Crown Esr5000

ESR 5000 SERIES
MAINTENANCE MANUAL
Order Number: 812577-006

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

European Headquarters
Moosacher Str. 52
80809 Mnchen
Germany
Tel +49 (0)89 93 00 2 0
All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2009
CROWN Equipment Corporation
TABLE OF CONTENTS
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Text mark-ups in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Personal safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Protecting the hazardous area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hazards from stored energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Restoring the truck to service after repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warning and instruction decals on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lifting gear and slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LUBRICATION & ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

Planned Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Annual inspection in accordance with FEM 4.004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Terms and abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Seat and seat panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Brake system and load wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Reach carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Electrical system - part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrical system - part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Travel and pump motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fork carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Standard torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Load wheel replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Special tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Load wheel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Load wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Support Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking the support block distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Adjusting the support block height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Before adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Replacing the support blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cleaning the Truck and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Effects of incorrect cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Roller and slide bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Corrosion-protected surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Cleaning the entire truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Cleaning removed components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cleaning lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cleaning other mechanical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Abbreviations Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Feature Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Extending the mast reach carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Retracting the mast reach carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fork tilt back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fork tilt down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Sideshift right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Sideshift left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Hydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Valve blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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Main valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

"Accessories" valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking and adjusting relief valve RV1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking the emergency lowering valve MVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Depressurising the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Bleeding and Flushing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the free lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the reach cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the sideshift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the tilt cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bleeding the 5th function cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Flushing the lift cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Drift tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Drift Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Lift cylinder drift test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Tilt cylinder drift test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ESR 5000S hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ESR 5000 hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Replacing the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Replacing the Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Replacing the return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Replacing the suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Replacing the breather filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Replacing the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Hydraulic Port Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Removing the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Repairing the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Dismantling the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Assembling the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Assembling the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Drive wheel disassembly / assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Drive wheel disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Drive wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ACS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
BS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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III
TABLE OF CONTENTS
ECR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ECR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ECR5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
EDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
ED1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FAN1, FAN4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FAN2, FAN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU5, FU6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
FU13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
HCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
HN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
HNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
HGTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
HGTRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
K1 & K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
K12 & K13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
K22 & K23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
KYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
MVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
ORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
POT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
POT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
POT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
POT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
POT5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
PVRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
RES1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
RES2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
RV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
SDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
SES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SFS 1SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SFS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SVR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SVS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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IV
TABLE OF CONTENTS
SVT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
THS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
THS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
THS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
THS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Service Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Software version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Overview of menu items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
A1Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C1 Acceleration Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C2 Raiser/Lower Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C3 Reach Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C4 Tilt Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C5 Side Shift Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C6 5th Function Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C7 Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C8 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
C9 Fork Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
C10 Reach Retract Slow Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
C11 Save? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Log Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Performance level defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Standard settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Service Menu - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Access to service level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Trucks with key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Trucks without key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Navigation and entry keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Display structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Access to service menu and selecting a sub-menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Analyzer Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
A1 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
A2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
A3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
C1 Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
C2 Raise / Lower Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
C3 Reach Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
C4 Tilt Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
C5 Side Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
C6 5th Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
C7 Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
C7.3 Height Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
C8 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
C9 Fork Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
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C10 Reach Retract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

C11 Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Features Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
F1 Truck Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
F2 Free Lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
F3 Height Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
F4 Lower Cut Out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
F5 5th Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
F6 Maximum Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
F7 Capacity Data Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
F8 Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
F9 Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
F10 User Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
F11 User Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
F12 Set Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
F13 Change Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
F14 Set Rack Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
F15 Height/Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
F16 Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
F17 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
F18 Operator Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
F19 Battery Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
F20 Fork Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
F21 Choose Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
F25 Keyless Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
F26 Right Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
F27 Options Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
F28 Truck Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
F29 Direction Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
F30 Save ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Hour Meter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
H1 Truck Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
H2 Traction Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
H3 Hydraulic Mod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
H4 Key On Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
H5 Set Service Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Log Events Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
L1 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
L2 Totals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
L3 Erase History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Performance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
P1 Setup P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
P2 Setup P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
P3 Setup P3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
P4 BDI Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
P5 Travel > LCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
P6 Travel > FLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
P7 Travel > Custom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
P8 Lower > Custom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
P9 Reach > Custom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
P10 5th Function Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
P11 5th Function Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
P12 Steer Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
P14 Brake at Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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P15 Set Default Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

P16 Save ? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Utilities Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
U1 Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
U2 Hour Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
U3 Brake Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
U4 Check Fan 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Malfunctions with event code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Log book display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Malfunctions without event code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Locating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Event Codes 100 - 186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event Code 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event Code 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Event Code 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Event Code 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Event Code 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Event Code 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Event Code 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Event Code 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event Code 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event Code 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event Code 130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Event Code 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Event Code 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Event Code 180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Event Code 181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Event Code 182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Event Code 183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Event Code 184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Event Code 186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Event Codes 200 - 286 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Event Code 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Event Code 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Event Code 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Event Code 211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Event Code 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Event Code 213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Event Code 214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Event Code 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Event Code 221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Event Code 222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Event Code 223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event Code 224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Event Code 225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Event Code 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Event Code 241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Event Code 243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Event Code 244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Event Code 246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Event Code 247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Event Code 249 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Event Code 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
ESR 5000
VII
TABLE OF CONTENTS
Event Code 260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Event Code 261 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Event Code 262 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Event Code 263 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Event Code 264 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Event Code 265 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Event Code 266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Event Code 267 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Event Code 268 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Event Code 280 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Event Code 281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Event Code 282 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Event Code 283 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Event Code 284 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Event Code 285 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Event Codes 300 - 385 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Event Code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Event Code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Event Code 311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Event Code 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Event Code 313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Event Code 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Event Code 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Event Code 321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Event Code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Event Code 323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Event Code 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Event Code 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Event Code 330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Event Code 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Event Code 341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Event Code 343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Event Code 380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Event Code 381 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Event Code 382 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Event Code 383 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Event Code 384 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Event Codes 430 - 465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event Code 430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event Code 431 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event Code 460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Event Code 461 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Event Code 462 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Event Code 463 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Event Code 464 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Event Code 465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Event Codes 840 - 886 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Event Code 840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Event Code 841 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Event Code 880 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Event Code 881 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Event Code 883 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Event Code 884 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Event Code 885 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
ESR 5000
VIII
TABLE OF CONTENTS
Event Code 886 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Control Modules and Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Replacing control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Replacing the main control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Replacing the traction control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Replacing the hydraulic control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Replacing the steering control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Replacing the display panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
PMT Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Preparing the control module safety test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Traction control module safety test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Hydraulic control module safety test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Steering control module safety test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Replacing the Height Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Replacing the HGT(R)S Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Removing the HGT(R)S switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Assembling the HGT(R)S switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Replacing the Armrest Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Trucks with fingertip control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Removing the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Assembling the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Trucks with dual axis hydraulic control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Trucks with multi-task handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Removing the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Assembling the controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Repairing Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Wear test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Checking contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Checking the coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Checking the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Repairing the Main Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Replacing the Danaher Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Traction motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Traction motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Replacing the Sensor Bearing on the Danaher Traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Sensor bearing disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Sensor bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Replacing the Crown Traction motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Traction motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Traction motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Replacing the Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Removing the pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Pump motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Replacing the Sensor Bearing on the Danaher Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Sensor bearing disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Sensor bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Choosing the Correct Battery Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Choosing cable lengths for a T-shaped battery (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
ESR 5000
IX
TABLE OF CONTENTS
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Service and Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Service and Parking Brake Danaher Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Disassembling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Dismantling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Fitting the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Assembling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Adjusting the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Measuring the coil resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Parking Brake - Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Disassembling the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Dismantling the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Fitting the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Assembling the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Adjusting the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Measuring the coil resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Load Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Checking the brake lining wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Replacing the brake linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Wheel brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Wheel brake cylinder disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Wheel brake cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Bleeding the load wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Replacing the brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Testing and Adjusting the Brake Pedal Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Adding Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Brake Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Generating a steering signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Steer motor activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Steer system monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Error correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Quadrant - definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Steering Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Error routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Ending the error routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Causes of error routine activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Other error causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Examples of steer faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Proximity Switches SFS2 and SFS1 SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Replacing and adjusting SFS2 or SFS1 SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Steer Motor and Steering Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Removing the steer motor and steering transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Disconnecting the steering transmission and steer motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Assembling the steering transmission and steer motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Installing the steer motor and steering transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
ESR 5000
X
TABLE OF CONTENTS
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Steering wheel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Steering wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Replacing Encoder ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Removing ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Assembling ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

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

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Free Lift Cylinder Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Chain Supports and Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Periodic inspection of chain supports and lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Periodic replacement of chain supports and lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Cleaning lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Inspecting Chain Supports and Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Checking the service hours for the lift chains and anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Checking the lift chain for elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Preparatory measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Freedom of movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Worn or missing plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Turned pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Chain lateral wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Checking chain supports and anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Checking the chain pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Checking and adjusting the chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Checking and adjusting the tension on the outer chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Checking and setting the free lift chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Checking the lifting components for misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Lubricating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Lubrication intervals and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Separating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Tools and equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Fork marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Checking fork tines for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Checking fork tip straightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Measuring the fork blade warping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Measuring the fork tip width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Measuring the fork tine height difference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Checking the fork stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Measuring the fork blade wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Reach Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Terms and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
"Left outrigger" and "Right outrigger" definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Reach carriage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Reach carriage assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
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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
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Repairing the Reach Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Dismantling the reach cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
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Wiring
Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Main Harness, ESR 5000, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Main Harness, ESR 5000S, Crown Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
Harness, ESR 5000 Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
Harness, ESR 5000S Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Harness, ESR 5000S Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
Connector table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Wire Harness: Terminal to Reach Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
Cable Assy Truck, Reach Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Cable Assy Valve Block, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
Cable Assy Valve Block, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
Fork Carriage Harness Extended, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Fork Carriage Harness Standard, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Fork Carriage Switch Assy, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Fork Carriage, 5th Function, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
Fork Carriage, LS Bridge, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
FKS Heater Assembly, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Cable Mast 10 Core Assy, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Cable Mast 6 Core Assy, ESR 5000, Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
VT Camera, Reach Carriage to Chassis, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
ESR 5000
XIV
TABLE OF CONTENTS
Plug connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460

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

Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481
Heated Seat, ESR 5000, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
DC/DC Converter Loom, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
DC/DC Converter Loom, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485
Reading Light Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487
Reading Light Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
Working Light 12V, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
Working Light 12V, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
InfoLink, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
InfoLink, Harness, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
DCDC Converter Loom NA, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
DC/DC Converter Loom NA, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
48V Supply, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Power Supply Cable, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Bypass Cable, Seat Heating Switch, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Supply Cable, ESR 5000, PSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Lights 12V, PSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509

Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
ESR 5000
XVI
INTRODUCTION
1
Notes:
2
INTRODUCTION
Important Information
Important Information Service personnel qualification

This maintenance manual details the maintenance and To maintain the safety and functionality of the
repair work to be carried out on the following truck truck, maintenance and repair work must only be
models: performed by service engineers who have been
:
authorised by Crown.
ESR 5000 Contact Crown if you wish to have your engineers
trained.
ESR 5000S
Ordering spare parts
Manual structure To order spare parts, use the spare parts catalog sup-
The manual is divided into the following sections: plied separately. Always quote the following numbers
when ordering spare parts:
Specification number
Section
Model number
Index Serial number
Introduction These numbers can be found on the truck data plate.
For details of your truck's technical specifications refer
Safety to the Technical Specifications chapter in the operator
Lubrication & Adjustment manual.
Note: Always use original Crown spare parts.
Hydraulic System
Drive Unit Ordering documentation
Spare parts catalogs, operator manuals, specification
Electrical System
sheets etc. can be obtained from:
Brake System
Steering CROWN Gabelstapler GmbH & Co.KG
Moosacher Str. 52
Lifting Mechanism 80809 Munich
Cylinders GERMANY
Schematic Diagrams Tel.: +49 (0)89 / 93 002 -0
Hydraulic Schematic Fax: +49 (0)89 / 93 002 -175 or 133
www.crown.com
Text mark-ups in the manual
The following symbols and mark-ups are used in the
manual:
1., 2., 3. denote work steps to be taken.
This arrow indicates the consequences of an
action.
This arrow indicates action to be taken to avoid the
hazards contained in a warnings.
(1), (2), (3) etc. indicate text references to item num-
bers in illustrations.
Indicates the first level in a list.
Indicates the second level in a list.
Note: Where the word "Note" appears before text, this
indicates important additional information.
ESR 5000 Rev.2 02/2009
3
INTRODUCTION
Specification Number
Specification Number Mast height and capacity

The specification number is located on the data plate.
No. Mast height Mast height Maximum
It contains important information on the truck's features retracted extended capacity
at the time of delivery. (mm) (mm) (t)(a)
9 2770 6690 1.4 or 1.6

10 2770 6395 2.0
11 2920 7140 1.4 or 1.6

12 2920 6845 2.0
Fig. 1 Specification number example 13 3040 7500 1.4 or 1.6
1 Maximum capacity (in tonnes)(a) 14 3040 7205 2.0
2 Model name (see Model name table) 15 3190 7950 1.4 or 1.6
3 Mast type TT (3 stage telescopic mast, full free lift)
16 3350 8415 1.4 or 1.6
4 Retracted height (see Mast height and capacity table)(b)
5
17 3350 8120 2.0
Fork length (see Fork length table)(b)
a. The capacity plate on the truck is binding. 18 3490 8850 1.4 or 1.6
b. For special designs the actual values are stated for
19 3690 9450 1.4 or 1.6
mast height retracted, mast height extended and the
fork length. 20 3690 9155 2.0
21 3840 9900 2.0
Model name 22 3840 9605 2.0

23 3950 10230 1.4 or 1.6
Abbreviation Description
24 3950 9935 2.0
ESR European Sitdown Rider Reach
25 4250 10835 2.0
ESRS European Sitdown Rider Reach,
S-Class 26 4450 11435 2.0
27 4420 9935 2.0 SD(b)
28 4720 10835 2.0 SD(b)
Mast height and capacity
29 4920 11435 2.0 SD(b)
No. Mast height Mast height Maximum
retracted extended capacity 30 5110 12000 2.0 SD(b)
(mm) (mm) (t)(a)
a. The capacity plate on the truck is binding.
b. SD = Super Duty Mast
1 2020 4440 1.4 or 1.6
2 2020 4145 2.0
3 2170 4890 1.4 or 1.6 Fork length
4 2170 4595 2.0 No. Fork length Number Fork length
5 2320 5340 1.4 or 1.6 (mm) (mm)
6 2470 5790 1.4 or 1.6 1 990 4 1220

7 2470 5495 2.0 2 1067 5 1500
8 2570 6090 1.4 or 1.6 3 1145 6 1600
ESR 5000
4
SAFETY
5
Notes:
6
SAFETY
Safety Notices
Safety Notices
The following symbols will help you to assess the risk
to yourself, other people and materials should you fail
to comply with a safety notice:
DANGER
This symbol warns of immediate danger to the life
and health of personnel.
Severe injury or death will result.
Follow all instructions indicated by this symbol in or-
der to avoid injury or death.
WARNING
This symbol warns of potential danger to the life
and health of personnel.
Severe injury or death may result.
Follow all instructions indicated by this symbol in
order to avoid injury or death.
CAUTION
This symbol warns of possible danger to the health
of personnel.
Injury may result.
Follow all instructions indicated by this symbol in
order to avoid injury.
CAUTION
This signal word without a symbol warns of
material damage.
Damage to the truck, tools and mechanisms may
result.
Follow all instructions indicated by this signal word
in order to avoid damage.
ESR 5000
7
SAFETY
Basic Safety Notices
Basic Safety Notices Protecting the hazardous area

When carrying out repair work that could be hazard-
Organisational measures ous to yourself and other people, seal off a large
Repair work must only be carried out by service en- part of the hazardous area with suitable marker
gineers approved by Crown. tape.
Work on electrical equipment must only be carried Before carrying out repair work, service personnel
out by specialist electricians in accordance with must ensure that there is no one in the hazardous
electrical regulations. area.
Note the basic and action-specific safety notices in Service personnel must stop work immediately if
the respective chapters of this manual. Refer also any unauthorised persons enter the hazardous
to the truck operator manual, in particular the Safety area. These persons must be removed immedi-
chapter. ately.
Service personnel must also observe statutory and Hazards from stored energy
other binding accident and environmental protec-
tion regulations. High pressure hydraulic oil can cause severe inju-
ries. Depressurise the hydraulic system before
The legal minimum age for performing repair work
opening any sections of it.
must be observed.
A 15 minute discharge time must be observed for
Service personnel must be trained and authorised
the electrical energy stored in the capacitors and
to operate industrial trucks and must be able to
coils. Alternatively, these components can undergo
demonstrate their competence.
a controlled discharge through an electrical resistor.
Personal safety equipment When carrying out work near the battery, always
cover the battery terminals with a suitable insulating
Always wear safety equipment such as safety
material (e.g. plywood board) to prevent short cir-
shoes and goggles when carrying out maintenance
cuits.
and repairs. Depending on requirements you may
also need to wear safety gloves and ear muffs. Before carrying out work underneath and on raised
components (e.g. fork carriages, extended mast
When carrying out work on the hydraulic system,
stages, the truck itself), attach suitable safety de-
e.g. bleeding the system, wear suitable protective
vices and supports with sufficient capacity.
clothing such as safety gloves, goggles or a face
mask. Springs and gas pressure dampers must be
checked and slowly discharged before removing
When handling batteries wear acid protective cloth-
them.
ing such as safety gloves, goggles and an apron.
Long hair, loose clothing and jewellery are prohib- Repair work
ited. They could get caught or drawn in, resulting in
Always carry out repair work in accordance with the
injury. Do not wear jewellery especially when work-
test and maintenance schedule contained in this
ing on electrical systems, as a short circuit could
manual and any applicable service bulletins.
cause burning.
Before carrying out repair work prepare the truck as
Always use insulated tools when working on electri-
follows:
cal systems.
Park the truck on a level surface
Lower the forks to the ground
Switch off the truck and prevent it from being
switched on again
Disconnect the battery and prevent the connector
from being attached by unauthorised personnel.
When carrying out work that requires battery sup-
ply, jack up the truck until the drive wheel is clear of
the ground.
ESR 5000
8
SAFETY
Do not use a naked flame near the truck or to check The charger must be appropriate to the battery volt-
fluid levels or for leaks. age and capacity. First connect the battery, then
Always have suitable fire protection equipment to switch the charger on.
hand when carrying out work. When handling batteries wear acid protective cloth-
Keep the truck clean; this makes it easier to find ing such as safety gloves, goggles and an apron.
loose or missing components. Do not use a naked flame and do not smoke when
Welding work must only be carried out after prior handling batteries.
consultation with Crown. Do not touch battery terminals with metal objects.
Keep the work area clean and well lit. An untidy or Cover the battery terminals with a suitable insula-
poorly lit work area can lead to accidents. tion (such as a plywood board) if you have to work
in this area.
Modifications to the original condition of the truck
must be examined and approved in writing by Always charge batteries in designated charging ar-
Crown beforehand. eas and make sure the area is well ventilated.
Only use original Crown spare parts and accesso- Remove battery acid stained clothing immediately.
ries. If acid comes into contact with the skin, rinse imme-
Never install or commission damaged components. diately with plenty of clean water. If it comes into
contact with the eyes, rinse immediately with clean
Restoring the truck to service after water for several minutes and then seek medical at-
tention.
repair work
Immediately neutralize and thoroughly rinse any
After carrying out repairs refit any safety mecha- spilled battery fluid.
nisms that have been removed and make sure they
are working correctly. Warning and instruction decals on
The truck may only be restored to service after re- the truck
pair work once all the truck functions have been
successfully tested, in particular on the following In accordance with the test and maintenance inter-
components: vals check that the warning and instruction decals
on the truck are complete and legible.
Brakes
Clean any dirty decals and replace any damaged or
Speed control
missing ones.
Direction switches
Note: The spare parts manual gives details of the la-
Steering belling and position of the warning and instruction de-
Lifting mechanism cals on the truck.
Warning devices (horn, warning indicator)
To avoid endangering other people, always test the
Lifting gear and slings
truck in an open area where there are no other peo- Always use suitable hoist devices and lifting gear
ple or obstacles. with sufficient capacity.
Attach lifting gear to the designated strap points
Cleaning work and prevent it from slipping. Make sure the lifting
Particular care is required when cleaning the truck and gear cannot touch other components during lifting.
components that have been removed. See page 57. Do not stand under a swinging load.
Repair work can only be performed under a raised
Handling batteries truck if the truck has been protected against acci-
Batteries may only be charged, serviced or re- dental lowering.
placed by trained personnel. Observe the instruc- Work may only be performed on the chassis, fork
tions contained in the operator manual, as well as carriage or mast if they have also been protected
the instructions of the battery and charger manufac- against accidental lowering.
turers. Lifting gear such as load slings routed around sharp
edges must be protected from cuts.
ESR 5000
9
SAFETY
Environmental protection
Any work that involves environmentally hazardous
substances being released must only be performed
in designated areas, to allow hazardous chemicals
and oils to be separated.
All substances released during maintenance and
repair work must be collected in the proper manner
and disposed of in accordance with national regula-
tions. Oil filters and dehumidifying inserts must be
treated as special waste.
Always act responsibly when carrying out repairs to
avoid damaging the environment.
ESR 5000
10
LUBRICATION & ADJUSTMENT
11
Notes:
12
Transport and Storage
Transport and Storage 2. Fully retract the mast.

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

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

A de-energised truck can be towed over short dis-
tances using a second truck without having to release
the drive wheel brake. This might be necessary
for example if it has been left in an aisle.
Fig. 2 Lifting the truck

ESR 5000
13
when the brakes have been released by an authorised

WARNING engineer.
Tipovers can result in fatal accidents

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

CAUTION
Avoid damaging the drive wheel WARNING
When the truck is de-energised the brakes are applied
to the drive wheel. If the drive wheel drags along the Tipovers can result in fatal accidents
ground while the truck is being towed it will get dam- Make sure the jack has sufficient capacity.
aged. Information on the capacity required can be found
Make sure the drive wheel does not touch the on the truck data plate under Truck Weight Less
ground as the truck is being towed. Battery and Battery Weight.
WARNING
Incorrect jacking procedures can cause fatal acci-
dents
Improper handling of the truck or the tools can result in
fatal accidents.
Never place your hands or other parts of your body
under the truck before it has been supported.
Always support a raised truck with wooden blocks
or other suitable equipment to relieve the jack.
Only jack up the truck so far as to raise the wheels
off the ground. Any further lifting will increase the
risk of tipover.
Fig. 4 Pulling the truck with a forklift truck

1. Position the forks of the towing truck underneath
the truck.
2. Raise only the front of the truck approx. 20 mm; the
load wheels will remain on the ground.
3. Pull the truck slowly and in a forward direction only
(see arrow).
Note: If there is no truck with sufficient lifting capacity
available, the de-energised truck can only be towed
ESR 5000
14
1
6 3
4 5
2
Fig. 5 Jacking up the truck

1. Apply the parking brake.
3. Switch off the truck and remove the key.
4. Chock both load wheels with wedges (1).
5. Apply a jack (2) to the centre of the skirting rail and
raise the truck by a maximum of 20 mm.
6. Place hard wooden blocks (3) underneath the
chassis on either side and lower the truck onto
them.
7. Place the jack (4) under the outrigger and raise it
until the load wheel is no more than 10 mm clear of
the ground.
8. Place a hard wooden block (5) under the load
wheel and lower the truck onto it.
9. Raise the second outrigger and lower it onto the
hard wooden block (6).
ESR 5000
15
Truck Assembly and Commissioning
Truck Assembly and Erecting the chassis

Commissioning
Truck assembly

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

The trucks are normally shipped with the mast and
chassis separate, lying flat on pallets.
The maximum component weight on a pallet is
1800 kg.
Required tools
Sufficient number of clevis, hooks and lifting acces-
sories with a 2 tonne capacity.
A crane with a minimum capacity of 2 tonnes.
Fig. 6 Attaching the shackles and clevis
A forklift truck with a minimum capacity of 2 tonnes
at the required lift height. 1 Shackle mounted on the outside of the outrigger
2 Shackle mounted on the front of the outrigger
3 Shackles mounted on the overhead guard
Erecting the chassis

1. Attach the shackles and clevis as shown in
Figure 6 to the outriggers and overhead guard.
2. Position the crane next to the overhead guard.
3. Position the forklift truck next to the outriggers.
Attach the load slings to the forks and prevent them
from slipping.
ESR 5000
16
Fig. 7 Lifting the truck with a forklift truck and crane

simultaneously
4. Raise the chassis with the crane and forklift truck
simultaneously by approx. 500 mm (see Fig. .7).
Fig. 9 Lowering the chassis slowly and simultaneously

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

5. Continue lifting with the crane. Continue raising
Brake failure can result in accidents
with the forklift truck until the chassis is no longer
If the transport retainer is not removed from the brake
touching the ground. At the same time travel for-
fluid container the foot brake will not work.
ward slowly so that the load slings remain upright.
Before using the truck replace the transport retainer
6. Continue lifting step by step with the crane and
with the original cover.
compensating with the forklift truck, as described in
step 8, until the chassis is suspended upright in the
load slings.
ESR 5000
17
CAUTION
Risk of hydraulic system and drive transmission unit
damage!
Remove the transport retainer from the reservoir
ventilation before using the truck for the first time.
Add the supplied transmission oil (Aral Degol PAS
150) before using the truck.
Note: Store the transport retainers for future use.

Removing the transport retainer from the brake
fluid reservoir
1. Take out the floorboard.
Fig. 11 Storage tank on main brake cylinder

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

Removing the transport retainer from the hydraulic
reservoir

1. Swivel out the seat.
Fig. 10 Brake fluid reservoir transport retainer

2. Take off the cover with the yellow marking
(1, Fig. 10) and store it for future use.
3. Screw on the black cover supplied in the plastic
bag (2, Fig. 10).
Fig. 12 Breather filter

1. Remove the bayonet cap (2, Fig. 12) from the
breather filter by turning it turn to the left.
ESR 5000
18
Fig. 13 Hydraulic reservoir transport retainer

2. Remove the light grey rubber seal (1, Fig. 8) and
store it for future use.
3. Insert the supplied filter element (1, Fig. 7).
4. Refit the bayonet cap.
Filling the drive transmission unit
Fig. 14 Refill plug on drive transmission unit

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

chassis
1. Lift up the mast from the pallet and assemble it
(see Mast removal and assembly, page 315 ff. and
page 319 ff).
2. Adjust the mast and check the settings (see
page 320).
ESR 5000
19
Placing the Truck in Storage
Placing the Truck in Storage Restoring the truck to service

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

2. Check the battery charge and re-charge the bat-
tery if required.
3. Check the hydraulic oil level. Top up if required.
4. Check the gear unit for leaks.
5. Apply all hydraulic functions.
Note: Approach all limit positions at least once to coat
the whole of the piston ram surfaces with oil.
6. Check the corrosion protection and replace if nec-
essary.
7. After inspection disconnect the battery.
ESR 5000
20
Component Access
Component Access Accessing components under the

Components in the chassis can be accessed by un- panels
screwing panels or swivelling out the driver's seat.
WARNING 1
A sudden drive system start-up can cause fatal
injuries
People can be fatally injured when carrying out mainte-
nance and adjustment work on the traction motor,
hydraulics or truck controller if the traction motor or a 2
hydraulic operation start suddenly.
Lower the forks and retract the mast.
Jack up the truck so that the drive wheel is clear of
the ground.
Fig. 16 Components under the panels

1. Undo the panel screws (1, 2, 3)
2. Remove the panels (1, 2, 3)
Note: Assembly is the reverse of disassembly.
Fig. 15 Component access

1 Panel
2 Driver's seat
3 Floorboard
ESR 5000
21
Component Access
Components under the panels

1 Battery connector 7 Emergency Disconnect

2 Start up card 8 Hydraulic control module HCM (Access 2)
3 Control fuses (FU1 - FU6) 9 Steering control module SCM (Access 5)
4 Traction control module TCM (Access 3) 10 Steering control module main fuse (FU13)
5 Main contactor 11 Main control module VCM (Access 4)
6 Main fuse (FU7)
ESR 5000
22
Component Access
Accessing the motor compartment
Fig. 18 Seat panel handle Fig. 20 Seat swivelled out
1 Seat panel Swivelling in and locking the seat panel

2 Handle 1. Lift up the driver' seat armrest.
2. Swivel the seat panel (1) in as far as the stop.
1. Push the handle (2) in the direction of the arrow.
The seat panel locks automatically.
You can now access the lock of the seat panel (1).
Fig. 19 Seat panel lock

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

unlock.
3. Lift up the driver's seat armrest.
4. Swivel out the seat panel (1) in full.
ESR 5000
23
Component Access
Motor compartment
7
6
2
Fig. 21 Motor compartment
1 Hydraulic reservoir and filter 5 Motor brake

2 Pump motor 6 Steer motor
3 Steering toothing ring gear 7 Dipstick
4 Traction motor
ESR 5000
24
Component Access
Accessing components under the

floorboard
Fig. 22 Removing the floorboard

1 Floorboard
2 Bolt
Removing the floorboard

1. Swivel the driver's seat out (see page 21).
2. Remove the bolts (2).
3. Remove the floorboard (1).
Assembling the floorboard
Note: Assembly is the reverse of disassembly. When
assembling the floorboard hold the accelerator pedal
up and make sure the lever of the accelerator pedal is
resting on the roller lever of the traction potentiometer.
ESR 5000
25
Component Access
Components below the floorboard
8 1 2
3
6
Fig. 23 Components below the floorboard
1 Accelerator pedal potentiometer and travel switch 5 Safety pedal sensor

2 Main plug assembly 6 Horn
3 Brake fluid reservoir with main brake cylinder and BFS 7 Brake pressure switch
4 DC / DC converter (option) 8 Brake pedal
ESR 5000
26
Recommended Lubricants and Consumables
Recommended Lubricants and Take care to protect all electrical connections and com-
ponents from corrosion. For detailed information, refer
Consumables to the Electrical System chapter.
The following tables list lubricants and consumables Service intervals (see page 29) must be adapted to the
that Crown uses in its factory. However, you can use conditions of use.
any lubricants provided they meet the same technical
criteria. Abbreviations used in the table
The lubricant type is indicated by letters. Individual let-
Cold store truck requirements ters (A, B, ...) denote lubricants for normal temperature
Special hydraulic oils, lubricants and grease must be ranges, double letters (AA, BB, ...) for low temperature
used for cold store applications (cold store trucks). ranges.
An anti-corrosion fluid (Crown no. 805236-004) must
be applied to all machine parts such as screws, wash-
ers, nuts, pins, retaining rings etc.
Type Lubricant Type Product Manufacturer Part No.
A and AA Transmission oil Degol PAS 150 Aral

Renolin UNISYN Fuchs Minerall- ---
CLP 150 werke GmbH
B Grease (Multi-Purpose) Aralube HLP2 Aral
LM Grease Castrol
Regulus A2 Century
Beacon EP2 Esso
F806118
EP2 Maxol
Mobiluxe EP2 Mobil
Retinax LX Shell
ALGWMI SKF
Low temperature grease Aralube SKL2 Aral
BB 053002-005
Unirex Lotemp EP Mobil
D Hydraulic oil Vitam GF 32 Aral
Hyspin AWS-32 Castrol
Nuto H32 Esso
DTE 24 Mobil
---
Tellus 32 Shell
Hydran LZ 32 Finol
B110 Fuchs Minerall-
werke GmbH
DD Hydraulic oil (Low Temp) Deutz Oel HVI 32 Klockner 053001-009
G Lubrication oil Essolube HDX+40 Esso
Kowal M 40 Aral ---
Delvac 1240 Mobil
ESR 5000
27
Recommended Lubricants and Consumables
Type Lubricant Type Product Manufacturer Part No.
Low temperature lubrication Mobil SHC 626 Mobil

GG ---
oil
M Special grease Molycote BR-2 Plus Dow Corning ---
Lubricants Product Application Part No.
Anti-corrosive agent Anticorit BW 366 Corrosion inhibitor for cold store

805236-004
trucks
Rubber & vinyl dress- Commercial Rubber components, plastic pan-
-------------
ing els
ESR 5000
28
Planned Maintenance and Inspection
Planned Maintenance and The lubricant type is indicated by letters. Individual let-
ters (A, B, ...) denote lubricants for normal temperature
Inspection ranges, double letters (AA, BB, ...) for low temperature
ranges.
Maintenance Schedule
This maintenance schedule assumes single shift oper-
ation under normal conditions.
The maintenance intervals must however always be
adapted to the prevailing operating conditions. In ex-
treme conditions (dust, dirt, humidity etc.) and in
cold stores the maintenance intervals should be re-
duced. Exact details should be discussed with a
Crown service engineer.
Routinely check for wear, corrosion, damage, and test
component operation and safety when carrying out
maintenance work. If in doubt, replace components.
Planned maintenance must be performed either after a
certain number of service hours or a certain period of
time (whichever is reached first).
The next higher inspection interval includes the
previous intervals.
For example: The 2000 hour service also includes the
inspection and lubrication items lists specified under
1000 hours and 500 hours.
Annual inspection in accordance

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

The following terms and abbreviations are used in the
subsequent tables:
M Months
h Service hours
X Perform on standard trucks
C Perform on cold store trucks
I Inspection item
L Lubrication item
ESR 5000
29
Seat and seat panel

Fig. 24 Seat and seat panel
ESR 5000
30
Lubricant type
12 M
24 M
3M
6M
Assembly Component Action
Item no.
1000 h
2000 h
5000 h
500 h
Seat and Seat rails Clean and check for:
seat panel - Wear
I-1
- Freedom of movement
- Secure attachment to the seat cover.
C/X
Apply a thin layer of grease to the seat B
L-1
rails(a). BB
Seat panel Test the seat panel lock. I-2
a. For the grade and application temperature refer to the Recommended Lubricants and Consumables
table, page 27.
ESR 5000
31
Brake system and load wheels

Fig. 25 Brake system and load wheels
ESR 5000
32
Lubricant type
12 M
24 M
3M
6M
Item no.
1000 h
2000 h
5000 h
500 h
Brake Service brake Check brake fluid level(a). I-1 C/X C/X
system
Replace the brake fluid (see L-1
C X
page 293)(a).
Test the brake fluid warning switch
I-2
(BFS).
C/X
Test the brake pedal slack on the main
I-3
brake cylinder (see page 294).
Grease the brake pedal mechanism(a). B

L-2 C X
BB
Check the brake lining wear on the
I-4
load wheel brakes (see page 292).
Check all brake lines and connections
---
for corrosion and leaks. C/X
Parking brake Apply compressed air and check the
air gap (see page 288).
I-5
Check operation.
Disassemble and check for wear, C/X
Load Tyres Check for:
wheels - Damage C/X
- Wear
Suspension Check bearing play. I-6
If there is bearing play, apply the ap-
C X
propriate torque to the screws (see
page 294).
a. For the grade and application temperature refer to the Recommended Lubricants and Consumables table on page 27.
ESR 5000
33
Drive unit

Fig. 26 Drive unit
ESR 5000
34
Lubricant type
12 M
24 M
3M
6M
Item no.
1000 h
2000 h
5000 h
500 h
Drive Unit Gear unit Check for:
- Leakage
I-1
- Unusual noise
- Oil level (see page 97) C X
- Check the drive unit mounting

I-2
screws on the chassis are secure.
- Replace the oil(a). L-1 C X

Traction motor - Ensure attachment is secure. I-3
Drive plate - Ensure attachment is secure. I-4
Drive wheel Check for:
- Wear(b) I-5
(wear limit 309 mm)
Secure (180 Nm)(c) C X
Both support blocks Check for wear and check the settings
I-6
on the chassis (see page 53).
Steer motor - Ensure attachment is secure. I-7
Steering toothing Clean and lubricate(a). B
L-2
ring gear BB
b. When replacing the drive wheel the support blocks must be reset (see page 53).
c. With new trucks and after removal or replacement, tighten bolts once after 50 - 100 hours. Then tighten according to the pre-
scribed intervals.
ESR 5000
35
Reach carriage

Fig. 27 Reach carriage
ESR 5000
36
Lubricant type
12 M
24 M
3M
6M
Item no.
1000 h
2000 h
5000 h
500 h
Reach Reach carriage Check for damage. I-1
carriage
Reach function Extend the reach mechanism the full
distance in both directions. Make sure
---
the speed reduction applies at the end
sections.
Rollers Check for freedom of movement:
- Rollers
I-2
- Backing rollers
- Side rollers
Lubricate the rollers(a). B/

L-1
BB
Adjust as required: C/X
- Backing rollers
I-3
- Side rollers
(See page 352.)
Roller track wear Clean, check for damage. Apply a thin B/
rails layer of grease. BB
Reach cylinder Check attachment (see page 336). I-4
Rubber buffer Check for wear. ---
Hydraulic manifold Ensure it is fitted securely.
I-5
cover
Electrical wiring in Ensure plug connections are tight.
I-6
the carriage Check presence of strain reliefs.
ESR 5000
37
Hydraulic system

Fig. 28 Hydraulic system
ESR 5000
38
Lubricant type
12 M
30 M
3M
6M
Item no.
1000 h
2000 h
5000 h
500 h
Hydraulic Hydraulic oil Check the oil level with the cylinders I-1 C X
system reservoir fully retracted.
D
Add oil(a) if required (see page 83). L-1 C/X
DD
Replace the return filter, breather filter
I-2
and suction strainer (see page 84).
C(b) X(c)
Change the hydraulic oil(a) (see
---
page 83 - requires approx. 36 L)
Hoses, lines and Check all hoses, lines and connections
---
connections for leaks and damage.
Check hose attachment in reach car-
riage for wear and make sure it is se- I-3
cure.
Cylinders Check all cylinders are secure, check
---
for leaks and damage.
C/X
Emergency Test the emergency lowering valve
I-4
lowering (see page 77).
Hydraulic manifolds Check the main valve block in the
I-5
reach carriage for leaks (see page 75).
Check the "Accessories" valve block in
the reach carriage for leaks (see I-6
page 76).
b. 1000 service hours or, deviating from the standard interval, every 12 months.
c. 2000 service hours or, deviating from the standard interval, every 24 months.
ESR 5000
39
Electrical system - part 1

Fig. 29 Electrical system - part 1
ESR 5000
40
Lubricant type
12 M
30 M
3M
6M
Item no.
1000 h
2000 h
5000 h
500 h
Electrical Display screen Test the display screen and check all
system displays are legible.
Controls Test the safety pedal.
Test the horn.
Test the parking brake switch and indi-
See operator manual

cator light.
Test the travel direction switch.
Test the seat switch.
Test the lift controls. C/X
Test the Emergency Disconnect
switch.
Ensure the potentiometer connections
---
are secure.
Control modules Check all control modules are clean
and power cables and secure.
Check the power cable connections to I-1
the control modules, fuses FU7, FU13
and contactor ED1 are secure.
Steering control Carry out the safety test (see
module (SCM) and page 261).
--- C/X
traction control
module (TCM)
ESR 5000
41
Electrical system - part 2

Fig. 30 Electrical system - part 2
ESR 5000
42
Lubricant type
12 M
30 M
3M
6M
Item no.
1000 h
2000 h
5000 h
500 h
Electrical Fans Test the fans using the Service menu
---
system (see page 172).
Connectors and Check wires and lines for insulation
---
lines damage.
Make sure plugs on the connector
I-1
panel are secure.
Traction motor (M1) Ensure the power cable connections
are secure and free of damage. For
I-1
torques and important installation
instructions see page 273.
Check the plug connections to encoder
ECR1 and thermal sensor THS1 for
I-3
damage and make sure they are
secure.
Pump motor (M2) Ensure the power cable connections C/X
are secure and free of damage. For
torques and important installation I-4
instructions see Connecting the power
cables, page 273 or page 277.
Check the plug connections to encoder
ECR2 and thermal sensor THS2 for
I-5
damage and make sure they are
secure.
Battery Check battery cables and connectors
for damage. I-6
Check terminal post condition.
Check battery in accordance with bat-
tery manufacturer's instructions (see
---
manufacturer's maintenance instruc-
tions).
ESR 5000
43
Travel and pump motors

Fig. 31 Travel and pump motors
ESR 5000
44
Lubricant type
12 M
30 M
3M
6M
Item no.
1000 h
2000 h
5000 h
500 h
Traction Motor output See Replacing the Danaher Traction
motor (M1) Motor, page 273:
- Remove the traction motor. I-1
M
- Clean the output toothing, check it L-1
for damage and apply grease(a).
- Re-assemble the traction motor.
Pump mo- Motor output See Replacing the Pump Motor,
tor (M2) page 279:
C/X
- Remove the pump motor. I-2
- Clean the output toothing, check it M
L-2
for damage and apply grease(a).
- Re-assemble the pump motor.
Motor attachment Check the rubber-bonded-to-metal
mounting (rubber buffer) on the pump
L-3
motor attachment for cracks and hard-
ening.
ESR 5000
45
Mast

Fig. 32 Mast
ESR 5000
46
Lubricant type
12 M
30 M
3M
6M
Item no.
1000 h
2000 h
5000 h
500 h
Mast Mast Check mounting bolts are secure (see
I-1
page 320).
Check and adjust mast chains and
I-2
chain supports (see page 340).
Clean the lift chains (see page 340)
G L-1
and lubricate them (see page 346).
Clean the running surfaces in the mast
I-3
channels and check for wear.
Grease the running surfaces in the B
L-2
mast channels(a). BB
Check the mast rollers freedom of
I-4
movement (see page 324).
C/X
Check the condition of the mast stage
end stops (poly stop blocks) and make I-5
sure they are secure (see page 316).
Mast cable Check the mast cable for damage,
check the tension jacks for damage I-6
and make sure they are secure.
Guide pulleys Check the guide pulleys for damage. I-7
Lubricate the guide pulley mountings. B
L-3
BB
Switches Check the condition and operation of
the height reset switches / lift speed re- --
duction switches.
Battery removal Ensure the battery removal stops are
stops(b) secure.
b. ESR 5000S with T battery only.
ESR 5000
47
Fork carriage

Fig. 33 Fork carriage
ESR 5000
48
Lubricant type
12 M
30 M
3M
6M
Item no.
1000 h
2000 h
5000 h
500 h
Fork Fork carriage Check the fork carriage for damage. I-1
carriage
Check the fork carriage rollers for free-
I-2
dom of movement.
Clean the slide blocks. Check for wear
I-3
and test operation (see page 330).
Grease slide blocks. B
L-1 C/X
BB
Lubricate the grease nipples on the B
L-2
fork carriage. BB
Load backrest Check load backrest for damage and
I-4
ensure it is securely fitted.
Fork tines Check the fork tines (see page 349). I-5
ESR 5000
49
Torques
Torques
Standard torques
Note: The torques listed in the manual always take
precedence over standard torques.
Standard screws and nuts
Grade: 8 and 8.87 10 and 10.9 12 and 12.9

Thread size Torque (Nm)
M5 x 0.8 5-6 7-8 8 - 10
M6 x 1 8 - 10 12 - 14 14 - 16
M8 x 1.25 20 - 25 30 - 35 34 - 40
M10 x 1.5 40 - 45 60 - 65 70 - 75
M12 x 1.75 70 - 80 100 - 110 115 - 130
M16 x 2 170 - 190 240 - 270 280 - 320
M20 x 2.5 340 - 380 450 - 500 550 - 600
M24 x 3 580 - 650 800 - 900 900 - 1050
M30 x 3.5 1150 - 1300 1600 - 1800 1850 - 2100
Umbrako screws and nuts
Grade 10 and 10.9 12 and 12.9

Thread size Torque (Nm)
M5 x 0.8 8 11
M6 x 1 14 19
M8 x 1.25 33 45
M10 x 1.5 63 86
M12 x 1.75 111 152
M16 x 2 270 372
M20 x 2.5 521 717
ESR 5000
50
Load Wheels
Load Wheels
Load wheel replacement

Special tools required
Grooved nut key (item no. 824842)
Guide bolt (item no. 825455)
Load wheel removal
WARNING
Risk of serious injury
Failure to handle the truck and/or the equipment
correctly could result in fatal injury.
Never reach with your hands or other parts of your Fig. 34 Load wheel attachment
body under the truck before it has been supported,
or when jacking up the truck. 4. Remove the screw (2, Fig. 34) and the cover
Always support a raised truck with hard wooden disk (3).
blocks or other appropriate equipment to relieve the 5. Loosen the retaining screw (4).
jack. 6. Loosen and unscrew the grooved nut (1) with the
special key (item no. 824842).
WARNING

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

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

shaft (3).
8. Pull off the load wheel (1) over the guide bolt.
Note: If the load wheel cannot be pulled off, place back
the brake lining slightly via the eccentric (can be
accessed via the holes 2, Fig. 36).
ESR 5000
51
Load Wheels
Fig. 36 Back of load wheel brake: holes for lining inspection

and access to eccentrics
Load wheel assembly

1. Push the load wheel over the guide bolt attached
during removal (in step 7).
2. Screw on the groove nut (1).
3. Using a special key (item no. 824842) torque to
150 Nm.
4. Torque the retaining screw (4) to 4 Nm.
5. Fix the cover disk (3) with the screw (2, Fig. 34)
and torque to 14 Nm.
ESR 5000
52
Support Blocks
Support Blocks 4. Measure the distance from the left and right sup-
port blocks to the ground again, and record
The support blocks prevent the truck from tipping over dimension H (see Fig. 37) for the 2nd point.
on its side when the mast is fully extended and the load
5. Continue turning the truck approx. 120 with the
centre of gravity may be in an unfavourable position.
steering at full lock.
The setting can change during operation due to the
6. Measure the distance from the left and right sup-
wearing of the drive wheel and support blocks (dimen-
port blocks to the ground again, and record
sion H, Fig. 37). Regular inspection and adjustment is
dimension H (see Fig. 37) for the 3rd point.
therefore required in the following cases:
During planned maintenance, every 1,000 hours or Analysing the measurements
6 months
When the drive wheel has been replaced Adjusting dimensions table
Mast type Dimension H
SD mast(a) 13 +1/-2 mm
TT mast 19 +1/-2 mm
Table 1
a. The last three digits of the serial number on Super Duty
(SD) masts contain one of the following codes:
-91, -92, -93 or -94.
1. Determine the mast type from the serial number on

the mast data plate.
Fig. 37 Dimension H on support block
2. Compare the calculated dimensions with the re-
1 Drive wheel spective H dimensions for the mast type from
2 Support block Table 1.
3 Warehouse floor 3. Dimension H should be no more than H + 1 mm on
H Dimension H any of the 3 measuring points.
If dimension H is greater than H + 1 mm on one
Checking the support block of the measuring points, Adjusting the support
block height, replace the worn support blocks if
distance necessary.
Requirements
Adjusting the support block height
Measurements are taken at three points offset by
approx. 120 within the truck's turning radius. This Before adjusting
compensates for any unevenness in the ground.
Note: The support blocks are worn if they have lost
The parking area must therefore be large enough for 5 mm of material.
the truck to turn in its radius without any danger.
Measurement
Measure at 3 points
1. Park the truck on a level surface.
2. Measure the distance from the left and right sup-
port blocks to the ground and record dimension H
(see Fig. 37) for the 1st point.
3. Continue turning the truck approx. 120 with the
steering at full lock.
ESR 5000
53
Support Blocks
Measure the remaining support block height 1. Jack up the truck (see page 14).
2. Loosen all the screws (3).
3. Push the required number of shims (1) between
the skid (2) and the chassis to achieve
dimension H (see Table 1).
Note: The shims come in 3 different thicknesses (see
spare parts manual).

