ES/ET

ES/ET4000 SERIES
MAINTENANCE MANUAL

Order Number: 812597-006

Revision: B • Printed in Germany
 This master manual is subject to continual updates.
It is intended solely for companies authorized by Crown.
The transfer of the content or copies thereof to third parties is prohibited.

Crown Gabelstapler GmbH & Co. KG

– European Headquarters –
Philipp-Hauck-Str. 12
85622 Feldkirchen
Germany

Phone +49 (0)89 93 00 2 – 0

Fax +49 (0)89 93 00 2 – 312

www.crown.com

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

Copyright 2014
Crown Equipment Corporation
TABLE OF CONTENTS
I
Notes:

II
 TABLE OF CONTENTS

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Text mark-ups in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brief description of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Truck Data Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Truck modifications and additions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Personal safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Protecting the hazardous area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hazards from stored energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Restoring the truck to service after maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warning and instruction decals on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lifting gear and slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety Mechanisms and Protective Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Truck safety mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Truck protective guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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
Raising the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Securing the Truck for Transport on a Truck Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Towing the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Jacking up the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Placing the Truck in Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Taking the truck out of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Testing trucks in storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Restoring the truck to service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Recommended Lubricants and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cold store truck requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

ES/ET4000 Series
Rev. B
III
TABLE OF CONTENTS

Abbreviations used in the table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Annual inspection in accordance with FEM 4.004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Terms and abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lifting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Drive system, steering and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Safety mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Replacing the Caster Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removing the caster wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installing the caster wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Repairing the Caster Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Replacing the Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Metric screws and nuts without flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Metric hex. bolts and nuts with flange (Unbrako® type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

COMPONENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Motor compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Adding hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Replacing the Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Replacing the Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Replacing the Relief Valve RV1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Testing the relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Flushing the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Preparing the drift test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Drift test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Hydraulic System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Trucks with mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Trucks with electric steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Replacing the Drive Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Drive wheel disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Drive wheel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Changing the Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Drive Gear Disassembly / Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Drive gear unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Drive gear unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

ES/ET4000 Series
Rev. B
IV
 TABLE OF CONTENTS

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Initial truck status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SAS and BRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Operating mode definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Pedestrian mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Comfort mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Rider mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Quick Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Brief description of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Platform and Side Restraint Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Brief description of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Folding platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Side restraint and platform setting definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Accessing the Service Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Operator Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Access 3 - Analyzer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Access 2 - Analyzer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Access 5 - Analyzer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Features - F1 to F3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Features - F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Features - F5 to F12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Features - F13 to F18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Features - F7 Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Hour - H1 to H5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Events - E1 to E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Performance P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Performance P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Performance P3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Performance P4 to P16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Utilities - U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Test Outputs - A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Software Parameter Settings ES 4020-MW /-EW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Brief description of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Software Parameter Settings ET 4040-MF / -EF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Brief description of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Selecting the CALIBRATION Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Electric steering calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Calibrating proportional lifting and lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Malfunctions with event code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Locating malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Event code groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Event Code - Group 100 (ES/ET -M, -E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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Event Code 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Event Code - Group 200 (ES/ET -M, -E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Event Code 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Event Code 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Event Code 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Event Code 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Event code 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Event code 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Event code 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Event code 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Event code 231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Event codes 232 and 233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Event code 234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Event code 235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Event code 236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Event Code - Group 300 (ES/ET -M, -E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Event code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Event code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Event code 302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Event code 303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Event Code 304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Event code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Event code 306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Event code 307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Event code 308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Event code 309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Event code 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Event code 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Event code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Event code 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Event code 317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Event code 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Event Code 334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Event Code 321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Event code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Event code 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Event code 328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Event code 329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Event code 333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Event Code 334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Event code 335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Event code 337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Event code 338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Event Code 340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Event code 341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Event code 342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Event code 343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Event code 348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Event code 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Event code 352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Event code 353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Event code 354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Event code 355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Event code 356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

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Event code 357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Event code 358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Event code 359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Event code 361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Event code 362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Event Code 364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Event code 365 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Event code 368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Event Code - Groups 500 and 800 (ES/ET-E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Event Code 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Event Code 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Event codes 502, 503, 504, 505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Event Code 506 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Event code 508 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Event code 509 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Event code 510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Event code 511 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Event code 512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Event code 513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Event code 514 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Event code 515 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Event code 516 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Event Code 517 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Event code 518 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Event code 519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Event codes 520, 521 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Event code 522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Event code 523 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Event code 524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Event code 525 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Event code 526 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Event codes 527, 528 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Event code 529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Event code 530 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Event code 531 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Event code 532 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Event code 535 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Event code 536 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Event code 537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Event code 538 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Event code 539 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Event code 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Event code 541 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Event codes 542, 543 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Event code 544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Event code 545 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event code 547 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Event codes 801 to 804 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Events Displayed as Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Platform Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Traction control module hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Traction motor hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Release control handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

ES/ET4000 Series
Rev. B
VII
TABLE OF CONTENTS

Travel switch applied too soon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Pedestrian mode only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Lower forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Steering controller hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Steer motor hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Control Module PMT Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
PMT Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Testing Access 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Testing Access 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Testing Access 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Servicing and Replacing the Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Discharging the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Servicing the control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Replacing control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Removing the control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Assembling the control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Set the parameters after replacing a control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Converting the truck from Enter key to key switch power-up function . . . . . . . . . . . . . . . . . . . . . . . . . 215
Mechanical conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Changing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Converting the truck from key switch to Enter key power-up function . . . . . . . . . . . . . . . . . . . . . . . . . 216
Mechanical conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Changing the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Battery Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Adjusting the BLS sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
General DC Motor Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Setting the Load Profile for the Battery Discharge Indicator (BDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Load profile and discharge curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Assigning a load profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Checking and Adjusting the BDI Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Checking the BDI Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Adjusting the BDI setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Traction motor Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Traction motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Traction motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Repairing the Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Rotor and bearing disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Rotor and bearing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Pump Motor (M2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Replacing the Steer Motor (M3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Special tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

ES/ET4000 Series
Rev. B
VIII
 TABLE OF CONTENTS

Steer motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Steer motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Repairing Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Wear test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Checking the contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Checking the coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Checking the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

ES4000 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
ET 4000 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
PWS, FLS, ALM and charger option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
InfoLink® option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Components and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Servicing the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Measuring the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Replacing the Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Parking brake disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Parking brake assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Testing the Braking Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Performing the test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Braking distance tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Maximum braking distances ES 4000 -MW or -EW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Maximum braking distances ET 4000 -MF or -EF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Repairing the Tiller Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Replacing the tiller handle shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Shell removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Shell assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Replacing the switch unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Switch unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Switch unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Replacing the “rabbit/turtle” toggle module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Toggle module removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Toggle module assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Replacing the tiller handle PC boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Hydraulic PC board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Hydraulic PC board assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Main PC board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Main PC board assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Replacing the traction potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Traction potentiometer removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Traction potentiometer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Replacing the brake switch (BRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Remove the brake switch (BRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
BRS switch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

ES/ET4000 Series
Rev. B
IX
TABLE OF CONTENTS

Replacing the grips and horn switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Repairing Tiller Handle Return Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Removing the covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Return spring pre-tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Replacing the return springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Return spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Return spring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Mechanical Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Repairing the steering transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Setting straight-ahead travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Checking the Assembled Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Checking the Fork Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Mast Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Mast disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Mast assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Correct Use of Tool 833158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Replacing the Fork Carriage Rollers and Adjusting the Slack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Repairing the Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
TF mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
TT mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Mast disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Mast assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Final tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Replacing the Mast Rollers and Adjusting the Slack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Fork Carriage Assembly and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Removing the fork carriage with the TF and TT masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Removing the fork carriage with a TL mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Lowering Plumb Test and Adjusting the Mast Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Preparing the lowering plumb test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Lowering plumb test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Adjusting the Mast Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Replacing the Mast Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Removing the mast guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Installing the mast guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Repairing Lift Chains and Chain Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Adapting the service intervals to the application conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Periodic replacement of the chain tensioners and lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Servicing lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Checking the service hours for the lift chains and anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Cleaning lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Lubricating and preserving lift chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Checking the Lift Chains for Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Checking the lift chain elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Test preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Checking the lift chain elongation with the wear gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

ES/ET4000 Series
Rev. B
X
 TABLE OF CONTENTS

Checking the lift chain elongation with the steel ruler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Checking the chain for other damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Separating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Tools and equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Checking forks for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Hydraulic system repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Small hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Producing extractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Groove aligning arbor for small rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Assembly devices for large rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Protective mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
Rod Seal Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Removing a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Removing a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Inserting a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
Fitting a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Rod seal assembly, sealing lip first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Lift Cylinder Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Removing the lift cylinder (TL mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Lift cylinder (TL mast) assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Lift cylinder (TF and TT mast) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Lift cylinder (TF and TT mast) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Lift cylinder (TF and TT mast) assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Free lift cylinder removal and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Free Lift Cylinder Removal (Method 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Free Lift Cylinder Assembly (Method 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Free Lift Cylinder Removal (Method 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Free Lift Cylinder Assembly (Method 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Repairing the Lift Cylinders on the TL and TT Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Repairing the Lift Cylinder for the TF Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Repairing the left lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Repairing the right lift cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Repairing the Free Lift Cylinder for the 1.2 and 1.4 ES/ET - TF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Repairing the Free Lift Cylinder for the 1.6 ES/ET - TF or TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Adjusting the Folding Platform Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Pre-tensioning the spring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Checking and adjusting switch PLS1 for rider mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Adjusting switch PLS2 for pedestrian mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Replacing the Folding Platform Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Spring assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

ES/ET4000 Series
Rev. B
XI
TABLE OF CONTENTS

SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

Wire Colour Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
General Contact Symbol Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Electrical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
ES 4000 with Mechanical Steering, Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
ES 4000 with mechanical steering and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
ES 4000 with electric steering and standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
ES 4000 with electric steering and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
ET 4000 with mechanical steering, standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
ET 4000 with mechanical steering and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
ET 4000 with electric steering and standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
ET 4000 with electric steering and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
ES/ET CAN-Bus Connections, Mechanical Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
ES/ET CAN-Bus connections, electric steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Main Wire Harness ES 4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Main wire harness ET 4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Electric steering harness for ES 4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Electric steering harness for ET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
InfoLink® wire harness for ES/ET 4000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
ES 4000 with TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
ET 4000 with TF Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
ET 4000 with TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359

ES/ET4000 Series
Rev. B
XII
INTRODUCTION
1
Notes:

2
 INTRODUCTION
IMPORTANT INFORMATION

Important Information Manual structure

This maintenance manual outlines the mainten- The manual is divided into the following sections:
ance work necessary for the following models of the
ES/ET4000 Series truck(1): Section
:

Table of Contents
ES 4040
ET 4040 Introduction
Safety
Service personnel qualification
Inspection and Lubrication
To maintain the safety and functionality of the
truck, maintenance and repair work must only be Hydraulic System
performed by service engineers who have been au- Drive Unit
thorised by Crown.
Electrical System
Contact Crown if you wish to have your engineers
trained. Electrical Components
Brake System
Ordering spare parts
To order spare parts, use the spare parts catalog sup- Steering
plied separately. Always quote the following numbers Lifting Mechanism
when ordering spare parts:
Cylinders
• Truck data number
• Serial number Platform
These numbers can be found on the truck data plate. Schematic Diagrams
For details of your truck's technical specifications refer Hydraulic Schematic
to the Technical Specifications chapter in the operator
manual.
Conventions
Note: Always use original Crown spare parts.
Text mark-ups in the manual
Ordering documentation The following symbols and mark-ups are used in the
Parts catalogs, operator manuals, specification sheets manual:
etc. can be obtained from: 1., 2., 3. etc. denote work steps to be taken.
 This arrow indicates the consequences of an action.
Crown Gabelstapler GmbH & Co. KG
 This arrow indicates action to be taken to avoid haz-
– European Headquarter –
ards contained in a warnings.
Philipp-Hauck-Str. 12
85622 Feldkirchen (1), (2), (3) etc. indicate text references to item numbers
Germany in illustrations.
• Indicates the first level in a list.
Tel: +49 (0)89 93 00 2 – 0 – Indicates the second level in a list.
Fax: +49 (0)89 93 00 002 – 312
Note: Where the word "Note" appears before text, this
indicates important additional information.
www.crown.com
Brief description of equipment
Parts of the truck data number (see Fig. 1) are used to
refer to the various types of equipment.
For example, the term “ES-M” denotes the ES model with
mechanical steering and a folding platform. The term “ET-
E” denotes the ET model with electric steering
1). See truck data number, page 4. See page 4 for details of the truck data number.

ES/ET4000 Series Rev.3 07/2009

Rev. B
3
INTRODUCTION
TRUCK DATA NUMBER

Truck Data Number

The truck data number is located on the data plate.
It contains important information concerning the truck's
features at the time of delivery.

1 2 3 4 5 6 7 8 9 10 11

1.6 ES 4040 -M 2 3 LXXX S F-TL - 2440

Fig. 1 Sample truck data number
1 Maximum capacity (in tonnes)(a)
2 Model name
ES = Pedestrian truck
ET = Platform truck
3 Model number
4 Steering type
M = Mechanical
E = Electric
5 Battery tray size:
1 = 200 - 240 Ah (212 x 624 x 627 mm)
2 = 315 - 375 Ah (284 x 624 x 627 mm)
6 Straddle width:
S = Special straddle width
1 = 520 mm / 524 mm
2 = 540 mm / 539 mm
3 = 560 mm / 564 mm
4 = 670 mm / 674 mm
5 = 585 mm / 589 mm
7 Fork length:
XXX = Placeholder for the fork length in mm or inches
Examples:
L1250 = fork length 1250 mm
L42 = fork length 42 inch
8 Load wheel version:
S = Single load wheels
T = Tandem load wheels
9 Operator position version:
W = Without platform
F = Folding platform and side restraints
O = Folding platform without side restraints
10 Mast type:
TT
TL
TF
11 Lift height in mm
a. The capacity plate on the truck is binding.

The truck data number in the example denotes an

ES 4040 pedestrian truck with 1.6 tonne capacity. The
truck is equipped with mechanical steering, single load
wheels and a folding platform. The battery tray can
hold 315 - 375 Ah batteries. The straddle width is
560 mm or 564 mm, the fork length is 1000 mm. The
TL mast has a maximum lift height of 2440 mm.

ES/ET4000 Series
Rev. B
4
SAFETY
5
Notes:

6
 SAFETY
SAFETY NOTICES

Safety Notices
The following symbols will help you to assess the risk
to yourself, other people and materials should you fail
to comply with a safety notice:

DANGER
This symbol warns of immediate danger to the life
and health of personnel.
Severe injury or death will result.
 Follow all instructions indicated by this symbol in or-
der to avoid injury or death.

WARNING
This symbol warns of potential danger to the life
and health of personnel.
Severe injury or death may result.
 Follow all instructions indicated by this symbol in or-
der to avoid injury or death.

CAUTION
This symbol warns of possible danger to the health
of personnel.
Injury may result.
 Follow all instructions indicated by this symbol in or-
der to avoid injury.

CAUTION
This signal word without a symbol warns of mate-
rial damage.
Damage to the truck, tools and mechanisms may re-
sult.
 Follow all instructions indicated by this signal word
in order to avoid damage.

ES/ET4000 Series Rev.2 08/2010

Rev. B
7
SAFETY
BASIC SAFETY NOTICES

Basic Safety Notices • When carrying out work on the hydraulic system,
e.g. bleeding the system, wear suitable protective
clothing such as safety gloves, goggles or a face
Organisational measures mask.
• Maintenance work must only be carried out by ser- • When handling batteries wear acid protective cloth-
vice engineers approved by Crown. ing such as safety gloves, goggles and an apron.
• Work on electrical equipment must only be carried • Long hair, loose clothing and jewellery are prohib-
out by specialist electricians in accordance with ited. They could get caught or drawn in, resulting in
electrical regulations. injury. Do not wear jewellery especially when work-
• Note the basic and action-specific safety notices in ing on electrical systems, as a short circuit could
the respective chapters of this manual. Refer also cause burning.
to the truck operator manual, in particular the Safety • Always use insulated tools when working on electri-
chapter. cal systems.
• Service personnel must also observe statutory and
other binding accident and environmental protec- Protecting the hazardous area
tion regulations.
• When carrying out maintenance work that could be
• The minimum legal age for performing mainte- hazardous to yourself and other people, seal off a
nance work must be observed. large part of the hazardous area with suitable
• Service personnel must be trained and authorised marker tape.
to operate industrial trucks and must be able to • Before carrying out maintenance work, service per-
demonstrate their competence. sonnel must ensure that there is no one in the haz-
ardous area.
Truck modifications and additions • Service personnel must stop work immediately if
• Modifications or additions to the truck may only be any unauthorised persons enter the hazardous
performed with Crown’s prior written approval. In area. These persons must be removed immedi-
such cases the data plate must be changed if nec- ately.
essary.
• If at a later time Crown is no longer in business or is Hazards from stored energy
not operating your country and there is no succes- • High pressure hydraulic oil can cause severe inju-
sor in the interest to the business, modifications and ries. Depressurise the hydraulic system before
alterations may only be performed if the following opening any sections of it.
conditions are met: • A 15 minute discharge time must be observed for
– Design, test(s) and implementation to be carried the electrical energy stored in the capacitors and
out only by an expert in industrial trucks and their coils. Alternatively, these components can undergo
safety a controlled discharge through an electrical resistor.
– Permanent records of the design, test(s) and im- • When carrying out work near the battery, always
plementation to be maintained cover the battery terminals with a suitable insulating
– Modifications must be incorporated into the truck material (e.g. plywood board) to prevent short cir-
labelling and documentation (operator, service cuits.
and parts manuals) • Before carrying out work underneath and on raised
– A permanent and readily visible label to be af- components (e.g. fork carriages, extended mast
fixed to the truck stating the manner in which the stages, the truck itself), attach suitable safety de-
truck has been modified or altered, the date and vices and supports with sufficient capacity.
name and address of the organisation responsi- • Springs and gas pressure dampers must be
ble checked and slowly discharged before removing
them.
Personal safety equipment
• Always wear safety equipment such as safety
shoes and goggles when carrying out maintenance
and repairs. Depending on requirements you may
also need to wear safety gloves and ear muffs.

Rev.1 04/2009 ES/ET4000 Series

Rev. B
8
 SAFETY
BASIC SAFETY NOTICES

Maintenance work Cleaning work

• Always carry out maintenance work in accordance Particular care is required when cleaning the truck and
with the test and maintenance schedule contained components that have been removed. See page 8.
in this manual and any applicable service bulletins.
• Before carrying out maintenance work prepare the Handling batteries
truck as follows: • Batteries may only be charged, serviced or re-
– Park the truck on a level surface placed by trained personnel. Observe the instruc-
– Lower the forks to the ground tions contained in the operator manual, as well as
the instructions of the battery and charger manufac-
– Switch off the truck and prevent it from being turers.
switched on again
• The charger must be appropriate to the battery volt-
– Disconnect the battery and prevent the connector age and capacity. First connect the battery, then
from being attached by unauthorised personnel. switch the charger on.
• When carrying out work that requires battery sup- • When handling batteries wear acid protective cloth-
ply, jack up the truck until the drive wheel is clear of ing such as safety gloves, goggles and an apron.
the ground.
• Do not use a naked flame and do not smoke when
• Do not use a naked flame near the truck or to check handling batteries.
fluid levels or for leaks.
• Do not touch battery terminals with metal objects.
• Always have suitable fire protection equipment to Cover the battery terminals with a suitable insula-
hand when carrying out work. tion (such as a plywood board) if you have to work
• Keep the truck clean; this makes it easier to find in this area.
loose or missing components. • Always charge batteries in designated charging ar-
• Welding work must only be carried out after prior eas and make sure the area is well ventilated.
consultation with Crown. • Remove battery acid stained clothing immediately.
• Keep the work area clean and well lit. An untidy or • If acid comes into contact with the skin, rinse imme-
poorly lit work area can lead to accidents. diately with plenty of clean water. If it comes into
• Only use original Crown spare parts and accesso- contact with the eyes, rinse immediately with clean
ries. water for several minutes and then seek medical at-
• Never install or commission damaged components. tention.
• Immediately neutralize and thoroughly rinse any
Restoring the truck to service after spilled battery fluid.
maintenance work
Warning and instruction decals on
• After carrying out maintenance refit any safety
mechanisms that have been removed and make the truck
sure they are working correctly. • In accordance with the test and service intervals
• The truck may only be restored to service after check that the warning and instruction decals on the
maintenance work once all the truck functions have truck are complete and legible.
been successfully tested, in particular on the follow- • Clean any dirty decals and replace any damaged or
ing components: missing ones.
– Brakes Note: The spare parts manual gives details of the la-
– Speed control belling and position of the warning and instruction de-
– Direction switches cals on the truck.
– Steering
– Lifting mechanism
– Warning devices (horn, warning indicator)
• To avoid endangering other people, always test the
truck in an open area where there are no other peo-
ple or obstacles.

ES/ET4000 Series Rev.1 04/2009

Rev. B
9
SAFETY
BASIC SAFETY NOTICES

Lifting gear and slings

• Always use suitable hoist devices and lifting gear
with sufficient capacity.
• Attach lifting gear to the designated strap points
and prevent it from slipping. Make sure the lifting
gear cannot touch other components during lifting.
• Do not stand under a swinging load.
• Repair work can only be performed under a raised
truck if the truck has been protected against acci-
dental lowering.
• Work may only be performed on the chassis, fork
carriage or mast if they have also been protected
against accidental lowering.
• Lifting gear such as load slings routed around sharp
edges must be protected from cuts.

Environmental protection
• Any work that involves environmentally hazardous
substances being released must only be performed
in designated areas, to allow hazardous chemicals
and oils to be separated.
• All substances released during maintenance and
repair work must be collected in the proper manner
and disposed of in accordance with national regula-
tions. Oil filters and dehumidifying inserts must be
treated as special waste.
• Always act responsibly when carrying out repairs to
avoid damaging the environment.

Rev.1 04/2009 ES/ET4000 Series

Rev. B
10
 SAFETY
SAFETY MECHANISMS AND PROTECTIVE GUARDS

Safety Mechanisms and

Protective Guards
Safety mechanisms and protective guards must only
be removed from service for maintenance and repair
work if absolutely necessary.
The safety mechanisms and protective guards must be
fully operational before the truck is restored to normal
service.
Note: As the service engineer, you are responsible for
ensuring that the safety mechanisms and protective
guards removed from service for maintenance and re-
pair work are restored to full operational order.

WARNING
Damaged safety mechanisms or protective guards
can cause accidents
Accidents with severe or fatal injuries can result if a
safety mechanism or protective guard is not working
properly.
 After working on the truck make certain that the
safety mechanisms and protective guards are in
good working order.
 Do not modify or bypass any safety mechanisms or
protective guards.
 Do not operate the truck if one of the safety mech-
anisms or protective guards is faulty or is missing.
 Repair any faulty safety mechanisms or protective
guards before allowing the truck to be used again.

Truck safety mechanisms

The safety mechanisms are:
• The Emergency Disconnect
• The safety reverse switch (in pedestrian mode) or
the brake switch (in rider and comfort modes).

Truck protective guards

The protective guards are:
• The mast guard or mast metal grill.
• The load backrest
The mast guard or metal mast grill prevent access to
the moving parts of the mast.
The load backrest provides additional stability for high
loads as well as additional operator protection against
falling objects.

ES/ET4000 Series
Rev. B
11
Notes:

12
INSPECTION AND LUBRICATION
13
Notes:

14
 INSPECTION AND LUBRICATION
CLEANING THE TRUCK AND COMPONENTS

Cleaning the Truck and Cleaning the entire truck

Components 1. Park the truck in an area with an oil separator.
2. Switch off the truck, disconnect and remove the
battery.
CAUTION
CAUTION
Health risk
Cleaning agents, lubricants and consumables can Incorrect cleaning procedures can damage the
damage your health. truck
 Observe the manufacturer’s safety instructions Incorrect cleaning can damage electrical components
when handling solvents and lubricants. as well as bearings and lift chains.
 When wet-cleaning the truck, do not aim the water
hose or high pressure cleaner at electrical compo-
Effects of incorrect cleaning nents, bearings or lift chains.
 Make sure that no water can penetrate electrical
Electrical components components.
Electrical components such as connectors, contacts,  Use only cleaning petroleum and cleaning petrol to
distributor boards, controllers and wiring can be dam- clean lift chains, and then apply new type H chain
aged by water, cleaning agents and solvents. oil (see page 282).
Mineral and chemical residue that automatically re-
main on or in components after cleaning, are a cause
of corrosion. This corrosion results in malfunctions and Cleaning the truck surface
premature failure. 3. It is preferable to dry clean the truck using a cloth,
soft brushes or weak, dry compressed air.
Roller and slide bearings 4. If you have to wet-clean the truck, do not aim the
Steam cleaning and solvents damage the lubricant film water hose or high pressure cleaner at electrical
on bearing surfaces. This results in dry running and components, bearings or lift chains. Avoid using
rapid damage to the bearing elements. cleaning agents where possible. If grease needs to
be removed, use a mild neutral cleaning agent.
Corrosion-protected surfaces
Note: High pressure cleaning can remove anti-corro-
The brake lines, screw connections and shiny metal sion agent and paint from surfaces.
surfaces in particular on cold store trucks are factory-
treated with an anti-corrosive agent (Anticorit BW 5. If a neutral cleaning agent has been used, rinse the
components thoroughly with clear water.
366®). This protection can be washed off by solvents
and steam cleaning. The above-mentioned compo- 6. Leave the cleaned truck to dry thoroughly.
nents will corrode as a result. Cleaning electrical components
7. Clean electrical components only with weak, dry
Environmental protection compressed air and a dry cloth.
Cleaning must only be performed in specially desig-
nated areas to enable hazardous chemicals and oils to Interior cleaning
be separated. 8. Clean detachable rubber mats with water and a
Collect any waste (such as oily cleaning cloths) and neutral cleaning agent.
dispose of them in accordance with local regulations. 9. Allow the rubber mats to dry out fully before return-
ing them to the truck.
10. Damp-wipe plastic parts with a neutral cleaner.
Note: If necessary use a standard commercial plastic
cleaning agent to remove obstinate dirt.

ES/ET4000 Series Rev.2 08/2010

Rev. B
15
INSPECTION AND LUBRICATION
CLEANING THE TRUCK AND COMPONENTS

After cleaning the truck 3. If a neutral cleaning agent has been used, rinse the
11. Wipe down the truck. components thoroughly with clear water.
12. Remove any paint damage. 4. Leave the cleaned components to dry thoroughly.
13. Add anti-corrosion agent if necessary. Note: Cleaned components must be dry and free of
cleaning agent residue before being refitted, lubricated
Returning the truck to operation after cleaning or painted.
Normally no special measures are required. 5. Re-lubricate, paint or apply anti-corrosion agent to
If however there is a possibility that damp may have the components as required.
penetrated electrical components, proceed as follows: 6. Refit the components.
1. Clean the truck with weak, dry compressed air and
7. For cold store trucks apply Anticorit BW 366® as an
a cloth.
anti-corrosion agent for screw connections and
2. Leave the truck to stand for at least 30 minutes in shiny metal surfaces.
a dry environment.
3. Insert the battery but do not connect it yet.
4. Jack up the truck so that the drive wheel is clear of
the ground (see page 21).
5. Connect the battery.
6. Power up the truck.
 If a function automatically starts, apply the
Emergency Disconnect immediately.
Note: If possible, apply compressed air to the respec-
tive switch or connector. Repeat steps 1 to 6.
 If the starting pattern is normal, proceed to step
7.
7. Check all functions.

Cleaning removed components

Cleaning other mechanical components
With the exception of lift chains, components that have
been removed can be pressure- or wet-cleaned under
certain conditions.

CAUTION
Steam-cleaning can damage electrical compo-
nents and bearings.
 Mechanical components may only be pressure- or
wet-cleaned if no electrical components or bearings
are affected.

1. Components that have been removed should be

cleaned by hand, ideally with warm water and a
mild neutral cleaning agent.
2. If high pressure cleaning cannot be avoided, it
should be done without a cleaning agent. If grease
needs to be removed, use a mild neutral cleaning
agent.
Note: High pressure cleaning can remove anti-corro-
sion agent and paint from surfaces.

Rev.2 08/2010 ES/ET4000 Series

Rev. B
16
 INSPECTION AND LUBRICATION
RAISING THE TRUCK

Raising the Truck

CAUTION
Battery acid can burn
Battery acid will spill if a filled battery tips over during
transport. This can cause injury to bystanders and
damage the truck and transportation equipment.
 Always remove the battery before transporting the
truck.

WARNING
Falling loads are hazardous
Fatal injuries can result if the truck or crane tip over or Fig. 2 Lifting a truck with side restraints
if a load falls.
5. Attach four lifting slings as shown in Fig. 2 and in-
 Make sure the crane, lifting truck and the load han- sert them into crane hooks.
dling attachments used have the required capacity.
Information on the capacity required can be found – Strap one lifting sling around each of the outrig-
on the truck data plate under “Truck Weight Less gers.
Battery” and “Battery Weight”. – Strap one lifting sling around either side of the
 Refer to the manufacturer's operating instructions folded-down side restraint.
when using load handling attachments. Pay partic- 6. Position the crane hook above the truck so that the
ular attention to the load handling attachment's ca- truck does not swing when lifted.
pacity and static coefficients (safety factor). 7. Hoist the truck carefully.
Lifting a truck without side restraints
1. Fully lower the forks.
WARNING 2. Switch off the truck and remove the key if neces-
sary.
A falling truck can result in fatal accidents 3. Press the Emergency Disconnect.
If components acting as strap points are insufficiently
4. Remove the guard or wire mesh screen from the
secured, they can loosen when the truck is lifted. The
mast.
truck or components of the truck could fall.
 Before lifting the truck make sure that the compo-
nents used as strap points are securely attached to
the entire truck.

Lifting a truck with side restraints

1. Fully lower the forks.
2. Switch off the truck and remove the key if neces-
sary.
3. Press the Emergency Disconnect.
4. Choose the length of the lifting slings so that the
truck remains horizontal when raised.

ES/ET4000 Series
Rev. B
17
INSPECTION AND LUBRICATION
RAISING THE TRUCK

Fig. 3 Truck without side restraints

5. Strap a lifting sling around the centre of all the mast
cross members as shown in Fig. 3 and insert it into
a crane hook.
6. Position the crane hook above the truck so that the
truck does not swing when lifted.
7. Hoist the truck carefully.

ES/ET4000 Series
Rev. B
18
 INSPECTION AND LUBRICATION
SECURING THE TRUCK FOR TRANSPORT ON A TRUCK BED

Securing the Truck for 5. Sling one tensioning belt (1, Fig. 4) respectively on
either side around the outer mast cross member.
Transport on a Truck Bed 6. Insert the tensioning belts in the fastening eyes (3)
The truck must be adequately protected against slip- and pull them taut.
ping and tipping over when being transported on a Chocking the truck with wedges
truck bed.
Note: Chock the forklift truck with at least six wedges
on the truck bed (see Fig. 4).
7. Push two wedges (4) underneath the outriggers on
CAUTION the left and right-hand sides behind the load
An incorrectly secured truck can cause accidents wheels.
Trucks that are not adequately protected from slipping 8. Push two wedges (5) underneath the outriggers at
and tipping over during transport can damage the load the front.
and cause accidents. 9. From the front, push two wedges (2) under the
 You must be trained and authorised to load the chassis on the left and right-hand sides.
truck. 10. Secure all wedges to the truck bed (e.g. by nailing
 Note that load securing measures must be applied them).
and assessed correctly in each individual case.  The truck is now adequately secured for transport-
 Ensure the tensioning belts used are taut. ing on the truck bed.
 Prevent the tensioning belts from becoming slack
or loosening on their own.

Securing the truck

1
5

3 2

Fig. 4 Truck secured for transport

1 Tensioning belt
2 Wedge
3 Fastening eye
4 Wedge
5 Wedge

Clamping the truck

1. Park the truck on the truck bed.
2. Fully lower the forks.
3. Switch off the truck and remove the key if neces-
sary.
4. Press the Emergency Disconnect.

ES/ET4000 Series
Rev. B
19
INSPECTION AND LUBRICATION
TOWING THE TRUCK

Towing the Truck

A de-energised truck can be towed over short dis-
tances using a second truck. The de-energised truck
can be raised slightly to prevent the braked drive wheel
from dragging along the floor.

1
WARNING
Tipovers can result in fatal accidents
A truck tipover can result in fatal injuries.
 Make sure the tow truck has sufficient capacity. In-
formation on the capacity required can be found on Fig. 5 Towing the truck
the truck data plate under “Truck Weight Less Bat-
5. Position the forks (1, Fig. 5) of the towing truck un-
tery” and “Battery Weight”.
derneath the truck. Take care not to damage the
 Make sure the drive and castor wheels of the truck drive and caster wheels.
in need of repair do not get damaged by the forks of
6. Raise the motor compartment side of the truck until
the towing truck.
the drive wheel is clear of the ground.
 Make sure the truck in need of repair does not slide
7. Pull the truck slowly and travel around slight bends
off the forks of the towing truck.
only.

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

Towing the truck

1. Lower the forks if possible.
2. Remove the load if possible.
3. Switch off the truck and remove the key if neces-
sary.
4. Press the Emergency Disconnect.

ES/ET4000 Series
Rev. B
20
 INSPECTION AND LUBRICATION
JACKING UP THE TRUCK

Jacking up the Truck Jacking up the truck

1. Fully lower the forks.
2. Switch off the truck and remove the key if neces-
sary.
WARNING
3. Press the Emergency Disconnect.
Tipovers can result in fatal accidents 4. Place wedges (1, Fig. 6) behind both of the load
You can be fatally injured by a truck tipover. wheels.
 Make sure the jack has sufficient capacity. Informa- 5. Place the jack centrally underneath the chassis at
tion on the capacity required can be found on the the contact point (2).
truck data plate under “Truck Weight Less Battery”
6. Raise the truck until the caster and drive wheels
and “Battery Weight”.
are clear of the ground.
7. Place hard wooden blocks (3) underneath the
chassis and lower the truck onto them.
WARNING 8. Place the jack centrally underneath the outrigger at
the contact point (4).
Incorrect jacking procedures can cause fatal acci- 9. Raise the truck until it is horizontal.
dents
10. Place a hard wooden block (5) underneath and
Improper handling of the truck or the tools can result in
lower the outriggers onto it.
fatal accidents.
 Never place your hands or other parts of your body
under the truck before it has been supported.
 Always support a raised truck with wooden blocks
or other suitable equipment to relieve the jack.
 Only jack up the truck so far as to raise the wheels
off the ground. Any further lifting will increase the
risk of tipover.

1 5 3
4

Fig. 6 Jack-up points

1 Wedge
2 Contact point
3 Hard wooden block
4 Contact point
5 Hard wooden block

ES/ET4000 Series
Rev. B
21
INSPECTION AND LUBRICATION
PLACING THE TRUCK IN STORAGE

Placing the Truck in Storage Note: Approach all limit positions at least once to coat
the whole of the cylinder surfaces with oil.
Trucks that will not be used for more than 3 months
must be placed in storage. Carrying out visual inspections
6. Check the hydraulics and gear unit for leaks.
Taking the truck out of service 7. Check the anti-corrosion agent and replace if nec-
essary.
Taking the truck out of service
8. After carrying out the checks switch off the truck
1. Switch off the truck and remove the key if neces-
and disconnect the battery.
sary.
2. Press the Emergency Disconnect. Restoring the truck to service
3. Disconnect the battery.
Restoring the Truck to Service
4. De-commission the battery in accordance with the
manufacturer's instructions. 1. Remove the anti-corrosion agent where neces-
sary.
5. Clean the truck (see page 15).
2. Lift up the truck, remove the hard wooden blocks,
6. Wipe down the truck.
lower the truck - in the reverse order as described
7. Store the truck in a dry room with constant temper- in Jacking up the Truck, on page 21.
ature and air humidity.
3. Charge the battery or install a charged battery (see
8. Do not park the truck in the open air or in a humid operator manual).
environment.
4. Connect the battery (see operator manual).
9. The surfaces of trucks subjected to hostile ambient
5. Pull the Emergency Disconnect switch up.
conditions such as saline atmosphere must be
treated with suitable preservatives to prevent cor- 6. Power up the truck.
rosion. 7. Carry out the safety inspection (see operator man-
10. Cover the truck with an air-permeable material to ual).
protect against dust. Do not use plastic sheets as
condensation could form.
11. Jack up the truck (see page 21) to prevent the
wheels from flattening.

Testing trucks in storage

Testing trucks in storage

CAUTION
Long periods of inactivity can result in damage to
the hydraulic system
If the hydraulic system remains unused for too long, the
hydraulic cylinders may suffer corrosion damage.
 Every 3 months test the hydraulic system on trucks
placed in storage.

1. Connect the battery.

2. Pull the Emergency Disconnect switch up.
3. Power up the truck.
4. Check the battery charge. Charge the battery if
necessary.
5. Apply all hydraulic functions.

ES/ET4000 Series
Rev. B
22
 INSPECTION AND LUBRICATION
RECOMMENDED LUBRICANTS AND CONSUMABLES

Recommended Lubricants and Carefully protect all electrical connections and compo-
nents against corrosion. For detailed information, refer
Consumables to the Electrical System chapter.
The following tables list lubricants and consumables Service intervals (see page 25) must be adapted to the
that Crown uses in its factory. However, you can use application conditions.
any lubricants provided they meet the same technical
criteria. Abbreviations used in the table
The lubricant type is indicated by letters. Individual let-
Cold store truck requirements ters (A, B, ...) denote lubricants for normal or multi tem-
Special hydraulic oils, lubricants and grease must be perature ranges, double letters (AA, BB, ...) for low
used for cold store applications (cold store trucks). temperature ranges.
An anti-corrosion fluid (Crown no. 805236-004) must
be applied to all machine parts such as screws, wash-
ers, nuts, pins, retaining rings etc.

Model Lubricant Type Product Manufacturer Part no.

A Transmission oil (multi-tem- Degol PAS 150 Aral

perature range)
Renolin UNISYN Fuchs Mineralöl-
CLP 150 werke GmbH
BP Enersyn EP-XF BP ---
150
Alphasyn T150 Castrol
SHC XMP 150 Mobil
B Grease (Multi-Purpose) Renolit MP Fuchs Mineralöl-
werke GmbH
LM Grease Castrol
Regulus A2 Century
Beacon EP2 Esso F806118
EP-2 Maxol
Mobiluxe EP2 Mobil
Retinax LX Shell
LGWM 1 SKF
BB Lubricating grease (multi- Aralube SKL2 Aral
purpose, low temperature 053002-005
Unirex Lotemp EP Mobil
grease)
D Hydraulic oil Vitam GF 32 Aral
Hyspin AWS-32 Castrol
Nuto H32 Esso
DTE 24 Mobil ---

Tellus T 32 Shell
Renolin Bio Fuchs Mineralöl-
werke GmbH

ES/ET4000 Series
Rev. B
23
INSPECTION AND LUBRICATION
RECOMMENDED LUBRICANTS AND CONSUMABLES

Model Lubricant Type Product Manufacturer Part no.

DD Hydraulic oil (low temp) Mobil Aero HF Mobil

Mobil Aero HF A Mobil 053001-008
Univis HVI 13 Mobil
Hydraulic additive (normal Renolin Anti-Stick-Slip Fuchs Mineralöl-
E 053001-010
and low temperature) werke GmbH
G General lubrication oil Essolube HDX+40 Esso
Kowal M 40 Aral ---
Delvac 1240 Mobil
Low temperature lubrication Mobil SHC 626 Mobil
GG ---
oil
H Lubrication oil (chain) Rexoil Rexnord Kette
824805
GmbH
N Special live ring bearing Renolit CX-HT2 Fuchs Mineralöl-
053002-013
grease werke GmbH

Lubricants Product Application Part no.

Anti-corrosive agent Anticorit BW 366® Corrosion inhibitor for cold store

805236-004
trucks
Rubber & vinyl Commercial Rubber Components, Plastic Pan-
-------------
dressing els

Rev.1 07/2010 ES/ET4000 Series

Rev. B
24
 INSPECTION AND LUBRICATION
PLANNED MAINTENANCE

Planned Maintenance Terms and abbreviations used

The following terms and abbreviations are used in the
Maintenance schedule subsequent tables:
This maintenance schedule assumes single shift oper- M Months
ation under normal conditions.
h Service hours
The service intervals must however always be adapted
to the prevailing operating conditions. In extreme con- X Perform on standard trucks
ditions (dust, dirt, humidity etc.) and in cold stores C Perform on cold store trucks
the maintenance intervals should be reduced. Ex- I Inspection item
act details should be discussed with a Crown ser-
vice engineer. L Lubrication item
Routinely check for wear, corrosion, damage, and test The lubricant type is indicated by letters. Individual let-
component operation and safety when carrying out ters (A, B, ...) denote lubricants for normal temperature
maintenance work. If in doubt, replace components. ranges, double letters (AA, BB, ...) for low temperature
Planned maintenance must be performed either after a ranges.
certain number of service hours or a certain period of
time (whichever is reached first).
The next higher inspection interval includes the
previous intervals.
For example: Let's assume the maintenance schedule
specifies intervals(1) of 500 h, 1000 h and 2000 h. The
maintenance schedule items listed under 500 h and
1000 h would then be included in the 2000 h service.

Annual inspection in accordance

with FEM 4.004
Guideline FEM 4.004 “Regular Inspection of Industrial
Trucks” requires the truck to be inspected by an expert.
This inspection must be carried out annually or in
intervals as specified by the owner's risk analysis.
National regulations must be taken into account.
Exact details of intervals should be discussed with a
Crown service engineer.

1). These intervals are only used as examples.

The binding intervals for the ES/
ET4000 Series are those listed in the main-
tenance schedule (see page 26).

ES/ET4000 Series Rev.1 08/2010

Rev. B
25
INSPECTION AND LUBRICATION
MAINTENANCE SCHEDULE

Maintenance Schedule

Electrical system

Lubricant type
Assembly Component Action

Item no.

1000 h

3000 h
12 M

36 M
Electrics Contactor (EDS) Check for wear (see page 230). I-1
LMS4 Test operation (lift cutout in rider mode at I-2
1800 mm lift height).
All switches, wires and Clean if necessary (see page 15). C/X
connections Check for corrosion and damaged insula-
tion. ---
All controls should revert to the neutral po-
sition automatically.
Pump motor (M2) Check condition of motor and brushes (see
I-3 C/X
page 219).
Control modules Check and analyse error log.
(Access 2&3, ---
Perform a PMT test (see page 210).
Access 5)
Parking brake (BRK) Check air gap (see page 244). I-4 C/X

Battery (BATT) Check the battery connector and cables for

I-5
damage, check contacts for burning.
Check battery compartment for spilled acid. I-6

ES/ET4000 Series
Rev. B
26
 INSPECTION AND LUBRICATION
MAINTENANCE SCHEDULE

I-6

I-5

I-1
I-4

I-3

I-2

Fig. 7 Electrical system inspection points

ES/ET4000 Series
Rev. B
27
INSPECTION AND LUBRICATION
MAINTENANCE SCHEDULE

Electrical system

Lubricant type
Assembly Component Action

Item no.

1000 h

3000 h
12 M

36 M
Electrics Display (Access 1) Switch on the truck and test all the displays
I-7
and alarms.
Horn (HN) Check operation. I-8
Emergency Discon- Check operation.
I-9
nect switch (EDS)
C/X
Safety reverse switch Check operation.
(SAS) or brake switch I-10
(BRS)
Side restraints and Check side restraint and platform logic (see
I-11
platform logic page 71).

ES/ET4000 Series
Rev. B
28
 INSPECTION AND LUBRICATION
MAINTENANCE SCHEDULE

I-10
I-8 I-8

I-7

I-9
I-11

I-11

Fig. 8 Electrical system inspection points

ES/ET4000 Series
Rev. B
29
INSPECTION AND LUBRICATION
MAINTENANCE SCHEDULE

Lifting mechanism

Lubricant type
Assembly Component Action

Item no.

1000 h

3000 h

5000 h
12 M

36 M

36 M
Lifting Lift cylinder Check for leaks. I-12
Mechanism C/X
Hydraulic oil reservoir Check hydraulic oil level (see
I-13
page 47). D/
Replace hydraulic oil and hydraulic DD L-1
C/X
oil filter (see page 48).
Outriggers Check for cracks and wear (see
I-14
page 291).
Lift chain, chain sup- Check lift chains, chain anchors and C/X
ports and chain bolts chain pins as detailed in section
Repairing Lift Chains and Chain Ten-
sioners, page281.
I-15
Replace lift chain, chain anchors,
chain pins and attachments. See
C/X
Periodic replacement of the chain
tensioners and lift chains, page 281.
Lubricate the lift chain H L-2
Guide pulleys Check for damage and smooth run-
I-16
ning (see page 281).
Tracks in mast Clean and lubricate (see page 265).
B/BB L-3
sections
Mast rollers Check for wear, faulty bearings and
I-17 C/X
excessive slack (see page 265).
Fork carriage Check for cracks and wear (see
I-18
page 291).
Mast cables Check for damage. I-19
Mast Torque the mast attachment bolts
I-20
(340 - 380 Nm).

ES/ET4000 Series
Rev. B
30
 INSPECTION AND LUBRICATION
MAINTENANCE SCHEDULE

I-12

I-12
L-3

L-3
I-17 I-17

I-18

I-14 I-14

I-16

I-15

I-15

L-2 I-12

L-1

Fig. 9 Lifting mechanism inspection and lubrication points

ES/ET4000 Series
Rev. B
31
INSPECTION AND LUBRICATION
MAINTENANCE SCHEDULE

Drive system, steering and wheels

Lubricant type
Assembly Component Action

Item no.

1000 h

3000 h
12 M

36 M
Drive system Load and castor Check bearings. Check tyres for wear.
I-21
and wheels wheels
Drive wheel Check torque.
I-22 C/X
Check tyres for wear.
Drive gear unit 1. Replace oil on trucks with mechanical
A/AA
steering.
2. Carry out oil change and all other oil L-4
A/AA
changes on trucks with mechanical
steering. C/X
Drive gear unit Replace oil on trucks with electric
E L-5
steering.
Folding control handle Check operation. ---
Electric steering Check the automatic reset and ensure there
---
is zero backlash.
C/X
Steering transmission Check steer motor pinion for wear. I-23
Grease steer motor pinion, B/BB L-6
Live ring bearing Lubricate B/BB L-7

ES/ET4000 Series
Rev. B
32
 INSPECTION AND LUBRICATION
MAINTENANCE SCHEDULE

I-23
L-6
L-7

I-21
I-21

L-4

L-5
I-17

I-21

Fig. 10 Drive system and wheel inspection and lubrication points

ES/ET4000 Series
Rev. B
33
INSPECTION AND LUBRICATION
MAINTENANCE SCHEDULE

Safety mechanisms

Lubricant type
Assembly Component Action

Item no.

1000 h

3000 h
12 M

36 M
Lifting Mast guards or metal Check that they are present, complete,
Mechanism mast grilles undamaged and securely attached (see I-25
page 280).
Load backrest Check operation and ensure it is securely
I-26
fitted. C/X
Chassis Battery retainer Check battery retainer for damage and en-
I-27
sure it is working correctly.
Test operation of battery lock sensor
I-28
(BLS).

ES/ET4000 Series
Rev. B
34
 INSPECTION AND LUBRICATION
REPLACING THE CASTER WHEEL ASSEMBLY

Replacing the Caster Wheel Removing the caster wheel assembly

1. Remove the screw (4).
Assembly 2. Loosen the counternut (6).
3. Insert the screw (5).
 The screw (5) spreads the caster wheel assem-
WARNING bly support apart.
 The caster wheel assembly can be removed
Accidental truck movement can cause injury
from underneath the chassis.
A powered up truck with a connected battery can move
suddenly when you are working on it. Note: Do not twist the adjusting screw (1). If the adjust-
You should therefore carry out the following safety pro- ing screw is twisted, the mast tilt will have to be re-ad-
cedures before starting any operations on the truck: justed.
 Lower the forks to the ground.
Installing the caster wheel assembly
 Switch the truck off.
 Disconnect the battery. Requirements
 Prevent the truck from being switched on again. • The truck is switched off and the battery discon-
nected.
• The truck is jacked up (see page 21) sufficiently to
allow the caster wheel assembly to be placed in the
1 chassis.
2
Preparation
1. Clean and mildly lubricate the support in the chas-
sis.
Installing the caster wheel assembly
2. Apply Loctite® 243 to the thread of the screw (4).
3. Insert but do not yet tighten the screw (4).
6
4. If not already done: Loosen the counternut (6) and
3
5 insert the screw (5) until the caster wheel assembly
can be pushed into the support on the chassis.
4 5. Push the caster wheel assembly into the support
as far as the stop on the adjusting screw (1).
Fig. 11 Caster wheel 6. Remove the screw (5).
7. Tighten the screw (4). Make sure the caster wheel
1 Adjusting screw assembly remains in the support as far as the stop
on the adjusting screw (1).
2 Chassis
3 Caster wheel assembly
8. Fix the screw (5) with the counternut (6).
4 Screw Note: The screw (5) must not contact the opposite side
of the chassis.
5 Screw
6 Counternut Final tasks
9. Jack up the truck
Removing the caster wheel 10. Carry out a lowering plumb test (see page 278).
assembly
Preparing the truck
1. Switch off the truck and disconnect the battery.
2. Jack up the truck (see page 21) until the caster
wheel assembly can be removed.

ES/ET4000 Series
Rev. B
35
INSPECTION AND LUBRICATION
REPAIRING THE CASTER WHEEL ASSEMBLY

Repairing the Caster Wheel

Assembly
Removing the caster wheel assembly
1. Remove the caster wheel assembly (see page 35).
2. Bring the caster wheel assembly to a workbench.
Dismantling the caster wheel assembly
Note: For single caster wheels see Figure 12. For tan-
dem caster wheels see Figure 13.
1. Dismantle the entire caster wheel assembly.
2. Clean all components.
3. Check components for wear and damage.
4. Replace any damaged or worn components.
Fitting the caster wheel assembly
1. Mildly lubricate any metal surfaces (apart from
threads) that contact each other.
2. Apply Loctite® 243 to the thread of screws (4) and
(8).
3. Fit the caster wheel assembly in accordance with
Figure 12 or 13.
Installing the caster wheel assembly
1. Install the caster wheel assembly (see page 35).

ES/ET4000 Series
Rev. B
36
 INSPECTION AND LUBRICATION
REPAIRING THE CASTER WHEEL ASSEMBLY

Fig. 12 Single caster wheel

ES/ET4000 Series
Rev. B
37
INSPECTION AND LUBRICATION
REPAIRING THE CASTER WHEEL ASSEMBLY

Fig. 13 Tandem caster wheel

ES/ET4000 Series
Rev. B
38
 INSPECTION AND LUBRICATION
REPLACING THE DRIVE WHEEL

Replacing the Drive Wheel

WARNING
Accidental truck movement can cause injury
A powered up truck with a connected battery can move
suddenly when you are working on it.
You should therefore carry out the following safety pro-
cedures before starting any operations on the truck:
 Lower the forks to the ground.
 Switch the truck off.
 Disconnect the battery.
 Prevent the truck from being switched on again.

Preparing the truck

1. Switch off the truck and disconnect the battery.
2. Jack up the truck (see page 21) until the drive
wheel assembly can be removed.
Drive wheel disassembly
1. Remove the wheel nuts.
2. Pull the drive wheel off the wheel bolts.
Drive wheel assembly
1. Push the drive wheel onto the wheel bolts.
2. Apply Loctite® 243 to the wheel bolts.
3. Attach and hand-tighten all wheel nuts. Make sure
the drive wheel is centred on the wheel bolts.
4. Torque wheel nuts M12 to 100 Nm, wheel nuts
M14 to 130 Nm.

CAUTION
Wheel nuts can cause material damage if they come
loose
 Re-tighten the wheel nuts approx. 50 hours after
assembling the drive wheel.

5. Carry out a lowering plumb test (see page 278).

ES/ET4000 Series
Rev. B
39
INSPECTION AND LUBRICATION
STANDARD TORQUES

Standard Torques
Metric screws and nuts without flange

Torque table - Metric screws and nuts without flange

Thread diameter Torque (Nm)

and pitch
Grade 8 and 8.8 Grade 10 and 10.9 Grade 12 and 12.9

M5 x 0.80 5-6 7-8 8 - 10

M6 x 1.00 8 - 10 12 - 14 14 - 16
M8 x 1.25 20 - 25 20 - 35 34 - 40
M10 x 1.50 40 - 45 60 - 65 70 - 75
M12 x 1.75 70 - 80 100 - 110 115 - 130
M16 x 2.00 170 - 190 240 - 270 280 - 320
M20 x 2.50 340 - 380 450- 500 550 - 600
M24 x 3.00 580 - 650 800 - 900 900 - 1050
M30 x 3.50 1150 - 1300 1600 - 1800 1850 - 2100
Note: The torques listed in the service manual take precedence over the standard torques.

Metric hex. bolts and nuts with flange

(Unbrako® type)

Torque table - Metric hex. bolts and nuts with flange (Unbrako® type)

Thread diameter Torque (Nm)

and pitch
Grade 10 and 10.9 Grade 12 and 12.9

M5 x 0.80 8 11
M6 x 1.00 14 19
M8 x 1.25 33 45
M10 x 1.50 63 86
M12 x 1.75 111 152
M16 x 2.00 270 372
M20 x 2.50 521 717
Note: The torques listed in the service manual take precedence over the standard torques.

ES/ET4000 Series
Rev. B
40
COMPONENTRY
41
Notes:

42
 COMPONENTRY
MAIN COMPONENTS

Main Components

16
1
15
2
3
14
4 5

13

6
7

12

11
10
9
8

Fig. 14 ET Main Components

1 Control handle 9 Motor compartment

2 Display and switch panel 10 Battery compartment
3 Emergency Disconnect 11 Outrigger
4 Side restraint release mechanism 12 Load wheel
5 Side restraint 13 Fork
6 Platform 14 Key switch*
7 Caster wheel 15 Mast guard or mesh screen
8 Drive wheel 16 Mast

ES/ET4000 Series

43
COMPONENTRY
MOTOR COMPARTMENT

Motor compartment
The example shown here is the ES -E model.

1
11

10
2
9

8
3

4 12
7

6 5
16
15

14

13
17

Fig. 15

1 Emergency Disconnect switch (ED) 10 Access 5

2 Fuses 11 Access 1
3 Access 2/3 12 Pump motor (M2)
4 Horn 13 Caster wheel
5 Hydraulic unit 14 Valve SV
6 Hydraulic reservoir 15 Valve PV
7 Gear unit 16 Steer motor M3
8 Traction motor (M1) 17 Drive wheel
9 Brake (BRK)

ES/ET4000 Series

44
HYDRAULIC SYSTEM
45
Notes:

46
 HYDRAULIC SYSTEM
HYDRAULIC OIL

Hydraulic Oil Adding hydraulic oil

Checking the hydraulic oil level
Preparing the truck CAUTION
1. Park the truck on a level surface. Health risk
2. Fully lower the forks. Cleaning agents, lubricants and consumables can
damage your health.
3. Remove the motor compartment panel.
 Observe the manufacturer’s safety instructions
Checking the hydraulic oil level when handling solvents and lubricants.
Note: The hydraulic reservoir has 2 different Min. and
Max. markings. Depending on the mast installed, either
the top or bottom marking will apply (see Fig. 16). Requirements
• The truck is on a level surface
• The forks are fully lowered
• The motor compartment panel is removed
Adding hydraulic oil
TT 1. Remove the hydraulic reservoir cap.
2. Add D/DD hydraulic oil (for grades see page 23) up
to the corresponding MAX. marking via a filter with
a minimum retention rate of 10µm (see Fig. 16).
TL/TF 3. Fit the hydraulic reservoir cap.
4. Switch on the truck and apply the hydraulic func-
tions several times through to the end stops.
Fig. 16 Mast-dependent markings 5. Check the hydraulic oil level and replenish if nec-
1. Check the hydraulic oil level. essary.
 If the hydraulic oil level is on or below the MIN 6. Attach the motor compartment panel.
marking, add hydraulic oil.
 If the hydraulic oil level lies between the respective
MIN and MAX. markings, the level is ok.

