Crown Forklift ESR 5200 SERIES MAINTENANCE MANUAL – PDF DOWNLOAD

Crown Forklift ESR 5200 SERIES MAINTENANCE MANUAL – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift ESR 5200 SERIES MAINTENANCE MANUAL – PDF DOWNLOAD

Language : English
Pages :796
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift ESR 5200 SERIES MAINTENANCE MANUAL – PDF DOWNLOAD

TABLE OF CONTENTS
INTRODUCTION 1
Important Information 3
Service personnel qualification 3
Ordering spare parts 3
Ordering documentation 3
Manual structure 3
Conventions 4
Options 4
Text mark-ups in the manual 4
Brief description of equipment 4
Truck data number 5
SAFETY 7
Safety Notices 9
Basic Safety Notices 10
Organisational measures 10
Truck modifications and additions 10
Personal safety equipment 10
Protecting the hazardous area 10
Hazards from stored energy 10
Maintenance work 11
Restoring the truck to service after maintenance work 11
Cleaning work 11
Handling batteries 11
Warning and instruction decals on the truck 11
Lifting gear and slings 12
Environmental protection 12
INSPECTION AND LUBRICATION 13
Cleaning the Truck and Components 15
Effects of incorrect cleaning 15
Electrical components 15
Roller and slide bearings 15
Corrosion-protected surfaces 15
Environmental protection 15
Cleaning the entire truck 15
Cleaning removed components 16
Cleaning other mechanical components 16
Transport and Storage 17
Safety notices 17
Lifting a non-cold store cab truck with a crane 17
Lifting a cold store cab truck by crane 17
Towing the truck 18
Raising the truck and pulling it with a forklift truck 18
Releasing the brake and towing the truck 19
Jacking up the truck 20
Truck Assembly and Commissioning 21
Truck assembly 21
Required tools 21
Erecting the chassis 21
ESR 5200 Series
Rev C
V
TABLE OF CONTENTS cnawn
Removing the transport retainers 23
Filling the drive transmission unit 24
Erecting the mast and attaching it to the chassis 24
Placing the Truck in Storage 25
Testing trucks in storage 25
Restoring the truck to service 25
Lubricants and Consumables 26
Cold store truck requirements 26
Abbreviations used in the table 26
Planned Maintenance 29
Maintenance schedule 29
Annual inspection in accordance with FEM 4004 29
Terms and abbreviations used 29
Maintenance Schedule 30
Seat and seat panel 30
Brake system and load wheels 32
Drive Unit 34
Reach carriage 36
Hydraulic system 38
Electrical system – part 1 40
Electrical system – part 2 42
Electrical system – part 3 44
Traction and pump motors 46
Mast 48
Fork carriage 50
Standard Torques 52
Metric screws and nuts without flange 52
Metric hex bolts and nuts with flange (Unbrako® type) 52
Load Wheel Replacement 53
Replacing a load wheel attached with a retaining ring 53
Load wheel removal 53
Load wheel assembly 53
Replacing a load wheel attached with a nut 53
Special tools required 53
Load wheel removal 53
Load wheel assembly 54
Repairing slide blocks 55
Checking the slide block distance 55
Requirements 55
Measurement 55
Adjusting the slide block distance 56
Before adjusting 56
Replacing the slide blocks 56
Live Ring Bearing Lubrication 57
Replacing the Heater Filter Element 58
COMPONENTRY • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 59
Component Access 61
Rev C
VI
Accessing components under the panels 61
Components under the panels 62
Accessing the motor compartment 63
Motor compartment components 64
Accessing components under the floorboard 66
Components below the floorboard 67
ESR 5200 Series
TABLE OF CONTENTS cnawn
HYDRAULIC SYSTEM 71
Abbreviations Used 73
Operation 75
Lifting (ESR 5220, ESR 5240, Mast Tilt) 75
Lowering (ESR 5220, ESR 5240, Mast Tilt) 76
Extend Mast Reach Carriage (ESR 5220, ESR 5240, Mast Tilt) 78
Retract Mast Reach Carriage (ESR 5220, ESR 5240, Mast Tilt) 79
Mast Tilt Towards Driver (ESR 5220, ESR 5240, Mast Tilt) 80
Mast Tilt Away from Driver (ESR 5220, ESR 5240, Mast Tilt) 81
Sideshift Right (ESR 5220, ESR 5240, Mast Tilt) 82
Sideshift Left (ESR 5220, ESR 5240, Mast Tilt) 83
Lifting (ESR 5240 > 7500 mm, ESR 5260, ESR 5280S, Fork Tilt) 84
Lowering (ESR 5240 > 7500 mm, ESR 5260, ESR 5280S, Fork Tilt) 85
