CROWN ESR4500 Series Forklift Service Repair Manual

ESR4500 Series Order Number: 812549-006 Printed in Germany ● Status 2, Revision Level A Maintenance Manual

This master manual is subject to continual updates. It is meant exclusively for businesses authorized by CROWN. It is not permitted to pass on the contents or copies thereof to third parties. CROWN Gabelstapler GmbH & Co. KG - European Headquarter - Moosacher Str. 52 80809 Munich Germany Phone +49 (0) 89 93 00 2 - 0 Fax +49 (0) 89 93 00 2 - 133 All rights reserved under international and Pan-American Copyright Agreement. Copyright 2004 CROWN Equipment Corporation

I Printed in Germany TABLE OF CONTENT

II Printed in Germany Blank page

ESR4500 06/2004 • Printed in Germany MS-IDX-2140 III TABLE OF CONTENT Table of Content MA – SAFETY PAGE SER-NO. CUT .................. REV. Safety Symbols used in the Manual ...................................... 3 General Maintenance and Repair Safety Notes ................... 3 Maintenance and Repair ................................................ 3 Before Leaving the Truck ................................................ 4 Before Carrying out Work on the Truck .......................... 4 Before Operating the Truck ............................................. 4 Warnings and Labels on the Truck ........................................ 4 ITD – INTRODUCTION PAGE SER-N0. CUT REV. General ..................................................................................... 7 Operating Instructions .................................................... 7 Service Training .............................................................. 7 Ordering Spare Parts ...................................................... 7 Using the Manual ............................................................ 7 M1 – LUBRICATION AND ADJUSTMENT PAGE SER-N0. CUT .................. REV. Lifting the Truck ....................................................................... 11 Towing the Truck ..................................................................... 11 Jacking up the Truck ............................................................... 12 Component Access ................................................................ 13 Access to the Motor Compartment ................................ 14 Removing the Floorboard ............................................... 14 Plastic Panel Disassembly / Assembly .......................... 14 Maintenance ............................................................................ 16 Recommended Lubricants and Oils .............................. 16 Lubricants ................................................................... 16 Cold Store Trucks ........................................................ 16 Truck Decommissioning .................................................. 16 Restoring the Truck to Service ....................................... 16 Battery Maintenance ....................................................... 16 Daily Safety Check .................................................................. 18 Inspection and Maintenance Schedule ................................. 20 Cold Store Trucks ........................................................ 20 Torques .................................................................................... 26 M2 – HYDRAULICS PAGE SER-N0. CUT .................. REV. Hydraulic Symbols .................................................................. 29 Functional Description ........................................................... 33 Abbreviations .................................................................. 33 Lifting ............................................................................... 35 Lowering .......................................................................... 35 Mast Reach Carriage Retraction ................................... 37 Mast Reach Carriage Extension .................................... 37 Tilt Back Circuit ............................................................... 39 Tilt Down Circuit .............................................................. 39 Sideshift Left ................................................................... 41 Sideshift Right ................................................................. 41 Hydraulic Components ........................................................... 42 Hydraulic Lines ............................................................... 42 Valve Block ...................................................................... 43 Relief Valve RV1 ......................................................... 43 Lowering Speed Adjustment Valve AVL ...................... 44 Pressure Load Switch PLS ............................................. 44 Hydraulic Reservoir ........................................................ 45

