Crown Forklift ESR4000 Series Service Manual – PDF DOWNLOAD
FILE DETAILS:
Crown Forklift ESR4000 Series Service Manual – PDF DOWNLOAD
Language : English
Pages :310
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Crown Forklift ESR4000 Series Service Manual – PDF DOWNLOAD
ESR4000 1
TABLE OF CONTENT 2
M-IDX-2140-001 4
M-IDX-2140-002 5
M-IDX-2140-003 6
M-IDX-2140-004 7
SAFETY 8
Safety Symbols used in the Manual 10
General Maintenance and Repair Safety Notes 10
Maintenance and Repair 10
Before Leaving the Truck 11
Before Carrying out Work on the Truck 11
Before Operating the Truck 11
Warnings and Labels on the Truck 11
INTRODUCTION 12
General 14
Service Training 14
Operating Instructions 14
Service Training 14
Ordering Spare Parts 14
Using the Manual 14
Page Numbering in the Manual 15
Model-Number 16
LUBRICATION AND ADJUSTMENT 18
Jacking up the Truck 20
Raising the Truck with a Crane 21
Towing the Truck 21
Component Access 22
Removing the Floorboard 23
Seat Disassembly / Installation 23
Plastic Panel Disassembly / Assembly 23
Maintenance 25
Driver Participation 25
Daily Maintenance Log 25
Recommended Lubricants and Oils 25
Lubricants 25
Cold Store Trucks 25
Table Recommended Lubricants 26
Grease Items / Grease Intervals 27
Inspection and Maintenance Schedule 28
Battery Maintenance 28
Daily or 8 service hours 28
Inspection Points Pictures 29
Daily or 8 service hours (contd) 30
Inspection Points Pictures (contd) 31
Daily or 8 service hours (contd) 32
Inspection Points Pictures (contd) 33
3 Months or 250 hours 34
Inspection Points Pictures (contd) 35
3 Months or 250 hours, part 2 36
Inspection Points Pictures (contd) 37
3 Months or 250 hours, part 3 38
Inspection Points Pictures (contd) 39
6 Months or every 500 hours 40
Inspection Points Pictures 41
Annually or every 1000 hours 42
Inspection Points Pictures 43
Every 2 years or 2000 hours 42
Inspection Points Pictures 43
Torques 44
Standard Screws and Nuts 45
Umbrako Screws and Nuts 45
HYDRAULICS 46
WARNING 48
Changing Hydraulic Oil 48
Hydraulic Pipes and Accessories 48
Filter 49
Tank 49
Drift Test 50
Drift Test Tilt Function 50
Drift Test Lift Function 50
Hydraulic System 52
No Demand for Steering SVT SVS SCV6 CV5 53
Description 54
Full Demand for Steering 55
Description 56
Low Speed Lift 57
Description 58
High Speed Lift 59
Description 60
Lower Circuit 61
Description 62
Reach Forward Circuit 63
Description 64
Tilt Down Circuit 65
Description 66
Tilt Back Circuit 67
Description 68
Sideshift Right Circuit 69
Description 70
Parking Brake Release Circuit 71
Description 72
Hydraulic Symbols 73
Valve Bank 77
Relief Valve #1 & #2 (RV1 & RV2) 77
Operation 77
Adjustment 77
RV1 77
RV2 77
Proportinal Valves PVA & PVH 78
DRIVE UNIT 80
General 82
Gear Unit Removal 82
Disassembly 82
Draining the oil 82
Steering Chain Removal 83
Drive Wheel Removal 83
Drive Motor 83
Maintenance 83
Bearing 83
Carbon Brushes 83
Commutator 83
Tools 84
Measurement Tools 85
Equipment 86
Equipment 2 87
Equipment 3 88
Gear Unit Maintenance 89
General 89
Gear Unit Main Components 89
Gear Unit Labelling 90
Setting Data 90
Disassembly 91
Gear Unit Cover Removal 91
Spur Bevel Gear and Wheel Shaft Removal 91
BEARING INNER RING REMOVAL 92
Wheel Shaft 92
Spur Bevel Gear 92
Wheel Bolt Removal 92
Pinion Shaft Disassembly 93
Extracting the Taper Bearing Inner Ring from the Pinion Shaft 93
Removing the Taper Bearing Cups from the Transmission Housing 93
Thread Protective Shield Removal 94
Pre-Assembly Test 94
Assembly 94
Pinion Shaft Installation Dimensions 94
l Press the bearing cup (2) into the bearing seat in Installing the Pinion Shaft Bearing Cup in the Housing 95
Bearing Inner Ring and Cup Installation 95
Inner Ring 95
Cup 95
Wheel Shaft Pre-Assembly 95
Wheel Bolt Assembly 95
Seal and Taper Bearing Assembly 96
Spur Bevel Gear Pre-Assembly 96
Pinion Shaft Pre-Assembly 96
Pinion Shaft Assembly 97
Pinion Shaft Pre-Assembly 97
Wheel Shaft Assembly 98
Spur Bevel Gear Play 99
Calculating the Torsional Flank Clearance 99
Adjusting the Bevel Wheel Set 99
Wheel Shaft Pre-Tension100
Second Torsional Flank Clearance Check100
Final Assembly100
Thread Shield Assembly100
Radial Shaft Packing Washer Assembly101
Wheel Shaft Assembly101
Housing Cover Assembly101
Gear Upper Section Assembly102
Live Ring Bearing Maintenance102
Lubrication102