Extend Mast Reach Carriage (ESR 5240 > 7500 mm, ESR 5260, ESR 5280S, Fork Tilt) 87
Retract Mast Reach Carriage (ESR 5240 > 7500 mm, ESR 5260, ESR 5280S, Fork Tilt) 88
Fork Tilt Back (ESR 5240 > 7500 mm, ESR 5260, ESR 5280S, Fork Tilt) 89
Fork Tilt Down (ESR 5240 > 7500 mm, ESR 5260, ESR 5280S, Fork Tilt) 90
Sideshift Right (ESR 5240 > 7500 mm, ESR 5260, ESR 5280S, Fork Tilt) 91
Sideshift Left (ESR 5240 > 7500 mm, ESR 5260, ESR 5280S, Fork Tilt) 92
Lifting and Regenerative Lowering (ESR 5260 Regen Lower) 93
Mast Extend (ESR 5260 Regen Lower) 95
Fork Tilt (ESR 5260 Regen Lower) 97
Sideshift (ESR 5260 Regen Lower) 99
Fifth Function (ESR 5260 Regen Lower) 101
Hydraulic Components 103
Hydraulic lines 103
Manifolds 103
Main manifold (ESR 5240 > 7500 mm, ESR 5260, ESR 5280) 103
Main manifold (ESR 5220, ESR 5240:::: 7500 mm) 104
Main manifold (ESR 5260 Regen Lower) 104
“Accessories” manifold (ESR 5240 > 7500 mm, ESR 5260 Regen Lower) 105
Checking and adjusting relief valve RV1 105
Checking the emergency lowering valve MVL 106
ESR 5240 > 7500 mm, ESR 5260, ESR 5280S 106
ESR 5220, ESR 5240:::: 7500 mm 106
ESR 5260 Regen Lower 106
Depressurising the Hydraulic System 108
Bleeding and Flushing the System 109
Safety notices 109
Bleeding the Free Lift Cylinder 109
Bleeding the lift cylinders 109
Bleeding the reach cylinder 109
Bleeding the sideshift cylinder 109
Bleeding the tilt cylinder 109
Bleeding the 5th function cylinder 110
Flushing the lift cylinders 110
Drift tests 110
Requirements 110
Drift Tests 110
Safety notices 110
Lift cylinder drift test 110
Tilt cylinder drift test 111
Hydraulic Reservoirs 112
Rev C
VII
Reservoir volume 112
ESR 5200 Series
TABLE OF CONTENTS
ESR 5280S Hydraulic Reservoir 112
ESR 5240 / 5260 Hydraulic Reservoir 112
Replacing the Hydraulic Oil 114
Replacing the Filter 115
Replacing the return filter 115
Replacing the suction filter 115
Replacing the breather filter 116
Replacing the Hydraulic Pump 117
ESR 5240 > 7500 mm, ESR 5260, ESR 5280S 117
ESR 5260 Regen Lower 120
Pump Auxiliary Hydraulics (9, Fig 95) 121
Hydraulic Port Torques (ESR 5220 / 5240) 125
Hydraulic port torques (ESR 5220 / 5240) 126
Hydraulic port torques (ESR 5240 >7500 mm lift height, ESR 5260, ESR 5280S) 127
Hydraulic port torques (ESR 5260 Regen Lower) 128
DRIVE UNIT 129
Gear Unit 131
Required tools 131
Removing the gear unit 131
Repairing the gear unit 133
Dismantling the gear unit 133
Fitting the gear unit 133
Assembling the gear unit 135
Drive wheel 136
Drive wheel disassembly / assembly 136
Drive wheel disassembly 136
Drive wheel assembly 136
ELECTRICAL SYSTEM 137
Control Modules and Display Screen 139
Replacing control modules 140
Replace the main control module 140
Replacing the traction control module 140
Replacing the hydraulic control module 140
Replacing the steering control module 141
Replacing the auxiliary hydraulic module 141
Replacing the display panel 142
PMT Test 142
General 142
Safety Notices 142
Required tools 142
Preparing the control module safety test 143
Traction control module safety test 143
Hydraulic control module safety test 144
Steering control module safety test 144
Auxiliary Hydraulic Module Safety Test 145
ESR 5220 / 5240 Service Menu Structure 147
Overview of menu items 147
Analyzer 147
Calibration 148
Features 148
Hour Meter 150
ESR 5200 Series
Rev C
VII I
TABLE OF CONTENTS cnawn
Log Events 150
Performance 151
Utilities 152
Performance – Level Defaults ESR 5220 / 5240 152
ESR 5240 > 7500 / 5260 / 5280S Service Menu Structure 154
Overview of menu items 154
Analyzer 154
A1Status 154
A2 Inputs 154
A3 Outputs 155
Calibration 155
Features 156
Hour Meter 157
Log Events 158
Performance 158
Utilities 159
Performance – Level Defaults ESR 5240 > 7500 / 5260 / 5280S 160
Service Menu Structure ESR 5260 Regen Lower 161
Overview of menu items 161
Analyzer 161
A1 Status 161
A2 Inputs 161
A3 Outputs 162
Calibration 162
Features 163
Hour Meter 165
Log Events 165
Performance 165
Utilities 166
Performance Level Defaults ESR 5260 Regen Lower 167
Access to Service Level 168
Trucks with key switch 168
