Maintenance Manual
ESR4500 Series Printed in Germany â—? Revision Level B Order Number: 812549-006
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 2006 CROWN Equipment Corporation
TABLE OF CONTENTS
Printed in Germany
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Printed in Germany
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TABLE OF CONTENTS Table of Contents MA – SAFETY
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Safety Symbols used in the Manual ...................................... 3 General Maintenance and Repair Safety Notes ................... 3
ITD – INTRODUCTION
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Maintenance and Repair ......................................................... Before Leaving the Truck ............................................... Before Carrying out Work on the Truck ......................... Before Operating the Truck ............................................ Warnings and Labels on the Truck ....................................... General ..................................................................................... Operating Instructions .................................................... Service Training .............................................................. Ordering Spare Parts ...................................................... Using the Manual ............................................................
3 4 4 4 4 7 7 7 7 7
M1 – LUBRICATION AND ADJUSTMENT
PAGE
Lifting the Truck ...................................................................... Towing the Truck ..................................................................... Jacking up the Truck .............................................................. Component Access ................................................................. Access to the Motor Compartment ................................ Removing the Floorboard ............................................... Plastic Panel Disassembly / Assembly .......................... Maintenance ............................................................................ Recommended Lubricants and Oils ............................... Lubricants ........................................................................ Cold Store Trucks ........................................................... Truck Decommissioning ................................................. Restoring the Truck to Service ....................................... Battery Maintenance ....................................................... Daily Safety Check .................................................................. Inspection and Maintenance Schedule ................................. Cold Store Trucks ........................................................... Torques .................................................................................... Screw Grade Marking ............................................................. Nut Grade Marking .................................................................. Hydraulic Symbols .................................................................. Functional Description ........................................................... Abbreviations .......................................................................... Lifting ............................................................................... Lowering .......................................................................... Mast Reach Carriage Retraction ................................... Mast Reach Carriage Extension .................................... Tilt Back Circuit ............................................................... Tilt Down Circuit .............................................................. Sideshift Left ................................................................... Sideshift Right .................................................................
11 11 12 13 14 14 14 16 16 16 16 16 16 16 18 20 20 26 26 26 29 33 33 35 35 37 37 39 39 41 41
M2 – HYDRAULICS
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Hydraulic Components ........................................................... Hydraulic Lines ............................................................... Valve Block ...................................................................... Relief Valve RV1 ......................................................... Lowering Speed Adjustment Valve AVL ...................... Pressure Load Switch PLS .............................................
42 42 43 43 44 44
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TABLE OF CONTENTS M2 – HYDRAULICS
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Hydraulic Reservoir ........................................................ Discharging the Hydraulic Reservoir ............................. Filling the Hydraulic Tank ............................................... Filter ................................................................................. Replacing the Return Filter ......................................... Replacing the Aeration Filter ...................................... Replacing the Suction Filter ........................................ Pump Motor ..................................................................... Hydraulic Pump ............................................................... Disassembly ............................................................... Commissioning ........................................................... Bleeding the Hydraulic System ............................................. Bleeding the Free Lift Cylinder ...................................... Bleeding the Lift Cylinders ............................................. Bleeding the Reach Cylinder ......................................... Bleeding the Sideshift Cylinder ...................................... Bleeding the Tilt Cylinders .............................................. Bleeding the 5th Function Cylinder ................................ Flushing the Cylinders .................................................... Drift Tests ................................................................................. Lift cylinder drift test ....................................................... Tilt cylinder drift test ........................................................ Causes of Drift ................................................................
45 45 45 46 46 47 47 48 48 48 48 50 50 50 51 51 51 51 51 52 52 52 52
M3 – DRIVE UNIT
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Gear unit .................................................................................. Preparation ...................................................................... Removal .......................................................................... Servicing .......................................................................... General ....................................................................... Gear Unit Disassembly / Assembly ................................ Disassembly ............................................................... Assembly .................................................................... Preparing the gear unit ............................................. Inserting the bevel pinion shaft ................................. Assembling the flange shaft ...................................... Adjusting the Bevel Wheel Set ................................. Checking the flank tooth bearing .............................. Final Assembly .......................................................... Re-Assembly ................................................................... Traction motor .................................................................
55 55 55 55 57 57 57 57 57 58 58 58 59 59 60 60
M4 – ELECTRICS
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Electrical Components ........................................................... ACS ............................................................................. BFS ............................................................................. BLS ............................................................................. BPS ............................................................................. BRS ............................................................................. BRAKE ........................................................................
