Crown Forklift ESR5000 Series Maintenance Manual by www.heydownloads.com

ESR 5000 SERIES MAINTENANCE MANUAL

M 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 München Germany Tel +49 (0)89 93 00 2 – 0

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 ESR 5000

TABLE OF CONTENTS Abbreviations used in the table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planned Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annual inspection in accordance with FEM 4.004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terms and abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat and seat panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake system and load wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reach carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical system - part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical system - part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel and pump motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load wheel replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load wheel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the support block distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the support block height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the support blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the Truck and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Effects of incorrect cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roller and slide bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosion-protected surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the entire truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning removed components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning other mechanical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 29 29 29 29 30 32 34 36 38 40 42 44 46 48 50 50 51 51 51 51 52 53 53 53 53 53 53 54 57 57 57 57 57 57 57 58 58 58

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Abbreviations Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feature Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extending the mast reach carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retracting the mast reach carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork tilt back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork tilt down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sideshift right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sideshift left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ESR 5000

63 65 65 67 69 70 71 72 73 74 75 75 75

TABLE OF CONTENTS 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECR5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ED1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN1, FAN4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FAN2, FAN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU5, FU6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FU13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HGTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HGTRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K1 & K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K12 & K13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K22 & K23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POT5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PVAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PVRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PVRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RES1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RES2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SFS 1SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SFS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ESR 5000

101 101 101 101 101 102 102 102 102 102 102 102 102 102 102 102 102 102 102 102 102 102 103 103 103 103 103 103 103 103 103 103 103 103 103 104 104 104 104 104 104 104 104 104 104 104 104 104 105 105 105 105 105 105

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 ESR 5000

TABLE OF CONTENTS C10 Reach Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C11 Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Features Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1 Truck Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2 Free Lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3 Height Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F4 Lower Cut Out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5 5th Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6 Maximum Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7 Capacity Data Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8 Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9 Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F10 User Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F11 User Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F12 Set Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F13 Change Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14 Set Rack Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F15 Height/Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F16 Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F17 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F18 Operator Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F19 Battery Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F20 Fork Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F21 Choose Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F25 Keyless Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F26 Right Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F27 Options Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F28 Truck Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F29 Direction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F30 Save ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hour Meter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H1 Truck Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H2 Traction Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3 Hydraulic Mod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4 Key On Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H5 Set Service Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Log Events Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L1 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L2 Totals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L3 Erase History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P1 Setup P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P2 Setup P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P3 Setup P3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P4 BDI Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P5 Travel > LCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P6 Travel > FLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P7 Travel > Custom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P8 Lower > Custom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P9 Reach > Custom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P10 5th Function Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P11 5th Function Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P12 Steer Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P14 Brake at Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ESR 5000

137 138 139 139 140 140 141 141 142 143 144 144 145 146 147 148 148 149 149 149 150 151 151 151 152 152 153 153 154 154 155 155 155 156 156 157 158 158 159 159 160 160 164 164 164 165 165 166 166 167 167 168 168 169

TABLE OF CONTENTS 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

TABLE OF CONTENTS BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Service and Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Parking Brake Danaher Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring the coil resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake - Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembling the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring the coil resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the brake lining wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel brake cylinder disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel brake cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding the load wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing and Adjusting the Brake Pedal Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

287 287 288 288 288 288 288 288 289 290 290 290 290 290 291 291 292 292 292 292 293 293 293 293 293 294 295 296 296 296 296

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

ESR 5000

301 301 301 301 301 302 303 303 303 303 303 304 306 306 307 307 307 308 308

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

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

336 336 337 337 337 338 340 340 340 340 340 341 341 341 341 341 342 342 343 343 343 343 344 344 344 344 345 346 346 346 347 347 348 348 348 348 349 349 349 350 350 350 350 351 352 352 352 352 352 352

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Harness, ESR 5000, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Harness, ESR 5000, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Harness, ESR 5000, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Harness, ESR 5000, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Harness, ESR 5000S, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Harness, ESR 5000S, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Harness, ESR 5000S, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harness, ESR 5000 Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harness, ESR 5000S Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harness, ESR 5000S Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connector table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wire Harness: Terminal to Reach Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Assy Truck, Reach Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Assy Valve Block, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Assy Valve Block, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork Carriage Harness Extended, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork Carriage Harness Standard, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork Carriage Switch Assy, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork Carriage, 5th Function, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork Carriage, LS Bridge, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FKS Heater Assembly, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Mast 10 Core Assy, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Mast 6 Core Assy, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VT Camera, Reach Carriage to Chassis, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ESR 5000

XIV

392 403 404 405 406 407 408 408 421 423 424 425 426 426 438 440 440 441 443 445 445 447 449 449 450 451 451 451 452 453 453 453 454 454 454 455 455 455 455 456 456 456 456 457 457 457 458 458 458 458 459 459 460

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

TABLE OF CONTENTS Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heated Seat, ESR 5000, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC/DC Converter Loom, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC/DC Converter Loom, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading Light Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading Light Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working Light 12V, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working Light 12V, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable lugs and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . InfoLink, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . InfoLink, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable lugs and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DCDC Converter Loom NA, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC/DC Converter Loom NA, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48V Supply, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply Cable, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass Cable, Seat Heating Switch, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supply Cable, ESR 5000, PSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable lugs and rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lights 12V, PSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

481 481 482 482 482 483 485 485 487 489 489 489 491 493 493 493 493 495 497 497 497 497 499 501 501 502 502 502 502 503 503 504 504 505 505 505 507

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509 Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515

ESR 5000

XVI

INTRODUCTION

Notes:

INTRODUCTION Important Information

Important Information

Service personnel qualification

This maintenance manual details the maintenance and repair work to be carried out on the following truck models:

To maintain the safety and functionality of the truck, maintenance and repair work must only be performed by service engineers who have been authorised by Crown.

Contact Crown if you wish to have your engineers trained.

ESR 5000 ESR 5000S

Ordering spare parts

Manual structure

To order spare parts, use the spare parts catalog supplied separately. Always quote the following numbers when ordering spare parts:

The manual is divided into the following sections:

•

Specification number

•

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 to the Technical Specifications chapter in the operator manual.

Section

Safety Lubrication & Adjustment

Note: Always use original Crown spare parts.

Hydraulic System Drive Unit

Ordering documentation

Electrical System

Spare parts catalogs, operator manuals, specification sheets etc. can be obtained from:

Brake System CROWN Gabelstapler GmbH & Co.KG Moosacher Str. 52 80809 Munich GERMANY

Steering Lifting Mechanism Cylinders Schematic Diagrams

Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 or 133 www.crown.com

Hydraulic Schematic

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 numbers 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

INTRODUCTION Specification Number

Specification Number

Mast height and capacity

The specification number is located on the data plate.

No.

Mast height retracted (mm)

Mast height extended (mm)

Maximum capacity (t)(a)

2770

6690

1.4 or 1.6

2770

6395

2.0

2920

7140

1.4 or 1.6

2920

6845

2.0

Fig. 1 Specification number example

3040

7500

1.4 or 1.6

Maximum capacity (in tonnes)(a)

3040

7205

2.0

Model name (see Model name table)

3190

7950

1.4 or 1.6

Mast type TT (3 stage telescopic mast, full free lift)

Retracted height (see Mast height and capacity table)(b)

3350

8415

1.4 or 1.6

Fork length (see Fork length table)(b)

3350

8120

2.0

3490

8850

1.4 or 1.6

3690

9450

1.4 or 1.6

3690

9155

2.0

3840

9900

2.0

3840

9605

2.0

3950

10230

1.4 or 1.6

3950

9935

2.0

4250

10835

2.0

4450

11435

2.0

4420

9935

2.0 SD(b)

4720

10835

2.0 SD(b)

4920

11435

2.0 SD(b)

5110

12000

2.0 SD(b)

It contains important information on the truck's features at the time of delivery.

a. The capacity plate on the truck is binding. b. For special designs the actual values are stated for mast height retracted, mast height extended and the fork length.

Model name Abbreviation

Description

ESR

European Sitdown Rider Reach

ESRS

European Sitdown Rider Reach, S-Class

Mast height and capacity No.

Mast height retracted (mm)

Mast height extended (mm)

Maximum capacity (t)(a)

2020

4440

1.4 or 1.6

2020

4145

2.0

2170

4890

1.4 or 1.6

2170

4595

2.0

2320

5340

1.4 or 1.6

2470

5790

2470

2570

a. The capacity plate on the truck is binding. b. SD = Super Duty Mast

Fork length No.

Fork length (mm)

Number

Fork length (mm)

1.4 or 1.6

990

1220

5495

2.0

1067

1500

6090

1.4 or 1.6

1145

1600

ESR 5000

SAFETY

Notes:

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 order 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

SAFETY Basic Safety Notices

Basic Safety Notices

Protecting the hazardous area

Organisational measures

•

When carrying out repair work that could be hazardous to yourself and other people, seal off a large part of the hazardous area with suitable marker tape.

•

Repair work must only be carried out by service engineers approved by Crown.

•

Work on electrical equipment must only be carried out by specialist electricians in accordance with electrical regulations.

•

Before carrying out repair work, service personnel must ensure that there is no one in the hazardous area.

•

Note the basic and action-specific safety notices in the respective chapters of this manual. Refer also to the truck operator manual, in particular the Safety chapter.

•

Service personnel must stop work immediately if any unauthorised persons enter the hazardous area. These persons must be removed immediately.

•

Service personnel must also observe statutory and other binding accident and environmental protection regulations.

Hazards from stored energy •

High pressure hydraulic oil can cause severe injuries. Depressurise the hydraulic system before opening any sections of it.

•

A 15 minute discharge time must be observed for the electrical energy stored in the capacitors and coils. Alternatively, these components can undergo a controlled discharge through an electrical resistor.

•

Always wear safety equipment such as safety shoes and goggles when carrying out maintenance and repairs. Depending on requirements you may also need to wear safety gloves and ear muffs.

When carrying out work near the battery, always cover the battery terminals with a suitable insulating material (e.g. plywood board) to prevent short circuits.

•

When carrying out work on the hydraulic system, e.g. bleeding the system, wear suitable protective clothing such as safety gloves, goggles or a face mask.

Before carrying out work underneath and on raised components (e.g. fork carriages, extended mast stages, the truck itself), attach suitable safety devices and supports with sufficient capacity.

•

Springs and gas pressure dampers must be checked and slowly discharged before removing them.

•

The legal minimum age for performing repair work must be observed.

•

Service personnel must be trained and authorised to operate industrial trucks and must be able to demonstrate their competence.

Personal safety equipment •

•

When handling batteries wear acid protective clothing such as safety gloves, goggles and an apron.

•

Long hair, loose clothing and jewellery are prohibited. They could get caught or drawn in, resulting in injury. Do not wear jewellery especially when working on electrical systems, as a short circuit could cause burning.

•

Always use insulated tools when working on electrical systems.

Repair work •

Always carry out repair work in accordance with the test and maintenance schedule contained in this manual and any applicable service bulletins.

•

Before carrying out repair work prepare the truck as follows: – 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 supply, jack up the truck until the drive wheel is clear of the ground.

ESR 5000

SAFETY Basic Safety Notices •

Always have suitable fire protection equipment to hand when carrying out work.

The charger must be appropriate to the battery voltage and capacity. First connect the battery, then switch the charger on.

•

Keep the truck clean; this makes it easier to find loose or missing components.

When handling batteries wear acid protective clothing such as safety gloves, goggles and an apron.

•

Welding work must only be carried out after prior consultation with Crown.

Do not use a naked flame and do not smoke when handling batteries.

•

Do not touch battery terminals with metal objects. Cover the battery terminals with a suitable insulation (such as a plywood board) if you have to work in this area.

•

Always charge batteries in designated charging areas and make sure the area is well ventilated.

•

Remove battery acid stained clothing immediately.

•

If acid comes into contact with the skin, rinse immediately with plenty of clean water. If it comes into contact with the eyes, rinse immediately with clean water for several minutes and then seek medical attention.

•

Immediately neutralize and thoroughly rinse any spilled battery fluid.

•

Do not use a naked flame near the truck or to check fluid levels or for leaks.

• • • •

Keep the work area clean and well lit. An untidy or poorly lit work area can lead to accidents.

•

Modifications to the original condition of the truck must be examined and approved in writing by Crown beforehand.

•

Only use original Crown spare parts and accessories.

•

Never install or commission damaged components.

Restoring the truck to service after repair work •

After carrying out repairs refit any safety mechanisms that have been removed and make sure they are working correctly.

•

The truck may only be restored to service after repair work once all the truck functions have been successfully tested, in particular on the following components: – Brakes – Speed control – Direction switches – Lifting mechanism – Warning devices (horn, warning indicator) To avoid endangering other people, always test the truck in an open area where there are no other people or obstacles.

Cleaning work Particular care is required when cleaning the truck and components that have been removed. See page 57.

Handling batteries •

•

In accordance with the test and maintenance intervals check that the warning and instruction decals on the truck are complete and legible.

•

Clean any dirty decals and replace any damaged or missing ones.

Note: The spare parts manual gives details of the labelling and position of the warning and instruction decals on the truck.

– Steering

•

Warning and instruction decals on the truck

Batteries may only be charged, serviced or replaced by trained personnel. Observe the instructions contained in the operator manual, as well as the instructions of the battery and charger manufacturers.

Lifting gear and slings •

Always use suitable hoist devices and lifting gear with sufficient capacity.

•

Attach lifting gear to the designated strap points and prevent it from slipping. Make sure the lifting gear cannot touch other components during lifting.

•

Do not stand under a swinging load.

•

Repair work can only be performed under a raised truck if the truck has been protected against accidental lowering.

•

Work may only be performed on the chassis, fork carriage or mast if they have also been protected against accidental lowering.

•

Lifting gear such as load slings routed around sharp edges must be protected from cuts.

ESR 5000

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 regulations. 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

LUBRICATION & ADJUSTMENT

Notes:

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 on the crane.

CAUTION Battery acid can scald Battery acid will spill if a filled battery tips over during transport. This can cause injury to bystanders and damage the truck and transportation equipment.

5. Carefully lift the truck with the crane.

Lifting the truck with a forklift truck

 Always remove the battery before transporting the truck.

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 handling equipment used have the required capacity. Information on the required capacity can be found on the truck data plate under “Truck Weight Less Battery” and “Battery Weight”.

Fig. 3 Lifting the truck with a forklift truck

1. Fully lower the forks. 2. Fully retract the mast. 3. Set the drive wheel (1) at an angle so that it is facing 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 distances 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

LUBRICATION & ADJUSTMENT Transport and Storage when the brakes have been released by an authorised engineer.

WARNING Tipovers can result in fatal accidents A truck tipover can result in fatal injuries.  Make sure the towing truck has sufficient capacity. Information on the capacity required can be found on the truck data plate under “Truck Weight Less Battery” and “Battery Weight”.  Make sure the drive and castor wheels of the broken down truck do not get damaged by the forks of the towing truck.  Make sure the broken down truck does not slide off the forks of the towing truck.

WARNING Risk of accidents Long stopping distances and excessive tow loads can result in accidents and serious injury.  Connect the truck to the tow truck (e.g. with a tow bar) to prevent it from rolling automatically.  Bear in mind that the brakes of the tow truck also have to stop the truck that is being towed.

Jacking up the Truck CAUTION Avoid damaging the drive wheel When the truck is de-energised the brakes are applied to the drive wheel. If the drive wheel drags along the ground while the truck is being towed it will get damaged.  Make sure the drive wheel does not touch the ground as the truck is being towed.

WARNING Tipovers can result in fatal accidents  Make sure the jack has sufficient capacity. Information on the capacity required can be found on the truck data plate under “Truck Weight Less Battery” and “Battery Weight”.

WARNING Incorrect jacking procedures can cause fatal accidents 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

LUBRICATION & ADJUSTMENT Transport and Storage

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

LUBRICATION & ADJUSTMENT Truck Assembly and Commissioning

Truck Assembly and Commissioning

Erecting the chassis

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 handling 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 accessories with a 2 tonne capacity.

•

A crane with a minimum capacity of 2 tonnes.

•

A forklift truck with a minimum capacity of 2 tonnes at the required lift height.

Fig. 6 Attaching the shackles and clevis 1

Shackle mounted on the outside of the outrigger

Shackle mounted on the front of the outrigger

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

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 with the forklift truck until the chassis is no longer touching the ground. At the same time travel forward slowly so that the load slings remain upright. 6. Continue lifting step by step with the crane and compensating with the forklift truck, as described in step 8, until the chassis is suspended upright in the load slings.

Brake failure can result in accidents If the transport retainer is not removed from the brake fluid container the foot brake will not work.  Before using the truck replace the transport retainer with the original cover.

ESR 5000

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

Test key for float switch BFS

Cover

Reservoir

“Max.” mark

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 ¼ turn to the left.

ESR 5000

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

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 3 months, proceed as follows:

Carry out the following steps to restore the truck to service after a period of storage:

1. Disconnect the battery from the truck's circuit.

1. Remove any anti-corrosion film that may have been applied.

2. De-commission the battery in accordance with the manufacturer's instructions. 3. Clean the truck (see “Cleaning the truck and components”, page 57). 4. Lubricate the truck in accordance with the maintenance schedule. 5. Store the truck in a dry room with constant temperature and air humidity. Do not park the truck outdoors or in a humid environment. 6. The surfaces of trucks subjected to hostile ambient conditions such as saline atmosphere must be treated with suitable preservatives to prevent corrosion. 7. Cover the truck with an air-permeable material to protect it from dust. Do not use plastic sheets as condensation could form.

2. Jack up the truck, remove the hard wooden blocks and lower the truck. 3. Charge the battery or install a charged battery. 4. Connect the battery. 5. Carry out the safety inspection.

Battery maintenance The condition of the battery has a considerable impact on the performance of the truck. Optimum maintenance (regular acid density and level checks, cleaning the cell covers) maintains the battery's performance and useful life. Always service the battery in accordance with the battery manufacturer's instructions.

8. Jack up the truck to prevent the wheels from flattening.

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 storage every 3 months. 1. Connect the battery. 2. Check the battery charge and re-charge the battery 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 necessary. 7. After inspection disconnect the battery.

ESR 5000

LUBRICATION & ADJUSTMENT Component Access

Component Access Components in the chassis can be accessed by unscrewing panels or swivelling out the driver's seat.

Accessing components under the panels

WARNING

A sudden drive system start-up can cause fatal injuries People can be fatally injured when carrying out maintenance and adjustment work on the traction motor, hydraulics or truck controller if the traction motor or a 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.

1 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.

2 Fig. 15 Component access 1

Panel

Driver's seat

Floorboard

ESR 5000

LUBRICATION & ADJUSTMENT Component Access Components under the panels

Fig. 17 Components under the panels 1

Battery connector

Emergency Disconnect

Start up card

Hydraulic control module HCM (Access 2)

Control fuses (FU1 - FU6)

Steering control module SCM (Access 5)

Traction control module TCM (Access 3)

Steering control module main fuse (FU13)

Main contactor

Main control module VCM (Access 4)

Main fuse (FU7)

ESR 5000

LUBRICATION & ADJUSTMENT Component Access Accessing the motor compartment

1 Fig. 18 Seat panel handle

Fig. 20 Seat swivelled out

Seat panel

Swivelling in and locking the seat panel

Handle

1. Lift up the driver' seat armrest.

1. Push the handle (2) in the direction of the arrow.  You can now access the lock of the seat panel (1).

2. Swivel the seat panel (1) in as far as the stop.  The seat panel locks automatically.

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

LUBRICATION & ADJUSTMENT Component Access Motor compartment

1 6

7 2

Fig. 21 Motor compartment 1

Hydraulic reservoir and filter

Pump motor

Steer motor

Steering toothing ring gear

Dipstick

Traction motor

ESR 5000

Motor brake

LUBRICATION & ADJUSTMENT Component Access Accessing components under the floorboard

1 2

Fig. 22 Removing the floorboard 1

Floorboard

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

LUBRICATION & ADJUSTMENT Component Access Components below the floorboard 1

7 3

5 4 Fig. 23 Components below the floorboard 1

Accelerator pedal potentiometer and travel switch

Safety pedal sensor

Main plug assembly

Horn

Brake fluid reservoir with main brake cylinder and BFS

Brake pressure switch

DC / DC converter (option)

Brake pedal

ESR 5000

LUBRICATION & ADJUSTMENT Recommended Lubricants and Consumables

Recommended Lubricants and Consumables

Take care to protect all electrical connections and components from corrosion. For detailed information, refer to the Electrical System chapter.

The following tables list lubricants and consumables that Crown uses in its factory. However, you can use any lubricants provided they meet the same technical criteria.

Service intervals (see page 29) must be adapted to the conditions of use.

Cold store truck requirements Special hydraulic oils, lubricants and grease must be used for cold store applications (cold store trucks).

Abbreviations used in the table The lubricant type is indicated by letters. Individual letters (A, B, ...) denote lubricants for normal temperature ranges, double letters (AA, BB, ...) for low temperature ranges.

An anti-corrosion fluid (Crown no. 805236-004) must be applied to all machine parts such as screws, washers, nuts, pins, retaining rings etc. Type

Lubricant Type

Product

Manufacturer

A and AA

Transmission oil

Degol PAS 150

Aral

Renolin UNISYN CLP 150

Fuchs Mineralölwerke GmbH

Aralube HLP2

Aral

LM Grease

Castrol

Regulus A2

Century

Beacon EP2

Esso

EP2

Maxol

Mobiluxe EP2

Mobil

Retinax LX

Shell

ALGWMI

SKF

Aralube SKL2

Aral

Unirex Lotemp EP

Mobil

Vitam GF 32

Aral

Hyspin AWS-32

Castrol

Nuto H32

Esso

DTE 24

Mobil

Tellus 32

Shell

Hydran LZ 32

Finol

B110

Fuchs Mineralölwerke GmbH

BB D

Grease (Multi-Purpose)

Low temperature grease Hydraulic oil

Hydraulic oil (Low Temp)

Deutz Oel HVI 32

Klockner

Lubrication oil

Essolube HDX+40

Esso

Kowal M 40

Aral

Delvac 1240

Mobil

Part No. ---

F806118

053002-005

---

053001-009 ---

ESR 5000

LUBRICATION & ADJUSTMENT Recommended Lubricants and Consumables Type

Lubricant Type

Product

Manufacturer

Low temperature lubrication Mobil SHC 626 oil

Mobil

Special grease

Dow Corning

Molycote® BR-2 Plus

Part No. -----

Lubricants

Product

Application

Anti-corrosive agent

Anticorit BW 366®

Corrosion inhibitor for cold store trucks

805236-004

Rubber & vinyl dressing

Commercial

Rubber components, plastic panels

-------------

ESR 5000

Part No.

LUBRICATION & ADJUSTMENT Planned Maintenance and Inspection

Planned Maintenance and Inspection

The lubricant type is indicated by letters. Individual letters (A, B, ...) denote lubricants for normal temperature ranges, double letters (AA, BB, ...) for low temperature ranges.

Maintenance Schedule This maintenance schedule assumes single shift operation under normal conditions. The maintenance intervals must however always be adapted to the prevailing operating conditions. In extreme conditions (dust, dirt, humidity etc.) and in cold stores the maintenance intervals should be reduced. 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

Service hours

Perform on standard trucks

Perform on cold store trucks

Inspection item

Lubrication item

ESR 5000

LUBRICATION & ADJUSTMENT Planned Maintenance and Inspection Seat and seat panel

Fig. 24 Seat and seat panel

ESR 5000

LUBRICATION & ADJUSTMENT

B L-1 BB

Seat panel

Test the seat panel lock.

24 M

Apply a thin layer of grease to the seat rails(a).

5000 h

I-1

12 M

Clean and check for: - Wear - Freedom of movement - Secure attachment to the seat cover.

2000 h

Seat rails

Seat and seat panel

1000 h

Action

Component

Item no.

Assembly

500 h

Lubricant type

Planned Maintenance and Inspection

C/X

I-2

a. For the grade and application temperature refer to the Recommended Lubricants and Consumables table, page 27.

ESR 5000

LUBRICATION & ADJUSTMENT Planned Maintenance and Inspection Brake system and load wheels

Fig. 25 Brake system and load wheels

ESR 5000

LUBRICATION & ADJUSTMENT

12 M

24 M

Assembly

Component

Action

Item no.

500 h

1000 h

2000 h

5000 h

Lubricant type

Planned Maintenance and Inspection

Brake system

Service brake

Check brake fluid level(a).

I-1

C/X

Replace the brake fluid (see page 293)(a).

L-1

Parking brake

Test the brake fluid warning switch (BFS).

I-2

Test the brake pedal slack on the main brake cylinder (see page 294).

I-3

Grease the brake pedal mechanism(a).

B L-2 BB

C/X

Check the brake lining wear on the load wheel brakes (see page 292).

I-4

Check all brake lines and connections for corrosion and leaks.

---

C/X

Apply compressed air and check the air gap (see page 288). Check operation.

I-5

Disassemble and check for wear, Load wheels

Tyres

Suspension

C/X

Check for: - Damage - Wear

C/X

Check bearing play. If there is bearing play, apply the appropriate torque to the screws (see page 294).

I-6 C

a. For the grade and application temperature refer to the Recommended Lubricants and Consumables table on page 27.

ESR 5000

LUBRICATION & ADJUSTMENT Planned Maintenance and Inspection Drive unit

Fig. 26 Drive unit

ESR 5000

LUBRICATION & ADJUSTMENT

I-2

- Replace the oil(a).

L-1

Traction motor

- Ensure attachment is secure.

I-3

Drive plate

- Ensure attachment is secure.

I-4

Drive wheel

Check for: - Wear(b) (wear limit Ø ≤ 309 mm)

24 M

- Check the drive unit mounting screws on the chassis are secure.

5000 h

I-1

12 M

Check for: - Leakage - Unusual noise - Oil level (see page 97)

2000 h

Gear unit

Drive Unit

1000 h

Action

Component

Item no.

Assembly

500 h

Lubricant type

Planned Maintenance and Inspection

I-5

Secure (180 Nm)(c)

Both support blocks Check for wear and check the settings on the chassis (see page 53).

I-6

Steer motor

- Ensure attachment is secure.

I-7

Steering toothing ring gear

Clean and lubricate(a).

B L-2 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 prescribed intervals.

ESR 5000

LUBRICATION & ADJUSTMENT Planned Maintenance and Inspection Reach carriage

Fig. 27 Reach carriage

ESR 5000

LUBRICATION & ADJUSTMENT

Extend the reach mechanism the full distance in both directions. Make sure the speed reduction applies at the end sections.

---

Check for freedom of movement: - Rollers - Backing rollers - Side rollers

I-2

Rollers

Lubricate the rollers(a).

B/ BB

Adjust as required: - Backing rollers - Side rollers (See page 352.)

24 M

Reach function

5000 h

I-1

12 M

Check for damage.

2000 h

Reach carriage

1000 h

Action

Component

Item no.

Assembly

500 h

Lubricant type

Planned Maintenance and Inspection

L-1 C/X I-3

Roller track wear rails

Clean, check for damage. Apply a thin layer of grease.

B/ BB

Reach cylinder

Check attachment (see page 336).

I-4

Rubber buffer

Check for wear.

---

Hydraulic manifold cover

Ensure it is fitted securely.

Electrical wiring in the carriage

Ensure plug connections are tight. Check presence of strain reliefs.

I-5 I-6

a. For the grade and application temperature refer to the Recommended Lubricants and Consumables table on page 27.

ESR 5000

LUBRICATION & ADJUSTMENT Planned Maintenance and Inspection Hydraulic system

Fig. 28 Hydraulic system

ESR 5000

LUBRICATION & ADJUSTMENT

12 M

30 M 5000 h

Check the oil level with the cylinders fully retracted. Add oil(a) if required (see page 83).

2000 h

Hydraulic oil reservoir

Hydraulic system

1000 h

Action

Component

500 h

Assembly

Item no.

Lubricant type

Planned Maintenance and Inspection

I-1

D L-1 DD

Replace the return filter, breather filter and suction strainer (see page 84).

I-2

Change the hydraulic oil(a) (see page 83 - requires approx. 36 L)

---

Check all hoses, lines and connections for leaks and damage.

---

Check hose attachment in reach carriage for wear and make sure it is secure.

I-3

Cylinders

Check all cylinders are secure, check for leaks and damage.

---

Emergency lowering

Test the emergency lowering valve (see page 77).

I-4

Hoses, lines and connections

C/X

C(b)

X(c)

C/X

Hydraulic manifolds Check the main valve block in the reach carriage for leaks (see page 75).

I-5

Check the "Accessories" valve block in the reach carriage for leaks (see page 76).

I-6

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

LUBRICATION & ADJUSTMENT Planned Maintenance and Inspection Electrical system - part 1

Fig. 29 Electrical system - part 1

ESR 5000

LUBRICATION & ADJUSTMENT

30 M

Test the safety pedal.

5000 h

Controls

12 M

Test the display screen and check all displays are legible.

2000 h

Display screen

Electrical system

1000 h

Action

Component

500 h

Assembly

Item no.

Lubricant type

Planned Maintenance and Inspection

Test the parking brake switch and indicator light. Test the travel direction switch. Test the seat switch. Test the lift controls. Test the Emergency Disconnect switch. Ensure the potentiometer connections are secure. Control modules and power cables

See operator manual

Test the horn.

C/X

---

Check all control modules are clean and secure. Check the power cable connections to the control modules, fuses FU7, FU13 and contactor ED1 are secure.

Carry out the safety test (see Steering control module (SCM) and page 261). traction control module (TCM)

I-1

---

C/X

ESR 5000

LUBRICATION & ADJUSTMENT Planned Maintenance and Inspection Electrical system - part 2

Fig. 30 Electrical system - part 2

ESR 5000

LUBRICATION & ADJUSTMENT

Check wires and lines for insulation damage.

---

Make sure plugs on the connector panel are secure.

I-1

Traction motor (M1) Ensure the power cable connections are secure and free of damage. For torques and important installation instructions see page 273.

I-1

Check the plug connections to encoder ECR1 and thermal sensor THS1 for damage and make sure they are secure.

I-3

Pump motor (M2)

Battery

Ensure the power cable connections are secure and free of damage. For torques and important installation instructions see Connecting the power cables, page 273 or page 277.

I-4

Check the plug connections to encoder ECR2 and thermal sensor THS2 for damage and make sure they are secure.

I-5

Check battery cables and connectors for damage.

30 M

Connectors and lines

5000 h

---

12 M

Test the fans using the Service menu (see page 172).

2000 h

Fans

Electrical system

1000 h

Action

Component

Item no.

Assembly

500 h

Lubricant type

Planned Maintenance and Inspection

C/X

I-6

Check terminal post condition. Check battery in accordance with battery manufacturer's instructions (see manufacturer's maintenance instructions).

---

ESR 5000

LUBRICATION & ADJUSTMENT Planned Maintenance and Inspection Travel and pump motors

Fig. 31 Travel and pump motors

ESR 5000

LUBRICATION & ADJUSTMENT

Motor output

Motor attachment

See Replacing the Pump Motor, page 279: - Remove the pump motor. - Clean the output toothing, check it for damage and apply grease(a). - Re-assemble the pump motor. Check the rubber-bonded-to-metal mounting (rubber buffer) on the pump motor attachment for cracks and hardening.

30 M

I-2 L-2

Pump motor (M2)

5000 h

I-1 L-1

12 M

2000 h

See Replacing the Danaher Traction Motor, page 273: - Remove the traction motor. - Clean the output toothing, check it for damage and apply grease(a). - Re-assemble the traction motor.

Motor output

1000 h

Traction motor (M1)

Action

500 h

Component

Item no.

Assembly

Lubricant type

Planned Maintenance and Inspection

C/X

L-3

a. For the grade and application temperature refer to the Recommended Lubricants and Consumables table on page 27.

ESR 5000

LUBRICATION & ADJUSTMENT Planned Maintenance and Inspection Mast

Fig. 32 Mast

ESR 5000

LUBRICATION & ADJUSTMENT

I-2

Clean the lift chains (see page 340) and lubricate them (see page 346).

Clean the running surfaces in the mast channels and check for wear. Grease the running surfaces in the mast channels(a).

Mast cable

Guide pulleys

Switches

Battery removal stops(b)

L-1 I-3

B BB

L-2

Check the mast rollers’ freedom of movement (see page 324).

I-4

Check the condition of the mast stage end stops (poly stop blocks) and make sure they are secure (see page 316).

I-5

Check the mast cable for damage, check the tension jacks for damage and make sure they are secure.

I-6

Check the guide pulleys for damage.

I-7

Lubricate the guide pulley mountings. Check the condition and operation of the height reset switches / lift speed reduction switches.

30 M

Check and adjust mast chains and chain supports (see page 340).

5000 h

I-1

12 M

Check mounting bolts are secure (see page 320).

2000 h

Mast

1000 h

Action

Component

Item no.

Assembly

500 h

Lubricant type

Planned Maintenance and Inspection

B BB

C/X

L-3 --

Ensure the battery removal stops are 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

LUBRICATION & ADJUSTMENT Planned Maintenance and Inspection Fork carriage

Fig. 33 Fork carriage

ESR 5000

LUBRICATION & ADJUSTMENT

I-2

Clean the slide blocks. Check for wear and test operation (see page 330).

I-3

Grease slide blocks.

B BB

L-1

Lubricate the grease nipples on the fork carriage.

B BB

L-2

Load backrest

Check load backrest for damage and ensure it is securely fitted.

I-4

Fork tines

Check the fork tines (see page 349).

I-5

30 M

Check the fork carriage rollers for freedom of movement.

5000 h

I-1

12 M

Check the fork carriage for damage.

2000 h

Fork carriage

1000 h

Action

Component

Item no.

Assembly

500 h

Lubricant type

Planned Maintenance and Inspection

C/X

ESR 5000

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

Thread size

12 and 12.9

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

Thread size

Torque (Nm)

M5 x 0.8

M6 x 1

M8 x 1.25

M10 x 1.5

M12 x 1.75

111

152

M16 x 2

270

372

M20 x 2.5

521

717

ESR 5000

12 and 12.9

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 body under the truck before it has been supported, or when jacking up the truck.  Always support a raised truck with hard wooden blocks or other appropriate equipment to relieve the jack.

Fig. 34 Load wheel attachment

4. Remove the screw (2, Fig. 34) and the cover disk (3). 5. Loosen the retaining screw (4). 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. 2. Jack up the truck (see page 14). 3. Remove the hub cap.

Fig. 35 Load wheel disassembly 1

Load wheel

Guide bolt (item no. 825455)

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

LUBRICATION & ADJUSTMENT Load Wheels

1 2

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

LUBRICATION & ADJUSTMENT Support Blocks

Support Blocks The support blocks prevent the truck from tipping over on its side when the mast is fully extended and the load centre of gravity may be in an unfavourable position. The setting can change during operation due to the wearing of the drive wheel and support blocks (dimension H, Fig. 37). Regular inspection and adjustment is therefore required in the following cases:

4. Measure the distance from the left and right support blocks to the ground again, and record dimension H (see Fig. 37) for the 2nd point. 5. Continue turning the truck approx. 120° with the steering at full lock. 6. Measure the distance from the left and right support blocks to the ground again, and record dimension H (see Fig. 37) for the 3rd point.

•

During planned maintenance, every 1,000 hours or 6 months

Analysing the measurements

•

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 1

Drive wheel

Support block

Warehouse floor

Dimension H

2. Compare the calculated dimensions with the respective H dimensions for the mast type from Table 1. 3. Dimension H should be no more than H + 1 mm on any of the 3 measuring points.  If dimension H is greater than H + 1 mm on one of the measuring points, Adjusting the support block height, replace the worn support blocks if necessary.

Checking the support block distance Requirements Measurements are taken at three points offset by approx. 120° within the truck's turning radius. This compensates for any unevenness in the ground. The parking area must therefore be large enough for the truck to turn in its radius without any danger.

Adjusting the support block height Before adjusting Note: The support blocks are worn if they have lost 5 mm of material.

Measurement Measure at 3 points 1. Park the truck on a level surface. 2. Measure the distance from the left and right support 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

LUBRICATION & ADJUSTMENT Support Blocks 1. Jack up the truck (see page 14).

Measure the remaining support block height

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 number

Wear limit X

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 previously 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

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 individual ones. 4. Now check the support block distance and adjust as required.

ESR 5000

Notes:

LUBRICATION & ADJUSTMENT Cleaning the Truck and Components

Cleaning the Truck and Components

Cleaning the entire truck 1. Park the truck in an area with an oil separator. 2. Switch off the truck, disconnect and remove the battery.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.

WARNING

 Observe the manufacturer’s safety instructions when handling solvents and lubricants.

Malfunctions when restarting the truck can cause serious injury Water can penetrate electrical components after steam 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, distributor boards, controllers and wiring can be damaged by water, cleaning agents and solvents. Mineral and chemical residue that automatically remain on or in components after cleaning, are a cause of corrosion. This corrosion results in malfunctions and premature failure.

Roller and slide bearings Steam cleaning and solvents damage the lubricant film on bearing surfaces. This results in dry running and rapid damage to the bearing elements.

Cleaning the truck surface 3. Dry clean the truck. To do this use cloths, soft brushes (not metal brushes) and if necessary weak, dry compressed air. Note: Local contamination that cannot be removed by dry cleaning can be treated with a damp cloth and a neutral cleaning agent. Make sure that neither water nor cleaning agent get into electrical components or bearings. Cleaning lift chains 4. See page 58.

Corrosion-protected surfaces

Cleaning electrical components

The brake lines, screw connections and shiny metal surfaces in particular on cold store trucks are factorytreated with an anti-corrosive agent (Anticorit BW 366®). This protection can be washed off by solvents and steam cleaning. The above-mentioned components will corrode as a result.

5. Clean electrical components only with each, dry compressed air and a dry cloth.

Environmental protection Cleaning must only be performed in specially designated areas to enable hazardous chemicals and oils to be separated. Collect any waste (such as oily cleaning cloths) and dispose of them in accordance with local regulations.

Interior cleaning 6. Clean detachable rubber mats with water and a neutral cleaning agent. 7. Allow the rubber mats to dry out fully before returning them to the truck. 8. Damp-wipe plastic parts with a neutral cleaner. Note: If necessary use a standard commercial plastic cleaning agent to remove obstinate dirt. After cleaning the truck 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

LUBRICATION & ADJUSTMENT Cleaning the Truck and Components If however there is a possibility that damp may have penetrated electrical components, proceed as follows:

Cleaning removed components

1. Clean the truck with weak, dry compressed air and a cloth.

Cleaning lift chains

2. Leave the truck to stand for at least 30 minutes in a dry environment. 3. Insert the battery but do not connect it yet. 4. Jack up the truck so that the drive wheel is clear of the ground.

WARNING Malfunctions when restarting the truck can cause serious injury Water or cleaning agent residue in electrical components can cause malfunctions when the truck is switched on.  You must be prepared to switch off the truck immediately with the Emergency Disconnect when the battery is connected and the truck is powered up.  Make sure that nobody can be injured by components accidentally starting up (lift mechanism, sideshifter etc.). 5. Connect the battery.

Improper cleaning can cause chains to crack A cracked chain can result in fatal injuries. Never clean lift chains with steam cleaners, cold cleaning agents or corrosive, acid-based agents. This can cause direct chain damage through hydrogen embrittlement.  Clean the chain surfaces only with paraffin derivatives such as cleaning petroleum or cleaning petrol.  Apply an approved chain oil immediately after cleaning (see Recommended Lubricants and Consumables table, page 27). 1. Remove persistent dirt with cleaning petroleum or cleaning petrol. Apply a thin layer of the cleaning agent with a hard bristle brush and wipe with a lintfree cloth. 2. Apply an approved chain oil immediately after cleaning (see Recommended Lubricants and Consumables table, page 27).

Cleaning other mechanical components

6. Switch on the truck.  If a function automatically starts, apply the Emergency Disconnect immediately. Note: If possible, apply compressed air to the respective switch or connector. Repeat steps 1 to 6.  Is the starting pattern is normal, proceed to step 7. 7. Check all functions.

WARNING

With the exception of lift chains, components that have been removed can be steam-cleaned under certain conditions.

CAUTION Steam-cleaning can damage electrical components and bearings  Mechanical components may only be steamcleaned 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

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

Notes:

HYDRAULIC SYSTEM

Notes:

HYDRAULIC SYSTEM Abbreviations Used

Abbreviations Used Abbreviation

Meaning(a)

Description

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

---

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:

MVL

Manual Valve Lower

•

from the pump to the lift cylinders (lift)

•

from the lift cylinders back to the reservoir (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 Accessories

For fork tilt, sideshift and 5th function

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 POT5

Hydraulic function potentiometers

The potentiometers are connected to their respective control levers and transmit an analog control signal to the truck control 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 selected.

PVAR(b)

Proportional Valve Accessories Right

PVAR governs the downward tilt speed of the forks when "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 selected. The lift speed is governed by the pump speed.

ESR 5000

HYDRAULIC SYSTEM Abbreviations Used Abbreviation

Meaning(a)

Description

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

HYDRAULIC SYSTEM Feature Descriptions

Feature Descriptions Lifting

Fig. 41 Hydraulic circuit for lifting

The lift speed is controlled by the pump motor speed in proportion to the movement of the control lever.

The following symbols are used in the diagrams:

The oil then flows from input P of the valve block through the DCVH slide valve via output A to the hydraulic cylinders. The hydraulic cylinders extend.

Pilot line Pressure line

During lifting, the “lower” control pressure side of the DCVH slide valve is connected to the reservoir return 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).

Suction line Return line

The “lift” function is requested by pulling the corresponding control lever. The voltage on the slider of lift potentiometer POT2 changes. The pump and the magnetic coil of the SVH lift pilot valve are activated. The SVH valve drives the DCVH slide valve. The slide valve opens.

If the "lift/lower" control lever is released, the pump and SVH valve are switched off. SVH switches over through bias spring force so that the “lift” control pressure side of the slide valve is connected to the reservoir return line. 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.

ESR 5000

HYDRAULIC SYSTEM Feature Descriptions Note: If the MVL manual lowering valve is open, i.e. turned in, lifting is inhibited.

ESR 5000

HYDRAULIC SYSTEM Feature Descriptions Lower

Fig. 42 Hydraulic circuit for lowering

slide valve via output T to the reservoir. The hydraulic cylinders retract.

The following symbols are used in the diagrams:

In proportion to the movement of the control lever, the lowering proportional valve PVL controls the oil pressure on the slide valve - and hence the degree of opening of the slide valve - and ultimately the lowering speed.

Pilot line Pressure line Suction line

The flow control valve PCL mounted in front of the slide valve provides a constant lowering speed for any control lever position.

Return line

The "lowering" function is requested by pulling on the corresponding control lever. The voltage on the slider of lift potentiometer POT2 changes. The magnetic coil of proportional valve PVL is activated. The PVL valve drives the DCVH slide valve. The slide valve opens. Oil flows from the hydraulic cylinders via port A of the valve block through flow control valve PCL and the

During lowering, the “lift” control pressure side of the DCVH slide valve is connected to the reservoir return line via the SVH raise valve. This is necessary to prevent any counter-pressure from building up (which would affect the movement of the slide valve). If the "lift/lower" control lever is released, the PVL solenoid is switched off. PVL switches over through bias spring force so that the “lower” control pressure side of the slide valve is connected to the reservoir return line.

ESR 5000

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 clockwise. Note: After the lowering operation, close the valve as far as the screw stop.

ESR 5000

HYDRAULIC SYSTEM Feature Descriptions Extending the mast reach carriage

Fig. 43 "Extend mast reach carriage" hydraulic circuit

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.

The following symbols are used in the diagrams: Pilot line

If the control lever is released, the pump and the PVRE valve are switched off.

Pressure line Suction line Return line

The “extend 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 PVRE proportional pilot valve are activated.

PVRE is closed through bias spring force and the flow of oil to the reach cylinder is interrupted. The pressure 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 restrained through the closed position of the brake valve. The cylinder remains in its current position.

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 proportional valve. PVRE opens in proportion to the movement of the control 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 regulate 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

HYDRAULIC SYSTEM Feature Descriptions Retracting the mast reach carriage

Fig. 44 "Retract mast reach carriage" hydraulic circuit

PVRT is closed through bias spring force and the flow of oil to the reach cylinder is interrupted.

The following symbols are used in the diagrams:

The pressure 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 restrained through the closed position of the brake valve. The cylinder remains in its current position.

Pilot line Pressure line Suction line Return line

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 proportional 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 proportional valve. PVRT opens in proportion to the movement of the control 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

HYDRAULIC SYSTEM Feature Descriptions Fork tilt back

Fig. 45 "Fork tilt back" function hydraulic circuit

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 to output T and finally back into the reservoir.

The following symbols are used in the diagrams: Pilot line Pressure line

If the control lever is released, the pump and the SVT and PVAL valves are switched off. The valves are set to the home position through bias spring force. The oil flow through SVT is interrupted. The tilt cylinder remains in its current position.

Suction line Return line

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 proportional 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 control lever. The oil flows through port P of the main valve block, the PCA flow control valve and the PVAL proportional 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 releases 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

HYDRAULIC SYSTEM Feature Descriptions Fork tilt down

Fig. 46 "Fork tilt down" function hydraulic circuit

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 pressure is below 90 bar CBV blocks so that any load on the forks cannot tilt down automatically.

The following symbols are used in the diagrams: Pilot line Pressure line Suction line Return line

The “fork tilt down“ 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 PVAR proportional 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 PVAR proportional valve.

The piston moves back and forces the oil out of the tilt cylinder. The oil flows via port B2 of the “tilt/sideshift” 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. If the control lever is released, the pump and the SVT and PVAR valves are switched off. The valves are set to the home position through bias spring force. The oil flow through SVT is interrupted. The drop in oil pressure in the pilot line causes CBV to close. The tilt cylinder remains in its current position.

PVAR opens in proportion to the movement of the control lever. The oil flows through port P of the main valve block, the PCA flow control valve and the PVAR proportional 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 releases 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. A pilot line of the counterbalance valve CBV is connected to the pressure circuit after SVT. The 2nd pilot ESR 5000

HYDRAULIC SYSTEM Feature Descriptions Sideshift right

Fig. 47 "Sideshift right" hydraulic circuit

The oil flowing out of the left port of the sideshift cylinder flows via port B1 of the "tilt/sideshift” valve block, through valve SVS 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 following symbols are used in the diagrams: Pilot line Pressure line

If the control lever is released, the pump and the SVS and PVAR valves are switched off. The valves are set to the home position through bias spring force. The oil flow through SVS is interrupted. The sideshift remains in its current position.

Suction line Return line

The "sideshift right” function (seen from the operator’s position) is requested by pulling the corresponding control lever. The voltage on the slider of sideshifter potentiometer POT5 changes. The pump and the magnetic 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 control lever. The oil flows through port P of the main valve block, the PCA flow control valve and the PVAR proportional 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 releases 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

HYDRAULIC SYSTEM Feature Descriptions Sideshift left

Fig. 48 "Sideshift left" hydraulic circuit

The oil flowing out of the right port of the sideshift cylinder flows via port A1 of the "tilt/sideshift” valve block, through valve SVS to port A. From here it continues on to port B1 of the main valve block, through valve PVAL to output T and back into the reservoir.

