Crown Forklift 1.5 TSP Service & Parts Manual by www.heydownloads.com

1.5 TSP Service & Parts Manual

Crown PF7777_00

TSP - INDEX

03 - 5/97

Introduction

X X

02 - 5/97

General Maintenance Lifting & Blocking Points

SECTION M1 X

07 - 6/98

03 - 10/96

02 - 4/88

SECTION M2 X

05 - 1/98

X X

02 - 5/98

02 - 10/97

X X

01 - 1/94

X X

01 - 1/94

X X

01 - 1/94

Title

Serial No. of Units Used For From: To: Standard Special Date

Revision No. - Date

Page Number

ITD–19.0–001

1A177140

12/01/96

MA–04.0–001 MA–18.1–100

LUBRICATION AND ADJUSTMENT Lubrication – Lubricant & Fluid Chart – Lube Identification Chart Lubrication & Adjustments – Platform – Lift Structure & Power Unit – Auxiliary Mast & Pivot – Power Unit & Lift Structure Torque Values

M1.0–04.0–001 M1.0–04.0–002 M1.0–04.0–003 M1.0–19.0–001 M1.0–19.0–002 M1.0–19.0–004 M1.0–19.0–006 M1.0–19.0–008 M1.9–14.0–001

HYDRAULIC MAINTENANCE Hydraulic System – Drift Test – Component Location – Operation Chart Hydraulic Schematic Symbols Pump, Gear-Lift – Pump, Disassembly – Pump, Start up Procedure Pump, Gear-Accessory – Pump, Disassembly Valve - Pivot, Extend/Retract – Relief Valve Manifold Valve - Lift/Lower – Troubleshooting Chart Manifold Valve - Traverse Manifold Valve - Pivot – Troubleshooting Chart Manifold Valve - Fork-Flow Divider Manifold Valve - Brake – Troubleshooting Chart Manifold Valve - Traverse – Troubleshooting Procedure Servo Lift/Lower Valve – Servo Motor Brush Replacement Pivot, Traverse Hydraulic Motor – Troubleshooting Chart – Disassembly – Reassembly Accumulator

Crown 1988 PF8188-1 Rev. 7/98

M2.0–19.0–001 M2.0–19.0–003 M2.0–19.0–004 M2.0–19.0–006 M2.1–00.0–001 M2.1–10.0–001 M2.1–10.0–002 M2.1–10.0–004 M2.1–18.0–001 M2.1–18.0–001 M2.3–18.0–001 M2.3–18.0–002 M2.4–19.0–001 M2.4–19.0–003 M2.4–19.0–100 M2.4–19.0–200 M2.4–19.0–201 M2.4–19.0–300 M2.4–19.0–400 M2.4–19.0–401 M2.4–19.0–500 M2.4–19.0–501 M2.5–18.0–100 M2.5–18.0–104 M2.5–19.0–001 M2.6–18.0–040 M2.6–18.0–041 M2.6–18.0–043 M2.6–18.0–049 M2.6–19.0–001

Printed in U.S.A.

07 REV. 7/98

IDX–19.0–001

TSP INDEX

Revision No. - Date

SECTION M3 X X

X X

01 - 6/95

SECTION M4

Serial No. of Units Used For From: To: Standard Special Date

Title

Page Number

DRIVE UNIT MAINTENANCE Drive Unit Repair/Rebuild Drive Unit – Tire Replacement – Axle Seal Replacement – Drive Unit Removal – Drive Unit Repair – Drive Axle Replacement – Drive Unit Lubrication System – Check List

M3.0–1430–050 M3.0–18.0–001 M3.0–18.0–001 M3.0–18.0–001 M3.0–18.0–002 M3.0–18.0–005 M3.0–18.0–012 M3.0–18.0–013 M3.0–18.0–014

ELECTRICAL MAINTENANCE

06 - 10/97

X X X X X X X

04 - 3/94 01 - 1/94 05 - 5/98 04 - 5/97 01 - 3/94 01 - 1/94

Electrical System – Steering Control – Traction Control – Brake Control – Main Lift/Lower Control – Auxiliary Lift/Lower Control – Pivot Control – Traverse, Fork Extend/Retract – Auto Steering Control – End Aisle Control – Component Locations – Fuses Switches Operation & Adjustments Encoders Speed Direction Sensors How To Read Wiring Diagrams Motor Control, Traction and Lift Tune Up Motor Control, Steering Servo (MRC-3)

01 - 1/94

Motor Control, Steering Servo (MRC-3)

X X X X

04 - 11/94 02 - 8/92 03 - 1/94 05 - 8/96

01 - 7/95

X X

Motor Control, Steering Servo (MRC-3) Electronic System Electronics Operation & Troubleshooting Wire Guidance System – Troubleshooting End Aisle Control – Adjustments – Troubleshooting Contactor-Steering, Dual Motor & Emergency Disconnect Contactor-Directional Contactor-Pump - Emergency Disconnect

Contactor-Pump - Emergency Disconnect

Crown 1988 PF8188-2 Rev. 7/98

M4.0–19.0–001 M4.0–19.0–004 M4.0–19.0–005 M4.0–19.0–006 M4.0–19.0–007 M4.0–19.0–008 M4.0–19.0–009 M4.0–19.0–010 M4.0–19.0–011 M4.0–19.0–012 M4.0–19.0–013 M4.0–19.0–018 M4.0–19.0–100 M4.0–19.0–200 M4.0–19.0–300 M4.1–12.0–001 M4.2–18.1–001 M4.2–18.1–200 M4.2–19.0–001

1A121060 1A121060

H-15666 6/89 H-15666 6/89 06/16/92 06/16/92

1A114747

10/08/91

M4.2–19.0–010 M4.2–19.0–020 M4.3–19.0–001 M4.3–19.0–400 M4.3–19.0–500 M4.3–19.0–503 M4.3–19.0–600 M4.3–19.0–601 M4.3–19.0–602 M4.4–19.0–001 M4.4–19.0–050 M4.4–19.0–100

1A121570 1A121570

07/01/92 07/01/92

M4.4–19.0–105

Printed in U.S.A.

07 REV. 7/98

IDX–19.0–002

TSP INDEX

X X X X X X X

Revision No. - Date

01 - 5/95 02 - 1/94

01 - 5/96

SECTION M5 X

03 - 1/94

SECTION M6 X

Serial No. of Units Used For From: To: Standard Special Date

Title

Traction Control Left Hand Control Steering Feedback Height Sensing System Curtis Battery Discharge Interrupt (BDI) Battery Motors – Drive Motor – Lift Motor – Accessory Motor – Motor Chart Troubleshooting Procedures

X X

04 - 5/98

X X

03 - 1/94

M4.5–19.0–001 M4.5–19.0–050 M4.5–19.0–100 M4.5–19.0–150 M4.6–18.1–001 M4.6–19.0–001 M4.7–19.0–001 M4.7–19.0–001 M4.7–19.0–002 M4.7–19.0–003 M4.7–19.0–004 M4.8–18.0–001

BRAKES MAINTENANCE Brake System – Brake Adjustment – Speed Sensor Adjustment – Load Wheel – Brake Adjustment – Brake Pad Replacement

M5.0–19.0–001 M5.0–19.0–002 M5.0–19.0–003 M5.0–19.0–004 M5.0–19.0–004 M5.0–19.0–006

STEERING MAINTENANCE Steering System – Linkage Adjustment

SECTION M7

Page Number

M6.0–19.0–001 M6.0–19.0–003

MAST MAINTENANCE Hose Take-up Cable, TF Mast Assembly – Power Unit/Main Frame Hydraulics – Column Roller Adjustment – Side Thrust Roller Adjustment – Stabilizer Roller Adjustment Load Wheels Lift Chain – Lubrication – Replacement Forks – Hanger Bore Measurement Chart – Definition/Check List

Crown 1988 PF8188-3 Rev. 7/98

M7.0–18.1–025 M7.0–19.0–001 M7.0–19.0–002 M7.0–19.0–005 M7.0–19.0–007 M7.0–19.0–008 M7.4–19.0–001 M7.5–18.0–001 M7.5–18.0–003 M7.5–18.0–004 M7.8–18.0–001 M7.8–18.0–002 M7.8–18.0–003

Printed in U.S.A.

07 REV. 7/98

IDX–19.0–003

TSP INDEX

Revision No. - Date

SECTION M8 X

01 - 1/94

02 - 2/95

X X X X X

X X

01 - 5/96 01 - 1/94

Cylinder, Lift and Free Lift, TF – Cylinder Removal – Cylinder Replacement Cylinder, Lift and Free Lift, TF – Cylinder Removal – Cylinder Replacement Cylinder, Lift - Mast, TN – Cylinder Repair – Cylinder, Lift Removal – Cylinder, Lift Installation Cylinder, Auxiliary Lift Cylinder, Fork - Extend/Retract Cylinder, Brake Drive Motor Cylinder, Brake Load Wheel Cylinder, Pivot Cylinder, Pivot Cylinder, Pivot Latch

Platform – Lubrication – Adjustments Load Handler – Lubrication – Fork Removal & Replacement – Column Roller Adjustment

SECTION M10

GLOSSARY

01 - 5/90 04 - 10/97

W-96011

H-18215

1/90

W-96011

H-18215

1/90

1A135868

11/01/93

1A122499 1A122499

08/06/92 08/06/92

M8.0–18.0–001 M8.0–18.0–006 M8.0–18.0–007 M8.0–18.1–001 M8.0–18.1–007 M8.0–18.1–008 M8.0–18.1–150 M8.0–18.1–152 M8.0–18.1–156 M8.0–18.1–157 M8.4–19.0–001 M8.7–19.0–001 M8.8–18.0–001 M8.8–18.0–050 M8.8–19.0–100 M8.8–19.0–104 M8.8–19.0–200

PLATFORM MAINTENANCE

03 - 5/98

Page Number

CYLINDER MAINTENANCE

SECTION M9 X

Serial No. of Units Used For From: To: Standard Special Date

Title

M9.0–19.0–001 M9.0–19.0–003 M9.0–19.0–006 M9.1–19.0–001 M9.1–19.0–003 M9.1–19.0–005 M9.1–19.0–006

Glossary

M10–19.0–001 1A114747 1A114747

Glossary

10/1/91 10/1/91

M10–19.0–012

WIRING DIAGRAMS X X

X X

04 - 10/97

Introduction Index

13 - 10/97

Index

DIA–ITD–001 DIA–19.0–001 1A114747 1A114747

10/08/91 10/08/91

DIA–19.0–025

11/01/93

HYD–19.0–001 HYD–19.0–050

HYDRAULIC SCHEMATICS X X

06 - 8/96 05 - 8/96

Hydraulic Schematic Hydraulic Schematic

1A135868

Crown 1988 PF8188-4 Rev. 7/98

Printed in U.S.A.

07 REV. 7/98

IDX–19.0–004

TSP INDEX

Revision No. - Date

SECTION 1 X X X

X X

01 - 9/88 03 - 10/97 01 - 10/97

SECTION 2 X

02 - 9/89

Serial No. of Units Used For From: To: Standard Special Date

Title

POWER UNIT PARTS Power Unit

01.0–19.0–001

Power Unit

Hydraulic System, Power Unit

02 - 4/94

Hydraulic System, Power Unit

02 - 8/95

Hydraulic System, Power Unit

X X

Hydraulic System, Power Unit Hydraulic System, Main Frame Hydraulic System - Main Frame

Hydraulic System - Main Frame

X X

04 - 5/97 01 - 8/88

Hydraulic System - Main Frame Hydraulic System, Platform

X X

01 - 9/88

Hydraulic System, Platform Hydraulic System, Load Handler

01 - 6/94

Hydraulic System - Load Handler

01 - 6/94

Hydraulic System - Load Handler

01 - 6/94

Hydraulic System - Load Handler

X X

02 - 5/97 01 - 9/88

Hydraulic System - Load Handler Pump 93501 72V

X X

01 - 6/90

Pump 116624 72V Pump 91191 48V

X X X

02 - 3/91 04 - 11/94

Pump 116625 48V Pump ,Accessory 110224 Motor, Accessory 91096 72 V

01 - 3/93

Motor, Servo 93137

X X

01 - 3/94

4/19/90 4/19/90 01/13/94 01/13/94 11/21/94 11/21/94 05/21/96 05/21/96

1A105220 1A113650 1A135868 1A105220 1A113650 1A135868 1A138496 1A138496

08/30/90 08/20/91 11/01/93 08/30/90 08/20/91 11/01/93 01/13/94 01/13/94

1A154205 1A154205

03/20/95 03/20/95

1A113650 1A122499 1A142990 1A113650 1A122499 1A142990 1A149519 1A149519

08/20/91 08/06/92 05/31/94 08/20/91 08/06/92 05/31/94 11/21/94 11/21/94

1A142313 1A142313

05/09/94 05/09/94

1A142313 1A142313

05/09/94 05/09/94

1A118149

03/04/92

1A191496 1A191496 1A118149

02/04/98 02/04/98 03/04/92

01.0–19.0–005

Hydraulic System, Power Unit

02 - 5/97

1A101875 1A101875 1A138496 1A138496 1A149519 1A149519 1A170275 1A170275

01.0–19.0–003

HYDRAULIC PARTS

03 - 5/93

1A141745 1A141745

H-15666 6/89 H-15666 6/89 04/26/94 04/26/94

Power Unit

Page Number

02.0–19.0–001 02.0–19.0–003 02.0–19.0–005 02.0–19.0–007 02.0–19.0–009 02.0–19.0–100 02.0–19.0–102 02.0–19.0–104 02.0–19.0–106 02.0–19.0–108 02.0–19.0–200 02.0–19.0–202 02.0–19.0–300 02.0–19.0–302 02.0–19.0–304 02.0–19.0–306 02.0–19.0–308 02.1–18.0–001 02.1–18.1–001 02.1–19.0–001 02.1–19.0–002 02.1–19.0–100 02.2–18.0–100 02.2–18.0–200

Motor, Servo Motor, Accessory 110565 72 V

†

02.2–18.0–201 02.2–18.1–100

† Denotes new form on this index. Crown 1988 PF8188-5 Rev. 7/98

Printed in U.S.A.

07 REV. 7/98

IDX–19.0–005

TSP INDEX

Revision No. - Date

02 - 11/94

Serial No. of Units Used For From: To: Standard Special Date

Title

Motor, Lift 101271 48V

02.2–19.0–001

X X

03 - 8/96 01 - 4/94

Motor, Lift 020230 48V Motor, Lift 106813 72V

X X X X

01 - 3/94 01 - 8/89 01 - 9/88

Motor, Lift 110361 72V Motor Accessory 104992 48V Valve, Spool - Raise/Lower 100286 Valve, Pivot 104942

X X

01 - 6/95

Valve, Pivot 119507 Valve, Traverse 104943

X X

02 - 8/89

Valve, Traverse Manifold, Lower 105604-002 Manifold, Main/Aux. Lower 105604-002

01 - 7/88

Manifold, Main/Aux. Lower 105604-002 Manifold, Traverse 105600-001, -002

X X

01 - 11/94

Manifold, Fork 112854

01 - 11/94

Manifold, Fork Flow Divider 112854

X X

01 - 7/88

Manifold, Fork Flow Divider Manifold, Brake 107336-001, -002

X X

Manifold, Traverse 112440-001,-002

02 - 5/93

Manifold, Traverse 112440-001, -002 Manifold, Pivot 112447-001, -002 Manifold, Pivot 112447-001, -002 Manifold, Fork 105602

01 - 1/94

02 - 1/94

Page Number

Manifold, Brake 107336-001, -002 Manifold, Traverse Cushion 108273-001, -002 Manifold, Traverse Cushion 112443-001 Manifold, Traverse Cushion 112443 Control Valve, Servo 93762

02 - 8/88

Control Valve, Servo 125654 Control Valve Linkage

01 - 4/88

Control Valve Linkage Hydraulic Motor 106650

1A133881 1A133881

08/20/93 08/20/93

1A118727 1A118727

03/23/92 03/23/92

1A154205 1A154205

03/20/95 03/20/95

1A154205 1A154205

03/20/95 03/20/95

1A137105 1A137105 1A142313 1A142313

11/29/93 11/29/93 05/09/94 05/09/94

1A107355 1A107355 1A142313 1A142313

11/26/90 11/26/90 05/09/94 05/09/94

1A142313 1A142313

05/09/94 05/09/94

W-88940 W-88940 1A142313 1A142313 1A148136 1A148136

10/24/89 10/24/89 05/09/94 05/09/94 10/20/94 10/20/94

1A142313 1A142313

05/09/94 05/09/94

1A110511 1A110511 1A142313 1A142313

04/03/91 04/03/91 05/09/94 05/09/94

1A191496 1A191496

02/04/98 02/04/98

1A154205 1A154205

03/20/95 03/20/95

02.2–19.0–002 02.2–19.0–050 02.2–19.0–051 02.2–19.0–100 02.3–18.0–001 02.3–19.0–001 02.3–19.0–002 02.3–19.0–050 02.3–19.0–051 02.4–19.0–001 02.4–19.0–002 02.4–19.0–004 02.4–19.0–100 02.4–19.0–102 02.4–19.0–104 02.4–19.0–200 02.4–19.0–201 02.4–19.0–300 02.4–19.0–301 02.4–19.0–302 02.4–19.0–303 02.4–19.0–400 02.4–19.0–402 02.4–19.0–500 02.4–19.0–501 02.4–19.0–503 02.5–18.0–100 †

02.5–18.0–101 02.5–19.0–001 02.5–19.0–003 02.6–18.0–003

† Denotes new form on this index.

Crown 1988 PF8188-6 Rev. 7/98

Printed in U.S.A.

07 REV. 7/98

IDX–19.0–006

TSP INDEX

Revision No. - Date

SECTION 3 X X

X X

X X X X X

01 - 6/83

Drive Unit Lubrication System Drive Unit Lubrication System Drive Unit

X X X

02 - 11/94 01 - 11/94

Drive Unit Motor, Drive 104078 48V Motor, Drive 104121 72V

X X

01 - 8/96 01 - 12/94

Motor Drive 020334 72V Tire, Drive

05 - 1/96

X X

X X X

02 - 8/95 03 - 9/89

Electrical Components, Platform Contactor Panel 107075-001 Contactor Panel 107075-001, -002

X X X X

02 - 10/97 03 - 10/97 02 - 5/96 01 - 5/89

Contactor Panel 107075-001, -002 SCR Panel, Traction 107869 SCR Panel, Lift - 102803 Motor Control, Steering Ser 105346-3,-4

1A115462 1A115462

11/06/91 11/06/91

1A151733 1A151733

01/25/95 01/25/95

1A170275 1A170275

05/21/96 05/21/96

1A113650 1A113650 W-94317

08/12/91 08/12/91 11/15/89

1A122720 1A122720

08/12/92 08/12/92

W-94126 W-94126 1A121060 1A121060

H-15666 6/89 H-15666 6/89 11/09/89 11/09/89 06/16/92 06/16/92

1A113650 1A113650 1A135868 1A135868

08/20/91 08/20/91 11/01/93 11/01/93

1A135868 1A135868

11/01/93 11/01/93

Electrical Components, Power Unit Electrical Components, Door Electrical Copmponents, Main Frame Electrical Components, Platform

Motor Control, Steering Ser 109331-3,-4

X X X

01 - 1/96 02 - 6/90

Motor Control, Steering Ser 109331-3,-4 Wire Guidance Components Electronic Box, Power Unit

01 - 6/92

Electronic Box, Power Unit

X X

02 - 10/96 03 - 6/92

Electronic Box, Power Unit Electronic Box, Platform

X X X X

02 - 10/96

Electronic Box, Platform Wire Guidance Components Line Driver 105824 Sensor Bar, End Aisle Control

01 - 12/93 01 - 12/93

1A114747

10/8/91

03.0–1430–200 03.0–18.0–005 03.0–18.0–007 03.1–14.0–005 03.1–18.0–002 03.1–18.1–001 03.2–19.0–001

04.0–19.0–001

Motor Control, Steering Ser 109331-3,-4

X X X

03/12/93 03/12/93

Electrical Components, Power Unit

X X X X

X X X

03.0–14.0–200 1A128989 1A128989

ELECTRICAL PARTS

X X X

03 - 8/95 03 - 6/94 01 - 9/88

Page Number

DRIVE UNIT PARTS

03 - 11/97 02 - 5/90

SECTION 4 X

Serial No. of Units Used For From: To: Standard Special Date

Title

Crown 1988 PF8188-7 Rev. 7/98

04.0–19.0–003 04.0–19.0–100 04.0–19.0–200 04.0–19.0–300 04.0–19.0–302 04.1–18.1–001 04.1–19.0–001 04.1–19.0–003 04.2–19.0–050 04.2–19.0–100 04.2–19.0–150 04.2–19.0–151 04.2–19.0–152 04.2–19.0–153 04.3–18.1–400 04.3–19.0–001 04.3–19.0–003 04.3–19.0–005 04.3–19.0–100 04.3–19.0–102 04.3–19.0–500 04.3–19.0–550 04.3–19.0–600

Printed in U.S.A.

07 REV. 7/98

IDX–19.0–007

TSP INDEX

X X

X X X

03 - 10/97 01 - 3/95 01 - 2/92

Contactor, FB, RB 106842, 107258 Contactor, D 102061 Contactor, P3,P2,P1, ED1 102063

X X

X X X

01 - 10/96 05 - 5/95 03 - 5/91

Contactor, P3,P2,P1, ED1 114393 Control Linkage, L.H. Speed Controls 104620

X X X X X X X X

X X X X X X X X X

03 - 6/96

05 - 5/98 01 - 9/88 02 - 4/93

Speed Controls 113026-001,-002 Connectors Steering Feedback 106569 Height Cable Switch Limit Switch 107335-001 thru -004 Floor Pedal Display Panel Foot Pedestal Control Cables

05 - 12/93 01 - 9/93

Title

Serial No. of Units Used For From: To: Standard Special Date

Revision No. - Date

01 - 1/94

Control Cables

X X

01 - 9/95

Control Cables Flashing Light

X X

02 - 1/94 02 - 1/94

SECTION 5 X X X

X X

X X X X X

01 - 9/88 01 - 12/89

1A121570 1A121570

07/01/92 07/01/92

1A113650 1A113650

08/20/91 08/20/91

W-81876 1A135868 1A135868 1A156106 1A156106

02/06/89 11/01/93 11/01/93 05/08/95 05/08/95

Overhead Light & Fan L.H. Overhead Light Console, R.H.

H-17914 H-17914

2/90 2/90

H-15666 H-15666

5/89 5/89

04.4–19.0–102 04.5–19.0–001 04.6–19.0–001 04.6–19.0–003 04.8–18.1–170 04.8–19.0–001 04.8–19.0–050 04.8–19.0–100 04.8–19.0–150 04.8–19.0–200 04.8–19.0–250 04.8–19.0–500 04.8–19.0–502 04.8–19.0–504 04.9–19.0–001 04.9–19.0–003 04.9–19.0–050 04.9–19.0–052 04.9–19.0–100

BRAKE PARTS Brake System, Drive Unit

05.0–19.0–001

1A151601 1A151601

H-15666 7/89 H-15666 7/89 01/20/95 01/20/95

1A113650 1A113650

08/20/91 08/20/91

1A170196

05/08/96

1A170196

05/08/96

Brake System, Drive Unit

01 - 9/88

Brake System, Drive Unit Brake System, Load Wheel

01 - 6/87

Brake System, Load Wheel Brake Assembly 92228

SECTION 6

04.4–19.0–001 04.4–19.0–050 04.4–19.0–100

W-94894 W-94894

Flashing Light Overhead Light & Fan L.H.

Page Number

05.0–19.0–003 05.0–19.0–005 05.0–19.0–100 05.0–19.0–101 05.3–14.0–101

STEERING PARTS

X X

04 - 9/88

Steering Gearbox Steering Gearbox

X X X X

02 - 12/93 04 - 9/95 03 - 7/91 01 - 9/88

Steering System Steering Controls Motor, Steering Servo 93105 72V Motor, Steering Servo 107939 48V

Crown 1988 PF8188-8 Rev. 7/98

06.0–7330–102 06.0–18.0–100 06.0–19.0–001 06.0–19.0–050 06.2–18.0–001 06.2–19.0–001

Printed in U.S.A.

07 REV. 7/98

IDX–19.0–008

TSP INDEX

Revision No. - Date

SECTION 7 X

X X X

Mast TF

X X X X X X X X X X

02 - 5/98 01 - 1/94

Mast TF Mast - TN

02 - 5/98 03 - 12/94 01 - 12/93

Mast - TN Load Wheel Assembly Rail Guide Wheel

02 - 9/88 05 - 7/88

Guide Wheels Yoke Assembly, TF Mast Pulleys, Tip Out, TF

03 - 7/88

Mast Pulleys, Rear, TF Hose Take-Up, TF

X X X

01 - 9/93 01 - 2/94 01 - 5/93 01 - 7/90 01 - 9/88

Hose Take-Up Pulleys, TF Yoke Tip Out - TF Tip Out - TN Mast Pulleys, Rear Hose Take-Up, TF Lift Chain

X X

X X X

02 - 6/97 01 - 6/97 01 - 8/89

Lift Chain Lift Chain Mast Auxiliary

X X

01 - 4/94

Mast, Auxiliary Fork

X X

02 - 5/97

Fork Fork, Fixed

X X

07.1–19.0–001

W-94126 W-94126 1A124128 1A124128 1A155928 1A155928 1A135868 1A138496 1A138496

H-15666 6/89 H-15666 6/89 11/09/89 11/09/89 09/30/92 09/30/92 05/02/95 05/02/95 11/01/93 01/13/94 01/13/94

1A179139 1A179139

02/03/97 02/03/97

W-94317

11/15/89

Mast TF

01 - 7/88

Page Number

MAST PARTS Mast TF

Serial No. of Units Used For From: To: Standard Special Date

Title

07.1–19.0–003 07.1–19.0–005 07.1–19.0–007 07.1–19.0–009 07.1–19.0–050 07.1–19.0–052 07.4–18.0–002 07.4–19.0–100 07.4–19.0–101 07.5–18.0–002 07.5–18.0–100 07.5–18.0–201 07.5–18.0–302

W-94317

11/15/89

W-94317 W-94317 1A135868 W-94317 W-94317

11/15/89 11/15/89 11/01/93 11/15/89 11/15/89

1A135868 1A135868 1A166753

11/01/93 11/01/93 02/01/96 H-16736 H-16736

W-88940

5/89 5/89

H-17466 9/89 H-17466 9/89 10/24/89

07.5–18.0–401 07.5–18.1–001 07.5–18.1–100 07.5–18.1–150 07.5–18.1–200 07.5–18.1–300 07.6–19.0–001 07.6–19.0–003 07.6–19.0–050 07.7–19.0–001 07.7–19.0–003 07.9–19.0–001 07.9–19.0–003 07.9–19.0–050

Printed in U.S.A.

Crown 1988 PF8188-9 Rev. 7/98

07 REV. 7/98

IDX–19.0–009

TSP INDEX TN

Revision No. - Date

SECTION 8 X X X

01 - 9/88 01 - 9/88

Serial No. of Units Used For From: To: Standard Special Date

Title

CYLINDER PARTS Cylinder, Main Lift - TN 100432 Cylinder, Lift - Main TF 89346 Cylinder, Lift - Free Lift TF 89345

Cylinder, Lift - Free Lift TF 109271

X X X

Cylinder Free Lift 119010 Cylinder, Auxiliary Lift 101688 Cylinder, Fork 106063

01 - 9/92

X X X

01 - 9/88 04 - 9/92

Cylinder, Fork - Telescopic 112853Cylinder, Brake - Drive Wheel 90306 Cylinder, Brake - Load Wheel 100256

X X

X X X

02 - 8/95 02 - 8/95 02 - 5/98

Cylinder, Brake - Load Wheel 113295 Cylinder, Pivot Latch 101288 Cylinder, Pivot 110550

02 - 5/98

Cylinder, Pivot 114568

01 - 5/98

Cylinder, Pivot 114568

SECTION 9

02 - 8/89 01 - 1/95

1A135868

11/01/93

W-94456 W-94465 1A155751 1A155751

H-18215 12/89 H-18215 12/89 04/28/95 04/28/95

Cylinder, Fork - Telescopic 109475-

X X

Page Number

1A104883 1A104883

08.1–18.1–001 08.2–18.0–003 08.2–18.0–102 08.2–18.1–100 08.2–18.1–102 08.4–19.0–001 08.7–19.0–001

H-17466 9/89 H-17466 9/89 08/17/90 08/17/90 H-12551 4/86

1A113650 1A113650

08/20/91 08/20/91

1A122499 1A122499 1A142990 1A142990

08/06/92 08/06/92 05/31/94 05/31/94

1A135868 1A135868 1A155928 1A155928

H-15666 5/89 H-15666 5/89 11/01/93 11/01/93 05/02/95 05/02/95

1A135868 1A135868 1A155928 1A155928

11/01/93 11/01/93 05/02/95 05/02/95

1A135868 1A135868

11/01/93 11/01/93

1A187669 1A187669

10/03/97 10/03/97

1A145560 1A145560

08/16/94 08/16/94

08.7–19.0–002 08.7–19.0–003 08.8–18.0–003 08.8–18.0–050 08.8–18.1–050 08.8–19.0–001 08.8–19.0–100 08.8–19.0–101 08.8–19.0–102

PLATFORM PARTS Platform, View 1

09.0–19.0–001

Platform, View 1

02 - 1/95

Platform, View 1

X X

03 - 8/95 01 - 9/88

Platform, View 1 Platform, View 2

X X

X X X

03 - 5/98 02 - 9/88

Platform, View 2 Seat Shock Absorber

X X

01 - 4/94 02 - 12/93

Shock Absorber Height Sensor

X X

01 - 8/88

Height Sensor Gate

01 - 9/95

Gate

Platform, View 2

09.0–19.0–003 09.0–19.0–005 09.0–19.0–007 09.0–19.0–050 09.0–19.0–052 09.0–19.0–054 09.0–19.0–100 09.0–19.0–150 09.0–19.0–151 09.0–19.0–200 †

09.0–19.0–201 09.0–19.0–250 09.0–19.0–251

† Denotes new form on this index.

Printed in U.S.A.

Crown 1988 PF8188-10 Rev. 7/98

07 REV. 7/98

IDX–19.0–010

TSP INDEX

Revision No. - Date

Serial No. of Units Used For From: To: Standard Special Date

Title

Load Handler

X X

X X X

05 - 5/97 03 - 8/90

Load Handler Traverse Drive Pivot Mechanism

01 - 11/93

Pivot Mechanism

X X

01 - 5/97 02 - 9/88

Pivot Mechanism Fork Carriage - Telescopic

X X

02 - 8/96

Fork Carriage - Telescopic Fork Carriage - Fixed

02 - 8/96

Fork Carriage - Fixed

X X

09.1–19.0–001

Fork Carriage - Telescopic

SECTION 10 01 - 8/95 02 - 7/96

SECTION 11

Page Number

1A142990 1A142990

05/31/94 05/31/94

1A122499 1A122499 1A142990 1A142990

08/06/92 08/06/92 05/31/94 05/31/94

W-88940 W-88940 1A142990 1A142990 W-88940 1A142990 1A142990

10/24/89 10/24/89 05/31/94 05/31/94 10/24/89 05/31/94 05/31/94

1A160656 1A160656

08/28/95 08/28/95

09.1–19.0–003 09.1–19.0–100 09.1–19.0–200 09.1–19.0–202 09.1–19.0–204 09.1–19.0–300 09.1–19.0–301 09.1–19.0–303 09.1–19.0–350 09.1–19.0–351

ACCESSORIES Labels & Decals

10.9–19.0–001

Labels & Decals

10.9–19.0–005

MISCELLANEOUS SERVICE INFORMATION

06 - 7/98

Technical Service Bulletins - contains all service bulletins pertaining to this series.

11.0–19.0–100

04 - 7/98

Kit Instructions - contains part numbers of various service kits pertaining to this series, with instructions referenced.

11.0–19.0–200

Remanufactured Parts - contains part numbers of various frequently ordered remanufactured parts, not listed in service manual, for this series.

11.0–19.0–300

Printed in U.S.A.

Crown 1988 PF8188-11 Rev. 7/98

07 REV. 7/98

IDX–19.0–011

This page available for NOTES.

SAFETY General Maintenance Instructions

General Maintenance Instructions WARNING TO PREVENT SERIOUS RISK OF INJURY TO YOURSELF AND OTHERS OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS Power industrial trucks may become hazardous if adequate maintenance is neglected. Therefore, adequate maintenance facilities, trained personnel and procedures should be provided. Maintenance and inspection shall be performed in conformance with the following practices:

5. Before starting to operate truck— –

Be in operating position.

–

Apply brake.

–

Place directional control in neutral.

– Before operating truck, check functions of lift systems, directional control, speed control, steering, warning devices, brakes and any attachments if any used. 6. 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.

1. A scheduled planned maintenance, lubrication, and inspection system should be followed.

7. Keep shop well ventilated, clean and dry.

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

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

3. Before leaving the truck— –

Stop truck.

–

Fully lower the load engaging means.

–

Place directional controls in neutral.

–

Apply the parking brake.

–

Turn off power (power disconnect).

–

Remove key.

–

Block the wheels if truck is on an incline.

4. Before working on truck— – Raise drive wheel free of floor or disconnect power sources. – Use chocks or other positive positioning devices. – Block load engaging means, inter masts, or chassis before working under them. – Operation to check performance of truck or attachments shall be conducted in an authorized safe clearance area.

9. Capacity, operation and maintenance instruction plates or decals shall be maintained in legible condition. 10. All parts of lift mechanisms shall be inspected to maintain them in safe operating condition. 11. All hydraulic systems shall be regularly inspected and maintained in conformance with good practice. Cylinders, valves, and other similar parts shall be checked to assure 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 shall be maintained in conformance with good practice. Special attention shall be paid to the condition of electrical insulation. 13. Trucks shall be kept in a clean condition to minimize fire hazards and facilitate detection of loose or defective parts. 14. Modifications and additions which affect capacity and safe truck operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation and maintenance plates or decals shall be changed accordingly. 15. Care shall be taken to assure that all replacement parts are interchangeable with the original parts and of equal quality to that provided in the original equipment.

Crown 1976 PF2821-1 Rev. 10/06

MA-04.0-001 04 Rev. 10/06

SAFETY General Maintenance Instructions 16. Be sure that any equipment added to the 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. For further information pertaining to operating and maintenance procedures:

•

All trucks except Series B and Tow Tractors, refer to current ASME B56.1.

•

Series B trucks, refer to current ASME B56.10.

•

Tow Tractors, refer to current ASME B56.9.

MA-04.0-002 04 Rev. 10/06

Crown 1976 PF2821-2 Rev. 10/06

SAFETY Cleaning of Material Handling Equipment

Cleaning of Material Handling Equipment Cleaning Methods The preferred method of cleaning built up dirt and dust from electric material handling equipment is dry pressured air. For localized degreasing, use of an appropriate solvent is recommended. If these methods are not effective and power washing is the only alternative, extreme care must be exercised. Electrical components including connectors, terminal boards and wiring can be permanently damaged from water and/or cleaning solvents. Mineral and chemical residue left on or in components (i.e., circuit boards, contactors, encoders, switches, potentiometers, etc.) after washing is a proponent of oxidation and corrosion. Functional integrity of contaminated components may be questionable. Nuisance fault logging, intermittent

operation or immediate failure could be the resultant of power washing. For these reasons all electronic components including motors must be protected. Component removal is the best method to eliminate the risk of damage. Power washing will also remove and/or destroy lubricants in or on the surface of shafts, unsealed bearings, hinges, exposed gears, bushings, chains, linkages, etc. These Items must also be protected or properly lubricated after cleaning. Consideration must also be given to metal surfaces. The cleaning process can strip away paint and protective coatings applied to components (i.e., hydraulic lines, terminal strips, linkages) for freezer/corrosion environment. Paint and/or protective coating must be reapplied to these areas to reduce the chance of oxidation and corrosion. Before installing removed components, lubricating or returning the equipment to service it must be free of solvent residue and thoroughly dry.

Crown Cleaning Products Chart Cleaner Type

Part Number

Package Quanity

Degreaser & Cleaner

363105-001 363105-012

20 oz. Can (12) 20 oz. Cans

All Purpose Cleaner

363114-001 363114-012

20 oz. Can (12) 20 oz. Cans

Glass Cleaner

363101-001 363101-012

20 oz. Can (12) 20 oz. Cans

Waterless Hand Cleaner

363111-001 363111-012

15 oz. Tube (12) 15 oz. Tubes

Pumiced & Smooth Hand Cleaner

363112-001 363112-004

1 Gallon Jug (4) 1 Gallon Jugs

363122

Used with 363112-001

063009-005

1 Gallon Jug

Wall Mounted Deluxe Soap Dispenser Tough On Grease

Crown 2000 PF11969-1 Rev. 10/06

MA-1140-050 02 Rev. 10/06

MAINTENANCE 5538

LIFTING & BLOCKING POINTS TS, TSP SERIES TRUCKS NOTES: Move Truck to a Secure Non Traffic Maintenance Area With a Level Floor

Steer Wheel

No Load on Forks !

WARNING Do Not Raise Operator Compartment More Than 18 in. (450mm) From Floor

Disconnect Battery Hydraulic Jack - Capacity 8000 LBS. Crown P/N: 122599 Collapsed Height Minimum: 2.25 in. (57 mm) Raised Height Maximum: 16 in. (405 mm) Jack Stand - Capacity 10,000 LBS. Commercially Available

Side !

WARNING Do Not Raise Operator Compartment More Than 18 in. (450mm) From Floor

Wheel Chock Both Load Wheels

Set Jack Stand Height as Required Not to Exceed 13.5 in. (340 mm)

Load Wheel

WARNING Before Raising Steer Wheel End of Truck Check That Jack Does Not Interfere With Wire Guidance Sensor

Hard Wood Block

961201 Crown 1996 PF-11034

MA–18.1–100

WARNING

Do Not Raise Load Wheel More Than 0.5 in. (13mm) From Floor to Position Hard Wood Block

5099 Printed in U.S.A.

MA–18.1–100

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT TS, TSP 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 TS, TSP. Before performing any service or maintenance on the TS, TSP, 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.

6535 Crown 2000 PF11871-1 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–18.1–101

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT BATTERY REMOVAL

BATTERY INSTALLATION CAUTION

When removing the battery, move truck to area intended for battery care. Floor must be level. Turn keyswitch 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. Never move battery partially from truck without roller stand in place. 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) to cover the top of the battery before and during removal.

CAUTION When installing the battery, move truck to area intended for battery care. Floor must be level. Turn keyswitch or toggle switch to "off" position and remove key. Lockout or tagout truck as described in Battery - Lockout/Tagout in this section. If battery was 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 transporting or installing the battery. Use an insulator (such as plywood) to cover the top of the battery before and during installation.

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

8251

LOCKOUT - TAGOUT Always turn key switch to "off", remove key and apply tag to steering tiller with cable tie warning others truck is being serviced. When maintenance is to be performed and the battery will be left in the truck, remove the main power fuses and install a commercially available lockout device on the battery connector.

ING RN WA onnect

t c is no to th Dottery . e is bahiclenancrmed t ve inte erfo is no Maing phicler bed ve le fo anailab on. av erati 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.

8288

Crown 2000 PF11871-2

MA–18.1–102

Printed in U.S.A.

MA–18.1–102

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT BRAKE The brakes can be released through the use of the Drive/Tow switch (EMS-4) during a maintenance situation. When using this method to release the brakes, the truck will not have brakes available for stopping. The truck will not have traction control and the power steering system may not work.

WARNING Extreme care must be taken when using the Drive/Tow switch to release the brakes. The truck will be free-wheeling and the brake pedal in the operator compartment will have no effect on braking. Brakes will only be applied when EMS-4 is moved from the Tow to the Drive position.

Drive/Tow Switch EMS-4

1. Lockout or tagout truck as described in Battery Lockout/Tagout in this section. 8289

2. Chock wheels or make sure truck is secured by some means to keep it from free-wheeling. 3. When towing the truck make sure all operators are informed of the trucks lack of braking. 4. Connect battery. Move switch EMS-4 from the Drive position to the Tow position. 5. Move truck to level area intended for maintenance. 6. Move EMS-4 from the Tow to the Drive position. Disconnect battery.

Crown 2000 PF11871-3

MA–18.1–103

Printed in U.S.A.

MA–18.1–103

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT CAPACITANCE Due to capacitance voltage present in the traction motor controller and lift 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 positive and negative terminals of the capacitor for 3 or more seconds.

100 V E OL

NTR

O RC

Capacitor Terminals 8281-01

Crown 2000 PF11871-4 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–18.1–104

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, make certain the hydraulic system is not under pressure by: 1. Move truck to a secure non traffic maintenance area with a level floor.

7. Traverse System. Heed warning about high pressure fluids. Carefully loosen fitting at the sideshift cylinder to relieve pressure from traverse accumulator. 8. Open the manual lower valve to remove hydraulic pressure.

Manual Lower Valve 8290

ACCUMULATOR The accumulator (hydraulic system shock absorber and brake hydraulic system energy supply) contains a charge of inert gas such as dry nitrogen. Do not tamper with the gas valve on the accumulator in an attempt to reduce the amount of this charge. Use accumulator charging equipment and procedures as described in the M2.6 section of this manual.

Accumulator

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.

Gas Valve

4. Brake System. With key switch off, cycle the drive/tow switch repeatedly until brakes no longer apply. This removes pressure from the brake accumulator. 5. Lockout or tagout truck as described in Battery Lockout/Tagout in this section. 8266

Hydraulic Line Connection

6. Lift/Lower System. Open power unit doors and locate the manual lower valve on the right edge towards the top of the power unit.

Crown 2000 PF11871-5 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–18.1–105

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT LIFTING AND BLOCKING 1. Move truck to a secure non traffic maintenance area with a level floor.

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.

2. No load on forks. 3. Lockout or tagout truck as described in Battery Lockout/Tagout in this section.

Side Bracket Components: (1) - 109431 - Bracket (1) - 092832 - Pin (2) - 060030-054 - Flatwasher (2) - 060023-006 - Bolt (2) - 060005-023 - Lockwasher (2) - 060000-022 - Roll Pin

Steer Wheel !

WARNING Do Not Raise Operator Compartment More Than 18 in. (450mm) From Floor

Load Wheel Hard Wood Block

Wheel Chock Both Load Wheels

8291-01

WARNING Truck stability decreases dramatically if load wheels are raised more than 0.5 inch (13 mm). Attach overhead lifting device to bracket to prevent truck from tipping over when raising the side of the truck.

Set Jack Stand Height as Required Not to Exceed 13.5 in. (340 mm) !

WARNING Before Raising Steer Wheel End of Truck Check That Jack Does Not Interfere With Wire Guidance Sensor 8292

Crown 2000 PF11871-6 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–18.1–106

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT MAIN MAST AND AUXILIARY MAST Main Mast

Auxiliary Mast

Use 4 inch (100 mm) by 4 inch (100 mm) or bigger hardwood blocks of the appropriate length for holding mast channels. Block both mast rails of each stage to maintain truck stability. Platform cannot be blocked. After blocks are placed for second stage mast, lower platform to contact stops.

Use 4 inch (100 mm) by 4 inch (100 mm) or bigger hardwood blocks of the appropriate length for holding mast channels. Block both mast rails to maintain truck stability. 1. Chock wheels of truck. Refer to Lifting and Blocking in this section.

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

2. Connect battery.

3. Raise fork carriage to obtain desired height and position blocks of appropriate length in both rails.

3. Raise main mast to obtain desired second stage height and position block in each main frame rail of appropriate length.

4. Using a clamp, secure blocks to mast rail.

4. Using a clamp, secure blocks to main frame. 5. Lower mast so mast is resting on blocks and platform is against stops.

5. Lower fork carriage so carriage is resting on blocks. 6. Lockout or tagout truck as described in Battery - Lockout/ Tagout in this section.

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

Second Stage

Mainframe

8293 8283 Crown 2000 PF11871-7

MA–18.1–107

Printed in U.S.A.

MA–18.1–107

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT SPRINGS The pivot latch cylinder and the load wheel brake cylinder have an internal spring for moving the ram when hydraulic pressure is removed. If care is not taken during disassembly, personal injury can occur when spring tension is relieved. LOAD WHEEL BRAKE CYLINDER

PIVOT LATCH CYLINDER 1. With cylinder removed from truck as described in the M8.8 section of this manual, install a tool similar to the one shown to control the compressed spring and allow for cylinder cap removal.

1. With cylinder removed from truck as described in the M8.8 section of this manual, install a nut (1/2-13 thread) and flatwasher on the cylinder ram to keep the spring contained during disassembly.

3/8-16 Thread

1/2-13 Nut

Flatwasher

Brake Cylinder

8295

8294

2. Once cylinder cap is removed, turn the adjusting nut counterclockwise to relieve spring tension.

2. Once cylinder end cap is separated from the cylinder tube, slowly loosen nut installed to relieve tension on the spring.

Crown 2000 PF11871-8

MA–18.1–108

Printed in U.S.A.

MA–18.1–108

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT HEIGHT SENSOR

WARNING The spring is reverse wound and if not kept restrained, will unwind completely and rewind in the opposite direction. Personal injury is possible if extreme caution is not exercised. It is recommended to wear safety glasses and gloves when removing the spring. Tool Fabrication A tool for moving the spring in the reel can be fabricated as shown in the illustration. 3/16 inch (4.8 mm) diameter rod

8297P

2. Remove four screws from reel cover and allow the spring tension to release through cover rotation.

Cut and Weld at 90 degrees

Grind flat

3. Pull cover approximately 1 inch (25 mm) from housing and with a screwdriver work the arbor off the square shaft of the cover. 4. Separate cover and spacer. Wipe off grease. 5. Carefully pull the arbor from the spring with a needle nose pliers.

2 inches (50 mm)

8296

2 inches (50 mm)

Spring Removal

6. Move opening in inside spacer around until spring retainer mounting screws can be accessed. Remove retainer screws. 7. Using a fabricated rod or screwdriver, work spring out of reel 1/2 inch (15 mm) all the way around.

1. After the height sensor is removed from the truck, lock the sensor in a vise.

CAUTION

8. Securely grip the spring with a vise grip near the end of the spring on the outside diameter. Hold the vise grip with one hand and work the spring from the reel with the fabricated tool.

When the last screw is removed, spring tension will be released through cover rotation of approximately 5 revolutions.

8298P

9. Carefully wrap numerous cable ties around the spring so vise grip can be removed. Discard spring. Crown 2000 PF11871-9 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–18.1–109

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT Spring Installation 1. When height sensor is ready to have the spring installed, place a vise grip carefully on the reel shaft and secure the vise grip to keep the reel from turning. On the newer style sensor, place a bolt through the reel housing to lock the reel.

2. The new spring is shipped with a 1/4" diameter rod wrapped partially around the circumference of the spring and is wire tied. Make sure rod is center on the spring and remove the wire ties. 3. Move shipping rod around circumference of spring so end of spring protrudes between ends of rod.

8301P 8299P

4. Assemble hook of spring retainer in hole of spring. Retainer mounting tab must be on opposite side of spring as the diagonally cut corner at end of spring. 5. Position inside spacer between spring and spring retainer so raised portion of spacer is away from spring. 6. Slide assembly into reel, spring retainer first, and work shipping bar to outer edge of spring. Move assembly around until mounting holes of spring retainer and reel align. Start screws to hold spring retainer to reel.

8300S

Crown 2000 PF11871-10

MA–18.1–110

Printed in U.S.A.

MA–18.1–110

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT 7. Carefully push spring into reel and allow to expand inside reel. Tighten screws holding spring retainer.

8302P

8. Thoroughly soak spring with lubricant (063001-009). 9. Insert arbor into center of spring so when arbor is turned clockwise, flat on arbor pulls spring. 10. Coat both surfaces of end spacer with lubricant (063001-009) and place in reel housing. 11. Insert square shaft of cover into arbor and slide cover against housing. Turn cover clockwise five revolutions. Insert screws and tighten.

Crown 2000 PF11871-11

MA–18.1–111

Printed in U.S.A.

MA–18.1–111

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT AUXILIARY MAST and PLATFORM LIFTING Auxiliary Mast The platform weighs approximately 2000 lbs. (900 kg) and the load handler with sideshifter weighs approximately 2200 lbs. (1000 kg). Be sure equipment used to lift and support the load handler and platform is of sufficient capacity to safely handle this load.

7. Hook-up hoist to lifting tool and raise load handler just enough to transfer the load handler weight from the platform to the hoist.

1. Move truck to a secure non traffic maintenance area with a level floor. Aux. Mast Lifting Tool (110571)

2. Completely lower main and auxiliary masts. No load on forks. 3. Lockout or tagout truck as described in Battery Lockout/Tagout in this section. 4. Chock wheels as described in lifting and blocking in this section. 5. Prepare the auxiliary mast to be removed as described in section M9.0 in this manual. 6. Attach lifting tool (Crown 110571) to the top of the auxiliary mast.

TSP

8666

8. Slowly slide the load handler and sideshifter out of the left side (door side) of the platform being careful not to damage the gang hose and cable. 9. Carefully move load handler away from truck.

Crown 2000 PF11871-12 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–18.1–112

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT Platform 1. Move truck to a secure non traffic maintenance area with a level floor. 2. Completely lower main and auxiliary masts. No load on forks. 3. Lockout or tagout truck as described in Battery Lockout/Tagout in this section. 4. Chock wheels as described in lifting and blocking in this section. 5. Remove the load handler and sideshifter as described in section M9.0 in this manual. 6. Place a 4 x 4 (100 mm x 100 mm) hardwood block under the overhead guard, tight against the back of the platform. Be sure block is at least 1 foot (305 mm) longer than the overhead guard and is centered. If the truck is equipped with spotlights and overhead fan, disassemble these first from the overhead guard.

2477S

7. Using a 3-point hook-up, attach sling, chain, etc. to block and back of overhead guard. Raise platform to the desired height. 8. Block the platform as described in Mast and Platform of this section or remove platform as described in section M9.0 in this manual.

Crown 2000 PF11871-13

MA–18.1–113

Printed in U.S.A.

MA–18.1–113

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT SERVICE PLATFORM When performing maintenance to a primary lift cylinder, Crown recommends using a service platform. A service platform is available from Crown; the part no. is 109792-012. The platform is placed at the top of the mast with a fork lift or hoist with sling, etc. NOTE The service platform cannot be used on TS and TSP trucks having a collapsed height of 137 in. (3480 mm) or less. Utilize an appropriate maintenance platform fitted to another lift truck to perform maintenance to the lift cylinder area at the top of the mast. 1. Move truck to a secure non traffic maintenance area with a level floor. 2. No load on forks. 3. Lockout or tagout truck as described in Battery Lockout/Tagout in this section. 4. Chock wheels as described in lifting and blocking in this section. 5. Turn the two clamps at the top of the platform counterclockwise to allow for clearance of the I-beam flange before attempting to place platform on mast.

2488S

6. Secure the service platform to the forkplate of the fork lift, if used, before lifting. Wrap sling or chain to the four corner posts of the platform railing when utilizing a hoist to install platform.

WARNING Personnel are not to ride on the service platform while it is being lifted into position on the truck. 7. After the service platform has been properly positioned, maintenance personnel can take their position on the platform by using an appropriate length ladder to access platform. The clamps must be tightened, by turning clockwise, against the I-beam flange at this time. 2489S

Crown 2000 PF11871-14 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–18.1–114

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, troublefree operation of your Crown Lift Truck. For turret stockpicker operator instructions, refer to Crown publication, “You and Your Crown Turret Stockpicker” (PF-9973). DRIVER TRAINING Crown has available a complete series of Driver Training programs, in two parts concerning basic safety rules and operating characteristics of your turret stockpicker. To obtain this informative material, ask your Crown Dealer about “Its up to You” and “You and Your Turret Stockpicker”. 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. REPLACEMENT PARTS 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 TSP capacities, technical information and dimensional specifications, please refer to the following sales literature: TSP Literature TSP Specification

SF-4310 SF-12018

Copies of publications can be obtained from your Crown dealer or by writing to: Crown Equipment Corporation 40-44 S. Washington Street New Bremen, OH 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 the written maintenance. The back covers the replacement parts. The sectional descriptions are as follows: MAINTENANCE SECTION M1 M2 M3 M4 M5 M6 M7 M8 M9 M10

DESCRIPTION

REPLACEMENT PARTS SECTION

Lubrication and Adjustments Hydraulics Drive Unit Electrical Brake Steering Mast and Main Frame Cylinder Platform Glossary

1 2 3 4 5 6 7 8 9 10 11

DESCRIPTION Basic Chassis or Power Unit Hydraulic System and Components Drive Unit and Components Electrical Components Brake Assemblies and Brake Systems Steering System and Components Main Frame and Mast Assemblies Cylinders Platform Assembly Accessories Specifications 5445

Crown 1988 PF-8162-1 Rev. 5/97

Printed in U.S.A.

03 REV. 5/97

ITD–19.0–001

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. MODEL NUMBER SYSTEM 30

TSP

*CAPACITY Pound Rated (x 100) Ex. 30 x 100 = 3000 Ibs. (1360kg)

† GUIDE WHEEL SPREAD DASH IN.(mm) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

SERIES DESIGNATION TSP - Turret Stockpicker MAST T - Telescopic TYPE F - Full Free Lift L - Limited Free Lift N - No Free Lift

COLLAPSED HEIGHT DASH IN.(mm) 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

125 (3175) 131 (3330) 137 (3480) 143 (3630) 149 (3785) 155 (3935) 161 (4090) 167 (4240) 173 (4395) 179 (4545) 185 (4700) 191 (4850) 197 (5005) 203 (5150) 209 (5310) 215 (5460) 221 (5615) 227 (5765) 233 (5920) 239 (6070) 245 (6225) 251 (6375) 257 (6530) 263 (6680) 269 (6830)

LIFT HEIGHT IN.(mm) 208 (5285) 220 (5590) 232 (5890) 244 (6200) 256 (6500) 268 (6805) 280 (7110) 292 (7415) 304 (7720) 316 (8025) 328 (8330) 340 (8635) 352 (8940) 364 (9245) 376 (9550) 388 (9855) 400 (10160) 412 (10465) 424 (10770) 436 (11075) 448 (11380) 460 (11685) 472 (11990) 484 (12295) 496 (12600)

1.25 (30) 1.75 (45) 2.25 (60) 2.75 (70) 3.25 (85) 3.75 (90) 4.25 (110) 4.75 (120) 5.25 (135) 5.75 (145) 6.25 (160) 6.75 (170) 7.25 (185) 7.75 (195) 8.25 (210) 8.75 (220)

LOAD WHEEL OVERALL WIDTH DASH IN.(mm) DASH IN.(mm) 5 6 7 8 9 10 11 12 13 14

52 (1320) 53 (1345) 54 (1370) 55 (1395) 56 (1420) 57 (1445) 58 (1475) 59 (1500) 60 (1525) 61 (1550)

15 16 17 18 19 20 21 22 23 24 25

62 (1575) 63 (1600) 64 (1625) 65 (1650) 66 (1675) 67 (1700) 68 (1725) 69 (1750) 70 (1775) 71 (1805) 72 (1830)

EXAMPLE: A truck having the model number 30 TSPTF is a 3000 Ib. (1360kg) capacity Turret Stockpicker with telescopic full free lift, 125 in. (3175mm) collapsed height, 52 in. (1320mm) overall load wheel width and 1.25 in. (30mm) guide wheel spread. * Actual rated capacity may vary, depending upon special equipment or modifications. Consult serial number plate. † Beyond load wheel overall width.

Crown 1988 PF-8162-2 Rev. 5/97

Printed in U.S.A.

03 REV. 5/97

ITD–19.0–002

INTRODUCTION The truck data number provides you and your Crown dealer with a wealth of information to insure the selection of proper parts for your Crown truck. You may simply provide this number to your Crown dealer, or use the following breakdown if selecting your own part numbers or service information from this manual.

Clear Aisle Clear Aisle Value

Voltage 48 = 48 volts 72 = 72 volts

Battery Compartment Size B C D

Mast Type TN = No Telescopic Free Lift TF = Telescopic Full Free Lift

C TN 208 48 – 56 52 B Standard / Custom / Special – = Standard C = Custom S = Special

Lift Height 208 = 208 in. (5285mm) 220 = 220 in. (2590mm) 232 = 232 in. (3200mm) 244 = 244 in. (3810mm) 256 = 256 in. (3860mm) 268 = 268 in. (6805mm) 280 = 280 in. (7110mm) 292 = 292 in. (7415mm) 304 = 304 in. (7720mm) 316 = 316 in. (8025mm) 328 = 328 in. (8330mm) 340 = 340 in. (8635mm) 352 = 352 in. (8940mm)

Transverse Frame Width 52 thru 63 in. (1320 thru 1600mm)

Guidance System – = No Guidance System 1 = Wire 2 = Rail 3 = Wire/Rail

364 = 364 in. (9245mm) 376 = 376 in. (9550mm) 388 = 388 in. (9855mm) 400 = 400 in. (10.15m) 412 = 412 in. (10.45m) 424 = 424 in. (10.75m) 436 = 436 in. (11.05m) 448 = 448 in. (11.40m) 460 = 460 in. (11.70m) 472 = 472 in. (12.00m) 484 = 484 in. (12.30m) 496 = 496 in. (12.60m) SPC= Special

Crown 1988 PF-8162-3 Rev. 5/97

Printed in U.S.A.

03 REV. 5/97

ITD–19.0–003

This page available for NOTES.

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. 10/06

M1.0-04.0-001 16 Rev. 10/06

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

Gear Lube 80W-90 (Typical)

363506-001 363506-012

1 Quart (12) 1 Quart Cans

Automatic Transmission Fluid (Multi-Purpose)

363503-001 363503-012

1 Quart (12) 1 Quart Cans

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

Oil (SAE 40)

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

Channel Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

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

Grease (Lift Pump Coupling)

063002-039 127801S

1 lb 1 oz

Brake Fluid - Dot 5

063004-002 063004-003

12 oz 1 Gallon

Grease (Wheel Bearing)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

Metal Assembly Spray

063002-021

11 oz Spray

Silicon Grease (Clear)

063002-020

5.3 oz Tube

Package Quantity

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

M1.0-04.0-002 16 Rev. 10/06

Crown 1987 PF7886-2 Rev. 10/06

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

Part Number

Package Quantity

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

Penetrating Lubricant

363104-001 363104-012

20 oz Can (12) 20 oz Cans

Premium Formula Multi-Purpose Grease

363108-001 363108-012

11 oz Can (12) 11 oz Cans

White Lithium Grease

363110-001 363110-012

11 oz Can (12) 11 oz Cans

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

Electrical Connector Oxidation & Corrosion Inhibitor

127189-001

30 cc

Battery Cleaner

363124-001 363124-012

18 oz Can (12) 18 oz Cans

Battery Protector

363125-001 363125-012

15 oz Can (12) 15 oz Cans

Food Grade Machine Lubricant

363127-001 363127-012

12 oz Can (12) 12 oz Cans

Food Grade Silicone Spray

363126-001 363126-012

11 oz Can (12) 11 oz Cans

Crown 1987 PF7886-3 Rev. 10/06

M1.0-04.0-003 16 Rev. 10/06

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Alternate Lubricants & Fluids Chart Type of Lubricant

Manufacturer / Distributor

Product Name

Gear Lube 80W-90 (Typical)

Crown

Automatic Transmission Fluid (Multi-Purpose)

Crown

Grease (Multi-Purpose)

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

Mobil Union 76 Co. Shell Burmah Castrol Exxon

Grease (Low Temp) (2)

Lubriplate Alvania RA(1) Helveum O(1)

Fiske Bros Refining Co. Shell Burmah Castrol

Petro Canada Purity FG

Petro Canada

BBB Food Grade Grease (Multi-Purpose) C

Oil (SAE 40)

Hydraulic Oil

Crown

Hydraulic Oil (Low Temp) (2)

Crown

Mobil DTE 24

Mobil

DDD Hydraulic Oil - DTE24 (3) E

Channel Grease

Factran #2

Standard Oil Co.

Gear, Channel & Shaft Grease

Molykote BR-2 Plus

Dow Corning

Chain & Cable Lube

Crown

Premium Chain & Cable Lube

Crown

Final Finish - Rubber & Vinyl Dressing

Crown

Grease (Lift Pump Coupling)

Nyogel 774F-MS

NYE Lubricants

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.

Metal Assembly Spray

Dow Corning

Silicon Grease (Clear)

Dow Corning 111 Compound

Dow Corning

Brake & Parts Cleaner

Crown

Low VOC Brake & Parts Cleaner

Crown

Non-Flammable Brake & Parts Cleaner

Crown

(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 16 Rev. 10/06

Crown 1987 PF7886-4 Rev. 10/06

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

Product Name

Manufacturer / Distributor

Penetrating Lubricant

Crown

Premium Formula Multi-Purpose Grease Crown

Crown

White Lithium Grease

Crown

Choke & Carburetor Cleaner

Crown

Contact Cleaner

Crown

Electrical Connector Oxidation & Corrosion Inhibitor

Nye Grease

NYE Lubricants

Battery Cleaner

Crown

Battery Protector

Crown

Food Grade Machinery Lubricant

Crown

Food Grade Silicone Spray

Crown

Crown 1987 PF7886-5 Rev. 10/06

M1.0-04.0-005 16 Rev. 10/06

MAINTENANCE LUBRICATION AND ADJUSTMENT Component Accessibility For regular maintenance, access to various truck components is accomplished by removing covers, panels and/or doors. The following is a general explanation of what cover, panel, etc. must be removed to allow for the most efficient access when performing service and/or maintenance to components. Refer to the illustrations in this section as an aid in locating parts that require attention.

The power unit side panels can be removed to service battery, hydraulic components, accessory lift motor, etc. The top cover of the power unit can be lifted off to check battery condition and gain access to the flashing light. The mast has several covers, on top and sides, that allow for access to stops, rollers, chain, etc. Refer to the illustration and charts in this section as a guide.

NOTE Lubrication Be sure battery connectors are disconnected. The console, at the operator’s right, can be raised to allow access to the override switches. Within the operator compartment are numerous covers that must be removed to gain access to switches, encoders, linkage, etc. A panel at the lower right side of the operator compartment can be removed to gain access to the platform microprocessor, power supplies, etc. A panel below the seat can be removed to gain access to the height sensor, lift chain condition switches, seat motor and limit switches, etc. Covers to the operator’s left can be removed to access the horn, spool valves, valve linkage, and various hydraulic lines.

The following information is intended to provide guidelines for proper lubrication intervals as called out in the lubrication chart. Some operating conditions will require more frequent checks and lubrication than listed. Applications with much dust or moisture will require modification of the schedule to fit that particular application. 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 1-1 are typical and any lubricant with equal specifications may be used. † On trucks equipped to operate in below freezing temperatures, low temperature hydraulic oil and grease must be used. All screws, washers, nuts, etc., roll pins, retaining rings, brake linkage, etc. need to be coated with a film of rust preventive (078882-002) to protect against corrosion. Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts.

The power unit doors can be opened to allow access to service the following: drive units, steering, traction SCR, lift SCR, micro-processor, contactors, various electrical controls, fuse(s), etc. Within the exposed area is an electrical door assembly that has various components mounted that can also be opened or swung to the side adding to component access.

NOTE Use Planned Maintenance Inspection Reports (PF5732) for Turret Stockpicker and Wire Guidance (PF8185) as required to record and assure maintenance checks.

6488 Crown 1988 PF8160-1 Rev. 9/03

Printed in U.S.A.

05 REV. 9/03

M1.0–19.0–001

MAINTENANCE 2315S

ILLUSTRATION 1-3

Crown 1988 PF-8160-2 Rev. 9/93

Printed in U.S.A.

01 REV. 9/93

M1.0 - 19 - 002

MAINTENANCE LUBRICATION CHART

INDEX L-1 L-2 L-3 L-4 L-5 L-6 L-7 L-8

COMPONENT Accelerator Twist Grip Brake Pedal Chain Sensor Pivot Side Gate Pivots Pedestal/Floor Pedals Hydraulic Control Levers Seat Guides Steering Tiller

LUBE TYPE QTY. C AR C AR B AR C AR B AR C AR B AR C AR

100

250 † † † † † † † †

HOURS 500 1000

2000

See Illustration 1-3 for Index Call-outs. See Chart 1-2 for Lube Type designation explanation (M1.0 - 04 - 002). †-Check Chg.-Change AR-As Required (Pts.) No. Lube Fittings Lubrication intervals on Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts. CHART 1-4 INSPECTION & ADJUSTMENT CHART HOURS INDEX COMPONENT 100 250 500 I-1 Accelerator Twist Grip † I-2 Brake Operation † I-3 Brake Switch † I-4 Chain, Chain Anchors & Retainers † I-5 Chain Slack/Break Linkage & Switches † I-6 Gate Switch(es) † I-7 Emergency Disconnect † I-8 Lift Cutout Override † I-9 Horn Switch † I-10 Indicator Panel Lights & Switches † I-11 Lift Control Linkage † I-12 Override Switches † I-13 Pedestal/Floor Switches † I-14 Seat Switches † I-15 Steering Tiller Control † I-16 Steering Wheel Directional Lights † I-17 Key Switch †

1000

See Illustration 1-3 for Index Call-outs. Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. On units equipped with Wire Guidance additional inspections should be performed in accordance with the “Wire Guidance Planned Maintenance” check sheet. CHART 1-5 Crown 1988 PF-8160-3 Rev. 10/96

Printed in U.S.A.

03 REV. 10/96

M1.0–19.0–003

MAINTENANCE 2314S

TF MAST SHOWN I-10 L-6

* *

* FREE LIFT CYLINDERS AND ASSOCIATED COMPONENTRY ON TF MASTS ONLY. ILLUSTRATION 1-6

Crown 1988 PF-8160-4 Rev. 9/93

Printed in U.S.A.

01 REV. 9/93

M1.0 - 19 - 004

MAINTENANCE LUBRICATION CHART

INDEX L-1 L-2 L-3 L-4 L-5 L-6 L-7 L-8 L-9 L-10 * L-11 L-12 L-13

LUBE COMPONENT TYPE QTY. Aisle Guide Wheel-Rear (2 Pts.) B AR Battery Rollers B AR Hydraulic Filter Hydraulic Reservoir *D 22 Gal. Hydraulic Strainer Lift Chain G AR Load Wheel Axles B AR Load Wheel Brake Linkage (10 Pts.) B AR Mast Channels F AR Mast Pulleys (Nylon) H AR Mast Rollers B AR Power Unit Door Hinges C AR Steering Linkage (8 Pts.) B AR

100

250 † † †

HOURS 500 1000

Chg. †

†

2000

Chg. Chg. Chg.

† † † † † † † †

See Illustration 1-6 for Index Call-outs. See Chart 1-2 for Lube Type designation explanation (M1.0 - 04 - 002). †-Check Chg.-ChangeAR-As Required(Pts.) No. Lube Fittings Lubrication intervals on Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts. CHART 1-7 INSPECTION & ADJUSTMENT CHART HOURS INDEX COMPONENT 100 250 500 I-1 Aisle Guide Wheels † I-2 Aisle Guide Switches † I-3 Battery † I-4 Battery Connectors † I-5 Brake Cylinders † I-6 Brake Pads † I-7 Chain Anchors & Retainers † I-8 Column Rollers † I-9 Height Sensor Switch † I-10 Lift Chain † * I-11 Lift Cylinder † * I-12 Lift Cylinder Guides, Slides & Stops † I-13 Load Wheels † ** I-14 Power Unit & Mast Bolts † I-15 Steering Linkage †

1000

See Illustration 1-6 for Index Call-outs. * Free lift cylinders and associated componentry on TF masts only ** Prior to 4/25/94 – 300 Nm (220 ft.lbs.) of torque required for grade 5 bolts. From 4/25/94 – 380 Nm (280 ft.lbs.) of torque required for grade 8 bolts. Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. On units equipped with Wire Guidance additional inspections should be performed in accordance with the “Wire Guidance Planned Maintenance” check sheet. CHART 1-8 Crown 1988 PF8160-5 Rev. 11/01

Printed in U.S.A.

04 REV. 11/01

M1.0–19.0–005

MAINTENANCE 2313S

ILLUSTRATION 1-9

Crown 1988 PF-8160-6 Rev. 9/93

Printed in U.S.A.

01 REV. 9/93

M1.0 - 19 - 006

MAINTENANCE LUBRICATION CHART

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

COMPONENT Chain Slack/Break Sensor Clamp (Pivot Latch) Cyl. Cylinder Yoke Fork Slip Pin Lift Chain Mast Channels Mast Pulleys Mast Column Rollers Pivot Chain Pivot Cylinder Mount Fork Slides Traverse Gears Traverse Pinion (4 Pts.) Traverse Racks Hydraulic Motor Chain

LUBE TYPE QTY. C AR C AR B B AR G AR E AR B AR F AR G AR B AR F AR F AR B AR F AR G AR

100

250 † †

HOURS 500 1000

2000

† † † † † † † † † † † † †

See Illustration 1-9 for Index Call-outs. See Chart 1-2 for Lube Type designation explanation (M1.0 - 04 - 002). †-Check Chg.-Change AR-As Required

(Pts.) No. Lube Fittings

Lubrication intervals on Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts. CHART 1-10 INSPECTION & ADJUSTMENT CHART HOURS INDEX COMPONENT 100 250 500 I-1 Chain Anchors & Retainers † I-2 Chain Slack/Break Linkage & Switches t I-3 Clamp (Pivot Latch) Cylinder † I-4 Column Rollers & Channels † I-5 Forks † I-6 Hydraulic Lines, Hoses & Fittings † I-7 Lift Chain † I-8 Lift Cylinder † I-9 Lift Limit Switch † I-10 Pivot Cylinders † I-11 Hydraulic Motor † I-12 Traverse Limit Switches † I-13 Horn †

1000

See Illustration 1-9 for Index Call-outs. Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. On units equipped with Wire Guidance additional inspections should be performed in accordance with the “Wire Guidance Planned Maintenance” check sheet. CHART 1 -11 Crown 1988 PF-8160-7 Rev. 9/93

Printed in U.S.A.

01 REV. 9/93

M1.0 - 19 - 007

MAINTENANCE 2312S

* *

TF MAST SHOWN

* * *

* FREE LIFT CYLINDERS AND ASSOCIATED COMPONENTRY ON TF MASTS ONLY. ILLUSTRATION 1-12

Crown 1988 PF-8160-8 Rev. 9/93

Printed in U.S.A.

01 REV. 9/93

M1.0 - 19 - 008

MAINTENANCE LUBRICATION CHART LUBE INDEX COMPONENT TYPE QTY. L-1 Brake Linkage C AR * L-2 Cylinder Yokes B AR L-3 Drive Unit Level Left & Right A 1 1/2 Pts. ea. L-4 Drive Unit pivot Left & Right B AR L-5 Elec. Compartment Door Hinge C AR * L-6 Hose Take-up Cables G AR * L-7 Hose Take-up Cam Rollers & Pulleys B AR * L-8 Hoses H AR L-9 Platform & Mast Column Rollers F AR L-10 Rear Cover Hinge C AR L-11 Steering Gearbox Level R.H. & L.H. A 2 Pts. ea. L-12 Steering Gears Left & Right F AR L-13 Turret Head Pivot (2 Pts.) B AR L-14 Servo Control Valve C AR L-15 Steering Encoder Linkage C AR

100

†

250 † † † † t † † † † † Chg. † † † †

HOURS 500 1000

2000

Chg.

See Illustration 1-12 for Index Call-outs. See Chart 1-2 for Lube Type designation explanation (M1.0 - 04 - 002). †-Check Chg.-Change AR-As Required(Pts.) No. Lube Fittings Lubrication intervals on Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts. CHART 1-13 INSPECTION & ADJUSTMENT CHART HOURS INDEX COMPONENT 100 250 500 I-1 Brake Cylinders † I-2 Brake Linings † I-3 Brake Operation † I-4 Brake Switches † * I-5 Cable Tension Switches † I-6 Contactor Tips † I-7 Drive Tires † I-8 Electrical Connections † * I-9 Hose Take-up Cables † I-10 Hyd. Lines, Hoses & Fittings † I-11 Motor Brushes - Accessory † I-12 Motor Brushes- Drive (R.H. & L.H.) † I-13 Motor Brushes - Lift † I-14 Motor Brushes - Servo † I-15 Motor Brushes- Steering † I-16 Override Switches † I-17 Power Unit Flashing Light † I-18 Shock Absorbers † I-19 Steering Gears † I-20 Steering Linkage †

1000

See Illustration 1-12 for Index Call-outs. FREE LIFT CYLINDERS AND ASSOCIATED COMPONENTRY ON TF MASTS ONLY Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. On units equipped with Wire Guidance additional inspections should be performed in accordance with the “Wire Guidance Planned Maintenance” check sheet. CHART 1-14

Crown 1988 PF-8160-9 Rev. 9/93

Printed in U.S.A.

01 REV. 9/93

M1.0 - 19 - 009

LUBRICATION AND ADJUSTMENT

Component Accessibility For regular maintenance, access to various truck components is accomplished by removing covers, panels and/or doors. The following is a general explanation of what cover, panel, etc. must be removed to allow for the most efficient access when performing service and/or maintenance to components. Refer to the illustrations in this section as an aid in locating parts that require attention.

NOTE Lubrication

Be sure battery connectors are disconnected. The console, at the operator’s right, can be raised to allow access to the override switches. Within the operator compartment are numerous covers that must be removed to gain access to switches, encoders, linkage, etc. A panel at the lower right side of the operator compartment can be removed to gain access to the platform microprocessor, power supplies, etc. A panel below the seat can be removed to gain access to the height sensor, lift chain condition switches, seat motor and limit switches, etc. Covers to the operator’s left can be removed to access the horn, spool valves, valve linkage and various hydraulic lines. The power unit doors can be opened to allow access to service the following: drive units, steering, traction SCR, lift SCR, microprocessor, contactors, various electrical controls, fuse(s), etc. Within the exposed area is an electrical door assembly that has various components mounted that can also be opened or swung to the side adding to component access.

The following information is intended to provide guidelines for proper lubrication intervals as called out in the lubrication chart. Some operating conditions will require more frequent checks and lubrication than listed. Applications with much dust or moisture will require modification of the schedule to fit that particular application. 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 1-1 in section M1.0-04.0-001 are typical and any lubricant with equal specifications may be used. † On trucks equipped to operate in below freezing temperatures, low temperature hydraulic oil and grease must be used. All screws, washers, nuts, etc., roll pins, retaining rings, brake linkage, etc. need to be coated with a film of rust preventive (078882) to protect against corrosion. Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts.

981102

Use Planned Maintenance Inspection Reports (PF5732) for Turret Stockpicker and Wire Guidance (PF8185) as required to record and assure maintenance checks.

6489

Crown 1998 PF11523-1 Rev. 9/03

M1.0–19.0–010

NOTE

Printed in U.S.A.

04 REV. 9/03

M1.0–19.0–010

LUBRICATION AND ADJUSTMENT 2315S

ILLUSTRATION 1

Crown 1998 PF11523-2

M1.0–19.0–011

Printed in U.S.A.

M1.0–19.0–011

LUBRICATION AND ADJUSTMENT LUBRICATION CHART

INDEX L-1 L-2 L-3 L-4 L-5 L-6 L-7 L-8

COMPONENT Accelerator Twist Grip Brake Pedal Chain Sensor Pivot Side Gate Pivots Pedestal/Floor Pedals Hydraulic Control Levers Seat Guides Steering Tiller

LUBE TYPE QTY. C AR C AR B AR C AR B AR C AR B AR C AR

100

250 † † † † † † † †

HOURS 500 1000

2000

INSPECTION & ADJUSTMENT CHART

INDEX I-1 I-2 I-3 I-4 I-5 I-6 I-7 I-8 I-9 I-10 I-11 I-12 I-13 I-14 I-15 I-16 I-17

COMPONENT Accelerator Twist Grip Brake Operation Brake Switch Chain, Chain Anchors & Retainers Chain Slack/Break Linkage & Switches Gate Switch(es) Emergency Disconnect Lift Cutout Override Horn Switch Indicator Panel Lights & Switches Lift Control Linkage Override Switches Pedestal/Floor Switches Seat Switches Steering Tiller Control Steering Wheel Directional Lights Key Switch

100

HOURS 250 500 † † †

1000

† † † † † † † † † † † † † †

Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. On units equipped with Wire Guidance additional inspections should be performed in accordance with the “Wire Guidance Planned Maintenance” check sheet. See Illustration 1 for Chart 1 and Chart 2 Index Call-outs. CHART 2 Crown 1998 PF11523-3

M1.0–19.0–012

Printed in U.S.A.

M1.0–19.0–012

LUBRICATION AND ADJUSTMENT 2314S

TF MAST SHOWN I-10 L-6

* *

* FREE LIFT CYLINDERS AND ASSOCIATED COMPONENTRY ON TF MASTS ONLY. ILLUSTRATION 2

Crown 1998 PF11523-4

M1.0–19.0–013

Printed in U.S.A.

M1.0–19.0–013

LUBRICATION AND ADJUSTMENT LUBRICATION CHART

INDEX L-1 L-2 L-3 L-4 L-5 L-6 L-7 L-8 L-9 L-10 * L-11 L-12 L-13

LUBE COMPONENT TYPE QTY. Aisle Guide Wheel-Rear (2 Pts.) B AR Battery Rollers B AR Hydraulic Filter Hydraulic Reservoir *D 23 Gal. (87 L.) Hydraulic Strainer Lift Chain G AR Load Wheel Axles B AR Load Wheel Brake Linkage (10 Pts.) B AR Mast Channels F AR Mast Pulleys (Nylon) H AR Mast Rollers B AR Power Unit Door Hinges C AR Steering Linkage (8 Pts.) B AR

100

250 † †

HOURS 500 1000

Chg. †

†

2000

Chg. Chg. Chg.

† † † † † † † †

COMPONENT Aisle Guide Wheels Aisle Guide Switches Battery Battery Connectors Brake Cylinders Brake Pads Chain Anchors & Retainers Column Rollers Height Sensor Switch Lift Chain Lift Cylinder Lift Cylinder Guides, Slides & Stops Load Wheels Power Unit & Mast Bolts Steering Linkage

100

HOURS 250 500 † †

1000

† † † † † † † † † † † † †

* Free lift cylinders and associated componentry on TF masts only ** Prior to 4/25/94 – 300 Nm (220 ft.lbs.) of torque required for grade 5 bolts. From 4/25/94 – 380 Nm (280 ft.lbs.) of torque required for grade 8 bolts. Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. On units equipped with Wire Guidance additional inspections should be performed in accordance with the “Wire Guidance Planned Maintenance” check sheet. See Illustration 2 for Chart 3 and Chart 4 for Index Call-outs. CHART 4 Crown 1998 PF11523-5 Rev. 11/01

Printed in U.S.A.

02 REV. 11/01

M1.0–19.0–014

LUBRICATION AND ADJUSTMENT 2313S

ILLUSTRATION 3

Crown 1998 PF11523-6

M1.0–19.0–015

Printed in U.S.A.

M1.0–19.0–015

LUBRICATION AND ADJUSTMENT LUBRICATION CHART

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

†-Check

LUBE TYPE QTY. C AR C AR B B AR G AR E AR B AR F AR G AR B AR F AR F AR B AR F AR G AR

100

250 † †

HOURS 500 1000

2000

† † † † † † † † † † † † †

See Chart 1-2 for Lube Type designation explanation (M1.0 - 04 - 002). Chg.-Change AR-As Required (Pts.) No. Lube Fittings

Lubrication intervals on Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts. CHART 5

INSPECTION & ADJUSTMENT CHART

INDEX COMPONENT I-1 Chain Anchors & Retainers I-2 Chain Slack/Break Linkage & Switches I-3 Clamp (Pivot Latch) Cylinder I-4 Column Rollers & Channels I-5 Forks I-6 Hydraulic Lines, Hoses & Fittings I-7 Lift Chain I-8 Lift Cylinder I-9 Lift Limit Switch I-10 Pivot Cylinders I-11 Hydraulic Motor I-12 Traverse Limit Switches I-13 Horn

100

HOURS 250 500 †

1000

t † † † † † † † † † † †

Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. On units equipped with Wire Guidance additional inspections should be performed in accordance with the “Wire Guidance Planned Maintenance” check sheet. See Illustration 3 for Chart 5 and Chart 6 for Index Call-outs. CHART 6 Crown 1998 PF11523-7

M1.0–19.0–016

Printed in U.S.A.

M1.0–19.0–016

LUBRICATION AND ADJUSTMENT 2312S

* *

TF MAST SHOWN

* * *

* FREE LIFT CYLINDERS AND ASSOCIATED COMPONENTRY ON TF MASTS ONLY. ILLUSTRATION 4

Crown 1998 PF11523-8

M1.0–19.0–017

Printed in U.S.A.

M1.0–19.0–017

LUBRICATION AND ADJUSTMENT

LUBRICATION CHART LUBE INDEX COMPONENT TYPE QTY. 100 L-1 Brake Linkage C AR * L-2 Cylinder Yokes B AR L-3 Drive Unit Level Left & Right A 0.7 L.. (1 1/2 Pts.) ea. L-4 Drive Unit pivot Left & Right B AR L-5 Elec. Compartment Door Hinge C AR * L-6 Hose Take-up Cables G AR * L-7 Hose Take-up Cam Rollers & Pulleys B AR * L-8 Hoses H AR L-9 Platform & Mast Column Rollers F AR L-10 Rear Cover Hinge C AR L-11 Steering Gearbox Level R.H. & L.H. ‡DDD 1 L. (2 Pts.) ea. † L-12 Steering Gears Left & Right F AR L-13 Turret Head Pivot (2 Pts.) B AR L-14 Servo Control Valve C AR L-15 Steering Encoder Linkage C AR

250 † † † † t † † † † † Chg. † † † †

HOURS 500 1000

2000

Chg.

See Chart 1-2 for Lube Type designation explanation (M1.0 - 04 - 002). †-Check Chg.-Change AR-As Required (Pts.) No. Lube Fittings Lubrication intervals on Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts. ‡ Use "DDD" (see page M1.0-04.0-003) hydraulic oil in steering gearbox for both normal and low temperature applications. CHART 7 INSPECTION & ADJUSTMENT CHART HOURS INDEX COMPONENT 100 250 500 I-1 Brake Cylinders † I-2 Brake Linings † I-3 Brake Operation † I-4 Brake Switches † * I-5 Cable Tension Switches † I-6 Contactor Tips † I-7 Drive Tires † I-8 Electrical Connections † * I-9 Hose Take-up Cables † I-10 Hyd. Lines, Hoses & Fittings † I-11 Motor Brushes - Accessory † I-12 Motor Brushes- Drive (R.H. & L.H.) † I-13 Motor Brushes - Lift † I-14 Motor Brushes - Servo † I-15 Motor Brushes- Steering † I-16 Override Switches † I-17 Power Unit Flashing Light † I-18 Shock Absorbers † I-19 Steering Gears † I-20 Steering Linkage †

1000

* FREE LIFT CYLINDERS AND ASSOCIATED COMPONENTRY ON TF MASTS ONLY Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. On units equipped with Wire Guidance additional inspections should be performed in accordance with the “Wire Guidance Planned Maintenance” check sheet. See Illustration 4 for Chart 7 and Chart 8 for Index Call-outs. CHART 8 Crown 1998 PF11523-9 Rev. 12/01

Printed in U.S.A.

03 REV. 12/01

M1.0–19.0–018

This page available for NOTES.

LUBRICATION & ADJUSTMENT Torque Values

Torque Values All Crown Trucks are manufactured with Grade 5 or better screws and bolts. The information contained in this section will aid you when replacing any screws and bolts that are necessary when performing maintenance on your lift truck.

Grade Grade Marking (on Head)

Specification

Material

Bolt and Screw Size (Inches)

SAE - Grade 2

Low Carbon Steel

1/4 thru 1-1/2

SAE - Grade 5

Medium Carbon Steel, Quenched and Tempered

1/4 thru 1-1/2

SAE - Grade 8

Medium Carbon Alloy Steel, Quenched and Tempered

1/4 thru 1-1/2

NOTE: Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all of 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. Figure 14916

Crown 1979 PF5067-1 Rev. 9/06

M1.9-14.0-001 04 Rev. 9/06

LUBRICATION & ADJUSTMENT Torque Values

Torque Chart Bolt Diameter

Grade 5

Grade 8

Dry Torque Requirement

ft Ib

kgm

ft lb

kgm

1/4

9±3

1.2 ± .4

12 ± 4

13 ± 4

1.8 ± .5

17.5 ± 5.5

5/16

18 ± 5

2.5 ± .7

24.5 ± 7

25 ± 5

3.5 ± .7

34 ± 7

3/8

32 ± 5

4.4 ± .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

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

Mounting bolt torque requirements involving hydraulic valves. 5/16

13 ± 2

1.8 ± .3

17.5 ± 2.5

3/8

24 ± 2

3.3 ± .3

32.5 ± 2.5

7/16

39 ± 2

5.4 ± .3

53 ± 2.5

NOTE:Torque values called out in the maintenance section of this manual will take precedence over torque values found on this page.

M1.9-14.0-002 04 Rev. 9/06

Crown 1979 PF5067-2 Rev. 9/06

MAINTENANCE HYDRAULIC SYSTEM The hydraulic system in your truck is powered by gear type pumps. One pump supplies pressure for the main and auxiliary lift. Another pump supplies pressure for all the accessory functions.