ESR4500 06/2004 • Printed in Germany MS-IDX-2140 IV TABLE OF CONTENT M2 – HYDRAULICS PAGE SER-N0. CUT .................. REV. Discharging the Hydraulic Reservoir .......................... 45 Filling the Hydraulic Tank ............................................ 45 Filter ................................................................................. 46 Replacing the Return Filter ......................................... 46 Replacing the Aeration Filter ...................................... 47 Replacing the Suction Filter ........................................ 47 Pump Motor ..................................................................... 48 Hydraulic Pump ............................................................... 48 Disassembly ............................................................... 48 Commissioning ........................................................... 48 Bleeding the Hydraulic System ............................................. 50 Bleeding the Free Lift Cylinder ....................................... 50 Bleeding the Lift Cylinders ............................................. 50 Bleeding the Reach Cylinder ......................................... 51 Bleeding the Sideshift Cylinder ...................................... 51 Bleeding the Tilt Cylinders ............................................. 51 Bleeding the 5th Function Cylinder ................................ 51 Flushing the Cylinders .................................................... 51 Drift Tests ................................................................................. 52 Lift cylinder drift test ....................................................... 52 Tilt cylinder drift test ....................................................... 52 Causes of Drift ................................................................ 52 M3 – DRIVE UNIT PAGE SER-N0. CUT .................. REV. Gear unit .................................................................................. 55 Preparation .............................................................................. 55 Tools required: ............................................................ 55 Removal .......................................................................... 55 Servicing ......................................................................... 55 General ....................................................................... 57 Gear Unit Disassembly / Assembly ............................... 57 Disassembly ............................................................... 57 Assembly .................................................................... 57 .................................................................................. 57 Preparing the gear unit ............................................. 57 Inserting the bevel pinion shaft ................................. 58 Assembling the flange shaft ...................................... 58 Adjusting the Bevel Wheel Set .................................. 58 Checking the flank tooth bearing .............................. 59 Final Assembly ......................................................... 59 Re-Assembly ................................................................... 60 Traction motor ................................................................. 60 M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV. Electrical Components ........................................................... 63 SPS (Safety Switch) .................................................... 63 KYS (Key Switch) ........................................................ 63 HNS (Horn Switch) ..................................................... 63 HN (Horn) ................................................................... 63 FS (Forward Switch) ................................................... 63 RS (Reverse Switch) ................................................... 63 ACS (Accelerator Switch) ........................................... 63 BFS (Brake Fluid Switch) ............................................ 63 BLS (Battery Lock Switch) .......................................... 63 ................................................................................................................... BS (Flashing Beacon Switch) 63 FKS (Fork Tilt Switch) ................................................. 63 LS (Load Sensor) ........................................................ 63 POT1 (Traction potentiometer) .................................... 63

ESR4500 06/2004 • Printed in Germany MS-IDX-2140 V TABLE OF CONTENT M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV. POT2 (Raise potentiometer) ....................................... 63 POT3 (Reach potentiometer) ...................................... 64 POT4 (Tilt potentiometer) ........................................... 64 POT5 (Sideshift potentiometer) .................................. 64 POT6 (5th hydraulic function potentiometer) .............. 64 PLS (Pressure load switch) ........................................ 64 SES (Seat switch) ....................................................... 64 SFS 1SA (Forward travel steering feedback sensor).. 64 SFS 2 (Steering feedback sensor 2) ........................... 64 BRS (Parking brake switch) ........................................ 64 BPS (Brake pressure switch) ...................................... 64 ORS (Override switch) ................................................ 64 ECR1 (Travel encoder) ............................................... 64 ECR2 (Lift encoder) .................................................... 64 ECR3 (Steering feedback encoder) ............................ 65 ECR4 (Steering encoder) ........................................... 65 ECR5 (Height encoder) .............................................. 65 THS1 (Temperature sensor 1) .................................... 65 THS2 (Temperature sensor 2) .................................... 65 THS3 (Temperature switch 3) ..................................... 65 RES1 (Reach sensor 1) .............................................. 65 RES2 (Reach sensor 2) .............................................. 65 SVH (Lift valve) ........................................................... 65 PVL (Proportional valve lower) ................................... 65 PVRT (Proportional valve retract) ............................... 66 PVRE (Proportional valve extend) .............................. 66 PVAR (Proportional valve accessories right) .............. 66 PVAL (Proportional valve accessories left) ................. 66 RV (Relief valve) ......................................................... 66 MVL (Manual lowering valve) ...................................... 66 AVL (Lowering speed adjustment valve) .................... 66 FU1 (TDM / Display control fuse) ............................... 66 FU2 (VCM / HDM control fuse) ................................... 66 FU3 (Brake control fuse) ............................................. 66 FU4 (SDM power fuse) ............................................... 66 FU5 / FU6 (Options control fuses) ............................. 66 FU7 (Main fuse) .......................................................... 66 FAN1 (Electric compartment fan) .............................. 66 FAN2 (traction and hydraulic module fan) ................... 66 FAN3, FAN4 (Motor compartment fans) ..................... 66 K1(R1-R10 Heating resistor relays) ............................ 66 K2 (Heating fan relay) ................................................. 67 K3 / K4 (Brake light relay) ........................................... 67 K5 (Travel lights relay) ................................................ 67 K6 (Work lights relay) ................................................. 67 K7 / K8 (Travel alarm relay) ........................................ 67 K9 / K10 (Flashing beacon relay) ............................... 67 K12 / K13 (Options relay) ........................................... 67 SW (Work lights switch) .............................................. 67 SD (Travel lights switch) .............................................. 67 SI (Indicator switch) .................................................... 67 ESR4500 Status Codes ........................................................... 69 Status Codes ................................................................... 69 When a Service Code Occurs .................................... 69 Truck does not operate and there is no Status Code . 69 1. Fault during power-up ........................................... 69 2. The fault is not electrical ....................................... 69

