Crown Forklift WE WS 2000 Walkie Stacker Service Manual

C

INTRODUCTION

This manual is intended for the service mechanic who is seeking information about maintenance and service replacement parts. It contains a section on troubleshooting which will enable a qualified mechanic to locate and solve problems which may occur.

OPERATOR INSTRUCTIONS This manual does not contain operation instructions. Operator Instructions in tag or booklet form are sent with each truck. Additional copies can be ordered if required. These booklets are for you and your personnel to insure years of safe, trouble-free operation of your Crown Lift Truck. For WE/WS operator manual, refer to Crown publication, "You and "WE/WS Operator Manual" (PF-12579).

DRIVER TRAINING Crown has available a complete series of Driver Training programs; in two parts concerning basic safety rules and operating characteristics of your walkie stacker. To obtain this informative material, ask your Crown dealer about "WE/ WS Walkie Stacker" operator training program.

SERVICE TRAINING Complete Service Training is available to the lift truck mechanic, covering all Crown Lift Trucks, SCR systems, wire guidance, hydraulic and electrical systems. To obtain more information concerning service training, contact your Crown Dealer.

When ordering replacement parts from this manual, always specify, along with the part number, the model and serial number of the truck. This information will further enable us to give correct, fast and efficient service.

For Series WE/WS capacities, technical information and dimensional specifications, please refer to the following sales literature: WE/WS Literature CPG12597 WE/WS Specifications CPG12612 Copies of publications can be obtained from your Crown dealer or by writing to: Crown Equipment Corporation 44 South Washington Street New Bremen, Ohio 45869 This manual is arranged according to major sections. The first part of the page number, found at the bottom of each page, denotes the section in which a particular form will be located. The front of the manual covers written maintenance. The back covers replacement parts. The sectional descriptions are as follows: MAINTENANCE SECTION M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

DESCRIPTION Lubrication and Adjustment Hydraulic Maintenance Drive Unit Maintenance Electrical Maintenance Brake Maintenance Steering Maintenance Main Frame and Mast Maintenance Cylinder Maintenance Platform Covers Glossary

REPLACEMENT PARTS SECTION 1 2 3 4 5 6 7 8 9 10

DESCRIPTION Fork Carriage Parts Hydraulic Parts Drive Unit Parts Electrical Parts Brake Parts Steering Mast Parts Cylinders Parts Covers Labels And Decals 7146

Crown 1998 PF11439-1 Rev. 12/03

Printed in U.S.A.

02 REV. 12/03

ITD–4320–001

ITD–4320–001

C

INTRODUCTION

All Crown lift trucks are given a model number. This number is used as a brief description of the truck. The following chart gives a model number and shows how it was formed.

WS 2000 Series MODEL NUMBER SYSTEM

–

30

WS

TT

160

50 42

V

L

B

F

M

TRUCK – = Standard S = Special BATTERY TYPE – = Less Battery M = Maintenance Free F = Wet Cell

* CAPACITY Pound Rated (x 100) Ex. 30 x 100 = 3000 lbs.

Metric Rated (x 1000) 1.0 x 1000 = 1000 kg.

FREEZER CONDITIONING – = None F = Freezer Conditioning

MODEL DESIGNATION WS- Walkie Stacker (Straddle) MAST TYPE TL - Limited Free Lift TF - Full Free Lift TT - Three Stage

BATTERY DISCHARGE INTERRUPT – = None B = BDI

**COLLAPSED/LIFT HEIGHT MM (IN.) WS/TL, WS/TF 2130 (84)/ 3250 (128) WS/TT 1860 (73)/ 4050 (160)

LOAD BACKREST – = None L = Load Backrest

INSIDE STRADDLE DIMENSION 42 = 1067 mm (42 in.)

50 = 1270 mm (50 in.)

DRIVE TIRE Vulkolan

FORK LENGTH – Less Forks 991 mm (39 in.)

1067 mm (42 in.)

EXAMPLE: A truck having a model number– 30 WS TT 160 50 42 V L B F M is a standard, 1360 kg (3000 lbs.) capacity, walkie with three stage mast 1860 mm (73 in.) collapsed height/4050 mm (160 in.) lift height, 1270 mm (50 in.) inside straddle dimension, 1067 mm (42 in.) forks, equipped with a Vulkolan drive tire, load backrest and battery discharge interrupt meter, freezer/corrosion and maintenance free battery. * Actual rated capacity may vary, depending upon special equipment or modifications. Consult serial number plate. **Lift height may vary depending upon special equipment or modifications. Consult serial number plate.

Crown 1998 PF11439-2 Rev. 12/03

Printed in U.S.A.

02 REV. 12/03

ITD–4320–002

ITD–4320–002

C

INTRODUCTION

All Crown lift trucks are given a model number. This number is used as a brief description of the truck. The following chart gives a model number and shows how it was formed.

WE 2000 Series MODEL NUMBER SYSTEM

–

30 WE TT

161

22 42

1

V

L

T

B

F

M

TRUCK – = Standard S = Special

BATTERY TYPE – = Less Battery M = Maintenance Free F = Wet Cell

* CAPACITY Pound Rated (x 100) Ex. 30 x 100 = 3000 lbs.

Metric Rated (x 1000) 1.0 x 1000 = 1000 kg.

FREEZER CONDITIONING – = None F = Freezer Conditioning

MODEL DESIGNATION WE- Walkie Stacker

BATTERY DISCHARGE INTERRUPT – = None B = BDI

MAST TYPE TL - Limited Free Lift TF - Full Free Lift TT - Three Stage

LOAD WHEELS T = Tandem S = Single

**COLLAPSED/LIFT HEIGHT MM (IN.) WE/TL, WE/TF 2130 (84)/ 3330 (130) WE/TT 1860 (73)/ 4100 (161)

LOAD BACKREST – = None L = Load Backrest

WIDTH ACROSS FORKS 570 mm (22.4 in.)

686 mm (27 in.)

DRIVE TIRE Vulkolan

FORK LENGTH – Less Forks 991 mm (39 in.)

1067 mm (42 in.)

FORK WIDTH 1 = 180 mm (7.1 in.)

5 = 190 mm (7.5 in.)

EXAMPLE: A truck having a model number – 30 WE TT 161 22 42 1 V L T B F M is a standard, 1360 kg (3000 lbs.) capacity, walkie with three stage mast 1860 mm (73 in.) collapsed height/4100 mm (161 in.) lift height, width across forks 570 mm (22.4 in.), 1067 mm (42 in.) forks, equipped with a Vulkolan drive tire, load backrest, tandem load wheels and battery discharge interrupt meter, freezer/corrosion and maintenance free battery. * Actual rated capacity may vary, depending upon special equipment or modifications. Consult serial number plate. **Lift height may vary depending upon special equipment or modifications. Consult serial number plate.

Crown 1998 PF11439-3 Rev. 12/03

Printed in U.S.A.

02 REV. 12/03

ITD–4320–003

ITD–4320–003

SAFETY

General Maintenance Instructions

General Maintenance Instructions WARNING An injury could occur.

TO PREVENT SERIOUS RISK OF INJURY TO YOURSELF AND OTHERS OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS Power industrial lift trucks may become hazardous if adequate maintenance is not performed. Adequate maintenance facilities, trained personnel, and procedures must be provided.

Maintenance and inspection must be performed in conformance with the following practices: 1. A scheduled planned maintenance, lubrication, and inspection system should be followed.

2. Only qualified and authorized personnel shall be permitted to maintain, repair, adjust and inspect the lift truck.

3. Before performing maintenance on the lift truck: • Bring the lift truck to a complete stop.

• Fully lower the load engaging means.

• Put the directional control in neutral.

• Apply the parking brake.

• Turn off the lift truck.

• Remove the key.

• Chock the wheels of the lift truck.

• Raise the drive wheel off the floor or disconnect power sources.

• Use chocks or other positive positioning devices.

• Block the load engaging means, inner masts, or chassis before working under them. When working in these areas keep hands, arms, feet, and legs clear to prevent pinching or injury.

• To check the performance of the lift truck and attachments, move the lift truck to a secure non-traffic maintenance area with a level floor and adequate clearance.

4. Before operating the lift truck: • Be in the proper operating position.

• Apply the brake.

• Put the directional control in neutral.

Crown 1976 PF2821 Rev. 6/22

•

Make sure to check the functions of the lift systems, directional control, speed control, steering, warning devices, brakes, and attachments, if any are used.

5. Avoid fire hazards and have fire protection equipment present. Do not use an open flame to check level, or for leakage of electrolyte and fluids or oil.

Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

6. Keep the maintenance area well-ventilated, clean, and dry.

7. A tip-over can occur with the improper use of this lift truck, even when the forks are unloaded. In the event of a tip-over, do not jump from the lift truck.

Hold the steering wheel tightly and brace your feet.

8. The brakes, steering mechanisms, control mechanisms, lift overload devices, guards, and safety devices must be inspected regularly and maintained in a safe operating condition.

• All guards must be installed to the factory configuration and condition before operating the lift truck.

Do not operate the lift truck if any guards or fasteners are damaged, improperly installed, or missing.

9. The capacity, operation, and maintenance instruction plates or decals must be maintained in legible condition.

10. All the parts of the lifting mechanisms must be inspected to maintain them in safe operating condition.

11. All hydraulic systems must be regularly inspected and maintained in conformance with good practice.

The cylinders, valves, and other similar parts must be checked to make sure that drift has not developed to the extent that it would create a hazard.

12. Batteries, motors, controllers, limit switches, protective devices, electrical conductors, and connections must be maintained in conformance with good practice. Provide close attention to the condition of electrical insulation.

13. Keep the lift truck clean to minimize fire hazard and facilitate detection of loose or defective parts.

14. Modifications and additions that affect capacity and safe lift truck operation must not be performed by the customer or user without the manufacturer’s prior written approval. The capacity, operation and maintenance plates or decals are to be changed accordingly.

• Adding electrical devices (radio, terminal, lights, etc.) or changing existing components or wiring can MA-04.0-001 07 Rev. 6/22

3

SAFETY

General Maintenance Instructions affect the lift truck operation and could cause an accident. Contact an authorized Crown personnel before adding to or changing the electrical system.

Technician Tips: In North America, for EE-rated lift trucks, adding electrical devices could cause a fire or explosion, as well as void the EE rating. Written approval must be obtained from Crown prior to adding electrical device(s). Prior to use, inspection of installed device(s) must be performed by an appropriate nationally recognized testing laboratory (i.e. Underwriters Laboratories Inc) or the Authority Having Jurisdiction (see NFPA 505).

15. Make sure that all replacement parts are interchangeable with the original parts and of equal quality to the original equipment.

16. Make sure that any equipment added to the lift truck (terminal, fan, clipboard, etc.) is positioned so that it does not block your vision or interfere with safe and efficient operation of the truck.

Technician Tips: For more information about operation and maintenance procedures: • For all lift trucks, except, Series B and tow tractors, see ASME B56.1.

• For Series B lift trucks, see ASME B56.10.

• For tow tractors, see ASME B56.9.

Technician Tips: For European lift trucks, for more information about operation and maintenance procedures, see the F.E.M. safety code - Power Industrial Truck (section 4).

For copies send to: F.E.M 10 Avenue Hoche 75382 Paris Cedex 08 France

MA-04.0-002 07 Rev. 6/22

4

Crown 1976 PF 2821 Rev. 6/22

SAFETY

Cleaning of Material Handling Equipment

Cleaning of Material Handling Equipment Cleaning procedures Using dry, pressurized air and solvent • Clean the contamination from the material handling equipment with dry, pressurized air.

• Remove the grease from the material handling equipment with the applicable solvent.

Using a power washer

CAUTION

Make sure that these components are safe and correctly lubricated after cleaning.

• Be careful when using a power washer on metal surfaces.  When using a power washer, remove the paint and protective cover from components (hydraulic lines, terminal strips, and linkages) in a freezer condition environment.  Apply paint or protective cover to these areas to decrease the risk of corrosion.

• Before installing the removed components, or lubricating, or operating the equipment, make sure that the equipment does not contain solvent and is dry.

See the Crown Cleaning Products table for items used to clean the material handling equipment.

Material damage can occur.

If the above procedures are not satisfactory and you must use a power washer, be careful that you do not do damage to the lift truck.  The electrical components (connectors, terminal boards, and wires) can be permanently damaged from water or solvents.  Contamination on or in these components after you use a power washer can cause corrosion: • The circuit boards • The contactors • The encoders • The switches • The potentiometers •

Event codes and irregular lift truck operation can occur if using a power washer.

• Make sure that all the electronic components are safe from the power washer.  Removing the components is the best procedure to decrease the risk of damage.

• When a power washer is used, remove the lubricants in or on the surface of the following components: – Shafts – Bearings – Hinges – Gears – Bushings – Chains – Linkages

Crown 2000 PF11969 Rev. 9/21

MA-1140-050 05 Rev. 9/21

5

SAFETY

Cleaning of Material Handling Equipment Crown Cleaning Products Cleaner Type

Part Number

Package Quantity

Degreaser and cleaner

363105-001 363105-012

19 oz can (12) 19 oz cans

All-purpose cleaner

363114-001 363114-012

19 oz can (12) 20 oz cans

Glass cleaner

363101-001 363101-012

19 oz can (12) 19 oz cans

Waterless hand cleaner

363111-001 363111-012

15 oz tube (12) 15 oz tubes

Pumiced and smooth hand cleaner

363112-001 363112-004

1 gal jug (4) 1 gal jugs

Wall-mounted deluxe soap dispenser

363122

Use with P/N 363112-001

Tough on grease

063009-005

1 gal jug

Citrus degreaser spray

363156-001 363156-012

32 oz spray bottle (12) 32 oz spray bottles

Citrus degreaser spray

363157-101 363158-101

1 gal refill (use with P/N 363134-001) 1 gal concentrated (use with P/N 363134-001)

Citra-sol degreaser

363146-001 363146-012

19 oz can (12) 19 oz cans

Battery cleaner

363124-001 363124-012

18 oz can (12) 18 oz cans

MA-1140-051 05 Rev. 9/21

6

Crown 2000 PF11969 Rev. 9/21

C

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT WE/WS

In the interest of safety and to ensure compliance with the OSHA Regulations (Standards - 29 CFR), The control of hazardous energy (lockout/tagout) - 1910.147, Crown has developed guidelines for proper energy control when performing service and maintenance on the WE or WS. Before performing any service or maintenance on the WE or WS, review the appropriate sections in this service manual for additional procedures to be followed.

In addition, Crown recommends that all mechanics wear appropriate protective items, such as safety glasses, work gloves, and steel toed shoes, whenever performing service or maintenance work on Crown equipment.

BATTERY BATTERY CARE

SAFETY RULES • Wear protective clothing, such as, rubber apron, gloves, boots and full-face shield when performing any maintenance on batteries. Do not allow electrolyte to come in contact with eyes, skin, clothing or floor. If electrolyte comes in contact with eyes, flush immediately and thoroughly with clean water. Obtain medical attention immediately. Should electrolyte be spilled on skin, rinse promptly with clean water and wash with soap. A baking soda solution (one pound to one gallon of water) will neutralize acid spilled on clothing, floor or any other surface. Apply solution until bubbling stops and rinse with clean water.

• Keep vent plugs firmly in place at all times except when adding water or taking hydrometer readings.

• Do not bring any type of flame, spark, etc., near the battery. Gas formed while the battery is charging is highly explosive. This gas remains in the cells long after charging has stopped.

• Do not lay metallic or conductive objects on battery.

Arcing will result.

• Do not allow dirt, cleaning solution or other foreign material to enter cells. Impurities in electrolyte has a neutralizing effect reducing available charge.

• If battery repair is planned, follow the battery manufacturer's instructions concerning repair practices and procedures.

CAUTION

Only qualified and experienced personnel should perform maintenance and repair on batteries.

• Make certain the charger being used matches the voltage and amperage of the truck battery. This voltage is listed on the truck serial plate.

• Before disconnecting or connecting batteries to a charger, make sure the charger is “OFF”. If an attempt is made to do this while the charger is “ON”, serious injury to you, the battery and charger could result.

• Never use a match or lighter. Battery fumes are explosive.

• Make certain battery used meets weight, size and voltage requirements of truck (refer to serial plate).

NEVER operate truck with an undersized battery.

CHARGING

CAUTION

Never smoke or bring flame near the battery. Gas formed during charging is highly explosive and can cause serious injury.

Consult the charger manufacturer’s manual covering your charger for hints on operation and maintenance.

7147 Printed in U.S.A.

Crown 2000 PF11971-1 Rev. 12/03

01 REV. 12/03

MA–4320–101

MA–4320–101

C

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT BATTERY INSTALLATION

BATTERY REMOVAL CAUTION

CAUTION

When removing the battery, move truck to area intended for battery care. Floor must be level.

Turn key switch or toggle switch to "off" position and remove key. Disconnect battery and lockout or tagout truck as described in Battery - Lockout/ Tagout in this section. Lower load engaging means completely. If battery is removed with load engaging means raised, use hoist attached to mast to provide tip over protection. Don’t allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing, transporting the battery. Use an insulator (such as plywood, plastic caps) to cover the top of the battery posts before and during removal.

Industrial Type Battery

When installing the battery, move truck to area intended for battery care. Floor must be level.

Turn key switch or toggle switch to "off" position and remove key. Lockout or tagout truck as described in Battery - Lockout/Tagout in this section. Don’t allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when transporting or installing the battery. Use an insulator (such as plywood, plastic caps) to cover the top of the battery posts before and during installation.

CAUTION

Make certain battery used meets weight, size and voltage requirements of truck (refer to serial plate). NEVER operate truck with an undersized battery.

Automotive Type Battery

8554

Lockout/Tagout Always turn key switch to "off", remove key and apply tag to the twist grip with a cable tie warning others truck is being serviced.

When maintenance is to be performed and the battery will be left in the truck, disconnect battery, remove the main power fuses and install a commercially available lockout device on the battery connector.

G

IN RN

WA nnect t co is no to th is Dottery bahicle. ancemed t ve nten rforis no e Maiing pe hicl r bed ve e fo anailablion. av erat op

When maintenance is performed and the battery is removed from the truck, remove the main power fuses, install a lockout device on the trucks battery connector if possible, or if possible install a tag with a cable tie on the trucks battery connector so it cannot be removed easily warning that the truck is not available for operation.

8448

Printed in U.S.A.

Crown 2000 PF11971-2 Rev. 12/03

01 REV. 12/03

MA–4320–102

MA–4320–102

C

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT CAPACITANCE

Due to capacitance voltage present in the traction motor controller, whenever performing maintenance which may permit contact with the bus bars and associated power cables, discharge the capacitors.

1. Move truck to a secure non-traffic maintenance area with a level floor.

2. Lockout or tagout truck as described in Battery Lockout/Tagout in this section.

3. Place a minimum 100 ohm, 2 watt resistor between the B+ and B- terminals of the controller for 3 or more seconds.

IS

CU

RT

A2

B+

BM-

8445

Printed in U.S.A.

Crown 2000 PF11971-3 Rev. 12/03

01 REV. 12/03

MA–4320–103

MA–4320–103

C

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT HYDRAULIC WARNING

AVOID HIGH PRESSURE FLUIDS—Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.

Any fluid injected into the skin under high pressure should be considered as a serious medical emergency despite an initial normal appearance of the skin. There is a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately by a specialist who has had experience with this type of injury.

When maintenance is to be performed on the hydraulic system, to make sure the hydraulic system is not under pressure: 1. Move truck to a secure non-traffic maintenance area with a level floor.

2. No load on forks.

3. Completely lower load engaging means (mast) or, if required for maintenance, block mast sections at appropriate height as described in Mast of this section.

4. Lockout or tagout truck as described in Battery Lockout/Tagout in this section.

Lower forks completely

No load on forks

NING

WAR nect con not to this Do tery . is bat icle ce ed vehintenanform is not Mang per icle bei vehle for andilab on. ava rati ope

8636

Printed in U.S.A.

Crown 2000 PF11971-4 Rev. 12/03

01 REV. 12/03

MA–4320–104

MA–4320–104

C

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT NOTE

LIFTING AND BLOCKING 1. Move truck to a secure non-traffic maintenance area with a level floor.

2. No load on forks.

To raise truck for additional jack clearance, fabricate a 1/2" board for load wheel or 3/4" board for drive wheel (8" x 12" with stop and bevel). Drive truck onto board and proceed with step 3. If truck can not be moved, use overhead lifting device for additional jack clearance.

3. Lockout or tagout truck as described in Battery Lockout/Tagout in this section.

Side

NOTES: • Hydraulic Jack - Capacity 8000 lbs. (3620 kg.)

• Crown part number: 122599 • Collapsed height minimum: 2.25 in. (60 mm) • Raised height maximum: 16 in. (400 mm) • Jack Stand - capacity 10,000 lbs. (4500 kg.) Commercially available.

• Lifting Straps - Capacity 2000 lbs. (900 kg) Commercially available.

• Barrel Hooks - Capacity 2000 lbs. (900 kg) Commercially available.

Lower Forks Completely

Steer Wheel Fabricated Board

NING WAR nect con

not to this is Do tery . bat iclenance ed vehinte form is not Mang per icle bei vehle for andilab on. ava rati ope

Load Wheel

Raise Forks 3 to 6 in.

(70 to 150 mm) From Floor

Hard Wood Block

Wheel Chock Load Wheel Both Outriggers NING

WARNING

WAR nect con not to this Do tery . is bat icle ce ed vehintenanform is not Mang per icle bei vehle for andilab on. ava rati ope

Truck stability decreases dramatically if load wheels are raised more than 0.5 inch (13 mm).

Attach sling and overhead lifting device to all cross members of the mast to prevent truck from tipping over when raising the side of the truck.

Set Jack Stand Height as Required Not to Exceed 12 in. (300mm) 8637

!

WARNING

Do Not Lift On Cover.

Place Jack Under Articulation Pivot Point Printed in U.S.A.

Crown 2000 PF11971-5 Rev. 12/03

01 REV. 12/03

MA–4320–105

MA–4320–105

C

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT MAST

Blocking Masts

3. Connect battery.

Use 100 mm (4 inch) by 100 mm (4 inch) or bigger hardwood blocks of the appropriate length for supporting mast channels. Block both mast rails of each stage to maintain truck stability.

4. Raise forks and position block under second stage mast.

Remove any carriage mounted accessory (e.g. paper roll clamp, etc.) except sideshifters before blocking masts. These accessories add significant weight to the mast.

6. Lower mast and position appropriate length block under third stage mast.

1. Move truck to a secure non-traffic maintenance area with a level floor.

2. Chock wheels of truck. Refer to Lifting and Blocking in this section.

5. Using a clamp, secure block to mast channel.

7. Using a clamp, secure block to mast channel or second stage block.

8. Lower fork carriage until carriage rests on stops or place block under carriage and lower until weight rests on block.

9. Lockout or tagout truck as described in Battery Lockout/Tagout in this section.

Fork Carriage (shown raised slightly for clarity)

Third Stage Mast Second Stage Mast

First Stage Mast (or mainframe) 8269

Fork Carriage

Fork Carriage

Third Stage Second Stage

Second Stage

First Stage (or mainframe)

First Stage (or mainframe)

8270 Crown 2000 PF11971-6 Rev. 12/03

Printed in U.S.A.

01 REV. 12/03

MA–4320–106

MA–4320–106

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Lubrication and Adjustment To obtain maximum life of any industrial equipment, a well planned maintenance program (PM), performed by qualified technical personnel should be followed. In conjunction with, and an integral part of, any planned maintenance program should be daily operator input.

Operator involvement can greatly reduce truck down time, assist in determining planned maintenance (PM) schedules and ultimately save money. For these reasons, Crown recommends a checklist similar to the Operators Daily Checklist shown below.

Before performing maintenance to any unit, it should be taken to an area set aside for maintenance or a section where there is adequate space to perform required work. This is a must to insure the safety of others and to insure that proper maintenance is performed to the unit.

If desired, padded packs of this checklist (OF-3772) are available through your Crown dealer.

Figure 14990

Crown 1987 PF7886-1 Rev. 1/11

M1.0-04.0-001 19 Rev. 1/11

29

LUBRICATION & ADJUSTMENT Lubrication and Adjustment The following is a list of lubricants and maintenance products recommended when doing Planned Maintenance on Crown Lift Trucks.

Lubrication Identification Chart Type of Lubricant

Part Number

A

Gear Lube 80W-90 (Typical)

363506-001 363506-012

1 Quart (12) 1 Quart Cans

AA

Automatic Transmission Fluid (Multi-Purpose)

363503-001 363503-012

1 Quart (12) 1 Quart

AAA

Universal Hydraulic & Transmission Fluid

363513-001 363513-012

1 Quart (12) 1 Quart

AAAA

Synthetic Gear Oil 75W-90

363514-001 363514-012

1 Quart (12) 1 Quart

Grease (Multi-Purpose)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

BB(1)

Grease (Low Temperature)

063002-017 063002-046

14.5 oz Cartridge (40) 14.5 oz Cartridges

BBB

Food Grade Grease (Multi-Purpose)

363002-001 363002-030

14 oz Cartridge (30) 14 oz Cartridges

BBBB

Grease (Multi-Purpose) Premium

063002-025 063002-026

14.5 oz Cartridge 5 Gallon

B

Package Quantity

C

Oil (SAE 40)

CC

Engine Oil (10W30)

363500-001 363500-012

1 Quart (12) 1 Quart

D

Hydraulic Oil

363504-101 363504-106

1 Gallon (6) 1 Gallon

DD(1)

Hydraulic Oil (Low Temp)

363505-101 363505-106

1 Gallon (6) 1 Gallon

DDD

Hydraulic Oil - DTE24

063001-021

1 Gallon

E

Channel Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

F

Gear Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

Chain & Cable Lube

363107-001 363107-012

15 oz Can (12) 15 oz Cans

Premium Chain & Cable Lube

363115-001 363115-012

12 oz Can (12) 12 oz Cans

Final Finish - Rubber & Vinyl Dressing

363129-001 363129-012

11 oz Can (12) 11 oz Cans

G

H

(1) Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.

M1.0-04.0-002 19 Rev. 1/11

30

Crown 1987 PF7886-2 Rev. 1/11

LUBRICATION & ADJUSTMENT Lubrication and Adjustment Lubrication Identification Chart Type of Lubricant

Part Number

I

Grease (Lift Pump Coupling)

063002-039 127801S

1 lb 1 oz

J

Brake Fluid - Dot 5

063004-002 063004-003

12 oz 1 Gallon

K

Grease (Wheel Bearing)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

L

Metal Assembly Spray

063002-021

11 oz Spray

M

Silicone Grease (Clear)

063002-020

5.3 oz Tube

Brake & Parts Cleaner

363102-001 363102-012

14 oz Can (12) 14 oz Cans

Low VOC Brake & Parts Cleaner

363103-001 363103-012

14 oz Can (12) 14 oz Cans

Non-Flammable Brake & Parts Cleaner

363116-001 363116-012

19 oz Can (12) 19 oz Cans

O

Penetrating Lubricant

363104-001 363104-012

20 oz Can (12) 20 oz Cans

P

Premium Formula Multi-Purpose Grease

363108-001 363108-012

11 oz Can (12) 11 oz Cans

Q

White Lithium Grease

363110-001 363110-012

11 oz Can (12) 11 oz Cans

R

Choke & Carburetor Cleaner

363109-001 363109-012

15 oz Can (12) 16 oz Cans

Contact Cleaner - Non-Flammable

363106-001 363106-012

10 oz Can (12) 10 oz Cans

Contact Cleaner

363128-001 363128-012

11 oz Can (12) 11 oz Cans

T

Electrical Connector Oxidation & Corrosion Inhibitor

127189-001

30 cc

U

Battery Cleaner

363124-001 363124-012

18 oz Can (12) 18 oz Cans

V

Battery Protector

363125-001 363125-012

15 oz Can (12) 15 oz Cans

W

Food Grade Machine Lubricant

363127-001 363127-012

12 oz Can (12) 12 oz Cans

X

Food Grade Silicone Spray

363126-001 363126-012

11 oz Can (12) 11 oz Cans

Coolant

363509-101 363509-106

1 Gallon (6) 1 Gallon

Extended Life Coolant

363511-101 363511-106

1 Gallon (6) 1 Gallon

N

S

Y

Crown 1987 PF7886-3 Rev. 1/11

Package Quantity

M1.0-04.0-003 19 Rev. 1/11

31

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Alternate Lubricants & Fluids Chart Type of Lubricant

Product Name

Manufacturer/ Distributor

A

Gear Lube 80W-90 (Typical)

Crown

Crown

AA

Automatic Transmission Fluid (Multi-Purpose)

Crown

Crown

AAA Universal Hydraulic & Transmission Fluid Crown

Crown

AAAA Synthetic Gear Oil 75W-90

Crown

Crown Mobil Union 76 Co. Shell Burmah Castrol Exxon

B

Grease (Multi-Purpose)

Mobilgrease XHP 222 Special Union Unoba EP No 2 Retinax A(1) LM Grease Unirex EP-2

BB

Grease (Low Temp) (2)

Lubriplate Alvania RA(1) Helveum O(1)

Fiske Bros Refining Co. Shell Burmah Castrol

BBB Food Grade Grease (Multi-Purpose)

Petro Canada Purity FG

Petro Canada

BBBB Grease (Multi-Purpose) Premium

Mobilux EP2 64127-4 Retinax AM 71119 Chevron RPM Heavy Duty LC Grease EP

Mobil Shell Chevron

C

Oil (SAE 40)

D

Hydraulic Oil

Crown

Crown

DD

Hydraulic Oil (Low Temp) (2)

Crown

Crown

Mobil DTE 24

Mobil

DDD Hydraulic Oil - DTE24 (3) E

Channel Grease

Factran #2

Standard Oil Co.