The following symbols are used in the diagrams: Pilot line Pressure line

If the control lever is released, the pump and the SVS and PVAL valves are switched off. The valves are set to the home position through bias spring force. The oil flow through SVS is interrupted. The sideshift remains in its current position.

Suction line Return line

The "sideshift left” function (seen from the operator’s position) is requested by pulling the corresponding control lever. The voltage on the slider of sideshifter potentiometer POT5 changes. The pump and the magnetic 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 control lever. The oil flows through port P of the main valve block, the PCA flow control valve and the PVAL proportional 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 releases 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/sideshift" 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

HYDRAULIC SYSTEM Hydraulic Components

Hydraulic Components

Valve blocks

Hydraulic lines

Main valve block

General notes on inspection, installation and handling of hydraulic lines Prior to installation, apply dry compressed air to all hoses and lines to remove any loose foreign bodies. Rubber hoses with a wire braid inner construction, thermoplastic hoses and steel pipes that have collapsed or been kinked, are permanently damaged. They must be replaced even if there is no obvious external damage. Flexible thermoplastic hoses must be replaced if they distort in their normal operating position.

The main valve block is located under a cover in the mast reach carriage. The main valve block contains: •

The solenoids for controlling the various hydraulic functions

•

The AVL valve for adjusting the lowering speed

•

The MVL manual lowering valve

•

The RV1 relief valve.

Ports

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

To port B on the "Accessories" block

To the port on the mast reach cylinder (piston dome side)

To port A on the "Accessories" block

To the mast reach cylinder (piston ram side)

To the pressure side of the hydraulic pump

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 individually. In the event of a mechanical defect replace the entire block. The solenoid coils can be replaced.

ESR 5000

HYDRAULIC SYSTEM Hydraulic Components "Accessories" valve block This valve block is located in the fork carriage. It contains the solenoids for controlling the sideshifter and the tilt cylinder.

3. Raise a test load that is 10% +100 kg above the rated capacity.  If the RV1 relief valve applies, the setting is ok. If not, proceed to step 6. 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

To the sideshifter cylinder, "left" port

To the tilt cylinder, piston ram side

6. Loosen the counternut (2, Fig. 51) on valve RV1 (1).

To port A1 on the main valve block

To the sideshifter cylinder, "right" port

To the tilt cylinder, piston dome side

7. Adjust the setscrew (3) as required.  Turn clockwise to increase the contact pressure.  Turn anticlockwise to reduce the contact pressure.

Replacing the valves Valve bodies and the solenoid coils can be replaced on this block.

8. Tighten the counternut (1) again.

Checking and adjusting relief valve RV1

9. Repeat steps 1 to 8 until RV1 applies within the tolerance range.

The RV1 relief valve is preset to a pressure of 210+5 bar.

Checking the adjusted setting

Note: If the valve cannot be adjusted, it must be replaced.

Checking the setting 1. Raise a test load that is 10% above the rated capacity. 2. Raise the test load above the free lift height.  It should just be possible to raise this load.

ESR 5000

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 system 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

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

HYDRAULIC SYSTEM Bleeding and Flushing the System

Bleeding and Flushing the System

4. Tighten the bleed screw as soon as bubble-free oil emerges.

Safety notices

6. Clean up any oily components on the truck.

5. Carry out steps 2 to 4 on the other lift cylinder.

Bleeding the reach cylinder 1. Extend the forks and hold the control lever at the limit position for approx. 5 seconds.

WARNING High pressure hydraulic system High-pressure hydraulic oil can cause injury!

2. Retract the forks and hold the control lever at the limit position for approx. 5 seconds.

 Wear safety gloves and goggles or a face mask when depressurising the system.

3. Repeat steps 1 to 2 until the reach mechanism moves without any delay or jerky movement.

Bleeding the sideshift cylinder Note: This bleeds all the hydraulic lines to the fork carriage.

1. Extend the sideshifter and hold the control lever at the limit position for approx. 5 seconds. 2. Retract the sideshifter and hold the control lever at the limit position for approx. 5 seconds. 3. Repeat steps 1 to 2 until the sideshifter moves without any delay or jerky movement.

Bleeding the tilt cylinder Note: The sideshift cylinders must be bled beforehand! 1. Tilt the fork carriage back and hold the control lever at the limit position for approx. 5 seconds.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling cleaning agents, lubricants and consumables.

1. Fully extend the mast.

3. Open the bleed screw on the free lift cylinder. 4. Tighten the bleed screw as soon as bubble-free oil emerges.

2. Extend the lift cylinder as far as possible.

See “Bleeding the tilt cylinders”

Preparing for flushing

2. Fully extend the free lift cylinder.

1. Prepare the work area to collect spilled oil.

Bleeding the 5th function cylinder

Note: The lift cylinders must be bled.

1. Prepare the work area to collect spilled oil.

Bleeding the lift cylinders

3. Repeat steps 1 to 2 at least 10 times.

Flushing the lift cylinders

Bleeding the free lift cylinder

5. Clean up any oily components on the truck.

2. Tilt the fork carriage forward and hold the control lever at the limit position for approx. 5 seconds.

2. Check the lift cylinders for leaks.  If a cylinder is leaky, repair it (see page 363).  If the cylinders are sealed, proceed to step 3. Flushing the lift cylinders 3. Extend and retract the mast at maximum speed to the maximum lift height at least 10 times.  This flushes the lift cylinders.

3. Open the bleed screw on the free lift cylinder.

ESR 5000

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.

ESR 5000

HYDRAULIC SYSTEM Drift Tests

Drift Tests

Tilt cylinder drift test

After carrying out repairs on the hydraulic system check the drift on the lift and tilt cylinders.

Flush the tilt cylinders, attach a test load and plumb

Safety notices

1. Tilt the fork carriage several times from one end to 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 njuries Fatal injuries could result if the forks of the truck suddenly lower or if a load falls.  Do not stand under a swinging load.  Seal off the hazardous area to prevent access.

Lift cylinder drift test

4. Attach a lowering plumb with a piece of string approx. 3m long to the fork at an approximate distance of 1150 mm to the fork shank. Note: If the distance is not 1150 mm, you must calculate the drift nominal value accordingly! 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. 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 prevent it from sliding and falling.

Measuring the drift

3. Tilt the forks fully down.

10. Calculate the difference between the previously recorded measurement and the new measurement to establish the drift.  If the drift ≥ 50 mm, the internal leakage is too great. Replace the cylinder and repeat the drift test.

4. Attach a lowering plumb with a 3m long string to the fork tip. 5. Raise the forks beyond the free lift height so that the tip of the plumb is at least 100 mm above the ground. 6. Measure the height of the plumb above the ground and record the measurement.

9. After 5 minutes measure the plumb height again.

 If the drift < 50 mm, it has passed the drift test.

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 recorded 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

HYDRAULIC SYSTEM Hydraulic Oil Reservoir

Hydraulic Oil Reservoir

ESR 5000 hydraulic oil reservoir

The ESR 5000 and ESR 5000S use reservoirs with different 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

Fig. 52 ESR 5000S reservoir 1

Dipstick

Breather filter

Return filter cover

Return line port

Suction line port

Reservoir

Drain plug

Breather filter

Return filter cover

Return line port

Suction line port

Reservoir

Drain plug

ESR 5000

Dipstick

HYDRAULIC SYSTEM Replacing the Hydraulic Oil

Replacing the Hydraulic Oil Approx. 36 litres are required to replace the hydraulic oil. For the grade and application area see Recommended Lubricants and Consumables, page 27. Draining the hydraulic oil reservoir

Note: The return filter filters from outside to inside. It does not filter the oil you add to the reservoir via the opened return filter. 1. Fill up the reservoir (6, Fig. 52 or 53) once the entire hydraulic system has been bled. 2. Retract all the cylinders (mast reach on chassis, mast lowered, fork carriage tilted forward). 3. Add hydraulic oil via a 10 µm mesh filter up to the "MAX" mark on the dipstick (1, 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 environmental regulations. Replenishing the hydraulic oil reservoir

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

ESR 5000

HYDRAULIC SYSTEM Replacing the Filter

Replacing the Filter The system comprises two hydraulic filters and one breather filter. These must be replaced at regular intervals. See Maintenance Schedule, page 39.

4. Turn the filter element (3, Fig. 55) slightly to pull it out of the filter container and dispose of it. Filter element assembly 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 reservoir.

Health risk Cleaning agents, lubricants and consumables can damage your health.

4. Screw on the cover and tighten it only slightly by hand. Note: The cover is sealed and locked in place via the inserted O-ring. If tightened too fast it can only be released with a tool. This will also cause the O-ring to wear more quickly.

 Observe the manufacturer’s safety instructions when handling solvents and lubricants.

Replacing the suction filter

CAUTION 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

HYDRAULIC SYSTEM Replacing the Filter 3. Remove the four screws (3) from the reservoir flange.

Replacing the breather filter

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 attached filter element (2) out of the reservoir.

1. Remove the bayonet cap (2, Fig. 58) of the breather filter (2, Fig. 52 or 53) by turning it a ¼ turn to the left.

5. Unscrew and dispose of the filter element. Filter element assembly

2. Remove and dispose of the filter element (1, Fig. 58).

1. Push a new flange seal (3, Fig. 57) over the suction pipe.

Filter element assembly

2. Screw a new original Crown filter element onto the suction pipe. 3. Thread the suction pipe and filter element back into the reservoir and position them correctly on the flange.

1. Insert the new filter element. 2. Fit the bayonet cap and turn it a ¼ turn to the right to lock it.

4. Insert the screws (2, Fig. 56) and torque them crosswise to 25 Nm.

ESR 5000

HYDRAULIC SYSTEM Replacing the Hydraulic Pump

Replacing the Hydraulic Pump The hydraulic pump cannot be repaired. It must be replaced in full. Preparing to remove the hydraulic pump 1. Place a flat tray underneath the truck to collect any spilled hydraulic oil. 2. Switch off the truck, disconnect the battery and prevent it from being switched on again.

WARNING Trapping hazard An unsecured pump unit can trap your fingers if the bracket is loosened.  Secure the pump unit with a load handling device and support it with wooden wedges before undoing the mounting screws (5, Fig. 59). 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 removed. 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. Fig. 59 Hydraulic pump removal (ESR 5000S)

3. Secure the hydraulic pump with the screws (3, Fig. 60).

1. Remove the suction hose (1, Fig. 59) and seal the ports with clean filler plugs.

4. Attach the suction and pressure lines to the hydraulic pump using new seals.

2. Disconnect the pressure line from the union (2, Fig. 59) and seal the ports with clean filler plugs.

5. Lower the pump unit.

3. Disconnect the sensor cable and power cables (6, Fig. 59) from the pump motor. Note: The cables must be exposed sufficiently so that the pump unit can be raised approx. 250 mm without tilting or tipping over.

6. Attach the retaining plate (4, Fig. 59) via the screws (5). 7. Restore the pressure line connection (2, Fig. 59). 8. Restore the electrical connections. Note: Do not connect the suction hose at this stage.

ESR 5000

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 µm one way filter. For the grade and application area see Recommended Lubricants and Consumables, page 27. 2. Connect the suction hose (1, Fig. 59) to the reservoir. 3. Power up the truck. 4. Bleed the pump by activating the "sideshifter" function several times as far as the stop. 5. Check the hydraulic oil level and replenish if necessary (see page 83). 6. When you have reached operating temperature, check all the ports for leaks.

ESR 5000

HYDRAULIC SYSTEM Replacing the Hydraulic Pump

Fig. 60 Pump unit and connection lines ESR 5000

Fig. 61 Overview of Hydraulic Lines and Ports

90 - 95 Nm

24 - 27 Nm

Hydraulic Port Torques

80 - 88 Nm

34 - 37 Nm

ESR 5000

107 - 119 Nm

24 - 27 Nm

90 - 95 Nm

Valve block in mast reach carriage Valve block mounting screws(1)

 Counter the torque on the union (1) by holding tight the filter connection (2).

The filter can be damaged if the return line hose union is torqued incorrectly

CAUTION

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

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

Lift function hose system

Accessories hose system

Hydraulic Port Torques

HYDRAULIC SYSTEM

Notes:

Hydraulic Port Torques

HYDRAULIC SYSTEM

ESR 5000

DRIVE UNIT

Notes:

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 sufficient 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 injuries Fatal injuries could result if the truck is suddenly lowered.  Do not stand under a swinging load.

Fig. 62 Drive unit

8. Remove the six screws (1, Fig. 62). 9. Lower the pallet truck and pull it out from under the truck together with the gear unit.

3. Raise the truck with a second fork lift truck and prevent 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 supports.  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

DRIVE UNIT Gear Unit

1 2 3

4 7 2

8 15 12

9 10

11 14

44 38 36 18

2 35

34 19

27 28 22

30 41 20

40 39

21 33 22

Fig. 63 Gear unit exploded diagram ESR 5000

DRIVE UNIT Gear Unit Repairing the gear unit Note: The gear unit must only be repaired by trained and authorised Crown personnel. Otherwise the warranty will be invalid.

CAUTION Correcting the tooth flank bearing and pre-tensioning the shaft bearing requires years of experience with gear units. Incorrect adjustments and settings will result in premature failure of the gear unit.

In the next steps the flange shaft, the bevel pinion and their respective bearings are removed: 14. Push out the flange shaft (42) using a suitable device. 15. Extract the inner ring of the conical roller bearing (38) from the flange shaft (42). Note: When disassembling, mark the assembly location of the shims (18, 20, 35). The same number of shims will have to be put back temporarily in the same position at a later stage.

 It is preferable to replace the gear unit!

16. Take the bevel gear (22), spacer ring (36) and adjusting shim(s) (18) and (35) where applicable out of the housing.

Dismantling the gear unit

17. Extract the inner ring of the conical roller bearing (34) from the bevel gear (22).

Unless otherwise indicated, all item numbers refer to Fig. 63, page 94.

18. Extract the outer rings of the conical roller bearings (34, 38) from their seats in the transmission housing. 19. Remove the thread shield ring (41), radial shaft seal (40) and retaining ring (39) from the housing seat.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents and lubricants. 1. Prior to dismantling, thoroughly clean the gear unit with a cold cleaning solution and dry with low-pressure air. 2. Drain the oil (capacity approx. 3.6 litres). 3. Insert the gear unit with the wheel nuts (43) into a secure device to prevent it from twisting.

20. Press the bevel gear (22) down from out of the spur wheel (16) and the conical roller bearing (17). 21. Remove the conical roller bearing (17) and shim (18) where applicable. 22. Extract the outer ring of the conical roller bearing (21). 23. Remove the spacer bushing (19) from the bevel pinion shaft and extract the inner ring of the conical roller bearing (21) from the bevel pinion shaft. 24. Thoroughly clean all components and remove the remains of the sealant and adhesive.

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 Oring (24).

CAUTION

6. Remove the screws (1) and the lock washers (2). 7. Take off the live ring bearing (3). 8. Remove the O-ring (5) from the recess of the gear ring (8). 9. Remove the screws (29 and 31) and the lock washers (30). 10. Take off the gear ring (8). 11. Remove the screws (32) and the washer (33). 12. Undo the nut (15) of the bevel pinion shaft. 13. Take the gear unit out of the mechanism.

Used seals cause leaks and bearings can be damaged when removed. All bearings and seals must be replaced. Preparing the gear unit 1. Press the outer rings of the conical roller bearings (17, 21, 34 and 38) into their respective notches in the cleaned housing. Make sure they are positioned level in the housing. 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

DRIVE UNIT Gear Unit Adjusting the bevel gear set

3. Insert the retaining ring (39) in its corresponding groove. 4. Press the radial shaft seal (40) into the housing using a suitable tool. 5. Place the thread shield ring (41) onto its space in the housing and caulk it. 6. Press the inner ring of the conical roller bearing (34) onto the bevel gear (22) using a suitable tool. 7. Press the wheel nuts (43) into the flange shaft holes (42) using a suitable tool.

The correct setting can be calculated via the tooth flank bearing. Always adjust the bevel gear set to the correct flank position. The tooth ends should not form a straight line: •

The tooth flank bearing must always align with the inner tooth end.

•

The tooth flank bearing must range from high (top of tooth) to low (bottom of tooth).

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 flank bearings on the bevel pinion and bevel gear.

1. Press the inner ring of the conical roller bearing (21) onto the conical pinion shaft (22). 2. Place the shim(s) (20) and spacer bushing (19) on the conical pinion (22).

3. Insert the pre-assembled bevel pinion shaft (22) into the housing (23) from below.

2 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 ensure there is zero backlash. Reduce the torque if necessary.  Record the final torque. This will be needed again to adjust the bevel gear set.

Assembling the flange shaft 7. Bring the housing into its subsequent assembly position. 8. Insert the spacer ring (36) and the pre-assembled bevel gear (22) in the respective order through the housing opening. 9. Apply a thin layer of oil to the flange shaft (42) and carefully push it through the previously inserted unit parts in the housing. 10. Insert the housing with the wheel nuts into a secure device to prevent it from twisting. 11. Guide the hex. socket screws (32) through the washer (33) and torque them to max. 77 Nm to tension the flange shaft assembly. 12. Test the shaft can move freely; ensure there is zero backlash. Reduce the torque if necessary.  Record the final torque. This will be needed again to adjust the bevel gear set.

Fig. 64 Permissible tooth flank bearings 1

High tooth flank bearing on bevel pinion

Bevel pinion

Bevel gear

Low tooth flank bearing on bevel gear

High tooth flank bearing on bevel gear

Low tooth flank bearing on bevel pinion

Note: Carry out all checks and adjustments with care. Pre-tensioning the bearings and shims will affect the tooth flank bearing. Do not set the pre-tension too low. It will automatically reduce during normal operation. 13. Colour the tooth flanks of the bevel gear (22) with touch-up paste (striking colour) or a light oil colour. 14. Take the gear unit out of the mechanism. 15. Turn the bevel gear several times in one direction.  The tooth flank bearing will appear as a bright point (marked black in Fig. 64) on the tooth flanks.

ESR 5000

DRIVE UNIT Gear Unit 16. Check the tooth flank bearing. 17. Remove and/or add shims (18, 20, 35) to restore the tooth flank bearing to the tolerance limits (see Fig. 64). Change the bearing pre-tension if necessary. Take care not to exceed the max. levels (flange shaft max. 77 Nm, spur wheel max. 100 Nm).  Record the new torques. 18. Torque the screw (32) of the flange shaft and nut (15) of the spur wheel to the previously recorded levels. 19. Repeat the check and adjustment until the tooth flank bearing is within the tolerance range.

CAUTION Leave the surface and thread sealants to dry for at least 2 hours at room temperature. Then fill with oil. 36. Set the gear unit in the assembly position. 37. Add oil to suit the application temperature (see page 27) up to the bottom of the refill plug. The capacity is 3.6 litres.

Assembling the gear unit CAUTION

Final assembly 20. Re-assemble the bevel pinion shaft and flange shaft. 21. Clean all the components. 22. Apply a thin layer of Loctite 307 to the inside of the conical roller bearing inner rings.

New gear units are always supplied without oil  Add oil to suit the application temperature (see page 27) up to the bottom of the refill plug. The capacity is 3.6 litres.

23. Apply medium strength Loctite 242 to the threads of the nut (15) and the screws (32). 24. Refit the bevel pinion shaft and flange shaft and torque the screw (32) and nut (15) to the last recorded values. 25. Manually turn the gear unit through, while checking for freedom of movement and ensure it operates without any clearance.

CAUTION When assembling the gear unit take care not to damage the toothing of the spur pinion (14) or the spur wheel (16). Assembly is the reverse of disassembly (see page 93).

26. Apply a thin layer of Loctite 307 to the contact surfaces 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 transmission 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 surfaces 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

DRIVE UNIT Drive Wheel

Drive Wheel Note: The drive wheel must be replaced if its diameter is ≤ 309 mm.

3. Torque the wheel nuts (1) evenly and crosswise to 180 Nm. Note: After 50 service hours the wheel nuts (1) must be torqued to 180 Nm. Attach a sticker or notice to the operator position to act as a reminder. 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

Drive wheel

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

ELECTRICAL SYSTEM

Notes:

100

ELECTRICAL SYSTEM Electrical Components

Electrical Components

ECR1

ACS

Traction Encoder

Located below the accelerator pedal. Activates travel.

A sensor ball bearing, fitted in the top bearing shield of the traction motor. Captures the motor speed and transmits it to the TDM.

BFS

ECR2

Brake Fluid Switch

Lift Encoder

Installed in the cover of the brake fluid container on the main brake cylinder. Monitors the brake fluid level. A warning is displayed if the brake fluid drops below the permissible level.

A sensor ball bearing, fitted in the top bearing shield of the pump motor. Captures the motor speed and transmits it to the HDM.

Accelerator Switch

BLS

ECR3 Steering Feedback Encoder

Battery Latch Switch Installed on the battery latch in the motor compartment. Monitors the locking of the battery tray. If the battery tray is not retracted or not locked, travel is restricted to creep speed.

Fitted in the steer motor. Transmits a signal in proportion to the steering direction and speed of the steered wheel.

ECR4 Steer Encoder

BPS Brake Pressure Switch Attached to the brake cylinder. Closes at a brake pressure of 3 – 6 bar, thereby activating regenerative braking by changing travel direction, in addition to the mechanical brake.

A sensor bearing, located in the steering column below the steering wheel. Transmits a signal to the steering control module, depending on the rotary direction and speed of the steering wheel.

ECR5 Height Encoder

BRS Brake Switch Activates the parking brake and the parking brake symbol in the display when applied. If BRS is switched off again, the truck remains braked until the accelerator pedal is applied. It therefore prevents the truck from rolling away, for example when starting on a ramp.

BRAKE

Sensor bearing, installed at the top left (in the forks direction) of the outer mast (see page 265). ECR5 is driven by a crown gear adjacent to the 1st mast stage. Starts to acquire the lift height when the free lift is used up. Must be re-calibrated when the encoder is replaced (see C7 Height, page 131). If ECR5 is faulty or if the VCM does not detect any encoder signals, the lift speed is reduced and an event code is shown on the 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.

ESR 5000

101

ELECTRICAL SYSTEM Electrical Components EDS

FU2

Emergency Disconnect Switch

Control Fuse VCM/HDM/Horn

Installed in the electric compartment. When applied, disconnects the entire power supply.

This fuse (15 A/80 V) protects the control circuits of the main and hydraulic control modules.

ED1

FU3

Emergency Disconnect Contactor

Power Fuse Brake

Installed in the electric compartment. Disconnects the power supply to the HCM, TCM and SCM power circuits.

This fuse (10 A/80 V) protects the brake circuit.

FAN1, FAN4

Control Fuse SDM

FU4

Fan TCM

This fuse (10 A/80 V) protects the power circuit of the steer module.

Installed in the electric compartment. The traction control module switches the fans on at +35 °C, and off at +25 °C.

FU5, FU6

FAN2, FAN3

Control Fuses Options This fuse (15 A/80 V) protects the control circuits of the auxiliary functions.

Fan HCM Installed in the electric compartment. The hydraulic control module switches the fans on at +35 °C, and off at +25 °C.

FU7 Main Fuse

FKS

This fuse (425 A/48 V) protects the battery’s connection 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 horizontal.

Power Fuse SDM

FLS

This fuse (50 A/48 V) protects the steering power circuit.

HCM

Free Lift Switch Attached to the fork carriage. FLS is applied by a magnet attached to the inner mast. If the fork carriage is above free lift, the speed for this range can be set in the P6 Travel > FLS menu (see page 165)

Hydraulic Control Module

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 traction control module and the work lights.

Pressing the horn switch activates the horn.

Installed in the electric compartment. Controls the pump motor and takes the readings from the encoder ECR2 and the thermal sensor THS2.

ESR 5000

102

ELECTRICAL SYSTEM Electrical Components HGTS

Height Switch

Load Sensor

Attached to the top right (in fork direction) of the outer mast. Reduces the lift speed 500 mm before reaching the maximum lift height. A metal plate on the 1st mast stage actuates the proximity switch without contact.

Installed at the top of the tilt cylinder. LS captures the weight of a load resting on the forks. Connected in series with the FKS (fork switch).

HGTRS

MVL 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 mast. Activates the height encoder when the 1st mast stage has just been approached. A metal plate on the 1st mast stage actuates the proximity switch without contact.

Note: The manual lowering valve should then be closed again.

K1 & K2 Relays Keyless Entry Installed in the leg compartment. These connect the power supply to the VCM (Vehicle Control Module) when the “Keyless Entry” option is available.

K11

ORS Override Switch Installed in the control panel on the overhead guard column, to the left of the steering wheel. Lifting is inhibited when a programmed lift stop is reached. If the ORS switch is now pressed, lifting can continue to either the next lift stop or the end stop.

POT1 Traction Potentiometer

Start Up Relay K11 is integrated in the start up card in the start up module. It actuates ED1. If all systems are ok, the VCM connects pin 24 of CA205 to the negative terminal, thereby activating K11.

K12 & K13

Attached to the accelerator pedal. Supplies an analog signal to the main control module VCM to control the travel speed. POT1 must be recalibrated when replaced.

POT2 Lift/Lower Potentiometer

Options Relays Installed in the leg compartment. Activate the 48 V supply for the options packages.

K22 & K23

Hall sensor attached to the “Lift/Lower” control lever. Supplies an analog signal to the main control module VCM to control the lift/lower speed. Must be recalibrated when replaced.

POT3

Relay Working Light 12 V Installed in the leg compartment. Activate the 12 V work light.

KYS Key Switch

Reach Potentiometer Hall sensor attached to the “Reach” control lever. Supplies an analog signal to the main control module VCM to control the reach speed. Must be recalibrated when replaced.

Supplies power to the VCM (Vehicle Control Module).

ESR 5000

103

ELECTRICAL SYSTEM Electrical Components POT4(1)

PVRT

Tilt Potentiometer

Proportional Valve Retract

Hall sensor attached to the “Tilt” control lever. Supplies an analog signal to the main control module VCM to control the tilt speed. Must be recalibrated when replaced.

Controls the reach carriage retract speed.

POT5

Controls the reach carriage reach speed.

Sideshift Potentiometer or 5th Function Potentiometer

RES1

PVRE Proportional Valve Reach

Reach Sensor 1

Hall sensor attached to the “Sideshift” control lever. Supplies an analog signal to the main control module to control the sideshifter speed. Must be recalibrated when replaced.

Installed on the bottom right of the reach carriage (in fork direction). Activates “Reduced reach speed”.

After switching to the 5th function this Hall sensor supplies the analog signal for the 5th function.

Reach Sensor 2

PLS Pressure Load Switch Installed in the pipeline leading to the right (as seen in fork direction) lift cylinder. Factory set to switch at a 500 kg load. Prevents the fork carriage from stopping abruptly when lowering loads > 500 kg. Must be recalibrated when replaced.

RES2 Installed on the bottom right of the reach carriage (in fork direction). Senses the position of the reach carriage in the “Reduced reach speed” range. Note: Position sensing prevents the limit stops being struck at full speed if the reach carriage is just before the end stops.

RS Reverse Switch

PVL

Travel in forks direction.

Proportional Valve Lower

Integrated within a valve body together with the SVR (lift valve). Controls the lowering speed.

Relief Valve

PVAR

Adjustable valve. Restricts the hydraulic pressure to a maximum of 210 bar. Must be reset when replaced.

SDM

Proportional Valve Accessories Right Controls the downward tilt speed of the forks when "tilt" is selected. Controls the sideshift speed to the right when "sideshift" is selected.

PVAL

Steer Drive Module Installed in the electric compartment. Takes the readings from encoders ECR3, ECR4 and sensors SFS 1SA and SFS 2. Controls the steering motor and 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 ESR 5000

104

ELECTRICAL SYSTEM Electrical Components SES

SVT

Seat Switch

Solenoid Valve Tilt

Installed in the driver’s seat. Applies when the seat is occupied. Disconnects all truck functions apart from steering when the seat is vacated.

Installed on the manifold on the fork carriage. The SVT is a black/white valve. It opens when tilting is selected. The tilt speed is governed by the pump speed.

SFS 1SA

Steering Feedback Sensor 1 Straight Ahead

Switch Working Lights

Located in the motor compartment behind the traction motor. Captures the forward position of the drive wheel on the gear unit.

Installed in the control panel. Connects relay K6.

SFS 2

Traction Control Module

Steering Feedback Sensor 2 Located in the motor compartment to the right of the traction motor. Senses the quadrants.

SPS

TCM Installed in the electric compartment. Controls the traction motor. Reads the values of encoder ECR1 and thermal sensor THS1.

THS1 Thermal Sensor 1

Safety Pedal Switch Inductive switch installed below the floorboard on the safety pedal. The switch must be pressed to activate travel and hydraulic functions. The “safety switch” message is displayed if: •

the safety pedal is pressed and the truck is switched on.

•

the travel switch is pressed and the safety pedal is not.

•

a hydraulic function is applied and the safety pedal is not.

SVR Solenoid Valve Lift SVR is incorporated with PVL in a valve body. SVR is a black/white valve. It opens when lifting is selected. The lift speed is governed by the pump speed.

SVS

Installed in the traction motor. Captures the motor temperature. When the motor temperature reaches 145 °C the motor current is reduced to 250 A. If the motor temperature continues to rise, the motor current is further reduced until it reaches 0 amps at a motor temperature of 165°C and the motor cuts out.

THS2 Thermal Sensor 2 Installed in the pump motor. Captures the current motor temperature. When the motor temperature reaches 145 °C the motor current is reduced to 250 A. If the motor temperature continues to rise, the motor current is further reduced until it reaches 0 amps at a motor temperature of 165°C and the motor cuts out.

THS3 Thermal Sensor 3 Installed near the SPS. Controls the switching on and off of the heating resistors.

Solenoid Valve Sideshift Installed on the manifold on the fork carriage. The SVS is a black/white valve. It opens when sideshift operation is selected. The sideshift speed is governed by the pump speed.

Limits: On at +5 °C, off at +10 °C

THS4 Thermal Sensor 4 Installed in the steer motor. When the motor temperature reaches 145°C 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 180°C and the motor cuts out.

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Notes:

106

ELECTRICAL SYSTEM Service Menu Structure

Service Menu Structure

Analyzer

Software version

A1 A2 A3

The Service Menu Structure chapter describes software version V1 of 28.10.2008.

Status Inputs Outputs

Menu structure The service menu outlined on page 117 is divided into menu items.

A1Status

The text under the display messages describes the meaning and purpose of the display.

A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7 A1.8 A1.9 A1.10 A1.11 A1.12

Overview of menu items •

Analyzer – A1 Status checks – A2 Input signals – A3 Output signals

•

Calibration – Truck component calibration

•

Feature – For programming enhanced truck options and adapting to special applications.

•

Hour Meter – Setting the hour meter and service intervals.

•

Log Events – Calling up event codes and frequencies. – Deleting the error log

•

Performance – Programming the performance setting.

•

Utilities – U1 software versions of control modules – U2 Service hour settings – U3 Unblocking accessory functions for event codes.

Vehicle Control Module (VCM) Traction Control Module (TCM) Hydraulic Control Module (HCM) Steer Control Module (SCM) Main Contactor closed Battery Charge TEMP Trac. Module (TCM) TEMP Trac. Motor (M1) TEMP Hydr. Module (HCM) TEMP Pump Motor (M2) TEMP Steer Control Module (SCM) TEMP Steer Motor (M3)

A2 Inputs A2.1 A2.2 A2.3 A2.4 A2.5 A2.6 A2.7 A2.8 A2.9 A2.10 A2.11 A2.12 A2.13 A2.14 A2.15 A2.16 A2.17 A2.18 A2.19 A2.20 A2.21

Forward Switch (FS) Reverse Switch (RS) Pot1 Accelerator Pedal Pot2 Lift Lower Handle Pot3 Reach Handle Pot4 Tilt Handle Pot5 Side Shift Handle Pot6 5th Function Handle Accelerator Switch (ACS) Seat Switch (SES) Safety Pedal Switch (SPS) Battery Latch Switch (BLS) Brake Switch (BRS) Brake Pressure Switch (BPS) Brake Fluid Switch (BFS) Free Lift Switch (FLS) Height Switch(HGTS) Height Reset Switch (HGRTS) Height Encoder Load Sensor (LS) Override Switch (ORS)

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ELECTRICAL SYSTEM Service Menu Structure A2.22 A2.23 A2.24 A2.25 A2.26 A2.27 A2.28 A2.29 A2.30 A2.31 A2.32 A2.33 A2.34 A2.35 A2.36

Pressure Switch (PLS) Slow Down Area (RES1) Slow Down In/Out (RES2) Battery Current Traction Motor Set & Actual Speed Traction Motor Current Travel Speed Pump Motor Set & Actual Speed Pump Motor Current Steer Motor Speed Steer Motor Current Steer sensor St. Ahead (SFS 1) Steer sensor Quadrant (SFS 2) Steer Wheel Angle Battery Voltage

C8 C9 C10 C11

Weight Fork Positioning Reach Retract Slow Down Save

C1 Acceleration Pedal C1.1 C1.2

Released Depressed

C2 Raiser/Lower Handle C2.1 C2.2

Released Depressed

A3 Outputs

C3 Reach Handle

A3.1 A3.2 A3.3 A3.4 A3.5 A3.6 A3.7 A3.8 A3.9 A3.10 A3.11 A3.12 A3.13 A3.14 A3.15 A3.16

C3.1 C3.2 C3.3

Set TXN Speed Set Pump Speed Brake Output Main Con. Output Lift Valve (SVH) Lower Valve (PVL) Retract Valve (PVRT) Reach Out Valve (PVRE) Mast Right Valve (PVAR) Mast Left Valve (PVAL)n Tilt Valve (SVT) Side Shift Valve (SVS) 5th Function Valve (SV5) Alarm 2, Direction Beacon Fan

Calibration C1 C2 C3 C4 C5 C6 C7

Acceleration Pedal Raise/Lower Handle Reach Handle Tilt Handle Side Shift Handle 5th Function Handle Height

C4 Tilt Handle C4.1 C4.2 C4.3

Tilt Up Tilt Down Center

C5 Side Shift Handle C5.1 C5.2 C5.3

Right Left Center

C6 5th Function Handle C6.1 C6.2 C6.3

Right Left Center

C7 Height C7.1

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Retract Reach Center

R Cut 1

ELECTRICAL SYSTEM Service Menu Structure C7.1.1 C7.1.2 C7.1.3 C7.2

C7.3

None Override Set Height Stop

R Cut 2 C7.2.1 None C7.2.2 Override Set Height C7.2.3 Stop R Cut 3 C7.3.1 Saved Max. Height C7.3.2 Enter 2nd Height

Features F1 Truck Size F1.1 F1.2

Truck Size Free Lift Switch

F2 Free Lift Switch F2.1 F2.2

No Yes

F3 Height Encoder C7.4

R Cut 4 C7.4.1 None C7.4.2 Cut Height Lift to Limit

C8 Weight C8.1 C8.2

No Load Load

C9 Fork Positioning C9.1 C9.2

Adjust Tilt Up C9.1.1 Change Value ... Adjust Tilt Up C9.1.1 Change Value ...

C10 Reach Retract Slow Down

F3.1 F3.2

F4 Lower Cut Out F4.1 F4.2 F4.3

C11 Save? C11.1 C11.2

No Yes

No XXX Yes

F5 5th Function F5.1 F5.2 F5.3

Off On LCS

F6 Max. Load F6.1

C10.1 Adjust Reach C10.1.1 Change Value ... C10.2 Adjust Retract C9.1.1 Change Value ...

No Yes

Change Value ...

F7 Capacity Data M. F7.1 F7.2 F7.3 F7.4 F7.5 F7.6 F7.7

No Yes Set Zones Height1=xxx / Weight1=xxx Height2=xxx / Weight2=xxx Height3=xxx / Weight3=xxx Height4=xxx / Weight4=xxx

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ELECTRICAL SYSTEM Service Menu Structure F8 Travel Alarm F8.1 F8.2 F8.3

Alarm Off Alarm Reverse Alarm Forward

F9 Beacon F9.1 F9.2 F9.3 F9.4 F9.5

Beacon Off Key Switch Beacon Reverse Beacon Forward Beacon Forward and Reverse

F12.16 Slovenian F12.17 Greek F13 Change Unit F13.1 Euro F13.2 USA F14 Set Rack Select F14.1 No F14.2 Yes

F10 User Performance

F15 Height/Weight

F10.1 F10.2

F15.1 No F15.2 Yes

No Yes

F11 User Code

F16 Timer

F11.1 F11.2 F11.3 F11.4 F11.5

F16.1 No F16.2 Yes

No Yes View Add Delete

F12 Set Language F12.1 English F12.2 German F12.3 French F12.4 Italian F12.5 Dutch F12.6 Spanish F12.7 Danish F12.8 Finnish F12.9 Swedish F12.10 Norwegian F12.11 Portuguese F12.12 Turkish F12.13 Polish F12.14 Czech F12.15 Hungarian

F17 Error Log F17.1 No F17.2 Yes F18 Operator Alarm F18.1 No F18.2 Yes F19 Battery Alarm F19.1 No F19.2 Yes F20 Fork Positioning F20.1 No F20.2 Yes

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ELECTRICAL SYSTEM Service Menu Structure F21 Choose Steering

F27 Options Display

F21.1 F21.2 F21.3

F27.1 F27.2 F27.3 F27.4

180° 360° Both

F22 Speed Reduction Void F23 Cruise Control Void F24 High Speed Void F25 Keyless Entry F25.1

Keyless Enable F25.1.1 No F25.1.2 Yes F25.2.2 Shutdown Time F25.2.1 Change Value ... F26 Right Handle F26.1 F26.2

Hazard Warning Light Aud Travel Alarm Heated Screen Heated Seat F27.4.1 No F27.4.2 Yes

F28 Truck Lockout F28.1 F28.2

No Yes

F29 Direction Switch F29.1 F29.2

One Two

F30 Save ? F30.1 F30.2

No Yes

S/D Lever MTC

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ELECTRICAL SYSTEM Service Menu Structure Hour Meter

Performance

H1 Truck Complete

P1 Setup P1

H2 Traction Module

P1.1 P1.2 P1.3 P1.4 P1.5 P1.6 P1.7 P1.8 P1.9 P1.10 P1.11 P1.12 P1.13 P1.14

Full / Middle / Easy H3 Hydraulic Mod. Full / Middle / Easy H4 Key On Time H5 Set Service Time H5.1 H5.2

None Change Value ...

Log Events

P2 Setup P2

L1 History L1.1

Code

Work Hours

Temperature

Code

Work Hours

Temperature

 L1.15

L2 Totals L2.1

Event 0..=YYY

 L2.X

Event XXX = YYY

L3 Erase History L3.1

Erase History L3.1.1 Sure = No L3.1.2 Sure = Yes

P2.1 P2.2 P2.3 P2.4 P2.5 P2.6 P2.7 P2.8 P2.9 P2.10 P2.11 P2.12 P2.13 P2.14

Travel Speed FWD Travel Speed REV Acceleration Plugging Coasting Reduction Brake Pedal Brake Raise Speed Raise ACC Lower Speed Lower Stop Reach Speed Tilt Speed SS Speed

P3 Setup P3 P3.1 P3.2 P3.3 P3.4 P3.5 P3.6 P3.7

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Travel Speed FWD Travel Speed REV Acceleration Plugging Coasting Reduction Brake Pedal Brake Raise Speed Raise ACC Lower Speed Lower Stop Reach Speed Tilt Speed SS Speed

Travel Speed FWD Travel Speed REV Acceleration Plugging Coasting Reduction Brake Pedal Brake

ELECTRICAL SYSTEM Service Menu Structure P3.8 P3.9 P3.10 P3.11 P3.12 P3.13 P3.14

Raise Speed Raise ACC Lower Speed Lower Stop Reach Speed Tilt Speed SS Speed

P12 Steer Sensitivity P12.1 Change Value ... P13 Sens Steering P13.1 No P13.2 Yes

P4 BDI Setting P14 Brake at Ramp P4.1

Change Value ...

P5 Travel > LCS P5.1

Change Value ...

P6 Travel > FLS P6.1

P14.1 No P14.2 Yes P15 Set Default Values P15.1 No P15.2 Yes

Change Value ... P16 Save ?

P7 Travel > Custom P7.1

Change Value ...

P8 Lower > Custom

P16.1 No P16.2 Yes

Utilities U1 Software Version

P8.1

Change Value ...

P9 Reach > Custom P9.1

Change Value ...

P10 5th Func Left P10.1 Change Value ...

U1.1 U1.2 U1.3 U1.4 U1.5

U2 Hour Set U2.2

P11 5th Func Right P11.1

Vehicle Control Module (VCM) Traction Module (TCM) Hydraulic Module (HCM) Steer Drive Module (SCM) Display screen

Run = xxx U2.1.1 Save = No U2.1.2 Save = Yes

Change Value ... U3 Brake Override U3.1 U3.2

No Yes

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ELECTRICAL SYSTEM Service Menu Structure U4 Check Fan 1-4 U4.1 U4.2

Off On

U5 Keyless Time U5.1

Change Value ...

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ELECTRICAL SYSTEM Service Menu Structure Performance level defaults The text under the display messages describes the meaning and purpose of the display.

Standard settings P1 Setup - Defaults P1.1 P1.2 P1.3 P1.4 P1.5 P1.6 P1.7 P1.8 P1.9 P1.10 P1.11 P1.12 P1.13 P1.14

Travel Speed FWD Travel Speed REV Acceleration Plugging Coasting Reduction Brake Pedal Brake Raise Speed Raise ACC Lower Speed Lower Stop Reach Speed Tilt Speed SS Speed

12 12 8 8 8 7 9 5 3 9 Soft 5 5 5

P1.4 P1.5 P1.6 P1.7 P1.8 P1.9 P1.10 P1.11 P1.12 P1.13 P1.14

Plugging Coasting Reduction Brake Pedal Brake Raise Speed Raise ACC Lower Speed Lower Stop Reach Speed Tilt Speed SS Speed

6 6 7 9 5 3 9 Soft 5 5 5

P4 BDI Setting P4.1

Acid Battery 6 Maintenance Free Battery 8

P5 Travel > LCS P5.1

P6 Travel > FLS P2 Setup - Defaults P1.1 P1.2 P1.3 P1.4 P1.5 P1.6 P1.7 P1.8 P1.9 P1.10 P1.11 P1.12 P1.13 P1.14

Travel Speed FWD Travel Speed REV Acceleration Plugging Coasting Reduction Brake Pedal Brake Raise Speed Raise ACC Lower Speed Lower Stop Reach Speed Tilt Speed SS Speed

P6.1 11 11 7 8 8 7 9 5 3 9 Soft 5 5 5

P7 Travel > Custom P7.1

P8 Lower > Custom P8.1

P9 Reach > Custom P9.1

P10 5th Func Left P3 Setup - Defaults P1.1 P1.2 P1.3

Travel Speed FWD Travel Speed REV Acceleration

P10.1

10 10 5

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ELECTRICAL SYSTEM Service Menu Structure P11 5th Func Right P11.1

P12 Steer Sensitivity P12.1

P14 Brake at Ramp P14.2

Yes

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ELECTRICAL SYSTEM Service Menu - General

Service Menu - General

Enter letters from A to I and K on the numerical keypad. To enter A, press down on the number 1 for a while. For a B press down on number 2 ... The letter K is located on numerical key 0.

Access to service level Trucks with key switch Entering the service code 1. Press and hold down on the

Display structure

key.

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 operation.

Trucks without key switch Fig. 66 Display structure

Entering the service code 1. Press and hold down on the

key.

2. Press and hold down on the key.  The display will prompt you to enter the service code.

Menu item (Analyzer menu, item 1.12)

Component (steer motor)

Reading (t =105 °C)

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 numerical keypad.

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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 – 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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keys:

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 corresponding digital reading in the 2nd row. Item

Voltage

Digital reading

Neutral position

0.7 - 1.5 V

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

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 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

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

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 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

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 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

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 encoder 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 reduction.

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 current 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 keys.

2. Press the

key.

3. Menu item C1 opens up. 4. Use the or (C1 to C11).

keys to scroll through to the required sub-menu

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" direction 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 AVAILABLE” is displayed in the 2nd row. The submenus will not be accessible.

Up to 2 lift stops (RCUT1 and RCUT2) can be programmed with different settings:

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 displayed 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 displayed (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 Height”menu 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  Menu item C7.4 opens up again. 3. If a “Custom Height” is required, press item 7.4.2:

key.

to scroll through to menu

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 displayed. 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 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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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 item F2.2.

3. Press

key to activate NO (no FLS) or press

to open menu

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 item F3.2.

3. Press

key to activate NO (no ECR5) or press

to activate YES (ECR5 present).

 Menu item F3 opens up and the status is displayed.

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to open menu

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 menu item F4.2.

to open

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 menu item F4.2.

to open

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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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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ELECTRICAL SYSTEM Features Menu F7 Capacity Data Monitor

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

2. Press YES.

to activate NO or

3. Press

to scroll to menu item F7.2 to select

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 (corresponding 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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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. ESR 5000

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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. Performance 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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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. Performance 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

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 ESR 5000

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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

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. ESR 5000

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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 system.

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 3. Press the

to select YES (truck disabled) or NO (truck not disabled). 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 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:

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:

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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 H5.2.

to confirm NONE (service timer off) or

1. Press the

to open menu item

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 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 3. Press the

to select NO (do not clear) or YES (clear). 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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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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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 discharge 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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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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166

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 control 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 control 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 steering). 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 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)

The ESR 5000 is fitted with an electronic control system for the key operating functions.

•

HGTRS (Height reset switch)

•

BPS (Brake pressure switch)

•

ORS (Override switch)

•

PLS (Pressure load switch)

Malfunctions with event code display Event codes are produced from tests carried out on the inputs and outputs of control signals. For most faults the system generates an event code and stores it in the log book (see Fig. 68). The last 16 events are displayed in the Log Events Menu (see page 158).

Log book display

Event code number

Service hours at the time of the event

Component temperature at time of event (if available)

Brief component description

Component name

Malfunctions occur primarily on external components such as fuses, solenoids, contactors, motors etc. These components are necessarily subject to a certain degree of wear. The next possible causes include connectors, wiring and input devices such as switches, potentiometers or encoders. These are subject above all to ambient conditions. 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 troubleshooting on the component (the external component). This is the quickest way of obtaining a result. The following sections list the event code numbers in ascending order. In addition to each event code they also list the possible causes, the effect on the truck and troubleshooting notes.

Fig. 68 Example of a log book entry 1

Locating malfunctions

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 circuit 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 corresponding 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 malfunction. They include: •

HNS (Horn switch) ESR 5000

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:

ESR 5000

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

•

Emergency Disconnect pressed during plugging operation

•

Error in steer module

Possible Causes: 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

•

Emergency Disconnect pressed during plugging operation

•

Error in steer module

Possible Causes: 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:

•

Effect:

15 V supply in the steer module faulty

•

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

•

Steer module ventilation affected by:

Possible Causes:

– Excessive ambient temperature – Overload – Contamination • Remedy:

Malfunction in power part of steer module

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 consumption 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 transmission. 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 mechanical sluggishness.  If one of them is sluggish, replace or repair the corresponding component. 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.

