Crown Forklift ESR 1000 Series Service Manual - PDF DOWNLOAD

Crown Forklift ESR 1000 Series Service Manual - PDF DOWNLOAD

FILE DETAILS:

Crown Forklift ESR 1000 Series Service Manual - PDF DOWNLOAD

Language : English
Pages :1093
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift ESR 1000 Series Service Manual - PDF DOWNLOAD

Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction 1
Event Codes 9
000002006 10
000002058 10
000003006 11
000003058 11
000004000 12
000004003 12
000004004 13
000005000 13
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
Installing the Battery 14
Installation Procedure With a Battery Roller Stand 14
Installation Procedure With a Lifting Device 14
Securing the Battery in the Lift Truck 14
Discharging the Capacitors 15
General Hot Work Instructions 16
Releasing the Hydraulic Pressure 17
Parking Brake 17
Releasing the Parking Brake 17
Applying the Parking Brake 18
Towing the Lift Truck 18
Preparing for Towing the Lift Truck 19
Towing the Lift Truck by Lifting and Pulling in the Power Unit First Direction 19
Towing the Lift Truck by Pulling in the Forks First Direction 20
Lifting and Blocking 21
Lifting and Blocking the Outriggers 21
Lifting and Blocking the Power Unit 21
Blocking the Masts 22
Securing the Fork Carriage 23
Blocking the Reach Mechanism 23
Preparing the Mast for Removal 24
Lifting the Lift Truck 25
Lifting the Lift Truck 25
Preparing for Lifting the Lift Truck 25
Attaching the Lifting Equipment to the Overhead Guard 26
Attaching Lifting Equipment for Standard Overhead Guard 26
Attaching Lifting Equipment for Clear Overhead Guard 27
Attaching Lifting Equipment for Cold Storage Cabin 27
Completing Preparation for Lifting the Lift Truck 28
Transporting the Lift Truck 30
Securing a Lift Truck on a Loading Surface for Transport 30
Securing the Mast to a Loading Surface for Transport 31
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Icons 14
Visual Inspection 14
Operational Check and Test Drive 15
Preparing the Lift Truck for Maintenance 15
Inspection and Lubrication 16
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Access 31 14
Access 41 15
Access 51 16
Accessory Pump (ESR1060 -RX) 17
Accessory Pump Motor (ESR1060 -RX) 18
19
Adjustment Valve Lowering Speed 20
Auto Height Select Switch 22
Battery Latch Switch 23
Brake Fluid Switch 24
Brake Potentiometer 25
Brake Pressure Switch 26
Camera Switch 27
CAN Card 28
Card Reader 29
Emergency Disconnect Contactor 30
Emergency Disconnect Switch 1 31
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Removing the Main Pump 14
Inspecting the Main Pump 14
Assembly 15
Installing the Main Pump 15
Priming the Main Pump 16
Preparing the Lift Truck for Operation 16
Manifold - Main 18
Checking the 18
System 20
Functional Descriptions (ESR-F) 20
Lifting 20
Lowering 21
Extending the Reach Mechanism 23
Retracting the Reach Mechanism 25
Tilting the Fork Up 26
Tilting the Fork Down 28
Sideshift Right 29
Sideshift Left 31
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Removing the Fork Carriage Control Cable 15
Removing the Camera Control Cable 18
Inspecting the Control Cables 21
Assembly 21
Installing the Camera Control Cable 21
Installing the Fork Carriage Control Cable 24
Installing the Mast Control Cable 27
Adjusting the Tension 30
Preparing the Lift Truck for Operation 30
Troubleshooting 30
Troubleshooting 30
Cylinder - Primary 31
Technician Tips 31
Technician Tips 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Load Wheel 14
Theory of Operation 14
Theory of Operation 14
Tools and Equipment 14
Recommended Tools and Equipment 14
Additional Tools and Equipment 14
Load Wheel Attached with a Snap Ring 15
Disassembly 15
Preparing the Lift Truck for Maintenance 15
Removing a Load Wheel Attached with a Snap Ring 15
Inspecting the Load Wheel 15
Assembly 16
Installing a Load Wheel Attached with a Snap Ring 16
Preparing the Lift Truck for Operation 16
Load Wheel Attached with a Nut 16
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing a Load Wheel Attached with a Nut 17
Inspecting the Load Wheel 18
Assembly 18
Installing a Load Wheel Attached with a Nut 18
Preparing the Lift Truck for Operation 19
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
Preparing the Lift Truck for Operation 14
Steering Wheel 15
Technician Tips 15
Technician Tips 15
Theory of Operation 15
Theory of Operation 15
Tools and Equipment 15
Recommended Tools and Equipment 15
Additional Tools and Equipment 15
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing the Steering Wheel 16
Inspecting the Steering Wheel 18
Assembly 18
Installing the Steering Wheel 18
Preparing the Lift Truck for Operation 19
Troubleshooting 20
Troubleshooting 20
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Menu Structure 14
Introduction 14
Adjusting the Settings 16
Menus 16
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Preparing the Stopping Distance Test Route 14
Testing the Stopping Distance 14
Preparing the Lift Truck for Operation 15
Troubleshooting 16
Troubleshooting 16
Brake - M31 17
Theory of Operation 17
Theory of Operation 17
Tools and Equipment 17
Recommended Tools and Equipment 17
Additional Tools and Equipment 17
Disassembly 17
Preparing the Lift Truck for Maintenance 17
Removing the M31 Traction Brake 18
Disassembling the M31 Traction Brake 19
Inspecting the M31 Traction Brake 19
Assembly 19
Assembling the M31 Traction Brake 19
Installing the M31 Traction Brake 20
Checking the Brake Torque 21
Checking and Adjusting the Air Gap 22
Preparing the Lift Truck for Operation 22
Troubleshooting 23
Troubleshooting 23
Drive Tire 24
Tools and Equipment 24
Recommended Tools and Equipment 24
Additional Tools and Equipment 24
Disassembly 24
Preparing the Lift Truck for Maintenance 24
Removing the Drive Tire 25
Inspecting the Drive Tire 25
Assembly 25
Installing the Drive Tire 25
Preparing the Lift Truck for Operation 26
Drive Unit 27
Tools and Equipment 27
Recommended Tools and Equipment 27
Additional Tools and Equipment 27
Disassembly 27
Preparing the Lift Truck for Maintenance 27
Removing the Drive Unit 28
Inspecting the Drive Unit 28
Assembly 29
Installing the Drive Unit 29
Preparing the Lift Truck for Operation 29
Troubleshooting 30
Troubleshooting 30
Pinion Repair Set 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 31
Disassembly 31
Inspecting the Gearbox Pinion 31
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Diagram Key 14
Main Harness and Connector Figure 17
Pictorials - Electrical 19
Pictorials - Electrical (ESR1020 -F and ESR1040 -F) 19
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
Installing the Battery 14
Installation Procedure With a Battery Roller Stand 14
Installation Procedure With a Lifting Device 14
Securing the Battery in the Lift Truck 14
Discharging the Capacitors 15
General Hot Work Instructions 16
Releasing the Hydraulic Pressure 17
Parking Brake 17
Releasing the Parking Brake 17
Applying the Parking Brake 18
Towing the Lift Truck 18
Preparing for Towing the Lift Truck 19
Towing the Lift Truck by Lifting and Pulling in the Power Unit First Direction 19
Towing the Lift Truck by Pulling in the Forks First Direction 20
Lifting and Blocking 21
Lifting and Blocking the Outriggers 21
Lifting and Blocking the Power Unit 21
Blocking the Masts 22
Securing the Fork Carriage 23
Blocking the Reach Mechanism 23
Preparing the Mast for Removal 24
Lifting the Lift Truck 25
Lifting the Lift Truck 25
Preparing for Lifting the Lift Truck 25
Attaching the Lifting Equipment to the Overhead Guard 26
Attaching Lifting Equipment for Standard Overhead Guard 26
Attaching Lifting Equipment for Clear Overhead Guard 27
Attaching Lifting Equipment for Cold Storage Cabin 27
Completing Preparation for Lifting the Lift Truck 28
Transporting the Lift Truck 30
Securing a Lift Truck on a Loading Surface for Transport 30
Securing the Mast to a Loading Surface for Transport 31
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Icons 14
Visual Inspection 14
Operational Check and Test Drive 15
Preparing the Lift Truck for Maintenance 15
Inspection and Lubrication 16
Preparing the Lift Truck for Operation110
Final Operational Check and Test Drive110
Planned Maintenance Completion110
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Access 31 14
Access 41 15
Access 51 16
Accessory Pump (ESR1060 -RX) 17
Accessory Pump Motor (ESR1060 -RX) 18
19
Adjustment Valve Lowering Speed 20
Auto Height Select Switch 22
Battery Latch Switch 23
Brake Fluid Switch 24
Brake Potentiometer 25
Brake Pressure Switch 26
Camera Switch 27
CAN Card 28
Card Reader 29
Emergency Disconnect Contactor 30
Emergency Disconnect Switch 1 31
Emergency Disconnect Switch 2 32
Xpress Lower Proportional Valve 1 (ESR1060 -RX) 33
Xpress Lower Proportional Valve 2 (ESR1060 -RX) 34
Xpress Lower Proportional Valve 3 (ESR1060 -RX) 35
Forks First Switch 36
Free-Lift Switch 37
Fuse 1 39
Fuse 2 41
Fuse 3 43
Fuse 4 44
Fuse 5 45
Fuse 6 46
Fuse 7 47
Fuse 8 48
Fuse 9 49
Fuse 10 50
Fuse 11 (ESR1060 -RX) 51
Height Encoder 1 52
Height Encoder 2 53
Height Reset Switch 1 54
Height Reset Switch 2 55
Hoist Solenoid Valve 56
Horn 58
Horn Switch 59
Impact Sensor 60
Key Switch 61
Keyless Power Module 62
Left Accessory Proportional Valve 63
Left Accessory Solenoid Valve (ESR1060 -RX) 64
Main Pump 65
Line Contactor 66
Load Sensor 1 67
Load Sensor 2 68
Lower Proportional Valve 69
Lower Solenoid Valve (ESR1060 -RX) 71
M21 Encoder 72
M21 Fan (ESR1060) 73
M21 Thermal Sensor 74
M22 Encoder (ESR1060 -RX) 75
M22 Thermal Sensor (ESR1060 -RX) 76
M31 Encoder 77
M31 Fan (ESR1060) 78
M31 Thermal Sensor 79
M31 Traction Brake 80
M51 Sensor 1 81
M51 Sensor 2 82
M51 Thermal Sensor 83
Main Hoist Sensor 84
Main Pump Motor 86
Manual Lowering Valve 88
Override Switch 90
Power Unit First Switch 91
Reach Position Sensor 1 92
Reach Position Sensor 2 93
Reach Proportional Valve 94
Reach Sensor 96
Reach Solenoid Valve (ESR1060 -RX) 98
Relay 1 99
Relay 2100
Relay 3101
Relay 4102
Relay 5103
Relay 6104
Relay 9105
Relay 10106
Relay 22107
Relay 23108
Relief Valve 1109
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction 1
Event Codes 9
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Removing the Main Pump 14
Inspecting the Main Pump 14
Assembly 15
Installing the Main Pump 15
Priming the Main Pump 16
Preparing the Lift Truck for Operation 16
Manifold - Main 18
Checking the 18
System 20
Functional Descriptions (ESR-F) 20
Lifting 20
Lowering 21
Extending the Reach Mechanism 23
Retracting the Reach Mechanism 25
Tilting the Fork Up 26
Tilting the Fork Down 28
Sideshift Right 29
Sideshift Left 31
5th Function A 32
5th Function B 33
Functional Descriptions (ESR-T) 35
Lifting 35
Lowering 36
Extending the Reach Mechanism 38
Retracting the Reach Mechanism 39
Tilting the Mast Towards the Operator 41
Tilting the Mast in the Direction of the Forks 42
Sideshift Right 43
Sideshift Left 45
Functional Descriptions (ESR-RX) 46
Lifting 46
Regenerative Lowering 47
Extending the Reach Mechanism 48
Retracting the Reach Mechanism 49
Tilting the Fork Up 50
Tilting the Fork Down 52
Sideshift Right 53
Sideshift Left 55
5th Function A 56
5th Function B 58
Drift Tests 59
Preparing the Lift Truck for Maintenance 59
Drift Tests 59
Recommended Tools and Equipment 59
Additional Tools and Equipment 60
Requirements 60
Performing a Drift Test on the Primary and Secondary Cylinders 60
Performing a Drift Test on the Tilt Cylinder 61
Checking and Adjusting the Relief Valve 1 62
Preparing the Lift Truck for Operation 63
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Removing the Fork Carriage Control Cable 15
Removing the Camera Control Cable 18
Inspecting the Control Cables 21
Assembly 21
Installing the Camera Control Cable 21
Installing the Fork Carriage Control Cable 24
Installing the Mast Control Cable 27
Adjusting the Tension 30
Preparing the Lift Truck for Operation 30
Troubleshooting 30
Troubleshooting 30
Cylinder - Primary 31
Technician Tips 31
Technician Tips 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 32
Small Hook Tool 32
Disassembly 32
Preparing the Lift Truck for Maintenance 32
Removing the Primary Cylinder 33
Disassembling the Primary Cylinder 34
Inspecting the Primary Cylinder 34
Assembly 35
Assembling the Primary Cylinder 35
Installing the Primary Cylinder 36
Bleeding the Cylinder 36
Testing the Cylinder Seal for Leaks 38
Preparing the Lift Truck for Operation 39
Cylinder - Reach 40
Tools and Equipment 40
Recommended Tools and Equipment 40
Additional Tools and Equipment 40
Disassembly 41
Preparing the Lift Truck for Maintenance 41
Removing the Reach Cylinder 41
Disassembling the Reach Cylinder 43
Inspecting the Reach Cylinder 44
Assembly 44
Assembling the Reach Cylinder 44
Installing the Reach Cylinder 45
Bleeding the Reach Cylinder 45
Preparing the Lift Truck for Operation 45
Testing the Cylinder Seal for Leaks 46
Troubleshooting 47
Troubleshooting 47
Cylinder - Secondary 48
Tools and Equipment 48
Recommended Tools and Equipment 48
Additional Tools and Equipment 48
Disassembly 49
Preparing the Lift Truck for Maintenance 49
Removing the Secondary Cylinder from Masts with a Lift Height up to 8 m (315 in) 49
Removing the Secondary Cylinder from Masts with a Lift Height Greater Than 8 m (315 in) 52
Disassembling the Secondary Cylinder 55
Disassembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 57
Inspecting the Secondary Cylinder 59
Assembly 59
Assembling the Secondary Cylinder 59
Assembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 61
Installing the Secondary Cylinder on Masts with a Lift Height up to 8 m (315 in) 63
Installing the Secondary Cylinder on Masts with a Lift Height Greater than 8 m (315 in) 66
Bleeding the Secondary Cylinder 69
Preparing a Test Load 69
Secondary Cylinder Drift Test 69
Preparing the Lift Truck for Operation 70
Troubleshooting 71
Troubleshooting 71
Cylinder - Sideshift 72
Tools and Equipment 72
Recommended Tools and Equipment 72
Additional Tools and Equipment 72
Disassembly 73
Preparing the Lift Truck for Maintenance 73
Disassembling the Sideshift Cylinder 73
Inspecting the Sideshift Cylinder 74
Assembly 75
Assembling the Sideshift Cylinder 75
Bleeding the Sideshift Cylinder 76
Preparing the Lift Truck for Operation 76
Troubleshooting 76
Troubleshooting 76
Cylinder - Tilt 77
Theory of Operation 77
Theory of Operation 77
Tools and Equipment 77
Recommended Tools and Equipment 77
Additional Tools and Equipment 77
Disassembly 78
Preparing the Lift Truck for Maintenance 78
Removing the Tilt Cylinder 78
Inspecting the Tilt Cylinder 79
Assembly 80
Installing the Tilt Cylinder 80
Bleeding the Tilt Cylinder 81
Preparing the Lift Truck for Operation 81
Troubleshooting 81
Troubleshooting 81
Fork Inspection 82
Tools and Equipment 82
Recommended Tools and Equipment 82
Additional Tools and Equipment 82
Inspection 82
Preparing the Lift Truck for Maintenance 82
Introduction 83
Identification 84
Measuring the Fork Blade for Wear 84
Checking for Fatigue Cracks 86
Bent or Twisted Forks 86
Checking the Fork Tip for Straightness 87
Fork Locking Pin 88
Preparing the Lift Truck for Operation 88
Height Encoder 90
Tools and Equipment 90
Recommended Tools and Equipment 90
Disassembly 90
Preparing the Lift Truck for Maintenance 90
Removing Height Encoder 1 (ESR -F) 90
Removing Height Encoder 2 (ESR -F) 91
Assembly 92
Installing Height Encoder 1 (ESR -F) 92
Installing Height Encoder 2 (ESR -F) 92
Preparing the Lift Truck for Operation 93
Hydraulic Lines and Fittings 94
Technician Tips 94
Technician Tips 94
Lift Chains 95
Tools and Equipment 95
Recommended Tools and Equipment 95
Additional Tools and Equipment 95
Lift Chains - Primary Cylinder 95
Disassembly 95
Preparing the Lift Truck for Maintenance 95
Removing the Lift Chains from the Primary Cylinder 96
Inspecting the Lift Chains 96
Checking the Lift Chain Stretch 98
Assembly 99
Installing the Lift Chains on the Primary Cylinder 99
Inspecting the Fork Height101
Preparing the Lift Truck for Operation102
Lift Chains - Secondary Cylinder102
Disassembly102
Preparing the Lift Truck for Maintenance102
Removing the Lift Chains from the Secondary Cylinder102
Inspecting the Lift Chains103
Checking the Lift Chain Stretch105
Assembly106
Installing the Lift Chains on the Secondary Cylinder106
Inspecting the Fork Height108
Preparing the Lift Truck for Operation109
Mast110
Technician Tips110
Technician Tips110
Tools and Equipment110
Recommended Tools and Equipment110
Additional Tools and Equipment110
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Load Wheel 14
Theory of Operation 14
Theory of Operation 14
Tools and Equipment 14
Recommended Tools and Equipment 14
Additional Tools and Equipment 14
Load Wheel Attached with a Snap Ring 15
Disassembly 15
Preparing the Lift Truck for Maintenance 15
Removing a Load Wheel Attached with a Snap Ring 15
Inspecting the Load Wheel 15
Assembly 16
Installing a Load Wheel Attached with a Snap Ring 16
Preparing the Lift Truck for Operation 16
Load Wheel Attached with a Nut 16
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing a Load Wheel Attached with a Nut 17
Inspecting the Load Wheel 18
Assembly 18
Installing a Load Wheel Attached with a Nut 18
Preparing the Lift Truck for Operation 19
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
Preparing the Lift Truck for Operation 14
Steering Wheel 15
Technician Tips 15
Technician Tips 15
Theory of Operation 15
Theory of Operation 15
Tools and Equipment 15
Recommended Tools and Equipment 15
Additional Tools and Equipment 15
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing the Steering Wheel 16
Inspecting the Steering Wheel 18
Assembly 18
Installing the Steering Wheel 18
Preparing the Lift Truck for Operation 19
Troubleshooting 20
Troubleshooting 20
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Menu Structure 14
Introduction 14
Adjusting the Settings 16
Menus 16
Auto Height Select 34
Theory of Operation 34
Theory of Operation 34
System Interaction 34
System Interaction 34
Raise and Lower Cutouts 40
Theory of Operation 40
Theory of Operation 40
System Interaction 40
Raise and Lower Cutouts 40
5th and 6th Function 44
System Interaction 44
5th and 6th Function 44
User Performance 47
Theory of Operation 47
Theory of Operation 47
System Interaction 47
System Interaction 47
Performance Settings 50
System Interaction 50
Performance Settings 50
Performance Settings and Effects 54