F

Gear, Channel & Shaft Grease

Molykote BR-2 Plus

Dow Corning

Chain & Cable Lube

Crown

Crown

Premium Chain & Cable Lube

Crown

Crown

H

Final Finish - Rubber & Vinyl Dressing

Crown

Crown

I

Grease (Lift Pump Coupling)

Nyogel 774F-MS

NYE Lubricants

J

Brake Fluid - Dot 5

Q2-1141 Silicon Brake Fluid

Dow Corning

Grease (Wheel Bearing)

Mobilgrease XHP 222 Special Unirex EP-2 Lubriplate No. 1242(1)

Mobil Exxon Fiske Bros. Refining Co.

G

K

(1) Denotes allowable substitutes, contact factory if unavailable.

(2) Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.

(3) Premium antiwear hydraulic oil used in blending with low temp oil.

M1.0-04.0-004 19 Rev. 1/11

32

Crown 1987 PF7886-4 Rev. 1/11

LUBRICATION & ADJUSTMENT Lubrication and Adjustment Alternate Lubricants & Fluids Chart Type of Lubricant

Product Name

Manufacturer/ Distributor

L

Metal Assembly Spray

Dow Corning

Dow Corning

M

Silicon Grease (Clear)

Dow Corning 111 Compound

Dow Corning

Brake & Parts Cleaner

Crown

Crown

Low VOC Brake & Parts Cleaner

Crown

Crown

Non-Flammable Brake & Parts Cleaner

Crown

Crown

O

Penetrating Lubricant

Crown

Crown

P

Premium Formula Multi-Purpose Grease Crown

Crown

Q

White Lithium Grease

Crown

Crown

R

Choke & Carburetor Cleaner

Crown

Crown

S

Contact Cleaner

Crown

Crown

T

Electrical Connector Oxidation & Corrosion Inhibitor

Nye Grease

NYE Lubricants

U

Battery Cleaner

Crown

Crown

V

Battery Protector

Crown

Crown

W

Food Grade Machinery Lubricant

Crown

Crown

X

Food Grade Silicone Spray

Crown

Crown

Y

Extended Life Coolant

N

Crown 1987 PF7886-5 Rev. 1/11

M1.0-04.0-005 19 Rev. 1/11

33

Notes:

34

C

LUBRICATION & ADJUSTMENT

COMPONENT LOCATION

LUBRICATION

Many vehicle components are located behind the power unit cover and can be accessed by removing the cover. To remove the power unit cover, unscrew the attachment screws and swing open the cover (See Illustration 1).

The following information is intended to provide guidelines for proper lubrication intervals as called out in the lubrication chart. However, some operating conditions will require more frequent checks and lubrication than listed. For example, applications with excessive dust or moisture will require modification of the schedule to fit that particular application.

Access to the battery and the charging unit is gained by opening the battery cover.

The use of high grade lubricants and fluids should be used.

Sources of these lubricants may be from almost any of the oil companies; those listed on chart 1 are typical and any lubricant with equal specifications may be used.

For truck applications primarily operating in a cool environment with intermittent freezer entry, use a 50/50 blend of low temperature (063001-006) and standard (063001-021) hydraulic oils.

NOTE Use Planned Maintenance Inspection Reports (PF5316) as required to record and assure maintenance checks.

3 2 1 6750

ILLUSTRATION 1

LUBE TYPE

CAPACITY

PART NO.

A Gear Lube (90w)

3.5 pts. (1.7 litres) 063002-003

PACKAGE QTY. 1 Quart

B Grease (Multipurpose) AR

063002-025

14.5 oz. Cartridge

BB Grease (Low Temp)

AR

063002-017

14.5 oz. Cartridge

C Oil (SAE 40)

AR

D Hydraulic Oil

5 Gal. (19 litres)

063001-001

Gal.

DD Hydraulic (Low Temp) 5 Gal. (19 litres)

063001-006

Gal.

E Chain & Cable Lube

063001-009

14 oz. Spray

AR

LUBRICATION CHART 1 7153 Printed in U.S.A.

Crown 1998 PF11476-1 Rev. 12/03

01 REV. 12/03

M1.0–4320–001

M1.0–4320–001

C

LUBRICATION & ADJUSTMENT 15

9 11 5 7 10

16

13 2 1 6

8

14 17

6751

3,4

12

13

18

ILLUSTRATION 2

Lube Type

INDEX COMPONENT

30 da.

100 hr.

1

Battery and Battery Compartment

Check

2

Contacts and Contactor Tips

Check

90 da.

250 hr.

180 da.

500 hr.

3

Electrical Components

Check

4

Transistor Controller

Check

5

High/Low Speed Switch and Controls

Check

6

Brake Assembly

7

Protective Cover (Power Unit Door)

C

Check

Lube

8

Steering

C

Check

Lube

E, B

360 da.

1000 hr.

Check

9

Lifting Chain and Column Rollers

10

Mast Cylinder

Check

Check

11

Lift Cylinder

Check

Lube

12

Hydraulic Oil, Tank and Filter

D

Check

13

Load and Caster Wheels and Bearings

B

Check

Change

14

Drive Wheel

Check

15

Mast Stops

Check

16

Forks

17

Gearbox and Oil

A

Check

Change

18

Drive Unit and Articulated Undercarriage

B

Check

Lube

Lube

Check

INSPECTION, ADJUSTMENT AND LUBRICATION CHART 2 Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

Note: Hours are based on traction hours which are accessible by using Curtis handset.

Crown 1998 PF11476-2 Rev. 12/03

Printed in U.S.A.

01 REV. 12/03

M1.0–4320–002

M1.0–4320–002

INSPECTION AND LUBRICATION Metric Torque Values

Metric Torque Values It is important to tighten fasteners to the correct torque value. This section shows the standard torque values for the screws and bolts used in Crown lift trucks and vehicles. Special torque values in the maintenance and parts sections of this manual override the standard torque values in this section.

Grade

Grade Identification (on Head)

Specification

Bolt and Screw Size (mm)

5.8

Class 5.8

M5 through M36

8.8

Class 8.8

M5 through M36

10.9

Class 10.9

M5 through M36

12.9

Class 12.9

M5 through M36

NOTE: Even though a bolt head is unmarked, Crown uses nothing less than class 8.8 in all its bolted assemblies. Instances do occur when class 8.8 bolts are manufactured unmarked. When a fastener is replaced that is unmarked, replace the fastener with a class 8.8.

Fig. 1 (15048-01)

Crown 1989 PF8514 Rev. 2/16

M1.9-06.6-001 05 Rev. 2/16

67

INSPECTION AND LUBRICATION Metric Torque Values

Torque Chart–Metric Hex Head Cap Screws and Nuts Thread Diameter and Pitch

Torque Nm (ft lb) Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

5–8 (4–6)

7–8 (5–6)

8–10 (6–7)

M6 x 1.00

8–10 (6–7)

12–14 (9–10)

15–16 (11–12)

M8 x 1.25

20–25 (15–18)

28–31 (21–23)

34–37 (25–27)

M10 x 1.50

39–43 (29–32)

56–61 (41–45)

68–75 (50–54)

M12 x 1.75

71–76 (52–56)

100–107 (73–79)

119–127 (88–94)

M14 x 2.00

113–122 (83–90)

159–171 (117–126)

190–205 (140–151)

M16 x 2.00

175–190 (129–140)

247–267 (182–197)

296–320 (218–236)

M20 x 2.50

340 357 (251–271)

479–518 (353–382)

574–621 (423–458)

M24 x 3.00

587–635 (433–468)

824–892 (608–658)

990–1071 (730–790)

M30 x 3.50

1175–1274 (867–940)

1654–1792 (1220–1322)

1985–2150 (1464–1586)

Note: Special torque values in the maintenance and parts sections of this manual override the standard torque values in this section.

Torque Chart–Metric Hex Socket Countersink Head Screws Thread Diameter and Pitch

Torque Nm (ft lb) Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

4–7 (3–5)

5–8 (4–6)

7–10 (5–7)

M6 x 1.00

7–10 (5–7)

9–12 (7–9)

11–14 (8–10)

M8 x 1.25

16–19 (12–14)

23–26 (17–19)

27–30 (20–22)

M10 x 1.50

31–34 (23–25)

45–49 (33–36)

54–58 (40–43)

M12 x 1.75

56–60 (41–44)

79–84 (58–62)

94–102 (69–75)

M16 x 2.00

124–146 (99–108)

190–206 (140–152)

228–247 (168–182)

M20 x 2.50

259–281 (191–207)

363–395 (268–291)

437–473 (322–349)

M24 x 3.00

416–451 (307–333)

586–635 (432–468)

702–762 (518–562)

M14 x 2.00

M30 x 3.50 Note: Special torque values in the maintenance and parts sections of this manual override the standard torque values in this section.

M1.9-06.6-002 05 Rev. 2/16

68

Crown 1989 PF8514 Rev. 2/16

INSPECTION AND LUBRICATION Metric Torque Values

Torque Chart–Metric Socket Head Cap Screws Thread Diameter and Pitch

Torque Nm (ft lb) Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

5–8 (4–6)

7–9 (5–7)

8–11 (6–8)

M6 x 1.00

9–12 (7–9)

12–15 (9–11)

15–18 (11–13)

M8 x 1.25

22–24 (16–18)

30–33 (22–24)

35–38 (26–28)

M10 x 1.50

42–45 (31–33)

58–64 (43–47)

71–76 (52–56)

M12 x 1.75

72–77 (53–57)

102–110 (75–81)

122–132 (90–97)

M14 x 2.00

115–125 (85–92)

161–175 (119–129)

194–210 (143–155)

M16 x 2.00

179–194 (132–143)

251–273 (185–201)

301–327 (222–241)

M20 x 2.50

348–377 (257–278)

489–530 (361–391)

588–637 (434–470)

M24 x 3.00

601–651 (443–480)

846–915 (624–675)

1014–1098 (748–810)

M30 x 3.50

1196–1296 (882–956)

1681–1822 (1240–1344)

2017–2187 (1488–1613)

Note: Special torque values in the maintenance and parts sections of this manual override the standard torque values in this section.

Torque Chart–Metric Flanged Hex Head Cap Screws and Nuts Thread Diameter and Pitch

Torque Nm (ft lb) Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

5–8 (4–6)

8–11 (6–8)

9–12 (7–9)

M6 x 1.00

9–12 (7–9)

14–16 (10–12)

16–19 (12–14)

M8 x 1.25

22–24 (16–18)

31–34 (23–25)

38–41 (28–30)

M10 x 1.50

44–48 (33–35)

62–68 (46–50)

75–81 (55–60)

M12 x 1.75

77–83 (57–61)

108–117 (80–86)

130–141 (96–104)

M14 x 2.00

123–134 (91–98)

174–187 (128–138)

209–225 (154–166)

M16 x 2.00

193–210 (143–155)

273–294 (201–217)

327–354 (241–2610)

Note: Special torque values in the maintenance and parts sections of this manual override the standard torque values in this section.

Crown 1989 PF8514 Rev. 2/16

M1.9-06.6-003 05 Rev. 2/16

69

Notes:

70

INSPECTION & LUBRICATION SAE Torque Values

SAE Torque Values It is important to tighten fasteners to the correct torque value. This section shows the standard torque values for the screws and bolts used in Crown lift trucks and vehicles. Special torque values in the maintenance and parts sections of this manual override the standard torque values in this section.

Grade

Grade Identification (on Head)

Specification

Bolt and Screw Size (in)

SAE - Grade 2

1/4 through 1-1/2

SAE - Grade 5

1/4 through 1-1/2

SAE - Grade 8

1/4 through 1-1/2

NOTE: Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all its bolted assemblies. Instances do occur when Grade 5 bolts are manufactured unmarked. When a fastener is replaced that is unmarked, replace the fastener with a Grade 5.

Fig. 1 (14916-02)

Crown 1979 PF5067 Rev. 2/16

M1.9-14.0-001 06 Rev. 2/16

71

INSPECTION & LUBRICATION SAE Torque Values

Torque Chart Bolt Diameter

Grade 5

Grade 8

Dry Torque Specification

Dry Torque Specification

in

ft Ib

kg-m

Nm

ft lb

kg-m

Nm

1/4

9±3

1.2 ± 0.4

12 ± 4

13 ± 4

1.8 ± 0.5

17.5 ± 5.5

5/16

18 ± 5

2.5 ± 0.7

24.5 ± 7

25 ± 5

3.5 ± 0.7

34 ± 7

3/8

32 ± 5

4.4 ± 0.7

43.5 ± 7

48 ± 10

6.6 ± 1.3

65 ± 13.5

7/16

50 ± 10

6.9 ± 1.4

67.5 ± 13.5

75 ± 10

10.4 ± 1.4

102 ± 13.5

1/2

75 ± 10

10.4 ± 1.4

101.5 ± 13.5

112 ± 15

15.5 ± 2.0

152 ± 20.5

9/16

110 ± 15

15.2 ± 2.0

149 ± 20.5

163 ± 20

22.5 ± 3.0

221 ± 27

5/8

150 ± 20

20.7 ± 2.8

203.5 ± 27

225 ± 30

31.1 ± 4.1

305 ± 41

3/4

265 ± 35

36.6 ± 4.8

359 ± 47.5

400 ± 50

55.2 ± 6.9

542 ± 68

7/8

420 ± 60

58.1 ± 8.3

569 ± 81

640 ± 80

88.3 ± 11.0

868 ± 108

1

640 ± 80

88.5 ± 11.1

868 ± 109

960 ± 115

132.5 ± 15.9 1300 ± 156

1 1/8

800 ± 100

110.6 ± 13.8 1085 ± 136

1 1/4

1000 ± 120

138 ± 16.6

1356 ± 163

1 3/8

1200 ± 150

166 ± 20.7

1630 ± 203

1 1/2

1500 ± 200

207 ± 27.7

2034 ± 271

Torque specifications for bolts related to hydraulic valves.

5/16

13 ± 2

1.8 ± 0.3

17.5 ± 2.5

3/8

24 ± 2

3.3 ± 0.3

32.5 ± 2.5

7/16

39 ± 2

5.4 ± 0.3

53 ± 2.5

NOTE: Special torque values in the maintenance and parts sections of this manual override the standard torque values in this section.

M1.9-14.0-002 06 Rev. 2/16

72

Crown 1979 PF5067 Rev. 2/16

MAINTENANCE HYDRAULIC SYSTEM General The hydraulic system is supplied from a vented hydraulic tank. System pressure is created by way of a geared pump and regulated by a limit valve incorporated in the valve block. Hydraulic pressure is released to the cylinders through a solenoid valve, the cylinders then move up. A solenoid valve opens a throttled-controlled return line to enable the cylinders to be lowered slowly. The path across two current regulating valves connected in parallel is released by a second solenoid valve to enable the cylinders to be lowered quickly. The velocity fuse incorporated in the cylinders prevent the mast from lowering abruptly in the event of a sudden leakage.

Lift Cylinders

TL Velocity Fuse

Velocity Fuse

A P2

CYL Manifold Block

T2

CV

SV2

SV3 Proportional Valve CV RV1

1 Orifice

P1

T1

1

PM

6682

Orifice Size Will Be Different Depending Upon Truck Capacity.

ILLUSTRATION 2.0-1 5786

Crown 1998 PF11451-1

M2.0–4320–001

Printed in U.S.A.

M2.0–4320–001

MAINTENANCE

Velocity Fuse

TF

Velocity Fuse

Lift Cylinder

Lift Cylinder

Velocity Fuse

Velocity Fuse

Carriage Cylinder

Velocity Fuse

A CYL

TT Lift Cylinder

Lift Cylinder Carriage Cylinder

Velocity Fuse

Velocity Fuse

Velocity Fuse

A CYL 6683

Crown 1998 PF11451-2

M2.0–4320–002

ILLUSTRATION 2.0-2 Printed in U.S.A.

M2.0–4320–002

HYDRAULIC Hydraulic Schematic Symbols

Hydraulic Schematic Symbols VENTED RESERVOIR with the lines above the fluid level

VENTED RESERVOIR with the lines below the fluid level

FILTER or STRAINER

HYDRAULIC PLUMBING with full flow (this includes tubes, hoses, and the flow paths in the manifolds)

PILOT or DRAIN LINE limited flow

LINES CROSSING

M

ELECTRIC MOTOR operates in one direction and speed

M

ELECTRIC MOTOR operates in one direction in a speed that changes

M

ELECTRIC MOTOR operates in two opposite directions in a speed that changes

HYDRAULIC PUMP fixed displacement, operates in one direction

HYDRAULIC PUMP-MOTOR fixed displacement, operates in two opposite directions in a speed that changes

HYDRAULIC MOTOR operates in two opposite directions

LINES CONNECTED GAUGE pressure QUICK DISCONNECT (disconnected)

PLUGGED PORT (test port)

FLOW METER

GAUGE temperature

ACCUMULATOR gas charged, diaphragm type

Fig. 1 (3559-05) Crown 1979 PF5066-1 Rev. 6/12

M2.1-00.0-001 07 Rev. 6/12

169

HYDRAULIC Hydraulic Schematic Symbols

PRESSURE SWITCH

CYLINDER double-acting cylinder, unequal area

CYLINDER double acting cylinder, equal area (steer) (two end)

ACTUATOR MANUAL

SPRING (spring-bias in the de-energized position)

SOLENOID one coil or winding

CYLINDER single-acting cylinder with spring return (the rod end has a vent) HYDRAULIC PILOT OPERATED CYLINDER single-acting cylinder, ram type SOLENOID pilot operated

CYLINDER single-acting cylinder, with cushion SOLENOID DUAL

COMPONENT ENCLOSURE manifold block

ACTUATOR MANUAL LEVER

SOLENOID PROPORTIONAL

VALVE PILOT CHECK (pilot to open)

Fig. 2 (3560-05) M2.1-00.0-002 07 Rev. 6/12

170

Crown 1979 PF5066-2 Rev. 6/12

HYDRAULIC Hydraulic Schematic Symbols

ORIFICE THROTTLE fixed

VALVE SHUTTLE

ORIFICE THROTTLE adjustable VALVE SINGLE COUNTERBALANCE in manifold

FLOW CONTROL PRESSURE COMPENSATED fixed

FLOW CONTROL PRESSURE COMPENSATED fixed with reverse flow bypass

FLOW DIVIDER/COMBINER

FUSE VELOCITY BYPASS FLOW CONTROL controlled flow, pressure adjusted

VALVE RELIEF fixed

VALVE RELIEF adjustable

VALVE CHECK

VALVE MANUAL SHUTOFF

P T

T P

TORQUE GENERATOR

L R

STEER UNIT hydrostatic

Fig. 3 (3561-05) Crown 1979 PF5066-3 Rev. 6/12

M2.1-00.0-003 07 Rev. 6/12

171

HYDRAULIC Hydraulic Schematic Symbols

VALVE two-way valve with two positions

VALVE three-way valve with two positions spring-bias, solenoid control

VALVE three-way valve with two positions

VALVE four-way valve with two positions

VALVE four-way valve with three positions two spring centered, manual lever control

VALVE four-way valve with three positions

VALVE two-way valve with all positions

NOTE: The type of valve is the number of spools found in the component (the three spool valve is above)

VALVE four-way valve with all positions

Fig. 4 (3562-04) M2.1-00.0-004 07 Rev. 6/12

172

Crown 1979 PF5066-4 Rev. 6/12

C

HYDRAULIC SYSTEM Installation (Refer to Illustration 1)

Hydraulic Tank Cover

1. Install replacement tank cover gasket (15).

Removal (Refer to Illustration 1) 1. Disconnect battery and chock wheels.

2. Install cover and tighten nuts (13) to 12 Nm (8.85 ft. lbs.).

2. Open power unit door.

3. Reverse Steps 1 thru 8 in disassembly to finish tank assembly.

3. Loosen securing nut on electrical panel and swing open electrical panel.

4. Check hydraulic oil for proper level and add as needed.

4. Disconnect electrical cables to pump motor.

5. Bleed hydraulic system.

5. Loosen the hydraulic circuit on the valve block and shut off connections.

6. Remove electrical connections from solenoid valves.

7. Loosen securing nut (13) and remove bracket (12).

8. Remove seven (7) securing nuts (13) on tank cover.

9. Remove tank cover.

10. Cover hydraulic tank to keep dirt etc. out of hydraulic oil.

13

13 12

15

14

13 6687-01

ILLUSTRATION 1

7161 Printed in U.S.A.

Crown 1998 PF11452-1 Rev. 12/03

02 REV. 12/03

M2.1–4320–001

M2.1–4320–001

C

HYDRAULIC SYSTEM

Bleed Hydraulic System

TL Mast (Refer to Illustration 2)

TF and TT Mast (Refer to Illustration 2)

Use appropriate drip tray. Raise mast to its highest point four (4) times. Loosen bleed screws in sequence by half a revolution and then close once escaping oil is free of air bubbles:

Use appropriate drip tray. Raise mast to its highest point four (4) times. Loosen bleed screws in sequence by half a revolution and then close once escaping oil is free of air bubbles:

1. Bleed screw (3) on left mast cylinder

1. Bleed screw (1) on lifting cylinder.

2. Bleed screw (4) on right mast cylinder.

2. Bleed screw (2) on distributor block.

3. Check hydraulic oil level and add as needed.

3. Bleed screw (3) on left mast cylinder.

4. Bleed screw (4) on right mast cylinder.

5. Check hydraulic oil level and add as needed.

4 3

2 1

6688

ILLUSTRATION 2

Printed in U.S.A.

Crown 1998 PF11452-2 Rev. 12/03

02 REV. 12/03

M2.1–4320–002

M2.1–4320–002

C

HYDRAULIC SYSTEM

Valve Block

Repair

Removal (Refer to Illustration 3)

The valve block assembly is not repairable.

Installation (Refer to Illustration 3)

1. Remove hydraulic tank cover (1).

1. Install replacement gasket (8).

2. Remove return filter (13) and fitting (5).

2. Install valve block using screws (12) and sealant 053050-006 and tighten to 6 Nm (4.47 ft. lbs.).

3. Remove hydraulic line (4).

3. Install cleaned and/or replacement return filter (13) and fitting (5).

4. Remove screws (12), valve block (6) and gasket (8).

4. Install hydraulic line (4).

5. Install hydraulic tank cover (1).

6

8

16

12

7

1

15 3

14

9

5

11 10

7 3 13 4 11195

2

ILLUSTRATION 3

Crown 1998 PF11452-3 Rev. 12/03

Printed in U.S.A.

02 REV. 12/03

M2.1–4320–003

M2.1–4320–003

C

HYDRAULIC SYSTEM

Hydraulic Oil Pump

Repair

Removal (Refer to Illustration 4)

The hydraulic oil pump assembly is not repairable.

Installation (Refer to Illustration 4)

1. Remove hydraulic tank cover (1).

1. Inspect coupling (15) and replace if necessary.

2. Disconnect hydraulic lines (2), (3) and (4) from hydraulic pump (9) and seal connections.

2. Lubricate coupling (15) with multipurpose grease (053051-003).

3. Remove mounting screws (10) and remove hydraulic oil pump (9).

3. Install replacement O-ring (11).

4. Install hydraulic oil pump (9) using screws (10) and sealing agent, 053050-006.

5. Install hydraulic lines (2, 3 & 4).

6. Install hydraulic tank cover (1).

6

16

12

7

1

15 3

14

9

5

11 10

7 3 13 4 11196

2

ILLUSTRATION 4

Printed in U.S.A.

Crown 1998 PF11452-4 Rev. 12/03

02 REV. 12/03

M2.1–4320–004

M2.1–4320–004

C

HYDRAULIC SYSTEM Installation (Refer to Illustration 5)

Hydraulic Oil Tank The hydraulic oil tank is located behind protective cover on the right. The tank is vibration-free, having been mounted on rubber buffers. A low-noise geared pump is housed in the tank. A mesh filter is fitted to the suction line. The hydraulic oil is cleaned by a metal fiber filter. Pump motor and valve block are positioned at the top on the container. Located next to the valve block is the oil filler opening with oil dipstick. A venting flap is fitted to the oil dipstick. The hydraulic oil tank is automatically bled and vented via the ventilation flap. The oil drainage screw is located on the bottom of tank.

Removal (Refer to Illustration 5)

1. Clean hydraulic oil tank.

2. Inspect rubber buffers and replace if necessary.

3. Install hydraulic oil tank with washers and nuts.

4. Install replacement sealant washer to oil drain screw and tighten.

5. Install hydraulic oil tank cover.

6. Fill hydraulic oil tank.

1. Disconnect battery and chock wheels.

7. Bleed hydraulic system.

2. Completely lower mast.

8. Check hydraulic oil level and add as needed. Oil level must be between upper and lower marking on dipstick.

3. Open power unit door.

4. Loosen securing nut on electrical panel and swing open electrical panel.

5. Place suitable container beneath hydraulic oil tank drain screw (18).

6. Remove hydraulic oil tank drain screw (18) to drain tank.

7. Remove hydraulic oil tank cover (1).

8. Remove mounting hardware (16) that secures hydraulic oil tank (14) to the rubber buffers.

13

13

Maintenance (Refer to Illustration 5) 1. Remove hydraulic tank cover (1).

2. Remove filter and clean or replace as necessary.

3. Install replacement sealant washer to oil drain screw and tighten.

4. Fill hydraulic oil tank.

5. Bleed hydraulic system.

6. Check hydraulic oil level and add as needed. Oil level must be between upper and lower marking on dipstick.

1

12

15

14

16 13 6694-01

18

ILLUSTRATION 5 Printed in U.S.A.

Crown 1998 PF11452-5 Rev. 12/03

02 REV. 12/03

M2.1–4320–005

M2.1–4320–005

C

MANIFOLD BLOCK MAINTENANCE

Hydraulic System

Bleed Procedure:

General:

Before doing the bleed procedure verify the oil level in the hydraulic reservoir is full. Check oil level as it's explained in the maintenance section.

Manifold block details: Same hydraulic block (1) is used for all WE/WS2000 and WE/WS2300 Series trucks.

A different orifice (5) is used for WE2000-25/30, WS200030/40, WE2300-25/30 and WS2300-40.

Description: 1. Manifold block.

2. Solenoid valve (SV2).

3. Proportional valve (SV3).

4. Relief valve (RV1).

5. Orifice (flow reduction). Refer to parts section for correct orifice to be used with truck model.

6. Bleed screw.

7. Adjustment screw.

8. Locknut.

6

Bleeding of the valve block must be done whenever the hydraulic tank is cleaned or when the filter is cleaned or replaced. Please follow instructions when air is trapped in the system.

1. Raise mast to full height.

2. Remove bleed screw (6) from proportional valve (3) SV3.

3. Completely lower forks.

4. Install and tighten bleed screw (6) back into proportional valve (3) SV3.

5. Repeat steps 1 thru 4 six times until oil comes out through the bleed screw on proportional valve SV3. If no oil is present after six times, troubleshoot hydraulic system.

1

2 Manifold Block SV2 7

4 SV3 RV1

8 3 5 6691-01

ILLUSTRATION 1

7839 Crown 1998 PF11454-1 Rev. 3/04

Printed in U.S.A.

02 REV. 3/04

M2.1–4320–100

M2.1–4320–100

C

MANIFOLD BLOCK MAINTENANCE

Troubleshooting: Failure description: – Delay of lift function when raise switch is depressed.

– Sudden lower when lower switch is depressed.

Hydraulic manifold must be bled if any of the above mentioned malfunctions arise.

Lowering speed: Lowering speed of all WE and WS trucks are: – Lowering 1, speed between 86 and 99 mm (3.4 and 3.9 in.) per second.

– Lowering 2, speed between 198 and 250 mm (7.8 and 9.8 in.) per second.

When testing lowering speeds, oil temperature should be between 25 and 30 degrees Celsius (77 and 86 degrees Fahrenheit).

Crown 1998 PF11454-2 Rev. 3/04

Printed in U.S.A.

02 REV. 3/04

M2.1–4320–101

M2.1–4320–101

DRIVE UNIT Drive Tire Removal

General

Removal (Refer to Illustration 1)

The drive unit is located on the left side of the vehicle behind the power unit door. It consists of a compound-wound motor which is mounted vertically on the swivel bevel gearing. The bevel gears mounted in taper roller bearings and the gears operate in an oil bath.

