printed in Germany
This master manual is subject to continual updates.
It is intended solely for companies authorised by CROWN.
The transfer of the contents or copies thereof to third parties is strictly prohibited.

CROWN Gabelstapler GmbH & Co. KG


European Headquarters
Moosacher Str. 52
80809 Mnchen
Germany

Tel +49 (0)89 93 00 2 0

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


Copyright 2009
CROWN Equipment Corporation
TABLE OF CONTENTS

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Text mark-ups in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Personal safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Protecting the hazardous area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hazards from stored energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Restoring the truck to service after repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warning and instruction decals on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lifting gear and slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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


Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Lifting the truck with a forklift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Towing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Jacking up the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Truck Assembly and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Truck assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Erecting the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removing the transport retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filling the drive transmission unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Erecting the mast and fitting it to the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Placing the Truck in Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Testing trucks in storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Restoring the truck to service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Battery maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Accessing components under the panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Components under the panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Accessing the motor compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Motor compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Accessing components under the floorboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Components below the floorboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Recommended Lubricants and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cold store truck requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Abbreviations used in the table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27


Planned Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Annual inspection in accordance with FEM 4.004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Terms and abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Seat and seat panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Brake system and load wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Reach carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Electrical system - part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrical system - part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Travel and pump motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fork carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Standard torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Load wheel replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Special tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Load wheel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Load wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Support Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking the support block distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Adjusting the support block height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Before adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Replacing the support blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cleaning the Truck and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Effects of incorrect cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Roller and slide bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Corrosion-protected surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Cleaning the entire truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Cleaning removed components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cleaning lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cleaning other mechanical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Abbreviations Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Feature Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Extending the mast reach carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Retracting the mast reach carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fork tilt back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fork tilt down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Sideshift right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Sideshift left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Valve blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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Main valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75


"Accessories" valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking and adjusting relief valve RV1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking the emergency lowering valve MVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Depressurising the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Bleeding and Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the free lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the reach cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the sideshift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the 5th function cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Flushing the lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Drift tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Drift Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Lift cylinder drift test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Tilt cylinder drift test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ESR 5000S hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ESR 5000 hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Replacing the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Replacing the Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Replacing the return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Replacing the suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Replacing the breather filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Replacing the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Hydraulic Port Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Removing the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Repairing the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Dismantling the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Assembling the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Assembling the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Drive wheel disassembly / assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Drive wheel disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Drive wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ACS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

ESR 5000

III
TABLE OF CONTENTS

ECR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ECR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ECR5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
EDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
ED1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FAN1, FAN4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FAN2, FAN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU5, FU6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
HCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
HN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
HNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
HGTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
HGTRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
K1 & K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
K12 & K13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
K22 & K23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
KYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
MVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
ORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
POT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
POT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
POT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
POT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
POT5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
RES1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
RES2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
RV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
SDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
SES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SFS 1SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SFS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SVR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SVS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

ESR 5000

IV
TABLE OF CONTENTS

SVT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
THS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
THS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
THS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
THS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Service Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Software version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Overview of menu items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
A1Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C1 Acceleration Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C2 Raiser/Lower Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C3 Reach Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C4 Tilt Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C5 Side Shift Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C6 5th Function Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C7 Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C8 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
C9 Fork Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
C10 Reach Retract Slow Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
C11 Save? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Log Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Performance level defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Standard settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Service Menu - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Access to service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Trucks with key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Trucks without key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Navigation and entry keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Display structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Access to service menu and selecting a sub-menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Analyzer Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
A1 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
A2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
A3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
C1 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
C2 Raise / Lower Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
C3 Reach Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
C4 Tilt Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
C5 Side Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
C6 5th Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
C7 Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
C7.3 Height Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
C8 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
C9 Fork Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

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C10 Reach Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137


C11 Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Features Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
F1 Truck Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
F2 Free Lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
F3 Height Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
F4 Lower Cut Out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
F5 5th Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
F6 Maximum Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
F7 Capacity Data Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
F8 Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
F9 Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
F10 User Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
F11 User Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
F12 Set Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
F13 Change Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
F14 Set Rack Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
F15 Height/Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
F16 Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
F17 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
F18 Operator Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
F19 Battery Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
F20 Fork Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
F21 Choose Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
F25 Keyless Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
F26 Right Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
F27 Options Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
F28 Truck Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
F29 Direction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
F30 Save ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Hour Meter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
H1 Truck Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
H2 Traction Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
H3 Hydraulic Mod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
H4 Key On Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
H5 Set Service Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Log Events Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
L1 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
L2 Totals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
L3 Erase History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Performance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
P1 Setup P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
P2 Setup P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
P3 Setup P3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
P4 BDI Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
P5 Travel > LCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
P6 Travel > FLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
P7 Travel > Custom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
P8 Lower > Custom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
P9 Reach > Custom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
P10 5th Function Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
P11 5th Function Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
P12 Steer Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
P14 Brake at Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

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P15 Set Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169


P16 Save ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Utilities Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
U1 Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
U2 Hour Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
U3 Brake Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
U4 Check Fan 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Malfunctions with event code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Log book display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Malfunctions without event code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Locating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Event Codes 100 - 186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event Code 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event Code 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event Code 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Event Code 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Event Code 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Event Code 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Event Code 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Event Code 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event Code 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event Code 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event Code 130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Event Code 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Event Code 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Event Code 180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Event Code 181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Event Code 182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Event Code 183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Event Code 184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Event Code 186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Event Codes 200 - 286 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Event Code 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Event Code 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Event Code 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Event Code 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Event Code 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Event Code 213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Event Code 214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Event Code 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Event Code 221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Event Code 222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Event Code 223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event Code 224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Event Code 225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Event Code 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Event Code 241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Event Code 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Event Code 244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Event Code 246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Event Code 247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Event Code 249 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Event Code 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

ESR 5000

VII
TABLE OF CONTENTS

Event Code 260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208


Event Code 261 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Event Code 262 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Event Code 263 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Event Code 264 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Event Code 265 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event Code 266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Event Code 267 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Event Code 268 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Event Code 280 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Event Code 281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Event Code 282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Event Code 283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Event Code 284 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Event Code 285 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Event Codes 300 - 385 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Event Code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Event Code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Event Code 311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Event Code 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Event Code 313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Event Code 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Event Code 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Event Code 321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Event Code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Event Code 323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Event Code 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Event Code 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Event Code 330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Event Code 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Event Code 341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Event Code 343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Event Code 380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Event Code 381 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Event Code 382 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Event Code 383 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Event Code 384 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Event Codes 430 - 465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event Code 430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event Code 431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event Code 460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Event Code 461 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Event Code 462 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Event Code 463 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Event Code 464 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Event Code 465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Event Codes 840 - 886 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Event Code 840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Event Code 841 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Event Code 880 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Event Code 881 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Event Code 883 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Event Code 884 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Event Code 885 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

ESR 5000

VIII
TABLE OF CONTENTS

Event Code 886 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257


Control Modules and Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Replacing control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Replacing the main control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Replacing the traction control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Replacing the hydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Replacing the steering control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Replacing the display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
PMT Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Preparing the control module safety test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Traction control module safety test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Hydraulic control module safety test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Steering control module safety test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Replacing the Height Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Replacing the HGT(R)S Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Removing the HGT(R)S switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Assembling the HGT(R)S switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Replacing the Armrest Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Trucks with fingertip control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Removing the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Assembling the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Trucks with dual axis hydraulic control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Trucks with multi-task handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Removing the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Assembling the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Repairing Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Wear test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Checking contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Checking the coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Checking the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Repairing the Main Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Replacing the Danaher Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Traction motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Traction motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Replacing the Sensor Bearing on the Danaher Traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Sensor bearing disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Sensor bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Replacing the Crown Traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Traction motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Traction motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Replacing the Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Removing the pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Pump motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Replacing the Sensor Bearing on the Danaher Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Sensor bearing disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Sensor bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Choosing the Correct Battery Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Choosing cable lengths for a T-shaped battery (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

ESR 5000

IX
TABLE OF CONTENTS

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285


Service and Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Service and Parking Brake Danaher Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Disassembling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Dismantling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Fitting the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Assembling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Adjusting the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Measuring the coil resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Parking Brake - Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Disassembling the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Dismantling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Fitting the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Assembling the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Adjusting the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Measuring the coil resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Load Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Checking the brake lining wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Replacing the brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Wheel brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Wheel brake cylinder disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Wheel brake cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Bleeding the load wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Replacing the brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Testing and Adjusting the Brake Pedal Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Adding Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Brake Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Generating a steering signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Steer motor activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Steer system monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Error correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Quadrant - definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Steering Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Error routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Ending the error routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Causes of error routine activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Other error causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Examples of steer faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Proximity Switches SFS2 and SFS1 SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Replacing and adjusting SFS2 or SFS1 SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Steer Motor and Steering Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Removing the steer motor and steering transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Disconnecting the steering transmission and steer motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Assembling the steering transmission and steer motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Installing the steer motor and steering transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

ESR 5000

X
TABLE OF CONTENTS

Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310


Steering wheel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Steering wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Replacing Encoder ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Removing ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Assembling ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313


Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Safety instructions for working on the mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Lifting gear minimum capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Checking the assembled mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Flaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Checking the roller tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Checking the mast verticality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Checking the pulleys, hoses and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Checking the end stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Checking the fork setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Checking the mast tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Mast tilt tolerance tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Adjusting the Mast Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Mast Removal / Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Mast removal and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Mast removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Mast assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Mast checks and settings after assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Dismantling and Assembling the Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Tips & tricks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Dismantling the mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Fork carriage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Removing the 2nd mast stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
1st mast stage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Replacing the Mast Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Mast roller assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Calculating the roller diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Calculating the required number of shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Final tasks and settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Integrated Sideshifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Removing the integrated sideshifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Assembling the integrated sideshifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Lift Cylinder Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Lift cylinder removal on masts up to 8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Lift cylinder assembly on masts up to 8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Lift cylinder removal on masts beyond 8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Lift cylinder assembly on masts beyond 8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Reach Cylinder Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

ESR 5000

XI
TABLE OF CONTENTS

Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336


Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Free Lift Cylinder Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Chain Supports and Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Periodic inspection of chain supports and lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Periodic replacement of chain supports and lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Cleaning lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Inspecting Chain Supports and Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Checking the service hours for the lift chains and anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Checking the lift chain for elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Freedom of movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Worn or missing plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Turned pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Chain lateral wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Checking chain supports and anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Checking the chain pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Checking and adjusting the chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Checking and adjusting the tension on the outer chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Checking and setting the free lift chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Checking the lifting components for misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Lubricating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Lubrication intervals and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Separating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Tools and equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Fork marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Checking fork tines for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Checking fork tip straightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Measuring the fork blade warping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Measuring the fork tip width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Measuring the fork tine height difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Checking the fork stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Measuring the fork blade wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Reach Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Terms and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
"Left outrigger" and "Right outrigger" definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Reach carriage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Reach carriage assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

ESR 5000

XII
TABLE OF CONTENTS

Hydraulic System Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357


Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Small hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Producing extractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Groove aligning arbor for small rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Assembly devices for large rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Protective mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Rod Seal Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Removing a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Removing a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Inserting a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Fitting a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Rod seal assembly, sealing lip first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Repairing Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Replacing the rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Repairing Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Dismantling lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Lift cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Piston ram pre-assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Piston cap pre-assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Repairing the Free Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Dismantling the free lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Free lift cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Piston ram pre-assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Piston cap pre-assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Repairing the Reach Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Dismantling the reach cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Piston ram pre-assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Piston cap pre-assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Repairing the Sideshifter Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Dismantling the sideshifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Sideshifter cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375


Wire Colour Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
General Contact Symbol Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Electrical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Power Up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Wiring Diagram (Fingertip and Dual Axis Hydraulic Control Levers) . . . . . . . . . . . . . . . . . . . . . . . . . 383
Wiring Diagram (Fingertip and Dual Axis Hydraulic Control Levers) . . . . . . . . . . . . . . . . . . . . . . . . . 384
Wiring Diagram (Multitask Control Handle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Wiring Diagram (Multitask Control Handle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Main harness, ESR 5000, Danaher motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Main Harness, ESR 5000, Danaher Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
Main Harness, ESR 5000, Danaher Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Main Harness, ESR 5000, Danaher Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

ESR 5000

XIII
TABLE OF CONTENTS

Wiring
Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Main Harness, ESR 5000, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Main Harness, ESR 5000, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
Main Harness, ESR 5000, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Main Harness, ESR 5000, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Main Harness, ESR 5000S, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Main Harness, ESR 5000S, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Main Harness, ESR 5000S, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Harness, ESR 5000 Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
Harness, ESR 5000S Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Harness, ESR 5000S Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Connector table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Wire Harness: Terminal to Reach Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
Cable Assy Truck, Reach Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Cable Assy Valve Block, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
Cable Assy Valve Block, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
Fork Carriage Harness Extended, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Fork Carriage Harness Standard, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Fork Carriage Switch Assy, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Fork Carriage, 5th Function, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
Fork Carriage, LS Bridge, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
FKS Heater Assembly, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Cable Mast 10 Core Assy, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Cable Mast 6 Core Assy, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
VT Camera, Reach Carriage to Chassis, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

ESR 5000

XIV
TABLE OF CONTENTS

Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460


Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
VT Camera, DC / DC to Control Box, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
VT Camera, Mast, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
Assembly Remark: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
VT Camera, Box to Chassis, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
Motec Camera, Supply to b/w Monitor, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
Motec Camera, Component to Reach, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
Motec Camera, Supply to Display Box, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
Motec Camera, Fork Camera, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Motec Camera, Inner Mast, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
Assembly Remark: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468
Motec Camera, Reach to Display Box, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
Motec Camera, Mast (Fork Camera), Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
Assembly Remark: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470
Cold Store Harness, ESR 5000, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
Cold Store Harness, ESR 5000, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Cold Store, Armrest Harness, ESR 5000, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Cold Store, Armrest Harness, ESR 5000S, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Beacon Loom, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Beacon Loom, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Working Light 24V Loom, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Cable lugs and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Travel Alarm Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481

ESR 5000

XV
TABLE OF CONTENTS

Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481


Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
Heated Seat, ESR 5000, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
DC/DC Converter Loom, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
DC/DC Converter Loom, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
Reading Light Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
Reading Light Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
Working Light 12V, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
Working Light 12V, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
Cable lugs and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
InfoLink, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
InfoLink, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
Cable lugs and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
DCDC Converter Loom NA, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
DC/DC Converter Loom NA, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
48V Supply, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Power Supply Cable, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Bypass Cable, Seat Heating Switch, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Supply Cable, ESR 5000, PSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Cable lugs and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Lights 12V, PSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509


Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515

ESR 5000

XVI
INTRODUCTION

1
Notes:

2
INTRODUCTION
Important Information

Important Information Service personnel qualification


This maintenance manual details the maintenance and To maintain the safety and functionality of the
repair work to be carried out on the following truck truck, maintenance and repair work must only be
models: performed by service engineers who have been
:
authorised by Crown.
ESR 5000 Contact Crown if you wish to have your engineers
trained.
ESR 5000S
Ordering spare parts
Manual structure To order spare parts, use the spare parts catalog sup-
The manual is divided into the following sections: plied separately. Always quote the following numbers
when ordering spare parts:
Specification number
Section
Model number
Index Serial number
Introduction These numbers can be found on the truck data plate.
For details of your truck's technical specifications refer
Safety to the Technical Specifications chapter in the operator
Lubrication & Adjustment manual.
Note: Always use original Crown spare parts.
Hydraulic System
Drive Unit Ordering documentation
Spare parts catalogs, operator manuals, specification
Electrical System
sheets etc. can be obtained from:
Brake System
Steering CROWN Gabelstapler GmbH & Co.KG
Moosacher Str. 52
Lifting Mechanism 80809 Munich
Cylinders GERMANY
Schematic Diagrams Tel.: +49 (0)89 / 93 002 -0
Hydraulic Schematic Fax: +49 (0)89 / 93 002 -175 or 133
www.crown.com
Text mark-ups in the manual
The following symbols and mark-ups are used in the
manual:
1., 2., 3. denote work steps to be taken.
This arrow indicates the consequences of an
action.
This arrow indicates action to be taken to avoid the
hazards contained in a warnings.
(1), (2), (3) etc. indicate text references to item num-
bers in illustrations.
Indicates the first level in a list.
Indicates the second level in a list.
Note: Where the word "Note" appears before text, this
indicates important additional information.

ESR 5000 Rev.2 02/2009

3
INTRODUCTION
Specification Number

Specification Number Mast height and capacity


The specification number is located on the data plate.
No. Mast height Mast height Maximum
It contains important information on the truck's features retracted extended capacity
at the time of delivery. (mm) (mm) (t)(a)

9 2770 6690 1.4 or 1.6


    
10 2770 6395 2.0
11 2920 7140 1.4 or 1.6
 
  12 2920 6845 2.0
Fig. 1 Specification number example 13 3040 7500 1.4 or 1.6
1 Maximum capacity (in tonnes)(a) 14 3040 7205 2.0
2 Model name (see Model name table) 15 3190 7950 1.4 or 1.6
3 Mast type TT (3 stage telescopic mast, full free lift)
16 3350 8415 1.4 or 1.6
4 Retracted height (see Mast height and capacity table)(b)
5
17 3350 8120 2.0
Fork length (see Fork length table)(b)
a. The capacity plate on the truck is binding. 18 3490 8850 1.4 or 1.6
b. For special designs the actual values are stated for
19 3690 9450 1.4 or 1.6
mast height retracted, mast height extended and the
fork length. 20 3690 9155 2.0
21 3840 9900 2.0

Model name 22 3840 9605 2.0


23 3950 10230 1.4 or 1.6
Abbreviation Description
24 3950 9935 2.0
ESR European Sitdown Rider Reach
25 4250 10835 2.0
ESRS European Sitdown Rider Reach,
S-Class 26 4450 11435 2.0
27 4420 9935 2.0 SD(b)
28 4720 10835 2.0 SD(b)
Mast height and capacity
29 4920 11435 2.0 SD(b)
No. Mast height Mast height Maximum
retracted extended capacity 30 5110 12000 2.0 SD(b)
(mm) (mm) (t)(a)
a. The capacity plate on the truck is binding.
b. SD = Super Duty Mast
1 2020 4440 1.4 or 1.6
2 2020 4145 2.0
3 2170 4890 1.4 or 1.6 Fork length
4 2170 4595 2.0 No. Fork length Number Fork length
5 2320 5340 1.4 or 1.6 (mm) (mm)

6 2470 5790 1.4 or 1.6 1 990 4 1220


7 2470 5495 2.0 2 1067 5 1500
8 2570 6090 1.4 or 1.6 3 1145 6 1600

ESR 5000

4
SAFETY

5
Notes:

6
SAFETY
Safety Notices

Safety Notices
The following symbols will help you to assess the risk
to yourself, other people and materials should you fail
to comply with a safety notice:

DANGER
This symbol warns of immediate danger to the life
and health of personnel.
Severe injury or death will result.
Follow all instructions indicated by this symbol in or-
der to avoid injury or death.

WARNING
This symbol warns of potential danger to the life
and health of personnel.
Severe injury or death may result.
Follow all instructions indicated by this symbol in
order to avoid injury or death.

CAUTION
This symbol warns of possible danger to the health
of personnel.
Injury may result.
Follow all instructions indicated by this symbol in
order to avoid injury.

CAUTION
This signal word without a symbol warns of
material damage.
Damage to the truck, tools and mechanisms may
result.
Follow all instructions indicated by this signal word
in order to avoid damage.

ESR 5000

7
SAFETY
Basic Safety Notices

Basic Safety Notices Protecting the hazardous area


When carrying out repair work that could be hazard-
Organisational measures ous to yourself and other people, seal off a large
Repair work must only be carried out by service en- part of the hazardous area with suitable marker
gineers approved by Crown. tape.
Work on electrical equipment must only be carried Before carrying out repair work, service personnel
out by specialist electricians in accordance with must ensure that there is no one in the hazardous
electrical regulations. area.
Note the basic and action-specific safety notices in Service personnel must stop work immediately if
the respective chapters of this manual. Refer also any unauthorised persons enter the hazardous
to the truck operator manual, in particular the Safety area. These persons must be removed immedi-
chapter. ately.
Service personnel must also observe statutory and Hazards from stored energy
other binding accident and environmental protec-
tion regulations. High pressure hydraulic oil can cause severe inju-
ries. Depressurise the hydraulic system before
The legal minimum age for performing repair work
opening any sections of it.
must be observed.
A 15 minute discharge time must be observed for
Service personnel must be trained and authorised
the electrical energy stored in the capacitors and
to operate industrial trucks and must be able to
coils. Alternatively, these components can undergo
demonstrate their competence.
a controlled discharge through an electrical resistor.
Personal safety equipment When carrying out work near the battery, always
cover the battery terminals with a suitable insulating
Always wear safety equipment such as safety
material (e.g. plywood board) to prevent short cir-
shoes and goggles when carrying out maintenance
cuits.
and repairs. Depending on requirements you may
also need to wear safety gloves and ear muffs. Before carrying out work underneath and on raised
components (e.g. fork carriages, extended mast
When carrying out work on the hydraulic system,
stages, the truck itself), attach suitable safety de-
e.g. bleeding the system, wear suitable protective
vices and supports with sufficient capacity.
clothing such as safety gloves, goggles or a face
mask. Springs and gas pressure dampers must be
checked and slowly discharged before removing
When handling batteries wear acid protective cloth-
them.
ing such as safety gloves, goggles and an apron.
Long hair, loose clothing and jewellery are prohib- Repair work
ited. They could get caught or drawn in, resulting in
Always carry out repair work in accordance with the
injury. Do not wear jewellery especially when work-
test and maintenance schedule contained in this
ing on electrical systems, as a short circuit could
manual and any applicable service bulletins.
cause burning.
Before carrying out repair work prepare the truck as
Always use insulated tools when working on electri-
follows:
cal systems.
Park the truck on a level surface
Lower the forks to the ground
Switch off the truck and prevent it from being
switched on again
Disconnect the battery and prevent the connector
from being attached by unauthorised personnel.
When carrying out work that requires battery sup-
ply, jack up the truck until the drive wheel is clear of
the ground.

ESR 5000

8
SAFETY
Basic Safety Notices

Do not use a naked flame near the truck or to check The charger must be appropriate to the battery volt-
fluid levels or for leaks. age and capacity. First connect the battery, then
Always have suitable fire protection equipment to switch the charger on.
hand when carrying out work. When handling batteries wear acid protective cloth-
Keep the truck clean; this makes it easier to find ing such as safety gloves, goggles and an apron.
loose or missing components. Do not use a naked flame and do not smoke when
Welding work must only be carried out after prior handling batteries.
consultation with Crown. Do not touch battery terminals with metal objects.
Keep the work area clean and well lit. An untidy or Cover the battery terminals with a suitable insula-
poorly lit work area can lead to accidents. tion (such as a plywood board) if you have to work
in this area.
Modifications to the original condition of the truck
must be examined and approved in writing by Always charge batteries in designated charging ar-
Crown beforehand. eas and make sure the area is well ventilated.
Only use original Crown spare parts and accesso- Remove battery acid stained clothing immediately.
ries. If acid comes into contact with the skin, rinse imme-
Never install or commission damaged components. diately with plenty of clean water. If it comes into
contact with the eyes, rinse immediately with clean
Restoring the truck to service after water for several minutes and then seek medical at-
tention.
repair work
Immediately neutralize and thoroughly rinse any
After carrying out repairs refit any safety mecha- spilled battery fluid.
nisms that have been removed and make sure they
are working correctly. Warning and instruction decals on
The truck may only be restored to service after re- the truck
pair work once all the truck functions have been
successfully tested, in particular on the following In accordance with the test and maintenance inter-
components: vals check that the warning and instruction decals
on the truck are complete and legible.
Brakes
Clean any dirty decals and replace any damaged or
Speed control
missing ones.
Direction switches
Note: The spare parts manual gives details of the la-
Steering belling and position of the warning and instruction de-
Lifting mechanism cals on the truck.
Warning devices (horn, warning indicator)
To avoid endangering other people, always test the
Lifting gear and slings
truck in an open area where there are no other peo- Always use suitable hoist devices and lifting gear
ple or obstacles. with sufficient capacity.
Attach lifting gear to the designated strap points
Cleaning work and prevent it from slipping. Make sure the lifting
Particular care is required when cleaning the truck and gear cannot touch other components during lifting.
components that have been removed. See page 57. Do not stand under a swinging load.
Repair work can only be performed under a raised
Handling batteries truck if the truck has been protected against acci-
Batteries may only be charged, serviced or re- dental lowering.
placed by trained personnel. Observe the instruc- Work may only be performed on the chassis, fork
tions contained in the operator manual, as well as carriage or mast if they have also been protected
the instructions of the battery and charger manufac- against accidental lowering.
turers. Lifting gear such as load slings routed around sharp
edges must be protected from cuts.

ESR 5000

9
SAFETY
Basic Safety Notices

Environmental protection
Any work that involves environmentally hazardous
substances being released must only be performed
in designated areas, to allow hazardous chemicals
and oils to be separated.
All substances released during maintenance and
repair work must be collected in the proper manner
and disposed of in accordance with national regula-
tions. Oil filters and dehumidifying inserts must be
treated as special waste.
Always act responsibly when carrying out repairs to
avoid damaging the environment.

ESR 5000

10
LUBRICATION & ADJUSTMENT

11
Notes:

12
LUBRICATION & ADJUSTMENT
Transport and Storage

Transport and Storage 2. Fully retract the mast.


3. Attach two chains or lifting belts to the outriggers
and to the overhead guard.
4. Insert the chains or lifting belts into the load hooks
CAUTION
on the crane.
Battery acid can scald 5. Carefully lift the truck with the crane.
Battery acid will spill if a filled battery tips over during
transport. This can cause injury to bystanders and Lifting the truck with a forklift truck
damage the truck and transportation equipment.
Always remove the battery before transporting the
truck.
1

Lifting the truck


2
WARNING
Falling loads are hazardous
Fatal injuries can result if the truck or crane crash or if
a load falls.
Make sure the crane, lifting truck and the load han- Fig. 3 Lifting the truck with a forklift truck
dling equipment used have the required capacity.
1. Fully lower the forks.
Information on the required capacity can be found
on the truck data plate under Truck Weight Less 2. Fully retract the mast.
Battery and Battery Weight. 3. Set the drive wheel (1) at an angle so that it is fac-
ing towards the truck that is doing the lifting and the
gear unit (2) is facing in the drive direction.
This will ensure that the gear unit (2) does not get
damaged by the forks of the truck doing the lifting.
4. Lift the truck at angle.
Note: The centre of gravity should lie between the
forks of the truck doing the lifting. These forks must be
placed under both outriggers.
5. Attach the truck securely to the mast of the truck
doing the lifting (e.g. with a tensioning belt).
6. Raise the truck only as far as is necessary for
transporting.

Towing the truck


A de-energised truck can be towed over short dis-
tances using a second truck without having to release
the drive wheel brake. This might be necessary
for example if it has been left in an aisle.

Fig. 2 Lifting the truck


1. Fully lower the forks.

ESR 5000

13
LUBRICATION & ADJUSTMENT
Transport and Storage

when the brakes have been released by an authorised


WARNING engineer.

Tipovers can result in fatal accidents


A truck tipover can result in fatal injuries. WARNING
Make sure the towing truck has sufficient capacity.
Information on the capacity required can be found Risk of accidents
on the truck data plate under Truck Weight Less Long stopping distances and excessive tow loads can
Battery and Battery Weight. result in accidents and serious injury.
Make sure the drive and castor wheels of the bro- Connect the truck to the tow truck (e.g. with a tow
ken down truck do not get damaged by the forks of bar) to prevent it from rolling automatically.
the towing truck. Bear in mind that the brakes of the tow truck also
Make sure the broken down truck does not slide off have to stop the truck that is being towed.
the forks of the towing truck.

Jacking up the Truck


CAUTION
Avoid damaging the drive wheel WARNING
When the truck is de-energised the brakes are applied
to the drive wheel. If the drive wheel drags along the Tipovers can result in fatal accidents
ground while the truck is being towed it will get dam- Make sure the jack has sufficient capacity.
aged. Information on the capacity required can be found
Make sure the drive wheel does not touch the on the truck data plate under Truck Weight Less
ground as the truck is being towed. Battery and Battery Weight.

WARNING
Incorrect jacking procedures can cause fatal acci-
dents
Improper handling of the truck or the tools can result in
fatal accidents.
Never place your hands or other parts of your body
under the truck before it has been supported.
Always support a raised truck with wooden blocks
or other suitable equipment to relieve the jack.
Only jack up the truck so far as to raise the wheels
off the ground. Any further lifting will increase the
risk of tipover.

Fig. 4 Pulling the truck with a forklift truck


1. Position the forks of the towing truck underneath
the truck.
2. Raise only the front of the truck approx. 20 mm; the
load wheels will remain on the ground.
3. Pull the truck slowly and in a forward direction only
(see arrow).
Note: If there is no truck with sufficient lifting capacity
available, the de-energised truck can only be towed

ESR 5000

14
LUBRICATION & ADJUSTMENT
Transport and Storage

1
6 3

4 5
2

Fig. 5 Jacking up the truck


1. Apply the parking brake.
2. Fully lower the forks.
3. Switch off the truck and remove the key.
4. Chock both load wheels with wedges (1).
5. Apply a jack (2) to the centre of the skirting rail and
raise the truck by a maximum of 20 mm.
6. Place hard wooden blocks (3) underneath the
chassis on either side and lower the truck onto
them.
7. Place the jack (4) under the outrigger and raise it
until the load wheel is no more than 10 mm clear of
the ground.
8. Place a hard wooden block (5) under the load
wheel and lower the truck onto it.
9. Raise the second outrigger and lower it onto the
hard wooden block (6).

ESR 5000

15
LUBRICATION & ADJUSTMENT
Truck Assembly and Commissioning

Truck Assembly and Erecting the chassis


Commissioning
Truck assembly 


WARNING
Falling loads are hazardous
Fatal injuries can result if the truck or crane crash or if
a load falls.
Make sure the crane, lifting truck and the load han-
dling equipment used have the required capacity.
Information on the capacity required can be found
on the truck data plate under Truck Weight Less
Battery and Battery Weight.

The trucks are normally shipped with the mast and
chassis separate, lying flat on pallets.
The maximum component weight on a pallet is
1800 kg.

Required tools
Sufficient number of clevis, hooks and lifting acces-
sories with a 2 tonne capacity.
A crane with a minimum capacity of 2 tonnes.
Fig. 6 Attaching the shackles and clevis
A forklift truck with a minimum capacity of 2 tonnes
at the required lift height. 1 Shackle mounted on the outside of the outrigger
2 Shackle mounted on the front of the outrigger
3 Shackles mounted on the overhead guard

Erecting the chassis


1. Attach the shackles and clevis as shown in
Figure 6 to the outriggers and overhead guard.
2. Position the crane next to the overhead guard.
3. Position the forklift truck next to the outriggers.
Attach the load slings to the forks and prevent them
from slipping.

ESR 5000

16
LUBRICATION & ADJUSTMENT
Truck Assembly and Commissioning

Fig. 7 Lifting the truck with a forklift truck and crane


simultaneously
4. Raise the chassis with the crane and forklift truck
simultaneously by approx. 500 mm (see Fig. .7).

Fig. 9 Lowering the chassis slowly and simultaneously


7. Using both the crane and the forklift truck, lower
the chassis slowly and evenly (see Fig. 9).
8. Remove the lifting accessories.

Removing the transport retainers

Fig. 8 Erecting the truck slowly WARNING


5. Continue lifting with the crane. Continue raising
Brake failure can result in accidents
with the forklift truck until the chassis is no longer
If the transport retainer is not removed from the brake
touching the ground. At the same time travel for-
fluid container the foot brake will not work.
ward slowly so that the load slings remain upright.
Before using the truck replace the transport retainer
6. Continue lifting step by step with the crane and
with the original cover.
compensating with the forklift truck, as described in
step 8, until the chassis is suspended upright in the
load slings.

ESR 5000

17
LUBRICATION & ADJUSTMENT
Truck Assembly and Commissioning

CAUTION
Risk of hydraulic system and drive transmission unit
damage! 
Remove the transport retainer from the reservoir
ventilation before using the truck for the first time.  
Add the supplied transmission oil (Aral Degol PAS
150) before using the truck.  

Note: Store the transport retainers for future use.


Removing the transport retainer from the brake
fluid reservoir
1. Take out the floorboard.

Fig. 11 Storage tank on main brake cylinder


1 Test key for float switch BFS
2 Cover
3 Reservoir
4 Max. mark
 5 BFS ports

4. Test the BFS switch.


Removing the transport retainer from the hydraulic
reservoir

1. Swivel out the seat.

Fig. 10 Brake fluid reservoir transport retainer 


2. Take off the cover with the yellow marking
(1, Fig. 10) and store it for future use.
3. Screw on the black cover supplied in the plastic
bag (2, Fig. 10).

Fig. 12 Breather filter


1. Remove the bayonet cap (2, Fig. 12) from the
breather filter by turning it turn to the left.

ESR 5000

18
LUBRICATION & ADJUSTMENT
Truck Assembly and Commissioning

Fig. 13 Hydraulic reservoir transport retainer


2. Remove the light grey rubber seal (1, Fig. 8) and
store it for future use.
3. Insert the supplied filter element (1, Fig. 7).
4. Refit the bayonet cap.

Filling the drive transmission unit

Fig. 14 Refill plug on drive transmission unit


1. Remove the refill plug (1, Fig. 9).
2. Add the supplied transmission oil (Aral Degol PAS
150) as far as the bottom mark on the opening
(approx. 3.7 L).
3. Tighten the refill plug (1) again.

Erecting the mast and fitting it to the


chassis
1. Lift up the mast from the pallet and assemble it
(see Mast removal and assembly, page 315 ff. and
page 319 ff).
2. Adjust the mast and check the settings (see
page 320).

ESR 5000

19
LUBRICATION & ADJUSTMENT
Placing the Truck in Storage

Placing the Truck in Storage Restoring the truck to service


If the truck is to be out of service for more than Carry out the following steps to restore the truck to
3 months, proceed as follows: service after a period of storage:
1. Disconnect the battery from the truck's circuit. 1. Remove any anti-corrosion film that may have
2. De-commission the battery in accordance with the been applied.
manufacturer's instructions. 2. Jack up the truck, remove the hard wooden blocks
3. Clean the truck (see Cleaning the truck and com- and lower the truck.
ponents, page 57). 3. Charge the battery or install a charged battery.
4. Lubricate the truck in accordance with the mainte- 4. Connect the battery.
nance schedule. 5. Carry out the safety inspection.
5. Store the truck in a dry room with constant temper-
ature and air humidity. Battery maintenance
Do not park the truck outdoors or in a humid envi- The condition of the battery has a considerable impact
ronment. on the performance of the truck. Optimum mainte-
6. The surfaces of trucks subjected to hostile ambient nance (regular acid density and level checks, cleaning
conditions such as saline atmosphere must be the cell covers) maintains the battery's performance
treated with suitable preservatives to prevent cor- and useful life.
rosion.
Always service the battery in accordance with the
7. Cover the truck with an air-permeable material to battery manufacturer's instructions.
protect it from dust. Do not use plastic sheets as
condensation could form.
8. Jack up the truck to prevent the wheels from flat-
tening.

Testing trucks in storage

CAUTION
Long periods of inactivity can result in damage to
the hydraulic system
If the hydraulic system remains unused for too long, the
hydraulic cylinders may suffer corrosion damage.
Test the hydraulic system of trucks placed in stor-
age every 3 months.

1. Connect the battery.


2. Check the battery charge and re-charge the bat-
tery if required.
3. Check the hydraulic oil level. Top up if required.
4. Check the gear unit for leaks.
5. Apply all hydraulic functions.
Note: Approach all limit positions at least once to coat
the whole of the piston ram surfaces with oil.
6. Check the corrosion protection and replace if nec-
essary.
7. After inspection disconnect the battery.

ESR 5000

20
LUBRICATION & ADJUSTMENT
Component Access

Component Access Accessing components under the


Components in the chassis can be accessed by un- panels
screwing panels or swivelling out the driver's seat.

WARNING 1
A sudden drive system start-up can cause fatal
injuries
People can be fatally injured when carrying out mainte-
nance and adjustment work on the traction motor,
hydraulics or truck controller if the traction motor or a 2
hydraulic operation start suddenly.
Lower the forks and retract the mast.
Jack up the truck so that the drive wheel is clear of
the ground.

Fig. 16 Components under the panels


1. Undo the panel screws (1, 2, 3)
2. Remove the panels (1, 2, 3)
Note: Assembly is the reverse of disassembly.

Fig. 15 Component access


1 Panel
2 Driver's seat
3 Floorboard

ESR 5000

21
LUBRICATION & ADJUSTMENT
Component Access

Components under the panels




 




  


Fig. 17 Components under the panels

1 Battery connector 7 Emergency Disconnect


2 Start up card 8 Hydraulic control module HCM (Access 2)
3 Control fuses (FU1 - FU6) 9 Steering control module SCM (Access 5)
4 Traction control module TCM (Access 3) 10 Steering control module main fuse (FU13)
5 Main contactor 11 Main control module VCM (Access 4)
6 Main fuse (FU7)

ESR 5000

22
LUBRICATION & ADJUSTMENT
Component Access

Accessing the motor compartment

Fig. 18 Seat panel handle Fig. 20 Seat swivelled out

1 Seat panel Swivelling in and locking the seat panel


2 Handle 1. Lift up the driver' seat armrest.
2. Swivel the seat panel (1) in as far as the stop.
1. Push the handle (2) in the direction of the arrow.
The seat panel locks automatically.
You can now access the lock of the seat panel (1).

Fig. 19 Seat panel lock


3 Lock

2. Push the lock (3) in the direction of the arrow to


unlock.
3. Lift up the driver's seat armrest.
4. Swivel out the seat panel (1) in full.

ESR 5000

23
LUBRICATION & ADJUSTMENT
Component Access

Motor compartment

7
6
2

Fig. 21 Motor compartment

1 Hydraulic reservoir and filter 5 Motor brake


2 Pump motor 6 Steer motor
3 Steering toothing ring gear 7 Dipstick
4 Traction motor

ESR 5000

24
LUBRICATION & ADJUSTMENT
Component Access

Accessing components under the


floorboard

Fig. 22 Removing the floorboard


1 Floorboard
2 Bolt

Removing the floorboard


1. Swivel the driver's seat out (see page 21).
2. Remove the bolts (2).
3. Remove the floorboard (1).
Assembling the floorboard
Note: Assembly is the reverse of disassembly. When
assembling the floorboard hold the accelerator pedal
up and make sure the lever of the accelerator pedal is
resting on the roller lever of the traction potentiometer.

ESR 5000

25
LUBRICATION & ADJUSTMENT
Component Access

Components below the floorboard

8 1 2

3
6

Fig. 23 Components below the floorboard

1 Accelerator pedal potentiometer and travel switch 5 Safety pedal sensor


2 Main plug assembly 6 Horn
3 Brake fluid reservoir with main brake cylinder and BFS 7 Brake pressure switch
4 DC / DC converter (option) 8 Brake pedal

ESR 5000

26
LUBRICATION & ADJUSTMENT
Recommended Lubricants and Consumables

Recommended Lubricants and Take care to protect all electrical connections and com-
ponents from corrosion. For detailed information, refer
Consumables to the Electrical System chapter.
The following tables list lubricants and consumables Service intervals (see page 29) must be adapted to the
that Crown uses in its factory. However, you can use conditions of use.
any lubricants provided they meet the same technical
criteria. Abbreviations used in the table
The lubricant type is indicated by letters. Individual let-
Cold store truck requirements ters (A, B, ...) denote lubricants for normal temperature
Special hydraulic oils, lubricants and grease must be ranges, double letters (AA, BB, ...) for low temperature
used for cold store applications (cold store trucks). ranges.
An anti-corrosion fluid (Crown no. 805236-004) must
be applied to all machine parts such as screws, wash-
ers, nuts, pins, retaining rings etc.

Type Lubricant Type Product Manufacturer Part No.