ES/ET4000 Series
Rev. B
47
HYDRAULIC SYSTEM
REPLACING THE HYDRAULIC OIL

Replacing the Hydraulic Oil 4. Jack up the truck and secure it (see page 21) so
that the drain plug (1) can be reached.
5. Place a flat tray with a minimum capacity of 7 litres
underneath the hydraulic reservoir.
Replacing the hydraulic oil
6. Remove the drain plug (1) and fully drain the hy-
draulic oil.
7. Check the O ring on the drain plug for damage. If it
1
is damaged, use a new drain plug with an O ring.
8. Insert the drain plug with the O ring and torque to
20 – 24 Nm.
9. Add hydraulic oil (see page 47).

Fig. 17 Oil drain plug

WARNING
High pressure hydraulic system
Risk of injury from escaping hydraulic oil.
To avoid accidents:
 Depressurise the hydraulic system before opening
any sections of it.
 Tighten all connections before pressurising the sys-
tem.
 Keep hands and body away from pressurized fluid.
 Only trace leaks with a piece of paper or cardboard.
Whenever a high pressure fluid enters the skin it must
be treated as a medical emergency.
Seek medical assistance even if the skin appears nor-
mal at first.

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

Preparation
1. Park the truck on a level surface.
2. Fully lower the forks.
3. Remove the motor compartment panel.

ES/ET4000 Series
Rev. B
48
 HYDRAULIC SYSTEM
REPLACING THE HYDRAULIC FILTER

Replacing the Hydraulic Filter

Hydraulic unit disassembly
1. Drain the hydraulic oil (see Replacing the Hydrau-
lic Oil, page 48) and dispose of it in accordance
with environmental principles.
2. Remove all hydraulic and electrical connections
from the truck.
3. Remove the hydraulic unit and place it on a work-
bench.
Replacing the hydraulic filter
See Figure 18.
1. Remove the container (23).
2. Clean the reservoir.
3. Remove the intake filter (27) and return filter (26)
and dispose of them in accordance with environ-
mental principles.
4. Fit new hydraulic filters
Installing the hydraulic container
1. Fit the hydraulic container in the truck.
2. Attach the pressure line and electrical connections.
3. Add hydraulic oil (see page 47).
4. Bleed the hydraulic system (see page 51).
5. Flush the hydraulic system (see page 53).
6. Perform the drift test (see page 54).

ES/ET4000 Series
Rev. B
49
HYDRAULIC SYSTEM
REPLACING THE HYDRAULIC FILTER

Fig. 18 Hydraulic unit exploded diagram

ES/ET4000 Series
Rev. B
50
 HYDRAULIC SYSTEM
BLEEDING THE HYDRAULIC SYSTEM

Bleeding the Hydraulic System 4. Switch off the truck and leave it to stand for approx-
imately 10 minutes.
Note: During this time the air will separate from the oil
in the container.
WARNING
5. If there is no more foam, add hydraulic oil (see
High pressure hydraulic system page 47).
Risk of injury from escaping hydraulic oil.
To avoid accidents:
 Depressurise the hydraulic system before opening
any sections of it.
 Tighten all connections before pressurising the sys-
tem.
 Keep hands and body away from pressurized fluid.
 Only trace leaks with a piece of paper or cardboard.
Whenever a high pressure fluid enters the skin it must
be treated as a medical emergency.
Seek medical assistance even if the skin appears nor-
mal at first.

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

WARNING
Lowering forks can cause injury
The forks can automatically lower when the hydraulic
system is being depressurised and during the drift test.
 Never stand underneath a raised fork.
 Seal off the hazardous area to prevent other people
from entering and standing under a raised fork.

Bleeding the hydraulic system

1. Activate lifting several times to bleed the system.
 The oil in the reservoir will foam.
Note: After removing the free lift or a lift cylinder it may
be necessary to bleed the system directly from the cyl-
inder, via the bleed screw.
2. Fully lower the forks.
3. Check the pressure port and hydraulic compo-
nents for leaks.

ES/ET4000 Series
Rev. B
51
HYDRAULIC SYSTEM
REPLACING THE RELIEF VALVE RV1

Replacing the Relief Valve RV1

The relief valve protects the lifting mechanism against
overload.
Note: The relief valve is preset. It does not need to be
adjusted after replacement.

WARNING
Accidental truck movement can cause injury
A powered up truck with a connected battery can move
suddenly when you are working on it.
You should therefore carry out the following safety pro-
cedures before starting any operations on the truck:
 Lower the forks to the ground.
 Switch the truck off.
 Disconnect the battery.
 Prevent the truck from being switched on again.
 Jack up the truck until the drive wheel is clear of the
ground (see page 21).

Relief valve disassembly

The relief valve is located on the hydraulic unit (14,
Fig. 18).
1. Position the screwdriver on the hex. bolt and un-
screw the relief valve.
Relief valve assembly
Note: Assembly is the reverse of disassembly. Note
the following:
1. Apply a thin coat of hydraulic oil to the new relief
valve, insert it into the valve seat and torque to
45 Nm.
2. Test the hydraulics.
3. Flush the hydraulic system (see page 53).
4. Perform a drift test (see page 54).

Testing the relief valve

1. Place the maximum rated load (see capacity plate
on truck) on the forks and raise it.
 If the load cannot be raised, replace RV1.
 If the load is raised, proceed to step 2.
2. Raise the maximum permissible rated load +10%
load (see capacity plate on truck).
 If the load is raised, replace RV1.
 If the load cannot be raised, RV1 is ok.

ES/ET4000 Series
Rev. B
52
 HYDRAULIC SYSTEM
FLUSHING THE HYDRAULIC SYSTEM

Flushing the Hydraulic System

The hydraulic system must be flushed after carrying
out repairs to the system.

Requirements
• All hydraulic connections are sealed
• All filters are installed
• The hydraulic oil level is at the MAX marking
• The hydraulic system is bled

WARNING
Lowering forks can cause injury
Persons underneath lowering forks can be fatally in-
jured.
 Seal off the hazardous area to prevent other people
from entering and standing under raised forks.
 Watch out for people approaching the hazardous
area.

Flushing the hydraulic system

1. Fully raise the outriggers and forks.
2. Extend and retract the forks at least ten times at
maximum speed as far as the maximum lift height.
 The entire hydraulic system is flushed.
3. Perform a drift test (see page 54).

ES/ET4000 Series
Rev. B
53
HYDRAULIC SYSTEM
DRIFT TEST

Drift Test and repeat the drift test. If the drift is still exces-
sive, establish which components are leaking
Internal leakage in the hydraulic system can only be and repair them.
identified through a drift test.
 If the drift < 100 mm, it has passed the drift test.
Preparing the drift test
Prepare test loads and bring the truck up to operat-
ing temperature
1. Prepare a test load (weight to match the maximum
capacity of the truck).
Note: The test load must be evenly distributed. The
load centre of gravity must be centrally located, 600
mm in front of the fork shanks, and must not exceed the
capacity plate specification.
2. Measure the temperature of the hydraulic oil in the
hydraulic reservoir.
 When the temperature is at least 50°C you can
start with the drift test.
 If the temperature is too low, proceed to step 3.
3. Raise the forks with maximum load several times
until the hydraulic oil temperature is at least 50°C.

Drift test

WARNING
Lowering forks can cause injury
The forks automatically lower when the drift test is per-
formed.
 Never stand underneath the raised components.
 Seal off the hazardous area to prevent other people
from entering and standing underneath the raised
components.

Lifting a test load

1. Insert the forks under the maximum capacity load.
2. Fully raise the forks.
3. Measure the height of one fork tip above the
ground.
4. Switch off the truck and disconnect the battery.
5. Wait for 10 minutes.
Measuring the drift
6. After 10 minutes measure the fork tip height again.
7. Calculate the difference between the previously re-
corded measurement and the new measurement
to establish the drift.
 If the drift ≥ 100 mm, the internal leakage is too
great. First, flush the hydraulic system again

ES/ET4000 Series
Rev. B
54
 HYDRAULIC SYSTEM
HYDRAULIC SYSTEM TROUBLESHOOTING

Hydraulic System
Troubleshooting

Symptom Probable Cause Remedy

Noisy pump - Oil level too low. - Check oil level.

- Incorrect oil viscosity (e.g. standard oil - Use suitable hydraulic oil (see page 23).
used in cold store environment). - Check suction pipe connection to pump.
- Leak in suction pipe union (pump suc- - Replace suction filter.
tions air).
- Filter in suction pipe partly clogged.
Foaming hydraulic oil - Air in system - Check oil level.
- Water in oil - Check suction pipe connection to pump.
- Clean reservoir and replace hydraulic
oil.
Pump or oil overheating - Incorrect oil viscosity (e.g. cold store oil - Drain oil completely and add oil depend-
used at normal temperature). ing on the application conditions.
- Oil contaminated with water. - Drain oil completely, clean reservoir and
- Relief valve permanently open fill with clean oil.
- Check oil level.
- Check suction pipe / pump connection
(see “Foaming hydraulic oil” symptom).
- Test the relief valve (see page 52).
Low flow rate - Air in system - See “Foaming hydraulic oil” remedy.
- Relief valve faulty - See “Pump or oil overheating” remedy.
- Oil too hot - Test the relief valve (see page 52).
No build up of pressure - Faulty relief valve - Test the relief valve (see page 52), re-
- Oil level low place if faulty.
- Add hydraulic oil.
Lifting delay - Air in manifold - Bleed the hydraulic system (see
page 51).

ES/ET4000 Series Rev.\x11 1 06/2010

Rev. B
55
Notes:

56
DRIVE UNIT
57
Notes:

58
 DRIVE UNIT
COMPONENTS

Components Trucks with electric steering

A steering assembly with a steering gearbox and steer
Trucks with mechanical steering motor is incorporated via an intermediate flange.
The drive unit components comprise the following: The drive unit components comprise the following:

7 1
1

2 6

2
3

5
5
4

3
Fig. 19 Drive unit - mechanical steering
4
1 Brake
2 Traction motor
3 Live ring bearing (not visible)
4 Drive gear unit
5 Drive wheel

Fig. 20 Drive unit - electric steering

1 Steer motor
2 Steering assembly
3 Drive gear unit
4 Drive wheel
5 Live ring bearing (not visible)
6 Traction motor
7 Brake

ES/ET4000 Series
Rev. B
59
DRIVE UNIT
REPLACING THE DRIVE WHEEL

Replacing the Drive Wheel

WARNING
Risk of tipover
WARNING Replacing the drive or caster wheel can skew the mast.
If this results in the tolerance being exceeded, the truck
Accidental truck movement can cause injury
may tipover.
A powered up truck with a connected battery can move
suddenly when you are working on it.  Carry out a lowering plumb test after replacing the
You should therefore carry out the following safety pro- drive or caster wheel. See page 278.
cedures before starting any operations on the truck:
 Lower the forks to the ground. 4. Carry out a lowering plumb test (see page 278).
 Switch the truck off.
 Disconnect the battery.
 Prevent the truck from being switched on again.

Drive wheel disassembly

Preparation
1. Remove the panels so that the drive wheel can be
accessed.
2. Jack up the truck (see page 21) so that the drive
wheel is clear of the ground.
Drive wheel disassembly
1. Unscrew the wheel nuts.
2. Remove the wheel nuts.
3. Pull the drive wheel off the bolts.
4. Fit the new drive wheel.

Drive wheel assembly

CAUTION
Wheel nuts can cause material damage if they come
loose
 Re-tighten the wheel nuts approx. 50 hours after
assembling the drive wheel.

Drive wheel assembly

Assembly is the reverse of disassembly:
1. Place the drive wheel in position.
2. Apply Loctite® 243 to the stay bolts.
3. Torque the M14 wheel nuts to 130 Nm and the
M12 wheel nuts to100 Nm

ES/ET4000 Series
Rev. B
60
 DRIVE UNIT
CHANGING THE GEAR OIL

Changing the Gear Oil

WARNING
A falling truck can cause fatal injuries
CAUTION You can be fatally injured by a falling truck.
Health risk  Use load handling equipment, slings and blocks
Cleaning agents, lubricants and consumables can with sufficient capacity.
damage your health.  Before working underneath a raised truck:
 Observe the manufacturer’s safety instructions – Support the truck raised with a crane in such a
when handling solvents and lubricants. way that it cannot fall down even if the lifting gear
cracks or the crane fails.
Note: The oil should have reached operating tempera- – If the truck is raised with a forklift truck, it must be
ture before changing. This will ensure that it flows away secured on the forks of the truck doing the lifting,
quickly and any contamination is kept in suspension. to prevent it from slipping and falling off. The lift
mechanism of the truck doing the lifting must be
physically chocked before you can work under
the raised load.

Preparing to change the oil

1. Raise the truck with a crane or forklift truck only as
far as is absolutely necessary (see page 21). The
drive wheel must however be clear of the ground.
2. Secure the truck to prevent it from lowering acci-
dentally.
3. Apply the steering to turn the drive wheel so that
the refill plug (1) and the drain plug (2) on the gear
unit are accessible.
4. Place a flat tray with a minimum capacity of 1.5 li-
tres underneath to collect the used oil.
Draining the oil
1 5. Remove the filler plug (1).
6. Unscrew the oil drain plug (2) and collect the oil.
7. Dispose of used oil in accordance with environ-
mental and local regulations.
Adding oil
8. Clean the drain plug (2), screw it on and tighten.
Note: Make sure you use the correct oil grade. Cold
store trucks require a different type of oil than standard
trucks.
2 9. Add a suitable gear oil (see page 23) (approx. ca-
pacity 0.9 litres).
Fig. 21 Oil refill and drain plug positions
10. Clean the refill plug (1), screw it on and tighten.
11. Remove the jack from the truck and the device to
prevent it from being switched on.
12. Test the truck's operation.

ES/ET4000 Series
Rev. B
61
DRIVE UNIT
DRIVE GEAR DISASSEMBLY / INSTALLATION

Drive Gear Disassembly /

Installation
1

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

Fig. 22 SAHS sensor

WARNING 3. Only if the drive gear is being replaced: remove the
A falling truck can cause fatal injuries SAHS sensor (1) with its bracket and set it aside for
You can be fatally injured by a falling truck. later use.
 Use load handling equipment, slings and blocks 4. Raise the truck with a crane or forklift truck until the
with sufficient capacity. drive wheel is clear (see page 21).
 Before working underneath a raised truck: 5. Secure the truck to prevent it from lowering acci-
dentally.
– Support the truck raised with a crane in such a
way that it cannot fall down even if the lifting gear 6. Remove the drive wheel.
cracks or the crane fails. 7. Place a device on a lift truck underneath the truck
– If the truck is raised with a forklift truck, it must be so that the drive gear is covered.
secured on the forks of the truck doing the lifting, Note: The device should prevent the drive gear from
to prevent it from slipping and falling off. The lift falling when the truck is raised.
mechanism of the truck doing the lifting must be Drive gear unit removal
physically chocked before you can work under
the raised load.
2

Drive gear unit removal

Preparation
Note: The drive gear can only be removed from under-
neath the truck. To reduce the overall height before re- 2
moval, the M1 drive motor and the drive wheel must be
removed.
1. Disconnect all electrical connections to the drive 2
motor and the SAHS sensor. If a steer motor is pre-
sent, remove its electrical connections also.
2. Remove the drive motor M1.
Fig. 23 Attaching the drive gear to the chassis
8. Remove the screws (2).
9. Raise the truck with a crane or forklift truck until the
drive gear is clear (see page 21).
10. Pull the drive gear out from underneath the truck.

ES/ET4000 Series
Rev. B
62
 DRIVE UNIT
DRIVE GEAR DISASSEMBLY / INSTALLATION

Drive gear unit assembly

Note: New drive gears are supplied without oil and
without a grease nipple for the live ring bearing.
Drive gear unit assembly
1. Fix the drive gear in the device.
2. Align the drive gear under the truck and raise it until
it moves up against the flange.
3. Check the alignment.
4. Apply Loctite® 243 to the bolts (2), thereby secur-
ing the drive gear.
5. Torque the screws to 70 - 75Nm.
Fitting attachments
6. Fit the SAHS sensor. Torque the screw to 30 -
35 Nm.
7. Check the distance from the sensor to the cam.
 If the distance is 1 - 2 mm, the setting is ok.
 If the distance from the sensor to the cam is
more or less, set it to 1 - 2 mm.
8. Remove the dummy plug for the grease nipple
from the live ring bearing and screw in a grease
nipple. Torque the grease nipple to 20 - 25 Nm.
Checking the oil level
9. Check the oil level in the drive gear. Add oil if re-
quired (see page 61).
Drive motor assembly
10. Clean and lubricate the splined shaft.
11. Place the drive motor in position and align it.
12. Apply Loctite® 243 to the motor attachment bolts,
thereby securing the motor. Torque the bolts to 20
- 25 Nm.
Attaching the wiring
13. Restore all electrical connections.
14. Torque the power cable connections to the drive
motor to 7.5 Nm.
15. Torque the power cable connections to the steer
motor to 3.2 - 4.3 Nm.
16. Test the truck's operation.

ES/ET4000 Series
Rev. B
63
Notes:

64
ELECTRICAL SYSTEM
65
Notes:

66
 ELECTRICAL SYSTEM
INPUT SIGNALS

Input Signals Comfort mode

• Platform down
Initial truck status • Side restraint down
The following tables show the status of the most impor- In comfort mode the operator rides on the platform. The
tant inputs required to operate the truck. speed is restricted to pedestrian speed.
These inputs can be checked in the Analyzer menu.
Rider mode
It is assumed that the truck is in standby mode, i.e.:
• Platform down
• Truck is switched on and not in idle ( symbol is
• Side restraint closed
not displayed)
In rider mode the operator rides on the platform. The
• The operator is standing on the platform
speed can be restricted by the maximum setting in the
• The “Rabbit/Turtle” toggle switch is set to "Rabbit" software.
• The forks and outriggers are fully lowered
• The temperature of the electronic system and mo-
Quick Exit
tors does not exceed 45°C • Platform up
• Side restraint up
SAS and BRS or
In trucks with a fixed tiller and electric steering the SAS • Platform down
electrically assumes the function of the BRS.
• Side restraint up
Operating mode definition In Quick Exit mode the operator can ride on the plat-
form. However the speed is restricted to the maximum
The various operating modes of the truck are deter- crawl speed setting in the software.
mined by the position of the side restraints and the plat-
Quick Exit is therefore not a full operating mode in the
form:
technical sense. It is therefore not taken into account in
the following table.

Conventions
Brief description of equipment
1 Three components of the truck data number are used
2
to assign the truck's equipment to the parameters.
• Model number
• Steering type
3
• Operator position type
4
See page 4 for details of the truck data number.
In the following tables this part of the truck data number
describes the truck model.
Fig. 24 Side restraint and platform position definition
1 Side restraint up (Quick Exit)
2 Side restraint closed
3c Side restraint down
4 Platform down

Pedestrian mode
• Platform up
• Side restraint down

ES/ET4000 Series
Rev. B
67
Notes:

68
 ELECTRICAL SYSTEM
INPUT SIGNALS

Input Signals
,

(Sheet 1 of 2) ES 4020 -MW ET 4040 -MF ET 4020 -EW ET 4040 -EF

Control module

Display name in Function & comment Assembly location Pedestrian mode(a) Comfort mode Rider mode Pedestrian Comfort mode Rider mode
Analyzer menu (platform down, side (platform down, side mode(a) (platform down, (platform down,
restraint down) restraint closed) side restraint side restraint
down) closed)

RAS ENC Lift encoder, fork lift Tiller handle 0 0 0 0 0 0

LOS ENC Lower encoder, fork lift Tiller handle 0 0 0 0 0 0
PS1 Outrigger lift pressure sensor. Used for In manifold block on the hy-
Access 2

0 0 0 0 0 0
load-dependent speed reduction. draulic unit.
LMS3 Lift limit override switch Mast OFF OFF OFF OFF OFF OFF
LMS4 Lift limit in rider mode. Mast OFF OFF OFF OFF OFF OFF
BLS Battery retainer monitoring. Battery compartment OFF OFF OFF OFF OFF OFF
TEMP ACCESS 2&3 Temperature control, activates power re- In the control module(b)
≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C
duction when the temperature  85°C.
TS1 SENSOR Temperature sensor In the drive motor(b) ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C ≤ 45° C
FS SWITCH (PF DIREC- Forward travel switch Control handle grip
OFF OFF OFF OFF OFF OFF
TION)
RS SWITCH (FF DIREC- Reverse travel switch Control handle grip
OFF OFF OFF OFF OFF OFF
TION)
DRIVE POT Traction potentiometer slider Control handle grip 0 0 0 0 0 0
HSS “Rabbit/Turtle” toggle switch (R/T) Tiller handle ON ON ON ON ON ON
HNS1 + 2 Horn switches 1 + 2 Control handle grip OFF OFF OFF OFF OFF OFF
Access 3

BRS1 + 2 Brake switch Under the control handle

OFF OFF OFF OFF OFF OFF
knuckle
ORS Brake override zone toggle switch Under the control handle
OFF N/A(c) N/A(c) OFF N/A(c) N/A(c)
knuckle
PLS1 Sensor Platform sensor 1 On platform hinge N/A(c) OFF OFF N/A(c) OFF ON
PLS2 Sensor Platform sensor 2 On platform hinge N/A(c) OFF OFF N/A(c) OFF OFF
SR1 Sensor Side restraint sensor 1 On side restraint hinge N/A(c) OFF ON N/A(c) OFF ON
SR2 Sensor Side restraint sensor 2 On side restraint hinge N/A(c) OFF ON N/A(c) OFF ON
SAS Safety reverse switch Control handle grip OFF OFF OFF OFF OFF OFF
ECR Drive motor “B side” encoder, 64 pulses “B side” of drive motor(b) 0 0 0 0 0 0

ES/ET4000 Series
Rev. B
69
ELECTRICAL SYSTEM
INPUT SIGNALS

(Sheet 2 of 2) ES 4020 -MW ET 4040 -MF ET 4020 -EW ET 4040 -EF

Control module

Display name in Function & comment Assembly location Pedestrian mode(a) Comfort mode Rider mode Pedestrian Comfort mode Rider mode
Analyzer menu (platform down, side (platform down, side mode(a) (platform down, (platform down,
restraint down) restraint closed) side restraint side restraint
down) closed)

TEMP ACCESS 5 Thermal sensor; disconnects all truck In the control module(b) ≤ 45° C
≤ 45° C ≤ 45° C
functions when the temperature  80°C
TS3 (TEMP MOTOR) Temperature sensor; switches off all In the steer motor(b) ≤ 45° C
truck functions in event of overtempera- ≤ 45° C ≤ 45° C
ture
STEER POT1 Steering potentiometer, slider 1 In the TFD module(b) 2.5 V (0.2 V) 2.5 V (0.2 V) 2.5 V (0.2 V)
Access 5

STEER POT 2 Steering potentiometer, slider 2 N/A(c)

In the TFD module(b) 2.5 V (0.2 V) 2.5 V (0.2 V) 2.5 V (0.2 V)
ECR2 (ENCODER 48P) Steer motor encoder, 32 pulses Steer motor, “A side” of the
146 pulses (±20) 146 pulses (±20) 146 pulses (±20)
electric steering(b)
ECR3 (ENCODER 32P) Steer motor encoder, 48 pulses Steer motor, “B side” of the
107 pulses (±20) 107 pulses (±20) 107 pulses (±20)
electric steering(b)
SAHS SENSOR Straight Ahead Sensor Front of drive unit ON ON ON
RAS ENC Lift encoder, fork lift Tiller handle 0 0 0 0 0 0
LOS ENC Lower encoder, fork lift Tiller handle 0 0 0 0 0 0
PF switch Forward travel switch Control handle grip OFF OFF OFF OFF OFF OFF
Access 8.1

FF switch Reverse travel switch Control handle grip OFF OFF OFF OFF OFF OFF
DRIVE POT Traction potentiometer slider Control handle grip 0 0 0 0 0 0
HNS1 + 2 Horn switches 1 + 2 Control handle grip OFF OFF OFF OFF OFF OFF
HSS “Rabbit/Turtle” toggle switch (R/T) Tiller handle ON ON ON ON ON ON
SAS Safety reverse switch Control handle grip ON ON ON ON ON ON
a. The truck does not have a platform. Only pedestrian mode is available.
b. Not accessible
c. Not available.

ES/ET4000 Series
Rev. B
70
 ELECTRICAL SYSTEM
PLATFORM AND SIDE RESTRAINT LOGIC

Platform and Side Restraint Folding platform

Logic Side restraint and platform setting
definition
Brief description of equipment
Three components of the truck data number (see page
4) indicate the truck's features and equipment:
• Model number
1
• Steering type 2
• Operator position type
In the following table these components of the truck
data number describe the truck model. 3
4

Fig. 25 Side restraint and platform setting definition

1 Side restraint up (Quick Exit)
2 Side restraint closed
3 Side restraint down
4 Platform down

Note: The platform sensors only connect when the

platform has been folded down as far as the stop.
Someone must be standing on the platform.
,

Platform and Side Restraint Logic Platform Sensors Side restraint

sensors

Truck model Operating mode Platform and side V max. PLS1 PLS2 SR1 SR2
restraint positions (km/h)

ET 4040-MF Pedestrian mode Platform up

6 OFF ON OFF OFF
and Side restraint down
ET 4040-EF Comfort mode Platform down
6 ON OFF OFF OFF
Side restraint down
Rider mode Platform down
10 ON OFF ON ON
Side restraint closed
Quick Exit Platform up See
OFF ON OFF ON
Side restraint up footnote(a)
Platform down See
ON OFF OFF ON
Side restraint up footnote(a)
a. The maximum speed is the creep speed setting (Walkie Turtle Speed). Travel forks first is the only option.

ES/ET4000 Series
Rev. B
71
ELECTRICAL SYSTEM
ACCESSING THE SERVICE LEVELS

Accessing the Service Levels 3. Press the key.

 “LEVEL 3” is displayed.
You can navigate through the menu structures using
4. Press the key.
the cursor keys ( , , , , ) on the display
 "????” is displayed.
panel. An overview of the menu structure can be found
in Menu Structure, starting on page 74. 5. Enter password (PIN).
6. Confirm by pressing .
 The "ANALYZER" menu is displayed.

Fig. 26 Display panel

Switching the truck on
1. Press the key for 1 second.
 The display screen is activated.
Note: For trucks with a key switch, turn the key switch
right to the "On" position.
Accessing service level 2
Note: When you enter the password (PIN) for service
level 2 the display automatically changes to the “ANA-
LYZER” menu.
1. Use the key to select the “SERVICE” menu.
 “SERVICE” is displayed.
2. Press the key.
 “LEVEL 2” is displayed.
3. Press the key.
 "????” is displayed.
4. Enter password (PIN).
5. Confirm by pressing .
 The "ANALYZER" menu is displayed.
Accessing service level 3
Note: When you enter the PIN for service level 3 the
display automatically changes to the “ANALYZER”
menu.
1. Use the key to select the “SERVICE” menu.
 “SERVICE” is displayed.
2. Press the key.
 “LEVEL 2” is displayed.

ES/ET4000 Series
Rev. B
72
 ELECTRICAL SYSTEM
SOFTWARE VERSIONS

Software Versions
The following menu structure and the flow chart apply
to the following software versions:

Access 1 (display) software versions

Access 1 item number Software version Used in:

(truck data number)(a)

825777-030 732 ET
828657-001 732 ES
a. A breakdown of the truck data number can be found on page 4.

ACCESS 2&3 (TCM/HCM) software versions

ACCESS 2&3 item number Software version Used in:

(truck data number)(a)

829572 39 ES,
831930 39 ET
a. A breakdown of the truck data number can be found on page 4.

Access 5 (SCM) software versions

Access 5 item number Software version master Software version slave Used in:
(truck data number)(a)

816301-300 320 203 ES -E, ET -E

a. A breakdown of the truck data number can be found on page 4.

ES/ET4000 Series
Rev. B
73
ELECTRICAL SYSTEM
MENU STRUCTURE

Menu Structure

Note: Depending on the truck's

equipment some menu items may
be invisible or have no effect.

TI800-01_2D

Fig. 27

ES/ET4000 Series
Rev. B
74
 ELECTRICAL SYSTEM
OPERATOR MENU

Operator Menu

****

Page 76

Page 76
TI800-01_2D_2

Fig. 28

ES/ET4000 Series
Rev. B
75
ELECTRICAL SYSTEM
OPERATOR MENU

Page 75

Note: The Performance menu

item is only visible if activated in
the Features F6 menu (F6 PER-
FORMANCE = ENABLE). See
page 86.

Page 75

TI800-01_2D_3

1) An access code is required for service levels 2 and 3.

Fig. 29

ES/ET4000 Series
Rev. B
76
 ELECTRICAL SYSTEM
SERVICE MENU

Service menu

Page 78
Page 95

(1)

Page 79

1) This menu item is only displayed if the truck has electric steer-
ing.

A2.2, page 80

A2.3, page 81

Page 78 A2.4, page 82

(1)
A2.5, page 83

TI800-01 2D 4
Fig. 30

ES/ET4000 Series
Rev. B
77
ELECTRICAL SYSTEM
ACCESS 3 - ANALYZER OUTPUTS

Access 3 - Analyzer Outputs

A2, page 77

(1)

(2) A4.1, page 96

1) Displayed on electric steering trucks only.
2) Displayed only in service level 3.
TI800-01_2D_5
A1, page 77

Fig. 31

ES/ET4000 Series
Rev. B
78
 ELECTRICAL SYSTEM
CALIBRATION

Calibration

Page 77

Page 86

Note: Menu item C2 is only

displayed if the truck has
electric steering.
Note: Calibration is detailed
starting on page 103.

TI800-01_2D_6

Fig. 32

ES/ET4000 Series
Rev. B
79
ELECTRICAL SYSTEM
ACCESS 2 - ANALYZER OUTPUTS

Access 2 - Analyzer Outputs

A2.1, page 77

A2.3, page 77 (1)

TI800-01_2D_7

1) A2.2.3 is not displayed on the ES model.

Fig. 33

ES/ET4000 Series
Rev. B
80
 ELECTRICAL SYSTEM
ACCESS 2 - ANALYZER OUTPUTS

A2.2, page 77

ACCESS 3 A2.3.1 TEMP ACCESS 2&3 = Value C Value C Value C

A2.3.2 TS1 SENSOR = Value C Value C Value C

Value 0 = OFF
A2.3.3 FF SWITCH = Value Value
A2.4, page 77 Value 1 = ON

Value 0 = OFF
A2.3.4 PF SWITCH = Value Value
Value 1 = ON

Value = 0 – 255
A2.3.5 DRIVE POT = Value Value
Digits

Value 0 = OFF
A2.3.6 HSS = Value Value
Value 1 = ON

HNS1+2 = Value Value Value 0 = OFF

A2.3.7
Value 1 = ON
Note: Menu items A2.3.8 to
A2.3.12 are only present on ET
Value 0 = OFF
models. A2.3.8 BRS1+2 = Value Value
Value 1 = ON

Note: Menu item A2.3.16 is

only present on ES models. A2.3.9 PLS1 SENSOR = Value Value
Value 0 = OFF
Value 1 = ON

Value 0 = OFF
A2.3.10 PLS2 SENSOR = Value Value
Value 1 = ON

SR1 SENSOR = Value Value Value 0 = OFF

A2.3.11
Value 1 = ON

Value 0 = OFF
A2.3.12 SR2 SENSOR = Value Value
Value 1 = ON

Value 0 = OFF
A2.3.13 SAS = Value Value
Value 1 = ON

TRACTION MOTOR CURRENT

A2.3.14 Value A Value A
= Value A

A2.3.15 ECR1 = Value Value Value Pulses

Value 0 = OFF
A2.3.16 ORS SWITCH = Value Value
Value 1 = ON

TI800-01_2D_8

Fig. 34

ES/ET4000 Series
Rev. B
81
ELECTRICAL SYSTEM
ACCESS 2 - ANALYZER OUTPUTS

A2.3, page 77

A2.5, page 77

TI800-01_2D_9

Fig. 35

ES/ET4000 Series
Rev. B
82
 ELECTRICAL SYSTEM
ACCESS 5 - ANALYZER OUTPUTS

Access 5 - Analyzer Outputs

A2.4, page 77

ACCESS 5 A2.5.1 TEMP ACCESS 5 = Value C Value C Value C

TS3 (TEMP MOTOR)

A2.5.2 Value C Value C
= Value C

STEER MOTOR CURRENT

A2.1, page 77 A2.5.3
= Value A
Value A Value A

A2.5.4 STEER POT1 = Value V Value V Value V

A2.5.5 STEER POT2 = Value V Value V Value V

ECR2 (ENCODER 48P)

A2.5.6 Value Value Pulses
= Value

ECR3 (ENCODER 32P)

A2.5.7 Value Value Pulses
= Value

Value 0 = OFF
A2.5.8 SAHS SENSOR = Value Value
Value 1 = ON

TI800-01_2D_10

Note: This menu is only displayed if the truck has electric steering.

Fig. 36

ES/ET4000 Series
Rev. B
83
ELECTRICAL SYSTEM
FEATURES - F1 TO F3

Features - F1 to F3

CALIBRATION, page 79 F19, page 79

FEATURES F1 LANGUAGE = Value ENGLISH

GERMAN

Save? N
FRENCH

HOUR, page 89
SPANISH

Save? Y

DUTCH
TRAVEL ALARM
F2 OFF
ALM

ITALIAN
BOTH

POLISH
FF

CZECH
PF

DANISH

F3 BEACON FLS OFF

PORTUGESE

KEY

HUNGARIAN

BOTH

FINISH

FF

NORWEGIAN

PF

SWEDISH
Page 85

RUSSIAN

TURKISH

GREEK

SLOVENIAN

TI800-01_2D_11

Fig. 37

ES/ET4000 Series
Rev. B
84
 Fig. 38
Features - F4
F3, page 84

F4 TRUCK TYPE ES & ET

ESi & ETi F4.1 TRUCK MODEL 4040MW

DT 4040MF

4040EW

HOUR, page 86
4040EF

ES/ET4000 Series
TRUCK
F4.1.1 12
CAPACITY

14

16

TI800-01_2D_12

85
FEATURES - F4
ELECTRICAL SYSTEM

Rev. B
ELECTRICAL SYSTEM
FEATURES - F5 TO F12

Features - F5 to F12

F4, page 85

MESSAGE MODE
F5 ALL
= Value

SPEED
PERFORMANCE
F6 DISABLE
= Value

HOURS

ENABLE

BDI
USER CODES
F7 DISABLE
= Value

ENABLE F7.1 To Page 15

F8 EEPROM CLEAR NO

YES ACCESS 1 NO

TFD TORQUE
F9 CONSTANT
= Value

YES

ACCESS 2&3 NO

FREE

YES

LOW TO HIGH2
ACCESS 5 NO

LOW TO HIGH
YES

F10
HOUR METER
= Value
H1 Note: Menu item F9 is only displayed
if the truck has electric steering with
the TFD option.
H2

BELLY BUTTON
F11 COASTING
= Value

ON

F12 KEYLESS = Value DISABLE

OFF

KEYLESS Value
ENABLE F12.1
TIMEOUT (10-30 min)

F13, page 87 TI800-01_2D_13

Fig. 39

ES/ET4000 Series
Rev. B
86
 ELECTRICAL SYSTEM
FEATURES - F13 TO F18

Features - F13 to F18

F12, page 86

F1, page 84

TI800-01_2D_14

Fig. 40

ES/ET4000 Series
Rev. B
87
ELECTRICAL SYSTEM
FEATURES - F7 ENABLE

Features - F7 Enable

F6, page 86

S. 86

F6, page 86

TI800-01_2D_15

Fig. 41

ES/ET4000 Series
Rev. B
88
 ELECTRICAL SYSTEM
HOUR - H1 TO H5

Hour - H1 to H5

Features, page 84

Level2: View only

Level3: Increase only

HOUR H1 RUNTIME 1 = Value h Value h Value = h

Level 2: View only

Level 3: Increase only
RUNTIME 2 LEVEL = H2.1 RUNTIME2 Value = h
H2 Value = level 1 - 9
Value h = Value

Events, page 90

Level 2: View only

Level 3: Increase only

H3 ACCESS 2 = Value h Value h Value = h

Level 2: View only

Level 3: Increase only

H4 ACCESS 3 = Value h Value h Value = h

Level 2: View only

Level 3: Increase only

H5 ACCESS 5 = Value h Value h Value = h

TI800-01_2D_16
Note: Menu item H5 is only displayed if the truck has electric steering.

Fig. 42

ES/ET4000 Series
Rev. B
89
ELECTRICAL SYSTEM
EVENTS - E1 TO E3

Events - E1 to E3

HOUR, page 89

CHRON
EVENTS E1 E1.1 LAST CODE = Value Value
HISTORY

HOUR = Value h Value h

TEMP = Value C Value C

PERFORMANCE, page 91 E1.2 LAST-1 CODE = Value Value

HOUR = Value h Value h

TEMP = Value C Value C

E1.16 LAST-15 CODE = Value Value

HOUR = Value h Value h

TEMP = Value C Value C

ACCUM EVENT X
E2 Value
HISTORY OCCURENCES = Value

EVENT Y
Value
OCCURENCES = Value

EVENT Z
Value
OCCURENCES = Value

CLEAR CLEAR
E3 E3.1 NO
HISTORY CHRONOLOGICAL

Note: The parameters can be found in Software Param- YES

eter Settings ES 4020-MW /-EW. Page 97 and in Soft-
ware Parameter Settings ET 4040-MF / -EF, page 99.

E3.2 CLEAR ALL NO

YES TI800-01_2D_17

Fig. 43

ES/ET4000 Series
Rev. B
90
 ELECTRICAL SYSTEM
PERFORMANCE P1

Performance P1

P16, page 94
EVENTS, page 90

RIDER TRAVEL
PERFORMANCE P1 SET P1 P1.1 SPEED PF Edit 1 - 9
= Value

RIDER TRAVEL
P2, page 92 P1.2 SPEED FF
= Value
Edit 1 - 9

Save? N

RIDER
P1.3 ACCELERATION Edit 1 - 5
= Value
Save? Y

UTILITIES, page 95 RIDER

P1.4 PLUGGING Edit 1 - 9
= Value

WALKIE TRAVEL
P1.1 SPEED PF
= Value RIDER
P1.5 COASTING Edit 1 - 9
= Value

WALKIE TRAVEL
P1.2 SPEED FF
= Value PL UP
P1.6 SPEED PF Edit 1 - 9
= Value

WALKIE
P1.3 ACCELERATION
= Value
PL UP
P1.7 SPEED FF Edit 1 - 9
= Value
WALKIE
P1.4 PLUGGING
= Value
PL DOWN
P1.8 SPEED PF Edit 1 - 9
= Value
WALKIE
P1.5 COASTING
= Value

PL DOWN
Note: The parameters can be found in Software Parameter P1.9 SPEED FF
= Value
Edit 1 - 9

Settings ES 4020-MW /-EW. Page 97 and in Software Pa-

rameter Settings ET 4040-MF / -EF, page 99.
WALKIE
P1.10 ACCELERATION Edit 1 - 9
= Value

WALKIE
P1.11 PLUGGING Edit 1 - 9
= Value

WALKIE
P1.12 COASTING Edit 1 - 9
= Value

SPEED
REDUCTION ON
P1.13 Edit 1 - 4
TURNS
= Value

PANIC STEERING
P1.14 Edit 1 - 9
= Value

TI800-01_2D_18

Fig. 44

ES/ET4000 Series
Rev. B
91
ELECTRICAL SYSTEM
PERFORMANCE P2

Performance P2

P1, page 91
EVENTS, page 90

RIDER TRAVEL
PERFORMANCE P2 SET P2 P2.1 SPEED PF Edit 1 - 9
= Value

RIDER TRAVEL
P2.2 SPEED FF Edit 1 - 9
P3, page 92 = Value
Save? N

RIDER
P2.3 ACCELERATION Edit 1 - 5
= Value

Save? Y

UTILITIES, page 95 RIDER

P2.4 PLUGGING Edit 1 - 9
= Value

WALKIE TRAVEL
P2.1 SPEED PF
= Value RIDER
P2.5 COASTING Edit 1 - 9
= Value

WALKIE TRAVEL
P2.2 SPEED FF
= Value PL UP
P2.6 SPEED PF Edit 1 - 9
= Value

WALKIE
P2.3 ACCELERATION
= Value
PL UP
P2.7 SPEED FF Edit 1 - 9
= Value
WALKIE
P2.4 PLUGGING
= Value
PL DOWN
P2.8 SPEED PF Edit 1 - 9
= Value
WALKIE
P2.5 COASTING
= Value

PL DOWN
P2.9 SPEED FF Edit 1 - 9
= Value

Note: The parameters can be found in Software Parameter Set-

tings ES 4020-MW /-EW. Page 97 and in Software Parameter Set- WALKIE
Edit 1 - 9
P2.10 ACCELERATION
tings ET 4040-MF / -EF, page 99. = Value

WALKIE
P2.11 PLUGGING Edit 1 - 9
= Value

WALKIE
P2.12 COASTING Edit 1 - 9
= Value

SPEED
REDUCTION ON
P2.13 Edit 1 - 4
TURNS
= Value

PANIC STEERING
P2.14 Edit 1 - 9
= Value

TI800-01_2D_19

Fig. 45

ES/ET4000 Series
Rev. B
92
 ELECTRICAL SYSTEM
PERFORMANCE P3

Performance P3

P2, page 92
Events, page 90

RIDER TRAVEL
PERFORMANCE P3 SET P3 P3.1 SPEED PF Edit 1 - 9
= Value

RIDER TRAVEL
P4, page 94 P3.2 SPEED FF
= Value
Edit 1 - 9

Save? N

RIDER
P3.3 ACCELERATION Edit 1 - 5
= Value
Save? Y

Utilities, page 95 RIDER

P3.4 PLUGGING Edit 1 - 9
= Value

WALKIE TRAVEL
P3.1 SPEED PF
= Value RIDER
P3.5 COASTING Edit 1 - 9
= Value

WALKIE TRAVEL
P3.2 SPEED FF
= Value PL UP
P3.6 SPEED PF Edit 1 - 9
= Value

WALKIE
P3.3 ACCELERATION
= Value
PL UP
P3.7 SPEED FF Edit 1 - 9
= Value
WALKIE
P3.4 PLUGGING
= Value
PL DOWN
P3.8 SPEED PF Edit 1 - 9
= Value
WALKIE
P3.5 COASTING
= Value

PL DOWN
P3.9 SPEED FF Edit 1 - 9
= Value
Note: The parameters can be found in Software Pa-
rameter Settings ES 4020-MW /-EW. Page 97 and in
Software Parameter Settings ET 4040-MF / -EF, P3.10
WALKIE
ACCELERATION Edit 1 - 9
page 99. = Value

WALKIE
P3.11 PLUGGING Edit 1 - 9
= Value

WALKIE
P3.12 COASTING Edit 1 - 9
= Value

SPEED
REDUCTION ON
P3.13 Edit 1 - 4
TURNS
= Value

PANIC STEERING
P3.14 Edit 1 - 9
= Value

TI800-01_2D_20

Fig. 46

ES/ET4000 Series
Rev. B
93
ELECTRICAL SYSTEM
PERFORMANCE P4 TO P16

Performance P4 to P16

P3, page 93

Note: The parameters can be

found in Software Parameter
Settings ES 4020-MW /-EW.
Page 97 and in Software Pa-
rameter Settings ET 4040-
MF / -EF, page 99.

TI800-01_2D_21
P1, page 91

Fig. 47

ES/ET4000 Series
Rev. B
94
 ELECTRICAL SYSTEM
UTILITIES - U1

Utilities - U1

PERFORMANCE, page 91

ANALYZER, page 75

Note: Menu item U1.4 ACCESS 5 is only displayed if

the truck has electric steering.

TI800-01_2D_22

Fig. 48

ES/ET4000 Series
Rev. B
95
ELECTRICAL SYSTEM
TEST OUTPUTS - A4

Test Outputs - A4

PERFORMANCE, page 91

ANALYZER, page 75

TI800-01_2D_23

Fig. 49

ES/ET4000 Series
Rev. B
96
 ELECTRICAL SYSTEM
SOFTWARE PARAMETER SETTINGS ES 4020-MW /-EW

Software Parameter Settings ES 4020-MW /-EW

Brief description of equipment • Platform type In the following table this component of the truck data number describes the truck
The number ES 4020 -MW for example denotes an ES 4040 with mechanical model.
Three components of the truck data number are used to assign the truck's equip-
steering and no platform.
ment to the parameters: Markings
See page 4 for details of the truck data number.
• Model number X = Applicable
• Steering type — = Not applicable

ES 4020 -MW / -EW Factory Settings

Display Description Range Perfor- Perfor- Perfor-

mance mance mance
setting P1 setting P2 setting P3

Walkie Travel Speed PF Max. travel speed of unladen truck in the tiller direction. Values range from 1 - 9 in 0.5 km/h increments.
9 7 5
1 = 2 km/h, 3 = 3 km/h, 5 = 4 km/h, 7 = 5 km/h, 9 = 6 km/h
Walkie Travel Speed FF Max. travel speed of unladen truck in the forks direction. Values range from 1 - 9 in 0.5 km/h increments.
9 7 5
1 = 2 km/h, 3 = 3 km/h, 5 = 4 km/h, 7 = 5 km/h, 9 = 6 km/h
Walkie Acceleration Time(a) in which the drive motor can be accelerated in pedestrian mode from 0 rpm to a Values range from 1 - 9 in 0.2 s increments.
speed that corresponds to the 6 km/h for the unladen truck in performance setting P1. 1 corresponds to maximum acceleration, 9 corresponds to minimum acceleration. 7 8 9
1= 0.3 s, 4 = 1.0 s, 9 = 1.9 s
Walkie Plugging Time(b) in which the drive motor can be decelerated from a speed that corresponds to the Values range from 1 - 9 in 0.2 s increments.
6 km/h for the unladen truck to 0 rpm by changing direction. 1 corresponds to maximum deceleration, 9 corresponds to minimum deceleration. 3 4 7
1= 0.6 s, 4 = 1.2 s, 9 = 2.2 s
Walkie Coasting Time(b) in which the drive motor can be decelerated from a speed that corresponds to the Values range from 1 - 9 in 0.2 s increments.
6 km/h for the unladen truck to 0 rpm by coasting. 1 corresponds to maximum deceleration, 9 corresponds to minimum deceleration. 6 6 6
1= 1.0 s, 4 = 1.6 s, 9 = 2.6 s
a. This is the time required by the electronic system to accelerate the motor on the test bench from 0 rpm to the specified speed. In practice, inertia, fiction and other resistances will extend this time.
b. This is the time required by the electronic system to decelerate the motor on the testbench to 0 rpm In practice, inertia, fiction and other resistances will extend this time.

The following parameters are identical in all performance settings:

ES 4020 -MW / -EW Parameter Menu Factory Setting

BDI Setting Check BDI setting for different application profiles. Light Duty, Standard Duty, Heavy Duty, Maintenance Free P4 Standard Duty

Max EVP(a) Limit for maximum current through lowering valve PV. This determines the maximum low- Values range from 1 - 20 in 0.4% increments.
ering speed available. This parameter must only be changed after prior consultation with 1 = 45.1%, 10 = 54.5%, 20 = 65.5% P5 10
Crown.

Min EVP(a) Limit for minimum current through lowering valve PV. This determines the minimum low- Values range from 1 - 20 in 0.4% increments.
ering speed available. This parameter must only be changed after prior consultation with 1 = 11%, 10 = 14.5%, 20 = 18.4% P6 18
Crown.

EVP Open Delay(a) Delay in opening lowering valve PV. Time taken to reach min EVP. This setting affects the Values range from 1 - 9 in 0.05 s increments.
nature of lifting (soft or abrupt). This parameter must only be changed after prior consulta- 1= 0.0 s, 5 = 0.2 s, 9 = 0.4 s P7 5
tion with Crown.

EVP Close Delay(a) Delay in closing lowering valve PV. This setting affects how lifting stops (softly or abruptly) Values range from 1 - 9 in 0.05 s increments.
P8 3
when the lowering encoder has reached its zero setting. 1= 0.0 s, 5 = 0.2 s, 9 = 0.4 s
Pump Acceleration Time taken(b) to accelerate the pump motor from 0 rpm to maximum speed. Values range from 1 - 9 in 0.1 s increments.
P9 4
1= 0.1 s, 4 = 0.4 s, 9 = 0.9 s

ES/ET4000 Series
Rev. B
97
ELECTRICAL SYSTEM
SOFTWARE PARAMETER SETTINGS ES 4020-MW /-EW

ES 4020 -MW / -EW (Continued) Parameter Menu Factory Setting

Pump Deceleration Time taken(c) to decelerate the pump motor from maximum speed to 0 rpm. Values range from 1 - 9 in 0.1 s increments.
P10 1
1= 0.1 s, 4 = 0.4 s, 9 = 0.9 s
Adjust Batt Option to compare the battery voltage measured by the control module with the actual —
P11 Battery Voltage
voltage measured on the battery.(a)
Rider Turtle Speed The value can be adjusted but does not have any effect. (The platform switches are over- —
P12 5
riden as the truck does not have a platform.)
Walkie Turtle Speed Speed when the HSS switch is in the "Turtle" position. Values range from 1 - 9 in 0.5 km/h increments.
P13 5
1 = 1.1 km/h, 3 = 2.1 km/h, 9 = 5.1 km/h
Turtle Mode Brake Time(c) required by the drive motor to decelerate from maximum speed to 0 rpm when the Values range from 1 - 9 in 0.2 s increments.
P14 4
BRS switch is applied. 1= 2.2 s, 4 = 2.8 s, 9 = 3.8 s

BB Acceleration Time(b) required by the drive motor to accelerate from 0 rpm to maximum speed when the Values range from 1 - 9 in 0.1 s increments.
P15 6
SAS safety reverse switch is applied. 1= 1.2 s, 4 = 1.5 s, 9 = 2.0 s

BB Deceleration Time(c) required by the drive motor to decelerate from maximum speed to 0 rpm when the Values range from 1 - 9 in 0.2 s increments. P16 2
SAS safety reverse switch is released. 1= 0.9 s, 4 = 1.5 s, 9 = 2.5 s

a. Parameters must only be changed after prior consultation with Crown.

b. This is the time required by the electronic system to accelerate the motor on the test bench from 0 rpm to the specified speed. In practice, inertia, fiction and other resistances will extend this time.
c. This is the time required by the electronic system to decelerate the motor on the testbench to 0 rpm In practice, inertia, fiction and other resistances will extend this time.

ES/ET4000 Series
Rev. B
98
 ELECTRICAL SYSTEM
SOFTWARE PARAMETER SETTINGS ET 4040-MF / -EF

Software Parameter Settings ET 4040-MF / -EF

Brief description of equipment The number ET 4040 -MF for example denotes an ET 4040 with mechanical Operation Modes
steering and a folding platform. The position of the platform and side restraints determines the rider, pedestrian
Three components of the truck data number are used to assign the truck's equip-
See page 4 for details of the truck data number. and comfort modes. See page 71.
ment to the parameters:
In the following table this component of the truck data number describes the truck
• Model number Markings
model.
• Steering type X = Applicable
• Platform type — = Not applicable

ET 4040-MF / -EF Factory Settings

Display Description Range Perfor- Perfor- Perfor-

mance mance mance
setting P1 setting P2 setting P3

Rider Travel Speed PF Max. travel speed of unladen truck in the tiller direction. Values range from 1 - 9 in 0.5 km/h increments.
7 5 3
1 = 6.0 km/h, 3 = 7 km/h, 5 = 8 km/h, 7 = 9 km/h, 9 = 10 km/h
Rider Travel Speed FF Max. travel speed of unladen truck in the forks direction. Values range from 1 - 9 in 0.5 km/h increments.
7 5 3
1 = 6.0 km/h, 3 = 7 km/h, 5 = 8 km/h, 7 = 9 km/h, 9 = 10 km/h
Rider Acceleration Time(a) in which the drive motor can be accelerated in rider mode from 0 rpm to a speed Values range from 1 - 5.
3 3 4
that corresponds to the 8 km/h for the unladen truck in performance setting P1. 1 corresponds to maximum acceleration, 5 corresponds to minimum acceleration.

Rider Plugging Time(b) in which the drive motor can be decelerated from a speed that corresponds to the Values range from 1 - 9 in 0.2 s increments.
8 km/h for the unladen truck to 0 rpm by changing direction. 1 corresponds to maximum deceleration, 9 corresponds to minimum deceleration. 6 6 7
1= 0.6 s, 3 = 1 s, 9 = 2.2 s
Rider Coasting Time(b) in which the drive motor can be decelerated from a speed that corresponds to the Values range from 1 - 9 in 0.2 s increments.
8 km/h for the unladen truck to 0 rpm by coasting. 1 corresponds to maximum deceleration, 9 corresponds to minimum deceleration. 7 7 7
1= 0.6 s, 3 = 1 s, 9 = 2.2 s
PLT Up Speed PF Max. travel speed in pedestrian mode in the tiller direction. Values range from 1 - 9 in 0.5 km/h increments.
9 7 5
1 = 2 km/h, 3 = 3 km/h, 5 = 4 km/h, 7 = 5 km/h, 9 = 6 km/h
PLT Up Speed FF Max. travel speed in pedestrian mode in the forks direction. Values range from 1 - 9 in 0.5 km/h increments.
9 7 5
1 = 2 km/h, 3 = 3 km/h, 5 = 4 km/h, 7 = 5 km/h, 9 = 6 km/h
PLT Down Speed PF Max. travel speed in comfort mode in the tiller direction. Values range from 1 - 9 in 0.5 km/h increments.
9 7 5
1 = 2 km/h, 3 = 3 km/h, 5 = 4 km/h, 7 = 5 km/h, 9 = 6 km/h
PLT Down Speed FF Max. travel speed in comfort mode in the forks direction. Values range from 1 - 9 in 0.5 km/h increments.
9 7 5
1 = 2 km/h, 3 = 3 km/h, 5 = 4 km/h, 7 = 5 km/h, 9 = 6 km/h
Walkie Acceleration Time(a) in which the drive motor can be accelerated in pedestrian and comfort modes from Values range from 1 - 9 in 0.2 s increments.
0 rpm to a speed that corresponds to the 6 km/h for the unladen truck in performance 1 corresponds to maximum acceleration, 9 corresponds to minimum acceleration. 7 8 9
setting P1. 1= 0.3 s, 4 = 0.9 s, 9 = 1.9 s

Walkie Plugging Time(b) in which the drive motor can be decelerated in pedestrian and comfort modes from Values range from 1 - 9 in 0.2 s increments.
a speed that corresponds to the 6 km/h for the unladen truck to 0 rpm by changing direc- 1 corresponds to maximum deceleration, 9 corresponds to minimum deceleration. 3 4 7
tion. 1= 0.6 s, 4 = 1.2 s, 9 = 2.2 s

Walkie Coasting Time(b) in which the drive motor can be decelerated from a speed that corresponds to the Values range from 1 - 9 in 0.2 s increments.
6 km/h for the unladen truck to 0 rpm by coasting. 1 corresponds to maximum deceleration, 9 corresponds to minimum deceleration. 64 6 6
1= 0.6 s, 4 = 1.2 s, 9 = 2.2 s

ES/ET4000 Series
Rev. B
99
ELECTRICAL SYSTEM
SOFTWARE PARAMETER SETTINGS ET 4040-MF / -EF

ET 4040-MF / -EF (Continued) Factory Settings

Display Description Range Perfor- Perfor- Perfor-

mance mance mance
setting P1 setting P2 setting P3

Speed Reduction On Resulting maximum speed around bends for a 90° tiller angle. Values range from 1 - 4 in rider mode:
Turns 1 = 5.5km/h for 90° tiller angle.
2 = 6 km/h for 90° tiller angle.
3 = 5 km/h for 90° tiller angle. 2 2 3

Values range from 1 - 4 in pedestrian and comfort modes:

1 - 3 = 2.1 km/h for 90° tiller angle.
Panic Steering ET 4040 EF only: Reduces travel speed to the setting for sudden acute steering angles. Values range from 1 - 9
1 corresponds to maximum reduction, 9 switches the reduction off. 9 9 9
1 = 2.8 km/h, 4 = 6 km/h, 6 = 8 km/h, 9 = 10 km/h, 9 = 6 km/h = no reduction
a. This is the time required by the electronic system to accelerate the motor on the test bench from 0 rpm to the specified speed. In practice, inertia, fiction and other resistances will extend this time.
b. This is the time required by the electronic system to decelerate the motor on the test bench from the initial speed to 0 rpm In practice, inertia, fiction and other resistances will extend this time.