Filling the Gear Unit with Oil103
Gear Unit Assembly103
ELECTRICS104
ESR4000 Status Codes115
ACCESS 1-2-3115
Status Codes115
When a Service Code Occurs115
Truck does not Operate and there is no Status Code l HNS: Horn switch115
Fault during power-up115
The fault is not electrical115
ACCESS 1-2-3 switches the truck off115
Operating fault in an unmonitored input115
Power Up Circuit Diagram116
Maintenance116
STATUS CODE 211to xxx117
Electrics – General106
Wire Colour Codes106
Index of Abbreviations107
Index of Abbreviations (contd)108
Electrical Symbols109
Capacity Data Monitor110
Capacity Data Monitor (on ACCESS 1 operator display)110
Capacity Data Monitor (continued)111
Capacity Data Monitor (continued)112
Troubleshooting113
Height Encoder ECR2114
Troubleshooting114
Access 1-2-3, Description188
Access 1188
Battery Discharge Indicator189
Power “on”189
Operator Improper Sequence Error189
Service Required Light189
Navigation Keys190
Message Display190
Capacity Data Monitor190
Operator Menu191
Operator Menu (cont)192
Service Menu193
ANALYZER Menu194
ANALYZER Menu (contd), Inputs195
ANALYZER Menu (Contd), Inputs196
ANALYZER Menu (Contd), Outputs197
ANALYZER Menu (Contd), Test Outputs198
CALIBRATION Menu199
Accessing the CALIBRATION Menu l201
CALIBRATION Menu (Contd)200
When to calibrate 201
Calibration Procedures201
Calibration Complete201
Truck Calibration202
FEATURES Menu209
Drive Motor233
Access233
Maintenance233
Pump Motor233
Access233
Maintenance233
Emergency Disconnect Contactor235
Contactor Tips235
Contactor Coil Control235
Replacing the Contactor Tips235
Battery Maintenance236
Charging the Battery236
Replacing the Battery236
Replacing the Battery with a Battery Trolley239
BRAKE240
Brake Systems, Description242
Motor Brake System242
Load Wheel Brake System242
Bleeding the Brake System, general242
Motor Brake243
Operating Brake Adjustment243
Parking Brake244
Parking Brake Adjustment244
System Bleeding245
Brake Disassembly245
Load Wheel Brake System247
Load Wheel Brake Adjustment247
System Bleeding248
Load Wheel Brake Disassembly249
STEERING250
Steering, Function252
Steering Unit Disassembly253
Hydraulic Motor Disassembly254
Steering Chain Adjustment255
POT6 (Steer Angle Display) Replacement256
Assembly and Adjustment256
MAST258
Torque Requirements260
Fork Adjustments260
Mast Testing (Assembled)260
Flaking260
Shock Absorbers260
Mast Dampening Screws260
ADJUSTMENT260
Mast Disassembly262
Mast Assembly262
Mast Rollers263
Mast Roller Adjustment263
Mast Play Control263
Fork Carriage265
Before Disassembly265
Disassembly265
Fork Carriage Assembly265
Fork Carriage Roller Adjustment266
Lift Chains267
General267
INSPECTION267
Cleaning267
Wear267
Freedom of Movement268
Chain Tension268
Chain Anchor and Pulleys268
Worn or Missing Plates268
Protruding or Turned Chain Pins268
Corrosion269
Chain Lateral Wear269
Uneven Chain Tension269
Misalignment of Lift Components269
LIFT CHAIN LUBRICATION Dust will gather on oiled chains in dusty environments270
Fork Tine Test271
General271
Fork Identification271
Repairs271
Crack Inspection271
Fork Blade Warping272
Verticality Test272
Measuring the Fork Tip Width273
Fork Tine Height Difference273
Fork Stop273
Wear274
CYLINDERS276
Maintenance281
General278
Inspection281
Inspektion and repair of the parking brake cylinder281
Installing the Piston Seal282
Assembly of Small Rod Seals282
Assembly of Large Rod Seals282
Backup Ring Emergency Assembly283
Cylinder Disassembly283
Free-Lift Cylinder283
Prior to Disassembly283
Disassembly283
Assembly284
Lift Cylinder285
Prior to Disassembly285
Disassembly285
Assembly285
Reach Cylinder285
Prior to Disassembly285
Disassembly285
Assembly286
Sideshifter Cylinder286
Prior to Disassembly286
Disassembly286
Assembly286
Tilt Cylinder286
Prior to Disassembly286
Disassembly286
Assembly287
Parking Brake Cylinder287
Prior to Disassembly287
Disassembly287
Assembly288
ELECTRICAL DIAGRAMS290
Control Circuit292
Access1293
Access2294
Access3295
Switches and Operator Controls296
Switches and Operator Controls297
Switches and Operator Controls298
Mast, Hydraulic Components299
Fuses, Fans and Contactors300
Fuses, Fans and Contactors301
Star Point Loom Connections302
Star Point Loom Connections303
Power Cables304
HYDRAULIC SCHEMATIC306
Hydraulic System308
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