A and AA Transmission oil Degol PAS 150 Aral


Renolin UNISYN Fuchs Minerall- ---
CLP 150 werke GmbH
B Grease (Multi-Purpose) Aralube HLP2 Aral
LM Grease Castrol
Regulus A2 Century
Beacon EP2 Esso
F806118
EP2 Maxol
Mobiluxe EP2 Mobil
Retinax LX Shell
ALGWMI SKF
Low temperature grease Aralube SKL2 Aral
BB 053002-005
Unirex Lotemp EP Mobil
D Hydraulic oil Vitam GF 32 Aral
Hyspin AWS-32 Castrol
Nuto H32 Esso
DTE 24 Mobil
---
Tellus 32 Shell
Hydran LZ 32 Finol
B110 Fuchs Minerall-
werke GmbH
DD Hydraulic oil (Low Temp) Deutz Oel HVI 32 Klockner 053001-009
G Lubrication oil Essolube HDX+40 Esso
Kowal M 40 Aral ---
Delvac 1240 Mobil

ESR 5000

27
LUBRICATION & ADJUSTMENT
Recommended Lubricants and Consumables

Type Lubricant Type Product Manufacturer Part No.

Low temperature lubrication Mobil SHC 626 Mobil


GG ---
oil
M Special grease Molycote BR-2 Plus Dow Corning ---

Lubricants Product Application Part No.

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


805236-004
trucks
Rubber & vinyl dress- Commercial Rubber components, plastic pan-
-------------
ing els

ESR 5000

28
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Planned Maintenance and The lubricant type is indicated by letters. Individual let-
ters (A, B, ...) denote lubricants for normal temperature
Inspection ranges, double letters (AA, BB, ...) for low temperature
ranges.
Maintenance Schedule
This maintenance schedule assumes single shift oper-
ation under normal conditions.
The maintenance intervals must however always be
adapted to the prevailing operating conditions. In ex-
treme conditions (dust, dirt, humidity etc.) and in
cold stores the maintenance intervals should be re-
duced. Exact details should be discussed with a
Crown service engineer.
Routinely check for wear, corrosion, damage, and test
component operation and safety when carrying out
maintenance work. If in doubt, replace components.
Planned maintenance must be performed either after a
certain number of service hours or a certain period of
time (whichever is reached first).
The next higher inspection interval includes the
previous intervals.
For example: The 2000 hour service also includes the
inspection and lubrication items lists specified under
1000 hours and 500 hours.

Annual inspection in accordance


with FEM 4.004
In addition to these maintenance instructions, guideline
FEM 4.004 Regular Inspection of Industrial Trucks
also requires the inspection of the truck by an expert.
This must be carried out at least once a year and
must be recorded.
In extreme conditions (dust, dirt, humidity etc.) as well
as cold store applications, the inspection interval
should be reduced. Exact details should be discussed
with a Crown service engineer.

Terms and abbreviations used


The following terms and abbreviations are used in the
subsequent tables:
M Months
h Service hours
X Perform on standard trucks
C Perform on cold store trucks
I Inspection item
L Lubrication item

ESR 5000

29
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Seat and seat panel

  




Fig. 24 Seat and seat panel

ESR 5000

30
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Lubricant type

12 M

24 M
3M

6M
Assembly Component Action

Item no.

1000 h

2000 h

5000 h
500 h
Seat and Seat rails Clean and check for:
seat panel - Wear
I-1
- Freedom of movement
- Secure attachment to the seat cover.
C/X
Apply a thin layer of grease to the seat B
L-1
rails(a). BB
Seat panel Test the seat panel lock. I-2
a. For the grade and application temperature refer to the Recommended Lubricants and Consumables
table, page 27.

ESR 5000

31
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Brake system and load wheels

 







 





Fig. 25 Brake system and load wheels

ESR 5000

32
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Lubricant type

12 M

24 M
3M

6M
Assembly Component Action

Item no.

1000 h

2000 h

5000 h
500 h
Brake Service brake Check brake fluid level(a). I-1 C/X C/X
system
Replace the brake fluid (see L-1
C X
page 293)(a).
Test the brake fluid warning switch
I-2
(BFS).
C/X
Test the brake pedal slack on the main
I-3
brake cylinder (see page 294).

Grease the brake pedal mechanism(a). B


L-2 C X
BB
Check the brake lining wear on the
I-4
load wheel brakes (see page 292).
Check all brake lines and connections
---
for corrosion and leaks. C/X
Parking brake Apply compressed air and check the
air gap (see page 288).
I-5
Check operation.
Disassemble and check for wear, C/X
Load Tyres Check for:
wheels - Damage C/X
- Wear
Suspension Check bearing play. I-6
If there is bearing play, apply the ap-
C X
propriate torque to the screws (see
page 294).
a. For the grade and application temperature refer to the Recommended Lubricants and Consumables table on page 27.

ESR 5000

33
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Drive unit



 




 











Fig. 26 Drive unit

ESR 5000

34
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Lubricant type

12 M

24 M
3M

6M
Assembly Component Action

Item no.

1000 h

2000 h

5000 h
500 h
Drive Unit Gear unit Check for:
- Leakage
I-1
- Unusual noise
- Oil level (see page 97) C X

- Check the drive unit mounting


I-2
screws on the chassis are secure.

- Replace the oil(a). L-1 C X


Traction motor - Ensure attachment is secure. I-3
Drive plate - Ensure attachment is secure. I-4
Drive wheel Check for:
- Wear(b) I-5
(wear limit 309 mm)
Secure (180 Nm)(c) C X
Both support blocks Check for wear and check the settings
I-6
on the chassis (see page 53).
Steer motor - Ensure attachment is secure. I-7
Steering toothing Clean and lubricate(a). B
L-2
ring gear BB
a. For the grade and application temperature refer to the Recommended Lubricants and Consumables table on page 27.
b. When replacing the drive wheel the support blocks must be reset (see page 53).
c. With new trucks and after removal or replacement, tighten bolts once after 50 - 100 hours. Then tighten according to the pre-
scribed intervals.

ESR 5000

35
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Reach carriage






   





Fig. 27 Reach carriage

ESR 5000

36
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Lubricant type

12 M

24 M
3M

6M
Assembly Component Action

Item no.

1000 h

2000 h

5000 h
500 h
Reach Reach carriage Check for damage. I-1
carriage
Reach function Extend the reach mechanism the full
distance in both directions. Make sure
---
the speed reduction applies at the end
sections.
Rollers Check for freedom of movement:
- Rollers
I-2
- Backing rollers
- Side rollers

Lubricate the rollers(a). B/


L-1
BB
Adjust as required: C/X
- Backing rollers
I-3
- Side rollers
(See page 352.)
Roller track wear Clean, check for damage. Apply a thin B/
rails layer of grease. BB
Reach cylinder Check attachment (see page 336). I-4
Rubber buffer Check for wear. ---
Hydraulic manifold Ensure it is fitted securely.
I-5
cover
Electrical wiring in Ensure plug connections are tight.
I-6
the carriage Check presence of strain reliefs.
a. For the grade and application temperature refer to the Recommended Lubricants and Consumables table on page 27.

ESR 5000

37
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Hydraulic system














Fig. 28 Hydraulic system

ESR 5000

38
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Lubricant type

12 M

30 M
3M

6M
Assembly Component Action

Item no.

1000 h

2000 h

5000 h
500 h
Hydraulic Hydraulic oil Check the oil level with the cylinders I-1 C X
system reservoir fully retracted.
D
Add oil(a) if required (see page 83). L-1 C/X
DD
Replace the return filter, breather filter
I-2
and suction strainer (see page 84).
C(b) X(c)
Change the hydraulic oil(a) (see
---
page 83 - requires approx. 36 L)
Hoses, lines and Check all hoses, lines and connections
---
connections for leaks and damage.
Check hose attachment in reach car-
riage for wear and make sure it is se- I-3
cure.
Cylinders Check all cylinders are secure, check
---
for leaks and damage.
C/X
Emergency Test the emergency lowering valve
I-4
lowering (see page 77).
Hydraulic manifolds Check the main valve block in the
I-5
reach carriage for leaks (see page 75).
Check the "Accessories" valve block in
the reach carriage for leaks (see I-6
page 76).
a. For the grade and application temperature refer to the Recommended Lubricants and Consumables table on page 27.
b. 1000 service hours or, deviating from the standard interval, every 12 months.
c. 2000 service hours or, deviating from the standard interval, every 24 months.

ESR 5000

39
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Electrical system - part 1



Fig. 29 Electrical system - part 1

ESR 5000

40
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Lubricant type

12 M

30 M
3M

6M
Assembly Component Action

Item no.

1000 h

2000 h

5000 h
500 h
Electrical Display screen Test the display screen and check all
system displays are legible.
Controls Test the safety pedal.
Test the horn.
Test the parking brake switch and indi-

See operator manual


cator light.
Test the travel direction switch.
Test the seat switch.
Test the lift controls. C/X
Test the Emergency Disconnect
switch.
Ensure the potentiometer connections
---
are secure.
Control modules Check all control modules are clean
and power cables and secure.
Check the power cable connections to I-1
the control modules, fuses FU7, FU13
and contactor ED1 are secure.
Steering control Carry out the safety test (see
module (SCM) and page 261).
--- C/X
traction control
module (TCM)

ESR 5000

41
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Electrical system - part 2





 





Fig. 30 Electrical system - part 2

ESR 5000

42
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Lubricant type

12 M

30 M
3M

6M
Assembly Component Action

Item no.

1000 h

2000 h

5000 h
500 h
Electrical Fans Test the fans using the Service menu
---
system (see page 172).
Connectors and Check wires and lines for insulation
---
lines damage.
Make sure plugs on the connector
I-1
panel are secure.
Traction motor (M1) Ensure the power cable connections
are secure and free of damage. For
I-1
torques and important installation
instructions see page 273.
Check the plug connections to encoder
ECR1 and thermal sensor THS1 for
I-3
damage and make sure they are
secure.
Pump motor (M2) Ensure the power cable connections C/X
are secure and free of damage. For
torques and important installation I-4
instructions see Connecting the power
cables, page 273 or page 277.
Check the plug connections to encoder
ECR2 and thermal sensor THS2 for
I-5
damage and make sure they are
secure.
Battery Check battery cables and connectors
for damage. I-6
Check terminal post condition.
Check battery in accordance with bat-
tery manufacturer's instructions (see
---
manufacturer's maintenance instruc-
tions).

ESR 5000

43
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Travel and pump motors

  


 

Fig. 31 Travel and pump motors

ESR 5000

44
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Lubricant type

12 M

30 M
3M

6M
Assembly Component Action

Item no.

1000 h

2000 h

5000 h
500 h
Traction Motor output See Replacing the Danaher Traction
motor (M1) Motor, page 273:
- Remove the traction motor. I-1
M
- Clean the output toothing, check it L-1
for damage and apply grease(a).
- Re-assemble the traction motor.
Pump mo- Motor output See Replacing the Pump Motor,
tor (M2) page 279:
C/X
- Remove the pump motor. I-2
- Clean the output toothing, check it M
L-2
for damage and apply grease(a).
- Re-assemble the pump motor.
Motor attachment Check the rubber-bonded-to-metal
mounting (rubber buffer) on the pump
L-3
motor attachment for cracks and hard-
ening.
a. For the grade and application temperature refer to the Recommended Lubricants and Consumables table on page 27.

ESR 5000

45
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Mast















 









Fig. 32 Mast

ESR 5000

46
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Lubricant type

12 M

30 M
3M

6M
Assembly Component Action

Item no.

1000 h

2000 h

5000 h
500 h
Mast Mast Check mounting bolts are secure (see
I-1
page 320).
Check and adjust mast chains and
I-2
chain supports (see page 340).
Clean the lift chains (see page 340)
G L-1
and lubricate them (see page 346).
Clean the running surfaces in the mast
I-3
channels and check for wear.
Grease the running surfaces in the B
L-2
mast channels(a). BB
Check the mast rollers freedom of
I-4
movement (see page 324).
C/X
Check the condition of the mast stage
end stops (poly stop blocks) and make I-5
sure they are secure (see page 316).
Mast cable Check the mast cable for damage,
check the tension jacks for damage I-6
and make sure they are secure.
Guide pulleys Check the guide pulleys for damage. I-7
Lubricate the guide pulley mountings. B
L-3
BB
Switches Check the condition and operation of
the height reset switches / lift speed re- --
duction switches.
Battery removal Ensure the battery removal stops are
stops(b) secure.

a. For the grade and application temperature refer to the Recommended Lubricants and Consumables table on page 27.
b. ESR 5000S with T battery only.

ESR 5000

47
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Fork carriage


 

  



Fig. 33 Fork carriage

ESR 5000

48
LUBRICATION & ADJUSTMENT
Planned Maintenance and Inspection

Lubricant type

12 M

30 M
3M

6M
Assembly Component Action

Item no.

1000 h

2000 h

5000 h
500 h
Fork Fork carriage Check the fork carriage for damage. I-1
carriage
Check the fork carriage rollers for free-
I-2
dom of movement.
Clean the slide blocks. Check for wear
I-3
and test operation (see page 330).
Grease slide blocks. B
L-1 C/X
BB
Lubricate the grease nipples on the B
L-2
fork carriage. BB
Load backrest Check load backrest for damage and
I-4
ensure it is securely fitted.
Fork tines Check the fork tines (see page 349). I-5

ESR 5000

49
LUBRICATION & ADJUSTMENT
Torques

Torques
Standard torques
Note: The torques listed in the manual always take
precedence over standard torques.

Standard screws and nuts

Grade: 8 and 8.87 10 and 10.9 12 and 12.9


Thread size Torque (Nm)
M5 x 0.8 5-6 7-8 8 - 10
M6 x 1 8 - 10 12 - 14 14 - 16
M8 x 1.25 20 - 25 30 - 35 34 - 40
M10 x 1.5 40 - 45 60 - 65 70 - 75
M12 x 1.75 70 - 80 100 - 110 115 - 130
M16 x 2 170 - 190 240 - 270 280 - 320
M20 x 2.5 340 - 380 450 - 500 550 - 600
M24 x 3 580 - 650 800 - 900 900 - 1050
M30 x 3.5 1150 - 1300 1600 - 1800 1850 - 2100

Umbrako screws and nuts

Grade 10 and 10.9 12 and 12.9


Thread size Torque (Nm)
M5 x 0.8 8 11
M6 x 1 14 19
M8 x 1.25 33 45
M10 x 1.5 63 86
M12 x 1.75 111 152
M16 x 2 270 372
M20 x 2.5 521 717

ESR 5000

50
LUBRICATION & ADJUSTMENT
Load Wheels

Load Wheels
Load wheel replacement 

Special tools required
Grooved nut key (item no. 824842) 
Guide bolt (item no. 825455) 

Load wheel removal

WARNING
Risk of serious injury
Failure to handle the truck and/or the equipment
correctly could result in fatal injury.
Never reach with your hands or other parts of your Fig. 34 Load wheel attachment
body under the truck before it has been supported,
or when jacking up the truck. 4. Remove the screw (2, Fig. 34) and the cover
Always support a raised truck with hard wooden disk (3).
blocks or other appropriate equipment to relieve the 5. Loosen the retaining screw (4).
jack. 6. Loosen and unscrew the grooved nut (1) with the
special key (item no. 824842).

WARNING

Risk of tipover
A truck tipover can fatally injure you and other
people!
Refer to Position the forks of the towing truck 
underneath the truck on page 14. 
Jack up a load arm until you can pull off the load
wheel. The load wheel should be no more than
10 mm clear of the ground.
Support the load arm with hard wooden blocks to
relieve the jack.

1. Disconnect the battery and prevent the truck from


being switched on again. Fig. 35 Load wheel disassembly
2. Jack up the truck (see page 14). 1 Load wheel
3. Remove the hub cap. 2 Guide bolt (item no. 825455)
3 Stub shaft

7. Screw the guide bolt (2, Fig. 2) onto the stub


shaft (3).
8. Pull off the load wheel (1) over the guide bolt.
Note: If the load wheel cannot be pulled off, place back
the brake lining slightly via the eccentric (can be
accessed via the holes 2, Fig. 36).

ESR 5000

51
LUBRICATION & ADJUSTMENT
Load Wheels

Fig. 36 Back of load wheel brake: holes for lining inspection


and access to eccentrics

Load wheel assembly


1. Push the load wheel over the guide bolt attached
during removal (in step 7).
2. Screw on the groove nut (1).
3. Using a special key (item no. 824842) torque to
150 Nm.
4. Torque the retaining screw (4) to 4 Nm.
5. Fix the cover disk (3) with the screw (2, Fig. 34)
and torque to 14 Nm.

ESR 5000

52
LUBRICATION & ADJUSTMENT
Support Blocks

Support Blocks 4. Measure the distance from the left and right sup-
port blocks to the ground again, and record
The support blocks prevent the truck from tipping over dimension H (see Fig. 37) for the 2nd point.
on its side when the mast is fully extended and the load
5. Continue turning the truck approx. 120 with the
centre of gravity may be in an unfavourable position.
steering at full lock.
The setting can change during operation due to the
6. Measure the distance from the left and right sup-
wearing of the drive wheel and support blocks (dimen-
port blocks to the ground again, and record
sion H, Fig. 37). Regular inspection and adjustment is
dimension H (see Fig. 37) for the 3rd point.
therefore required in the following cases:
During planned maintenance, every 1,000 hours or Analysing the measurements
6 months
When the drive wheel has been replaced Adjusting dimensions table

Mast type Dimension H

SD mast(a) 13 +1/-2 mm
TT mast 19 +1/-2 mm
  Table 1
a. The last three digits of the serial number on Super Duty
  (SD) masts contain one of the following codes:
-91, -92, -93 or -94.

1. Determine the mast type from the serial number on


the mast data plate.
Fig. 37 Dimension H on support block
2. Compare the calculated dimensions with the re-
1 Drive wheel spective H dimensions for the mast type from
2 Support block Table 1.
3 Warehouse floor 3. Dimension H should be no more than H + 1 mm on
H Dimension H any of the 3 measuring points.
If dimension H is greater than H + 1 mm on one
Checking the support block of the measuring points, Adjusting the support
block height, replace the worn support blocks if
distance necessary.
Requirements
Adjusting the support block height
Measurements are taken at three points offset by
approx. 120 within the truck's turning radius. This Before adjusting
compensates for any unevenness in the ground.
Note: The support blocks are worn if they have lost
The parking area must therefore be large enough for 5 mm of material.
the truck to turn in its radius without any danger.

Measurement
Measure at 3 points
1. Park the truck on a level surface.
2. Measure the distance from the left and right sup-
port blocks to the ground and record dimension H
(see Fig. 37) for the 1st point.
3. Continue turning the truck approx. 120 with the
steering at full lock.

ESR 5000

53
LUBRICATION & ADJUSTMENT
Support Blocks

Measure the remaining support block height 1. Jack up the truck (see page 14).
2. Loosen all the screws (3).
3. Push the required number of shims (1) between
the skid (2) and the chassis to achieve
dimension H (see Table 1).
Note: The shims come in 3 different thicknesses (see
spare parts manual).

4. Tighten the screws (3) to the standard torque (see
page 50).
5. Adjust the opposite support block as outlined
above.

Replacing the support blocks


Fig. 38 Support block wear limit, dimension X
1. Measure the support block height (dimension X).
If the material is below the wear limit X (see
Table 2), first replace the support blocks (see
page 54).

Support block wear limits

Mast type Support block part Wear limit X


number

SD mast(a) 820666-003 41 mm 
TT mast 820666-001 35 mm

Table 2
a. The last three digits of the serial number on Super Duty
(SD) masts contain one of the following codes:
-91, -92, -93 or -94. 
Adjusting the support block Fig. 40 Support block mounting and adjustment
Removing the support blocks
1. Jack up the truck (see page 14).
2. Remove the two screws (3, Fig. 5).
3. Measure the length of the screw shaft:
If it is 40 mm long dispose of the screws.
If it is 55 mm long the screws can be re-used.
4. Take off the support block (2) and the shims (3).
Note: Store the shims so that they can be refitted later
on the same side.
 5. Dispose of the worn support block.
Fitting a new support block

1. Fit the new support block using the shims previ-
ously removed from this side.
Note: Only use screws with a 55 mm shaft length (part
 no. 050005-102).

Fig. 39 Support block mounting and adjustment

ESR 5000

54
LUBRICATION & ADJUSTMENT
Support Blocks

2. Tighten the screws (3) to the standard torque (see


page 50).
3. Adjust the opposite support block as outlined
above.
Note: Always replace both support blocks, never indi-
vidual ones.
4. Now check the support block distance and adjust
as required.

ESR 5000

55
Notes:

56
LUBRICATION & ADJUSTMENT
Cleaning the Truck and Components

Cleaning the Truck and Cleaning the entire truck


Components 1. Park the truck in an area with an oil separator.
2. Switch off the truck, disconnect and remove the
battery.
CAUTION
Health risk WARNING
Cleaning agents, lubricants and consumables can
damage your health. Malfunctions when restarting the truck can cause
serious injury
Observe the manufacturers safety instructions
Water can penetrate electrical components after steam
when handling solvents and lubricants.
cleaning or hose washing. This can accidentally trigger
certain functions when the truck starts up again.
Effects of incorrect cleaning Do not steam-clean the truck or wash it down with
a hose.
Electrical components
Electrical components such as connectors, contacts, Cleaning the truck surface
distributor boards, controllers and wiring can be dam- 3. Dry clean the truck. To do this use cloths, soft
aged by water, cleaning agents and solvents. brushes (not metal brushes) and if necessary
Mineral and chemical residue that automatically re- weak, dry compressed air.
main on or in components after cleaning, are a cause Note: Local contamination that cannot be removed by
of corrosion. This corrosion results in malfunctions and dry cleaning can be treated with a damp cloth and a
premature failure. neutral cleaning agent. Make sure that neither water
Roller and slide bearings nor cleaning agent get into electrical components or
bearings.
Steam cleaning and solvents damage the lubricant film
on bearing surfaces. This results in dry running and Cleaning lift chains
rapid damage to the bearing elements. 4. See page 58.
Corrosion-protected surfaces Cleaning electrical components
The brake lines, screw connections and shiny metal 5. Clean electrical components only with each, dry
surfaces in particular on cold store trucks are factory- compressed air and a dry cloth.
treated with an anti-corrosive agent (Anticorit Interior cleaning
BW 366). This protection can be washed off by sol-
6. Clean detachable rubber mats with water and a
vents and steam cleaning. The above-mentioned com-
neutral cleaning agent.
ponents will corrode as a result.
7. Allow the rubber mats to dry out fully before return-
Environmental protection ing them to the truck.
8. Damp-wipe plastic parts with a neutral cleaner.
Cleaning must only be performed in specially desig-
nated areas to enable hazardous chemicals and oils to Note: If necessary use a standard commercial plastic
be separated. cleaning agent to remove obstinate dirt.
Collect any waste (such as oily cleaning cloths) and After cleaning the truck
dispose of them in accordance with local regulations. 9. Wipe down the truck.
10. Remove any paint damage.
11. Add anti-corrosion agent if necessary.
Returning the truck to operation after cleaning
Normally no special measures are required.

ESR 5000 Rev. 1, Feb 09

57
LUBRICATION & ADJUSTMENT
Cleaning the Truck and Components

If however there is a possibility that damp may have Cleaning removed components
penetrated electrical components, proceed as follows:
1. Clean the truck with weak, dry compressed air and Cleaning lift chains
a cloth.
2. Leave the truck to stand for at least 30 minutes in
a dry environment. WARNING
3. Insert the battery but do not connect it yet.
Improper cleaning can cause chains to crack
4. Jack up the truck so that the drive wheel is clear of A cracked chain can result in fatal injuries.
the ground. Never clean lift chains with steam cleaners, cold clean-
ing agents or corrosive, acid-based agents. This can
cause direct chain damage through hydrogen embrit-
WARNING tlement.
Clean the chain surfaces only with paraffin deriva-
Malfunctions when restarting the truck can cause
tives such as cleaning petroleum or cleaning petrol.
serious injury
Water or cleaning agent residue in electrical compo- Apply an approved chain oil immediately after
nents can cause malfunctions when the truck is cleaning (see Recommended Lubricants and Con-
switched on. sumables table, page 27).
You must be prepared to switch off the truck imme-
diately with the Emergency Disconnect when the 1. Remove persistent dirt with cleaning petroleum or
battery is connected and the truck is powered up. cleaning petrol. Apply a thin layer of the cleaning
agent with a hard bristle brush and wipe with a lint-
Make sure that nobody can be injured by compo-
free cloth.
nents accidentally starting up (lift mechanism, side-
shifter etc.). 2. Apply an approved chain oil immediately after
cleaning (see Recommended Lubricants and Con-
sumables table, page 27).
5. Connect the battery.
6. Switch on the truck. Cleaning other mechanical components
If a function automatically starts, apply the With the exception of lift chains, components that have
Emergency Disconnect immediately. been removed can be steam-cleaned under certain
Note: If possible, apply compressed air to the respec- conditions.
tive switch or connector. Repeat steps 1 to 6.
Is the starting pattern is normal, proceed to
step 7. CAUTION
7. Check all functions. Steam-cleaning can damage electrical compo-
nents and bearings
Mechanical components may only be steam-
cleaned if no electrical components or bearings are
affected.

1. Components that have been removed should be


cleaned by hand, ideally with warm water and a
mild neutral cleaning agent.
2. If steam-cleaning cannot be avoided, it should be
done without a cleaning agent. If grease needs to
be removed, use a mild neutral cleaning agent.
Note: Steam-cleaning can remove anti-corrosion
agent and paint from surfaces.
3. If a neutral cleaning agent has been used, rinse the
components thoroughly with clear water.
4. Leave the cleaned components to dry thoroughly.

Rev. 1, Feb 09 ESR 5000

58
LUBRICATION & ADJUSTMENT
Cleaning the Truck and Components

Note: Cleaned components must be dry and free of


cleaning agent residue before being refitted, lubricated
or painted.
5. Re-lubricate, paint or apply anti-corrosion agent to
the components as required.
6. Refit the components.
7. For cold store trucks apply Anticorit BW 366 as
an anti-corrosion agent for screw connections and
shiny metal surfaces.

ESR 5000 Rev. 1, Feb 09

59
Notes:

60
HYDRAULIC SYSTEM

61
Notes:

62
HYDRAULIC SYSTEM
Abbreviations Used

Abbreviations Used

Abbrevia- Meaning(a) Description


tion

AVL Adjustment Valve Lowering Speed The AVL allows you to set the maximum lowering speed
when PVL is fully opened (see Main valve block section on
page 75).
CBV Counterbalanced Valve ---
CV Check Valve Ensures flow in only one direction.
DCVH Directional Control Valve Hoist DCVH is located inside the valve block. The valve releases
the hydraulic oil path depending on the command:
from the pump to the lift cylinders (lift)
from the lift cylinders back to the reservoir (lower)
MVL Manual Valve Lower In an emergency, MVL can be used to manually lower the
fork carriage.
Note: When the fork carriage has been lowered, unscrew
the valve up to the stop.
PCA Pressure Compensation Accesso- For fork tilt, sideshift and 5th function
ries
PCL Pressure Compensation Lowering ---
PCR Pressure Compensation Reach ---
PLS Pressure Load Switch When a load > 400 kg is being lowered, PLS prevents the
fork carriage from stopping abruptly. This prevents the mast
from swaying. If replaced, the new PLS must be set to trip at
400 kg in free lift.
POT2 to Hydraulic function potentiometers The potentiometers are connected to their respective control
POT5 levers and transmit an analog control signal to the truck con-
trol module.

PVAL(b) Proportional Valve Accessories Left PVAL governs the upward tilt speed of the forks when "Tilt"
is selected, and the sideshift left speed when sideshift is se-
lected.

PVAR(b) Proportional Valve Accessories PVAR governs the downward tilt speed of the forks when
Right "tilt" is selected, and the sideshift right speed when sideshift
is selected.
PVL Proportional Valve Lower ---

PVRE(b) Proportional Valve Reach ---

PVRT(b) Proportional Valve Retract ---

RV1 Relief Valve RV1 restricts the operating pressure to a maximum of


210 bar. Must be reset when replaced.
SV5 Solenoid Valve 5th Function ---
SVH Solenoid Valve Hoist SVH is a black and white valve and opens when lifting is se-
lected. The lift speed is governed by the pump speed.

ESR 5000

63
HYDRAULIC SYSTEM
Abbreviations Used

Abbrevia- Meaning(a) Description


tion

SVS Solenoid Valve Sideshift ---


SVT Solenoid Valve Tilt ---
a. The first letters of the term in brackets give the component abbreviation.
b. In the event of a mechanical failure the entire valve block must be replaced. The magnetic coils can be replaced individually.

ESR 5000

64
HYDRAULIC SYSTEM
Feature Descriptions

Feature Descriptions
Lifting

Fig. 41 Hydraulic circuit for lifting

The following symbols are used in the diagrams: The lift speed is controlled by the pump motor speed in
proportion to the movement of the control lever.
Pilot line The oil then flows from input P of the valve block
through the DCVH slide valve via output A to the hy-
Pressure line draulic cylinders. The hydraulic cylinders extend.
Suction line During lifting, the lower control pressure side of the
DCVH slide valve is connected to the reservoir return
Return line line via the lowering valve PVL. This is necessary to
prevent any counter-pressure from building up (which
would affect the movement of the slide valve).
The lift function is requested by pulling the corre- If the "lift/lower" control lever is released, the pump and
sponding control lever. The voltage on the slider of lift SVH valve are switched off. SVH switches over
potentiometer POT2 changes. The pump and the mag- through bias spring force so that the lift control pres-
netic coil of the SVH lift pilot valve are activated. sure side of the slide valve is connected to the reservoir
The SVH valve drives the DCVH slide valve. The slide return line. The drop in pressure moves the slide valve
valve opens. to its home position. The connection to the cylinders is
lost. The cylinders remain in their current position.

ESR 5000

65
HYDRAULIC SYSTEM
Feature Descriptions

Note: If the MVL manual lowering valve is open,


i.e. turned in, lifting is inhibited.

ESR 5000

66
HYDRAULIC SYSTEM
Feature Descriptions

Lower

Fig. 42 Hydraulic circuit for lowering

The following symbols are used in the diagrams: slide valve via output T to the reservoir. The hydraulic
cylinders retract.
Pilot line In proportion to the movement of the control lever, the
lowering proportional valve PVL controls the oil pres-
Pressure line sure on the slide valve - and hence the degree of open-
ing of the slide valve - and ultimately the lowering
Suction line speed.
Return line The flow control valve PCL mounted in front of the slide
valve provides a constant lowering speed for any con-
trol lever position.
The "lowering" function is requested by pulling on the During lowering, the lift control pressure side of the
corresponding control lever. The voltage on the slider DCVH slide valve is connected to the reservoir return
of lift potentiometer POT2 changes. The magnetic coil line via the SVH raise valve. This is necessary to pre-
of proportional valve PVL is activated. vent any counter-pressure from building up (which
The PVL valve drives the DCVH slide valve. The slide would affect the movement of the slide valve).
valve opens. If the "lift/lower" control lever is released, the PVL sole-
Oil flows from the hydraulic cylinders via port A of the noid is switched off. PVL switches over through bias
valve block through flow control valve PCL and the spring force so that the lower control pressure side of
the slide valve is connected to the reservoir return line.

ESR 5000

67
HYDRAULIC SYSTEM
Feature Descriptions

The drop in pressure moves the slide valve to its home


position. The connection to the cylinders is lost. The
cylinders remain in their current position.
Pressure switch PLS is fitted on the hydraulic line to the
lift cylinders. If more than 400 kg is placed on the forks,
the pressure switch converts the switch limit of PVL.
This prevents the load from suddenly stopping during a
lowering operation, and hence the mast from swaying.
The valve block contains the AVL valve which is used
to set the maximum lowering speed when PVL is fully
opened.
The maximum lowering speed for 1.4 t and 1.6 t trucks
is 0.58 m/s, and for 2.0 t trucks 0.51 m/s.
When the main valve block is replaced, AVL is supplied
preset to 0.58 m/s and must be set to 0.51 m/s for 2.0 t
trucks (see Main valve block, page 75).
The MVL emergency lowering valve allows the mast to
be lowered manually in the event of hydraulic failure.
To lower, turn the emergency lowering valve clock-
wise.
Note: After the lowering operation, close the valve as
far as the screw stop.

ESR 5000

68
HYDRAULIC SYSTEM
Feature Descriptions

Extending the mast reach carriage

Fig. 43 "Extend mast reach carriage" hydraulic circuit

The following symbols are used in the diagrams: The extending reach cylinder pushes the oil out of the
cylinder. The oil can flow back to the reservoir via the
return line of the PVRE valve.
Pilot line
If the control lever is released, the pump and the PVRE
Pressure line valve are switched off.
Suction line PVRE is closed through bias spring force and the flow
of oil to the reach cylinder is interrupted. The pressure
Return line on the pilot line of the brake valve reduces, the brake
piston is moved to the neutral position through bias
spring force. The pressure on the reach cylinder is re-
The extend mast reach carriage" function is requested strained through the closed position of the brake valve.
by pulling the corresponding control lever. The voltage The cylinder remains in its current position.
on the slider of reach potentiometer POT3 changes.
The pump and the magnetic coil of the PVRE propor-
tional pilot valve are activated.
The speed of the reach carriage is determined by the
movement of the control lever. It is governed by the
pump motor speed and the position of the PVRE pro-
portional valve.
PVRE opens in proportion to the movement of the con-
trol lever. Oil flows from input P of the valve block
through the flow control valve PCR and the PVRE
valve via the bypass check valve to output A2. From A2
on to the piston dome side of the reach cylinder. The
reach carriage extends.
The two pilot lines on the flow control valve PCR regu-
late this so that the flow of oil and hence the speed of
the reach carriage are kept constant depending on the
oil pressure and the potentiometer setting.
The flow of oil to A2 moves the brake piston and the
return line from B2 to PVRE opens.

ESR 5000

69
HYDRAULIC SYSTEM
Feature Descriptions

Retracting the mast reach carriage


Fig. 44 "Retract mast reach carriage" hydraulic circuit

The following symbols are used in the diagrams: PVRT is closed through bias spring force and the flow
of oil to the reach cylinder is interrupted.
Pilot line The pressure on the pilot line of the brake valve re-
duces, the brake piston is moved to the neutral position
Pressure line through bias spring force. The pressure on the reach
cylinder is restrained through the closed position of the
Suction line brake valve. The cylinder remains in its current posi-
Return line tion.

The retract mast reach carriage" function is requested


by pulling the corresponding control lever. The voltage
on the slider of reach potentiometer POT3 changes.
The pump and the magnetic coil of the PVRT propor-
tional valve are activated.
The speed of the reach carriage is determined by the
movement of the control lever. It is governed by the
pump motor speed and the position of the PVRT pro-
portional valve.
PVRT opens in proportion to the movement of the con-
trol lever. Oil flows from input P of the valve block
through the flow control valve PCR and the PVRE
valve via the bypass check valve to output B2. From B2
on to the piston ram side of the reach cylinder. The
mast reach carriage retracts.
The flow of oil to B2 moves the brake piston and the
return line from A2 to PVRT opens.
The retracting reach cylinder pushes the oil out of the
cylinder. The oil can flow back to the reservoir via the
return line of the PVRT valve.
If the control lever is released, the pump and the PVRT
valve are switched off.

ESR 5000

70
HYDRAULIC SYSTEM
Feature Descriptions

Fork tilt back





 

 

Fig. 45 "Fork tilt back" function hydraulic circuit

The following symbols are used in the diagrams: flows via port A2 of the tilt/sideshift valve block,
through valve SVT to port A. From here it continues on
to port B1 of the main valve block, through valve PVAL
Pilot line
to output T and finally back into the reservoir.
Pressure line If the control lever is released, the pump and the SVT
and PVAL valves are switched off. The valves are set
Suction line to the home position through bias spring force. The oil
Return line flow through SVT is interrupted. The tilt cylinder re-
mains in its current position.

The fork tilt back function is requested by pulling the


corresponding control lever. The voltage on the slider
of tilt potentiometer POT4 changes. The pump and the
magnetic coils of the SVT valves and the PVAL propor-
tional valve are activated.
The tilt speed is determined by the movement of the
control lever. It is governed by the pump motor speed
and the position of the PVAL proportional valve.
PVAL opens in proportion to the movement of the con-
trol lever. The oil flows through port P of the main valve
block, the PCA flow control valve and the PVAL propor-
tional valve to output A1. From here it flows on to port
B of the "tilt/sideshift" valve block, through the open
SVT valve and the CV check valve to port B2. From B2
to the piston side of the tilt cylinder. The piston extends,
and the forks tilt up (back).
The oil pressure created displaces the ball of the twin
check valve (behind PVAL) from left to right and re-
leases the control pressure on PCA. The two pilot lines
on the flow control valve PCA regulate this in such a
way that the flow of oil is kept constant depending on
the oil pressure and the potentiometer setting.
The forward moving piston of the tilt cylinder forces the
oil out of the front section of the tilt cylinder. The oil

ESR 5000

71
HYDRAULIC SYSTEM
Feature Descriptions

Fork tilt down




 



Fig. 46 "Fork tilt down" function hydraulic circuit

The following symbols are used in the diagrams: line is connected to the cylinder return line. When an
overall pressure of 90 bar is applied, CBV opens and
releases the line for the returning oil. If the overall pres-
Pilot line
sure is below 90 bar CBV blocks so that any load on
Pressure line the forks cannot tilt down automatically.
The piston moves back and forces the oil out of the tilt
Suction line cylinder. The oil flows via port B2 of the tilt/sideshift
Return line valve block, through CBV and valve SVT to port B.
From here it continues on to port A1 of the main valve
block, through valve PVAR to output T and back into
the reservoir.
The fork tilt down function is requested by pulling the
corresponding control lever. The voltage on the slider If the control lever is released, the pump and the SVT
of tilt potentiometer POT4 changes. The pump and the and PVAR valves are switched off. The valves are set
magnetic coils of the SVT valves and the PVAR propor- to the home position through bias spring force. The oil
tional valve are activated. flow through SVT is interrupted. The drop in oil pres-
sure in the pilot line causes CBV to close. The tilt cylin-
The tilt speed is determined by the movement of the
der remains in its current position.
control lever. It is governed by the pump motor speed
and the position of the PVAR proportional valve.
PVAR opens in proportion to the movement of the con-
trol lever. The oil flows through port P of the main valve
block, the PCA flow control valve and the PVAR pro-
portional valve to output B1. From here on to port A of
the "tilt/sideshift" valve block, through the open SVT
valve to port A2 and to the piston ram side of the tilt
cylinder. The piston retracts, and the forks tilt down.
The oil pressure created displaces the ball of the twin
check valve (behind PVAR) from left to right and re-
leases the control pressure on PCA.
The two pilot lines on the flow control valve PCA regu-
late this in such a way that the flow of oil is kept con-
stant depending on the oil pressure and the
potentiometer setting.
A pilot line of the counterbalance valve CBV is con-
nected to the pressure circuit after SVT. The 2nd pilot

ESR 5000

72
HYDRAULIC SYSTEM
Feature Descriptions

Sideshift right







Fig. 47 "Sideshift right" hydraulic circuit

The following symbols are used in the diagrams: The oil flowing out of the left port of the sideshift cylin-
der flows via port B1 of the "tilt/sideshift valve block,
through valve SVS to port B. From here it continues on
Pilot line
to port A1 of the main valve block, through valve PVAR
Pressure line to output T and back into the reservoir.
If the control lever is released, the pump and the SVS
Suction line and PVAR valves are switched off. The valves are set
Return line to the home position through bias spring force. The oil
flow through SVS is interrupted. The sideshift remains
in its current position.
The "sideshift right function (seen from the operators
position) is requested by pulling the corresponding
control lever. The voltage on the slider of sideshifter po-
tentiometer POT5 changes. The pump and the mag-
netic coils of the SVS valves and the PVAR
proportional valve are activated.
The sideshift speed is determined by the movement of
the control lever. It is governed by the pump motor
speed and the position of the PVAR proportional valve.
PVAR opens in proportion to the movement of the con-
trol lever. The oil flows through port P of the main valve
block, the PCA flow control valve and the PVAR pro-
portional valve to output B1 of the hydraulic manifold.
The oil pressure created displaces the ball of the twin
check valve (behind PVAR) from left to right and re-
leases the control pressure on PCA. The two pilot lines
on the flow control valve PCA regulate this in such a
way that the flow of oil is kept constant depending on
the oil pressure and the potentiometer setting.
From B1 the oil flows on to port A of the "tilt/sideshift"
valve block. From port A through the open SVS valve
via port A1 to the right port of the sideshift cylinder. The
fork carriage moves to the right.

