PDF Maintenance Manual Crown ESR4500 Series Forklift - 1 MB
This maintenance manual provides comprehensive instructions for servicing the Crown ESR4500 Series reach trucks.
It is designed for trained technicians and covers scheduled maintenance, troubleshooting, and component repair procedures.
The detailed information on hydraulic and electrical systems helps ensure that all service work is performed correctly and efficiently.
Keep your Crown reach truck fleet reliable and productive with this essential guide.
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Maintenance Manual
ESR4500 Series
Printed in Germany ● Status 2, Revision Level A
Order Number: 812549-006
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TABLE OF CONTENT
M4 – ELEKTRICS PAGE SER-N0. CUT .................. REV.
A2.1 - A2.6 Inputs ....................................................... 143
A2.7 - A2.13 Inputs ..................................................... 144
A2.14 - A2.20 Inputs ................................................... 145
A2.21 - A2.25 Inputs .................................................. 146
A2.26 - A2.32 Inputs ................................................... 147
A2.33 - A2.37 Inputs ................................................... 148
A3.1 - A3.9 Outputs .................................................... 149
A3.10 - A3.16 Outputs ................................................ 150
A3.17 - A3.18 Outputs ................................................ 151
Calibration ....................................................................... 152
C1 - C3 Calibration ..................................................... 152
C4 - C5 Calibration ..................................................... 153
C6 - C7.1 Calibration .................................................. 154
C7.1.3 Calibration ....................................................... 155
C7.2 Calibration .......................................................... 156
C7.3 Calibration .......................................................... 157
C7.3.4 - C7.5 Calibration ............................................ 158
C8 Calibration ............................................................. 159
C9 Calibration ............................................................. 160
C10 - 11.2 Calibration ................................................. 161
Feature ............................................................................ 162
F1 - F3 Features ......................................................... 162
F4 - F6 Features ......................................................... 163
F7 - F7.7 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 - L3.2 Features ...................................................... 173
L3.2.1 - L4 Features ................................................... 174
Performance .................................................................... 175
P1 - P1.5.1 Performance ............................................ 175
P1.6 - P1.10.1 Performance ....................................... 176
P1.11 - P1.15 Performance ........................................ 177
P2 - P6 Performance .................................................. 178
P7 - P10 Performance ................................................ 179
P11 - P15.2 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
ESR4500 06/2004 • Printed in Germany MS-IDX-2140
IX
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INTRODUCTION
Printed in Germany
5
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LUBRIFICATION AND ADJUSTMENT
Emergency Disconnect Switch
Display
Main Fuse FU7 Fuses
Vehicle Steer Traction Hydraulic
Control Drive Travel Main Drive Drive
Module Module Direction Contactor Module Module
Switch Start Up
VCM SDM TDM HDM
Module
Optional
Switches
Steer
Sensor
Hydraulic
Tank
MS-2140-017
Brake Pedal Steer Motor Pump Motor
Safety Pedal
Brake Fluid Reservoir + Brake Connector
Main Brake Cylinder panel
Drive Motor
ESR4500 06/2004 • PRINTED IN GERMANY MS-M1-2140
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LUBRIFICATION AND ADJUSTMENT
Inspection and Maintenance Schedule (X = Standard, C = Cold Store)
I = Inspection, L = Lubricate / A, M, ... = Lubricant Years / Service Hours
1/4 1/2 1 2.5
Item Action
500 1000 2000 5000
I-46 Check the controllers are fixed. X/C
Make sure line connections to traction and lift drive modules, EMERGENCY
I-47 X/C
DISCONNECT switch and main fuse FU7 are secure
I-48 Make sure potentiometer connections are secure X/C
I-49 Make sure plugs on the connector panel are secure X/C
I-50 Test fan operation (drive module operating temperature must exceed 35°C) X/C
I-51 Check contactor, replace worn par ts as necessary X/C
I-52 Make sure all line connections from drive and lift motors are secure X/C
I-53 Check power cables from drive and lift motors for damage X/C
I-54 Check drive and lift motor attachments X/C
L-14 M Check and grease motor shaft toothing X/C
I-55 Check rubber buffer on hydraulic motor X/C
I-56 Check sensor and temperature gauge connections X/C
I-57 Check battery cables and connectors for damage C X
I-58 Check battery terminals C X
I-59 Check battery condition C X
I-60 Check acid density and acid level C X
I-61 Check mast attachment X/C
L-15 G Check, adjust and lubricate lift chains and chain anchors X/C
I-62 Check mast cables and tension jacks for damage and position X/C
I-63 Check diver ter rollers X/C
L-16 B Check mast sections for wear and apply grease X/C
I-64 Check mast rollers and stops X/C
I-65 Check height sensor and height sensor cable X/C
I-66 Check height reset switch or mast switch for lift speed reduction X/C
I-67 Check fork carriage for damage X/C
I-68 Check forks for damage and wear X/C
Sideshift: check rollers and slide blocks for wear, clean, grease and test
L-17 B C X
operation
L-18 B/BB Lubricate the fork carriage slide rail via grease nipple C X
I-69 Check if load backrest is secure, check for damage X/C
C 1 = every 1000 h or annually X 2 = every 2000 h or twice L06-gb
ESR4500 06/2004 • PRINTED IN GERMANY MS-M1-2140
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HYDRAULICS
Lifting
“Lifting” is requested by pulling the raise/lower control counter-pressure from building up (which would affect
lever. This changes the voltage on the loop of the raise the movement of the spool).