1. Disconnect battery and chock wheels.

2. Raise rear of truck and block. Refer to Control Of Hazardous Energy Section for lifting and blocking instructions.

Removal (Refer to Illustration 2)

3. Rotate drive unit until lug nuts are accesable.

1. Disconnect battery and chock wheels.

4. Remove lug nuts.

2. Raise rear of truck and block.

5. Remove drive tire from truck.

3. Open power unit door.

6. Inspect tire for wear, cuts or foreign materials in tire.

Replace tire if needed.

4. Remove steering chain.

Tire Installation (Refer to Illustration 1)

5. Disconnect brake.

6. Disconnect electrical cables from drive motor.

1. Install drive tire and secure with five lug nuts.

2. Torque lug nuts to 130 Nm (95 ft. lbs.).

7. Remove screws (2) that mount drive unit to power unit.

8. Remove drive unit from truck.

3. Remove blocking material, lower truck to floor.

FO

RK

1

EN

2

D

Drive Tire

0

Lug Nut

130 Nm (95 ft. lbs.)

11374

ILLUSTRATION 1 6699-01

ILLUSTRATION 2

7849 Printed in U.S.A.

Crown 1998 PF11455-1 Rev. 3/04

02 REV. 3/04

M3.0–4320–001

M3.0–4320–001

DRIVE UNIT Oil Change

Installation Reverse steps 1 thru 8 to install drive unit into truck. Install screws removed in step 7 with sealant, 053050-005 and tighten.

1. Disconnect battery and chock wheels.

DRIVE UNIT

3. Rotate shaft fully to the left.

Removal (Refer to Illustration 2)

4. Remove oil filter.

Use appropriate container to collect draining oil.

5. Rotate shaft fully to the right.

2. Raise and block truck.

6. Place oil container below drain screw, remove drain screw and allow oil to drain from drive unit.

1. Disconnect battery and chock wheels.

2. Raise and block truck.

7. Clean oil drain screw.

3. Remove drive wheel.

4. Rotate shaft fully to the left.

8. Install replacement sealant ring to drain screw install and tighten.

5. Remove oil filter screw.

9. Install cleaned and/or replacement oil filter.

6. Rotate shaft fully to the right.

10. Fill with gear oil. Oil level must reach the thread on the filler opening.

7. Place container underneath oil drain screw.

11. Install replacement sealant ring on fill screw.

8. Remove drain screw.

12. Install oil fill screw and tighten.

9. Remove drive unit.

10. Remove screws (1) and remove gear box.

Installation Unit is assembled in reverse sequence.

1. Clean oil drain screw.

2. Install replacement sealant ring to oil drain screw and tighten.

3. Fill with gear oil (1.5 litre [3.5 pts.]). Oil level must reach thread of the filler opening.

4. Lubricate turntable bearing with grease.

Crown 1998 PF11455-2 Rev. 3/04

Printed in U.S.A.

02 REV. 3/04

M3.0–4320–002

M3.0–4320–002

DRIVE UNIT Turntable Gear Removal 1. Remove drive unit.

2

1

3

2. Remove drive motor.

3. Remove screws from turntable (9) plate and remove turntable gear.

4 5

Installation

6

Install turntable gear unit in reverse order.

7

8 9

Part Of Undercarriage

10

12 FO EN RK D

11

7

14

13

15

6579-01

ILLUSTRATION 3

Crown 1998 PF11455-3 Rev. 3/04

Printed in U.S.A.

02 REV. 3/04

M3.0–4320–003

M3.0–4320–003

C

CARRIAGE MAINTENANCE

Pivoting Carriage

Installation

General

1. Inspect bearing (6) and replace if necessary.

2. Reverse steps 1 thru 5 to install pivot carriage onto truck.

The pivoting carriage is mounted to the truck's vertical axis.

On WS trucks the pivoting carriage is movable and can consequently compensate for uneven surfaces. This improves traction of the drive wheel. If the pivoting carriage is not required to move then it can be fixed mounted, as with the WE trucks.

Setting The Pivot Carriage WE Trucks 1. Place truck on level surface.

2. Remove locknuts (8).

3. Remove screws (7) until they are no longer attached to the pivoting carriage.

4. Install both screws until they are positioned against the pivoting carriage.

5. Tighten locknuts.

Removal (Refer to Illustration 1) 1. Dismantle drive unit.

2. Dismantle hydraulic tanks.

3. Dismantle electrical panel.

4. Remove screws (3) and remove bracket (2).

5. Remove pivoting carriage (5).

Setting The Pivot Carriage WS Trucks 1. Place truck on level surface.

2. Remove locknuts (8).

3. Set a gap of 12 mm (0.47 in.) on both sides between pivoting carriage and screws.

4. Tighten locknuts.

Frame

7 7 8

8

1 Pivoting Carriage 6

2 5

3 6

11381

4

ILLUSTRATION 1

7855 Crown 1998 PF11456 Rev. 3/04

Printed in U.S.A.

01 REV. 3/04

M3.9–4320–001

M3.9–4320–001

ELECTRICAL MAINTENANCE SAFETY INSTRUCTIONS

Brake Override Switch (ORS)

Before any electrical repairs are carried out and before looking for cause of any failure, the truck must be raised and blocked.

The brake override switch allows the truck to be maneuvered in the upper brake position of the control handle. The switch is located at the control handle mounting.

Switches

Horn (HNS)

General

The horn switch is found in the control handle and activated by pressing switch (HNS).

A maximum of 10 mA will be used on all utilized switches.

Speed Limit Switch (LMS) Key Switch (KYS) The key switch allows voltage to be supplied to the transistor controller.

The LMS switch, switches to slow speed when the forks are raised above 27.5 in. (0.7m). The speed limit switch is positioned underneath, next to the left mast profile.

Brake Switch (BRS)

Battery Connector/Emergency Battery Disconnect

The brake switch is activated as soon as the control pad reaches the brake position. This causes an interruption of the electrical supply to the brake (BR) and drive motor. The brake switch is found below the control handle mounting.

The battery connector is positioned top left in the truck and easily accessible. In an emergency, the emergency battery disconnect removes all power to the truck.

Fuses (FU)

Safety Reverse Switch (SAS) The safety reverse switch (SAS) when activated interrupts the voltage supply to the forward contactor (F) and activates the reverse contactor (R).

The main circuit is protected with a fuse for lifting and driving function (FU1). The steering circuit is protected by FU2.

Freezer/corrosion trucks have fuse FU4 and is on the distribution panel which controls the control pad heating elements.

Direction Control (POT, FS, RS) The direction control works as a two sided potentiometer with neutral mid-position. By pressing the rocker in either direction the movement of the rocker is converted by the potentiometer into a signal. The direction control activates via the transistor controller the direction contactors F/R and regulates driving speed.

Lift/Lower Switches (RAS, LOS1 & LOS2) The lift switch (RAS) activates the lift contactor (P) in the lift mode. The lower switch (LOS) activates the solenoid valve SV1 in the lower mode. Both switches are found on the control pod.

5790 Crown 1998 PF11457-1

M4.0–4320–001

Printed in U.S.A.

M4.0–4320–001

ELECTRICAL MAINTENANCE ELECTRIC PARTS LAYOUT RAS LOS2 LOS1 HNS

PC412 PC410 (8P)

POT & FS/RS

PC411 (6P)

SAS

BRS PC406 PC407

TT/BDI KYS

ORS

EDS HN

PC405 PC404 (In Side Of Shaft) LMS (On Mast) PM SV2 SV1

PC403 U1

PC401 PC402

P F/R

FU3

FU1 CA204 CA205 CA201 CA202 CA203

Traction Motor Shunt Field Driver 6710

Crown 1998 PF11457-2

M4.0–4320–002

Distribution Board

ILLUSTRATION 4.0-1

Printed in U.S.A.

M4.0–4320–002

C

TRANSISTOR CONTROLLER MAINTENANCE TRANSISTOR (MOSFET) CONTROLLER

The Transistor Control is a solid state electronic speed control which enables the energy from a fixed voltage DC source to be fed to an electric motor smoothly and without the power losses associated with other means of speed control.

The operation of the system consists of switching the full battery voltage to the traction motor for very short periods of time. The motor does not respond to the individual voltage pulses but rotates at a speed corresponding to the average voltage which is determined by the pulse width. The pulse frequency is constant and the pulse width duty cycle is set by the truck accelerator (twist grip). Therefore the average motor voltage can be varied anywhere from zero up to battery voltage, smoothly and with minimal energy losses.

The battery voltage pulses are made possible by a device known as a Metal Oxide Semiconductor Field Effect Transistor (MOSFET). This is simply a solid state switch that is capable of handling high currents.

The MOSFET is a three terminal device (Illustration 1). The two main terminals which are called the SOURCE and the DRAIN carry the working current. The third electrode, known as the GATE, is the switching electrode.

Normally the transistor is non-conducting (open circuit).

However, if a positive voltage is applied to the anode with respect to the source and then a gate signal is applied to the gate electrode, the transistor will switch to a conducting state (short circuit). The transistor will continue to conduct as long as the gate signal is present. The gate's "on" time is set by the accelerator (twist grip) position, and is supplied by the electronics in the controller. At slow speeds the transistor "on" times are short in duration and the "off" times are long in comparison. This allows little current to flow through the motor and consequently the motor output shaft rotates slowly. As the transistor "on" times become longer the motor output shaft will turn at a speed proportional to the increased current.

During the transistor “on” times, the current flowing in the motor windings sets up a magnetic field. During the “off” times, the magnetic field set up by the motor windings, collapses and induces a voltage in the windings. This voltage would be wasted under normal conditions, however, a diode (flyback diode, Illustration 2) is placed around the motor which routes the induced voltage of the collapsing magnetic field back through the motor.

DRAIN TRANSISTOR (MOSFET)

GATE

MOTOR

FLYBACK CURRENT

BATTERY CURRENT

FLYBACK DIODE

SOURCE MOSFET METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (MOSFET) 0284 0285-01 ILLUSTRATION 1

ILLUSTRATION 2

7178 Crown 1998 PF11469-1 Rev. 12/03

Printed in U.S.A.

01 REV. 12/03

M4.2–4320–001

M4.2–4320–001

C

TRANSISTOR CONTROLLER MAINTENANCE

This “flyback” current causes current flow in the motor during the transistor “off” times. This makes the average motor current greater than the average battery current. Illustration 3 is a graphic comparison of the battery current, flyback current and motor current.

TRANSISTOR SWITCHING ON

A total of fourteen (14) fault events can be recorded and stored in the controllers memory. Multiple occurrences of the same fault are recorded as one occurrence. The fault events list can be downloaded into the programmer for readout.

2 1 BATTERY CURRENT

Fault Detection

FLYBACK CURRENT

An internal microcontroller automatically maintains surveillance over the functioning of the controller. When a fault is detected, the appropriate fault code is signalled via the LED readout. If the fault is critical, the controller is disabled. Most faults are temporary and can easily be reset, for example, an undervoltage fault is cleared when the condition is removed.

1. AVERAGE BATTERY CURRENT 2. AVERAGE FLYBACK CURRENT 3. AVERAGE MOTOR CURRENT 0286

The dynamic throttle response (duty factor as a function of time) is shaped by the acceleration rate setting. Dynamic throttle response is linear.

Fault Recording

OFF 3

Throttle Response

ILLUSTRATION 3

FEATURE DESCRIPTION Automatic Fault Detection System Emergency Reverse Emergency reverse is activated when the brake is released.

KSI is activated, and the emergency reverse switch (the SAS, or "belly button" switch) is pressed. After the SAS switch is released, normal controller operation is not resumed until neutral (no direction) is selected and the brake is cycled (brake, then release). However, repeatedly pressing the SAS switch will reactivate the emergency release function each time.

The brake must be released (brake input "high") for the controller to operate. This is a safety interlock used on most material handling vehicles. Cycling the brake or KSI will clear most faults and enables operation. The brake must be applied; causing a low brake input when connecting the handheld programmer. The automatic fault detection system monitors for the following conditions: • Contactor coils open or shorted (F/R and Shunt )

Acceleration / Deceleration Rate

• Contactor driver overcurrent or shorted

The acceleration rate (time required for the controller to increase from 0% to 100% duty factor) is adjustable manually via the appropriate trimpot on top of the controller, or electronically by using the hand held programmer.

• Contactor welded • Emergency reverse circuit check • Overvoltage cutout

Brake • Internal power supply out of range The brake must be released (brake input "high") for the controller to operate. This is a safety interlock used on most material handling vehicles. Cycling the brake or KSI will clear most faults and enables operation. The brake must be applied; causing a low brake input when connecting the handheld programmer.

• M-fault (shorted MOSFET transistors) • Diagnostic memory check upon start-up • Throttle faults

Throttle

• Under voltage cutbacks

The throttle produces a range of 0% to 100% duty factor at the controller output (unless limited by other conditions).

Throttle detect is performed on the throttle input signal.

• Watchdog feature (both internal and external)

Crown 1998 PF11469-2 Rev. 12/03

Printed in U.S.A.

01 REV. 12/03

M4.2–4320–002

M4.2–4320–002

C

TRANSISTOR CONTROLLER MAINTENANCE

Arcless Contactor Switching

Key Switch

The controller output duty factor is quickly reduced to zero any time a direction is de-selected, so that the controller current is reduced to zero before the direction contactor drops out.

The key switch provides power to the logic board and initializes and starts diagnostics. In combination with the brake input, KYS enables all logic functions.

Quick Start

Plug Braking Plug braking takes place when a series motor is driven electrically in a direction opposite from the direction it is turning. The Curtis 1207 controller controls the field current to obtain smooth and uniform plug braking torque. During plug braking, the maximum current limit is automatically changed to the plug current limit and the PWM frequency is changed to 1.5 kHz. The high speed plug current limit is adjustable both manually and electronically.

Creep (Turtle) Speed Creep or turtle speed is activated when a direction is first selected. The output maintains creep speed until the throttle is rotated out of the throttle deadband (typically 10% of the throttle). Creep speed is adjustable from 0 to 25% of the controller duty factor; the adjustment can be made manually or electronically.

Low Speed Low speed operation allows less than the full speed range available. The user can adjust the maximum duty factor in low speed manually or electronically. The throttle input into the controller is rescalable to use all the throttle movement.

These low speed values can only be set using the 1207 programmer. The manually adjusted pots have no effect on low speed current limits.

Upon receiving a quick throttle demand from neutral, the controller will exceed normal acceleration momentarily in order to overcome inertia.

Watchdog (External, Internal) The external watchdog time guards against a complete failure of the microprocessor, which could disable the internal watchdog timer. This independent system check on the microprocessor meets the EEC's requirement for backup fault detection. The external watchdog safety circuit shuts down the controller (and microprocessor) if the software fails to generate a periodic external pulse train. It can only be reset by cycling the KSY. Overvoltage Cutoff Overvoltage resets the microprocessor, opens PWM, opens the contactors, and shuts down the controller. Controller operation resumes when the voltage is brought within the acceptable range.

Overtemperature At an overtemperature or maximum temperature of 185°200°F (85°-95°C), the current limit is linearly decreased from full set current down to zero.

Undervoltage Cutback

MOSFET A MOSFET (metal oxide semiconductor field effect transistor) is a type of transistor characterized by its fast switching speeds and very low losses.

Pulse Width Modulation (PWM)

Undervoltage protection automatically disables the controller output if battery voltage is detected below the undervoltage point at start-up, or when the battery voltage is pulled below the undervoltage point by an external load. If the motor current is such that the batteries are being pulled below the minimum point, the duty factor will be reduced until the battery voltage recovers to the minimum level.

Pulse width modulation is a technique that switches battery voltage to the motor on and off very quickly, thereby controlling the speed of the motor.

Ramp Start (anti roll-back) The ramp start feature allows the vehicle to be started with a higher plug current limit to prevent rolling down hill. Ramp start increases the plug current limit for the selected direction only. When the opposite direction is selected, ramp start will be canceled.

Crown 1998 PF11469-3 Rev. 12/03

Printed in U.S.A.

01 REV. 12/03

M4.2–4320–003

M4.2–4320–003

C

TRANSISTOR CONTROLLER MAINTENANCE

Controller Connector I/O (Model 1207)

Adjustment Panel (1207-1115)

• PC403-1 Shunt field output (without function)

The adjustment panel is located on top of the 1207 controller, under a sliding protective cover.

• PC403-2 Reverse contactor output TROUBLESHOOTING LED

• PC403-3 Forward contactor output • PC403-4 Not Connected 1

• PC403-5 Controller 3 wire

1

2

1

2

1

2

1

2

2

0

3

0

3

0

3

0

3

0

3

OFF

4

OFF

4

OFF

4

OFF

4

OFF

4

MAIN

PLUG

ACCEL

CURRENT LIMIT

CREEP

LOW

STATUS

SPEED LIMIT

• PC403-6 Direction controller 3 wire potentiometer PROGRAMMER CONNECTOR

• PC403-7 Direction controller potentiometer, negative • PC403-8 Not Connected

2617

• PC403-9 Not Connected

ILLUSTRATION 4

Manually Adjustable Potentiometer

• PC403-10 Safety reverse switch input

• PC403-13 Safety reverse switch input

Five (5) screwdriver adjustable potentiometers allow manual adjustment of high speed plug and main current limit, acceleration rate, and maximum low and creep (turtle) speeds.

See illustration 4 for panel layout. To adjust any of these parameters electronically with the programmer, its potentiometer must be set to "off".

• PC403-14 Speed restriction switch input

Programmer Connector

• PC403-15 Not Connected

A modular connector is provided for the handheld programmer. The connecting cable is supplied with the programmer.

• PC403-11 Reverse input • PC403-12 Forward input

• PC403-16 Key switch input

Status LED

Power Cable Connections M- Output to armature of drive motor

The LED displays flashing codes to indicate controller status. See section M4.6 for a complete listing of LED codes.

B- Connection to battery negative

LED Diagnostics

B+ Connection to battery positive and shunt field of drive motor

During normal operation, with no faults present, the Status LED flashes a single flash at approximately one (1) second intervals. If the controller detects a fault, a 2-digit code is flashed continuously until the fault is corrected.

A2 Connection to armature and series field for reverse torque control

Crown 1998 PF11469-4 Rev. 12/03

Printed in U.S.A.

01 REV. 12/03

M4.2–4320–004

M4.2–4320–004

C

TRANSISTOR CONTROLLER MAINTENANCE

Maintenance

3. Raise vehicle so drive wheel can rotate freely.

There are no user serviceable parts inside the Curtis PMC 1207 controller. No attempt should be made to open the controller. Opening the controller may damage it and will void the warranty. It is recommended that the controller exterior be cleaned periodically. If a hand-held programmer is available, the periodic cleaning provides a good opportunity to check the controllers diagnostic history file.

4. Open covering hood.

5. Discharge controller capacitor by switching an electrical load (i.e. activating horn).

6. Disconnect connector assembly.

7. Remove power cables.

Safety The 1207 controller is inherently a high power device. When working around any battery powered vehicle, proper safety precautions should be taken. These include, but are not limited to:

8. Remove securing screws and take out controller.

9. Installation can be performed by following these steps in reverse order.

Controller Check

• Properly trained personnel • Wearing proper eye protection

CAUTION

Before any inspection, adjustments, servicing, parts replacement or any other act is performed requiring physical contact with the electrical working components or wiring of system controller, disconnect battery, raise drive wheels clear of floor and place blocks under vehicle frame. Place Key switch to off and Brake switch open. Do not stand in path of vehicle while performing test.

• Avoid wearing any jewelry • Avoid wearing loose clothing • Use insulated wrenches and hand tools Cleaning the 1207 Controller 1. Disconnect battery.

1. Slide open cover on top of controller (Model 1207 only).

2. Block vehicle wheels to insure vehicle will not roll.

3. Raise vehicle so drive wheel can rotate freely.

4. Discharge controller capacitor by switching an electrical load (i.e. activating horn).

2. Connect programmer.

3. Turn the key switch to the "on" position.

• The programmer should power up.

• The controller status LED should begin blinking.

NOTE

5. Remove the cable.

6. Remove any dirt or corrosion from contact area.

7. Wipe controller with a clean, damp cloth.

8. Before connecting cables check to see that the controller is completely dry. Reattach cable with correct tool.

If neither happens, check for continuity in the key switch circuit and controller ground B-.

4. Switch program to diagnostic mode.

• Display should show "No faults found".

• The controller status LED should remain blinking.

5. Bring control pod to the walkie position • Display should show "No faults found".

• The controller status LED should remain blinking.

Removal and Installation of 1207 Controller 1. Disconnect battery.

2. Block vehicle wheels to insure vehicle will not roll.

Crown 1998 PF11469-5 Rev. 12/03

Printed in U.S.A.

01 REV. 12/03

M4.2–4320–005

M4.2–4320–005

C

TRANSISTOR CONTROLLER MAINTENANCE NOTE

If the display indicates a fault, the problem can be defined by referring to the fault codes shown in section M4.6. When the fault has been corrected, it may be necessary to cycle the brake to clear the fault code.

6. Press the direction controller in the desired direction.

• The motor should begin to turn in the selected direction.

NOTE If the motor does not respond as desired, verify the wiring to the forward/reverse switches, forward and reverse contactors, and motor.

7. Press the Test key.

8. Scroll down and observe the status of the forward/ reverse brake and safety reverse switch. Each input should show the correct state on the programmer.

9. Remove blocking and operate vehicle to verify: • Smooth acceleration to maximum speed.

• Plug braking operates smooth and evenly.

• Verify that high pedal (HPD) and directional controls are adjusted properly.

• Check safety reverse switch for proper operation.

10. Disconnect cable from safety reverse switch.

• Controller should turn off.

• Display will show fault.

• LED will flash diagnostic code.

11. Close the sliding cover over the controller.

Crown 1998 PF11469-6 Rev. 12/03

Printed in U.S.A.

01 REV. 12/03

M4.2–4320–006

M4.2–4320–006

DISTRIBUTION BOARD MAINTENANCE ELECTRICAL SYSTEM

3.

4.

5.

6.

SAFETY INSTRUCTIONS

Remove screws on electrical panel and swing open .

Remove nuts (18) and remove cover.

Remove five (5) connectors.

Remove spacers (13) and remove distribution board (14).

Before any electrical repairs are carried out and before looking for cause of any failure, the truck must be raised and blocked.

Repair

Distribution Board

The distribution board is not repairable.

Removal (Refer to Illustration 4.3-1)

Installation (Refer to Illustration 4.3-1)

1. Disconnect battery and chock wheels.

2. Raise and block truck.

Install distribution board by reversing steps 1 thru 6.

23

22

28 27

6

25

24

21

17

26

20

19 14 13

18 16

15

29

1 3

11

4 12 5

10 8 6

6711

ILLUSTRATION 4.0-1

7

9 5790

Crown 1998 PF11459-1

M4.3–4320–001

Printed in U.S.A.

M4.3–4320–001

ELECTRICAL Distribution Board Maintenance

Distribution Board Maintenance Electrical System

2. Raise and block truck.

3. Remove screws on electrical panel and swing open.

4. Remove nuts (18) and remove cover (14).

Safety Instructions

5. Remove five connectors.

Before any electrical repairs are carried out and before looking for cause of any failure, the truck must be raised and blocked.

6. Remove spacers (13) and remove distribution board (17).

Repair

Distribution Board

The distribution board is not repairable.

Removal (Refer to Figure 15005)

Installation (Refer to Figure 15005)

1. Disconnect battery and chock wheels.

Install distribution board by reversing steps 1 thru 6.

Figure 15005

Crown 2006 PF15556-1

M4.3-4323-001

CONTACTOR MAINTENANCE Forward/Reverse Contactor

Checking Coils

Checking Safety Contacts

1.

2.

3.

4.

Safety contacts are normally black on color and the surface rough. This does not affect the trouble-free functioning. The contacts must be replaced if the silver coating has been completely burned off and the subsurface visible. Always replace contacts in pairs.

1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Carefully lift contacts.

Disconnect battery and chock wheels.

Raise and block truck.

Remove all electrical connections from contactor coil.

Coil resistance should be 29 ± 5% ohms. Replace if needed.

Removal (Refer to Illustration 4.4-1 1.

2.

3.

4.

Disconnect battery and chock wheels.

Raise and block truck.

Dismantle distribution board.

Remove all electrical connections from Forward/Re verse (F/R) contactor.

5. Remove screws (4) and remove contactor.

23

22

28 27

6

25

24

21

17

26

20

19 14 13

18 16

15

29

1 3

11

4 12 5

10 8

6711

ILLUSTRATION 4.4-1

6 7

9 5790

Crown 1998 PF11460-1

M4.4–4320–001

Printed in U.S.A.

M4.4–4320–001

CONTACTOR MAINTENANCE Repair (Refer to Illustration 4.4-2) 1. Remove screws (1) and remove top section of the casing (7).

2. Remove both movable safety contacts (2) by pressing down on spring (6).

3. Remove contact plate (5) from the bottom section (3).

4. Remove coil cover (9).

5. Clean and inspect. Replace components as needed.

1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Carefully lift contacts.

Checking Coils 1.

2.

3.

4.

Installation (Refer to Illustration 4.4-2) 1. Install movable contacts (2) into the holes provided.

2. Install screws with thread locking adhesive, 053050006.

3. Complete assembly by reverse sequence.

1 8

1

Disconnect battery and chock wheels.

Raise and block truck.

Remove all electrical connections from contactor coil.

Coil resistance should be 29 ± 5% ohms. Replace if needed.

Removal (Refer to Illustration 4.4-3 1.

2.

3.

4.

Disconnect battery and chock wheels.

Raise and block truck.

Dismantle distribution board.

Remove all electrical connections from pump (24) contactor.

5. Remove screws (25) and remove contactor.

1

Repair (Refer to Illustration 4.4-3)

8

1. Remove screws (6) and remove upper section of casing (5).

2. Remove movable contactor tips (2).

3. Remove mounting hardware for fixed contacts (1).

4. Clean, inspect and replace components as necessary.

7

6 6

2

2 1 5

9

Installation (Refer to Illustration 4.4-3) 1. Install movable contacts (2) into the holes provided.

2. Install screws with thread locking adhesive, 053050006.

3. Complete assembly by reverse sequence.

4

6

3 1 5

1

4 6713

ILLUSTRATION 4.4-2

Pump Contactor

2

Checking Safety Contacts Safety contacts are normally black on color and the surface rough. This does not affect the trouble-free functioning. The contacts must be replaced if the silver coating has been completely burned off and the subsurface visible. Always replace contacts in pairs.

Crown 1998 PF11460-2

M4.4–4320–002

3

6714

ILLUSTRATION 4.4-3 Printed in U.S.A.

M4.4–4320–002

FUSE MAINTENANCE Fuses

Removal of Control Fuses

General Fuses are used to protect valuable components from current surges. The cause of a blown fuse lies in the malfunction of a different component. Before replacing the fuse the cause of the blown fuse must first be determined.

1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Remove securing nut on electrical panel and open panel.

4. Remove cover on distribution panel (13).

5. Check fuses FU4, FU5 & FU2 (26 & 29).

Removal of Main Fuses

Installation (Refer to Illustration 4.4-4

1.

2.

3.

4.

1. Assemble fuses in reverse order.

Disconnect battery and chock wheels.

Raise and block truck.

Remove nuts (8) on fuse holder (6).

Remove fuse (9).

23

22

28 27

6

25

24

21

17

26

20

19 14 13

18 16

15

29

1 3

11

4 12 5

10 8

6711

ILLUSTRATION 4.4-4

6 7

9 5790

Crown 1998 PF11461-1

M4.4–4320–050

Printed in U.S.A.

M4.4–4320–050

ELECTRICAL Contactor Maintenance

Contactor Maintenance

Checking Coils 1. Disconnect battery and chock wheels.

Forward/Reverse Contactor Checking Safety Contacts Safety contacts are normally black on color and the surface rough. This does not affect the trouble-free functioning. The contacts must be replaced if the silver coating has been completely burned off and the subsurface visible. Always replace contacts in pairs.

2. Raise and block truck.

3. Remove all electrical connections from contactor coil.

4. Coil resistance should be 29 ± 5% ohms. Replace if needed.

Removal

1. Disconnect battery and chock wheels.

Refer to Figure 15005

2. Raise and block truck.

1. Disconnect battery and chock wheels.

3. Carefully lift contacts.

2. Raise and block truck.

3. Dismantle distribution board.

4. Remove all electrical connections from Forward/ Reverse (F/R) contactor.

5. Remove screws (4) and remove contactor.

Figure 15005

Crown 2006 PF15564-1

M4.4-4323-001

23

ELECTRICAL Contactor Maintenance Repair

Pump Contactor

Refer to Figure 15094

Checking Safety Contacts

1. Remove screws (1) and remove top section of the casing (7).

Safety contacts are normally black on color and the surface rough. This does not affect the trouble-free functioning. The contacts must be replaced if the silver coating has been completely burned off and the subsurface visible. Always replace contacts in pairs.

