Crown ESR 5000 Forklift Service Manual
534 pages · Publication 812577-006
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- Models
- ESR 5000
- Manual type
- Service Manual
- Pages
- 534
- Publication
- 812577-006
- Condition
- Brand new
What's inside
From the manual's own table of contents: 598 sections, 612 entries. See sample pages (PDF, 863 KB)
General1 topic
- TABLE OF CONTENTS INTRODUCTION
Important Information
Manual structure
Text mark-ups in the manual
Service personnel qualification
Ordering spare parts
Ordering documentation
Specification Number
SAFETY
Safety Notices
Basic Safety Notices
Organisational measures
Personal safety equipment
Protecting the hazardous area
Hazards from stored energy
Repair work
Restoring the truck to service after repair work
Cleaning work
Handling batteries
Warning and instruction decals on the truck
Lifting gear and slings
Environmental protection
LUBRICATION & ADJUSTMENT
Transport and Storage
Show all 599 sections
Lifting the truck
Lifting the truck with a forklift truck
Towing the truck
Jacking up the Truck
Truck Assembly and Commissioning
Truck assembly
Required tools
Erecting the chassis
Removing the transport retainers
Filling the drive transmission unit
Erecting the mast and fitting it to the chassis
Placing the Truck in Storage
Testing trucks in storage
Restoring the truck to service
Battery maintenance
Component Access
Accessing components under the panels
Components under the panels
Accessing the motor compartment
Motor compartment
Accessing components under the floorboard
Components below the floorboard
Recommended Lubricants and Consumables
Cold store truck requirements1 topic
- TABLE OF CONTENTS Abbreviations used in the table
Planned Maintenance and Inspection
Maintenance Schedule
Annual inspection in accordance with FEM 4.004
Terms and abbreviations used
Seat and seat panel
Brake system and load wheels
Drive unit
Reach carriage
Hydraulic system
Electrical system - part 1
Electrical system - part 2
Travel and pump motors
Mast
Fork carriage
Torques
Standard torques
Load Wheels
Load wheel replacement
Special tools required
Load wheel removal
Load wheel assembly
Support Blocks
Checking the support block distance
Requirements
Measurement
Adjusting the support block height
Before adjusting
Replacing the support blocks
Cleaning the Truck and Components
Effects of incorrect cleaning
Electrical components
Roller and slide bearings
Corrosion-protected surfaces
Cleaning the entire truck
Cleaning removed components
Cleaning lift chains
Cleaning other mechanical components
Abbreviations Used
Feature Descriptions
Lifting
Lower
Extending the mast reach carriage
Retracting the mast reach carriage
Fork tilt back
Fork tilt down
Sideshift right
Sideshift left
Hydraulic Components
Hydraulic lines
Valve blocks1 topic
- TABLE OF CONTENTS Main valve block
Accessories" valve block
Checking and adjusting relief valve RV1
Checking the emergency lowering valve MVL
Depressurising the Hydraulic System
Bleeding and Flushing the System
Bleeding the free lift cylinder
Bleeding the lift cylinders
Bleeding the reach cylinder
Bleeding the sideshift cylinder
Bleeding the tilt cylinder
Bleeding the 5th function cylinder
Flushing the lift cylinders
Drift tests
Lift cylinder drift test
Tilt cylinder drift test
Hydraulic Oil Reservoir
ESR 5000S hydraulic oil reservoir
ESR 5000 hydraulic oil reservoir
Replacing the Hydraulic Oil
Replacing the Filter
Replacing the return filter
Replacing the suction filter
Replacing the breather filter
Replacing the Hydraulic Pump
Hydraulic Port Torques
Gear Unit
Removing the gear unit
Repairing the gear unit
Dismantling the gear unit
Assembling the gear unit
Drive Wheel
Drive wheel disassembly / assembly
Drive wheel disassembly
Drive wheel assembly
ELECTRICAL SYSTEM
BRAKE1 topic
- TABLE OF CONTENTS ECR1
FAN1, FAN4
FAN2, FAN3
HGTS
HGTRS
PVAR
PVAL
PVRT
PVRE
SFS 1SA1 topic
- TABLE OF CONTENTS SVT
Service Menu Structure
Software version
Menu structure
Overview of menu items
Analyzer
A1Status
Calibration
C1 Acceleration Pedal
C2 Raiser/Lower Handle
C3 Reach Handle
C4 Tilt Handle
C5 Side Shift Handle
C6 5th Function Handle
C7 Height
C8 Weight
C9 Fork Positioning
C10 Reach Retract Slow Down
C11 Save?