potentiometer POT2. As a result, the main control mod-
ule VCM switches on the pump and the magnet of the If the raise/lower control lever is released, the main con-
SVH raise pilot valve. trol module VCM switches off the pump and the current
to the SVH solenoid. SVH changes through bias spring
The SVH valve drives the DCVH raise/lower spool. The force so that the “raise” control pressure side of the spool
spool opens. is connected to the tank return line. The drop in pressure
causes the spool to return to its home position and breaks
The lift speed is controlled by the pump motor speed in the connection to the cylinders. The cylinders remain in
proportion to the movement of the control lever. their current position.
The oil flows from input P of the valve block through the Note: If the MVL manual lowering valve is open, i.e. turned
DCVH spool via output A to the hydraulic cylinders. The in, raising is inhibited.
hydraulic cylinders extend.
During raising, the “lower” control pressure side of the
DCVH spool is connected to the tank return line via the
lowering valve PVL. This is necessary to prevent any
Lowering
“Lowering” is requested by pushing the raise/lower con- If the raise/lower control lever is released, the main con-
trol lever forward. This changes the voltage on the loop trol module VCM switches off the current to the PVL so-
of the raise potentiometer POT2. As a result, the main lenoid. PVL changes through bias spring force so that
control module VCM switches on the magnet of the low- the “lower” control pressure side of the spool is connected
ering proportional valve PVL. to the tank return line. The drop in pressure causes the
spool to return to its home position and breaks the con-
The PVL valve drives the DCVH raise/lower spool. The nection to the cylinders. The cylinders remain in their
spool opens. current position.
The oil then flows from the hydraulic cylinders, via port A Pressure switch PLS is fitted on the hydraulic line to the
of the valve block through the flow control valve PCL and lift cylinders. If more than 400 kg is placed on the forks,
the spool to output T, and from there via the return line the pressure switch converts the switch limit of PVL. This
back to the tank. The hydraulic cylinders retract. prevents the load from stopping abruptly when being low-
ered. This prevents the mast from swaying.
In proportion to the movement of the control lever, the
lowering proportional valve PVL controls the oil pressure The valve block contains the AVL valve which is used to
on the spool, and hence the amount of opening of the set the maximum lowering speed when PVL is fully
spool and ultimately the lowering speed. opened. The maximum lowering speed for 1.4 t and 1.6 t
trucks is 0.58 m/s, and for 2.0 t trucks 0.51 m/s. Replace-
The flow control valve PCL installed before the spool ment AVLs are preset to 0.58 m/s and must be set to
ensures that the lowering speed is kept constant for each 0.51 m/s for 2.0 t trucks (see description in the “Valve
control lever position. Block” section).
During lowering, the “raise” control pressure side of the The MVL emergency lowering valve allows the mast to
DCVH spool is connected to the tank return line via the be lowered manually in the event of hydraulic failure. To
raise valve PVL. This is necessary to prevent any coun- lower, turn the emergency lowering valve clockwise.
ter-pressure from building up (which would affect the
movement of the spool).
ESR4500 06/2004 • PRINTED IN GERMANY MS-MA-2140
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HYDRAULICS
Hydraulic Reservoir
5
The hydraulic reservoir has a capacity of approx. 36
litres.
Discharging the Hydraulic Reservoir
● Unscrew the filter lid (5).
● Suction off the hydraulic oil via the filler port.
● Fully discharge the reservoir into a suitable
collection tray by opening the drain plug (4) (Fig.
MS-2140-054).
Filling the Hydraulic Tank
MAX
All hydraulic systems are extremely sensitive to contami-
nation.
MIN
Therefore, the oil must be filtered through a 10 micron
filter or strainer 100 before entering the system.
Note: The return filter filters the return flow, i.e. from out-
side to inside. It does not filter the oil you add to the res- MS-2140-026
ervoir via the filler port.
● Bleed the entire hydraulic system and then fill the
reservoir.
● All cylinders must be fuly retracted (mast carriage
on chassis, mast lowered, fork carriage tilted
forward).
● Keep filling until the oil is at the “Max” level (Fig. 4
MS-2140-026).