Trucks without key switch 168
Navigation and entry keys 168
Display structure 168
Analyzer Menu (ESR 5220, ESR 5240) 169
Access to service menu and selecting a sub-menu 169
A1 Status 169
A2 Inputs 170
A3 Outputs 175
Analyzer Menu (ESR 5240 / 5260 / 5280S) 177
Access to service menu and selecting a sub-menu 177
A1 Status 177
A2 Inputs 178
A3 Outputs 184
Analyzer Menu (ESR 5260 Regen Lower) 186
Access to service menu and selecting a sub-menu 186
A1 Status 186
A2 Inputs 188
A3 Outputs 193
Calibration Menu (ESR 5220, ESR 5240) 196
C1 Acceleration Pedal 196
C2 Raise / Lower Handle 197
Rev C
IX
C3 Reach Handle 197
ESR 5200 Series
TABLE OF CONTENTS
C4 Tilt Handle 198
CS Side Shift 199
C6 Brake Pedal 200
C9 Reach Retract 200
C10 Save? 201
Calibration Menu (ESR 5240 > 7500 mm / 5260 / 5280$) 202
C1 Accelerator Pedal 202
C2 Raise / Lower Handle 203
C3 Reach Handle 203
C4 Tilt Handle 204
CS Side Shift 205
C6 Height 206
C63 Height Encoder 207
C64 Custom Height 209
C7 Weight 210
ca Fork Positioning 211
C9 Reach Retract 212
C10 Save? 213
Features Menu (ESR 5220, ESR 5240) 214
F1 Truck Size 214
F2 Free Lift Switch 215
F3 (function not available) 215
F4 Lower Cut Out Switch 215
FS to F7 (function not available) 215
F8 Travel Alarm 216
F9 Beacon 216
F10 User Performance 217
F11 User Code 217
F12 Set Language 220
F13 Change Unit 221
F14 to F15 (function not available) 221
F16Timer 221
F17 Error Log 222
F18 Operator Alarm 222
F19 Battery Alarm 223
F21 Choose Steering 223
F22 Select Sideshift 224
F23 Optimised Cornering Speed 224
F24 Sensitive Steering 225
F25 (function not available) 225
F26 Keyless Entry 225
F27 Operation Control 226
F28 Direction Switch 226
F29 Heated Seat 227
F30 lnfolink 227
F31 Save? 228
Features Menu (ESR 5240 > 7500 mm / 5260 / 5280$) 229
F1 Truck Size 229
F2 Free Lift Switch 230
F3 Height Encoder 230
F4 Lower Cut Out Switch 231
FS 5th Function 232
F6 Maximum Load 232
F7 Capacity Data Monitor 233
ESR 5200 Series
Rev C
X
TABLE OF CONTENTS
F8 Travel Alarm 234
F9 Beacon 234
F10 User Performance 235
F11 User Code 236
F12 Set Language 238
F13 Change Unit 239
F14 Set Rack Select 239
F15 Height/Weight 240
F16 Timer 240
F17 Error Log 240
F18 Operator Alarm 241
F19 Battery Alarm 242
F20 Fork Positioning 242
F21 Choose Steering 243
F23 Optimized Cornering Speed (Speed Reduction in Turns) 243
F24 Sensitive Steering 243
F25 14 km/h 244
F26 Keyless Entry 245
F27 Operation Control 245
F28 Direction Switch 246
F29 Heated Seat 246
F30 lnfoLink 247
F31 Save? 247
Hour Meter Menu 248
H1 Truck Complete 248
H2 Traction Module 248
H3 Hydraulic Mod 249
H4 Key On Time (not applicable to ESR 5260 Regen Lower) 249
H4 Hydraulic Mod (ESR 5260 Regen Lower) 250
HS Set Service Time (not applicable to ESR 5260 Regen Lower) 250
H4 Key On Time (ESR 5260 Regen Lower) 251
H6 Set Service Time (ESR 5260 Regen Lower) 251
Log Events Menu 252
L 1 History 252
L2 Totals 253
L3 Erase History 253
Performance Menu 254
P1 Setup P1 254
P2 Setup P2 258
P3 Setup P3 258
P4 SDI Setting 259
PS Travel > LCS 259
P6 Travel > FLS 260
P7 Travel > Custom 260
PS Lower > Custom 261
P9 Reach > Custom 261
P10 5th Function Left 262
P11 5th Function Right 262
P12 Steer Sensitivity 263
P13 Brake at Ramp 263
P14 Set Default Values 264
P15 Save? 264
Utilities Menu 265
U 1 Software 265
ESR 5200 Series
Rev C
XI
TABLE OF CONTENTS cnawn
U2 Hour set 266
U3 Brake 267
U4 Fan 267
US Truck lock 268
Event Codes (ESR 5220 / 5240 S 7500 mm) 269
Malfunctions with event code display 269
Log book display 269
Malfunctions without event code display 269
Locating malfunctions 269
Event Codes 100 -186 (ESR 5220 / 5240 S 7500 mm) 270
Event Code 100 270
Event Code 101 270
Event Code 102 271
Event Code 110 271
Event Code 111 272
Event Code 112 273
Event Code 120 273
Event Code 121 274
Event Code 123 275
Event Code 124 275
Event Code 130 275
Event Code 131 276
Event Code 160 277
Event Code 180 278
Event Code 181 279
Event Code 182 280
Event Code 183 281
Event Code 184 282
Event Code 186 283
Event Codes 200 – 286 (ESR 5220 / 5240 S 7500 mm) 284
Rev C
XII
Event Code 200 284
Event Code 201 285
Event Code 210 285