2. Remove both movable safety contacts (2) by pressing down on spring (6).

3. Remove contact plate (5) from the bottom section (3).

1. Disconnect battery and chock wheels.

2. Raise and block truck.

4. Remove coil cover (9).

5. Clean and inspect. Replace components as needed.

3. Carefully lift contacts.

Checking Coils

Installation

1. Disconnect battery and chock wheels.

Refer to Figure 15094

2. Raise and block truck.

1. Install movable contacts (2) into the holes provided.

3. Remove all electrical connections from contactor coil.

2. Install screws with thread locking adhesive, 053050-006.

4. Coil resistance should be 29 ± 5% ohms. Replace if needed.

3. Complete assembly by reverse sequence.

Figure 15094

M4.4-4323-002

24

Crown 2006 PF15564-2

ELECTRICAL Contactor Maintenance Removal

Installation

Refer to Figure 15095

Refer to Figure 15095

1. Disconnect battery and chock wheels.

1. Install movable contacts (2) into the holes provided.

2. Raise and block truck.

3. Dismantle distribution board.

2. Install screws with thread locking adhesive, 053050-006.

4. Remove all electrical connections from pump (24) contactor.

3. Complete assembly by reverse sequence.

5. Remove screws (25) and remove contactor.

Repair Refer to Figure 15095 1. Remove screws (6) and remove upper section of casing (5).

2. Remove movable contactor tips (2).

3. Remove mounting hardware for fixed contacts (1).

4. Clean, inspect and replace components as necessary.Installation (Refer to Figure 15095)

Figure 15095

Crown 2006 PF15564-3

M4.4-4323-003

25

C

SWITCH MAINTENANCE

Reverse Safety Switch (SAS)

2

Removal

5 6

1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Remove screws on the handle and raise the switch cover.

4. Disconnect three (3) connectors and remove switch cover.

5. Remove screws and bracket.

6. Remove screws securing switch to handle and remove switch.

4 3 12

5

1

12

8

3

Installation

11

1. Reverse Steps 1 thru 6 to assemble switch into handle.

9

8

10

11

7

ILLUSTRATION 1

6715

Adjusting Drive Switch (Refer to Illustration 2)

Key Switch (KYS) Removal 1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Open power unit door.

4. Disconnect connectors.

5. Remove nut and washer.

6. Remove switch.

Installation 1. Reverse Steps 1 thru 6 to assemble switch into truck.

Drive Switch (POT, FS/RS)

1. Raise and block truck.

2. Remove screws on handle and raise switch cover.

3. Adjust the drive switch rocker by rotating the right eccentric screw (1) until there is no play.

4. Connect the programmable handset to the traction controller.

5. Call-up test menu and view drive switch % display.

6. Loosen screws (2) on the drive switch (3).

7. Move the drive switch until the % displayed on the handset is zero (0).

8. Average out the amount of play and tighten screws (2).

9. Activate the drive switch completely in both directions.

The display should read 100%.

Removal (Refer to Illustration 1) 1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Remove screws on handle and raise switch cover.

4. Disconnect three (3) connectors and remove switch cover.

5. Remove mounting screws (3) and drive switch.

6. Remove items 4 to 11.

Installation (Refer to Illustration 1)

1

3

2

6716

ILLUSTRATION 2

Verification of Drive Switch Setting

1. Rotate adjustment pin (12) until it is flush with the drive switch rocker (4).

2. Install drive switch so it is located in the center of the recess on the switch cover.

3. Install screws (3).

4. Press brackets (1) and (2) together gently so there is no noticeable play on the switch rocker.

5. Complete assembly in reverse order of steps 1 thru 6.

6. Tighten the attachment screws.

7. Verify switch operation.

1. Raise and block truck.

2. Connect the programmable handset to the traction controller.

3. Call-up test menu and view throttle % display.

The display must be 0% in neutral and 100% when activated in any direction.

There must not be any noticeable play in the neutral position.

The drive rocker switch must operate freely in the cover and must immediately return to the neutral position after being activated.

7187 Printed in U.S.A.

Crown 1998 PF11462-1 Rev. 12/03

01 REV. 12/03

M4.5–4320–001

M4.5–4320–001

C

SWITCH MAINTENANCE

Raise/Lower 1/Lower 2 Switches (RAS, LOS1 & LOS2) 1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Remove screws on the handle and raise switch cover.

4. Disconnect the connectors and remove switch cover.

5. Disconnect electrical connections.

6. Remove screws and nuts and remove switches.

Installation

Brake Override Switch (ORS) 1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Open power unit door.

4. Disconnect all electrical connections to switch.

5. Remove mounting hardware and override switch along with activator and spacer.

Installation

1. Install switches by reversing steps 1 thru 6.

2. No adjustments are required.

1. Install switch by reversing steps 1 thru 5.

2. No adjustments are required.

Horn Switch (HNS)

Emergency Disconnect Switch (EDS)

1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Remove screws on the handle and raise switch cover.

4. Disconnect the connectors and remove switch cover.

5. Disconnect electrical connections.

6. Remove screws and nuts and switch.

Installation

1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Open power unit door.

4. Remove nut securing electronics panel door and swing open door.

5. Disconnect electrical connections.

6. Remove mounting hardware and switch.

Installation

1. Install switches by reversing steps 1 thru 6.

2. No adjustments are required.

1. Install switch by reversing steps 1 thru 6.

2. No adjustments are required.

3. Verify switch operation.

4. Switch is not repairable.

Speed Limit Switch (LMS) 1. Raise fork carriage and block.

2. Disconnect battery and chock wheels.

3. Raise and block truck.

4. Remove electrical connections.

5. Remove mounting hardware and switch.

Horn (HN)

Installation 1. Install switch by reversing steps 1 thru 5.

2. Verify operation of switch. Switch should slow speed of truck when forks are raised to 700 mm (27.5 in.) and above.

Brake Switch (BRS) 1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Open protective power unit door.

4. Disconnect electrical connections.

5. Remove switch mounting hardware and brake switch along switch activator and spacer.

1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Open power unit door.

4. Disconnect all electrical connections to horn.

5. Remove mounting hardware and horn.

6. Remove screws from bracket.

Installation 1. Install horn by reversing steps 1 thru 6.

2. No adjustments are required.

3. Verify horn operation.

Electrical Panel The traction controller, Forward/Reverse (F/R) contactor and distribution board are housed on the swivel mounted electronics panel.

Installation 1. Install switch by reversing steps 1 thru 5.

2. Verify operation of switch.

Printed in U.S.A.

Crown 1998 PF11462-2 Rev. 12/03

01 REV. 12/03

M4.5–4320–002

M4.5–4320–002

C

SWITCH MAINTENANCE

Removal

2

1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Open power unit door.

4. Remove electronic panel mounting hardware and swing open.

5. Remove Forward/Reverse (F/R) contactor.

6. Remove traction controller.

7. Remove distribution board.

8. Remove electrical panel.

1

Installation 1. Install electrical panel by reversing steps 1 thru 8.

6717

ILLUSTRATION 3

Battery Connections The battery connector is located beneath the battery cover.

Both connector components are identical in shape. The battery connector is fitted with a handle for easy removal.

Removal 1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Remove battery cables from battery poles.

4. Remove screws on the connector path on the battery cover.

5. Disconnect cable terminals and remove cables.

Repair 1. Hold down stop spring (1) beneath connector contact (2) and remove the connector contact.

2. Check contacts, if necessary replace entire cable.

WARNING

Ensure cables are connected to the correct poles.

Cable ends which have connector contacts are color coded. The positive (+) pole is colored red, the negative (-) pole is blue.

Cable ends with cable eyes have differing diameters. The positive (+) cable leads to the emergency disconnect switch (EDS), the negative (-) cable to the pump motor (P). The positive (+) and negative (-) symbols are embossed on the connector housing.

Installation 1. Reverse steps 1 thru 5 to assemble connector paying attention with respect to positive (+) and negative (-) cabling.

Crown 1998 PF11462-3 Rev. 12/03

Printed in U.S.A.

01 REV. 12/03

M4.5–4320–003

M4.5–4320–003

ELECTRICAL Unigage

Unigage

Operation

The upper portion of the Unigage is a battery discharge indicator with lift interrupt and the lower portion is an hour meter.

The green and yellow LED's on the battery discharge indicator show how much charge is left in the battery. A flashing red LED is a warning the battery is getting low.

When two red LED's flash, the meter locks out lift and, at this point, the battery must be recharged or exchanged for a fully charged battery to resume full truck operation.

Adjustment The standard factory setting for the battery discharge indicator is "N". Refer to Figure 22767 for selector setting location. The indicator must be set according to the battery type.

Figure 22766

The purpose of the lift interrupt is to monitor and protect the battery as well as electrical components of the truck. To protect the battery, the discharge cycle must not exceed 80% discharge under full current load. For wet cell batteries, an 80% discharge equals 1.73 volts per cell (VPC) with electrolyte temperature at 25°C (77°F) and for maintenance free batteries, an 80% discharge equals 1.86 VPC under load or 2.02 VPC (open circuit).

CAUTION Allowing the battery to go deeper into discharge will permanently damage the battery and possibly the electrical components on the truck.

Figure 22767 1

Setting selector

2

Back of meter

A new battery requires between 5 to 10 discharge cycles before it reaches its full capacity.

Crown 2000 PF11852-1 Rev. 10/09

M4.6-2720-100 05 Rev. 10/09

ELECTRICAL Unigage When maintenance free batteries are being used, set the selector to "P". No further adjustment is necessary.

When wet cell batteries are being used, adjust the setting following the procedure outlined below.

•

Measure the electrolyte density on a fully charged battery.

The density should be measured on three different battery cells and should be at least 1.27 to 1.28 or 1.29 to 1.30 for high density batteries (consult battery manufacturer for exact values).

•

Measure the electrolyte density again as soon as the two red LED's on the battery discharge indicator flash and lift is locked out. It should not measure less than 1.12 to 1.13.

For a higher reading change the indicator setting to "K", for lower reading change to "U".

• •

Troubleshooting

Figure 22768

Connector Terminal - 824819

Check the setting by measuring the electrolyte density with the battery charged and discharged.

Pin No.

Relay Option K

1

No Connection

The reset is the amount of charge the battery must have to reset the control. The control comes set from the factory. The setting equals 2.09 VPC, 25.2 V open circuit voltage for 24 V batteries. The specific gravity (SG) of the battery at 2.09 VPC is approximately 1250 SG with electrolyte temperature at 25°C (77°F) and the battery under full current load.

2

+Keyswitch

3

Relay Arm (+) Lockout

4

Relay N.C (-) Lockout

5

Common (BNEG)

6

Truck Hours

7

B+ Low (24 V)

8

B+ High (48 V)

Connector Terminal - 130997

M4.6-2720-101 05 Rev. 10/09

Pin No.

Relay Option K

1

No Connection

2

+Keyswitch

3

N.C. Holding FET Switch + (Lockout)

4

N.C. Holding FET Switch - (Lockout)

5

Common

6

Traction Hours

7

Low Voltage + (12 V)

8

High Voltage + (24 V)

Crown 2000 PF11852-2 Rev. 10/09

ELECTRICAL Unigage

SYMPTOM

CHECK

Gauges will not reset.

Check battery state-of-charge, both voltage and specific gravity. The setting equals 2.09 VPC. Batteries charged to 1250 SG with the electrolyte temperature at 25°C (77°F) and battery under full current load or better will have this voltage. If a battery is not able to produce a reset, the battery and charger must be checked.

Truck comes in too soon Check the specific gravity of the battery when the meter’s red LED’s flash. for a battery change.

Do not turn the DISCHARGE setting towards “K” if the specific gravity of the battery corresponds to more than 80% discharge (1150 SG for most batteries with electrolyte temperature at 25°C (77°F) and under full current load). More running time can be obtained by turning the DISCHARGE setting from “N” towards “K”, providing the battery does not show 80% discharge.

Lift is not disabled when red LED’s are flashing.

Check wiring, relay and meter.

High speed travel is not Check wiring, relay and meter. disabled when red LED’s are flashing.

WARNING Tow tractors must use the 824819 battery indicator. Installing the 130997 battery indicator in tow tractors could result in damage to the gage.

Crown 2000 PF11852-3 Rev. 10/09

M4.6-2720-102 05 Rev. 10/09

CONTROLLER MAINTENANCE PROGRAMMER OPERATION The display window presents a 4-line LCD display. The display is visible even in bright sunlight. You can adjust the display contrast in the Special Program mode.

The optional universal Curtis PMC handheld programmer, Crown P/N 117617, allows you to program, test, and diagnose Curtis PMC 1207 controllers. The programmer is powered by the host 1207 controller, via an RJ11 modular connector located in the adjustment panel on top of the controller.

When one of the menu keys is pressed, the LED at the corner of the key lights up, identifying the mode of programmer operation. For example, if the TEST key is pressed, the LED at the corner of the key indicates that the programmer is now in the Test mode, and the Test Menu is displayed.

When the programmer is first plugged into the controller, the brake switch must be open (brake applied) until the programmer has acquired all the controller parameters. When this step has been completed, the programmer displays the controller’s model number, date of manufacture, and software revision code. Following this initial display, the programmer displays a prompt for further instructions.

Four lines of a menu are displayed at a time. The item at the top of the display window is the selected item. To select an item, scroll within the menu until the desired item is positioned at the top of the display window. The selected item is always the top line. (In the Program mode, the selected item is highlighted by a flashing arrow.) To modify a parameter or obtain more information about it, must be scrolled to the top position in the display window.

The programmer is operated via an 8-key keypad. Three keys select operating modes (Program, Test, Diagnostics), two scroll the display up and down, and two change the values of selected parameters. The eighth key, the MORE INFO key, is used to display further information about selected items within any of the three standard modes. In addition, when pressed together with the PROGRAM or the DIAGNOSTICS key, the MORE INFO key selects the Special Program mode or the Special Diagnostics mode.

DISPLAY A 4-line LCD display is presented in this window.

TEST MODE LED Illuminates to identify the mode of operation.

DIAGNOSTICS MODE PROGRAM

TEST

DIAGNOSTICS

PROGRAM MODE SCROLL DISPLAY

SCROLL DISPLAY Scroll the 4-line display (up and down) with these keys.

CHANGE VALUE

MORE INFO

CURTIS PMC A DIVISION OF CURTIS INSTRUMENTS INC

2622

Crown 1998 PF11453-1

M4.6-4320–001

CHANGE VALUE Change selected item's value (up or down) with these keys.

MORE INFO Get more information about selected items with this key. Also, use this key in combination with other keys to put the programmer in Special modes.

ILLUSTRATION 4.2-6

Printed in U.S.A.

M4.6-4320–001

CONTROLLER MAINTENANCE

To scroll up and down within a menu, use the two SCROLL DISPLAY arrow keys. The SCROLL DISPLAY arrow keys can be pressed repeatedly or be held down.

When a key is held down, the scrolling speed increases

ILLUSTRATION 4.2-8 The two CHANGE VALUE arrow keys are used to increase or decrease the value of a selected menu item. Like the SCROLL DISPLAY arrow keys, the CHANGE VALUE arrow keys can be pressed repeatedly or be held down. The longer a key is held, the faster the parameter changes. This allows

SCROLL DISPLAY

CHANGE VALUE

2623

the longer the key is held.

ILLUSTRATION 4.2-7

2625

A small scroll bar at the left of the display window provides a rough indication of the position of the four displayed items within the entire menu. That is, when the bar is at the top of the window, the top of the menu is displayed. As you scroll through the menu, the bar moves downward. When the bar is at the very bottom of the window, you have reached the end of the menu. This

An LED on each CHANGE VALUE arrow key indicates whether the key is active and whether change is permissible.

When the value of a parameter is being increased, the LED on the “up” CHANGE VALUE key is on until you reach the maximum value for that parameter. When the LED goes off, you cannot increase the value.

SCROLL BAR PLUG C/L L/S PLUG C/L EMR REV C/L L/S EMR REV C/L

SELECTED ITEM 100 80 140 80

rapid changing of any parameter.

ILLUSTRATION 4.2-9

The MORE INFO key has three functions: (1) to display more information about the selected item, (2) to access the Special Program and Special Diagnostics modes (when used together with the PROGRAM and DIAGNOSTICS keys), and (3) to initiate certain commands (such as the Self Test).

“More information” is available in all of the programmer operating modes. After using the MORE INFO key to display additional information about the selected item, press the

2624

sample display is from the Program Menu:

Crown 1998 PF11453-2

M4.6-4320 - 002

Printed in U.S.A.

M4.6-4320 - 002

CONTROLLER MAINTENANCE MORE INFO key again to return to the original list.

OPERATING MODES: PROGRAM, TEST, DIAGNOSTICS, SPECIAL PROGRAM, SPECIAL DIAGNOSTICS In the Program mode, accessed by pressing the PROGRAM key, all the adjustable parameters and features of the controller are displayed (four at a time), along with their present settings. The setting of the selected item—the item at the top of the display, with the flashing arrow—can be

Some parameters on some controllers have dependencies on other parameters. This means that the available settings for one parameter may be dependent on the limits of another parameter. For example, your controller may not allow the main current limit to be set below some other current limit, such as the emergency reverse current limit. In this example, if you attempt to reduce the main current limit below that of emergency reverse, a message will be displayed indicating that the minimum main current limit is dependent on the emergency reverse current limit. The Program Menu is presented at the end of this section.

NOTE Some items may not be available on all 1207 models.

PROGRAM 2626

changed, using the two CHANGE VALUE keys.

ILLUSTRATION 4.2-10 The LEDs on these keys indicate whether there is still room for change. That is, when the upper limit of a parameter’s range is reached, the LED on the “up” key no longer lights up, indicating that the present value cannot be increased; when the lower limit is reached, the LED on the “down” key no longer lights up. The MORE INFO key, when used in the Program mode, displays a bar graph along with the minimum and maximum values possible for the selected parameter.

Parameters can be changed either from the main Program Menu or after the MORE INFO key has been pressed and the

In the Test mode, accessed by pressing the TEST key, realtime information is displayed about the status of the inputs, outputs, and controller temperature. For example, when the status of the forward switch is displayed, it should read “On/ Off/On/Off/On/Off as the switch is repeatedly turned on and off. In the Test mode, the item of interest does not need to be the top item on the list; it only needs to be among the four items visible in the window. The Test mode is useful for checking out the operation of the controller during initial installation, and also for troubleshooting should problems occur.

The MORE INFO key, when used in the Test mode, causes additional information to be displayed about the selected item (top line in the window). The Test Menu is presented at the end of this section.

NOTE

SELECTED PARAMETER SET VALUE UNITS

Some items may not be available on all 1207 models.

BAR GRAPH

MAIN LIMIT AMPS MIN 20

100 MAX 250

TEST MINIMUM VALUE

MAXIMUM VALUE

2628

ILLUSTRATION 4.2-12

2627

additional information is being displayed (see illustration 6).

ILLUSTRATION 4.2-11

Crown 1998 PF11453-3

M4.6-4320-003

Printed in U.S.A.

M4.6-4320-003

CONTROLLER MAINTENANCE In the Diagnostics mode, accessed by pressing the DIAGNOSTIC key, currently active faults detected by the controller are displayed. The MORE INFO key, when used in the Diagnostics mode, causes additional information to be displayed about the selected item. A list of the abbreviations used in the Diagnostics display is included at the end of this section.

DIAGNOSTICS 2629

ILLUSTRATION 4.2-13

The Special Program mode allows you to perform a variety of tasks, most of which are self-explanatory. Through the Special Program Menu, you can revert to earlier settings, save controller settings into the programmer memory, load the controller settings from the programmer into a controller, clear the controller’s diagnostic history, adjust the contrast of the programmer’s LCD display, select the language to be displayed by the programmer, and display basic information (model number, etc.) about the controller and the programmer.

MORE INFO 2630

PROGRAM

ILLUSTRATION 4.2-14

To access the Special Program mode, first press the MORE INFO key. Then, while continuing to hold the MORE INFO key, press the PROGRAM key. The LED on the PROGRAM key will light, just as when the programmer is in Program mode. To distinguish between the Program and Special Program modes, look at the menu items in the display. Two of the Special Program Menu items—”Save Controller Settings in Programmer” and “Load programmer Settings into Controller”—allow you to “clone” controllers. To do this, simply program one controller to the desired settings, save these settings in the programmer, and then load them into other similar (same model number) controllers, thus creating a family of controllers with identical settings.

Crown 1998 PF11453-4

M4.6-4320-004

The MORE INFO key is used initially to access the Special Program mode, and once you are within the Special Program mode, it is used to perform the desired tasks. To adjust the contrast in the display window, for example, select “Contrast Adjustment” by scrolling until this item is at the top of the screen, and then press MORE INFO to find out how to make the adjustment. The Special Program Menu is presented at the end of this section In the Special Diagnostics mode, the controller’s diagnostic history file is displayed. This file includes a list of all faults observed and recorded by the controller since the history was last cleared. (Note): The maximum and minimum temperatures recorded by the controller are included in the Test Menu.) Each fault is listed in the diagnostic history file only once, regardless of the number of times it occurred.

MORE INFO 2631

DIAGNOSTICS

ILLUSTRATION 4.2-15

To access Special Diagnostics, first press the MORE INFO key. Then, while continuing to hold the MORE INFO key, press the DIAGNOSTICS key. The LED on the DIAGNOSTICS key will light, just as when the programmer is in Diagnostics mode. The brake must be applied (brake switch open) in order to access the diagnostic history file. The MORE INFO key, when used within the Special Diagnostics mode, causes additional information to be displayed about the selected item. To clear the diagnostic history file, put the programmer into the Special Program mode, select “Clear Diagnostic History,” and press the MORE INFO key for instructions. Clearing the diagnostic history file also resets the maximum/ minimum temperatures in the Test Menu.

Printed in U.S.A.

M4.6-4320-004

CONTROLLER MAINTENANCE PROGRAMMER OPERATION

Programmer Self Test

Each time the programmer is connected to the controller, it acquires all the controller’s parameters and stores them in its temporary memory. You can revert back to these original settings at any time during a programming session via the Special Program Menu. Select “Revert to Previous Settings” by scrolling it to the top of the display window, press the MORE INFO key, and follow the instructions displayed. Any inadvertent changing of parameters can be “undone” using this procedure—even if you can’t remember what the previous settings were—as long as the programmer has not been unplugged and power has not been removed from the controller.

You can test the programmer by displaying two special test screens. Press the MORE INFO key while the programmer is powering up. During the Self Test, you can toggle between the two test screens by pressing the SCROLL DISPLAY keys. The first screen turns on every LCD element, and the second screen displays all the characters used in the various menus. As part of the Self Test, you can also test the keys by pressing each one and observing whether its corner LED lights up. To exit the Self Test, unplug the programmer or turn off the controller, and then repower it without holding the MORE INFO key.

SCROLL DISPLAY ! " # $ % & ' ( ) * + , - . / 0123456789:;<=>? @ABCDEFGHIJKLMNO PQRSTUVWXYZx >

2632

Crown 1998 PF11453-5

M4.6-4320-005

ILLUSTRATION 4.2-16

Printed in U.S.A.

M4.6-4320-005

CONTROLLER MAINTENANCE PROGRAMMER MENUS The Program, Test, and Special Program Menus are presented here. The abbreviations used in the Diagnostics and Special Diagnostics displays are also listed.

Program Menu (not all items available on all controllers) MAIN C/L L/S MAIN C/L PLUG C/L L/S PLUG C/L EMR REV C/L L/S EMR REV C/L RAMP C/L L/S RAMP C/L ACCEL RATE THROTTLE TYPE CREEP SPEED LOW SPEED EMR REV SPEED SEQUENCING DLY VARIABLE PLUG HIGH PEDAL DIS SRO ANTI-TIEDOWN QUICK START

Crown 1998 PF11453-6

M4.6-4320-006

Main current limit Low speed main current limit Plug current limit Low speed plug current limit Emergency reverse current limit Low speed emergency reverse current limit Ramp start current limit Low speed ramp start current limit Acceleration rate, in seconds Throttle type Creep speed, as percent of full throttle Low speed, as percent of full throttle Emergency reverse speed, as percent Sequencing delay, in seconds Throttle-Variable plug braking: on or off High pedal disable (HPD) Static return to off (SRO) Anti-tiedown: on or off Quick-start throttle factor

Printed in U.S.A.

M4.6-4320-006

CONTROLLER MAINTENANCE Test Menu (not all items available on all controllers) FORWARD SWITCH REVERSE SWITCH BRAKE SWITCH THROTTLE % SPEED SWITCH EMR REV SWITCH MAIN CONTACTOR FWD CONTACTOR REV CONTACTOR BATT VOLTAGE HEAT SINK °C MAX TEMP °C MIN TEMP °C

Forward switch: on/off Reverse switch: on/off Brake switch: on/off Throttle reading, in percent of full Speed switch: on/off Emergency reverse switch: on/off Main contactor: on/off Forward contactor: on/off Reverse contactor: on/off Battery voltage Heatsink temperature Maximum temperature seen * Minimum temperature seen *

* Maximum/minimum temperatures recorded since Diagnostic History was last cleared.

Special Program Menu RESET ALL SETTINGS CONT SETTINGS › PROG PROG SETTINGS › CONT CLEAR DIAG HISTORY CONTRAST ADJUSTMENT LANGUAGE SELECTION PROGRAMMER INFO CONTROLLER INFO

Revert to original settings Save controller settings in programmer Load programmer settings in controller Clear diagnostic history memory Adjust display contrast Select displayed language Display programmer information Display controller information

Diagnostics and Special Diagnostics “Menu” This is not a menu as such, but simply a list of the possible messages you may see displayed when the programmer is operating in either of the Diagnostics modes. The messages are listed in alphabetical order for easy reference.

B B WIRING CHECK CONT DRVR OC DIR CONT WELDED HPD HW FAILSAFE LOW BATTERY VOLTAGE M - FAULT MISSING CONTACTOR NO KNOWN FAULTS OVERVOLTAGE SRO THERMAL CUTBACK THROTTLE FAULT 1 THROTTLE FAULT 2

Crown 1998 PF11453-7

M4.6-4320-007

BB wiring check failed Contactor driver overcurrent Direction contactor welded High-pedal-disable activated Hardware failsafe activated Low battery voltage (< 16 V) M - output fault Missing contactor No known faults Overvoltage (> 45 V) Static-return-to-off activated Thermal cutback due to temperature Throttle input fault Throttle low input fault

Printed in U.S.A.

M4.6-4320-007

CONTROLLER MAINTENANCE Controller Settings: WE 2500 LBS. (1135kg), WS 3000 LBS. (1360kg) Parameter

Range

Access

Setting

Units

C/L Main

20 - 250

User

180

Amps.

C/L Low Speed Main

20 - 250

User

100

Amps

C/L Plug

20 - 250

User

110

Amps.

CL Low Speed Plug

20 - 250

User

60

Amps.

C/L Emergency Reverse

20 - 250

*OEM

140

Amps.

C/L Low Speed Emergency Reverse

20 - 250

*OEM

110

Amps.

C/L Ramp Start

20 - 250

*OEM

180

Amps.

C/L Low Speed Ramp Start

20 - 250

*OEM

90

Amps.

Acceleration Rate

0-3

User

1,0

Seconds

Quick Start Throttle Factor

0-6

*OEM

0

Throttle type

See Specifications

*OEM

2

Type

Ramp Shape

30 - 70

*OEM

50

%

Creep Speed/Minimum duty

0 - 25

User

0

%

Low Speed

40 - 100

*OEM

40

%

High Speed

40 - 100

*OEM

100

%

Emergency Reverse Speed

25 - 100

*OEM

30

%

0-3

*OEM

0

Seconds

ON/OFF

*OEM

ON

High Pedal Disable

0/1/2

*OEM

0

Static Return To Off (SRO)

0/1/2

*OEM

0

Anti-Tie Down

ON/OFF

*OEM

OFF

Emergency Reverse (BB) Check

ON/OFF

*OEM

Shunt Field Drive Output

ON/OFF

*OEM

Shunt Field Delay

0,0 - 0,5

*OEM

Sequencing Delay Variable Plug

Seconds

Input Polarities

F, R, SS Brake, *OEM EMR, R *Accessable with OEM handset only. Do Not adjust without first obtaining factory authorization. Failure to do so will result in Warranty being Voided.

Crown 1998 PF11453-8

M4.6-4320-008

Printed in U.S.A.

M4.6-4320-008

CONTROLLER MAINTENANCE Controller Settings: WE 3000 LBS. (1360kg), WS 4000 LBS. (1815kg) Parameter

Range

Access

Setting

Units

C/L Main

20 - 250

User

220

Amps.

C/L Low Speed Main

20 - 250

User

140

Amps

C/L Plug

20 - 250

User

120

Amps.

CL Low Speed Plug

20 - 250

User

70

Amps.

C/L Emergency Reverse

20 - 250

*OEM

160

Amps.

C/L Low Speed Emergency Reverse

20 - 250

*OEM

110

Amps.

C/L Ramp Start

20 - 250

*OEM

250

Amps.

C/L Low Speed Ramp Start

20 - 250

*OEM

100

Amps.