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

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

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

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

1. Fit the new support block using the shims previ-
ously removed from this side.
Note: Only use screws with a 55 mm shaft length (part
no. 050005-102).
Fig. 39 Support block mounting and adjustment
ESR 5000
54
Support Blocks
2. Tighten the screws (3) to the standard torque (see

page 50).
3. Adjust the opposite support block as outlined
above.
Note: Always replace both support blocks, never indi-
vidual ones.
4. Now check the support block distance and adjust
as required.
ESR 5000
55
Notes:
56
Cleaning the Truck and Components
Cleaning the Truck and Cleaning the entire truck

Components 1. Park the truck in an area with an oil separator.
2. Switch off the truck, disconnect and remove the
battery.
CAUTION
Health risk WARNING
Cleaning agents, lubricants and consumables can
damage your health. Malfunctions when restarting the truck can cause
serious injury
Observe the manufacturers safety instructions
Water can penetrate electrical components after steam
when handling solvents and lubricants.
cleaning or hose washing. This can accidentally trigger
certain functions when the truck starts up again.
Effects of incorrect cleaning Do not steam-clean the truck or wash it down with
a hose.
Electrical components
Electrical components such as connectors, contacts, Cleaning the truck surface
distributor boards, controllers and wiring can be dam- 3. Dry clean the truck. To do this use cloths, soft
aged by water, cleaning agents and solvents. brushes (not metal brushes) and if necessary
Mineral and chemical residue that automatically re- weak, dry compressed air.
main on or in components after cleaning, are a cause Note: Local contamination that cannot be removed by
of corrosion. This corrosion results in malfunctions and dry cleaning can be treated with a damp cloth and a
premature failure. neutral cleaning agent. Make sure that neither water
Roller and slide bearings nor cleaning agent get into electrical components or
bearings.
Steam cleaning and solvents damage the lubricant film
on bearing surfaces. This results in dry running and Cleaning lift chains
rapid damage to the bearing elements. 4. See page 58.
Corrosion-protected surfaces Cleaning electrical components
The brake lines, screw connections and shiny metal 5. Clean electrical components only with each, dry
surfaces in particular on cold store trucks are factory- compressed air and a dry cloth.
treated with an anti-corrosive agent (Anticorit Interior cleaning
BW 366). This protection can be washed off by sol-
6. Clean detachable rubber mats with water and a
vents and steam cleaning. The above-mentioned com-
neutral cleaning agent.
ponents will corrode as a result.
7. Allow the rubber mats to dry out fully before return-
Environmental protection ing them to the truck.
8. Damp-wipe plastic parts with a neutral cleaner.
Cleaning must only be performed in specially desig-
nated areas to enable hazardous chemicals and oils to Note: If necessary use a standard commercial plastic
be separated. cleaning agent to remove obstinate dirt.
Collect any waste (such as oily cleaning cloths) and After cleaning the truck
dispose of them in accordance with local regulations. 9. Wipe down the truck.
10. Remove any paint damage.
11. Add anti-corrosion agent if necessary.
Returning the truck to operation after cleaning
Normally no special measures are required.
ESR 5000 Rev. 1, Feb 09
57
If however there is a possibility that damp may have Cleaning removed components
penetrated electrical components, proceed as follows:
1. Clean the truck with weak, dry compressed air and Cleaning lift chains
a cloth.
2. Leave the truck to stand for at least 30 minutes in
a dry environment. WARNING
3. Insert the battery but do not connect it yet.
Improper cleaning can cause chains to crack
4. Jack up the truck so that the drive wheel is clear of A cracked chain can result in fatal injuries.
the ground. Never clean lift chains with steam cleaners, cold clean-
ing agents or corrosive, acid-based agents. This can
cause direct chain damage through hydrogen embrit-
WARNING tlement.
Clean the chain surfaces only with paraffin deriva-
Malfunctions when restarting the truck can cause
tives such as cleaning petroleum or cleaning petrol.
serious injury
Water or cleaning agent residue in electrical compo- Apply an approved chain oil immediately after
nents can cause malfunctions when the truck is cleaning (see Recommended Lubricants and Con-
switched on. sumables table, page 27).
You must be prepared to switch off the truck imme-
diately with the Emergency Disconnect when the 1. Remove persistent dirt with cleaning petroleum or
battery is connected and the truck is powered up. cleaning petrol. Apply a thin layer of the cleaning
agent with a hard bristle brush and wipe with a lint-
Make sure that nobody can be injured by compo-
free cloth.
nents accidentally starting up (lift mechanism, side-
shifter etc.). 2. Apply an approved chain oil immediately after
cleaning (see Recommended Lubricants and Con-
sumables table, page 27).
6. Switch on the truck. Cleaning other mechanical components
If a function automatically starts, apply the With the exception of lift chains, components that have
Emergency Disconnect immediately. been removed can be steam-cleaned under certain
Note: If possible, apply compressed air to the respec- conditions.
tive switch or connector. Repeat steps 1 to 6.
Is the starting pattern is normal, proceed to
step 7. CAUTION
7. Check all functions. Steam-cleaning can damage electrical compo-
nents and bearings
Mechanical components may only be steam-
cleaned if no electrical components or bearings are
affected.
1. Components that have been removed should be

cleaned by hand, ideally with warm water and a
mild neutral cleaning agent.
2. If steam-cleaning cannot be avoided, it should be
done without a cleaning agent. If grease needs to
be removed, use a mild neutral cleaning agent.
Note: Steam-cleaning can remove anti-corrosion
agent and paint from surfaces.
3. If a neutral cleaning agent has been used, rinse the
components thoroughly with clear water.
4. Leave the cleaned components to dry thoroughly.
Rev. 1, Feb 09 ESR 5000
58
Note: Cleaned components must be dry and free of

cleaning agent residue before being refitted, lubricated
or painted.
5. Re-lubricate, paint or apply anti-corrosion agent to
the components as required.
6. Refit the components.
7. For cold store trucks apply Anticorit BW 366 as
an anti-corrosion agent for screw connections and
shiny metal surfaces.
ESR 5000 Rev. 1, Feb 09
59
Notes:
60
HYDRAULIC SYSTEM
61
Notes:
62
HYDRAULIC SYSTEM
Abbreviations Used
Abbreviations Used
Abbrevia- Meaning(a) Description

tion
AVL Adjustment Valve Lowering Speed The AVL allows you to set the maximum lowering speed
when PVL is fully opened (see Main valve block section on
page 75).
CBV Counterbalanced Valve ---
CV Check Valve Ensures flow in only one direction.
DCVH Directional Control Valve Hoist DCVH is located inside the valve block. The valve releases
the hydraulic oil path depending on the command:
from the pump to the lift cylinders (lift)
from the lift cylinders back to the reservoir (lower)
MVL Manual Valve Lower In an emergency, MVL can be used to manually lower the
fork carriage.
Note: When the fork carriage has been lowered, unscrew
the valve up to the stop.
PCA Pressure Compensation Accesso- For fork tilt, sideshift and 5th function
ries
PCL Pressure Compensation Lowering ---
PCR Pressure Compensation Reach ---
PLS Pressure Load Switch When a load > 400 kg is being lowered, PLS prevents the
fork carriage from stopping abruptly. This prevents the mast
from swaying. If replaced, the new PLS must be set to trip at
400 kg in free lift.
POT2 to Hydraulic function potentiometers The potentiometers are connected to their respective control
POT5 levers and transmit an analog control signal to the truck con-
trol module.
PVAL(b) Proportional Valve Accessories Left PVAL governs the upward tilt speed of the forks when "Tilt"
is selected, and the sideshift left speed when sideshift is se-
lected.
PVAR(b) Proportional Valve Accessories PVAR governs the downward tilt speed of the forks when
Right "tilt" is selected, and the sideshift right speed when sideshift
is selected.
PVL Proportional Valve Lower ---
PVRE(b) Proportional Valve Reach ---
PVRT(b) Proportional Valve Retract ---
RV1 Relief Valve RV1 restricts the operating pressure to a maximum of

210 bar. Must be reset when replaced.
SV5 Solenoid Valve 5th Function ---
SVH Solenoid Valve Hoist SVH is a black and white valve and opens when lifting is se-
lected. The lift speed is governed by the pump speed.
ESR 5000
63
HYDRAULIC SYSTEM
Abbreviations Used
Abbrevia- Meaning(a) Description

tion
SVS Solenoid Valve Sideshift ---

SVT Solenoid Valve Tilt ---
a. The first letters of the term in brackets give the component abbreviation.
b. In the event of a mechanical failure the entire valve block must be replaced. The magnetic coils can be replaced individually.
ESR 5000
64
HYDRAULIC SYSTEM
Feature Descriptions
Lifting
Fig. 41 Hydraulic circuit for lifting
The following symbols are used in the diagrams: The lift speed is controlled by the pump motor speed in
proportion to the movement of the control lever.
Pilot line The oil then flows from input P of the valve block
through the DCVH slide valve via output A to the hy-
Pressure line draulic cylinders. The hydraulic cylinders extend.
Suction line During lifting, the lower control pressure side of the
DCVH slide valve is connected to the reservoir return
Return line line via the lowering valve PVL. This is necessary to
prevent any counter-pressure from building up (which
would affect the movement of the slide valve).
The lift function is requested by pulling the corre- If the "lift/lower" control lever is released, the pump and
sponding control lever. The voltage on the slider of lift SVH valve are switched off. SVH switches over
potentiometer POT2 changes. The pump and the mag- through bias spring force so that the lift control pres-
netic coil of the SVH lift pilot valve are activated. sure side of the slide valve is connected to the reservoir
The SVH valve drives the DCVH slide valve. The slide return line. The drop in pressure moves the slide valve
valve opens. to its home position. The connection to the cylinders is
lost. The cylinders remain in their current position.
ESR 5000
65
HYDRAULIC SYSTEM
Note: If the MVL manual lowering valve is open,

i.e. turned in, lifting is inhibited.
ESR 5000
66
HYDRAULIC SYSTEM
Lower
Fig. 42 Hydraulic circuit for lowering
The following symbols are used in the diagrams: slide valve via output T to the reservoir. The hydraulic
cylinders retract.
Pilot line In proportion to the movement of the control lever, the
lowering proportional valve PVL controls the oil pres-
Pressure line sure on the slide valve - and hence the degree of open-
ing of the slide valve - and ultimately the lowering
Suction line speed.
Return line The flow control valve PCL mounted in front of the slide
valve provides a constant lowering speed for any con-
trol lever position.
The "lowering" function is requested by pulling on the During lowering, the lift control pressure side of the
corresponding control lever. The voltage on the slider DCVH slide valve is connected to the reservoir return
of lift potentiometer POT2 changes. The magnetic coil line via the SVH raise valve. This is necessary to pre-
of proportional valve PVL is activated. vent any counter-pressure from building up (which
The PVL valve drives the DCVH slide valve. The slide would affect the movement of the slide valve).
valve opens. If the "lift/lower" control lever is released, the PVL sole-
Oil flows from the hydraulic cylinders via port A of the noid is switched off. PVL switches over through bias
valve block through flow control valve PCL and the spring force so that the lower control pressure side of
the slide valve is connected to the reservoir return line.
ESR 5000
67
HYDRAULIC SYSTEM
The drop in pressure moves the slide valve to its home

position. The connection to the cylinders is lost. The
cylinders remain in their current position.
Pressure switch PLS is fitted on the hydraulic line to the
lift cylinders. If more than 400 kg is placed on the forks,
the pressure switch converts the switch limit of PVL.
This prevents the load from suddenly stopping during a
lowering operation, and hence the mast from swaying.
The valve block contains the AVL valve which is used
to set the maximum lowering speed when PVL is fully
opened.
The maximum lowering speed for 1.4 t and 1.6 t trucks
is 0.58 m/s, and for 2.0 t trucks 0.51 m/s.
When the main valve block is replaced, AVL is supplied
preset to 0.58 m/s and must be set to 0.51 m/s for 2.0 t
trucks (see Main valve block, page 75).
The MVL emergency lowering valve allows the mast to
be lowered manually in the event of hydraulic failure.
To lower, turn the emergency lowering valve clock-
wise.
Note: After the lowering operation, close the valve as
far as the screw stop.
ESR 5000
68
HYDRAULIC SYSTEM
Extending the mast reach carriage
Fig. 43 "Extend mast reach carriage" hydraulic circuit
The following symbols are used in the diagrams: The extending reach cylinder pushes the oil out of the
cylinder. The oil can flow back to the reservoir via the
return line of the PVRE valve.
Pilot line
If the control lever is released, the pump and the PVRE
Pressure line valve are switched off.
Suction line PVRE is closed through bias spring force and the flow
of oil to the reach cylinder is interrupted. The pressure
Return line on the pilot line of the brake valve reduces, the brake
piston is moved to the neutral position through bias
spring force. The pressure on the reach cylinder is re-
The extend mast reach carriage" function is requested strained through the closed position of the brake valve.
by pulling the corresponding control lever. The voltage The cylinder remains in its current position.
on the slider of reach potentiometer POT3 changes.
The pump and the magnetic coil of the PVRE propor-
tional pilot valve are activated.
The speed of the reach carriage is determined by the
movement of the control lever. It is governed by the
pump motor speed and the position of the PVRE pro-
portional valve.
PVRE opens in proportion to the movement of the con-
trol lever. Oil flows from input P of the valve block
through the flow control valve PCR and the PVRE
valve via the bypass check valve to output A2. From A2
on to the piston dome side of the reach cylinder. The
reach carriage extends.
The two pilot lines on the flow control valve PCR regu-
late this so that the flow of oil and hence the speed of
the reach carriage are kept constant depending on the
oil pressure and the potentiometer setting.
The flow of oil to A2 moves the brake piston and the
return line from B2 to PVRE opens.
ESR 5000
69
HYDRAULIC SYSTEM
Retracting the mast reach carriage

Fig. 44 "Retract mast reach carriage" hydraulic circuit
The following symbols are used in the diagrams: PVRT is closed through bias spring force and the flow
of oil to the reach cylinder is interrupted.
Pilot line The pressure on the pilot line of the brake valve re-
duces, the brake piston is moved to the neutral position
Pressure line through bias spring force. The pressure on the reach
cylinder is restrained through the closed position of the
Suction line brake valve. The cylinder remains in its current posi-
Return line tion.
The retract mast reach carriage" function is requested

by pulling the corresponding control lever. The voltage
on the slider of reach potentiometer POT3 changes.
The pump and the magnetic coil of the PVRT propor-
tional valve are activated.
The speed of the reach carriage is determined by the
movement of the control lever. It is governed by the
pump motor speed and the position of the PVRT pro-
portional valve.
PVRT opens in proportion to the movement of the con-
trol lever. Oil flows from input P of the valve block
through the flow control valve PCR and the PVRE
valve via the bypass check valve to output B2. From B2
on to the piston ram side of the reach cylinder. The
mast reach carriage retracts.
The flow of oil to B2 moves the brake piston and the
return line from A2 to PVRT opens.
The retracting reach cylinder pushes the oil out of the
cylinder. The oil can flow back to the reservoir via the
return line of the PVRT valve.
If the control lever is released, the pump and the PVRT
valve are switched off.
ESR 5000
70
HYDRAULIC SYSTEM
Fork tilt back

Fig. 45 "Fork tilt back" function hydraulic circuit
The following symbols are used in the diagrams: flows via port A2 of the tilt/sideshift valve block,
through valve SVT to port A. From here it continues on
to port B1 of the main valve block, through valve PVAL
Pilot line
to output T and finally back into the reservoir.
Pressure line If the control lever is released, the pump and the SVT
and PVAL valves are switched off. The valves are set
Suction line to the home position through bias spring force. The oil
Return line flow through SVT is interrupted. The tilt cylinder re-
mains in its current position.
The fork tilt back function is requested by pulling the

corresponding control lever. The voltage on the slider
of tilt potentiometer POT4 changes. The pump and the
magnetic coils of the SVT valves and the PVAL propor-
tional valve are activated.
The tilt speed is determined by the movement of the
control lever. It is governed by the pump motor speed
and the position of the PVAL proportional valve.
PVAL opens in proportion to the movement of the con-
trol lever. The oil flows through port P of the main valve
block, the PCA flow control valve and the PVAL propor-
tional valve to output A1. From here it flows on to port
B of the "tilt/sideshift" valve block, through the open
SVT valve and the CV check valve to port B2. From B2
to the piston side of the tilt cylinder. The piston extends,
and the forks tilt up (back).
The oil pressure created displaces the ball of the twin
check valve (behind PVAL) from left to right and re-
leases the control pressure on PCA. The two pilot lines
on the flow control valve PCA regulate this in such a
way that the flow of oil is kept constant depending on
the oil pressure and the potentiometer setting.
The forward moving piston of the tilt cylinder forces the
oil out of the front section of the tilt cylinder. The oil
ESR 5000
71
HYDRAULIC SYSTEM
Fork tilt down

Fig. 46 "Fork tilt down" function hydraulic circuit
The following symbols are used in the diagrams: line is connected to the cylinder return line. When an
overall pressure of 90 bar is applied, CBV opens and
releases the line for the returning oil. If the overall pres-
Pilot line
sure is below 90 bar CBV blocks so that any load on
Pressure line the forks cannot tilt down automatically.
The piston moves back and forces the oil out of the tilt
Suction line cylinder. The oil flows via port B2 of the tilt/sideshift
Return line valve block, through CBV and valve SVT to port B.
From here it continues on to port A1 of the main valve
block, through valve PVAR to output T and back into
the reservoir.
The fork tilt down function is requested by pulling the
corresponding control lever. The voltage on the slider If the control lever is released, the pump and the SVT
of tilt potentiometer POT4 changes. The pump and the and PVAR valves are switched off. The valves are set
magnetic coils of the SVT valves and the PVAR propor- to the home position through bias spring force. The oil
tional valve are activated. flow through SVT is interrupted. The drop in oil pres-
sure in the pilot line causes CBV to close. The tilt cylin-
The tilt speed is determined by the movement of the
der remains in its current position.
control lever. It is governed by the pump motor speed
and the position of the PVAR proportional valve.
PVAR opens in proportion to the movement of the con-
block, the PCA flow control valve and the PVAR pro-
portional valve to output B1. From here on to port A of
the "tilt/sideshift" valve block, through the open SVT
valve to port A2 and to the piston ram side of the tilt
cylinder. The piston retracts, and the forks tilt down.
check valve (behind PVAR) from left to right and re-
leases the control pressure on PCA.
The two pilot lines on the flow control valve PCA regu-
late this in such a way that the flow of oil is kept con-
stant depending on the oil pressure and the
potentiometer setting.
A pilot line of the counterbalance valve CBV is con-
nected to the pressure circuit after SVT. The 2nd pilot
ESR 5000
72
HYDRAULIC SYSTEM
Sideshift right

Fig. 47 "Sideshift right" hydraulic circuit
The following symbols are used in the diagrams: The oil flowing out of the left port of the sideshift cylin-
der flows via port B1 of the "tilt/sideshift valve block,
through valve SVS to port B. From here it continues on
Pilot line
to port A1 of the main valve block, through valve PVAR
Pressure line to output T and back into the reservoir.
If the control lever is released, the pump and the SVS
Suction line and PVAR valves are switched off. The valves are set
Return line to the home position through bias spring force. The oil
flow through SVS is interrupted. The sideshift remains
in its current position.
The "sideshift right function (seen from the operators
position) is requested by pulling the corresponding
control lever. The voltage on the slider of sideshifter po-
tentiometer POT5 changes. The pump and the mag-
netic coils of the SVS valves and the PVAR
proportional valve are activated.
The sideshift speed is determined by the movement of
the control lever. It is governed by the pump motor
speed and the position of the PVAR proportional valve.
PVAR opens in proportion to the movement of the con-
block, the PCA flow control valve and the PVAR pro-
portional valve to output B1 of the hydraulic manifold.
check valve (behind PVAR) from left to right and re-
From B1 the oil flows on to port A of the "tilt/sideshift"
valve block. From port A through the open SVS valve
via port A1 to the right port of the sideshift cylinder. The
fork carriage moves to the right.
ESR 5000
73
HYDRAULIC SYSTEM
Sideshift left

Fig. 48 "Sideshift left" hydraulic circuit
The following symbols are used in the diagrams: The oil flowing out of the right port of the sideshift cyl-
inder flows via port A1 of the "tilt/sideshift valve block,
through valve SVS to port A. From here it continues on
Pilot line
to port B1 of the main valve block, through valve PVAL
Pressure line to output T and back into the reservoir.
If the control lever is released, the pump and the SVS
Suction line and PVAL valves are switched off. The valves are set
Return line to the home position through bias spring force. The oil
flow through SVS is interrupted. The sideshift remains
in its current position.
The "sideshift left function (seen from the operators
position) is requested by pulling the corresponding
control lever. The voltage on the slider of sideshifter po-
tentiometer POT5 changes. The pump and the mag-
netic coils of the SVS valves and the PVAL proportional
valve are activated.
The sideshift speed is determined by the movement of
the control lever. It is governed by the pump motor
speed and the position of the PVAL proportional valve.
PVAL opens in proportion to the movement of the con-
block, the PCA flow control valve and the PVAL propor-
tional valve to output A1 of the hydraulic manifold.
check valve (behind PVAL) from left to right and re-
From port A1 the oil flows on to port B of the "tilt/side-
shift" valve block through the open SVS valve via port
B1. From B1 to the left port of the sideshift cylinder. The
fork carriage moves to the left.
ESR 5000
74
HYDRAULIC SYSTEM
Hydraulic Components
Hydraulic Components Valve blocks

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

lines so that they do not get jammed.

All connections must be completely sealed.
The elbows on suction connections must be positioned
so that the suction hose has the full flow and does not
collapse.
Fig. 49 Port references on the valve block

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

The mechanical section of the valves is fully integrated
in the block, the valve bodies cannot be obtained indi-
vidually. In the event of a mechanical defect replace the
entire block.
The solenoid coils can be replaced.
ESR 5000
75
HYDRAULIC SYSTEM
"Accessories" valve block 3. Raise a test load that is 10% +100 kg above the
rated capacity.
This valve block is located in the fork carriage. It con-
If the RV1 relief valve applies, the setting is ok.
tains the solenoids for controlling the sideshifter and
If not, proceed to step 6.
the tilt cylinder.
Setting relief valve RV1
4. Lower the load.
5. Remove the cover over the valve block.

Fig. 50 "Accessories" valve block ports

A To port B1 on the main valve block Fig. 51 Relief valve RV1 and manual lowering valve MVL
A1 To the sideshifter cylinder, "left" port 6. Loosen the counternut (2, Fig. 51) on valve RV1
A2 To the tilt cylinder, piston ram side (1).
B To port A1 on the main valve block 7. Adjust the setscrew (3) as required.
B1 To the sideshifter cylinder, "right" port Turn clockwise to increase the contact pres-
B2 To the tilt cylinder, piston dome side
sure.
Turn anticlockwise to reduce the contact pres-
Replacing the valves sure.
Valve bodies and the solenoid coils can be replaced on 8. Tighten the counternut (1) again.
this block. Checking the adjusted setting
Checking and adjusting relief valve 9. Repeat steps 1 to 8 until RV1 applies within the tol-
erance range.
RV1 Note: If the valve cannot be adjusted, it must be re-
The RV1 relief valve is preset to a pressure of placed.
210+5 bar.
Checking the setting
1. Raise a test load that is 10% above the rated ca-
pacity.
2. Raise the test load above the free lift height.
It should just be possible to raise this load.
ESR 5000
76
HYDRAULIC SYSTEM
Checking the emergency lowering

valve MVL
1. Lower the forks.
2. Remove the cover over the main valve block.
3. Raise the forks without load above free lift height.
WARNING
Lowering forks can cause injury
The forks automatically lower when the hydraulic sys-
tem is being bled.
Never stand underneath a raised fork.
Seal off the hazardous area to prevent other people
from entering and standing under a raised fork.
4. Slowly open MVL (4, Fig. 51).

If the forks do not lower even when MVL is fully
opened, replace the main valve block and check
MVL again.
If the forks lower in full, the MVL valve is ok.
ESR 5000
77
HYDRAULIC SYSTEM
Depressurising the Hydraulic System
Depressurising the Hydraulic

System
2. Set the forks horizontal.
3. Set the sideshifter to the centre position.
4. Switch off the truck, disconnect the battery and
prevent the truck from being switched on again.
5. Wait 2 minutes.
The hydraulic system is depressurised.
ESR 5000
78
HYDRAULIC SYSTEM
Bleeding and Flushing the System
Bleeding and Flushing the 4. Tighten the bleed screw as soon as bubble-free oil
emerges.
System 5. Carry out steps 2 to 4 on the other lift cylinder.
6. Clean up any oily components on the truck.
Safety notices
Bleeding the reach cylinder
1. Extend the forks and hold the control lever at the
WARNING limit position for approx. 5 seconds.
High pressure hydraulic system 2. Retract the forks and hold the control lever at the
High-pressure hydraulic oil can cause injury! limit position for approx. 5 seconds.
Wear safety gloves and goggles or a face mask 3. Repeat steps 1 to 2 until the reach mechanism
when depressurising the system. moves without any delay or jerky movement.
Bleeding the sideshift cylinder

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

Bleeding the free lift cylinder
Note: The lift cylinders must be bled.
1. Prepare the work area to collect spilled oil.
Preparing for flushing
2. Fully extend the free lift cylinder.
1. Fully extend the mast.
3. Open the bleed screw on the free lift cylinder.
2. Check the lift cylinders for leaks.
4. Tighten the bleed screw as soon as bubble-free oil
If a cylinder is leaky, repair it (see page 363).
emerges.
If the cylinders are sealed, proceed to step 3.
5. Clean up any oily components on the truck.
Flushing the lift cylinders
Bleeding the lift cylinders 3. Extend and retract the mast at maximum speed to
the maximum lift height at least 10 times.
1. Prepare the work area to collect spilled oil.
This flushes the lift cylinders.
2. Extend the lift cylinder as far as possible.
3. Open the bleed screw on the free lift cylinder.
ESR 5000
79
HYDRAULIC SYSTEM
Bleeding and Flushing the System
Drift tests
Carry out a drift test after:
repairing or replacing hydraulic cylinders.
repairing or replacing valve blocks or valves.
This is the only way of identifying internal leakage.
Requirements
Prepare a test load:
Weight must correspond to the maximum capacity
The test load must be evenly distributed.
The load centre of gravity must be centrally located,
600 mm in front of the fork shanks, and must not
exceed the capacity plate specification.
Note: Whenever you carry out a drift test the hydraulic
oil temperature must be 30 - 40.
1. Measure the temperature in the hydraulic reservoir
before carrying out the drift test.
If the temperature is 30 - 40 C you can start
with the drift test.
If the temperature is too low, proceed to step 2.
2. Raise the forks several times up to the free lift limit
until the temperature is 30 - 40 C.
ESR 5000
80
HYDRAULIC SYSTEM
Drift Tests
Drift Tests Tilt cylinder drift test

After carrying out repairs on the hydraulic system Flush the tilt cylinders, attach a test load and
check the drift on the lift and tilt cylinders. plumb
1. Tilt the fork carriage several times from one end to
Safety notices the other to flush the hydraulic system.
2. Raise the test load and secure it on the forks to
prevent it from sliding and falling.
WARNING 3. Tilt the forks down fully.
Standing under a raised load can cause fatal 4. Attach a lowering plumb with a piece of string ap-
njuries prox. 3m long to the fork at an approximate dis-
Fatal injuries could result if the forks of the truck sud- tance of 1150 mm to the fork shank.
denly lower or if a load falls. Note: If the distance is not 1150 mm, you must calcu-
Do not stand under a swinging load. late the drift nominal value accordingly!
Seal off the hazardous area to prevent access. 5. Raise the test load with the fork carriage tilted back
beyond the free lift height so that the tip of the
plumb is at least 50 mm above the ground.
Lift cylinder drift test 6. Measure the height of the plumb above the ground
and record the measurement.
Flush the lift cylinders, attach a test load and
plumb 7. Switch off the truck and disconnect the battery.
1. Flush the lift cylinders (see page 79). 8. Wait for 5 minutes.
2. Raise the test load and secure it on the forks to Measuring the drift
prevent it from sliding and falling. 9. After 5 minutes measure the plumb height again.
3. Tilt the forks fully down. 10. Calculate the difference between the previously re-
4. Attach a lowering plumb with a 3m long string to corded measurement and the new measurement
the fork tip. to establish the drift.
5. Raise the forks beyond the free lift height so that If the drift 50 mm, the internal leakage is too
the tip of the plumb is at least 100 mm above the great. Replace the cylinder and repeat the drift
ground. test.
6. Measure the height of the plumb above the ground If the drift < 50 mm, it has passed the drift test.
and record the measurement.
7. Switch off the truck and disconnect the battery.
8. Wait for 10 minutes.
Measuring the drift
9. After 10 minutes measure the plumb height again.
10. Calculate the difference between the previously re-
corded measurement and the new measurement
to establish the drift.
If the drift 100 mm, the internal leakage is too
great. Repair the cylinder (see page 363) and
repeat the drift test.
If the drift < 100 mm, it has passed the drift test.
ESR 5000
81
HYDRAULIC SYSTEM
Hydraulic Oil Reservoir
Hydraulic Oil Reservoir ESR 5000 hydraulic oil reservoir

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

The same filter is used on both reservoirs.
ESR 5000S hydraulic oil reservoir

Fig. 53 ESR 5000 reservoir

1 Dipstick
Fig. 52 ESR 5000S reservoir 2 Breather filter

3 Return filter cover
1 Dipstick
4 Return line port
2 Breather filter
5 Suction line port
3 Return filter cover
6 Reservoir
4 Return line port
7 Drain plug
5 Suction line port
6 Reservoir
7 Drain plug
ESR 5000
82
HYDRAULIC SYSTEM
Replacing the Hydraulic Oil
Replacing the Hydraulic Oil Note: The return filter filters from outside to inside. It
does not filter the oil you add to the reservoir via the
Approx. 36 litres are required to replace the hydraulic opened return filter.
oil. For the grade and application area see Recom-
1. Fill up the reservoir (6, Fig. 52 or 53) once the en-
mended Lubricants and Consumables, page 27.
tire hydraulic system has been bled.
Draining the hydraulic oil reservoir 2. Retract all the cylinders (mast reach on chassis,
mast lowered, fork carriage tilted forward).
3. Add hydraulic oil via a 10 m mesh filter up to the
CAUTION "MAX" mark on the dipstick (1, Fig. 52 or 53).
Health risk
damage your health.
1. Unscrew the filter cover (3, Fig. 52 or 53).
Fig. 54 Filter insert and handle

2. Pull out the filter insert (2, Fig. 54) from the handle
(1).
3. Draw off and collect the hydraulic oil via the port.
4. Place a suitable bowl underneath the truck.
5. Open the drain plug (7, Fig. 52 or 53) and drain the
remaining oil and deposits out of the reservoir
sump.
6. Dispose of the oil in accordance with environmen-
tal regulations.
Replenishing the hydraulic oil reservoir
CAUTION
Hydraulic systems are sensitive to contamination.
Filter the new oil via a 10 m mesh one-way filter.
ESR 5000
83
HYDRAULIC SYSTEM
Replacing the Filter
Replacing the Filter 4. Turn the filter element (3, Fig. 55) slightly to pull it
out of the filter container and dispose of it.
The system comprises two hydraulic filters and one
breather filter. These must be replaced at regular inter- Filter element assembly
vals. See Maintenance Schedule, page 39. 1. Clean the filter container.
2. Turn a new, original Crown filter element down
slightly to insert it in the filter container.
CAUTION 3. Insert the filter container into the hydraulic oil res-
ervoir.
Health risk
4. Screw on the cover and tighten it only slightly by
hand.
damage your health.
Note: The cover is sealed and locked in place via the
inserted O-ring. If tightened too fast it can only be re-
leased with a tool. This will also cause the O-ring to
wear more quickly.
CAUTION Replacing the suction filter

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

Always use new and original Crown filter elements
as replacements.
Replacing the return filter

Removing the filter element

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

Fig. 56 Suction port (ESR 5000S)

Removing the filter element
1. Loosen the suction hose (4, Fig. 56).
2. Seal the ports with clean filler plugs.
Fig. 55 Filter container and filter element

3. Lift up the handle (1, Fig. 55) on the filter and
remove the filter container (2, Fig. 55) and the filter
element.
ESR 5000
84
HYDRAULIC SYSTEM
Replacing the Filter
3. Remove the four screws (3) from the reservoir Replacing the breather filter
flange.

Fig. 58 Breather filter

Fig. 57 Suction pipe and filter element Removing the filter element
4. Thread the suction pipe (1, Fig. 57) and the at- 1. Remove the bayonet cap (2, Fig. 58) of the
tached filter element (2) out of the reservoir. breather filter (2, Fig. 52 or 53) by turning it a turn
to the left.
5. Unscrew and dispose of the filter element.
2. Remove and dispose of the filter element
Filter element assembly (1, Fig. 58).
1. Push a new flange seal (3, Fig. 57) over the suction
Filter element assembly
pipe.
1. Insert the new filter element.
2. Screw a new original Crown filter element onto the
suction pipe. 2. Fit the bayonet cap and turn it a turn to the right
to lock it.
3. Thread the suction pipe and filter element back into
the reservoir and position them correctly on the
flange.
4. Insert the screws (2, Fig. 56) and torque them
crosswise to 25 Nm.
ESR 5000
85
HYDRAULIC SYSTEM
Replacing the Hydraulic Pump

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

to a lifting mechanism and remove any slack.
5. Remove the screws (5, Fig. 59).
Removing the hydraulic pump
1. Raise the pump unit so that the pump can be re-
moved.
2. Support the pump unit so that it cannot lower.
4. Remove the suction and pressure lines (screws 5
and 8, Fig. 60).
5. Dispose of the seals (2 and 6, Fig. 60).
6. Pull the hydraulic pump (1, Fig. 60) out of the pump
motor toothing without tilting it.
Assembling the hydraulic pump
1. Apply a thin layer of grease part no. 794860-007
(Shell Calithia HDX) to the hydraulic pump drive
shaft toothing.
2. Place the hydraulic pump on the pump motor.
3. Secure the hydraulic pump with the screws
Fig. 59 Hydraulic pump removal (ESR 5000S)
(3, Fig. 60).
1. Remove the suction hose (1, Fig. 59) and seal the 4. Attach the suction and pressure lines to the hy-
ports with clean filler plugs. draulic pump using new seals.
2. Disconnect the pressure line from the union (2, 5. Lower the pump unit.
Fig. 59) and seal the ports with clean filler plugs.
6. Attach the retaining plate (4, Fig. 59) via the
3. Disconnect the sensor cable and power cables (6, screws (5).
Fig. 59) from the pump motor.
7. Restore the pressure line connection (2, Fig. 59).
Note: The cables must be exposed sufficiently so that
8. Restore the electrical connections.
the pump unit can be raised approx. 250 mm without
tilting or tipping over. Note: Do not connect the suction hose at this stage.
ESR 5000
86
HYDRAULIC SYSTEM
Starting up the hydraulic pump

1. Add hydraulic oil to the suction hose (1, Fig. 59) via
a 10 m one way filter. For the grade and applica-
tion area see Recommended Lubricants and Con-
sumables, page 27.
2. Connect the suction hose (1, Fig. 59) to the reser-
voir.
3. Power up the truck.
4. Bleed the pump by activating the "sideshifter" func-
tion several times as far as the stop.
5. Check the hydraulic oil level and replenish if nec-
essary (see page 83).
6. When you have reached operating temperature,
check all the ports for leaks.
ESR 5000
87
HYDRAULIC SYSTEM

Fig. 60 Pump unit and connection lines
ESR 5000
88
HYDRAULIC SYSTEM
Hydraulic Port Torques

1 Accessories hose system
24 - 27 Nm 1 90 - 95 Nm 2 Lift function hose system
3 Valve block in mast reach carriage
1
4 Valve block mounting screws(1)
1. Insert with Loctite 242, part no. 053050-006.

107 - 119 Nm 2
Note: Torque the hose clamp mounting screws to
20 - 25 Nm.
CAUTION
The filter can be damaged if the return line hose
union is torqued incorrectly
Counter the torque on the union (1) by holding tight
80 - 88 Nm the filter connection (2).
34 - 37 Nm
90 - 95 Nm
24 - 27 Nm
3 3
Fig. 61 Overview of Hydraulic Lines and Ports
ESR 5000
89
HYDRAULIC SYSTEM
Notes:
ESR 5000
90
DRIVE UNIT
91
Notes:
92
DRIVE UNIT
Gear Unit
Gear Unit
Required tools
Fork lift truck with sufficient capacity, lift height and
fork length to raise the truck, or a crane with suffi-
cient capacity.
Safety device to keep the raised truck on the forks
of the truck doing the lifting.
Sufficient number of wooden blocks (surface area
of at least 250 x 250 mm, approx. 550 mm long) or
suitable supports to secure the raised truck.
Suitable mechanism for securing the gear unit on a
pallet truck.
Removing the gear unit

being switched on again.
2. Disassemble the traction motor (see page 276).
1
WARNING
Standing under a raised load can cause fatal Fig. 62 Drive unit
injuries
8. Remove the six screws (1, Fig. 62).
Fatal injuries could result if the truck is suddenly low-
ered. 9. Lower the pallet truck and pull it out from under the
truck together with the gear unit.
Do not stand under a swinging load.
3. Raise the truck with a second fork lift truck and pre-
vent the truck from slipping, or lift it with a crane
(see page 13).
4. Raise the truck and bring a pallet truck with a
mechanism for securing the gear unit into position.
5. Raise the front of the truck by approximately
another 50 mm.
6. Lower the truck onto the wooden blocks or sup-
ports.
The truck is now secured and the gear unit can
be removed:
7. Raise the pallet truck with the mechanism for
securing the gear unit until the mechanism is
touching the gear unit.
ESR 5000
93
DRIVE UNIT
Gear Unit
1
2
3
4
2 6 5
15
9 12
10 13 16
11
14
17
37
18
13
24
23
25
44
38
36
18 27
42 30 2
26
35 27
28
29 34
19
22
43 30
41
40 20
31
39 21
33
32
22
Fig. 63 Gear unit exploded diagram
ESR 5000
94
DRIVE UNIT
Gear Unit
Repairing the gear unit In the next steps the flange shaft, the bevel pinion and
their respective bearings are removed:
Note: The gear unit must only be repaired by trained
14. Push out the flange shaft (42) using a suitable de-
and authorised Crown personnel. Otherwise the war-
vice.
ranty will be invalid.
15. Extract the inner ring of the conical roller bearing
(38) from the flange shaft (42).
CAUTION Note: When disassembling, mark the assembly loca-
Correcting the tooth flank bearing and pre-tensioning tion of the shims (18, 20, 35). The same number of
the shaft bearing requires years of experience with shims will have to be put back temporarily in the same
gear units. Incorrect adjustments and settings will re- position at a later stage.
sult in premature failure of the gear unit. 16. Take the bevel gear (22), spacer ring (36) and ad-
It is preferable to replace the gear unit! justing shim(s) (18) and (35) where applicable out
of the housing.
17. Extract the inner ring of the conical roller bearing
Dismantling the gear unit (34) from the bevel gear (22).
Unless otherwise indicated, all item numbers refer 18. Extract the outer rings of the conical roller bearings
to Fig. 63, page 94. (34, 38) from their seats in the transmission hous-
ing.
19. Remove the thread shield ring (41), radial shaft
CAUTION seal (40) and retaining ring (39) from the housing
seat.
Health risk 20. Press the bevel gear (22) down from out of the spur
Cleaning agents, lubricants and consumables can wheel (16) and the conical roller bearing (17).
damage your health.
21. Remove the conical roller bearing (17) and shim
Observe the manufacturers safety instructions (18) where applicable.
22. Extract the outer ring of the conical roller bearing
(21).
1. Prior to dismantling, thoroughly clean the gear unit
23. Remove the spacer bushing (19) from the bevel
with a cold cleaning solution and dry with low-pres-
pinion shaft and extract the inner ring of the conical
sure air.
roller bearing (21) from the bevel pinion shaft.
2. Drain the oil (capacity approx. 3.6 litres).
24. Thoroughly clean all components and remove the
3. Insert the gear unit with the wheel nuts (43) into a remains of the sealant and adhesive.
secure device to prevent it from twisting.
4. Remove the screws (26) and the lock washers (2). Assembling the gear unit
5. Take off the gear unit cover (25) and loosen the O-
ring (24). CAUTION
6. Remove the screws (1) and the lock washers (2).
Used seals cause leaks and bearings can be damaged
7. Take off the live ring bearing (3). when removed. All bearings and seals must be
8. Remove the O-ring (5) from the recess of the gear replaced.
ring (8).
9. Remove the screws (29 and 31) and the lock wash-
Preparing the gear unit
ers (30).
1. Press the outer rings of the conical roller bearings
10. Take off the gear ring (8).
(17, 21, 34 and 38) into their respective notches in
11. Remove the screws (32) and the washer (33). the cleaned housing. Make sure they are posi-
12. Undo the nut (15) of the bevel pinion shaft. tioned level in the housing.
13. Take the gear unit out of the mechanism. 2. Insert the inner ring of the conical roller bearing
(38) in the pre-assembled outer ring of the conical
roller bearing (blade wheel side).
ESR 5000
95
DRIVE UNIT
Gear Unit
3. Insert the retaining ring (39) in its corresponding Adjusting the bevel gear set
groove. The correct setting can be calculated via the tooth flank
4. Press the radial shaft seal (40) into the housing us- bearing. Always adjust the bevel gear set to the correct
ing a suitable tool. flank position. The tooth ends should not form a
5. Place the thread shield ring (41) onto its space in straight line:
the housing and caulk it. The tooth flank bearing must always align with the
6. Press the inner ring of the conical roller bearing inner tooth end.
(34) onto the bevel gear (22) using a suitable tool. The tooth flank bearing must range from high (top
7. Press the wheel nuts (43) into the flange shaft of tooth) to low (bottom of tooth).
holes (42) using a suitable tool. To adjust, add and/or remove shims (18, 20, 35) or
change the pre-tension of the bearings.
Inserting the bevel pinion shaft
Figure 64 shows the limits of the permissible tooth
1. Press the inner ring of the conical roller bearing
flank bearings on the bevel pinion and bevel gear.
(21) onto the conical pinion shaft (22).
2. Place the shim(s) (20) and spacer bushing (19) on
the conical pinion (22). 1
3. Insert the pre-assembled bevel pinion shaft (22)
2
into the housing (23) from below.
3
4. Push the inner ring of the conical roller bearing (17)
over the shaft of the bevel pinion shaft into the
outer ring of the conical roller bearing (17).
5. Assemble the spur wheel (16) and torque the new
nut (15) to max. 100 Nm.
6. Test the bevel pinion shaft can move freely and en- 5
sure there is zero backlash. Reduce the torque if 6
necessary.
Record the final torque. This will be needed
again to adjust the bevel gear set. 4
Assembling the flange shaft
7. Bring the housing into its subsequent assembly po-
sition. Fig. 64 Permissible tooth flank bearings
8. Insert the spacer ring (36) and the pre-assembled 1 High tooth flank bearing on bevel pinion
bevel gear (22) in the respective order through the 2 Bevel pinion
housing opening. 3 Bevel gear
9. Apply a thin layer of oil to the flange shaft (42) and 4 Low tooth flank bearing on bevel gear
carefully push it through the previously inserted
5 High tooth flank bearing on bevel gear
unit parts in the housing.
6 Low tooth flank bearing on bevel pinion
10. Insert the housing with the wheel nuts into a secure
device to prevent it from twisting. Note: Carry out all checks and adjustments with care.
11. Guide the hex. socket screws (32) through the Pre-tensioning the bearings and shims will affect the
washer (33) and torque them to max. 77 Nm to tooth flank bearing. Do not set the pre-tension too low.
tension the flange shaft assembly. It will automatically reduce during normal operation.
12. Test the shaft can move freely; ensure there is zero 13. Colour the tooth flanks of the bevel gear (22) with
backlash. touch-up paste (striking colour) or a light oil colour.
Reduce the torque if necessary. 14. Take the gear unit out of the mechanism.
Record the final torque. This will be needed 15. Turn the bevel gear several times in one direction.
again to adjust the bevel gear set. The tooth flank bearing will appear as a bright
point (marked black in Fig. 64) on the tooth
flanks.
ESR 5000
96
DRIVE UNIT
Gear Unit
16. Check the tooth flank bearing.

CAUTION
17. Remove and/or add shims (18, 20, 35) to restore
the tooth flank bearing to the tolerance limits (see Leave the surface and thread sealants to dry for at
Fig. 64). Change the bearing pre-tension if neces- least 2 hours at room temperature. Then fill with oil.
sary. Take care not to exceed the max. levels
(flange shaft max. 77 Nm, spur wheel max.
36. Set the gear unit in the assembly position.
100 Nm).
Record the new torques. 37. Add oil to suit the application temperature (see
page 27) up to the bottom of the refill plug. The
18. Torque the screw (32) of the flange shaft and nut
capacity is 3.6 litres.
(15) of the spur wheel to the previously recorded
levels. Assembling the gear unit
19. Repeat the check and adjustment until the tooth
flank bearing is within the tolerance range.
Final assembly
CAUTION
20. Re-assemble the bevel pinion shaft and flange New gear units are always supplied without oil
shaft. Add oil to suit the application temperature (see
21. Clean all the components. page 27) up to the bottom of the refill plug. The
22. Apply a thin layer of Loctite 307 to the inside of the capacity is 3.6 litres.
conical roller bearing inner rings.
23. Apply medium strength Loctite 242 to the threads
of the nut (15) and the screws (32). CAUTION
24. Refit the bevel pinion shaft and flange shaft and
torque the screw (32) and nut (15) to the last re- When assembling the gear unit take care not to dam-
corded values. age the toothing of the spur pinion (14) or the spur
wheel (16).
25. Manually turn the gear unit through, while checking
for freedom of movement and ensure it operates
without any clearance. Assembly is the reverse of disassembly (see page 93).
26. Apply a thin layer of Loctite 307 to the contact sur-
faces of the housing cover.
27. Screw the drain plug (28) with the copper ring (27)
underneath it into the transmission lid (25).
28. Insert the O-ring (24) into its groove in the trans-
mission lid.
29. Attach the gear unit cover (25) to the housing (23)
so that the drain plug is at the lowest position when
the gear unit is installed again.
30. Secure the gear unit cover with the screws (26)
and lockwashers (2).
31. Torque the screws (26) evenly and crosswise.
32. Apply a thin layer of Loctite 307 to the contact sur-
faces of the transmission housing to the ring gear.
33. Fit the ring gear.
34. Insert the O-ring (5) into the recess of the ring gear
(8).
35. Fit the live ring bearing.
ESR 5000
97
DRIVE UNIT
Drive Wheel
Drive Wheel 3. Torque the wheel nuts (1) evenly and crosswise to
180 Nm.
Note: The drive wheel must be replaced if its diameter
Note: After 50 service hours the wheel nuts (1) must be
is 309 mm.
torqued to 180 Nm.
Attach a sticker or notice to the operator position to act
1 as a reminder.
3 4. Jack up the truck
5. Adjust the support blocks (see page 53).
Note: It is very important to adjust the support blocks
after replacing the drive wheel. It prevents the truck
from tipping over if the load is poorly distributed at
height.
Fig. 65 Drive wheel

1 Gear unit
2 Drive wheel
3 Wheel nut
Drive wheel disassembly / assembly

Drive wheel disassembly
1. Jack up the truck (see page 14), disconnect the
battery and prevent it from being switched on
again.
WARNING
Risk of serious injury
Failure to handle the truck and/or the equipment
correctly could result in fatal injury.
Never reach with your hands or other parts of your
body under the truck before it has been supported,
or when jacking up the truck.
Always lower a raised truck onto hard wooden
blocks or other appropriate equipment to relieve the
jack.
2. Remove the hub cap.