Features
Hour Meter
Log Events
Performance
Utilities
Performance level defaults
Standard settings
Service Menu - General
Access to service level
Trucks with key switch
Trucks without key switch
Navigation and entry keys
Display structure
Access to service menu and selecting a sub-menu
Analyzer Menu
A1 Status
A2 Inputs
A3 Outputs
Calibration Menu
C1 Accelerator Pedal
C2 Raise / Lower Handle
C5 Side Shift
C6 5th Function
C7.3 Height Encoder1 topic
- TABLE OF CONTENTS C10 Reach Retract
C11 Save
Features Menu
F1 Truck Size
F2 Free Lift Switch
F3 Height Encoder
F4 Lower Cut Out Switch
F5 5th Function
F6 Maximum Load
F7 Capacity Data Monitor
F8 Travel Alarm
F9 Beacon
F10 User Performance
F11 User Code
F12 Set Language
F13 Change Unit
F14 Set Rack Select
F15 Height/Weight
F16 Timer
F17 Error Log
F18 Operator Alarm
F19 Battery Alarm
F20 Fork Positioning
F21 Choose Steering
F25 Keyless Entry
F26 Right Handle
F27 Options Display
F28 Truck Lockout
F29 Direction Switch
Hour Meter Menu
H1 Truck Complete
H2 Traction Module
H3 Hydraulic Mod
H4 Key On Time
H5 Set Service Time
Log Events Menu
L1 History
L2 Totals
L3 Erase History
Performance Menu
P1 Setup P1
P2 Setup P2
P3 Setup P3
P4 BDI Setting
P5 Travel > LCS
P6 Travel > FLS
P7 Travel > Custom
P8 Lower > Custom
P9 Reach > Custom
P10 5th Function Left
P11 5th Function Right
P12 Steer Sensitivity
P14 Brake at Ramp1 topic
- TABLE OF CONTENTS P15 Set Default Values
Utilities Menu
U1 Software Version
U2 Hour Set
U3 Brake Override
Event Codes
Malfunctions with event code display
Log book display
Malfunctions without event code display
Locating malfunctions
Event Code 100
Event Code 101
Event Code 102
Event Code 110
Event Code 111
Event Code 112
Event Code 120
Event Code 121
Event Code 123
Event Code 124
Event Code 130
Event Code 131
Event Code 160
Event Code 180
Event Code 181
Event Code 182
Event Code 183
Event Code 184
Event Code 186
Event Code 200
Event Code 201
Event Code 210
Event Code 211
Event Code 212
Event Code 213
Event Code 214
Event Code 220
Event Code 221
Event Code 222
Event Code 223
Event Code 224
Event Code 225
Event Code 240
Event Code 241
Event Code 243
Event Code 244
Event Code 246
Event Code 247
Event Code 249
Event Code 2501 topic
- TABLE OF CONTENTS Event Code 260
Event Code 261
Event Code 262
Event Code 263
Event Code 264
Event Code 265
Event Code 266
Event Code 267
Event Code 268
Event Code 280
Event Code 281
Event Code 282
Event Code 283
Event Code 284
Event Code 285
Event Code 300
Event Code 301
Event Code 311
Event Code 312
Event Code 313
Event Code 314
Event Code 320
Event Code 321
Event Code 322
Event Code 323
Event Code 324
Event Code 325
Event Code 330
Event Code 340
Event Code 341
Event Code 343
Event Code 380
Event Code 381
Event Code 382
Event Code 383
Event Code 384
Event Code 430
Event Code 431
Event Code 460
Event Code 461
Event Code 462
Event Code 463
Event Code 464
Event Code 465
Event Code 840
Event Code 841
Event Code 880
Event Code 881
Event Code 883
Event Code 884
Event Code 8851 topic
- TABLE OF CONTENTS Event Code 886
Control Modules and Display Screen
Replacing control modules
Replacing the main control module
Replacing the traction control module
Replacing the hydraulic control module
Replacing the steering control module
Replacing the display panel
PMT Test
General
Preparing the control module safety test
Traction control module safety test
Hydraulic control module safety test
Steering control module safety test
Replacing the Height Encoder
Replacing the HGT(R)S Switch
Removing the HGT(R)S switch
Assembling the HGT(R)S switch
Replacing the Armrest Controls
Trucks with fingertip control levers
Removing the controls
Assembling the controls
Trucks with dual axis hydraulic control levers
Trucks with multi-task handle
Repairing Contactors
Wear test
Checking contacts
Checking the coils
Checking the springs