Acceleration Rate

0-3

User

1,0

Seconds

Quick Start Throttle Factor

0-6

*OEM

0

Throttle type

See Specifications

*OEM

2

Type

Ramp Shape

30 - 70

*OEM

50

%

Creep Speed/Minimum duty

0 - 25

User

0

%

Low Speed

40 - 100

*OEM

40

%

High Speed

40 - 100

*OEM

100

%

Emergency Reverse Speed

25 - 100

*OEM

30

%

0-3

*OEM

0

Seconds

ON/OFF

*OEM

ON

High Pedal Disable

0/1/2

*OEM

0

Static Return To Off (SRO)

0/1/2

*OEM

0

Anti-Tie Down

ON/OFF

*OEM

OFF

Emergency Reverse (BB) Check

ON/OFF

*OEM

Shunt Field Drive Output

ON/OFF

*OEM

Shunt Field Delay

0,0 - 0,5

*OEM

Sequencing Delay Variable Plug

Seconds

Input Polarities

F, R, SS Brake, *OEM EMR, R *Accessable with OEM handset only. Do Not adjust without first obtaining factory authorization. Failure to do so will result in Warranty being Voided.

Crown 1998 PF11453-9

M4.6-4320-009

Printed in U.S.A.

M4.6-4320-009

CONTROLLER MAINTENANCE WE/WS LED Status Codes LED Code

LCD Display

Explanation

Possible Cause

1,2

HW FAILSAFE

Hardware fail-safe error

Defective controller

1,3

M-FAULT

M-output shorted

Output shorted to ground.

Direction contactor not closing.

Direction contactor closing too slow.

Internal motor short to ground.

1,4

SRO

SRO Fault

Wrong sequence of KSY, brake, or direction inputs.

Wrong SRO type selected.

Brake or direction switch circuit open.

Sequencing delay too short.

2,1

THROTTLE FAULT 1

5-0 volt or wiper fault

Throttle input wire open.

Throttle input wire shorted to ground or B+.

Defective throttle potentiometer.

Wrong throttle type selected.

2,2

BB WIRING CHECK

Emergency reverse wiring fault.

BB wire open.

BB check wire open.

2,3

HPD

HPR sequencing fault

Wrong sequence of KYS, brake, or throttle inputs.

Incorrect HPD type selected.

Misadjusted throttle potentiometer.

2,4

THROTTLE FAULT 2

Potentiometer shorted or broken.

Potentiometer Low wire open.

Potentiometer Low wire shorted.

Incorrect throttle type selected.

3,1

CONT DRVR OC

Driver output overcurrent

Direction contactor coil shorted.

Shunt field shorted.

3,2

DIR CONT WELD

Welded direction contactor

Direction contactor stuck closed.

3,4

MISSING CONTACTOR

Missing contactor or shunt

Direction contactor coil open.

Direction contactor missing.

Shunt field open.

Wire to shunt or direction contactor is open.

4,1

LOW BATTERY VOLTAGE

Low battery voltage

Battery voltage less than 16 volts.

Corroded battery terminal.

Loose battery or controller terminal.

4,2

OVERVOLTAGE

Overvoltage

Battery voltage greater than 45 volts.

Vehicle operating with charger attached.

4,3

THERMAL CUTBACK

temperature out of operational range.

Temp above 85°C or below -25°C. Excessive vehicle load weight.

Incorrect mounting of controller.

Operations in extreme environments.

Crown 1998 PF11453-10

M4.6-4320-010

Printed in U.S.A.

M4.6-4320-010

CONTROLLER MAINTENANCE PROGRAMMER OPERATION The optional universal Curtis handheld programmer (Illustration 1) allows you to program, test, and diagnose Curtis PMC 1207 controllers. The programmer is powered by the host 1207 controller, via an RJ11 modular connector located in the adjustment panel on top of the controller.

When the programmer is first plugged into the controller, the brake switch must be open (brake applied) until the programmer has acquired all the controller parameters. After the data is uploaded the Curtis controller will flash a 1,2 status code until the brake switch is closed, after which the Main Menu (Illustration 2) appears which is the starting point for all basic programmer functions. If there are no entries within a Menu, then that Menu title will not be displayed.

MAIN MENU Program Monitor Faults Functions Information Programmer Setup 10468

DISPLAY SCREEN LCD screen capable of displaying up to 7 lines of text & graphics simultaneously.

MENU NAVIGATION KEY Moves screen cursor up or down through Menu list (top and bottom arrows), and opens or closes Sub Menus (right and left arrows).

DATA INC/DEC KEY Changes value of the parameter indicated by the cursor.

BOOKMARK KEYS Allow you to quickly go back to your favorite selections without having to navigate back through the Menu.

10466

ILLUSTRATION 2

ILLUSTRATION 1

020923

4053 - EO7709

Crown 2002 PF13421-1

Printed in U.S.A.

M4.6–4320–015

M4.6–4320–015

CONTROLLER MAINTENANCE The blinking square indicates the location of the cursor.

When at the top-level Menu only one column of cursor positions exist. Additional columns will be shown using the 4directional Menu Navigation Key to go deeper into the Menu structure. Using the right arrow on the Menu Navigation Key to enter a Main Menu Title brings up a Sub-Menu indented to the right and displayed in a second column. (Illustration 3)

Program MAIN C/L L/S MAIN C/L PLUG C/L L/S PLUG C/L ACCEL RATE CREEP SPEED 10469

250A 250A 80A 80A 0.6s 11%

ILLUSTRATION 3

From this Sub-Menu you can go to another Sub-Menu using the right arrow on the Menu Navigation Key to a screen with additional information and bar graph. (Illustration 4)

P# 113

Program

MAIN LIMIT

250 Amp Min 20 10470

Max 250 ILLUSTRATION 4

To change the value of the parameter use the Data Inc/Dec Key. Use the left arrow on the Menu Navigation Key to back out of the Sub-Menus to the Main Menu.

To bookmark a position in the Menu, hold down a Bookmark Key for 3 seconds, until the Bookmark set screen is displayed. After bookmark is set use the appropriate Bookmark Key to jump to the wanted bookmark position. The bookmarks are not permanently stored and are cleared when the programmer is unplugged.

Crown 2002 PF13421-2

M4.6–4320–016

Printed in U.S.A.

M4.6–4320–016

CONTROLLER MAINTENANCE PROGRAMMER MENUS The Main Menu is the starting point for all Curtis programmable products. All basic functions are readily accessed from this point.

Program Menu The Program Menu may contain several Sub-Menus of parameters. The unit is setup with specific operating conditions using the Curtis handheld programmer in this Menu. (not all items available on all controllers) MAIN C/L L/S MAIN C/L PLUG C/L L/S PLUG C/L EMR REV C/L L/S EMR REV C/L RAMP C/L L/S RAMP C/L ACCEL RATE THROTTLE TYPE CREEP SPEED LOW SPEED EMR REV SPEED SEQUENCING DLY VARIABLE PLUG HIGH PEDAL DIS SRO ANTI-TIEDOWN QUICK START

Crown 2002 PF13421-3

M4.6–4320–017

Main current limit Low speed main current limit Plug current limit Low speed plug current limit Emergency reverse current limit Low speed emergency reverse current limit Ramp start current limit Low speed ramp start current limit Acceleration rate, in seconds Throttle type Creep speed, as percent of full throttle Low speed, as percent of full throttle Emergency reverse speed, as percent Sequencing delay, in seconds Throttle-Variable plug braking: on or off High pedal disable (HPD) Static return to off (SRO) Anti-tiedown: on or off Quick-start throttle factor

Printed in U.S.A.

M4.6–4320–017

CONTROLLER MAINTENANCE Monitor Menu The Monitor Menu contains a list of all variables that can be read and displayed. (not all items available on all controllers) THROTTLE % BATT VOLTAGE HEAT SINK °C BRAKE INPUT SPEED IN EMR REV INPUT FORWARD INPUT REVERSE INPUT FWD CONT REV CONT MAX TEMP °C MIN TEMP °C

Throttle reading, in percent of full Battery voltage Heatsink temperature Brake switch: on/off Speed switch: on/off Emergency reverse switch: on/off Forward switch: on/off Reverse switch: on/off Forward contactor: on/off Reverse contactor: on/off Maximum temperature seen * Minimum temperature seen *

* Maximum/minimum temperatures recorded since Diagnostic History was last cleared.

Faults Menu The Faults Menu provides the present status and access to past fault history.

SYSTEM FAULTS FAULT HISTORY CLEAR FAULT HISTORY This is not a menu as such, but simply a list of the possible messages you may see displayed when the programmer is operating in Faults Menu. The messages are listed in alphabetical order for easy reference.

BRAKE DRIVER OC BRAKE FAULT CAN C/L CODE INPUT CONFIG LOST CUR MEASURE DRIVE THROTTLE FRAM FAULT FRAM WARNING GATE HARDWARE FAILSAFE 1 HARDWARE FAILSAFE 2 INHIBIT LEFT POWER FAULT LOW BATTERY VOLTAGE MAIN CONT DRVR OC MAIN CONT FAULT MOTOR COVER WARNING MOTOR SHORT

Crown 2002 PF13421-4

M4.6–4320–018

MOTOR STALL NO KNOWN FAULTS OVERVOLTAGE PRESENCE SENSOR RIGHT POWER FAULT SFW SRO FAULT STEER THROTTLE THERMAL HIGH THERMAL LOW THERMAL WARNING

Printed in U.S.A.

M4.6–4320–018

CONTROLLER MAINTENANCE Functions Menu The Curtis handheld programmer can also be used to copy data between units, reset data and many other functions unique to the unit.

SETTINGS - GET SETTINGS FROM CONTROLLER - WRITE SETTINGS TO CONTROLLER - RESET ALL SETTINGS Information Menu When the Curtis handheld programmer is connected to the unit information, such as software, hardware and parameter block versions are also uploaded.

MODEL # SERIAL # MFG DATE SOFTWARE VERSION Programmer Setup Menu There are several setup options and information that can be accessed in this Menu.

PROGRAM - LCD CONTRAST - LANGUAGE INFORMATION - OEM INFO - RECONFIGURED - MODEL # - SERIAL # - MFG DATE - SOFTWARE VERSION - HDWE VERSION - MC - PROTOCOL VERSION - ES - PROTOCOL VERSION - S - PROTOCOL VERSION - DEVICE TYPE

Crown 2002 PF13421-5

M4.6–4320–019

Printed in U.S.A.

M4.6–4320–019

CONTROLLER MAINTENANCE Controller Settings: WE 1135kg (2500 LBS.), WS 1360kg (3000 LBS.) Parameter

Range

Access

Setting

Units

C/L Main

20 - 250

User

180

Amps.

C/L Low Speed Main

20 - 250

User

100

Amps

C/L Plug

20 - 250

User

110

Amps.

CL Low Speed Plug

20 - 250

User

60

Amps.

C/L Emergency Reverse

20 - 250

*OEM

140

Amps.

C/L Low Speed Emergency Reverse

20 - 250

*OEM

110

Amps.

C/L Ramp Start

20 - 250

*OEM

180

Amps.

C/L Low Speed Ramp Start

20 - 250

*OEM

90

Amps.

Acceleration Rate

0-3

User

1,0

Seconds

Quick Start Throttle Factor

0-6

*OEM

0

Throttle type

See Specifications

*OEM

2

Type

Ramp Shape

30 - 70

*OEM

50

%

Creep Speed/Minimum duty

0 - 25

User

0

%

Low Speed

40 - 100

*OEM

40

%

High Speed

40 - 100

*OEM

100

%

Emergency Reverse Speed

25 - 100

*OEM

30

%

0-3

*OEM

0

Seconds

ON/OFF

*OEM

ON

High Pedal Disable

0/1/2

*OEM

0

Static Return To Off (SRO)

0/1/2

*OEM

0

Anti-Tie Down

ON/OFF

*OEM

OFF

Emergency Reverse (BB) Check

ON/OFF

*OEM

Shunt Field Drive Output

ON/OFF

*OEM

Shunt Field Delay

0,0 - 0,5

*OEM

Sequencing Delay Variable Plug

Seconds

Input Polarities

F, R, SS Brake, *OEM EMR, R *Accessible with OEM handset only. Do Not adjust without first obtaining factory authorization. Failure to do so will result in Warranty being Voided.

Crown 2002 PF13421-6

M4.6–4320–020

Printed in U.S.A.

M4.6–4320–020

CONTROLLER MAINTENANCE Controller Settings: WE 1360kg (3000 LBS.), WS 1815kg (4000 LBS.) Parameter

Range

Access

Setting

Units

C/L Main

20 - 250

User

220

Amps.

C/L Low Speed Main

20 - 250

User

140

Amps

C/L Plug

20 - 250

User

120

Amps.

CL Low Speed Plug

20 - 250

User

70

Amps.

C/L Emergency Reverse

20 - 250

*OEM

160

Amps.

C/L Low Speed Emergency Reverse

20 - 250

*OEM

110

Amps.

C/L Ramp Start

20 - 250

*OEM

250

Amps.

C/L Low Speed Ramp Start

20 - 250

*OEM

100

Amps.

Acceleration Rate

0-3

User

1,0

Seconds

Quick Start Throttle Factor

0-6

*OEM

0

Throttle type

See Specifications

*OEM

2

Type

Ramp Shape

30 - 70

*OEM

50

%

Creep Speed/Minimum duty

0 - 25

User

0

%

Low Speed

40 - 100

*OEM

40

%

High Speed

40 - 100

*OEM

100

%

Emergency Reverse Speed

25 - 100

*OEM

30

%

0-3

*OEM

0

Seconds

ON/OFF

*OEM

ON

High Pedal Disable

0/1/2

*OEM

0

Static Return To Off (SRO)

0/1/2

*OEM

0

Anti-Tie Down

ON/OFF

*OEM

OFF

Emergency Reverse (BB) Check

ON/OFF

*OEM

Shunt Field Drive Output

ON/OFF

*OEM

Shunt Field Delay

0,0 - 0,5

*OEM

Sequencing Delay Variable Plug

Seconds

Input Polarities

F, R, SS Brake, *OEM EMR, R *Accessible with OEM handset only. Do Not adjust without first obtaining factory authorization. Failure to do so will result in Warranty being Voided.

Crown 2002 PF13421-7

M4.6–4320–021

Printed in U.S.A.

M4.6–4320–021

CONTROLLER MAINTENANCE WE/WS LED Status Codes LED Code

LCD Display

Explanation

Possible Cause

1,2

HW FAILSAFE

Hardware fail-safe error

Defective controller

1,3

M-FAULT

M-output shorted

Output shorted to ground.

Direction contactor not closing.

Direction contactor closing too slow.

Internal motor short to ground.

1,4

SRO

SRO Fault

Wrong sequence of KSY, brake, or direction inputs.

Wrong SRO type selected.

Brake or direction switch circuit open.

Sequencing delay too short.

2,1

THROTTLE FAULT 1

5-0 volt or wiper fault

Throttle input wire open.

Throttle input wire shorted to ground or B+.

Defective throttle potentiometer.

Wrong throttle type selected.

2,2

BB WIRING CHECK

Emergency reverse wiring fault.

BB wire open.

BB check wire open.

2,3

HPD

HPR sequencing fault

Wrong sequence of KYS, brake, or throttle inputs.

Incorrect HPD type selected.

Misadjusted throttle potentiometer.

2,4

THROTTLE FAULT 2

Potentiometer shorted or broken.

Potentiometer Low wire open.

Potentiometer Low wire shorted.

Incorrect throttle type selected.

3,1

CONT DRVR OC

Driver output overcurrent

Direction contactor coil shorted.

Shunt field shorted.

3,2

DIR CONT WELD

Welded direction contactor

Direction contactor stuck closed.

3,4

MISSING CONTACTOR

Missing contactor or shunt

Direction contactor coil open.

Direction contactor missing.

Shunt field open.

Wire to shunt or direction contactor is open.

4,1

LOW BATTERY VOLTAGE

Low battery voltage

Battery voltage less than 16 volts.

Corroded battery terminal.

Loose battery or controller terminal.

4,2

OVERVOLTAGE

Overvoltage

Battery voltage greater than 45 volts.

Vehicle operating with charger attached.

4,3

THERMAL CUTBACK

temperature out of operational range.

Temp above 85°C or below -25°C. Excessive vehicle load weight.

Incorrect mounting of controller.

Operations in extreme environments.

Crown 2002 PF13421-8

M4.6–4320–022

Printed in U.S.A.

M4.6–4320–022

ELECTRICAL MAINTENANCE UNIGAGE

0

LED BATTERY CHARGE INDICATOR

1

+

–

HOUR METER FAULT DATA

1/10

DISPLAY FACE

LIFT INTERRUPT CONTROLS A

K L

B E

D C RESET

M N

P O DISCHARGE

1

8

9

15

CONNECTOR CA10

DISPLAY BACK 1062-01

931206

4061LH - 37800

Crown 1993 PF-9988-1

Printed in U.S.A.

M4.6 - 6435 - 001

M4.6 - 6435 - 001

ELECTRICAL MAINTENANCE BATTERY DISCHARGE INDICATOR/LIFT INTERRUPT • Unlike previous lift interrupts, this unit contains the controller and meter in the same housing.

• The purpose of a Battery Discharge Interrupt is to monitor and protect the battery as well as electrical components of the truck. To protect the battery, the discharge cycle must not exceed 80% discharge (1.73 volts per cell [VPC] electrolyte temperature at 77 degrees F [25 degrees C] and battery under full current load).

Meter 25 - 30% CHARGE 100% CHARGE 50 - 55% CHARGE

YELLOW

GREEN

• When the yellow LED next to the green LED is illuminated, enough battery charge remains to allow time for the operator to return to the charging area to recharge the trucks battery or to exchange for a fully charged battery.

• When the control turns on the last yellow LED, the two yellow LED’s alternately flash and the control locks out the lift contactors. At this point the battery must be recharged or exchanged for a fully charged battery to resume truck operation.

1063-01

Controller

• Control has 2 adjustments, RESET and DISCHARGE. • The DISCHARGE setting is how far the battery can be discharged before K L A M lift lockout occurs. The control comes set from the factory with DISB N CHARGE at N. The DISCHARGE setting of N equals 1.73 VPC, 20.9 volts E D C P O open circuit voltage for 24 volt batteries, 31.32 volts open circuit voltage for RESET DISCHARGE 36 volt batteries. The specific gravity (SG) of the battery at 1.73 VPC is 8 1 approximately 1150 SG electrolyte temperature at 77 degrees F (25 9 15 degrees C) and battery under full current load. This setting represents the 80% discharge point of the battery and is the level that recharge is recommended. Discharge beyond this level can cause permanent damage to the battery.

• The RESET setting is the amount of charge the battery must have to reset of the control. The control comes set from the factory with RESET at B. The RESET setting of B equals 2.09 volts per cell (VPC), 25.2 volts open circuit BACK OF DISPLAY 1101-01 voltage for 24 volt batteries, 37.8 volts open circuit voltage for 36 volt batteries. The specific gravity (SG) of the battery at 2.09 VPC is approximately 1250 SG electrolyte temperature at 77 degrees F (25 degrees C) and battery under full current load.

• A battery’s condition, or capacity, will decline due to age and/or improper maintenance making a 2.09 VPC reading not possible. To utilize a battery in this condition it is necessary to make a RESET adjustment toward A. Refer to Chart 1 for voltages of each setting. The DISCHARGE setting can also be changed to allow the battery to go deeper into discharge or not as far into discharge. Refer to Chart 1 for voltages of each setting.

Crown 1993 PF-9988-2

M4.6 - 6435 - 002

Printed in U.S.A.

M4.6 - 6435 - 002

ELECTRICAL MAINTENANCE

CAUTION

The RESET and DISCHARGE adjustment should only be done to allow time to make necessary repairs to the battery. Continued use could cause permanent damage to the battery, charger and truck.

K L

A

M

B

N P

E

O

1103

Allowing battery to go deeper into discharge will permanently damage battery and possibly the electrical components on the truck.

If a battery capable of resetting the control is connected to the truck, it will take approximately 10 seconds before the meter will read properly and for reset to occur. If a discharged battery is then connected to the truck, it will take approximately 36 minutes before lock-out will occur. This additional discharge to the battery can cause severe component and battery damage due to deep discharge.

K L M N O P

C

1104

DISCHARGE

CAUTION

D

1.56 1.63 1.68 1.73 1.78 1.82

PRESET TO N

RESET FULL CCW A B C D E

2.00 2.06 2.09 2.12 2.15 2.18

PRESET TO B CHART 1

TROUBLESHOOTING

CONNECTOR TERMINAL

1

8

9

15

Connector CA601 1102

Crown 1993 PF-9988-3

M4.6 - 6435 - 003

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

SIGNAL Battery Voltage Keyswitch No Connection Jumper to terminal 15 on 12 volt trucks No Connection Lift lock out Lift lock out Battery Negative No Connection No Connection Traction Hour Register No Connection No Connection No Connection Jumper to terminal 4 (12 volt)

Printed in U.S.A.

M4.6 - 6435 - 003

ELECTRICAL MAINTENANCE

SYMPTOM:

CHECK:

Gage will not reset.

Check battery state-of-charge, both voltage and specific gravity. The B setting equals 2.09 volts per cell. Batteries charged to 1250 SG with the electrolyte temperature at 77 degrees F (25 degrees C) and battery under full current load or better will have this voltage. The A setting equals 2.06 volts per cell equaling a 1210 SG with the electrolyte temperature at 77 degrees F (25 degrees C) and battery under full current load. If a battery is not able to produce reset at the A setting, the battery and/or charger must be checked.

Truck comes in too soon for a battery change.

Check specific gravity of battery when the meter's yellow LEDs flash. Do not turn the DISCHARGE setting towards K if the specific gravity of the battery corresponds to more than 80% discharge (1150 SG for most batteries with the electrolyte temperature at 77 degrees F [25 degrees C] and battery under full current load). More running time can be obtained by turning the DISCHARGE setting from N towards K, providing the battery does not show 80% discharge.

Lift is not disabled when yellow LED’s are flashing. Check wiring, relay and meter.

Crown 1993 PF-9988-4

M4.6 - 6435 - 004

Printed in U.S.A.

M4.6 - 6435 - 004

C

MOTOR MAINTENANCE

General

Compound Motor

The pump and drive motors are compound wound motors.

A compound motor has two (2) field windings, as shown in Illustration 2. One is a shunt field connected in parallel with the armature; the other is a series field that is connected in series with the armature. The shunt field gives this type of motor the constant speed advantage of a regular shunt motor. The series field gives it the advantage of being able to develop a large torque when the motor is started under heavy load. It should not be a surprise that the compound motor has both shunt and series motor characteristics.

Shunt Motor A shunt motor is connected in the same way as a shunt generator. The field windings are connected in parallel (shunt) with the armature windings. The circuit for a shunt motor is shown in Illustration 1.

Input Voltage

When the shunt field is connected in parallel with the series field armature, it is called a long shunt as shown in Illustration 2. Otherwise, it is called a short shunt.

Shunt Field Armature

Input Voltage

ILLUSTRATION 1

Once the speed has been set on a D.C. shunt motor, the speed remains relatively constant even under changing load conditions. One reason for this is that the field flux remains constant. A constant voltage across the field makes the field independent of variations in the armature circuit.

If the load on the motor is increased, the motor tends to slow down. This decreases the counter emf generated in the armature. This decreases the opposition to the flow of battery current through the armature. Armature current increases, causing the motor to speed up. The conditions that established the original speed are re-established, and the original speed is maintained.

Conversely, if the motor load is decreased, the motor tends to increase speed; counter emf increases, armature current decreases, and the speed decreases.

In each case, all of this happens so rapidly that any actual change in speed is slight. There is an instantaneous tendency to change rather than a large fluctuation in speed.

Series Field

Input Voltage

Shunt Field Long

Shunt Wound D.C. Motor 6846

Series Field

Shunt Field Short

Armature Long Shunt

Armature Short Shunt

Compound Wound D.C. Motor 6847

ILLUSTRATION 2

Pump Motor Removal (Refer to Illustration 3) 1. Disconnect battery and chock wheels.

2. Open power unit door.

3. Remove hydraulic tank cover.

4. Remove mounting hardware (10 & 11) on hydraulic pump (9).

5. Remove screws (2) and pump motor (1).

Installation (Refer to Illustration 3) 1. Inspect coupling (21) and replace as needed.

2. Inspect gasket (4) and replace as needed.

3. Replace gaskets 3 and 11.

4. Install screws (2 & 10) using sealant 053050-006 and tighten.

5. Finish assembling unit in reverse order of steps 1 thru 5.

7191 Printed in U.S.A.

Crown 1998 PF11463-1 Rev. 12/03

01 REV. 12/03

M4.7–4320–001

M4.7–4320–001

C

MOTOR MAINTENANCE Drive Motor Removal 1

1. Disconnect battery and chock wheels.

2. Raise and block truck.

3. Open power unit door.

4. Remove steering chain.

5. Disconnect all connections to brake.

6. Remove all electrical connections to motor.

7. Remove screws that secure drive unit to truck.

8. Remove drive unit from truck.

9. Remove gearbox.

10. Remove brake assembly from motor.

21 4

Maintenance 1. Open protective grill using snap on lever and place on top of motor.

2. Remove brush dust using dry compressed air.

3. Remove screws that secure brushes to motor and remove motor brushes.

4. Check length of motor brushes. Minimum brush length should be 15 mm (0.59 in.). Replace all brushes as needed.

5. Inspect commutator for wear.

6. Check motor brushes for smooth action, clean guides if necessary.

7. Inspect spiral springs for even compression pressure and discoloration, replace as needed.

3 2 9 11 10 6718-01

ILLUSTRATION 3

Maintenance Use the view hole on the side of motor and brush retaining tool (1) (803547) to check carbon brushes for wear and to ensure they are moving freely, replace brushes as needed.

Minimum brush length should be 11 mm (0.43 in.).

1

2

1

6699 6720

ILLUSTRATION 4

ILLUSTRATION 5 Printed in U.S.A.

Crown 1998 PF11463-2 Rev. 12/03

01 REV. 12/03

M4.7–4320–002

M4.7–4320–002

BATTERY MAINTENANCE WET CELL The care and maintenance of the battery is very important to obtain efficient truck operation and maximum battery life.

CAUTION

Gases produced by a battery can be explosive.

Do not smoke, use an open flame, create an arc or sparks in the vicinity of the battery. Ventilate an enclosed area well when charging.

Batteries contain sulfuric acid which may cause severe burns. Avoid contact with eyes, skin or clothing. In case of contact, flush immediately and thoroughly with clean water. Obtain medical attention when eyes are affected. A baking soda solution (one pound to one gallon of water) applied to spilled acid until bubbling stops, neutralizes the acid for safe handling and disposal.

Leakage voltage from battery terminals to battery case can cause misleading trouble symptoms with the truck electrical system. Since components of the truck electrical system are insulated from truck frame, leakage voltage will not normally affect truck operation unless a short circuit or breakdown of circuit wire insulation to truck frame occurs.

A voltage check from battery connector terminal to battery case should indicate near zero volts. Typically, however, the sum of the voltages at both terminals will equal battery volts.

This leakage voltage will discharge the battery. As battery cleanliness deteriorates, the usable charge of the battery decreases due to this self discharge.

Although a leakage voltage reading of zero volts may not be possible, a cleaner battery will have more usable charge for truck operation and not affect operation of electronic devices on the unit.

Safety Rules • Wear protective clothing, such as, rubber apron, gloves, boots and goggles when performing any maintenance on batteries. Do not allow electrolyte to come in contact with eyes, skin, clothing or floor. If electrolyte comes in contact with eyes, flush immediately and thoroughly with clean water. Obtain medical attention immediately. Should electrolyte be spilled on skin, rinse promptly with clean water and wash with soap. A baking soda solution (one pound to one gallon of water) will neutralize acid spilled on clothing, floor or any other surface. Apply solution until bubbling stops and rinse with clean water.

• Keep vent plugs firmly in place at all times except when adding water or taking hydrometer readings.

• Do not bring any type of flame, spark, etc., near the battery. Gas formed while the battery is charging, is highly explosive. This gas remains in the cells long after charging has stopped.

• Do not lay metallic or conductive objects on battery.

Arcing will result.

• Do not allow dirt, cleaning solution or other foreign material to enter cells. Impurities in electrolyte has a neutralizing effect reducing available charge.

• If battery repair is planned, follow the battery manufacturer's instructions concerning repair practices and procedures.

Checking Battery electrolyte level should be checked before each charge of the battery. The level should be maintained at onehalf inch above plates or just below the lower lip of the filler hole at all times. If low, add distilled water or approved local supply (consult battery manufacturer) at the end of a charge cycle. Do not overfill. For maximum battery life, specific gravity readings should be taken daily on a pilot cell and recorded. A different pilot cell should be selected on a monthly basis with readings taken on all cells at semi annual or annual intervals. Do not take specific gravity readings immediately after adding water. Water and electrolyte must be thoroughly mixed by charging before a reliable reading can be taken. Normal full charged specific gravity should be between 1.265 and 1.285.