63 63 63 63 63 63 63
BS ..................................................................... ECR1 .......................................................................... ECR2 .......................................................................... ECR3 .......................................................................... ECR4 ..........................................................................
63 63 63 63 63
ECR5 up to serial no. 5A203818 .................... 63
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TABLE OF CONTENTS M4 – ELECTRICS
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ECR5 from serial no. 5A203820 ....................... 64 EDS ............................................................................. 64 ED1 ............................................................................. 64 ED2 ................................................................... 64 ED3 ................................................................... 64 FAN1 ................................................................. 64 FAN2 ........................................................................... 64 FAN3, FAN4 ................................................................ 64 FKS ................................................................... 64 FLS ................................................................... FS ............................................................................... FU1 (15 A) .................................................................. FU2 (15 A) .................................................................. FU3 (15 A) up to serial no. 5A204796 ........................ FU3 (10 A) from serial no. 5A204798 ......................... FU4 (30 A) up to serial no. 5A204796 ........................ FU4 (10 A) from serial no. 5A204798 .........................
64 64 64 64 64 64 65 65
FU5 (15 A) & FU6 (15 A) .................................. 65 FU7 (425 A) ................................................................ 65 FU8 (30 A) ........................................................ 65 FU9 (50 A) ........................................................ FU13 (50 A) from serial no. 5A204798 ....................... HDM ............................................................................ HN ............................................................................... HNS ............................................................................ HGTS (up to serial no. 5A203818) ............................. HGTS from serial no. 5A203820 .................................
65 65 65 65 65 65 65
HGTRS up to serial no. 5A203818 ................... 65 HGTRS from serial no. 5A203820 .................... 65 K1 & K2 ............................................................ 65 K3 & K4 ............................................................ 65 .................................................................................... 65 K5 ..................................................................... 66 K6 ..................................................................... 66 K7& K8 ............................................................. 66 K9 & K10 .......................................................... 66 K11 .............................................................................. 66 K12 & K13 ........................................................ 66 K14 ................................................................... KYS ............................................................................. LS ................................................................................ MVL .............................................................................
66 66 66 66
ORS .................................................................. POT1 ........................................................................... POT2 ........................................................................... POT3 ...........................................................................
66 66 66 66
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TABLE OF CONTENTS M4 – ELECTRICS
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POT4 ........................................................................... 67 POT5 ........................................................................... 67 POT6 ................................................................ PLS ............................................................................. PVL ............................................................................. PVAR .......................................................................... PVAL ........................................................................... PVRT ........................................................................... PVRE .......................................................................... RES1 ........................................................................... RES2 ........................................................................... RS ............................................................................... RV ...............................................................................
67 67 67 67 67 67 67 67 67 67 67
SD ..................................................................... SDM ............................................................................ SES ............................................................................. SFS 1SA ..................................................................... SFS 2 ..........................................................................
68 68 68 68 68
SI ...................................................................... SPS ............................................................................. SVR ............................................................................. SVS ............................................................................. SVT .............................................................................
68 68 68 68 68
SW .................................................................... TDM ............................................................................ THS1 ........................................................................... THS2 ...........................................................................
68 68 69 69
THS3 ................................................................. THS4 (from serial no. 5A203820) ............................... ESR4500 Status Codes ........................................................... Status Codes ................................................................... When a Service Code Occurs .................................... Truck does not operate and there is no Status Code . 1. Fault during power-up ........................................... 2. The fault is not electrical ....................................... 3. Malfunction in one of a group of unmonitored inputs ........................................................................ Power Up Circuit up to Ser. No. 5A204796 ................ Power Up Circuit up from Ser. No. 5A204798 ............ Statuscode 100 - 102 ...................................................... Statuscode 110 - 111 ...................................................... Statuscode 112 - 120 .................................................... Statuscode 121 - 130 ...................................................... Statuscode 131 - 160 ...................................................... Statuscode 180 - 181 ...................................................... Statuscode 182 - 183 ...................................................... Statuscode 184 - 186 ...................................................... Statuscode 200 ............................................................... Statuscode 201 - 210 ...................................................... Statuscode 211 - 213 ...................................................... Statuscode 214 - 220 ...................................................... Statuscode 221 - 222 ...................................................... Statuscode 223 - 224 ...................................................... Statuscode 225 - 230 ...................................................... Statuscode 240 (up to Ser. No. 5A204796) ...................
69 69 71 71 71 71 71 71
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71 72 73 74 75 76 77 79 80 81 82 83 84 85 86 87 88 89 90 ESR4500 06/2004 • Printed in Germany
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