Crown Forklift ES ET 4000 Series Service Manual – PDF DOWNLOAD

Crown Forklift ES ET 4000 Series Service Manual – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift ES ET 4000 Series Service Manual – PDF DOWNLOAD

Language : English
Pages :374
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift ES ET 4000 Series Service Manual – PDF DOWNLOAD

Introduction 1
Important Information 1
Service personnel qualification 1
Ordering spare parts 1
Ordering documentation 1
Manual structure 1
Conventions 1
Text mark-ups in the manual 1
Brief description of equipment 1
Truck Data Number 3
Safety 4
Safety Notices 4
Basic Safety Notices 5
Organisational measures 5
Truck modifications and additions 5
Personal safety equipment 5
Protecting the hazardous area 5
Hazards from stored energy 5
Maintenance work 6
Restoring the truck to service after maintenance work 6
Cleaning work 6
Handling batteries 6
Warning and instruction decals on the truck 6
Lifting gear and slings 7
Environmental protection 7
Safety Mechanisms and Protective Guards 8
Truck safety mechanisms 8
Truck protective guards 8
Inspection and Lubrication 0
Cleaning the Truck and Components 0
Effects of incorrect cleaning 0
Electrical components 0
Roller and slide bearings 0
Corrosion-protected surfaces 0
Environmental protection 0
Cleaning the entire truck 0
Cleaning removed components 0
Cleaning other mechanical components 0
Raising the Truck 0
Securing the Truck for Transport on a Truck Bed 0
Towing the Truck 0
Jacking up the Truck 0
Placing the Truck in Storage 0
Taking the truck out of service 0
Testing trucks in storage 0
Restoring the truck to service 0
Recommended Lubricants and Consumables 0
Cold store truck requirements 0
Abbreviations used in the table 0
Planned Maintenance 0
Maintenance schedule 0
Annual inspection in accordance with FEM 4004 0
Terms and abbreviations used 0
Maintenance Schedule 0
Electrical system 0
Electrical system 0
Lifting mechanism 0
Drive system, steering and wheels 0
Safety mechanisms 0
Removing the caster wheel assembly 0
Installing the caster wheel assembly 0
Requirements 0
Repairing the Caster Wheel Assembly 0
Replacing the Drive Wheel 0
Standard Torques 0
Metric screws and nuts without flange 0
Metric hex bolts and nuts with flange (Unbrako® type) 0
Main Components 0
Motor compartment 0
Inspection and Lubrication 0
Cleaning the Truck and Components 0
Effects of incorrect cleaning 0
Electrical components 0
Roller and slide bearings 0
Corrosion-protected surfaces 0
Environmental protection 0
Cleaning the entire truck 0
Cleaning removed components 0
Cleaning other mechanical components 0
Raising the Truck 0
Securing the Truck for Transport on a Truck Bed 0
Towing the Truck 0
Jacking up the Truck 0
Placing the Truck in Storage 0
Taking the truck out of service 0
Testing trucks in storage 0
Restoring the truck to service 0
Recommended Lubricants and Consumables 0
Cold store truck requirements 0
Abbreviations used in the table 0
Planned Maintenance 0
Maintenance schedule 0
Annual inspection in accordance with FEM 4004 0
Terms and abbreviations used 0
Maintenance Schedule 0
Electrical system 0
Electrical system 0
Lifting mechanism 0
Drive system, steering and wheels 0
Safety mechanisms 0
Removing the caster wheel assembly 0
Installing the caster wheel assembly 0
Requirements 0
Repairing the Caster Wheel Assembly 0
Replacing the Drive Wheel 0
Standard Torques 0
Metric screws and nuts without flange 0
Metric hex bolts and nuts with flange (Unbrako® type) 0
Main Components 0
Motor compartment 0
Componentry 65
Hydraulic System 67
Hydraulic Oil 67
Checking the hydraulic oil level 67
Adding hydraulic oil 67
Requirements 67
Replacing the Hydraulic Oil 68
Replacing the Hydraulic Filter 69
Bleeding the Hydraulic System 71
Replacing the Relief Valve RV1 72
Testing the relief valve 72
Flushing the Hydraulic System 73
Requirements 73
Drift Test 74
Preparing the drift test 74
Drift test 74
Hydraulic System Troubleshooting 75
Drive Unit 76
Components 76
Trucks with mechanical steering 76