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

1. Push the drive wheel (2) onto the wheel bolts.
2. Fit the wheel nuts (1).
ESR 5000
98
ELECTRICAL SYSTEM
99
Notes:
100
ELECTRICAL SYSTEM
Electrical Components
Electrical Components ECR1

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

Attached to the traction motor. Electrically actuated as
a parking brake. On trucks with a Danaher motor it is
hydraulically actuated by the brake pedal to act as a
service brake.
BS
Beacon Switch
Fitted in the console. Switches the beacon on or off.
ESR 5000
101
ELECTRICAL SYSTEM
EDS FU2
Emergency Disconnect Switch Control Fuse VCM/HDM/Horn
Installed in the electric compartment. When applied, This fuse (15 A/80 V) protects the control circuits of the
disconnects the entire power supply. main and hydraulic control modules.
ED1 FU3
Emergency Disconnect Contactor Power Fuse Brake
Installed in the electric compartment. Disconnects the This fuse (10 A/80 V) protects the brake circuit.
power supply to the HCM, TCM and SCM power cir-
cuits. FU4
FAN1, FAN4 Control Fuse SDM
This fuse (10 A/80 V) protects the power circuit of the
Fan TCM steer module.
Installed in the electric compartment. The traction con-
trol module switches the fans on at +35 C, and off at FU5, FU6
+25 C.
Control Fuses Options
FAN2, FAN3 This fuse (15 A/80 V) protects the control circuits of the
auxiliary functions.
Fan HCM
Installed in the electric compartment. The hydraulic FU7
control module switches the fans on at +35 C, and off
at +25 C. Main Fuse
This fuse (425 A/48 V) protects the batterys connec-
FKS tion wires.'
Fork Switch FU13

Attached to the fork carriage, actuated by a trip cam.
The load weight display switches off if the forks are not Power Fuse SDM
horizontal. This fuse (50 A/48 V) protects the steering power cir-
cuit.
FLS
HCM
Free Lift Switch
Attached to the fork carriage. FLS is applied by a mag- Hydraulic Control Module
net attached to the inner mast. If the fork carriage is Installed in the electric compartment. Controls the
above free lift, the speed for this range can be set in the pump motor and takes the readings from the encoder
P6 Travel > FLS menu (see page 165) ECR2 and the thermal sensor THS2.
FS HN
Forward Switch Horn
Travel opposite to the fork direction. Installed below the floorboard.
FU1 HNS
Control Fuse TCM/Display Horn Switch
This fuse (15 A/80 V) protects the control circuits of the Pressing the horn switch activates the horn.
traction control module and the work lights.
ESR 5000
102
ELECTRICAL SYSTEM
HGTS LS
Height Switch Load Sensor
Attached to the top right (in fork direction) of the outer Installed at the top of the tilt cylinder. LS captures the
mast. Reduces the lift speed 500 mm before reaching weight of a load resting on the forks. Connected in se-
the maximum lift height. A metal plate on the 1st mast ries with the FKS (fork switch).
stage actuates the proximity switch without contact.
MVL
HGTRS
Manual Valve Lower
Height Reset Switch Emergency lowering of fork carriage and mast stages.
Attached to the top right (in fork direction) of the outer Note: The manual lowering valve should then be
mast. Activates the height encoder when the 1st mast closed again.
stage has just been approached. A metal plate on the
1st mast stage actuates the proximity switch without ORS
contact.
Override Switch
K1 & K2 Installed in the control panel on the overhead guard
column, to the left of the steering wheel. Lifting is inhib-
Relays Keyless Entry
ited when a programmed lift stop is reached. If the ORS
Installed in the leg compartment. These connect the switch is now pressed, lifting can continue to either the
power supply to the VCM (Vehicle Control Module) next lift stop or the end stop.
when the Keyless Entry option is available.
POT1
K11
Traction Potentiometer
Start Up Relay
Attached to the accelerator pedal. Supplies an analog
K11 is integrated in the start up card in the start up signal to the main control module VCM to control the
module. It actuates ED1. If all systems are ok, the VCM travel speed. POT1 must be recalibrated when re-
connects pin 24 of CA205 to the negative terminal, placed.
thereby activating K11.
POT2
K12 & K13
Lift/Lower Potentiometer
Options Relays
Hall sensor attached to the Lift/Lower control lever.
Installed in the leg compartment. Activate the 48 V sup- Supplies an analog signal to the main control module
ply for the options packages. VCM to control the lift/lower speed. Must be recali-
brated when replaced.
K22 & K23
Relay Working Light 12 V
POT3
Installed in the leg compartment. Activate the 12 V Reach Potentiometer
work light. Hall sensor attached to the Reach control lever. Sup-
plies an analog signal to the main control module VCM
KYS to control the reach speed. Must be recalibrated when
Key Switch replaced.
Supplies power to the VCM (Vehicle Control Module).
ESR 5000
103
ELECTRICAL SYSTEM
POT4(1) PVRT
Tilt Potentiometer Proportional Valve Retract
Hall sensor attached to the Tilt control lever. Supplies Controls the reach carriage retract speed.
an analog signal to the main control module VCM to
control the tilt speed. Must be recalibrated when re- PVRE
placed. Proportional Valve Reach
POT5 Controls the reach carriage reach speed.
Sideshift Potentiometer RES1

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

hydraulic control levers only
ESR 5000
104
ELECTRICAL SYSTEM
SES SVT
Seat Switch Solenoid Valve Tilt
Installed in the drivers seat. Applies when the seat is Installed on the manifold on the fork carriage. The SVT
occupied. Disconnects all truck functions apart from is a black/white valve. It opens when tilting is selected.
steering when the seat is vacated. The tilt speed is governed by the pump speed.
SFS 1SA SW
Steering Feedback Sensor 1 Straight Ahead Switch Working Lights
Located in the motor compartment behind the traction Installed in the control panel. Connects relay K6.
motor. Captures the forward position of the drive wheel
on the gear unit. TCM
SFS 2 Traction Control Module
Installed in the electric compartment. Controls the trac-
Steering Feedback Sensor 2 tion motor. Reads the values of encoder ECR1 and
Located in the motor compartment to the right of the thermal sensor THS1.
traction motor. Senses the quadrants.
THS1
SPS
Thermal Sensor 1
Safety Pedal Switch Installed in the traction motor. Captures the motor tem-
Inductive switch installed below the floorboard on the perature. When the motor temperature reaches 145 C
safety pedal. The switch must be pressed to activate the motor current is reduced to 250 A. If the motor tem-
travel and hydraulic functions. The safety switch mes- perature continues to rise, the motor current is further
sage is displayed if: reduced until it reaches 0 amps at a motor temperature
the safety pedal is pressed and the truck is of 165C and the motor cuts out.
switched on.
the travel switch is pressed and the safety pedal is
THS2
not. Thermal Sensor 2
a hydraulic function is applied and the safety pedal Installed in the pump motor. Captures the current motor
is not. temperature. When the motor temperature reaches
145 C the motor current is reduced to 250 A. If the mo-
SVR tor temperature continues to rise, the motor current is
further reduced until it reaches 0 amps at a motor tem-
Solenoid Valve Lift
perature of 165C and the motor cuts out.
SVR is incorporated with PVL in a valve body. SVR is
a black/white valve. It opens when lifting is selected. THS3
The lift speed is governed by the pump speed.
Thermal Sensor 3
SVS Installed near the SPS. Controls the switching on and
off of the heating resistors.
Solenoid Valve Sideshift
Limits: On at +5 C, off at +10 C
Installed on the manifold on the fork carriage. The SVS
is a black/white valve. It opens when sideshift opera- THS4
tion is selected. The sideshift speed is governed by the
pump speed. Thermal Sensor 4
Installed in the steer motor. When the motor tempera-
ture reaches 145C the motor current is reduced. If the
motor temperature continues to rise, the motor current
is further reduced until it reaches 0 amps at a motor
temperature of 180C and the motor cuts out.
ESR 5000
105
Notes:
106
ELECTRICAL SYSTEM
Service Menu Structure
Service Menu Structure Analyzer
Software version A1 Status

A2 Inputs
The Service Menu Structure chapter describes soft-
ware version V1 of 28.10.2008. A3 Outputs
Menu structure
The service menu outlined on page 117 is divided into A1Status
menu items.
The text under the display messages describes the A1.1 Vehicle Control Module (VCM)
meaning and purpose of the display. A1.2 Traction Control Module (TCM)
A1.3 Hydraulic Control Module (HCM)
Overview of menu items
A1.4 Steer Control Module (SCM)
Analyzer
A1.5 Main Contactor closed
A1 Status checks
A1.6 Battery Charge
A2 Input signals A1.7 TEMP Trac. Module (TCM)
A3 Output signals A1.8 TEMP Trac. Motor (M1)
Calibration A1.9 TEMP Hydr. Module (HCM)
Truck component calibration A1.10 TEMP Pump Motor (M2)
Feature A1.11 TEMP Steer Control Module (SCM)
For programming enhanced truck options and A1.12 TEMP Steer Motor (M3)
adapting to special applications.
Hour Meter
A2 Inputs
Setting the hour meter and service intervals.
Log Events A2.1 Forward Switch (FS)
Calling up event codes and frequencies. A2.2 Reverse Switch (RS)
Deleting the error log A2.3 Pot1 Accelerator Pedal
Performance A2.4 Pot2 Lift Lower Handle
Programming the performance setting. A2.5 Pot3 Reach Handle
Utilities A2.6 Pot4 Tilt Handle
U1 software versions of control modules A2.7 Pot5 Side Shift Handle
A2.8 Pot6 5th Function Handle
U2 Service hour settings
A2.9 Accelerator Switch (ACS)
U3 Unblocking accessory functions for event
codes. A2.10 Seat Switch (SES)
A2.11 Safety Pedal Switch (SPS)
A2.12 Battery Latch Switch (BLS)
A2.13 Brake Switch (BRS)
A2.14 Brake Pressure Switch (BPS)
A2.15 Brake Fluid Switch (BFS)
A2.16 Free Lift Switch (FLS)
A2.17 Height Switch(HGTS)
A2.18 Height Reset Switch (HGRTS)
A2.19 Height Encoder
A2.20 Load Sensor (LS)
A2.21 Override Switch (ORS)
ESR 5000
107
ELECTRICAL SYSTEM
A2.22 Pressure Switch (PLS) C8 Weight

A2.23 Slow Down Area (RES1) C9 Fork Positioning
A2.24 Slow Down In/Out (RES2) C10 Reach Retract Slow Down
A2.25 Battery Current C11 Save
A2.26 Traction Motor Set & Actual Speed
A2.27 Traction Motor Current
A2.28 Travel Speed C1 Acceleration Pedal
A2.29 Pump Motor Set & Actual Speed
C1.1 Released
A2.30 Pump Motor Current
C1.2 Depressed
A2.31 Steer Motor Speed
A2.32 Steer Motor Current
A2.33 Steer sensor St. Ahead (SFS 1) C2 Raiser/Lower Handle
A2.34 Steer sensor Quadrant (SFS 2)
A2.35 Steer Wheel Angle C2.1 Released
A2.36 Battery Voltage C2.2 Depressed
A3 Outputs C3 Reach Handle
A3.1 Set TXN Speed C3.1 Retract

A3.2 Set Pump Speed C3.2 Reach
A3.3 Brake Output C3.3 Center
A3.4 Main Con. Output
A3.5 Lift Valve (SVH)
C4 Tilt Handle
A3.6 Lower Valve (PVL)
A3.7 Retract Valve (PVRT)
C4.1 Tilt Up
A3.8 Reach Out Valve (PVRE)
C4.2 Tilt Down
A3.9 Mast Right Valve (PVAR)
C4.3 Center
A3.10 Mast Left Valve (PVAL)n
A3.11 Tilt Valve (SVT)
A3.12 Side Shift Valve (SVS) C5 Side Shift Handle
A3.13 5th Function Valve (SV5)
A3.14 Alarm 2, Direction C5.1 Right
A3.15 Beacon C5.2 Left
A3.16 Fan C5.3 Center
Calibration C6 5th Function Handle
C6.1 Right
C1 Acceleration Pedal
C6.2 Left
C2 Raise/Lower Handle
C6.3 Center
C3 Reach Handle
C4 Tilt Handle
C5 Side Shift Handle C7 Height
C6 5th Function Handle
C7 Height C7.1 R Cut 1
ESR 5000
108
ELECTRICAL SYSTEM
C7.1.1 None Features

C7.1.2 Override Set Height F1 Truck Size
C7.1.3 Stop
F1.1 Truck Size
C7.2 R Cut 2 F1.2 Free Lift Switch
C7.2.1 None
C7.2.2 Override Set Height
F2 Free Lift Switch
C7.2.3 Stop
F2.1 No
C7.3 R Cut 3
F2.2 Yes
C7.3.1 Saved Max. Height
C7.3.2 Enter 2nd Height
F3 Height Encoder
C7.4 R Cut 4
C7.4.1 None F3.1 No
C7.4.2 Cut Height Lift to Limit F3.2 Yes
F4 Lower Cut Out

C8 Weight
F4.1 No
C8.1 No Load
F4.2 XXX
C8.2 Load
F4.3 Yes
C9 Fork Positioning F5 5th Function
C9.1 Adjust Tilt Up F5.1 Off

C9.1.1 Change Value ... F5.2 On
C9.2 Adjust Tilt Up F5.3 LCS
C9.1.1 Change Value ...
F6 Max. Load
C10 Reach Retract Slow Down
F6.1 Change Value ...
C10.1 Adjust Reach
F7 Capacity Data M.
C10.2 Adjust Retract
F7.1 No
F7.2 Yes
C11 Save? F7.3 Set Zones
F7.4 Height1=xxx / Weight1=xxx
C11.1 No F7.5 Height2=xxx / Weight2=xxx
C11.2 Yes F7.6 Height3=xxx / Weight3=xxx
F7.7 Height4=xxx / Weight4=xxx
ESR 5000
109
ELECTRICAL SYSTEM
F8 Travel Alarm F12.16 Slovenian

F12.17 Greek
F8.1 Alarm Off
F8.2 Alarm Reverse
F8.3 Alarm Forward F13 Change Unit
F13.1 Euro
F9 Beacon F13.2 USA
F9.1 Beacon Off

F9.2 Key Switch F14 Set Rack Select
F9.3 Beacon Reverse
F9.4 Beacon Forward F14.1 No
F9.5 Beacon Forward and Reverse F14.2 Yes
F10 User Performance F15 Height/Weight
F10.1 No F15.1 No
F10.2 Yes F15.2 Yes
F11 User Code F16 Timer
F11.1 No F16.1 No
F11.2 Yes F16.2 Yes
F11.3 View
F11.4 Add F17 Error Log
F11.5 Delete
F17.1 No
F17.2 Yes
F12 Set Language
F12.1 English F18 Operator Alarm

F12.2 German
F12.3 French F18.1 No
F12.4 Italian F18.2 Yes
F12.5 Dutch
F12.6 Spanish
F19 Battery Alarm
F12.7 Danish
F12.8 Finnish F19.1 No
F12.9 Swedish F19.2 Yes
F12.10 Norwegian
F12.11 Portuguese
F12.12 Turkish F20 Fork Positioning
F12.13 Polish
F20.1 No
F12.14 Czech
F20.2 Yes
F12.15 Hungarian
ESR 5000
110
ELECTRICAL SYSTEM
F21 Choose Steering F27 Options Display
F21.1 180 F27.1 Hazard Warning Light

F21.2 360 F27.2 Aud Travel Alarm
F21.3 Both F27.3 Heated Screen
F27.4 Heated Seat
F27.4.1 No
F22 Speed Reduction
F27.4.2 Yes
Void
F23 Cruise Control
F28 Truck Lockout
Void
F24 High Speed
F28.1 No
Void F28.2 Yes
F25 Keyless Entry

F29 Direction Switch
F25.1 Keyless Enable F29.1 One

F25.1.1 No
F29.2 Two
F25.1.2 Yes
F25.2.2 Shutdown Time
F25.2.1 Change Value ... F30 Save ?
F30.1 No
F26 Right Handle F30.2 Yes
F26.1 S/D Lever

F26.2 MTC
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ELECTRICAL SYSTEM
Hour Meter Performance

H1 Truck Complete P1 Setup P1
H2 Traction Module
P1.1 Travel Speed FWD
Full / Middle / Easy P1.2 Travel Speed REV
P1.3 Acceleration
P1.4 Plugging
H3 Hydraulic Mod. P1.5 Coasting
P1.6 Reduction Brake
Full / Middle / Easy
P1.7 Pedal Brake
P1.8 Raise Speed
H4 Key On Time P1.9 Raise ACC
H5 Set Service Time P1.10 Lower Speed
P1.11 Lower Stop
H5.1 None P1.12 Reach Speed
H5.2 Change Value ... P1.13 Tilt Speed
P1.14 SS Speed
Log Events
P2 Setup P2
L1 History
L1.1 Code Work Hours Temperature
P2.2 Travel Speed REV
P2.3 Acceleration
L1.15 Code Work Hours Temperature P2.4 Plugging
P2.5 Coasting
L2 Totals P2.6 Reduction Brake
P2.7 Pedal Brake
L2.1 Event 0..=YYY P2.8 Raise Speed
P2.9 Raise ACC
L2.X Event XXX = YYY P2.10 Lower Speed
P2.11 Lower Stop
P2.12 Reach Speed
L3 Erase History
P2.13 Tilt Speed
P2.14 SS Speed
L3.1 Erase History
L3.1.1 Sure = No
L3.1.2 Sure = Yes P3 Setup P3

P3.2 Travel Speed REV
P3.3 Acceleration
P3.4 Plugging
P3.5 Coasting
P3.6 Reduction Brake
P3.7 Pedal Brake
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ELECTRICAL SYSTEM
P3.8 Raise Speed P12 Steer Sensitivity

P3.9 Raise ACC
P3.10 Lower Speed P12.1 Change Value ...
P3.11 Lower Stop
P3.12 Reach Speed P13 Sens Steering
P3.13 Tilt Speed
P3.14 SS Speed P13.1 No
P13.2 Yes
P4 BDI Setting
P14 Brake at Ramp
P4.1 Change Value ...
P14.1 No
P14.2 Yes
P5 Travel > LCS
P5.1 Change Value ... P15 Set Default Values
P15.1 No
P6 Travel > FLS
P15.2 Yes

P16 Save ?
P7 Travel > Custom

P16.1 No
P16.2 Yes
P8 Lower > Custom Utilities

U1 Software Version
U1.1 Vehicle Control Module (VCM)
U1.2 Traction Module (TCM)
P9 Reach > Custom
U1.3 Hydraulic Module (HCM)
P9.1 Change Value ... U1.4 Steer Drive Module (SCM)
U1.5 Display screen
P10 5th Func Left

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

U3 Brake Override
U3.1 No
U3.2 Yes
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ELECTRICAL SYSTEM
U4 Check Fan 1-4
U4.1 Off
U4.2 On
U5 Keyless Time
U5.1 Change Value ...
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ELECTRICAL SYSTEM
Performance level defaults P1.4 Plugging 6

P1.5 Coasting 6
P1.6 Reduction Brake 7
The text under the display messages describes the
meaning and purpose of the display. P1.7 Pedal Brake 9
P1.8 Raise Speed 5
Standard settings P1.9 Raise ACC 3
P1 Setup - Defaults P1.10 Lower Speed 9
P1.11 Lower Stop Soft
P1.1 Travel Speed FWD 12 P1.12 Reach Speed 5
P1.2 Travel Speed REV 12 P1.13 Tilt Speed 5
P1.3 Acceleration 8 P1.14 SS Speed 5
P1.4 Plugging 8
P1.5 Coasting 8
P1.6 Reduction Brake 7 P4 BDI Setting
P1.7 Pedal Brake 9
P4.1 Acid Battery 6
P1.8 Raise Speed 5
Maintenance Free Battery 8
P1.9 Raise ACC 3
P1.10 Lower Speed 9
P1.11 Lower Stop Soft P5 Travel > LCS
P1.12 Reach Speed 5
P1.13 Tilt Speed 5 P5.1 9
P1.14 SS Speed 5
P6 Travel > FLS
P2 Setup - Defaults
P6.1 9
P1.1 Travel Speed FWD 11
P1.2 Travel Speed REV 11 P7 Travel > Custom
P1.3 Acceleration 7
P1.4 Plugging 8 P7.1 9
P1.5 Coasting 8
P1.6 Reduction Brake 7
P8 Lower > Custom
P1.7 Pedal Brake 9
P1.8 Raise Speed 5
P8.1 9
P1.9 Raise ACC 3
P1.10 Lower Speed 9
P1.11 Lower Stop Soft P9 Reach > Custom
P1.12 Reach Speed 5
P1.13 Tilt Speed 5 P9.1 9
P1.14 SS Speed 5
P10 5th Func Left
P3 Setup - Defaults
P10.1 10
P1.1 Travel Speed FWD 10
P1.2 Travel Speed REV 10
P1.3 Acceleration 5
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ELECTRICAL SYSTEM
P11 5th Func Right
P11.1 10
P12 Steer Sensitivity
P12.1 7
P14 Brake at Ramp
P14.2 Yes
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116
ELECTRICAL SYSTEM
Service Menu - General

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

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

eration.
Trucks without key switch
Entering the service code Fig. 66 Display structure

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

The following table lists the navigation and entry
options within the service menu:
Press this key to access a higher level in

the menu.
Press this key to access a lower level in the
menu.
Press briefly to scroll down an item in a
menu.
Hold down on this key to scroll through to
the next menu item every 750 ms.
Press briefly to scroll up an item in a menu.
Hold down on this key to scroll through to
the next menu item every 750 ms.
Press this key to acknowledge data.
To enter a number, type it out on the numer-

ical keypad.
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ELECTRICAL SYSTEM
Access to service menu and selecting a sub-menu

Entering the service code

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

2. Enter the service code using the numerical keys.

3. Press the key.
The truck is ready for operation. You are now in the enhanced service
menu.
Selecting a sub-menu
4. Select the required menu item with the or keys:
Analyzer (see page 119)
Calibrate (see page 127)
Features (see page 139)
Hourmeter (see page 155)
Log Events (see page 158)
Performance (see page 160)
Utilities (see page 170)
5. Press the key.
ESR 5000
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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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119
ELECTRICAL SYSTEM
Analyzer Menu

Steering control module (SCM) temperature

Steer motor (M3) temperature
A2 Inputs

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

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

Voltage reading on slider of "Travel" potentiometer (POT1) and corre-
sponding digital reading in the 2nd row.
Item Voltage Digital reading
Neutral position 0.7 - 1.5 V 0

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

Voltage reading on slider of "Lift" potentiometer (POT2) and corresponding
digital reading in the 2nd row.
Neutral position 4.3 - 4.7 V 460 - 570

Max. lower 0.7 - 1.5 V 0
Max. lift 7.8 - 8.2 V 1023
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ELECTRICAL SYSTEM
Analyzer Menu

Voltage reading on slider of "Reach" potentiometer (POT3) and corre-

Max. lower 0.7 - 1.5 V 0
Max. lift 7.8 - 8.2 V 1023

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

Max. lower 0.7 - 1.5 V 0
Max. lift 7.8 - 8.2 V 1023

Voltage reading on slider of "Sideshift" potentiometer (POT5) and corre-

Max. lower 0.7 - 1.5 V 0
Max. lift 7.8 - 8.2 V 1023
ESR 5000
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ELECTRICAL SYSTEM
Analyzer Menu

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

Max. lower 0.7 - 1.5 V 0
Max. lift 7.8 - 8.2 V 1023

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Actual battery current display.
ESR 5000
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ELECTRICAL SYSTEM
Analyzer Menu

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

Actual traction motor current

Current speed

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

Actual pump motor current

Current steer motor speed

Actual steer motor current

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

For 360 steering

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

Current battery voltage
A3 Outputs

VCM speed specification for the traction motor.

VCM speed specification for the pump motor.

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

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

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

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

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

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

ESR 5000
125
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).
ESR 5000
126
ELECTRICAL SYSTEM
Calibration Menu
Calibration Menu
Note: Save the changes in menu item C11 (Save ?) before switching off the truck, otherwise you will lose the
changes.
1. Activate the Service menu (see page 117) and scroll through to menu item CALIBRATE using the or
keys.

2. Press the key.

3. Menu item C1 opens up.
4. Use the or keys to scroll through to the required sub-menu
(C1 to C11).
C1 Accelerator Pedal
Calibrating the "Accelerator pedal" potentiometer

1. Press the key.

Menu item C1.1 opens up.

2. Release the accelerator pedal.

3. Press the key.

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.
ESR 5000
127
ELECTRICAL SYSTEM
Calibration Menu
C2 Raise / Lower Handle

Calibrating the "Raise/lower" potentiometer

1. Press the key.


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

4. Move the control handle as far as the stop in the "Lower" direction and
hold it in position.
5. Press the key.

6. Release the control handle.

7. Press the key.
C3 Reach Handle
Calibrating the "Reach" control handle

1. Press the key.


2. Move the "Reach" control handle as far as the stop in the "Retract"
direction and hold it in position.
3. Press the key.
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ELECTRICAL SYSTEM
Calibration Menu

4. Move the "Reach" control handle as far as the stop in the "Extend"
5. Press the key.


7. Press the key.
C4 Tilt Handle
Calibrating the fork tilt

1. Press the key.


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

4. Move the "Tilt" control handle as far as the stop in the "Down" direction
and hold it in position.
5. Press the key.


7. Press the key.
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ELECTRICAL SYSTEM
Calibration Menu
C5 Side Shift
Calibrating the "Sideshift" control handle

1. Press the key.


1. Move the "Sideshift" control handle as far as the stop in the "Right"
2. Press the key.

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


6. Press the key.
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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130
ELECTRICAL SYSTEM
Calibration Menu
C7 Height Progamming lift stops

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

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

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

1. Press the key.

Menu item C7.1.1 opens up.

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

3. Press the key.

The following instruction is displayed:

4. Raise the forks to the required height.

Note: Once the fork carriage is above free lift height, the fork height is
displayed in real time.
5. When the forks are at the required height, press the key.
Menu item C7.1 opens up and shows the previously selected status
and the fork height.
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ELECTRICAL SYSTEM
Calibration Menu
Programming lift stop RCUT2

Note: If STOP or NONE have been selected for RCUT1, menu item C7.2
for programming RCUT2 is not displayed.
1. Starting from menu item C7.1. press to scroll to menu item C7.2.
2. The 2nd lift stop (RCUT2) is programmed in the same way as the
1st lift stop (RCUT1).
C7.3 Height Encoder

Calibrating the height encoder

1. Press the key.

2. Menu item C7.3.1 opens up.

Approaching and storing the maximum lift height

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

4. Raise the forks to the maximum lift height.

Note: Make sure the mast is fully extended.

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

6. Enter the recording.
7. Press the key.

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

9. Slowly lower the forks.

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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

15. Enter the recording.

16. Press the key
ESR 5000
133
ELECTRICAL SYSTEM
Calibration Menu
C7.4 Custom Height

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

1. Press the key.


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

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

4. Press the key.


5. Raise the forks to the required lift height.

6. Press the key.
Menu item C7.4 opens up and the status and lift height are dis-
played.
Note: If the fork carriage is within the free lift height the message
INVALID is displayed for 1 second. The display returns to menu item
C7.4 and status NONE is displayed.
ESR 5000
134
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.


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.
ESR 5000
135
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.


2. Press the key.


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.


6. Enter the required adjustment factor.

7. Press the key.
The adjustment factor for TILT DOWN is accepted.
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136
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.


Adjusting the deceleration ramp for extending the reach carriage

2. Press the key.

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.

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.


Rejecting changes
2. Press the key.
The changes are rejected.
Saving changes
1. Press the key

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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138
ELECTRICAL SYSTEM
Features Menu
Features Menu
The Features menu allows you to select truck-specific defaults and activate or deactivate options, as well as
other basic functions.
Note: Save the changes in menu item F30 (Save ?) before switching off the truck, otherwise you will lose the
changes.
1. Activate the Service menu (see page 107) and scroll through to menu item FEATURES using the or
keys.

2. Press the key.
Menu item F1 opens up.
F1 Truck Size
Determining truck-specific defaults

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

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

1. Press the key.
The basic settings for trucks with a 2.0 t capacity are loaded for the
next time the trucks starts.
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139
ELECTRICAL SYSTEM
Features Menu
F2 Free Lift Switch

1. Press the key.

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

3. Press to activate YES (FLS present).
Menu item F2 opens up and the status is displayed.
F3 Height Encoder

1. Press the key.

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

item F3.2.

3. Press to activate YES (ECR5 present).
ESR 5000
140
ELECTRICAL SYSTEM
Features Menu
F4 Lower Cut Out Switch

1. Press the key.

1. Press the key to activate NOT INSTALLED or press to open
menu item F4.2.

1. Press the key to activate INACTIVE (present, but not activated) or
press to open menu item F4.3.

2. Press the key to activate ACTIVE (LCS present and activated) or
F5 5th Function

1. Press the key.

1. Press the key to activate OFF (not present) or press to open
menu item F4.2.

1. Press the key to activate INACTIVE (present, but not activated) or

2. Press the key to activate ACTIVE (LCS present and activated) or
ESR 5000
141
ELECTRICAL SYSTEM
Features Menu
F6 Maximum Load

1. Press the key.

2. Enter the weight with maximum capacity (see capacity plate on truck).
ESR 5000
142
ELECTRICAL SYSTEM
Features Menu
F7 Capacity Data Monitor

1. Press the key.

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

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

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

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

Fig. 67 CDM zones 1 to 4 (correspond-

ing to WT1 to WT4 and HT1 to
HT4)
7. Press to scroll to menu item F7.4.

The display shows the weight currently set for the selected
zone together with the height up to which the zone is valid
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143
ELECTRICAL SYSTEM
Features Menu

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

9. Enter the maximum permissible weight for this zone.
F8 Travel Alarm

1. Press the key.

2. Press to select the required status (ON or OFF).
3. Press the key.

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 .

6. If the alarm is to be activated for both forward and reverse travel
(BOTH), press .
F9 Beacon

1. Press the key.

2. Press to select the required status (ON or OFF).
3. Press the key.
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144
ELECTRICAL SYSTEM
Features Menu

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

5. If the beacon is only to be activated for reverse travel (REV), press .

6. If the beacon is only to be activated for forward travel (FWD), press .

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.

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

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.

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

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

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

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

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

3. Enter the required performance setting (P1, P2 or P3).
Deleting user PINs
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ELECTRICAL SYSTEM
Features Menu
1. Starting at menu item F11.4 press .


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

2. Press or to select the required entry.
3. Press to delete the entry.
The display returns to F11.5.
F12 Set Language

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

Enter the user message language
1. Press the key.

2. Press to scroll to the required language.
3. Press the key.
Menu item F12 opens up again and displays the required language.
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ELECTRICAL SYSTEM
Features Menu
F13 Change Unit

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

Changing the unit system
1. Press the key.

2. Press to select the required unit system.
3. Press the key.
Menu item F13 opens up again and displays the required unit sys-
tem.
F14 Set Rack Select

Switching Rack Select on or off
1. Press the key.

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.

2. Press to select YES (display on) or NO (display off).
3. Press the key.
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.

2. Press to select YES (timer on) or NO (timer off).
3. Press the key.
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.

2. Press to select YES (error log on) or NO (errr log off).
3. Press the key.
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ELECTRICAL SYSTEM
Features Menu
F18 Operator Alarm

Switching the audible signal for malfunctions on or off
1. Press the key.

2. Press to select YES (alarm on) or NO (alarm off).
3. Press the key.
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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.

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.
F20 Fork Positioning

Switching Tilt Position Assist on or off
1. Press the key.

2. Press to select YES (alarm on) or NO (alarm off).
3. Press the key.
F21 Choose Steering

Choosing the type of steering
1. Press the key.

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.

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.

2. Press the key.

3. Enter the waiting period (in minutes).
F26 Right Handle

Setting the hydraulic function controls
1. Press the key.

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.
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ELECTRICAL SYSTEM
Features Menu
F27 Options Display

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

3. Press the key.

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.

2. Press to select YES (truck disabled) or NO (truck not disabled).
3. Press the key.
The next time the truck starts Truck locked by Service is displayed.
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ELECTRICAL SYSTEM
Features Menu
F29 Direction Switch

Selecting the type of direction switch
1. Press the key.

2. Press ONE (1 direction switch) or TWO (2 direction switches).
3. Press the key.
F30 Save ?

1. Press the key.

Rejecting changes
2. Press the key.
The changes are rejected.
Saving changes
1. Press the key

2. Press the key.
The changes are saved.
3. Switch the truck off and on again.
The changed values are imported when the truck starts up.
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ELECTRICAL SYSTEM
Hour Meter Menu
Hour Meter Menu
1. Activate the Service menu (see page 107) and scroll through to menu item HOUR METER using the or
keys.

2. Press the key.
Menu item H1 opens up.
H1 Truck Complete
Reading the total service hours

The total service hours are displayed.
3. Press the key.
Menu item H2 opens up.
H2 Traction Module
Reading the traction control module (TCM) service hours

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

The service hours (in seconds) are shown for the 3 temperature
ranges Easy, Middle, Full :
Easy = temperature < 50 C
Middle = temperature > 50 C to 85 C
Full = temperature > 85 C
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ELECTRICAL SYSTEM
Hour Meter Menu
H3 Hydraulic Mod.
Reading the hydraulic control module (HCM) service hours

The hydraulic control module (HCM) service hours are displayed.'
1. Press the key.

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.

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ELECTRICAL SYSTEM
Hour Meter Menu
H5 Set Service Time

Setting the service interval hours

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

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

1. Press the key.
2. Enter the service interval.
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ELECTRICAL SYSTEM
Log Events Menu
Log Events Menu
1. Activate the Service menu (see page 118) and scroll through to menu item LOG EVENTS using the or
keys.

2. Press the key.
Menu item L1 opens up.
L1 History
Displaying the last 16 events

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

The codes are as follows:
120 = event code
12345 H = service hours since the event occurred
123C = temperature
OVER TEMP. = Over-temperature
STM = Steer motor
Note: A more detailed description of the event codes can be found starting
on page 173.
2. Press the key.
The next stored event opens up.
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ELECTRICAL SYSTEM
Log Events Menu
L2 Totals
Displaying the frequency of an event

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

The codes are as follows:
EVENT 120 @ 10 = event code 120 has occurred 10 times.
Note: An event can be recorded up to a maximum of 255 times at which
point the counter starts again from scratch.
12345 H = service hours since the event occurred
OVER TEMP. = Over-temperature
STM = Steer motor
Note: A more detailed description of the event codes can be found starting
on page 173.
2. Press the key.
The next stored event opens up.
L3 Erase History
Clearing the event log

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

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

2. Press to select NO (do not clear) or YES (clear).
3. Press the key.
The LOG EVENTS display opens up again.
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ELECTRICAL SYSTEM
Performance Menu
Performance Menu
1. Activate the Service menu (see page 107) and scroll through to menu item PERFORMANCE using the
or keys.

2. Press the key.
Menu item P1 opens up.
P1 Setup P1
Entering the performance setting

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

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

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

Entering the maximum reverse speed
1. Press the key.

4. Press the key.
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ELECTRICAL SYSTEM
Performance Menu

Entering the maximum acceleration
1. Press the key.

4. Press the key.

Setting inversion braking
1. Press the key.

Note: Check the braking distance after changing the setting!
(see page 296).
4. Press the key.

Setting the coasting brake
1. Press the key.

4. Press the key.
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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.

4. Press the key.

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.

4. Press the key.

Setting the lift speed
1. Press the key.

4. Press the key.
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ELECTRICAL SYSTEM
Performance Menu

Setting the lift acceleration
1. Press the key.

4. Press the key.

Setting the lowering speed
1. Press the key.

4. Press the key.

Setting the lower speed limit range
1. Press the key.

3. Press to choose between SOFT and HARD.
4. Press the key.

Setting the mast "retract" speed
1. Press the key.
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ELECTRICAL SYSTEM
Performance Menu

4. Press the key.

Setting the tilt speed
1. Press the key.

4. Press the key.

Setting the sideshifter speed
1. Press the key.

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.


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

Setting the travel speed above the LOWER CUT OUT SWITCH

1. Press the key.

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.
P6 Travel > FLS

Setting the travel speed above the FREE LIFT SWITCH

1. Press the key.
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ELECTRICAL SYSTEM
Performance Menu

speed. However the value cannot be greater than the setting in menu item
P5.
3. Press the key.
P7 Travel > Custom

Setting the travel speed above the CUSTOM HEIGHT

1. Press the key.

speed. However the value cannot be greater than the setting in menu item
P6.
3. Press the key.
P8 Lower > Custom

Setting the lowering speed above the CUSTOM HEIGHT

1. Press the key.

Note: 5 corresponds to the maximum speed.
3. Press the key.
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ELECTRICAL SYSTEM
Performance Menu
P9 Reach > Custom

Setting the reach speed above the CUSTOM HEIGHT

1. Press the key.

Note: 5 corresponds to the maximum speed.
3. Press the key.
P10 5th Function Left

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

1. Press the key.

2. Enter a value between 6 L and 28 L.
Note: The value corresponds to the maximum volume flow when the con-
trol handle is fully applied.
3. Press the key.
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ELECTRICAL SYSTEM
Performance Menu
P11 5th Function Right

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

1. Press the key.

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

Setting the steering sensitivity

1. Press the key.

Note: 9 corresponds to the maximum sensitivity (very aggressive steer-
ing).
3. Press the key.
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ELECTRICAL SYSTEM
Performance Menu
P14 Brake at Ramp

Setting the brake pattern on ramps

1. Press the key.

2. Use to choose either NO (truck does not automatically brake on
ramps) or YES (truck brakes automatically on ramps).
3. Press the key.
P15 Set Default Values

Resetting all values in the Performance menu to defaults

1. Press the key.

2. Use to choose either NO (values are not reset) or YES (values are
reset).
3. Press the key.
P16 Save ?
Saving the changes in the Performance menu

1. Press the key.

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

2. Press the key.
Menu item U1 opens up.
U1 Software Version
Displaying the software version

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

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

Displaying the hydraulic control module (HCM) software version

3. Press the key.

Displaying the steering control module (SCM) software version

4. Press the key.

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ELECTRICAL SYSTEM
Utilities Menu
Displaying the display software version

5. Press the key.

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.


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.

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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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.

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.

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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ELECTRICAL SYSTEM
Event Codes
Event Codes HGTS (Height switch)

HGTRS (Height reset switch)
The ESR 5000 is fitted with an electronic control sys-
tem for the key operating functions. BPS (Brake pressure switch)
ORS (Override switch)
Malfunctions with event code PLS (Pressure load switch)
display Locating malfunctions
Event codes are produced from tests carried out on the Malfunctions occur primarily on external components
inputs and outputs of control signals. For most faults such as fuses, solenoids, contactors, motors etc.
the system generates an event code and stores it in the These components are necessarily subject to a certain
log book (see Fig. 68). The last 16 events are dis- degree of wear.
played in the Log Events Menu (see page 158).
The next possible causes include connectors, wiring
Log book display and input devices such as switches, potentiometers or
encoders. These are subject above all to ambient con-
ditions.

The least likely to fail are the VCM (main module), TCM
(traction module), HCM (hydraulic module) and SCM
(steer module) control modules.

The easiest way of locating a fault is to start trouble-
shooting on the component (the external component).
This is the quickest way of obtaining a result.
The following sections list the event code numbers in
Fig. 68 Example of a log book entry
ascending order. In addition to each event code they
1 Event code number also list the possible causes, the effect on the truck and
2 Service hours at the time of the event troubleshooting notes.
3 Component temperature at time of event (if available)
4 Brief component description
5 Component name
Malfunctions without event code

display
The malfunctions that can occur without providing an
event code can fall into one of three categories.
Malfunction during start-up
Malfunctions in the power-up circuit can keep the truck
from powering up correctly (refer to the Power up cir-
cuit diagram, page 382).
Mechanical or hydraulic malfunctions
The malfunction occurs after the truck has started up,
but without an event code display.
The fault is mechanical or hydraulic. The correspond-
ing section in the maintenance section of this manual
can be used for troubleshooting purposes.
Malfunction in one of a group of unmonitored
inputs
One of the unmonitored inputs is causing the malfunc-
tion. They include:
HNS (Horn switch)
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ELECTRICAL SYSTEM
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.
Possible Causes: Error in internal power circuit of steer module
Remedy: Restart
If the fault persists, proceed to step 2.
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ELECTRICAL SYSTEM
Event Code 102

Display: ERROR STEER MOT.
Explanation: Open or shorted steer motor power circuit.
Effect: Parking brake applied.
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.
Traction and hydraulic modules deactivated
Possible Causes: Emergency Disconnect pressed during plugging operation
Error in steer module
Remedy: Note: If no cause can be found and the truck works correctly after restarting,
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ELECTRICAL SYSTEM
Event Code 111

Display: LOW VOLTAGE SDM
Explanation: Low voltage (< 24 V) in steer module power circuit.
Error in steer module
Remedy: Check power cables
1. Check power cables.
If there is no damage, proceed to step 2.
Check battery voltage with load
2. In the Analyzer menu select item A2.36.
3. Raise a heavy load and monitor the battery voltage during the lifting
operation.
If the battery voltage drops significantly, proceed to step 4.
Note: If the truck works after restarting, monitor the frequency of the fault (see
Log Events Menu, page 158). If the event occurs frequently, contact the Crown
service department.
Repair the battery
4. Repair the battery in accordance with the manufacturers instructions or
replace it.
Event Code 112

Display: 15 VOLT SUPPLY SDM
Explanation: 15 V supply in the steer module faulty
Possible Causes: Error in steer module
Remedy: 1. Replace the steer module.
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ELECTRICAL SYSTEM
Event Code 120

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

9. Replace the steer motor.
10. Check the current consumption with the steer motor installed.
If the consumption is still too high with the steer motor installed, the
steer module may be faulty. Proceed to step 7.
If the consumption is still too high, contact the Crown service department.
Event Code 121

Display: HIGH TEMP SDM
Explanation: Steer module internal temperature is > 75 C.
Effect: The display shows: HIGHTEMP STEERING MOTOR
Possible Causes: See event code 120, page 174.
Remedy: See event code 120, page 174.
Event Code 123

Display: OVER TEMP SMOT
Explanation: Steer motor coil temperature is > 150 C.
Event Code 124

Display: OVER TEMP SMOT
Explanation: Steer motor overtemperature (t > 125 C).
Effect: The display shows: HIGHTEMP STEERING MOTOR
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ELECTRICAL SYSTEM
Event Code 130

Display: ERROR CANBUS SDM
Explanation: Communication error on the CAN Bus between the main module (VCM) and
the steer module (SCM).
Effect: Main contactor ED1 de-energised
Possible Causes: Wiring error
Error in main module (VCM)
Error in steer module (SCM)
Remedy: Measure the load resistance of the CAN Bus wiring between the main
module and the steer module
1. Measure the resistance between PC416-1 and -2.
If the resistance is 60 , the main and steer modules are ok.
service department.
If the resistance is 120 , then either the main module or steer module
is faulty. Proceed to step 2.
Measure the load resistance in the main module (VCM)
2. Disconnect PC205 from the main module.
3. Measure the resistance on the main module between PC205-22 and -23.
If the resistance is 120 , the main module is ok. Proceed to step 5:
If a different reading is obtained, the main module is faulty.
4. Replace the main module.
Measure the load resistance in the steer module (SCM)
5. Disconnect PC20 from the steer module.'
6. Measure the resistance on the steer module between PC205-10 and -11.
If the resistance is 120 , the steer module is ok.
service department.
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ELECTRICAL SYSTEM
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
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.
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ELECTRICAL SYSTEM
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.
Possible Causes: Fuse FU3 faulty
Wiring or connector damaged
Brake coil faulty
Remedy: Check fuse FU3
1. Check fuse FU3.
Replace if faulty. If the fuse is ok, proceed to step 2.
Check wires and connections
2. Check wires and connections for discontinuity and short circuits.
Measure the brake coil resistance
3. Using an ohmmeter measure the brake coil resistance.
Rated resistance approx. 32 (Crown motor) or 46.6 (Danaher mo-
tor). If the reading differs significantly, the brake coil is faulty. Proceed
to step 4.
Replace the brake coil
4. Replace the brake coil (see page 290).
Note: A truck with a faulty parking brake can be driven out of the aisle at creep
speed (see U3 Brake Override, page 172).
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ELECTRICAL SYSTEM
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.
Possible Causes: Wiring or connectors damaged
No +5 V supply
Remedy: Check wires and connections
Check +5 V supply
2. Disconnect PC414.
3. Using a voltmeter measure the voltage between PC414-5 and -6 and be-
tween PC414-7 and -8.
If there is a +5 V supply, proceed to step 4.
If there is no +5 V supply, proceed to step 6.
4. Reconnect PC414.
5. Using a voltmeter measure the voltage between PC436-1 and -2.
If there is no +5 V supply, this indicates that a wire has been discon-
nected. Proceed to step 8.
Replace steer module
Replace steer motor
Repair wiring
8. Repair the wiring.
ESR 5000
182
ELECTRICAL SYSTEM
Event Code 181

Display: ECR4 STEPPER MOTOR
Explanation: Error in steer encoder ECR4 (fitted on steering wheel).
ECR4 is a 4-channel Hall sensor fitted in the steer motor. This event code is
generated if a channel is not correctly identified or if 2 channels are shorted.
Possible Causes: Wiring or connectors damaged
No +5 V supply
Remedy: Check wiring
9. Check the wiring between PC414 and CA204 for discontinuity and short
circuits.
If the wiring is faulty, proceed to step 12.
If the wiring is ok, proceed to step 10.
Check +5 V supply
11. Using a voltmeter measure the voltage between PC414-5 and -6 and be-
If there is no 5 V supply, proceed to step 13.
Repair 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 no 5 V supply, proceed to step 15
Replace sensor bearing ECR4
16. Replace sensor bearing ECR4.
ESR 5000
183
ELECTRICAL SYSTEM
Event Code 182

Display: SW1 OR 2 SW ERROR
Explanation: Switch signal of sensor switch SFS1 SA or SFS2 not detected.
The expected signal change did not occur when the drive wheel was turned.
Effect: An error routine is started (see page 303).
Possible Causes: Wiring or connector damaged
Incorrect screw depth of sensor SFS1 SA or SFS2
Sensor SFS1 SA or SFS2 faulty
12 V supply in display faulty
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 Code 183

Display: SFS2 SW EXPECTED
Explanation: Switch signal of sensor switch SFS2 not detected.
Quadrant recognition error.
Effect: An error routine is started (see page 303)
Screw depth of sensor SFS2 incorrectly set
Sensor SFS2 faulty
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.
step 3.
Check sensor SFS2
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.
Replace the display
Check wiring
9. Check the wires for discontinuity.
ESR 5000
185
ELECTRICAL SYSTEM
Event Code 184

Display: START ERROR SDM
Explanation: Incorrect drive wheel position detected. The stored drive wheel position does
not match the current position.
Effect: An error routine is started (see page 303)
Screw depth of sensor SFS1 SA incorrectly set
Sensor SFS1 SA faulty
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.
step 3.
Check sensor SFS1 SA
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.
ESR 5000
186
ELECTRICAL SYSTEM
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
Thermal sensor faulty
1. Check wires and connections (PC436) for discontinuity and short circuits.
Measure the thermal sensor resistance
3. Using an ohmmeter measure the resistance between PC436-4 and
PC436-5. Rated resistance at t =20 C: 570 (PTC resistance, the resist-
ance increases as the temperature rises)
If the resistance < 500 or > 1 k, replace the steer motor.
If the resistance > 500 and < 1 k, proceed to step 4.
ESR 5000
187
ELECTRICAL SYSTEM
Event Code 200

Display: HIGH CURRENT HM
Explanation: Current in power part of hydraulic module is too high (> 787 A).
Possible Causes: Short circuit in following components:
Power cable to pump motor
Pump motor coil
Hydraulic module output stage
Hydraulic pump blocked
1. Check wires for short circuits.
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 Code 201

Display: SHORT CIRCUIT HM
Explanation: Short circuit in power circuit of hydraulic module.
Effect: Traction and hydraulic modules deactivated
Parking brake applied
Power cable to pump motor
Pump motor coil
Hydraulic module output stage
Remedy: Measure the pump motor insulation resistance
2. Check motor coil insulation resistance.
If the motor coils are ok, proceed to step 4.
ESR 5000
189
ELECTRICAL SYSTEM
Event Code 210

Display: HIGH VOLTAGE HM
Explanation: Overvoltage in hydraulic module power circuit (> 63 V).
Hydraulic module error
Remedy: Rule out operator errors
1. Ask the operator if the Emergency Disconnect has been applied during a
plugging operation.
If the Emergency Disconnect was not pressed during a plugging oper-
ation, proceed to step 2.
service department.
Event Code 211

Display: LOW VOLTAGE HM
Explanation: Overvoltage in hydraulic module power circuit (V < 18 V).
Faulty battery
Hydraulic module error
Remedy: Check power cables
1. Check power cables.
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.
service department.
ESR 5000
190
ELECTRICAL SYSTEM
Repair the battery

4. Repair the battery in accordance with the manufacturers instructions or
replace it.
ESR 5000
191
ELECTRICAL SYSTEM
Event Code 212

Display: 15 VOLT SUPPLY HM
Explanation: Internal 15 V hydraulic module supply faulty.
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
1. Replace the hydraulic module (see page 259)
ESR 5000
192
ELECTRICAL SYSTEM
Event Code 214

Display: CAP CHARGE HM
Explanation: Capacitor charge time exceeded.
Effect: Main contactor ED1 does not close
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 damage, proceed to step 7.
Check B+ supply to hydraulic module
4. Connect voltmeter to B+ and B- of the hydraulic module.
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.
ESR 5000
193
ELECTRICAL SYSTEM
Event Code 220

Display: OVER TEMP. HM
Explanation: Hydraulic module overtemperature (t > 115 C)
Effect: Hydraulic drive module is deactivated
Travel at creep speed enabled
The display shows: OVER TEMP. HM
Possible Causes: Hydraulic module ventilation affected by:
Overload
Contamination
Malfunction in power part of hydraulic module
Remedy: Test the fans
1. Test the fans (see U4 Check Fan 1 - 4, page 170).
If a faulty fan is discovered, proceed to step 2.
If the fans are working, proceed to step 3.
Replace the fans
2. Replace the fans.
Clean contaminated hydraulic module and air supplies
3. Clean the hydraulic module and air supplies if contaminated.
If the hydraulic module and air supplies are clean, proceed to step 4.
Check the application conditions
load.
See Performance Menu, page 160.
If the application conditions are not difficult and the error occurs fre-
quently, proceed to step 5.
ESR 5000
194
ELECTRICAL SYSTEM
Event Code 221

Display: OVER TEMP. HMOT
Explanation: Hydraulic motor coil overtemperature (t > 165 C)
Effect: Hydraulic module is deactivated
The display shows: OVER TEMP. HMOT
Overload
Contamination
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.
load.
Monitor the frequency of the event
5. Monitor the frequency of the event.
service department.
ESR 5000
195
ELECTRICAL SYSTEM
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
Overload
Contamination
Malfunction in power part of hydraulic module
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.
load.
ESR 5000
196
ELECTRICAL SYSTEM
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.
service department.
ESR 5000
197
ELECTRICAL SYSTEM
Event Code 224

Display: HIGH TEMP. HMOT
Explanation: Excessive temperature in hydraulic motor coil (t > 145 C)
Effect: Between 145 C and 165 C the hydraulic module output current is re-
duced in proportion to the rise in temperature down to 0 A.
The display shows: HIGH TEMP. HMOT
Overload
Contamination
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.
load.
service department.
ESR 5000
198
ELECTRICAL SYSTEM
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.
step 2
step 3
below 0 C.
service department.
ESR 5000
199
ELECTRICAL SYSTEM
Event Code 240

Display: POT2 ABOVE LIMIT
Explanation: The voltage on the slider of potentiometer POT2 is permanently monitored
during power-up and operation. The upper limit of 10.8 volts has been ex-
ceeded.
Effect: Hydraulic functions are deactivated
Possible Causes: Wiring short circuit
Potentiometer faulty
Remedy: Check the voltage readings
1. In the Analyzer menu select item A2.4 (see page 119).
2. Apply Lift/Lower".
If approx. 12 V is displayed, either there is a short circuit or an input on
the VCM is faulty. Proceed to step 3.
Check the potentiometer wiring
3. Check the potentiometer wiring for a short circuit.
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.
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.
If normal readings are taken in steps 5 to 7, this indicates the potentiome-
ter is ok.
Compare the readings taken with the multimeter with those in the Ana-
lyzer menu display.
If normal readings are taken in steps 5 to 7 but approx. 12 V are displayed
in the Analyzer menu, this indicates that the VCM input is faulty. Proceed
to step 9.
Replace the potentiometer
8. Replace the potentiometer POT2 (see page 268).
Replace the main module (VCM)
9. Replace the VCM (see page 258).
ESR 5000
200
ELECTRICAL SYSTEM
Event Code 241

Display: POT2 UNDER LIMIT
during power-up and operation. The reading has dropped below the lower limit
of 0.6 volts.
Possible Causes: Short circuit or discontinuity in wiring
Faulty contact in connector or potentiometer
If approx. 0 V are displayed, there is either an open circuit between
CA407-2, CA407-1 and the main module (VCM) or a short circuit be-
tween CA407-2 and CA407-3. proceed to step 3.
3. Check the wiring to connectors PC407 and PC205 for discontinuity and
short circuits.
ter is ok.
lyzer menu display.
in the Analyzer menu, this indicates a transient event.
ESR 5000
201
ELECTRICAL SYSTEM
Event Code 243

ceeded.
Proceed to step 8.
ter is ok.
lyzer menu display.
to step 9.
ESR 5000
202
ELECTRICAL SYSTEM
Event Code 244

of 0.6 volts.
short circuits.
ter is ok.
lyzer menu display.
ESR 5000
203
ELECTRICAL SYSTEM
Event Code 246

ceeded.
Note: For trucks with the multi-task control handle (MTC) this event code indi-
cates an incorrect setting in the F26 Right Handle menu, page 152.
Proceed to step 8.
ter is ok.
lyzer menu display
to step 9.
ESR 5000
204
ELECTRICAL SYSTEM
Event Code 247

of 0.6 volts.
Note: For trucks with the multi-task control handle (MTC) this event code indi-
cates an incorrect setting in the F26 Right Handle menu, page 152.
short circuits.
ter is ok.
lyzer menu display.
ESR 5000
205
ELECTRICAL SYSTEM
Event Code 249

ceeded.
Proceed to step 8.
ter is ok.
lyzer menu display.
to step 9.
ESR 5000
206
ELECTRICAL SYSTEM
Event Code 250

of 0.6 volts.
short circuits.
ter is ok.
lyzer menu display.
ESR 5000
207
ELECTRICAL SYSTEM
Event Code 260

Display: SVH LIFT VALVE
Explanation: Overcurrent detected on SVH valve coil during lifting operation. Output to SVH
cut out by VCM.
Effect: All outputs to the hydraulic valve coils are cut out.
Possible Causes: Faulty coil
Wiring short circuit
Main module VCM faulty
Remedy: Measure the coil resistance
1. Disconnect PC807 from valve.
2. Measure resistance between pin 2 and pin 3 on the coil.
If the resistance is 75 , proceed to step 4.
If the resistance is not 75 , proceed to step 3.
Replace the coil
3. Replace the coil.
Check the wiring for short circuits
4. Attach connector PC807.
5. Start up the truck.
6. Leave the "Lift/Lower" control handle in neutral and measure the voltage
between PC422-9 and B.
If B+ is present, proceed to step 7. If not, proceed to step 10.
7. Disconnect PC807 from the valve and measure the voltage again between
PC422-9 and B.
If B+ is still present, this indicates a short circuit to B+ between PC807-
3 and PC205-1. Proceed to step 12.
If B+ is not present, proceed to step 8.
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.
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)
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.
ESR 5000
208
ELECTRICAL SYSTEM
Event Code 261

Display: PVL LOWER VALVE
Explanation: Overcurrent detected on PVL valve coil during lowering operation. Output to
PVL cut out by VCM.
Replace the coil
6. Leave the "Lift/Lower" control handle in neutral and measure the voltage
PC422-42 and B.
15. Activate "Lift" as far as the stop and record the voltage.
ESR 5000
209
ELECTRICAL SYSTEM
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.
Replace the coil
4. Connect PC810.
6. Leave the "Reach" control handle in neutral and measure the voltage be-
tween PC422-16 and B.
PC422-16 and B.
15. Activate "Retract reach carriage" as far as the stop and record the voltage.
ESR 5000
210
ELECTRICAL SYSTEM
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.
Replace the coil
4. Connect PC808.
6. Leave the "Reach" control handle in neutral and measure the voltage be-
PC422-10 and B.
15. Activate "Extend reach carriage" as far as the stop and record the voltage.
ESR 5000
211
ELECTRICAL SYSTEM

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.
Replace the coil
4. Connect PC809.
6. Leave the "5th function" control handle in neutral and measure the voltage
PC422-12 and B.
ESR 5000
212
ELECTRICAL SYSTEM

15. Change to the 5th function.
16. Apply 5th function left as far as the stop and record the voltage.
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.
Replace the coil
PC422-11 and B.
ESR 5000
213
ELECTRICAL SYSTEM

15. Change to the 5th function.
16. Apply 5th function right as far as the stop and record the voltage.
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.
Replace the coil
ESR 5000
214
ELECTRICAL SYSTEM