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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:

•

Possible Causes:

See event code 120, page 174.

Remedy:

See event code 120, page 174.

The display shows: HIGHTEMP STEERING MOTOR

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.

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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 Ω, 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 Ω, 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 Ω, 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 Ω, 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

•

Fuse FU3 faulty

•

Wiring or connector damaged

•

Brake coil faulty

Possible Causes:

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 Ω (Crown motor) or 46.6 Ω (Danaher motor). 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:

Possible Causes: Remedy:

•

Parking brake applied

•

Traction module deactivated

•

Main contactor ED1 de-energised

•

Wiring or connectors damaged

•

No +5 V supply

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 between 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 disconnected. 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: Explanation:

ECR4 STEPPER MOTOR 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:

Possible Causes: Remedy:

•

Parking brake applied

•

Traction module deactivated

•

Main contactor ED1 de-energised

•

Wiring or connectors damaged

•

No +5 V supply

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 between 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: Explanation:

SW1 OR 2 SW ERROR 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: Explanation:

SFS2 SW EXPECTED 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:

•

Possible Causes:

Remedy:

An error routine is started (see page 303)

•

Wiring or connector damaged

•

Screw depth of sensor SFS1 SA incorrectly set

•

Sensor SFS1 SA faulty

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

•

Wiring or connector damaged

•

Thermal sensor faulty

Possible Causes: 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 Ω (PTC resistance, the resistance increases as the temperature rises)  If the resistance < 500 Ω or > 1 kΩ, replace the steer motor.  If the resistance > 500 Ω and < 1 kΩ, 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

•

Short circuit in following components:

Possible Causes:

– Power cable to pump motor – Pump motor coil – Hydraulic module output stage • Remedy:

Hydraulic pump blocked

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

•

Short circuit in following components:

Possible Causes:

– 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

•

Emergency Disconnect pressed during plugging operation

•

Hydraulic module error

Possible Causes: 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 operation, 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:

Possible Causes:

Remedy:

•

Traction and hydraulic modules deactivated

•

Main contactor ED1 de-energised

•

Parking brake applied

•

Wiring error

•

Faulty battery

•

Hydraulic module error

ESR 5000

190

ELECTRICAL SYSTEM Event Codes 200 - 286 Repair the battery 4. Repair the battery in accordance with the manufacturer’s 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

•

Hydraulic module ventilation affected by:

Possible Causes:

– Excessive ambient temperature – Overload – Contamination • Remedy:

Malfunction in power part of hydraulic module

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 frequently, 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

•

Hydraulic module ventilation affected by:

Possible Causes:

– 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 frequently, 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

•

Hydraulic module ventilation affected by:

Possible Causes:

– Excessive ambient temperature – Overload – Contamination • Remedy:

Malfunction in power part of hydraulic module

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 reduced in proportion to the rise in temperature down to 0 A.

•

The display shows: HIGH TEMP. HMOT

•

Hydraulic module ventilation affected by:

Possible Causes:

– 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 frequently, 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 exceeded.

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 potentiometer is ok. Compare the readings taken with the multimeter with those in the Analyzer 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 between 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 potentiometer is ok. Compare the readings taken with the multimeter with those in the Analyzer 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 exceeded.

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 potentiometer is ok. Compare the readings taken with the multimeter with those in the Analyzer 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 between 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 potentiometer is ok. Compare the readings taken with the multimeter with those in the Analyzer 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 exceeded. Note: For trucks with the multi-task control handle (MTC) this event code indicates 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 potentiometer is ok. Compare the readings taken with the multimeter with those in the Analyzer 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 indicates 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 between 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 potentiometer is ok. Compare the readings taken with the multimeter with those in the Analyzer 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 exceeded.

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 potentiometer is ok. Compare the readings taken with the multimeter with those in the Analyzer 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 between 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 potentiometer is ok. Compare the readings taken with the multimeter with those in the Analyzer 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 Ω, proceed to step 4.  If the resistance is not 75 Ω, 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 PC8073 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 Ω, proceed to step 4.  If the resistance is not 27 Ω, 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 PC8071 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 Ω, proceed to step 4.  If the resistance is not 25 Ω, 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 between 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 PC8101 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 Ω, proceed to step 4.  If the resistance is not 25 Ω, 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 between 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 PC8082 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 Ω, proceed to step 4.  If the resistance is not 25 Ω, 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 PC8092 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 Ω, proceed to step 4.  If the resistance is not 25 Ω, 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 PC8112 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 Ω, proceed to step 4.  If the resistance is not 39 Ω, proceed to step 3. Replace the coil 3. Replace the coil.

ESR 5000

214

ELECTRICAL SYSTEM Event Codes 200 - 286 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 between 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 PC8012 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 Ω, proceed to step 4.  If the resistance is not 39 Ω, proceed to step 3. Replace the coil 3. Replace the coil.

ESR 5000

215

ELECTRICAL SYSTEM 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 PC8015 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. Output 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 Ω, proceed to step 4.  If the resistance is not 39 Ω, proceed to step 3.

ESR 5000

216

ELECTRICAL SYSTEM 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 PC8018 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).

ESR 5000

217

ELECTRICAL SYSTEM 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

•

Encoder ECR2 faulty

•

Encoder wiring short circuit

•

Main module or hydraulic module faulty

Possible Causes:

Remedy:

ESR 5000

218

ELECTRICAL SYSTEM 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:

Remedy:

•

Encoder ECR2 faulty

•

Encoder wiring disconnected

•

Main module or hydraulic module faulty

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).

ESR 5000

219

ELECTRICAL SYSTEM 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

•

Encoder ECR2 faulty

•

Encoder wiring disconnected

•

Main module or hydraulic module faulty

Possible Causes:

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

•

Faulty wiring

•

THS2 faulty

Possible Causes: 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.

ESR 5000

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 Ω or > 1 kΩ, proceed to step 5.  If the resistance is approx. 600 Ω (rated resistance for t =20 °C is 600 Ω), 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).

ESR 5000

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

•

Short circuit in following components:

Possible Causes:

– Power cable to traction motor – Traction motor coil – Traction module output stage • Remedy:

Blocked drive

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

•

Short circuit in following components:

Possible Causes:

– Power cable to traction motor – Traction motor coil – Traction module output stage

ESR 5000

222

ELECTRICAL SYSTEM 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

•

Wiring error

•

Faulty battery

•

Error in traction drive module

Possible Causes:

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.

ESR 5000

223

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)

ESR 5000

224

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

•

Traction module ventilation affected by:

Possible Causes:

– Excessive ambient temperature – Overload – Contamination • Remedy:

Malfunction in power part of traction module

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 frequently, proceed to step 5. Replace hydraulic module 5. Replace the hydraulic module (see page 259).

ESR 5000

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

•

Traction motor ventilation affected by:

Possible Causes:

– 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 frequently, 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

226

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

•

Traction module ventilation affected by:

Possible Causes:

– Excessive ambient temperature – Overload – Contamination • Remedy:

Malfunction in power part of traction module

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 frequently, proceed to step 5. Replace traction module 5. Replace the traction module (see page 259).

ESR 5000

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:

ESR 5000

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

•

Traction module ventilation affected by:

Possible Causes:

– 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 frequently, 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

229

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:

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 Ω, 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 Ω, then either the main module or traction module is faulty. Proceed to step 2.

ESR 5000

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 Ω, 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 Ω, 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).

ESR 5000

231

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 exceeded.

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 CA4072 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 potentiometer is ok. If not, proceed to step 233. Compare the readings taken with the multimeter with those in the Analyzer 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).

ESR 5000

232

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:

ESR 5000

233

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 CA4182 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.

ESR 5000

234

ELECTRICAL SYSTEM 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).

ESR 5000

235

ELECTRICAL SYSTEM 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

•

Encoder ECR1 faulty

•

Encoder wiring short circuit

•

Main module or traction module faulty

Possible Causes:

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.

ESR 5000

236

ELECTRICAL SYSTEM 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:

Remedy:

•

Encoder ECR1 faulty

•

Encoder wiring disconnected

•

Main module or hydraulic module faulty

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.

ESR 5000

237

ELECTRICAL SYSTEM 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

•

Encoder ECR1 faulty

•

Encoder wiring short circuit

•

Main module or traction module faulty

Possible Causes:

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).

ESR 5000

238

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 Ω, 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 Ω, 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 Ω, 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 Ω, 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) ESR 5000

239

ELECTRICAL SYSTEM 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 Ω, 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 Ω, 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 Ω, 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 Ω, 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

240

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 resistance with an ohmmeter.  If the resistance is approx. 1.5 kΩ, the contactor coil is ok.  If the resistance is approx. 0 Ω, 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).

ESR 5000

241

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

•

Faulty fan

•

Short circuit

Possible Causes: Remedy:

ESR 5000

242

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 circuits.  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).

ESR 5000

243

ELECTRICAL SYSTEM Event Codes 430 - 465 Repair contacts on PC205 and PC206 16. Repair contacts. Replace the main module 17. Replace the main module.

ESR 5000

244

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 circuits.  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.

ESR 5000

245

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 deactivated 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.

ESR 5000

246

ELECTRICAL SYSTEM 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 components 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).

ESR 5000

247

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.

ESR 5000

248

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

•

Wiring short circuit

•

Encoder faulty

Possible Causes:

ESR 5000

249

ELECTRICAL SYSTEM 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).

ESR 5000

250

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

•

Faulty wiring

•

Height reset switch (HGTRS) does not connect

•

Height encoder ECR5 faulty

•

12 V supply faulty

•

Main module VCM faulty

Possible Causes:

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.

ESR 5000

251

ELECTRICAL SYSTEM 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).

ESR 5000

252

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

•

Slip in height encoder drive

•

Height encoder calibration faulty

Possible Causes: 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).

ESR 5000

253

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

•

Faulty wiring

•

Height reset switch (HGTRS) does not connect

•

Height encoder ECR5 faulty

•

12 V supply faulty

•

Main module VCM faulty

Possible Causes:

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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ELECTRICAL SYSTEM 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

•

Faulty wiring

•

Height reset switch (HGTRS) does not connect

Possible Causes: 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

•

Height reset switch (HGTRS) does not connect reliably

•

Slip in height encoder drive

Possible Causes: 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 Screen

•

Traction control module TCM

•

Hydraulic control module HCM

The following control modules communicate with each other and the display screen via the CAN Bus.

•

Steering control module SCM

•

Display screen

•

Main module VMC

The display screen also provides the 12 volt supply.

Fig. 69 Components under the panels 1

Battery connector

Emergency Disconnect

Start up card

Hydraulic control module HCM (Access 2)

Control fuses (FU1 - FU6)

Steering control module SCM (Access 5)

Traction control module TCM (Access 3)

Steering control module main fuse (FU13)

Main contactor

Main control module VCM (Access 4)

Main fuse (FU7)

Replacing control modules

Replacing the traction control module

Replacing the main control module

Replacing the traction control module

Preparing to replace the main control module

1. Switch off the truck, disconnect the battery and prevent it from being switched on again.

2. Remove the panel.

WARNING

Removing the main control module 3. Remove the connector. 4. Remove the main control module mounting screws and take out the main control module. Installing the main control module 5. Install the main control module in the reverse order of disassembly. 6. Check operation.

Short circuits can cause fires Charging capacitors in the control module have energy stored. The capacitors are suddenly discharged in the event of a short circuit.  Either discharge the capacitors with a resistance of 100 Ω/50 W over terminals B+ und B- of the control module or wait 15 minutes. 3. Before the next step wait for 15 minutes or perform a controlled discharge of the capacitors with a resistance of 100 Ω/50 W over terminals B+ and B-.

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ELECTRICAL SYSTEM Control Modules and Display Screen Replacing the steering control module

Removing the traction control module 4. Remove the power cable. Note: Observe the number and arrangement of washers and nuts. The washers are convex. They must be fitted in the same position during assembly. 5. Remove the connector.

Preparing to replace the steering control module 1. Switch off the truck, disconnect the battery and prevent it from being switched on again. 2. Remove the panel.

6. Remove the main control module mounting screws and take out the traction control module. Installing the traction control module 7. Assemble the traction control module in the reverse order of disassembly. 8. Torque the power cable nuts to 15 ±2 Nm. 9. Check operation.

Replacing the hydraulic control module

Preparing to replace the hydraulic control module 1. Switch off the truck, disconnect the battery and prevent it from being switched on again. 2. Remove the panel.

3. Before the next step wait for 15 minutes or perform a controlled discharge of the capacitors with a resistance of 100 Ω/50 W over terminals B+ and B-. Removing the steering control module 4. Remove the power cable.

WARNING Short circuits can cause fires Charging capacitors in the control module have energy stored. The capacitors are suddenly discharged in the event of a short circuit.  Either discharge the capacitors with a resistance of 100 Ω/50 W over terminals B+ und B- of the control module or wait 15 minutes. 3. Before the next step wait for 15 minutes or perform a controlled discharge of the capacitors with a resistance of 100 Ω/50 W over terminals B+ and B-. Removing the hydraulic control module

Note: Observe the number and arrangement of washers and nuts. The washers are convex. They must be fitted in the same position during assembly. 5. Remove the connector. 6. Remove the steering control module mounting screws and take out the steering control module. Installing the steering control module 7. Assemble the steering control module in the reverse order of disassembly. 8. Check operation.

Replacing the display panel Preparing to replace the display panel

4. Remove the power cable and bus bar. Note: Observe the number and arrangement of washers and nuts. The washers are convex. They must be fitted in the same position during assembly.

1. Switch off the truck, disconnect the battery and prevent it from being switched on again. 2. Remove the panel.

5. Remove the connector.

Removing the display panel

6. Remove the hydraulic control module mounting screws and take out the hydraulic control module.

1. Remove the faulty display panel.

Installing the hydraulic control module

2. Fit the new display panel.

7. Assemble the hydraulic control module in the reverse order of disassembly.

Note: All new display panels respond only to a key switch. The truck must therefore be started with a key switch whenever the display panel or the PCB is replaced. The starting method can then be re-programmed.

8. Torque the power cable nuts to 15 ±2 Nm. 9. Check operation.

Assembling the display panel

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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 circuits 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 annually 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 Accident risk from accidental start-up during test If a safety circuit is faulty, the truck or parts of it can suddenly move. Fatal accidents may result.  Before carrying out the safety test jack the truck up so that the drive wheel is clear of the ground.  Insert wedges under the load wheels.

Power cable

Power fuse 355 A, encapsulated

Insulating caps

Power fuse 50 A, encapsulated

You will require: Quantity

Item

Part no.

Power cable

821634-010

Insulating cap

125588-001

Fuse holder

805824

802816-011

 Always wear protective glasses and appropriate protective clothing.

Power fuse 355 A, encapsulated

802816-006

 Always use encapsulated power fuses. With these fuses, the fuse strip is covered to prevent liquid metal particles from spraying.

Power fuse 50 A, encapsulated

Nut

050008-010

Copper shim

054152-003

Insulating plate --approx. 150 mm x 100 mm

WARNING Risk of scalding and injury to eyes The power fuse can burn, causing burning metal particles to explode. These particles can cause serious eye injuries and scald the skin.

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 test Jacking up the truck

7. Disconnect the battery. Testing the short circuit detection for phase W to V on the traction control module

1. Disconnect the battery.

1. Remove the test wiring (355 A fuse) from 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 modules.

3. Carefully check the entire unit again for possible 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 on the traction control module 1. Fit a 355 A fuse on the test wiring. 2. Connect the test wiring with additional nuts to terminals U and V of the traction control module. 3. Place the fuse holder on the floor. 4. Carefully check the entire unit again for possible short circuits.  Is everything is ok, proceed to step 5.

5. Apply the safety pedal, direction switch and accelerator pedal.  The test has been successful if the main contactor ED1 is de-energised and event code 301 is displayed.  If the fuse blows in the test cable, the traction control module is faulty. Replace the traction control module immediately (see page 258). 6. Power down the truck. 7. Disconnect the battery.

5. Switch on the truck. 6. Apply the safety pedal, direction switch and accelerator pedal.  The test has been successful if the main contactor ED1 is de-energised and event code 301 is displayed.  If the fuse blows in the test cable, the traction control module is faulty. Replace the traction control module immediately (see page 258).

Removing the test wiring 8. Remove the test wiring. Checking travel functions after the test 9. Check the travel functions after the test.

Hydraulic control module safety test

7. Power down the truck.

Testing the short circuit detection for phase U to V 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 on the traction control module

2. Connect the test wiring with additional nuts to terminals U and V of the hydraulic control module.

1. Remove the test wiring (355 A fuse) from terminal V and connect it to terminal W.

3. Place the fuse holder on the floor. 4. Carefully check the entire unit again for possible short circuits.  Is everything is ok, proceed to step 5.

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.

5. Connect the battery. 6. Power up the truck.

4. Switch on the truck. 5. Apply the safety pedal, direction switch and accelerator pedal.  The test has been successful if the main contactor ED1 is de-energised and event code 301 is displayed.  If the fuse blows in the test cable, the traction control module is faulty. Replace the traction control module immediately (see page 258).

7. Apply the safety pedal and activate lifting.  The test has been successful if the main contactor ED1 is de-energised immediately and event code 201 is displayed.  If the fuse blows in the test cable, the hydraulic control module is faulty. Replace the hydraulic module immediately (see page 259). 8. Power down the truck. 9. Disconnect the battery.

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ELECTRICAL SYSTEM PMT Test Testing the short circuit detection for phase U to W on the hydraulic control module 1. Remove the test wiring (355 A fuse) from terminal V and connect it to terminal W.

Steering control module safety test Testing the short circuit detection for phase U to V 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 short circuits.  Is everything is ok, proceed to step 4.

2. Connect the test wiring with additional nuts to terminals U and V of the steer motor. 3. Place the fuse holder on the floor.

4. Connect the battery.

4. Carefully check the entire unit again for possible short circuits.  Is everything is ok, proceed to step 5.

5. Power up the truck. 6. Apply the safety pedal and activate lifting.  The test has been successful if the main contactor ED1 is de-energised immediately and event code 201 is displayed.  If the fuse blows in the test cable, the hydraulic control module is faulty. Replace the hydraulic module immediately (see page 259). 7. Power down the truck. 8. Disconnect the battery. Testing the short circuit detection for phase W to V on the hydraulic control module 1. Remove the test wiring (355 A fuse) from terminal U and connect it to terminal W.

5. Connect the battery. 6. Power up the truck. 7. Apply the safety pedal and activate lifting.  The test has been successful if the main contactor 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). 8. Power down the truck. 9. Disconnect the battery.

2. Place the fuse holder on the floor.

Testing the short circuit detection for phase U to W on the steering control module

3. Carefully check the entire unit again for possible short circuits.  Is everything is ok, proceed to step 4.

1. Remove the test wiring (50 A fuse) from terminal V and connect it to terminal W. 2. Place the fuse holder on the floor.

4. Connect the battery.

3. Carefully check the entire unit again for possible short circuits.  Is everything is ok, proceed to step 4.

5. Power up the truck. 6. Apply the safety pedal and activate lifting.  The test has been successful if the main contactor ED1 is de-energised immediately and event code 201 is displayed.  If the fuse blows in the test cable, the hydraulic control module is faulty. Replace the hydraulic module immediately (see page 259). 7. Power down the truck. 8. Disconnect the battery. Removing the test wiring 9. Remove the test wiring.

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 contactor 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.

Checking lifting after the test 10. Check lifting after the test.

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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 contactor 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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ELECTRICAL SYSTEM Replacing the Height Encoder

Replacing the Height Encoder 6

4 5

Fig. 72 Height encoder

Removing the height encoder

1. Remove connector (16). Note: The pre-tensioned spring (4) is relieved when the screws (15) are loosened.

1 Fig. 71 Height encoder assembly location, HGT(R)S switch

2. Loosen the screws (15) and remove the entire height encoder.

1st mast stage (outer mast)

2nd mast stage

Replacing the sensor bearing

3rd mast stage

HGTS switch (optionally HGTRS)

Height encoder

3. Loosen the screw (12) and remove the attachment (11), seal (10), heating resistor (14) and attachment (13).

HGTRS shifting gate

4. Loosen the screw (9).

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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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.

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. Depending on the settings in “F3 Features / Height Encoder” of the service menu (see page 140), the switch will be either an HGTR or an HGTRS.

4 3

4 5

Fig. 74 HGTR-, HGTRS switch 1

1st mast stage (outer mast)

HGTR or HGTRS switch

Bolt

Connector

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

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

2 1 Fig. 73 Height encoder assembly location, HGT(R)S switch 1

1st mast stage (outer mast)

2nd mast stage

3rd mast stage

HGTS switch (optionally HGTRS switch)

Height encoder

HGTRS shifting gate

HGTS shifting gate

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ELECTRICAL SYSTEM Replacing the Armrest Controls

Replacing the Armrest Controls Trucks with fingertip control levers

Fig. 75 Replacing switches and potentiometers

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ELECTRICAL SYSTEM Replacing the Armrest Controls Removing the controls Note: Unless otherwise stated, the following item numbers refer to Figure 75.

Trucks with dual axis hydraulic control levers

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 the same way.

Assembling the controls Note: Assembly is the reverse order of disassembly.

Fig. 76 Replacing switches and potentiometers

Note: The switches and potentiometers are removed/ assembled in the same way as for trucks with fingertip control levers (see page 267).

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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ELECTRICAL SYSTEM Replacing the Armrest Controls Trucks with multi-task handle

Fig. 77 Replacing switches and potentiometers

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ELECTRICAL SYSTEM Replacing the Armrest Controls Removing the controls Note: Unless otherwise stated, the following item numbers 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 associated 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) potentiometers.

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

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ELECTRICAL SYSTEM Repairing Contactors

Repairing Contactors

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

Checking the coils

CAUTION The use of other manufacturers’ contactors can damage the truck!' The original contactors are designed for Crown trucks.  Only use original Crown contactors as replacements.  Do not change the place or the angle where they are positioned and do not change the wiring.

1. Using an ohmmeter measure the resistance between the connections on the coil (2).  If either an endless resistance or no resistance are recorded, the coil (2) is faulty and must be replaced.

Checking the springs 1. Check the spring (1) for corrosion or discolouring caused by heat.  Replace any corroded or discoloured springs (1).

Wear test

Fig. 78 Example of a contactor 1

Spring

Coil

Contact (moving)

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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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.

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).

Fig. 79 Main contactor (ED1)

5. Insert the screws (1) and washers and apply threadlocker (053050-006).

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

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ELECTRICAL SYSTEM Replacing the Danaher Traction Motor

Replacing the Danaher Traction Motor Traction motor disassembly

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

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 capacity.

 Attach the slings securely to the component to be lifted.  Watch out for your hands as there is a risk of trapping.

7. Insert the load hook in the eye bolt and lift out the 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.

Connecting the power cables

1 2

4 2

Fig. 80 Danaher traction motor 1

Service and parking brake

Terminal board and power cable connections

Connector for sensor bearing and thermal sensor

Screws

Traction motor

4 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 described on page 288. 3. Unplug the connector for sensor bearing and thermal sensor (2).

Fig. 81 Connecting the power cables

4. Loosen all the screws (3).

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ELECTRICAL SYSTEM Replacing the Danaher Traction Motor 1

Nut

Power cable

Curved washer

Terminal board

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.

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ELECTRICAL SYSTEM Replacing the Sensor Bearing on the Danaher Traction motor

Replacing the Sensor Bearing on the Danaher Traction motor

7 8 9 10 11

13 14

Fig. 82 Overview - traction motor (Danaher)

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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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ELECTRICAL SYSTEM Replacing the Crown Traction motor

Replacing the Crown Traction motor

WARNING Incorrect handling of the lifting gear and slings can cause injury You can be injured if a component falls on you.

Traction motor disassembly

 Always use lifting gear and slings with sufficient capacity.  Attach the slings securely to the component to be lifted.

 Watch out for your hands as there is a risk of trapping. 6. Secure the slings to the traction motor (4) and using suitable lifting gear lift it out of the truck.

2 4

Traction motor assembly 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 terminal board.

Connecting the power cables 1 2 3

Fig. 83 Crown traction motor 1

Parking brake

Terminal board

Bolt

Traction motor

1. Switch off the truck, disconnect the battery and prevent the truck from being switched on again.

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 thermal sensor.

Fig. 84 Connecting the power cables 1

Nut

5. Loosen all the bolts (3).

Power cable

Curved washer

Terminal board

Traction motor

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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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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 capacity.  Attach the slings securely to the component to be lifted.

 Watch out for your hands as there is a risk of trapping. 6. Raise the pump motor (2) using load lifting equipment 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

Bolt

Power cable

Connector for thermal sensor and sensor bearing

Suction line

Pump motor assembly Assembly of the pump motor is the reverse order of disassembly. Note the following: 1. Clean the output side toothing of the pump motor (2) and apply a thin layer of grease part no. 794860-007 (Shell Calithia HDX) to it. 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 prevent it from being switched on again.

Note: For more information on assembling and commissioning 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).

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ELECTRICAL SYSTEM Replacing the Pump Motor Connecting the power cables 1 2

3 2 3

4 5

Fig. 86 Power cable 1

Nut

Power cable

Curved washer

Terminal board

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 terminal board (4). 3. Insert the nuts (1) and torque them to 8.1 - 9.9 Nm.

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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)

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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.

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ELECTRICAL SYSTEM Choosing the Correct Battery Cable Length

Choosing the Correct Battery Cable Length

Choosing cable lengths for a Tshaped battery (example)

To avoid damaging the battery cable when the battery is retracted, the cable length must be individually dimensioned due to the various sizes and shapes of batteries used.

The following example shows how to choose the correct battery cable length for a T-shaped battery. The procedure for dimensioning the battery cables must be 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 compartment.

WARNING Battery short circuits can cause severe injury Incorrectly sized and routed battery cables can be damaged when fed into the battery compartment, resulting in short circuits. This poses a risk of: •

1 2

Burning due to high temperatures.

•

Scalding from battery acid.

•

Fire caused by arcs.

 Make sure the battery cable is the correct length to avoid it becoming damaged when fed into the compartment.

 Whenever a battery is used for the first time, make sure it can be fed into the battery compartment without the battery cables jamming or getting caught.  Note the following instructions on choosing the correct battery cable length.

Fig. 88 Example of a T-shaped battery 1

Battery connector

Battery cable

Tape

Negative terminal

Battery tray

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 battery tray to create strain relief on the battery terminals (4, 6).

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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 cable type against the above items. Extend and retract 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).

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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 hydraulically 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 linings that are oily.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents and lubricants.

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BRAKE SYSTEM Service and Parking Brake Danaher Motor

Service and Parking Brake Danaher Motor

Disassembling the brake See Figure 89. 1. Switch off the truck, disconnect the battery and prevent the truck from being switched on again.

2. Jack up the truck until the drive wheel is free; support the truck and prevent it from rolling away (see page 14). 3. Remove connector CA431 (7). 4. Disconnect the brake line from the connection (9) of the brake cylinder in the coil body and seal the ports immediately. 5. Remove three screws (1).

6. Remove the magnetic body (2) including everything connected to it.

Dismantling the brake Note: Do not allow brake components to come into contact with oil or grease. 7. Remove the pinion (5), friction plate (3) and rotor (4).

Checking components for damage and wear 8. Check all components for uneven wear, deep grooves, cracks and burning. Replace any worn or damaged components. 9. Measure the thickness of the rotor (4) over the brake linings.  If the thickness ≤ 9.5 mm (new = 12.5 mm), replace the rotor.

Fitting the brake 1. Assembly is the reverse order of disassembly.

Assembling the brake

1. Place the brake in the correct position on the motor flange. 2. Secure it with the screws (1). 3. Fit the connector plug.

Fig. 89 Service brake

4. Adjust the air gap.

Screws (3x)

Coil body

Friction plate

See Figure 89.

Rotor and brake linings

Pinion

Measure and adjust the air gap (L) when the brake is released:

Hollow screws

Connector CA431

1. Unscrew the hollow screws (6) until they are in fixed contact the friction plate (3).

Rotor thickness

2. Torque the screws to 22 ±2 Nm.

Air gap

Adjusting the air gap

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BRAKE SYSTEM Service and Parking Brake Danaher Motor 3. Check the operating air gap at several points along the circumference using a feeler gauge.  The air gap L must be the same all along the circumference. The dimension should be 0.3 +0.1/-0.05 mm. 4. If necessary, adjust the air gap: To increase the air gap unscrew the hollow screws (6). To reduce the air gap, screw them in. 5. If necessary, repeat steps 3 and 4 until the air gap has been set correctly. 6. Torque screws (1) to 22 ±2 Nm.

Measuring the coil resistance 1. Switch off the truck, disconnect the battery and prevent the truck from being switched on again. 2. Remove connector CA431 (7). 3. Using an ohmmeter measure the resistance between PC431-1 and -2.  If the coil resistance is 46.6 Ω, the coil is ok.  If you do not measure 46.6 Ω, the coil is faulty. Replace the coil.

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BRAKE SYSTEM Parking Brake - Crown Motor

Parking Brake - Crown Motor

Disassembling the parking brake See Figure 90. Note: Do not allow brake components to come into contact with oil or grease.

1. Disconnect the battery and prevent the truck from being switched on again.

2. Jack up the truck until the drive wheel is free; support the truck and prevent it from rolling away (see page 14). 3. Remove connector (1). 4. Inset the M6x40 retaining screws in the thread (3).  The tie plate is drawn to the coil body.

5. Remove the screws (2).

6. Remove the coil body (4) including everything connected to it.

Dismantling the brake

1. Remove screws (9).

2. Take off the friction disk (6), pinion (7) and rotor (8) together with the brake linings.

Checking components for damage and wear 3. Check all components for uneven wear, deep grooves, cracks and burning. Replace any worn or damaged components. 4. Measure the thickness of the rotor (8) over the brake linings. If the thickness ≤ 9.5 mm (new = 12.5 mm), replace the rotor.

Fig. 90 Parking brake 1

Connector plug CA431

Motor flange attachment screws

M6 thread

Coil body

Fitting the brake 1. Assembly is the reverse order of disassembly.

Assembling the parking brake 1. Place the brake in the correct position on the motor flange.

Tie plate

2. Secure it with the screws (2) and torque the screws to 22 Nm.

Friction disk

3. Fit the connector plug.

Pinion

4. Adjust the air gap.

Rotor and brake linings

Friction disk mounting screws

Hollow screws

Brake rotor thickness dimension

Air gap

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BRAKE SYSTEM Parking Brake - Crown Motor Adjusting the air gap Note: We strongly advise replacing the brake in full if the air gap is found to be out of range on a single occasion. The adjustment is extremely complicated and time-consuming. Checking the air gap 1. Check the operating air gap at several points along the circumference using a feeler gauge. The air gap L should be 0.3 +0.1/-0.05 mm all along the circumference.  Adjust if the air gap is out of range. Adjusting the air gap See Figure 90. 2. Disassemble the brake (see Disassembling the parking brake). 3. Remove also the screws (9) and take off the friction disk. 4. Adjust the air gap. To increase: unscrew the hollow screws (10). To reduce: screw in the hollow screws (10). 5. Insert the friction disk and fasten with the screws (9). 6. Torque screws (9) to 22 ±2 Nm. 7. Refit the brake (see Assembling the parking brake). 8. Check the operating air gap at several points along the circumference using a feeler gauge. The air gap L should be 0.3 +0.1/-0.05 mm all along the circumference.  Repeat steps 2 to 8 if the air gap is out of range.

Measuring the coil resistance 1. Switch off the truck, disconnect the battery and prevent the truck from being switched on again. 2. Remove connector CA431 (7). 3. Using an ohmmeter measure the resistance between PC431-1 and -2.  If the coil resistance is 32 Ω, the coil is ok.  If you do not measure 32 Ω, the coil is faulty. Replace the coil.

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BRAKE SYSTEM Load Wheel Brake

Load Wheel Brake

WARNING

General The load wheel brake is self-adjusting. There is no need for regular adjustment.

Checking the brake lining wear

Pre-tensioned springs can cause injury Pre-tensioned springs can cause serious eye injuries.  Always wear a splint-proof protective glasses and suitable clothing to prevent injuries to your eyes and body. 2. Remove the springs (2, Fig. 92).

3. Using a blunt, burr-free lever, lever one brake shoe towards the inside. This pushes the brake cylinder piston (1, Fig. 92) towards the inside.

4. Remove the brake shoe from the brake piston groove. 5. Remove the second brake shoe in the same way. Brake lining assembly Fig. 91 Back of load wheel brake: holes for lining check and access to eccentrics

1. De-grease all components with a brake solvent prior to assembly.

1. Visually inspect the brake lining wear (see holes 1, Fig. 91).  The wear limit is 2 mm.

2. Assemble the brake shoes in the reverse order of disassembly.

Replacing the brake linings Load wheel removal

4. Push the load wheel and brake drum onto the steering knuckle and fit the retaining ring.

1. Remove the load wheel (see page 51)

5. Apply the brake pedal approx. 10 times to adjust the brake shoes.

Brake lining removal

6. Check the brake fluid level in the container on the main brake cylinder. Add oil if necessary (see page 295).

3. Set the brake shoes via the eccentric to a gap of 199.4 +/- 0.2 mm. Otherwise the load wheel cannot be pushed over the brake shoes.

Fig. 92 Load wheel brake: Brake cylinders and springs

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BRAKE SYSTEM Load Wheel Brake Wheel brake cylinder

4. Refit the brake shoes and load wheel (see Brake lining assembly). Bleed the load wheel brake before using it for the first time!

Bleeding the load wheel brake

WARNING Brake failure can result in accidents Faulty wheel brake cylinders must not be dismantled and repaired. Fatal accidents could result from incorrect repairs.  Replace a faulty wheel brake cylinder with a new one.

Note: Bleeding is normally only required on the wheel brake cylinder where the brake line has been opened.

WARNING The use of incorrect brake fluid can cause brake failure The use of hydraulic or lubrication oil as a brake fluid will cause the brake to fail. Fatal accidents could result.  Use only DOT 4 brake fluid (see Recommended Lubricants and Consumables chart on page 27). 1. Use wedges to prevent the truck from rolling away. 2. Remove the cap from the bleed screw (4, Fig. 93).

3. Fit the end of a transparent hose onto the bleed screw and insert the free end into a clean, transparent container that already contains some new brake fluid. The hose end should dip into the brake fluid.

Fig. 93 Wheel brake cylinder

4. Get an assistant to apply and hold down the brake pedal.

Bolt

Brake line connection

5. While the brake pedal is depressed, open the bleed screw half a turn.

Wheel brake cylinder

Bleed screw

6. While the assistant is pressing down on the brake pedal, close the bleed screw. Release the brake pedal again when the bleed screw is closed.

Wheel brake cylinder disassembly 1. Jack up the truck and remove the brake shoes (see Brake lining removal, page 292). 2. Push a flat tray underneath the jacked up load wheel to collect the brake fluid. 3. Unscrew the brake line (2, Fig. 93) from the wheel brake cylinder and seal it immediately with clean filler plugs. 4. Remove both screws (1).

Wheel brake cylinder assembly 1. De-grease all components with a brake solvent. 3. Refit and tighten the brake line.

8. Add brake fluid as soon as the fluid is below the "Max" mark to prevent air from being suctioned in. 9. Repeat steps 4 to 7 until the brake fluid emerges without bubbles.

Replacing the brake fluid The procedure for replacing the brake fluid proceed is in principle the same as described in Bleeding the load wheel brake.

5. Remove the wheel brake cylinder (3).

2. Insert and tighten the wheel brake cylinder.

7. During bleeding always check the brake fluid level in the main brake cylinder storage tank.

The difference is that the bleed screws on both wheel brake cylinders must be opened and closed simultaneously. Note: The system is considered filled with a new brake fluid if at least 0.5 litres have been replaced.

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BRAKE SYSTEM Testing and Adjusting the Brake Pedal Clearance

Testing and Adjusting the Brake Pedal Clearance

Fig. 94 Adjusting the brake pedal clearance 1

Nut

Setscrew

Counternut

Measuring the clearance 1. Using a steel ruler measure the clearance X on the brake pedal: It should be: X = 3 +/- 1 mm. Adjusting the clearance 2. Loosen the counternut (3). 3. Adjust the clearance with the setscrew (2). 4. Measure the clearance.  Repeat steps 3 and 4 until the clearance is within the tolerance range. 5. Counter fix nut (1) with nut (3).

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BRAKE SYSTEM Adding Brake Fluid

Adding Brake Fluid

7. Restore the electrical connections to the BFS switch (5, Fig. 95). 8. Connect the battery and switch on the truck.

WARNING Incorrect brake fluid will result in brake failure The use of hydraulic or lubrication oil as a brake fluid will cause the brake to fail. Fatal accidents could result.  Use only DOT 4 brake fluid. See Recommended Lubricants and Consumables chart on page 27.

9. Press the test button (1) to check the BFS switch.  The "brake fluid level" indicator light on the display lights up, event code 841 is displayed. It is working correctly.  The "brake fluid level" warning indicator does not light up on the display. Wiring or switch error. For troubleshooting see page 249.

Note: Brake fluid does not easily disappear. Determine the cause (leak, brake lining wear etc.). Rectify the cause before filling the container.

Fig. 95 Storage tank on main brake cylinder 1

Test key for float switch BFS

Cover

Reservoir

“Max.” mark

BFS ports

Preparation 1. Switch off the truck, disconnect the battery and prevent it from being switched on again. 2. Remove the floorboard from the floor area. 3. Remove the electrical connections from the BFS switch (5, Fig. 95). Adding brake fluid 4. Remove the cover (2). 5. Add DOT4 brake fluid up to the mark (4). 6. Screw the cover back on.

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BRAKE SYSTEM Brake Power Control

Brake Power Control

Brake test

The brake power must be checked in the following cases: •

After replacing the brake linings and brake drums on the wheel brakes.

•

After replacing the main brake cylinder, the wheel brake cylinders and the brake lines.

•

After replacing the brake disk and the friction plate on the electro-mechanical brake on the traction motor.

WARNING Unauthorised persons can cause serious accidents People suddenly stepping onto the test route can be fatally injured.  Use suitable equipment to block the test route.  If necessary use assistants to prevent unauthorised access.

•

After adjusting the air gap on the electro-mechanical brake on the traction motor.

•

After replacing the traction motor.

1. Bring the truck up to test speed.

•

After changing the plugging setting in the Performance menu.

•

When testing the truck in accordance with FEM 4.004.

Note: If the test route is sufficiently long, the test speed is generally the maximum speed for the respective performance level (P1 - P3). If there is not a sufficiently long test route available, a lower speed can be selected temporarily.

Requirements •

There must be no load on the truck.

•

A sealed off, clearly visible test route of sufficient length must be available.

•

The floor of the test route must be clean.

2. When you pass over the marker and the marker on the floorboard coincides with the marker on the warehouse floor, brake immediately. 3. Switch off the truck when it comes to rest. 4. Measure the braking distance.  If the braking distance is within the tolerance range (see braking distance table), the brake power is ok.  If the braking distance is too long, continue with steps 5 to 7.

Required tools •

5 m measuring tape

•

Adhesive tape

•

Barrier tape to seal off the test route

Determining the cause of excessive braking distances

Brake test

5. Check the brake linings and brake drums on the wheel brakes for damage.

Preparing the test route 1. Clean the test route and prevent unauthorised personnel from accessing it (see also Protecting the hazardous area, page 8). 2. Attach a marker with adhesive tape to the floor of the test route. 3. Attach a marker with adhesive tape to the floorboard.

6. Check the brake disk and friction plate on the electro-mechanical brake on the traction motor for damage. Check the air gap. 7. Check the plugging setting in the Performance menu. Note: When you have established the cause, repeat the brake test.

Note: The truck should be able to reach the required test speed by this marker. 4. Position the unladen truck at the start of the test route and lower the forks.

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BRAKE SYSTEM Brake Power Control

Braking distance table Travel speed (v) Braking distance (m) in km/h 5

< 1.81

< 2.18

< 2.54

7.5

< 2.72

< 2.90

8.5

< 3.08

< 3.26

9.5

< 3.45

< 3.63

10.5

< 3.81

< 3.99

11.5

< 4.17

< 4.35

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Notes:

298

STEERING

299

Notes:

300

STEERING Function

Function The steering system consists of the following main components: •

Steering control module Access 5 (SCM)

•

Steering setpoint device (ECR4)

•

Steering feedback encoder (ECR3)

•

Steer motor (M3)

This is a 4 quadrant steering system.

Generating a steering signal A steering wheel revolution generates a steering command on the steer module input (SCM) via the steering encoder (ECR4).

Encoder ECR4 is a sensor bearing. The output phase position depends on the rotational direction, while the voltage depends on the rotational speed.

Steer motor activation The steering control module generates a voltage corresponding to the input signal to power the steer motor.

Steer system monitoring

Fig. 96 Proximity switch SFS 2

The position of the steered wheel is monitored by the steering feedback encoder (ECR3) fitted in the steer motor (M3). The steering feedback encoder supplies the steering control module with data regarding the position of the steered wheel with a tolerance of +/- 0.5°.

LED

An inductive proximity switch (SFS 2) identifies the quadrants. The second inductive proximity switch (SFS 1SA) identifies the 0° position of the steered wheel.

Error correction Whenever SFS 1SA is switched, the value calculated by the steer module is set to 0°. This corrects any deviation in the calculated position and allows a zero position to be defined via an error routine (e.g. after the drive wheel has been turned manually). The sensors are activated by a cam on the gear unit cover (2, Fig. 97). If the cam turns past a sensor, the sensor switches. If a sensor has switched, an LED in the sensor lights up (1, Fig. 96). This allows the status of the sensor to be checked at a glance.

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STEERING Function Quadrant - definition SFS 1SA

1 0° 3

II SFS 2 - 90°

90° III

179° -179°

Fig. 97 Illustration of 4 quadrant steering system 1

Cam on gear unit cover

Steered wheel

Travel direction

The quadrants are defined as follows: The grey areas in Fig. 97 correspond to an angle of approx. +/-5°, with reference to 0°, 90° and-90°. The steering control module (SDM) waits for the sensors to switch in these sectors.

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STEERING Steering Errors

Steering Errors

Other error causes

Error routine

With all other errors the steering control module disconnects the power supply to the brake (truck brakes) and travel is disabled.

The steering system stores the steer angle at the time the truck is switched off. The next time the truck is powered up (during the self test), the steering control module (SDM) compares the current position of the steered wheel with the stored value.

A status code is displayed, depending on the cause (see page 173).

If the new angle position is not in the same quadrant as the stored angle, an error routine begins. •

the travel speed is reduced to creep mode.

•

The maximum steer motor speed is restricted to 1500 rpm.

•

The steer angle display is switched off.

•

the “Service” display is lit.

•

the message "STEERING SENSOR. TURN STEER WHEEL" is shown on the message display.

Ending the error routine To terminate the error routine and return to normal mode, the SFS 1SA sensor must switch a single time. 1. Release the accelerator pedal. 2. Keep turning the steering wheel in one direction until "STEERING SENSOR. TURN STEER WHEEL" is no longer displayed.

Causes of error routine activation In most cases the cause will be manual turning of the steered wheel (wheel change, repairs to the drive system while the truck is jacked up). During the next self test, the following error message is entered in the service menu logbook when the truck starts up. 184 Start Error SDM Cause: wrong quadrant detected The same error message can however be generated by a faulty sensor being identified as faulty during truck power up. If a sensor fails while the truck is travelling, the following error messages may appear in the service menu log. 182 SFS 1 SW expected Cause: SFS 1SA sensor does not switch. 183 SFS 2 SW expected Cause: SFS 2 sensor does not switch. ESR 5000

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STEERING Steering Errors Examples of steer faults The following 2 examples provide a better understanding of the causes of steer faults.

SFS 1SA

Manual wheel change, drive wheel turned 160° to the right

0°

SFS 1SA

SFS 2

0°

II - 90°

90° III

II SFS 2 - 90°

90°

179° -179°

III

Fig. 100 Error routine completed

The steering control module has stored the position of the drive wheel when the truck was parked at 80°. The drive wheel is therefore in the 1st quadrant (see Fig. 99).

179° -179°

The drive wheel is now replaced. The steered wheel is turned manually 160° to the right in order to access the wheel bolts (see Fig. 99).

Fig. 98 Drive wheel in 1st quadrant at 80°

SFS 1SA

What is the result? The next time the truck starts up the steering control module compares the stored position (80°) with the current position (-80°). It identifies a false quadrant (2nd quadrant) and the error routine starts. The error routine can only be ended if SFS 1SA has been switched once. There are 2 directions in which you can steer:

0°

Right steering

II SFS 2

90°

- 90°

100° further on, the drive wheel reaches the -179° position (see Fig. 100). The error routine ends as the switch area of proximity switch SFS 1SA has been reached. The steer angle display shows 180°. Left steering The switch area of proximity switch SFS 1SA is reached. The proximity switch applies. This switch signal resets the stored and the currently calculated values in the traction control module to 0°.

Fig. 99 Steered wheel turned 160° to the right

If you now release the accelerator pedal (assuming it was applied), the error routine ends and the truck returns to normal travel mode.

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STEERING Steering Errors Manual wheel change, drive wheel turned 70° to the right

The drive wheel is now replaced. The steered wheel is turned manually 70° to the right (see Fig. 102).

SFS 1SA

The next time the truck starts up the steering control module compares the stored position (80°) with the current position (10° (80°-70°=10°)). As the drive wheel is still in the 1st quadrant, the error routine does not start. Steering remains in normal mode.

0°

When the truck is started, provided the last stored value and the current calculated value for the drive wheel position are in the same quadrant, the error routine will not start.

II SFS 2 - 90°

90°

You will only recognise this error by the fact that the steering wheel display does not match the actual steer angle on the drive wheel and the full 360° steering range is not reached. Left steering

III

If the steering wheel is turned to the left, starting from a stored value of 80° the 90° level is reached 10° later. The steer angle display shows 90°. However, the steer angle on the drive wheel is actually only 20° with respect to 0° for normal forward travel. The error routine does not start, as the drive wheel is still within the 1st quadrant.

179° -179° Fig. 101 Steered wheel in 80° position

70° later the mechanical 90° position is reached (SFS 1SA switches, SFS 2 has not switched). The steer angle display shows 160° and the error routine starts.

SFS 1SA

To reset the steering to 180° or 0°, simply turn another 90° to the left or right. This resets the steering to 180° or 0°.

0°

Right steering

II SFS 2 - 90°

90° IV

III

Starting from 80° as the stored value, after a further 10° you reach the switch area of the proximity switch SFS 1SA. The proximity switch applies. This switch signal resets the stored and calculated values in the traction control module to 0°. The steering angle display now matches the actual position of the drive wheel. The full steering range of 360° is now available again. There is no message displayed when the calculated and stored angles are reset, as the steering control module is not going through the error routine. This happens in the normal mode of the steering control module each time the cam on the gear unit cover enters the switch area of the proximity switch SFS 1SA.

179° -179° Fig. 102 Steered wheel turned 70° to the right

When the truck was parked, the steering control module stored the position of the drive wheel at 80°. The drive wheel is therefore in the 1st quadrant (see Fig. 101).

To rectify this error, you just need to steer accordingly so that the cam on the gear unit cover enters the switch area of proximity switch SFS 1SA.

