CROWN Lift Truck ESR4000 Series Service Maintenance Manual

Service Manual ESR4000 Series

Printed in Germany TABLE OF CONTENT

Printed in Germany Page intentionally left blank Seite absichtlich freigelassen Page intentionellement laissée blanche

Printed in Germany M-IDX-2140-001 TABLE OF CONTENTS Index MA – SAFETY PAGE SER. NO. SEC. ISSUE Symbols Used In The Manual .............................................. M/P-MA-0000-001 . General Maintenance and Repair Safety Instructions ........ M/P-MA-0000-001 - Maintenance and Repair ................................................. M/P-MA-0000-002 - Before Parking the Truck ................................................. M/P-MA-0000-002 - Before Working on the Truck ........................................... M/P-MA-0000-002 - Before Starting the Truck ................................................ M/P-MA-0000-002 Truck Warnings and Labels ................................................. M/P-MA-0000-002 ITD – INTRODUCTION PAGE SER. NO. SEC. ISSUE General ................................................................................. M/P-ITD-2140-001 - Operating Instructions ..................................................... M/P-ITD-2140-001 - Service Training .............................................................. M/P-ITD-2140-001 - Ordering Spare Parts ...................................................... M/P-ITD-2140-001 - Using the Manual ............................................................ M/P-ITD-2140-001 - Page Numbering in the Manual ....................................... M/P-ITD-2140-002 Model Number ...................................................................... M/P-ITD-2140-003 M1 – LUBRICATION AND ADJUSTMENT PAGE SER. NO. SEC. ISSUE Jacking up the Truck ............................................................ M-1.0-2140-001 Raising the Truck with a Crane ............................................ M-1.0-2140-002 Towing the Truck .................................................................. M-1.0-2140-002 Component Access .............................................................. M-1.0-2140-003 - Removing the Floorboard ................................................ M-1.0-2140-004 ---------------------------------- Rev.1 08/00 - Seat Disassembly / Installation ...................................... M-1.0-2140-004 - Plastic Panel Disassembly / Assembly ........................... M-1.0-2140-004 Maintenance ......................................................................... M-1.1-2140-001 - Driver Participation ......................................................... M-1.1-2140-001 - Daily Maintenance Log .................................................... M-1.1-2140-001 - Recommended Lubricants and Oils ................................ M-1.1-2140-002 - Lubrication Items and Intervals ....................................... M-1.2-2140-001 - Inspection and Maintenance Schedule ............................ M-1.2-2140-002 ---------------------------------- Rev.1 08/00 Torques ................................................................................. M-1.9-0000-001 M2 – HYDRAULICS PAGE SER. NO. SEC. ISSUE Changing Hydraulic Oil ....................................................... M-2.0-0000-001 Hydraulic Pipes and Accessories ....................................... M-2.1-2140-001 - Filter .......................................................................... M-2.2-2140-002 - Tank ........................................................................... M-2.3-2140-002 - System Bleeding ....................................................... M-2.3-2140-002 - Drift Test .................................................................... M-2.3-2140-002 Funtional Description .......................................................... M-2.3-2140-003 Hydraulic Symbols .............................................................. M-2.3-2140-013 Valve Block ........................................................................... M-2.4-2140-001 - Safety Valve Setting (RV1 and RV2) ............................... M-2.4-2140-001 - Proportional Valve Setting (PVA and PVH) ...................... M-2.4-2140-001 M3 – DRIVE UNIT PAGE SER. NO. SEC. ISSUE Drive Unit .............................................................................. M-3.1-2140-001 - Removal ......................................................................... M-3.1-2140-001 - Draining the Oil .......................................................... M-3.1-2140-001 - Steering Chain Removal ............................................ M-3.1-2140-002 - Drive Wheel Removal ................................................. M-3.1-2140-002 - Tools ............................................................................... M-3.1-2140-003 Rev.1 08/00