Event Code 211 286
Event Code 212 287
Event Code 213 287
Event Code 214 287
Event Code 220 288
Event Code 221 289
Event Code 222 290
Event Code 223 291
Event Code 224 292
Event Code 225 293
Event Code 240 293
Event Code 241 295
Event Code 243 296
Event Code 244 297
Event Code 246 298
Event Code 247 299
Event Code 249 300
Event Code 250 301
Event Code 252 302
Event Code 253 303
Event Code 260 305
ESR 5200 Series
TABLE OF CONTENTS
Event Code 261 306
Event Code 262 308
Event Code 263 309
Event Code 264 310
Event Code 265 311
Event Code 266 312
Event Code 267 314
Event Code 280 315
Event Code 281 315
Event Code 282 316
Event Code 283 316
Event Code 284 317
Event Code 285 318
Event Codes 300 – 385 (ESR 5220 / 5240 S 7500 mm) 319
Event Code 300 319
Event Code 301 319
Event Code 311 320
Event Code 312 321
Event Code 313 321
Event Code 314 322
Event Code 320 323
Event Code 321 324
Event Code 322 325
Event Code 323 326
Event Code 324 326
Event Code 325 327
Event Code 330 328
Event Code 340 328
Event Code 341 329
Event Code 343 330
Event Code 380 331
Event Code 381 332
Event Code 382 332
Event Code 383 333
Event Code 384 333
Event Code 385 335
Event Codes 430 – 465 (ESR 5220 / 5240 S 7500) 336
Event Code 430 336
Event Code 431 337
Event Code 460 338
Event Code 461 338
Event Code 462 339
Event Code 463 339
Event Code 464 340
Event Code 465 342
Event Code 840 (ESR 5220 / 5240 S 7500 mm) 344
Event Code 840 344
Event Codes (ESR 5240 > 7500 mm / 5260 / 5280$) 345
Malfunctions with event code display 345
Log book display 345
Malfunctions without event code display 345
Locating malfunctions 345
Event Codes 100 – 186 (ESR 5240 > 7500 mm / 5260 / 5280$) 346
Event Code 100 346
ESR 5200 Series
Rev C
XIII
TABLE OF CONTENTS cnawn
Event Code 101 346
Event Code 102 34 7
Event Code 110 347
Event Code 111 348
Event Code 112 349
Event Code 120 349
Event Code 121 350
Event Code 123 351
Event Code 124 351
Event Code 130 351
Event Code 131 352
Event Code 160 353
Event Code 180 354
Event Code 181 355
Event Code 182 356
Event Code 183 357
Event Code 184 358
Event Code 186 359
Event Codes 200 – 286 (ESR 5240 > 7500 mm I 5260 I 5280$) 360
Rev C
XIV
Event Code 200 360
Event Code 201 361
Event Code 210 361
Event Code 211 362
Event Code 212 363
Event Code 213 363
Event Code 214 363
Event Code 220 364
Event Code 221 365
Event Code 222 366
Event Code 223 367
Event Code 224 368
Event Code 225 369
Event Code 240 369
Event Code 241 371
Event Code 243 373
Event Code 244 37 4
Event Code 246 375
Event Code 247 376
Event Code 249 378
Event Code 250 379
Event Code 260 380
Event Code 261 381
Event Code 262 382
Event Code 263 383
Event Code 264 385
Event Code 265 386
Event Code 266 387
Event Code 267 388
Event Code 267 389
Event Code 280 391
Event Code 281 391
Event Code 282 391
Event Code 283 392
Event Code 284 393
ESR 5200 Series
TABLE OF CONTENTS
Event Code 285 394
Event Codes 300 – 384 (ESR 5240 > 7500 mm / 5260 / 5280$) 395
Event Code 300 395
Event Code 301 395
Event Code 311 396
Event Code 312 397
Event Code 313 397
Event Code 314 397
Event Code 320 398
Event Code 321 399
Event Code 322 400
Event Code 323 401
Event Code 324 401
Event Code 325 402
Event Code 330 403
Event Code 340 403
Event Code 341 404
Event Code 343 405
Event Code 380 406
Event Code 381 407
Event Code 382 407
Event Code 383 408
Event Code 384 408
Event Codes 430 – 465 (ESR 5240 > 7500 mm / 5260 / 5280$) 410
Event Code 430 410
Event Code 431 411
Event Code 460 412
Event Code 461 412
Event Code 462 413
Event Code 463 413
Event Code 464 414
Event Code 465 416
Event Codes 840 – 886 (ESR 5240 > 7500 mm / 5260 / 5280$) 418
Event Code 840 418
Event Code 841 419
Event Code 880 419
Event Code 881 420
Event Code 883 422
Event Code 884 423
Event Code 885 425
Event Code 886 425
Event Codes (ESR 5260 Regen Lower) 427
Malfunctions with event code display 427
Log book display 427
Malfunctions without event code display 427
Locating malfunctions 427
Event Codes 100 – 186 (ESR 5260 Regen Lower) 428
Event Code 100 428
Event Code 101 428
Event Code 102 429
Event Code 110 429
Event Code 111 430
Event Code 112 430
Event Code 120 431