Performance Settings and Effects 54
Operational Hours 76
System Interaction 76
Set the Operational Hours After Replacing the Access 41 76
Widgets 79
System Interaction 79
System Interaction 79
Widgets 80
Adding a Widget to the Home Screen 82
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Preparing the Stopping Distance Test Route 14
Testing the Stopping Distance 14
Preparing the Lift Truck for Operation 15
Troubleshooting 16
Troubleshooting 16
Brake - M31 17
Theory of Operation 17
Theory of Operation 17
Tools and Equipment 17
Recommended Tools and Equipment 17
Additional Tools and Equipment 17
Disassembly 17
Preparing the Lift Truck for Maintenance 17
Removing the M31 Traction Brake 18
Disassembling the M31 Traction Brake 19
Inspecting the M31 Traction Brake 19
Assembly 19
Assembling the M31 Traction Brake 19
Installing the M31 Traction Brake 20
Checking the Brake Torque 21
Checking and Adjusting the Air Gap 22
Preparing the Lift Truck for Operation 22
Troubleshooting 23
Troubleshooting 23
Drive Tire 24
Tools and Equipment 24
Recommended Tools and Equipment 24
Additional Tools and Equipment 24
Disassembly 24
Preparing the Lift Truck for Maintenance 24
Removing the Drive Tire 25
Inspecting the Drive Tire 25
Assembly 25
Installing the Drive Tire 25
Preparing the Lift Truck for Operation 26
Drive Unit 27
Tools and Equipment 27
Recommended Tools and Equipment 27
Additional Tools and Equipment 27
Disassembly 27
Preparing the Lift Truck for Maintenance 27
Removing the Drive Unit 28
Inspecting the Drive Unit 28
Assembly 29
Installing the Drive Unit 29
Preparing the Lift Truck for Operation 29
Troubleshooting 30
Troubleshooting 30
Pinion Repair Set 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 31
Disassembly 31
Inspecting the Gearbox Pinion 31
Preparing the Lift Truck for Maintenance 32
Removing the Gearbox Pinion 33
Assembly 34
Installing the Gearbox Pinion 34
Preparing the Lift Truck for Operation 36
Rotor Repair Set 37
Theory of Operation 37
Theory of Operation 37
Tools and Equipment 37
Recommended Tools and Equipment 37
Disassembly 38
Inspecting the Rotor Teeth 38
Preparing the Lift Truck for Maintenance 38
Removing the Rotor 38
Assembly 42
Installing the Rotor 42
Preparing the Lift Truck for Operation 46
Motor - M31 47
Technician Tips 47
Technician Tips 47
Theory of Operation 47
Theory of Operation 47
Tools and Equipment 47
Recommended Tools and Equipment 47
Additional Tools and Equipment 48
Disassembly 48
Preparing the Lift Truck for Maintenance 48
Removing the Traction Motor 48
Disassembling the Traction Motor 49
Inspecting the Traction Motor 51
Assembly 51
Assembling the Traction Motor 51
Installing the Traction Motor 53
Preparing the Lift Truck for Operation 53
Troubleshooting 54
Troubleshooting 54
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Diagram Key 14
Main Harness and Connector Figure 17
Pictorials - Electrical 19
Pictorials - Electrical (ESR1020 -F and ESR1040 -F) 19
Pictorials - Electrical (ESR1020 -T and ESR1040 -T) 42
Pictorials - Electrical (ESR1060, Standard) 61
Pictorials - Electrical (ESR1060 -RX) 86
Schematics - Electrical110
Schematics - Electrical (ESR 1020/1040)110
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
General Maintenance 0
Standard Torque Values 1
Power Source 0
General Information 1
Componentry 0
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Event Codes 0
Introduction 1
Hydraulic 0
Theory of Operation 1
Lifting Mechanism 0
Theory of Operation 1
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Steering 0
Theory of Operation 1
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
Installing the Battery 14
Installation Procedure With a Battery Roller Stand 14
Installation Procedure With a Lifting Device 14
Securing the Battery in the Lift Truck 14
Discharging the Capacitors 15
General Hot Work Instructions 16
Releasing the Hydraulic Pressure 17
Parking Brake 17
Releasing the Parking Brake 17
Applying the Parking Brake 18
Towing the Lift Truck 18
Preparing for Towing the Lift Truck 19
Towing the Lift Truck by Lifting and Pulling in the Power Unit First Direction 19
Towing the Lift Truck by Pulling in the Forks First Direction 20
Lifting and Blocking 21
Lifting and Blocking the Outriggers 21
Lifting and Blocking the Power Unit 21
Blocking the Masts 22
Securing the Fork Carriage 23
Blocking the Reach Mechanism 23
Preparing the Mast for Removal 24
Lifting the Lift Truck 25
Lifting the Lift Truck 25
Preparing for Lifting the Lift Truck 25
Attaching the Lifting Equipment to the Overhead Guard 26
Attaching Lifting Equipment for Standard Overhead Guard 26
Attaching Lifting Equipment for Clear Overhead Guard 27
Attaching Lifting Equipment for Cold Storage Cabin 27
Completing Preparation for Lifting the Lift Truck 28
Transporting the Lift Truck 30
Securing a Lift Truck on a Loading Surface for Transport 30
Securing the Mast to a Loading Surface for Transport 31
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Icons 14
Visual Inspection 14
Operational Check and Test Drive 15
Preparing the Lift Truck for Maintenance 15
Inspection and Lubrication 16
Preparing the Lift Truck for Operation110
Final Operational Check and Test Drive110
Planned Maintenance Completion110
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Access 31 14
Access 41 15
Access 51 16
Accessory Pump (ESR1060 -RX) 17
Accessory Pump Motor (ESR1060 -RX) 18
19
Adjustment Valve Lowering Speed 20
Auto Height Select Switch 22
Battery Latch Switch 23
Brake Fluid Switch 24
Brake Potentiometer 25
Brake Pressure Switch 26
Camera Switch 27
CAN Card 28
Card Reader 29
Emergency Disconnect Contactor 30
Emergency Disconnect Switch 1 31
Emergency Disconnect Switch 2 32
Xpress Lower Proportional Valve 1 (ESR1060 -RX) 33
Xpress Lower Proportional Valve 2 (ESR1060 -RX) 34
Xpress Lower Proportional Valve 3 (ESR1060 -RX) 35
Forks First Switch 36
Free-Lift Switch 37
Fuse 1 39
Fuse 2 41
Fuse 3 43
Fuse 4 44
Fuse 5 45
Fuse 6 46
Fuse 7 47
Fuse 8 48
Fuse 9 49
Fuse 10 50
Fuse 11 (ESR1060 -RX) 51
Height Encoder 1 52
Height Encoder 2 53
Height Reset Switch 1 54
Height Reset Switch 2 55
Hoist Solenoid Valve 56
Horn 58
Horn Switch 59
Impact Sensor 60
Key Switch 61
Keyless Power Module 62
Left Accessory Proportional Valve 63
Left Accessory Solenoid Valve (ESR1060 -RX) 64
Main Pump 65
Line Contactor 66
Load Sensor 1 67
Load Sensor 2 68
Lower Proportional Valve 69
Lower Solenoid Valve (ESR1060 -RX) 71
M21 Encoder 72
M21 Fan (ESR1060) 73
M21 Thermal Sensor 74
M22 Encoder (ESR1060 -RX) 75
M22 Thermal Sensor (ESR1060 -RX) 76
M31 Encoder 77
M31 Fan (ESR1060) 78
M31 Thermal Sensor 79
M31 Traction Brake 80
M51 Sensor 1 81
M51 Sensor 2 82
M51 Thermal Sensor 83
Main Hoist Sensor 84
Main Pump Motor 86
Manual Lowering Valve 88
Override Switch 90
Power Unit First Switch 91
Reach Position Sensor 1 92
Reach Position Sensor 2 93
Reach Proportional Valve 94
Reach Sensor 96
Reach Solenoid Valve (ESR1060 -RX) 98
Relay 1 99
Relay 2100
Relay 3101
Relay 4102
Relay 5103
Relay 6104
Relay 9105
Relay 10106
Relay 22107
Relay 23108
Relief Valve 1109
Relief Valve 2111
Retract Proportional Valve112
Retract Solenoid Valve (ESR1060 -RX)114
Right Accessory Proportional Valve115
Right Accessory Solenoid Valve (ESR1060 -RX)116
Safety Pedal Sensor117
Seat Heater Switch118
Seat Switch119
Selector Encoder120
Selector Switch121
Sideshift Left Solenoid Valve (ESR1020 -T and ESR1040 -T)122
Sideshift Position Sensor123
Sideshift Right Solenoid Valve (ESR1020 -T and ESR1040 -T)124
Sideshift Sensor125
Sideshift Solenoid Valve127
Speaker129
Steer Motor130
Steer Sensor 1132
Steer Sensor 2133
Steering Sensor 1134
Steering Sensor 2135
Temperature Sensor136
Tilt Down Solenoid Valve (ESR1020 -T and ESR1040 -T)137
Tilt Position Sensor138
Tilt Sensor139
Tilt Solenoid Valve141
Tilt Up Solenoid Valve (ESR1020 -T and ESR1040 -T)143
Traction Motor144
Traction Potentiometer146
Traction Switch147
Travel Alarm148
Warning Light 1149
Warning Light 2150
Warning Light 3151
Worklight 1152
Worklight 2153
Worklight Switch154
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction 1
Event Codes 9
000002006 10
000002058 10
000003006 11
000003058 11
000004000 12
000004003 12
000004004 13
000005000 13
000006059 14
000008001 15
000021000 17
000021001 17
000021016 17
000086000 18
000086016 18
000087000 18
000088003 20
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000158004 23
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000441001 26
000441016 26
000441018 26
000444001 26
000447002 27
000501002 28
000502059 29
000503004 30
000505004 30
000506003 30
000506004 30
000508000 31
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000508018 32
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000586003 34
000586004 35
000587003 37
000587004 38
000588003 38
000588004 38
000599000 40
000600003 41
000600004 42
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000602004 43
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000625003 49
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000826003 60
000826004 61
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000883003 67
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000911003 68
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000913003 70
000913004 71
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001194003 76
001195004 77
001196003 78
001196004 79
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001198004 79
001491003 80
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001492003 80
001492004 81
001497001 81
001498001 82
001502004 82
001502005 83
001502006 84
001505005 85
001505006 86
001506005 86
001507004 88
001507005 89
001509004 89
001509005 91
001509006 92
001511004 93
001511005 94
001511006 94
001512003 95
001512004 96
001512005 97
001512006 97
001513003 97
001513004 98
001513006 98
001514003 98
001514004 99
001514005100
001514006100
001515003100
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001517003102
001517004102
001517006104
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002931003148
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003514004152
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003597004153
003598003154
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Removing the Main Pump 14
Inspecting the Main Pump 14
Assembly 15
Installing the Main Pump 15
Priming the Main Pump 16
Preparing the Lift Truck for Operation 16
Manifold - Main 18
Checking the 18
System 20
Functional Descriptions (ESR-F) 20
Lifting 20
Lowering 21
Extending the Reach Mechanism 23
Retracting the Reach Mechanism 25
Tilting the Fork Up 26
Tilting the Fork Down 28
Sideshift Right 29
Sideshift Left 31
5th Function A 32
5th Function B 33
Functional Descriptions (ESR-T) 35
Lifting 35
Lowering 36
Extending the Reach Mechanism 38
Retracting the Reach Mechanism 39
Tilting the Mast Towards the Operator 41
Tilting the Mast in the Direction of the Forks 42
Sideshift Right 43
Sideshift Left 45
Functional Descriptions (ESR-RX) 46
Lifting 46
Regenerative Lowering 47
Extending the Reach Mechanism 48
Retracting the Reach Mechanism 49
Tilting the Fork Up 50
Tilting the Fork Down 52
Sideshift Right 53
Sideshift Left 55
5th Function A 56
5th Function B 58
Drift Tests 59
Preparing the Lift Truck for Maintenance 59
Drift Tests 59
Recommended Tools and Equipment 59
Additional Tools and Equipment 60
Requirements 60
Performing a Drift Test on the Primary and Secondary Cylinders 60
Performing a Drift Test on the Tilt Cylinder 61
Checking and Adjusting the Relief Valve 1 62
Preparing the Lift Truck for Operation 63
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Removing the Fork Carriage Control Cable 15
Removing the Camera Control Cable 18
Inspecting the Control Cables 21
Assembly 21
Installing the Camera Control Cable 21
Installing the Fork Carriage Control Cable 24
Installing the Mast Control Cable 27
Adjusting the Tension 30
Preparing the Lift Truck for Operation 30
Troubleshooting 30
Troubleshooting 30
Cylinder - Primary 31
Technician Tips 31
Technician Tips 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 32
Small Hook Tool 32
Disassembly 32
Preparing the Lift Truck for Maintenance 32
Removing the Primary Cylinder 33
Disassembling the Primary Cylinder 34
Inspecting the Primary Cylinder 34
Assembly 35
Assembling the Primary Cylinder 35
Installing the Primary Cylinder 36
Bleeding the Cylinder 36
Testing the Cylinder Seal for Leaks 38
Preparing the Lift Truck for Operation 39
Cylinder - Reach 40
Tools and Equipment 40
Recommended Tools and Equipment 40
Additional Tools and Equipment 40
Disassembly 41
Preparing the Lift Truck for Maintenance 41
Removing the Reach Cylinder 41
Disassembling the Reach Cylinder 43
Inspecting the Reach Cylinder 44
Assembly 44
Assembling the Reach Cylinder 44
Installing the Reach Cylinder 45
Bleeding the Reach Cylinder 45
Preparing the Lift Truck for Operation 45
Testing the Cylinder Seal for Leaks 46
Troubleshooting 47
Troubleshooting 47
Cylinder - Secondary 48
Tools and Equipment 48
Recommended Tools and Equipment 48
Additional Tools and Equipment 48
Disassembly 49
Preparing the Lift Truck for Maintenance 49
Removing the Secondary Cylinder from Masts with a Lift Height up to 8 m (315 in) 49
Removing the Secondary Cylinder from Masts with a Lift Height Greater Than 8 m (315 in) 52
Disassembling the Secondary Cylinder 55
Disassembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 57
Inspecting the Secondary Cylinder 59
Assembly 59
Assembling the Secondary Cylinder 59
Assembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 61
Installing the Secondary Cylinder on Masts with a Lift Height up to 8 m (315 in) 63
Installing the Secondary Cylinder on Masts with a Lift Height Greater than 8 m (315 in) 66
Bleeding the Secondary Cylinder 69
Preparing a Test Load 69
Secondary Cylinder Drift Test 69
Preparing the Lift Truck for Operation 70
Troubleshooting 71
Troubleshooting 71
Cylinder - Sideshift 72
Tools and Equipment 72
Recommended Tools and Equipment 72
Additional Tools and Equipment 72
Disassembly 73
Preparing the Lift Truck for Maintenance 73
Disassembling the Sideshift Cylinder 73
Inspecting the Sideshift Cylinder 74
Assembly 75
Assembling the Sideshift Cylinder 75
Bleeding the Sideshift Cylinder 76
Preparing the Lift Truck for Operation 76
Troubleshooting 76
Troubleshooting 76
Cylinder - Tilt 77
Theory of Operation 77
Theory of Operation 77
Tools and Equipment 77
Recommended Tools and Equipment 77
Additional Tools and Equipment 77
Disassembly 78
Preparing the Lift Truck for Maintenance 78
Removing the Tilt Cylinder 78
Inspecting the Tilt Cylinder 79
Assembly 80
Installing the Tilt Cylinder 80
Bleeding the Tilt Cylinder 81
Preparing the Lift Truck for Operation 81
Troubleshooting 81
Troubleshooting 81
Fork Inspection 82
Tools and Equipment 82
Recommended Tools and Equipment 82
Additional Tools and Equipment 82
Inspection 82
Preparing the Lift Truck for Maintenance 82
Introduction 83
Identification 84
Measuring the Fork Blade for Wear 84
Checking for Fatigue Cracks 86
Bent or Twisted Forks 86
Checking the Fork Tip for Straightness 87
Fork Locking Pin 88
Preparing the Lift Truck for Operation 88
Height Encoder 90
Tools and Equipment 90
Recommended Tools and Equipment 90
Disassembly 90
Preparing the Lift Truck for Maintenance 90
Removing Height Encoder 1 (ESR -F) 90
Removing Height Encoder 2 (ESR -F) 91
Assembly 92
Installing Height Encoder 1 (ESR -F) 92
Installing Height Encoder 2 (ESR -F) 92
Preparing the Lift Truck for Operation 93
Hydraulic Lines and Fittings 94
Technician Tips 94
Technician Tips 94
Lift Chains 95
Tools and Equipment 95
Recommended Tools and Equipment 95
Additional Tools and Equipment 95
Lift Chains - Primary Cylinder 95
Disassembly 95
Preparing the Lift Truck for Maintenance 95
Removing the Lift Chains from the Primary Cylinder 96
Inspecting the Lift Chains 96
Checking the Lift Chain Stretch 98
Assembly 99
Installing the Lift Chains on the Primary Cylinder 99
Inspecting the Fork Height101
Preparing the Lift Truck for Operation102
Lift Chains - Secondary Cylinder102
Disassembly102
Preparing the Lift Truck for Maintenance102
Removing the Lift Chains from the Secondary Cylinder102
Inspecting the Lift Chains103
Checking the Lift Chain Stretch105
Assembly106
Installing the Lift Chains on the Secondary Cylinder106
Inspecting the Fork Height108
Preparing the Lift Truck for Operation109
Mast110
Technician Tips110
Technician Tips110
Tools and Equipment110
Recommended Tools and Equipment110
Additional Tools and Equipment110
Mast Torque Requirements111
Mast Torque Requirements111
Inspecting and Lubricating the Mast112
Inspecting and Lubricating the Mast112
Fixed Mast113
Disassembly113
Preparing the Lift Truck for Maintenance113
Preparing for Removing the Fixed Mast113
Removing the Fixed Mast116
Disassembling the Mast119
Assembly122
Assembling the Mast122
Installing the Fixed Mast125
After Installing the Fixed Mast127
Preparing the Lift Truck for Operation130
Tilting Mast130
Disassembly130
Preparing the Lift Truck for Maintenance130
Preparing for Removing the Tilting Mast131
Removing the Tilting Mast135
Disassembling the Mast135
Assembly139
Assembling the Mast139
Installing the Tilting Mast142
After Installing the Tilting Mast142
Preparing the Lift Truck for Operation146
Adjustments146
Checking the Mast146
Adjusting the Mast Tilt147
Removing the Mast Rollers150
Calculating the Mast Roller Diameter151
Installing the Mast Rollers153
Calculating the Number of Shims Required153
Shims Required for First and Second Mast Section153
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Load Wheel 14
Theory of Operation 14
Theory of Operation 14
Tools and Equipment 14
Recommended Tools and Equipment 14
Additional Tools and Equipment 14
Load Wheel Attached with a Snap Ring 15
Disassembly 15
Preparing the Lift Truck for Maintenance 15
Removing a Load Wheel Attached with a Snap Ring 15
Inspecting the Load Wheel 15
Assembly 16
Installing a Load Wheel Attached with a Snap Ring 16
Preparing the Lift Truck for Operation 16
Load Wheel Attached with a Nut 16
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing a Load Wheel Attached with a Nut 17
Inspecting the Load Wheel 18
Assembly 18
Installing a Load Wheel Attached with a Nut 18
Preparing the Lift Truck for Operation 19
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