Printed in Germany M-IDX-2140-002 TABLE OF CONTENTS - Measurement Tools ......................................................... M-3.1-2140-004 - Equipment ...................................................................... M-3.1-2140-005 Gear Unit Maintenance ......................................................... M-3.1-2140-008 - Disassembly ................................................................... M-3.1-2140-510 - Pre-Assembly Test .......................................................... M-3.1-2140-013 - Assembly ....................................................................... M-3.1-2140-013 - Final Assembly ............................................................... M-3.1-2140-019 - Gear Upper Section Assembly ........................................ M-3.1-2140-021 - Live Ring Bearing Maintenance ....................................... M-3.1-2140-021 - Gear Unit Assembly ........................................................ M-3.1-2140-022 M4 – ELECTRICS PAGE SER. NO. SEC. ISSUE Electrics - General ................................................................ M-4.0-0000-001 - Wire Colour Codes .......................................................... M-4.0-0000-001 - Abbreviations .................................................................. M-4.0-0000-002 - Electrical Symbols .......................................................... M-4.0-0000-004 Load Monitor (Display) ........................................................ M-4.3-2140-200 - Troubleshooting ............................................................... M-4.3-2140-203 Encoder ECR2 ...................................................................... M-4.3-2140-300 ESR4000 Status Codes ........................................................ M-4.3-2140-400 - Power-up circuit diagram ................................................. M-4.3-2140-401 - Status codes 200 to 294 ................................................. M-4.3-2140-402 - Status codes 311 to 399 ................................................. M-4.3-2140-427 - Status codes 813 to 838 ................................................. M-4.2-2140-403 ---------------------------------- Rev.1 08/00 Access 1-2-3 ......................................................................... M-4.3-2140-600 - Access 1, Design and Function ...................................... M-4.3-2140-600 - Battery Discharge Indicator ....................................... M-4.3-2140-601 - Power "on" ................................................................. M-4.3-2140-601 - Operator Improper Sequence Error ............................. M-4.3-2140-601 - Service Due Key Display .......................................... M-4.3-2140-601 - Navigation Keys ......................................................... M-4.3-2140-602 - Message Display ....................................................... M-4.3-2140-602 - Load Monitor .............................................................. M-4.3-2140-601 Operator Menu .................................................................. M-4.3-2140-603 Service Menu .................................................................... M-4.3-2140-605 Analyzer Menu .................................................................. M-4.3-2140-606 Calibration Menu ............................................................... M-4.3-2140-611 - Accessing the CALIBRATION Menu .......................... M-4.3-2140-613 - When to calibrate ....................................................... M-4.3-2140-613 - Calibration Procedures ............................................... M-4.3-2140-613 - Calibration Complete .................................................. M-4.3-2140-613 Features Menu ................................................................. M-4.3-2140-621 Menü HOUR METERS ...................................................... M-4.3-2140-629 ---------------------------------- Rev.1 08/00 Log Events Menu .............................................................. M-4.3-2140-630 Performance Menu ............................................................ M-4.3-2140-631 Utilities Menu .................................................................... M-4.3-2140-644 ---------------------------------- Rev.1 08/00 Emergency Disconnect Contactor ....................................... M-4.4-2140-001 Battery Maintenance ............................................................. M-4.6-2140-001 Charging the Battery ......................................................... M-4.6-2140-001 Replacing the Battery ........................................................ M-4.6-2140-001 Traction / Pump Motor Maintenance ................................... M-4.35-2140-001 - Access ........................................................................... M-4.35-2140-001 - Maintenance ................................................................... M-4.35-2140-001 M5 – BRAKE PAGE SER. NO. SEC. ISSUE Brake System ....................................................................... M-5.0-2140-001 - Bleeding the Brake System ............................................ M-5.0-2140-001 - Motor Brake .................................................................... M-5.0-2140-002 Rev.1 08/00