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STEERING Proximity Switches SFS2 and SFS1 SA

Proximity Switches SFS2 and SFS1 SA

2. Disconnect and remove the faulty proximity switch (1 or 2, Fig. 103).

Replacing and adjusting SFS2 or SFS1 SA

CAUTION

Note: The procedure is identical for SFS2 and SFS1 SA.

The proximity switches are damaged by the cam rotating past if they are set longer than 46.5 mm.  Do not exceed a length of 46.5 mm. 3. Set the new proximity switch length to 46 ± 0.5 mm, measured from the bottom of the assembly angle to the top of the proximity switch (see Fig. 104). 4. Install the proximity switch. 5. Reconnect the wiring.

6. Check operation.

Fig. 103 Proximity switches SFS 1SA and SFS2 Proximity switch SFS2

Proximity switch SFS1 SA

46 ± 0.5 mm

Fig. 104 Proximity switch setting dimension

1. Switch off the truck, disconnect the battery and prevent it from being switched on again.

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STEERING Steer Motor and Steering Transmission

Steer Motor and Steering Transmission

Disconnecting the steering transmission and steer motor S

Removing the steer motor and steering transmission Unless otherwise indicated, all item numbers refer to Fig. 106, page 309. 1. Switch off the truck, disconnect the battery and prevent it from being switched on again. 2. Disconnect all plug connections and connections U, V, W from the steer motor. 3. Remove the mounting screws (14) from the steer motor (13). 4. Pull the steer motor up.

CAUTION The motor can be damaged when placed in a vice  Use braces and do not over tighten the vice. 5. Place the steer motor on the drive pinion (16) in a vice to prevent the motor shaft from twisting. 6. Remove the screw (18) and the washer (17) from the drive pinion (16). 7. Take the steer motor out of the vice and mount it on the housing. 8. Using a suitable extractor take out the drive pinion.  The traction motor can now be separated from the reduction gear unit.

Fig. 105 Steer motor and reduction gear unit

9. Remove the screws (4, Fig. 105). 10. Carefully pull off the reduction gear unit (3, Fig. 105). 11. Pull off the coupling (2, Fig. 105).

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STEERING Steer Motor and Steering Transmission Assembling the steering transmission and steer motor 12. Clean the coupling (2, Fig. 105 ) and grease it again (grease type M, see page 27). 13. Place the coupling (2, Fig. 105) on the shaft of the reduction gear unit (3, Fig. 105).  The traction motor and reduction gear unit can now be re-assembled. 14. Push the reduction gear unit and coupling onto the drive shaft of the motor. 15. Align the motor and gear unit so that after assembly in the truck the electrical system can be connected. 16. Attach the gear unit to the motor with the screws (4, Fig. 105).

Installing the steer motor and steering transmission CAUTION Metal hammers will damage the feather key and the drive pinion  Use a plastic hammer. 17. Apply a thin layer of type M grease (see page 27) to the drive shaft, the pinion and the contact surface (front side) of the steer motor. 18. Fit the steer motor in the reverse of disassembly. 19. Check operation.

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STEERING Steer Motor and Steering Transmission

Fig. 106 Steer motor and drive unit

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STEERING Steering Wheel

Steering Wheel

2 3 Fig. 107 Steering wheel and steering column 1

Steering wheel

Access to steering wheel mounting screw

Steering column panel

Steering wheel removal 1. Turn the steering wheel (1, Fig. 107) until the hex. socket screw (6, Fig. 108) in the steering wheel axle can be reached via the opening (2, Fig. 107). 2. Undo the hex. socket screw. 3. Take off the steering wheel.

Steering wheel assembly 1. Assemble the steering wheel in the reverse order of disassembly.

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STEERING Steering Wheel

Fig. 108 Steering wheel, steering wheel panel and encoder ECR4 ESR 5000

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STEERING Replacing Encoder ECR2

Replacing Encoder ECR2 The encoder cannot be repaired.

Removing ECR4 1. Disassemble the steering wheel (see page 310). 2. Remove the screws (3, Fig. 108). 3. Lift up encoder ECR4 (20, Fig. 108) and remove the plug connections. 4. Take out encoder ECR4. 5. Remove the encoder retaining plate; this will be used for the new component.

Assembling ECR4 1. Attach the retaining plate to the new steer motor. 2. Refit encoder ECR4 in the steering column in the reverse order. 3. Check operation.

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LIFTING MECHANISM

313

Notes:

314

LIFTING MECHANISM Mast

Mast

General

Safety instructions for working on the mast

Torques All screw connections on the mast must be torqued to the standard values (see page 50).

Lifting gear minimum capacities WARNING Risk of trapping and severing limbs Unsecured components can sever limbs and cause fatal injuries. When carrying out work on the mast and the attachments:  Always block the mast stages and attachments to prevent them from accidentally moving.  Make sure the equipment used has sufficient strength.

WARNING Note the minimum capacity for the lifting gear whenever carrying out work on the mast. The following table lists the minimum capacities for masts with a fork carriage, but without forks or attachments: Mast capacity Lifting gear minimum capacity

WARNING High-pressure hydraulic oil can cause severe injury Whenever a high pressure hydraulic oil enters the skin it must be treated as a medical emergency. Seek medical assistance even if the skin appears normal at first. To avoid accidents:  Depressurise the hydraulic system before opening any sections of it.  Tighten all connections before pressurising the system.  Keep hands and body away from pressurized fluid.  Only trace leaks with a piece of paper or cardboard.

1.4 t

2000 kg

1.6 t

2000 kg

2.0 t

2500 kg

Checking the assembled mast Flaking It is not uncommon for a new mast to appear as if it's flaking or peeling. This appearance indicates that the rollers are seating on the mast channel and this is considered normal. Eventually this condition will disappear. The grease applied to the mast channels retains these particles. Traces of nicks or cuts in the channel are not permitted.

Checking the roller tracks 1. Clean the mast channels.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents and lubricants.

2. Check the roller track wear in the mast channels: There should only be wear in the rear section of the I beam where the rollers slide. If nicks or cuts are visible at the side of the rollers approx. 10 mm above the channel face, the mast rollers will have to be adjusted. (See Replacing the Mast Rollers, page 324).

Checking the mast verticality 1. Extend the mast almost as far as it will go: It should be vertical and should not lean to the left or the right. All mast stages should be aligned. If a tilting condition exists, it is a sign that the shim-

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LIFTING MECHANISM Mast ming is too loose or unbalanced and will need to be adjusted: Adjust the mast rollers as described in Replacing the Mast Rollers on page 324.

Checking the mast tilt 1

Checking the pulleys, hoses and cables

1. Check all pulleys for damage and freedom of movement. 2. Check hoses and wiring for any signs of chafing.

Checking the end stops WARNING Missing end stops can cause accidents If the end stops are missing, a mast stage can be pushed out of the channel and drop down. You or other people could be fatally injured.  End stops must always be in place and properly secured. 1. Check the end stops ("polystop blocks") for wear and make sure they are properly secured. Replace any faulty or missing end stops.

Checking the fork setting 3

1. Fully lower the forks and set them horizontal. 2. Measure the height of the fork tips from the floor to the top of the forks:  It should be 55 mm for 1.4 t trucks.  It should be 50 mm for 1.6 t and 2.0 t trucks.

3. Set the fork height if necessary. 4. Attach a lowering plumb to the fork tips and extend the mast fully. 5. Check the maximum height with a lowering plumb attached to the fork tips. The height should lie within +/-25 mm of the maximum height indicated on the data plate.

Fig. 109 Permissible and non-permissible mast tilt ranges and lowering plumb position 1

Area where mast tilt is permissible.

Area where mast tilt is not permissible.

Lowering plumb position on fork for measuring mast tilt.

Floor (evenness in all directions 0.7 mm per 2 m).

Note: The mast should be installed tilted only backwards (–) within narrow tolerance levels (green area 1 in Fig. 109). Checking the mast tilt 1. Park the truck on a level(1) surface. 2. Set the forks horizontal and lower them fully.

1. Maximum permissible parking area unevenness: 0.7 mm over a 2 m length. ESR 5000

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LIFTING MECHANISM Mast 3. Apply a very narrow colour marking as close as possible to the heel area, but still on the straight upper side of the forks, and copy this marking vertically to the floor. 4. Raise the forks slightly and attach a lowering plumb with the string lying exactly on the fork marking.

Masts with 2.0 t capacities Maximum lift height

Max. permissible tilt (mm)

4145 mm

– 16 mm

5 mm

4595 mm

– 18 mm

6 mm

5495 mm

– 21 mm

7 mm

6395 mm

– 25 mm

8 mm

6. When it has finished swinging, measure the distance from the marking on the ground to to the top of the lowering plumb and compare this distance with the entry in the tolerance table.  The mast tilt should be negative (–) and lie between 0 mm and the maximum value indicated in the table.

6845 mm

– 26 mm

9 mm

7205 mm

– 28 mm

9 mm

7500 mm

– 29 mm

10 mm

7950 mm

– 31 mm

10 mm

8415 mm

– 32 mm

11 mm

7. Set the mast tilt, if necessary (see page 318).

8850 mm

– 34 mm

11 mm

Mast tilt tolerance tables

8120 mm

– 31 mm

10 mm

9155 mm

– 35 mm

12 mm

9605 mm

– 37 mm

12 mm

9935 mm

– 38 mm

13 mm

10835 mm

– 42 mm

13 mm

10230 mm

– 39 mm

14 mm

Note: The string of the lowering plumb, from the top of the forks to the top of the lowering plumb, must be length (L), corresponding to the maximum lift height (h3) minus 20 mm (L = h3-20 mm). 5. Extend the mast until the top of the lowering plumb just swings clear above the ground.

Masts with 1.4 t and 1.6 t capacities Maximum lift height

Max. permissible tilt (mm)

1 mm shim thickness corrected by x mm

4440 mm

– 17 mm

6 mm

10835 mm

– 42 mm

14 mm

4890 mm

– 19 mm

6 mm

11435 mm

– 44 mm

15 mm

5340 mm

– 21 mm

7 mm

5790 mm

– 22 mm

7 mm

6090 mm

– 23 mm

8 mm

6690 mm

– 26 mm

9 mm

7140 mm

– 27 mm

9 mm

7500 mm

– 29 mm

10 mm

7950 mm

– 31 mm

10 mm

8415 mm

– 32 mm

11 mm

8850 mm

– 34 mm

11 mm

9450 mm

– 36 mm

12 mm

9900 mm

– 38 mm

13 mm

10230 mm

– 39 mm

13 mm

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LIFTING MECHANISM Adjusting the Mast Tilt

Adjusting the Mast Tilt You can adjust the mast tilt by adding or removing shims between the mast and chassis. Shims come in 3 mm, 6 mm and 8 mm thicknesses (see spare parts manual). 1. Remove the mast (see Mast removal and assembly, page 319). 2. Calculate and assemble the required number of shims, see Mast tilt tolerance tables, page 317). 3. Re-assemble the mast (see page 320).

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LIFTING MECHANISM Mast Removal / Assembly

Mast Removal / Assembly

13. Remove the load slings from the 1st and 2nd mast stages and attach them to the centre of the highest tie bars on all the mast stages (see Fig. 110).

General The mast must be removed in order to: •

Replace the mast rollers

•

Remove the fork carriage

•

Transport the truck on a lorry etc.

Mast removal and assembly Mast removal (See Fig. 111, page 321) Preparation 1. Fully extend the mast. 2. Remove the forks or attachment. 3. Remove the load backrest. 4. Place a load sling around the top tie bar of the 1st and 2nd mast stages and maintain tension using a crane.

14. Tension the mast with the crane.

5. Depressurise the hydraulic system (see page 78).

15. Remove the covers (22 & 23, Fig. 111).

Securing the mast stages and disconnecting the hydraulic line

16. If applicable, mark the hydraulic hose connections for the 5th function on the left channel of the 1st mast stage for later re-assembly. It is possible to mix up the screws.

6. Place a flat tray underneath the mast area to collect any spilled hydraulic oil. 7. Raise the 1st and 2nd mast stages until the main hydraulic line on the manifold and the mast attachment bolts are accessible. 8. Insert hard wooden blocks into the outer mast tracks and secure them with screw clamps. 9. Lower the 1st and 2nd mast stages onto the hard wooden blocks. 10. Unscrew the main hydraulic line on the manifold block (at the bottom of the mast) and seal both ends immediately with filler plugs.

Fig. 110 Raising the mast with load slings

17. Disconnect the hydraulic hoses for the 5th function and fit filler plugs to all the open ports. 18. Remove all connectors and where necessary all the electrical wire connections from the reach carriage to the mast. 19. Pull all the wires from the reach carriage to the mast out and up. Temporarily attach the loose wires to the mast. 20. Secure the fork carriage with a load sling to prevent it from moving in the mast.

Preparing the mast for removal

Removing the mast

11. Loosen but do not remove the bolts (27) attaching the mast to the reach carriage.

21. Remove the nuts and bolts securing the mast to the reach carriage together with the shims.

12. Remove the hard wooden blocks and fully lower the 1st and 2nd mast stages.

Note: Store the shims so that they can be used in the same position and the same overall thickness for subsequent assembly.

Note: Use load slings with a wire spiral warp - not chains - to raise the mast. Do not place wooden blocks under the load slings when the mast is raised from the highest tie bars. Some mast versions have tie bars consisting of a sandwich of 2 thin sheets. Wooden blocks and chains can damage them.

22. Lift the mast up out of the reach carriage. 23. Place the mast with its back (the side facing the driver) lying on a suitable surface with sufficient capacity (pallets, steel benches).

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LIFTING MECHANISM Mast Removal / Assembly Mast assembly WARNING Tipover hazard - do not exceed the maximum mast tilt You or bystanders could be fatally injured if the mast tilt is out of range or even in the wrong direction.  When assembling the original mast, make sure you fit the shims removed in step 21 in the same position and with the same overall thickness.  When assembling a new or a different mast always check the mast tilt (see page 318). Assembly is the reverse of disassembly.

Mast checks and settings after assembly The following items must be performed after assembly: •

Flush the lift and free lift cylinders (see page 79).

•

Check and adjust the mast tilt if necessary (see page 318).

•

Check the hydraulic functions.

•

Check and adjust the chain tension (see page 344).

•

Check and calibrate the height encoder (see page 132).

•

Check and calibrate the load sensor (see page 135).

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LIFTING MECHANISM Mast Removal / Assembly

Fig. 111 Mast exploded diagram

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LIFTING MECHANISM Dismantling and Assembling the Mast

Dismantling and Assembling the Mast

6. Using the crane, move the fork carriage “down” from the 2nd mast stage.

Removing the 2nd mast stage

Safety notices

7. Remove all mast cables, hydraulic hoses and if applicable the height encoder and the camera system with the wiring and ropes - up to the outer mast. The wires and hoses should not run into the inner area of the mast stages. This would damage them when the mast is dismantled further.

WARNING Risk of trapping and severing limbs Unsecured components can sever limbs and cause fatal injuries. When carrying out work on the mast and the attachments:

8. Remove the lift chain and chain pulley from the free lift cylinder. Store the chain so that it is protected from contamination. 9. Remove the lift chains. Store the lift chains so that they are protected from contamination, marking the position of the chains (left / right). They will subsequently have to be reassembled in their original positions.

 Always block the mast stages and attachments to prevent them from accidentally moving.  Make sure the equipment used has sufficient strength.

10. Using a crowbar push the 2nd mast stage down until the bottom mast rollers can be accessed. 11. Remove the bottom mast rollers and shims out of the 2nd mast stage. Store the rollers and shims so that they can later be fitted in the same position.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.

12. Attach two load slings (one in the bottom, one in the top area of the 2nd mast stage) and using the crane pull the 2nd mast stage (without rollers!) out of the 1st mast stage.

 Observe the manufacturer’s safety instructions when handling solvents and lubricants.

13. Place the 2nd mast stage onto a suitable surface.

Tips & tricks

1st mast stage removal

Switches and lines (electrical, hydraulic): •

Undo the mast attachments (base plates, clamps). This facilitates positioning for later re-assembly and normally saves having to adjust the switches.

Lift chains: •

Remove the chain bolt, not the chain support. This also normally saves subsequent adjustment.

Dismantling the mast

14. Remove the guide pulleys for the hoses and chains at the top left and right of the 1st mast stage. 15. Remove the anti-bend pins (10, FIg. 111) and the locking screws (13). 16. Using a crowbar, push the 1st mast stage up until the mast stage can be attached to the crane with 2 load slings. Note: The ends of the lift cylinder piston rams should now lie freely, no longer in the mast stage seats.

Fork carriage removal 1. Remove the mast (see page 319). 2. Remove the free lift switch (FLS), otherwise it will be damaged when the fork carriage is extended. 3. Remove the free lift cylinder chain. 4. Disconnect all hydraulic lines and if applicable electrical lines to the fork carriage. 5. Using a load sling raise and maintain the fork carriage.

17. Using the crane, pull the 1st mast stage out until the mast stops become visible through the circular hole at the bottom. 18. Remove the screws (19, Fig. 111) and take out the mast stops (18) with the brackets (16 17) and the shims (16). Note: Store all the parts so that they can be re-assembled later in the same position.

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LIFTING MECHANISM Dismantling and Assembling the Mast 19. Using a crowbar push the 1st mast stage in the outer mast down until the top and bottom mast rollers can be removed. 20. Using the crane pull the 1st mast stage fully out of the outer mast and place it on a suitable surface.

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LIFTING MECHANISM Replacing the Mast Rollers

Replacing the Mast Rollers

Calculating the roller diameter

General

CAUTION

The mast rollers are replaced in 2 main stages: •

•

Calculate the roller diameter required to prevent jamming or excessive play above the running area of the roller in the mast channel. Calculate the number of shims required to prevent lateral jamming or tipping between the left and righthand mast channels.

Using mast rollers with the wrong part number can cause material damage!  Always use mast rollers with part number 824031. These rollers have a 4 point suspension which is tailored to this mast. Rollers with part number 807334 will soon wear in this mast!

Safety notices 1

WARNING Risk of trapping and severing limbs Unsecured components can sever limbs and cause fatal injuries. When carrying out work on the mast and the attachments:  Always block the mast stages and attachments to prevent them from accidentally moving.  Make sure the equipment used has sufficient strength.

2 Fig. 112 Calculating the load roller diameter

CAUTION

Special tool part no. 824031

Mast channel

There are three roller diameters available:

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

Code

Ø mm

Part No.

101.47

824031-002

102.14

824031-003

102.45

824031-004

Preparation 1. Disassemble and dismantle the mast (see previous sections).

Note: Always start with the largest diameter, a code D roller.

2. Clean the mast channels and remove all mast rollers and shims.

3. Place a roller (code D) on the tool (1, Fig. 112).

Mast roller assembly Note: Always use the special tool part no. 810705 (1, Fig. 112) to calculate the roller diameter required. The mast roller bearing journals are slightly angled. The roller should not be pulled through the channel manually as this produces inaccurate results.

Rollers do not run into the 500 mm areas (see Fig. 113). Always place the tool outside these areas to calculate the required roller diameter: 4. Using the tool pull the roller through the corresponding running area in the mast channel (see Fig. 113). The bottom of the tool should always be in contact with the mast channel. The roller should not jam or move sluggishly at any point. If it does, repeat the process with the next

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LIFTING MECHANISM Replacing the Mast Rollers smallest roller. If the roller runs through the area without jamming store it so that you cannot mix up its assembly position. Note: For fork carriages with 6 rollers, always select the mean roller diameter one level lower than calculated. This will prevent jamming when the rollers enter the mast channel. 5. Repeat step 4 for all mast rollers and the fork carriage rollers in their respective mast channels.

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LIFTING MECHANISM

Fig. 113 Mast roller - running areas Indicates the assembled position of the bottom mast rollers of the 1st mast stage and their running area. Indicates the assembled position of the top mast rollers of the outer mast and their running area. Indicates the assembled position of the top mast rollers of the 1st mast stage and their running area. Indicates the assembled position of the bottom mast rollers of the 2nd mast stage and their running area. Indicates the running area of all mast rollers on the fork carriage.

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500 mm

1st mast stage

2nd mast stage

500 mm

Outer mast

500 mm

Replacing the Mast Rollers

LIFTING MECHANISM Replacing the Mast Rollers Calculating the required number of shims There are shim sizes available:

13. Using the crane pull the 1st mast stage up into the outer mast until the mast stoppers can be refitted. 14. Fit the mast stoppers.

Thickness

Part No.

Checking the clearance again

1.6 mm

060030-05

With the 1st mast stage at the stop, check the clearance of the top mast rollers again:

0.7 mm

060030-85

0.4 mm

795534

15. Using a crowbar press against the top mast rollers of the 1st mast stage until they contact the opposite mast rollers of the outer mast.

Outer mast and 1st mast stage Calculating the required number of shims 1. Fit both top mast rollers (without shims) to the outer mast. 2. Push the 1st mast stage into the outer mast. 3. Using a crowbar push the 1st mast stage in the outer mast down until you can fit the top and bottom rollers (without shims) of the 1st mast stage. 4. Fit the rollers and push the 1st mast stage back into the outer mast (same position as for retracted mast). 5. Prepare a pile of shims 1.4 mm, 0.7 mm and 0.4 mm thick. 6. Using a crowbar push near the top mast rollers of the 1st mast stage until they contact the opposite rollers in the outer mast. 7. Try to push the pile of shims into the gap between the outside of the roller and the mast channel. Add or reduce the number of shims as required.  It should be possible to push the shims without them becoming stiff or jamming. Note: Try to use as few shims as possible. Therefore try first with a thick shim before using thinner ones. Often you can use one thick shim instead of several thin ones. 8. When you have calculated the number of shims required, distribute the shims over both rollers but do not fit them yet. 9. Repeat steps 1 to 8 for the bottom mast rollers. 10. Take the 1st mast stage out of the outer mast and store it safely. Fitting shims and mast rollers In the next stage do not distribute the shims crosswise (see Fig. 114, page 329). 11. Place the number of shims correctly distributed as calculated in step 8 under the respective top and bottom mast rollers and fit the mast rollers. 12. Push the 1st mast stage back into the outer mast.

16. Try to push one of the thinnest shims into the gap between the outside of the roller and the mast channel.  It should not be possible to push the shim in, but there should be a small amount of clearance. Fitting the inner mast in the outer mast 17. Push the 1st mast stage back fully into the outer mast. Fitting attachments 18. Re-assemble both lift cylinders. 19. Re-assemble the pulleys for the lift chains and hoses. Pre-assemble the hoses together with the rollers. It will not be possible to assemble the hoses at a later stage for reasons of space. 1st and 2nd mast stages Calculating the required number of shims 1. Push the 2nd mast stage into the 1st mast stage. 2. Using a crowbar push the 2nd mast stage in the 1st mast stage down until you can fit the bottom and top rollers of the 2nd mast stage. 3. Fit the rollers (without shims) and push the 2nd mast stage back into the 1st mast stage (same position as for retracted mast). 4. Prepare a pile of shims: with 1.4 mm, 0.7 mm and 0.4 mm thickness. 5. Place a crowbar between the 2nd mast stage and the 1st mast stage and push the 2nd mast stage towards the 1st mast stage the mast roller opposite the crowbar contacts the mast channel in the 1st mast stage. 6. Try to push the pile of shims into the gap between the outside of the roller and the mast channel.  It should be possible to push the shims without them becoming stiff or jamming. Add or reduce the number of shims as required. Note: Try to use as few shims as possible. Therefore try first with a thick shim before using thinner ones. Often you can use one thick shim instead of several thin ones.

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LIFTING MECHANISM Replacing the Mast Rollers 7. When you have calculated the number of shims required, distribute the shims over both rollers but do not fit them yet. 8. Repeat steps 1 to 7 for the bottom mast rollers. Fitting shims and mast rollers

Calculating the number of shims on the centre rollers (6 roller fork carriages only) 7. For 6 roller fork carriages, push the fork carriage further up until the centre rollers are at the end of the mast channel.

9. Push the 2nd mast stage down until the mast rollers can be removed.

8. Try to push the pile of shims into the gap between the outside of the roller and the mast channel. Add or reduce the number of shims as required.  It should be possible to push the shims without them becoming stiff or jamming.

10. Place the number of shims correctly distributed as calculated in step 7 under the respective top and bottom mast rollers and fit the mast rollers.

9. When you have calculated the number of shims required, distribute the shims over both rollers but do not fit them yet.

11. Push the 2nd mast stage back to its neutral position.

10. Pull the fork carriage out of the 2nd mast stage.

Note: In the next stage do not distribute the shims crosswise (see Fig. 114, page 329).

Fitting attachments

Calculating the number of shims on the bottom rollers

12. Refit all components (but not the free lift switch) which are not in direct contact with the fork carriage.

Note: The bottom rollers on the fork carriage are not accessible in the highest mast position. Note: In the next stage do not distribute the shims crosswise (see Fig. 114, page 329).

Fork carriage Note: For fork carriages with 6 rollers, always select the mean roller diameter one level lower than calculated. This will prevent jamming when the rollers enter the mast channel. Calculating the number of shims required 1. Fit all rollers (without shims) to the fork carriage. 2. Insert the fork carriage from underneath into the 2nd mast stage. 3. Push the fork carriage right up until the top rollers are at the end of the mast channel. 4. Prepare a pile of shims 1.4 mm, 0.7 mm and 0.4 mm thick. 5. Using a crowbar push near the area of the top mast rollers of the fork carriage until they contact the opposite rollers in the channel. 6. Try to push the pile of shims into the gap between the outside of the roller and the mast channel.  It should be possible to push the shims without them becoming stiff or jamming. Add or reduce the number of shims as required. Note: Try to use as few shims as possible. Therefore try first with a thick shim before using thinner ones. Often you can use one thick shim instead of several thin ones. If the fork carriage has 4 rollers continue with step 10. For fork carriages with 6 rollers continue with step 7.

11. Initially, use the same number of shims on the bottom fork carriage rollers as for the top (for 4 rollers) or centre (for 6 rollers) rollers. Note: Try to use as few shims as possible. Therefore try first with a thick shim before using thinner ones. Often you can use one thick shim instead of several thin ones. 12. Insert the fork carriage back into the 2nd mast stage. 13. Manually push the fork carriage up as far as the stop.  The fork carriage should not jam. Checking the clearance of the bottom fork carriage rollers in the 2nd mast stage 14. Using a crowbar push near the bottom mast rollers of the fork carriage until they contact the opposite rollers in the channel.  The clearance should not be greater than that of the centre or top rollers. 15. To compare, you can move the fork carriage and check the top and bottom clearance alternately. Correcting the clearance of the bottom fork carriage rollers 16. Pull the fork carriage out of the 2nd mast stage until the bottom rollers can be accessed an place another thin shim (0.4 mm) underneath. 17. Manually push the fork carriage back up as far as the stop on the stoppers and check the clearance

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LIFTING MECHANISM Replacing the Mast Rollers again. If necessary, place another thin shim underneath.  It should be possible to push the fork carriage manually to the top stop without jamming.

Final tasks and settings 18. Attach the components. 19. Refit all parts that have been removed. 20. Assemble the mast (see page 320) and carry out the tasks listed under “Mast checks and settings after assembly” on page 320.

(1)

Checking the mast stoppers 21. Check the mast lateral alignment.  When the mast is fully extended it should not tilt to the side.  The left and right stops on the mast stages should strike the stoppers at the same time. 22. If necessary, fit shims. Note the assembly position of the plastic block. The plastic must face the mast stop (see spare parts manual for details).

(2) (2)

(1)

(2)

(2) (1)

(1)

(2)

(1)

(2)

Figures in brackets indicate the number of shims to be positioned.

Fig. 114 Distributing the shims under the mast rollers ESR 5000

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LIFTING MECHANISM Integrated Sideshifter

Integrated Sideshifter Removing the integrated sideshifter (See Fig. 115) 1. Remove the forks. 2. Lower the fork carriage onto a pallet. 3. Switch off the truck, disconnect the battery and prevent the truck from rolling away. 4. Remove the load backrest. 5. Depressurise the hydraulic system (see page 78). 6. Prepare a flat tray to collect any spilled hydraulic oil. 7. Remove the stopper (25). 8. Undo all hydraulic connections from the sideshifter and seal all ports immediately with filler plugs. 9. Remove the lug (18).

WARNING Risk of injury from flying components If the sideshifter is pressurised when the chassis (20) is removed, the piston rams (6) will fly out like bullets. They could fatally injure you or other people.  Make sure the sysem is depressurised and cannot be started up again before the chassis is removed. 10. Tilt the frame (20) up and slide it to the side of the fork carriage frame (1). Take care not to push the slide pieces (12) out of their seats.

Assembling the integrated sideshifter 1. Clean all sliding surfaces and check them for wear. Replace any worn slide pieces (12). 2. Grease the sliding surfaces (for lubricant see page 27). 3. Re-assemble all parts in the reverse order of disassembly. 4. Flush the sideshifter cylinder (see page 79). 5. Flush the tilt cylinder (see page 79).

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LIFTING MECHANISM Integrated Sideshifter

11 34

10 32

26 1

5 4

8 7

28 29 17 16

13 14

18 15 17 21

27 2

3 4

20 22

6 23

Fig. 115 Integrated sideshifter ESR 5000

331

LIFTING MECHANISM Lift Cylinder Removal and Assembly

Lift Cylinder Removal and Assembly

Lift cylinder removal on masts up to 8m

The removal and assembly procedure differs depending on the lift height. Beyond an 8 m lift height the mast must be removed before the lift cylinders can be removed from a horizontal mast (see page 335).

See Fig. 116

Safety notices

Removal preparation 1. Fully lower the fork carriage. 2. Place a flat tray underneath the work area to collect any spilled hydraulic oil. 3. Remove the panels (22 & 30). 4. Extend the mast until the 2nd mast stage has been raised approx. 500 mm.

WARNING

5. Place approx. 200 mm long hard wooden blocks in the channels of the outer mast and secure them with clamps.

Risk of trapping and severing limbs Unsecured masts stages and attachments can sever limbs or even cause fatal injuries.  Before starting assembly always block and secure the relevant components with equipment with sufficient strength and stability.

6. Place 350 - 400 mm long hard wooden blocks in the channels of the 1st mast stage and secure them with clamps. 7. Slowly lower the fork carriage in full. The lift chains are now relieved. Lift cylinder removal

8. Switch off the truck, disconnect the battery and prevent it from being switched on again. 9. Remove the anti-bend pin (10) and screw (13). 10. Remove the chain bolts from the top of the cylinder tube connection and use wire to prevent the lift chains on the mast stage from falling down. 11. Depressurise the hydraulic system (see page 78).

 Depressurise the hydraulic system before opening any sections of it.

CAUTION

 Tighten all connections before pressurising the system.

Do not use any tools in step 12. Tools will damage the piston ram.

 Keep hands and body away from pressurized fluid.  Only trace leaks with a piece of paper or cardboard.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.

12. Manually pull the piston ram down and out of the top seat and push it as far as the stop in the lift cylinder. 13. Place a load sling below the tappets of the cylinder tube and gently tension the cylinder using the crane. 14. Undo the hydraulic port from the lift cylinder. 15. Raise the lift cylinder out of the mast.

 Observe the manufacturer’s safety instructions when handling solvents and lubricants.

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LIFTING MECHANISM Lift Cylinder Removal and Assembly Lift cylinder assembly on masts up to 8 m See Fig. 116

WARNING Risk of trapping or severing fingers and hands You can trap or sever hands and fingers when inserting the piston ram into the top seat on the mast.  When assembling the cylinder guide it always by the cylinder tube, not the piston ram. Note: You will need an assistant to activate lifting when inserting the piston ram in the top seat. Ideally this should be a forklift driver with experience in operating this truck. 1. Guide the piston ram into the seat (only hold the cylinder by the cylinder tube), while the assistant slowly and carefully activates lifting. 2. Fit the anti-bend pin (10). 3. Adjust the screw (13) so that there is no longer any clearance in the bottom cylinder seat. Torque the counternut on the screw to 70 - 80 Nm. 4. Attach the lift chain. 5. Now add hydraulic oil to the maximum mark and bleed the hydraulic system (see page 79).

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333

LIFTING MECHANISM Lift Cylinder Removal and Assembly

Fig. 116 Mast exploded diagram ESR 5000

334

LIFTING MECHANISM Lift Cylinder Removal and Assembly Lift cylinder removal on masts beyond 8 m 1. Remove the mast (see page 319) and lay it down horizontally. 2. Remove the anti-bend pin (10) and screw (13). 3. Remove the chain bolts from the top of the cylinder tube connection and use wire to prevent the lift chains on the mast stage from falling down. 4. Manually pull the piston ram down and out of the top seat and push it as far as the stop in the lift cylinder. 5. Place a load sling around the cylinder tube and gently tension the cylinder using the crane. 6. Undo the hydraulic port from the lift cylinder. 7. Extract the mast stages from the horizontal mast. 8. Remove the cylinder from the mast.

Lift cylinder assembly on masts beyond 8 m See Fig. 116

WARNING Risk of trapping or severing fingers and hands You can trap or sever hands and fingers when inserting the piston ram into the top seat on the mast.  When assembling the cylinder, always guide it manually by the cylinder tube, not the piston ram. 1. Insert the lift cylinder in the mast. 2. Push the mast stages in fully. 3. Fit the anti-bend pin (10). 4. Assemble the mast (see page 330). 5. Adjust the screw (13) so that there is no longer any clearance in the bottom cylinder seat. Torque the counternut on the screw to 70 - 80 Nm. 6. Attach the lift chain. 7. Connect the hydraulic line. 8. Now add hydraulic oil to the maximum mark and bleed the hydraulic system (see page 79).

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335

LIFTING MECHANISM Reach Cylinder Removal and Assembly

Reach Cylinder Removal and Assembly

Safety notices

Fig. 117 Reach cylinder - reach carriage attachment

 Tighten all connections before pressurising the system.  Keep hands and body away from pressurized fluid.  Only trace leaks with a piece of paper or cardboard.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents and lubricants. The reach cylinder is installed at the bottom right of the truck. The piston ram is attached to the chassis (see Fig. 118), the cylinder base to the reach carriage (see Fig. 117).

Fig. 118 Reach cylinder - chassis attachment

Removal Removal preparation 1. Extend the reach carriage fully. 2. Lower the fork carriage to the ground. 3. Place a flat tray underneath the truck to collect any spilled hydraulic oil. 4. Jack up the truck and secure it (see page 14). 5. Depressurise the hydraulic system (see page 78) Reach cylinder removal 6. Unscrew the hydraulic hoses from the cylinder and immediately seal all ports with filler plugs. 7. Remove any attachments present for the cylinder cables and hoses.

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LIFTING MECHANISM Free Lift Cylinder Removal and Assembly

Free Lift Cylinder Removal and Assembly

2. Place a load sling around the fork carriage and with the crane raise the fork carriage until the FLS switch is accessible.

The following section describes how to remove and assemble the free lift cylinder with the mast assembled.

3. Chock the fork carriage with suitable hard wooden blocks to prevent it from accidentally lowering.

Safety notices

CAUTION CAUTION

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

The free lift switch will be damaged if you raise the fork carriage beyond the free lift height. Remove the free lift switch (FLS) before raising the fork carriage beyond free lift height. 4. Remove the free lift switch (FLS). 5. Place a flat tray underneath the mast area to collect any spilled hydraulic oil. 6. Depressurise the hydraulic system (see page 78). 7. Disconnect all hydraulic lines and electrical connections from the fork carriage. Seal open hydraulic ports with filler plugs.

WARNING Risk of trapping and severing limbs Unsecured mast stages and attachments can sever limbs or even cause fatal injuries.  Before starting assembly always block and secure the relevant components with equipment with sufficient strength and stability.

8. Remove the mounting bolt from the free lift chain. Removing the fork carriage 9. Using the crane lower the fork carriage down onto a pallet positioned underneath it. 10. Place a load sling around the highest tie bar on the 2nd mast stage (for minimum capacity see table on page 315). 11. With the crane slowly raise the 2nd mast stage until the fork carriage rests freely on the pallet.

12. Bring the fork carriage out of the work area with a forklift truck. 13. Lower the 2nd mast stage onto hard wooden blocks. Removing the free lift cylinder 14. Remove the pressure line from the bottom of the free lift cylinder.

 Depressurise the hydraulic system before opening any sections of it.

15. Remove the two steel hydraulic lines attached to the free lift cylinder in full.

 Tighten all connections before pressurising the system.

16. Place a load sling below the middle attachment plate around the free lift cylinder. Using the crane tension the load sling slightly to prevent the cylinder from falling out when the last two mounting screws are loosened.

 Keep hands and body away from pressurized fluid.  Only trace leaks with a piece of paper or cardboard.

17. Remove the two mounting screws (31, Fig. 119) from the free lift cylinder.

Removal Preparation 1. Switch off the truck, disconnect the battery and prevent it from being switched on again.

18. Lift out the cylinder with the crane and place it on the ground.

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LIFTING MECHANISM Free Lift Cylinder Removal and Assembly Assembly Note: When assembling the free lift cylinder in a horizontal mast, note the following: •

The free lift cylinder must stand in the ball pan before the mast is erected.

•

Only tighten the mounting screws (31, Fig. 119) when the mast is vertical.

1. Assemble the free lift cylinder in the reverse order of disassembly. 2. Now add hydraulic oil to the maximum mark and bleed the hydraulic system (see page 79). 3. Test the free lift switch (FLS). 4. Make sure the cylinder is vertical and that there is a minimum gap of 5 mm between the pulley and the cross brace of the mast stage when the free lift cylinder is extended. If not, adjust with shims (5, Fig. 119).

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338

LIFTING MECHANISM Free Lift Cylinder Removal and Assembly

Fig. 119 Mast exploded diagram ESR 5000

339

LIFTING MECHANISM Chain Supports and Lift Chains

Chain Supports and Lift Chains

Cleaning lift chains

General Lift chains are safety components. Careful maintenance and repairs are a prerequisite for safe truck operation and long uptime.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.

WARNING Improper cleaning can cause chains to crack A cracked chain can result in fatal injuries. Never clean lift chains with steam cleaners, cold cleaning agents or corrosive, acid-based agents. This can cause direct chain damage through hydrogen embrittlement.  Clean the chain surfaces only with paraffin derivatives such as cleaning petroleum or cleaning petrol. Apply a thin layer of the cleaning agent with a hard bristle brush and wipe with a lint-free cloth.

 Observe the manufacturer’s safety instructions when handling solvents and lubricants.

 Apply an approved chain oil immediately after cleaning or inspection (see Recommended Lubricants and Consumables table, page 27). The oil acts as an anti-corrosion agent.

Periodic inspection of chain supports and lift chains CAUTION Lift chains and chain supports must be periodically cleaned, inspected and lubricated (see Planned Maintenance and Inspection, page 47). The interval must be adapted for corrosive or dusty environments, i.e. reduced accordingly so that safety is not affected.

Periodic replacement of chain supports and lift chains For safety reasons chain supports, lift chains, anchor bolts and attachment items must be replaced periodically irrespective of their external condition. Irrespective of the condition and inspection results you must replace the following components after every 6000 service hours or 3 calendar years at the latest: •

Lift chains

•

Chain supports and their attachment items

•

Anchor bolts and their attachment items

Note: Chain supports are marked with the date of manufacture / assembly (week/year).

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LIFTING MECHANISM Inspecting Chain Supports and Lift Chains

Inspecting Chain Supports and Lift Chains CAUTION If damage is detected on the lift chains during inspection, replace the lift chains and the chain supports, chain bolts and attachment items before returning the truck to service. If 2 chains are used paired, replace in pair.

supports, anchor bolts and lift chains together with all their attachments.

Checking the lift chain for elongation General The chain bends as it passes over the chain rollers. This gradually causes the chain links and the chain plate eyelets to wear. The chain therefore elongates over time.

Preparatory measures 1. Remove the lift chain if it cannot be fully inspected when installed.

WARNING Crashing loads can cause injury Lift chains, chain supports, chain bolts and their attachments are safety components. Their failure can cause the load to crash, resulting in fatal injuries.

2. Clean the lift chain (see page 340). Tools required: •

Wear gauge (see Fig. 120) or steel ruler

 Never repair lift chains, chain supports or chain bolts - always replace them with original spare parts. The inspection covers the following points: Checking the service hours for the chain supports and lift chains.

•

Checking the lift chain for elongation.

•

Checking for wear on the edges of the chain connection plates.

•

Checking for pitting due to corrosion, in particular on the outer surfaces of the connection plates.

•

Checking for twisted and protruding pins.

•

Checking for loss of freedom in the chain links.

•

Checking for damage to the anchor bolts and their attachments.

•

Checking for wear and corrosion of the chain supports and anchor bolts.

Checking the service hours for the lift chains and anchor bolts 1. Check the chain support date of manufacture (see engraving on chain support): If the chain supports are 3 years or older, replace the chain supports, anchor bolts and lift chains together with all their attachments. 2. Check the number of service hours since the chain support and lift chains were last replaced: If the chain supports or lift chains have been in service for 6000 hours or more, replace the chain

ROLLER AND LEAF CHAIN WEAR SCALE

•

Fig. 120 Crown wear gauge

Chain wear can be measured with a wear gauge (part no. 106440) or a steel tape measure. The Crown wear gauge (see Fig. 120) has two scales: •

Scale “A” is used for 19.05 mm (0.75 inch) and 25.4 mm (1 inch) pitch chains.

•

Scale “B” is used for 15.88 mm (0.625 inch) pitch chains.

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LIFTING MECHANISM Inspecting Chain Supports and Lift Chains Note: For twin chains always replace the second lift chain with the chain support and anchor bolts.

Checking the chain for elongation 1. Raise the fork carriage to tension the lift chain. (Pull removed lift chains taut in order to measure them.)

Checking the lift chains This section lists the inspection items that can be performed in one step: •

Check for loss of freedom in the chain links.

•

Check for worn or missing plates.

•

Check for twisted and protruding pins.

•

Check for lift chain lateral wear.

•

Check for lift chain corrosion.

Freedom of movement Each individual chain link must flex freely. Tight joints (see Fig. 122) increase friction and the chain tension during lifting. Excessive chain tension in turn accelerates material wear.

Fig. 122 Tight joints

Possible causes of stiff chain links are as follows: Fig. 121 Measurement section (A) on the lift chain

Make sure you measure a part of the chain that passes over a pulley.

•

Bent pins or plates

•

Rusty chain links

•

Peened plate edges.

2. With taut lift chain check section (A) either in front or rear of pulley for elongation.

Plate edge distortion is caused by:

3. Repeat the measurement on 3 parts of the chain that always pass over a pulley during operation.

– Constant overloading of the chain.

Note: If you are using a steel ruler, the measurement must include at least 10 links. See following table: Pitch

No. of chain links

Length new

305 mm 12 inch

314 mm 12.375 inch

19.05 mm 0.75 inch

305 mm 12 inch

314 mm 12.375 inch

15.88 mm 0.625 inch

318 mm 12.5 inch

327 mm 12.875 inch

Replace lift chains, chain supports, anchor bolts and attachments if the chain has elongated by more than 3%! Rev.1 02/2009

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– Chain striking the mast components.

Worn or missing plates Generally speaking, material wear is the cause of worn or missing connection plates. The plates near the chain pin hole (see Fig. 123) can crack after a high number of lifting cycles with heavy loads.

Wear limit

25.4 mm 1 inch

– Ruptured chain pinion.

Fig. 123 Worn connection plate

ESR 5000

LIFTING MECHANISM Inspecting Chain Supports and Lift Chains Turned pins Considerable frictional forces between the connection plates and the pins occur when lifting heavy loads with an insufficient or non-existent film of oil. In extreme cases the frictional torque in the joints can be such that the pins turn and gradually work out of the chain (see Fig. 124). The chain can break as a result. Turned pins can be rapidly identified if the flat ends are not all pointing in the same direction.

nizing process is an excellent protection and fully penetrates the joints. Do not remove this layer of grease! Checking lift chains for rust, rust marks and cracking caused by corrosion 1. If you have not already done so, with the mast fully lowered undo the lift chain bolts from the top chain supports (remove the anchor bolts) and thread them out far enough that they can accessed along their whole length. 2. Check the chain links for corrosion and corrosion damage (marks, pitting). 3. Rust film on lift chains can be removed with chain oil. Now check again for rust marks. 4. Immediately replace any chains with rust marks or pitting along with the chain supports, anchor bolts and attachments. Chains used in pairs must also be replaced in pairs.

Chain lateral wear Wear traces along a stretch of the chain on the pin heads and the outer plates indicate misalignment. This can have one of two causes: Fig. 124 Turned pin

•

Checking chain links for freedom of movement, worn connection plates and turned pins

Uneven chain tension (see Checking and adjusting the chain tension, page 344).

•

Misalignment between the pulleys and the chain supports (see Checking the lifting components for misalignment, page 345).

1. With the mast fully lowered, undo the lift chain bolts from the top chain supports (remove the anchor bolts) and thread them out so that they can accessed along their whole length. 2. Check the chain links for freedom of movement, worn connection plates and turned pins. Immediately replace any damaged chains along with the chain supports, anchor bolts and attachments. Chains used in pairs must also be replaced in pairs.

Checking chain supports and anchor bolts Checking chain supports 1. Check the chain supports for: – Assembly period expiry (max. 6000 hours or 3 years, see date on chain support head)

Corrosion

– Cracks

Corrosion considerably reduces the capacity of a lift chain. It results in cracking in the side plates.

– Corrosion – Finger wear 2. Replace any damaged or worn chain supports. Checking the anchor bolts – Check the anchor bolts for: – Cracks – Corrosion – Wear

Fig. 125 Cracking caused by corrosion

Lift chains must therefore be protected from corrosion. The layer of grease applied in the factory hot dip galva-

3. Replace any damaged anchor bolts.

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LIFTING MECHANISM Inspecting Chain Supports and Lift Chains 4. Check the condition of the anchor bolt retaining element. Replace any corroded or missing retaining elements.

Checking the chain pulleys 1. Check the chain pulleys for: – Wear in the flange area – Running surface wear A

Worn flanges are due to misalignment. If the pulleys are worn: 2. Check or adjust the chain tension and mast roller setting.

Checking and adjusting the chain tension Checking and adjusting the tension on the outer chains When installed, both outer lift chains should be equally tensioned to ensure even distribution of the load over the two chains during lifting operations. Checking the chain tension Note: Adjust the outer chain tension via the top chain supports. The bottom chain supports must not be adjusted as they have fixed settings.

Fig. 126 Screw depth (A) of bottom chain support on mast

1. Check the screw depth (A, Fig. 126) of the bottom chain support: It should be = 70 mm. Adjust if necessary. 1. Setting the chain tension 2. Undo the counternut on the top chain supports. 3. Set the chain tension by adjusting the top chain supports. 4. Re-tighten the counternuts on the chain supports (for standard torque see page 50). Both lift chains must be taut and equally tensioned.

Checking and setting the free lift chain tension Checking the chain tension 1. Fully lower the fork carriage. 2. Measure the fork tip height: The chain tension is correctly set when the fork tip height is 50 mm (for 1.4 t capacity) or 55 mm (for 1.6 t and 2.0 t capacities).