Should it be necessary to lower the operator compartment in an emergency or for service, this can be done by operating the manual emergency lowering valve even with the battery disconnected.

Maximum pressure is limited by relief valves for all lift and accessory functions. Normal relief valve settings are noted on the hydraulic schematic which is applicable to your unit.

WARNING

The following is a brief description of the hydraulic system for the TSP , which is typical of current standard units. (Your unit may vary, see appropriate schematic in this manual). A 100 mesh strainer, mounted in the reservoir, filters hydraulic oil as it enters the suction line of the main lift pump or accessory pump. A manifold diverts the flow to either of the above pumps. Pressurized oil from the lift pump flows through a servo lift valve (SV-1), a combination valve consisting of integral relief valve (RV-1 & RV-2) and solenoid valves (SV-2 & SV-3), a flow control valve and to the free lift, main lift or auxiliary lift cylinders. When the control handle is positioned for lowering the solenoid valve (SV-2) shifts and the oil in the lift cylinder is permitted to return to the reservoir at a rate controlled by the operator through SV-1. The flow control meters maximum flow rate of the oil returning to the reservoir, controlling the cylinders maximum rate of descent. A lift circuit accumulator cushions the lowering when the control handle is moved from the lower position. A manual emergency lowering valve can be utilized if an electrical malfunction prevents the lift cylinder(s) from lowering. A 10 micron return line filter filters the oil as it returns to reservoir.

Before using Manual Lowering Valve warn operator to keep all body members within the operator’s compartment. Make sure the forks are clear of the rack. Close valve immediately if chains become slack. All lift cylinders have velocity fuses to prevent lowering should a major hydraulic failure occur. An accumulator is in the traverse circuit to cushion the stop when full left or right. As the forks are pivoted full clockwise or counter-clockwise the pivot latch cylinder is actuated to lock the forks in this position. The brake circuit is equipped with a dual pressure switch that will maintain proper hydraulic pressure to the brake cylinders.

Pressurized oil from the accessory pump when required, enters the brake manifold assembly containing solenoid valves (SV-6, SV-7, SV-8 & SV-9), and goes on to the drive wheel brakes and load wheel brakes. Pressure in the brake accumulator will release the brakes when the brake pedal is released. Oil from the accessory pump enters the traverse cushion manifold. When the appropriate control lever (pivot) is actuated, oil from the pivot control valve flows through the pivot manifold assembly and is diverted to the appropriate pivot cylinder. When the appropriate control lever (traverse) is actuated, oil from the the traverse cushion manifold containing solenoid valve (SV-12) flows through the traverse valve to the traverse manifold onto the hydraulic motor supplying power to traverse. The traverse manifold assembly containing solenoid valves (SV-4, SV-5, SV-10) will divert oil to the fork manifold and to the fork cylinders when the traverse function is complete. The direction of spool movement determines the direction of the accessory functions. The oil travels through the system as above returning to the reservoir. 5994 Crown 1988 PF8168-1 Rev. 2/99

M2.0–19.0–001

Printed in U.S.A.

06 REV. 2/99

M2.0–19.0–001

MAINTENANCE Relieving Pressure from Lift Hydraulic System

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.

1. Lower platform & forks to lowest position. 2. Turn key switch to OFF position. 3. Open emergency manual lowering valve, located at upper right hand rear of the power unit. After the hydraulic pressure is totally relieved close valve. 4. Perform maintenance service on lift hydraulic system. 5. After maintenance service is completed and all hydraulic fittings have been replaced and tightened, turn key switch to ON position. 6. Follow Lift Cylinder Bleeding procedure described in section M8.0 of this service manual. 7. Check lift hydraulic system for proper operation. If the lift hydraulic system does not operate properly because of remaining air in the hydraulic system, repeat the lift cylinder bleeding procedure as required.

Printed in U.S.A.

Crown 1988 PF-8168-2 Rev. 9/93

03 REV . 9/93

M2.0 - 19 - 002

MAINTENANCE Reservoir

NOTE

With all cylinders in the retracted position and after all air has been bled from the hydraulic system, the oil level in the reservoir is to be between 1/2" (13mm) to 2" (51mm) on the reservoir oil level dipstick. The total capacity of the hydraulic system at this level should be approximately 22 gallons (100 litres). Hydraulic Lines and Fittings 1. Blow air through all hose and lines to remove loose particles before installing. Any rubber hose with wire braid inner construction or any steel tube lines which have been collapsed or kinked are permanently damaged and must be replaced even if the damage is not externally visible. 2 Flexible hose shall be replaced if it collapses in its normal operating position. 3. All hoses and lines are to be clear of any surface or edge which will cause damaging wear and cuts, or on which they can become caught.

Do not tighten filter with the use of a wrench. A wrench should only be used for removal of the filter. Use only a good grade of hydraulic oil such as Mobil DTE 24 (Crown No. 063001-001) or equal. On trucks equipped to operate in below freezing temperatures, a mixture of 20% Mobil DTE 24 (Crown No. 063001-001) or equal and 80% Mobil Aero HFA (Crown No. 063001-006) or equal is recommended.

NOTE Do not use hydraulic brake fluid. DRIFT TEST All drift tests should be conducted with a capacity load (refer to serial plate for the rated capacity of your truck). The material used for the test load must be evenly stacked within the limits of a four foot square pallet and must be secured to the fork carriage with the forks spread to their maximum width.

NOTE

4. All connections are to be leak free.

The lift measurement is to be taken from the tip of the fork to the floor.

5. The beaded elbows in suction ports of all pumps must be positioned such that the suction hose retains its full volume flow, and does not collapse.

CAUTION

Never stand or work under a suspended load.

WARNING

Lift Drift Test

Elevate the test load on the auxiliary mast approximately 1 to 2 feet (305 to 610mm) and raise the operator’s compartment until the second stage mast has raised approximately 2 to 3 feet (610 to 915mm). Shut off truck. After five minutes, measure the distance the forks have drifted. Drifting in excess of 1/2" (13mm) per minute, over a period of five minutes (2 1/2" or [64mm] total drift) is considered unacceptable. The five minute duration of this test is necessary due to the centering time required for the control valve spool(s).

Occasionally, a slight creep of the fork assembly may occur due to internal leakage in the piston pak, but it can also be caused by leakage in the check or control valve. To seat these valves properly when this occurs, raise and lower the forks to flush out any foreign material from the valve seat.

Filter The spin on filter cartridge has been tightened by Crown. When replacing filter, apply a film of oil 063001-001 to the seal and hand tighten until seal snugly contacts filter head.

A thorough check for leaks in the sytem should be conducted if abnormal oil losses occur. The hydraulic system is designed to eliminate mechanical damage even if fittings become loose.

Crown 1988 PF-8168-3 Rev. 1/94

M2.0 - 19 - 003

Printed in U.S.A.

04 REV. 1/94

M2.0 - 19 - 003

MAINTENANCE HYDRAULIC COMPONENT CHART Chart 2-1 illustrates which motor operates, when the manual valves are operated and which solenoid valves are energized for each hydraulic function. (e.g. During main lower, the solenoid valves SV-1 and SV-2 are energized.)

FUNCTION Main Raise (Note 1) Main Lower Auxiliary Raise (Note 2) Auxiliary Lower Brake Release Brake Applied (0 - 2.3 MPH) (Note 4) Brake Applied (2.3 - 6 MPH) (Note 3) Hyd. Brake Recharge (Note 5) Traverse In Cushion Traverse Out of Cushion Fork Extend - Right Fork Retract - Right Fork Extend - Left Fork Retract - Left Pivot

PUMP MOTOR LIFT ACC’Y. X

MANUAL CONTROL VALVE PIVOT TRAVERSE

X X X X X X X X

* SOLENOID VALVE SV1 SV1,SV2 SV1 SV1, SV3 SV6, SV7 SV9 SV8

X X X X X X X

SV12 SV4, SV5 SV4, SV5 SV4, SV5, SV10 SV4, SV5, SV10 SV11

*Indicates component is energized for function to operate. CHART 2-1 NOTE 1: Relief valve 1 (RV-1) limits the capacity and is adjustable. NOTE 2: Relief valve 2 (RV-2) limits the capacity and is adjustable. NOTE 3: Above 2.3 MPH, load wheel and drive unit brakes are applied. NOTE 4: Below 2.3 MPH, only the load wheel brakes are applied. NOTE 5: Controlled by the brake pressure switch (BPS).

Crown 1988 PF-8168-6 Rev. 9/91

M2.0 - 19 - 006

Printed in U.S.A.

02 REV. 9/91

M2.0 - 19 - 006

MAINTENANCE FREEZER PREPARATION Crown trucks may require a mixture of low temperature hydraulic oil, Crown P/N 063001-006 (gal.), blended with standard hydraulic oil, Crown P/N 063001-021 (gal.) when used in a freezer or cooler. 100% low temperature oil is too thin for most cold storage operations and therefore could shorten the life of cylinder packings and pumps if used in higher ambient temperatures. NOTE Trucks equipped with velocity fuses may experience staging issues if an insufficient mix of low temperature oil has been used. For truck applications operating continually in temperatures at or above 32 degrees Fahrenheit, use 100% standard hydraulic oil. For truck applications operating continually at temperatures of 32 Degrees Fahrenheit or below, use a 80/20 blend, 80% low temperature (063001-006) and 20% standard hydraulic oil (063001-021). The proper mixture of freezer hydraulic oil will ensure the best and most efficient operation of your Crown equipment.

80/20 Mix of Low-Temp (063001-006 [80%] & Standard Hydraulic Oil (063001-021 [20%])

50 40 30 20 10 0 10 20 30 40 C

120 100 80 60 40 20 0 20 40 F

Standard Hydraulic Oi (063001-001 [100%])

TS/TSP Models 6354

ILLUSTRATION 2-7

Crown 1988 PF8168-7 Rev. 1/98

M2.0–19.0–007

Printed in U.S.A.

05 REV. 1/98

M2.0–19.0–007

HYDRAULIC Hydraulic Schematic Symbols

Hydraulic Schematic Symbols VENTED RESERVOIR with lines above fluid level

ELECTRIC MOTOR unidirectional single speed

VENTED RESERVOIR with lines below fluid level ELECTRIC MOTOR unidirectional variable speed

FILTER or STRAINER

HYDRAULIC LINE with full flow (plumbing - may be tubing, hose, or flow passage in manifold

PILOT or DRAIN LINE limited flow

HYDRAULIC PUMP fixed displacement unidirectional

HYDRAULIC MOTOR bi-directional

LINES CROSSING

LINES CONNECTED

QUICK DISCONNECT (disconnected)

GAUGE pressure

GAUGE temperature

PLUGGED PORT (test port) ACCUMULATOR gas charged diaphragm type FLOW METER Figure 3559-03

Crown 1979 PF5066-1 Rev. 9/06

M2.1-00.0-001 04 Rev 9/06

HYDRAULIC Hydraulic Schematic Symbols

PRESSURE SWITCH

CYLINDER double acting unequal area

CYLINDER double acting equal area (steer) (double end)

ACTUATOR MANUAL

SPRING (bias to normal de-energized position)

SOLENOID single coil or winding

CYLINDER single acting spring returned (rod end vented) HYDRAULIC PILOT OPERATED CYLINDER single acting ram type SOLENOID pilot operated

CYLINDER single acting with cushion SOLENOID DUAL

COMPONENT ENCLOSURE manifold block

ACTUATOR MANUAL LEVER

SOLENOID PROPORTIONAL

VALVE PILOT CHECK (pilot to open) Figure 3560-03

M2.1-00.0-002 04 Rev 9/06

Crown 1979 PF5066-2 Rev. 9/06

HYDRAULIC Hydraulic Schematic Symbols

ORIFICE THROTTLE fixed

VALVE SHUTTLE

ORIFICE THROTTLE adjustable

FLOW CONTROL PRESSURE COMPENSATED fixed

FLOW CONTROL PRESSURE COMPENSATED fixed with reverse flow bypass

VALVE SINGLE COUNTERBALANCE in manifold

FLOW DIVIDER/COMBINER

FUSE VELOCITY BYPASS FLOW CONTROL regulated flow pressure compensated

VALVE RELIEF fixed setting

VALVE RELIEF adjustable

VALVE CHECK

VALVE MANUAL SHUTOFF

TORQUE GENERATOR

STEER UNIT hydrostatic

Figure 3561-03

Crown 1979 PF5066-3 Rev. 9/06

M2.1-00.0-003 04 Rev 9/06

HYDRAULIC Hydraulic Schematic Symbols

VALVE 2 way 2 position

VALVE 3 way 2 position spring bias, solenoid control

VALVE 3 way 2 position

VALVE 4 way 2 position

VALVE 4 way 3 position dual spring centered, manual lever control

VALVE 4 way 3 position

VALVE 2 way infinite positions

NOTE: The type of valve depends on the number of spools found in the component enclosure (Triple spool valve shown)

VALVE 4 way infinite positions

Figure 3562-03

M2.1-00.0-004 04 Rev 9/06

Crown 1979 PF5066-4 Rev. 9/06

HYDRAULIC Pump Maintenance

Pump Maintenance

Figure 9221-01

Pump - Gear

Oil Seal Removal

Overhaul the pump only in a clean, dust-free location, using clean tools and equipment. Dirt or grit will damage the highly polished machined surfaces and will result in leakage or premature failure of the pump.

The oil seal (index 11) is best removed by applying pressure simultaneously to the pump inlet and outlet ports. This has the effect of pressurizing the seal cavity and forcing out the oil seal while ensuring that the pressure on each side of the lobe seals (item 3 & 4) is equalized so that these seals are not displaced. If the oil seal is distorted and leaking badly, it may not be possible to build up sufficient pressure to remove it in this way. In this case, disassemble the pump as far as step 5 of the "DISASSEMBLY PROCEDURE" and clamp the mounting flange securely in a soft-jawed vice. The seal can then be removed with the use of a seal removing tool. Be careful not to damage the mounting flange seal bore or the drive shafts sealing surface.

Before beginning the disassembly, scribe match marks on the body assembly, the end cover and mounting flange to insure that the pump will be reassembled properly. This pump can be assembled for either clockwise or counter-clockwise rotation as viewed from the end of the splined drive gear assembly. Arrows are molded in to the body assembly and the word "ROTATION" appears on the mounting flange to aid in determining the pumps rotation. Note which direction the arrow is pointing next to the word "ROTATION" prior to disassembly.

Crown 1982 PF5372-1 Rev. 9/06

M2.1-10.0-001 01 Rev. 9/06

HYDRAULIC Pump Maintenance Oil Seal Replacement 1. Make sure the seal housing in the pump mounting flange is clean and free from burrs. 2. Pack the space between the lips of the seal with a high melting point, mineral based grease. 3. Seat the oil seal. –

If the mounting flange has been removed: Start the oil seal squarely into the housing, with the garter spring facing inward and press home to the full depth of the recess. –

If the pump is assembled: Slide an "Assembly Sleeve" (available from Crown [#93170]) over the shaft splines until it comes in contact with the shaft shoulder. Lightly grease the sleeve. Slide the oil seal, with the garter spring facing inwards, over the sleeve and start it squarely into the housing.

7. Hold the pump body vertically with the mounting flange end downward and with one hand underneath to prevent the bushings (index 5) from falling out. Tap the side of the body with a rawhide mallet to dislodge the lower bushings, and slide them carefully out of the body. Keep the bushings as a pair and place them on or near the mounting flange. 8. Invert the body and lift out the drive (index 9) and the idler (index 8) gears. 9. Remove the remaining pair of bushings as described in step 7 and place on or near the end cover.

Parts Inspection Wash all metal parts thoroughly with a good cleaning fluid. Inspect, in the order disassembled, for wear and damage.

4. Press the seal into the full depth of the recess. 5. Remove the Assembly Sleeve.

Pump Disassembly 1. Remove the bolts which hold the pump to the lift motor. 2. Lightly mark or scribe the end cover (index 2), the body (index 7) and the mounting flange (index 10) to ensure re-assembly in the correct relationship. Also note the direction of rotation of the pump. 3. Loosen the bolts and lockwashers (index 1) and pull out the bolts. 4. Remove the end cover (index 2) and carefully lift out the two backing washers (index 3), the lobe seals (index 4) and the body "O" ring seals (index 6). The body seal is a moulded rubber seal on early pumps but changed to an "O" ring on newer units (Specify when ordering). 5. Fit an "Assembly Sleeve" tool (available from Crown [#93170]) over the splines on the drive shaft before withdrawing the mounting flange. Lightly tap the mounting flange clear of the two hollow dowels in the pump body and slide it squarely off of the shaft. 6. Carefully lift out the body "O" ring seal (index 6), the two backing washers (index 3) and the lobe seal (index 4).

M2.1-10.0-002 01 Rev. 9/06

Body To obtain high efficiency the design allows for the tips of the gear teeth to wipe the walls of the body bores when the pump is running. Pressure will force the gears against the inlet side of the bores a wear pattern will be visible in this area. If excessive wear of the bushing inserts or gear journals occurs this wear pattern will deepen to form a step in the bore. Examine the body bores and if a pronounced step is felt the body should be rejected. It is not advisable to fit worn bushings into a new body. Check to make sure the two hollow dowels are not loose.

Composite Bushings Examine the bearing inserts for signs of wear and check the bushing faces adjacent to the gears for scoring or pitting. Make sure the holes and slots in the bushings are not plugged. Light scored on the bushings faces can be polished out on a lapping plate.

NOTE If new bushings are to be used in an old body, check for any burrs at the edge of the wear track. If present, this burr must be polished out or it may hold the bushing faces away from the gears and increase the internal leakage.

Crown 1982 PF5372-2 Rev. 9/06

HYDRAULIC Pump Maintenance Gears Examine the gears for discoloration, caused by overheating. Check the shafts for scoring. Make sure the contact marks on the teeth are evenly distributed across each tooth surface and that none of the teeth are chipped.

NOTE Bushings and/or gears are matched for widths within 0.005 mm (0.0002 in) and can only be sold and replaced as a matched pair.

End Cover Examine the cover to insure flatness and inspect for scoring and pitting.

Mounting Flange Check for damage and check the condition of the oil seal. If the seal needs replacement refer to the "Oil Seal Replacement" section.

Lobe Seal

Backing Washers

Figure 9222-01

Crown 1982 PF5372-3 Rev. 9/06

M2.1-10.0-003 01 Rev. 9/06

HYDRAULIC Pump Maintenance Clockwise Rotation Cover End

Mounting Flange End

Flat

Bushing Lobes

Assemble Drive Gear in this Bore

Assemble Drive Gear in this Bore Cover End

Flat

Mounting Flange End

Bushing Lobes

Flat

Assemble Drive Gear in this Bore Assemble Drive Gear in this Bore Counter-Clockwise Rotation Figure 9223-01

Pump Reassembly Make sure that all pump components are perfectly clean and lubricated with the hydraulic oil to be used in the pump, prior to assembly. 1. Prepare the bushings (index 5) for mounting flange end of the body for assembly as follows: (Refer to Figure 9222-01) Place the bushings on the workbench with their lobes up and the flats in contact. Lubricate the lobe seal (index 4) with a mineral based grease and fit it around the bushing lobes. Fit a backing washer (index 3) inside each lobe seal. When fitted correctly, the backing washer must be level and flush with the top surface of the bushing lobes. 2. Prepare the bushings for the cover end of the body for installation into the pump in the same manner.

M2.1-10.0-004 01 Rev. 9/06

3. Pack the space between the lips of the oil seal (index 11) with a high melting point, mineral based grease. 4. Pick up the body and hold it with the hollow dowels up and with the fingers of one hand inside the bores of the body, ready to support the bushings. 5. Pick up the mounting flange bushing complete with lobe seal and backing washers, and slide them into the body bores with the lobes facing outwards and away from the flat at the intersection of the body bores. The bushings must be inserted squarely into the bores and must be kept square to each other. Do not use force when installing the bushings. If the bushings should cock in the bores, remove them and examine for scored body walls. Light scoring can be stoned out with a fine grit hand stone.

Crown 1982 PF5372-4 Rev. 9/06

HYDRAULIC Pump Maintenance 6. Lubricate the body seals "O" ring (index 6) with a mineral based grease and seat it in the body. 7. Refer to Figure 9223-01to find the position of the drive gear bore for the direction of rotation you require. Lay the pump body on its side and slide the drive gear (index 9) through the drive gear bore (as called out in Figure 9223-01) so that the shaft protrudes out of the hollow dowel end of the body. 8. Slide the "Assembly Sleeve" (#93170) over the end of the splined shaft. Hold the drive gear journal with one hand and slide the mounting flange (index 10) squarely over the shaft and onto the two hollow dowels, flush against the body. The "Assembly Sleeve" provides a lead-in for the oil seal. Remove the "Sleeve" and clamp the mounting flange in a soft jawed vice with the pump body above the flange. If the sleeve is stuck on the splines it can be removed by tightening a 1/4"-28 bolt into the end of the "Assembly Sleeve". 9. Check that the bushings are flush against the mounting flange face and that the lobe seals (index 4) and backing washers (index 3) have not become dislodged. Check to see that the arrow on the body, adjacent to the word "ROTATION" is pointing in the correct pump rotation. 10. Mesh the idler gear (index 8) with the drive gear. If the original gears are being replaced on a new shaft, make sure that the marked side of the teeth are in contact so the bedded-in position of the teeth is maintained. 11. Pick up the bushings for the end cover side of the pump, complete with lobe seals and backing washers and slide them over the gear journals with the lobes facing outward and away from the flats in the bores. Again, the bushings must be installed squarely and without force.

Start Up Procedure A pump that has been re-assembled with new gears, bushings or body must be carefully broke-in before it is subjected to full load working conditions. When test rig facilities are not available the following procedure must be carried out: 1. Install the pump on the application. 2. Where the pump speed is variable set the speed to 1500 rev/min; otherwise run the pump at its normal operating speed. 3. Run the pump at this speed for a period of 10 minutes at minimum pressure, that is, with the hydraulic system unloaded. 4. If the pump operating pressure can be directly controlled, ensure that the pressure is progressively increased up to full working requirements over the first hour of operation. In circumstances where the pressure cannot be directly controlled the same effect can be obtained by progressively increasing the work load on the machine, over the same period of time. 5. During this period make frequent checks of the pump casing temperature, or the oil temperature, if a temperature gauge is included in the system. The temperature should not exceed that experienced under normal working conditions. If the temperature does rise excessively then it is possible that the pump has been assembled incorrectly and it must be dismantled to check this. If no fault is found then further period of running-in at low pressure, as in step 3, must be carried out.

12. Lubricate the body seal "O" ring (index 6) and seat it in the body. 13. Place the end cover in position, aligning the scribe marks made earlier. 14. Insert the bolts and lockwashers into the body and hand tighten into the tapped holes in the mounting flange. Apply a torque load of 4.7 to 5 kgm (34 to 36 ft lbs) to each bolt head. 15. Pour a small amount of hydraulic oil into the ports and check the pump for freeness and direction of rotation.

Crown 1982 PF5372-5 Rev. 9/06

M2.1-10.0-005 01 Rev. 9/06

HYDRAULIC Steer Pump

Steer Pump

Figure 11075-01

Pump - Gear Preparation for Disassembly Pump repair should be performed in a clean, dust-free location, using clean tools and equipment. Dirt or grit will damage the highly machined surfaces and will result in leakage or premature failure of the pump. Before proceeding with pump disassembly, scribe match marks on the stator (item 8) and the gear housing (item 19) to insure the pump will be reassembled in the same manner as it was shipped from the factory. If the stator or gear housing is replaced during repair, scribe a match mark on the new part in the same location as on the part it replaces. Pump Disassembly Refer to Figure 11075-01. Clean the outside of the pump with a good grade solvent and thoroughly dry. Secure the unit in a vice (using light clamping pressure) at the area of the mounting flange (“A”). Loosen and remove the eight assembly screws (item 20). Separate the gear housing (item 19) from the stator (item 8). It may be necessary to lightly tap the sides of the housing to facilitate the separation.

Crown 1984 PF5875-1 Rev. 11/06

CAUTION Never insert a screwdriver or other similar instrument between the housing and the stator for the purpose of prying the two halves apart as permanent damage may result. Once the housings are separated, remove the dowel pins (item 18). Also remove the idler gear and drive gear assemblies which includes the retaining rings (item 11), the gears (item 12), the keys as well as the idler shaft (item 14) and the drive shaft (item 15). When removing the plastic shim, located between the gear housing face and the stator face, note the color of the shim. These shims are supplied in different colors which corresponds to different thicknesses. When replacing the shim, the same color shim must be reinstalled as was removed. Further disassemble the shaft assemblies and place all components in the solvent. Part Inspection, Evaluation and Replacement Thoroughly wash all pump components in a good grade solvent and blow dry. Lay the cleaned components on a dirt-free bench or shop-cloth and individually inspect each part for the symptoms mentioned below:

M2.1-18.0-001 01 Rev. 11/06

HYDRAULIC Steer Pump Drive Shaft (item 15) - Inspect the drive shaft for wear or cracking on the end of the shaft, grooving on the area of the shaft where the oil seal seats, wear or flaking on the area of the shaft where the needle bearings travel, and metal distortion around the keyway or the retaining ring grooves. If any of these conditions exist, the drive shaft should be replaced. Idler Shaft (item 14) - Check the idler shaft for wear or flaking on the area of the shaft where the needle bearings travel and metal distortion around the keyway or the retaining ring grooves. If any of these conditions exist, the idler shaft should be replaced. Gears (item 12) - Inspect the gears for any signs of galling or metal build-up on the side faces of the gears as well as on the outside diameter of the teeth. If these conditions exist, the gears must be replaced. When replacing gears, always replace both gears as a set. Oil Seal (item 6) - Check the oil seal rubber for wear, cracks, chips or any other condition that would cause the seal to lose its sealing ability. Should any of these conditions exist, Crown recommends seal replacement. To replace the seal, pry out the old seal being careful not to damage the stator oil seal bore. Locate and squarely press in the new seal “lip first”. Needle Bearings (item 10) - With the use of a new shaft (idler or drive) or a metal rod ground to a dimension of 12.7000 to 12.6924 mm (0.5000 to 0.4997 in) in diameter, inserted into the bearing bores, check for excessive bearing to shaft clearance in the stator bearings as well as the gearhousing bearings. Although replacement bearings are available, Crown recommends the replacement of the entire stator and (or) gear housing because bearing wear or damage usually damages the bearing bores. Stator (item 8) - Inspect the innerface of the stator for signs of scoring, excessive wear or metal build-up. If a slight metal build-up is evident, the stator face can be lapped smooth with the use of a solvent soaked crocus cloth (280 or 320 grit) placed on a flat surface. Care should be taken to remove only enough material to clean up the build-ups. A stator having a scored or worn innerface should be replaced.

Pump Reassembly Begin the reassembly by placing the shim (item 9) in position on the innerface of stator (item 8). A thin film of hydraulic oil will help maintain the location of the shim. If a new shim is being installed, make sure the shim’s color corresponds to the color of the shim removed during disassembly. Preassemble the idler and drive gear assemblies by installing the keys, gears (item 12) and retaining rings (item 17) onto their respective shafts (items 14 and 15). The drive shaft should be installed. Once in position, introduce the end of the drive shaft into the sleeve bore and slide the shaft to a position where the side of the gear is in contact with the stator innerface. Insert the idler gear shaft into its respective bore after aligning and meshing the gear teeth properly. Once both shafts are in position, check to make sure the shim is free of the gear teeth. Replace the two (2) dowel pins (item 18) and after aligning the scribed match marks, carefully slide the gear housing in place and install screws. If for some reason the scribe marks are not visible, a check to assure proper assembly is as follows: Hold the pump in a position where you are viewing the outside face of the gear housing (screw heads should be visible). Rotate the pump to a position where the idler shaft is directly below the drive shaft. From that position, the 12.7 mm (0.5 in) NPTF port should be on your left side. After you are sure of the positioning, finger tighten the eight (8) assembly screws and check to see that the drive shaft rotates freely. If it does, the screws can be tightened to a torque reading of between 10.8 to 13.6 Nm (8 to 10 ft lb). Again check to see that the shaft turns freely.

Gear Housing (item 19) - Inspect the gear housing’s gear pocket face and wall for scoring or excessive wear. If either of the conditions exist, the housing should be replaced. Keys - Check the keys for any cracks or shear marks and replace if necessary.

M2.1-18.0-002 01 Rev. 11/06

Crown 1984 PF5875-2 Rev. 11/06

MANIFOLD VALVE MAIN/AUXILIARY LIFT/LOWER MANIFOLD VALVE

2695S

ILLUSTRATION 1

The main/auxiliary lift/lower manifold assembly is an integrated circuit manifold valve consisting of a body, two adjustable relief valves (RV1 and RV2), two spring loaded normally closed solenoid valves (SV2 and SV3), and the necessary O-rings and plugs. The body is constructed of aluminum, bored to contain interconnected passages for a series parallel circuit. All body ports are tapped with SAE straight thread “O” ring ports which provide leak proof connections and reduce possible body distortion when installing and tightening fittings, valves or the plugs.

Component Operation RELIEF VALVE (RV1) This adjustable relief valve is incorporated in the manifold assembly to prevent component damage by relieving excessive oil pressure build up in the main lift circuit. The relief valve is located in the port marked with the symbol (RV1) of the manifold block. The relief setting is made by backing-off the locking nut and turning the adjusting screw with a blade screwdriver until the desired load (not to exceed nameplate rating) can be lifted. Turning the adjusting screw clockwise will increase (a) the amount of weight the truck will lift (b) system PSI (c) current draw of lift motor. Turning counterclockwise will decrease the above. Refer to Chart 1. Once adjusted, the locking nut should be tightened.

7438 Crown 1988 PF8172-1 Rev. 2/04

M2.4–19.0–001

Printed in U.S.A.

04 REV. 2/04

M2.4–19.0–001

MANIFOLD VALVE

MODELS

RATED CAPACITY (*)

MINIMUM LIFT

MAXIMUM LIFT

(†) LOAD CENTER

30 TSPTF

1360 kg (3000 lbs.)

1450 kg (3200 Ibs.)

1560 kg (3450 Ibs.)

610 mm (24 in.)

* = Refer to identification plate for actual capacity. † = The load center is the horizontal distance along the forks from the load backrest to the center of gravity of the load. All trucks must be able to lift this load above free lift height. CHART 1 RELIEF VALVE (RV2)

SOLENOID VALVE (SV2)

This adjustable relief valve is incorporated in the manifold assembly to prevent component damage by relieving excessive oil pressure build up in the auxiliary lift circuit. The relief valve is located in the port marked with the symbol (RV2) of the manifold block. The relief setting is made by backing-off the locking nut and turning the adjusting screw with a blade screwdriver until the desired load can be lifted. Turning the adjusting screw clockwise will increase (a) the amount of weight the truck will lift (b) system PSI (c) current draw of lift motor. Turning counter-clockwise will decrease the above. Refer to Chart 1. Once adjusted, the locking nut should be tightened.

The solenoid valve, located in the port marked SV2, controls the flow of hydraulic oil from the main lift cylinder. The valve is two position, coil (electrically) operated, spring loaded with an internal check valve in its static position. When energized, the spool shifts allowing free flow from the main lift cylinder back to the reservoir. Should the solenoid ever have to be removed or replaced, it should be tightened to a torque value of 18.0 - 19.2 Nm (160 to 170 in. lb.). NOTE Over-torque valve components may cause components to malfunction. Follow torque requirements closely.

NOTE After relief valves are adjusted to proper capacity, apply security sealant to the adjusting screw of the relief valve to hinder tampering.

SOLENOID VALVE (SV3)

When replacing the entire relief valve in the manifold, torque to 20.3 - 23.0 Nm (15 - 17 ft. lbs.) to reduce the possibility of component damage. Over-torque valve components may cause components to malfunction. Follow torque requirements closely.

The solenoid valve, located in the port marked SV3, controls the flow of hydraulic oil from the auxiliary lift cylinder. The valve is two position, coil (electrically) operated, spring loaded with an internal check valve in its static position. When energized, the spool shifts allowing free flow from the auxiliary lift cylinder back to the reservoir. Should the solenoid ever have to be removed or replaced, it should be tightened to a torque value of 18.0 - 19.2 Nm (160 to 170 in. lb.).

Crown 1988 PF8172-2 Rev. 2/04

M2.4–19.0–002

Printed in U.S.A.

04 REV. 2/04

M2.4–19.0–002

MANIFOLD VALVE Troubleshooting Procedure Before beginning any repair or disassembly of the valve assembly perform the following steps to prevent wasted time, additional damage or recurring problems. 1. Obtain as much factual information as possible – discuss malfunction with truck's operator. 2. Operate truck, all functions – verify malfunction. 3. Know the truck's hydraulic system – refer to appropriate hydraulic schematic. 4. Determine symptom, possible cause and solutions. (Refer to Illustration 1 and Charts 1 and 2) Before removal or disassembly of the valve assembly, make sure the valve is clean and free of any contaminates. Also, have a means of containing and controlling any hydraulic oil that may escape.

When it has been determined that one or more of the components are faulty, the following procedure should be followed in trying to isolate or pinpoint the problem valve. Begin by inspecting the body for fresh hydraulic oil around component valves, plugs and fittings. If any leaks are found the components should be removed and its thread sealing "O" ring replaced. Next, inspect the solenoid valve (SV1 and SV2) for any visual signs of damage. If the coil feels hot, the coil is shorted and should be replaced. Coils can be faulty even if no heat is detected. Overtightening the valve can also keep the valve from shifting correctly. The torque requirements for the solenoid valve is 18.0 - 19.2 Nm (160 to 170 in. lbs.) (max.). The relief valves (RV1 and RV2) should be checked next. If the proper system pressure can not be obtained, the pressure spring in the valve could be broke and the valve should be replaced.

TROUBLESHOOTING CHART (REFER TO ILLUSTRATION 1) TROUBLES

PROBABLE CAUSE

REMEDY

1. Oil present around manifold.

A. Defective "O" rings on valves, fittings or plugs.

A. Replace "O" rings and "O" rings on hydraulic fittings.

2. Main lift cylinders will not raise capacity load.

A. Relief valve not adjusted correctly.

A. Readjust relief valve in accordance with Chart 1.

B. Solenoid valve stuck in open (free flow) position.

B. Replace valve [*].

C. Manual lowering valve left open.

C. Close valve.

A. Defective "O" rings or back-up rings.

A. Replace "O" rings and back-up rings [*].

B. Dirt caught in seat on solenoid valve.

B. Actuate to flush out dirt. If dirt continues, replace valve [*].

C. Manual lowering valve open slightly or leaking.

C. Close or replace "O" rings and back-up rings [*].

A. Solenoid coil failure.

A. Replace solenoid coil.

B. Electrical malfunction, switch malfunction, etc...

B. Refer to "Electrical" Section.

3. (†) Operator compartment drifts down.

4. Operator compartment will not lower.

[*] = Torque required is 18.0 - 19.2 Nm (160 to 170 in. lbs.) (max.) (†) = In excess of drift test. CHART 2

Crown 1988 PF8172-3 Rev. 2/04

M2.4–19.0–003

Printed in U.S.A.

04 REV. 2/04

M2.4–19.0–003

MAINTENANCE PIVOT MANIFOLD VALVE

2696S

ILLUSTRATION 2.4-1

The pivot manifold assembly is an integrated circuit manifold valve consisting of a body, (2) preset cross-over relief valves (RV), (2) counterbalance valves (CBV), a shuttle valve, a spring loaded normally closed solenoid valve (SV11) and the necessary “O” rings and plugs. The aluminum body contains interconnected passages for a series parallel circuit. All ports are SAE straight thread “O” ring ports which provide leak proof connections while preventing possible body distortion when installing and tightening fittings, valves or plugs. Component Operation RELIEF VALVE (RV) The cross-over relief valves incorporated in this manifold are designed to prevent pivot cylinder damage by relieving excessive oil pressure build up in the pivot circuit. The relief valves are located in the sides of the manifold. Both relief valve ports are marked with the symbol (RV). These relief valves are factory set at 1500 PSI (10.3 MPa) and under normal conditions should not need adjustments. COUNTERBALANCE VALVE (CBV)

ized side opens the circuit. This allows the oil from the opposite pivot cylinder to return to the reservoir. “Crack” pressure of this valve is 25 PSI (172.3 kPa). SHUTTLE VALVE The shuttle valve is a simple ball and seat valve. It is designed to allow hydraulic oil to counteract the spring force of the pivot lock cylinder while rotating in either direction. When the pivot circuit is not energized, the oil in the pivot lock circuit returns to the reservoir and the spring resets the pivot lock. SOLENOID VALVE (SV11) This solenoid valve, located in the port marked with the symbol SV11 of the manifold block, allows the forks to pivot only when the forks are retracted. This valve is two position, coil (electrically) operated and spring loaded. When energized, the spool shifts allowing oil flow to the pivot cylinders. Should the solenoid ever be removed or replaced, it should be tightened to a torque value of 160 to 170 in./lb. (18.0 - 19.2 Nm).

The counterbalance valves are located in the sides of the manifold (marked CBV). These valves check the return of oil back to the reservoir. When hydraulic pressure is applied to a given pivot cylinder, an internal pilot line from the pressurCrown 1988 PF-8173-1 Rev. 1/94

M2.4 - 19 - 200

NOTE Over-torque valve components may cause components to malfunction. Follow torque requirements closely

4260

Printed in U.S.A.

01 REV. 1/94

M2.4 - 19 - 200

MAINTENANCE BRAKE MANIFOLD VALVE

2697S

ILLUSTRATION 2.4-1

The brake manifold assembly is an integrated circuit manifold valve consisting of a body, an adjustable relief valve (RV3), three spring loaded normally open solenoid valves (SV7, SV8, SV9), one spring loaded normally closed solenoid valve (SV6), a check valve (CV) and the necessary “O” rings, plugs, etc. The body is constructed of aluminum, bored to contain interconnected passages for a series parallel circuit. All body ports are tapped with SAE straight thread “O” ring ports which provide leak proof connections and reduce possible body distortion when installing and tightening fittings, valves or plugs.

CHECK VALVE (CV) The check valve is located in the upper port of the manifold block marked with the symbol (CV). It prevents the back flow of hydraulic oil from the brake cylinders, from reentering the de-energized pump and returning to the reservoir via the suction line. ORIFICE

Component Operation

The orifice is located in the port of the manifold block marked with the symbol (C2). It restricts the flow of hydraulic oil from the accumulator allowing for smoother brake release.

RELIEF VALVE (RV3)

SOLENOID VALVE (SV6)

The relief valve is incorporated in the manifold assembly to prevent component damage by relieving excessive oil pressure build up in the brake circuit. The relief valve is located in the port marked with the symbol (RV3) of the manifold block. This relief valve is pre-set at 2000 PSI (13.8 MPa). Under normal conditions this valve should not require adjustment. When replacing the entire relief valve in the manifold, torque to 15 - 17 ft./lbs. (20.3 - 23.0 Nm) to reduce the possibility of component damage. Over-torque valve components may cause components to malfunction. Follow torque requirements closely.

The solenoid valve (SV6), located in the port of the manifold marked with the symbol (SV6) is a normally closed valve. It controls the releasing of the brake cylinders. The valve is a spring loaded, two positioned, coil (electrically) operated valve with an internal check valve in its static (home) position. When energized, the spool shifts allowing hydraulic pressure to counteract spring pressure which releases the brakes. The solenoid valve (SV6) works in conjunction with (SV7) solenoid valve.

4260 Crown 1988 PF-8177-1 Rev. 1/94

M2.4 - 19 - 400

Printed in U.S.A.

01 REV. 1/94

M2.4 - 19 - 400

MAINTENANCE SOLENOID VALVE (SV7)

Troubleshooting Procedure

The solenoid valve (SV7), located in the port of the manifold marked with the symbol (SV7) is a normally open valve. This solenoid keeps the spring pressure from applying the brakes. The valve is a spring loaded, two position, coil (electrically) operated valve with an internal check valve in its energized (applied) position. When energized, the spool shifts preventing hydraulic oil from returning to the reservoir, maintaining the release of the brakes.

Before beginning any repair or disassembly of the valve assembly perform the following steps to prevent wasted time, additional damage or recurring problems.

SOLENOID VALVE (SV8)

3.Know the truck’s hydraulic system —refer to appropriate hydraulic schematic.

The solenoid valve (SV8), located in the port of the manifold block marked with the symbol (SV8) is a normally open valve. This solenoid is used to keep the brake circuit charged when the brakes are being used frequently without working the accessory functions. This valve is two position, coil (electrically) operated and spring loaded. When energized, the spool shifts allowing the brake circuit to recharge without the need to operate an accessory function . SOLENOID VALVE (SV9) The solenoid valve (SV9), is located in the port of the manifold block marked with the symbol (SV9) is a normally open valve. This solenoid keeps the drive unit brakes released to soften braking when truck travel speed is less 2.4 MPH (3.8 Kph) and the brakes are applied. The valve is a spring loaded, two position, coil (electrically) operated valve with an internal check valve in its energized (applied) position. When energized, the spool shifts not allowing hydraulic oil from returning to the reservoir, maintaining the release of the brakes.

1.Obtain as much factual information as possible— discuss malfunction with truck’s operator. 2.Operate truck, all functions—verify malfunction.

4.Determine symptom, possible cause & solutions. (Refer to Illustration 2.4-1 and Chart 2.4-1) Before removal or disassembly of the valve assembly, make sure the valve is clean and free of any contaminates. Also, have a means of containing and controlling any hydraulic oil that may escape. When it has been determined that one or more of the components are faulty, the following procedure should be followed in trying to isolate or pinpoint the problem valve. Begin by inspecting the body for fresh hydraulic oil around component valves, plugs and fittings. If any leaks are found the components should be removed and its thread sealing “O” ring replaced. Next, inspect the solenoid valve for any visual signs of damage. If the coil feels hot, the coil is shorted and should be replaced. Coils can be faulty even if no heat is detected. Over tightening the valve can also keep the valve from shifting correctly. The torque requirements for the solenoid valve is 160 to 170 in./lbs. (18.0 - 19.2 Nm) (max.). The check valve should be checked next. If the brakes accumulator will not release the brakes when the pump is not energized, the check valve could have a broken spring or chipped seat. The check valve should be replaced.

TROUBLES

PROBABLE CAUSE

REMEDY

1. Oil present around manifold.

A. Defective “O” rings on valves, fittings or plugs.

A. Replace “O” rings and “O” rings on hydraulic fittings.

2. Brakes will not release.

A. Solenoid coil failure (SV6 or SV7). B. Orifice plugged.

A. Replace solenoid coil(s). B. Remove and clean.

3. Accumulator loses charge.

A. Dirt caught in check valve seat of SV8. B. Defective “O” rings or back-up rings of SV8. ring [*].

A. Actuate to flush out dirt. Replace if necessary. B. Replace “O” ring and back-up

[*] = Torque required is 160 - 170 inch Ibs. (18.0 - 19.2 Nm) (max.). CHART 2.4-1 Crown 1988 PF-8177-2

M2.4 - 19 - 401

Printed in U.S.A.

01 REV. 1/94

M2.4 - 19 - 401

ACCUMULATOR The Accumulator is a device in which compressed gas and hydraulic oil is stored for the purpose of absorbing shock in hydraulic circuits or storing and releasing pressurized oil. As a shock absorber, the accumulator relieves pressure surges in the circuit by the compression of inert gas. As a storage unit, the accumulator can deliver limited amounts of pressurized oil without the need of energizing the systems hydraulic pump. The main raise circuit uses an accumulator as a shock absorber to smooth the lift to stop or lower to stop transitions. The brake circuit accumulator has the capability of storing enough pressurized oil to release the drive and load wheel brakes. The traverse circuit accumulator provides a cushion effect to obtain a smooth transition from traverse to fork extend or retract. Precharging Use an inert gas, such as nitrogen for precharging accumulators. Size “T” bottle dry nitrogen, 300 cu. ft., 2600 PSI recommended.

Remove cap of gas valve, then attach charging hose to nitrogen bottle and to gas valve using the following instructions. Refer to Illustration 1. Procedure is similar when using only charging hose with or without other accessories. 1. Use thread sealing and lubricating compound on pipe threads of gage. 2. Back gas chuck stem all the way out before attaching assembly to accumulator gas valve. 3. Use wrench to tighten gas chuck swivel nut onto gas valve. Close bleeder valve. 4. Turn gas chuck stem all the way down, which will depress core in accumulator gas valve. 5. Only crack open nitrogen bottle valve to slowly fill accumulator. Shut off when gage indicates desired precharge. Lift/lower and brake accumulators are to be charged to 350 PSI. Traverse cushion accumulator is to be charged to 100 PSI. 6. If desired precharge pressure is exceeded, make sure nitrogen bottle valve is closed, then open bleeder valve (opposite gas valve, below gage) slightly, but only momentarily, to reduce pressure. 7. Before loosening swivel nut, turn gas chuck stem out all the way, then open bleeder valve. 8. Loosen swivel nut, remove assembly. 9. When precharging has been completed, replace cap on gas valve. CAUTION

2701S

ILLUSTRATION 1

Do not loop or twist hoses as it will stiffen when gas pressure is released from nitrogen bottle. Never loosen swivel nut attached to gas valve in accumulator without first backing gas chuck stem out all the way. Do not reduce accumulator precharge by depressing valve core (high pressure may rupture rubber valve seat).

5939 Crown 1988 PF8179 Rev. 6/03

M2.6–19.0–001

Printed in U.S.A.

02 REV. 6/03

M2.6–19.0–001

MAINTENANCE DRIVE UNIT REPAIR/REBUILD The drive unit used on your Crown Lift Truck, is a double reduction gearbox incorporated spiral bevel gears for strength, quietness and smooth operation. The unit is totally enclosed and oil is pumped throughout to give maximum lubrication to both bearings and gears. DRIVE UNIT COMPONENT OVER VIEW Shown in the illustrations below is a parts breakdown and two cross sectional views of the drive unit components. The views shown may vary slightly between the RR, RS, RD, SP 3000, TS and TSP trucks.

2910S RR, RS, & RD SHOWN

RR, RS, & RD SHOWN

1199S-02

2911S 4295MI Crown 1994 PF10344-1

Printed in U.S.A.

01 REV. 6/95

M3.0–1430–050

MAINTENANCE FIELD INSPECTIONS AND REPAIRS This drive unit location facilitates the inspection of the drive unit as well as the replacement of the drive axle seal. To inspect the drive unit, the bottom side cover can be removed. This will allow access to the drive unit lower half which consists of the axle nut and spiral bevel gear. REMOVING AXLE SEAL

To remove the drive axle seal, drill two holes 180 degrees apart into the seals steel lip. Attach a small sheet metal screw to the end of a slide hammer. Insert the screw into each of the holes and gently remove seal.

2876P

INSTALLING NEW AXLE SEAL

When installing the new seal apply a thin coat of sealant (part # 065005-001) to the outer diameter of the seal. Next push seal into place. To seat the seal, place a wood block over the seal and use a rubber mallet to drive in as shown. This will prevent damage to the seal.

2875P

NOTE RR truck shown. Access to axle on SP 3000, TS and TSP trucks may vary. Refer to appropriate truck service manual, section M3.0.

Crown 1994 PF10344-2

M3.0–1430–051

Printed in U.S.A.

M3.0–1430–051

MAINTENANCE DRIVE UNIT DISASSEMBLY Once the drive unit is removed it is ready to be taken to the bench for disassembly.

1. REMOVING RETAINING RING FROM MOTOR PINION GEAR To begin drive unit disassembly, remove the retaining ring from the motor pinion gear area.

3048P

2. SLIDE PULLER ON MOTOR PINION GEAR The pinion gear is drilled and tapped to facilitate use of a slide hammer for removal as shown. If the pinon gear and associated components are to be reused, record the position and number of shims removed.

3049P

3. REMOVING PINION AREA O-RING FROM CASTING Remove the O-Ring from the pinion area of the housing.

3050P Crown 1994 PF10344-3

M3.0–1430–052

Printed in U.S.A.

M3.0–1430–052

MAINTENANCE

4. REMOVING UPPER PINION GEAR Remove the locknut securing the upper reduction gear to the pinion gear. Remove the pinion mounted reduction gear as shown.

3051P

5. REMOVING IDLER GEAR SHAFT Insert a 5/16" course thread screw into the idler gear shaft and remove it with a pry bar.

3052P

6. REMOVING 6 BOLTS FROM PINION BEARING RETAINER Remove the 6 bolts from the pinion bearing retainer.

3053P

Crown 1994 PF10344-4

M3.0–1430–053

Printed in U.S.A.

M3.0–1430–053

MAINTENANCE

7. PULLING PINION GEAR The pinion gear can now be pulled as an assembly with bearings and spacer. If the pinion gear and bearings are reused record and retain the shim pack. Once the pinion assembly is removed the idler gear and spacers can now be removed. Inspect the bearings and gear for excessive wear. The gear and bearings can be replaced separately.

3054P

8. REMOVING MOTOR PINION GEAR, BEARING AND RETAINER Remove the motor pinion gear bearing and bearing retainer from the drive housing. The bearing cup can be driven out from the bottom. Now remove the O-ring from the housing bore that seals the bearing and retainer just removed.

3055P

9. STUD BEARING REMOVAL When the motor pinion gear and lower bearing are removed the stud bearing can be driven out from the top. If the drive unit is not to be rebuilt, but the stud bearing requires replacement it can be removed separately. To remove the stud bearing, split the bearing shell with a chisel. Use pliers to bend the retainer over and remove the stud bearing.

3056P

Crown 1994 PF10344-5

M3.0–1430–054

Printed in U.S.A.

M3.0–1430–054

MAINTENANCE

10. OIL PUMP REMOVAL Remove the oil pump from the housing. This will facilitate removal of the drive axle. Inspect the oil pump for contaminates or damage. Rebuilding or replacement of the oil pump is recommended before drive unit reassembly.

3057P

11. REMOVING LOCKNUT FROM AXLE Remove axle locknut. Due to the thread locking adhesive the locknut may need to be heated during removal. Cut the wirelocks and remove the 8 bolts that secure the ring gear to the hub.

3058P

12. REMOVING GEAR AND SHIMS The spiral bevel gear can be removed with a slide hammer using a 3/8" course threaded bit.

3059P

Crown 1994 PF10344-6

M3.0–1430–055

Printed in U.S.A.

M3.0–1430–055

MAINTENANCE

13. SPIRAL BEVEL GEAR REMOVED Behind the spiral bevel gear is the shim pack used to control backlash between the spiral bevel gear and the pinion. These shims can be reused provided the axle, hub or related components are not removed or replaced.

3060P

14. REMOVING HUB WITH PULLER The hub is heat press fitted to the axle. Depending on wear pulling may require the use of a puller and heat. If the hub can be removed without a puller, the hub and axle assembly should be replaced. The axle can be removed. Do not use the seal flange for support if pressing is required to remove the axle, use the housing. Replace the seal.

3061P

15. PRESSING OR DRIVING OUT BEARING RACE If the bearings are to be replaced, remove the two cups from the housing as shown.

3062P

Crown 1994 PF10344-7

M3.0–1430–056

Printed in U.S.A.

M3.0–1430–056

MAINTENANCE ASSEMBLING DRIVE UNIT

1. DRIVE UNIT COMPONENTS Shown are all the components that make up the drive unit. Before reassembly be sure to inspect all components for wear or damage. Install the housing components which include the bearing cups and oil pump tubing.

3063P

2. PINION COMPONENTS The pinion assembly can be completely disassembled when bearing removal is required. Inspect and replace any components showing signs of wear.

3044P

3. INSTALLING PINION Install the pinion assembly with a starting shim pack of .050 or five .010 in. (1.3 or five .25 mm) shims. With the pinion gear in place install two bolts 180 degrees apart and tighten.

3064P

Printed in U.S.A.

Crown 1994 PF10344-8

01 REV. 6/95

M3.0–1430–057

MAINTENANCE

4. PINION HEIGHT ADJUSTMENT TOOL PART NUMBER 116207 The tool shown is required to accurately determine the correct pinion gear height or pinion gear to spiral gear relation. After the bearing cups are installed insert the tool with the nut side toward the axle seal retainer. Tighten the nut until it is snug.

3065P

5. TOOL INSTALLED The face of the tool shown has a radius of exactly 1 in. (25mm) from the center of the axle bore.

3066P

6. SLIDING PARALLEL Place the sliding parallel supplied in the kit between the tool and the pinion gear. Squeeze the sliding parallel firmly together and tighten down the screws.

3067P

Crown 1994 PF10344-9

M3.0–1430–058

Printed in U.S.A.

M3.0–1430–058

MAINTENANCE

7. MEASURING THE SLIDING PARALLEL Remove the sliding parallel. With a micrometer measure the dimension of the sliding parallel and record. In this example the measured dimension is 1.378 in. (35mm).

3068P

8. ETCHED PINION GEAR DIMENSION Located on the bottom of the pinion gear is a etched dimension that represents the distance from the bottom of the pinion gear to the center of the axle bore. In this example the etched dimension is 2.378 in. (60mm). 3069P

9. AXLE CENTER TOTAL

3045P

Crown 1994 PF10344-10

M3.0–1430–059

The dimension stamped on the bottom of the pinion gear, in the previous step, is used to identify the proper depth of the pinion gear to the axle center line. The pinion height tool measures exactly 1 in. (25mm) from the center to any side (radius). In this example the sliding parallel measured exactly 1.378 in. (35mm). These two numbers added together equal 2.378 in. (60mm) which exactly matches the dimension on the bottom of the pinion assembly. The measured dimension and the pinions etched measurement should not be more than + .003 in. (.08mm) difference. If the measured dimension did not check within the maximum tolerance the shims under the pinion gear will require adjustment. The shims are available in .008, .010 and .013 in. (.2, .25 and .3mm) thickness.

Printed in U.S.A.

M3.0–1430–059

MAINTENANCE 10. AXLE INSPECTION Inspect the axle before installation to insure there are no nicks or scratches. Before installing bearings on the axle heat each bearing and the pump cam to 250°F (120°C) for approximately 25 minutes. To insure proper heating only use a temperature controlled oven or oil bath. Heating the bearings by any other method or exceeding the 250°F (120°C) will cause bearing damage. The hub should be heated to 450°F (232°C) for approximately 35 minutes. Heating the hub will ease installation and insure proper seating. 3070P

11. AXLE ASSEMBLED After the axle is assembled install it.

3071P

12. PRESSING THE HUB Press the hub onto the axle.

3072P

Crown 1994 PF10344-11

M3.0–1430–060

Printed in U.S.A.

M3.0–1430–060

MAINTENANCE

13. UPPER HOUSING ASSEMBLY The axle and hub are assembled into the drive unit, begin assembly of the upper half. Install the drive motor pinions lower bearing and cup. Pre-lubricate the bearing by filling it 1/4 of the way with drive unit oil.

3073P

14. IDLER GEAR Temporarily remove the main pinion assembly. Install the idler gear and spacer. To ease installation grease each spacer and place it on the bearing of the idler gear.

3074P

15. TIMING MARK ON PINION AND SPIRAL BEVEL GEAR

3075P

Crown 1994 PF10344-12

M3.0–1430–061

The pinion gear and spiral bevel gear are matched sets and should never be replaced individually. Each of the gears are marked with X’s. To time the gears correctly, the pinion gears X should be placed between the two X’s on the spiral bevel gear. Before installation of either gear, mark the tooth of the pinion gear and outside surface of the spiral bevel gear with a black marker.

Printed in U.S.A.

M3.0–1430–061

MAINTENANCE

16. PINION GEAR INSTALLATION Install the pinion gear and proper shim pack. Install the bolts for the pinion gear and tighten. Install the woodruff key on the pinion gear shaft and install the gear.

3076P

17. TIGHTENING NUT Tighten the nut with Crown tool part number 100253-001. Once the nut is tight bend the tab over on the locking washer.

3077P

18. IDLER GEAR SHAFT INSTALLATION Position the idler gear and align the spacers. Install a 5/16" course thread screw into the idler shaft. Carefully tap the shaft until it is fully seated.

3078P

Crown 1994 PF10344-13

M3.0–1430–062

Printed in U.S.A.

M3.0–1430–062

MAINTENANCE

19. DRIVE MOTOR PINION INSTALLATION Install the drive motor pinion and bearing.

3079P

20. SEATING DRIVE MOTOR PINION Using a piece of 2 3/8 pipe, carefully drive the pinion and bearing until fully seated.

3080P

21. O-RING INSTALLATION Lubricate and install the O-ring.

3081P

Crown 1994 PF10344-14

M3.0–1430–063

Printed in U.S.A.

M3.0–1430–063

MAINTENANCE

22. SHIMS AND SPACER The size of the shim pack must be determined. Shim sizes include .008, .010 and .013 in. (.2, .25 and .3mm).

3082P

23. BEARING DEPTH To determine the proper shim pack size, measure the dimension from the top of the pinion bearing to the top of the drive unit housing and record. In this example it is 1.125 in. (30mm). Install the snap ring, measure its depth and record. Example .275 in. (7mm). 3083P

24. SPACER DIMENSION Measure the spacer thickness and record. Example .720 in. (18mm).

3084P

Crown 1994 PF10344-15

M3.0–1430–064

Printed in U.S.A.

M3.0–1430–064

MAINTENANCE

25. SNAP RING THICKNESS Measure the snap ring thickness. Example .095 in. (2.4mm).

3085P

26. MEASUREMENT ILLUSTRATION With the previously recorded dimensions calculate the shim pack required. Take the total depth dimension 1.125 in. (30mm), subtract the dimensions of the snap ring, spacer, and snap ring depth. .275 in. (7 mm) Snap ring depth .095 in. (2.4mm) Snap ring thickness + .720 in. (18.3mm) Spacer thickness 1.090 in. (27.6mm) Total measured dimensions 1.125 in. (30mm) Top of bearing to top of drive unit housing - 1.090 in. (27.6mm) Total measured dimension .035 in. (.9mm) + .030 in. (.8mm) Added Dimension .065 in. (1.7mm) Total

3046P

The snap ring groove inherently adds an additional .030 in. (.8mm) that was not measured during the previous procedure. For this reason add .030 in. (.8mm) to your total measurement. In this example the total shim pack measures .065 in. (1.7mm). The dimension tolerance is +.003 in. (.08mm), therefore a shim pack of four .010 in. (.25mm) shims and two .013 in. (.3mm) shims will provide a total of .066 in. (1.7mm) meeting our dimension.

27. SPACER AND SHIM INSTALLATION Install the shims and spacer with the 2 3/8 pipe as shown. After the spacer is seated install the snap ring.

3086P

Crown 1994 PF10344-16

Printed in U.S.A.

01 REV. 6/95

M3.0–1430–065

MAINTENANCE

28. COVER INSTALLATION Install the cover and fasten the screws.

3087P

29. SPIRAL BEVEL GEAR INSTALLATION The shims between the spiral bevel gear and hub are used to set the backlash between the spiral bevel and pinion gears. The shim sizes available are .005, .007 and .020 in. (.13, .18 and .5mm). Begin with three .020 in. (.5mm) shims and install the gear. Install at least two of the spiral bevel gear bolts and tighten.

3088P

30. NUT INSTALLATION Install the axle nut and torque to a 100 ft. lbs. (135Nm).

3089P

Crown 1994 PF10344-17

M3.0–1430–066

Printed in U.S.A.

M3.0–1430–066

MAINTENANCE

31. CHECK BACKLASH With the use of a dial micrometer, measure the backlash of the gear at the axle nut. This dimensions should be between .003 to .006 in. (.08 to .15mm) total. Be sure to place the micrometer feeler arm tip, or ball, on the very edge of the nut cutout as shown. The addition of shims will increase backlash while the removal of shims will decrease the backlash. A change of .006 in. (.15mm) shim will change this dimension by .002 in. (.05mm), or a 3-1 ratio. 3090P

32. SPIRAL BEVEL INSTALLATION Install the remaining gear bolts and tighten. Next install the lock retainer wire around each of the bolts.

3091P

TORQUE REQUIRED 14 FT./LBS. (1.9 MKG)

TORQUE REQUIRED 100 FT./LBS. (13.8 MKG)

TORQUE REQUIRED 90-110 FT./LBS. (12.4-15.2 MKG)

3116S

Crown 1994 PF10344-18

M3.0–1430–067

Printed in U.S.A.

M3.0–1430–067

MAINTENANCE

33. AXLE NUT INSTALLATION Remove the axle nut and apply red thread lock adhesive to the axle threads.

3092P

34. NUT INSTALLED Install and torque the axle nut to a 100 ft. lbs. (135Nm).

3093P

35. OIL PUMP INSTALLATION Install the oil pump. Install the lower cover and gasket.

3094P

Crown 1994 PF10344-19

M3.0–1430–068

Printed in U.S.A.

M3.0–1430–068

MAINTENANCE

36. CHECKING PUMP OPERATION Fill the drive unit with oil. Use an old motor coupling connected to a 1/2 drill to operate the drive unit. Remove the pipe plug at the top of the drive unit and look for oil flow as the drive unit turns. Oil should start to flow out of the pipe plug hole. If oil does not appear the oil pump or pump lines are malfunctioning and disassembly will be required.

3095P

Crown 1994 PF10344-20

M3.0–1430–069

Printed in U.S.A.

M3.0–1430–069

DRIVE UNIT

Your Crown Turret Sideloader truck has dual drive units located at the corners of the power unit. Each drive unit is a double reduction gearbox incorporating spiral bevel gears for strength, quietness and smooth operation. Each unit is totally enclosed and oil is pumped throughout to give maximum lubrication to bearings and gears. The drive motors, located on the sides of the power unit, directly above the drive units, are equipped with a hydraulically released, spring applied, brake system. DRIVE TIRE REPLACEMENT

1. Press the drive tire off hub and press replacement tire on. The outside of the hub must be pressed flush with outside edge of the tire. 2. Inspect hub and remove any paint that may be present on tapered lug seats or on inner hub face that contacts truck axle. See Illustration 2. 3. Finger tighten lug bolts, then tighten to 135/150 Nm (100/110 ft.lbs.) making sure that they are tightened in the sequence shown in Illustration 2. If Present, Remove Paint on Tapered Lug Seats and on Inner Hub Face that Contacts Truck Axle

CAUTION

Chock the load wheels and raise the power unit end of the truck until the drive tire is clear of the floor. Block the power unit securely in this position.

Hub

Remove the side cover plate. Refer to Illustration 1 for bolt number and location.

Tapered Lug Seats

Inner Hub Face

1 4

5 8

7 3

060020-027

2 6

060023-014 11245

ILLUSTRATION 1

Tighten Lug Nuts in Sequence Shown

Open power unit door and remove from power unit. When replacing drive tire, make sure the composition and size are such that maneuverability and braking requirements are maintained. Remove the eight lug bolts and remove drive tire and hub. The drive tire is a "press-on" type.

11150

ILLUSTRATION 2

7371 - EO12027 Crown 1984 PF5829-1 Rev. 2/04

M3.0–18.0–001

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–001

DRIVE UNIT

AXLE SEAL REPLACEMENT 1. Raise rear of the truck so that the drive wheel does not make contact with the floor. Place necessary hardwood blocks under truck in this position to prevent any injury if hoist or jack should fail.) 2. Remove drive tire from axle. 3. Drill two (2) .125 in. holes 180° apart through the outer wall only, of the seal to be replaced. Use a "slide puller", similar to the one shown in Illustration 3, and remove the old seal. Screw the puller into the face of the seal. After the threads are sufficiently secured into the seal, operate the puller gently, but firmly, until one side of the seal is removed. Move to the other side, if necessary, and repeat. Do not scratch or nick the seating area of the seal or the sealing surface on the axle.

4. Clean the seal seating thoroughly. Apply a light coat of gasket sealer (065005-001) to the O.D. of the seal. Before installation wipe the sealing element, or lip, with the lubricant being retained. 5. Slip the new seal gently on to the axle and squarely up against the seal retainer making sure the lip of the seal faces the fluid to be sealed. 6. Seat the seal into the seal retainer. Use a hardwood block and a rawhide or rubber mallet to seat the seal squarely into the retainer. Do not hammer directly on the seal and avoid cocking the seal when seating. Check and make sure the new seal outer surface is flush with the seal retainer.

Seal (In Proper Position)

Surfaces To Be Inspected

Slide Puller

Seal Retainer Axle 11247

ILLUSTRATION 4

ILLUSTRATION 3

11246

Inspect the O.D. of the axle for any possible groove or other marks that could cause any leakage after the new seal is installed. If a slight groove is present, due to seal wear, the seal can be installed a little deeper into the seal retainer. Any severe wear, nicks, or scratches present on the sealing surface of the axle will necessitate its replacement.

Crown 1984 PF5829-2 Rev. 2/04

M3.0–18.0–002

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–002

DRIVE UNIT

DRIVE UNIT REMOVAL

CAUTION

Be sure battery is disconnected before preforming any maintenance operation. 1. Disconnect and remove battery from truck. Remove power unit door. 2. Remove side cover plate from power unit skirt area. Refer to Illustration 1 for related removal information.

33 3 4

14 26

33 32 6

29 30

19 15 34 12 14 13

NOTE

Chock load wheels and raise power unit end of truck until drive unit is clear of floor. Block power unit securely in position.

3. Remove drain plug in bottom of drive unit housing with a .25 in. hex key wrench and drain gear oil.

19 20

17 16

13 25 13 24 22

12 11

23 13

4. Remove eight lug nuts and hub tire assembly from drive unit. 11248

ILLUSTRATION 5

5. Refer to Illustration 5. Remove fan (2), drum (5), and brake assembly (7) from top of drive motor. Remove brake cylinder (11) from mounting bracket (15). Stabilize the brake cylinder so that unnecessary movement of cylinder and brake lines is avoided. The remaining brake components can remain intact on the brake bracket. Take care and remove bracket from motor and secure in a position that will allow the drive motor (9) to be lifted up. Avoid moving bracket to the point of straining any electrical connections.

Crown 1984 PF5829-3 Rev. 2/04

M3.0–18.0–003

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–003

DRIVE UNIT

32 26

29 42

70 46 49 48

34 33

43 44

51 50

37 36

38 28

25 21 1

18 22 64

6 11249

61 3

ILLUSTRATION 6

Crown 1984 PF5829-4 Rev. 2/04

M3.0–18.0–004

13 12 8

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–004

DRIVE UNIT

6. Remove drive motor cables from drive motor. Note the routing and location of all cables for reference at assembly. Also, note position of the drive motor and remove the four fasteners at the motor base. Install a 1/2-20 eye bolt in the top of the motor shaft. Attach hoist, or other suitable lifting equipment, to eye bolt and move motor aside taking care to lift motor straight up until it is clear of seal area of drive unit. 7. Install a 3/8-16 eye bolt in the pinion shaft of the drive unit. Attach a hoist, or other suitable lifting equipment, to eye bolt and lift just enough to remove slack from lifting equipment. 8. Refer to Illustration 6 and remove six bolts attaching the steering bracket to the sides of the drive unit housing. Remove the four hex socket head bolts (68) and drive the two dowel pins (69) on through the mounting bracket until the clamp stud (67) is free. As these fasteners are removed the weight of the drive unit will be transferred to the hoist. Lower the drive unit to the floor and remove lifting equipment from drive unit. Remove two dowel pins from the clamp stud assembly. Dowel pins will be used again when installing drive unit. 9. Move drive unit to a clean work area if further disassembly is required. DRIVE UNIT INSTALLATION

3. Apply thread locking adhesive to four bolts and secure clamp stud assembly to the power unit frame. Do not torque these bolts at this particular time. Install the two dowel pins to maintain proper drive unit alignment. Torque the four bolts securing the clamp stud assembly to power unit frame 340 to 375 Nm (250 to 275 ft.lbs.). 4. Apply thread locking adhesive and install the six bolts securing the steering bracket to the drive unit housing. Torque these fasteners to 34 Nm (25 ft.lbs.). Remove lifting device from drive unit pinion shaft. 5. Install drive motor to power unit mounting bracket. Utilize hoist, or suitable lifting device, to lift motor by 1/2-20 eye bolt in top of drive motor armature shaft. Position drive motor and carefully lower motor onto top of drive unit pinion shaft. Secure drive motor to mounting bracket with four appropriate screws and lockwashers. Remove eye bolt and all other lifting equipment from top of drive motor. 6. Route and connect drive motor cables to drive motor. Carefully mount the drive motor brake bracket to the drive motor. Check components of brake bracket for satisfactory condition and operation. Place the brake assembly on top of brake bracket and install four fasteners securing brake assembly and bracket to the top of the drive motor. Torque four bolts to 35 Nm (25 ft.lbs.).

1. Position drive unit under mounting bracket of power unit. Install a 3/8-16 eye bolt in pinion shaft at top of drive unit. Attach a hoist, or other suitable lifting device, to eye bolt. The hook up must come down through the mounting bracket.

7. Orient and attach brake cylinder to the brake bracket. Attach brake assembly actuator arm to brake linkage. Install brake drum, lockwasher, nut, and fan to top of drive motor. Be sure to lock nut, before installing fan. Check for proper brake linkage operation.

2. Raise the drive unit. Mesh the steering gears properly. Refer to Illustration 6. Position the clamp stud assembly with felt seal (66 & 67) into drive unit. Align the drive unit assembly with the steering bracket.

8. Inspect drive tire hub assembly, remove any paint present on lug bolt seats or inner face of hub that contacts truck axle, then install and torque lug bolts as specified in the "Drive Tire Replacement" on the first page of this section.

Crown 1984 PF5829-5 Rev. 2/04

M3.0–18.0–005

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–005

DRIVE UNIT

Drive Motor (62)

Oil Seal (55)

Screw (63)

Retaining Ring (56)

Undercarriage Assembly

"O" Ring (54) Spacer (54)

Bearing (59)

Shim Pack (53) Bearing Retainer (52)

Steering Gear (57)

Ball Bearing (51)

Drive Unit Casting (1)

Pinion Shaft (Motor) (50) Idler Gear (45) Ball Bearing (70)

Stud Assembly (67)

"O" Ring (48) Bearing Retainer (49)

Dowel Pin (69)

Needle Bearing (64)

Bolt (68)

Needle Bearing Sleeve (65) Felt Seal (66)

11250

ILLUSTRATION 7

DRIVE UNIT REPAIR Motor Pinion Disassembly 1. Refer to Illustration 6 & 7. Remove retaining ring (56). 2. Attach a slide hammer puller to the pinion shaft and pull the pinion shaft from drive unit. 3. Remove bearing (51) from pinion shaft. Record number and position of shims (53) for reference during assembly. 4. Remove upper O-ring (48) from drive unit housing.

5. Remove ring gear (57) and idler gear shaft (46). Remove cover (40), nut (38) and lockwasher (37). Lift reduction gear (35) from top of pinion shaft (19). The woodruff key (36) should remain in top of pinion shaft (19). 6. Slide idler gear (45) aside and remove the cupped retainer (49), with bearing (44), from drive unit housing (1) and inspect lower O-ring (48).

Crown 1984 PF5829-6 Rev. 2/04

M3.0–18.0–006

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–006

DRIVE UNIT

Motor Pinion Assembly 1. Refer to Illustration 6 & 7. Inspect and/or replace lower O-ring (48), if needed. Lubricate O-ring with clean hydraulic oil to prevent possible damage when installing cupped retainer (49) and bearing (44).

6. Measure width of spacer (54); add shims (53) until the distance is within .127 mm (.005 in.) of the distance obtained in step 5. NOTE

2. Fill retainer (49) one third to one half full with gear oil that is of the same type in drive unit. Press bearing (70), with seal up, into cupped retainer (49) and install into drive unit housing. DO NOT OVER FILL RETAINER, too much oil will cause the bearing seal to be damaged when the idler shaft is pressed in. 3. Slide idler gear (45) into position and install idler shaft (46). Install woodruff key (36), reduction gear (35), lockwasher (37), and nut (38) to top of pinion shaft (14). Secure cover (40) and install ring gear (57). 4. Press bearing (51) onto pinion shaft (50). Place retainer (52) on top of bearing (51) and put into drive unit housing.

Measure width of snap ring groove and width of snap ring. Add shims to take up any additional play at this point. Shims are available in the following thickness: .203 mm (.008 in.), .254 mm (.010 in.), and .330 mm (.013 in.). 7. Install upper O-ring (48) into housing, lubricate O-ring with clean hydraulic oil to prevent possible damage when installing spacer (54). 8. Press seal (55) into spacer (54), then install in housing on top of shims (53). 9. Install retaining ring (56) and check for end play.

5. Measure the distance from top of retainer (52) to the bottom of the snap ring groove, record the distance.

Idler Shaft (46) "O" Ring (47)

Steering Gear (57)

Ball Bearing (44) Retaining Ring (43)

Pinion Shaft (50)

Idler Gear (45) Drive Unit Housing (1)

11251

ILLUSTRATION 8 Reduction Gear Replacement 1. Refer to Illustration 6, 7 & 8. Remove ring gear (57) from drive unit. 2. Remove cover (40), located above spiral bevel pinion and reduction gear. 3. Remove spanner nut (38), lockwasher (37), and reduction gear (35).

Crown 1984 PF5829-7 Rev. 2/04

M3.0–18.0–007

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–007

DRIVE UNIT Spiral Bevel Gear & Pinion Replacement

Idler Gear Replacement 1. Refer to Illustration 6, 7 & 8. Remove ring gear (57) from drive unit.

1. Refer to Illustration 6 & 9. Remove cover (4) and gasket (61) from side of drive unit.

2. Remove cover (40), located above spiral bevel pinion and reduction gear.

2. Remove lock wire (25) from bolts securing spiral gear (21) to hub (19). Remove bolts (23) securing gear to hub. Remove defective gear from hub.

3. Remove spanner nut (38), lockwasher (37) and reduction gear (35). 4. Remove cover (23) and gasket (22) from side of drive unit. 5. Remove six screws (31) that secure the spiral bevel pinion in the drive unit. Remove pinion from drive unit. 6. Remove idler shaft (46) with O-ring (47) from drive unit.

3. Clean any dirt or grease from drive unit. Check bearings for binding or gritty effects, looseness or wobble. SPIRAL BEVEL GEARS ARE INSTALLED AS SETS, DO NOT MISMATCH. 4. Spiral bevel pinion (21) must be replaced if necessary or when replacing spiral bevel gear. Follow steps listed to remove spiral bevel pinion from drive unit.

7. Remove idler gear (45) and spacers (42). 8. Remove bearings (44) from idler gear. Inspect and replace bearings if required, install into new idler gear. 9. Reverse steps 1 through 7 to assemble.

A. Remove cover (40) and gasket (39) from drive unit. Remove spanner nut (38), lockwasher (37) from top of pinion. Remove gear (35) from pinion shaft. B. Remove bolts (31) securing pinion shaft assembly to the drive unit housing. Lift pinion shaft out of drive unit. The shim pack (29) must also be removed.

Drive Unit Housing (1) Spacer (28) Drive Tire (5)

Bearing Cup (27) Bearing Cone (26)

Seal Retainer (12)

Spiral Bevel Pinion (21) Cam (16)

Lug Bolt (6)

Hub (19) Locknut (22)

Axle (8)

Bearing Cone (18)

Bearing Cone (14)

Bearing Cup (15)

Shim Pack (20)

Seal (9)

Spiral Bevel Gear (21)

Hub (7)

Cover (4) Oil Pump

11252

ILLUSTRATION 9

Crown 1984 PF5829-8 Rev. 2/04

M3.0–18.0–008

Bearing Cup (17)

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–008

DRIVE UNIT

Lockwasher (33)

Locknut (34)

Bearing Cone (26)

Washer Special (32)

Bearing Retainer (30)

Bearing Cup (27) Spacer (28)

Spiral Bevel Pinion (19) Bearing Cup (27)

Bearing Cone (26)

ILLUSTRATION 10

11253

C. Remove parts from spiral bevel pinion. Refer to Illustration 10. 5. Assemble parts removed from defective pinion to replacement pinion. Clean and inspect parts before assembly. Replace any part that shows any sign of excessive wear, looseness, chips, cracks, etc. Install parts to pinion per the following steps.

A. Place bearing cone (26) onto pinion followed by bearing cup (27), place spacer (28) on top of bearing cup. B. Press bearing cup (27) into bearing retainer (30) and place on top of spacer (28). C. Place bearing cone (26), special washer (32), lockwasher (33) and locknut (34) on pinion shaft. D. Tighten locknut (34) to eliminate end play.

CAUTION

Never "Spin Dry" a bearing using air pressure, after removing from cleaning solvent, as this could cause the bearing to explode.

Crown 1984 PF5829-9 Rev. 2/04

M3.0–18.0–009

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–009

DRIVE UNIT

6. Position pinion shaft assembly into drive unit housing per the following: A. Measure pinion gear assembly from end of gear to bottom of bearing retainer. Refer to Illustration 11.

230 ± .4 mm 9.062 ± .016 in.

Bearing Cup Diameter

Gear And Axle Centerline

11255

ILLUSTRATION 11

11254

B. Measure distance from centerline of axle to shim stock surface. See Illustration 12, dimension 230 ± .4 mm (9.062 ±.016 in.). C. Subtract the pinion gear assembly measurement from the shim stock surface length. D. Read measurement etched on bottom of pinion gear.

ILLUSTRATION 12 F. Make up shim pack to equal figure in step "E". Place pinion gear assembly and shim pack into power unit housing and tighten six bolts (31) to 35 Nm (26 ft.lbs.), refer to Illustration 6. NOTE Take measurement for verification purposes from the end of the pinion gear to the centerline of the axle. If measurement is incorrect, add or remove shims as required.

E. Subtract figure obtained in step "C" from figure obtained in step "D".

Crown 1984 PF5829-10 Rev. 2/04

M3.0–18.0–010

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–010

DRIVE UNIT

Position Dial Indicator Arm Here for T.I.R. Measurement on Spiral Bevel Gear

75 mm Radius 2.875 in. Radius

55 mm Radius 2.188 in. Radius

Position Dial Indicator Arm Here for T.I.R. Measurement on Hub

ILLUSTRATION 13

11256

7. Spiral Bevel Gear Installation. A. Put together a shim pack (20). An initial pack made up of two .508 mm (.020 in.), two .178 mm (.007 in.) and one .127 mm (.005 in.) shims, which equals a shim pack thickness of 1.499 mm (.059 in.), is a recommended starting point. A shim pack as described, or similar, should yield a backlash of .127 mm (.005 in.) to .178 mm (.007 in.). Backlash in this instance is checked by feel only.

Blue all teeth on spiral bevel gear. Locate the "X" etched on the bottom of the spiral bevel pinion, and position mark so that it will be towards the open side of the drive unit housing and will mesh between the pair of "X"s etched on the spiral bevel, as shown in Illustration 14.

B. Refer to Illustration 13. Take a total indicator reading with a dial indicator, with the arm positioned as shown, on the hub. If a T.I.R. reading of more than .076 mm (.003 in.) is obtained, the hub must be removed, rotated approximately 90° and reinstalled until a reading of .076 mm (.003 in.) or less is obtained.

Gear Spiral Bevel

Pinion

C. Apply a light coat of grease to the hub diameter where the spiral bevel gear will be seated. Place the shim pack, with a thickness range of 1.397 mm (.055 in.) to 1.499 mm (.059 in.), onto hub back face. 11257 Crown 1984 PF5829-11 Rev. 2/04

M3.0–18.0–011

ILLUSTRATION 14 Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–011

DRIVE UNIT E. Check backlash, it should be from .127 mm (.005 in.) to .178 mm (.007 in.). An axial movement of .076 mm (.003 in.) will change backlash .051 mm (.002 in.). Remove spiral bevel gear and add or remove shims to obtain desired amount of backlash. Replace gear and check backlash.

Spiral Bevel Gears – Typical Preferred Tooth Contact (Pinion Member Left Hand in All Cases Shown) Correct

Top Side Central Toe Contact

Bottom Side Central Toe Contact

F. Check foot print in the following manner: • Apply enough force to either the pinion or ring gear to create drag. • Rotate either gear a minimum of two full turns in either direction. • Compare the resulting footprint with patterns shown in Illustration 15.

Bottom Side Central Toe Contact

Incorrect Profile Error: To Correct – Move Out On Pinion Cone

NOTE The spiral bevel pinion must be installed in the drive unit in such a manner that the "X" on the bottom of the pinion mates with the "X"s located on the O.D. of the gear.

Error Top Side High Toe Contact

Top Side Low Toe Contact

Bottom Side Low Heel Contact

NOTE Disregard any shaft angle or cross contact error. If a profile error exists, correct by repeating steps A through F of step 6, "Position Pinion Shaft Assembly into Drive Unit Housing".

Bottom Side High Heel Contact

G. After desired backlash has been obtained and components of axle assembly have been assembled, lockwire the bolts securing the spiral bevel gear to the hub. The lockwire used is especially designed for this purpose.

Incorrect Profile Error: To Correct – Move In On Pinion Cone Error Top Side Low Heel Contact

Bottom Side High Toe Contact

Top Side High Heel Contact

Torque Required 13.5 Nm (10 ft.lbs.)

Bottom Side Low Toe Contact

ILLUSTRATION 15

11258

D. Place the spiral bevel gear onto the hub backface. Use only a soft face or rubber mallet to help seat gear. Apply thread locking adhesive to the eight bolts securing the ring gear to the hub. Torque bolts to 80-95 Nm (60-70 ft.lbs.). Torque Required 80-95 Nm (60-70 ft.lbs.) 11259 Crown 1984 PF5829-12 Rev. 2/04

M3.0–18.0–012

Torque Required 68 Nm (50 ft.lbs.)

ILLUSTRATION 16 Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–012

DRIVE UNIT

The following guidelines should be used when securing fasteners with safety wire. • In an application where several fasteners are to be secured with one piece of safety wire, the wire holes in the bolt head should be in approximately the same relationship to each other.

Drive Axle Replacement 1. Refer to Illustration 17. Remove safety wire (25) from the screws locking the gear (21) to the hub. This safety wire can be cut off and thrown away, it must not be used again. 2. Remove screws (23 & 24) and locknut (22).

DO NOT OVER TORQUE OR UNDER TORQUE BOLTS TO OBTAIN PROPER RELATIONSHIP.

3. Remove the spiral bevel gear (21) by inserting a brass rod thru the inspection window and tapping with a rubber mallet, the spiral bevel gear can be driven from the hub. Rotate the axle at the same time until gear is off. If tapped holes, 3/8-24 UNF, are available in the gear then a puller can be used.

• The direction of wrap and twist of the wire should be made in such a manner that the loop around the bolt comes under the strand protruding from the hole to keep the loop down. • Route wire so that the wire tension will keep the bolt from coming loose.

NOTE Check the quantity and thickness of shim pack (20) for future reference.

NOTE Do Not overstress safety wire. Extreme care must be taken when twisting wires to insure they are tight but not overstressed to the degree that breakage will occur under a light load or vibration.

4. Remove the hub (19). A gear puller will be required to remove the hub from axle (8). 5. Use an arbor or hydraulic hand press and remove the axle from the drive unit housing. The outer bearing (18) will be forced off the axle at this time.

• After wiring the last fastener, twist wire ends to form a pigtail of 6 to 8 twists, cut off excess wire. Bend pigtail in such a manner to prevent it from being snagged. • Check the completed wiring and make sure the safety wire is not cracked or peeled as a result of kinking, nicking, or over twisting. Refer to Illustration 16.

25 21 1

18 22 4 19 17

16 14

10 13 12 8

15 61 3

7 6 11260

ILLUSTRATION 17

Crown 1984 PF5829-13 Rev. 2/04

M3.0–18.0–013

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–013

DRIVE UNIT HUB POSITIONING GAUGE

NOTE

75 mm(3.0 in.)

Make sure all blocks are positioned under the drive unit housing and not in contact with the seal retainer.

53.924/53.950 mm (2.123/2.124 in.) "C" Dimenson

6. To remove the cam (16), inner bearing (14) and cup (15) an appropriate puller should be used.

20 mm (.81 in.)

Thoroughly clean the drive unit housing and all components with solvent to remove all grit and sludge build ups. A close inspection of the gears and pinion should be made to check for chips, cracks, or irregular wear patterns on gear teeth. Also check bearings by turning them with your fingers. Feel for binding or gritty effects, excessive looseness or wobble.

75 mm(3.0 in.) 35 mm(1.38 in.) 1-12 x 2 in. Set Screw

Brass Sleeve 53.924/53.950 mm(2.123/2.124 in.) O.D. x 48 mm(1.88 in.) I.D. x 35 mm(1.38 in.) Long .250-20 x.75 in. Nylock Tip Set Screw

CAUTION 11261

Never spin dry a bearing using air pressure, after removing from cleaning solvent, as these conditions could cause the bearing to explode. SPIRAL BEVEL GEARS ARE INSTALLED AS SETS, DO NOT MISMATCH. 7. Clean the axle thoroughly. If the axle needs replacing, the splined hub must also be replaced. The axle and hub are sized into matched sets at the factory and must be replaced as a set. Likewise, if the splined hub needs replacement, the axle must also be replaced. 8. Inspect and clean the two bearing cups, (15 & 17), in the drive unit housing. 9. The bearing cones (14 & 18), cam (16), and hub (19) must be preheated for proper assembly. The hub must be preheated to 176° C (350° F) to 204° C (400° F). The bearing cones and cam must be heated to 120° C (250° F).

