Crown ESR4000 Forklift Service Manual
311 pages · Publication 812550-006
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- Models
- ESR4000
- Manual type
- Service Manual
- Pages
- 311
- Publication
- 812550-006
- Condition
- Brand new
What's inside
From the manual's own table of contents: 14 sections, 210 entries. See sample pages (PDF, 462 KB)
SAFETY6 topics
- Safety Symbols used in the Manual
- General Maintenance and Repair Safety Notes
- Maintenance and Repair
- Before Leaving the Truck
- Before Carrying out Work on the Truck
- Before Operating the Truck
INTRODUCTION6 topics
- General
- Service Training
- Operating Instructions
- Ordering Spare Parts
- Using the Manual
- Model-Number
LUBRICATION AND ADJUSTMENT18 topics
- Jacking up the Truck
- Raising the Truck with a Crane
- Towing the Truck
- Component Access
- Removing the Floorboard
- Seat Disassembly / Installation
- Plastic Panel Disassembly / Assembly
- Maintenance
- Driver Participation
- Daily Maintenance Log
- Recommended Lubricants and Oils
- Inspection and Maintenance Schedule
- Daily or 8 service hours
- Months or 250 hours
- Months or every 500 hours
- Annually or every 1.000 hours
- Every 2 years or 2.000 hours
- Torques
HYDRAULICS20 topics
- WARNING
- Changing Hydraulic Oil
- Hydraulic Pipes and Accessories
- Filter
- Tank
- Drift Test
- Drift Test Tilt Function
- Drift Test Lift Function
- Hydraulic System
- No Demand for Steering SVT SVS SCV6 CV5
- Full Demand for Steering
- Low Speed Lift
- High Speed Lift
- Lower Circuit
- Reach Forward Circuit
- Tilt Down Circuit
- Tilt Back Circuit
- Sideshift Right Circuit
- Parking Brake Release Circuit
- Hydraulic Symbols
Valve Bank3 topics
- Operation
- Adjustment
- Proportinal Valves PVA & PVH
DRIVE UNIT32 topics
- Gear Unit Removal
- Disassembly
- Draining the oil
- Steering Chain Removal
- Drive Wheel Removal
- Drive Motor
- Maintenance
- Tools
- Measurement Tools
- Equipment
- Equipment 2
- Equipment 3
- Gear Unit Maintenance
- General
- Gear Unit Main Components
- Gear Unit Labelling
- Setting Data
- Disassembly
- Pre-Assembly Test
- Assembly
- Pinion Shaft Installation Dimensions
- l Press the bearing cup (2) into the bearing seat in Installing the Pinion Shaft Bearing Cup in the Housing
- Bearing Inner Ring and Cup Installation
- Wheel Shaft Pre-Assembly
- Spur Bevel Gear Pre-Assembly
- Pinion Shaft Pre-Assembly
- Pinion Shaft Assembly
- Wheel Shaft Assembly
- Spur Bevel Gear Play
- Wheel Shaft Pre-Tension
- Final Assembly
- Gear Unit Assembly
ELECTRICS43 topics
- ESR4000 Status Codes
- Status Codes
- When a Service Code Occurs
- Truck does not Operate and there is no Status Code l HNS: Horn switch
- Power Up Circuit Diagram
- Maintenance
- STATUS CODE 211to xxx
- Electrics - General
- Wire Colour Codes
- Electrical Symbols
- Capacity Data Monitor
- Capacity Data Monitor (on ACCESS 1 operator display)
- Capacity Data Monitor (continued)
- Troubleshooting
- Height Encoder ECR2
- Troubleshooting
- Access 1-2-3, Description
- Access 1
- Operator Menu
- Operator Menu (cont.)
- Service Menu
- ANALYZER Menu
- ANALYZER Menu (contd.), Inputs
- ANALYZER Menu (Contd.), Outputs
- CALIBRATION Menu
- CALIBRATION Menu (Contd.)
- When to calibrate
- Calibration Procedures
- Truck Calibration
- FEATURES Menu
- Access
- Maintenance
- Pump Motor
- Access
- Maintenance
- Emergency Disconnect Contactor
- Contactor Tips
- Contactor Coil Control
- Replacing the Contactor Tips
- Battery Maintenance
- Charging the Battery
- Replacing the Battery
- Replacing the Battery with a Battery Trolley
BRAKE12 topics
- Brake Systems, Description
- Motor Brake System
- Load Wheel Brake System
- Bleeding the Brake System, general
- Motor Brake
- Operating Brake Adjustment
- Parking Brake
- Parking Brake Adjustment
- Brake Disassembly
- Load Wheel Brake System
- Load Wheel Brake Adjustment
- Load Wheel Brake Disassembly
STEERING6 topics
- Steering, Function
- Steering Unit Disassembly
- Hydraulic Motor Disassembly
- Steering Chain Adjustment
- POT6 (Steer Angle Display) Replacement
- Assembly and Adjustment
MAST31 topics
- Torque Requirements
- Fork Adjustments
- Mast Testing (Assembled)
- Flaking
- Shock Absorbers
- Mast Dampening Screws
- Mast Disassembly
- Mast Assembly
- Mast Rollers
- Mast Roller Adjustment
- Mast Play Control
- Fork Carriage
- Before Disassembly
- Disassembly
- Fork Carriage Assembly
- Fork Carriage Roller Adjustment
- Lift Chains
- General
- INSPECTION
- LIFT CHAIN LUBRICATION Dust will gather on oiled chains in dusty environments
- Fork Tine Test
- General
- Fork Identification
- Repairs
- Crack Inspection
- Fork Blade Warping
- Verticality Test
- Measuring the Fork Tip Width
- Fork Tine Height Difference
- Fork Stop
- Wear
CYLINDERS13 topics
- Inspection
- Inspektion and repair of the parking brake cylinder
- Installing the Piston Seal
- Assembly of Small Rod Seals
- Assembly of Large Rod Seals
- Backup Ring Emergency Assembly
- Cylinder Disassembly
- Free-Lift Cylinder
- Lift Cylinder
- Reach Cylinder
- Sideshifter Cylinder
- Tilt Cylinder
- Parking Brake Cylinder
ELECTRICAL DIAGRAMS6 topics
- Control Circuit
- Switches and Operator Controls
- Mast, Hydraulic Components
- Fuses, Fans and Contactors
- Star Point Loom Connections
- Power Cables
Inside this manual
Real pages from this service manual (311 pages). Open the sample pages (PDF, 460 KB)
- Specifications, page 111: ELECTRICS
- Diagram, page 187: Code changes: Faulty wiring or BFS. Repair / replace.
- Troubleshooting, page 219: ACCESS 1-2-3
- Color page, page 263: Printed in Germany
This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 311 pages
Quantity one is the manual described above.
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Binder not included
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).