ESR 5000

73
HYDRAULIC SYSTEM
Feature Descriptions

Sideshift left






 

Fig. 48 "Sideshift left" hydraulic circuit

The following symbols are used in the diagrams: The oil flowing out of the right port of the sideshift cyl-
inder flows via port A1 of the "tilt/sideshift valve block,
through valve SVS to port A. From here it continues on
Pilot line
to port B1 of the main valve block, through valve PVAL
Pressure line to output T and back into the reservoir.
If the control lever is released, the pump and the SVS
Suction line and PVAL valves are switched off. The valves are set
Return line to the home position through bias spring force. The oil
flow through SVS is interrupted. The sideshift remains
in its current position.
The "sideshift left function (seen from the operators
position) is requested by pulling the corresponding
control lever. The voltage on the slider of sideshifter po-
tentiometer POT5 changes. The pump and the mag-
netic coils of the SVS valves and the PVAL proportional
valve are activated.
The sideshift speed is determined by the movement of
the control lever. It is governed by the pump motor
speed and the position of the PVAL proportional valve.
PVAL opens in proportion to the movement of the con-
trol lever. The oil flows through port P of the main valve
block, the PCA flow control valve and the PVAL propor-
tional valve to output A1 of the hydraulic manifold.
The oil pressure created displaces the ball of the twin
check valve (behind PVAL) from left to right and re-
leases the control pressure on PCA. The two pilot lines
on the flow control valve PCA regulate this in such a
way that the flow of oil is kept constant depending on
the oil pressure and the potentiometer setting.
From port A1 the oil flows on to port B of the "tilt/side-
shift" valve block through the open SVS valve via port
B1. From B1 to the left port of the sideshift cylinder. The
fork carriage moves to the left.

ESR 5000

74
HYDRAULIC SYSTEM
Hydraulic Components

Hydraulic Components Valve blocks


Hydraulic lines Main valve block
The main valve block is located under a cover in the
General notes on inspection, installation and han- mast reach carriage.
dling of hydraulic lines
The main valve block contains:
Prior to installation, apply dry compressed air to all
The solenoids for controlling the various hydraulic
hoses and lines to remove any loose foreign bodies.
functions
Rubber hoses with a wire braid inner construction, ther-
The AVL valve for adjusting the lowering speed
moplastic hoses and steel pipes that have collapsed or
been kinked, are permanently damaged. They must be The MVL manual lowering valve
replaced even if there is no obvious external damage. The RV1 relief valve.
Flexible thermoplastic hoses must be replaced if they Ports
distort in their normal operating position.
Rubber hoses must always be replaced if they leak.
Hoses and pipes must not rest loosely against other 
components. This could result in chafing or cuts. Route
 
lines so that they do not get jammed. 

All connections must be completely sealed. 
The elbows on suction connections must be positioned
so that the suction hose has the full flow and does not
collapse. 

Fig. 49 Port references on the valve block


A To the lift cylinders
A1 To port B on the "Accessories" block
A2 To the port on the mast reach cylinder (piston dome side)
B1 To port A on the "Accessories" block
B2 To the mast reach cylinder (piston ram side)
P To the pressure side of the hydraulic pump
T Return flow to reservoir

Replacing the valves


The mechanical section of the valves is fully integrated
in the block, the valve bodies cannot be obtained indi-
vidually. In the event of a mechanical defect replace the
entire block.
The solenoid coils can be replaced.

ESR 5000

75
HYDRAULIC SYSTEM
Hydraulic Components

"Accessories" valve block 3. Raise a test load that is 10% +100 kg above the
rated capacity.
This valve block is located in the fork carriage. It con-
If the RV1 relief valve applies, the setting is ok.
tains the solenoids for controlling the sideshifter and
If not, proceed to step 6.
the tilt cylinder.
Setting relief valve RV1
4. Lower the load.
5. Remove the cover over the valve block.


  









Fig. 50 "Accessories" valve block ports


A To port B1 on the main valve block Fig. 51 Relief valve RV1 and manual lowering valve MVL
A1 To the sideshifter cylinder, "left" port 6. Loosen the counternut (2, Fig. 51) on valve RV1
A2 To the tilt cylinder, piston ram side (1).
B To port A1 on the main valve block 7. Adjust the setscrew (3) as required.
B1 To the sideshifter cylinder, "right" port Turn clockwise to increase the contact pres-
B2 To the tilt cylinder, piston dome side
sure.
Turn anticlockwise to reduce the contact pres-
Replacing the valves sure.
Valve bodies and the solenoid coils can be replaced on 8. Tighten the counternut (1) again.
this block. Checking the adjusted setting
Checking and adjusting relief valve 9. Repeat steps 1 to 8 until RV1 applies within the tol-
erance range.
RV1 Note: If the valve cannot be adjusted, it must be re-
The RV1 relief valve is preset to a pressure of placed.
210+5 bar.
Checking the setting
1. Raise a test load that is 10% above the rated ca-
pacity.
2. Raise the test load above the free lift height.
It should just be possible to raise this load.

ESR 5000

76
HYDRAULIC SYSTEM
Hydraulic Components

Checking the emergency lowering


valve MVL
1. Lower the forks.
2. Remove the cover over the main valve block.
3. Raise the forks without load above free lift height.

WARNING
Lowering forks can cause injury
The forks automatically lower when the hydraulic sys-
tem is being bled.
Never stand underneath a raised fork.
Seal off the hazardous area to prevent other people
from entering and standing under a raised fork.

4. Slowly open MVL (4, Fig. 51).


If the forks do not lower even when MVL is fully
opened, replace the main valve block and check
MVL again.
If the forks lower in full, the MVL valve is ok.

ESR 5000

77
HYDRAULIC SYSTEM
Depressurising the Hydraulic System

Depressurising the Hydraulic


System
1. Fully lower the forks.
2. Set the forks horizontal.
3. Set the sideshifter to the centre position.
4. Switch off the truck, disconnect the battery and
prevent the truck from being switched on again.
5. Wait 2 minutes.
The hydraulic system is depressurised.

ESR 5000

78
HYDRAULIC SYSTEM
Bleeding and Flushing the System

Bleeding and Flushing the 4. Tighten the bleed screw as soon as bubble-free oil
emerges.
System 5. Carry out steps 2 to 4 on the other lift cylinder.
6. Clean up any oily components on the truck.
Safety notices
Bleeding the reach cylinder
1. Extend the forks and hold the control lever at the
WARNING limit position for approx. 5 seconds.
High pressure hydraulic system 2. Retract the forks and hold the control lever at the
High-pressure hydraulic oil can cause injury! limit position for approx. 5 seconds.
Wear safety gloves and goggles or a face mask 3. Repeat steps 1 to 2 until the reach mechanism
when depressurising the system. moves without any delay or jerky movement.

Bleeding the sideshift cylinder


Note: This bleeds all the hydraulic lines to the fork car-
WARNING riage.
1. Extend the sideshifter and hold the control lever at
Lowering forks can cause injury the limit position for approx. 5 seconds.
The forks automatically lower when the hydraulic sys-
2. Retract the sideshifter and hold the control lever at
tem is being bled.
the limit position for approx. 5 seconds.
Never stand underneath a raised fork.
3. Repeat steps 1 to 2 until the sideshifter moves
Seal off the hazardous area to prevent other people without any delay or jerky movement.
from entering and standing under a raised fork.
Bleeding the tilt cylinder
Note: The sideshift cylinders must be bled beforehand!
1. Tilt the fork carriage back and hold the control lever
CAUTION at the limit position for approx. 5 seconds.
Health risk 2. Tilt the fork carriage forward and hold the control
Cleaning agents, lubricants and consumables can lever at the limit position for approx. 5 seconds.
damage your health. 3. Repeat steps 1 to 2 at least 10 times.
Observe the manufacturers safety instructions
when handling cleaning agents, lubricants and con- Bleeding the 5th function cylinder
sumables. See Bleeding the tilt cylinders

Flushing the lift cylinders


Bleeding the free lift cylinder
Note: The lift cylinders must be bled.
1. Prepare the work area to collect spilled oil.
Preparing for flushing
2. Fully extend the free lift cylinder.
1. Fully extend the mast.
3. Open the bleed screw on the free lift cylinder.
2. Check the lift cylinders for leaks.
4. Tighten the bleed screw as soon as bubble-free oil
If a cylinder is leaky, repair it (see page 363).
emerges.
If the cylinders are sealed, proceed to step 3.
5. Clean up any oily components on the truck.
Flushing the lift cylinders
Bleeding the lift cylinders 3. Extend and retract the mast at maximum speed to
the maximum lift height at least 10 times.
1. Prepare the work area to collect spilled oil.
This flushes the lift cylinders.
2. Extend the lift cylinder as far as possible.
3. Open the bleed screw on the free lift cylinder.

ESR 5000

79
HYDRAULIC SYSTEM
Bleeding and Flushing the System

Drift tests
Carry out a drift test after:
repairing or replacing hydraulic cylinders.
repairing or replacing valve blocks or valves.
This is the only way of identifying internal leakage.

Requirements
Prepare a test load:
Weight must correspond to the maximum capacity
The test load must be evenly distributed.
The load centre of gravity must be centrally located,
600 mm in front of the fork shanks, and must not
exceed the capacity plate specification.
Note: Whenever you carry out a drift test the hydraulic
oil temperature must be 30 - 40.
1. Measure the temperature in the hydraulic reservoir
before carrying out the drift test.
If the temperature is 30 - 40 C you can start
with the drift test.
If the temperature is too low, proceed to step 2.
2. Raise the forks several times up to the free lift limit
until the temperature is 30 - 40 C.

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80
HYDRAULIC SYSTEM
Drift Tests

Drift Tests Tilt cylinder drift test


After carrying out repairs on the hydraulic system Flush the tilt cylinders, attach a test load and
check the drift on the lift and tilt cylinders. plumb
1. Tilt the fork carriage several times from one end to
Safety notices the other to flush the hydraulic system.
2. Raise the test load and secure it on the forks to
prevent it from sliding and falling.
WARNING 3. Tilt the forks down fully.
Standing under a raised load can cause fatal 4. Attach a lowering plumb with a piece of string ap-
njuries prox. 3m long to the fork at an approximate dis-
Fatal injuries could result if the forks of the truck sud- tance of 1150 mm to the fork shank.
denly lower or if a load falls. Note: If the distance is not 1150 mm, you must calcu-
Do not stand under a swinging load. late the drift nominal value accordingly!
Seal off the hazardous area to prevent access. 5. Raise the test load with the fork carriage tilted back
beyond the free lift height so that the tip of the
plumb is at least 50 mm above the ground.
Lift cylinder drift test 6. Measure the height of the plumb above the ground
and record the measurement.
Flush the lift cylinders, attach a test load and
plumb 7. Switch off the truck and disconnect the battery.
1. Flush the lift cylinders (see page 79). 8. Wait for 5 minutes.
2. Raise the test load and secure it on the forks to Measuring the drift
prevent it from sliding and falling. 9. After 5 minutes measure the plumb height again.
3. Tilt the forks fully down. 10. Calculate the difference between the previously re-
4. Attach a lowering plumb with a 3m long string to corded measurement and the new measurement
the fork tip. to establish the drift.
5. Raise the forks beyond the free lift height so that If the drift 50 mm, the internal leakage is too
the tip of the plumb is at least 100 mm above the great. Replace the cylinder and repeat the drift
ground. test.
6. Measure the height of the plumb above the ground If the drift < 50 mm, it has passed the drift test.
and record the measurement.
7. Switch off the truck and disconnect the battery.
8. Wait for 10 minutes.
Measuring the drift
9. After 10 minutes measure the plumb height again.
10. Calculate the difference between the previously re-
corded measurement and the new measurement
to establish the drift.
If the drift 100 mm, the internal leakage is too
great. Repair the cylinder (see page 363) and
repeat the drift test.
If the drift < 100 mm, it has passed the drift test.

ESR 5000

81
HYDRAULIC SYSTEM
Hydraulic Oil Reservoir

Hydraulic Oil Reservoir ESR 5000 hydraulic oil reservoir


The ESR 5000 and ESR 5000S use reservoirs with dif-
ferent shapes. However, the respective capacities are  
the same at approximately 36 litres. 
 
The same filter is used on both reservoirs.

ESR 5000S hydraulic oil reservoir


 

 


 

Fig. 53 ESR 5000 reservoir


1 Dipstick

Fig. 52 ESR 5000S reservoir 2 Breather filter


3 Return filter cover
1 Dipstick
4 Return line port
2 Breather filter
5 Suction line port
3 Return filter cover
6 Reservoir
4 Return line port
7 Drain plug
5 Suction line port
6 Reservoir
7 Drain plug

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82
HYDRAULIC SYSTEM
Replacing the Hydraulic Oil

Replacing the Hydraulic Oil Note: The return filter filters from outside to inside. It
does not filter the oil you add to the reservoir via the
Approx. 36 litres are required to replace the hydraulic opened return filter.
oil. For the grade and application area see Recom-
1. Fill up the reservoir (6, Fig. 52 or 53) once the en-
mended Lubricants and Consumables, page 27.
tire hydraulic system has been bled.
Draining the hydraulic oil reservoir 2. Retract all the cylinders (mast reach on chassis,
mast lowered, fork carriage tilted forward).
3. Add hydraulic oil via a 10 m mesh filter up to the
CAUTION "MAX" mark on the dipstick (1, Fig. 52 or 53).

Health risk
Cleaning agents, lubricants and consumables can
damage your health.
Observe the manufacturers safety instructions
when handling solvents and lubricants.

1. Unscrew the filter cover (3, Fig. 52 or 53).

Fig. 54 Filter insert and handle


2. Pull out the filter insert (2, Fig. 54) from the handle
(1).
3. Draw off and collect the hydraulic oil via the port.
4. Place a suitable bowl underneath the truck.
5. Open the drain plug (7, Fig. 52 or 53) and drain the
remaining oil and deposits out of the reservoir
sump.
6. Dispose of the oil in accordance with environmen-
tal regulations.
Replenishing the hydraulic oil reservoir

CAUTION
Hydraulic systems are sensitive to contamination.
Filter the new oil via a 10 m mesh one-way filter.

ESR 5000

83
HYDRAULIC SYSTEM
Replacing the Filter

Replacing the Filter 4. Turn the filter element (3, Fig. 55) slightly to pull it
out of the filter container and dispose of it.
The system comprises two hydraulic filters and one
breather filter. These must be replaced at regular inter- Filter element assembly
vals. See Maintenance Schedule, page 39. 1. Clean the filter container.
2. Turn a new, original Crown filter element down
slightly to insert it in the filter container.
CAUTION 3. Insert the filter container into the hydraulic oil res-
ervoir.
Health risk
4. Screw on the cover and tighten it only slightly by
Cleaning agents, lubricants and consumables can
hand.
damage your health.
Note: The cover is sealed and locked in place via the
Observe the manufacturers safety instructions
inserted O-ring. If tightened too fast it can only be re-
when handling solvents and lubricants.
leased with a tool. This will also cause the O-ring to
wear more quickly.

CAUTION Replacing the suction filter


Do not clean filters
Solvents destroy or alter the filter materials. This can
result in damage to the hydraulic system.

Always use new and original Crown filter elements 
as replacements.

Replacing the return filter



Removing the filter element

1. Wipe around the reservoir cover (2, Fig. 56) with a
clean cloth.
2. Unscrew the cover.



Fig. 56 Suction port (ESR 5000S)

Removing the filter element
1. Loosen the suction hose (4, Fig. 56).
2. Seal the ports with clean filler plugs.

Fig. 55 Filter container and filter element


3. Lift up the handle (1, Fig. 55) on the filter and
remove the filter container (2, Fig. 55) and the filter
element.

ESR 5000

84
HYDRAULIC SYSTEM
Replacing the Filter

3. Remove the four screws (3) from the reservoir Replacing the breather filter
flange.




Fig. 58 Breather filter


Fig. 57 Suction pipe and filter element Removing the filter element
4. Thread the suction pipe (1, Fig. 57) and the at- 1. Remove the bayonet cap (2, Fig. 58) of the
tached filter element (2) out of the reservoir. breather filter (2, Fig. 52 or 53) by turning it a turn
to the left.
5. Unscrew and dispose of the filter element.
2. Remove and dispose of the filter element
Filter element assembly (1, Fig. 58).
1. Push a new flange seal (3, Fig. 57) over the suction
Filter element assembly
pipe.
1. Insert the new filter element.
2. Screw a new original Crown filter element onto the
suction pipe. 2. Fit the bayonet cap and turn it a turn to the right
to lock it.
3. Thread the suction pipe and filter element back into
the reservoir and position them correctly on the
flange.
4. Insert the screws (2, Fig. 56) and torque them
crosswise to 25 Nm.

ESR 5000

85
HYDRAULIC SYSTEM
Replacing the Hydraulic Pump

Replacing the Hydraulic Pump


The hydraulic pump cannot be repaired. It must be
WARNING
replaced in full. Trapping hazard
Preparing to remove the hydraulic pump An unsecured pump unit can trap your fingers if the
bracket is loosened.
1. Place a flat tray underneath the truck to collect any
spilled hydraulic oil. Secure the pump unit with a load handling device
and support it with wooden wedges before undoing
2. Switch off the truck, disconnect the battery and
the mounting screws (5, Fig. 59).
prevent it from being switched on again.

4. Using a load handling device attach the pump unit


to a lifting mechanism and remove any slack.
  5. Remove the screws (5, Fig. 59).
Removing the hydraulic pump
1. Raise the pump unit so that the pump can be re-
moved.
 2. Support the pump unit so that it cannot lower.
 3. Remove the screws (3, Fig. 60).
4. Remove the suction and pressure lines (screws 5
and 8, Fig. 60).
5. Dispose of the seals (2 and 6, Fig. 60).
6. Pull the hydraulic pump (1, Fig. 60) out of the pump
motor toothing without tilting it.
Assembling the hydraulic pump
1. Apply a thin layer of grease part no. 794860-007
(Shell Calithia HDX) to the hydraulic pump drive
  shaft toothing.
2. Place the hydraulic pump on the pump motor.
3. Secure the hydraulic pump with the screws
Fig. 59 Hydraulic pump removal (ESR 5000S)
(3, Fig. 60).
1. Remove the suction hose (1, Fig. 59) and seal the 4. Attach the suction and pressure lines to the hy-
ports with clean filler plugs. draulic pump using new seals.
2. Disconnect the pressure line from the union (2, 5. Lower the pump unit.
Fig. 59) and seal the ports with clean filler plugs.
6. Attach the retaining plate (4, Fig. 59) via the
3. Disconnect the sensor cable and power cables (6, screws (5).
Fig. 59) from the pump motor.
7. Restore the pressure line connection (2, Fig. 59).
Note: The cables must be exposed sufficiently so that
8. Restore the electrical connections.
the pump unit can be raised approx. 250 mm without
tilting or tipping over. Note: Do not connect the suction hose at this stage.

ESR 5000

86
HYDRAULIC SYSTEM
Replacing the Hydraulic Pump

Starting up the hydraulic pump


1. Add hydraulic oil to the suction hose (1, Fig. 59) via
a 10 m one way filter. For the grade and applica-
tion area see Recommended Lubricants and Con-
sumables, page 27.
2. Connect the suction hose (1, Fig. 59) to the reser-
voir.
3. Power up the truck.
4. Bleed the pump by activating the "sideshifter" func-
tion several times as far as the stop.
5. Check the hydraulic oil level and replenish if nec-
essary (see page 83).
6. When you have reached operating temperature,
check all the ports for leaks.

ESR 5000

87
HYDRAULIC SYSTEM
Replacing the Hydraulic Pump




 





Fig. 60 Pump unit and connection lines

ESR 5000

88
HYDRAULIC SYSTEM
Hydraulic Port Torques

Hydraulic Port Torques


1 Accessories hose system
24 - 27 Nm 1 90 - 95 Nm 2 Lift function hose system
3 Valve block in mast reach carriage
1
4 Valve block mounting screws(1)

1. Insert with Loctite 242, part no. 053050-006.


107 - 119 Nm 2
Note: Torque the hose clamp mounting screws to
20 - 25 Nm.

CAUTION
The filter can be damaged if the return line hose
union is torqued incorrectly
Counter the torque on the union (1) by holding tight
80 - 88 Nm the filter connection (2).

34 - 37 Nm
90 - 95 Nm
24 - 27 Nm

3 3

Fig. 61 Overview of Hydraulic Lines and Ports

ESR 5000

89
HYDRAULIC SYSTEM
Hydraulic Port Torques

Notes:

ESR 5000

90
DRIVE UNIT

91
Notes:

92
DRIVE UNIT
Gear Unit

Gear Unit
Required tools
Fork lift truck with sufficient capacity, lift height and
fork length to raise the truck, or a crane with suffi-
cient capacity.
Safety device to keep the raised truck on the forks
of the truck doing the lifting.
Sufficient number of wooden blocks (surface area
of at least 250 x 250 mm, approx. 550 mm long) or
suitable supports to secure the raised truck.
Suitable mechanism for securing the gear unit on a
pallet truck.

Removing the gear unit


1. Disconnect the battery and prevent the truck from
being switched on again.
2. Disassemble the traction motor (see page 276).
1

WARNING
Standing under a raised load can cause fatal Fig. 62 Drive unit
injuries
8. Remove the six screws (1, Fig. 62).
Fatal injuries could result if the truck is suddenly low-
ered. 9. Lower the pallet truck and pull it out from under the
truck together with the gear unit.
Do not stand under a swinging load.

3. Raise the truck with a second fork lift truck and pre-
vent the truck from slipping, or lift it with a crane
(see page 13).
4. Raise the truck and bring a pallet truck with a
mechanism for securing the gear unit into position.
5. Raise the front of the truck by approximately
another 50 mm.
6. Lower the truck onto the wooden blocks or sup-
ports.
The truck is now secured and the gear unit can
be removed:
7. Raise the pallet truck with the mechanism for
securing the gear unit until the mechanism is
touching the gear unit.

ESR 5000

93
DRIVE UNIT
Gear Unit

1
2

3
4

2 6 5

15
9 12
10 13 16

11
14
17
37
18
13
24
23
25

44
38
36
18 27
42 30 2
26
35 27
28
29 34
19
22
43 30
41

40 20
31
39 21

33
32
22

Fig. 63 Gear unit exploded diagram

ESR 5000

94
DRIVE UNIT
Gear Unit

Repairing the gear unit In the next steps the flange shaft, the bevel pinion and
their respective bearings are removed:
Note: The gear unit must only be repaired by trained
14. Push out the flange shaft (42) using a suitable de-
and authorised Crown personnel. Otherwise the war-
vice.
ranty will be invalid.
15. Extract the inner ring of the conical roller bearing
(38) from the flange shaft (42).
CAUTION Note: When disassembling, mark the assembly loca-
Correcting the tooth flank bearing and pre-tensioning tion of the shims (18, 20, 35). The same number of
the shaft bearing requires years of experience with shims will have to be put back temporarily in the same
gear units. Incorrect adjustments and settings will re- position at a later stage.
sult in premature failure of the gear unit. 16. Take the bevel gear (22), spacer ring (36) and ad-
It is preferable to replace the gear unit! justing shim(s) (18) and (35) where applicable out
of the housing.
17. Extract the inner ring of the conical roller bearing
Dismantling the gear unit (34) from the bevel gear (22).
Unless otherwise indicated, all item numbers refer 18. Extract the outer rings of the conical roller bearings
to Fig. 63, page 94. (34, 38) from their seats in the transmission hous-
ing.
19. Remove the thread shield ring (41), radial shaft
CAUTION seal (40) and retaining ring (39) from the housing
seat.
Health risk 20. Press the bevel gear (22) down from out of the spur
Cleaning agents, lubricants and consumables can wheel (16) and the conical roller bearing (17).
damage your health.
21. Remove the conical roller bearing (17) and shim
Observe the manufacturers safety instructions (18) where applicable.
when handling solvents and lubricants.
22. Extract the outer ring of the conical roller bearing
(21).
1. Prior to dismantling, thoroughly clean the gear unit
23. Remove the spacer bushing (19) from the bevel
with a cold cleaning solution and dry with low-pres-
pinion shaft and extract the inner ring of the conical
sure air.
roller bearing (21) from the bevel pinion shaft.
2. Drain the oil (capacity approx. 3.6 litres).
24. Thoroughly clean all components and remove the
3. Insert the gear unit with the wheel nuts (43) into a remains of the sealant and adhesive.
secure device to prevent it from twisting.
4. Remove the screws (26) and the lock washers (2). Assembling the gear unit
5. Take off the gear unit cover (25) and loosen the O-
ring (24). CAUTION
6. Remove the screws (1) and the lock washers (2).
Used seals cause leaks and bearings can be damaged
7. Take off the live ring bearing (3). when removed. All bearings and seals must be
8. Remove the O-ring (5) from the recess of the gear replaced.
ring (8).
9. Remove the screws (29 and 31) and the lock wash-
Preparing the gear unit
ers (30).
1. Press the outer rings of the conical roller bearings
10. Take off the gear ring (8).
(17, 21, 34 and 38) into their respective notches in
11. Remove the screws (32) and the washer (33). the cleaned housing. Make sure they are posi-
12. Undo the nut (15) of the bevel pinion shaft. tioned level in the housing.
13. Take the gear unit out of the mechanism. 2. Insert the inner ring of the conical roller bearing
(38) in the pre-assembled outer ring of the conical
roller bearing (blade wheel side).

ESR 5000

95
DRIVE UNIT
Gear Unit

3. Insert the retaining ring (39) in its corresponding Adjusting the bevel gear set
groove. The correct setting can be calculated via the tooth flank
4. Press the radial shaft seal (40) into the housing us- bearing. Always adjust the bevel gear set to the correct
ing a suitable tool. flank position. The tooth ends should not form a
5. Place the thread shield ring (41) onto its space in straight line:
the housing and caulk it. The tooth flank bearing must always align with the
6. Press the inner ring of the conical roller bearing inner tooth end.
(34) onto the bevel gear (22) using a suitable tool. The tooth flank bearing must range from high (top
7. Press the wheel nuts (43) into the flange shaft of tooth) to low (bottom of tooth).
holes (42) using a suitable tool. To adjust, add and/or remove shims (18, 20, 35) or
change the pre-tension of the bearings.
Inserting the bevel pinion shaft
Figure 64 shows the limits of the permissible tooth
1. Press the inner ring of the conical roller bearing
flank bearings on the bevel pinion and bevel gear.
(21) onto the conical pinion shaft (22).
2. Place the shim(s) (20) and spacer bushing (19) on
the conical pinion (22). 1
3. Insert the pre-assembled bevel pinion shaft (22)
2
into the housing (23) from below.
3
4. Push the inner ring of the conical roller bearing (17)
over the shaft of the bevel pinion shaft into the
outer ring of the conical roller bearing (17).
5. Assemble the spur wheel (16) and torque the new
nut (15) to max. 100 Nm.
6. Test the bevel pinion shaft can move freely and en- 5
sure there is zero backlash. Reduce the torque if 6
necessary.
Record the final torque. This will be needed
again to adjust the bevel gear set. 4
Assembling the flange shaft
7. Bring the housing into its subsequent assembly po-
sition. Fig. 64 Permissible tooth flank bearings
8. Insert the spacer ring (36) and the pre-assembled 1 High tooth flank bearing on bevel pinion
bevel gear (22) in the respective order through the 2 Bevel pinion
housing opening. 3 Bevel gear
9. Apply a thin layer of oil to the flange shaft (42) and 4 Low tooth flank bearing on bevel gear
carefully push it through the previously inserted
5 High tooth flank bearing on bevel gear
unit parts in the housing.
6 Low tooth flank bearing on bevel pinion
10. Insert the housing with the wheel nuts into a secure
device to prevent it from twisting. Note: Carry out all checks and adjustments with care.
11. Guide the hex. socket screws (32) through the Pre-tensioning the bearings and shims will affect the
washer (33) and torque them to max. 77 Nm to tooth flank bearing. Do not set the pre-tension too low.
tension the flange shaft assembly. It will automatically reduce during normal operation.
12. Test the shaft can move freely; ensure there is zero 13. Colour the tooth flanks of the bevel gear (22) with
backlash. touch-up paste (striking colour) or a light oil colour.
Reduce the torque if necessary. 14. Take the gear unit out of the mechanism.
Record the final torque. This will be needed 15. Turn the bevel gear several times in one direction.
again to adjust the bevel gear set. The tooth flank bearing will appear as a bright
point (marked black in Fig. 64) on the tooth
flanks.

ESR 5000

96
DRIVE UNIT
Gear Unit

16. Check the tooth flank bearing.


CAUTION
17. Remove and/or add shims (18, 20, 35) to restore
the tooth flank bearing to the tolerance limits (see Leave the surface and thread sealants to dry for at
Fig. 64). Change the bearing pre-tension if neces- least 2 hours at room temperature. Then fill with oil.
sary. Take care not to exceed the max. levels
(flange shaft max. 77 Nm, spur wheel max.
36. Set the gear unit in the assembly position.
100 Nm).
Record the new torques. 37. Add oil to suit the application temperature (see
page 27) up to the bottom of the refill plug. The
18. Torque the screw (32) of the flange shaft and nut
capacity is 3.6 litres.
(15) of the spur wheel to the previously recorded
levels. Assembling the gear unit
19. Repeat the check and adjustment until the tooth
flank bearing is within the tolerance range.
Final assembly
CAUTION
20. Re-assemble the bevel pinion shaft and flange New gear units are always supplied without oil
shaft. Add oil to suit the application temperature (see
21. Clean all the components. page 27) up to the bottom of the refill plug. The
22. Apply a thin layer of Loctite 307 to the inside of the capacity is 3.6 litres.
conical roller bearing inner rings.
23. Apply medium strength Loctite 242 to the threads
of the nut (15) and the screws (32). CAUTION
24. Refit the bevel pinion shaft and flange shaft and
torque the screw (32) and nut (15) to the last re- When assembling the gear unit take care not to dam-
corded values. age the toothing of the spur pinion (14) or the spur
wheel (16).
25. Manually turn the gear unit through, while checking
for freedom of movement and ensure it operates
without any clearance. Assembly is the reverse of disassembly (see page 93).
26. Apply a thin layer of Loctite 307 to the contact sur-
faces of the housing cover.
27. Screw the drain plug (28) with the copper ring (27)
underneath it into the transmission lid (25).
28. Insert the O-ring (24) into its groove in the trans-
mission lid.
29. Attach the gear unit cover (25) to the housing (23)
so that the drain plug is at the lowest position when
the gear unit is installed again.
30. Secure the gear unit cover with the screws (26)
and lockwashers (2).
31. Torque the screws (26) evenly and crosswise.
32. Apply a thin layer of Loctite 307 to the contact sur-
faces of the transmission housing to the ring gear.
33. Fit the ring gear.
34. Insert the O-ring (5) into the recess of the ring gear
(8).
35. Fit the live ring bearing.

ESR 5000

97
DRIVE UNIT
Drive Wheel

Drive Wheel 3. Torque the wheel nuts (1) evenly and crosswise to
180 Nm.
Note: The drive wheel must be replaced if its diameter
Note: After 50 service hours the wheel nuts (1) must be
is 309 mm.
torqued to 180 Nm.
Attach a sticker or notice to the operator position to act
1 as a reminder.
3 4. Jack up the truck
5. Adjust the support blocks (see page 53).
Note: It is very important to adjust the support blocks
after replacing the drive wheel. It prevents the truck
from tipping over if the load is poorly distributed at
height.

Fig. 65 Drive wheel


1 Gear unit
2 Drive wheel
3 Wheel nut

Drive wheel disassembly / assembly


Drive wheel disassembly
1. Jack up the truck (see page 14), disconnect the
battery and prevent it from being switched on
again.

WARNING
Risk of serious injury
Failure to handle the truck and/or the equipment
correctly could result in fatal injury.
Never reach with your hands or other parts of your
body under the truck before it has been supported,
or when jacking up the truck.
Always lower a raised truck onto hard wooden
blocks or other appropriate equipment to relieve the
jack.

2. Remove the hub cap.


3. Remove the wheel nuts (1, Fig. 65).
4. Take off the drive wheel (2).

Drive wheel assembly


1. Push the drive wheel (2) onto the wheel bolts.
2. Fit the wheel nuts (1).

ESR 5000

98
ELECTRICAL SYSTEM

99
Notes:

100
ELECTRICAL SYSTEM
Electrical Components

Electrical Components ECR1


Traction Encoder
ACS
A sensor ball bearing, fitted in the top bearing shield of
Accelerator Switch the traction motor. Captures the motor speed and
Located below the accelerator pedal. Activates travel. transmits it to the TDM.

BFS ECR2
Brake Fluid Switch Lift Encoder
Installed in the cover of the brake fluid container on the A sensor ball bearing, fitted in the top bearing shield of
main brake cylinder. Monitors the brake fluid level. A the pump motor. Captures the motor speed and trans-
warning is displayed if the brake fluid drops below the mits it to the HDM.
permissible level.
ECR3
BLS Steering Feedback Encoder
Battery Latch Switch Fitted in the steer motor. Transmits a signal in propor-
Installed on the battery latch in the motor compartment. tion to the steering direction and speed of the steered
Monitors the locking of the battery tray. If the battery wheel.
tray is not retracted or not locked, travel is restricted to
creep speed. ECR4
Steer Encoder
BPS
A sensor bearing, located in the steering column below
Brake Pressure Switch the steering wheel. Transmits a signal to the steering
Attached to the brake cylinder. Closes at a brake pres- control module, depending on the rotary direction and
sure of 3 6 bar, thereby activating regenerative brak- speed of the steering wheel.
ing by changing travel direction, in addition to the
mechanical brake. ECR5
Height Encoder
BRS
Sensor bearing, installed at the top left (in the forks di-
Brake Switch rection) of the outer mast (see page 265). ECR5 is
Activates the parking brake and the parking brake sym- driven by a crown gear adjacent to the 1st mast stage.
bol in the display when applied. If BRS is switched off Starts to acquire the lift height when the free lift is used
again, the truck remains braked until the accelerator up. Must be re-calibrated when the encoder is replaced
pedal is applied. It therefore prevents the truck from (see C7 Height, page 131). If ECR5 is faulty or if the
rolling away, for example when starting on a ramp. VCM does not detect any encoder signals, the lift
speed is reduced and an event code is shown on the
BRAKE display.

Motor and Parking Brake


Attached to the traction motor. Electrically actuated as
a parking brake. On trucks with a Danaher motor it is
hydraulically actuated by the brake pedal to act as a
service brake.

BS
Beacon Switch
Fitted in the console. Switches the beacon on or off.

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101
ELECTRICAL SYSTEM
Electrical Components

EDS FU2
Emergency Disconnect Switch Control Fuse VCM/HDM/Horn
Installed in the electric compartment. When applied, This fuse (15 A/80 V) protects the control circuits of the
disconnects the entire power supply. main and hydraulic control modules.

ED1 FU3
Emergency Disconnect Contactor Power Fuse Brake
Installed in the electric compartment. Disconnects the This fuse (10 A/80 V) protects the brake circuit.
power supply to the HCM, TCM and SCM power cir-
cuits. FU4
FAN1, FAN4 Control Fuse SDM
This fuse (10 A/80 V) protects the power circuit of the
Fan TCM steer module.
Installed in the electric compartment. The traction con-
trol module switches the fans on at +35 C, and off at FU5, FU6
+25 C.
Control Fuses Options
FAN2, FAN3 This fuse (15 A/80 V) protects the control circuits of the
auxiliary functions.
Fan HCM
Installed in the electric compartment. The hydraulic FU7
control module switches the fans on at +35 C, and off
at +25 C. Main Fuse
This fuse (425 A/48 V) protects the batterys connec-
FKS tion wires.'

Fork Switch FU13


Attached to the fork carriage, actuated by a trip cam.
The load weight display switches off if the forks are not Power Fuse SDM
horizontal. This fuse (50 A/48 V) protects the steering power cir-
cuit.
FLS
HCM
Free Lift Switch
Attached to the fork carriage. FLS is applied by a mag- Hydraulic Control Module
net attached to the inner mast. If the fork carriage is Installed in the electric compartment. Controls the
above free lift, the speed for this range can be set in the pump motor and takes the readings from the encoder
P6 Travel > FLS menu (see page 165) ECR2 and the thermal sensor THS2.

FS HN
Forward Switch Horn
Travel opposite to the fork direction. Installed below the floorboard.

FU1 HNS
Control Fuse TCM/Display Horn Switch
This fuse (15 A/80 V) protects the control circuits of the Pressing the horn switch activates the horn.
traction control module and the work lights.

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102
ELECTRICAL SYSTEM
Electrical Components

HGTS LS
Height Switch Load Sensor
Attached to the top right (in fork direction) of the outer Installed at the top of the tilt cylinder. LS captures the
mast. Reduces the lift speed 500 mm before reaching weight of a load resting on the forks. Connected in se-
the maximum lift height. A metal plate on the 1st mast ries with the FKS (fork switch).
stage actuates the proximity switch without contact.
MVL
HGTRS
Manual Valve Lower
Height Reset Switch Emergency lowering of fork carriage and mast stages.
Attached to the top right (in fork direction) of the outer Note: The manual lowering valve should then be
mast. Activates the height encoder when the 1st mast closed again.
stage has just been approached. A metal plate on the
1st mast stage actuates the proximity switch without ORS
contact.
Override Switch
K1 & K2 Installed in the control panel on the overhead guard
column, to the left of the steering wheel. Lifting is inhib-
Relays Keyless Entry
ited when a programmed lift stop is reached. If the ORS
Installed in the leg compartment. These connect the switch is now pressed, lifting can continue to either the
power supply to the VCM (Vehicle Control Module) next lift stop or the end stop.
when the Keyless Entry option is available.
POT1
K11
Traction Potentiometer
Start Up Relay
Attached to the accelerator pedal. Supplies an analog
K11 is integrated in the start up card in the start up signal to the main control module VCM to control the
module. It actuates ED1. If all systems are ok, the VCM travel speed. POT1 must be recalibrated when re-
connects pin 24 of CA205 to the negative terminal, placed.
thereby activating K11.
POT2
K12 & K13
Lift/Lower Potentiometer
Options Relays
Hall sensor attached to the Lift/Lower control lever.
Installed in the leg compartment. Activate the 48 V sup- Supplies an analog signal to the main control module
ply for the options packages. VCM to control the lift/lower speed. Must be recali-
brated when replaced.
K22 & K23
Relay Working Light 12 V
POT3
Installed in the leg compartment. Activate the 12 V Reach Potentiometer
work light. Hall sensor attached to the Reach control lever. Sup-
plies an analog signal to the main control module VCM
KYS to control the reach speed. Must be recalibrated when
Key Switch replaced.
Supplies power to the VCM (Vehicle Control Module).

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ELECTRICAL SYSTEM
Electrical Components

POT4(1) PVRT
Tilt Potentiometer Proportional Valve Retract
Hall sensor attached to the Tilt control lever. Supplies Controls the reach carriage retract speed.
an analog signal to the main control module VCM to
control the tilt speed. Must be recalibrated when re- PVRE
placed. Proportional Valve Reach
POT5 Controls the reach carriage reach speed.