Trucks with electric steering 76
Replacing the Drive Wheel 77
Drive wheel disassembly 77
Drive wheel assembly 77
Changing the Gear Oil 78
Drive Gear Disassembly / Installation 79
Drive gear unit removal 79
Drive gear unit assembly 80
Electrical System Part 1 0
Input Signals 0
Initial truck status 0
SAS and BRS 0
Operating mode definition 0
Pedestrian mode 0
Comfort mode 0
Rider mode 0
Quick Exit 0
Conventions 0
Brief description of equipment 0
Input Signals 0
Platform and Side Restraint Logic 0
Brief description of equipment 0
Folding platform 0
Side restraint and platform setting definition 0
Accessing the Service Levels 0
Software Versions 0
Menu Structure (without Quick Pick® Remote Lift Technology) 0
Operator Menu 0
Service menu 0
Access 3 – Analyzer Outputs 0
Calibration 0
Access 2 – Analyzer Outputs 0
Access 5 – Analyzer Outputs 0
Features – F1 to F3 0
Features – F4 0
Features – F5 to F12 0
Features – F13 to F18 0
Features – F7 Enable 0
Hour – H1 to H5 0
Events – E1 to E3 0
Performance P1 0
Performance P2 0
Performance P3 0
Performance P4 to P16 0
Utilities – U1 0
Test Outputs – A4 0
Quick Pick® Remote Lift Technology Option Menu Structure 0
Quick Pick® Remote Lift Technology – operator menu 0
Quick Pick® Remote Lift Technology- Analyzer menu A18 Status 0
Quick Pick® Remote Lift Technology- Access 82 Inputs 0
Quick Pick® Remote Lift Technology- Features menu F24 Remote System 0
Quick Pick® Remote Lift Technology- Hours menu H8 Access 82 0
Quick Pick® Remote Lift Technology- Performance menu P23 0
Quick Pick® Remote Lift Technology- Utilities menu U18 Access 82 0
Software Parameter Settings ES 4020-MW /- EW 0
Brief description of equipment 0
Markings 0
Software Parameter Settings ET 4040-MF / -EF 0
Brief description of equipment 0
Operation Modes 0
Markings 0
Electrical System Part 2124
Calibration124
Selecting the CALIBRATION Menu124
Electric steering calibration124
Calibrating proportional lifting and lowering126
Error codes127
Malfunctions with event code display127
Locating malfunctions127
Event code groups127
Event Code – Group 100 (ES/ET -M, -E)128
Event code 100128
Event Code 126 & 127130
Event code 144131
Event code 191132
Event Code – Group 200 (ES/ET -M, -E)133
Event Code 202133
Event Code 203135
Event Code 204135
Event Code 205137
Event code 208139
Event code 228140
Event code 229141
Event code 230142
Event code 231144
Event codes 232 and 233145
Event code 234146
Event code 235147
Event code 236148
Event Code – Group 300 (ES/ET -M, -E)149
Event code 300149
Event code 301150
Event code 302150
Event code 303151
Event code 304151
Event code 305153
Event code 306154
Event code 307154
Event code 308155
Event code 309156
Event code 310156
Event code 314156
Event code 315158
Event code 316158
Event code 317159
Event code 320161
Event code 334161
Event code 321162
Event code 322163
Event code 326164
Event code 328165
Event code 329165
Event code 333165
Event code 334166
Event code 335166
Event code 337167
Event code 338168
Event code 340170
Event code 341171
Event code 342171
Event code 343172
Event code 348174
Event code 351174
Event code 352175
Event code 353175
Event code 354176
Event code 355177
Event code 356177
Event code 357177
Event code 358179
Event code 359179
Event code 361181
Event code 362182
Event code 364183
Event code 365184
Event code 368185
Event Code – Group 500 (ES/ET -E)186
Event code 500186
Event code 501187
Event codes 502, 503, 504, 505187
Event code 506187
Event code 508188
Event code 509188
Event code 510189
Event code 511192
Event code 512192
Event code 513193
Event code 514193
Event code 515194
Event code 516195
Event code 517196
Event code 518198
Event code 519199
Event codes 520, 521200
Event code 522200
Event code 523201
Event code 524202
Event code 525203
Event code 526204
Event codes 527, 528205
Event code 529206
Event code 530207
Event code 531208
Event code 532209
Event code 535211
Event code 536211
Event code 537212
Event code 538213
Event code 539214
Event code 540215
Event code 541216
Event codes 542, 543216
Event code 544218