ES/ET4000 Series
Rev. B
100
 ELECTRICAL SYSTEM
SOFTWARE PARAMETER SETTINGS ET 4040-MF / -EF

The following parameters are identical in all performance levels:

ET 4040-MF / -EF Parameter Menu Factory Setting

BDI Setting Check BDI setting for different application profiles. Light Duty, Standard Duty, Heavy Duty, Maintenance Free P4 Standard Duty
Max EVP Limit for maximum current through lowering valve PV. This determines the maximum low- Values range from 1 - 20 in 1.6 % increments.
P5 10
ering speed available.(a) 1 = 45.1%, 10 = 54.5%, 20 = 65.5%

Min EVP Limit for minimum current through lowering valve PV. This determines the minimum low- Values range from 1 - 20 in 0.4% increments.
1 = 11 %, 18 = 17.7 %, 20 = 18.5 % P6 18
ering speed available.(a)
EVP Open Delay Delay in opening lowering valve PV. Time taken to reach min EVP. This setting affects the Values range from 1 - 9 in 0.05 s increments.
P7 5
nature of lifting (soft or abrupt).(a) 1= 0.0 s, 5 = 0.2 s, 9 = 0.4 s

EVP Close Delay Delay in closing lowering valve PV. This setting affects how lifting stops (softly or abruptly) Values range from 1 - 9 in 0.05 s increments.
P8 3
when the lowering encoder has reached its zero setting.(a) 1= 0.0 s, 4 = 0.15 s, 9 = 0.4 s

Pump Acceleration Time taken to accelerate the pump motor from 0 rpm to maximum speed.(b) Values range from 1 - 9 in 0.1 s increments.
P9 4
1= 0.1 s, 4 = 0.4 s, 9 = 0.9 s
Pump Deceleration Time taken to decelerate the pump motor from maximum speed to 0 rpm.(c) Values range from 1 - 9 in 0.1 s increments.
P10 1
1= 0.1 s, 4 = 0.4 s, 9 = 0.9 s
Adjust Batt Option to compare the battery voltage measured by the control module with the actual —
P11 Battery Voltage
voltage measured on the battery.(a)
Rider Turtle Speed Speed in rider mode when the HSS switch is in the "Turtle" position. Values range from 1 - 9 in 0.5 km/h increments.
P12 5
1 = 4 km/h, 7 = 7 km/h, 9 = 8 km/h
Walkie Turtle Speed Speed in pedestrian and comfort modes when the HSS switch is in the "Turtle" position. Values range from 1 - 9 in 0.5 km/h increments.
P13 5
1 = 1.1 km/h, 3 = 2.1 km/h, 9 = 5.1 km/h
Turtle Mode Brake Time(c) required by the drive motor to decelerate from maximum speed to 0 rpm when the Values range from 1 - 9 in 0.2 s increments. P14 4
BRS switch is applied. 1= 2.2 s, 4 = 2.8 s, 9 = 3.8 s

BB Acceleration Time(b) required by the drive motor to accelerate from 0 rpm to maximum speed when the Values range from 1 - 9 in 0.1 s increments. P15 6
SAS safety reverse switch is applied. 1= 1.2 s, 4 = 1.5 s, 9 = 2.0 s

BB Deceleration Time(c) required by the drive motor to decelerate from maximum speed to 0 rpm when the Values range from 1 - 9 in 0.2 s increments.
P16 2
SAS safety reverse switch is released. 1= 0.9 s, 4 = 1.5 s, 9 = 2.5 s

a. This parameter must only be changed after prior consultation with Crown.
b. This is the time required by the electronic system to accelerate the motor on the test bench from 0 rpm to the specified speed. In practice, inertia, fiction and other resistances will extend this time.
c. This is the time required by the electronic system to decelerate the motor on the test bench from the initial speed to 0 rpm In practice, inertia, fiction and other resistances will extend this time.

ES/ET4000 Series
Rev. B
101
Notes:

102
 ELECTRICAL SYSTEM
CALIBRATION

Calibration Electric steering calibration

Calibration is performed in the “SERVICE” menu under Calibration takes place in the following stages:
the “CALIBRATION” menu item on the display. To se- • Calibrating the control handle centre position
lect the “CALIBRATION” menu proceed as follows: • Calibrating the drive wheel forward travel
Selecting the CALIBRATION Menu • Calibrating the right steering lock
• Left steering lock calibration
You can navigate through the menu structures using
the cursor keys ( , , , , ) on the display panel. Requirements
An overview of the menu structure can be found in • The front cover to the drive compartment is re-
Menu Structure, starting on page 74. moved so that the drive wheel position can be seen.
• The “CALIBRATION” menu is selected (see
“Selecting the CALIBRATION Menu” on page 103).
Selecting steering calibration
1. Press to scroll to the “C2 STEER SYS” menu.
2. Press the key.
 The safety prompt “SURE? N” is displayed.
Note: If you wish to cancel calibration, press the key
now.
3. Press the key.
 The safety prompt “SURE? Y” appears.
4. Press the key.
Fig. 50 Display panel  The “C2.1 ACQUIRE TILLER CENTER” menu
for calibrating the control handle centre position
Switching the truck on is selected.
1. Press the key for 1 second. Calibrating the control handle centre position
 The display screen is activated.
1. Set the control handle to the centre position.
Note: For trucks with a key switch, turn the key switch
right to the "On" position. 2. To confirm the centre position press the key to
select “CONFIRM” and press .
Selecting the Calibration menu
3. Press the key several times to select the “C2.6
2. Press the key 3 times. ADJ DRIVE TIRE CENTER” menu.
 The "SERVICE" menu is displayed.
Calibrating the drive wheel forward travel
3. Press the key until “LEVEL 2” appears.
The “C2.6 ADJ DRIVE TIRE CENTER” menu is se-
4. Press the key until you are requested to enter lected.
your PIN.
1. Press the key.
5. Enter the service PIN with the and keys and  The setting is displayed (factory setting = 200).
confirm with .
2. Using the and keys, set the drive wheel to
 The "ANALYZER" menu is displayed.
forward travel.
6. Press the key until the “CALIBRATION” menu  Press the key to turn the drive wheel clock-
appears. wise.
 Press the key to turn the drive wheel anti-
clockwise.
Note: The position of the drive wheel only changes
when you confirm with the key.
3. Confirm the drive wheel position with .
 The drive wheel position changes.

ES/ET4000 Series
Rev. B
103
ELECTRICAL SYSTEM
CALIBRATION

Note: Check forward travel by carrying out a test run. 4. Using the and keys, set the drive wheel ex-
Repeat the calibration as required. actly to the 90 degree position.
4. Press the key.  Press the key to increase the angle of the
 The “C2.7 2ND ENCODER” menu is selected. drive wheel.
 Press the key to decrease the angle of the
Note: The “C2.7 2ND ENCODER” menu must not be
drive wheel.
changed. The encoder setting must be “ON”.
5. Confirm the drive wheel position with .
Calibrating the right steering lock
6. Check the drive wheel position again.
Settings can be made from 1 to 9 for approximate and
fine calibration tuning. For fine calibration the settings Note: If the drive wheel is not set exactly to the 90°
1 to 9 correspond to an approximate calibration tuning. position, press to select the “C2.5 ADJ FULL RIGHT
There are therefore 9 x 9 settings available. FINE” menu and perform fine-tuning again.
The steering lock must be set so that for a full lock the Calibrating the left steering lock
drive wheel is set 90° to the right. If not, proceed as Note: The left steering lock is calibrated in the same
follows: way as for the right steering lock via the “C2.3 ADJ
Fine-tuning the right steering lock FULL LEFT FINE” and “C2.2 ADJ FULL LEFT
COARSE” menus.
1. Press to select the “C2.5 ADJ FULL RIGHT
FINE” menu Saving and activating all settings
2. Move the tiller anti-clockwise as far as the stop and 1. Press the key.
hold it in this position.  The saving prompt "SAVE? N” is displayed.
3. Press the key to view the setting.  If you do not wish to accept the settings, press
to cancel the calibration.
4. Use the and keys to change the reading by
just one unit. This will indicate how far the drive 2. To save the settings, press “SAVE? Y”.
wheel position changes. 3. To confirm the settings, press .
 Press the key to increase the angle of the  The display changes to the “C2 STEER SYS”
drive wheel. menu.
 Press the key to decrease the angle of the 4. Wait approximately 5 seconds until the new set-
drive wheel. tings are stored.
5. Confirm the drive wheel position with and posi- 5. Switch the truck off and on again.
tion the tiller centrally.  The new settings are now activated.
6. Check the drive wheel again to see if the 90 degree 6. Carry out a test run.
position is reached for a full steering lock.
 If the steering lock has been set correctly, the load
 If not, carry out the fine calibration tuning again. wheels should turn in the opposite direction for a
Note: If the setting is 9 and the drive wheel is still not full steering lock when the truck is travelling very
in the 90° position for a full steering lock, the steering slowly. Check this for both directions.
lock should only be given an approximate pre-setting.
To do this, proceed as follows:
Right steering lock rough calibration
1. Press to select the “C2.4 ADJ FULL RIGHT
COARSE” menu.
2. Move the tiller anti-clockwise as far as the stop and
hold it in this position.
3. Press the key to view the setting (1 to 9) (factory
setting = 3).

ES/ET4000 Series
Rev. B
104
 ELECTRICAL SYSTEM
CALIBRATION

Calibrating proportional lifting and

lowering
Requirements
• The “CALIBRATION” menu is selected (see “Se-
lecting the CALIBRATION Menu” on page 103).
Selecting the calibration
1. Press to scroll through to the “C3 LIFT/LOWER
ROTARY ENCODER” menu.
2. Press the key.
 The safety prompt “SURE? N” is displayed.
Confirming the security prompt
3. To continue press the key.
 The safety prompt “SURE? Y” appears.
4. Press the key.
 “C3.1 PRESS LIFT MAX & LOWER MAX THEN
ENTER” is displayed.
Calibration
5. Press the "fork lift" switch and fully extend the
mast.
6. Press the "fork lower" switch and fully lower the
mast.
Saving the calibration and quitting the calibration
menu
7. Press the key.
 The new settings are stored.
 The display changes back to the “C3 LIFT/
LOWER ROTARY ENCODER” menu.
8. Wait for 5 seconds.
 After 5 seconds the new settings are stored.
Activating the new setting
9. Switch the truck off and on again.
 The new settings are activated.

ES/ET4000 Series
Rev. B
105
ELECTRICAL SYSTEM
ERROR CODES

Error codes Event code groups

This truck is fitted with an electronic control system for The first digit of an event code represents the group
the key operating functions. number. For example, if an event code starts with the
digit 2, then the event has occurred in the Access 2
Malfunctions with event code module.
display
Event code groups
Event codes are produced from tests carried out on the
inputs and outputs of control signals. For most faults Starting Module concerned
the system generates an event code and stores it in the digit
log book. The last 15 events are displayed in the
Events menu. 1 Access 1 (Display)
Locating malfunctions 2 Access 2 (Hydraulic control module)
(HCM)
Malfunctions occur primarily on external components
such as fuses, solenoids, contactors, motors etc. 3 Access 3 (Traction control module)
These components are necessarily subject to a certain (TCM)
degree of wear.
4 Not used
The next possible causes include connectors, wiring
and input devices such as switches, potentiometers or 5 Access 5 (Steering control module)
encoders. These are subject above all to ambient con- (SCM)
ditions. 6 Not used
Experience shows that control modules are very sel-
7 Not used
dom the cause of the problem.
The easiest way of locating a fault is to start trouble- 8 Access 8.x (CAN interfaces)
shooting on the component (the external component). 9 Access 8.2 (CAN Interfaces)
The following sections list the event code numbers in
ascending order. In addition to each event code they
also list the possible causes, the effect on the truck and
troubleshooting notes.

ES/ET4000 Series
Rev. B
106
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 100 (ES/ET -M, -E)

Event Code - Group 100 (ES/ET -M, -E)

Note: If an event code occurs without an obvious rea- Software Parameter Settings ES 4020-MW /-EW,
son, clearing the control module EEPROM can be ef- page 97 and Software Parameter Settings ET 4040-
fective. Attempt this before you replace the control MF / -EF, page 99. If necessary, recalibrate the truck
module. This will restore the factory settings. See (see page 103).

Event Code 100

Display: EV 200
Service LED: On
Operator LED: Off
Explanation: Access 1 does not receive a response from Access 3 within the 3 second
timeout
Possible causes: • Wiring error
• Access 1 faulty
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 1.
Check status of Access 1
1. Select service level 2 (see page 72).
2. Press the key 3 times.
 A1.1 ACCESS_1 ON or OFF is displayed.
 If the status is ON, proceed to step 1.
 If the status is OFF, proceed to step 3.
Check connector CA201 for damage
3. Disconnect CA200 and CA201.
4. Measure the resistance between CA200-8 and CA201-28.
5. Measure the resistance between PC200-9 and PC201-27.
 If the resistance of one or both wires > 2 , repair the wiring.
 If the resistance < 2 , proceed to step 7.
Check the display software version
1. Select service level 2 (see page 72).
2. Using the key scroll through to the UTILITIES menu.
3. Press the key 4 times.
 The software version (PN) of ACCESS 1 is displayed.
4. Compare the version number with the list on page 73.
5. If the software version matches the other modules, proceed to step 17.
6. If the software version does not match the other modules, install the cor-
rect software version or proceed to step 17.

ES/ET4000 Series
Rev. B
107
ELECTRICAL SYSTEM
EVENT CODE - GROUP 100 (ES/ET -M, -E)

Check the display power supply

7. Connect PC200 and PC201.
8. Power up the truck.
9. Measure the voltage between CA201-10 and B–.
 If the voltage is approx. 24 V, proceed to step 10.
 If there is no voltage or if the voltage is less than 24 V, proceed to step
16.
Check CAN-Bus wiring and termination
10. Power down the truck.
11. Measure the resistance between CA210-1 and CA210-2.
 If the resistance is 60 , the CAN-Bus termination is ok. Proceed to
step 1.
 If the resistance is not 60 , proceed to step 72.
12. Disconnect CA220.
13. Measure the resistance between PC220-4 and PC220-5.
 If the resistance is 120 , the resistor at PC220 is ok. Proceed to step
14.
 If the resistance is not 120 , the resistor at PC220 is faulty. Replace
the resistor.
14. Disconnect CA200.
15. Measure the resistance on the display at JC200-8 and JC200-9.
 If the resistance is 120 , the resistor in the display is ok. Proceed to
step 16.
 If the resistance is not 120 , the display is faulty. Proceed to step 17.
Repair wiring
16. Repair the wiring.
Replace Access 1
17. Replace Access 1

ES/ET4000 Series
Rev. B
108
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 200 (ES/ET -M, -E)

Event Code - Group 200 (ES/ET -M, -E)

Note: If an event code occurs without an obvious Software Parameter Settings ES 4020-MW /-EW,
reason, clearing the control module EEPROM can be page 97 and Software Parameter Settings ET 4040-
effective. Attempt this before you replace the control MF / -EF, page 99. If necessary, recalibrate the truck
module. This will restore the factory settings. See (see page 103).

Event Code 202

Display: EV 202
Service LED: On
Operator LED: Off
Explanation: Voltage at terminal -P of Access 2 (HCM) too low.
Possible causes: If the event is displayed during power up, but before the main contactor
applies:
• The power cables to pump motor M2 have a poor contact, are damaged or
connected incorrectly
• Access 2 output stage is faulty
If the event is displayed during power up, but after the main contactor
has applied:
• Check the power cable connections on pump motor M2
• Insulation resistances from the power cables or the winding of pump motor
M2 to the truck frame are too low
If the event is displayed during lifting:
• The power cables to pump motor M2 have a poor contact, are damaged or
connected incorrectly
• Insulation resistances from the power cables or the winding of pump motor
M2 to the truck frame are too low
• Contacts of main contactor EDS are worn
Remedy: If the event is displayed during power up, but before the main contactor
applies:
Check the power cables and connections
1. Check the power cables to pump motor M2 and its connections are secure
and check for damage.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the connections are ok, proceed to step 2.
Check the insulation resistance
2. Measure the insulation resistances of the motor coil and power cables
against the truck frame.
 If the insulation resistance is ok, proceed to step 3.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
Check the output stage of Access 2 for internal short circuits
3. Disconnect power cable from terminal -P on Access 2.

ES/ET4000 Series
Rev. B
109
ELECTRICAL SYSTEM
EVENT CODE - GROUP 200 (ES/ET -M, -E)

4. Using an ohmmeter measure the resistance from terminal –P on Access 2

to –Batt.
 If the resistance < 3 k, the output stage is faulty. Replace Access 2/3.
 If the resistance > 100 k, the output stage is ok. In this case the error
lies in the wiring from -P to pump motor M2 or in the terminal on pump
motor M2.
If the event is displayed during power up, but after the main contactor
has applied:
Check the power cables and connections
5. Check the power cables to pump motor M2 and its connections are secure
and check for damage.
 If any cables are loose or damaged, rectify the cause.
 If the power cables and the connections are ok, proceed to step 7.
Check the insulation resistance
6. Measure the insulation resistances of the motor coil and power cables
against the truck frame.
 If the insulation resistance is ok, proceed to step 7.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
7. Switch the truck off and on while checking if the error now occurs when the
truck is switched on.
 If the error now occurs when the truck is switched on, carry out steps3
to 4.
If the event is displayed during lifting:
8. Check the power cables to pump motor M2 and its connections are secure
and check for damage.
 If any cables are loose or damaged, rectify the cause.
 If the power cables and the connections are ok, proceed to step 9.
9. Measure the insulation resistances of the motor coil and power cables
against the truck frame.
 If the insulation resistance is ok, proceed to step 10.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
Check main contactor EDS
10. Check the main contactor contacts for wear and damage (see page 230).
 If the contacts are worn, repair the contactor.
 If all the above measures have been taken and the event code still per-
sists, then replace Access2/3.

ES/ET4000 Series
Rev. B
110
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 200 (ES/ET -M, -E)

Event Code 203

Display: EV 203
Service LED: On
Operator LED: Off
Explanation: Voltage at terminal -P of Access 2 (HCM) is higher than the battery voltage.
Possible causes: • The power cables to pump motor M2 have a poor contact, are damaged or
connected incorrectly
• Access 2 faulty
Remedy: Check the power cables and connections
1. Check the power cables to pump motor M2 and its connections are secure
and check for damage.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the connections are ok, proceed to step 2.
Check the insulation resistance
2. Measure the insulation resistances of the motor coil and power cables
against the truck frame.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
 If the insulation resistance is ok, replace Access2/3.

Event Code 204

Display: EV 204
Service LED: On
Operator LED: Off
Explanation: As the pump motor starts up the current measured by Access 2 is either zero
or out of range.
Possible causes: • The power cables to pump motor M2 have a poor contact, are damaged or
connected incorrectly
• Access 2 faulty
Remedy: Check the power cables and connections
1. Check the power cables to pump motor M2 and its connections are secure
and check for damage.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the connections are ok, proceed to step 2.
Test the current sensor in Access 2
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.

ES/ET4000 Series
Rev. B
111
ELECTRICAL SYSTEM
EVENT CODE - GROUP 200 (ES/ET -M, -E)

4. Press the key.

 A2 Inputs is displayed.
5. Press the key.
 A2.1 ACCESS 1 is displayed.
6. Press the key.
 A2.2 ACCESS 2 is displayed.
7. Press the key.
 A2.2.1 RAS ENC is displayed.
8. Using the key scroll through to A2.2.4.
 A2.2.4 PUMP MOTOR CURRENT is displayed.
9. Press the key.
 The current reading is displayed in Amps.
10. Activate lifting and check the reading.
 If the reading remains at 0 A as the motor is running, proceed to step 11.
 If a current > 0 A is displayed while the motor is running, there is no
error. Restart the truck and check the event log.
Clear the EEPROM in Access 2/3
11. Select service level 2 (see page 72).
12. Clear the EEPROM in Access 2/3 (see menu item F8, page 86).
 The EEPROM in Access 2/3 is cleared.
13. Switch the truck off and on again.
14. Fully re-calibrate the truck (see page 103).
 If the event code persists, proceed to step 15.
Check the insulation resistance
15. Measure the insulation resistances of the motor coil and power cables
against the truck frame.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
 If the insulation resistance is ok, replace Access2/3.

ES/ET4000 Series
Rev. B
112
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 200 (ES/ET -M, -E)

Event Code 205

Display: EV 205
Service LED: On
Operator LED: Off
Explanation: While the pump motor is idle the current measured by Access 2 is > 0A.
Possible causes: • The power cables to pump motor M2 have a poor contact, are damaged or
connected incorrectly
• Access 2 faulty
Remedy: Check the power cables and connections
1. Check the power cables to pump motor M2 and its connections are secure
and check for damage.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the connections are ok, proceed to step 2.
Test the current sensor in Access 2
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press the key.
 A2 Inputs is displayed.
5. Press the key.
 A2.1 ACCESS 1 is displayed.
6. Press the key.
 A2.2 ACCESS 2 is displayed.
7. Press the key.
 A2.2.1 RAS ENC is displayed.
8. Using the key scroll through to A2.2.4.
 A2.2.4 PUMP MOTOR CURRENT is displayed.
9. Press the key.
 The current reading is displayed in Amps.
10. Activate lifting and check the reading.
 If the reading remains at 0 A as the motor is running, proceed to step 11.
 If a current > 0 A is displayed while the motor is running, there is no
error. Restart the truck and check the event log.
Clear the EEPROM in Access 2/3
11. Select service level 2 (see page 72).
12. Clear the EEPROM in Access 2/3 (see menu item F8, page 86).
 The EEPROM in Access 2/3 is cleared.
13. Switch the truck off and on again.
14. Fully re-calibrate the truck (see page 103).
 If the event code persists, proceed to step 15.

ES/ET4000 Series
Rev. B
113
ELECTRICAL SYSTEM
EVENT CODE - GROUP 200 (ES/ET -M, -E)

Clear the EEPROM in Access 2/3

15. Select service level 2 (see page 72).
16. Clear the EEPROM in Access 2/3 (see menu item F8, page 86).
 The EEPROM in Access 2/3 is cleared.
17. Switch the truck off and on again.
18. Fully re-calibrate the truck (see page 103).
 If the event code persists, proceed to step 19.
Check the insulation resistance
19. Measure the insulation resistances of the motor coil and power cables
against the truck frame.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
 If the insulation resistance is ok, replace Access2/3.

ES/ET4000 Series
Rev. B
114
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 200 (ES/ET -M, -E)

Event code 208

Display: EV 208
Service LED: On
Operator LED: Off
Explanation: As the truck is powered the voltage on the power part of Access 2 is not 0V.
Possible causes: • The power cables to pump motor M2 have a poor contact, are damaged or
are shorted with respect to each other
• Access 2/3 is faulty
Remedy: Check the power cables and connections
1. Check the power cables to pump motor M2 and its connections are secure
and check for damage.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the connections are ok, proceed to step 2.
Check the insulation resistance
2. Measure the insulation resistances of the motor coil and power cables
against the truck frame.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
 If the insulation resistance is ok, proceed to step 3.
Check power cables for short circuits with respect to each other
3. Unscrew both power cables from the motor (+/-) and Access 2 (+Batt/–P).
4. Measure the resistance of the cables with respect to each other.
 If there is a short replace the power cables.
 If the resistance is endless (> 1 M), there is no short circuit. Proceed
to step 5.
Replace Access 2/3
5. Replace Access 2/3

ES/ET4000 Series
Rev. B
115
ELECTRICAL SYSTEM
EVENT CODE - GROUP 200 (ES/ET -M, -E)

Event code 228

Display: EV 228
Service LED: On
Operator LED: Off
Explanation: One or more drivers for FAN, SV, HN, ALM or FLS are damaged.
Possible causes: • Physical damage to one of the attached components
• Short circuit in one of the attached components
• Access 2/3 is faulty
Remedy: Check the components connected to the drivers for physical damage
1. Check FAN, SV, HN, ALM and FLS for physical damage.
 If one component is damaged, replace the faulty component.
 If the components are ok, proceed to step 2.
Locate the affected driver
2. Switch the truck off and on again.
3. Activate the connected components SV, HN, ALM and FLS in turn and
individually. In the process check if event 228 is displayed for one of these
components.
 If the event is displayed on one of the components, replace the compo-
nent or repair its wiring.
 If no short is found in SV, HN, ALM or FLS, proceed to step 9.
Switch on the fan
4. Select service level 3 (see page 72).
5. Press the key.
 A1 Status is displayed.
6. Using the key scroll through to the A4 TEST OUTPUTS menu.
7. Press the key.
 A4.1 FAN is displayed.
8. Press the key.
 ENTER TO CANCEL is displayed and the fan runs for 5 seconds.
Note: Press to cancel the test prematurely.
 If event 228 is displayed, repair the wiring to the fan or replace the fan.
 If no short is found in SV, HN, ALM or FLS, proceed to step 9.
Replace Access 2/3
9. Replace Access 2/3

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Event code 229

Display: EV 229
Service LED: On
Operator LED: Off
Explanation: One or more drivers for FAN, SV, HN, ALM or FLS have a short.
Possible causes: • Physical damage to one of the attached components
• Short circuit in the feed wire to one of the attached components
• Access 2 faulty
Remedy: Check the components connected to the drivers for physical damage
1. Check FAN, SV, HN, ALM and FLS for physical damage.
 If one component is damaged, replace the faulty component.
 If the components are ok, proceed to step 2.
Check terminals for short circuits or open connections
2. Check connections and wiring for FAN, SV, HN, ALM and FLS for shorts
or open connections.
 If there is a short or an open connection, repair the wiring.
 If the wiring is ok, proceed to step 3.
Activate the travel alarm driver output
Note: All drivers are internally monitored even if some options are not in-
stalled. All drivers must therefore be activated in order to test.
3. Select service level 2 (see page 72).
4. Press the key.
 A1 Status is displayed.
5. Press to scroll to the FEATURES menu.
6. Press the key.
 F1 LANGUAGE is displayed.
7. Using the key scroll through to the F2 TRAVEL ALARM ALM menu.
 The current setting OFF, BOTH, FF or PF is displayed.
8. If BOTH is not set, press .
 OFF is displayed.
9. Using the key, select BOTH.
10. Press the key.
 The travel alarm driver ALM is activated for both travel directions.
Activate the beacon driver output
11. Press the key.
 F2 TRAVEL ALARM ALM is displayed.
12. Using the key scroll through to the F3 BEACON FLS menu.
 The current setting OFF, BOTH, FF or PF is displayed.
13. If BOTH is not set, press .
 OFF is displayed.

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14. Using the key, select BOTH.

15. Press the key.
 The beacon driver FLS is activated for both travel directions.
16. Disconnect the +wires (red/white) from all the components connected to
the drivers. Make wires to the unused driver outputs accessible.
17. Using an ohmmeter measure in turn each driver output from the -terminals
(green/white) to +Batt.
 If the resistance is at least 10 k, the respective driver output is ok.
 If less than 10 k is measured on a driver output, proceed to step 18.
Replace Access 2/3
18. Replace Access 2/3

Event code 230

Display: EV 230
Service LED: On
Operator LED: Off
Explanation: One or more of the following components have an internal short circuit: FAN,
SV1, SV2, HN, ALM or FLS
Possible causes: • Short circuit in one of the attached components
• Access 2 faulty
Remedy: Rule out the main contactor circuit
1. Switch the truck off and on again.
 If the error occurs when the truck is switched on, the main contactor
circuit is affected. Proceed to step 8.
 If the truck starts normally, proceed to step 2.
Isolate the error in the power circuits of the connected components
2. Activate the connected components BR, SV1, SV2, HN, ALM and FS in
turn and individually. In the process check for which component event EV
230 is displayed.
Note: If both options ALM and FS are installed, adjust them before the test so
that they do not switch simultaneously. (In the FEATURES menu set the op-
tions F2 TRAVEL ALARM ALM to FF and F3 BEACON FLS to PF.)
 If event 230 is displayed for one of these components, proceed to step
9.
 If event 230 is not displayed, switch on the fan (FAN). Proceed to step 3.
Note: The fan (FAN) must be switched on via level 3:
Switch on the fan
3. Select service level 3 (see page 72).
4. Press the key.
 A1 Status is displayed.

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5. Using the key scroll through to the A4 TEST OUTPUTS menu.

6. Press the key.
 A4.1 FAN is displayed.
7. Press the key.
 ENTER TO CANCEL is displayed and the fan runs for 5 seconds.
Note: Press to cancel the test prematurely.
 If event 230 is displayed, repair the wiring to the fan or replace the fan.
 If event 230 is not displayed, proceed to step 10.
Measure the affected component
8. Disconnect the +wire (red/white) and the –wire (green/white) from the re-
spective component.
Note: If ALM or FLS are affected, disconnect the +wire (red/white) and the –
wire (green/white) from both components.
9. Using an ohmmeter measure the resistance of the actuating components:
– EDS = 18 
– BR = 13 
– FAN > 100 k
– PV = 21 
– HN > 100 k
– ALM > 100 k
– FLS > 100 k
 If the resistance at ALM and FLS is at least 6 M these components are
ok. Proceed to step 10.
 If the resistance at FLS or ALM is still only approx. 10 , replace the
component.
 If the resistances for all other components match the above values, all
the components are ok. Proceed to step 10.
 If the resistance of one component (apart from ALM and FLS) does not
match the above readings, replace the component.
Replace Access 2/3
10. Replace Access 2/3

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ELECTRICAL SYSTEM
EVENT CODE - GROUP 200 (ES/ET -M, -E)

Event code 231

Display: EV 231
Service LED: On
Operator LED: Off
Explanation: The control module detects an open circuit on the lowering valve (PV)
Possible causes: • Faulty coil in lowering valve
• Disconnected circuit to lowering valve
• Access 2 faulty
Remedy: Test the lowering command
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press the key.
 A2 Inputs is displayed.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Press the key.
 A2.2 ACCESS 2 is displayed.
6. Press the key.
 A2.2.1 RAS ENC is displayed.
7. Press the key.
 A2.2.1 LOS ENC is displayed.
8. Press the key.
 The current reading (0 if not applied) is displayed.
9. Press the fork lift switch (RAS ENC) and monitor the display.
 If a reading > 0 is displayed, there is no fault. Restart the truck and
check the event log.
 If the reading remains at 0, proceed to step 10.
Check the wiring and lowering valve for physical damage
10. Check the wiring and lowering valve (PV) for physical damage.
 If there is no physical damage, proceed to step 11.
 If there is physical damage, repair the damaged parts.
Check the coil of the lowering valve (PV)
11. Disconnect CA209 and measure the resistance of the valve coil
 If the resistance > 100 Ω, replace the valve coil.
 If the resistance < 100 Ω, proceed to step 12.
Check the lowering valve power supply
12. Using an voltmeter measure from the +wire (red/white) on PV to −Batt.
 If the voltage is not the same as +Batt, check fuse FU3 and the wiring
to the lowering valve.
 If the voltage is the same as +Batt, proceed to step 13.

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Replace Access 2&3

13. Replace Access 2&3

Event codes 232 and 233

Display: EV 232
Service LED: On
Operator LED: Off
Explanation: The control module has detected an open circuit leading to EVP2.
Note: Output EVP2 is not used. Pin CA201-23 is therefore not occupied.
Possible causes: • Incorrect wiring of pin CA201-23 on Access 2&3, or a short circuit to this
pin.
• Access 2 faulty
Remedy: Check pin CA201-23 for shorts and incorrect wiring
1. Check pin CA201-23 for connected wires or a short to the surrounding
pins.
 Remove any connected wires. Repair any shorts discovered.
 If there is no error, proceed to step 2.
Replace Access 2&3
2. Replace Access 2&3

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ELECTRICAL SYSTEM
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Event code 234

Display: EV 234
Service LED: On
Operator LED: Off
Explanation: The control module detects a fault on the coil of the lowering valve (PV).
Possible causes: • Faulty coil in lowering valve (PV)
• Disconnected circuit to lowering valve (PV)
• Access 2 faulty
Remedy: Test the lowering command
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press the key.
 A2 Inputs is displayed.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Press the key.
 A2.2 ACCESS 2 is displayed.
6. Press the key.
 A2.2.1 RAS ENC is displayed.
7. Press the key.
 A2.2.1 LOS ENC is displayed.
8. Press the key.
 The current reading (0 if not applied) is displayed.
9. Press the fork lower switch (LOS ENC) and monitor the display.
 If a reading > 0 is displayed, proceed to step 11.
 If the reading remains at 0, proceed to step 10.
Check the wiring and lowering valve for physical damage
10. Check LOS ENC, wiring and lowering valve for physical damage.
 If there is no physical damage, proceed to step 11.
 If there is physical damage, repair the damaged parts.
Check the lowering valve coil resistance
11. Disconnect CA209 and measure the resistance of the valve coil.
 If the resistance is 16 - 26 Ω, the coil is ok. Proceed to step 12.
 If the resistance is not in the range of 16 - 26 Ω, replace the coil.
Replace Access 2&3
12. Replace Access 2&3

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122
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 200 (ES/ET -M, -E)

Event code 235

Display: EV 235
Service LED: On
Operator LED: Off
Explanation: Lift/lower encoder signal out of range.
Possible causes: • Proportional lifting and lowering not calibrated
• Lift/lower encoder is faulty
• Access 2 faulty
Remedy: Calibrate proportional lifting and lowering
1. Calibrate proportional lifting and lowering (see page 103).
 If the event code is then still displayed, proceed to step 2.
Check the hydraulic PC board
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press the key.
 A2 Inputs is displayed.
5. Press the key.
 A2.1 ACCESS 1 is displayed.
6. Using the key scroll through to A2.4 Access 8.1.
7. Press the key.
 A2.4.1 RAS ENC is displayed.
8. Press the key.
 If an output reading (0 - 255 digits) is displayed, proceed to step 9.
 If nothing is displayed, replace the hydraulic PC board (see page 255).
9. Press the key.
 A2.4.1 RAS ENC is displayed.
10. Press the key.
 A2.4.2 LOS ENC is displayed.
11. Press the key.
 If an output reading (0 - 255 digits) is displayed, proceed to step 12.
 If nothing is displayed, replace the hydraulic PC board (see page 255).
Replace Access 2&3
12. Replace Access 2&3

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ELECTRICAL SYSTEM
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Event code 236

Display: EV 236
Service LED: On
Operator LED: Off
Explanation: The reading supplied by the pressure sensor is out of the normal range.
Possible causes: • Pressure sensor faulty
• Pressure sensor replaced but not calibrated
Remedy: Test the basic operation of the pressure sensor
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press to scroll to the A2 INPUTS menu.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Press the key.
 A2.2 RAS ENC is displayed.
6. Press the key.
 A2.2.1 TEMP ACCESS 2&3 is displayed.
7. Using the key scroll through to the A2.2.3 PRESSURE TRANSDUCER
PS1 menu.
8. Press the key.
 The current reading (0 - 255) is displayed.
9. Collect, raise and then fully lower a load using fork lift. Monitor the display
in the process.
 If the load reading changes during lifting and does not reset when the
load is deposited, the wiring and sensor are ok.
 If the display does not change, proceed to step 10.
Check the power supply
10. Measure the voltage from CA215-2 (on the pressure sensor) to battery
negative. It should be ≈ +13 V.
11. Measure the voltage (GND) from CA215-1 to battery negative. It should be
≈ 0 V.
 If the voltages measured are correct, the 13 volt power supply is ok.
Replace the pressure sensor.
 If there is no +13 V supply, repair the disconnection in the wiring be-
tween CA215-2 and CA201-25.
 If a reading higher than 13 V is measured at CA215-2, the control mod-
ule is faulty. Replace the control module.
 If a reading higher than 1 V is measured at CA215-2, the control module
is faulty. Replace the control module.

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EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event Code - Group 300 (ES/ET -M, -E)

Note: If an event code occurs without an obvious Software Parameter Settings ES 4020-MW /-EW,
reason, clearing the control module EEPROM can be page 97 and Software Parameter Settings ET 4040-
effective. Attempt this before you replace the control MF / -EF, page 99. If necessary, recalibrate the truck
module. This will restore the factory settings. See (see page 103).

Event code 300

Display: EV 300
Service LED: On
Operator LED: Off
Explanation: Watchdog error
Effect: • The traction current is cut out and the main contactor ED drops.
Possible causes: • Communication error on the CAN bus
• Access 1 faulty
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Press the key.
 E1.1 LAST is displayed.
7. Check the time and temperature for the last recorded event.
Note: For details on navigating through the EVENTS menu see page 90.
 If an event is logged and the service hours and temperature match the
event, Access1 is ok.
 If no event is recorded, proceed to step 8.
Replace Access 2&3
8. Replace Access 2/3

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ELECTRICAL SYSTEM
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Event code 301

Display: EV 301
Service LED: On
Operator LED: Off
Explanation: EEPROM memory error in Access 3
Possible causes: • Intermittent internal error in Access 3
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Replace Access 2/3
2. Replace Access 2/3

Event code 302

Display: EV 302
Service LED: On
Operator LED: Off
Explanation: As the truck is switched on, before the main contactor closes, a current > 0 A
is detected in the output stage.
Possible causes: • +Batt and –Batt terminals on Access 3
• Access 3 faulty
Remedy: Check power cable terminals
1. Check the power cable terminals on Access 3, in particular +Batt and -
Batt.
 Repair the terminals if faulty.
 If the connections are ok, proceed to step 2.
Replace Access 2/3
2. Replace Access 2/3.

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 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 303

Display: EV 303
Service LED: On
Operator LED: Off
Explanation: Phase voltage out of range
Possible causes: • +Batt and –Batt terminals on Access 3
• Access 3 faulty
Remedy: Check power cable terminals
1. Check power cable connections, in particular on +Batt and -Batt of
Access 3. Check terminals for corrosion and overheating.
 Repair the terminals if faulty.
 If the connections are ok, proceed to step 2.
Replace Access 2/3
2. Replace Access 2/3.

Event Code 304

Display: EV 304
Service LED: On
Operator LED: Off
Explanation: Low voltage or overvoltage(a) detected.
The event occurs if the voltage at pin PC201-10 drops below 9 V or the voltage
at the battery positive terminal of Access 2/3 exceeds 35 V.
Possible causes: • Battery fails
• Voltage drops via fuse FU2, relay K or key switch
• Transitional resistance in terminal of a power cable
• Access 3 faulty
• Battery used with excessive voltage
Remedy: Compare internally measured battery voltage with actual battery voltage
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Using the key scroll through to the A3 OUTPUTS menu.
4. Press the key.
 A3.1 BATTERY % is displayed.
5. Press the key.
 A3.2 BATTERY VOLTAGE is displayed.
6. Press the key.
 The current battery voltage reading is displayed.

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7. Make a note of the reading (it should be ≈ 24 V).

Note: Do not use 48 V batteries.
8. Using a voltmeter measure the battery voltage at the battery connector
and compare it with the previous reading from the Analyzer menu.
 If the two readings are identical, proceed to step 15.
 If there is a difference, proceed to step 9.
Compare internally measured battery voltage with actual battery voltage
9. Press to scroll back to the ANALYZER menu.
10. Press to scroll through to the PERFORMANCE menu.
11. Press the key.
 P1 SET P1 is displayed.
12. Press to scroll through to the P11 ADJUST BATTERY menu.
13. Press the key.
 The current reading is displayed.
14. Press and to set the reading previously recorded on the battery and
press to accept it.
Check for battery voltage drop
15. Press to scroll back to the PERFORMANCE menu.
16. Press to scroll to the ANALYZER menu.
17. Press the key.
 A1 STATUS is displayed.
18. Using the key scroll through to the A3 OUTPUTS menu.
19. Press the key.
 A3.1 BATTERY % is displayed.
20. Press the key.
 A3.2 BATTERY VOLTAGE is displayed.
21. Press the key.
 The current battery voltage reading is displayed.
22. Raise a load of approx.1000 kg up to the lift limit cutout while monitoring
the battery voltage in the display.
 If the battery voltage drops below 22 V, repair the battery or replace it
with a new one.
 If the battery voltage remains above 22 V during the lift test, the battery
is ok. Proceed to step 23.
Measure the voltage drop on the signal line from Access 2/3
23. Measure the voltage from CA201-10 to battery negative.
 If the voltage is approximately the same as the battery voltage (≈ 24 V),
the signal line is ok. Proceed to step 28.
Note: The voltage at CA201-10 is always slightly less than the battery voltage.
This is due to the voltage drop via the signal switch in the main contactor, fuse
FU2, relay K or the key switch. However, this is only a few tenths of a volt.
 If the voltage is less than 22 V, proceed to step 24.

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 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Determine the cause of the voltage drop on the signal line

24. Measure the input and output voltage of the signal switch on the main
contactor.
 If there is no significant voltage drop, proceed to step 25.
 If the voltage drops extremely, replace main contactor ED.
25. Measure the input and output voltage of fuse FU2.
 If there is no significant voltage drop, proceed to step 26.
 If the voltage drops extremely, replace FU2.
26. Measure the voltage at pin 30 (input) and pin 87 (output) of relay K. If the
truck has a key switch, measure the key switch input and output voltages.
 If there is no significant voltage drop, proceed to step 27.
 If the voltage drops significantly, replace relay K or the key switch.
27. Measure the voltage drop over the wires:
– Between the signal switch on the main contactor and fuse FU2
– Between FU2 and pin 30 on relay K
– Pin 87 on relay K and pin CA201-10
 If there is no significant voltage drop, proceed to step 28.
 If the voltage drops extremely on one wire, repair the wire or connec-
tions.
Replace Access 2&3
28. Replace Access 2&3
a. Theoretically, this event code could be displayed for an overvoltage if there had been a conversion to a 48 volt battery connector
and someone had installed a 48 volt battery.

Event code 305

Display: EV 305
Service LED: On
Operator LED: Off
Explanation: Voltage on one of the phases U, V or W too low.
Possible causes: • The power cables to traction motor M1 have a poor contact or transition
resistances on the terminals.
• Access 3 faulty
Remedy: Check power cable terminals
1. Check motor power cable terminals. Check terminals for corrosion and
overheating.
 Repair the terminals if faulty.
 If the connections are ok, proceed to step 2.
Check the insulation resistance
2. Check the motor housing insulation resistance to +BV/–Batt.
 If there is a short to +BV/–Batt, replace the motor.
 If the insulation resistance is ok, proceed to step 3.
Replace Access 2/3
3. Replace Access 2/3.

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ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 306

Display: EV 306
Service LED: On
Operator LED: Off
Explanation: Voltage on one of the phases U, V or W too high.
Possible causes: • Power cables to traction motor M1 have a short or the motor itself has a
short.
• Access 3 faulty
Remedy: Check power cable terminals
1. Check terminals and motor power cables for short circuits.
 If there is a short, repair the wiring.
 If the cables are ok, proceed to step 2.
Check the insulation resistance
2. Check the motor housing insulation resistance to +BV/–Batt.
 If there is a short to +BV/–Batt, replace the motor.
 If the insulation resistance is ok, proceed to step 3.
Replace Access 2/3
3. Replace Access 2/3.

Event code 307

Display: EV 307
Service LED: On
Operator LED: Off
Explanation: On power up a test is performed to check if the main contactor contacts are
open. If the circuit which the main contactor contacts close is already closed,
this event code will be issued.
Possible causes: • Main contactor power contacts are welded
• Short circuit in the power routing on main contactor
• Access 3 faulty
Remedy: Check power cable terminals
1. Check if power cable terminals on the main contactor have shorted.
 If there is a short, repair the wiring.
 If the cables are ok, proceed to step 2.
Check main contactor contacts
2. Check the main contactor tips (see page 230).
 If the contacts are welded, replace the contacts or the main contactor.
 If the main contactor is ok, proceed to step 3.
Replace Access 2/3
3. Replace Access 2/3.

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 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 308

Display: EV 308
Service LED: On
Operator LED: Off
Explanation: Main contactor contacts do not close.
Possible causes: • Main contactor contacts jamming
• Fuse FU1 faulty
• Coil routing disconnected
• Main contactor coil faulty
• Access 3 faulty
Remedy: Check fuse FU1
1. Measure the voltage on +Batt of Access 2/3.
 If there is no voltage, replace fuse FU1.
 If FU1 is ok, proceed to step 2.
Check the contactor coil (LINE) power supply
2. Connect the positive lead of a voltmeter to the +terminal of the coil (2909).
Connect the negative lead of the voltmeter to –Batt and switch on the
truck.
 If there is no voltage, proceed to step 3.
 If the voltage  24 V , the positive power supply to the coil is ok. Proceed
to step 4.
3. Measure the positive power supply over the following components and
wires:
– From the signal switch input on the main contactor (EDS) to fuse FU2
– From the output of fuse FU2 over pin 30 to pin 87 on relay K1
– From pin 87 on relay K1 to the +pin of the main contactor coil (LINE).
 If there is no significant voltage drop, proceed to step 4.
 If the voltage on one wire drops extremely or if there is no voltage, repair
the wire or connections.
Check the control line and coil connections
4. Check the negative lead (5904) to the coil on the main contactor (LINE) for
continuity to pin PC201-12.
 If it is disconnected, repair the wiring.
 If the wiring is ok, proceed to step 5.
Check the main contactor coil
5. Remove both control lines (2909 and 5904) from the coil.
6. Measure the coil resistance with an ohmmeter.
 If the coil resistance is significantly less or more than  18 , replace the
main contactor or coil.
 If the coil is ok, proceed to step 7.
Replace Access 2/3
7. Replace Access 2/3.

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ELECTRICAL SYSTEM
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Event code 309

Display: EV 309
Service LED: On
Operator LED: Off
Explanation: Current flows to output stage when truck is idle
Possible causes: • Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Replace Access 2/3
2. Replace Access 2/3.

Event code 310

Display: EV 310
Service LED: On
Operator LED: Off
Explanation: Internal capacitor bank charge time exceeded
Possible causes: • Additional unauthorised consumers installed
• Access 3 faulty
Remedy: Check for additional consumers
1. Using the wiring diagram and Crown's list of options, check if non-ap-
proved consumers are connected along with the capacitor bank of +Batt
at Access 3 to –Batt.
 Disconnect any non-approved consumers. Proceed to step 2.
 If no non-approved consumers are installed, proceed to step 5.
2. Switch the truck off and on again.
 If the event code occurs again, proceed to step 3.
3. Override the contacts of the main contactor EDS with a 10 /5W power
resistor.
4. Switch the truck off and on again.
 If the event code now no longer occurs, the control module is faulty.
Proceed to step 5.
Replace Access 2/3
5. Replace Access 2/3.

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Event code 314

Display: EV 314
Service LED: On
Operator LED: Off
Explanation: Main contactor driver shorted or wiring disconnected
Possible causes: • Short circuit or disconnection in the wire from CA201-12 to the main con-
tactor coil
• Access 3 faulty
Remedy: Check the wiring for short circuits
1. With the truck switched off, use an ohmmeter to measure from CA201-12
to −Batt on Access 2/3.
 If the resistance is < 5 kΩ, repair the short in the wiring.
 If the resistance > 5 kΩ, proceed to step 2.
2. Power up the truck.
3. With the main contactor open, measure the voltage on the main contactor
coil on both terminals for the signal lines.
 If the voltage ≈ 24 V, the coil is ok. Proceed to step 4.
 If the voltage is not ≈ 24 V, the coil is faulty. Proceed to step 5.
Replace Access 2&3
4. Replace Access 2&3
Repair the main contactor
5. Replace the coil.

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ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 315

Display: EV 315
Service LED: On
Operator LED: Off
Explanation: Driver cannot close the main contactor.
Possible causes: • Main contactor coil routing disconnected
• Main contactor coil faulty
• Access 3 faulty
Remedy: Check the contactor coil power supply
1. Connect the positive lead of a voltmeter to the +terminal (2909) of the main
contactor coil (LINE). Connect the negative lead of the voltmeter to –Batt
and switch on the truck.
 If there is no voltage applied, the wiring has been disconnected. Repair
the contactor coil wiring.
 If the voltage  24 V , the positive power supply to the coil is ok. Proceed
to step 2.
Check the control line and coil connections
2. Check the negative lead (5904) to the coil on the main contactor for conti-
nuity to pin PC200-17.
 If it is disconnected, repair the wiring.
 If the wiring is ok, proceed to step 3.
Check the main contactor coil
3. Remove both signal cables from the coil.
4. Measure the coil resistance with an ohmmeter.
 If the coil resistance is less than  18 , replace the main contactor or
coil.
 If the coil is ok, proceed to step 5.
Replace Access 2/3
5. Replace Access 2/3.

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134
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 316

Display: EV 316
Service LED: On
Operator LED: Off
Explanation: Excessive current through the driver for the main contactor or brake coil
Possible causes: • Short in brake coil circuit or brake coil itself
• Short in main contactor coil circuit or main contactor coil itself
• Access 3 faulty
Remedy: Check the wiring to the main contactor coil and the brake for short cir-
cuits
1. Check wiring to coil (LINE) of main contactor and to brake (BRK) for
shorts.
2. Check if the terminals on the main contactor have been shorted by a for-
eign body.
 Remove any short circuits found.
 If there is no short, proceed to step 3.
Check the coils of the main contactor coil and the of brake for short cir-
cuits
Note: A short is detected at a resistance of < 2 .
3. Remove lines 2909 and 5904 from the coil (LINE) of the main contactor.
4. Measure the coil resistance with an ohmmeter.
 If the coil resistance is less than  18 , replace the main contactor or
coil.
 If the coil is ok, proceed to step 5.
5. Disconnect lines 2917 and 5901 from the brake (BRK).
6. Measure the brake coil resistance.
Note: Measure the resistance when the brake is cold (approx. room tempera-
ture), otherwise the reading will be falsified.
 If the resistance is less than 13  ±10%, replace the coil.
 If the coil is ok, proceed to step 7.
Replace Access 2/3
7. Replace Access 2/3.

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135
ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 317

Display: EV 317
Service LED: On
Operator LED: Off
Explanation: The zero point of the traction potentiometer deviates from the calibrated value
by more than 1 V and the travel switch is open.
Possible causes: • Physical defect on the traction potentiometer
• Traction potentiometer replaced but not calibrated
Remedy: Check the traction potentiometer for physical damage
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press to scroll to the A2 INPUTS menu.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Press the key 2 times.
 A2.3 ACCESS 3 is displayed.
6. Press the key.
 A2.3.1 TEMP Access 2/3 is displayed.
7. Using the key scroll through to the A2.3.5 > DRIVE POT menu.
8. Activate the travel switch in both directions and then restore it to neutral
while observing the display.
 If the display always reverts to the same reading in neutral, the traction
potentiometer is ok. If the error persists, replace the hydraulic PC board
(see page 255).
 If the display does not revert to the same reading in neutral, the traction
potentiometer is faulty. Replace the traction potentiometer (see
page 256).

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 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 320

Display: EV 320
Service LED: On
Operator LED: Off
Explanation: Error in CAN BUS communication between the control modules.
Possible causes: • Wiring damaged
• Load resistor faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Check CAN-Bus wiring and termination
2. Power down the truck.
3. Measure the resistance between CA210-1 and CA210-2.
 If the resistance is 60 Ω, the CAN-Bus termination is ok. Proceed to
step 4.
 If the resistance is not 60Ω, proceed to step 8.
4. Disconnect PC200 from Access 1.
5. Disconnect PC201 from Access 2/3.
6. Measure the resistance between CA210-4 and CA210-2 again.
 If the resistance is 120 Ω, the CAN Bus wiring is ok. Proceed to step 11.
 If the resistance is not 120 Ω, proceed to step 9.
Test termination in Access 1
7. Measure the load resistance between JC200-8 and JC200-9 (socket on
Access 1).
 If the resistance is 120 Ω, proceed to step 8.
 If the resistance is not 120 Ω, proceed to step 8.
Test termination in Access 2/3
8. Measure the resistance between PC201-27 and PC201-28.
 If the resistance is 120 Ω, Access 2&3 is ok. Restart the truck and mon-
itor the event log.
 If the resistance is not 120 Ω, proceed to step 10.
Repair wiring
9. Repair the wiring.
Replace Access 2&3
10. Replace Access 2&3.
Replace Access 1
11. Replace Access 1.

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ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event Code 334

Display: EV 334
Service LED: On
Operator LED: Off
Explanation: Occurs only in connection with EV 328
Possible causes: • None
Remedy: 1. No action required, the alarm goes out automatically.

Event Code 321

Display: EV 321
Service LED: On
Operator LED: Off
Explanation: Incorrect truck
selected
Possible causes: • Control module replaced and not set
Remedy: Set truck type
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press to scroll to the FEATURES menu.
4. Press the key,
 F1 LANGUAGE is displayed.
5. Press to scroll to the F4 TRUCK TYPE menu.
6. Press the key.
 ES & ET is displayed.
7. Press the key to select the truck type. (See truck data plate).
Set the truck model
8. Press the key.
 F4.1 TRUCK MODEL is displayed.
9. Press the key.
 4040MW is displayed.
10. Press the key to select the truck model.
Note: The truck model can be found on the truck data plate.
Set the maximum capacity
11. Press the key.
 TRUCK CAPACITY is displayed.

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EVENT CODE - GROUP 300 (ES/ET -M, -E)

12. Press the key.

 12 is displayed.
13. Press the key to select the maximum truck capacity.
Note: The maximum truck capacity can be found on the truck data plate.
Save truck type, truck model and capacity
14. Press the key.
 The truck type, truck model and capacity are now saved.
15. Restart the truck.
16. If necessary adjust the parameters (see page 97 for the ES model or page
99 for the ET model).
17. Calibrate the truck (see page 103).
18. Restart the truck.

Event code 322

Display: EV 322
Service LED: On
Operator LED: Off
Explanation: Short circuit in the brake positive wire
Possible causes: • Wiring short circuit
Remedy: Check the wiring
1. Measure voltage from CA201-2 to -Batt.
 If the voltage  +BV, proceed to step 2.
 If the voltage is not  +BV, rectify the short between the positive wire
(2917) on the brake and PC201-2.
2. Undo the brake negative terminal (5901) from CA201-4.
 If the event code persists, proceed to step 3.
Replace Access 2/3
3. Replace Access 2/3.

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139
ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 326

Display: EV 326
Service LED: On
Operator LED: Off
Explanation: Power output stage short circuit
Possible causes: • Short circuit in the power cables
• Control module faulty
Remedy: Check the power cables and connections
1. Switch off the truck and disconnect the battery.
2. Check the power cable to the traction motor M1 and its terminals for short
circuits.
3. Check the power cable connections on the controller for shorts with +Batt
and -Batt connections.
 If any cables or terminals are shorted, rectify the cause.
 If the power cables and the connections are ok, proceed to step 4.
Check the insulation resistance
4. Measure the insulation resistances of the motor coil and power cables
against the truck frame.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
 If the insulation resistance is ok, proceed to step 5.
Check control module
5. On the control module unscrew the wires from terminals U, V and W.
6. Using an ohmmeter measure the resistance from terminal U on the control
module to +Batt and then to -Batt.
7. Repeat step 6 with phase V and phase W.
 If the resistance at one of the phases is  100 , the output stage is
faulty. Proceed to step 8.
 If no error is found, restart the truck. Monitor the event log.
Replace Access 2/3
8. Replace Access 2/3.

ES/ET4000 Series
Rev. B
140
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 328

Display: EV 328
Service LED: On
Operator LED: Off
Explanation: Control module faulty
Possible causes: • Control module faulty
Remedy: Replace Access 2/3
1. Replace Access 2/3.

Event code 329

Display: EV 329
Service LED: On
Operator LED: Off
Explanation: Control module faulty
Possible causes: • Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Replace Access 2/3
2. Replace Access 2/3.

Event code 333

Display: EV 333
Service LED: On
Operator LED: Off
Explanation: The driver cannot activate the brake
Possible causes: • Wiring disconnected
• Open brake coil
• Control module faulty
Remedy: Check the wiring
1. Measure the voltage from CA201-2 to battery negative.
 If the voltage  +BV, proceed to step 2.
 If the voltage is not  +BV, repair wire 2917 between the brake and
PC200-30.

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ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Check the brake coil

2. Disconnect lines 2917 and 5901 from the brake (BRK).
3. Measure the brake coil resistance.
Note: Measure the resistance when the brake is cold (approx. room tempera-
ture), otherwise the reading will be falsified.
 If the resistance is less than 13  ±10 %, replace the coil.
 If the coil is ok, proceed to step 4.
Replace Access 2/3
4. Replace Access 2/3.