Printed in Germany M-IDX-2140-003 TABLE OF CONTENTS - Operating Brake Adjustment ........................................... M-5.0-2140-002 Parking Brake ....................................................................... M-5.0-2140-003 - Parking Brake Adjustment .............................................. M-5.0-2140-003 - Brake System Bleeding .................................................. M-5.0-2140-004 - Motor Brake Disassembly ............................................... M-5.0-2140-004 Load Wheel Brake System ................................................... M-5.0-2140-006 - Load Wheel Brake Adjustment ........................................ M-5.0-2140-006 - Brake System Bleeding .................................................. M-5.0-2140-007 M6 – STEERING PAGE SER. NO. SEC. ISSUE - Steering .......................................................................... M-6.0-2140-001 - Steering Unit Disassembly ......................................... M-6.0-2140-002 - Hydraulic Motor Disassembly .................................... M-6.0-2140-003 - Steering Chain Adjustment ........................................ M-6.0-2140-004 - POT6 (Steer Angle Display) Replacement ....................... M-6.0-2140-005 - Assembly and Adjustment ......................................... M-6.0-2140-005 M7 – MAST PAGE SER. NO. SEC. ISSUE Mast ...................................................................................... M-7.0-2140-001 - Torque Requirements ...................................................... M-7.0-2140-001 - Fork Adjustments ........................................................... M-7.0-2140-001 - Mast Testing (Assembled) ............................................... M-7.0-2140-001 - Flaking ............................................................................ M-7.0-2140-001 - Shock Absorbers ............................................................ M-7.0-2140-001 - Mast Dampening Screws, Adjustment ............................ M-7.0-2140-001 - Mast Disassembly .......................................................... M-7.0-2140-003 - Mast Assembly .............................................................. M-7.0-2140-003 - Mast Rollers ................................................................... M-7.0-2140-004 - Mast Roller Adjustment ............................................. M-7.0-2140-004 - Mast Play Control ...................................................... M-7.0-2140-004 - Fork Carriage .................................................................. M-7.0-2140-006 - Disassembly .............................................................. M-7.0-2140-006 - Assembly .................................................................. M-7.0-2140-006 - Fork Carriage Roller Adjustment ................................ M-7.0-2140-007 Lift Chains ............................................................................ M-7.5-2140-001 - General ........................................................................... M-7.5-0000-001 - Inspection ....................................................................... M-7.5-0000-001 - Cleaning .................................................................... M-7.5-0000-001 - Wear .......................................................................... M-7.5-0000-001 - Freedom of Movement ............................................... M-7.5-0000-002 - Chain Tension ............................................................ M-7.5-0000-002 - Chain Anchor and Pulleys .......................................... M-7.5-0000-002 - Worn or Missing Plates .............................................. M-7.5-0000-002 - Protruding or Turned Chain Pins ................................. M-7.5-0000-002 - Corrosion ................................................................... M-7.5-0000-003 - Chain Lateral Wear ..................................................... M-7.5-0000-003 - Uneven Chain Tension ................................................ M-7.5-0000-003 - Misalignment of Lift Components ............................... M-7.5-0000-003 - Lift Chain Lubrication ...................................................... M-7.6-0000-001 Fork Tine Test ....................................................................... M-7.6-0000-002 - General ........................................................................... M-7.6-0000-002 - Fork Identification ........................................................... M-7.6-0000-002 - Repairs ........................................................................... M-7.6-0000-002 - Crack Inspection ............................................................. M-7.6-0000-002 - Fork Identification ........................................................... M-7.6-0000-002 - Fork Blade Warping ......................................................... M-7.6-0000-003 - Verticality Test ................................................................ M-7.6-0000-003 - Measuring the Fork Tip Width .......................................... M-7.6-0000-004 - Fork Tine Height Difference ............................................. M-7.6-0000-004