Sideshift Potentiometer RES1


or
5th Function Potentiometer Reach Sensor 1
Hall sensor attached to the Sideshift control lever. Installed on the bottom right of the reach carriage (in
Supplies an analog signal to the main control module fork direction). Activates Reduced reach speed.
to control the sideshifter speed. Must be recalibrated
when replaced.
RES2
After switching to the 5th function this Hall sensor sup- Reach Sensor 2
plies the analog signal for the 5th function. Installed on the bottom right of the reach carriage (in
fork direction). Senses the position of the reach car-
PLS riage in the Reduced reach speed range.
Pressure Load Switch Note: Position sensing prevents the limit stops being
Installed in the pipeline leading to the right (as seen in struck at full speed if the reach carriage is just before
fork direction) lift cylinder. Factory set to switch at a the end stops.
500 kg load. Prevents the fork carriage from stopping
abruptly when lowering loads > 500 kg. Must be recal-
RS
ibrated when replaced. Reverse Switch
Travel in forks direction.
PVL
Proportional Valve Lower RV
Integrated within a valve body together with the SVR Relief Valve
(lift valve). Controls the lowering speed.
Adjustable valve. Restricts the hydraulic pressure to a
maximum of 210 bar. Must be reset when replaced.
PVAR
Proportional Valve Accessories Right SDM
Controls the downward tilt speed of the forks when "tilt" Steer Drive Module
is selected. Controls the sideshift speed to the right
Installed in the electric compartment. Takes the read-
when "sideshift" is selected.
ings from encoders ECR3, ECR4 and sensors
SFS 1SA and SFS 2. Controls the steering motor and
PVAL
the parking brake.
Proportional Valve Accessories Left
Controls the upward tilt speed of the forks when "tilt" is
selected. Controls the sideshift speed to the left when
"sideshift" is selected.

1. "Fingertip" control levers and dual-axis


hydraulic control levers only

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104
ELECTRICAL SYSTEM
Electrical Components

SES SVT
Seat Switch Solenoid Valve Tilt
Installed in the drivers seat. Applies when the seat is Installed on the manifold on the fork carriage. The SVT
occupied. Disconnects all truck functions apart from is a black/white valve. It opens when tilting is selected.
steering when the seat is vacated. The tilt speed is governed by the pump speed.

SFS 1SA SW
Steering Feedback Sensor 1 Straight Ahead Switch Working Lights
Located in the motor compartment behind the traction Installed in the control panel. Connects relay K6.
motor. Captures the forward position of the drive wheel
on the gear unit. TCM
SFS 2 Traction Control Module
Installed in the electric compartment. Controls the trac-
Steering Feedback Sensor 2 tion motor. Reads the values of encoder ECR1 and
Located in the motor compartment to the right of the thermal sensor THS1.
traction motor. Senses the quadrants.
THS1
SPS
Thermal Sensor 1
Safety Pedal Switch Installed in the traction motor. Captures the motor tem-
Inductive switch installed below the floorboard on the perature. When the motor temperature reaches 145 C
safety pedal. The switch must be pressed to activate the motor current is reduced to 250 A. If the motor tem-
travel and hydraulic functions. The safety switch mes- perature continues to rise, the motor current is further
sage is displayed if: reduced until it reaches 0 amps at a motor temperature
the safety pedal is pressed and the truck is of 165C and the motor cuts out.
switched on.
the travel switch is pressed and the safety pedal is
THS2
not. Thermal Sensor 2
a hydraulic function is applied and the safety pedal Installed in the pump motor. Captures the current motor
is not. temperature. When the motor temperature reaches
145 C the motor current is reduced to 250 A. If the mo-
SVR tor temperature continues to rise, the motor current is
further reduced until it reaches 0 amps at a motor tem-
Solenoid Valve Lift
perature of 165C and the motor cuts out.
SVR is incorporated with PVL in a valve body. SVR is
a black/white valve. It opens when lifting is selected. THS3
The lift speed is governed by the pump speed.
Thermal Sensor 3
SVS Installed near the SPS. Controls the switching on and
off of the heating resistors.
Solenoid Valve Sideshift
Limits: On at +5 C, off at +10 C
Installed on the manifold on the fork carriage. The SVS
is a black/white valve. It opens when sideshift opera- THS4
tion is selected. The sideshift speed is governed by the
pump speed. Thermal Sensor 4
Installed in the steer motor. When the motor tempera-
ture reaches 145C the motor current is reduced. If the
motor temperature continues to rise, the motor current
is further reduced until it reaches 0 amps at a motor
temperature of 180C and the motor cuts out.

ESR 5000

105
Notes:

106
ELECTRICAL SYSTEM
Service Menu Structure

Service Menu Structure Analyzer

Software version A1 Status


A2 Inputs
The Service Menu Structure chapter describes soft-
ware version V1 of 28.10.2008. A3 Outputs

Menu structure
The service menu outlined on page 117 is divided into A1Status
menu items.
The text under the display messages describes the A1.1 Vehicle Control Module (VCM)
meaning and purpose of the display. A1.2 Traction Control Module (TCM)
A1.3 Hydraulic Control Module (HCM)
Overview of menu items
A1.4 Steer Control Module (SCM)
Analyzer
A1.5 Main Contactor closed
A1 Status checks
A1.6 Battery Charge
A2 Input signals A1.7 TEMP Trac. Module (TCM)
A3 Output signals A1.8 TEMP Trac. Motor (M1)
Calibration A1.9 TEMP Hydr. Module (HCM)
Truck component calibration A1.10 TEMP Pump Motor (M2)
Feature A1.11 TEMP Steer Control Module (SCM)
For programming enhanced truck options and A1.12 TEMP Steer Motor (M3)
adapting to special applications.
Hour Meter
A2 Inputs
Setting the hour meter and service intervals.
Log Events A2.1 Forward Switch (FS)
Calling up event codes and frequencies. A2.2 Reverse Switch (RS)
Deleting the error log A2.3 Pot1 Accelerator Pedal
Performance A2.4 Pot2 Lift Lower Handle
Programming the performance setting. A2.5 Pot3 Reach Handle
Utilities A2.6 Pot4 Tilt Handle
U1 software versions of control modules A2.7 Pot5 Side Shift Handle
A2.8 Pot6 5th Function Handle
U2 Service hour settings
A2.9 Accelerator Switch (ACS)
U3 Unblocking accessory functions for event
codes. A2.10 Seat Switch (SES)
A2.11 Safety Pedal Switch (SPS)
A2.12 Battery Latch Switch (BLS)
A2.13 Brake Switch (BRS)
A2.14 Brake Pressure Switch (BPS)
A2.15 Brake Fluid Switch (BFS)
A2.16 Free Lift Switch (FLS)
A2.17 Height Switch(HGTS)
A2.18 Height Reset Switch (HGRTS)
A2.19 Height Encoder
A2.20 Load Sensor (LS)
A2.21 Override Switch (ORS)

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107
ELECTRICAL SYSTEM
Service Menu Structure

A2.22 Pressure Switch (PLS) C8 Weight


A2.23 Slow Down Area (RES1) C9 Fork Positioning
A2.24 Slow Down In/Out (RES2) C10 Reach Retract Slow Down
A2.25 Battery Current C11 Save
A2.26 Traction Motor Set & Actual Speed
A2.27 Traction Motor Current
A2.28 Travel Speed C1 Acceleration Pedal
A2.29 Pump Motor Set & Actual Speed
C1.1 Released
A2.30 Pump Motor Current
C1.2 Depressed
A2.31 Steer Motor Speed
A2.32 Steer Motor Current
A2.33 Steer sensor St. Ahead (SFS 1) C2 Raiser/Lower Handle
A2.34 Steer sensor Quadrant (SFS 2)
A2.35 Steer Wheel Angle C2.1 Released
A2.36 Battery Voltage C2.2 Depressed

A3 Outputs C3 Reach Handle

A3.1 Set TXN Speed C3.1 Retract


A3.2 Set Pump Speed C3.2 Reach
A3.3 Brake Output C3.3 Center
A3.4 Main Con. Output
A3.5 Lift Valve (SVH)
C4 Tilt Handle
A3.6 Lower Valve (PVL)
A3.7 Retract Valve (PVRT)
C4.1 Tilt Up
A3.8 Reach Out Valve (PVRE)
C4.2 Tilt Down
A3.9 Mast Right Valve (PVAR)
C4.3 Center
A3.10 Mast Left Valve (PVAL)n
A3.11 Tilt Valve (SVT)
A3.12 Side Shift Valve (SVS) C5 Side Shift Handle
A3.13 5th Function Valve (SV5)
A3.14 Alarm 2, Direction C5.1 Right
A3.15 Beacon C5.2 Left
A3.16 Fan C5.3 Center

Calibration C6 5th Function Handle

C6.1 Right
C1 Acceleration Pedal
C6.2 Left
C2 Raise/Lower Handle
C6.3 Center
C3 Reach Handle
C4 Tilt Handle
C5 Side Shift Handle C7 Height
C6 5th Function Handle
C7 Height C7.1 R Cut 1

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108
ELECTRICAL SYSTEM
Service Menu Structure

C7.1.1 None Features


C7.1.2 Override Set Height F1 Truck Size
C7.1.3 Stop
F1.1 Truck Size
C7.2 R Cut 2 F1.2 Free Lift Switch
C7.2.1 None
C7.2.2 Override Set Height
F2 Free Lift Switch
C7.2.3 Stop

F2.1 No
C7.3 R Cut 3
F2.2 Yes
C7.3.1 Saved Max. Height
C7.3.2 Enter 2nd Height
F3 Height Encoder
C7.4 R Cut 4
C7.4.1 None F3.1 No
C7.4.2 Cut Height Lift to Limit F3.2 Yes

F4 Lower Cut Out


C8 Weight
F4.1 No
C8.1 No Load
F4.2 XXX
C8.2 Load
F4.3 Yes

C9 Fork Positioning F5 5th Function

C9.1 Adjust Tilt Up F5.1 Off


C9.1.1 Change Value ... F5.2 On
C9.2 Adjust Tilt Up F5.3 LCS
C9.1.1 Change Value ...

F6 Max. Load
C10 Reach Retract Slow Down
F6.1 Change Value ...
C10.1 Adjust Reach
C10.1.1 Change Value ...
F7 Capacity Data M.
C10.2 Adjust Retract
C9.1.1 Change Value ...
F7.1 No
F7.2 Yes
C11 Save? F7.3 Set Zones
F7.4 Height1=xxx / Weight1=xxx
C11.1 No F7.5 Height2=xxx / Weight2=xxx
C11.2 Yes F7.6 Height3=xxx / Weight3=xxx
F7.7 Height4=xxx / Weight4=xxx

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109
ELECTRICAL SYSTEM
Service Menu Structure

F8 Travel Alarm F12.16 Slovenian


F12.17 Greek
F8.1 Alarm Off
F8.2 Alarm Reverse
F8.3 Alarm Forward F13 Change Unit

F13.1 Euro
F9 Beacon F13.2 USA

F9.1 Beacon Off


F9.2 Key Switch F14 Set Rack Select
F9.3 Beacon Reverse
F9.4 Beacon Forward F14.1 No
F9.5 Beacon Forward and Reverse F14.2 Yes

F10 User Performance F15 Height/Weight

F10.1 No F15.1 No
F10.2 Yes F15.2 Yes

F11 User Code F16 Timer

F11.1 No F16.1 No
F11.2 Yes F16.2 Yes
F11.3 View
F11.4 Add F17 Error Log
F11.5 Delete
F17.1 No
F17.2 Yes
F12 Set Language

F12.1 English F18 Operator Alarm


F12.2 German
F12.3 French F18.1 No
F12.4 Italian F18.2 Yes
F12.5 Dutch
F12.6 Spanish
F19 Battery Alarm
F12.7 Danish
F12.8 Finnish F19.1 No
F12.9 Swedish F19.2 Yes
F12.10 Norwegian
F12.11 Portuguese
F12.12 Turkish F20 Fork Positioning
F12.13 Polish
F20.1 No
F12.14 Czech
F20.2 Yes
F12.15 Hungarian

ESR 5000

110
ELECTRICAL SYSTEM
Service Menu Structure

F21 Choose Steering F27 Options Display

F21.1 180 F27.1 Hazard Warning Light


F21.2 360 F27.2 Aud Travel Alarm
F21.3 Both F27.3 Heated Screen
F27.4 Heated Seat
F27.4.1 No
F22 Speed Reduction
F27.4.2 Yes
Void
F23 Cruise Control
F28 Truck Lockout
Void
F24 High Speed
F28.1 No
Void F28.2 Yes

F25 Keyless Entry


F29 Direction Switch

F25.1 Keyless Enable F29.1 One


F25.1.1 No
F29.2 Two
F25.1.2 Yes
F25.2.2 Shutdown Time
F25.2.1 Change Value ... F30 Save ?

F30.1 No
F26 Right Handle F30.2 Yes

F26.1 S/D Lever


F26.2 MTC

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111
ELECTRICAL SYSTEM
Service Menu Structure

Hour Meter Performance


H1 Truck Complete P1 Setup P1
H2 Traction Module
P1.1 Travel Speed FWD
Full / Middle / Easy P1.2 Travel Speed REV
P1.3 Acceleration
P1.4 Plugging
H3 Hydraulic Mod. P1.5 Coasting
P1.6 Reduction Brake
Full / Middle / Easy
P1.7 Pedal Brake
P1.8 Raise Speed
H4 Key On Time P1.9 Raise ACC
H5 Set Service Time P1.10 Lower Speed
P1.11 Lower Stop
H5.1 None P1.12 Reach Speed
H5.2 Change Value ... P1.13 Tilt Speed
P1.14 SS Speed

Log Events
P2 Setup P2
L1 History
P2.1 Travel Speed FWD
L1.1 Code Work Hours Temperature
P2.2 Travel Speed REV
P2.3 Acceleration
L1.15 Code Work Hours Temperature P2.4 Plugging
P2.5 Coasting
L2 Totals P2.6 Reduction Brake
P2.7 Pedal Brake
L2.1 Event 0..=YYY P2.8 Raise Speed
P2.9 Raise ACC
L2.X Event XXX = YYY P2.10 Lower Speed
P2.11 Lower Stop
P2.12 Reach Speed
L3 Erase History
P2.13 Tilt Speed
P2.14 SS Speed
L3.1 Erase History
L3.1.1 Sure = No
L3.1.2 Sure = Yes P3 Setup P3

P3.1 Travel Speed FWD


P3.2 Travel Speed REV
P3.3 Acceleration
P3.4 Plugging
P3.5 Coasting
P3.6 Reduction Brake
P3.7 Pedal Brake

ESR 5000

112
ELECTRICAL SYSTEM
Service Menu Structure

P3.8 Raise Speed P12 Steer Sensitivity


P3.9 Raise ACC
P3.10 Lower Speed P12.1 Change Value ...
P3.11 Lower Stop
P3.12 Reach Speed P13 Sens Steering
P3.13 Tilt Speed
P3.14 SS Speed P13.1 No
P13.2 Yes

P4 BDI Setting
P14 Brake at Ramp
P4.1 Change Value ...
P14.1 No
P14.2 Yes
P5 Travel > LCS

P5.1 Change Value ... P15 Set Default Values

P15.1 No
P6 Travel > FLS
P15.2 Yes

P6.1 Change Value ...


P16 Save ?

P7 Travel > Custom


P16.1 No
P16.2 Yes
P7.1 Change Value ...

P8 Lower > Custom Utilities


U1 Software Version
P8.1 Change Value ...
U1.1 Vehicle Control Module (VCM)
U1.2 Traction Module (TCM)
P9 Reach > Custom
U1.3 Hydraulic Module (HCM)
P9.1 Change Value ... U1.4 Steer Drive Module (SCM)
U1.5 Display screen

P10 5th Func Left


U2 Hour Set
P10.1 Change Value ...
U2.2 Run = xxx
U2.1.1 Save = No
P11 5th Func Right U2.1.2 Save = Yes

P11.1 Change Value ...


U3 Brake Override

U3.1 No
U3.2 Yes

ESR 5000

113
ELECTRICAL SYSTEM
Service Menu Structure

U4 Check Fan 1-4

U4.1 Off
U4.2 On

U5 Keyless Time

U5.1 Change Value ...

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114
ELECTRICAL SYSTEM
Service Menu Structure

Performance level defaults P1.4 Plugging 6


P1.5 Coasting 6
P1.6 Reduction Brake 7
The text under the display messages describes the
meaning and purpose of the display. P1.7 Pedal Brake 9
P1.8 Raise Speed 5
Standard settings P1.9 Raise ACC 3
P1 Setup - Defaults P1.10 Lower Speed 9
P1.11 Lower Stop Soft
P1.1 Travel Speed FWD 12 P1.12 Reach Speed 5
P1.2 Travel Speed REV 12 P1.13 Tilt Speed 5
P1.3 Acceleration 8 P1.14 SS Speed 5
P1.4 Plugging 8
P1.5 Coasting 8
P1.6 Reduction Brake 7 P4 BDI Setting
P1.7 Pedal Brake 9
P4.1 Acid Battery 6
P1.8 Raise Speed 5
Maintenance Free Battery 8
P1.9 Raise ACC 3
P1.10 Lower Speed 9
P1.11 Lower Stop Soft P5 Travel > LCS
P1.12 Reach Speed 5
P1.13 Tilt Speed 5 P5.1 9
P1.14 SS Speed 5
P6 Travel > FLS
P2 Setup - Defaults
P6.1 9
P1.1 Travel Speed FWD 11
P1.2 Travel Speed REV 11 P7 Travel > Custom
P1.3 Acceleration 7
P1.4 Plugging 8 P7.1 9
P1.5 Coasting 8
P1.6 Reduction Brake 7
P8 Lower > Custom
P1.7 Pedal Brake 9
P1.8 Raise Speed 5
P8.1 9
P1.9 Raise ACC 3
P1.10 Lower Speed 9
P1.11 Lower Stop Soft P9 Reach > Custom
P1.12 Reach Speed 5
P1.13 Tilt Speed 5 P9.1 9
P1.14 SS Speed 5
P10 5th Func Left
P3 Setup - Defaults
P10.1 10
P1.1 Travel Speed FWD 10
P1.2 Travel Speed REV 10
P1.3 Acceleration 5

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115
ELECTRICAL SYSTEM
Service Menu Structure

P11 5th Func Right

P11.1 10

P12 Steer Sensitivity

P12.1 7

P14 Brake at Ramp

P14.2 Yes

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116
ELECTRICAL SYSTEM
Service Menu - General

Service Menu - General 


Enter letters from A to I and K on the numer-
ical keypad.
Access to service level To enter A, press down on the number 1 for
a while. For a B press down on number 2 ...
Trucks with key switch The letter K is located on numerical key 0.

Entering the service code


1. Press and hold down on the key. Display structure
2. Switch on the truck with the key switch. The following graphic illustrates the display structure:
3. Press down on the key
The display will prompt you to enter the service
code.   
4. Enter the service code.
The service menu opens. The truck is ready for op-


























eration.

Trucks without key switch 

Entering the service code Fig. 66 Display structure


1 Menu item (Analyzer menu, item 1.12)
1. Press and hold down on the key.
2 Component (steer motor)
2. Press and hold down on the key.
3 Reading (t =105 C)
The display will prompt you to enter the service
code. 4 Additional text, warning or instruction (in this case a warning
that the steer motor temperature is too high).
3. Enter the service code.
The service menu opens. The truck is ready for
operation.

Navigation and entry keys


The following table lists the navigation and entry
options within the service menu:

Press this key to access a higher level in


the menu.
Press this key to access a lower level in the
menu.
Press briefly to scroll down an item in a
menu.
Hold down on this key to scroll through to
the next menu item every 750 ms.
Press briefly to scroll up an item in a menu.
Hold down on this key to scroll through to
the next menu item every 750 ms.
Press this key to acknowledge data.

 To enter a number, type it out on the numer-


ical keypad.

ESR 5000

117
ELECTRICAL SYSTEM
Service Menu - General

Access to service menu and selecting a sub-menu


          

Entering the service code


1. When the truck starts up press down on the key.
A display will prompt you to enter the service code.

       
     

2. Enter the service code using the numerical keys.


3. Press the key.
The truck is ready for operation. You are now in the enhanced service
menu.
Selecting a sub-menu
4. Select the required menu item with the or keys:
Analyzer (see page 119)
Calibrate (see page 127)
Features (see page 139)
Hourmeter (see page 155)
Log Events (see page 158)
Performance (see page 160)
Utilities (see page 170)
5. Press the key.

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118
ELECTRICAL SYSTEM
Analyzer Menu

Analyzer Menu
A1 Status

       


       


        
 
     
VCM (main truck control module) status display. The VCN controls travel
and hydraulic functions as well as system communication via the CAN bus.

       
    
     
Traction control module (TCM) status display

      
    
    
Hydraulic control module (HCM) status display

     

      
 
Steering control module (SCM) status display

      
      
  
Main contactor status display

        
    

Battery residual capacity display in %.

         

      

Traction control module (TCM) temperature

          

      
Traction motor (M1) temperature

        

     

Hydraulic control module (HCM) temperature

    

    




Pump motor (M2) temperature

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ELECTRICAL SYSTEM
Analyzer Menu

      
    

 
 
Steering control module (SCM) temperature

       
    

 

Steer motor (M3) temperature

A2 Inputs
       


      
     
 
Direction switch status display when in forward position (ON = activated,
OFF = deactivated).

    
 
      
Direction switch status display when in reverse position (ON = activated,
OFF = deactivated).

            
  
     
Voltage reading on slider of "Travel" potentiometer (POT1) and corre-
sponding digital reading in the 2nd row.

Item Voltage Digital reading

Neutral position 0.7 - 1.5 V 0


Maximum setting 8.5 - 9.5 V 1023
Note: If the digital readings 0 and 1023 are not reached, the potentiometer
is not correctly calibrated.


           

       
Voltage reading on slider of "Lift" potentiometer (POT2) and corresponding
digital reading in the 2nd row.

Item Voltage Digital reading

Neutral position 4.3 - 4.7 V 460 - 570


Max. lower 0.7 - 1.5 V 0
Max. lift 7.8 - 8.2 V 1023
Note: If the digital readings 0 and 1023 are not reached, the potentiometer
is not correctly calibrated.

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ELECTRICAL SYSTEM
Analyzer Menu

           

    
Voltage reading on slider of "Reach" potentiometer (POT3) and corre-
sponding digital reading in the 2nd row.

Item Voltage Digital reading

Neutral position 4.3 - 4.7 V 460 - 570


Max. lower 0.7 - 1.5 V 0
Max. lift 7.8 - 8.2 V 1023
Note: If the digital readings 0 and 1023 are not reached, the potentiometer
is not correctly calibrated.


          
     
Voltage reading on slider of "Tilt" potentiometer (POT4) and corresponding
digital reading in the 2nd row.

Item Voltage Digital reading

Neutral position 4.3 - 4.7 V 460 - 570


Max. lower 0.7 - 1.5 V 0
Max. lift 7.8 - 8.2 V 1023
Note: If the digital readings 0 and 1023 are not reached, the potentiometer
is not correctly calibrated.

            
 
       
Voltage reading on slider of "Sideshift" potentiometer (POT5) and corre-
sponding digital reading in the 2nd row.

Item Voltage Digital reading

Neutral position 4.3 - 4.7 V 460 - 570


Max. lower 0.7 - 1.5 V 0
Max. lift 7.8 - 8.2 V 1023
Note: If the digital readings 0 and 1023 are not reached, the potentiometer
is not correctly calibrated.

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ELECTRICAL SYSTEM
Analyzer Menu

     
    
      
   
Voltage reading on slider of "5th Function" potentiometer (POT6) and cor-
responding digital reading in the 2nd row.

Item Voltage Digital reading

Neutral position 4.3 - 4.7 V 460 - 570


Max. lower 0.7 - 1.5 V 0
Max. lift 7.8 - 8.2 V 1023
Note: If the digital readings 0 and 1023 are not reached, the potentiometer
is not correctly calibrated.

       
   
        
Travel switch input signal (ON = activated; OFF = deactivated).

      
   
 
Seat switch input signal (ON = activated; OFF = deactivated).

     
 
        
Safety switch input signal (ON = activated; OFF = deactivated).

        
       
 
Battery latch switch input signal (ON = activated; OFF = deactivated, the
battery tray is extended).

         

      
Parking brake switch input signal (ON = activated, the display light is on
and the brake coil is de-energised; OFF = deactivated, the brake coil is
energised, the brake is released and the truck is operational).

       
 
       
Brake pressure switch input signal (ON = activated; OFF = deactivated).

        
  
    
Brake fluid level switch (ON = activated, brake fluid level is too low;
OFF = deactivated)

      
       

Free lift switch input signal (ON = activated, the fork carriage is below the
1st mast stage height; OFF = deactivated, the fork carriage is above the
1st mast stage height.)

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ELECTRICAL SYSTEM
Analyzer Menu

    
  

    
Lift speed reduction switch input signal on mast, applies 500 mm before
the maximum lift height (ON = activated, actuation point reached;
OFF = deactivated).

    
   

        
The height reset switch starts the measurement through the height en-
coder and resets this meter to 0 each time it is actuated. (ON = activated
when the 2nd mast stage has not yet been extended; OFF = deactivated)

    
      


  

Height encoder. The encoder pulses are displayed. They count up for lifting
and down for lowering.

      

  

Load sensor. FKS open (forks tilted fully forward or back, reading approx.
10 - 20). FKS closed

      
 
   
 
Override switch for lift stop (ON = button pressed).

    
  
           
Pressure switch for load sensing
(ON = load 0 - 400 kg; OFF = load > 400 kg)

        

    
Reduced reach speed sensing (ON = when speed is not reduced;
OFF = when speed is reduced). RES1 generally activates reach speed re-
duction.

         

         
Reduced reach speed range detection (ON = rear reduced; OFF = front
reduced).
RES2 detects the position of the reach carriage. This ensures that the
reach carriage starts again at the appropriate speed depending on the
range:
If the reach carriage is at the front, the speed must remain reduced as the
reach carriage is further extended. The speed must pick up when the reach
carriage is retracted.

    
      
    
Actual battery current display.

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ELECTRICAL SYSTEM
Analyzer Menu


    


      
 





 


 
   
 
  
  
Displays the traction motor speed (SET) specified by the VCM and the
current traction motor speed (RPMACT), calculated on the basis of the
encoder pulses.
This display is useful for troubleshooting if the traction motor turns slowly
or not at all when a travel function is applied.
No SET speed, VCM has detected a fault (e. g. potentiometer) and
does not specify a speed.
SET speed available but no RPM ACT: Fault in encoder, traction motor
or the respective wiring.


    


 
    





 


    

   

Actual traction motor current



     
 

   




 
 
 
  
  
 
  
Current speed
          



      

Displays the pump motor speed (SET) specified by the VCM and the cur-
rent pump motor speed (RPMACT), calculated on the basis of the encoder
pulses.
This display is useful for troubleshooting if the pump motor turns slowly or
not at all when a lift function is applied.
No SET speed, VCM has detected a fault (e. g. potentiometer) and
does not specify a speed.
SET speed available but no RPM ACT: Fault in encoder, pump motor
or their respective wiring.

    
      
        
Actual pump motor current

          
  
  
Current steer motor speed

           
   
    
Actual steer motor current

       
      
  
Reset switch for the steer angle. When the signal changes (ON/OFF) the
steer angle is reset to 0.
This sensor also acts as a quadrant monitor.

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ELECTRICAL SYSTEM
Analyzer Menu

        
         

For 360 steering

         
    

Steer angle display (0 - 179; -179 - 0)

              
       

Current battery voltage

A3 Outputs
        



 
  
 


  
 
 



 

 






 

VCM speed specification for the traction motor.


   
 




  
 
 



 
 

 



  


VCM speed specification for the pump motor.


 
   
 
 
  
    
 



 
 
 

 




 

Brake modulation (ON = activated; OFF = deactivated).


   
 
 
 


 
    
 


 
 

 










Main contactor modulation (ON = activated; OFF = deactivated).


 
  
 
 
 
      
 


  

 



 
 




Lift valve modulation (ON = activated; OFF = deactivated).


 
   

       
 


 
 
 


  


 




Lower valve modulation (ON = activated; OFF = deactivated).


    
 


  
 
 
 
 

 


 


 
 



 



"Mast retract" valve modulation (ON = activated; OFF = deactivated).


 
   
 

 
   
  
 

  
 
 

 
 



 



"Mast reach" valve modulation (ON = activated; OFF = deactivated).


    
 
 

   
  
 

 

 
  
 

 


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ELECTRICAL SYSTEM
Analyzer Menu

"Right" mast function modulation


(ON = activated; OFF = deactivated):
Tilt
Sideshift
5th function


    
 
 

  
 
  
 

 

 

  
 



"Left" mast function modulation
(ON = activated; OFF = deactivated):
Tilt
Sideshift
5th function


   
 

 

    
 
 


 

 

 
 






Tilt valve modulation (ON = activated; OFF = deactivated)


 
   
 

   
  



  
 



 

 




Sideshift valve modulation (ON = activated; OFF = deactivated).


    

 
 
   
   
 


 

  


  



  



5th function valve modulation (ON = activated; OFF = deactivated).

 
  
  



 
  
 
 
 



 




 
 


 


Travel alarm output (ON = activated; OFF = deactivated).


   
 
 

 
 
  
 





 
 


 
 


 


Beacon output (ON = activated; OFF = deactivated).


      
 
   
   
 


 
 
 




 

Fan output (ON = activated; OFF = deactivated).

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ELECTRICAL SYSTEM
Calibration Menu

Calibration Menu
Note: Save the changes in menu item C11 (Save ?) before switching off the truck, otherwise you will lose the
changes.
1. Activate the Service menu (see page 117) and scroll through to menu item CALIBRATE using the or
keys.
        


2. Press the key.


3. Menu item C1 opens up.
4. Use the or keys to scroll through to the required sub-menu
(C1 to C11).

C1 Accelerator Pedal
Calibrating the "Accelerator pedal" potentiometer
         

    

1. Press the key.


Menu item C1.1 opens up.
           
  


2. Release the accelerator pedal.


3. Press the key.
Menu item C1.2 opens up.
           

  

4. Depress the accelerator pedal gently through to the mechanical stop.


5. Press the key.
Note: If the calibration has failed, Wrong Calibration is displayed for
2 seconds. Repeat steps 2 to 5.
If the calibration was successful, menu item C2 opens up.

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ELECTRICAL SYSTEM
Calibration Menu

C2 Raise / Lower Handle


Calibrating the "Raise/lower" potentiometer
       
 
  

1. Press the key.


Menu item C2.1 opens up.
           
 


2. Move the control handle as far as the stop in the "Raise" direction and
hold it in position.
3. Press the key.
Menu item C2.2 opens up.
          

  

4. Move the control handle as far as the stop in the "Lower" direction and
hold it in position.
5. Press the key.
Menu item C2.3 opens up.
     
     

  

6. Release the control handle.


7. Press the key.
If the calibration was successful, menu item C3 opens up.

C3 Reach Handle
Calibrating the "Reach" control handle
     
      

1. Press the key.


Menu item C3.1 opens up.
    
  

      
 


2. Move the "Reach" control handle as far as the stop in the "Retract"
direction and hold it in position.
3. Press the key.
Menu item C3.2 opens up.

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ELECTRICAL SYSTEM
Calibration Menu

            
 
 

4. Move the "Reach" control handle as far as the stop in the "Extend"
direction and hold it in position.
5. Press the key.
Menu item C3.3 opens up.
        

   

6. Release the control handle.


7. Press the key.
If the calibration was successful, menu item C4 opens up.

C4 Tilt Handle
Calibrating the fork tilt
 
 

     

1. Press the key.


Menu item C4.1 opens up.

   
    
  
 
  






 

2. Move the "Tilt" control handle as far as the stop in the "Up" direction
and hold it in position.
3. Press the key.
Menu item C4.2 opens up.
            
  


4. Move the "Tilt" control handle as far as the stop in the "Down" direction
and hold it in position.
5. Press the key.
Menu item C4.3 opens up.
     
     

  

6. Release the control handle.


7. Press the key.
If the calibration was successful, menu item C5 opens up.

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ELECTRICAL SYSTEM
Calibration Menu

C5 Side Shift
Calibrating the "Sideshift" control handle
       
 
  

1. Press the key.


Menu item C5.1 opens up.

    
 
 
     

 



1. Move the "Sideshift" control handle as far as the stop in the "Right"
direction and hold it in position.
2. Press the key.
Menu item C5.2 opens up.
   
       
   

3. Move the "Sideshift" control handle as far as the stop in the "Left" di-
rection and hold it in position.
4. Press the key.
Menu item C5.3 opens up.
     
     

  

5. Release the control handle.


6. Press the key.
If the calibration was successful, menu item C6 opens up.

C6 5th Function
Calibrating the 5th function
      
  
 

Note: The 5th function is calibrated automatically.


1. Press the key.
Menu item C7 is displayed.

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ELECTRICAL SYSTEM
Calibration Menu

C7 Height Progamming lift stops


Note: If there is no height encoder installed, NOT Up to 2 lift stops (RCUT1 and RCUT2) can be pro-
AVAILABLE is displayed in the 2nd row. The sub- grammed with different settings:
menus will not be accessible. The options are:
NONE (no lift stop)
OVERRIDE (lift stop can be bypassed using the
override switch ORS)
STOP (lift stop cannot be bypassed)

       


Note: If there is no height encoder installed, NOT AVAILABLE is dis-


played in the 2nd row and the sub-menus cannot be accessed.
Programming lift stop RCUT1
1. Press the key.
Menu item C7.1 opens up and the lift stop type currently selected for
RCUT1 (STATUS) is displayed together with the height if applicable.

   


  
  
 
  
 




 



 
 


1. Press the key.


Menu item C7.1.1 opens up.
     


   

1. Using the key scroll through until the required lift stop type is dis-
played (NONE, OVERRIDE or STOP).
2. Press the key.
If OVERRIDE or STOP are selected, menu item C7.1.2 opens up.
Note: If you have selected NONE, the display returns to menu item C7.1
and indicates the status as NONE.
       
 
  
  

3. Press the key.


The following instruction is displayed:

  

    

        

4. Raise the forks to the required height.


Note: Once the fork carriage is above free lift height, the fork height is
displayed in real time.
5. When the forks are at the required height, press the key.
Menu item C7.1 opens up and shows the previously selected status
and the fork height.

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ELECTRICAL SYSTEM
Calibration Menu

Programming lift stop RCUT2


Note: If STOP or NONE have been selected for RCUT1, menu item C7.2
for programming RCUT2 is not displayed.
1. Starting from menu item C7.1. press to scroll to menu item C7.2.
2. The 2nd lift stop (RCUT2) is programmed in the same way as the
1st lift stop (RCUT1).

C7.3 Height Encoder


Calibrating the height encoder
   
 
  
  
 
  
 




 




      


1. Press the key.


2. Menu item C7.3.1 opens up.
          
     

 

Approaching and storing the maximum lift height


3. Press the key.
The following instruction is displayed for 2 seconds, after which
menu item C7.3.2 opens up.
     
         
               

4. Raise the forks to the maximum lift height.


Note: Make sure the mast is fully extended.
          
     

  

5. Measure the height of the fork tips above the ground.


6. Enter the recording.
7. Press the key.
Menu item C7.30.3 opens up.
          
     

  

Approaching and storing the minimum lift height


Note: The minimum height which the encoder can capture is the maximum
free lift height. In other words, the zero point for the encoder starts at the
point where the 1st mast stage just starts to approach.
8. Press the key
The following instruction is displayed:
         

9. Slowly lower the forks.


The following instruction is displayed:

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ELECTRICAL SYSTEM
Calibration Menu

        

10. Slowly raise the forks.


11. Keep repeating steps 9 to 10 until the following instruction is displayed:

     
     

12. Do not activate fork lift any more.


13. Measure the height of the fork tips above the ground.
14. Press the key
Menu item C7.30.4 opens up.
          
    
  

15. Enter the recording.


16. Press the key
Menu item C7.4 opens up.

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ELECTRICAL SYSTEM
Calibration Menu

C7.4 Custom Height


Programming Custom Height
The Custom Heightmenu items provides functions such as lift height reduction from a specific height.
      
      
   

 

1. Press the key.


Menu item C7.4.1 opens up.
     



  

2. No Custom Height. If this is required, press the key.


Menu item C7.4 opens up again.
3. If a Custom Height is required, press to scroll through to menu
item 7.4.2:
          

     

4. Press the key.


The following instruction is displayed:
  

    

        

5. Raise the forks to the required lift height.


6. Press the key.
Menu item C7.4 opens up and the status and lift height are dis-
played.
Note: If the fork carriage is within the free lift height the message
INVALID is displayed for 1 second. The display returns to menu item
C7.4 and status NONE is displayed.

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ELECTRICAL SYSTEM
Calibration Menu

C8 Weight
Calibrating the load sensor
Note: A minimum test weight of 1400 kg is required and the FKS switch must be closed (fork tilt in neutral
position). If one of the above conditions is not met, WRONG CALIBRATION is displayed when the key is
pressed.
       


1. Press the key.


Menu item C8.1 opens up.
     

  

2. Raise the forks slightly without load.


3. Enter 0 kg if required.
4. Press the key.
The load sensor is now calibrated to 0 kg and menu item C8.2
opens up.
       

      

WARNING
Exceeding the maximum capacity can result in accidents
You yourself or bystanders can be fatally injured if the lift mechanism is
overloaded and the load falls down.
Do not exceed the maximum capacity as indicated on the capacity
plate.
5. Raise a known test load 1400 kg.
6. Raise the forks slightly.
7. Enter the weight of the known test load.
8. Press the key.
The load sensor is now calibrated over the entire measurement range.

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ELECTRICAL SYSTEM
Calibration Menu

C9 Fork Positioning
Adjusting the fork tilt
The fork tilt "notch ponts" can be adjusted here within limits. The adjustment factor can be entered separately for
TILT UP and TILT DOWN. The values can range from -3 to +3.
   

        

1. Press the key.


Menu item C8.1 opens up.
      



2. Press the key.


Menu item C9.1.1 opens up.
        

        

3. Enter the required adjustment factor.


4. Press the key.
The adjustment factor for TILT UP is accepted. Menu item 9.2
opens up.

       
  


5. Press the key.


Menu item C9.2.1 opens up.

          
        

6. Enter the required adjustment factor.


7. Press the key.
The adjustment factor for TILT DOWN is accepted.

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ELECTRICAL SYSTEM
Calibration Menu

C10 Reach Retract


Adjusting the deceleration ramp for the reach carriage limit sections
The values can be set from 0 to 5. The lower the value, the more gentle the deceleration.
             
  


1. Press the key.


Menu item C10.1 opens up.
      
 
    

Adjusting the deceleration ramp for extending the reach carriage


2. Press the key.
Menu item C10.1.1 opens up.
      
   
  

3. Enter the required value.


4. Press the key.
The value is accepted and menu item C10.2 opens up.
    
     
   

Adjusting the deceleration ramp for retracting the reach carriage


5. Press the key.
Menu item C10.1.1 opens up.
      
  
 

6. Enter the required value.


7. Press the key.
The value is accepted.

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ELECTRICAL SYSTEM
Calibration Menu

C11 Save
Saving or rejecting changed values
The values changed in the Calibration menu are not stored permanently. In this menu item the values are either
written to the flash memory or the changes are rejected.
       
 

1. Press the key.


Menu item C11.1 opens up.
        


  

Rejecting changes
2. Press the key.
The changes are rejected.
Saving changes
1. Press the key
Menu item C10.1.1 opens up.
            
 


2. Press the key.


The changes are saved.
3. Switch the truck off and on again.
The changed values are imported when the truck starts up.

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ELECTRICAL SYSTEM
Features Menu

Features Menu
The Features menu allows you to select truck-specific defaults and activate or deactivate options, as well as
other basic functions.
Note: Save the changes in menu item F30 (Save ?) before switching off the truck, otherwise you will lose the
changes.

1. Activate the Service menu (see page 107) and scroll through to menu item FEATURES using the or
keys.

       

2. Press the key.
Menu item F1 opens up.

F1 Truck Size
Determining truck-specific defaults

         
 
  
1. Press the key.
Menu item F1.1 opens up.

          

  
Loading basic settings for trucks with 1.4 t or 1.6 t capacities
Only if the truck has a 1.4 t or 1.6 t capacity:
1. Press the key.
The basic settings for trucks with 1.4 t or 1.6 t capacities are loaded for
the next time the trucks starts.
Loading basic parameters for trucks with a 2.0 t capacity
1. Press the key.
Menu item F1.2 opens up.

   
     
  







 


1. Press the key.
The basic settings for trucks with a 2.0 t capacity are loaded for the
next time the trucks starts.

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139
ELECTRICAL SYSTEM
Features Menu

F2 Free Lift Switch


   
 

     
  
1. Press the key.
Menu item F2.1 opens up.

      


  
Loading basic settings for trucks with 1.4 or 1.6 t capacities
2. Press the key to activate NO (no FLS) or press to open menu
item F2.2.