Repairing the Main Contactor
Replacing the Danaher Traction Motor
Traction motor disassembly
Traction motor assembly
Connecting the power cables
Replacing the Sensor Bearing on the Danaher Traction motor
Sensor bearing disassembly
Sensor bearing assembly
Replacing the Crown Traction motor
Replacing the Pump Motor
Removing the pump motor
Pump motor assembly
Replacing the Sensor Bearing on the Danaher Pump Motor
Choosing the Correct Battery Cable Length
Choosing cable lengths for a T-shaped battery (example)1 topic
- TABLE OF CONTENTS BRAKE SYSTEM
Service and Parking Brake
Service and Parking Brake Danaher Motor
Disassembling the brake
Dismantling the brake
Fitting the brake
Assembling the brake
Adjusting the air gap
Measuring the coil resistance
Parking Brake - Crown Motor
Disassembling the parking brake
Assembling the parking brake
Load Wheel Brake
Checking the brake lining wear
Replacing the brake linings
Wheel brake cylinder
Wheel brake cylinder disassembly
Wheel brake cylinder assembly
Bleeding the load wheel brake
Replacing the brake fluid
Testing and Adjusting the Brake Pedal Clearance
Adding Brake Fluid
Brake Power Control
Brake test
STEERING
Function
Generating a steering signal
Steer motor activation
Steer system monitoring
Error correction
Quadrant - definition
Steering Errors
Error routine
Ending the error routine
Causes of error routine activation
Other error causes
Examples of steer faults
Proximity Switches SFS2 and SFS1 SA
Replacing and adjusting SFS2 or SFS1 SA
Steer Motor and Steering Transmission
Removing the steer motor and steering transmission
Disconnecting the steering transmission and steer motor
Assembling the steering transmission and steer motor
Installing the steer motor and steering transmission1 topic
- TABLE OF CONTENTS Steering Wheel
Steering wheel removal
Steering wheel assembly
Replacing Encoder ECR2
Removing ECR4
Assembling ECR4
LIFTING MECHANISM
Safety instructions for working on the mast
Lifting gear minimum capacities
Checking the assembled mast
Flaking
Checking the roller tracks
Checking the mast verticality
Checking the pulleys, hoses and cables
Checking the end stops
Checking the fork setting
Checking the mast tilt
Mast tilt tolerance tables
Adjusting the Mast Tilt
Mast Removal / Assembly
Mast removal and assembly
Mast removal
Mast assembly
Mast checks and settings after assembly
Dismantling and Assembling the Mast
Tips & tricks
Dismantling the mast
Fork carriage removal
Removing the 2nd mast stage
1st mast stage removal
Replacing the Mast Rollers
Preparation
Mast roller assembly
Calculating the roller diameter
Calculating the required number of shims
Final tasks and settings
Integrated Sideshifter
Removing the integrated sideshifter
Assembling the integrated sideshifter
Lift Cylinder Removal and Assembly
Lift cylinder removal on masts up to 8 m
Lift cylinder assembly on masts up to 8 m
Lift cylinder removal on masts beyond 8 m
Lift cylinder assembly on masts beyond 8 m
Reach Cylinder Removal and Assembly1 topic
- TABLE OF CONTENTS Safety notices
Removal
Free Lift Cylinder Removal and Assembly
Assembly
Chain Supports and Lift Chains
Periodic inspection of chain supports and lift chains
Periodic replacement of chain supports and lift chains
Inspecting Chain Supports and Lift Chains
Checking the service hours for the lift chains and anchor bolts
Checking the lift chain for elongation
Preparatory measures
Freedom of movement
Worn or missing plates
Turned pins
Corrosion
Chain lateral wear
Checking chain supports and anchor bolts
Checking the chain pulleys
Checking and adjusting the chain tension
Checking and adjusting the tension on the outer chains
Checking and setting the free lift chain tension
Checking the lifting components for misalignment
Lubricating Lift Chains
General information
Lubrication intervals and lubricants
Separating Lift Chains
Tools and equipment required