Preparing the Lift Truck for Operation 14
Steering Wheel 15
Technician Tips 15
Technician Tips 15
Theory of Operation 15
Theory of Operation 15
Tools and Equipment 15
Recommended Tools and Equipment 15
Additional Tools and Equipment 15
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing the Steering Wheel 16
Inspecting the Steering Wheel 18
Assembly 18
Installing the Steering Wheel 18
Preparing the Lift Truck for Operation 19
Troubleshooting 20
Troubleshooting 20
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Menu Structure 14
Introduction 14
Adjusting the Settings 16
Menus 16
Auto Height Select 34
Theory of Operation 34
Theory of Operation 34
System Interaction 34
System Interaction 34
Raise and Lower Cutouts 40
Theory of Operation 40
Theory of Operation 40
System Interaction 40
Raise and Lower Cutouts 40
5th and 6th Function 44
System Interaction 44
5th and 6th Function 44
User Performance 47
Theory of Operation 47
Theory of Operation 47
System Interaction 47
System Interaction 47
Performance Settings 50
System Interaction 50
Performance Settings 50
Performance Settings and Effects 54
Performance Settings and Effects 54
Operational Hours 76
System Interaction 76
Set the Operational Hours After Replacing the Access 41 76
Widgets 79
System Interaction 79
System Interaction 79
Widgets 80
Adding a Widget to the Home Screen 82
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Preparing the Stopping Distance Test Route 14
Testing the Stopping Distance 14
Preparing the Lift Truck for Operation 15
Troubleshooting 16
Troubleshooting 16
Brake - M31 17
Theory of Operation 17
Theory of Operation 17
Tools and Equipment 17
Recommended Tools and Equipment 17
Additional Tools and Equipment 17
Disassembly 17
Preparing the Lift Truck for Maintenance 17
Removing the M31 Traction Brake 18
Disassembling the M31 Traction Brake 19
Inspecting the M31 Traction Brake 19
Assembly 19
Assembling the M31 Traction Brake 19
Installing the M31 Traction Brake 20
Checking the Brake Torque 21
Checking and Adjusting the Air Gap 22
Preparing the Lift Truck for Operation 22
Troubleshooting 23
Troubleshooting 23
Drive Tire 24
Tools and Equipment 24
Recommended Tools and Equipment 24
Additional Tools and Equipment 24
Disassembly 24
Preparing the Lift Truck for Maintenance 24
Removing the Drive Tire 25
Inspecting the Drive Tire 25
Assembly 25
Installing the Drive Tire 25
Preparing the Lift Truck for Operation 26
Drive Unit 27
Tools and Equipment 27
Recommended Tools and Equipment 27
Additional Tools and Equipment 27
Disassembly 27
Preparing the Lift Truck for Maintenance 27
Removing the Drive Unit 28
Inspecting the Drive Unit 28
Assembly 29
Installing the Drive Unit 29
Preparing the Lift Truck for Operation 29
Troubleshooting 30
Troubleshooting 30
Pinion Repair Set 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 31
Disassembly 31
Inspecting the Gearbox Pinion 31
Preparing the Lift Truck for Maintenance 32
Removing the Gearbox Pinion 33
Assembly 34
Installing the Gearbox Pinion 34
Preparing the Lift Truck for Operation 36
Rotor Repair Set 37
Theory of Operation 37
Theory of Operation 37
Tools and Equipment 37
Recommended Tools and Equipment 37
Disassembly 38
Inspecting the Rotor Teeth 38
Preparing the Lift Truck for Maintenance 38
Removing the Rotor 38
Assembly 42
Installing the Rotor 42
Preparing the Lift Truck for Operation 46
Motor - M31 47
Technician Tips 47
Technician Tips 47
Theory of Operation 47
Theory of Operation 47
Tools and Equipment 47
Recommended Tools and Equipment 47
Additional Tools and Equipment 48
Disassembly 48
Preparing the Lift Truck for Maintenance 48
Removing the Traction Motor 48
Disassembling the Traction Motor 49
Inspecting the Traction Motor 51
Assembly 51
Assembling the Traction Motor 51
Installing the Traction Motor 53
Preparing the Lift Truck for Operation 53
Troubleshooting 54
Troubleshooting 54
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Diagram Key 14
Main Harness and Connector Figure 17
Pictorials - Electrical 19
Pictorials - Electrical (ESR1020 -F and ESR1040 -F) 19
Pictorials - Electrical (ESR1020 -T and ESR1040 -T) 42
Pictorials - Electrical (ESR1060, Standard) 61
Pictorials - Electrical (ESR1060 -RX) 86
Schematics - Electrical110
Schematics - Electrical (ESR 1020/1040)110
Schematics - Electrical (ESR 1060)112
Schematics - Electrical (ESR 1060 -RX)114
Schematics - Hydraulic116
ESR -F116
ESR -F118
ESR -T120
ESR1060 -RX122
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction 1
Event Codes 9
000002006 10
000002058 10
000003006 11
000003058 11
000004000 12
000004003 12
000004004 13
000005000 13
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
Installing the Battery 14
Installation Procedure With a Battery Roller Stand 14
Installation Procedure With a Lifting Device 14
Securing the Battery in the Lift Truck 14
Discharging the Capacitors 15
General Hot Work Instructions 16
Releasing the Hydraulic Pressure 17
Parking Brake 17
Releasing the Parking Brake 17
Applying the Parking Brake 18
Towing the Lift Truck 18
Preparing for Towing the Lift Truck 19
Towing the Lift Truck by Lifting and Pulling in the Power Unit First Direction 19
Towing the Lift Truck by Pulling in the Forks First Direction 20
Lifting and Blocking 21
Lifting and Blocking the Outriggers 21
Lifting and Blocking the Power Unit 21
Blocking the Masts 22
Securing the Fork Carriage 23
Blocking the Reach Mechanism 23
Preparing the Mast for Removal 24
Lifting the Lift Truck 25
Lifting the Lift Truck 25
Preparing for Lifting the Lift Truck 25
Attaching the Lifting Equipment to the Overhead Guard 26
Attaching Lifting Equipment for Standard Overhead Guard 26
Attaching Lifting Equipment for Clear Overhead Guard 27
Attaching Lifting Equipment for Cold Storage Cabin 27
Completing Preparation for Lifting the Lift Truck 28
Transporting the Lift Truck 30
Securing a Lift Truck on a Loading Surface for Transport 30
Securing the Mast to a Loading Surface for Transport 31
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Icons 14
Visual Inspection 14
Operational Check and Test Drive 15
Preparing the Lift Truck for Maintenance 15
Inspection and Lubrication 16
Preparing the Lift Truck for Operation110
Final Operational Check and Test Drive110
Planned Maintenance Completion110
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Access 31 14
Access 41 15
Access 51 16
Accessory Pump (ESR1060 -RX) 17
Accessory Pump Motor (ESR1060 -RX) 18
19
Adjustment Valve Lowering Speed 20
Auto Height Select Switch 22
Battery Latch Switch 23
Brake Fluid Switch 24
Brake Potentiometer 25
Brake Pressure Switch 26
Camera Switch 27
CAN Card 28
Card Reader 29
Emergency Disconnect Contactor 30
Emergency Disconnect Switch 1 31
Emergency Disconnect Switch 2 32
Xpress Lower Proportional Valve 1 (ESR1060 -RX) 33
Xpress Lower Proportional Valve 2 (ESR1060 -RX) 34
Xpress Lower Proportional Valve 3 (ESR1060 -RX) 35
Forks First Switch 36
Free-Lift Switch 37
Fuse 1 39
Fuse 2 41
Fuse 3 43
Fuse 4 44
Fuse 5 45
Fuse 6 46
Fuse 7 47
Fuse 8 48
Fuse 9 49
Fuse 10 50
Fuse 11 (ESR1060 -RX) 51
Height Encoder 1 52
Height Encoder 2 53
Height Reset Switch 1 54
Height Reset Switch 2 55
Hoist Solenoid Valve 56
Horn 58
Horn Switch 59
Impact Sensor 60
Key Switch 61
Keyless Power Module 62
Left Accessory Proportional Valve 63
Left Accessory Solenoid Valve (ESR1060 -RX) 64
Main Pump 65
Line Contactor 66
Load Sensor 1 67
Load Sensor 2 68
Lower Proportional Valve 69
Lower Solenoid Valve (ESR1060 -RX) 71
M21 Encoder 72
M21 Fan (ESR1060) 73
M21 Thermal Sensor 74
M22 Encoder (ESR1060 -RX) 75
M22 Thermal Sensor (ESR1060 -RX) 76
M31 Encoder 77
M31 Fan (ESR1060) 78
M31 Thermal Sensor 79
M31 Traction Brake 80
M51 Sensor 1 81
M51 Sensor 2 82
M51 Thermal Sensor 83
Main Hoist Sensor 84
Main Pump Motor 86
Manual Lowering Valve 88
Override Switch 90
Power Unit First Switch 91
Reach Position Sensor 1 92
Reach Position Sensor 2 93
Reach Proportional Valve 94
Reach Sensor 96
Reach Solenoid Valve (ESR1060 -RX) 98
Relay 1 99
Relay 2100
Relay 3101
Relay 4102
Relay 5103
Relay 6104
Relay 9105
Relay 10106
Relay 22107
Relay 23108
Relief Valve 1109
Relief Valve 2111
Retract Proportional Valve112
Retract Solenoid Valve (ESR1060 -RX)114
Right Accessory Proportional Valve115
Right Accessory Solenoid Valve (ESR1060 -RX)116
Safety Pedal Sensor117
Seat Heater Switch118
Seat Switch119
Selector Encoder120
Selector Switch121
Sideshift Left Solenoid Valve (ESR1020 -T and ESR1040 -T)122
Sideshift Position Sensor123
Sideshift Right Solenoid Valve (ESR1020 -T and ESR1040 -T)124
Sideshift Sensor125
Sideshift Solenoid Valve127
Speaker129
Steer Motor130
Steer Sensor 1132
Steer Sensor 2133
Steering Sensor 1134
Steering Sensor 2135
Temperature Sensor136
Tilt Down Solenoid Valve (ESR1020 -T and ESR1040 -T)137
Tilt Position Sensor138
Tilt Sensor139
Tilt Solenoid Valve141
Tilt Up Solenoid Valve (ESR1020 -T and ESR1040 -T)143
Traction Motor144
Traction Potentiometer146
Traction Switch147
Travel Alarm148
Warning Light 1149
Warning Light 2150
Warning Light 3151
Worklight 1152
Worklight 2153
Worklight Switch154
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Removing the Main Pump 14
Inspecting the Main Pump 14
Assembly 15
Installing the Main Pump 15
Priming the Main Pump 16
Preparing the Lift Truck for Operation 16
Manifold - Main 18
Checking the 18
System 20
Functional Descriptions (ESR-F) 20
Lifting 20
Lowering 21
Extending the Reach Mechanism 23
Retracting the Reach Mechanism 25
Tilting the Fork Up 26
Tilting the Fork Down 28
Sideshift Right 29
Sideshift Left 31
5th Function A 32
5th Function B 33
Functional Descriptions (ESR-T) 35
Lifting 35
Lowering 36
Extending the Reach Mechanism 38
Retracting the Reach Mechanism 39
Tilting the Mast Towards the Operator 41
Tilting the Mast in the Direction of the Forks 42
Sideshift Right 43
Sideshift Left 45
Functional Descriptions (ESR-RX) 46
Lifting 46
Regenerative Lowering 47
Extending the Reach Mechanism 48
Retracting the Reach Mechanism 49
Tilting the Fork Up 50
Tilting the Fork Down 52
Sideshift Right 53
Sideshift Left 55
5th Function A 56
5th Function B 58
Drift Tests 59
Preparing the Lift Truck for Maintenance 59
Drift Tests 59
Recommended Tools and Equipment 59
Additional Tools and Equipment 60
Requirements 60
Performing a Drift Test on the Primary and Secondary Cylinders 60
Performing a Drift Test on the Tilt Cylinder 61
Checking and Adjusting the Relief Valve 1 62
Preparing the Lift Truck for Operation 63
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Removing the Fork Carriage Control Cable 15
Removing the Camera Control Cable 18
Inspecting the Control Cables 21
Assembly 21
Installing the Camera Control Cable 21
Installing the Fork Carriage Control Cable 24
Installing the Mast Control Cable 27
Adjusting the Tension 30
Preparing the Lift Truck for Operation 30
Troubleshooting 30
Troubleshooting 30
Cylinder - Primary 31
Technician Tips 31
Technician Tips 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 32
Small Hook Tool 32
Disassembly 32
Preparing the Lift Truck for Maintenance 32
Removing the Primary Cylinder 33
Disassembling the Primary Cylinder 34
Inspecting the Primary Cylinder 34
Assembly 35
Assembling the Primary Cylinder 35
Installing the Primary Cylinder 36
Bleeding the Cylinder 36
Testing the Cylinder Seal for Leaks 38
Preparing the Lift Truck for Operation 39
Cylinder - Reach 40
Tools and Equipment 40
Recommended Tools and Equipment 40
Additional Tools and Equipment 40
Disassembly 41
Preparing the Lift Truck for Maintenance 41
Removing the Reach Cylinder 41
Disassembling the Reach Cylinder 43
Inspecting the Reach Cylinder 44
Assembly 44
Assembling the Reach Cylinder 44
Installing the Reach Cylinder 45
Bleeding the Reach Cylinder 45
Preparing the Lift Truck for Operation 45
Testing the Cylinder Seal for Leaks 46
Troubleshooting 47
Troubleshooting 47
Cylinder - Secondary 48
Tools and Equipment 48
Recommended Tools and Equipment 48
Additional Tools and Equipment 48
Disassembly 49
Preparing the Lift Truck for Maintenance 49
Removing the Secondary Cylinder from Masts with a Lift Height up to 8 m (315 in) 49
Removing the Secondary Cylinder from Masts with a Lift Height Greater Than 8 m (315 in) 52
Disassembling the Secondary Cylinder 55
Disassembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 57
Inspecting the Secondary Cylinder 59
Assembly 59
Assembling the Secondary Cylinder 59
Assembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 61
Installing the Secondary Cylinder on Masts with a Lift Height up to 8 m (315 in) 63
Installing the Secondary Cylinder on Masts with a Lift Height Greater than 8 m (315 in) 66
Bleeding the Secondary Cylinder 69
Preparing a Test Load 69
Secondary Cylinder Drift Test 69
Preparing the Lift Truck for Operation 70
Troubleshooting 71
Troubleshooting 71
Cylinder - Sideshift 72
Tools and Equipment 72
Recommended Tools and Equipment 72
Additional Tools and Equipment 72
Disassembly 73
Preparing the Lift Truck for Maintenance 73
Disassembling the Sideshift Cylinder 73
Inspecting the Sideshift Cylinder 74
Assembly 75
Assembling the Sideshift Cylinder 75
Bleeding the Sideshift Cylinder 76
Preparing the Lift Truck for Operation 76
Troubleshooting 76
Troubleshooting 76
Cylinder - Tilt 77
Theory of Operation 77
Theory of Operation 77
Tools and Equipment 77
Recommended Tools and Equipment 77
Additional Tools and Equipment 77
Disassembly 78
Preparing the Lift Truck for Maintenance 78
Removing the Tilt Cylinder 78
Inspecting the Tilt Cylinder 79
Assembly 80
Installing the Tilt Cylinder 80
Bleeding the Tilt Cylinder 81
Preparing the Lift Truck for Operation 81
Troubleshooting 81
Troubleshooting 81
Fork Inspection 82
Tools and Equipment 82
Recommended Tools and Equipment 82
Additional Tools and Equipment 82
Inspection 82
Preparing the Lift Truck for Maintenance 82
Introduction 83
Identification 84
Measuring the Fork Blade for Wear 84
Checking for Fatigue Cracks 86
Bent or Twisted Forks 86
Checking the Fork Tip for Straightness 87
Fork Locking Pin 88
Preparing the Lift Truck for Operation 88
Height Encoder 90
Tools and Equipment 90
Recommended Tools and Equipment 90
Disassembly 90
Preparing the Lift Truck for Maintenance 90
Removing Height Encoder 1 (ESR -F) 90
Removing Height Encoder 2 (ESR -F) 91
Assembly 92
Installing Height Encoder 1 (ESR -F) 92
Installing Height Encoder 2 (ESR -F) 92
Preparing the Lift Truck for Operation 93
Hydraulic Lines and Fittings 94
Technician Tips 94
Technician Tips 94
Lift Chains 95
Tools and Equipment 95
Recommended Tools and Equipment 95
Additional Tools and Equipment 95
Lift Chains - Primary Cylinder 95
Disassembly 95
Preparing the Lift Truck for Maintenance 95
Removing the Lift Chains from the Primary Cylinder 96
Inspecting the Lift Chains 96
Checking the Lift Chain Stretch 98
Assembly 99
Installing the Lift Chains on the Primary Cylinder 99
Inspecting the Fork Height101
Preparing the Lift Truck for Operation102
Lift Chains - Secondary Cylinder102
Disassembly102
Preparing the Lift Truck for Maintenance102
Removing the Lift Chains from the Secondary Cylinder102
Inspecting the Lift Chains103
Checking the Lift Chain Stretch105
Assembly106
Installing the Lift Chains on the Secondary Cylinder106
Inspecting the Fork Height108
Preparing the Lift Truck for Operation109
Mast110
Technician Tips110
Technician Tips110
Tools and Equipment110
Recommended Tools and Equipment110
Additional Tools and Equipment110
Mast Torque Requirements111
Mast Torque Requirements111
Inspecting and Lubricating the Mast112
Inspecting and Lubricating the Mast112
Fixed Mast113
Disassembly113
Preparing the Lift Truck for Maintenance113
Preparing for Removing the Fixed Mast113
Removing the Fixed Mast116
Disassembling the Mast119
Assembly122
Assembling the Mast122
Installing the Fixed Mast125
After Installing the Fixed Mast127
Preparing the Lift Truck for Operation130
Tilting Mast130
Disassembly130
Preparing the Lift Truck for Maintenance130
Preparing for Removing the Tilting Mast131
Removing the Tilting Mast135
Disassembling the Mast135
Assembly139
Assembling the Mast139
Installing the Tilting Mast142
After Installing the Tilting Mast142
Preparing the Lift Truck for Operation146
Adjustments146
Checking the Mast146
Adjusting the Mast Tilt147
Removing the Mast Rollers150
Calculating the Mast Roller Diameter151
Installing the Mast Rollers153
Calculating the Number of Shims Required153
Shims Required for First and Second Mast Section153
Shims Required for Second and Third Mast Section155
After Calculating the Number of Shims Required156
Adjusting the Guide Pads156
Adjusting the Anti-Rattle Screws on Fixed Masts159
Adjusting the Anti-Rattle Screws on Tilting Masts160
Reach Assembly162
Theory of Operation162
Theory of Operation162
Tools and Equipment162
Recommended Tools and Equipment162
Additional Tools and Equipment162
Disassembly163
Preparing the Lift Truck for Maintenance163
Removing the Reach Carriage163
Inspecting the Reach Carriage164
Assembly164
Installing the Reach Carriage164
Adjusting the Reach Carriage with Side Rollers165
Adjusting the Backing Rollers on Reach Carriages with Side Rollers167
Adjusting the Reach Carriage with Slide Bolts168
Adjusting the Backing Rollers on Reach Carriages with Slide Bolts170
Adjusting the Reach Carriage to the Battery Tray171
Preparing the Lift Truck for Operation172
Troubleshooting172
Troubleshooting172
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Load Wheel 14
Theory of Operation 14
Theory of Operation 14
Tools and Equipment 14
Recommended Tools and Equipment 14
Additional Tools and Equipment 14
Load Wheel Attached with a Snap Ring 15
Disassembly 15
Preparing the Lift Truck for Maintenance 15
Removing a Load Wheel Attached with a Snap Ring 15
Inspecting the Load Wheel 15
Assembly 16
Installing a Load Wheel Attached with a Snap Ring 16
Preparing the Lift Truck for Operation 16
Load Wheel Attached with a Nut 16
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing a Load Wheel Attached with a Nut 17
Inspecting the Load Wheel 18
Assembly 18
Installing a Load Wheel Attached with a Nut 18
Preparing the Lift Truck for Operation 19
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
Preparing the Lift Truck for Operation 14
Steering Wheel 15
Technician Tips 15
Technician Tips 15
Theory of Operation 15
Theory of Operation 15
Tools and Equipment 15
Recommended Tools and Equipment 15
Additional Tools and Equipment 15