ESR 5200 Series
Rev C
xv
TABLE OF CONTENTS
Event Code 121 432
Event Code 123 432
Event Code 124 433
Event Code 130 433
Event Code 131 434
Event Code 160 434
Event Code 180 435
Event Code 181 436
Event Code 182 437
Event Code 183 438
Event Code 184 439
Event Code 186 440
Event Codes 200 – 286 (ESR 5260 Regen Lower) 441
Event Code 200 441
Event Code 201 442
Event Code 210 443
Event Code 211 443
Event Code 212 444
Event Code 213 444
Event Code 214 445
Event Code 220 446
Event Code 221 447
Event Code 222 448
Event Code 223 449
Event Code 224 449
Event Code 225 450
Event Code 240 451
Event Code 241 452
Event Code 243 453
Event Code 244 454
Event Code 246 455
Event Code 247 456
Event Code 249 457
Event Code 250 459
Event Code 260 460
Event Code 261 461
Event Code 262 462
Event Code 263 463
Event Code 264 465
Event Code 265 466
Event Code 266 467
Event Code 267 468
Event Code 268 469
Event Code 280 471
Event Code 281 471
Event Code 282 471
Event Code 283 472
Event Code 284 473
Event Code 285 474
Event Codes 300 – 384 (ESR 5260 Regen Lower) 475
Event Code 300 475
Event Code 301 476
Event Code 311 477
Event Code 312 477
ESR 5200 Series
Rev C
XVI
TABLE OF CONTENTS
Event Code 313 478
Event Code 314 478
Event Code 320 479
Event Code 321 480
Event Code 322 481
Event Code 323 482
Event Code 324 483
Event Code 325 484
Event Code 330 484
Event Code 340 485
Event Code 341 486
Event Code 343 487
Event Code 380 488
Event Code 381 488
Event Code 382 489
Event Code 383 490
Event Code 384 491
Event Code 385 491
Event Codes 430 – 465 (ESR 5260 Regen Lower) 493
Event Code 430 493
Event Code 431 494
Event Code 460 495
Event Code 461 495
Event Code 462 496
Event Code 463 496
Event Code 464 497
Event Code 465 499
Event Codes 700 – 787 (ESR 5260 Regen Lower) 501
Event Code 700 501
Event Code 701 502
Event Code 710 503
Event Code 711 503
Event Code 712 504
Event Code 713 504
Event Code 714 505
Event Code 720 506
Event Code 721 507
Event Code 722 508
Event Code 723 509
Event Code 724 510
Event Code 725 510
Event Code 730 511
Event Code 764 512
Event Code 780 513
Event Code 782 514
Event Code 784 515
Event Code 786 515
Event Code 787 516
Event Codes 840 – 886 (ESR 5260 Regen Lower) 517
Event Code 840 517
Event Code 841 518
Event Code 880 519
Event Code 881 520
Event Code 883 522
ESR 5200 Series
Rev C
XVII
TABLE OF CONTENTS
Event Code 884 522
Event Code 885 524
Event Code 886 525
Replacing the Height Encoder 526
Replacing the HGT(R)S Switch 527
Removing the HGT(R)S Switch 527
Assembling the HGT(R)S Switch 527
Setting the Reach Deceleration Ramp in the Limit Positions 528
Replacing the Armrest Controls 529
Trucks with fingertip control levers 529
Removing the controls 530
Assembling the controls 530
Trucks with dual axis hydraulic control levers 530
Trucks with multi-task handle 531
Removing the controls 532
Assembling the controls 532
Wiring the Multi-Task Control Handle (ESR 5260 / 5280S) 533
Wiring the Dual Axis Hydraulic Control Levers (ESR 5260 / 5280S) 535
Wiring the Fingertip Control Levers (ESR 5260 / 5280S) 536
Replacing the Mast Cables 537
Transfer Point Definition 537
Mast cable removal 537
Mast cable assembly 538
Attaching the mast cable clamps 539
Attaching clamping shoes for a 6 core mast cable 539
Attaching clamping shoes for a 10 core mast cable 539
Replacing the Lowering / Stop Switch (LSS, Regen Lower) 540
Replacing the Camera Cable on the Fork Camera 541
Transfer Point Definition 541
Removing the camera cable 541
Camera cable assembly 542
Fitting the camera cable clamps 543
Replacing the Camera Cable on the Mast Camera 544
Transfer Point Definition 544
Removing the camera cable 544
Camera cable assembly 545
Fitting the camera cable clamps 546
Repairing Contactors 547
Wear test 547
Checking the contacts 547
Checking the coils 547
Checking the springs 547
Repairing the Main Contactor (MC) 548
Replacing the Traction Motor 549
Traction motor disassembly 549
Traction motor assembly 549
Connecting the power cables 549
Replacing the Pump Motor 551
Pump motor removal 551
Pump motor assembly 551
Connecting the power cables 552