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LIFTING MECHANISM Inspecting Chain Supports and Lift Chains Presetting the chain supports for new lift chains 3. Check the screw depth of the top chain support (on the mast): It should be = 70 mm. Adjust if necessary. 4. Check the screw depth of the bottom chain support (on the fork carriage): It should be = 80 mm. Adjust if necessary. Setting the chain tension 5. Undo the counternut on the top chain support. 6. Set the chain tension by adjusting the chain supports. The chain tension is correctly set when the fork tip height is 50 mm (for 1.4 t capacity) or 55 mm (for 1.6 t and 2.0 t capacities). 7. Re-tighten the counternuts on the chain supports (for standard torque see page 50).

Checking the lifting components for misalignment Misalignment of the chain pinion and the chain due to the wrong number of washers on the mast or a damaged mast or cylinder components can also contribute to wearing of the chain sides. To test whether this is the case, proceed as follows: 1. Park the truck on a level surface. 2. Support the fork carriage and disassemble the anchor bolts on both ends of the lift chains. 3. Visually inspect the alignment with the anchor slots. If the chain ends are not aligned with the chain support slots: – Check the mast, cylinder and piston rams for damage. – Check the alignment of the mast stages (see page 324).

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LIFTING MECHANISM Lubricating Lift Chains

Lubricating Lift Chains

CAUTION

General information

A lift chain must never be allowed to dry.

Lubrication is the most important factor in lift chain maintenance. It considerably affects the chain's useful life. Highly stressed chains under constant use cannot last sufficiently long if they are not regularly lubricated. As with all contact surfaces, the tensiled steel precision moving parts require a durable lubricant film between the contact surfaces to avoid excessive wear.

In dusty operating conditions the multi-plate chains can be more efficiently lubricated than roller chains. Multiplate chains consist of several plates. Therefore they provide several paths for the lubricant to reach the chain bolt (see Fig. 127) and allow the oil to penetrate to the bearing surface on the chain bolt, even when the chain is dirty.

The key thing is that the lubricant oil can penetrate into the chain bolts. This is impossible if the chains are covered in grease and dirt.

Maintaining a lubricant film on all the chain surfaces provides the following benefits: •

Restricts joint wear to a minimum (chain elongation).

•

Avoids corrosion.

•

Reduces the risk of chain bolts turning.

•

Restricts the danger of chain links turning in to a minimum.

•

Ensures an even movement of the chains and thus reduces noise levels.

•

Reduces the chain tension due to less friction in the chain system.

Key factors when considering which lubricant to use are as follows: •

High degree of penetration in the narrowest of gaps

•

Maximum tolerance of pressure and shearing forces before the lubricant film comes off.

•

Suitability to the operating temperature range, especially important for cold store trucks.

Fig. 127 Oil film (1) in a multi-plate chain

Lubrication intervals and lubricants Under normal operating conditions the chains should be cleaned according to the intervals specified in the maintenance schedule (see page 29), and then lubricated with an approved chain lubricant (see page 27). In extreme conditions this interval must be reduced accordingly.

Lubrication intervals depend on the operating conditions and the environment. Trucks parked outdoors, in cold stores or which are subjected to extreme weather conditions must be lubricated more frequently. Dust will gather on oiled chains in dusty environments. However, even in these conditions, regular lubrication can considerably reduce wear. A paste mixture of oil and dirt will gather on the chain links, but they will not wear as fast as they would if they were left to dry, leaving a metal to metal contact between the pins and plates.

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ESR 5000

LIFTING MECHANISM Separating Lift Chains

Separating Lift Chains

Cutting the lift chain

Lift chains are supplied by the meter and must be cut to the required length.

WARNING

Tools and equipment required •

Risk of eye damage Splinters can fly off during grinding operations.

A secure working plate with a hole slightly larger than the head diameter of a chain bolt. The hole must be deeper than the chain bolt length.

•

 Wear goggles to avoid eye injuries.

A backring (washer) with a hole slightly larger than the head diameter of a chain bolt. The backring thickness must be slightly larger than the height of the head of a chain bolt. The backring prevents the inner plate surface from being damaged when you drive out the chain bolt.

•

A grinder.

•

A hammer and hole with a diameter slightly shorter than the chain bolt. Or a press with a suitable mandrel.

1. Carefully grind the head of the chain bolt, taking care not to damage the chain plate eyelet. 2. Place the backring onto the hole in the working plate. 3. Insert the head of the chain bolt to be driven out into the backring.  Align the chain bolt, backring and hole in the working plate. 4. Drive out the chain bolt. 1

Chain plate eyelet

Backring

Hole in working plate

Grinder

ESR 5000

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LIFTING MECHANISM Forks

Forks

Fork marking

General The fork tines and forks must be checked by trained personnel under the maintenance schedule (see page 49) for cracks, damage and wear.

If the forks are used to transport abrasive loads the inspection must be carried out at shorter intervals.

Terms 1

Fig. 129 Fork marking

The marking is on the side of the fork shank (see Fig. 129) and comprises the following data: – Capacity – Load centre of gravity

– Manufacturing data (month / year) – Company logo

Fig. 128 Fork tines 1

Fork blade

Fork hanger

Fork shank

Heel (curved area)

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– Manufacturing site

ESR 5000

LIFTING MECHANISM Fork Inspection

Fork Inspection

Checking weld seams for cracks

WARNING Crashing loads can cause injury If a fork breaks under load it can fatally injure you or other people.  Never carry out repair welding to surface cracks, damaged or worn parts around the heel of the fork.  Forks must only be repaired by the fork manufacturer.

Checking fork tines for cracks Visually inspect all fork tine surfaces for signs of cracks. The heel area and weld seams must be checked particularly carefully. If in doubt carry out a non-rupturing crack test (paint penetration process or Magnaflux®):

Fig. 131 Fork hanger

1. Check for cracks on the weld seams by the upper and lower fork hangers (see Fig. 131) including their fork shank attachments. Remove the fork in question if any cracking is discovered.

Checking fork tip straightness (See Figs. 132 and 133)

Checking the heel area for cracks Fatigue cracking (1, Fig. 130) tends to occur around the heel of the forks. 1. Check the fork heel area particularly carefully.

1. Check the fork tip (2) for straightness using a ruler (1). Replace the fork if the tolerance level has been exceeded.

2 1 1 2 mm 250 mm Fig. 130 Fatigue cracking in the heel area

Fig. 132 Vertical fork tip straightness

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LIFTING MECHANISM Fork Inspection

Fig. 135 Fork tip width

500 mm

Measuring the fork tine height difference

1. Check the height of the fork tips in relation to each other (1 and 2, Fig. 136136) if the forks are fixed to the fork carriage. If the difference is more than 3% (3) of the fork blade length (L), the fork tines must be aligned professionally.

max. 6 mm Fig. 133 Horizontal fork tip straightness

Measuring the fork blade warping 1. Measure the angle deflection between the top of the fork blade and the front of the fork shank (see Fig. 134). If dimension x is outside the tolerance range, the fork must be aligned by a specialist and rechecked.

For example: If the fork blade is1150 mm long the maximum permissible deviation is approx. 35mm. However, this would prevent the fork from working. In practice, forks must be aligned if the deviation is max. 10 mm.

500 mm

x - 17 mm x + 8,5 mm

Fig. 136 Height difference Fig. 134 Fork blade warping

Checking the fork stop

Measuring the fork tip width

1. Check the stop mechanism (1, Fig. 137) on both fork tines. The mechanism should lock securely, otherwise the fork must be replaced.

1. Measure the fork tip width with a calliper gauge. If the fork tip width S is less than a = 6 mm (a = fork shank width) take the fork out of service (see Fig. 135).

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LIFTING MECHANISM Fork Inspection

a=100% 1

Fig. 137 Fork stop

Fig. 139 Fork blade wear

Measuring the fork blade wear The heel is particularly sensitive to wear. If the width is 90% or less than the original value, the fork must be replaced. Use calliper part no. 107330 to measure.

90%

Fig. 138 Calliper (part no. 107330)

This calliper has 2 opposite tappets (see Fig. 138). 1. Using the outer tappets calculate the original fork blade width on the fork shank: 2. Using the outer tappets scan the fork shank width (item a = 100% in Fig. 139) and fix the calliper. This determines the 100% value. The inner tappets correspond to 90% of the value previously obtained. 3. Now use the inner tappets (90%) to scan the fork blade between the shank and the start of the curved area (1, Fig 139). If the calliper fits at any point over the fork blade, then the fork is worn. Remove the worn fork from service.

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LIFTING MECHANISM Reach Carriage

Reach Carriage

"Left outrigger" and "Right outrigger" definition

Terms and definitions Terms

21.5 mm

965 mm

21.5 mm

Fig. 140 Reach carriage terms

Fig. 141 "Left" and "Right" definitions for the outriggers

Reach carriage

"Right" outrigger

Roller

"Left" outrigger

Side roller

Backing roller

Reach carriage removal

The reach carriage (1, Fig. 140) has two rollers (2), two side rollers (3) and one backing roller (4) on each outrigger. The side rollers absorb lateral forces and guide the reach carriage parallel into the outriggers. The side rollers in the left outrigger are adjustable. This ensures smooth operation with virtually no slack along the entire reach path. A backing roller (4) with downward pretension on each outrigger reduces the vertical slack of the rear rollers.

1. Disassemble the mast (see page 319). 2. Remove all electrical and hydraulic connections from the reach carriage. 3. Loosen the connection between the reach cylinder and reach carriage (see page 336). 4. Secure the reach carriage with a crane and push it out of the outriggers.

Reach carriage assembly Pre-assemble the reach carriage 1. Replace any worn rails. 2. Replace faulty side rollers, rollers and backing rollers on the reach carriage. 3. Turn back the adjusting screws on the right side rollers. The side rollers are adjusted when the reach carriage is installed. 4. Loosen the mounting nut of the eccentric bolts on both backing rollers. They should only be handtightened. 5. Turn the eccentric bolts of the backing rollers so that the backing rollers are no longer resting in the outrigger section when the reach carriage is installed.

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LIFTING MECHANISM Reach Carriage Pushing the reach carriage into the outriggers 6. Push the pre-assembled reach carriage into the outriggers using a crane.

Note: Note that the same number of spacers must be used on the front and rear rollers to avoid tilting the reach carriage. 11. Repeat steps 7 to 9 until the gap lies within the tolerance range of ± 2 mm.

Adjusting the side rollers

Tightening and securing the side roller setscrews 12. Using a mounting iron push the entire reach carriage against the channel in the left outrigger until both side rollers are resting against the web of the channel.

13. Turn both setscrews of the right side rollers on the reach carriage until the side rollers are resting against the outrigger channel. 14. Hold the setscrews and torque the counternuts to 70 ± 5 Nm. Checking the freedom of movement of the reach carriage

15. Move the reach carriage by hand approx. 10 times over the entire path up to the limit positions.  It should be possible to move the reach carriage manually without it jamming. If not, repeat steps 12 to 15.

Checking the lateral clearance on the reach carriage

Fig. 142 Reach carriage and chassis

Chassis back plate

16. Using a mounting iron push against the channel in the left outrigger until both left side rollers are resting against the web of the channel. (See Fig. 141 for the definition of left and right).

Reach carriage cover plate

17. Measure and record the gap on the right outrigger.

"Right" outrigger

"Left" outrigger

Note: The aim is to obtain approximately the same gap on the left and right hand side rollers so that the reach carriage is centrally aligned in the chassis. 7. Push the reach carriage forward until the reach carriage cover plate (4, Fig. 142), covers the chassis back plate (3). 8. Using a mounting iron push against the channel in the left outrigger until both side rollers are resting against the web of the channel. 9. Measure the gap on both sides between the U section of the outrigger and the side plate (see Fig. 141) of the reach carriage by the side roller (it should be 21.5 mm):  If the difference is greater than ± 2 mm, proceed to step 10.  If the difference is less than ± 2 mm, proceed to step 12. 10. Compensate the gap on the left side rollers with additional 1 mm spacers.

18. Using a mounting iron push against the channel in the right outrigger until both right side rollers are resting against the web of the channel. 19. Measure and record again the gap on the right outrigger. 20. Compare both measurements. They should not deviate from each other by more than 0.5 mm.  If necessary, adjust the setting via the setscrews on the right side rollers (repeat steps 12 to 20). Refitting the mast 21. Fit the mast (see page 319) and then adjust the backing rollers. Setting the backing rollers Note: The mast must be fitted in order to adjust the backing rollers. Without the mast there will be no additional tilt moment and the setting will be wrong.

ESR 5000

353

LIFTING MECHANISM Reach Carriage

Fig. 143 Setting the backing rollers

22. Check the nut (2, Fig. 143) on the eccentric bolt (3).  The nut should only be hand-tightened. 23. Manually turn the nut (5) on the eccentric bolt until it contacts the reach carriage plate. 24. Using a torque wrench (set to 20 - 25 Nm) turn the eccentric bolt (3) on the backing roller (4) until the torque wrench is activated. Note: This will ensure that the backing roller rests on the running strip in the outrigger with the correct pretension. 25. Hold the eccentric bolt (4) and torque the nut (5) to 350 - 400 Nm. Do not turn the eccentric bolt in the process!

ESR 5000

354

CYLINDERS

355

Notes:

356

CYLINDERS General

General Safety notices CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents and lubricants.

Hydraulic System Repair Instructions •

Hydraulic systems are sensitive to dirt.

•

Thoroughly clean disassembled hydraulic components before dismantling them.

•

Always repair hydraulic components at a clean workstation.

•

Immediately protect cleaned and de-greased components with a thin coating of hydraulic oil.

•

Protect components against re-contamination before assembling them.

•

Immediately seal open hydraulic ports on repaired assemblies with dummy plugs. This also applies to open ports and lines on the truck.

•

Do not refinish any cylinder surfaces. Replace any damaged parts.

•

Always replace all the seals on the assembly. Used seals can cause leaks.

ESR 5000

357

CYLINDERS Tools

Tools

Producing extractors 1. Hard solder a self-tapping 4 mm screw (3) onto the shaft (min. 150 mm, long, max. Ø 4 mm) of a screwdriver (1).

CAUTION Cylinder surfaces can be damaged through the use of unsuitable tools.  Do not use a screwdriver or similar tools.

2. Sand the soldering joint. 3. Wrap insulating tape (1) around the shaft and soldering joint of the screwdriver.

 Use burr-free tools made of soft metal (brass, aluminium) without sharp edges or a suitable plastic.

Groove aligning arbor for small rod seals

You must produce the following tools yourself:

The outer diameter of the groove aligning arbor must fit the internal diameter of the cylinder cap.

Small hook

The arbor should end flush with the bottom of the seal seat.

Use small hooks to remove small seals (see Fig. 144).

3 Fig. 146 Groove aligning arbor in a cylinder cap 1

Cylinder cap

Fig. 144 Hook

Seal seat

Extractor

Groove aligning arbor

Two extractors to remove rod seals (see Fig. 145) .

Fig. 145 Extractor

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358

CYLINDERS Tools Assembly devices for large rod seals Produce a tool body (12, Fig. 147) with a diameter to match the internal diameter of the cylinder caps.

1 2

3 4

Fig. 147 Assembly device for large rod seals 1

Tool body

Fixed pin

Rod seal (shown for illustration purposes only)

Axial moving pins

Protective mechanisms If the seal has to be pushed over sharp edges, cracks or nicks, use appropriate plastic protective mechanisms.

ESR 5000

359

CYLINDERS Rod Seal Removal and Assembly

Rod Seal Removal and Assembly

Removing a large rod seal

2 3

1. Turn one extractor (see Fig. 145) respectively into the opposite parts of the rod seal.

2. Pull the seal out of its seat using the grips of the tools. 3. Dispose of the rod seal.

Removing a small rod seal

1. Using a small hook (see Fig. 144) pull the rod seal out of the seal seat.

2. Dispose of the rod seal.

Inserting a large rod seal 1. Apply a thin coating of hydraulic oil to the rod seal and the seal seat in the cylinder cap. 2. Place the rod seal over the fixed pin (1, Fig. 148). 3. Bend the rod seal under the pin (2). 4. Now bend the resultant loop up so that the pin (3) can be moved into the loop.

Fig. 149 Wound rod seal

5. Push the tool body (1, Fig. 5) into the cylinder cap (2) until the rod seal (6) is aligned with the seal seat in the cylinder cap. 6. Retract the pin (1, Fig. 150).  One segment of the rod seal jumps into the seal seat.

2 Fig. 148 Threading the rod seal

Fig. 150 The first rod seal segment is located in the seal seat.

7. Retract the pin (2, Fig. 150).  The rod seal is now fully located in the seal seat (see Fig. 151)

ESR 5000

360

CYLINDERS Rod Seal Removal and Assembly Rod seal assembly, sealing lip first The sealing lip is sensitive and must not be damaged. Special protective sleeves (1) are required when pushing the seal (2, Fig. 153) over the thread and holes.

CAUTION Incorrectly assembled rod seals will leak  Fit the rod seal with the sealing lip facing the pressure side.

Fig. 151 Rod seal fully inserted in seal seat

8. Pull the tool body out of the cylinder cap.

Fitting a small rod seal 6 1

5 2 3 Fig. 153 Sealing lip facing the pressure side

Cylinder tube

Inner thread

Protective sleeve for assembly

Rod seal

Sealing lip

Backring

Fig. 152 Small rod seal assembly

•

Apply a thin coating of hydraulic oil to the rod seal (2, Fig. 152) and the seal seat (3) in the cylinder cap (1).

•

Place the cylinder cap on the groove aligning arbor (4).

•

Gently bend the rod seal (2) together.

•

Place one part of the rod seal into the seal seat (3).

•

Press the rod seal into the seal seat using a burrfree aluminium or plastic arbor (1).

ESR 5000

361

CYLINDERS Repairing Cylinders

Repairing Cylinders

Replacing the rod seals

Removal and assembly details can be found as follows: •

Free lift cylinder starting on page 337.

•

Lift cylinders starting on page 332.

•

Sideshift cylinder starting on page 330.

•

Reach cylinder starting on page 336.

CAUTION Damaged or contaminated seal seats and piston rams will result in immediate leaks, even with new seals. The same applies to the use of unsuitable tools for seal removal and fitting.

The tilt cylinder cannot be repair with standard tools. It must be replaced if faulty.

 Before fitting a new seal check the seal seats and piston rams for damage and make sure they are clean.

Safety notices

 When replacing rod seals use assembly equipment and tools made of soft metal or plastic without sharp edges. Suitable tools and assembly procedures are described starting on page 358.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents and lubricants.

General Carefully check the cylinder before starting repair work. After removal from the truck: •

Check the piston rams for nicks, scratches, corrosion and other surface damage. Replace any damaged piston rams.

•

Check the dirt deflectors for wear and unusual leakage.

•

If excess hydraulic oil emerges from the ram at the cylinder head it may be due to a damaged rod seal.

After dismantling: •

Clean the individual parts in a clean solvent and dry them with weak compressed air.

•

Before assembling, apply a thin layer of hydraulic oil to the cleaned components and replacement parts.

•

Replace all backrings and seals.

ESR 5000

362

CYLINDERS Repairing Lift Cylinders

Repairing Lift Cylinders

6. Protect shiny metal surfaces immediately with a thin layer of hydraulic oil.

Before carrying out repairs read the Safety notices and General sections on page 362.

Removing the piston

Lift cylinder removal is detailed on page 332.

1. Remove the piston ram (1) from cylinder tube (8). 2. Take off the guide ring (11).

Dismantling lift cylinders

3. Remove the piston (10) from the piston ram.

Unless otherwise indicated, all item numbers refer to Fig. 154.

Removing the shut-off piston and spring 1. Using suitable pliers carefully remove the retaining ring (12). 2. Take the shut-off piston (13) and spring (9) out of the piston ram.

CAUTION The cylinder tube can easily be damaged when you clamp the cylinder  Tighten the tensioners very slightly and use prismshaped braces.

Removing the velocity fuse 1. Unscrew the velocity fuse (14) from the hydraulic port on the cylinder tube.

Lift cylinder assembly Rod seal removal 1. Tension the cylinder tube to prevent the cylinder from twisting.

Unless otherwise indicated, all item numbers refer to Fig. 154.

2. Unscrew the cylinder cap (2) from the cylinder tube (8).

CAUTION

Note: If the cylinder cap does not loosen, heat up the cylinder cap carefully and consistently with hot air.

Incorrect handling during assembly can result in leaks.

3. Remove and dispose of the following parts from the cylinder cap:

 Take care not to damage the piston ram and the new seals during assembly.

– Dirt deflector (3)

 Use guide bushing and burr-free tools without sharp edges.

– Rod seal (4)

 Apply a thin coating of hydraulic oil to all seals and components prior to assembly.

– Backring (5) – Guide ring (7)

 Observe the general instructions on assembling seal rods starting on page 357.

– O-ring (6)

Piston ram pre-assembly and installation

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents and lubricants. 4. Thoroughly clean all metallic components with a suitable light solvent. In particular, the seats of the seals and the backrings must be absolutely clean and free of foreign bodies.

1. Insert the piston (10) consisting of 2 half shells in the groove of the piston ram (1). 2. Pull a new guide ring (11) onto the piston. 3. Push the piston ram into the cylinder tube.

Piston cap pre-assembly and installation Fit the following components in the cylinder cap: – Dirt deflector (3) – Rod seal (4) – Backring (5)

5. Apply dry compressed air to the cleaned components.

– Guide ring (7) – O-ring (6)

ESR 5000

363

CYLINDERS Repairing Lift Cylinders 4. De-grease the threads of the cylinder cap and the cylinder tube, taking care not to degrease the seals.  The cylinder cap is now ready for assembly. 5. Push the cylinder cap carefully over the lubricated piston ram, taking care not to oil the thread. 6. Apply two drops of Loctite 242 to the start of the thread. 7. Screw the cylinder cap a few turns onto the cylinder tube. Now grease the rest of the thread and screw the cylinder cap on in full. 8. Torque the cylinder cap to 130 ±10 Nm. 9. If the bleed screw (16) has been removed, insert it again and torque to 5 - 6 Nm.

Final tasks 1. Refit the lift cylinder (see page 332). 2. Bleed the hydraulic system (see page 79). 3. Perform the drift test (see page 81).

ESR 5000

364

CYLINDERS Repairing Lift Cylinders

2 5 3

8 9

5 6

12 10 11

8 9 Legend

10 12 13

Piston ram

Cylinder cap

Dirt deflector

Rod seal

Backring

O-ring

Guide ring

Cylinder tube

Spring

Piston

Guide ring

Retaining ring

Shut-off piston

Velocity fuse

Seal

Bleed screw

Fig. 154 Lift cylinder

ESR 5000

365

CYLINDERS Repairing the Free Lift Cylinder

Repairing the Free Lift Cylinder

6. Protect shiny metal surfaces immediately with a thin layer of hydraulic oil.

Before carrying out repairs read the Safety notices and General sections on page 362.

Removing the piston

Free lift cylinder removal is detailed on page 337.

1. Remove the piston ram (1) from cylinder tube (8). 2. Take off the retaining ring (16).

Dismantling the free lift cylinder

3. Remove the piston (15) from the piston ram (1).

Unless otherwise indicated, all item numbers refer to Fig. 155.

Removing the shut-off piston and spring 1. Using suitable pliers carefully remove the retaining ring (11). 2. Take the shut-off piston (10) and spring (9) out of the piston ram.

CAUTION The cylinder tube can easily be damaged when you clamp the cylinder.  Tighten the tensioners very slightly and use prismshaped braces.

Removing the velocity fuse 1. Unscrew the velocity fuse (17) from the hydraulic port on the cylinder tube.

Free lift cylinder assembly Rod seal removal

Unless otherwise indicated, all item numbers refer to Fig. 155.

1. Tension the cylinder tube to prevent the cylinder from twisting. 2. Unscrew the cylinder cap (4) from the cylinder tube (8).

CAUTION

Note: If the cylinder cap does not loosen, heat up the cylinder cap carefully and consistently with hot air.

Incorrect handling during assembly can result in leaks.

3. Remove and dispose of the following parts from the cylinder cap:

 Take care not to damage the piston ram and the new seals during assembly.

– Dirt deflector (2)

 Use guide bushing and burr-free tools without sharp edges.

– Rod seal (3)

 Apply a thin coating of hydraulic oil to all seals and components prior to assembly.

– Guide ring (5) – Backring (6)

 Observe the general instructions on assembling seal rods starting on page 357.

– O-ring (7)

Piston ram pre-assembly and installation

CAUTION

2. Insert the spring (9) and shut-off piston (10) in the piston ram.

Health risk Cleaning agents, lubricants and consumables can damage your health.

1. Carefully insert the retaining ring (11). 1. Insert the piston (15) in the groove of the piston ram (1).

 Observe the manufacturer’s safety instructions when handling solvents and lubricants.

2. Pull a new guide ring (11) onto the piston. 4. Thoroughly clean all metallic components with a suitable light solvent. In particular, the seats of the seals and the backrings must be absolutely clean and free of foreign bodies.

3. Push the piston ram into the cylinder tube.

5. Apply dry compressed air to the cleaned components.

ESR 5000

366

CYLINDERS Repairing the Free Lift Cylinder Piston cap pre-assembly and installation 1. Fit the following components in the cylinder cap: – Dirt deflector (2) – Rod seal (3) – Guide ring (5) – Backring (6) – O-ring (7) 2. Carefully de-grease the threads of the cylinder cap and the cylinder tube with a solvent.  The cylinder cap is now ready for assembly. 3. Push the cylinder cap carefully over the lubricated piston ram, taking care not to oil the thread. 4. Apply two drops of Loctite 242 to the start of the thread. 5. Screw the cylinder cap a few turns onto the cylinder tube and then grease the rest of the thread and screw the cylinder cap on in full. 6. Torque the cylinder cap to 130 ±10 Nm. 7. If the bleed screw has been removed, insert it again and torque to 5 - 6 Nm.

Final tasks 1. Refit the free lift cylinder (see page 337). 2. Bleed the hydraulic system (see page 79). 3. Perform the drift test (see page 81).

ESR 5000

367

CYLINDERS Repairing the Free Lift Cylinder 1

2 3

18 19

3 4 5

1 9 10

11 12 13 15 14 16

Legend

11 12 13 14 15

16 17

Piston ram

Dirt deflector

Rod seal

Cylinder cap

Guide ring

Backring

O-ring

Cylinder tube

Spring

Shut-off piston

Guide ring

Retaining ring

Guide ring

Seal

Piston

Retaining ring

Velocity fuse

Seal

Bleed screw

Fig. 155 Free lift cylinder ESR 5000

368

CYLINDERS Repairing the Reach Cylinder

Repairing the Reach Cylinder

seals and the backrings must be absolutely clean and free of foreign bodies.

Before carrying out repairs read the Safety notices and General sections on page 362.

9. Apply dry compressed air to the cleaned components.

Reach cylinder removal is detailed on page 336.

10. Protect shiny metal surfaces immediately with a thin layer of hydraulic oil.

Dismantling the reach cylinder

Removing the piston ram and seals

Unless otherwise indicated, all item numbers refer to Fig. 156.

1. Pull out the piston ram. 2. Remove and dispose of the guide ring (13). 3. Remove and dispose of the seal (12).

CAUTION The cylinder tube can easily be damaged when you clamp the cylinder.  Tighten the tensioners very slightly and use prismshaped braces. Rod seal removal 1. Tension the cylinder tube (10) to prevent the cylinder from twisting. 2. Measure and record the screw depth of the ball joint (1).

Assembling the reach cylinder CAUTION Incorrect handling during assembly can result in leaks.  Take care not to damage the piston ram and the new seals during assembly.  Use guide bushing and burr-free tools without sharp edges.

3. Unscrew the ball joint (1).

 Apply a thin coating of hydraulic oil to all seals and components prior to assembly.

4. Pull the spacer sleeve (4) and the O-rings (5) off the piston ram (11).

 Observe the general instructions on assembling seal rods starting on page 357.

5. Bead the retaining plate (15) in order to unscrew the cylinder cap (16). 6. Unscrew the cylinder cap from the cylinder tube. 7. Remove and dispose of the following parts from the cylinder cap: – Dirt deflector (6) – Rod seal (7)

Piston ram pre-assembly and installation 1. Pull a new seal (12) onto the piston ram (11). 2. Fit a new guide ring (13). 3. Use a guide sleeve in the cylinder tube and push the piston ram into the cylinder tube. 4. Removing the guide sleeve.

– Guide ring (14) – Backring (8)

Piston cap pre-assembly and installation

– O-ring (9)

1. Fit the following components in the cylinder cap: – Dirt deflector (6) – Rod seal (7)

CAUTION

– Guide ring (14) – Backring (8)

Health risk Cleaning agents, lubricants and consumables can damage your health.

 The cylinder cap is now ready for assembly.

 Observe the manufacturer’s safety instructions when handling solvents and lubricants.

2. Carefully push the cylinder cap over the lubricated piston ram.

8. Thoroughly clean all metallic components with a suitable light solvent. In particular, the seats of the

– O-ring (9)

3. Screw the cylinder cap onto the cylinder tube and torque it to 130 ±10 Nm. 4. Screw on the ball joint and apply the screw depth recorded during removal.

ESR 5000

369

CYLINDERS Repairing the Reach Cylinder 5. Torque the counternut (2) to 190 ±10 Nm.

Final tasks 1. Refit the reach cylinder (see page 337). 2. Bleed the hydraulic system (see page 79). 3. Perform the drift test (see page 80).

ESR 5000

370

CYLINDERS Repairing the Reach Cylinder

190 ±10 Nm

10 3

130 ±10 Nm

5 6 7

8 15

8 9

5 10

Legend

12 13

Joint head

Counternut

Washer

Spacer sleeve

O-ring

Dirt deflector

Rod seal

Backring

O-ring

Cylinder tube

Piston ram

Seal

Guide ring

Retaining plate

Cylinder cap

Fig. 156 Reach cylinder

ESR 5000

371

CYLINDERS Repairing the Sideshifter Cylinder

Repairing the Sideshifter Cylinder Sideshifter removal 1. Remove the sideshifter from the mast (see page 330).

Dismantling the sideshifter WARNING Risk of injury from components flying off at high speed! The piston rams will fly off the cylinder tube if driven off with compressed air or the hydraulic system, and can cause fatal injuries.  Pull the piston rams manually out of the cylinder tube. 2. Pull the left and right piston rams (6) out of the cylinder tube. 3. Push the washers (4) out of the guides. 4. Remove and dispose of the dirt deflectors (5) and rod seals (3). 5. Remove the slide bearings (2) and coupling pieces (27). 6. Carefully clean all components and seal seats with a solvent. 7. Remove small burrs from the ends of the piston ram with emery cloth, replace any parts with grooves or other damage.

Sideshifter cylinder assembly 1. Apply hydraulic oil to all components. Note: Fit the rod seals with the sealing lips facing the pressure side. 2. Assemble the cylinder in the reverse order of removal.

Final tasks 1. Refit the sideshifter (see page 330). 2. Bleed the hydraulic system (see page 79). 3. Perform the drift test (see page 81).

ESR 5000

372

CYLINDERS Repairing the Sideshifter Cylinder

11 34

10 32

26 1

5 4

8 7

28 29 17 16

13 14

18 15 17 21

27 2

3 4

20 22

6 23

Fig. 157 Integrated sideshifter

ESR 5000

373

Notes:

374

SCHEMATIC DIAGRAMS

375

Notes:

376

SCHEMATIC DIAGRAMS Wire Colour Code

Wire Colour Code The wires used in the truck are colour-coded and numbered according to their function:

•

The first or first two digits designate the wire colour.

•

The last two digits are a sequence number.

Note: Third party component wires may pose an exception to this rule:

Abbreviation

Colour

Colour number

Function

BLK

Black

0 **

Digital signal

BRN

Brown

1 **

Analog signal

RED

Red

2 **

Positive not connected

ORG

Orange

3 **

+12 VDC - transformer

YEL

Yellow

4 **

Third DC - transformer

GRN

Green

5 **

Negative not connected

BLU

Blue

6 **

Negative, insulated

VIO

Violet

7 **

+5 VDC - transformer

GREY

Gray

8 **

Fourth DC - transformer

WHT

White

9 **

Miscellaneous

RED/WHT

Red/White

29 **

Positive connected

GRN/WHT

Green/White

59 **

Negative connected

** Numbers 01 to 99

ESR 5000

Rev.1 02/2009

377

SCHEMATIC DIAGRAMS General Contact Symbol Abbreviations

General Contact Symbol Abbreviations Note: If one of the above abbreviations is used more than once, a number extension will be used, e.g. SV1, SV2 etc. Abbreviation

Description

Abbreviation

Description (Sheet 1 of 2)

Relay

LMS

Limit switch

ACS

Travel switch

LOS

Lower switch

AXS

Accessories switch

ORS

Override switch

BRS

Brake switch

POT

Potentiometer

DIS

Direction switch

Raise potentiometer

DRS

Door switch

RAS

Raise switch

EDS

Emergency power disconnect

REA

Reach potentiometer

Encoder module

Reverse switch

ENC

Encoder

SAS

Safety Reverse Switch

Forward switch

SDS

Start switch

HBS

Handbrake switch

SES

Seat switch

HNS

Horn switch

SSS

Sideshifter switch

HSS

Rabbit/Turtle toggle switch

THS

Thermal switch

KYS

Key switch

TLT

Tilt switch

LGS

Light switch

WAS

Walk-along / pedestrian mode switch

BV (AK)

Battery voltage after the key switch

M2 (PM)

Pump motor

BDI

Battery discharge indicator

MRC

Control module

Brakes

OHGD

Overhead guard display

BWI

Brush wear display

Pump contactor

Cable connection

Plug connection

Field coil connection

PCB

Printed circuit board

FAN

Fan

Shunt field

Fuse

STI

Steering wheel indicator

Horn

Solenoid valve

IFD

Information display

Terminal block

Socket = counterpart to PC

TMM

Truck management module

LINE

Main contactor

Hourmeter

M1 (TM)

Traction motor

VMN

Motor driver (volt motor negative)

GPCSR

Safety switch - RH side restraint

GCSL

Safety switch - LH side restraint

Rev.1 02/2009

378

ESR 5000

SCHEMATIC DIAGRAMS General Contact Symbol Abbreviations Abbreviation

Description

Abbreviation

Description (Sheet 2 of 2)

PLS

Platform switch

TCM

Traction motor

Pressure switch

Heating

HCM

Hydraulic control module

ALM

Travel Alarm

RECEIVER Receiver

TRANSMITTER Transmitter

BDI

Combination instrument

CHARGER

On-board charger

BRK

Electromagnetic brake

Driver

SLS

Sideshift left switch

SRS

Sideshift right switch

ECS

Lift control switch

---

ESR 5000

Rev.1 02/2009

379

SCHEMATIC DIAGRAMS Electrical Wiring Diagrams

Electrical Wiring Diagrams Europe

USA

Description

Europe

USA

Description

Wires joining

Switch applied manually

Wires crossing

Solenoid valve

Wire connection

Throttle / coil

Plug / socket

Resistor

Wire strap

Capacitor

Clip Pad

Potentiometer

Fuse

Varistor V

Rev.1 02/2009

380

Assembly

Thermal protector

Contact, normally open

Lamp

Contact, normally closed

Horn

Selective switch

Battery

Contactors / relays

Diode

Slow release contactor / relay

Breakdown diode

Time delay contactor / relay

LED

Switch, normally open

Transistor

ESR 5000

SCHEMATIC DIAGRAMS Electrical Wiring Diagrams Europe

USA

Description

Europe

USA

Description

Push button, mechanically actuated

MOSFET

Pushbutton, hydraulically actuated

Thyristor

Emergency power disconnect

Comparator

Motor armature ---

ESR 5000

Rev.1 02/2009

381

SCHEMATIC DIAGRAMS Power Up Circuit Power Up Circuit

,'&)%-*&%+

! ! "

)%.('

Fig. 158 Power up circuit

ESR 5000

382

302

2 623

L-

Fig. 159

SPS

CA 806

1 317

3 028

L+

2 106

A 48V after Main Contact B 48V Key C 12V Display D GND E B+ after Key F Main Contactor G CAN BUS H 48V FU2 K 48V FU5 Z GND

CA 407 3 ACC PED Pot 1 1

602

B 622

L-

A 316

L+

C 027

CA 805

2998

2960

blk 3

4 blk 4 3 blk 2 2 blk 1 1

CA803

GND

B 669

A 3100

+12V SIG GND

CA 408

1 2 POT 2 3

CA 407

CA 405 5 th Function Switch OPTION

CA 409 Side Shift Lever

not connected with MTC only with Lever

CA 422

5902

32 310 6 31 613 7

CA 422

301

300

29141

008

007

004

022

018

017

019

020

021

005

5914

023

2901

6 12V Out

21 Ain1 CA205

11 Main Contactor

9 Di 13 Ch. A

38 Di 14 Ch. B

digital Inputs

16 Di 5 SPS

24 POUT_15 Horn

17 Di 6 KYS

39 Di 17 PLS

32 Di 11 BPS

31 Di 10 BFS

5 Di 4 ACS

19 Di 8 RES 2

18 Di 7 RES 1

25 Di 16 FLS/LCS

30 Di 9 HGT(R)S

14 BV+

2930

KYS

2951

POUT_9 26

009

5911

905

900 CAN_H 22

CA 205

Di 12 BRS 33

CA 206

AN_21 BLS 12

120 Ohm

5909

5907

5908

5906

5905

5903

5904

POUT_8 12 5910 5

POUT_7 41

POUT_6 27

POUT_5 13

POUT_4 29

POUT_3 15

POUT_1 42

CA205

K11

2902 9

5925

5926

5924

5923

5921

5922

CA 811

CA 809

CA 810

CA 808

3101

006

SV5

SVS

SVT

PVAR

PVAL

PVRT

PVRE

PVL

SVH

CA 807

+ CA 801

+ CA 811

+ CA 809

+ CA 810

+ CA 808

CA 404

GND 3 POT3 4 POT5 5 Heat Seat SIG 6 Seat 48V+ 7 Seat SIG 8

CA 428 POT2 2

053

7 8

2 3 4 5

601

CA 474 -6 2917

CA 471

2 Di 1 SES CA206

20 Ain5/ POT5

504 28 BV-

H 001

104

7 GND_Out

36 Ain3/ POT3 CA 205

600

102

101 35 Ain2 /POT2

POut_14 10 1

2935

5920

CA 433

2940

CA 434 5941 A

LAMP

CA 435

2923 2

2948

2947

2946

2945

2944

2943

2942 2938

2921 14 CA 422

CAN_H & CAN_L are twisted, not GND!!!

Beacon Loom 5940

CA 402

5928 10

5902

607

U_Mess

I_Mess

U_Batt

Control Card

2926

203 / 204

1 CAN_H 2 CAN_L 3 CAN_GND

905/906 614/615

PC416 6 GND Display 5 +12V Display 900/901

319

625

E to SDM, TDM & Display

CAP

CA 201

12 ID1

21/13 ID GND

8/7 CAN_GND

15/14 CAN_L

23/22 CAN_H

HORN

FU2 = 15A

ESR 5000

617/618

908/909

903/904

KYS

5914

5901

2928

2927 4

2929

C1,C2

START UP CARD

Display CA 472 Pin 2

CA 426

CA 601 CA 801

Charge R1

K11

B to TDM & Display

2904

Main

Screw S1 Contactor S2 Screw

CA 422 CA 604 CA 807

UB-

502

+ K13

927

+ K12

Relay Options

POUT_2 1

CA 420 2924

to Display

CA 420

202

FU1 = 15A

200

BUSBAR

CAN_L 23 C 055 1 614 4 FWD Switch CAN_GND 8 Travel Alarm 2 002 CA 203-13 003 3 Sel. direction Travel Alarm Loom 3 CA 206 CA 421 CA 436 CA 437 399 4 14 Horn Input VCM 5913 5980 5981 5 2 1 2 A B POut_7 7 052 15 Tilt Down 7 1 Tilt up/ POT4 7 6 29147 Tilt Up/ POT4 051 37 2980 2925 K 8 Heat Seat 48V+ 8 29148 Coldstore 10

CA 470

029

CA 604

CA 471

CA 417

CA 604

29140

201

Not-Aus

EDS mechanical

CA 473

EDS

CA 422

CA 604 13 CA 422

2909

CA 406 12V Display 1 FWD Switch 2 5th Function 3 Sel. Dir. 4 Horn 5 Tilt down 6

CA 601

2921

CA 600 5

CA 601 3

CA 422

CA 428 +12V VCM 1

red/blk

4 396 3 grn/blk 2 666 1

CA 600

CA 802

Display CA 472 Pin 3

Seat 48V+ 1 1 5th Switch + Seat SIG 2 Connection to 2 5th Switch Heat Seat 48V+ 3 Seat Harness 3 5th LED D Heat Seat GND 4 4 5th LED +

CA 405

+12V 1 SIG 2 POT 5 GND 3

CA 409

1 2 POT 4 3 only with lever

CA 410

2910

Armrest Interface Box

5 Horn 6 7 Tilt down 8 only with MTC 9 Tilt up 10 only with MTC

CA 408 +12V 1 Reach / Retrac SIG 2 POT 3 Lever GND 3

CA 407 Lift / Lower Lever

Tilt down

Tilt up

HORN

5936

CA 801

932

Option: Keyless

CA 422 CA 604

2916

2915

CA 600

CA 411 N.C. 1 FWD Switch N.C. 2 3 Selc. Dir Direction Switch 4

blk

blu

red

wht

L-

L+

509

508 5

2913

CA 440

3 OPTIONS 1

2958

2999

2957

206 / 207

CA 419

G GND

2954

K13

K12

4 3 2 1

CA411

CH. B + 12V CH. A GND

Height Encoder ECR 5

CA 422

GND

310 1

314

315 12 CA 604

RES 2

RES1

569

500

48V Batt.

15A

FU6

207

CA 422

BUSBAR

KEY

FU7 = 425A

CA 604

BUSBAR

UB-

5919

GND

CH.B

CH.A

Motor Shunt

Temp

Busbar / 500 / 508 509 / 569 / 570

5915

2 608

ECR 2 Speed Sensor

011

010 3

307 1

CA 425 CROWN Motor Main Loom: 819850 Main Loom: 825335

to TDM Pin 2

GND CH. B CH. A + 12V

CA 401

5934

Only wired with CROWN Motor Main Loom: 819850 Main Loom: 825335

Fan1 48V

2931

to TDM Traction-controller and SDM

CA 429 Danaher Motor Main Loom: 819849

5918

CA 435

29136 1

CA 430

107

609

608

011

010

307

Fan4 48V

CA 201 +12V

Temp GND

5934

CA 434

2933 1

B-

Fan3 48V

FAN

5916

HCM

B+

Fan2 48V

CA 415

2932 1

BUSBAR

THS 2

Wiring Diagram (Fingertip and Dual Axis Hydraulic Control Levers)

CA 601

SCHEMATIC DIAGRAMS

822617-2F_1

383

Wiring Diagram (Fingertip and Dual Axis Hydraulic Control Levers)

PTC

312

SFS 2

311

SFS 1SA

L-

GND

620

L+

CA 438

Z GND

619

L+

CA 439

UB-

CA 402

5927

CA 431

Brake Coil

5912

384

Fig. 160

VCM Canion

900 CAN H 905 CAN L

2936

802

801

Display

901 CAN H 906 CAN L

803

B-

13 SFS 2

CA 204

19 SFS 1 SA

1 B+ 2 Brake

PC 416 Connector

566

026

025

CA 402

CAN BUS wiring series production

Integrated in Start Up Card

CA 431

2950

CA 402

FU4 = 10A

FU3 = 15A

2903

205

902 CAN H 907 CAN L

SCM

618

THS 2

TCM Traction

112

111

110

109

054

GND CH. A CH. B + 5V

541

8 1 2 3 4

119 109 110 111 112

+ 5V

GND

HCM Pump

CH. 1B CH. 1A

+ 5V GND

wht

blk

904 CAN H 909 CAN L

ID1

CAP

GND

CA 203

U_Mess

ESR 5000

CA 202

18 BV+ Key

3/6 CAN_GND

2/5 CAN_L

KEY

Busbar

B-

Motor Shunt

U_Mess

1/4 CAN_H

Only wired with CROWN Motor Main Loom: 819850 Main Loom: 825335

1 2905 +12V 3 308 CH.A 5 012 CH.B 6 013 610 GND 4 611 Temp GND 17 108 Temp 16

2908

615 / 616

901 / 902

906 / 907

113

19 BV+ 318 14 12V Out 319 16 12V Out

202

U_Mess

Motor Shunt

UB-

B+

I_Mess

U_Batt

Control Card

TCM

FAN

5919

to Fan 1 Pin 2

310

CAN_GND

21/13 ID GND

8/7

15/14 CAN_L

616 / 617

907 / 908

113

7 613

23/22 CAN_H

CA 202

902 / 903

SCM Steering

ECR4

to VCM, HDM & PC 416

PC 474 Coldstore

910 CAN H 911 CAN L

120

GND

117

CA 414 + 5V

116

4 3 2 1

315

2 316

4 115

CA 801 CA 601 CA 422

1 616

CA 812

LS FKS

CA 805

Option Load Sensor

CAN_H & CAN_L are twisted, not GND!!!

ECR 3 Speed Sensor

903 CAN H 908 CAN L

PTC

053

CA 436

4 612 309 +5 V 3 015 CH.B 6 014 CH.A 5 115 Temp 16

GND

CA 204

CH. 2B 20

CH. 1A 11

CH. 2A 17

CH. 1B 10

540

CA 474 Coldstore

2970

Option Coldstore / Heated Seat

8 15 909 CAN_H 23 904

CAN_L

CAN_GND

B+

29128

FU13 = 50A

29127

yel

204

29147 / 29148

GND GND

blk

204 / 205

wht

15A

FU 5

206

909 / 911 2

red

grn

CH. 2A CH. 2B

904 / 910

Wiring Diagram (Fingertip and Dual Axis Hydraulic Control Levers)

SCHEMATIC DIAGRAMS

GND + 5V

THS 1

CA 427

516

507

514

GND

GND CH. B CH. A + 12V

ECR 1 Speed Sensor

PTC

013

012

308

2 610

822617-2F_2

K2 5936

CA 425 CROWN Motor Main Loom: 819850 Main Loom: 825335

517

6 515

624 CA 429 Z Danaher Motor GND Main Loom: 819849

D GND

CA 203

DISPLAY

GND

Working Light HIGH SIDE BRS HIGH SIDE Keyless LOW SIDE

BV+

CA 473 5 209 Workinglight 4 210 D 572 2 29143 GND 1 1 2 009 VCM CA 205 PIN 33 3 5936

PC 472 BV+

302

2 623

L-

Fig. 161

SPS

CA 806

1 317

3 028

L+

106

A 48V after Main Contact B 48V Key C 12V Display D GND E B+ after Key F Main Contactor G CAN BUS H 48V FU2 K 48V FU5 Z GND

CA 407 3 ACC PED Pot 1 1

602

B 622

L-

A 316

L+

C 027

CA 805

4 3 2 1

blk

blu

red

wht

L-

L+

CA 440

+12V SIG GND

CA 408

1 2 POT 2 3

CA 407

CA 405 5 th Function Switch OPTION

CA 409 Side Shift Lever

not connected with MTC only with Lever

+12V SIG GND

CA 802

CA 417

CA 604

2909

5902

CA 404

GND 3 POT3 4 POT5 5 Heat Seat SIG 6 Seat 48V+ 7 Seat SIG 8

Box

053

300

29140

29141

023

020

021

005

5914

CA 422

008

007

004

022

018

017

019

KYS

2901

2951

7 8

3 4 5

CA 474 -6 2917

601

6 12V Out

21 Ain1 CA 205

11 Main Contactor

9 Di 13 Ch. A

38 Di 14 Ch. B

digital Inputs

16 Di 5 SPS

2 Di 1 SES CA206

504 28 BV-

H 001

20 Ain5/ POT5

36 Ain3/ POT3 CA

104

7 GND_Out

600

102

101 35 Ain2 /POT2

2924

5909

5907

5908

5906

5905

5903

5904

CA 205

009

5911

P Out_14 10

VCM

P Out_7

Charge R1

5925

5926

5924

5923

5921

5922

CA 811

CA 809

CA 810

CA 808

2948

2947

2946

2945

2944

2943

2942 2938

2921 14 CA422

607

617/618

908/909

903/904

2929

C1,C2

HORN

U_Mess

I_Mess

U_Batt

Control Card

2935

5920

CA 433

2925

5913 1

5940 1

2980

2940

CA 434

Beacon Loom

5980

CA 436

5941 A

5981

Travel Alarm Loom

LAMP

CA 435

HCM

2926

203 / 204

3 CAN_GND

ESR 5000

2 CAN_L 614/615

1 CAN_H 905/906

900/901

PC416 6 GND Display 5 +12V Display

G to SDM, TDM & Display

CAP

CA 201

12 ID1

21/13 ID GND

8/7 CAN_GND

15/14 CAN_L

23/22 CAN_H

KYS

5914

5901

2928

2927 4

FU2 = 15A

319

CA 437

CAN_H & CAN_L are twisted, not GND!!!