Event Code 334

Display: EV 334
Service LED: On
Operator LED: Off
Explanation: Occurs only in connection with EV 328
Possible causes: • None
Remedy: 1. No action required, the alarm goes out automatically.

Event code 335

Display: EV 335
Service LED: On
Operator LED: Off
Explanation: Error in CAN BUS communication between the control modules.
Possible causes: • Wiring damaged
• Load resistor faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Check CAN-Bus wiring and termination
2. Power down the truck.
3. Measure the resistance between CA210-1 and CA210-2.
 If the resistance is 60 Ω, the CAN-Bus termination is ok. Proceed to
step 4.
 If the resistance is not 60 Ω, proceed to step 8.
4. Disconnect PC200 from Access 1.
5. Disconnect PC240 from Access 5.

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 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

6. Measure the resistance between CA210-4 and CA210-2 again.

 If the resistance is 120 Ω, the CAN Bus wiring is ok. Proceed to step 11.
 If the resistance is not 120 Ω, proceed to step 9.
Test termination in Access 1
7. Measure the load resistance between JC200-8 and JC200-9 (socket on
Access 1).
 If the resistance is 120 Ω, proceed to step 8.
 If the resistance is not 120 Ω, proceed to step 11.
Test termination in Access 5
8. Measure the resistance between PC240-14 and PC240-6.
 If the resistance is 120 Ω, Access 5 is ok. Restart the truck and monitor
the event log.
 If the resistance is not 120 Ω, proceed to step 10.
Repair wiring
9. Repair the wiring.
Replace Access 5
10. Replace Access 2/3
Replace Access 1
11. Replace Access 1.

Event code 337

Display: EV 337
Service LED: On
Operator LED: Off
Explanation: Thermal sensor in the control module returns values beyond the measuring
range of -80°C to +120°C.
Possible causes: • Display faulty
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press to scroll to the EVENTS menu.
4. Press the key 2 times.
 E1.1 LAST is displayed.

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ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

5. Use keys and to scroll through to the service hours and temperature
of the most recently logged event.
 If an event is logged and the service hours and temperature match the
event, Access1 is ok. Proceed to step 6.
 If no event is logged, replace Access 1.
Replace Access 2/3
6. Replace Access 2/3.

Event code 338

Display: EV 338
Service LED: On
Operator LED: Off
Explanation: Battery voltage out of range.
Possible causes: • Display faulty
• Access 3 faulty
Remedy: Check the battery condition
1. Check the battery for physical damage.
2. Check the battery terminals for corrosion.
3. Ensure the battery cable is attached securely.
 If the items in steps 1 to 3 are ok, proceed to step 4.
Check the condition of the battery cells
4. Measure the individual voltages of the battery cells.
 Replace any faulty cells.
 If all the cells are ok and the sum of the cell voltages is  24 V, proceed
to step 5.
Compare internally measured battery voltage with actual battery voltage
5. Select service level 2 (see page 72).
6. Press the key.
 A1 Status is displayed.
7. Using the key scroll through to the A3 OUTPUTS menu.
8. Press the key.
 A3.1 BATTERY % is displayed.
9. Press the key.
 A3.2 BATTERY VOLTAGE is displayed.
10. Press the key.
 The current battery voltage reading is displayed.
11. Make a note of the reading (it should be ≈ 24 V).
Note: Do not use 48 V batteries.

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 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

12. Using a voltmeter measure the battery voltage at the battery connector
and compare it with the previous reading from the Analyzer menu.
 If the two readings are identical, proceed to step 15.
 If there is a difference, proceed to step 9.
Compare internally measured battery voltage with actual battery voltage
13. Press to scroll back to the ANALYZER menu.
14. Press to scroll through to the PERFORMANCE menu.
15. Press the key.
 P1 SET P1 is displayed.
16. Press to scroll through to the P11 ADJUST BATTERY menu.
17. Press the key.
 The current reading is displayed.
18. Press and to set the reading previously recorded on the battery and
press to accept it.
Check for battery voltage drop
19. Press to scroll back to the PERFORMANCE menu.
20. Press to scroll to the ANALYZER menu.
21. Press the key.
 A1 STATUS is displayed.
22. Using the key scroll through to the A3 OUTPUTS menu.
23. Press the key.
 A3.1 BATTERY % is displayed.
24. Press the key.
 A3.2 BATTERY VOLTAGE is displayed.
25. Press the key.
 The current battery voltage reading is displayed.
26. Raise a load of approx.1000 kg up to the lift limit cutout while monitoring
the battery voltage in the display.
 If the battery voltage drops below 22 V, repair the battery or replace it
with a new one.
 If the battery voltage remains above 22 V during the lift test, the battery
is ok. Proceed to step 23.
Measure the voltage drop on the signal line from Access 2/3
27. Measure the voltage from CA201-10 to battery negative.
 If the voltage is approximately the same as the battery voltage (≈ 24 V),
the signal line is ok. Proceed to step 28.
Note: The voltage at CA201-10 is always slightly less than the battery voltage.
This is due to the voltage drop via the signal switch in the main contactor, fuse
FU2, relay K or the key switch. However, this is only a few tenths of a volt.
 If the voltage is less than 22V, proceed to step 24.

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ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Determine the cause of the voltage drop on the signal line

28. Measure the input and output voltage of the signal switch on the main
contactor.
 If there is no significant voltage drop, proceed to step 25.
 If the voltage drops extremely, replace main contactor ED.
29. Measure the input and output voltage of fuse FU2.
 If there is no significant voltage drop, proceed to step 26.
 If the voltage drops extremely, replace FU2.
30. Measure the voltage at pin 30 (input) and pin 87 (output) of relay K. If the
truck has a key switch, measure the key switch input and output voltages.
 If there is no significant voltage drop, proceed to step 27.
 If the voltage drops significantly, replace relay K or the key switch.
31. Measure the voltage drop over the wires:
– Between the signal switch on the main contactor and fuse FU2
– Between FU2 and pin 30 on relay K
– Pin 87 on relay K and pin CA201-10
 If there is no significant voltage drop, proceed to step 28.
 If the voltage drops extremely on one wire, repair the wire or connec-
tions.
Replace Access 2&3
32. Replace Access 2&3.

Event Code 340

Display: EV340
Service LED: On
Operator LED: Off
Explanation: Parameters for drive motor M1 are faulty.
Possible causes: • EEPROM error
• Access 3 faulty
Remedy: Clear the EEPROM in Access 2/3
1. Select service level 2 (see page 72).
2. Clear the EEPROM in Access 2/3 (see menu item F8, page 86).
 The EEPROM in Access 2/3 is cleared.
3. Switch the truck off and on again.
4. Fully re-calibrate the truck (see page 103).
 If the event code persists, proceed to step 7.
Clear the EEPROM in Access 2/3
5. Select service level 2 (see page 72).
6. Clear the EEPROM in Access 2/3 (see menu item F8, page 86).
Replace Access 2&3
7. Replace Access 2/3

ES/ET4000 Series
Rev. B
146
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 341

Display: EV 341
Service LED: On
Operator LED: Off
Explanation: Short circuit on the negative side of the brake driver
Possible causes: • Open connection in the brake positive wire
• Short circuit between positive wire leading to brake and −Batt.
• Short circuit on the negative side of the driver in Access 3
Remedy: Check wiring and power supply
1. Disconnect PC201 from Access 3 and wire 5901 from the brake.
2. Check wire (goes to pin PC201-4) for continuity.
 If the wire is ok, proceed to step 3.
 If the wire is disconnected, repair the wire.
3. Connect PC201 and wire 5901 to the brake.
4. Measure the voltage from both brake terminals to BATT NEG.
 If the voltage is ≈ 24 V, proceed to step 5.
 If there is no 24 volt supply, replace the brake.
5. Measure the resistance between PC201-4 and -Batt.
 If the resistance < 5 kΩ, proceed to step 6.
 If the resistance > 5 kΩ, repair the wiring.
Replace Access 2&3
6. Replace Access 2/3

Event code 342

Display: EV 342
Service LED: On
Operator LED: Off
Explanation: Forward and reverse travel commands applied simultaneously.
Possible causes: • Open connection, corrosion or short circuit
• Access 3 faulty
Remedy: Check travel switch zero position
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press the key.
 A2 Inputs is displayed.
4. Press the key.
 A2.1 ACCESS 1 is displayed.

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ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

5. Press the key 2 times.

6. A2.3 ACCESS 3 is displayed.
7. Press the key.
 A2.2.3 TEMP ACCESS 2&3 is displayed.
8. Using the key scroll through to A2.3.3 FF SWITCH.
9. Press the key.
 If OFF is displayed, the switch is ok. Proceed to step 10.
 If ON is displayed, the fault lies either in plug connector CA411 or the
controller is faulty. Proceed to step 13.
10. Using the key scroll back to A2.2.3 TEMP ACCESS 2&3.
11. Press the key.
 A2.3.4 PF SWITCH is displayed.
12. Press the key.
 If OFF is displayed, the switch is ok. Proceed to step 15.
 If ON is displayed, the fault lies either in plug connector CA411 or the
controller is faulty. Proceed to step 13.
Check wiring
13. Check plug connector CA411 in the tiller for corrosion and shorts.
 If the plug connector is ok, proceed to step 15.
 If the plug connector is not ok, proceed to step 14.
Replace potentiometer and main PC board
14. Replace the potentiometer and main PC board in the tiller.
Replace Access 2&3
15. Replace Access 2/3

Event code 343

Display: EV 343
Service LED: On
Operator LED: Off
Explanation: Encoder ECR1 in the traction motor has a fault. The event code is issued if the
encoder detects a change of more than 40 Hz in less than 16 ms.
Possible causes: • Slip in encoder drive
• Wiring error
• Access 3 faulty
Remedy: Check encoder pulses in Analyzer menu
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.

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EVENT CODE - GROUP 300 (ES/ET -M, -E)

3. Press the key.

 A2 Inputs is displayed.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Press the key 2 times.
 A2.3 ACCESS 3 is displayed.
6. Press the key.
 A2.2.3 TEMP ACCESS 2&3 is displayed.
7. Using the key scroll through to A2.3.15 ECR1.
8. Press the key.
 The encoder pulses are displayed (0 pulses when system idle).
9. Accelerate the truck and monitor the display.
 If 0 pulses are shown when truck is idle and ±15000 pulses are shown
at full speed, the encoder is ok. Restart the truck and check the event
log.
 If 0 pulses are not displayed when the truck is idle and/or ±15000 pulses
are not displayed at full speed, proceed to step 10.
Check wiring
10. Check the encoder wiring, including connector CA202, for:
– Corrosion
– Loose connections
– Faulty crimp connections on the pins
– Trapped wires
 Repair the wiring if faulty.
 If there is no damage, proceed to step 11
Check 12 volt supply
11. Measure the voltage (+13 V) at CA202-1 (on ECR1) to battery negative. It
should be ≈ +13 V.
12. Measure voltage (GND) from CA202-2 to −Batt. It should be ≈ 0 V.
 If the voltages measured in steps11 and 12 are correct, the 13V supply
is ok. Proceed to step 13.
 If there is no +13 V supply, repair the disconnection in the wiring be-
tween CA202-1 and CA201-25.
 If a reading higher than +13V is measured at CA202-1, the control mod-
ule is faulty. Proceed to step 14.
 If a reading higher than 1 V is measured at CA202-5, the control module
is faulty. Proceed to step 14.
Check the sensor bearing for physical damage
13. Monitor the running noise of the traction motor.
 If the motor rattles, encoder ECR1 (sensor bearing) is probably dam-
aged. Repair or replace the motor.
 If no physical damage is found, restart the truck and check the event
log.
Replace Access 2&3
14. Replace Access 2/3

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ELECTRICAL SYSTEM
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Event code 348

Display: EV 348
Service LED: On
Operator LED: Off
Explanation: Parking brake does not hold.
When the truck is idle, the control module checks if the traction motor is turn-
ing. The event code is displayed if a rotary movement with at least 0.75 Hz is
detected for more than 2 s.
Possible causes: • Brake faulty
Remedy: Check the parking brake
1. Check the parking brake for damage (see page 243).

Event code 351

Display: EV 351
Service LED: On
Operator LED: Off
Explanation: RAM copy error.
Possible causes: • Static charge
• Insulation resistance too low
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Check for static charge
2. Operate the truck for a while, then leave the truck and touch the panel.
 If you feel an electrostatic charge, proceed to step 3.
 If you do not feel an electrostatic charge, proceed to step 6.
Fit the anti-static strap
3. Fit a commercial anti-static strap to the bottom of the truck.
Note: The connection point on the truck must be bare metal prior to assembly.
4. Protect the connection point on the truck against corrosion.
5. Operate the truck again for a while.
 If the event code occurs again, proceed to step 6.
 If the event code no longer occurs, the cause has been rectified.
Test the truck's insulation resistance
6. Test the truck's insulation resistance.
 If the insulation resistance is too low, locate and replace the faulty com-
ponents.
 If the insulation resistance is ok, replace Access 2/3.

ES/ET4000 Series
Rev. B
150
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 352

Display: EV 352
Service LED: On
Operator LED: Off
Explanation: Incorrect software version.
Possible causes: • Incorrect software version
Remedy: Update software
1. Install the correct software version using the download tool.
2. If this is not possible, replace Access 2/3.

Event code 353

Display: EV 353
Service LED: On
Operator LED: Off
Explanation: Thermal sensor TS1 in the drive motor returns values beyond the measuring
range of -40 °C to +200 °C.
Possible causes: • Wiring error
• Thermal sensor faulty
• Access 2/3 faulty.
Remedy: Check the traction potentiometer for physical damage
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press to scroll to the A2 INPUTS menu.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Press the key 2 times.
 A2.3 ACCESS 3 is displayed.
6. Press the key.
 A2.3.1 TEMP Access 2/3 is displayed.
7. Check temperature reading.
8. Measure the temperature on the motor housing.
 If the temperature on the motor housing is approx. 10°C lower, thermal
sensor TS1 is ok. Proceed to step 13.
 If the temperature difference is greater than approx. 10°C, proceed to
step 9.

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Rev. B
151
ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Check thermal sensor

Note: For the following test the internal motor temperature should be approx.
20°C.
9. Disconnect CA203 and measure the resistance of thermal sensor TS1 be-
tween pins JC203-1 and JC203-2.
 If the resistance ≈ 600 Ω (at 20 °C internal motor temperature), proceed
to step 10.
 If the resistance differs significantly from this value, the thermal sensor
is faulty. Replace traction motor M1.
Check wiring
10. Check lines from PC203-2 to PC201-5 and PC203-1 to PC201-22 using
an ohmmeter.
 If the resistance in a line ≈ 0 Ω, the wiring is ok. Proceed to step 11.
 If the resistance differs significantly from this value, repair the wiring.
Check the thermal sensor voltage readings
11. Connect PC212 and switch on the truck.
12. Measure the voltage between CA201-5 and CA201-22. It should be: ≈ 3 V
for tM1 ≈ 150°C and > 0.7 V for tM1 ≈ -25°C
 If the voltage is ok, proceed to step 13.
 If the voltage is incorrect, replace traction motor M1 (see page 224).
Replace Access 2&3
13. Replace Access 2/3

Event code 354

Display: EV 354
Service LED: On
Operator LED: Off
Explanation: No positive power supply for the SMART driver within Access 2/3.
Possible causes: • FU3 faulty
• Faulty wiring
• Access 2/3 faulty.
Remedy: Check fuse
1. Check fuse FU3.
 If FU3 has blown, replace with a new 4A / 32V fuse.
 If the fuse is ok, proceed to step 2.
Check wiring
2. Measure the voltage from CA201-3 to battery negative.
 If there is no ≈ 24 V supply, repair the wire between FU3 and CA201-3.
 If there is a ≈ 24 V supply, the wiring is ok. Proceed to step 3.
Replace Access 2&3
3. Replace Access 2/3

ES/ET4000 Series
Rev. B
152
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 355

Display: EV 355
Service LED: On
Operator LED: Off
Explanation: Overvoltage or low voltage when the truck is switched on
Possible causes: • See event code 304.
Remedy: See event code 304.

Event code 356

Display: EV 356
Service LED: On
Operator LED: Off
Explanation: Error in FLASH memory of Access 2/3
Possible causes: • Static charge
• Access 2/3 faulty.
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Fit the anti-static strap
2. Fit a commercial anti-static strap to the bottom of the truck.
Note: The connection point on the truck must be bare metal prior to assembly.
3. Protect the connection point on the truck against corrosion.
4. Switch the truck on and then off again.
5. Disconnect the battery, wait for 6 seconds, then connect the battery.
6. Power up the truck.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 7.
Importing the software
7. If possible and applicable, download software for Access 3.
8. Clear the EEPROM and reset and calibrate the truck.
Note: If you cannot re-install the software, replace Access 2&3.
Replace Access 2&3
9. Replace Access 2/3

ES/ET4000 Series
Rev. B
153
ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 357

Display: EV 357
Service LED: On
Operator LED: Off
Explanation: Brake driver (SMART driver) does not supply an output signal
Possible causes: • Faulty wiring
• Brake coil faulty
• Access 2/3 faulty.
Remedy: Check the wiring
1. Check the wiring between CA201-2, the brake and CA201-4 for disconti-
nuity and short circuits.
 Repair the wiring if damaged.
 If the wiring is ok, proceed to step 2.
Check the parking brake
2. Check the parking brake for signs of overheating and physical damage.
 Repair the brake if damaged or overheated.
 If the brake is ok, proceed to step 3.
3. Disconnect lines 2917 and 5901 from the brake (BRK).
4. Measure the brake coil resistance.
Note: Measure the resistance when the brake is cold (approx. room tempera-
ture), otherwise the reading will be falsified.
 If the resistance is less than 13  ±10 %, replace the coil.
 If the coil is ok, proceed to step 5.
5. Measure the voltage from CA201-3 to battery negative.
 If there is no ≈ 24 V supply, repair the wire between FU3 and CA201-3.
 If there is a ≈ 24 V supply, the wiring is ok. Proceed to step 6.
Replace Access 2&3
6. Replace Access 2/3

ES/ET4000 Series
Rev. B
154
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 358

Display: EV 358
Service LED: On
Operator LED: Off
Explanation: Current sensor measuring range limits in Access 3 exceeded.
Possible causes: • Access 2/3 faulty.
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Replace Access 2&3
2. Replace Access 2/3

Event code 359

Display: EV 359
Service LED: On
Operator LED: Off
Explanation: Traction potentiometer voltage exceeds the limits set during calibration by
more than 0.4 V.
Possible causes: • Potentiometer drift
• Travel direction switch drift
• Faulty calibration
• Sluggish or jerky moving parts
• Wiring error
• Access 2/3 faulty.
Remedy: Check the mechanical system
1. Check the mechanical system of the travel switch for excessive friction
and freedom of movement.
 Repair the mechanical system if faulty.
 If the mechanical system is ok, proceed to step 2.
Check travel direction switch
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press the key.
 A2 Inputs is displayed.
4. Press the key.
 A2.1 ACCESS 1 is displayed.

ES/ET4000 Series
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155
ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

5. Press the key 2 times.

 A2.3 ACCESS 3 is displayed.
6. Press the key.
 A2.2.3 TEMP ACCESS 2&3 is displayed.
7. Using the key scroll through to A2.3.3 FF SWITCH.
8. Press the key.
 The current status is displayed.
9. Apply the travel switch in the forks direction (FF) and monitor the display.
 If the travel switch changes from OFF to ON, proceed to step 10.
 If the switch does not work correctly, replace the traction potentiometer
(see page 256).
10. Using the key scroll back to A2.2.3 TEMP ACCESS 2&3.
11. Press the key.
 A2.3.4 PF SWITCH is displayed.
12. Press the key.
 The current status is displayed.
13. Apply the travel switch in opposite direction to the forks (PF) and monitor
the display.
 If the travel switch changes from OFF to ON, proceed to step 10.
 If the switch does not work correctly replace the traction potentiometer.
Check the traction potentiometer for interruptions.
14. Using the key scroll back to A2.2.3 TEMP ACCESS 2&3.
15. Using the key scroll through to A2.3.5 DRIVE POT.
16. Press the key.
 The current digital reading is displayed.
17. Apply the travel switch slowly in both directions while monitoring the dis-
play.
 If the reading increases without leaps from 0 to 255 and returns to 0 in
the same way, the traction potentiometer is ok. Restart the truck and
check the event log.
 If there are interruptions or leaps in the signal, replace the traction po-
tentiometer.

ES/ET4000 Series
Rev. B
156
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 361

Display: EV 361
Service LED: On
Operator LED: Off
Explanation: Voltage reference for ACCESS 2/3 differs from the voltage +BV(AK)
Possible causes: • FU3 faulty
• Main contactor faulty
• Faulty wiring
Remedy: Check fuse FU3
1. Check fuse FU3.
 Replace the fuse if faulty.
 If the fuse is ok, proceed to step 2.
Check wiring
2. Check the wiring between FU3 and CA201-3 for discontinuity and short to
-Batt.
 Repair the wiring if damaged.
 If the wiring is ok, proceed to step 3.
Check main contactor contacts
3. Check the condition of the contacts of the main contactor for wear (see
page 230).
 If the contacts are damaged, repair the contactor.
 If the contacts are ok, proceed to step 4.
Check the main contactor power cable connections
4. Check the main contactor power cable connections for loose cables, cor-
rosion and burning.
 If there is any damage, repair the affected parts.
 If the connections are ok, proceed to step 5.
Replace Access 2&3
5. Replace Access 2/3

ES/ET4000 Series
Rev. B
157
ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 362

Display: EV 362
Service LED: On
Operator LED: Off
Explanation: Watchdog error
Effect: • The traction current is cut out and the main contactor ED drops.
Possible causes: • Communication error on the CAN bus
• Access 1 faulty
• Access 3 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Check the time and temperature for the last recorded event.
 If an event is logged and the service hours and temperature match the
event, Access1 is ok.
 If no event is recorded, proceed to step 8.
Replace Access 2&3
7. Replace Access 2&3.

ES/ET4000 Series
Rev. B
158
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event Code 364

Display: EV 364
Service LED: On
Operator LED: Off
Explanation: Side restraint logic and truck model do not match
Possible causes: • Incorrect truck model set
• Side restraint sensor faulty
• Wiring error
• Incorrect software installed
Remedy: Check switch status of side restraint sensors SR1 and SR2
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press the key.
 A2 Inputs is displayed.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Press the key 2 times.
 A2.3 ACCESS 3 is displayed.
6. Press the key.
 A2.2.3 TEMP ACCESS 2&3 is displayed.
7. Using the key scroll through to A2.3.11 SR1 SENSOR.
8. Press and check the reading of sensor SR1 (ON or OFF).
9. Press the key.
10. Using the key scroll through to A2.3.12 SR2 SENSOR.
11. Press and check the reading of sensor SR2 (ON or OFF).
12. Compare the switch status of SR1 and SR2 with the Input Signals table on
page 69.
 If the statuses match, proceed to step 21.
 If the statuses do not match, proceed to step 13.
Check connection and attachment.
13. Check the connection and attachment of the sensors.
 Repair the connection or attachment if they are not ok.
 If they are ok, proceed to step 14.
Test sensors
14. Using a suitable piece of metal switch SR1 and SR2 directly while moni-
toring the display and the sensor LEDs.
 If the sensors are ok, proceed to step 15.
 Replace any faulty sensors.

ES/ET4000 Series
Rev. B
159
ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Check the truck model setting

15. Check the settings for the truck type, modeal and capacity. See Event
Code 321, page 138.
Checking the software version number
16. Select service level 2 (see page 72).
17. Press the key.
 A1 Status is displayed.
18. Using the key scroll through to the UTILITIES menu.
19. Select menu item U1.2.2 SOFTWARE PN (see page 95).
20. Check the version number of the software for Access 2/3 and compare it
with the table on page 73.
 If the software version is correct, proceed to step 21.
 If the software version is incorrect, install the correct version or proceed
to step 21.
Replace Access 2&3
21. Replace Access 2/3

Event code 365

Display: EV 365
Service LED: On
Operator LED: Off
Explanation: Short in one of the phases U, V or W.
Possible causes: • Short circuit in the power cables
• Traction motor M1 faulty
Remedy: Check wiring
1. Check the power cables of Access 2/3 to traction motor M1 for damage.
 Replace any cables that are physically damaged.
 If the cables are ok, proceed to step 2.
2. Unscrew the power cables from the traction motor and Access 2/3.
3. Using an ohmmeter check the power cables for shorts with respect to each
other.
 If there are short circuits, replace the power cables in question.
 If there are no short circuits, replace traction motor M1.

ES/ET4000 Series
Rev. B
160
 ELECTRICAL SYSTEM
EVENT CODE - GROUP 300 (ES/ET -M, -E)

Event code 368

Display: EV 368
Service LED: On
Operator LED: Off
Explanation:
Possible causes: • Intermittent error due to high vertical acceleration
• Steer sensor or TFD module faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Replace steer sensor or TFD module
2. Replace steer sensor or TFD module.

ES/ET4000 Series
Rev. B
161
ELECTRICAL SYSTEM
EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event Code - Groups 500 and 800 (ES/ET-E)

Note: If an event code occurs without an obvious page 97 and Software Parameter Settings ET 4040-
reason, clearing the control module EEPROM can be MF / -EF, page 99. If necessary, recalibrate the truck
effective. Attempt this before you replace the control (see page 103).
module. This will restore the factory settings. See
Software Parameter Settings ES 4020-MW /-EW,

Event Code 500

Display: EV500
Service LED: On
Operator LED: Off
Explanation: Serial communication error in Access 5
Possible causes: • CAN bus communication with Access 1 faulty
• Access 5 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Check the time and temperature for the last recorded event.
 If an event is logged and the service hours and temperature match the
event, Access1 is ok.
 If no event is recorded, proceed to step 7.
Replace Access 5
7. Replace Access 5.

ES/ET4000 Series
Rev. B
162
 ELECTRICAL SYSTEM
EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event Code 501

Display: EV501
Service LED: On
Operator LED: Off
Explanation: EEPROM error in Access 5.
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Replace Access 5
2. Replace Access 5.

Event codes 502, 503, 504, 505

Display: EV502, EV503, EV504 or EV505
Service LED: On
Operator LED: Off
Explanation: Access 5 faulty
Possible causes: • Access 5 faulty
Remedy: Replace Access 5
1. Replace Access 5.

ES/ET4000 Series
Rev. B
163
ELECTRICAL SYSTEM
EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event Code 506

Display: EV506
Service LED: On
Operator LED: Off
Explanation: When the truck is switched on there is an incorrect voltage on the outputs of
the amplifiers in Access 5.
Possible causes: • The power cables to steer motor M3 have a poor contact, are damaged or
connected incorrectly
• Access 5 faulty
Remedy: Check the power cables and connections
1. Check the power cable leading to steer motor M3 and its terminals to en-
sure they are securely attached and not damaged.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the connections are ok, proceed to step 2.
Check the insulation resistance
2. Check the insulation resistance of the motor housing to Batt NEG/POS.
 If there is a short, locate and replace the faulty component.
 If the insulation resistance is ok, replace Access 5.

Event code 508

Display: EV508
Service LED: On
Operator LED: Off
Explanation: While the steering is idle the current at steer motor M3 measured by Access 5
is > 0 A.
Possible causes: • Error in output stage of Access 5
• Error in current sensor of Access 5
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Replace Access 5
2. Replace Access 5.

ES/ET4000 Series
Rev. B
164
 ELECTRICAL SYSTEM
EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event code 509

Display: EV509
Service LED: On
Operator LED: Off
Explanation: The current at steer motor M3 measured by Access 5 is too high.
Possible causes: • The power cables to steer motor M3 have a poor contact, are damaged or
connected incorrectly
• Access 5 faulty
Remedy: Check the power cables and connections
1. Check the power cable leading to steer motor M3 and its terminals to en-
sure they are securely attached and not damaged.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the connections are ok, proceed to step 2.
Check current sensor
2. Select service level 2 (see page 72).
3. Press to scroll to the A2 INPUTS menu.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Using the key scroll through to the A2 5 ACCESS 5 menu.
6. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
7. Using the key scroll through to the A2.5.3 STEER MOTOR CURRENT
menu.
8. Press the key.
 The current flowing through the output stage of Access 5 is displayed.
 If the reading is 0A, restart the truck. Monitor the event log.
 If the reading with the steer motor idle > 15 A, proceed to step 9.
Clear the EEPROM in Access 5
9. Select service level 2 (see page 72).
10. Clear the EEPROM in Access 5 (see menu item F8, page 86).
11. Switch the truck off and on again.
12. Re-calibrate the truck' steering
 If the event code persists, proceed to step 13.
Check the insulation resistance
13. Check the insulation resistance on the motor coils and the power cables.
 If there is a short, locate and replace the faulty component.
 If the insulation resistance is ok, replace Access 5.

ES/ET4000 Series
Rev. B
165
ELECTRICAL SYSTEM
EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event code 510

Display: EV510
Service LED: On
Operator LED: Off
Explanation: No current at phase V
Possible causes: • Wiring voltage drop
• Battery voltage drop
• Main contactor faulty
• Access 5 faulty
Remedy: Check power fuse FU5
1. Check power fuse FU5 (30A) on Access 5.
 Replace the fuse if faulty.
 If the fuse is ok, proceed to step 2.
Compare internally measured battery voltage with actual battery voltage
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Using the key scroll through to the A3 OUTPUTS menu.
5. Press the key.
 A3.1 BATTERY % is displayed.
6. Press the key.
 A3.2 BATTERY VOLTAGE is displayed.
7. Press the key.
 The current battery voltage reading is displayed.
8. Make a note of the reading (it should be ≈ 24 V).
Note: Do not use 48 V batteries.
9. Using a voltmeter measure the battery voltage at the battery connector
and compare it with the previous reading from the Analyzer menu.
 If the two readings are identical, proceed to step 16.
 If there is a difference, proceed to step 10.
Compare internally measured battery voltage with actual battery voltage
10. Press to scroll back to the ANALYZER menu.
11. Press to scroll through to the PERFORMANCE menu.
12. Press the key.
 P1 SET P1 is displayed.
13. Press to scroll through to the P11 ADJUST BATTERY menu.

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 ELECTRICAL SYSTEM
EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

14. Press the key.

 The current reading is displayed.
15. Press and to set the reading previously recorded on the battery and
press to accept it.
Check for battery voltage drop
16. Press to scroll back to the PERFORMANCE menu.
17. Press to scroll to the ANALYZER menu.
18. Press the key.
 A1 STATUS is displayed.
19. Using the key scroll through to the A3 OUTPUTS menu.
20. Press the key.
 A3.1 BATTERY % is displayed.
21. Press the key.
 A3.2 BATTERY VOLTAGE is displayed.
22. Press the key.
 The current battery voltage reading is displayed.
23. Raise a load of approx.1000 kg up to the lift limit cutout while monitoring
the battery voltage in the display.
 If the battery voltage drops below 22 V, repair the battery or replace it
with a new one.
 If the battery voltage remains above 22 V during the lift test, the battery
is ok. Proceed to step 24.
Measure the voltage drop on the signal line from Access 5
24. Measure the voltage from CA240-A7/A5 to battery negative.
 If the voltage is approximately the same as the battery voltage (≈ 24 V),
the signal line is ok. Proceed to step 28.
Note: The voltage at CA240-A7/A5 is always slightly less than the battery volt-
age. This is due to the voltage drop via the signal switch in the main contactor,
fuse FU2, relay K or the key switch. However, this is only a few tenths of a volt.
 If the voltage is less than 22V, proceed to step 25.
Determine the cause of the voltage drop on the signal line
25. Measure the input and output voltage of the signal switch on the main
contactor.
 If there is no significant voltage drop, proceed to step 26.
 If the voltage drops extremely, replace main contactor ED.
26. Measure the input and output voltage of fuse FU5.
 If there is no significant voltage drop, proceed to step 27.
 If the voltage drops significantly, replace FU5.
27. Measure the voltage at pin 30 (input) and pin 87 (output) of relay K. If the
truck has a key switch, measure the key switch input and output voltages.
 If there is no significant voltage drop, proceed to step 28.
 If the voltage drops significantly, replace relay K or the key switch.

ES/ET4000 Series
Rev. B
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ELECTRICAL SYSTEM
EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Check Access 5 for possible input voltage drop

28. Measure the voltage between CA201-A7 (on Access 5) and -Batt.
 If the voltage is considerably less than Batt POS, locate and remove the
transitional resistance in the wiring.
 If the voltage  24 V, the wiring is ok. Proceed to step 29.
Check the power cables and connections
29. Check the power cables to steer motor M3 and its connections are secure
and check for damage.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the connections are ok, proceed to step 30.
Check voltage drop over fuse F5
30. Measure voltage at input and output of FU5 to -Batt.
 If the input and output voltages are different, replace FU5 and check the
contacts for corrosion.
 If the input and output voltages are identical, proceed to step 31.
Check the signal switch in the main contactor
31. Measure the input and output voltage of the signal switch in the main con-
tactor to Batt.
 If the input and output voltages are different, replace the main contactor.
 If the input and output voltages are identical, proceed to step 32.
Check the power part of the main contactor
32. Check the power cables on the main contactor and its connections are
secure and check for damage.
 If any cables are loose, damaged or swapped, rectify the cause. If the
main contactor is overheated (recognisable from blue colouring), re-
place the main contactor.
 If the power cables, connections and main contactor are ok, proceed to
step 33.
Replace Access 5
33. Replace Access 5.

Event code 511

Display: EV511
Service LED: On
Operator LED: Off
Explanation: No current at phase U
Possible causes: • Wiring voltage drop
• Battery voltage drop
• Main contactor faulty
• Access 5 faulty
Remedy: See event code 510.

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Event code 512

Display: EV512
Service LED: On
Operator LED: Off
Explanation: No current at phase W
Possible causes: • Wiring voltage drop
• Battery voltage drop
• Main contactor faulty
• Access 5 faulty
Remedy: See event code 510.

Event code 513

Display: EV513
Service LED: On
Operator LED: Off
Explanation: Channels A and B of encoder ECR2 were swapped when connected.
Possible causes: • Wiring error
Remedy: Check wiring
1. Check wiring for damage.
 Repair the wiring if damaged.
 If the wiring is not damaged, proceed to step 2.
Check the ECR2 encoder connector is wired correctly
2. Using the circuit diagram and the cable numbers indicated, check if wires
to CA242 or CA243 have been connected incorrectly.
 If CA243 has been wired incorrectly, replace PC243-2 with PC243-3.
 If CA242 has been wired incorrectly, replace PC242-2 with PC242-3.

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Event code 514

Display: EV514
Service LED: On
Operator LED: Off
Explanation: An error in one of the 2 redundant steering potentiometer curves has occurred.
Possible causes: • Wiring error
• Excessive impact on truck
• Steering potentiometer faulty
Remedy: Has the truck travelled over a pothole?
1. Ask the operator if the error occurred after the truck had received a hefty
impact.
 If so, restart the truck. Monitor the event log.
 If not, proceed to step 2.
Test the steering potentiometer
2. Set the steering to the centre position.
3. Select service level 2 (see page 72).
4. Press the key.
 A1 Status is displayed.
5. Press to scroll to the A2 INPUTS menu.
6. Press the key.
 A2.1 ACCESS 1 is displayed.
7. Using the key scroll through to the A2 5 ACCESS 5 menu.
8. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
9. Press to scroll to the A2.5.4 STEER POT1 menu.
10. Press the key.
 The output voltage of STEER POT1 is displayed.
11. Slowly change the steering from the left stop to the right while monitoring
the display.
 The readings should increase or decrease without interruption and be
approximately the same (approx. 2.5 V).
12. Press the key twice.
13. Press the key.
 A2.5.5 STEER POT2 is displayed.
14. Press the key.
 The output voltage of STEER POT 2 is displayed.
 If both potentiometers are working correctly, re-calibrate the steering.
Proceed to step 15.
 If there is a disconnection in one of the two potentiometers, proceed to
step 16.

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15. Switch the truck off and on again.

 If the event occurs again, proceed to step 16.
Check the steer sensor module wiring
16. Check the connections from CA243 (steer sensor module) to CA241 (Ac-
cess 5) and CA200 (Access 2&3). If there is a wiring error, repair the wir-
ing.
 If the wiring is ok, replace the steer sensor module or TFD module.

Event code 515

Display: EV515
Service LED: Off
Operator LED: On
Explanation: Maximum angle reached on steered wheel
Possible causes: • LIMIT DEVICE is set to ON
Remedy: The event deletes itself after the steering has been set to neutral.

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Event code 516

Display: EV516
Service LED: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 does not close.
Possible causes: • Wiring error
Remedy: Check if the Access 5 wiring has shorted
1. Check if the Access 5 wiring has shorted.
 If there is a short, repair the wiring.
 If the wiring is ok, proceed to step 2.
Check for other shorts
2. Disconnect CA240.
3. Remove wire from PC240-A4.
4. Reconnect PC240.
5. Measure voltage on wire 2955 to -Batt.
 If the voltage is 0 VDC, proceed to step 6.
 If the voltage  24 V, proceed to step 8.
Check wire 2955 for a short
6. Measure voltage on wire 2955 to -Batt.
 If there is a short to -Batt, proceed to step 7.
 If the resistance (> M), proceed to step 9.
7. Repair the short to -Batt in wire 2955 from PC201-A4 to connector CA200
on Access 2/3.
8. Repair the short to +Batt in wire 2955 from PC201-A4 to connector CA200
on Access 2/3.
9. Switch the truck off and on again.
 If the event occurs again, proceed to step 10.
Replace Access 5
10. Replace Access 5.

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Event Code 517

Display: EV517
Service LED: On
Operator LED: Off
Explanation: When the steering is in neutral the SAHS sensor switches around.
Possible causes: • Steering bearing faulty
• Wiring error
• Access 5 faulty
Remedy: Check steering bearing for slack
1. Jack up the truck and check the steering bearing for slack.
Note: If there is any slack in the bearing the gear unit will tip and the cam will
be removed from the sensor.
 If there is any slack in the bearing, replace the bearing.
 If there is no slack, proceed to step 2.
Check encoder ECR2
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the A2 INPUTS menu.
5. Press the key.
 A2.1 ACCESS 1 is displayed.
6. Using the key scroll through to the A2 5 ACCESS 5 menu.
7. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
8. Using the key scroll through to the A2.5.6 ECR2 menu.
9. Press the key.
 The output pulses for ECR2 are displayed.
10. Leave the steering in neutral and make a note of the reading.
11. Slowly move the steering to the left stop while monitoring the display for
fluctuations and recording the final reading.
12. Slowly bring the steering to the right-hand stop, check the display for sud-
den jumps and check the final reading.
Note: With the steering in the centre position, the reading should be 120 10
pulses. In the end stops minimum 1510, maximum 22010. ECR2 and ECR3
rotate in opposite directions: if the number of pulses on ECR2 increase, they
decrease on ECR3.

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13. Repeat steps 10 to 12 and compare the readings with the ones previously
recorded.
 If the display jumps significantly as you steer, or if there are large devi-
ations in the number of pulses counted at the end stops, replace steer
motor M3.
 If encoder ECR2 is ok, proceed to step 14.
Check the SAHS sensor
14. Check the LED on the sensor while moving the steering to the left and
right.
 If the LED lights up when you steer to the left and goes out when you
steer to the right, sensor SAHS is ok.
 If the LED is lit either steadily or not at all, proceed to step 15.
15. Check the gap between SAHS and the cam on the gear unit for foreign
bodies and accumulation of dirt.
 Remove any foreign bodies or accumulation of dirt.
 If there are no foreign bodies or accumulation of dirt, proceed to step 16.
16. Check the distance between the SAHS sensor and the cam.
 If the distance > 2.5 mm, set it to 2.5 mm. Repeat step 14.
 If the distance = 2.5 mm, proceed to step 17.
 If the problem persists, proceed to step 18.
Replace the SAHS sensor
17. Replace SAHS sensor and set the switch distance.
Replace Access 5
18. Replace Access 5.

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Event code 518

Display: EV518
Service LED: On
Operator LED: Off
Explanation: The processors in Access 5 measure a difference of more than 0.7 V in the
steering potentiometer.
Possible causes: • Access 5 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Check the time and temperature for the last recorded event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is recorded, proceed to step 7.
Replace Access 5
7. Replace Access 5.

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Event code 519

Display: EV519
Service LED: On
Operator LED: Off
Explanation: The processors in Access 5 detect different direction messages from the steer-
ing potentiometer.
Possible causes: • Access 5 faulty
• Access 1 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Check the time and temperature for the last recorded event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is recorded, proceed to step 7.
Replace Access 5
7. Replace Access 5.

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Event codes 520, 521

Display: EV520 or EV521
Service LED: On
Operator LED: Off
Explanation: The processors in Access 5 detect different signals from channel A or B, or
from A and B of steering encoder ECR3.
Possible causes: • Access 5 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Check the time and temperature for the last recorded event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is recorded, proceed to step 7.
Replace Access 5
7. Replace Access 5.

Event code 522

Display: EV522
Service LED: On
Operator LED: Off
Explanation: Internal error in Access 5.
Possible causes: • Access 5 faulty
Remedy: Replace Access 5
1. Replace Access 5.

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Event code 523

Display: EV523
Service LED: On
Operator LED: Off
Explanation: The steer motor draws the maximum current for more than 1 second.
Possible causes: • The power cables to steer motor M3 have a poor contact, are damaged or
connected incorrectly
• Access 5 faulty
Remedy: Check the power cables and connections
1. Check the power cable leading to steer motor M3 and its terminals to en-
sure they are securely attached and not damaged.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the connections are ok, proceed to step 2.
Check current sensor
2. Select service level 2 (see page 72).
3. Press to scroll to the A2 INPUTS menu.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Using the key scroll through to the A2 5 ACCESS 5 menu.
6. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
7. Using the key scroll through to the A2.5.3 STEER MOTOR CURRENT
menu.
8. Press the key.
 The current flowing through the output stage of Access 5 is displayed.
 If the reading is 0A, restart the truck. Monitor the event log.
 If the reading with the steer motor idle > 15 A, proceed to step 9.
Clear the EEPROM in Access 5
9. Select service level 2 (see page 72).
10. Clear the EEPROM in Access 5 (see menu item F8, page 86).
11. Switch the truck off and on again.
12. Re-calibrate the truck' steering
 If the event code persists, proceed to step 13.
Check the insulation resistance
13. Check the insulation resistance on the motor coils and the power cables.
 If there is a short, locate and replace the faulty component.
 If the insulation resistance is ok, replace Access 5.

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Event code 524

Display: EV524
Service LED: On
Operator LED: Off
Explanation: Internal error in Access 5.
Possible causes: • Access 5 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Check the time and temperature for the last recorded event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is recorded, proceed to step 7.
Replace Access 5
7. Replace Access 5.

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Event code 525

Display: EV525
Service LED: On
Operator LED: Off
Explanation: This event only occurs when the steering is applied very quickly: Access 5 has
tried to drive the steer motor but encoder ECR2 does not provide an output
signal.
Possible causes: • Encoder ECR2 faulty
• Insulation resistance too low
• Access 5 faulty
Remedy: Check encoder ECR2
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press to scroll to the A2 INPUTS menu.
4. Press the key.
 A2.1 ACCESS 1 is displayed.
5. Using the key scroll through to the A2 5 ACCESS 5 menu.
6. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
7. Using the key scroll through to the A2.5.6 ECR2 menu.
8. Press the key.
 The output pulses for ECR2 are displayed.
9. Leave the steering in neutral and check the reading.
10. Slowly move the steering to the left stop while monitoring the display for
fluctuations and recording the final reading.
11. Slowly move the steering to the right stop while monitoring the display for
fluctuations and recording the final reading.
12. Repeat steps 10 to 12 and compare the readings with the ones previously
recorded.
 If the display jumps significantly as you steer, or if there are large devi-
ations in the number of pulses counted at the end stops, replace steer
motor M3.
 If encoder ECR2 is ok, proceed to step 13.
Note: With the steering in the centre position, the reading should be 120 ±10
pulses. In the end stops minimum 1510, maximum 22010. ECR2 and ECR3
rotate in opposite directions: if the number of pulses on ECR2 increase, they
decrease on ECR3.

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Check the power cables and connections

13. Check the power cable leading to steer motor M3 and its terminals to en-
sure they are securely attached and not damaged.
 If any cables are loose, damaged or swapped, rectify the cause.
14. If the power cables and the connections are ok, proceed to step 15.
Check the insulation resistance
15. Check the insulation resistance on the motor coils and the power cables.
 If there is a short, locate and replace the faulty component.
 If the insulation resistance is ok, proceed to step 16.
Replace Access 5
16. Replace Access 5.

Event code 526

Display: EV526
Service LED: On
Operator LED: Off
Explanation: The output signal of the steering potentiometer has risen by more than
0.3 VDC in less than 16ms.
Possible causes: • Steer sensor module faulty
• Access 5 faulty
Remedy: Checking the steer sensor module attachment
1. Check the steer sensor module attachment.
 If the steer sensor module is loose, attach it securely.
 If it is attached securely, proceed to step 2.
Test the steering potentiometer
2. Set the steering to the centre position.
3. Select service level 2 (see page 72).
4. Press the key.
 A1 Status is displayed.
5. Press to scroll to the A2 INPUTS menu.
6. Press the key.
 A2.1 ACCESS 1 is displayed.
7. Press to scroll to the A2.5 ACCESS 5 menu.
8. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
9. Press to scroll to the A2.5.4 STEER POT1 menu.

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10. Press the key.

 The output voltage of STEER POT1 is displayed.
11. Slowly change the steering from the left stop to the right while monitoring
the display.
 The readings should increase or decrease without interruption and be
approximately the same (approx. 2.5 V).
12. Press the key twice.
13. Press the key.
 A2.5.5 STEER POT2 is displayed.
14. Press the key.
 The output voltage of STEER POT 2 is displayed.
 If both potentiometers are working correctly, re-calibrate the steering.
Proceed to step 15.
 If there is a disconnection in one of the two potentiometers, proceed to
step 16.
15. Switch the truck off and on again.
 If the event occurs again, proceed to step 16.
Check the steer sensor module wiring
16. Check connections from CA246 (steer sensor module) to CA240
(Access 5) and CA200 (Access 2&3).
 If there is a wiring error, repair the wiring.
 If the wiring is ok, replace the steer sensor module.

Event codes 527, 528

Display: EV527 or EV528
Service LED: On
Operator LED: Off
Explanation: Internal error in Access 5.
Possible causes: • Access 5 faulty
Remedy: Replace Access 5
1. Replace Access 5.

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Event code 529

Display: EV529
Service LED: On
Operator LED: Off
Explanation: Internal error in Access 5.
Possible causes: • Access 5 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Check the time and temperature for the last recorded event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is recorded, proceed to step 7.
Replace Access 5
7. Replace Access 5.

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Event code 530

Display: EV530
Service LED: On
Operator LED: Off
Explanation: Output signals of encoders ECR2 and ECR3 do not match.
Possible causes: • Wiring error
• ECR3 or ECR2 in steer motor M3 faulty
Remedy: Check wiring
1. Check wiring on encoders ECR2 and ECR3 from CA242 and CA243 to
CA240 and CA241 on Access 5 for shorts and damage.
 Repair the wiring if faulty.
 If the wiring is ok, proceed to step 2.
Check encoder ECR2
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the A2 INPUTS menu.
5. Press the key.
 A2.1 ACCESS 1 is displayed.
6. Press to scroll to the A2.5 ACCESS 5 menu.
7. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
8. Using the key scroll through to the A2.5.6 ECR2 menu.
9. Press the key.
 The output pulses for ECR2 are displayed.
10. Leave the steering in neutral and check the reading.
11. Slowly move the steering to the left stop while monitoring the display for
fluctuations and recording the final reading.
12. Slowly move the steering to the right stop while monitoring the display for
fluctuations and recording the final reading.
Note: With the steering in the centre position, the reading should be 120 ±10
pulses. In the end stops minimum 1510, maximum 22010. ECR2 and ECR3
rotate in opposite directions: if the number of pulses on ECR2 increase, they
decrease on ECR3.
Check encoder ECR3
13. Press the key.
 A2.5.6 ECR2 is displayed.
14. Press the key.
 A2.5.7 ECR3 is displayed.

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15. Press the key.

 The output pulses for ECR3 are displayed.
16. Leave the steering in neutral and check the reading.
17. Slowly move the steering to the left stop while monitoring the display for
fluctuations and recording the final reading.
18. Slowly move the steering to the right stop while monitoring the display for
fluctuations and recording the final reading.
 If there are no fluctuations in the displays, re-start the truck and monitor
the event.
 If there are significant fluctuations, replace steer motor M3.
Note: With the steering in the centre position, the reading should be 120 ±10
pulses. In the end stops minimum 1510, maximum 22010. ECR2 and ECR3
rotate in opposite directions: if the number of pulses on ECR2 increase, they
decrease on ECR3.

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Event code 531

Display: EV531
Service LED: On
Operator LED: Off
Explanation: When the truck is powered up the data required by Access 5 was not received
from Access 3.
Possible causes: • Wiring error
• Access 1 faulty
• Access 5 faulty
Remedy: Check module status
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Scroll through from A1.1 to A1.7 and check the status of the modules.
 If one of the modules is OFF, proceed to step 4.
 If all modules are ON, restart the truck. Monitor the event log.
Check the CAN Bus wiring
4. Check CAN Bus wiring between Access 3 and Access 5 for shorts and
damage.
 Repair the wiring if faulty.
 If the wiring is ok, proceed to step 5.
Check terminal resistance on PC210
5. With the truck switched off, measure the resistance between PC210-1 and
PC210-2
 If the resistance is 60  , the terminal resistance is ok, proceed to step
6.
 If the resistance is not 60 , replace the resistor.
Test terminal resistance in Access 1
6. Disconnect JC400 from Access 1
7. Measure the resistance between JC400-8 and JC400-9.
 If the resistance is 120W, the terminal resistance is ok.
 If the resistance is not 120 , replace Access 1.

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Event code 532

Display: EV532
Service LED: On
Operator LED: Off
Explanation: On power up SAHS cannot find the cam within a 270° rotation.
Possible causes: • Steering bearing faulty
• Wiring error
• Contamination
• Faulty sensor adjustment
• Sensor faulty
• Access 1 faulty
• Access 5 faulty
Remedy: Check steering bearing for slack
1. Jack up the truck and check the steering bearing for slack.
Note: If there is any slack in the bearing the gear unit will tip and the cam will
be removed from the sensor.
 If there is any slack in the bearing, replace the bearing.
 If there is no slack, proceed to step 2.
Check communication of SAHS with Access 5
2. Check wiring of SAHS sensor and connector CA245 for shorts and dam-
age.
 Repair the wiring if faulty.
 If the wiring is ok, proceed to step 3.
Check if SAHS switches
3. Select service level 2 (see page 72).
4. Press the key.
 A1 Status is displayed.
5. Press to scroll to the A2 INPUTS menu.
6. Press the key.
 A2.1 ACCESS 1 is displayed.
7. Using the key scroll through to the A2 5 ACCESS 5 menu.
8. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
9. Press to scroll to the A2.5.8 SAHS SENSOR menu.
10. Press the key.
 The switch status of sensor SAHS is displayed (0 = OFF, 1 = ON).

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11. Move the tiller to the left and right while checking if the switch status in the
display and on the LED of the SAHS change at the same time.
 If the switch conditions change at the same time, SAHS and communi-
cation with Access 5 are ok. Restart the truck. Monitor the event log.
 If the switch status does not change, or not at the same time, proceed
to step 12.
Check the cam for contamination
12. Check the gap between SAHS and the cam on the gear unit for foreign
bodies and accumulation of dirt.
 Remove any foreign bodies or accumulation of dirt.
 If there are no foreign bodies or accumulation of dirt, proceed to step 13.
Check the screw-in depth of SAHS
13. Check the distance between the SAHS sensor and the cam.
 If the distance is incorrectly set, adjust it and repeat step 11.
 If the distance is within range and the sensor still does not switch, pro-
ceed to step 14.
Replace the SAHS sensor
14. Replace SAHS sensor and set the switch distance.
15. Repeat step 11.
16. If the problem still persists, replace Access 5.

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EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event code 535

Display: EV535
Service LED: On
Operator LED: Off
Explanation: Internal error in Access 5.
Possible causes: • Access 5 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Check the time and temperature for the last recorded event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is recorded, proceed to step 7.
Replace Access 5
7. Replace Access 5.

Event code 536

Display: EV536
Service LED: On
Operator LED: Off
Explanation: Access 5 needs time to calculate the motor resistance and adapt the current
gain accordingly.
Possible causes: • Transient error
Remedy: Restart the truck
1. Restart the truck.

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Event code 537

Display: EV537
Service LED: On
Operator LED: Off
Explanation: Internal error in Access 5.
Possible causes: • Access 5 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Check the time and temperature for the last recorded event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is recorded, proceed to step 7.
Replace Access 5
7. Replace Access 5.

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190
 ELECTRICAL SYSTEM
EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event code 538

Display: EV538
Service LED: On
Operator LED: Off
Explanation: CAN-Bus error.
Possible causes: • Wiring error
• Access 1 faulty
• Access 5 faulty
Remedy: Check module status
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press the key.
 A1.1 ACCESS 1 is displayed.
4. Press the key.
 The status of the module (ON or OFF) is displayed.
 If one module is OFF, proceed to step 6.
5. Scroll through to A1.2 to A1.7 in turn and check the status of the modules
(see menu structure).
 If one of the modules is OFF, proceed to step 6.
 If all modules are ON, restart the truck. Monitor the event log.
Note: To view the next module, press the key twice. Now press the key,
followed by the key twice.
Check the CAN Bus wiring
6. Check CAN Bus wiring between Access 3 and Access 5 for shorts and
damage.
 Repair the wiring if faulty.
 If the wiring is ok, proceed to step 7.
7. Power down the truck.
8. Measure the load resistance between PC210-1 and PC210-2 (CAN con-
nection).
 If the resistance is 60 , the CAN-Bus termination is ok. Restart the
truck and monitor the event log.
 If the resistance is not 60 , proceed to step 9.
Test terminal resistance in Access 5
9. Disconnect CA201 from Access 5.
10. Measure the resistance between JC240-6 and JC240-14.
 If the resistance is 120 , the terminal resistance in Access 5 is ok,
proceed to step 11.
 If the resistance is not 120 , replace Access 5.

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Test terminal resistance in Access 1

11. Disconnect CA200 from Access 1
12. Measure the resistance between PC200-8 and PC200-9.
 If the resistance is 120 , the terminal resistance is ok. Restart the truck
and check the event log.
 If the resistance is not 120 , replace Access 1.

Event code 539

Display: EV539
Service LED: On
Operator LED: Off
Explanation: The sum of the voltages of the two steering potentiometers is out of range.
Possible causes: • Wiring error
• Steer sensor module faulty
Remedy: Show the voltages of the steering potentiometers in the display
1. Set the steering to the centre position.
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the A2 INPUTS menu.
5. Press the key.
 A2.1 ACCESS 1 is displayed.
6. Using the key scroll through to the A2 5 ACCESS 5 menu.
7. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
8. Press to scroll to the A2.5.4 STEER POT1 menu.
9. Press the key.
 The output voltage of STEER POT1 is displayed.
10. Note the reading.
11. Press the key twice.
12. Press the key.
 A2.5.5 STEER POT2 is displayed.
13. Press the key.
 The output voltage of STEER POT 2 is displayed.
14. Note the reading.
15. Add the readings to obtain the overall voltage.
 If the sum of the two voltages is 4.5 - 5.5V, the steering potentiometers
are ok. Restart the truck. Monitor the event log.
 If the sum of the two voltages is not within the 4.5 - 5.5V range, proceed
to step 16.

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Measure the voltage of the steering potentiometers at the connectors

16. Measure the voltage from PC241-6 to PC241-1
17. Measure the voltage from PC201-15 to PC241-1.
 If the readings match those shown in the display, the wiring is ok.
Restart the truck. Monitor the event log.
 If the readings differ from those shown on the display, proceed to
step 18.
Check the steer sensor module wiring
18. Check connections from CA246 (steer sensor module) to CA241
(Access 5) and CA201 (Access 2/3).
 If there is a wiring error, repair the wiring.
 If the wiring is ok, replace the steer sensor module.

Event code 540

Display: EV540
Service LED: On
Operator LED: Off
Explanation: Switch status of SAHS does not match the output of ECR3.
Possible causes: • Wiring error
• Access 5 faulty
Remedy: See event code 517, page 173.