4. Connect PC801.
6. Leave the "fork tilt" control handle in neutral and measure the voltage be-
PC422-1 and B.
15. Activate "fork tilt" as far as the stop and record the voltage.
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.
Replace the coil
ESR 5000
215
ELECTRICAL SYSTEM

4. Connect PC801.
6. Leave the "sideshift" control handle in neutral and measure the voltage
PC422-5 and B.
15. Activate "sideshift" as far as the stop and record the voltage.
Event Code 268

Display: SV5 5TH FUNC. AV
Explanation: Overcurrent detected on SV5 valve coil as the 5th function is performed. Out-
put to SV5 cut out by VCM.
ESR 5000
216
ELECTRICAL SYSTEM
Replace the coil

4. Connect PC801.
PC422-18 and B.
15. Apply the 5th function as far as the stop and record the voltage.
ESR 5000
217
ELECTRICAL SYSTEM
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
Possible Causes: Hydraulic module faulty
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
Event Code 282

Display: ECR2 SHORT CIRC.
Explanation: Short circuit between channels A and B of encoder ECR2.
Possible Causes: Encoder ECR2 faulty
Encoder wiring short circuit
Main module or hydraulic module faulty
Remedy: Check the module and encoder
1. Select Analyzer menu A2.29 (see page 120).
2. Extend and retract the reach carriage.
If SET SPEED = 1000 (for reach carriage extend) and
SET SPEED = 530 (for reach carriage retract) are displayed, proceed
to step 5.
If SET SPEED = 0 is displayed, proceed to step 3.
ESR 5000
218
ELECTRICAL SYSTEM
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.
Event Code 283

Display: ECR2 OPEN CIRC.
Explanation: Open circuit or no power supply to encoder ECR2.
Encoder wiring disconnected
Remedy: Check the encoder power supply
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:
Check the module and encoder
to step 5.
6. Check the wiring between PC429 and CA 201.
ESR 5000
219
ELECTRICAL SYSTEM
Event Code 284

Display: ECR2 LOST CHANN.
Explanation: No channel A or B on encoder ECR2.
to step 4.
3. Check for disconnect wires between PC429 and CA 201.
Event Code 285

Display: TEMP. SENSOR HMOT
Explanation: Open circuit or short circuit detected in pump motor thermal sensor.
Possible Causes: Faulty wiring
THS2 faulty
Remedy: Check the wiring
1. Check for short circuits or wire disconnections between CA201-17,
CA201-16 and CA430-1 and CA430-2.
If the wiring is faulty, proceed to step 2. If not, proceed to step 3.
Repair wiring
ESR 5000
220
ELECTRICAL SYSTEM
Measure THS2 resistance

4. Measure THS2 resistance between CA430-1 and -2.
If the resistance < 500 or > 1 k, proceed to step 5.
If the resistance is approx. 600 (rated resistance for t =20 C is
600 ), monitor the error frequency.
ESR 5000
221
ELECTRICAL SYSTEM
Event Code 300

Display: HIGH CURRENT TM
Explanation: Current in power part of traction module is too high (> 525 A).
Power cable to traction motor
Traction motor coil
Traction module output stage
Blocked drive
1. Check wires for short circuits.
Measure the traction motor insulation resistance
3. Check the motor coil insulation resistance.
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.
Power cable to traction motor
Traction motor coil
Traction module output stage
ESR 5000
222
ELECTRICAL SYSTEM
Remedy: Measure the traction motor insulation resistance

2. Check the motor coil insulation resistance.
If the motor coils are ok, proceed to step 4.
Replace the traction motor
3. Replace the traction motor (see page 273).
Event Code 311

Display: LOW VOLTAGE TM
Explanation: Low voltage in traction module power circuit (V < 18 V).
Faulty battery
Error in traction drive module
Remedy: 1. Check power cables.
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.
service department.
ESR 5000
223
ELECTRICAL SYSTEM
Event Code 312

Display: 15 VOLT SUPPLY TM
Explanation: 15 V traction module supply faulty.
Effect: Truck stops through plugging
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
Possible Causes: Error in traction module
Remedy: Replace traction module
Event Code 314

Display: CAP CHARGE TM
Explanation: Capacitor charge time exceeded.
Effect: Main contactor ED1 does not close
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.
Check B+ supply to traction module
3. Connect voltmeter to B+ and B- of the traction module.
The voltage should rise from 0 V on B+ within 2 seconds. If not, proceed
to step 5.
Replace traction module
ESR 5000
224
ELECTRICAL SYSTEM
Event Code 320

Display: OVER TEMP. TM
Explanation: Traction module overtemperature (t > 115 C)
Effect: Traction module deactivated
The display shows: OVER TEMP. TM
Possible Causes: Traction module ventilation affected by:
Overload
Contamination
Malfunction in power part of traction module
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.
load.
Replace hydraulic module
ESR 5000
225
ELECTRICAL SYSTEM
Event Code 321

Display: OVER TEMP. TMOT
Explanation: Traction motor coil overtemperature (t > 165 C)
The display shows: OVER TEMP. TMOT
Possible Causes: Traction motor ventilation affected by:
Overload
Contamination
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.
load.
service department.
ESR 5000
226
ELECTRICAL SYSTEM
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
Overload
Contamination
Malfunction in power part of traction module
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.
load.
Replace traction module
ESR 5000
227
ELECTRICAL SYSTEM
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
step 2
step 3
below 0 C.
service department.
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ELECTRICAL SYSTEM
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
Overload
Contamination
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.
load.
service department.
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ELECTRICAL SYSTEM
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.
step 2
step 3
below 0 C.
service department.
Event Code 330

Display: ERROR CANBUS TM
Explanation: Communication error on the CAN Bus between the main module (VCM) and
the traction module (TCM).
module and the traction module
If the resistance is 60 , the main and traction modules are ok.
service department.
If the resistance is 120 , then either the main module or traction mod-
ule is faulty. Proceed to step 2.
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ELECTRICAL SYSTEM

Measure the load resistance in the traction module (TCM)
5. Disconnect PC204 from the traction module.
6. Measure the resistance on the traction module between PC205-22 and -
23.
If the resistance is 120 , the traction module is ok.
service department.
If a different reading is obtained, the traction module is faulty. Proceed
to step 7.
Replace the traction module (TCM)
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ELECTRICAL SYSTEM
Event Code 340

ceeded.
Effect: Travel functions are deactivated
2. Depress accelerator.
If 0 V is displayed, there is either an open circuit between CA407-2,
CA407-1 and the main module (VCM) or a short circuit between CA407-
2 and CA407-3. Proceed with step 3.
short circuits.
4. Leave the accelerator pedal in neutral and using a multimeter measure the
5. Depress the accelerator pedal as far as the stop and using a multimeter
measure the voltage between CA407-2 and CA407-1.
ter is ok. If not, proceed to step 233.
lyzer menu display.
6. Replace potentiometer POT1 (see page 267).
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ELECTRICAL SYSTEM
Event Code 341

of 0.6 volts.
2 and CA407-3. Proceed with step 3.
short circuits.
ter is ok. If not, proceed to step 233.
lyzer menu display.
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ELECTRICAL SYSTEM
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.
ACS switch faulty
Potentiometer POT1 faulty
Calibration faulty
Remedy: Test potentiometer POT1
2 und CA418-3. Proceed with step 3.
short circuits.
Record the voltage readings on the potentiometer with a multimeter and
compare them with the display in the Analyzer menu
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
If the error message persists after restarting, proceed to step 8.
Test the ACS switch
9. Press the ACS switch and check its operation.
If ACS does not switch, proceed to step 10.
If the switch is ok, proceed to step 11.
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ELECTRICAL SYSTEM
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).
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ELECTRICAL SYSTEM
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.
Remedy: Replace the traction module
Event Code 381

Display: TEMP. SENSOR TM
Explanation: Open circuit or short circuit detected in traction module thermal sensors.
Possible Causes: Traction module faulty
Remedy: Replace the traction module
Event Code 382

Display: ECR1 SHORT CIRC.
Explanation: Short circuit between channels A and B of encoder ECR1.
Main module or traction module faulty
2. Apply travel function.
If SET SPEED = 685 is displayed (when accelerator pedal applied), the
traction and main modules are ok.
event occurs frequently, contact the Crown service department.5
If ACTUAL SPEED = 0 is displayed, proceed to step 3.
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ELECTRICAL SYSTEM
Check the wiring between VCM and TCM

3. Check the wiring between PC425 and CA 201 for short circuits.
4. Replace encoder (ECR1).
Event Code 383

Display: ECR1 OPEN CIRC.
Explanation: Open circuit or no power supply to encoder ECR1.
Remedy: Check the encoder power supply
For Danaher motors:
For Crown motors:
Check the module and encoder
6. Check the wiring between PC425 and CA 201.
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ELECTRICAL SYSTEM

Event Code 384

Display: ECR1 LOST CHANN.
Explanation: No channel A or B on encoder ECR1.
Main module or traction module faulty
2. Apply travel.
event occurs frequently, contact the Crown service department.5
Check the wiring between VCM and TCM
3. Check for disconnected wiring between PC425 and CA 201.
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ELECTRICAL SYSTEM
Event Code 430

Display: ERROR CANBUS VM
Explanation: Communication error on CAN Bus of main module (VCM).
service department.
5. Disconnect PC204 from the steer module.
service department.
Event Code 431

Display: ERROR CANBUS DSPLAY
Explanation: Communication error on CAN Bus of main module (VCM) and display.
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ELECTRICAL SYSTEM
service department.
5. Disconnect PC204 from the steer module.
service department.
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ELECTRICAL SYSTEM
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
2. Remove PC402 from the start up card.
3. Remove control cable from contactor.
4. Check control cable to contactor (PC402-10 and -9) for short circuit.
If there is a short circuit, proceed to step 5.
If there is no short circuit in the wiring, proceed to step 6.
Repair wiring
5. Repair wiring.
Check contactor coil
6. With the control cables still removed, measure the contactor coil resist-
ance with an ohmmeter.
If the resistance is approx. 1.5 k, the contactor coil is ok.
If the resistance is approx. 0 , proceed to step 7.
Repair contactor
7. Repair contactor ED1 (see page 271).
Event Code 461

Display: MAINC WELDED
Explanation: Battery voltage applied to CA205-14 although truck has not been powered up.
Effect: Main contactor ED1 not energised
Possible Causes: Contactor welded.
Remedy: 1. Repair or replace contactor (see page 271).
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ELECTRICAL SYSTEM
Event 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
Possible Causes: Faulty fan
Short circuit
Replace the fans
2. Replace any faulty fans.
Trace short circuit
3. Trace for a short circuit between PC415 or PC435 to CA201-2 on HCM.
Repair faulty wiring.
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ELECTRICAL SYSTEM
Event 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
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
7. Disconnect JC433.
8. Switch on the truck and strobe.
9. Check wiring between JC433-1 and - 2 to PC435-1 and -2 for short cir-
cuits.
Check main wire harness for short circuits
11. Disconnect PC205 and PC206.
12. Check the wiring between PC433-1 and -2 for short circuits.
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
Replace the coil
15. Replace the coil (fitted on the relay bracket underneath the floorboard).
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ELECTRICAL SYSTEM
Repair contacts on PC205 and PC206

16. Repair contacts.
Replace the main module
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ELECTRICAL SYSTEM
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.
Possible Causes: Travel alarm faulty
Coil (fitted between travel and pump motors) is faulty
Wire harness error
Main module error
Remedy: Check travel alarm
2. Disconnect PC437 (fitted between the travel and pump motors).
3. Power up the truck and activate the travel alarm.
Check wiring to travel alarm and coil
5. Disconnect JC421.
6. Power up the truck and activate the travel alarm.
7. Check wiring between JC421-1 and - 2 to PC437-1 and -2 for short cir-
cuits.
Check main wire harness for short circuits
9. Disconnect PC205 and PC206.
10. Check the wiring between PC421-1 and -2 for short circuits.
11. Check contacts are securely connected to PC205 and PC206.
If the contacts are damaged, proceed to step 14.
Repair wiring
Replace the coil
13. Replace the coil (fitted between travel and pump motors).
Repair contacts on PC205 and PC206
14. Repair contacts.
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ELECTRICAL SYSTEM
Event Code 465

Display: VMC OUTPUTS
Explanation: Overcurrent detected on VCM outputs. The overcurrent could not be assigned
directly to an output. All outputs are switched off by the VCM.
Effect: Either SVH, PVL, PVRE, PVRT, PVAL, PVAR or SVT, SVS, SV5 are deac-
tivated or main contactor ED1 is de-energised.
Possible Causes: Wire harness error
Error in mast reach wire harness (see page 443)
Error in reach carriage wire harness (see page 447)
Error in mast cable (see page 458 or 459)
Error in fork carriage wire harness (see page 450 ff.)
Valve modulation error
Main module error
Horn modulation error
Remedy: Trace short circuit
1. Troubleshoot as described in event codes 463 and 464.
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)
Check contacts
4. Check contact pins are properly connected to the following:
PC205, PC206, CA422 (on mast)
CA601, CA604 (in reach carriage)
If a contact error is found, proceed to step 9.
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ELECTRICAL SYSTEM
Test components individually

Note: Each of the components named in step 3 must be tested individually.
The following shows for example how to test the SVH valve. The other compo-
nents are tested in the same way.
6. Remove PC807 from the SVH valve.
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.
12. Replace the main module (VCM).
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ELECTRICAL SYSTEM
Event Code 840

Display: FS&RS CLOSED
Explanation: Forward and reverse switches detected simultaneously on the VCM inputs.
Faulty switch
Remedy: Check direction switches
2. Disconnect CA411 (in armrest).
If the event code disappears, monitor the error frequency (see Log
Events Menu, page 158). If the event occurs frequently, contact the
Check interface
5. Reconnect CA411.
6. Disconnect CA406.
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.
Replace interface
9. Replace the interface PCB.
Repair wiring
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ELECTRICAL SYSTEM
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.
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
Encoder faulty
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ELECTRICAL SYSTEM

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.
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).
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ELECTRICAL SYSTEM
Event Code 881

Display: NO COUNTS LIFT
Explanation: No pulses from height encoder ECR5 detected during lifting.
Effect: Lift speed reduced to 50%
Height reset switch (HGTRS) does not connect
Height encoder ECR5 faulty
12 V supply faulty
Remedy: Test HGTRS
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
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.
Check wiring and operation of channel A on height encoder ECR5
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
Check wiring and operation of channel B on height encoder ECR5

very slowly.
If the voltage jumps between 0 V and 5 V, channel B is ok. Proceed to
step 17.
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.
CA803-4.
Repair wiring
15. Repair wiring.
Replace the display
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ELECTRICAL SYSTEM
Event Code 883

Display: EXEED MAX HEIGHT
Explanation: Height encoder ECR5 records a value above maximum lift height.
Possible Causes: Slip in height encoder drive
Height encoder calibration faulty
Remedy: Check drive of height encoder ECR5 for slip
1. Check drive of ECR5 for slip.
If slip is discovered in the drive, proceed to step 2.
If the drive is ok, proceed to step 3.
Repair the drive of height encoder ECR5
2. Replace faulty drive components.
Calibrate height encoder ECR5
3. Calibrate ECR5 (see page 132).
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ELECTRICAL SYSTEM
Event Code 884

Display: NO COUNTS LOWER
Explanation: No pulses from height encoder ECR5 detected during lowering.
Height encoder ECR5 faulty
12 V supply faulty
Remedy: Test HGTRS
exceeds free lift height, it is ok. Proceed to step 4.
step 3.
Replace HGTRS
Test height encoder ECR5
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.
7. Using a voltmeter measure the voltage between PC803-1 (GND) and -
3 (+12 V) on height encoder ECR5.
Check wiring and operation of channel A on height encoder ECR5
very slowly.
If the voltage jumps between 0 V and 5 V, channel A is ok. Proceed to
step 10.
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ELECTRICAL SYSTEM
Check wiring and operation of channel B on height encoder ECR5

very slowly.
If the voltage jumps between 0 V and 5 V, channel B is ok. Proceed to
step 17.
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.
CA803-2.
CA803-4.
Repair wiring
15. Then repair wiring.
Replace the display
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ELECTRICAL SYSTEM
Event Code 885

Display: ERROR HGTRS
Explanation: Height reset switch HGTRS malfunction
Remedy: Test HGTRS
step 3.
exceeds free lift height, it is ok.
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
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ELECTRICAL SYSTEM
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.
Possible Causes: Height reset switch (HGTRS) does not connect reliably
Slip in height encoder drive
Remedy: Check drive of height encoder ECR5 for slip
1. See Event Code 883, page 253.
If the height encoder drive is ok, proceed to step 2.
Check height reset switch HGTRS
2. See Event Code 885, page 256.
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ELECTRICAL SYSTEM
Control Modules and Display Screen
Control Modules and Display Traction control module TCM

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

1 Battery connector 7 Emergency Disconnect

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

Replacing the traction control module
Replacing the main control module
Preparing to replace the main control module prevent it from being switched on again.
1. Switch off the truck, disconnect the battery and 2. Remove the panel.
2. Remove the panel.
Removing the main control module WARNING
3. Remove the connector. Short circuits can cause fires
4. Remove the main control module mounting screws Charging capacitors in the control module have energy
and take out the main control module. stored. The capacitors are suddenly discharged in the
Installing the main control module event of a short circuit.
5. Install the main control module in the reverse order Either discharge the capacitors with a resistance of
of disassembly. 100 /50 W over terminals B+ und B- of the control
module or wait 15 minutes.
6. Check operation.
3. Before the next step wait for 15 minutes or perform

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

3. Provisionally connect a key switch to JC420.
5. In the Features menu select sub-menu F25 (see
page 152).
6. Activate "keyless entry" and save the change.
8. Remove the key switch from JC420.
9. Connect JC420 to JC473.
The truck is now programmed to start without a key
switch.
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ELECTRICAL SYSTEM
PMT Test
PMT Test Required tools

A self-assembled test unit:
General
EN 1175-1 requires regular inspection of the safety cir-

cuits of electronic control modules in electric lift trucks,
which is known as the PMT test (Pulse Monitor Trip
Test).
We recommend that this test be carried out at least an-
nually as part of planned maintenance (see page 29)
on the following control modules:
Steering control module (SCM)
Traction control module (TCM)
Hydraulic control module (HCM)
Safety notices
Fig. 70
WARNING
1 Power cable
Accident risk from accidental start-up during test 2 Power fuse 355 A, encapsulated
If a safety circuit is faulty, the truck or parts of it can
3 Insulating caps
suddenly move. Fatal accidents may result.
4 Power fuse 50 A, encapsulated
Before carrying out the safety test jack the truck up
so that the drive wheel is clear of the ground. You will require:
Insert wedges under the load wheels.
Quan- Item Part no.
tity
WARNING 2 Power cable 821634-010
Risk of scalding and injury to eyes 2 Insulating cap 125588-001

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

1. Fit the fuse holder on the insulating plate.
2. Attach both ends of the power cable to the fuse
holder.
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ELECTRICAL SYSTEM
PMT Test
Preparing the control module safety 7. Disconnect the battery.

test Testing the short circuit detection for phase W to V
on the traction control module
Jacking up the truck
1. Remove the test wiring (355 A fuse) from
1. Disconnect the battery. terminal U and connect it to terminal W.
2. Jack up the truck (see page 14). 2. Place the fuse holder on the floor.
3. Remove the panels to gain access to the control 3. Carefully check the entire unit again for possible
modules. short circuits.
Is everything is ok, proceed to step 4.
Traction control module safety test 4. Switch on the truck.
Testing the short circuit detection for phase U to V 5. Apply the safety pedal, direction switch and accel-
on the traction control module erator pedal.
1. Fit a 355 A fuse on the test wiring. The test has been successful if the main contac-
tor ED1 is de-energised and event code 301 is
2. Connect the test wiring with additional nuts to
displayed.
terminals U and V of the traction control module.
If the fuse blows in the test cable, the traction
3. Place the fuse holder on the floor. control module is faulty. Replace the traction
4. Carefully check the entire unit again for possible control module immediately (see page 258).
short circuits. 6. Power down the truck.
7. Disconnect the battery.
5. Switch on the truck.
Removing the test wiring
6. Apply the safety pedal, direction switch and accel-
erator pedal. 8. Remove the test wiring.
The test has been successful if the main contac- Checking travel functions after the test
tor ED1 is de-energised and event code 301 is
9. Check the travel functions after the test.
displayed.
If the fuse blows in the test cable, the traction
control module is faulty. Replace the traction
Hydraulic control module safety test
control module immediately (see page 258). Testing the short circuit detection for phase U to V
7. Power down the truck. on the hydraulic control module
8. Disconnect the battery. 1. Fit a 355 A fuse on the test wiring.
Testing the short circuit detection for phase U to W 2. Connect the test wiring with additional nuts to
on the traction control module terminals U and V of the hydraulic control module.
1. Remove the test wiring (355 A fuse) from 3. Place the fuse holder on the floor.
terminal V and connect it to terminal W. 4. Carefully check the entire unit again for possible
2. Place the fuse holder on the floor. short circuits.
3. Carefully check the entire unit again for possible
short circuits. 5. Connect the battery.
Is everything is ok, proceed to step 4. 6. Power up the truck.
4. Switch on the truck. 7. Apply the safety pedal and activate lifting.
5. Apply the safety pedal, direction switch and accel- The test has been successful if the main contac-
erator pedal. tor ED1 is de-energised immediately and event
The test has been successful if the main contac- code 201 is displayed.
tor ED1 is de-energised and event code 301 is If the fuse blows in the test cable, the hydraulic
displayed. control module is faulty. Replace the hydraulic
If the fuse blows in the test cable, the traction module immediately (see page 259).
control module is faulty. Replace the traction 8. Power down the truck.
control module immediately (see page 258). 9. Disconnect the battery.
ESR 5000
262
ELECTRICAL SYSTEM
PMT Test
Testing the short circuit detection for phase U to W Steering control module safety test
on the hydraulic control module
1. Remove the test wiring (355 A fuse) from Testing the short circuit detection for phase U to V
terminal V and connect it to terminal W. on the steering control module
2. Place the fuse holder on the floor. 1. Fit a 50 A fuse on the test wiring.
3. Carefully check the entire unit again for possible 2. Connect the test wiring with additional nuts to
short circuits. terminals U and V of the steer motor.
Is everything is ok, proceed to step 4. 3. Place the fuse holder on the floor.
4. Connect the battery. 4. Carefully check the entire unit again for possible
5. Power up the truck. short circuits.
6. Apply the safety pedal and activate lifting.
The test has been successful if the main contac- 5. Connect the battery.
tor ED1 is de-energised immediately and event 6. Power up the truck.
code 201 is displayed. 7. Apply the safety pedal and activate lifting.
If the fuse blows in the test cable, the hydraulic The test has been successful if the main contac-
control module is faulty. Replace the hydraulic tor ED1 is de-energised immediately and event
module immediately (see page 259). code 100 is displayed.
7. Power down the truck. If the fuse blows in the test cable, the steering
8. Disconnect the battery. control module is faulty. Replace the steering
control module immediately (see page 259).
Testing the short circuit detection for phase W to V
on the hydraulic control module
1. Remove the test wiring (355 A fuse) from
terminal U and connect it to terminal W. Testing the short circuit detection for phase U to W
2. Place the fuse holder on the floor. on the steering control module
3. Carefully check the entire unit again for possible 1. Remove the test wiring (50 A fuse) from terminal V
short circuits. and connect it to terminal W.
Is everything is ok, proceed to step 4. 2. Place the fuse holder on the floor.
4. Connect the battery. 3. Carefully check the entire unit again for possible
5. Power up the truck. short circuits.
The test has been successful if the main contac- 4. Connect the battery.
tor ED1 is de-energised immediately and event 5. Power up the truck.
code 201 is displayed. 6. Apply the safety pedal and activate lifting.
If the fuse blows in the test cable, the hydraulic The test has been successful if the main contac-
control module is faulty. Replace the hydraulic tor ED1 is de-energised immediately and event
module immediately (see page 259). code 100 is displayed.
7. Power down the truck. If the fuse blows in the test cable, the steering
8. Disconnect the battery. control module is faulty. Replace the steering
9. Remove the test wiring.
Checking lifting after the test
10. Check lifting after the test.
ESR 5000
263
ELECTRICAL SYSTEM
PMT Test
Testing the short circuit detection for phase W to V

on the steering control module
1. Remove the test wiring (50 A fuse) from terminal U
and connect it to terminal W.
2. Place the fuse holder on the floor.
3. Carefully check the entire unit again for possible
short circuits.
The test has been successful if the main contac-
tor ED1 is de-energised immediately and event
code 100 is displayed.
If the fuse blows in the test cable, the steering
control module is faulty. Replace the steering
9. Remove the test wiring.
Checking the steering after the test
10. Check the steering after the test.
ESR 5000
264
ELECTRICAL SYSTEM
Replacing the Height Encoder
Replacing the Height Encoder
4
5
3 Fig. 72 Height encoder

Removing the height encoder
2 1. Remove connector (16).
Note: The pre-tensioned spring (4) is relieved when
1
the screws (15) are loosened.
Fig. 71 Height encoder assembly location, HGT(R)S switch 2. Loosen the screws (15) and remove the entire
1 1st mast stage (outer mast)
height encoder.
2 2nd mast stage Replacing the sensor bearing
3 3rd mast stage 3. Loosen the screw (12) and remove the attachment
4 HGTS switch (optionally HGTRS) (11), seal (10), heating resistor (14) and attach-
5 Height encoder ment (13).
6 HGTRS shifting gate 4. Loosen the screw (9).
7 HGTS shifting gate 5. Remove the washer (8) and sensor bearing (7).
6. Fit a new sensor bearing in the bracket (3).
Note: Carry out assembly in the reverse order and then
calibrate the height encoder.
Calibrating the height encoder
7. Calibrate the height encoder via the Service menu
(see page 132).
ESR 5000
265
ELECTRICAL SYSTEM
Replacing the HGT(R)S Switch
Replacing the HGT(R)S Switch

The HGTS switch is fitted as standard to reduce the lift
speed before the limit position. 1
Optionally, an HGTRS height reset switch can be used
instead of the HGTS switch. HGTRS resets the height
calculated by the height encoder to 0.
Note: The same switch is used for both functions. 2
Depending on the settings in F3 Features / Height En-
coder of the service menu (see page 140), the switch
will be either an HGTR or an HGTRS.
4
6 3
4
5
Fig. 74 HGTR-, HGTRS switch

2 HGTR or HGTRS switch
3 Bolt
4 Connector
7 Removing the HGT(R)S switch

1. Remove connector (4).
2. Loosen the screws (3).
3. Remove the switch (2).
Assembling the HGT(R)S switch

3
Note: Carry out the assembly in the reverse order,
ensure the switch distance between the shifting gate
2 and the sensor is set to 9.2 - 13 mm.
Fig. 73 Height encoder assembly location, HGT(R)S switch

2 2nd mast stage
3 3rd mast stage
4 HGTS switch (optionally HGTRS switch)
5 Height encoder
6 HGTRS shifting gate
7 HGTS shifting gate
ESR 5000
266
ELECTRICAL SYSTEM
Replacing the Armrest Controls

Trucks with fingertip control levers
Fig. 75 Replacing switches and potentiometers
ESR 5000
267
ELECTRICAL SYSTEM
Removing the controls Trucks with dual axis hydraulic

Note: Unless otherwise stated, the following item num- control levers
bers refer to Figure 75.
Removing the covers
1. Push the armrest back as far as the stop.
2. Remove the three screws from the rear cover (42)
and take off the cover (42).
3. Remove the three screws (22, 23, 24) and take off
the cover (1).
Removing the direction switch
4. Remove the bracket (35).
5. Remove the connector of the direction switch (41)
from the interface.
6. Remove the direction switch (41).
Horn switch disassembly
7. Remove the bracket (6).
8. Remove the connector of the horn switch (5) from
the interface.
9. Remove the horn switch (5).
Removing the hydraulic function potentiometers
10. Remove the screw (7) from the control lever (8).
11. Extract the control lever (8).
12. Remove the connector of the potentiometer (10)
from the interface.
13. Remove the screws (9) and potentiometer (10).
Note: The remaining potentiometers are removed in Fig. 76 Replacing switches and potentiometers
the same way. Note: The switches and potentiometers are removed/
assembled in the same way as for trucks with fingertip
Assembling the controls control levers (see page 267).
Note: Assembly is the reverse order of disassembly.
WARNING
Incorrect operation can cause serious injury
Swapping potentiometers will result in malfunctions
during operation.
Make sure the potentiometers are connected to the
correct interface slot.
When you have finished, carry out a functional test.
ESR 5000
268
ELECTRICAL SYSTEM
Trucks with multi-task handle
Fig. 77 Replacing switches and potentiometers
ESR 5000
269
ELECTRICAL SYSTEM
Removing the controls

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

Note: Assembly of all components is the reverse order
of disassembly.
WARNING
Incorrect operation can cause serious injury
Swapping potentiometers will result in malfunctions
during operation.
Make sure the potentiometers are connected to the
correct interface slot.
When you have finished, carry out a functional test.
ESR 5000
270
ELECTRICAL SYSTEM
Repairing Contactors
Repairing Contactors contacts must not be treated, as this would cause them
to wear even faster.
Checking the coils

CAUTION
1. Using an ohmmeter measure the resistance be-
The use of other manufacturers contactors can tween the connections on the coil (2).
damage the truck!' If either an endless resistance or no resistance are
The original contactors are designed for Crown trucks. recorded, the coil (2) is faulty and must be re-
Only use original Crown contactors as replace- placed.
ments.
Do not change the place or the angle where they
Checking the springs
are positioned and do not change the wiring. 1. Check the spring (1) for corrosion or discolouring
caused by heat.
Replace any corroded or discoloured springs (1).
Wear test
4
1
Fig. 78 Example of a contactor

1 Spring
2 Coil
3 Contact (moving)
4 Contact (fixed)
Checking contacts
1. Check the silver coating of the contacts (3,4).
If the silver coating has worn to the extent that the
support material is visible, both contacts (3, 4)
must be replaced.
Note: The contacts (3, 4) are subject to natural wear
during operation. Blackened, tarnished or scarified
ESR 5000
271
ELECTRICAL SYSTEM
Repairing the Main Contactor
Repairing the Main Contactor Disassembling the main contactor
CAUTION
The incorrect assembly of contacts can result in
failure and excess wear
Contacts already worked in with each other must be
placed together again on assembly.
Mark the contacts (8, 9) when disassembling the
contactor.
0
1. Loosen and remove the screws (1).
2. Remove the housing (2).
3. Mark the contacts that are placed together (8, 9).
4. Remove the contact (8) and the plunger (7).
5. Unscrew the nuts (10) and remove the contacts
(9).
6. Clean all the components.
Wear check
1. Carry out a wear check as described on page 271.
Reassembling the main contactor
1. Insert the contacts (9) according to their markings.
2. Insert the washers (10) and fasten the nuts (11).
Take care not to damage the housing (2).
3. Insert the contact (8) according to the markings
and the plunger (7) into the receptacle of the base
plate (4) and the magnetic coil (5).
4. Fit the housing (2).
5. Insert the screws (1) and washers and apply
Fig. 79 Main contactor (ED1) threadlocker (053050-006).
WARNING
Before working on the contactors disconnect the
battery from the truck.
ESR 5000
272
ELECTRICAL SYSTEM
Replacing the Danaher Traction Motor
Replacing the Danaher Traction 5. Insert the ring screw into the shaft of the traction
motor (5).
Motor 6. Disassemble the power cable (2) from the terminal
board.
Traction motor disassembly
WARNING
Incorrect handling of the lifting gear and slings can
cause injury
You can be injured if a component falls on you.
1 Always use lifting gear and slings with sufficient ca-
pacity.
Attach the slings securely to the component to be
lifted.
Watch out for your hands as there is a risk of trap-
ping.
7. Insert the load hook in the eye bolt and lift out the
2 traction motor (5) using suitable lifting gear.
Traction motor assembly

5 Note: Assembly is the reverse of disassembly. Ensure
that the traction motor (5) is positioned as shown in Fig.
80 so that the power cables can be connected to the
terminal board.
4 3
Connecting the power cables
1
2 1
3
4
2
Fig. 80 Danaher traction motor
1 Service and parking brake
3
2 Terminal board and power cable connections
3 Connector for sensor bearing and thermal sensor
4 Screws 4
5 Traction motor
5
2. Remove the service and parking brake (1) as de-
scribed on page 288.
3. Unplug the connector for sensor bearing and ther- Fig. 81 Connecting the power cables
mal sensor (2).
4. Loosen all the screws (3).
ESR 5000
273
ELECTRICAL SYSTEM
Replacing the Danaher Traction Motor
1 Nut
2 Power cable
3 Curved washer
4 Terminal board
5 Traction motor
1. Insert the power cables (2) with references U, V, W

in the adaptors of the terminal board (4).
2. Insert the washers (3) with the curve facing down
(see Figure 81) into the adaptors of the terminal
board (4).
3. Insert the nuts (1) and torque them to 8.1 - 9.9 Nm.
ESR 5000
274
ELECTRICAL SYSTEM
Replacing the Sensor Bearing on the Danaher Traction motor
16
7
8
10
11
12
13
14
15
Fig. 82 Overview - traction motor (Danaher)
ESR 5000
275
ELECTRICAL SYSTEM
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.
ESR 5000
276
ELECTRICAL SYSTEM
Replacing the Crown Traction motor
Replacing the Crown Traction

WARNING
motor
Traction motor disassembly cause injury
Always use lifting gear and slings with sufficient
capacity.
1 Attach the slings securely to the component to be
lifted.
ping.
6. Secure the slings to the traction motor (4) and us-

ing suitable lifting gear lift it out of the truck.
2
Traction motor assembly
4 Note: Assembly is the reverse of disassembly. Ensure
that the traction motor is positioned as shown in Fig. 83
so that the power cables can be connected to the ter-
minal board.
1
2 1
3 3
3
2
Fig. 83 Crown traction motor
1 Parking brake
3
2 Terminal board
3 Bolt
4 Traction motor 4

prevent the truck from being switched on again. 5
2. Remove the parking brake (1) as described on
page 290.
3. Unscrew the power cable from the terminal board
(2).
4. Remove the connector for sensor bearing and Fig. 84 Connecting the power cables
thermal sensor. 1 Nut
2 Power cable
5. Loosen all the bolts (3).
3 Curved washer
4 Terminal board
5 Traction motor
ESR 5000
277
ELECTRICAL SYSTEM
Replacing the Crown Traction motor

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.
ESR 5000
278
ELECTRICAL SYSTEM
Replacing the Pump Motor

WARNING
cause injury
Always use lifting gear and slings with sufficient ca-
pacity.
Attach the slings securely to the component to be
lifted.

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

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

down on a suitable support.
9. Undo the mounting screws on the hydraulic pump.
10. Pull the hydraulic pump out of the pump motor
toothing without tilting it.
11. Loosen the screws (3) and take off the bracket.
Fig. 85 Pump motor (ESR 5000S)
1 Pressure line Pump motor assembly
2 Pump motor Assembly of the pump motor is the reverse order of
3 Bolt disassembly. Note the following:
4 Bolt 1. Clean the output side toothing of the pump motor
5 Power cable (2) and apply a thin layer of grease part no.
6 Connector for thermal sensor and sensor bearing 794860-007 (Shell Calithia HDX) to it.
7 Suction line 2. Check the rubber pad on the screws (3) for cracks
and hardening and replace if necessary.
Removing the pump motor 3. Torque the screws (3) to 70 - 80 Nm.
1. Switch off the truck, disconnect the battery and Note: For more information on assembling and com-
prevent it from being switched on again. missioning the hydraulic pump refer to page 86.
2. Unplug the connector for the thermal sensor and
sensor bearing (6).
3. Disassemble the power cable (5) from the terminal
board.
4. Loosen the union on the pressure line (1).
5. Disassemble the suction line (7).
ESR 5000
279
ELECTRICAL SYSTEM
1
2 1
3
Fig. 86 Power cable

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

2. Insert the curved washers (3) with the curve facing
down (see Figure 86) into the adaptors of the ter-
minal board (4).
3. Insert the nuts (1) and torque them to 8.1 - 9.9 Nm.
ESR 5000
280
ELECTRICAL SYSTEM
Replacing the Sensor Bearing on the Danaher Pump Motor
Fig. 87 Overview - pump motor (Danaher)
ESR 5000
281
ELECTRICAL SYSTEM
Sensor bearing disassembly

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

1. Use a press to press the sensor bearing (7) onto
the rotor (8).
2. Insert the spring washer (7).
3. Insert the sensor bearing (7) into the bearing shield
(4).
4. Place the nuts (1) onto the tie rod and torque them
to 12.6 - 15.4 Nm.
ESR 5000
282
ELECTRICAL SYSTEM
Choosing the Correct Battery Cable Length
Choosing the Correct Battery Choosing cable lengths for a T-

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

5. Size the length of the battery cables (2) so that it
remains within the geometry of the battery tray (5)
when the battery is extended and retracted. The
battery cables (2) must not slide over the battery
tray (5).
Note: It must be possible to place the battery cables (2)
flat on the battery before it is retracted (see Fig. 88).
6. Connect a PVC insulating tape (3) to both battery
cables (2) starting from the battery connector (1)
over a length of approx. 700 mm.
7. Attach the battery cables (2) to the top of the bat-
tery tray to create strain relief on the battery termi-
nals (4, 6).
ESR 5000
283
ELECTRICAL SYSTEM
Choosing the Correct Battery Cable Length
8. Route the battery cables (2) within the geometry of

the battery tray to both the negative terminal (4)
and the positive terminal (6).
9. After a battery has been used for the first time
check the battery cable lengths and the battery ca-
ble type against the above items. Extend and re-
tract the battery several times into the
compartment to make sure that the battery cables
(2) do not jam, extend or get caught.
Note: The battery cables (2) should "slide" along the
battery and remain within the geometry of the battery
tray (5).
ESR 5000
284
BRAKE SYSTEM
285
Notes:
286
BRAKE SYSTEM
Service and Parking Brake
Service and Parking Brake

Note: Different brakes are used, depending on the
traction motor manufacturer (Danaher or Crown):
The service brake for Danaher motors is hydrauli-
cally supported by the brake pressure from the
main brake cylinder.
The brake for Crown motors does not have any
hydraulic support. It relies solely on the brake
torque supplied by the motor.
Safety notices
WARNING
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
damage your health.
ESR 5000
287
BRAKE SYSTEM
Service and Parking Brake Danaher Motor
Service and Parking Brake Disassembling the brake

Danaher Motor See Figure 89.
2. Jack up the truck until the drive wheel is free; sup-
port 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 every-
thing 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.
1 Screws (3x)
2 Coil body Adjusting the air gap
3 Friction plate See Figure 89.
4 Rotor and brake linings
Measure and adjust the air gap (L) when the brake is
5 Pinion released:
6 Hollow screws 1. Unscrew the hollow screws (6) until they are in
7 Connector CA431 fixed contact the friction plate (3).
D Rotor thickness 2. Torque the screws to 22 2 Nm.
L Air gap
ESR 5000
288
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

3. Using an ohmmeter measure the resistance
between PC431-1 and -2.
If the coil resistance is 46.6 , the coil is ok.
If you do not measure 46.6 , the coil is faulty.
Replace the coil.
ESR 5000
289
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.
being switched on again.
2. Jack up the truck until the drive wheel is free; sup-
port 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 con-
nected 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.

Fitting the brake

1. Assembly is the reverse order of disassembly.
Fig. 90 Parking brake
1 Connector plug CA431
Assembling the parking brake
2 Motor flange attachment screws 1. Place the brake in the correct position on the motor
3 M6 thread flange.
4 Coil body 2. Secure it with the screws (2) and torque the screws
5 Tie plate
to 22 Nm.
6 Friction disk 3. Fit the connector plug.
7 Pinion 4. Adjust the air gap.
8 Rotor and brake linings
9 Friction disk mounting screws
10 Hollow screws
D Brake rotor thickness dimension
L 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 occa-
sion. The adjustment is extremely complicated and
time-consuming.
Checking the air gap
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).
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

3. Using an ohmmeter measure the resistance be-
If the coil resistance is 32 , the coil is ok.
If you do not measure 32 , the coil is faulty.
Replace the coil.
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291
BRAKE SYSTEM
Load Wheel Brake
Load Wheel Brake

WARNING
General Pre-tensioned springs can cause injury
The load wheel brake is self-adjusting. There is no Pre-tensioned springs can cause serious eye injuries.
need for regular adjustment. Always wear a splint-proof protective glasses and
suitable clothing to prevent injuries to your eyes and
Checking the brake lining wear body.
2. Remove the springs (2, Fig. 92).

1
3. Using a blunt, burr-free lever, lever one brake shoe
towards the inside.
2 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 1. De-grease all components with a brake solvent
access to eccentrics
prior to assembly.
1. Visually inspect the brake lining wear (see holes 1, 2. Assemble the brake shoes in the reverse order of
Fig. 91). disassembly.
The wear limit is 2 mm.
3. Set the brake shoes via the eccentric to a gap of
Replacing the brake linings 199.4 +/- 0.2 mm. Otherwise the load wheel cannot
be pushed over the brake shoes.
Load wheel removal 4. Push the load wheel and brake drum onto the
1. Remove the load wheel (see page 51) steering knuckle and fit the retaining ring.
Brake lining removal 5. Apply the brake pedal approx. 10 times to adjust
the brake shoes.
6. Check the brake fluid level in the container on the
main brake cylinder. Add oil if necessary (see
1 page 295).
2
2
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!
WARNING Bleeding the load wheel brake

Note: Bleeding is normally only required on the wheel
brake cylinder where the brake line has been opened.
Faulty wheel brake cylinders must not be dismantled
and repaired. Fatal accidents could result from incor-
rect repairs.
Replace a faulty wheel brake cylinder with a new WARNING
one. 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.
1 4 1
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, trans-
parent container that already contains some new
brake fluid.
3 2 The hose end should dip into the brake fluid.
4. Get an assistant to apply and hold down the brake
Fig. 93 Wheel brake cylinder pedal.
5. While the brake pedal is depressed, open the
1 Bolt
bleed screw half a turn.
2 Brake line connection
6. While the assistant is pressing down on the brake
3 Wheel brake cylinder pedal, close the bleed screw.
4 Bleed screw Release the brake pedal again when the bleed
screw is closed.
Wheel brake cylinder disassembly 7. During bleeding always check the brake fluid level
1. Jack up the truck and remove the brake shoes (see in the main brake cylinder storage tank.
Brake lining removal, page 292). 8. Add brake fluid as soon as the fluid is below the
2. Push a flat tray underneath the jacked up load "Max" mark to prevent air from being suctioned in.
wheel to collect the brake fluid. 9. Repeat steps 4 to 7 until the brake fluid emerges
3. Unscrew the brake line (2, Fig. 93) from the wheel without bubbles.
brake cylinder and seal it immediately with clean
filler plugs. Replacing the brake fluid
4. Remove both screws (1). The procedure for replacing the brake fluid proceed is
5. Remove the wheel brake cylinder (3). in principle the same as described in Bleeding the load
wheel brake.
Wheel brake cylinder assembly
The difference is that the bleed screws on both wheel
1. De-grease all components with a brake solvent. brake cylinders must be opened and closed simulta-
2. Insert and tighten the wheel brake cylinder. neously.
3. Refit and tighten the brake line. 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
2 Setscrew
3 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).
ESR 5000
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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.
9. Press the test button (1) to check the BFS switch.
WARNING
The "brake fluid level" indicator light on the dis-
Incorrect brake fluid will result in brake failure play lights up, event code 841 is displayed. It is
The use of hydraulic or lubrication oil as a brake fluid working correctly.
will cause the brake to fail. Fatal accidents could result. The "brake fluid level" warning indicator does
not light up on the display. Wiring or switch
Use only DOT 4 brake fluid. See Recommended
error. For troubleshooting see page 249.
Lubricants and Consumables chart on page 27.
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
2 Cover
3 Reservoir
4 Max. mark
5 BFS ports
Preparation
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:
WARNING
After replacing the brake linings and brake drums
on the wheel brakes. Unauthorised persons can cause serious
After replacing the main brake cylinder, the wheel accidents
brake cylinders and the brake lines. People suddenly stepping onto the test route can be
fatally injured.
After replacing the brake disk and the friction plate
on the electro-mechanical brake on the traction Use suitable equipment to block the test route.
motor. If necessary use assistants to prevent unauthorised
After adjusting the air gap on the electro-mechani- access.
cal 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 Perform- Note: If the test route is sufficiently long, the test speed
ance menu. is generally the maximum speed for the respective per-
formance level (P1 - P3). If there is not a sufficiently
When testing the truck in accordance with
long test route available, a lower speed can be se-
FEM 4.004.
lected temporarily.
Requirements 2. When you pass over the marker and the marker on
the floorboard coincides with the marker on the
There must be no load on the truck.
warehouse floor, brake immediately.
A sealed off, clearly visible test route of sufficient
3. Switch off the truck when it comes to rest.
length must be available.
4. Measure the braking distance.
The floor of the test route must be clean.
If the braking distance is within the tolerance range
Required tools (see braking distance table), the brake power is ok.
5 m measuring tape If the braking distance is too long, continue with
steps 5 to 7.
Adhesive tape
Barrier tape to seal off the test route Determining the cause of excessive braking dis-
tances
Brake test 5. Check the brake linings and brake drums on the
wheel brakes for damage.
Preparing the test route
6. Check the brake disk and friction plate on the elec-
1. Clean the test route and prevent unauthorised per- tro-mechanical brake on the traction motor for
sonnel from accessing it (see also Protecting the damage. Check the air gap.
hazardous area, page 8).
7. Check the plugging setting in the Performance
2. Attach a marker with adhesive tape to the floor of menu.
the test route.
Note: When you have established the cause, repeat
3. Attach a marker with adhesive tape to the floor- the brake test.
board.
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
6 < 2.18
7 < 2.54
7.5 < 2.72
8 < 2.90
8.5 < 3.08
9 < 3.26
9.5 < 3.45
10 < 3.63
10.5 < 3.81
11 < 3.99
11.5 < 4.17
12 < 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 com- 1
mand 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 corre-
sponding 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 1 LED
steering feedback encoder (ECR3) fitted in the steer
motor (M3). The steering feedback encoder supplies
the steering control module with data regarding the po-
sition of the steered wheel with a tolerance of +/- 0.5.
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 de-
viation in the calculated position and allows a zero po-
sition 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
3
I II
SFS 2
90 - 90
IV III
2
179 -179
Fig. 97 Illustration of 4 quadrant steering system

1 Cam on gear unit cover
2 Steered wheel
3 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

With all other errors the steering control module dis-
Error routine connects the power supply to the brake (truck brakes)
The steering system stores the steer angle at the time and travel is disabled.
the truck is switched off. The next time the truck is pow- A status code is displayed, depending on the cause
ered up (during the self test), the steering control mod- (see page 173).
ule (SDM) compares the current position of the steered
wheel with the stored value.
If the new angle position is not in the same quad-
rant 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 sys-
tem 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 follow-
ing 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 understand- SFS 1SA
ing of the causes of steer faults.
Manual wheel change, drive wheel turned 160 to
the right
0
SFS 1SA
I II
SFS 2
0
90 - 90
IV III
I II
SFS 2
90 - 90
179 -179
IV 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
179 -179
Fig. 99).
Fig. 98 Drive wheel in 1st quadrant at 80 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).
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
0 been switched once. There are 2 directions in which
you can steer:
Right steering
I II 100 further on, the drive wheel reaches the -179 po-
SFS 2 sition (see Fig. 100). The error routine ends as the
switch area of proximity switch SFS 1SA has been
90 - 90
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 sig-
nal resets the stored and the currently calculated val-
ues in the traction control module to 0.
If you now release the accelerator pedal (assuming it
Fig. 99 Steered wheel turned 160 to the right was applied), the error routine ends and the truck re-
turns to normal travel mode.
ESR 5000
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STEERING
Steering Errors
Manual wheel change, drive wheel turned 70 to the The drive wheel is now replaced. The steered wheel is
right turned manually 70 to the right (see Fig. 102).
The next time the truck starts up the steering control
module compares the stored position (80) with the
SFS 1SA 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.
When the truck is started, provided the last stored
0 value and the current calculated value for the drive
wheel position are in the same quadrant, the error
routine will not start.
You will only recognise this error by the fact that
I II
the steering wheel display does not match the ac-
SFS 2 tual steer angle on the drive wheel and the full 360
90 - 90 steering range is not reached.
Left steering
IV 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
179 -179 only 20 with respect to 0 for normal forward travel.
The error routine does not start, as the drive wheel is
Fig. 101 Steered wheel in 80 position still within the 1st quadrant.
70 later the mechanical 90 position is reached
(SFS 1SA switches, SFS 2 has not switched). The
SFS 1SA steer angle display shows 160 and the error routine
starts.
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
Starting from 80 as the stored value, after a further 10
you reach the switch area of the proximity switch
I II SFS 1SA. The proximity switch applies. This switch
SFS 2 signal resets the stored and calculated values in the
90 - 90 traction control module to 0. The steering angle dis-
play now matches the actual position of the drive
wheel. The full steering range of 360 is now available
IV III 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 hap-
179 -179 pens in the normal mode of the steering control module
each time the cam on the gear unit cover enters the
Fig. 102 Steered wheel turned 70 to the right
switch area of the proximity switch SFS 1SA.
When the truck was parked, the steering control mod- To rectify this error, you just need to steer accordingly
ule stored the position of the drive wheel at 80. The so that the cam on the gear unit cover enters the switch
drive wheel is therefore in the 1st quadrant (see area of proximity switch SFS 1SA.
Fig. 101).
ESR 5000
305
STEERING
Proximity Switches SFS2 and SFS1 SA
Proximity Switches SFS2 and 2. Disconnect and remove the faulty proximity switch
(1 or 2, Fig. 103).
SFS1 SA
Replacing and adjusting SFS2 or CAUTION
SFS1 SA The proximity switches are damaged by the cam rotat-
ing past if they are set longer than 46.5 mm.
Note: The procedure is identical for SFS2 and
Do not exceed a length of 46.5 mm.
SFS1 SA.
3. Set the new proximity switch length to

46 0.5 mm, measured from the bottom of the as-
sembly 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

1 Proximity switch SFS2
2 Proximity switch SFS1 SA
46 0.5 mm
Fig. 104 Proximity switch setting dimension

ESR 5000
306
STEERING
Steer Motor and Steering Transmission
Steer Motor and Steering Disconnecting the steering transmission

and steer motor
Transmission S
Removing the steer motor and steer-

ing transmission
Unless otherwise indicated, all item numbers refer
to Fig. 106, page 309.
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

10. Carefully pull off the reduction gear unit (3,
Fig. 105).
11. Pull off the coupling (2, Fig. 105).
ESR 5000
307
STEERING
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 assem-
bly in the truck the electrical system can be con-
nected.
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 sur-
face (front side) of the steer motor.
18. Fit the steer motor in the reverse of disassembly.
19. Check operation.
ESR 5000
308
STEERING
Fig. 106 Steer motor and drive unit
ESR 5000
309
STEERING
Steering Wheel
Steering Wheel
Fig. 107 Steering wheel and steering column