ESR4500 06/2004 • Printed in Germany MS-IDX-2140 VI TABLE OF CONTENT M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV. 3. Malfunction in one of a group of unmonitored inputs ........................................................................ 69 Statuscode 100 - 102 ..................................................... 71 Statuscode 110 - 120 ..................................................... 72 Statuscode 121 - 130 ..................................................... 73 Statuscode 131 - 160 ..................................................... 74 Statuscode 180 - 181 ..................................................... 75 Statuscode 182 - 183 ..................................................... 76 Statuscode 184 - 200 ..................................................... 77 Statuscode 201 - 210 ..................................................... 78 Statuscode 211 - 213 ..................................................... 79 Statuscode 214 - 220 ..................................................... 80 Statuscode 221 - 222 ..................................................... 81 Statuscode 223 - 224 ..................................................... 82 Statuscode 225 - 230 ..................................................... 83 Statuscode 240 ............................................................... 84 Statuscode 241 ............................................................... 85 Statuscode 243 ............................................................... 86 Statuscode 244 ............................................................... 87 Statuscode 246 ............................................................... 88 Statuscode 247 ............................................................... 89 Statuscode 249 ............................................................... 90 Statuscode 250 ............................................................... 91 Statuscode 252 ............................................................... 92 Statuscode 253 ............................................................... 93 Statuscode 260 ............................................................... 94 Statuscode 261 ............................................................... 95 Statuscode 262 ............................................................... 96 Statuscode 263 ............................................................... 97 Statuscode 264 ............................................................... 98 Statuscode 265 ............................................................... 99 Statuscode 266 ............................................................... 100 Statuscode 267 ............................................................... 101 Statuscode 268 ............................................................... 102 Statuscode 280 - 282 ..................................................... 103 Statuscode 283 - 284 ..................................................... 104 Statuscode 285 - 300 ..................................................... 105 Statuscode 301 - 310 ..................................................... 106 Statuscode 311 - 313 ..................................................... 107 Statuscode 314 - 320 ..................................................... 108 Statuscode 321 - 322 ..................................................... 109 Statuscode 323 - 324 ..................................................... 110 Statuscode 325 - 330 ..................................................... 111 Statuscode 340 ............................................................... 112 Statuscode 341 ............................................................... 113 Statuscode 343 - 381 ..................................................... 114 Statuscode 382 - 383 ..................................................... 115 Statuscode 384 - 385 ..................................................... 116 Statuscode 430 - 431 ..................................................... 117 Statuscode 460 - 462 ..................................................... 118 Statuscode 463 - 465 ..................................................... 119 Statuscode 840 - 841 ..................................................... 120 Statuscode 880 ............................................................... 121 Statuscode 881 ............................................................... 122 Statuscode 883 ............................................................... 123 Statuscode 884 ............................................................... 124 Statuscode 885 ............................................................... 125 Statuscode 886 ............................................................... 126

ESR4500 06/2004 • Printed in Germany MS-IDX-2140 VII TABLE OF CONTENT M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV. APPENDIX ...................................................................... 127 Display not active ........................................................ 127 Main contactor switches continuously ON/OFF ...................................................................... 127 Only battery discharge indicator and message display active ............................................... 127 Main contactor briefly activated after power up .......... 127 Service Level ........................................................................... 129 Display ............................................................................. 129 Design and Functions ................................................. 129 Steer Angle Display .................................................. 129 Travel Direction Display ............................................ 129 Battery Charge Status Display ................................. 129 Operator error display ............................................... 129 Service Display ......................................................... 130 Function Keys ........................................................... 130 Message Display ...................................................... 130 Capacity Data Monitor ................................................ 130 Brake Fluid Level Indicator ....................................... 130 Steer Fault Display .................................................... 130 Parking Brake Display ............................................... 130 Performance Setting Display .................................... 130 Operator Menu ........................................................................ 131 Tilt Position - Assist On / Off ....................................... 132 Rack Height Select On / Off ........................................ 133 Programming Rack Height Select ............................... 133 Programming Rack Height Select ... ........................... 134 Service Level ........................................................................... 135 Chapter structure : .......................................................... 135 ANALYZER ................................................................. 135 A1 STATUS ............................................................... 135 A2 INPUTS ................................................................. 135 A3 OUTPUTS ............................................................. 135 CALIBRATION ............................................................ 135 C1 Accelerator Pedal ................................................ 135 C2 Raise Lower Handle ............................................ 135 C3 Reach Handle ..................................................... 135 C4 Tilt Handle ........................................................... 135 C5 Sideshift Handle .................................................. 136 C6 5th Function Handle ............................................ 136 C7 Height .................................................................. 136 C8 Weight ................................................................. 136 C9 Fork Positioning ................................................... 136 C10 Reach retract slow down ................................... 136 C11 Save? ................................................................ 136 FEATURE .................................................................... 136 F1 Truck size ............................................................. 136 F2 FLS Switch .......................................................... 136 F3 Height Encoder .................................................... 136 F4 Lower Cut out ...................................................... 136 F5 Fifth Function ....................................................... 136 F6 Max Load ............................................................. 136 F7 Capacity Data Monitor CDM ................................ 136 F8 Alarm 2 ................................................................ 136 F9 Beacon ................................................................ 137 F10 User Performance .............................................. 137 F11 User Codes ........................................................ 137 F12 Language ........................................................... 137

ESR4500 06/2004 • Printed in Germany MS-IDX-2140 VIII TABLE OF CONTENT M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV. F13 Truck lockout ...................................................... 137 F14 Rack select ........................................................ 137 F15 Height & weight on/off ....................................... 137 F16 Timer on/off ........................................................ 137 F17 Error log on/off ................................................... 137 F18 Operator Alarm1 on/off ...................................... 137 F19 Battery low level alarm ...................................... 137 F20 Fork positioning ................................................. 137 F21 Change value Euro/US ...................................... 137 F22 Save ................................................................... 137 HOUR METER ............................................................ 137 H1 Run ...................................................................... 137 H2 TDM Traction Drive Module ................................. 137 H3 HDM Pump Drive Module ................................... 137 H4 VCM Vehicle Controll Module .............................. 137 H5 SDM Steer Drive Module .................................... 137 H6 Display ................................................................. 137 H7 Set Service Timer ................................................ 137 H8 Escape ................................................................ 137 LOG EVENTS ............................................................. 137 L1 History .................................................................. 137 L2 Totals .................................................................... 137 L3 Erase ................................................................... 137 L4 Escape ................................................................. 137 PERFORMANCE ........................................................ 138 P1 Setup P1 .............................................................. 138 P2 Setup P2 .............................................................. 138 P3 Setup P3 .............................................................. 138 P4 BDI setting ........................................................... 138 P5 Travel > LCS ........................................................ 138 P6 Travel > FLS ......................................................... 138 P7 Travel > Custom ................................................... 138 P8 Lower > Custom .................................................. 138 P9 Reach > Custom ................................................. 138 P10 5th Function left ................................................. 138 P11 5th Function right .............................................. 138 P12 Steer low speed ................................................. 138 P13 Steer high speed ............................................... 138 P14 Brake at ramp .................................................... 138 P15 Save .................................................................. 138 UTILITIES ................................................................... 138 U1 Software Version ................................................. 138 U2 Hour Set .............................................................. 138 U3 Accy Override ...................................................... 138 U4 Escape ................................................................ 138 Overview of Performance Default Settings .......................... 139 Service Menu ........................................................................... 140 Access to Service Level ................................................. 140 Overview of menu items ............................................. 140 Analyzer .................................................................... 140 Calibration ................................................................. 140 Feature ...................................................................... 140 Hour Meter ................................................................ 140 Log Events ................................................................ 140 Performance ............................................................. 140 Utilities ...................................................................... 140 Analyzer ........................................................................... 142 A1.1 - A1.12 Status ..................................................... 142

You're Reading a Preview

CROWN ESR4500 Series Forklift Service Repair Manual

Description

Reviews

Q&A

Recently Viewed