ILLUSTRATION 18

10. Use an arbor or hydraulic hand press to press bearing cone (14) onto axle, and cam (16) onto axle. Apply a light coat of grease to the seating area of the bearing and cam before pressing into position. Install axle into drive unit housing and press bearing (18) into position on axle. 11. Measure the distance from the cone back face of bearing (18), record this as dimension "A". Measure thickness of the hub (19), add .025-.050 mm (.001-.002 in.) for clearance. Subtract "B" dimension from "A" dimension to get "C" dimension. Set the Hub Positioning Gauge to the "C" dimension. 12. Apply a coating of anti-seize compound, 065005-003, to the splined area of the axle. Press hub (19) into position on the axle using the Hub Positioning Gauge. Turn or rotate the axle shaft assembly by hand to check for proper pre-load of bearing setup.

CAUTION

Do Not heat the bearings beyond this temperature. Damage to bearings will occur if temperature is allowed to go beyond 120° C (250° F). The hub should reach its required temperature in 25 to 30 minutes. The bearings and cam should reach their required temperature in approximately 15 minutes. Use an electric oven or electrically heated oil bath that are thermostatically controlled to preheat components.

Crown 1984 PF5829-14 Rev. 2/04

M3.0–18.0–014

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–014

DRIVE UNIT Oil Pump Assembly

DRIVE UNIT LUBRICATION SYSTEM

NOTE

Disassembly of Oil Pump

Inspect all component parts and drive unit housing for dirt and burrs before assembly.

1. Refer to Illustration 19 & 20. Remove drain plug (23) and drain oil from drive unit. 2. Remove oil pump housing (1) from drive unit.

1. Place ball (4) and spring (5) into oil pump housing (1).

3. Take oil pump assembly to clean work area for disassembly.

2. Place ball (7), Spring (8) and special pipe plug into piston (9). Lubricate piston with oil and install into pump housing.

Axle Bearing Cone

Cam O-Ring (3) Drive Unit Housing

Bearing Cup Piston (9) Spring (8) Ball (7)

O-Ring (2)

19 20 21

Tubing is Installed Through Cored Hole in Casting

Plug, Special (6) Spring (5)

Oil Pump Housing

Ball (4) 11262

3. Visually check the alignment of the cam on axle to be sure of proper contact with oil pump piston when installed in drive unit housing.

22 16

ILLUSTRATION 19

13 12

4. Check O-rings (2) and (3) for damage.

5. Remove piston (9), spring (8), and ball (7) from oil pump housing. 6. Remove special pipe plug (6), spring (5) and ball (4) from oil pump housing.

7. Thoroughly clean housing and all parts.

3 3 2 1

11263

Crown 1984 PF5829-15 Rev. 2/04

M3.0–18.0–015

8 7 6

ILLUSTRATION 20

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–015

DRIVE UNIT

4. Install O-rings (2) and (3) onto pump body. 5. Thoroughly lubricate pump body and port with gear oil, then screw pump assembly into housing until seated. 6. Install drain plug and fill drive unit with .71 liter (1 1/2 pints) of gear oil. 7. To check oil pump output remove pipe plug (15) and observe oil flow from port. DRIVE UNIT ASSEMBLY CHECK LIST Thoroughly clean drive unit housing and all parts. Keep matched gears or lapped gears in their original pairs. Always replace both members of a spiral bevel gear set. Properly mesh the teeth marked with "X" on spiral bevel gear set. Set spiral bevel pinion to correct mounting distance to obtain desirable "foot print". Check gear set for recommended "backlash". Be sure all locknuts, bolts, plugs, etc., are in place and tightened to their recommended torque value. Check gear oil for proper level in unit before operating under a loaded condition. 10825

Crown 1984 PF5829-16 Rev. 2/04

M3.0–18.0–016

Printed in U.S.A.

01 REV. 2/04

M3.0–18.0–016

MAINTENANCE ELECTRICAL The electrical system of the Crown Turret Stockpicker, depending on truck model, is powered by either one (1) fortyeight (48) volt battery for a forty-eight (48) volt system or two (2) thirty-six (36) volt batteries connected in series for a seventy-two (72) volt system. Twelve (12) and five (5) volt power supplies provide power to the electronics boxes for internal electronics. Both supplies are designed and marked as isolated supplies, however, the 12 volt power supply negative output is connected to battery negative. When connected to battery negative, the output is no longer isolated. The 5 volt supply output is isolated and has its own isolated negative (not connected to battery negative). When making voltage measurements on the 5 volt supply, the negative meter lead must be connected to isolated negative. When making voltage measurements on the 12 volt supply, the negative meter lead must be connected to battery negative. Each Turret Stockpicker has two on-board electronic boxes, one on the platform and one on the power unit. Each box has

a microprocessor chip on a CPU (Central Processing Unit) board. The combination of the CPU board and microprocessor chip is a computer. These computers are totally dedicated to truck operation. Data from operator controls and monitoring devices is interfaced, processed and compared by these electronics boxes which then operate systems to make the truck function as desired. Illustration 4.0-1 is a basic block diagram of the TSP electrical system. The platform and power unit electronic boxes transmit and receive data “talk” through mast cable wires which is called the serial link. Basically the system operates by the platform electronics box receiving information from an operator controlled device processes the information and sends the result to the power unit electronics box. The power unit electronics box determines and outputs the necessary signals to operate the truck as set out by the operator controlled device. The power unit electronics box also receives feedback from a monitoring device to verify the command was performed.

DANGER HAZARD OF ELECTRIC SHOCK OR BURN To prevent serious risk of death or injury to yourself and others, observe the following safety instructions. —

Always use extreme caution when performing inspection, maintenance and/or repairs to the electrical system of this unit to avoid contact with any of the 48 or 72 volt D. C. circuits. Before attempting any maintenance:

—

— — —

—

Remove jewelry from hands and arms. Turn keyswitch to “off” and remove key. Disconnect batteries and install warning tags, warning other personnel that maintenance is being performed. Never touch electrical equipment with bare hands, unless certain power has been disconnected.

— —

Never perform checks or maintenance to “live” (power applied) circuits while standing in water or on wet surfaces. Should checks to “live” (power applied) circuits become necessary, never assume a position which may allow parts of the body to accidentally come in contact with 48 or 72 volt circuits. Never jumper fuses and replace only with fuses of same type and amperage rating. Never modify the electrical system of the truck. If truck must be left unattended before maintenance work is completed, disconnect power and install warning tags.

6521 Crown 1988 PF8147-1 Rev. 8/00

Printed in U.S.A.

08 REV. 8/00

M4.0–19.0–001

MAINTENANCE 0671

BASIC BLOCK DIAGRAM

STEERING

STEERING SERVO MOTOR CONTROL

TRACTION CONTROL

TRACTION SCR CONTROL

BRAKE

PLATFORM ELECTRONICS BOX

POWER UNIT ELECTRONICS BOX

MAIN & AUXILIARY LIFT/LOWER ACCESSORY FUNCTION CONTROLS

LIFT PUMP MOTOR SCR CONTROL ACCESSORY PUMP MOTOR

SERIAL LINK

BRAKE VALVE SOLENOID

ILLUSTRATION 4.0-1 The various truck functions are treated as individual systems; steering system, traction system, brake system, main and auxiliary lift/lower system and accessory function systems. The steering system begins by the operator turning the steering tiller and these inputs go to the platform electronics box. The input is processed and sent to the power unit electronics box which sends a signal to the steering servo motor control. The steering servo motor controller applies voltage to the steering motors which turns the steered wheels in the direction and at the speed requested. Verification of this movement is through the steering angle encoder feedback. The traction system input to the platform electronics box is the twist grip input, which provides direction and speed commands. This input is processed and sent to the power unit electronics box which determines and outputs signals to energize the appropriate contactor (forward or reverse) and operate the traction SCR control. Traction verification is through feedback from speed/direction sensors. The brake system uses inputs to the platform electronics box from various switches in brake pedal assemblies and the parking brake switch. These inputs are processed and the results sent to the power unit electronics box which outputs the necessary signal to the brake valve solenoids to apply or release the brakes. Verification of brake status is from switches monitoring brake linkage position.

The main and auxiliary lift/lower system inputs to the platform electronics box includes the inputs from the left-hand control lever encoder and the palm switch on the traction control twist grip. These inputs are processed and the results sent to the power unit electronics box. The power unit electronics box determines the control signals required and outputs these signals to the pump contactor, pump motor SCR control, servo control valve and solenoid valves for operation of the main or auxiliary, lift or lower as requested. Verification of operation is through feedback from the servo control valve LVDT and height sensor encoder. The pivot, traverse, extend/retract (accessory) system inputs to the platform electronics box are from switches sensing movement of the linkage between the left-hand control levers and the spool valves, and from a palm switch in the traction control twist grip. The platform electronics box processes these inputs and sends the results to the power unit electronics box. The power unit electronics box outputs a signal to energize the accessory pump contactor. Feedback is received by the platform electronics box from switches which indicate the accessory function limits. The following pictorial diagrams illustrate the various components of the truck concerned with each system. Some systems are split up for ease of explanation.

Crown 1988 PF-8147-2 Rev. 8/91

Printed in U.S.A.

02 REV. 8/91

M4.0 - 19 - 002

MAINTENANCE 0689

ELECTRICAL INTERLOCKS GTSL FLOOR PEDAL ASSEMBLIES (DMS-4, DMS-5)

SEAT SWITCH (SES)

FOOT PEDESTAL (DMS-2,DMS-3)

POWER UNIT ELEC. BOX

SERIAL LINK PLAT. ELEC. BOX

GTSR

PALM/FOOT INDICATOR LIGHT (LGT-18)

GATE INDICATOR LIGHT (LGT-6)

ILLUSTRATION 4.0-2 Electrical interlocks are switches which when “read” by the electronic boxes, verify that the operator has performed specific tasks and is positioned correctly in the operator compartment before traction or any hydraulic function can be performed. In addition, the electronics software program “looks” for a sequence of input changes so switches are not physically bypassed. Since the software program is looking for a sequence, the input changes must occur after the truck is powered-up.

is standing or seated as determined by the seat switch (SES) input, inputs from the floor pedal switches (DMS-4 and DMS5), if standing, or foot pedestal switches (DMS-2 and DMS3), if seated, must be present. At this time the “gate” light and “palm/foot” light should be off and the conditions for the function desired must be met.

To perform the traction or hydraulic functions of the truck, the gate switches (GTSL and GTSR) must indicate that the gates are closed. Also, depending on whether the operator

Printed in U.S.A.

Crown 1988 PF-8147-3 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 003

MAINTENANCE MANUAL STEERING CONTROL

STEERING SERVO MOTOR

STEERING SERVO MOTOR CONTROL (MRC-3)

0673

STEERING CONTACTOR (S)

STEERING INDICATOR LIGHTS

STEERING ENCODER (ECR-1)

BATTERY POSITIVE

POWER UNIT ELEC. BOX

SERIAL LINK PLAT. ELEC. BOX

STEERING SERVO MOTOR

STEERING FEEDBACK ENCODER (ECR-5)

ILLUSTRATION 4.0-3 The steering tiller turns an encoder, an electro-mechanical device which translates mechanical motion to electrical pulses. The platform electronics box “reads” the encoder and determines the direction and speed of the requested turn. This information is sent to the power unit electronics box thru the serial link. The power unit electronics box outputs a control signal to the steering servo motor control. This, in turn, controls the voltage level and polarity to the servo motors. the servo motors turn the wheels in the direction and at the speed requested by the steering tiller motion. As the steered wheels turn, the power unit electronics box “reads” the steering feedback encoder and compares these pulses with the tiller pulses. When these match, the power unit electronics box removes the signal from the motor control.

If at anytime the steering command leads the feedback by more than a predetermined amount, the steering contactor is opened and the truck brakes are set. Also when the steered wheels are turned more than 5° from the straight ahead position, the power unit electronics box sends a signal to the platform electronics box which turns off the steered wheels “centered” indicator and turns on the appropriate yellow indicator. When the steering tiller is turned the electronics box outputs a signal to turn the steered wheels the requested amount. When obtained, the output signal is removed. As the tires move the steered wheels back slightly due to tire squirm , the electronics box will output a signal to maintain tire position for 5 seconds. If the tiller is not turned and truck movement is not sensed in this amount of time, the electronics box output is removed and the steering system turned "off" until additional input is received from the tiller or truck movement is sensed.

Printed in U.S.A.

Crown 1988 PF-8147-4 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 004

MAINTENANCE 0690-01

TRACTION CONTROL * CABLE TENSION SWITCH (CTS) top of mast TRACTION MOTOR

SS1

HEIGHT SENSOR ENCODER (ECR-4)

HEIGHT CABLE SWITCH (HCS)

AUXILIARY CHAIN SLACK/BROKEN SWITCH (CHS-3)

BATTERY POSITIVE

STEERING FEEDBACK ENCODER (ECR-5)

POWER UNIT ELEC. BOX

TRACTION ENCODER (ECR-3)

SCR CONTROL AND CONTACTOR PANEL SERIAL LINK PLAT. ELEC. BOX

TRACTION MOTOR

SS2

AUXILIARY HEIGHT 12" SWITCH (AHS) MAIN CHAIN SLACK/BROKEN SWITCHES (CHS-1, 2, 4, 5)

* TF MAST ONLY

ILLUSTRATION 4.0-4 Input from the traction control twist grip encoder (ECR-3) to the platform electronics box is processed for direction and speed commands and is sent to the power unit electronics box. The power unit electronics box outputs a control signal which energizes the appropriate directional contactor and operates the traction SCR control to pulse the traction motors with battery voltage. As the speed request input varies, the power unit electronics box output varies to obtain the speed requested. Feedback from the speed sensors (SS1 and SS2) to the power unit electronics box is compared to the speed request input for verification. In traction control, situations with other truck functions put restrictions on the maximum allowable traction speed. These are; forks not in clear aisle position, fork and platform height

and steering angle. For a clear aisle fork position, the forks must be retracted, the traverse mechanism must be full right with the forks pivoted left or traverse mechanism full left with the forks pivoted right. Platform height, monitored by the height sensor encoder and fork height, monitored by the auxiliary mast 31" (790mm) switch, (EEC specifications require for 12 " [300mm] for out of aisle operation and 31" [790mm] for in aisle operation), decrease the maximum allowable speed as determined by the trucks specification. Also when the steered wheels are turned more than 10° from the straight ahead position, maximum allowable speed is limited. Switches which monitor mast chain slack/break, mast cable tension (TF mast only) and height sensor cable break are monitored by the electronics boxes. Whenever these switches indicate a malfunction, traction is limited or not possible at all.

Printed in U.S.A.

Crown 1988 PF-8147-5 Rev. 1/94

04 REV. 1/94

M4.0 - 19 - 005

MAINTENANCE 0691

BRAKE CONTROL FLOOR PEDAL ASSEMBLIES (BRS-4, BRS-5) BRAKE CYLINDER

BRS-6 BATTERY POSITIVE

K4 RELAY POWER UNIT ELEC. BOX

FOOT PEDESTAL (BRS-2, BRS-3) SEAT SWITCH (SES)

SERIAL LINK

PLAT. ELEC. BOX BRAKE CYLINDER

BRS-7

ACCESSORY PUMP AND MOTOR

BRAKE MANIFOLD (SV7, 8, 9)

BPS BRAKE APPLIED INDICATOR (LGT-12)

PARKING BRAKE SWITCH (BRS-1)

ILLUSTRATION 4.0-5 Brakes on the Turret Stockpicker are spring applied, hydraulically released. Hydraulic pressure in the brake system is developed by the accessory pump and motor. When the operator is standing as determined by the seat switch (SES) input to the platform electronics box, inputs from the floor pedal brakes switches (BRS-4 and BRS-5) are monitored. The operator must be standing on both floor pedals to release the brakes. When the operator is seated, again determined by the seat switch input to the platform electronics box, inputs from the foot pedestal brake switches (BRS-2 and BRS-3) and the parking brake switch (BRS-1) are monitored. To release the brakes when seated, the momentary contact of the parking brake switch must be closed momentarily. To apply the brakes when seated, the brake pedal on the foot-pedestal must be depressed or the parking brake switch turned on. The platform electronics box monitors all inputs and when determined whether the operator is standing or seated and the correct brake switch inputs present, the platform electronics box sends the results to the power unit electronics box. The power unit electronics box outputs a signal to energize relay K4 which applies power to the brake release solenoids (SV6 and SV7). Switches (BRS-6 and BRS-7) mounted on the traction motor brake assemblies provide feedback to the power unit electronics box that verifies the brakes are released.

ics box. The power unit electronics box removes the signal to relay K4 which removes power from the brake release solenoids and the brakes are spring applied. The platform electronics box then outputs a signal to illuminate the brake applied indicator light (LGT-12) in the operator console. Whenever truck speed is below 2.3 MPH and braking is requested, the power unit electronics box outputs a signal to energize SV9 on the brake manifold block. Energizing this solenoid keeps the drive unit brakes released to soften braking. If the brakes are used frequently without working the accessory hydraulic functions, hydraulic pressure drops slightly each time brakes are cycled. To avoid losing pressure to the point insufficient pressure is present to release the brakes, a low pressure contact of the brake pressure switch (BPS) closes and is “read” by the power unit electronics box. The power unit electronics box then outputs signals to energize solenoid SV8 on the brake manifold block and to energize contactor P3. Energizing SV8 isolates the brake hydraulic circuit from the accessory function hydraulic circuit and energizing P3 starts the accessory pump and motor. When pressure builds back up, a high pressure contact of BPS closes and is “read” by the power unit electronics box. The outputs to SV8 and P3 are then removed and the brake hydraulic system has been recharged.

When inputs to the platform electronics box change, the information is processed and sent to the power unit electronPrinted in U.S.A.

Crown 1988 PF-8147-6 Rev. 8/91

02 REV. 8/91

M4.0 - 19 - 006

MAINTENANCE 0692-01

MAIN LIFT/LOWER CONTROL * STAGING SWITCH (LMS-2)

* CABLE TENSION SWITCH (CTS) top of mast

HEIGHT RESET SWITCH (LMS-1)

R/L ENCODER (ECR-2) BATTERY POSITIVE

POWER UNIT ELEC. BOX

HEIGHT SENSOR ENCODER (ECR-4)

SCR CONTROL AND CONTACTOR PANEL

MAIN CHAIN SLACK/BROKEN SWITCHES (CHS-1, 2, 4, 5) CUTOUT ZONE INDICATOR (LGT-21)

SERIAL LINK PLAT. ELEC. BOX

LOWER MANIFOLD BLOCK (SV2)

SERVO CONTROLLED VALVE (SV1)

LVDT

SS3

LIFT PUMP AND MOTOR

RIGHT HAND PALM SWITCH (DMS-1)

AUXILIARY CHAIN SLACK/BROKEN SWITCH (CHS-3)

* TF MASTS ONLY

ILLUSTRATION 4.0-6 The encoder (ECR-2) of the lift/lower control lever, staging switch (LMS-2) and reset switch (LMS-1) provides the lift or lower and speed inputs to the platform electronics box. The platform electronics box processes these inputs and the input from the palm switch (DMS-1) on the traction control twist grip and sends the results to the power unit electronics box. When the raise function is selected, the power unit electronics box outputs a signal to energize the P1 contactor and a control signal to the pump SCR control to operate the lift pump and motor at a predetermined speed. Verification of pump speed is from the lift pump speed sensor (SS3) feedback to the power unit electronics box. A signal is also sent to the servo controlled valve (SV1) which regulates oil flow to control the lift speed up to the predetermined pump speed. When the servo valve is full open, as verified by the LVDT feedback, the signal to the pump SCR control is increased. When the control lever is moved to the maximum raise position, the power unit electronics box outputs a signal to energize contactor P2 which supplies full battery voltage to the pump motor. As the control lever is returned to neutral, the sequences are reversed. When the lower function is requested through movement of the control lever, the platform electronics box processes the input commands and sends the results to the power unit

electronics box. The power unit electronics box outputs a signal to energize a solenoid (SV2) on the lower manifold block and a control signal to the servo controlled valve. As the control lever is moved for increased lowering speed, the power unit computer outputs a control signal to the servo controlled valve to open the valve farther. Verification of valve spool movement is from the LVDT to the power unit computer. Actual platform height is determined through feedback from an encoder (ECR4) in the height sensor. The counter which keeps track of the actual platform height is reset whenever the input from the reset switch (LMS-1) changes (when platform is within 18 inches of lowest position). Resetting the counter will remove any accumulated error which may be present. Switches that monitor main and auxiliary chain slack/broken condition will disable main and auxiliary lower if chain slack is indicated. Main and auxiliary raise and lower are disabled if main chain switches indicate chain broken. TF MASTS ONLY The platform electronics box also monitors the mast staging switch (LMS-2). Whenever the main mast begins staging, LMS-2 input to the platform electronics box changes. When above this staging point, lower cutouts cannot be programmed into the system. Below the staging point, lift cutouts cannot be programmed into the system. Printed in U.S.A.

Crown 1988 PF-8147-7 Rev. 1/94

04 REV. 1/94

M4.0 - 19 - 007

MAINTENANCE 0693-01

AUXILIARY LIFT/LOWER CONTROL * CABLE TENSION SWITCH (CTS) top of mast

BATTERY POSITIVE

POWER UNIT ELEC. BOX

HEIGHT SENSOR ENCODER (ECR-4)

R/L ENCODER (ECR-2)

AUXILIARY SWITCH (AXS) MAIN CHAIN SLACK/BROKEN SWITCHES (CHS-1, 2, 4, 5)

SCR CONTROL AND CONTACTOR PANEL SERIAL LINK PLAT. ELEC. BOX

LOWER MANIFOLD BLOCK (SV2)

SERVO CONTROLLED VALVE (SV1)

LVDT

SS3

LIFT PUMP AND MOTOR

RIGHT HAND PALM SWITCH (DMS-1)

AUXILIARY CHAIN SLACK/BROKEN SWITCH (CHS-3)

* TF MASTS ONLY

ILLUSTRATION 4.0-7 When compared to main lift/lower, the operation is similar. One additional input is required to the platform electronics box to obtain the auxiliary function which is the auxiliary switch (AXS) input from the knob on the raise/lower control lever. The output signal from the power unit electronics box to the servo controlled valve (SV1 ) is of the opposite polarity to move the valve spool in the opposite direction as when in main raise.

When lowering, again the servo controlled valve spool is moved in the opposite direction as when in main lower and a control signal is sent to energize the auxiliary lower solenoid (SV3) on the lower manifold block.

Printed in U.S.A.

Crown 1988 PF-8147-8 Rev. 9/93

03 REV. 9/93

M4.0 - 19 - 008

MAINTENANCE 0694-01

PIVOT CONTROL MAIN CHAIN SLACK/BROKEN SWITCHES (CHS-1, 2, 4, 5)

SS1 P3 BATTERY POSITIVE

POWER UNIT ELEC. BOX

PIVOT "COMMAND" SWITCH (PTS) PIVOT CONTROL LEVER

PIVOT BLOCKING SOLENOID VALVE (SV11)

PIVOT LIMIT SWITCHES (PLS, PRS)

SERIAL LINK PLAT. ELEC. BOX

SS2

ACCESSORY PUMP AND MOTOR

PIVOT "HOME" LIGHT (LGT-5)

PALM SWITCH (DMS-1)

ILLUSTRATION 4.0-8 Inputs to the platform electronics box for pivot control include the palm switch (DMS-1 ) of the traction control twist grip and a switch (PTS) sensing movement of the pivot control valve linkage. These inputs are processed and the results sent to the power unit electronics box. The power unit electronics box outputs signals to energize contactor P3, which operates the accessory pump and motor and solenoid valve (SV11) which allows the pivot function hydraulically.

Speed of the pivot function is controlled by the operator through linkage between the control lever and spool valve. When the pivot function reaches its mechanical limit, a limit switch (PLS or PRS) at that limit is actuated which is “read” by the platform electronics box. The platform electronics box then outputs a signal to illuminate the pivot “home” indicator (LGT-5) in the operator console. Switches that monitor main chain slack/broken conditions will disable the pivot function if a main chain slack or broken condition is indicated. The pivot function will not operate at traction speeds in excess of 1.3 mph.

Printed in U.S.A.

Crown 1988 PF-8147-9 Rev. 9/93

03 REV. 9/93

M4.0 - 19 - 009

MAINTENANCE TRAVERSE/FORK EXTEND/RETRACT CONTROL

SS1

0695-02

TRAVERSE SLOWDOWN SOLENOID VALVE (SV12)

TRAVERSE "COMMAND" SWITCHES (TVSL, TVSR)

TRAVERSE CONTROL LEVER

BATTERY POSITIVE

POWER UNIT ELEC. BOX

MAIN CHAIN SLACK/BROKEN SWITCHES (CHS-1, 2, 4, 5)

TRAVERSE LIMIT SWITCHES (TLS, TRS)

SERIAL LINK

TRAVERSE SLOWDOWN SWITCH (TDSL)

FORK "HOME" SWITCHES (FHSL, FHSR)

PLAT. ELEC. BOX ACCESSORY PUMP AND MOTOR SS2

TRAVERSE "HOME" LIGHT (LGT-4)

PALM SWITCH (DMS-1)

TRAVERSE TRAVERSE MANIFOLD SLOWDOWN BLOCK SWITCH (SV4, 5, 10) (TDSL)

PIVOT LIMIT SWITCHES (PLS, PRS)

ILLUSTRATION 4.0-9 The platform electronics box processes inputs from the traction control twist grip palm switch (DMS-1) and the traverse switches (TVSL and TVSR) sensing movement of the linkage between the traverse control lever and traverse spool valve. The results are sent to the power unit electronics box which outputs a signal to energize contactor P3. This action starts the accessory pump motor. Speed of the traverse function is controlled by the operator through linkage between the control lever and spool valve. Three components which are not related to the electronics system and affect the traverse function is the traverse slowdown sub-system. This sub-system includes two (2) switches (TDSL and TDSR) and a solenoid valve (SV12). When the traverse mechanism is within 1 inch (25.4mm) of the stops, the corresponding switch is actuated and power is removed from SV12. This action diverts a portion of the traverse motor oil flow to the reservoir, slowing the traverse mechanism which contacts the stops gently. For maximum traverse speed, SV12 must be energized. When the traverse mechanism reaches its mechanical limit a traverse limit switch (TLS or TRS) input to the platform electronics box is processed. If the forks are pointed in a direction opposite the traverse mechanism movement, as determined by pivot limit switch (PLS or PRS) inputs, the platform electronics box outputs a signal to illuminate the traverse “home” indicator light (LGT-4). If the forks are pointed in the direction of traverse movement, as determined by pivot limit switch inputs, the platform electronics box outputs signals to energize solenoids SV4 & SV5. When these solenoids energize, hydraulic pressure to the traverse motor is diverted to the fork cylinders and the forks will extend.

When the control lever is returned to neutral, the change in input status to the platform electronics box is processed and sent to the power unit electronics box. The power unit electronics box removes the signal from the P3 contactor which turns off the accessory pump and motor. At the same time the platform electronics box removes the signals to the solenoid valves. When the traverse control lever is moved in the opposite direction from neutral as before, the platform electronics box processes the input signals from the traction control twist grip palm switch and the traverse valve linkage switch and sends the results to the power unit electronics box. The power unit electronics box outputs a signal to energize contactor P3, which starts the accessory pump and motor. At the same time the platform electronics box outputs signals to energize solenoids SV4, SV5 and SV10 if the forks are extended as determined by inputs from the fork “home” switches (FHSL and FHSR). Solenoids SV4 and SV5 divert hydraulic pressure from the traverse motor to the forks and SV10 channels hydraulic pressure to retract the forks. SV10 is only energized when extending or retracting the forks on the left side of the truck. When the forks are retracted as determined by the fork “home” switch inputs, the platform electronics box removes the signals to solenoids SV4, SV5 and SV10. Hydraulic pressure is now diverted to the traverse motor. Switches that monitor main chain slack/broken conditions will disable the traverse and sideshift functions if a main chain slack or borken condition is indicated. The traverse and sideshift functions will not operate at speeds in excess of 1.3 mph. Printed in U.S.A.

Crown 1988 PF8147-10 Rev. 8/00

05 REV. 8/00

M4.0–19.0–010

MAINTENANCE 0696

AUTOMATIC STEERING CONTROL (Wire Guidance, Rail Guidance) RAIL GUIDE SWITCH STEERING (RGSL) SERVO MOTOR

STEERING SERVO MOTOR CONTROL (MRC-3)

STEERING CONTACTOR (S)

STEERING INDICATOR LIGHTS LOAD WHEEL SENSOR BAR STEERING ENCODER (ECR-1)

BATTERY POSITIVE

STEERED WHEEL SENSOR BAR

STEERING FEEDBACK ENCODER (ECR-5) STEERING SERVO MOTOR

POWER UNIT ELEC. BOX

SERIAL LINK PLAT. ELEC. BOX

RAIL GUIDE SWITCH (RGSR)

GUIDANCE SWITCH (GUS)

SIGNAL STRENGTH INDICATOR (LGT-9)

GUIDANCE INDICATORS (LGT-10, LGT-11)

ILLUSTRATION 4.0-10 Wire Guidance

Rail Guidance

When the guidance switch (GUS) is placed in the “AUTO” mode, the electronics go into the search mode of operation. During the search mode, the electronics is looking for a signal from the sensor bars indicating the guide wire has been detected, travel speed is limited to 1.5 MPH and steering remains manual. The electronics automatically goes into the acquisition mode of operation. During the acquisition mode, the electronics is looking for sufficient signal from the sensor bars to guide the truck, travel speed is limited to 1.5 MPH and steering remains manual. When sufficient signal is present, the truck is automatically steered over the guide wire through information from the sensor assemblies to the power unit electronics box. During the automatic mode, the power unit electronics box tells the platform electronics box to ignore the steering encoder input and the travel speed limit is removed.

Switches in the rail guide roller assemblies of the power unit are the on-off control for rail guidance. When in an open area, rollers not contacting guide rails, steering control is as described in manual steering control. When the rollers contact the guide rails, the rail guide switch inputs to the power unit electronics box change. The power unit electronics box then turns the steering servo motor control on to center the steer wheels, as verified by the steering angle feedback encoder (ECR-5), for approximately 10 seconds. After the 10 second time has elapsed, the power unit electronics box turns the steering servo motor control off and guidance is provided by the rollers against the guide rails. During this time the power unit electronics box tells the platform electronics box to ignore the steering encoder input.

Printed in U.S.A.

Crown 1988 PF-8147-11 Rev. 8/91

02 REV. 8/91

M4.0 - 19 - 011

MAINTENANCE 0697

END AISLE CONTROL (EAC) TRACTION MOTOR

SS1 EAC SENSORS

BATTERY POSITIVE BRAKE CYLINDER POWER UNIT ELEC. BOX

SCR CONTROL AND CONTACTOR PANEL

EAC OVERRIDE SWITCH (ORS-4) SERIAL LINK

TRACTION ENCODER (ECR-3) PLAT. ELEC. BOX

TRACTION MOTOR

BRAKE SS2 CYLINDER

BRAKE MANIFOLD (SV6, 7, 8, 9) EAC ZONE INDICATOR (LGT-23)

ILLUSTRATION 4.0-11 The power unit electronics box monitors inputs from magnetic field sensors mounted on the mainframe. The inputs from these sensors are processed by the power unit electronics box and sends outputs to the traction SCR control or brakes to obtain the traction control required for the inputs received. Feedback from the speed sensors (SS1 and SS2) to the power unit electronics box is used to verify the traction speed.

Whenever within a limitation zone of EAC, the indicator in the EAC override button illuminates and a 4 second alarm sounds. When the EAC indicator is illuminated and the EAC override button is depressed, the limitations in force are overridden until additional inputs from the sensors are received.

Printed in U.S.A.

Crown 1988 PF-8147-12 Rev. 8/91

02 REV. 8/91

M4.0 - 19 - 012

MAINTENANCE

TB619

BPS1 BPS2

FLASHING LIGHT (LGT16)

TB617

SS3 MAIN LIFT MOTOR (M1) MAIN & AUX. LIFT/ LOWER MANIFOLD (SB66, SV2 & SV3)

TB618 SERVO VALVE (M7 & SV1) TB615 TB616

BRAKE MANIFOLD (SB67, SB68, SV6, SV7, SV8 & SV9)

ACCESSORY MOTOR (M2)

RGSR

POWER UNIT ILLUSTRATION 4.0-12

TB609 TB610

SWING-OUT DOOR (SEE ILL. 4.0-15)

CONTACTOR PANEL (SEE ILL. 4.0-14)

SS1

BRS6

STEERING MOTOR-LEFT (M5) TRACTION MOTOR-LEFT (M3)

TB611 TB612

RGSL

SS2

TB613

W/G SENSOR BAR

BRS7 STEERING MOTORECR5 RIGHT (M6)

TRACTION MOTOR-RIGHT (M4)

POWER UNIT ILLUSTRATION 4.0-13 0682S-01 Printed in U.S.A.

Crown 1988 PF-8147-13 Rev. 10/97

06 REV. 10/97

M4.0–19.0–013

MAINTENANCE TRACTION SCR (MRC1)

SB62 RIGHT MOTOR DIRECTIONAL CONTACTORS (MRC5 [FR & RR])

SB63

FU12 ED1

PUMP SCR (MRC2)

LEFT MOTOR DIRECTIONAL CONTACTORS (MRC4 [FL &RL])

STEERING SERVO MOTOR CONTROL (MRC3)

SB61 PLUGGING MODULE

P1 FU10 TB614

FU11

P3 FU14

FU13

ED2 SB65

S SB64

FU15 CONTACTOR PANEL & SWING-OUT DOOR ASM. ILLUSTRATION 4.0-14

ELECTRONIC BOX

FU1 THRU FU8 CURTIS CONTROLLER

EMS4

EMS3 DISTRIBUTION PANEL LGT15 K4 LGT14 POWER SUPPLY LGT13 HOUR METER

TES1

SWING-OUT DOOR ASM. ILLUSTRATION 4.0-15 0683S-02 Crown 1988 PF-8147-14 Rev. 5/97

Printed in U.S.A.

05 REV. 5/97

M4.0–19.0–014

MAINTENANCE 0698S-02

FLOOR PEDAL BRAKE/ INTERLOCK SWITCHES (BRS4, BRS5, DMS-4 & DMS-5)

STEERING IND. LIGHTS (LGT1, LGT2 & LGT3)

EMERGENCY OVERRIDE SWITCHES (EMS1 & EMS2)

TRACTION CONTROL (ECR3, DMS1, EDS, HNS, ORS-1, TB509, TB510, ORS-4 & LGT-29)

ECR1 ECR2

KYS AXS

DISPLAY PANEL (LGT4 THRU 12, 18 & 21, BRS1, FNS, GUS, LGS1, LGS2 & SWH1)

TB526 TB527

SB52

FU16 SEAT ADJ. MOTOR (M8)

HN2

LMS1 *LMS2

ECR4

SEAT ADJ. SWITCHES (LMS3 & LMS4)

SES

TB524

TB523

LIFT CHAIN SLACK/ BREAK SWITCHES (CHS1, CHS2, CHS4 & CHS5)

* TF MASTS ONLY

PLATFORM ILLUSTRATION 4.0-16

Crown 1988 PF-8147-15 Rev. 10/97

Printed in U.S.A.

06 REV. 10/97

M4.0–19.0–015

MAINTENANCE 0699S-01

* CTS LGT17 TB502 FAN LGT20

TDSR

SB51

LGT19 TDSL

PTS TVSL TVSR

BDI INTERFACE CARD

TB528

DISTRIBUTION PANEL (FU9, K1, K2, K3 & POWER SUPPLIES)

TRAVERSE CUSHION MANIFOLD (SV12)

ELECTRONIC BOX

SB54 GTSR HN1

PEDASTAL SWITCHES (BRS3 & DMS3) PEDASTAL SWITCHES (BRS2 & DMS2)

SB53

EAC SENSOR BAR GTSL TB525 * TF MASTS ONLY

HCS W/G SENSOR BAR

PLATFORM & MAINFRAME ILLUSTRATION 4.0-17 Printed in U.S.A.

Crown 1988 PF-8147-16 Rev. 9/93

03 REV. 9/93

M4.0 - 19 - 016

MAINTENANCE TB704 TB703

TRAVERSE MANIFOLD (SB72, SV4, SV5 & SV10)

PIVOT LIMIT SWITCHES (PLS & PRS) TRAVERSE LIMIT SWITCHES (TLS & TRS)

PIVOT MANIFOLD (SB71, SV11)

AHS1

TB701

AHS2

TB702 TB705

FORK HOME/DIFF. SWITCHES—RIGHT (FHSR & FRS)

FORK HOME/DIFF. SWITCHES—LEFT (FHSL & FLS)

LOAD HANDLER ILLUSTRATION 4.0-18

0700S-01 Printed in U.S.A.

Crown 1988 PF-8147-17 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 017

MAINTENANCE FUSES Whenever a fuse opens (blows), an electrical malfunction is normally indicated. The associated circuitry should be checked for short circuits before a new fuse is installed. Never jumper a fuse or serious damage to associated circuitry may occur. Always replace fuses with the same type and rating as specified. Refer to following chart for listing of all fuses. FUSE FU-1 FU-2 FU-3 FU-4 FU-5 FU-6 FU-7 FU-8 FU-9 FU-10 FU-11 FU-12 FU-13 FU-14 FU-15 FU-16

LOCATION Power Unit Dist. Board Power Unit Dist. Board Power Unit Dist. Board Power Unit Dist. Board Power Unit Dist. Board Power Unit Dist. Board Power Unit Dist. Board Power Unit Dist. Board Platform Distribution Board Contactor Panel Assembly Contactor Panel Assembly Contactor Panel Assembly Contactor Panel Assembly Contactor Panel Assembly Contactor Panel Assembly Seat Adjustment Post

CIRCUIT Power Unit Power Supplies Platform Control Circuit Platform Emer. Circuit Platform Lights & Fan Flashing Light Quad Driver 2 & “D” Contactor Quad Driver 3 R/L Servo Motor Plat. Power Supplies & QD4 Traction SCR Control Card Lift SCR Control Card Traction Motor Circuit Lift Motor Circuit Accessory Motor Circuit Steering Servo Motor Circuit Seat Motor

TYPE & SIZE ABC-41, 4A ABC-15, 15A ABC-15, 15A ABC-15, 15A ABC-15, 15A ABC-15, 15A ABC-15, 15A ABC-15, 15A ABC-15, 15A ABC-15, 15A ABC-15, 15A ACK-300, 300A ALS-300, 300A ACK-60, 60A ALS-200, 200B ABC-4, 4A

CROWN PART NO. 094362-001 094362-002 094362-002 094362-002 094362-002 094362-002 094362-002 094362-002 094362-002 094362-002 094362-002 076924-022 076924-021 076924-001 076924-002 094362-001

Printed in U.S.A.

Crown 1988 PF8147-18 Rev. 5/99

07 REV. 5/99

M4.0–19.0–018

MAINTENANCE SWITCHES All switches should be checked regularly to assure safe and efficient operation. When adjustments are performed to any switches, make certain the locking devices are tightened to maintain correct adjustment. Also verify the operation of the switches before replacing covers.

AXS

Fork Extend Override

AHS Auxiliary Mast Height Switch (Illustration 4.0-1) The auxiliary mast height switch is located in the fork carriage assembly, next to the auxiliary mast chain anchor. This switch requires no adjustment.

Raise/Lower Lever

Traverse Lever

ILLUSTRATION 4.0-2

1545-01

BPS Brake Pressure Switch (Illustration 4.0-3) The brake pressure switch has two (2) switch contacts which have different functions. One contact closes when the hydraulic pressure drops to a predetermined point and the other switch contact opens when the hydraulic pressure increases to a predetermined point. This switch block is used to maintain hydraulic pressure in the brake system during times of minimal accessory function use. This switch is factory preset and does not require further adjustment. Pictorial

1544

ILLUSTRATION 4.0-1

AXS Auxiliary Switch (Illustration 4.0-2) The auxiliary switch is located in the knob of the raise/lower control lever. Depressing the actuator on the side of the knob pushes the actuator away from the switch allowing the switch contact to reset. When depressed and the raise/lower control lever moved, the auxiliary lift/lower function will operate. This switch does not require adjustment.

Schematic

Fork Extend Override Switch (Illustration 4.0-2) The fork extend override switch is located in the knob of the traverse control lever. Depressing the actuator on the side of the knob pushes the actuator away from the switch allowing the switch contact to reset. When depressed and the traverse control lever moved, the forks extend function will operate. This switch does not require adjustment.

1546

ILLUSTRATION 4.0-3

6674 Crown 1988 PF8148-1 Rev. 7/00

Printed in U.S.A.

05 REV. 7/00

M4.0–19.0–100

MAINTENANCE BRS-1 Parking Brake Switch (Illustration 4.0-4)

BRS-2 & BRS-3 Pedestal Brake Switches (Illustration 4.0-5)

The parking brake switch is located in the switch and indicator console of the operator compartment. When this switch is placed in the “on” position, the brakes are applied and an amber “brakes applied” indicator will illuminate. When placed in the “off” position, the brakes will release when the floor pedals are depressed if the operator is operating the truck while standing. If the operator is seated to operate the truck, the momentary contact of the switch must be cycled to transfer control to brake pedal on foot pedestal. This switch does not require adjustment.

When the operator is seated and the pedestal brake pedal is depressed, the switch contacts open and truck brakes are applied. To access these switches, remove the two (2) nuts and lockwashers at the bottom of the foot pedestal assembly, pull assembly out to clear mounting studs then lift up to unhook assembly from mounting tabs. The assembly can now be placed on the floor and access to the switches gained through the back of the housing. Adjust switches so normally open contacts are held closed when actuator is against mounting weldment. When pedal is depressed, switch contacts must reset.

2426S

ILLUSTRATION 4.0-4

2425S

Crown 1988 PF-8148-2 Rev. 9/93

ILLUSTRATION 4.0-5

Printed in U.S.A.

01 REV. 9/93

M4.0 - 19 - 101

MAINTENANCE BRS-4 & BRS-5 Floor Pedal Brake Switches (Illustration 4.0-6)

BRS-6 & BRS-7 Brake Linkage Switches (Illustration 4.0-7)

When the operator is standing to operate the truck and the parking brake switch is in the “off” position. The floor pedals must be depressed, moving the switch actuator away from the switches and resetting the contacts, to release the brakes. If either pedal is released, opening a switch contact, the brakes will be applied.

These switches are located on the brake mounting bracket of the drive units. When the brakes are applied, the switch actuator moves away from the switches, opening the contacts. The contacts are monitored by the power unit electronics box to determine brake status before travel is allowed.

To access these switches, raise platform and set 2 jackstands (2000 Ib. capacity minimum each) under platform frame. Remove 2 screws from side cover and remove. When floor pedal is released, the switch actuator is resting against mounting weldment. Loosen switch mounting screws and adjust switches so normally closed contacts are held open at this point. When pedal is depressed, switch contacts must reset.

BRS-6 (L.H.) BRS-7 (R.H.) 2386

2427S

ILLUSTRATION 4.0-7

ILLUSTRATION 4.0-6

Printed in U.S.A.

Crown 1988 PF-8148-3 Rev. 9/93

01 REV. 9/93

M4.0 - 19 - 102

MAINTENANCE CHS-1 & CHS-2 Chain Break Switches CHS-4 & CHS-5 Chain Slack Switches (Illustration 4.0-8)

SEE ILLUSTRATION 4.0-10

POLY STOP

These switches are located behind the seat height adjustment assembly. Two stepped shafts relate chain status to the switches through their position. When the chain becomes slack, the actuator shaft is forced down by a spring. The rollers of the chain slack switches encounter a step down on the shaft which opens the normally open contacts of the switch. If the chain becomes slack to the point that the chain break switch rollers go off the end of the actuator shaft, the normally open contacts of these switches would open and a chain break condition would be in force.

TAKE UP ASM. STOP PULLEY MOUNTED AT TOP OF MAST

1/4" to 3/8" WITH PLATFORM FULLY LOWERED.

PULLEY PART OF TAKE UP ASSEMBLY

CHAIN SLACK

PULLEY ON BRACKET FASTENED TO FREE LIFT CYLINDER ADJUSTOR

CHAIN BREAK

UNDER COVER ON MAST

USE ADJUSTOR TOOL NUMBER 108641 TO ADJUST CABLE TENSION

2393S-01

2398S-01

ILLUSTRATION 4.0-9

2428S

ILLUSTRATION 4.0-10

ILLUSTRATION 4.0-8

CTS (TF Mast Only) Cable Tension Switch (Illustration 4.0-10) CTS is located at the top of the main mast and monitors the hose take-up cable. Provided the hoses are free in the mast, a switch actuator will maintain contact with the CTS plunger, however, if the hoses become hung up, the cable will become slack and the compression spring will force the actuator away from the switch. In this condition, all main mast lift and lower functions are inhibited. NOTE When this switch is adjusted or replaced, first adjust hose tension so there is 1/4" to 3/8" (6 - 9mm) clearance between the hose take-up assembly stop and the poly stop. (See Illustration 4.0-9) Adjust bracket so switch actuates when switch plunger is pushed down flush with bracket.

Printed in U.S.A.

Crown 1988 PF-8148-4 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 103

MAINTENANCE DMS-1 Palm Operated Interlock Switch (Illustration 4.0-11)

DMS-2 & DMS-3 Foot Pedestal Interlock Switches (Illustration 4.0-12)

This palm operated switch is located in the twist grip of the traction control. When the button in the twist grip is depressed, the switch actuator is moved away from the switch, closing the normally closed contact. The switch actuator must be depressed to perform any hydraulic function. This switch requires no adjustments.

These switches are located in the foot pedestal of the operator compartment. When the pedal is depressed, the switch actuator is moved away from the switch, closing the normally closed contact. When the operator is operating the truck while in the seated position, these pedals must be depressed to operate the traction system or any hydraulic function of the truck.

DMS-1

ORS-1 HNS ORS-4

To gain access to these switches, remove two (2) nuts and lockwashers below the pedestal assembly, pull assembly out to clear mounting studs then lift up to unhook assembly from mounting tabs. The assembly can now be placed on the floor and access to the switches gained through the back of the housing. Adjust switches so normally closed contacts are held open when actuator is against mounting weldment. When pedal is depressed switch contacts must reset.

EDS

2429S-01

ILLUSTRATION 4.0-11

2430S

Crown 1988 PF-8148-5 Rev. 1/94

ILLUSTRATION 4.0-12

Printed in U.S.A.

03 REV. 1/94

M4.0 - 19 - 104

MAINTENANCE DMS-4 & DMS-5 Floor Pedal Interlock Switches (Illustration 4.0-13)

EDS Emergency Power Disconnect Switch (Illustration 4.0-14)

These pedal operated switches are located in the floor pedal assemblies of the platform. When the operator is standing to operate the truck, these pedals must be depressed moving the switch actuators away from the switches and resetting the contacts. When the normally closed contacts are closed in this condition, traction, lift/lower and accessory functions are operable.

EDS is located in the right arm of the traction control twist grip mount. When the actuator for this switch is depressed, power is removed from the emergency power disconnect contactor coil which consequently removes all power from the truck. To access this switch, remove 3 screws from cover on right side of traction control twist grip assembly.

To access these switches, raise platform and set 2 jackstands (2000 Ib. capacity minimum each) under platform frame. Remove 2 screws from side cover and remove.

DMS-1

When the pedal is released, the switch actuator is resting against the mounting weldment. Loosen the switch mounting screws and adjust switches so normally closed contacts are held open. When pedal is depressed, switch contact must reset.

ORS-1 HNS ORS-4

EDS

2429S-01

2431S

ILLUSTRATION 4.0-14

ILLUSTRATION 4.0-13

Printed in U.S.A.

Crown 1988 PF-8148-6 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 105

MAINTENANCE EMS-1 & EMS-2 Accessory Override Switches (Illustration 4.0-15)

EMS-3 Accessory Override Switch (Illustration 4.0-16)

These switches are located under a cover behind the traction control twist grip assembly and next to the keyswitch. To access EMS-1 and EMS-2, lift cover to right of the seat. These switches are momentary contact, spring return to “OFF”.

EMS-3 is a toggle switch which is located on the power unit distribution board. If EMS-2 (on the platform) does not start the accessory pump motor, due to a broken mast cable for instance, EMS-3 can be used to perform that function. Then by using the accessory control levers, the function should operate.

EMS-1 and EMS-2 are used during an electrical malfunction situation to allow the operation of the traverse and fork extend/retract functions. When the keyswitch is “ON” and the appropriate interlock switches are closed for operator standing or seated, EMS-1 will start the accessory pump motor. The traverse control lever can now be moved to operate the corresponding function. Using EMS-2 energizes the fork extend/retract solenoids. EMS-1 must be used with EMS-2. The traverse control lever can now be used to extend or retract the forks. EMS-4

EMS-2 EMS-1

1548

ILLUSTRATION 4.0-15 1547

ILLUSTRATION 4.0-16

EMS-4 Drive / Tow Switch (Illustration 4.0-16) The drive/tow toggle switch is located on the power unit distribution board. The normally open contact of this switch is placed between the battery and the brake valve solenoids. The normally closed contact of this switch is placed between the battery and the traction SCR control card. If the truck becomes disabled and needs to be towed to the maintenance area, connect the battery and place this switch in the “TOW” position. This action energizes the brake valve solenoids to release the brakes and disables the traction SCR control card to prevent accidental traction start-up. Before placing the truck back in service, EMS-4 must be placed in the “DRIVE” position to allow normal truck operation.

Crown 1988 PF-8148-7 Rev. 9/93

Printed in U.S.A.

02 REV. 9/93

M4.0 - 19 - 106

MAINTENANCE FHSL, FHSR, FLS, FRS Fork Home and Differential Switches (Illustration 4.0-17) These switches are located in a box which is bolted to the back of the fork assembly. An actuator pin on the fork extension, contacts the switch actuator when the forks are retracted. The switch actuator is pushed back and actuates these switches. During normal operation, the forks may drift out of “home” position. When the “home” switch (FHSL or FHSR) is reset, the electronics box ignores the input as fork out of “home”, until the differential switch (FLS or FRS) resets. This input is interpreted as fork out of “home” position and the pivot function will be locked out electronically. Retract forks to clear electronics for normal operation. This allows approximately 1/2" (12mm) of fork cylinder drift. To access these switches, remove the two (2) mounting bolts which hold the switch mounting weldment to the fork. Lay assembly on its back and remove four (4) screws holding the switch assembly to the mounting weldment. An alternate method of accessing switches is to extend forks, which allows access to switch assembly mounting screws.

2432S

ILLUSTRATION 4.0-17

FNS Fan Switch (Illustration 4.0-18) FNS is located in the operator switch and indicator panel of the platform. This is a three (3) position switch providing a high and low fan speed. There are no adjustments to this switch.

To adjust switches, loosen switch mounting screws slightly so switches can be moved and are still held. With the switch actuator in the fork extended position move the upper (differential) switch until the switch plunger only touches the actuator. Tighten the top screw to hold this switch in position. Push the switch actuator away from the access hole and place a 1/2" diameter pin on top of gage blocks in front of access hole. Adjust the lower (home) switch so switch plunger is fully depressed. Tighten remaining two (2) mounting screws. Remove 1/2" diameter pin. Verify switch adjustment by pushing switch actuator back. When actuator moves approximately 1/16", measured at centerline of access hole, the differential switch should actuate. When actuator is released, the switch must reset. Push switch actuator back 1/2", measured at centerline of access hole. The home switch should actuate.

2426S

ILLUSTRATION 4.0-18

Printed in U.S.A.

Crown 1988 PF-8148-8 Rev. 9/93

01 REV. 9/93

M4.0 - 19 - 107

MAINTENANCE GTSL & GTSR Gate Switches (Illustration 4.0-19)

GUS Guidance Switch (Illustration 4.0-20)

Before truck operation can be achieved the truck gates must be closed. The gate switches supply the signal to the electronics box whether the gates are open or closed. To access these switches, remove two (2) mounting screws from plastic cover at the lower arm pivot point.

This switch is used to select “manual” or “automatic” steering on trucks equipped with wire guidance and is located in the operator switch and indicator panel. When switched to “automatic”, steering control will remain manual until the sensors receive sufficient signal from the wire. When sufficient signal is present the steering function is taken over automatically by the wire guidance system. After automatic steering is acquired the electronics box ignores input from the steering tiller encoder.

To adjust, close gate and loosen switch mounting screws and move switch so the normally open contact closes and roller on switch is centered on the actuator. Tighten mounting screws. Open gate. The normally open contact must open.

2433S

ILLUSTRATION 4.0-19 2426S

ILLUSTRATION 4.0-20

Printed in U.S.A.

Crown 1988 PF-8148-9 Rev. 9/93

01 REV. 9/93

M4.0 - 19 - 108

MAINTENANCE HCS Height Cable Broken Switch (Illustration 4.0-21)

HNS Horn Switch (Illustration 4.0-22)

HCS is mounted on the main frame base, below the platform. The cable for the height sensor is anchored in the assembly with the switch. If the cable were to become slack or break, a spring in this assembly will push the switch actuator away from the switch, opening the normally open contact. In this condition maximum travel speed is limited. Place two (2) jackstands (2000 Ib. capacity minimum each) under platform. Adjust switch so normally open contact closes when actuator arm is against set screw inside spring, and resets when actuator arm is against roll pin.

The horn switch is located in the left arm of the traction control twist grip mount. When the actuator for this switch is depressed, the actuator moves away from the switch closing the normally closed contact. When closed, power is supplied to the horn and the horn will sound. To access this switch, remove two (2) mounting screws from cover on left side of arm. This switch requires no adjustment.

DMS-1

ORS-1 HNS ORS-4

EDS

2429S-01 2434S

ILLUSTRATION 4.0-22

ILLUSTRATION 4.0-21

Printed in U.S.A.

Crown 1988 PF-8148-10 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 109

MAINTENANCE KYS Keyswitch (Illustration 4.0-23) KYS is located to the right of the traction control assembly, along the operator compartment wall. When in the “off” position, power to the control and power circuits is removed. The “start” position applies power to the control circuit and the power supplies for the electronics boxes. With the electronics boxes powered-up, an output signal is applied to the emergency disconnect contactor coil which energizes the contactor and supplies battery voltage to the power circuit. When the keyswitch is placed in the “on” position, power is maintained on circuits powered-up in the start position and an electronic system self-test is initiated by the electronics boxes. To access the keyswitch, the cover panel below the traction control assembly must first be removed. Through an access hole below the keyswitch the nuts, lockwashers and flatwashers can be removed which hold the keyswitch mounting plate in place.

LMS-1 & LMS-2 (TF Mast Only) Height Reset Switch Staging Switch (TF Mast Only) (Illustration 4.0-25) LMS-1 and LMS-2 are located in the main mast chain anchor area of the platform. Actuators welded to the second stage mast actuate these switches to signal the electronics box that the mast is staging (LMS-2) and to reset the height counter (LMS-1). LMS-1 is used by the electronics to clear any accumulated error which may be present for calculating actual platform height. LMS-2 is a cross over point used by the truck electronics. When above the point that the mast begins staging, only lift cutouts can be programmed into the system. Below the staging point, only lower cutouts can be programmed into the system. To adjust these switches, remove lower center cover below seat. Loosen mounting bolts and adjust switches for a .19 to .25 inch (5 to 6 mm) gap between switch roller and second stage mast I-beam.

EMS-2 EMS-1

1548

ILLUSTRATION 4.0-23

LGS Work and Dome Light Switches (Illustration 4.0-24) These switches are located in the operator switch and indicator panel. When placed to the right “on” position, power is supplied to illuminate the lights. These switches require no adjustment. 2435S

SECOND STAGE MAST MOUNTING BOLTS LMS-2

ROLLER 8405

2426S

ILLUSTRATION 4.0-25

ILLUSTRATION 4.0-24 Printed in U.S.A.

Crown 1988 PF8148-11 Rev. 7/00

05 REV. 7/00

M4.0–19.0–110

MAINTENANCE LMS-3 & LMS-4 Seat Adjustment Limit Switches (Illustration 4.0-26)

ORS-1 R/L Override Switch (Illustration 4.0-27)

These switches are located in the seat height adjustment mechanism assembly. To access LMS-3 and LMS-4, remove cover under seat. The switches are to the left of the height adjustment mechanism. Actuator blocks on the mechanism contact the switch actuators which opens the normally closed contact and opens the seat motor circuit. A diode in each side of the motor circuit allows the mechanism to be driven in the opposite direction after reaching the limit.

The Raise/Lower override switch is in the left arm of the traction control twist grip mount. When the truck has a raise or lower cutout programmed into the system which is less than the maximum, this switch must be depressed while performing the raise or lower function to go to the maximum limit. To access ORS-1, remove two (2) mounting screws from cover on left side of arm. This switch requires no adjustment.

Adjust these switches so the normally closed contact opens when contacting the actuator blocks and reset when losing contact. DMS-1

ORS-1 HNS ORS-4

EDS

2429S-01

2436S

ILLUSTRATION 4.0-27

ILLUSTRATION 4.0-26

Printed in U.S.A.

Crown 1988 PF-8148-12 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 111

MAINTENANCE ORS-4 EAC Override Switch (Illustration 4.0-28)

PLS & PRS Pivot Function Limit Switches (Illustration 4.0-29)

The End Aisle Control override switch is in the left arm of the traction control twist grip mount. This switch is used to override the end of aisle reduced speed mode when entering a new aisle and must be maintained depressed for override. This switch is also used on trucks programmed for the End Aisle Stop option. Cycling this switch after the stop is complete allows end of aisle reduced speed mode.

PLS & PRS are located under a cover on top of the load handler. These switches verify the mechanical limit of the pivot function. Actuators on the hose guide, which is mounted to the top of the pivot sprocket assembly, contacts the switches when at the mechanical limit left and right. Adjust the corresponding switch to actuate when the fork carriage assembly contacts the poly stops.

To access ORS-4, remove two (2) mounting screws from cover on left side of arm. This switch requires no adjustment.

DMS-1

ORS-1 HNS ORS-4

EDS 2437S

2429S-01

ILLUSTRATION 4.0-29

ILLUSTRATION 4.0-28

Printed in U.S.A.

Crown 1988 PF-8148-13 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 112

MAINTENANCE PTS Pivot Command Switch (Illustration 4.0-30)

RGSL & RGSR Rail Guide Switches (Illustration 4.0-31)

PTS is located with the pivot control valve linkage below the cover with the pencil tray. When the pivot control lever is moved slightly in either direction, switch PTS normally open contact will close, starting the accessory pump and motor.

These switches are mounted toward the steered end of the truck, behind the guide rail rollers. When the rollers come in contact with the guide rail, the roller mounting assembly is pushed away from the switch closing the normally closed switch contact. The electronics box “reads” this change and outputs signals which drive the steered wheels to center for ten (10) seconds. After this period of time all steering commands are removed and the truck is guided by the guide rails.

To adjust, first make certain switch roller is centered in notch of cam. If not, loosen locknuts on linkage between valve and ball joints and turn adjusting rod to center switch roller in notch. When centered, secure adjustment with locknuts. Loosen switch mounting screws and pivot switch toward cam until switch actuates. Now back switch up until switch contacts reset, signified by a “click” sound, and tighten mounting screws. When adjusted properly, the switch will actuate before the valve spool moves .030" (0.7mm). This will start the accessory pump and motor before the valve opens.

Adjust switches so .12" - .25" (3 - 6mm) inward movement of the guide wheel closes the normally closed contacts.

2401S

2438S

ILLUSTRATION 4.0-31

ILLUSTRATION 4.0-30

Printed in U.S.A.

Crown 1988 PF-8148-14 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 113

MAINTENANCE SES Seat Switch (Illustration 4.0-32 )

SWH1 Seat Height Adjustment Switch (Illustration 4.0-33)

SES is mounted to a platform frame member above the seat height limit switches. When an operator is in the seat, the entire seat mechanism lowers slightly moving the actuator away from the switch resetting the contacts. This change is “read” by the electronics box which then determines the interlock switches required for this condition. When the operator is standing to operate the truck this switch is actuated. Again this condition is “read” by the electronics box which then determines the interlock switches required before truck operation will be permitted.

This switch is located in the operator switch and indicator panel. When the switch is toggled right, the seat will raise and when toggled left, the seat will lower. This switch requires no adjustment.

To access, remove wall cover below the seat. Adjust switch so contacts reset when operator is on seat and actuate when seat is empty.

2426S

2439S

ILLUSTRATION 4.0-33

ILLUSTRATION 4.0-32

Printed in U.S.A.

Crown 1988 PF-8148-15 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 114

MAINTENANCE TES Bulb Test Switch (Illustration 4.0-34)

TDSL & TDSR Traverse Cushion Switches (Illustration 4.0-35)

TES is located on the power unit distribution board. When held in the “on” position, power is applied to the PROCESSOR, CHAIN and CABLE indicator lights above this switch. This only tests the lamps of these indicators.

The traverse cushion switches are mounted on top of the overhead guard at both sides and actuate when a block on the load handler contacts the switch roller. To adjust, position load handler so traverse stop is approximately 2" (51 mm) from poly stop. Adjust switch actuator arm so switch normally closed contact is open at this point.

EMS-4

1547

ILLUSTRATION 4.0-34

2442S

ILLUSTRATION 4.0-35

Printed in U.S.A.

Crown 1988 PF-8148-16 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 115

MAINTENANCE TLS & TRS Traverse Function Limit Switches (Illustration 4.0-36)

TVSL & TVSR Traverse Command Switches (Illustration 4.0-37)

The traverse limit switches are located below the upper traverse drive. TLS and TRS verify the mechanical limit of the traverse mechanism for the electronic system. When the traverse mechanism nears the poly stop at its mechanical limit, the switch actuator is moved away from the switch by the poly stop. This action closes the normally closed switch contact. Depending on the direction of the fork tips, this input change is interpreted by the electronics box as “home” or “fork extend”.

These switches are located with the traverse control valve linkage, below the cover with the pencil tray. When the traverse control lever is moved slightly in either direction, TVSL or TVSR is actuated closing the normally open contact. With this input, the electronics box outputs signals to start the accessory pump motor.

To adjust these switches, center the load handler on the traverse rack. Loosen the adjusting bracket mounting screws and adjust assembly so end of switch actuator is .25" - .37" (6 - 9mm) past the edge of the traverse stop.

To adjust, first make certain switch rollers are an equal distance from their corresponding cam lobe. If not, loosen locknuts on adjusting rod between valve and ball joint and turn adjusting rod to adjust switch rollers on cams. Tighten locknuts to secure this adjustment. Loosen switch mounting screws and pivot switch towards cam until switch actuates. Now back switch up until switch contacts reset, signified by a “click” sound, and tighten mounting screws. When adjusted properly, the switch will actuate before the valve spool moves .030" (0.7mm). This will start the accessory pump and motor before the valve opens.

2441S 2440S

ILLUSTRATION 4.0-37

ILLUSTRATION 4.0-36

Printed in U.S.A.

Crown 1988 PF-8148-17 Rev. 1/94

03 REV. 1/94

M4.0 - 19 - 116

MAINTENANCE ENCODERS Encoders are similar to potentiometers in appearance and function. Both are used to convert mechanical movement into electrical information. With potentiometers this information must be converted from analog to digital coded information which can be used directly by the microprocessor. Another advantage of using encoders in place of potentiometer is that there are no contacting parts to wear and become electrically noisy.

2750S

ILLUSTRATION 4.0-2

ECR-2 Raise/Lower Command Encoder (Illustration 4.0-2)

2739S

ILLUSTRATION 4.0-1

To achieve no contacting parts, a light source is optically arranged to shine onto a disk as shown in Illustration 4.0-1. As the input shaft is rotated, openings in the disk permit light passage to photosensors. When light strikes the photosensor, current flows and when the disk blocks the light, current flow ceases. This provides the output which can be used directly by the microprocessor. The encoder being used has three (3) outputs; 1) Index, 2) Channel A and 3) Channel B. The index is used as neutral for traction and raise/lower controls and for center indication on steering feedback. Channels A and B are out of phase which when compared provide a direction and speed signal. When adjusting the encoders the truck must be powered-up and self-test complete. ECR-1 Steering Command Encoder (Illustration 4.0-2)

The raise/lower command encoder is located at the pivot point of the raise/lower control lever. To access ECR-2 remove the cover with the pencil tray, next to the control lever assemblies. Before adjusting the encoder, make certain control handle assembly is adjusted properly as described in the M4.5 section of this manual. When adjusted, the index (neutral) of the encoder must be set. Connect a digital meter to TB526-6 (positive) and TB526-9 (negative). Loosen the adjustment retainer locking screw and move retainer to obtain a reading of approximately 5 volts dc. Move retainer back and forth to determine the width of the encoder index, meter will maintain 5 volt reading while in the index, and secure when positioned in center of index. To verify the adjustment, move control lever to maximum raise position and release. Meter reading should drop to near 0 volts when out of the index position and return to 5 volts (index) when in neutral position. Repeat test moving control lever to maximum lower position and releasing. Meter reading should drop to near 0 volts when out of index position and returns to approximately 5 volts when in neutral position.

ECR-1 is located on the end of the steering tiller assembly. To access the encoder, remove cover from back of steering tiller post. Remove screw holding bracket and friction block/ spring assembly. Pull friction block/spring assembly from post. Disconnect encoder leads from terminal board and lift steering tiller assembly from post. This device requires no adjustment. Crown 1988 PF-8157-1 Rev. 1/94

M4.0 - 19 - 200

Printed in U.S.A.

01 REV. 1/94

M4.0 - 19 - 200

MAINTENANCE ECR-3 Traction Command Encoder (Illustration 4.0-3)

ECR-4 Height Sensing Encoder (Illustration 4.0-4)

ECR-3 is located under the cover on the right side of the traction control twist grip assembly. Before adjusting the encoder, make certain twist grip is adjusted properly as described in the M4.5 section of this manual.

The height sensing encoder is located with the cable reel assembly behind the seat height adjustment mechanism. Remove the cup shaped cover on the assembly to expose the encoder. No adjustments are required for this encoder.

When twist grip is adjusted, the index (neutral) of the encoder must be set. Connect a digital meter to TB509-5 (negative) and TB509-2 (positive). TB509 is located under hinged console cover behind traction control assembly. Loosen the adjustment retainer locking screw and move to obtain a reading of approximately 5 volts dc. Move retainer back and forth to determine the width of the encoder index, meter will maintain 5 volt reading while in the index, and secure when positioned in the center of the index. Verify adjustment by turning twist grip to stop and releasing in both directions. Meter reading should drop near o volts when leaving index position and returns to approximately 5 volts when grip is in neutral. 2745S

2751S

ILLUSTRATION 4.0-4

ILLUSTRATION 4.0-3

Crown 1988 PF-8157-2

M4.0 - 19 - 201

Printed in U.S.A.

M4.0 - 19 - 201

MAINTENANCE ECR-5 Steering Feedback Encoder (Illustration 4.0-6) The steering feedback assembly is mounted on the power unit frame cross member, between the steered wheels. Correct operation of the feedback assembly is important for acceptable steering performance. Encoder body movement, improper belt tension and loose pulley set screws will cause unsatisfactory performance. In each instance the steered wheels can be moved slightly without turning the encoder input shaft.

When the encoder is assembled correctly, the flat on the encoder shaft will be at the eleven (11) O’clock position on the opposite side of the assembly that the lever arm protrudes when wheels are in the straight ahead position (Illustration 4.0-6). To adjust, loosen the encoder mounting bracket locking screw and move mounting bracket to release tension on the timing belt. Turn encoder shaft and pulley as necessary to align flat on encoder shaft and release mounting bracket to allow spring to tighten belt. Secure mounting bracket with locking screw.

TB613

PIVOT PLATE LOCKING SCREW

NOTE

LINKAGE ARM LEVER ARM

Whenever any component of the steering feedback arrangement is replaced or adjusted, calibrate the wire guidance system to maintain satisfactory wire guidance performance.

90° 90°

To access the encoder, loosen cover mounting screws and lift cover from the assembly. Before adjusting the steering feedback encoder make certain linkage to the feedback assembly is adjusted properly as described in the M6.0 section of this manual. Turn steered wheels to the straight forward position so notch in top flange of drive unit is aligned with hole in power unit weldment as shown in Illustration 4.0-5. Insert 1/2 " (12.7mm) diameter wooden dowel through hole and into notch.

ECR-5 MOUNTING BRACKET LOCKING SCREWS 2747

FLAT ON ENCODER SHAFT

ILLUSTRATION 4.0-6

BELT TENSION Belt tension is automatically set when the mounting bracket locking screws are loosened (Illustration 4.0-6). The spring at one end of the mounting bracket, pushes the mounting bracket to provide the proper belt tension. When belt tension is set, tighten the locking screws. ENCODER BODY MOVEMENT A spring between the encoder retainer and locating pin takes up any tolerance between the retainer locating slot and the locating pin as shown in Illustration 4.0-7.

2747

ILLUSTRATION 4.0-5

2748S

Crown 1988 PF-8157-3 Rev. 1/94

M4.0 - 19 - 202

ILLUSTRATION 4.0-7 Printed in U.S.A.

01 REV. 1/94

M4.0 - 19 - 202

MAINTENANCE SET SCREWS

INDEX

One set screw in each pulley is seated against the flat on the associated shaft. The other set screw is 90° from the first (Illustration 4.0-8). Make certain these set screws are tight on both pulleys.

Set the encoder index when the steered wheels are in the straight ahead position and all other adjustments have been made. Remove cover from power unit electronics box. When index is present the green indicator (SC) on the Digital Card (position #8) will be “on”. NOTE An alternative to observing the indicator is to connect a digital meter to terminals TB613-5 (negative) and TB613-2 (positive). When indicator is “on” meter reading will be approximately 5 volts.

2749S

ILLUSTRATION 4.0-8

Crown 1988 PF-8157-4

M4.0 - 19 - 203

Loosen the pivot plate locking screw (Illustration 4.0-6) on the feedback assembly and move back and forth until green indicator (SC) on the digital card is “on”. Tighten locking screw to secure adjustment while making certain green indicator remains “on”.

Printed in U.S.A.

M4.0 - 19 - 203

ELECTRICAL WIRING WIRING COLOR CODES The following information is an explanation of terms and symbols which are being standardized on Crown wiring diagrams. The leads used are limited to the following colors. The color of the wire is based on the function of the circuit in which it is used. Each wire is assigned a three or four digit number. The first one or two numbers identify the color of the lead. The last two numerals number the lead from one thru ninety-nine. (See chart below) Exceptions to this can be leads supplied by vendors with components. The color of each function shall be shown on the schematic. Each wire shall be identified by a number on the wiring pictorial.

ABBR.

COLOR

NUMBER

FUNCTION

BLK BRN RED ORG YEL GRE BLU VIO GRAY WHT R/W

Black Brown Red Orange Yellow Green Blue Violet Gray White Red Stripe/White

0 ** 1 ** 2 ** 3 ** 4 ** 5 ** 6 ** 7 ** 8 ** 9 ** 29 **

G/W

Green Stripe/White

59 **

†Reverse †Potentiometer or 2nd Speed †Positive †Hydraulic Solenoid Valves †Forward †Negative †Bypass or 3rd Speed †Hydraulic Pump Motor †Horn †Miscellaneous †Positive that has gone thru a switch †Negative that has gone thru a switch

‡Traction Inputs/Outputs ‡Analog Inputs ‡Battery Positive ‡Non-Battery Positive ‡Status Inputs/Outputs ‡Battery Negative ‡Isolated Negative ‡Load Position Inputs/Outputs ‡Indicators and Warning Devices ‡Miscellaneous ‡Positive that has gone thru a switch ‡Negative that has gone thru a switch or resistor

** - 01 thru 99 †Trucks Prior to 1988 ‡Trucks 1988 to Present

4233 Crown 1978 PF3452-1 Rev. 11/02

Printed in U.S.A.

06 REV. 11/02

M4.1–12.0–001

ELECTRICAL WIRING WIRING HARNESS Shown here is a section of a pictorial wiring diagram showing a wiring harness. The wires shown coming from the wiring harness are all labeled on the diagram in such a way as to be able to tell where the other end of a particular wire is connected. Following is an example taken from this wiring diagram. There are two wires coming from the harness which lead to HNS (Horn Switch) terminal 1 and terminal 2, labeled 2904-TB1-1 and 801-TB1-8 respectively. 2904-TB1-1 is a red stripe wire marked 2904 (see “Wiring Color Codes”), which goes through the wiring harness to Terminal Board 1 (TB1), terminal 1.

801-TB1-8 is a gray wire marked 801 which goes through the wiring harness to connect to Terminal Board 1, terminal 8. The wires are labeled similarly at Terminal Board 1. The wire shown coming from terminal 1 of TB1 which leads to the Horn Switch is labeled on the diagram 2904-HNS-1 (Red stripe wire marked 2904 which leads to horn switch, terminal 1). The wire leading to the horn switch, terminal 2 is labeled 801-HNS-2 on the diagram.

6011SI

POWER CABLES Power cables are designated using one of the following abbreviations, followed by a dash number. Abbreviation PC # 1 PC # 2 PC # 4 PC # 6 PC#10 PC # 1/0 PC # 2/0 PC # 3/0

Part No. 084571 084570 084569 084568 090963 084572 084573 086749

An example of such a cable is PC # 1/0 - 10. The part number for this cable is 084572-010.

Crown 1978 PF3452-2 Rev. 11/02

Printed in U.S.A.

06 REV. 11/02

M4.1–12.0–002

ELECTRICAL WIRING SYMBOL NOMENCLATURE Abbreviation F# R# A B C P* S K* 1A ACS AS AXA AXB AXC AXF AXR AXS* BRS* BS CA* CAP* CHS* CLS CS DB* DIS DMS* DRS ECR* EDS EMS* FS FU* GUS HF* HN HNS HSC HSS JC* KYS

Component

Abbreviation

Forward Contactor Reverse Contactor Speed Contactor Speed Contactor Speed Contactor Pump Contactor Power Steering Contactor Relay Contactor SCR Bypass Contactor Accelerator Switch Switch for A Auxiliary Switch A Auxiliary Switch B Auxiliary Switch C Auxiliary Forward Switch Auxiliary Reverse Switch Auxiliary Switch Brake Switch Switch for B Connector Assembly Capacitor Chain Switch Clamp Switch Switch for C Diode Block Directional Switch Safety Switch Door Switch

LGS* LMS* LOS MFS* ORS PC* PLS POT* PRS PTS PUS RAS* RES* RIS RLS ROS RRS RS RTS SAS SB* SES* SLS SQS* SRS SSC SSS STS SV* TB* TD* TDS TES TLS TRS TT TBS TVS V XC*

Emergency Disconnect Switch Emergency Switch Forward Switch Fuse Guidance Switch Hash Filter Horn Horn Switch High Speed Card High Speed Switch Jack (Receptacle) Part of CA Key Switch

Component Light Switch Limit Switch Lower Switch Multi-Function Switch Override Switch Plug Part of CA Pivot Left Switch Potentiometer Pivot Right Switch Pivot Switch Pump Switch Raise Switch Resistor Reach In Switch Rotate Left Switch Reach Out Switch Rotate Right Switch Reverse Switch Rotate Switch Safety Switch Suppressor Block Seat Switch Side Shift Left Switch Sequence Switch Side shift Right Switch Safety Switch Card Side Shift Switch Power Steering Switch Solenoid Valve (Hydraulic) Terminal Board Time Delay Tilt Down Switch Test Switch Traverse Left Switch Traverse Right Switch Hour Meter (Travel Time) Tilt Back Switch Traverse Switch Discharge Meter (Volt Meter) Card Edge Connector

* If more than one, use suffix 1, 2, 3... # If more than one, use suffix A, B, C....Z NOTE The abbreviations listed above are examples of abbreviations found on wiring diagrams. It’s not a complete list of all abbreviations on wiring diagrams in this manual. For a complete list, refer to the glossary located in section M10. Crown 1978 PF3452-3 Rev. 11/02

Printed in U.S.A.

06 REV. 11/02

M4.1–12.0–003

ELECTRICAL WIRING 3804

Maintained Contact Switches Operator Actuated

Momentary Contact Switches Operator Actuated

Normally Open

Normally Closed

Held Open

Center Off

Normally Closed

Double Throw

Held Closed

2 Circuit

Multiple Pole Break Before Make

Center Off Multiple Pole Make Before Break Double Throw Start Acc Ign

Key Switch

Momentary Contact Switches Mechanically Actuated Normally Open

Off Momentary Contact Switches Mechanically Operator Actuated

Normally Open Held Closed

Normally Open

Normally Closed Held Open

Held Closed

Normally Closed

Held Open

Normally Closed Open On Rise

Close On Rise

Double Throw

2 Circuit

Crown 1978 PF3452-4 Rev. 11/02

Printed in U.S.A.

06 REV. 11/02

M4.1–12.0–004

ELECTRICAL WIRING 3805

Thermistor PM Motor

Rheostat

Mov or Transzorb Suppressor

Wound Motor Armature Motor Field

Current Shunt

Lamp

Zener Diode Diode

SCR

Connection Point Tach Sensor Power Termination Mast Cable

Encoder

Common Isolated LED

Battery Negative Fuse

Horn

Transformer

SIP Resistor Coil Battery Solenoid Valve or Relay With Suppression

Inductor

Normally Closed

Polarized Capacitor

Normally Open

Non-Polarized Capacitor

Plug PC

LVDT

Connector CA

Resistor

Jack JC Test Point

Potentiometer

Crown 1978 PF3452-5 Rev. 11/02

Printed in U.S.A.

06 REV. 11/02

M4.1–12.0–005

MAINTENANCE TUNE UP TS and TSP series trucks with C1 and P2 control cards (EV100) Panels are factory adjusted for a particular motor and truck and should not need adjustment. The card is supplied with single turn potentiometer adjustments and the box is marked with “dial” setting. Turning pots C.W. increases the particular function, for example, C.W. adjustment increases creep speed, acceleration rate, current limit, 1A time, stiffness of plug, etc. On new or mistuned cards, turn pots fully CCW to “ 1 “ then set each pot to the setting for the particular truck as listed.

ILLUSTRATION 4.2-1

2870S

NOTE Illustration for adjustment arrangement on card only. CAUTION

Care must be taken when replacing the EV100 control card. Installation of the wrong control card may not allow control to function or will cause improper operation. Refer to chart and parts breakdown for card style and part number required.

CONTROL TYPE

CARD TYPE

*CREEP

*C/A

C/L

1A TIME

*PLUG

SPEED1 SPEED2 SPEED3

TRACTION

2.5

N/A

PUMP

N/A

* Check adjustments to meet the specifications listed for your unit under each function listed as follows and adjust as necessary.

Crown 1989 PF-8626-1 Rev. 3/94

M4.2 - 18.1 - 200

Printed in U.S.A.

01 REV. 3/94

M4.2 - 18.1 - 200

MAINTENANCE Creep Speed TRACTION—Creep speed and controlled acceleration (C/A) interact with each other. The settings will typically be close to the same number. The lower the numerical setting, the slower the initial movement of the truck. The 1 to 3 range setting provides slow to moderate initial movement. Set as required. P2 Card Speed 1, 2, 3 Adjustments PUMP—Although these are not used on this model, the trimpots must be set to 1. Further adjustments are not required. TRACTION—This is a factory predetermined setting. Set as listed in chart. 1A Time TRACTION—This is not used on this model . Trimpot must be set to 1. Further adjustments are not required. PUMP—Move main lift control lever from neutral to maximum lift position. Adjust 1A Time trimpot to energize contactor P2 for a smooth transition from SCR range to bypass, approximately 2 seconds after requesting maximum speed main lift. Controlled Acceleration (C/A) TRACTION—Controlled acceleration (C/A) and creep speed interact with each other. The settings will typically be close to the same number. The lower the numerical setting, the slower the initial movement of the truck. The 1 to 3 range setting provides slow to moderate initial movement. Set as required. PU M P—This adjustment controls the rate of acceleration of the lift pump motor. On this model set trimpot to 9. Further adjustment is not required. PLUG TRACTION—With forks empty, lowered and in “home” position, travel at maximum speed. Move speed control rapidly to maximum speed opposite direction. Adjust so truck stops in 18 to 20 feet (5. 5 to 6.1m). After all adjustments have been set, seal cover with silicone rubber compound 065031.

4321 - 39016 Crown 1989 PF-8626-2 Rev. 3/94

Printed in U.S.A.

01 REV. 3/94

M4.2 - 18.1 - 201

MAINTENANCE STEERING SERVO MOTOR CONTROL (MRC-3) The Crown Steering Servo Motor Control is placed between the battery and the steering servo motor. This electronic device controls the direction and rate of speed the unit is steered.

Switching of battery volts to the servo motor and controlling the direction of this voltage through the motor is accomplished by the use of power transistors. Transistors are universal solid state devices which can be used to amplify, oscillate or, as they are used in the output circuit, solid state switches. Illustration 4.2-50 shows the schematic representation and basic elements of an NPN Transistor. To turn the transistor “on”, the base must be more positive than the emitter by + 1.5 volts DC (measured base to emitter).The transistor will conduct emitter to collector. To turn the transistor “off”, the base must be brought to a potential which is less positive than the emitter.

2799P

Operation of the system consists of switching battery voltage to the steering servo in a specific direction for periods of time. The servo does not respond to the individual pulses but rotates at a speed corresponding to the average voltage determined by the pulse width. The steering tiller sets up the pulse width and direction signals and therefore can control the motor direction and speed from zero up to maximum speed.

SCHEMATIC

The output transistors of the servo motor control are electrically arranged in an “H” bridge configuration as shown in Illustration 4.2-51. Transistors Q1 and Q2 switch battery voltage to the servo motor for speed control and transistors Q3 and Q4 determine the direction the switched voltage passes through the motor. Transistors Q1 and Q4 will conduct simultaneously when steering one direction, and transistors Q2 and Q3 when steering the opposite direction.

LINEAR CARD DIRECTION

COLLECTOR

48 VDC or 72 VDC

DIRECTION

BASE

TO SERVO MOTOR Q2

EMITTER PICTORIAL

SPEED

COLLECTOR

BATTERY NEGATIVE

SPEED

BASE 2801

ILLUSTRATION 4.2-51

EMITTER NPN TYPE TRANSISTOR 2800S

ILLUSTRATION 4.2-50

4260 Crown 1988 PF-7837-1 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M4.2 - 19 - 001

MAINTENANCE Circuit Operation

Testing

Illustration 4.2-52 is a block diagram of the Steering Servo Motor Control. Connections to the control include + 12VDC, 12V common, speed, direction, diagnostic monitor, + 48V or + 72V, battery negative and motor leads. The 12VDC and 12V common inputs are for the control card electronics. The direction latch circuitry takes the direction input, 12VDC or 0VDC, and switches transistor Q3 or Q4 “ON”. The direction latch also activates the circuitry which routes the speed input to transistor Q1 or Q2, to correspond with the direction transistor selected.

Test procedures described are resistance, continuity and power applied voltage checks. Refer to Illustration 4.2-53 for location of testing points.

The variable pulse width speed input is accepted by the speed buffer and is routed to transistor Q1 or Q2, as enabled by the direction input. Diagnostic is connected to the microprocessor for the electrical system diagnostic test.

Following is a series of voltage checks which will isolate a problem to a specific area. Then, in some instances, by making continuity and resistance checks, a problem component can be pinpointed. Disconnect and insulate one (1 ) lead from each servo motor when following checkout procedure.

DANGER

Some tests are performed with power applied. Since heatsinks of SCR Controls and surrounding wiring are 48 or 72 volt conductors, use extreme caution to avoid contact with these potentially hazardous conductors. Place wheel chocks in front and back of load wheels.

Normal operating current draw is 20-25 amps. When the steering mechanism is against the stops, current draw will increase to 90 amps. The current sensing circuitry, however, will disable the Current Latch and the direction transistors when current draw reaches 40 amps. The direction latch is enabled again when current draw reaches zero, but is disabled with each speed signal pulse unless overcurrent does not exist. If the overcurrent condition does exist at each pulse, the “ON” time realized by the servo motor will be at a minimum.

48 or 72 VDC TAB 3 RED

+12 VDC

DIRECTION

9v or 0v

NOTE 1

TAB 6 DIRECTION LATCH WHT

DIRECTION LOGIC

SPEED

2v-off to 6v

TAB 5 BLK

DIAGNOSTIC MONITOR

0v to 4v depending on tiller speed COMMON

PREDRIVER

DRIVER

TO SERVO Q2 MOTORS

SPEED BUFFER 20 OHM (48 V) 33 OHM (72 V)

TAB 7 ORG

TAB 4 GRN

CURRENT LATCH

CURRENT SENSE

NOTE 1: 48v or 72v when "on" and 0v when "off" NOTE 2: 0v to 2v depending on tiller speed. 2802

NOTE 2

CURRENT SENSE RESISTOR .01 OHM BATTERY NEGATIVE

ILLUSTRATION 4.2-52

Crown 1988 PF-7837-2 Rev. 1/94

Printed in U.S.A.

01 REV. 2/94

M4.2 - 19 - 002

MAINTENANCE CONTROL INPUT/OUTPUT TEST 1. Connect digital meter on dc voltage range, between the direction input, TAB 6 (positive lead), and battery negative (negative lead). 2. Power-up truck and monitor the meter display. 3. If meter was indicating 9 volts, the reading should drop to zero volts then back to 9 volts. If the meter was indicating zero volts, the reading should go to 9 volts then back to zero. This signal originates at the command card of the power unit microprocessor. 4. Connect meter between the speed input, TAB 5 (positive lead), and battery negative (negative lead).