1 Steering wheel
2 Access to steering wheel mounting screw
3 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.
ESR 5000
310
STEERING
Steering Wheel
Fig. 108 Steering wheel, steering wheel panel and encoder ECR4
ESR 5000
311
STEERING
Replacing Encoder ECR2
Replacing Encoder ECR2

The encoder cannot be repaired.
Removing ECR4
1. Disassemble the steering wheel (see page 310).
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.
ESR 5000
312
LIFTING MECHANISM
313
Notes:
314
LIFTING MECHANISM
Mast
Mast General
Safety instructions for working on Torques
All screw connections on the mast must be torqued to
the mast the standard values (see page 50).
Lifting gear minimum capacities

WARNING
Risk of trapping and severing limbs WARNING
Unsecured components can sever limbs and cause
fatal injuries. Note the minimum capacity for the lifting gear when-
When carrying out work on the mast and the attach- ever carrying out work on the mast.
ments:
Always block the mast stages and attachments to The following table lists the minimum capacities for
prevent them from accidentally moving. masts with a fork carriage, but without forks or attach-
Make sure the equipment used has sufficient ments:
strength.
Mast capacity Lifting gear
minimum capacity
1.4 t 2000 kg
WARNING
1.6 t 2000 kg
High-pressure hydraulic oil can cause severe
injury 2.0 t 2500 kg
Whenever a high pressure hydraulic oil enters the skin
it must be treated as a medical emergency. Checking the assembled mast
Seek medical assistance even if the skin appears nor-
mal at first. Flaking
To avoid accidents: It is not uncommon for a new mast to appear as if it's
Depressurise the hydraulic system before opening flaking or peeling. This appearance indicates that the
any sections of it. rollers are seating on the mast channel and this is con-
Tighten all connections before pressurising the sys- sidered normal. Eventually this condition will disap-
tem. pear. The grease applied to the mast channels retains
these particles.
Keep hands and body away from pressurized fluid.
Traces of nicks or cuts in the channel are not permitted.
Only trace leaks with a piece of paper or cardboard.
Checking the roller tracks
1. Clean the mast channels.
2. Check the roller track wear in the mast channels:
CAUTION There should only be wear in the rear section of the
I beam where the rollers slide. If nicks or cuts are
Health risk
visible at the side of the rollers approx. 10 mm
above the channel face, the mast rollers will have
damage your health.
to be adjusted. (See Replacing the Mast Rollers,
Observe the manufacturers safety instructions 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-
ESR 5000
315
LIFTING MECHANISM
Mast
ming is too loose or unbalanced and will need to be Checking the mast tilt
adjusted:
Adjust the mast rollers as described in Replacing
the Mast Rollers on page 324. 1 0 2
- +
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 se-
cured.
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

1. Fully lower the forks and set them horizontal. 3
2. Measure the height of the fork tips from the floor to
the top of the forks:
4
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. Fig. 109 Permissible and non-permissible mast tilt ranges
5. Check the maximum height with a lowering plumb and lowering plumb position
attached to the fork tips. 1 Area where mast tilt is permissible.
The height should lie within +/-25 mm of the maxi- 2 Area where mast tilt is not permissible.
mum height indicated on the data plate. 3 Lowering plumb position on fork for measuring mast tilt.
4 Floor (evenness in all directions 0.7 mm per 2 m).
Note: The mast should be installed tilted only back-

wards () 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 uneven-

ness: 0.7 mm over a 2 m length.
ESR 5000
316
LIFTING MECHANISM
Mast
3. Apply a very narrow colour marking as close as

possible to the heel area, but still on the straight
Masts with 2.0 t capacities
upper side of the forks, and copy this marking ver-
tically to the floor.
4. Raise the forks slightly and attach a lowering Maximum Max. permissi- 1 mm shim
plumb with the string lying exactly on the fork mark- lift height ble tilt (mm) thickness cor-
ing. rected by x mm
Note: The string of the lowering plumb, from the top of
4145 mm 16 mm 5 mm
the forks to the top of the lowering plumb, must be
length (L), corresponding to the maximum lift 4595 mm 18 mm 6 mm
height (h3) minus 20 mm (L = h3-20 mm).
5495 mm 21 mm 7 mm
5. Extend the mast until the top of the lowering plumb
just swings clear above the ground. 6395 mm 25 mm 8 mm
6. When it has finished swinging, measure the dis- 6845 mm 26 mm 9 mm
tance from the marking on the ground to to the top
7205 mm 28 mm 9 mm
of the lowering plumb and compare this distance
with the entry in the tolerance table. 7500 mm 29 mm 10 mm
The mast tilt should be negative () and lie be-
7950 mm 31 mm 10 mm
tween 0 mm and the maximum value indicated
in the table. 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
Masts with 1.4 t and 1.6 t capacities
9605 mm 37 mm 12 mm
9935 mm 38 mm 13 mm
Maximum Max. permissi- 1 mm shim
lift height ble tilt (mm) thickness 10835 mm 42 mm 13 mm
corrected by x mm 10230 mm 39 mm 14 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
ESR 5000
317
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 assem-
bly, 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).
ESR 5000
318
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 Fig. 110 Raising the mast with load slings
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 16. If applicable, mark the hydraulic hose connections
hydraulic line for the 5th function on the left channel of the
6. Place a flat tray underneath the mast area to col- 1st mast stage for later re-assembly. It is possible
lect any spilled hydraulic oil. to mix up the screws.
7. Raise the 1st and 2nd mast stages until the main 17. Disconnect the hydraulic hoses for the 5th function
hydraulic line on the manifold and the mast attach- and fit filler plugs to all the open ports.
ment bolts are accessible. 18. Remove all connectors and where necessary all
8. Insert hard wooden blocks into the outer mast the electrical wire connections from the reach car-
tracks and secure them with screw clamps. riage to the mast.
9. Lower the 1st and 2nd mast stages onto the hard 19. Pull all the wires from the reach carriage to the
wooden blocks. mast out and up. Temporarily attach the loose
wires to the mast.
10. Unscrew the main hydraulic line on the manifold
block (at the bottom of the mast) and seal both 20. Secure the fork carriage with a load sling to prevent
ends immediately with filler plugs. it from moving in the mast.
Preparing the mast for removal Removing the mast

11. Loosen but do not remove the bolts (27) attaching 21. Remove the nuts and bolts securing the mast to
the mast to the reach carriage. the reach carriage together with the shims.
12. Remove the hard wooden blocks and fully lower Note: Store the shims so that they can be used in the
the 1st and 2nd mast stages. same position and the same overall thickness for sub-
sequent assembly.
Note: Use load slings with a wire spiral warp - not
chains - to raise the mast. Do not place wooden 22. Lift the mast up out of the reach carriage.
blocks under the load slings when the mast is raised 23. Place the mast with its back (the side facing the
from the highest tie bars. Some mast versions have tie driver) lying on a suitable surface with sufficient ca-
bars consisting of a sandwich of 2 thin sheets. Wooden pacity (pallets, steel benches).
blocks and chains can damage them.
ESR 5000
319
LIFTING MECHANISM
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 posi-
tion 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).
ESR 5000
320
LIFTING MECHANISM
Fig. 111 Mast exploded diagram
ESR 5000
321
LIFTING MECHANISM
Dismantling and Assembling the Mast
Dismantling and Assembling 6. Using the crane, move the fork carriage down
from the 2nd mast stage.
the Mast
Removing the 2nd mast stage
Safety notices 7. Remove all mast cables, hydraulic hoses and if ap-
plicable 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
WARNING area of the mast stages. This would damage them
Risk of trapping and severing limbs when the mast is dismantled further.
Unsecured components can sever limbs and cause 8. Remove the lift chain and chain pulley from the free
fatal injuries. lift cylinder.
When carrying out work on the mast and the attach- Store the chain so that it is protected from contam-
ments: ination.
Always block the mast stages and attachments to 9. Remove the lift chains.
prevent them from accidentally moving. Store the lift chains so that they are protected from
Make sure the equipment used has sufficient contamination, marking the position of the chains
strength. (left / right). They will subsequently have to be re-
assembled in their original positions.
10. Using a crowbar push the 2nd mast stage down
until the bottom mast rollers can be accessed.
CAUTION 11. Remove the bottom mast rollers and shims out of
the 2nd mast stage.
Health risk Store the rollers and shims so that they can later be
Cleaning agents, lubricants and consumables can fitted in the same position.
damage your health. 12. Attach two load slings (one in the bottom, one in
Observe the manufacturers safety instructions the top area of the 2nd mast stage) and using the
when handling solvents and lubricants. crane pull the 2nd mast stage (without rollers!) out
of the 1st mast stage.
13. Place the 2nd mast stage onto a suitable surface.
Tips & tricks
1st mast stage removal
Switches and lines (electrical, hydraulic):
14. Remove the guide pulleys for the hoses and chains
Undo the mast attachments (base plates, clamps).
at the top left and right of the 1st mast stage.
This facilitates positioning for later re-assembly and
normally saves having to adjust the switches. 15. Remove the anti-bend pins (10, FIg. 111) and the
locking screws (13).
Lift chains:
16. Using a crowbar, push the 1st mast stage up until
Remove the chain bolt, not the chain support. This
the mast stage can be attached to the crane with 2
also normally saves subsequent adjustment.
load slings.
Dismantling the mast Note: The ends of the lift cylinder piston rams should
now lie freely, no longer in the mast stage seats.
Fork carriage removal 17. Using the crane, pull the 1st mast stage out until
1. Remove the mast (see page 319). the mast stops become visible through the circular
2. Remove the free lift switch (FLS), otherwise it will hole at the bottom.
be damaged when the fork carriage is extended. 18. Remove the screws (19, Fig. 111) and take out the
3. Remove the free lift cylinder chain. mast stops (18) with the brackets (16 17) and the
shims (16).
4. Disconnect all hydraulic lines and if applicable
electrical lines to the fork carriage. Note: Store all the parts so that they can be re-assem-
bled later in the same position.
5. Using a load sling raise and maintain the fork car-
riage.
ESR 5000
322
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 roll-
ers 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.
ESR 5000
323
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:
Using mast rollers with the wrong part number can
Calculate the roller diameter required to prevent cause material damage!
jamming or excessive play above the running area
Always use mast rollers with part number 824031.
of the roller in the mast channel.
These rollers have a 4 point suspension which is tai-
Calculate the number of shims required to prevent lored to this mast. Rollers with part number 807334 will
lateral jamming or tipping between the left and right- soon wear in this mast!
hand mast channels.
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 attach-
ments:
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
1 Special tool part no. 824031
CAUTION 2 Mast channel
Health risk There are three roller diameters available:

damage your health. Code mm Part No.
when handling solvents and lubricants. B 101.47 824031-002
C 102.14 824031-003
Preparation D 102.45 824031-004
1. Disassemble and dismantle the mast (see previ- Note: Always start with the largest diameter, a code D
ous sections). roller.
2. Clean the mast channels and remove all mast roll- 3. Place a roller (code D) on the tool (1, Fig. 112).
ers and shims. Rollers do not run into the 500 mm areas (see
Fig. 113). Always place the tool outside these areas to
Mast roller assembly calculate the required roller diameter:
Note: Always use the special tool part no. 810705 4. Using the tool pull the roller through the corre-
(1, Fig. 112) to calculate the roller diameter required. sponding running area in the mast channel (see
The mast roller bearing journals are slightly angled. Fig. 113). The bottom of the tool should always be
The roller should not be pulled through the channel in contact with the mast channel.
manually as this produces inaccurate results. The roller should not jam or move sluggishly at any
point. If it does, repeat the process with the next
ESR 5000
324
LIFTING MECHANISM
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 calcu-
lated. This will prevent jamming when the rollers enter
the mast channel.
5. Repeat step 4 for all mast rollers and the fork car-
riage rollers in their respective mast channels.
ESR 5000
325
LIFTING MECHANISM
500 mm
500 mm
500 mm
500 mm
2nd mast stage

1st mast stage
Outer mast
500 mm
500 mm
500 mm
500 mm
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.
ESR 5000
326
LIFTING MECHANISM
Calculating the required number of shims 13. Using the crane pull the 1st mast stage up into the
outer mast until the mast stoppers can be refitted.
There are shim sizes available:
14. Fit the mast stoppers.
Thickness Part No. Checking the clearance again

With the 1st mast stage at the stop, check the clear-
1.6 mm 060030-05
ance of the top mast rollers again:
0.7 mm 060030-85 15. Using a crowbar press against the top mast rollers
0.4 mm 795534 of the 1st mast stage until they contact the oppo-
site mast rollers of the outer mast.
Outer mast and 1st mast stage 16. Try to push one of the thinnest shims into the gap
between the outside of the roller and the mast
Calculating the required number of shims
channel.
1. Fit both top mast rollers (without shims) to the outer It should not be possible to push the shim in, but
mast. there should be a small amount of clearance.
2. Push the 1st mast stage into the outer mast.
Fitting the inner mast in the outer mast
3. Using a crowbar push the 1st mast stage in the
17. Push the 1st mast stage back fully into the outer
outer mast down until you can fit the top and bot-
mast.
tom rollers (without shims) of the 1st mast stage.
4. Fit the rollers and push the 1st mast stage back Fitting attachments
into the outer mast (same position as for retracted 18. Re-assemble both lift cylinders.
mast). 19. Re-assemble the pulleys for the lift chains and
5. Prepare a pile of shims 1.4 mm, 0.7 mm and hoses. Pre-assemble the hoses together with the
0.4 mm thick. rollers. It will not be possible to assemble the hoses
6. Using a crowbar push near the top mast rollers of at a later stage for reasons of space.
the 1st mast stage until they contact the opposite 1st and 2nd mast stages
rollers in the outer mast.
Calculating the required number of shims
7. Try to push the pile of shims into the gap between
the outside of the roller and the mast channel. Add 1. Push the 2nd mast stage into the 1st mast stage.
or reduce the number of shims as required. 2. Using a crowbar push the 2nd mast stage in the
It should be possible to push the shims without 1st mast stage down until you can fit the bottom
them becoming stiff or jamming. and top rollers of the 2nd mast stage.
Note: Try to use as few shims as possible. Therefore 3. Fit the rollers (without shims) and push the
try first with a thick shim before using thinner ones. Of- 2nd mast stage back into the 1st mast stage (same
ten you can use one thick shim instead of several thin position as for retracted mast).
ones. 4. Prepare a pile of shims: with 1.4 mm, 0.7 mm and
8. When you have calculated the number of shims re- 0.4 mm thickness.
quired, distribute the shims over both rollers but do 5. Place a crowbar between the 2nd mast stage and
not fit them yet. the 1st mast stage and push the 2nd mast stage
9. Repeat steps 1 to 8 for the bottom mast rollers. towards the 1st mast stage the mast roller opposite
10. Take the 1st mast stage out of the outer mast and the crowbar contacts the mast channel in the 1st
store it safely. mast stage.
Fitting shims and mast rollers
the outside of the roller and the mast channel.
In the next stage do not distribute the shims crosswise
It should be possible to push the shims without
(see Fig. 114, page 329).
them becoming stiff or jamming. Add or reduce
11. Place the number of shims correctly distributed as the number of shims as required.
calculated in step 8 under the respective top and
Note: Try to use as few shims as possible. Therefore
bottom mast rollers and fit the mast rollers.
try first with a thick shim before using thinner ones. Of-
12. Push the 1st mast stage back into the outer mast. ten you can use one thick shim instead of several thin
ones.
ESR 5000
327
LIFTING MECHANISM
7. When you have calculated the number of shims re- Calculating the number of shims on the centre roll-
quired, distribute the shims over both rollers but do ers (6 roller fork carriages only)
not fit them yet. 7. For 6 roller fork carriages, push the fork carriage
8. Repeat steps 1 to 7 for the bottom mast rollers. further up until the centre rollers are at the end of
the mast channel.
Fitting shims and mast rollers
Note: In the next stage do not distribute the shims
the outside of the roller and the mast channel. Add
crosswise (see Fig. 114, page 329).
or reduce the number of shims as required.
9. Push the 2nd mast stage down until the mast roll- It should be possible to push the shims without
ers can be removed. them becoming stiff or jamming.
10. Place the number of shims correctly distributed as 9. When you have calculated the number of shims re-
calculated in step 7 under the respective top and quired, distribute the shims over both rollers but do
bottom mast rollers and fit the mast rollers. not fit them yet.
11. Push the 2nd mast stage back to its neutral posi- 10. Pull the fork carriage out of the 2nd mast stage.
tion.
Calculating the number of shims on the bottom
Fitting attachments rollers
12. Refit all components (but not the free lift switch) Note: The bottom rollers on the fork carriage are not
which are not in direct contact with the fork car- accessible in the highest mast position.
riage.
Note: In the next stage do not distribute the shims
Fork carriage crosswise (see Fig. 114, page 329).
Note: For fork carriages with 6 rollers, always select 11. Initially, use the same number of shims on the bot-
the mean roller diameter one level lower than calcu- tom fork carriage rollers as for the top (for 4 rollers)
lated. This will prevent jamming when the rollers enter or centre (for 6 rollers) rollers.
the mast channel. Note: Try to use as few shims as possible. Therefore
Calculating the number of shims required try first with a thick shim before using thinner ones. Of-
ten you can use one thick shim instead of several thin
1. Fit all rollers (without shims) to the fork carriage.
ones.
2. Insert the fork carriage from underneath into the
12. Insert the fork carriage back into the 2nd mast
2nd mast stage.
stage.
3. Push the fork carriage right up until the top rollers
13. Manually push the fork carriage up as far as the
are at the end of the mast channel.
stop.
4. Prepare a pile of shims 1.4 mm, 0.7 mm and The fork carriage should not jam.
0.4 mm thick.
Checking the clearance of the bottom fork carriage
5. Using a crowbar push near the area of the top mast
rollers in the 2nd mast stage
rollers of the fork carriage until they contact the op-
posite rollers in the channel. 14. Using a crowbar push near the bottom mast rollers
of the fork carriage until they contact the opposite
rollers in the channel.
the outside of the roller and the mast channel.
The clearance should not be greater than that of
It should be possible to push the shims without
the centre or top rollers.
them becoming stiff or jamming. Add or reduce
the number of shims as required. 15. To compare, you can move the fork carriage and
check the top and bottom clearance alternately.
Note: Try to use as few shims as possible. Therefore
try first with a thick shim before using thinner ones. Of- Correcting the clearance of the bottom fork car-
ten you can use one thick shim instead of several thin riage rollers
ones. 16. Pull the fork carriage out of the 2nd mast stage un-
If the fork carriage has 4 rollers continue with step 10. til the bottom rollers can be accessed an place an-
For fork carriages with 6 rollers continue with step 7. other 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
ESR 5000
328
LIFTING MECHANISM
again. If necessary, place another thin shim under- Checking the mast stoppers
neath. 21. Check the mast lateral alignment.
It should be possible to push the fork carriage When the mast is fully extended it should not tilt
manually to the top stop without jamming. to the side.
The left and right stops on the mast stages
Final tasks and settings
should strike the stoppers at the same time.
18. Attach the components.
22. If necessary, fit shims. Note the assembly position
19. Refit all parts that have been removed. of the plastic block. The plastic must face the mast
20. Assemble the mast (see page 320) and carry out stop (see spare parts manual for details).
the tasks listed under Mast checks and settings
after assembly on page 320.
(1) (2)
(2) (1)
(1) (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
329
LIFTING MECHANISM
Integrated Sideshifter
Removing the integrated sideshifter
(See Fig. 115)
1. Remove the forks.
2. Lower the fork carriage onto a pallet.
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 disas-
sembly.
4. Flush the sideshifter cylinder (see page 79).
5. Flush the tilt cylinder (see page 79).
ESR 5000
330
LIFTING MECHANISM
11
10
34 9
32
33 31 26
30
1
5
4
8 3
7 2 12
27
6
28
29 13
17
14
16
18
15
17 27
21 2
19
3
4
21 5
20
22
6
23
7
8
24
25
Fig. 115 Integrated sideshifter
ESR 5000
331
LIFTING MECHANISM
Lift Cylinder Removal and Assembly
Lift Cylinder Removal and Lift cylinder removal on masts up to

Assembly 8m
The removal and assembly procedure differs depend- See Fig. 116
ing on the lift height. Beyond an 8 m lift height the mast Removal preparation
must be removed before the lift cylinders can be re-
moved from a horizontal mast (see page 335). 1. Fully lower the fork carriage.
2. Place a flat tray underneath the work area to collect
Safety notices any spilled hydraulic oil.
3. Remove the panels (22 & 30).
4. Extend the mast until the 2nd mast stage has been
WARNING raised approx. 500 mm.
5. Place approx. 200 mm long hard wooden blocks in
Risk of trapping and severing limbs
the channels of the outer mast and secure them
Unsecured masts stages and attachments can sever
with clamps.
limbs or even cause fatal injuries.
6. Place 350 - 400 mm long hard wooden blocks in
Before starting assembly always block and secure
the channels of the 1st mast stage and secure
the relevant components with equipment with suffi-
them with clamps.
cient strength and stability.
7. Slowly lower the fork carriage in full.
The lift chains are now relieved.
Lift cylinder removal
WARNING 8. Switch off the truck, disconnect the battery and
9. Remove the anti-bend pin (10) and screw (13).
injury
Whenever a high pressure hydraulic oil enters the skin 10. Remove the chain bolts from the top of the cylinder
it must be treated as a medical emergency. tube connection and use wire to prevent the lift
Seek medical assistance even if the skin appears nor- chains on the mast stage from falling down.
mal at first. 11. Depressurise the hydraulic system (see page 78).
To avoid accidents:
Depressurise the hydraulic system before opening
CAUTION
any sections of it.
Tighten all connections before pressurising the sys- Do not use any tools in step 12. Tools will damage
tem. the piston ram.
Only trace leaks with a piece of paper or cardboard. 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
CAUTION
crane.
Health risk 14. Undo the hydraulic port from the lift cylinder.
Cleaning agents, lubricants and consumables can 15. Raise the lift cylinder out of the mast.
damage your health.
ESR 5000
332
LIFTING MECHANISM
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).
ESR 5000
333
LIFTING MECHANISM
ESR 5000
334
LIFTING MECHANISM
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.
ESR 5000
335
LIFTING MECHANISM
Reach Cylinder Removal and Assembly
Reach Cylinder Removal and

Assembly

Safety notices

WARNING
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 nor-
mal at first.
To avoid accidents:
Depressurise the hydraulic system before opening
any sections of it. Fig. 117 Reach cylinder - reach carriage attachment
Tighten all connections before pressurising the sys-
tem.

CAUTION
Health risk
damage your health.
The reach cylinder is installed at the bottom right of the

Fig. 118 Reach cylinder - chassis attachment
truck. The piston ram is attached to the chassis (see
Fig. 118), the cylinder base to the reach carriage (see Removal
Fig. 117).
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.
ESR 5000
336
LIFTING MECHANISM
Free Lift Cylinder Removal and Assembly
Free Lift Cylinder Removal and 2. Place a load sling around the fork carriage and with
the crane raise the fork carriage until the FLS
Assembly switch is accessible.
The following section describes how to remove and as- 3. Chock the fork carriage with suitable hard wooden
semble the free lift cylinder with the mast assembled. blocks to prevent it from accidentally lowering.
Safety notices CAUTION

The free lift switch will be damaged if you raise the fork
CAUTION carriage beyond the free lift height.
Remove the free lift switch (FLS) before raising the fork
Health risk carriage beyond free lift height.
damage your health. 4. Remove the free lift switch (FLS).
Observe the manufacturers safety instructions 5. Place a flat tray underneath the mast area to col-
when handling solvents and lubricants. lect any spilled hydraulic oil.
6. Depressurise the hydraulic system (see page 78).
7. Disconnect all hydraulic lines and electrical con-
nections from the fork carriage. Seal open hydrau-
WARNING lic ports with filler plugs.
Risk of trapping and severing limbs 8. Remove the mounting bolt from the free lift chain.
Unsecured mast stages and attachments can sever Removing the fork carriage
limbs or even cause fatal injuries.
9. Using the crane lower the fork carriage down onto
Before starting assembly always block and secure a pallet positioned underneath it.
the relevant components with equipment with suffi-
cient strength and stability. 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 un-
til the fork carriage rests freely on the pallet.
WARNING
12. Bring the fork carriage out of the work area with a
High-pressure hydraulic oil can cause severe forklift truck.
injury 13. Lower the 2nd mast stage onto hard wooden
Whenever a high pressure hydraulic oil enters the skin blocks.
it must be treated as a medical emergency.
Seek medical assistance even if the skin appears nor- Removing the free lift cylinder
mal at first. 14. Remove the pressure line from the bottom of the
To avoid accidents: free lift cylinder.
Depressurise the hydraulic system before opening 15. Remove the two steel hydraulic lines attached to
any sections of it. the free lift cylinder in full.
Tighten all connections before pressurising the sys- 16. Place a load sling below the middle attachment
tem. plate around the free lift cylinder. Using the crane
Keep hands and body away from pressurized fluid. tension the load sling slightly to prevent the cylin-
der from falling out when the last two mounting
screws are loosened.
17. Remove the two mounting screws (31, Fig. 119)
Removal from the free lift cylinder.
18. Lift out the cylinder with the crane and place it on
Preparation
the ground.
ESR 5000
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LIFTING MECHANISM
Assembly
Note: When assembling the free lift cylinder in a hori-
zontal mast, note the following:
The free lift cylinder must stand in the ball pan be-
fore 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.
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).
ESR 5000
338
LIFTING MECHANISM
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 mainte- WARNING
nance and repairs are a prerequisite for safe truck op-
Improper cleaning can cause chains to crack
eration and long uptime.
A cracked chain can result in fatal injuries.
Never clean lift chains with steam cleaners, cold clean-
ing agents or corrosive, acid-based agents. This can
CAUTION cause direct chain damage through hydrogen embrit-
tlement.
Health risk
Cleaning agents, lubricants and consumables can Clean the chain surfaces only with paraffin deriva-
damage your health. tives such as cleaning petroleum or cleaning petrol.
Apply a thin layer of the cleaning agent with a hard
bristle brush and wipe with a lint-free cloth.
Apply an approved chain oil immediately after
cleaning or inspection (see Recommended Lubri-
Periodic inspection of chain cants and Consumables table, page 27). The oil
acts as an anti-corrosion agent.
supports and lift chains
CAUTION
Lift chains and chain supports must be periodically
cleaned, inspected and lubricated (see Planned Main-
tenance and Inspection, page 47).
The interval must be adapted for corrosive or dusty en-
vironments, i.e. reduced accordingly so that safety is
not affected.
Periodic replacement of chain sup-

ports and lift chains
For safety reasons chain supports, lift chains, anchor
bolts and attachment items must be replaced periodi-
cally 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 man-
ufacture / assembly (week/year).
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LIFTING MECHANISM
Inspecting Chain Supports and Lift Chains
Inspecting Chain Supports and supports, anchor bolts and lift chains together with
all their attachments.
Lift Chains
Checking the lift chain for
CAUTION elongation
If damage is detected on the lift chains during inspec- General
tion, replace the lift chains and the chain supports, The chain bends as it passes over the chain rollers.
chain bolts and attachment items before returning the This gradually causes the chain links and the chain
truck to service. If 2 chains are used paired, replace in plate eyelets to wear. The chain therefore elongates
pair. over time.
Preparatory measures
1. Remove the lift chain if it cannot be fully inspected
when installed.
WARNING
2. Clean the lift chain (see page 340).
Crashing loads can cause injury
Lift chains, chain supports, chain bolts and their attach- Tools required:
ments are safety components. Their failure can Wear gauge (see Fig. 120) or steel ruler
cause the load to crash, resulting in fatal injuries.
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.
CHAIN WEAR SCALE
Checking the lift chain for elongation.

ROLLER AND LEAF
Checking for wear on the edges of the chain con-

nection plates.
Checking for pitting due to corrosion, in particular
on the outer surfaces of the connection plates.
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 sup-
ports and anchor bolts.
Checking the service hours for the

lift chains and anchor bolts Fig. 120 Crown wear gauge
1. Check the chain support date of manufacture (see Chain wear can be measured with a wear gauge (part
engraving on chain support): no. 106440) or a steel tape measure.
If the chain supports are 3 years or older, replace The Crown wear gauge (see Fig. 120) has two scales:
the chain supports, anchor bolts and lift chains to-
gether with all their attachments. Scale A is used for 19.05 mm (0.75 inch) and
25.4 mm (1 inch) pitch chains.
2. Check the number of service hours since the chain
support and lift chains were last replaced: Scale B is used for 15.88 mm (0.625 inch) pitch
If the chain supports or lift chains have been in chains.
service for 6000 hours or more, replace the chain
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LIFTING MECHANISM
Checking the chain for elongation Note: For twin chains always replace the second lift
1. Raise the fork carriage to tension the lift chain. chain with the chain support and anchor bolts.
(Pull removed lift chains taut in order to measure Checking the lift chains
them.)
This section lists the inspection items that can be per-
formed in one step:
Check for loss of freedom in the chain links.
Check for worn or missing plates.
Check for twisted and protruding pins.
Check for lift chain lateral wear.
Check for lift chain corrosion.
Freedom of movement
Each individual chain link must flex freely. Tight joints
(see Fig. 122) increase friction and the chain tension
during lifting. Excessive chain tension in turn acceler-
ates material wear.
Fig. 122 Tight joints

Possible causes of stiff chain links are as follows:
Bent pins or plates
Fig. 121 Measurement section (A) on the lift chain
Rusty chain links
Make sure you measure a part of the chain that passes
Peened plate edges.
over a pulley.
2. With taut lift chain check section (A) either in front Plate edge distortion is caused by:
or rear of pulley for elongation.
Ruptured chain pinion.
3. Repeat the measurement on 3 parts of the chain
Constant overloading of the chain.
that always pass over a pulley during operation.
Chain striking the mast components.
Note: If you are using a steel ruler, the measurement
must include at least 10 links. See following table: Worn or missing plates
Generally speaking, material wear is the cause of worn
Pitch No. of Length Wear limit or missing connection plates. The plates near the chain
chain links new pin hole (see Fig. 123) can crack after a high number
of lifting cycles with heavy loads.
25.4 mm 12 305 mm 314 mm
1 inch 12 inch 12.375 inch
19.05 mm 16 305 mm 314 mm
0.75 inch 12 inch 12.375 inch
15.88 mm 20 318 mm 327 mm
0.625 inch 12.5 inch 12.875 inch
Replace lift chains, chain supports, anchor bolts Fig. 123 Worn connection plate
and attachments if the chain has elongated by
more than 3%!
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LIFTING MECHANISM
Turned pins nizing process is an excellent protection and fully pen-

etrates the joints. Do not remove this layer of grease!
Considerable frictional forces between the connection
plates and the pins occur when lifting heavy loads with Checking lift chains for rust, rust marks and crack-
an insufficient or non-existent film of oil. ing caused by corrosion
In extreme cases the frictional torque in the joints can 1. If you have not already done so, with the mast fully
be such that the pins turn and gradually work out of the lowered undo the lift chain bolts from the top chain
chain (see Fig. 124). The chain can break as a result. supports (remove the anchor bolts) and thread
Turned pins can be rapidly identified if the flat ends are them out far enough that they can accessed along
not all pointing in the same direction. 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 Uneven chain tension (see Checking and adjusting
Checking chain links for freedom of movement, the chain tension, page 344).
worn connection plates and turned pins Misalignment between the pulleys and the chain
1. With the mast fully lowered, undo the lift chain bolts supports (see Checking the lifting components for
from the top chain supports (remove the anchor misalignment, page 345).
bolts) and thread them out so that they can ac-
cessed along their whole length. Checking chain supports and
2. Check the chain links for freedom of movement, anchor bolts
worn connection plates and turned pins.
Immediately replace any damaged chains along Checking chain supports
with the chain supports, anchor bolts and attach- 1. Check the chain supports for:
ments. Chains used in pairs must also be replaced Assembly period expiry
in pairs. (max. 6000 hours or 3 years, see date on chain
support head)
Corrosion Cracks
Corrosion considerably reduces the capacity of a lift Corrosion
chain. It results in cracking in the side plates.
Finger wear
2. Replace any damaged or worn chain supports.
Checking the anchor bolts
Check the anchor bolts for:
Cracks
Corrosion
Fig. 125 Cracking caused by corrosion Wear
3. Replace any damaged anchor bolts.
Lift chains must therefore be protected from corrosion.
The layer of grease applied in the factory hot dip galva-
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LIFTING MECHANISM
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
Worn flanges are due to misalignment. If the pulleys
are worn:
A
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
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.
4. Check the screw depth of the bottom chain support
(on the fork carriage): It should be = 80 mm.
Setting the chain tension
5. Undo the counternut on the top chain support.
6. Set the chain tension by adjusting the chain sup-
ports.
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 dam-
aged 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).
ESR 5000 Rev.1 02/2009
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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 In dusty operating conditions the multi-plate chains can
life. be more efficiently lubricated than roller chains. Multi-
plate chains consist of several plates. Therefore they
Highly stressed chains under constant use cannot last
provide several paths for the lubricant to reach the
sufficiently long if they are not regularly lubricated.
chain bolt (see Fig. 127) and allow the oil to penetrate
As with all contact surfaces, the tensiled steel precision to the bearing surface on the chain bolt, even when the
moving parts require a durable lubricant film between chain is dirty.
the contact surfaces to avoid excessive wear.
The key thing is that the lubricant oil can penetrate into
the chain bolts. This is impossible if the chains are cov- 1
ered in grease and dirt.
Maintaining a lubricant film on all the chain surfaces
provides the following benefits:
Restricts joint wear to a minimum (chain elonga-
tion).
Avoids corrosion.
Reduces the risk of chain bolts turning.
Restricts the danger of chain links turning in to a
minimum.
Ensures an even movement of the chains and thus
reduces noise levels. Fig. 127 Oil film (1) in a multi-plate chain
Reduces the chain tension due to less friction in the
Lubrication intervals and lubricants
chain system.
Under normal operating conditions the chains should
Key factors when considering which lubricant to use
be cleaned according to the intervals specified in the
are as follows:
maintenance schedule (see page 29), and then lubri-
High degree of penetration in the narrowest of gaps cated with an approved chain lubricant (see page 27).
Maximum tolerance of pressure and shearing In extreme conditions this interval must be reduced ac-
forces before the lubricant film comes off. cordingly.
Suitability to the operating temperature range, es-
pecially important for cold store trucks.
Lubrication intervals depend on the operating condi-
tions and the environment. Trucks parked outdoors, in
cold stores or which are subjected to extreme weather
conditions must be lubricated more frequently.
Dust will gather on oiled chains in dusty environments.
However, even in these conditions, regular lubrication
can considerably reduce wear.
A paste mixture of oil and dirt will gather on the chain
links, but they will not wear as fast as they would if they
were left to dry, leaving a metal to metal contact be-
tween the pins and plates.
Rev.1 02/2009 ESR 5000
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LIFTING MECHANISM
Separating Lift Chains
Separating Lift Chains Cutting the lift chain
Lift chains are supplied by the meter and must be cut

to the required length.
WARNING
Tools and equipment required Risk of eye damage
A secure working plate with a hole slightly larger Splinters can fly off during grinding operations.
than the head diameter of a chain bolt. The hole Wear goggles to avoid eye injuries.
must be deeper than the chain bolt length.
A backring (washer) with a hole slightly larger than 1. Carefully grind the head of the chain bolt, taking
the head diameter of a chain bolt. The backring care not to damage the chain plate eyelet.
thickness must be slightly larger than the height of
2. Place the backring onto the hole in the working
the head of a chain bolt. The backring prevents the
plate.
inner plate surface from being damaged when you
drive out the chain bolt. 3. Insert the head of the chain bolt to be driven out
into the backring.
A grinder.
Align the chain bolt, backring and hole in the
A hammer and hole with a diameter slightly shorter working plate.
than the chain bolt. Or a press with a suitable man-
4. Drive out the chain bolt.
drel. 1
4
1
3 2
1 Chain plate eyelet 3 Backring
2 Hole in working plate 4 Grinder
ESR 5000 Rev.1 02/2009
347
LIFTING MECHANISM
Forks
Forks Fork marking

General
The fork tines and forks must be checked by trained
personnel under the maintenance schedule (see 1
page 49) for cracks, damage and wear.
If the forks are used to transport abrasive loads the in-
spection must be carried out at shorter intervals.
Terms
1 2
3 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
4 Manufacturing data (month / year)
Company logo
Fig. 128 Fork tines Manufacturing site
1 Fork blade
2 Fork hanger
3 Fork shank
4 Heel (curved area)
Rev.1 02/2009 ESR 5000
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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 manu-
facturer.
Fig. 131 Fork hanger
1. Check for cracks on the weld seams by the upper
Checking fork tines for cracks and lower fork hangers (see Fig. 131) including
their fork shank attachments.
Visually inspect all fork tine surfaces for signs of
Remove the fork in question if any cracking is dis-
cracks. The heel area and weld seams must be
covered.
checked particularly carefully. If in doubt carry out a
non-rupturing crack test (paint penetration process or
Magnaflux):
Checking fork tip straightness
(See Figs. 132 and 133)
Checking the heel area for cracks
1. Check the fork tip (2) for straightness using a
Fatigue cracking (1, Fig. 130) tends to occur around
ruler (1).
the heel of the forks.
Replace the fork if the tolerance level has been
1. Check the fork heel area particularly carefully. exceeded.
2
1
1
2 mm
250 mm
Fig. 130 Fatigue cracking in the heel area

Fig. 132 Vertical fork tip straightness
ESR 5000 Rev.1 02/2009
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LIFTING MECHANISM
Fork Inspection
Fig. 135 Fork tip width
Measuring the fork tine height

500 mm
1 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
max. 6 mm
blade length (L), the fork tines must be aligned pro-
fessionally.
Fig. 133 Horizontal fork tip straightness
For example: If the fork blade is1150 mm long the
Measuring the fork blade warping maximum permissible deviation is approx. 35mm.
However, this would prevent the fork from working. In
1. Measure the angle deflection between the top of
practice, forks must be aligned if the deviation is max.
the fork blade and the front of the fork shank (see
10 mm.
Fig. 134).
If dimension x is outside the tolerance range, the
fork must be aligned by a specialist and re- L
checked.
3
500 mm 1
x - 17 mm
x + 8,5 mm
x 2
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.
1. Measure the fork tip width with a calliper gauge.
The mechanism should lock securely, otherwise
If the fork tip width S is less than a = 6 mm (a = fork
the fork must be replaced.
shank width) take the fork out of service (see
Fig. 135).
Rev.1 02/2009 ESR 5000
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LIFTING MECHANISM
Fork Inspection
a=100%
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 ob-
tained.
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.
ESR 5000 Rev.1 02/2009
351
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
1 Reach carriage 1 "Right" outrigger
2 Roller 2 "Left" outrigger
3 Side roller
4 Backing roller Reach carriage removal
1. Disassemble the mast (see page 319).
The reach carriage (1, Fig. 140) has two rollers (2), two
side rollers (3) and one backing roller (4) on each out- 2. Remove all electrical and hydraulic connections
rigger. from the reach carriage.
The side rollers absorb lateral forces and guide the 3. Loosen the connection between the reach cylinder
reach carriage parallel into the outriggers. The side roll- and reach carriage (see page 336).
ers in the left outrigger are adjustable. This ensures 4. Secure the reach carriage with a crane and push it
smooth operation with virtually no slack along the en- out of the outriggers.
tire reach path. A backing roller (4) with downward pre-
tension on each outrigger reduces the vertical slack of Reach carriage assembly
the rear rollers.
Pre-assemble the reach carriage
1. Replace any worn rails.
2. Replace faulty side rollers, rollers and backing roll-
ers 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 hand-
tightened.
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 in-
stalled.
ESR 5000
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LIFTING MECHANISM
Reach Carriage
Pushing the reach carriage into the outriggers Note: Note that the same number of spacers must be
6. Push the pre-assembled reach carriage into the used on the front and rear rollers to avoid tilting the
outriggers using a crane. reach carriage.
11. Repeat steps 7 to 9 until the gap lies within the
Adjusting the side rollers
tolerance range of 2 mm.
Tightening and securing the side roller setscrews
12. Using a mounting iron push the entire reach car-
riage 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
16. Using a mounting iron push against the channel in
1 "Right" outrigger the left outrigger until both left side rollers are rest-
2 "Left" outrigger ing against the web of the channel. (See Fig. 141
3 Chassis back plate for the definition of left and right).
4 Reach carriage cover plate 17. Measure and record the gap on the right outrigger.
18. Using a mounting iron push against the channel in
Note: The aim is to obtain approximately the same gap the right outrigger until both right side rollers are
on the left and right hand side rollers so that the reach resting against the web of the channel.
carriage is centrally aligned in the chassis.
19. Measure and record again the gap on the right
7. Push the reach carriage forward until the reach outrigger.
carriage cover plate (4, Fig. 142), covers the chas-
sis back plate (3). 20. Compare both measurements. They should not
deviate from each other by more than 0.5 mm.
8. Using a mounting iron push against the channel in If necessary, adjust the setting via the set-
the left outrigger until both side rollers are resting screws on the right side rollers (repeat steps 12
against the web of the channel. to 20).
9. Measure the gap on both sides between the U sec-
tion of the outrigger and the side plate (see Refitting the mast
Fig. 141) of the reach carriage by the side roller (it 21. Fit the mast (see page 319) and then adjust the
should be 21.5 mm): backing rollers.
If the difference is greater than 2 mm, proceed Setting the backing rollers
to step 10.
If the difference is less than 2 mm, proceed to Note: The mast must be fitted in order to adjust the
step 12. backing rollers. Without the mast there will be no addi-
tional tilt moment and the setting will be wrong.
10. Compensate the gap on the left side rollers with
additional 1 mm spacers.
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 pre-
tension.
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
damage your health.
Hydraulic System Repair

Instructions
Hydraulic systems are sensitive to dirt.
Thoroughly clean disassembled hydraulic compo-
nents before dismantling them.
Always repair hydraulic components at a clean
workstation.
Immediately protect cleaned and de-greased com-
ponents with a thin coating of hydraulic oil.
Protect components against re-contamination be-
fore assembling them.
Immediately seal open hydraulic ports on repaired
assemblies with dummy plugs. This also applies to
open ports and lines on the truck.
Do not refinish any cylinder surfaces. Replace any
damaged parts.
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. 4 mm) of a
CAUTION screwdriver (1).
Cylinder surfaces can be damaged through the use 2. Sand the soldering joint.
of unsuitable tools. 3. Wrap insulating tape (1) around the shaft and sol-
Do not use a screwdriver or similar tools. dering joint of the screwdriver.
Use burr-free tools made of soft metal (brass, alu- Groove aligning arbor for small rod
minium) without sharp edges or a suitable plastic.
seals
You must produce the following tools yourself: The outer diameter of the groove aligning arbor must fit
the internal diameter of the cylinder cap.
Small hook The arbor should end flush with the bottom of the seal
seat.
Use small hooks to remove small seals (see Fig. 144).
1
2
Fig. 146 Groove aligning arbor in a cylinder cap

1 Cylinder cap
Fig. 144 Hook 2 Seal seat
Extractor 3 Groove aligning arbor
Two extractors to remove rod seals (see Fig. 145)

.
Fig. 145 Extractor
ESR 5000
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.
3
4
Fig. 147 Assembly device for large rod seals

1 Tool body
2 Fixed pin
3 Rod seal (shown for illustration purposes only)
4 Axial moving pins
Protective mechanisms
If the seal has to be pushed over sharp edges, cracks
or nicks, use appropriate plastic protective mecha-
nisms.
ESR 5000
359
CYLINDERS
Rod Seal Removal and Assembly
Rod Seal Removal and

Assembly 1 2
Removing a large rod seal 3

1. Turn one extractor (see Fig. 145) respectively into
the opposite parts of the rod seal. 4
2. Pull the seal out of its seat using the grips of the
tools.
3. Dispose of the rod seal.
Removing a small rod seal 5

1. Using a small hook (see Fig. 144) pull the rod seal 6
out of the seal seat.
2. Dispose of the rod seal.
Inserting a large rod seal

1. Apply a thin coating of hydraulic oil to the rod seal Fig. 149 Wound rod seal
and the seal seat in the cylinder cap.
5. Push the tool body (1, Fig. 5) into the cylinder cap
2. Place the rod seal over the fixed pin (1, Fig. 148).
(2) until the rod seal (6) is aligned with the seal seat
3. Bend the rod seal under the pin (2). in the cylinder cap.
4. Now bend the resultant loop up so that the pin (3) 6. Retract the pin (1, Fig. 150).
can be moved into the loop. One segment of the rod seal jumps into the seal
seat.
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 push-
ing 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.
3
1 2
Fig. 151 Rod seal fully inserted in seal seat
4
8. Pull the tool body out of the cylinder cap.
Fitting a small rod seal