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing the Steering Wheel 16
Inspecting the Steering Wheel 18
Assembly 18
Installing the Steering Wheel 18
Preparing the Lift Truck for Operation 19
Troubleshooting 20
Troubleshooting 20
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Menu Structure 14
Introduction 14
Adjusting the Settings 16
Menus 16
Auto Height Select 34
Theory of Operation 34
Theory of Operation 34
System Interaction 34
System Interaction 34
Raise and Lower Cutouts 40
Theory of Operation 40
Theory of Operation 40
System Interaction 40
Raise and Lower Cutouts 40
5th and 6th Function 44
System Interaction 44
5th and 6th Function 44
User Performance 47
Theory of Operation 47
Theory of Operation 47
System Interaction 47
System Interaction 47
Performance Settings 50
System Interaction 50
Performance Settings 50
Performance Settings and Effects 54
Performance Settings and Effects 54
Operational Hours 76
System Interaction 76
Set the Operational Hours After Replacing the Access 41 76
Widgets 79
System Interaction 79
System Interaction 79
Widgets 80
Adding a Widget to the Home Screen 82
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Preparing the Stopping Distance Test Route 14
Testing the Stopping Distance 14
Preparing the Lift Truck for Operation 15
Troubleshooting 16
Troubleshooting 16
Brake - M31 17
Theory of Operation 17
Theory of Operation 17
Tools and Equipment 17
Recommended Tools and Equipment 17
Additional Tools and Equipment 17
Disassembly 17
Preparing the Lift Truck for Maintenance 17
Removing the M31 Traction Brake 18
Disassembling the M31 Traction Brake 19
Inspecting the M31 Traction Brake 19
Assembly 19
Assembling the M31 Traction Brake 19
Installing the M31 Traction Brake 20
Checking the Brake Torque 21
Checking and Adjusting the Air Gap 22
Preparing the Lift Truck for Operation 22
Troubleshooting 23
Troubleshooting 23
Drive Tire 24
Tools and Equipment 24
Recommended Tools and Equipment 24
Additional Tools and Equipment 24
Disassembly 24
Preparing the Lift Truck for Maintenance 24
Removing the Drive Tire 25
Inspecting the Drive Tire 25
Assembly 25
Installing the Drive Tire 25
Preparing the Lift Truck for Operation 26
Drive Unit 27
Tools and Equipment 27
Recommended Tools and Equipment 27
Additional Tools and Equipment 27
Disassembly 27
Preparing the Lift Truck for Maintenance 27
Removing the Drive Unit 28
Inspecting the Drive Unit 28
Assembly 29
Installing the Drive Unit 29
Preparing the Lift Truck for Operation 29
Troubleshooting 30
Troubleshooting 30
Pinion Repair Set 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 31
Disassembly 31
Inspecting the Gearbox Pinion 31
Preparing the Lift Truck for Maintenance 32
Removing the Gearbox Pinion 33
Assembly 34
Installing the Gearbox Pinion 34
Preparing the Lift Truck for Operation 36
Rotor Repair Set 37
Theory of Operation 37
Theory of Operation 37
Tools and Equipment 37
Recommended Tools and Equipment 37
Disassembly 38
Inspecting the Rotor Teeth 38
Preparing the Lift Truck for Maintenance 38
Removing the Rotor 38
Assembly 42
Installing the Rotor 42
Preparing the Lift Truck for Operation 46
Motor - M31 47
Technician Tips 47
Technician Tips 47
Theory of Operation 47
Theory of Operation 47
Tools and Equipment 47
Recommended Tools and Equipment 47
Additional Tools and Equipment 48
Disassembly 48
Preparing the Lift Truck for Maintenance 48
Removing the Traction Motor 48
Disassembling the Traction Motor 49
Inspecting the Traction Motor 51
Assembly 51
Assembling the Traction Motor 51
Installing the Traction Motor 53
Preparing the Lift Truck for Operation 53
Troubleshooting 54
Troubleshooting 54
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Diagram Key 14
Main Harness and Connector Figure 17
Pictorials - Electrical 19
Pictorials - Electrical (ESR1020 -F and ESR1040 -F) 19
Pictorials - Electrical (ESR1020 -T and ESR1040 -T) 42
Pictorials - Electrical (ESR1060, Standard) 61
Pictorials - Electrical (ESR1060 -RX) 86
Schematics - Electrical110
Schematics - Electrical (ESR 1020/1040)110
Schematics - Electrical (ESR 1060)112
Schematics - Electrical (ESR 1060 -RX)114
Schematics - Hydraulic116
ESR -F116
ESR -F118
ESR -T120
ESR1060 -RX122
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
Installing the Battery 14
Installation Procedure With a Battery Roller Stand 14
Installation Procedure With a Lifting Device 14
Securing the Battery in the Lift Truck 14
Discharging the Capacitors 15
General Hot Work Instructions 16
Releasing the Hydraulic Pressure 17
Parking Brake 17
Releasing the Parking Brake 17
Applying the Parking Brake 18
Towing the Lift Truck 18
Preparing for Towing the Lift Truck 19
Towing the Lift Truck by Lifting and Pulling in the Power Unit First Direction 19
Towing the Lift Truck by Pulling in the Forks First Direction 20
Lifting and Blocking 21
Lifting and Blocking the Outriggers 21
Lifting and Blocking the Power Unit 21
Blocking the Masts 22
Securing the Fork Carriage 23
Blocking the Reach Mechanism 23
Preparing the Mast for Removal 24
Lifting the Lift Truck 25
Lifting the Lift Truck 25
Preparing for Lifting the Lift Truck 25
Attaching the Lifting Equipment to the Overhead Guard 26
Attaching Lifting Equipment for Standard Overhead Guard 26
Attaching Lifting Equipment for Clear Overhead Guard 27
Attaching Lifting Equipment for Cold Storage Cabin 27
Completing Preparation for Lifting the Lift Truck 28
Transporting the Lift Truck 30
Securing a Lift Truck on a Loading Surface for Transport 30
Securing the Mast to a Loading Surface for Transport 31
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Icons 14
Visual Inspection 14
Operational Check and Test Drive 15
Preparing the Lift Truck for Maintenance 15
Inspection and Lubrication 16
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Access 31 14
Access 41 15
Access 51 16
Accessory Pump (ESR1060 -RX) 17
Accessory Pump Motor (ESR1060 -RX) 18
19
Adjustment Valve Lowering Speed 20
Auto Height Select Switch 22
Battery Latch Switch 23
Brake Fluid Switch 24
Brake Potentiometer 25
Brake Pressure Switch 26
Camera Switch 27
CAN Card 28
Card Reader 29
Emergency Disconnect Contactor 30
Emergency Disconnect Switch 1 31
Emergency Disconnect Switch 2 32
Xpress Lower Proportional Valve 1 (ESR1060 -RX) 33
Xpress Lower Proportional Valve 2 (ESR1060 -RX) 34
Xpress Lower Proportional Valve 3 (ESR1060 -RX) 35
Forks First Switch 36
Free-Lift Switch 37
Fuse 1 39
Fuse 2 41
Fuse 3 43
Fuse 4 44
Fuse 5 45
Fuse 6 46
Fuse 7 47
Fuse 8 48
Fuse 9 49
Fuse 10 50
Fuse 11 (ESR1060 -RX) 51
Height Encoder 1 52
Height Encoder 2 53
Height Reset Switch 1 54
Height Reset Switch 2 55
Hoist Solenoid Valve 56
Horn 58
Horn Switch 59
Impact Sensor 60
Key Switch 61
Keyless Power Module 62
Left Accessory Proportional Valve 63
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction 1
Event Codes 9
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Removing the Main Pump 14
Inspecting the Main Pump 14
Assembly 15
Installing the Main Pump 15
Priming the Main Pump 16
Preparing the Lift Truck for Operation 16
Manifold - Main 18
Checking the 18
System 20
Functional Descriptions (ESR-F) 20
Lifting 20
Lowering 21
Extending the Reach Mechanism 23
Retracting the Reach Mechanism 25
Tilting the Fork Up 26
Tilting the Fork Down 28
Sideshift Right 29
Sideshift Left 31
5th Function A 32
5th Function B 33
Functional Descriptions (ESR-T) 35
Lifting 35
Lowering 36
Extending the Reach Mechanism 38
Retracting the Reach Mechanism 39
Tilting the Mast Towards the Operator 41
Tilting the Mast in the Direction of the Forks 42
Sideshift Right 43
Sideshift Left 45
Functional Descriptions (ESR-RX) 46
Lifting 46
Regenerative Lowering 47
Extending the Reach Mechanism 48
Retracting the Reach Mechanism 49
Tilting the Fork Up 50
Tilting the Fork Down 52
Sideshift Right 53
Sideshift Left 55
5th Function A 56
5th Function B 58
Drift Tests 59
Preparing the Lift Truck for Maintenance 59
Drift Tests 59
Recommended Tools and Equipment 59
Additional Tools and Equipment 60
Requirements 60
Performing a Drift Test on the Primary and Secondary Cylinders 60
Performing a Drift Test on the Tilt Cylinder 61
Checking and Adjusting the Relief Valve 1 62
Preparing the Lift Truck for Operation 63
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Removing the Fork Carriage Control Cable 15
Removing the Camera Control Cable 18
Inspecting the Control Cables 21
Assembly 21
Installing the Camera Control Cable 21
Installing the Fork Carriage Control Cable 24
Installing the Mast Control Cable 27
Adjusting the Tension 30
Preparing the Lift Truck for Operation 30
Troubleshooting 30
Troubleshooting 30
Cylinder - Primary 31
Technician Tips 31
Technician Tips 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 32
Small Hook Tool 32
Disassembly 32
Preparing the Lift Truck for Maintenance 32
Removing the Primary Cylinder 33
Disassembling the Primary Cylinder 34
Inspecting the Primary Cylinder 34
Assembly 35
Assembling the Primary Cylinder 35
Installing the Primary Cylinder 36
Bleeding the Cylinder 36
Testing the Cylinder Seal for Leaks 38
Preparing the Lift Truck for Operation 39
Cylinder - Reach 40
Tools and Equipment 40
Recommended Tools and Equipment 40
Additional Tools and Equipment 40
Disassembly 41
Preparing the Lift Truck for Maintenance 41
Removing the Reach Cylinder 41
Disassembling the Reach Cylinder 43
Inspecting the Reach Cylinder 44
Assembly 44
Assembling the Reach Cylinder 44
Installing the Reach Cylinder 45
Bleeding the Reach Cylinder 45
Preparing the Lift Truck for Operation 45
Testing the Cylinder Seal for Leaks 46
Troubleshooting 47
Troubleshooting 47
Cylinder - Secondary 48
Tools and Equipment 48
Recommended Tools and Equipment 48
Additional Tools and Equipment 48
Disassembly 49
Preparing the Lift Truck for Maintenance 49
Removing the Secondary Cylinder from Masts with a Lift Height up to 8 m (315 in) 49
Removing the Secondary Cylinder from Masts with a Lift Height Greater Than 8 m (315 in) 52
Disassembling the Secondary Cylinder 55
Disassembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 57
Inspecting the Secondary Cylinder 59
Assembly 59
Assembling the Secondary Cylinder 59
Assembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 61
Installing the Secondary Cylinder on Masts with a Lift Height up to 8 m (315 in) 63
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Load Wheel 14
Theory of Operation 14
Theory of Operation 14
Tools and Equipment 14
Recommended Tools and Equipment 14
Additional Tools and Equipment 14
Load Wheel Attached with a Snap Ring 15
Disassembly 15
Preparing the Lift Truck for Maintenance 15
Removing a Load Wheel Attached with a Snap Ring 15
Inspecting the Load Wheel 15
Assembly 16
Installing a Load Wheel Attached with a Snap Ring 16
Preparing the Lift Truck for Operation 16
Load Wheel Attached with a Nut 16
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing a Load Wheel Attached with a Nut 17
Inspecting the Load Wheel 18
Assembly 18
Installing a Load Wheel Attached with a Nut 18
Preparing the Lift Truck for Operation 19
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
Preparing the Lift Truck for Operation 14
Steering Wheel 15
Technician Tips 15
Technician Tips 15
Theory of Operation 15
Theory of Operation 15
Tools and Equipment 15
Recommended Tools and Equipment 15
Additional Tools and Equipment 15
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing the Steering Wheel 16
Inspecting the Steering Wheel 18
Assembly 18
Installing the Steering Wheel 18
Preparing the Lift Truck for Operation 19
Troubleshooting 20
Troubleshooting 20
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Menu Structure 14
Introduction 14
Adjusting the Settings 16
Menus 16
Auto Height Select 34
Theory of Operation 34
Theory of Operation 34
System Interaction 34
System Interaction 34
Raise and Lower Cutouts 40
Theory of Operation 40
Theory of Operation 40
System Interaction 40
Raise and Lower Cutouts 40
5th and 6th Function 44
System Interaction 44
5th and 6th Function 44
User Performance 47
Theory of Operation 47
Theory of Operation 47
System Interaction 47
System Interaction 47
Performance Settings 50
System Interaction 50
Performance Settings 50
Performance Settings and Effects 54
Performance Settings and Effects 54
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Preparing the Stopping Distance Test Route 14
Testing the Stopping Distance 14
Preparing the Lift Truck for Operation 15
Troubleshooting 16
Troubleshooting 16
Brake - M31 17
Theory of Operation 17
Theory of Operation 17
Tools and Equipment 17
Recommended Tools and Equipment 17
Additional Tools and Equipment 17
Disassembly 17
Preparing the Lift Truck for Maintenance 17
Removing the M31 Traction Brake 18
Disassembling the M31 Traction Brake 19
Inspecting the M31 Traction Brake 19
Assembly 19
Assembling the M31 Traction Brake 19
Installing the M31 Traction Brake 20
Checking the Brake Torque 21
Checking and Adjusting the Air Gap 22
Preparing the Lift Truck for Operation 22
Troubleshooting 23
Troubleshooting 23
Drive Tire 24
Tools and Equipment 24
Recommended Tools and Equipment 24
Additional Tools and Equipment 24
Disassembly 24
Preparing the Lift Truck for Maintenance 24
Removing the Drive Tire 25
Inspecting the Drive Tire 25
Assembly 25
Installing the Drive Tire 25
Preparing the Lift Truck for Operation 26
Drive Unit 27
Tools and Equipment 27
Recommended Tools and Equipment 27
Additional Tools and Equipment 27
Disassembly 27
Preparing the Lift Truck for Maintenance 27
Removing the Drive Unit 28
Inspecting the Drive Unit 28
Assembly 29
Installing the Drive Unit 29
Preparing the Lift Truck for Operation 29
Troubleshooting 30
Troubleshooting 30
Pinion Repair Set 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 31
Disassembly 31
Inspecting the Gearbox Pinion 31
Preparing the Lift Truck for Maintenance 32
Removing the Gearbox Pinion 33
Assembly 34
Installing the Gearbox Pinion 34
Preparing the Lift Truck for Operation 36
Rotor Repair Set 37
Theory of Operation 37
Theory of Operation 37
Tools and Equipment 37
Recommended Tools and Equipment 37
Disassembly 38
Inspecting the Rotor Teeth 38
Preparing the Lift Truck for Maintenance 38
Removing the Rotor 38
Assembly 42
Installing the Rotor 42
Preparing the Lift Truck for Operation 46
Motor - M31 47
Technician Tips 47
Technician Tips 47
Theory of Operation 47
Theory of Operation 47
Tools and Equipment 47
Recommended Tools and Equipment 47
Additional Tools and Equipment 48
Disassembly 48
Preparing the Lift Truck for Maintenance 48
Removing the Traction Motor 48
Disassembling the Traction Motor 49
Inspecting the Traction Motor 51
Assembly 51
Assembling the Traction Motor 51
Installing the Traction Motor 53
Preparing the Lift Truck for Operation 53
Troubleshooting 54
Troubleshooting 54
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Diagram Key 14
Main Harness and Connector Figure 17
Pictorials - Electrical 19
Pictorials - Electrical (ESR1020 -F and ESR1040 -F) 19
Pictorials - Electrical (ESR1020 -T and ESR1040 -T) 42
Pictorials - Electrical (ESR1060, Standard) 61
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
Installing the Battery 14
Installation Procedure With a Battery Roller Stand 14
Installation Procedure With a Lifting Device 14
Securing the Battery in the Lift Truck 14
Discharging the Capacitors 15
General Hot Work Instructions 16
Releasing the Hydraulic Pressure 17
Parking Brake 17
Releasing the Parking Brake 17
Applying the Parking Brake 18
Towing the Lift Truck 18
Preparing for Towing the Lift Truck 19
Towing the Lift Truck by Lifting and Pulling in the Power Unit First Direction 19
Towing the Lift Truck by Pulling in the Forks First Direction 20
Lifting and Blocking 21
Lifting and Blocking the Outriggers 21
Lifting and Blocking the Power Unit 21
Blocking the Masts 22
Securing the Fork Carriage 23
Blocking the Reach Mechanism 23
Preparing the Mast for Removal 24
Lifting the Lift Truck 25
Lifting the Lift Truck 25
Preparing for Lifting the Lift Truck 25
Attaching the Lifting Equipment to the Overhead Guard 26
Attaching Lifting Equipment for Standard Overhead Guard 26
Attaching Lifting Equipment for Clear Overhead Guard 27
Attaching Lifting Equipment for Cold Storage Cabin 27
Completing Preparation for Lifting the Lift Truck 28
Transporting the Lift Truck 30
Securing a Lift Truck on a Loading Surface for Transport 30
Securing the Mast to a Loading Surface for Transport 31
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Icons 14
Visual Inspection 14
Operational Check and Test Drive 15
Preparing the Lift Truck for Maintenance 15
Inspection and Lubrication 16
Preparing the Lift Truck for Operation110
Final Operational Check and Test Drive110
Planned Maintenance Completion110
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Access 31 14
Access 41 15
Access 51 16
Accessory Pump (ESR1060 -RX) 17
Accessory Pump Motor (ESR1060 -RX) 18
19
Adjustment Valve Lowering Speed 20
Auto Height Select Switch 22
Battery Latch Switch 23
Brake Fluid Switch 24
Brake Potentiometer 25
Brake Pressure Switch 26
Camera Switch 27
CAN Card 28
Card Reader 29
Emergency Disconnect Contactor 30
Emergency Disconnect Switch 1 31
Emergency Disconnect Switch 2 32
Xpress Lower Proportional Valve 1 (ESR1060 -RX) 33
Xpress Lower Proportional Valve 2 (ESR1060 -RX) 34
Xpress Lower Proportional Valve 3 (ESR1060 -RX) 35
Forks First Switch 36
Free-Lift Switch 37
Fuse 1 39
Fuse 2 41
Fuse 3 43
Fuse 4 44
Fuse 5 45
Fuse 6 46
Fuse 7 47
Fuse 8 48
Fuse 9 49
Fuse 10 50
Fuse 11 (ESR1060 -RX) 51
Height Encoder 1 52
Height Encoder 2 53
Height Reset Switch 1 54
Height Reset Switch 2 55
Hoist Solenoid Valve 56
Horn 58
Horn Switch 59
Impact Sensor 60
Key Switch 61
Keyless Power Module 62
Left Accessory Proportional Valve 63
Left Accessory Solenoid Valve (ESR1060 -RX) 64
Main Pump 65
Line Contactor 66
Load Sensor 1 67
Load Sensor 2 68
Lower Proportional Valve 69
Lower Solenoid Valve (ESR1060 -RX) 71
M21 Encoder 72
M21 Fan (ESR1060) 73
M21 Thermal Sensor 74
M22 Encoder (ESR1060 -RX) 75
M22 Thermal Sensor (ESR1060 -RX) 76
M31 Encoder 77
M31 Fan (ESR1060) 78
M31 Thermal Sensor 79
M31 Traction Brake 80
M51 Sensor 1 81
M51 Sensor 2 82
M51 Thermal Sensor 83
Main Hoist Sensor 84
Main Pump Motor 86
Manual Lowering Valve 88
Override Switch 90
Power Unit First Switch 91
Reach Position Sensor 1 92
Reach Position Sensor 2 93