7. When truck is powered-up and selftest complete, check the input voltage to the control between TAB 3, positive, and TAB 4, negative. Input voltage should be 11.5 to 12.5 volts. 8. Connect the positive meter lead to the emitter of Q3 and the negative meter lead to the emitter of Q4. Leave the operator compartment door open and turn the steering tiller. A positive or negative voltage between zero and 48 or 72 volts should be indicated. Voltage level depends on how fast the tiller is turned. 9. Turn steering tiller in opposite direction. A voltage of the opposite polarity as obtained in Step 8 will be realized. Again the voltage will be between zero and 48 or 72 volts, depending on how fast the tiller is turned. NOTE

5. Power-up truck and monitor the meter display.

If input and output voltages are as described, refer to Troubleshooting Procedures later in this section.

6. An exact meter indication on this test will not be possible due to the frequency of the input. If the meter appears to be attempting to measure a voltage, it can be assumed this input is okay. This signal originates at the command card of the power unit microprocessor.

20 OHM (48V) 33 OHM (72 V) RESISTORS

48 or 72 VOLT BATTERY CONNECTION NEGATIVE MOTOR CONNECTION

BATTERY NEGATIVE

POSITIVE MOTOR CONNECTION

CONTROL CARD CURRENT SENSE RESISTOR

BATTERY NEGATIVE CONNECTION DIAGNOSTIC MONITOR 2803S

DIRECTION INPUT

SPEED INPUT

COMMON

12 VDC INPUT

ILLUSTRATION 4.2-53

Crown 1988 PF-7837-3 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M4.2 - 19 - 003

MAINTENANCE CONTROL CARD TEST

TRANSISTOR TEST

If input voltages are as described in Control Input/Output Test but output voltages are not, check the control card outputs. Leave operator compartment gates open when performing this test.

If input voltages are as described in Control Input/Output Test and control card output voltages are as described in Control Card Test, check condition of transistors.

1. Turn steering tiller in either direction. 48 or 72 volts should be present at the base terminal of transistor Q3 or Q4. 2. Turning steering tiller in same direction as Step 1 should place 2 to 4 volts on base terminal of transistor Q1 or Q2. NOTE If transistor Q3 had 48 or 72 volts on the base terminal in Step 1, transistor Q2 should have 2 to 4 volts on its base terminal in Step 2.

In-circuit transistor resistance tests in the past have proven unreliable. The test described will be reliable only for the transistors in this control and should not be considered a standard testing procedure for all transistors. 1. Disconnect battery and chock wheels. 2. Isolate transistors from other components in the control by disconnecting buss bars and other leads from the transistors. 3. Test the base to collector and emitter to collector junctions as shown in Illustration 4.2-54 if using an analog meter with 20,000 ohms/volt input impedance (i.e. Simpson 260). Refer to Illustration 4.2-55 when using a test light.

If transistor Q4 had 48 or 72 volts on the base terminal in Step 1, transistor Q1 should have 2 to 4 volts on its base terminal in Step 2.

NOTE

3. Turn steering tiller in opposite direction. 48 or 72 volts should be present at the base terminal of opposite transistor as in Step 1. 4. Turning steering tiller in same direction as in Step 3 should place 2 to 4 volts on base terminal of opposite transistor as in Step 2. 5. If voltage levels at the base of transistors Q1 and Q2 are not as described, disconnect battery and check resistance of two (2) resistors 33 ohm on 72 volt trucks, 20 ohm on 48 volt trucks. If resistors are within tolerance, the card is defective. CURRENT SENSE RESISTOR TEST

When using a digital meter, refer to the meter operator manual for any special transistor or diode testing procedures. If a testing procedure is not covered in the meters operator manual, reliable testing results will not be obtained. When going through these tests, if during any step the transistor fails, it is not necessary to continue testing on that transistor. The transistor is defective and must be replaced. 4. Check resistance between transistor collector terminals and the heatsink. Resistance measured should be greater than 30,000 ohms. If resistance is less than 30,000 ohms, check for holes in insulating material between transistor and heatsink.

Check the resistance of the .01 ohm resistor. To check requires a sensitive meter, however, a quick check for continuity will determine if the control will function.

Crown 1988 PF-7837-4 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M4.2 - 19 - 004

MAINTENANCE TEST TRANSISTORS EMITTER TO COLLECTOR 20

RX1 - +

- +

2785

R X 10,000

2786

R x 1 scale. Negative lead to collector and positive lead to emitter. A reading of less than 20 ohms is desirable.

R x 10K scale. Negative lead to emitter and positive lead to collector. A reading in excess of 50,000 ohms is desirable.

TEST TRANSISTORS BASE TO COLLECTOR 5

RX1

- +

R X 10,000

2787

2788

R x 1 scale. Negative lead to collector and positive lead to base. A reading of less than 20 ohms is desirable.

R x 10K scale. Negative lead to base and positive lead to collector. A reading in excess of 50,000 ohms is desirable.

TEST TRANSISTORS BASE TO EMITTER 20

RX1

- +

2789

2790

R x 1 scale. Negative lead to emitter and positive lead to base. A reading of more than zero ohms but less than 25 ohms is desirable.

R x 1 scale. Negative lead to base and positive lead to emitter. A reading of more than zero ohms but less than 25 ohms is desirable.

This testing procedure will only work with transistors in the steering servo amplifier. ILLUSTRATION 4.2-54

Crown 1988 PF-7837-5 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M4.2 - 19 - 005

MAINTENANCE TEST TRANSISTORS EMITTER TO COLLECTOR

2791

2792

Negative lead to collector and positive lead to emitter. Test light should illuminate.

Negative lead to emitter and positive lead to collector. Test light should remain off.

TEST TRANSISTORS BASE TO COLLECTOR

2793

2794

Negative lead to collector and positive lead to base. Test light should illuminate.

Negative lead to base and positive lead to collector. Test light should remain off.

TEST TRANSISTORS BASE TO EMITTER

2795

2796

Negative lead to emitter and positive lead to base. Test light should Illuminate.

Negative lead to base and positive lead to emitter. Test light should remain off.

This testing procedure will only work with transistors in the steering servo amplifier. ILLUSTRATION 4.2-55

Crown 1988 PF-7837-6 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M4.2 - 19 - 006

MAINTENANCE TRANSISTOR REPLACEMENT

Component Replacement (Illustration 4.2-56) When components are replaced on the servo motor control, ensure all connections are tight and heat sink compound (Crown No. 93983) applied, as directed, to prolong component life. Disconnect battery whenever performing maintenance on this control.

1. Disconnect wires from transistor in question. 2. Remove buss bars. 3. Remove two (2) mounting screws holding transistor in place.

CONTROL CARD REPLACEMENT 1. Disconnect wires between control card and control. 2 Remove five (5) screws securing control card to housing. Lift control card from housing. 3. Position replacement control card in housing and secure in place with mounting screws. 4. Connect wires between control card and control as shown in Illustration 4.2-56.

4. Lift transistor from control and test transistor to verify its condition. Wipe insulator clean and inspect for holes or tears. If insulator is damaged, replace as described in Insulator Replacement. 5. Lightly smear heatsink compound on mating surfaces of replacement transistor and insulator. 6. Position transistor on insulator and secure in place with mounting screws. 7. Install buss bars and tighten securely.

5. Make certain all connections are tight. 8. Connect wires as shown in Illustration 4.2-56.

2797S

ILLUSTRATION 4.2-56

Crown 1988 PF-7837-7 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M4.2 - 19 - 007

MAINTENANCE Troubleshooting

INSULATOR REPLACEMENT 1. Disconnect wires from transistors, leaving bull bars in place. 2. Remove eigfht (8) transistor mounting screws (2 from each transistor) and lift transistors from control as a unit. 3. Lift insulator from control.

Use this section when the “wrench light” illuminates and service #49 or #73 is logged into service history but the steering servo and steering feedback servo check out okay. The steering system has an electrical safety interlock which disables traction and steering if the steered wheel movement and steering tiller command are not within a programmed window. A problem with the steering mechanism can cause this situation.

4. Clean mating surfaces of heatsindk and transistors. 5. Lightly smear mating surfaces of replacement insulator, heatsink and transistors with heatsink compound. 6. Position insulator on heatsink, aligning holes in insulator with threaded holes of heatsink. 7. Position transistors on insulator and secure in place with mounting screws. 8. Connect wires to transistors as shown in illustration 4.256.

If steered wheels jerk back and forth when steering from stop to stop, check lubrication of pivot points and condition of all linkage components between the steering linkage and steering feedback potentiometer. Disconnect battery, remove four (4) mounting bolts from one (1 ) steering gearbox. Lift end of gearbox opposite the servo motor and place blocks under housing so drive gear is free to rotate. Connect battery and power-up truck. Observe steered wheels while truck is running through selftest. Wheels should move from side to side. If movement does not occur, check all components from the steering ring gear mounting bolts on the drive unit to the brushes of the servo motor.

RESISTOR REPLACEMENT (33 ohm 72 V, 20 ohm 48 V) If wheels moved during selftest, turn wheels from stop to stop, slowly, with the steering tiller. Observe wheel movement and watch for any apparent binding in the steering gearbox or steering linkage.

1. Remove transistors. 2. Unsolder wires from defective resistor. 3. Remove mounting screws and lift resistor from housing. Clean mating surface of housing. 4. Lightly smear heatsink compound on mating surfaces of housing and replacement resistor. 5. Secure resistor to housing with mounting screws. Solder wires removed from defective resistor to replacement resistor. 6. Install transistors.

Disconnect battery. Secure steering gearbox, which was removed, in place with four (4) mounting bolts. Remove four (4) mounting bolts of opposite steering gearbox. Lift end of gearbox opposite the servo motor and place blocks under housing so drive gear is free to rotate. Connect battery and power-up truck. Observe steered wheels while truck is running through selftest. Wheels should move from side to side. If movement does not occur, check all components from steering ring gear mounting bolts on the drive unit to the brushes of the servo motor. If wheels moved during selftest, turn wheels from stop to stop, slowly, with steering tiller. Observe wheel movement and watch for any apparent binding in the steering gearbox or steering linkage.

RESISTOR REPLACEMENT (.01 ohm) 1. Unsolder wires from defective resistor. 2. Remove mounting screws and lift resistor from housing. Clean mating surface of heatsink. 3. Lightly smear heatsink compound on mating surfaces of housing and replacement resistor. 4. Secure resistor in place and solder wires to resistor.

If binding was apparent when both tests were run, check floor and tire condition, steering mechanism pivot point lubrication and condition. If binding was apparent only when one (1) gearbox was driving the steered wheels, disconnect battery and remove four (4) mounting bolts from the suspect gearbox. Move gearbox so drive gear is over edge of truck. Wrap a protective cover around the gear to protect gear from damage. Using a suitable tool, turn gear and feel for any binding or tight spots. Repair as necessary.

Crown 1988 PF-7837-8 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M4.2 - 19 - 008

Switching of battery volts to the servo motor and controlling the direction of this voltage through the motor is accomplished by the use of power transistors. Transistors are universal solid state devices which can be used to amplify, oscillate or, as they are used in the output circuit, solid state switches. Illustration 4.2-1 shows the schematic representation and basic elements of an NPN Transistor. To turn the transistor “on”, the base must be more positive than the emitter by + 1.5 volts DC (measured base to emitter).The transistor will conduct emitter to collector. To turn the transistor “off”, the base must be brought to a potential which is less positive than the emitter.

0444P-01

The output transistors of the servo motor control are electrically arranged in an “H” bridge configuration as shown in Illustration 4.2-2. Transistors Q1 and Q2 switch battery voltage to the servo motor for speed control and transistors Q3 and Q4 determine the direction the switched voltage passes through the motor. Transistors Q1 and Q4 will conduct simultaneously when steering one direction, and transistors Q2 and Q3 when steering the opposite direction. LINEAR CARD DIRECTION

C1 (COLLECTOR)

SCHEMATIC

48 VDC or 72 VDC

DIRECTION

B1 (BASE) E1 (EMITTER) C2 (COLLECTOR) B2 (BASE)

SPEED

E2 (EMITTER) C1 B1 E1,C2 B2 E2

PICTORIAL

TO SERVO MOTOR Q2 BATTERY NEGATIVE

SPEED 0429

ILLUSTRATION 4.2-2

NPN TYPE TRANSISTOR

0428

ILLUSTRATION 4.2-1 4260

Crown 1989 PF-8455-1 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M4.2 - 19 - 010

MAINTENANCE Circuit Operation Illustration 4.2-3 is a block diagram of the Steering Servo Motor Control. Connections to the control include + 12VDC, 12V common, speed, direction, diagnostic monitor, + 48V or + 72V, battery negative and motor leads. The 12VDC and 12V common inputs are for the control card electronics. The direction latch circuitry takes the direction input, 12VDC or 0VDC, and switches transistor Q3 or Q4 “ON”. The direction latch also activates the circuitry which routes the speed input to transistor Q1 or Q2, to correspond with the direction transistor selected.

Normal operating current draw is 20-25 amps. When the steering mechanism is against the stops, current draw will increase to 90 amps. The current sensing circuitry, however, will disable the Speed Buffer and the direction transistors when current draw reaches 40 amps. The direction latch is enabled again when current draw reaches zero, but is disabled with each speed signal pulse unless overcurrent does not exist. If the overcurrent condition does exist at each pulse, the “ON” time realized by the servo motor will be at a minimum.

+12 VDC

DIRECTION

9v or 0v

NOTE 1

TAB 6 DIRECTION LATCH WHT

DIRECTION LOGIC

SPEED

2v-off to 6v

TAB 5 BLK

DIAGNOSTIC MONITOR

DRIVER

SPEED BUFFER

TAB 4 GRN

TO SERVO Q2 MOTORS

NOTE 2 20 OHM (48 V) 33 OHM (72 V)

TAB 7 ORG

0v to 4v depending on tiller speed COMMON

PREDRIVER

CURRENT LATCH

CURRENT SENSE

CURRENT SENSE RESISTOR .01 OHM BATTERY NEGATIVE

NOTE 1: 48v or 72v when "on" and 0v when "off" NOTE 2: 0v to 2v depending on tiller speed. 0430-01

ILLUSTRATION 4.2-3

Crown 1989 PF-8455-2 Rev. 1/94

Printed in U.S.A.

01 REV. 2/94

M4.2 - 19 - 011

MAINTENANCE 111268 Control Card Adjustment The steering servo circuit board is programmable to enhance the speed of corrections made to the steering system when operating in the auto guidance mode. The correction speed is not intended to make up for a steering system or wire guidance system that is in need of adjustment or repair. Make certain the steering feedback assembly, sensor bars, sensor cards, guidance calibration and truck wiring are not the cause of unsatisfactory steering performance. Programming pins are located near the center of the printed circuit board. A jumper is placed over a pair of pins (1, 2 or 3) to set the sensitivity of the steering system. Absence of a jumper will cause operation as if the jumper is over pin set 1. 1. Make certain the steering system and wire guidance system is in good state of repair and that the wire guidance system is calibrated.

2. Place the program jumper over pin set 1. 3. Operate the truck on the wire several passes to observe the tracking capabilities. 4. If the truck follows the wire within 1/2 inch (12 mm) on either side of the wire, additional adjustment is not necessary. If the weave is greater than that mentioned, move the program jumper to pin set 2. 5. Observe the tracking of the truck. Setting the program jumper to a higher setting when the truck is tracking within the deviation mentioned, will cause an uncomfortable feeling for the operator due to the correction speed. If the weave is greater than that mentioned, move the program jumper to pin set 3.

TAB4

GRN R7 CR1

TAB3

C1 RED

R11 CR5

PIN SET 2

C15 C16

1 2 3

CR6 C4

U4 R16 R28

LD9 LD10 BLU YEL

JUMPER (062161)

R31

BLU

TAB9

CR12

PIN SET 3

R2 YEL LD8

BLU LD7

PIN SET 1

R3 CR14 C14 R34

VR2

CR11

VR1

R48 R49

LD2 GRN

R1 R47 R4 C17

Further adjustment is not available with this circuit board.

PIN SET

J1 LD1 RED

1373

ILLUSTRATION 4.2-4

Testing Test procedures described are resistance, continuity and power applied voltage checks. Refer to Illustration 4.2-4 for location of testing points.

Disconnect and insulate one (1 ) lead from each servo motor when following checkout procedure.

Following is a series of voltage checks which will isolate a problem to a specific area. Then, in some instances, by making continuity and resistance checks, a problem component can be pinpointed.

Crown 1989 PF-8455-3 Rev. 1/94

DANGER

Printed in U.S.A.

01 REV. 1/94

M4.2 - 19 - 012

MAINTENANCE CONTROL INPUT/OUTPUT TEST 1. Connect digital meter on dc voltage range, between the direction input, TAB 6 (positive lead), and battery negative (negative lead).

7. When truck is powered-up and selftest complete, check the input voltage to the control between TAB 3, positive, and TAB 4, negative. Input voltage should be 11.5 to 12.5 volts.

2. Power-up truck and monitor the meter display. 3. If meter was indicating 9 volts, the reading should drop to zero volts then back to 9 volts. If the meter was indicating zero volts, the reading should go to 9 volts then back to zero. This signal originates at the command card of the power unit microprocessor. 4. Connect meter between the speed input, TAB 5 (positive lead), and battery negative (negative lead). 5. Power-up truck and monitor the meter display.

8. Connect the positive meter lead to the emitter of Q3 and the negative meter lead to the emitter of Q4. Leave the operator compartment door open and turn the steering tiller. A positive or negative voltage between zero and 48 or 72 volts should be indicated. Voltage level depends on how fast the tiller is turned. 9. Turn steering tiller in opposite direction. A voltage of the opposite polarity as obtained in Step 8 will be realized. Again the voltage will be between zero and 48 or 72 volts, depending on how fast the tiller is turned. NOTE

TAB 3 12 VDC INPUT

TAB 4 COMMON

TAB 5 SPEED INPUT

If input and output voltages are as described, refer to Troubleshooting Procedures later in this section.

TAB 6 DIRECTION INPUT

TAB 7 DIAGNOSTIC MONITOR

CURRENT SENSE RESISTOR .01 OHM

BATTERY NEGATIVE

CONTROL CARD

BATTERY POSITIVE

DUAL TRANSISTOR Q1 = E2, B2, C2 Q3 = E1, B1, C1

0445P-02

MOTOR NEGATIVE

RESISTORS 20 OHM (48 VOLT UNITS) 33 OHM (72 VOLT UNITS)

MOTOR POSITIVE

DUAL TRANSISTOR Q2 = E2, B2, C2 Q4 = E1, B1, C1

ILLUSTRATION 4.2-4

Crown 1989 PF-8455-4 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M4.2 - 19 - 013

Switching of battery volts to the servo motor and controlling the direction of this voltage through the motor is accomplished by the use of power transistors. Transistors are universal solid state devices which can be used to amplify, oscillate or, as in the output circuit, solid state switches. Illustration 4.2-1 shows the schematic representation and basic elements of an NPN Transistor. To turn the transistor ON, the base must be more positive than the emitter by + 1.5 volts DC (measured base to emitter).The transistor will conduct emitter to collector. To turn the transistor OFF, the base must be brought to a potential which is less positive than the emitter.

0444P-01

The output transistors of the servo motor control are electrically arranged in an H bridge configuration as shown in Illustration 4.2-2. Transistors Q1 and Q2 switch battery voltage to the servo motor for speed control and transistors Q3 and Q4 determine the direction the switched voltage passes through the motor. Transistors Q1 and Q4 will conduct simultaneously when steering one direction, and transistors Q2 and Q3 when steering the opposite direction. LINEAR CARD DIRECTION

C1 (COLLECTOR)

SCHEMATIC

48 VDC or 72 VDC

DIRECTION

B1 (BASE) E1 (EMITTER) C2 (COLLECTOR) B2 (BASE)

SPEED

E2 (EMITTER) C1 B1 E1,C2 B2 E2

PICTORIAL

TO SERVO MOTOR Q2 BATTERY NEGATIVE

SPEED 0429

ILLUSTRATION 4.2-2

NPN TYPE TRANSISTOR

0428

ILLUSTRATION 4.2-1 4489

Crown 1991 PF9075-1 Rev. 11/94

Printed in U.S.A.

04 REV. 11/94

M4.2–19.0–020

MAINTENANCE Circuit Operation Illustration 4.2-3 is a block diagram of the Steering Servo Motor Control. Connections to the control include + 12VDC, 12V common, speed, direction, diagnostic monitor, + 48V or + 72V, battery negative and motor leads. The 12VDC and 12V common inputs are for the control card electronics. The direction latch circuitry takes the direction input, 12VDC or 0VDC, and switches transistor Q3 or Q4 ON. The direction latch also activates the circuitry which routes the speed input to transistor Q1 or Q2, to correspond with the direction transistor selected.

Normal operating current draw is 20-25 amps. When the steering mechanism is against the stops, current draw will increase to 70 amps. The current sensing circuitry, disables the speed buffer when current draw reaches 70 amps. The speed buffer is enabled again when current draw reaches zero, but is disabled with each speed signal pulse unless overcurrent does not exist. If the overcurrent condition does exist at each pulse, the ON time realized by the servo motor will be at a minimum.

+12 VDC

DIRECTION

9v or 0v

NOTE 1

TAB 6 DIRECTION LATCH WHT

DIRECTION LOGIC

SPEED

2v-off to 6v

TAB 5 BLK

DIAGNOSTIC MONITOR

0v to 4v depending on tiller speed COMMON

PREDRIVER

DRIVER

SPEED BUFFER

TO SERVO Q2 MOTORS

NOTE 2 20 OHM (48 V) 33 OHM (72 V)

TAB 7 ORG

TAB 4 GRN

CURRENT LATCH

CURRENT SENSE

CURRENT SENSE RESISTOR .01 OHM BATTERY NEGATIVE

NOTE 1: 48v or 72v when "on" and 0v when "off" NOTE 2: 0v to 2v depending on tiller speed. 0430-01

ILLUSTRATION 4.2-3

Crown 1991 PF9075-2 Rev. 11/94

Printed in U.S.A.

04 REV. 11/94

M4.2–19.0–021

TAB4

GRN R7 CR1

TAB3

C1 RED

R11 CR5

PIN SET 2

C15 C16

1 2 3

CR6 C4

U4 R16 R28

LD9 LD10 BLU YEL

JUMPER (062161)

R31

BLU

TAB9

CR12

PIN SET 3

R2 YEL LD8

BLU LD7

PIN SET 1

R3 CR14 C14 R34

VR2

CR11

VR1

R48 R49

LD2 GRN

R1 R47 R4 C17

Further adjustment is not available with this circuit board.

PIN SET

J1 LD1 RED

1373

ILLUSTRATION 4.2-4

Testing Test procedures described are resistance, continuity and power applied voltage checks. Refer to Illustration 4.2-4 for location of testing points.

Disconnect and insulate one (1 ) lead from each servo motor when following checkout procedure.

Following is a series of voltage checks which will isolate a problem to a specific area. Then, in some instances, by making continuity and resistance checks, a problem component can be pinpointed.

Crown 1991 PF-9075-3 Rev. 6/92

DANGER

Printed in U.S.A.

02 REV. 6/92

M4.2 - 19 - 022

MAINTENANCE CONTROL INPUT/OUTPUT TEST 1. Connect digital meter on dc voltage range, between the direction input, TAB 6 (positive lead), and battery negative (negative lead).

7. When truck is powered-up and selftest complete, check the input voltage to the control between TAB 3, positive, and TAB 4, negative. Input voltage should be 11.5 to 12.5 volts.

TAB 3 12 VDC INPUT

TAB 4 COMMON

TAB 5 SPEED INPUT

If input and output voltages are as described, refer to Troubleshooting Procedures later in this section.

TAB 6 DIRECTION INPUT

TAB 7 DIAGNOSTIC MONITOR

CURRENT SENSE RESISTOR .01 OHM

BATTERY NEGATIVE

CONTROL CARD

BATTERY POSITIVE

DUAL TRANSISTOR Q1 = E2, B2, C2 Q3 = E1, B1, C1

0445P-02

MOTOR NEGATIVE

RESISTORS 20 OHM (48 VOLT UNITS) 33 OHM (72 VOLT UNITS)

MOTOR POSITIVE

DUAL TRANSISTOR Q2 = E2, B2, C2 Q4 = E1, B1, C1

ILLUSTRATION 4.2-4

Crown 1991 PF-9075-4 Rev. 1/94

Printed in U.S.A.

03 REV. 1/94

M4.2 - 19 - 023

MAINTENANCE CONTROL CARD TEST

TRANSISTOR TEST

If input voltages are as described in Control Input/Output Test but output voltages are not, check the control card outputs. Leave operator compartment gates open when performing this test.

If input voltages are as described in Control Input/Output Test and control card output voltages are as described in Control Card Test, check condition of transistors.

In-circuit transistor resistance tests in the past have proven unreliable. The test described will be reliable only for the transistors in this control and should not be considered a standard testing procedure for all transistors. 1. Disconnect battery and chock wheels. 2. Isolate transistors from other components in the control by disconnecting buss bars and other leads from the transistors. 3. Test the base to collector and emitter to collector junctions as shown in Illustration 4.2-5 if using an analog meter with 20,000 ohms/volt input impedance (i.e. Simpson 260). Refer to Illustration 4.2-6 when using a test light.

If transistor Q4 had 48 or 72 volts on the base terminal in Step 1, transistor Q1 should have 2 to 4 volts on its base terminal in Step 2.

NOTE

When using a digital meter, refer to the meter operator manual for any special diode testing procedures and use Illustration 4.2-5 as a guide for polarity. 4. Check resistance between transistor collector terminals and the housing. Resistance measured should be greater than 30,000 ohms.

5. If voltage levels at the base of transistors Q1 and Q2 are not as described, disconnect battery and check resistance of two (2) resistors 33 ohm on 72 volt trucks, 20 ohm on 48 volt trucks. If resistors are within tolerance, the card is defective. CURRENT SENSE RESISTOR TEST Check the resistance of the .01 ohm resistor. To check requires a sensitive meter, however, a quick check for continuity will determine if the control will function.

Crown 1991 PF-9075-5 Rev. 6/92

Printed in U.S.A.

02 REV. 6/92

M4.2 - 19 - 024

MAINTENANCE TEST TRANSISTORS EMITTER TO COLLECTOR 20

RX1 - +

- +

B1 C1

R X 10,000

E1 C2

B1 C1

E1 C2

0431

0432

R x 1 scale. Negative lead to collector and positive lead to emitter. A reading of less than 20 ohms is desirable.

R x 10K scale. Negative lead to emitter and positive lead to collector. A reading in excess of 50,000 ohms is desirable.

TEST TRANSISTORS BASE TO COLLECTOR 5

RX1 - +

- +

E1 C2

B1 C1

R X 10,000

E1 C2

0433

0434

R x 1 scale. Negative lead to collector and positive lead to base. A reading of less than 20 ohms is desirable.

R x 10K scale. Negative lead to base and positive lead to collector. A reading in excess of 50,000 ohms is desirable.

This testing procedure will only work with transistors in the steering servo amplifier. ILLUSTRATION 4.2-5

Crown 1991 PF-9075-6 Rev. 6/92

Printed in U.S.A.

02 REV. 6/92

M4.2 - 19 - 025

MAINTENANCE TEST TRANSISTORS EMITTER TO COLLECTOR

+ POS

+ POS + POS - NEG. NEG. -- NEG.

+ POS

- NEG. -- NEG. NEG.

B1 C1

E1 C2

0435

Negative lead to collector and positive lead to emitter. Test light should illuminate.

E1 C2

0436

Negative lead to emitter and positive lead to collector. Test light should remain off.

TEST TRANSISTORS BASE TO COLLECTOR

+ POS

- NEG.

B1 C1 0437

+ POS

- NEG.

E1 C2

C1 0438

Negative lead to collector and positive lead to base. Test light should illuminate.

NEG. -- NEG.

B2 E1 C2

Negative lead to base and positive lead to collector. Test light should remain off.

This testing procedure will only work with transistors in the steering servo amplifier. ILLUSTRATION 4.2-6

Crown 1991 PF-9075-7 Rev. 6/92

Printed in U.S.A.

02 REV. 6/92

M4.2 - 19 - 026

MAINTENANCE TRANSISTOR REPLACEMENT

Component Replacement (Illustration 4.2-7) When components are replaced on the servo motor control, ensure all connections are tight and heat sink compound (Crown No. 93983) applied, as directed, to prolong component life. Disconnect battery whenever performing maintenance on this control.

1. Disconnect wires from transistor in question. 2. Remove buss bars. 3. Remove two (2) mounting screws holding transistor in place.

CONTROL CARD REPLACEMENT 1. Disconnect wires between control card and control.

4. Lift transistor from control and test transistor to verify its condition.

2 Remove five (5) screws securing control card to housing. Lift control card from housing.

5. Position transistor in housing and secure in place with mounting screws.

3. Position replacement control card in housing and secure in place with mounting screws.

6. Install buss bars and tighten securely. 7. Connect wires as shown in Illustration 4.2-7.

4. Connect wires between control card and control as shown in Illustration 4.2-7. 5. Make certain all connections are tight.

0439S

ILLUSTRATION 4.2-7

Crown 1991 PF-9075-8 Rev. 6/92

Printed in U.S.A.

02 REV. 6/92

M4.2 - 19 - 027

MAINTENANCE RESISTOR REPLACEMENT (33 ohm 72 V, 20 ohm 48 V) 1. Remove transistors. 2. Unsolder wires from defective resistor. 3. Remove mounting screws and lift resistor from housing. Clean mating surface of housing. 4. Lightly smear heatsink compound on mating surfaces of housing and replacement resistor. 5. Secure resistor to housing with mounting screws. Solder wires removed from defective resistor to replacement resistor. 6. Install transistors. RESISTOR REPLACEMENT (.01 ohm) 1. Unsolder wires from defective resistor. 2. Remove mounting screws and lift resistor from housing. Clean mating surface of heatsink. 3. Lightly smear heatsink compound on mating surfaces of housing and replacement resistor.

Disconnect battery, remove four (4) mounting bolts from one (1 ) steering gearbox. Lift end of gearbox opposite the servo motor and place blocks under housing so drive gear is free to rotate. Connect battery and power-up truck. Observe steered wheels while truck is running through selftest. Wheels should move from side to side. If movement does not occur, check all components from the steering ring gear mounting bolts on the drive unit to the brushes of the servo motor. If wheels moved during selftest, turn wheels from stop to stop, slowly, with the steering tiller. Observe wheel movement and watch for any apparent binding in the steering gearbox or steering linkage. Disconnect battery. Secure steering gearbox, which was removed, in place with four (4) mounting bolts. Remove four (4) mounting bolts of opposite steering gearbox. Lift end of gearbox opposite the servo motor and place blocks under housing so drive gear is free to rotate. Connect battery and power-up truck. Observe steered wheels while truck is running through selftest. Wheels should move from side to side. If movement does not occur, check all components from steering ring gear mounting bolts on the drive unit to the brushes of the servo motor.

Troubleshooting

If wheels moved during selftest, turn wheels from stop to stop, slowly, with steering tiller. Observe wheel movement and watch for any apparent binding in the steering gearbox or steering linkage.

Use this section when the “wrench light” illuminates and service #49 or #73 is logged into service history but the steering servo and steering feedback servo check out okay.

If binding was apparent when both tests were run, check floor and tire condition, steering mechanism pivot point lubrication and condition.

The steering system has an electrical safety interlock which disables traction and steering if the steered wheel movement and steering tiller command are not within a programmed window. A problem with the steering mechanism can cause this situation.

If binding was apparent only when one (1) gearbox was driving the steered wheels, disconnect battery and remove four (4) mounting bolts from the suspect gearbox. Move gearbox so drive gear is over edge of truck. Wrap a protective cover around the gear to protect gear from damage. Using a suitable tool, turn gear and feel for any binding or tight spots. Repair as necessary.

4. Secure resistor in place and solder wires to resistor.

Crown 1991 PF-9075-9 Rev. 6/92

Printed in U.S.A.

02 REV. 6/92

M4.2 - 19 - 028

MAINTENANCE TROUBLESHOOTING Diagnostics is part of the TSP computer software program. Service conditions are stored as numbers and when referenced to the Service Terminal Instruction Book, will direct the service technician to a specific portion of the truck electrical system. Service history is stored in two (2) formats; (1 ) the total number of times a malfunction occurs is stored under the appropriate service number and (2) the sequence of occurrence. The diagnostics is accessible only through an optional service terminal which plugs directly into either electronics box. Total troubleshooting cannot always be accomplished solely through the use of the service terminal, however, reduces troubleshooting time. The various truck functions are treated as electrical subsystems; steering, traction, brakes, main and auxiliary lift/ lower and accessory functions. Each sub-system uses specific components which the block diagrams in this section illustrate. When a problem is encountered, it is recommended to first check isolated power supply voltage. This voltage must not drop below 4.75 volts. Remember to use isolated common when checking this voltage.

When the problem is isolated to a card(s) in the electronics box, begin a card substitution routine. Card substitution involves replacing a card with a “known good” card and determining if the problem has been remedied or symptoms changed. If the problem is not remedied and symptoms do not change, return the card removed to the electronics box since it is okay. When symptoms change but the problem is not remedied, it can be assumed that more than one card is at fault. CHARTS The charts which follow each block diagram provide voltages for the inputs and outputs of the electronics boxes for the condition listed. Column I/O lists if the signal is an input (I) or output (O) of the electronics box. The Test Point column provides a convenient termination point for checking the signal. Following each chart is a list of test point locations (TPL). The condition listed in the Condition column is that which is necessary to achieve the end result of the system being checked.

To isolate a problem component within a sub-system, check the electronic box outputs initially. If all outputs are present, the problem is with the driven component. When an electronics box output is not present, check inputs to the electronics box. If an input is not present, the electronics box cannot provide the necessary output. This method of troubleshooting has isolated the problem component to an input device, output device or the electronics box.

NOTE Use a digital meter (e.g. Beckman Tech 300 series) for making voltage checks. Take all readings in reference to battery negative unless otherwise specified.

When an output is not present at the driven device and all inputs are present at the input device, make certain the input signals are present at the connector on the card in the electronics box. Likewise make certain outputs are not present at the card connector. An open wire in the wiring harness could prevent signals from reaching their destination. Using the Truck Wiring Chart at the end of this section, along with the block diagrams, enables the service technician to trace a signal from its originating device, whether a truck mounted component or card in the electronics box, to its destination.

4121MG - 37979 Crown 1988 PF-8193-1 Rev. 1/94

M4.3 - 19 - 400

Printed in U.S.A.

03 REV. 1/94

M4.3 - 19 - 400

MAINTENANCE ENCODER CHECKOUT For detailed description and adjustment procedures for the encoders used on the Turret Stockpicker, refer to the M4.0 section of this manual. The input (red wire positive, black wire negative) is 5 volts battery from the power supply on the serial link card. Index output (blue wire) will be 5 volts when the index is present. The index must be present on the raise/lower command and traction command when the controls are in neutral. Index must be present on the steering feedback encoder when the steered wheels are in the straight ahead position. The index output is not used in the steering command and height sensor assemblies. Channel A (orange wire) output will alternate between 5 volts and 0 volts when the encoder input shaft is turned very slowly. Channel B (white wire) output will also alternate between 5 volts and 0 volts. If the speed of shaft rotation is increased, the voltage reading will go to 2.5 volts which is the average of the on-off voltages seen by the meter. Following are test points for the encoders: Traction Command Encoder Input - TB509-1 Common - TB509-5 Index - TB509-2 Channel A - TB509-3 Channel B - TB509-4

Steering Command Encoder Input - TB526-1 Common - TB526-4 Index - not used Channel A - TB526-2 Channel B - TB526-3 Raise/Lower Command Encoder Input - TB526-5 Common - TB526-9 Index - TB526-6 Channel A - TB526-7 Channel B - TB526-8 Steering Feedback Encoder Input - TB613-1 Common - TB613-5 Index - TB613-2 Channel A - TB613-3 Channel B - TB613-4 TPL: TB509 - under emergency override switch mounting plate. TB524 - on height sensor under seat. TB526 under cover with pencil tray by raise/lower control lever. TB613 - on steering feedback assembly between steered wheels.

Height Sensor Encoder Input - TB524-1 Common - TB524-4 Index - not used Channel A - TB524-2 Channel B - TB524-3

Crown 1988 PF-8193-2 Rev. 5/90

M4.3 - 19 - 401

Printed in U.S.A.

01 REV. 5/90

M4.3 - 19 - 401

MAINTENANCE Steering The steering amplifier is turned “on” whenever input from the steering tiller is received in manual mode and motion is detected when in automatic guidance mode. 5 seconds after the last steering tiller input in manual mode or 5 seconds after the last motion input is received when in automatic guidance mode, the steering amplifier is turned off. When the guidance switch (GUS) is placed in the “automatic” position, the steering tiller encoder (ECR-1 ) input is ignored by the electronics box and steering is controlled by the wire guidance system.

2446S

When the rail guide rollers contact the guide rail and close the rail guide switch (RGSL and RGSR) contacts, the steered wheels are driven to the calibrated center position for approximately 10 seconds. After this time period, the steering amplifier is turned off and guidance is provided by the guide rollers against the guide rail. During rail guidance the steering tiller encoder (ECR-1) input is ignored by the electronics box.

ILLUSTRATION 4.3-1

Crown 1988 PF-8193-3 Rev.9/93

Printed in U.S.A.

02 REV. 9/93

M4.3 - 19 - 402

MAINTENANCE Signal GUS GATE * DMS-2 * DMS-3 * DMS-4 * DMS-5 SES

I/O I I I I I I I

S RGSL RGSR Direction

O I I O

Speed Power

O O

Test Point CA521-3 CA522-7 CA519-7 CA521-8 CA520-5 CA522-5 CA514-8 CA515-3 Contactor coil TB616-1 TB616-2 TAB 6 TAB 5 TAB 3 (+) TAB 4 (-)

Condition - Manual position - Gates closed - Left pedestal pedal released - Right pedestal pedal released - Left floor pedal depressed - Right floor pedal depressed - Operator standing - Operator standing - Powered up, no steering faults - Out of guided aisle - Out of guided aisle - Turning tiller in one direction - Turning tiller in opposite direction - Turning tiller - Powered up and self-test complete

Voltage 0 0 12 12 0 0 36/48 0 36/48 12 12 9 0 (NOTE 1) 11.5 - 12.5

* = Switch status given is for operator standing. NOTE 1: An exact reading is not possible due to frequency. If meter seems to be attempting a reading, it can be assumed output is okay. TPL: CA519, CA520, CA521, CA522 - Resistor pull-up on platform electronics box. CA514- Platform power distribution board. TB616 - Power unit hydraulic wall. STEERING CONTACTOR(“S”) COIL - Contactor panel. TABS 3 thru 6 Steering amplifier (MRC-3). CHART 4.3-1

Crown 1988 PF-8193-4 Rev. 5/90

M4.3 - 19 - 403

Printed in U.S.A.

01 REV. 5/90

M4.3 - 19 - 403

MAINTENANCE Traction For maximum possible traction speed, the gates must be closed with operator in position, platform lift height and auxiliary lift height within limits of applicable speed curve, steered wheels within 10° of straight ahead position, load handler in “home” position, direction selected, brakes released and forks in “home” position. When forks are in the “home” position switches FHSL and FHSR must be open. FLS and FRS can be open or closed.

2447S

When wire guidance mode of operation is selected, the wire must be acquired to allow maximum traction speed. Height Sensor cable broken switch (HCS) will limit traction speed when cable is slack or broken which opens the switch contact.

ILLUSTRATION 4.3-2

Crown 1988 PF-8193-5 Rev. 9/93

M4.3 - 19 - 404

Printed in U.S.A.

02 REV. 9/93

M4.3 - 19 - 404

MAINTENANCE Brakes Brakes are spring applied, hydraulically released. Hydraulic pressure for releasing the brakes is developed through the accessory pump. If the brakes are applied frequently without using an accessory function to start the accessory pump, it is possible to have insufficient hydraulic pressure to release the brakes after a period of time. To avoid this situation, brake pressure switch (BPS) monitors hydraulic pressure in the brake hydraulic system. When pressure drops to a predetermined point, a contact of BPS closes. Solenoid SV8 is energized to isolate the brake hydraulic system and the accessory pump is started. When hydraulic pressure builds back up, another contact of BPS opens which turns the accessory pump off and the hydraulic system is recharged. When the operator is seated and pedestal pedals depressed, the momentary contact of BRS-1 must be closed before the brakes will release. Once relay K3 is energized the momentary contact of BRS-1 can be opened.

2448S-01

When traveling at speeds less than 2.3 MPH (3.7Km/h) and braking, other than parking and service condition braking, is requested, the rear brakes (power unit) are blocked to soften the braking effect. Blocking the rear brakes is accomplished by energizing solenoid SV9 which holds hydraulic pressure in the rear brake hydrualic circuit and keeps the brakes released. At speeds above 2.3 MPH (3.7Km/h), solenoid SV9 remains de-energized and full braking is experienced. If brake linkage switches (BRS-6 & BRS-7) are not adjusted properly, the amount of time required for the brake linkage switches to indicate brakes applied will exceed a predetermined time and the electronics system will execute an Auto E.D. In this condition the emergency disconnect contactor (ED1) will open. The battery indicator light will be the only light “on” in the console when in Auto E.D. Refer to the M4.0 section of this manual for proper adjustment of these switches.

ILLUSTRATION 4.3-3

Crown 1988 PF-8193-7 Rev. 1/94

M4.3 - 19 - 406

Printed in U.S.A.

03 REV. 1/94

M4.3 - 19 - 406

MAINTENANCE Signal BRS-3 SES

I/O I I

Test Point CA520-1 CA514-8 CA515-3

BRS-2

CA514-8

BRS-1

CA515-7

K4 SV6/SV7 BRS-6/BRS-7 SV9 BPS-2

O I I O I

CA601-7 CA605-1 TB612-9 SB67-3 TB616-6

BPS-1

TB616-5

SV8

SB68-1

Condition - Pedestal brake pedal released - Operator standing, floor pedals depressed - Operator seated, pedestal pedals depressed - Operator standing, floor pedals depressed - Operator seated, pedestal pedals depressed, BRS-1 momentary contacts closed - Operator seated, brake release sequence complete - Brake applied position - Brake release position - Brake release sequence complete - Brake release sequence complete - Brakes released - Braking requested at less than 1.5 MPH (2.4Km/h) - Brake hydraulic pressure 490 - 510 PSI (3370 - 3520 KPa) - Brake hydraulic pressure 1715 - 1785 PSI (11820 12300 KPa) - Recharging brake hydraulic system

Voltage 0 36/48 0 0 36/48 36/48 36/48 0 36/48 36/48 12 36/48 0 12 36/48

TPL: CA520 - Resistor pull-up on platform electronics box. CA514, CA515 - Platform power distribution board. TB601, TB605 - Power unit distribution board. TB612 - Power unit rear wall, right side. SB67, SB68, TB616 - Power unit hydraulic wall. CHART 4.3-3

Crown 1988 PF-8193-8 Rev. 5/90

M4.3 - 19 - 407

Printed in U.S.A.

01 REV. 5/90

M4.3 - 19 - 407

MAINTENANCE Main and Auxiliary Raise To perform a raise function, all electrical interlock conditions must be satisfied and sufficient charge on battery available for battery discharge interrupt. Separate charts are listed for main and auxiliary raise.

LVDT CHECKOUT - Power truck down and disconnect the white and black wires. Check resistance between the white and yellow wires of the LVDT. Resistance should be between 50 and 70 ohms. Check resistance between red and black wires of LVDT. Resistance should be between 500 and 700 ohms.

NOTE 1

NOTE 1: CTS present on TF mast only 2449S

ILLUSTRATION 4.3-4

Main Raise When main raise is in a raise cutout zone, as displayed by the cutout indicator in the switch and indicator panel, the cutout override button (ORS) must be depressed to continue raise.

Crown 1988 PF-8193-9 Rev. 9/93

M4.3 - 19 - 408

Printed in U.S.A.

02 REV. 9/93

M4.3 - 19 - 408

MAINTENANCE Signal AXS CHS-4 CHS-5 DMS-1 *DMS-2 *DMS-3 *DMS-4 *DMS-5 GATE LMS-1 LMS-2 ORS SES

(NOTE 3) (NOTE 3) (NOTE 2) (NOTE 1)

I/O I I I I I I I I I I I

Test Point CA519-5 CA520-4 CA520-3 CA521-5 CA519-7 CA521-8 CA520-5 CA522-5 CA522-7 CA519-8 CA519-6

Condition - Button released - Lift chain not broken - Lift chain not broken - Palm button depressed - Pedestal pedal released - Pedestal pedal released - Floor pedal depressed - Floor pedal depressed - Gates closed - Platform within 18 in. (457mm) of floor - Main mast below staging point

Voltage 12 0 0 0 12 12 0 0 0 0 0

I I

CA521-1 CA514-8

- Button released - Operator standing - Operator seated - Operator standing - Operator seated - Hose take-up adjusted properly - Raise enabled - Raise inhibited - Bypass inhibited - Bypass enabled - Requesting lift, slow/fast - Raise requested - Raise inhibited - Attempting raise - Truck powered-up, self-test complete

12 36/48 0 0 36/48 0 0 8 8 0 3.75/0 8 0 ±0-36/48 5

CA515-3 CTS (NOTE 2) Command Enable Bypass Enable

I O

TB616-4 TB11P-5

TB11P-6

Command Driver Enable

O O

TB11P-1 PCBT-4

Servo SS3

O O

Servo Motor TB617-1 (+) TB617-3 (-) TB617-2

- Sprocket tooth in front of sensor - Sensor between sprocket teeth

5 0

* = Switch status given relates to operator standing NOTE 1: NOTE 2: NOTE 3:

Raise/lower cutout override switch. LMS-2 and CTS present on TF mast only. LMS-1 and LMS-2 are actuated when platform is fully lowered. As the platform raises, the switches reset when they lose contact with the tripper bar. At mast staging LMS-2 again actuates and is maintained actuated while the mast is staged. If either of these switches fail, fault #61 will be registered.

TPL: CA519, CA520, CA521, CA522 - Resistor pull-up on platform electronics box. CA514, CA515 - Platform distribution board. TB616, TB617, SERVO MOTOR - Power unit hydraulic wall. TB11P, PCBT - Lift SCR control card. CHART 4.3-4

Crown 1988 PF-8193-10 Rev. 9/93

M4.3 - 19 - 409

Printed in U.S.A.

02 REV. 9/93

M4.3 - 19 - 409

MAINTENANCE Auxiliary Raise Signal AXS CHS-4 CHS-5 * DMS-1 * DMS-2 * DMS-3 * DMS-4 * DMS-5 GATE SES

I/O I I I I I I I I I I

Test Point CA519-5 CA520-4 CA520-3 CA521-5 CA519-7 CA521-8 CA520-5 CA522-5 CA522-7 CA514-8

Condition - Button depressed - Lift chain not broken - Lift chain not broken - Palm button depressed - Pedestal pedal released - Pedestal pedal released - Floor pedal depressed - Floor pedal depressed - Gates closed - Operator standing - Operator seated - Operator standing - Operator seated - Hose take-up adjusted properly - Raise enabled - Raise inhibited - Bypass inhibited - Bypass enabled - Requesting lift, slow/fast - Raise requested - Raise inhibited - Attempting raise - Truck powered-up, selftest complete

CA515-3 CTS (NOTE 1) Command Enable Bypass Enable

I O

TB616-4 TB11P-5

TB11P-6

Command Driver Enable

O O

TB11P-1 PCBT-4

Servo SS3

O I

Servo Motor TB617-1 ( + ) TB617-3 (-) TB617-2

- Sprocket tooth in front of sensor - Sensor between sprocket teeth

Voltage 0 0 0 0 12 12 0 0 0 36/48 0 0 36/48 0 0 8 8 0 3.75/0 8 0 ±0 - 36/48 5 5 0

* = Switch status given relates to operator standing NOTE 1: CTS present on TF mast only. TPL: CA519, CA520, CA521, CA522 - Resistor pull-up on platform electronics box. CA514, CA515 - Platform distribution board. TB616, TB617, SERVO MOTOR - Power unit hydraulic wall. TB11P, PCBT - Lift SCR control card. CHART 4.3-5

Crown 1988 PF-8193-11 Rev. 9/93

M4.3 - 19 - 410

Printed in U.S.A.

02 REV. 9/93

M4.3- -19 - 410

MAINTENANCE Main and Auxiliary Lower To perform a lower function, all electrical interlock conditions must be satisfied. Separate charts are listed for main and auxiliary lower.

NOTE 1

NOTE 1: CTS present on TF mast only 2450S

ILLUSTRATION 4.3-5

Crown 1988 PF-8193-12 Rev. 9/93

M4.3 - 19 - 411

Printed in U.S.A.

02 REV. 9/93

M4.3 - 19 - 411

MAINTENANCE Main Lower When main lower is in a lower cutout zone, as displayed by the cutout indicator in the switch and indicator panel, the cutout override button (ORS) must be depressed to continue lower. Signal AXS CHS-1 CHS-2 CHS-4 CHS-5 DMS-1 * DMS-2 * DMS-3 * DMS-4 * DMS-5 GATE LMS-1 ORS SES

CTS SV2 SV3 Servo

(NOTE 1)

(NOTE 2)

l/O I I I I I I I I I I I I I I

Test Point CA519-5 CA520-7 CA520-6 CA520-4 CA520-3 CA521-5 CA519-7 CA521-8 CA520-5 CA522-5 CA522-7 CA519-8 CA521-1 CA514-8

CA515-3

I O O O

TB616-4 SB66-1 SB66-3 Servo Motor

Condition - Button released - Lift chain not slack or broken - Lift chain not slack or broken - Lift chain not broken - Lift chain not broken - Palm button depressed - Pedestal pedal released - Pedestal pedal released - Floor pedal depressed - Floor pedal depressed - Gates closed - Platform within 18 in. (457mm) of floor - Button released - Operator standing - Operator seated - Operator standing - Operator seated - Hose take-up adjusted properly - Requesting main lower - Requesting main lower - Requesting main lower

Voltage 12 0 0 0 0 0 12 12 0 0 0 0 12 36/48 0 0 36/48 0 36/48 0 ±0 - 36/48

* = Switch status given relates to operator standing NOTE 1: Raise/lower cutout override switch. NOTE 2: CTS present on TF mast only. TPL: CA519, CA520, CA521, CA522 - Resistor pull-up on platform electronics box. CA514, CA515 - Platform distribution board. TB616, TB617, SERVO MOTOR - Power unit hydraulic wall. TB616, SB66, SERVO MOTOR - Power unit hydraulic wall. CHART 4.3-6

Crown 1988 PF-8193-13 Rev. 9/93

M4.3 - 19 - 412

Printed in U.S.A.

02 REV. 9/93

M4.3 - 19 - 412

MAINTENANCE Auxiliary Lower Signal AXS CHS-1 CHS-2 CHS-4 CHS-5 DMS-1 * DMS-2 * DMS-3 * DMS-4 * DMS-5 GATE SES

I/O I I I I I I I I I I I I

Test Point CA519-5 CA520-7 CA520-6 CA520-4 CA520-3 CA521-5 CA519-7 CA521-8 CA520-5 CA522-5 CA522-7 CA514-8 CA515-3

SV2 SV3 Servo

O O O

SB66-1 SB66-3 Servo Motor

Condition - Button depressed - Lift chain not slack or broken - Lift chain not slack or broken - Lift chain not broken - Lift chain not broken - Palm button depressed - Pedestal pedal released - Pedestal pedal released - Floor pedal depressed - Floor pedal depressed - Gates closed - Operator standing - Operator seated - Operator standing - Operator seated - Requesting auxiliary lower - Requesting auxiliary lower - Requesting auxiliary lower

Voltage 0 0 0 0 0 0 12 12 0 0 0 36/48 0 0 36/48 0 36/48 ±0 - 36/48

Crown 1988 PF-8193-14 Rev. 5/90

M4.3 - 19 - 413

Printed in U.S.A.

01 REV. 5/90

M4.3 - 19 - 413

MAINTENANCE Accessory To perform an accessory function, all electrical interlock conditions must be satisfied and switches monitoring main lift chain status must indicate status okay. These conditions are covered in the first chart. The following charts then provide conditions as required for each function.

2451S

ILLUSTRATION 4.3-6

Crown 1988 PF-8193-15 Rev. 5/90

Printed in U.S.A.

01 REV. 5/90

M4.3 - 19 - 414

MAINTENANCE Signal CHS-1 CHS-2 CHS-4 CHS-5 DMS-1 * DMS-2 * DMS-3 * DMS-4 * DMS-5 GATE SES

l/O I I I I I I I I I I I

Test Point CA520-7 CA520-6 CA520-4 CA520-3 CA521-5 CA519-7 CA521-8 CA520-5 CA522-5 CA522-7 CA514-8 CA515-3

Condition - Lift chain not slack or broken - Lift chain not slack or broken - Lift chain not broken - Lift chain not broken - Palm button depressed - Pedestal pedal released - Pedestal pedal released - Floor pedal depressed - Floor pedal depressed - Gates closed - Operator standing - Operator seated - Operator standing - Operator seated

Voltage 0 0 0 0 0 12 12 0 0 0 36/48 0 0 36/48

* = Switch status given relates to operator standing TPL: CA519, CA520, CA521, CA522 - Resistor pull-up on platform electronics box. CA514, CA515 - Platform distribution board. CHART 4.3-8 PIVOT The electronics box looks for the closure of switch PTS to energize contactor P3 and start the accessory pump motor. Mechanical linkage from the lever to the valve controls the direction and speed of pivot. Before pivot can be performed, the forks must be retracted as indicated by FHSL and FHSR. Signal PTS FHSL FHSR SV11 P3

l/O I I I O O

Test Point CA521-6 CA521-2 CA521-7 TB528-12 P3 COIL

Condition - Pivot control lever moved from neutral - Left fork “home” - Right fork “home” - Attempting pivot - Attempting pivot

Voltage 0 0 0 36/48 36/48

TPL: CA521 - Resistor pull-up on platform electronics box. TB528 - Pivot and traverse spool valve mounting plate on platform wall. P3 COIL - Contactor panel on power unit rear wall. CHART 4.3-9

Crown 1988 PF-8193-16 Rev. 5/90

M4.3 - 19 - 415

Printed in U.S.A.

01 REV. 5/90

M4.3 - 19 - 415

MAINTENANCE TRAVERSE - FORK EXTEND/RETRACT For both traverse and fork extend/retract, the electronics box looks for contact closure of switch TVSL or TVSR to energize contactor P3 and start the accessory pump motor. Speed and direction of the function is controlled by movement of the traverse lever through mechanical linkage between the lever and spool valve. To go from the traverse function to the fork extend function, the traverse mechanism must be at its mechanical limit and Signal TVSL

l/O I

Test Point CA520-8

TVSR

CA522-2

PLS

CA519-3

PRS

CA519-2

TLS

CA519-1

TRS

CA522-1

FHSL FHSR FLS FRS SV10

I I I I O

CA521-2 CA521-7 CA522-3 CA522-6 TB528-11

SV4 & SV5 P3

O O

TB528-10 P3 COIL

the forks pointed in the proper direction. To extend when traversed left, the forks must be pivoted left and to extend when traversed right, the forks must be pivoted right. Extending and retracting when traversed right, pivoted left requires solenoid SV10 to be energized. When the forks are retracted as indicated by the fork “home” switches FLS and FRS, the hydraulic circuit is changed automatically to provide the traverse function.

Condition - Lever in neutral or traverse right position - Lever moved for traverse left - Lever in neutral or traverse left position - Lever moved for traverse right - Forks out of left “home” - Forks “home” left - Forks out of right “home” - Forks “home” right - Traverse mechanism out of “home” left - Traverse mechanism “home” left - Traverse mechanism out of “home” right - Traverse mechanism “home” right - Left fork “home” - Right fork “home” - Left fork “home” - Right fork “home” - Attempting extend right - Attempting extend left - Attempting extend - Attempting traverse-fork extend/retract

Voltage 12 0 12 0 12 0 12 0 0 12 0 12 0 0 0 0 0 36/48 36/48 36/48

TPL: CA519, CA520, CA521, CA522 - Resistor pull-up on platform electronics box. TB528 - Pivot and traverse spool valve mounting plate on platform wall. P3 COIL - Contactor panel on power unit rear wall. CHART 4.3-10

Crown 1988 PF-8193-17 Rev. 1/94

M4.3 - 19 - 416

Printed in U.S.A.

03 REV. 1/94

M4.3 - 19 - 416

MAINTENANCE WIRE GUIDANCE The Wire Guidance System automatically steers the lift truck down the aisle without the use of guide rails. A set frequency (5.2KHZ, 6.25KHZ, 7.0KHZ, 10KHZ ) is transmitted through wire embedded in the floor down the middle of each aisle.

Sensor bars mounted on the centerline of both ends of the truck, near the floor, contain coils which act as antennas to receive the transmitted signal. The closer a coil gets to being directly over the wire, the higher the amplitude of signal received by the coil. Using the coil signal amplitude comparisons, the truck will “sense” the signal path. With this data, steering is electronically controlled to follow the signal. However, the peak value (reading) seen by each sensor in the same bar must be within 15% of each other. Coil construction tolerances, steel structure of truck, floor conditions; may each effect the signal readings. Differences of more than 15% indicate a deteriorating coil or amplifier channel. A guidance selector switch (GUS) in the switch panel on the truck selects manual or automatic steering. When in the manual mode, truck steering is controlled by the operator. Steering remains in the operator’s control when switching to automatic until the guidance signal is detected. When the guidance signal is detected, steering control is automatically changed to the guidance system.

1552S

ILLUSTRATION 4.3-1

The Line Driver generates the signal which is transmitted through the embedded wire, as shown in Illustration 4.3-2.

1553S

To align a truck to the wire guide signal, the approach angle must be within 30° and traction speed must be below 1.8 MPH. The brakes are automatically applied when the approach angle and/or approach speed are not within limits, when in the automatic mode.

ILLUSTRATION 4.3-2

1554S

ILLUSTRATION 4.3-3

Traction speed is limited to 1.5 MPH in the automatic mode until the truck is aligned with the wire. When aligned, the acquisition speed limit is removed and the applicable speed vs. height curve will be in force.

5105 Crown 1988 PF-8195-1 Rev. 8/96

Printed in U.S.A.

05 REV. 8/96

M4.3–19.0–500

MAINTENANCE

1555S

ILLUSTRATION 4.3-4

The wire guidance components mounted on the truck are shown in Illustration 4.3-4. The truck’s manual steering components are also shown. When the truck is powered-up and no steering faults are present, the power unit electronics box outputs a signal to energize the steering contactor “S”. When energized, battery voltage is connected to the steering motor control (MRC-3). If the guidance selector switch (GUS) is in the “manual” position, or in the “automatic” position and not near a guidance signal, the operator has steering control. When the truck is driven with guidance selector switch (GUS) in the “manual” mode, the alarm will “beep” and the “manual “ indicator will flash at a rate of approximately 1/4 second “on” and 2 seconds “off” when the guidance signal is not detected. If the guidance signal is detected by the load wheel or steered wheel sensors, the alarm and indicator rate will increase to approximately 1/4 second “on” and 1/2 second “off”. Each sensor bar contains four (4) coils which act as separate antennas. When the amplitude of guidance signals received are compared, the higher amplitude signals are from the coils in closer proximity to the embedded wire. The sensors mounted on the truck, electronically “senses” where the truck is in reference to the guidance signal. When guidance

selector switch (GUS) is in the “automatic” mode, the electronics box outputs signals to MRC-3 which provides the correct polarity and amplitude of voltage to the steering motors to keep the truck centered over the guidance signal. Feedback from the steering feedback encoder (ECR-5) verifies steered wheels are turned in the direction and at the speed required. Whenever the guidance signal strength drops to near the minimum required to guide the truck, the platform electronics box outputs a signal to illuminate the signal strength light (LGT-9). The power unit electronics box sends the signal to the traction SCR control for 1.5 MPH maximum traction speed. If signal strength comes back, the signal strength indicator is turned off and the traction speed limit is removed. If there is loss of the guidance signal, or if signal strength is below the minimum required to guide the truck, the platform electronics box will output signals to operate the alarm continuously, turn the “automatic” indicator off and turn the “manual” indicator on. The power unit electronics box removes the signal from K4 which removes power from SV6 and SV7 and the brakes are applied. Feedback to the power unit electronics box from BRS-6 and BRS-7 verify brakes are applied. Guidance selector switch (GUS) must be placed in the “manual” position to release the brakes.

Crown 1988 PF-8195-2 Rev. 9/92

Printed in U.S.A.

02 REV. 9/92

M4.3 - 19 - 501

MAINTENANCE OPERATION MODES MANUAL When the guidance selector switch (GUS) is in the “manual” position, truck steering is in the operator’s control. The alarm and manual indicator light operate at a rate of approximately 1/4 second on and 2 seconds off when the guidance signal is not detected by the sensor bars. The alarm and indicator will operate at a rate of approximately 1/4 second “on” and 1/2 second “off” when either sensor bar detects the guidance signal. In both instances steering control is manual and speed is limited by the applicable speed curve. AUTOMATIC When the guidance selector switch (GUS) is placed in the “automatic” position, the electronics enter the Search mode. The alarm operates 1 second to indicate status change. At this time the guidance signal has not been detected by the sensors. The “auto” and “manual” indicators are both on and traction speed is limited to 1.5 MPH. Steering control remains in the manual mode. When either sensor bar detects the guidance signal, Acquisition mode will be indicated by a 1 second operation of the alarm. If traction speed at this time is greater than 1.5 MPH or the angle of the truck to the wire is greater than 40°, the brakes will be applied. To release the brakes, guidance selector switch (GUS) must be placed in the manual position. If the angle and speed of the truck are within the limits when the signal is detected the manual indicator is turned off and steering is controlled by the electronics. Traction speed is still limited to 1.5 MPH. The electronics will align the truck with the guidance signal and when the truck is within 3/4" and/or 1° of angular alignment, Auto Tracking mode is indicated by a 1 second operation of the alarm. In this mode the truck is automatically guided by the electronics and after 5 seconds the traction speed limit is removed.

Three (3) variations to normal operation are encountered during the Auto Tracking mode: 1 ) Auto Field Strength; 2) Auto Track Deviation; 3) Auto Wire Lost. Auto Field Strength variation is encountered when the guidance signal received by the sensors decreases to near the minimum required to continue Auto Tracking Mode. When entering Auto Field Strength the alarm is sounded for 1 second, the field strength indicator is turned on and traction speed is limited to 1.5 MPH. When the guidance signal received returns to above minimum levels the alarm is sounded for 1 second, the field strength indicator turned off and the speed limit removed. Auto Track Deviation is encountered if the center of the truck leaves the guidance signal between .75 - 1.25 inches or 1 1.5 degrees. When this happens the alarm is sounded at a rate of approximately 1/8 second on and 1/8 second off, manual steering indicator is turned on and traction speed is limited to 1 MPH. When the truck returns to acceptable tracking characteristics, the alarm is sounded for 1 second, the manual steering indicator is turned off and the traction speed limit is removed. Auto Wire Lost will occur if one or more of four (4) situations are present; 1) guidance signal lost; 2) centerline of truck leaves signal path is more than 1.25 inches; 3) angle of truck to guidance signal is more than 1.5 degrees; 4) steer wheels are turned more than 5 degrees during Auto Track. When in Auto Wire Lost, the alarm is operated continuously, the manual indicator flashes 1/8 second on and 1/8 second off, brakes are applied and truck steering is controlled by the operator. Guidance selector switch (GUS) must be placed in the “manual” position to release the brakes after this situation occurs.

Crown 1988 PF-8195-3 Rev. 9/92

Printed in U.S.A.

02 REV. 9/92

M4.3 - 19 - 502

MAINTENANCE SENSORS The sensor bars are fastened to adjustable brackets which permit adjusting the distance between the sensor bars and the floor. When the line driver current output is set to 220 ma., the sensor mounting surface of the adjustable bracket should be within 4.25 - 4.38 inches (108 - 111mm) from the floor. This tolerance must be set on each end of the adjustable bracket.

Components which affect wire guidance calibration include the front and rear sensor bars, two (2) sensor amplifier printed circuit boards in the power unit electronics box, the CPU card of either electronics box, the steering servo amplifier and the steering angle feedback encoder (ECR-5). Whenever any of these components are changed or adjusted, the wire guidance system must be calibrated. Wire guidance calibration consists of four (4) parts: 1 ) Peak sensor coil search; 2) Center wheel position; 3) Vehicle angle; and 4) X-offset position. Peak sensor coil search determines the maximum coil value of each coil when passed over an active guide wire. The maximum values are compared and each channel is given a value to be multiplied by so all coils will appear equal (at least 95). This is electronic correction for weak coils.

1556S

ILLUSTRATION 4.3-5

The adjustable bracket has a cutout in the center of the sensor bar mounting surface for the wire harness connector. The connector is off center to the mounting holes which permit the sensor bar to be mounted only one way. The sensor bar connector must face up.

Steer wheel position calibration determines the steer wheel center position which will provide straight line travel. Vehicle angle calibration determines angular deviation of the truck assembly which would cause “dog-tracking”. X-offset position calibration positions the mechanical center of the truck over the guidance signal. To perform the wire guidance calibration procedures, the Service Terminal must be used. Refer to the Service Terminal Instruction Book for a detailed step by step procedure. TROUBLESHOOTING Components concerned only with wire guidance are functionally checked by the software diagnostics and are covered by five (5) Service numbers.

1557S

ILLUSTRATION 4.3-6

Voltage required by the sensor bar to operate is 5 volts, isolated between terminals 5 (positive) and 3 (negative). CALIBRATION Wire guidance calibration sets up components of the wire guidance system to guide the truck automatically while centered over the signal wire embedded in the floor. It is important to calibrate the truck at the installation with the highest field reading. If the truck has been calibrated on wire at the lowest strength, on wire with a higher strength, the system can become saturated and allow the truck to weave as much as the length of the sensor bar.

SERVICE #66— Checks if the guidance sensor coil voltages are less than 0.47V. Location: power unit Fault type: latched Functions disabled: traction Brake status: applied Tested: during normal run time Probable cause: faulty sensor amplifier card, bar or cabling, latch-up of guidance logic encountered when wire guidance is selected just prior to system detecting wire while traveling

Crown 1988 PF-8195-4 Rev. 1/94

Printed in U.S.A.

03 REV. 1/94

M4.3 - 19 - 503

MAINTENANCE SERVICE #67— Checks during guidance selftest if the steer wheel sensor amplifier card coil voltages are less than 0.47V. Checks during normal guidance run if the A/D conversion does not complete. Location: power unit (steer wheel sensor amplifier card) Fault type: latched Functions disabled: traction Brake status: applied Tested: during guidance selftest and normal run time Probable cause: faulty steer wheel sensor amplifier card

Two (2) conditions can exist which will cause unsatisfactory wire guidance performance by not tracking properly: 1) Incorrect feedback information from the steering feedback assembly; and 2) Saturated sensor bar coils.

SERVICE #68—Checks during guidance selftest if the load wheel sensor amplifier card coil voltages are less than 0.47V. Checks during normal guidance run if the A/D conversion does not complete. Location: power unit (load wheel sensor amplifier card) Fault type: latched Functions disabled: traction Brake status: applied Tested: during guidance selftest and normal run time Probable cause : faulty load wheel sensor amplifier card

A spring between the encoder retainer and the locating pin takes up any tolerance between the retainer locating slot and the locating pin.

SERVICE #69— Checks if the steer wheel sensor bar coil voltages are less than 0.47V. Location: power unit (steer wheel sensor bar) Fault type: latched Functions disabled: traction Brake status: applied Tested: during guidance selftest Probable cause: faulty steer wheel sensor bar or cable

The incorrect feedback information in the FIRST condition can occur if the wheels move slightly without turning the encoder input shaft. Encoder body movement, improper belt tension or loose pulley screws will cause this condition. Also included in the improper feedback category is the use of the wide index of the encoder rather than the narrow index.

1558S

ILLUSTRATION 4.3-7

One set screw in the pulley is seated against the shaft 90 degrees from the other. Make certain these set screws are tight on both pulleys.

SERVICE #70— Checks if the load wheel sensor bar coil voltages are less than 0.47V. Location: power unit (load wheel sensor bar) Fault type: latched Functions disabled: traction Brake status: applied Tested: during guidance selftest Probable cause: faulty load wheel sensor bar or cable In each instance all traction is disabled and the brakes are applied. Service conditions 67, 68, 69 and 70 are tested during guidance selftest. Guidance selftest is performed each time the truck is powered up and each time the guidance selector switch (GUS) is placed in the “automatic” position.

1559S

Crown 1988 PF-8195-5 Rev. 1/94

ILLUSTRATION 4.3-8

Printed in U.S.A.

03 REV. 1/94

M4.3 - 19 - 504

MAINTENANCE Belt tension is automatically set when the mounting bracket locking screws are loosened. The spring at one end of the mounting bracket, pushes the mounting bracket to provide the proper belt tension. When belt tension is set, tighten the locking screws. PIVOT PLATE LOCKING SCREW

LINKAGE ARM

90° 90°

The flat on the encoder shaft will be facing within the 90 degrees shown in Illustration 4.3-9. When the flat on the shaft is facing the correct direction, remove cover from the power unit electronics box and power up truck. Loosen the pivot plate locking screw on the feedback assembly and move back and forth until green indicator light (SC) on the digital card is “on”. Tighten locking screw to secure adjustment while making certain green indicator remains “on”. If all electronics components check okay, the manual steering mode of operation should be providing satisfactory performance. Refer to the steering portion of the M4.3-19400 section in this manual for voltage checks and test points.

ECR-5

2747

NOTE

TB613 LEVER ARM

MOUNTING BRACKET LOCKING SCREWS

When dowels are in the notches, the steered wheels are straight ahead.

FLAT ON ENCODER SHAFT

ILLUSTRATION 4.3-9

The setting of the encoder is correct when the steered wheels are in the straight ahead position. When in the straight ahead position the lever arm on the bottom of the assembly will be at a 90° angle with the truck frame member the assembly is mounted on. To assure steered wheels are in the straight ahead position, raise steer wheels clear of the floor, block frame and power up truck. Disconnect coil wire from steering contactor (S) and insulate wire terminal. Insert a 1/2" diameter wooden dowel through the power unit skirt next to the drive units and into a notch in the flange below the steering gear. Steering linkage may have to be manually positioned to allow for dowel pin insertion. If only one dowel pin will fit, refer to section M6.0-19.0-001 for steering linkage adjustment.

To check if the coils in the sensor bars are saturated as stated in the SECOND condition, with truck centered over the guide wire, use the Service Terminal to check the RAW values of each coil as described in the SHOW-8 mode of operation in the Service Terminal Instruction Book. The outboard sensor raw and scaled values will be substantially lower than the inboard sensor values, due to signal appearance. When each individual coil is directly over the guide wire (see Service Terminal Operator Book for determining when a coil is directly over the guide wire) and the RAW values are above 90%, the sensor bar should be raised to bring the RAW values into the 70% to 80% range. Typically this will not be required since the sensor height described earlier in this section is correct for a line amplitude, measured with a field strength meter (112953), of 220 ma of current. Keep the bracket height from side to side within 1/8" (3 mm). Power down truck. Remove dowel pins and connect coil wire to steering contactor (S).

1561S

ILLUSTRATION 4.3-10

Crown 1988 PF-8195-6 Rev. 6/95

Printed in U.S.A.

04 REV. 6/95

M4.3–19.0–505

MAINTENANCE 114393 CONTACTOR EMER. DISCONNECT (ED1) PUMP (P1, P2, P3 )

1525P

ILLUSTRATION 4.4-1 The purpose of these instructions is to instruct the user on proper care and maintenance to obtain satisfactory service from these devices. Crown has tested and applied these contactors according to the requirements of our vehicle. No modifications or changes should be made in the layout, physical arrangement or electrical connections without permission from Crown. 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 these contactors; disconnect battery, raise drive wheels clear of floor and place blocks under truck frame. Inspection The following information is intended to assist during periods of normal maintenance and to provide checks for maintaining adjustments. As these devices are tested and adjusted at the factory, they should not normally require further adjustments. However, if factory adjustments are tampered with or otherwise changed, the checks contained in the following information may be made. Crown 1992 PF-9494-1

M4.4 - 19 - 105

CONTACTS In normal operation, the contacts will become blackened, discolored, and roughened. This will not interfere with proper operation and cleaning is not necessary. The contacts should be replaced before the silver contact facing is completely eroded through to the backing material. The silver contact facing may transfer to either the moving or stationary contact and cause buildup on one contact. This can be expected under certain conditions and does not require contact dressing or filing. It is recommended that contacts always be replaced in mating pairs. Use inspection mirror to inspect contacts to rear of the contactor. COIL Remove all electrical connections. Resistance reading of the coil should be between 90 - 105 ohms. If reading does not fall within the limits, replace. SUPPRESSOR A visual inspection for cracked or broken potting material is necessary. Cracked or broken potting material indicates a faulty suppressor. Printed in U.S.A.

M4.4 - 19 - 105

MAINTENANCE Component Replacement Refer to parts breakdown in Illustration 4.4-2 when replacing components. CONTACT REPLACEMENT 1. Remove electrical connections to contacts (coil does not have to be disconnected for this procedure). 2. Remove one (1) hex locknut (Index 16) from bridge and four (4) screws (Index 17) from bus bars. 3. Lift contact assembly from truck. Replace contacts as necessary. 4. Place contact assembly on mounting block and secure bus bars (Index 10) with four (4) screws (Index 19) . 5. Secure bridge (Index 13) with one (1) hex locknut (Index 16) . 6. Reconnect electrical wiring.

14 13

12 8 7 6 21 22 4 5

COIL REPLACEMENT 1. Disconnect all electrical wiring. 2. Remove three (3) mounting bolts from mounting bracket and lift entire contactor from truck. 3. Remove one (1) hex locknut (Index 16) with bridge (Index 13). 4. Remove four (4) screws (Index 17)and bus bars (Index 10). 5. Remove two (2) hex locknuts (Index 16) with spacers (Index 11) . Separate contact assembly from coil assembly. 6. Remove four (4) torx head screws with washers (Indexes 21and 22 ) from sides of mounting brackets which hold coil. 7. Select replacement coil and fasten in place, using four (4) torx head screws with washers (Index 21and 22)on mounting brackets.[Must be torqued to 25 pound-inches]. 8. Transfer armature from coil being replaced to replacement coil. Reassemble. Fasten with two (2) hex locknuts with spacers (Indexes 16 and 11). 9. Reassemble contact assembly to coil assembly and secure with four (4) screws (Index 19) on bus bars, and with one (1) hex locknut (Index 16) on bridge. 10. Mount contactor on truck and reconnect all electrical wiring.

19 20

16 11 17 18

3 2 1 1518

Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Part Name Base O-Ring Coil 48V (Suppressor Incl.) Frame Upper Brackets Mounting Insulator Lower Spring Armature Plate Mounting Bar Bus Spacer Bushing Bridge Spring Washer Fiber Locknut Screw 5/16" Lockwasher Screw #8 Lockwasher Screw Flatwasher ILLUSTRATION 4.4-2

Crown 1992 PF-9494-2

M4.4 - 19 - 106

Printed in U.S.A.

M4.4 - 19 - 106

MAINTENANCE LEFT HAND CONTROL ASSEMBLY ADJUSTMENTS

Raise/Lower Encoder (ECR-2)

For adjustments to the traverse and pivot controls, refer to M2.5 section of manual. Adjustments to the steering tiller assembly are described in the M6.0 section of this manual.

1. Chock wheels.

Raise/Lower Control Lever

3. Power up truck. Connect digital meter to TB526-6 (positive) and TB526-9 (negative).

The control lever is automatically centered in the slot. If the lever does not have free movement back and forth in neutral, spring adjustment is not necessary. If the lever does have free movement, adjust as follows:

2. Remove cover back of the control assembly.

NOTE When the encoder index is present, the meter reading will be approximately 5 volts dc. When the index is not present, the meter reading will be near zero volts.

1. Disconnect battery and chock wheels. 2. Remove cover behind control assembly. 3. Loosen torsion spring adjusting bar mounting screws slightly and move adjusting bar to remove any free movement of the control lever.

3784S

3785S

ILLUSTRATION 4.5-1

4. Tighten adjusting bar mounting screws. NOTE If torsion spring adjusting bar was moved, the encoder (ECR-2) should be adjusted to maintain satisfactory performance.

ILLUSTRATION 4.5-2

4. Loosen adjustment locking screw. Move adjustment retainer back and forth until encoder index is found (meter reading of approximately 5 volts). 5. When in the index, move adjustment retainer back and forth to determine width of the index. Position adjustment retainer in center of index and tighten locking screw. 6. Move control lever to the maximum raise position and release. Make certain meter reading goes to near zero volts when control lever is in the maximum position and returns to 5 volts when returned to neutral. Repeat check moving control lever to maximum lower position. 7. Install cover and remove wheel chocks.

4699 Crown 1989 PF-8256-1 Rev. 5/95

M4.5–19.0–050

Printed in U.S.A.

01 REV. 5/95

M4.5–19.0–050

MAINTENANCE ASSEMBLY REMOVAL/INSTALLATION When replacing components in the control lever assemblies, remove the left hand assembly form the truck and place on work bench. Then refer to the individual component replacmenet procedures. Replacing components in the steering tiller assembly (Steering Encoder and Indicator Lights) and auxiliary switch (AXS) in the raise/lower control can be performed with the assembly in the truck. Removal 1. Disconnect battery and chock wheels. 2. Remove cover (pencil tray) behind left hand assembly. 3. Disconnect wires of cable number 3 and cable number 4 from TB526 and TB527.

3783S

ILLUSTRATION 4.5-3

5. Connect wires in cable number 4 as shown in Illustration 4.5-4.

4. Disconnect wires 5906, 5919, 5920, 5921 and 506 from TB527 if applicable. 5. Disconnect wires going to pivot and traverse switches from TB527, if applicable. 6. Disconnect ball joints of linkage arms at pivot point on valve plate. 7. Hold assembly and remove two (2) mounting bolts. 8. Place assembly on work bench and refer to component replacement. Installation 1. Position assembly on truck and secure in place with two (2) mounting screws.

3782S

ILLUSTRATION 4.5-4

6. Connect wires to TB527 as shown in Illustration 4.5-5 if applicable.

2. Connect linkage arms to pivot points on valve plate. 3. If control levers are not centered in the slot of the housing, loosen locknuts at both ends of rod and turn rod to center levers. Tighten locknuts to secure adjustment. 4. Connect wires in cable number 3 as shown in Illustration 4.5 3.

3781S

ILLUSTRATION 4.5-5

7. Make adjustments, if applicable, to raise/lower encoder (ECR-2). 8. Install cover, remove wheel chocks and connect battery. Crown 1989 PF-8256-2 Rev. 5/95

M4.5–19.0–051

Printed in U.S.A.

01 REV. 5/95

M4.5–19.0–051

MAINTENANCE COMPONENT REPLACEMENT 8. Remove cotter pin and loosen set screw at end of steering tiller shaft, by the encloder, and pull encoder from the shaft.

Steering Encoder (ECR-1) NOTE Four (4) ring tongue terminals (Crown No. 062007-065) are required when replacing encoder.

9. Transfer the retainer (index 23) from the encoder being replaced to the replacement encoder.

1. Disconnect battery and chock wheels. 2. Remove cover (pencil tray) behind left hand controls. 3. Remove cover on steering tiller post. 4. Disconnect encoder leads from TB526-1 thru -4. 5. Remove bolt (index 39, Illustration 4.5-6) and pull bracket (index 38) from housing.

10. Inser encoder shaft in tiller shaft, aligning holes for cotter pin and making certain slot in retainer is positioned over locating pin (index 21). Install cotter pin and tighten set screw. 11. Insert steering assembly into housing, encoder leads first. Opening in sleeve (index 18) must be towards opening in tiller housing post. Route encoder leads to TB526. 12. Install friction block shaft and washers in sleeve. 13. Slide spring over friction block shaft and position bracket over shaft with spring. Install mounting bolt. 14. Install ring tongue terminals (Crown no. 62007-65) on encoder red, white, orange and black leads. Cut the exposed wire from the blue lead and insulate to avoid short circuiting. 15. Connect leads to TB526 as shown in Illustration 4.5-7.

3801S

ILLUSTRATION 4.5-6

3780S

6. Remove spring (index 37) and pull friction block, with shaft (index 34 and 35), from housing.

ILLUSTRATION 4.5-7

16. Install covers, remove wheel chocks and connect battery.

7. Lift steering tiller to pull steering assembly from housing.

Crown 1989 PF-8256-3 Rev. 5/95

M4.5–19.0–052

Printed in U.S.A.

01 REV. 5/95

M4.5–19.0–052

MAINTENANCE 10. Feed light panel leads through housing to TB527 and connect as shown in Illustration 4.5-9.

Steering Indicator Lights 1. Disconnect battery and chock wheels. 2. Remove cover from steering tiller post and cover behind left hand controls. 3. Disconnect indicator light panel leads from TB527-6 thru -9. 4. Remove screws (index 30, Illustration 4.5-8) from light panel mounting bracket (index 29).

3779S

ILLUSTRATION 4.5-9

11. Install covers, remove wheel chocks and connect battery. Pivot and Traverse Control Levers 1. Remove left hand assembly from truck as described earlier in this section. 2. Remove terminal board mounting screws (index 26, Illustration 4.5-10) and move terminal boards (index 24, 25) to the side. 3. Remove grommets from housing around control levers. 4. Remove three (3) screws from under housing which hold the control lever mounting plate (index 29, Illustration 4.5-10).

3802S

ILLUSTRATION 4.5-8

5. Lower mounting bracket and pull bracket, light panel and leads from the housing. 6. Remove light panel mounting screws (index 27). Note indicator orientation for correct installation of replacement panel. 7. Position replacement light panel on mounting bracket and secure in place with mounting screws. 8. Position mounting bracket in housing and install mounting screws: Do not tighten screws at this time. 9. Carefully move bracket up until all lights are touching the display. Tighten mounting screws.

3803S

Crown 1989 PF-8256-4 Rev. 5/95

M4.5–19.0–053

ILLUSTRATION 4.5-10 Printed in U.S.A.

01 REV. 5/95

M4.5–19.0–053

MAINTENANCE 5. Pull mounting plate with control levers from housing.

7. Snap knob cover in place.

6. Remove linkage arm (index 16) from lever to be replaced.

8. Remove wheel chocks and connect battery.

7. Remove snap ring (index 18) from end of shaft (index 19) with control lever to be replaced. 8. Slide shim washers and control lever from shaft. 9. Install bushings in replacement control lever and slide lever onto shaft. 10. Add shim washers to shaft to remove any lateral movement yet allows handle to move freely. Install retaining ring. 11. Secure linkage arm to control lever. 12. Assemble mounting plate to housing. Secure in place with mounting screws. 13. Fasten terminal boards to mounting plate. TB526 is index 24, Illustration 4.5-10. 14. Install grommets in housing around control levers. 15. Transfer knob cover (index 6) and side covers (index 7, index 8) from lever being replaced to replacement lever. 16. Install assembly in truck as described earlier in this section. Auxiliary Switch (AXS)

Raise/Lower Control Lever Assembly To replace the raise/lower control lever, torsion spring or encoder (ECR-2), the control lever must be removed from the housing. The following steps describe the procedure for removing and installing the control lever assembly. Once removed, refer to individual component replacement for procedure. REMOVAL 1. Remove left hand control assembly as described earlier in this section. 2. Disconnect encoder (ECR-2) wires from TB526-5 through -9. Disconnect auxiliary switch (AXS) from TB527-4 and TB527-5. 3. Remove grommet from housing around control lever. 4. Remove two (2) screws from bottom of housing holding lever assembly. 5. Pull lever assembly from housing. INSTALLATION 1. Position assembly in housing and secure in place with mounting screws.

1. Disconnect battery and chock wheels.

2. Install grommet in housing around control lever.

2. Insert flat blade screwdriver in screwdriver slot of raise/ lower lever knob and turn to remove cover.

3. Connect green wire from auxiliary switch (AXS) to TB5275. Connect green stripe/white wire from AXS to TB527-4. 4. Connect encoder (ECR-2) wires as shown in Illustration 4.5-12.

3778S

ILLUSTRATION 4.5-11

3. Use soldering iron to remove wires from switch. 4. Remove two (2) switch mounting screws and lift switch from knob. 5. Position replacement switch in knob and secure with mounting screws. 6. Solder wires to the switch normally closed (N.C.) terminals.

3782S

5. Install assembly in truck as described earlier in this section. 6. Adjust encoder as described in Adjustment.

Crown 1989 PF-8256-5 Rev. 5/95

M4.5–19.0–054

ILLUSTRATION 4.5-12

Printed in U.S.A.

01 REV. 5/95

M4.5–19.0–054

MAINTENANCE ENCODER 1. Remove raise/lower control lever assembly as described in Removal. 2. Loosen set screw (index 43, Illustration 4.5-13) and pull encoder from shaft.

3767S

ILLUSTRATION 4.5-13 3766S

3. Transfer retainer (index 50) from encoder being replaced to replacement encoder. 4. Insert encoder shaft into pivot shaft (index 42), aligning flat on encoder shaft with set screw in pivot shaft. Set screw must seat against flat on encoder shaft. Pin on alignment bracket (index 48) must locate in notch of retainer. 5. When encoder shaft is fully inserted, tighten set screw. 6. Install raise/lower control lever assembly as described in Installation. TORSION SPRING

ILLUSTRATION 4.5-14

5. Remove spring retainer (index 38) and spring collar (index 36). Remove torsion spring. 6. Work grease (Crown no. 63002-25) into coils ~f replacement spring. 7. Make certain inside spring collar (index 36) is in place on control lever. Slide torsion spring onto control lever, positioning spring ends on roll pin (index 35) as shown in Illustration 4.5-14. 8. Place outside spring collar (index 36) and spring retainer (index 38) in position.