6
1
5
2
3
Fig. 153 Sealing lip facing the pressure side
4 1 Cylinder tube
2 Inner thread
3 Protective sleeve for assembly
4 Rod seal
5 Sealing lip
6 Backring
Fig. 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 burr-
free 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 fol-
lows: CAUTION
Free lift cylinder starting on page 337.
Damaged or contaminated seal seats and piston
Lift cylinders starting on page 332. rams will result in immediate leaks, even with new
Sideshift cylinder starting on page 330. seals. The same applies to the use of unsuitable
Reach cylinder starting on page 336. tools for seal removal and fitting.
The tilt cylinder cannot be repair with standard tools. It Before fitting a new seal check the seal seats and
must be replaced if faulty. 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
damage your health.
General
Carefully check the cylinder before starting repair work.
After removal from the truck:
Check the piston rams for nicks, scratches, corro-
sion and other surface damage. Replace any dam-
aged piston rams.
Check the dirt deflectors for wear and unusual leak-
age.
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
Removing the piston
and General sections on page 362.
1. Remove the piston ram (1) from cylinder tube (8).
Lift cylinder removal is detailed on page 332.
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 Removing the shut-off piston and spring
to Fig. 154. 1. Using suitable pliers carefully remove the retaining
ring (12).
CAUTION 2. Take the shut-off piston (13) and spring (9) out of
the piston ram.
The cylinder tube can easily be damaged when you
Removing the velocity fuse
clamp the cylinder
1. Unscrew the velocity fuse (14) from the hydraulic
Tighten the tensioners very slightly and use prism-
port on the cylinder tube.
shaped braces.
Lift cylinder assembly
Rod seal removal
1. Tension the cylinder tube to prevent the cylinder to Fig. 154.
from twisting.
2. Unscrew the cylinder cap (2) from the cylinder tube
(8). CAUTION
Note: If the cylinder cap does not loosen, heat up the Incorrect handling during assembly can result in
cylinder cap carefully and consistently with hot air. leaks.
3. Remove and dispose of the following parts from Take care not to damage the piston ram and the
the cylinder cap: new seals during assembly.
Dirt deflector (3) Use guide bushing and burr-free tools without
Rod seal (4) sharp edges.
Backring (5) Apply a thin coating of hydraulic oil to all seals and
Guide ring (7) components prior to assembly.
O-ring (6) Observe the general instructions on assembling

seal rods starting on page 357.
CAUTION Piston ram pre-assembly and installation

1. Insert the piston (10) consisting of 2 half shells in
Health risk
the groove of the piston ram (1).
damage your health. 2. Pull a new guide ring (11) onto the piston.
Observe the manufacturers safety instructions 3. Push the piston ram into the cylinder tube.
Piston cap pre-assembly and installation
4. Thoroughly clean all metallic components with a
suitable light solvent. In particular, the seats of the Fit the following components in the cylinder cap:
seals and the backrings must be absolutely clean Dirt deflector (3)
and free of foreign bodies. Rod seal (4)
Backring (5)
5. Apply dry compressed air to the cleaned compo- Guide ring (7)
nents.
O-ring (6)
ESR 5000
363
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 cylin-
der 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
3
1
4
2
15
16
2
1
5
3 6
4 7
8
9
5
6
13
7
12
10
8 11
9
14
Legend
1 Piston ram
2 Cylinder cap
3 Dirt deflector
10 4 Rod seal
5 Backring
11 6 O-ring
12
7 Guide ring
13 8 Cylinder tube
9 Spring
10 Piston
11 Guide ring
12 Retaining ring
14 13 Shut-off piston
14 Velocity fuse
15 Seal
16 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
Before carrying out repairs read the Safety notices
Removing the piston
and General sections on page 362.
1. Remove the piston ram (1) from cylinder tube (8).
Free lift cylinder removal is detailed on page 337.
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 Removing the shut-off piston and spring
to Fig. 155. 1. Using suitable pliers carefully remove the retaining
ring (11).
CAUTION 2. Take the shut-off piston (10) and spring (9) out of
the piston ram.
Removing the velocity fuse
clamp the cylinder.
1. Unscrew the velocity fuse (17) from the hydraulic
Tighten the tensioners very slightly and use prism-
port on the cylinder tube.
shaped braces.
Free lift cylinder assembly
Rod seal removal
1. Tension the cylinder tube to prevent the cylinder to Fig. 155.
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 Incorrect handling during assembly can result in
cylinder cap carefully and consistently with hot air. leaks.
3. Remove and dispose of the following parts from Take care not to damage the piston ram and the
the cylinder cap: new seals during assembly.
Dirt deflector (2) Use guide bushing and burr-free tools without
Rod seal (3) sharp edges.
Guide ring (5) Apply a thin coating of hydraulic oil to all seals and
Backring (6) components prior to assembly.
O-ring (7) Observe the general instructions on assembling

seal rods starting on page 357.
CAUTION Piston ram pre-assembly and installation

2. Insert the spring (9) and shut-off piston (10) in the
Health risk
piston ram.
damage your health. 1. Carefully insert the retaining ring (11).
Observe the manufacturers safety instructions 1. Insert the piston (15) in the groove of the piston
when handling solvents and lubricants. ram (1).
2. Pull a new guide ring (11) onto the piston.
4. Thoroughly clean all metallic components with a 3. Push the piston ram into the cylinder tube.
suitable light solvent. In particular, the seats of the
seals and the backrings must be absolutely clean
and free of foreign bodies.
5. Apply dry compressed air to the cleaned compo-
nents.
ESR 5000
366
CYLINDERS
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 cylin-
der 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).
ESR 5000
367
CYLINDERS
1
2
3
2
18 19
3
4 4
6 1
5
5
7 9
6
7 10
8
11
12
13
15
14
16
17
Legend
1 Piston ram
10 2 Dirt deflector
3 Rod seal
4 Cylinder cap
5 Guide ring
11
6 Backring
12 7 O-ring
8 Cylinder tube
13
9 Spring
14
10 Shut-off piston
15 11 Guide ring
12 Retaining ring
13 Guide ring
16 14 Seal
15 Piston
17
16 Retaining ring
17 Velocity fuse
18 Seal
19 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 9. Apply dry compressed air to the cleaned compo-
and General sections on page 362. nents.
Reach cylinder removal is detailed on page 336. 10. Protect shiny metal surfaces immediately with a
Dismantling the reach cylinder
Removing the piston ram and seals
1. Pull out the piston ram.
to Fig. 156.
2. Remove and dispose of the guide ring (13).
3. Remove and dispose of the seal (12).
CAUTION
Assembling the reach cylinder
clamp the cylinder.
Tighten the tensioners very slightly and use prism- CAUTION
shaped braces.
Incorrect handling during assembly can result in
leaks.
Rod seal removal Take care not to damage the piston ram and the
1. Tension the cylinder tube (10) to prevent the cylin- new seals during assembly.
der from twisting. Use guide bushing and burr-free tools without
2. Measure and record the screw depth of the ball sharp edges.
joint (1). Apply a thin coating of hydraulic oil to all seals and
3. Unscrew the ball joint (1). components prior to assembly.
4. Pull the spacer sleeve (4) and the O-rings (5) off Observe the general instructions on assembling
the piston ram (11). seal rods starting on page 357.
5. Bead the retaining plate (15) in order to unscrew
the cylinder cap (16).
Piston ram pre-assembly and installation
6. Unscrew the cylinder cap from the cylinder tube.
1. Pull a new seal (12) onto the piston ram (11).
7. Remove and dispose of the following parts from
2. Fit a new guide ring (13).
the cylinder cap:
3. Use a guide sleeve in the cylinder tube and push
Dirt deflector (6)
the piston ram into the cylinder tube.
Rod seal (7)
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)
Health risk Backring (8)
Cleaning agents, lubricants and consumables can O-ring (9)
damage your health. The cylinder cap is now ready for assembly.
Observe the manufacturers safety instructions 2. Carefully push the cylinder cap over the lubricated
when handling solvents and lubricants. piston ram.
3. Screw the cylinder cap onto the cylinder tube and
8. Thoroughly clean all metallic components with a torque it to 130 10 Nm.
suitable light solvent. In particular, the seats of the 4. Screw on the ball joint and apply the screw depth
recorded during removal.
ESR 5000
369
CYLINDERS
5. Torque the counternut (2) to 190 10 Nm.
Final tasks
1. Refit the reach cylinder (see page 337).
ESR 5000
370
CYLINDERS
1
190 10 Nm
10
2
3
4 13
12
130 10 Nm
16 5
5 9
6
8 11
7
8 15
9
15 4 16
14
7
14 5 6
3
10 2
1
Legend
11 1 Joint head
2 Counternut
3 Washer
4 Spacer sleeve
5 O-ring
6 Dirt deflector
7 Rod seal
8 Backring
9 O-ring
10 Cylinder tube
12
11 Piston ram
13 12 Seal
13 Guide ring
14 Guide ring
15 Retaining plate
16 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 cyl-
inder 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 re-
moval.
Final tasks
1. Refit the sideshifter (see page 330).
ESR 5000
372
CYLINDERS
Repairing the Sideshifter Cylinder
11
10
34 9
32
33 31 26
30
1
5
4
8 3
7 2 12
27
6
28
29 13
17
14
16
18
15
17 27
21 2
19
3
4
21 5
20
22
6
23
7
8
24
25
Fig. 157 Integrated sideshifter
ESR 5000
373
Notes:
374
SCHEMATIC DIAGRAMS
375
Notes:
376
SCHEMATIC DIAGRAMS
Wire Colour Code
Wire Colour Code The first or first two digits designate the wire colour.
The last two digits are a sequence number.
The wires used in the truck are colour-coded and num-
bered according to their function: Note: Third party component wires may pose an ex-
ception 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.
Abbre- Description Abbreviation Description (Sheet 1 of 2)

viation
K Relay LMS Limit switch

ACS Travel switch LOS Lower switch
AXS Accessories switch ORS Override switch
BRS Brake switch POT Potentiometer
DIS Direction switch RA Raise potentiometer
DRS Door switch RAS Raise switch
EDS Emergency power disconnect REA Reach potentiometer
EM Encoder module RS Reverse switch
ENC Encoder SAS Safety Reverse Switch
FS Forward switch SDS Start switch
HBS Handbrake switch SES Seat switch
HNS Horn switch SSS Sideshifter switch
HSS Rabbit/Turtle toggle switch THS Thermal switch
KYS Key switch TLT Tilt switch
LGS Light switch WAS Walk-along / pedestrian mode switch
BV (AK) Battery voltage after the key switch M2 (PM) Pump motor
BDI Battery discharge indicator MRC Control module
BR Brakes OHGD Overhead guard display
BWI Brush wear display P Pump contactor
CA Cable connection PC Plug connection
F Field coil connection PCB Printed circuit board
FAN Fan SF Shunt field
FU Fuse STI Steering wheel indicator
HN Horn SV Solenoid valve
IFD Information display TB Terminal block
JC Socket = counterpart to PC TMM Truck management module
LINE Main contactor TT Hourmeter
M1 (TM) Traction motor VMN Motor driver (volt motor negative)
GPCSR Safety switch - RH side restraint GCSL Safety switch - LH side restraint
Rev.1 02/2009 ESR 5000
378
SCHEMATIC DIAGRAMS
General Contact Symbol Abbreviations
Abbre- Description Abbreviation Description (Sheet 2 of 2)

viation
PLS Platform switch TCM Traction motor

PS Pressure switch HR Heating
HCM Hydraulic control module ALM Travel Alarm
RECEIVER Receiver TRANSMITTER Transmitter
BDI Combination instrument CHARGER On-board charger
BRK Electromagnetic brake DR Driver
SLS Sideshift left switch SRS Sideshift right switch
ECS Lift control switch --- ---
ESR 5000 Rev.1 02/2009
379
SCHEMATIC DIAGRAMS
Electrical Wiring Diagrams
Europe USA Description Europe USA Description
Wires joining Switch applied manually
Wires crossing Solenoid valve
Wire connection Throttle / coil
Plug / socket Resistor
Wire strap Capacitor
Clip Pad Potentiometer
Fuse Varistor
V
Assembly Thermal protector
Contact, normally Lamp

open
Contact, normally Horn

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

contactor / relay
Time delay contactor LED

/ relay
Switch, normally Transistor

open
Rev.1 02/2009 ESR 5000
380
SCHEMATIC DIAGRAMS
Europe USA Description Europe USA Description
Push button, MOSFET

mechanically
actuated
Pushbutton, Thyristor
hydraulically
actuated
Emergency power Comparator
disconnect
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
SCHEMATIC DIAGRAMS
Wiring Diagram (Fingertip and Dual Axis Hydraulic Control Levers)

EDS Not-Aus
Main
FU7 = 425A Screw S1 Contactor S2 Screw
BUSBAR BUSBAR BUSBAR BUSBAR 1 A to TDM Traction-controller
200 203 / 204 and SDM
FU1 = 15A + FU2 = 15A

206 / 207 Relay Options L 5902
207
F
2926
Option: Keyless 201 202 +
FU6 2999 2902 5928 2923 2927 2932 2933 29136 2931
EDS 1 E K12
15A 9 R2 10 2 4
+ mechanical 2928 1 CA 415 1 CA 434 1 CA 435 1 CA 401
to Display CA 402 12
K1 2951 927
CA 473 + Fan2 Fan3 Fan4 Fan1
+ A A CA 420 HORN 48V 48V 48V 48V
2960 2957
3 OPTIONS 1 932 29140 K13 K11 V5 C5 C1,C2
K11
KEY
+ V2 2 2 2 2
2958
CA 440 K1
4 K2 KYS 5916 5934 5918 5934
48V Batt. F1 V1
2998
502 1 5901
K12 508 5 2904 3
K2 C CA 420
29141 C 5914 5915
- 509 5936 2924 UB- 11 to TDM Pin 2
6 2901 Charge R1
K13 START UP CARD
2954 Display CA 472 Pin 3
CA 429 CA 425
B to TDM & Display Danaher Motor CROWN Motor
Main Loom: Main Loom:
2921
819849 819850
2921 5919 Main Loom:
14 CA 422
14 H 825335
2929 2 CA 201
CA 801 1 KYS
CA 422
CA 601 B+ 307
3 4 4 2930 2942 2938 307 1
CA 422 CA 604 CA 807 + 903/904 FAN +12V 3 1
CA 802 14 14 23/22 CAN_H
5904 5922
C A 5
CA 600 14 BV+ POUT_2 1 9 4 3 SVH 010 2 010
2943
908/909 CH.A 5 3
500 15/14 CAN_L
D CA 600 CA 422 019
CA205 + CA 807 011
CA 604
CA 601
6 2 30 Di 9 HGT(R)S 617/618 CH.B 6 3 011
5903 5921 2944 8/7 CAN_GND HCM 4
569 POUT_1 42 8 3 1 PVL 2
608
017 GND 4 4
3
CA 601 3
25 Di 16 FLS/LCS 3 21/13 ID GND 2 608
CA 808 + CA 808 607 609
CA 805 5905 5923 2945 Temp GND 17
RES1 POUT_3 15 10 5 2 PVRE 1 12 ID1
C 027 018
8
CA 604 13 CA 422
18 Di 7 RES 1 107
L+ CA 810 + CA 810 CA 201 Temp 16
A 316
CA 604 CA 422 022 5906 5924 2946
1 4 19 Di 8 RES 2 POUT_4 29 16 9 2 PVRT 1
L- B 622 CA 430
G GND CA 417 1 2
2913 004 CA 809 + CA 809
A C 5 Di 4 ACS 5908 5926 2947
4 POUT_5 13 12 7 2 PVAL 1 Control
RES 2 2915 007
3 028 31 Di 10 BFS Card
CA 811 + CA 811
L+ 1 317 5907 5925 2948
2916 008 POUT_6 27 11 6 2 PVAR 1
32 Di 11 BPS
THS 2
L- U_Batt
2 623 G GND CA 601 CA 801 + CA 801
PTC
CA 806 5909
1 1 1 2
CA 422 CA 604 POUT_7 41 SVT
CA 604 CA 422
2910 029 023
315 14 11 10 17 39 Di 17 PLS
SPS CA 419 +
12 CA 604 5910
C POUT_8 12 5 5 5 SVS 6 CAP
2909
314 L+ B 17 Di 6 KYS
A 3100 I_Mess
6 CA 422
+ U
L- 5914 5911
B 669 24 POUT_15 Horn POUT_9 26 18 8 8 SV5 7
310 I_Mess Motor Shunt
Height M2
1 Encoder
Z C 005 V
GND 16 Di 5 SPS
ECR 5 CA803 CA 600 CA 422 U_Mess Motor Shunt
digital Inputs CA 426 W
C wht blk 3 red/blk 021 006
CH. B 4 4 4 32 38 Di 14 Ch. B AN_21 BLS 12 C U_Mess
red blk 4 396 310
+ 12V 3 3 3 6 C 3101 U_Mess
grn/blk C A
blu blk 2 020
CH. A 2 2 2 31 9 Di 13 Ch. A GND -
blk blk 1 666 613
GND 1 1 1 7 Z CH. B -
CA 206
5902 CH. A -
GND F 11 Main Contactor 20
009 + 12V -
602
Di 12 BRS 33 Display CA 472 Pin 2 21
CA 407 3 Only ECR 2 Speed Sensor
ACC wired
PED 2 106 with
Pot 1 1 CA 411 CA 428 CA 471
21 Ain1 CA205 CROWN
302 301 300 CA 205 Motor
CA411 N.C. 1 FWD Switch +12V VCM 1 1 6 12V Out
N.C. 2 B- Main Loom:
900 819850
3 Selc. Dir 120
CAN_H 22 3
Direction Switch 4 Busbar / 500 / 508 Main Loom:
Ohm 905 3 CAN_H & CAN_L are twisted, not GND!!! E to SDM, TDM & Display 825335
5 Horn CA 406 CA 470 CAN_L 23 509 / 569 / 570
HORN 6 12V Display 1 1 C PC416
055 614 625
4 FWD Switch CAN_GND 8 6 GND Display
7 Tilt down FWD Switch 2 2 Travel Alarm 319 UB-
Tilt up 002 CA 203-13003 5 +12V Display
8 only with MTC 5th Function 3 3 3 Sel. direction Travel Alarm Loom
9 Tilt up CA 206 CA 421 3 4
Tilt down Sel. Dir. 4 4 399 CA 436 CA 437
10 only with MTC 14 Horn Input VCM 900/901
Horn 5 5913 5980 5981 1 CAN_H
CA 407 5 052 POut_7 7 2 1 2 A B 905/906
15 Tilt Down 2 CAN_L
CA 407 +12V 1 Tilt down 6 7 614/615
Lift / Lower SIG 2 POT 2 1 3 CAN_GND
Tilt up/ POT4 7 6 051 37 Tilt Up/ POT4 2980
Lever GND 3 29147
Heat Seat 48V+ 8 8 K 2925
CA 408 29148
CA 408 +12V 1 Coldstore 10
Reach / Retrac SIG 2 POT 3 CA 471
Lever GND 3 Armrest CA 428 101
POT2 2 2 35 Ain2 /POT2
CA 410 Interface 601 H
1 3 3 600
A 48V after Main Contact not connected Box GND 7 GND_Out
with MTC only 2 POT 4 POT3 4 4 102
B 48V Key with Lever 3 only with lever 5 36 Ain3/ POT3 CA 205 Beacon Loom
C 12V Display POT5 5
CA 409 053 CA 474 -6 CA 433 CA 434 CA 435
Heat Seat SIG 6 104 20 Ain5/ POT5
D GND 1 2917 5920 5940 5941
CA 409 +12V 7 POut_14 10 2 1 2 A B
2 POT 5 Seat 48V+ 7 H 001
E B+ after Key Side Shift SIG
F Main Contactor Lever GND 3 Seat SIG 8 8 2 Di 1 SES 1 LAMP
CA 405 CA 404 2940
G CAN BUS 5th Switch + Seat 48V+ 1 CA206 2935
CA 405 1
H 48V FU2 5 th Function 2 5th Switch - Seat SIG 2 Connection to
K 48V FU5 Switch 3 5th LED - Heat Seat 48V+ 3 Seat Harness 504
OPTION Heat Seat GND D 28 BV-
Z GND 4 5th LED + 4 H 822617-2F_1
Fig. 159
ESR 5000
383
SCHEMATIC DIAGRAMS
A 1
CA 203 PC 472
206
209 CA 473
Option Load Sensor 1 202 BV+ 5 Workinglight
FU 5 CA 805 E 19 BV+
CA 801 CA 601 CA 422 210 D
15A 1 318 BV+ 4 572
GND 2
204 / 205 1 616 4 4 7 613 C 14 12V Out
U Z 29143 GND
319 Working Light 1 1
2 GND GND 4 115 113 16 12V Out HIGH SIDE
K 10 10 33
29147 / 29148 P BRS 009
2 316 315 310 2
540 541 9 9 C HIGH SIDE
6 VCM CA 205 PIN 33
2970 LS Keyless 5936
1 3
204 205 29127 113 LOW SIDE
2 4 5 wht 8 LS K2 5936
515
FKS GND 6
CA 474 2
Coldstore blk
FU3 = 15A FU4 = 10A FU13 = 50A CA 812 906 / 907 DISPLAY
6 7 3 1 1/4 CAN_H
2903 to Fan 1 Pin 2
2936 3 901 / 902
29128 053 054 E D 2/5 CAN_L
6 CA 402 to VCM, HDM & PC 416 615 / 616
Integrated in Start Up Card GND
904 / 910
909 / 911
3/6 CAN_GND
Option 2908
BV+ Key CA 203 20 15 17
Coldstore / Heated 18
V3 Seat 5919
507 514 517
3 D 516
2
1 B+ CA 202 2 GND
2950 Brake Coil 5927 5912
B+ FAN
B+ CA 202 CA 425
14 A B 13 5 Brake 902 / 903 CA 429 624
2 23/22 CAN_H Z CROWN Motor
2905 Danaher Motor Main Loom: 819850
CA 402 CA 431 CA 431 CA 402 CA 402 618 KEY 1 Main Loom: 819849 GND
CAN_GND 8 3 907 / 908 B Main Loom: 825335
15/14 CAN_L
308 308
909 3 +12V 3 1 1
CAN_L 15 616 / 617
SFS 1SA CA 439 8/7 CAN_GND
025 CAN_H & CAN_L are twisted, not GND!!! 012 012
C SFS 1 SA 904 CH.A 5 2 3
19 CAN_H 23 21/13 ID GND
L+ A 013 013
CH.B 6 3 4
L- B
12 ID1 TCM
610
GND 4 4 2 610
619
611
Z GND CA 414 Temp GND 17
311 116 + 5V + 5V
CA 204 SCM 5 108
CA 438 117 GND Temp 16
6
GND
4
SFS 2 109 120 + 5V CH. 1B
3 026 CH. 1B 7 CH. 1A
13 SFS 2 10 110 1 CA 427 2
119 GND ECR4
L+ 1 CH. 2A 17 111 8
109 1B Control
L- 2 CH. 1A 1
11 112
2A
Card
110
CH. 2B 2
620 20
Z 111 1A
GND 3
+ 5V
CH. 2A
U_Batt
GND
112 2B
CH. 2B
CA 204 4
312 612 THS 1

GND 4
309 PTC
+5 V 3 CAP
015 I_Mess T
B- CH.B 6
566 U
C 014
CH.A 5 I_Mess Motor Shunt GND -
115
V M1 CH. B -
Temp 16 Motor Shunt CH. A -
U_Mess
UB- W V U 6 5 4 3 2 1 W + 12V -
CA 436 U_Mess
U_Mess ECR 1 Speed Sensor
red
yel
grn
blk
wht
803 802 801
THS 2
PTC
T
U 20
GND 4
V M3 CH. A 3 21
CH. B 2
B- Only
wired
W + 5V 1 with
Busbar CROWN
Motor
ECR 3 Speed Sensor Main Loom:
UB- 819850
CAN BUS wiring series production Main Loom:
825335
900 CAN H 901 CAN H 902 CAN H 903 CAN H 910 CAN H 904 CAN H
905 CAN L 906 CAN L 907 CAN L 908 CAN L 911 CAN L 909 CAN L
VCM PC 416 TCM HCM PC 474 SCM

Canion Connector Display Traction Pump Coldstore Steering
822617-2F_2
Fig. 160
ESR 5000
384
SCHEMATIC DIAGRAMS
Wiring Diagram (Multitask Control Handle)
EDS Not-Aus
Main
FU7 = 425A Screw S1 Contactor S2 Screw
BUSBAR BUSBAR BUSBAR BUSBAR 1 A to TDM Traction-controller
200 203 / 204 and SDM
FU1 = 15A + FU2 = 15A

206 / 207 Relay Options L 5902
207
F
2926
Option: Keyless 201 202 +
FU6 2999 2902 5928 2923 2927 2932 2933 29136 2931
EDS 1 E K12
15A 9 R2 10 2 4
+ mechanical 2928 1 CA415 1 CA 434 1 CA 435 1 CA 401
to Display CA402 12
K1 2951 927
CA 473 + Fan2 Fan3 Fan4 Fan1
+ A A CA 420 HORN 48V 48V 48V 48V
2960 2957
3 OPTIONS 1 932 29140 K13 K11 V5 C5 C1,C2
K11
KEY
+ V2 2 2 2 2
2958
CA 440 K1
4 K2 KYS 5916 5934 5918 5934
48V Batt. F1 V1
2998
502 1 5901
K12 508 5 2904 3
K2 C CA 420
29141 C 5914 5915
- 509 5936 2924 UB- 11 to TDM Pin 2
6 Charge R1
2901 START UP CARD
K13
2954 Display CA 472 Pin 3
CA 429 CA 425
B to TDM & Display Danaher Motor CROWN Motor
Main Loom: Main Loom:
2921
819849 819850
2921 5919 Main Loom:
14 CA422 825335
14 H 2929 2 CA 201
CA 801 1 KYS
CA 422
CA 601 B+ 307
3 4 4 2942 2938 307 1
2930 CA 422 CA 604 CA 807 + 903/904 FAN +12V 3 1
CA 802 14 14 23/22 CAN_H
5904 5922
C A 5
CA 600 14 BV+ P OUT_2 1 9 4 3 SVH 010 2 010
2943
908/909 CH.A 5 3
500 15/14 CAN_L
D CA 600 CA 422 019
CA 205 + CA 807 011 011
CA 601
CH.B 6 3
CA 604
6 2 30 Di 9 HGT(R)S 617/618 4
5903 5921 2944 8/7 CAN_GND HCM
569 P OUT_1 42 8 3 1 PVL 2
608
017 GND 4 4
3
CA 601 3
25 Di 16 FLS/LCS 3 21/13 ID GND 2 608
CA 808 + CA 808 609
607
CA 805 5905 5923 2945 Temp GND 17
RES1 P OUT_3 15 10 5 2 PVRE 1 12 ID1
C 027 018
8
CA 604 13 CA 422
18 Di 7 RES 1 107
L+ CA 810 + CA 810 CA 201 Temp 16
A 316
CA 604 CA 422 022 5906 5924 2946
1 4 19 Di 8 RES 2 P OUT_4 29 16 9 2 PVRT 1
L- B 622 CA 430
G GND CA 417 1 2
2913 004 CA 809 + CA 809
A C 5 Di 4 ACS 5908 5926 2947
4 P OUT_5 13 12 7 2 PVAL 1 Control
RES2 2915 007
3 028 31 Di 10 BFS Card
CA 811 + CA 811
L+ 1 317 5907 5925 2948
2916 008 P OUT_6 27 11 6 2 PVAR 1
32 Di 11 BPS
THS 2
L- U_Batt
2 623 G GND CA 601 CA 801 + CA 801
PTC
CA 806 5909
1 1 1 2
CA 422 CA 604 P OUT_7 41 SVT
CA 604 CA 422
2910 029 023
315 14 11 10 17 39 Di 17 PLS
SPS CA 419 +
12 CA 604 5910
C P OUT_8 12 5 5 5 SVS 6 CAP
2909
314 L+ B 17 Di 6 KYS
A 3100 I_Mess
6 CA 422
+ U
L- 5914 5911
B 669 24 POUT_15 Horn P OUT_9 26 18 8 8 SV5 7
310 I_Mess Motor Shunt
Height V M2
1 Encoder
Z C 005
GND 16 Di 5 SPS
ECR 5 CA 803 CA 600 CA 422 U_Mess Motor Shunt
digital Inputs CA 426 W
C wht blk 3 red/blk 021 006
CH. B 4 4 4 32 38 Di 14 Ch. B AN_21 BLS 12 C U_Mess
red blk 4 396 310
+ 12V 3 3 3 6 C 3101 U_Mess
grn/blk C A
blu blk 2 020
CH. A 2 2 2 31 9 Di 13 Ch. A GND -
blk blk 1 666 613
GND 1 1 1 7 Z CH. B -
CA 206
5902 CH. A -
GND F 11 Main Contactor 20
+ 12V -
Di 12 BRS 33 Display CA 472 Pin 2
602 009 21
CA 407 3 Only ECR 2 Speed Sensor
106
ACC wired
PED 2 with
21 Ain1 CA 205
Pot 1 1 CA 411 CA
CA 428 CA 471 CROWN
302 301 300 6 12V Out Motor
CA411 N.C. 1 FWD Switch +12V VCM 11 1 CA 205
N.C. 2 B- Main Loom:
900 819850
3 Selc. Dir 120
CAN_H 22 3
Direction Switch Busbar / 500 / 508 Main Loom:
4 Ohm 905 3 CAN_H & CAN_L are twisted, not GND!!! G to SDM, TDM & Display 825335
5 Horn CA 406 CA 470 CAN_L 23 509 / 569 / 570
HORN 12V Display 1 PC416
6 1 C 614 625
055 4 FWD Switch 6 GND Display
7 Tilt down FWD Switch 2 2 CAN_GND 8 Travel Alarm 319 UB-
Tilt up 8 only with MTC 002 CA 203-13003 5 +12V Display
5th Function 3 3 3 Sel. direction Travel Alarm Loom
9 Tilt up CA 206 CA 421 3 4
Tilt down Sel. Dir. 4 4 399 CA 436 CA 437
10 only with MTC 14 Horn Input 900/901
5913 5980 5981 1 CAN_H
CA 407
Horn 5 5 052 P Out_7 7 2 1 2 A B 905/906
15 Tilt Down 2 CAN_L
CA 407 +12V 1 Tilt down 6 7 614/615
Lift / Lower SIG 2 POT 2 1 3 CAN_GND
Tilt up/ POT4 7 6 051 37 Tilt Up/ POT4 2980
Lever GND 3 29147
Heat Seat 48V+ 8 8 K 2925
CA 408 29148
CA 408 +12V 1 10
Reach / Retrac SIG Coldstore VCM
2 POT 3 CA 471
Lever GND 3 Armrest CA 428 101
2 35 Ain2 /POT2
CA 410 Interface POT2 2 601 H
1 3 3 600
A 48V after Main Contact not connected Box GND 7 GND_Out
B 48V Key with MTC only 2 POT 4 POT3 4 4 102
with Lever 3 5 36 Ain3/ POT3 CA Beacon Loom
C 12V Display POT5 5 CA 433
CA 409 053 CA 474 -6 CA 434 CA 435
Heat Seat SIG 6 104 20 Ain5/ POT5
D GND 1 2917 5920 5940 5941
CA 409 +12V P Out_14 10 2 1 2 A B
E B+ after Key SIG 2 POT 5 Seat 48V+ 7 7 H
Side Shift 001
F Main Contactor Lever GND 3 Seat SIG 8 8 2 Di 1 SES 1 LAMP
CA 405 CA 404 2940
G CAN BUS 5th Switch + Seat 48V+ 1 CA206 2935
CA 405 1
H 48V FU2 5 th Function 2 5th Switch - Seat SIG 2 Connection to
K 48V FU5 Switch 3 5th LED - Heat Seat 48V+ 3 Seat Harness 504
OPTION Heat Seat GND D 28 BV-
Z GND 4 5th LED + 4 H 822618-2F_1
Fig. 161
ESR 5000
385
SCHEMATIC DIAGRAMS
A 1
CA 203 PC 472
206
209 CA 473
Option Load Sensor 1 202 BV+ 5 Workinglight
FU 5 CA 805 E 19 BV+
CA 801 CA 601 CA 422 210 D
15A 1 318 BV+ 4 572
GND 2
204 / 205 1 616 4 4 7 613 C 14 12V Out
U Z 29143 GND
319 Working Light 1 1
2 GND GND 4 115 113 16 12V Out HIGH SIDE
K 10 10 33
29147 / 29148 P BRS 009
2 316 315 310 2
540 541 9 9 C HIGH SIDE
LS 6 VCM CA 205 PIN 33
2970 Keyless 5936
1 3
204 205 29127 113 LOW SIDE
2 4 5 wht 8 LS K2 5936
515
FKS GND 6
CA 474 2
Coldstore blk
FU3 = 15A FU4 = 10A FU13 = 50A CA 812 906 / 907 DISPLAY
6 7 3 1 1/4 CAN_H
2903 to Fan 1 Pin 2
2936 3 901 / 902
29128 053 054 G G 2/5 CAN_L
6 CA 402 to VCM, HDM & PC 416 615 / 616
Integrated in Start Up Card GND
904 / 910
909 / 911
3/6 CAN_GND
Option 2908
BV+ Key CA 203 20 15 17
Coldstore / Heated 18
V3 Seat 5919
507 514 517
3 D 516
2
1 B+ CA 202 2 GND
2950 Brake Coil 5927 5912
B+ FAN
B+ CA 202 CA 425
14 A B 13 5 Brake 902 / 903 CA 429 624
2 23/22 CAN_H Z CROWN Motor
2905 Danaher Motor Main Loom: 819850
CA 402 CA 431 CA 431 CA 402 CA 402 618 KEY 1 GND
CAN_GND 8 3 907 / 908 B Main Loom: 819849 Main Loom: 825335
15/14 CAN_L
308 308
909 3 +12V 3 1 1
CAN_L 15 616 / 617
SFS 1SA CA 439 8/7 CAN_GND
025 904 CAN_H & CAN_L are twisted, not GND!!! 012 012
C SFS 1 SA CH.A 5 2 3
19 CAN_H 23 21/13 ID GND
L+ A 013
3 013
CH.B 6 4
L- B
12 ID1 TCM
610
GND 4 4 2 610
619
611
Z GND CA 414 Temp GND 17
311 116 + 5V + 5V
CA 204 5 108
CA 438 117 GND Temp 16
6
GND
4
SFS 2 SCM 103 120 + 5V CH. 1B
026 CH. 1B 7 CH. 1A
3 13 SFS 2 10 110 119 GND ECR4 1 CA 427 2
L+ 1 CH. 2A 17 8
111 109 1B Control
L- 2 CH. 1A 11 1
112 2A
Card
110
CH. 2B 2
620 20
Z 111 1A
GND 3
+ 5V
CH. 2A
U_Batt
GND
112 2B
CH. 2B
CA 204 4
312 612 THS 1

GND 4
309 PTC
+5 V 3 CAP
01
15 I_Mess T
B- CH.B 6
566 U
C 014
CH.A 5 I_Mess Motor Shunt GND -
11
15
V M1 CH. B -
Temp 16 Motor Shunt CH. A -
U_Mess
UB- W V U CA 436 6 5 4 3 2 1 W + 12V -
U_Mess
U_Mess ECR 1 Speed Sensor
red
yel
grn
blk
wht
803 802 801
THS 2
PTC
T
U 20
GND 4
V M3 CH. A 3 21
CH. B 2
B- Only
wired
W + 5V 1 with
Busbar CROWN
Motor
ECR 3 Speed Sensor Main Loom:
UB- 819850
CAN BUS wiring series production Main Loom:
825335
900 CAN H 901 CAN H 902 CAN H 903 CAN H 910 CAN H 904 CAN H
905 CAN L 906 CAN L 907 CAN L 908 CAN L 911 CAN L 909 CAN L
VCM PC 416 TCM HCM PC 474 SCM

Canion Connector Display Traction Pump Coldstore Steering
822618-2F_2
Fig. 162
ESR 5000
386
SCHEMATIC DIAGRAMS
Main harness, ESR 5000, Danaher motor
Screw M10 S2 (Line Cont.) Screw M10 S1 (Line Cont.) EDS(aux. Contactor)
PC 204 (SDM) Screw M10 FU13 Screw M6 (SDM) Screw M6 (SDM) PC 473 Work Light PC 433 (Beacon) PC 414 (Stepper ECR 4)
B+ Ring Terminal B+ Ring Terminal Crimp
B+ Ring Terminal B- Ring Terminal Ring Terminal (U) S Wire No. S Wire No. Wire No.
Pin Wire No. S Wire No. S Wire No. S Wire No. Wire No. Pin Wire No. Pin Wire No. 2 1 200 /207 1 201
203 / 205 / 206 /2023
1 2936 B+ (Fu4) 1 29127 1 566 1 801 1 29143 1 2935 1 109 CH 1B 2 2951
2 5912 Brake 2 572 2 5920 2 110 CH 2A
3 309 +5V ECR3 3 2959 3 111 CH 1A
4 612 GND ana/dig Screw M6 (SDM) 4 512 4 112 CH 2B
PC 202 (Traction TDM)
5 014 CH.1 ECR3 Ring Terminal (V) 5 116 +5V
6 015 CH.2 ECR3 S Wire No. 6 117 GND
7 7 120 +5V Pin Wire No.
1 802 1 2905
8 618 CAN GND 8 119 GND
9 PC 415 (Fan2) 2 5915
10 109 CH. 1B 3 308 12V
11 111 CH. 1A Screw M6 (SDM) Pin Wire No. 4 610 GND
12 Ring Terminal (W) 1 2932 5 012 CH. A
13 026 SFS 2 S Wire No. 2 5916 6 013 CH. B
SP 8 SP 17 SP 5 SP 3 SP 1 7 616 CAN GND
14 1 803
15 909 CAN L 8 617 CAN GND
16 115 THS 3 9
17 110 CH. 2A 10
18 11
Screw M8 (HDM)
19 025 SFS 1 SA SP 16 12
B- Ring Terminal
20 112 CH. 2B PC 416 (CAN Conn.) 13
S Wire No.
21 14 907 CAN L
1 569 /570
22 Pin Wire No. ED1 (Line Contactor) 15 908 CAN L
1 900 / 901 CAN H Crimp 16 108 TMP
23 904 CAN H SP 19
2 905 / 906 CAN L Wire No. 17 611 TMP GND
Screw M8 (HDM)
3 614 / 615 CAN GND 1 2902 18
B- Ring Terminal
4 ---- 2 5902/5928 19
S Wire No.
5 319 11V + 20
1 566
6 625 GND Display 21
22 902 CAN H
SP 21 SP 9 Screw M8 (HDM) SP 2
PC 420 (KYS) 23 903 CAN H
B- Ring Terminal
PC 206 (VCM) PC 205 (VCM) S Wire No.
Pin Wire No. 1 500
Pin Wire No. A 2951
Pin Wire No.
B --- PC 402 (Start up Card)
1 1 5904 SVH Screw M8 (HDM)
SP 18 2 2 001 SES C 2901
B+ Ring Terminal Start Up card Intern
Pin Wire No.
3 3 003 Sel. Switch S Wire No. 1 2904
4 4 055 FWD Switch 1 29127 Charge Capacity
2 2923
5 5 004 ACS
3 5901
6 6 300 12V + JC 473 (KEYLESS) PC 472 (Brake/Opt.) PC 203 (Display) PC 201 (Pump HDM) Horn
4 2927
7 5913 Travel Alarm 7 600 12V -
5 5912
8 8 614 CAN GND Pin Wire No. Pin Wire No. Pin Wire No. Pin Wire No. Brake
6 2903
9 9 020 ECR 5 A A 29140 1 29143 Work L. 1 906 CAN L 1 2929
7 ----
10 10 5920 BEACON B --- 2 009 Brake 2 901 CAN H 2 5919 -------
8 ----
11 11 5902 ED 1 C 29141 3 5936 Relais - 3 615 CAN GND 3 307 12V
9 2902
12 006 BLS 12 5910 SVS 4 209 B+ 48V 4 907 CAN L 4 608 GND Relay Main Cont.
10 5928
13 13 5908 PVAL 5 210 B+ 48V 5 902 CAN H 5 010 CH. A
11 5914
14 399 Horn switch 14 2930 B+ 6 515 GND B- 6 616 CAN GND 6 011 CH. B
12 2928
15 052 Tilt down 15 5905 PVRE 7 7 617 CAN GND
13 5927
16 16 005 SPS 8 113 LS/ FKS 8 618 CAN GND
14 2950
17 2909 KYS 9 9
15 ----
18 018 RES 1 10 10
16 ----
19 022 RES 2 11 11
Fusebox
20 104 Pot 5 12 12 607
Crimp
21 106 Pot 1 13 002 5th Function 13 607
Fuse No. Pin Wire No.
22 900 CAN H 14 318 V+ Output 14 908 CAN L
FU1 1 200
23 905 CAN L 15 517 GND B- 15 911 CAN L PC 401 (FAN1)
15A / 80V 7 201 / 208
24 5914 Horn out 16 319 V+ Output 16 107 TMP
FU2 2 203 / 204
17 514 GND B- 17 609 TMP GND Pin Wire No.
25 017 FLS / LCS 15A / 80V 8 2926
26 5911 SV 5 18 2908 B+ Key 18 1 2931
FU3 3 204
27 5907 PVAR 19 202 B+ perm. 19 2 5935
15A / 80V 9 2903
28 504 B- 20 507 GND B- 20 627
FU4 4 205
29 5906 PVRT 21 627
10A / 80V 10 2936
30 019 HGT(R)S 22 903 CAN H
FU5 5 206
31 007 BFS Screw M6 (SDM) Screw M10 FU13 23 910 CAN H 15A / 80V 11 2959/2996
32 008 BPS B+ Ring Terminal B+ Ring Terminal FU6 6 207
33 009 BRS S Wire No. S Wire No. 15A / 80V 12 2960/2997
34 1 29128 1 29128
35 101 Pot 2
36 102 Pot 3
37 051 Tilt up
38 021 ECR 5 B
39 024 PLS
40
41 5909 SVT
42 5903 PVL 819849-2I_1
Fig. 163 Main harness, ESR 5000, Danaher motor
ESR 5000
387
SCHEMATIC DIAGRAMS
Main Harness, ESR 5000, Danaher Motor
PC 422 (Mast)
SP 1 after Key B+ SP 2 after ED 1 SP 3 after ED 1 SP 4 after ED1 SP 5 GND B-
PC 438 (SFS 2) Wire No. Wire No. Wire No. Wire No. Wire No.
Pin Wire No.
SP 4 2901 2926 2910 2913 500
1 5909 SVT
SP 11 SP 10 Pin Wire No. 2927 2929 2915 502
2 019 HGT(R)S
1 312 +12V 2904 2931 2930 2916 503
3 017 FLS / LCS
2 620 GND 2905 2952 2932 2917 504
4 022 RES 2
3 026 Sig. 2908 2935 2921
PC 439 (SFS 1 SA) 5 5910 SVS
PC 417 (ACS) PC 418 (Pot1 ACC) 4 2909 2952 2925 512
PC 436 (ECR 3) 6 310 12V +
SP 6 29139 2933 503
PC 474 Coldstore Pin Wire No. 7 613 12V -
Pin Wire No. Pin Wire No. 8 5903 PVL 29136 516
8 polig A 311 +12V Pin Wire No.
A 2913 1 302 9 5904 SVH 29139
Pin B 619 GND 1 118 +5 V
B --- 2 106 10 5905 PVRE
1 904/910 CAN H C 025 Sig. 2 114 GND an.
C 004 3 602 11 5907 PVAR
2 2970 BV+ 3 014 CH.1
SP 7 4 12 5908 PVAL SP 6 +12V SP 7 GND 12V- SP 8 GND ana./dig. SP 9 SP 16
3 909/911 CAN L 4 015 CH.2
4 540 5 115 THS 3 13 018 RES 1 Wire No. Wire No. Wire No. Wire No. Wire No.
5 541 6 ---- 14 2921 BV + 300 600 114 5916 5915
6 053 HeatSeat 15 503 BV - 301 601 117 5919 5918
7 054 ColdStore 16 5906 PVRT 302 602 612 5934 5935
JC 431 (Brake) 17 024 PLS 119
8
18 5911 SV 5
Pin Wire No. 19 ---
A 2950 SP 10 11V+ Display SP 11 GND Display SP 13 FU6 Option
SP 15 20 --- Wire No. Wire No. Wire No.
BFS PC 440 (Option +/- BV) B 5927 21 ---
C --- 310 613 2954
Crimp 22 --- 311 619 2957
Wire No. Pin Wire No. 23 - - - 312 620 2958
1 2915 1 PC 426 (BLS)
24 - - - 318 624
2 007 2
25 - - - 3100 625
3 2957 Pin Wire No.
26 - - - 3101 669
4 2958 A 006
27 - - - 3102 --- SP 14 GND Option SP 15 GND Option
5 508 B ---
28 - - - --- Wire No. Wire No.
SP 14 6 509 C 3101
29 - - - 569 570
7
30 - - - 508 540
8 Screw M6 (SDM) Screw M6 (SDM) Screw M6 (SDM) 31 020 ECR 5 A SP 17 +5V SP 18 FU5 509 541
SP 13 Ring Terminal (U) Ring Terminal (V) Ring Terminal (W) 32 021 ECR 5 B Wire No. Wire No.
S Wire No. S Wire No. S Wire No. 33 113 LS 116 2996 SP 19 B+ SP 20 B+
30 1 801 1 802 1 803 34 Coldstore R 8 118 29147 Wire No. Wire No.
86 2924 35 Coldstore R 8 309
K 12 2970 208 2997
85 927
87 PC 427 (THS 1) 36 - - - 120 29148 209 2998
37 Coldstore R 9 210 2999
30 2998 Pin Wire No. 38 Coldstore R 9 202
86 927 39 Coldstore R 10
85 502
K 13 1 108
2 611 40 Coldstore R 10 SP 21 B-
87 2954
Wire No.
SP 20 Relay socket see 514
PC 425 (Tract. ECR 1) 515
Parts Table 516
Pin Wire No. 517
30 29140 507
86 2999 1 308
2 012 624
85 932 K1
87 29141 3 013
4 610
30 STARPOINTS = SP
86 932
85 5936 K2
87
PC 430 (THS 2) PC 429 (Pump ECR 2)
Pin Wire No. Pin Wire No.

Horn BPS 1 107 1 307
Crimp Crimp PC 421 (Travel Alarm) PC 434 (FAN 3) 2 609 2 010
PC 419 (SPS) Wire No. Wire No. 3 011
1 2928 1 2916 Pin Wire No. Pin Wire No. 4 608
Pin Wire No. 2 5901 2 008
A 3100 1 2925 1 2933 PC 470 (PS) PC 471 (POT)
B 669 2 5913 2 5934
C 005 3 2960 Pin Wire No. Pin Wire No.
4 513 PC 435 (FAN 4) 1 3102 +12V Disp. 1 301 +12V
2 055 FWD Switch 2 101 Pot 2
Pin Wire No. 3 002 5th Function 3 601 GND 12V
1 29136 4 003 Sel. switch 4 102 Pot 3
2 5918 5 399 Horn 5 104 Pot 5
6 051 Tilt up 6 053 Heat St.Sig
7 052 Tilt down 7 2917 Seat +
8 29147 HeatSeat 8 001 Seat Signal
9 9
10 29148 Coldstore 10
11 054 Coldstore 11
12 12
819849-2I_2
Fig. 164 Main harness, ESR 5000, Danaher motor
ESR 5000
388
SCHEMATIC DIAGRAMS

Label / Con. Manuf. Pin Part-No.: Crown Plug / CROWN Pin Pins
Cap. Part-No.: Part No.:
ORS Crimp Faston 6,3 Female --- 793217-022 2

Insulation Sleeve (wht housing) 793217-027
Horn Crimp Faston 6,3 Female --- 793217-022 2
BPS Crimp Faston 6,3 Female --- 793217-022 2
BFS Crimp Faston 6,3 Female --- 793217-022 2
Shrink Sleeve 793217-00x
EDS Crimp Faston 6,3 Female --- 793217-022 2
ED 1 Crimp Faston 6,3 Female --- 793217-022 2
Fuse Box Crimp Faston 6,3 Female 821003 793217-00x 12
Shrink Sleeve 806703-001 793217-022
806703-004
Relay Option / Crimp Faston 6,3 Female 811996-003 813444-001 14
Keyless with Claw ---
Screw M10 S1 Ring-T M10, --- 793217-037 1
Power B+ Shrink Sleeve 793409-00x
Screw M10 S2 Ring-T M10, --- 793217-038 1
Screw M8 Ring-T M10, --- 793217-036 1
B+ HDM Shrink Sleeve 793409-00x
Screw M8 Ring-T M10, --- 793217-035 1
Screw M8 Ring-T M10, --- 793217-034 1
B- HDM Shrink Sleeve 793409-00x
Screw M5 Ring-T M5, --- 793217-043 1
B+ Fuse 50A Shrink Sleeve 793409-00x
Screw M6 Ring-T M6 --- 816812-034 1
SDM Shrink Sleeve 793409-00x
PC 201 770520-1 Tape --- --- 23
770854-1 Stick
PC 202 770520-1 Tape --- --- 23
770854-1 Stick
PC 203 3900-0077 (-1.3mm) 803450-025 803450-026 20
PC 204 770520-1 Tape --- --- 23
770854-1 Stick
ESR 5000
389
SCHEMATIC DIAGRAMS
PC 205 0-964263-2 (0.5 - 1.0mm) --- --- 42

Micro Timer II (36 small /
6 medium)
0-964284-2 (1.5 - 2.5mm)
Junior Power Timer
PC 206 0-964284-2 (1.5 - 2.5mm) --- --- 16
Junior Power Timer
Replacement Parts
Connector Part No. Part No. Part No.
Housing Anti-Backout 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 793091-002 792883
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
ESR 5000
390
SCHEMATIC DIAGRAMS

PC 471 792881-006 793091-006 792883

PC 472 116851 116858
PC 473 792881-001 793091-001 792883
JC 473 792880-002 793090-002 792882
PC 474 792881-005 793091-005 792883
ESR 5000
391
SCHEMATIC DIAGRAMS

Wiring
From connector Pin number Wire number To connector / Pin number
neutral point
PC 201 1 2929 SP 3 ---

HDM
2 5919 SP 9 ---
3 307 12V+ PC 429 1
4 608 GND PC 429 4
5 010 CH. A PC 429 2
6 011 CH. B PC 429 3
7 617 CANGND PC 202 8
8 618 CANGND PC 204 8
12 607 PC 201 13
13 607 PC 201 12
14 908 CAN L PC 202 15
15 911 CAN L PC 474 3
16 107 TMP PC 430 1
17 609 TMPGND PC 430 2
22 903 CAN H PC 202 23
23 910 CAN H PC 474 1
PC 202 1 2905 SP 1 ---
TDM
2 5915 SP 16 ---
3 308 12V+ PC 425 1
4 610 GND PC 425 4
5 012 CH. A PC 425 2
6 013 CH. B PC 425 3
7 616 CANGND PC 203 6
8 617 CANGND PC 201 7
14 907 CAN L PC 203 4
15 908 CAN L PC 201 14
16 108 TMP PC 427 1
17 611 TMPGND PC 427 2
22 902 CAN H PC 203 5
23 903 CAN H PC 201 22
ESR 5000
392
SCHEMATIC DIAGRAMS

neutral point
PC 203 1 906 CAN L PC 416 2

Display screen
2 901 CAN H PC 416 1
3 615 CANGND PC 416 3
4 902 CAN H PC 202 14
5 907 CAN L PC 202 22
6 616 CAN GND PC 202 7
8 113 LS/FKS PC 422 33
13 002 5th Fnct PC 470 3
14 318 11V+ SP 10 ---
15 517 GND B- SP 21 ---
16 319 11V+ PC 416 5
17 514 GND B- SP 21 ---
18 2908 B+ KEY SP 1 ---
19 202 B+ SP 19 ---
20 507 GND B- SP 21 ---
PC 204 1 2936 B+ FU4 Fuse Box 10
SDM
2 5912 BRAKE PC 402 5
3 309+5V SP 17 ---
4 612 GND A/D SP 8 ---
5 014 CH. 1 PC 436 3
6 015 CH. 2 PC 436 4
8 618 CAN GND PC 201 8
10 109 CH. 1B PC 414 1
11 111 CH. 1A PC 414 3
13 026 SFS 2 PC 438 3
14 --- --- ---
15 909 CAN L PC 474 3
16 115 THS 3 PC 436 5
17 110 CH. 2A PC 414 2
19 025 SFS1 SA PC 439 C
20 112 CH. 2B PC 414 4
22 --- --- ---
23 904 CAN H PC 474 1
ESR 5000
393
SCHEMATIC DIAGRAMS

neutral point
PC 205 1 5904 SVH PC 422 9

Canion VCM
2 001 SES PC 471 8
3 003 Sel. PC 470 4
4 055 FWD Swt PC 470 2
5 004 ACS PC 417 C
6 300 12V+ SP 6 ---
7 600 12V- SP 7 ---
8 614 CAN GND PC 416 3
9 020 ECR 5A PC 422 31
10 5920 Beacon PC 433 2
11 5902 ED1 ED1 Crimp
12 5910 SVS PC 422 5
13 5908 PVAL PC 422 12
14 2930 B+ SP 3 ---
15 5905 PVRE PC 422 10
16 005 SPS PC 419 C
17 2909 KYS SP 1 ---
18 018 RES 1 PC 422 13
19 022 RES 2 PC 422 4
20 104 POT5 PC 471 5
21 106 POT1 PC 418 2
22 900 CAN H PC 416 1
23 905 CAN L PC 416 2
24 5914 Horn out PC 402 11
25 017 FLS/LCS PC 422 3
26 5911 SV5 PC 422 18
27 5907 PVAR PC 422 11
28 504 B- SP 5 ---
29 5906 PVRT PC 422 16
30 019 HGT(R)S PC 422 2
31 007 BFS BFS Crimp
32 008 BPS BPS Crimp
33 009 BRS PC 472 2
ESR 5000
394
SCHEMATIC DIAGRAMS

neutral point
34
35 101 POT 2 PC 471 2
36 102 POT 3 PC 471 4
37 051 tilt up PC 470 6
38 021 ECR 5B PC 422 32
39 024 PLS PC 422 17
40
41 5909 SVT PC 422 1
42 5903 PVL PC 422 8
PC206 7 5913 Travel Al. PC 421 2
VCM
12 006 BLS PC 426 C
13
14 399 Horn sw. PC 470 5
15 052 Tilt down PC 470 7
PC 401 1 2931 SP 2 ---
FAN 1 48V
2 5935 SP 16 ---
PC 402 1 2904 SP 1 ---
Start Up Card
2 2923 Screw M10S2 Ring - T
3 5901 Horn Crimp
4 2927 SP 2 ---
5 5912 PC 204 2
6 2903 Fuse Box 9
9 2902 ED 1 Crimp
10 5928 ED 1 Crimp
11 5914 PC 205 24
12 2928 Horn Crimp
13 5927 PC 431 B
14 2950 PC 431 A
ESR 5000
395
SCHEMATIC DIAGRAMS

neutral point
PC 414 1 109 Ch 1B PC 204 10

Stepper ECR 4
2 110 Ch 2A PC 204 17
3 111 Ch 1A PC 204 11
4 112 Ch 2B PC 204 20
5 116 SP 17 ---
6 117 SP 8 ---
7 120 SP 17 ---
8 119 SP 8 ---
PC 415 1 2932 SP 3 ---
FAN 2 48V
2 5916 SP 9 ---
PC 416 1 900 / 901CAN H PC 205 / 203 22 / 2
CAN Con.
2 905 / 906CAN L PC 205 / 203 23 / 1
3 614 /615 GND PC 205 / 203 8/3
5 319 11V+ PC 203 16
6 625 GND SP 11 ---
PC 417 A 2913 SP 4 ---
ACS
C 004 PC 205 5
PC 418 1 302 12V+ SP 6 ---
POT 1 ACC.
2 106 Sig PC 205 21
3 602 GND SP 7 ---
PC 419 A 3100 11V+ SP 10 ---
SPS
B 669 11V- SP 11 ---
C 005 PC 205 16
PC 420 A 2951 EDS Crimp
KYS
C 2901 SP 1 ---
PC 421 1 2925 SP 4 ---
Travel Alarm
2 5913 PC 206 7
3 2960 Fuse Box 12
4 513 SP 5 ---
ESR 5000
396
SCHEMATIC DIAGRAMS

neutral point
PC 422 1 5909 SVT PC 205 41

Mast
2 019 HGT(R)S PC 205 30
3 017 FLS/LCS PC 205 25
4 022 RES 2 PC 205 19
5 5910 SVS PC 205 12
6 310 12V+ SP 10 ---
7 613 GND SP 11 ---
8 5903 PVL PC 205 42
9 5904 SVH PC 205 1
10 5905 PVRE PC 205 15
11 5907 PVAR PC 205 27
12 5908 PVAL PC 205 13
13 018 RES 1 PC 205 18
14 2921 BV + SP 4 ---
15 503 BV - SP 5 ---
16 5906 PVRT PC 205 29
17 024 PLS PC 205 39
18 5911 SV5 PC 205 26
31 020 ECR 5 A PC 205 9
32 021 ECR 5 B PC 205 38
33 113 LS PC 203 8
PC 425 1 308 PC 202 3
Tract. ECR1
2 012 PC 202 5
3 013 PC 202 6
4 610 PC 202 4
PC 426 A 006 PC 206 12
BLS
B --- --- ---
C 3101 SP 10 ---
PC 427 1 108 PC 202 16
THS1
2 611 PC 202 17
PC 429 1 307 PC 201 3
Pump ECR2
2 010 PC 201 5
3 011 PC 201 6
4 608 PC 201 4
ESR 5000
397
SCHEMATIC DIAGRAMS

neutral point
PC 430 1 107 PC 201 16

THS2
2 609 PC 201 17
JC 431 A 2950 PC 402 14
Brake
B 5927 PC 402 13
PC 433 1 2935 SP 3 ---
Beacon
2 5920 PC 205 10
3 2959 Fuse Box 11
4 512 SP 5 ---
PC 434 1 2933 SP 4 ---
FAN 3 48V
2 5934 SP 9 ---
PC 435 1 29136 SP 4 ---
FAN 4 48V
2 5918 SP 16 ---
PC 436 1 118+5V SP 17 ---
Steer ECR 3
2 114 GND SP 8 ---
3 015 CH A PC 204 9
4 014 CH B PC 204 6
5 115 THS 3 PC 204 16
6 --- ---
PC 438 1 312 12V+ SP 10 ---
SFS 2
2 620 GND SP 11 ---
3 026 Sig. PC 204 13
PC 439 A 311 12V+ SP 10 ---
SFS 1
B 619 GND SP 11 ---
C 025 Sig. PC 204 19
PC 440 1 ---
Option
2 ---
3 2957 SP 13 ---
4 2958 SP 13 ---
5 508 SP 14 ---
6 509 SP 14 ---
7
8
ESR 5000
398
SCHEMATIC DIAGRAMS

neutral point
PC 470 1 3102 SP10 ---

PS
2 055 FWD PC 205 4
3 002 5th Select PC 203 13
4 003 SEl. Direct PC 205 3
5 399 Horn PC 206 14
6 051 Tilt up PC 206 15
8 29147 SP18 ---
9 --- --- ---
10 27148 SP18 ---
11 054 Cold store PC 474 ---
12 --- --- ---
PC 471 1 301 SP 6 ---
POT
2 101 PC 205 35
3 601 SP 7 ---
4 102 PC 205 36
5 104 PC 205 5
6 053 Heat Sig PC 474 6
7 2917 Seat Ht. SP 4 ---
8 001 Seat Sig. PC 205 2
9 --- --- ---
10 --- --- ---
11 --- --- ---
12 --- --- ---
PC 472 1 29143 PC 473 1
Brake Opt.
2 009 PC 205 33
3 5936 Relay K2 85
4 209 SP 19 ---
5 210 SP 19 ---
6 515 GND B- SP 21
PC 473 1 29143 PC 472 1
Working
2 572 SP 5 ---
Lights
ESR 5000
399
SCHEMATIC DIAGRAMS

neutral point
JC 473 A 29140 Relay K1 30

Keyless
C 29141 Relay K1 87
PC 474 1 904 / 910 PC 204/201 23 / 23
CAN OUT Card
2 2970 SP 18 ---
3 909 / 911 PC 204/201 15/15
4 540 SP 15 ---
5 541 SP 15 ---
6 053 Heat Seat PC 471 6
7 054 Cold store PC 470 11
8
Fuse Box 1 200 Screw M10 S1 Ring-T
7 201 / 208 EDS / SP 19 Ring-T / ---
2 203 / 204 Screw M10 S2/Fu Ring-T / 3
box
8 2926 SP 2 ---
3 204 Fuse Box 2
9 2903 PC 402 6
4 205 Screw M10 B+ Ring-T
10 2936 PC 204 1
5 206 Screw M10 S1 Ring-T
11 2959 / 2996 PC 433 / SP18 3
12 2960 / 2997 PC 421 / SP 20 3 / ---
EDS Crimp 201 Fuse Box 7
Crimp 2951 PC 420 A
ED1 Crimp 2902 PC 402 9
Crimp 5902 / 5928 PC 205 / PC 402 24 / 10
Relay Options 30
K 12
86 2924 SP 1 ---
85 927 K 13 86
87
ESR 5000
400
SCHEMATIC DIAGRAMS

neutral point
Relay Options 30 2998 SP 20 ---

K 13
86 927 K 12 85
85 502 SP 5 ---
87 2954 SP 13 ---
Horn Crimp 2928 PC 402 12
Crimp 5901 PC 402 3
BFS Crimp 2915 SP 4 ---
Crimp 007 PC 205 31
BPS Crimp 2916 SP 4 ---
Crimp 008 PC 205 32
Screw M10 S1 Ring-T 200 / 206 / 207 Fuse Box 1/5/6
Screw M10 S2 Ring-T 203 / 205 / 2923 FuBox / FuBox / 2/4/2
PC 402
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 Ring-T
(S1)
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 30 29140 JC 473 A
K1
86 2999 SP 20 ---
85 932 K2 86
87 29141 JC 473 C
ESR 5000
401
SCHEMATIC DIAGRAMS

neutral point
Relay Keyless 30
K2
86 932 K1 85
85 5936 PC 472 3
87
Replacement parts
Part No. Description
819849 Harness, complete
ESR 5000
402
SCHEMATIC DIAGRAMS
Main Harness, ESR 5000, Crown Motor