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EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event code 541

Display: EV541
Service LED: On
Operator LED: Off
Explanation: Internal error in Access 5.
Possible causes: • Access 5 faulty
Remedy: The first time the event code appears
1. Switch off the truck, disconnect the battery, wait for 6 seconds, connect the
battery and switch the truck on again.
 If the event code no longer occurs, the problem is resolved.
 If the event code occurs again, proceed to step 2.
Test Access 1
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the EVENTS menu.
5. Press the key.
 E1 CHRON HISTORY is displayed.
6. Check the time and temperature for the last recorded event.
 If an event is logged and the service hours and temperature match the
event, Access 1 is ok.
 If no event is recorded, proceed to step 7.
Replace Access 5
7. Replace Access 5.

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 ELECTRICAL SYSTEM
EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event codes 542, 543

Display: EV542 or EV543
Service LED: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 is open.
Possible causes: • Wiring error
• Access 5 faulty
Remedy: Check status of Access 5
1. Select service level 2 (see page 72).
2. Press the key.
 A1 STATUS is displayed.
3. Press the key.
 A1.1 ACCESS 1 is displayed.
4. Press to scroll to A1.4 ACCESS 5.
5. Press the key 2 times.
 The status (ON or OFF) of Access 5 is displayed.
 If the status is ON, proceed to step 6.
 If the status is OFF, re-start the truck. Monitor the event log.
6. Disconnect the wire from PC240-4 and measure the voltage at JC401-4 to
-Batt.
 If the reading is not  24 VDC, there is an error in the positive wire.
Repair the wiring.
 If the voltage  24 V, proceed to step 7.
Check entries in event log
7. Press to scroll back to A1 STATUS.
8. Press to scroll to the EVENTS menu.
9. Press the key.
 E1 CHRON HISTORY is displayed.
 If, in addition to event code 542 another event with identical time and
temperature is logged, rectify this other error first.
 If no further event is logged with an identical time and temperature, pro-
ceed to step 10.
Replace Access 5
10. Replace Access 5.

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EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event code 544

Display: EV544
Service LED: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 is closed.
Remedy: Check status of Access 5
1. Select service level 2 (see page 72).
2. Press the key.
 A1 STATUS is displayed.
3. Press the key.
 A1.1 ACCESS 1 is displayed.
4. Press to scroll to A1.4 ACCESS 5.
5. Press the key 2 times.
 The status (ON or OFF) of Access 5 is displayed.
 If the status is ON, proceed to step 6.
 If the status is OFF, re-start the truck. Monitor the event log.
6. Disconnect the wire from PC240-4 and measure the voltage at JC240-4 to
-Batt.
 If the reading is not  24 VDC, there is an error in the positive wire.
Repair the wiring.
 If the voltage  24 V, proceed to step 7.
Check the wiring at CA201-4 and CA201-5 for shorts
7. Disconnect PC200 and measure the resistance between JC200-4 and
JC200-5.
 If the resistance (> M), proceed to step 8.
 If the resistance is less, proceed to step 11.
Check entries in event log
8. Press to scroll back to A1 STATUS.
9. Press to scroll to the EVENTS menu.
10. Press the key.
 E1 CHRON HISTORY is displayed.
 If, in addition to event code 542 another event with identical time and
temperature is logged, rectify this other error first.
 If no further event is logged with an identical time and temperature, pro-
ceed to step 11.
Replace Access 5
11. Replace Access 5.

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 ELECTRICAL SYSTEM
EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event code 545

Display: EV545
Service LED: On
Operator LED: Off
Explanation: One of the two safety relays in Access 5 is closed.
Possible causes: • Wiring error
• Access 5 faulty
Remedy: See event code 544

Event code 547

Display: EV 547
Service LED: On
Operator LED: Off
Explanation: Voltage on one of the phases U, V or W of Access 5 (SCM) is higher than the
reference voltage setting.
Possible causes: • The power cables to steer motor M3 have a poor contact, are damaged or
connected incorrectly
• Access 5 faulty
Remedy: Check the power cables and terminals
1. Check the power cables to steer motor M3 and the power supply cables to
Access 5 for loose attachment and damage.
 If any cables are loose, damaged or swapped, rectify the cause.
 If the power cables and the terminals are ok, proceed to step 2.
Check the insulation resistance
2. Measure the insulation resistances from the motor coil and power cables
to the truck frame.
 If there is a short to the truck frame, locate and replace the faulty com-
ponent.
 If the insulation resistance is ok, replace Access 5.

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EVENT CODE - GROUPS 500 AND 800 (ES/ET-E)

Event codes 801 to 804

Display: EV8XX
Service LED: On
Operator LED: Off
Explanation: Error in Access 8.1
Possible causes: • Access 8.1 faulty
Remedy: 1. Replace Access 8.1 (in the tiller handle)
2. Calibrate proportional lifting and lowering (see page 105).

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 ELECTRICAL SYSTEM
EVENTS DISPLAYED AS TEXT

Events Displayed as Text In some cases the fault may be due to an incorrect
choice of option, truck model or a component malfunc-
These events are normally caused by operator error. tion. This will require the intervention of a service engi-
The text message in the display informs the operator. neer.
The remedial measures the operator can perform are
detailed in the operating instructions.

Platform Error
Display: PLATFORM FAILURE
Service LED: Off
Operator LED: On
Explanation: Discrepancy in the platform side restraint logic.
Possible causes: • Platform or side restraint sensors faulty
• Incorrect truck model set
• Wiring error
Remedy: Check the truck type and model setting
1. Check the truck type and model setting (see event code 321, page 138).
 If the correct type and model are set, proceed to step 2.
 If the wrong type has been set, set the correct type and model.
Check switch status of side restraint sensors SR1 and SR2
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press the key.
 A2 Inputs is displayed.
5. Press the key.
 A2.1 ACCESS 1 is displayed.
6. Press the key 2 times.
 A2.3 ACCESS 3 is displayed.
7. Press the key.
 A2.2.3 TEMP ACCESS 2&3 is displayed.
8. Using the key scroll through to A2.3.11 SR1 SENSOR.
9. Press and record the reading of sensor SR1 (ON or OFF).
10. Press the key.
11. Using the key scroll through to A2.3.12 SR2 SENSOR.
12. Press and record the reading of sensor SR2 (ON or OFF).
Check switch status of platform sensors PLS1 and PLS2
13. Press the key.
14. Using the key scroll through to A2.3.10 PLS2 SENSOR.
15. Press and record the reading of sensor PLS2 (ON or OFF).

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16. Press the key.

17. Using the key scroll through to A2.3.9 PLS1 SENSOR.
18. Press and record the reading of sensor PLS1 (ON or OFF).
19. Compare the switch status of PLS1, PLS2, SR1 and SR2 with the Input
Signals table on page 67.
 If the statuses match, proceed to step 22.
 If the statuses do not match, proceed to step 20.
Check wiring of affected sensor
20. Check wiring of sensor considered to be questionable in step 19.
 Repair the wiring if faulty.
 If the wiring is ok, proceed to step 21.
Test sensors
21. Using a suitable piece of metal switch the questionable sensor directly
while monitoring the display.
 If the sensor is ok, proceed to step 22.
 Replace the sensor if faulty.
Test sensor actuator
22. Activate the affected sensor with the platform or side restraints. Monitor
the display in the process.
 If the sensor does not switch, adjust the actuator or sensor.

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Rev. B
200
 ELECTRICAL SYSTEM
EVENTS DISPLAYED AS TEXT

Stopped
Display: TRUCK STOPPED
Service LED: Off
Operator LED: On
Explanation: Battery residual capacity below the permissible level.
Possible causes: • Battery faulty
• BDI setting does not match the performance setting
• Battery voltage set incorrectly
Remedy: Charge the battery or install a charged battery
1. Charge the battery fully or replace it with a fully charged battery.
 If this resolves the error, return the truck to service.
 If the BDI still does not show a fully charged battery, proceed to step 1.
Check load profile in the BDI setting
1. Select service level 2 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Press the key.
 P1 SET P1 is displayed.
4. Using the key scroll through to the P4 BDI SETTING menu.
5. Check that the setting matches the actual load profile of the truck. (see
Setting the Load Profile for the Battery Discharge Indicator (BDI),
page 220).
 If the setting and the actual load profile match, proceed to step 6.
 If the setting does not match the actual load profile, adjust the load pro-
file (see page 220).
Check battery voltage and battery condition
6. Check battery voltage and battery condition, as described for event
code 304. See page 127.

ES/ET4000 Series
Rev. B
201
ELECTRICAL SYSTEM
EVENTS DISPLAYED AS TEXT

Traction control module hot

Display: HIGHTEMP TCM
Service LED: Off
Operator LED: On
Explanation: Temperature of traction control module Access 3 too high
Possible causes: • Fan faulty
• Thermal sensor in Access 3 faulty
• Wiring error
Remedy: Test fan
1. Select service level 3 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Wait until the temperature in Access 3 has dropped.
4. Using the key scroll through to the A4 TEST OUTPUTS menu.
5. Press the key.
 A4.1 FAN is displayed.
6. Press the key.
 ENTER TO CANCEL is displayed.
 If the fan is working, proceed to step 7.
 If the fan is not working, proceed to step 12.
Note: The fan cuts out after 5 seconds. Press to cancel the test prematurely.
Check the fan status in the display
7. Press to scroll back to the ANALYZER menu.
8. Press the key.
 A1 STATUS is displayed.
9. Using the key scroll through to the A3 OUTPUTS menu.
10. Press the key.
 A3.1 BATTERY % is displayed.
11. Using the key scroll through to the A3.10 FAN menu.
 If the status is ON but the fan does not start up, proceed to step 12.
 If the status is OFF and the fan does not start up, proceed to step 14.
Check the fan wiring
12. Using a voltmeter measure the battery voltage between -Batt and
CA221-1 (fan).
 If the reading ≈ 24 V, the positive power supply is ok, proceed to
step 14.
 If no voltage is measured, check fuse FU3 and the wires to CA221 for
continuity.

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EVENTS DISPLAYED AS TEXT

13. Disconnect JC201 from Access 2/3 and check the wire between JC201-9
and CA221-2 (fan) for continuity.
 If the wire is continuous, proceed to step 14.
 If the wire is disconnected, repair the wiring.
Compare the actual temperature with the temperature display
14. Press to scroll back to the ANALYZER menu
15. Press the key.
 A1 STATUS is displayed.
16. Press to scroll to the A2 INPUTS menu.
17. Press the key.
 A2.1 ACCESS 1 is displayed.
18. Press to scroll to the A2.3 ACCESS 3 menu
19. Press the key.
 A2.3 TEMP ACCESS 2&3 is displayed.
20. Press the key.
 The temperature of Access 2&3 is displayed.
21. Measure the temperature on the assembly plate and compare the temper-
ature readings.
 If the temperature on the assembly board is approx. 10°C lower than the
temperature display, the thermal sensor is ok.
 If the temperature readings differ by more than 10°C, replace Access 3.

Traction motor hot

Display: HIGHTEMP TRACTION MOTOR
Service LED: Off
Operator LED: On
Explanation: Temperature in traction motor M1 too high
Possible causes: • Wiring error
• Thermal sensor faulty
• Access 2/3 faulty.
Remedy: Measure and check the temperature
1. Wait until the traction motor temperature has dropped.
2. Select service level 2 (see page 72).
3. Press the key.
 A1 Status is displayed.
4. Press to scroll to the A2 INPUTS menu.
5. Press the key.
 A2.1 ACCESS 1 is displayed.
6. Press to scroll to the A2.3 ACCESS 3 menu
7. Press the key.
 A2.3.1 TEMP Access 2/3 is displayed.

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EVENTS DISPLAYED AS TEXT

8. Press to scroll to the A2.3.2 TS1 SENSOR menu.

9. Press the key.
 The traction motor temperature is displayed.
10. Measure the temperature on the motor housing.
 If the temperature on the motor housing is approx. 10°C lower than the
temperature display, thermal sensor TS1 is ok. Proceed to step 12.
 If the temperature difference is greater than approx. 10°C, proceed to
step 11.
Check thermal sensor
Note: For the following test the internal motor temperature should be approx.
20°C.
11. Disconnect CA203 and measure the resistance of thermal sensor TS1 be-
tween pins JC203-1 and JC203-2.
 If the resistance ≈ 600 Ω (at 20°C internal motor temperature), the ther-
mal sensor in the motor is ok. Proceed to step 12.
 If the resistance differs significantly from this value, the thermal sensor
is faulty. Proceed to step 13.
Replace Access 2&3
12. Replace Access 2/3
Replace traction motor M1
13. Replace traction motor M1.

Release control handle

Display: RELEASE CONTROL HANDLE
Service LED: Off
Operator LED: On
Explanation: Incorrect starting sequence.
Possible causes: • Tiller is in travel position when the truck is switched on.
Remedy: Release the control handle, then start the truck
1. Release the tiller and then start.

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204
 ELECTRICAL SYSTEM
EVENTS DISPLAYED AS TEXT

Travel switch applied too soon

Display: RELEASE TRAVEL CONTROL
Service LED: Off
Operator LED: On
Explanation: Incorrect starting sequence.
Possible causes: • Traction potentiometer applied while the control handle was still in the
travel position, or before the truck was switched on.
Remedy: Release the travel switch and control handle, then start the truck
1. Release the travel switch, power up the truck, set the control handle to the
travel position and then apply the traction potentiometer.

Pedestrian mode only

Display: WALKIE ONLY
Service LED: Off
Operator LED: On
Explanation: Rider mode is inhibited when the the forks are above 1800 mm lift height
Possible causes: • Forks above 1800 mm. The truck is in rider mode.
Note: Details of the operating modes can be found starting on page 71.
Remedy: Lower the load or change to pedestrian mode
1. Lower the load or change to pedestrian mode.

Lower forks
Display: LOWER FORKS
Service LED: Off
Operator LED: On
Explanation: The truck is in rider mode and the lift height is more than 1800 mm.
Possible causes: • The truck is in rider mode. Forks above 1800 mm.
Note: Details of the operating modes can be found starting on page 71.
Remedy: Lower the load
1. Lower the load.

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ELECTRICAL SYSTEM
EVENTS DISPLAYED AS TEXT

Steering controller hot

Display: HIGHTEMP STEERING CONTROLLER
Service LED: Off
Operator LED: On
Explanation: Temperature of steering control module Access 5 too high
Possible causes: • Fan faulty
• Thermal sensor in Access 5 faulty
• Wiring error
Remedy: Test fan
1. Select service level 3 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Wait until the temperature in Access 5 has dropped.
4. Using the key scroll through to the A4 TEST OUTPUTS menu.
5. Press the key.
 A4.1 FAN is displayed.
6. Press the key.
 ENTER TO CANCEL is displayed.
 If the fan is working, proceed to step 7.
 If the fan is not working, proceed to step 12.
Note: The fan cuts out after 5 seconds. Press to cancel the test prematurely.
Check the fan status in the display
7. Press to scroll back to the ANALYZER menu.
8. Press the key.
 A1 STATUS is displayed.
9. Using the key scroll through to the A3 OUTPUTS menu.
10. Press the key.
 A3.1 BATTERY % is displayed.
11. Using the key scroll through to the A3.10 FAN menu.
 If the status is ON but the fan does not start up, proceed to step 12.
 If the status is OFF and the fan does not start up, proceed to step 14.
Check the fan wiring
12. Using a voltmeter measure the battery voltage between -Batt and CA212-
1 (fan).
 If the reading ≈ 24 V, the positive power supply is ok, proceed to
step 13.
 If no voltage is measured, check fuse FU4 and the wire to CA213-1 for
continuity.

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EVENTS DISPLAYED AS TEXT

13. Disconnect JC201 from Access2&3 and check the wire between JC201-9
and CA212-2 (fan) for continuity.
 If the wire is continuous, proceed to step 14.
 If the wire is disconnected, repair the wiring.
Compare the actual temperature with the temperature display
14. Press to scroll back to the ANALYZER menu
15. Press the key.
 A1 STATUS is displayed.
16. Press to scroll to the A2 INPUTS menu.
17. Press the key.
 A2.1 ACCESS 1 is displayed.
18. Press to scroll to the A2.5 ACCESS 5 menu.
19. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
20. Press the key.
 The temperature of Access 5 is displayed.
21. Measure the temperature on the assembly plate and compare the temper-
ature readings.
 If the temperature on the assembly board is approx. 10°C lower than the
temperature display, the thermal sensor is ok.
 If the temperature readings differ by more than 10°C, replace Access 3.

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EVENTS DISPLAYED AS TEXT

Steer motor hot

Display: HIGHTEMP STEERING MOTOR
Service LED: Off
Operator LED: On
Explanation: Temperature in steer motor M1 too high
Possible causes: • Fan faulty
• Wiring error
• Thermal sensor faulty
• Access 5 faulty
Remedy: Test fan
1. Select service level 3 (see page 72).
2. Press the key.
 A1 Status is displayed.
3. Wait until the temperature in Access 3 has dropped.
4. Using the key scroll through to the A4 TEST OUTPUTS menu.
5. Press the key.
 A4.1 FAN is displayed.
6. Press the key.
 ENTER TO CANCEL is displayed.
 If the fan is working, proceed to step 7.
 If the fan is not working, proceed to step 12.
Note: The fan cuts out after 5 seconds. Press to cancel the test prematurely.
Check the fan status in the display
7. Press to scroll back to the ANALYZER menu.
8. Press the key.
 A1 STATUS is displayed.
9. Using the key scroll through to the A3 OUTPUTS menu.
10. Press the key.
 A3.1 BATTERY % is displayed.
11. Using the key scroll through to the A3.10 FAN menu.
 If the status is ON but the fan does not start up, proceed to step 12.
 If the status is OFF and the fan does not start up, proceed to step 14.
Check the fan wiring
12. Using a voltmeter measure the battery voltage between -Batt and CA212-
1 (fan).
 If the reading ≈ 24 V, the positive power supply is ok, proceed to
step 23.
 If no voltage is measured, check fuse FU4 and the wire to CA213-1 for
continuity.

ES/ET4000 Series
Rev. B
208
 ELECTRICAL SYSTEM
EVENTS DISPLAYED AS TEXT

13. Disconnect JC201 from Access 2&3 and check the wire between JC201-
9 and CA212-2 (fan) for continuity.
 If the wire is continuous, proceed to step 14.
 If the wire is disconnected, repair the wiring.
Measure and check the temperature
14. Press to scroll back to the ANALYZER menu.
15. Press the key.
 A1 STATUS is displayed.
16. Press to scroll to the A2 INPUTS menu.
17. Press the key.
 A2.1 ACCESS 1 is displayed.
18. Press to scroll to the A2.5 ACCESS 5 menu.
19. Press the key.
 A2.5.1 TEMP ACCESS 5 is displayed.
20. Press to scroll to the A2.5.2 TS3 (TEMP MOTOR) menu.
21. Press the key.
 The steer motor temperature is displayed.
22. Measure the temperature on the motor housing.
 If the temperature on the motor housing is approx. 10°C lower than the
temperature display, thermal sensor TS1 is ok. Proceed to step 24.
 If the temperature difference is greater than approx. 10°C, proceed to
step 23.
Check thermal sensor
Note: For the following test the internal motor temperature should be approx.
20°C.
23. Disconnect CA225 and measure the resistance of thermal sensor TS3 be-
tween pins JC225-1 and JC225-2.
 If the resistance ≈ 600 Ω (at 20°C internal motor temperature), the ther-
mal sensor in the motor is ok. Proceed to step 24.
 If the resistance differs significantly from this value, the thermal sensor
is faulty. Proceed to step 13.
Replace Access 5
24. Replace Access 5.
Replace steer motor M3
25. Replace steer motor M3.

ES/ET4000 Series
Rev. B
209
ELECTRICAL SYSTEM
CONTROL MODULE PMT TEST

Control Module PMT Test Testing Access 2

(HCM) (hydraulic control module)
General
Note: In the following test the power output-P of
EN 1175-1 requires regular testing of the safety circuits Access 2 is shorted against the -B connection of the
for the control modules used. control module.
The test is a "Pulse Monitor Trip Test”, or PMT for short.
Trucks whose control modules fail the PMT must
not be operated. They must be repaired immedi-
ately.

Required tools Access 2 / Access 3

• A test wire, approx. 500 mm long with a 1 mm2

10
-B

A
cross section. The wire must have a 10 A fuse and
testing terminals at both ends.

PMT Test
-P

WARNING + BF FU 7 +
+ + M2
400A
You or other people could be fatally injured.
The truck or moving parts can start accidentally during
the test. Fig. 51 Test setup for Access 2
 Jack up the truck until the drive wheel is clear of the Test preparation
ground.
1. Disconnect the battery if it is still connected.
 Before connecting the test wire, disconnect the bat-
2. Connect the test wire to -B and -P.
tery from the truck.
3. Connect the battery.

Preparing the truck Performing the test

4. Power up the truck.
1. Switch off the truck and disconnect the battery.
 The test is successful if:
2. Jack up the truck (see page 21) so that the drive – The traction motor does not start up
wheel is clear of the ground.
– The display shows EV = 310.
 If one of the above conditions is not met, take the
truck out of service and replace the control module.
5. Power down the truck.
6. Disconnect the battery.
Completing the test
7. Remove the test wire.
8. Connect the battery.
9. Test the truck's functions.
 If the truck is functioning normally, test Access 3.

ES/ET4000 Series
Rev. B
210
 ELECTRICAL SYSTEM
CONTROL MODULE PMT TEST

Testing Access 3 9. Test the truck's functions.

 If the truck is functioning normally, repeat steps 1
(TCM) (traction control module)
to 9 with the test wire between -B and terminal V
Note: In the following test phases U, V and W of the and then W respectively.
Access 3 power part are shorted in turn against the
 If the truck is working normally, now test the steer-
BATT NEG. terminal on the control module.
ing control module Access 5 if applicable.
Performing the test

Access 2 / Access 3

W
W
V
V M1
U 3
U AC

-B
-
A
10

Fig. 52 Access 3 test setup

Test preparation
1. Disconnect the battery if it is still connected.
2. Connect the test wire to -B and U.
3. Connect the battery.
Performing the test
4. Power up the truck.
 The test is successful if:
– The traction motor does not start up
– The display shows EV = 326.
 If one of the above conditions is not met, take the
truck out of service and replace the control module.
5. Power down the truck.
6. Disconnect the battery.
Completing the test
7. Remove the test wire.
8. Connect the battery.

ES/ET4000 Series
Rev. B
211
ELECTRICAL SYSTEM
CONTROL MODULE PMT TEST

Testing Access 5
(SCM) (Steering control module)
Note: In the following test phases U, V and W of the
Access 5 power part are shorted in turn against the
BATT NEG. terminal on the control module.

Access 5

W
W
V
V M3
U 3
U AC

-B
-
A
10

Fig. 53 Access 5 test setup

Test preparation
1. Disconnect the battery if it is still connected.
2. Connect the test wire to -B and U.
3. Connect the battery.
Performing the test
4. Power up the truck.
 The test is successful if:
– The steering and traction motors do not start
– Lifting operations can be performed.
– The display shows EV = 547.
 If one of the above conditions is not met, take the
truck out of service and replace the control module.
5. Power down the truck.
6. Disconnect the battery and remove the test wire.
7. Connect the battery.
8. Test the truck's functions.
If the truck is functioning normally, repeat the test with
the test wire between –B and V and W respectively.

ES/ET4000 Series
Rev. B
212
 ELECTRICAL SYSTEM
SERVICING AND REPLACING THE CONTROL MODULES

Servicing and Replacing the Discharging the capacitors

Control Modules The truck must be de-energised and secured, see
safety notices. Once this has been done:
The number of control modules and assembly loca-
1. Short the positive and negative connections of the
tions will vary depending on the truck’s specific equip-
control module over a resistor (10 - 100 Ω,
ment and features. See Electrical Components,
min. 5 W) for a few seconds.
starting on page 231 for more detailed information on
this.  The stored energy has been discharged safely via
the resistor.
Travel, lifting and power steering are controlled by
modules which communicate with each other via a
common CAN-Bus:
Servicing the control modules
• Access 1 (Display panel) (Display) The truck must be de-energised and secured, see
safety notices.
• Access 2 (Traction control module) (TCM)
1. Discharge the capacitors.
• Access 3 (Hydraulic control module) (HCM)
2. Dry clean the outside of the control module (see
• Access 5 (Steering control module) (SCM) Cleaning the Truck and Components, page 15).
• Access 8.1 (CAN interface) (CAN-Interface) 3. Check that the nuts attaching the power cables are
Access 2 and Access 3 are located in the same hous- tight.
ing. Access 8.1 in the tiller handle. 4. Check the logged events.

Replacing control modules

WARNING
Removing the control module
Short circuits can cause fires
Control modules operate at high currents. Please note: Securing the truck
 You must be trained to carry out this work. The truck must be de-energised and secured, see
safety notices. Once this has been done:
 Use non-fatigue eye protection.
1. Discharge the capacitors.
 Wear close-fitting clothing.
 Do not wear jewellery. Removing the control module
 Always use insulated tools. 2. Remove / disconnect all wires (mark the wires if
necessary).
Note: Note the number and assembly position of the
shims and retaining elements on the power cable con-
nections. They must be fitted in exactly the same posi-
WARNING tion during assembly.
Risk of serious injury! 3. Remove the bus bars if present.
Avoid accidents by: 4. Remove the control module mounting screws.
 Switching the truck off 5. Remove the control module.
 Disconnecting the battery.
Checking the assembly plate tooth pattern
 Preventing the truck from being switched on again.
6. Check the tooth pattern left by the back plate of the
 Jacking up the truck and preventing it from rolling control module on the assembly plate. The full sur-
away face area of the control module must be in contact
with the plate.
 If there are large areas with no contact to the
control module, replace the assembly plate to
avoid thermal problems.

ES/ET4000 Series
Rev. B
213
ELECTRICAL SYSTEM
SERVICING AND REPLACING THE CONTROL MODULES

Set the parameters after replacing a con-

CAUTION trol module
Health risk Clearing the EEPROM of the replaced control mod-
Cleaning agents, lubricants and consumables can ule
damage your health. 1. Clear the EEPROM of the replaced control module
 Observe the manufacturer’s safety instructions (menu F8 EEPROM CLEAR, page 86).
when handling solvents and lubricants.  The factory settings are now installed.
2. Only after changing from Access_2/3: Set the
7. Remove the heat conducting paste remains on the truck type (menu F4, page 85) and model.
assembly plate with a lint-free cloth and a commer- 3. Activate Truck Features as required.
cial silicon removing agent. 4. Check parameter settings for the replaced control
module. Adjust if necessary (see page 97 for the
Assembling the control module ES model or page 99 for the ET model).
Note: Use a control module with the right software ver-
sion. Setting the control module parameters and cali-
brating the truck
Assembling the control module
5. Set the parameters (starting on page 97) and cali-
1. Apply heat conducting paste (Dow Corning® 340, brate the truck (see page 103).
item no. 053051-008) thin and evenly to the base
Note: A lift/lower function calibration is only necessary
plate of the new control module.
if the PC board in the tiller has been replaced.
2. Attach the control module to the assembly plate.
Functional test
3. If necessary clean the power cable connections.
6. Carry out a functional test.

CAUTION
Control modules become damaged if the power cable
attachment is tightened too firmly or too loosely.
 Tighten the power cable attachment to the correct
torque. See the "Power Cable Torques" table.

4. Refit / connect all wires. Attach the bus bars if ap-

plicable.
5. Tighten the power cable attachment to the correct
torque. See following table.

Power cable torques

Access 2&3 5.6 - 8.4 Nm

Access 5 5 Nm (standard torque)

6. Leave the truck jacked up.

7. Connect the battery and remove the immobilizer.
8. Set the truck type and model.

ES/ET4000 Series
Rev. B
214
 ELECTRICAL SYSTEM
MODIFICATIONS

Modifications 3. Press the key.

 “PASSWORD” is displayed.
Converting the truck from Enter key 4. Enter password (PIN).
to key switch power-up function 5. Confirm by pressing .
 The "ANALYZER" menu is displayed.
Select the “FEATURES” sub-menu
WARNING 6. Press the key until the “FEATURES” sub-menu
appears.
Accidental truck movement can cause injury
A powered up truck with a connected battery can move 7. Press the key.
suddenly when you are working on it.  F1 LANGUAGE is displayed.
You should therefore carry out the following safety pro- 8. Press to scroll to F14 KEYLESS.
cedures before starting any operations on the truck:  F14 KEYLESS = ENABLE is displayed.
 Lower the forks to the ground.
9. Press the key.
 Switch the truck off.  DISABLE is displayed.
 Disconnect the battery. 10. Press the key.
 Prevent the truck from being switched on again.  The key switch is now enabled for power-up.
11. Restart the truck.
Mechanical conversion
Note: These conversion instructions apply only to main
harnesses with item numbers 825410 and 829539.
1. Switch off the truck and disconnect the battery.
2. Prevent the truck from being switched on again
and rolling away.
Relay K1 removal
3. Disconnect the battery and prevent the truck from
being switched on again.
4. Remove relay K from its socket and replace it with
the key switch adapter (item no. 820143).
Assembling and wiring the key switch
5. Assemble the key switch.
6. Connect the wiring of the key switch adapter with
the key switch.
7. Cut wire 204 at terminal 30 of the relay socket and
insulate the ends.

Changing the software

Switch the truck on
1. Press the key for 1 second.
 The display screen is activated.
Select service level 2
1. Select service level 2 (see page 72).
1. Use the key to select the “SERVICE” menu.
 “SERVICE” is displayed.
2. Press the key.
 “LEVEL 2” is displayed.

ES/ET4000 Series
Rev. B
215
ELECTRICAL SYSTEM
MODIFICATIONS

Converting the truck from key Activate keyless power-up

switch to Enter key power-up 1. Press the key.
 DISABLE is displayed.
function
2. Press the key.
 ENABLE is displayed.
 Set the truck's cutout time
WARNING
1. Press the key.
Accidental truck movement can cause injury  F14.1 KEYLESS TIMEOUT is displayed.
A powered up truck with a connected battery can move 2. Press the key.
suddenly when you are working on it.  VALUE XX min is displayed.
You should therefore carry out the following safety pro-  Press and to enter the required time (10 –
cedures before starting any operations on the truck: 30 min) until the truck cuts out.
 Lower the forks to the ground.
3. Confirm by pressing .
 Switch the truck off.
4. Restart the truck.
 Disconnect the battery.
 The new settings are activated.
 Prevent the truck from being switched on again.

Mechanical conversion
Note: These conversion instructions apply only to main
harnesses with item numbers 825410 and 829539.
1. Switch off the truck and disconnect the battery.
2. Prevent the truck from being switched on again
and rolling away.
Key switch removal
3. Remove the key switch adapter (item no. 820143).
4. Remove the key switch.
Relay K assembly and wiring
5. Strip line 204 and connect to terminal 30 on the
relay socket.
6. Insert relay K (item no. 811995-006) into the
socket.
Switching the truck on
7. Press the key for 1 second.
 The display screen is activated.

Changing the software

Select service level 2
1. Select service level 2 (see page 72).
Select the “FEATURES” sub-menu
1. Press the key until the “FEATURES” sub-menu
appears.
2. Press the key.
 F1 LANGUAGE is displayed.
3. Press to scroll to F14 KEYLESS.

ES/ET4000 Series
Rev. B
216
 ELECTRICAL SYSTEM
BATTERY INFORMATION

Battery Information
The condition of the battery has a considerable impact
on the performance of the truck. Optimum mainte-
nance is key to maintaining the performance and useful
life of the battery.

Charging the battery

CAUTION
The battery must be serviced and charged strictly
in accordance with the battery and charger manu-
facturers' instructions.
Unsuitable chargers and incorrect maintenance will re-
sult in reduced truck performance in the short term. In
the medium term it will lead to premature battery fail-
ure.

Replacing the battery

WARNING
Incorrect battery sizes and weights can result in fa-
tal accidents.
An incorrect battery weight and size will affect the
truck’s centre of gravity which can result in accidents.
 Only use batteries with the right dimensions, weight
and capacity requirements for this truck.

1. Replace the battery as outlined in the truck opera-

tor manual.

ES/ET4000 Series
Rev. B
217
ELECTRICAL SYSTEM
ADJUSTING THE BLS SENSOR

Adjusting the BLS sensor

The BLS sensor is only available on trucks with battery
rollers. It is located in the battery compartment below
the battery latch.

1
2

Fig. 54 Adjusting the BLS sensor

Adjusting the trip point on the BLS sensor
1. Loosen the nuts (3).
2. Push the battery onto the truck as far as the stop
and lock it.
3. Push the spring plate (1) until the sensor (2) trips
but the spring plate does not touch the sensor.
Note: Adapt the inflection of the spring plate if neces-
sary.
4. Tighten the nuts (3).
Test
1. Unlock the battery and move it away slightly from
the sensor.
2. Push the battery onto the truck as far as the stop
and lock it.
3. If the sensor does not trip, or if the spring plate
touches the sensor, re-adjust the setting.

ES/ET4000 Series
Rev. B
218
 ELECTRICAL SYSTEM
GENERAL DC MOTOR MAINTENANCE INSTRUCTIONS

General DC Motor Maintenance CAUTION

Instructions Place the pressure springs carefully on the brush be-
fore fitting the brush. Otherwise the brush could be
damaged.
WARNING
Note: Make sure that all brushes contact the commu-
Accidental truck movement can cause injury
tator at the same pressure.
A powered up truck with a connected battery can move
suddenly when you are working on it. • New brushes must be run in with a medium load in
You should therefore carry out the following safety pro- the first hours. Never fully charge the motor straight
cedures before starting any operations on the truck: away.
 Lower the forks to the ground. Motor
 Switch the truck off.
• Blast the motor with dry compressed air.
 Disconnect the battery.
 Prevent the truck from being switched on again.
 Jack up the truck until the drive wheel is clear of the CAUTION
ground (see page 21).
Health risk
Cleaning agents, lubricants and consumables can
Brushes damage your health.
• Remove all brushes and check for wear. The length  Observe the manufacturer’s safety instructions
of the shortest brush determines whether the brush when handling solvents and lubricants.
set needs to be replaced.
• If one or more brushes need to be replaced, replace • If oil or grease is found in the motor commutator
all brushes and their pressure springs at the same compartment (usually a paste consisting of oil, oil
time. This will ensure the correct contact pressure. vapour, dust and carbon particles), immediately re-
move the cause and clean the motor thoroughly:
Note: If the minimum brush length has not been
reached, the brushes should still be replaced as they Note: Oil or grease burns in the brush sparks and
could wear fully before the time of the next inspection. leaves behind a highly abrasive oil ash which can very
quickly destroy the commutator and the brushes.
• The brushes must be able to move freely in the
brush support, without spring tension and without
twisting. Never modify the brushes if one or more
Rotor
cannot move freely. In this case replace all brushes • Check the commutator for unevenness, burning,
as they will probably have been thermally over- grooves and cracking of the multi-plate edges. Turn
loaded. the rotor if necessary.
Note: Thermal overloading causes the brushes to Note: A non-oily, evenly distributed layer on the brush
swell up. Brushes which jam in the brush support pro- surfaces is normal.
duce intense sparking and destroy the commutator.
• The brush edges must not be cracked. Brushes
with cracking along the long edge of the surface will
have been damaged by a worn commutator.
Note: If information is provided in the manual, restore
the commutator to the specified limits. Otherwise, re-
place the rotor or the motor.
• Loose brush connections are a clear sign of motor
overload. In this case inspect the commutator for
burning and repair or replace as necessary.

ES/ET4000 Series Rev.1 07/2010

Rev. B
219
ELECTRICAL SYSTEM
SETTING THE LOAD PROFILE FOR THE BATTERY DISCHARGE INDICATOR (BDI)

Setting the Load Profile for the Assigning a load profile

Battery Discharge Indicator You can navigate through the menu structure using the
cursor keys ( , , , , ) on the display panel. An
(BDI) overview of the menu structure can be found in Menu
Note: Before changing the load profile calibrate the Structure, starting on page 74.
BDI (see page 222).
A non-calibrated BDI will feed back incorrect values for
the actual battery voltage. The software will then inter-
pret the discharge curves incorrectly and the battery
capacity will either be only partially used or the battery
even fully discharged.

Load profile and discharge curve

Depending on the load weight that is predominantly
moved, the load profile setting for the BDI will match
more or less the actual battery discharge curve.
A better adaptation of the load profile to the application
therefore has the potential to extend the battery runt-
ime significantly. Fig. 55 Display panel
The factory setting is “Standard Duty”. This setting cov- Switching the truck on
ers applications with loads predominantly ranging from
> 650 kg to max.  950 kg. 1. Press the key for 1 second.
 The display screen is activated.
The following table shows the corresponding load pro-
files for the loads predominantly moved: Note: For trucks with a key switch, turn the key switch
right to the "On" position.

BDI parameters Selecting the PEFORMANCE menu

2. Press the key 3 times.
Load profile Load predominantly  The "SERVICE" menu is displayed.
moved (kg)
3. Press the key until “LEVEL 2” appears.
Light Duty 0 kg to < 650 kg 4. Press the key until you are requested to enter
Standard Duty > 650 kg to  950 kg your PIN.
Medium Duty > 950 kg to  1450 kg 5. Enter the service PIN with the and keys and
confirm with .
Heavy Duty > 1450 kg to  1750 kg(a)  The "ANALYZER" menu is displayed.
Maintenance Free Do not use(b) 6. Press the key until the “PERFORMANCE” menu
appears.
a. Not suitable for 1.2 and 1.6 tonne capacity trucks!
b. This load profile is only suitable for lead-acid batteries. 7. Press the key.
This battery type is not approved for this truck.  “P1” appears.
The discharge curve assumed by the BDI can be 8. Press the key until the “P4” menu appears.
adapted to the actual discharge curve in the “Perfor- 9. Press the key.
mance P4” menu.
 “BDI SETTING = (Value)(1)” appears.
10. Press the key.
11. Press the key until the required setting is dis-
played (see BDI parameters table on page 220).

1). The current setting is displayed. (= Value)

Rev. 1 04/2014 ES/ET4000 Series

Rev. C
220
 ELECTRICAL SYSTEM
SETTING THE LOAD PROFILE FOR THE BATTERY DISCHARGE INDICATOR (BDI)

12. Press the key to confirm the selection.

13. Press the key.
 The prompt for saving the new value “SAVE?N”
is displayed.
Note: To cancel the setting, press the key.
Confirming the security prompt
14. Press the key.
 The prompt for saving "SAVE?Y” appears.
15. To confirm, press .
16. Wait for 5 seconds.
 After 5 seconds the new settings are stored.
Activating the new setting and checking accept-
ance
17. Switch the truck off and on again.
18. In the P4 BDI SETTING menu check that the load
profile has been accepted. If not, repeat the set-
ting.

ES/ET4000 Series Rev. 1 04/2014

Rev. C
221
ELECTRICAL SYSTEM
CHECKING AND ADJUSTING THE BDI SETTING

Checking and Adjusting the BDI

Setting
The calibration of the BDI must be checked in the fol-
lowing cases:
• When the truck is used for the first time
• After replacing Access 2/3
Calibrating the BDI ensures that the load profile used
(see page 220) makes optimum use of the battery ca-
pacity.

Requirements
• The battery must have at least 30% residual capac-
Fig. 56 Display panel
ity.
• A calibrated multimeter must be used. Selecting service level 2
5. Press the key 3 times.
Checking the BDI Setting  The "SERVICE" menu is displayed.
Preparing the truck 6. Press the key until “LEVEL 2” appears.
1. Operate the truck for 5 - 10 minutes with load. 7. Press the key until you are requested to enter
2. Park the truck (do not switch it off) and wait for 10 your PIN.
- 15 minutes. 8. Enter the service PIN with the and keys and
Note: Wait for at least 10 minutes. Otherwise you can- confirm with .
not measure the battery resting voltage required for the  The "ANALYZER" menu is displayed.
calibration.
Selecting the Performance menu
9. Press the key until the “PERFORMANCE” menu
CAUTION appears.
Risk of battery damage through incorrect voltage 10. Press the key.
measurement  “P1” appears.
An incorrect battery voltage measurement caused by a
11. Press the key until the “P11” menu appears.
non-calibrated multimeter can result in fully discharged
batteries. 12. Press the key.
 Make sure the multimeter used is calibrated.  “ADJUST BATT= (Value)(1)” is displayed.
13. Press the key and check the reading.
3. Using a calibrated digital voltmeter measure the  If the reading displayed is 0.2 V greater than the
voltage directly at the battery terminals. rounded up value displayed on the battery, the
Note: Do not use under any circumstances the battery setting is ok.
voltage displayed in the “ANALYZER” menu, A3.2. This  If the reading displayed is greater or less than
is the value to be corrected. the rounded up value displayed on the battery +
0.2 V (see following example) continue with
4. Round up the reading to one decimal place and re- step 14.
cord it.
Example: 23.656 volts are measured on the battery.
Navigating in the menus Rounded up to a decimal place this gives 23.7 V. Add
You can navigate through the menus using the cursor 0.2 V. The result is 23.9 V.
keys ( , , , , ) on the display panel. An over-
view of the menu structure can be found in Menu Struc-
ture, starting on page 74.

1). The current reading (= value) is displayed

ES/ET4000 Series

222
 ELECTRICAL SYSTEM
CHECKING AND ADJUSTING THE BDI SETTING

Adjusting the BDI setting

Adjusting the BDI setting
14. Set the rounded up and recorded reading + 0.2 V.
15. Press the key to confirm the selection.
16. Press the key.
 The prompt for saving the new value “SAVE?N”
is displayed.
Note: To cancel the setting, press the key.
Confirming the security prompt
17. Press the key.
 The prompt for saving "SAVE?Y” appears.
18. To confirm, press .
19. Wait for 5 seconds.
 After 5 seconds the new settings are stored.
Activating the new setting and checking accept-
ance
20. Switch the truck off and on again.
 The new settings are activated.
21. Check that the previous setting has actually been
accepted in the “Performance P11” menu.

ES/ET4000 Series

223
ELECTRICAL SYSTEM
TRACTION MOTOR INSTALLATION AND REMOVAL

Traction motor Installation and Traction motor disassembly

Removal
1
WARNING
Risk of serious injury!
Avoid accidents by:
 Switching the truck off
 Disconnecting the battery.
2
 Preventing the truck from being switched on again.
 Jacking up the truck and preventing it from rolling
away

CAUTION
Health risk
Cleaning agents, lubricants and consumables can
damage your health.
 Observe the manufacturer’s safety instructions 4
when handling solvents and lubricants.

Fig. 57 Traction motor (M1)

ES/ET4000 Series
Rev. B
224
 ELECTRICAL SYSTEM
TRACTION MOTOR INSTALLATION AND REMOVAL

Preparation Restoring the electrical connections

1. Switch off the truck and disconnect the battery. 6. Connect the motor to the brake. Torque the power
2. Prevent the truck from being switched on again cable nuts on the traction motor to 7.5 Nm.
and rolling away. Functional test
3. Jack up the truck until the drive wheel is clear of the 7. Check operation.
ground (see page 21).
Disconnecting the wiring
4. Undo all the connections on the traction motor (3,
Fig. 57) and the brake (2).
Brake removal
5. Remove the brake (2).
Traction motor disassembly
6. Remove the tie rod (1).
7. Lift off of traction motor.

CAUTION
The splined shaft and motor bearing may be dam-
aged.
Lack of care when depositing the motor on the splined
shaft can damage the shaft or destroy the motor bear-
ing.
 Deposit the motor in such a way that it does not ex-
ert any load on the splined shaft.

Traction motor assembly

Traction motor assembly
1. Apply grease type B or BB to the splined shaft (4,
Fig. 57) (see page 23).

CAUTION
Take care not to damage the gearing when fitting the
motor.

2. Place the motor in the correct position on the trans-

mission while ensuring that the splined shaft en-
gages with the gearing on the transmission.
3. Apply Loctite® 243 to the tie rod, bolt it on and
torque to 20 - 25Nm.
4. If the gearing with the brake has been removed,
attach it again.
Brake assembly
5. Assemble the brake (see page 244)

ES/ET4000 Series
Rev. B
225
ELECTRICAL SYSTEM
REPAIRING THE TRACTION MOTOR

Repairing the Traction Motor Preparation

1. Disassemble the traction motor (see page 224).

Rotor and bearing disassembly

Rotor disassembly
1. Remove the retaining ring (13) and gear (12).
2. Remove the key (17).
3. Remove the retaining ring (14).
4. Lift out the rotor (4) from the bottom.
Bearing disassembly
5. Remove the retaining ring (16).
6. Pull or push the bearing (15) out of the bearing
plate (9).

Rotor and bearing assembly

Bearing assembly
7. Insert the bearing (15) into the bearing shield (9).
8. Insert the retaining ring (16).
Rotor assembly
1. Insert the rotor (4) into the bearing.
2. Insert the retaining ring (14).
3. Insert the gear (12).
4. Insert the retaining ring (13).

Final tasks
1. Assemble the traction motor (see page 225).

Fig. 58 Traction motor

ES/ET4000 Series
Rev. B
226
 ELECTRICAL SYSTEM
PUMP MOTOR (M2)

Pump Motor (M2)

Fig. 59 Pump motor

1 Pump motor, complete
2 Clamp
3 Screw

Brushes
1. Disconnect the battery and prevent the truck from
being switched on again.
2. Prevent the truck from rolling away.
3. Loosen the screw (1) from the clamp (2) and re-
move the clamp.
4. Apply dry compressed air to the motor.

Rotor
1. Check the rotor (see page 219).
Note: Do not overwind the rotor. Replace the motor (1)
if the rotor appears worn or damaged.

ES/ET4000 Series
Rev. B
227
ELECTRICAL SYSTEM
REPLACING THE STEER MOTOR (M3)

Replacing the Steer Motor (M3)

84

83 52 1
85 18 2
53
82 19
81 3
80 54 20 4
57
79 55 21
5
22
78 56

6
77 23
24
76

75 7
58
87 25
59
74 26
73 27
28 8
60 9
61 10
12 13
72 64 62 11
63 29
30
88 14
31
32 15
71
16
33
70
17
69 34 35
86 36
37 38 39
68 40 41
67
66
45
44

46
65 42
47
43

48

49 51
50

Fig. 60 Complete drive unit

ES/ET4000 Series
Rev. B
228
 ELECTRICAL SYSTEM
REPLACING THE STEER MOTOR (M3)

Special tools required

• Tool for the tie rod (part no. 822672).

Steer motor disassembly

Note: The following item numbers refer to Fig. 60.
1. Undo all connections from the steer motor.
2. Open the strain relief to remove the steering trans-
mission connector from the retaining plate (85) (on
the traction motor).
3. Disassemble the tie rod (1) using the special tool
(part no. 822672).
4. Lift the steer motor, complete with B bearing plate
and frame and field, from off the end cap (24).

Steer motor assembly

1. Apply grease type B or BB to the pinion (17) (see
page 23).
2. Fit the steer motor, complete with B bearing plate
and frame and field, onto the end cap (14).
3. Attach the tie rod (1) and using the special tool
(item no. 822672) torque it to 1.8 Nm.
4. Attach the drive system connector to the retaining
plate (85).
5. Screw on the strain relief firmly.
6. Connect the steer motor.
7. Test the steering.

ES/ET4000 Series
Rev. B
229
ELECTRICAL SYSTEM
REPAIRING CONTACTORS

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

Checking the coils

CAUTION
1. Using an ohmmeter measure the resistance be-
The use of other manufacturers' contactors can tween the connections on the coil (2).
damage the truck Note: If there is a freewheel diode between the con-
The original contactors are designed for Crown trucks. nections, desolder it on one side and then test the coil.
 Only use original Crown contactors as replace- Otherwise the results will be false.
ments.  If either an endless resistance or no resistance are
 Do not change the place or the angle where they recorded, the coil (2) is faulty and must be re-
are positioned and do not change the wiring. placed.

Checking the springs

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

4
1

Fig. 61 Example of a contactor

1 Spring
2 Coil
3 Contact (moving)
4 Contact (fixed)

Checking the contacts

1. Check the silver coating of the contacts (3,4).
 If the silver coating has worn to the extent that the
support material is visible, both contacts (3, 4)
must be replaced.
Note: The contacts (3, 4) are subject to natural wear
during operation. Blackened, tarnished or scarified

Rev.1 04/2009 ES/ET4000 Series

Rev. B
230
ELECTRICAL COMPONENTS
231
Notes:

232
 ELECTRICAL COMPONENTS
ES4000 MODEL

ES4000 Model

Access 1
EDS
FU1
FU1, FU2, FU3

BRK Access 2/3

M1
SV
HN

M2

PV

CA220
CA207
CA211
CA206

CA205 CA212

CA201

CA215

Fig. 62 ES 4000 Series Electrical Components

ES/ET4000 Series
Rev. B
233
ELECTRICAL COMPONENTS
ES4000 MODEL
0

CA208
Access 1
CA200
1

CA209

CA202
CA243

Mechanical Steering CA245

CA203

CA203
CA202
Electric steering

Fig. 63 ES 4000 Series Electrical Components

1 Adapter for key switch or relay K1

ES/ET4000 Series
Rev. B
234
 ELECTRICAL COMPONENTS
ET 4000 MODEL

ET 4000 Model

FU1

EDS

FU2, FU3, FU4

Access 2/3
BRK
M2
FU5

M2 SV
Access 5

HN

PS1

PV

Fig. 64 ET 4000 Series Electrical Components

ES/ET4000 Series
Rev. B
235
ELECTRICAL COMPONENTS
ET 4000 MODEL

SR2
1
Access 1

SR1

PLS1 PLS2

CA212

CA207 CA211

CA206

CA205
CA201

CA205
CA241
CA220 CA240

Fig. 65 ET 4000 Series Electrical Components

1 Adapter for key switch or relay K1

ES/ET4000 Series
Rev. B
236
 ELECTRICAL COMPONENTS
ET 4000 MODEL

CA200

CA218

CA219

Fig. 66 ET 4000 Series Electrical Components

1 Adapter for key switch or relay K1

ES/ET4000 Series
Rev. B
237
ELECTRICAL COMPONENTS
ET 4000 MODEL

CA208

CA209

CA242 CA244 CA246

CA245

PS1 CA215

ECR

CA202

CA203

Fig. 67 ET 4000 Series Electrical Components

ES/ET4000 Series
Rev. B
238
 ELECTRICAL COMPONENTS
PWS, FLS, ALM AND CHARGER OPTION

PWS, FLS, ALM and charger option

CA213

CA207 FLS

PWS

1
2

ALM
3

Fig. 68 Options

1 Charging indicator (LED) 2 Mains plug

3 Charging indicator plug connector 4 Charger

ES/ET4000 Series
Rev. B
239
ELECTRICAL COMPONENTS
INFOLINK® OPTION

InfoLink® option

CA204

CA252 CA250

CA253 CA251

CA254

Shock Sensor

Fig. 69 InfoLink

ES/ET4000 Series
Rev. B
240
BRAKE SYSTEM
241
Notes:

242
 BRAKE SYSTEM
COMPONENTS AND OPERATION

Components and Operation

The brake system on this truck consists of two compo-
nents:
• Service brake
• Parking brake

Service brake
The service brake is wear-free as the drive motor in
regenerative mode (EGen®) provides all the brake
power. The brake power is controlled by the traction
controller software.

Parking brake
The parking brake (electromechanical brake) is applied
only when:
• The truck is idle (automatically through the traction
controller).
• The Emergency Disconnect is pressed.
It acts as a parking brake and becomes an emergency
brake as soon as the Emergency Disconnect is pulled.
It is not used as a service brake and is therefore virtu-
ally wear-free.

ES/ET4000 Series
Rev. B
243
BRAKE SYSTEM
SERVICING THE PARKING BRAKE

Servicing the Parking Brake Troubleshooting

Servicing is limited to checking the air gap every 1000 Symptom: Parking brake does not release.
service hours.
Check the power supply
Measuring the air gap 1. Jack up the truck until the drive wheel is clear (see
page 21).
2. Attach a digital voltmeter (measuring range
>30 VDC) to the brake terminals.
Note: Do not pull the connections off the brake, the coil
must remain in the circuit.
1 3. Switch on the truck and apply the travel switch.
Check that 16 to 24 V is applied to the brake's elec-
trical connector.
 If there is no voltage supply, check the electrical
system.
 If at least 16V is displayed, proceed to step 4.

3 Checking the coil resistance

4. Switch off the truck, disconnect the battery and
prevent it from being switched on again.
5. Remove the electrical connection from the brake.
6. Using a precise digital ohmmeter measure the coil
2
resistance in the magnetic body and compare it
Fig. 70 Parking brake with the figures in the following table.

Preparation
4040 -MW 4040 -EF
1. Switch off the truck, disconnect the battery and
4040 -MF 4040 -EW
prevent the truck from being switched on again.
2. Take off motor compartment panel. Rrated(a) 13.3 Ω 10 Ω
3. Remove the dust shield ring (3).
Rmin(a) 12.7 Ω 9.56 Ω
4. Apply weak pressurized air to the abrasion.
5. Use a feeler gauge to measure the air gap between Rmax(a) 14 Ω 10.45 Ω
the brake lining (2) and the armature disk (1).
a. At 20°C
Repair the brake if the air gap > 0.5 mm. The air gap is
not adjustable. A wear part kit is available (see parts  If the coil resistance is within range, the mag-
catalog). netic coil is ok.
The wear part kit consists of the following:  If the coil resistance is out of range, the mag-
– Friction plate netic body is faulty. Replace the brake.
– Brake disk
– Elastic band and 2 screws to aid installation and
to secure during transport.

ES/ET4000 Series
Rev. B
244
 BRAKE SYSTEM
REPLACING THE PARKING BRAKE

Replacing the Parking Brake Parking brake assembly

Preparation
1 The brake is supplied pre-assembled. Two screws and
2 one elastic band serve as a transport safety mecha-
3 nism and assembly aid.
4

CAUTION
1
Do not remove the elastic band or the screws. The
1 brake will come apart without this transport safety
mechanism.

10
1. Place the brake on a work surface so that the elas-
tic band is facing up.
9

8 6 5
7

Fig. 71 Brake attached to the motor

Parking brake disassembly

Preparation B
1. Switch off the truck, disconnect the battery and
prevent the truck from being switched on again.
2. Jack up the truck until the drive wheel is clear (see
page 21).
Parking brake disassembly
5
3. Remove the panel.
4. Remove the connector from the brake.
5. Remove the dust shield ring (9, Fig. 71).
6. Remove the retaining ring (3).
Fig. 72 Brake transport safety mechanism
7. Remove the three brake mounting screws (1).
2. Remove the elastic band (B, Fig. 72) and put it to
8. Remove and dispose of the magnetic body (2),
one side. Do not throw it away!
carrier (4), brake disk (6), spacer sleeves (5) and
friction plate (7).

ES/ET4000 Series
Rev. B
245
BRAKE SYSTEM
REPLACING THE PARKING BRAKE

Removing the transport safety mechanism

1
2
3 WARNING
4
Fatal accidents can result from brake failure when
starting the truck for the first time
1 The brake will not work if the transport safety mecha-
nism is not removed.
1
 Remove the two transport safety mechanism
screws before operating the truck for the first time.
10

8 6 5
7

Fig. 73 Brake assembly

3. Remove the friction plate (7, Fig. 73), taking care
not to lose the spacer sleeves (5).
A
Fitting the carrier, brake disk and friction plate to
the motor
4. Remove the carrier (4) and push it onto the drive
shaft of the motor (8).
5. Secure the carrier (4) onto the drive shaft with the Fig. 74 Transport safety mechanism screws
retaining ring (3). 13. Remove the two screws from the transport retainer
6. Place the friction plate (7) in the correct position on (A, Fig. 74).
the bearing plate of the motor. 14. Attach the dust shield ring (9, Fig. 73).
7. Take out the brake disk (6) and remove the paper. 15. Restore the electrical connections.
8. Place the brake disk (6) on the carrier (4) on the
Operational check
motor.
16. Test the parking brake.
Fitting the brake body
9. Make sure the spacer bushings (5, Fig. 72) are
pushed up. Pull the elastic band (B, Fig. 72) pro-
vided over the three brake mounting screws to se-
cure them.
10. Position the brake so that it is correctly aligned with
the motor (8).
Note: The connector socket (10) for the power supply
must be back at the wire.
11. Insert the mounting screws (1), then cut through
the elastic band and dispose of it.
12. Torque the mounting screws to 10 Nm.