        

  
3. Press to activate YES (FLS present).
Menu item F2 opens up and the status is displayed.

F3 Height Encoder
         


      
1. Press the key.
Menu item F3.1 opens up.

       
 


2. Press the key to activate NO (no ECR5) or press to open menu


item F3.2.

          
 

3. Press to activate YES (ECR5 present).
Menu item F3 opens up and the status is displayed.

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140
ELECTRICAL SYSTEM
Features Menu

F4 Lower Cut Out Switch


     
    


1. Press the key.
Menu item F4.1 opens up.
     

     
1. Press the key to activate NOT INSTALLED or press to open
menu item F4.2.
   
    
    
1. Press the key to activate INACTIVE (present, but not activated) or
press to open menu item F4.3.
   
   
   
2. Press the key to activate ACTIVE (LCS present and activated) or
press to open menu item F4.3.
Menu item F4 opens up and the status is displayed.

F5 5th Function
 
 
  

 
 

 




 
 
 
 


 



1. Press the key.
Menu item F5.1 opens up.


  
 
 
  
 





 

     
1. Press the key to activate OFF (not present) or press to open
menu item F4.2.
   
    
    
1. Press the key to activate INACTIVE (present, but not activated) or
press to open menu item F4.3.
   
   
   
2. Press the key to activate ACTIVE (LCS present and activated) or
press to open menu item F4.3.
Menu item F4 opens up and the status is displayed.

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141
ELECTRICAL SYSTEM
Features Menu

F6 Maximum Load
 
  

    
1. Press the key.
Menu item F6.1 opens up.

  
      
     
 
2. Enter the weight with maximum capacity (see capacity plate on truck).

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142
ELECTRICAL SYSTEM
Features Menu

F7 Capacity Data Monitor


    

         
1. Press the key.
Menu item F7.1 opens up.

      


  
2. Press to activate NO or to scroll to menu item F7.2 to select
YES.

     
   
 

3. Press to confirm YES.
4. Press to scroll to menu item F7.3.
The number of zones currently set (1 - 4) is displayed.

       
 
    
5. Press the key.
Menu item F7.3.1 opens up.

       
  
  
6. Enter the required total number of zones (1-4).
The selected zones light up in green on the capacity data monitor.









Fig. 67 CDM zones 1 to 4 (correspond-


ing to WT1 to WT4 and HT1 to
HT4)

7. Press to scroll to menu item F7.4.


The display shows the weight currently set for the selected
zone together with the height up to which the zone is valid

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143
ELECTRICAL SYSTEM
Features Menu

      




   




8. Press the key.
The display in menu item F7.4 changes to the weight entry.


            
   
9. Enter the maximum permissible weight for this zone.

F8 Travel Alarm
        

     
 
1. Press the key.
Menu item F8.1 opens up.

      

  
  
2. Press to select the required status (ON or OFF).
3. Press the key.
Menu item F8.2 opens up.

    
   
         
4. If the alarm is only to be activated for reverse travel (REV), press .
Otherwise press to scroll to menu item F8.3.


     
 
   
      
5. If the alarm is only to be activated for forward travel (FWD), press .
Otherwise press to scroll to menu item F8.4.

          
    
   
6. If the alarm is to be activated for both forward and reverse travel
(BOTH), press .

F9 Beacon
         

1. Press the key.
Menu item F9.1 opens up.

       

 
  
2. Press to select the required status (ON or OFF).
3. Press the key.
Menu item F9.2 opens up.

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144
ELECTRICAL SYSTEM
Features Menu

         
 
   
4. If the beacon is to be activated as soon as the truck is switched on,
press . Otherwise press to scroll to menu item F9.3.

         
 
      
5. If the beacon is only to be activated for reverse travel (REV), press .
Otherwise press to scroll to menu item F9.4.


      
 
   
   
6. If the beacon is only to be activated for forward travel (FWD), press .
Otherwise press to scroll to menu item F9.5.

   
     
   
  
 
7. If the beacon is to be activated for both forward and reverse travel
(BOTH), press . Otherwise press to scroll to menu item F9.6.

        
     

8. If the beacon is only to be activated manually with the switch, press .

F10 User Performance


Allocating user PINs and performance settings.

      
   
   
1. Press the key.
Menu item F9.1 opens up.


 
  
 

 

 

 

 

 













 



 
 


    
2. Press to select NO.
Note: If NO is selected each user is assigned performance setting P2. Per-
formance settings P1 and P3 are no longer available.
3. If performance settings P1 - P3 are to be made available to the user,
press .
Menu item F10.2 opens up.


    
 



 
 

 








    
4. Press to select YES.
Note: If YES is selected a user can be assigned performance settings P1,
P2 or P3.

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145
ELECTRICAL SYSTEM
Features Menu

F11 User Code


Menu F11 administers the user PINs (user codes).

        

   
1. Press the key.
Menu item F11.1 opens up.




 
  
 



 

 


 









 




 

 

   
Deactivating PIN use
2. Press to select NO.
PIN use is deactivated.
Note: If NO is selected each user is assigned performance setting P2. Per-
formance settings P1 and P3 are no longer available.
Activating PIN use
1. Press until YES is displayed.
2. Press the key.
Menu item F11.3 opens up.
        

Viewing user PINs and performance settings
1. Press the key.
The list with users opens up.

    

 
     
2. Press or to scroll through the list.
3. To abandon the list, press .
Adding user PINs and assigning performance settings
1. Starting at menu item F11.3 press .
Menu item F11.4 opens up.
       

1. Press the key.
The display changes to a prompt for the PIN and performance level.

      
  
    
2. Enter the 4-digit pin (user code).
The cursor jumps ahead for the performance setting entry.
       

     
3. Enter the required performance setting (P1, P2 or P3).
Deleting user PINs

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ELECTRICAL SYSTEM
Features Menu

1. Starting at menu item F11.4 press .


Menu item F11.5 opens up.
          

1. Press the key.
The display changes to user selection.

     
     
2. Press or to select the required entry.
3. Press to delete the entry.
The display returns to F11.5.

F12 Set Language


Menu F12 sets the language for the user messages.
The following languages are available:
English
German
French
Italian
Dutch
Spanish
Danish
Finnish
Swedish
Norwegian
Portuguese
Turkish
Polish
Czech
Hungarian
Slovenian
Greek

   
  
 
    
Enter the user message language
1. Press the key.
Menu item F12.1 opens up.




   
 
 


 

 











 



    
2. Press to scroll to the required language.
3. Press the key.
Menu item F12 opens up again and displays the required language.

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ELECTRICAL SYSTEM
Features Menu

F13 Change Unit


The following unit systems are available:
US (inch, lbs, mph etc.)
EURO (mm, kg, km/h etc.)

        

    
Changing the unit system
1. Press the key.
Menu item F13.1 opens up.





 
  

 




 


 

 

















 




    
2. Press to select the required unit system.
3. Press the key.
Menu item F13 opens up again and displays the required unit sys-
tem.

F14 Set Rack Select


       
    
     
Switching Rack Select on or off
1. Press the key.
Menu item F14.1 opens up.





   
 

 




 


 


 













 
 


    
2. Press to select YES (on) or NO (off).
3. Press the key.
Menu item F14 opens up again and displays the required status.

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ELECTRICAL SYSTEM
Features Menu

F15 Height/Weight
        

  
 
Switching lift height and weigth display on or off
Note: If NO is set here, the height and weight display is no longer active
for the user. However, the height encoder remains activated.
1. Press the key.
Menu item F15.1 opens up.





 
  



 

 

 



 


















 




    
2. Press to select YES (display on) or NO (display off).
3. Press the key.
Menu item F15 opens up again and displays the required status.

F16 Timer
  
     

    
Switching the timer on or off
Note: If NO is set, the timer in the display is no longer active for the user.
1. Press the key.
Menu item F16.1 opens up.





   


 



 


 













 





    
2. Press to select YES (timer on) or NO (timer off).
3. Press the key.
Menu item F16 opens up again and displays the required status.

F17 Error Log


        

     
Switching the error log on or off
Note: If NO is set, the error log in the display is no longer active for the
user.
1. Press the key.
Menu item F16.1 opens up.





   
 





 


 

















 



    
2. Press to select YES (error log on) or NO (errr log off).
3. Press the key.
Menu item F15 opens up again and displays the required status.

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ELECTRICAL SYSTEM
Features Menu

F18 Operator Alarm



      
  





 


      
Switching the audible signal for malfunctions on or off
1. Press the key.
Menu item F18.1 opens up.





   
 





 


 

















 




    
2. Press to select YES (alarm on) or NO (alarm off).
3. Press the key.
Menu item F18 opens up again and displays the required status.

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ELECTRICAL SYSTEM
Features Menu

F19 Battery Alarm


 
 
 
  
 
 
 

 


 


 
  
  
Switching the "Battery Discharged" message on and off or
determining the threshold
1. Press the key.
Menu item F19.1 opens up.





   
 
 

 

 



















 


 



    
2. Press to select the required status or alarm threshold.
Note: The statuses are OFF or there is an alarm at 20%, 30% or 40%
battery residual capacity.
3. Press the key.
Menu item F19 opens up again and displays the required status.

F20 Fork Positioning


 
 
 



 
  






 
  
 

Switching Tilt Position Assist on or off
1. Press the key.
Menu item F20.1 opens up.





 
  

 



 

 






















 
 



    
2. Press to select YES (alarm on) or NO (alarm off).
3. Press the key.
Menu item F20 opens up again and displays the required status.

F21 Choose Steering



 
 
 
 

 


  

 





 

 
 


   
Choosing the type of steering
1. Press the key.
Menu item F21.1 opens up.





   

 

 



 




 












 






 




    
2. Press to select the type of steering (180, 360 or BOTH).
Note: If BOTH is selected, the operator can choose himself.
3. Press the key.
Menu item F21 opens up again and displays the setting.

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ELECTRICAL SYSTEM
Features Menu

F25 Keyless Entry



        


 


 

  
 
 
Setting keyless truck power-up
1. Press the key.
Menu item F25.1 opens up.




 
  



 
 




 





















 

 


 

 
   

2. Press to select YES (power up without a key switch) or NO (power
up with a key switch).
3. Press the key.
Menu item F25.1 opens up again and displays the setting.
Entering the waiting period for rest mode
1. Otherwise press to scroll to menu item F25.2.
Menu item F25.2 opens up.





 

  



 
 




  
 

























 


 




 
 

  
   

2. Press the key.
Menu item F25.2.1 opens up.





 

  

  


 
 





 























 


 




 

  
   
3. Enter the waiting period (in minutes).

F26 Right Handle



  
 

 
  

 



 

 

   
Setting the hydraulic function controls
1. Press the key.
Menu item F26.1 opens up.




 
  

 

 




 






 















 






    
2. Press to select the control lever versions for the hydraulic functions:
S/D = Fingertip control lever or dual-axis hydraulic control lever
MTC = Multitask control handle
3. Press the key.
Menu item F26 opens up again and displays the setting.

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ELECTRICAL SYSTEM
Features Menu

F27 Options Display



   
   
  


 

     
Adjusting the seat heating
1. Press the key.
Menu item F27.1 opens up.
2. Otherwise press to scroll to menu item F27.4.
Note: Menu items F27.1 to F27.3 are void.





 
  

 

 

 



 












 



    

3. Press the key.
Menu item F27.4.1 opens up.




 
  
  

 


 

 
















 




    
4. Press to select Yes (seat heating on) or NO (seat heating off).
5. Press the key.

F28 Truck Lockout



  
 

 
   





 


 
  
Disabling the truck
1. Press the key.
Menu item F28.1 opens up.





 
  
 





 





















 
 


    
2. Press to select YES (truck disabled) or NO (truck not disabled).
3. Press the key.
The next time the truck starts Truck locked by Service is displayed.

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ELECTRICAL SYSTEM
Features Menu

F29 Direction Switch


     

   
  
Selecting the type of direction switch
1. Press the key.
Menu item F29.1 opens up.

         
 
 
2. Press ONE (1 direction switch) or TWO (2 direction switches).
3. Press the key.
Menu item F29 opens up again and displays the setting.

F30 Save ?
      

1. Press the key.
Menu item F30.1 opens up.

        

 
Rejecting changes
2. Press the key.
The changes are rejected.
Saving changes
1. Press the key
Menu item F30.2 opens up.

           

 
2. Press the key.
The changes are saved.
3. Switch the truck off and on again.
The changed values are imported when the truck starts up.

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ELECTRICAL SYSTEM
Hour Meter Menu

Hour Meter Menu

1. Activate the Service menu (see page 107) and scroll through to menu item HOUR METER using the or
keys.

        

2. Press the key.
Menu item H1 opens up.

H1 Truck Complete
Reading the total service hours

  
        
        
The total service hours are displayed.
3. Press the key.
Menu item H2 opens up.

H2 Traction Module
Reading the traction control module (TCM) service hours

          
    
     
The truck controller module (TCM) service hours are displayed.'
1. Press the key.
The following display opens up:

         











The service hours (in seconds) are shown for the 3 temperature
ranges Easy, Middle, Full :
Easy = temperature < 50 C
Middle = temperature > 50 C to 85 C
Full = temperature > 85 C

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ELECTRICAL SYSTEM
Hour Meter Menu

H3 Hydraulic Mod.
Reading the hydraulic control module (HCM) service hours

            
    
   
The hydraulic control module (HCM) service hours are displayed.'
1. Press the key.
The following display opens up:

         











The service hours (in seconds) are shown for the 3 temperature
ranges Easy, Middle, Full :
Easy = temperature < 50 C
Middle = temperature > 50 C to 85 C
Full = temperature > 85 C

H4 Key On Time
Reading the main control module (VCM) service hours

       
  
 
The hydraulic control module (VCM) service hours are displayed.'
1. Press the key.
The following display opens up:

         











The service hours (in seconds) are shown for the 3 temperature
ranges Easy, Middle, Full :
Easy = temperature < 50 C
Middle = temperature > 50 C to 85 C
Full = temperature > 85 C

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ELECTRICAL SYSTEM
Hour Meter Menu

H5 Set Service Time


Setting the service interval hours

   

    
  
1. Press the key.
Menu item H5.1 opens up.

    
  
 

2. Press to confirm NONE (service timer off) or to open menu item
H5.2.

          

   
1. Press the key.
2. Enter the service interval.

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ELECTRICAL SYSTEM
Log Events Menu

Log Events Menu

1. Activate the Service menu (see page 118) and scroll through to menu item LOG EVENTS using the or
keys.

        

2. Press the key.
Menu item L1 opens up.

L1 History
Displaying the last 16 events

       

1. Press the key.
The following display (example) opens up:

       
   
     
The codes are as follows:
120 = event code
12345 H = service hours since the event occurred
123C = temperature
OVER TEMP. = Over-temperature
STM = Steer motor
Note: A more detailed description of the event codes can be found starting
on page 173.
2. Press the key.
The next stored event opens up.

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ELECTRICAL SYSTEM
Log Events Menu

L2 Totals
Displaying the frequency of an event

       

1. Press the key.
The following display (example) opens up:

         
   
 
The codes are as follows:
EVENT 120 @ 10 = event code 120 has occurred 10 times.
Note: An event can be recorded up to a maximum of 255 times at which
point the counter starts again from scratch.
12345 H = service hours since the event occurred
OVER TEMP. = Over-temperature
STM = Steer motor
Note: A more detailed description of the event codes can be found starting
on page 173.
2. Press the key.
The next stored event opens up.

L3 Erase History
Clearing the event log

      

1. Press the key.
Menu item L3.1 opens up.

     
 
 
1. Press the key.
Menu item L3.1.1 opens up.

        
  

2. Press to select NO (do not clear) or YES (clear).
3. Press the key.
The LOG EVENTS display opens up again.

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ELECTRICAL SYSTEM
Performance Menu

Performance Menu

1. Activate the Service menu (see page 107) and scroll through to menu item PERFORMANCE using the
or keys.

        

2. Press the key.
Menu item P1 opens up.

P1 Setup P1
Entering the performance setting

        

1. Press to select performance setting P2 or P3.
2. Press to select P1.
Menu item P1.1 opens up.

         
     
 
Entering the maximum forward speed
3. Press the key.
4. Menu item P1.1.1 opens up.

           


   
     
1. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
2. Press the key.


        

      
Entering the maximum reverse speed
1. Press the key.
2. Menu item P1.2.1 opens up.

          


    
     
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
4. Press the key.
Menu item P1.3 opens up.

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ELECTRICAL SYSTEM
Performance Menu

       
       

Entering the maximum acceleration
1. Press the key.
2. Menu item P1.3.1 opens up.

         
 
    
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
4. Press the key.
Menu item P1.4 opens up.

   


     
Setting inversion braking
1. Press the key.
2. Menu item P1.4.1 opens up.

       
  
    
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
Note: Check the braking distance after changing the setting!
(see page 296).
4. Press the key.
Menu item P1.5 opens up.

   
 

   
Setting the coasting brake
1. Press the key.
2. Menu item P1.5.1 opens up.

       
 
      
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
4. Press the key.
Menu item P1.6 opens up.

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ELECTRICAL SYSTEM
Performance Menu

        
    
   
Setting the braking pattern
This setting affects the deceleration rate for speed changes.
1. Press the key.
2. Menu item P1.6.1 opens up.

       
  
    
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
4. Press the key.
Menu item P1.7 opens up.

    
  
   
Setting the service brake (brake pedal)
This setting determines the amount of additional brake force produced by
the electro-mechanical brake.
1. Press the key.
2. Menu item P1.7.1 opens up.


    
  
       
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
4. Press the key.
Menu item P1.8 opens up.

  
  

      
Setting the lift speed
1. Press the key.
2. Menu item P1.7.1 opens up.


        
       
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
4. Press the key.
Menu item P1.9 opens up.

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162
ELECTRICAL SYSTEM
Performance Menu


       
         
Setting the lift acceleration
1. Press the key.
2. Menu item P1.9.1 opens up.

         
  
    
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
4. Press the key.
Menu item P1.10 opens up.

      
  
   
Setting the lowering speed
1. Press the key.
2. Menu item P1.10.1 opens up.


      

 
      
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
4. Press the key.
Menu item P1.11 opens up.

      

   
 
Setting the lower speed limit range
1. Press the key.
2. Menu item P1.11.1 opens up.

     
     
       
3. Press to choose between SOFT and HARD.
4. Press the key.
Menu item P1.12 opens up.

     
 
   
Setting the mast "retract" speed
1. Press the key.
2. Menu item P1.12.1 opens up.

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ELECTRICAL SYSTEM
Performance Menu

     

 
       
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
4. Press the key.
Menu item P1.13 opens up.

     
 
  
Setting the tilt speed
1. Press the key.
2. Menu item P1.13.1 opens up.


        
      
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
4. Press the key.
Menu item P1.14 opens up.


    
   
  
Setting the sideshifter speed
1. Press the key.
2. Menu item P1.14.1 opens up.

     




       
3. Enter the new value.
Note: The default and maximum settings are shown in the 2nd row.
4. Press the key.

P2 Setup P2
Performance setting P2 is configured in the same way as P1. Refer to page 160.

P3 Setup P3
Performance setting P3 is configured in the same way as P1. Refer to page 160.

P4 BDI Setting
Setting the battery discharge indicator

     

  


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164
ELECTRICAL SYSTEM
Performance Menu

1. Press the key.


Menu item P4.1 opens up.

    
    
 
      
2. Enter a value between 1 and 9 to adapt the display to the battery dis-
charge characteristic curve.
Note: The lower the value, the further the battery will be discharged before
a warning is displayed.
3. Press the key.
Menu item P5 opens up.

P5 Travel > LCS


Setting the travel speed above the LOWER CUT OUT SWITCH

    
     

1. Press the key.
Menu item P5.1 opens up.

     
  
    
2. Enter a value between 1 and 9.
Note: 9 corresponds to the maximum speed, 1 corresponds to creep
speed.
Note: This setting affects the maximum values in menu items P6 and P7.
The value in P5 has priority over P6 and P7. P6 in turn has priority over the
value in P7.
Example: P5 is set to 5. P6 and P7 can only be 5. If however P6 is set to
4, P7 can only be 4.
3. Press the key.
Menu item P6 opens up.

P6 Travel > FLS


Setting the travel speed above the FREE LIFT SWITCH

    
     

1. Press the key.
Menu item P6.1 opens up.

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165
ELECTRICAL SYSTEM
Performance Menu

     
  
    
2. Enter a value between 1 and 9.
Note: 9 corresponds to the maximum speed, 1 corresponds to creep
speed. However the value cannot be greater than the setting in menu item
P5.
3. Press the key.
Menu item P7 opens up.

P7 Travel > Custom


Setting the travel speed above the CUSTOM HEIGHT


    
        
1. Press the key.
Menu item P6.1 opens up.

      
 
    
2. Enter a value between 1 and 9.
Note: 9 corresponds to the maximum speed, 1 corresponds to creep
speed. However the value cannot be greater than the setting in menu item
P6.
3. Press the key.
Menu item P8 opens up.

P8 Lower > Custom


Setting the lowering speed above the CUSTOM HEIGHT

     
   
    
1. Press the key.
Menu item P8.1 opens up.

      
 
    
2. Enter a value between 1 and 5.
Note: 5 corresponds to the maximum speed.
3. Press the key.
Menu item P9 opens up.

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ELECTRICAL SYSTEM
Performance Menu

P9 Reach > Custom


Setting the reach speed above the CUSTOM HEIGHT


    
        
1. Press the key.
Menu item P9.1 opens up.

      
  
    
2. Enter a value between 1 and 5.
Note: 5 corresponds to the maximum speed.
3. Press the key.
Menu item P10 opens up.

P10 5th Function Left


Setting the volume flow for the 5th function (left)

      
  
   
1. Press the key.
Menu item P10.1 opens up.

     
  
          
2. Enter a value between 6 L and 28 L.
Note: The value corresponds to the maximum volume flow when the con-
trol handle is fully applied.
3. Press the key.
Menu item P11 opens up.

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167
ELECTRICAL SYSTEM
Performance Menu

P11 5th Function Right


Setting the volume flow for the 5th function (right)

      
   
    
1. Press the key.
Menu item P11.1 opens up.

     
   
          
2. Enter a value between 6 L and 28 L.
Note: The value corresponds to the maximum volume flow when the con-
trol handle is fully applied.
3. Press the key.
Menu item P12 opens up.

P12 Steer Sensitivity


Setting the steering sensitivity

  


     
  
1. Press the key.
Menu item P12.1 opens up.


     
      
2. Enter a value between 1 and 9.
Note: 9 corresponds to the maximum sensitivity (very aggressive steer-
ing).
3. Press the key.
Menu item P14 opens up.

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168
ELECTRICAL SYSTEM
Performance Menu

P14 Brake at Ramp


Setting the brake pattern on ramps

    

       
1. Press the key.
Menu item P14.1 opens up.

       
 

2. Use to choose either NO (truck does not automatically brake on
ramps) or YES (truck brakes automatically on ramps).
3. Press the key.
Menu item P15 opens up.

P15 Set Default Values


Resetting all values in the Performance menu to defaults

 
     
    

1. Press the key.
Menu item P15.1 opens up.

       


  
2. Use to choose either NO (values are not reset) or YES (values are
reset).
3. Press the key.
Menu item P16 opens up.

P16 Save ?
Saving the changes in the Performance menu

      

1. Press the key.
Menu item P15.1 opens up.

        
  

2. Use to choose either NO (values are not saved) or YES (values are
saved).
3. Press the key.
Menu item PERFORMANCE opens up.

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169
ELECTRICAL SYSTEM
Utilities Menu

Utilities Menu

1. Activate the Service menu (see page 107) and scroll through to menu item UTILITIES using the or
keys.


 
  
  
  
 

2. Press the key.
Menu item U1 opens up.

U1 Software Version
Displaying the software version

  
  
     
1. Press the key.
Menu item U1.1 opens up.

      
  
Displaying the main control module (VCM) service hours
The software version of the main control module is displayed.
Displaying the traction control modules(TCM)softwareversion'
2. Press the key.
Menu item U1.2 opens up.

     







Displaying the hydraulic control module (HCM) software version


3. Press the key.
Menu item U1.3 opens up.

     







Displaying the steering control module (SCM) software version


4. Press the key.
Menu item U1.4 opens up.

     










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170
ELECTRICAL SYSTEM
Utilities Menu

Displaying the display software version


5. Press the key.
Menu item U1.5 opens up.

   
  
         
Note: EU indicates a display with all languages available for the operator
menu except Russian. RU indicates display with Russian for the operator
menu.

U2 Hour Set
Setting the service hours
Note: First read the current total number of service hours, see page 155.

        

1. Press the key.


Menu item U2.1 opens up.

        


 

    
2. Enter the required service hours.
Note: The number must be higher than the previous total.
3. Press the key.
4. Menu item U2.1.1 opens up.

          
 
     
5. Press to select YES (change setting) or NO (reject change).
6. Press the key.
The following display opens up:

        
   
  
7. Press and do not switch off the truck for at least 6 minutes.
Note: The main control module (VCM) stores the new setting every
0.1 hours. It will therefore take at most 6 minutes for the new setting to be
stored.

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171
ELECTRICAL SYSTEM
Utilities Menu

U3 Brake Override
Temporarily overriding the parking brake
If the steering control module identifies that the parking brake is not connected or has a short circuit, the main
contactor will not close. The truck cannot move. If this function is set to YES, the truck can be moved at creep
speed.

     

   
    
1. Press the key.
Menu item U3.1 opens up.

         
 
 
2. Press to select YES (override parking brake) or NO (do not override
parking brake).
3. Press the key.
Menu item U3 opens up and the status is displayed.

U4 Check Fan 1 - 4
1. Testing the fans

   
  
     
1. Press the key.
Menu item U4.1 opens up.

         
 

2. Press to select ON (FANs 1 - 4 on).
3. Press and test FANs 1-4
Menu item U4 opens up and the status is displayed.

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172
ELECTRICAL SYSTEM
Event Codes

Event Codes HGTS (Height switch)


HGTRS (Height reset switch)
The ESR 5000 is fitted with an electronic control sys-
tem for the key operating functions. BPS (Brake pressure switch)
ORS (Override switch)
Malfunctions with event code PLS (Pressure load switch)
display Locating malfunctions
Event codes are produced from tests carried out on the Malfunctions occur primarily on external components
inputs and outputs of control signals. For most faults such as fuses, solenoids, contactors, motors etc.
the system generates an event code and stores it in the These components are necessarily subject to a certain
log book (see Fig. 68). The last 16 events are dis- degree of wear.
played in the Log Events Menu (see page 158).
The next possible causes include connectors, wiring
Log book display and input devices such as switches, potentiometers or
encoders. These are subject above all to ambient con-
ditions.
  
The least likely to fail are the VCM (main module), TCM
(traction module), HCM (hydraulic module) and SCM
             (steer module) control modules.
    
    
The easiest way of locating a fault is to start trouble-
shooting on the component (the external component).
  This is the quickest way of obtaining a result.
The following sections list the event code numbers in
Fig. 68 Example of a log book entry
ascending order. In addition to each event code they
1 Event code number also list the possible causes, the effect on the truck and
2 Service hours at the time of the event troubleshooting notes.
3 Component temperature at time of event (if available)
4 Brief component description
5 Component name

Malfunctions without event code


display
The malfunctions that can occur without providing an
event code can fall into one of three categories.
Malfunction during start-up
Malfunctions in the power-up circuit can keep the truck
from powering up correctly (refer to the Power up cir-
cuit diagram, page 382).
Mechanical or hydraulic malfunctions
The malfunction occurs after the truck has started up,
but without an event code display.
The fault is mechanical or hydraulic. The correspond-
ing section in the maintenance section of this manual
can be used for troubleshooting purposes.
Malfunction in one of a group of unmonitored
inputs
One of the unmonitored inputs is causing the malfunc-
tion. They include:
HNS (Horn switch)

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173
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Codes 100 - 186


Event Code 100
Display: OVER CURRENT SDM
Explanation: Current in power part of steer module (SCM) > 40 A.
Effect: Parking brake applied
Traction module deactivated
Main contactor ED1 de-energised
Possible Causes: Error in internal power circuit of steer module
Remedy: Restart
1. Restart the truck.
If the fault persists, proceed to step 2.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
Replace the steer module
2. Replace the steer module (see page 259).

Event Code 101


Display: HIGH CURRENT SDM
Explanation: Current in power part of steer module (SCM) > 27 A and < 40 A.
Effect: Parking brake applied
Traction module deactivated
Main contactor ED1 de-energised
Possible Causes: Error in internal power circuit of steer module
Remedy: Restart
1. Restart the truck.
If the fault persists, proceed to step 2.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
Replace the steer module
2. Replace the steer module (see page 259).

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174
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 102


Display: ERROR STEER MOT.
Explanation: Open or shorted steer motor power circuit.
Effect: Parking brake applied.
Traction module deactivated
Main contactor ED1 de-energised
Possible Causes: Open circuit in or short circuit between phases R, S or T
Remedy: 1. Check power cables and connections.
2. Assess motor. Replace if faulty.

Event Code 110


Display: HIGH VOLTAGE SDM
Explanation: Overvoltage (> 63 V) in steer module power circuit.
Effect: Parking brake applied
Traction and hydraulic modules deactivated
Main contactor ED1 de-energised
Possible Causes: Emergency Disconnect pressed during plugging operation
Error in steer module
Remedy: Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.

ESR 5000

175
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 111


Display: LOW VOLTAGE SDM
Explanation: Low voltage (< 24 V) in steer module power circuit.
Effect: Parking brake applied
Traction and hydraulic modules deactivated
Main contactor ED1 de-energised
Possible Causes: Emergency Disconnect pressed during plugging operation
Error in steer module
Remedy: Check power cables
1. Check power cables.
If there is no damage, proceed to step 2.
Check battery voltage with load
2. In the Analyzer menu select item A2.36.
3. Raise a heavy load and monitor the battery voltage during the lifting
operation.
If the battery voltage drops significantly, proceed to step 4.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.
Repair the battery
4. Repair the battery in accordance with the manufacturers instructions or
replace it.

Event Code 112


Display: 15 VOLT SUPPLY SDM
Explanation: 15 V supply in the steer module faulty
Effect: Parking brake applied
Traction and hydraulic modules deactivated
Main contactor ED1 de-energised
Possible Causes: Error in steer module
Remedy: 1. Replace the steer module.

ESR 5000

176
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 120


Display: OVER TEMP SDM
Explanation: Steer module overtemperature (t > 85 C).
Effect: Parking brake applied
Traction module deactivated
Main contactor ED1 de-energised
Possible Causes: Steer module ventilation affected by:
Excessive ambient temperature
Overload
Contamination
Malfunction in power part of steer module
Remedy: Check application conditions and check for contamination
1. Check the application conditions with regard to ambient temperature and
load.
If the application conditions are difficult, adapt the performance setting.
2. Check the steer module for contamination.
Clean the steer module if contaminated.
Check the current consumption
3. Select item A2.32 in the Analyzer menu and check the steer motor con-
sumption when stationary and for slow steer operations.
If the consumption is consistently > 18 A there may be a mechanical
problem with the gear unit of the steer motor or with the drive transmis-
sion.
4. Jack up the truck and check the steer motor consumption again.
If the consumption is consistently > 6 A there may be a mechanical
problem with the gear unit of the steer motor or with the steering head
bearing.
Check for mechanical sluggishness
5. Check the steer motor gear unit and the steering head bearing for mechan-
ical sluggishness.
If one of them is sluggish, replace or repair the corresponding compo-
nent.
Check the steer motor and steer module
6. Check the current consumption with the steer motor and steering bearing
head installed.
If the consumption is still too high with the steer motor and steering
bearing head installed, the steer motor or steer module may be faulty.
Proceed to step 9.
Replace the steer module (SCM)
7. Replace the steer module (see page 259).
8. Check the current consumption with the steer motor and steering bearing
head installed.

ESR 5000

177
ELECTRICAL SYSTEM
Event Codes 100 - 186

Replace the steer motor


9. Replace the steer motor.
10. Check the current consumption with the steer motor installed.
If the consumption is still too high with the steer motor installed, the
steer module may be faulty. Proceed to step 7.
If the consumption is still too high, contact the Crown service department.

Event Code 121


Display: HIGH TEMP SDM
Explanation: Steer module internal temperature is > 75 C.
Effect: The display shows: HIGHTEMP STEERING MOTOR
Possible Causes: See event code 120, page 174.
Remedy: See event code 120, page 174.

Event Code 123


Display: OVER TEMP SMOT
Explanation: Steer motor coil temperature is > 150 C.
Effect: Parking brake applied
Traction module deactivated
Main contactor ED1 de-energised
Possible Causes: See event code 120, page 174.
Remedy: See event code 120, page 174.

Event Code 124


Display: OVER TEMP SMOT
Explanation: Steer motor overtemperature (t > 125 C).
Effect: The display shows: HIGHTEMP STEERING MOTOR
Possible Causes: See event code 120, page 174.
Remedy: See event code 120, page 174.

ESR 5000

178
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 130


Display: ERROR CANBUS SDM
Explanation: Communication error on the CAN Bus between the main module (VCM) and
the steer module (SCM).
Effect: Main contactor ED1 de-energised
Possible Causes: Wiring error
Error in main module (VCM)
Error in steer module (SCM)
Remedy: Measure the load resistance of the CAN Bus wiring between the main
module and the steer module
1. Measure the resistance between PC416-1 and -2.
If the resistance is 60 , the main and steer modules are ok.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 173). If the event occurs frequently, contact the Crown
service department.
If the resistance is 120 , then either the main module or steer module
is faulty. Proceed to step 2.
Measure the load resistance in the main module (VCM)
2. Disconnect PC205 from the main module.
3. Measure the resistance on the main module between PC205-22 and -23.
If the resistance is 120 , the main module is ok. Proceed to step 5:
If a different reading is obtained, the main module is faulty.
4. Replace the main module.
Measure the load resistance in the steer module (SCM)
5. Disconnect PC20 from the steer module.'
6. Measure the resistance on the steer module between PC205-10 and -11.
If the resistance is 120 , the steer module is ok.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.
If a different reading is obtained, the main module is faulty.
Replace the steer module (SCM)
7. Replace the steer module (see page 259).

ESR 5000

179
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 131


Display: ERROR EEPROM SDM
Explanation: Malfunction in memory module of steer module.
Effect: No direct effect
Possible Causes: Error in steer module
Remedy: Restart
1. Restart the truck.
If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the
Crown service department.
If the truck does not work, proceed to step 2.
Replace the steer module (SCM)
2. Replace the steer module (see page 259).

ESR 5000

180
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 160


Display: BRAKE COIL
Explanation: Open circuit or excessive current on steer module output to parking brake.
Effect: Truck comes to rest through plugging.
Traction module deactivated
Main contactor ED1 de-energised
Possible Causes: Fuse FU3 faulty
Wiring or connector damaged
Brake coil faulty
Remedy: Check fuse FU3
1. Check fuse FU3.
Replace if faulty. If the fuse is ok, proceed to step 2.
Check wires and connections
2. Check wires and connections for discontinuity and short circuits.
If there is no damage, proceed to step 3.
Measure the brake coil resistance
3. Using an ohmmeter measure the brake coil resistance.
Rated resistance approx. 32 (Crown motor) or 46.6 (Danaher mo-
tor). If the reading differs significantly, the brake coil is faulty. Proceed
to step 4.
Replace the brake coil
4. Replace the brake coil (see page 290).
Note: A truck with a faulty parking brake can be driven out of the aisle at creep
speed (see U3 Brake Override, page 172).

ESR 5000

181
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 180


Display: ECR3 HALL SENSOR
Explanation: Error in encoder ECR3 of steer motor.
ECR3 is a 2-channel Hall sensor fitted in the steer motor. This event code is
generated if a channel is not correctly identified or if 2 channels are shorted.
Effect: Parking brake applied
Traction module deactivated
Main contactor ED1 de-energised
Possible Causes: Wiring or connectors damaged
No +5 V supply
Remedy: Check wires and connections
1. Check wires and connections for discontinuity and short circuits.
If there is no damage, proceed to step 3.
Check +5 V supply
2. Disconnect PC414.
3. Using a voltmeter measure the voltage between PC414-5 and -6 and be-
tween PC414-7 and -8.
If there is a +5 V supply, proceed to step 4.
If there is no +5 V supply, proceed to step 6.
4. Reconnect PC414.
5. Using a voltmeter measure the voltage between PC436-1 and -2.
If there is a +5 V supply, proceed to step 7.
If there is no +5 V supply, this indicates that a wire has been discon-
nected. Proceed to step 8.
Replace steer module
6. Replace the steer module (see page 259).
Replace steer motor
7. Replace the steer module (see page 307).
Repair wiring
8. Repair the wiring.

ESR 5000

182
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 181


Display: ECR4 STEPPER MOTOR
Explanation: Error in steer encoder ECR4 (fitted on steering wheel).
ECR4 is a 4-channel Hall sensor fitted in the steer motor. This event code is
generated if a channel is not correctly identified or if 2 channels are shorted.
Effect: Parking brake applied
Traction module deactivated
Main contactor ED1 de-energised
Possible Causes: Wiring or connectors damaged
No +5 V supply
Remedy: Check wiring
9. Check the wiring between PC414 and CA204 for discontinuity and short
circuits.
If the wiring is faulty, proceed to step 12.
If the wiring is ok, proceed to step 10.
Check +5 V supply
10. Disconnect PC414.
11. Using a voltmeter measure the voltage between PC414-5 and -6 and be-
tween PC414-7 and -8.
If there is no 5 V supply, proceed to step 13.
If there is a +5 V supply, proceed to step 16.
Repair wiring
12. Repair the wiring.
Check +5 V output on the steer module
13. Disconnect CA204 from the steer module.
14. Measure the voltage between CA204-3 and -4.
If there is a +5 V supply, proceed to step 16.
If there is no 5 V supply, proceed to step 15
Replace the steer module
15. Replace the steer module (see page 259).
Replace sensor bearing ECR4
16. Replace sensor bearing ECR4.

ESR 5000

183
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 182


Display: SW1 OR 2 SW ERROR
Explanation: Switch signal of sensor switch SFS1 SA or SFS2 not detected.
The expected signal change did not occur when the drive wheel was turned.
Effect: An error routine is started (see page 303).
Possible Causes: Wiring or connector damaged
Incorrect screw depth of sensor SFS1 SA or SFS2
Sensor SFS1 SA or SFS2 faulty
12 V supply in display faulty
Remedy: Check wires and connections
1. Check wires and connections for discontinuity and short circuits.
If there is no damage, proceed to step 2.
Check 12 V sensor supply
2. Using a voltmeter measure the voltage (rated +12 V DC) at the following
points:
between CA203-14 and CA203-15 (with display connected)
between PC439-A and PC439-B
between PC438-1 and PC438-2
If there is no voltage present at PC439, but there is at CA203, check the
wires for discontinuity.
If there is a +12 V DC supply present on both connectors, proceed to
step 3.
Check sensor SFS1 SA
3. Set the drive wheel to the forward position.
4. Monitor the sensor LED while moving the drive wheel 20 to the left and to
the right. When moved to the left the LED should remain off and when
steered to the right it should be on.
If there is no change, the sensor may be loose or require adjusting:
check the attachment and screw depth (see page 306).
5. If the attachment and screw depth are ok, remove the sensor and hold the
front against a metal surface.
If the LED does not light up, replace the sensor (see page 306).
Replace the display
6. Replace the display (see page 259).

ESR 5000

184
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 183


Display: SFS2 SW EXPECTED
Explanation: Switch signal of sensor switch SFS2 not detected.
Quadrant recognition error.
Effect: An error routine is started (see page 303)
Possible Causes: Wiring or connector damaged
Screw depth of sensor SFS2 incorrectly set
Sensor SFS2 faulty
Remedy: Check wires and connections
1. Check wires and connections for discontinuity and short circuits.
If there is no damage, proceed to step 2.
Check 12 V sensor supply
2. Using a voltmeter measure the voltage between CA203-14 and CA203-15
(on the display) and between PC438-1 and PC438-2: Rated
voltage +12 V DC.
If there is no voltage at CA203, proceed to step 8.
If there is no voltage present at PC438, but there is at CA203, proceed
to step 9.
If there is a +12 V DC supply present on both connectors, proceed to
step 3.
Check sensor SFS2
3. Set the drive wheel to the forward position.
4. Monitor the sensor LED while moving the drive wheel more than 90 to the
right. When the wheel passes beyond 90 the LED should go out.
If there is no change, the sensor may be loose or require adjusting.
Proceed to step 5.
If the attachment and screw depth are ok, proceed to step 6.
Check the SFS2 attachment and screw depth
5. Check the attachment and screw depth (see page 306).
Test SFS2
6. Remove the sensor and connect it again.
7. Hold the front of the sensor against a metal surface.
If the LED does not light up, replace the sensor (see page 306).
Replace the display
8. Replace the display (see page 259).
Check wiring
9. Check the wires for discontinuity.