5790 Crown 1998 PF11464-1

M4.8–4320–001

Printed in U.S.A.

M4.8–4320–001

BATTERY MAINTENANCE BATTERY CARE

CHARGING

Your truck is powered by an electrical storage battery. Here are a few suggestions which will help you give the battery proper care.

Charging requirements will vary depending on use. A battery with a specific gravity of 1.160 should be recharged. In some applications more than one battery is required to provide ample power to the unit during the service period.

The battery is located between mast and power unit.

CAUTION 1. Charge the battery only in areas designated for that use.

2. Make certain the charger being used matches the voltage and amperage of the truck battery. This voltage is listed on the truck serial plate.

3. Before disconnecting or connecting batteries to a charger, make sure the charger is "OFF". If an attempt is made to do this while the charger is "ON", serious injury to you, the battery and charger could result.

4. Before charging, make sure the battery cells contain the correct amount of water. Charging batteries with a low water level might result in damage to the cells.

When checking water levels, never use a match or lighter. Battery fumes are explosive.

5. Before connecting the battery cable to the truck’s receptacle, make sure the key switch is off and all controls are in the off position and the brakes are locked. The battery cable must be fully connected before the truck is used. If the plug is not making good contact, heat will weld the two parts of the battery connector together, making it difficult to remove and necessary to replace.

6. Battery terminals should be checked and cleaned of corrosion regularly. Good battery terminal contact is essential not only for operation, but also for proper charging of the battery.

7. The charging requirements will vary depending on the use of the truck. The battery should be given an equalizing charge on a weekly basis. This charge should normally be an additional three hours at the finish rate.

8. Refer to charger manufacturer’s instruction for specific charging procedures.

9. Make certain battery used meets weight and size requirements of truck (refer to serial plate). NEVER operate truck with an undersized battery.

Crown 1998 PF11464-2

M4.8–4320–002

Never smoke or bring flame near the battery. Gas formed during charging is highly explosive and can cause serious injury.

Consult the charger manufacturer’s manual for hints on operation and maintenance. Some of the basic rules are as follows: Placing battery on charge: — Park truck at charging station with forks lowered and key removed.

— Make certain charger control is in the off position.

— Connect battery to charger and make certain connectors are mated completely.

— Set timer for specified time. Set for Normal (Daily Charge, except one night a week when the Equalize [Weekend] Charge should be used).

— Check ammeter to make certain it shows charge.

Removing battery from charge: — Make certain charger is turned off.

— Unplug the connector, using both hands with a straight pulling motion.

— Hang up the charger cable to prevent damage to the cable. (Broken connectors can cause poor connections and connector failures).

— Make daily battery checks, add water as needed.

— Connect battery to truck. Make certain connectors are mated completely.

BATTERY CLEANING Always keep vent plugs tightly in place when cleaning battery. When properly watered and charged, the battery will remain clean and dry. All that is necessary is to brush or blow off any dust or dirt which may accumulate on them. However, if electrolyte is spilled or overflows from a cell, it should be neutralized with a solution of baking soda and water (one pound soda to a gallon of water). To do this, remove battery from truck and clean with the solution of soda and water, brushing the soda solution beneath the connectors and removing grime from the covers. Then rinse the battery with cool water from a low pressure supply to remove the soda and loosened dirt. If batteries stay wet consistently, they may be either overcharge or overfilled. This condition should be investigated and corrected.

Printed in U.S.A.

M4.8–4320–002

BATTERY MAINTENANCE BATTERY INSTALLATION

TROUBLESHOOTING Records of battery specific gravity readings, charger used, truck used, etc. can be the most effective troubleshooting aid. Contact your dealer for charts designed specifically for this purpose.

Voltage readings of each cell taken at the normal charger finish rate also indicate battery condition. New batteries will have cell voltages ranging from 2.55 volts to 2.65 volts. Older batteries may however range from 2.45 volts to 2.55 volts.

These readings still indicate a battery in good condition.

A variation of .20 volts may be normal if certain cells are exposed to higher temperatures during discharge. Voltage differences that cannot be attributed to battery age or operating conditions indicate a weak cell(s) and maintenance is required.

CAUTION

Only qualified and experienced personnel should perform maintenance and repair on batteries.

CAUTION

Don’t allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing, installing or transporting the battery. Use an insulator (such as plywood) to cover the top of the battery before and during removal and installation.

1. Check to be sure key switch is turned off.

2. Remove battery retainer.

3. Position battery roller stand next to truck. Align stand with battery compartment. Battery roller stand should be the same height as the truck’s battery compartment rollers and as long as or longer than battery.

4. Using approved spreader bar, move battery onto roller stand and push battery into battery compartment.

5. Remove roller stand and install battery retainer.

BATTERY REMOVAL & INSTALLATION BATTERY REMOVAL

6. Connect battery.

7. Turn key switch on and check truck operation.

CAUTION

Don’t allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing, installing or transporting the battery. Use an insulator (such as plywood) to cover the top of the battery before and during removal and installation.

CAUTION

Make certain same battery or battery of equal weight is loaded into truck for truck stability. See nameplate for minimum battery weight.

1. Turn key switch off.

2. Disconnect battery.

3. Remove battery retainer (one side only).

4. Position battery roller stand next to truck. Align stand with battery. Battery roller stand should be the same height as the truck’s battery compartment rollers and as long or longer than battery.

5. Roll battery onto stand. Using approved spreader bar, lift and move battery to charging area.

Crown 1998 PF11464-3

M4.8–4320–003

Printed in U.S.A.

M4.8–4320–003

C

BATTERY MAINTENANCE FREE

GENERAL CAUTION Some WE/WS trucks may be equipped with maintenance free batteries. These batteries are completely sealed and will not require any watering.These batteries have a full 80% discharge available.

Gases produced by a battery can be explosive.

Do not smoke, use an open flame, create an arc or sparks in the vicinity of the battery. Ventilate an enclosed area well when charging.

The battery charger features an automatic start/stop charge cycle which will cause less battery damage resulting from over/under charging.

Batteries contain sulfuric acid which may cause severe burns. Avoid contact with eyes, skin or clothing. In case of contact, flush immediately and thoroughly with clean water. Obtain medical attention when eyes are affected. A baking soda solution (one pound to one gallon of water) applied to spilled acid until bubbling stops, neutralizes the acid for safe handling and disposal.

Battery The care and maintenance of the battery is very important to obtain efficient truck operation and maximum battery life.

Sealed Maintenance Free batteries contain a pressure release valve and under normal operating conditions do not require any special ventilation.

CAUTION

Do not try to open this battery or remove the pressure release valve.

In GNB battery, the sulfuric acid is absorbed within a glass separator, which acts like a sponge, and the gasses generated while on charge are recombined. Only under severe overcharging, such as connected to an improperly sized charger, will any significant amount of gasses be released from the battery. Also, being a valve regulated battery, it never requires watering.

Leakage voltage from battery terminals to battery case can cause misleading trouble symptoms with the truck electrical system. Since components of the truck electrical system are insulated from truck frame, leakage voltage will not normally affect truck operation unless a short circuit or breakdown of circuit wire insulation to truck frame occurs.

A voltage check from battery connector terminal to battery case should indicate near zero volts. Typically the sum of the voltages at both terminals will equal battery volts. This leakage voltage will discharge the battery. As battery cleanliness deteriorates, the usable charge of the battery decreases due to this self discharge.

Although a leakage voltage reading of zero volts may not be possible, a cleaner battery will have more usable charge for truck operation and not effect operation of electronic devices on the unit.

7206 Crown 1998 PF11465-1 Rev. 1/04

Printed in U.S.A.

03 REV. 1/04

M4.8–4320–025

M4.8–4320–025

C

BATTERY

Safety Rules CAUTION • Wear protective clothing, such as rubber apron, gloves, boots and goggles when performing any maintenance on batteries. Do not allow electrolyte to come in contact with eyes, skin, clothing or floor. If electrolyte comes in contact with eyes, flush immediately and thoroughly with clean water. Obtain medical attention immediately. Should electrolyte be spilled on skin, rinse promptly with clean water and wash with soap. A baking soda solution (one pound to one gallon of water) will neutralize acid spilled on clothing, floor or any other surface. Apply solution until bubbling stops and rinse with clean water.

• Do not bring any type of flame, spark, etc., near the battery. Gas formed while the battery is charging is highly explosive. This gas remains in cells long after charging has stopped.

• Do not lay metallic or conductive objects on battery.

Arcing will result.

• Do not touch uninsulated parts of DC output connector or battery terminals to avoid possible electrical shock.

• De-energize all AC and DC power connections before servicing the power pack.

• Charger is NOT for outdoor use. Do not expose charger to rain or snow or charge a frozen battery.

• Charger is designed to charge lead acid batteries ONLY. Attempting to charge dry-cell batteries may cause them to burst and result in personal injuries and property damage.

• Do not use charger if it has been dropped or otherwise damaged.

• Do not use an extension cord.

• If battery repair is planned, follow the battery manufacturer's instructions concerning repair practices and procedures.

Never smoke or bring flame near the battery. Gas formed during charging is highly explosive and can cause serious injury.

The charger is fully automatic. Disconnect battery from truck and plug into battery charger. Plug the charger into any 120V, 15 amp (230V if truck is equipped with 230V charger) AC outlet.

CAUTION

Make sure battery and charger plug are the same polarity. Reversing the two polarities could result in a blown fuse and/or charger damage.

When the battery is plugged in, the charger goes through a diagnostic self-test and then starts the charge cycle automatically. The "yellow" CHARGER ON and "red" INCOMPLETE LED's will illuminate. When battery reaches an 80% state of charge, the "yellow" 80% LED will illuminate. When battery is fully charged the "green" COMPLETE LED is illuminated.

To stop the charger anytime during charging process, press the "red" stop button on top of charger. If for any reason charging is not completed within 16 hours, or if an overcurrent condition occurs, the "red" ABNORMAL LED will illuminate. Press stop button to clear and press again to restart charger.

Indicator Lamp Self-Test Sequence AC Power Applied

Checking Battery(s) should be checked for corroded terminals, cracks, and inter-tier cable connections.

CHARGING Charging requirements will vary depending on use of truck.

It will take 10 hours to charge an 80% discharged battery.

Before connecting or disconnecting battery to charger, make sure the battery charger is "off" to prevent any arcing.

All 5 LED's will flash 3 times, then each LED will flash individually once, then all LED's will be off.

Charger is now ready for use.

AC and DC Power Applied and Battery Plugged into Charger All 5 LED's will flash 3 times, then each LED will flash individually checking AC power. With battery connected, all 5 LED's will flash 3 times and after a 3-5 second delay the charger will turn on.

Refer to Troubleshooting Chart 1 for symptoms, possible cause(s) and possible solution(s).

Crown 1998 PF11465-2 Rev. 1/04

Printed in U.S.A.

03 REV. 1/04

M4.8–4320–026

M4.8–4320–026

C

BATTERY Shut Down Fault Codes (Numeric Display On The 2 Digital LED)

Battery Pack Testing Following is a testing procedure for verifying the integrity of the battery pack.

• Fault Code 0: Manual stop button depressed.

1. Fully charge battery pack: allow 12 hours for full charge.

• Fault Code 1: Low volts per cell (less than 1.5VPC).

Over discharged battery or shorted cells within battery.

2. After charge is complete, again place battery pack on charge. The 80% charge light on the battery charger should come "on" within 5 minutes. Measure the overall battery voltage while on charge. Should be greater than 28.4 volts.

• Fault Code 2: High volts per cell; greater than 2.7VPC or 2.8VPC (set with 80% point). Mismatched battery/ charger condition occurs.

If the 80% charge light does not come "on", continue charging until light comes "on".

If the abnormal light comes "on", the charger is malfunctioning and should be replaced.

3. Turn charger "off" and measure the open circuit voltage of the battery pack. Should be 25.3 volts to 26.0 volts.

• Fault Code 3: Battery disconnected from the charger during charge without first depressing the Stop button.

• Fault Code 4: Charge time exceeded. When the battery voltage does not reach the gassing voltage within 9.0 hours.

• Fault Code 5: Low charging current. Charging current is less than approximately 3A. It may be due to a faulty DC connection or blown DC fuse.

4. Measure and record the voltage across each battery while lifting empty forks and also with key switch "off".

Each battery should be between 6.3 volts and 6.5 volts.

5. Replace any battery that measures less than 6.0 volts.

If there are batteries which are 0.3 volts lower than associated batteries, the battery pack could be showing signs of under charging.

6. Return truck to operation.

Crown 1998 PF11465-3 Rev. 1/04

Printed in U.S.A.

03 REV. 1/04

M4.8–4320–027

M4.8–4320–027

C

BATTERY Troubleshooting Chart

Symptom

Possible Cause

Possible Solution

Charger will not turn "ON" Does not go thru self-test

• Circuit breaker is open at circuit breaker panel • AC circuit breaker is open on charger • Loose or broken auxiliary winding

– Check for AC voltage, close.

Charger will not turn "ON" after self-test

Charger cycling between "ON" and "OFF"

• Charger is not connected to battery • Incorrect plug polarity between charger and battery • Loose DC connection to charger or circuit board • AC Voltage to charger is low • Defective circuit board • Low charging current

• AC line voltage too low • Defective SCR’s or circuit board Red abnormal LED flashes

• Output current is too high due to sudden short at charger output connector • SCR’s or circuit board failure

RED abnormal LED stays "ON"

• Battery not fully charged

• Battery and charger voltage doesn’t match • Shorted battery cell(s) • Broken or loose connection from battery to charger or circuit board Charger cannot be turned "OFF" will not "SHUT OFF"

• Loose or broken connection between stop button and circuit board • Defective stop button

• Defective SCR’s or circuit board Decreased run time

• Battery failure • Insufficient charge time

– Reset circuit breaker.

– Tighten and or repair connection.

Check winding connection, resistance and continuity.

– Connect battery to charger.

– Connect plugs according to polarity.

– Tighten connection, check resistance.

– Check for proper AC voltage.

– Replace circuit board.

– Battery and charger voltage do not match. Battery voltage is too high.

Make sure charger and battery voltage is properly matched.Reconnect battery to charger to reset voltage readings.

– Check for proper AC line voltage.

– Replace SCR’s or circuit board.

– Remove short circuit condition, press red stop button to clear flashing.

RED abnormal LED and press red start button to restart charger.

– Replace SCR’s or circuit board.

– Battery disconnected from charger before charge cycle was complete.

"Stop button not pushed".

– Match correct battery voltage to charger voltage.

– Check battery for open or shorted battery cells.

– Check for continuity. Tighten connections and restart charge cycle.

– Disconnect battery, remove AC power. Check for continuity and repair or tighten connection.

– Check with multi-meter, should read short when button is depressed. Replace if defective.

– Replace defective SCR’s or circuit board.

– Test batteries as described in Battery Pack Testing.

– Allow 10-12 hours charging time for battery pack to reach full charge.

CHART 1 Printed in U.S.A.

Crown 1998 PF11465-4 Rev. 1/04

03 REV. 1/04

M4.8–4320–028

M4.8–4320–028

C

CONNECTOR MAINTENANCE TOOLS

GENERAL The connectors used in this truck require special insertion and crimping tools. These tools can be purchased from Crown under the part numbers listed below.

6732

ILLUSTRATION 4

Crimping tool for contactors 117636.

6729

ILLUSTRATION 1

Extraction tool for contactors 803965.

803452-006

6733

ILLUSTRATION 5

The contactors are marked on the connector housing with numbers stamped on them. Insert the contactor with the crimped end showing towards the number until it has locked into the connector housing.

6730

ILLUSTRATION 2

Pin Housing

Crimping tool for contactors 803964.

803450-010 116858

6731

Male Housing

ILLUSTRATION 3

Extraction tool for contactors 117615.

6734

ILLUSTRATION 6

The contactors 1 to 3 are marked on the connector housing by stamped lines. Insert the contactor with the crimping showing away from the stamped lines until it has locked into the connector housing.

7203 Crown 1998 PF11472-1 Rev. 1/04

Printed in U.S.A.

01 REV. 1/04

M4.8–4320–050

M4.8–4320–050

C

CONNECTOR MAINTENANCE

Connector Designation (PC, JC, CA)

Connector Type

Part Number

Number of Pins

Male

803452-001

8

202,205

Male

803452-002

16

101, 203, 204

Male

803450-005

2

401, 402

Male

803450-006

4

404, 406, 407, 412

Male

803450-007

6

411

Male

803450-008

8

405, 410

Male

116851

16

403

Female

803450-001

2

401, 402

Female

803450-002

4

404, 406, 407, 412

Female

803450-003

6

411

Female

803450-004

8

410

Crown 1998 PF11472-2 Rev. 1/04

Printed in U.S.A.

01 REV. 1/04

M4.8–4320–051

M4.8–4320–051

C

BRAKE

GENERAL

Installation (Refer to Illustration 1 & 2)

The drive wheel brake is a disc brake and is mounted on top of the drive motor. The brake is directly mounted to the motor shaft. The brake is applied if no voltage is supplied to the coil.

The brake is released electromagnetically. The WE/WS 1135/1360 kg (2500/3000 lbs) trucks use two springs and caps. The WE/WS 1360/1815 kg (3000/4000 lbs.) trucks use four springs and caps. An axial force is created through compression springs and is transmitted to the armature disc.

The force generated by the springs and transmitted through the armature disc, clamps the rotor between the armature and friction plate. A magnetic force is created by applying power to the coil, which in turn effects the armature and compresses the springs. The rotor and therefore the brake is released.

NOTE Do Not let friction area of brake to come into contact with grease or oil.

1. Reverse steps 1 thru 11.

2. Set air gap.

3. Torque screws (9) to 9.5 Nm (7.0 ft. lbs.).

4. Set brake torque.

5. Verify brakes are working.

5 9.5Nm (7.0 ft. lbs.)

9

Removal (Refer to Illustration 1 & 2) 1. Disconnect battery and chock wheels.

0

0

Drive Wheel Brake

9.5Nm (7.0 ft. lbs.)

9

2. Raise and block truck so drive tire is off the floor.

1

3. Open power unit door.

4. Remove screws (9) on top of brake.

5. Remove seal ring (10).

8 3

6. Remove brake housing and friction insert.

4

7. Remove springs from retaining ring and remove hub (8).

2

8. Loosen adjustable holders (6).

9. Clean parts thoroughly.

6 6

10. Inspect armature disc (2), friction plate (11) and rotor for furrows, rips and burnt patches, replace parts as needed.

7

11. Measure thickness of brake lining. A minimum thickness of 7.3 mm (0.29 in.).

10

11

7.3mm (0.29 in.)

6724S-01

ILLUSTRATION 1

6723-02

Crown 1998 PF11466-1 Rev. 3/04

ILLUSTRATION 2

7858 Printed in U.S.A.

02 REV. 3/04

M5.0–4320–001

M5.0–4320–001

C

BRAKE

Brake Adjustment

1. Chock load wheels and open power unit doors to access brake assembly.

AIR GAP ADJUSTMENT The "air gap" is the distance between the magnet body and the armatures with the brake applied. As the brake pads and rotor wear normally, the air gap will increase and should be readjusted when it measures 0.2 mm (0.008 in.).

2. Using low pressure air, remove any dirt between armatures and magnet body.

3. Loosen (only) the brake assembly screws.

4. Rotate adjustable spacers evenly and adjust air gap to 0.2 mm (0.008 in.). Check gap near each spacer.

NOTE If the air gap measures more than 0.2 mm (0.008 in.), the brake may not release properly.

5. Tighten the brake assembly screws 9.5Nm (7.0 ft. lbs.).

6. Remove chocks and check operation.

Air gap adjustment can be performed as long as the brake pads and rotor function properly or until the adjustable spacer threads are fully engaged (adjustment limit reached).

To adjust gap (brake applied):

Springs

Spring Adjuster

Brake Torque 7.3 mm (0.29 in.)

Magnet

Air Gap 0.2mm (0.008 in.)

0.2mm (0.008 in.)

Air Gap Magnet Body

Adjustable Brake Spacers Assembly Screws 6737-01

Adjustable Spacer Feeler Gauge

6739-01

Hub

Rotor

Pad

ILLUSTRATION 4

Armature

ILLUSTRATION 3

Crown 1998 PF11466-2 Rev. 3/04

Printed in U.S.A.

02 REV. 3/04

M5.0–4320–002

M5.0–4320–002

C

BRAKE

STOPPING DISTANCE ADJUSTMENT

NOTE

The stopping distance of the truck should require minimal adjustment. However, this distance should be checked with each planned maintenance.

Using a warmed up empty truck, run truck up to it's top speed on an even dry concrete surface. Move control handle into the lower braking position. Measure length of braking path from the actuation point of the brakes until the truck has stopped. The length of the braking path should be between 800 – 1000 mm (2 ft. 7 in. – 3 ft. 3 in.).

Stopping distance may vary depending upon condition of brake, drive tire and floor surface conditions. The above is to be used as a guide for checking stopping distance on trucks.

To adjust stopping distance, proceed as follows: 1. Chock wheels. Open power unit door to access brake assembly.

2. Rotate the spring adjuster clockwise to SHORTEN the stopping distance or counterclockwise to LENGTHEN the stopping distance.

3. Remove load wheel blocks and check operation.

Troubleshooting

Sympton

Probable Cause

Remedy

Brakes will not release

• Air gap more than 0.2 mm (0.008 in.)

Adjust

• Brake temperature above 137.7 degrees C (280 degrees F)

Allow to cool and check air gap

• Open circuit in brake module circuitry or wiring

Make voltage checks at test points of the brake module

• Air gap less than 0.2 mm (0.008 in.)

Adjust

• Brake pad mounting plates or rotor distorted

Replace

• Armatures movement restricted by dirt, foreign material

Clean with low pressure air

• Pads soiled with grease

Replace

• Incorrect stopping distance adjustment

Adjust

• Brake pad mounting plates or rotor distorted

Replace

• Brake pads loose or soiled with grease

Replace

• Brake pad mounting plates or rotor distorted

Replace

Brakes drag

Brakes grab

Abnormal noise and chatter when brakes applied

• Brake pads worn out, loose, soiled with grease, Replace foreign material embedded • Rotor thin, cracked, or spline worn

Replace

CHART 1

Crown 1998 PF11466-3 Rev. 3/04

Printed in U.S.A.

02 REV. 3/04

M5.0–4320–003

M5.0–4320–003

C

STEERING MAINTENANCE

GENERAL

Chain Tensioner

The steering works by using two gears connected by a chain on the drive wheel. The chain is held under tension by a spring loaded chain tensioner. This construction ensures that lateral impacts against the drive wheel are dampened before being transmitted to the shaft. The dual universal joint compensates for the axle offset caused by the pivoting carriage.

Removal (Refer to Illustration 2)

Dual Cross Joint Steering

1. Disconnect battery and chock wheels.

2. Raise and block truck so drive tire is off floor.

3. Open power unit door.

4. Remove steering chain (1).

5. Remove dual universal joint.

6. Remove gear (1).

7. Remove chain tensioner (2).

Installation (Refer to Illustration 2)

Removal (Refer to Illustration 1) 1. Disconnect battery and chock wheels.

2. Raise and block truck so drive tire is off floor.

3. Open power unit door.

4. Mark the installation position of the shaft seating to the frame.

5. Mark the installation position of the chain gear (1) to the chain tensioner (2).

6. Remove the lower mounting hardware (7 & 8) and push gear down.

7. Remove the upper clamping mounting hardware (7 & 8).

8. Remove dual universal joint (6) from steering pivot.

1. Reverse steps 1 thru 7.

1

Installation (Refer to Illustration ) 12 2

1. Reverse steps 1 thru 8. Pay attention to markings made in steps 4 & 5.

11

7 8 6 6726

ILLUSTRATION 2

8 1 9 2

6725

12

ILLUSTRATION 1

7866 Crown 1998 PF11467-1 Rev. 3/04

Printed in U.S.A.

01 REV. 3/04

M6.0–4320–001

M6.0–4320–001

C

STEERING MAINTENANCE

Steering Chain 5

Removal (Refer to Illustration 3)

3

1. Disconnect battery and chock wheels.

2. Raise and block truck so drive tire is off floor.

3. Open power unit door.

4. Rotate shaft until chain catch link (10) is visible.

5. Mark the position of the drive wheel to the chassis.

6. Mark the installation position of the chain gear (1) to the chain tensioner (2).

7. Remove screw (12).

8. Insert device into hole on chain tensioner (2).

9. Press chain tensioner (2) against the compression spring (11) and secure with a wooden block.

10. Remove chain latch (10) and remove steering chain.

4 3 5

7

8

10 7

8 1

Installation (Refer to Illustration 3) 9

12

1. Pull steering chain around the drive motor pinion using an electrical fish tape.

2. Align chain gear (1) and drive wheel to markings made in steps 5 and 6.

3. Reverse steps 1 thru 10.

11 2 6727

Crown 1998 PF11467-2 Rev. 3/04

ILLUSTRATION 3

Printed in U.S.A.

01 REV. 3/04

M6.0–4320–002

M6.0–4320–002

CONTROL HANDLE Control Handle Removal (Refer to Illustrations 1 & 2)

Installation (Refer to Illustrations 1 & 2) Install control handle by reversing steps 1 thru 8.

CAUTION

Run operational check on control handle functions.

The control handle contains pre-loaded springs.

Remove tension from springs before removal to avoid injury.

1. Disconnect battery and chock wheels.

2. Disconnect PC205 in control handle.

1

3. Remove screws that secure knuckle cover to handle and push knuckle cover upwards.

4. Secure pivot pin (2) in position.

5. Remove pin (4) 6. Twist pivot pin (2) upwards to unload spring(s).

7. Push out pivot pin (2) and remove springs (3), pulley (4) and cable guide (6).

3 4 2

5 6

8. Remove control handle from truck.

6874S

ILLUSTRATION 2

1

Unload Spring(s)

2 3 4 6873S

ILLUSTRATION 1

5915 Crown 1998 PF11526

M6.0–4320–050

Printed in U.S.A.

M6.0–4320–050

C

MAST MAINTENANCE

GENERAL TL Mast The TL mast configuration consists of an outer and inner mast. Support is provided by two bearing mounted rollers on each of the inner and outer masts. The inner mast is raised by way of two mast cylinders attached to the external profiles of the outer mast. The fork carriage is mounted on four rollers and mounted to the inner mast.

The fork carriage is raised by a chain running across the carriage cylinder in a return roller. Because of the larger diameter of the carriage cylinder, initially only the fork carriage is raised in the inner mast. Once the full lift stroke has been reached, the mast cylinders take over the task of continuing the lift.

Mast Removal

CAUTION The fork carriage is raised indirectly by chains running on return rollers secured to the inner mast. The twin chain design creates a lifting ratio of the fork carriage to the inner mast of 2:1.

TF Mast The TF mast configuration consists of an outer and inner masts. Support is provided by two bearing mounted rollers on each of the inner and outer masts. The inner mast is raised by way of two mast cylinders attached to the external profiles of the outer mast. The fork carriage is mounted on four rollers and mounted to the inner mast.

The fork carriage is raised by a chain running across the carriage cylinder in a return roller. Because of the larger diameter of the carriage cylinder, initially only the fork carriage is raised on the inner mast. Once the full lifting stroke has been reached, the mast cylinders take over the task of continuing the lift.

Always block masts when working on masts in an elevated position, even though connected to a hoist.

1. Place truck under appropriate lifting device.

2. Lower fork carriage.

3. Disconnect battery and chock wheels.

4. Drain off hydraulic oil pressure.

5. Remove forks (WE only).

6. Disconnect all electrical connections to speed limiter switch (LMS).

7. Disconnect hydraulic lines from cylinders and seal connections.

8. Attach lifting device at top of all sections of the mast assembly.

9. Remove mounting screws that secure outer mast to power unit.

10. Remove mast and fork carriage assembly away from truck.

Installation

TT Mast The TT mast configuration consists of an outer, middle and inner mast. Support is provided by bearing mounted rollers on each of the inner, middle and outer masts. The first inner mast is raised directly by two mast cylinders secured behind the external profiles of the outer mast. The middle mast is raised indirectly by chains. The chains are attached by the piston rods of the mast cylinder and over return rollers. The chains are attached at top of the outer mast and at the bottom of the middle mast. The double chain design creates a lifting ratio between the first lifting and second lifting mast of 2:1.

The fork carriage is mounted on four rollers and the lift cylinders are mounted to the inner mast.

WARNING

Wear appropriate safety items, such as safety glasses and shoes, whenever performing maintenance. To avoid injury, do not place fingers, hands, arms or feet through mast or position them at pinch points.

1. Reverse steps 1 thru 10.

2. Torque outer mast mounting screws removed in step 9 to 80 Nm (59 ft. lbs.).

7867 Crown 1998 PF11468-1 Rev. 3/04

Printed in U.S.A.