ES/ET4000 Series
Rev. B
246
 BRAKE SYSTEM
TESTING THE BRAKING DISTANCE

Testing the Braking Distance Note: Always select the speed in the table that is near-
est to the speed travelled.
Requirements  The braking distance recorded should always be
less than the figure in the table.
Carry out the test only on an uncoated, dry, level and
 If the braking distance is too long, faulty motor wir-
clean concrete surface.
ing or a faulty motor may be the cause (loose
The test route must be sealed off over a large area to power cables on the motor and controller, transi-
prevent unauthorised access. tion resistances etc.).
Performing the test Braking distance tables
Preparing the truck
Maximum braking distances ES 4000 -MW
1. Place the maximum rated load on the forks and or -EW
prevent it from slipping.
Note: If the maximum rated load is not available, the
test can also be performed without load. SPEED Maximum braking distance
(km/h) (m)
2. Lay down a marker to act as the measurement
starting point for the test route. 6.0 2.2
Calculating the braking distance 5.0 1.8
4.0 1.3

WARNING Maximum braking distances ET 4000 -MF

Risk of injury to third parties or -EF
M

The brake test requires you to concentrate fully on the

truck. As a result, persons running into the travel zone SPEED Maximum braking distance
could be easily hit and fatally injured. (km/h) (m)
 Use marker tape over a large area to block off the
test route. 9.0 3.3
 If necessary use assistants to secure critical points 8.0 2.9
along the route. 7.0 2.5
 Do not perform the test unless you have full control
over the test route.

1. Accelerate within the test route up to one of the

speeds listed in the corresponding table.
2. At the marker point (measurement starting point)
brake by changing direction.
3. Measure the braking distance.
4. Repeat steps 1 to 3 for the opposite travel direc-
tion.
Analysing the result
1. Calculate the maximum braking distance for the
speed travelled in the corresponding table.

ES/ET4000 Series
Rev. B
247
Notes:

248
STEERING
249
Notes:

250
 STEERING
REPAIRING THE TILLER HANDLE

Repairing the Tiller Handle

Fig. 75 Main tiller handle components

1 Switch unit 4 Tiller tube

2 Hand grip 5 Upper shell
3 Lower shell

ES/ET4000 Series Rev. 1 05/2014

Rev. B
251
STEERING
REPAIRING THE TILLER HANDLE

Replacing the tiller handle shells

2 2

WARNING
Accidental truck movement can cause injury
A powered up truck with a connected battery can move
suddenly when you are working on it.
You should therefore carry out the following safety pro-
cedures before starting any operations on the truck:
 Lower the forks to the ground. 3
 Switch the truck off. 3
 Disconnect the battery.
 Prevent the truck from being switched on again.
 Jack up the truck until the drive wheel is clear of the
ground (see page 21).

Shell removal

Fig. 77 Switch unit removal

2. Press the thumb markings (3) or pull on the thumb-
wheels (2).
 The switch unit will slide up out of the bottom shell.
3. Remove the tiller wire harness plug connections
and the horn buttons from the PC boards.

1 4

Fig. 76 Shell removal

1. Remove the screws (1).

Fig. 78 Cover removal

4. Lever off the covers (4) on each hand grip.

Rev. 1 05/2014 ES/ET4000 Series

Rev. B
252
 STEERING
REPAIRING THE TILLER HANDLE

5 7

8
7
Fig. 79 Horn switch disassembly
5. Carefully push the horn switch (5) in and pull it off 9
the grip.
6. Remove the connector (5) from the horn switch.

Fig. 81 Shell removal

8. Remove the screws (7) and (9).
9. Remove the shells (8).

Shell assembly
Note: Assembly of the shells is the reverse order of
disassembly. Take care not to damage the wiring.
1. After assembly, connect the battery and test all the
functions of the tiller handle.
6
Replacing the switch unit
The switch unit contains the:
Fig. 80 Grip removal
• Brake switch
7. Remove the screws (6) and pull off the grips. • Travel switch / traction potentiometer
• “Rabbit/turtle” toggle module
• Main PC board
Hydraulic PC board (lift / lower switches)
• Initial lift switch
Note: Replacing any of these components requires the
entire switch unit to be replaced.

ES/ET4000 Series Rev. 1 05/2014

Rev. B
253
STEERING
REPAIRING THE TILLER HANDLE

Switch unit removal Switch unit assembly

Note: Assembly is the reverse of disassembly. Note
the following:
1. Re-connect the tiller wire harness and horn wiring
to the PC boards.
2. After assembly, connect the battery and test all the
functions of the tiller handle.

Replacing the “rabbit/turtle” toggle

module
There are no parts of the toggle module (HSS) that can
be repaired. It must be replaced as a complete unit.
1
CAUTION
Use of the wrong toggle module can damage the
truck
1 The module is available as either a standard or a cold
store version.
Fig. 82 Shell removal
 Make sure you use the right module.

1. Remove the screws (1).

Toggle module removal
2 2

3
1
3

Fig. 84 “Rabbit/turtle” toggle module

1. Remove the switch unit (see page 254).
Fig. 83 Switch unit removal 2. Remove the screws (2) and take off the toggle
module (1).
2. Press the thumb markings (3) or pull on the thumb-
wheels (2).
 The switch unit will slide up out of the bottom shell.
3. Remove the tiller wire harness plug connections
and the horn buttons from the PC boards.

Rev. 1 05/2014 ES/ET4000 Series

Rev. B
254
 STEERING
REPAIRING THE TILLER HANDLE

Toggle module assembly Hydraulic PC board assembly

Note: Assembly is the reverse of disassembly. Note Note: Assembly is the reverse of disassembly. Note
the following: the following:
1. Re-fit the switch unit (see page 254). 1. Re-fit the switch unit (see page 254).
2. After assembly, connect the battery and test all the 2. After assembly, connect the battery and test all the
functions of the tiller handle. functions of the tiller handle.

Replacing the tiller handle PC Main PC board removal

boards
The main PC board (Main PCB) and the hydraulic PC
board (HYD PCB) are located in the tiller handle. The
main PC board is the larger of the two. Neither of the
PC boards contains components that can be repaired;
they must be replaced as complete units.

CAUTION
Use of the wrong PC board can damage the truck
This hydraulic and main PC boards are available as ei-
ther standard or cold store versions.
 Make sure you use the right PC boards.

Hydraulic PC board removal

2 1

Fig. 86 Main PC board removal

1. Remove the switch unit (see page 254).
2. Remove the connector of the potentiometer from
the main PC board.
3. Remove the screws (1).
4. Remove the brake switch connector from the main
PC board (2).
1 5. Remove the main PC board.
Note: If you cannot reach the connector on the main
2 PC board, remove the thumbwheels, the bottom cover
and the upper shell cover (see "Replacing the Traction
Fig. 85 Hydraulic PC board removal Potentiometer" on page 256).
1. Remove the switch unit (see page 254). Main PC board assembly
2. Remove the screws (2) from the hydraulic PC Note: Assembly is the reverse of disassembly. Note
board. the following:
3. Remove the hydraulic PC board (1). 1. Re-fit the switch unit (see page 254).
2. After assembly, connect the battery and test all the
functions of the tiller handle.

ES/ET4000 Series Rev. 1 05/2014

Rev. B
255
STEERING
REPAIRING THE TILLER HANDLE

Replacing the traction

potentiometer 6
There are no parts of the traction potentiometer (POT
travel switch) that can be repaired. It must be replaced
as a complete unit.

CAUTION
Use of the wrong potentiometer can damage the
truck
The traction potentiometer is available as either a 7
standard or a cold store version.
 Make sure you use the right potentiometer.

Traction potentiometer removal

1 1
2 7

Fig. 88 Cover removal

6. Remove the screws (7).
7. Remove the cover (6).
3

5 11

8
4
10
Fig. 87 Thumbwheel removal
1. Remove the switch unit (see page 254).
2. Remove the screws (3).
Note: Take care not to lose the slide bearings (2) when
removing the thumbwheels (1).
3. Extract the thumbwheels (1).
4. Remove the screws (4) while holding on to the low- 9
ering switch cap (5).
Fig. 89 Traction potentiometer removal
5. Remove the lowering switch cap (5).
8. Remove the screws (11).
9. Remove the connectors from the PC boards.
10. Remove the traction potentiometer (8) from the
square axle.

Rev. 1 05/2014 ES/ET4000 Series

Rev. B
256
 STEERING
REPAIRING THE TILLER HANDLE

Traction potentiometer assembly

Note: Assembly is the reverse of disassembly. Note 6
the following:
1. Fill the socket (10) with grease (part no. 053002-
005).
Note: The socket (10) must only be filled with grease
(part no. 053002-005). Do not use any other type of
grease.
2. Re-fit the switch unit (see page 254).
3. After assembly, connect the battery and test all the
functions of the tiller handle. 7

Replacing the brake switch (BRS)

Remove the brake switch (BRS)

1 1
2
7

Fig. 91 Cover removal

6. Remove the screws (7).
3 7. Remove the cover (6).

5
9

10
4

8
Fig. 90 Thumbwheel removal
1. Remove the switch unit (see page 254).
2. Remove the screws (3).
Note: Take care not to lose the slide bearings (2) when 11
removing the thumbwheels (1).
3. Extract the thumbwheels (1). 12
4. Remove the screws (4) while holding on to the low-
ering switch cap (5).
5. Remove the lowering switch cap (5).
Fig. 92 Removing the brake switch
8. Remove the screw (8).
9. Remove the switch bypass (12).
10. Remove the screws (11).
11. Disconnect the micro switch (9) from the main PC
board.
12. Take off the brake switch (10).

ES/ET4000 Series Rev. 1 05/2014

Rev. B
257
STEERING
REPAIRING THE TILLER HANDLE

BRS switch assembly

Note: Assembly is the reverse of disassembly. Note
the following:
1. Fill the socket of the micro switch cable (9) with
grease (part no. 053002-005).
Note: The socket should only be filled with grease (part
no. 053002-005). Do not use any other type of grease.
2. Re-fit the switch unit (see page 254).
3. After assembly, connect the battery and test all the
functions of the tiller handle.

Replacing the grips and horn switch

Note: Refer to page 252 for the removal and assembly
of the grips and horn switch.

Rev. 1 05/2014 ES/ET4000 Series

Rev. B
258
 STEERING
REPAIRING TILLER HANDLE RETURN SPRINGS

Repairing Tiller Handle Return

Springs 7
If the return spring bias spring force reduces over time,
the pre-tension can be adjusted in several stages. Re-
turn springs whose pre-tension cannot be increased
any further must be replaced.

6
WARNING
Accidental truck movement can cause injury
A powered up truck with a connected battery can move 4
suddenly when you are working on it.
You should therefore carry out the following safety pro-
cedures before starting any operations on the truck:
 Lower the forks to the ground.
 Switch the truck off.
 Disconnect the battery.
 Prevent the truck from being switched on again. 5
 Jack up the truck until the drive wheel is clear of the Fig. 94 Pre-tension adjustment
ground (see page 21).
4 Return spring
5 Spacer ring
Removing the covers 6 Axle
7 Dowel pin

2. Set the control handle upright.

1
3. Fix the axle (6) using a fork wrench.
 This prevents the return springs (4) from discharg-
ing when the dowel pin (7) is deflected.
4. Remove the dowel pin (7).
5. Turn the axle (6) 90 degrees with the fork wrench.
2  This will tension the springs.
6. Strike the dowel pin (7) in.
 This increases the pre-tension of the return springs
(4).
7. Make sure the return springs have sufficient pre-
Fig. 93 Removing the covers tension. The control handle should move automat-
1. Loosen two screws (1) and push the panel (2) up. ically to the horizontal position.
 The control handle springs are now accessible. 8. If necessary increase the pre-tension of the return
Note: Assembly is the reverse of disassembly. springs further.
9. After adjusting, grease the return springs (4) (for
Return spring pre-tension lubricant see page 23).
adjustment 10. Assemble all the panels.
Note: The axle (6) contains 2 holes for the dowel pin 11. Test the truck's brakes.
which are offset by 90 degrees. This allows you to ad-
just the pre-tension of the return springs by 90 degrees
respectively by turning the axle.

ES/ET4000 Series
Rev. B
259
STEERING
REPAIRING TILLER HANDLE RETURN SPRINGS

Replacing the return springs Pre-assembling the return springs

1. Push the return springs (4) with the spacer ring (5)
onto the shortened axle (8). The inner, angled end
of the return springs should enter the groove of the
WARNING shortened axle (8) in the process.
Pre-tensioned springs can cause injury Note: Note that the shortened axle (8) moves with the
Pre-tensioned springs can snap off with extreme force. axle (6). The return springs are pushed onto the axle
 Be particularly careful when handling springs and (6) at the same time. When inserting the axles make
wear protective goggles. sure the grooves are positioned accordingly (see Fig.
95).
Return spring assembly
Return spring removal
2. Insert the pre-assembled return springs (4) with
1. Remove the cover (see page 259).
the control handle into the control handle knuckle
2. Set the control handle upright. (9).
3. Remove the dowel pin (7). 3. Insert the axle (6) from the left hand side and make
 The axle (6) turns and the return springs (4) are sure that the position of the groove corresponds to
discharged. the groove of the shortened axle (8).
4. Set the control handle all the way down to fully dis- 4. Strike in the axle (6) carefully and drive out the
charge the return springs (4). shortened axle (8).
Note: If the axle is jammed, turn it approx. 20 degrees  The return springs are pushed onto the axle (6) in
clockwise with a fork wrench in order to discharge the the process.
return springs.
Return spring pre-tension adjustment
5. Drive out the axle (6) from the right hand side.
5. Set the control handle upright.
6. Remove the return springs (4).
6. Starting from the neutral position of the return
Return spring assembly springs, turn the axle (6) 90 degrees using a fork
wrench and increase the pre-tension of the return
springs.
7 4 7. Strike the dowel pin (7) in.
8. Make sure the return springs have sufficient pre-
tension.
 The control handle should move automatically to
6 8 the upright position.
9. If necessary increase the pre-tension of the return
springs further.
10. After adjusting, grease the return springs (4) (for
lubricant see page 23).
11. Assemble all the panels.
12. Test the truck's brakes.
9
Fig. 95 Return spring assembly
8 Shortened axle
9 Control handle knuckle

Tools required:
Shortened axle (8) on which the return springs can be
pre-assembled. The axle must be shorter than 119 mm
so that it can be inserted with the control handle in the
control handle knuckle (9).

ES/ET4000 Series
Rev. B
260
 STEERING
MECHANICAL STEERING

Mechanical Steering Repairing the steering transmission

WARNING
Accidental truck movement can cause injury
A powered up truck with a connected battery can move
suddenly when you are working on it.
You should therefore carry out the following safety pro-
cedures before starting any operations on the truck:
 Lower the forks to the ground.
 Switch the truck off.
 Disconnect the battery.
 Prevent the truck from being switched on again.
 Jack up the truck until the drive wheel is clear of the
ground (see page 21).

Dismantling the steering transmission

1 1. Dismantle the steering transmission in accordance
with Figure 96.

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

2. Clean the components and check for damage

3. Replace any faulty components.
Assembling the steering transmission
1. Assemble the steering transmission in accordance
with Figure 96.
2. Apply Loctite® 243 to the 4 screws and torque
them to 14 - 16 Nm.
3. Torque the 2 nuts (2) to 45 Nm.

Fig. 96 Steering transmission

ES/ET4000 Series
Rev. B
261
STEERING
MECHANICAL STEERING

Setting straight-ahead travel

After replacing one or both chains the steering must set
so that the truck travels straight ahead when the tiller is
in the centre position.

Fig. 97 Disconnecting the steering in the centre position

3 Tube auxiliary device 25x2mm L = 30 mm
4 Flat steel auxiliary device 20x90x4 mm

Centring the steering

1. Open the link of the top and bottom steering
chains.
2. Disconnect the tiller with the auxiliary device (3).
 The tiller is now in the centre position.
3. Place the auxiliary device (4) by the hub of the
chassis and turn the drive unit so that the transmis-
sion is in contact with the auxiliary device (4).
 The drive wheel is in the centre position.
4. Fit the top and bottom steering chains.
5. Insert the links from the top and insert the spring or
cotter pin from the bottom.
6. If required, spray the chain with type H oil (see
page 24).
Checking and adjusting the chain tension
1. Manually push the chain in the middle of the sec-
tion that is not supported by the gear.
 If the chain can be pushed through approx.
2-3 mm, the chain tension is ok.
 Re-tension the chain if it is too loose.

ES/ET4000 Series
Rev. B
262
LIFTING MECHANISM
263
Notes:

264
 LIFTING MECHANISM
CHECKING THE ASSEMBLED MAST

Checking the Assembled Mast Checking the end stops

Note: It is not uncommon for a new mast to appear as

if it's flaking or peeling. This appearance indicates that
the rollers are seating on the mast channel and this is
WARNING
considered normal. Eventually this condition will disap- Missing end stops can cause accidents
pear. The grease applied to the mast channels retains If the end stops are missing, a mast stage can be
these particles. pushed out of the channel and drop down. You or other
people could be fatally injured.
 End stops must always be in place and properly se-
WARNING cured.
Risk of trapping and severing limbs
Unsecured components can sever limbs and cause fa- 1. Check the end stops for wear and make sure they
tal injuries. are properly secured.
When carrying out work on the mast and the attach- Replace any faulty or missing end stops.
ments:
 Always block the mast stages and attachments to
prevent them from accidentally moving.
 Make sure the equipment used has sufficient
strength.

Checking the roller tracks

1. Clean the mast channels.
2. Check the roller track wear in the mast channels.
 There should only be wear in the rear section of
the I beam where the rollers slide.
 If nicks or cuts are visible at the side of the roll-
ers approx. 10 mm above the channel face, the
mast rollers will have to be adjusted.
Checking the mast verticality
1. Extend the mast almost as far as it will go.
 It should be vertical and should not lean to the
left or the right. All mast stages should be
aligned.
 If a tilting condition exists, it is a sign that the
shimming is too loose or unbalanced and will
need to be adjusted.
Checking the pulleys, hoses and cables
1. Check all pulleys for damage and freedom of
movement.
2. Check hoses and wiring for any signs of chafing.

ES/ET4000 Series
Rev. B
265
LIFTING MECHANISM
CHECKING THE FORK HEIGHT

Checking the Fork Height

Fig. 98 Measuring the fork height

Measuring the fork height
1. Fully lower the forks.
2. Place a steel ruler over both forks at the load wheel
pivot points.
3. Calculate dimension X. To do this, measure the
height of the forks from the floor to the bottom of
the steel ruler.
 If X < 90mm, the setting is ok.
 If X  mm, adjust the fork height using the
chain anchor.

ES/ET4000 Series
Rev. B
266
 LIFTING MECHANISM
MAST REMOVAL AND ASSEMBLY

Mast Removal and Assembly 3. Remove the battery.

4. Undo and secure all the electric wires attached to
the mast so that they will not be damaged when the
mast is removed.
WARNING
Risk of trapping and severing limbs
Unsecured components can sever limbs and cause
fatal injuries.
When carrying out work on the mast and the attach-
ments:
 Always block the mast stages and attachments to
prevent them from accidentally moving.
 Make sure the equipment used has sufficient
strength.

WARNING
High pressure hydraulic oil can cause severe
injury 1
Whenever a high pressure hydraulic oil enters the skin
it must be treated as a medical emergency.
Seek medical assistance even if the skin appears nor-
mal at first.
To avoid accidents:
 Depressurise the hydraulic system before opening
any sections of it.
 Tighten all connections before pressurising the sys-
tem. Fig. 99 Hydraulic coupling
 Keep hands and body away from pressurised fluid. 5. Place a flat tray underneath the coupling (1) of the
 Always trace leaks with a piece of paper or card- hydraulic line.
board.

CAUTION
Improper tools will destroy the coupling
CAUTION  Always use the tool with part number 833158.
Health risk  Do not use the tool as a lever
Cleaning agents, lubricants and consumables can  Note the instructions for using this tool on page 269.
damage your health.
 Observe the manufacturer’s safety instructions 6. Open the coupling with tool part no. 833158 (see
when handling solvents and lubricants. page 269).
7. Seal the ports and remove any oil that has es-
caped.
Mast disassembly 8. Strap load slings around the cross members of all
Preparation mast stages and gently tension them with a crane
1. Remove the fork carriage (see page 277). (minimum capacity 1000 kg).
2. Activate lowering for 10 seconds.
 The hydraulic system is depressurised.

ES/ET4000 Series
Rev. B
267
LIFTING MECHANISM
MAST REMOVAL AND ASSEMBLY

Mast disassembly Mast assembly

Mast assembly
1. Assemble the mast in the reverse order of disas-
sembly.
2 2
2. Between the mast and the chassis re-assemble
the same number and thickness of shims on the
same sides as previously removed.
3. Torque the mast nuts (2, Fig. 100) to 340 - 380 Nm
Final tasks
1. Bleed the hydraulic system (see page 51).
2. Carry out a lowering plumb test (see page 278).

Fig. 100 Mast nuts

1. Remove the mast nut (2).

Fig. 101 Mast bolt head

2. Push the mast bolts (3) into the battery compart-
ment.
 The mast is now clear.
3. Carefully lift the mast up from out of the chassis
and place it on a surface of pallets or secure tres-
tles.
Note: Store any shims between the mast and chassis
in such a way that they can be installed again in the
same thickness and on the same side when the mast
is re-assembled.

ES/ET4000 Series
Rev. B
268
 LIFTING MECHANISM
CORRECT USE OF TOOL 833158

Correct Use of Tool 833158 CAUTION

Correct use of tool 833158 Pulling or levering with the tool can cause damage
to the coupling
 Do not use the tool as a lever
 Do not pull on the tool. Pull the hose on the connec-
2 tor out of the coupling.
1
2. Leave the tool in this position.
3. Pull the hose on the connector out of the coupling.
 The plug connection is now released.
4. Push the tool off the flange.
1

2
3

3
Fig. 102 Opening the hydraulic coupling
1. Push the tool (2, Fig. 102) onto the flange (1) of the
connector.
 The flange is pushed down and a red O ring (3)
becomes visible.
 The plug connection is now released.

ES/ET4000 Series
Rev. B
269
LIFTING MECHANISM
REPLACING THE FORK CARRIAGE ROLLERS AND ADJUSTING THE SLACK

Replacing the Fork Carriage Adjusting the fork carriage roller clearance
Slack on the fork carriage rollers is compensated by
Rollers and Adjusting the Slack using shims. The shims come in thicknesses of
Removing the fork carriage 0.5 mm, 1.0 mm and 1.5 mm.

1. Remove the fork carriage (see page 277). Note: Try to use as few shims as possible. Several thin
shims should be replaced by one thick one. Note that
Replacing the fork carriage rollers the number of shims required on the left and right
fork carriage rollers should be the same for each
mast stage. Refer to Figure 109 on page 276.
1
1. Attach lifting gear (min. capacity 150 kg) to the fork
carriage.
2. Slowly pull the fork carriage up as far as the stop.
 If the fork carriage jams, remove it again and re-
move one shim (with the least thickness) from
the stub shafts on the left or right-hand side re-
spectively. Repeat step 2.
 If the fork carriage runs through to the stop, use
2 a pry bar to press the fork carriage as far as the
3
stop in the opposite mast section. Measure the
slack. It should not exceed 0.5 mm. If it is
4 greater, remove the fork carriage and add shims
to the stub shaft on the left or right sides. Repeat
Fig. 103 Fork carriage rollers on the fork carriage step 2.
1 Fork carriage Fitting the Lift Chain
2 Shims 1. Fit the lift chains.
3 Fork carriage roller
4 Stub shaft

Note: Discard the shims under the fork carriage rollers

in such a way that the same number and thickness of
shims can be re-assembled later in the same position.
1. Remove the fork carriage rollers (3) and shims (2).
2. Clean the shims and stub shaft (4) on the fork car-
riage. Now apply grease (type B/BB).
3. Check the fork carriage rollers can run smoothly
and check for wear.
 Replace any damaged fork carriage rollers.
 Re-fit any undamaged fork carriage rollers.
4. Clean and lubricate the running surfaces of the fork
carriage in the mast channel (type B/BB)
Assembling the fork carriage rollers
1. Push the shims and fork carriage rollers onto the
stub shafts.
Note: Restore the shims back to the same position us-
ing the same number and thickness as found during
removal.
Fork Carriage Assembly
1. Assemble the fork carriage (see page 277), but do
not yet refit the lift chains.

ES/ET4000 Series
Rev. A
270
 LIFTING MECHANISM
REPAIRING THE MAST

Repairing the Mast

Repairs to the various mast types are restricted to re-
WARNING
placing the mast rollers and repairing the chain an- Accidental truck movement can cause injury
chors and lift chains. A powered up truck with a connected battery can move
The truck can be equipped with one of the following suddenly when you are working on it.
masts: You should therefore carry out the following safety pro-
• TL mast (Simplex) cedures before starting any operations on the truck:
• TF mast (Duplex)  Lower the forks to the ground.
• TT mast (Triplex)  Switch the truck off.
 Disconnect the battery.
TL Mast  Prevent the truck from being switched on again.
The TL mast consists of a static outer mast (1st mast
stage) which contains an inner mast (the 2nd mast
stage).
They are supported by two embedded mast rollers. WARNING
The 2nd mast stage is raised by a centrally located lift
cylinder. The fork carriage runs on four rollers in the Lifting gear failure can cause accidents
2nd mast stage. Note the minimum capacity for the lifting gear when-
ever carrying out work on the mast.
The fork carriage is raised indirectly by a chain running
on the roller secured to the inner mast.

TF mast
The TF mast consists of a static outer mast (1st mast WARNING
stage) which contains an inner mast (the 2nd mast Risk of trapping and severing limbs
stage). Unsecured components can sever limbs and cause fa-
They are supported by embedded mast rollers. The in- tal injuries.
ner mast is raised by two mast cylinders. The fork car- When carrying out work on the mast and the attach-
riage is mounted on four rollers; the free lift cylinder is ments:
connected to the inner mast.  Always block the mast stages and attachments to
The fork carriage is raised by a chain running across prevent them from moving accidentally.
the free lift cylinder in a return roller.  Make sure the equipment used has sufficient
Due to the large diameter of the free lift cylinder, at first strength.
only the fork carriage is raised in the 2nd mast stage.
The overall height of the truck remains unchanged
when the fork carriage is raised within free lift. Once the
free lift cylinder has extended as far as the stop, the
mast cylinders take over the task of completing the lift-
ing operation.

TT mast
Designed in principle in the same way as a TF mast,
but contains three mast stages.

ES/ET4000 Series
Rev. A
271
LIFTING MECHANISM
REPAIRING THE MAST

6.
WARNING
High-pressure hydraulic oil can cause severe in-
jury
Whenever a high pressure hydraulic oil enters the skin
it must be treated as a medical emergency.
Seek medical assistance even if the skin appears nor- 1
mal at first. 2
To avoid accidents:
 Depressurise the hydraulic system before opening
any sections of it.
 Tighten all connections before pressurising the sys-
tem.
 Keep hands and body away from pressurized fluid.
 Always use a piece of paper or cardboard to trace
leaks.

Fig. 104 Attaching load slings

Mast disassembly
Note: The mast rollers are replaced in the same way 7. Place the load slings around the centre of the top
for all mast types. Note that the hydraulic lines and con- cross member on the inner mast stage and gently
nections connections differ slightly. tension them with the lifting gear.
The minimum capacity requirements for the load Mast disassembly
handling equipment and lifting gear are:
• TL mast 2100 mm: 300 kg
• TF mast 2600 mm: 500 kg
• TT mast: 800 kg
• Fork carriage: 150 kg
1
• Battery: see details on truck battery
Preparation
1. Remove the fork carriage (see page 277).
2. Remove the battery.
3. Disassemble the mast guard (see page 280).
4. Disconnect the hydraulic line from the mast. Seal
any open ports with dummy plugs.
Fig. 105 Mast nuts
5. Remove the lift limit switch. Remove any other ca-
bles routed to the mast. 1. Remove the mast nut (1).
2. Push the mast bolts into the battery compartment.
 The mast is now clear.
3. Remove the mast bolts and shims.
Note: Shims are located between the mast and the
chassis. Mark and store the shims so that their position
can be identified. The same number and thickness of
shims will have to be restored on assembly.
4. Check again that all the lines have been discon-
nected from the mast and cannot be damaged
when the mast is raised.

ES/ET4000 Series
Rev. A
272
 LIFTING MECHANISM
REPAIRING THE MAST

5. Carefully raise the mast and place the back of the

mast on a suitable base.

Mast assembly

Fig. 106 Torque the mast bolts

Mast assembly
1. Assembly is the reverse of disassembly.
Note: Re-assemble the shims in the same position, us-
ing the same number and thickness as found during
disassembly. Torque the mast attachment bolts (1) to
340 - 380 Nm.

Final tasks
Final tasks
1. Assemble the fork carriage (see page 277).
1. Install the mast guard.
2. Bleed the hydraulic system (see page 51).
3. Flush the hydraulic system (see page 53).
4. Test the lift limit switch (LMS).
5. Perform a drift test (see page 54).
6. Carry out a lowering plumb test (see page 278).

ES/ET4000 Series
Rev. A
273
LIFTING MECHANISM
REPLACING THE MAST ROLLERS AND ADJUSTING THE SLACK

Replacing the Mast Rollers and Note: Restore the shims back to the same position us-
ing the same number and thickness as found during
Adjusting the Slack removal.
Note: The adjustment is outlined using the example of Calculating the mast roller slack
a TL/TF mast. The adjustment is identical for a TT 1. Attach load slings to the 2nd mast stage and using
mast, only the 3rd mast stage needs to be adjusted as a crane insert it into the 1st mast stage.
well.
2. On the flat mast pull the 2nd mast stage apart so
that approximately the maximum lift height is
reached.
WARNING
Lifting gear failure can cause accidents
 Note the minimum capacity for the lifting gear
whenever carrying out work on the mast.

Slack on the mast rollers is compensated by using

shims. The shims come in thicknesses of 0.5 mm,
1.0 mm and 1.5 mm.
Note: Try to use as few shims as possible. Several thin 1
shims should be replaced by one thick one. Note that
the number of shims required on the left and right
mast rollers should be the same for each mast
stage. Refer to Figure 109 on page 276.
Preparation
1. Remove the fork carriage (see page 277). Fig. 107 Pressing the mast stage into the section
2. Remove the lift cylinder (see page 300 and follow-
3. Using a suitable lever push the mast roller of the
ing).
2nd mast stage into the channel of the 1st mast
3. Remove the mast (see page 267). stage.
Removing the 2nd mast stage
1. Attach load slings to the 2nd mast stage and using
a crane pull it out of the 1st mast stage and put it to
one side.
Replacing the mast rollers
1. Remove the mast rollers and shims.
Note: Discard the shims under the mast rollers in such
a way that they can be re-assembled later in the same
position, using the same number and thickness.
2
2. Clean the shims and stub shaft on the fork car-
riage. Now apply grease (type B/BB).
3. Check the mast rollers can run smoothly and check
for wear.
 Replace any damaged mast rollers.
 Re-use any undamaged mast rollers. Fig. 108 Calculating the slack
4. Clean and lubricate the running surfaces of the fork
4. Using a feeler gauge or the relevant number of
carriage in the mast channel (type B/BB)
shims, calculate the slack between the mast rollers
Mast roller assembly and the stub shafts.
1. Push the shims and mast rollers onto the stub
shaft.

ES/ET4000 Series
Rev. A
274
 LIFTING MECHANISM
REPLACING THE MAST ROLLERS AND ADJUSTING THE SLACK

Adjusting the mast roller slack

1. Attach load slings to the 2nd mast stage and using
a crane pull it out of the 1st mast stage and put it to
one side.
2. Use the same number of shims on one mast side
of the 1st mast stage as the 2nd mast stage (see
Fig. 109).
3. Attach load slings to the 2nd mast stage and using
a crane insert it into the 1st mast stage.
4. Check that the slack is as little as possible by man-
ually moving the mast along its entire length.
Note: Adjust so that there is as little slack as possible.
When you move the mast stage manually there should
be no point at which it moves sluggishly.
5. If necessary, remove the 2nd mast stage and cal-
culate and adjust the slack.

ES/ET4000 Series
Rev. A
275
LIFTING MECHANISM
REPLACING THE MAST ROLLERS AND ADJUSTING THE SLACK
.

(1) (2)

(2) (1)

(1) (2)
(1) (2)

(2) (1)

(1) (2)

(1) (2)

Figures in brackets indicate the number of shims to be positioned. Note that the same number of shims
must always be used on any side of the mast

Fig. 109 Distributing the shims on the mast rollers

ES/ET4000 Series
Rev. A
276
 LIFTING MECHANISM
FORK CARRIAGE ASSEMBLY AND REMOVAL

Fork Carriage Assembly and Removing the fork carriage with the
Removal TF and TT masts
Removing the fork carriage
1. Lower the fork carriage onto a pallet.
WARNING
2. Remove the chain pins from the fork carriage.
Risk of trapping and severing limbs
3. Activate lifting. Raise the mast until the fork car-
Unsecured components can sever limbs and cause fa-
riage is clear.
tal injuries.
When carrying out work on the mast and the attach- 4. Keep the mast stages in this position using a lifting
ments: device.
 Always block the mast stages and attachments to 5. Remove the pallet with the fork carriage.
prevent them from accidentally moving.
6. Lower the mast stage(s) onto suitable hard
 Make sure the equipment used has sufficient
wooden blocks.
strength.
7. Disconnect the battery. Secure the truck to prevent
it from being switched on again.
8. Remove the fork carriage.
WARNING
Assembly
High-pressure hydraulic oil can cause severe in-
jury Assembly is the reverse of disassembly. Now adjust
Whenever a high pressure hydraulic oil enters the skin the chain tension.
it must be treated as a medical emergency.
Seek medical assistance even if the skin appears nor- Removing the fork carriage with a
mal at first. TL mast
To avoid accidents:
Removing the fork carriage
 Depressurise the hydraulic system before opening
any sections of it. 1. Disconnect the battery. Secure the truck to prevent
it from being switched on again.
 Tighten all connections before pressurising the sys-
tem. 2. Secure the fork carriage with load belts and a lifting
device.
 Keep hands and body away from pressurized fluid.
 Only trace leaks with a piece of paper or cardboard. 3. Remove both chain pins from the lift chain recepta-
cles on the fork carriage.
4. Remove the stop screws for the fork carriage at the
top of the mast stage.
CAUTION 5. Pull the fork carriage up out of the mast stage and
Health risk place it on a pallet.
Cleaning agents, lubricants and consumables can
damage your health. Assembly
 Observe the manufacturer’s safety instructions Assembly is the reverse of disassembly. Now adjust
when handling solvents and lubricants. the chain tension.

ES/ET4000 Series
Rev. A
277
LIFTING MECHANISM
LOWERING PLUMB TEST AND ADJUSTING THE MAST TILT

Lowering Plumb Test and 5. Drop the lowering plumb.

 If the lowering plumb is outside of the rectangle,
Adjusting the Mast Tilt the mast tilt must be adjusted.
The lowering plumb test checks the mast tilt in the lon-  The lowering test is successful if the lowering
gitudinal and lateral axes. plumb is within the rectangle you have drawn.
To ensure the stability of the truck, the mast deviation
from the vertical should lie within a narrow tolerance
Adjusting the Mast Tilt
range. Note: Generally speaking, longitudinal axis deviations
The lowering plumb test must be carried out after re- can only occur when the mast has been replaced and
placing: the load wheels were extremely worn. In such cases
replace the load wheels before adjusting the mast tilt.
• Drive wheel
• Castor wheel Adjusting the longitudinal axis mast tilt
• Load wheels 1. Secure the mast with lifting gear.
• After removing and assembling the mast 2. Remove the mast attachment bolts.
3. Add or remove spacers between the mast and
Requirements chassis.
• A test load corresponding to the maximum capacity 4. Torque the mast attachment bolts to 340 - 380 Nm.
of the truck at maximum height. See truck capacity 5. Carry out the lowering plumb test.
data plate.  If the longitudinal axis setting is still out of range,
• A level surface. The surface is considered level if repeat the setting.
the height difference at the wheel contact points is  If the longitudinal axis setting is in range but the
less than 1 mm. lateral axis setting is not, adjust the lateral axis
mast tilt.
Preparing the lowering plumb test Adjusting the lateral axis mast tilt
Preparing the lowering plumb test
1. Park the truck with the suitable test load on a level 1
surface. 2
2. Raise forks to approximately 300 mm.
3. Attach the lowering plumb to the back of the fork
carriage and let it swing to and fro.
4. Draw a 20 x 50 mm rectangle and its centre point
on a piece of cardboard.

Lowering plumb test 6

Lowering plumb test
3
5
1. Push the cardboard underneath the lowering
plumb and align the centre point of the rectangle 4
with the lowering plumb.
Note: The long side of the rectangle should be facing
Fig. 110 Castor wheel
the longitudinal axis of the truck.
2. Attach the rectangle to the floor using adhesive The lateral axis mast tilt is determined by the height of
strips. the castor wheel.
3. Extend the mast until it is just before the limit stop. Note: When you adjust the lateral axis mast tilt you af-
fect the longitudinal axis slightly.
4. Extend the string of the lowering plump until it is
just above the ground. 1. Loosen the screw (4).
2. Loosen the counternut (6) and using the screw (5)
slightly loosen the clamping of the castor wheel as-
sembly (3) in the chassis (2).

ES/ET4000 Series
Rev. B
278
 LIFTING MECHANISM
LOWERING PLUMB TEST AND ADJUSTING THE MAST TILT

3. Using the adjusting screw (1) set the height of the

castor wheel so that the lowering plumb lies within
the 20 x 50 mm rectangle.
4. Tighten the screw (4).
5. Fix the screw (5) with the counternut (6).
Note: The screw (5) must not contact the opposite
bracket of the chassis.

ES/ET4000 Series
Rev. B
279
LIFTING MECHANISM
REPLACING THE MAST GUARD

Replacing the Mast Guard Installing the mast guard

Mast guards fitted to the mast made of transparent Installing the mast guard
plastic or metal grill prevent people from reaching 1. Position the shim.
through the raised mast. Note: The angled surface should be facing up and in
They protect against the risk of severing from lowering the direction of the tiller.
machine parts. 2. Fit the attachments.
Note: In this manual the term mast guard is used syn- 3. Torque the domed cap nuts to 40 - 45 Nm, torque
onymously for metal mast grill. the bolts to 10 - 15 Nm.
The mast guards or grilles are a safety mechanism.
Do not operate the truck without mast guards.
Note: The versions will differ depending on the lift
height. The assembly locations can be found in the
spare parts catalog.

WARNING
Risk of trapping and severing limbs from moving
machine parts
When working on an extended mast, body parts can be
trapped or severed by machine parts lowering auto-
matically or accidentally.
 Secure the raised mast stages and forks with suita-
ble, adequately sized supporting equipment to pre-
vent them from lowering.

Preparation
Preparing the truck
1. Power down the truck.
2. Disconnect the battery and prevent the truck from
being switched on again.

Removing the mast guard

Removing the mast guard
Note: On removal, mark the position of the chassis
shims under the domed cap nuts to which the mast
guard is attached.
1. Remove the domed cap nuts, bolts and any chas-
sis shims.
2. Pull the shim off the stay bolts.

ES/ET4000 Series
Rev. B
280
 LIFTING MECHANISM
REPAIRING LIFT CHAINS AND CHAIN TENSIONERS

Repairing Lift Chains and Chain

Tensioners
Lift chains, chain tensioners and their attachments
are safety components. Regular, conscientious main-
tenance and inspection are pre-requisites for safe truck
operation and a long lift chain service life.

Adapting the service intervals to the

application conditions
The ambient conditions at the place of operation deter-
mine how frequently a lift chain needs to be serviced.
The following factors have a considerable influence:
• High dust levels
• Humidity
• Corrosive atmosphere (acid and alkali steam, salts,
chlorine, hydrogen etc.)
• Condensation formation through changing from
warm / cold environments (cold store application)
• Load peaks, caused by travelling over holes in the
ground and thresholds with a raised load
Note: The interval specified in the maintenance sched-
ule should be considered as a starting point for normal
ambient conditions at the place of operation. Adapt the
maintenance intervals to the ambient conditions at the
place of operation. Optimum adjustment will achieve
the maximum lift chain service life.

Periodic replacement of the chain

tensioners and lift chains
For safety reasons the following components must be
replaced - irrespective of their condition - after 5000
service hours or 3 calendar years after assembly.
• Lift chains
• Chain tensioners and their attachments
• Anchor bolts and their attachments
Note: The chain tensioners are marked with the date of
manufacture / assembly (week/year).

ES/ET4000 Series Rev. 4 11/2012

Rev. B
281
LIFTING MECHANISM
SERVICING LIFT CHAINS

Servicing lift chains chain tensioners, anchor bolts and lift chains to-
gether with all their attachments.
 If the chain tensioners and lift chains still have
Service work enough service time until the next inspection,
Maintenance covers the following work: clean and check the lift chains as described be-
• Checking the service hours for the chain tensioners low.
and lift chains
• Cleaning and lubricating the lift chains
Cleaning lift chains
• Measuring the elongation of the lift chains
• Checking the lift chains for damage
WARNING
• Checking the chain tensioners, anchor bolts, at-
tachment and retaining components for damage Improper cleaning can cause chains to crack
A cracked lift chain can result in fatal injuries.
Never clean lift chains with steam cleaners, cold clean-
WARNING ing agents or corrosive, acid-based agents. This can
cause direct damage through hydrogen embrittlement.
Crashing loads can cause injury  Clean the lift chains only using paraffin derivatives
Lift chains, chain tensioners, chain pins and their at- such as cleaning petroleum or cleaning petrol.
tachments are safety components. Their failure can
 After the solvent has evaporated, immediately ap-
cause the load to crash, resulting in fatal injuries.
ply a type H oil (see page 24).
 Replace damaged lift chains and their chain ten-
sioners, lift chain pins and connecting items with
original spare parts before restoring the truck to ser- Preparing to clean
vice. 1. Remove the lift chains if the entire length of the
 Always replace lift chains in pairs. chain cannot be accessed when assembled.
2. Prepare a pan to collect the solvent.
Cleaning lift chains
3. Clean lift chains thoroughly with a hard brush and
CAUTION cleaning petroleum or cleaning petrol.
Health risk Note: Clean the lift chains carefully in order to make
Cleaning agents, lubricants and consumables can damage such as cracking or wear marks visible during
damage your health. the subsequent inspection.
 Observe the manufacturer’s safety instructions 4. Apply compressed air to the solvent while moving
when handling solvents and lubricants. the chain links at the same time.
5. When the solvent has completely evaporated, lu-
bricate and preserve the lift chains as outlined be-
Checking the service hours for the low.
lift chains and anchor bolts Lubricating and preserving lift
1. Check the chain tensioner date of manufacture
(see engraving on chain tensioner):
chains
 If the chain tensioners are 3 years or older, re- Note: The lift chains must be clean before being lubri-
place the chain tensioners, anchor bolts and lift cated. If oil is applied to a dirty layer, it will not penetrate
chains together with all their attachments. the important lubrication points of the lift chain.
 If the chain tensioners are not yet 3 years old,
Preparing to lubricate lift chains
proceed with step 2.
1. Wipe the lift chains with a clean, lint-free cloth.
2. Check the number of service hours since the chain
tensioners and lift chains were last replaced: 2. Clean the lift chains (see page 282) if wiping them
 If the chain tensioners or lift chains have been in does not make them shiny.
service for 5000 hours or more, replace the 3. When the lift chains are clean and shiny, proceed
to step 4.

Rev. 4 11/2012 ES/ET4000 Series

Rev. B
282
 LIFTING MECHANISM
SERVICING LIFT CHAINS

Lubricating and preserving lift chains

4. Lubricate and preserve lift chains with type H oil
(see page 24).
 The lift chain is ideally lubricated and preserved if
a thin but enclosed oil film can be seen on all the
surfaces.
Note: Spray on the oil carefully. If possible move the
links on the lift chain at the same time to allow the oil to
penetrate the joints.

ES/ET4000 Series Rev. 4 11/2012

Rev. B
283
LIFTING MECHANISM
CHECKING THE LIFT CHAINS FOR WEAR AND DAMAGE

Checking the Lift Chains for Checking the wear gauge

2. Check the measuring jaws of the wear gauge (1,
Wear and Damage Fig. 111) for damage.
 If the measuring jaws are damaged, replace the
Checking the lift chain elongation wear gauge.
 If the measuring jaws are undamaged, proceed
to step 3.
1

2 4
5

3 6

Fig. 112 Checking the calibration

3. Push the wear gauge together.
 Calibration (5, Fig. 112) is displayed in the PER-
CENTAGE WEAR window.
4. Check the display in the viewing window (4).
 If the arrow (6) is pointing between the + and -
marks in the white area, the wear gauge can be
1 used.
 If the arrow (6) is facing one of the red fields (4),
Fig. 111 Wear gauge (part no. 818041) the wear gauge is faulty and cannot be used.

Tools required
• A wear gauge (part no. 818041) or a steel ruler
Note: Crown recommends wear gauge part no.
818041. The resolution of this gauge is 0.25%. This
level cannot be achieved with standard gauges or the
steel ruler.

Test preparation
Make the lift chain accessible and clean it
1. Remove the lift chain if it cannot be fully inspected
when installed.
Note: Before removing the chain, mark approx.1 m of
the area on the chain that continually passes over a
pulley during operation.

Rev. 4 11/2012 ES/ET4000 Series

Rev. B
284
 LIFTING MECHANISM
CHECKING THE LIFT CHAINS FOR WEAR AND DAMAGE

Checking the lift chain elongation with the

wear gauge
8
Determining the pitch of the lift chain and the
length required for the chain section 9

10
Fig. 113 Determining the pitch 11
1. Align the arrow (6) with the centre of the chain pins
Fig. 114 Determining the lift chain elongation
of an outside plate on the lift chain.
Note: Turn the wear gauge over if no reading is dis- 2. Place the top jaw (8) of the wear gauge on a chain
played in the PITCH window. The gauge has 2 scales pin.
(A SCALE and B SCALE) for different pitches. 3. Count the number of chain pins calculated previ-
2. Check the pitch (in inches) in the PITCH window. ously in the MEASURE OVER __PINS window
and place the bottom jaw (11) on the last chain pin.
3. Check the number of chain links required in the
MEASURE OVER __PINS window. 4. Check the lift chain elongation reading in the PER-
CENTAGE WEAR window.
Checking the lift chain elongation
5. Repeat the measurement on two other parts of the
Note: If there are two lift chains check each one indi- chain that always pass over a pulley during opera-
vidually to ensure a correct reading. To do this, relieve tion.
one of the lift chains initially.
6. Use the highest of the 3 measurements and take
Note: The net weight of the fork carriage and forks is the action detailed in Table 1.
sufficient to tension the installed chain. Pull the re-
moved lift chains taut for the measurement.
1. Activate lifting (without load on the forks) until ap-
prox.1 m of lift chain which permanently passes
over a pulley is accessible.

ES/ET4000 Series Rev. 4 11/2012

Rev. B
285
LIFTING MECHANISM
CHECKING THE LIFT CHAINS FOR WEAR AND DAMAGE

Table 2 (Continued)
Table 1
Pitch No. of Length Wear limit
Lift chain Action chain links new
elongation
15.88 mm 20 318 mm 327 mm
< 2% The lift chain can continue to be 0.625 inch 12.5 inch 12.875 inch
used.
Checking the lift chain elongation
 2% It is necessary to estimate
whether the lift chain elongation Note: If there are two lift chains check each one indi-
will remain below 3% by the time vidually to ensure a correct reading. To do this, relieve
of the next inspection. If this can- one of the lift chains initially.
not be ensured, replace the lift Note: The net weight of the fork carriage and forks is
chain, the chain tensioners and sufficient to tension the installed chain. Pull the re-
the chain pins. moved lift chains taut for the measurement.
Note: For twin chains always re- 1. Activate lifting (without load on the forks) until ap-
place the second lift chain with prox.1 m of lift chain which permanently passes
the chain tensioners and chain over a pulley is accessible.
pins. 2. Count the number of chain links previously calcu-
3% Replace the lift chain, the chain lated.
tensioners and the chain pins im- 3. Measure the length of from the centre of the first
mediately. The truck must not chain pin to the centre of the last chain pin.
continue to be used with this lift 4. Record the elongation level of the lift chain.
chain elongation.
5. Repeat the measurement on two other parts of the
Note: For twin chains always re- lift chain that always pass over a pulley during op-
place the second lift chain with eration.
the chain tensioners and chain
6. Use the highest of the 3 measurements and calcu-
pins.
late the lift chain elongation x.
Lift chain elongation x in % = [measured length
Checking the lift chain elongation with the / (new length / 100)] - 100
steel ruler Example: The lift chain elongation is 25.4 mm. Table 2
indicates that the "New length" for this lift chain pitch is
Determining the pitch of the lift chain and the
305 mm. Let's assume the "measured length" is 309
length required for the chain section
mm.
1. Measure the lift chain pitch from the centre to the
x = [309 / (305 /100)] - 100;
centre of the chain pins of an outside plate.
x = 309 mm / 3.05 -100;
2. Find the corresponding value in the "Pitch" column
of Table 2 and check the number of chain links re- x = 101.3 -100;
quired for the measurement. x = 1.3;
In this example the lift chain elongation is 1.3%.
Table 2 7. Find the calculation in Table 1 (see page 286) and
take the action outlined.
Pitch No. of Length Wear limit
chain links new

25.4 mm 12 305 mm 314 mm

1 inch 12 inch 12.375 inch
19.05 mm 16 305 mm 314 mm
0.75 inch 12 inch 12.375 inch

Rev. 4 11/2012 ES/ET4000 Series

Rev. B
286
 LIFTING MECHANISM
CHECKING THE LIFT CHAINS FOR WEAR AND DAMAGE

Checking the chain for other

damage

Table 3: Lift chain inspection points

Damage illustration Damage and Cause Remedy

symptom

Noise • Insufficient lubricant in 1. Check the chain elongation.

• Mild squeaking to the chain joints  If the chain elongation is
louder creaking Note: When the chain within the tolerance level,
during operation runs over the pulley the clean and lubricate the
None
movement in the joints chain (type H chain oil)
produced metallic friction.  If the chain elongation is
outside the tolerance level,
replace the chain.
Joint rust • Insufficient lubrication 1. Replace the chain.
• Reddy brown col- • Grease or thickening 2. Use type H chain oil to lubri-
our (1) in the joint oils have been used cate and improve ongoing
area that do not penetrate chain maintenance.
the chain joint
1

Surface rust • No anti-corrosion or 1. Remove the rust from the

• Brown colouring extremely corrosive chain with type H chain oil.
(2) on connecting ambient conditions  If this is not possible, re-
plates place the chain.
2. Check the rust-free chain for
pitting (small craters on the
wear points) and superficial
2
rusting.
 Replace the chain if any
rusting or pitting is found.
Rigid joints • Cold shut or joint cor- 1. Replace the chain.
• The chain joints (3) rosion due to lack of 2. Improve ongoing chain main-
do not automati- lubrication tenance.
cally revert to the
3
stretched position
Turned chain pins • Insufficient lubrication 1. Replace the chain.
• One or more chain Note: Turned chain pins 2. Improve ongoing chain main-
4 pins (4) are turned. are a direct result of rigid tenance.
joints.

Images and technical information provided with kind permission of Rexnord Kette GmbH • www.rexnord.com

ES/ET4000 Series Rev. 4 11/2012

Rev. B
287
LIFTING MECHANISM
CHECKING THE LIFT CHAINS FOR WEAR AND DAMAGE

Table 3: Lift chain inspection points (Continued)

Damage illustration Damage and Cause Remedy

symptom

Loose chain pin • Insufficient lubrication 1. Replace the chain.

• One or more chain Note: Turned chain pins 2. Improve ongoing chain main-
pins (5) are pro- are a direct result of rigid tenance.
5 truding. joints.

Excessive outer • The chain runs on 1. Measure the width of the wear
wear mast section or at the zone and calculate the per-
• The outer plates side on the pulley centage wear in relation to the
(6) are grounded overall width of the plate.
down  If the wear is  5% of the
overall width, replace the
chain and correct the faulty
alignment of the lift compo-
nents or the pulleys.
6  If the wear is 5% of the
overall width, you must cor-
rect the faulty alignment of
the lift components or the
pulleys. The lift chain can
then be used again.
Punch marks or dis- • The chain strikes 1. Remove the cause of the
tortion against parts of the punch marks or distortion.
• Parts of the chain mast 2. Replace the chain.
are nicked (7) or
distorted
7

Broken plates • Fatigue crack due to 1. Determine and rectify the

• The head section overload cause of the overload.
of the plate is miss- • Corrosion 2. Replace the chain.
ing or the crack is
8 protruding (8)

Broken pins • Pitting on the pins due 1. Replace the chain.

• The outer plate (9) to corrosion. Pitting 2. Improve ongoing chain main-
lifts out slightly will result in perma- tenance.
nent damage to the
Note: These defects
9 pin.
are not easy to detect
as the chain's appear-
ance does not change
significantly in the ini-
tial stages
Images and technical information provided with kind permission of Rexnord Kette GmbH • www.rexnord.com

Rev. 4 11/2012 ES/ET4000 Series

Rev. B
288
 LIFTING MECHANISM
CHECKING THE LIFT CHAINS FOR WEAR AND DAMAGE

Table 3: Lift chain inspection points (Continued)

Damage illustration Damage and Cause Remedy

symptom

Contamination • Grease used instead 1. Thoroughly clean the chain

• A thick layer of dirt of type H chain oil (see page 282) and check for
mixed with oil or • The chain has not damage.
grease (10) con- been cleaned prior to  If the chain can be used, lu-
10 bricate it with type H chain
tained on the chain lubrication
oil.
 Replace the chain if dam-
aged.
2. Improve ongoing chain main-
tenance.
Hydrogen embrittle- • The chain has come 1. Replace the chain.
ment into contact with hy-
2. Check the operating condi-
11 • Non-distorting brit- drogen tions for sources of hydrogen.
tle fracture (11), Note: Hydrogen is always 3. Refer to the lift chain cleaning
generally only on freely produced during instructions (see page 282).
the outer plate electrolysis. Chlorine
based solvents also emit
hydrogen.
Chain elongation • Wear due to move-
1. Replace the chain if the per-
• The chain elonga- ment in the joints. missible chain elongation has
tion check (see Note: This is normal been reached or exceeded.
page 284) found wear, even with correct Note: Check if the lift chain service
the chain to be be- lubrication. life can be increased by reducing
yond the tolerance the maintenance interval..
level

Images and technical information provided with kind permission of Rexnord Kette GmbH • www.rexnord.com

ES/ET4000 Series Rev. 4 11/2012

Rev. B
289
LIFTING MECHANISM
SEPARATING LIFT CHAINS

Separating Lift Chains Cutting the lift chain

Lift chains are supplied by the meter and must be cut

to the required length.
WARNING
Tools and equipment required Risk of eye damage
• A secure working plate with a hole slightly larger Splinters can fly off during grinding operations.
than the head diameter of a chain bolt. The hole  Wear protective goggles to avoid damaging your
must be deeper than the chain bolt length. eyes.
• A backring (washer) with a hole slightly larger than
the head diameter of a chain bolt. The backring 1. Carefully grind the head of the chain bolt, taking
thickness must be slightly larger than the height of care not to damage the chain plate eyelet.
the head of a chain bolt. The backring prevents the
2. Place the bearing ring onto the hole in the working
inner plate surface from being damaged when you
plate.
drive out the chain bolt.
3. Insert the head of the chain bolt to be driven out
• A grinder.
into the backring.
• A hammer and hole with a diameter slightly shorter  Align the chain bolt, backring and hole in the
than the chain bolt. Or a press with a suitable man- working plate.
drel.
4. Drive out the chain bolt.
1

4
1

3 2

1 Chain plate eyelet 3 Backring

2 Hole in working plate 4 Grinder

ES/ET4000 Series

290
 LIFTING MECHANISM
FORKS

Forks
General 1
The forks must be checked by trained personnel under
the maintenance schedule (see page 26) for cracks,
damage and wear.
Note: If the forks are used to transport abrasive loads
the inspection must be carried out at shorter intervals.

Fork inspection

WARNING
Falling loads can cause injury
If a fork breaks under load it can fatally injure you or
other people.
 Never carry out repair welding to cracks, damaged
or worn parts around the heel of the fork.
 Forks must only be repaired by the fork manu- Fig. 115 Welding seams between forks and fork carriage
facturer.