ESR 5000

185
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 184


Display: START ERROR SDM
Explanation: Incorrect drive wheel position detected. The stored drive wheel position does
not match the current position.
Effect: An error routine is started (see page 303)
Possible Causes: Wiring or connector damaged
Screw depth of sensor SFS1 SA incorrectly set
Sensor SFS1 SA faulty
Remedy: Check wires and connections
1. Check wires and connections for discontinuity and short circuits.
If there is no damage, proceed to step 2.
Check 12 V sensor supply
2. Using a voltmeter measure the voltage between CA203-14 and CA203-15
(on the display) and between PC439-A and PC439-B: Rated
voltage: +12 V DC.
If there is no voltage supply at CA203, replace the display.
If there is no voltage present at PC439, but there is at CA203, check the
wires for discontinuity.
If there is a +12 V DC supply present on both connectors, proceed to
step 3.
Check sensor SFS1 SA
3. Set the drive wheel to the forward position.
4. Monitor the sensor LED while moving the drive wheel 20 to the left and to
the right. When moved to the left the LED should remain off and when
steered to the right it should be on.
If there is no change, the sensor may be loose or require adjusting:
check the attachment and screw depth (see page 306).
5. If the attachment and screw depth are ok, remove the sensor and hold the
front against a metal surface.
If the LED does not light up, replace the sensor (see page 306).

ESR 5000

186
ELECTRICAL SYSTEM
Event Codes 100 - 186

Event Code 186


Display: TEMP. SENSOR SMOT
Explanation: Short circuit or open circuit in control circuit of steer motor thermal sensor
THS3.
Effect: Mast reach and lowering only
Travel only at crawl speed
Possible Causes: Wiring or connector damaged
Thermal sensor faulty
Remedy: Check wires and connections
1. Check wires and connections (PC436) for discontinuity and short circuits.
If there is no damage, proceed to step 2.
Measure the thermal sensor resistance
2. Disconnect PC436.
3. Using an ohmmeter measure the resistance between PC436-4 and
PC436-5. Rated resistance at t =20 C: 570 (PTC resistance, the resist-
ance increases as the temperature rises)
If the resistance < 500 or > 1 k, replace the steer motor.
If the resistance > 500 and < 1 k, proceed to step 4.
Replace the steer module (SCM)
4. Replace the steer module (see page 259).

ESR 5000

187
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Codes 200 - 286

Event Code 200


Display: HIGH CURRENT HM
Explanation: Current in power part of hydraulic module is too high (> 787 A).
Effect: Parking brake applied
Traction and hydraulic modules deactivated
Main contactor ED1 de-energised
Possible Causes: Short circuit in following components:
Power cable to pump motor
Pump motor coil
Hydraulic module output stage
Hydraulic pump blocked
Remedy: Check wires and connections
1. Check wires for short circuits.
If there is no damage, proceed to step 2.
Measure the pump motor insulation resistance
2. Power down the truck.
3. Check motor coil insulation resistance.
If a coil fails, proceed to step 4.
If the coils are ok, proceed to step 5.
Replace the pump motor
4. Replace the pump motor (see page 307).
Check the hydraulic pump for blockage
5. Remove the pump motor and check the pump for freedom of movement.
If the pump moves freely, proceed to step 6.
Replace the hydraulic module
6. Replace the hydraulic module (see page 259).

ESR 5000

188
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 201


Display: SHORT CIRCUIT HM
Explanation: Short circuit in power circuit of hydraulic module.
Effect: Traction and hydraulic modules deactivated
Main contactor ED1 de-energised
Parking brake applied
Possible Causes: Short circuit in following components:
Power cable to pump motor
Pump motor coil
Hydraulic module output stage
Remedy: Measure the pump motor insulation resistance
1. Power down the truck.
2. Check motor coil insulation resistance.
If a coil fails, proceed to step 3.
If the motor coils are ok, proceed to step 4.
Replace the pump motor
3. Replace the pump motor (see page 307).
Replace the hydraulic module
4. Replace the hydraulic module (see page 259).

ESR 5000

189
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 210


Display: HIGH VOLTAGE HM
Explanation: Overvoltage in hydraulic module power circuit (> 63 V).
Effect: Traction and hydraulic modules deactivated
Main contactor ED1 de-energised
Parking brake applied
Possible Causes: Emergency Disconnect pressed during plugging operation
Hydraulic module error
Remedy: Rule out operator errors
1. Ask the operator if the Emergency Disconnect has been applied during a
plugging operation.
If the Emergency Disconnect was not pressed during a plugging oper-
ation, proceed to step 2.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.
Replace the hydraulic module
2. Replace the hydraulic module (see page 259).

Event Code 211


Display: LOW VOLTAGE HM
Explanation: Overvoltage in hydraulic module power circuit (V < 18 V).
Effect: Traction and hydraulic modules deactivated
Main contactor ED1 de-energised
Parking brake applied
Possible Causes: Wiring error
Faulty battery
Hydraulic module error
Remedy: Check power cables
1. Check power cables.
If there is no damage, proceed to step 2.
Check battery voltage with load
2. In the Analyzer menu select item A2.36.
3. Raise a heavy load and monitor the battery voltage during the lifting
operation.
If the battery voltage drops significantly, proceed to step 4.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.

ESR 5000

190
ELECTRICAL SYSTEM
Event Codes 200 - 286

Repair the battery


4. Repair the battery in accordance with the manufacturers instructions or
replace it.

ESR 5000

191
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 212


Display: 15 VOLT SUPPLY HM
Explanation: Internal 15 V hydraulic module supply faulty.
Effect: Parking brake applied
Traction and hydraulic modules deactivated
Main contactor ED1 de-energised
Possible Causes: Hydraulic module error
Remedy: Replace the hydraulic module
1. Replace the hydraulic module (see page 259)

Event Code 213


Display: 5 VOLT SUPPLY HM
Explanation: Internal 5 V hydraulic module supply faulty.
Effect: Hydraulic drive module is deactivated
Travel at crawl speed enabled
Possible Causes: Hydraulic module error
Remedy: Replace the hydraulic module
1. Replace the hydraulic module (see page 259)

ESR 5000

192
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 214


Display: CAP CHARGE HM
Explanation: Capacitor charge time exceeded.
Effect: Main contactor ED1 does not close
Possible Causes: Wiring error
No B+ supply to hydraulic module
Hydraulic module faulty
Remedy: Check fuse FU7
1. Check fuse FU7.
Is FU7 has blown, proceed to step 6.
Is FU7 is ok, proceed to step 2.
Check wires (B+, B) and connections
2. Check wires for discontinuity and ensure connections are secure.
If there is no damage, proceed to step 3.
If there is damage, proceed to step 7.
Check B+ supply to hydraulic module
3. Power down the truck.
4. Connect voltmeter to B+ and B- of the hydraulic module.
5. Power up the truck.
The voltage should rise from 0 V on B+ within 2 seconds. If not, proceed
to step 8.
Replace fuse FU7
6. Replace fuse FU7.
7. Repair wiring or connections.
Replace the hydraulic module
8. Replace the hydraulic module (see page 259).

ESR 5000

193
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 220


Display: OVER TEMP. HM
Explanation: Hydraulic module overtemperature (t > 115 C)
Effect: Hydraulic drive module is deactivated
Travel at creep speed enabled
The display shows: OVER TEMP. HM
Possible Causes: Hydraulic module ventilation affected by:
Excessive ambient temperature
Overload
Contamination
Malfunction in power part of hydraulic module
Remedy: Test the fans
1. Test the fans (see U4 Check Fan 1 - 4, page 170).
If a faulty fan is discovered, proceed to step 2.
If the fans are working, proceed to step 3.
Replace the fans
2. Replace the fans.
Clean contaminated hydraulic module and air supplies
3. Clean the hydraulic module and air supplies if contaminated.
If the hydraulic module and air supplies are clean, proceed to step 4.
Check the application conditions
4. Check the application conditions with regard to ambient temperature and
load.
If the application conditions are difficult, adapt the performance setting.
See Performance Menu, page 160.
If the application conditions are not difficult and the error occurs fre-
quently, proceed to step 5.
Replace the hydraulic module
5. Replace the hydraulic module (see page 259).

ESR 5000

194
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 221


Display: OVER TEMP. HMOT
Explanation: Hydraulic motor coil overtemperature (t > 165 C)
Effect: Hydraulic module is deactivated
Travel at crawl speed enabled
The display shows: OVER TEMP. HMOT
Possible Causes: Hydraulic module ventilation affected by:
Excessive ambient temperature
Overload
Contamination
Remedy: Test the fans
1. Test the fans (see U4 Check Fan 1 - 4, page 170).
If a faulty fan is discovered, proceed to step 2.
If the fans are working, proceed to step 3.
Replace the fans
2. Replace the fans.
Clean contaminated hydraulic motor and air supplies
3. Clean the hydraulic motor and air supplies.
If the hydraulic motor and air supplies are clean, proceed to step 4.
Check the application conditions
4. Check the application conditions with regard to ambient temperature and
load.
If the application conditions are difficult, adapt the performance setting.
See Performance Menu, page 160.
If the application conditions are not difficult and the error occurs fre-
quently, proceed to step 5.
Monitor the frequency of the event
5. Monitor the frequency of the event.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.

ESR 5000

195
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 222


Display: HIGH TEMP. HM
Explanation: Excessive temperature in hydraulic module (t > 85 C)
Effect: Between 85 C and 115 C the hydraulic module output current is reduced
in proportion to the rise in temperature down to 0 A.
The display shows: HIGH TEMP. HM
Possible Causes: Hydraulic module ventilation affected by:
Excessive ambient temperature
Overload
Contamination
Malfunction in power part of hydraulic module
Remedy: Test the fans
1. Test the fans (see U4 Check Fan 1 - 4, page 170).
If a faulty fan is discovered, proceed to step 2.
If the fans are working, proceed to step 3.
Replace the fans
2. Replace the fans.
Clean contaminated hydraulic module and air supplies
3. Clean the hydraulic module and air supplies if contaminated.
If the hydraulic module and air supplies are clean, proceed to step 4.
Check the application conditions
4. Check the application conditions with regard to ambient temperature and
load.
If the application conditions are difficult, adapt the performance setting.
See Performance Menu, page 160.
If the application conditions are not difficult and the error occurs fre-
quently, proceed to step 5.
Replace the hydraulic module
5. Replace the hydraulic module (see page 259).

ESR 5000

196
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 223


Display: LOW TEMP. HM
Explanation: Too low temperature in hydraulic module (t < -20 C)
Effect: The display shows: LOW TEMP. HM
Possible Causes: Truck has been parked for too long in a cold environment
Remedy: Check the application conditions
1. Check the application conditions.
If the truck has been parked in temperatures below -20 C, proceed to
step 2
If the truck has been parked in temperatures above 0 C, proceed to
step 3
Instruct the operator
2. Inform the operator that the truck must never be parked in temperatures
below 0 C.
Monitor the frequency of the event
3. Monitor the frequency of the event.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.

ESR 5000

197
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 224


Display: HIGH TEMP. HMOT
Explanation: Excessive temperature in hydraulic motor coil (t > 145 C)
Effect: Between 145 C and 165 C the hydraulic module output current is re-
duced in proportion to the rise in temperature down to 0 A.
The display shows: HIGH TEMP. HMOT
Possible Causes: Hydraulic module ventilation affected by:
Excessive ambient temperature
Overload
Contamination
Remedy: Test the fans
1. Test the fans (see U4 Check Fan 1 - 4, page 170).
If a faulty fan is discovered, proceed to step 2.
If the fans are working, proceed to step 3.
Replace the fans
2. Replace the fans.
Clean contaminated hydraulic motor and air supplies
3. Clean the hydraulic motor and air supplies.
If the hydraulic motor and air supplies are clean, proceed to step 4.
Check the application conditions
4. Check the application conditions with regard to ambient temperature and
load.
If the application conditions are difficult, adapt the performance setting.
See Performance Menu, page 160.
If the application conditions are not difficult and the error occurs fre-
quently, proceed to step 5.
Monitor the frequency of the event
5. Monitor the frequency of the event.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.

ESR 5000

198
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 225


Display: LOW TEMP. HMOT
Explanation: Too low temperature in hydraulic motor (t < -30 C)
Effect: The display shows: LOW TEMP. HMOT
Possible Causes: Truck has been parked for too long in a cold environment.
Remedy: Check the application conditions
1. Check the application conditions.
If the truck has been parked in temperatures below -30 C, proceed to
step 2
If the truck has been parked in temperatures above 0 C, proceed to
step 3
Instruct the operator
2. Inform the operator that the truck must never be parked in temperatures
below 0 C.
Monitor the frequency of the event
3. Monitor the frequency of the event.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.

ESR 5000

199
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 240


Display: POT2 ABOVE LIMIT
Explanation: The voltage on the slider of potentiometer POT2 is permanently monitored
during power-up and operation. The upper limit of 10.8 volts has been ex-
ceeded.
Effect: Hydraulic functions are deactivated
Possible Causes: Wiring short circuit
Potentiometer faulty
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.4 (see page 119).
2. Apply Lift/Lower".
If approx. 12 V is displayed, either there is a short circuit or an input on
the VCM is faulty. Proceed to step 3.
Check the potentiometer wiring
3. Check the potentiometer wiring for a short circuit.
If the wiring is ok, proceed to step 4.
Measure the voltage levels on the potentiometer with a multimeter
4. Using a multimeter measure the voltage between CA407-2 and CA407-1.
If approx. 12 V are displayed, this indicates the potentiometer is faulty.
Proceed to step 8.
5. Leave the control handle in neutral and using a multimeter measure the
voltage between CA407-2 and CA407-1.
It should be 4.3 5.3 V.
6. Move the control handle as far as the stop in the "Lift" position and using
a multimeter measure the voltage between CA407-2 and CA407-1.
It should be 7.8 9.5 V.
7. Move the control handle as far as the stop in the "Lower" position and
using a multimeter measure the voltage between CA407-2 and CA407-1.
It should be 0.7 1.9 V.
If normal readings are taken in steps 5 to 7, this indicates the potentiome-
ter is ok.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display.
If normal readings are taken in steps 5 to 7 but approx. 12 V are displayed
in the Analyzer menu, this indicates that the VCM input is faulty. Proceed
to step 9.
Replace the potentiometer
8. Replace the potentiometer POT2 (see page 268).
Replace the main module (VCM)
9. Replace the VCM (see page 258).

ESR 5000

200
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 241


Display: POT2 UNDER LIMIT
Explanation: The voltage on the slider of potentiometer POT2 is permanently monitored
during power-up and operation. The reading has dropped below the lower limit
of 0.6 volts.
Effect: Hydraulic functions are deactivated
Possible Causes: Short circuit or discontinuity in wiring
Potentiometer faulty
Faulty contact in connector or potentiometer
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.4 (see page 119).
2. Apply Lift/Lower".
If approx. 0 V are displayed, there is either an open circuit between
CA407-2, CA407-1 and the main module (VCM) or a short circuit be-
tween CA407-2 and CA407-3. proceed to step 3.
Check the potentiometer wiring
3. Check the wiring to connectors PC407 and PC205 for discontinuity and
short circuits.
If the wiring is ok, proceed to step 4.
Measure the voltage levels on the potentiometer with a multimeter
4. Leave the control handle in neutral and using a multimeter measure the
voltage between CA407-2 and CA407-1.
It should be 4.3 5.3 V.
5. Move the control handle as far as the stop in the "Lift" position and using
a multimeter measure the voltage between CA407-2 and CA407-1.
It should be 7.8 9.5 V.
6. Move the control handle as far as the stop in the "Lower" position and
using a multimeter measure the voltage between CA407-2 and CA407-1.
It should be 0.7 1.9 V.
If normal readings are taken in steps 5 to 7, this indicates the potentiome-
ter is ok.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display.
If normal readings are taken in steps 5 to 7 but approx. 0 V are displayed
in the Analyzer menu, this indicates a transient event.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
Replace the potentiometer
7. Replace the potentiometer POT2 (see page 268).

ESR 5000

201
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 243


Display: POT3 ABOVE LIMIT
Explanation: The voltage on the slider of potentiometer POT3 is permanently monitored
during power-up and operation. The upper limit of 10.8 volts has been ex-
ceeded.
Effect: Hydraulic functions are deactivated
Possible Causes: Wiring short circuit
Potentiometer faulty
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.5 (see page 119).
2. Apply Lift/Lower".
If approx. 12 V is displayed, either there is a short circuit or an input on
the VCM is faulty. Proceed to step 3.
Check the potentiometer wiring
3. Check the potentiometer wiring for a short circuit.
If the wiring is ok, proceed to step 4.
Measure the voltage levels on the potentiometer with a multimeter
4. Using a multimeter measure the voltage between CA408-2 and CA408-1.
If approx. 12 V are displayed, this indicates the potentiometer is faulty.
Proceed to step 8.
5. Leave the control handle in neutral and using a multimeter measure the
voltage between CA408-2 and CA408-1.
It should be 4.3 5.3 V.
6. Move the control handle as far as the stop in the "Lift" position and using
a multimeter measure the voltage between CA408-2 and CA408-1.
It should be 7.8 9.5 V.
7. Move the control handle as far as the stop in the "Lower" position and
using a multimeter measure the voltage between CA408-2 and CA408-1.
It should be 0.7 1.9 V.
If normal readings are taken in steps 5 to 7, this indicates the potentiome-
ter is ok.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display.
If normal readings are taken in steps 5 to 7 but approx. 12 V are displayed
in the Analyzer menu, this indicates that the VCM input is faulty. Proceed
to step 9.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
Replace the potentiometer
8. Replace the potentiometer POT3 (see page 268).
Replace the main module (VCM)
9. Replace the VCM (see page 258).

ESR 5000

202
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 244


Display: POT3 UNDER LIMIT
Explanation: The voltage on the slider of potentiometer POT3 is permanently monitored
during power-up and operation. The reading has dropped below the lower limit
of 0.6 volts.
Effect: Hydraulic functions are deactivated
Possible Causes: Short circuit or discontinuity in wiring
Potentiometer faulty
Faulty contact in connector or potentiometer
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.5 (see page 119).
2. Apply Lift/Lower".
If approx. 0 V are displayed, there is either an open circuit between
CA408-2, CA408-1 and the main module (VCM) or a short circuit be-
tween CA408-2 and CA408-3. proceed to step 3.
Check the potentiometer wiring
3. Check the wiring to connectors PC408 and PC205 for discontinuity and
short circuits.
If the wiring is ok, proceed to step 4.
Measure the voltage levels on the potentiometer with a multimeter
4. Leave the control handle in neutral and using a multimeter measure the
voltage between CA408-2 and CA408-1.
It should be 4.3 5.3 V.
5. Move the control handle as far as the stop in the "Lift" position and using
a multimeter measure the voltage between CA408-2 and CA408-1.
It should be 7.8 9.5 V.
6. Move the control handle as far as the stop in the "Lower" position and
using a multimeter measure the voltage between CA408-2 and CA408-1.
It should be 0.7 1.9 V.
If normal readings are taken in steps 5 to 7, this indicates the potentiome-
ter is ok.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display.
If normal readings are taken in steps 5 to 7 but approx. 0 V are displayed
in the Analyzer menu, this indicates a transient event.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
Replace the potentiometer
7. Replace the potentiometer POT2 (see page 268).

ESR 5000

203
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 246


Display: POT4 ABOVE LIMIT
Explanation: The voltage on the slider of potentiometer POT4 is permanently monitored
during power-up and operation. The upper limit of 10.8 volts has been ex-
ceeded.
Note: For trucks with the multi-task control handle (MTC) this event code indi-
cates an incorrect setting in the F26 Right Handle menu, page 152.
Effect: Hydraulic functions are deactivated
Possible Causes: Wiring short circuit
Potentiometer faulty
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.6 (see page 119).
2. Apply Lift/Lower".
If approx. 12 V is displayed, either there is a short circuit or an input on
the VCM is faulty. Proceed to step 3.
Check the potentiometer wiring
3. Check the potentiometer wiring for a short circuit.
If the wiring is ok, proceed to step 4.
Measure the voltage levels on the potentiometer with a multimeter
4. Using a multimeter measure the voltage between CA409-2 and CA409-1.
If approx. 12 V are displayed, this indicates the potentiometer is faulty.
Proceed to step 8.
5. Leave the control handle in neutral and using a multimeter measure the
voltage between CA409-2 and CA409-1.
It should be 4.3 5.3 V.
6. Move the control handle as far as the stop in the "Lift" position and using
a multimeter measure the voltage between CA409-2 and CA409-1.
It should be 7.8 9.5 V.
7. Move the control handle as far as the stop in the "Lower" position and
using a multimeter measure the voltage between CA409-2 and CA409-1.
It should be 0.7 1.9 V.
If normal readings are taken in steps 5 to 7, this indicates the potentiome-
ter is ok.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display
If normal readings are taken in steps 5 to 7 but approx. 12 V are displayed
in the Analyzer menu, this indicates that the VCM input is faulty. Proceed
to step 9.
Replace the potentiometer
8. Replace the potentiometer POT4 (see page 268).
Replace the main module (VCM)
9. Replace the VCM (see page 258).

ESR 5000

204
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 247


Display: POT4 UNDER LIMIT
Explanation: The voltage on the slider of potentiometer POT4 is permanently monitored
during power-up and operation. The reading has dropped below the lower limit
of 0.6 volts.
Note: For trucks with the multi-task control handle (MTC) this event code indi-
cates an incorrect setting in the F26 Right Handle menu, page 152.
Effect: Hydraulic functions are deactivated
Possible Causes: Short circuit or discontinuity in wiring
Potentiometer faulty
Faulty contact in connector or potentiometer
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.6 (see page 119).
2. Apply Lift/Lower".
If approx. 0 V are displayed, there is either an open circuit between
CA409-2, CA409-1 and the main module (VCM) or a short circuit be-
tween CA409-2 and CA409-3. proceed to step 3.
Check the potentiometer wiring
3. Check the wiring to connectors PC409 and PC205 for discontinuity and
short circuits.
If the wiring is ok, proceed to step 4.
Measure the voltage levels on the potentiometer with a multimeter
4. Leave the control handle in neutral and using a multimeter measure the
voltage between CA409-2 and CA409-1.
It should be 4.3 5.3 V.
5. Move the control handle as far as the stop in the "Lift" position and using
a multimeter measure the voltage between CA409-2 and CA409-1.
It should be 7.8 9.5 V.
6. Move the control handle as far as the stop in the "Lower" position and
using a multimeter measure the voltage between CA409-2 and CA409-1.
It should be 0.7 1.9 V.
If normal readings are taken in steps 5 to 7, this indicates the potentiome-
ter is ok.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display.
If normal readings are taken in steps 5 to 7 but approx. 0 V are displayed
in the Analyzer menu, this indicates a transient event.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
Replace the potentiometer
7. Replace the potentiometer POT4 (see page 268).

ESR 5000

205
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 249


Display: POT5 ABOVE LIMIT
Explanation: The voltage on the slider of potentiometer POT5 is permanently monitored
during power-up and operation. The upper limit of 10.8 volts has been ex-
ceeded.
Effect: Hydraulic functions are deactivated
Possible Causes: Wiring short circuit
Potentiometer faulty
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.7 (see page 119).
2. Apply Lift/Lower".
If approx. 12 V is displayed, either there is a short circuit or an input on
the VCM is faulty. Proceed to step 3.
Check the potentiometer wiring
3. Check the potentiometer wiring for a short circuit.
If the wiring is ok, proceed to step 4.
Measure the voltage levels on the potentiometer with a multimeter
4. Using a multimeter measure the voltage between CA410-2 and CA410-1.
If approx. 12 V are displayed, this indicates the potentiometer is faulty.
Proceed to step 8.
5. Leave the control handle in neutral and using a multimeter measure the
voltage between CA41008-2 and CA410-1.
It should be 4.3 5.3 V.
6. Move the control handle as far as the stop in the "Lift" position and using
a multimeter measure the voltage between CA410-2 and CA410-1.
It should be 7.8 9.5 V.
7. Move the control handle as far as the stop in the "Lower" position and
using a multimeter measure the voltage between CA410-2 and CA410-1.
It should be 0.7 1.9 V.
If normal readings are taken in steps 5 to 7, this indicates the potentiome-
ter is ok.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display.
If normal readings are taken in steps 5 to 7 but approx. 12 V are displayed
in the Analyzer menu, this indicates that the VCM input is faulty. Proceed
to step 9.
Replace the potentiometer
8. Replace the potentiometer POT5 (see page 268).
Replace the main module (VCM)
9. Replace the VCM (see page 258).

ESR 5000

206
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 250


Display: POT5 UNDER LIMIT
Explanation: The voltage on the slider of potentiometer POT5 is permanently monitored
during power-up and operation. The reading has dropped below the lower limit
of 0.6 volts.
Effect: Hydraulic functions are deactivated
Possible Causes: Short circuit or discontinuity in wiring
Potentiometer faulty
Faulty contact in connector or potentiometer
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.7 (see page 119).
2. Apply Lift/Lower".
If approx. 0 V are displayed, there is either an open circuit between
CA410-2, CA410-1 and the main module (VCM) or a short circuit be-
tween CA410-2 and CA410-3. proceed to step 3.
Check the potentiometer wiring
3. Check the wiring to connectors PC410 and PC205 for discontinuity and
short circuits.
If the wiring is ok, proceed to step 4.
Measure the voltage levels on the potentiometer with a multimeter
4. Leave the control handle in neutral and using a multimeter measure the
voltage between CA41008-2 and CA410-1.
It should be 4.3 5.3 V.
5. Move the control handle as far as the stop in the "Lift" position and using
a multimeter measure the voltage between CA410-2 and CA410-1.
It should be 7.8 9.5 V.
6. Move the control handle as far as the stop in the "Lower" position and
using a multimeter measure the voltage between CA410-2 and CA410-1.
It should be 0.7 1.9 V.
If normal readings are taken in steps 5 to 7, this indicates the potentiome-
ter is ok.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display.
If normal readings are taken in steps 5 to 7 but approx. 0 V are displayed
in the Analyzer menu, this indicates a transient event.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
Replace the potentiometer
7. Replace the potentiometer POT5 (see page 268).

ESR 5000

207
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 260


Display: SVH LIFT VALVE
Explanation: Overcurrent detected on SVH valve coil during lifting operation. Output to SVH
cut out by VCM.
Effect: All outputs to the hydraulic valve coils are cut out.
Possible Causes: Faulty coil
Wiring short circuit
Main module VCM faulty
Remedy: Measure the coil resistance
1. Disconnect PC807 from valve.
2. Measure resistance between pin 2 and pin 3 on the coil.
If the resistance is 75 , proceed to step 4.
If the resistance is not 75 , proceed to step 3.
Replace the coil
3. Replace the coil.
Check the wiring for short circuits
4. Attach connector PC807.
5. Start up the truck.
6. Leave the "Lift/Lower" control handle in neutral and measure the voltage
between PC422-9 and B.
If B+ is present, proceed to step 7. If not, proceed to step 10.
7. Disconnect PC807 from the valve and measure the voltage again between
PC422-9 and B.
If B+ is still present, this indicates a short circuit to B+ between PC807-
3 and PC205-1. Proceed to step 12.
If B+ is not present, proceed to step 8.
8. Power down the truck.
9. Re-connect PC807. Proceed to step 13.
Locate and repair disconnected wires
10. Check for disconnected wires.
Is a wire is disconnected, proceed to step 11.
If not, proceed to step 7.
11. Repair the wire.
Locate and clear short circuits
12. Clear the short circuit to B+ in the wire from PC807-3 to PC205-1.
Check the driver output from the main module (VCM)
13. Start up the truck.
14. Connect the voltmeter between PC422-9 and B.
15. Activate "Lift" as far as the stop and record the voltage.
The reading should drop to approx. 15 V. If not, proceed to step 16.
Replace the main module (VCM)
16. Replace the VCM (see page 258).

ESR 5000

208
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 261


Display: PVL LOWER VALVE
Explanation: Overcurrent detected on PVL valve coil during lowering operation. Output to
PVL cut out by VCM.
Effect: All outputs to the hydraulic valve coils are cut out.
Possible Causes: Faulty coil
Wiring short circuit
Main module VCM faulty
Remedy: Measure the coil resistance
1. Disconnect PC807 from valve.
2. Measure resistance between pin 1 and pin 2 on the coil.
If the resistance is 27 , proceed to step 4.
If the resistance is not 27 , proceed to step 3.
Replace the coil
3. Replace the coil.
Check the wiring for short circuits
4. Attach connector PC807.
5. Start up the truck.
6. Leave the "Lift/Lower" control handle in neutral and measure the voltage
between PC422-8 and B.
If B+ is present, proceed to step 7. If not, proceed to step 10.
7. Disconnect PC807 from the valve and measure the voltage again between
PC422-42 and B.
If B+ is still present, this indicates a short circuit to B+ between PC807-
1 and PC205-42. Proceed to step 12.
If B+ is not present, proceed to step 8.
8. Power down the truck.
9. Re-connect PC807. Proceed to step 13.
Locate and repair disconnected wires
10. Check for disconnected wires.
Is a wire is disconnected, proceed to step 11.
If not, proceed to step 7.
11. Repair the wire.
Locate and clear short circuits
12. Clear the short circuit to B+ in the wire from PC807-1 to PC205-42.
Check the driver output from the main module (VCM)
13. Start up the truck.
14. Connect the voltmeter between PC422-8 and B.
15. Activate "Lift" as far as the stop and record the voltage.
The reading should drop to approx. 15 V. If not, proceed to step 16.
Replace the main module (VCM)
16. Replace the VCM (see page 258).

ESR 5000

209
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 262


Display: PVRT RETRACT VA.
Explanation: Overcurrent detected on PVRT valve coil during mast reach carriage retract
operation. Output to PVRT cut out by VCM.
Effect: All outputs to the hydraulic valve coils are cut out.
Possible Causes: Faulty coil
Wiring short circuit
Main module VCM faulty
Remedy: Measure the coil resistance
1. Disconnect PC810 from valve.
2. Measure resistance between pin 1 and pin 2 on the coil.
If the resistance is 25 , proceed to step 4.
If the resistance is not 25 , proceed to step 3.
Replace the coil
3. Replace the coil.
Check the wiring for short circuits
4. Connect PC810.
5. Start up the truck.
6. Leave the "Reach" control handle in neutral and measure the voltage be-
tween PC422-16 and B.
If B+ is present, proceed to step 7. If not, proceed to step 10.
7. Disconnect PC810 from the valve and measure the voltage again between
PC422-16 and B.
If B+ is still present, this indicates a short circuit to B+ between PC810-
1 and PC205-29. Proceed to step 12.
If B+ is not present, proceed to step 8.
8. Power down the truck.
9. Re-connect PC810. Proceed to step 13.
Locate and repair disconnected wires
10. Check for disconnected wires.
Is a wire is disconnected, proceed to step 11.
If not, proceed to step 7.
11. Repair the wire.
Locate and clear short circuits
12. Clear the short circuit to B+ in the wire from PC810-1 to PC205-29.
Check the driver output from the main module (VCM)
13. Start up the truck.
14. Connect the voltmeter between PC422-16 and B.
15. Activate "Retract reach carriage" as far as the stop and record the voltage.
The reading should drop to approx. 35 V. If not, proceed to step 16.
Replace the main module (VCM)
16. Replace the VCM (see page 258).

ESR 5000

210
ELECTRICAL SYSTEM
Event Codes 200 - 286

Event Code 263


Display: PVRE REACH VALVE
Explanation: Overcurrent detected on PVRE valve coil during mast reach carriage extend
operation. Output to PVRE cut out by VCM.
Effect: All outputs to the hydraulic valve coils are cut out.
Possible Causes: Faulty coil
Wiring short circuit
Main module VCM faulty
Remedy: Measure the coil resistance
1. Disconnect PC808 from valve.
2. Measure resistance between pin 1 and pin 2 on the coil.
If the resistance is 25 , proceed to step 4.
If the resistance is not 25 , proceed to step 3.
Replace the coil
3. Replace the coil.
Check the wiring for short circuits
4. Connect PC808.
5. Start up the truck.
6. Leave the "Reach" control handle in neutral and measure the voltage be-
tween PC422-10 and B.
If B+ is present, proceed to step 7. If not, proceed to step 10.
7. Disconnect PC808 from the valve and measure the voltage again between
PC422-10 and B.
If B+ is still present, this indicates a short circuit to B+ between PC808-
2 and PC205-15. Proceed to step 12.
If B+ is not present, proceed to step 8.
8. Power down the truck.
9. Re-connect PC808. Proceed to step 13.
Locate and repair disconnected wires
10. Check for disconnected wires.
Is a wire is disconnected, proceed to step 11.
If not, proceed to step 7.
11. Repair the wire.
Locate and clear short circuits
12. Clear the short circuit to B+ in the wire from PC808-2 to PC205-15.
Check the driver output from the main module (VCM)
13. Start up the truck.
14. Connect the voltmeter between PC422-10 and B.
15. Activate "Extend reach carriage" as far as the stop and record the voltage.
The reading should drop to approx. 31 V. If not, proceed to step 16.

ESR 5000

211
ELECTRICAL SYSTEM
Event Codes 200 - 286

Replace the main module (VCM)


16. Replace the VCM (see page 258).

Event Code 264


Display: PVAL ACCESSORY L
Explanation: Overcurrent detected on PVAL valve coil as 5th function left is performed.
Output to PVAL cut out by VCM.
Effect: All outputs to the hydraulic valve coils are cut out.
Possible Causes: Faulty coil
Wiring short circuit
Main module VCM faulty
Remedy: Measure the coil resistance
1. Disconnect PC809 from valve.
2. Measure resistance between pin 1 and pin 2 on the coil.
If the resistance is 25 , proceed to step 4.
If the resistance is not 25 , proceed to step 3.
Replace the coil
3. Replace the coil.
Check the wiring for short circuits
4. Connect PC809.
5. Start up the truck.
6. Leave the "5th function" control handle in neutral and measure the voltage
between PC422-12 and B.
If B+ is present, proceed to step 7. If not, proceed to step 10.
7. Disconnect PC809 from the valve and measure the voltage again between
PC422-12 and B.
If B+ is still present, this indicates a short circuit to B+ between PC809-
2 and PC205-13. Proceed to step 12.
If B+ is not present, proceed to step 8.
8. Power down the truck.
9. Re-connect PC809. Proceed to step 13.
Locate and repair disconnected wires
10. Check for disconnected wires.
Is a wire is disconnected, proceed to step 11.
If not, proceed to step 7.
11. Repair the wire.
Locate and clear short circuits
12. Clear the short circuit to B+ in the wire from PC809-2 to PC205-13.

ESR 5000

212
ELECTRICAL SYSTEM
Event Codes 200 - 286

Check the driver output from the main module (VCM)


13. Start up the truck.
14. Connect the voltmeter between PC422-12 and B.
15. Change to the 5th function.
16. Apply 5th function left as far as the stop and record the voltage.
The reading should drop to approx. 29 V. If not, proceed to step 17.
Replace the main module (VCM)
17. Replace the VCM (see page 258).

Event Code 265


Display: PVAR ACCESSORY R
Explanation: Overcurrent detected on PVAR valve coil as 5th function right is performed.
Output to PVAR cut out by VCM.
Effect: All outputs to the hydraulic valve coils are cut out.
Possible Causes: Faulty coil
Wiring short circuit
Main module VCM faulty
Remedy: Measure the coil resistance
1. Disconnect PC811 from valve.
2. Measure resistance between pin 1 and pin 2 on the coil.
If the resistance is 25 , proceed to step 4.
If the resistance is not 25 , proceed to step 3.
Replace the coil
3. Replace the coil.
Check the wiring for short circuits
4. Attach connector PC811.
5. Start up the truck.
6. Leave the "5th function" control handle in neutral and measure the voltage
between PC422-11 and B.
If B+ is present, proceed to step 7. If not, proceed to step 10.
7. Disconnect PC811 from the valve and measure the voltage again between
PC422-11 and B.
If B+ is still present, this indicates a short circuit to B+ between PC811-
2 and PC205-27. Proceed to step 12.
If B+ is not present, proceed to step 8.
8. Power down the truck.
9. Re-connect PC811. Proceed to step 13.

ESR 5000

213
ELECTRICAL SYSTEM
Event Codes 200 - 286

Locate and repair disconnected wires


10. Check for disconnected wires.
Is a wire is disconnected, proceed to step 11.
If not, proceed to step 7.
11. Repair the wire.
Locate and clear short circuits
12. Clear the short circuit to B+ in the wire from PC811-2 to PC205-27.
Check the driver output from the main module (VCM)
13. Start up the truck.
14. Connect the voltmeter between PC422-11 and B.
15. Change to the 5th function.
16. Apply 5th function right as far as the stop and record the voltage.
The reading should drop to approx. 29 V. If not, proceed to step 17.
Replace the main module (VCM)
17. Replace the VCM (see page 258).

Event Code 266


Display: SVT TILT VALVE
Explanation: Overcurrent detected on SVT valve coil as tilting is performed. Output to SVT
cut out by VCM.
Effect: All outputs to the hydraulic valve coils are cut out.
Possible Causes: Faulty coil
Wiring short circuit
Main module VCM faulty
Remedy: Measure the coil resistance
1. Disconnect PC801 from valve.
2. Measure resistance between pin 1 and pin 2 on the coil.
If the resistance is 39 , proceed to step 4.
If the resistance is not 39 , proceed to step 3.
Replace the coil
3. Replace the coil.

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Check the wiring for short circuits


4. Connect PC801.
5. Start up the truck.
6. Leave the "fork tilt" control handle in neutral and measure the voltage be-
tween PC422-1 and B.
If B+ is present, proceed to step 7. If not, proceed to step 10.
7. Disconnect PC801 from the valve and measure the voltage again between
PC422-1 and B.
If B+ is still present, this indicates a short circuit to B+ between PC801-
2 and PC205-41. Proceed to step 12.
If B+ is not present, proceed to step 8.
8. Power down the truck.
9. Re-connect PC801. Proceed to step 13.
Locate and repair disconnected wires
10. Check for disconnected wires.
Is a wire is disconnected, proceed to step 11.
If not, proceed to step 7.
11. Repair the wire.
Locate and clear short circuits
12. Clear the short circuit to B+ in the wire from PC801-2 to PC205-41.
Check the driver output from the main module (VCM)
13. Start up the truck.
14. Connect the voltmeter between PC422-1 and B.
15. Activate "fork tilt" as far as the stop and record the voltage.
The reading should drop to approx. 15 V. If not, proceed to step 16.
Replace the main module (VCM)
16. Replace the VCM (see page 258).

Event Code 267


Display: SVS SIDE SHIFT V
Explanation: Overcurrent detected on SVS valve coil as sideshift is performed. Output to
SVS cut out by VCM.
Effect: All outputs to the hydraulic valve coils are cut out.
Possible Causes: Faulty coil
Wiring short circuit
Main module VCM faulty
Remedy: Measure the coil resistance
1. Disconnect PC801 from valve.
2. Measure resistance between pin 5 and pin 6 on the coil.
If the resistance is 39 , proceed to step 4.
If the resistance is not 39 , proceed to step 3.
Replace the coil
3. Replace the coil.