Reach Proportional Valve 94
Reach Sensor 96
Reach Solenoid Valve (ESR1060 -RX) 98
Relay 1 99
Relay 2100
Relay 3101
Relay 4102
Relay 5103
Relay 6104
Relay 9105
Relay 10106
Relay 22107
Relay 23108
Relief Valve 1109
Relief Valve 2111
Retract Proportional Valve112
Retract Solenoid Valve (ESR1060 -RX)114
Right Accessory Proportional Valve115
Right Accessory Solenoid Valve (ESR1060 -RX)116
Safety Pedal Sensor117
Seat Heater Switch118
Seat Switch119
Selector Encoder120
Selector Switch121
Sideshift Left Solenoid Valve (ESR1020 -T and ESR1040 -T)122
Sideshift Position Sensor123
Sideshift Right Solenoid Valve (ESR1020 -T and ESR1040 -T)124
Sideshift Sensor125
Sideshift Solenoid Valve127
Speaker129
Steer Motor130
Steer Sensor 1132
Steer Sensor 2133
Steering Sensor 1134
Steering Sensor 2135
Temperature Sensor136
Tilt Down Solenoid Valve (ESR1020 -T and ESR1040 -T)137
Tilt Position Sensor138
Tilt Sensor139
Tilt Solenoid Valve141
Tilt Up Solenoid Valve (ESR1020 -T and ESR1040 -T)143
Traction Motor144
Traction Potentiometer146
Traction Switch147
Travel Alarm148
Warning Light 1149
Warning Light 2150
Warning Light 3151
Worklight 1152
Worklight 2153
Worklight Switch154
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction 1
Event Codes 9
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Removing the Main Pump 14
Inspecting the Main Pump 14
Assembly 15
Installing the Main Pump 15
Priming the Main Pump 16
Preparing the Lift Truck for Operation 16
Manifold - Main 18
Checking the 18
System 20
Functional Descriptions (ESR-F) 20
Lifting 20
Lowering 21
Extending the Reach Mechanism 23
Retracting the Reach Mechanism 25
Tilting the Fork Up 26
Tilting the Fork Down 28
Sideshift Right 29
Sideshift Left 31
5th Function A 32
5th Function B 33
Functional Descriptions (ESR-T) 35
Lifting 35
Lowering 36
Extending the Reach Mechanism 38
Retracting the Reach Mechanism 39
Tilting the Mast Towards the Operator 41
Tilting the Mast in the Direction of the Forks 42
Sideshift Right 43
Sideshift Left 45
Functional Descriptions (ESR-RX) 46
Lifting 46
Regenerative Lowering 47
Extending the Reach Mechanism 48
Retracting the Reach Mechanism 49
Tilting the Fork Up 50
Tilting the Fork Down 52
Sideshift Right 53
Sideshift Left 55
5th Function A 56
5th Function B 58
Drift Tests 59
Preparing the Lift Truck for Maintenance 59
Drift Tests 59
Recommended Tools and Equipment 59
Additional Tools and Equipment 60
Requirements 60
Performing a Drift Test on the Primary and Secondary Cylinders 60
Performing a Drift Test on the Tilt Cylinder 61
Checking and Adjusting the Relief Valve 1 62
Preparing the Lift Truck for Operation 63
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Removing the Fork Carriage Control Cable 15
Removing the Camera Control Cable 18
Inspecting the Control Cables 21
Assembly 21
Installing the Camera Control Cable 21
Installing the Fork Carriage Control Cable 24
Installing the Mast Control Cable 27
Adjusting the Tension 30
Preparing the Lift Truck for Operation 30
Troubleshooting 30
Troubleshooting 30
Cylinder - Primary 31
Technician Tips 31
Technician Tips 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 32
Small Hook Tool 32
Disassembly 32
Preparing the Lift Truck for Maintenance 32
Removing the Primary Cylinder 33
Disassembling the Primary Cylinder 34
Inspecting the Primary Cylinder 34
Assembly 35
Assembling the Primary Cylinder 35
Installing the Primary Cylinder 36
Bleeding the Cylinder 36
Testing the Cylinder Seal for Leaks 38
Preparing the Lift Truck for Operation 39
Cylinder - Reach 40
Tools and Equipment 40
Recommended Tools and Equipment 40
Additional Tools and Equipment 40
Disassembly 41
Preparing the Lift Truck for Maintenance 41
Removing the Reach Cylinder 41
Disassembling the Reach Cylinder 43
Inspecting the Reach Cylinder 44
Assembly 44
Assembling the Reach Cylinder 44
Installing the Reach Cylinder 45
Bleeding the Reach Cylinder 45
Preparing the Lift Truck for Operation 45
Testing the Cylinder Seal for Leaks 46
Troubleshooting 47
Troubleshooting 47
Cylinder - Secondary 48
Tools and Equipment 48
Recommended Tools and Equipment 48
Additional Tools and Equipment 48
Disassembly 49
Preparing the Lift Truck for Maintenance 49
Removing the Secondary Cylinder from Masts with a Lift Height up to 8 m (315 in) 49
Removing the Secondary Cylinder from Masts with a Lift Height Greater Than 8 m (315 in) 52
Disassembling the Secondary Cylinder 55
Disassembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 57
Inspecting the Secondary Cylinder 59
Assembly 59
Assembling the Secondary Cylinder 59
Assembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 61
Installing the Secondary Cylinder on Masts with a Lift Height up to 8 m (315 in) 63
Installing the Secondary Cylinder on Masts with a Lift Height Greater than 8 m (315 in) 66
Bleeding the Secondary Cylinder 69
Preparing a Test Load 69
Secondary Cylinder Drift Test 69
Preparing the Lift Truck for Operation 70
Troubleshooting 71
Troubleshooting 71
Cylinder - Sideshift 72
Tools and Equipment 72
Recommended Tools and Equipment 72
Additional Tools and Equipment 72
Disassembly 73
Preparing the Lift Truck for Maintenance 73
Disassembling the Sideshift Cylinder 73
Inspecting the Sideshift Cylinder 74
Assembly 75
Assembling the Sideshift Cylinder 75
Bleeding the Sideshift Cylinder 76
Preparing the Lift Truck for Operation 76
Troubleshooting 76
Troubleshooting 76
Cylinder - Tilt 77
Theory of Operation 77
Theory of Operation 77
Tools and Equipment 77
Recommended Tools and Equipment 77
Additional Tools and Equipment 77
Disassembly 78
Preparing the Lift Truck for Maintenance 78
Removing the Tilt Cylinder 78
Inspecting the Tilt Cylinder 79
Assembly 80
Installing the Tilt Cylinder 80
Bleeding the Tilt Cylinder 81
Preparing the Lift Truck for Operation 81
Troubleshooting 81
Troubleshooting 81
Fork Inspection 82
Tools and Equipment 82
Recommended Tools and Equipment 82
Additional Tools and Equipment 82
Inspection 82
Preparing the Lift Truck for Maintenance 82
Introduction 83
Identification 84
Measuring the Fork Blade for Wear 84
Checking for Fatigue Cracks 86
Bent or Twisted Forks 86
Checking the Fork Tip for Straightness 87
Fork Locking Pin 88
Preparing the Lift Truck for Operation 88
Height Encoder 90
Tools and Equipment 90
Recommended Tools and Equipment 90
Disassembly 90
Preparing the Lift Truck for Maintenance 90
Removing Height Encoder 1 (ESR -F) 90
Removing Height Encoder 2 (ESR -F) 91
Assembly 92
Installing Height Encoder 1 (ESR -F) 92
Installing Height Encoder 2 (ESR -F) 92
Preparing the Lift Truck for Operation 93
Hydraulic Lines and Fittings 94
Technician Tips 94
Technician Tips 94
Lift Chains 95
Tools and Equipment 95
Recommended Tools and Equipment 95
Additional Tools and Equipment 95
Lift Chains - Primary Cylinder 95
Disassembly 95
Preparing the Lift Truck for Maintenance 95
Removing the Lift Chains from the Primary Cylinder 96
Inspecting the Lift Chains 96
Checking the Lift Chain Stretch 98
Assembly 99
Installing the Lift Chains on the Primary Cylinder 99
Inspecting the Fork Height101
Preparing the Lift Truck for Operation102
Lift Chains - Secondary Cylinder102
Disassembly102
Preparing the Lift Truck for Maintenance102
Removing the Lift Chains from the Secondary Cylinder102
Inspecting the Lift Chains103
Checking the Lift Chain Stretch105
Assembly106
Installing the Lift Chains on the Secondary Cylinder106
Inspecting the Fork Height108
Preparing the Lift Truck for Operation109
Mast110
Technician Tips110
Technician Tips110
Tools and Equipment110
Recommended Tools and Equipment110
Additional Tools and Equipment110
Mast Torque Requirements111
Mast Torque Requirements111
Inspecting and Lubricating the Mast112
Inspecting and Lubricating the Mast112
Fixed Mast113
Disassembly113
Preparing the Lift Truck for Maintenance113
Preparing for Removing the Fixed Mast113
Removing the Fixed Mast116
Disassembling the Mast119
Assembly122
Assembling the Mast122
Installing the Fixed Mast125
After Installing the Fixed Mast127
Preparing the Lift Truck for Operation130
Tilting Mast130
Disassembly130
Preparing the Lift Truck for Maintenance130
Preparing for Removing the Tilting Mast131
Removing the Tilting Mast135
Disassembling the Mast135
Assembly139
Assembling the Mast139
Installing the Tilting Mast142
After Installing the Tilting Mast142
Preparing the Lift Truck for Operation146
Adjustments146
Checking the Mast146
Adjusting the Mast Tilt147
Removing the Mast Rollers150
Calculating the Mast Roller Diameter151
Installing the Mast Rollers153
Calculating the Number of Shims Required153
Shims Required for First and Second Mast Section153
Shims Required for Second and Third Mast Section155
After Calculating the Number of Shims Required156
Adjusting the Guide Pads156
Adjusting the Anti-Rattle Screws on Fixed Masts159
Adjusting the Anti-Rattle Screws on Tilting Masts160
Reach Assembly162
Theory of Operation162
Theory of Operation162
Tools and Equipment162
Recommended Tools and Equipment162
Additional Tools and Equipment162
Disassembly163
Preparing the Lift Truck for Maintenance163
Removing the Reach Carriage163
Inspecting the Reach Carriage164
Assembly164
Installing the Reach Carriage164
Adjusting the Reach Carriage with Side Rollers165
Adjusting the Backing Rollers on Reach Carriages with Side Rollers167
Adjusting the Reach Carriage with Slide Bolts168
Adjusting the Backing Rollers on Reach Carriages with Slide Bolts170
Adjusting the Reach Carriage to the Battery Tray171
Preparing the Lift Truck for Operation172
Troubleshooting172
Troubleshooting172
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Load Wheel 14
Theory of Operation 14
Theory of Operation 14
Tools and Equipment 14
Recommended Tools and Equipment 14
Additional Tools and Equipment 14
Load Wheel Attached with a Snap Ring 15
Disassembly 15
Preparing the Lift Truck for Maintenance 15
Removing a Load Wheel Attached with a Snap Ring 15
Inspecting the Load Wheel 15
Assembly 16
Installing a Load Wheel Attached with a Snap Ring 16
Preparing the Lift Truck for Operation 16
Load Wheel Attached with a Nut 16
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing a Load Wheel Attached with a Nut 17
Inspecting the Load Wheel 18
Assembly 18
Installing a Load Wheel Attached with a Nut 18
Preparing the Lift Truck for Operation 19
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
Preparing the Lift Truck for Operation 14
Steering Wheel 15
Technician Tips 15
Technician Tips 15
Theory of Operation 15
Theory of Operation 15
Tools and Equipment 15
Recommended Tools and Equipment 15
Additional Tools and Equipment 15
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing the Steering Wheel 16
Inspecting the Steering Wheel 18
Assembly 18
Installing the Steering Wheel 18
Preparing the Lift Truck for Operation 19
Troubleshooting 20
Troubleshooting 20
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Menu Structure 14
Introduction 14
Adjusting the Settings 16
Menus 16
Auto Height Select 34
Theory of Operation 34
Theory of Operation 34
System Interaction 34
System Interaction 34
Raise and Lower Cutouts 40
Theory of Operation 40
Theory of Operation 40
System Interaction 40
Raise and Lower Cutouts 40
5th and 6th Function 44
System Interaction 44
5th and 6th Function 44
User Performance 47
Theory of Operation 47
Theory of Operation 47
System Interaction 47
System Interaction 47
Performance Settings 50
System Interaction 50
Performance Settings 50
Performance Settings and Effects 54
Performance Settings and Effects 54
Operational Hours 76
System Interaction 76
Set the Operational Hours After Replacing the Access 41 76
Widgets 79
System Interaction 79
System Interaction 79
Widgets 80
Adding a Widget to the Home Screen 82
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Preparing the Stopping Distance Test Route 14
Testing the Stopping Distance 14
Preparing the Lift Truck for Operation 15
Troubleshooting 16
Troubleshooting 16
Brake - M31 17
Theory of Operation 17
Theory of Operation 17
Tools and Equipment 17
Recommended Tools and Equipment 17
Additional Tools and Equipment 17
Disassembly 17
Preparing the Lift Truck for Maintenance 17
Removing the M31 Traction Brake 18
Disassembling the M31 Traction Brake 19
Inspecting the M31 Traction Brake 19
Assembly 19
Assembling the M31 Traction Brake 19
Installing the M31 Traction Brake 20
Checking the Brake Torque 21
Checking and Adjusting the Air Gap 22
Preparing the Lift Truck for Operation 22
Troubleshooting 23
Troubleshooting 23
Drive Tire 24
Tools and Equipment 24
Recommended Tools and Equipment 24
Additional Tools and Equipment 24
Disassembly 24
Preparing the Lift Truck for Maintenance 24
Removing the Drive Tire 25
Inspecting the Drive Tire 25
Assembly 25
Installing the Drive Tire 25
Preparing the Lift Truck for Operation 26
Drive Unit 27
Tools and Equipment 27
Recommended Tools and Equipment 27
Additional Tools and Equipment 27
Disassembly 27
Preparing the Lift Truck for Maintenance 27
Removing the Drive Unit 28
Inspecting the Drive Unit 28
Assembly 29
Installing the Drive Unit 29
Preparing the Lift Truck for Operation 29
Troubleshooting 30
Troubleshooting 30
Pinion Repair Set 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 31
Disassembly 31
Inspecting the Gearbox Pinion 31
Preparing the Lift Truck for Maintenance 32
Removing the Gearbox Pinion 33
Assembly 34
Installing the Gearbox Pinion 34
Preparing the Lift Truck for Operation 36
Rotor Repair Set 37
Theory of Operation 37
Theory of Operation 37
Tools and Equipment 37
Recommended Tools and Equipment 37
Disassembly 38
Inspecting the Rotor Teeth 38
Preparing the Lift Truck for Maintenance 38
Removing the Rotor 38
Assembly 42
Installing the Rotor 42
Preparing the Lift Truck for Operation 46
Motor - M31 47
Technician Tips 47
Technician Tips 47
Theory of Operation 47
Theory of Operation 47
Tools and Equipment 47
Recommended Tools and Equipment 47
Additional Tools and Equipment 48
Disassembly 48
Preparing the Lift Truck for Maintenance 48
Removing the Traction Motor 48
Disassembling the Traction Motor 49
Inspecting the Traction Motor 51
Assembly 51
Assembling the Traction Motor 51
Installing the Traction Motor 53
Preparing the Lift Truck for Operation 53
Troubleshooting 54
Troubleshooting 54
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Diagram Key 14
Main Harness and Connector Figure 17
Pictorials - Electrical 19
Pictorials - Electrical (ESR1020 -F and ESR1040 -F) 19
Pictorials - Electrical (ESR1020 -T and ESR1040 -T) 42
Pictorials - Electrical (ESR1060, Standard) 61
Pictorials - Electrical (ESR1060 -RX) 86
Schematics - Electrical110
Schematics - Electrical (ESR 1020/1040)110
Schematics - Electrical (ESR 1060)112
Schematics - Electrical (ESR 1060 -RX)114
Schematics - Hydraulic116
ESR -F116
ESR -F118
ESR -T120
ESR1060 -RX122
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
Installing the Battery 14
Installation Procedure With a Battery Roller Stand 14
Installation Procedure With a Lifting Device 14
Securing the Battery in the Lift Truck 14
Discharging the Capacitors 15
General Hot Work Instructions 16
Releasing the Hydraulic Pressure 17
Parking Brake 17
Releasing the Parking Brake 17
Applying the Parking Brake 18
Towing the Lift Truck 18
Preparing for Towing the Lift Truck 19
Towing the Lift Truck by Lifting and Pulling in the Power Unit First Direction 19
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Icons 14
Visual Inspection 14
Operational Check and Test Drive 15
Preparing the Lift Truck for Maintenance 15
Inspection and Lubrication 16
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Access 31 14
Access 41 15
Access 51 16
Accessory Pump (ESR1060 -RX) 17
Accessory Pump Motor (ESR1060 -RX) 18
19
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction 1
Event Codes 9
000002006 10
000002058 10
000003006 11
000003058 11
000004000 12
000004003 12
000004004 13
000005000 13
000006059 14
000008001 15
000021000 17
000021001 17
000021016 17
000086000 18
000086016 18
000087000 18
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Removing the Main Pump 14
Inspecting the Main Pump 14
Assembly 15
Installing the Main Pump 15
Priming the Main Pump 16
Preparing the Lift Truck for Operation 16
Manifold - Main 18
Checking the 18
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Removing the Fork Carriage Control Cable 15
Removing the Camera Control Cable 18
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Load Wheel 14
Theory of Operation 14
Theory of Operation 14
Tools and Equipment 14
Recommended Tools and Equipment 14
Additional Tools and Equipment 14
Load Wheel Attached with a Snap Ring 15
Disassembly 15
Preparing the Lift Truck for Maintenance 15
Removing a Load Wheel Attached with a Snap Ring 15
Inspecting the Load Wheel 15
Assembly 16
Installing a Load Wheel Attached with a Snap Ring 16
Preparing the Lift Truck for Operation 16
Load Wheel Attached with a Nut 16
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing a Load Wheel Attached with a Nut 17
Inspecting the Load Wheel 18
Assembly 18
Installing a Load Wheel Attached with a Nut 18
Preparing the Lift Truck for Operation 19
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
Preparing the Lift Truck for Operation 14
Steering Wheel 15
Technician Tips 15
Technician Tips 15
Theory of Operation 15
Theory of Operation 15
Tools and Equipment 15
Recommended Tools and Equipment 15
Additional Tools and Equipment 15
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing the Steering Wheel 16
Inspecting the Steering Wheel 18
Assembly 18
Installing the Steering Wheel 18
Preparing the Lift Truck for Operation 19
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Menu Structure 14
Introduction 14
Adjusting the Settings 16
Menus 16
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Preparing the Stopping Distance Test Route 14
Testing the Stopping Distance 14
Preparing the Lift Truck for Operation 15
Troubleshooting 16
Troubleshooting 16
Brake - M31 17
Theory of Operation 17
Theory of Operation 17
Tools and Equipment 17
Recommended Tools and Equipment 17
Additional Tools and Equipment 17
Disassembly 17
Preparing the Lift Truck for Maintenance 17
Removing the M31 Traction Brake 18
Disassembling the M31 Traction Brake 19
Inspecting the M31 Traction Brake 19
Assembly 19
Assembling the M31 Traction Brake 19
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Diagram Key 14
Main Harness and Connector Figure 17