Checking forks for cracks

Checking forks for cracks
1. Visually inspect all fork surfaces for cracks.
2. Check the welding seams (1, Fig. 115) between
the forks, fork carriage and fork shank for cracks.
Note: Use a non-destructive crack test procedure (dye
penetrant or Magnaflux ® process), if you are unsure
whether there are any cracks.
 Replace the forks if any cracks are detected.

ES/ET4000 Series Rev.2 05/2012

Rev. B
291
Notes:

292
CYLINDERS
293
Notes:

294
 CYLINDERS

General
Safety notices

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

WARNING
High pressure hydraulic oil can cause severe in-
jury
Whenever a high pressure hydraulic oil enters the skin
it must be treated as a medical emergency.
Seek medical assistance even if the skin appears nor-
mal at first.
To avoid accidents:
• Depressurise the hydraulic system before opening
any sections of it.
• Tighten all connections before pressurising the sys-
tem.
• Keep hands and body away from pressurised fluid.
• Always trace leaks with a piece of paper or card-
board.

Hydraulic system repair instructions

• Hydraulic systems are sensitive to dirt.
• Thoroughly clean disassembled hydraulic compo-
nents before dismantling them.
• Always repair hydraulic components at a clean
workstation.
• Immediately protect cleaned and de-greased com-
ponents with a thin coating of hydraulic oil.
• Protect components against re-contamination be-
fore assembling them.
• Immediately seal open hydraulic ports on repaired
assemblies with dummy plugs. This also applies to
open ports and lines on the truck.
• Do not refinish any cylinder surfaces. Replace any
damaged parts.
• Always replace all the seals on the assembly. Used
seals can cause leaks.

ES/ET4000 Series
Rev. B
295
CYLINDERS
TOOLS

Tools Producing extractors

1. Hard solder a self-tapping 4mm screw (3) onto the
shaft (min.150 mm, long, max. Ø 4 mm) of a screw-
CAUTION driver (1).
Cylinder surfaces can be damaged through the use 2. Sand the soldering joint.
of unsuitable tools. 3. Wrap insulating tape (1) around the shaft and sol-
 Do not use a screwdriver or similar tools. dering joint of the screwdriver.
 Use burr-free tools made of soft metal (brass, alu- Groove aligning arbor for small rod
minium) without sharp edges or a suitable plastic.
seals
You must produce the following tools yourself: The outer diameter of the groove aligning arbor must fit
the internal diameter of the cylinder cap.
Small hook The arbor should end flush with the bottom of the seal
seat.
Use small hooks to remove small seals (see Fig. 116).

1
2

Fig. 118 Groove aligning arbor in a cylinder cap

1 Cylinder cap
Fig. 116 Hanger 2 Seal seat

Extractor 3 Groove aligning arbor

Two extractors to remove rod seals (see Fig. 117)

.

Fig. 117 Extractor

ES/ET4000 Series
Rev. B
296
 CYLINDERS
TOOLS

Assembly devices for large rod

seals
Produce a tool body (12, Fig. 119) with a diameter to
match the internal diameter of the cylinder caps.

3
4

Fig. 119 Assembly device for large rod seals

1 Tool body
2 Fixed pin
3 Rod seal (shown for illustration purposes only)
4 Axial moving pins

Protective mechanisms
If the seal has to be pushed over sharp edges, cracks
or nicks, use appropriate plastic protective mecha-
nisms.

ES/ET4000 Series
Rev. B
297
CYLINDERS
ROD SEAL REMOVAL AND ASSEMBLY

Rod Seal Removal and

Assembly 1 2

Removing a large rod seal 3

1. Turn one extractor (see Fig. 117) respectively into
the opposite parts of the rod seal. 4
2. Pull the seal out of its seat using the grips of the
tools.
3. Dispose of the rod seal.

Removing a small rod seal 5

1. Using a small hook (see Fig. 116) pull the rod seal 6
out of the seal seat.
2. Dispose of the rod seal.

Inserting a large rod seal

1. Apply a thin coating of hydraulic oil to the rod seal Fig. 121 Wound rod seal
and the seal seat in the cylinder cap.
5. Push the tool body (1, Fig. 5) into the cylinder cap
2. Place the rod seal over the fixed pin (1, Fig. 120).
(2) until the rod seal (6) is aligned with the seal seat
3. Bend the rod seal under the pin (2). in the cylinder cap.
4. Now bend the resultant loop up so that the pin (3) 6. Retract the pin (1, Fig. 122).
can be moved into the loop.  One segment of the rod seal jumps into the seal
seat.

Fig. 120 Threading the rod seal

Fig. 122 The first rod seal segment is located in the seal seat.
7. Retract the pin (2, Fig. 122).
 The rod seal is now fully located in the seal seat
(see Fig. 123)

ES/ET4000 Series
Rev. B
298
 CYLINDERS
ROD SEAL REMOVAL AND ASSEMBLY

Rod seal assembly, sealing lip first

The sealing lip is sensitive and must not be damaged.
Special protective sleeves (1) are required when push-
ing the seal (2, Fig. 125) over the thread and holes.

CAUTION
Incorrectly assembled rod seals will leak
 Fit the rod seal with the sealing lip facing the pres-
sure side.

3
1 2
Fig. 123 Rod seal fully inserted in seal seat
4
8. Pull the tool body out of the cylinder cap.

Fitting a small rod seal

6
1
5
2

3
Fig. 125 Sealing lip facing the pressure side
4 1 Cylinder tube
2 Inner thread
3 Protective sleeve for assembly
4 Rod seal
5 Sealing lip
6 Backring

Fig. 124 Small rod seal assembly

1. Apply a thin coating of hydraulic oil to the rod seal
(2, Fig. 124) and the seal seat (3) in the cylinder
cap.
2. Place the cylinder cap on the groove aligning arbor
(4).
3. Gently bend the rod seal (2) together.
4. Place one part of the rod seal into the seal seat (3).
5. Press the rod seal into the seal seat using a burr-
free aluminium or plastic arbor (5).

ES/ET4000 Series
Rev. B
299
CYLINDERS
LIFT CYLINDER REMOVAL AND ASSEMBLY

Lift Cylinder Removal and Removing the lift cylinder (TL mast)
Assembly
WARNING
WARNING Accidental truck movement can cause injury
A powered up truck with a connected battery can move
High pressure hydraulic system suddenly when you are working on it.
Risk of injury from escaping hydraulic oil. You should therefore carry out the following safety pro-
To avoid accidents: cedures before starting any operations on the truck:
 Depressurise the hydraulic system before opening  Lower the forks to the ground.
any sections of it.
 Switch the truck off.
 Tighten all connections before pressurising the sys-
 Disconnect the battery.
tem.
 Prevent the truck from being switched on again.
 Keep hands and body away from pressurized fluid.
 Only trace leaks with a piece of paper or cardboard.
Whenever a high pressure fluid enters the skin it must
be treated as a medical emergency.
Seek medical assistance even if the skin appears nor- WARNING
mal at first. Risk of trapping and severing limbs
Unsecured mast stages and attachments can sever
limbs or even cause fatal injuries.
 Before starting assembly always block and secure
CAUTION the relevant components with equipment with suffi-
cient strength and stability.
Health risk
Cleaning agents, lubricants and consumables can
damage your health. Note: The following item numbers refer to Fig. 126.
 Observe the manufacturer’s safety instructions Preparation
when handling solvents and lubricants. 6. Place two wooden blocks on the outriggers.
7. Lower the fork carriage onto the wooden blocks.
8. Continue to activate lowering for approx. 20 sec-
onds.
WARNING  The hydraulic system is depressurised.
Lifting gear failure can cause accidents 9. Disconnect the battery and prevent the truck from
 Note the minimum capacity for the lifting gear being switched on again.
whenever carrying out work on the mast. 10. Disassemble the mast guards (see page 280).
Lift chain removal
11. Remove one of the cotter pins (12) from the top
chain pin and pull out the chain pin (11).
12. Take the lift chain (15) out of the pulley and store it
so that it is out of the way.
Lift cylinder removal
13. Cut all the cable ties from the lift cylinder and store
the cables so that they are out of the way.
14. Remove the retaining ring (28) and shims (27).
15. Push a flat tray underneath the lift cylinder.
16. Disconnect the hydraulic port from the lift cylinder.

ES/ET4000 Series
Rev. B
300
 CYLINDERS
LIFT CYLINDER REMOVAL AND ASSEMBLY

Note: Seal the lines and port immediately with dummy

plugs.
17. Raise the 2nd mast stage (30) with a crane (mini-
mum capacity 600 kg) until the piston ram is free
and the lift cylinder can be lifted out from the bot-
tom receptacle.
18. Secure the 2nd mast stage (30) with wooden
blocks in the channels of the 1st mast stage (1) to
prevent it from lowering.
19. Take the lift cylinder out of the bottom receptacle in
the 1st mast stage (1).
 The lift cylinder is removed.

Lift cylinder (TL mast) assembly

Installing the lift cylinder
1. Assemble the lift cylinder in the reverse order of
disassembly.
Note: Choose the number of shims (27) so that the lift
cylinder has as little slack as possible when installed
vertically.
Note: Torque the hydraulic ports to 50 - 60 Nm.
2. Install the mast guards.
3. Bleed the hydraulic system (see page 51).
4. Flush the hydraulic system (see page 53).
5. Perform a drift test (see page 54).

ES/ET4000 Series
Rev. B
301
CYLINDERS
LIFT CYLINDER REMOVAL AND ASSEMBLY

Fig. 126 TL mast

ES/ET4000 Series
Rev. B
302
 CYLINDERS
LIFT CYLINDER REMOVAL AND ASSEMBLY

Lift cylinder (TF and TT mast) 8. Remove the retaining ring (16) and shims (15).
removal 9. Secure the lift cylinder (14, 17) on the 1st mast
stage (30) so that it does not drop with the 2nd
mast stage (29) is raised.
10. Raise the 2nd mast stage (29) and for a TT mast
WARNING also the 3rd mast stage with a crane (minimum
Accidental truck movement can cause injury capacity 600 kg for TF and 800 kg for TT masts)
A powered up truck with a connected battery can move until the lift cylinder becomes clear of the 2nd mast
suddenly when you are working on it. stage.
You should therefore carry out the following safety pro- 11. Secure the 2nd mast stage (29) and for a TT mast
cedures before starting any operations on the truck: also the 3rd mast stage with wooden blocks in the
 Lower the forks to the ground. mast stage channels to prevent accidental lower-
ing.
 Switch the truck off.
12. Using lifting gear raise the lift cylinder (10) out of
 Disconnect the battery. the 1st mast stage and place it on a suitable sup-
 Prevent the truck from being switched on again. port.
 The lift cylinder is removed.

Lift cylinder (TF and TT mast)

WARNING assembly
Risk of trapping and severing limbs Installing the lift cylinder
Unsecured mast stages and attachments can sever
1. Assemble the lift cylinder in the reverse order of
limbs or even cause fatal injuries.
disassembly.
 Before starting assembly always block and secure
Note: Choose the number of shims (15) so that the lift
the relevant components with equipment with suffi-
cylinder has as little slack as possible when installed
cient strength and stability.
vertically.
Note: Torque the hydraulic ports to 70 - 75 Nm.
Lift cylinder (TF and TT mast) 2. Install the mast guards.
removal 3. Bleed the hydraulic system (see page 51).
4. Flush the hydraulic system (see page 53).
Note: The following item numbers refer to Fig. 127.
5. Perform a drift test (see page 54).
Preparation
1. Fully lower the forks.
2. Continue to activate lowering for approx. 20 sec-
onds.
 The hydraulic system is depressurised.
3. Disconnect the battery and prevent the truck from
being switched on again.
4. Disassemble the mast guards (see page 280).
Lift cylinder removal
5. Cut all the cable ties from the lift cylinder and store
the cables so that they are out of the way.
6. Push a flat tray underneath the hydraulic cylinder.
7. Disconnect the bottom and (if applicable) top hy-
draulic port from the respective lift cylinder.
Note: Seal the lines and ports immediately with dummy
plugs.

ES/ET4000 Series
Rev. B
303
CYLINDERS
LIFT CYLINDER REMOVAL AND ASSEMBLY

Fig. 127 TF mast

ES/ET4000 Series
Rev. B
304
 CYLINDERS
FREE LIFT CYLINDER REMOVAL AND ASSEMBLY

Free lift cylinder removal and There are two methods of securing the free lift cylinder:
• Method 1: The free lift cylinder is guided loosely
assembly through a receptacle (1) on the cross member of the
mast stage. The cylinder base is bolted onto a re-
ceptacle on the mast stage.
• Method 2: The free lift cylinder is bolted onto the
cross member of a mast stage. The cylinder base is
contained in a receptacle welded to the mast stage.

Fig. 128

ES/ET4000 Series
Rev. B
305
CYLINDERS
FREE LIFT CYLINDER REMOVAL AND ASSEMBLY

Free Lift Cylinder Removal Preparation

(Method 1) 6. Place two wooden blocks on the outriggers.
7. Lower the fork carriage onto the wooden blocks.
8. Continue to activate lowering for approx. 20 sec-
onds.
 The hydraulic system is depressurised.
9. Disconnect the battery and prevent the truck from
being switched on again.
10. Disassemble the mast guards (see page 280).
Free lift chain removal

WARNING

18 Risk of trapping and severing limbs

Unsecured mast stages and attachments can sever
limbs or even cause fatal injuries.
 Before starting assembly always block and secure
23 the relevant components with equipment with suffi-
cient strength and stability.
22 21
1. Remove the cotter pin (23) from the top chain bolt
20 (22) and pull out the chain bolt.
2. Take the lift chain (218) out of the pulley and store
it so that it is out of the way.
19
Chain support removal
Note: If the free lift cylinder is removed for repairs and
not replaced, the chain support can remain in place on
the truck.
1. Remove the cotter pin (20) from the chain support
(21).
2. Remove the jam nuts (19) from the chain support.
3. Remove the chain support (21).

24

Fig. 129 Free lift cylinder (method 1)

ES/ET4000 Series
Rev. B
306
 CYLINDERS
FREE LIFT CYLINDER REMOVAL AND ASSEMBLY

Removing the pulley the angle cleat to the new free lift cylinder and torque
to 50 - 60 Nm.
3. Install the mast guards.
4. Bleed the hydraulic system (see page 51).
5. Flush the hydraulic system (see page 53).
6. Perform a drift test (see page 54).

Fig. 130 Free lift cylinder pulley yoke

1. Remove the retaining ring (3, Fig. 130) and the
washers.
2. Take off the pulley yoke.
Free lift cylinder removal
1. Push a flat tray underneath the free lift cylinder.
2. Disconnect the hydraulic port on the free lift cylin-
der.
Note: Seal the line and port immediately with dummy
plugs.
3. Remove the screw (24).
4. Lift out the free lift cylinder from the top.
 The lift cylinder is removed.

Free Lift Cylinder Assembly

(Method 2)
Free lift cylinder assembly
1. Assemble the free lift cylinder in the reverse order
of disassembly.
2. Counter fix the nuts (19) on the chain support to
170 - 190 Nm.
Note: When assembling a new free lift cylinder, re-
move the angle cleat from the old free lift cylinder. Fit

ES/ET4000 Series
Rev. B
307
CYLINDERS
FREE LIFT CYLINDER REMOVAL AND ASSEMBLY

Free Lift Cylinder Removal Removing the pulley

(Method 2)
Note: Unless otherwise indicated, the following item
numbers refer to Fig. 132.
Preparation
7. Place two wooden blocks on the outriggers.
8. Lower the fork carriage onto the wooden blocks.
9. Continue to activate lowering for approx. 20 sec-
onds.
 The hydraulic system is depressurised.
10. Disconnect the battery and prevent the truck from
being switched on again. 3
11. Disassemble the mast guards (see page 280).
Free lift chain removal

WARNING
Risk of trapping and severing limbs
Unsecured mast stages and attachments can sever
limbs or even cause fatal injuries.
 Before starting assembly always block and secure Fig. 131 Free lift cylinder pulley yoke
the relevant components with equipment with suffi-
cient strength and stability. 1. Remove the retaining ring (3, Fig. 131) and the
washers.
1. Remove the cotter pin (23) from the top chain bolt 2. Take off the pulley yoke.
(22) and pull out the chain bolt. Free lift cylinder removal
2. Take the free lift chain (26) out of the pulley (24) 1. Push a flat tray underneath the free lift cylinder.
and store it so that it is out of the way.
2. Disconnect the hydraulic port from the free lift cyl-
Chain support removal inder (18).
Note: If the free lift cylinder is removed for repairs and Note: Seal the line and port immediately with dummy
not replaced, the chain support can remain in place on plugs.
the truck. 3. Secure the free lift cylinder (18) so that it cannot fall
1. Remove the cotter pin (21) from the chain support over on removal.
(20). 4. Loosen the screws (16) from the tie bar, take out
2. Remove the jam nuts (19) from the chain support. the shims (17) and remove the screws.
3. Remove the chain support (20). 5. Remove the free lift cylinder (18) from its socket in
the 1st mast stage (1).
 The lift cylinder is removed.

ES/ET4000 Series
Rev. B
308
 CYLINDERS
FREE LIFT CYLINDER REMOVAL AND ASSEMBLY

Free Lift Cylinder Assembly

(Method 2)
Free lift cylinder assembly
1. Assemble the free lift cylinder in the reverse order
of disassembly.
2. Counter fix the nuts (19) on the chain support to
170 - 190 Nm.
Note: Make sure the free lift cylinder is centred in the
receptacle on the mast base.
Note: When assembling a new free lift cylinder, re-
move the angle cleat from the old free lift cylinder. Fit
the angle cleat to the new free lift cylinder and torque
to 50 - 60 Nm.
3. Install the mast guards.
4. Bleed the hydraulic system (see page 51).
5. Flush the hydraulic system (see page 53).
6. Perform a drift test (see page 54).

ES/ET4000 Series
Rev. B
309
CYLINDERS
FREE LIFT CYLINDER REMOVAL AND ASSEMBLY

23
25
26
22
21
20

16 24

19
29

18

17
23
22

Fig. 132 Free lift cylinder (method 2)

ES/ET4000 Series
Rev. B
310
 CYLINDERS
REPAIRING THE LIFT CYLINDERS ON THE TL AND TT MASTS

Repairing the Lift Cylinders on age. Make sure they are clean. If a seat is dam-
aged, replace the respective component.
the TL and TT Masts 2. Check the piston rod for damage. Dispose of the
Note: The following item numbers refer to Fig. 133. rod if you find any grooves, corrosion pitting or
scoring.
3. Apply a thin layer of hydraulic oil to the piston rod
CAUTION and bare surfaces on the cylinder tube.
Damaged or contaminated seal seats and piston  The cylinder tube and piston rod are protected
rods will result in immediate leaks, even with new against corrosion and are prepared for assembly.
seals. The same applies to the use of unsuitable
Fitting the lift cylinder
tools for seal removal and fitting.
 Before fitting a new seal check the seal seats and
piston rods for damage and make sure they are CAUTION
clean.
Used sealing components can result in leaks
 When replacing rod seals use assembly equipment
 Always use new components from the seal kit,
and tools made of soft metal or plastic without sharp
never used ones, for assembly purposes.
edges. Suitable tools and assembly procedures are
described starting on page 296.
 Do not re-use sealing elements that have been re- 1. Apply a thin coat of hydraulic oil to the new wiper
moved. ring (1), rod seal (2), backring (6), guide ring (3)
and seals (7).
2. Carefully install the above-mentioned parts. Fit the
Preparation rod seal (2) with the sealing lip first.
1. Remove the lift cylinder (see page 300). 3. Fit the new piston (10).
Dismantling lift cylinders Note: Refer to the assembly instructions for rod seals
1. Pull the piston rod (8) off the cylinder tube (12). on page 298.
2. Unscrew the cylinder cap (3). 4. Coat the piston rod with hydraulic oil and carefully
3. Using suitable tools (see page 296) remove the fol- insert it into the cylinder tube without twisting. Take
lowing parts from the seats in the cylinder cap (5) care not to damage the seals in the process.
or cylinder tube (12): 5. Carefully screw on the cylinder cap and torque it to
– Wiper ring (1) 120 - 140 Nm.

– Rod seal (2)  The lift cylinder is now repaired and ready for as-
sembly.
– Backring (6)
– Guide ring (3) Final tasks

– Seal (7) 1. Assemble the lift cylinder (see page 300).

Note: Refer to the rod seal disassembly instructions on

page 298.
4. Dispose of parts 1, 2, 3 and 7.
5. Remove the piston (10) from the piston rod and
dispose of it.
6. Clean all parts thoroughly and apply dry com-
pressed air.
 The cylinder is now dismantled and can be
checked for damage.
Checking the cylinder tube and piston rod
1. Check the seats for the seal and guide items in the
cylinder tube (12) and the cylinder cap (5) for dam-

ES/ET4000 Series
Rev. B
311
CYLINDERS
REPAIRING THE LIFT CYLINDERS ON THE TL AND TT MASTS

3 9
1
10
5 4
11
2 5

3 6

4 7
6
7

12

12

10

11

13

13

Fig. 133 TL mast lift cylinder

ES/ET4000 Series
Rev. B
312
 CYLINDERS
REPAIRING THE LIFT CYLINDER FOR THE TF MAST

Repairing the Lift Cylinder for 7. Clean all parts thoroughly and apply dry com-
pressed air.
the TF Mast  The cylinder is now dismantled and can be
Left and right lift cylinders are not identical. checked for damage.
Checking the cylinder tube and piston rod
Repairing the left lift cylinder 1. Check the seats for the seal and guide items in the
Note: The following item numbers refer to Fig. 134. cylinder tube (14) and the cylinder cap (4) for dam-
age. Make sure they are clean. If a seat is dam-
aged, replace the respective component.
CAUTION
2. Check the piston rod for damage. Dispose of the
Damaged or contaminated seal seats and piston rod if you find any grooves, corrosion pitting or
rods will result in immediate leaks, even with new scoring.
seals. The same applies to the use of unsuitable 3. Apply a thin coat of hydraulic oil to the piston rod
tools for seal removal and fitting. and the bare surfaces of the cylinder tube and cap.
 Before fitting a new seal check the seal seats and  The cylinder tube and piston rod are protected
piston rods for damage and make sure they are against corrosion and are prepared for assembly.
clean.
Fitting the lift cylinder
 When replacing rod seals use assembly equipment
and tools made of soft metal or plastic without sharp
edges. Suitable tools and assembly procedures are CAUTION
described starting on page 296.
Used sealing components can result in leaks
 Do not re-use sealing elements that have been re-
moved.  Always use new components from the seal kit,
never used ones, for assembly purposes.

Preparation
1. Apply a thin coat of hydraulic oil to the new dirt de-
1. Remove the lift cylinder (see page 300). flector (2), rod seal (3), guide ring (7) and seals (8,
Removing the piston rod and cylinder cap from the 19).
cylinder tube 2. Install the above-mentioned parts. Fit the rod seal
1. Loosen the cylinder cap (4) fully. (5) with the sealing lip first.
1. Pull the piston rod (10) off the cylinder tube (14). Note: Refer to the assembly instructions for rod seals
on page 298.
2. Remove the retaining rings (11) and cylinder cap
(13). 3. Push a new elastomer (1) up onto the piston rod as
far as the stop.
3. Take off the rod (12).
4. Push the pre-assembled cylinder cap (4) carefully
4. Pull the elastomer (1) and the cylinder cap (4) off
onto the piston rod as far as the elastomer.
the piston rod.
5. Fit the stop ring (11).
Removing the seals from the cylinder cap
6. Fit the new piston (12) and secure it with the retain-
5. Using suitable tools (see page 296) remove the fol- ing ring (13).
lowing components from the seats in the cylinder
7. Apply a generous amount of hydraulic oil to the
cap (4):
pre-assembled piston rod and carefully insert it into
– Deflector (2) the cylinder tube without twisting. Take care not to
– Rod seal (3) damage the seals in the process.
– Guide ring (7) 8. Screw on the cylinder cap and torque it to 120 - 140
– Seals (8, 9) Nm.
Note: Refer to the rod seal disassembly instructions on  The lift cylinder is now repaired and ready for as-
page 298. sembly.
6. Dispose of all seals. Final tasks
1. Assemble the lift cylinder (see page 298).

ES/ET4000 Series
Rev. B
313
CYLINDERS
REPAIRING THE LIFT CYLINDER FOR THE TF MAST

2
3
1

2 4
3
4 6
7 5
7
8 14
8
6
9
9 5

10

10

14

11

12

13
11
15
12

13
15

Fig. 134 Left TF mast lift cylinder

ES/ET4000 Series
Rev. B
314
 CYLINDERS
REPAIRING THE LIFT CYLINDER FOR THE TF MAST

Repairing the right lift cylinder Checking the cylinder tube and piston rod

Note: The following item numbers refer to Fig. 135. 1. Check the seats for the seal and guide items in the
cylinder tube (15) and the cylinder cap (6) for dam-
age. Make sure they are clean. If a seat is dam-
CAUTION aged, replace the respective component.
2. Check the piston rod for damage. Dispose of the
Damaged or contaminated seal seats and piston
rod if you find any grooves, corrosion pitting or
rods will result in immediate leaks, even with new
scoring.
seals. The same applies to the use of unsuitable
tools for seal removal and fitting. 3. Apply a thin coat of hydraulic oil to the piston rod
and the bare surfaces of the cylinder tube and cap.
 Before fitting a new seal check the seal seats and
piston rods for damage and make sure they are  The cylinder tube and piston rod are protected
clean. against corrosion and are prepared for assembly.
 When replacing rod seals use assembly equipment Fitting the lift cylinder
and tools made of soft metal or plastic without sharp
edges. Suitable tools and assembly procedures are
described starting on page 296. CAUTION
 Do not re-use sealing elements that have been re- Used sealing components can result in leaks
moved.  Always use new components from the seal kit,
never used ones, for assembly purposes.
Preparation
1. Remove the lift cylinder (see page 298). 1. Apply a thin coat of hydraulic oil to the new wiper
(4), rod seal (5), guide ring (9), backring (10) and
Removing the piston rod and cylinder cap from the the seal (11).
cylinder tube
2. Install the above-mentioned parts. Fit the rod seal
1. Loosen the cylinder cap (6) fully. (5) with the sealing lip first.
1. Pull the piston rod (2) off the cylinder tube (15). Note: Refer to the assembly instructions for rod seals
2. Remove the retaining rings (12) and (14). on page 298.
3. Take off the rod (13). 3. Push a new elastomer (3) up onto the piston rod as
4. Pull the elastomer (3) and the cylinder cap (6) off far as the stop.
the piston rod. 4. Push the pre-assembled cylinder cap (6) carefully
Removing the seals from the cylinder cap onto the piston rod as far as the elastomer.

5. Using suitable tools (see page 296) remove the fol- 5. Fit the stop ring (12).
lowing components from the seats in the cylinder 6. Fit the new piston (13) and secure it with the retain-
cap (6): ing ring (14).
– Deflector (4) 7. Apply a generous amount of hydraulic oil to the
– Rod seal (5) pre-assembled piston rod and carefully insert it into
the cylinder tube without twisting. Take care not to
– Guide ring (9) damage the seals in the process.
– Seal (11) 8. Screw on the cylinder cap and torque it to 120 -
– Backring (10) 140 Nm.
Note: Refer to the rod seal disassembly instructions on  The lift cylinder is now repaired and ready for as-
page 298. sembly.
6. Dispose of all seals. Final tasks
7. Clean all parts thoroughly and apply dry com- 1. Assemble the lift cylinder (see page 298).
pressed air.
 The cylinder is now dismantled and can be
checked for damage.

ES/ET4000 Series
Rev. B
315
CYLINDERS
REPAIRING THE LIFT CYLINDER FOR THE TF MAST

Fig. 135 Right TF mast lift cylinder

ES/ET4000 Series
Rev. B
316
 CYLINDERS
REPAIRING THE FREE LIFT CYLINDER FOR THE 1.2 AND 1.4 ES/ET - TF

Repairing the Free Lift Cylinder age. Make sure they are clean. If a seat is dam-
aged, replace the respective component.
for the 1.2 and 1.4 ES/ET - TF 2. Check the piston rod for damage. Dispose of the
Note: The following item numbers refer to Fig. 136. rod if you find any grooves, corrosion pitting or
scoring.
3. Apply a thin layer of hydraulic oil to the piston rod
CAUTION and bare surfaces on the cylinder tube.
Damaged or contaminated seal seats and piston  The cylinder tube and piston rod are protected
rods will result in immediate leaks, even with new against corrosion and are prepared for assembly.
seals. The same applies to the use of unsuitable
Free lift cylinder assembly
tools for seal removal and fitting.
 Before fitting a new seal check the seal seats and
piston rods for damage and make sure they are CAUTION
clean.
Used sealing components can result in leaks
 When replacing rod seals use assembly equipment
 Always use new components from the seal kit,
and tools made of soft metal or plastic without sharp
never used ones, for assembly purposes.
edges. Suitable tools and assembly procedures are
described starting on page 296.
 Do not re-use sealing elements that have been re- 1. Apply a thin coat of hydraulic oil to the new wiper
moved. ring (1), rod seal (2), guide ring (5), backring (6)
and the seal (7).
2. Install the above-mentioned parts. Fit the rod seal
Preparation (2) with the sealing lip first.
1. Disassemble the free lift cylinder (see page 305). Note: Refer to the assembly instructions for rod seals
Dismantling the free lift cylinder on page 298.
1. Unscrew the cylinder cap (3). 3. Fit the new piston (10) and secure it with the retain-
2. Remove the piston ram (8) from cylinder tube (12). ing ring (11).

3. Using suitable tools (see page 296) remove the fol- 4. Apply a generous amount of hydraulic oil to the pis-
lowing components from the seats in the cylinder ton rod and carefully insert it into the cylinder tube
cap (3): without twisting. Take care not to damage the
seals in the process.
– Wiper ring (1)
5. Carefully screw on the cylinder cap and torque it to
– Rod seal (2) 120 - 140 Nm.
– Guide ring (5)  The free lift cylinder is repaired and ready for as-
– Backring (6) sembly.
– Seal (7) Final tasks
Note: Refer to the rod seal disassembly instructions on 1. Assemble the free lift cylinder (see page 305).
page 298.
4. Dispose of all seals.
5. Remove the piston (10) from the piston rod and
dispose of it.
6. Clean all parts thoroughly and apply dry com-
pressed air.
 The cylinder is now dismantled and can be
checked for damage.
Checking the cylinder tube and piston rod
1. Check the seats for the seal and guide items in the
cylinder tube (12) and the cylinder cap (3) for dam-

ES/ET4000 Series
Rev. B
317
CYLINDERS
REPAIRING THE FREE LIFT CYLINDER FOR THE 1.2 AND 1.4 ES/ET - TF

1 2

3
3 4
2

5
5
4
6
6
7
7

8
~

12

12

10

11

13
9

10
13
11

Fig. 136 TF mast free lift cylinder

ES/ET4000 Series
Rev. B
318
 CYLINDERS
REPAIRING THE FREE LIFT CYLINDER FOR THE 1.6 ES/ET - TF OR TT

Repairing the Free Lift Cylinder Checking the cylinder tube and piston rod
1. Check the seats for the seal and guide items in the
for the 1.6 ES/ET - TF or TT cylinder tube (12) and the cylinder cap (3) for dam-
Note: The following item numbers refer to Fig. 136. age. Make sure they are clean. If a seat is dam-
aged, replace the respective component.
2. Check the piston rod for damage. Dispose of the
CAUTION rod if you find any grooves, corrosion pitting or
Damaged or contaminated seal seats and piston scoring.
rods will result in immediate leaks, even with new 3. Check the piston (10) and its seat in the cylinder
seals. The same applies to the use of unsuitable base for damage and make sure it is clean. Dis-
tools for seal removal and fitting. pose of any damaged components.
 Before fitting a new seal check the seal seats and 4. Apply a thin coat of hydraulic oil to all bare metal
piston rods for damage and make sure they are surfaces.
clean.  The components are protected against corrosion
 When replacing rod seals use assembly equipment and are prepared for assembly.
and tools made of soft metal or plastic without sharp
Free lift cylinder assembly
edges. Suitable tools and assembly procedures are
described starting on page 296.
 Do not re-use sealing elements that have been re- CAUTION
moved.
Used sealing components can result in leaks
 Always use new components from the seal kit,
Preparation never used ones, for assembly purposes.
1. Disassemble the free lift cylinder (see page 305).
Dismantling the free lift cylinder 1.
1. Unscrew the cylinder cap (3). 1. Apply a thin coat of hydraulic oil to the new wiper
2. Remove the piston ram (8) from cylinder tube (2). ring (5), rod seal (4), guide ring (17), backring (15)
and the seal (16).
3. Using suitable tools (see page 296) remove the fol-
lowing components from the seats in the cylinder 2. Install the above-mentioned parts. Fit the rod seal
cap (3): (2) with the sealing lip first.

– Wiper ring (5) Note: Refer to the assembly instructions for rod seals
on page 298.
– Rod seal (4)
3. Install the piston (10) with the spring (9) into the
– Guide ring (17) piston rod and secure it with the retaining ring (11).
– Backring (15) 4. Fit the new piston (13) and guide ring.
– Seal (16) 5. Apply a generous amount of hydraulic oil to the pis-
Note: Refer to the rod seal disassembly instructions on ton rod and carefully insert it into the cylinder tube
page 298. without twisting. Take care not to damage the
4. Dispose of all seals. seals in the process.
5. Remove the guide ring (14) and piston (13) and 6. Carefully screw on the cylinder cap and torque it to
dispose of them. 120 - 140 Nm.
6. Remove the retaining ring (11) and the piston (10)  The free lift cylinder is repaired and ready for as-
with the spring (9). sembly.
7. Clean all parts thoroughly and apply dry com- Final tasks
pressed air. 1. Assemble the free lift cylinder (see page 305).
 The cylinder is now dismantled and can be
checked for damage.

ES/ET4000 Series
Rev. B
319
CYLINDERS
REPAIRING THE FREE LIFT CYLINDER FOR THE 1.6 ES/ET - TF OR TT

1 2

3
3 4
2

5
5
4
6
6
7
7

8
~

12

12

10

11

13
9

10
13
11

Fig. 137 TF mast free lift cylinder

ES/ET4000 Series
Rev. B
320
PLATFORM
321
Notes:

322
 PLATFORM
ADJUSTING THE FOLDING PLATFORM SWITCH

Adjusting the Folding Platform Checking and adjusting switch

Switch PLS1 for rider mode

Pre-tensioning the spring assembly

2
1

2
1

Fig. 139 Panel removal

1 Bolts
2 Panel

Testing switch PLS1

3 1. Remove the four bolts (1) and take off the panel
(2).

Fig. 138 Pre-tensioning the spring assembly 3 4

1 Bolt
2 Counternut
3 Spindle (located on the inside)

1. Remove the front cover from the motor compart-

ment.
2. Fold the platform out approx. 45°.
5
3. Adjust the spindle (3) with the bolt (1) to produce a
distance of 1.5 mm to 2.0 mm from the top of the
spindle to the block (see Fig. 138).
Fig. 140 Checking switch PLS1
4. Using a flat iron (t = 15 mm) jam the bottom end of
the spindle (3) and fix the position with the counter- 3 Switch PLS1
nut, applying a torque of 20 - 25 Nm.
4 Screw
5 Screw

2. Fold the platform down and apply gentle pressure

to it.
 The LED on switch PLS1 (3) should light up.
 When the platform is discharged the LED on the
switch (3) should go out.
Note: If not, the switch must be adjusted.
Adjusting switch PLS1
1. Loosen the two M10 bolts (4, 5) on the inside and
outside of the chassis.

ES/ET4000 Series
Rev. B
323
PLATFORM
ADJUSTING THE FOLDING PLATFORM SWITCH

2. Move the bracket of the switch so that the LED of

switch PLS1 lights up when gentle pressure is ap-
plied to the platform.
3. Torque the screws (4,5) to 20 - 25 Nm.

Adjusting switch PLS2 for

pedestrian mode
Testing switch PLS2
1. Remove the cover from the platform (see Fig. 139).

3
1

Fig. 141 Checking switch PLS2

1 Lever arm
2 Switch PLS2
3 Bolt

1. Raise the platform to full extension.

 The LED on switch PLS2 (2) should light up.
Note: If not, the switch must be adjusted.
Adjusting switch PLS2
1. Raise the platform to full extension.
2. Loosen both bolts (3).
3. Using a feeler gauge, adjust switch PLS2 (2) to
produce a 2 mm gap from the lever arm (1).
 The LED on switch PLS2 should light up.
4. Torque the two bolts (3) on switch PLS2 (2) to 1 to
2 Nm.

ES/ET4000 Series
Rev. B
324
 PLATFORM
REPLACING THE FOLDING PLATFORM SPRINGS

Replacing the Folding Platform

Springs
Spring removal 5

6
8 7 6
1
Fig. 144 Spring removal
5 Dowel pin
6 Bolt
7 Bracket
Fig. 142 Cover removal 8 Axle (located on the inside) and pipe
1 Bolts
2 Panel

1. Remove the four bolts (1) and take off the panel
CAUTION
(2). Risk of injury from heavy component
The platform weighs approximately 31 kg.
 Use suitable lifting gear to remove and assemble
the platform.

4 3. Loosen the bolts (6) of the bracket (7) and remove

the complete platform. Note the wiring.
4. Remove the dowel pin (5).
3 5. Take out the axle (8) from the right.
Note: Be careful not to lose the two flanged sleeves
supporting the axle (8).

Spring assembly
Note: Assembly is the reverse of disassembly. Note
Fig. 143 Discharging the springs
the following:
3 Spring
1. If necessary replace the two flanged sleeves sup-
4 Screw
porting the axle (8).
2. After assembly, tension the spring (3) with the bolt
WARNING (4).

Pre-tensioned springs can cause injury

Pre-tensioned springs can snap off with extreme force.
 Be particularly careful when handling springs and
wear protective goggles.

2. Remove the bolt (4) to discharge the spring (3).

ES/ET4000 Series
Rev. B
325
Notes:

326
SCHEMATIC DIAGRAMS
327
Notes:

328
 SCHEMATIC DIAGRAMS
WIRE COLOUR CODE

Wire Colour Code • The last two digits are a sequence number.
Note: Third party component wires may pose an ex-
The wires used in the truck are colour-coded and num-
ception to this rule:
bered according to their function:
• The first or first two digits designate the wire colour.

Abbreviation Colour Colour number Function

BLK Black 0 ** Digital signal

BRN Brown 1 ** Analog signal
RED Red 2 ** Positive, not switched
ORG Orange 3 ** +12 VDC transformer
YEL Yellow 4 ** Third DC transformer
GRN Green 5 ** Negative, not switched
BLU Blue 6 ** Negative, insulated
VIO Violet 7 ** +5 VDC transformer
GREY Gray 8 ** Fourth DC transformer
WHT White 9 ** Miscellaneous
RED/WHT Red/White 29 ** Positive switched
GRN/WHT Green/White 59 ** Negative switched
** Numbers 01 to 99

ES/ET4000 Series Rev.3 05/2014

Rev. C
329
SCHEMATIC DIAGRAMS
GENERAL CONTACT SYMBOL ABBREVIATIONS

General Contact Symbol

Abbreviations
Note: If one of the above abbreviations is used more
than once, a number extension will be used, e.g. SV1,
SV2 etc.

Abbrevia- Description Abbreviation Description (Sheet 1 of 2)

tion

K Relay LMS Limit switch

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

Rev.3 05/2014 ES/ET4000 Series

Rev. C
330
 SCHEMATIC DIAGRAMS
GENERAL CONTACT SYMBOL ABBREVIATIONS

Abbrevia- Description Abbreviation Description (Sheet 2 of 2)

tion

PLS Platform switch TCM Traction motor

PS Pressure switch HR Heating
HCM Hydraulic control module ALM Travel Alarm
RECEIVER Receiver TRANSMITTER Transmitter
BDI Combination instrument CHARGER On-board charger
BRK Electromagnetic brake DR Driver
SLS Sideshift left switch SRS Sideshift right switch
ECS Lift control switch --- ---

ES/ET4000 Series Rev.3 05/2014

Rev. C
331
SCHEMATIC DIAGRAMS
ELECTRICAL WIRING DIAGRAMS

Electrical Wiring Diagrams

Europe USA Description Europe USA Description

Wires joining Switch applied manually

Wires crossing Solenoid valve

Wire connection Throttle / coil

Plug / socket Resistor

Wire strap Capacitor

Terminal board Potentiometer

Fuse Varistor
V

Assembly Thermal protector

Contact, normally Lamp

open

Contact, normally Horn

closed

Selective switch Battery

Contactor/relay Diode

Slow release contac- Breakdown diode

tor / relay

Time delay contactor LED

/ relay

Switch, normally Transistor

open

Rev.3 05/2014 ES/ET4000 Series

Rev. C
332
 SCHEMATIC DIAGRAMS
ELECTRICAL WIRING DIAGRAMS

Europe USA Description Europe USA Description

Push button, me- MOSFET

chanically actuated

Pushbutton, hydrau- Thyristor

lically actuated

Emergency power Comparator

disconnect

Motor armature Hall sensor

ES/ET4000 Series Rev.3 05/2014

Rev. C
333
Notes:

334
 SCHEMATIC DIAGRAMS
ES 4000 WITH MECHANICAL STEERING, STANDARD EQUIPMENT

ES 4000 with Mechanical Steering, Standard Equipment

CA211 CA410 CA420 12 11 10 9 8 7 6 5 4 3 2 1 CA411

B+ (FU2) 206 YEL 5

RS (FF)
FS (PF)
5 5 6

IC

FS

+
B+
B+ (AK) 2910 GRY 1

ACC
3 3 B+
nu 2

Out

U+
U-

-
FS
908 CAN-L 911 WHT
CAN-L 27 1 1 CAN-L

IC

RS
3

B+

-
CS1
CAN-H 28 900 CAN-H 903 BRN B- GND POT
4 4 CAN-H

Out
4

U+
U-
+13V RS

+
CS2
CA215 2919 2919 PINK CLK 7
302 SAS DI6 7 6 6 DATA BB B-
2 CA201 207 504 GRN R/T
CA412
002 CA201 2 2 B- μ-PROCESSOR

ACC
BLU
3

-
30 (μP)

ACC
4

HNS
ON BOARD CHARGER B- CA418 1 SAS

BLK
B+
B-
211

U+
U-
204 205

-
1
3 ACCESS 1
3 CLK SAS Signal
2
BLK
7 DATA

BLK
603

NTC
GRY
211 205 B+ (AK) held closed

Out +BV_F

IC
(DISPLAY DCM) 1

ࢡ
+
CS1

T
GND DI9 29 2 CS2

CA210

U+
U-
2917 + OUT 86 + 30 6 HNS 1
2 SMART + IN K CAN-H 9 3 1

IC
B+
B-
902 901 B- CA417

120 Ohm
DI4 31 85 - 87 8 1 12 1 2

Out
CAN CONNECTION
GND
2911 CA200 9
910 909
2
8 DC CONVERTER +10 V

BRK 5901
K 5900
4 10 V +10 V
U out U Reg. HNS 2
4 2 4 CAN-L 3 5 UB in
GND
4 1
CA419
11 R/T
B+ (AK) MAIN PCB 2 2

503

BLK12

BLK11
BLK10
4 10

BLK3
BLK7
BLK1
BLK2
BLK6

BLK8
BLK4
BLK5
DI10 16 5 4
CA208 CA201 B- HSS
2903 5907 6 3
1 SV1 2 34
CA201 CA414
1
ACCESS 8.1
SV MAST LIFT
33 DI7 35
1 R/T PCB (OCM 1)
CA209 CA204

10 V
2905 5905 906 MAGNETIC ROTARY ENCODER & IC MAGNETIC ROTARY ENCODER & IC
1 PV 2 24 CA213 1 1 10 V 360°
DC CONVERTER
UB in
360°
2922 2916 4 DSP DSP
DI8 17 C A 914
2 2 GND
HALL
ARRAY
GND U out HALL
ARRAY
PROP. V LOWER
ACCESS 2/3 6 OTP
TX +5V OTP
TX

INFO LINK
BLS Battery Latch B+ (Heating sw) X X
505 CA214 507 8
ABSOLUTE U Reg. ABSOLUTE
HN
CA201
(HCM / TCM) B-
B
2 WHT
B- 3 3 B+ (FU3)
INTERFACE SSI
VDD VDD
INTERFACE SSI

CLK

CLK
CSn

CSn
PNP LOS ENC RAS ENC

DO

DO
1 BRS 210 7 VSS VSS

2904 5906 BRN BRN 4 4 CS2

2
26 DI0 1 2
207 CS1
DI1 20 GRN GRN 5 5 1
2902 3 DATA
2908 5
3 B+ 2923 YEL
4 ORS 6 6 CLK
CA221 DI5 19 3
2914 5909 2927 CA415 HYDR. PCB
1 2 9 DI3 32

CA206
2907 5902
1 2 8
DI12 21 CA212 CA212.1
2915 BRN BLU
DI11 18 1 1 3
2923 WHT BRN
2 2 6
2927
3 LMS4
506 Speed reduction /
4
001 Rider Lift Stop
CA205 CA201 CHNL B 14
2906 5903 000 +13V
1 2 11 CHNL A 13 B-
2912 B+ 300
10 +13 V 25
2909 5904 600
LINE 12 GND 5
+ - 100
TS1 22
GND
CA207 2 1 TRACTION CA203
PWS MOTOR TS1 + BRN 100
1
502

209

T WHT / BRN 602

2
2901

CA202 STEER. CONN.

CONTROL LOGIC
208

B- B+
U CA 220
U AC BLK GND 2
601
2928
301
V 3 RED +13 V 1 1 1
FU4 FU2 FU3 V BLU CHNL B 4
000 5908
4A 4A 4A W M1 WHTCHNL A 3
001 2 2
W 101
3 3
B- ECR1
2900
203

202

907

120 Ohm
4 4
A/D 5908 915
(EVP2) 23 5 5
201

101 B+ (AK) 2929

200
B+
AN. 15 6 6
CONTROL LOGIC

2930 +IN SMART (from EPS - Safety Relais) 2930

DI2 6 7 7
510
-P 8 8
Ax B-
EDS
FU1 B+ B-
D2E2 D1E1
355A
5 EDS
M2
PUMP MOTOR
500
B- B-
BD:1 BD:2

829540_2I-1
24V BATT

Fig. 145

ES/ET4000 Series
Rev. B
335
SCHEMATIC DIAGRAMS
ES 4000 WITH MECHANICAL STEERING AND OPTIONS

ES 4000 with mechanical steering and options

CA211 CA420 12 11 10 9 8 7 6 5 4 3 2 1 CA411

B+ (FU2) CA410 5
206 YEL

RS (FF)
FS (PF)
5 5 6

IC

FS

+
B+
B+ (AK) 2910 GRY 1

ACC
3 3 B+
nu 2

Out

U+
U-

-
FS
908 CAN-L 911 WHT
CAN-L 27 1 1 CAN-L

IC

RS
3

B+

-
CS1
900 CAN-H 903 BRN B- GND POT
CAN-H 28 4 4 CAN-H

Out
4

U+
U-
RS

+
+13V CS2
CA215 2919 2919
6
PINK CLK 7
302 SAS DI6 7 6 DATA BB B-

2 CA201 504 GRN R/T

CA412
CA201 2 2 B- μ-PROCESSOR

ACC
BLU
002 3

-
30 (μP)

ACC
HNS
4
B- CA418 1 SAS /BRS2

BLK
B+
B-

U+
U-

+
205

-
205
211
1 3 ACCESS 1 3 CLK SAS Signal
BLK
KEYPAD 7 DATA 2

BLK
NTC
GRY
603 B+ (AK) held closed

Out +BV_F

IC

ࢡ
+
1
RED RED
(DISPLAY DCM) CS1

T
1 86 30

*
2
*

ADAPTER
GND DI9 29 RED/WHT RED/WHT
CS2
7

U+
U-
+ OUT 2 232
2917
2 SMART + IN KEYPAD BLACK BLK 232 CAN-H CA210 6
9 3 1
HNS 1

IC
B+
4 B-
B- CA417
902 901

120 Ohm
DI4 31 GRN
3
GRN
* KYS 2982 8 1 12 1 2

Out
CAN CONNECTION
GND
WHITE 2981 2983 87 2911 CA200 910 909 8
5 9 2 4 10 V
DC CONVERTER
+10 V
U out U Reg.
+10 V
HNS 2
BRK 5901 5900
4 6 85 2 4 5 UB in 4 1

501
CAN-L 3 GND CA419
11 R/T
B+ (AK)
MAIN PCB 2 2

503

BLK12
4 10

BLK8
BLK4
BLK5
BLK6
BLK3
BLK7
BLK1
BLK2

BLK11
BLK10
B-
DI10 16 5
CA208 CA201 B- 4 7
2903 5907 6 3 * HSS ACCESS 8.1
1 SV1 2 34
SV MAST LIFT
CA201 CA414 1 (OCM 1)
DI7 35 1 R/T PCB
33 CA204
CA209
2905 5905 906 980 CA415
CA213

10 V
1 PV 2 24 2916
1 1 10 V
MAGNETIC ROTARY ENCODER & IC DC CONVERTER
UB in
MAGNETIC ROTARY ENCODER & IC

2922 4 360°
DSP 360°
DI8 17 C A 914 985 DSP HALL GND U out HALL
PROP. V LOWER
ACCESS 2/3 BLS Battery Latch
2 2 GND
6 OTP
ARRAY
TX +5V OTP
ARRAY
TX
DC/DC
* 505 CA214 507 580 B+ (Heating sw) ABSOLUTE X U Reg. ABSOLUTE X
CONVERTER HN
CA201
(HCM / TCM) B
PNP
2 WHT
B- 3 3
B+ (FU3)
8 INTERFACE SSI
VDD VDD
INTERFACE SSI

BRS 280

CLK
CSn
CLK
CSn
(UL) 1 210 LOS ENC RAS ENC

DO
DO
B- 4 4 7 VSS VSS
2904 5906 BRN BRN CS2
OUTPUT INPUT 26 DI0 1 2
207 281 2
+ - + - GRN GRN 5 5 CS1
1
2902
DI1 20 3
2908 2980 DATA
3 B+ 2923 YEL
4 ORS 6 6 5
CA221 DI5 19 CLK
3
2914
1 2
5909
9 DI3 32
2927 HYDR. PCB
WHT

GRN
BRN

YEL

CA251
PC277

JC207

READER
CA206 15 24 25 13 5 4 781 RED 7 CA416

PROX.
* 1
082
1
GRN
1
*
BRN

BLK

2 3 3 1 2
1 2 2 1 2907
1 2
5902
8 CA250 3
083
4
WHT
4
DI12 21 CA212 CA212.1 14
681
2
BLK
2 1 2
ALM BLU 7
* 2915
1 BRN POT PCB F/C * CA416
DC/DC * DI11 18
2923
1
BRN
3 INFOLINK CA254
2 WHT

SENSOR
CONVERTER 2 6 780 VIO

SHOCK
2927 6 1 1
(non UL) FLS 3 LMS4 7
680
2
GRN
2
* 001
506
4 Speed reduction / 8
080
081
3
BRN
WHT
3
Rider Lift Stop 9 4 4
CHNL B 14
CA420 2 1

BRN
YEL
000 +13V CA212.2 *

681
CHNL A 13 B-
CA252
BLU
BLUE

BRN

BLK
GRN

300
RED

1
BLK

CA205 CA201 25 3
PC236

+13 V
JC240

BRN 084
2906 5903 600 2 11
085
1 RS232
2 1 11 GND 5 LMS3
12 2
1 2 2 1 2912 B+ 100 Lift limit override CA253
10 TS1 22 282
GND 26 1
2 ALM
2909 5904 581
PC207 2 1 LINE 12 TRACTION
TS1
CA203 27

PWS + - MOTOR + BRN 100

1
502

209

T WHT / BRN 602

2
2901

CA202 STEER. CONN.

CONTROL LOGIC

B+
208

B- U
U 601 CA 220
AC BLK GND 2
2928
301 1 1
FU4 FU2 FU3 V
V 3 RED +13 V 1
000
BLU CHNL B 4 5908
4A 4A 4A W M1 WHTCHNL A 3
001 2 2
W 101
3 3
B- ECR1 907
2900

120 Ohm
202
203

4 4
A/D 5908 915
(EVP2) 23 5 5
201

101 B+ (AK) 2929

200
B+
AN. 15 6 6
CONTROL LOGIC

2930 +IN SMART (from EPS - Safety Relais) 2930

DI2 6 7 7
510
8 8
Ax -P B-
EDS
FU1 B+ B-
211 207

D2E2 D1E1
355A LED PCB
5 EDS WHT RED
M2 BLK
1 1
BLK
PUMP MOTOR * RED RED
ON BOARD CHARGER
CHARGER
500 2 2
B- B- BRN BRN *
3 3
BD:1 BD:2

24V BATT
* OPTIONS
829540_2I-2

Fig. 146

ES/ET4000 Series
Rev. B
336
 SCHEMATIC DIAGRAMS
ES 4000 WITH ELECTRIC STEERING AND STANDARD EQUIPMENT

ES 4000 with electric steering and standard equipment

CA211 CA410 CA420 12 11 10 9 8 7 6 5 4 3 2 1 CA411

B+ (FU2) 206 YEL 5

RS (FF)
FS (PF)
5 5 6

IC

FS

+
B+
B+ (AK) 2910 GRY 1

ACC
3 3 B+
nu 2

Out

U+
U-

-
FS
908 CAN-L 911 WHT
CAN-L 27 1 1 CAN-L

IC

RS
3

B+

-
CS1
CAN-H 28 900 CAN-H 903 BRN B- GND POT
4 4 CAN-H

Out
4

U+
U-
+13V RS

+
CS2
CA215 2919 2919 PINK CLK 7
302 SAS DI6 7 6 6 DATA BB B-
2 CA201 207 504 GRN R/T
CA412
002 CA201 2 2 B- μ-PROCESSOR

ACC
BLU
3

-
4 30 (μP)

ACC
HNS
ON BOARD CHARGER B- CA418 1 SAS

BLK
B+
B-
211

U+
U-
204 205

-
1
3 ACCESS 1 3 CLK SAS Signal
2
BLK
7 DATA

BLK
603

NTC
GRY
211 205 B+ (AK) held closed

Out +BV_F

IC
(DISPLAY DCM) 1

ࢡ
+
CS1

T
GND DI9 29 2 CS2

CA210

U+
U-
2917 + OUT 86 + 30 6 HNS 1
2 SMART + IN K CAN-H 9 3 1

IC
B+
B-
902 901 B- CA417

120 Ohm
DI4 31 85 - 87 8 1 12 1 2

Out
CAN CONNECTION
GND
2911 CA200 9
910 909
2
8 DC CONVERTER +10 V

BRK 5901
K 5900
4 10 V +10 V
U out U Reg. HNS 2
4 2 4 CAN-L 3 5 UB in
GND
4 1
CA419
11 R/T
B+ (AK) MAIN PCB 2 2

503

BLK12

BLK11
BLK10
4 10

BLK3
BLK7
BLK1
BLK2
BLK6

BLK8
BLK4
BLK5
DI10 16 5 4
CA208 CA201 B- HSS
2903 5907 6 3
1 SV1 2 34
CA201 CA414
1
ACCESS 8.1
SV MAST LIFT
33 DI7 35
1 R/T PCB (OCM 1)
CA209 CA204
2905 5905

10 V
906 MAGNETIC ROTARY ENCODER & IC MAGNETIC ROTARY ENCODER & IC
1 PV 2 24 CA213 1 1 10 V 360°
DC CONVERTER
UB in
360°
2922 2916 4 DSP DSP
DI8 17 C A 914
2 2 GND
HALL
ARRAY
GND U out HALL
ARRAY
PROP. V LOWER
ACCESS 2/3 6 OTP
TX +5V OTP
TX

INFO LINK
BLS Battery Latch B+ (Heating sw) X X
505 CA214 507 8
ABSOLUTE U Reg. ABSOLUTE
HN
CA201
(HCM / TCM) B-
B
2 WHT
B- 3 3 B+ (FU3)
INTERFACE SSI
VDD VDD
INTERFACE SSI

CLK

CLK
CSn

CSn
PNP LOS ENC RAS ENC

DO

DO
1 BRS 210 7 VSS VSS

2904 5906 BRN BRN 4 4 CS2

2
26 DI0 1 2
207 CS1
DI1 20 GRN GRN 5 5 1
2902 3 DATA
2908 5
3 B+ 2923 YEL
4 ORS 6 6 CLK
CA221 FAN DI5 19 3
2914 5909 2927 CA415 HYDR. PCB
1 2 9 DI3 32

CA206
2907 5902
1 2 8
DI12 21 CA212 CA212.1
2915 BRN BLU
DI11 18 1 1 3
2923 WHT BRN
2 2 6
2927
3 LMS4
506 Speed reduction /
4
001 Rider Lift Stop
CA205 CA201 CHNL B 14
2906 5903 000 +13V
1 2 11 CHNL A 13 B-
2912 B+ 300
10 +13 V 25
2909
LINE
5904
12 GND 5
600 CA246
+ - 100 2950
TS1 22 5
GND
CA207 2 1 TRACTION CA203 5950 STEER SENS.
PWS MOTOR TS1 + BRN 100 6
1 BLU
502

209

150
T WHT / BRN 602 4 W2
2
680 Ohm GRN WHT
2901

CA202 STEER. CONN.