Replacing the auxiliary hydraulics pump motor 553
Removing the auxiliary hydraulics pump motor 553
Installing the auxiliary hydraulics pump motor 553
ESR 5200 Series
Rev C
XVIII
TABLE OF CONTENTS cnawn
Connecting the power cables 554
Battery Information 555
Charging the battery 555
Replacing the battery 555
Installing the Battery Cable Guide 556
Correct Battery Cable Lengths ESR 5220 / 40 / 60 14 t 559
DIN C 420 Ah and DIN B 280 Ah batteries 559
DIN C 560 Ah and DIN B 420 Ah batteries 559
DIN C 720 Ah and DIN B 560 Ah batteries 560
Correct Battery Cable Lengths: ESR 5260 / 5280$, 16 t I 20 t 561
DIN C 560 Ah battery 561
DIN C 720 Ah battery 561
DIN C 840 Ah battery 562
Replacing the battery cable loom in the truck 563
Hole patterns for the battery connectors on the base plate 564
DIN 160 battery connector (819801-001) 564
DIN 160 battery connector (819801-101) 564
SSE 160 battery connector (819801-002) 565
SSE 160 battery connector (819801-102) 565
SB 350 battery connector (819801-003) 565
SB 350 battery connector (819801-103) 565
Repairing the Heater Module in the Door 566
Removing the heater module 566
Replace the fans 566
Replacing the heater element 567
Replacing the temperature gauge 567
Heater module assembly 567
Repairing the Heater Module in the Roof Console 568
Removing the heater module 568
Replacing the fan 568
Replacing the heater element 569
Replacing the temperature gauge 569
Heater module assembly 569
ELECTRICAL COMPONENTS 571
Component Description 573
Rev C
X IX
ACS 573
AUX HCM 573
BFS 573
BLS 573
BPS(2) 573
BRS 573
BRAKE 573
BS 573
ECR1 573
ECR2 573
ECR3 573
ECR4 573
ECR5 574
ECR6 574
EDS 574
ED1 574
FAN1 and FAN2 574
FAN3 and FAN4<1> 574
ESR 5200 Series
TABLE OF CONTENTS
FKS(1l 574
FLS 574
FS / RS 575
FU1 575
FU2 575
FU3 575
FU4 575
FUS, FU6 575
FU? 575
FU13 575
FU14 575
HCM 575
HN 575
HNS 575
HGTS 575
HGTRS 576
K1 and K2 576
K11 576
K12 & K13 576
K22 & K23 576
KYS 576
LS 576
LSS(2l 576
MVL 576
ORS 576
POT1 576
POT2 576
POT3 577
POT4 577
POTS 577
POT6 577
PLS<2l 577
PV1 577
PVL 577
PVAR(5l 577
PVAL<2l(5l 577
PVRT(5l 577
PVRE 577
RES1 577
RES2 578
RV/ RV1 578
SCM 578
SES 578
SFS 1SA 578
SFS 2 578
SPS 578
SV1 578
SVAR 579
SVAL<1l 579
SVH 579
SVRT<1l 579
SVRE<1l 579
SVL<1l 579
svs 579
ESR 5200 Series
Rev C
xx
TABLE OF CONTENTS
SVSL<1l 579
SVSR<1l<4l 579
SVT<3l 579
SVTD(2l 580
SVTU<1 l 580
SW 580
TCM 580
THS1 580
THS2 580
THS3 580
THS4 580
THS6<1l 580
12 VOC/24 voe and 48 voe Option Transfer Points 581
Connector Locations 581
Mast Switch Position and Setting, TL Tilting Mast 583
Mast Switch Position and Setting, TT Tilting Mast 584
BRAKE SYSTEM 585
Repairing the Parking Brake 587
Checking the parking brake torque 588
Parking brake disassembly 588
Dismantling the brake 588
Fitting the brake 588
Parking brake assembly 588
Adjusting the air gap 589
Measuring the coil resistance 589
Releasing the parking brake mechanically 590
Releasing the parking brake 590
Towing the truck 590
Activating the parking brake 590
Repairing the load wheel brake 591
General 591
Checking the brake lining wear 591
Replacing the brake linings 591
Replacing the wheel brake cylinder 592
Wheel brake cylinder disassembly 592
Wheel brake cylinder assembly 593
Bleeding the load wheel brake 593
Replacing the brake fluid 593
Testing and Adjusting the Brake Pedal Clearance 594
Hydraulic brake 594
Electric brake 594
Adding Brake Fluid 595
Checking the Brake Power 596
Requirements 596
Required tools 596
Brake test 596
STEERING 599
Operation 601
Generating a steering signal 601
Steer motor activation 601
Steer system monitoring 601
ESR 5200 Series
Rev C
XXI
TABLE OF CONTENTS cnawn
Error correction 601
Quadrant – definition 602
Steering Errors 603
Error routine 603
Ending the error routine 603
Causes of error routine activation 603
Other error causes 603
Examples of steer faults 604
Replacing and Adjusting SFS2 or SFS1 SA 606
Steer Motor and Steering Transmission 607
Removing the steer motor and steering transmission 607
Disconnecting the steering transmission and steer motor 607
Assembling the steering transmission and steer motor 608