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Event Codes 200 - 286

Check the wiring for short circuits


4. Connect PC801.
5. Start up the truck.
6. Leave the "sideshift" control handle in neutral and measure the voltage
between PC422-5 and B.
If B+ is present, proceed to step 7. If not, proceed to step 10.
7. Disconnect PC801 from the valve and measure the voltage again between
PC422-5 and B.
If B+ is still present, this indicates a short circuit to B+ between PC801-
5 and PC205-12. Proceed to step 12.
If B+ is not present, proceed to step 8.
8. Power down the truck.
9. Re-connect PC801. Proceed to step 13.
Locate and repair disconnected wires
10. Check for disconnected wires.
Is a wire is disconnected, proceed to step 11.
If not, proceed to step 7.
11. Repair the wire.
Locate and clear short circuits
12. Clear the short circuit to B+ in the wire from PC801-5 to PC205-12.
Check the driver output from the main module (VCM)
13. Start up the truck.
14. Connect the voltmeter between PC422-5 and B.
15. Activate "sideshift" as far as the stop and record the voltage.
The reading should drop to approx. 15 V. If not, proceed to step 16.
Replace the main module (VCM)
16. Replace the VCM (see page 258).

Event Code 268


Display: SV5 5TH FUNC. AV
Explanation: Overcurrent detected on SV5 valve coil as the 5th function is performed. Out-
put to SV5 cut out by VCM.
Effect: All outputs to the hydraulic valve coils are cut out.
Possible Causes: Faulty coil
Wiring short circuit
Main module VCM faulty
Remedy: Measure the coil resistance
1. Disconnect PC801 from valve.
2. Measure resistance between pin 7 and pin 8 on the coil.
If the resistance is 39 , proceed to step 4.
If the resistance is not 39 , proceed to step 3.

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Event Codes 200 - 286

Replace the coil


3. Replace the coil.
Check the wiring for short circuits
4. Connect PC801.
5. Start up the truck.
6. Leave the "5th function" control handle in neutral and measure the voltage
between PC422-5 and B.
If B+ is present, proceed to step 7. If not, proceed to step 10.
7. Disconnect PC801 from the valve and measure the voltage again between
PC422-18 and B.
If B+ is still present, this indicates a short circuit to B+ between PC801-
8 and PC205-26. Proceed to step 12.
If B+ is not present, proceed to step 8.
8. Power down the truck.
9. Re-connect PC801. Proceed to step 13.
Locate and repair disconnected wires
10. Check for disconnected wires.
Is a wire is disconnected, proceed to step 11.
If not, proceed to step 7.
11. Repair the wire.
Locate and clear short circuits
12. Clear the short circuit to B+ in the wire from PC801-8 to PC205-26.
Check the driver output from the main module (VCM)
13. Start up the truck.
14. Connect the voltmeter between PC422-18 and B.
15. Apply the 5th function as far as the stop and record the voltage.
The reading should drop to approx. 15 V. If not, proceed to step 17.
Replace the main module (VCM)
16. Replace the VCM (see page 258).

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Event Codes 200 - 286

Event Code 280


Display: CURR SENSOR HM
Explanation: Offset error detected in current sensors to monitor the hydraulic module power
circuit during power-up.
Effect: Hydraulic module is deactivated
Travel at crawl speed enabled
Possible Causes: Hydraulic module faulty
Remedy: Replace the hydraulic module
1. Replace the hydraulic module (see page 259).

Event Code 281


Display: TEMP. SENSOR HM
Explanation: Open circuit or short circuit detected in hydraulic module thermal sensors.
Effect: Reach and fork lower are still enabled
Travel at crawl speed enabled
Possible Causes: Hydraulic module faulty
Remedy: Replace the hydraulic module
1. Replace the hydraulic module (see page 259).

Event Code 282


Display: ECR2 SHORT CIRC.
Explanation: Short circuit between channels A and B of encoder ECR2.
Effect: Reach and fork lower are still enabled
Travel at crawl speed enabled
Possible Causes: Encoder ECR2 faulty
Encoder wiring short circuit
Main module or hydraulic module faulty
Remedy: Check the module and encoder
1. Select Analyzer menu A2.29 (see page 120).
2. Extend and retract the reach carriage.
If SET SPEED = 1000 (for reach carriage extend) and
SET SPEED = 530 (for reach carriage retract) are displayed, proceed
to step 5.
If SET SPEED = 0 is displayed, proceed to step 3.

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Event Codes 200 - 286

Check the wiring between VCM and HCM


3. Check the wiring between PC429 and CA 201 for short circuits.
If no error is found, proceed to step 4.
Replace encoder ECR2
4. Replace sensor bearing (ECR2).
If the event code persists, proceed to step 5.
Replace the hydraulic module
5. Replace the hydraulic module (see page 259).

Event Code 283


Display: ECR2 OPEN CIRC.
Explanation: Open circuit or no power supply to encoder ECR2.
Effect: Reach and fork lower are still enabled
Travel at crawl speed enabled
Possible Causes: Encoder ECR2 faulty
Encoder wiring disconnected
Main module or hydraulic module faulty
Remedy: Check the encoder power supply
1. Disconnect PC429.
For Danaher motors:
2. Measure the voltage between PC429-1 and PC429-4.
It should be 12 V. If not, proceed to step 6.
If there is a 12 V supply, proceed to step 4.
For Crown motors:
3. Measure the voltage between PC429-1 and PC429-2.
It should be 12 V. If not, proceed to step 6.
If there is a 12 V supply, proceed to step 4.
Check the module and encoder
4. Select Analyzer menu A2.29 (see page 120).
5. Extend and retract the reach carriage.
If SET SPEED = 1000 (for reach carriage extend) and
SET SPEED = 530 (for reach carriage retract) are displayed, proceed
to step 5.
If SET SPEED = 0 is displayed, proceed to step 7.
Check the wiring between VCM and HCM
6. Check the wiring between PC429 and CA 201.
If no error is found, proceed to step 7.
Replace encoder ECR2
7. Replace sensor bearing (ECR2).
Replace the hydraulic module
8. Replace the hydraulic module (see page 259).

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Event Codes 200 - 286

Event Code 284


Display: ECR2 LOST CHANN.
Explanation: No channel A or B on encoder ECR2.
Effect: Reach and fork lower are still enabled
Travel at crawl speed enabled
Possible Causes: Encoder ECR2 faulty
Encoder wiring disconnected
Main module or hydraulic module faulty
Remedy: Check the module and encoder
1. Select Analyzer menu A2.29 (see page 120).
2. Extend and retract the reach carriage.
If SET SPEED = 1000 (for reach carriage extend) and
SET SPEED = 530 (for reach carriage retract) are displayed, proceed
to step 4.
If SET SPEED = 0 is displayed, proceed to step 3.
Check the wiring between VCM and HCM
3. Check for disconnect wires between PC429 and CA 201.
If no error is found, proceed to step 4.
Replace encoder ECR2
4. Replace sensor bearing (ECR2).
If the event code persists, proceed to step 5.
Replace the hydraulic module
5. Replace the hydraulic module (see page 259).

Event Code 285


Display: TEMP. SENSOR HMOT
Explanation: Open circuit or short circuit detected in pump motor thermal sensor.
Effect: Reach and fork lower are still enabled
Travel at crawl speed enabled
Possible Causes: Faulty wiring
THS2 faulty
Remedy: Check the wiring
1. Check for short circuits or wire disconnections between CA201-17,
CA201-16 and CA430-1 and CA430-2.
If the wiring is faulty, proceed to step 2. If not, proceed to step 3.
Repair wiring
2. Repair the wiring.

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220
ELECTRICAL SYSTEM
Event Codes 200 - 286

Measure THS2 resistance


3. Disconnect PC430.
4. Measure THS2 resistance between CA430-1 and -2.
If the resistance < 500 or > 1 k, proceed to step 5.
If the resistance is approx. 600 (rated resistance for t =20 C is
600 ), monitor the error frequency.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
Replace the pump motor
5. Replace the pump motor (see page 279).

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221
ELECTRICAL SYSTEM
Event Codes 300 - 385

Event Codes 300 - 385

Event Code 300


Display: HIGH CURRENT TM
Explanation: Current in power part of traction module is too high (> 525 A).
Effect: Parking brake applied
Traction and hydraulic modules deactivated
Main contactor ED1 de-energised
Possible Causes: Short circuit in following components:
Power cable to traction motor
Traction motor coil
Traction module output stage
Blocked drive
Remedy: Check wires and connections
1. Check wires for short circuits.
If there is no damage, proceed to step 2.
Measure the traction motor insulation resistance
2. Power down the truck.
3. Check the motor coil insulation resistance.
If a coil fails, proceed to step 4.
If the coils are ok, proceed to step 5.
Replace the traction motor
4. Replace the traction motor (see page 273).
Check the drive for blockage
5. Check the drive for freedom of movement.
If the drive moves freely, proceed to step 6.
Replace the traction module
6. Replace the traction module (see page 258).

Event Code 301


Display: SHORT CIRCUIT TM
Explanation: Short circuit in power circuit of traction module.
Effect: Traction and hydraulic modules deactivated
Main contactor ED1 de-energised
Parking brake applied
Possible Causes: Short circuit in following components:
Power cable to traction motor
Traction motor coil
Traction module output stage

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Event Codes 300 - 385

Remedy: Measure the traction motor insulation resistance


1. Power down the truck.
2. Check the motor coil insulation resistance.
If a coil fails, proceed to step 3.
If the motor coils are ok, proceed to step 4.
Replace the traction motor
3. Replace the traction motor (see page 273).
Replace the traction module
4. Replace the traction module (see page 258).

Event Code 311


Display: LOW VOLTAGE TM
Explanation: Low voltage in traction module power circuit (V < 18 V).
Effect: Traction and hydraulic modules deactivated
Main contactor ED1 de-energised
Parking brake applied
Possible Causes: Wiring error
Faulty battery
Error in traction drive module
Remedy: 1. Check power cables.
If there is no damage, proceed to step 2.
2. Check battery voltage with load:
In the Analyzer menu select item A2.36.
Raise a heavy load and monitor the battery voltage during the lifting
operation.
If the battery voltage drops significantly, repair the battery.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.

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ELECTRICAL SYSTEM
Event Codes 300 - 385

Event Code 312


Display: 15 VOLT SUPPLY TM
Explanation: 15 V traction module supply faulty.
Effect: Truck stops through plugging
Traction module deactivated
Mast reach and lowering only
Possible Causes: Error in traction module
Remedy: Replace traction module
1. Replace the traction module (see page 258)

Event Code 313


Display: 5 VOLT SUPPLY TM
Explanation: 5 V traction module supply faulty.
Effect: Truck stops through plugging
Traction module deactivated
Mast reach and lowering only
Possible Causes: Error in traction module
Remedy: Replace traction module
1. Replace the traction module (see page 258)

Event Code 314


Display: CAP CHARGE TM
Explanation: Capacitor charge time exceeded.
Effect: Main contactor ED1 does not close
Possible Causes: Wiring error
No B+ supply to traction module
Traction module faulty
Remedy: Check wires (B+, B) and connections
1. Check for disconnected wires and make sure connections are secure.
If there is no damage, proceed to step 2.
Check B+ supply to traction module
2. Power down the truck.
3. Connect voltmeter to B+ and B- of the traction module.
4. Power up the truck.
The voltage should rise from 0 V on B+ within 2 seconds. If not, proceed
to step 5.
Replace traction module
5. Replace the traction module (see page 258)

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ELECTRICAL SYSTEM
Event Codes 300 - 385

Event Code 320


Display: OVER TEMP. TM
Explanation: Traction module overtemperature (t > 115 C)
Effect: Traction module deactivated
Mast reach and lowering only
The display shows: OVER TEMP. TM
Possible Causes: Traction module ventilation affected by:
Excessive ambient temperature
Overload
Contamination
Malfunction in power part of traction module
Remedy: Test the fans
1. Test the fans (see U4 Check Fan 1 - 4, page 170).
If a faulty fan is discovered, proceed to step 2.
If the fans are working, proceed to step 3.
Replace the fans
2. Replace the fans.
Clean contaminated traction module and air supplies
3. Clean contaminated traction module and air supplies.
If the traction module and air supplies are clean, proceed to step 4.
Check the application conditions
4. Check the application conditions with regard to ambient temperature and
load.
If the application conditions are difficult, adapt the performance setting.
See Performance Menu, page 160.
If the application conditions are not difficult and the error occurs fre-
quently, proceed to step 5.
Replace hydraulic module
5. Replace the hydraulic module (see page 259).

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225
ELECTRICAL SYSTEM
Event Codes 300 - 385

Event Code 321


Display: OVER TEMP. TMOT
Explanation: Traction motor coil overtemperature (t > 165 C)
Effect: Traction module deactivated
Travel at crawl speed enabled
The display shows: OVER TEMP. TMOT
Possible Causes: Traction motor ventilation affected by:
Excessive ambient temperature
Overload
Contamination
Remedy: Test the fans
1. Test the fans (see U4 Check Fan 1 - 4, page 170).
If a faulty fan is discovered, proceed to step 2.
If the fans are working, proceed to step 3.
Replace the fans
2. Replace the fans.
Clean contaminated traction motor and air supplies
3. Clean traction motor and air supplies.
If the traction motor and air supplies are clean, proceed to step 4.
Check the application conditions
4. Check the application conditions with regard to ambient temperature and
load.
If the application conditions are difficult, adapt the performance setting.
See Performance Menu, page 160.
If the application conditions are not difficult and the error occurs fre-
quently, proceed to step 5.
Monitor the frequency of the event
5. Monitor the frequency of the event.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.

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ELECTRICAL SYSTEM
Event Codes 300 - 385

Event Code 322


Display: HIGH TEMP. TM
Explanation: Excessive temperature in traction module (t > 85 C)
Effect: Between 85 C and 115 C the traction module output current is reduced in
proportion to the rise in temperature down to 0 A.
The display shows: HIGH TEMP. TM
Possible Causes: Traction module ventilation affected by:
Excessive ambient temperature
Overload
Contamination
Malfunction in power part of traction module
Remedy: Test the fans
1. Test the fans (see U4 Check Fan 1 - 4, page 170).
If a faulty fan is discovered, proceed to step 2.
If the fans are working, proceed to step 3.
Replace the fans
2. Replace the fans.
Clean contaminated traction module and air supplies
3. Clean contaminated traction module and air supplies.
If the traction module and air supplies are clean, proceed to step 4.
Check the application conditions
4. Check the application conditions with regard to ambient temperature and
load.
If the application conditions are difficult, adapt the performance setting.
See Performance Menu, page 160.
If the application conditions are not difficult and the error occurs fre-
quently, proceed to step 5.
Replace traction module
5. Replace the traction module (see page 259).

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227
ELECTRICAL SYSTEM
Event Codes 300 - 385

Event Code 323


Display: LOW TEMP. TM
Explanation: Too low temperature in traction module (t < -20 C)
Effect: The display shows: LOW TEMP. TM
Possible Causes: Truck has been parked for too long in a cold environment
Remedy: Check the application conditions
1. Check the application conditions.
If the truck has been parked in temperatures below -20 C, proceed to
step 2
If the truck has been parked in temperatures above 0 C, proceed to
step 3
Instruct the operator
2. Inform the operator that the truck must never be parked in temperatures
below 0 C.
Monitor the frequency of the event
3. Monitor the frequency of the event.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.

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228
ELECTRICAL SYSTEM
Event Codes 300 - 385

Event Code 324


Display: HIGH TEMP. TMOT
Explanation: Excessive temperature in traction motor coil (t > 145 C)
Effect: Between 145 C and 165 C the traction module output current is reduced
in proportion to the rise in temperature down to 0 A.
The display shows: HIGH TEMP. TMOT
Possible Causes: Traction module ventilation affected by:
Excessive ambient temperature
Overload
Contamination
Remedy: Test the fans
1. Test the fans (see U4 Check Fan 1 - 4, page 170).
If a faulty fan is discovered, proceed to step 2.
If the fans are working, proceed to step 3.
Replace the fans
2. Replace the fans.
Clean contaminated traction motor and air supplies
3. Clean traction motor and air supplies.
If the traction motor and air supplies are clean, proceed to step 4.
Check the application conditions
4. Check the application conditions with regard to ambient temperature and
load.
If the application conditions are difficult, adapt the performance setting.
See Performance Menu, page 160.
If the application conditions are not difficult and the error occurs fre-
quently, proceed to step 5.
Monitor the frequency of the event
5. Monitor the frequency of the event.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.

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ELECTRICAL SYSTEM
Event Codes 300 - 385

Event Code 325


Display: LOW TEMP. TMOT
Explanation: Too low temperature in traction motor (t < -30 C)
Effect: The display shows: LOW TEMP. TMOT
Possible Causes: Truck has been parked for too long in a cold environment.
Remedy: Check the application conditions
1. Check the application conditions.
If the truck has been parked in temperatures below -30 C, proceed to
step 2
If the truck has been parked in temperatures above 0 C, proceed to
step 3
Instruct the operator
2. Inform the operator that the truck must never be parked in temperatures
below 0 C.
Monitor the frequency of the event
3. Monitor the frequency of the event.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.

Event Code 330


Display: ERROR CANBUS TM
Explanation: Communication error on the CAN Bus between the main module (VCM) and
the traction module (TCM).
Effect: Main contactor ED1 de-energised
Possible Causes: Wiring error
Error in main module (VCM)
Error in steer module (SCM)
Remedy: Measure the load resistance of the CAN Bus wiring between the main
module and the traction module
1. Measure the resistance between PC416-1 and -2.
If the resistance is 60 , the main and traction modules are ok.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.
If the resistance is 120 , then either the main module or traction mod-
ule is faulty. Proceed to step 2.

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230
ELECTRICAL SYSTEM
Event Codes 300 - 385

Measure the load resistance in the main module (VCM)


2. Disconnect PC205 from the main module.
3. Measure the resistance on the main module between PC205-22 and -23.
If the resistance is 120 , the main module is ok. Proceed to step 5:
If a different reading is obtained, the main module is faulty.
4. Replace the main module.
Measure the load resistance in the traction module (TCM)
5. Disconnect PC204 from the traction module.
6. Measure the resistance on the traction module between PC205-22 and -
23.
If the resistance is 120 , the traction module is ok.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.
If a different reading is obtained, the traction module is faulty. Proceed
to step 7.
Replace the traction module (TCM)
7. Replace the traction module (see page 258).

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ELECTRICAL SYSTEM
Event Codes 300 - 385

Event Code 340


Display: POT1 ABOVE LIMIT
Explanation: The voltage on the slider of potentiometer POT1 is permanently monitored
during power-up and operation. The upper limit of 10.8 volts has been ex-
ceeded.
Effect: Travel functions are deactivated
Possible Causes: Wiring short circuit
Potentiometer faulty
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.3 (see page 119).
2. Depress accelerator.
If 0 V is displayed, there is either an open circuit between CA407-2,
CA407-1 and the main module (VCM) or a short circuit between CA407-
2 and CA407-3. Proceed with step 3.
Check the potentiometer wiring
3. Check the wiring to connectors PC407 and PC205 for discontinuity and
short circuits.
If the wiring is ok, proceed to step 4.
Measure the voltage levels on the potentiometer with a multimeter
4. Leave the accelerator pedal in neutral and using a multimeter measure the
voltage between CA407-2 and CA407-1.
It should be 0.7 1.5 V.
5. Depress the accelerator pedal as far as the stop and using a multimeter
measure the voltage between CA407-2 and CA407-1.
It should be 9.5 10.5 V.
If normal readings are taken in steps 4 to 5, this indicates the potentiome-
ter is ok. If not, proceed to step 233.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display.
If normal readings are taken in steps 4 to 5 but approx. 0 V are displayed
in the Analyzer menu, this indicates a transient event.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
Replace the potentiometer
6. Replace potentiometer POT1 (see page 267).

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ELECTRICAL SYSTEM
Event Codes 300 - 385

Event Code 341


Display: POT1 UNDER LIMIT
Explanation: The voltage on the slider of potentiometer POT1 is permanently monitored
during power-up and operation. The reading has dropped below the lower limit
of 0.6 volts.
Effect: Travel functions are deactivated
Possible Causes: Short circuit or discontinuity in wiring
Potentiometer faulty
Faulty contact in connector or potentiometer
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.3 (see page 119).
2. Depress accelerator.
If 0 V is displayed, there is either an open circuit between CA407-2,
CA407-1 and the main module (VCM) or a short circuit between CA407-
2 and CA407-3. Proceed with step 3.
Check the potentiometer wiring
3. Check the wiring to connectors PC407 and PC205 for discontinuity and
short circuits.
If the wiring is ok, proceed to step 4.
Measure the voltage levels on the potentiometer with a multimeter
4. Leave the accelerator pedal in neutral and using a multimeter measure the
voltage between CA407-2 and CA407-1.
It should be 0.7 1.5 V.
5. Depress the accelerator pedal as far as the stop and using a multimeter
measure the voltage between CA407-2 and CA407-1.
It should be 9.5 10.5 V.
If normal readings are taken in steps 4 to 5, this indicates the potentiome-
ter is ok. If not, proceed to step 233.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display.
If normal readings are taken in steps 4 to 5 but approx. 0 V are displayed
in the Analyzer menu, this indicates a transient event.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
Replace the potentiometer
6. Replace potentiometer POT1 (see page 267).

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ELECTRICAL SYSTEM
Event Codes 300 - 385

Event Code 343


Display: POT1/ACS STATUS
Explanation: The voltage reading supplied from POT1 does not match the value expected
by the current switch position of the ACS.
Effect: Travel functions are deactivated
Possible Causes: Short circuit or discontinuity in wiring
ACS switch faulty
Potentiometer POT1 faulty
Calibration faulty
Remedy: Test potentiometer POT1
1. In the Analyzer menu select item A2.3 (see page 119).
2. Depress accelerator.
If 0 V is displayed, there is either an open circuit between CA418-2,
CA418-1 and the main module (VCM) or a short circuit between CA418-
2 und CA418-3. Proceed with step 3.
Check the potentiometer wiring
3. Check the wiring to connectors PC418 and PC205 for discontinuity and
short circuits.
If the wiring is ok, proceed to step 4.
Record the voltage readings on the potentiometer with a multimeter and
compare them with the display in the Analyzer menu
4. Leave the accelerator pedal in neutral and using a multimeter measure the
voltage between CA418-2 and CA418-1.
It should be 0.7 1.5 V.
5. Depress the accelerator pedal as far as the stop and using a multimeter
measure the voltage between CA418-2 and CA418-1.
It should be 9.5 10.5 V.
6. In the Analyzer menu, item A2.3 (see page 119) compare the recordings
with the display reading.
If normal readings are taken in steps 4 to 5 but approx. 0 V is displayed
in the Analyzer menu, this indicates a transient event. Proceed to
step 7.
Restart the truck
7. Restart the truck
If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the
Crown service department.
If the error message persists after restarting, proceed to step 8.
Test the ACS switch
8. In the Analyzer menu select item A2.9 (see page 119).
9. Press the ACS switch and check its operation.
If ACS does not switch, proceed to step 10.
If the switch is ok, proceed to step 11.

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Event Codes 300 - 385

Check the ACS switch wiring


10. Check the wiring between CA417 and CA205 for discontinuity and short
circuits.
If the wiring is ok, replace the ACS switch
If the wiring is faulty, repair the wiring.
Calibrate the travel function
11. Calibrate the travel function (see page 127).
Replace the potentiometer
12. Replace potentiometer POT1 (see page 267).

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Event Codes 300 - 385

Event Code 380


Display: CURR SENSOR TM
Explanation: Offset error detected in current sensors to monitor the traction module power
circuit during power-up.
Effect: Traction module remains deactivated.
Mast reach and lowering only
Possible Causes: Hydraulic module faulty
Remedy: Replace the traction module
1. Replace the traction module (see page 259).

Event Code 381


Display: TEMP. SENSOR TM
Explanation: Open circuit or short circuit detected in traction module thermal sensors.
Effect: Reach and fork lower are still enabled
Travel at crawl speed enabled
Possible Causes: Traction module faulty
Remedy: Replace the traction module
1. Replace the traction module (see page 259).

Event Code 382


Display: ECR1 SHORT CIRC.
Explanation: Short circuit between channels A and B of encoder ECR1.
Effect: Reach and fork lower are still enabled
Travel at crawl speed enabled
Possible Causes: Encoder ECR1 faulty
Encoder wiring short circuit
Main module or traction module faulty
Remedy: Check the module and encoder
1. Select Analyzer menu A2.26 (see page 120).
2. Apply travel function.
If SET SPEED = 685 is displayed (when accelerator pedal applied), the
traction and main modules are ok.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.5
If ACTUAL SPEED = 0 is displayed, proceed to step 3.

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Event Codes 300 - 385

Check the wiring between VCM and TCM


3. Check the wiring between PC425 and CA 201 for short circuits.
If no error is found, proceed to step 4.
Replace encoder ECR1
4. Replace encoder (ECR1).
If the event code persists, proceed to step 5.
Replace the traction module
5. Replace the traction module (see page 258).

Event Code 383


Display: ECR1 OPEN CIRC.
Explanation: Open circuit or no power supply to encoder ECR1.
Effect: Reach and fork lower are still enabled
Travel at crawl speed enabled
Possible Causes: Encoder ECR1 faulty
Encoder wiring disconnected
Main module or hydraulic module faulty
Remedy: Check the encoder power supply
1. Disconnect PC425.
For Danaher motors:
2. Measure the voltage between PC425-1 and PC425-4.
It should be 12 V. If not, proceed to step 6.
If there is a 12 V supply, proceed to step 4.
For Crown motors:
3. Measure the voltage between PC425-1 and PC425-2.
It should be 12 V. If not, proceed to step 6.
If there is a 12 V supply, proceed to step 4.
Check the module and encoder
4. Select Analyzer menu A2.29 (see page 120).
5. Extend and retract the reach carriage.
If SET SPEED = 685 is displayed (when accelerator pedal applied), the
traction and main modules are ok.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
If ACTUAL SPEED = 0 is displayed, proceed to step 6.
Check the wiring between VCM and HCM
6. Check the wiring between PC425 and CA 201.
If no error is found, proceed to step 8.

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Event Codes 300 - 385

Replace encoder ECR1


7. Replace encoder (ECR1).
Replace the traction module
8. Replace the traction module (see page 258).

Event Code 384


Display: ECR1 LOST CHANN.
Explanation: No channel A or B on encoder ECR1.
Effect: Reach and fork lower are still enabled
Travel at crawl speed enabled
Possible Causes: Encoder ECR1 faulty
Encoder wiring short circuit
Main module or traction module faulty
Remedy: Check the module and encoder
1. Select Analyzer menu A2.26 (see page 120).
2. Apply travel.
If SET SPEED = 685 is displayed (when accelerator pedal applied), the
traction and main modules are ok.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.5
If ACTUAL SPEED = 0 is displayed, proceed to step 3.
Check the wiring between VCM and TCM
3. Check for disconnected wiring between PC425 and CA 201.
If no error is found, proceed to step 4.
Replace encoder ECR1
4. Replace encoder (ECR1).
If the event code persists, proceed to step 5.
Replace the traction module
5. Replace the traction module (see page 258).

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ELECTRICAL SYSTEM
Event Codes 430 - 465

Event Codes 430 - 465

Event Code 430


Display: ERROR CANBUS VM
Explanation: Communication error on CAN Bus of main module (VCM).
Effect: Main contactor ED1 de-energised
Possible Causes: Wiring error
Error in main module (VCM)
Error in steer module (SCM)
Remedy: Measure the load resistance of the CAN Bus wiring between the main
module and the steer module
1. Measure the resistance between PC416-1 and -2.
If the resistance is 60 , the main and steer modules are ok.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.
If the resistance is 120 , then either the main module or steer module
is faulty. Proceed to step 2.
Measure the load resistance in the main module (VCM)
2. Disconnect PC205 from the main module.
3. Measure the resistance on the main module between PC205-22 and -23.
If the resistance is 120 , the main module is ok. Proceed to step 5:
If a different reading is obtained, the main module is faulty.
4. Replace the main module.
Measure the load resistance in the steer module (SCM)
5. Disconnect PC204 from the steer module.
6. Measure the resistance on the steer module between PC205-10 and -11.
If the resistance is 120 , the steer module is ok.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.
If a different reading is obtained, the main module is faulty.
Replace the steer module (SCM)
7. Replace the steer module (see page 259).

Event Code 431


Display: ERROR CANBUS DSPLAY
Explanation: Communication error on CAN Bus of main module (VCM) and display.
Effect: Main contactor ED1 de-energised
Possible Causes: Wiring error
Error in main module (VCM)
Error in steer module (SCM)

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Event Codes 430 - 465

Remedy: Measure the load resistance of the CAN Bus wiring between the main
module and the steer module
1. Measure the resistance between PC416-1 and -2.
If the resistance is 60 , the main and steer modules are ok.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.
If the resistance is 120 , then either the main module or steer module
is faulty. Proceed to step 2.
Measure the load resistance in the main module (VCM)
2. Disconnect PC205 from the main module.
3. Measure the resistance on the main module between PC205-22 and -23.
If the resistance is 120 , the main module is ok. Proceed to step 5:
If a different reading is obtained, the main module is faulty.
4. Replace the main module.
Measure the load resistance in the steer module (SCM)
5. Disconnect PC204 from the steer module.
6. Measure the resistance on the steer module between PC205-10 and -11.
If the resistance is 120 , the steer module is ok.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.
If a different reading is obtained, the main module is faulty.
Replace the steer module (SCM)
7. Replace the steer module (see page 259).

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ELECTRICAL SYSTEM
Event Codes 430 - 465

Event Code 460


Display: MAINC NOT CLOSED
Explanation: During power-up VCM detects an overcurrent in the coil of contactor ED1 and
switches off the driver output to ED1.
Effect: Main contactor ED1 not energised
Possible Causes: Short circuit in contactor coil
Wiring short circuit
Remedy: Check wiring
1. Power down the truck.
2. Remove PC402 from the start up card.
3. Remove control cable from contactor.
4. Check control cable to contactor (PC402-10 and -9) for short circuit.
If there is a short circuit, proceed to step 5.
If there is no short circuit in the wiring, proceed to step 6.
Repair wiring
5. Repair wiring.
Check contactor coil
6. With the control cables still removed, measure the contactor coil resist-
ance with an ohmmeter.
If the resistance is approx. 1.5 k, the contactor coil is ok.
If the resistance is approx. 0 , proceed to step 7.
Repair contactor
7. Repair contactor ED1 (see page 271).

Event Code 461


Display: MAINC WELDED
Explanation: Battery voltage applied to CA205-14 although truck has not been powered up.
Effect: Main contactor ED1 not energised
Possible Causes: Contactor welded.
Remedy: 1. Repair or replace contactor (see page 271).

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ELECTRICAL SYSTEM
Event Codes 430 - 465

Event Code 462


Display: FAN OUTPUT
Explanation: Overcurrent detected on HCM output to fans during power-up. Output to fans
switched off by the HCM.
Effect: Travel at crawl speed enabled
Mast reach and lowering only
Possible Causes: Faulty fan
Short circuit
Remedy: Test the fans
1. Test the fans (see U4 Check Fan 1 - 4, page 170).
If a faulty fan is discovered, proceed to step 2.
If the fans are working, proceed to step 3.
Replace the fans
2. Replace any faulty fans.
Trace short circuit
3. Trace for a short circuit between PC415 or PC435 to CA201-2 on HCM.
Repair faulty wiring.

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ELECTRICAL SYSTEM
Event Codes 430 - 465

Event Code 463


Display: BEACON OUTPUT
Explanation: Overcurrent detected on output of VCM to strobe. Output to strobe switched
off by VCM.
Effect: SVH, PVL, PVRE, PVRT, PVAL and PVAR deactivated.
Possible Causes: Faulty strobe
Coil (on relay bracket under the floorboard) is faulty
Wire harness error
Main module error
Remedy: Check strobe
1. Power down the truck.
2. Disconnect PC435 from the strobe .
3. Switch on the truck and strobe .
If the event code no longer occurs, proceed to step 5.
If the event code is still displayed, proceed to step 6.
4.
Replace strobe
5. Replace the strobe.
Check strobe and coil wiring
6. Power down the truck.
7. Disconnect JC433.
8. Switch on the truck and strobe.
If the event code no longer occurs, proceed to step 9.
If the event code is still displayed, proceed to step 10.
9. Check wiring between JC433-1 and - 2 to PC435-1 and -2 for short cir-
cuits.
If there is a short circuit, proceed to step 14.
If the wiring is ok, proceed to step 15.
Check main wire harness for short circuits
10. Power down the truck.
11. Disconnect PC205 and PC206.
12. Check the wiring between PC433-1 and -2 for short circuits.
If there is a short circuit, proceed to step 14.
If no short circuit is found, proceed to step 13.
13. Check contacts are securely connected to PC205 and PC206.
If the contacts are damaged, proceed to step 16.
If the contacts are ok, proceed to step 17.
Repair wiring
14. Repair the wiring.
Replace the coil
15. Replace the coil (fitted on the relay bracket underneath the floorboard).

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Event Codes 430 - 465

Repair contacts on PC205 and PC206


16. Repair contacts.
Replace the main module
17. Replace the main module.

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ELECTRICAL SYSTEM
Event Codes 430 - 465

Event Code 464


Display: ALARM2 OUTPUT
Explanation: Overcurrent detected on output of VCM to travel alarm (CA205-11). Output to
travel alarm switched off by VCM.
Effect: Main contactor ED1 de-energised
Possible Causes: Travel alarm faulty
Coil (fitted between travel and pump motors) is faulty
Wire harness error
Main module error
Remedy: Check travel alarm
1. Power down the truck.
2. Disconnect PC437 (fitted between the travel and pump motors).
3. Power up the truck and activate the travel alarm.
If the event code no longer occurs, proceed to step 4.
If the event code is still displayed, proceed to step 6.
Check wiring to travel alarm and coil
4. Power down the truck.
5. Disconnect JC421.
6. Power up the truck and activate the travel alarm.
If the event code no longer occurs, proceed to step 7.
If the event code is still displayed, proceed to step 8.
7. Check wiring between JC421-1 and - 2 to PC437-1 and -2 for short cir-
cuits.
If there is a short circuit, proceed to step 12.
If the wiring is ok, proceed to step 13.
Check main wire harness for short circuits
8. Power down the truck.
9. Disconnect PC205 and PC206.
10. Check the wiring between PC421-1 and -2 for short circuits.
If there is a short circuit, proceed to step 12.
If no short circuit is found, proceed to step 11.
11. Check contacts are securely connected to PC205 and PC206.
If the contacts are damaged, proceed to step 14.
If the contacts are ok, proceed to step 15.
Repair wiring
12. Repair the wiring.
Replace the coil
13. Replace the coil (fitted between travel and pump motors).
Repair contacts on PC205 and PC206
14. Repair contacts.
Replace the main module
15. Replace the main module.

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ELECTRICAL SYSTEM
Event Codes 430 - 465

Event Code 465


Display: VMC OUTPUTS
Explanation: Overcurrent detected on VCM outputs. The overcurrent could not be assigned
directly to an output. All outputs are switched off by the VCM.
Effect: Either SVH, PVL, PVRE, PVRT, PVAL, PVAR or SVT, SVS, SV5 are deac-
tivated or main contactor ED1 is de-energised.
Possible Causes: Wire harness error
Error in mast reach wire harness (see page 443)
Error in reach carriage wire harness (see page 447)
Error in mast cable (see page 458 or 459)
Error in fork carriage wire harness (see page 450 ff.)
Valve modulation error
Main module error
Horn modulation error
Remedy: Trace short circuit
1. Troubleshoot as described in event codes 463 and 464.
If no error is found, proceed to step 2.
2. Check the valve modulation and horn wiring for short circuits.
3. Check the valve modulation and horn wiring for short circuits:
SVH (PC807 on main valve block)
PVRE (PC808 on main valve block)
PVRT (PC810 on main valve block)
PVAL (PC809 on main valve block)
PVAR (PC811 on main valve block)
SVT, SVS (PC801 on Auxiliary functions valve block)
Horn (PC402-3 and -12 on the start up card)
If there is a short circuit, proceed to step 10.
If no short circuit is found, proceed to step 4.
Check contacts
4. Check contact pins are properly connected to the following:
PC205, PC206, CA422 (on mast)
CA601, CA604 (in reach carriage)
If the contacts are ok, proceed to step 5.
If a contact error is found, proceed to step 9.

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Event Codes 430 - 465

Test components individually


Note: Each of the components named in step 3 must be tested individually.
The following shows for example how to test the SVH valve. The other compo-
nents are tested in the same way.
5. Power down the truck.
6. Remove PC807 from the SVH valve.
7. Power up the truck.
8. Check the event code displayed.
If the event code is shown again, the problem lies with one of the other
components. Repeat steps 5 to 8 for the next component.
Note: Re-fit the connector before powering up the truck again.
If the event code is no longer displayed, that component is the cause of
the error. Proceed to step 11.
If the error is shown for all components, the main module is the cause.
Proceed to step 12.
Repair connector
9. Repair the connector.
Repair wiring
10. Eradicate the short circuit.
Replace faulty component
11. Replace the faulty component.
Replace the main module
12. Replace the main module (VCM).

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ELECTRICAL SYSTEM
Event Codes 840 - 886

Event Codes 840 - 886

Event Code 840


Display: FS&RS CLOSED
Explanation: Forward and reverse switches detected simultaneously on the VCM inputs.
Effect: Traction module deactivated
Possible Causes: Wiring error
Faulty switch
Error in main module (VCM)
Remedy: Check direction switches
1. Power down the truck.
2. Disconnect CA411 (in armrest).
3. Start up the truck.
If the event code persists, proceed to step 4.
If the event code disappears, monitor the error frequency (see Log
Events Menu, page 158). If the event occurs frequently, contact the
Crown service department.
Check interface
4. Power down the truck.
5. Reconnect CA411.
6. Disconnect CA406.
7. Power up the truck.
If the event code persists, proceed to step 8.
If the event code disappears, the interface PCB is faulty. Proceed to
step 9.
Check wiring and switches
8. Check wiring from CA406-2 to CA470-2 and on to CA205-4.
If the wiring is faulty, proceed to step 10.
If the wiring is ok, proceed to step 11.
Replace interface
9. Replace the interface PCB.
Repair wiring
10. Repair the wiring.
Replace the main module (VCM)
11. Replace the main module.

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ELECTRICAL SYSTEM
Event Codes 840 - 886

Event Code 841


Display: LOW BRAKE FLUID
Explanation: Brake fluid level too low.
Effect: Brake fluid level indicator lights up
Possible Causes: Brake fluid level too low
Faulty wiring
Faulty switch
Remedy: Check brake fluid level
1. Check brake fluid container level.
If the level is ok, proceed to step 2.
If there is insufficient brake fluid, rectify the cause (worn brake linings in
the load wheels, leaks etc.) (see page 292). Then add brake fluid
(DOT4) (see page 295).
Check BFS switch
Note: The lid must be screwed onto the container and the brake fluid filled to
the max. marking.
2. Remove the wiring from the BFS switch.
3. Using an ohmmeter check the switch.
If the switch has continuity, the switch is faulty and must be replaced.
If the switch does not have continuity, proceed to step 4.
Check wiring
4. Measure the voltage between CA204-31 and B.
If the voltage is approx. B+, there is a short circuit to B+. Proceed to
step 5.
If the reading is 0 V, the main module (VCM) is faulty. Proceed to
step 6.
Repair wiring
5. Clear short circuit in wire no. 007 between BFS and CA205-31.
Replace the main module (VCM)
6. Replace the VCM (see page 258).

Event Code 880


Display: SHORT CIRCUIT ECR5
Explanation: Short circuit between channels A and B of the height encoder
Effect: Lift speed reduced to 50 %
Graphic height display switched off
The display shows: height measurement switched off
Possible Causes: Wiring short circuit
Encoder faulty

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Event Codes 840 - 886

Remedy: Check wiring


1. Power down the truck.
2. Disconnect CA205 from the VCM and PC803 from height encoder ECR5.
3. Using an ohmmeter check the wires between CA205-9 and -38 for short
circuits.
If there is a short circuit, proceed to step 4.
If the wiring is ok, proceed to step 5.
Repair wiring
4. Repair wiring.
Check height encoder ECR5
5. In the Analyzer menu open item A2.19.
6. Continue raising the fork carriage above free lift height while monitoring
the display.
If the number of encoder pulses does not continually rise, ECR5 is
faulty. Proceed to step 7.
If the number of encoder pulses rises continually, ECR5 is ok. Proceed
to step 8.
Replace height encoder ECR5
7. Replace ECR5 (see page 265).
Replace the main module (VCM)
8. Replace the VCM (see page 258).