Forks
Terms
Fork marking
Fork Inspection
Checking fork tines for cracks
Checking fork tip straightness
Measuring the fork blade warping
Measuring the fork tip width
Measuring the fork tine height difference
Checking the fork stop
Measuring the fork blade wear
Terms and definitions
Left outrigger" and "Right outrigger" definition
Reach carriage removal
Reach carriage assembly
CYLINDERS1 topic
- TABLE OF CONTENTS Hydraulic System Repair Instructions
Tools
Small hook
Extractor
Producing extractors
Groove aligning arbor for small rod seals
Assembly devices for large rod seals
Protective mechanisms
Rod Seal Removal and Assembly
Removing a large rod seal
Removing a small rod seal
Inserting a large rod seal
Fitting a small rod seal
Rod seal assembly, sealing lip first
Repairing Cylinders
Replacing the rod seals
Repairing Lift Cylinders
Dismantling lift cylinders
Lift cylinder assembly
Piston ram pre-assembly and installation
Piston cap pre-assembly and installation
Final tasks
Repairing the Free Lift Cylinder
Dismantling the free lift cylinder
Free lift cylinder assembly
Repairing the Reach Cylinder
Dismantling the reach cylinder
Repairing the Sideshifter Cylinder
Dismantling the sideshifter
Sideshifter cylinder assembly
SCHEMATIC DIAGRAMS
Wire Colour Code
General Contact Symbol Abbreviations
Electrical Wiring Diagrams
Power Up Circuit
Wiring Diagram (Fingertip and Dual Axis Hydraulic Control Levers)
Wiring Diagram (Multitask Control Handle)
Main harness, ESR 5000, Danaher motor
Replacement Parts
Main Harness, ESR 5000, Crown Motor
Wiring
Main Harness, ESR 5000S, Crown Motor
Harness, ESR 5000 Armrest
Harness, ESR 5000S Armrest
Connector table
Wire Harness: Terminal to Reach Carriage
Cable Assy Truck, Reach Carriage
Cable Assy Valve Block, Mast
Fork Carriage Harness Extended, ESR 5000, Mast
Plug connector housing
Contact pins
Fork Carriage Harness Standard, ESR 5000, Mast
Fork Carriage Switch Assy, ESR 5000, Mast
Fork Carriage, 5th Function, ESR 5000, Mast
Fork Carriage, LS Bridge, ESR 5000, Mast
FKS Heater Assembly, Mast
Cable Mast 10 Core Assy, ESR 5000, Mast
Cable Mast 6 Core Assy, ESR 5000, Mast
VT Camera, Reach Carriage to Chassis, Option1 topic
- TABLE OF CONTENTS Plug connector housing
VT Camera, DC / DC to Control Box, Option
VT Camera, Mast, Option
Assembly Remark
VT Camera, Box to Chassis, Option
Motec Camera, Supply to b/w Monitor, Option
Motec Camera, Component to Reach, Option
Motec Camera, Supply to Display Box, Option
Motec Camera, Fork Camera, Option
Motec Camera, Inner Mast, Option
Motec Camera, Reach to Display Box, Option
Motec Camera, Mast (Fork Camera), Option
Cold Store Harness, ESR 5000, Option
Cold Store, Armrest Harness, ESR 5000, Option
Cold Store, Armrest Harness, ESR 5000S, Option
Beacon Loom, Option
Working Light 24V Loom, Option
Cable lugs and rings
Travel Alarm Harness, Option
Heated Seat, ESR 5000, Option
DC/DC Converter Loom, Option
Reading Light Harness, Option
Working Light 12V, Harness, Option
InfoLink, Harness, Option
DCDC Converter Loom NA, Option
DC/DC Converter Loom NA, Option
48V Supply, Option
Power Supply Cable, Option
Bypass Cable, Seat Heating Switch, Option
Supply Cable, ESR 5000, PSA
Lights 12V, PSA
HYDRAULIC SCHEMATIC
Hydraulic Symbols
Hydraulic Diagram
Inside this manual
Real pages from this service manual (534 pages). Open the sample pages (PDF, 862 KB)
- Specifications, page 32: LUBRICATION & ADJUSTMENT
- Troubleshooting, page 248: Event Codes 300 - 385
- Diagram, page 456: SCHEMATIC DIAGRAMS
- Color page, page 344: LIFTING MECHANISM
- Foldout diagram (color), page 461: SCHEMATIC DIAGRAMS
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 534 pages
Quantity one is the manual described above.
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Other editions and similar models
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