When replacing torsion spring, have grease (Crown no. 63002-25) available to lubricate replacement spring. 1. Remove raise/lower control lever assembly as described in Removal. 2. Loosen set screw (index 43, Illustration 4.5-14) and pull encoder from pivot shaft.

NOTE For ease of assembling, place mounting bracket in bench vise sideways. As pivot shaft is inserted from the bottom the shim washers and control lever can be aligned using a screwdriver or other tool.

3. Remove screw (index 33) from control lever and pivot shaft. 4. Slide pivot shaft (index 42) from assembly and lift lever from mounting bracket (index 44).

Crown 1989 PF-8256-6 Rev. 5/95

M4.5–19.0–055

Printed in U.S.A.

01 REV. 5/95

M4.5–19.0–055

MAINTENANCE 9. Assemble control lever and shim washers to the mounting bracket with the pivot pin. Shim washers are used to remove any side to side movement of the control lever, yet allows free movement of the control lever.

5. Transfer spring retainer (index 38), spring collars (index 36) and torsion spring (index 37) from control lever being replaced to replacement control lever. NOTE

11. Align flat on encoder shaft with set screw in pivot shaft. Slide encoder shaft into pivot shaft making certain pin on alignment bracket (index 48) is in notch of encoder retainer. Tighten set screw. 12. Install raise/lower control lever assembly as described in Installation.

For ease of assembly, place mounting bracket in bench vise sideways. As pivot shaft is inserted from bottom, the shim washers and control lever can be aligned using a screwdriver or other tool.

13. Adjust the control lever and encoder as described in Adjustments.

6. Assemble control lever and shim washers to the mounting bracket with the pivot pin. Add shim washers as necessary to remove any side to side movement of the control lever yet permits free movement.

CONTROL LEVER

7. Install screw through control lever and into pivot shaft.

1. Remove raise/lower control lever assembly as described in Removal. 2. Loosen set screw (index 43, Illustration 4.5-15) and pull encoder from pivot shaft. 3. Remove screw (index 33) from control lever and pivot shaft. 4. Slide pivot shaft (index 42) from assembly and lift lever from mounting bracket (index 44).

8. Align flat on encoder shaft with set screw in pivot shaft. Slide encoder shaft into pivot shaft making certain pin on alignment bracket (index 48) is in notch of encoder retainer. Tighten set screw. 9. Insert blade of flat blade screwdriver into screwdriver slot of knob on control lever being replaced and turn to remove knob cover. 10. Place thumb on side cover and depress button completely. Lift side cover, springs and button from knob. Set aside. 11. Remove switch mounting screws. Lift switch from knob while pulling wires from control lever. 12. Feed switch wires through replacement lever and fasten switch to knob. 13. Place thumb on side panel and depress button to hold springs in position. Install in replacement knob. When button is released make certain switch is held actuated. 14. Snap knob cover in place. 15. Install raise/lower control lever assembly in housing as described in Installation. 16. Adjust control lever and encoder as described in adjsutment.

3766S

ILLUSTRATION 4.5-15

Crown 1989 PF-8256-7 Rev. 5/95

M4.5–19.0–056

Printed in U.S.A.

01 REV. 5/95

M4.5–19.0–056

MAINTENANCE STEERING FEEDBACK ASSEMBLY Adjustments required for the steering feedback assembly when components are not replaced are covered in detail in M4.0 Encoder section of this manual.

1 2 3

When replacing components on the steering feedback assembly, remove assembly from truck. Following are the removal and installation procedures. Removal

4 5 TB613 2763

1. Disconnect battery and chock wheels. 2. Open power unit doors. Open swing out electrical door. 3. Loosen four (4) cover mounting bolts. while lifting cover, work grommet with cable from slot in cover. 4. Disconnect cable wires from TB613. 5. Slide keeper on ball joint of lever arm back to disconnect ball joint.

RED BLUE ORANGE WHITE BLACK

ILLUSTRATION 4.5-1

5. Remove cover from power unit electronics box. Power up truck. 6. Turn the steered wheels to the straight forward position so notch in top flange of drive units is aligned withholes in powerunitweldment. Disconnect coil wire from steering contactor (S)and insulate. Insert 1/2 " (12.7mm) diameter wooden dowels through hole and into notch of each drive unit as shown in Illustration 4.5-2.

CAUTION

A slight spring preload may be present on the lever arm. Use caution when disconnecting ball joint to avoid personal injury. 6. Remove the two (2) mounting bolts holding feedback assembly to frame cross member. 7. Lift feedback assembly from truck. Installation 1. When components have been replaced and encoder properly aligned, position feedback assembly on frame cross member with terminal board towards the battery compartment. 2. Secure assembly in position with mounting bolts. 3. Turn lever arm clockwise until spring tension begins. Slide keeper on ball joint back and connect to lever arm. Make certain keeper locks joint together.

2746S

ILLUSTRATION 4.5-2

7. With the steered wheels in this position, the narrow encoder index should be present as indicated by the green indicator (SC) on the digital card of the power unit electronics box. If SC is not “on”, loosen the pivot plate locking screw.

4. Connect wires in cable to TB613 as shown in Illustration 4.5-1.

Crown 1989 PF-8214-1 Rev. 1/94

M4.5 - 19 - 100

Printed in U.S.A.

02 REV. 1/94

M4.5 - 19 - 100

MAINTENANCE PIVOT PLATE LOCKING SCREW

COMPONENT REPLACEMENT

TB613 TIGHTENER SPRING Encoder LINKAGE ARM LEVER ARM

When replacing encoder it is recommended to have two (2) bearings (Crown P/N 065081-050) and at least five (5) ring tongue terminals (Crown P/N 062007-065) on hand.

90° 90° ECR-5 MOUNTING BRACKET LOCKING SCREWS 2747

FLAT ON ENCODER SHAFT

ILLUSTRATION 4.5-3

8. Move pivot plate back and forth until green indicator is “on”. Tighten locking screw to secure adjustment while making certain green indicator remains “on”. 9. Disconnect battery. 10. Remove wooden dowels and install cover on power unit electronics box. 11. Position cover over feedback assembly. Insert grommet with cable into slot of cover and secure cover. 12. Close electrical swing out door and secure in place. Close power unit doors and secure. 13. Remove wheel chocks and connect battery.

1. Remove feedback assembly from truck as described in REMOVAL procedures of this section. 2. Place assembly in bench vise. 3. Loosen mounting bracket locking screws and compress tightener spring with mounting bracket. Tighten locking screws. 4. Lift belt off and pull from around large pulley. 5. Disconnect encoder leads from TB613. 6. Loosen two (2) set screws in the small pulley on encoder shaft. 7. Lift encoder from mounting bracket. Upper bearing may stay on the encoder shaft. Remove set screw marks from encoder shaft and slide bearing from shaft. If bearing cannot be removed without force, discard and replace (Crown P/N 065081-050). 8. Inspect lower bearing for any tight spots and wear. If bearing does not move freely or shows signs of wear, replace. 9. Place upper bearing in mounting bracket. 10. Transfer the retainer and spring from encoder being replaced to replacement encoder. 11. Before sliding encoder into bearings, lightly use emery cloth on encoder shaft to remove any roughness making it difficult to slide shaft into bearings. 12. Slide encoder shaft through upper bearing until shaft sticks past bottom of plate. Slide flatwasher onto shaft and position belt so belt will be around the shaft when fully inserted.

Crown 1989 PF-8214-2

M4.5 - 19 - 101

Printed in U.S.A.

M4.5 - 19 - 101

MAINTENANCE 13. The bore of the small pulley is shaped so that one (1) set screw will be on the flat of the encoder shaft. Mark this set screw for future use. 14. Position pulley below flatwasher on encoder shaft and slide encoder shaft into pulley. Make certain belt is in position.

position and tighten locking screws. 21. Remove sleeving from encoder being replaced and install on replacement encoder. 22. Install terminals (Crown P/N 062007-065 )on encoder wires. 23. Connect encoder wires to TB613 as shown in

15. Before inserting shaft into lower bearing, position locating slot in retainer over locating pin. Make certain both ends of torsion spring are on same side of locating pin

1 2 3 4 5 TB613 2763

RED BLUE ORANGE WHITE BLACK

ILLUSTRATION 4.5-5

Illustration 45.-5. 24. Install feedback assembly in truck as described in the INSTALLATION procedures of this section. Belt 2748S

1. Remove feedback assembly from truck as described in REMOVAL procedures of this section.

ILLUSTRATION 4.5-4

(Illustration 4.5-4). Either side of locating pin is correct. 16. Fully insert encoder shaft in lower bearing. Lift pulley so flatwasher is close to, but does not touch, weldment and tighten set screws. 17. Position belt on both pulleys. Turn lever arm on bottom of assembly clockwise (when looking down on top of assembly) until spring tension is encountered.

2. Place assembly in bench vise. 3. Loosen mounting bracket locking screws and compress tightener spring with mounting bracket. Tighten locking PIVOT PLATE LOCKING SCREW

18. Continue turning lever arm clockwise until spring stop pins on lever arm and assembly weldment line up. Lever armshould be at a 90° angle to the left side of the assembly whepins are aligned. Hold lever arm in this position. 19. Turn pulley on encoder shaft so set screw on flat of encoder shaft is at the eleven (11) O’clock position (Illustration 4.5-6). 20. When aligned, loosen mounting bracket locking screws and allow spring to tighten belt. Make certain flay on encoder shaft is still facing the eleven (11) O’clock

90° 90° ECR-5 MOUNTING BRACKET LOCKING SCREWS 2747

Crown 1989 PF-8214-3 Rev. 1/94

M4.5 - 19 - 102

TB613 TIGHTENER SPRING LINKAGE ARM LEVER ARM

FLAT ON ENCODER SHAFT

ILLUSTRATION 4.5-6

Printed in U.S.A.

02 REV. 1/94

M4.5 - 19 - 102

MAINTENANCE Tighten locking screws.

screws. 4. Lift belt off and from around large pulley. 5. Loosen the two (2) set screws in the small pulley on the encoder shaft.

4. Loosen the two (2) set screws on large pulley. Pull l ever arm from assembly. 5. Remove retaining ring on end of tube.

6. Lift encoder from mounting bracket.

6. Lift flatwasher and spring collar from tube.

7. Remove belt.

7. Remove torsion spring.

8. Slide encoder shaft through upper bearing until shaft sticks past bottom of plate. Slide flatwasher onto shaft and position replacement belt so belt will be around encoder shaft when fully inserted.

8. Position replacement torsion spring on tube. Rotate spring counter-clockwise (looking at the bottom of the assembly) until spring end contacts stop pin.

9. Perform steps 13 thru 20 as described in ENCODER replacement of this section. 10. Install feedback assembly in truck as described in the INSTALLATION procedures of this section. Torsion Spring 1. Remove feedback assembly from truck as described in REMOVAL procedures of this section. 2. Place assembly in bench vise. 3. Loosen mounting bracket locking screws and compress tightener spring with mounting bracket. PIVOT PLATE LOCKING SCREW

TB613 TIGHTENER SPRING LINKAGE ARM LEVER ARM

90° 90° ECR-5 MOUNTING BRACKET LOCKING SCREWS 2747

9. Install spring collar, flatwasher and retaining ring on tube. 10. Insert shaft of lever arm in tube. Make certain plastic bushings are in place in both ends of tube. 11. Install large pulley on shaft with hub towards tube. Make certain shaft is inserted all the way and hub of pulley is against the tube bushing. Tighten set screws. 12. Turn lever arm counter-clockwise (looking at bottom of assembly) until spring ends contact both stop pins. Turn lever arm counter-clockwise enough to align the two (2) spring stop pins and hold. 13. With pins aligned, rotate small pulley on encoder shaft so flat on encoder is facing the eleven (11) O’clock position. Tighten locking screws. Refer to Illustration 4.5-7. 14. Loosen mounting bracket locking screws to allow tightener spring to tighten belt. Make certain flat on encoder shaft is still at the eleven (11) O’clock position. Tighten locking screws. 15. Install feedback assembly in truck as described in INSTALLATION procedures of this section.

FLAT ON ENCODER SHAFT

ILLUSTRATION 4.5-7

Crown 1989 PF-8214-4 Rev. 1/94

M4.5 - 19 - 103

Printed in U.S.A.

02 REV. 1/94

M4.5 - 19 - 103

MAINTENANCE MOTORS DRIVE MOTOR

DANGER

Brush Inspection

Disconnect battery before checking brushes. The inspection of both the traction and pump motors should include checking the connecting cables for tightness at motor terminals and to be sure cables are not worn or damaged. Remove the brush bands to inspect the commutator and brushes. Check the commutator for any discoloration that may show signs of raised bars or stalls. Blow out all dirt and grit with compressed air.

1. Disconnect battery connectors. 2. Open power unit doors. 3. Clean brush band area of motor and remove band. 4. Clean carbon dust and dirt from brush holders with low pressure air supply. Use a clean dry cloth to clean commutator (do not use emery cloth). 5. Brushes should be changed when they reach a length of .57 in. (15 mm) or will reach that length before the next scheduled maintenance inspection. 6. Check brush springs to see they maintain tension against the commutator equally on all brushes. Brush Replacement

CAUTION

Do not use emery cloth to clean commutator. Check brushes to see that they are not chipped, broken or oil soaked. If any of these conditions exist, they must be replaced. If brushes are dirty, clean with a clean dry cloth to remove loose particles of dirt. Be sure the brushes slide freely in their holders and make full contact with the commutator. Brushes that are worn beyond one-half their original length should be replaced. Inspect the brush spring for signs of heating that may change the tension of the brushes on the commutator. With brushes in place, be sure the spring and brush pigtails do not interfere with the brushes movement through its usable length.

1. Disconnect battery connectors. 2. Clean brush band area of motor and remove band. 3. Remove screws holding brush pigtails. 4. Disconnect brush springs or move to side (varies with motor mfg.). 5. Remove brushes. 6. Check commutator for roughness and high spots. Turn commutator if required. 7. Install new brushes, fasten pigtails and connect or secure brush springs. 8. Check to see that pigtails will not interfere with brush movement as the brushes wear. 9. Replace band. Motor Removal

Check motor for shorts between terminals and motor frame by use of an ohmmeter on a high resistance scale such as R x 10,000. If a reading of less than 50,000 ohms is observed, the source of trouble should be repaired before unit is placed into operation to prevent future damage.

1. Disconnect battery connectors. 2. Open power unit doors. WARNING

Before performing maintenance on drive motor, be sure to block wheels to prevent truck movement in either direction. 3. Release brakes. Remove fan from brake drum. Remove brake drum. 4. Remove brake assembly.

4825 Crown 1988 PF-8187-1 Rev. 5/96

Printed in U.S.A.

01 REV. 5/96

M4.7–19.0–001

MAINTENANCE 5. Apply brakes. Relieve all hydraulic pressure to the brake cylinder mounted to the bracket on drive motor. Remove brake cylinder from brake mounting bracket. Stabilize the brake cylinder to avoid unnecessary cylinder and line movement. 6. Do not remove speed sensor or remove brake switch wires. Support brake bracket assembly to the side of the truck, without disturbing electrical connections to switches, speed sensor, etc. 7. Remove all electrical cables from drive motor. Note cable routing and location for future reference. 8. Remove four screws securing motor to the power unit. Install a 1/2"-20 eye-bolt into the top of the motor shaft. Connect hoist, or other suitable lifting equipment, to eye-bolt and lift motor straight up and off of drive unit pinion shaft. Motor Replacement

Brush Replacement 1. Disconnect battery connectors. 2. Clean brush band area of motor and remove band. Remove end head. 3. Remove screws holding brush pigtails. 4. Disconnect brush springs or move to side (varies with motor mfg.). 5. Remove brushes. 6. Check commutator for roughness and high spots. Turn commutator if required. 7. Install new brushes, fasten pigtails and connect or secure brush springs. 8. Check to see that pigtails will not interfere with brush movement as the brushes wear. 9. Replace end head and band. Removal

1. Carefully lower motor onto drive unit pinion shaft. Disconnect lifting equipment and remove eye-bolt from top of motor shaft. Install four bolts securing motor to power unit. 2. Connect drive motor cables to motor properly. Tighten terminal stud nuts to 9 ft./lbs. (max.). 3. Replace brake mounting plate to the top of drive motor. Attach brake cylinder to the mounting plate. Install brake assembly to top of motor. Install brake drum, lockwasher, nut and fan. Refer to Brake Maintenance Section for proper brake adjustments. 4. Run operational check. LIFT MOTOR

1. Disconnect battery connectors. 2. Remove cover from right side of mast/main frame protecting lift motor. 3. Securely attach a sling about the pump motor and connect to hoist or other suitable lifting equipment. 4. Disconnect power cables and hydraulic lines from motor and pump respectively. Note locations for future reference. 5. Remove the four screws mounting motor to main frame. Make sure the lifting equipment is supporting the weight of the motor when removing mounting hardware. Carefully move pump and motor assembly to clean, well lighted work area. 6. Remove the two bolts attaching pump to motor and remove pump from motor.

Brush Inspection Replacement 1. Disconnect battery connectors. 2. Remove cover from right side of mast/main frame protecting lift motor. 3. Clean brush band area of motor and remove band. 4. Clean carbon dust and dirt from brush holders with low pressure air supply. Use a clean, dry cloth to clean commutator (do not use emery cloth). 5. Brushes should be changed when they reach a length of .98 in. (25 mm) or will reach that length before the next scheduled maintenance inspection. 6. Check brush springs to see they maintain tension against the commutator equally on all brushes.

1. Attach pump to motor. Attach a sling securely to the motor in its relative mounting position. Carefully lift motor to its mounting bracket on the side of the main frame. 2. Install four bolts through motor mounting bracket into bracket of main frame. 3. Connect hydraulic lines to lift pump. Attach power cables to lift motor properly. Tighten terminal stud nuts to 9 ft./lbs. (max.). 4. Replace cover. Run operational check.

Crown 1988 PF-8187-2 Rev. 5/96

Printed in U.S.A.

01 REV. 5/96

M4.7–19.0–002

MAINTENANCE ACCESSORY MOTOR

Removal

Brush Inspection 1. Disconnect battery connectors. 2. Remove cover from right side of power unit. 3. Clean brush band area of motor and remove band. 4. Clean carbon dust and dirt from brush holders with a low pressure compressed air supply. Use a clean dry cloth to clean commutator (do not use emery cloth). 5. Brushes should be changed when they reach a length of .57 in. (15 mm) or will reach that length before the next scheduled inspection. 6. Check brush springs to see they maintain tension against the commutator equally on all brushes.

1. Disconnect battery connectors. 2. Remove cover from right side of power unit. 3. Disconnect power cables from motor, and hydraulic lines from pump. Attempt to absorb any oil that may drain from pump or lines. Note cable and hydraulic line locations and routing for future reference. 4. Remove the four bolts securing the motor to the support bars that are “shock mounted,” i.e. mounted with rubber grommets to absorb vibration. 5. Remove the outboard support bar and lift pump and motor from operating location. Carefully move pump and motor to clean, well lighted work area. 6. Remove the four bolts securing pump to motor and remove pump from motor.

Brush Replacement Replacement 1. Disconnect battery connectors. 2. Clean brush band area of motor and remove band. 3. Remove screws holding brush pigtails. 4. Disconnect brush springs or move to side (varies with motor mfg.). 5. Remove brushes. 6. Check commutator for roughness and high spots. 7. Install new brushes, fasten pigtails and connect or secure brush springs. 8. Check to see that pigtails will not interfere with brush movement as the brushes wear. 9. Replace band.

1. Attach pump to motor. Carefully position pump and motor in operating position. 2. Place outboard support bar in proper position and tighten in place. Attach motor to support bars with four bolts and tighten securely. The motor mounting bracket should be below the support bars, not resting on top. 3. Connect hydraulic lines to pump. Attach power cables to lift motor. Tighten terminal stud nuts to 9 ft./lbs. (max.). Replace cover. Run operational check.

Crown 1988 PF-8187-3 Rev. 5/96

Printed in U.S.A.

01 REV. 5/96

M4.7–19.0–003

MAINTENANCE

MOTOR INFORMATION CHART Drive 72V 104121

48V 101271

72V 106813

Accessory 48V 72V 104992 091096

4 8 8 1.38 in.

4 8 8 1.75 in.

4 4 4 1.10 in.

4 4 4 1.38 in.

.57 in.

.98 in.

.45 in.

.57 in.

30 to 36 oz.

28 oz.

31 oz.

36 oz.

16 oz.

12 oz.

16 oz.

Commutator: Max. Diameter – new 3.063 in. Min. Diameter – Reslotting 2.998 in. Min. Diameter – Replace 2.938 in.

3.063 in. 2.998 in. 2.938 in.

4.000 in. 3.935 in. 3.875 in.

1.990 in. 1.900 in. 1.800 in.

3.000 in. 2.935 in. 2.875 in.

Bearings: Lubricant

Special

Shell Dolium R or Equiv. 25%-30% fill

Special

Cond. of Performance: (No Load) Volts Max. Amperes RPM Lb./Ft.

12 22 2090 min. 0

12 14 1340 min. 0

12 32 2400 min. 0

12 25 1625 min. 0

48 2.64 2009 min. 3.1 ft. lbs.

24 6.05 1350 min. 0

Field Resistance: (each at 77° F. [25° C.]) Series Ohms Shunt Ohms

.0067-.0082 —

.0257-.0212 —

.0030-.0034 —

.0064-.0078 —

— —

.039-.032 64-68

Armature Resistance: (each at 77° F. [25° C.]) Ohms Measured Between Bars

— —

.0173-.0156 1 & 15

— —

.0057-.0067 1 & 13

.070 side by side

.123-.100 1 & 15

Frame Diameter:

7.25 in.

9.25 in.

5.6 in.

6.5 in.

Wound In:

Series

Reversible

—

48V 104078 Brushes: No. of Brush Holders 4 No. of Brush Assemblies 8 No. of Brush Springs 8 Brush Length – New 1.38 in. Minimum Brush Length – Replace .57 in. Spring Tension on New Brushes 30 to 36 oz. Spring Tension Before Replacement 16 oz.

Direction of Rotation:

Lift

Crown 1988 PF-8187-4 Rev. 5/96

Compound CWDE

—

Printed in U.S.A.

01 REV. 5/96

M4.7–19.0–004

BRAKE Brake

Brake The brake system on your Turret truck has a hydraulically released, spring applied brake assembly on each drive motor and load wheel. These brakes function as both a service brake and parking brake for either the standing or seated operation. The parking brake is applied by placing the parking brake switch (BRS1) on the display panel in the up position. Service brake standing position - When operating in the standing position the brakes are released by the operator applying pressure to both floor pedals. When the operator releases pressure from either of the floor pedals the brakes are applied. Service brake seated position - When operating in the seated position the operator must momentarily move the brake switch BRS1 down after in the seated position to release the brakes and transfer control to the pedestal brake switch. The brakes then remain released until the operator applies pressure to the pedestal brake switch. An accumulator is pressurized to override the brake springs when the brakes are not applied and the accessory pump is not operating. When truck speed is less than 3.7 km/h (2.3 mph) and braking is requested, the truck electronics energizes SV9 and keeps the drive unit brakes released to soften braking. When brakes are used frequently, without working the accessory hydraulic functions, hydraulic pressure drops slightly each time brakes are cycled. A brake pressure switch is used to maintain operating pressure to release the brakes when accessory hydraulic functions have not been used.

Brake Lines Use care to avoid kinking any brake lines. Permanent damage to the line will result if this occurs.

Drive Motor Brake Lining Replacement

Figure 21024

1. Open power unit doors. Make sure the brakes are not applied. 2. Remove the fan, nut, lockwasher and brake drum. Inspect the condition of the drum, especially for grooves worn on the inside by worn linings. 3. Remove the two springs connecting brake shoes. Remove the hardware, nut, and washers etc., securing the brakes shoes to the brake mounting plate. Check brake components for signs of excessive wear, deformation, etc. that may also need replaced or repaired at this time. 4. Install new linings in position and secure to the mounting plate with appropriate mounting hardware. Attach springs connecting the brake linings. 5. Install the brake drum, lockwasher with tab, and bolt. Torque the bolt securing the brake drum to the drive motor shaft to 75 Nm (55 ft Ib). Crimp the flatwasher against the nut to lock in this position. Do not crimp the same area of the washer a second time, move to a new area of the lockwasher to obtain a proper lock. Crimping the lockwasher in the same area will weaken or possibly break the lockwasher. 6. Install the fan to top of the brake drum.

Refer to Figure 21024.

WARNING Before performing maintenance on brakes, be sure to block wheels to prevent movement in either direction.

Crown 1988 PF8180-1 Rev. 3/09

M5.0-19.0-001 04 Rev. 3/09

BRAKE Brake

Figure 21350 1

Adjust Rod End

5° - 10° In OFF Position (Cylinder Extended)

Compression Spring

Loosen

Brake Cylinder

Pivot Block

Roller At Crest of Ramp with Brake Off, 0.75 - 1.50 mm (0.030 - 0.060 in Over Travel

Actuator Bar

Adjust Rod End

Clevis Pin

4.6 - 6.4 mm (0.18 - 0.25 in) Initial Measurement

Locknut

Initial ON Position

Push Rod

OFF Position

OFF

Initial Spring Setting 120.7 mm (4.75 in)

M5.0-19.0-002 04 Rev. 3/09

Crown 1988 PF8180-2 Rev. 3/09

BRAKE Brake Drive Motor Brake Adjustment 1. Verify that the brake assembly is in the not applied position, drive brake cylinder fully extended. Adjust the rod ends (10 & 14) on the brake cylinder so that the pivot block (item 35) tilts away from the brake cylinder 5° - 10°. Refer to Figure 21350. 2. Be sure the brake cylinder is extended completely. Adjust the brake switches so they will actuate and have (0.75 - 1.50 mm (0.030 - 0.060 in) over travel. The actuator bar should be adjusted so the roller(s) of the brake switches are in the relative position as shown in Figure 21350. 3. The brake actuator arm should be installed to the brake plate at a position as shown in Figure 21025.

Figure 21351 1

0° - 10° In OFF Position (Cylinder Extended)

Adjust Clevis Here

Adjust Actuator Arm Here

The brake actuator arm should be off-set 0° - 10° and the actuation of the brake gives 4.6 - 6.4 mm (0.18 - 0.25 in) movement at the switch actuator bar. Refer to Figure 21352.

Brake Plate Assembly Figure 21025

4. The brake shoe clearance with the brake drum can be adjusted in the following manner: lengthen the push rod until the shoes contact the brake drum with the brake cylinder fully extended or brakes not applied. The push rod must be shortened until the drum can be rotated freely by hand. Lock the adjustment at this point with locknut. Refer to Figure 21351. Figure 21352

Crown 1988 PF8180-3 Rev. 3/09

M5.0-19.0-003 04 Rev. 3/09

BRAKE Brake 5. Install compression spring and adjust the over-all length of spring, including cupped washers to 120.7 mm (4.75 in) with the brake in the not applied position. Refer to Figure 21353. Proceed to adjust spring pressure to give a stopping distance of 3450 - 3650 mm (135 - 145 in) 40TS and 4350 - 4700 mm (170 - 185 in) 1.8TS. The truck must have a capacity load and travel on dry, level concrete at maximum speed in the direction towards the forks. Be sure all brake components and adjustments are tight, locked, etc. Carefully lubricate all pivot points throughout the linkage. Lightly coat with grease, the area of the mounting bracket where the switch actuator bar slides.

Speed Sensor Adjustment The speed sensor is located at the top of the drive units, next to the brake drums. The speed sensor sends data to the truck's microprocessor for proper truck operation. The sensor must be positioned in such a manner that the orientation notch is centered directly on top. The clearance between the speed sensor and the brake drum is to be 0.4 - 0.6 mm (0.015 - 0.025 in). Refer to Figure 21353.

Figure 21353 1

Brake Drum

Clamp

Orientation Notch

Speed Sensor

0.4 - 0.6 mm (0.015 - 0.025 in) Gap

Top View

M5.0-19.0-004 04 Rev. 3/09

Crown 1988 PF8180-4 Rev. 3/09

BRAKE Brake Load Wheel Brake Adjustment Refer to Figure 21354. With NEW brake pads the following information must be used when making brake adjustments.

WARNING Before performing maintenance on brakes be sure to block Wheel's to prevent movement in either direction.

1. Elevate the operator's compartment enough so the load wheel brake parts are easily accessible. Block the operator's compartment with 100 x 10 mm (4.0 x 4.0 in) hardwood blocks at this height. Do not attempt to work on brakes without blocking the operator's compartment adequately. 2. Block the load wheel outrigger in a position that the load wheel is just off the floor. Remove cover (2) and guard (12).

LH Brake System Shown

Figure 21354

Crown 1988 PF8180-5 Rev. 3/09

M5.0-19.0-005 04 Rev. 3/09

BRAKE Brake 3. With a 6.35 mm (0.2 in) diameter roll pin in the cylinder rod, check or adjust the rod end to 120.7 mm (4.75 in) from the top of the cylinder tube. Be sure the lubrication fitting is in line with cylinder port.

Lock the adjustment in this position by securing the jam nut against the rod end. Refer to Figure 21355. After the cylinder has been properly mounted to the truck, remove the roll pin.

Figure 21355 1

Hydraulic Port

Rod

Roll Pin, 6.35 mm (0.25 in) Diameter

Lubrication Fitting

Jam Nut

Load Wheel Brake Cylinder

4. When the pads are worn approximately 50% an adjustment will be required. The cylinder rod has a chamfer near the threaded end of the rod. This is an indicator of pad wear. When this chamfer is even with the end of the cylinder tube, with the brakes applied, adjust the cylinder per Figure 21357.

Chamfer Figure 21356

Figure 21357

M5.0-19.0-006 04 Rev. 3/09

Crown 1988 PF8180-6 Rev. 3/09

BRAKE Brake 5. The brake linkage must be adjusted in the following manner when brake pads are worn approximately 50%. Refer to Figure 21358.

Load Wheel Brake Pad Replacement 1. Block truck securely as indicated in Brake Adjustment earlier in this section. 2. Remove wheel cover, retaining ring, and six bolts securing brake rotor or disc to hub. Remove load wheel with hub. Remove the load wheel sleeve. Refer to Figure 21359.

Figure 21358 1

Bolt Position with New Pads

Bolt Position with 50% Pad Remaining

Install a 6.35 mm (0.25 in) pin in the cylinder rod with the brakes not applied to allow for easier servicing when the brakes are applied. The cylinder is designed in such a way that hydraulic pressure releases the brakes and a spring inside the cylinder applies the brakes. By installing the pin in the rod enables the brake linkage, etc. to be in a neutral position for easier servicing. Pressurize cylinder or brakes not applied and remove roll pin.

Figure 21359 1

Rotor Bolts

Hub and wheel

Retaining Ring

Rotor

Load Wheel Sleeve

Wheel Cover

3. Inspect rotor for scratches, nicks, and excessive wear. Replace rotor if any of these signs exist. Do not attempt to clean up or machine the rotors with a lathe. 4. Remove nut (7) and bolt (9). Lift pads out of caliper (8). Install new pads properly. Always replace pads in pairs. Adjust brake cylinder and linkage per instructions for new pads found earlier in this section. Refer to Figure 21354.

Crown 1988 PF8180-7 Rev. 3/09

M5.0-19.0-007 04 Rev. 3/09

BRAKE Brake 5. Install load wheel and hub to the brake rotor. Secure load wheel to sleeve with retaining ring. Install the load wheel eccentric sleeve. The 19 mm (0.75 in) diameter bolt in the center of the sleeve must be torque to 260 Nm (190 ft Ib). The 9.5 mm (0.375 in) diameter adjustment bolt must be torque to 28 Nm (20 ft Ib). The identity, as to left or right, and the location of the adjustment bolt is stamped on the end of the sleeve. Refer to Figure 21360

Bleed Screw

Figure 21361

Figure 21360

The adjustment must be maintained to keep the truck level. Replace wheel cover.

Relieving Brake System Hydraulic Pressure for Maintenance or Replacement of the Brake Accumulator or Brake Cylinder. 1. Turn key switch to OFF position.

NOTE Lubricate all grease fittings. Apply a light coat of grease to brake linkage travel surfaces.

Brake Bleeding WARNING Do not attempt to bleed brake cylinder(s) with the brake off or not applied. Brakes must be on or applied when bleeding brake cylinders. Each brake cylinder has a bleed port. If a cylinder has been disassembled or hydraulic lines removed from the cylinder for maintenance after the cylinder is reinstalled on the truck, but before the truck is put back into operation, air must be bled from the brake cylinder and lines Loosen the small bleeding screw located on the cylinder(s) until all air escapes and only oil continues to flow from the screw. Tighten the screw and wipe off all excess oil. Refer to Figure 21361.

2. Remove wire 5938 from terminal 5 on TB616 to make the brake release seated-parking brake switch (BPS1) inoperable. 3. Cycle the Emergency Switch, Drive/Tow Switch (EMS4) until the brakes no longer release, then cycle EMS4 four or five times more to assure that all hydraulic pressure in the brake system is totally relieved. 4. Disconnect the battery. 5. Disconnect the brake lines as required to perform maintenance or to replace the brake accumulator or the brake cylinder. 6. After service has been completed and all hydraulic fittings are reconnected and tightened, reconnect wire 5938 to terminal 5 on TB616. 7. Connect the battery. 8. Turn key switch to ON position. 9. Cycle brakes several times. 10. Follow brake bleeding procedure. 11. Check brakes for proper operation. If brakes are not functioning correctly because of remaining air in the brake system, repeat the brake bleeding procedure as required.

M5.0-19.0-008 04 Rev. 3/09

Crown 1988 PF8180-8 Rev. 3/09

STEERING

10140

ILLUSTRATION 4

Steering Tiller Adjustment (Refer to Illustration 4) The steering tiller arm shaft has machined "dimples", 180 º apart, that are to have set screws securing the drive pulley properly aligned at installation. The encoder shaft has a machined flat to be aligned with the set screw securing the pulley when installed. A friction block that puts a slight resistance on the steering tiller must have the proper amount of spring force. The

amount of spring force is controlled by adding or removing flatwashers. The surfaces of the drive pulley and the friction block must be smooth; No scrathes, nicks or damage of any kind. If not enough friction is applied to the hub of the drive pulley, the steering tiller will continue to rotate after the operator's hand has been removed and cause improper truck operation.

Crown 1988 PF8181-2 Rev. 2/02

Printed in U.S.A.

01 REV. 2/02

M6.0–19.0–002

STEERING Steering Linkage Assembly and Adjustment (Refer to Illustration 5) Connecting the steerable dual drive units is a steering linkage that maintains proper alignment. A major portion of the linkage is located beneath the battery compartment. In order to service this linkage the battery, battery rollers and tray must be removed. The power unit end of truck should be raised until the drive tires are off the floor and securely blocked in this position.

After adjustments and proper lubrication the steering linkage should be free enough to turn by hand providing the steering servo motor gearboxes are not in place. Before installing battery tray, battery rollers and battery apply a small amount of grease to all bolt heads, nuts, etc. under the battery compartment area which may have to be removed for adjustment and/or repair.

CAUTION

Before performing maintenance to steering linkage be sure to block load wheels to prevent truck movement in either direction. The left and right hand steering linkage is aligned vertically with the steering arm and the drive unit mounting brackets by using flatwasher shims as required. The drive unit mounting brackets are secured to the drive unit housings by .375 in. dia. bolts. These fasteners should be torqued to 34 Nm (25 ft. lbs.).

10137

The steer drive tires are to be aligned in such a manner that dimension "X" and "Y" to the centerline of bolt pattern at the side of the drive unit casting are the same within 2mm (.090 in.). Adjusting nuts are turned appropriately to obtain this adjustment. The pivot bolt should be loosened before attempting any adjustment. After proper adjustment, torque the adjusting nuts to 305 Nm (225 ft. lbs.). The pivot bolt should be torqued to 163 Nm (120 ft. lbs.) at this time.

Steering Servo Motor Gearbox (Refer to Illustration 6) The steering servo motor gearbox should be filled to the level indicator plug on the end of the gearbox with DTE 24 lubrication. Capacity of the gearbox is 0.95 liter (2 pints).

ILLUSTRATION 5 10138

Crown 1990 PF8631-3 Rev. 2/02

ILLUSTRATION 6

Printed in U.S.A.

01 REV. 2/02

M6.0–18.1–003

MAINTENANCE MAST Masts are constructed of hot rolled carbon steel I-beams continuously welded to a flat and formed plate. They telescope on alloy steel column and carriage rollers. Elevated load sway due to mast twisting, plus forward and side bowing are minimized through the use of closed cross section construction. The lift cylinders, hydraulic hoses, electrical cables and lift chains are nested within the mast and are readily accessible. The "TN" (telescopic no free lift) mast is a two stage mast assembly which incorporates a single lift cylinder assembly. When the main raise function of the truck is used the mast begins staging and the platform raises simultaneously to the full lifting height of the truck. The main mast chains are attached to the operator compartment and are routed over a chain roller in the tip-out assembly at the top of the mast. The chains are anchored to the top of the main frame. The “TF” (telescopic full free lift) mast is a two stage mast assembly which incorporates a shorter, twin free lift cylinder assembly and a longer single cylinder assembly. The operator compartment will raise to the top of the second stage mast through the extension of the two shorter rams in the free lift cylinder assembly. After these cylinders are fully extended, the remaining cylinder ram will push the second stage from the first stage until the maximum lift height is attained. The main mast chains are attached to the operator compartment and are routed over a chain roller at the top of the single lift cylinder, through the yoke assembly of the free lift cylinder, and attached to a chain anchor at top of the second stage tip out assembly.

LOAD WHEELS BLOCKS CHOCKED (BOTH SIDES) 2034S

NOTE Maintenance information pertaining to cylinder repair and removal, 2nd stage mast blocking, etc. is found in section M8.0. This section pertains only to second stage mast removal and column and side thrust roller adjustments.

Second Stage Mast Removal Remove auxiliary mast assembly from operator compartment. Refer to maintenance section M9.0 explaining auxiliary mast removal for proper procedure. Remove operator compartment from second stage mast assembly. Refer to maintenance section M9.0 explaining operator compartment removal for proper procedure. CAUTION

On "TF" masts, the Free lift cylinder is suspended; remove mast cover and secure free lift cylinder. Remove the power unit from the main frame per the following information, refer to Illustration 7-1: Remove power unit doors and covers. Remove batteries. Block truck in such a manner that the main frame will be selfsupporting when the power unit is unbolted. Block the power unit in the same manner so that it will not drop to the floor when removed from the main frame.

LOAD WHEELS CHOCKED

ILLUSTRATION 7-1 5714 - 43635/44315

Crown 1988 PF8191-1 Rev. 5/98

Printed in U.S.A.

04 REV. 5/98

M7.0–19.0–001

MAINTENANCE POWER UNIT HYDRAULICS

MAIN FRAME HYDRAULICS

2036S 2035S

ILLUSTRATION 7-2 D. Disconnect hydraulic line at point 4, point 5 and point 6.

NOTE If the height of the truck and the equipment available is such that the mast cannot be removed from the top of mast safely, the main frame needs to be laid down. Hydraulic lines must be disconnected on the right side of the truck, at and/or near the main lift pump of the main frame and power unit. When disconnecting hydraulic lines have appropriate caps, plugs, etc. available and avoid oil draining from disconnected lines. Be sure mast is completely collapsed and pressure has been released from hydraulic system. Drain the hydraulic reservoir. Refer to Illustration 7-2 and disconnect the following hydraulic lines. A. Disconnect the high pressure line from the outlet port of the main lift pump, at point 1. B. Disconnect hydraulic line at point 2.

E. Disconnect the return line at point 7. F. Disconnect the hydraulic line from the load wheel brakes at point 8. Lines should be capped and coiled and secured to the main frame, if possible, to prevent damage and/or debris from contaminating the hydraulic system. Electrical cables are routed out of the main frame area to the rear of the power unit. These cables must be disconnected prior to power unit removal. Record wire termination points for reference at assembly. Remove cable that goes to the height sensor cable break limit switch (if equipped). Main lift motor cables must be removed from motor. Note cable connections for reference at assembly. Trucks equipped with wire guidance have a cable that needs to be removed from the sensor bar at the front of the main frame. Note termination points for future reference.

C. Disconnect low pressure line at point 3. Crown 1988 PF8191-2 Rev. 5/93

Printed in U.S.A.

01 REV. 5/93

M7.0 - 19 - 002

MAINTENANCE Secure any and all cables that have been disconnected, to the main frame when removed to prevent possible damage when removing the second stage mast.

BRACKET 109431

Six bolts, two at the top and four at the bottom, secure the power unit to the main frame. When removing the top two mounting bolts record the number and position of all spacers and shims. The shims are available in two sizes, 060030-148 is 0.06 in. (1.5mm) thick and the 060030-149 is 0.12 in. (3.0mm) thick. This information will be used when the power unit is bolted to the main frame at assembly. There are four bolts at the base of the power unit, two bolts on each side. Remove these bolts and record number and position of all mounting hardware. Mounting bolts should be installed with the bolt head toward the battery compartment. The power unit is mounted to the main frame in this manner to maintain the proper amount of main frame tilt, toward the power unit, for stability. Refer to Illustration 7-3.

SCREW (2) 060023-006 LOCKWASHER (2) 060005-023 FLATWASHER (2) 060030-054 ROLL PIN (2) 060000-022 PIN 092832

SHIMS 2038S

TORQUE REQUIRED Prior to 4/25/94 for grade 5 screws 220 FT. LBS. (300 Nm) TORQUE REQUIRED From 4/25/94 for grade 8 screws 400 FT. LBS. (545 Nm)

2037S-01

ILLUSTRATION 7-3

Make a visual check about the power unit to confirm that all cables and hydraulic lines connecting the power unit to the main frame have been disconnected. At this time carefully separate the power unit and main frame.

ILLUSTRATION 7-4

The mast assembly must be in an area that will allow the second stage mast to be extended completely when laid down. A bracket (109431) is attached to the top of the mast assembly utilizing (2) 060023-006 3/4 in. bolts, (2) 060030054 flatwashers, (2) 060005-023 lockwashers, (2) 060000022 roll pins and 092832 pin. Refer to Illustration 7-4. The bracket is positioned on top of the second stage mast and the bolts are installed through the bracket and into the top of the main frame. Make lifting equipment connections at top of mast assembly and at base of main frame. The equipment used to lift and move the mast assembly into a horizontal position must be of sufficient capacity or size to safely handle the mast assembly. Lifting equipment such as hoists or other lift trucks with insufficient capacity may break or become unstable and an unsafe condition may arise, which must be prevented. The weight of the mast assembly is approximately 8000 Ibs. (3650 kg). The lifting equipment must have the capability to safely handle such a load. Extreme care must be exercised during this procedure.

Crown 1988 PF8191-3 Rev. 3/94

Printed in U.S.A.

02 REV. 3/94

M7.0 - 19 - 003

MAINTENANCE Take care when extending the second stage and guide mast chains, hydraulic lines, and electrical cables from mast assembly if necessary. Recording location and/or position of the parts attached to the second stage and main frame for reference at assembly is recommended. Connect lifting equipment to the top and bottom of the second stage mast. As the second stage is extended completely, the bottom of the second stage will drop from the main frame l-beam area. Make sure lifting equipment is attached to the second stage in such a manner to prevent shifting of the mast and/or main frame. Move the second stage aside, either to the floor or onto supports while performing repair to main frame and/or second stage.

COVERS POLY STOP ASSEMBLIES

SECOND STAGE

ATTACH SLING, CHAIN, ETC.

MAIN FRAME ILLUSTRATION 7-5

2039S

As the mast assembly becomes horizontal, block as shown in Illustration 7-1. Disconnect lifting equipment from bracket (109431) at top of second stage mast. Remove bracket. Load wheels should remain chocked securely throughout this procedure. Remove two covers from second stage mast, that allow access to the poly stops mounted to the main frame. Refer to Illustration 7-5. Attach lifting equipment to the top of the second stage. Refer to Illustration 7-6.

WHEEL CHOCKS

2040S

Refer to “Free Lift Cylinder Removal” located in the Cylinder Maintenance Section (M8.0) of this manual. Raise the mast assembly slightly. The support must not be in contact with the second stage mast. Carefully move the second stage toward the top of the main frame. As the main frame and second stage are near full extension, replace the support under the main frame. Refer to Illustration 7-7.

2041S

WHEEL CHOCKS

ILLUSTRATION 7-6

ATTACH SLING, CHAIN, ETC.

ILLUSTRATION 7-7 Printed in U.S.A.

Crown 1988 PF8191-4 Rev. 5/93

01 REV. 5/93

M7.0 - 19 - 004

MAINTENANCE Column Roller Adjustment - TF Mast (Trucks Manufactured Prior to 4/95)

NOTE The minimum clearance per side should be 0.110 in. (2.80mm). Using shim washers, adjust the clearance to be 0.110 in. to 0.140 in. (2.80mm to 3.55mm) per side.

Column rollers located at the top of the main frame and at the bottom of the second stage must be adjusted properly to obtain satisfactory mast to main frame operation. The following information should be used to obtain proper column roller adjustment. Clean column roller studs. If any paint or rust is evident on studs remove with emery cloth and grease with multipurpose grease (Crown No. 063002-007).

Shims are available in thickness of 0.031 in. (0.78mm [060030-085]) and 0.063 in. (1.60mm l060030-057]) to facilitate the proper mast shimming. TF MAST (Manufactured Prior to 4/95)

Arbitrarily place one shim on each stud and install column rollers. With the use of an inside caliper (see Illustration 7-8), measure between the two rollers.

Column Roller

Shims

OUTSIDE CALIPER

2nd Stage Mast

0.110 in. (2.80mm) 0.140 in. (3.55mm) 6539

COLUMN ROLLER ADJUSTMENT - TN & TF MAST (TN Manufactured From 10/93 & TF From 4/95 to Present)

INSIDE CALIPER 1908S

ILLUSTRATION 7-9

1. Clean column roller studs. If any paint or rust is evident on studs, remove with emery cloth and lubricate with multi-purpose grease (Crown 063002-025).

ILLUSTRATION 7-8 NOTE The column roller studs are canted, so be certain to take the measurement on the correct portion of the roller (narrowest dimension possible).

Measure the outside of the first stage mast along the area where the second stage column rollers will travel, with an outside caliper (see Illustration 7-8). After finding the widest contact point, lock the thumb screws and place the inside and outside calipers together and determine the amount of shim to be added to (or removed from) the column rollers. When shimming column rollers, try to balance out the number of shims (Example: 2 shims right, 2 shims left). If an uneven number of shims are required, note the side to which the extra shim was added and install all other odd shims to that side.

2. Install column rollers with large radius of roller towards stud shoulder. Refer to Illustration 7-9. 3. Install retaining rings. 4. Extend 2nd stage to the main stops and adjust cam shafts to their loosest setting. 5. Apply a light film of grease to both ends of cam if needed. 6. At the bottom of 2nd stage mast, with column rollers pushed against the stud shoulders and 2nd stage forced to one side, measure the distance, on both sides, between column roller face and web of the "I" beam.

Crown 1988 PF8191-5 Rev. 5/98

Printed in U.S.A.

04 REV. 5/98

M7.0–19.0–005

MAINTENANCE 7. Divide the sum of these two (2) gaps by (2) and place this amount of shim or gage, between column roller and web on one side of the mast.

(109431) on top of second stage mast and install bolts through bracket and into top of main frame. Refer to Illustration 7-4. Both load wheels should be chocked.

Example: Gap = 0.070 in. (1.80mm) ÷ 2 = 0.035 in. (0.90mm)

ALIGNMENT MARKS

8. Adjust cam on opposite side so that the thrust roller contacts the flange of the "I" beam. 9. Remove the shim/gage and adjust other cam so the thrust roller contacts the flange of the "I" beam. 10. Move the 2nd stage up and down the mainframe. The thrust rollers should roll about 75% of the time or more, without heavy marking of the mast. 11. Repeat steps 1 thru 10 for top thrust rollers. TN (Manufactured From 10/93 to Present) & TF (Manufactured From 4/95 to Present) Large Radius Towards Mounting Stud

Column Roller

No Shims

2nd Stage Mast

2042S

Carefully raise the top of the mast until in a vertical position and block as shown in Illustration 7-1. Secure the mast assembly in a manner that will prevent the mast from going beyond a vertical position. Check to be sure that lift cylinders are installed properly. Refer to cylinder installation information in this manual (section M8.0) for proper procedures.

0.030 in. (0.75mm) 0.062 in. (1.60mm) 6540

ILLUSTRATION 7-11

ILLUSTRATION 7-10

Second Stage Installation Lift the second stage mast and position properly with the top of the main frame. Slide the second stage onto the main frame and install stops to main frame (refer to Illustration 7-5). Use extreme care and be sure nothing can obstruct the second stage in relation to the main frame. The lifting equipment and main frame supports must be positioned properly during this operation. Control the main frame and second stage to prevent unnecessary weight shifting, etc. Manually slide the second stage on the main frame to check for running clearance. Refer to “Free-Lift Cylinder Installation”, section M8.0 of this manual for procedure to be performed at this time. Confirm at this time that related parts, lift chains, hydraulic hoses, electrical cables, etc. are installed as noted when removing second stage. Place bracket

Position power unit in proper alignment with mast assembly. Install four mounting bolts at base of power unit and mast. Bolt heads should be toward power unit. Install two bolts at top of power unit along with shims. Refer to information taken during removal to be sure mounting hardware is replaced exactly as it was removed. Snug these mounting bolts at this time. Refer to Illustration 7-11 and align the top of the power unit. The alignment marks must be straight from power unit to mast assembly. Torque mounting bolts per Illustration 7-3. Remove lifting bracket from top of mast assembly. Make electrical connections per information recorded during disassembly. Pump motor cables, mast cables, wire guidance (if so equipped), etc. must be connected. Maintain routing of the above to prevent possible damage, etc. Connect hydraulic lines per Illustration 7-2. Fill hydraulic reservoir. Install batteries, replace power unit covers and doors.

Crown 1988 PF8191-6 Rev. 5/98

Printed in U.S.A.

04 REV. 5/98

M7.0–19.0–006

MAINTENANCE MAIN FRAME TOP

Install operator compartment to second stage mast per instructions found in section M9.0 of this manual.

SECOND STAGE BOTTOM

Install auxiliary mast to operator compartment per instructions found in section M9.0 of this manual. Run operational check. CAUTION

Be sure all stops and safety devices are in place before cycling mast to check for proper operation. Side Thrust Roller Adjustment - TF Mast (Trucks Manufactured Prior to 4/95) (Refer to Illustrations 7-12 & 7-13) Side thrust rollers located at the top of the main frame should be adjusted while the second stage mast is collapsed completely. Turn the cam shaft(s) until the rollers have 0.110 in. (2.80mm) clearance with l-beam flange on each side of the second stage mast. Side thrust rollers located at the bottom of the second stage mast should be adjusted with the second stage mast fully extended. Position the cam shaft(s) until the rollers are snug against the l-beam flange on each side of the main frame.

SNUG FIT CAM SHAFT

SIDE THRUST ROLLER LOWER ROLLER ADJUSTMENT ILLUSTRATION 7-13

2044S

NOTE Apply a light film of multi-purpose grease to cam shaft(s) before installation.

SIDE THRUST ROLLER ADJUSTMENT (TF Manufactured From 4/95 & TN From 10/93 to Present) 1. Insure column rollers are installed with large radius toward stud shoulder and retaining rings are intact.

0.110 in. (2.80 mm) MINIMUM CLEARANCE

2. Adjust cam shafts to their loosest setting and slide platform to top of the 2nd stage. Apply a light film of grease to both ends of cam shaft if needed.

MAIN FRAME TOP

SECOND STAGE TOP

CAM SHAFT

3. Force the platform to one side of the 2nd stage and push column rollers against stud shoulders.

SIDE THRUST ROLLER

4. Measure the gap, on both sides, between the column roller face and web of the "I" beam.

SECOND STAGE TOP

5. Divide the sum of these two (2) gaps by (2) and place this amount of shim, or gage, between column roller and web on side of platform. Example: Gap = 0.070 in. (1.80mm) ÷ 2 = 0.035 in. (0.90mm)

UPPER ROLLER ADJUSTMENT 2043S-01

ILLUSTRATION 7-12 Printed in U.S.A.

Crown 1988 PF8191-7 Rev. 5/98

04 REV. 5/98

M7.0–19.0–007

MAINTENANCE 6. Adjust cam on the opposite side of shim/gage so the thrust roller contacts the flange of the "I" beam. 7. Remove the shim/gage and adjust the other cam so the thrust roller contacts the flange of the "I" beam.

COVER 2nd STAGE MAST

8. Repeat steps 1 thru 7 for the upper set of thrust rollers.

MAST STABILIZING ROLLER

9. Move the platform up and down 2nd stage mast. Check to see if the thrust rollers roll about 75% of the time without heavy marking of the mast.

SHIM

10. Inspect platform to see if the gaps between the uprights and 2nd stage mast are relatively even. If platform rubs on the 2nd stage mast or does not appear to sit square on mast, readjust side thrust rollers.

ROLLER STUD R.H.

Stabilizer Roller Adjustment Stabilizer rollers located at the bottom of the 2nd stage mast should be adjusted with the 2nd stage mast raised 4 ft. (1.2m) from floor level.The clearance between the mast and roller should measure 0.003 to 0.008 in. (0.08 to 0.20 mm). Shim roller studs to obtain this measurement. Refer to Illustration 7-14 and 7-15

ILLUSTRATION 7-14

2026

0.003 To 0.008 in. (0.08 To 0.20mm)

After the 0.003 to 0.008 in. (0.08 to 0.20 mm) clearance has been set, raise platform fully with auxiliary mast completely to the right side and then left side. Check to be sure that rollers don't rub the mast. Adjust if necessary. The roller stud mounting holes are slotted to allow for adjustment. Since the I-beam is tapered and the roller is canted, adjusting the stud will probably change the 0.003 to 0.008 in. (0.08 to 0.20 mm) clearance. Therefore, after adjusting studs, recheck the 0.003 to 0.008 in. (0.08 to 0.20 mm) clearance.

2nd Stage Mast

Main Frame Mast

Shim Roller Stud Roller Check To Be Sure Roller Doesn't Rub This Area of Mast

6560

Crown 1988 PF8191-8 Rev. 5/98

ILLUSTRATION 7-15

Printed in U.S.A.

04 REV. 5/98

M7.0–19.0–008

This page available for NOTES.

LIFTING MECHANISM Lift Chains

Lift Chains Lift chains are highly important components on fork lift trucks. The chain system on your mast was designed for efficient, reliable transmission of lifting force from hydraulic cylinder(s) to the mast, platform (if present) and forks. Safe, uninterrupted use of your lift truck depends on the proper care and maintenance of the lift chains.

Inspection After every 100 hours of truck operation, lift chains should be inspected and lubricated. When used in an extremely corrosive environment, inspect chains every 50 working hours. During inspection, check for the following:

Roller and Leaf Chain Wear Scale

Most complaints of unsatisfactory chain performance can be traced directly to inadequate maintenance. Highly stressed precision chains require periodic maintenance to deliver maximum service life.

Wear As the chain flexes on and off pulleys, the joints gradually wear. The "stretch" a chain develops during usage is due to material being worn off of pin outside diameter and pin hole inside diameter on the inside plates.

Crown 1984 PF5856-1 Rev. 8/06

Figure 2771-01

Chain wear can be measured by using a 106440 wear scale or a steel tape (Refer to Figure 2771-01). When chains have elongated 3%, as represented on scale "A" (19 mm [0.75 in] or 25 mm [1.0 in] pitch chain) or scale "B" (16 mm [0.625 in] pitch chain) of the wear scale, they should be discarded. On chain with 19 mm (0.75 in) between pins, for example, 305 mm (12.0 in) of chain contains 16 pitches or links. When 16 pitches measure 314 mm (12.375 in) the chain should be replaced. On chain with 16 mm (0.625 in) between pins, 20 pitches or links equal 318 mm (12.5 in). When 20 pitches measure 327 mm (12.875 in) the chain should be replaced. Crown currently uses 16 mm (0.625 in) pitch (20 links in 318 mm [12.5 in]), 19 mm (0.75 in) pitch (16 links in 305 mm [12.0 in]) and 25 mm (1.0 in) pitch (12 links in 305 mm [12.0 in]) chain. When checking chain wear, be sure to measure a segment of chain that operates over a pulley. Do not repair chain(s) by cutting out the worn section and splicing in a new piece. If part of a chain is worn, replace lift chain(s). If truck has a matched set of lift chains replace both chains at same time.

M7.5-18.0-001 07 Rev. 8/06

LIFTING MECHANISM Lift Chains

Corroded Chain (with Stress-Corrosion Cracks)

Figure 2773S-01

Heavy motor oil serves both as a joint lubricant and corrosion inhibitor. During inspection, carefully examine external chain surfaces for the presence of an oily film. Under certain operating or environmental conditions it may be necessary to oil chains more frequently than 100 hour intervals. In all cases, the external surface of the chain must be protected with a film of oil.

With Forks Lowered Check Either Front or Rear Pulley for Chain Wear

Figure 7771-01

Corroded chains should be inspected for cracked plates. Outside plates are particularly susceptible to stress corrosion cracking. If chains are heavily rusted or corroded they should be removed from the mast for a thorough inspection for cracked plates. If plates are cracked, both chains on the truck must be replaced. Oil chains when they are reinstalled on the mast.

Rust and Corrosion Chains used on lift trucks are highly stressed precision components. It is very important that "as-manufactured" ultimate strength and fatigue strength be maintained throughout the chain service life. Corrosion will cause a major reduction in the load-carrying capacity of lift chain or roller chain because corrosion causes side plate cracking. It is extremely important to protect lift chains from corrosion, whether in service or in storage. The initial factory lubrication on chains is an excellent rust and corrosion inhibitor. Factory lube is applied in a hot dip tank to insure complete penetration into the joint. Do not steam clean or degrease new chains. After the chain has been placed in service, factory lube must be supplemented by a maintenance lubrication program. Refer to applicable lubrication and adjustment section for your particular truck series and/or the lubrication information later in this section.

M7.5-18.0-002 07 Rev. 8/06

Cracked Plates The most common cause of plate cracking is fatigue failure. Fatigue is a phenomenon that affects most metals and many plastics. After many repeated heavy loads the plates may crack and the chains will eventually break. Fatigue Cracks

Figure 2774S-01

Fatigue cracks are almost always found through the pin holes perpendicular to the pitch line. (Refer to Figure 2774S-01) Contrast this failure mode to the random failures caused by stress-corrosion cracking. (Refer to Figure 2773S-01) If any fatigue cracks are discovered during planned maintenance (PM) inspections, both lift chains should be replaced. Many apparently sound plates will be on the verge of cracking, making chain failure very likely.

Crown 1984 PF5856-2 Rev. 8/06

LIFTING MECHANISM Lift Chains Tight Joints All joints in lift chain should flex freely. Tight joints resist flexure, increase internal friction, thus increasing chain tension required to lift a given load. Increased tension accelerates wear and fatigue problems. Refer to Figure 2775S-01.

Protruding & Turned Pin

Tight Joints

Figure 2776S-01 Figure 2775S-01

Tight joints in lift chains can be caused by: 1. Bent pins or plates, 2. Rusty joints, 3. Peened plate edges. Oil rusty chains and replace chains that appear bent or peened. Peening of plate edges may be caused by worn pulleys, unusually heavy loads, or chain sliding past a guide or obstruction in the mast.

Chain Side Wear A continuous wear pattern on pin heads and outside plates indicates misalignment. Misalignment can be caused by two different factors: unequal chain tension or nonalignment between pulleys and chain anchors.

•

Unequal Chain Tension - When a lift chain is installed or adjusted, care should be taken to "load" the chains evenly. When changing fork heel height or platform height for example, the chain anchors should be loosened until both forks come in contact with the floor. At this point both chains should display the same tension or slack. The chain anchor nuts should be tightened an equal number of revolutions on both chain anchors to put equal tension on chains. When the desired height setting is achieved the locking nut should be tightened to secure setting.

•

Non Alignment of Lifting Components - Non alignment of the pulley and chain due to incorrect shimming of the mast or bent or damaged mast or cylinder components can also contribute to chain side wear. A check for this condition is to place the truck on a level area in your maintenance area. After supporting the fork carriage, disconnect each end of the lift chain at the chain anchor and visually inspect its alignment with the anchor slots.

Protruding or Turned Pins Heavily loaded chains operating with little lube generate tremendous friction between pin and plates (pin and bushing in roller chain). In extreme cases, the frictional torque in the joint can actually turn pins in the press-fit outside plates. If chain is allowed to operate in this condition, the pins slowly work out of the chain, causing chain failure. Turned pins can be quickly spotted because the flats on the "V" heads are no longer in line. Refer to Figure 2776S-01, pin has turned 45 degrees. Chains with turned or protruding pins should be replaced immediately. Never attempt to repair the chain by driving pins back into the chain.

Crown 1984 PF5856-3 Rev. 8/06

M7.5-18.0-003 07 Rev. 8/06

LIFTING MECHANISM Lift Chains Lift Chain Lubrication The most important consideration in field maintenance of lift chains is LUBRICATION. Hard working, heavily loaded chains cannot be expected to give satisfactory wear life without scheduled periodic lubrication. Like all bearing surfaces, the precision-manufactured, hardened-steel, joint-wearing surfaces require a film of oil between mating parts to prevent rapid wear. Maintaining an oil film on all chain surfaces will:

•

Minimize joint wear (chain stretch).

•

Prevent corrosion.

•

Reduce the possibility of pin turning.

•

Minimize tight joints in roller chain.

•

Promote smooth, quiet chain action.

•

Lower chain tension by reducing internal friction in the chain system.

tremely severe service, may require more frequent lubrication to maintain an oil film on all chain surfaces. In dusty operating conditions, lubed chains will gather dust. Even under these conditions wear life will be greatly improved by periodic lubrication. Joints may acquire a "paste" made up of oil and dirt, but joint wear will still be much less than if the chain is allowed to run dry with metal-to-metal contact between pins and plates. At 100 hour intervals, clean chains to remove accumulation of dirt-and lubricate immediately. (Do not steam clean chains.)

Lubricant

Heavy motor oil is an excellent chain lubricant-even used motor oil is adequate to lubricate exposed lift chains. Laboratory wear tests show SAE 40 oil to have greater ability to prevent wear than SAE 10 oil. Also, SAE 40 oil is superior to hydraulic fluid or automatic transmission fluid. Generally, the heaviest (highest viscosity) oil that will penetrate the joint works best. Laboratory wear testing shows dry film lubes to be less effective in preventing joint wear than fluid petroleum based products. Some aerosol spray lubes, such as Crown part number 063001-009, are effective, more convenient and less messy than applying motor oils. Whatever method is used, the oil must penetrate the chain joint to prevent wear. Applying oil to external surfaces will prevent rust, but oil must flow into the live bearing surfaces for maximum wear life. (Refer to Figure 2777S-01). Apply oil to chains with a narrow paint brush. A plastic liquid detergent bottle makes a handy lube applicator. Flood the chain with oil over its entire length every lube-inspection period. Frequency of lubrication will vary with operating conditions and environment. The best estimate of lube period is 100 hours actual operating truck time. Trucks parked outdoors, used in freezers or trucks in ex-

M7.5-18.0-004 07 Rev. 8/06

Figure 2777S-01

Lift Chain Replacement The first step in chain replacement is to find the chain part number in your service manual parts list. An important factor in ordering replacement chain from the truck manufacturer is that special chains may be specified for your truck with certified minimum ultimate strength. If the unit is equipped with two strands, replace chains as a pair. It will be virtually impossible to maintain uniform loading between the strands if a new chain is put into service opposite an old chain. The joints in the old chain will have worn through the hardest layer of the case-hardened pin. Therefore, the wear rate on the old chain will be greater than that on the new chain, greatly complicating the problem of maintaining equal chain tension. The new chain will wear more slowly, causing it to bear the major portion of the load, resulting in premature wear and fatigue failure.

Crown 1984 PF5856-4 Rev. 8/06

LIFTING MECHANISM Lift Chains Never steam clean or degrease new chains. The manufacturer's grease is effective in reducing wear and corrosion. If the original factory lube is dried out or wiped off, soak the new chain in heavy engine oil for at least 0.5 hour prior to installing on truck. After the existing chains have been removed from the mast, very carefully inspect chain anchors and sheaves. Broken, cracked, or worn anchors must be replaced. Replace worn sheaves, and check sheave bearings for wear. Do not paint the replacement chain before or after it has been installed. Paint will help prevent corrosion, but will prevent oil from reaching the pin surface for good joint lubrication. Install the new chains, using new anchor pins. Existing pins may contain invisible fatigue cracks that could lead to pin failure. After chains have been connected to the anchors, adjust chain tension to obtain proper fork or platform height. Correct chain installation and mast adjustment will increase chain service life.

Chain Anchors and Pulleys An inspection of the chain system should include a close examination of chain anchors, anchor tension devices and pulleys. Check chain anchors for wear, breakage, and radial misalignment. Anchors with worn or broken fingers should be replaced. Anchors should be adjusted to eliminate twisting or other misalignment in the chain. When chain is misaligned, the load is not distributed uniformly between the plates-prolonged operation will result in premature fatigue failure. Pulleys with badly worn flanges and outside diameter should be replaced. Heavy flange wear indicates chain misalignment. Investigate cause by checking chain tension and mast shimming.

Leaf Chain Disconnect

2. A support ring (flatwasher) with an inside diameter slightly greater than the pin diameter and a height equal to the head height of the pin. 3. Grinding wheel. 4. Pin punch with a diameter slightly less than the pin diameter, hammer or pressing equipment.

Disconnect Procedures: (Refer to Figure 2782-01) 1. Grind the top head of the pin flush with the pin link plate. Be careful not to grind or damage the pin link plate. 2. Position the support ring over opening of the work surface. The support ring serves to support the bottom pin link plate and avoids damage to chain components while driving the pin through the chain. 3. Stand the chain on its side and seat pin in the support ring. 4. Remove the pin from the chain through the top pin link plate.

Grinding Wheel Grind Pin Flush With Link Plate

Pin Link Plate

Support Ring

Work Surface Knock Out Aperture Figure 2782-01

To minimize the risk of damaging (cracking, etc.) the chain, refer to the following when disconnecting leaf chain. Tools Required: 1. A sturdy work surface with an opening slightly greater than the pin diameter, and should be thick enough to allow the pin to extend beneath the work surface as it is driven through the bottom pin link plate.

Crown 1984 PF5856-5 Rev. 8/06

M7.5-18.0-005 07 Rev. 8/06

MAINTENANCE LIFT CYLINDERS Great care and cleanliness should be exercised in the disassembly and assembly of any hydraulic cylinders. Wipe all surfaces clean of dirt and oil before attempting disassembly. Care should be taken when removing the ram from the cylinder to prevent damage to the packing on the piston end. After cylinder components are disassembled and seals, “O” rings and wipers are removed, thoroughly wash all metallic parts in solvent and blow dry with compressed air. Carefully inspect the ram assembly and cylinder bore. Replace if scored, grooved, pitted or worn. Minor damage to the cylinder bore can be removed with the use of a cylindrical honing tool. Place washed components in a clean container until reassembly. Whenever new packings are required, new wiper rings should also be installed.

NOTE The service platform cannot be used on TS trucks having a collapsed height of 137" (3480 mm) or less. Utilize an appropriate maintenance platform fitted to another lift truck to perform maintenance to the lift cylinder area at the top of the mast. Turn the two clamps at the top of the platform counterclockwise to allow for clearance of the l-beam flange before attempting to place platform on truck. Secure the service platform to the fork plate of the fork lift, if used, before lifting. Connect sling or chain to the four corners of the platform railing when utilizing a hoist to install platform.

Lift Cylinder Repair WARNING

A service platform is available from Crown to allow maintenance to be performed to the primary lift cylinders. The platform is placed at the top of the mast with a fork lift or hoist with sling, etc.

SERVICE PLATFORM (PART NO. 109792-012)

No personnel should ride on the service platform while it is being lifted into position on the truck. After the service platform has been properly positioned, maintenance personnel can take their position on the platform. The clamps must be tightened, by turning clockwise, against the “I”-beam flange at this time.

2489S

ILLUSTRATION 8-2

The top of mast has a cover that must be removed to gain access to the top of the mast. A short chain is attached to the cover to allow it to be conveniently moved or allowed to hang aside.

2488S

ILLUSTRATION 8-1 4260

Crown 1984 PF-5853-1 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18 - 001

MAINTENANCE Secure the free lift cylinder tube assembly to the top of the mast or main frame. A hole is available at the top of the pulley plate mounting bracket to allow for chain, cable, etc. to secure free lift cylinder. The free lift cylinder must be secured prior to removing mounting bolts from the free lift cylinder rams and/or raising the operator compartment to obtain chain, hydraulic hose, and cable slack.

The operator compartment must be raised with a hoist or other lift truck to an approximate height of 12" to 15" (305 to 380 mm) from the collapsed position to obtain enough slack in the lift chain etc. Block the operator compartment securely with 4 x 4 hardwood blocks. Remove the two bolts (A) securing each free lift cylinder ram to the mast tip-out assembly (D). Remove the one bolt (B) securing the second stage cylinder ram to the tip-out assembly. Refer to Illustration 8-4.

2711S

5ILLUSTRATlON 8-4

Remove the four bolts (C), two on each side, that hold the tipout in the operating position to the second stage mast. Refer to Illustration 8-4.

2703S

ILLUSTRATION 8-3

Crown 1984 PF-5853-2 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18 - 002

MAINTENANCE Rotate the tip-out assembly up and out of second stage mast. Move the tip out to a position past vertical and place a rod between l-beam and tip-out to prevent the return to its operating position unintentionally.

2705S

ILLUSTRATION 8-6

To remove the cylinder cap, turn cylinder cap counterclockwise utilizing a spanner wrench with 3/16" (5 mm)pins and unscrew it from the cylinder tube.

2494S

The seals used in the cylinders are made of an extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

ILLUSTRATION 8-5 NOTE Before the tip out is raised make sure any and all loose parts are moved aside to prevent falling into the bottom of the mast assembly. The free lift cylinder rams have a spacer for each mounting bolt along with a button rest for each ram that must be carefully removed to prevent being dropped into the mast/main frame area.

Make sure all hydraulic pressure has been removed from the lift cylinders. Carefully remove hydraulic fittings from lift cylinder rams. Attempt to absorb any hydraulic oil draining from lines during this procedure. Free Lift Cylinder Repair When an excessive amount of hydraulic oil is evident on the top of the cylinder where the ram exits from the cap, the rod packing is probably bad and should be replaced. The replacement of the packing can be accomplished without removing the ram assembly from the cylinder tube or truck.

2706S

ILLUSTRATION 8-4

A bushing is located below the cap and remains in the cylinder bore after the cap is removed.

Crown 1984 PF-5853-3 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18 - 003

MAINTENANCE Remove the bushing by inserting an 8-32 x 3" bolt into each hole located in the top of bushing and lifting straight up. Refer to illustration.

0390S

ILLUSTRATION 8-10

ILLUSTRATION 8-8

NOTE

The packing is located below the cap and remains in the cylinder bore after the bushing is removed. A pair of special tools can be utilized to facilitate packing removal. Refer to illustration 8-9.

Extreme care should be taken to prevent damage to cylinder wall and ram assembly.

2707S

At this time, the wiper ring should also be removed since packings and wiper rings should always be replaced in pairs. Thoroughly clean the area where the seals seat. Any burrs, dirt or seal debris must be removed before installing new seals. CAUTION

Close inspection of critical seal seating areas should be made before new seal(s) is installed. Your seal failure may not have been caused by a worn seal, but rather, by burrs, nicks and dirt located on the seal seating area, causing the seal to deform and lose its sealing ability. 0389S

ILLUSTRATION 8-9

To make these tools, weld or braze a headless No. 8 metal screw to the end of a screwdriver. The screwdriver must have at least 6" of shank length with no larger than 5/32" shank diameter. After attaching the screw to the screwdriver, grind off excess weld to a diameter of 5/32". Wrap the shank with electrical tape from the tip of the screw to the screwdriver handle. This will prevent scratching of the cylinder bore or the ram. Insert the tools between the ram and the cylinder walls, 180° apart, and screw into the face of the packing (See illustration 8-10). After the threads are sufficiently secured into the packing, evenly pull on the screwdriver handles until the packing is removed.

Tools used to install hydraulic seals should be of soft metal or suitable plastic, free of burrs and sharp edges. Screwdrivers and other similar tools should not be used as they may damage the sealing edges. The area in contact with the seal should be free of burrs, sharp edges and nicks. If necessary to force seal over sharp edges, slots or undercuts, protective devices should be used. Use a Crown seal installation tool (part number 091240-009). Light lubrication should be applied to the seal and installation groove prior to installation. The same oil as will be used later in the cylinder should be applied.

Crown 1984 PF-5853-4 Rev. 1/94

M8.0 - 18 - 004

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18 - 004

MAINTENANCE Cylinder U-Cup Installation For “lip first” installation, a sleeve similar to that shown in Illustration 8-11 should be used to protect the seal from damage on threads and shoulders.

2708S 1906S

ILLUSTRATION 8-11

After packings, seals, bushings, etc. are in place, install the cap.

CAUTION

Care should be taken when inserting the cylinder cap, to prevent threads and sharp edges from damaging new seals and packings.

ILLUSTRATION 8-12

Secure the second stage lift cylinder to the “tip-out” assembly with single bolt. Refer to Illustration 8-13 . Lift the operator’s compartment with hoist or other lift truck and remove hardwood blocks. Lower operator’s compartment while making sure lift chains, hydraulic hoses, control cables, etc. are routed properly in the top of the mast assembly.

Screw the cap clockwise until the cap is tight with the top of the cylinder tube. Lower the “tip-out” assembly down to its normal operating position. Two 5/8" bolts at each side must be installed to secure “tip-out” to second stage. Secure the free lift cylinder rams to the “tip-out”. Make sure the button rest is properly positioned on top of each ram. Make sure sleeves are properly positioned through the “tip-out” and the 1/2" bolts are placed through the sleeves and tightened into the ram(s). NOTE Apply thread locking adhesive (061004-012) to the threads of the four 1/2" bolts securing the free lift cylinder rams to the “tip-out”. Do not tighten these bolts with such force that the sleeves compress.

2712S

ILLUSTRATION 8-13

Printed in U.S.A.

Crown 1984 PF-5853-5 Rev. 1/94

01 REV. 1/94

M8.0 - 18 - 005

MAINTENANCE Free Lift Cylinder Removal The service platform should be utilized during cylinder removal procedure. Refer to service platform information in this section. Remove cover from top of mast assembly. Secure the free lift cylinder tube to the top of the main frame. Refer to Illustration 8-14 . Use the hole at the top of the pulley bracket to hook a chain, steel cable, etc. to hold the cylinder assembly at the top of the mast. If the cylinder assembly is not secured to the top of the mast it will be free to fall into the mast assembly when the rams are disconnected from the “tip-out” assembly later.

Raise the operator’s compartment approximately 15" (380 mm) and carefully place hardwood blocks under compartment. This procedure will allow for sufficient slack in lift chain, hydraulic hoses, electrical cables, etc. to pivot the “tip-out” at the top of the mast. Remove the four bolts that secure the “tip-out” to the second stage mast. Remove the two bolts, sleeves, washers, etc. from the top of each ram of the free lift cylinder. Remove the bolt securing the second stage cylinder to the “tip-out”. Make sure that parts are handled carefully to prevent dropping into the mast assembly. Raise the “tipout” to the “up” position and secure in that position with steel rod (refer to Illustration 8-4 and 8-5). Disconnect lift chain(s) from anchor on “tip-out”. Make sure lift chain(s) are secured in such a manner that prevent them from falling to the floor. The chains need only to be removed from the yoke at the top of the free lift cylinder at this time. Remove the hydraulic lines from each free lift ram. Place a chain or sling of proper capacity about the area under the yoke and between the cylinder tubes and connect to hoist. Transfer the weight of the cylinder assembly from previous hook-up to the hoist at this time. Raise the cylinder carefully. The “take-up” cable must be removed from pulley near the bottom of the cylinder. The rollers at the bottom of the cylinder will align themselves with a notch in the main frame “I’ beam; push the cylinder assembly away and out of the main frame at this point. Refer to Illustration 8-14. Move the cylinder assembly to a clean work area if further repair is necessary. Second Stage Cylinder Removal Refer to Free Lift Cylinder Removal and follow procedure to the point of hoist connection. Connect hoist to second stage cylinder with chain or sling looped about the bar used for stabilization welded to the top of the cylinder tube.

2703S

ILLUSTRATION 8-14 LIFTING RINGS

2503

Crown 1984 PF-5853-6 Rev. 1/94

ILLUSTRATION 8-15 Printed in U.S.A.

01 REV. 1/94

M8.0 - 18 - 006

MAINTENANCE Move to the base of the main frame and disconnect hydraulic line at the bottom of cylinder. Take necessary steps to catch the oil that will drain from the cylinder.

2709S

ILLUSTRATION 8-16

2504S

Remove the two bolts securing the bottom of the cylinder to the main frame. Raise the cylinder assembly until it is clear of the mast assembly. NOTE Make the hoist connection as close to the top of the cylinder assembly as possible. Reduce the amount of wasted vertical distance as possible. The height of the mast and height of the cylinder assembly may be such that the hoist’s connection must be as short as possible . Move cylinder assembly to a clean work area if further disassembly is required. Free Lift Cylinder Installation Make sure service platform is installed properly. TS trucks having a collapsed height of 143" (3630 mm)or more should utilize the service platform. Carefully move the cylinder over the main frame utilizing a hoist with proper chain or sling connected to the top of the cylinder, below the yoke assembly. Lower the cylinder slowly until the rollers at the bottom of cylinder can be positioned onto the main frame l-beam flange. Continue to lower cylinder assembly making sure the hose take-up cable, poly stops, etc. are properly assembled to cylinder. As the cylinder is lowered to its home position secure the cylinder as described in “Free Lift Cylinder Repair.”

ILLUSTRATION 8-17

Install stop blocks to cross brace at top of main frame. A 1/420 tapped hole in the top of the stop block can be utilized as an aid when removing and/or installing to top of main frame. Inserting a bolt of appropriate length can be used to hold the block in position while bolting to cross brace and reduce the risk of dropping block(s) down into main frame. Connect hydraulic lines that connect free lift cylinders to second stage cylinder. Pivot the tip-out down into operating position. Place button rest on top of each free lift cylinder ram. Install sleeves, bolts, washers, etc. and secure rams to the tip-out. Refer to Illustration 8-12 for proper installation. Install bolts securing tip-out to second stage mast. Make sure lift chain(s), hydraulic and/or electrical lines are properly installed. Secure the second stage cylinder ram to the tipout. Remove hardwood blocks from beneath operator’s compartment and lower compartment. Bleed lift cylinders; refer to Cylinder Bleeding located in this section . Second Stage Cylinder Installation Make sure service platform is installed properly. TS trucks with a collapsed height of 143" (3630 mm)or more should utilize the service platform. Carefully move the cylinder over the main frame utilizing a hoist with proper chain or sling connected to the top of the cylinder tube. A stabilizer bar with loops welded near the top of the tube can make for a suitable pick-up point. Use extreme care when making secure hook up. Position the cylinder assembly in such a manner that the mounting flange at the base of cylinder is toward the tip-out.

Crown 1984 PF-5853-7 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18 - 007

MAINTENANCE Lift Cylinder Bleeding After the cylinder is installed in the truck air must be bled from the hydraulic system. Without a load on the forks, pressurize the cylinders. Do not raise the operator compartment through the extension of the lift cylinders. With the operator compartment lowered completely, check the hydraulic fluid and add fluid if necessary.

2505S

ILLUSTRATION 8-18

Lower cylinder carefully into main frame. Near the top of cylinder is a stabilizer bar. Holes in this bar are fitted to stabilizers welded at the top of the main frame.

Any air that may be trapped in the system will be forced to the top of the cylinder(s). When bleeding the second stage cylinder, an access hole is in the second stage and main frame. The bleed screw can be loosened with a blade screwdriver until all air escapes and only oil continues to flow from the cylinder. Tighten the screw and wipe off all excess oil. Access for the purpose of bleeding the two free lift cylinders must be done from the top of the mast assembly. Loosen the small bleed screw located at the top of the cylinder(s) until all air escapes and only oil continues to flow from the cylinder. Tighten the screw and wipe off all excess oil.

STABILIZERS WELDED TO INSIDE FRONT OF MAIN FRAME 2506

ILLUSTRATION 8-19

Move to the bottom of the cylinder and install spacers, lockwashers, and screws that secure cylinder to the base of the main frame. Connect hydraulic lines connecting lift cylinders. Pivot the tip-out down into operating position. Insert bolt securing ram of second stage cylinder to the tipout. Make sure the proper hardware is in proper position for securing the free lift cylinder rams to the tip-out. Refer to Free Lift Cylinder Installation for proper procedure, etc. Install four bolts securing tip-out to second stage mast. Make sure lift chain(s), hydraulic and/or electrical lines are properly installed. Remove hardwood blocks from below the operator’s compartment and lower compartment. Bleed lift cylinders. Refer to Cylinder Bleeding in this section for proper procedure.

2710S

ILLUSTRATION 8-20

Occasionally, a slight creep of the fork assembly may occur. This may be due to internal leakage in the piston pak but it can also be caused by leakage in the solenoid or check valve. To seat these valves properly when this occurs, raise and lower the forks to flush out any foreign material from the valve seat. A thorough check of the system for leaks should be conducted if abnormal oil losses occur. The hydraulic system is designed to eliminate mechanical damage even if fittings become loose.

Crown 1984 PF-5853-8 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18 - 008

MAINTENANCE LIFT CYLINDERS Great care and cleanliness should be exercised in the disassembly and assembly of hydraulic cylinders. Wipe all surfaces clean of dirt and oil before attempting disassembly. Care should be taken when removing the ram from the cylinder to prevent damage to the packing on the piston end. After cylinder components are disassembled and seals, “O” rings and wipers are removed, thoroughly wash all metallic parts in solvent and blow dry with low pressure air. Carefully inspect the ram assembly and cylinder bore. Replace if scored, grooved, pitted or worn. Minor damage to the cylinder bore can be removed with the use of a cylindrical honing tool. Place washed components in a clean container until reassembly. Whenever new packings are required, new wiper rings should also be installed.

NOTE The service platform cannot be used on TS trucks having a collapsed height of 137 in. (3480mm) or less. Utilize an appropriate maintenance platform fitted to another lift truck to perform maintenance to the lift cylinder area at the top of the mast. Turn the two clamps at the top of the platform counterclockwise to allow for clearance of the I-beam flange before attempting to place platform on truck. Secure the service platform to the forkplate of the fork lift, if used, before lifting. Connect sling or chain to the four corners of the platform railing when utilizing a hoist to install platform.

Service Platform

WARNING

When performing maintenance to a primary lift cylinder, Crown recommends using a service platform. A service platform is available from Crown; the part no. is 109792-012. The platform is placed at the top of the mast with a fork lift or hoist with sling, etc.

SERVICE PLATFORM (PART NO. 109792-012)

2489S

2488S

ILLUSTRATION 8-2

ILLUSTRATION 8-1 4586

Crown 1990 PF-8635-1 Rev. 2/95

Printed in U.S.A.

02 REV. 2/95

M8.0–18.1–001

MAINTENANCE Pivoting the Tip-Out Assembly (Accessing the Lift Cylinder) To gain access to the lift cylinder for repair or removal, proceed as follows:

6. The free lift cylinder must be secured prior to removing mounting bolts from the cylinder rams otherwise it will be free to fall into the mast. A hole is located at the top of the pulley plate mounting bracket to allow for chain, cable, etc. to secure the free lift cylinder (refer to Illustration 8-4).

1. The second stage mast must be blocked to allow the mast tip-out assembly to be pivoted. To block the mast, raise the second stage mast so that the column roller covers on the bottom of the mast can be easily removed. 2. Position approximately 10 in. (250 mm) square steel plates, 0.5 to 1.0 in. (13 to 25 mm) thick, on top of the base of the main frame, against each main frame Ibeam (refer to Illustration 8-3). CAUTION

Do not use blocking that is more than 1.0 in (25 mm) thick. Using thicker blocking may deform and damage the hydraulic tubes located at the top of the mast when lowering the second stage mast. 3. Completely lower the second stage mast onto the steel plates.

2703S 2490S

ILLUSTRATION 8-3

4. Disconnect battery and chock load wheels. 5. Remove the cover on the top of the mast. A short chain is attached to the cover to allow it to be moved or hung aside.

ILLUSTRATION 8-4

7. Using a hoist, other lift truck, etc., raise the operator compartment approximately 2 feet (0.5m). This procedure will produce slack in the lift chain, cables and hoses. Block the operator compartment securely with 4 x 4 (100 mm x 100 mm) hardwood blocks.

Crown 1990 PF-8635-2 Rev. 2/95

Printed in U.S.A.

02 REV. 2/95

M8.0–18.1–002

MAINTENANCE 8. Remove the one bolt (A) securing the main lift cylinder to the tip-out assembly. Refer to Illustration 8-5.