Installing the steer motor and steering transmission 608
LIFTING MECHANISM 611
Mast 613
Safety instructions for working on the mast 613
General 613
Torques 613
Checking the assembled mast 613
Flaking 613
Checking the roller tracks 613
Checking the mast verticality 613
Checking the pulleys, hoses and cables 613
Checking the end stops 614
Checking the fork setting 614
Checking the tilt on fixed masts 614
Fixed mast tilt tolerance tables 615
Adjusting the tilt on fixed masts 617
Mast Removal and Assembly 618
Lifting gear minimum capacities 618
Mast disassembly 618
Mast assembly 619
Checks and adjustments after assembly 620
Tilting mast removal and assembly 622
Converting to a different mast height 622
Safety instructions for working on the mast 622
General 622
Torques 622
Tilting mast removal and assembly 622
Lifting gear minimum capacities 622
Removing the tilting mast 623
Tilting mast assembly 624
Checks and adjustments after assembly 624
Dismantling and Assembling the Mast 627
Safety notices 627
Tips and tricks 627
Dismantling the mast 627
Removing the fork carriage 627
Removing the 2nd mast stage (TT masts only) 627
Removing the 1st mast stage 628
Mast Roller Removal and Assembly 629
Rev C
XXII
Safety notices 629
ESR 5200 Series
TABLE OF CONTENTS cnawn
Mast roller removal 629
Mast roller assembly 629
Overview of available roller diameters 629
Calculating the roller diameter 630
Calculating the number of shims required 632
Outer mast and 1st mast stage 632
Final tasks and settings 634
Adjusting the “anti-rattle” screws 636
Adjustments on the fixed mast 636
Tilting mast adjustment 637
Sideshifter 639
Repairing an integrated sideshifter (fixed mast) 639
Removing an integrated sideshifter 639
Assembling the integrated sideshifter 639
Repairing a hook-on sideshifter 641
Removing a hook-on sideshifter 641
Installing a hook-on sideshifter 641
Repairing an integrated sideshifter (tilting mast) 643
Removing an integrated sideshifter 643
Fork Carriage Removal and Assembly 645
Safety Notices 645
Removal 645
Free Lift Cylinder Removal and Assembly 646
Safety notices 646
Removal 64 7
Installing the free lift cylinder in an upright mast 647
Installing the free lift cylinder in a horizontal mast 647
Lift Cylinder Removal and Assembly 649
Safety notices 649
Lift cylinder removal on masts up to 8 m 649
Lift cylinder assembly on masts up to 8 m 650
Lift cylinder removal on masts above 8 m 652
Lift cylinder assembly on masts above 8 m 652
Reach Cylinder Removal and Assembly 653
Safety notices 653
Removal 654
Assembly 654
Mast Tilt Cylinder Removal and Assembly 655
Safety notices 655
Mast tilt cylinder removal 655
Assembly 657
Repairing Lift Chains and Chain Tensioners 658
Adapting the service intervals to the application conditions 658
Periodic replacement of the chain tensioners and lift chains 658
Servicing lift chains 659
Service work 659
Checking the service hours for the lift chains and anchor bolts 659
Cleaning lift chains 659
Lubricating and preserving lift chains 659
Checking the Lift Chains for Wear and Damage 661
Rev C
XXIII
Checking the lift chain elongation 661
Tools required 661
Test preparation 661
Checking the lift chain elongation with the wear gauge 662
ESR 5200 Series
TABLE OF CONTENTS
Checking the lift chain elongation with the steel ruler 663
Checking the chain for other damage 664
Fork Tines – Terms and Identification 667
Terms 667
Identification 667
Checking the fork tines 668
Checking fork tines for cracks 668
Checking the fork tip for straightness 668
Checking the blade warping 669
Measuring the fork tip width 669
Checking the fork tine height difference 669
Checking the fork stop 670
Measuring the fork blade wear 670
Reach Carriage, Terms and Definitions 671
Terms 671
Reach carriage with side rollers 671
Reach carriage with slide bolts 671
“Left outrigger” and “Right outrigger” definition 672
Reach Carriage Removal and Assembly 672
Reach carriage removal 672
Reach carriage assembly 672
Adjusting the reach carriage 673
Reach carriage with side rollers 673
Reach carriage with slide bolts 67 4
CYLINDERS 677
Repair Tools 679
Small hook 679