Pictorials - Electrical 19
Pictorials - Electrical (ESR1020 -F and ESR1040 -F) 19
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
Installing the Battery 14
Installation Procedure With a Battery Roller Stand 14
Installation Procedure With a Lifting Device 14
Securing the Battery in the Lift Truck 14
Discharging the Capacitors 15
General Hot Work Instructions 16
Releasing the Hydraulic Pressure 17
Parking Brake 17
Releasing the Parking Brake 17
Applying the Parking Brake 18
Towing the Lift Truck 18
Preparing for Towing the Lift Truck 19
Towing the Lift Truck by Lifting and Pulling in the Power Unit First Direction 19
Towing the Lift Truck by Pulling in the Forks First Direction 20
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Icons 14
Visual Inspection 14
Operational Check and Test Drive 15
Preparing the Lift Truck for Maintenance 15
Inspection and Lubrication 16
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Access 31 14
Access 41 15
Access 51 16
Accessory Pump (ESR1060 -RX) 17
Accessory Pump Motor (ESR1060 -RX) 18
19
Adjustment Valve Lowering Speed 20
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction 1
Event Codes 9
000002006 10
000002058 10
000003006 11
000003058 11
000004000 12
000004003 12
000004004 13
000005000 13
000006059 14
000008001 15
000021000 17
000021001 17
000021016 17
000086000 18
000086016 18
000087000 18
000088003 20
000088004 20
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Removing the Main Pump 14
Inspecting the Main Pump 14
Assembly 15
Installing the Main Pump 15
Priming the Main Pump 16
Preparing the Lift Truck for Operation 16
Manifold - Main 18
Checking the 18
System 20
Functional Descriptions (ESR-F) 20
Lifting 20
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Removing the Fork Carriage Control Cable 15
Removing the Camera Control Cable 18
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Load Wheel 14
Theory of Operation 14
Theory of Operation 14
Tools and Equipment 14
Recommended Tools and Equipment 14
Additional Tools and Equipment 14
Load Wheel Attached with a Snap Ring 15
Disassembly 15
Preparing the Lift Truck for Maintenance 15
Removing a Load Wheel Attached with a Snap Ring 15
Inspecting the Load Wheel 15
Assembly 16
Installing a Load Wheel Attached with a Snap Ring 16
Preparing the Lift Truck for Operation 16
Load Wheel Attached with a Nut 16
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing a Load Wheel Attached with a Nut 17
Inspecting the Load Wheel 18
Assembly 18
Installing a Load Wheel Attached with a Nut 18
Preparing the Lift Truck for Operation 19
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
Preparing the Lift Truck for Operation 14
Steering Wheel 15
Technician Tips 15
Technician Tips 15
Theory of Operation 15
Theory of Operation 15
Tools and Equipment 15
Recommended Tools and Equipment 15
Additional Tools and Equipment 15
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing the Steering Wheel 16
Inspecting the Steering Wheel 18
Assembly 18
Installing the Steering Wheel 18
Preparing the Lift Truck for Operation 19
Troubleshooting 20
Troubleshooting 20
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Menu Structure 14
Introduction 14
Adjusting the Settings 16
Menus 16
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Preparing the Stopping Distance Test Route 14
Testing the Stopping Distance 14
Preparing the Lift Truck for Operation 15
Troubleshooting 16
Troubleshooting 16
Brake - M31 17
Theory of Operation 17
Theory of Operation 17
Tools and Equipment 17
Recommended Tools and Equipment 17
Additional Tools and Equipment 17
Disassembly 17
Preparing the Lift Truck for Maintenance 17
Removing the M31 Traction Brake 18
Disassembling the M31 Traction Brake 19
Inspecting the M31 Traction Brake 19
Assembly 19
Assembling the M31 Traction Brake 19
Installing the M31 Traction Brake 20
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Diagram Key 14
Main Harness and Connector Figure 17
Pictorials - Electrical 19
Pictorials - Electrical (ESR1020 -F and ESR1040 -F) 19
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
Installing the Battery 14
Installation Procedure With a Battery Roller Stand 14
Installation Procedure With a Lifting Device 14
Securing the Battery in the Lift Truck 14
Discharging the Capacitors 15
General Hot Work Instructions 16
Releasing the Hydraulic Pressure 17
Parking Brake 17
Releasing the Parking Brake 17
Applying the Parking Brake 18
Towing the Lift Truck 18
Preparing for Towing the Lift Truck 19
Towing the Lift Truck by Lifting and Pulling in the Power Unit First Direction 19
Towing the Lift Truck by Pulling in the Forks First Direction 20
Lifting and Blocking 21
Lifting and Blocking the Outriggers 21
Lifting and Blocking the Power Unit 21
Blocking the Masts 22
Securing the Fork Carriage 23
Blocking the Reach Mechanism 23
Preparing the Mast for Removal 24
Lifting the Lift Truck 25
Lifting the Lift Truck 25
Preparing for Lifting the Lift Truck 25
Attaching the Lifting Equipment to the Overhead Guard 26
Attaching Lifting Equipment for Standard Overhead Guard 26
Attaching Lifting Equipment for Clear Overhead Guard 27
Attaching Lifting Equipment for Cold Storage Cabin 27
Completing Preparation for Lifting the Lift Truck 28
Transporting the Lift Truck 30
Securing a Lift Truck on a Loading Surface for Transport 30
Securing the Mast to a Loading Surface for Transport 31
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Icons 14
Visual Inspection 14
Operational Check and Test Drive 15
Preparing the Lift Truck for Maintenance 15
Inspection and Lubrication 16
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Access 31 14
Access 41 15
Access 51 16
Accessory Pump (ESR1060 -RX) 17
Accessory Pump Motor (ESR1060 -RX) 18
19
Adjustment Valve Lowering Speed 20
Auto Height Select Switch 22
Battery Latch Switch 23
Brake Fluid Switch 24
Brake Potentiometer 25
Brake Pressure Switch 26
Camera Switch 27
CAN Card 28
Card Reader 29
Emergency Disconnect Contactor 30
Emergency Disconnect Switch 1 31
Emergency Disconnect Switch 2 32
Xpress Lower Proportional Valve 1 (ESR1060 -RX) 33
Xpress Lower Proportional Valve 2 (ESR1060 -RX) 34
Xpress Lower Proportional Valve 3 (ESR1060 -RX) 35
Forks First Switch 36
Free-Lift Switch 37
Fuse 1 39
Fuse 2 41
Fuse 3 43
Fuse 4 44
Fuse 5 45
Fuse 6 46
Fuse 7 47
Fuse 8 48
Fuse 9 49
Fuse 10 50
Fuse 11 (ESR1060 -RX) 51
Height Encoder 1 52
Height Encoder 2 53
Height Reset Switch 1 54
Height Reset Switch 2 55
Hoist Solenoid Valve 56
Horn 58
Horn Switch 59
Impact Sensor 60
Key Switch 61
Keyless Power Module 62
Left Accessory Proportional Valve 63
Left Accessory Solenoid Valve (ESR1060 -RX) 64
Main Pump 65
Line Contactor 66
Load Sensor 1 67
Load Sensor 2 68
Lower Proportional Valve 69
Lower Solenoid Valve (ESR1060 -RX) 71
M21 Encoder 72
M21 Fan (ESR1060) 73
M21 Thermal Sensor 74
M22 Encoder (ESR1060 -RX) 75
M22 Thermal Sensor (ESR1060 -RX) 76
M31 Encoder 77
M31 Fan (ESR1060) 78
M31 Thermal Sensor 79
M31 Traction Brake 80
M51 Sensor 1 81
M51 Sensor 2 82
M51 Thermal Sensor 83
Main Hoist Sensor 84
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction 1
Event Codes 9
000002006 10
000002058 10
000003006 11
000003058 11
000004000 12
000004003 12
000004004 13
000005000 13
000006059 14
000008001 15
000021000 17
000021001 17
000021016 17
000086000 18
000086016 18
000087000 18
000088003 20
000088004 20
000091003 21
000091004 22
000091061 23
000158003 23
000158004 23
000233003 24
000233004 24
000237002 25
000441000 25
000441001 26
000441016 26
000441018 26
000444001 26
000447002 27
000501002 28
000502059 29
000503004 30
000505004 30
000506003 30
000506004 30
000508000 31
000508001 32
000508016 32
000508018 32
000509002 33
000586003 34
000586004 35
000587003 37
000587004 38
000588003 38
000588004 38
000599000 40
000600003 41
000600004 42
000601003 43
000601004 43
000602003 43
000602004 43
000602058 45
000605004 45
000605059 46
000609012 47
000609052 48
000609100 49
000622002 49
000625003 49
000625004 51
000625009 51
000627003 52
000627004 52
000629012 54
000629052 54
000629056 55
000629057 55
000819000 55
000819016 56
000820000 57
000820016 57
000821003 57
000821004 57
000823003 58
000823004 58
000824000 59
000824016 59
000826003 60
000826004 61
000826005 61
000826006 62
000826059 63
000827016 63
000871009 63
000874003 64
000874004 64
000879006 65
000882003 66
000882004 67
000883003 67
000883004 68
000911003 68
000911004 69
000912003 69
000912004 70
000913003 70
000913004 71
000929003 71
000929004 72
000930003 72
000930004 73
000930053 73
000944003 74
000944004 74
000960006 74
000960058 75
000964061 76
000989003 76
001005003 76
001194003 76
001195004 77
001196003 78
001196004 79
001198003 79
001198004 79
001491003 80
001491004 80
001492003 80
001492004 81
001497001 81
001498001 82
001502004 82
001502005 83
001502006 84
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Removing the Main Pump 14
Inspecting the Main Pump 14
Assembly 15
Installing the Main Pump 15
Priming the Main Pump 16
Preparing the Lift Truck for Operation 16
Manifold - Main 18
Checking the 18
System 20
Functional Descriptions (ESR-F) 20
Lifting 20
Lowering 21
Extending the Reach Mechanism 23
Retracting the Reach Mechanism 25
Tilting the Fork Up 26
Tilting the Fork Down 28
Sideshift Right 29
Sideshift Left 31
5th Function A 32
5th Function B 33
Functional Descriptions (ESR-T) 35
Lifting 35
Lowering 36
Extending the Reach Mechanism 38
Retracting the Reach Mechanism 39
Tilting the Mast Towards the Operator 41
Tilting the Mast in the Direction of the Forks 42
Sideshift Right 43
Sideshift Left 45
Functional Descriptions (ESR-RX) 46
Lifting 46
Regenerative Lowering 47
Extending the Reach Mechanism 48
Retracting the Reach Mechanism 49
Tilting the Fork Up 50
Tilting the Fork Down 52
Sideshift Right 53
Sideshift Left 55
5th Function A 56
5th Function B 58
Drift Tests 59
Preparing the Lift Truck for Maintenance 59
Drift Tests 59
Recommended Tools and Equipment 59
Additional Tools and Equipment 60
Requirements 60
Performing a Drift Test on the Primary and Secondary Cylinders 60
Performing a Drift Test on the Tilt Cylinder 61
Checking and Adjusting the Relief Valve 1 62
Preparing the Lift Truck for Operation 63
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Removing the Fork Carriage Control Cable 15
Removing the Camera Control Cable 18
Inspecting the Control Cables 21
Assembly 21
Installing the Camera Control Cable 21
Installing the Fork Carriage Control Cable 24
Installing the Mast Control Cable 27
Adjusting the Tension 30
Preparing the Lift Truck for Operation 30
Troubleshooting 30
Troubleshooting 30
Cylinder - Primary 31
Technician Tips 31
Technician Tips 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 32
Small Hook Tool 32
Disassembly 32
Preparing the Lift Truck for Maintenance 32
Removing the Primary Cylinder 33
Disassembling the Primary Cylinder 34
Inspecting the Primary Cylinder 34
Assembly 35
Assembling the Primary Cylinder 35
Installing the Primary Cylinder 36
Bleeding the Cylinder 36
Testing the Cylinder Seal for Leaks 38
Preparing the Lift Truck for Operation 39
Cylinder - Reach 40
Tools and Equipment 40
Recommended Tools and Equipment 40
Additional Tools and Equipment 40
Disassembly 41
Preparing the Lift Truck for Maintenance 41
Removing the Reach Cylinder 41
Disassembling the Reach Cylinder 43
Inspecting the Reach Cylinder 44
Assembly 44
Assembling the Reach Cylinder 44
Installing the Reach Cylinder 45
Bleeding the Reach Cylinder 45
Preparing the Lift Truck for Operation 45
Testing the Cylinder Seal for Leaks 46
Troubleshooting 47
Troubleshooting 47
Cylinder - Secondary 48
Tools and Equipment 48
Recommended Tools and Equipment 48
Additional Tools and Equipment 48
Disassembly 49
Preparing the Lift Truck for Maintenance 49
Removing the Secondary Cylinder from Masts with a Lift Height up to 8 m (315 in) 49
Removing the Secondary Cylinder from Masts with a Lift Height Greater Than 8 m (315 in) 52
Disassembling the Secondary Cylinder 55
Disassembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 57
Inspecting the Secondary Cylinder 59
Assembly 59
Assembling the Secondary Cylinder 59
Assembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 61
Installing the Secondary Cylinder on Masts with a Lift Height up to 8 m (315 in) 63
Installing the Secondary Cylinder on Masts with a Lift Height Greater than 8 m (315 in) 66
Bleeding the Secondary Cylinder 69
Preparing a Test Load 69
Secondary Cylinder Drift Test 69
Preparing the Lift Truck for Operation 70
Troubleshooting 71
Troubleshooting 71
Cylinder - Sideshift 72
Tools and Equipment 72
Recommended Tools and Equipment 72
Additional Tools and Equipment 72
Disassembly 73
Preparing the Lift Truck for Maintenance 73
Disassembling the Sideshift Cylinder 73
Inspecting the Sideshift Cylinder 74
Assembly 75
Assembling the Sideshift Cylinder 75
Bleeding the Sideshift Cylinder 76
Preparing the Lift Truck for Operation 76
Troubleshooting 76
Troubleshooting 76
Cylinder - Tilt 77
Theory of Operation 77
Theory of Operation 77
Tools and Equipment 77
Recommended Tools and Equipment 77
Additional Tools and Equipment 77
Disassembly 78
Preparing the Lift Truck for Maintenance 78
Removing the Tilt Cylinder 78
Inspecting the Tilt Cylinder 79
Assembly 80
Installing the Tilt Cylinder 80
Bleeding the Tilt Cylinder 81
Preparing the Lift Truck for Operation 81
Troubleshooting 81
Troubleshooting 81
Fork Inspection 82
Tools and Equipment 82
Recommended Tools and Equipment 82
Additional Tools and Equipment 82
Inspection 82
Preparing the Lift Truck for Maintenance 82
Introduction 83
Identification 84
Measuring the Fork Blade for Wear 84
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Load Wheel 14
Theory of Operation 14
Theory of Operation 14
Tools and Equipment 14
Recommended Tools and Equipment 14
Additional Tools and Equipment 14
Load Wheel Attached with a Snap Ring 15
Disassembly 15
Preparing the Lift Truck for Maintenance 15
Removing a Load Wheel Attached with a Snap Ring 15
Inspecting the Load Wheel 15
Assembly 16
Installing a Load Wheel Attached with a Snap Ring 16
Preparing the Lift Truck for Operation 16
Load Wheel Attached with a Nut 16
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing a Load Wheel Attached with a Nut 17
Inspecting the Load Wheel 18
Assembly 18
Installing a Load Wheel Attached with a Nut 18
Preparing the Lift Truck for Operation 19
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
Preparing the Lift Truck for Operation 14
Steering Wheel 15
Technician Tips 15
Technician Tips 15
Theory of Operation 15
Theory of Operation 15
Tools and Equipment 15
Recommended Tools and Equipment 15
Additional Tools and Equipment 15
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing the Steering Wheel 16
Inspecting the Steering Wheel 18
Assembly 18
Installing the Steering Wheel 18
Preparing the Lift Truck for Operation 19
Troubleshooting 20
Troubleshooting 20
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Menu Structure 14
Introduction 14
Adjusting the Settings 16
Menus 16
Auto Height Select 34
Theory of Operation 34
Theory of Operation 34
System Interaction 34
System Interaction 34
Raise and Lower Cutouts 40
Theory of Operation 40
Theory of Operation 40
System Interaction 40
Raise and Lower Cutouts 40
5th and 6th Function 44
System Interaction 44
5th and 6th Function 44
User Performance 47
Theory of Operation 47
Theory of Operation 47
System Interaction 47
System Interaction 47
Performance Settings 50
System Interaction 50
Performance Settings 50
Performance Settings and Effects 54
Performance Settings and Effects 54
Operational Hours 76
System Interaction 76
Set the Operational Hours After Replacing the Access 41 76
Widgets 79
System Interaction 79
System Interaction 79
Widgets 80
Adding a Widget to the Home Screen 82
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Preparing the Stopping Distance Test Route 14
Testing the Stopping Distance 14
Preparing the Lift Truck for Operation 15
Troubleshooting 16
Troubleshooting 16
Brake - M31 17
Theory of Operation 17
Theory of Operation 17
Tools and Equipment 17
Recommended Tools and Equipment 17
Additional Tools and Equipment 17
Disassembly 17
Preparing the Lift Truck for Maintenance 17
Removing the M31 Traction Brake 18
Disassembling the M31 Traction Brake 19
Inspecting the M31 Traction Brake 19
Assembly 19
Assembling the M31 Traction Brake 19
Installing the M31 Traction Brake 20
Checking the Brake Torque 21
Checking and Adjusting the Air Gap 22
Preparing the Lift Truck for Operation 22
Troubleshooting 23
Troubleshooting 23
Drive Tire 24
Tools and Equipment 24
Recommended Tools and Equipment 24
Additional Tools and Equipment 24
Disassembly 24
Preparing the Lift Truck for Maintenance 24
Removing the Drive Tire 25
Inspecting the Drive Tire 25
Assembly 25
Installing the Drive Tire 25
Preparing the Lift Truck for Operation 26
Drive Unit 27
Tools and Equipment 27
Recommended Tools and Equipment 27
Additional Tools and Equipment 27
Disassembly 27
Preparing the Lift Truck for Maintenance 27
Removing the Drive Unit 28
Inspecting the Drive Unit 28
Assembly 29
Installing the Drive Unit 29
Preparing the Lift Truck for Operation 29
Troubleshooting 30
Troubleshooting 30
Pinion Repair Set 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 31
Disassembly 31
Inspecting the Gearbox Pinion 31
Preparing the Lift Truck for Maintenance 32
Removing the Gearbox Pinion 33
Assembly 34
Installing the Gearbox Pinion 34
Preparing the Lift Truck for Operation 36
Rotor Repair Set 37
Theory of Operation 37
Theory of Operation 37
Tools and Equipment 37
Recommended Tools and Equipment 37
Disassembly 38
Inspecting the Rotor Teeth 38
Preparing the Lift Truck for Maintenance 38
Removing the Rotor 38
Assembly 42
Installing the Rotor 42
Preparing the Lift Truck for Operation 46
Motor - M31 47
Technician Tips 47
Technician Tips 47
Theory of Operation 47
Theory of Operation 47
Tools and Equipment 47
Recommended Tools and Equipment 47
Additional Tools and Equipment 48
Disassembly 48
Preparing the Lift Truck for Maintenance 48
Removing the Traction Motor 48
Disassembling the Traction Motor 49
Inspecting the Traction Motor 51
Assembly 51
Assembling the Traction Motor 51
Installing the Traction Motor 53
Preparing the Lift Truck for Operation 53
Troubleshooting 54
Troubleshooting 54
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Diagram Key 14