2493S

ILLUSTRATION 8-6 NOTE The free lift cylinder rams have a spacer for each mounting bolt along with a button rest for each ram that must be carefully removed to prevent being dropped into the mast main frame area when pivoting the tip-out.

2704S

ILLUSTRATION 8-5

9. Remove the two bolts (B) securing each free lift cylinder ram to the tip-out assembly.

15. Pivot the tip-out assembly just enough to pull the pin out of the chain anchor. The chain anchor should fall free from the tip-out and hang from the attached cable, chain, etc. used in step 11.

10. Remove the four tip-out assembly mounting bolts (C). 11. Attach a cable, chain, etc. to the chain anchor mounted on the back of the tip-out assembly and secure. This will prevent the anchor and chain from falling into the mast. 12. Remove one of the retaining rings (D) securing the pin in the chain anchor. This will allow easier removal of the chain anchor later. 13. Open the manual lower valve (refer to Illustration 8-6) located on the back of the power unit. This will relieve pressure causing the main lift cylinder ram to retract. 14. Pull the cables and hoses free of the tip-out assembly, move to the side and secure. Crown 1990 PF-8635-3 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18.1 - 003

MAINTENANCE 16. Pivot the tip-out assembly past vertical and place a rod between the I-beam and tip-out to prevent the inadvertent return of the tip-out to its operating position.

2705S

ILLUSTRATION 8-8

To remove the cylinder cap, turn cylinder cap counterclockwise utilizing a spanner wrench 0.188 in. pins and unscrew it from the cylinder tube. 2494S

ILLUSTRATION 8-7

17. For easier access to the free lift cylinders, remove the tip-out assembly mounting blocks from the second stage mast.

The seals used in the cylinders are made of an extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

Free Lift Cylinder Repair When an excessive amount of hydraulic oil is evident on the top of the cylinder where the ram exits from the cap, the rod packing is probably bad and should be replaced. The replacement of the packing can be accomplished without removing the ram assembly from the cylinder tube or truck. Make sure all hydraulic pressure has been removed from the lift cylinders. Carefully remove hydraulic fittings from lift cylinder rams. Attempt to absorb any hydraulic oil draining from lines during this procedure.

2706S

ILLUSTRATION 8-9

A bushing is located below the cap and remains in the cylinder bore after the cap is removed.

Crown 1990 PF-8635-4 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18.1 - 004

MAINTENANCE Remove the bushing by inserting an 8-32 x 3 in. bolt into each hole located in the top of bushing and lift straight up. Refer to Illustration 8-10.

0390S

2707S

ILLUSTRATION 8-12 NOTE

ILLUSTRATION 8-10

The packing is located below the cap and remains in the cylinder bore after the bushing is removed. A pair of special tools can be utilized to facilitate packing removal . Refer to Illustration 8-11.

Extreme care should be taken to prevent damage to cylinder wall and ram assembly. At this time, the wiper ring should also be removed since packings and wiper rings should always be replaced in pairs. Thoroughly clean the area where the seals seat. Any burrs, dirt or seal debris must be removed before installing new seals. CAUTION

ILLUSTRATION 8-11

To make these tools, weld or braze a headless No. 8 metal screw to the end of a screwdriver. The screwdriver must have at least 6 in. (152 mm) of shank length with no larger than 0.156 in. (4 mm) shank diameter. After attaching the screw to the screwdriver, grind off excess weld to a diameter of 0.156 in. (4 mm). Wrap the shank with electrical tape from the tip of the screw to the screwdriver handle. This will prevent scratching of the cylinder bore or the ram. Insert the tools between the ram and the cylinder walls, 180° apart, and screw into the face of the packing (see illustration 8-12). After the threads are sufficiently secured into the packing, evenly pull on the screwdriver handles until the packing is removed.

Crown 1990 PF-8635-5 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18.1 - 005

MAINTENANCE Cylinder U-Cup Installation

NOTE

For “lip first” installation, a sleeve similar to that shown in Illustration 8-13 should be used to protect the seal from damage on threads and shoulders.

1906S

The 0.5 in. bolts must not be tightened too excessively so that the sleeves compress.

ILLUSTRATION 8-13

After packings, seals, bushings, etc. are in place, install the cap. 2708S

CAUTION

ILLUSTRATION 8-14

5. Remove cable, chain etc. securing the free lift cylinders used when disassembling.

Care should be taken when inserting the cylinder cap, to prevent threads and sharp edges from damaging new seals and packings.

6. Assemble chain anchor onto tip-out assembly.

Screw the cap clockwise until the cap is tight with the top of the cylinder tube.

7. Check to be sure chains, hoses and cables are properly routed in the top of the mast.

Reassembling Mast Tip-Out

8. Remove blocks from platform and lower.

1. If the tip-out mounting blocks have been removed from the main frame, assemble onto main frame. 2. Position button rests on free lift cylinder rams and lower the tip-out assembly to its normal operating position. 3. Secure the tip-out assembly onto the mounting blocks. Torque the four 0.625 in. bolts to 80 to 90 ft. Ibs. (108 to 122 Nm).

9. Connect battery and raise platform just enough to allow the main lift cylinder ram to extend into the tipout assembly. 10. Disconnect battery. Raise and block platform to allow slack in mast chains.

4. Make sure the button rests are properly positioned on top of the rams and the sleeves are properly positioned in the tip-out. Apply thread locking adhesive (061004012) to the four 0.5 in. bolts and secure free lift cylinder rams to the tip-out (refer to Illustration 8-14).

Crown 1990 PF-8635-6 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18.1 - 006

MAINTENANCE 11. Insert the single bolt into the tip-out assembly that secures the main lift cylinder ram to the tip-out and tighten.

4. Attach a sling, chain, etc. under the yoke, connect to hoist and apply just enough tension to keep the cylinders in place.

12. Assemble cover to top of mast.

5. Remove the cable, chain, etc. securing the free lift cylinders used when disassembling the tip-out.

13. Remove blocks from platform and lower. 6. Raise the cylinder carefully. The “take-up” cable must be removed from pulley near the bottom of the cylinder. The rollers at the bottom of the cylinder will align themselves with a notch in the main frame I-beam; push the cylinder assembly away and out of the main frame at this point. Refer to Illustration 8-16.

14. Raise 2nd stage mast and remove blocks. 15. Connect battery and check operation. Free Lift Cylinder Removal To gain access to the free lift cylinders, refer to Pivoting the Tip-Out Assembly previously explained in this section. After following those procedures: 1. Disconnect the mast chains from the chain anchor and remove them from the yoke at the top of the free lift cylinders. Lay the chains over the top of the tip-out assembly and secure. 2. Disconnect the hydraulic lines from each free lift ram. 3. Remove stop blocks to cross brace at top of main frame. A 0.25-20 tapped hole in the top of the stop block can be utilized as an aid when removing and/or installing to top of main frame. Inserting a bolt of appropriate length can be used to hold the block in position while removing or installing to cross brace and reduce the risk of dropping block(s) down into main frame.

2703S

2709S

ILLUSTRATION 8-15

ILLUSTRATION 8-16

7. Move the cylinder assembly to a clean work area if further repair is necessary.

Crown 1990 PF-8635-7 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18.1 - 007

MAINTENANCE Main Lift Cylinder Removal

5. Remove the two bolts securing the bottom of the cylinder to the main frame.

To gain access to the main lift cylinder, refer to Pivoting the Tip-Out Assembly previously explained in this section. After following those procedures:

6. Raise the cylinder assembly until it is clear of the mast assembly.

1. Disconnect the mast chains from the chain anchor and remove them from the yoke at the top of the free lift cylinders. Lay the chains over the top of the tip-out assembly and secure.

NOTE Make the hoist connection as close to the top of the cylinder assembly as possible. Reduce the amount of wasted vertical distance as possible. The height of the mast and height of the cylinder assembly may be such that the hoist’s connection must be as short as possible.

2. Disconnect the hydraulic lines from the main lift cylinder ram. 3. Connect hoist to main lift cylinder with chain or sling looped about the bar (used for stabilization) welded to the top of the cylinder tube. Refer to Illustration 8-17.

7. Move cylinder assembly to a clean work area if further disassembly is required. Free Lift Cylinder Installation 1. Carefully move the cylinder over the main frame utilizing a hoist with proper chain or sling connected to the top of the cylinder, below the yoke assembly. 2. Lower the cylinder slowly until the rollers at the bottom of cylinder can be positioned onto the main frame Ibeam flange. Continue to lower cylinder assembly making sure the hose take-up cable, poly stops, etc. are properly assembled to cylinder.

LIFTING RINGS

3. Assemble stop blocks and connect hydraulic lines. 2503

For further procedures refer to Reassembling the Tip-Out and Cylinder Bleeding located in this section.

ILLUSTRATION 8-17

4. Move to the base of the main frame and disconnect hydraulic line at the bottom of cylinder. Take necessary steps to catch the oil that will drain from the cylinder.

2504S

Main Lift Cylinder Installation 1. Carefully move the cylinder over the main frame utilizing a hoist with proper chain or sling connected to the top of the cylinder tube. A stabilizer bar with loops welded near the top of the tube can make for a suitable pick-up point. Use extreme care when making secure hook up. Position the cylinder assembly in such a manner that the mounting flange at the base of cylinder is toward the tip-out. Refer to Illustration 8-19.

ILLUSTRATION 8-18

Crown 1990 PF-8635-8 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18.1 - 008

2505S

ILLUSTRATION 8-19 2. Lower cylinder carefully into main frame. Near the top of cylinder is a stabilizer bar. Holes in this bar are fitted to stabilizers welded at the top of the main frame.

Any air that may be trapped in the system will be forced to the top of the cylinder(s). When bleeding the main lift cylinder, an access hole is in the second stage and main frame. The bleed screw can be loosened with a blade screwdriver until all air escapes and only oil continues to flow from the cylinder. Tighten the screw and wipe off all excess oil. Access for the purpose of bleeding the two free lift cylinders must be done from the top of the mast assembly. Loosen the small bleed screw located at the top of the cylinder(s) until all air escapes and only oil continues to flow from the cylinder. Tighten the screw and wipe off all excess oil.

STABILIZERS WELDED TO INSIDE FRONT OF MAIN FRAME

2506

ILLUSTRATION 8-20 3. Move to the bottom of the cylinder and install spacers, lockwashers and screws that secure cylinder to the base of the main frame. Connect hydraulic lines connecting lift cylinders.

For further procedures refer to Reassembling the Tip-Out and Cylinder Bleeding located in this section.

2710S

ILLUSTRATION 8-21 Occasionally, a slight creep of the fork assembly may occur. This may be due to internal leakage in the piston pak but it can also be caused by leakage in the solenoid or check valve. To seat these valves properly when this occurs, raise and lower the platform to flush out any foreign material from the valve seat. A thorough check of the system for leaks should be conducted if abnormal oil losses occur.

Crown 1990 PF-8635-9 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M8.0 - 18.1 - 009

MAINTENANCE TN MAST LIFT CYLINDER Great care and cleanliness should be exercised in the disassembly and assembly of hydraulic cylinders. Wipe all surfaces clean of dirt and oil before attempting disassembly. Care should be taken when removing the ram from the cylinder to prevent damage to the packing on the piston end. After cylinder components are disassembled and seals, “O” rings and wipers are removed, thoroughly wash all metallic parts in solvent and blow dry with low pressure air. Carefully inspect the ram assembly and cylinder bore. Replace if scored, grooved, pitted or worn. Minor damage to the cylinder bore can be removed with the use of a cylindrical honing tool. Place washed components in a clean container until reassembly. Whenever new packings are required, new wiper rings should also be installed. Service Platform When performing maintenance to a primary lift cylinder, Crown recommends using a service platform. A service platform is available from Crown; the part no. is 109792-012. The platform is placed at the top of the mast with a fork lift or hoist with sling, etc. SERVICE PLATFORM (PART NO. 109792-012)

NOTE The service platform cannot be used on TS trucks having a collapsed height of 137 in. (3480mm) or less. Utilize an appropriate maintenance platform fitted to another lift truck to perform maintenance to the lift cylinder area at the top of the mast. Turn the two clamps at the top of the platform counterclockwise to allow for clearance of the l-beam flange before attempting to place platform on truck. Secure the service platform to the forkplate of the fork lift, if used, before lifting. Connect sling or chain to the four cornersof the platform railing when utilizing a hoist to installplatform.

WARNING

2489S

2488S

ILLUSTRATION 8-2

ILLUSTRATION 8-1

931015

4121MI - 37979

Crown 1993 PF-9990-1

Printed in U.S.A.

M8.0 - 18.1 - 150

MAINTENANCE Pivoting the Tip-Out Assembly (Accessing the Lift Cylinder) To gain access to the lift cylinder for repair or removal, proceed as follows:

7. Drive pin out holding chain anchor to main frame. Access holes in the main frame and second stage mast are in line with chain anchor pin.

1. Chock wheels. 2. Raise the platform approximately 2 feet (0.5m). Block the platform securely with 4 in. x 4 in. (100mm x 100mm) hardwood blocks. Lower the cylinder completely. This procedure will produce slack in the lift chain, cables and hoses. 3. Disconnect battery. 4. Secure lift chains to top of platform so all slack is above platform. 5. Remove the cover on top of the mast. A short chain is attached to the cover to allow it to be moved and hung aside.

8. Hang chain out over edge of mast and secure. 9. Remove bolt (A) holding lift cylinder to tip-out. 10. Attach a hoist, other lift truck, etc., to the lifting bar on the tip-out and lift so cylinder pulls out of tip-out. 11. Position approximately 10in. (250mm) square steel plates, 0.5 to 1.0in. (13 to 25mm) thick, on top of the base of the main frame, against each main frame Ibeam of sufficient quantity to keep cylinder from contacting the tip-out. Refer to Illustration 8-3.

6. Remove snap rings (C) from chain anchor pin. Refer to Illustration 8-3. (B)

CAUTION

Do not use blocking that is more than 1.0 in. (25mm) thick.

LIFTING BAR

TIP-OUT ASSEMBLY (A) MAIN LIFT CYLINDER RAM TIP-OUT MOUNTING BLOCKS

SECOND STAGE MAST (C) PART OF MAIN MAST 2492 Crown 1993 PF-9990-2

M8.0 - 18.1 - 151

ILLUSTRATION 8-3 Printed in U.S.A.

M8.0 - 18.1 - 151

MAINTENANCE

2490S

ILLUSTRATION 8-4

12. Lower second stage mast onto steel plates. ILLUSTRATION 8-6

2493S

13. Remove tip-out bolts (B). Refer to Illustration 8-3. Pivot tip-out. Place rod between tip-out and I-beam to prevent the inadvertent return of the tip-out to its operating position. Refer to Illustration 8-5.

Cylinder Repair When an excessive amount of hydraulic oil is evident on top of the cylinder where the ram exits from the cap, the rod packing is probably bad and should be replaced. The replacement of the packing can be accomplished without removing the ram assembly from the cylinder tube or truck. 1. Make sure all hydraulic pressure has been removed from the main cylinder.

WARNING

AVOID HIGH PRESSURE FLUIDS—Escaping fluids 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.

2494S

ILLUSTRATION 8-5

14. Open the manual lower valve (refer to Illustration 8-6) located on the back of the power unit. This will relieve pressure causing the main lift cylinder ram to retract.

Crown 1993 PF-9990-3

M8.0 - 18.1 - 152

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. 2. Remove the cylinder cap by turning cylinder cap counterclockwise utilizing a cap socket, Crown part number 117318, and unscrew it from the cylinder tube. Printed in U.S.A.

M8.0 - 18.1 - 152

MAINTENANCE NOTE The seals used in the cylinder is made of an extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

4. Insert the tools between the ram and the cylinder walls,180° apart, and screw into the face of the packing (see Illustration 8-10). 5. After the threads are sufficiently secured into the packing, evenly pull on the screwdriver handles until the packing is removed.

WIPER RING NOTE Extreme care should be taken to prevent damage to cylinder wall and ram assembly.

COLLAR BUSHING

2496S

6. At this time, remove the wiper ring from the cylinder cap since packings and wiper rings should always be replaced in pairs.

ILLUSTRATION 8-8

3. The packing is located below the cap and remains in the cylinder bore after the cylinder cap is removed. A pair of special tools can be utilized to facilitate packing removal. Refer to Illustration 8-9.

0390S

0389S

ILLUSTRATION 8-10

ILLUSTRATION 8-9

Crown 1993 PF-9990-4

M8.0 - 18.1 - 153

Printed in U.S.A.

M8.0 - 18.1 - 153

MAINTENANCE 7. Thoroughly clean the area where the seals seat. Any burrs, dirt or seal debris must be removed before installing new seals. CAUTION

Close inspection of critical seal seating areas should be made before new seal(s) is installed. Refer to Illustration 8-11. Your seal failure may not have been caused by a worn seal, but rather, by burrs, nicks and dirt located on the seal seating area, causing the seal to deform and lose its sealing ability.

Cylinder Packing Installation For “ lip first” installation, a sleeve similar to that shown in Illustration 8-11 should be used to protect the seal from damage on threads and shoulders. (Crown has a packing sleeve available, part number 091240-015.) NOTE Tools used to install hydraulic seals should be of soft metal or suitable plastic, free of burrs and sharp edges. Screwdrivers and other similar tools should not be used as they, may damage the sealing edges. 1. After packings, seals, bushings, etc. are in place, install the cap. CAUTION

Care should be taken when inserting the cylinder cap, to prevent threads and sharp edges from damaging new seals and packings. 2. Screw the cap clockwise until the cap is tight in the top of the cylinder tube.

ILLUSTRATION 8-11

1906

NOTE Tools used to install hydraulic seals should be of soft metal or suitable plastic, free of burrs and sharp edges. Screwdrivers and other similar tools should not be used as they, may damage the sealing edges. 8. The area in contact with the seal should be free of burrs, sharp edges and nicks. 9. Apply light lubrication to the seal and installation groove. The same oil as will be used later in the cylinder should be applied.

Crown 1993 PF-9990-5

M8.0 - 18.1 - 154

Printed in U.S.A.

M8.0 - 18.1 - 154

MAINTENANCE Reassembling Mast Tip-Out 1. If the tip-out mounting blocks have been removed from the main frame, assemble onto main frame. Refer to Illustration 8-12.

7. Insert the single bolt into the tip-out assembly that secures the lift cylinder to the tip-out and tighten. 8. Align holes of chain anchor and mounting blocks and install chain anchor pin. Use the access holes in the main frame and second stage mast.

2. Remove rod from between tip-out and I-beam. 3. Pivot tip-out onto top on mast. 4. Secure the tip-out assembly onto the mounting blocks. Torque the four 0.625 in. bolts to 80 to 90 ft. Ibs. (108 to 122 Nm). 5. Attach lifting device to tip-out. Raise and remove blocks under second stage mast. 6. Lower to couple lift cylinder and tip-out.

9. Remove hardware used to secure chains to top of platform. 10. Connect battery and raise to permit removal of blocks under platform. Lower platform. 11. Bleed air from lift cylinder, if necessary, as described in Lift Cylinder Bleeding at the end of this section. 12. Install cover to top of mast.

(B) LIFTING BAR

TIP-OUT ASSEMBLY (A) MAIN LIFT CYLINDER RAM TIP-OUT MOUNTING BLOCKS

SECOND STAGE MAST (C) PART OF MAIN MAST 2492

Crown 1993 PF-9990-6

M8.0 - 18.1 - 155

ILLUSTRATION 8-12

Printed in U.S.A.

M8.0 - 18.1 - 155

MAINTENANCE 3. Remove the two bolts securing the bottom of the cylinder to the main frame. Refer to Illustration 8-14.

Lift Cylinder Removal

4. Raise the cylinder assembly until it is clear of the mast assembly. NOTE Make the hoist connection as close to the top of the cylinder assembly as possible. Reduce the amount of wasted vertical distance as possible. The height of the mast and height of the cylinder assembly may be such that the hoist’s connection must be as short as possible. If overhead clearance is not sufficient to facilitate cylinder removal, the mast may have to be laid down for cylinder removal. Refer to Section M7.

LIFTING RINGS

ILLUSTRATION 8-13

2503

To gain access to the lift cylinder, refer to Pivoting the TipOut Assembly previously explained in this section. After following those procedures: 1. Connect hoist to main lift cylinder with chain or sling looped through lifting rings welded at the top of the cylinder tube. Refer to Illustration 8-13. 2. Move to the base of the main frame and disconnect hydraulic line at the bottom of cylinder. Take necessary steps to catch the oil that will drain from the cylinder.

WARNING

2504S

ILLUSTRATION 8-14

5. Move cylinder assembly to a clean work area if further disassembly is required.

Crown 1993 PF-9990-7

M8.0 - 18.1 - 156

Printed in U.S.A.

M8.0 - 18.1 - 156

MAINTENANCE Lift Cylinder Installation 1. Carefully move the cylinder over the main frame utilizing a hoist with proper chain or sling connected to the top of the cylinder tube. A stabilizer bar with loops welded near the top of the tube can make for a suitable pick-up point. Use extreme care to make secure hook up. Position the cylinder assembly in such a manner that the mounting flange at the base of cylinder is toward the tip-out. Refer to Illustration 8-15.

For remaining procedures refer to Reassembling the TipOut and Cylinder Bleeding located in this section. Cylinder Bleeding After the cylinder is installed in the truck air must be bled from the hydraulic system. Without a load on the forks, pressurize the cylinders. Do not raise the operator compartment through the extension of the main cylinder. With the operator compartment lowered completely, check the hydraulic fluid and add fluid if necessary. Any air that may be trapped in the system will be forced to the top of the cylinder. When bleeding the lift cylinder, an access hole is in the second stage and main frame. The bleed screw can be loosened with a blade screwdriver until all air escapes and only oil continues to flow from the cylinder. Tighten the screw and wipe off all excess oil. Refer to Illustration 8-17.

ILLUSTRATION 8-15

2505S

2. Lower cylinder carefully into main frame. Near the top of cylinder is a stabilizer bar. Holes in this bar are fitted to stabilizers welded at the top of the main frame. 3. Move to the bottom of the cylinder and install spacers, lockwashers and screws that secure cylinder to the base of the main frame. Connect hydraulic line to lift cylinder.

2507S

ILLUSTRATION 8-17

Occasionally, a slight creep of the fork assembly may occur. This may be due to internal leakage in the piston pak but it can also be caused by leakage in the solenoid or check valve. To seat these valves properly when this occurs, raise and lower the platform to flush out any foreign material from the valve seat. A thorough check of the system for leaks should be conducted if abnormal oil losses occur.

STABILIZERS WELDED TO INSIDE FRONT OF MAIN FRAME 2506

ILLUSTRATION 8-16

Crown 1993 PF-9990-8

M8.0 - 18.1 - 157

Printed in U.S.A.

M8.0 - 18.1 - 157

MAINTENANCE CYLINDER TUBE WIRE RETAINER BREATHER VENT

BACK-UP RING PISTON

CYLINDER CAP CASTLE NUT FLATWASHER 2818

O-RING

PISTON ROD

BACK-UP RING

NEEDLE VALVE

PISTON CUSHION WIPER RING

END CAP O-RING PISTON U-CUP

DRILLED PLUG

PACKING ROD SPRING BALL

ILLUSTRATION 8.8-1 Cylinder Removal

CYLINDERS—PIVOT The two pivot cylinders are located in the top of the turret carriage. The cylinders are single acting, piston type. As one cylinder becomes pressurized and retracts, the other becomes non-pressurized and is extended. A mechanical linkage between the cylinders pivots the fork carriage and permits smooth pivot action when required. Care and cleanliness should be exercised in the removal and or repair of hydraulic cylinders. Wipe all surfaces clean of oil and dirt build-up before attempting cylinder removal from truck or cylinder disassembly. When an excessive amount of hydraulic oil is evident at the rod end of the pivot cylinder, the rod u-cup seal or wiper ring is probably bad and should be replaced. If an excessive amount of hydraulic oil is appearing at the vent plug at the bottom of the cylinder tube, the piston u-cup seal is bad and should be replaced.

CAUTION

Be sure all hydraulic pressure is removed from pivot cylinder. Disconnect batteries before performing any maintenance on truck. The auxiliary mast should be in the maximum lowered position. Remove cover from top of turret carriage. Disconnect chain from end of cylinder rods. Remove hydraulic line from cylinders. Attempt to absorb any oil that will drain from lines. Remove the bolts securing the pivot cylinder(s) to the rear of the turret carriage. If further cylinder disassembly is necessary, move to a clean, well lighted work area.

When replacing u-cup seals, wiper rings, etc. install all parts contained in seal kit.

Crown 1994 PF-10127-1 Rev. 5/96

Printed in U.S.A.

01 REV. 5/96

M8.8–19.0–104

MAINTENANCE Cylinder Disassembly Remove retaining ring, washer, spacer and mounting block surrounding cylinder tube. Place cylinder in a vise. Care must be taken to avoid overtightening as tube damage will result. Remove the tube end cap. On cylinders using a wire retaining ring, carefully rotate the cap to back end of the wire retainer out of the cylinder tube slot. A spanner wrench should be used to rotate the cap. The cap is designed to accommodate a spanner wrench with .25 in.(6.3mm) pin and 2.375 in.(60.3mm) diameter. Remove cap. Remove vent plug from cap. Carefully remove the piston rod assembly from tube. Never allow the rod to come in contact with any sharp edges. Remove the rod end cap with a 1.5 in.(38mm) wrench. turn counter-clockwise until free of tube. The rod u-cup seal will remain in the cylinder tube. A hooked tool should be used to remove seal. Refer to Illustration 8.8-3. Thoroughly clean the area where the seal seats. Any burrs, dirt or seal debris must be removed before installing new seal.

2820S

ILLUSTRATION 8.8-3

Inspect the cylinder tube for any signs of scoring. If scoring is evident, the tube must be replaced. The tube should be honed to remove any burrs that may be present. Remove 5/32" (0.156 in.[4mm]) roll pin locking nut to piston rod. Remove nut from rod. Remove flatwasher and piston assembly from rod. Inspect rod for scoring. If scoring is evident, replace rod. With the use of a small hooked tool, carefully remove the piston seal, o-ring and back-up ring from mounting grooves in piston. CAUTION

Never use a screwdriver to remove seals, as damage and leakage may result. Inspect the seal contact surfaces on the piston for scoring. If light scoring is evident, sand with a fine emery paper until high areas are removed. Heavily scored components must be replaced. After all parts are inspected, wash all cylinder components in a good grade solvent and dry with air pressure. CAUTION

When cleaning piston, be sure to clean seal seating areas. Protect eyes and face when using compressed air After all parts are thoroughly cleaned, place in a clean area until ready for assembly. ILLUSTRATION 8.8-2

2819S

CAUTION

Close inspection of seal seating critical areas should be made before new seal is installed. Your seal failure may not have been caused by a worn seal, but rather, by burrs, nicks and dirt located on the seal seating area, causing the seal to deform and lose its sealing ability. Crown 1994 PF-10127-2

M8.8 - 19 - 105

Cylinder Assembly The seals used in the cylinders are made of extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

Printed in U.S.A.

M8.8 - 19 - 105

MAINTENANCE Tools used to install hydraulic seals should be of soft metal or suitable plastic, free of burrs and sharp edges. screwdrivers and other similiar tools should not be used as they damage the sealing edges. The area in contact with the seal should be free of burrs, sharp edges and nicks.

Snap one side of the u-cup into the installation groove in piston (Illustration 8.8-4). Hold u-cup in installation groove with thumb while inserting tool (Illustration 8.8-5) in guide hole. Apply downward force on installation tool while rotating handle 360° (Illustrations 8.8-6,-7 & -8). This will snap u-cup into groove (Illustration 8.8-9).

The installation device described can be used for all u-cups with a cross-section to outer diameter ratio equal to or greater than 1:8. For seals with a smaller ratio, use split designs. Installation tool: The installation tool consists of a circular pivot with an arm inserted through it. The circular pivot is sized so as to fit in the piston guide hole. the installation tool may be made of steel. Cone-shaped installation tools should not be used to install snap-in type piston seals as this will cause the seal to be stretched to a much larger diameter which will require very high assembly force.

2821S

ILLUSTRATION 8.8-6

2824S

ILLUSTRATION 8.8-7

2825S

ILLUSTRATION 8.8-8

ILLUSTRATION 8.8-4

Installation wil be facilitated if piston can be clamped to vise during u-cup installation. Lubrication of seal for this type of installation is mandatory.

2822S

2823S

ILLUSTRATION 8.8-5

Crown 1994 PF-10127-3

M8.8 - 19 - 106

Printed in U.S.A.

M8.8 - 19 - 106

MAINTENANCE cap with tapered slot. Insert hooked end of wire retainer into hole of cap and turn with spanner wrench until end of wire retainer is flush with tube. Refer to Illustration 8.8-11. Avoid turning end of wire retainer too far and into the tube, making removal difficult.

CYLINDER CAP

2826S

ILLUSTRATION 8.8-9

Carefully position o-ring and back-up ring in piston bore. Place piston assembly and piston cushion on piston rod along with washer and nut. Tighten nut and lock nut by installing roll pin. Refer to Illustration 8.8-1 for proper component location and or position.

WIRE RETAINER

Install rod u-cup seal to rod end of cylinder tube. For "lip first" installation, a sleeve similar to that shown in Illustration 8.810 should be used to protect the seal from damage by threads and or shoulders.

CYLINDER

2828S

ILLUSTRATION 8.8-11

Cylinder Installation

2827S

ILLUSTRATION 8.8-10

Light lubrication should be applied to the seal and installation groove prior to installation. The same oil as will be used later in the cylinder should be applied. Install wiper ring to rod and cap. Apply thread locking adhesive (061004-012) sparingly to the cap threads. Turn cap into cylinder tube until tight. Carefully guide the piston rod end through the u-cup seal and wiper ring in the rod end cylinder cap. Push the piston rod assembly into the tube to allow for cylinder cap installation. Insert vent plug to cap and position cap in tube. Align hole in Crown 1994 PF-10127=4

M8.8 - 19 - 107

Make sure the mounting block surrounding the cylinder, spacer, washer and retaining ring are positioned properly. Position shim washers and cylinder(s) in same relative position as they were previously. Install mounting bolts securing cylinder to turret carriage. Connect chain to cylinder rod ends. Make sure fork carriage is sychronized with pivot cylinder rod position. Connect hydraulic line(s) to cylinder(s). Run operational check. Replace cover to top of turret carriage. Cylinder Adjustment(Cushion Time) Cylinder "cushion" time must be set for one (1) second. The needle valve, refer to Illustration 8.8-1 must be adjusted to achieve the one (1) second "cushion" time. There should be no delay on swing out of forks.

Printed in U.S.A.

M8.8 - 19 - 107

MAINTENANCE GLOSSARY Components of the Turret Stockpicker have been listed in chart form to assist the maintenance mechanic in locating these components on the Electrical and Hydraulic Diagrams as well as the Parts Breakdowns. The chart is in columns: COMPONENT; LOCATION; FUNCTION; DIAGRAM; PARTS BREAKDOWN. The COMPONENT column contains the abbreviation of the component as it appears on the Diagrams and in the Maintenance Section. The LOCATION column indicates 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 indicates 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 the component. The PARTS BREAKDOWN column includes the parts breakdown page number on which the component is located along with the index number, in parenthesis, if applicable. In instances where components have similar configurations, (e.g. switches, relays, etc.) the components are listed in alphabetical order under that subtitle. (For example on switches the use of the N.O. & N.C. contacts are listed on how wired as I input or O output.) All other components are included under the miscellaneous subtitle.

ELECTRICAL COMPONENTS

AUDIBLE INDICATORS

HN1 HN2 HN3 HN3 HN3

Location

Function

Diagram

Parts Breakdown

Platform Platform Power Unit Power Unit Power Unit

Truck Horn Travel Alarm Forks Last Travel Alarm Forks First Travel Alarm Both Directions Travel Alarm

DIA - 19 - 036 (C-3) DIA - 19 - 031 (C-2) DIA - 19 - 042 (A-1) DIA - 19 - 042 (B-1) DIA - 19 - 042 (C-1)

4 - 19 - 302 (29) 4 - 19 - 302 (5) 4 - 19 - 001 (41) 4 - 19 - 001 (41) 4 - 19 - 001 (41)

Function

Diagram

Parts Breakdown

Serial Serial Serial Serial Serial Serial Serial Serial BDI BDI BDI Battery Common Battery Common Brake Command + BV to QD-1 K1 to Power Supplies P.U. + BV to Platform + BV to Platform + BV Options + BV Accessory Spare Emergency Battery Common Battery Common

DIA - 19 - 045 (B-1) DIA - 19 - 045 (B-1) DIA - 19 - 045 (B-1) DIA - 19 - 045 (B-1) DIA - 19 - 045 (B-1) DIA - 19 - 045 (B-1) DIA - 19 - 045 (B-1) DIA - 19 - 045 (B-1) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3)

4.8 - 19 - 502 (12) 4.8 - 19 - 502 (12) 4.8 - 19 - 502 (12) 4.8 - 19 - 502 (12) 4.8 - 19 - 502 (12) 4.8 - 19 - 502 (12) 4.8 - 19 - 502 (12) 4.8 - 19 - 502 (12) 4.8 - 19 - 502 (13) 4.8 - 19 - 502 (13) 4.8 - 19 - 502 (13) 4.8 - 19 - 502 (13) 4.8 - 19 - 502 (13) 4.8 - 19 - 502 (13) 4.8 - 19 - 502 (13) 4.8 - 19 - 502 (13) 4.8 - 19 - 502 (14) 4.8 - 19 - 502 (14) 4.8 - 19 - 502 (14) 4.8 - 19 - 502 (14) 4.8 - 19 - 502 (14) 4.8 - 19 - 502 (14) 4.8 - 19 - 502 (14) 4.8 - 19 - 502 (14)

CABLES, CONTROL Number

Color

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Red Orange Green Blue Black Black/Red White Black/White Red Orange Green Blue Black Black/Red White Black/White Red Orange Green Blue Black Black/Red White Black/White

Cable 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3

Crown 1991 PF-9163-1 Rev. 10/97

5600

Printed in U.S.A.

04 REV. 10/97

M10–19.0–012

MAINTENANCE CONNECTORS (PLUG IN) Location

Function

Diagram

Parts Breakdown

CA301 * CA302 * CA303 *

Platform Platform Platform

DIA - 19 - 028 (A-1) DIA - 19 - 028 (A-1) DIA - 19 - 028 (A-2)

4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170

CA304 * CA305 *

Platform Platform

DIA - 19 - 028 (A-3) DIA - 19 - 028 (A-3)

4.8 - 18.1 - 170 4.8 - 18.1 - 170

CA306 * CA401 * CA402 * CA403 * CA404 * CA405 * CA406 * CA407 * CA408 * CA409 * CA410 CA503 CA504 CA505 CA506 CA507 CA508 CA511 CA512 CA513 CA514 CA515 CA516 CA517 CA518 CA519 CA520 CA521 CA522 CA601 CA602 CA603 CA604 CA605 CA606 CA607 CA620 * CA621 *

Platform Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit

Service Term. Connection Serial Data Link Indicator Lights, Traction Encoder, Alarm Connections Switch, Solenoid Valve Connection Steer, R/L & Height Encoders, Steer Light Connections Power Connections Serial Data Various Command Outputs Service Terminal Feedback Connections Lift SCR & Feedback Connections Wire Guidance Wire Guidance Steering Servo Amp Connections EAC Connection Display Panel Connector Display Panel Connector Display Panel Connector BDI Interface Connector Display Panel Connector Display Panel Connector Distribution Panel Connectors Distribution Panel Connectors Distribution Panel Connectors Distribution Panel Connectors Distribution Panel Connectors Distribution Panel Connectors Distribution Panel Connectors Distribution Panel Connectors Switch Input Connectors Switch Input Connectors Switch Input Connectors Switch Input Connectors Distribution Panel Connections Distribution Panel Connections Distribution Panel Connections Distribution Panel Connections Distribution Panel Connections Distribution Panel Connections Distribution Panel Connections Wire Guide Connector Wire Guide Connector

DIA - 19 - 028 (C-3) DIA - 19 - 037 (B-1) DIA - 19 - 037 (B-2) DIA - 19 - 037 (B-3) DIA - 19 - 037 (B-4) DIA - 19 - 038 (B-1) DIA - 19 - 038 (B-2) DIA - 19 - 038 (B-3) DIA - 19 - 038 (B-4) DIA - 19 - 038 (B-4) DIA - 19 - 039 DIA - 19 - 030 (A-1) DIA - 19 - 030 (C-2) DIA - 19 - 030 (B-2) DIA - 19 - 030 (B-2) DIA - 19 - 030 (B-3) DIA - 19 - 030 (B-4) DIA - 19 - 032 (A-4) DIA - 19 - 032 (A-3) DIA - 19 - 032 (A-3) DIA - 19 - 032 (A-2) DIA - 19 - 032 (A-2) DIA - 19 - 032 (B-4) DIA - 19 - 032 (B-1) DIA - 19 - 032 (B-1) DIA - 19 - 033 (B-1) DIA - 19 - 033 (B-2) DIA - 19 - 033 (B-3) DIA - 19 - 033 (B-4) DIA - 19 - 040 (A-4) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-3) DIA - 19 - 040 (A-2) DIA - 19 - 040 (A-2) DIA - 19 - 040 (A-1) DIA - 19 - 040 (B-1) DIA - 19 - 046 (B-1) DIA - 19 - 046 (B-3)

4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170 4.8 - 18.1 - 170

NOTE: CA Connectors are a combination of the JC-000 jack and PC-000 plug components (example CA601 is a combination of PC601 and JC601). * PC Connector only shown. Crown 1991 PF-9163-2 Rev. 12/94

Printed in U.S.A.

02 REV. 12/94

M10–19.0–013

MAINTENANCE CONTACTORS Location

Function

Diagram

Parts Breakdown

Power Unit

D Contact or Traction

ED1

Power Unit

Emergency Disconnect

ED2

Power Unit

Emergency Disconnect

DIA - 19 - 042 (C-2) DIA - 19 - 043 (C-4) DIA - 19 - 044 (D-3) DIA - 19 - 043 (C-1) DIA - 19 - 041 (B-2)

Power Unit

Forward Travel (Left)

Power Unit

Forward Travel (Right)

Power Unit

Main Pump On

DIA - 19 - 042 (C-1) DIA - 19 - 043 (C-3) DIA - 19 - 042 (C-2) DIA - 19 - 043 (C-4) DIA - 19 - 044 (C-2)

Power Unit

Main Pump Bypass

DIA - 19 - 044 (C-2)

Power Unit

Accessory Pump On

DIA - 19 - 044 (B-2)

Power Unit

Reverse Travel (Left)

Power Unit

Reverse Travel (Right)

Power Unit

Steering

DIA - 19 - 042 (C-1) DIA - 19 - 043 (C-3) DIA - 19 - 042 (C-2) DIA - 19 - 043 (C-4) DIA - 19 - 041 (B-2)

4.1 - 19 - 003 (9) 4.4 - 19 - 050 4.1 - 19 - 003 (36) 4.4 - 19 - 102 4 - 19 - 100 (4) 4.4 - 19 - 050 4.1 - 19 - 003 (53) 4.4 - 19 - 001 4.1 - 19 - 003 (12) 4.4 - 19 - 001 4.1 - 19 - 003 (35) 4.4 - 19 - 102 4.1 - 19 - 003 (34) 4.4 - 19 - 102 4.1 - 19 - 003 (33) 4.4 - 19 - 102 4.1 - 19 - 002 (53) 4.4 - 19 - 001 4.1 - 19 - 003 (12) 4.4 - 19 - 001 4 - 19 - 100 (6) 4.4 - 19 - 050

Location

Function

Diagram

Parts Breakdown

Power Unit Power Unit Power Unit Power Unit

Pump Flyback Traction Flyback Plugging Diode Diode Block Travel Alarm

DIA - 19 - 044 (B-4) DIA - 19 - 043 (B-1) DIA - 19 - 043 (B-1) DIA - 19 - 042 (C-1)

4.2 - 19 - 100 (33) 4.2 - 19 - 050 (33) 4.2 - 19 - 050 (34) 4 - 19 - 001 (43)

DIODES

3REC 3REC 4REC DBI

DRIVERS, CONTACTOR

DDR PMTD P2DR PMTD PGM

Location

Function

Diagram

Parts Breakdown

Contactor Panel Contactor Panel Contactor Panel Contactor Panel Contactor Panel

D Contactor Driver P1 Contactor Driver P2 Contactor Driver F & R Contactor Driver Plugging Mode

DIA - 19 - 043 (B-3) DIA - 19 - 044 (B-2) DIA - 19 - 044 (B-2) DIA - 19 - 043 (B-4) DIA - 19 - 043 (B-2)

4.1 - 19 - 003 (17) 4.1 - 19 - 003 (17) 4.1 - 19 - 003 (17) 4.1 - 19 - 003 (17) 4.1 - 19 - 003 (30)

Location

Function

Diagram

Parts Breakdown

Platform Platform Platform Platform Power Unit

Steering Command Raise/Lower Command Traction Command Height Sense Steering Feedback

DIA - 19 - 035 (C-1) DIA - 19 - 035 (C-2) DIA - 19 - 031 (B-1) DIA - 19 - 034 (B-3) DIA - 19 - 042 (C-4)

6 - 19 - 050 (24) 4.5 - 19 - 001 (51) 4.6 - 19 - 003 (34) 9 - 19 - 200 (18) 4.8 - 19 - 001 (4)

ENCODERS

ECR1 ECR2 ECR3 ECR4 ECR5

Crown 1991 PF-9163-3 Rev. 12/94

Printed in U.S.A.

02 REV. 12/94

M10–19.0–014

MAINTENANCE FAN

Fan

Location

Function

Diagram

Parts Breakdown

Platform

Operator Cab

DIA - 19 - 029 (C-2)

4.9 - 19 - 052 (13)

FUSES Number

Location

Size

Function

Diagram

Parts Breakdown

FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 FU9

Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Platform

4A 15A 15A 15A 15A 15A 15A 15A 15A

DIA - 19 - 040 (B-3) DIA - 19 - 040 (B-3) DIA - 19 - 040 (B-3) DIA - 19 - 040 (B-3) DIA - 19 - 040 (B-2) DIA - 19 - 040 (B-2) DIA - 19 - 040 (B-2) DIA - 19 - 040 (B-2) DIA - 19 - 032 (B-3)

4 - 19 - 100 (25) 4 - 19 - 100 (26) 4 - 19 - 100 (26) 4 - 19 - 100 (26) 4 - 19 - 100 (26) 4 - 19 - 100 (26) 4 - 19 - 100 (26) 4 - 19 - 100 (26) 4 - 19 - 302 (17)

FU10 FU11 FU12 FU13 FU14 FU15 FU16

Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Platform

15A 15A 250A 300A 60A 30A 4A

Power Supplies Platform Power Platform Options Platform Accessory Flasher & BDI Quad Driver 2 & D Con. Quad Driver 3 R/L Servo Power Supplies & Quad Driver 4 Traction SCR Logic Lift SCR Logic Traction SCR Power Lift SCR Power Aux. Motor Power (P3) Steer Servo Power Seat Switch

DIA - 19 - 043 (A-2) DIA - 19 - 044 (B-1) DIA - 19 - 048 (B-1) DIA - 19 - 048 (C-3) DIA - 19 - 048 (C-3) DIA - 19 - 048 (B-1) DIA - 19 - 034 (C-2)

4.1 - 19 - 003 (24) 4.1 - 19 - 003 (24) 4.1 - 19 - 003 (48) 4.1 - 19 - 003 (41) 4.1 - 19 - 003 (42) 4.1 - 19 - 003 (43) 9 - 19 - 100 (56)

HOUR METER

Location

Function

Diagram

Parts Breakdown

Power Unit

DIA - 19 - 040 (B-3)

4 - 19 - 100 (28)

LIGHTS Location

Function

Diagram

Parts Breakdown

LGT1 LGT2 LGT3 LGT4 LGT5 LGT6 LGT7 LGT8 LGT9 LGT10 LGT11 LGT12 LGT13 LGT14 LGT15 LGT16

Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Power Unit Power Unit Power Unit Power Unit

Steer Wheel Indicator - Left Steer Wheel Indicator - Center Steer Wheel Indicator - Right Traverse Home Pivot Home Gate Open Service (Wrench) Calibration Active (Calipers) Guidance - Field Strength Guidance - Manual Guidance - Auto Brake Status Processor Fault Chain Slack or Break Cable Slack or Break Flashing Light

DIA - 19 - 035 (B-3) DIA - 19 - 035 (B-3) DIA - 19 - 035 (B-3) DIA - 19 - 030 (B-2) DIA - 19 - 030 (C-1) DIA - 19 - 030 (B-2) DIA - 19 - 030 (C-1) DIA - 19 - 030 (B-1) DIA - 19 - 030 (B-1) DIA - 19 - 030 (B-1) DIA - 19 - 030 (C-1) DIA - 19 - 030 (B-1) DIA - 19 - 040 (C-4) DIA - 19 - 040 (C-4) DIA - 19 - 040 (B-4) DIA - 19 - 045 (C-4)

LGT17

Platform

Dome Light

DIA - 19 - 029 (C-3)

6 - 19 - 050 (28) 6 - 19 - 050 (28) 6 - 19 - 050 (28) 4.8 - 19 - 200 (13) 4.8 - 19 - 200 (13) 4.8 - 19 - 200 (13) 4.8 - 19 - 200 (13) 4.8 - 19 - 200 (13) 4.8 - 19 - 200 (13) 4.8 - 19 - 200 (13) 4.8 - 19 - 200 (13) 4.8 - 19 - 200 (13) 4 - 19 - 100 (15) 4 - 19 - 100 (15) 4 - 19 - 100 (15) 4 - 19 - 001 (37) 4.9 - 19 - 003 (8) 4.9 - 19 - 100 (14)

Crown 1991 PF-9163-4 Rev. 12/94

Printed in U.S.A.

02 REV. 12/94

M10–19.0–015

MAINTENANCE LIGHTS (Continued)

LGT18 LGT19 LGT20 LGT21 LGT22 LGT23 LGT24

Location

Function

Diagram

Parts Breakdown

Platform Platform Platform Platform Power Unit Platform Platform

Palm Light Work Light - Left Work Light - Right Lift Cut - Out Zone Indicator Tow Light EAC Active (Button) Lift Cut - Out Indicator (Button)

DIA - 19 - 030 (C-2) DIA - 19 - 029 (C-2) DIA - 19 - 029 (C-3) DIA - 19 - 029 (C-3) DIA - 19 - 040 (B-4) DIA - 19 - 031 (C-3) DIA - 19 - 031 (C-3)

4.8 - 19 - 200 (13) 4.9 - 19 - 052 (28) 4.9 - 19 - 100 (18) 4.8 - 19 - 200 (13) 4.6 - 19 - 003 (44) 4.6 - 19 - 003 (14)

MOTORS Location

Function

Diagram

Parts Breakdown

Power Unit

Lift Pump

72V 48V 72V 48V 72V 48V

DIA - 19 - 049 (A1) DIA - 19 - 048 (A-1) DIA - 19 - 049 (B-2) DIA - 19 - 048 (B-2) DIA - 19 - 049 (B-1) DIA - 19 - 048 (B-1)

Traction - Right

72V

DIA - 19 - 049 (B-4)

Power Unit

Steering - Left

48V 72V

DIA - 19 - 048 (B-4) DIA - 19 - 049 (C-1)

Power Unit

Steering - Right

48V 72V

DIA - 19 - 048 (C-1) DIA - 19 - 049 (C-4)

48V M7 M8

Power Unit Platform

Servo - Valve Seat Adjustment

DIA - 19 - 048 (C-4) DIA - 19 - 045 (C-4) DIA - 19 - 034 (C-2)

2.2 - 19 - 051 2.2 - 19 - 002 2.2 - 18.1 - 100 2.2 - 19 -100 3 - 18 - 007 (62) 3.1 - 18 - 002 3.1 - 14 - 005 3 - 18 - 007 (62) 3.1 - 18 - 002 3.1 - 14 - 005 6 - 18 - 100 (1) 6.2 - 18 - 001 6.2 - 19 - 001 6 - 18 - 100 (1) 6.2 - 18 - 001 6.2 - 19 - 001 2.2 - 18 - 200 9 - 19 - 100 (31) 2.5 - 18 - 100 (1)

Power Unit

Accessory Pump

Power Unit

Traction - Left

Power Unit

MOTOR CONTROLLERS Location

Function

Diagram

Parts Breakdown

MRC1

Power Unit

Traction SCR

DIA - 19 - 043 (B-2)

MRC2

Power Unit

Pump SCR

DIA - 19 - 044 (B-1)

MRC3

Power Unit

Steering Servo

DIA - 19 - 041 (B-3)

4.1 - 19 - 003 (50) 4.2 - 19 - 050 4.1 - 19 - 003 (46) 4.2 - 19 - 100 4 - 19 - 100 (8) 4.2 - 19 - 153

POWER SUPPLIES

PS501 PS502 PS601 PS602

Location

Function

Diagram

Parts Breakdown

Platform Platform Power Unit Power Unit

5V Isolated Supply 12V Non-lsolated Supply 5V Isolated Supply 12V Non-lsolated Supply

DIA - 19 - 032 (C-3) DIA - 19 - 032 (C-2) DIA - 19 - 040 (C-3) DIA - 19 - 040 (C-1)

4 - 19 - 302 (19) 4 - 19 - 302 (18) 4 - 19 - 100 (20) 4 - 19 - 100 (23)

Crown 1991 PF-9163-5 Rev. 10/97

Printed in U.S.A.

04 REV. 10/97

M10–19.0–016

MAINTENANCE RELAYS

K1 K2 K3 K4

Location

Contact NO NC

Function

Diagram

Parts Breakdown

Platform Platform Platform Power Unit

2 2 2 1

Key Operated (Start) Key Operated (On) Brake Latch Brake Relay

DIA - 19 - 032 (C-3) DIA - 19 - 032 (C-2) DIA - 19 - 032 (C-3) DIA - 19 - 040 (C-3)

4 - 19 - 302 (17) 4 - 19 - 302 (17) 4 - 19 - 302 (17) 4 - 19 - 100 (19)

0 0 0 0

SCR’s

1 REC 1 REC

Location

Function

Diagram

Parts Breakdown

Power Unit Power Unit

Main Commutating SCR Traction Main Commutating SCR Pump

DIA - 19 - 043 (B-1) DIA - 19 - 044 (B-3)

4.2 - 19 - 050 (13) 4.2 - 19 - 100 (13)

SOLENOID VALVES Location

Function

Diagram

Parts Breakdown

SV1

Power Unit

Raise/Lower Servo Valve

DIA - 19 - 045 (B-4)

SV2 SV3 SV4 SV5 SV6 SV7 SV8 SV9 SV10 SV11 SV12

Power Unit Power Unit Aux Mast Aux Mast Power Unit Power Unit Power Unit Power Unit Aux Mast Aux Mast Platform

Main Lower Auxiliary Lower Fork Extend Fork Extend Brake Release Brake Release Brake Recharge Brake Rear Blocking Traverse Flip/Flop Pivot Blocking Traverse Cushion

DIA - 19 - 045 (B-3) DIA - 19 - 045 (B-3) DIA - 19 - 036 (B-2) DIA - 19 - 036 (B-2) DIA - 19 - 045 (B-3) DIA - 19 - 045 (B-2) DIA - 19 - 045 (B-3) DIA - 19 - 045 (B-2) DIA - 19 - 036 (B-1) DIA - 19 - 036 (C-1) DIA - 19 - 036 (C-3)

2 - 19 - 005 (45) 2.5 - 18 - 100 2.4 - 19 - 004 (16) 2.4 - 19 - 004 (12) 2.4 - 19 - 104 (2) 2.4 - 19 - 104 (2) 2.4 - 19 - 402 (12) 2.4 - 19 - 402 (1) 2.4 - 19 - 402 (21) 2.4 - 19 - 402 (8) 2.4 - 19 - 104 (21) 2.4 - 19 - 201 (21) 2.4 - 19 - 503 (13)

Location

Function

Diagram

Parts Breakdown

Power Unit Power Unit Power Unit

Traction Speed Tach (Left) Traction Speed Tach (Right) Lift Speed Tach

DIA - 19 - 041 (C-3) DIA - 19 - 042 (C-3) DIA - 19 - 045 (B-3)

5 - 19 - 003 (30) 5 - 19 - 003 (30) 4 - 19 - 200 (6)

SPEED SENSORS

SS1 SS2 SS3

Crown 1991 PF-9163-6 Rev. 12/94

Printed in U.S.A.

02 REV. 12/94

M10–19.0–017

MAINTENANCE SWITCHES Location

Contact NO NC

Function

AHS1

Load Hand

AHS2

Load Hand

AXS BPS1

Platform Power Unit

0 0

1 1

Aux. Mast Above 31 in. (785mm) Aux. Mast Above 12 in. (305mm) Main/Aux. Select Switch Brake Pressure Switch Low

BPS2

Power Unit

BRS1

Platform

BRS2 BRS3 BRS4 BRS5 BRS6 BRS7 CHS1 CHS2 CHS4 CHS5 CTS DMS1 DMS2

Platform Platform Platform Platform Power Unit Power Unit Platform Platform Platform Platform Main Mast Platform Platform

1 1 0 0 0 0 1 1 1 1 1 0 0

0 0 1 1 1 1 0 0 0 0 0 1 1

DMS3

Platform

DMS4

Platform

DMS5

Platform

EDS

Platform

EMS1

Platform

EMS2

Platform

EMS3

Power Unit

EMS4

Power Unit

FHSL FHSR FLS FNS FRS

Load Hand Load Hand Load Hand Platform Load Hand

1 1 1 2 1

0 0 0 0 0

GTSL GTSR GUS

Platform Platform Platform

1 1 0

0 0 1

Diagrams

Parts Breakdown

DIA - 19 - 036 (B-1)

9.1 - 19 - 303 (21)

DIA - 19 - 036 (B-1) DIA - 19 - 035 (B-3) DIA - 19 - 045 (B-2)

7.7 - 19 - 003 (34) 4.5 - 19 - 001 (12) 2 - 19 - 005 (20) 4 - 19 - 001 (31) 2 - 19 - 005 (20) 4 - 19 - 001 (31) 4.8 - 19 - 200 (30)

Brake Pressure Switch DIA - 19 - 045 (B-2) High Brake Release Seated DIA - 19 - 030 (B-4) Parking Brake Service Brake Seated DIA - 19 - 034 (C-2) Service Brake Seated DIA - 19 - 034 (C-2) Service Brake Standing (L) DIA - 19 - 034 (C-1) Service Brake Standing (R) DIA - 19 - 034 (C-1) Left Brake Status DIA - 19 - 041 (C-4) Right Brake Status DIA - 19 - 042 (C-3) Main Chain Slack DIA - 19 - 034 (B-3) Main Chain Slack DIA - 19 - 034 (B-3) Main Chain Broken DIA - 19 - 034 (B-3) Main Chain Broken DIA - 19 - 034 (B-3) Cable Tension Switch DIA - 19 - 045 (C-2) Deadman Switch - Palm DIA - 19 - 031 (B-2) Deadman Switch - Left DIA - 19 - 034 (C-2) Foot (Seated) Deadman Switch - Right DIA - 19 - 034 (C-2) Foot (Seated) Deadman Switch - Left DIA - 19 - 034 (C-1) Foot (Standing) Deadman Switch - Right DIA - 19 - 034 (C-1) Foot (Standing) Emergency Disconnect DIA - 19 - 031 (B-3) Switch Emergency Switch DIA - 19 - 031 (B-1) Traverse Ext. Emergency Switch DIA - 19 - 031 (B-2) Aux. Function Emergency Switch DIA - 19 - 040 (B-4) Aux. Function Emergency Switch DIA - 19 - 040 (B-4) Drive/Tow Fork Home Switch - Left DIA - 19 - 036 (A-1) Fork Home Switch - Right DIA - 19 - 036 (A-1) Fork Differential Switch - Left DIA - 19 - 036 (B-1) Fan Switch DIA - 19 - 030 (B-4) Fork Differential Switch DIA - 19 - 036 (A-1) Right Gate Switch - Left DIA - 19 - 036 (C-3) Gate Switch - Right DIA - 19 - 036 (C-3) Wire Guidance DIA - 19 - 030 (B-4) Manual/Automatic

Crown 1991 PF-9163-7 Rev. 12/94

4.8 - 19 - 250 (12) 4.8 - 19 - 250 (8) 4.8 - 19 - 150 (16) 4.8 - 19 - 150 (16) 5 - 19 - 003 (17) 5 - 19 - 003 (17) 7.6 - 19 - 003 (2) 7.6 - 19 - 003 (7) 7.6 - 19 - 003 (3) 7.6 - 19 - 003 (6) 7.5 - 18.1 - 300 (18) 4.6 - 19 - 003 (4) 4.8 - 19 - 250 (2) 4.8 - 19 - 250 (3) 4.8 - 19 - 150 (17) 4.8 - 19 - 150 (17) 4.6 - 19 - 003 (38) 4 - 19 - 302 (7) 4 - 19 - 302 (6) 4 - 19 - 100 (32) 4 - 19 - 100 (33) 7.9 - 19 - 003 (19) 7.9 - 19 - 003 (19) 7.9 - 19 - 003 (18) 4.8 - 19 - 200 (28) 7.9 - 19 - 003 (18) 9 - 19 - 251 (14) 9 - 19 - 251 (14) 4.8 - 19 - 200 (31) Printed in U.S.A.

02 REV. 12/94

M10–19.0–018

MAINTENANCE SWITCHES (Continued) Location

Contact NO NC

Function

Diagrams

Parts Breakdown

HCS HNS KYS LGS LGS LMS1 LMS2 LMS3 LMS4 ORS1 ORS2 ORS3 ORS4 PLS PRS PTS RGSL RGSR SES

Main Mast Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Load Hand Load Hand Platform Power Unit Power Unit Platform

1 0 2 1 1 1 0 0 0 0 1 0 0 1 1 1 0 0 1

0 1 0 0 0 0 1 1 1 1 0 1 1 0 0 0 1 1 1

DIA - 19 - 045 (C-2) DIA - 19 - 031 (B-3) DIA - 19 - 031 (B-3) DIA - 19 - 030 (B-3) DIA - 19 - 030 (C-3) DIA - 19 - 034 (A-3) DIA - 19 - 034 (A-3) DIA - 19 - 034 (A-2) DIA - 19 - 034 (B-2) DIA - 19 - 031 (C-2) DIA - 19 - 031 (C-2) DIA - 19 - 035 (C-3) DIA - 19 - 031 (C-4) DIA - 19 - 036 (C-2) DIA - 19 - 036 (C-2) DIA - 19 - 035 (B-3) DIA - 19 - 045 (C-1) DIA - 19 - 045 (C-2) DIA - 19 - 034 (A-3)

4.8 - 19 - 050 (5) 4.6 - 19 - 003 (12) 4 - 19 - 302 (3) 4.8 - 19 - 200 (29) 4.8 - 19 - 200 (29) 4.8 - 19 - 100 (4) 4.8 - 19 - 100 (4) 9 - 19 - 100 (24) 9 - 19 - 100 (25) 4.6 - 19 - 003 (11)

4.6 - 19 - 003 (45) 9.1 - 19 - 204 (6) 9.1 - 19 - 204 (5) 2.5 - 19 - 001 (22) 7.4 - 19 - 100 (15) 7.4 - 19 - 100 (15) 9 - 19 - 100 (43)

SWH1 TES1 TLS TRS

Platform Power Unit Load Hand Load Hand

2 1 0 0

0 0 1 1

DIA - 19 - 030 (B-3) DIA - 19 - 040 (C-4) DIA - 19 - 036 (A-2) DIA - 19 - 036 (A-2)

4.8 - 19 - 200 (27) 4 - 19 - 100 (33) 9.1 - 19 - 100 (52) 9.1 - 19 - 100 (52)

TVSL

Platform

DIA - 19 - 035 (B-3)

2.5 - 19 - 001 (24)

TVSR

Platform

DIA - 19 - 035 (B-3)

2.5 - 19 - 001 (25)

TDSL TDSR

Platform Platform

0 0

1 1

Height Cable Broken Horn Switch Key Switch Work Light Switch Dome Light Switch Height Reset Switch Staging Switch Seat Down Limit Switch Seat Up Limit Switch Raise/Lower Override Raise/Lower Override (Key) Extend Override EAC Override Pivot Home Switch - Left Pivot Home Switch - Right Pivot Command Switch Rail Guide Switch - Left Rail Guide Switch - Right Seat Switch (Operator On/Off) Seat Height Adj. Switch Lamp Test Traverse Home Switch - Left Traverse Home Switch Right Traverse Command Switch - Left Traverse Command Switch - Right Traverse Diff. Switch - Left Traverse Diff. Switch Right

DIA - 19 - 029 (B-3) DIA - 19 - 029 (B-2)

4 - 19 - 302 (38) 4 - 19 - 302 (40)

SUPPPRESSOR BLOCKS Location

Function

Diagram

Parts Breakdown

SB51 SB52 SB53 SB54 SB61

Platform Platform Platform Load Hand Power Unit

Fan Seat Motor Horn Traverse Cushion Left Traction Contactor

4.9 - 19 - 052 (24) 9 - 19 - 100 (22) 4 - 19 - 302 (30) 2.5 - 19 - 001 (40) 4.1 - 19 - 003 (15)

SB62

Power Unit

D Contactor

SB63

Power Unit

Right Traction Contactor

SB64 SB65 SB66

Power Unit Power Unit Power Unit

ED2 Steering Contactor SV2 (Main Lower) & SV3 (Aux. Lower)

DIA - 19 - 029 (B-2) DIA - 19 - 034 (A-2) DIA - 19 - 036 (C-3) DIA - 19 - 036 (C-3) DIA - 19 - 042 (C-1) DIA - 19 - 043 (C-3) DIA - 19 - 042 (C-2) DIA - 19 - 043 (C-4) DIA - 19 - 042 (C-2) DIA - 19 - 043 (C-4) DIA - 19 - 041 (C-1) DIA - 19 - 041 (C-2) DIA - 19 - 045 (B-3)

Crown 1991 PF-9163-8 Rev. 12/94

4.1 - 19 - 003 (10) 4.1 - 19 - 003 (11) 4 - 19 - 100 (5) 4 - 19 - 100 (7) 2.4 - 19 - 004 (6) Printed in U.S.A.

02 REV. 12/94

M10–19.0–019

MAINTENANCE SUPPRESSOR BLOCKS (Continued) Location

Function

Diagram

Parts Breakdown

SB67

Power Unit

DIA - 19 - 045 (B-2)

2.4 - 19 - 402 (29)

SB68 SB71 SB72

Power Unit Aux. Mast Aux. Mast

SV6 & SV7 (Brake Release) and SV9 (Brake Rear Blocking) SV8 (Brake Recharge) SV11 (Pivot Blocking) SV4 & SV5 (Fork Extend) and SV10 (Traverse Flip/Flop)

DIA - 19 - 045 (B-3) DIA - 19 - 036 (C-2) DIA - 19 - 036 (B-2)

2.4 - 19 - 402 (30) 2.4 - 19 - 201 (19) 2.4 - 19 - 104 (12)

TERMINAL BOARDS Location

Function

Diagram

Parts Breakdown

TB501 TB502 TB509 TB510 TB523 TB524 TB525 TB526 TB527 TB528 TB608 TB609 TB610

Platform Platform Platform Platform Platform Platform Platform Platform Platform Platform Power Unit Power Unit Power Unit

Left Overhead Guard Conn. Right Overhead Guard Conn. Traction Control Connections Traction Control Connections Seat Assembly. Connections Height Sensor Connections Foot Controls Connections L.H. Controls Connections L.H.Controls Connections Accessory Valve Asm. Conn. Reference Only L.H. Traction Connections L.H. Contactor Connections

4.9 - 19 - 052 (24) 4.9 - 19 - 100 (10) 4.6 - 19 - 003 4.6 - 19 - 003 9 - 19 - 100 (41) 9 - 19 - 200 (25) 4.8 - 19 - 250 (40) 4.5 - 19 - 001 (24) 4.5 - 19 - 001(25) 2.5 - 19 - 001 (33)

TB611

Power Unit

R.H. & D Contactor Connections

TB612 TB613 TB614 TB615 TB616 TB617 TB618 TB619 TB623 TB627 TB701 TB702 TB703 TB704 TB705 TB11T TB11P

Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Load Hand Load Hand Load Hand Load Hand Load Hand Power Unit Power Unit

R.H. Traction Connections Steering Feedback Contactor Panel Serial Connections Switch Input Connections Pump Tach Connections SV1 Connections Flashing Light EAC Connnections EAC Connnections Lower Cable Connections Lower Cable Connections Upper Cable Connections Upper Cable Connections Fork Plate Traction Card Inputs Pump Card Inputs

DIA - 19 - 029 (B-2) DIA - 19 - 029 (B-3) DIA - 19 - 031 (B-1) DIA - 19 - 031 (B-2) DIA - 19 - 034 (A-4) DIA - 19 - 034 (B-4) DIA - 19 - 034 (B-4) DIA - 19 - 035 (B-1) DIA - 19 - 035 (B-3) DIA - 19 - 036 (A-4) DIA - 19 - 041 (B-1) DIA - 19 - 041 (B-3) DIA - 19 - 042 (B-1) DIA - 19 - 043 (C-3) DIA - 19 - 042 (B-2) DIA - 19 - 043 (C-4) DIA - 19 - 042 (B-3) DIA - 19 - 042 (B-4) DIA - 19 - 043 (B-2) DIA - 19 - 045 (B-1) DIA - 19 - 045 (B-2) DIA - 19 - 045 (B-3) DIA - 19 - 045 (B-4) DIA - 19 - 045 (B-4) DIA - 19 - 047 (B-1) DIA - 19 - 047 (B-2) DIA - 19 - 036 (A-3) DIA - 19 - 036 (B-3) DIA - 19 - 036 (A-3) DIA - 19 - 036 (B-3) DIA - 19 - 036 (A-2) DIA - 19 - 043 (B-3) DIA - 19 - 044 (B-1)

Crown 1991 PF-9163-9 Rev. 12/94

4 - 19 - 001 (2) 4 - 19 - 001 (3) 4 - 19 - 001 (5) 4 - 19 - 001 (6) 4.8 - 19 - 001 (19) 4.1 - 19 - 003 (20) 4 - 19 - 001 (26) 4 - 19 - 001 (27) 4 - 19 - 001 (32) 4 - 19 - 001 (29) 4.9 - 19 - 003 (4) 4.3 - 19 - 600 (17) 4.3 - 19 - 600 (17) 9.1 - 19 - 204 (48) 9.1 - 19 - 204 (50) 9.1 - 19 - 204 (1) 9.1 - 19 - 204 (2) 2.4 - 19 - 301 (19) 4.2 - 19 - 050 4.2 - 19 - 100

Printed in U.S.A.

02 REV. 12/94

M10–19.0–020

MAINTENANCE HYDRAULIC COMPONENTS

ACCUMULATORS

ACC

Function

Hydraulic Schematic

Parts Breakdown

Brake TN Lift TN Traverse Cushion TN

HYD - 19 - 001 (A-4) HYD - 19 - 050 (A-4) HYD - 19 - 001 (B-2) HYD - 19 - 050 (B-2) HYD - 19 - 002 (B-1) HYD - 19 - 051 (B-1)

2 - 19 - 005 (26)

Function

Hydraulic Schematic

Parts Breakdown

Auxiliary Lift TN Brake - Drive Unit TN Brake - Load Wheel TN Fork - Extend/Retract TN Lift - Main

HYD - 19 - 002 (A-4) HYD - 19 - 051 (A-4) HYD - 19 - 001 (A-3) HYD - 19 - 050 (A-3) HYD - 19 - 001 (A-2) HYD - 19 - 050 (A-2) HYD - 19 - 002 (B-1) HYD - 19 - 051 (C-1) HYD - 19 - 001 (B-1)

TN Lift - Free Lift

HYD - 19 - 050 (B-1) HYD - 19 - 001 (B-1)

2 - 19 - 306 (8) 8.4 - 19 - 001 2 - 19 - 005 (1) 8.8 - 18 - 003 5 - 19 - 101 (30) 8.8 - 18.1 - 050 7.9 - 19 - 003 (1) 8.7 - 19 - 002 2 - 19 - 108 (67) 8.2 - 18 - 003 8.1 - 18.1 - 001 2 - 19 - 108 (61) 8.2 - 18.1 - 100

TN Pivot TN Pivot Latch TN

HYD - 19 - 050 (B-1) HYD - 19 - 002 (A-1) HYD - 19 - 051 (A-1) HYD - 19 - 002 (A-1) HYD - 19 - 051 (A-1)

9. 1 - 19 - 204 (10) 8.8 - 19 - 102 9.1 - 19 - 204 (8) 8.8 - 19 - 001

Function

Hydraulic Schematic

Parts Breakdown

Cap Strainer TN Inlet Strainer TN Return Line TN

HYD - 19 - 001 (C-3) HYD - 19 - 050 (C-3) HYD - 19 - 001 (C-3) HYD - 19 - 050 (C-3) HYD - 19 - 001 (C-3) HYD - 19 - 050 (C-3)

2 - 19 - 108 (2)

Function

Hydraulic Schematic

Parts Breakdown

Part of Main Lift Cyl. TN Part of Free Lift Cyl. TN Auxiliary TN

HYD - 19 - 001 (B-1) HYD - 19 - 050 (B-1) HYD - 19 - 001 (B-1) HYD - 19 - 050 (B-1) HYD - 19 - 001 (A-4) HYD - 19 - 050 (A-4)

8.2 - 18 - 003

2 - 19 - 005 (25) 2 - 19 - 306 (43)

CYLINDERS

FILTERS

2 - 19 - 108 (12) 2 - 19 - 108 (3)

FUSE-VELOCITY

Crown 1991 PF-9163-10 Rev. 12/94

8.2 - 18.1 - 100 2 - 19 - 306 (45) Printed in U.S.A.

02 REV. 12/94

M10–19.0–021

MAINTENANCE MANIFOLD Function

Hydraulic Schematic

Parts Breakdown

Main/Auxiliary Lower TN Traverse TN Pivot TN Fork-Flow Divider TN Brake TN Traverse Cushion TN

HYD - 19 - 001 (B-3) HYD - 19 - 050 (B-3) HYD - 19 - 002 (A-3) HYD - 19 - 051 (A-3) HYD - 19 - 002 (A-2) HYD - 19 - 051 (A-2) HYD - 19 - 002 (B-2) HYD - 19 - 051 (B-2) HYD - 19 - 001 (A-4) HYD - 19 - 050 (A-4) HYD - 19 - 001 (C-4) HYD - 19 - 050 (C-4)

2.4 - 19 - 004

Function

Hydraulic Schematic

Parts Breakdown

Traverse

HYD - 19 - 002 (B-2)

2 - 19 - 306 (16) 2.6 - 18 - 003

2.4 - 19 - 104 2.4 - 19 - 201 2.4 - 19 - 302 2.4 - 19 - 402 2.4 - 19 - 503

MOTOR

TN Lift Pump

HYD - 19 - 051 (B-2) DIA - 19 - 048 (A-1) DIA - 19 - 049 (A-1) DIA - 19 - 048 (B-1) DIA - 19 - 049 (B-1) DIA - 19 - 048 (B-1) DIA - 19 - 049 (B-1) DIA - 19 - 048 (B-4) DIA - 19 - 049 (B-4) DIA - 19 - 048 (C-1) DIA - 19 - 049 (C-1) DIA - 19 - 048 (C-4) DIA - 19 - 049 (C-4) DIA - 19 - 045 (C-3)

2.2 - 19 - 002 2.2 - 19 - 051 2.2 - 19 - 100 2.2 - 18.1 - 100 3.1 - 14 - 005 3.1 - 18 - 002 3.1 - 14 - 005 3.1 - 18 - 002 6.2 - 19 - 001 6.2 - 18 - 001 6.2 - 19 - 001 6.2 - 18 - 001 2.2 - 18 - 200

Accessory

Drive B

Drive A

Steer

Servo Valve

Function

HydraulicSchematic

Parts Breakdown

Main Lift TN

HYD - 19 - 001 (B-4) HYD - 19 - 050 (B-4)

2 - 19 - 108 (43)

48V 72V 48V 72V 48V 72V 48V 72V 48V 72V 48V 72V 48V

PUMPS

72V Units 48V Units P2

Accessory

HYD - 19 - 001 (B-4)

HYD - 19 - 050 (B-4)

Crown 1991 PF-9163-11 Rev. 5/96

2.1 - 18 - 001 2.1 - 19 - 002 2 - 19 - 005 (33) 2.1 - 19 - 100

Printed in U.S.A.

03 REV. 5/96

M10–19.0–022

MAINTENANCE VALVES

CV CV

Function

Hydraulic Schematic

Parts Breakdown

Check TN Check TN Control - Pivot TN Control - Traverse TN Flow Control Main TN

HYD - 19 - 002 (C-4) HYD - 19 - 051 (C-4) HYD - 19 - 001 (A-4) HYD - 19 - 050 (A-4) HYD - 19 - 002 (C-4) HYD - 19 - 051 (C-4) HYD - 19 - 002 (C-3) HYD - 19 - 051 (C-3) HYD - 19 - 001 (B-2) HYD - 19 - 050 (B-2) HYD - 19 - 001 (B-2) HYD - 19 - 050 (B-2) HYD - 19 - 002 (C-2) HYD - 19 - 051 (C-2) HYD - 19 - 002 (A-2) HYD - 19 - 051 (A-2) HYD - 19 - 001 (C-2) HYD - 19 - 050 (C-2) HYD - 19 - 002 HYD - 19 - 051 HYD - 19 - 001 (B-3) HYD - 19 - 050 (B-3) HYD - 19 - 001 (B-3) HYD - 19 - 050 (B-3) HYD - 19 - 001 (A-4) HYD - 19 - 050 (A-4) HYD - 19 - 002 (A-1) HYD - 19 - 051 (A-1) HYD - 19 - 002 (A-2) HYD - 19 - 051 (A-2) HYD - 19 - 002 HYD - 19 - 051

2.4 - 19 - 503 (9)

Aux.

CBV

PCV RV1 RV2 RV3 RV4 RV5

TN Flow Divider TN Counterbalance TN Manual Lower TN Pilot Check TN Relief - Main Lift TN Relief - Auxiliary TN Relief - Brake TN Pivot TN Pivot TN Relief, Priority TN

Crown 1991 PF-9163-12 Rev. 12/94

2.4 - 19 - 104 (11) 2.3 - 19 - 001 2.3 - 19 - 050

2.4 - 19 - 302 (10) 2.4 - 19 - 201 (9) 2 - 19 - 005 (11) 2.4 - 19 - 302 (3) 2.4 - 19 - 004 (1) 2.4 - 19 - 004 (1) 2.4 - 19 - 402 (25) 2.4 - 19 - 201 (15) 2.4 - 19 - 201 (15)

Printed in U.S.A.

02 REV. 12/94

M10–19.0–023

MAINTENANCE VALVES (Continued)

SV1 SV2 SV3 SV4

Function

Hydraulic Schematic

Parts Breakdown

Servo, Raise-Lower TN Main Lower TN Auxiliary Lower TN Fork Extend TN

HYD - 19 - 001 (B-3) HYD - 19 - 050 (B-3) HYD - 19 - 001 (B-3) HYD - 19 - 050 (B-3) HYD - 19 - 001 (B-3) HYD - 19 - 050 (B-3) HYD - 19 - 002 (A-3) HYD - 19 - 051 (A-3) HYD - 19 - 002 (A-3) HYD - 19 - 051 (A-3) HYD - 19 - 001 (A-4) HYD - 19 - 050 (A-4) HYD - 19 - 001 (A-4) HYD - 19 - 050 (A-4) HYD - 19 - 001 (A-4) HYD - 19 - 050 (A-4) HYD - 19 - 001 (A-4) HYD - 19 - 050 (A-4) HYD - 19 - 002 (A-3) HYD - 19 - 051 (A-3) HYD - 19 - 002 (A-2) HYD - 19 - 051 (A-2) HYD - 19 - 002 (C-4) HYD - 19 - 051 (C-4) HYD - 19 - 002 (A-2) HYD - 19 - 051 (A-2)

2.5 - 18 - 100

SV5 SV6 SV7 SV8 SV9 SV10 SV11 SV12 SV

TN Brake Release TN Brake Release TN Brake Recharge TN Brake Rear Blocking TN Traverse Flip/Flop TN Pivot Blocking TN Traverse Cushion TN Shuttle TN

Crown 1991 PF-9163-13 Rev. 12/94

2.4 - 19 - 004 (16) 2.4 - 19 - 004 (12) 2.4 - 19 - 104 (2) 2.4 - 19 - 104 (2) 2.4 - 19 - 402 (12) 2.4 - 19 - 402 (1) 2.4 - 19 - 402 (21) 2.4 - 19 - 402 (8) 2.4 - 19 - 104 (21) 2.4 - 19 - 201 (21) 2.4 - 19 - 501 (13) 2.4 - 19 - 201 (3)

Printed in U.S.A.

02 REV. 12/94

M10–19.0–024

This page available for NOTES.

WIRING DIAGRAMS Introduction to Diagram Usage

Introduction to Diagram Usage

•

The truck has been sectioned with one page covering each section. When options affect the wiring in a section, an additional page is added which duplicates wiring that is identical and adds the option wiring. In this way only one page of the truck section is required for the applicable truck configuration.

•

Wiring that is identified by color rather than number will typically be a cable or wires with vendor componentry.

•

Page titles, listed at the beginning of the electrical diagrams, indicate the subsystem or section of truck wiring that is covered by each page.

Schematic •

Power up diagram. Illustrates the circuitry involved in getting the truck system to an operating mode (e.g. interlock switches, relays, SCR systems etc.).

•

Circuitry which stands alone and is separate from truck operation is shown in block form with the pictorials detailing the circuitry (e.g. light package, displays, wire guidance, freezer condition).

Pictorials •

Terminal board and connector numbering on the pictorials are in two classes; power unit and platform. Power unit TB's and CA's are even 100's (200, 400, 600 etc.) and platform TB's and CA's are odd 100's (100, 300, 500 etc.). On manup trucks (SP, TS, TSP etc.), odd and even 100's will be present on the wiring diagrams. Man-down trucks, which don't have a platform (stand-up rider, pallet etc.), only even 100's will be present.

•

Wiring starts at a central location (e.g. distribution board) and wiring connection points are numbered with the lowest number odd or even. The next wiring connection point from the distribution board are then numbered with the next group of 100's and so on for each connection point removed from the central location.

•

Terminal board and connector numbering is sequential on each consecutive page. In this way a wiring address giving a connector number or terminal board number will indicate which direction to look in the diagrams for the other end of the wire. When wiring goes to a component and not a terminal board or connector, a reference terminal board is used and is shown with a dashed line box with the reference terminal board number in parenthesis. This terminal board will not appear on the truck and only present as a wiring directory.

•

Input/Output arrows may appear at terminal boards and connectors. These indicate whether what the wire is carrying is incoming or outgoing. This is helpful when tracing the origin of the signal or voltage.

Crown 1991 PF8974-1 Rev. 9/06

DIA-ITD-001 01 Rev. 9/06

ELECTRICAL DIAGRAMS

This electrical diagram index for the TSP Turret Stockpicker, lists the diagrams with portion of truck covered by each diagram. Title

Page Number

Functional Block Diagram

DIA–19.0–026

Schematic Electrical

DIA–19.0–027

Revision

01 - 9/03

Schematic Pictorial Platform Platform Electronic Box

DIA–19.0–028

Platform Accessory

DIA–19.0–029

Platform Display Console

DIA–19.0–030

Right Console Sub-Asm.

DIA–19.0–031

04 - 6/01

Distribution Relay Panel

DIA–19.0–032

06 - 9/03

Switch Input

DIA–19.0–033

01 - 9/93

Platform Center & Floor

DIA–19.0–034

05 - 9/03

Left Console Sub-Asm.

DIA–19.0–035

01 - 8/95

Load Handler

DIA–19.0–036

02 - 6/01

Power Unit Electronic Box (1 of 3)

DIA–19.0–037

03 - 2/04

Power Unit Electronic Box (2 of 3)

DIA–19.0–038

01 - 9/03

Power Unit Electronic Box (3 of 3)

DIA–19.0–039

01 - 9/03

Distribution Panel

DIA–19.0–040

01 - 10/95

Rear Wall (1 of 2)

DIA–19.0–041

02 - 9/03

Rear Wall (2 of 2)

DIA–19.0–042

02 - 9/03

Power Panel (1 of 2)

DIA–19.0–043

01 - 9/03

Power Panel (2 of 2)

DIA–19.0–044

01 - 9/03

Hydraulic Wall

DIA–19.0–045

03 - 9/93

Wire Guidance

DIA–19.0–046

End Aisle Control (EAC)

DIA–19.0–047

Power Cables (48V. Units)

DIA–19.0–048

02 - 9/98

Power Cables (72V. Units)

DIA–19.0–049

02 - 9/98

Wire Harnesses

DIA–19.0–050

01 - 9/03

Schematic Pictorial Power Unit

NOTE: See the glossary for component designations and page locations. Further information on wire color codes and symbols is available in Section M4.1.

7489 Crown 1991 PF9150-1 Rev. 2/04

DIA–19.0–025

Printed in U.S.A.

17 REV. 2/04

DIA–19.0–025

SERIAL CABLE

ED2

+5 VB

CPU

SV 4-5

SV3

PMTD

FWD

REV

QUAD DRIVER #2

V +5 VB

+5 VB

QUAD DRIVER #4

SV 11

SV2

SV 10

FU-3 PLATFORM OPTIONS

SV8 SV9

FU-7

BRAKES FU-6

QUAD DRIVER #3

V +5 VB

+12V

12V = ON

LAMP DRIVER

FU-4 PLATFORM ACCESSORIES

STEERING

ED2

QUAD DRIVER #1

V +5 VB

SWITCH INPUT CARD

ED1

V +5 VB

FOR SERVICE TERMINAL

POWER UNIT ELECTRONICS BOX

SERIAL & +5 VB P.S.

+5 VB

CPU

+12V PULLUP CARD

+12V

3 TO LIFT SCR

12V = OPEN 0V = CLOSED 20 MA

48/72V

FU-11

48/72V

FU-15

STEERING CONTROL

DIN BUS

ENCODER

TRACTION O

36/48V

DRIVER

TACH (3) TRAC - SS1 & 2 LIFT - SS3

FROM BDI

4V = OFF 0V = FULL ON

LINEAR

V +5 VB

+5 VB

STEERING

RAISELOWER

LIFT SCR CARD

N = NARROW INDEX O = NO INDEX REQ'D W = WIDE INDEX

HEIGHT

V +5 VB

12V = ON

ENCODER STEERING FEEDBACK

DIGITAL

POWER UNIT

PLATFORM

KEY ON

EDS

K2A

48/72V

TRACTION CONTACTOR PANEL

RAISE LOWER

+5 VB

RAISE LOWER MOTOR

LVDT

5 VI +BV

ISOLATED POWER SUPPLY & FILTER

K1A

FU-12

4V = OFF 0V = FULL ON TRACTION SCR

NONISOLATED POWER SUPPLY & FILTER +12 VB

FU-9

K1B

FU-8

SENSOR BAR

SENSOR AMP

+5 VI

EAC SENSOR (4)

+5 VI

V V

SENSOR BAR

+12 VB

END AISLE CONTROL

5 VI +BV

ISOLATED POWER SUPPLY & FILTER

FU-1

SENSOR AMP

+5 VI

NONISOLATED POWER SUPPLY & FILTER +12 VB

POWER UNIT

PLATFORM

2. CPU CARDS CONTAIN THE SOFTWARE PROGRAMS AND BOTH CARDS AND PROGRAMS ARE IDENTICAL.

BATTERY 36 or 48 VOLT

FU-2

+5 VB V

SERIAL & +5 VB P.S.

PLATFORM ELECTRONICS BOX

DIA–19.0–026 RED +5V BLK 0V BLU INDEX ORG 0 OR 5V NOT TURNING WHI 2.5V TURNING

ENCODERS (5)

Crown 1991 PF9150-2

FOR SERVICE TERMINAL V

3 K2

RUN

NOTE: 1. ALL INPUT/OUTPUT INFORMATION GOES THRU CPU (MICROPROCESSOR) CARDS, EXCEPT SERIAL WHICH IS A COMMUNICATION LINK BETWEEN MICROPROCESSORS.

12V = OPEN 0V = CLOSED 20 MA

KYS

TO BDI (TEST)

START

C ELECTRICAL DIAGRAMS C

FUNCTIONAL BLOCK DIAGRAM

Printed in U.S.A.