+ CA 801

+ CA 811

+ CA 809

+ CA 810

Display CA 472 Pin 2

SV5

SVS

SVT

CA 807

+ CA 808

2923 2

START UP CARD

CA402

625

CA 426

PVAR

PVAL

PVRT

PVRE

PVL

SVH

5928 10

5902

614

3101

006

CA 601 CA 801

K11

Travel Alarm

CA 206 CA 421

CAN_L 23

905

900 CAN_H 22

CAN_GND

120 Ohm

Di 12 BRS 33

CA 206

AN_21 BLS 12

P OUT_9 26

B to TDM & Display

2904

K11

2902

Main

Screw S1 Contactor S2 Screw

CA 422 CA 604 CA 807

UB-

502

P OUT_8 12 5910 5

P OUT_7 41

P OUT_6 27

P OUT_5 13

P OUT_4 29

P OUT_3 15

P OUT_1 42

CA 205

P OUT_2 1

CA 420

+ K13

927

+ K12

Relay Options

BUSBAR

to Display

CA 420

202

FU1 = 15A

200

24 POUT_15 Horn

17 Di 6 KYS

39 Di 17 PLS

32 Di 11 BPS

31 Di 10 BFS

5 Di 4 ACS

19 Di 8 RES 2

18 Di 7 RES 1

25 Di 16 FLS/LCS

30 Di 9 HGT(R)S

14 BV+

2930

CA 473

EDS mechanical

201

Not-Aus

C 055 1 4 FWD Switch 2 002 CA 203-13 003 3 Sel. direction 3 399 4 14 Horn Input 5 052 15 Tilt Down 7 6 29147 051 37 Tilt Up/ POT4 K 8 29148 10

Heat Seat 48V+ 8 Coldstore CA 471 CA 428 Armrest 2 Interface POT2 2

Tilt up/ POT4 7

301

CA 470

CA 604

CA 422

029

CA 471

32 310 6 31 613 7

CA 406 12V Display 1 FWD Switch 2 5th Function 3 Sel. Dir. 4 Horn 5 Tilt down 6

CA 422

CA 604 13 CA 422

CA 422

CA 428 CA +12V VCM 11

red/blk

4 396 3 grn/blk 2 666 1

CA 600 5

CA 601 3

CA 600

Seat 48V+ 1 1 5th Switch + Seat SIG 2 Connection to 2 5th Switch Heat Seat 48V+ 3 Seat Harness 3 5th LED D Heat Seat GND 4 4 5th LED +

CA 405

1 2 POT 5 3

CA 409

1 2 POT 4 3

CA 410

CA 408 +12V 1 Reach / Retrac SIG 2 POT 3 Lever GND 3

CA 407 Lift / Lower Lever

Tilt down

Tilt up

HORN

2921

CA 601 4

Display CA 472 Pin 3

5936

+ K2

CA 801

932

+ K1

Option: Keyless

CA 422 CA 604

2916

2915

2910

CA 600

4 5 Horn 6 7 Tilt down 8 only with MTC 9 Tilt up 10 only with MTC

blk 3

509

508 5

2913

3 OPTIONS 1

2958

2999

2957

4 blk 4 3 blk 2 2 blk 1 1

CA 803

GND

B 669

A 3100

CA 419

G GND

2954

K13

K12

2998

2960

CA 411 N.C. 1 FWD Switch N.C. 2 3 Selc. Dir Direction Switch

CA411

CH. B + 12V CH. A GND

Height Encoder ECR 5

CA 422

GND

310 1

314

315 12 CA 604

RES2

RES1

569

500

48V Batt.

15A

FU6

206 / 207

CA 422

207

EDS

KEY

BUSBAR

CA 601

FU7 = 425A

CA 604

BUSBAR

5919

GND

CH.B

CH.A

Motor Shunt

Temp

Busbar / 500 / 508 509 / 569 / 570

5915

2 608

011

010 3

307

CA 425 CROWN Motor Main Loom: 819850 Main Loom: 825335 1

ECR 2 Speed Sensor

SCHEMATIC DIAGRAMS

822618-2F_1

385

Wiring Diagram (Multitask Control Handle)

to TDM Pin 2

GND CH. B CH. A + 12V

CA 401

5934

Only wired with CROWN Motor Main Loom: 819850 Main Loom: 825335

Fan1 48V

2931

to TDM Traction-controller and SDM

CA 429 Danaher Motor Main Loom: 819849

5918

CA 435

29136 1

CA 430

107

609

608

011

010

307

Fan4 48V

CA 201 +12V

Temp GND

5934

CA 434

2933 1

B-

Fan3 48V

FAN

5916

UB-

B+

Fan2 48V

CA415

2932 1

BUSBAR

THS 2

Wiring Diagram (Multitask Control Handle)

PTC

312

SFS 2

311

SFS 1SA

L-

GND

620

L+

CA 438

Z GND

619

L+

CA 439

UB-

CA 402

5927

CA 431

Brake Coil

5912

386

Fig. 162

VCM Canion

900 CAN H 905 CAN L

1 B+ 2 Brake

2936

802

618

THS 2

112

111

110

103

054

GND CH. A CH. B + 5V

541

8 1 2 3 4

119 109 110 111 112

+ 5V

GND

HCM Pump

CH. 1B CH. 1A

+ 5V GND

wht

blk

904 CAN H 909 CAN L

ID1

CAP

GND

CA 203

U_Mess

ESR 5000

CA 202

18 BV+ Key

3/6 CAN_GND

2/5 CAN_L

KEY

Busbar

B-

Motor Shunt

U_Mess

1/4 CAN_H

Only wired with CROWN Motor Main Loom: 819850 Main Loom: 825335

1 2905 +12V 3 308 CH.A 5 012 CH.B 6 013 GND 4 610 Temp GND 17 611 Temp 16 108

2908

615 / 616

901 / 902

906 / 907

113

19 BV+ 318 14 12V Out 319 16 12V Out

202

U_Mess

Motor Shunt

UB-

B+

I_Mess

U_Batt

Control Card

TCM

FAN

5919

to Fan 1 Pin 2

310

CAN_GND

21/13 ID GND

8/7

15/14 CAN_L

616 / 617

907 / 908

113

7 613

23/22 CAN_H

CA 202

902 / 903

SCM Steering

ECR4

to VCM, HDM & PC 416

PC 474 Coldstore

910 CAN H 911 CAN L

120

GND

117

CA 414 + 5V

116

4 3 2 1

315

2 316

4 115

CA 801 CA 601 CA 422

1 616

CA 812

FKS

CA 805

Option Load Sensor

CAN_H & CAN_L are twisted, not GND!!!

ECR 3 Speed Sensor

903 CAN H 908 CAN L

PTC

053

CA 436

4 612 309 +5 V 3 01 15 CH.B 6 014 CH.A 5 11 15 Temp 16

GND

CA 204

CH. 2B 20

CH. 1A 11

CH. 2A 17

CH. 1B 10

540

CA 474 Coldstore

2970

GND GND

Option Coldstore / Heated Seat

8 15 909 CAN_H 23 904

CAN_L

CAN_GND

B+

29128

29147 / 29148

FU13 = 50A

29127

TCM Traction

902 CAN H 907 CAN L

801

SCM

Display

901 CAN H 906 CAN L

803

B-

13 SFS 2

CA 204

19 SFS 1 SA

PC 416 Connector

566

026

025

CA 402

CAN BUS wiring series production

Integrated in Start Up Card

CA 431

2950

CA 402

FU4 = 10A

FU3 = 15A

2903

205

204 / 205

204

15A

FU 5

206

yel

blk

904 / 910

wht

Wiring Diagram (Multitask Control Handle)

909 / 911 2

red

grn

Wiring Diagram (Multitask Control Handle)

CH. 2A CH. 2B

SCHEMATIC DIAGRAMS

GND + 5V

THS 1

CA 427

516

507

20 514

GND

GND CH. B CH. A + 12V

2 610

013 4

012

308 1

K2 5936

CA 425 CROWN Motor Main Loom: 819850 Main Loom: 825335

517

6 515

ECR 1 Speed Sensor

PTC

624 CA 429 Z Danaher Motor GND Main Loom: 819849

D GND

CA 203

DISPLAY

GND

Working Light HIGH SIDE BRS HIGH SIDE Keyless LOW SIDE

BV+

CA 473 5 209 Workinglight 4 210 D 572 2 29143 GND 1 1 2 009 VCM CA 205 PIN 33 3 5936

PC 472 BV+

822618-2F_2

SP 18

CAN H

SP 8

Pin Wire No. 1 2 3 4 5 6 7 5913 Travel Alarm 8 9 10 11 12 006 BLS 13 14 399 Horn switch 15 052 Tilt down 16

PC 206 (VCM)

SP 17

Screw M10 FU13 B+ Ring Terminal S Wire No. 1 29127

CAN L

Horn out FLS / LCS SV 5 PVAR BPVRT HGT(R)S BFS BPS BRS

Pot 2 Pot 3 Tilt up ECR 5 B PLS

SVT PVL

5914 017 5911 5907 504 5906 019 007 008 009

101 102 051 021 024

5909 5903

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Wire No. 5904 SVH 001 SES Sel. Switch 003 055 FWD Switch 004 ACS 300 12V + 600 12V 614 CAN GND 020 ECR 5 A 5920 BEACON ED 1 5902 5910 SVS 5908 PVAL 2930 B+ 5905 PVRE 005 SPS KYS 2909 018 RES 1 022 RES 2 Pot 5 104 106 Pot 1 900 CAN H

1 2

SP 9

SP 3

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Pin 1 2 3 4 5 6 7 8

LS/ FKS

002 5th Function 318 V+ Output 517 GND B319 V+ Output GND B514 2908 B+ Key 202 B+ perm. 507 GND B-

113

Wire No. CH 1B CH 2A CH 1A CH 2B +5V GND +5V GND

CAN H

627 627 903 910

Pin 1 2

S 1

SP 2

SP 16

B+ Ring Terminal Wire No. 200 /207

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Wire No. 2904 2923 5901 2927 5912 2903 ------2902 5928 5914 2928 5927 2950 -------

Pin 1 2

Wire No. 2931 5935

PC 401 (FAN1)

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

819849-2I_1

Relay Main Cont.

-------

Brake

Horn

Charge Capacity

Start Up card Intern

CAN H

902 903

CAN L CAN L TMP TMP GND

907 908 108 611

Wire No. 2905 5915 308 12V 610 GND 012 CH. A 013 CH. B 616 CAN GND 617 CAN GND

PC 202 (Traction TDM)

EDS(aux. Contactor) Crimp Wire No. 1 201 2 2951

PC 402 (Start up Card)

Screw M10 S1 (Line Cont.)

ED1 (Line Contactor) Crimp Wire No. 1 2902 2 5902/5928

Fusebox Crimp Fuse No. Pin Wire No. FU1 1 200 15A / 80V 7 201 / 208 2 203 / 204 FU2 15A / 80V 8 2926 3 FU3 204 15A / 80V 9 2903 4 FU4 205 10A / 80V 10 2936 5 FU5 206 15A / 80V 11 2959/2996 6 FU6 207 15A / 80V 12 2960/2997

Screw M8 (HDM) B+ Ring Terminal S Wire No. 1 29127

Screw M8 (HDM) B- Ring Terminal S Wire No. 1 500

Screw M8 (HDM) B- Ring Terminal S Wire No. 1 566

Wire No. 2932 5916

SP 1

203 / 205 / 206 /2023

B+ Ring Terminal Wire No.

PC 415 (Fan2)

S 2

Screw M10 S2 (Line Cont.)

Screw M8 (HDM) B- Ring Terminal S Wire No. 1 569 /570

ESR 5000

CAN H

CAN L CAN L TMP TMP GND

607 607 908 911 107 609

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Wire No. 2929 5919 307 12V 608 GND 010 CH. A 011 CH. B 617 CAN GND 618 CAN GND

PC 201 (Pump HDM)

109 110 111 112 116 117 120 119

PC 414 (Stepper ECR 4)

Wire No. CAN L CAN H CAN GND CAN L CAN H CAN GND 616 906 901 615 907 902

PC 203 (Display)

SP 21

SP 19

Wire No. 2935 5920 2959 512

Screw M10 FU13 B+ Ring Terminal S Wire No. 1 29128

Pin Wire No. 1 29143 Work L. 2 009 Brake 3 5936 Relais 4 209 B+ 48V 5 210 B+ 48V 6 515 GND B-

Pin A B C

Wire No. 29140 --29141

PC 472 (Brake/Opt.)

Wire No. 2951 --2901

SP 5

Pin 1 2 3 4

PC 433 (Beacon)

JC 473 (KEYLESS)

Pin A B C

PC 420 (KYS)

Pin Wire No. 1 900 / 901 CAN H 2 905 / 906 CAN L 3 614 / 615 CAN GND 4 ---11V + 5 319 6 625 GND Display

PC 416 (CAN Conn.)

Wire No. 29143 572

PC 473 Work Light

Screw M6 (SDM) B+ Ring Terminal S Wire No. 1 29128

Screw M6 (SDM) Ring Terminal (W) S Wire No. 1 803

Screw M6 (SDM) Ring Terminal (V) S Wire No. 1 802

Screw M6 (SDM) Ring Terminal (U) S Wire No. 1 801

23 905

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

PC 205 (VCM)

Screw M6 (SDM) B- Ring Terminal S Wire No. 1 566

Fig. 163 Main harness, ESR 5000, Danaher motor

23 904

Pin Wire No. 1 2936 B+ (Fu4) 2 5912 Brake 3 309 +5V ECR3 4 612 GND ana/dig 5 014 CH.1 ECR3 6 015 CH.2 ECR3 7 8 618 CAN GND 9 10 109 CH. 1B 11 111 CH. 1A 12 13 026 SFS 2 14 15 909 CAN L 16 115 THS 3 17 110 CH. 2A 18 19 025 SFS 1 SA 20 112 CH. 2B 21 22

PC 204 (SDM)

Main harness, ESR 5000, Danaher motor

387

Wiring Diagram (Multitask Control Handle)

SCHEMATIC DIAGRAMS

Wire No. 3100 669 005

1 2

Pin A B C

Horn Crimp Wire No. 2928 5901

Wire No. 2913 --004

PC 417 (ACS)

SP 11

1 2

SP 15

Wire No. 302 106 602

BPS Crimp Wire No. 2916 008

SP 20

SP 14

SP 13

Pin 1 2 3 4

PC 418 (Pot1 ACC)

388

SP 10

Pin A B C

K2 PC 430 (THS 2)

Wire No. 2925 5913 2960 513

Wire No. 2933 5934

Pin 1 2

Wire No. 29136 5918

PC 435 (FAN 4)

Pin 1 2

PC 434 (FAN 3)

PC 471 (POT) Pin Wire No. 1 301 +12V 2 101 Pot 2 3 601 GND 12V 4 102 Pot 3 5 104 Pot 5 6 053 Heat St.Sig 7 2917 Seat + 8 001 Seat Signal 9 10 11 12

Pin Wire No. 1 3102 +12V Disp. 2 055 FWD Switch 3 002 5th Function 4 003 Sel. switch 5 399 Horn 6 051 Tilt up 7 052 Tilt down 8 29147 HeatSeat 9 10 29148 Coldstore 11 054 Coldstore 12

Wire No. 107 609

PC 470 (PS)

Pin 1 2

932 5936

30 86 85 87

29140 2999 932 29141

30 86 85 87

Pin 1 2 3 4

Wire No. 307 010 011 608

37 38 39 40

Coldstore R 9 Coldstore R 9 Coldstore R 10 Coldstore R 10

Wire No. 5909 SVT 019 HGT(R)S FLS / LCS 017 RES 2 022 SVS 5910 12V + 310 12V 613 PVL 5903 5904 SVH 5905 PVRE PVAR 5907 PVAL 5908 RES 1 018 BV + 2921 BV 503 PVRT 5906 024 PLS SV 5 5911 --------23 - - 24 - - 25 - - 26 - - 27 - - 28 - - 29 - - 30 - - 31 020 ECR 5 A ECR 5 B 32 021 LS 33 113 34 Coldstore R 8 35 Coldstore R 8 36 - - -

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

PC 422 (Mast)

ESR 5000

PC 429 (Pump ECR 2)

Wire No. 308 012 013 610

PC 425 (Tract. ECR 1) Pin 1 2 3 4

Wire No. 108 611

Relay socket see Parts Table

K 13

Pin 1 2

3101

Wire No. 006 ---

2998 927 502 2954

PC 421 (Travel Alarm)

Pin 1 2 3 4

Wire No. 2950 5927 ---

PC 426 (BLS)

Pin A B C

Screw M6 (SDM) Ring Terminal (W) S Wire No. 1 803

GND an. CH.1 CH.2 THS 3

Wire No. +5 V

JC 431 (Brake)

118 114 014 015 115 ----

30 86 85 87

Screw M6 (SDM) Ring Terminal (V) S Wire No. 1 802

Pin 1 2 3 4 5 6

PC 436 (ECR 3)

PC 427 (THS 1)

Screw M6 (SDM) Ring Terminal (U) Wire No. S 801 1

Pin Wire No. A 311 +12V B 619 GND C 025 Sig.

PC 439 (SFS 1 SA)

2924 927

K 12

2957 2958 508 509

Wire No.

Pin Wire No. 1 312 +12V 2 620 GND 3 026 Sig. 4

PC 438 (SFS 2)

30 86 85 87

Pin 1 2 3 4 5 6 7 8

PC 440 (Option +/- BV)

PC 474 Coldstore 8 polig Pin 1 904/910 CAN H 2 2970 BV+ 3 909/911 CAN L 4 540 5 541 6 053 HeatSeat 7 054 ColdStore 8

Fig. 164 Main harness, ESR 5000, Danaher motor

Pin A B C

PC 419 (SPS)

1 2

BFS Crimp Wire No. 2915 007

SP 7

SP 6

SP 4

Main Harness, ESR 5000, Danaher Motor

SCHEMATIC DIAGRAMS

SP 3 after ED 1 Wire No. 2910 2929 2930 2932 2935 2952 29139

2996 29147 2970 29148

116 118 309 120

STARPOINTS = SP

SP 18 FU5 Wire No.

SP 17 +5V Wire No.

SP 11 GND Display Wire No. 613 619 620 624 625 669 -----

SP 9 Wire No. 5916 5919 5934

SP 4 after ED1 Wire No. 2913 2915 2916 2917 2921 2925 2933 29136 29139

2997 2998 2999 208 209 210 202

819849-2I_2

SP 15 GND Option Wire No. 570 540 541 SP 20 B+ Wire No.

SP 21 BWire No. 514 515 516 517 507 624

SP 16 Wire No. 5915 5918 5935

512 503 516

SP 5 GND BWire No. 500 502 503 504

SP 13 FU6 Option Wire No. 2954 2957 2958

SP 19 B+ Wire No.

SP 14 GND Option Wire No. 569 508 509

SP 8 GND ana./dig. Wire No. 114 117 612 119

SP 2 after ED 1 Wire No. 2926 2927 2931 2952

SP 7 GND 12VWire No. 600 601 602

SP 10 11V+ Display Wire No. 310 311 312 318 3100 3101 3102

SP 6 +12V Wire No. 300 301 302

2904 2905 2908 2909

SP 1 after Key B+ Wire No. 2901

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor

Main Harness, ESR 5000, Danaher Motor Label / Con.

Manuf. Pin Part-No.:

Crown Plug / Cap. Part-No.:

CROWN Pin Part No.:

Pins

ORS

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

Horn

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

BPS

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

BFS

Crimp Faston 6,3 Female Shrink Sleeve

---

793217-022 793217-00x

EDS

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

ED 1

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

Fuse Box

Crimp Faston 6,3 Female Shrink Sleeve

821003 806703-001 806703-004

793217-00x 793217-022

Relay Option / Keyless

Crimp Faston 6,3 Female with Claw

811996-003

813444-001 ---

Screw M10 S1 Power B+

Ring-T M10, Shrink Sleeve

---

793217-037 793409-00x

Screw M10 S2 Power B+

Ring-T M10, Shrink Sleeve

---

793217-038 793409-00x

Screw M8 B+ HDM

Ring-T M10, Shrink Sleeve

---

793217-036 793409-00x

Screw M8 B+ HDM

Ring-T M10, Shrink Sleeve

---

793217-035 793409-00x

Screw M8 B- HDM

Ring-T M10, Shrink Sleeve

---

793217-034 793409-00x

Screw M5 B+ Fuse 50A

Ring-T M5, Shrink Sleeve

---

793217-043 793409-00x

Screw M6 SDM

Ring-T M6 Shrink Sleeve

---

816812-034 793409-00x

PC 201

770520-1 Tape 770854-1 Stick

---

PC 202

770520-1 Tape 770854-1 Stick

---

PC 203

3900-0077 (-1.3mm²)

803450-025

803450-026

PC 204

770520-1 Tape 770854-1 Stick

---

ESR 5000

389

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor Label / Con.

Manuf. Pin Part-No.:

Crown Plug / Cap. Part-No.:

CROWN Pin Part No.:

Pins

PC 205

0-964263-2 (0.5 - 1.0mm²) Micro Timer II

---

42 (36 small / 6 medium)

---

0-964284-2 (1.5 - 2.5mm²) Junior Power Timer PC 206

0-964284-2 (1.5 - 2.5mm²) Junior Power Timer

Replacement Parts Connector

Part No. Housing

Part No. Anti-Backout

Part No. Contact pins

PC 401

792881-001

793091-001

792883

PC 402

116851

116858

PC 414

803450-007

116858

PC 415

792881-001

793091-001

792883

PC 416

792881-004

793091-004

792883

PC 417

792881-002

793091-002

792883

PC 418

792881-003

793091-003

792883

PC 419

792881-002

793091-002

792883

PC 420

792881-002

793091-002

792883

PC 421

792881-003

793091-003

792883

PC 422

812339-001

792883

PC 425

814142

814143

PC 426

792881-002

PC 427

814144

814143

PC 429

814142

814143

PC 430

814144

814143

JC 431

792880-002

793090-002

792882

PC 433

792881-003

793091-003

792883

PC 434

792881-001

793091-001

792883

PC 435

792881-001

793091-001

792883

PC 436

818925-004

818926-004

818927

PC 438

792881-003

793091-003

792883

PC 439

792881-002

793091-002

792883

PC 440

792881-005

793091-005

792883

PC 470

792881-006

793091-006

792883

793091-002

ESR 5000

390

792883

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor Connector

Part No. Housing

Part No. Anti-Backout

Part No. Contact pins

PC 471

792881-006

793091-006

792883

PC 472

116851

PC 473

792881-001

793091-001

792883

JC 473

792880-002

793090-002

792882

PC 474

792881-005

793091-005

792883

116858

ESR 5000

391

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor

Main Harness, ESR 5000, Danaher Motor Wiring From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 201 HDM

2929

SP 3

---

5919

SP 9

---

307 12V+

PC 429

608 GND

PC 429

010 CH. A

PC 429

011 CH. B

PC 429

617 CANGND

PC 202

618 CANGND

PC 204

607

PC 201

607

PC 201

908 CAN L

PC 202

911 CAN L

PC 474

107 TMP

PC 430

609 TMPGND

PC 430

903 CAN H

PC 202

910 CAN H

PC 474

2905

SP 1

---

5915

SP 16

---

308 12V+

PC 425

610 GND

PC 425

012 CH. A

PC 425

013 CH. B

PC 425

616 CANGND

PC 203

617 CANGND

PC 201

907 CAN L

PC 203

908 CAN L

PC 201

108 TMP

PC 427

611 TMPGND

PC 427

902 CAN H

PC 203

903 CAN H

PC 201

PC 202 TDM

ESR 5000

392

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 203 Display screen

906 CAN L

PC 416

901 CAN H

PC 416

615 CANGND

PC 416

902 CAN H

PC 202

907 CAN L

PC 202

616 CAN GND

PC 202

113 LS/FKS

PC 422

002 5th Fnct

PC 470

318 11V+

SP 10

---

517 GND B-

SP 21

---

319 11V+

PC 416

514 GND B-

SP 21

---

2908 B+ KEY

SP 1

---

202 B+

SP 19

---

507 GND B-

SP 21

---

2936 B+ FU4

Fuse Box

5912 BRAKE

PC 402

309+5V

SP 17

---

612 GND A/D

SP 8

---

014 CH. 1

PC 436

015 CH. 2

PC 436

618 CAN GND

PC 201

109 CH. 1B

PC 414

111 CH. 1A

PC 414

026 SFS 2

PC 438

---

909 CAN L

PC 474

115 THS 3

PC 436

110 CH. 2A

PC 414

025 SFS1 SA

PC 439

112 CH. 2B

PC 414

---

904 CAN H

PC 474

PC 204 SDM

ESR 5000

393

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 205 Canion VCM

5904 SVH

PC 422

001 SES

PC 471

003 Sel.

PC 470

055 FWD Swt

PC 470

004 ACS

PC 417

300 12V+

SP 6

---

600 12V-

SP 7

---

614 CAN GND

PC 416

020 ECR 5A

PC 422

5920 Beacon

PC 433

5902 ED1

ED1

Crimp

5910 SVS

PC 422

5908 PVAL

PC 422

2930 B+

SP 3

---

5905 PVRE

PC 422

005 SPS

PC 419

2909 KYS

SP 1

---

018 RES 1

PC 422

022 RES 2

PC 422

104 POT5

PC 471

106 POT1

PC 418

900 CAN H

PC 416

905 CAN L

PC 416

5914 Horn out

PC 402

017 FLS/LCS

PC 422

5911 SV5

PC 422

5907 PVAR

PC 422

504 B-

SP 5

---

5906 PVRT

PC 422

019 HGT(R)S

PC 422

007 BFS

BFS

Crimp

008 BPS

BPS

Crimp

009 BRS

PC 472

ESR 5000

394

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

101 POT 2

PC 471

102 POT 3

PC 471

051 tilt up

PC 470

021 ECR 5B

PC 422

024 PLS

PC 422

5909 SVT

PC 422

5903 PVL

PC 422

5913 Travel Al.

PC 421

006 BLS

PC 426

399 Horn sw.

PC 470

052 Tilt down

PC 470

PC 401 FAN 1 48V

2931

SP 2

---

5935

SP 16

---

PC 402 Start Up Card

2904

SP 1

---

2923

Screw M10S2

Ring - T

5901

Horn

Crimp

2927

SP 2

---

5912

PC 204

2903

Fuse Box

2902

ED 1

Crimp

5928

ED 1

Crimp

5914

PC 205

2928

Horn

Crimp

5927

PC 431

2950

PC 431

PC206 VCM

ESR 5000

395

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 414 Stepper ECR 4

109 Ch 1B

PC 204

110 Ch 2A

PC 204

111 Ch 1A

PC 204

112 Ch 2B

PC 204

116

SP 17

---

117

SP 8

---

120

SP 17

---

119

SP 8

---

PC 415 FAN 2 48V

2932

SP 3

---

5916

SP 9

---

PC 416 CAN Con.

900 / 901CAN H

PC 205 / 203

22 / 2

905 / 906CAN L

PC 205 / 203

23 / 1

614 /615 GND

PC 205 / 203

8/3

319 11V+

PC 203

625 GND

SP 11

---

PC 417 ACS

2913

SP 4

---

004

PC 205

PC 418 POT 1 ACC.

302 12V+

SP 6

---

106 Sig

PC 205

602 GND

SP 7

---

3100 11V+

SP 10

---

669 11V-

SP 11

---

005

PC 205

PC 420 KYS

2951

EDS

Crimp

2901

SP 1

---

PC 421 Travel Alarm

2925

SP 4

---

5913

PC 206

2960

Fuse Box

513

SP 5

---

PC 419 SPS

ESR 5000

396

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 422 Mast

5909 SVT

PC 205

019 HGT(R)S

PC 205

017 FLS/LCS

PC 205

022 RES 2

PC 205

5910 SVS

PC 205

310 12V+

SP 10

---

613 GND

SP 11

---

5903 PVL

PC 205

5904 SVH

PC 205

5905 PVRE

PC 205

5907 PVAR

PC 205

5908 PVAL

PC 205

018 RES 1

PC 205

2921 BV +

SP 4

---

503 BV -

SP 5

---

5906 PVRT

PC 205

024 PLS

PC 205

5911 SV5

PC 205

020 ECR 5 A

PC 205

021 ECR 5 B

PC 205

113 LS

PC 203

308

PC 202

012

PC 202

013

PC 202

610

PC 202

006

PC 206

---

3101

SP 10

---

PC 427 THS1

108

PC 202

611

PC 202

PC 429 Pump ECR2

307

PC 201

010

PC 201

011

PC 201

608

PC 201

PC 425 Tract. ECR1

PC 426 BLS

ESR 5000

397

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 430 THS2

107

PC 201

609

PC 201

JC 431 Brake

2950

PC 402

5927

PC 402

PC 433 Beacon

2935

SP 3

---

5920

PC 205

2959

Fuse Box

512

SP 5

---

PC 434 FAN 3 48V

2933

SP 4

---

5934

SP 9

---

PC 435 FAN 4 48V

29136

SP 4

---

5918

SP 16

---

PC 436 Steer ECR 3

118+5V

SP 17

---

114 GND

SP 8

---

015 CH A

PC 204

014 CH B

PC 204

115 THS 3

PC 204

---

312 12V+

SP 10

---

620 GND

SP 11

---

026 Sig.

PC 204

311 12V+

SP 10

---

619 GND

SP 11

---

025 Sig.

PC 204

PC 438 SFS 2

PC 439 SFS 1

PC 440 Option

---

2957

SP 13

---

2958

SP 13

---

508

SP 14

---

509

SP 14

---

7 8

ESR 5000

398

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 470 PS

3102

SP10

---

055 FWD

PC 205

002 5th Select

PC 203

003 SEl. Direct

PC 205

399 Horn

PC 206

051 Tilt up

PC 206

052 Tilt down

PC 205

29147

SP18

---

27148

SP18

---

054 Cold store

PC 474

---

301

SP 6

---

101

PC 205

601

SP 7

---

102

PC 205

104

PC 205

053 Heat Sig

PC 474

2917 Seat Ht.

SP 4

---

001 Seat Sig.

PC 205

---

29143

PC 473

009

PC 205

5936

Relay K2

209

SP 19

---

210

SP 19

---

515

GND B-

SP 21

29143

PC 472

572

SP 5

---

PC 471 POT

PC 472 Brake Opt.

PC 473 Working Lights

ESR 5000

399

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

JC 473 Keyless

29140

Relay K1

29141

Relay K1

PC 474 CAN OUT Card

904 / 910

PC 204/201

23 / 23

2970

SP 18

---

909 / 911

PC 204/201

15/15

540

SP 15

---

541

SP 15

---

053 Heat Seat

PC 471

054 Cold store

PC 470

200

Screw M10 S1

Ring-T

201 / 208

EDS / SP 19

Ring-T / ---

203 / 204

Screw M10 S2/Fu box

Ring-T / 3

2926

SP 2

---

204

Fuse Box

2903

PC 402

205

Screw M10 B+

Ring-T

2936

PC 204

206

Screw M10 S1

Ring-T

2959 / 2996

PC 433 / SP18

207

Screw M10 S1

Ring-T

2960 / 2997

PC 421 / SP 20

3 / ---

Crimp

201

Fuse Box

Crimp

2951

PC 420

Crimp

2902

PC 402

Crimp

5902 / 5928

PC 205 / PC 402

24 / 10

2924

SP 1

---

927

K 13

8 Fuse Box

EDS ED1 Relay Options K 12

ESR 5000

400

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

Relay Options K 13

2998

SP 20

---

927

K 12

502

SP 5

---

2954

SP 13

---

Crimp

2928

PC 402

Crimp

5901

PC 402

Crimp

2915

SP 4

---

Crimp

007

PC 205

Crimp

2916

SP 4

---

Crimp

008

PC 205

Screw M10 S1

Ring-T

200 / 206 / 207

Fuse Box

1/5/6

Screw M10 S2

Ring-T

203 / 205 / 2923

FuBox / FuBox / PC 402

2/4/2

Screw M8 B-

Ring-T

500

SP 5

---

Screw M8 B-

Ring-T

569 / 570

SP 14 / SP 15

---

Screw M8 B+

Ring-T

29127

Screw M10 FU13 (S1)

Ring-T

Screw M10 FU

Ring-T

29127

Screw M8 B+

Ring-T

Screw M6 SDM

Ring-T

29128

Screw M5 B+

Ring-T

Screw M5 B+

Ring-T

29128

Screw M6 SDM (B+) Ring-T

Screw M8 B-

Ring-T

566

Screw M6 SDM (B-)

Ring-T

Screw M6 SDM

Ring-T

566

Screw M8 B-

Ring-T

Screw M6 SDM

Ring-T

801

Screw M6 (U)

Ring-T

Screw M6 SDM

Ring-T

802

Screw M6 (V)

Ring-T

Screw M6 SDM

Ring-T

803

Screw M6 (W)

Ring-T

Screw M6 U

Ring-T

801

Screw M6 (SDM U)

Ring-T

Screw M6 V

Ring-T

802

Screw M6 (SDM V)

Ring-T

Screw M6 W

Ring-T

803

Screw M6 (SDM W)

Ring-T

Relay Keyless K1

29140

JC 473

2999

SP 20

---

932

29141

JC 473

Horn BFS BPS

ESR 5000

401

SCHEMATIC DIAGRAMS Main Harness, ESR 5000, Danaher Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

Relay Keyless K2

30 86

932

5936

PC 472

Replacement parts Part No.

Description

819849

Harness, complete

ESR 5000

402

SP 18

CAN H

SP 8

Pin Wire No. 1 2 3 4 5 6 7 5913 Travel Alarm 8 9 10 11 12 006 BLS 13 14 399 Horn switch 15 052 Tilt down 16

PC 206 (VCM)

SP 17

Screw M10 FU13 B+ Ring Terminal S Wire No. 1 29127

CAN L

Horn out FLS / LCS SV 5 PVAR BPVRT HGT(R)S BFS BPS BRS

Pot 2 Pot 3 Tilt up ECR 5 B PLS

SVT PVL

5914 017 5911 5907 504 5906 019 007 008 009

101 102 051 021 024

5909 5903

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Wire No. 5904 SVH 001 SES Sel. Switch 003 055 FWD Switch 004 ACS 300 12V + 600 12V 614 CAN GND ECR 5 A 020 BEACON 5920 ED 1 5902 5910 SVS 5908 PVAL 2930 B+ 5905 PVRE 005 SPS 2909 KYS RES 1 018 022 RES 2 104 Pot 5 Pot 1 106 900 CAN H

1 2

SP 9

SP 3

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Pin 1 2 3 4 5 6 7 8

LS/ FKS

002 5th Function 318 V+ Output 517 GND B319 V+ Output GND B514 2908 B+ Key 202 B+ perm. 507 GND B-

113

Wire No. CH 1B CH 2A CH 1A CH 2B +5V GND +5V GND

CAN H

627 627 903 910

S 2

Pin 1 2

ED1 (Line Contactor) Crimp Wire No. 1 2902 2 5902/5928

Screw M8 (HDM) B+ Ring Terminal S Wire No. 1 29127

Screw M8 (HDM) B- Ring Terminal S Wire No. 1 500

Screw M8 (HDM) B- Ring Terminal S Wire No. 1 566

Wire No. 2932 5916

SP 1

203 / 205 / 206 /2023

B+ Ring Terminal Wire No.

Screw M10 S2 (Line Cont.)

PC 415 (Fan2)

Screw M8 (HDM) B- Ring Terminal S Wire No. 1 569 /570

ESR 5000

CAN H

CAN L CAN L TMP TMP GND

607 607 908 911 107 609

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Wire No. 2929 5919 307 12V 608 GND 010 CH. A 011 CH. B 617 CAN GND 618 CAN GND

PC 201 (Pump HDM)

109 110 111 112 116 117 120 119

PC 414 (Stepper ECR 4)

Wire No. CAN L CAN H CAN GND CAN L CAN H CAN GND 616 906 901 615 907 902

PC 203 (Display)

SP 21

SP 19

Wire No. 2935 5920 2959 512

ScrewM10 FU13 B+ Ring Terminal S Wire No. 1 29128

Pin Wire No. 1 29143 Work L. 2 009 Brake 3 5936 Relais 4 209 B+ 48V 5 210 B+ 48V 6 515 GND B-

Pin A B C

Wire No. 29140 --29141

PC 472 (Brake/Opt.)

Wire No. 2951 --2901

SP 5

Pin 1 2 3 4

PC 433 (Beacon)

JC 473 (KEYLESS)

Pin A B C

PC 420 (KYS)

Pin Wire No. 1 900 / 901 CAN H 2 905 / 906 CAN L 3 614 / 615 CAN GND 4 ---11V + 5 319 6 625 GND Display

PC 416 (CAN Conn.)

Wire No. 29143 572

PC 473 Work Light

Screw M6 (SDM) B+ Ring Terminal S Wire No. 1 29128

Screw M6 (SDM) Ring Terminal (W) S Wire No. 1 803

Screw M6 (SDM) Ring Terminal (V) S Wire No. 1 802

Screw M6 (SDM) Ring Terminal (U) S Wire No. 1 801

23 905

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

PC 205 (VCM)

Screw M6 (SDM) B- Ring Terminal S Wire No. 1 566

Fig. 165 Main harness, ESR 5000, Crown motor

23 904

PC 204 (SDM)

Main Harness, ESR 5000, Crown Motor S 1

SP 2

SP 16

B+ Ring Terminal Wire No. 200 /207

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Wire No. 2904 2923 5901 2927 5912 2903 ------2902 5928 5914 2928 5927 2950 -------

Pin 1 2

Wire No. 2931 5935

PC 401 (FAN1)

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

825335-2A_1

Relay Main Cont.

-------

Brake

Horn

Charge Capacity

Start Up card Intern

CAN H

626 626 902 903

CAN L CAN L TMP TMP GND

907 908 108 611

Wire No. 2905 5915 308 12V 610 GND 012 CH. A 013 CH. B 616 CAN GND 617 CAN GND

PC 202 (Traction TDM)

EDS(aux. Contactor) Crimp Wire No. 1 201 2 2951

PC 402 (Start up Card)

Screw M10 S1 (Line Cont.)

403

Main Harness, ESR 5000, Crown Motor

SCHEMATIC DIAGRAMS

Wire No. 3100 669 005

1 2

Pin A B C

Horn Crimp Wire No. 2928 5901

Wire No. 2913 --004

PC 417 (ACS)

SP 11

1 2

SP 15

Wire No. 302 106 602

BPS Crimp Wire No. 2916 008

SP 20

SP 14

SP 13

Pin 1 2 3 4

PC 418 (Pot1 ACC)

Pin 1 2 3 4

404

GND an. CH.1 CH.2 THS 3

Wire No. +5 V

Pin A B C

Wire No. 2925 5913 2960 513

Wire No. 2933 5934

Pin 1 2

Wire No. 29136 5918

PC 435 (FAN 4)

Pin 1 2

PC 434 (FAN 3)

PC 471 (POT) Pin Wire No. 1 301 +12V 2 101 Pot 2 3 601 GND 12V 4 102 Pot 3 5 104 Pot 5 6 053 Heat St.Sig 7 2917 Seat + 8 001 Seat Signal 9 10 11 12

Pin Wire No. 1 3102 +12V Disp. 2 055 FWD Switch 3 002 5th Function 4 003 Sel. switch 5 399 Horn 6 051 Tilt up 7 052 Tilt down 8 29147 HeatSeat 9 10 29148 Coldstore 11 054 Coldstore 12

Wire No. 107 609

PC 470 (PS)

Pin 1 2

932 5936

30 86 85 87

Pin 1 2 3 4

Wire No. 307 608 010 011

37 38 39 40

Coldstore R 9 Coldstore R 9 Coldstore R 10 Coldstore R 10

Wire No. SVT 5909 HGT(R)S 019 FLS / LCS 017 RES 2 022 SVS 5910 12V + 310 12V 613 PVL 5903 SVH 5904 PVRE 5905 PVAR 5907 PVAL 5908 RES 1 018 BV + 2921 BV 503 PVRT 5906 024 PLS SV 5 5911 --------23 - - 24 - - 25 - - 26 - - 27 - - 28 - - 29 - - 30 - - 31 020 ECR 5 A ECR 5 B 32 021 LS 33 113 34 Coldstore R 8 35 Coldstore R 8 36 - - -

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

PC 422 (Mast)

ESR 5000

PC 429 (Pump ECR 2)

Wire No. 308 610 012 013

29140 2999 932 29141

Wire No. 108 611

30 86 85 87

Pin 1 2

PC 427 (THS 1)

3101

Wire No. 006 ---

PC 426 (BLS)

Wire No. 2950 5927 ---

JC 431 (Brake)

118 114 014 015 115 ----

Pin A B C

Screw M6 (SDM) Ring Terminal (W) S Wire No. 1 803

Pin 1 2 3 4 5 6

PC 436 (ECR 3)

PC 425 (Tract. ECR 1)

PC 430 (THS 2)

Screw M6 (SDM) Ring Terminal (V) S Wire No. 1 802

Pin Wire No. A 311 +12V B 619 GND C 025 Sig.

PC 439 (SFS 1 SA)

Pin 1 2 3 4

K 13

2998 927 502 2954

30 86 85 87

Screw M6 (SDM) Ring Terminal (U) Wire No. S 801 1

Pin Wire No. 1 312 +12V 2 620 GND 3 026 Sig. 4

PC 438 (SFS 2)

Relay socket see Parts Table

K 12

2924 927

2957 2958 508 509

Wire No.

30 86 85 87

Pin 1 2 3 4 5 6 7 8

PC 440 (Option +/- BV)

PC 474 Coldstore 8 polig Pin 1 904/910 CAN H 2 2970 BV+ 3 909/911 CAN L 4 540 5 541 6 053 HeatSeat 7 054 ColdStore 8

SP 10

PC 421 (Travel Alarm)

Fig. 166 Main harness, ESR 5000, Crown motor

Pin A B C

PC 419 (SPS)

1 2

BFS Crimp Wire No. 2915 007

SP 7

SP 6

SP 4

Main Harness, ESR 5000, Crown Motor

SCHEMATIC DIAGRAMS

2996 29147 2970 29148

116 118 309 120

STARPOINTS = SP

SP 18 FU5 Wire No.

SP 11 GND Display Wire No. 613 619 620 624 625 669 -----

SP 17 +5V Wire No.

2929 2930 2932 2935 2952 29139

SP 3 after ED 1 Wire No.

SP 9 Wire No. 5916 5919 5934

SP 4 after ED1 Wire No. 2913 2915 2916 2917 2921 2925 2933 29136 29139

2997 2998 2999 208 209 210 202

SP 15 GND Option Wire No. 570 540 541 SP 20 B+ Wire No.

SP 21 BWire No. 514 515 516 517 507 624

SP 16 Wire No. 5915 5918 5935

SP 5 GND BWire No. 500 502 503 504 572 512 503 516

SP 13 FU6 Option Wire No. 2954 2957 2958

SP 19 B+ Wire No.

SP 14 GND Option Wire No. 569 508 509

SP 8 GND ana./dig. Wire No. 114 117 612 119

SP 2 after ED 1 Wire No. 2926 2927 2931 2952

SP 7 GND 12VWire No. 600 601 602

SP 10 11V+ Display Wire No. 310 311 312 318 3100 3101 3102

SP 6 +12V Wire No. 300 301 302

SP 1 after Key B+ Wire No. 2901 2904 2905 2908 2909 2924

825335-2A_2

CYLINDERS Main Harness, ESR 5000, Crown Motor

Main Harness, ESR 5000, Crown Motor Label / Con.

Manuf. Pin Part-No.:

Crown Plug / Cap. Part-No.:

CROWN Pin Part No.:

Pins

ORS

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

Horn

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

BPS

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

BFS

Crimp Faston 6,3 Female Shrink Sleeve

---

793217-022 793217-00x

EDS

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

ED 1

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

Fuse Box

Crimp Faston 6,3 Female Shrink Sleeve

821003 806703-001 806703-004

793217-00x 793217-022

Relay Option / Keyless

Crimp Faston 6,3 Female with Claw

811996-003

813444-001 ---

Screw M10 S1 Power B+

Ring-T M10, Shrink Sleeve

---

793217-037 793409-00x

Screw M10 S2 Power B+

Ring-T M10, Shrink Sleeve

---

793217-038 793409-00x

Screw M8 B+ HDM

Ring-T M10, Shrink Sleeve

---

793217-036 793409-00x

Screw M8 B+ HDM

Ring-T M10, Shrink Sleeve

---

793217-035 793409-00x

Screw M8 B- HDM

Ring-T M10, Shrink Sleeve

---

793217-034 793409-00x

Screw M5 B+ Fuse 50A

Ring-T M5, Shrink Sleeve

---

793217-043 793409-00x

Screw M6 SDM

Ring-T M6 Shrink Sleeve

---

816812-034 793409-00x

PC 201

770520-1 Tape 770854-1 Stick

---

PC 202

770520-1 Tape 770854-1 Stick

---

PC 203

3900-0077 (-1.3mm²)

803450-025

803450-026

PC 204

770520-1 Tape 770854-1 Stick

---

ESR 5000

405

CYLINDERS Main Harness, ESR 5000, Crown Motor Label / Con.