Main Harness and Connector Figure 17
Pictorials - Electrical 19
Pictorials - Electrical (ESR1020 -F and ESR1040 -F) 19
Pictorials - Electrical (ESR1020 -T and ESR1040 -T) 42
Pictorials - Electrical (ESR1060, Standard) 61
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
Installing the Battery 14
Installation Procedure With a Battery Roller Stand 14
Installation Procedure With a Lifting Device 14
Securing the Battery in the Lift Truck 14
Discharging the Capacitors 15
General Hot Work Instructions 16
Releasing the Hydraulic Pressure 17
Parking Brake 17
Releasing the Parking Brake 17
Applying the Parking Brake 18
Towing the Lift Truck 18
Preparing for Towing the Lift Truck 19
Towing the Lift Truck by Lifting and Pulling in the Power Unit First Direction 19
Towing the Lift Truck by Pulling in the Forks First Direction 20
Lifting and Blocking 21
Lifting and Blocking the Outriggers 21
Lifting and Blocking the Power Unit 21
Blocking the Masts 22
Securing the Fork Carriage 23
Blocking the Reach Mechanism 23
Preparing the Mast for Removal 24
Lifting the Lift Truck 25
Lifting the Lift Truck 25
Preparing for Lifting the Lift Truck 25
Attaching the Lifting Equipment to the Overhead Guard 26
Attaching Lifting Equipment for Standard Overhead Guard 26
Attaching Lifting Equipment for Clear Overhead Guard 27
Attaching Lifting Equipment for Cold Storage Cabin 27
Completing Preparation for Lifting the Lift Truck 28
Transporting the Lift Truck 30
Securing a Lift Truck on a Loading Surface for Transport 30
Securing the Mast to a Loading Surface for Transport 31
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Icons 14
Visual Inspection 14
Operational Check and Test Drive 15
Preparing the Lift Truck for Maintenance 15
Inspection and Lubrication 16
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Access 31 14
Access 41 15
Access 51 16
Accessory Pump (ESR1060 -RX) 17
Accessory Pump Motor (ESR1060 -RX) 18
19
Adjustment Valve Lowering Speed 20
Auto Height Select Switch 22
Battery Latch Switch 23
Brake Fluid Switch 24
Brake Potentiometer 25
Brake Pressure Switch 26
Camera Switch 27
CAN Card 28
Card Reader 29
Emergency Disconnect Contactor 30
Emergency Disconnect Switch 1 31
Emergency Disconnect Switch 2 32
Xpress Lower Proportional Valve 1 (ESR1060 -RX) 33
Xpress Lower Proportional Valve 2 (ESR1060 -RX) 34
Xpress Lower Proportional Valve 3 (ESR1060 -RX) 35
Forks First Switch 36
Free-Lift Switch 37
Fuse 1 39
Fuse 2 41
Fuse 3 43
Fuse 4 44
Fuse 5 45
Fuse 6 46
Fuse 7 47
Fuse 8 48
Fuse 9 49
Fuse 10 50
Fuse 11 (ESR1060 -RX) 51
Height Encoder 1 52
Height Encoder 2 53
Height Reset Switch 1 54
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction 1
Event Codes 9
000002006 10
000002058 10
000003006 11
000003058 11
000004000 12
000004003 12
000004004 13
000005000 13
000006059 14
000008001 15
000021000 17
000021001 17
000021016 17
000086000 18
000086016 18
000087000 18
000088003 20
000088004 20
000091003 21
000091004 22
000091061 23
000158003 23
000158004 23
000233003 24
000233004 24
000237002 25
000441000 25
000441001 26
000441016 26
000441018 26
000444001 26
000447002 27
000501002 28
000502059 29
000503004 30
000505004 30
000506003 30
000506004 30
000508000 31
000508001 32
000508016 32
000508018 32
000509002 33
000586003 34
000586004 35
000587003 37
000587004 38
000588003 38
000588004 38
000599000 40
000600003 41
000600004 42
000601003 43
000601004 43
000602003 43
000602004 43
000602058 45
000605004 45
000605059 46
000609012 47
000609052 48
000609100 49
000622002 49
000625003 49
000625004 51
000625009 51
000627003 52
000627004 52
000629012 54
000629052 54
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Removing the Main Pump 14
Inspecting the Main Pump 14
Assembly 15
Installing the Main Pump 15
Priming the Main Pump 16
Preparing the Lift Truck for Operation 16
Manifold - Main 18
Checking the 18
System 20
Functional Descriptions (ESR-F) 20
Lifting 20
Lowering 21
Extending the Reach Mechanism 23
Retracting the Reach Mechanism 25
Tilting the Fork Up 26
Tilting the Fork Down 28
Sideshift Right 29
Sideshift Left 31
5th Function A 32
5th Function B 33
Functional Descriptions (ESR-T) 35
Lifting 35
Lowering 36
Extending the Reach Mechanism 38
Retracting the Reach Mechanism 39
Tilting the Mast Towards the Operator 41
Tilting the Mast in the Direction of the Forks 42
Sideshift Right 43
Sideshift Left 45
Functional Descriptions (ESR-RX) 46
Lifting 46
Regenerative Lowering 47
Extending the Reach Mechanism 48
Retracting the Reach Mechanism 49
Tilting the Fork Up 50
Tilting the Fork Down 52
Sideshift Right 53
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Removing the Fork Carriage Control Cable 15
Removing the Camera Control Cable 18
Inspecting the Control Cables 21
Assembly 21
Installing the Camera Control Cable 21
Installing the Fork Carriage Control Cable 24
Installing the Mast Control Cable 27
Adjusting the Tension 30
Preparing the Lift Truck for Operation 30
Troubleshooting 30
Troubleshooting 30
Cylinder - Primary 31
Technician Tips 31
Technician Tips 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 32
Small Hook Tool 32
Disassembly 32
Preparing the Lift Truck for Maintenance 32
Removing the Primary Cylinder 33
Disassembling the Primary Cylinder 34
Inspecting the Primary Cylinder 34
Assembly 35
Assembling the Primary Cylinder 35
Installing the Primary Cylinder 36
Bleeding the Cylinder 36
Testing the Cylinder Seal for Leaks 38
Preparing the Lift Truck for Operation 39
Cylinder - Reach 40
Tools and Equipment 40
Recommended Tools and Equipment 40
Additional Tools and Equipment 40
Disassembly 41
Preparing the Lift Truck for Maintenance 41
Removing the Reach Cylinder 41
Disassembling the Reach Cylinder 43
Inspecting the Reach Cylinder 44
Assembly 44
Assembling the Reach Cylinder 44
Installing the Reach Cylinder 45
Bleeding the Reach Cylinder 45
Preparing the Lift Truck for Operation 45
Testing the Cylinder Seal for Leaks 46
Troubleshooting 47
Troubleshooting 47
Cylinder - Secondary 48
Tools and Equipment 48
Recommended Tools and Equipment 48
Additional Tools and Equipment 48
Disassembly 49
Preparing the Lift Truck for Maintenance 49
Removing the Secondary Cylinder from Masts with a Lift Height up to 8 m (315 in) 49
Removing the Secondary Cylinder from Masts with a Lift Height Greater Than 8 m (315 in) 52
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Load Wheel 14
Theory of Operation 14
Theory of Operation 14
Tools and Equipment 14
Recommended Tools and Equipment 14
Additional Tools and Equipment 14
Load Wheel Attached with a Snap Ring 15
Disassembly 15
Preparing the Lift Truck for Maintenance 15
Removing a Load Wheel Attached with a Snap Ring 15
Inspecting the Load Wheel 15
Assembly 16
Installing a Load Wheel Attached with a Snap Ring 16
Preparing the Lift Truck for Operation 16
Load Wheel Attached with a Nut 16
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing a Load Wheel Attached with a Nut 17
Inspecting the Load Wheel 18
Assembly 18
Installing a Load Wheel Attached with a Nut 18
Preparing the Lift Truck for Operation 19
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
Preparing the Lift Truck for Operation 14
Steering Wheel 15
Technician Tips 15
Technician Tips 15
Theory of Operation 15
Theory of Operation 15
Tools and Equipment 15
Recommended Tools and Equipment 15
Additional Tools and Equipment 15
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing the Steering Wheel 16
Inspecting the Steering Wheel 18
Assembly 18
Installing the Steering Wheel 18
Preparing the Lift Truck for Operation 19
Troubleshooting 20
Troubleshooting 20
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Menu Structure 14
Introduction 14
Adjusting the Settings 16
Menus 16
Auto Height Select 34
Theory of Operation 34
Theory of Operation 34
System Interaction 34
System Interaction 34
Raise and Lower Cutouts 40
Theory of Operation 40
Theory of Operation 40
System Interaction 40
Raise and Lower Cutouts 40
5th and 6th Function 44
System Interaction 44
5th and 6th Function 44
User Performance 47
Theory of Operation 47
Theory of Operation 47
System Interaction 47
System Interaction 47
Performance Settings 50
System Interaction 50
Performance Settings 50
Performance Settings and Effects 54
Performance Settings and Effects 54
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Preparing the Stopping Distance Test Route 14
Testing the Stopping Distance 14
Preparing the Lift Truck for Operation 15
Troubleshooting 16
Troubleshooting 16
Brake - M31 17
Theory of Operation 17
Theory of Operation 17
Tools and Equipment 17
Recommended Tools and Equipment 17
Additional Tools and Equipment 17
Disassembly 17
Preparing the Lift Truck for Maintenance 17
Removing the M31 Traction Brake 18
Disassembling the M31 Traction Brake 19
Inspecting the M31 Traction Brake 19
Assembly 19
Assembling the M31 Traction Brake 19
Installing the M31 Traction Brake 20
Checking the Brake Torque 21
Checking and Adjusting the Air Gap 22
Preparing the Lift Truck for Operation 22
Troubleshooting 23
Troubleshooting 23
Drive Tire 24
Tools and Equipment 24
Recommended Tools and Equipment 24
Additional Tools and Equipment 24
Disassembly 24
Preparing the Lift Truck for Maintenance 24
Removing the Drive Tire 25
Inspecting the Drive Tire 25
Assembly 25
Installing the Drive Tire 25
Preparing the Lift Truck for Operation 26
Drive Unit 27
Tools and Equipment 27
Recommended Tools and Equipment 27
Additional Tools and Equipment 27
Disassembly 27
Preparing the Lift Truck for Maintenance 27
Removing the Drive Unit 28
Inspecting the Drive Unit 28
Assembly 29
Installing the Drive Unit 29
Preparing the Lift Truck for Operation 29
Troubleshooting 30
Troubleshooting 30
Pinion Repair Set 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 31
Disassembly 31
Inspecting the Gearbox Pinion 31
Preparing the Lift Truck for Maintenance 32
Removing the Gearbox Pinion 33
Assembly 34
Installing the Gearbox Pinion 34
Preparing the Lift Truck for Operation 36
Rotor Repair Set 37
Theory of Operation 37
Theory of Operation 37
Tools and Equipment 37
Recommended Tools and Equipment 37
Disassembly 38
Inspecting the Rotor Teeth 38
Preparing the Lift Truck for Maintenance 38
Removing the Rotor 38
Assembly 42
Installing the Rotor 42
Preparing the Lift Truck for Operation 46
Motor - M31 47
Technician Tips 47
Technician Tips 47
Theory of Operation 47
Theory of Operation 47
Tools and Equipment 47
Recommended Tools and Equipment 47
Additional Tools and Equipment 48
Disassembly 48
Preparing the Lift Truck for Maintenance 48
Removing the Traction Motor 48
Disassembling the Traction Motor 49
Inspecting the Traction Motor 51
Assembly 51
Assembling the Traction Motor 51
Installing the Traction Motor 53
Preparing the Lift Truck for Operation 53
Troubleshooting 54
Troubleshooting 54
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Diagram Key 14
Main Harness and Connector Figure 17
Pictorials - Electrical 19
Pictorials - Electrical (ESR1020 -F and ESR1040 -F) 19
Pictorials - Electrical (ESR1020 -T and ESR1040 -T) 42
Introduction 0
Overview 1
General Information 1
Operator Information 1
How to Use This Manual 1
Model Number Information 6
Data Number Information 8
Capacity Plate and Serial Number Information 11
Global Contact Information 12
Safety 0
General Safety 1
Introduction 1
Safety Messages 1
Standards and Regulations 2
Environmental Protection 3
Organizational Requirements 3
General Maintenance 3
General Hot Work Instructions 4
Personal Protective Equipment (PPE) 4
Hazards From Stored Energy 5
Returning the Lift Truck to Service 5
Lift Truck Cleaning 5
Safe Battery Handling 5
Hydraulic System Safety 6
Safety Labels on the Lift Truck 6
Lifting Equipment 6
Cleaning the Lift Truck 7
Cleaning the Lift Truck 7
Preparing for Cleaning 7
General Cleaning 7
Steam Cleaning and Power Washing 8
Returning to Operation 8
Control of Hazardous Energy 10
Control of Hazardous Energy (Lockout/Tagout) 10
Lockout/Tagout Procedures 10
Tagout Procedure 11
Lockout Procedure with the Battery Installed 11
Lockout Procedure Without the Battery Installed 11
Preparing the Lift Truck for Maintenance 11
Battery 12
Battery Care 12
Preparing the Battery for Removal 12
Removing the Battery 13
Removal Procedure With a Battery Roller Stand 13
Removal Procedure With a Lifting Device 13
Installing the Battery 14
Installation Procedure With a Battery Roller Stand 14
Installation Procedure With a Lifting Device 14
Securing the Battery in the Lift Truck 14
Discharging the Capacitors 15
General Hot Work Instructions 16
Releasing the Hydraulic Pressure 17
Parking Brake 17
Releasing the Parking Brake 17
Applying the Parking Brake 18
Towing the Lift Truck 18
Preparing for Towing the Lift Truck 19
Towing the Lift Truck by Lifting and Pulling in the Power Unit First Direction 19
Towing the Lift Truck by Pulling in the Forks First Direction 20
Lifting and Blocking 21
Lifting and Blocking the Outriggers 21
Lifting and Blocking the Power Unit 21
Blocking the Masts 22
Securing the Fork Carriage 23
Blocking the Reach Mechanism 23
Preparing the Mast for Removal 24
Lifting the Lift Truck 25
Lifting the Lift Truck 25
Preparing for Lifting the Lift Truck 25
Attaching the Lifting Equipment to the Overhead Guard 26
Attaching Lifting Equipment for Standard Overhead Guard 26
Attaching Lifting Equipment for Clear Overhead Guard 27
Attaching Lifting Equipment for Cold Storage Cabin 27
Completing Preparation for Lifting the Lift Truck 28
Transporting the Lift Truck 30
Securing a Lift Truck on a Loading Surface for Transport 30
Securing the Mast to a Loading Surface for Transport 31
General Maintenance 0
Standard Torque Values 1
Lubricants 4
Handling of Static Sensitive Components 7
Slide Blocks 8
Theory of Operation 8
Theory of Operation 8
Disassembly 8
Inspecting the Slide Block Distance 8
Analyzing the Measurements 9
Measuring the Remaining Slide Block Height 10
Adjusting the Slide Block Distance 10
Assembly 12
Installing the Slide Block 12
Planned Maintenance 13
Introduction 13
Guideline FEM 4004 13
Lubricants 13
Icons 14
Visual Inspection 14
Operational Check and Test Drive 15
Preparing the Lift Truck for Maintenance 15
Inspection and Lubrication 16
Preparing the Lift Truck for Operation110
Final Operational Check and Test Drive110
Planned Maintenance Completion110
Power Source 0
General Information 1
Componentry 0
5th Function Switch (ESR1060) 5
6th Function Switch (ESR1060) 6
A21 Fan 7
A31 Fan 8
Access 11 9
Access 12 10
Access 13 11
Access 21 12
Access 22 (ESR1060 -RX) 13
Access 31 14
Access 41 15
Access 51 16
Accessory Pump (ESR1060 -RX) 17
Accessory Pump Motor (ESR1060 -RX) 18
19
Adjustment Valve Lowering Speed 20
Auto Height Select Switch 22
Battery Latch Switch 23
Brake Fluid Switch 24
Brake Potentiometer 25
Brake Pressure Switch 26
Camera Switch 27
CAN Card 28
Card Reader 29
Emergency Disconnect Contactor 30
Emergency Disconnect Switch 1 31
Emergency Disconnect Switch 2 32
Xpress Lower Proportional Valve 1 (ESR1060 -RX) 33
Xpress Lower Proportional Valve 2 (ESR1060 -RX) 34
Xpress Lower Proportional Valve 3 (ESR1060 -RX) 35
Forks First Switch 36
Free-Lift Switch 37
Fuse 1 39
Fuse 2 41
Fuse 3 43
Fuse 4 44
Fuse 5 45
Fuse 6 46
Fuse 7 47
Fuse 8 48
Fuse 9 49
Fuse 10 50
Fuse 11 (ESR1060 -RX) 51
Height Encoder 1 52
Height Encoder 2 53
Height Reset Switch 1 54
Height Reset Switch 2 55
Hoist Solenoid Valve 56
Horn 58
Horn Switch 59
Impact Sensor 60
Key Switch 61
Keyless Power Module 62
Left Accessory Proportional Valve 63
Left Accessory Solenoid Valve (ESR1060 -RX) 64
Main Pump 65
Line Contactor 66
Load Sensor 1 67
Load Sensor 2 68
Lower Proportional Valve 69
Lower Solenoid Valve (ESR1060 -RX) 71
M21 Encoder 72
M21 Fan (ESR1060) 73
M21 Thermal Sensor 74
M22 Encoder (ESR1060 -RX) 75
M22 Thermal Sensor (ESR1060 -RX) 76
M31 Encoder 77
M31 Fan (ESR1060) 78
M31 Thermal Sensor 79
M31 Traction Brake 80
M51 Sensor 1 81
M51 Sensor 2 82
M51 Thermal Sensor 83
Main Hoist Sensor 84
Main Pump Motor 86
Manual Lowering Valve 88
Override Switch 90
Power Unit First Switch 91
Reach Position Sensor 1 92
Reach Position Sensor 2 93
Reach Proportional Valve 94
Reach Sensor 96
Reach Solenoid Valve (ESR1060 -RX) 98
Relay 1 99
Relay 2100
Relay 3101
Relay 4102
Relay 5103
Relay 6104
Relay 9105
Relay 10106
Relay 22107
Relay 23108
Relief Valve 1109
Relief Valve 2111
Retract Proportional Valve112
Retract Solenoid Valve (ESR1060 -RX)114
Right Accessory Proportional Valve115
Right Accessory Solenoid Valve (ESR1060 -RX)116
Safety Pedal Sensor117
Seat Heater Switch118
Seat Switch119
Selector Encoder120
Selector Switch121
Sideshift Left Solenoid Valve (ESR1020 -T and ESR1040 -T)122
Sideshift Position Sensor123
Sideshift Right Solenoid Valve (ESR1020 -T and ESR1040 -T)124
Sideshift Sensor125
Electrical 0
Contactor 1
Theory of Operation 1
Theory of Operation 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Disassembly 1
Preparing the Lift Truck for Maintenance 1
Removing the Line Contactor 2
Inspecting the Line Contactor 3
Assembly 3
Installing the Line Contactor 3
Preparing the Lift Truck for Operation 5
Troubleshooting 5
Troubleshooting 5
Emergency Disconnect Contactor 6
Theory of Operation 6
Theory of Operation 6
Tools and Equipment 6
Recommended Tools and Equipment 6
Additional Tools and Equipment 6
Disassembly 7
Preparing the Lift Truck for Maintenance 7
Removing the Emergency Disconnect Contactor 7
Assembly 8
Installing the Emergency Disconnect Contactor 8
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Reach Sensor 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Inspecting the Reach Sensor 11
Assembly 12
Reach Sensor Adjustment 12
Event Codes 0
Introduction 1
Event Codes 9
000002006 10
000002058 10
000003006 11
000003058 11
000004000 12
000004003 12
000004004 13
000005000 13
000006059 14
000008001 15
000021000 17
000021001 17
000021016 17
000086000 18
000086016 18
000087000 18
000088003 20
000088004 20
000091003 21
000091004 22
000091061 23
000158003 23
000158004 23
000233003 24
000233004 24
000237002 25
000441000 25
000441001 26
000441016 26
000441018 26
000444001 26
000447002 27
000501002 28
000502059 29
000503004 30
000505004 30
000506003 30
000506004 30
000508000 31
000508001 32
000508016 32
000508018 32
000509002 33
000586003 34
000586004 35
000587003 37
000587004 38
000588003 38
000588004 38
000599000 40
000600003 41
000600004 42