02 REV. 3/04

M7.0–4320–001

M7.0–4320–001

C

MAST MAINTENANCE

Fork Carriage Removal

Mast Maintenance Lubricating Roller Tracks

WARNING

Wear appropriate safety items, such as safety glasses and shoes, whenever performing maintenance. To avoid injury, do not place fingers, hands, arms or feet through mast or position them at pinch points.

1. Lower fork carriage completely.

2. Disconnect battery and chock wheels.

3. Clean roller tracks.

4. Lubricate entire roller path.

Disassembling Column Rollers

1. Raise fork carriage approximately 510 mm (20.0 in.).

2. Disconnect battery and chock wheels.

3. Remove stay pins on chain anchor.

4. Lower fork carriage completely.

5. Remove tension on lift chain.

6. Remove chain screws on chain anchor.

7. Raise mast until fork carriage is clear of mast.

8. Secure mast and remove fork carriage.

Installation

1. Disassemble fork carriage or mast(s).

2. Remove column rollers, being careful not to damage or lose shims.

Assembling Column Rollers 1. Reverse steps 1 thru 2 to assemble column rollers.

2. Adjust column roller play on fork carriage and mast(s) as needed.

1. Reverse steps 1 thru 8.

2. Adjust lift chain tension.

Fork Carriage Adjustment 1. Raise fork carriage up to its end position.

2. Lower fork carriage slightly until fork carriage is free.

3. Press upper fork carriage roller against inner mast and secure with clamp.

3. Measure play between roller and spacer using a feeler gage. Nominal value should be 0 - 0.5 mm (0 - 0.02 in.).

Shimming Fork Carriage

WARNING

Wear appropriate safety items, such as safety glasses and shoes, whenever performing maintenance. To avoid injury, do not place fingers, hands, arms or feet through mast or position them at pinch points.

1. Disassemble fork carriage.

2. Insert spacers on upper right roller of fork carriage, until the play is between 0 - 0.5 mm (0 - 0.02 in.).

3. Install the same number of rollers on the lower right roller.

4. Assemble fork carriage.

5. Measure fork carriage play to verify play is between 0 0.5 mm (0 - 0.02 in.).

6. The fork carriage must not bind at the highest point on the mast when raised.

Crown 1998 PF11468-2 Rev. 3/04

Printed in U.S.A.

02 REV. 3/04

M7.0–4320–002

M7.0–4320–002

C

LOAD WHEEL

General

Tandem Axle Load Wheel

The non-driven wheels on WE/WS trucks run on permanently lubricated ball bearings which require no special maintenance.

Removal (Refer to Illustration 2) 1. Disconnect battery and chock wheels.

Single Axle Load Wheel

2. Raise and block truck.

Removal (Refer to Illustration 1)

3. Remove pin (15) on the axle (14).

1. Disconnect battery and chock wheels.

4. Remove axle (14) and load wheel (13).

2. Raise and block truck.

5. Remove rockers (12).

3. Remove pin (18) on the axle (17).

6. Remove bearing bushing (11).

4. Remove axle and load wheel (16).

Installation (Refer to Illustration 2)

Installation (Refer to Illustration 1)

1. Inspect bearing bushing (11) for wear and replace if necessary.

1. Reverse steps 1 thru 4 to assemble single axle load wheels.

2. Reverse steps 1 thru 6 to assemble tandem axle load wheels.

16

15

17

11

13

18

12 15

14

11 12 6703-01 6702-01

ILLUSTRATION 2

ILLUSTRATION 1

7856 Crown 1998 PF11478 Rev. 3/04

M7.4–4320–001

02 REV. 3/04

Printed in U.S.A.

M7.4–4320–001

LIFTING MECHANISM Lift Chain

Lift Chain Correct lift chain maintenance is necessary for the safe operation of the lift truck. It is necessary to do intermittent maintenance on the lift chains for the maximum service life. Incorrect maintenance intervals can cause unsatisfactory lift chain performance.

WARNING Falling loads can cause injury.

Lift chains, chain anchors, chain pins, and their attachments are safety components. Their failure can cause the load to fall, causing serious injury or death.  Replace damaged lift chains and their components with original spare parts before returning the lift truck to operation.  Always replace lift chains in pairs.

Cleaning and lubricating the lift chain See the INSPECTION AND LUBRICATION section for the applicable lubricant and planned maintenance intervals for the lift truck.

Note: The frequency of lubrication changes with the conditions of operation and environment.

Cleaning the lift chains Note: The initial factory lubricant on the lift chains prevents corrosion. Do not clean or remove the lubricant from the new lift chains.

Lubricating the lift chain Lubricate the lift chains at the specified maintenance intervals for maximum service life. A layer of lubricant between the chain components and on all lift chain surfaces is necessary to: – Decrease the wear on the joint

WARNING Cracks in the lift chains can cause injury Incorrect cleaning can cause cracks in the lift chain and can result in serious injury or death.  Do not clean lift chains with steam, cold cleaning agents, or agents that cause corrosion. This can damage the lift chains.  Clean the lift chains only with Crown chain and cable lubricant or Crown Premium chain and cable lubricant.

– Prevent corrosion – Decrease the frequency of turned pins – Decrease tight joints in the roller chain – Cause smooth lift chain movement – Decrease the lift chain tension Special tools and equipment: – Crown chain and cable lubricant, P/N 363107-001 – Crown premium chain and cable lubricant, P/N 363115-001 1. Spray the lubricant onto the lift chain.

WARNING Incorrect or missing safety procedures and safety equipment can cause death or injury.

Use the correct protective equipment and obey all safety procedures to do work on a lift truck.

2. See Figure 1. The oil must go into the lift chain joints (1).

– Lubrication on the lift chain and in the joints prevents wear and provides maximum service life.

 Obey all recommended safety precautions in the applicable Crown Service Manual.  Use the correct protective items, such as eye protection, work gloves, and safety-toe shoes.

Crown 2020 PF5856 Rev. 2/20

M7.5-18.0-001 10 Rev. 2/20

147

LIFTING MECHANISM Lift Chain

1

1

Fig. 1 (33490)

Inspecting the lift chain See the INSPECTION AND LUBRICATION section for the applicable lubricant and planned maintenance intervals for the lift truck.

Checking the lift chains for wear

Fig. 2 (33491)

Special tools and equipment:

4. Replace the lift chain if the elongation is more than 3% or will be more than 3% before the next maintenance interval.

– Chain wear scale, P/N 106440, or steel tape measure As the lift chain bends on and off the pulleys, the joints gradually wear. Material wears off the outside diameter of the pin and the inside diameter of the holes for the pins on the inner plates. This wear causes the lift chain to elongate.

Measuring the lift chains for wear with a chain wear scale

– Do not repair a chain link by removing a worn section of a lift chain and installing a new piece.

– If the lift truck has two lift chains, replace both lift chains at the same time.

– If a part of the lift chain is worn, replace both lift chains at the same time.

1. Raise the forks 152 mm (6 in).

2. Select a section of the lift chain that moves over a pulley during operation.

3. See Figure 2. Measure the lift chain with a chain wear scale (1).

– Use Scale A for lift chains with a pitch of 19 mm (0.75 in) or 25 mm (1.0 in) – Use Scale B for lift chains with a pitch of 16 mm (0.625 in) Note: The pitch is the distance between the pins.

M7.5-18.0-002 10 Rev. 2/20

148

Crown 2020 PF5856 Rev. 2/20

LIFTING MECHANISM Lift Chain Measuring the lift chains for wear with a steel tape measure 1. Raise the forks 152 mm (6 in).

2. Select a section of the lift chain that moves over a pulley during operation.

3. See Figure 3. Measure the lift chain pitch (1) from the center to the center of two chain pins of an outer plate.

Checking the lift chain elongation 1. Using the chain link number found in the Lift Chain Wear table, count the chain links on the lift truck.

2. See Figure 3. Measure the length (2) from the center of the first chain pin to the center of the last chain pin.

Note: The pitch is the distance between the pins.

3. Calculate the percent of lift chain elongation (x).

Percent of the lift chain elongation = [measured length /(new length/100)]-100 Example: The lift chain pitch is 25 mm (1.0 in). The Lift Chain Wear table shows that the new length for this lift chain pitch is 305 mm (12.0 in). The measured length with the steel tape measure is 309 mm (12.2 in). x = [309 / (305 / 100)] - 100 x = 309 / 3.05 - 100 x = 101.3 - 100 x = 1.3 In this example, the lift chain elongation is 1.3%.

4. Replace the lift chain if the elongation is more than 3% or if it will be more than 3% before the next maintenance interval. See the Lift Chain Wear table.

– Do not repair lift chains by removing a worn section of a lift chain and installing a new piece.

– If the lift truck has two lift chains, replace both lift chains at the same time.

– If a part of the lift chain is worn, replace both lift chains.

Fig. 3 (33492)

4. See the pitch value in the Lift Chain Wear table to find the number of chain links that are necessary for the measurement.

Lift Chain Wear Pitch

Chain Links

mm

in

25.4

1.0

19.05

New Length

Wear Limit

mm

in

mm

in

12

305

12.0

314

12.375

0.75

16

305

12.0

314

12.375

15.88 0.625

20

318

12.5

327

12.875

Crown 2020 PF5856 Rev. 2/20

M7.5-18.0-003 10 Rev. 2/20

149

LIFTING MECHANISM Lift Chain Checking the lift chains for damage Lift Chain Inspection Damage Example

Damage and Symptom Noise •

•

Mild squeaking or loud creaking during opera- • tion

Joint corrosion •

Cause

•

Red or brown color (1) • in the joint area

1

Surface corrosion •

2

Red or brown color (2) on the connecting plates

•

Insufficient lubrication in the lift chain joints

Solution 1. Check the lift chain elongation.

When the lift chain goes • over the pulley the movement in the joints causes friction.

If the lift chain is within the tolerance level, clean and lubricate the lift chain.

•

If the lift chain elongation is out of the tolerance level, replace the lift chain.

Insufficient lubrication

1. Replace the lift chain.

Grease or oils that do not 2. Lubricate the lift chain. go into the joint 3. Increase the frequency of the planned maintenance intervals.

Insufficient lubrication or anti-corrosion

1. Remove the corrosion from the lift chain with the correct cleaning agent.

•

If it is not possible to remove the corrosion, replace the lift chain.

2. Check the lift chain for pitting and other corrosion.

•

If other pitting is found or corrosion, replace the lift chain.

3. Increased frequency for planned maintenance intervals is necessary because of the conditions in the operating environment.

Images and technical information provided with the permission of Rexnord Kette GmbH • www.rexnord.com Figures 28009, 28010, 28011, 28012, 28013, 28014, 28015, 28016, 28017, 28018, 28019, and 28020 are used in this table.

M7.5-18.0-004 10 Rev. 2/20

150

Crown 2020 PF5856 Rev. 2/20

LIFTING MECHANISM Lift Chain Lift Chain Inspection Damage Example

Damage and Symptom Rigid joints •

3

4

•

Cause

Solution

Insufficient lubrication

1. Replace the lift chain.

The lift chain joints do not return to the extended position easily.

2. Increase the frequency of the planned maintenance intervals.

Turned lift chain pins

•

•

Note: Turned chain pins are 2. Increase the frequency a result of rigid joints. of the planned maintenance intervals.

One or more chain pins (4) turned.

Loose lift chain pins •

5

•

The lift chain is not aligned correctly and is operating against mast sections or at the side of the pulley.

•

The lift chains tension is not equal.

The outer plates (6) are worn down.

6

Nicks or distortion •

Insufficient lubrication

1. Replace the lift chain.

1. Replace the lift chain.

One or more chain Note: Loose chain pins are a 2. Increase the frequency pins (5) are protruding. result of rigid joints. of the planned maintenance intervals.

Too much outer wear •

•

Insufficient lubrication

Parts of the lift chain have nicks (7) or are distorted.

•

1. Measure the width of the wear zone and calculate the percentage of wear in relation to the overall width of the plate.

•

If the wear is greater than or equal to 5% of the full width, replace the lift chain. Correct the alignment of the lift components and pulleys after replacing.

•

If the wear is less than 5% of the full width, correct the alignment of the lift components and the pulleys.

The lift chain hits against 1. Remove the cause of parts of the mast. the nicks or distortion.

2. Replace the lift chain.

7 Images and technical information provided with the permission of Rexnord Kette GmbH • www.rexnord.com Figures 28009, 28010, 28011, 28012, 28013, 28014, 28015, 28016, 28017, 28018, 28019, and 28020 are used in this table.

Crown 2020 PF5856 Rev. 2/20

M7.5-18.0-005 10 Rev. 2/20

151

LIFTING MECHANISM Lift Chain Lift Chain Inspection Damage Example

Damage and Symptom Broken plates •

8

9

•

The head section of the plate is missing or • the crack is protruding.

Broken pins •

Cause

•

The outer plate (9) is lifted out a small distance

Solution

Fatigue crack because of 1. Find and correct the overload cause of the overload.

Corrosion

2. Replace the lift chain.

Pitting on the pins because of corrosion. Pitting permanently damages the pin.

1. Replace the lift chain.

1. Clean the lift chain and check for damage.

2. Increase the frequency of the planned maintenance intervals.

Note: These defects are not easy to see in the initial stages of inspection.

10

Contamination

•

Incorrect lubricant used.

•

•

The lift chain was not cleaned before lubrication.

A thick layer of dirt mixed with oil or grease (10) is on the lift chain.

•

If the lift chain is not damaged, lubricate it with the correct lubricant.

•

Replace the lift chain if it is damaged.

2. Increase the frequency of the planned maintenance intervals.

11

Hydrogen absorption

•

•

2.

Note: Electrolysis always makes hydrogen. Solvents made with chlorine also emit 3. hydrogen.

Non-distorting brittle fracture (11), only on the outer plate

Lift chain elongation •

•

The lift chain came into contact with hydrogen.

Wear caused by movement in the joints.

1. Replace the lift chain.

Check the operating conditions for sources of hydrogen.

See the cleaning the lift chains for instructions.

1. Replace the lift chain.

The lift chain elongaNote: Check if increasing tion check found the lift Note: This type of wear is the frequency of the chain to be out of the typical. planned maintenance intertolerance level. vals can increase the life of the lift chain.

Images and technical information provided with the permission of Rexnord Kette GmbH • www.rexnord.com Figures 28009, 28010, 28011, 28012, 28013, 28014, 28015, 28016, 28017, 28018, 28019, and 28020 are used in this table.

M7.5-18.0-006 10 Rev. 2/20

152

Crown 2020 PF5856 Rev. 2/20

LIFTING MECHANISM Lift Chain Replacing the lift chain 1. Find the part number for the lift chain in the service and parts manual. Make sure that the replacement lift chain is applicable to the lift truck.

Note: The lift chains must be replaced as a pair. Equal lift chain tension cannot easily be kept between the new lift chain and the existing lift chain.

2. If the lubricant dried or there is no lubricant, soak the new lift chains in heavy engine oil for a minimum of 30 min before installing.

3. After removing the existing lift chains from the mast, carefully examine the chain anchors and pulleys.

1. Use the grinding wheel to remove the top head of the pin (4) flush with the pin link plate (1). Be careful not to damage the pin link plate.

2. Put the flat washer (2) above the opening of the work surface.

– The flat washer holds the bottom pin link plate (1) and prevents damage to the lift chain components while pushing the pin through the lift chain.

3. Put the lift chain on its side and seat the pin in the flat washer (2).

4. Remove the pin from the lift chain through the top pin link plate (1).

4. Replace the chain anchors that are broken, cracked, or are worn.

3

5. Replace the pulleys that are worn and examine the pulley bearings for wear.

4

1

6. Do not paint the new lift chains.

7. Install the new lift chains with new pins. Do not use the existing pins.

8. After connecting the new lift chains to the chain anchors, adjust the lift chain tension for the correct fork or platform height.

– The correct lift chain installation and mast adjustment increase the service life.

Disconnecting a chain leaf

2 Fig. 4 (33505)

See Figure 4.

Special tools and equipment: – A stable work surface with an opening that is larger than the pin diameter. The work surface must be of sufficient thickness to let the pin (4) extend below the work surface to push it through the pin link plate (1) on the bottom.

– A flat washer (2) with an inside diameter more than the pin diameter and a height that is equal to the head height of the pin.

– A grinding wheel (3).

– A punch with a diameter that is less than the pin diameter.

– A hammer or press.

Crown 2020 PF5856 Rev. 2/20

M7.5-18.0-007 10 Rev. 2/20

153

Notes:

154

LIFTING MECHANISM Fork Inspection

Fork Inspection

WARNING If the fork locking pin is not fully engaged, the fork could become unintentionally disengaged.

DANGER This section shows causes of fork failure. Fork failure causes loss of equipment, damaged materials, bodily injury, and loss of life. Inspect and measure the forks at each planned maintenance interval to check for wear, overload, fatigue, bends, and so on.

WARNING

Abrasion See Figure 1.

Abrasion gradually reduces the thickness of the fork.

Make sure that the fork thickness is within the specifications. Do not allow the forks to rub against the floor during operation. If the forks rub the floor when the mast is vertical, then check the lift chain adjustment.

 Use the proper fork for how it was designed to be used.  Avoid using fork extensions.  Do not modify the forks.  Only qualified personnel can make repairs.  Visually inspect the forks each work day.

(a)

100 90 80 70 60 (b)

50 40 30 20 10 0

0

10

20

30

40

50

60

70

80

90

100

(c)

Fig. 1 (16858-02) (a)

Fork wear versus load capacity

(b)

Percentage remaining of specified fork load capacity

Fork wear at the fork heel must not exceed 10% of the original thickness. When the fork heel has worn 10% of the original thickness, 80% of rated capacity is the Crown 1988 PF7393 Rev. 10/21

(c)

Percentage reduction in fork blade thickness

maximum load that the forks can support. The rated capacity of the fork decreases exponentially as the fork wears. Use the fork wear calipers, a measuring instruM7.8-04.2-001 07 Rev. 10/21

329

LIFTING MECHANISM Fork Inspection

ment such as a vernier, or a quality 160 mm (6.0 in) scale. For allowable fork wear thickness, see the Allowable Fork Wear table.

2

Allowable Fork Wear Standard Fork Thickness

1

Allowable 10% Wear Fork Thickness

mm

in

mm

in

31.5

1.25

28.5

1.12

38.0

1.50

35.0

1.38

44.5

1.75

39.5

1.56

51.0

2.00

46.0

1.81

57.0

2.25

51.0

2.00

63.5

2.50

57.0

2.25

3

Fig. 3 (16855-02)

1. See Figure 4. To set the outside jaws, hold the calipers square across the shank and measure the thickness of the middle of the shank (1).

Measuring fork wear with the fork wear calipers Special tools and equipment: • Fork wear calipers, P/N 107330 See Figure 2. The fork wear calipers have two measuring points or jaws. The inside jaws (2) measure 10% less than the outside jaws (1).

1 Fig. 4 (16856-02)

1

2

2. See Figure 5. Check if the inside jaws of the calipers pass over the flanks of the fork blade at any point between the end of the taper and the heel of the fork blade (1).

Fig. 2 (16854-02)

See Figure 3. The fork wear calipers are used to measure the area (3) on the shank (2) to measure the fork blade (1). This area (3) on the shank (2) receives almost no wear.

1 Fig. 5 (16857-02)

3. Check the caliper setting again by measuring the shank. Make sure that the caliper setting did not change.

M7.8-04.2-002 07 Rev. 10/21

330

Crown 1988 PF7393 Rev. 10/21

LIFTING MECHANISM Fork Inspection

Overloading WARNING 1

Fork damage.

Overloading can cause permanent damage to the forks.  Know the load capacity of the forks and lift truck.

See Figure 6.

Fork load capacity and load center are stamped (1) on the fork.

2 Fig. 7 (16860-02)

1

2. Make a visual inspection for cracks during daily operator checks. When a more accurate inspection is necessary, use dye penetrants or Magnaflux.

3. Replace the forks when cracks are found.

Fig. 6 (16859-02)

Fatigue See Figure 7.

A fatigue crack starts in the fork heel area of the fork.

Cracks can be detected in the early stages by inspecting the fork heel area.

Inspecting the fork for fatigue 1. Check for cracks that go across the fork in an area up to 130 mm (5.0 in) either side of the outer fork heel radius (1) and (2). The cracks indicate that an area is weakened or damaged.

Crown 1988 PF7393 Rev. 10/21

M7.8-04.2-003 07 Rev. 10/21

331

LIFTING MECHANISM Fork Inspection

Bent or Twisted Forks Overloading, hitting solid objects, or picking up loads that are uneven can bend or twist the fork, resulting in replacing the fork. The maximum allowable difference in fork tip height from one fork to another is 3% of the fork length.

See Figure 8. The angle (1) between the top of the fork blade to the back surface of the shank must be less than 93°. Replace the fork if the angle is greater than 93°. Contact a Crown Equipment Corporation representative for additional information on repairing the forks.

the result in step 3, replace the fork. The dimension indicates that the fork is bent more than 93°.

Hanger See Figure 10.

1. Check for cracks or damage to the fork pins, spring, handle, and roll pin (1).

2. Check for cracks or damage to the area of fork attachment (2).

3. Check the fork carriage for excessive wear or cracks. Repair or replace parts if necessary.

WARNING If the fork locking pin is not fully engaged, the fork could become unintentionally disengaged.

1

4. Check the condition of the fork locking pin, spring, handle, and roll pin for proper operation, if the forks have these parts installed.

1

Fig. 8 (16861-02)

Using a carpenters square to check the fork 1. See Figure 9. Hold the square (1) against the shank above the radius of the fork heel.

1

2 Fig. 10 (16863-02)

2

3

Fig. 9 (16862-02)

2. Measure the distance (2) closest to the radius of the fork heel of the fork blade and square.

3. Add 31.8 mm (1.25 in) to this measurement and note the dimension.

4. Measure the distance (3) between the end of the square and blade. If the distance is greater than

M7.8-04.2-004 07 Rev. 10/21

332

Crown 1988 PF7393 Rev. 10/21

POWER UNIT COVERS MAINTENANCE

C GENERAL

Brake Switch (BRS) Cover

All covers and panels on this truck contribute towards operator safety or truck protection. They must be replaced in the event they are damaged or lost. The truck must not be operated without the corresponding covers in place.

Removal

Protective Cover Removal 1. Disconnect battery and chock wheels.

2. Remove mounting screws.

3. Remove protective cover.

1. Disconnect battery and chock wheels.

2. Remove mounting screws on handle switch cover.

3. Disconnect three connectors on switch cover and remove cover.

4. Remove screws that secure handle to truck and remove handle.

5. Remove screws that secure shaft cover to shaft and remove cover.

Installation 1. Assemble by reversing steps 1 thru 5.

Installation

Knuckle Cover Adjustment

1. Reverse steps 1 thru 3.

The edge of the shaft cover must be positioned approximately 5 mm (0.02 in.) below the adjacent covers.

Battery Cover Removal 1. Disconnect battery and chock wheels.

2. Remove mounting screws (1).

3. Remove battery cover (2) from the lower cover (3).

Installation

1. Disconnect battery and chock wheels.

2. Loosen mounting nuts on the knuckle.

3. Adjust knuckle up or down until a gap of 5 mm (0.02 in.) is achieved.

4. Tighten mounting nuts loosened in step 2 to 60 Nm (44.25 ft. lbs.).

1. Install replacement adhesive strips (4) to lower cover (3).

2. Insure that the slip-on nuts (5) are securely in place.

3. Complete assembly by reversing steps 1 thru 3.

1 2 1 5 4 3 5

6728

ILLUSTRATION 1 7192

Crown 1998 PF11471 Rev. 12/03

Printed in U.S.A.

01 REV. 12/03

M9.0–4320–001

M9.0–4320–001

C

CYLINDER MAINTENANCE

GENERAL CAUTION All cylinders used are designed as ram type cylinders i.e. without pistons. When the forks are raised the carriage cylinder with the larger diameter operates first since the movement takes place at a lower pressure.

All lift cylinders are equipped with velocity fuses which prevent the mast from suddenly dropping in the event of a hose break. Flow regulators fitted in the valve block regulate the lowering speed.

Don't allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing, installing or transporting the battery. Use an insulator (such as plywood) to cover the top of the battery before and during removal and installation.

3. Connect appropriate rated lifting device at center of the masts.

WARNING

WARNING

AVOID HIGH PRESSURE FLUIDS—Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.

Wear appropriate safety items, such as safety glasses and shoes, whenever performing maintenance work. To avoid injury, do not place fingers, hands, arms or feet through mast or position them at pinch points.

4. Remove hydraulic line through frame opening in the battery compartment.

5. Seal all hydraulic connections.

6. Remove retaining ring on cylinder that secures it to mast.

7. Raise mast until the cylinder is clear of mast.

8. Remove mounting screws on the cylinder holder and lift cylinder from the lower mounting.

Any fluid injected into the skin under high pressure should be considered as a serious medical emergency despite an initial normal appearance of the skin. There is a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately by a specialist who has had experience with this type of injury.

Carriage Cylinder

The utmost care and clean conditions are required when working with hydraulic cylinders. All operating surfaces must be free of dirt and oil. Seals and seal surfaces must be inspected carefully before assembly. Burrs and damage to edges to be covered by seals must be removed or repaired.

Seals must be lightly coated with acid free oil prior to installation.

Mast Cylinder Removal 1. Disconnect battery and chock wheels.

2. Remove battery.

Installation 1. Lower fork carriage completely.

2. Disconnect battery and chock wheels.

3. Provide appropriate oil collection container.

4. Disconnect hydraulic line from cylinder and seal hydraulic connections.

5. Raise fork carriage until lift chain is loose. Securely block fork carriage.

6. Remove lift chain from fork carriage and return roller.

7. Remove carriage cylinder mounting clamp and associated hardware.

8. Lift carriage cylinder out of its mounting hole.

9. Remove return roller from carriage cylinder.

7871 Crown 1998 PF11470 Rev. 3/04

Printed in U.S.A.

01 REV. 3/04

M8.0–4320–001

M8.0–4320–001

GLOSSARY WE/WS SERIES 2000 Components of the WE/WS Series 2000 truck have been listed in chart form to assist the maintenance mechanic in locating these components on the Electrical Diagrams and Exploded Parts pages.

The chart is in columns: COMPONENT; LOCATION; FUNCTION; DIAGRAM; PARTS PAGE. The COMPONENT column contains the abbreviation of the component as it appears on the Diagrams in the Maintenance Section. The LOCATION column gives the general location on the truck

such as on platform or in power unit. the FUNCTION column then explains the function or circuit of that device. The DIAGRAM column gives the page number of the diagram on which the component can be found. The callout in parenthesis following the page number corresponds to the grid callouts on that diagram, locating that component. The PARTS PAGE column includes the exploded parts page number on which the component is located along with the index number, in parenthesis, if applicable.

AUDIBLE INDICATORS Location

Function

Diagram

Parts Page

HN

Power Unit

Horn

DIA–4320–002 (B-1) DIA–1450–003 (C-3)

04.0–4320–001 (19)

Location

Function

Diagram

Parts Page

Power Unit

Power

DIA–4320–002 (B-4) DIA–4320–005 (B-4) DIA–4320–008 (A-1)

Function

Diagram DIA–4320–003 (A-1) DIA–4320–003 (A-3) DIA–4320–003 (B-4) DIA–4320–005 (C-1) DIA–4320–005 (C-3)

BATTERY

Battery

CONNECTORS Location CA201 CA202 CA203 CA204 CA205 CA206

Distribution Panel Distribution Panel Distribution Panel Distribution Panel Distribution Panel Manifold Block

CA401 CA402 CA403 CA404 CA405

Traction Controller Traction Controller Traction Controller Traction Controller Power Unit

Key Switch Override, Brake Switches SAS, Brake Switches HNS, RAS, LOS1 Switches SV2, Pump, LMS Switch SV3, RAS, LOS1/2 Switches PWM Logic S.F. Traction Motor BR Switch Inputs & Outputs LMS Switch Curtis Meter

CA406 CA407 CA410 CA411

Traction Controller Traction Controller Handle Handle

BRS Switch ORS Switch RAS, LOS1/2 HNS Switches SAS, RS, FS POT Switches

Parts Page

DIA–4320–007 (B-2) DIA–4320–006 (B-2) DIA–4320-006 (B-2) DIA–4320–005 (B-1) DIA–4320–006 (B-3) DIA–4320–003 (A-2) DIA–4320–004 (B-1) DIA–4320–006 (B-1) DIA–4320–006 (B-1 DIA–4320–004 (B-2) DIA–4320–004 (B-3)

5915 Crown 1998 PF11510-1 Rev. 11/98

Printed in U.S.A.