Manuf. Pin Part-No.:

Crown Plug / Cap. Part-No.:

CROWN Pin Part No.:

Pins

PC 205

0-964263-2 (0.5 - 1.0mm²) Micro Timer II

---

42 (36 small / 6 medium)

---

0-964284-2 (1.5 - 2.5mm²) Junior Power Timer PC 206

0-964284-2 (1.5 - 2.5mm²) Junior Power Timer

Replacement Parts Connector

Part No. Housing

Part No. Anti-Backout

Part No. Contact pins

PC 401

792881-001

793091-001

792883

PC 402

116851

116858

PC 414

803450-007

116858

PC 415

792881-001

793091-001

792883

PC 416

792881-004

793091-004

792883

PC 417

792881-002

793091-002

792883

PC 418

792881-003

793091-003

792883

PC 419

792881-002

793091-002

792883

PC 420

792881-002

793091-002

792883

PC 421

792881-003

793091-003

792883

PC 422

812339-001

792883

PC 425

062755-003

062797-006

PC 426

792881-002

PC 427

062755-001

062797-006

PC 429

062755-003

062797-006

PC 430

062755-001

062797-006

JC 431

792880-002

793090-002

792882

PC 433

792881-003

793091-003

792883

PC 434

792881-001

793091-001

792883

PC 435

792881-001

793091-001

792883

PC 436

818925-004

818926-004

818927

PC 438

792881-003

793091-003

792883

PC 439

792881-002

793091-002

792883

PC 440

792881-005

793091-005

792883

793091-002

ESR 5000

406

792883

CYLINDERS Main Harness, ESR 5000, Crown Motor Connector

Part No. Housing

Part No. Anti-Backout

Part No. Contact pins

PC 470

792881-006

793091-006

792883

PC 471

792881-006

793091-006

792883

PC 472

116851

PC 473

792881-001

793091-001

792883

JC 473

792880-002

793090-002

792882

PC 474

792881-005

793091-005

792883

116858

Replacement Parts Part No.

Description

825335

Harness, complete

ESR 5000

407

CYLINDERS Main Harness, ESR 5000, Crown Motor

Main Harness, ESR 5000, Crown Motor Wiring From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 201 HDM

2929

SP 3

---

5919

SP 9

---

307 12V+

PC 429

608 GND

PC 429

010 CH. A

PC 429

011 CH. B

PC 429

617 CAN GND

PC 202

618 CAN GND

PC 204

607

PC 201

607

PC 201

908 CAN L

PC 202

911 CAN L

PC 474

107 TMP

PC 430

609 TMP GND

PC 430

627

903 CAN H

PC 202

910 CAN H

PC 474

ESR 5000

408

CYLINDERS Main Harness, ESR 5000, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 202 TDM

2905

SP 1

---

5915

SP 16

---

308 12V+

PC 425

610 GND

PC 425

012 CH. A

PC 425

013 CH. B

PC 425

616 CAN GND

PC 203

617 CAN GND

PC 201

907 CAN L

PC 203

908 CAN L

PC 201

108 TMP

PC 427

611 TMP GND

PC 427

626

902 CAN H

PC 203

903 CAN H

PC 201

906 CAN L

PC 416

901 CAN H

PC 416

615 CAN GND

PC 416

902 CAN H

PC 202

907 CAN L

PC 202

616 CAN GND

PC 202

113 LS/FKS

PC 422

002 5th Fnct

PC 470

318 11V+

SP 10

---

517 GND B-

SP 21

---

319 11V+

PC 416

514 GND B-

SP 21

---

2908 B+ KEY

SP 1

---

202 B+

SP 19

---

507 GND B-

SP 21

---

PC 203 Display screen

ESR 5000

409

CYLINDERS Main Harness, ESR 5000, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 204 SDM

2936 B+ FU4

Fuse Box

5912 BRAKE

PC 402

309+5V

SP 17

---

612 GND A/D

SP 8

---

014 CH. 1

PC 436

015 CH. 2

PC 436

618 CAN GND

PC 201

109 CH. 1B

PC 414

111 CH. 1A

PC 414

026 SFS 2

PC 438

---

909 CAN L

PC 474

115 THS 3

PC 436

110 CH. 2A

PC 414

025 SFS1 SA

PC 439

112 CH. 2B

PC 414

---

904 CAN H

PC 474

ESR 5000

410

CYLINDERS Main Harness, ESR 5000, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 205 Canion VCM

5904 SVH

PC 422

001 SES

PC 471

003 Sel.

PC 470

055 FWD Swt

PC 470

004 ACS

PC 417

300 12V+

SP 6

---

600 12V-

SP 7

---

614 CAN GND

PC 416

020 ECR 5A

PC 422

5920 Beacon

PC 433

5902 ED1

ED1

Crimp

5910 SVS

PC 422

5908 PVAL

PC 422

2930 B+

SP 3

---

5905 PVRE

PC 422

005 SPS

PC 419

2909 KYS

SP 1

---

018 RES 1

PC 422

022 RES 2

PC 422

104 POT5

PC 471

106 POT1

PC 418

900 CAN H

PC 416

905 CAN L

PC 416

5914 Horn out

PC 402

017 FLS/LCS

PC 422

5911 SV5

PC 422

5907 PVAR

PC 422

504 B-

SP 5

---

5906 PVRT

PC 422

019 HGT(R)S

PC 422

007 BFS

BFS

Crimp

008 BPS

BPS

Crimp

009 BRS

PC 472

ESR 5000

411

CYLINDERS Main Harness, ESR 5000, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

101 POT 2

PC 471

102 POT 3

PC 471

051 tilt up

PC 470

021 ECR 5B

PC 422

024 PLS

PC 422

5909 SVT

PC 422

5903 PVL

PC 422

5913 Travel Al.

PC 421

006 BLS

PC 426

399 Horn sw.

PC 470

052 Tilt down

PC 470

PC 401 FAN 1 48V

2931

SP 2

---

5935

SP 16

---

PC 402 Start Up Card

2904

SP 1

---

2923

Screw M10 S2

Ring - T

5901

Horn

Crimp

2927

SP 2

---

5912

PC 204

2903

Fuse Box

2902

ED 1

Crimp

5928

ED 1

Crimp

5914

PC 205

2928

Horn

Crimp

5927

PC 431

2950

PC 431

PC206 VCM

ESR 5000

412

CYLINDERS Main Harness, ESR 5000, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 414 Stepper ECR 4

109 Ch 1B

PC 204

110 Ch 2A

PC 204

111 Ch 1A

PC 204

112 Ch 2B

PC 204

116

SP 17

---

117

SP 8

---

120

SP 17

---

119

SP 8

---

PC 415 FAN 2 48V

2932

SP 3

---

5916

SP 9

---

PC 416 CAN Con.

900 / 901CAN H

PC 205 / 203

22 / 2

905 / 906CAN L

PC 205 / 203

23 / 1

614 /615 GND

PC 205 / 203

8/3

319 11V+

PC 203

625 GND

SP 11

---

PC 417 ACS

2913

SP 4

---

004

PC 205

PC 418 POT 1 ACC.

302 12V+

SP 6

---

106 Sig

PC 205

602 GND

SP 7

---

3100 11V+

SP 10

---

669 11V-

SP 11

---

005

PC 205

PC 420 KYS

2951

EDS

Crimp

2901

SP 1

---

PC 421 Travel Alarm

2925

SP 4

---

5913

PC 206

2960

Fuse Box

513

SP 5

---

PC 419 SPS

ESR 5000

413

CYLINDERS Main Harness, ESR 5000, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 422 Mast

5909 SVT

PC 205

019 HGT(R)S

PC 205

017 FLS/LCS

PC 205

022 RES 2

PC 205

5910 SVS

PC 205

310 12V+

SP 10

---

613 GND

SP 11

---

5903 PVL

PC 205

5904 SVH

PC 205

5905 PVRE

PC 205

5907 PVAR

PC 205

5908 PVAL

PC 205

018 RES 1

PC 205

2921 BV +

SP 4

---

503 BV -

SP 5

---

5906 PVRT

PC 205

024 PLS

PC 205

5911 SV5

PC 205

020 ECR 5 A

PC 205

021 ECR 5 B

PC 205

113 LS

PC 203

308

PC 202

610

PC 202

012

PC 202

013

PC 202

006

PC 206

---

3101

SP 10

---

PC 427 THS1

108

PC 202

611

PC 202

PC 429 Pump ECR2

307

PC 201

608

PC 201

010

PC 201

011

PC 201

PC 425 Tract. ECR1

PC 426 BLS

ESR 5000

414

CYLINDERS Main Harness, ESR 5000, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 430 THS2

107

PC 201

609

PC 201

JC 431 Brake

2950

PC 402

5927

PC 402

PC 433 Beacon

2935

SP 3

---

5920

PC 205

2959

Fuse Box

512

SP 5

---

PC 434 FAN 3 48V

2933

SP 4

---

5934

SP 9

---

PC 435 FAN 4 48V

29136

SP 4

---

5918

SP 16

---

PC 436 Steer ECR 3

118+5V

SP 17

---

114 GND

SP 8

---

015 CH A

PC 204

014 CH B

PC 204

115 THS 3

PC 204

---

312 12V+

SP 10

---

620 GND

SP 11

---

026 Sig.

PC 204

311 12V+

SP 10

---

619 GND

SP 11

---

025 Sig.

PC 204

PC 438 SFS 2

PC 439 SFS 1

PC 440 Option

---

2957

SP 13

---

2958

SP 13

---

508

SP 14

---

509

SP 14

---

7 8

ESR 5000

415

CYLINDERS Main Harness, ESR 5000, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 470 PS

3102

SP10

---

055 FWD

PC 205

002 5th Selec

PC 203

003 SEl. Direct

PC 205

399 Horn

PC 206

051 Tilt up

PC 206

052 Tilt down

PC 205

29147

SP18

---

27148

SP18

---

054 Cold store

PC 474

---

301

SP 6

---

101

PC 205

601

SP 7

---

102

PC 205

104

PC 205

053 Heat Sig

PC 474

2917 Seat Ht.

SP 4

---

001 Seat Sig.

PC 205

---

29143

PC 473

009

PC 205

5936

Relay K2

209

SP 19

---

210

SP 19

---

515

GND B-

SP 21

29143

PC 472

572

SP 5

---

PC 471 POT

PC 472 Brake Opt.

PC 473 Working Lights

ESR 5000

416

CYLINDERS Main Harness, ESR 5000, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

JC 473 Keyless

29140

Relay K1

29141

Relay K1

PC 474 CAN OUT Card

904 / 910

PC 204 / 201

23 / 23

2970

SP 18

---

909 / 911

PC 204 / 201

15 / 15

540

SP 15

---

541

SP 15

---

053 Heat Seat

PC 471

054 Cold store

PC 470

200

Screw M10 S1

Ring-T

201 / 208

EDS / SP 19

Ring-T / ---

203 / 204

Screw M10 S2/Fu box

Ring-T / 3

2926

SP 2

---

204

Fuse Box

2903

PC 402

205

Screw M10 B+

Ring-T

2936

PC 204

206

Screw M10 S1

Ring-T

2959 / 2996

PC 433 / SP18

207

Screw M10 S1

Ring-T

2960 / 2997

PC 421 / SP 20

3 / ---

Crimp

201

Fuse Box

Crimp

2951

PC 420

Crimp

2902

PC 402

Crimp

5902 / 5928

PC 205 / PC 402

24 / 10

2924

SP 1

---

927

K 13

8 Fuse Box

EDS ED1 Relay Options K 12

ESR 5000

417

CYLINDERS Main Harness, ESR 5000, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

Relay Options K 13

2998

SP 20

---

927

K 12

502

SP 5

---

2954

SP 13

---

Crimp

2928

PC 402

Crimp

5901

PC 402

Crimp

2915

SP 4

---

Crimp

007

PC 205

Crimp

2916

SP 4

---

Crimp

008

PC 205

Screw M10 S1

Ring-T

200 / 206 / 207

Fuse Box

1/5/6

Screw M10 S2

Ring-T

203 / 205 / 2923

FuBox / FuBox / PC 402

2/4/2

Screw M8 B-

Ring-T

500

SP 5

---

Screw M8 B-

Ring-T

569 / 570

SP 14 / SP 15

---

Screw M8 B+

Ring-T

29127

Screw M10 FU13 (S1)

Ring-T

Screw M10 FU

Ring-T

29127

Screw M8 B+

Ring-T

Screw M6 SDM

Ring-T

29128

Screw M5 B+

Ring-T

Screw M5 B+

Ring-T

29128

Screw M6 SDM (B+) Ring-T

Screw M8 B-

Ring-T

566

Screw M6 SDM (B-)

Ring-T

Screw M6 SDM

Ring-T

566

Screw M8 B-

Ring-T

Screw M6 SDM

Ring-T

801

Screw M6 (U)

Ring-T

Screw M6 SDM

Ring-T

802

Screw M6 (V)

Ring-T

Screw M6 SDM

Ring-T

803

Screw M6 (W)

Ring-T

Screw M6 U

Ring-T

801

Screw M6 (SDM U)

Ring-T

Screw M6 V

Ring-T

802

Screw M6 (SDM V)

Ring-T

Screw M6 W

Ring-T

803

Screw M6 (SDM W)

Ring-T

Relay Keyless K1

29140

JC 473

2999

SP 20

---

932

29141

JC 473

Horn BFS BPS

ESR 5000

418

CYLINDERS Main Harness, ESR 5000, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

Relay Keyless K2

30 86

932

5936

PC 472

ESR 5000

419

Notes:

420

SP 18

CAN H

SP 8

Pin Wire No. 1 2 3 4 5 6 7 5913 Travel Alarm 8 9 10 11 12 006 BLS 13 14 399 Horn switch 15 052 Tilt down 16

PC 206 (VCM)

SP 17

Screw M10 FU13 B+ Ring Terminal S Wire No. 1 29127

CAN L

Horn out FLS / LCS SV 5 PVAR BPVRT HGT(R)S BFS BPS BRS

Pot 2 Pot 3 Tilt up ECR 5 B PLS

SVT PVL

5914 017 5911 5907 504 5906 019 007 008 009

101 102 051 021 024

5909 5903

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Wire No. SVH 5904 SES 001 003 Sel. switch 055 FWD Switch ACS 004 12V + 300 12V 600 CAN GND 614 ECR 5 A 020 BEACON 5920 ED 1 5902 SVS 5910 PVAL 5908 B+ 2930 5905 PVRE 005 SPS 2909 KYS 018 RES 1 RES 2 022 Pot 5 104 Pot 1 106 900 CAN H

1 2

SP 19

Wire No. 2935 5920 2959 512

SP 9

SP 3

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Pin 1 2 3 4 5 6 7 8

B+ Key B+ perm. GND B-

2908 202 507

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 910

627 627 903

607 607 908 911 107 609

CAN H

CAN L CAN L TMP TMP GND

Wire No. 2929 5919 307 12V 608 GND 010 CH. A 011 CH. B 617 CAN GND 618 CAN GND

ESR 5000

5th Function V+ Output GND BV+ Output

LS/ FKS

002 318 624 319

113

Wire No. CH 1B CH 2A CH 1A CH 2B +5V GND +5V GND

PC 201 (Pump HDM)

109 110 111 112 116 117 120 119

PC 414 (Stepper ECR 4)

Wire No. CAN L CAN H CAN GND CAN L CAN H CAN GND 616

906 901 615 907 902

PC 203 (Display)

SP 21

Screw M10 FU13 B+ Ring Terminal S Wire No. 1 29128

Pin Wire No. 1 29143 Work L. 2 009 Brake 3 29142 Relais + 4 29137 B+ 48V 5 29138 B+ 48V Relais 6 571

Pin A B C

Wire No. 29140 --29141

JC 473 (KEYLESS)

Wire No. 2951 --2901

SP 5

Pin 1 2 3 4

PC 433 (Beacon)

PC 472 (Brake/Opt.)

Pin A B C

PC 420 (KYS)

Pin Wire No. 1 900 / 901 CAN H 2 905 / 906 CAN L 3 614 / 615 CAN GND 4 ---5 319 11V + 6 625 GND Display

PC 416 (CAN Conn.)

Wire No. 29143 572

PC 473 Work Light

Screw M6 (SDM) B+ Ring Terminal S Wire No. 1 29128

Screw M6 (SDM) Ring Terminal (W) S Wire No. 1 803

Screw M6 (SDM) Ring Terminal (V) S Wire No. 1 802

Screw M6 (SDM) Ring Terminal (U) S Wire No. 1 801

23 905

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

PC 205 (VCM)

Screw M6 (SDM) B- Ring Terminal S Wire No. 1 566

Fig. 167 Main harness, ESR 5000S, Crown motor

23 904

Pin Wire No. 1 2936 B+ (Fu4) 2 5912 Brake +5V ECR3 3 309 4 612 GND ana/dig CH.1 ECR3 5 014 CH.2 ECR3 6 015 7 CAN GND 8 618 9 10 109 CH. 1B 11 111 CH. 1A 12 SFS 2 13 026 14 CAN L 15 909 THS 3 16 115 17 110 CH. 2A 18 19 025 SFS 1 SA 20 112 CH. 2B 21 22

PC 204 (SDM)

Main Harness, ESR 5000S, Crown Motor

Wire No. 2932 5916

S 1

SP 2

SP 16

B+ Ring Terminal Wire No. 200 / 207

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Wire No. 2904 2923 5901 2927 5912 2903 ------2902 5928 5914 2928 5927 2950 -------

Pin 1 2

Wire No. 2931 5935

PC 401 (FAN1)

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

CAN H

CAN L CAN L TMP TMP GND

819850-2J_1

Relay Main Cont.

-------

Brake

Horn

Charge Capacity

Sart up Card intern

903

626 626 902

907 908 108 611

Wire No. 2905 5915 308 12V 610 GND 012 CH. A CH. B 013 CAN GND 616 CAN GND 617

PC 202 (Traction TDM)

EDS (aux.Contactor) Crimp Wire No. 1 201 2 2951

PC 402 (Start up Card)

Screw M10 S1 (Line Cont.)

ED1 (Line Contactor) Crimp Wire No. 1 2902 2 5902/5928

Fusebox Crimp Fuse No. Pin Wire No. 200 FU1 1 15A / 80V 7 201 / 202 FU2 2 203 / 204 2926 15A / 80V 8 204 FU3 3 2903 15A / 80V 9 205 FU4 4 2936 10A / 80V 10 206 FU5 5 15A / 80V 11 2959/2996 207 FU6 6 15A / 80V 12 2960/2997

Screw M8 (HDM) B+ Ring Terminal S Wire No. 1 29127

Screw M8 (HDM) B- Ring Terminal S Wire No. 1 500

Screw M8 (HDM) B- Ring Terminal S Wire No. 1 566

Screw M8 (HDM) B- Ring Terminal S Wire No. 1 569 / 570

Pin 1 2

SP 1

203 / 205 / 206 /2023

PC 415 (Fan2)

S 2

B+ Ring Terminal Wire No.

Screw M10 S2 (Line Cont.)

421

Main Harness, ESR 5000S, Crown Motor

SCHEMATIC DIAGRAMS

Wire No. 3100 669 005

1 2

Pin A B C

Horn Crimp Wire No. 2928 5901

Wire No. 2913 --004

PC 417 (ACS)

SP 11

1 2

Pin 1 2 3 4

BPS Crimp Wire No. 2916 008

SP 20

SP 13

SP 14

SP 15

Wire No. 302 106 602

PC 418 (Pot1 ACC)

SP 10

2998 927 502 2954

30 86 85 87

422

K 13

K 12

2957 2958 508 509

Wire No.

932 5936

30 86 85 87

Pin 1 2 3 4

Wire No. 2925 5913 2960 513

PC 421 (Travel Alarm)

29140 2999 932 29141

30 86 85 87

Wire No. 29136 5918

PC 435 (FAN 4)

Wire No. 2933 5934

PC 434 (FAN 3)

Relay socket see Parts Table

2924 927

30 86 85 87

Pin 1 2 3 4 5 6 7 8

PC 440 (Option +/- BV)

PC 474 Coldstore 8 polig Pin 1 904/910 CAN H 2 2970 BV+ 3 909/911 CAN L 4 540 5 541 6 053 HeatSeat 7 054 ColdStore 8

Fig. 168 Main harness, ESR 5000S, Crown motor

Pin A B C

PC 419 (SPS)

1 2

BFS Crimp Wire No. 2915 007

SP 7

SP 6

SP 4

Main Harness, ESR 5000S, Crown Motor

SCHEMATIC DIAGRAMS

Wire No. +5 V GND an. CH.1 CH.2 THS 3

Wire No. 2950 5927 ---

Wire No. 108 611

Pin Wire No. 1 301 +12V 2 101 Pot 2 3 601 GND 12V 4 102 Pot 3 5 104 Pot 5 6 053 Heat St.Sig 7 2917 Seat + 8 001 Seat Signal 9 10 11 12

10 29148 Coldstore 11 054 Coldstore 12

PC 471 (POT)

37 38 39 40

Coldstore R 9 Coldstore R 9 Coldstore R 10 Coldstore R 10

Wire No. 5909 SVT 019 HGT(R)S FLS / LCS 017 RES 2 022 SVS 5910 310 12V + 613 12V 5903 PVL 5904 SVH 5905 PVRE 5907 PVAR PVAL 5908 RES 1 018 2921 BV + 503 BV 5906 PVRT 024 PLS 5911 SV 5 --------23 - - 24 - - 25 - - 26 - - 27 - - 28 - - 29 - - 30 - - 31 020 ECR 5 A ECR 5 B 32 021 LS 33 113 34 Coldstore R 8 35 Coldstore R 8 36 - - -

Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

PC 422 (Mast)

ESR 5000

Wire No. 307 608 010 011

Pin 1 2 3 4

Wire No. 107 609

Pin 1 2

013

Wire No. 308 610 012

PC 429 (Pump ECR 2)

Pin 1 2 3 4

PC 425 (Tract. ECR 1)

Pin 1 2

PC 427 (THS 1)

3101

Wire No. 006 ---

PC 426 (BLS) Pin A B C Screw M6 (SDM) Ring Terminal (W) S Wire No. 1 803

118 114 014 015 115 ---JC 431 (Brake)

Pin A B C

Pin 1 2 3 4 5 6

PC 436 (ECR 3)

PC 430 (THS 2)

Screw M6 (SDM) Ring Terminal (V) S Wire No. 1 802

Pin Wire No. A 311 +12V B 619 GND C 025 Sig.

PC 439 (SFS 1 SA)

Pin Wire No. 1 3102 +12V Disp. 2 055 FWD Switch 3 002 5th Function 4 003 Sel. switch 5 399 Horn 6 051 Tilt up 7 052 Tilt down 8 29147 HeatSeat 9

PC 470 (PS)

Screw M6 (SDM) Ring Terminal (U) Wire No. S 801 1

Pin Wire No. 1 312 +12V 2 620 GND 3 026 Sig. 4

PC 438 (SFS 2)

SP 3 after ED 1 Wire No. 2910 2929 2930 2932 2935 2952 29139

2996 29147 2970 29148

116 118 309 120

STARPOINTS = SP

SP 18 FU5 Wire No.

SP 17 +5V Wire No.

SP 11 GND Display Wire No. 613 619 620 624 625 669 -----

SP 9 Wire No. 5916 5919 5934

SP 4 after ED1 Wire No. 2913 2915 2916 2917 2921 2925 2933 29136 29139

SP 20 B+ Wire No. 2997 2998 2999

819850-2J_2

SP15 GND Option Wire No. 570 540 541

208 209 210 202 SP 21 BWire No. 514 515 516 517 507 624

SP 16 Wire No. 5915 5918 5935

512 513 516

SP 5 GND BWire No. 500 502 503 504

SP13 FU6 Option Wire No. 2954 2957 2958

SP 19 B+ Wire No.

SP14 GND Option Wire No. 569 508 509

SP 8 GND ana./dig. Wire No. 114 117 612 119

SP 2 after ED 1 Wire No. 2926 2927 2931 2952

SP 7 GND 12VWire No. 600 601 602

SP 10 11V+ Display Wire No. 310 311 312 318 3100 3101 3102

SP 6 +12V Wire No. 300 301 302

2904 2905 2908 2909

SP 1 after Key B+ Wire No. 2901

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor

Main Harness, ESR 5000S, Crown Motor Label / Con.

Manuf. Pin Part-No.:

Crown Plug / Cap. Part-No.:

CROWN Pin Part No.:

Pins

ORS

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

Horn

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

BPS

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

BFS

Crimp Faston 6,3 Female Shrink Sleeve

---

793217-022 793217-00x

EDS

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

ED 1

Crimp Faston 6,3 Female Insulation Sleeve (wht housing)

---

793217-022 793217-027

Fuse Box

Crimp Faston 6,3 Female Shrink Sleeve

821003 806703-001 806703-004

793217-00x 793217-022

Relay Option / Keyless

Crimp Faston 6,3 Female with Claw

811996-003

813444-001 ---

Screw M10 S1 Power B+

Ring-T M10, Shrink Sleeve

---

793217-037 793409-00x

Screw M10 S2 Power B+

Ring-T M10, Shrink Sleeve

---

793217-038 793409-00x

Screw M8 B+ HDM

Ring-T M10, Shrink Sleeve

---

793217-036 793409-00x

Screw M8 B+ HDM

Ring-T M10, Shrink Sleeve

---

793217-035 793409-00x

Screw M8 B- HDM

Ring-T M10, Shrink Sleeve

---

793217-034 793409-00x

Screw M5 B+ Fuse 50A

Ring-T M5, Shrink Sleeve

---

793217-043 793409-00x

Screw M6 SDM

Ring-T M6 Shrink Sleeve

---

816812-034 793409-00x

PC 201

770520-1 Tape 770854-1 Stick

---

PC 202

770520-1 Tape 770854-1 Stick

---

PC 203

3900-0077 (-1.3mm²)

803450-025

803450-026

PC 204

770520-1 Tape 770854-1 Stick

---

ESR 5000

423

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor Label / Con.

Manuf. Pin Part-No.:

Crown Plug / Cap. Part-No.:

CROWN Pin Part No.:

Pins

PC 205

0-964263-2 (0.5 - 1.0mm²) Micro Timer II

---

42 (36 small / 6 medium)

---

0-964284-2 (1.5 - 2.5mm²) Junior Power Timer PC 206

0-964284-2 (1.5 - 2.5mm²) Junior Power Timer

Replacement Parts Connector

Part No. Housing

Part No. Anti-Backout

Part No. Contact pins

PC 401

792881-001

793091-001

792883

PC 402

116851

116858

PC 414

803450-007

116858

PC 415

792881-001

793091-001

792883

PC 416

792881-004

793091-004

792883

PC 417

792881-002

793091-002

792883

PC 418

792881-003

793091-003

792883

PC 419

792881-002

793091-002

792883

PC 420

792881-002

793091-002

792883

PC 421

792881-003

793091-003

792883

PC 422

812339-001

792883

PC 425

062755-003

062797-006

PC 426

792881-002

PC 427

062755-001

062797-006

PC 429

062755-003

062797-006

PC 430

062755-001

062797-006

JC 431

792880-002

793090-002

792882

PC 433

792881-003

793091-003

792883

PC 434

792881-001

793091-001

792883

PC 435

792881-001

793091-001

792883

PC 436

818925-004

818926-004

818927

PC 438

792881-003

793091-003

792883

PC 439

792881-002

793091-002

792883

PC 440

792881-005

793091-005

792883

793091-002

ESR 5000

424

792883

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor Connector

Part No. Housing

Part No. Anti-Backout

Part No. Contact pins

PC 470

792881-006

793091-006

792883

PC 471

792881-006

793091-006

792883

PC 472

116851

PC 473

792881-001

793091-001

792883

JC 473

792880-002

793090-002

792882

PC 474

792881-005

793091-005

792883

116858

Replacement Parts Part No.

Description

819850

Harness, complete

ESR 5000

425

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor

Main Harness, ESR 5000S, Crown Motor Wiring From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 201 HDM

2929

SP 3

---

5919

SP 9

---

307 12V+

PC 429

608 GND

PC 429

010 CH. A

PC 429

011 CH. B

PC 429

617 CAN GND

PC 202

618 CAN GND

PC 204

607

PC 201

607

PC 201

908 CAN L

PC 202

911 CAN L

PC 474

107 TMP

PC 430

609 TMP GND

PC 430

627

903 CAN H

PC 202

910 CAN H

PC 474

ESR 5000

426

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 202 TDM

2905

SP 1

---

5915

SP 16

---

308 12V+

PC 425

610 GND

PC 425

012 CH. A

PC 425

013 CH. B

PC 425

616 CAN GND

PC 203

617 CAN GND

PC 201

907 CAN L

PC 203

908 CAN L

PC 201

108 TMP

PC 427

611 TMP GND

PC 427

626

902 CAN H

PC 203

903 CAN H

PC 201

906 CAN L

PC 416

901 CAN H

PC 416

615 CAN GND

PC 416

902 CAN H

PC 202

907 CAN L

PC 202

616 CAN GND

PC 202

113 LS / FKS

PC 422

002 5th Fnct

PC 470

318 11V+

SP 10

---

517 GND B-

SP 21

---

319 11V+

PC 416

514 GND B-

SP 21

---

2908 B+ KEY

SP 1

---

202 B+

SP 19

---

507 GND B-

SP 21

---

PC 203 Display screen

ESR 5000

427

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 204 SDM

2936 B+ FU4

Fuse Box

5912 BRAKE

PC 402

309+5V

SP 17

---

612 GND A/D

SP 8

---

014 CH. 1

PC 436

015 CH. 2

PC 436

618 CAN GND

PC 201

109 CH. 1B

PC 414

111 CH. 1A

PC 414

026 SFS 2

PC 438

---

909 CAN L

PC 474

115 THS 3

PC 436

110 CH. 2A

PC 414

025 SFS1 SA

PC 439

112 CH. 2B

PC 414

---

904 CAN H

PC 474

ESR 5000

428

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 205 Canion VCM

5904 SVH

PC 422

001 SES

PC 471

003 Sel.

PC 470

055 FWD Swt

PC 470

004 ACS

PC 417

300 12V+

SP 6

---

600 12V-

SP 7

---

614 CAN GND

PC 416

020 ECR 5A

PC 422

5920 Beacon

PC 433

5902 ED1

ED1

Crimp

5910 SVS

PC 422

5908 PVAL

PC 422

2930 B+

SP 3

---

5905 PVRE

PC 422

005 SPS

PC 419

2909 KYS

SP 1

---

018 RES 1

PC 422

022 RES 2

PC 422

104 POT5

PC 471

106 POT1

PC 418

900 CAN H

PC 416

905 CAN L

PC 416

5914 Horn out

PC 402

017 FLS/LCS

PC 422

5911 SV5

PC 422

5907 PVAR

PC 422

504 B-

SP 5

---

5906 PVRT

PC 422

019 HGT(R)S

PC 422

007 BFS

BFS

Crimp

008 BPS

BPS

Crimp

009 BRS

PC 472

ESR 5000

429

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

101 POT 2

PC 471

102 POT 3

PC 471

051 tilt up

PC 470

021 ECR 5B

PC 422

024 PLS

PC 422

5909 SVT

PC 422

5903 PVL

PC 422

5913 Travel Al.

PC 421

006 BLS

PC 426

399 Horn sw.

PC 470

052 Tilt down

PC 470

PC 401 FAN 1 48V

2931

SP 2

---

5935

SP 16

---

PC 402 Start Up Card

2904

SP 1

---

2923

Screw M10 S2

Ring - T

5901

Horn

Crimp

2927

SP 2

---

5912

PC 204

2903

Fuse Box

2902

ED 1

Crimp

5928

ED 1

Crimp

5914

PC 205

2928

Horn

Crimp

5927

PC 431

2950

PC 431

PC206 VCM

ESR 5000

430

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 414 Stepper ECR 4

109 Ch 1B

PC 204

110 Ch 2A

PC 204

111 Ch 1A

PC 204

112 Ch 2B

PC 204

116

SP 17

---

117

SP 8

---

120

SP 17

---

119

SP 8

---

PC 415 FAN 2 48V

2932

SP 3

---

5916

SP 9

---

PC 416 CAN Con.

900 / 901CAN H

PC 205 / 203

22 / 2

905 / 906CAN L

PC 205 / 203

23 / 1

614 /615 GND

PC 205 / 203

8/3

319 11V+

PC 203

625 GND

SP 11

---

PC 417 ACS

2913

SP 4

---

004

PC 205

PC 418 POT 1 ACC.

302 12V+

SP 6

---

106 Sig

PC 205

602 GND

SP 7

---

3100 11V+

SP 10

---

669 11V-

SP 11

---

005

PC 205

PC 420 KYS

2951

EDS

Crimp

2901

SP 1

---

PC 421 Travel Alarm

2925

SP 4

---

5913

PC 206

2960

Fuse Box

513

SP 5

---

PC 419 SPS

ESR 5000

431

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 422 Mast

5909 SVT

PC 205

019 HGT(R)S

PC 205

017 FLS/LCS

PC 205

022 RES 2

PC 205

5910 SVS

PC 205

310 12V+

SP 10

---

613 GND

SP 11

---

5903 PVL

PC 205

5904 SVH

PC 205

5905 PVRE

PC 205

5907 PVAR

PC 205

5908 PVAL

PC 205

018 RES 1

PC 205

2921 BV +

SP 4

---

503 BV -

SP 5

---

5906 PVRT

PC 205

024 PLS

PC 205

5911 SV5

PC 205

020 ECR 5 A

PC 205

021 ECR 5 B

PC 205

113 LS

PC 203

308

PC 202

610

PC 202

012

PC 202

013

PC 202

006

PC 206

---

3101

SP 10

---

PC 427 THS1

108

PC 202

611

PC 202

PC 429 Pump ECR2

307

PC 201

010

PC 201

011

PC 201

608

PC 201

PC 425 Tract. ECR1

PC 426 BLS

ESR 5000

432

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 430 THS2

107

PC 201

609

PC 201

JC 431 Brake

2950

PC 402

5927

PC 402

PC 433 Beacon

2935

SP 3

---

5920

PC 205

2959

Fuse Box

512

SP 5

---

PC 434 FAN 3 48V

2933

SP 4

---

5934

SP 9

---

PC 435 FAN 4 48V

29136

SP 4

---

5918

SP 16

---

PC 436 Steer ECR 3

118+5V

SP 17

---

114 GND

SP 8

---

015 CH A

PC 204

014 CH B

PC 204

115 THS 3

PC 204

---

312 12V+

SP 10

---

620 GND

SP 11

---

026 Sig.

PC 204

311 12V+

SP 10

---

619 GND

SP 11

---

025 Sig.

PC 204

PC 438 SFS 2

PC 439 SFS 1

PC 440 Option

---

2957

SP 13

---

2958

SP 13

---

508

SP 14

---

509

SP 14

---

7 8

ESR 5000

433

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

PC 470 PS

3102

SP 10

---

055 FWD

PC 205

002 5th Selec

PC 203

003 SEl. Direct

PC 205

399 Horn

PC 206

051 Tilt up

PC 206

052 Tilt down

PC 205

29147

SP 18

---

27148

SP 18

---

054 Cold store

PC 474

---

301

SP 6

---

101

PC 205

601

SP 7

---

102

PC 205

104

PC 205

053 Heat Sig

PC 474

2917 Seat Ht.

SP 4

---

001 Seat Sig.

PC 205

---

29143

PC 473

009

PC 205

5936

Relay K2

209

SP 19

---

210

SP 19

---

515

GND B-

SP 21

29143

PC 472

572

SP 5

---

PC 471 POT

PC 472 Brake Opt.

PC 473 Working Lights

ESR 5000

434

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

JC 473 Keyless

29140

Relay K1

29141

Relay K1

PC 474 CAN OUT Card

904 / 910

PC 204 / 201

23 / 23

2970

SP 18

---

909 / 911

PC 204 / 201

15 / 15

540

SP 15

---

541

SP 15

---

053 Heat Seat

PC 471

054 Cold store

PC 470

200

Screw M10 S1

Ring-T

201 / 208

EDS / SP 19

Ring-T / ---

203 / 204

Screw M10 S2/Fu box

Ring-T / 3

2926

SP 2

---

204

Fuse Box

2903

PC 402

205

Screw M10 B+

Ring-T

2936

PC 204

206

Screw M10 S1

Ring-T

2959 / 2996

PC 433 / SP 18

207

Screw M10 S1

Ring-T

2960 / 2997

PC 421 / SP 20

3 / ---

Crimp

201

Fuse Box

Crimp

2951

PC 420

Crimp

2902

PC 402

Crimp

5902 / 5928

PC 205 / PC 402

24 / 10

2924

SP 1

---

927

K 13

8 Fuse Box

EDS ED1 Relay Options K 12

ESR 5000

435

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

Relay Options K 13

2998

SP 20

---

927

K 12

502

SP 5

---

2954

SP 13

---

Crimp

2928

PC 402

Crimp

5901

PC 402

Crimp

2915

SP 4

---

Crimp

007

PC 205

Crimp

2916

SP 4

---

Crimp

008

PC 205

Screw M10 S1

Ring-T

200 / 206 / 207

Fuse Box

1/5/6

Screw M10 S2

Ring-T

203 / 205 / 2923

FuBox / FuBox / PC 402

2/4/2

Screw M8 B-

Ring-T

500

SP 5

---

Screw M8 B-

Ring-T

569 / 570

SP 14 / SP 15

---

Screw M8 B+

Ring-T

29127

Screw M10 FU13 (S1)

Ring-T

Screw M10 FU

Ring-T

29127

Screw M8 B+

Ring-T

Screw M6 SDM

Ring-T

29128

Screw M5 B+

Ring-T

Screw M5 B+

Ring-T

29128

Screw M6 SDM (B+) Ring-T

Screw M8 B-

Ring-T

566

Screw M6 SDM (B-)

Ring-T

Screw M6 SDM

Ring-T

566

Screw M8 B-

Ring-T

Screw M6 SDM

Ring-T

801

Screw M6 (U)

Ring-T

Screw M6 SDM

Ring-T

802

Screw M6 (V)

Ring-T

Screw M6 SDM

Ring-T

803

Screw M6 (W)

Ring-T

Screw M6 U

Ring-T

801

Screw M6 (SDM U)

Ring-T

Screw M6 V

Ring-T

802

Screw M6 (SDM V)

Ring-T

Screw M6 W

Ring-T

803

Screw M6 (SDM W)

Ring-T

Relay Keyless K1

29140

JC 473

2999

SP 20

---

932

29141

JC 473

Horn BFS BPS

ESR 5000

436

SCHEMATIC DIAGRAMS Main Harness, ESR 5000S, Crown Motor From connector

Pin number

Wire number

To connector / neutral point

Pin number

Relay Keyless K2

30 86

932

5936

PC 472

ESR 5000

437

SCHEMATIC DIAGRAMS Harness, ESR 5000 Armrest

Harness, ESR 5000 Armrest JC 470 Pin Wire No. 1 3102 +12V Disp. 2 055 FWD Switch 3 5th Selected 4 003 Sel. switch 5 399 Horn 6 051 Tilt up / POT 4 7 052 Tilt Down 8 29147 Heat Seat + 9 10 11 12

PC 406 Pin

Wire No.

3102 +12V Disp.

055 FWD Switch

5th Selected

003 Sel. switch

399 Horn

052 Tilt Down

051 Tilt up / POT 4

29147 Heated Seat +

PC 428 Pin

JC 471 Pin Wire No. 1 301 +12V 2 101 Pot 1 3 601 GND 12V 4 102 Pot 2 5 104 Pot 5 6 053 Heat Seat 7 2917 Seat +48V 8 001 Seat Signal 9 10 11 12

Wire No.

301 +12V

101 Pot 1

601 GND 12V

102 Pot 2

104 Pot 5

053 Heat Seat GND

001 Seat Signal

2917 Seat +

from Connector JC 470 PS

from Connector JC 471 POT

Pin no. 1 2 3 4 5 6 7 8 9 10 11 12

Colour to Connector white PC 406 brown PC 406 yellow PC 406 green PC 406 pink PC 406 blue PC 406 black PC 406 yellow-brown PC 406 N.C. N.C. N.C. N.C.

Pin no. 1 2 3 4 5 7 6 8

Colour to Connector red PC 428 violet PC 428 grey PC 428 brown-green PC 428 white-green PC 428 white-yellow PC 428 grey-pink PC 428 red-blue PC 428 N.C. N.C. N.C. N.C.

Pin no. 1 2 3 4 5 6 7 8

822619-2F

Fig. 169 Harness, ESR 5000 armrest

ESR 5000

438

SCHEMATIC DIAGRAMS Harness, ESR 5000 Armrest Connector table Connector

Part No. Housing

Part No. Contact pins

PC 470

792880-006

792882

PC 471

792880-006

792882

PC 428

803450-008

116858

PC 406

803450-008

116858

ESR 5000

439

SCHEMATIC DIAGRAMS Harness, ESR 5000S Armrest

Harness, ESR 5000S Armrest JC 601 Reach Carriage

1 1 2 1 3 1 4 1 5 1 6 7 8 1 9 1 10 1 11 1 12 1

PC 801 Switch Side

BLACK

RED-BLACK

RED

WHITE-BLACK

BLUE

2 1 SP16

ORANGE

ORANGE RED RED

GREEN

SPLINE 16

GREEN

RED

RED-BLACK / JC601-2 RED / PC801-2

RED

RED / PC801-6

WHITE

RED / PC801-7

ORANGE-BLACK

WHITE ORANGE-BLACK GREEN-BLACK

GREEN-BLACK

JC 601 Pin no. 1 2 3 4 5 6 7 8 9 10 11 12

2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12

PC 801 Pin no. 1 2 3 4 5 6 7 8 9 10 11 12

Discription SVT + BV FLS / LCS GND - 12 V SVS

SV5 + 12 V LS Coldstore R8 Coldstore R8

Discription SVT + BV FLS / LCS GND - 12 V SVS + BV + BV SV5 + 12 V LS Coldstore R8 Coldstore R8 823618-2A

Harness, ESR 5000S Armrest

Fig. 170 Harness, ESR 5000S Armrest

ESR 5000

440

SCHEMATIC DIAGRAMS Harness, ESR 5000S Armrest Connector table Connector

Part No. Housing

Part No. Contact pins

PC 470

792880-006

792882

PC 471

792880-006

792882

PC 447

803450-008

116858

PC 448

803450-008

116858

ESR 5000

441

Notes:

442

Wire no. 1 3 1 2 1 1 2 2 2 2 2 2 2 1 3 2 2 1 3 3 --------------------3 3 1 1 1 1 3 3 3 3

Coldst. R 9 Coldst. R 9 Coldst. R 10 Coldst. R 10

Discription SVT HGT(R)S FLS / LCS RES 2 SVS + 12 V GND - 12 V PVL SVH PVRT PVAR PVAL RES 1 + BV GND -BV PVRE PLS SV5 ------------------------ECR6 Ch. A ECR6 Ch. B LS Coldst. R 8 Coldst. R 8

SP14 + BV

2942

2941

2938

Colour green-black blue white-black black blue orange red-black white-black red blue orange green white red orange-black orange-black green-black white white-black orange --------------------green-black red-black orange-black black green red-black green white red black

SP15 +12V

10 20 30 40

9 19 29 39

8 18 28 38

7 17 27 37

6 16 26 36

5 15 25 35

4 14 24 34

3 13 23 33

2 12 22 32

1 11 21 31

JC 422

+ 12 V (orange)

Fig. 171 Wire Harness: Terminal to Reach Carriage

+ BV (red)

STARPOINTS SP:

Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

JC 422

Wire Harness: Terminal to Reach Carriage

314

396

313

GND 12 V (red-black)

SP38 GND 12V -

SP15 +12V

ESR 5000

667

666

665

SP38 GND 12V -

SP14 + BV

7 1 8 2 9 3 10 4 11 5 12 6

JC 600

and R 10 ECR 5 (Height enc.) to pin 11 & 12

COLDSTORE!

---------

---

* *---

Colour 1 2 3 4 1 2 -------------

Discription GND - 12 V ECR5 Ch. A + 12 V ECR5 Ch. B + BV HGT(R)S ----Coldst. R 9 Coldst. R 9 Coldst. R 10 Coldst. R 10 Wire no.

Pin no. 1 2 3 4 5 6 7 8 9 10 11 12

Wire no. 666 --396 --2941 ---------------

Wire no. --665 ----------------2942 314

Wire no. --2938 --667 --------313 -------

Cable C63 and C62 must be insert into a 12 way DEUTSCH Pin-housing!

Pin no. 1 2 3 4 5 6 7 8 9 10 11 12

PC 600

Pin no. 1 2 3 4 5 6 7 8 9 10 11 12

PC 604

Pin no. 1 2 3 4 5 6 7 8 9 10 11 12

JC 600

1 7 2 8 3 9 4 10 5 11 6 12

PC 600

1 7 2 8 3 9 4 10 5 11 6 12

PC 604

1 7 2 8 3 9 4 10 5 11 6 12

PC 601

Colour blue green-black orange red-black red-white blue white-black orange green white red black

Colour black blue white-black red orange-black orange green white blue green-black red-white orange

Colour green-black red-white white-black blue blue red-black --white orange orange-black black green

Pin 11 & 12 are reserved for R 8 (LS / FKS)

Discription Wire no. GND - 12 V 1 ECR5 Ch. A 2 + 12 V 3 4 ECR5 Ch. B Insert the cable into JC 600

JC 603

Pin no. 1 2

Discription + BV HGT(R)S

822740-2H

* Insert the cable into JC 600

Wire no. 1 2

CABLE C62 HGT(R)S 823871

Pin no. 1 2 3 4 JC 602

443

COLDSTORE!

CABLE C63 ECR5 823870

Discription GND - 12 V ECR5 Ch. A + 12 V ECR5 Ch. B + BV HGT(R)S ----Coldst. R 9 Coldst. R 9 Coldst. R 10 Coldst. R 10

Discription RES 2 GND - 12 V PVL SVH PVRE PVAR PVAL RES 1 PVRT PLS + BV + 12 V

Discription SVT + BV FLS / LCS GND - 12 V SVS ----SV5 + 12 V LS Coldst. R 8 Coldst. R 8

Wire Harness: Terminal to Reach Carriage

SCHEMATIC DIAGRAMS

444

Notes:

SCHEMATIC DIAGRAMS Cable Assy Truck, Reach Carriage

Cable Assy Truck, Reach Carriage Replacement Parts Item no.

Part no.