000601003 43
000601004 43
000602003 43
000602004 43
000602058 45
000605004 45
000605059 46
000609012 47
000609052 48
000609100 49
000622002 49
000625003 49
000625004 51
000625009 51
000627003 52
000627004 52
000629012 54
000629052 54
000629056 55
000629057 55
000819000 55
000819016 56
000820000 57
000820016 57
000821003 57
000821004 57
000823003 58
000823004 58
000824000 59
000824016 59
000826003 60
000826004 61
000826005 61
000826006 62
000826059 63
000827016 63
000871009 63
000874003 64
000874004 64
000879006 65
000882003 66
000882004 67
000883003 67
000883004 68
000911003 68
000911004 69
000912003 69
000912004 70
000913003 70
000913004 71
000929003 71
000929004 72
000930003 72
000930004 73
000930053 73
000944003 74
000944004 74
000960006 74
000960058 75
000964061 76
000989003 76
001005003 76
001194003 76
001195004 77
001196003 78
001196004 79
001198003 79
001198004 79
001491003 80
001491004 80
001492003 80
001492004 81
001497001 81
001498001 82
001502004 82
001502005 83
001502006 84
001505005 85
001505006 86
001506005 86
001507004 88
001507005 89
001509004 89
001509005 91
001509006 92
001511004 93
001511005 94
001511006 94
001512003 95
001512004 96
001512005 97
001512006 97
001513003 97
001513004 98
001513006 98
001514003 98
001514004 99
001514005100
001514006100
001515003100
001515004101
001515006102
001517003102
001517004102
001517006104
001520004104
001520005105
001520006105
001521004106
001521006107
001523005107
001523006109
001524005110
001524006111
001525005112
001525006113
001526005114
001526006116
001527005117
001527006118
001528003119
001528004120
001528005120
001528006121
001529003121
001529004121
001529005122
001529006122
001530001122
001531005123
001531006124
001532005124
Hydraulic 0
Theory of Operation 1
Motor - M21 2
Theory of Operation 2
Theory of Operation 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Main Pump Motor 3
Inspecting the Main Pump Motor 5
Assembly 5
Installing the Main Pump Motor 5
Preparing the Lift Truck for Operation 8
Pump - Accessory 9
Tools and Equipment 9
Recommended Tools and Equipment 9
Additional Tools and Equipment 9
Disassembly 9
Preparing the Lift Truck for Maintenance 9
Removing the Accessory Pump 10
Inspecting the Accessory Pump 10
Assembly 10
Installing the Accessory Pump 10
Removing Air from the Circuit for the Accessory Pump 11
Preparing the Lift Truck for Operation 11
Pump - Main 13
Tools and Equipment 13
Recommended Tools and Equipment 13
Additional Tools and Equipment 13
Disassembly 13
Preparing the Lift Truck for Maintenance 13
Removing the Main Pump 14
Inspecting the Main Pump 14
Assembly 15
Installing the Main Pump 15
Priming the Main Pump 16
Preparing the Lift Truck for Operation 16
Manifold - Main 18
Checking the 18
System 20
Functional Descriptions (ESR-F) 20
Lifting 20
Lowering 21
Extending the Reach Mechanism 23
Retracting the Reach Mechanism 25
Tilting the Fork Up 26
Tilting the Fork Down 28
Sideshift Right 29
Sideshift Left 31
5th Function A 32
5th Function B 33
Functional Descriptions (ESR-T) 35
Lifting 35
Lowering 36
Extending the Reach Mechanism 38
Retracting the Reach Mechanism 39
Tilting the Mast Towards the Operator 41
Tilting the Mast in the Direction of the Forks 42
Sideshift Right 43
Sideshift Left 45
Functional Descriptions (ESR-RX) 46
Lifting 46
Regenerative Lowering 47
Extending the Reach Mechanism 48
Retracting the Reach Mechanism 49
Tilting the Fork Up 50
Tilting the Fork Down 52
Sideshift Right 53
Sideshift Left 55
5th Function A 56
5th Function B 58
Drift Tests 59
Preparing the Lift Truck for Maintenance 59
Drift Tests 59
Recommended Tools and Equipment 59
Additional Tools and Equipment 60
Requirements 60
Performing a Drift Test on the Primary and Secondary Cylinders 60
Performing a Drift Test on the Tilt Cylinder 61
Checking and Adjusting the Relief Valve 1 62
Preparing the Lift Truck for Operation 63
Lifting Mechanism 0
Theory of Operation 1
Carriage - Fork 2
Tools and Equipment 2
Recommended Tools and Equipment 2
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Fork Carriage 3
Inspecting the Fork Carriage 3
Assembly 4
Installing the Fork Carriage 4
Preparing the Lift Truck for Operation 4
Carriage - Mast 5
Theory of Operation 5
Theory of Operation 5
Tools and Equipment 5
Recommended Tools and Equipment 5
Additional Tools and Equipment 5
Disassembly 6
Preparing the Lift Truck for Maintenance 6
Removing the Free-Lift Switch 6
Removing the Mast Carriage 8
Inspecting the Mast Carriage 8
Assembly 8
Installing the Mast Carriage 8
Installing the Free-Lift Switch 9
Troubleshooting 10
Troubleshooting 10
Control Cable 11
Technician Tips 11
Technician Tips 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 12
Preparing the Lift Truck for Maintenance 12
Removing the Mast Control Cable 12
Removing the Fork Carriage Control Cable 15
Removing the Camera Control Cable 18
Inspecting the Control Cables 21
Assembly 21
Installing the Camera Control Cable 21
Installing the Fork Carriage Control Cable 24
Installing the Mast Control Cable 27
Adjusting the Tension 30
Preparing the Lift Truck for Operation 30
Troubleshooting 30
Troubleshooting 30
Cylinder - Primary 31
Technician Tips 31
Technician Tips 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 32
Small Hook Tool 32
Disassembly 32
Preparing the Lift Truck for Maintenance 32
Removing the Primary Cylinder 33
Disassembling the Primary Cylinder 34
Inspecting the Primary Cylinder 34
Assembly 35
Assembling the Primary Cylinder 35
Installing the Primary Cylinder 36
Bleeding the Cylinder 36
Testing the Cylinder Seal for Leaks 38
Preparing the Lift Truck for Operation 39
Cylinder - Reach 40
Tools and Equipment 40
Recommended Tools and Equipment 40
Additional Tools and Equipment 40
Disassembly 41
Preparing the Lift Truck for Maintenance 41
Removing the Reach Cylinder 41
Disassembling the Reach Cylinder 43
Inspecting the Reach Cylinder 44
Assembly 44
Assembling the Reach Cylinder 44
Installing the Reach Cylinder 45
Bleeding the Reach Cylinder 45
Preparing the Lift Truck for Operation 45
Testing the Cylinder Seal for Leaks 46
Troubleshooting 47
Troubleshooting 47
Cylinder - Secondary 48
Tools and Equipment 48
Recommended Tools and Equipment 48
Additional Tools and Equipment 48
Disassembly 49
Preparing the Lift Truck for Maintenance 49
Removing the Secondary Cylinder from Masts with a Lift Height up to 8 m (315 in) 49
Removing the Secondary Cylinder from Masts with a Lift Height Greater Than 8 m (315 in) 52
Disassembling the Secondary Cylinder 55
Disassembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 57
Inspecting the Secondary Cylinder 59
Assembly 59
Assembling the Secondary Cylinder 59
Assembling the Secondary Cylinder with Regen Lower and Xpress™ Lower Option 61
Installing the Secondary Cylinder on Masts with a Lift Height up to 8 m (315 in) 63
Installing the Secondary Cylinder on Masts with a Lift Height Greater than 8 m (315 in) 66
Bleeding the Secondary Cylinder 69
Preparing a Test Load 69
Secondary Cylinder Drift Test 69
Preparing the Lift Truck for Operation 70
Troubleshooting 71
Troubleshooting 71
Cylinder - Sideshift 72
Tools and Equipment 72
Recommended Tools and Equipment 72
Additional Tools and Equipment 72
Disassembly 73
Preparing the Lift Truck for Maintenance 73
Disassembling the Sideshift Cylinder 73
Inspecting the Sideshift Cylinder 74
Assembly 75
Assembling the Sideshift Cylinder 75
Bleeding the Sideshift Cylinder 76
Preparing the Lift Truck for Operation 76
Troubleshooting 76
Troubleshooting 76
Cylinder - Tilt 77
Theory of Operation 77
Theory of Operation 77
Tools and Equipment 77
Recommended Tools and Equipment 77
Additional Tools and Equipment 77
Disassembly 78
Preparing the Lift Truck for Maintenance 78
Removing the Tilt Cylinder 78
Inspecting the Tilt Cylinder 79
Assembly 80
Installing the Tilt Cylinder 80
Bleeding the Tilt Cylinder 81
Preparing the Lift Truck for Operation 81
Troubleshooting 81
Troubleshooting 81
Fork Inspection 82
Tools and Equipment 82
Recommended Tools and Equipment 82
Additional Tools and Equipment 82
Inspection 82
Preparing the Lift Truck for Maintenance 82
Introduction 83
Identification 84
Measuring the Fork Blade for Wear 84
Checking for Fatigue Cracks 86
Bent or Twisted Forks 86
Checking the Fork Tip for Straightness 87
Fork Locking Pin 88
Preparing the Lift Truck for Operation 88
Height Encoder 90
Tools and Equipment 90
Recommended Tools and Equipment 90
Disassembly 90
Preparing the Lift Truck for Maintenance 90
Removing Height Encoder 1 (ESR -F) 90
Removing Height Encoder 2 (ESR -F) 91
Assembly 92
Installing Height Encoder 1 (ESR -F) 92
Installing Height Encoder 2 (ESR -F) 92
Preparing the Lift Truck for Operation 93
Hydraulic Lines and Fittings 94
Technician Tips 94
Technician Tips 94
Lift Chains 95
Tools and Equipment 95
Recommended Tools and Equipment 95
Additional Tools and Equipment 95
Lift Chains - Primary Cylinder 95
Disassembly 95
Preparing the Lift Truck for Maintenance 95
Removing the Lift Chains from the Primary Cylinder 96
Inspecting the Lift Chains 96
Checking the Lift Chain Stretch 98
Assembly 99
Installing the Lift Chains on the Primary Cylinder 99
Inspecting the Fork Height101
Preparing the Lift Truck for Operation102
Lift Chains - Secondary Cylinder102
Disassembly102
Preparing the Lift Truck for Maintenance102
Removing the Lift Chains from the Secondary Cylinder102
Inspecting the Lift Chains103
Checking the Lift Chain Stretch105
Assembly106
Installing the Lift Chains on the Secondary Cylinder106
Inspecting the Fork Height108
Preparing the Lift Truck for Operation109
Mast110
Technician Tips110
Technician Tips110
Tools and Equipment110
Recommended Tools and Equipment110
Additional Tools and Equipment110
Mast Torque Requirements111
Mast Torque Requirements111
Inspecting and Lubricating the Mast112
Inspecting and Lubricating the Mast112
Fixed Mast113
Disassembly113
Preparing the Lift Truck for Maintenance113
Preparing for Removing the Fixed Mast113
Removing the Fixed Mast116
Disassembling the Mast119
Assembly122
Assembling the Mast122
Installing the Fixed Mast125
Power Unit 0
Cab 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 1
Cab Heater and Filter Element 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Cab Heater Filter Element 2
Inspecting the Cab Heater Filter Element 3
Assembly 4
Installing the Cab Heater Filter Element 4
Preparing the Lift Truck for Operation 5
Cab Window 5
Disassembly 5
Preparing the Lift Truck for Maintenance 5
Removing the Cab Window 5
Assembly 6
Installing the Cab Window 6
Preparing the Lift Truck for Operation 8
Polycarbonate Door Window 8
Disassembly 8
Preparing the Lift Truck for Maintenance 8
Removing the Polycarbonate Door Window 9
Assembly 9
Installing the Polycarbonate Door Window 9
Preparing the Lift Truck for Operation 11
Cab Fuses 11
Disassembly 11
Improved Fuse Holder on the Control Board 11
Access to the Fuses 11
Assignment of the Fuses in the Overhead Console to the Power Circuits 12
Assembly 12
Installing the Fuse Cover 12
Load Wheel 14
Theory of Operation 14
Theory of Operation 14
Tools and Equipment 14
Recommended Tools and Equipment 14
Additional Tools and Equipment 14
Load Wheel Attached with a Snap Ring 15
Disassembly 15
Preparing the Lift Truck for Maintenance 15
Removing a Load Wheel Attached with a Snap Ring 15
Inspecting the Load Wheel 15
Assembly 16
Installing a Load Wheel Attached with a Snap Ring 16
Preparing the Lift Truck for Operation 16
Load Wheel Attached with a Nut 16
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing a Load Wheel Attached with a Nut 17
Inspecting the Load Wheel 18
Assembly 18
Installing a Load Wheel Attached with a Nut 18
Preparing the Lift Truck for Operation 19
Steering 0
Theory of Operation 1
Motor - M51 and Gearbox Assembly 3
Tools and Equipment 3
Recommended Tools and Equipment 3
Additional Tools and Equipment 3
Disassembly 3
Preparing the Lift Truck for Maintenance 3
Removing the Steer Motor and Gearbox Assembly 4
Removing M51 Sensor 1 and M51 Sensor 2 5
Disassembling the Steer Motor and the Gearbox Assembly 5
Inspecting the Steer Motor and the Gearbox Assembly 6
Assembly 6
Assembling the Steer Motor and Gearbox Assembly 6
Installing M51 Sensor 1 and M51 Sensor 2 8
Installing the Steer Motor and Gearbox Assembly 9
Preparing the Lift Truck for Operation 10
Troubleshooting 10
Troubleshooting 10
Steering Sensor 11
Tools and Equipment 11
Recommended Tools and Equipment 11
Additional Tools and Equipment 11
Disassembly 11
Preparing the Lift Truck for Maintenance 11
Removing Steering Sensor 1 or Steering Sensor 2 12
Assembly 12
Adjusting the Steering Sensor 1 or Steering Sensor 2 12
Installing Steering Sensor 1 or Steering Sensor 2 13
Preparing the Lift Truck for Operation 14
Steering Wheel 15
Technician Tips 15
Technician Tips 15
Theory of Operation 15
Theory of Operation 15
Tools and Equipment 15
Recommended Tools and Equipment 15
Additional Tools and Equipment 15
Disassembly 16
Preparing the Lift Truck for Maintenance 16
Removing the Steering Wheel 16
Inspecting the Steering Wheel 18
Assembly 18
Installing the Steering Wheel 18
Preparing the Lift Truck for Operation 19
Troubleshooting 20
Troubleshooting 20
User Interface 0
Software Installation 1
System Interaction 1
Software Installation - Serial Number Search 1
After Software Installation 3
Start up Process for Trucks not connected to InfoLink 4
System Interaction 4
Start up Process for Trucks not connected to InfoLink® 4
Parameterization of the Steering Motor 6
System Interaction 6
Parameterization of the Steer Motor 6
Display Overview 7
Touchscreen 7
Dashboard 7
Turning on the Lift Truck 8
System Interaction 8
InfoLink® or Login Required is Enabled 8
InfoLink® or Login Required Is Disabled 9
Main Menu Overview 12
Main Menu Overview 12
Menu Structure 14
Introduction 14
Adjusting the Settings 16
Menus 16
Auto Height Select 34
Theory of Operation 34
Theory of Operation 34
System Interaction 34
System Interaction 34
Raise and Lower Cutouts 40
Theory of Operation 40
Theory of Operation 40
System Interaction 40
Raise and Lower Cutouts 40
5th and 6th Function 44
System Interaction 44
5th and 6th Function 44
User Performance 47
Theory of Operation 47
Theory of Operation 47
System Interaction 47
System Interaction 47
Performance Settings 50
System Interaction 50
Performance Settings 50
Performance Settings and Effects 54
Performance Settings and Effects 54
Operational Hours 76
System Interaction 76
Set the Operational Hours After Replacing the Access 41 76
Widgets 79
System Interaction 79
System Interaction 79
Widgets 80
Adding a Widget to the Home Screen 82
Traction and Brake 0
Brake - Load Wheel 1
Technician Tips 1
Technician Tips 1
Tools and Equipment 1
Recommended Tools and Equipment 1
Additional Tools and Equipment 2
Disassembly 2
Preparing the Lift Truck for Maintenance 2
Removing the Brake Linings 3
Removing the Load Wheel Brake Cylinder 3
Inspecting the Brake Linings 4
Assembly 5
Installing the Load Wheel Brake Cylinder 5
Installing the Brake Linings 6
Bleeding the Load Wheel Brake 8
Adding Brake Fluid 9
Replacing the Brake Fluid 10
Adjusting the Hydraulic Brake Pedal Clearance 12
Adjusting the Electric Brake Pedal Clearance 13
Preparing the Stopping Distance Test Route 14
Testing the Stopping Distance 14
Preparing the Lift Truck for Operation 15
Troubleshooting 16
Troubleshooting 16
Brake - M31 17
Theory of Operation 17
Theory of Operation 17
Tools and Equipment 17
Recommended Tools and Equipment 17
Additional Tools and Equipment 17
Disassembly 17
Preparing the Lift Truck for Maintenance 17
Removing the M31 Traction Brake 18
Disassembling the M31 Traction Brake 19
Inspecting the M31 Traction Brake 19
Assembly 19
Assembling the M31 Traction Brake 19
Installing the M31 Traction Brake 20
Checking the Brake Torque 21
Checking and Adjusting the Air Gap 22
Preparing the Lift Truck for Operation 22
Troubleshooting 23
Troubleshooting 23
Drive Tire 24
Tools and Equipment 24
Recommended Tools and Equipment 24
Additional Tools and Equipment 24
Disassembly 24
Preparing the Lift Truck for Maintenance 24
Removing the Drive Tire 25
Inspecting the Drive Tire 25
Assembly 25
Installing the Drive Tire 25
Preparing the Lift Truck for Operation 26
Drive Unit 27
Tools and Equipment 27
Recommended Tools and Equipment 27
Additional Tools and Equipment 27
Disassembly 27
Preparing the Lift Truck for Maintenance 27
Removing the Drive Unit 28
Inspecting the Drive Unit 28
Assembly 29
Installing the Drive Unit 29
Preparing the Lift Truck for Operation 29
Troubleshooting 30
Troubleshooting 30
Pinion Repair Set 31
Theory of Operation 31
Theory of Operation 31
Tools and Equipment 31
Recommended Tools and Equipment 31
Additional Tools and Equipment 31
Disassembly 31
Inspecting the Gearbox Pinion 31
Preparing the Lift Truck for Maintenance 32
Removing the Gearbox Pinion 33
Assembly 34
Installing the Gearbox Pinion 34
Preparing the Lift Truck for Operation 36
Rotor Repair Set 37
Theory of Operation 37
Theory of Operation 37
Tools and Equipment 37
Recommended Tools and Equipment 37
Disassembly 38
Inspecting the Rotor Teeth 38
Preparing the Lift Truck for Maintenance 38
Removing the Rotor 38
Assembly 42
Installing the Rotor 42
Preparing the Lift Truck for Operation 46
Motor - M31 47
Technician Tips 47
Technician Tips 47
Theory of Operation 47
Theory of Operation 47
Tools and Equipment 47
Recommended Tools and Equipment 47
Additional Tools and Equipment 48
Disassembly 48
Preparing the Lift Truck for Maintenance 48
Removing the Traction Motor 48
Disassembling the Traction Motor 49
Inspecting the Traction Motor 51
Assembly 51
Assembling the Traction Motor 51
Installing the Traction Motor 53
Preparing the Lift Truck for Operation 53
Troubleshooting 54
Troubleshooting 54
Diagrams 0
Introduction 1
Introduction 1
Schematics 1
Pictorials 1
Components 1
Connectors 1
Wiring 1
Wire Numbers and Colors 2
Reference Designators 2
Diagram Key 14
Main Harness and Connector Figure 17
Pictorials - Electrical 19
Pictorials - Electrical (ESR1020 -F and ESR1040 -F) 19
Pictorials - Electrical (ESR1020 -T and ESR1040 -T) 42
Pictorials - Electrical (ESR1060, Standard) 61
Pictorials - Electrical (ESR1060 -RX) 86
Schematics - Electrical110
Schematics - Electrical (ESR 1020/1040)110
Schematics - Electrical (ESR 1060)112
Schematics - Electrical (ESR 1060 -RX)114
Schematics - Hydraulic116
ESR -F116
ESR -F1ESR -T120
ESR1060 -RX12