MS-2140-054
ESR4500 06/2004 • PRINTED IN GERMANY MS-MA-2140
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DRIVE UNIT
Gear unit
Preparation
Raise the truck approx. 500 mm to remove the gear unit.
See Chapter 1, Raising and Jacking up the Truck
Tools required:
● Forklift truck with sufficient capacity, lift height
and fork length for the truck to be raised.
● Safety mechanism for the forks of the lifting truck,
required to hold the raised truck.
● Sufficient number of wooden blocks (surface area
of at least 250 x 250 mm) or suitable supports to
secure the raised truck.
MS-2140-082
● Device to carry the gear unit onto a jack or pallet
truck. ● Undo the six gear unit mounting screws (A) and
the six motor mounting screws (B) in Fig. MS-
2140-082.
Removal
● Lower the device together with the gear unit and
● Disconnect the battery and remove the key. pull it out from under the truck.
● Secure the truck to prevent it from being switched
on again.
Servicing
WARNING
● Secure the truck with a second forklift and pre-
vent it from sliding away. The gear unit must only be serviced by
trained and authorised Crown personnel.
DANGER Failure to comply will invalidate the
warranty.
Never work underneath a suspended
load. Correcting the flank tooth bearing and
pre-tensioning the shaft support requires
Fatal injuries could result if the truck is years of experience with gear units.
suddenly lowered. Incorrect adjustments and settings will
result in premature failure of the gear
● Raise the truck until you can push a jack / pallet unit.
truck underneath the truck to support it.
It is therefore generally preferable to
● Raise the truck again by approx. 50 mm in order replace the whole gear unit.
to be able to loosen the gear unit from the
toothing at a later time. New gear units are always supplied
without oil.
● Lower the truck onto the wooden blocks/sup-
ports. Before using the gear unit for the first
time, fill oil in accordance with the
● Raise the device on the jack/pallet truck until it “Lubricant Table”.
contacts the gear unit.
● Remove the electrical connections from the
motor.
ESR4500 06/2004 • Printed in Germany MS-3.0-2140
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ELECTRICS
The lift encoder is a sensor ball bearing in the top bear- THS3 (Temperature switch 3)
ing plate of the pump motor. The lift encoder monitors
the current motor speed and relays this to the HDM. Switch THS3 is used only with cold store trucks. It is at-
tached near to the accelerator pedal. The thresholds are:
ECR3 (Steering feedback encoder)
ON: +2°C
The steering feedback encoder is installed in the steer
motor. It feeds back a signal in proportion to the steering OFF: +12°C
direction and the steering speed.
RES1 (Reach sensor 1)
ECR4 (Steering encoder)
SLOW Down range identified for forward/reverse reach,
The steering encoder is located in the steering column
below the steering wheel. When the steering wheel is ”OFF“ = Reduced fwd./rev. reach
turned it transmits a signal to the steer module which is
based on the direction of turn and the speed of turn. (OFF = in slow down range, ON in “normal” range)
ECR5 (Height encoder) RES1 generally activates reach speed reduction
The height encoder is located on the top cross member RES2 (Reach sensor 2)
of the outer mast. It monitors the lift height when the free
lift has been exceeded. It must be re-calibrated when Slow Down range identified.
replaced (see Calibration in the Service menu). Lifting is
inhibited if the height encoder is faulty or if there are no (ON = Slow Down rear, OFF = Slow Down front)
height encoder signals to the VCM after 30 seconds.
RES2 identifies the position of the mast in order to set off
THS1 (Temperature sensor 1) again at the appropriate speed.
THS 1 is located in the drive motor and monitors the cur- (If the mast is in the Slow Down range, the speed must
rent motor temperature. When the motor temperature be reduced for Fwd. reach activation). For Rev. reach
reaches 145 °C, the maximum current is restricted to 250 activation start again at normal reverse speed.
A. If the motor temperature continues to rise, the current
is reduced in proportion up to 0 A for a temperature of SVH (Lift valve)
165°C. At a motor temperature of 165°C and 0 A current,
the motor cuts out. SVR is incorporated with PVL in a single valve. SVR is a
black and white valve and opens when lifting is selected.
THS2 (Temperature sensor 2) The lift speed is governed by the pump speed.
THS2 is located in the hydraulic pump motor and moni- PVL (Proportional valve lower)
tors the current motor temperature. When the motor tem-
perature reaches 145 °C, the maximum current is re- PVL is incorporated with SVR in a single valve. The low-
stricted to 250 A. If the motor temperature continues to ering speed is governed proportionally by PVL.
rise, the current is reduced in proportion up to 0 A for a
temperature of 165°C. At a motor temperature of 165°C
and 0 A current, the motor cuts out.