CONTROL LOGIC

B+
208

B- U 650 650 GRN BLK RED

U 601 CA 220 Low B1 2
AC BLK GND 2
2928 2950 151 151 BRN W1
301
V 3 RED +13 V 1 1 1 A1 W1 B6 3
FU4 FU2 FU3 V CHNL B 4
000 5908 5950 350 350 RED
4A 4A 4A W M1 BLU

WHTCHNL A 3
001 2 2 A2 High B2 1
W 101
3 3
150
A12 GND A10 651

B- ECR1 950 CAN-H

2900
203

202

120 Ohm
907 950 050
4 4 A14 CHNL B A8
5908 915 951 951 CAN-L 051
A/D 23 5 5 A6 CHNL A A9
(EVP2)
201

101 B+ (AK) 2929 2952 351

200
B+
AN. 15 6 6 2951 A5 CA240 = A +12 V B5
CONTROL LOGIC

2930 +IN SMART (from EPS - Safety Relais) 2930 2955 2955 652
DI2 6 7 7 A4 CA241 = B GND A11
510 550 052
-P 8 8 CHNL B B7
Ax B- 053
EDS
FU1 B+ SAHS 2
- 550 CHNL A B8
B- 352
D2E2 D1E1 3
5951 5951
A3 +12 V B4
355A
5 EDS NPN ACCESS 5 STEERING MOTOR ECR2 ECR3

351
2954 2953
M2 1 + A7

352
(SCM) W +12 V 1 +12 V 1
PUMP MOTOR CA 245 W
M3 CHNL A 3 053 CHNL A 3 051
B+ FU 5 V
500
B- V 3 CHNL B 2 052 CHNL B 2 050
B- U
+ + U
AC
GND 4 652 GND 4 651
BD:1 BD:2 30 A
CA242
- B- TS M3 B3 152
1
+ _ CA243
24V BATT 653 TS 3 T CA244
A13 2

829540 2I-3

Fig. 147

ES/ET4000 Series
Rev. B
337
SCHEMATIC DIAGRAMS
ES 4000 WITH ELECTRIC STEERING AND OPTIONS

ES 4000 with electric steering and options

CA211 CA420 12 11 10 9 8 7 6 5 4 3 2 1 CA411

B+ (FU2) CA410 5
206 YEL

RS (FF)
FS (PF)
5 5 6

IC

FS

+
B+
B+ (AK) 2910 GRY 1

ACC
3 3 B+
nu 2

Out

U+
U-

-
FS
908 CAN-L 911 WHT
CAN-L 27 1 1 CAN-L

IC

RS
3

B+

-
CS1
CAN-H 28 900 CAN-H 903 BRN B- GND POT
4 4 CAN-H

Out
4

U+
U-
+13V RS

+
CS2
CA215 2919 2919 PINK CLK 7
302 SAS DI6 7 6 6 DATA BB B-
2 CA201 504 GRN R/T
CA412
002 CA201 2 2 B- μ-PROCESSOR

ACC
BLU
3

-
4 30 (μP)

ACC
HNS
B- CA418 1 SAS /BRS2

BLK
B+
B-

U+
U-
205

-
211

205
1
3 ACCESS 1
3 CLK SAS Signal
BLK
KEYPAD 7 DATA 2

BLK
603

NTC
GRY
B+ (AK) held closed

Out +BV_F

IC
RED RED
(DISPLAY DCM) 1

ࢡ
+
CS1
86 30

T
1

*
GND *

ADAPTER
2 CS2
7
DI9 29 RED/WHT RED/WHT

U+
U-
+ OUT 2 232
2917
2 SMART + IN KEYPAD BLACK BLK 232 CAN-H CA210 6
3 1
HNS 1
4 9

IC
B+
B-
902 901 B- CA417

120 Ohm
DI4 31 GRN
3
GRN
* KYS 2982 8 1 12 1 2

Out
CAN CONNECTION
GND
WHITE
5 2981 2983 87 2911 CA200 9
910 909
2
8 DC CONVERTER +10 V
4 10 V +10 V
HNS 2
BRK 5901 5900 U out U Reg.

4 6 85 2 4 5 4 1

501
UB in
CAN-L 3 GND
CA419
11 R/T
B+ (AK) MAIN PCB 2 2

503

BLK12
4 10

BLK3
BLK7
BLK1
BLK2
BLK6

BLK8
BLK4
BLK5
BLK11
BLK10
B-
DI10 16 5
CA208 CA201 B- 4 7
2903
1 SV1 2
5907
34
6 3 * HSS ACCESS 8.1
SV MAST LIFT
CA201 CA414
1 (OCM 1)
33 DI7 35 1 R/T PCB
CA209 CA204
2905 5905 906 980
24 CA213 1 1 CA415

10 V
1 PV 2 MAGNETIC ROTARY ENCODER & IC DC CONVERTER MAGNETIC ROTARY ENCODER & IC
2922 2916 10 V 360°
UB in
360°
DI8 17 C A 914 985 4 DSP HALL DSP HALL
PROP. V LOWER
ACCESS 2/3 BLS Battery Latch
2 2 GND
6 OTP
ARRAY
TX
GND U out
OTP
ARRAY
TX
DC/DC CA214 +5V

CONVERTER
* HN (HCM / TCM)
505
B B-
507
3 3
580 B+ (Heating sw)
8
ABSOLUTE X U Reg. ABSOLUTE X
2 INTERFACE SSI INTERFACE SSI

(UL) CA201 PNP WHT

1 BRS 280 B+ (FU3) VDD VDD

CLK

CLK
CSn

CSn
210 LOS ENC RAS ENC

DO

DO
2904 5906 BRN B- BRN 4 4 7 VSS VSS

26 DI0 1 2 CS2
OUTPUT INPUT 207 281 2
+ - + -
DI1 20 GRN GRN 5 5 CS1
1
2902 3 2980
2908 DATA
3 B+ 2923 YEL
4 ORS 6 6 5
CA221 FAN DI5 19 CLK
2914 5909 2927
3
1 2 9 DI3 32 HYDR. PCB
WHT

GRN
BRN

YEL

CA251
PC277

JC207

READER
CA206 15 24 25 13 5 4 781 RED 7 CA416

PROX.
1
082
1
GRN
1
*
BRN

BLK

1 2 2 1 2907
1 2
5902
8 CA250 2
3
083
3
4
WHT
3
4
1 2
DI12 21 CA212 CA212.1 14
681
2
BLK
2 1 2
ALM BLU
* * 2915
1 BRN POT PCB F/C 7
DC/DC DI11 18
2923
1
BRN
3 INFOLINK CA254 * CA416
CONVERTER 2 WHT 2

SENSOR
6 780 VIO

SHOCK
(non UL) FLS 2927 6 1 1
3 LMS4 680 GRN
7 2 2
* 001
506
4 Speed reduction / 8
080
081
3
BRN
WHT
3
Rider Lift Stop 9
CHNL B 14 4 4

681
CA420 2 1

BRN
YEL
000 +13V CA212.2 CA252
CHNL A 13 B- * 084 3
BLUE

BLU
BRN

BLK
GRN

300 RS232
RED

1 11 1
BLK

CA205 CA201 25
PC236

+13 V 085
JC240

BRN 12 2
2906 5903 600 2
2 1 11 GND 5 LMS3
CA253
1 2 2 1 2912 B+ 100 26
282
1
10 TS1 22 Lift limit override
27
581
2 Alarm
CA246
2909 5904 GND 2950
CA207 2 1 LINE 12 TRACTION CA203 5950
5
STEER SENS.
PWS + - MOTOR TS1 + BRN 100 6
1 BLU
502

209

150
T WHT / BRN 602 4
2 W2
680 Ohm
2901

GRN WHT
CA202 STEER. CONN.
CONTROL LOGIC

B+
208

B- U 650 GRN BLK RED

U 601 CA 220 Low B1 2
AC BLK GND 2
2928 2950 151 BRN W1
301
V 3 RED +13 V 1 1 1 A1 W1 B6 3
FU4 FU2 FU3 V CHNL B 4
000 5908 5950 350 RED
4A 4A 4A W M1 BLU

WHTCHNL A 3
001 2 2 A2 High B2 1
W 101
3 3
150
A12 GND A10 651
B- ECR1 CAN-H
2900
203

202

907 950

120 Ohm
950 050
4 4 A14 CHNL B A8
5908 915 CAN-L 951
A/D
(EVP2) 23 5 5 951 A6 CHNL A A9
051
201

101 B+ (AK) 2929

200
B+
AN. 15 6 6 2951 2952
A5 CA240 = A +12 V B5
351
CONTROL LOGIC

2930 +IN SMART (from EPS - Safety Relais) 2930 2955 2955 652
DI2 6 7 7 A4 CA241 = B GND A11
211 207 510 550 052
-P 8 8 CHNL B B7
Ax LED PCB B- 053
EDS
FU1 B+ B- BLK BLK
WHT RED SAHS 2
- 550 CHNL A B8
* 1 1 5951 5951 B4 352
D2E2 D1E1 RED RED
ON BOARD CHARGER 3 A3 +12 V
355A 2 2 CHARGER
NPN ECR3
5 EDS
M2 1 +
2954 2953
A7 ACCESS 5 STEERING MOTOR ECR2

351
352
BRN
3 3
BRN * (SCM) W +12 V 1 +12 V 1
PUMP MOTOR CA 245 W
V M3 CHNL A 3
053
CHNL A 3 051
500
B- B+ FU 5 V 3 052 050
B- CHNL B 2 CHNL B 2
+ + U AC 651
U GND 4 652 GND 4
BD:1 BD:2 30 A
- B- _ CA242 CA243
TS M3 B3 152 1
+
24V BATT 653 TS 3 T CA244
A13 2
* OPTIONS
829540_2I-4

ES/ET4000 Series
Rev. B
338
 SCHEMATIC DIAGRAMS
ET 4000 WITH MECHANICAL STEERING, STANDARD EQUIPMENT

ET 4000 with mechanical steering, standard equipment

CA211 CA410 CA420 12 11 10 9 8 7 6 5 4 3 2 1 CA411

B+ (FU2) 206 YEL 5

RS (FF)
FS (PF)
5 5 6

IC

FS

+
B+
B+ (AK) 2910 GRY 1

ACC
3 3 B+
nu 2

Out

U+
U-

-
FS
908 CAN-L 911 WHT
CAN-L 27 1 1 CAN-L

IC

RS
3

B+

-
CS1
CAN-H 28 900 CAN-H 903 BRN B- GND POT
4 4 CAN-H

Out
4

U+
U-
RS

+
CS2
2919 2919 PINK CLK 7
MAST SAS DI6 7 6 6 DATA BB B-
+13V R/T
207 504 GRN
PS1 CA201 2 2 B- μ-PROCESSOR CA412
302

ACC
BLU
3

-
(μP)
CA201

ACC
HNS
P 2
ON BOARD CHARGER B- CA418 1 SAS
002

BLK
B+
B-
211

U+
U-
204 205

-
1 U 4 30 3 3 CLK SAS Signal
ACCESS 1 7 DATA 2
BLK

BLK
603 CA215

NTC
GRY
211 205 B+ (AK) held closed

Out +BV_F

IC
(DISPLAY DCM) 1

ࢡ
+
CS1

T
GND 2 CS2
DI9 29 CA210

U+
U-
2917 + OUT 86 + 30 6 HNS 1
2 SMART + IN K CAN-H 9 3 1

IC
B+
B-
902 901 B- CA417

120 Ohm
DI4 31 85 - 87 8 1 12 1 2

Out
CAN CONNECTION
GND
2911 CA200 9
910 909
2
8 DC CONVERTER +10 V

BRK 5901
K 5900
4 10 V +10 V
U out U Reg. HNS 2
4 2 4 CAN-L 3 5 UB in
GND
4 1
CA419
11 R/T
B+ (AK) MAIN PCB 2 2

503
CA217

BLK12

BLK11
BLK10
4 10

BLK3
BLK7
BLK1
BLK2
BLK6

BLK8
BLK4
BLK5
2926 2924
DI10 16 C A 5 4
CA208 CA201 PLS2 B-

B+ (AK)
508 3 HSS
2903 5907 B PNP PLS1 6
1 SV1 2 34
CA201 PNP 4 5
509
B 4 5 CA414
1
ACCESS 8.1
B-
SV MAST LIFT
33 DI7 35
2925 B-
A
2918
C
1 R/T PCB (OCM 1)
CA209 CA204
CA216

10 V
2905 5905 906 MAGNETIC ROTARY ENCODER & IC MAGNETIC ROTARY ENCODER & IC
1 PV 2 24 CA213 1 1 10 V 360°
DC CONVERTER
UB in
360°
2922 2916 4 DSP DSP
DI8 17 C A 914
2 2 GND
HALL
ARRAY
GND U out HALL
ARRAY
PROP. V LOWER
ACCESS 2/3 CA214 6 OTP
TX +5V OTP
TX

INFO LINK
BLS Battery Latch B+ (Heating sw) ABSOLUTE X U Reg. ABSOLUTE X
505 507
HN (HCM / TCM) B 1 BRS B- 3 3 8 INTERFACE SSI INTERFACE SSI
B- 2 B+ (FU3) VDD VDD

CA201

CLK

CLK
CSn

CSn
PNP 2913 LOS ENC RAS ENC

DO

DO
2 210 7 VSS VSS

2904 5906 2920 2920 4 4 CS2

2
26 DI0 1 3
207 CS1
DI1 20 4 5 5 1
2902 2908 DATA
3 B+ 2923 6 6 5
DI5 19 CLK
CA221 3
2914 5909 2927 CA415 HYDR. PCB
1 2 9 DI3 32

CA206 CA219 SR2

605 4 5
2907 5902 GND B
1 2 8 004 A
304
DI12 21 C NPN CA212 CA212.1
003 303 2915 BRN BLU
DI11 18 C A 1 1 3
604 2923 WHT BRN
GND B 2 2 6
NPN 4 5 2927
3 LMS4
CA218 SR1 506 Speed reduction /
4
001 Rider Lift Stop
CA205 CA201 CHNL B 14
2906 5903 000 +13V
1 2 11 CHNL A 13 B-
2912 B+ 300
10 +13 V 25
2909 5904 600
LINE 12 GND 5
+ - 100
TS1 22
GND
CA207 2 1 TRACTION CA203
PWS MOTOR TS1 + BRN 100
1
502

209

T WHT / BRN 602

2
2901

CA202 STEER. CONN.

CONTROL LOGIC
208

B- B+
U CA 220
U AC BLK GND 2
601
2928
301
V 3 RED +13 V 1 1 1
FU4 FU2 FU3 V BLU CHNL B 4
000 5908
4A 4A 4A W M1 WHTCHNL A 3
001 2 2
W 101
3 3
B- ECR1
2900
203

202

907

120 Ohm
4 4
A/D 5908 915
(EVP2) 23 5 5
201

101 B+ (AK) 2929

200
B+
AN. 15 6 6
CONTROL LOGIC

2930 +IN SMART (from EPS - Safety Relais) 2930

DI2 6 7 7
510
-P 8 8
Ax B-
EDS
FU1 B+ B-
D2E2 D1E1
355A
5 EDS
M2
PUMP MOTOR
500
B- B-
BD:1 BD:2

24V BATT 829540_2I-5

Fig. 148

ES/ET4000 Series
Rev. B
339
SCHEMATIC DIAGRAMS
ET 4000 WITH MECHANICAL STEERING AND OPTIONS

ET 4000 with mechanical steering and options

CA211 CA420 12 11 10 9 8 7 6 5 4 3 2 1 CA411

B+ (FU2) CA410 5
206 YEL

RS (FF)
FS (PF)
5 5 6

IC

FS

+
B+
B+ (AK) 2910 GRY 1

ACC
3 3 B+
nu 2

Out

U+
U-

-
FS
908 CAN-L 911 WHT
CAN-L 27 1 1 CAN-L

IC

RS
3

B+

-
CS1
CAN-H 28 900 CAN-H 903 BRN B- GND POT
4 4 CAN-H

Out
4

U+
U-
RS

+
CS2
2919 2919 PINK CLK 7
MAST SAS DI6 7 6 6 DATA BB B-
+13V R/T
504 GRN
PS1 CA201 2 2 B- μ-PROCESSOR CA412
302

ACC
BLU
3

-
CA201 (μP)

ACC
HNS
P 2
B- CA418 1 SAS /BRS2
002

BLK
B+
B-

U+
U-
205

-
U 4 30

211

205
1 3 ACCESS 1
3 CLK SAS Signal
2
BLK
7 DATA
CA215

BLK
603

NTC
GRY
held closed
(DISPLAY DCM) B+ (AK)

Out +BV_F

IC
RED RED 1

ࢡ
+
CS1
86 30

T
*
*

ADAPTER
GND 2 CS2
7
DI9 29 RED/WHT RED/WHT

U+
U-
+ OUT 232
2917
2 SMART + IN KEYPAD BLACK BLK 232 CAN-H CA210 6
3 1
HNS 1
9

IC
B+
B-
902 901 B- CA417

120 Ohm
DI4 31 GRN GRN
* KYS 2982 8 1 12 1 2

Out
CAN CONNECTION
GND
2981 2983 87 2911 CA200 9
910 909
2
8 DC CONVERTER +10 V
4 10 V +10 V
HNS 2
BRK 5901 5900 U out U Reg.

4 85 2 4 5 4 1

501
UB in
CAN-L 3 GND
CA419
11 R/T
B+ (AK) MAIN PCB 2 2
CA217

503

BLK12
4 10

BLK3
BLK7
BLK1
BLK2
BLK6

BLK8
BLK4
BLK5
BLK11
BLK10
B-
2926 2924
DI10 16 C A 5
CA208 CA201 PLS2 B- 4 7

B+ (AK)
2903
1 SV1 2
5907
34
508
B 509
PNP PLS1 6 3 * HSS ACCESS 8.1
PNP 4 5 B 4 5
SV MAST LIFT
CA201 B-
B-
CA414
1 (OCM 1)
33 DI7 35
2925
A
2918
C 1 R/T PCB
CA209 CA204
2905 5905
CA216 906 980
24 CA213 1 1 CA415

10 V
1 PV 2 MAGNETIC ROTARY ENCODER & IC DC CONVERTER MAGNETIC ROTARY ENCODER & IC
2922 2916 10 V 360°
UB in
360°
DI8 17 C A 914 985 4 DSP HALL DSP HALL
PROP. V LOWER
ACCESS 2/3 BLS Battery Latch CA214 2 2 GND
6 OTP
ARRAY
TX
GND U out
OTP
ARRAY
TX
DC/DC +5V

CONVERTER
* HN (HCM / TCM)
505
B 1 BRS B-
507
3 3 580 B+ (Heating sw)
8
ABSOLUTE X U Reg. ABSOLUTE X
2 INTERFACE SSI INTERFACE SSI

(UL) CA201 PNP 2913 280 B+ (FU3) VDD VDD

CLK

CLK
CSn

CSn
2 210 LOS ENC RAS ENC

DO

DO
2904 5906 2920 B- 2920 4 4 7 VSS VSS

26 DI0 1 3 CS2
OUTPUT INPUT 207 281 2
+ - + -
DI1 4 5 5 CS1
1
2902 20 2908 2980 DATA
3 B+
DI5 2923 6 6 5
CA221 19 CLK
3
2914 5909 2927 HYDR. PCB
1 2 9 DI3 32
WHT

GRN
BRN

YEL

CA251
PC277

JC207

CA219 SR2

READER
CA206 4 5 15 24 25 13 5 4 781 RED 7 CA416

PROX.
605 * 1
082
1
GRN
1
*
BRN

BLK

1 2 2 1 2907 5902 GND B CA250 2 3 3 1 2

1 2 8 004 A
304 3
083
4
WHT
4
DI12 21 C NPN CA212 CA212.1 14
681
2
BLK
2 1 2
ALM BLU
* * 003 303 2915
1 BRN POT PCB F/C 7
DC/DC DI11 18 C A
2923
1
BRN
3 INFOLINK CA254 * CA416
CONVERTER 604 2 WHT 2

SENSOR
GND B 6 780 VIO

SHOCK
(non UL) FLS
NPN 4 5 2927 6
680
1
GRN
1
3 LMS4
* CA218 SR1 506 Speed reduction /
7
8
080
2
3
BRN
2
3
4 081 WHT
001 Rider Lift Stop 9
CHNL B 14 4 4
CA420 2 1

BRN
YEL
000 +13V CA212.2
13 *

681
CHNL A B-
CA252
BLUE

BLU
BRN

BLK
GRN

300
RED

1
BLK

CA205 CA201 25
PC236

+13 V 3
JC240

BRN 084
2906 5903 600 2 11
085
1 RS232
2 1 11 GND 5 LMS3
12 2
1 2 2 1 2912 B+ 100 CA253
10 TS1 22 Lift limit override
282
GND 26 1
2 Alarm
2909 5904 581
CA207 2 1 LINE 12 TRACTION CA203 27
PWS + - MOTOR TS1 + BRN 100
1
502

209

T WHT / BRN 602

2
2901

CA202 STEER. CONN.

CONTROL LOGIC

B+
208

B- U
U 601 CA 220
AC BLK GND 2
2928
301
V 3 RED +13 V 1 1 1
FU4 FU2 FU3 V BLU CHNL B 4
000 5908
4A 4A 4A W M1 WHTCHNL A 3
001 2 2
W 101
3 3
B- ECR1
2900
203

202

907

120 Ohm
4 4
A/D 5908 915
(EVP2) 23 5 5
201

101 B+ (AK) 2929

200
B+
AN. 15 6 6
CONTROL LOGIC

2930 +IN SMART (from EPS - Safety Relais) 2930

DI2 6 7 7
510
-P 8 8
Ax B-
EDS
FU1 B+ B-
211 207

D2E2 D1E1
355A LED PCB
5 EDS WHT RED
M2 BLK
1 1
BLK
PUMP MOTOR * RED RED
ON BOARD CHARGER
2 2 CHARGER
500
B- B- BRN BRN *
3 3
BD:1 BD:2

24V BATT
* OPTIONS
829540_2I-6

Fig. 149

ES/ET4000 Series
Rev. B
340
 SCHEMATIC DIAGRAMS
ET 4000 WITH ELECTRIC STEERING AND STANDARD EQUIPMENT

ET 4000 with electric steering and standard equipment

CA211 CA410 CA420 12 11 10 9 8 7 6 5 4 3 2 1 CA411

B+ (FU2) 206 YEL 5

RS (FF)
FS (PF)
5 5 6

IC

FS

+
B+
B+ (AK) 2910 GRY 1

ACC
3 3 B+
nu 2

Out

U+
U-

-
FS
908 CAN-L 911 WHT
CAN-L 27 1 1 CAN-L

IC

RS
3

B+

-
CS1
CAN-H 28 900 CAN-H 903 BRN B- GND POT
4 4 CAN-H

Out
4

U+
U-
RS

+
CS2
2919 2919 PINK CLK 7
MAST SAS DI6 7 6 6 DATA BB B-
+13V R/T
207 504 GRN
PS1 CA201 2 2 B- μ-PROCESSOR CA412
302

ACC
BLU
3

-
(μP)
CA201

ACC
HNS
P 2
ON BOARD CHARGER B- CA418 1 SAS
002

BLK
B+
B-
211

U+
U-
204 205

-
1 U 4 30 3 3 CLK SAS Signal
ACCESS 1 7 DATA 2
BLK

BLK
603 CA215

NTC
GRY
211 205 B+ (AK) held closed

Out +BV_F

IC
(DISPLAY DCM) 1

ࢡ
+
CS1

T
GND 2 CS2
DI9 29 CA210

U+
U-
2917 + OUT 86 + 30 6 HNS 1
2 SMART + IN K CAN-H 9 3 1

IC
B+
B-
902 901 B- CA417

120 Ohm
DI4 31 85 - 87 8 1 12 1 2

Out
CAN CONNECTION
GND
2911 CA200 9
910 909
2
8 DC CONVERTER +10 V

BRK 5901
K 5900
4 10 V +10 V
U out U Reg. HNS 2
4 2 4 CAN-L 3 5 UB in
GND
4 1
CA419
11 R/T
B+ (AK) MAIN PCB 2 2

503
CA217

BLK12

BLK11
BLK10
4 10

BLK3
BLK7
BLK1
BLK2
BLK6

BLK8
BLK4
BLK5
2926 2924
DI10 16 C A 5 4
CA208 CA201 PLS2 B-

B+ (AK)
508 3 HSS
2903 5907 B PNP PLS1 6
1 SV1 2 34
CA201 PNP 4 5
509
B 4 5 CA414
1
ACCESS 8.1
B-
SV MAST LIFT
33 DI7 35
2925 B-
A
2918
C
1 R/T PCB (OCM 1)
CA209 CA204
CA216

10 V
2905 5905 906 MAGNETIC ROTARY ENCODER & IC MAGNETIC ROTARY ENCODER & IC
1 PV 2 24 CA213 1 1 10 V 360°
DC CONVERTER
UB in
360°
2922 2916 4 DSP DSP
DI8 17 C A 914
2 2 GND
HALL
ARRAY
GND U out HALL
ARRAY
PROP. V LOWER
ACCESS 2/3 CA214 6 OTP
TX +5V OTP
TX

INFO LINK
BLS Battery Latch B+ (Heating sw) ABSOLUTE X U Reg. ABSOLUTE X
505 507
HN (HCM / TCM) B 1 BRS B- 3 3 8 INTERFACE SSI INTERFACE SSI
B- 2 B+ (FU3) VDD VDD

CA201 2913

CLK

CLK
CSn

CSn
PNP LOS ENC RAS ENC

DO

DO
2 210 7 VSS VSS

2904 5906 2920 2920 4 4 CS2

2
26 DI0 1 3
207 CS1
4 5 5 1
2902 DI1 20 2908 DATA
3 B+ 6 6 5
2923 CLK
CA221 FAN DI5 19 3
2914 5909 2927 CA415 HYDR. PCB
1 2 9 DI3 32

CA206 CA219 SR2

605 4 5
2907 5902 GND B
1 2 8 004 A
304
DI12 21 C NPN CA212 CA212.1
003 303 2915 BRN BLU
DI11 18 C A 1 1 3
604 2923 WHT BRN
GND B 2 2 6
NPN 4 5 2927
3 LMS4
CA218 SR1 506 Speed reduction /
4
001 Rider Lift Stop
CA205 CA201 CHNL B 14
2906 5903 000 +13V
1 2 11 CHNL A 13 B-
2912 B+ 300
10 +13 V 25
2909
LINE
5904
12 GND 5
600 CA246
+ - 100 2950 BLU TFD UNIT
TS1 22 5
+
GND Coil
CA207 2 1 TRACTION CA203 5950 WHT
PWS MOTOR TS1 + BRN 100 6
1
502

209

150 ORN
T WHT / BRN 602 4
2 W2
680 Ohm
2901

CA202 STEER. CONN.

CONTROL LOGIC
208

B- B+ 650 650 BLK

U CA 220 Low B1 2
U AC BLK GND 2
601
2928 2950 151 151 GRN W1
301
V 3 RED +13 V 1 1 1 A1 W1 B6 3
FU4 FU2 FU3 V CHNL B 4
000 5908 5950 350 350 RED
4A 4A 4A W M1 BLU

WHTCHNL A 3
001 2 2 A2 High B2 1
W 101
3 3
150
A12 GND A10 651

B- ECR1 950 CAN-H

2900
203

202

120 Ohm
907 950 050
4 4 A14 CHNL B A8
5908 915 951 951 CAN-L 051
A/D 23 5 5 A6 CHNL A A9
(EVP2)
201

101 B+ (AK) 2929 2952 351

200
B+
AN. 15 6 6 2951 A5 CA240 = A +12 V B5
CONTROL LOGIC

2930 +IN SMART (from EPS - Safety Relais) 2930 2955 2955 652
DI2 6 7 7 A4 CA241 = B GND A11
510 550 052
-P 8 8 CHNL B B7
Ax B- 053
EDS
FU1 B+ SAHS 2
- 550 CHNL A B8
B- 352
D2E2 D1E1 3
5951 5951
A3 +12 V B4
355A
5 EDS NPN ACCESS 5 STEERING MOTOR ECR2 ECR3

351
2954 2953
M2 1 + A7

352
(SCM) W +12 V 1 +12 V 1
PUMP MOTOR CA 245 W
M3 CHNL A 3 053 CHNL A 3 051
B+ FU 5 V
500
B- V 3 CHNL B 2 052 CHNL B 2 050
B- U
+ + U
AC
GND 4 652 GND 4 651
BD:1 BD:2 30 A
CA242
- B- TS M3 B3 152
1
+ _ CA243
24V BATT 653 TS 3 T CA244
A13 2

829540_2I-7

Fig. 150

ES/ET4000 Series
Rev. B
341
SCHEMATIC DIAGRAMS
ET 4000 WITH ELECTRIC STEERING AND OPTIONS

ET 4000 with electric steering and options

CA211 CA420 12 11 10 9 8 7 6 5 4 3 2 1 CA411

B+ (FU2) CA410 5
206 YEL

RS (FF)
FS (PF)
5 5 6

IC

FS

+
B+
B+ (AK) 2910 GRY 1

ACC
3 3 B+
nu 2

Out

U+
U-

-
FS
908 CAN-L 911 WHT
CAN-L 27 1 1 CAN-L

IC

RS
3

B+

-
CS1
CAN-H 28 900 CAN-H 903 BRN B- GND POT
4 4 CAN-H

Out
4

U+
U-
RS

+
CS2
2919 2919 PINK CLK 7
MAST SAS DI6 7 6 6 DATA BB B-
+13V R/T
504 GRN
PS1 CA201 2 2 B- μ-PROCESSOR CA412
302

ACC
BLU
3

-
CA201 (μP)

ACC
HNS
P 2
B- CA418 1 SAS /BRS2
002

BLK
B+
B-

U+
U-
205

-
U 4 30

211

205
1 3 ACCESS 1
3 CLK SAS Signal
2
BLK
7 DATA
CA215

BLK
603

NTC
GRY
held closed
(DISPLAY DCM) B+ (AK)

Out +BV_F

IC
RED RED 1

ࢡ
+
CS1
86 30

T
*
*

ADAPTER
GND 2 CS2
7
DI9 29 RED/WHT RED/WHT

U+
U-
+ OUT 232
2917
2 SMART + IN KEYPAD BLACK BLK 232 CAN-H CA210 6
3 1
HNS 1
9

IC
B+
B-
902 901 B- CA417

120 Ohm
DI4 31 GRN GRN
* KYS 2982 8 1 12 1 2

Out
CAN CONNECTION
GND
2981 2983 87 2911 CA200 9
910 909
2
8 DC CONVERTER +10 V
4 10 V +10 V
HNS 2
BRK 5901 5900 U out U Reg.

4 85 2 4 5 4 1

501
UB in
CAN-L 3 GND
CA419
11 R/T
B+ (AK) MAIN PCB 2 2

503
CA217

BLK12
4 10

BLK3
BLK7
BLK1
BLK2
BLK6

BLK8
BLK4
BLK5
BLK11
BLK10
B-
2926 2924
DI10 16 C A 5
CA208 CA201 PLS2 B- 4 7

B+ (AK)
2903
1 SV1 2
5907
34
508
B 509
PNP PLS1 6 3 * HSS ACCESS 8.1
PNP 4 5 B 4 5
SV MAST LIFT
CA201 B-
B-
CA414
1 (OCM 1)
33 DI7 35
2925
A
2918
C 1 R/T PCB
CA209 CA204
2905 5905
CA216 906 980
24 CA213 1 1 CA415

10 V
1 PV 2 MAGNETIC ROTARY ENCODER & IC DC CONVERTER MAGNETIC ROTARY ENCODER & IC
2922 2916 10 V 360°
UB in
360°
DI8 17 C A 914 985 4 DSP HALL DSP HALL
PROP. V LOWER
ACCESS 2/3 BLS Battery Latch CA214 2 2 GND
6 OTP
ARRAY
TX
GND U out
OTP
ARRAY
TX
DC/DC +5V

CONVERTER
* HN (HCM / TCM)
505
B 1 BRS B-
507
3 3 580 B+ (Heating sw)
8
ABSOLUTE X U Reg. ABSOLUTE X
2 INTERFACE SSI INTERFACE SSI

(UL) CA201 PNP 2913 280 B+ (FU3) VDD VDD

CLK

CLK
CSn

CSn
2 210 LOS ENC RAS ENC

DO

DO
2904 5906 2920 B- 2920 4 4 7 VSS VSS

26 DI0 1 3 CS2
OUTPUT INPUT 207 281 2
+ - + -
DI1 4 5 5 CS1
1
2902 20 2908 2980 DATA
3 B+
DI5 2923 6 6 5
CA221 FAN 19 CLK
3
2914 5909 2927 HYDR. PCB
1 2 9 DI3 32
WHT

GRN
BRN

YEL

CA251
PC277

JC207

CA219 SR2

READER
CA206 4 5 15 24 25 13 5 4 781 RED 7 CA416

PROX.
605
1
082
1
GRN
1
*
BRN

BLK

1 2 2 1 2907 5902 GND B CA250 2 3 3 1 2

1 2 8 004 A
304 3
083
4
WHT
4
DI12 21 C NPN CA212 CA212.1 14
681
2
BLK
2 1 2
ALM BLU
* * 003 303 2915
1 BRN POT PCB F/C 7
DC/DC DI11 18 C A
2923
1
BRN
3 INFOLINK CA254 * CA416
CONVERTER 604 2 WHT 2

SENSOR
GND B 6 780 VIO

SHOCK
(non UL) FLS
NPN 4 5 2927 6
680
1
GRN
1
3 LMS4
* CA218 SR1 506 Speed reduction /
7
8
080
2
3
BRN
2
3
4 081 WHT
001 Rider Lift Stop 9
CHNL B 14 4 4
CA420 2 1

BRN

681
YEL
000 +13V CA212.2 CA252
CHNL A 13 B- * 084 3
BLUE

BLU
BRN

BLK
GRN

300 RS232
RED

1 11 1
BLK

CA205 CA201 25
PC236

+13 V 085
JC240

BRN 12 2
2906 5903 600 2
2 1 11 GND 5 CA253
1 2 2 1 2912 B+ 100
LMS3
26
282
1
TFD UNIT
10 TS1 22 Lift limit override
27
581
2 Alarm
CA246 +
2909 5904 GND 2950 BLU
CA207 2 1 5 Coil
LINE 12 TRACTION
TS1
CA203 5950 WHT
PWS + - MOTOR + BRN 100 6
1
502

209

150 ORN
T WHT / BRN 602 4
2 W2
680 Ohm
2901

CA202 STEER. CONN.

CONTROL LOGIC

B+
208

B- U 650 BLK
U 601 CA 220 Low B1 2
AC BLK GND 2
2928 2950 151 GRN W1
301
V 3 RED +13 V 1 1 1 A1 W1 B6 3
FU4 FU2 FU3 V CHNL B 4
000 5908 5950 350 RED
4A 4A 4A W M1 BLU

WHTCHNL A 3
001 2 2 A2 High B2 1
W 101
3 3
150
A12 GND A10 651
B- ECR1 CAN-H
2900
203

202

907 950

120 Ohm
950 050
4 4 A14 CHNL B A8
5908 915 CAN-L 951
A/D
(EVP2) 23 5 5 951 A6 CHNL A A9
051
201

101 B+ (AK) 2929

200
B+
AN. 15 6 6 2951 2952
A5 CA240 = A +12 V B5
351
CONTROL LOGIC

2930 +IN SMART (from EPS - Safety Relais) 2930 2955 2955 652
DI2 6 7 7 A4 CA241 = B GND A11
211 207 510 550 052
-P 8 8 CHNL B B7
Ax LED PCB B- 053
EDS
FU1 B+ B- BLK BLK
WHT RED SAHS 2
- 550 CHNL A B8
* 1 1 5951 5951 B4 352
D2E2 D1E1 RED RED
ON BOARD CHARGER 3 A3 +12 V
355A 2 2 CHARGER
NPN ECR3
5 EDS
M2 1 +
2954 2953
A7 ACCESS 5 STEERING MOTOR ECR2

351
352
BRN
3 3
BRN * (SCM) W +12 V 1 +12 V 1
PUMP MOTOR CA 245 W
V M3 CHNL A 3
053
CHNL A 3 051
500
B- B+ FU 5 V 3 052 050
B- CHNL B 2 CHNL B 2
+ + U AC 651
U GND 4 652 GND 4
BD:1 BD:2 30 A
- B- _ CA242 CA243
TS M3 B3 152 1
+
24V BATT 653 TS 3 T CA244
A13 2
* OPTIONS
829540_2I-8

Fig. 151

ES/ET4000 Series
Rev. B
342
 SCHEMATIC DIAGRAMS
ES/ET CAN-BUS CONNECTIONS, MECHANICAL STEERING

ES/ET CAN-Bus Connections, Mechanical Steering

CAN CONNECTION INFO LINK

1 3 4 5 6 2 CA210 1 3 4 5 6 2 CA204
901 909 906 914

SP12
906 CAN-H

SP13
914 CAN-L

905 913
915
SP11
912
SP9 910 907
SP10
904 904
SP8

911 903 907 915

1 2 3 5 6 4 CA211 1 2 3 4 5 6 7
6 8 CA220
1 2 3 4 5 6 7
6 8

900 908 WHT BRN 902 910

120 Ohm
CA201 CA410 CA200
28

27

USED FOR
MECH. STEERING
CAN CAN CAN CAN 120 Ohm
HIGH LOW LOW HIGH
CAN CAN
HIGH LOW

ACCESS 2/3 ACCESS 8.1 ACCESS 1

(HCM / TCM) (INTERFACE) (DISPLAY) 829540_2I-9

Fig. 152

ES/ET4000 Series
Rev. B
343
SCHEMATIC DIAGRAMS
ES/ET CAN-BUS CONNECTIONS, ELECTRIC STEERING

ES/ET CAN-Bus connections, electric steering

CAN CONNECTION INFO LINK

1 3 4 5 6 2 CA210 1 3 4 5 6 2 CA204
901 909 906 914

SP12
906 CAN-H

SP13
914 CAN-L

905 913
915
SP11
912
SP9 910 907
SP10
904 904
SP8

911 903 907 915

1 2 3 5 6 4 CA211 1 2 3 4 5 6 7
6 8 CA220
1 2 3 4 5 6 7
6 8

900 908 WHT BRN 902 910 950 951

A14
CA201 CA410 CA200 CA240

A6
28

27

CAN CAN CAN CAN 120 Ohm 120 Ohm

HIGH LOW LOW HIGH
CAN CAN CAN CAN
HIGH LOW HIGH LOW

ACCESS 2/3 ACCESS 8.1 ACCESS 1 ACCESS 5

(HCM / TCM) (INTERFACE) (DISPLAY) (SCM)
829540_2I-10

Fig. 153

ES/ET4000 Series
Rev. B
344
 SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS ES 4000

Main Wire Harness ES 4000

LINE CONTACTOR
Coil Contact
86 85 87 30
Access 1 (DISPLAY) CONTACT EDS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 PC200 COIL+ COIL- IN OUT IN OUT FU2 4A FU3 4A FU4 4A

204
211
5900
2911
205
204

5900
205
503

902
910

2909
5904

200
2900

200
201
IN OUT IN OUT IN OUT

202
208

2900
2901

203
209
501
KEYPAD

2917
BRK 5901

PC211
PC202 911
1 Handle
301 504
ECR 1 2
601 400 2910
2 3
001 SP8 SP9 SP3 SP7 SP6 SP2 903
3 4
000 206
K 4
PC221 5

SP4
2919
2914 6
1 FAN
PC203 5909
2
JC214

SP5
100
TS1 1 WHT
602 BRS 1
L 2 BRN 2904
2 PC212
GRN 5906 HN
ORS 3 2915
4
YEL 1 LMS
PC220 120 2923
2
2928 2927
STEER CONN. 1 3
5908

SP1
506
2 500 4
3
101 BATT -
907
4

SP10
915
5
2929
6

SP11
2930
7
510
8

CROWN PN
PC207
209
PWS 1
SP13

502

2905
5905
2
603
302

002

2903
5907
Spline Table
PC206 1 2 3 4 PC215 1 2 PC208 1 2 PC209
SP12

SPLINE 1 (BATT NEG.) SPLINE 3 (B+ AK) SPLINE 6 (B+ FU2) SPLINE 10 (CAN HIGH)

SP14
2907
ALM 1 PS1 SV1 PV 500 BATT- 2908 PC204-5 206 PC211-5 900 PC201-28
5902
2
501 Keypad 2909 Line Coil 208 FU2 OUT 904 SPLINE 8
502 PC207-2 2910 PC211-3 210 PC204-4 905 SPLINE 12
PC205 PC201
2906
503 PC200-4 2911 Socket 87 SPLINE 7 SPLINE 11 (CAN LOW)
FL) 1 504 PC211-2 2912 PC201-10 201 EDS OUT 908 PC201-27
5903
2
505 PC213-B WHT JC214-1 202 FU2 IN 912 SPLINE 9
BRN
2917
2902
5901

2919
5902
5909
2912
5903
5904

2922

2923
GRN

5908
5905

5906

2927

5907
2930
600

000
001
101

100

300

908
900

002
506 PC212-4 YEL JC214-4 203 FU4 IN 913 SPLINE 13
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 12 1 12 1 1 12 1 1 1 1 1 1 1 12 1 12 1 12 1 12
PC210 507 PC204-3 2915 PC212-1 SPLINE 8 (CAN HIGH) SPLINE 12 (CAN HIGH)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
901 211 510 PC220-8 2916 PC213-A 902 PC200-8 901 PC210-1
CAN 1 21+22 ON BOARD
CONNECTION 2
909 207
9+10 CHARGER Access 3/2 (TCM/HCM) SPLINE 2 (FU3 OUT) 2929 PC220-6 903 PC211-4 905 SPLINE 10
w/o charger terminals must be connected
2901 FU3 OUT SPLINE 4 (+13V) 904 SPLINE 10 906 PC204-1
3
4
2902 PC201-3 300 PC201-25 907 PC220-4 SPLINE 13 (CAN LOW)
5
2903 PC208-1 301 PC202-1 SPLINE 9 (CAN LOW) 909 PC210-2
6
2904 Horn 302 PC215-2 910 PC200-9 913 SPLINE 11
2905 PC209-1 SPLINE 5 (GND) 911 PC211-1 914 PC204-2
PC204 2906 PC205-1 600 PC201-5 912 SPLINE 11
906 Adapter 2907 PC206-1 601 PC202-2 915 PC220-5
INFOLINK 1 Truck with Display w/o KYS
2
914 see Detail A Detail B KYS 205
2914 PC221-1 602 PC203-2
30
507 Truck with Display w/ KYS 2981 2982 2928 PC220-1 603 PC215-1
3 87 2911
210
see Detail B 2983
4 1) Cut off and isolate Wire 204 232 86 211
2908 232
5 2) Use Adapter PN820143 for KYS
207
6

Detail A
PC213
2916
BLS A
505
B
C
2922 825410_2G-1

Fig. 154

ES/ET4000 Series
Rev. B
345
SCHEMATIC DIAGRAMS
MAIN WIRE HARNESS ET 4000

Main wire harness ET 4000

SR2 SR1 LINE CONT. Access 1 (DISPLAY) FU2 4A FU3 4A FU4 4A

CONT.CONT. EDS
A B C PC219 A B C PC218 COIL+ COIL- IN OUT IN OUT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PC200 IN OUT IN OUT IN OUT
KEYPAD

304
605
004

303
604
003

2909
5904

200
2900

200
201

5900
205
503

902
910

202
208

2900
2901
Socket

203
209
130

130
501
Coil Contact
Detail A
204
211
5900
2911
205
204

PC211
911
1 Handle
2917 504
2
BRK 5901 2910
3
SP7 SP6 SP2 903
4
206
PC202

SP4
5
301 2919
ECR 1 6
601
2 500
3
001 SP8 SP9 SP3 BATT -
000
PC212
4
JC214 2915
1 LMS

SP5
2923
BRS 1 2
PC203 2
2913 2904 2927
3
TS1 1
100
3
2920 5906 HN 506
4
602
2 4
PC221
2914
FAN
1
PC220

SP1
5909
2
2928
STEER CONN. 1
5908
2

SP10
101
3
907
4
915

SP11
5
2929
6
2930
7
510
8

PC207 Spline Table

2918

2925

2924

2926

2905
5905
603
302

002

2903
5907
509

508

PWS 1 209
SP13

502 PC216 PC217 PC215 PC208 PC209

CROWN PN
2 A B C A B C 1 2 3 4 1 2 1 2
SPLINE 1 (BATT NEG.) SPLINE 3 (B+ AK) SPLINE 6 (B+ FU2) SPLINE 10 (CAN HIGH)
PLS 1 PLS 2 PS1 SV1 PV 500 BATT- 2908 PC204-5 206 PC211-5 900 PC201-28
PC206 Platform down Platform up
SP12

ALM 1 2907 501 Keypad 2909 Line Coil 208 FU2 OUT 904 SPLINE 8
2
5902 502 PC207-2 2910 PC211-3 210 PC204-4 905 SPLINE 12
503 PC200-4 2911 Socket 87 SPLINE 7 SPLINE 11 (CAN LOW)
PC205 PC201 504 PC211-2 2912 PC201-10 201 EDS OUT 908 PC201-27
FLS 1 2906
505 PC213-B 2913 JC214-2 202 FU2 IN 912 SPLINE 9
5903
2
506 PC212-4 2915 PC212-1 203 FU4 IN 913 SPLINE 13
2920
2917
2902
5901

2930
2919
5902
5909
2912
5903
5904

2926
2922

2923

5908
5905

5906

2927

5907
2925
211
ON BOARD
600

000
001

003

004
100

300

908
900

002
101

507 PC204-3 2916 PC213-A SPLINE 8 (CAN HIGH) SPLINE 12 (CAN HIGH)
207
CHARGER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
PC210 w./o. charger, Terminals must be connected together 508 PC217-B 2918 PC216-A 902 PC200-8 901 PC210-1
901
CAN CONN. 1 Access 3/2 (TCM/HCM) 509 PC216-B 2924 PC217-A 903 PC211-4 905 SPLINE 10
909
2
510 PC220-8 2929 PC220-6 904 SPLINE 10 906 PC204-1
3
SPLINE 2 (FU3 OUT) SPLINE 4 (+13V) 907 PC220-4
4
5 Detail B 2901 FU3 OUT 300 PC201-25 SPLINE 9 (CAN LOW) SPLINE 13 (CAN LOW)
Truck with Display w/o KYS
Adapter
6 see Detail A KYS 2902 PC201-3 301 PC202-1 910 PC200-9 909 PC210-2
30 205
2981 2982 2903 PC208-1 302 PC215-2 911 PC211-1 913 SPLINE 11
Truck with Display w/ KYS 87 2911
PC204 see Detail B 2983 2904 Horn 303 PC218-A 912 SPLINE 11 914 PC204-2
906 1) Cut off and isolate Wire 204 232 86 211
INFOLINK 1 2) Use Adapter PN820143 for KYS 232 2905 PC209-1 304 PC219-A 915 PC220-5
914
2 2906 PC205-1 SPLINE 5 (GND)
507
3
210 2907 PC206-1 600 PC201-5
4
2908 2914 PC221-1 601 PC202-2
5
6 207 2928 PC220-1 602 PC203-2
603 PC215-1
PC213 604 PC218-B
BLS A 2916
605 PC219-B
505
B
C
2922 829535_2F-1

Fig. 155

ES/ET4000 Series
Rev. B
346
 SCHEMATIC DIAGRAMS
ELECTRIC STEERING HARNESS FOR ES 4000

Electric steering harness for ES 4000

SAHS ECR3 STEER CONN.

1 2 3 PC245 1 2 3 4 PC243 1 2 3 4 5 6 7 8 JC220 PC240

2954
550
5951

351
050
051
651

150
950
951
2951
2955
550
1
2
5951
3
2955
4
2952
5
951
6
2953
7

SCM (A)
Access 5
PC242 050
8
352 051
ECR2 1 9
052 651
2 10
053 652
3 11
652
4 12
653
13
950
14

PC244
152
TS3 1
653 SP1 CROWN PN
2
2951, 2952, 2953, 2954

PC246 PC241
350 150 150 650
Steer Sensor

1 (PC246-4) (JC220-3) 1
650 350
2 2
151 152
3 3
4
150 680 Ohm 352
4

SCM (B)
Access 5
0,25W 351
5
151
6
052
7
053
8

829558_2B-1

Fig. 156

ES/ET4000 Series
Rev. B
347
SCHEMATIC DIAGRAMS
ELECTRIC STEERING HARNESS FOR ET

Electric steering harness for ET

ECR2 TS3 TFD

PC242 1 2 3 4 PC244 1 2 PC246 1 2 3 4 5 6 PC240

352
052
053
652

350
650
151
150
2950
5950
152
653
1
2
5951
3
2955
4
2952
5

SCM (A)
Access 5
951
6
2953
7
050
8
051
9
651
10
150 150 652
11
(PC246-4) (JC220-3) 12
653
13
JC220 950
2950 14
1
STEER CONN.

5950 680 Ohm, 0,25W

2
150
3
950
4
951 SP1 CROWN PN
5
2951
6 2951, 2952, 2953, 2954
2955
7
550
8

PC241
650
1
350
2

(SCM) (B)
152

Access 5
3
352
4
351
5
151
6
052
7
053
8
2954

5951
550

351
050
051
651
PC245 1 2 3 PC243 1 2 3 4

SAHS ECR3 829559_2C-1

Fig. 157

ES/ET4000 Series
Rev. B
348
 SCHEMATIC DIAGRAMS
INFOLINK® WIRE HARNESS FOR ES/ET 4000

InfoLink® wire harness for ES/ET 4000

InfoLink Box
PROX. CAN SHOCK POWER
READER BUS SENSOR RS232 ALARM SUPPLY
1 2 3 14 4 5 6 7 8 9 10 11 12 15 16 17 18 19 20 21 26 27 24 25 13 22 23 28 29 30 31 32 33 34 35 PC250

(+BV_AK) 2980
(POWER) 781

(-B) 581
(X_AXIS) 080
(Y-AXIS) 081
(CLOCK) 083

(CAN HIGH) 980

(DATA) 082

(CAN LOW) 985

( POWER) 780

(TX) 084

(+BV) 282

(POWER TO KYS) 281

(RX) 085

(+BV) 280
(GROUND) 683

(GROUND) 680

(GROUND) 580
Ferrite Ferrite

1 JC251 3 4 2

Prox. Reader

PC254
780
1 SHOCK SENSOR
682
2
Spline Table Crown PN 080
3
081
SPLINE 1 4
SP1

680 PC250-7
681 PC252-3
682 PC254-2
PC252
084
1 RS232
085
2
681
3
282
581

1 PC253
2

ALARM
2980
980
985
580
280

281

1 2 3 4 5 6 JC204
TRUCK
CONNECTION
829571_2H-1

Fig. 158

ES/ET4000 Series
Rev. B
349
Notes:

350
HYDRAULIC SCHEMATIC
351
Notes:

352
 HYDRAULIC SCHEMATIC
HYDRAULIC SYMBOLS

Hydraulic Symbols

Icon Meaning Icon Meaning

Vented reservoir with Electric motor unidi-

lines above fluid level rectional single speed
M

Vented reservoir with Hydraulic pump fixed

lines below fluid level displacement unidirec-
tional

Filter or strainer Spring, (bias to normal

de-energised position)

Hydraulic line with full Solenoid single coil or

flow winding

Pilot or drain line, lim- Component enclosure

ited flow manifold block

Lines crossing; not con- Resistor orifice throttle

nected (adjustable)

Lines crossing and con- Throttle, fixed

nected

Closed line port Relief valve, adjusta-

ble

Accumulator, gas Check valve

charged, diaphragm
type

ES/ET4000 Series Rev.2 08/2010

Rev. B
353
HYDRAULIC SCHEMATIC
HYDRAULIC SYMBOLS

Icon Meaning Icon Meaning

2/2 way valve Hydraulic steer unit

(2 ways, 2 connections)
T L
P R

3/2 way valve Torque generator

(3 ways, 2 connections)
P
T

3/2 way valve Shut-off valve, manual

(3 ways, 2 connections;
Spring bias solenoid
control

4/2 way valve Bypass flow control

(4 ways, 2 connections) with controlled flow,
pressure-regulated

4/3 way valve Flow divider/combiner

(4 ways, 3 connections)

4/3 way valve Single pre-tension

(4 ways, 3 connections; valve assembly in
manual activation and manifold
spring centred

Flow meter Electric motor unidi-

rectional variable
M speed

Rev.2 08/2010 ES/ET4000 Series

Rev. B
354
 HYDRAULIC SCHEMATIC
HYDRAULIC SYMBOLS

Icon Meaning Icon Meaning

Valve block with 3 oper- Proportional solenoid

ating units

Shuttle valve Dual solenoid

Relief valve, fixed Solenoid valve,

hydraulic pilot
operated

Velocity fuse Hydraulic pilot oper-

ated hydraulic valve

Pressure-compensated Manual actuator

flow control with reverse
flow bypass; fixed.

Pressure-compensated Single-acting cylinder,

flow control, fixed with cushion

Pilot check valve (pilot Single-acting cylinder

to open) ram type

Manual lever actuator Single-acting cylinder

with spring returned
(rod end vented)

ES/ET4000 Series Rev.2 08/2010

Rev. B
355
HYDRAULIC SCHEMATIC
HYDRAULIC SYMBOLS

Icon Meaning Icon Meaning

Double-acting cylinder; Thermometer

equal area

Double-acting cylinder; Pressure gauge

unequal area

Pressure switch Hydraulic motor,

bi-directional

Rev.2 08/2010 ES/ET4000 Series

Rev. B
356
 HYDRAULIC SCHEMATIC
ES 4000 WITH TT MAST

ES 4000 with TT Mast

2
1

8
9

PVL PCL
7 3 3

CV1

10

SV1
11

RV1

6
M2

4
5

Fig. 159 Hydraulic diagram ES 4000 with TT mast

1 Free lift cylinder 7 Check valve (CV1)

2 Lift cylinder 8 Lowering valve (PVL)
3 Velocity fuse 9 Compensation valve (PCL)
4 Return line filter 10 Lift valve (SV1)
5 Suction filter 11 Relief valve (RV1)
6 Pump

ES/ET4000 Series
Rev. B
357
HYDRAULIC SCHEMATIC
ET 4000 WITH TF MAST

ET 4000 with TF Mast

1 2
PS

3
9
10

PVL PCL
8

CV1
4
11

SV1
12

RV1 3

7
M2

6 5

Fig. 160 Hydraulic diagram ET 4000 with TT mast

1 Pressure sensor (PS) 7 Pump

2 Free lift cylinder 8 Check valve (CV1)
3 Velocity fuse 9 Lowering valve (PVL)
4 Lift cylinder 10 Compensation valve (PCL)
5 Return line filter 11 Lift valve (SV1)
6 Suction filter 12 Relief valve (RV1)

ES/ET4000 Series
Rev. B
358
 HYDRAULIC SCHEMATIC
ET 4000 WITH TL MAST

ET 4000 with TL Mast

1
PS

8
9

PVL PCL
3
7
CV1

10

SV1

11

RV1

6
M2

4
5

Fig. 161 Hydraulic diagram ET 4000 with TL mast

1 Pressure sensor (PS) 7 Check valve (CV1)

2 Lift cylinder 8 Lowering valve (PVL)
3 Velocity fuse 9 Compensation valve (PCL)
4 Return line filter 10 Lift valve (SV1)
5 Suction filter 11 Relief valve (RV1)
6 Pump

ES/ET4000 Series
Rev. B
359
Notes:

360