Event code 545219
Event code 547219
Event Code Group 800 (ES/ET -E)220
Event code 801220
Event code 802220
Event code 804221
Event Code Group 800222
Trucks with QuickPick® Remote Lift Technology222
Event code 801222
Event code 804224
Event code 805224
Event code 806224
Event code 816224
Event code 821225
Event code 832225
Event code 833226
Event code 834226
Event code 835227
Event Code 836 & 837227
Event code 838227
Event code 844227
Event Code 845 & 846228
Event Code – Group 1000229
Event code 1000229
Event code 1001 or 1002230
Events Displayed as Text231
Platform Error231
Stopped233
Traction control module hot234
Traction motor hot235
Release control handle236
Travel switch applied too soon237
Pedestrian mode only237
Lower forks237
Steering controller hot238
Steer motor hot240
Pairing Failed Enter to Retry242
Release remote brake button243
Low signal strength243
Electrical System Part 3244
Control Module PMT Test244
General244
Required tools244
PMT Test244
Testing Access 2244
Testing Access 3245
Testing Access 5246
Servicing and Replacing the Control Modules247
Discharging the capacitors247
Servicing the control modules247
Replacing control modules247
Removing the control module247
Assembling the control module248
Set the parameters after replacing a control module248
Modifications249
Converting the truck from Enter key to key switch power-up function249
Mechanical conversion249
Changing the software249
Converting the truck from key switch to Enter key power-up function250
Mechanical conversion250
Changing the software250
Battery Information251
Charging batteries251
Lithium ion battery251
Charging a lithium ion battery251
Lead Acid Battery251
Servicing a lead acid battery251
Replacing a lead acid battery251
Adjusting the BLS sensor252
General DC Motor Maintenance Instructions253
Brushes253
Motor253
Rotor253
Setting the Load Profile for the Battery Discharge Indicator (BDI)254
Load profile and discharge curve254
Assigning a load profile254
Checking and Adjusting the BDI Setting256
Requirements256
Checking the BDI Setting256
Adjusting the BDI setting257
Traction motor Installation and Removal258
Traction motor disassembly258
Traction motor assembly259
Repairing the Traction Motor260
Preparation260
Rotor and bearing disassembly260
Rotor and bearing assembly260
Final tasks260
Pump Motor (M2)261
Brushes261
Rotor261
Replacing the Steer Motor (M3)262
Special tools required263
Steer motor disassembly263
Steer motor assembly263
Repairing Contactors264
Wear test264
Checking the contacts264
Checking the coils264
Checking the springs264
Electrical Components265
ES4000 Model265
ET 4000 Model267
PWS, FLS, ALM and charger option271
InfoLink® option272
Quick Pick® Remote lift technology273
Braking System275
Components and Operation275
Service brake275
Parking brake275
Servicing the Parking Brake276
Measuring the air gap276
Troubleshooting276
Replacing the Parking Brake277
Parking brake disassembly277
Parking brake assembly277
Testing the Braking Distance279
Requirements279
Performing the test279
Braking distance tables279
Maximum braking distances ES 4000 -MW or -EW279
Maximum braking distances ET 4000 -MF or -EF279
Steering 0
Repairing the Tiller Handle280
Replacing the tiller handle shells281
Shell removal281
Shell assembly282
Replacing the switch unit282
Switch unit removal283
Switch unit assembly283
Replacing the “rabbit/turtle” toggle module283
Toggle module removal283
Toggle module assembly284
Replacing the tiller handle PC boards284
Hydraulic PC board removal284
Hydraulic PC board assembly284
Main PC board removal284
Main PC board assembly284
Replacing the traction potentiometer285
Traction potentiometer removal285
Traction potentiometer assembly286
Replacing the brake switch (BRS)286
Remove the brake switch (BRS)286
BRS switch assembly287
Replacing the grips and horn switch287
Repairing Tiller Handle Return Springs288
Removing the covers288
Return spring pre-tension adjustment288
Replacing the return springs289
Return spring removal289
Return spring assembly289
Tools required:289