01 REV. 11/98

M10–4320–001

M10–4320–001

GLOSSARY CONTACTORS Location

Function

Diagram

Parts Page

F/R

Contactor Panel

Forward/Reverse

04.0–4320–001 (3) 04.4–4320–050

P

Hydraulic Assembly

Pump Contactor

DIA–4320–002 (B-4) DIA–4320–005 (C-4) DIA–4320–008 (B-3) DIA–4320–002 (B-2) DIA–4320–003 (C-3) DIA–4320–008 (B-2)

Location

Function

Diagram

Parts Page

FU1

Electrical Panel

Traction

04.0–4320–001 (9)

FU2

Distribution Panel

KYS

FU3

Hydraulic Assembly

Hydraulic Pump & Contactor

FU4

Distribution Panel

Curtis BDI-TT

FU5

Distribution Panel

Freezer/Corrosion

DIA–4320–002 (A-4) DIA–4320–005 (B-3) DIA–4320–008 (A-3) DIA–4320–002 (A-4) DIA–4320–003 (B-1) DIA–4320–002 (A-4) DIA–4320–008 (B-2) DIA–4320–002 (A-4) DIA–4320–003 (A-1) DIA–4320–002 (B-1) DIA–4320–003 (B-1)

04.0–4320–001 (24) 04.4–4320–001 04.4–4320–100 (F/C)

FUSES

04.0–4320–001 (29) 04.0–4320–001 (28) 04.0–4320–001 (26) 04.0–4320–001 (26)

MISCELLANEOUS Location

Function

Diagram

Parts Page

LO1 Driver Distribution Panel

SV2, Lower

04.0–4320–001 (14)

LO2 Driver Distribution Panel HNS Driver Distribution Panel

Lower Horn

RAS Driver Distribution Panel

Raise

Shunt Field Traction Motor Driver Brake Distribution Panel

Torque

PWM Logic Manifold Block

Raise/Lower

DIA–4320–002 (C-1) DIA–4320–003 (C-2) DIA–4320–003 (C-2) DIA–4320–002 (B-1) DIA–4320–003 (C-2) DIA–4320–002 (C-2) DIA–4320–003 (B-2) DIA–4320–002 (B-3) DIA–4320–003 (B-3) DIA–4320–002 (B-2) DIA–4320–006 (B-1) DIA–4320–002 (B-1) DIA–4320–007 (A-3)

Brake

04.0–4320–001 (14) 04.0–4320–001 (14) 04.0–4320–001 (14) 03.2–4320–001 (4) 04.0–4320–001 (14) 02.1–4320–100

MOTORS Location

Function

Diagram

Parts Page

TM

Drive Unit

Traction Motor

03.0–4320–001 (7) 03.2–4320–001

PM

Hydraulic Asm.

Lift Pump Motor

DIA–4320–002 (B-4) DIA–4320–006 (C-3) DIA–4320–008 (B-3) DIA–4320–002 (C-4) DIA–4320–003 (B-1) DIA–4320–008 (C-2)

Crown 1998 PF11510-2 Rev. 11/98

02.1–4320–001 (1) 02.9–4320–001 02.9–4320–050

Printed in U.S.A.

01 REV. 11/98

M10–4320–002

M10–4320–002

GLOSSARY

POTENTIOMETERS Location

Function

Diagram

Parts Page

POT

Travel

DIA–4320–002 (C-4) DIA–4320–004 (C-4)

04.2–4320–001 (13)

SOLENOIDS VALVES Location

Function

Diagram

Parts Page

SV2

Manifold Block

Raise/Lower

02.1–4320–100

SV3

Manifold Block

Proportional Valve

DIA–4320–002 (B-2) DIA–4320–003 (C-3) DIA–4320–002 (B-1) DIA–4320–007 (C-2)

Location

Function

Diagram

Parts Page

DIA–4320–002 (B-2) DIA–4320–006 (C-1) DIA–4320–002 (A-4) DIA–4320–005 (B-3) DIA–4320–002 (B-2) DIA–4320–004 (B-3) DIA–4320–002 (B-1) DIA–4320–004 (B-2) DIA–4320–002 (A-3) DIA–4320–003 (A-4) DIA–4320–002 (B-3) DIA–4320–006 (C-3) DIA–4320–002 (B-2) DIA–4320–004 (B-2) DIA–4320–002 (B-1) DIA–4320–004 (B-2) DIA–4320–002 (B-2) DIA–4320–006 (C-2) DIA–4320–002 (B-3) DIA–4320–004 (B-3) DIA–4320–002 (B-3) DIA–4320–004 (C-3)

04.2–4320–001 (11)

Control Handle

02.1–4320–100

SWITCHES

BRS

Control Handle (Base) Brake Switch

EDS

Power Unit (Top)

Emergency Disconnect

FS

Control Handle

Travel

HNS

Control Handle

Horn

KYS

Key Switch

LMS

Power Unit Top (Right Side) Control Handle

LOS1

Control Handle

Raise/Lower

LOS2

Control Handle

Raise/Lower

ORS

Control Handle

Brake Override Switch

RS

Control Handle

Travel

SAS

Control Handle

Reverse Travel

Lift

Crown 1998 PF11510-3 Rev. 11/98

04.9–4320–001

04.2–4320–001 (4) 04.2–4320–001 (14) 04.2–4320–001 (12) 04.2–4320–001 (4) 04.2–4320–001 (4) 04.2–4320–001 (11)

04.2–4320–001 (10)

Printed in U.S.A.

01 REV. 11/98

M10–4320–003

M10–4320–003

ELECTRICAL DIAGRAMS INDEX This electrical diagram index for the WE/WS 2000 Series lists the diagrams with portion of truck covered by each diagram.

Title

Page Number

Revision

WE/WS 2000 Series Wiring Diagram

DIA–4320–002

02 - 2/02

WS 2000 Series Wiring Diagram 1815 kg (4000 lbs.)

– TL & TT Capacity Trucks W/Auxiliary Attachments

DIA–4320–003

02 - 2/02

WE/WS 2000 Series Distributional Panel

DIA–4320–004

02 - 11/00

WS 2000 Series Distributional Panel 1815 kg (4000 lbs.)

– TL & TT Capacity Trucks W/Auxiliary Attachments

DIA–4320–005

01 - 11/00

WE/WS 2000 Series Handle And Timer

DIA–4320–006

02 - 11/00

WS 2000 Series Handle And Timer 1815 kg (4000 lbs.)

– TL & TT Capacity Trucks W/Auxiliary Attachments

DIA–4320–007

01 - 11/00

WE/WS 2000 Series Traction Controller - Curtis

DIA–4320–008

01 - 11/00

WE/WS 2000 Series Brake - Curtis

DIA–4320–009

01 - 11/98

WE/WS 2000 Series Proportional Electronic

DIA–4320–010

03 - 11/00

WS 2000 Series Proportional Electronic 1815 kg (4000 lbs.)

– TL & TT Capacity Trucks W/Auxiliary Attachments

DIA–4320–011

01 - 11/00

WE/WS 2000 Series Power Cables

DIA–4320–012

01 - 11/00

WE/WS 2000 Series Wiring Harness

DIA–4320–013

02 - 10/02

1833 - EO6126 Crown 1998 PF11449-1 Rev. 10/02

Printed in U.S.A.

05 REV. 10/02

DIA–4320–001

DIA–4320–001

C

ELECTRICAL DIAGRAMS B

A

C

WE/WS SCHEMATIC WIRING DIAGRAM HN NOTE:

1

HNS DRIVER

C HNS

1 Only Present On Trucks With Freezer/Corrosion

1 FU5

F/C PACKAGE

2A HIGH - SIDE - DRIVER

2 For North American Trucks only: FU3 = 125A

1

SV3

FILTER

PROPORTIONAL VALVE

PWM LOGIC

C LOS2 SV2 C

OUT

DELAY 1S

LOS1 IN

P

LO1 DRIVER RAS DRIVER

LOW C RAS

2

2 CURTIS BDI - TT

+FIL

BR IN

C ORS

OUT

PC403-15

IN OR IN

C

F R LS

HIGH

3

BR

R

PC403-2

F

PC403-3 PC403-13 PC403-16 PC403-10

C

C SAS

KYS

PC403-12

FS

C

PC403-11

RS

C

PC403-14 SHUNT FIELD DRIVER

SHUNT FIELD

PC403-1 B+

FU2 10A R

FU1 125A C EDS PC 1:1

A

D1

D2 TM

1 A1

F A2

FU3

2

160A 2

P 24V

A2 R F

PC403-5

POT

PC403-6 PC403-7

M-

BAT. NEG.

4

PM PC 1:2

+

4

3

LMS

C

FU4 2A

CURTIS CONTROLLER 1207

+BV (AK1)

LOW BRS

B

Crown 1998 PF11449-2 Rev. 2/02

C

2377 804369 B Sh 1 Printed in U.S.A.

02 REV. 2/02

DIA–4320–002

DIA–4320–002

C

ELECTRICAL DIAGRAMS B

A

C

WS SCHEMATIC WIRING DIAGRAM (Trucks W/Auxiliary Attachments) HN HNS DRIVER

C

HNS

1

1 FU5

NOTES: 1 Only Present On Trucks With Freezer/Corrosion

PRIORITY LOGIC

2 For North American Trucks only: FU3 = 125A

F/C PAKAGE

1

2A COV DRIVER

SV4 SLS DRIVER

SLS SRS DRIVER

SRS

1

SV6

SV5

HIGH-SIDE-DRIVER SV3 PWM LOGIC

C

FILTER

PROPORTIONAL VALVE

LOS2

2

SV2 C

OUT

DELAY 1S

LOS1 IN

LOS2 DRIVER

2

RAS DRIVER

P

LOW C

RAS CURTIS BDI-TT LOW BRS

BR 10A IN

+FIL

+BV(AK)

C

ORS

CURTIS CONTROLLER 1207 PC403-15

IN OR

C

3

BR

OUT

HIGH

F R LS

IN

R

PC403-2

F

PC403-3 PC403-13 PC403-16 PC403-10

C

C

PC403-12

FS

SAS C

PC403-11

RS C

FU4 2A

FIELD SHUNT

SHUNT FIELD DRIVER

FU2 10A FU1

4

125A

+ D1

D2

R F

TM FU3

C

EDS PC 1:1

A

PC403-14

LMS

KYS C

3

1 A1

A2 2

R F

PC403-1 B+

PC403-5

A2

PC403-6

-

POT

PC403-7

4

MBat. Neg. PM

160A 2

P +

24V

PC 1:2

B

Crown 1998 PF11449-3 Rev. 2/02

C

2377 807230 B Sh 1 Printed in U.S.A.

02 REV. 2/02

DIA–4320–003

DIA–4320–003

C

DISTRIBUTION PANEL B

A

KYS

BLK +BV EDS OUT WHT +BV BRN +BV (AK) VIO +BV EDS IN

GRAY/PINK GRAY/PINK R RED/BLU F WHT/GRE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

2

0V +24V

FU4 2A

2A

FR

LOW

CA202

(GRE/YEL)

3

S.F. DRIVER

LIFT CONTROLLER CA205 8 7 6 5 4 3 2 1

1 2 3 4 5 6 7 8

2

HN DRIVER

IN LOW OUT

OUT OR BR IN LS

BRAKE CIRCUIT

1

PINK CA206-7 RAS (7) BLU PC410-1 +FIL

LO1 DRIVER

IN LOW OUT

HIGH

(14) BRN/GRE PC411-6 UNUSED (13) WHT/GRE PC410-8 2 (1) WHT PC410-6 SAS (11) GRAY/PINK PC411-2 FS (10) VIO PC411-1 RS (2) BRN PC410-7 SAS UNUSED (9) BLK PC410-5 HNS (5) GRAY PC411-5 POT LOW (4) YEL PC411-4 WIPER (3) GRE PC411-3 POT HIGH RED/BLU CA206-3 LOS1

LO2 DRIVER

IN LOW OUT

RAS DRIVER

CURTIS 803

BLU PC401-1 (S.F.) RED PC401-2 (S.F.) YEL PC407-1 ORS N.C. (1) WHT PC406-2 BRS COMM. (2) BRN PC406-3 BRS N.O. (3) GRE PC407-3 ORS N.O. GRAY PC402-1 (BR) PINK PC402-2 (BR)

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

FU5

TT BDI

Bat.Neg

+24

CA204

LOW OUT

OUT

PC405 1 2 3 4 5 6 7 8 1

IN

IN LOW

YEL BLU GRAY RED PINK GRE

BRN/GRE BAT. NEG CA206-10 WHT/GRE CA206-1 WHT/RED

FU2 20A

6677-01

HANDLE

FILTER

CA201

1

C

BRN/BLU PC404-2 LMS WHT/BLU PC404-3 LMS PINK/BRN P GRAY/BRN SV2

3

YEL/BRN WHT/GRAY WHT/YEL

OUT

HN

IN LOW

WHT/GRAY WHT/GRAY

IN

2 Option F/C

4

3 Numbers In Parenthesis Pertain to Freezer/Corrosion Trucks Only. Disregard Color And Use Number To Identify Lead.

A

TRACTION CONTROLLER

1 Option TT/BDI.

WHT PC403-1 (S.F.) BRN PC403-2 R GRE PC403-3 F UNUSED GRAY PC403-5 HIGH PINK PC 403-6 WIPER BLU PC403-7 LOW UNUSED UNUSED VIO PC403-10 SAS GRAY/PINK PC403-11 RS RED/BLU PC403-12 FS WHT/GRE PC403-13 SAS BRN/GRE PC403-14 LS WHT/YEL PC403-15 BR YEL/BRN PC403-16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

NOTE:

B

Crown 1998 PF11449-4 Rev. 11/00

CA203

4

C

6396 804369 Sh2 Printed in U.S.A.

02 REV. 11/00

DIA–4320–004

DIA–4320–004

C

DISTRIBUTION PANEL B

A

C

WS 1815 kg (4000 lbs.) TL & TT Capacity Trucks (W/Auxiliary Attachments)

1 KYS

BLK +BV EDS OUT WHT +BV BRN +BV(AK) VIO +BV EDS IN

GRAY/PINK R GRAY/PINK WHT/GRE F

RED/BLU

BRN/GRE -B CA206-10 WHT/GRE CA206- 1 WHT/RED

0V +24 V FU4 2A

CURTIS 803

2A

PINK CA206-7 RAS (7) BLU PC410-1 +FIL

2 LO2 DRIVER

IN

OUT RAS DRIVER

LOW OUT

LO1 DRIVER

F R

IN LOW OUT

HIGH

LOW OUT

LS

OUT OR BR IN

CA202 (GRE/YEL)

HN DRIVER IN

BRAKE CIRCUIT

BLU PC401-1 (S.F.) RED PC401-2 (S.F.) YEL PC407-1 ORS N.C. (1) WHT PC406-2 BRS COMM. (2) BRN PC406-3 BRS N.O. (3) GRE PC407-3 ORS N.O. GRAY PC402-1 (BR) PINK PC402-2 (BR)

1

(14) (GRE/YEL) BRN/GRE PC411-6 2 UNUSED (13) WHT/GRE PC410-8 2 (1) WHT PC410-6 SAS (11) GRAY/PINK PC411-2 FS (10) VIO PC411-1 RS (2) BRN PC410-7 SAS UNUSED (9) BLK PC410-5 HNS (5) GRAY PC411-5 POT LOW (4) YEL PC411-4 WIPER (3) GRE PC411-3 POT HIGH RED/BLU CA206-3 LOS1

IN LOW

LOW

3

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

FU5

0V TT BDI

1

CA204

LOW OUT

1 2 3 4 5 6 7 8

+24

PC405

IN

FU2 20A

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

YEL BLU GRAY RED PINK GRE

2

HANDLE

FILTER

CA201

1 2 3 4 5 6 7 8

LIFT CONTROLLER CA205

8 7 6 5 4 3 2 1

BRN/BLU PC404-2 LMS WHT/BLU PC404-3 LMS P PINK/BRN SV2

GRAY/BRN YEL/BRN WHT/GRAY WHT/YEL

3

HN OUT IN S.F DRIVER

NOTE:

1 Optional TT/BDI

WHT/GRAY WHT/GRAY

LOW IN

1 2 3 4 5 6 7 8 9 10 111213141516

3 Numbers In Parenthesis Pertain To Freezer/Corrosion Trucks Only.

Disregard Color And Use Number To Identify Lead

4

WHT PC403-1 (S.F.) BRN PC403-2 R GRE PC403-3 F UNUSED GRAY PC403-5 HIGH PINK PC 403-6 WIPPER BLU PC403-7 LOW UNUSED UNUSED VIO PC403-10 SAS GRAY/PINK PC403-11 RS RED/BLU PC403-12 FS WHT/GRE PC403-13 SAS BRN/GRE PC403-14 LS WHT/YEL PC403-15 BR YEL/BRN PC403-16

2 Optional Freezer/Corrosion

CA203

4

TRACTION CONTROLLER

A

B

Crown 1998 PF11449-5 Rev. 11/00

C

6396 807230 B Sh2 Printed in U.S.A.

01 REV. 11/00

DIA–4320–005

DIA–4320–005

C

HAND & TRAVEL TIMER B

A

C

PC405

1

6678-01

TRAVEL TIMER

1

1 YEL

1 +24V

YEL CA201-6

2

BLU CA201-12

3

GRAY CA201-10

4

RED CA201-13

5

RED

2 Bat. Neg.

PINK CA201-11

6

PINK

3 TT

GRE CA201-5

7

BRN

8

HANDLE

2

2 PC410

2

3

(7) BLU CA204-1 +FIL

1

BLU

(6) PINK CA206-6

2

PINK

RAS

C

(8) RED CA206-4

3

RED

LOS2

C

BLU

(12) RED/BLU CA204-2

4

RED/BLU

LOS1

C

BLU

5

BLK

HNS

C

83019

(9) BLK CA204-8 (1) WHT CA204-13

6

WHT

(2) BRN CA204-10

7

BRN

(13) WHT/GRE CA204-14

8

BLU PC412 RED

SAS 1 1

PC411

2

RS C

(10) VIO CA204-11

1

ORN

(11) GRAY/PINK CA204-12

2

YEL

FS C COMMAND

(3) GRE CA204-5

3

VIO

(4) YEL CA204-6

4

BRN

(5) GRAY CA204-7

5

WHT

(14) BRN/GRE CA204-16

6

3

2

C

3 SAS

4

COMMAND BLK BLK WHT POT

NOTES:

4

A

1

Resistors Between PC410-8 And PC411-6 For Optional Freezer/Corrosion.

2

Numbers In Parenthesis Pertain To Freezer/Corrosion Trucks Only. Disregard Color And Use Number to Identify Lead.

B

Crown 1998 PF11449-6 Rev. 11/00

4

C

6396 804369 Sh3 Printed in U.S.A.

02 REV. 11/00

DIA–4320–006

DIA–4320–006

C

HAND & TRAVEL TIMER B

A

C

WS 1815 kg (4000 lbs.) TL & TT Capacity Trucks (W/Auxiliary Attachments) PC405

1

1

YEL CA201-6

2

BLU CA201-12

3

GRAY CA201-10

4

RED CA201-13

1

YEL

1 +24V

BRN

TRAVEL TIMER

5

RED

2 0V

PINK CA201-11

6

PINK

3 TT

GRE CA201-5

7 8

BLU PC410-1 WHT/GRN CA207-2

2 YEL/BRN CA207-1

BLU PC414-1 (7) BLU CA204-1 +FIL (6) PINK CA207-5

3

PC414

1

BLU

2

WHT/GRN

3

BLU

4

YEL/BRN

C SLS

2 C

SRS

PC410

1

BLU

2

PINK

(8) RED CA206-4

3

RED

(12) RED/BLU CA206-2

4

RED/BLU

(9) BLK CA204-8

5

BLK

(1) WHT CA204-13

6

WHT

(2) BRN CA204-10

7

BRN

(13) WHT/GRE CA204 -14

8

RAS

C

LOS2

C

BLU

LOS1

C

BLU

HNS

C

83019 BLU

PC412

3

RED (GRAY)

SAS 1 1 PC411

(10) VIO CA204-11

1

ORN

(11) GRAY/PINK CA204-12

2

YEL

(3) GRE CA204-5

3

VIO

(4) YEL CA204-6

4

BRN

(5) GRAY CA204-7

5

WHT

(14) BRN/GRE CA204-16

6

RS FS

2

C

C

3

C

SAS

4

COMMAND COMMAND

BLK

BLK WHT (BLU)

4

(GRE/YEL)

A

4

POT

NOTES: 1

Resistors Between PC410-8 And PC411-6 Are For Optional Freezer/Corrosion

2

Items In Parenthsis () Pertain To Freezer/Corrosion Trucks Only.

B

Crown 1998 PF11449-7 Rev. 11/00

C

6396 807230 B Sh5 Printed in U.S.A.

01 REV. 11/00

DIA–4320–007

DIA–4320–007

C

TRACTION CONTROLLER B

A

C

CURTIS PC403 1

1

2

WHT CA203-1

1

S.F.DRIVER

BRN CA203-2

2

R NEG

1

CURTIS

GRE CA203-3

3

F NEG

GRAY CA203-5

5

ACCEL +5V

PINK CA203-6

6

WIPER

BLU CA203-7

7

ACCEL NEG 2

VIO CA203-10

10

SAS (BB CHECK)

GRAY/PINK CA203-11

11

RS N.O.

RED/BLU CA203-12

12

FS N.O.

WHT/GRE CA203-13

13

SAS

BRN/GRE CA203-14

14

LOW SPEED INPUT

WHT/YEL CA203-15

15

BR INPUT

YEL/BRN CA203-16

16

KYS +BV(AK)

2

B+

NOTE:

2

A2

B-

M-

1 In PC403 Pin Numbers 4, 8 And 9 Are Not Used.

3

2 Voltage Between PC403-6 And PV403-7: 5 Volts = Full Speed 0 Volts = No Command

D1

3

D2

FU1

BLK CA201-1 +BV

C

TM

+

EDS F

VIO CA201-4 +BV

+

4

24V

A

B

Crown 1998 PF11449-8 Rev. 11/00

A2

A1

R

2

1

F

R

4

–

C

6396 807230 Sh3 Printed in U.S.A.

01 REV. 11/00

DIA–4320–008

DIA–4320–008

C

BRAKE B

A

C

PC406 1

1

RED

(1) WHT CA202-4

2

BLK

(2) BRN CA202-5

3

WHT

1

C

BRS

4

BRN 104 PC407 (GRE/YEL) YEL CA202-3 (3) GRE CA202-6

1

RED

2

BLK

3

WHT

C

ORS

4

2

2

PC402 GRAY CA202-7

1

BLU

PINK CA202-8

2

BLK

BR

PC401

3

BLU CA202-1

1

E1

RED CA202-2

2

E2

SF 3

PC404 1

BRN/BLU CA205-8

2

BLK

WHT/BLU CA205-7

3

WHT

LMS

4

NOTE: 1

Items In Parenthesis () Are Only For Freezer/Corrosion.

4

4

A

B

Crown 1998 PF11449-9 Rev. 11/00

C

6396 807230 Sh5 Printed in U.S.A.

02 REV. 11/00

DIA–4320–009

DIA–4320–009

C

PROPORTIONAL ELECTRONIC B

A

C

6681-02

1

1

12 11 10 9

WHT/GRE PC201-15 BRN 1 SV3 WHT PROPORTIONAL PINK PC204-2 VALVE PINK PC410-2 (6) RAS

8 7

2

6

2

5 4 3

RED PC410-3 (8) LOS2 RED/BLU 204-4

2

RED/BLU 410-4 (12) LOS1 WHT/RED PC201-16 +

1 +

+24V

3

CA206 NOTE: 1 Center Connector Is Not Used On Proportional Valve (SV3).

PWM LOGIC

3

Bat. Neg.

4

4

A

B

Crown 1998 PF11449-10 Rev. 11/00

C

6396 804369 Sh6 Printed in U.S.A.

03 REV. 11/00

DIA–4320–010

DIA–4320–010

C

PROPORTIONAL ELECTRONIC B

A

C

PC 20 42

W ht /G

re

1

Pi nk

Brn

Wht

SV3

CA206 12 11 10 9

R ed R PC ed 4 1 R /Blu 0-3 ed P (8 W /Blu C2 ) L ht 0 O /R PC 4-4 S2 ed 41 PC 0-4 20 (1 1- 2) 16 LO

PC 20 115

S1

WS 1815 kg (4000 lbs.) TL & TT Capacity Trucks (W/Auxiliary Attachments)

1

NOTE: 1 Items In Parenthsis () Pertain To Freezer/Corrosion Trucks Only.

8 7

6 5

4 3 2

1 Batt.

Neg.

+

2

2 PWM LOGIC

PRIORITY LOGIC

3

CA204-1 +Fil

A

8 Wht

Blk

Red

SLS

5 6 7

Wht/Pink Main Harness

SRS

3 4

Pink RAS PC410-2

4

Wht/Gry PC414-2

1 2 Yel/Brn PC414-4

CA207

COV DRIVER

SSL Driver

SSR Driver

3

8 7

6 5

4 3 2

CA417

1

4

SV6 SV5 SV4

B

Crown 1998 PF11449-11 Rev. 11/00

C

6396 807230 Sh6 Printed in U.S.A.

01 REV. 11/00

DIA–4320–011

DIA–4320–011

C

POWER CABLES B

A

C

6749

24 Volt Battery + –

1

1

Battery Disconnect 052050-002

052050-001 IN EDS 052065-002

052065-004

804364

OUT

2

+

FU3

P

–

E2

PM

2

DIE1 052065-005 052065-008

1 –

052065-009

R/F

FU1

+

3

052065-006

803674

3

2

A2 A1

D2 D1

052065-004

M– A2

B+

TM

U1

052065-001 B–

4

4

A

B

Crown 1998 PF11449-12 Rev. 11/00

C

6396 803466 Printed in U.S.A.

01 REV. 11/00

DIA–4320–012

DIA–4320–012

WIRING HARNESS Following are the wire harness part numbers for the WE/WS 2000 Series Trucks. This list also includes the area of the truck where each harness is used.

Harnesses

Components Connected By:

803459

Frame PC201, PC205, PC404, PC405, HN, EDS

807229

Frame PC201, PC205, PC404, PC405, HN, EDS – W/Auxiliary Attachments

803545

PC405, TT

803460

PC202, PC401, PC402, PC406, PC407, BRS, ORS, BR, S.F.

803461

Handle Standard, PC204, PC410, PC411

807234

Handle , PC204, PC410, PC411, PC414 – W/Auxiliary Attachments

803462

PC203, PC403

803468

PC201, PC204, PC206, SV3

803889

Handle F/C, PC204, PC410, PC411

807227

Frame – W/Auxiliary Attachments

807228

Mast TL & TT – W/Auxiliary Attachments

803676

Freezer/Corrosion Resistors Wiring Harness

804368

Proportional Valve

1833 - EO6126 Crown 1998 PF11449-13 Rev. 10/02

Printed in U.S.A.

02 REV. 10/02

DIA–4320–013

DIA–4320–013

C

HYDRAULIC SCHEMATIC 6682

WE/WS 2000/2300 SERIES

Lift Cylinders

TL Velocity Fuse

Velocity Fuse

A P2

CYL Manifold Block

T2

CV

SV2

SV3 Proportional Valve CV RV1

1 Orifice

P1

T1

1

PM

Orifice Size Will Be Different Depending Upon Truck Capacity.

7903 Crown 1998 PF11450-1 Rev. 3/04

Printed in U.S.A.

02 REV. 3/04

HYD–4320–001

HYD–4320–001

C

HYDRAULIC SCHEMATIC 6683

WE/WS 2000/2300 SERIES

Velocity Fuse

TF

Velocity Fuse

Lift Cylinder

Lift Cylinder

Velocity Fuse

Velocity Fuse

Carriage Cylinder

Velocity Fuse

A CYL

TT Lift Cylinder

Lift Cylinder Carriage Cylinder

Velocity Fuse

Velocity Fuse

Velocity Fuse

A CYL Crown 1998 PF11450-2 Rev. 3/04

Printed in U.S.A.

01 REV. 3/04

HYD–4320–002

HYD–4320–002

C

HYDRAULIC SCHEMATIC 8785

TL Mast W/Auxilliary Attachments

Sideshift Cylinder

Lift Cylinders

SV5/SV6 Velocity Fuse

Velocity Fuse

SV4 Crossover Valve

A

Cylinder

P2 Manifold Block

CV

1

SV2

T2

SV3 Proportional Valve

CV RV1

P1

T1 1 Orifice Size Will Be Different Depending Upon Truck Size

PM

Filters

810470 A Printed in U.S.A.

Crown 1998 PF11450-3 Rev. 2/01

01 REV. 2/01

HYD–4320–003

HYD–4320–003

C

HYDRAULIC SCHEMATIC 8786

TT Mast W/Auxilliary Attachments Carriage Cylinder Sideshift Cylinder Lift Cylinder

Lift Cylinder

SV5/SV6 Velocity Fuse

Velocity Fuse

Velocity Fuse

SV4

Crossover Valve

A

Cylinder

P2

Manifold Block CV

1 SV2

T2

SV3 CV RV1

Proportional Valve

T1

P1

1 Orifice Size Will Be Different Depending Upon Truck Size

PM

Filters 810471 A Crown 1998 PF11450-4 Rev. 2/01

Printed in U.S.A.

01 REV. 2/01

HYD–4320–004

HYD–4320–004