Description

792881-006

Socket Housing

792883

Socket Crimp

792882

Pin Crimp

793222

Blanking Pin

793217-018

Butt Connector

793091-006

Anti-Backout

792880-006

Pin Housing

822740

Harness, complete

ESR 5000

445

Notes:

446

Wire no. 028 621 5921 5922 5923 5925 5926 027 5924 029 2943 315

Discription RES 2 GND - 12 V PVL SVH PVRE PVAR PVAL RES 1 PVRT PLS + BV + 12 V

Colour black blue white-green white-green white-green white-green white-green black white-green black red-white orange

7 8 9 10 11 12

Fig. 172 Cable Assy Valve Block, Mast

Pin no. 1 2 3 4 5 6 7 8 9 10 11 12

JC 604

1 2 3 4 5 6

STARPOINTS SP:

Cable Assy Valve Block, Mast

2943

SP16

SP16 +BV

2944 2945 2946 2947 2948 2949 315

ESR 5000

SP17 +12V

Pin no. 1 2

PVAR

PVAL

PC 811

Pin no. 1 2

Wire no. 2947 5926

PC 809

Pin no. 1 2

PVRT

PVRE

PC 810 Wire no. 2945 5923

Wire no. 2948 5925

Wire no. 2946 5924

SVH

PVL

Pin no. 1 2

Wire no. 5921 2944 5922

PC 808

Pin no. 1 2 3

PC 807

Wire no. 316 622 027

317

316 621

Discription + 12 V GND - 12 V RES 1

Colour orange blue black

SP18 GND -12V

SP17 SP18

Pin no. A B C

PC 805

623

622

Pin no. 1 2 3 4

PC 806

Discription + 12 V GND - 12 V RES 2 ---

PLS

Wire no. 317 623 028 ---

PC 806

PC 805

Colour orange blue black ---

812327-2I

447

Cable Assy Valve Block, Mast

SCHEMATIC DIAGRAMS

448

Notes:

SCHEMATIC DIAGRAMS Cable Assy Valve Block, Mast

Cable Assy Valve Block, Mast Replacement Parts Item no.

Part no.

Description

792880-006

Pin Housing

792881-002

Socket Housing

793091-002

Anti-Backout

792881-003

Socket Housing

793091-003

Anti-Backout

792883

Socket Crimp

792882

Pin Crimp

793222

Blanking Pin

814156-001

Housing

814156-002

Housing

814164

Housing

793217-022

Cromp Faston Female

793217-027

Insulation Sleeve

793090-006

Anti-Backout

812327

Harness, complete

ESR 5000

449

SCHEMATIC DIAGRAMS Fork Carriage Harness Extended, ESR 5000, Mast

Fork Carriage Harness Extended, ESR 5000, Mast

2 2

black white

115

316

616

SP20

Description SVT + BV FLS / LCS GND - 12 V SVS + BV + BV SV5 + 12 V LS Coldstore R8 Coldstore R8

Colour green-black red-white white-black red-black --------orange brown -----

2945 2946 5912 5913 115 315 316 616 red black

Fig. 173 Fork Carriage Harness Extended, ESR 5000, Mast

ESR 5000

450

SP21

Wire No. 2944

Wire no. 5912 2944 --616 5913 ------315 115 -----

1 2 3 4 PC 805

SP19

1 2 3

5913

3 3 2946

3 3 5912

LS D

FKS

JC 801 Pin no. 1 2 3 4 5 6 7 8 9 10 11 12

SVS B 1 2 PC 804

2945

Fork carriage JC 801 1 1 5912 2 1 2944 3 4 1 616 5 1 5913 6 7 8 9 1 315 115 10 1 11 12 A

SVT B 1 2 PC 803

Connection JC 801-2 SPLINE 19 SPLINE 19 PC 803-1 SPLINE 19 PC 804-1 JC 801-1 PC 803-2 JC 801-5 PC 804-2 JC 801-10 PC 805-4 JC 801-9 SPLINE 21 PC 805-2 SPLINE 20 JC 801-1 PC 805-1 FKS SPLINE 20 FKS SPLINE 21

SPLINE 19 2944 / JC 801-2 2945 / PC 803-1 2946 / PC 804-1

SPLINE 20 FKS / white 316 / PC 805-2

SPLINE 21 FKS / black 315 / PC 801-9

822755-1_2F_1

SCHEMATIC DIAGRAMS Fork Carriage Harness Extended, ESR 5000, Mast Plug connector housing Type Housing Part no.

Description

792880-006

Housing

793090-006

Anti-Backout

792881-003

Housing

793091-003

Anti-Backout

793222

Pin Sealing

814156-002

Housing

823252-001

Seal

823353

Rubber Grommet

802836

Limit Switch

JC 801 PC 805

PC 803, PC 804

FKS

Contact pins Item No.

Part no.

792882

792883

823251-001

Replacement Parts Part no.

Description

822755

Harness, complete

ESR 5000

451

SCHEMATIC DIAGRAMS Fork Carriage Harness Standard, ESR 5000, Mast

Fork Carriage Harness Standard, ESR 5000, Mast

5913

3 3 2946

3 3 5912

SVS B 1 2 PC 804

2945

SVT B 1 2 PC 803

Fork Carriage JC 801 1 1 5912 2 1 2944 3 4 5 1 5913 6 7 8 9 10 11 12 A

JC 801 Pin no. 1 2 5

Wire no. 5912 2944 5913

Description SVT + BV SVS

Colour green-black red-white blue

Wire No.

Connection

SPLINE 19

2944

JC 801-2 SPLINE 19

2944 / JC 801-2 2945 / PC 803-1

2945

SPLINE 19 PC 803-1

2946 / PC 804-1

2946

SPLINE 19 PC 804-1

5912

JC 801-1 PC 803-2

5913

JC 801-5 PC 804-2 822754-2E

Fig. 174 Fork Carriage Harness Standard, ESR 5000, Mast

ESR 5000

452

SCHEMATIC DIAGRAMS Fork Carriage Harness Standard, ESR 5000, Mast Plug connector housing Type Housing Part no.

Description

792880-006

Housing

793090-006

Anti-Backout

793222

Pin Sealing

814156-002

Housing

823252-001

Seal

823353

Rubber Grommet

JC 801

PC 803, PC 804

Contact pins Item No.

Part no.

792882

823251-001

Replacement Parts Part no.

Description

822754

Harness, complete

ESR 5000

453

SCHEMATIC DIAGRAMS Fork Carriage Switch Assy, ESR 5000, Mast

Fork Carriage Switch Assy, ESR 5000, Mast FLS / LCS

BLUE BROWN

1 1

connect to connector JC 801-6 (822754 / 822755) connect to connector JC 801-3 (822754 / 822755)

82275

Fig. 175 Fork Carriage Switch Assy, ESR 5000, Mast

Contact pins Item No.

Part no.

792882

Replacement Parts Part no.

Description

822756

Harness, complete

ESR 5000

454

SCHEMATIC DIAGRAMS Fork Carriage, 5th Function, ESR 5000, Mast

Fork Carriage, 5th Function, ESR 5000, Mast PC 806

1 1

2947

59144

5914 2947 5914

3 1 3 2

SV5 B

connect to connector JC 801-7 connect to connector JC 801-8

822757-2D

Fig. 176 Fork Carriage, 5th Function, ESR 5000, Mast

Plug connector housing Type Housing Part no.

Description

814156-002

Housing

823252-001

Seal

823353

Rubber Grommet

PC 806

Contact pins Item No.

Part no.

792882

823251-001

Replacement Parts Part no.

Description

822757

Harness, complete

ESR 5000

455

SCHEMATIC DIAGRAMS Fork Carriage, LS Bridge, ESR 5000, Mast

Fork Carriage, LS Bridge, ESR 5000, Mast 617

2 3

JC 805 822758-2C

Fig. 177 Fork Carriage, LS Bridge, ESR 5000, Mast

Plug connector housing Type Housing Part no.

Description

792880-003

Housing

793090-003

Anti-Backout

793222

Pin Sealing

JC 805

Contact pins Item No.

Part no.

792882

Replacement Parts Part no.

Description

822758

Harness, complete

ESR 5000

456

SCHEMATIC DIAGRAMS FKS Heater Assembly, Mast

FKS Heater Assembly, Mast 1 1

2948 548

823547-2A

Fig. 178 FKS Heater Assembly, Mast

Contact pins Item No.

Part no.

792882

Replacement Parts Item no.

Description

823547

Harness, complete

ESR 5000

457

SCHEMATIC DIAGRAMS Cable Mast 10 Core Assy, ESR 5000, Mast

Cable Mast 10 Core Assy, ESR 5000, Mast JC 601 Reach Carriage

1 1 2 1 3 1 4 1 5 1 6 7 8 1 9 1 10 1 11 1 12 1

PC 801 Switch Side

BLACK

RED-BLACK

RED

WHITE-BLACK

BLUE

2 1 SP16

ORANGE

ORANGE RED RED

GREEN

SPLINE 16

GREEN

RED

RED-BLACK / JC601-2 RED / PC801-2

RED

RED / PC801-6

WHITE

RED / PC801-7

ORANGE-BLACK

WHITE ORANGE-BLACK GREEN-BLACK

GREEN-BLACK

2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 B

JC 601 Pin no. 1 2 3 4 5 6 7 8 9 10 11 12

PC 801 Pin no. 1 2 3 4 5 6 7 8 9 10 11 12

Discription SVT + BV FLS / LCS GND - 12 V SVS

SV5 + 12 V LS Coldstore R8 Coldstore R8

Discription SVT + BV FLS / LCS GND - 12 V SVS + BV + BV SV5 + 12 V LS Coldstore R8 Coldstore R8 823618-2A

Fig. 179 Cable Mast 10 Core Assy, ESR 5000, Mast

Plug connector housing

Contact pins

Type Housing Part no.

Description

Item No.

Part no.

792880-006

Housing

792882

793090-006

Anti-Backout

792883

792881-006

Housing

793091-006

Anti-Backout

793222

Pin Sealing

793217-018

Butt Connector

JC 601 PC 801

Replacement Parts Item no.

Description

823618

Harness, complete

ESR 5000

458

SCHEMATIC DIAGRAMS Cable Mast 6 Core Assy, ESR 5000, Mast

Cable Mast 6 Core Assy, ESR 5000, Mast JC 601 Reach Carriage

1 1 2 1 3 1 4 1 5 1 6 7 8 1 9 10 11 12

PC 801 Switch Side

BLACK 1

BLACK 2

RED

BLACK 3

BLACK 4

2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 9 10 11 12

BLACK 4

2 SP16

BLACK 5

BLACK 5 RED RED

SPLINE 16

BLACK 6

BLACK 2 / JC601-2 RED / PC801-2 RED / PC801-6 RED / PC801-7

JC 601 Pin no. 1 2 3 4 5 6 7 8

PC 801 Discription SVT + BV FLS / LCS

Pin no. 1 2 3 4 5 6 7 8

SVS

SV5

Discription SVT + BV FLS / LCS SVS + BV + BV SV5 823619-2A

Fig. 180 Cable Mast 6 Core Assy, ESR 5000, Mast

Plug connector housing

Ersatzteile

Type Housing Part no.

Description

Item no.

Description

792880-006

Housing

823619

Harness, complete

793090-006

Anti-Backout

792881-006

Housing

793091-006

Anti-Backout

JC 601 PC 801

Contact pins Item No.

Part no.

792882

792883

ESR 5000

459

SCHEMATIC DIAGRAMS VT Camera, Reach Carriage to Chassis, Option

VT Camera, Reach Carriage to Chassis, Option JC 453 Chassis 1 1 2 1 3 1

PC 454 Reach Carriage WHITE (C1)

WHITE (C1)

screen (C1 & C2)

YELLOW (C2)

2 1 2 2 2 3 B 823588-2B

Fig. 181 Cable VT Camera - Reach Carriage to Chassis, Option

Plug connector housing Type Housing Part no.

Description

808123-002

Housing

793090-002

Anti-Backout

808124-002

Housing

793091-006

Anti-Backout

JC 402 PC 403

Contact pins Item No.

Part no.

792882

792883

Replacement Parts Part no.

Description

823588

Harness, complete

ESR 5000

460

SCHEMATIC DIAGRAMS VT Camera, DC / DC to Control Box, Option

VT Camera, DC / DC to Control Box, Option PC 400 Control Box VT 1 1 2 3 1 4 1

JC 401 Power Supply

WHITE WHITE

BROWN WHITE WHITE

BROWN

1 2 2 3 2 4 B

A PC 400 Pin no. 1 2 3 4

JC 401 Wire Colour white

Description + 12 V

white brown

+ 12 V GND

Pin no. 1 2 3 4

Wire Colour

Description

brown

GND

white

+ 12 V 823612-2C

Fig. 182 VT Camera, DC / DC to Control Box, Option

Plug connector housing Type Housing Part no.

Description

PC 400

803450-006

Molex Receptacle

PC 401

808124-003

Housing

793091-003

Anti-Backout

793222

Pin Sealing

052063-002

Shrinking Tube

Contact pins Item No.

Part no.

116858

792883

Replacement Parts Part no.

Description

823612

Harness, complete

ESR 5000

461

SCHEMATIC DIAGRAMS VT Camera, Mast, Option

VT Camera, Mast, Option JC 454 1 1 2 1 3 1

PC 455 WHITE

WHITE screen C1 & C2

screen C1 & C2 YELLOW

YELLOW

2 1 2 2 2 3 B 823620-2D

Fig. 183 VT Camera, Mast, Option

Assembly Remark:

Plug connector housing Type Housing Part no.

Description

808123-002

Housing

793090-002

Anti-Backout

808124-002

Housing

793091-002

Anti-Backout

796412

Cable Mast

Part no.

Mast height (collapsed)

823620-001

2022 mm

823620-002

2172 mm

823620-003

2322 mm

823620-004

2472 mm

823620-005

2572 mm

823620-006

2772 mm

823620-007

2922 mm

823620-008

3042 mm

Item No.

Part no.

823620-009

3192 mm

792882

823620-010

3347 mm

792883

823620-011

3492 mm

823620-012

3692 mm

823620-013

3842 mm

823620-014

3952 mm

823620-015

4252 mm

823620-016

4452 mm

823620-091

4419 mm

823620-092

4719 mm

823620-093

4919 mm

823620-094

5106 mm

PC 455

Contact pins

Replacement Parts Part no.

Description

823620

Harness, complete

ESR 5000

462

JC 454

SCHEMATIC DIAGRAMS VT Camera, Box to Chassis, Option

VT Camera, Box to Chassis, Option JC 454 Control Box

PC 455 Chassis

1 1 2 1 3 1 4 1

YELLOW BRAID WHITE 1 WHITE

4-pin mini DIN

Pin no. A B C

Wire Colour yellow braid white 1 white

Description + 12 V GND Video Signal

2 A 2 B 2 C B

823649-2C

Fig. 184 VT Camera, Box to Chassis, Option

Plug connector housing Type Housing Part no.

Description

792881-002

Housing

793091-002

Anti-Backout

PC 401

Contact pins Item No.

Part no.

792883

Replacement Parts Part no.

Description

823649

Harness, complete

ESR 5000

463

SCHEMATIC DIAGRAMS Motec Camera, Supply to b/w Monitor, Option

Motec Camera, Supply to b/w Monitor, Option JC 443 JC 444 Power Supply 1 2 1 3 4 1

PC 444 M55-K Monitor b/w BROWN

WHITE

BROWN

WHITE

2 1 2 3 2 4 B

A JC 443 / JC 444 Pin no. 1 2 3 4

PC 444

Wire Colour

Description

white

GND

brown

+ 12/24 V

Pin no. 1 2 3 4

Wire Colour brown

Description + 12/24 V

white

GND

823613-2C

Fig. 185 Motec Camera, Supply to b/w Monitor, Option

Plug connector housing Type Housing Part no.

Description

792880-003

Housing

793090-003

Anti-Backout

803450-006

Housing

819279-003

Seal

793222

Pin Sealing

796174

Cable

JC 443 PC 444

Contact pins Item No.

Part no.

792882

116858

Replacement Parts Part no.

Description

823613

Harness, complete

ESR 5000

464

SCHEMATIC DIAGRAMS Motec Camera, Component to Reach, Option

Motec Camera, Component to Reach, Option JC 453 Comp. 1 1 2 1 3 1 4 1

PC 454 Reach WHITE

WHITE

BRAID WHITE

YELLOW

BLACK

Pin no. 1 2 3 4

Wire Colour braid white white yellow black

Description VID SH VCC GND

2 1 2 2 2 3 2 4 B

823614-2D

Fig. 186 Motec Camera, Component to Reach, Option

Plug connector housing Type Housing Part no.

Description

808123-003

Housing

793090-003

Anti-Backout

808124-003

Housing

793091-003

Anti-Backout

JC 453 PC 454

Contact pins Item No.

Part no.

792882

792883

Replacement Parts Item no.

Description

823614

Harness, complete

ESR 5000

465

SCHEMATIC DIAGRAMS Motec Camera, Supply to Display Box, Option

Motec Camera, Supply to Display Box, Option JC 443 JC 444 Power Supply

BROWN BROWN

1 2 1 3 4 1

WHITE

BROWN

PC 444 Display 3 1 2 2 3 2 4 5 6 B

JC 443 , JC 444 Pin no. 1 2 3 4

PC 444

Wire Colour

Description

white

GND

brown

+ 12 V

Pin no. 1 2 3 4 5 6

Wire Colour brown white

Description + 12 V GND

brown

+ 12 V SEL 1

823616-2D

Fig. 187 Motec Camera, Supply to Display Box, Option

Plug connector housing Type Housing Part no.

Description

792881-003

Housing

793091-003

Anti-Backout

803450-007

Socket

793222

Pin Sealing

796174

Cable

JC 443 PC 444

Contact pins Item No.

Part no.

792883

116858

Replacement Parts Part no.

Description

823616

Harness, complete

ESR 5000

466

SCHEMATIC DIAGRAMS Motec Camera, Fork Camera, Option

Motec Camera, Fork Camera, Option JC 455 Mast 1 1 2 1 3 1 4 1

Fork Camera MC 925C TRANSPARENT

TRANSPARENT

BRAID WHITE

RED

BRAID WHITE

Pin no. 1 2 3 4

Wire Colour transparent braid white red braid white

2 1 2 2 2 3 2 4

Description VID SH VCC GND

823617-2D

Fig. 188 Motec Camera, Fork Camera, Option

Plug connector housing Type Housing Part no.

Description

808124-003

Housing

793091-003

Anti-Backout

PC 455

Contact pins Item No.

Part no.

792883

Replacement Parts Part no.

Description

823617

Harness, complete

ESR 5000

467

SCHEMATIC DIAGRAMS Motec Camera, Inner Mast, Option

Motec Camera, Inner Mast, Option JC 454 WHITE 1 1 BRAID WHITE 2 1 YELLOW 3 1 BLACK 4 1

WHITE

BRAID WHITE YELLOW BLACK

PC 455 1 1 1 2 1 3 1 4 B

Pin no. 1 2 3 4

Description VID SH VCC GND

Wire Colour white braid white yellow black

823650-2B

Fig. 189 Motec Camera, Inner Mast, Option

Assembly Remark:

Plug connector housing Type Housing Part no.

Description

792880-003

Housing

793090-003

Anti-Backout

792881-003

Housing

793091-003

Anti-Backout

Part no.

Mast height (collapsed)

823650-001

2022 mm

823650-002

2172 mm

823650-003

2322 mm

823650-004

2472 mm

823650-005

2572 mm

823650-006

2772 mm

823650-007

2922 mm

Item No.

Part no.

823650-008

3042 mm

792882

823650-009

3192 mm

792883

823650-010

3347 mm

823650-011

3492 mm

823650-012

3692 mm

823650-013

3842 mm

823650-014

3952 mm

823650-015

4252 mm

823650-016

4452 mm

823650-091

4419 mm

823650-092

4719 mm

823650-093

4919 mm

823650-094

5106 mm

PC 455

Contact pins

Replacement Parts Part no.

Description

823650

Harness, complete

ESR 5000

468

JC 454

SCHEMATIC DIAGRAMS Motec Camera, Reach to Display Box, Option

Motec Camera, Reach to Display Box, Option Connection: Monitor 1 1 2 1 3 1 4 1

PC 453

transparent

braid white

red

braid white

2 2 2 2

1 2 3 4

Connection JC 453 from 814407

B Pin no. 1 2 3 4

Wire Colour transparent braid white red braid white

Description VID SH VCC GND

Pin no. 1 2 3 4

Wire Colour transparent braid white red braid white

Description VID SH VCC GND 824680-2B

Fig. 190 Motec Camera, Reach to Display Box, Option

Plug connector housing Type Housing Part no.

Description

792881-003

Housing

793091-003

Anti-Backout

814406-001

Cable with plug

PC 453

Contact pins Item No.

Part no.

792883

Replacement Parts Part no.

Description

824680

Harness, complete

ESR 5000

469

SCHEMATIC DIAGRAMS Motec Camera, Mast (Fork Camera), Option

Motec Camera, Mast (Fork Camera), Option JC 454 1 1 2 1 3 1 4 1

JC 455 WHITE

WHITE

BRAID WHITE

YELLOW

BLACK

Pin no. 1 2 3 4

Wire Colour white braid white yellow black

Description VID SH VCC GND

1 1 1 2 1 3 1 4 B

824702-2B

Fig. 191 Motec Camera, Mast (Fork Camera), Option

Assembly Remark:

Plug connector housing

Part no.

Mast height (collapsed)

Type Housing Part no.

Description

823650-001

2022 mm

808123-003

Housing

823650-002

2172 mm

793090-003

Anti-Backout

823650-003

2322 mm

808123-003

Housing

823650-004

2472 mm

793090-003

Anti-Backout

823650-005

2572 mm

796412

Cable

823650-006

2772 mm

052063-002

Shrinking Tube

823650-007

2922 mm

823650-008

3042 mm

823650-009

3192 mm

Item No.

Part no.

823650-010

3347 mm

792882

823650-011

3492 mm

823650-012

3692 mm

823650-013

3842 mm

823650-014

3952 mm

823650-015

4252 mm

823650-016

4452 mm

823650-091

4419 mm

823650-092

4719 mm

823650-093

4919 mm

823650-094

5106 mm

JC 455

Contact pins

Replacement Parts Part no.

Description

824702

Harness, complete

ESR 5000

470

JC 454

550

551

5910 Heated Seat

5908 Coldstore 2

5911

554

100

SP 22

100

5913

SP 20

2976

PC 480

12 11 10 9 8 7 6 5 4 3 2 1

2 1

Fig. 192 Cold Store Harness, ESR 5000, Option

2 1

2975

PC 483

920

2971

R1 A ACS / ACC (double R)

Option Plug

1 2 3 4 5 6 7 8

554

921 CAN H

SP 25 SP 21

2972

Socket Pin

1 1

5916 2976

1 2

LS / FKS R5 2979 1 Insert into PIN 34 PC 422 (Main Loom) 5918 1 Insert into PIN 35 PC 422 (Main Loom)

ESR 5 Height Encoder R6 2980 1 Insert into PIN 39 PC 422 (Main Loom) 5917 1 Insert into PIN 40 PC 422 (Main Loom)

M 422 Mast

ESR 5000

PC 481

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

SP 23

920

JC 474

553

SP 24 5910

5914

BLS 5909

2973

EDS A 1 2 R4

552

Key (double R) A 1 2 R3

921

2977 5908

Cold Store Harness, ESR 5000, Option

550

Wire No. Connection 2971 JC 474-2 SP 20 2972 PC 481-16 SP 20 PC 481-13 2973 SP 20 2974 SP 20 SP 21 2975 SP 21 R 1-2 2976 SP 21 R 3-2 2977 SP 21 R 4-2 2978 SP 21 R 2-2 2979 SP 21 Socket Crimp 2980 SP 21 Socket Crimp 550 JC 474-4 PC 481-1 551 JC 474-5 SP 22 552 SP 22 PC 481-2 553 SP 22 PC 481-6 554 PC 480-6 PC 483-2 PC 481-3 5908 JC 474-7 5909 PC 481-4 SP 23 PC 481-18 5910 JC 474-6 5911 SP 23 R 1-1 5912 SP 23 SP 24 5913 SP 24 R 3-1 5914 SP 24 R 4-1 5915 SP 23 SP 25 SP 25 5916 R 2-1 SP 25 5917 Socket Crimp SP 25 5918 Socket Crimp

Wire No. Connection 920 JC 474-3 PC 481-9 921 JC 474-1 PC 481-10 100 PC 480-5 PC 483-1

824316-2C

SPLINE 25 5915 5916 5917 5918

SPLINE 24 5912 5913 5914 5915

SPLINE 23 5909 5911 5912 5915

SPLINE 22 551 552 553

SPLINE 21 2974 2975 2976 2977 2978 2979 2980

SPLINE 20 2971 2972 2973 2974

471

Cold Store Harness, ESR 5000, Option

SCHEMATIC DIAGRAMS

472

Notes:

SCHEMATIC DIAGRAMS Cold Store Harness, ESR 5000, Option

Cold Store Harness, ESR 5000, Option Plug connector housing Type Housing Part no.

Description

792881-001

Housing

793091-001

Anti-Backout

792880-005

Housing

793090-005

Anti-Backout

803450-009

Housing

819279-006

Seal

803450-047

Housing

819279-011

Seal

062755-001

Housing

062798-002

Seal

B C D

R1, R2, R3, R4 JC 474 JC 480 JC 481

PC 483

Contact pins Type

Part no.

792883

116858

792882

062797-006

Replacement Parts Part no.

Description

824316

Harness, complete

ESR 5000

473

SCHEMATIC DIAGRAMS Cold Store, Armrest Harness, ESR 5000, Option

Cold Store, Armrest Harness, ESR 5000, Option PC 412 1 1 2 1 3 1 4 1 5 1 6 1

5970

29170

170

5970

170

2 2

plug in PC 470-10 plug in PC 470-11

171 171 29170

Wire No. 29170

5970 170 171

Connection Socket Crimp PC 412-6 Socket Crimp PC 412-1 PC 412-2 PC 412-3 PC 412-4 PC 412-5

To Main Harness PC 470

824317-2A

Fig. 193 Cold Store, Armrest, ESR 5000, Option

Plug connector housing Type Housing Part no.

Description

803450-007

Housing

819279-003

Seal

PC 412

Contact pins Type

Part no.

116858

792882

Replacement Parts Part no.

Description

824317

Harness, complete

ESR 5000

474

SCHEMATIC DIAGRAMS Cold Store, Armrest Harness, ESR 5000S, Option

Cold Store, Armrest Harness, ESR 5000S, Option PC 412 1 1 2 1 3 1 4 1 5 1 6 1

5970

29170

170

5970

170

2 2

Insert into PIN 10 Insert into PIN 11

171 171 29170

Wire No. 29170

5970 170 171

Connection Socket Crimp PC 412-6 Socket Crimp PC 412-1 PC 412-2 PC 412-3 PC 412-4 PC 412-5

To Main Harness PC 470

824372-2A

Fig. 194 Cold Store, Armrest, ESR 5000S, Option

Plug connector housing Type Housing Part no.

Description

803450-007

Housing

819279-003

Seal

PC 412

Contact pins Type

Part no.

116858

792882

Replacement Parts Part no.

Description

824372

Harness, complete

ESR 5000

475

Notes:

476

Fig. 195 Beacon Loom, Option

To Main Harness PC 433 A

1 2 3 4

JC 433

5940

2940

B PC 434

1 2

5940

Beacon Loom, Option

5941

ESR 5000

2 2

2940 5941

1 2

PC 435

824318-2B

477

Beacon Loom, Option

SCHEMATIC DIAGRAMS

478

Notes:

SCHEMATIC DIAGRAMS Beacon Loom, Option

Beacon Loom, Option Plug connector housing Type Housing Part no.

Description

JC 433

Housing

PC 434 PC 435

792880-003

Housing 792881-001

Housing

Contact pins Type

Part no.

792882

792883

Replacement Parts Part no.

Description

824318

Harness, complete

ESR 5000

479

SCHEMATIC DIAGRAMS Working Light 24V Loom, Option

Working Light 24V Loom, Option A 1 2

29144 29144

1 573

29145

573

29145

JC 473

Fig. 196 Working Light 24V Loom, Option

Plug connector housing Type Housing Part no.

Description

Housing

JC 473

792880-001

Contact pins Type

Part no.

792882

Cable lugs and rings Type Part no.

Description

Faston Receptacle

793217-022

Replacement Parts Part no.

Description

824319

Harness, complete

ESR 5000

480

824319-2B

SCHEMATIC DIAGRAMS Travel Alarm Harness, Option

Travel Alarm Harness, Option JC 421 To 1 1 2980 Main 2 1 5980 Harness 3 1 A 4 1

5981 2980

2 2

A B C

5981

5980

C PC 437

1 2

B PC 436

824320-2B

Fig. 197 Travel Alarm Harness, Option

Plug connector housing Type Housing Part no.

Description

JC 421

792880-003

Housing

PC 436

792881-001

Housing

PC 437

792881-001

Housing

Contact pins Type

Part no.

792882

792883

Replacement Parts Part no.

Description

824320

Harness, complete

ESR 5000

481

SCHEMATIC DIAGRAMS Heated Seat, ESR 5000, Option

Heated Seat, ESR 5000, Option

SP 20

5910 Heated Seat

Wire No. Connection 2971 JC 474-2 SP 20 2972 PC 481-16 SP 20 PC 481-13 2973 SP 20 550 JC 474-4 PC481-1 551 JC 474-5 SP 22 552 SP 22 PC 481-2 553 SP 22 PC 481-6 PC 481-18 5910 JC 474-6 920 JC 474-3 PC 481-9 921 JC 474-1 PC 481-10

550

SP 22

551

552

550

553

920

2971

921

921 CAN H

2973

2972

Option Plug

1 2 3 4 5 6 7 8

5910

JC 474

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

A PC 481

SPLINE 20 2971 2972 29473

SPLINE 22 551 552 553

824321-2B

Fig. 198 Heated Seat ESR 5000, Option

Plug connector housing

Contact pins

Type Housing Part no.

Description

Type

Part no.

803450-047

Housing

116858

819279-011

Seal

792882

792880-005

Housing

709030-005

Anti-Backout

PC 481 JC 474

Replacement Parts Part no.

Description

824321

Harness, complete

ESR 5000

482

Fig. 199 DCDC Converter Loom, Option

12 / 24 V GND 641 / 668

CRIMP Terminal

+ 12 V 352 / 397

- BV 539

CRIMP Terminal

+ 48 V 2986

Converter Side

DC/DC Converter Loom, Option

ESR 5000

Jumper (353)

Jumper (398)

1 2 3 4

5 6 7 8

JC 440

1 3 2 4

PC 443

1 3 2 4

PC 452

Wire no. 398 668 398 397

Wire no. 353 641 353 352

Pin no. 1 2 3 4 5 6 7 8

2986 539

Wire no.

JC 440 OPTIONS

Pin no. 1 2 3 4

PC 443 (12 / 24 V)

Pin no. 1 2 3 4

PC 452 (12 / 24 V)

Harness Main Loom & Option Side

824322-2A

+ 48 BV - BV

Description

+ 12 / 24 V

GND

Description

+ 12 / 24 V

GND

Description

483

DC/DC Converter Loom, Option

SCHEMATIC DIAGRAMS

484

Notes:

SCHEMATIC DIAGRAMS DC/DC Converter Loom, Option

DC/DC Converter Loom, Option Replacement Parts Item no.

Part no.

Description

792880-003

Pin Housing

793090-005

Anti-Backout

792880-005

Pin Housing

793090-005

Anti-Backout

792882

Pin Crimp

793222

Blanking Pin

816812-086

Faston Receptacle

793217-027

Insulation Sleeve

793217-028

Faston Receptacle

824322

Harness, complete

ESR 5000

485

Notes:

486

Fig. 200 Reading Light Harness, Option

To Main Harness PC 440 A

1 2 3 4 5 6 7 8

2991

550

551

2990

552

SP 28

C PC 450

1 2 3 4 5 6 7 8

2991

JC 441

2992

Reading Light Harness, Option

551

ESR 5000

SP 29

Wire No. Connection 2990 JC 441-3 SP 28 2991 JC 441-4 PC 450-3 SP28 2992 PC 450-4 2994 SP 28 RL-1 2995 RL-2 RL-3 550 JC 441-5 SP 30 551 JC 441-6 PC 450-6 552 SP 29 PC 450-5 554 SP 29 RL-4 SPLINE 28 2990 2992 2994

SPLINE 29 550 552 554

3 3 3 3

2994 2995 2995 554

1 2 3 4

824371-2B

487

Reading Light Harness, Option

SCHEMATIC DIAGRAMS

488

Notes:

SCHEMATIC DIAGRAMS Reading Light Harness, Option

Reading Light Harness, Option Plug connector housing Type Housing Part no.

Description

JC 441

792880-005

Housing

792881-003

Housing

PC 450

792881-005

Housing

Contact pins Item No.

Part no.

792882

792883

Replacement Parts Part no.

Description

824371

Harness, complete

ESR 5000

489

Notes:

490

Fig. 201 Working Light 12V, Harness, Option

1 2

573

86 932

85 573

K 22 K 23

87 312

29144

85 932

86 29144

JC 473

30 313

To Main Harness PC 473

312

ESR 5000

672

1 2 3 4

SP 27

Wire No. Connection 29144 JC 473-1 K 23-86 573 JC 473-2 K 22-85 K 22-86 932 K 23-85 312 PC 452-4 K 23-87 672 PC 452-2 SP 27 673 SP 22 Workinglight1 674 SP 22 Workinglight2 313 K 23-30 SP 27 314 SP 27 Workinglight2 315 SP 27 Workinglight1

Workinglight2

Connection to DCDC Loom

PC 452

SP 26

SPLINE 26 313 314 315

2 2

674

Working Light 12V, Harness, Option

314

SPLINE 27 672 673 674

315

Workinglight1

673

491

824383-2B

Working Light 12V, Harness, Option

SCHEMATIC DIAGRAMS

492

Notes:

SCHEMATIC DIAGRAMS Working Light 12V, Harness, Option

Working Light 12V, Harness, Option Plug connector housing Type Housing Part no.

Description

JC 473

792880-001

Housing

PC 452

792881-003

Housing

K22, K23 811996-003

Relay Socket

Contact pins Item No.

Part no.

792882

813444-001

792883

Cable lugs and rings Type Part no.

Description

Faston Receptacle

793217-022

Replacement Parts Part no.

Description

824383

Harness, complete

ESR 5000

493

Notes:

494

19_ACC

23_BRK

24_KEY

25_BV+

13_GND

30_NEG

Fig. 202 InfoLink Harness, Option

1 35

29_PhB

31_NEG 1 32 1 33 1

28_PhA

22_Seat

21_NEG

18_NEG

15_IGN

1 27_AUX

4_CANH

26_PWR

1 16_Fw 17_Rev 1

1 10 11 1 12 1

14_PRG

3_PRD1

1 5_CANL 6_5V 1 7_GND 1 8_XIN 1 9_YIN 1

2_PRD0

1_PR5V

1 3 4 2

remove PC 420.A -> connect to PC 526.1 connect PC 526.2 to PC 526.A

JC 526

KYS

SP5

connect to BS wire 008

F PC 529

G JC 529

PC_BYP

SP4

JC 524

remove PC 471.C -> connect to PC 529.2 connect PC 529.1 to PC 417.C

G 11 2

JC_CAP 11 1

PC 520 F

PC 524

ESR 5000

connect to Shock Sensor

PC 521

do not connect / disconnect / remove this pins 11 2

JC 522

Ferrite

PC 526 1

G 25_BV+

5 1

2 4 5 2

KYS_IN 23_BRK

1 4

25_BV+ 19_Acc

3 11 3 11

2 11 2 4

1 11 1 4

CAN 4 11 4 11

Bypass

11 2

1 4 4 1

1 5

KYS_IN

ACS

5 11 5 11

I PC 523 H

JC 523

G F

PC 528

SP2

JC 528

SP3

SP1

SP1: PC 527-1, PC 527-4, PC 520-28 SP2: PC 527-2, PC 527-3, PC 520-29 SP3: PC 528-1, PC 528-2, PC 520-22 SP4: PC 529-1, PC 529-2, PC 520-19 SP3: PC 520-25, PC 526-1, PC_BYP-1

4_CANH

Bypass-Mode: connect JC 524 with BYPASS Normal-Mode: connect JC 524 with PC 524

9 YIN 4 2

6 11 6

5_CANL

Info Link Box

Prox. Reader

remove PC 471.7 -> connect to PC 528.2 connect PC 528.1 to PC 471.7

Bat-

ED1

3 4 3 3

29_PhB 28_PhA

3 1

29_PhB

3 2

29_PhB

28_PhA

29_PhB

28_PhA

823899-2D

remove PC 429.3 -> connect to PC 527.3 connect PC 527.2 to PC 429.3 remove PC 429.4 -> connect to PC 527.4 connect PC 527.1 to PC 429.4

CROWN-Motor Deutsch-Connector

3 2

4 2

2 2

Danaher-Motor AMP Connector

3 2

4 2

2 2

ECR2 Speedsensor Hydraulic-Motor

495

InfoLink, Harness, Option

SCHEMATIC DIAGRAMS

28_PhA

30_NEG

18_NEG

21_NEG

13_GND

15_IGN

B+ (AK)

SES

InfoLink, Harness, Option

8 XIN 3 2

19_Acc 2 4 2

11 2

7 GND 2 2

JC 527

24_KEY 6 5V 2

PC 527

22_Seat 1 5 4 1

22_Seat 2 5 2 4

remove PC 429.2 -> connect to PC 527.3 connect PC 527.2 to PC 429.2 remove PC 429.3 -> connect to PC 527.4 connect PC 527.1 to PC 429.3

496

Notes:

SCHEMATIC DIAGRAMS InfoLink, Harness, Option

InfoLink, Harness, Option

Cable lugs and rings

Plug connector housing

Type Part no.

Description

816812-038

Ring Terminal

816812-006

Cable lug

Type Housing Part no.

Description

062720-002

Housing

793222

Pin-Sealing

770768-1

Sealing Pins

814143

Housing

062756-003

Housing

Replacement Parts

062798-005

Anti-Backout

062755-003

Housing

062798-006

Anti-Backout

792881-001

Housing

793091-001

Anti-Backout

792880-001

Housing

793090-001

Anti-Backout

792881-004

Housing

793091-004

Anti-Backout

792880-004

Housing

793090-004

Anti-Backout

H I

PC 520 JC 527, JC 522 PC 527, PC 521

PC 524, -526, -528, -529, -_BYP JC 524, -526, -528, -529, -_CAP PC 523 JC 523

Part no.

Description

823899

Harness, complete

Contact pins Item No.

Part no.

---

062797-002

062797-001

792883

792882

ESR 5000

497

Notes:

498

12 / 24 V GND 641 / 668

CRIMP Terminal

+ 12 V 352 / 397

- BV 539

CRIMP Terminal

+ 48 V 2986

Converter Side

Fig. 203 DCDC Converter Loom NA, Option

DCDC Converter Loom NA, Option

ESR 5000

Jumper (353)

Jumper (398)

1 2 3 4

5 6 7 8

JC 440

1 3 2 4

PC 443

1 3 2 4

PC 452

Wire no. 398 668 398 397

Wire no. 353 641 353 352

Pin no. 1 2 3 4 5 6 7 8

Wire no. ------2986 539 -------

JC 440 OPTIONS

Pin no. 1 2 3 4

PC 443 (12 / 24 V)

Pin no. 1 2 3 4

PC 452 (12 / 24 V)

Harness Main Loom & Option Side

Description ------+ 48 BV - BV -------

Description --GND --+ 12 / 24 V

499

824593-2A

DCDC Converter Loom NA, Option

SCHEMATIC DIAGRAMS

500

Notes:

SCHEMATIC DIAGRAMS DC/DC Converter Loom NA, Option

DC/DC Converter Loom NA, Option Replacement Parts Item no.

Part no.

Description

792882

Pin Crimp

793222

Blanking Pin

793217-043

Ring Terminal

793217-027

Insulation Sleeve

793217-005

Socket Crimp

824593

Harness, complete

ESR 5000

501

SCHEMATIC DIAGRAMS 48V Supply, Option

48V Supply, Option PC 460

29201

1 1 2 1 3 1 4 1 5 1 6 1

29200 29202 SP31

SP32

5800

5801 5802

Wire No. Connection 29200 Socket Crimp SP31 29201 SP31 PC 460-1 SP31 29202 PC 460-2 Socket Crimp 5800 SP32 SP32 5801 PC 460-4 5802 SP 32 PC 460-5

Fig. 204 48V Supply, Option

Plug connector housing Type Housing Part no.

Description

Housing

PC 460

792881-004

Contact pins Item No.

Part no.

792883

792882

Replacement Parts Part no.

Application

824652-001

Using with DC/DC harness: 824322 or 824593 pin in connector JC 440

824652-002

Harness with Deutsch connector JC 440 Deutsch DTO 8 pole Part no. 792880-005

824652

Harness, complete

ESR 5000

502

2 Insert into JC 440-3 2 Insert into JC 440-6

824652-2B

SCHEMATIC DIAGRAMS Power Supply Cable, Option

Power Supply Cable, Option Connection: 12 / 24 V or 48 V Supply (3rd Corner) PC 452 RED

2 1

GREEN

4 JC 443 / 444

PC 452 Pin no. 1 2

Wire Colour brown black

Description + Supply GND

Wire_No_2Way

JC 443 / 444 - optional ! Pin no. 1 2 3 4

Wire Colour

Description

black

GND

brown

+ 12 / 24

825322-001

Wire_No_4Way

JC 460 1

JC 460 Pin no. 1 2 3 4 5 6

Wire Colour brown

Description + 48 V 825322-002

black

B-

Wire_No_6Way 825322-2A

Fig. 205 Power Supply Cable, Option

Replacement Parts Part no.

Housing

Crimp

Anti-Backout

Description

825322-001

792881-003

792883 Socket Crimp

793091-003

Application for 12 / 24 V Supply opt. with DC-DC Conv.-Loom 813753 or Option Loom 813445

825322-002

792881-0047

792883 Socket Crimp

793091-003

Application for 48 V Supply

792882

---

Pin Crimp

793222

---

Blanking Pin

793217-043

---

Ring Terminal

793217-027

---

Insulation Sleeve

825322

---

Harness, complete

ESR 5000

503

SCHEMATIC DIAGRAMS Bypass Cable, Seat Heating Switch, Option

Bypass Cable, Seat Heating Switch, Option Shrinking Tube

Shrinking Tube

816067-006_2D

Fig. 206 Bypass cable, seat heating switch, option

Replacement Parts Part no.

Description

816067-006

Bypass cable, seat heating switch

ESR 5000

504

SCHEMATIC DIAGRAMS Supply Cable, ESR 5000, PSA

Supply Cable, ESR 5000, PSA RED

RED

A C 1

RED GREEN GREEN

B C 1

825160-2A

Fig. 207 Supply Cable, ESR 5000, PSA

Cable lugs and rings Type Part no.

Description

793217-037

Ring Terminal

793217-035

Ring Terminal

793409-007

Shrink Sleeve

Replacement Parts Part no.

Description

819633

Fuse Holder

052071-004

Fuse

Replacement Parts Part no.

Description

825160

Harness, complete

ESR 5000

505

Notes:

506

SPLINE 28 677 672 678

SPLINE 26 313 314 315 316 317

Fig. 208 Lights 12V, PSA

SPLINE 29 318 319 312

Wire No. Connection 677 PC 452-2 SP 28 678 BPS OPT SP 28 PC 455-1 316 SP 26 317 PC 453-1 SP 26 318 SP 29 PC 452-4 319 SP 29 PC 454-1 675 SP 27 PC 455-2 676 SP 27 PC 453-2 678 SP 28 BPS OPT 679 BPS OPT PC 454-2

Wire No. Connection 29144 JC 473-1 K 23-86 573 JC 473-2 K 22-85 K 22-86 932 K 23-85 312 SP 29 K 23-87 672 SP 28 SP 27 673 SP 27 Workinglight1 674 SP 27 Workinglight2 K 23-30 313 SP 27 314 SP 26 Workinglight2 315 SP 26 Workinglight1

SPLINE 27 672 673 674 675 676

573

679

678

BPS OPT

Crimp Terminal

29144

K 22

85 573

86 932

1 2

SP 28

K 23

ESR 5000

SP 29

87 312

85 932

JC 473

86 29144

To Main Harness PC 473

30 313

1 2 4

4 316

675

1 2 3 4

2 674 Connection to DCDC Loom

SP 27

Position Light2

312

PC 455

672

PC 452

SP 26

2 314

2 1

679

Lights 12V, PSA

319

E PC 454

Break Light

315

4 4

317 676

Workinglight1

673

1 2

507

825430-2A

E PC 453

Position Light1

Lights 12V, PSA

SCHEMATIC DIAGRAMS

508

Notes:

HYDRAULIC SCHEMATIC

509

Notes:

510

HYDRAULIC SCHEMATIC Hydraulic Symbols

Hydraulic Symbols Icon

Meaning

Icon

Vented reservoir with lines above the fluid level

Meaning

Electric motor unidirectional single speed

Vented reservoir with lines above the fluid level

Hydraulic pump fixed displacement unidirectional

Filter or strainer

Spring, (bias to normal de-energised position)

Hydraulic line with full flow

Solenoid single coil or winding

Control line or drainage with restricted flow

Component enclosure manifold block

Lines crossing; not connected

Resistor orifice throttle (adjustable)

Lines crossing and connected

Throttle, fixed

Plugged port

Relief valve adjustable

Accumulator gas charged diaphragm type

Check valve

ESR 5000

Rev.1 02/2009

511

HYDRAULIC SCHEMATIC Hydraulic Symbols Icon

Meaning

Icon

Meaning

2/2 way valve (2 ways, 2 connections)

Hydraulic steer unit L R

T P

3/2 way valve (3 ways, 2 connections)

Torque generator P T

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

Shut-off valve, manual

4/2 way valve (4 ways, 2 connections)

Bypass flow control with controlled flow, pressure-regulated

4/3 way valve (4 ways, 3 connections)

Flow divider/combiner

4/3 way valve (4 ways, 3 connections; manual activation and spring centred

Single pre-tension valve assembly in manifold

Flow meter

Electric motor unidirectional variable speed

Rev.1 02/2009

512

ESR 5000

HYDRAULIC SCHEMATIC Hydraulic Symbols Icon

Meaning

Icon

Meaning

Valve block with 3 operating units

Proportional solenoid

Shuttle valve

Dual solenoid

Relief valve, fixed setting

Hydraulic pilot operated solenoid valve

Velocity fuse

Hydraulic pilot operated hydraulic valve

Pressure-compensated flow control with reverseflow bypass; fixed.

Manual actuator

Pressure-compensated flow controll, fixed

Single-acting cylinder, with cushion

Pilot check valve (pilot to open)

Single-acting cylinder ram type

Manual lever actuator

Single-acting cylinder with spring returned (rod end vented)

ESR 5000

Rev.1 02/2009

513

HYDRAULIC SCHEMATIC Hydraulic Symbols Icon

Rev.1 02/2009

514

Meaning

Icon

Meaning

Double-acting cylinder; equal area

Thermometer

Double-acting cylinder; unequal area

Pressure gauge

Pressure switch

Hydraulic motor, bi-directional

ESR 5000

Fig. 209 Hydraulic diagram

Hydraulic Diagram

ESR 5000

5th function connections Reach cylinder Reservoir ventilation and filter

7 8 9

Abbreviations and acronyms used in the hydraulic diagram are detailed on page 63.

Suction filter

Sideshifter cylinder

Return line filter

Tilt cylinder

Velocity fuse

Free lift cylinder LH lift cylinder

RH lift cylinder

Legend

515

Hydraulic Diagram

HYDRAULIC SCHEMATIC

516

Notes: