Crown Forklift ESR4500 Serie Maintenance Manual 812549-006 – PDF DOWNLOAD

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Crown Forklift ESR4500 Serie Maintenance Manual 812549-006 – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift ESR4500 Serie Maintenance Manual 812549-006 – PDF DOWNLOAD

Language : English
Pages :328
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift ESR4500 Serie Maintenance Manual 812549-006 – PDF DOWNLOAD

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
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
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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
MS-IDX-2140 ESR4500 06/2004 • Printed in Germany
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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
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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
MS-IDX-2140 ESR4500 06/2004 • Printed in Germany
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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
A11 – A112 Status 142
ESR4500 06/2004 • Printed in Germany MS-IDX-2140
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TABLE OF CONTENT
M4 – ELEKTRICS PAGE SER-N0 CUT REV
A21 – A26 Inputs 143
A27 – A213 Inputs 144
A214 – A220 Inputs 145
A221 – A225 Inputs 146
A226 – A232 Inputs 147
A233 – A237 Inputs 148
A31 – A39 Outputs 149
A310 – A316 Outputs 150
A317 – A318 Outputs 151
Calibration 152
C1 – C3 Calibration 152
C4 – C5 Calibration 153
C6 – C71 Calibration 154
C713 Calibration 155
C72 Calibration 156
C73 Calibration 157
C734 – C75 Calibration 158
C8 Calibration 159
C9 Calibration 160
C10 – 112 Calibration 161
Feature 162
F1 – F3 Features 162
F4 – F6 Features 163
F7 – F77 Features 164
F8 Features 165
F9 – F10 Features 166
F11 Features 167
F12 – F14 Features 168
F15 – F19 Features 169
F20 – F22 Features 170
H1 – H3 Hourmeter 171
H4 – H8 Hourmeter 172
Log Events 173
L1 – L32 Features 173
L321 – L4 Features 174
Performance 175
P1 – P151 Performance 175
P16 – P1101 Performance 176
P111 – P115 Performance 177
P2 – P6 Performance 178
P7 – P10 Performance 179
P11 – P152 Performance 180
Utilities 181
U1 – U2 Utilities 181
U3 – U4 Utilities 182
Control Module Safety Test 183
General 183
Steer Module Safety Test 183
Preparatory measures 183
Procedure 183
Drive Module Safety Test 184
Tools required 184
Preparatory measures 184
Procedure 184
Final procedure 185
MS-IDX-2140 ESR4500 06/2004 • Printed in Germany
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TABLE OF CONTENT
M5 – BRAKE PAGE SER-N0 CUT REV
Load Wheel Brake 189
General 189
Brake Lining 189
Disassembly 189
Assembly 189
Wheel Brake Cylinder 190
General 190
Disassembly 190
Assembly 190
Bleeding the load wheel brake and replacing
the brake fluid 190
Operating Brake 192
Disassembly 192
Test and Inspection 192
Assembly 192
Air gap setting 192
Setting the brake pedal clearance 194
M6 – STEERING PAGE SER-N0 CUT REV
Steering 197
General 197
Functional Description 197
Quadrant – Definition 198
Error routine 198
When the error routine starts … 198
Ending the error routine 198
Causes of error routine activation 198
Other error causes 198
Examples of steer faults 199
Example 1: Manual wheel change, drive wheel turned
160° to the right 199
Ending the error routine 199
Example 2:
Manual wheel change, drive wheel turned
70° to the right 200
Setting the SFS … proximity switches 202
Replacing the steer motor 202
Disassembly 202
Assembly 202
Steering wheel 204
Disassembly 204
Assembly 204
Steering Sensor (ECR4) 206
Disassembly 206
Assembly 206
M7 – MAST PAGE SER-N0 CUT REV
Mast 211
General 211
Torque Requirements 211
Lifting Gear Minimum Capacity 211
Mast Testing (Assembled) 212
Flaking 212
Mast Shock Absorbers 212
Mast end stops 212
Fork Adjustment 212
Mast Removal and Assembly 213
ESR4500 06/2004 • Printed in Germany MS-IDX-2140
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TABLE OF CONTENT
M7 – MAST PAGE SER-N0 CUT REV
General 213
Disassembly 213
Assembly 215
Dismantling and Assembling the Mast 216
General 216
Dismantling 216
Fork Carriage Removal 216
2nd Mast Stage Removal 216
1st Mast Stage Removal 216
Replacing the Mast Rollers 218
General 218
Mast Roller Assembly 218
Calculating the Roller Diameter 218
Calculating the Required Number of Shims 218
Outer Mast / 1st Mast Stage 218
1st Mast Stage / 2nd Mast Stage 220
Fork Carriage 222
Final Work and Settings 223
Free lift cylinder removal / installation with mast attached 224
General 224
Torque Requirements 224
Lifting Gear Minimum Capacity 224
Disassembly 224
Assembly 225
Lift cylinder removal / assembly 228
General 228
Lifting Gear Minimum Capacity 228
Disassembly 228
Assembly 230
Lift Chains 232
General 232
Inspection 232
Cleaning 232
Wear 232
Freedom of Movement of Chain Links 233
Chain Tension 233
Chain Anchor and Pulleys 234
Worn Connection Plates 234
Protruding or Turned Chain Pins 234
Corrosion 234
Chain Lateral Wear 235
Uneven Chain Tension 235
Misalignment of Lift Components 235
Lift Chain Lubrication 236
Detaching Lift Chains 237
Tools and Equipment Required 237
Detachment 237
Fork Tines 238
General 238
Terms 238
Fork Identification 238
Repairs 238
Checking the Fork 238
Crack Inspection 238
Verticality Test 239
Fork Blade Warping 239
Measuring the Fork Tip Width 239
Fork Tine Height Difference 239
MS-IDX-2140 ESR4500 06/2004 • Printed in Germany
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TABLE OF CONTENT
M7 – MAST PAGE SER-N0 CUT REV
Stop Mechanism 240
Fork Blade Wear 240
Reach 242
Disassembly 242
Assembly 242
Side Roller Adjustment 242
Backing Roller Adjustment 243
Reach Cylinder 244
Disassembly 244
Assembly 244
Integrated Sideshifter 245
Disassembly 245
Assembly 245
M8 – CYLINDERS PAGE SER-N0 CUT REV
Cylinders 249
General 249
Safety when working on hydraulic systems 249
General Instructions for Repairing Hydraulic
Components 249
Rod Seal Assembly 250
General 250
Large Rod Seal Assembly 250
Small Seal Rod Assembly 251
Rod Seal Assembly, Sealing Lip First 252
Lift cylinder 255
General 255
Removal and Assembly 255
Dismantling 255
Rod Seal Removal 255
Piston Rod Removal 255
Assembly 255
Piston Rod Assembly 255
Installing the Rod Seal 255
Free-Lift Cylinder 259
General 259
Removal and Assembly 259
Dismantling 259
Rod Seal Removal 259
Piston Rod Removal 259
Cushion Removal 259
Assembly 259
Cushion Installation 259
Piston Rod Assembly 259
Installing the Rod Seal 259
Reach Cylinder 263
General 263
Removal and Assembly 263
Dismantling 263
Rod Seal Removal 263
Piston Rod Removal 263
Assembly 263
Piston Rod Assembly 263
Installing the Rod Seal 263
Sideshift, Cylinder 266
Dismantling 266
Assembly 266
ESR4500 06/2004 • Printed in Germany MS-IDX-2140
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TABLE OF CONTENT
DIA – ELECTRICAL DIAGRAMS PAGE SER-N0 CUT REV
Wiring Diagram – AC System 273
Wiring Diagram – AC System 274
Wiring Diagram Option 275
Wiring Diagram Coldstore Cabin 276
Main Harness 279
Main Harness 280
PARTS_TABLE 281
Connector Table 281
PARTS_TABLE 281
WIRE_TABLE 281
Connector Table 282
WIRE_TABLE 282
WIRE_TABLE 282
Harness: Connector Panel to Reach Carriage 283
Harness: Reach Carriage 284
Harness Options 285
Harness Beacon 286
Harness Beacon Switch 287
Harness Coldstore 288
Harness Working Light12 V 289
Harness Working Light 24 V 290
Harness Driving Light 291
Harness Travel Alarm 292
Harness DC/DC Converter
with Harness Options 813445 293
Harness DC/DC Converter
without Harness Options 813445 294
Harness Heated Seat 295
Harness 12V / 24V Supply to B/W Screen 296
Harness Monitor B/W or Connection Box
to Connector Panel 297
Harness (Camera) Connector Panel to Reach Carriage 298
Harness (Camera) Reach Carriage to Mast 299
Harness (Camera) Mast to Camera 300
Harness (Camera) TFT Display to Connection Box 301
Harness 12 V Supply to Connection Box 302
Harness and Installation Drawing 6th Function 303
Harness Davis Derby System 304
Davis Derby EV 16 Circuit Program 305
Davis Derby S 16 Circuit Program 306
Harness 1 Coldstore Cabin 307
Harness 2 Coldstore Cabin 308
HYD – HYDRAULIC SCHEMATICS PAGE SER-N0 CUT REV
Hydraulic Schematic 311
Hydraulic Lines to the Valve Block 312

IMAGES PREVIEW OF THE MANUAL:

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