Extractor 679
Producing extractors 679
Groove aligning arbor for small rod seals 679
Assembly devices for large rod seals 680
Protective mechanisms 680
Rod Seal Removal and Assembly 681
Removing a large rod seal 681
Removing a small rod seal 681
Inserting a large rod seal 681
Fitting a small rod seal 682
Rod seal assembly, sealing lip first 682
Repairing Cylinders 683
Safety notices 683
General 683
Replacing the rod seals 683
Repairing the lift cylinder 684
Hydraulic system repair instructions 684
Dismantling lift cylinders 684
Lift cylinder assembly 684
Piston ram pre-assembly and installation 685
Piston cap pre-assembly and installation 685
Final tasks 685
Repairing the Free Lift Cylinder 687
Hydraulic system repair instructions 687
Dismantling the free lift cylinder 687
Free lift cylinder assembly 687
ESR 5200 Series
Rev C
XXIV
TABLE OF CONTENTS cnawn
Piston ram pre-assembly and installation 688
Piston cap pre-assembly and installation 688
Final tasks 688
Repairing the Reach Cylinder 690
Hydraulic system repair instructions 690
Dismantling the reach cylinder 690
Piston ram pre-assembly and installation 690
Piston cap pre-assembly and installation 691
Final tasks 691
Repairing the Sideshifter Cylinder 693
Hydraulic system repair instructions 693
Dismantling the sideshifter 693
Sideshifter cylinder assembly 693
Final tasks 693
Repairing the Mast Tilt Cylinder 695
Hydraulic system repair instructions 695
Mast tilt cylinder removal 695
Replacing the seals on the mast tilt cylinder 695
Dismantling the mast tilt cylinder 695
Mast tilt cylinder assembly 696
Final tasks 696
Tilt angle and lift height 698
SCHEMATIC DIAGRAMS 699
Wire Colour Code 701
General Contact Symbol Abbreviations 702
Electrical wiring diagrams 704
Circuit and Wiring Diagram Assignment 706
Power Up Circuit 001055 708
Circuit Diagram 831737 709
Main wire harness 831635 712
Main wire harness spline list 831635 714
Main wire harness wiring list 831635 715
Reach wire harness 830464 716
Main Wire Harness 829674 717
Main Wire Harness Spline List 829674 719
Main Wire Harness Wiring List 82967 4 720
Circuit Diagram 829790 721
Cold store truck option, circuit diagram 829790 723
Main wire harness 828191 724
Main wire harness wiring list 828191 726
Main wire harness spline list 828191 727
Reach wire harness 827091-030 728
Reach wire harness 827091-030 729
Cold Store Truck with Seat Heating Option, Additional Harness 824316 730
Strobe Wire Harness 824318 731
Travel alarm wire harness 824320 732
DC/DC converter wire harness (12 V or 24 V) 733
Power supply wire harness 825322 734
Mast valve block wire harness 812327 735
Armrest wire harness 822619 / 822620 736
Cold store truck additional wire harness 824316 737
Cold store truck additional wire harness 824317 738
Cold store truck additional wire harness 833054 739
Seat heating option wire harness 824321 7 40
Load sensor and height encoder wire harness 822754 741
Load sensor and height encoder wire harness 822755 742
Load sensor and height encoder wire harness 822756 743
Jumper 822758 for PC805 7 44
LED work lights wire harness (48 V) 827979 7 45
Bulb work lights wire harness (24 V) 824319 746
Mast camera wire harness 823650 747
Mast camera wire harness 826962 7 48
Fork camera wire harness 828247 749
Fork camera wire harness 828250 750
Fork camera wire harness 828251 751
Reading light wire harness 824371 752
Cold Store Cab Main Wire Harness (ESR 5260 / 5280S) 753
Cold store cab door wire harness (ESR 5260 / 5280 S) 754
Cold store cab circuit diagram (ESR 5260 / 5280S) 755
Cold store cab circuit diagram, Sheet 2 (ESR 5260 / 5280S) 756
Cold store cab circuit diagram, Sheet 3 (ESR 5260 / 5280S) 757
Cold store cab circuit diagram, Sheet 4 (ESR 5260 / 5280S) 758
Cold store cab circuit diagram, Sheet 5 (ESR 5260 / 5280S) 759
HYDRAULIC SCHEMATIC 761
Hydraulic Symbols 763
Hydraulic Circuit Diagram ESR 5240 > 7500 mm lift height, ESR 5260, ESR 5280S 767
Hydraulic circuit diagram ESR 5220, ESR 5240 with tilting mast 768
Hydraulic diagram, ESR 5260 with Regen Lower option 769
Rev C

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