108247 D

DIA–19.0–026

DIA–19.0–027

Crown 1991 PF9150-3 Rev. 9/03

01 REV. 9/03

SV6

SV7

BRAKES

QD-3

SV8

FU-7

FU-8

EMS-1

K2A

TRAVERSE CUSHION

SV10

QD-4

TRAVERSE FLIP-FLOP

EDS

FU-1

FU-6

PIVOT BLOCKING

SV11

ED2

ED1

K3A

BRS-2

SEATED

BRS-5

QD-4

MOM

F B

K3B

P2 DRIVER

FROM COMPUTER BOX

TB1 TB5 TB6

PB5

TB4

FU-11

MAIN PUMP MOTOR

BRS-4

SES

MRC-2

LIFT SCR

PB4

STANDING

ACC'Y PUMP MOTOR

R/L

DENOTES MAST WIRE

P3 ACCY

EMS-3

SV12

SV9 OHG

BRAKES

QD-3

SV5

EMS-2

START

SERVO AMP STEERING

FROM QD-4 +BV

SV4

TO PLATFORM OPTIONS

TO BDI "TEST"

KEY

FU-9

S MRC-3

FU-13

BRS-1

P1 DRIVER

R F B A

TRAC SCR PANEL

1 - REC

MRC-1

FU-12

R A

MRC-1

PLATFORM COMPUTER

QD-4

ISOLATED POWER SUPPLY & FILTER PS501

NONISOLATED POWER SUPPLY & FILTER PS502

+ BV

I-COMM

+5 VI

B-COMM

+12 VB

SEATED KEY ON SERVICE BRAKE PARKING BRAKE QD-4

FROM COMPUTER BOX

TB 1

TRACTION CARD

TB TB TB TB TB 4 2 3 6 5

EMS-4B DRIVE/TOW

FU-10

ISOLATED POWER SUPPLY & FILTER PS601

NONISOLATED POWER SUPPLY & FILTER PS602

PB6

PB4

F/B

SB63

QD-1

+ BV

I-COMM

+5 VI

B-COMM + BV

R/A

DCD

COMM

FOR RAISE/ LOWER CARD

PMTD

F/A

+12 VB

QD-1

QD-3

QD-2

POWER UNIT COMPUTER

R/B

SB61

FROM COMPUTER BOX

PLATFORM ACCY'S

FROM QD-3

EMS-4A DRIVE/TOW

FU-3

FU-2

K1B

K1A

BUSS BAR

36V or 48V

FU-5

COMPUTER BOX

FU-14

FU-4

BDI SENSOR

BDI DISPLAY

ED2

ED-1

FU-15

ONLY ONE BATTERY USED ON 48V TRUCK

FILTER & FLASHER

BUSS BAR

C ELECTRICAL DIAGRAMS C

SCHEMATIC ELECTRICAL

2 2

6510 - EO9583 108248 F

Printed in U.S.A.

DIA–19.0–027

ELECTRICAL DIAGRAMS

PLATFORM ELECTRONIC BOX WIRE COLOR / #

MTA PIN

WIRE COLOR

CPU

104A-7

VIO

SERVICE TERMINAL

BATTERY COMMON

CPU

104A-3

ORG

SERVICE TERMINAL

TRANSMIT DATA-A

CARD

FUNCTION

TERMINATION POINT

PC301

CPU

104A-2

RED

SERVICE TERMINAL

RECEIVED DATA-A

CPU

104A-6

BLU

SERVICE TERMINAL

BATTERY COMMON

CPU

104A-8

GRY

SERVICE TERMINAL

+12 VB

CPU

104A-9

WHI

SERVICE TERMINAL

+12 VB

CPU

104A-4

YEL

SERVICE TERMINAL

TRANSMIT DATA-B

CPU

104A-5

GRN

SERVICE TERMINAL

RECEIVED DATA-B

SERIAL

103A-2

RED

TB615-1

TRANSMIT +A

SERIAL

103A-3

ORG

TB615-2

TRANSMIT -A

SERIAL

103A-4

YEL

GRN

TB615-3

TRANSMIT -B

SERIAL

103A-5

GRN

BLU

TB615-4

TRANSMIT +B

SERIAL

103A-6

BLU

BLK

TB615-5

RECIEVED +A

SERIAL

103A-7

VIO

R/B

TB615-6

RECIEVED -A

SERIAL

103A-8

GRY

WHI

TB615-7

RECIEVED -B

SERIAL

103A-9

WHI

W/B

TB615-8

RECIEVED +B

LAMP

107A-2

RED

806

CA503-14

GATE LIGHT

LAMP

107A-3

ORG

811

CA503-5

BRAKE LIGHT

LAMP

107A-4

YEL

804

CA503-11

SERVICE LIGHT

LAMP

107A-10

BLK

801

TB510-5

LIFT CUT OUT

LAMP

PC302

MAST CABLE #1

PC303

107A-11

BRN

810

CA503-3

GUIDANCE FIELD STRENGTH LIGHT

ENCODER 106B-2

RED

1RED

TB509-1

TRACTION ENCODER +5 VB

ENCODER 106B-3

ORG

1 BLU

TB509-2

TRACTION ENCODER INDEX

ENCODER 106B-4

YEL

1 ORG

TB509-3

TRACTION ENCODER CHANNEL A TRACTION ENCODER CHANNEL B

ENCODER 106B-5

GRN

1 WHI

TB509-4

ENCODER 106B-6

BLU

1 BLK

TB509-5

TRACTION ENCODER COMMON

ENCODER 106B-7

VIO

812

(TB510) ALARM +

ALARM OUTPUT HN2

LAMP

107A-12

RED

808

CA503-2

GUIDANCE ACTIVE LIGHT

LAMP

107A-13

ORG

809

CA503-4

GUIDANCE MANUAL LIGHT

LAMP

107A-14

YEL

802

CA503-9

CALIBRATION LIGHT

LAMP

107A-15

GRN

807

CA503-15

PALM LIGHT

LAMP

107A-16

BLU

803

CA503-10

PIVOT LIGHT

LAMP

107A-17

VIO

805

CA503-13

TRAVERSE LIGHT

MOTHER BRD

110A-4

YEL

LAMP

107A-18

GRY

310

CA518-5

12 VB INPUT

MOTHER BRD

110A-9

BLU

301

CA518-2

+5 VI

QUAD 4

109A-11

BRN

2920

CA515-8

+ BV INPUT

MOTHER BRD

110A-7

VIO

601

CA518-3

I COMM

MOTHER BRD

110A-3

ORG

311

CA518-4

+12 VB

MOTHER BRD

110A-5

GRN

511

CA518-7

BAT COM

MOTHER BRD

110A-2

RED

201

CA518-6

+ BV

PC304

ENCODER 106A-2

RED

402

CA514-8

SERVICE BRAKE

ENCODER 106A-3

ORG

405

CA515-7

PARKING BRAKE

ENCODER 106A-4

YEL

403

CA515-3

SEAT SWITCH

ENCODER 106A-5

GRN

401

CA514-4

KEY ON

QUAD 4

109A-7

VIO

2924

TB528-12

PIVOT BLOCKING SV11

QUAD 4

109A-8

GRY

2925

TB528-11

TRAVERSE FF SV10

QUAD 4

109A-9

WHI

2926

TB528-10

EXTEND SV4 & SV5

QUAD 4

109A-10

BLK

2915

CA513-7

START RELAY K1

ENCODER 106A-9

WHI

3 RED

TB526-1

STEER ENCODER +5 VB

ENCODER 106A-11

BRN

3 ORG

TB526-2

STEER ENCODER CHANNEL A

ENCODER 106A-12

RED

3 WHI

TB526-3

STEER ENCODER CHANNEL B STEER ENCODER COMMON

PC306 NOT USED

+5 VB

PC305

ENCODER 106A-13

ORG

3 BLK

TB526-4

ENCODER 106B-7

VIO

4 RED

TB526-5

R/L ENCODER +5 VB

ENCODER 106B-8

GRY

4 BLU

TB526-6

R/L ENCODER INDEX

ENCODER 106B-10

BLK

4 ORG

TB526-7

R/L ENCODER CHANNEL A

ENCODER 106B-9

WHI

4 WHI

TB526-8

R/L ENCODER CHANNEL B

ENCODER 106B-11

BRN

4 BLK

TB526-9

R/L ENCODER COMMON

ENCODER 106B-12

RED

2 RED

TB524-1

HEIGHT ENCODER +5 VB

ENCODER 106B-13

ORG

ENCODER 106B-14

YEL

2 ORG

TB524-2

HEIGHT ENCODER CHANNEL A

ENCODER 106B-15

GRN

2 WHI

TB524-3

HEIGHT ENCODER CHANNEL B

ENCODER 106B-16

BLU

2 BLK

TB524-4

HEIGHT ENCODER COMMON

LAMP

107A-7

VIO

3 BLU

TB527-7

RIGHT STEER LIGHT

LAMP

107A-8

GRY

3 GRN

TB527-8

CENTER STEER LIGHT

LAMP

107A-9

WHI

4 GRN

TB527-9

LEFT STEER LIGHT

LAMP

107A-5

GRN

803

CA503-12

SPARE LIGHT

LAMP

107A-6

BLU

827

(TB510) EAC LGT+

EAC ACTIVE LIGHT

A Crown 1991 PF9150-4

DIA–19.0–028

HEIGHT ENCODER INDEX

# - DENOTES SHIELDED CABLE

108286 D Printed in U.S.A.

DIA–19.0–028

ELECTRICAL DIAGRAMS

PLATFORM ACCESSORY TRAVERSE DIFF. (OPEN WHEN HOME) TDSL

1 N.C.

COM WORK LIGHT LGT-19 BLK RED

SB51

TB501

2931

519

2929 CA508-9

2930 CA508-8

25W (72V UNITS)

L E F T

FAN

4 5 1

FROM SWITCH PANEL

30 12

25W (48V UNITS) 25W (72V UNITS) WORK LIGHT LGT-20

TB502 2927 CA507-6

518 CA514-1 BATT. 2928 CA507-7

COMM

RED

BLK

3 4

5959 (TB528) SB54

C O R N E R

10 25W (48V UNITS)

DOME LIGHT LGT-17

R I G H T C O R N E R

N.C. COM TDSR TRAVERSE DIFF. (OPEN WHEN HOME)

4 1 FAN NEGATIVE TO TB501-5 ON 72 VOLT TRUCKS FAN NEGATIVE TO TB501-2 ON 48 VOLT TRUCKS (8 RESISTOR NOT USED)

Crown 1991 PF9150-5 Rev. 9/03

DIA–19.0–029

6510 - EO9583 108234 D Printed in U.S.A.

01 REV. 9/03

DIA–19.0–029

ELECTRICAL DIAGRAMS

PLATFORM DISPLAY CONSOLE CA503

826 TB510-5

CUT OUT ZONE

808 PC303-M

GUIDANCE ACTIVE

810 PC303-E

GUIDANCE FIELD STRENGTH

809 PC303-N

GUIDANCE MANUAL

811 PC303-B

BRAKE

501 CA517-7

GND

502 CA508-2

GND

1 LGT-10

LGT-12

SPARE

802 PC303-P

CALIBRATION

804 PC303-S

PIVOT

803 PC303-C

SERVICE (WRENCH)

816 PC305-U

SPARE

805 PC303-T

TRAVERSE

806 PC303-A

GATE

807 PC303-R

PALM

LGT-4

LGT-9

LGT-11

LGT-21

LGT-8

LGT-5

LGT-7

LGT-6

LGT-18

CA504

CA505

2 RIBBON CABLE

BATTERY INDICATOR

CA506 5948 CA516-5

5949 CA516-4

110 CA516-3

2967 CA516-2

225 CA516-1

BDI DISPLAY DRIVER CARD

SPARE

SEAT

WORK LIGHT

CA507

LGS

SWH1

DOME LIGHT

2905 (TB523) SB52-1

2906 (TB523) SB52-4

503 CA514-2

2907 TB510-9

2927 TB502-1

2928 TB502-3

7 8 9 CA508

502 CA503-7

5901 CA521-3

2902 CA515-4

2901 CA513-8

2904 CA515-6

2903 CA515-1

2930 TB501-4

2929 TB501-3

RAIL GUIDE ONLY GUS BRS1

9 FNS

A FAN

A Crown 1991 PF9150-6

DIA–19.0–030

M B

BRAKE

GUIDANCE

SPARE

108235 D Printed in U.S.A.

DIA–19.0–030

ELECTRICAL DIAGRAMS

RIGHT CONSOLE SUB-ASM.

1 TB509 1 RED PC303-F +5 VB

RED

1 BLU PC303-G INDEX

BLU

1 ORG PC303-H CHANNEL A

ORG

1 WHI PC303-J CHANNEL B

WHI

1 BLK PC303-K BATT COMM

BLK

2911 CA513-1

2991

2992

2917 CA514-6

2993

2921 TB528-10

2994

ECR-3 TRAC ENCODER

TRAVERSE

EMS-1 N.O.

RETRACT

EMS-2 N.O.

HN2 ALARM

TB510

812 PC303-L 505 CA517-1 5902 CA521-1

OVERRIDE

5903 CA521-5

PALM

517

COM.

N.C.

COM.

N.C.

ORS-1

DMS-1

826 CA503-1 801 PC303-D

2916 CA514-5 2961 (TB528)-SB54

2913 CA513-5

2922 (TB528)-SB53-IN

2912 CA513-3

GRN R/W

HORN

COM.

N.C.

2907 CA507-5 2908 CA513-2

BATTERY

2909 CA514-3

START

2910 CA513-4

IGNITION

1 2

EDS N.O.

HNS N.C.

LGT24 LIFT CUT-OUT ZONE (ORS-1)

OFF 3 ON START

KYS

GRN

R/W

827 PC305-V

LGT23 EAC ACTIVE

5974 CA522-4

G/W

N.C. 1

GRN

EAC OVERRIDE ORS-4

NOTE: 1

WIRED TO NORMALLY CLOSED, HELD OPEN.

U.S. TRUCKS WIRED TO NORMALLY OPEN, HELD CLOSED EUROPEAN TRUCKS WIRED TO NORMALLY CLOSED.

Crown 1991 PF9150-7 Rev. 6/01

DIA–19.0–031

408 - EO5673 108236 I Printed in U.S.A.

04 REV. 6/01

DIA–19.0–031

Crown 1991 PF9150-8 Rev. 9/03

06 REV. 9/03

5949 CA506-2

110 CA506-3

2967 CA506-4

225 CA506-5

FOR BDI DISPLAY

CA516

WHI BLK

5948 CA506-1

ACCESSORY POWER OPTION

4 K

TP1

7 ^

8 1

2 3

6 ^

8 V

C504 1000

CR506 VHE620

MOV504 68V ZA10

R501 1 .5W

C503 1.0

C511 FU-9 1OOO 15A PLATFORM P.S.

K2B

5 V

4 V

CR505 VHE620

R505 5 3W

R504 5 3W

CA512

LK WH K1 T O I P.U + BR BV T . P. S O AK E R QD . BL -1 K E BL BA LEAS TT U E BA CO M TT CO M GR MM N BD OR I G RE BDI D BD I 7

MOV503 68V ZA10 K1A

-VIN COMM PS501 OUT +12V +VIN TRIM

6 ^

7 V

C508

K1B

5 ^

4 V

B MOV505 68V K1 ZA10 A

3 ^

2 ^

1 V

CA513

K2 A

MOV506 68V ZA10

5 ^

6 ^

K2A

CR501 VHE620

8 ^

K3B

2 V

3 ^

.1, 200V

C502 1.0

R503 1 .5W

-VIN COMM PS502 OUT +5V +VIN TRIM

MOV502 68V ZA10

CA515

K3A

7 ^

R511

C509

C510

8 ^

R506 22.1K

CR508 VHE620

506 TB527-5 507 TB528-13 508 TB528-16 504 (TB528)-HN1-2 509 (TB523)-LMS1 501 CA503-6 510 TB525-9

2 3 4 5 6 7 8

R510

580 PC520-2 BATT COMM

+5 VI TP4

I-COMM TP5

511 PC306-E BATT COMM

310 PC303-U +12 VB 5

311 PC306-D +12 VB 4

201 PC306-F + VB

601 PC306-C I-COMM 3

301 PC306-B +5 VI 2

312 PC522-8 +12 VB 1

CA518

505 (TB510)-HN2 (-) 1

CA517 - BATT COMM

C506 1000

B K3 A

7 V

CR507 VHE620

CR504 VHE620

4 ^

3 V

B-COMM TP3 +12 VB TP2

R502 1 .5W

C501 1.0

2 ^

1 ^

CR503 VHE620

CA514

MOV501 68V ZA10

CR502 VHE620

I/B

LK WH BAT I B TC AT OM RE T CO M D/ BL MM BL K E MS BL K GR U +B SPA N V A RE +B C V O CY PT 'S OR ION S G +B RE V D +B V

I/B

DIA–19.0–032 RE WH

3 V

29 01 CA 29 (TB 15 P 5085 C3 52 3)0 TO SE 4-H B S2T 29 FR RS-1 2 1 9 O O A 29 0 (T 13 S EA M Q TB 12 B5 D T 5 10 TB )-K 10-7 SW -4 51 29 I Y T 0 3 08 CH FR TO (TB 9 OM ED T 5 29 10)- O H S 11 OR KEY KY N 1 TB ON S T 50 9-6 O K WITC EY H FR WIP OM E EM R S1

CA511

20 PC 30 PC 3-V 30 4+B 29 B VT 04 TO O C QD 29 A50 COM -4 34 8-6 P" 40 29 TB P 3 0 52 PC 2 TO ARK 5 C -4 A5 BR " 29 304 -C 08 19 -4 TO S-1A (TB B 52 TO 29 3)CO TO B RS-2 03 S R CA ES- MP 3 S "SE S-1B 50 8-7 EA A T S TED " FR W OM ITC BR H S1B 40 29 2 PC 18 3 TB 04-A 29 52517 TO 3 TB FR CO 50 9-8 OM MP "B B RA 2 TO RS-2 K 4 916 29 EM & B E" 09 01 P TB S(TB C3 510 1 & RS-5 04 -6 51 EM 0)- -D SKY FR 2 50 2 T O 3 FR O C M E C OM DS 51 A50 OM 7-4 8 KE P "O TB Y S N" 50 2-2 BAT TAR T T BA COM TT M CO MM

MAST CABLE #3 TO CA603

1 V

MAST CABLE #2 TO CA602

C ELECTRICAL DIAGRAMS C

DISTRIBUTION RELAY PANEL

R508

R509

6510 - EO9583 108237 H

Printed in U.S.A.

DIA–19.0–032

ELECTRICAL DIAGRAMS

SWITCH INPUT RIBBON CONNECTOR TO 32 INPUT CARD

CA519

5910 TB528-6

TRAVERSE LEFT - HOME

5909 TB528-14

PIVOT RIGHT - HOME

5908 TB528-15

PIVOT LEFT - HOME

5907 TB528-5

AUX

5906 TB527-4

AUX R/L COMMAND

5951 (TB523)-LMS2

STAGING SWITCH

5905 TB525-5

DEADMAN SEATED - LEFT

5904 (TB523)-LMS1

HEIGHT RESET SWITCH

31"

CA520

5952 TB525-11

SERVICE BRK -MONITER

R19

580 PC518-8

KEYED OVERRIDE

R21

5916 (TB523) CHS5

MAIN CHAIN BROKE

R23

5914 (TB523) CHS4

MAIN CHAIN BROKE

R25

5913 TB525-7

DEADMAN STAND - LEFT

R27

5912 (TB523) CHS2

MAIN CHAIN SLACK

R29

5911 (TB523) CHS1

MAIN CHAIN SLACK

R31

5921 (TB527) TVSL

TRAVERSE LEFT - CMD

R20

CA521 5902 TB510-1

CUTOUT OVERRIDE

R13

5969 TB527-1

EXTEND OVERRIDE SWITCH (OPT)

R15

5901 CA508-3

GUIDANCE SWITCH

R17

R24

5903 TB510-2

DEADMAN - PALM

R22

5919 (TB527) PTS

PIVOT - COMMAND

R16

5918 TB528-2

FORK EXTEND DIFFER.

R14

5928 TB525-6

DEADMAN SEATED - RT

R12

CA522

5915 TB528-7

TRAVERSE RIGHT - HOME

R10

5920 (TB527) TVSR

TRAVERSE RIGHT - CMD

R18

5923 TB528-3

AUX - 12"

R30

5974 (TB510)-ORS4

EAC OVERRIDE

R11

5958 TB525-8

DEADMAN STAND - RIGHT

R26

5924 TB528-1

FORK EXTEND - HOME

5922 (TB528) GTSR

GATES (DOOR)

R28

312 CA518-1

+12 VB

NOTE: 1 ALL RESISTORS ARE 620 , 1/2 WATT. 2 A KEY SWITCH IS INSTALLED BETWEEN PC518-8 & PC520-2 FOR OPTION. 3 NOT USED ON TN MAST TRUCKS.

Crown 1991 PF9150-9 Rev. 9/93

DIA–19.0–033

4121B - 37979 108238 F Printed in U.S.A.

01 REV. 9/93

DIA–19.0–033

DIA–19.0–034

Crown 1991 PF9150-10 Rev. 9/03

05 REV. 9/03

5952 CA520-1

510 CA517-8

5958 CA522-5

5913 CA520-5

5928 CA521-8

5905 CA519-7

2934 CA515-5

2918 CA514-7

NO CONNECTION

2 BLK PC305-P

2 WHI PC305-N

2923

ORG CHANNEL A WHI CHANNEL B BLK BATT COMM BLU INDEX

2 3 4 5

2938 2936 2933 5927 5926 5931 5929 520 557 5950

2 3 4 5 6 7 8 9 10 11 13

2937

5930

521

561

2932

2935

TB525 (IN PEDESTAL)

RED +5 VB

TB524

CHS1 2

N.O.

N.C. 3

COM

HEIGHT

WIRED TO NORMALLY OPEN, HELD CLOSED LMS2 NOT USED ON TN MAST TRUCKS; WIRES 572 REMOVED, 5951 CAPPED

LEFT PEDAL N.C. 1

DMS-2

BRS-2

N.O.

WIRED TO NORMALLY CLOSED, HELD OPEN

COM.

PEDESTAL

BLK RED

COM. DMS-3

BRS-3

COM.

N.C.

N.O.

BLK

RED

3 1

WHT

WHT 4

SB52

RIGHT PEDAL

CENTER PEDAL

ECR-4

CHS5 2

N.O.

CHS2 2

N.O.

2971

2970

2988

2986

2969

2968

2938

N.C.

521

N.C.

5931

N.C. 1

2936

FRONT

REAR

2937

1.5TSP CHAIN SENSE

2987

BRS-4

DMS-4

COM.

LEFT FLOOR PEDAL

CH2

CH1

LMS4 - UP LIMIT

COM.

FU-16 4A

COM.

LMS3 - DOWN LIMIT

BLK

SEAT MOTOR

RED

5930

COM.

DMS-5 5929

N.C.

BRS-5

N.C.

RIGHT FLOOR PEDAL

CH5

CH4

2935

25W RESISTOR ON 48V TRUCKS ONLY 2989

NOTES:

ENCODER

CHS4 2

N.O.

30TSP CHAIN SENSE

SEATED

SES - SEAT SWITCH

STANDING

LMS2 - STAGING (UPPER SWITCH) CLOSED BELOW STAGING

LMS1 - HEIGHT RESET (LOWER SWITCH) CLOSED BELOW 18"

572

2 ORG PC305-M

2 RED PC305-K

5912 CA520-6

5916 CA520-3

5914 CA520-4

5911 CA520-7

2906 CA507-3

2905 CA507-2

2919 CA515-2

N.O. 1

COM.

2914 CA513-6

512

N.C.

N.O.

5951 CA519-6

(TB523) REF ONLY

509 CA517-6 BATTERY COMMON

5904 CA519-8

C ELECTRICAL DIAGRAMS C

PLATFORM CENTER & FLOOR

6510 - EO9583 108239 J

Printed in U.S.A.

DIA–19.0–034

ELECTRICAL DIAGRAMS

LEFT CONSOLE SUB-ASM.

1 TB526 3 RED PC305-A

RED +5 VB

3 ORG PC305-B

ORG CHANNEL A

3 WHI PC305-C

WHI CHANNEL B

3 BLK PC305-D

BLK BATT COMM

3 BLU PC305-R

ECR-1 STEER ENCODER

BLU INDEX (CAPPED)

3 GRN PC305-S

4 RED PC305-E

RED +5 VB

4 BLU PC305-F

BLU INDEX

4 ORG PC305-G

ORG CHANNEL A

4 WHI PC305-H

WHI CHANNEL B

4 BLK PC305-J

BLK BATT COMM

ECR-2 R/L ENCODER

4 GRN PC305-T

TB527

5920 CA522-2

TVSR

5921 CA520-8

TVSL

5919 CA521-6

PTS 1

5969 CA521-2

ORS-1

N.O.

COM.

N.O.

COM.

576

N.O.

COM.

575

N.C.

COM.

PIVOT EXTEND OVERRIDE (OPT)

TRAV. RT TRAV. LT

3 5906 CA519-5

506 CA517-2

5 6

AXS

N.C.

COM.

1 MAIN/AUX 574

GRN GRN

570

GRY

819

RIGHT

GRY

817

CENTER LGT-2

GRY

818

LEFT

LGT-3

LGT-1

NOTE: 1

WIRED TO NORMALLY CLOSED, HELD OPEN

Crown 1991 PF9150-11 Rev. 8/95

DIA–19.0–035

4762 - 40640 108240 E Printed in U.S.A.

01 REV. 8/95

DIA–19.0–035

DIA–19.0–036

Crown 1991 PF9150-12 Rev. 6/01

02 REV. 6/01 12 13 14 15 16

2924 PC304-E FROM QD-4

507 CA517-3 BATT COMM

5909 CA519-2 TO SWITCH INPUT

5908 CA519-3 TO SWITCH INPUT

508 CA517-4 BATT COMM

5922 CA522-7 TO SWITCH INPUT

504 CA517-5 BATT COMM

2922 TB510-8 FROM HORN SWITCH

N.O.

COM.

N.O.

COM.

2990

5690

GATES

SB54

WHT/BLK

WHT

RED/BLK

BLK

BLU

526

WHT/BLK

WHT

RED/BLK

BLK

BLU

GRN

ORG

RED

GTSR

GTSL

SV12 TRAVERSE CUSHION

TB702 (LOWER-BOTTOM)

THRU AUX MAST

WHT/BLK

WHT

GRN GRN/WHT GRN/WHT

5 7

N.O.

COM.

5925

SB53 OUT

PIVOT CLOSED WHEN HOME

N.O.

COM.

PRS

5932

522

2939

528

527

HORN HN1

PLS

2941

2940

TRS

TLS

5933

525

RED/WHT

GRN

RED/WHT

TB704 (UPPER-LEFT)

524

COM.

N.C. TRAVERSE CLOSED WHEN HOME

COM.

5935

5934

N.C.

RED/BLK

GRN

WHT/BLK

GRN/WHT

6 GRN/WHT

BLK

WHT

BLU

GRN

ORG

SB71

523

SB72

529

N.O.

LEFT FORK

COM. COM.

N.O.

AHS2

AHS1

SV11 - PIVOT BLOCKING (ENERGIZED TO PIVOT)

4 WIRED TO NORMALLY OPEN, HELD CLOSED.

PORTIONS INSIDE THIS BORDER ARE ABSENT ON TRUCKS WITH NON-TELESCOPIC FORKS.

2 FOR EUROPEAN TRUCKS ONLY. 3

ENERGIZED DURING ( ) EXTEND & RETRACT

SV10 - TRAVERSE FLIP/FLOP (ENERGIZED TO EXTEND/RETRACT LEFT)

2944 SV5 - EXTEND

FLS (DIFF)

FHSL

CLOSED WHEN HOME

FRS (DIFF)

FHSR

(CLOSED BELOW 12")

AUX HEIGHT (CLOSED BELOW 31")

COM. COM.

N.O.

COM. COM.

N.O. N.O.

N.O.

RED

ORG

GRN

WHT NO CONNECTION

BLK NO CONNECTION

WHT

BLK

1 WIRED TO NORMALLY CLOSED, HELD OPEN

NOTES:

2942

2943

531

RIGHT FORK

SEE NOTE

GRN NO CONNECTION

ORG

RED

SV4 - EXTEND

AHS1

5936 533 2945

530

532

5967

577

COM.

N.O.

AHS2

2961 TB510-7 +BV

5959 TB502-5 FROM OHG SWITCH

2925 PC304-F FROM QD-4 GRN

ORG

2926 PC304-G FROM QD-4

513

THIS JUMPER USED ONLY WITH NON-TELESCOPING FORK PACKAGE.

RED

WHT/BLK

RED

TB705 (FORK PLATE)

COM.

N.O.

2921 TB509-9 FROM EMS-2

SPARE

WHT

5915 CA522-1 TO SWITCH INPUT

RED/BLK

SPARE

RED/BLK

5910 CA519-1 TO SWITCH INPUT

BLK

BLU

5907 CA519-4 TO SWITCH INPUT

ORG

BLK

SPARE

2 GRN

ORG

RED

GRN BLU

5923 CA522-3 TO SWITCH INPUT

5918 CA521-7 TO SWITCH INPUT

RED

TB703 (UPPER-RIGHT)

BLK

WHT

TB701 (LOWER-TOP)

BLK WHT

5924 CA522-6 TO SWITCH INPUT

TB528

WIRING OF AUX HEIGHT SWITCHES WHEN NON-TELESCOPIC FORK CARRIAGE IS USED

C ELECTRICAL DIAGRAMS C

LOAD HANDLER

408 - EO5673 108241 I

Printed in U.S.A.

DIA–19.0–036

ELECTRICAL DIAGRAMS

POWER UNIT ELECTRONIC BOX (1 OF 3) CARD

WIRE TERMINATION COLOR / # POINT

MTA WIRE PIN COLOR

FUNCTION

PC401

SERIAL 203A-6 BLU

RED

TB615-1

SERIAL 203A-7 VIO

ORG

TB615-2

RECIEVED +A RECIEVED -A

SERIAL 203A-8 GRY

GRN

TB615-3

RECIEVED -B

SERIAL 203A-9 WHI

BLU

TB615-4

RECIEVED +B

SERIAL 203A-2 RED

BLK

TB615

TRANSMIT +A

SERIAL 203A-3 ORG

R/B

TB615-6

TRANSMIT -A

SERIAL 203A-4 YEL

WHI

TB615-7

TRANSMIT -B

SERIAL 203A-5 GRN

W/B

TB615-8

TRANSMIT +B

MAST CABLE #1

PC402

QUAD 1 212A-11 BRN

207

CA605-2

+BV TO QUAD 1

QUAD 2 213A-11 BRN

209

CA605-4

+BV TO QUAD 2

QUAD3

214A-11 BRN

210

CA605-5

+BV TO QUAD 3

R/L

211A-6

BLU

211

CA605-6

+BV TO R/L

R/L

211A-8

GRY

538

NEG STANDOFF

BATTERY COMMON TO R/L

QUAD 1 212A-10 BLK

2952

(TB608)-S+

+BV TO STEER CONTACTOR

DIGITAL 208B-9

WHI

815

CA606-2

PROC LIGHT

DIGITAL 208B-11 BRN

814

CA606-1

CHAIN LIGHT

DIGITAL 208B-12 RED

813

CA605-8

CABLE LIGHT

DIGITAL 208B-10 BLK

2986

(TB614)-PGM1

PLUG COMPLETE

DIGITAL 208A-4

YEL

5937

CA605-7

LAMP TEST SWITCH

211A-7

VIO

571

NEG STANDOFF

BATTERY COMMON TO R/L

DIGITAL 208B-7

VIO

701

(TB616)-SB67-1

BRAKE COMMAND MONITOR BRAKE HIGH PRESSURE SWITCH

R/L

DIGITAL 208A-2

RED

5938

TB616-5

DIGITAL 208A-5

GRN

5939

TB616-6

BRAKE LOW PRESSURE SWITCH

QUAD 1 212A-8

GRY

2946

CA601-1

+BV TO ACCY CONTACTOR (P3)

QUAD 1 212A-9

WHI

2953

(TB608)-ED2

+BV TO ED2 CONTACTOR

2954

(TB617)-SB66-3

+BV TO AUX LOWER SOLONOID

U QUAD 2 212A-7

VIO

LINEAR 209A-5

GRN

304

TB614-3

TRACTION +8 V

LINEAR 209A-6

BLU

104

(TB614)-TB11T-1

TRACTION SCR COMMAND

LINEAR 209A-7

VIO

539

(TB614)-NEG BB

BATTERY COMMON FROM TRAC SCR

PC403

R/L

211A-9

WHI

305

(TB618)-M7(+)

R/L SERVO MOTOR +

R/L

211A-10 BLK

703

(TB618)-M7(-)

R/L SERVO MOTOR -

(TB617)-SB66-1

+BV TO MAIN LOWER SOLONOID

G QUAD 2 213A-8

GRY

QUAD 3 214A-10 BLK

QUAD 3 214A-9

2955

SPARE QUAD OUT

WHI

2956

(TB616)-SB67-3

QUAD 3 214A-8 GRY

2957

CA601-7

+BV TO SV9 REAR BLOCKING +BV TO K4 BRAKE RELEASE

QUAD 3 214A-7

VIO

2958

(TB616)-SB68-1

+BV TO SV8 BRAKE RECHARGE

QUAD 1 212A-7

VIO

2948

CA601-3

+BV TO ED1 CONTACTOR

DIGITAL 208A-9

WHI

5940

TB616-4

CABLE TENSION SWITCH

DIGITAL 208A-8

GRY

5941

TB616-2

SPARE

DIGITAL 208A-7

VIO

5942

TB616-1

RGS INPUT

DIGITAL 208A-6

BLU

5943

TB612-9

BRAKE STATUS SWITCH

QUAD 2 213A-9

WHI

2959

TB611-7

+BV TO REV CONTACTOR

PC404

CPU

201A-7

VIO

SERVICE TERMINAL BATTERY COMMON

CPU

201A-3

ORG

SERVICE TERMINAL

CPU

201A-2

RED

SERVICE TERMINAL RECEIVED DATA-A

CPU

201A-6

BLU

SERVICE TERMINAL BATTERY COMMON

CPU

201A-8

GRY

SERVICE TERMINAL

+12 VB

CPU

201A-9

WHI

SERVICE TERMINAL

+12 VB

TRANSMIT DATA-A

CPU

201A-4

YEL

SERVICE TERMINAL

TRANSMIT DATA-B

CPU

201A-5

GRN

SERVICE TERMINAL

RECEIVED DATA-B

Crown 1991 PF9150-13 Rev. 2/04

DIA–19.0–037

NOTE: 1

NOT USED ON TN MAST TRUCKS

# - DENOTES SHIELDED CABLE

7489 108233 (1 OF 3) F Printed in U.S.A.

03 REV. 2/04

DIA–19.0–037

ELECTRICAL DIAGRAMS

POWER UNIT ELECTRONIC BOX (2 OF 3) CARD

MTA WIRE PIN COLOR

WIRE TERMINATION COLOR / # POINT

FUNCTION

PC405

R/L

211A-2 RED

4 WHI

TB618-3

R/L

211A-3 ORG

4 RED

TB618-2

LVDT PRIMARY LVDT SECONDARY

R/L

211A-4 YEL

4 ORG

TB618-4

LVDT PRIMARY

R/L

211A-5 GRN

4 BLK

TB618-1

LVDT SECONDARY

E DIGITAL 208B-2 RED

3 RED

TB613-1

STEER ENCODER +5 BV

DIGITAL 208B-4 YEL

3 BLU

TB613-2

STEER ENCODER INDEX

DIGITAL 208B-5 GRN

3 ORG

TB613-3

STEER ENCODER CHANNEL A

DIGITAL 208B-3 ORG

3 WHI

TB613-4

STEER ENCODER CHANNEL B

DIGITAL 208B-6 BLU

3 BLK

TB613-5

STEER ENCODER COMMON

LINEAR 209B-2 RED

5 RED

TB609-1

LEFT TRACTION TACH +5 VB

LINEAR 209B-3 ORG

1 GRN

TB612-3

RIGHT TRACTION TACH CHANNEL A

LINEAR 209B-4 YEL

5 BLK

TB609-4

LEFT TRACTION TACH COMMON

LINEAR 209B-6 BLU

1 RED

TB612-1

RIGHT TRACTION TACH +5 VB

LINEAR 209B-7 VIO

1 ORG

TB612-2

RIGHT TRACTION TACH CHANNEL B

LINEAR 209B-8 GRY

1 BLK

TB612-4

RIGHT TRACTION TACH COMMON

LINEAR 209B-5 GRN

5 GRN

TB609-3

LEFT TRACTION TACH CHANNEL A

5 ORG

TB609-2

LEFT TRACTION TACH CHANNEL B

LIFT SCR +8 V

U LINEAR 209B-12 RED

PC406

LINEAR 209A-2 RED

306

TB614-7

LINEAR 209A-3 ORG

105

(TB614)-TB11P-1

LIFT SCR COMMAND

LINEAR 209A-4 YEL

540

TB614-9

LIFT SCR COMMON

DIGITAL 208B-16 BLU

406

TB614-8

LIFT SCR POWER INHIBIT

DIGITAL 208B-14 YEL

407

(TB614)-TB11P-5

LIFT SCR COMMAND ENABLE

DIGITAL 208B-15 GRN

404

(TB614)-TB11P-6

LIFT SCR BYPASS ENABLE

LINEAR 209B-10 BLK

2 WHI

TB617-2

LIFT PUMP TAC SIGNAL

QUAD 2 213A-10 BLK

TB611-3

+BV TO FORWARD CONTACTOR

LINEAR 209B-9 WHI

DIGITAL 208B-13 ORG

2960 2 RED

TB617-1

LIFT PUMP TACH +5 VB

541

TB614-9

LIFT COMMON INPUT

5944

TB616-3

HEIGHT CABLE SWITCH +5 VI

L MOM BRD 215A-4 YEL

DIGITAL 208A-3 ORG

+5 VB

MOM BRD 215A-9 WHI

302

CA606-4

MOM BRD 215A-7 VIO

702

CA606-5

I COMMON

MOM BRD 215A-3 ORG

303

CA606-6

+12 VB

MOM BRD 215A-5 GRN

536

CA606-7

BATTERY COMMON

MOM BRD 215A-2 RED

212

CA606-8

+BV

LINEAR 209B-11 BRN

2 BLK

TB617-3

LIFT PUMP TACH COMMON

PC407

GUIDANCE 205A-7 VIO

8 RED

PC620-7

COIL #3

GUIDANCE205A-18 GRY

8 ORG

PC620-6

SELFTEST

GUIDANCE205A-11 BRN

8 GRN

PC620-1

COIL #1

GUIDANCE 205A-10 BLK

8 BLU

PC620-5

+5 VI

GUIDANCE205A-9

WHI

8 BLK

PC620-2

COIL #2

GUIDANCE 205A-5 GRN

8 BRN

PC620-8

COIL #4

GUIDANCE 205A-6 BLU

8 WHI

PC620-3

I COMMON

3 LOAD WHEEL SENSOR BAR

PC408 GUIDANCE 206A-7 VIO

7 RED

PC621-7

COIL #7

GUIDANCE 206A-18 GRY

7 ORG

PC621-6

SELFTEST

GUIDANCE 206A-11 BRN

7 GRN

PC621-1

COIL #5

GUIDANCE 206A-10 BLK

7 BLU

PC621-5

+5 VI

GUIDANCE 206A-9 WHI

7 BLK

PC621-2

COIL #6

GUIDANCE 206A-5 GRN

7 BRN

PC621-8

COIL #8

GUIDANCE 206A-6 BLU

7 WHI

PC621-3

I COMMON

STEER WHEEL SENSOR BAR

PC409

LINEAR 209A-10 BLK

6 WHI

SERVO STEER AMP

STEER SERVO DIRECTION

LINEAR 209A-9 WHI

6 BLK

SERVO STEER AMP

STEER SERVO SPEED

LINEAR 209A-11 BRN

6 ORG

SERVO STEER AMP

STEER SERVO DIAG

LINEAR 209A-8

GRY

6 RED

SERVO STEER AMP

STEER SERVO +12 VB

LINEAR 209A-12 RED

6 GRN

SERVO STEER AMP

STEER SERVO COMMON

F G

Crown 1991 PF9150-14 Rev. 9/03

DIA–19.0–038

- DENOTES SHIELDED CABLE

C 6510 - EO9583 108233 (2 OF 3) F Printed in U.S.A.

01 REV. 9/03

DIA–19.0–038

ELECTRICAL DIAGRAMS

POWER UNIT ELECTRONIC BOX (3 OF 3)

CARD

MTA WIRE PIN COLOR

TERMINATION WIRE POINT COLOR / # PC410

9 ORG

TB623-4

EAC

204A-6

BLU

9 WHT

TB623-9

EAC

204A-3

ORG

9 BLU

TB623-7

EAC

204A-2

RED

9 RED

TB623-3

EAC

204A-11 BRN

9 BLK

TB623-1

EAC

204A-12 RED

9 YEL

TB623-5

EAC

204A-16 BLU

9 BRN

TB623-2

EAC

204A-17 VIO

9 GRN

TB623-6

EAC

204A-14 YEL

10 ORG

TB627-4

10 WHT

TB627-9

10 BLU

TB627-7

EAC

204A-13 ORG

10 RED

TB627-3

EAC

204A-4

YEL

10 BLK

TB627-1

EAC

204A-15 GRN

10 YEL

TB627-5

EAC

204A-18 GRY

10 BRN

TB627-2

EAC

204A-5

S T

10 GRN 10 VIO

TB627-6 TB627-8

9 VIO

TB623-8

EAC

GRN

204A-10 BLK

Crown 1991 PF9150-15 Rev. 9/03

DIA–19.0–039

C 6510 - EO9583 108233 (3 OF 3) F Printed in U.S.A.

01 REV. 9/03

DIA–19.0–039

ELECTRICAL DIAGRAMS

DISTRIBUTION PANEL

+5 VI TP4

I-COMM TP5

7 7

410 PWR COMM

C602 1000 80V CR607

VHE620

R608

5 OHM 3W

TRIM -VIN COMM PS602 +5VI +VIN 5V

R609 R610 10K

C604 .1

C605 .1

409 SIG COMM

408 SIGNAL

219 +BV IN

2979 +BV OUT

FU-8 15A SERVO FU-7 15A QUAD3 FU-6 15A QUAD2

+12 VB TP2

B-COMM TP3

L601 L602

FU-4 15A PLATFORM ACCESSORY

C603 .1 VHE620

90.9

R603

LGT-13

90.9

R602

LGT-14

90.9

R601

2 3 LAMP TEST SWITCH

2 3 4 1

8 7 6 5

PROC LGT

2 3 4 1

CHAIN LGT

8 7 6 5

2 3 4 1

CABLE LGT

8 7 6 5

2 3 AUXILIARY EMS SWITCH

TES-1

EMS-3

DRIVE/TOW SWITCH

5 EMS-4

6 4 3 1

2 3 4

CR601 VHE620

TOW LGT24

V V

8 7 6 5

3 2

CR602 VHE620

CA601

LGT-15

R604

1.5K, 2W

CA602

5 OHM 3W

MOV601 68V

CR606

C601 1000 80V

R605

B K4 A

2995

FU2 15A PLATFORM POWER

578 V V V

FU-1 4A POWER UNIT P.S.

V V V

5 4

TRIM -VIN COMM PS601 +12V +VIN 12V

CA603

V V V

3 2

R606 R607

5 4

FU-3 15A PLATFORM OPTIONS

7 6

CA604

V CR604 VHE620

3 2

FU-5 15A FLASHER BDI

V V

5 4

V V V

TP1

CA605

CR603 VHE620

Crown 1991 PF9150-16 Rev. 10/95

DIA–19.0–040

LIFT C/O 3

BDI 1 1

CA607

V V V V

CR605 VHE620

5 4

CA606 V

7 6

MAST CABLE #3 TO CA512 ON PLATFORM

V V V

MAST CABLE #2 TO CA511 ON PLATFORM

V V

2 29 50 957 P ( 20 TB61 C40 2 3-L T 4) T SP 29 B61 B11 49 4-1 T-3 FRO ARE M (TB 29 + 48 61 +BV BV T QD-3 4 T 29 PC4 ) ED O D O M 47 R 03 R + PO IVE C1 (TB -P 29 WE /TO 46 61 Q W PC 4) P UAD R TO 3 40 ED 2-S + P DR OW TO E E QU RT D AD O P3 DR TO P3

K1 RE T D/B WH O P .U. LK I + BR BV T - P.S AK O . BL E RE QD-1 K LE AS BL BAT E T U BA CO M TT CO M GR MM N OR BD I G BD RE I D BD I

WH I/B LK

7 6

V V

WH I/B LK WH BAT I B TC OM A RE TT C M D/B OM M LK EM BL BLK S U +B SPA GR V A RE N +B CC VO Y PT 'S OR IONS G RE +BV D +B V

ST AN DO 21 F 7 (TB F BA T 60 8)- T CO ED MM 53 2-1 21 6 +B PC 2 P V 40 C4 6-T 06 30 -U 3 PC BAT +B 70 TC V 4 2 PC 06-S OM M 30 406 +1 -R 2 2V P 81 C4 5 06 I-CO B -P MM 81 PC4 4 0 +5 PC 2-G VI 40 2-H PR SPA O R CH C LIG E AIN H LIG T HT 81 3 59 PC 37 4 21 PC4 02-J 1 02 P CA 21 C4 -L B 0 02 PC -D LIG LE L H 20 I 4 0 9 2-C +B T TE GHT P V ST 20 C4 8 0 +B TO R SW TB 2-B V / LS T 2 61 29 1-1 74 07 +B O QU ER V (TB PC4 AD +B TO 0 61 V T QU 3 6)- 2-A A SB O DC D2 +B 67 V -1 BR TO ONT AK QU ER A EL D 1 EA SE 29 51 (TB 61 4 20 )-P2 + 6 22 (T BD 0 TB 205 B608 I LIF 61 ( 9-1 TB6 )-ED T C/ 2-1 O 0 20 8 4 +B )-ED +BV ( 2-1 20 TB6 V T O 0 3 +B 8 53 F 5 (TB6 )-ED LAS V 2-2 NE 08) HE 53 G + R E B 4 B.B D2 -2 V -E NE . D G BA +BV B.B -ED TT . BA COM TT M CO MM

V V

NE G

56 6

108242 D Printed in U.S.A.

01 REV. 10/95

DIA–19.0–040

ELECTRICAL DIAGRAMS

3570S

REAR WALL (1 OF 2) ( TB608 ) REF. ONLY 538 PC402-E 571 PC402-M 566 (CA607)-BDI-8

NEGATIVE STANDOFF ELECTRONICS DOOR

537 TB616-7 535 CA604-1 534 CA604-2 217 (CA607)-BDI-4

558

206 CA604-7 +BV TO DIST PANEL 205 CA604-6 +BV TO DIST PANEL

SB64

FROM BATTERY

204 CA604-4 +BV-ED

G/W ED2 R/W

203 CA604-3 +BV-ED 2953 PC402-T FROM QD-1 560 SB65 FROM FU-15 +BV

G/W

S 2

R/W

2952 PC402-F FROM QD-1

MRC-3

FROM BATTERY NEG.

STEERING SERVO AMP

3 LEFT TRACTION TACH TB609 5 RED PC405-L

RED

5 ORG PC405-V

YEL

CHANNEL B

5 GRN PC405-T

GRN

CHANNEL A

5 BLK PC405-N

5VB

B SS-1

BLK

BATTERY COMM.

5 6 7

N.C. COM.

5954 TB612-8 TO SWITCH BRS7

G/W

5961

545 NEG B.B.

GRN

573

LEFT BRAKE STATUS SWITCH (N.C.) OPEN WHEN BRAKE RELEASED

WHT (TB610) HN3 WHT (TB610) HN4

WHT (TB610) HN5

POINT OF CONNECTION TO BUSS BAR - SEE POWER CABLE DRAWING.

Crown 1991 PF9150-17 Rev. 9/03

DIA–19.0–041

BRS-6

C6510 - EO9583 108243 (1 OF 2) E Printed in U.S.A.

02 REV. 9/03

DIA–19.0–041

ELECTRICAL DIAGRAMS

3571S

REAR WALL (2 OF 2) FORKS LAST

BOTH DIRECTIONS

FORKS FIRST BLK

BLK HN3

BLK

DBI

HN4

HN5

WHT

BLK

RED

WHT

WHT TB609-9 WHT TB609-9 WHT TB609-9 TB610 1

SB61 R/W

R/W

2 2961

002

BLK

G/W

004

BLK

2962

5955

(TB614) PMTD-3

G/W

G/W RA

8 9

R/W

SB62

TB611 208

CA605-3 +BV FROM FU-6

5945

(TB614) D-DR-3

R/W

D G/W

BLK

SB63

R/W

R/W 2960

PC406-H FROM QD-2

G/W

003 (TB614) TRAC-TB5 FWD SENSE

BLK

5953 (TB614) PMTD-4

G/W

005 (TB614) TRAC-TB6 REV SENSE

BLK

2959

PC403-V FROM QD-2

8 9

G/W RB R/W

R/W

3 RIGHT TRACTION TACH

TB612 1 RED PC405-P

RED

5 VB

1 ORG PC405-R

YEL

CHANNEL B

1 GRN PC405-M

GRN

CHANNEL A

1 BLK PC405-S

B SS-2

BATTERY COMM.

BLK

5 6 7

N.C. COM.

5954

TB609-8 FROM SWITCH BRS-6

G/W

5962

5943

PC403=U TO SWITCH INPUT

G/W

5963

RIGHT BRAKE STATUS SWITCH (N.C.) OPEN WHEN BRAKE RELEASED

TB613

3 RED PC405-F

RED +5 VB

3 BLU PC405-G

BLU INDEX

3 ORG PC405-H

ORG CHANNEL A

3 WHI PC405-J

WHI CHANNEL B

3 BLK PC405-K

BLK BATT COMM

Crown 1991 PF9150-18 Rev. 9/03

DIA–19.0–042

BRS-7

ERC-5 STEER FEED BACK ENCODER

C6510 - EO9583 108243 (2 OF 2) E Printed in U.S.A.

02 REV. 9/03

DIA–19.0–042

ELECTRICAL DIAGRAMS

POWER PANEL (1 OF 2) FU-12

P 1 REC

ED 19

18 FA

25 LEFT DRIVE ARM

21 D1

1 BATTERY

RIGHT DRIVE ARM

4 REC - RIGHT PLUGGING

48/72V A2

4 REC - LEFT PLUGGING 23 FIL

TO FU-11

GRN

3 REC FLYBACK

SENSOR

YEL BRN

FU-10 15 AMP

N 1 PGM

TB614

202 CA601-5 TO DR/TOW SW

304 PC403-A +8V TO LINEAR CARD

547 NEG B.B.

214

2 309

559

PLG MOD

901

4 TRACTION SCR PC- B

2986 PC402-K (0 VOLTS = RUN) (12 VOLTS = PLUG)

MRC-1

104 PC403-B TRAC CMD (4 VOLTS - OFF) (0 VOLTS = FULL ON)

215

TB11T 2 003 3

2950 CA601-6 FROM DR/TOW SW

005

TB610

539 PC403-C TRAC COMM TO LINEAR CARD

2 2961

002

5955

004

2962

4 3

5945 SB62 (RIGHT)

2 2976

D DR

SB61 (LEFT)

PC- Z

TB611

550

2960 PC406-H FROM QD-2 (+BV FOR FWD) 208 CA605-3 +BV SB63 (RIGHT)

2959 PC403-V FROM QD-2 (+BV FOR REV)

PMTD 5953

549

2975

2 1

2 VOLTS WHEN PLUGGING

2 VOLTS WHEN DIRECTION SELECTED UNLESS PMT HAS TRIPPED

7 8

Crown 1991 PF9150-19 Rev. 9/03

DIA–19.0–043

C6510 - EO9583 108244 (1 OF 2) E Printed in U.S.A.

01 REV. 9/03

DIA–19.0–043

ELECTRICAL DIAGRAMS

POWER PANEL (2 OF 2) TB614 (CONT.) 547

NEG B.B.

551

LIFT SCR 308

6 306 PC406-A +8 VOLTS

2 406 PC406-D PWR INHIBIT 540 PC406-C SIGNAL COMM

7 8 9

PC-B

307

2972

2973

544

MRC-2

541 PC406-K SIGNAL COMM 1

105 PC406-B LIFT CMD

1 213

FU-10 48/72V

TB11P

FU11 15A

407 PC406-E CMD ENABLE

404 PC406-F BYPASS ENABLE

3 2977

2951 CA604-8 +BV FROM BDI P2 PMTD

4 3

2949 CA601-4 FROM QD-1

2978

ED1 548

P2 DR

552

2947 CA601-2 FROM QD-1

P3 546 NEG BB

5956

5957

BYPASS 1 REC T2

POWER D

FU13 300A

PUMP FIELD 23 FIL

3 REC ED

PUMP ARM A

0 VOLTS WHEN LIFT NOT SELECTED 3.5 VOLTS AFTER CMD ENABLE 3.5-0 VOLTS FOR SPEED COMMAND

0 VOLTS ON LIFT INDEX 2 VOLTS OFF LIFT INDEX

8 VOLTS = OFF 0 VOLTS = ENABLE

SENSOR

POINT OF CONNECTION TO BUSS BAR - SEE POWER CABLE DRAWING.

Crown 1991 PF9150-20 Rev. 9/03

DIA–19.0–044

BATTERY

C6510 - EO9583 108244 (2 OF 2) E Printed in U.S.A.

01 REV. 9/03

DIA–19.0–044

ELECTRICAL DIAGRAMS

HYDRAULIC WALL

TB615

SERIAL

RED PC401-A

RED PC302-A

ORG PC401-B

ORG PC302-B

GRN PC401-C

GRN PC302-C

BLU PC401-D

BLU PC302-D

BLK PC401-E

BLK PC302-E

R/B PC401-F

R/B PC302-F

WHT PC401-G

WHT PC302-G

W/B PC401-H

W/B PC302-H

MAST CABLE #1 TO PLATFORM

9 TB616

RGSL N.C.

SW INPUT

5942 PC403-T SWITCH INPUT

5941 PC403-S SWITCH INPUT

5944 PC406-N SWITCH INPUT

HEIGHT CABLE

5940 PC403-R SWITCH INPUT

TAKE-UP CABLE

RAIL GUIDE SWITCHES

CRIMPED CONNECTION HCS N.O.

CTS N.O.

5938 PC402-P SWITCH INPUT

WHT/YEL LOW

BPS1

5939 PC402-R SWITCH INPUT

BPS2

537 (TB608) NEG. STANDOFF

WHT/ HI BLK/YEL BLK

8 9

2 6 5

BLK BLK BLK

701 PC402-N MONITOR

2974 CA605-1 BRAKE RELEASE

R/W

2983

542 NEG B.B.

GRN

567

R/W

2956 PC403-K

SV6

BRAKE RELEASE

SV7

2984

RGSR 1 N.C.

568

SB67 2985

569 SV9 BRAKE REAR BLOCKING

SB68 2958 PC403-M

R/W

561

GRN

2982 SV8 BRAKE RECHARGE 565

3 TB617 2 RED PC406-J

RED

2 WHT PC406-G

WHT

2 BLK PC406-V

BLK

SV7

SS-3 LIFT PUMP TACH

SV9 BRAKE MANIFOLD BLOCK

2980

SB66 2955 PC403-H FROM QD-2

R/W

543 NEG B.B.

GRN

2954 PC402-V FROM QD-2

R/W

SV8 SV2

563 564

SV6

MAIN LOWERING

SV3

AUX

SOLENOID ARRANGEMENT AT TB616

2981 TB618

SV1

4 BLK PC405-D +5BV

BLK

4 RED PC405-B SIGNAL

RED

4 WHT PC405-A COMMON

WHT

4 ORG PC405-C

YEL

RED DOT SERVO MOTOR M7

L.V.D.T.

R/L MOTOR 305 PC403-E

R/L MOTOR

2 , 25W (48V UNITS ONLY)

703 PC403-F TB619 220 CA604-5

RED

2 008 BATT B.B.

FLASHING LIGHT LGT-16

RED

BLK

3 WHT

4 WIRED TO NORMALLY CLOSED - HELD OPEN WIRED TO NORMALLY OPEN - HELD CLOSED BPS2 OPENS ABOVE 1800 PSI (12V) BPS1 CLOSES BELOW 500 PSI ( 0V) 5 CONDUCTOR CABLE IS USED IN PLACE OF 2 CONDUCTOR CABLE ON COLD CONDITION. 6 NOT USED ON TN MAST TRUCKS

1 2 3 4 5

BLK

POINT OF CONNECTION TO BUSS BAR

Crown 1991 PF9150-21 Rev. 9/93

DIA–19.0–045

FILTER

4121B - 37979 108245 L Printed in U.S.A.

03 REV. 9/93

DIA–19.0–045

ELECTRICAL DIAGRAMS

WIRE GUIDANCE

1 LOAD WHEEL SENSOR BAR

PC620

8 GRN PC407-C

8 BLK PC407-E

8 WHI PC407-G

COIL #5 COIL #6 I - COMM I

8 BLU PC407-D

8 ORG PC407-B

8 RED PC407-A

8 BRN PC407-F

5 VI SELFTEST COIL #7

COIL #8

STEER WHEEL SENSOR BAR

PC621

7 GRN PC408-C

7 BLK PC408-E

7 WHI PC408-G

COIL #1 COIL #2 I - COMM I

4 7 BLU PC408-D

7 ORG PC408-B

7 RED PC408-A

7 BRN PC408-F

5 VI SELFTEST COIL #3 COIL #4

A Crown 1991 PF9150-22

DIA–19.0–046

108246 A Printed in U.S.A.

DIA–19.0–046

ELECTRICAL DIAGRAMS

END AISLE CONTROL (EAC)

TB623

9 BLK JC410-E SENSOR A1 DIGITAL

9 BRN JC410-G SENSOR A1 TEST

9 RED JC410-D SENSOR A1 ANALOG

9 ORG JC410-A NOT USED

9 YEL JC410-F SENSOR A2 DIGITAL

9 GRN JC410-H SENSOR A2 TEST

9 BLU JC410-C SENSOR A2 ANALOG

9 VIO JC410-U BATTERY COMMON

9 WHT JC410-B +12VB

TB627 10 BLK JC410-N SENSOR B1 ANALOG

10 BRN JC410-R SENSOR B1 TEST

10 RED JC410-M SENSOR B1 DIGITAL

10 ORG JC410-J SENSOR B2 DIGITAL

10 YEL JC410-P SENSOR B2 TEST

10 GRN JC410-S SENSOR B2 ANALOG

10 BLU JC410-L NOT USED

10 VIO JC410-T NOT USED

10 WHT JC410-K NOT USED

CA622

CA624

TO EAC SENSOR A1

TO EAC SENSOR A2

TB623

CA626

CA625

TO EAC SENSOR B1

TB627

TO EAC SENSOR B2

EAC DISTRIBUTION PANEL

A Crown 1991 PF9150-23

DIA–19.0–047

113493 A Printed in U.S.A.

DIA–19.0–047

DIA–19.0–048

Crown 1991 PF9150-24 Rev. 9/98

02 REV. 9/98

1 2 3 4

STEER MOTOR M6

PC# 4-81

PC# 4-173

C PC# 2/0-45 PC# 2/0-47 PC# 2/0-133 PC# 2/0-132

LOCATED ON DOOR

DENOTES BUSS BAR TIE POINT

B PC# 2/0-47 PC# 2/0-46 PC# 2/0-131 PC# 2/0-130

BATTERY SIZE

DRIVE MOTOR A

PC# 4-57

RA C

PC# 6-6

FU-14

FU-13

ED2 2

FU-15

4RECA

T2 P

1 REC

MRC-3 PC# 6-8

STEER AMP

3 REC

LIFT SCR MRC-2 PC# 6-8

1 REC

PC# 4-53

3 REC

PC# 4-109

TRACTION SCR MRC-1

4RECB

2 1

FU-12

TO DISTRIBUTION PANEL

PC# 6-31

ED1

PC# 4-116

NEG.

PC# 4-52

PC# 4-173

D1 DRIVE MOTOR B M3

PC# 4-57

ACCY PUMP MOTOR M2

PC# 4-104

LIFT PUMP MOTOR M1

PART NO. 84571 84570 84569 84568 90963 84572 84573 86749

PC# 10-4

STEER MOTOR M5

48V

PC# 10-4

NEGATIVE STANDOFF

AN EXAMPLE OF SUCH A CABLE IS PC# 1/0 - 10. THE PART NUMBER FOR THIS CABLE IS 84572-10

ABBREVIATION PC# 1 PC# 2 PC# 4 PC# 6 PC# 10 PC# 1/0 PC# 2/0 PC# 3/0

POWER CABLES ARE DESIGNATED USING ONE OF THE FOLLOWING ABBREVIATIONS, FOLLOWED BY A DASH NUMBER.

CABLE NUMBER

4 FA C

3 PC# 4-20

PC# 6-33

CABLE #4

PC# 4-87

BATTERY

CABLE #2

CABLE #1

PC# 6-34

2 CABLE #3

C ELECTRICAL DIAGRAMS C

POWER CABLES (48 VOLT UNITS)

C 5866 - 44726 108249 (1 OF 2) H

Printed in U.S.A.

DIA–19.0–048

DIA–19.0–049

Crown 1991 PF9150-25 Rev. 9/98

02 REV. 9/98 A2

D PC# 6-36 PC# 2/0-45

C PC# 6-32 PC# 2/0-47

PC# 2/0-41

PC# 2/0-40

PC# 2/0-48

FU-14

FU-13

ED2 2

FU-15

4RECA

1 TO DISTRIBUTION PANEL

S 2

PC# 6-31

ED1

PC# 4-116

FU-12

1 REC

PC #6-8

MRC-3

TIE POINT

1 REC

3 REC

PC# 4-53

STEER AMP

PC# 6-8

MRC-2

LIFT SCR

MRC-1

PC# 4-109 3 REC

TRACTION SCR

4RECB

PC# 4-52

PC# 4-173

ACCY PUMP MOTOR M2

DRIVE MOTOR B M3

PC# 4-57

PC# 4-104

LIFT PUMP MOTOR M1

PART NO. 84571 84570 84569 84568 90963 84572 84573 86749

3 PC# 10-4

NEGATIVE STANDOFF

PC# 10-4

72V

STEER MOTOR

AN EXAMPLE OF SUCH A CABLE IS PC# 1/0 - 10. THE PART NUMBER FOR THIS CABLE IS 84572-10

PC# 1 PC# 2 PC# 4 PC# 6 PC# 10 PC# 1/0 PC# 2/0 PC# 3/0

ABBREVIATION

POWER CABLES ARE DESIGNATED USING ONE OF THE FOLLOWING ABBREVIATIONS, FOLLOWED BY A DASH NUMBER.

STEER MOTOR M6

LOCATED ON DOOR

PC# 2/0-43

PC# 2/0-42

DENOTES BUSS BAR

PC# 2/0-45

PC# 2/0-47

PC# 2/0-147

B PC# 6-34

PC# 4-81

PC# 2/0-46

BATTERY SIZE

DRIVE MOTOR A

PC# 4-173

PC# 4-57

PC# 4-20

PC# 6-33

CABLE #5

PC# 4-87

BATTERY

1 NEG.

BATTERY

PC# 2/0-20

CABLE #3

CABLE #2

PC# 6-34 CABLE #4

NUMBER

CABLE

PC# 2/0-19

CABLE #1

C ELECTRICAL DIAGRAMS C

POWER CABLES (72 VOLT UNITS)

C 5866 - 44726 108249 (2 OF 2) H

Printed in U.S.A.

DIA–19.0–049

ELECTRICAL DIAGRAMS

The following are the wire harness numbers for the TSP Turret Stockpicker. This index lists the area of the truck covered by each harness. Platform Harnesses 105698 105704 106390 108914 105703 105699 105700 105701 105095 106391 105796 106118-004 thru 106118-016 Power Unit Harnesses 106106 107951 107970 108897 108569 108913 108915 105912 107954 112066 105918 105919 113234

Crown 1991 PF9150-26

DIA–19.0–050

Components Connected By: Main platform wire harness Overhead guard, accessories to switch panel Seat, seat suppressor to seat limit switches EMS switches, EMS switches to terminal board Auxiliary height switch, auxiliary height switch to terminal board Sit-down foot pedestal, sit-down dead man and brake switches to terminal board Left standing foot pedal, left switches to terminal board Right standing foot pedal, right switches to terminal board Load handler, load handler solenoids and switches to terminal board Display driver module, relay distribution panel to display driver module Platform electronic box, internal wiring in platform electronic box Platform serial cable, serial cable from platform thru mast to power unit

Components Connected By: Main power unit harness Power unit serial cable, power unit serial from power unit to terminal board BDI control, harness from distribution panel to BDI controller Hour meter, harness from distribution panel to hour meter Brake solenoids, brake solenoids suppressor blocks to solenoids Right side brake status switch, right steered wheel brake switch to terminal board Left side brake status switch, left steered wheel brake switch to terminal board Power unit electronic box, internal wiring in power unit electronic box Power unit electronic box wiring for guidance, internal to box wiring Power unit electronic box wiring for EAC, internal to box wiring Load wheel sensor power unit electronic box to load wheel sensor bar Steered wheel sensor, power unit electronic box to steered wheel sensor bar EAC sensor bar, power unit electronic box to EAC sensor bar

Printed in U.S.A.

DIA–19.0–050

HYDRAULIC SCHEMATIC 5547

POWER UNIT & MAINFRAME

16 17

BPS

SV6

14 C2

ACC

SV9

SV7

RV3

SV8 T

SV1

P2 M1

SV3 C2 RV2

B T

SV2

RV1

9 18

B A T

1. 2. 3. 4. 5. 6. 7. 8.

Reservoir Suction Filter 100 Mesh Return Line Filter 10 Micron Nominal Lift Pump & Motor P1 & M1 Accessory Pump & Motor P2 & M2 Servo Lift/Lower Control Valve SV1 Brake & Accessory Manifold SV6, SV7, SV8, SV9, CV, RV3 set at 2000 p.s.i. Main & Auxiliary Lift/Lower Manifold SV2, SV3, RV1, RV2

9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Lift/Lower Accumulator 350 p.s.i. Precharge Main Lower Flow Control Valve Auxiliary Lower Flow Control Valve Manual Lower Valve Front Brake Cylinders (Load Wheel) Rear Brake Cylinders (Steer Wheel) Main Lift Cylinders Brake Pressure Switch 1750 p.s.i., 500 p.s.i. Brake Accumulator 350 p.s.i. Precharge Pump Manifold Block

5941 108292 AC Sht 1 Crown 1988 PF7848-1 Rev. 6/03

HYD–19.0–001

Printed in U.S.A.

07 REV. 6/03

HYD–19.0–001

HYDRAULIC SCHEMATIC 5548

PLATFORM & LOAD HANDLER - TELESCOPIC FORKS

26 B

SV5

SV4 SPC1 SHV

SV10 5 4 3 2 1

RV4 C1

V1 T1

SV11

SHV

CBV1

RV5

CBV2

SPC2

ACC

F2 F1

A B

SPC1

C1 FDC

C2 C3

V2 PRF1

SPC2

SV12 PB PRF2 CV

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

Fork Extension Cylinders Pivot Valve set at 1500 p.s.i. Traverse Valve set at 1500 p.s.i. Traverse Manifold SV4, SV5, SPC, SHV, SV10 Pivot Manifold CBV1, CBV2, SV11, SHV, RV4 and RV5 set at 1500 p.s.i. Traverse Cushion Manifold PRF1, PRF2, SV12, CV Pivot Cylinders Auxiliary Lift Cylinder Pivot Latch Cylinder Velocity Fuse Traverse Motor Fork Manifold SPC1, SPC2, FDC Accumulator 100 p.s.i. Precharge 5941 108292 AC Sht 2.

Crown 1988 PF7848-2 Rev. 6/03

HYD–19.0–002

Printed in U.S.A.

07 REV. 6/03

HYD–19.0–002

HYDRAULIC SCHEMATIC 5549

PLATFORM & LOAD HANDLER - NONTELESCOPIC FORKS

26 27

CBV1

RV4 C1

V1 SV11 SHV

RV5

CBV2 5 4

3 2

PRF1

SV12 PB T PRF2 CV

T V2

A B

20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Pivot Valve set at 1500 p.s.i. Traverse Valve set at 1500 p.s.i. Traverse Manifold Pivot Manifold CBV1, CBV2, SV11, SHV, RV4 and RV5 set at 1500 p.s.i. Traverse Cushion Manifold PRF1, PRF2, SV12, CV Pivot Cylinders Auxiliary Lift Cylinder Pivot Latch Cylinder Velocity Fuse Traverse Motor

5941 108292 AC Sht 3 Crown 1988 PF7848-3 Rev. 6/03

HYD–19.0–003

Printed in U.S.A.

07 REV. 6/03

HYD–19.0–003

HYDRAULIC SCHEMATIC 5554

TN POWER UNIT & MAINFRAME

7 14 16

BPS

C2 SV9

SV6

ACC

SV7 RV3

SV8

P2 M1

SV1

SV3

10 RV2 B T

SV3

RV1

17 12

B A T

1. 2. 3. 4. 5. 6. 7. 8.

Reservoir Suction Filter 100 Mesh Return Line Filter 10 Micron Nominal Lift Pump & Motor P1 & M1 Accessory Pump & Motor P2 & M2 Servo Lift/Lower Control Valve SV1 Brake & Accessory Manifold SV6, SV7, SV8, SV9, CV, RV3 (set at 2000 p.s.i.) Main & Auxiliary Lift/Lower Manifold SV2, SV3, RV1, RV2

9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

931015

5942 117044 K Sht 1

Crown 1993 PF9956-1 Rev. 6/03

HYD–19.0–050

Brake Accumulator 350 p.s.i. Precharge Main Lower Flow Control Valve Auxiliary Lower Flow Control Valve Manual Lower Valve Front Brake Cylinders (Load Wheel) Rear Brake Cylinders (Steer Wheel) Main Lift Cylinder Brake Pressure Switch 1750 p.s.i., 500 p.s.i. Lift/Lower Accumulator 350 p.s.i. Precharge Pump Manifold Block

Printed in U.S.A.

06 REV. 6/03

HYD–19.0–050

HYDRAULIC SCHEMATIC 5555

TN PLATFORM & LOAD HANDLER - TELESCOPIC FORKS

22 B

A SV4

SPC1

V1 T1

SHV

SV5

5 4

2 1

RV5

V2 SV10

RV4 C1

SV11

SHV

F2 F1

CBV1

SPC2

CBV2

ACC

29 A B

SPC1

C2 C3

PRF1 SV12 PRF2 CV

T CV

T V2

SPC2 FDC

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

Fork Extension Cylinders Pivot Valve set at 1500 p.s.i. Traverse Valve set at 1500 p.s.i. Traverse Manifold SV4, SV5, SPC1, SPC2, SHV, SV10 Pivot Manifold CBV1, CBV2, SV11, SHV, RV5, RV4 (set at 1500 p.s.i.) Traverse Cushion Manifold PRF1, PRF2, SV12, CV Pivot Cylinders Auxiliary Lift Cylinder Pivot Latch Cylinder Velocity Fuse Traverse Motor Fork Manifold SPC1, SPC2, FDC Accumulator 100 p.s.i. Precharge

931015

5942 117044 K Sht 2

Crown 1993 PF9956-2 Rev. 6/03

HYD–19.0–051

Printed in U.S.A.

06 REV. 6/03

HYD–19.0–051

HYDRAULIC SCHEMATIC 5556

TN PLATFORM & LOAD HANDLER - NONTELESCOPIC FORKS 27

CBV1 V1

RV4

SV11

SHV RV5

CBV2

28 5

PRF1

V1 SV12

T T

PRF2

B T

20. 21. 22. 23. 24.

Pivot Valve set at 1500 p.s.i. Traverse Valve set at 1500 p.s.i. Traverse Manifold Pivot Manifold CBV1, CBV2, SV11, SHV, RV4, RV5 set at 1500 p.s.i. Traverse Cushion Manifold PRF1, PRF2, SV12, CV

25. 26. 27. 28. 29.

931015

5942 117044 K Sht 3

Crown 1993 PF9956-3 Rev. 6/03

HYD–19.0–052

Pivot Cylinders Auxiliary Lift Cylinder Pivot Latch Cylinder Velocity Fuse Traverse Motor

Printed in U.S.A.

06 REV. 6/03

HYD–19.0–052

POWER UNIT 2682S

Crown 1989 PF-8464 Rev. 10/97

Printed in U.S.A.

03 REV. 10/97

01.0–19.0–003

POWER UNIT Index Part No. 1

Part Name

No. Req.

091638 Cover Top "B" Battery Comp. 1 107584 Cover Top "C" Battery Comp. 1 107585 Cover Top "D" Battery Comp. 1 2 107511 Stud 6 3 104167 Retainer 6 4 107510 Receptacle 6 5 060017-021 Screw 4 060005-009 Lockwasher 4 6 * Bracket Flashing Light 1 7 * Cover Battery L.H. 1 8 * Power Unit Includes Index 9 & 10 1 9 093565 Cover Skirt L.H. Shown 1 093672 Cover Skirt R.H. 1 093666 Spacer 4 10 060023-014 Screw 4 11 060023-009 Screw 2 060030-064 Flatwasher 4 060005-023 Lockwasher 2 060021-049 Nut 2 12 060023-006 Screw 4 060030-064 Flatwasher 8 060005-023 Lockwasher 4 060021-049 Nut 4 13 060030-148 Flatwasher .06 in.(1.5mm) Thick AR 060030-149 Flatwasher .12 in.(3.0mm) Thick AR 14 106418 Cover Rear 1 110483 Cover Rear Freezer/Corrosion 1 15 060015-053 Screw 8 16 106621 Support Cover 1 17 060038-006 Pin Cotter 4 18 092204 Shaft 2 19 060017-007 Screw 2 060005-009 Lockwasher 2 20 * Cover Battery R.H. 1 21 * Skirt R.H. Units Equipped With Wire Guidance 1 * Skirt R.H. Units Equipped With Rail Guidance 1 22 060019-010 Screw 2 060021-047 Nut 2 23 060017-007 Screw 8 060005-009 Lockwasher 8 060030-049 Flatwasher 8 24 060030-041 Flatwasher AR 25 092198-001 Bracket R.H. Upper 1

Index Part No. 26 27 28 29 30 31 32 33 34 * * 35 36 * 37 * 38 * 39 * *

40 * * 41 * * 42 * * 43 * * 44 45 46

47 48 49 50 51 52 53 54

Part Name

No. Req.

092198-002 Bracket R.H. Lower 1 106358 Door Rear R.H. 1 060017-007 Screw 2 060005-009 Lockwasher 2 106359 Door Rear L.H. 1 092199-001 Bracket L.H. Upper 1 092199-002 Bracket R.H. Lower 1 073988-005 Spacer 20 065081-010 Bearing Ball 20 Roller 10 Roller Assembly Includes Index 33 & 34 1 060000-027 Pin Roll 10 Shaft Roller 10 Tray Roller 1 Skirt Upper L.H. 1 Skirt Lower L.H. Units Equipped With Wire Guidance 1 Skirt Lower L.H. Units Equipped With Rail Guidance 1 060005-012 Lockwasher 3 060021-030 Nut 3 060030-059 Flatwasher 3 Spacer 2 Screw 4 Spacer 72 Volt Units 2 Screw 4 060005-008 Lockwasher 4 Spacer 48 Volt Units 1 Screw 4 060005-008 Lockwasher 4 Battery 48 Volt Not Shown 1 Battery 72 Volt Not Shown 2 108804 Bumper 4 108808 Handle 2 060015-008 Screw 4 061004-012 Adhesive Thread Locking AR 060030-012 Flatwasher 4 108807 Guide Poly 2 070959 Spring 4 060030-238 Flatwasher 4 108811 Wedge 2 060030-059 Flatwasher 4 060038-005 Pin Cotter 4 108807 Guide Poly 3 060015-008 Screw 6 061004-012 Adhesive Thread Locking AR 060030-012 Flatwasher 6

Always Specify Model, Data & Serial Numbers * See the following supplemental form 890525

5591 Printed in U.S.A.

03 REV. 10/97

01.0–19.0–004

POWER UNIT 9451S-01

Crown 1994 PF10198-1 Rev. 8/04

01.0–19.0–005

Printed in U.S.A.

06 REV. 8/04

01.0–19.0–005

C Index Part No. 1 2 3 4 5 6 7 8 9 10 11

14 15 16 17 18 19 20 21

22 23 24 25 26 27

POWER UNIT Part Name

No. Req.

126225 Top Cover "B" Battery Comp. 1 126226 Top Cover "C" Battery Comp. 1 126227 Top Cover "D" Battery Comp. 1 107511 Stud 6 104167 Retainer 6 107510 Receptacle 6 060017-021 Screw 4 060005-009 Lockwasher 4 * Flashing Light Bracket 1 * Battery Cover L.H. 1 * Power Unit Includes Index 9 & 10 1 093565 Skirt L.H. Shown 1 093672 Skirt R.H. 1 093666 Spacer 4 060023-014 Screw 4 060023-024 Screw 4 061004-026 Thread Locking Adhesive AR 060030-292 Flatwasher 8 060021-049 Nut 4 060023-023 Screw 2 061004-026 Thread Locking Adhesive AR 060030-292 Flatwasher 4 060021-049 Nut 2 060030-148 Flatwasher 1.5 mm (.06 in.) Thick AR 060030-149 Flatwasher 3.0 mm (.12 in.) Thick AR 106418 Rear Cover 1 110483 Rear Cover Freezer/Corrosion 1 060015-053 Screw 8 106621 Support Cover 1 060038-006 Cotter Pin 4 092204 Shaft 2 060017-006 Screw 2 060005-009 Lockwasher 2 * Battery Cover R.H. 1 * Skirt R.H. Units Equipped With Wire Guidance 1 * Skirt R.H. Units Equipped With Rail Guidance 1 060019-010 Screw 2 060021-047 Nut 2 060017-007 Screw 8 060005-009 Lockwasher 8 060030-049 Flatwasher 8 060030-041 Flatwasher AR 092198-001 Bracket R.H. Upper 1 092198-002 Bracket R.H. Lower 1 106358 Door R.H. 1

Index Part No. 28

Part Name

No. Req.

060017-007 Screw 2 060005-009 Lockwasher 2 106359 Door L.H. 1 092199-001 Bracket L.H. Upper 1 092199-002 Bracket R.H. Lower 1 073988-005 Spacer 20 065081-010 Bearing 20 * Roller 10 * Roller Assembly Includes Index 33 & 34 1 060000-027 Roll Pin 10 * Roller Shaft 10 * Tray 1 * Upper Skirt L.H. 1 * Lower Skirt L.H. Units Equipped With Wire Guidance 1 * Lower Skirt L.H. Units Equipped With Rail Guidance 1 060005-012 Lockwasher 3 060021-030 Nut 3 060030-059 Flatwasher 3 * Spacer 2 * Screw 4 * Spacer 72 Volt Units 2 * Screw 4 060005-008 Lockwasher 4 * Spacer 48 Volt Units 1 * Screw 4 060005-008 Lockwasher 4 * Battery 48 Volt Not Shown 1 * Battery 72 Volt Not Shown 2 108804 Bumper 4 108808 Handle 2 060015-008 Screw 4 061004-012 Thread Locking Adhesive AR 060030-012 Flatwasher 4 108807 Guide 2 070959 Spring 4 060030-238 Flatwasher 4 108811 Wedge 2 060030-059 Flatwasher 4 060038-005 Cotter Pin 4 108807 Guide 3 060015-008 Screw 6 061004-012 Thread Locking Adhesive AR 060030-012 Flatwasher 6 060020-027 Screw 2 060005-014 Lockwasher 2

29 30 31 32 33 34 35 36 37 38 39

40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

Always Specify Model, Data & Serial Numbers * See the following supplemental form

940425

8780 - EO13325

Crown 1994 PF10198-2 Rev. 8/04

Printed in U.S.A.

01.0–19.0–006

06 REV. 8/04

01.0–19.0–006

POWER UNIT

First Dash Number Battery Compartment Size Index

Part No.

"B"

"C"

"D"

094483-

002

003

004

108834-

002

003

004

107792-

001

003

107792-

002

004

005

108835-

002

003

004

107781-

002

003

004

107780-

002

003

004

094035-

001

002

003

100671-

001

002

003

094036-

001

002

003

107774-

001

002

003

108830-

002

003

004

107779-

002

003

004

107778-

002

003

004

Battery Specifications Index 43

Part No.

Batt. (*) Comp. Truck Size Voltage

48 V.

Truck Voltage

72 V.

Battery Spacers and Hardware († ) Amp Hour Range

Battery Size (Actual)

Second Dash Number

Index 40 & 42 Spacer

Screw

Spacer

Screw

107516

060016-014

107516

060016-014

107502-002

27.00" x 38.50" 880/1040 108803-001 060016-030

107983-001

33.00" x 38.75" 1200/1550

107983-002

33.00" x 38.50" 1200/1300 103803-001 060016-030 107984-001 060016-015

107503-001

13.50" x 38.44"

600/775

108803-001 060016-030 091312-001 060017-060

107503-002

13.50" x 38.25"

600/725

108803-002 060016-030 091312-001 060017-060

107503-003

13.38" x 38.00"

600/725

108803-002 060016-030 091312-002 060017-047

087219-002

15.88" x 38.38"

600/930

108803-001 060016-030 091312-004 060017-069

087219-004

15.69" x 38.19"

660/780

108803-002 060016-030 091312-003 060017-041

087219-005

15.81" x 38.00"

720/830

108803-002 060016-030 091312-003 060017-041

094072-001

18.00" x 38.69" 700/1000

094072-003

18.00" x 38.44" 770/1085 108803-001 060016-030

094072-005

17.88" x 38.25"

107502-001

27.00" x 38.75" 880/1240

Index 41 & 42

840/910

107984-001 060016-015

108803-002 060016-030 091312-001 060017-060

(*) = On trucks equipped with a 72 volt electrical system (2) 36 v. batteries are used. (†) = Typical capacity at 6 hour rate.

Crown 1994 PF10198-3 Rev. 8/04

01.0–19.0–005-SUP

Printed in U.S.A.

06 REV. 8/04

01.0–19.0–005-SUP

HYDRAULIC SYSTEM - POWER UNIT 1540S

BRAKE CYLINDER PLUMBING LOCATED AT REAR OF POWER UNIT

SEE HYDRAULIC SYSTEM - MAIN FRAME FOR "A" THRU "H"

R.H. SIDE OF POWER UNIT

Crown 1990 PF-8798 Rev. 5/97

Printed in U.S.A.

02 REV. 5/97

02.0–19.0–003

HYDRAULIC SYSTEM - POWER UNIT Index Part No. 1 2 3

4 5 6 7 8 9 10 11

13 14 15 16 17 18 19 20

21 22 23 24 25

27 28

Part Name

No. Req.

090306 Cylinder Brake See Section 8.8 064004-003 Connector 107058 Tube 061002-005 Clamp 060014-001 Screw 060005-005 Lockwasher 107403 Tube 107402 Tube 064064-002 Tee 108790 Knob 061004-010 Thread Locking Adhesive 106578 Handle Includes 7, 8 & 68 106579 Tube 060012-046 Screw 061004-020 Thread Locking Adhesive 105169 Adapter 061004-010 Thread Locking Adhesive 106042 Valve Needle 064019-030 O-Ring Large 064019-028 O-Ring Small 064074-031 Ring Back-Up 104523 Block Manifold 106577 Valve Lowering Includes 10, 11, 12 & 69 060015-019 Screw 060005-007 Lockwasher 060030-012 Flatwasher 064004-001 Connector * Tube 064061-003 Elbow 064009-001 Tee 064065-001 Elbow Swivel 107487 Tube * Hose 107201 Switch Pressure BPS 071198 Connector Wire 060014-024 Screw 060005-005 Lockwasher 064006-012 Elbow 107488 Tube 064004-004 Connector 064207-002 Adapter Orifice 100003 Accumulator 100304 Clamp 060016-003 Screw 060005-008 Lockwasher 060030-017 Flatwasher 100257 Accumulator 100303 Clamp 060016-003 Screw 060005-008 Lockwasher 060030-017 Flatwasher 064061-002 Elbow 108774 Tube

2 2 1 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1

Index Part No.

Part Name

No. Req.

Manifold See Section 2.4 060016-044 Screw 060005-008 Lockwasher 064098-002 Elbow 45° 064004-003 Connector * Hose 110224 Pump See Section 2.1 064061-009 Elbow 064155-092 Hose 064143-001 Nipple Hose 061022-003 Clamp * Hose * Hose * Hose 064065-004 Elbow Swivel 064157-090 Hose 064004-016 Connector 064061-005 Elbow 093762 Control Valve Servo SV1 - See Section 2.5 060015-069 Screw 060005-006 Lockwasher 064002-008 Nut 064060-002 Reducer 064080-005 Tee 064009-003 Tee 107495 Tube 061022-002 Clamp 064100-084 Hose 064156-011 Hose 064005-006 Connector 094345-005 Valve Flow Control 064222-002 Elbow 90° 064083-009 Beaded Insert 064100-086 Hose 107492 Tube 064004-012 Connector 064157-054 Hose 064061-005 Elbow Manifold See Section 2.4 060017-059 Screw 060005-009 Lockwasher Nut 064060-005 Reducer Includes 64 064080-006 Tee 064221-001 Hose 060000-046 Pin Roll 060000-100 Pin Roll 111318 Tube 061022-007 Clamp 064071-001 Tee 064128-002 Cap 064010-002 Tee

1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2

29 * 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74

1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 1

Always Specify Model, Data & Serial Numbers 900417

5425 Printed in U.S.A.

02 REV. 5/97

02.0–19.0–004

HYDRAULIC SYSTEM - POWER UNIT

Index 14 19 32 38 39 40

Part Number 107490064161064155064100064155064155-

Battery Compartment Size B C D 001 002 003 072 073 074 091 097 098 080 081 082 094 095 096 094 095 096

Crown 1990 PF-8798 Rev. 5/97

Printed in U.S.A.