Screw M10 S2 (Line Cont.) Screw M10 S1 (Line Cont.) EDS(aux. Contactor)
Pin Wire No. S Wire No. S Wire No. S Wire No. Wire No. Pin Wire No. Pin Wire No. 2 1 200 /207 1 201
203 / 205 / 206 /2023
1 2936 B+ (Fu4) 1 29127 1 566 1 801 1 29143 1 2935 1 109 CH 1B 2 2951
2 5912 Brake 2 572 2 5920 2 110 CH 2A
3 309 +5V ECR3 3 2959 3 111 CH 1A
5 014 CH.1 ECR3 5 116 +5V PC 202 (Traction TDM)
Ring Terminal (V)
7 7 120 +5V Pin Wire No.
1 802 1 2905
8 618 CAN GND 8 119 GND
9 PC 415 (Fan2) 2 5915
10 109 CH. 1B 3 308 12V
11 111 CH. 1A Screw M6 (SDM) Pin Wire No. 4 610 GND
12 Ring Terminal (W) 1 2932 5 012 CH. A
13 026 SFS 2 S Wire No. 2 5916 6 013 CH. B
14 1 803
15 909 CAN L 8 617 CAN GND
16 115 THS 3 9
17 110 CH. 2A 10
18 11
Screw M8 (HDM)
19 025 SFS 1 SA SP 16 12
B- Ring Terminal
20 112 CH. 2B PC 416 (CAN Conn.) 13
S Wire No.
21 14 907 CAN L
1 569 /570
22 Pin Wire No. ED1 (Line Contactor) 15 908 CAN L
1 900 / 901 CAN H Crimp 16 108 TMP
23 904 CAN H SP 19
2 905 / 906 CAN L Wire No. 17 611 TMP GND
Screw M8 (HDM)
3 614 / 615 CAN GND 1 2902 18
B- Ring Terminal
4 ---- 2 5902/5928 19
S Wire No.
5 319 11V + 20 626
1 566
6 625 GND Display 21 626
22 902 CAN H
SP 21 SP 9 Screw M8 (HDM) SP 2
PC 420 (KYS) 23 903 CAN H
B- Ring Terminal
PC 206 (VCM) PC 205 (VCM) S Wire No.
Pin Wire No. 1 500
Pin Wire No. A 2951
Pin Wire No.
B --- PC 402 (Start up Card)
1 1 5904 SVH Screw M8 (HDM)
SP 18 2 2 001 SES C 2901
B+ Ring Terminal Pin Wire No. Start Up card Intern
3 3 003 Sel. Switch S Wire No. 1 2904
4 4 055 FWD Switch 1 29127 Charge Capacity
2 2923
5 5 004 ACS
3 5901
6 6 300 12V + JC 473 (KEYLESS) PC 472 (Brake/Opt.) PC 203 (Display) PC 201 (Pump HDM) Horn
4 2927
7 5913 Travel Alarm 7 600 12V -
5 5912
8 8 614 CAN GND Pin Wire No. Pin Wire No. Pin Wire No. Pin Wire No. Brake
6 2903
9 9 020 ECR 5 A A 29140 1 29143 Work L. 1 906 CAN L 1 2929
7 ----
10 10 5920 BEACON B --- 2 009 Brake 2 901 CAN H 2 5919 -------
8 ----
11 11 5902 ED 1 C 29141 3 5936 Relais - 3 615 CAN GND 3 307 12V
9 2902
12 006 BLS 12 5910 SVS 4 209 B+ 48V 4 907 CAN L 4 608 GND Relay Main Cont.
10 5928
13 13 5908 PVAL 5 210 B+ 48V 5 902 CAN H 5 010 CH. A
11 5914
14 399 Horn switch 14 2930 B+ 6 515 GND B- 6 616 CAN GND 6 011 CH. B
12 2928
15 052 Tilt down 15 5905 PVRE 7 7 617 CAN GND
13 5927
16 16 005 SPS 8 113 LS/ FKS 8 618 CAN GND
14 2950
17 2909 KYS 9 9
15 ----
18 018 RES 1 10 10
16 ----
19 022 RES 2 11 11
Fusebox
20 104 Pot 5 12 12 607
Crimp
21 106 Pot 1 13 002 5th Function 13 607
Fuse No. Pin Wire No.
22 900 CAN H 14 318 V+ Output 14 908 CAN L
FU1 1 200
23 905 CAN L 15 517 GND B- 15 911 CAN L PC 401 (FAN1)
15A / 80V 7 201 / 208
24 5914 Horn out 16 319 V+ Output 16 107 TMP
FU2 2 203 / 204
17 514 GND B- 17 609 TMP GND Pin Wire No.
25 017 FLS / LCS 15A / 80V 8 2926
26 5911 SV 5 18 2908 B+ Key 18 1 2931
FU3 3 204
27 5907 PVAR 19 202 B+ perm. 19 2 5935
15A / 80V 9 2903
28 504 B- 20 507 GND B- 20 627
FU4 4 205
29 5906 PVRT 21 627
10A / 80V 10 2936
30 019 HGT(R)S 22 903 CAN H
FU5 5 206
31 007 BFS Screw M6 (SDM) ScrewM10 FU13 23 910 CAN H 15A / 80V 11 2959/2996
32 008 BPS B+ Ring Terminal B+ Ring Terminal FU6 6 207
33 009 BRS S Wire No. S Wire No. 15A / 80V 12 2960/2997
34 1 29128 1 29128
35 101 Pot 2
36 102 Pot 3
37 051 Tilt up
38 021 ECR 5 B
39 024 PLS
40
41 5909 SVT
42 5903 PVL 825335-2A_1
Fig. 165 Main harness, ESR 5000, Crown motor
ESR 5000
403
SCHEMATIC DIAGRAMS

PC 422 (Mast)
Pin Wire No.
SP 4 2901 2926 2913 500
1 5909 SVT
SP 11 SP 10 Pin Wire No. 2904 2927 2929 2915 502
2 019 HGT(R)S
1 312 +12V 2905 2931 2930 2916 503
3 017 FLS / LCS
2 620 GND 2908 2952 2932 2917 504
4 022 RES 2
3 026 Sig. 2909 2935 2921 572
PC 439 (SFS 1 SA) 5 5910 SVS
PC 417 (ACS) PC 418 (Pot1 ACC) 4 2924 2952 2925 512
PC 436 (ECR 3) 6 310 12V +
SP 6 29139 2933 503
PC 474 Coldstore Pin Wire No. 7 613 12V -
Pin Wire No. Pin Wire No. 8 5903 PVL 29136 516
8 polig A 311 +12V Pin Wire No.
A 2913 1 302 9 5904 SVH 29139
Pin B 619 GND 1 118 +5 V
B --- 2 106 10 5905 PVRE
1 904/910 CAN H C 025 Sig. 2 114 GND an.
C 004 3 602 11 5907 PVAR
2 2970 BV+ 3 014 CH.1
SP 7 4 12 5908 PVAL SP 6 +12V SP 7 GND 12V- SP 8 GND ana./dig. SP 9 SP 16
3 909/911 CAN L 4 015 CH.2
5 541 6 ---- 14 2921 BV + 300 600 114 5916 5915
6 053 HeatSeat 15 503 BV - 301 601 117 5919 5918
7 054 ColdStore 16 5906 PVRT 302 602 612 5934 5935
JC 431 (Brake) 17 024 PLS 119
8
18 5911 SV 5
Pin Wire No. 19 ---
A 2950 SP 10 11V+ Display SP 11 GND Display SP 13 FU6 Option
BFS PC 440 (Option +/- BV) B 5927 21 ---
C --- 310 613 2954
Crimp 22 --- 311 619 2957
Wire No. Pin Wire No. 23 - - - 312 620 2958
1 2915 1 PC 426 (BLS)
24 - - - 318 624
2 007 2
25 - - - 3100 625
3 2957 Pin Wire No.
26 - - - 3101 669
4 2958 A 006
27 - - - 3102 --- SP 14 GND Option SP 15 GND Option
5 508 B ---
28 - - - --- Wire No. Wire No.
SP 14 6 509 C 3101
29 - - - 569 570
7
30 - - - 508 540
8 Screw M6 (SDM) Screw M6 (SDM) Screw M6 (SDM) 31 020 ECR 5 A SP 17 +5V SP 18 FU5 509 541
SP 13 Ring Terminal (U) Ring Terminal (V) Ring Terminal (W) 32 021 ECR 5 B Wire No. Wire No.
S Wire No. S Wire No. S Wire No. 33 113 LS 116 2996 SP 19 B+ SP 20 B+
30 1 801 1 802 1 803 34 Coldstore R 8 118 29147 Wire No. Wire No.
86 2924 35 Coldstore R 8 309
K 12 2970 208 2997
85 927
87 PC 427 (THS 1) 36 - - - 120 29148 209 2998
37 Coldstore R 9 210 2999
30 2998 Pin Wire No. 38 Coldstore R 9 202
86 927 39 Coldstore R 10
85 502
K 13 1 108
2 611 40 Coldstore R 10 SP 21 B-
87 2954
Wire No.
SP 20 Relay socket see 514
PC 425 (Tract. ECR 1) 515
Parts Table 516
Pin Wire No. 517
30 29140 507
86 2999 1 308
2 610 624
85 932 K1
87 29141 3 012
4 013
30 STARPOINTS = SP
86 932
85 5936 K2
87

Horn BPS 1 107 1 307
Crimp Crimp PC 421 (Travel Alarm) PC 434 (FAN 3) 2 609 2 608
1 2928 1 2916 Pin Wire No. Pin Wire No. 4 011
Pin Wire No. 2 5901 2 008
A 3100 1 2925 1 2933 PC 470 (PS) PC 471 (POT)
B 669 2 5913 2 5934
C 005 3 2960 Pin Wire No. Pin Wire No.
4 513 PC 435 (FAN 4) 1 3102 +12V Disp. 1 301 +12V
2 055 FWD Switch 2 101 Pot 2
Pin Wire No. 3 002 5th Function 3 601 GND 12V
1 29136 4 003 Sel. switch 4 102 Pot 3
2 5918 5 399 Horn 5 104 Pot 5
9 9
11 054 Coldstore 11
12 12
825335-2A_2
Fig. 166 Main harness, ESR 5000, Crown motor
ESR 5000
404
CYLINDERS


Shrink Sleeve 806703-001 793217-022
806703-004
Screw M10 S1 Ring-T M10, --- 793217-037 1
Screw M10 S2 Ring-T M10, --- 793217-038 1
Screw M8 Ring-T M10, --- 793217-036 1
Screw M8 Ring-T M10, --- 793217-035 1
Screw M8 Ring-T M10, --- 793217-034 1
Screw M5 Ring-T M5, --- 793217-043 1
Screw M6 Ring-T M6 --- 816812-034 1
PC 201 770520-1 Tape --- --- 23
770854-1 Stick
PC 202 770520-1 Tape --- --- 23
770854-1 Stick
PC 203 3900-0077 (-1.3mm) 803450-025 803450-026 20
PC 204 770520-1 Tape --- --- 23
770854-1 Stick
ESR 5000
405
CYLINDERS
PC 205 0-964263-2 (0.5 - 1.0mm) --- --- 42

6 medium)
0-964284-2 (1.5 - 2.5mm)
Junior Power Timer
PC 206 0-964284-2 (1.5 - 2.5mm) --- --- 16
Junior Power Timer
Replacement Parts

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 793091-002 792883
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
ESR 5000
406
CYLINDERS

PC 470 792881-006 793091-006 792883

PC 471 792881-006 793091-006 792883
PC 472 116851 116858
PC 473 792881-001 793091-001 792883
JC 473 792880-002 793090-002 792882
PC 474 792881-005 793091-005 792883
Replacement Parts
ESR 5000
407
CYLINDERS

Wiring
neutral point
PC 201 1 2929 SP 3 ---

HDM
2 5919 SP 9 ---
3 307 12V+ PC 429 1
4 608 GND PC 429 2
5 010 CH. A PC 429 3
6 011 CH. B PC 429 4
7 617 CAN GND PC 202 8
8 618 CAN GND PC 204 8
12 607 PC 201 13
13 607 PC 201 12
14 908 CAN L PC 202 15
15 911 CAN L PC 474 3
16 107 TMP PC 430 1
17 609 TMP GND PC 430 2
20 627
21 627
22 903 CAN H PC 202 23
23 910 CAN H PC 474 1
ESR 5000
408
CYLINDERS

neutral point
PC 202 1 2905 SP 1 ---

TDM
2 5915 SP 16 ---
3 308 12V+ PC 425 1
4 610 GND PC 425 2
5 012 CH. A PC 425 3
6 013 CH. B PC 425 4
7 616 CAN GND PC 203 6
8 617 CAN GND PC 201 7
14 907 CAN L PC 203 4
15 908 CAN L PC 201 14
16 108 TMP PC 427 1
17 611 TMP GND PC 427 2
20 626
21 626
22 902 CAN H PC 203 5
23 903 CAN H PC 201 22
PC 203 1 906 CAN L PC 416 2
Display screen
2 901 CAN H PC 416 1
3 615 CAN GND PC 416 3
4 902 CAN H PC 202 14
5 907 CAN L PC 202 22
6 616 CAN GND PC 202 7
8 113 LS/FKS PC 422 33
13 002 5th Fnct PC 470 3
14 318 11V+ SP 10 ---
15 517 GND B- SP 21 ---
16 319 11V+ PC 416 5
17 514 GND B- SP 21 ---
18 2908 B+ KEY SP 1 ---
19 202 B+ SP 19 ---
20 507 GND B- SP 21 ---
ESR 5000
409
CYLINDERS

neutral point
PC 204 1 2936 B+ FU4 Fuse Box 10

SDM
2 5912 BRAKE PC 402 5
3 309+5V SP 17 ---
4 612 GND A/D SP 8 ---
5 014 CH. 1 PC 436 3
6 015 CH. 2 PC 436 4
8 618 CAN GND PC 201 8
10 109 CH. 1B PC 414 1
11 111 CH. 1A PC 414 3
13 026 SFS 2 PC 438 3
14 --- --- ---
15 909 CAN L PC 474 3
16 115 THS 3 PC 436 5
17 110 CH. 2A PC 414 2
19 025 SFS1 SA PC 439 C
20 112 CH. 2B PC 414 4
22 --- --- ---
23 904 CAN H PC 474 1
ESR 5000
410
CYLINDERS

neutral point
PC 205 1 5904 SVH PC 422 9

Canion VCM
2 001 SES PC 471 8
3 003 Sel. PC 470 4
4 055 FWD Swt PC 470 2
5 004 ACS PC 417 C
6 300 12V+ SP 6 ---
7 600 12V- SP 7 ---
8 614 CAN GND PC 416 3
9 020 ECR 5A PC 422 31
10 5920 Beacon PC 433 2
12 5910 SVS PC 422 5
13 5908 PVAL PC 422 12
14 2930 B+ SP 3 ---
15 5905 PVRE PC 422 10
16 005 SPS PC 419 C
17 2909 KYS SP 1 ---
18 018 RES 1 PC 422 13
19 022 RES 2 PC 422 4
20 104 POT5 PC 471 5
21 106 POT1 PC 418 2
22 900 CAN H PC 416 1
23 905 CAN L PC 416 2
24 5914 Horn out PC 402 11
25 017 FLS/LCS PC 422 3
26 5911 SV5 PC 422 18
27 5907 PVAR PC 422 11
28 504 B- SP 5 ---
29 5906 PVRT PC 422 16
30 019 HGT(R)S PC 422 2
33 009 BRS PC 472 2
ESR 5000
411
CYLINDERS

neutral point
34
35 101 POT 2 PC 471 2
36 102 POT 3 PC 471 4
37 051 tilt up PC 470 6
38 021 ECR 5B PC 422 32
39 024 PLS PC 422 17
40
41 5909 SVT PC 422 1
42 5903 PVL PC 422 8
PC206 7 5913 Travel Al. PC 421 2
VCM
12 006 BLS PC 426 C
13
14 399 Horn sw. PC 470 5
PC 401 1 2931 SP 2 ---
FAN 1 48V
2 5935 SP 16 ---
PC 402 1 2904 SP 1 ---
Start Up Card
2 2923 Screw M10 S2 Ring - T
3 5901 Horn Crimp
4 2927 SP 2 ---
5 5912 PC 204 2
6 2903 Fuse Box 9
9 2902 ED 1 Crimp
10 5928 ED 1 Crimp
11 5914 PC 205 24
12 2928 Horn Crimp
13 5927 PC 431 B
14 2950 PC 431 A
ESR 5000
412
CYLINDERS

neutral point
PC 414 1 109 Ch 1B PC 204 10

Stepper ECR 4
2 110 Ch 2A PC 204 17
3 111 Ch 1A PC 204 11
4 112 Ch 2B PC 204 20
5 116 SP 17 ---
6 117 SP 8 ---
7 120 SP 17 ---
8 119 SP 8 ---
PC 415 1 2932 SP 3 ---
FAN 2 48V
2 5916 SP 9 ---
PC 416 1 900 / 901CAN H PC 205 / 203 22 / 2
CAN Con.
2 905 / 906CAN L PC 205 / 203 23 / 1
3 614 /615 GND PC 205 / 203 8/3
5 319 11V+ PC 203 16
6 625 GND SP 11 ---
PC 417 A 2913 SP 4 ---
ACS
C 004 PC 205 5
PC 418 1 302 12V+ SP 6 ---
POT 1 ACC.
2 106 Sig PC 205 21
3 602 GND SP 7 ---
PC 419 A 3100 11V+ SP 10 ---
SPS
B 669 11V- SP 11 ---
C 005 PC 205 16
KYS
C 2901 SP 1 ---
PC 421 1 2925 SP 4 ---
Travel Alarm
2 5913 PC 206 7
3 2960 Fuse Box 12
4 513 SP 5 ---
ESR 5000
413
CYLINDERS

neutral point
PC 422 1 5909 SVT PC 205 41

Mast
2 019 HGT(R)S PC 205 30
3 017 FLS/LCS PC 205 25
4 022 RES 2 PC 205 19
5 5910 SVS PC 205 12
6 310 12V+ SP 10 ---
7 613 GND SP 11 ---
8 5903 PVL PC 205 42
9 5904 SVH PC 205 1
10 5905 PVRE PC 205 15
11 5907 PVAR PC 205 27
12 5908 PVAL PC 205 13
13 018 RES 1 PC 205 18
14 2921 BV + SP 4 ---
15 503 BV - SP 5 ---
16 5906 PVRT PC 205 29
17 024 PLS PC 205 39
18 5911 SV5 PC 205 26
31 020 ECR 5 A PC 205 9
32 021 ECR 5 B PC 205 38
33 113 LS PC 203 8
PC 425 1 308 PC 202 3
Tract. ECR1
2 610 PC 202 4
3 012 PC 202 5
4 013 PC 202 6
PC 426 A 006 PC 206 12
BLS
B --- --- ---
C 3101 SP 10 ---
PC 427 1 108 PC 202 16
THS1
2 611 PC 202 17
PC 429 1 307 PC 201 3
Pump ECR2
2 608 PC 201 4
3 010 PC 201 5
4 011 PC 201 6
ESR 5000
414
CYLINDERS

neutral point
PC 430 1 107 PC 201 16

THS2
2 609 PC 201 17
JC 431 A 2950 PC 402 14
Brake
B 5927 PC 402 13
PC 433 1 2935 SP 3 ---
Beacon
2 5920 PC 205 10
3 2959 Fuse Box 11
4 512 SP 5 ---
PC 434 1 2933 SP 4 ---
FAN 3 48V
2 5934 SP 9 ---
PC 435 1 29136 SP 4 ---
FAN 4 48V
2 5918 SP 16 ---
PC 436 1 118+5V SP 17 ---
Steer ECR 3
2 114 GND SP 8 ---
3 015 CH A PC 204 9
4 014 CH B PC 204 6
5 115 THS 3 PC 204 16
6 --- ---
PC 438 1 312 12V+ SP 10 ---
SFS 2
2 620 GND SP 11 ---
3 026 Sig. PC 204 13
PC 439 A 311 12V+ SP 10 ---
SFS 1
B 619 GND SP 11 ---
C 025 Sig. PC 204 19
PC 440 1 ---
Option
2 ---
3 2957 SP 13 ---
4 2958 SP 13 ---
5 508 SP 14 ---
6 509 SP 14 ---
7
8
ESR 5000
415
CYLINDERS

neutral point
PC 470 1 3102 SP10 ---

PS
2 055 FWD PC 205 4
3 002 5th Selec PC 203 13
5 399 Horn PC 206 14
6 051 Tilt up PC 206 15
8 29147 SP18 ---
9 --- --- ---
10 27148 SP18 ---
11 054 Cold store PC 474 ---
12 --- --- ---
PC 471 1 301 SP 6 ---
POT
2 101 PC 205 35
3 601 SP 7 ---
4 102 PC 205 36
5 104 PC 205 5
6 053 Heat Sig PC 474 6
7 2917 Seat Ht. SP 4 ---
8 001 Seat Sig. PC 205 2
9 --- --- ---
10 --- --- ---
11 --- --- ---
12 --- --- ---
PC 472 1 29143 PC 473 1
Brake Opt.
2 009 PC 205 33
3 5936 Relay K2 85
4 209 SP 19 ---
5 210 SP 19 ---
6 515 GND B- SP 21
PC 473 1 29143 PC 472 1
Working
2 572 SP 5 ---
Lights
ESR 5000
416
CYLINDERS

neutral point
JC 473 A 29140 Relay K1 30

Keyless
C 29141 Relay K1 87
PC 474 1 904 / 910 PC 204 / 201 23 / 23
CAN OUT Card
2 2970 SP 18 ---
3 909 / 911 PC 204 / 201 15 / 15
4 540 SP 15 ---
5 541 SP 15 ---
8
7 201 / 208 EDS / SP 19 Ring-T / ---
2 203 / 204 Screw M10 S2/Fu Ring-T / 3
box
8 2926 SP 2 ---
3 204 Fuse Box 2
9 2903 PC 402 6
10 2936 PC 204 1
11 2959 / 2996 PC 433 / SP18 3
12 2960 / 2997 PC 421 / SP 20 3 / ---
Crimp 2951 PC 420 A
ED1 Crimp 2902 PC 402 9
Crimp 5902 / 5928 PC 205 / PC 402 24 / 10
Relay Options 30
K 12
86 2924 SP 1 ---
85 927 K 13 86
87
ESR 5000
417
CYLINDERS

neutral point

K 13
86 927 K 12 85
85 502 SP 5 ---
87 2954 SP 13 ---
Crimp 5901 PC 402 3
Crimp 007 PC 205 31
Crimp 008 PC 205 32
PC 402
(S1)
K1
86 2999 SP 20 ---
85 932 K2 86
87 29141 JC 473 C
ESR 5000
418
CYLINDERS

neutral point
Relay Keyless 30
K2
86 932 K1 85
85 5936 PC 472 3
87
ESR 5000
419
Notes:
420
SCHEMATIC DIAGRAMS
Main Harness, ESR 5000S, Crown Motor

Screw M10 S2 (Line Cont.) Screw M10 S1 (Line Cont.) EDS (aux.Contactor)
Pin Wire No. S Wire No. S Wire No. S Wire No. Wire No. Pin Wire No. Pin Wire No. 2 1 200 / 207 1 201
203 / 205 / 206 /2023
1 2936 B+ (Fu4) 1 29127 1 566 1 801 1 29143 1 2935 1 109 CH 1B 2 2951
2 5912 Brake 2 572 2 5920 2 110 CH 2A
3 309 +5V ECR3 3 2959 3 111 CH 1A
PC 202 (Traction TDM)
5 014 CH.1 ECR3 Ring Terminal (V) 5 116 +5V
7 120 +5V Pin Wire No.
7 1 802
8 119 GND 1 2905
8 618 CAN GND
PC 415 (Fan2) 2 5915
9
3 308 12V
10 109 CH. 1B
Screw M6 (SDM) Pin Wire No. 4 610 GND
11 111 CH. 1A
Ring Terminal (W) 1 2932 5 012 CH. A
12
S Wire No. 2 5916 6 013 CH. B
13 026 SFS 2
14 1 803
8 617 CAN GND
15 909 CAN L
9
16 115 THS 3
10
17 110 CH. 2A
11
18 Screw M8 (HDM)
SP 16 12
19 025 SFS 1 SA B- Ring Terminal
PC 416 (CAN Conn.) 13
20 112 CH. 2B S Wire No.
14 907 CAN L
21 1 569 / 570
Pin Wire No. ED1 (Line Contactor) 15 908 CAN L
22
1 900 / 901 CAN H Crimp 16 108 TMP
23 904 CAN H 17 611 TMP GND
2 905 / 906 CAN L SP 19 Wire No.
Screw M8 (HDM)
3 614 / 615 CAN GND 1 2902 18
PC 206 (VCM) PC 205 (VCM) B- Ring Terminal
4 ---- 2 5902/5928 19
S Wire No.
Pin Wire No. 5 319 11V + 20 626
Pin Wire No. 1 566
1 5904 SVH 6 625 GND Display 21 626
1
2 001 SES 22 902 CAN H
2 SP 21 SP 9 Screw M8 (HDM) SP 2
3 3 003 Sel. switch PC 420 (KYS) 23 903 CAN H
B- Ring Terminal
4 4 055 FWD Switch
S Wire No.
5 5 004 ACS Pin Wire No. 1 500
SP 18 6 6 300 12V + A 2951
7 5913 Travel Alarm 7 600 12V - B --- PC 402 (Start up Card)
8 8 614 CAN GND Screw M8 (HDM)
C 2901
9 9 020 ECR 5 A B+ Ring Terminal Pin Wire No. Sart up Card intern
10 10 5920 BEACON S Wire No. 1 2904
1 29127 Charge Capacity
11 11 5902 ED 1 2 2923
12 006 BLS 12 5910 SVS 3 5901
JC 473 (KEYLESS) PC 472 (Brake/Opt.) PC 203 (Display) PC 201 (Pump HDM) Horn
13 13 5908 PVAL 4 2927
14 399 Horn switch 14 2930 B+ 5 5912
Pin Wire No. Pin Wire No. Pin Wire No. Pin Wire No. Brake
15 052 Tilt down 15 5905 PVRE 6 2903
A 29140 1 29143 Work L. 1 906 CAN L 1 2929
16 16 005 SPS 7 ----
B --- 2 009 Brake 2 901 CAN H 2 5919 -------
17 2909 KYS 8 ----
C 29141 3 29142 Relais + 3 615 CAN GND 3 307 12V
18 018 RES 1 9 2902
4 29137 B+ 48V 4 907 CAN L 4 608 GND Relay Main Cont.
19 022 RES 2 10 5928
5 29138 B+ 48V 5 902 CAN H 5 010 CH. A
20 104 Pot 5 11 5914
6 571 Relais - 6 616 CAN GND 6 011 CH. B
21 106 Pot 1 12 2928
7 7 617 CAN GND
22 900 CAN H 13 5927
8 113 LS/ FKS 8 618 CAN GND
23 905 CAN L 14 2950
9 9
24 5914 Horn out 15 ----
10 10
25 017 FLS / LCS 16 ----
11 11
26 5911 SV 5 Fusebox
12 12 607
27 5907 PVAR Crimp
13 002 5th Function 13 607
28 504 B- Fuse No. Pin Wire No.
14 318 V+ Output 14 908 CAN L
29 5906 PVRT FU1 1 200
15 624 GND B- 15 911 CAN L PC 401 (FAN1)
30 019 HGT(R)S 15A / 80V 7 201 / 202
16 319 V+ Output 16 107 TMP FU2 2 203 / 204
31 007 BFS 17 Pin Wire No.
17 609 TMP GND 15A / 80V 8 2926
32 008 BPS 18 2908 B+ Key 1 2931
18 FU3 3 204
33 009 BRS 19 202 B+ perm. 2 5935
19 15A / 80V 9 2903
34 20 507 GND B- 20 627 FU4 4 205
35 101 Pot 2
21 627 10A / 80V 10 2936
36 102 Pot 3
22 903 CAN H FU5 5 206
37 051 Tilt up
Screw M6 (SDM) Screw M10 FU13 23 910 CAN H 15A / 80V 11 2959/2996
38 021 ECR 5 B
B+ Ring Terminal B+ Ring Terminal FU6 6 207
39 024 PLS
S Wire No. S Wire No. 15A / 80V 12 2960/2997
40
1 29128 1 29128
41 5909 SVT
42 5903 PVL
819850-2J_1
Fig. 167 Main harness, ESR 5000S, Crown motor
ESR 5000
421
SCHEMATIC DIAGRAMS
PC 422 (Mast)
Pin Wire No.
SP 4 1 5909 SVT 2901 2926 2910 2913 500
SP 11 SP 10 Pin Wire No.
2 019 HGT(R)S 2927 2929 2915 502
1 312 +12V 2904 2931 2930 2916 503
2 620 GND 3 017 FLS / LCS
4 022 RES 2 2905 2952 2932 2917 504
3 026 Sig. 2908 2935 2921
4 PC 439 (SFS 1 SA) 5 5910 SVS
PC 417 (ACS) PC 418 (Pot1 ACC) 6 310 12V + 2909 2952 2925 512
PC 474 Coldstore PC 436 (ECR 3)
SP 6 7 613 12V - 29139 2933 513
8 polig Pin Wire No.
Pin Wire No. Pin Wire No. 29136 516
Pin A 311 +12V Pin Wire No. 8 5903 PVL
A 2913 1 302 9 5904 SVH 29139
1 904/910 CAN H B 619 GND 1 118 +5 V
B --- 2 106 2 2970 BV+ C 025 Sig. 10 5905 PVRE
2 114 GND an.
C 004 3 602 3 909/911 CAN L 11 5907 PVAR
3 014 CH.1
4 12 5908 PVAL SP 6 +12V SP 7 GND 12V- SP 8 GND ana./dig. SP 9 SP 16
SP 7 4 540 4 015 CH.2
6 053 HeatSeat 6 ---- 14 2921 BV + 300 600 114 5916 5915
7 054 ColdStore 15 503 BV - 301 601 117 5919 5918
8 16 5906 PVRT 302 602 612 5934 5935
JC 431 (Brake)
17 024 PLS 119
18 5911 SV 5
Pin Wire No.
19 --- SP 10 11V+ Display SP 11 GND Display
A 2950 SP13 FU6 Option
B 5927
BFS 21 --- 310 613 2954
PC 440 (Option +/- BV) C ---
Crimp 22 --- 311 619 2957
Wire No. 23 - - - 312 620 2958
Pin Wire No. PC 426 (BLS)
1 2915 24 - - - 318 624
1
2 007 Pin Wire No. 25 - - - 3100 625
2
A 006 26 - - - 3101 669
3 2957
B --- 27 - - - 3102 --- SP14 GND Option SP15 GND Option
4 2958
C 28 - - - --- Wire No. Wire No.
5 508 3101
29 - - - 569 570
6 509
30 - - - 508 540
7 Screw M6 (SDM) Screw M6 (SDM) Screw M6 (SDM)
SP 14 31 020 ECR 5 A SP 17 +5V SP 18 FU5 509 541
8 Ring Terminal (U) Ring Terminal (V) Ring Terminal (W)
32 021 ECR 5 B Wire No. Wire No.
S Wire No. S Wire No. S Wire No.
33 113 LS 116 2996
SP 13 1 801 1 802 1 803
34 Coldstore R 8 118 29147 SP 19 B+ SP 20 B+
30 35 Coldstore R 8 309 2970 Wire No. Wire No.
86 2924 36 - - - 120 29148
85 927 208 2997
K 12 PC 427 (THS 1) 37 Coldstore R 9 209
87 2998
38 Coldstore R 9
210 2999
30 2998 Pin Wire No. 39 Coldstore R 10
202
86 927 1 108 40 Coldstore R 10
85 502 K 13 2 611 SP 21 B-
87 2954 Wire No.
SP 20 514
Relay socket see PC 425 (Tract. ECR 1)
Parts Table 515
Pin Wire No. 516
30 29140 517
86 2999 1 308
2 610 507
85 932 K1
87 29141 3 012 624
4 013
30
86 932
85 5936 K2
87 STARPOINTS = SP

Horn BPS 1 107 1 307
Crimp Crimp PC 421 (Travel Alarm) 2 609 2 608
PC 434 (FAN 3)
1 2928 1 2916 4 011
Pin Wire No. Wire No.
Pin Wire No. 2 5901 2 008 1 2925 2933
A 3100
2 5913 5934 PC 470 (PS) PC 471 (POT)
B 669
3 2960
C 005
4 513 PC 435 (FAN 4) Pin Wire No. Pin Wire No.
1 3102 +12V Disp. 1 301 +12V
Wire No. 2 055 FWD Switch 2 101 Pot 2
29136 3 002 5th Function 3 601 GND 12V
5918 4 003 Sel. switch 4 102 Pot 3
5 399 Horn 5 104 Pot 5
9 9
11 054 Coldstore 11
12 12 819850-2J_2
Fig. 168 Main harness, ESR 5000S, Crown motor
ESR 5000
422
SCHEMATIC DIAGRAMS


Shrink Sleeve 806703-001 793217-022
806703-004
Screw M10 S1 Ring-T M10, --- 793217-037 1
Screw M10 S2 Ring-T M10, --- 793217-038 1
Screw M8 Ring-T M10, --- 793217-036 1
Screw M8 Ring-T M10, --- 793217-035 1
Screw M8 Ring-T M10, --- 793217-034 1
Screw M5 Ring-T M5, --- 793217-043 1
Screw M6 Ring-T M6 --- 816812-034 1
PC 201 770520-1 Tape --- --- 23
770854-1 Stick
PC 202 770520-1 Tape --- --- 23
770854-1 Stick
PC 203 3900-0077 (-1.3mm) 803450-025 803450-026 20
PC 204 770520-1 Tape --- --- 23
770854-1 Stick
ESR 5000
423
SCHEMATIC DIAGRAMS
PC 205 0-964263-2 (0.5 - 1.0mm) --- --- 42

6 medium)
0-964284-2 (1.5 - 2.5mm)
Junior Power Timer
PC 206 0-964284-2 (1.5 - 2.5mm) --- --- 16
Junior Power Timer
Replacement Parts

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 793091-002 792883
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
ESR 5000
424
SCHEMATIC DIAGRAMS

PC 470 792881-006 793091-006 792883

PC 471 792881-006 793091-006 792883
PC 472 116851 116858
PC 473 792881-001 793091-001 792883
JC 473 792880-002 793090-002 792882
PC 474 792881-005 793091-005 792883
Replacement Parts
ESR 5000
425
SCHEMATIC DIAGRAMS

Wiring

neutral point
PC 201 1 2929 SP 3 ---

HDM
2 5919 SP 9 ---
3 307 12V+ PC 429 1
4 608 GND PC 429 4
5 010 CH. A PC 429 2
6 011 CH. B PC 429 3
7 617 CAN GND PC 202 8
8 618 CAN GND PC 204 8
12 607 PC 201 13
13 607 PC 201 12
14 908 CAN L PC 202 15
15 911 CAN L PC 474 3
16 107 TMP PC 430 1
17 609 TMP GND PC 430 2
20 627
21 627
22 903 CAN H PC 202 23
23 910 CAN H PC 474 1
ESR 5000
426
SCHEMATIC DIAGRAMS

neutral point
PC 202 1 2905 SP 1 ---

TDM
2 5915 SP 16 ---
3 308 12V+ PC 425 1
4 610 GND PC 425 4
5 012 CH. A PC 425 2
6 013 CH. B PC 425 3
7 616 CAN GND PC 203 6
8 617 CAN GND PC 201 7
14 907 CAN L PC 203 4
15 908 CAN L PC 201 14
16 108 TMP PC 427 1
17 611 TMP GND PC 427 2
20 626
21 626
22 902 CAN H PC 203 5
23 903 CAN H PC 201 22
PC 203 1 906 CAN L PC 416 2
Display screen
2 901 CAN H PC 416 1
3 615 CAN GND PC 416 3
4 902 CAN H PC 202 14
5 907 CAN L PC 202 22
6 616 CAN GND PC 202 7
8 113 LS / FKS PC 422 33
13 002 5th Fnct PC 470 3
14 318 11V+ SP 10 ---
15 517 GND B- SP 21 ---
16 319 11V+ PC 416 5
17 514 GND B- SP 21 ---
18 2908 B+ KEY SP 1 ---
19 202 B+ SP 19 ---
20 507 GND B- SP 21 ---
ESR 5000
427
SCHEMATIC DIAGRAMS

neutral point
PC 204 1 2936 B+ FU4 Fuse Box 10

SDM
2 5912 BRAKE PC 402 5
3 309+5V SP 17 ---
4 612 GND A/D SP 8 ---
5 014 CH. 1 PC 436 3
6 015 CH. 2 PC 436 4
8 618 CAN GND PC 201 8
10 109 CH. 1B PC 414 1
11 111 CH. 1A PC 414 3
13 026 SFS 2 PC 438 3
14 --- --- ---
15 909 CAN L PC 474 3
16 115 THS 3 PC 436 5
17 110 CH. 2A PC 414 2
19 025 SFS1 SA PC 439 C
20 112 CH. 2B PC 414 4
22 --- --- ---
23 904 CAN H PC 474 1
ESR 5000
428
SCHEMATIC DIAGRAMS

neutral point
PC 205 1 5904 SVH PC 422 9

Canion VCM
2 001 SES PC 471 8
3 003 Sel. PC 470 4
4 055 FWD Swt PC 470 2
5 004 ACS PC 417 C
6 300 12V+ SP 6 ---
7 600 12V- SP 7 ---
8 614 CAN GND PC 416 3
9 020 ECR 5A PC 422 31
10 5920 Beacon PC 433 2
12 5910 SVS PC 422 5
13 5908 PVAL PC 422 12
14 2930 B+ SP 3 ---
15 5905 PVRE PC 422 10
16 005 SPS PC 419 C
17 2909 KYS SP 1 ---
18 018 RES 1 PC 422 13
19 022 RES 2 PC 422 4
20 104 POT5 PC 471 5
21 106 POT1 PC 418 2
22 900 CAN H PC 416 1
23 905 CAN L PC 416 2
24 5914 Horn out PC 402 11
25 017 FLS/LCS PC 422 3
26 5911 SV5 PC 422 18
27 5907 PVAR PC 422 11
28 504 B- SP 5 ---
29 5906 PVRT PC 422 16
30 019 HGT(R)S PC 422 2
33 009 BRS PC 472 2
ESR 5000
429
SCHEMATIC DIAGRAMS

neutral point
34
35 101 POT 2 PC 471 2
36 102 POT 3 PC 471 4
37 051 tilt up PC 470 6
38 021 ECR 5B PC 422 32
39 024 PLS PC 422 17
40
41 5909 SVT PC 422 1
42 5903 PVL PC 422 8
PC206 7 5913 Travel Al. PC 421 2
VCM
12 006 BLS PC 426 C
13
14 399 Horn sw. PC 470 5
PC 401 1 2931 SP 2 ---
FAN 1 48V
2 5935 SP 16 ---
PC 402 1 2904 SP 1 ---
Start Up Card
2 2923 Screw M10 S2 Ring - T
3 5901 Horn Crimp
4 2927 SP 2 ---
5 5912 PC 204 2
6 2903 Fuse Box 9
9 2902 ED 1 Crimp
10 5928 ED 1 Crimp
11 5914 PC 205 24
12 2928 Horn Crimp
13 5927 PC 431 B
14 2950 PC 431 A
ESR 5000
430
SCHEMATIC DIAGRAMS

neutral point
PC 414 1 109 Ch 1B PC 204 10

Stepper ECR 4
2 110 Ch 2A PC 204 17
3 111 Ch 1A PC 204 11
4 112 Ch 2B PC 204 20
5 116 SP 17 ---
6 117 SP 8 ---
7 120 SP 17 ---
8 119 SP 8 ---
PC 415 1 2932 SP 3 ---
FAN 2 48V
2 5916 SP 9 ---
PC 416 1 900 / 901CAN H PC 205 / 203 22 / 2
CAN Con.
2 905 / 906CAN L PC 205 / 203 23 / 1
3 614 /615 GND PC 205 / 203 8/3
5 319 11V+ PC 203 16
6 625 GND SP 11 ---
PC 417 A 2913 SP 4 ---
ACS
C 004 PC 205 5
PC 418 1 302 12V+ SP 6 ---
POT 1 ACC.
2 106 Sig PC 205 21
3 602 GND SP 7 ---
PC 419 A 3100 11V+ SP 10 ---
SPS
B 669 11V- SP 11 ---
C 005 PC 205 16
KYS
C 2901 SP 1 ---
PC 421 1 2925 SP 4 ---
Travel Alarm
2 5913 PC 206 7
3 2960 Fuse Box 12
4 513 SP 5 ---
ESR 5000
431
SCHEMATIC DIAGRAMS

neutral point
PC 422 1 5909 SVT PC 205 41

Mast
2 019 HGT(R)S PC 205 30
3 017 FLS/LCS PC 205 25
4 022 RES 2 PC 205 19
5 5910 SVS PC 205 12
6 310 12V+ SP 10 ---
7 613 GND SP 11 ---
8 5903 PVL PC 205 42
9 5904 SVH PC 205 1
10 5905 PVRE PC 205 15
11 5907 PVAR PC 205 27
12 5908 PVAL PC 205 13
13 018 RES 1 PC 205 18
14 2921 BV + SP 4 ---
15 503 BV - SP 5 ---
16 5906 PVRT PC 205 29
17 024 PLS PC 205 39
18 5911 SV5 PC 205 26
31 020 ECR 5 A PC 205 9
32 021 ECR 5 B PC 205 38
33 113 LS PC 203 8
PC 425 1 308 PC 202 3
Tract. ECR1
2 610 PC 202 5
3 012 PC 202 6
4 013 PC 202 4
PC 426 A 006 PC 206 12
BLS
B --- --- ---
C 3101 SP 10 ---
PC 427 1 108 PC 202 16
THS1
2 611 PC 202 17
PC 429 1 307 PC 201 3
Pump ECR2
2 010 PC 201 5
3 011 PC 201 6
4 608 PC 201 4
ESR 5000
432
SCHEMATIC DIAGRAMS

neutral point
PC 430 1 107 PC 201 16

THS2
2 609 PC 201 17
JC 431 A 2950 PC 402 14
Brake
B 5927 PC 402 13
PC 433 1 2935 SP 3 ---
Beacon
2 5920 PC 205 10
3 2959 Fuse Box 11
4 512 SP 5 ---
PC 434 1 2933 SP 4 ---
FAN 3 48V
2 5934 SP 9 ---
PC 435 1 29136 SP 4 ---
FAN 4 48V
2 5918 SP 16 ---
PC 436 1 118+5V SP 17 ---
Steer ECR 3
2 114 GND SP 8 ---
3 015 CH A PC 204 9
4 014 CH B PC 204 6
5 115 THS 3 PC 204 16
6 --- ---
PC 438 1 312 12V+ SP 10 ---
SFS 2
2 620 GND SP 11 ---
3 026 Sig. PC 204 13
PC 439 A 311 12V+ SP 10 ---
SFS 1
B 619 GND SP 11 ---
C 025 Sig. PC 204 19
PC 440 1 ---
Option
2 ---
3 2957 SP 13 ---
4 2958 SP 13 ---
5 508 SP 14 ---
6 509 SP 14 ---
7
8
ESR 5000
433
SCHEMATIC DIAGRAMS

neutral point
PC 470 1 3102 SP 10 ---

PS
2 055 FWD PC 205 4
3 002 5th Selec PC 203 13
5 399 Horn PC 206 14
6 051 Tilt up PC 206 15
8 29147 SP 18 ---
9 --- --- ---
10 27148 SP 18 ---
11 054 Cold store PC 474 ---
12 --- --- ---
PC 471 1 301 SP 6 ---
POT
2 101 PC 205 35
3 601 SP 7 ---
4 102 PC 205 36
5 104 PC 205 5
6 053 Heat Sig PC 474 6
7 2917 Seat Ht. SP 4 ---
8 001 Seat Sig. PC 205 2
9 --- --- ---
10 --- --- ---
11 --- --- ---
12 --- --- ---
PC 472 1 29143 PC 473 1
Brake Opt.
2 009 PC 205 33
3 5936 Relay K2 85
4 209 SP 19 ---
5 210 SP 19 ---
6 515 GND B- SP 21
PC 473 1 29143 PC 472 1
Working
2 572 SP 5 ---
Lights
ESR 5000
434
SCHEMATIC DIAGRAMS

neutral point
JC 473 A 29140 Relay K1 30

Keyless
C 29141 Relay K1 87
PC 474 1 904 / 910 PC 204 / 201 23 / 23
CAN OUT Card
2 2970 SP 18 ---
3 909 / 911 PC 204 / 201 15 / 15
4 540 SP 15 ---
5 541 SP 15 ---
8
7 201 / 208 EDS / SP 19 Ring-T / ---
2 203 / 204 Screw M10 S2/Fu Ring-T / 3
box
8 2926 SP 2 ---
3 204 Fuse Box 2
9 2903 PC 402 6
10 2936 PC 204 1
11 2959 / 2996 PC 433 / SP 18 3
12 2960 / 2997 PC 421 / SP 20 3 / ---
Crimp 2951 PC 420 A
ED1 Crimp 2902 PC 402 9
Crimp 5902 / 5928 PC 205 / PC 402 24 / 10
Relay Options 30
K 12
86 2924 SP 1 ---
85 927 K 13 86
87
ESR 5000
435
SCHEMATIC DIAGRAMS

neutral point

K 13
86 927 K 12 85
85 502 SP 5 ---
87 2954 SP 13 ---
Crimp 5901 PC 402 3
Crimp 007 PC 205 31
Crimp 008 PC 205 32
PC 402
(S1)
K1
86 2999 SP 20 ---
85 932 K2 86
87 29141 JC 473 C
ESR 5000
436
SCHEMATIC DIAGRAMS

neutral point
Relay Keyless 30
K2
86 932 K1 85
85 5936 PC 472 3
87
ESR 5000
437
SCHEMATIC DIAGRAMS
Harness, ESR 5000 Armrest
PC 406 JC 470
1 3102 +12V Disp. 1 3102 +12V Disp.
2 055 FWD Switch 2 055 FWD Switch
3 5th Selected
3 5th Selected
4 003 Sel. switch
4 003 Sel. switch 5 399 Horn
5 399 Horn 6 051 Tilt up / POT 4
6 052 Tilt Down 7 052 Tilt Down
7 051 Tilt up / POT 4 8 29147 Heat Seat +
8 29147 Heated Seat + 9 -
10 -
11 -
12 -
PC 428 JC 471
1 301 +12V 1 301 +12V
2 101 Pot 1
2 101 Pot 1
3 601 GND 12V
3 601 GND 12V
4 102 Pot 2
4 102 Pot 2 5 104 Pot 5
5 104 Pot 5 6 053 Heat Seat -
6 053 Heat Seat GND 7 2917 Seat +48V
7 001 Seat Signal 8 001 Seat Signal
8 2917 Seat + 9 -
10 -
11 -
12 -
from Connector JC 470 PS from Connector JC 471 POT

Pin no. Colour to Connector Pin no. Pin no. Colour to Connector Pin no.
1 white PC 406 1 1 red PC 428 1
2 brown PC 406 2 2 violet PC 428 2
3 yellow PC 406 3 3 grey PC 428 3
4 green PC 406 4 4 brown-green PC 428 4
5 pink PC 406 5 5 white-green PC 428 5
6 blue PC 406 7 6 white-yellow PC 428 6
7 black PC 406 6 7 grey-pink PC 428 7
8 yellow-brown PC 406 8 8 red-blue PC 428 8
9 N.C. 9 N.C.
10 N.C. 10 N.C.
11 N.C. 11 N.C.
12 N.C. 12 N.C.
822619-2F
Fig. 169 Harness, ESR 5000 armrest
ESR 5000
438
SCHEMATIC DIAGRAMS
Connector table
Connector Part No. Part No.
Housing 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
JC 601 PC 801
Reach Carriage Switch Side
BLACK BLACK
1 1 2 1
RED-BLACK RED
2 1 2 2
WHITE-BLACK WHITE-BLACK
3 1 2 3
BLUE BLUE
4 1 2 2 4
ORANGE 1 3 ORANGE
5 1 SP16 2 5
6 4 RED
2 6
RED
7 2 7
GREEN SPLINE 16 GREEN
8 1 2 8
RED RED-BLACK / JC601-2 RED
9 1 RED / PC801-2 2 9
WHITE WHITE
10 1 RED / PC801-6 2 10
ORANGE-BLACK RED / PC801-7 ORANGE-BLACK
11 1 2 11
GREEN-BLACK GREEN-BLACK
12 1 2 12
A B
JC 601 PC 801
Pin no. Discription Pin no. Discription
1 SVT 1 SVT
2 + BV 2 + BV
3 FLS / LCS 3 FLS / LCS
4 GND - 12 V 4 GND - 12 V
5 SVS 5 SVS
6 6 + BV
7 7 + BV
8 SV5 8 SV5
9 + 12 V 9 + 12 V
10 LS 10 LS
11 Coldstore R8 11 Coldstore R8
823618-2A

Fig. 170 Harness, ESR 5000S Armrest
ESR 5000
440
SCHEMATIC DIAGRAMS
Connector table
Connector Part No. Part No.