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ELECTRICAL SYSTEM
Event Codes 840 - 886

Event Code 881


Display: NO COUNTS LIFT
Explanation: No pulses from height encoder ECR5 detected during lifting.
Effect: Lift speed reduced to 50%
Graphic height display switched off
The display shows: height measurement switched off
Possible Causes: Faulty wiring
Height reset switch (HGTRS) does not connect
Height encoder ECR5 faulty
12 V supply faulty
Main module VCM faulty
Remedy: Test HGTRS
1. In the Analyzer menu open item A2.18.
2. Raise the fork carriage above free lift height.
If the HGTRS switch changes from ON to OFF when the fork carriage
exceeds free lift height, it is ok. Proceed to step 4.
If it does not change, the HGTRS switch is not working. Proceed to
step 3.
Replace HGTRS
3. Replace the HGTRS switch (see page 266).
Test height encoder ECR5
4. In the Analyzer menu open item A2.19.
5. Raise the fork carriage slowly above free lift height while monitoring if the
number of encoder pulses rises continually up to maximum lift height.
If the number of pulses does not rise, either the wiring, the power supply
(display), the encoder or the VCM are faulty. Proceed to step 7.
If the number of pulses does rise, proceed to step 17.
Check 12 V supply of height encoder ECR5
6. Using a voltmeter measure the voltage between CA203-14 and B- on the
display.
If there is a 12 V supply present, proceed to step 7.
If there is no supply, proceed to step 13.
7. Using a voltmeter measure the voltage between PC803-1 (GND) and -
3 (+12 V) on height encoder ECR5.
If there is a 12 V supply present, proceed to step 9.
If there is no supply, proceed to step 18.
Check wiring and operation of channel A on height encoder ECR5
8. Connect the voltmeter between PC205-9 and B.
9. Raise the fork carriage above free lift height and then continue raising it
very slowly.
If the voltage jumps between 0 V and 5 V, channel A is ok. Proceed to
step 10.
If 0 V is constantly displayed, proceed to step 13.

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Event Codes 840 - 886

Check wiring and operation of channel B on height encoder ECR5


10. Connect the voltmeter between PC205-38 and B.
11. Raise the fork carriage above free lift height and then continue raising it
very slowly.
If the voltage jumps between 0 V and 5 V, channel B is ok. Proceed to
step 17.
If 0 V is constantly displayed, proceed to step 14.
Check 12 V supply wiring
12. Check for disconnected wiring from CA203-14 (on display) to CA803-3
and from CA203-20 to CA803-1.
If there is a disconnection, proceed to step 15.
If there is no disconnection, proceed to step 18.
Check channel A wiring on ECR5
13. Check for disconnected wiring from CA205-9 via CA422-31, CA600-2 to
CA803-2.
If there is a disconnection, proceed to step 15.
If there is no disconnection, proceed to step 16.
Check channel A wiring on ECR5
14. Check for disconnected wiring from CA205-38 via CA422-32, CA600-4 to
CA803-4.
If there is a disconnection, proceed to step 15.
If there is no disconnection, proceed to step 16.
Repair wiring
15. Repair wiring.
Replace encoder ECR5
16. Replace ECR5 (see page 265).
Replace the main module (VCM)
17. Replace the VCM (see page 258).
Replace the display
18. Replace the display (see page 259).

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ELECTRICAL SYSTEM
Event Codes 840 - 886

Event Code 883


Display: EXEED MAX HEIGHT
Explanation: Height encoder ECR5 records a value above maximum lift height.
Effect: Lift speed reduced to 50%
Graphic height display switched off
The display shows: height measurement switched off
Possible Causes: Slip in height encoder drive
Height encoder calibration faulty
Remedy: Check drive of height encoder ECR5 for slip
1. Check drive of ECR5 for slip.
If slip is discovered in the drive, proceed to step 2.
If the drive is ok, proceed to step 3.
Repair the drive of height encoder ECR5
2. Replace faulty drive components.
Calibrate height encoder ECR5
3. Calibrate ECR5 (see page 132).

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ELECTRICAL SYSTEM
Event Codes 840 - 886

Event Code 884


Display: NO COUNTS LOWER
Explanation: No pulses from height encoder ECR5 detected during lowering.
Effect: Lift speed reduced to 50%
Graphic height display switched off
The display shows: height measurement switched off
Possible Causes: Faulty wiring
Height reset switch (HGTRS) does not connect
Height encoder ECR5 faulty
12 V supply faulty
Main module VCM faulty
Remedy: Test HGTRS
1. In the Analyzer menu open item A2.18.
2. Raise the fork carriage above free lift height.
If the HGTRS switch changes from ON to OFF when the fork carriage
exceeds free lift height, it is ok. Proceed to step 4.
If it does not change, the HGTRS switch is not working. Proceed to
step 3.
Replace HGTRS
3. Replace the HGTRS switch (see page 266).
Test height encoder ECR5
4. In the Analyzer menu open item A2.19.
5. Raise the fork carriage far beyond the free lift height. Then lower it and
monitor if the number of encoder pulses falls continuously.
If the number of pulses does not fall, either the wiring, the power supply
(display), the encoder or the VCM are faulty. Proceed to step 7.
If the number of pulses does rise, proceed to step 17.
Check 12 V supply of height encoder ECR5
6. Using a voltmeter measure the voltage between CA203-14 and B- on the
display.
If there is a 12 V supply, proceed to step 7.
If there is no supply, proceed to step 13.
7. Using a voltmeter measure the voltage between PC803-1 (GND) and -
3 (+12 V) on height encoder ECR5.
If there is a 12 V supply, proceed to step 9.
If there is no supply, proceed to step 18.
Check wiring and operation of channel A on height encoder ECR5
8. Connect the voltmeter between PC205-9 and B.
9. Raise the fork carriage above free lift height and then continue raising it
very slowly.
If the voltage jumps between 0 V and 5 V, channel A is ok. Proceed to
step 10.
If 0 V is constantly displayed, proceed to step 13.

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Event Codes 840 - 886

Check wiring and operation of channel B on height encoder ECR5


10. Connect the voltmeter between PC205-38 and B.
11. Raise the fork carriage above free lift height and then continue raising it
very slowly.
If the voltage jumps between 0 V and 5 V, channel B is ok. Proceed to
step 17.
If 0 V is constantly displayed, proceed to step 14.
Check 12 V supply wiring
12. Check for disconnected wiring from CA203-14 (on display) to CA803-3
and from CA203-20 to CA803-1.
If there is a disconnection, proceed to step 15.
If there is no disconnection, proceed to step 18.
Check channel A wiring on ECR5
13. Check for disconnected wiring from CA205-9 via CA422-31, CA600-2 to
CA803-2.
If there is a disconnection, proceed to step 15.
If there is no disconnection, proceed to step 16.
Check channel A wiring on ECR5
14. Check for disconnected wiring from CA205-38 via CA422-32, CA600-4 to
CA803-4.
If there is a disconnection, proceed to step 15.
If there is no disconnection, proceed to step 16.
Repair wiring
15. Then repair wiring.
Replace encoder ECR5
16. Replace ECR5 (see page 265).
Replace the main module (VCM)
17. Replace the VCM (see page 258).
Replace the display
18. Replace the display (see page 259).

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ELECTRICAL SYSTEM
Event Codes 840 - 886

Event Code 885


Display: ERROR HGTRS
Explanation: Height reset switch HGTRS malfunction
Effect: Lift speed reduced to 50%
Graphic height display switched off
The display shows: height measurement switched off
Possible Causes: Faulty wiring
Height reset switch (HGTRS) does not connect
Remedy: Test HGTRS
1. In the Analyzer menu open item A2.18.
2. Raise the fork carriage above free lift height.
If it does not change, the HGTRS switch is not working. Proceed to
step 3.
If the HGTRS switch changes from ON to OFF when the fork carriage
exceeds free lift height, it is ok.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.
Check wiring
3. Disconnect PC802 and raise the fork carriage above free lift height.
If ON is still displayed, there is a short circuit to B+. Proceed to step 4.
If OFF is displayed, HGTRS is faulty. Proceed to step 5.
Repair wiring
4. Repair wiring.
Replace HGTRS
5. Replace the HGTRS switch (see page 266).

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ELECTRICAL SYSTEM
Event Codes 840 - 886

Event Code 886


Display: ERROR ECR5 - HGTRS
Explanation: This test compares the number of count pulses of a lifting operation with those
of a lowering operation. The event code is generated if a permissible difference
is exceeded.
Effect: Lift speed reduced to 50%
Graphic height display switched off
The display shows: height measurement switched off
Possible Causes: Height reset switch (HGTRS) does not connect reliably
Slip in height encoder drive
Remedy: Check drive of height encoder ECR5 for slip
1. See Event Code 883, page 253.
If the height encoder drive is ok, proceed to step 2.
Check height reset switch HGTRS
2. See Event Code 885, page 256.
Note: If no cause can be found and the truck works correctly after restarting,
monitor the frequency of the fault (see Log Events Menu, page 158). If the
event occurs frequently, contact the Crown service department.

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ELECTRICAL SYSTEM
Control Modules and Display Screen

Control Modules and Display Traction control module TCM


Hydraulic control module HCM
Screen Steering control module SCM
The following control modules communicate with each Display screen
other and the display screen via the CAN Bus.
The display screen also provides the 12 volt supply.
Main module VMC




 




  


Fig. 69 Components under the panels

1 Battery connector 7 Emergency Disconnect


2 Start up card 8 Hydraulic control module HCM (Access 2)
3 Control fuses (FU1 - FU6) 9 Steering control module SCM (Access 5)
4 Traction control module TCM (Access 3) 10 Steering control module main fuse (FU13)
5 Main contactor 11 Main control module VCM (Access 4)
6 Main fuse (FU7)

Replacing control modules Replacing the traction control module


Replacing the traction control module
Replacing the main control module
1. Switch off the truck, disconnect the battery and
Preparing to replace the main control module prevent it from being switched on again.
1. Switch off the truck, disconnect the battery and 2. Remove the panel.
prevent it from being switched on again.
2. Remove the panel.
Removing the main control module WARNING
3. Remove the connector. Short circuits can cause fires
4. Remove the main control module mounting screws Charging capacitors in the control module have energy
and take out the main control module. stored. The capacitors are suddenly discharged in the
Installing the main control module event of a short circuit.

5. Install the main control module in the reverse order Either discharge the capacitors with a resistance of
of disassembly. 100 /50 W over terminals B+ und B- of the control
module or wait 15 minutes.
6. Check operation.

3. Before the next step wait for 15 minutes or perform


a controlled discharge of the capacitors with a re-
sistance of 100 /50 W over terminals B+ and B-.

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ELECTRICAL SYSTEM
Control Modules and Display Screen

Removing the traction control module Replacing the steering control module
4. Remove the power cable.
Preparing to replace the steering control module
Note: Observe the number and arrangement of wash-
1. Switch off the truck, disconnect the battery and
ers and nuts. The washers are convex. They must be
prevent it from being switched on again.
fitted in the same position during assembly.
2. Remove the panel.
5. Remove the connector.
6. Remove the main control module mounting screws
and take out the traction control module.
WARNING
Installing the traction control module
Short circuits can cause fires
7. Assemble the traction control module in the re-
Charging capacitors in the control module have energy
verse order of disassembly.
stored. The capacitors are suddenly discharged in the
8. Torque the power cable nuts to 15 2 Nm. event of a short circuit.
9. Check operation. Either discharge the capacitors with a resistance of
100 /50 W over terminals B+ und B- of the control
Replacing the hydraulic control module module or wait 15 minutes.
Preparing to replace the hydraulic control module
1. Switch off the truck, disconnect the battery and 3. Before the next step wait for 15 minutes or perform
prevent it from being switched on again. a controlled discharge of the capacitors with a re-
2. Remove the panel. sistance of 100 /50 W over terminals B+ and B-.
Removing the steering control module
4. Remove the power cable.
WARNING Note: Observe the number and arrangement of wash-
ers and nuts. The washers are convex. They must be
Short circuits can cause fires
fitted in the same position during assembly.
Charging capacitors in the control module have energy
stored. The capacitors are suddenly discharged in the 5. Remove the connector.
event of a short circuit. 6. Remove the steering control module mounting
Either discharge the capacitors with a resistance of screws and take out the steering control module.
100 /50 W over terminals B+ und B- of the control Installing the steering control module
module or wait 15 minutes.
7. Assemble the steering control module in the re-
verse order of disassembly.
3. Before the next step wait for 15 minutes or perform
8. Check operation.
a controlled discharge of the capacitors with a re-
sistance of 100 /50 W over terminals B+ and B-. Replacing the display panel
Removing the hydraulic control module
Preparing to replace the display panel
4. Remove the power cable and bus bar.
1. Switch off the truck, disconnect the battery and
Note: Observe the number and arrangement of wash- prevent it from being switched on again.
ers and nuts. The washers are convex. They must be
2. Remove the panel.
fitted in the same position during assembly.
5. Remove the connector. Removing the display panel
6. Remove the hydraulic control module mounting 1. Remove the faulty display panel.
screws and take out the hydraulic control module. Assembling the display panel
Installing the hydraulic control module 2. Fit the new display panel.
7. Assemble the hydraulic control module in the re- Note: All new display panels respond only to a key
verse order of disassembly. switch. The truck must therefore be started with a key
8. Torque the power cable nuts to 15 2 Nm. switch whenever the display panel or the PCB is re-
placed. The starting method can then be re-pro-
9. Check operation. grammed.

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ELECTRICAL SYSTEM
Control Modules and Display Screen

Setting the starting method to keyless entry


3. Provisionally connect a key switch to JC420.
4. Start up the truck.
5. In the Features menu select sub-menu F25 (see
page 152).
6. Activate "keyless entry" and save the change.
7. Power down the truck.
8. Remove the key switch from JC420.
9. Connect JC420 to JC473.
The truck is now programmed to start without a key
switch.

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ELECTRICAL SYSTEM
PMT Test

PMT Test Required tools


A self-assembled test unit:
General
EN 1175-1 requires regular inspection of the safety cir-
 
cuits of electronic control modules in electric lift trucks,
which is known as the PMT test (Pulse Monitor Trip
Test).
We recommend that this test be carried out at least an-
nually as part of planned maintenance (see page 29)
on the following control modules: 
Steering control module (SCM) 
Traction control module (TCM)
Hydraulic control module (HCM)

Safety notices

Fig. 70
WARNING
1 Power cable
Accident risk from accidental start-up during test 2 Power fuse 355 A, encapsulated
If a safety circuit is faulty, the truck or parts of it can
3 Insulating caps
suddenly move. Fatal accidents may result.
4 Power fuse 50 A, encapsulated
Before carrying out the safety test jack the truck up
so that the drive wheel is clear of the ground. You will require:
Insert wedges under the load wheels.
Quan- Item Part no.
tity

WARNING 2 Power cable 821634-010

Risk of scalding and injury to eyes 2 Insulating cap 125588-001


The power fuse can burn, causing burning metal parti- 1 Fuse holder 805824
cles to explode. These particles can cause serious eye
injuries and scald the skin. 1 Power fuse 355 A, 802816-011
encapsulated
Always wear protective glasses and appropriate
protective clothing. 1 Power fuse 50 A, 802816-006
Always use encapsulated power fuses. With these encapsulated
fuses, the fuse strip is covered to prevent liquid 4 Nut 050008-010
metal particles from spraying.
4 Copper shim 054152-003
1 Insulating plate ---
approx. 150 mm x 100 mm

Creating the test unit


1. Fit the fuse holder on the insulating plate.
2. Attach both ends of the power cable to the fuse
holder.

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ELECTRICAL SYSTEM
PMT Test

Preparing the control module safety 7. Disconnect the battery.


test Testing the short circuit detection for phase W to V
on the traction control module
Jacking up the truck
1. Remove the test wiring (355 A fuse) from
1. Disconnect the battery. terminal U and connect it to terminal W.
2. Jack up the truck (see page 14). 2. Place the fuse holder on the floor.
3. Remove the panels to gain access to the control 3. Carefully check the entire unit again for possible
modules. short circuits.
Is everything is ok, proceed to step 4.
Traction control module safety test 4. Switch on the truck.
Testing the short circuit detection for phase U to V 5. Apply the safety pedal, direction switch and accel-
on the traction control module erator pedal.
1. Fit a 355 A fuse on the test wiring. The test has been successful if the main contac-
tor ED1 is de-energised and event code 301 is
2. Connect the test wiring with additional nuts to
displayed.
terminals U and V of the traction control module.
If the fuse blows in the test cable, the traction
3. Place the fuse holder on the floor. control module is faulty. Replace the traction
4. Carefully check the entire unit again for possible control module immediately (see page 258).
short circuits. 6. Power down the truck.
Is everything is ok, proceed to step 5.
7. Disconnect the battery.
5. Switch on the truck.
Removing the test wiring
6. Apply the safety pedal, direction switch and accel-
erator pedal. 8. Remove the test wiring.
The test has been successful if the main contac- Checking travel functions after the test
tor ED1 is de-energised and event code 301 is
9. Check the travel functions after the test.
displayed.
If the fuse blows in the test cable, the traction
control module is faulty. Replace the traction
Hydraulic control module safety test
control module immediately (see page 258). Testing the short circuit detection for phase U to V
7. Power down the truck. on the hydraulic control module
8. Disconnect the battery. 1. Fit a 355 A fuse on the test wiring.
Testing the short circuit detection for phase U to W 2. Connect the test wiring with additional nuts to
on the traction control module terminals U and V of the hydraulic control module.
1. Remove the test wiring (355 A fuse) from 3. Place the fuse holder on the floor.
terminal V and connect it to terminal W. 4. Carefully check the entire unit again for possible
2. Place the fuse holder on the floor. short circuits.
Is everything is ok, proceed to step 5.
3. Carefully check the entire unit again for possible
short circuits. 5. Connect the battery.
Is everything is ok, proceed to step 4. 6. Power up the truck.
4. Switch on the truck. 7. Apply the safety pedal and activate lifting.
5. Apply the safety pedal, direction switch and accel- The test has been successful if the main contac-
erator pedal. tor ED1 is de-energised immediately and event
The test has been successful if the main contac- code 201 is displayed.
tor ED1 is de-energised and event code 301 is If the fuse blows in the test cable, the hydraulic
displayed. control module is faulty. Replace the hydraulic
If the fuse blows in the test cable, the traction module immediately (see page 259).
control module is faulty. Replace the traction 8. Power down the truck.
control module immediately (see page 258). 9. Disconnect the battery.
6. Power down the truck.

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ELECTRICAL SYSTEM
PMT Test

Testing the short circuit detection for phase U to W Steering control module safety test
on the hydraulic control module
1. Remove the test wiring (355 A fuse) from Testing the short circuit detection for phase U to V
terminal V and connect it to terminal W. on the steering control module
2. Place the fuse holder on the floor. 1. Fit a 50 A fuse on the test wiring.
3. Carefully check the entire unit again for possible 2. Connect the test wiring with additional nuts to
short circuits. terminals U and V of the steer motor.
Is everything is ok, proceed to step 4. 3. Place the fuse holder on the floor.
4. Connect the battery. 4. Carefully check the entire unit again for possible
5. Power up the truck. short circuits.
Is everything is ok, proceed to step 5.
6. Apply the safety pedal and activate lifting.
The test has been successful if the main contac- 5. Connect the battery.
tor ED1 is de-energised immediately and event 6. Power up the truck.
code 201 is displayed. 7. Apply the safety pedal and activate lifting.
If the fuse blows in the test cable, the hydraulic The test has been successful if the main contac-
control module is faulty. Replace the hydraulic tor ED1 is de-energised immediately and event
module immediately (see page 259). code 100 is displayed.
7. Power down the truck. If the fuse blows in the test cable, the steering
8. Disconnect the battery. control module is faulty. Replace the steering
control module immediately (see page 259).
Testing the short circuit detection for phase W to V
8. Power down the truck.
on the hydraulic control module
9. Disconnect the battery.
1. Remove the test wiring (355 A fuse) from
terminal U and connect it to terminal W. Testing the short circuit detection for phase U to W
2. Place the fuse holder on the floor. on the steering control module
3. Carefully check the entire unit again for possible 1. Remove the test wiring (50 A fuse) from terminal V
short circuits. and connect it to terminal W.
Is everything is ok, proceed to step 4. 2. Place the fuse holder on the floor.
4. Connect the battery. 3. Carefully check the entire unit again for possible
5. Power up the truck. short circuits.
Is everything is ok, proceed to step 4.
6. Apply the safety pedal and activate lifting.
The test has been successful if the main contac- 4. Connect the battery.
tor ED1 is de-energised immediately and event 5. Power up the truck.
code 201 is displayed. 6. Apply the safety pedal and activate lifting.
If the fuse blows in the test cable, the hydraulic The test has been successful if the main contac-
control module is faulty. Replace the hydraulic tor ED1 is de-energised immediately and event
module immediately (see page 259). code 100 is displayed.
7. Power down the truck. If the fuse blows in the test cable, the steering
8. Disconnect the battery. control module is faulty. Replace the steering
control module immediately (see page 259).
Removing the test wiring
7. Power down the truck.
9. Remove the test wiring.
8. Disconnect the battery.
Checking lifting after the test
10. Check lifting after the test.

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263
ELECTRICAL SYSTEM
PMT Test

Testing the short circuit detection for phase W to V


on the steering control module
1. Remove the test wiring (50 A fuse) from terminal U
and connect it to terminal W.
2. Place the fuse holder on the floor.
3. Carefully check the entire unit again for possible
short circuits.
Is everything is ok, proceed to step 4.
4. Connect the battery.
5. Power up the truck.
6. Apply the safety pedal and activate lifting.
The test has been successful if the main contac-
tor ED1 is de-energised immediately and event
code 100 is displayed.
If the fuse blows in the test cable, the steering
control module is faulty. Replace the steering
control module immediately (see page 259).
7. Power down the truck.
8. Disconnect the battery.
Removing the test wiring
9. Remove the test wiring.
Checking the steering after the test
10. Check the steering after the test.

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264
ELECTRICAL SYSTEM
Replacing the Height Encoder

Replacing the Height Encoder

4
5

3 Fig. 72 Height encoder


Removing the height encoder
2 1. Remove connector (16).
Note: The pre-tensioned spring (4) is relieved when
1
the screws (15) are loosened.
Fig. 71 Height encoder assembly location, HGT(R)S switch 2. Loosen the screws (15) and remove the entire
1 1st mast stage (outer mast)
height encoder.
2 2nd mast stage Replacing the sensor bearing
3 3rd mast stage 3. Loosen the screw (12) and remove the attachment
4 HGTS switch (optionally HGTRS) (11), seal (10), heating resistor (14) and attach-
5 Height encoder ment (13).
6 HGTRS shifting gate 4. Loosen the screw (9).
7 HGTS shifting gate 5. Remove the washer (8) and sensor bearing (7).
6. Fit a new sensor bearing in the bracket (3).
Note: Carry out assembly in the reverse order and then
calibrate the height encoder.
Calibrating the height encoder
7. Calibrate the height encoder via the Service menu
(see page 132).

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265
ELECTRICAL SYSTEM
Replacing the HGT(R)S Switch

Replacing the HGT(R)S Switch


The HGTS switch is fitted as standard to reduce the lift
speed before the limit position. 1
Optionally, an HGTRS height reset switch can be used
instead of the HGTS switch. HGTRS resets the height
calculated by the height encoder to 0.
Note: The same switch is used for both functions. 2
Depending on the settings in F3 Features / Height En-
coder of the service menu (see page 140), the switch
will be either an HGTR or an HGTRS.
4

6 3

4
5

Fig. 74 HGTR-, HGTRS switch


1 1st mast stage (outer mast)
2 HGTR or HGTRS switch
3 Bolt
4 Connector

7 Removing the HGT(R)S switch


1. Remove connector (4).
2. Loosen the screws (3).
3. Remove the switch (2).

Assembling the HGT(R)S switch


3
Note: Carry out the assembly in the reverse order,
ensure the switch distance between the shifting gate
2 and the sensor is set to 9.2 - 13 mm.

Fig. 73 Height encoder assembly location, HGT(R)S switch


1 1st mast stage (outer mast)
2 2nd mast stage
3 3rd mast stage
4 HGTS switch (optionally HGTRS switch)
5 Height encoder
6 HGTRS shifting gate
7 HGTS shifting gate

ESR 5000

266
ELECTRICAL SYSTEM
Replacing the Armrest Controls

Replacing the Armrest Controls


Trucks with fingertip control levers

Fig. 75 Replacing switches and potentiometers

ESR 5000

267
ELECTRICAL SYSTEM
Replacing the Armrest Controls

Removing the controls Trucks with dual axis hydraulic


Note: Unless otherwise stated, the following item num- control levers
bers refer to Figure 75.
Removing the covers
1. Push the armrest back as far as the stop.
2. Remove the three screws from the rear cover (42)
and take off the cover (42).
3. Remove the three screws (22, 23, 24) and take off
the cover (1).
Removing the direction switch
4. Remove the bracket (35).
5. Remove the connector of the direction switch (41)
from the interface.
6. Remove the direction switch (41).
Horn switch disassembly
7. Remove the bracket (6).
8. Remove the connector of the horn switch (5) from
the interface.
9. Remove the horn switch (5).
Removing the hydraulic function potentiometers
10. Remove the screw (7) from the control lever (8).
11. Extract the control lever (8).
12. Remove the connector of the potentiometer (10)
from the interface.
13. Remove the screws (9) and potentiometer (10).
Note: The remaining potentiometers are removed in Fig. 76 Replacing switches and potentiometers
the same way. Note: The switches and potentiometers are removed/
assembled in the same way as for trucks with fingertip
Assembling the controls control levers (see page 267).
Note: Assembly is the reverse order of disassembly.

WARNING
Incorrect operation can cause serious injury
Swapping potentiometers will result in malfunctions
during operation.
Make sure the potentiometers are connected to the
correct interface slot.
When you have finished, carry out a functional test.

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268
ELECTRICAL SYSTEM
Replacing the Armrest Controls

Trucks with multi-task handle

Fig. 77 Replacing switches and potentiometers

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269
ELECTRICAL SYSTEM
Replacing the Armrest Controls

Removing the controls


Note: Unless otherwise stated, the following item num-
bers refer to Figure 77.
Removing the covers
1. Remove the three screws from the rear cover (37)
and take off the cover (37).
2. Remove the three screws (18, 19, 20) and take off
the cover (2).
Removing the sideshifter (POT5) potentiometer
3. Remove the screws (1) and (29).
4. Remove the shell (36).
5. Unplug connector PC411 of the potentiometer (34)
from the interface.
6. Remove the potentiometer (34) and wiring.
Removing the horn and tilt switches
1. Remove the handle and thumbwheel (35).
2. Removing the horn and tilt switches and associ-
ated wiring.
Remove the potentiometers for mast reach (POT3)
and fork lift (POT2).
3. Loosen the four screws (21) and remove the entire
multi-task handle.
4. Unplug the connectors for the mast reach (24) and
fork lift (25) potentiometers from the interface.
5. Remove the mast reach (24) and fork lift (25) po-
tentiometers.

Assembling the controls


Note: Assembly of all components is the reverse order
of disassembly.

WARNING
Incorrect operation can cause serious injury
Swapping potentiometers will result in malfunctions
during operation.
Make sure the potentiometers are connected to the
correct interface slot.
When you have finished, carry out a functional test.

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270
ELECTRICAL SYSTEM
Repairing Contactors

Repairing Contactors contacts must not be treated, as this would cause them
to wear even faster.

Checking the coils


CAUTION
1. Using an ohmmeter measure the resistance be-
The use of other manufacturers contactors can tween the connections on the coil (2).
damage the truck!' If either an endless resistance or no resistance are
The original contactors are designed for Crown trucks. recorded, the coil (2) is faulty and must be re-
Only use original Crown contactors as replace- placed.
ments.
Do not change the place or the angle where they
Checking the springs
are positioned and do not change the wiring. 1. Check the spring (1) for corrosion or discolouring
caused by heat.
Replace any corroded or discoloured springs (1).
Wear test

4
1

Fig. 78 Example of a contactor


1 Spring
2 Coil
3 Contact (moving)
4 Contact (fixed)

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

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271
ELECTRICAL SYSTEM
Repairing the Main Contactor

Repairing the Main Contactor Disassembling the main contactor

CAUTION
The incorrect assembly of contacts can result in
failure and excess wear
Contacts already worked in with each other must be
placed together again on assembly.
Mark the contacts (8, 9) when disassembling the
contactor.
0
1. Loosen and remove the screws (1).
2. Remove the housing (2).
3. Mark the contacts that are placed together (8, 9).
4. Remove the contact (8) and the plunger (7).
5. Unscrew the nuts (10) and remove the contacts
(9).
6. Clean all the components.
Wear check
1. Carry out a wear check as described on page 271.
Reassembling the main contactor
1. Insert the contacts (9) according to their markings.
2. Insert the washers (10) and fasten the nuts (11).
Take care not to damage the housing (2).
3. Insert the contact (8) according to the markings
and the plunger (7) into the receptacle of the base
plate (4) and the magnetic coil (5).
4. Fit the housing (2).
5. Insert the screws (1) and washers and apply
Fig. 79 Main contactor (ED1) threadlocker (053050-006).

WARNING
Short circuits can cause fires
Before working on the contactors disconnect the
battery from the truck.

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272
ELECTRICAL SYSTEM
Replacing the Danaher Traction Motor

Replacing the Danaher Traction 5. Insert the ring screw into the shaft of the traction
motor (5).
Motor 6. Disassemble the power cable (2) from the terminal
board.
Traction motor disassembly

WARNING
Incorrect handling of the lifting gear and slings can
cause injury
You can be injured if a component falls on you.
1 Always use lifting gear and slings with sufficient ca-
pacity.
Attach the slings securely to the component to be
lifted.
Watch out for your hands as there is a risk of trap-
ping.

7. Insert the load hook in the eye bolt and lift out the
2 traction motor (5) using suitable lifting gear.

Traction motor assembly


5 Note: Assembly is the reverse of disassembly. Ensure
that the traction motor (5) is positioned as shown in Fig.
80 so that the power cables can be connected to the
terminal board.

4 3
Connecting the power cables

1
2 1
3
4
2
Fig. 80 Danaher traction motor
1 Service and parking brake
3
2 Terminal board and power cable connections
3 Connector for sensor bearing and thermal sensor
4 Screws 4
5 Traction motor

5
1. Switch off the truck, disconnect the battery and
prevent the truck from being switched on again.
2. Remove the service and parking brake (1) as de-
scribed on page 288.
3. Unplug the connector for sensor bearing and ther- Fig. 81 Connecting the power cables
mal sensor (2).
4. Loosen all the screws (3).

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273
ELECTRICAL SYSTEM
Replacing the Danaher Traction Motor

1 Nut
2 Power cable
3 Curved washer
4 Terminal board
5 Traction motor

1. Insert the power cables (2) with references U, V, W


in the adaptors of the terminal board (4).
2. Insert the washers (3) with the curve facing down
(see Figure 81) into the adaptors of the terminal
board (4).
3. Insert the nuts (1) and torque them to 8.1 - 9.9 Nm.

ESR 5000

274
ELECTRICAL SYSTEM
Replacing the Sensor Bearing on the Danaher Traction motor

Replacing the Sensor Bearing on the Danaher Traction motor

16
7
8

10

11

12

13

14
15

Fig. 82 Overview - traction motor (Danaher)

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275
ELECTRICAL SYSTEM
Replacing the Sensor Bearing on the Danaher Traction motor

Sensor bearing disassembly


1. Loosen the nuts (1) on the tie rod (2).
2. Remove the rotor (13) and bearing shield (6).
3. Loosen the screws (5).
4. Use an extractor to remove the bearing shield (6)
from the sensor bearing (10).
5. Loosen the retaining ring (7) and remove the
washer (8).
6. Use the extractor to remove the sensor bearing
(10) from the rotor (13).
7. Remove the backring (11).

Sensor bearing assembly


1. Place the backring (11) on the rotor (13).
2. Use a press to press the sensor bearing (10) onto
the rotor (13).
3. Place the conical nipple (9) and washer (8) onto
the rotor (13) and secure with the retaining ring (7).
4. Pull the sensor bearing (10) onto the bearing plate
(6) with the screws (5).
5. Place the nuts (1) onto the tie rod and torque them
to 12.6 - 15.4 Nm.

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276
ELECTRICAL SYSTEM
Replacing the Crown Traction motor

Replacing the Crown Traction


WARNING
motor
Incorrect handling of the lifting gear and slings can
Traction motor disassembly cause injury
You can be injured if a component falls on you.
Always use lifting gear and slings with sufficient
capacity.
1 Attach the slings securely to the component to be
lifted.
Watch out for your hands as there is a risk of trap-
ping.

6. Secure the slings to the traction motor (4) and us-


ing suitable lifting gear lift it out of the truck.
2
Traction motor assembly
4 Note: Assembly is the reverse of disassembly. Ensure
that the traction motor is positioned as shown in Fig. 83
so that the power cables can be connected to the ter-
minal board.

Connecting the power cables

1
2 1
3 3
3

2
Fig. 83 Crown traction motor
1 Parking brake
3
2 Terminal board
3 Bolt
4 Traction motor 4

1. Switch off the truck, disconnect the battery and


prevent the truck from being switched on again. 5
2. Remove the parking brake (1) as described on
page 290.
3. Unscrew the power cable from the terminal board
(2).
4. Remove the connector for sensor bearing and Fig. 84 Connecting the power cables
thermal sensor. 1 Nut
2 Power cable
5. Loosen all the bolts (3).
3 Curved washer
4 Terminal board
5 Traction motor

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277
ELECTRICAL SYSTEM
Replacing the Crown Traction motor

1. Insert the power cables (2) with references U, V, W


in the adaptors of the terminal board (4).
2. Insert the washers (3) with the curve facing down
(see Figure 84) into the adaptors of the terminal
board (4).
3. Insert the nuts (1) and torque them to 23 - 24 Nm.

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278
ELECTRICAL SYSTEM
Replacing the Pump Motor

Replacing the Pump Motor


WARNING
  Incorrect handling of the lifting gear and slings can
cause injury
You can be injured if a component falls on you.
Always use lifting gear and slings with sufficient ca-
pacity.
Attach the slings securely to the component to be
lifted.

 Watch out for your hands as there is a risk of trap-
 ping.

6. Raise the pump motor (2) using load lifting equip-


ment and remove any slack from it.
 7. Remove the screws (4).
8. Lift the pump motor (2) out of the truck and place it

down on a suitable support.
9. Undo the mounting screws on the hydraulic pump.
10. Pull the hydraulic pump out of the pump motor
 toothing without tilting it.
11. Loosen the screws (3) and take off the bracket.
Fig. 85 Pump motor (ESR 5000S)
1 Pressure line Pump motor assembly
2 Pump motor Assembly of the pump motor is the reverse order of
3 Bolt disassembly. Note the following:
4 Bolt 1. Clean the output side toothing of the pump motor
5 Power cable (2) and apply a thin layer of grease part no.
6 Connector for thermal sensor and sensor bearing 794860-007 (Shell Calithia HDX) to it.
7 Suction line 2. Check the rubber pad on the screws (3) for cracks
and hardening and replace if necessary.
Removing the pump motor 3. Torque the screws (3) to 70 - 80 Nm.
1. Switch off the truck, disconnect the battery and Note: For more information on assembling and com-
prevent it from being switched on again. missioning the hydraulic pump refer to page 86.
2. Unplug the connector for the thermal sensor and
sensor bearing (6).
3. Disassemble the power cable (5) from the terminal
board.
4. Loosen the union on the pressure line (1).
5. Disassemble the suction line (7).

ESR 5000

279
ELECTRICAL SYSTEM
Replacing the Pump Motor

Connecting the power cables

1
2 1
3

Fig. 86 Power cable


1 Nut
2 Power cable
3 Curved washer
4 Terminal board
5 Pump motor

1. Insert the power cables (2) with references U, V, W


in the adaptors of the terminal board (4).
2. Insert the curved washers (3) with the curve facing
down (see Figure 86) into the adaptors of the ter-
minal board (4).
3. Insert the nuts (1) and torque them to 8.1 - 9.9 Nm.

ESR 5000

280
ELECTRICAL SYSTEM
Replacing the Sensor Bearing on the Danaher Pump Motor

Replacing the Sensor Bearing on the Danaher Pump Motor

Fig. 87 Overview - pump motor (Danaher)

ESR 5000

281
ELECTRICAL SYSTEM
Replacing the Sensor Bearing on the Danaher Pump Motor

Sensor bearing disassembly


1. Loosen the nuts (1) of the tie rod (3).
2. Remove the rotor (8) and bearing shield (4).
3. Use an extractor to remove the bearing shield (4)
from the sensor bearing (7).
4. Use the extractor to remove the sensor bearing (7)
from the rotor (8).

Sensor bearing assembly


1. Use a press to press the sensor bearing (7) onto
the rotor (8).
2. Insert the spring washer (7).
3. Insert the sensor bearing (7) into the bearing shield
(4).
4. Place the nuts (1) onto the tie rod and torque them
to 12.6 - 15.4 Nm.

ESR 5000

282
ELECTRICAL SYSTEM
Choosing the Correct Battery Cable Length

Choosing the Correct Battery Choosing cable lengths for a T-


Cable Length shaped battery (example)
To avoid damaging the battery cable when the battery The following example shows how to choose the cor-
is retracted, the cable length must be individually di- rect battery cable length for a T-shaped battery. The
mensioned due to the various sizes and shapes of bat- procedure for dimensioning the battery cables must be
teries used. transferable to other battery shapes and sizes. This will
prevent the battery cables from jamming or getting
caught when they are fed back into the battery com-
partment.
WARNING
Battery short circuits can cause severe injury
Incorrectly sized and routed battery cables can be 1
damaged when fed into the battery compartment, re-
2
sulting in short circuits. This poses a risk of:
Burning due to high temperatures.
Scalding from battery acid.
Fire caused by arcs.
6
Make sure the battery cable is the correct length to 3
avoid it becoming damaged when fed into the com-
partment.
Whenever a battery is used for the first time, make
sure it can be fed into the battery compartment with-
out the battery cables jamming or getting caught. 5 4
Note the following instructions on choosing the cor-
rect battery cable length. Fig. 88 Example of a T-shaped battery
1 Battery connector
2 Battery cable
3 Tape
4 Negative terminal
5 Battery tray
6 Positive terminal

To size the cable length proceed as follows:


5. Size the length of the battery cables (2) so that it
remains within the geometry of the battery tray (5)
when the battery is extended and retracted. The
battery cables (2) must not slide over the battery
tray (5).
Note: It must be possible to place the battery cables (2)
flat on the battery before it is retracted (see Fig. 88).
6. Connect a PVC insulating tape (3) to both battery
cables (2) starting from the battery connector (1)
over a length of approx. 700 mm.
7. Attach the battery cables (2) to the top of the bat-
tery tray to create strain relief on the battery termi-
nals (4, 6).

ESR 5000

283
ELECTRICAL SYSTEM
Choosing the Correct Battery Cable Length

8. Route the battery cables (2) within the geometry of


the battery tray to both the negative terminal (4)
and the positive terminal (6).
9. After a battery has been used for the first time
check the battery cable lengths and the battery ca-
ble type against the above items. Extend and re-
tract the battery several times into the
compartment to make sure that the battery cables
(2) do not jam, extend or get caught.
Note: The battery cables (2) should "slide" along the
battery and remain within the geometry of the battery
tray (5).

ESR 5000

284
BRAKE SYSTEM

285
Notes:

286
BRAKE SYSTEM
Service and Parking Brake

Service and Parking Brake


Note: Different brakes are used, depending on the
traction motor manufacturer (Danaher or Crown):
The service brake for Danaher motors is hydrauli-
cally supported by the brake pressure from the
main brake cylinder.
The brake for Crown motors does not have any
hydraulic support. It relies solely on the brake
torque supplied by the motor.

Safety notices

WARNING
Brake failure can result in accidents
Oily brake linings reduce the brake force significantly.
You or other people could be fatally injured.
Do not allow brake linings to come into contact with
oil or grease. Remove any grease or oil from brake
components; replace any brake lining