Printed in Germany M-IDX-2140-004 TABLE OF CONTENTS - Fork Stop ........................................................................ M-7.6-0000-004 - Wear ............................................................................... M-7.6-0000-005 M8 – CYLINDERS PAGE SER. NO. SEC. ISSUE General ................................................................................. M-8.0-0000-001 - Plunger Cylinders ............................................................ M-8.0-0000-001 - Piston Cylinder ............................................................... M-8.0-0000-002 - Maintenance ................................................................... M-8.0-0000-003 - Inspection ....................................................................... M-8.0-0000-003 Installing the Piston Seals .................................................. M-8.0-2340-001 Cylinder Disassembly .......................................................... M-8.0-2340-002 - Free-Lift Cylinder Disassembly and Assembly ................ M-8.0-2340-002 - Lift Cylinder Disassembly and Assembly ........................ M-8.6-2340-002 - Reach Cylinder Disassembly and Assembly ................... M-8.6-2340-002 - Sideshifter Cylinder Disassembly and Assembly ............ M-8.6-2340-003 - Tilt Cylinder Disassembly and Assembly ........................ M-8.6-2340-003 - Parking Brake Cylinder Disassembly and Assembly ....... M-8.6-2340-002 DIA – WIRING DIAGRAMS PAGE SER. NO. SEC. ISSUE Standard Layout ................................................................... M/P-DIA-2140-001 - Control Circuit ................................................................. M/P-DIA-2140-001------------------------------- Rev.2 09/00 - Acces1 ........................................................................... M/P-DIA-2140-002------------------------------- Rev.2 09/00 - Access2 ......................................................................... M/P-DIA-2140-003 - Access3 ......................................................................... M/P-DIA-2140-004 - Switches and Controls .................................................... M/P-DIA-2140-005 - Mast, Hydraulic Components .......................................... M/P-DIA-2140-008------------------------------- Rev.2 09/00 - Fuses, Fans and Contactors ........................................... M/P-DIA-2140-008 - Node points .................................................................... M/P-DIA-2140-011------------------------------- Rev.2 09/00 - Power cable .................................................................... M/P-DIA-2140-013 HYD – HYDRAULIC DIAGRAM PAGE SER. NO. SEC. ISSUE Hydraulic Diagram ............................................................. M/P-HYD-2140-001------------------------------ Rev.1 09/00 Rev.2 09/00

Printed in Germany SAFETY

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Printed in Germany 1 M/P-MA-0000-001 SAFETY OPTION Safety Symbols used in the Manual To help guide you through the manual and to highlight particular danger areas, we have used graphic illustra- tions: DANGER This symbol indicates life-threatening risks Failure to comply with this notice may result in severe or fatal injuries to yourself or other people. WARNING This symbol indicates the risk of serious injury and/or serious material damage. Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage. CAUTION This symbol indicates the risk of minor injury and/or minor material damage. Failure to comply with this notice may result in minor injuries to yourself or other people and/or minor material damage. INFORMATION Contains additional information with supplementary notes and hints. OPTION These items relate to optional features not supplied with the standard version. General Maintenance and Repair Safety Notes DANGER Read the safety notices in the truck Mainte- nance and Operator's Manuals. Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons. Motorised vehicles can be dangerous if maintenance and service are neglected. For this reason maintenance and inspections must be carried out at regular short intervals by trained personnel working to approved company guidelines. DANGER Follow all national/local safety regulations applicable for maintenance work, e.g. for work on higher levels. Failure to do so could result in severe or fatal injuries to maintenance personnel and/ or other persons. Maintenance and Repair 1. Maintenance work must only be carried out in accordance with the test and maintenance pro- gram contained in the present Maintenance Manual and any applicable service notices. 2. Only qualified and authorised personnel may carry out work on the truck. 3. Always keep fire extinguishers in good working condition. Do not approach fluid levels or leaks with a naked flame. 4. To clean, use a non flammable, non combustible cleaning solution which is groundwater-neutral. Only carry out cleaning with an oil separator. Protect the electrical system from dampness. 5. Keep the service area clean, dry and well-venti- lated. 6. Do not allow oil to penetrate the ground or enter the draining system. Used oil must be recycled. Oil filters and desiccants must be treated as special waste products. Relevant applicable regulations must be followed.

CROWN Lift Truck ESR4000 Series Service Maintenance Manual

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