Mechanical Steering290
Repairing the steering transmission290
Setting straight-ahead travel291
Lifting Mechanism292
Checking the Assembled Mast292
Checking the Fork Height293
Mast Removal and Assembly294
Mast disassembly294
Mast assembly295
Correct Use of Tool 833158296
Replacing the Fork Carriage Rollers and Adjusting the Slack297
Repairing the Mast298
TL Mast298
TF mast298
TT mast298
Mast disassembly299
Mast assembly300
Final tasks300
Replacing the Mast Rollers and Adjusting the Slack301
Fork Carriage Assembly and Removal304
Removing the fork carriage with the TF and TT masts304
Assembly304
Removing the fork carriage with a TL mast304
Assembly304
Lowering Plumb Test and Adjusting the Mast Tilt305
Requirements305
Preparing the lowering plumb test305
Lowering plumb test305
Adjusting the Mast Tilt305
Replacing the Mast Guard307
Preparation307
Removing the mast guard307
Installing the mast guard307
Repairing Lift Chains and Chain Tensioners308
Adapting the service intervals to the application conditions308
Periodic replacement of the chain tensioners and lift chains308
Servicing lift chains309
Service work309
Checking the service hours for the lift chains and anchor bolts309
Cleaning lift chains309
Lubricating and preserving lift chains309
Checking the Lift Chains for Wear and Damage311
Checking the lift chain elongation311
Tools required311
Test preparation311
Checking the lift chain elongation with the wear gauge312
Checking the lift chain elongation with the steel ruler313
Checking the chain for other damage314
Separating Lift Chains317
Tools and equipment required317
Forks318
General318
Fork inspection318
Checking forks for cracks318
Cylinders319
Safety notices319
Hydraulic system repair instructions319
Tools320
Small hook320
Extractor320
Producing extractors320
Groove aligning arbor for small rod seals320
Assembly devices for large rod seals321
Protective mechanisms321
Rod Seal Removal and Assembly322
Removing a large rod seal322
Removing a small rod seal322
Inserting a large rod seal322
Fitting a small rod seal323
Rod seal assembly, sealing lip first323
Lift Cylinder Removal and Assembly324
Removing the lift cylinder (TL mast)324
Lift cylinder (TL mast) assembly325
Lift cylinder (TF and TT mast) removal327
Lift cylinder (TF and TT mast) removal327
Lift cylinder (TF and TT mast) assembly327
Free lift cylinder removal and assembly329
Free Lift Cylinder Removal (Method 1)330
Free Lift Cylinder Assembly (Method 2)331
Free Lift Cylinder Removal (Method 2)332
Free Lift Cylinder Assembly (Method 2)333
Repairing the Lift Cylinders on the TL and TT Masts335
Repairing the Lift Cylinder for the TF Mast337
Repairing the left lift cylinder337
Repairing the right lift cylinder339
Repairing the Free Lift Cylinder for the 12 and 14 ES/ET – TF341
Repairing the Free Lift Cylinder for the 16 ES/ET – TF or TT343
Platform345
Adjusting the Folding Platform Switch345
Pre-tensioning the spring assembly345
Checking and adjusting switch PLS1 for rider mode345
Adjusting switch PLS2 for pedestrian mode346
Replacing the Folding Platform Springs347
Spring removal347
Spring assembly347
Schematic Diagrams348
Wire Colour Code348
General Contact Symbol Abbreviations349
Electrical Wiring Symbols351
ES -M with standard equipment (up to S/N 5A151757)353
ES -M with options (up to S/N 5A151757)354
ES -M with standard equipment (from S/N 5A151758)355
ES -M with options (from S/N 5A151758)356
ES -E with standard equipment (from S/N 5A151758)357
ES -E with options (from S/N 5A151758)358
ES/ET CAN-Bus connections, mechanical steering359
ES/ET CAN-Bus connections, electric steering360
Lithium Ion Battery Provision Option361
With Key Switch361
With Keypad362
Main Wire Harness ES 4000363
Main wire harness ET 4000364
Electric steering harness for ES 4000365
Electric steering harness for ET366
InfoLink® wire harness for ES/ET 4000367
Hydraulic Schematic368
Hydraulic Symbols368
ES 4000 with TT Mast372
ET 4000 with TF Mast373
ET 4000 with TL Mast374

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