Housing 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
SCHEMATIC DIAGRAMS
Wire Harness: Terminal to Reach Carriage
Wire Harness: Terminal to Reach Carriage
JC 422 PC 601
Pin no. Wire no. Discription Colour Pin no. Wire no. Discription Colour
1 1 SVT green-black PC 601 1 --- SVT green-black
2 3 HGT(R)S blue SP15 +12V 2 2938 + BV red-white
3 1 FLS / LCS white-black 1 7 3 --- FLS / LCS white-black
4 2 RES 2 black SP14 + BV 2 8 4 667 GND - 12 V blue
5 1 SVS blue 5 --- SVS blue
6 1 + 12 V orange
3 9 6 --- --- red-black
1 1
7 2 GND - 12 V red-black 4 10 7 --- --- ---
8 2 PVL white-black 5 11 8 --- SV5 white
9 2 SVH red JC 422 9 313 + 12 V orange
10 2 PVRT blue 6 12 10 --- LS orange-black
11 2 PVAR orange
10 11 --- Coldst. R 8 black
1 11 21 31 COLDSTORE!
12 2 PVAL green 12 --- Coldst. R 8 green Pin 11 & 12
13 2 RES 1 white 2 12 22 32 are reserved
14 1 + BV red 3 13 23 33 for R 8 (LS / FKS)
15 3 GND -BV orange-black
PC 604
PC 604 Pin no. Wire no. Discription Colour
16 2 PVRE orange-black 4 14 24 34 SP38 GND 12V -
1 --- RES 2 black
17 2 PLS green-black 5 15 25 35 1 7
2 665 GND - 12 V blue
18 1 SV5 white 2 8 3 --- PVL white-black
19 3 --- white-black
2 2 3 9 4 --- SVH red
20 3 --- orange 6 16 26 36 5 --- PVRE orange-black
21 --- --- --- 4 10
7 17 27 37 6 --- PVAR orange
22 --- --- ---
5 11 7 --- PVAL green
23 --- --- --- 8 18 28 38
6 12 8 --- RES 1 white
24 --- --- ---
9 19 29 39 9 --- PVRT blue
25 --- --- ---
10 --- PLS green-black
26 --- --- --- 10 20 30 40 11 2942 + BV red-white
27 --- --- ---
12 314 + 12 V orange
28 --- --- ---
29 --- --- ---
30 --- --- --- PC 600 PC 600
31 3 ECR6 Ch. A green-black Pin no. Wire no. Discription Colour
32 3 ECR6 Ch. B red-black 1 7 1 666 GND - 12 V blue
33 1 LS orange-black 3 3 2 --- ECR5 Ch. A green-black
2 8
34 1 Coldst. R 8 black 3 396 + 12 V orange
35 1 Coldst. R 8 green 3 9
4 --- ECR5 Ch. B red-black
36 1 red-black 4 10 5 2941 + BV red-white
37 3 Coldst. R 9 green 6 --- HGT(R)S blue
38 3 Coldst. R 9 white
5 11
7 --- --- white-black
39 3 Coldst. R 10 red 6 12 8 --- --- orange
40 3 Coldst. R 10 black 9 --- Coldst. R 9 green
10 --- Coldst. R 9 white
3 4 6 11 --- Coldst. R 10 red
12 --- Coldst. R 10 black
5 6 11
Cable C63 and C62 must be insert CABLE C63 ECR5 823870
STARPOINTS SP: 14 JC 600 into a 12 way DEUTSCH Pin-housing! Pin no. Wire no. Discription
Pin no. Wire no. Discription Colour 1 1 GND - 12 V
2938 313 665 1 GND - 12 V 1 2 2 ECR5 Ch. A
JC 600 2 ECR5 Ch. A 2 3 3 + 12 V
SP14 + BV SP15 +12V SP38 GND 12V - 3 + 12 V 3 4 4 ECR5 Ch. B
+ BV 2941 + 12 V 396 GND 12 V - 666 7 1 4 ECR5 Ch. B 4 JC 602 Insert the cable into JC 600
(red) (orange) (red-black) 5 + BV 1
8 2 *
6 HGT(R)S 2 CABLE C62 HGT(R)S 823871
2942 314 667 9 3 7 *--- --- ---
Pin no. Wire no. Discription
10 4 8 --- --- --- 1 1 + BV
9 --- Coldst. R 9 ---
11 5 2 2 HGT(R)S
10 --- Coldst. R 9 ---
12 6 11 --- Coldst. R 10 ---
12 --- Coldst. R 10 ---
JC 603
COLDSTORE! * Insert the cable into JC 600
* and R 10 ECR 5 (Height enc.) to pin 11 & 12
822740-2H
Fig. 171 Wire Harness: Terminal to Reach Carriage
ESR 5000
443
Notes:
444
SCHEMATIC DIAGRAMS
Cable Assy Truck, Reach Carriage
Cable Assy Truck, Reach Carriage

Replacement Parts
Item no. Part no. Description
3 792881-006 Socket Housing

4 792883 Socket Crimp
5 792882 Pin Crimp
6 793222 Blanking Pin
10 793217-018 Butt Connector
11 793091-006 Anti-Backout
14 792880-006 Pin Housing
ESR 5000
445
Notes:
446
SCHEMATIC DIAGRAMS
Cable Assy Valve Block, Mast
PC 805
PC 805 A
C 2 3 6
Pin no. Wire no. Discription Colour B
A 316 + 12 V orange
B 622 GND - 12 V blue
C 027 RES 1 black
PC 806
1 3
4 5 6
2 4
8
PC 806
Pin no. Wire no. Discription Colour
1 317 + 12 V orange
2 623 GND - 12 V blue
SP16 SP17 SP18 3 028 RES 2 black
4 --- --- ---
12 14
PC 807
Pin no. Wire no.
1 5921 PVL
2 2944
3 5922 SVH
PLS
1 2 3 4 5 6
JC 604 7 8 9 10 11 12
PC 808 PC 810
Pin no. Wire no. Pin no. Wire no. 15 16
JC 604 1 7 18 1 2945 1 2946
PVRE PVRT
Pin no. Wire no. Discription Colour 2 5923 2 5924
1 028 RES 2 black
2 621 GND - 12 V blue 13 14
3 5921 PVL white-green
4 5922 SVH white-green
5 5923 PVRE white-green PC 809 PC 811
6 5925 PVAR white-green Pin no. Wire no. Pin no. Wire no.
7 5926 PVAL white-green 1 2947 PVAL PVAR 1 2948
8 027 RES 1 black 2 5926 2 5925
9 5924 PVRT white-green
10 029 PLS black
13 14
11 2943 + BV red-white
12 315 + 12 V orange
2944
2945 316 622
2946
SP16 +BV 2947
SP17 +12V SP18 GND -12V
STARPOINTS SP: 2943 315 621
2948
2949
317 623
812327-2I
Fig. 172 Cable Assy Valve Block, Mast
ESR 5000
447
Notes:
448
SCHEMATIC DIAGRAMS

Replacement Parts

6 792883 Socket Crimp
7 792882 Pin Crimp
12 814156-001 Housing
13 814156-002 Housing
14 814164 Housing
15 793217-022 Cromp Faston Female
16 793217-027 Insulation Sleeve
ESR 5000
449
SCHEMATIC DIAGRAMS
Fork Carriage Harness Extended, ESR 5000, Mast
SVT SVS LS
B B D
1 2 PC 803 1 2 PC 804 1 2 3 4 PC 805
3 3 3 3 2 2 2
2945
5912
2946
5913
616
316
115
Fork carriage
JC 801
1 1 5912
2 1 2944
3
4 1 616
5 1 5913 FKS
SP19
6 1
black
7 2 white
8 3
9 1 315
115
10 1
11
12 SP21
A
SP20
Wire No. Connection SPLINE 19

2944 JC 801-2 2944 / JC 801-2
JC 801 SPLINE 19
2945 / PC 803-1
Pin no. Wire no. Description Colour 2945 SPLINE 19
1 5912 SVT green-black PC 803-1 2946 / PC 804-1
2 2944 + BV red-white 2946 SPLINE 19 SPLINE 20
3 --- FLS / LCS white-black PC 804-1
FKS / white
4 616 GND - 12 V red-black 5912 JC 801-1
5 5913 SVS --- PC 803-2 316 / PC 805-2
6 --- + BV --- 5913 JC 801-5 SPLINE 21
7 --- + BV --- PC 804-2
--- FKS / black
8 SV5 --- 115 JC 801-10
9 315 + 12 V orange PC 805-4 315 / PC 801-9
10 115 LS brown 315 JC 801-9
11 --- Coldstore R8 --- SPLINE 21
12 --- Coldstore R8 --- 316 PC 805-2
SPLINE 20
616 JC 801-1
PC 805-1
red FKS
SPLINE 20
black FKS
SPLINE 21 822755-1_2F_1
Fig. 173 Fork Carriage Harness Extended, ESR 5000, Mast
ESR 5000
450
SCHEMATIC DIAGRAMS
Plug connector housing

Type Housing Part no. Description
A JC 801 792880-006 Housing

793090-006 Anti-Backout
D PC 805 792881-003 Housing
793222 Pin Sealing
B PC 803, 814156-002 Housing
PC 804
823252-001 Seal
823353 Rubber
Grommet
C FKS 802836 Limit Switch
Contact pins
Item No. Part no.
1 792882
2 792883
3 823251-001
Replacement Parts
Part no. Description
ESR 5000
451
SCHEMATIC DIAGRAMS
Fork Carriage Harness Standard, ESR 5000, Mast
SVT SVS
B B
1 2 PC 803 1 2 PC 804
3 3 3 3
2945
5912
2946
5913
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. Wire no. Description Colour Wire No. Connection SPLINE 19
1 5912 SVT green-black 2944 JC 801-2 2944 / JC 801-2
2 2944 + BV red-white SPLINE 19 2945 / PC 803-1
5 5913 SVS blue
2945 SPLINE 19 2946 / PC 804-1
PC 803-1
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

A JC 801 792880-006 Housing

793222 Pin Sealing
B PC 803, 814156-002 Housing
PC 804
823252-001 Seal
823353 Rubber
Grommet
Contact pins
Item No. Part no.
1 792882
3 823251-001
Replacement Parts
ESR 5000
453
SCHEMATIC DIAGRAMS
Fork Carriage Switch Assy, ESR 5000, Mast
Fork Carriage Switch Assy, ESR 5000, Mast
FLS / LCS
1 BLUE
1 connect to connector JC 801-6 (822754 / 822755)
BROWN 1 connect to connector JC 801-3 (822754 / 822755)
2
82275
Fig. 175 Fork Carriage Switch Assy, ESR 5000, Mast
Contact pins
Item No. Part no.
1 792882
Replacement Parts
ESR 5000
454
SCHEMATIC DIAGRAMS
Fork Carriage, 5th Function, ESR 5000, Mast
Fork Carriage, 5th Function, ESR 5000, Mast
PC 806
2947 2947
1 3 1 SV5
1 59144 5914 3 2 B
2947 connect to connector JC 801-7

5914 connect to connector JC 801-8
822757-2D
Fig. 176 Fork Carriage, 5th Function, ESR 5000, Mast

B PC 806 814156-002 Housing

823252-001 Seal
823353 Rubber Grom-
met
Contact pins
Item No. Part no.
1 792882
3 823251-001
Replacement Parts
ESR 5000
455
SCHEMATIC DIAGRAMS
Fork Carriage, LS Bridge, ESR 5000, Mast
Fork Carriage, LS Bridge, ESR 5000, Mast

617
1 1
A 1 2 3 4 JC 805
822758-2C
Fig. 177 Fork Carriage, LS Bridge, ESR 5000, Mast

A JC 805 792880-003 Housing

793222 Pin Sealing
Contact pins
Item No. Part no.
1 792882
Replacement Parts
ESR 5000
456
SCHEMATIC DIAGRAMS
FKS Heater Assembly, Mast
FKS Heater Assembly, Mast
1 2948
548
1
823547-2A
Fig. 178 FKS Heater Assembly, Mast
Contact pins
Item No. Part no.
1 792882
Replacement Parts
Item no. Description
ESR 5000
457
SCHEMATIC DIAGRAMS
Cable Mast 10 Core Assy, ESR 5000, Mast

JC 601 PC 801
BLACK BLACK
1 1 2 1
RED-BLACK RED
2 1 2 2
WHITE-BLACK WHITE-BLACK
3 1 2 3
BLUE BLUE
4 1 2 2 4
ORANGE 1 3 ORANGE
5 1 SP16 2 5
6 4 RED
2 6
RED
7 2 7
GREEN SPLINE 16 GREEN
8 1 2 8
RED RED-BLACK / JC601-2 RED
9 1 RED / PC801-2 2 9
WHITE WHITE
10 1 RED / PC801-6 2 10
ORANGE-BLACK RED / PC801-7 ORANGE-BLACK
11 1 2 11
GREEN-BLACK GREEN-BLACK
12 1 2 12
A B
JC 601 PC 801
1 SVT 1 SVT
2 + BV 2 + BV
4 GND - 12 V 4 GND - 12 V
5 SVS 5 SVS
6 6 + BV
7 7 + BV
8 SV5 8 SV5
9 + 12 V 9 + 12 V
10 LS 10 LS
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.
A JC 601 792880-006 Housing 1 792882

793090-006 Anti-Backout 2 792883
B PC 801 792881-006 Housing
Replacement Parts
793222 Pin Sealing Item no. Description
2 793217-018 Butt Connector
ESR 5000
458
SCHEMATIC DIAGRAMS
JC 601 PC 801
BLACK 1 BLACK 1
1 1 2 1
BLACK 2 RED
2 1 2 2
BLACK 3 BLACK 3
3 1 2 3
BLACK 4 BLACK 4
4 1 2 2 4
BLACK 5 BLACK 5
5 1 SP16 2 5
RED
6 2 6
RED
7 2 7
BLACK 6 SPLINE 16 BLACK 6
8 1 BLACK 2 / JC601-2 2 8
9 RED / PC801-2 9
RED / PC801-6
10 10
RED / PC801-7
11 11
12 12
A B
JC 601 PC 801
1 SVT 1 SVT
2 + BV 2 + BV
4 4
5 SVS 5 SVS
6 6 + BV
7 7 + BV
8 SV5 8 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
A JC 601 792880-006 Housing 823619 Harness, complete

B PC 801 792881-006 Housing
Contact pins
Item No. Part no.
1 792882
2 792883
ESR 5000
459
SCHEMATIC DIAGRAMS
VT Camera, Reach Carriage to Chassis, Option
VT Camera, Reach Carriage to Chassis, Option
JC 453 PC 454
Chassis Reach Carriage
WHITE (C1) WHITE (C1)
1 1 2 1
screen (C1 & C2) screen (C1 & C2)
2 1 2 2
YELLOW (C2) YELLOW (C2)
3 1 2 3
A B
823588-2B
Fig. 181 Cable VT Camera - Reach Carriage to Chassis, Option

A JC 402 808123-002 Housing

B PC 403 808124-002 Housing
Contact pins
Item No. Part no.
1 792882
2 792883
Replacement Parts
ESR 5000
460
SCHEMATIC DIAGRAMS
VT Camera, DC / DC to Control Box, Option
VT Camera, DC / DC to Control Box, Option
PC 400 JC 401
Control Box VT WHITE
Power Supply
WHITE
1 1 1
BROWN
2 2 2
WHITE 3
3 1
BROWN WHITE
4 1 2 4
A B
PC 400 JC 401
Pin no. Wire Colour Description Pin no. Wire Colour Description
1 white + 12 V 1
2 2 brown GND
3 white + 12 V 3
4 brown GND 4 white + 12 V
823612-2C
Fig. 182 VT Camera, DC / DC to Control Box, Option

A PC 400 803450-006 Molex

Receptacle
B PC 401 808124-003 Housing
793222 Pin Sealing
052063-002 Shrinking Tube
Contact pins
Item No. Part no.
1 116858
2 792883
Replacement Parts
ESR 5000
461
SCHEMATIC DIAGRAMS
VT Camera, Mast, Option
VT Camera, Mast, Option
JC 454 PC 455
WHITE WHITE
1 1 1 2 1
screen C1 & C2 screen C1 & C2
2 1 2 2
YELLOW YELLOW
3 1 2 3
A B
823620-2D
Fig. 183 VT Camera, Mast, Option
Assembly Remark: Plug connector housing

Part no. Mast height (collapsed)
A JC 454 808123-002 Housing
823620-001 2022 mm
823620-002 2172 mm
B PC 455 808124-002 Housing
823620-003 2322 mm
823620-004 2472 mm
1 796412 Cable Mast
823620-005 2572 mm
823620-006 2772 mm
Contact pins
823620-007 2922 mm
823620-008 3042 mm Item No. Part no.
823620-009 3192 mm 1 792882

823620-010 3347 mm 2 792883
823620-011 3492 mm
823620-012 3692 mm
Replacement Parts
823620-013 3842 mm Part no. Description
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
ESR 5000
462
SCHEMATIC DIAGRAMS
VT Camera, Box to Chassis, Option
VT Camera, Box to Chassis, Option
JC 454 PC 455
Control Box Chassis
1 1 YELLOW
2 A
2 1 BRAID WHITE 1
2 B
3 1 WHITE
2 C
4 1
Pin no. Wire Colour Description B
4-pin mini DIN A yellow + 12 V
B braid white 1 GND
C white Video Signal
823649-2C
Fig. 184 VT Camera, Box to Chassis, Option

B PC 401 792881-002 Housing

Contact pins
Item No. Part no.
2 792883
Replacement Parts
ESR 5000
463
SCHEMATIC DIAGRAMS
Motec Camera, Supply to b/w Monitor, Option
Motec Camera, Supply to b/w Monitor, Option
JC 443 PC 444
JC 444 M55-K Monitor b/w
Power Supply
1 BROWN
WHITE 1 2 1
2 1 2
3 3
BROWN WHITE
4 1 2 4
A B
JC 443 / JC 444 PC 444

1 1 brown + 12/24 V
2 white GND 2
3 3
4 brown + 12/24 V 4 white GND
823613-2C
Fig. 185 Motec Camera, Supply to b/w Monitor, Option

A JC 443 792880-003 Housing

B PC 444 803450-006 Housing
819279-003 Seal
793222 Pin Sealing
796174 Cable
Contact pins
Item No. Part no.
1 792882
2 116858
Replacement Parts
ESR 5000
464
SCHEMATIC DIAGRAMS
Motec Camera, Component to Reach, Option
Motec Camera, Component to Reach, Option
JC 453 PC 454
Comp. Reach
WHITE WHITE
1 1 2 1
BRAID WHITE BRAID WHITE
2 1 2 2
YELLOW YELLOW
3 1 2 3
BLACK BLACK
4 1 2 4
Pin no. Wire Colour Description
A 1 braid white
B
VID
2 white SH
3 yellow VCC
4 black GND
823614-2D
Fig. 186 Motec Camera, Component to Reach, Option

A JC 453 808123-003 Housing

B PC 454 808124-003 Housing
Contact pins
Item No. Part no.
1 792882
2 792883
Replacement Parts
Item no. Description
ESR 5000
465
SCHEMATIC DIAGRAMS
Motec Camera, Supply to Display Box, Option
Motec Camera, Supply to Display Box, Option
JC 443
JC 444 PC 444
BROWN Display
Power Supply
BROWN
1 3 1
WHITE WHITE
2 1 1 2 2
3 3
BROWN
4 1 BROWN 2 4
A 5
6
B
JC 443 , JC 444 PC 444
1 1 brown + 12 V
2 white GND 2 white GND
3 3
4 brown + 12 V 4 brown + 12 V SEL 1
5
6
823616-2D
Fig. 187 Motec Camera, Supply to Display Box, Option

A JC 443 792881-003 Housing

B PC 444 803450-007 Socket
1 793222 Pin Sealing
796174 Cable
Contact pins
Item No. Part no.
1 792883
2 116858
Replacement Parts
ESR 5000
466
SCHEMATIC DIAGRAMS
Motec Camera, Fork Camera, Option
Motec Camera, Fork Camera, Option
JC 455 Fork Camera

Mast MC 925C
TRANSPARENT TRANSPARENT
1 1 2 1
2 1 2 2
RED RED
3 1 2 3
4 1 2 4
A 1 transparent VID
2 braid white SH
3 red VCC
4 braid white GND
823617-2D
Fig. 188 Motec Camera, Fork Camera, Option

A PC 455 808124-003 Housing

Contact pins
Item No. Part no.
1 792883
Replacement Parts
ESR 5000
467
SCHEMATIC DIAGRAMS
Motec Camera, Inner Mast, Option
Motec Camera, Inner Mast, Option
JC 454 PC 455
WHITE WHITE
1 1 1 1
2 1
BRAID WHITE 1 BRAID WHITE
1 2
YELLOW YELLOW
3 1 1 3
BLACK BLACK
4 1 1 4
A B

1 white VID
2 braid white SH
3 yellow VCC
4 black GND
823650-2B
Fig. 189 Motec Camera, Inner Mast, Option

Part no. Mast height (collapsed)
823650-001 2022 mm A JC 454 792880-003 Housing
823650-002 2172 mm 793090-003 Anti-Backout
823650-003 2322 mm B PC 455 792881-003 Housing
823650-004 2472 mm 793091-003 Anti-Backout
823650-005 2572 mm
Contact pins
823650-006 2772 mm
823650-007 2922 mm Item No. Part no.
823650-008 3042 mm 1 792882

823650-009 3192 mm 1 792883
823650-010 3347 mm
823650-011 3492 mm
Replacement Parts
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
ESR 5000
468
SCHEMATIC DIAGRAMS
Motec Camera, Reach to Display Box, Option
Motec Camera, Reach to Display Box, Option
Connection: Monitor PC 453

Connection
transparent transparent JC 453
1 1 2 1 from 814407
braid white braid white
2 1 2 2
red red
3 1 2 3
braid white braid white
4 1 2 4
B
1 transparent VID 1 transparent VID
2 braid white SH 2 braid white SH
3 red VCC 3 red VCC
4 braid white GND 4 braid white GND
824680-2B
Fig. 190 Motec Camera, Reach to Display Box, Option

B PC 453 792881-003 Housing

814406-001 Cable with plug
Contact pins
Item No. Part no.
2 792883
Replacement Parts
ESR 5000
469
SCHEMATIC DIAGRAMS
Motec Camera, Mast (Fork Camera), Option
Motec Camera, Mast (Fork Camera), Option
JC 454 JC 455
WHITE WHITE
1 1 1 1
2 1 1 1 2
YELLOW YELLOW
3 1 1 3
BLACK BLACK
4 1 1 4
A 1 white
B
VID
2 braid white SH
3 yellow VCC
4 black GND
824702-2B
Fig. 191 Motec Camera, Mast (Fork Camera), Option
Part no. Mast height (collapsed) Type Housing Part no. Description
A JC 454 808123-003 Housing

823650-001 2022 mm
823650-002 2172 mm 793090-003 Anti-Backout
823650-003 2322 mm B JC 455 808123-003 Housing
823650-004 2472 mm 793090-003 Anti-Backout

1 796412 Cable
823650-005 2572 mm
052063-002 Shrinking Tube
823650-006 2772 mm
823650-007 2922 mm
Contact pins
823650-008 3042 mm
823650-009 3192 mm Item No. Part no.
823650-010 3347 mm 1 792882

823650-011 3492 mm
823650-012 3692 mm
Replacement Parts
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
ESR 5000
470
SCHEMATIC DIAGRAMS
Cold Store Harness, ESR 5000, Option
Key (double R) EDS Wire No. Connection Wire No. Connection SPLINE 20
A 1 2 R3 A 1 2 R4 2971 JC 474-2 920 JC 474-3 2971
SP 20 PC 481-9 2972
1 1 1 1
2972 PC 481-16 921 JC 474-1
SP 20 2973
PC 481-10
2973 PC 481-13 100 PC 480-5 2974
5913
2976
5914
2977
SP 20 PC 483-1
2974 SP 20 SPLINE 21
SP 21 2974
2975 SP 21 2975
R 1-2
2976 SP 21 2976
R 3-2 2977
JC 474 B M 422 2977 SP 21 2978
921 CAN H
Mast R 4-2 2979
SP 24
1 3 2978 SP 21
2971 ESR 5 Height Encoder R6 2980
2 3 2980 R 2-2
920 Socket Pin 1 Insert into PIN 39 PC 422 (Main Loom) 2979 SP 21
Option 3 3 5917 Socket Crimp SPLINE 22
550 1 Insert into PIN 40 PC 422 (Main Loom)
Plug 4 3 SP 22 SP 20 2980 SP 21 551
551 LS / FKS R5 Socket Crimp
3
552
5 2979 1 Insert into PIN 34 PC 422 (Main Loom)
550 JC 474-4
5910 Heated Seat Socket Pin 5918 553
6 3 1 Insert into PIN 35 PC 422 (Main Loom) PC 481-1
5908 Coldstore 2 E 551 JC 474-5
7 3 SPLINE 23
SP 22
SP 25
5909
8 552 SP 22
PC 481-2 5911
R1 A 553 SP 22 5912
PC 481-6 5915
SP 21
ACS / ACC (double R) A
5916 554 PC 480-6
2975 1 PC 483-2
2 1 1 SPLINE 24
5911 2976 5908 PC 481-3
1
BLS
1 1 2 JC 474-7 5912
5909 PC 481-4 5913
R2
PC 483 SP 23 5914
100 5910 PC 481-18 5915
2 4
SP 23
JC 474-6
F 554
1 4 5911 SP 23 SPLINE 25
R 1-1
5912 SP 23 5915
SP 24 5916
5913 SP 24 5917
R 3-1 5918
5914 SP 24
R 4-1
921
920
553
552
550
5915 SP 23
5909
5908
554
100
5910
2972
2973
SP 25
2 2 2 2 2 2 2 2 2 2 2 2 5916 SP 25
2 2 2 2 2 2 2 2 2 2 R 2-1
12 11 10 9 8 7 6 5 4 3 2 1 5917 SP 25
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C Socket Crimp
PC 480 D PC 481 5918 SP 25
Socket Crimp
824316-2C
Fig. 192 Cold Store Harness, ESR 5000, Option
ESR 5000
471
Notes:
472
SCHEMATIC DIAGRAMS

A R1, R2, 792881-001 Housing

R3, R4
B JC 474 792880-005 Housing
C JC 480 803450-009 Housing
819279-006 Seal
D JC 481 803450-047 Housing
819279-011 Seal
F PC 483 062755-001 Housing
062798-002 Seal
Contact pins
Type Part no.
1 792883
2 116858
3 792882
4 062797-006
Replacement Parts
ESR 5000
473
SCHEMATIC DIAGRAMS
Cold Store, Armrest Harness, ESR 5000, Option
Cold Store, Armrest Harness, ESR 5000, Option
PC 412
5970
1 1 29170
170 2 plug in PC 470-10
2 1 5970
170 2 plug in PC 470-11
3 1
171 B
4 1
171 To Main Harness
5 1
29170 Wire No. Connection PC 470
6 1
29170 Socket Crimp
A PC 412-6
5970 Socket Crimp
PC 412-1
170 PC 412-2
PC 412-3
171 PC 412-4
PC 412-5
824317-2A
Fig. 193 Cold Store, Armrest, ESR 5000, Option

A PC 412 803450-007 Housing

819279-003 Seal
Contact pins
Type Part no.
1 116858
2 792882
Replacement Parts
ESR 5000
474
SCHEMATIC DIAGRAMS
Cold Store, Armrest Harness, ESR 5000S, Option
Cold Store, Armrest Harness, ESR 5000S, Option
PC 412
5970
1 1 29170
170 2 Insert into PIN 10
2 1 5970
170 2 Insert into PIN 11
3 1
171 B
4 1
171 To Main Harness
5 1
29170 Wire No. Connection PC 470
6 1
29170 Socket Crimp
A PC 412-6
5970 Socket Crimp
PC 412-1
170 PC 412-2
PC 412-3
171 PC 412-4
PC 412-5
824372-2A
Fig. 194 Cold Store, Armrest, ESR 5000S, Option

A PC 412 803450-007 Housing

819279-003 Seal
Contact pins
Type Part no.
1 116858
2 792882
Replacement Parts
ESR 5000
475
Notes:
476
SCHEMATIC DIAGRAMS
Beacon Loom, Option
Beacon Loom, Option
JC 433
2940 PC 435
To Main Harness 1 1 2940
5940 2 1
PC 433 2 1 5941
2 2
A 3 1
B
4 1
5940
5941
2 2
1 2
B PC 434
824318-2B
Fig. 195 Beacon Loom, Option
ESR 5000
477
Notes:
478
SCHEMATIC DIAGRAMS
Beacon Loom, Option
Beacon Loom, Option

A JC 433 792880-003 Housing

B PC 434 Housing
PC 435 792881-001 Housing
Contact pins
Type Part no.
1 792882
2 792883
Replacement Parts
ESR 5000
479
SCHEMATIC DIAGRAMS
Working Light 24V Loom, Option
Working Light 24V Loom,

Option
A 29144
1 1 29144
2
2 1 573 29145
2
JC 473 B
29145
573
2 2 824319-2B
Fig. 196 Working Light 24V Loom, Option

A JC 473 792880-001 Housing
Contact pins
Type Part no.
1 792882
Cable lugs and rings

Type Part no. Description
2 793217-022 Faston Receptacle
Replacement Parts
ESR 5000
480
SCHEMATIC DIAGRAMS
Travel Alarm Harness, Option
Travel Alarm Harness, Option
JC 421
2980
To 1 1 5981
5980 2 A
Main 2 1 2980
Harness 3 1 2 B
C
A 4 1
C PC 437
5981
5980
2 2
1 2
B PC 436 824320-2B
Fig. 197 Travel Alarm Harness, Option

A JC 421 792880-003 Housing

B PC 436 792881-001 Housing
C PC 437 792881-001 Housing
Contact pins
Type Part no.
1 792882
2 792883
Replacement Parts
ESR 5000
481
SCHEMATIC DIAGRAMS
Heated Seat, ESR 5000, Option
Heated Seat, ESR 5000, Option
JC 474 B
921 CAN H
1 3
2971
2 3
Option 920
3 3
Plug 550
4 3 SP 22 SP 20
551
5 3
5910
6 3
Heated Seat
7
8
5910
2972
2973
921
920
553
552
550
Wire No. Connection
2971 JC 474-2
SP 20
2 2 2 2 2 2 2 2
2972 PC 481-16
SP 20 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
2973 PC 481-13
SP 20
550 JC 474-4
A PC 481
PC481-1
551 JC 474-5
SP 22
552 SP 22
PC 481-2
553 SP 22
PC 481-6
5910 PC 481-18
JC 474-6 SPLINE 20 SPLINE 22
920 JC 474-3
PC 481-9 2971 551
921 JC 474-1 2972 552
PC 481-10 29473 553 824321-2B
Fig. 198 Heated Seat ESR 5000, Option
Plug connector housing Contact pins

Type Housing Part no. Description Type Part no.
A PC 481 803450-047 Housing 2 116858

819279-011 Seal 3 792882
B JC 474 792880-005 Housing
Replacement Parts
ESR 5000
482
SCHEMATIC DIAGRAMS
DC/DC Converter Loom, Option
Harness Main Loom & Option Side

2 3 6
PC 452 PC 452 (12 / 24 V)

Pin no. Wire no. Description
1 3
1 398
Jumper (398)
2 4 2 668 GND
3 398
4 397 + 12 / 24 V
Converter Side
+ 48 V
2986
CRIMP Terminal PC 443 PC 443 (12 / 24 V)
1 3
- BV 1 353
Jumper (353) 2 4 2 641 GND
539
15 3 353
2 3 6 4 352 + 12 / 24 V
+ 12 V
352 / 397 1
CRIMP Terminal JC 440 JC 440 OPTIONS
1 5
1
12 / 24 V GND 2 6 2
641 / 668 3 7 3
8 4 8 4 2986 + 48 BV
5 539 - BV
6
4 5 6 7 7
8
824322-2A
Fig. 199 DCDC Converter Loom, Option
ESR 5000
483
Notes:
484
SCHEMATIC DIAGRAMS

Replacement Parts

6 792882 Pin Crimp
ESR 5000
485
Notes:
486
SCHEMATIC DIAGRAMS
Reading Light Harness, Option
JC 441
1 1 2994
To Main Harness 3 1
2 1 SP 28 SP 29 2995
PC 440 2990 3 2
A 3 1 2995
2991 3 3
4 1 554
550 3 4
5 1
551 RL
6 1
7 1
8 1
Wire No. Connection SPLINE 28 SPLINE 29
2990 JC 441-3 2990 550
SP 28 2992 552
2991
552
2991 JC 441-4
2992
551
2994 554
PC 450-3
2992 SP28
3 3 3 PC 450-4
1 2 3 4 5 6 7 8 2994 SP 28
RL-1
C PC 450 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
824371-2B
Fig. 200 Reading Light Harness, Option
ESR 5000
487
Notes:
488
SCHEMATIC DIAGRAMS

A JC 441 792880-005 Housing

B RL 792881-003 Housing
C PC 450 792881-005 Housing
Contact pins
Item No. Part no.
1 792882
3 792883
Replacement Parts
ESR 5000
489
Notes:
490
SCHEMATIC DIAGRAMS
Working Light 12V, Harness, Option
JC 473
To Main Harness 29144
1 1 673
PC 473 A 573 2
D
2 1 SP 26 SP 27 315
2
Workinglight1
PC 452
1
672
4 2
3
312
4 4
B
Connection to DCDC Loom
674
314
2 2
87
85
86
30
87
85
86
30
Workinglight2 2
D
2
573
932
312
932
313
29144
Wire No. Connection SPLINE 26 SPLINE 27
29144 JC 473-1 313 672
C K 23-86 314 673
K 22 K 23 573 JC 473-2 315 674
K 22-85
932 K 22-86
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
824383-2B
Fig. 201 Working Light 12V, Harness, Option
ESR 5000
491
Notes:
492
SCHEMATIC DIAGRAMS

A JC 473 792880-001 Housing

B PC 452 792881-003 Housing
C K22, K23 811996-003 Relay Socket
Contact pins
Item No. Part no.
1 792882
3 813444-001
4 792883

Replacement Parts
ESR 5000
493
Notes:
494
SCHEMATIC DIAGRAMS
InfoLink, Harness, Option
Bypass
Bypass-Mode: connect JC 524 with BYPASS CAN
Info Link Box Normal-Mode: connect JC 524 with PC 524
1 11
2 11
3 11
4 11
5 11
6 11
JC 522
do not connect / PC 520 JC 523 I
disconnect / JC_CAP PC_BYP JC 524 PC 524
1
2
3
4
5
6
remove this pins B KYS PC 523 H
1_PR5V
4
4
11
11
11
11
3
1
1
1
1 1 1 G F G F B+ (AK)
2_PRD0
4
5
4
4
11 2
11 1
3 15_IGN
11 2
11 2
11 2
2 1 3 9 ED1
3_PRD1
3 1 3 4
Prox. Reader
5_CANL
14_PRG
4_CANH
14 1 3 2
PC 526
13_GND
25_BV+
KYS_IN
4_CANH
24_KEY
4 1
21_NEG
5 1 5_CANL 18_NEG 6 Bat-
1
2 4
F
6_5V 30_NEG
remove PC 420.A -> connect to PC 526.1

connect PC 526.2 to PC 526.A
6 1
7_GND
7 1
G
8_XIN JC 526
1
5 1
5 2
8
9_YIN
9 1
Ferrite
1 10 10
11
1
KYS_IN
25_BV+
11
12
1 12
15_IGN
15 1
1 16_Fw 16 ECR2 Speedsensor
17_Rev
1 17 Hydraulic-Motor
18_NEG
18 1
SP5 SP1: PC 527-1, PC 527-4, PC 520-28 28_PhA
19_ACC 2 2 12
19 1 SP2: PC 527-2, PC 527-3, PC 520-29 29_PhB
20 1 2 12
1 20 SP3: PC 528-1, PC 528-2, PC 520-22
21_NEG SP4: PC 529-1, PC 529-2, PC 520-19 4 2
21 1
PC 527
JC 527
22_Seat SP3: PC 520-25, PC 526-1, PC_BYP-1 3 2

22 1 28_PhA
3 2 2
23_BRK
23 1 29_PhB
3 1 1
24_KEY
1
Ferrite
24 29_PhB
SP1 SP2 3 4 4
25_BV+
25 1 28_PhA
3 3 3
13_GND SP4
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
13 1 SP3
26_PWR Danaher-Motor
1 26
B C AMP Connector
1 27_AUX 27
28_PhA
28 1 28_PhA
29_PhB 2 2 2
19_Acc
19_Acc
22_Seat
22_Seat
29 1 29_PhB
30_NEG 1 2 2
30 1
1 4
2 4
1 5
2 5
31_NEG G JC 529 JC 528 G 4 2

1 31
23_BRK
9 YIN
8 XIN
7 GND
6 5V
32 3 2
1 32
2
2
33 9 F PC 529 PC 528 F
1
4 1
4 1
33
34
connect to
4 2
3 2
2 2
1
1 34 BS CROWN-Motor
SES
ACS
1 35 A 35 wire 008 Deutsch-Connector

4
PC 521 C
4
connect to remove PC 429.3 -> connect to PC 527.3

remove PC 471.C -> connect to PC 529.2 remove PC 471.7 -> connect to PC 528.2 connect PC 527.2 to PC 429.3
connect PC 529.1 to PC 417.C Shock Sensor connect PC 528.1 to PC 471.7 remove PC 429.4 -> connect to PC 527.4
823899-2D
Fig. 202 InfoLink Harness, Option
ESR 5000
495
Notes:
496
SCHEMATIC DIAGRAMS
InfoLink, Harness, Option Cable lugs and rings

Plug connector housing Type Part no. Description
6 816812-038 Ring Terminal

9 816812-006 Cable lug
A PC 520 062720-002 Housing 11 793222 Pin-Sealing
770768-1 Sealing Pins 12 814143 Housing
B JC 527, 062756-003 Housing

JC 522 Replacement Parts
C PC 527, 062755-003 Housing
PC 521 823899 Harness, complete
F PC 524, 792881-001 Housing
-526,
-528,
-529,
-_BYP
G JC 524, 792880-001 Housing
-526,
-528,
-529,
-_CAP
H PC 523 792881-004 Housing
I JC 523 792880-004 Housing
Contact pins
Item No. Part no.
1 ---
2 062797-002
3 062797-001
4 792883
5 792882
ESR 5000
497
Notes:
498
SCHEMATIC DIAGRAMS
DCDC Converter Loom NA, Option
DCDC Converter Loom NA, Option

0
Harness Main Loom & Option Side

6
PC 452 PC 452 (12 / 24 V)

1 3
1 398 ---
Jumper (398)
2 4 2 668 GND
3 398 ---
4 397 + 12 / 24 V
Converter Side
+ 48 V
2986
CRIMP Terminal PC 443 PC 443 (12 / 24 V)
1 3
- BV 1 353 ---
Jumper (353) 2 4 2 641 GND
539
3 353 ---
15
6 4 352 + 12 / 24 V
+ 12 V
352 / 397 1
CRIMP Terminal JC 440 JC 440 OPTIONS
1 5
1 --- ---
12 / 24 V GND 2 6 2 --- ---
641 / 668 3 7 3 --- ---
4 8 4 2986 + 48 BV
8
5 539 - BV
6 --- ---
6 7 7 --- ---
8 --- ---
824593-2A
Fig. 203 DCDC Converter Loom NA, Option
ESR 5000
499
Notes:
500
SCHEMATIC DIAGRAMS
DC/DC Converter Loom NA, Option
DC/DC Converter Loom NA, Option

Replacement Parts
6 792882 Pin Crimp

8 793217-043 Ring Terminal
15 793217-005 Socket Crimp
ESR 5000
501
SCHEMATIC DIAGRAMS
48V Supply, Option
48V Supply, Option
PC 460
29201
1 1 29200
29202 2 Insert into JC 440-3
2 1 SP31 SP32 5800
2 Insert into JC 440-6
A 3 1
5801
4 1
5802 Wire No. Connection
5 1 29200 Socket Crimp
6 1 SP31
29201 SP31
PC 460-1
29202 SP31
PC 460-2
5800 Socket Crimp
SP32
5801 SP32
PC 460-4
5802 SP 32
PC 460-5
824652-2B
Fig. 204 48V Supply, Option

A PC 460 792881-004 Housing
Contact pins
Item No. Part no.
1 792883
2 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
ESR 5000
502
SCHEMATIC DIAGRAMS
Power Supply Cable, Option
Power Supply Cable, Option
Connection: 12 / 24 V or 48 V Supply (3rd Corner)

PC 452
2 RED
1 GREEN
2 3 4
PC 452 JC 443 / 444 JC 443 / 444 - optional !

1 brown + Supply 1 3 1
2 black GND 2 black GND 825322-001
2 4 3
Wire_No_2Way
4 brown + 12 / 24
Wire_No_4Way
JC 460 JC 460
1 4 1 brown + 48 V
2
2 5 3 825322-002
4
3 6 5 black B-
6
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

16 16
816067-006_2D
Fig. 206 Bypass cable, seat heating switch, option
Replacement Parts
816067-006 Bypass cable, seat heating switch
ESR 5000
504
SCHEMATIC DIAGRAMS
Supply Cable, ESR 5000, PSA
Supply Cable, ESR 5000, PSA

RED RED
RED
A C 1 RED
GREEN
GREEN
B C 1
825160-2A
Fig. 207 Supply Cable, ESR 5000, PSA

A 793217-037 Ring Terminal

B 793217-035 Ring Terminal
C 793409-007 Shrink Sleeve
Replacement Parts
819633 Fuse Holder

052071-004 Fuse
Replacement Parts
ESR 5000
505
Notes:
506
SCHEMATIC DIAGRAMS
Lights 12V, PSA
Lights 12V, PSA

0
2 2
674
314
JC 473
To Main Harness 29144
1 1 673
PC 473 A 573 2
D
2 1 SP 26 SP 27 315
2
Workinglight1
PC 452
1
678 672
4 2
SP 28 SP 29
Crimp Terminal 3
679 312
4 4
Wire No. Connection Wire No. Connection BPS OPT B
Connection to DCDC Loom
29144 JC 473-1 677 PC 452-2
K 23-86 SP 28
573 JC 473-2 678 BPS OPT PC 455 Position Light1
K 22-85 SP 28 675 317
1 4 4 1
932 K 22-86 316 PC 455-1 A 316 676 E
K 23-85 SP 26 2 4 4 2
312 SP 29 317 PC 453-1
PC 453
Position Light2
K 23-87 SP 26
672 SP 28 318 SP 29
SP 27 PC 452-4
673 SP 27 319 SP 29
Workinglight1 PC 454-1
674 SP 27 675 SP 27
87
85
86
30
87
85
86
30
Workinglight2 PC 455-2
313 K 23-30 676 SP 27
679
319
SP 27 PC 453-2
573
932
312
932
313
314 SP 26 678 SP 28
29144
Workinglight2 BPS OPT Break Light
4 4
315 SP 26 679 BPS OPT E
Workinglight1 PC 454-2 C 2 1
PC 454
K 22 K 23
SPLINE 26 SPLINE 27 SPLINE 28 SPLINE 29
313 672 677 318
314 673 672 319
315 674 678 312
316 675
317 676
825430-2A
Fig. 208 Lights 12V, PSA
ESR 5000
507
Notes:
508
HYDRAULIC SCHEMATIC
509
Notes:
510
HYDRAULIC SCHEMATIC
Hydraulic Symbols
Hydraulic Symbols
Icon Meaning Icon Meaning
Vented reservoir with Electric motor unidi-

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

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

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

flow winding
Control line or drainage Component enclosure

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

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

nected
Plugged port Relief valve adjustable
Accumulator gas Check valve

charged diaphragm
type
ESR 5000 Rev.1 02/2009
511
HYDRAULIC SCHEMATIC
Hydraulic Symbols
2/2 way valve Hydraulic steer unit

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

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

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

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

4/3 way valve Single pre-tension

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

rectional variable
speed
Rev.1 02/2009 ESR 5000
512
HYDRAULIC SCHEMATIC
Hydraulic Symbols
Valve block with Proportional solenoid

3 operating units
Shuttle valve Dual solenoid
Relief valve, fixed set- Hydraulic pilot

ting operated solenoid
valve
Velocity fuse Hydraulic pilot oper-

ated hydraulic valve
Pressure-compensated Manual actuator

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

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

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

with spring returned
(rod end vented)
ESR 5000 Rev.1 02/2009
513
HYDRAULIC SCHEMATIC
Hydraulic Symbols
Double-acting cylinder; Thermometer

equal area
Double-acting cylinder; Pressure gauge

unequal area
Pressure switch Hydraulic motor,

bi-directional
Rev.1 02/2009 ESR 5000
514
HYDRAULIC SCHEMATIC
Hydraulic Diagram
Hydraulic Diagram
Legend

1 RH lift cylinder

2 Free lift cylinder
3 LH lift cylinder
4 Velocity fuse
5 Tilt cylinder

6 Sideshifter cylinder
7 5th function connections
8 Reach cylinder
9 Reservoir ventilation and filter
10 Return line filter
11 Suction filter

Abbreviations and acronyms used in the hydraulic diagram are

detailed on page 63.

Fig. 209 Hydraulic diagram
ESR 5000
515
Notes:
516

Crown Esr5000

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Crown Esr5000

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Formats disponibles

ESR 5000 SERIES

Order Number: 812577-006

CROWN Gabelstapler GmbH & Co. KG

Tel +49 (0)89 93 00 2 0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Important Information Service personnel qualification

ESR 5000 Rev.2 02/2009

Specification Number Mast height and capacity

9 2770 6690 1.4 or 1.6

Model name 22 3840 9605 2.0

6 2470 5790 1.4 or 1.6 1 990 4 1220

Basic Safety Notices Protecting the hazardous area

Transport and Storage 2. Fully retract the mast.

Lifting the truck

Towing the truck

Fig. 2 Lifting the truck

when the brakes have been released by an authorised

Tipovers can result in fatal accidents

Jacking up the Truck

Fig. 4 Pulling the truck with a forklift truck

Fig. 5 Jacking up the truck

Truck Assembly and Erecting the chassis

Erecting the chassis

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

Fig. 9 Lowering the chassis slowly and simultaneously

Removing the transport retainers

Fig. 8 Erecting the truck slowly WARNING

Note: Store the transport retainers for future use.

Fig. 11 Storage tank on main brake cylinder

4. Test the BFS switch.

Fig. 10 Brake fluid reservoir transport retainer

Fig. 12 Breather filter

Fig. 13 Hydraulic reservoir transport retainer

Filling the drive transmission unit

Fig. 14 Refill plug on drive transmission unit

Erecting the mast and fitting it to the

Placing the Truck in Storage Restoring the truck to service

Testing trucks in storage

1. Connect the battery.

Component Access Accessing components under the

Fig. 16 Components under the panels

Fig. 15 Component access

Components under the panels

Fig. 17 Components under the panels

1 Battery connector 7 Emergency Disconnect

Accessing the motor compartment

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

1 Seat panel Swivelling in and locking the seat panel