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ELECTRICS
Statuscode 180 - 181
Status Code 180 Fehler am Lenkmotor - Encoder ECR3
Error Steer Feedback Encoder ECR3
LOG BOOK display: 1 8 0 X X X X X h X X X C
E C R 3 H A L L S E N S O R
Explanation: ECR3 is a 3-channel hall sensor. An error is generated if a channel is not
correctly identified or if 2 channels are short-circuited.
Effect on truck: - Parking brake applied
- Traction drive module deactivated
- Main contactor deactivated
Possible Causes: - Check lines and connections
- Disconnect PC412 and check +5V between pins 4 and 6.
Present: SDM OK.
Not present: Replace SDM.
- Re-connect plug. Check +5V between PC436-4 and 6.
Not present: Check line.
Present: Replace motor
Status Code 181 Fehler am Lenkencoder ECR4
Error Steer Encoder ECR4
LOG BOOK display: 1 8 1 X X X X X h X X X C
E C R 4 S T E P P E R M O T
Explanation: ECR4 is a stage motor which when applied sends an induced voltage
signal to the steer drive module. An open line or short circuit are
identified.
Effect on truck: - Parking brake applied
- Traction drive module deactivated
- Main contactor deactivated
Possible Causes: - Check lines and connections
- Disconnect PC414 and measure +5V between pin 5 or pin 2 (purple
line) and BATT NEG.
Present: Replace ESR4.
Not present: Check connection to SDM, replace steer drive module
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ELECTRICS
Statuscode 241
Status Code 241 Eingangsspannung von POT2 ist unter dem Grenzwert
Input Voltage from POT2 under Limit
LOG BOOK display: 2 4 1 X X X X X h X X X C
P O T 2 U N D E R L I M I T
Explanation: The loop voltage from POT2 is continually monitored during start-up and
operation. The lower limit of 0.6 volt is exceeded during this time.
Effect on truck: Hydraulic function completely disabled.
Possible Causes: - Select menu item A2.4 (POT2).
Activate “Raise/Lower”.
- Take readings from display.
Approx. 0 V: open circuit between potentiometer CA407-2 (red),
CA407-1 (green) and VCM or short circuit between CA407-2 (red) and
CA407-3 (yellow).
Check connection PC407 and PC205.
If the wiring is ok, replace the potentiometer.
Approx. 5.0 – 6.0 V: correct reading when control lever is in neutral.
0.7 – 1.5 V: correct reading when control lever is in max “Lower”
position.
9.5 – 10.5 V: correct reading when control lever is in max “Raise”
position.
If the readings are correct, there is probably an intermittent fault in the
potentiometer circuit. Check wire connections and potentiometer.
Note: Recalibrate potentiometer after carrying out repairs
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ELECTRICS
Statuscode 261
Status Code 261 Kurzschluss PVL (Absenkventil)
Short Circuit PVL (Lower Valve)
LOG BOOK display: 2 6 1 X X X X X h X X X C
P V L L O W E R V A L V E
Explanation: On the VCM main controller an overcurrent is detected on the PVL output
during lifting and the contactor output is cut out.
Effect on truck: - Hydraulic valves are cut out
- Pump continues to operate.
Possible Causes: Check coil resistance
Disconnect PC807 connector from solenoid valve. Connect measuring
device between pins 1 and 2 to PVL and measure the coil resistance.
Resistance = 27 Ohm.
If the coil resistance is excessive or 0 ohms, PVL must be replaced.
Missing Positive Test
- Power up the truck and record the voltage between PC422-8 and the
battery negative. Battery voltage should be applied.
- Disconnect PC807 from the solenoid valve and record the voltage
between PC422-8 and the battery negative.
If battery positive is still applied, there is a short circuit between PC807-
1 and PC205-42 against the battery positive.
After recording, re-connect PC807.
- Power up the truck and connect the measuring device between PC422-
9 and the battery negative.
Without applying POT2 (raise/lower) battery positive should be applied.
When activating POT2 (lower) the voltage should drop to approx. 33
volt. If not, replace the VCM.
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ELECTRICS
Statuscode 285 - 300
Status Code 285 Temperatursensor Kurzschluss oder offener Stromkreis
Temp. Sensor Short or Open Circuit
LOG BOOK display: 2 8 5 X X X X X h X X X C
T E M P . S E N S O R H M O T
Explanation: Short circuit or open circuit on hydraulic motor temperature sensor.
Effect on truck: - Truck starts up.
- Main contactor activated
- Fwd./rev. reach and lowering possible.
- Creep mode possible.
Possible Causes: Faulty temperature sensor. Disconnect PC430 and measure the
resistance between pins 1 and 2. Resistance at 25°C approx. 600 ohms.
If the resistance level deviates significantly: Replace motor.
Status Code 300 Fahrsteuerung hat konstanten Überstrom
Continuous Over Current Traction Module
LOG BOOK display: 3 0 0 X X X X X h X X X C
H I G H C U R R E N T T M