02 REV. 5/97

02.0–19.0–003-SUP

HYDRAULIC SYSTEM - POWER UNIT 1540S-02

BRAKE CYLINDER PLUMBING LOCATED AT REAR OF POWER UNIT

3 62

* 4

5 9

63 76

69 66

18 11

60 20 21

54 51 52 50

48 24

45 23 44 27

E 42

G 73 74

27 30

39 35

38 36

SEE HYDRAULIC SYSTEM — MAIN FRAME FOR "A" THRUOGH "H"

R.H. SIDE OF POWER UNIT

Crown 1994 PF10106 Rev. 4/94

Printed in U.S.A.

02 REV. 4/94

02.0-19.0-005

HYDRAULIC SYSTEM - POWER UNIT Index Part No. 1 2 3

4 5 6 7 8 9 10 11

13 14 15 16 17 18 19 20

21 22 23 24 25

27 28 29

Part Name

No. Req.

090306 Cylinder Brake See Section 8.8 2 064004-003 Connector 2 107058 Tube 1 061002-005 Clamp 4 060014-001 Screw 4 060005-005 Lockwasher 4 107403 Tube 1 107402 Tube 1 064064-002 Tee 1 108790 Knob 1 061004-010 Thread Locking Adhesive 1 106578 Handle Includes Index 7, 8 & 68 1 106579 Tube 1 060012-046 Screw #6 1 061004-020 Thread Locking Adhesive 1 105169 Adapter 1 061004-010 Thread Locking Adhesive 1 106042 Valve Needle 1 064019-030 O-Ring Large 1 064019-028 O-Ring Small 1 064074-031 Ring Back-Up 2 104523-001 Block Manifold 1 106577 Valve Lowering Includes Index 10, 11, 12 & 69 1 060015-019 Screw 1/4" 2 060005-007 Lockwasher 2 060030-012 Flatwasher 2 064004-001 Connector 1 * Tube 1 064061-003 Elbow 1 064009-001 Tee 1 064065-001 Elbow Swivel 1 107487 Tube 1 * Hose 1 107201 Switch Pressure BPS 1 071198 Connector Wire 2 060014-024 Screw #10 2 060005-005 Lockwasher 2 064006-012 Elbow 2 107488 Tube 1 064004-004 Connector 1 064207-002 Adapter Orifice 1 100003 Accumulator 1 100304 Clamp 1 060016-003 Screw 5/16" 1 060005-008 Lockwasher 1 060030-017 Flatwasher 1 100257 Accumulator 1 100303 Clamp 1 060016-003 Screw 5/16" 1 060005-008 Lockwasher 1 060030-017 Flatwasher 1 064061-002 Elbow 2 108744 Tube 1 * Manifold See Section 2.4 1 060016-044 Screw 5/16" 2 060005-008 Lockwasher 2

Index Part No. 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76

940110

Part Name

No. Req.

064098-002 Elbow 45° 064004-003 Connector * Hose 110224 Pump See Section 2.1 064061-009 Elbow 064155-092 Hose 064143-001 Nipple Hose 061022-003 Clamp * Hose * Hose * Hose 064010-002 Tee 064157-090 Hose 48V 064157-091 Hose 72V 064241-004 Fitting 088840 Nipple 064231-002 Cap Dust 064061-005 Elbow 093762 Control Valve Servo SV1 - See Section 2.5 060015-069 Screw 1/4" 060005-006 Lockwasher 064002-008 Nut 064060-002 Reducer 064080-005 Tee 064009-003 Tee 107495 Tube 061022-001 Clamp 064100-084 Hose 064156-011 Hose 064005-006 Connector 094345-005 Valve Flow Control 064222-002 Elbow 90° 064083-009 Beaded Insert 064100-086 Hose 107492 Tube 064004-012 Connector 064157-054 Hose Assembly 064061-005 Elbow Manifold See Section 2.4 060017-059 Screw 3/8" 060005-009 Lockwasher Nut 064060-005 Reducer Includes Index 64 064080-006 Tee 064157-036 Hose 060000-046 Pin Roll 060000-100 Pin Roll 111318 Tube 061022-007 Clamp 064071-001 Tee 064128-002 Cap 064143-001 Hose Nipple 90° Elbow 117341-002 Valve Flow Control 064246-001 Elbow 90°

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1

Always Specify Model & Serial Number 4297 - 39260 Printed in U.S.A.

02 REV. 4/94

02.0-19-006

02.0-19.0-006

HYDRAULIC SYSTEM - POWER UNIT

Index 14 19 32 38 39 40

Part Number 107490064161064155064100064100064155-

Battery Compartment Size B C D 001 002 003 072 073 074 091 097 098 080 081 082 094 088 093 094 095 096

Crown 1994 PF-10106 Rev. 2/94

Printed in U.S.A.

01 REV. 2/94

2 - 19 - 005 - SUP

HYDRAULIC SYSTEM - POWER UNIT 3502S-01

BRAKE CYLINDER PLUMBING LOCATED AT REAR OF POWER UNIT

3 62

* 4

5 9

63 76

75 66

8 12

18 11

64 65

67 A

60 20 21

54 50

48 24

C D

45 23 44 27

29 31

E 42

28 40

G 73 74 37

77 32

39 35

38 36

SEE HYDRAULIC SYSTEM — MAIN FRAME FOR "A" THRUOGH "H"

R.H. SIDE OF POWER UNIT

Crown 1994 PF-10423 Rev. 8/95

Printed in U.S.A.

02 REV. 8/95

02.0–19.0–007

HYDRAULIC SYSTEM - POWER UNIT Index 1 2 3

4 5 6 7

8 9 10 11

Part No.

Part Name

090306 064004-003 119587 061002-005 060014-001 060005-005 119586 107402 064064-002 108790 061004-010 106578 106579 060012-046 061004-020 105169 061004-010 106042 064019-030 064019-028 064074-031 104523-001 106577

Cylinder Brake See Section 8.8 Connector Tube Clamp Screw Lockwasher Tube Tube Tee Knob Thread Locking Adhesive Handle Includes Index 7, 8 & 68 Tube Screw #6 Thread Locking Adhesive Adapter Thread Locking Adhesive Valve Needle O-Ring Large O-Ring Small Ring Back-Up Block Manifold Valve Lowering Includes Index 10, 11, 12 & 69 Screw 1/4" Lockwasher Flatwasher Connector Tube Elbow Tee Elbow Swivel Tube Tube Switch Pressure BPS Connector Wire Screw #10 Lockwasher Elbow Tube Connector Adapter Orifice Accumulator Lift Accumulator Lift Freezer Condition Clamp Screw 5/16" Lockwasher Flatwasher Accumulator Brake Accumulator Brake Freezer Condition Clamp Screw 5/16" Lockwasher Flatwasher Elbow Elbow TN Tube

060015-019 060005-007 060030-012 064004-001

13 14 * 15 064061-003 16 064009-001 17 064065-001 18 107487 19 * 20 107201 071198 060014-024 060005-005 21 064006-012 22 107488 23 064004-004 24 064250-002 25 117768 118841

27 28

118843 060016-003 060005-008 060030-017 119224 119225 119226 060016-003 060005-008 060030-017 064061-002 064098-002 108774

No. Req. 2 2 1 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Index

Part No.

29 *

30 31 32 33 34 35 36 37 38 39 40 41 42 43

44 45

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

64 65 66 67 68 69 70 71 72 73 74 75 76 77

060016-044 060005-008 064098-002 064098-002 * 110224 064061-009 064155-092 064143-006 061022-003 * * * 064010-002 064157-141 064157-091 064241-004 088840 064231-002 064061-005 093762 060015-069 060005-006 064002-008 064060-002 064080-005 064009-003 119585 061022-001 064100-084 064156-011 064005-006 094345-005 064222-001 064083-009 064100-086 107492 064004-012 064157-054 064061-005 060017-059 060005-009 064009-004 064060-005 064061-005 064157-140 060000-046 060000-100 111318 061022-001 064071-001 064128-002 064143-001 117341-002 064246-001 064061-002

Part Name

No. Req.

Manifold See Section 2.4 Screw 5/16" Lockwasher Elbow 45° Elbow Hose Pump See Section 2.1 Elbow Hose Nipple Hose Clamp Hose Hose Hose Tee Hose 48V Hose 72V Fitting Nipple Cap Dust Elbow Control Valve Servo SV1 - See Section 2.5 Screw 1/4" Lockwasher Nut Reducer Tee Tee Tube Clamp Hose Hose Connector Valve Flow Control Elbow 90° Beaded Insert Hose Tube Connector Hose Assembly Elbow Manifold See Section 2.4 Screw 3/8" Lockwasher Tee Reducer Elbow Hose Pin Roll Pin Roll Tube Clamp Tee Cap Hose Nipple 90° Elbow Valve Flow Control Elbow 90° Elbow

Always Specify Model & Serial Number

941121

1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 4747 Printed in U.S.A.

02 REV. 8/95

02.0–19.0–008

HYDRAULIC SYSTEM - POWER UNIT

Index 14 19 32 38 39 40

Part Number 107490119537064155064100064100064155-

Battery Compartment Size B C D 001 002 003 001 002 003 091 097 098 080 081 082 094 088 093 094 095 096

Crown 1994 PF-10423 Rev. 8/95

Printed in U.S.A.

02 REV. 8/95

02.0–19.0–007-SUP

HYDRAULIC SYSTEM - POWER UNIT 4267S

BRAKE CYLINDER PLUMBING LOCATED AT REAR OF POWER UNIT

3 62

* 4

5 9

63 76

75 66

8 12

18 11

64 65

67 A

60 20 21

54 50

48 24

C D

45 23 44 27

29 31

E 42

28 40

G 73 74

37 32

38 36

SEE HYDRAULIC SYSTEM — MAIN FRAME FOR "A" THRUOGH "H"

R.H. SIDE OF POWER UNIT

Crown 1996 PF10974 Rev. 9/98

Printed in U.S.A.

01 REV. 9/98

02.0–19.0–009

HYDRAULIC SYSTEM - POWER UNIT Index 1 2 3

4 5 6 7

8 9 10 11

Part No.

Part Name

Cylinder Brake See Section 8.8 Connector Tube Clamp Screw Lockwasher Tube Tube Tee Knob Thread Locking Adhesive Handle Includes Index 7, 8 & 68 Tube Screw Thread Locking Adhesive Adapter Thread Locking Adhesive Valve Needle O-Ring Large O-Ring Small Ring Back-Up Block Manifold Valve Lowering Includes Index 10, 11, 12 & 69 Screw Lockwasher Flatwasher Connector Tube Elbow Tee Elbow Swivel Tube Tube Switch Pressure BPS Connector Wire Screw Lockwasher Elbow Tube Connector Adapter Orifice Accumulator Lift Clamp Screw Lockwasher Flatwasher Accumulator Brake Clamp Screw Lockwasher Flatwasher Elbow Elbow TN Tube Manifold See Section 2.4 Screw Lockwasher

060015-019 060005-007 060030-012 064004-001

13 14 * 15 064061-003 16 064009-001 17 064065-001 18 107487 19 * 20 107201 071198 060014-024 060005-005 21 064006-012 22 107488 23 064004-004 24 064250-002 25 118841 118843 060016-003 060005-008 060030-017 26 119225 119226 060016-003 060005-008 060030-017 27 064061-002 064098-002 28 108774 29 * 060016-044 060005-008

No. Req.

Index

2 2 1 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1

30 31 32 33 34 35 36 37 38 39 40 41 42

1 2 2 2 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2

44 45

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

64 65 66 67 68 69 70 71 72 73 74 75 76 77

960521

Part No.

Part Name

064061-002 064098-002

Elbow Elbow 45° Hose Pump See Section 2.1 Connector Hose Nipple Hose Clamp Hose Hose Hose Tee Hose 48V Hose 72V Fitting Nipple Cap Dust Elbow Control Valve Servo SV1 - See Section 2.5 Screw Lockwasher Nut Reducer Tee Tee Tube Clamp Hose Hose Connector Valve Flow Control Elbow 90° Beaded Insert Hose Tube Connector Hose Assembly Elbow Manifold See Section 2.4 Screw Lockwasher Tee Reducer Elbow Hose Pin Roll Pin Roll Tube Clamp Tee Cap Hose Nipple 90° Elbow Valve Flow Control Elbow 90° Elbow

* 110224 064004-001 064255-306 064143-006 061022-003 * * * 064010-002 064257-141 064257-091 064241-004 088840 064231-002 064061-005 093762 060015-069 060005-006 064002-008 064060-002 064080-005 064009-003 119585 061022-001 064100-084 064156-011 064005-006 094345-005 064222-001 064083-009 064100-086 107492 064004-012 064257-054 064061-005 060017-059 060005-009 064009-004 064060-005 064061-005 064157-140 060000-046 060000-100 111318 061022-001 064071-001 064128-002 064143-001 117341-002 064246-001 064061-002

No. Req. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1

Always Specify Model, Data & Serial Numbers 5868 - 44896 Printed in U.S.A.

01 REV. 9/98

02.0–19.0–010

HYDRAULIC SYSTEM - POWER UNIT

Index 14 19 32 38 39 40

Part Number 107490119537064255064100064100064255-

Battery Compartment Size B C D 001 002 003 001 002 003 091 097 098 080 081 082 094 088 093 094 095 096

Crown 1996 PF10974 Rev. 9/98

Printed in U.S.A.

01 REV. 9/98

02.0–19.0–009-SUP

HYDRAULIC SYSTEM - POWER UNIT 12759

48 VOLT Brake Cylinder Plumbing Located at Rear of Power Unit

See Hydraulic System - Main Frame for "A" Thru "H" Crown 2005 PF15077-1

02.0–19.0–012

R.H. Side of Power Unit

Printed in U.S.A.

02.0–19.0–012

C Index Part No. 1 2 3

4 5 6 7 8 9 10 11

13 14 15 16 17 18 19 20

21 22 23 24 25

HYDRAULIC SYSTEM - POWER UNIT Part Name

No. Req.

090306 Cylinder Brake See Section 8.8 2 064004-003 Connector 2 119587 Tube 1 061002-005 Clamp 4 060014-001 Screw 4 060005-005 Lockwasher 4 119586 Tube 1 107402 Tube 1 064064-002 Tee 1 108790 Knob 1 061004-010 Thread Locking Adhesive 1 106578 Handle Includes Index 7, 8 & 68 1 106579 Tube 1 060012-046 Screw 1 061004-020 Thread Locking Adhesive 1 105169 Adapter 1 061004-010 Thread Locking Adhesive 1 106042 Valve Needle 1 064019-030 O-Ring Large 1 064019-028 O-Ring Small 1 064074-031 Ring Back-Up 2 104523-001 Block Manifold 1 106577 Valve Lowering Includes Index 10, 11, 12 & 69 1 060015-019 Screw 2 060005-007 Lockwasher 2 060030-012 Flatwasher 2 064004-001 Connector 1 * Tube 1 064061-003 Elbow 1 064009-001 Tee 1 064065-001 Elbow Swivel 1 107487 Tube 1 * Tube 1 107201 Switch Pressure BPS 1 071198 Connector Wire 2 060014-024 Screw 2 060005-005 Lockwasher 2 064006-012 Elbow 2 107488 Tube 1 064004-004 Connector 1 064250-002 Adapter Orifice 1 118841 Accumulator Lift 1 118843 Clamp 1 060016-003 Screw 1 060005-008 Lockwasher 1 060030-017 Flatwasher 1

960521 Crown 2005 PF15077-2

02.0–19.0–013

Index Part No. 26

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

Part Name

No. Req.

119225 Accumulator Brake 119226 Clamp 060016-003 Screw 060005-008 Lockwasher 060030-017 Flatwasher 064061-002 Elbow 064098-002 Elbow TN 108774 Tube * Manifold See Section 2.4 060016-044 Screw 060005-008 Lockwasher 064061-002 Elbow 064098-002 Elbow 45° * Hose 110224 Pump See Section 2.1 064004-001 Connector 064255-306 Hose 064143-006 Nipple Hose 061022-003 Clamp * Hose * Hose * Hose 064010-002 Tee 064257-141 Hose 064241-004 Fitting 088840 Nipple 064231-002 Cap Dust 064061-005 Elbow 093762 Control Valve Servo SV1 - See Section 2.5 060015-069 Screw 060005-006 Lockwasher 064002-008 Nut 064060-002 Reducer 064080-005 Tee 064009-003 Tee 119585 Tube 061022-001 Clamp 064100-084 Hose 064156-011 Hose 064005-006 Connector 094345-005 Valve Flow Control 064222-001 Elbow 90° 064083-009 Beaded Insert 064100-086 Hose 107492 Tube 064004-012 Connector 064257-054 Hose Assembly 064061-005 Elbow

1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

5868 - 44896 Printed in U.S.A.

02.0–19.0–013

HYDRAULIC SYSTEM - POWER UNIT Index Part No. 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77

Part Name

No. Req.

Manifold See Section 2.4 060017-059 Screw 060005-009 Lockwasher 064009-004 Tee 064060-005 Reducer 064061-005 Elbow 064157-140 Hose 060000-046 Pin Roll 060000-100 Pin Roll 111318 Tube 061022-001 Clamp 064071-001 Tee 064128-002 Cap 064143-001 Hose Nipple 90° Elbow 117341-002 Valve Flow Control 064246-001 Elbow 90° 064061-002 Elbow

1 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1

Always Specify Model, Data & Serial Numbers

050613 Crown 2005 PF15077-3

02.0–19.0–014

11376 Printed in U.S.A.

02.0–19.0–014

HYDRAULIC SYSTEM - POWER UNIT

CHART 1 Index

Crown 2005 PF15077-4

02.0–19.0–012-SUP

Part Number

Battery Compartment Size B

107490-

001

002

003

119537-

001

002

003

064255-

091

097

098

064100-

080

081

082

064100-

094

088

093

064255-

094

095

096

Printed in U.S.A.

02.0–19.0–012-SUP

HYDRAULIC SYSTEM - POWER UNIT 12750

Brake Cylinder Plumbing Located at Rear of Power Unit

72 VOLT

R.H. Side of Power Unit See Hydraulic System - Main Frame for "A" Thru "H" Crown 2005 PF15068-1

02.0–19.0–050

Printed in U.S.A.

02.0–19.0–050

C Index Part No. 1 2 3

4 5 6 7 8 9 10 11

13 14 15 16 17 18 19 20

21 22 23 24 25

HYDRAULIC SYSTEM - POWER UNIT Part Name

No. Req.

Crown 2005 PF15068-2

02.0–19.0–051

Index Part No. 26

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

46 47 48 49 50 51 52 53 54 55 56 57 58 59

Part Name

No. Req.

119225 Accumulator Brake 119226 Clamp 060016-003 Screw 060005-008 Lockwasher 060030-017 Flatwasher 064061-002 Elbow 064098-002 Elbow TN 108774 Tube * Manifold See Section 2.4 060016-044 Screw 060005-008 Lockwasher 064061-002 Elbow 064098-002 Elbow 45° * Hose 110224 Pump See Section 2.1 064004-001 Connector 064255-306 Hose 064143-006 Nipple Hose 061022-003 Clamp * Hose * Hose * Hose 064010-002 Tee * Hose 064241-004 Fitting 088840 Nipple 064231-002 Cap Dust 064061-005 Elbow 093762 Control Valve Servo SV1 - See Section 2.5 060015-069 Screw 060005-006 Lockwasher 064002-008 Nut 064060-002 Reducer 064080-005 Tee 064009-003 Tee 119585 Tube 061022-001 Clamp 064100-084 Hose 064156-011 Hose 064005-006 Connector 094345-005 Valve Flow Control 064222-001 Elbow 90° 064083-009 Beaded Insert 064100-086 Hose 107492 Tube

1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Printed in U.S.A.

02.0–19.0–051

HYDRAULIC SYSTEM - POWER UNIT Index Part No. 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77

Part Name

No. Req.

064004-012 Connector 064257-054 Hose Assembly 064061-005 Elbow Manifold See Section 2.4 060017-059 Screw 060005-009 Lockwasher 064009-004 Tee 064060-005 Reducer 064061-005 Elbow 064157-140 Hose 060000-046 Pin Roll 060000-100 Pin Roll 111318 Tube 061022-001 Clamp 064071-001 Tee 064128-002 Cap 064143-001 Hose Nipple 90° Elbow 117341-002 Valve Flow Control 064246-001 Elbow 90° 064061-002 Elbow

1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1

Always Specify Model, Data & Serial Numbers

050613 Crown 2005 PF15068-3

02.0–19.0–052

11374 Printed in U.S.A.

02.0–19.0–052

HYDRAULIC SYSTEM - POWER UNIT

CHART 1 Battery Compartment Size

Crown 2005 PF15068-4

02.0–19.0–050-SUP

Index

Part Number

107490-

001

002

003

119537-

001

002

003

064255-

091

097

098

064100-

080

081

082

064100-

094

088

093

064255-

094

095

096

064257-

211

212

Printed in U.S.A.

02.0–19.0–050-SUP

HYDRAULIC SYSTEM — MAIN FRAME Collapsed Height

Index 20 & 25

Index 26

125"

064155-079

064157-048

131"

064155-080

064157-049

137"

064155-027

064157-008

143"

064155-028

064157-09

149"

064155-029

064157-010

155"

064155-030

064157-011

161"

064155-031

064157-012

167"

064155-032

064157-013

173"

064155-033

064157-014

179"

064155-034

064157-015

185"

064155-035

064157-016

191"

064155-036

064157-017

197"

064155-037

064157-018

203"

064155-038

064157-019

209"

064155-039

064157-020

215"

064155-040

064157-021

221"

064155-041

064157-022

227"

064155-042

064157-023

233"

064155-043

064157-024

239"

064155-044

064157-025

245"

064155-045

064157-026

251"

064155-046

064157-027

257"

064155-047

064157-028

Index 32 34 35 36

Part Number 064155064155064155064100-

Battery Compartment Size B C D 135 136 137 135 136 137 091 097 098 080 081 082 Printed in U.S.A.

Crown 1988 PF-8107 Rev. 5/93

01 REV. 5/93

2 - 19 - 100 - SUP

HYDRAULIC SYSTEM — MAIN FRAME 0659S

HOSE ROUTING OVER TOP OF MAST

SEE HYDRAULIC SYSTEM— PLATFORM FOR "J", "K" & "L"

CYLINDER PLUMBING IN TOP OF MAST

55 56 HOSE ROUTING THRU MAST

RK FO ND E

HOSE ROUTING THRU MAIN FRAME BASE

SEE HYDRAULIC SYSTEM—POWER UNIT FOR "A" THRU "G"

Crown 1991 PF-9137 Rev. 5/93

Printed in U.S.A.

03 REV. 5/93

2 - 19 - 102

HYDRAULIC SYSTEM — MAIN FRAME Index

Part No.

101618 060015-003 060005-007 060030-092 074105 060014-006 060005-005 076755 077145 064006-013 107592 102802 064006-005 064006-004 090940 090943 064020-016 091021 064019-073 093779 060015-006 060005-007 061022-002 064173-012 107591 064034-002 064030-003 † 064155 061022-001 061002-005 060013-005 060005-004 060030-045 060021-004 064100-084 064161-023 † 064155 † 064157 064221-001 064033-001 064033-002 064030-002 064157-090 * 064155 * 064156-011 * 064155 * 064155 * 064100 074415-004 064143-001 093772 060017-011 060005-009 061022-001 064100-083 064100-079 064143-003 064201-001

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

* 060017-028 060005-009 *

060019-025 060005-012 064061-005 064061-021

Part Name Shield Screw 1/4" Lockwasher Flatwasher Cap Filter Screw#10 Lockwasher Filter Oil Filter Element Replacement Elbow Tube Tube Elbow Elbow Dip Stick Oil Reservoir Hydraulic Plug Pipe Strainer Sump O-Ring Cap Reservoir Screw 1/4" Lockwasher Clamp Hose Hose Tube Elbow Bulkhead Nut Hose Clamp Clamp Screw #8 Lockwasher Flatwasher Nut Hose Hose Hose Hose Hose Fitting Bulkhead Fitting Bulkhead Nut Hose Hose Hose Hose Hose Hose Clamp Hose Elbow Manifold Block Screw 3/8" Lockwasher Clamp Hose Hose 48 V. Units Hose 72 V. Units Nipple Hose 48 V. Units Insert Beaded Includes Screws 72 V. Units Pump Lift - 48 V. Units See Section 2.1 Screw 3/8" Lockwasher Pump Lift - 72 V. Units See Section 2.1 Screw 1/2" Lockwasher Elbow 48 V. Units Elbow 72 V. Units

No. Req.

Index

1 2 2 2 1 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 8 8 2 1 1 1 2 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1

45 46 47 48 49 50 51 52 53 54 55 56 57

Part No.

Part Name

064065-001 064010-001 064004-014 091229 060017-011 060005-009 065004-021 107579 064065-004 064004-016 064065-002 064064-002

Elbow Tee Connector Valve Load Lowering Screw 3/8" Lockwasher Grommet Tube Elbow Swivel Connector Elbow Swivel Tee Cylinder Brake See Section 8.8 Elbow Hose 48 in. (1220mm) to 55 in. (1400mm) Load Wheel Width Hose 56 in. (1422mm) to 65 in. (1650mm) Load Wheel Width Hose 66 in. (1675mm) to 72 in. (1830mm) Load Wheel Width Hose 48 in. (1220mm) to 55 in. (1400mm) Load Wheel Width Hose 56 in. (1422mm) to 65 in. (1650mm) Load Wheel Width Hose 66 in. (1675mm) to 72 in. (1830mm) Load Wheel Width Clamp Hose Screw 1/4" Lockwasher Hose Cylinder Free Lift Cluster See Section 8.2 Elbow 45° Clamp Tube Screw #8 Lockwasher Tube L.H. Elbow Tube R.H. Cylinder Main Lift See Section 8.2 Clamp Clamp Screw #8 Lockwasher Flatwasher Nut

* 064061-002 064155-238 064155-090 064155-239

064155-238 064155-090 064155-239

59 60 61 62 63 64 65 66 67 68 69

100619 060015-003 060005-007 064157-007 064098-005 061002-005 060013-004 060005-033 094583-002 064061-019 094583-001 061002-002 061002-003 060013-005 060005-004 060030-045 060021-004

No. Req. 1 1 1 1 2 2 2 1 1 3 1 1 2 2 1 1 1 1 1 1 4 4 4 2 1 2 2 2 2 1 2 1 1 1 1 1 1 2 1

Always Specify Model & Serial Number † Specify Collapsed Height or Lift Height when ordering. * See the Following Supplemental List COMPARTMENT SIZE

BATTERY VOLTAGE

MAXIMUM BATTERY SIZE

48 V.

27.00" X 38.75" X 31"Ht. (685 mm X 985 mm X 785 mm)

72 V.

13.50" X 38.44"X 31.00" Ht. (345 mm X 975 mm X 785 mm)

48 V.

33.00" X 38.75" X 31" Ht. (685 mm X 985 mm X 785 mm)

72 V.

15.88" X 38.38"X 31.00" Ht. (405 mm X 970 mm X 785 mm)

72 V.

18.00" X 38.69"X 31.00" Ht. (455 mm X 980 mm X 785 mm)

1 1 2 2 1 2 2 1 1

910812

4067 - 37620 Printed in U.S.A.

03 REV. 5/93

2 - 19 - 103

HYDRAULIC SYSTEM — MAIN FRAME Collapsed Height

Index 20 & 25

Index 26

125"

064155-079

064157-048

131"

064155-080

064157-049

137"

064155-027

064157-008

143"

064155-028

064157-09

149"

064155-029

064157-010

155"

064155-030

064157-011

161"

064155-031

064157-012

167"

064155-032

064157-013

173"

064155-033

064157-014

179"

064155-034

064157-015

185"

064155-035

064157-016

191"

064155-036

064157-017

197"

064155-037

064157-018

203"

064155-038

064157-019

209"

064155-039

064157-020

215"

064155-040

064157-021

221"

064155-041

064157-022

227"

064155-042

064157-023

233"

064155-043

064157-024

239"

064155-044

064157-025

245"

064155-045

064157-026

251"

064155-046

064157-027

257"

064155-047

064157-028

Index 32 34 35 36 Crown 1991 PF-9137

2 - 19 - 102 - SUP

Part Number 064155064155064155064100-

Battery Compartment Size B C D 135 136 137 135 136 137 091 097 098 080 081 082 Printed in U.S.A.

2 - 19 - 102 - SUP

HYDRAULIC SYSTEM — MAIN FRAME 0659S

HOSE ROUTING OVER TOP OF MAST

SEE HYDRAULIC SYSTEM— PLATFORM FOR "J", "K" & "L"

CYLINDER PLUMBING IN TOP OF MAST

55 56 HOSE ROUTING THRU MAST

RK FO ND E

HOSE ROUTING THRU MAIN FRAME BASE

SEE HYDRAULIC SYSTEM—POWER UNIT FOR "A" THRU "G"

Crown 1993 PF-9840

2 - 19 - 104

Printed in U.S.A.

2 - 19 - 104

HYDRAULIC SYSTEM — MAIN FRAME Index

Part No.

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

* 060017-028 060005-009 *

060019-025 060005-012 064061-005 064061-021

900829

No. Req.

Index

1 2 2 2 1 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 8 8 2 1 1 1 2 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1

45 46 47 48 49 50 51 52 53 54 55 56 57

Part No.

Part Name

064065-001 064010-001 064004-014 091229 060017-011 060005-009 065004-021 107579 064065-004 064004-016 064065-002 064064-002

* 064061-002 064155-238 064155-090 064155-239

064155-238 064155-090 064155-239

59 60 61 62 63 64 65 66 67 68 69

100619 060015-003 060005-007 064157-007 064098-005 061002-005 060013-004 060005-033 094583-002 064061-019 094583-001 061002-002 061002-003 060013-005 060005-004 060030-045 060021-004

No. Req. 1 1 1 1 2 2 2 1 1 3 1 1 2 2 1 1 1 1 1 1 4 4 4 2 1 2 2 2 2 1 2 1 1 1 1 1 1 2 1

Always Specify Model & Serial Number † Specify Collapsed Height or Lift Height when ordering. * See the Following Supplemental List COMPARTMENT SIZE

BATTERY VOLTAGE

MAXIMUM BATTERY SIZE

48 V.

27.00" X 38.75" X 31"Ht. (685 mm X 985 mm X 785 mm)

72 V.

13.50" X 38.44"X 31.00" Ht. (345 mm X 975 mm X 785 mm)

48 V.

33.00" X 38.75" X 31" Ht. (685 mm X 985 mm X 785 mm)

72 V.

15.88" X 38.38"X 31.00" Ht. (405 mm X 970 mm X 785 mm)

72 V.

18.00" X 38.69"X 31.00" Ht. (455 mm X 980 mm X 785 mm)

1 1 2 2 1 2 2 1 1

2971 - 34341 Printed in U.S.A.

2 - 19 - 105

HYDRAULIC SYSTEM — MAIN FRAME Collapsed Height in. mm

Lift Height in. mm

Index 20 & 25

Index 26

125"

3175

208

5285

064155-143

064157-055

131"

3330

220

5590

064155-144

064157-056

137"

3480

232

5890

064155-145

064157-057

143"

3630

244

6200

064155-146

064157-058

149"

3785

256

6500

064155-147

064157-059

155"

3935

268

6805

064155-148

064157-060

161"

4090

280

7110

064155-149

064157-061

167"

4240

292

7415

064155-150

064157-062

173"

4395

304

7720

064155-151

064157-063

179"

4545

316

8025

064155-152

064157-064

185"

4700

328

8330

064155-153

064157-065

191"

4850

340

8635

064155-154

064157-066

197"

5005

352

8940

064155-155

064157-067

203"

5150

364

9245

064155-156

064157-068

209"

5310

376

9550

064155-157

064157-069

215"

5460

388

9855

064155-158

064157-070

221"

5615

400

10160

064155-159

064157-071

227"

5765

412

10465

064155-160

064157-072

233"

5920

424

10770

064155-161

064157-073

239"

6070

436

11075

064155-162

064157-074

245"

6225

448

11380

064155-163

064157-075

251"

6375

460

11685

064155-164

064157-076

257"

6530

472

11990

064155-046

064157-077

263"

6680

484

12295

064155-248

064157-078

269"

6830

496

12600

064155-249

064157-079

Index 32 34 35 36

Part Number 064155064155064155064100-

Battery Compartment Size B C D 135 136 137 135 136 137 091 097 098 080 081 082

Crown 1993 PF-9840 Rev. 6/93

Printed in U.S.A.

01 REV. 6/93

2 - 19 - 104 - SUP

HYDRAULIC SYSTEM — MAIN FRAME 0659S-01

Crown 1993 PF-9948

2 - 19 - 106

Printed in U.S.A.

2 - 19 - 106

HYDRAULIC SYSTEM — MAIN FRAME Index

Part No.

101618 060015-003 060005-007 060030-092 074105 060014-006 060005-005 076755 077145 064006-013 107592 102802 064006-005 064006-004 090940 090943 064020-016 091021 064019-073 093779 060015-006 060005-007 061022-002 064173-012 107591 064034-002 064030-003 * 064155 061022-001 061002-005 060013-005 060005-004 060030-045 060021-004 064100-084 064161-023 * 064155 * 064157 064221-001 064033-001 064033-002 064030-002 064157-090 * 064155 064156-011 * 064155 * 064155 * 064100 074415-004 064143-001 093772 060017-011 060005-009 061022-001 064100-083 064100-079 064143-003 064201-001

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

15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

40 41 42

931015

No. Req. 1 2 2 2 1 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 8 8 2 1 1 1 2 1 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1

Index

Part No.

43 060017-028 060005-009

44 45 46 47 48

49 50 51 52 53 54 55 56 57

060019-025 060005-012 064061-005 064061-021 064065-001 064010-001 064004-014 091229 060017-011 060005-009 065004-021 107579 064065-004 064004-016 064065-002 064064-002 064061-002 064155-238 064155-090 064155-239

064155-238 064155-090 064155-239

60 61 62 63

64 65 66 67 68 69

100619 060015-003 060005-007 064157-007

064098-005 061002-005 060013-004 060005-033 094583-002 064061-019 094583-001 061002-002 061002-003 060013-005 060005-004 060030-045 060021-004

Part Name

No. Req.

Pump Lift - 48 V. Units See Section 2.1 Screw 3/8" Lockwasher Pump Lift - 72 V. Units See Section 2.1 Screw 1/2" Lockwasher Elbow 48 V. Units Elbow 72 V. Units Elbow Tee Connector Valve Load Lowering Screw 3/8" Lockwasher Grommet Tube Elbow Swivel Connector Elbow Swivel Tee Cylinder Brake See Section 8.8 Elbow Hose 48 in. (1220mm) to 55 in. (1400mm) Load Wheel Width Hose 56 in. (1422mm) to 65 in. (1650mm) Load Wheel Width Hose 66 in. (1675mm) to 72 in. (1830mm) Load Wheel Width Hose 48 in. (1220mm) to 55 in. (1400mm) Load Wheel Width Hose 56 in. (1422mm) to 65 in. (1650mm) Load Wheel Width Hose 66 in. (1675mm) to 72 in. (1830mm) Load Wheel Width Clamp Hose Screw 1/4" Lockwasher Hose Cylinder Free Lift Cluster See Section 8.2 Elbow 45° Clamp Tube Screw #8 Lockwasher Tube L.H. Elbow Tube R.H. Cylinder Main Lift See Section 8.2 Clamp Clamp Screw #8 Lockwasher Flatwasher Nut

1 2 2 1 2 2 1 1 1 1 1 1 2 2 2 1 1 3 1 1 2 2 1 1 1 1 1 1 4 4 4 2 1 2 2 2 2 1 2 1 1 1 1 1 1 2 1

Always Specify Model & Serial Number * See the Following Supplemental List 4121F - 37979 Printed in U.S.A.

2 - 19 - 107

HYDRAULIC SYSTEM — MAIN FRAME Collapsed Height in. mm

in.

Lift Height mm

125 131 137 143 149 155 161 167 173 179 185 191 197 203 209 215 221 227 233 239 245 251 257 263 269

208 220 232 244 256 268 280 292 304 316 328 340 352 364 376 388 400 412 424 436 448 460 472 484 496

5285 5590 5890 6200 6500 6805 7110 7415 7720 8025 8330 8635 8940 9245 9550 9855 10160 10465 10770 11075 11380 11685 11990 12295 12600

Index 32 34 35 36

Base Part Number 064155064155064155064100-

3175 3330 3480 3630 3785 3935 4090 4240 4395 4545 4700 4850 5005 5150 5310 5460 5615 5765 5920 6070 6225 6375 6530 6680 6830

Index 20 & 25 TF TN 064155-143 064155-144 064155-145 064155-146 064155-147 064155-148 064155-149 064155-150 064155-151 064155-152 064155-153 064155-154 064155-155 064155-156 064155-157 064155-158 064155-159 064155-160 064155-161 064155-162 064155-163 064155-164 064155-046 064155-248 064155-249

064155-294 064155-167 064155-260 064155-262 064155-195 064155-197 064155-266 064155-268 064155-231 064155-029 064155-030 064155-031 064155-032 064155-033 064155-275 064155-277 064155-279 064155-281 064155-283 064155-284 064155-285 064155-286 064155-287 064155-289 064155-291

Index 26 TF

064157-055 064157-056 064157-057 064157-058 064157-059 064157-060 064157-061 064157-062 064157-063 064157-064 064157-065 064157-066 064157-067 064157-068 064157-069 064157-070 064157-071 064157-072 064157-073 064157-074 064157-075 064157-076 064157-077 064157-078 064157-079

064157-129 064157-130 064157-131 064157-133 064157-135 064157-137 064157-102 064157-104 064157-105 064157-106 064157-107 064157-109 064157-111 064157-112 064157-113 064157-114 064157-115 064157-116 064157-117 064157-118 064157-119 064157-120 064157-121 064157-123 064157-125

Part Number Dash Battery Compartment Size B C D 135 136 137 135 136 137 091 097 098 080 081 082

COMPARTMENT SIZE

BATTERY VOLTAGE

MAXIMUM BATTERY SIZE

48 V.

27.00" X 38.75" X 31"Ht. (685 mm X 985 mm X 785 mm)

72 V.

13.50" X 38.44"X 31.00" Ht. (345 mm X 975 mm X 785 mm)

48 V.

33.00" X 38.75" X 31" Ht. (685 mm X 985 mm X 785 mm)

72 V.

15.88" X 38.38"X 31.00" Ht. (405 mm X 970 mm X 785 mm)

72 V.

18.00" X 38.69"X 31.00" Ht. (455 mm X 980 mm X 785 mm)

Crown 1993 PF-9948 Rev. 2/94

Printed in U.S.A.

01 REV. 2/94

2 - 19 - 106 - SUP

HYDRAULIC SYSTEM — MAIN FRAME 7380S

Hose Routing Over Top Of TF Mast

62 61

66 J

K L See Hydraulic System– Platform For "J", "K" & "L"

Cylinder Plumbing In Top Of TF Mast

55 56

Hose Routing Thru Mast

8 10

53 67

21 23

52 24

18 14

Hose Routing Thru Main Frame Base

19 20

41 29

40 19

28 16

47 46

30 33

35 37

See Hydraulic System–Power Unit For "A" Thru "G"

36 F

Crown 1994 PF10108 Rev. 6/00

38 45 32 Printed in U.S.A.

06 REV. 6/00

02.0–19.0–108

HYDRAULIC SYSTEM — MAIN FRAME Index 1

3 4 5 6

7 8 9 10 11 12 13 14

Part No.

Part Name

101618 060015-003 060005-007 060030-092 074105 060014-006 060005-005 076755 077145 064006-013 107592 061002-002 060013-005 060005-004 060030-045 060021-004 064020-005 064006-004 090940 090943 064020-016 091021 064019-073 093779 060015-006 060005-007 061022-002 064173-012 107591 064034-002 064030-003

Shield Screw Lockwasher Flatwasher Cap Filter Screw Lockwasher Filter Oil Filter Element Replacement Elbow Tube Clamp Screw Lockwasher Flatwasher Nut Pipe Plug Elbow Dip Stick Oil Reservoir Hydraulic Plug Pipe Strainer Sump O-Ring Cap Reservoir Screw Lockwasher Clamp Hose Hose Tube Elbow Bulkhead Nut Hose Clamp Clamp Screw Lockwasher Flatwasher Nut Hose Bracket Screw Lockwasher Hose Hose Hose Fitting Bulkhead Fitting Bulkhead Nut Hose 48V Hose 72V Hose Hose Hose Hose Hose Clamp Hose Elbow

15 16 17 18 19 20 * 21 061022-001 22 061002-005 060013-005 060005-004 060030-045 060021-004 23 064100-084 24 118130 060017-021 060005-009 25 * 26 * 27 064257-140 28 064033-001 29 064033-002 30 064030-002 31 064257-141 064257-091 32 * 33 064256-011 34 * 35 * 36 * 37 061022-003 38 064143-001

No. Req.

Index

1 2 2 2 1 3 3 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 8 8 2 1 1 1 2 1 1 1 1 1 2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

40 41 42

Part No.

Part Name

118131 060017-011 060005-009 061022-001 064100-083 064100-079 064143-003 064201-001

Manifold Block Screw Lockwasher Clamp Hose Hose 48 V Units Hose 72 V Units Nipple Hose 48 V Units Insert Beaded Includes Screws 72 V Units Pump Lift 48 V Units See Section 2.1 Screw Lockwasher Pump Lift 72 V Units See Section 2.1 Screw Lockwasher Elbow 48 V Elbow 72 V Clamp Tube Connector Nut Bulkhead Grommet Tube Fitting Bulkhead Connector Elbow Swivel Tee Cylinder Brake See Section 8.8 Elbow Hose 48 in. (1220mm) to 55 in. (1400mm) Load Wheel Width Hose 56 in. (1422mm) to 65 in. (1650mm) Load Wheel Width Hose 66 in. (1675mm) to 72 in. (1830mm) Load Wheel Width Hose 48 in. (1220mm) to 55 in. (1400mm) Load Wheel Width Hose 56 in. (1422mm) to 65 in. (1650mm) Load Wheel Width Hose 66 in. (1675mm) to 72 in. (1830mm) Load Wheel Width Clamp Hose Screw Lockwasher Hose Cylinder Free Lift Cluster See Section 8.2 Elbow 45° Clamp Tube Screw Lockwasher Tube L.H. Connector Tube R.H. Cylinder Main Lift See Section 8.2

43 060017-054 060005-009

44 45 46 47 48 49 50 51 52 53 54 55 56 57

060019-025 060005-012 064061-005 064061-021 061022-003 118133 064004-001 064030-008 065004-021 119584 064164-003 064004-016 064065-002 064064-002 064061-002 064255-238 064255-090 064255-239

064255-238 064255-090 064255-239

60 61 62 63

64 65 66 67

100619 060015-003 060005-007 064257-007

064098-005 061002-005 060013-004 060005-033 109223 064004-001 109222

No. Req. 1 2 2 2 1 1 1 1 1 2 2 1 2 2 1 1 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 1 1 1 4 4 4 2 1 2 2 2 2 1 2 1 1

Always Specify Model, Data & Serial Numbers * See the Following Supplemental List

940110

6641 Printed in U.S.A.

06 REV. 6/00

02.0–19.0–109

HYDRAULIC SYSTEM — MAIN FRAME Collapsed Height in. mm

in.

Lift Height mm

125 131 137 143 149 155 161 167 173 179 185 191 197 203 209 215 221 227 233 239 245 251 257 263 269 275 281 287

208 220 232 244 256 268 280 292 304 316 328 340 352 364 376 388 400 412 424 436 448 460 472 484 496 508 520 532

5285 5590 5890 6200 6500 6805 7110 7415 7720 8025 8330 8635 8940 9245 9550 9855 10160 10465 10770 11075 11380 11685 11990 12295 12600 12905 13210 13515

Index 32 34 35 36

Base Part Number 064100064255064255064100-

3175 3330 3480 3630 3785 3935 4090 4240 4395 4545 4700 4850 5005 5150 5310 5460 5615 5765 5920 6070 6225 6375 6530 6680 6830 6985 7140 7290

Index 20 & 25 TF TN 064255-143 064255-144 064255-145 064255-146 064255-147 064255-148 064255-149 064255-150 064255-151 064255-152 064255-153 064255-154 064255-155 064255-156 064255-038 064255-039 064255-040 064255-041 064255-161 064255-162 064255-163 064255-164 064255-046 064255-248 064255-249 064255-342 064255-343 064255-344

064255-294 064255-295 064255-260 064255-262 064255-296 064255-297 064255-266 064255-268 064255-298 064255-029 064255-030 064255-031 064255-032 064255-033 064255-275 064255-277 064255-279 064255-281 064255-283 064255-284 064255-285 064255-286 064255-287 064255-289 064255-291 064255-345 064255-346 064255-347

Index 26 TF

064257-055 064257-056 064257-057 064257-104 064257-059 064257-060 064257-061 064257-062 064257-063 064257-064 064257-065 064257-066 064257-067 064257-068 064257-069 064257-070 064257-071 064257-072 064257-073 064257-074 064257-075 064257-076 064257-077 064257-078 064257-079 065257-199 065257-200 065257-201

064257-129 064257-130 064257-131 064257-133 064257-135 064257-137 064257-102 064257-195 064257-105 064257-106 064257-107 064257-109 064257-111 064257-112 064257-113 064257-114 064257-115 064257-116 064257-117 064257-118 064257-119 064257-120 064257-121 064257-123 064257-125 064257-202 064257-203 064257-204

Part Number Dash Battery Compartment Size B C D 094 088 093 094 095 096 091 097 098 080 081 082

COMPARTMENT SIZE

BATTERY VOLTAGE

MAXIMUM BATTERY SIZE

48 V.

27.00" X 38.75" X 31"Ht. (685 mm X 985 mm X 785 mm)

72 V.

13.50" X 38.44"X 31.00" Ht. (345 mm X 975 mm X 785 mm)

48 V.

33.00" X 38.75" X 31" Ht. (685 mm X 985 mm X 785 mm)

72 V.

15.88" X 38.38"X 31.00" Ht. (405 mm X 970 mm X 785 mm)

72 V.

18.00" X 38.69"X 31.00" Ht. (455 mm X 980 mm X 785 mm)

Crown 1994 PF10108 Rev. 6/00

Printed in U.S.A.

06 REV. 6/00

02.0–19.0–108-SUP

HYDRAULIC SYSTEM — MAIN FRAME 7380S

Hose Routing Over Top Of TF Mast

61 66

K L See Hydraulic System– Platform For "J", "K" & "L"

Cylinder Plumbing In Top Of TF Mast

Hose Routing Thru Mast

8 10

53 67

21 23

52 24

18 14

Hose Routing Thru Main Frame Base

19 20

41 29

40 19

28 16

35 37

See Hydraulic System–Power Unit For "A" Thru "G"

36 F

Crown 1998 PF11521 Rev. 4/99

47 46

30 33

45 32 Printed in U.S.A.

01 REV. 4/99

02.0–19.0–110

HYDRAULIC SYSTEM — MAIN FRAME Index 1

3 4 5 6

7 8 9 10 11 12 13 14

Part No.

Part Name

126151 060015-003 060005-007 060030-092 074105 060014-006 060005-005 076755 077145 064006-013 126153 061002-002 060013-005 060005-004 060030-045 060021-004 064020-005 064006-004 090940 126140 064020-016 091021 064019-073 093779 060015-006 060005-007 061022-002 064173-012 126152 064034-002 064030-003

No. Req. 1 2 2 2 1 3 3 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 8 8 2 1 1 1 2 1 1 1 1 1 2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Index 39

40 41 42

Part No.

Part Name

118131 060017-011 060005-009 061022-001 064100-083 064100-079 064143-003 064201-001

Manifold Block Screw Lockwasher Clamp Hose Hose 48 V Units Hose 72 V Units Nipple Hose 48 V Units Insert Beaded Includes Screws 72 V Units Pump Lift 48 V Units See Section 2.1 Screw Lockwasher Pump Lift 72 V Units See Section 2.1 Screw Lockwasher Elbow 48 V Elbow 72 V Clamp Tube Connector Nut Bulkhead Grommet Tube Fitting Bulkhead Connector Elbow Swivel Tee Cylinder Brake See Section 8.8 Elbow Hose 48 in. (1220mm) to 55 in. (1400mm) Load Wheel Width Hose 56 in. (1422mm) to 65 in. (1650mm) Load Wheel Width Hose 66 in. (1675mm) to 72 in. (1830mm) Load Wheel Width Hose 48 in. (1220mm) to 55 in. (1400mm) Load Wheel Width Hose 56 in. (1422mm) to 65 in. (1650mm) Load Wheel Width Hose 66 in. (1675mm) to 72 in. (1830mm) Load Wheel Width Clamp Hose Screw Lockwasher Hose Cylinder Free Lift Cluster See Section 8.2 Elbow 45° Clamp Tube Screw Lockwasher Tube LH Connector Tube RH Cylinder Main Lift See Section 8.2

43 060017-054 060005-009

44 45 46 47 48 49 50 51 52 53 54 55 56 57

060019-025 060005-012 064061-005 064061-021 061022-003 118133 064004-001 064030-008 065004-021 119584 064164-003 064004-016 064065-002 064064-002 064061-002 064255-238 064255-090 064255-239

064255-238 064255-090 064255-239

60 61 62 63

64 65 66 67

100619 060015-003 060005-007 064257-007

064098-005 061002-005 060013-004 060005-033 109223 064004-001 109222

No. Req. 1 2 2 2 1 1 1 1 1 2 2 1 2 2 1 1 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 1 1 1 4 4 4 2 1 2 2 2 2 1 2 1 1

Always Specify Model, Data & Serial Numbers * See the Following Supplemental List 981102

6071 Printed in U.S.A.

01 REV. 4/99

02.0–19.0–111

HYDRAULIC SYSTEM — MAIN FRAME Collapsed Height in. mm

in.

Lift Height mm

125 131 137 143 149 155 161 167 173 179 185 191 197 203 209 215 221 227 233 239 245 251 257 263 269 275 281 287

208 220 232 244 256 268 280 292 304 316 328 340 352 364 376 388 400 412 424 436 448 460 472 484 496 508 520 532

5285 5590 5890 6200 6500 6805 7110 7415 7720 8025 8330 8635 8940 9245 9550 9855 10160 10465 10770 11075 11380 11685 11990 12295 12600 12905 13210 13515

Index 32 34 35 36

Base Part Number 064100064255064255064100-

3175 3330 3480 3630 3785 3935 4090 4240 4395 4545 4700 4850 5005 5150 5310 5460 5615 5765 5920 6070 6225 6375 6530 6680 6830 6985 7140 7290

Index 26 TF

Part Number Dash Battery Compartment Size B C D 094 088 093 094 095 096 091 097 098 080 081 082

COMPARTMENT SIZE

BATTERY VOLTAGE

MAXIMUM BATTERY SIZE

48 V.

27.0 in. X 38.75 in. X 31.0 in. Ht. (685 mm X 985 mm X 785 mm)

72 V.

13.50 in. X 38.44 in. X 31.0 in. Ht. (345 mm X 975 mm X 785 mm)

48 V.

33.0 in. X 38.75 in. X 31.0 in. Ht. (685 mm X 985 mm X 785 mm)

72 V.

15.88 in. X 38.38 in. X 31.0 in. Ht. (405 mm X 970 mm X 785 mm)

72 V.

18.00 in. X 38.69 in. X 31.0 in. Ht. (455 mm X 980 mm X 785 mm)

Crown 1998 PF11521 Rev. 4/99

Printed in U.S.A.

01 REV. 4/99

02.0–19.0–110-SUP

HYDRAULIC SYSTEM — MAIN FRAME 12760

48 VOLT Hose Routing Over Top of TF Mast

See Hydraulic System - Platform for "J", "K" & "L"

Cylinder Plumbing In Top of TF Mast

Hose Routing Thru Mast

Hose Routing Thru Main Frame Base

See Hydraulic System - Power Unit for "A" Thru "H" Crown 2005 PF15078-1

02.0–19.0–112

Printed in U.S.A.

02.0–19.0–112

C Index Part No. 1

2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30

HYDRAULIC SYSTEM — MAIN FRAME Part Name

No. Req.

126151 Shield 060015-003 Screw 060005-007 Lockwasher 060030-092 Flatwasher 074105 Cap Filter 060014-006 Screw 060005-005 Lockwasher 076755 Filter Oil 077145 Filter Element Replacement 064006-013 Elbow 126153 Tube 061002-002 Clamp 060013-005 Screw 060005-004 Lockwasher 060030-045 Flatwasher 060021-004 Nut 064020-005 Pipe Plug 064006-004 Elbow 090940 Dip Stick Oil 126140 Reservoir Hydraulic 064020-016 Plug Pipe 091021 Strainer Sump 064019-073 O-Ring 093779 Cap Reservoir 060015-006 Screw 060005-007 Lockwasher 061022-002 Clamp Hose 064173-012 Hose 126152 Tube 064034-002 Elbow Bulkhead 064030-003 Nut * Hose 061022-001 Clamp 061002-005 Clamp 060013-005 Screw 060005-004 Lockwasher 060030-045 Flatwasher 060021-004 Nut 064100-084 Hose 118130 Bracket 060017-021 Screw 060005-009 Lockwasher * Hose * Hose 064257-140 Hose 064033-001 Fitting Bulkhead 064033-002 Fitting Bulkhead 064030-002 Nut

1 2 2 2 1 3 3 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 8 8 2 1 1 1 2 1 1 1 1 1 2 1 1 1 2 2 1 1 1 1 1 1

981102 Crown 2005 PF15078-2

02.0–19.0–113

Index Part No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

Part Name

No. Req.

064257-141 Hose Hose 064256-011 Hose * Hose * Hose * Hose 061022-003 Clamp Hose 064143-001 Elbow 118131 Manifold Block 060017-011 Screw 060005-009 Lockwasher 061022-001 Clamp Hose 064100-083 Hose 064143-003 Nipple Hose Pump Lift See Section 2.1 060017-054 Screw 060005-009 Lockwasher 064061-005 Elbow 061022-003 Clamp 118133 Tube 064004-001 Connector 064030-008 Nut Bulkhead 065004-021 Grommet 119584 Tube 064164-003 Fitting Bulkhead 064004-016 Connector 064065-002 Elbow Swivel 064064-002 Tee Cylinder Brake See Section 8.8 064061-002 Elbow 064255-238 Hose 1220mm (48 in.) to 1400mm (55 in.) Load Wheel Width 064255-090 Hose 1422mm (56 in.) to 1650mm (65 in.) Load Wheel Width 064255-239 Hose 1675mm (66 in.) to 1830mm (72 in.) Load Wheel Width 064255-238 Hose 1220mm (48 in.) to 1400mm (55 in.) Load Wheel Width 064255-090 Hose 1422mm (56 in.) to 1650mm (65 in.) Load Wheel Width 064255-239 Hose 1675mm (66 in.) to 1830mm (72 in.) Load Wheel Width 100619 Clamp Hose 060015-003 Screw 060005-007 Lockwasher *

1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 2 2 1 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 1 1 1 4 4 4

6071 Printed in U.S.A.

02.0–19.0–113

HYDRAULIC SYSTEM — MAIN FRAME Index Part No. 60 61 62 63 64 65 66 67

Part Name

No. Req.

064257-007 Hose Cylinder Free Lift Cluster See Section 8.2 064098-005 Elbow 45° 061002-005 Clamp Tube 060013-004 Screw 060005-033 Lockwasher 109223 Tube LH 064004-001 Connector 109222 Tube RH Cylinder Main Lift See Section 8.2

2 1 2 2 2 2 1 2 1 1

Always Specify Model, Data & Serial Numbers * See the Following Supplemental List

050613 Crown 2005 PF15078-3

02.0–19.0–114

11377 Printed in U.S.A.

02.0–19.0–114

HYDRAULIC SYSTEM — MAIN FRAME CHART 1

Collapsed Height

Lift Height

Index 20 & 25

Index 26

in.

3175

125

5285

208

064255-143

064255-294

064257-055

064257-129

3330

131

5590

220

064255-144

064255-295

064257-056

064257-130

3480

137

5890

232

064255-145

064255-260

064257-057

064257-131

3630

143

6200

244

064255-146

064255-262

064257-104

064257-133

3785

149

6500

256

064255-147

064255-296

064257-059

064257-135

3935

155

6805

268

064255-148

064255-297

064257-060

064257-137

4090

161

7110

280

064255-149

064255-266

064257-061

064257-102

4240

167

7415

292

064255-150

064255-268

064257-062

064257-195

4395

173

7720

304

064255-151

064255-298

064257-063

064257-105

4545

179

8025

316

064255-152

064255-029

064257-064

064257-106

4700

185

8330

328

064255-153

064255-030

064257-065

064257-107

4850

191

8635

340

064255-154

064255-031

064257-066

064257-109

5005

197

8940

352

064255-155

064255-032

064257-067

064257-111

5150

203

9245

364

064255-156

064255-033

064257-068

064257-112

5310

209

9550

376

064255-038

064255-275

064257-069

064257-113

5460

215

9855

388

064255-039

064255-277

064257-070

064257-114

5615

221

10160

400

064255-040

064255-279

064257-071

064257-115

5765

227

10465

412

064255-041

064255-281

064257-072

064257-116

5920

233

10770

424

064255-161

064255-283

064257-073

064257-117

6070

239

11075

436

064255-162

064255-284

064257-074

064257-118

6225

245

11380

448

064255-163

064255-285

064257-075

064257-119

6375

251

11685

460

064255-164

064255-286

064257-076

064257-120

6530

257

11990

472

064255-046

064255-287

064257-077

064257-121

6680

263

12295

484

064255-248

064255-289

064257-078

064257-123

6830

269

12600

496

064255-249

064255-291

064257-079

064257-125

6985

275

12905

508

064255-342

064255-345

064257-199

064257-202

7140

281

13210

520

064255-343

064255-346

064257-200

064257-203

7290

287

13515

532

064255-344

064255-347

064257-201

064257-204

Crown 2005 PF15078-4

02.0–19.0–112-SUP-1

Printed in U.S.A.

02.0–19.0–112-SUP-1

HYDRAULIC SYSTEM — MAIN FRAME

CHART 2 Index

Base Part Number

Part Number Dash Battery Compartment Size B

C 088

064100-

094

064255-

094

095

064255-

091

097

064100-

080

081

CHART 3 Compartment Battery Size Voltage

Crown 2005 PF15078-5

02.0–19.0–112-SUP-2

Maximum Battery Size

48 V.

685 mm x 985 mm x 785 mm Ht. (27.0 in. x 38.75 in. x 31.0 in.)

48 V.

685 mm x 985 mm x 785 mm Ht. (33.0 in. x 38.75 in. x 31.0 in.)

Printed in U.S.A.

02.0–19.0–112-SUP-2

HYDRAULIC SYSTEM — MAIN FRAME 72 VOLT

12753

Cylinder Plumbing in Top of TF Mast

Hose Routing Over Top of TF Mast

See Hydraulic System - Platform for "J", "K" & "L"

Hose Routing Thru Mast

Hose Routing Thru Main Frame Base

See Hydraulic System - Power Unit for "A" Thru "H" Crown 2005 PF15069-1

02.0–19.0–150

Printed in U.S.A.

02.0–19.0–150

C Index Part No. 1

2 3 4 5 6

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30

HYDRAULIC SYSTEM — MAIN FRAME Part Name

No. Req.

1 2 2 2 1 3 3 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 8 8 2 1 1 1 2 1 1 1 1 1 2 1 1 1 2 2 1 1 1 1 1 1

Crown 2005 PF15069-2

02.0–19.0–151

Index Part No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57

* *

Part Name

No. Req.

Hose Hose 064256-011 Hose * Hose * Hose * Hose 061022-003 Clamp Hose 064143-001 Elbow 118131 Manifold Block 060017-011 Screw 060005-009 Lockwasher 061022-001 Clamp Hose 064100-137 Hose 064201-001 Insert Beaded Includes Screws Pump Lift See Section 2.1 060019-025 Screw 060005-012 Lockwasher 064061-021 Connector 061022-003 Clamp 118133 Tube 064004-001 Connector 064030-008 Nut Bulkhead 065004-021 Grommet 119584 Tube 064164-003 Fitting Bulkhead 064004-016 Connector 064065-002 Elbow Swivel 064064-002 Tee Cylinder Brake See Section 8.8 064061-002 Elbow 064255-238 Hose 1220mm (48 in.) to 1400mm (55 in.) Load Wheel Width 064255-090 Hose 1422mm (56 in.) to 1650mm (65 in.) Load Wheel Width 064255-239 Hose 1675mm (66 in.) to 1830mm (72 in.) Load Wheel Width 064255-238 Hose 1220mm (48 in.) to 1400mm (55 in.) Load Wheel Width 064255-090 Hose 1422mm (56 in.) to 1650mm (65 in.) Load Wheel Width 064255-239 Hose 1675mm (66 in.) to 1830mm (72 in.) Load Wheel Width

1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 2 2 1 1 1 1 1 2 1 1 1 1 1 2 2 1 1 1 1 1 1

Printed in U.S.A.

02.0–19.0–151

HYDRAULIC SYSTEM — MAIN FRAME Index Part No. 59 60 61 62 63 64 65 66 67

Part Name

No. Req.

100619 Clamp Hose 060015-003 Screw 060005-007 Lockwasher 064257-007 Hose Cylinder Free Lift Cluster See Section 8.2 064098-005 Elbow 45° 061002-005 Clamp Tube 060013-004 Screw 060005-033 Lockwasher 109223 Tube LH 064004-001 Connector 109222 Tube RH Cylinder Main Lift See Section 8.2

4 4 4 2 1 2 2 2 2 1 2 1 1

Always Specify Model, Data & Serial Numbers * See the Following Supplemental List

050613 Crown 2005 PF15069-3

02.0–19.0–152

11375 Printed in U.S.A.

02.0–19.0–152

HYDRAULIC SYSTEM — MAIN FRAME CHART 1

Collapsed Height

Lift Height

Index 20 & 25

Index 26

in.

3175

125

5285

208

064255-143

064255-294

064257-055

064257-129

3330

131

5590

220

064255-144

064255-295

064257-056

064257-130

3480

137

5890

232

064255-145

064255-260

064257-057

064257-131

3630

143

6200

244

064255-146

064255-262

064257-104

064257-133

3785

149

6500

256

064255-147

064255-296

064257-059

064257-135

3935

155

6805

268

064255-148

064255-297

064257-060

064257-137

4090

161

7110

280

064255-149

064255-266

064257-061

064257-102

4240

167

7415

292

064255-150

064255-268

064257-062

064257-195

4395

173

7720

304

064255-151

064255-298

064257-063

064257-105

4545

179

8025

316

064255-152

064255-029

064257-064

064257-106

4700

185

8330

328

064255-153

064255-030

064257-065

064257-107

4850

191

8635

340

064255-154

064255-031

064257-066

064257-109

5005

197

8940

352

064255-155

064255-032

064257-067

064257-111

5150

203

9245

364

064255-156

064255-033

064257-068

064257-112

5310

209

9550

376

064255-038

064255-275

064257-069

064257-113

5460

215

9855

388

064255-039

064255-277

064257-070

064257-114

5615

221

10160

400

064255-040

064255-279

064257-071

064257-115

5765

227

10465

412

064255-041

064255-281

064257-072

064257-116

5920

233

10770

424

064255-161

064255-283

064257-073

064257-117

6070

239

11075

436

064255-162

064255-284

064257-074

064257-118

6225

245

11380

448

064255-163

064255-285

064257-075

064257-119

6375

251

11685

460

064255-164

064255-286

064257-076

064257-120

6530

257

11990

472

064255-046

064255-287

064257-077

064257-121

6680

263

12295

484

064255-248

064255-289

064257-078

064257-123

6830

269

12600

496

064255-249

064255-291

064257-079

064257-125

6985

275

12905

508

064255-342

064255-345

064257-199

064257-202

7140

281

13210

520

064255-343

064255-346

064257-200

064257-203

7290

287

13515

532

064255-344

064255-347

064257-201

064257-204

Crown 2005 PF15069-4

02.0–19.0–150-SUP-1

Printed in U.S.A.

02.0–19.0–150-SUP-1

HYDRAULIC SYSTEM — MAIN FRAME

CHART 2 Index

Base Part Number

Part Number Dash Battery Compartment Size B

064257-

211

212

064100-

094

088

093

064255-

094

095

096

064255-

091

097

098

064100-

080

081

082

CHART 3

Crown 2005 PF15069-5

02.0–19.0–150-SUP-2

Compartment Size

Battery Voltage

Maximum Battery Size

72 V.

345 mm x 975 mm x 785 mm Ht. (13.50 in. x 38.44 in. x 31.0 in.)

72 V.

405 mm x 970 mm x 785 mm Ht. (15.88 in. x 38.38 in. x 31.0 in.)

72 V.

455 mm x 980 mm x 785 Ht. (18.00 in. x 38.69 in. x 31.0 in.)

Printed in U.S.A.

02.0–19.0–150-SUP-2

This page available for NOTES.

HYDRAULIC SYSTEM - PLATFORM 3597

Crown 1995 PF-10471

02.0–19.0–202

Printed in U.S.A.

02.0–19.0–202

HYDRAULIC SYSTEM - PLATFORM Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29

Part Name

No. Req.

064030-002 Nut Bulkhead 2 064034-001 Elbow Bulkhead 1 105463 Tube 1 064030-003 Nut Bulkhead 2 064034-002 Elbow Bulkhead 2 105460 Tube 1 105461 Tube 1 064004-003 Connector 4 064004-004 Connector 8 119508 Valve Traverse See Section 2.3 1 064009-002 Tee 1 105456 Tube 1 064065-002 Elbow 5 064061-002 Elbow 3 119507 Valve Pivot See Section 2.3 1 105454 Tube 1 105455 Tube 1 064071-001 Tee 1 108273-001 Manifold 48V See Section 2.4 1 108273-002 Manifold 72V See Section 2.4 1 105457 Tube 1 064033-001 Fitting Bulkhead 1 064060-001 Reducer 1 064002-006 Nut 1 108576 Hose Gang 5 Hoses/2 Cables 1 108575 Hose Less Cables 1 083603-002 Cable 25.94 ft. 1 061003-003 Ties Cable 16 106711 Clamp Hose 1 060016-018 Screw 5/16" 1 060005-008 Lockwasher 1 064004-008 Connector 2 108230 Tube 1 094377 Check Valve 1 Always Specify Model & Serial Number

950320

4551 - 40613 Printed in U.S.A.

02.0–19.0–203

HYDRAULIC SYSTEM—LOAD HANDLER 1511S-01

20 33

47 15

43 13

REFER TO "PIVOT MECHANISM" SECTION 9.1

28 25

30 12

26 4

30 32

LOCATED AT TOP OF LOAD HANDLER WELDMENT

34 35

10 9

INDEXES 2, 3, 4, 5, 9, 10, 11, 12, 15, 17, 18, 19, 20,21, 22, 33, 43, 44, 46, 47 USED WITH TELESCOPIC FORKS ONLY.

HOSE ROUTING THRU LOAD HANDLER 8

TO PLATFORM 7

5 3

3 2

40 1

2 3 4

4 LOCATED INSIDE LOWER LOAD HANDLER WELDMENT

41 40

Crown 1992 PF9486 Rev. 6/94

Printed in U.S.A.

01 REV. 6/94

02.0–19.0–302

HYDRAULIC SYSTEM—LOAD HANDLER Index Part No. 1 2 3 4 5

6 7 8 9 10 11 12

13 14 15 16 17

18 19 20 21

22 23

Part Name

No. Req.

Fork See Section 7.9 2 064061-004 Elbow 4 064004-007 Connector 6 064152-029 Hose 4 105602 Manifold See Section 2.4 1 060015-019 Screw 1/4" 2 060005-007 Lockwasher 2 064084-003 Elbow 1 064154-080 Hose 1 101688 Cylinder Auxiliary Lift See Section 8.4 1 064153-034 Hose 2 064030-003 Nut Bulkhead 2 064033-002 Fitting Bulkhead 2 064153-036 Hose Used on Units with a 23" Load Handler Head Length 2 064153-037 Hose Used on Units With a 27" Load Handler Head Length 2 061003-003 Tie Cable AR 064061-020 Elbow 2 064004-008 Connector 2 106650 Motor Hydraulic See Section 2.6 1 105600-001 Manifold Traverse 48 volt See Section 2.4 1 105600-002 Manifold Traverse 72 volt See Section 2.4 1 083942 Valve Pilot Check Non-Telescopic Fork 1 060017-023 Screw 3/8" 2 060005-009 Lockwasher 2 108502 Plate Non-Telescopic Fork 1 064171-001 Elbow 1 103825 Tube 1 108504 Tube Non-Telescopic Fork 1 103826 Tube 1 108503 Tube Non-Telescopic Fork 1 064153-042 Hose Used on Units with a 23" Load Handler Head Length 1 064153-043 Hose Used on Units with a 27" Load Handler Head Length 1 064005-005 Connector 1 064004-003 Connector 2

Index Part No. 24 25

26 27 28 29 30 31

33 34 35 36 37 38 39 40 41 42

43 44 45 46 47

920803

Part Name

No. Req.

064218-002 Hose 2 105603-001 Manifold Pivot 48 volt See Section 2.4 1 105603-002 Manifold Pivot 72 volt See Section 2.4 1 060017-064 Screw 3/8" 2 060005-009 Lockwasher 2 064098-001 Elbow 45° 3 064197-002 Orifice 2 064152-025 Hose 2 064030-003 Nut Bulkhead 1 064061-004 Elbow 2 114568-002 Cylinder Pivot 23" Load Handler See Section 8.8 2 114568-003 Cylinder Pivot 27" Load Handler See Section 8.8 2 064153-031 Hose Used on Units with a 23" Load Handler Head Length 1 064153-032 Hose Used on Units with a 27" Load Handler Head Length 1 064061-002 Elbow 2 101288 Cylinder Pivot Latch See Section 8.8 1 064218-003 Hose 1 064034-002 Fitting Bulkhead 1 064153-038 Hose 2 064030-003 Nut Bulkhead 3 064030-004 Nut Bulkhead 2 064034-003 Fitting Bulkhead 2 064164-001 Fitting Bulkhead 3 108576 Hose Gang 5 Hose/2 Cables 1 108575 Hose Less Cables 1 083603-002 Cable 25.94 ft. 1 061003-003 Cable Ties 16 100003 Accummulator 1 087808 Spacer 1 061022-005 Clamp 1 108285 Fuse Velocity 1 064004-007 Connector 1 064065-003 Elbow 1 Always Specify Model & Serial Number

4397 Printed in U.S.A.

01 REV. 6/94

02.0–19.0–303

HYDRAULIC SYSTEM—LOAD HANDLER 1511S-01

20 33

47 15

43 13

REFER TO "PIVOT MECHANISM" SECTION 9.1

26 4

30 32 33

1 31

LOCATED AT TOP OF LOAD HANDLER WELDMENT

34 35

10 9

INDEXES 2, 3, 4, 5, 9, 10, 11, 12, 15, 17, 18, 19, 20,21, 22, 33, 43, 44, 46, 47 USED WITH TELESCOPIC FORKS ONLY.

HOSE ROUTING THRU LOAD HANDLER 8

TO PLATFORM 7

5 3

3 2

40 1

2 3 4

4 LOCATED INSIDE LOWER LOAD HANDLER WELDMENT

41 40

Crown 1993 PF9811 Rev. 6/94

Printed in U.S.A.

01 REV. 6/94

02.0–19.0–304

HYDRAULIC SYSTEM—LOAD HANDLER Index Part No. 1 2 3 4 5

6 7 8 9 10 11 12

13 14 15 16 17

18 19 20 21

Part Name

No. Req.

Fork See Section 7.9 2 064061-004 Elbow 4 064004-007 Connector 6 064152-035 Hose 4 112854 Manifold Fork Flow Divider See Section 2.4 1 060015-019 Screw 1/4" 2 060005-007 Lockwasher 2 064084-003 Elbow 1 064154-080 Hose 1 101688 Cylinder Auxiliary Lift See Section 8.4 1 064153-034 Hose 2 064030-003 Nut Bulkhead 2 064033-002 Fitting Bulkhead 2 064153-036 Hose Used on Units with a 23" Load Handler Head Length 2 064153-037 Hose Used on Units With a 27" Load Handler Head Length 2 061003-003 Tie Cable AR 064061-020 Elbow 2 064004-008 Connector 2 106650 Motor Hydraulic See Section 2.6 1 105600-001 Manifold Traverse 48 volt See Section 2.4 1 105600-002 Manifold Traverse 72 volt See Section 2.4 1 083942 Valve Pilot Check Non-Telescopic Fork 1 060017-023 Screw 3/8" 2 060005-009 Lockwasher 2 108502 Plate Non-Telescopic Fork 1 064171-001 Elbow 1 103825 Tube 1 108504 Tube Non-Telescopic Fork 1 103826 Tube 1 108503 Tube Non-Telescopic Fork 1 064153-042 Hose Used on Units with a 23" Load Handler Head Length 1 064153-043 Hose Used on Units with a 27" Load Handler Head Length 1 064005-005 Connector 1

Index Part No. 23 24 25

26 27 28 29 30 31

33 34 35 36 37 38 39 40 41 42

43 44 45 46 47

Part Name

No. Req.

064004-003 Connector 2 064218-002 Hose 2 105603-001 Manifold Pivot 48 volt See Section 2.4 1 105603-002 Manifold Pivot 72 volt See Section 2.4 1 060017-064 Screw 3/8" 2 060005-009 Lockwasher 2 064098-001 Elbow 45° 3 064197-002 Orifice 2 064152-025 Hose 2 064030-003 Nut Bulkhead 1 064061-004 Elbow 2 114568-002 Cylinder Pivot 23" Load Handler See Section 8.8 2 114568-003 Cylinder Pivot 27" Load Handler See Section 8.8 2 064153-031 Hose Used on Units with a 23" Load Handler Head Length 1 064153-032 Hose Used on Units with a 27" Load Handler Head Length 1 064061-002 Elbow 2 101288 Cylinder Pivot Latch See Section 8.8 1 064218-003 Hose 1 064034-002 Fitting Bulkhead 1 064153-038 Hose 2 064030-003 Nut Bulkhead 3 064030-004 Nut Bulkhead 2 064034-003 Fitting Bulkhead 2 064164-001 Fitting Bulkhead 3 108576 Hose Gang 5 Hose/2 Cables 1 108575 Hose Less Cables 1 083603-002 Cable 25.94 ft. 1 061003-003 Cable Ties 16 100003 Accummulator 1 087808 Spacer 1 061022-005 Clamp 1 108285 Fuse Velocity 1 064004-007 Connector 1 064065-003 Elbow 1 Always Specify Model & Serial Number

891023

4397 Printed in U.S.A.

01 REV. 6/94

02.0–19.0–305

HYDRAULIC SYSTEM—LOAD HANDLER 1511S-01

20 33

47 15

43 13

REFER TO "PIVOT MECHANISM" SECTION 9.1

28 25

30 12

26 4

30 32

LOCATED AT TOP OF LOAD HANDLER WELDMENT

34 35

10 9

INDEXES 2, 3, 4, 5, 9, 10, 11, 12, 15, 17, 18, 19, 20,21, 22, 33, 43, 44, 46, 47 USED WITH TELESCOPIC FORKS ONLY.

HOSE ROUTING THRU LOAD HANDLER 8

TO PLATFORM 7

5 3

3 2

40 1

2 3 4

4 LOCATED INSIDE LOWER LOAD HANDLER WELDMENT

41 40

Crown 1994 PF10227 Rev. 6/94

Printed in U.S.A.

01 REV. 6/94

02.0–19.0–306

HYDRAULIC SYSTEM—LOAD HANDLER Index Part No. 1 2 3 4

6 7 8 9 10 11 12 13 14 15 16 17

18 19 20 21

Part Name

No. Req.

Fork See Section 7.9 2 064061-004 Elbow 4 064004-007 Connector 6 064152-035 Hose 30" (762mm) Carriage Width 4 064152-036 Hose 42" (1067mm) and 54" (1732mm) Carriage Width 4 112854 Manifold Fork Flow Divider See Section 2.4 1 060015-019 Screw 1/4" 2 060005-007 Lockwasher 2 064084-003 Elbow 1 * Hose 1 101688 Cylinder Auxiliary Lift See Section 8.4 1 064153-034 Hose 2 064030-003 Nut Bulkhead 2 064033-002 Fitting Bulkhead 2 * Hose 2 061003-003 Tie Cable AR 064061-020 Elbow 2 064004-008 Connector 2 106650 Motor Hydraulic See Section 2.6 1 105600-001 Manifold Traverse 48 volt See Section 2.4 1 105600-002 Manifold Traverse 72 volt See Section 2.4 1 083942 Valve Pilot Check Non-Telescopic Forks 1 060017-023 Screw 3/8" 2 060005-009 Lockwasher 2 108502 Plate Non-Telescopic Forks 1 064171-001 Elbow 1 103825 Tube 1 108504 Tube Non-Telescopic Forks 1 103826 Tube 1 108503 Tube Non-Telescopic Forks 1 064153-042 Hose Used on Units with a 23" (584mm) and 30" (762mm) thru 54" (1372mm) Load Handler 1 064153-043 Hose Used on Units with a 27" (686mm) Load Handler 1

Index Part No. 22 23 24 25

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

43 44 45 46 47

940531

Part Name

No. Req.

064005-005 Connector 1 064004-003 Connector 2 064218-002 Hose 2 105603-001 Manifold Pivot 48 volt See Section 2.4 1 105603-002 Manifold Pivot 72 volt See Section 2.4 1 060017-064 Screw 3/8" 2 060005-009 Lockwasher 2 064098-001 Elbow 45° 3 064197-001 Orifice 2 064152-025 Hose 2 064030-003 Nut Bulkhead 1 064061-004 Elbow 2 Cylinder Pivot See Section 8.8 2 * Hose 1 064061-002 Elbow 2 101288 Cylinder Pivot Latch See Section 8.8 1 064218-003 Hose 1 064034-002 Fitting Bulkhead 1 064153-038 Hose 2 064030-003 Nut Bulkhead 3 064030-004 Nut Bulkhead 2 064034-003 Fitting Bulkhead 2 064164-001 Fitting Bulkhead 3 108576 Hose Gang 5 Hose/2 Cables 1 108575 Hose Less Cables 1 083603-002 Cable 25.94 ft. 1 061003-003 Cable Ties 16 100003 Accummulator 1 087808 Spacer 1 061022-005 Clamp 1 108285 Fuse Velocity 1 064004-007 Connector 1 064065-003 Elbow 1 Always Specify Model & Serial Number *See Following Supplemental List

4397 Printed in U.S.A.

01 REV. 6/94

02.0–19.0–307

HYDRAULIC SYSTEM—LOAD HANDLER Load Handler Length inches mm

23 584

27 686

30 762

33 838

36 914

39 990

42 1067

45 1143

48 1219

51 1295

54 1372

Index 7 Hose 064154-

080

196

197

198

199

200

Index 12 Hose 064153-

036

037

057

058

059

060

061

062

063

064

065

Index 32 Hose 064153-

031

032

047

048

049

050

051

052

053

054

055

Crown 1994 PF10227

02.0–19.0–306-SUP

Printed in U.S.A.

02.0–19.0–306-SUP

HYDRAULIC SYSTEM—LOAD HANDLER 6776

44 13

22 15

32 34

37 33

35 3

26 4

25 27

See Section 9.1

20 33

Top Of Load Handler

10 9

To Hose #4 To Hose #2 For Trucks NOT Equipped With Telescopic Forks V

Indexes 2, 3, 4, 5, 9, 10, 11, 12,15, 17, 19, 20, 21,22, 43, 44, 46, & 48 Used Only With Tele-Scopic Forks. Hose Routing Thru Load Handler

5 3

To Platform

3 2 4

40 38 Inside Lower Load Handler Weldment

Crown 1994 PF10409 Rev. 10/98

02.0–19.0–308

1 2

3 4

Printed in U.S.A.

04 REV. 10/98

02.0–19.0–308

HYDRAULIC SYSTEM—LOAD HANDLER Index Part No. 1 2 3 4

6 7 8 9 10 11 12 13 14 15 16 17

18 19 20 21

Part Name

No. Req.

Fork See Section 7.9 2 064061-004 Elbow 4 064004-007 Connector 6 064152-035 Hose 30 in. (760mm) Carriage Width 4 064152-036 Hose 42 in. (1065mm) and 54 in. (1730mm) Carriage Width 4 112854 Manifold Fork Flow Divider See Section 2.4 1 110041 Spacer Not Shown AR 060015-019 Screw 2 060005-007 Lockwasher 2 060030-012 Flatwasher 4 064084-003 Elbow 1 * Hose 1 101688 Cylinder Auxiliary Lift See Section 8.4 1 064253-034 Hose 2 064030-003 Nut Bulkhead 2 064033-002 Fitting Bulkhead 2 * Hose 2 061003-003 Tie Cable AR 064061-020 Elbow 2 064004-008 Connector 2 125714 Motor Hydraulic See Section 2.6 1 112440-001 Manifold Traverse 48 volt See Section 2.4 1 112440-002 Manifold Traverse 72 volt See Section 2.4 1 083942 Valve Pilot Check Non-Telescopic Forks 1 060017-023 Screw Telescopic Forks 2 060017-034 Screw Non-Telescopic Forks 2 060005-009 Lockwasher 2 108502 Plate Non-Telescopic Forks 1 064171-001 Elbow 1 103825 Tube 1 108504 Tube Non-Telescopic Forks 1 103826 Tube 1 108503 Tube Non-Telescopic Forks 1 064253-070 Hose Used on Units with a 23 in. (585mm) and 30 in. (760mm) thru 54 in. (1370mm) Load Handler 1 064253-043 Hose Used on Units with a 27 in. (685mm) Load Handler 1

Index Part No. 22 23 24 25

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

43 44 45 46 47 48

Part Name

No. Req.

064004-007 Connector 1 064004-003 Connector 3 064266-002 Hose 2 112439-001 Manifold Pivot 48 volt See Section 2.4 1 112439-002 Manifold Pivot 72 volt See Section 2.4 1 060017-064 Screw 2 060005-009 Lockwasher 2 064098-001 Elbow 45° 3 064197-001 Orifice 2 064252-025 Hose 2 064030-003 Nut Bulkhead 1 064061-004 Elbow 2 Cylinder Pivot See Section 8.8 2 * Hose 1 064061-002 Elbow 2 101288 Cylinder Pivot Latch See Section 8.8 1 064254-080 Hose 1 064034-002 Fitting Bulkhead 1 064253-038 Hose 1 064030-003 Nut Bulkhead 3 064030-004 Nut Bulkhead 2 064034-003 Fitting Bulkhead 2 064164-001 Fitting Bulkhead 3 122978 Hose Gang 5 Hose/2 Cables 1 122979 Hose Less Cables 1 119203-001 Cable 25.94 ft. 1 109572 Hose Gang 64 in. (1625mm) Platform 1 109571 Hose Less Cable 1 119203-001 Cable 26.5 ft. 1 061003-003 Cable Ties 16 118841 Accummulator 1 087808-002 Spacer AR 061022-005 Clamp 1 108285 Fuse Velocity 1 064065-003 Elbow 1 064253-038 Hose 1 064061-002 Elbow Non-Telescopic Forks 1 Always Specify Model, Data & Serial Numbers *See Following Supplemental List

5904 - 43529 Printed in U.S.A.

02.0–19.0–309

04 REV. 10/98

02.0–19.0–309

HYDRAULIC SYSTEM—LOAD HANDLER Load Handler Length Inches (mm)

23 (585)

27 (685)

30 (760)

33 (840)

36 (915)

39 42 45 48 51 54 (990) (1065) (1145) (1220) (1295) (1370)

Index 7 Hose 064254-

080

196

197

198

199

200

Index 12 Hose 064253-

036

037

057

058

059

060

061

062

063

064

065

Index 32 Hose 064253-

031

032

047

048

049

050

051

052

053

054

055

Crown 1994 PF10409 Rev. 10/98

02.0–19.0–308-SUP

Printed in U.S.A.

04 REV. 10/98

02.0–19.0–308-SUP

PUMP 2858S

LIFT - 72 VOLT

1 2

†3

†15

†16

†17 †7

†9 †10

†11

†8

†12

†8

†7

COUNTERCLOCKWISE ROTATION

*13

*14

116624 LIFT PUMP ASSEMBLY Index Part No.

Part Name

1 118625 2 118626 3† 4 * 5 * 6 * 7† 8† 9† 10 † 11 † 12 † 13 * 14 *

Screw 3/8" Flatwasher Serrated M12 Cover O-Ring Seal Back-Up Seal Bushing Bushing Bushing Body Gear Drive Gear Drive Flange Mounting Seal Ring Retaining

No. Req. 4 4 1 2 2 2 2 2 1 1 1 1 1 1

Index Part No.

Part Name

15 † 16 † 17 †

Valve O-Ring Cap

No. Req. 1 1 1

MISCELLANEOUS 118627

Kit Seal Includes Indexes 4, 5, 6, 13 and 14

Always Specify Model & Serial Number

* Included In Seal Kit † Internal pump components are not available (except seals) due to matched set requirements. Since components must be replaced as matched sets, pump replacement is more economical. Relief valve (indexes 15 thru 17) are pre-set and not adjustable in the field

940502 Ultra Hydraulics Crown 1994 PF-10190

2.1 - 18.1 - 001

4067A - 37620 Printed in U.S.A.

2.1 - 18.1 - 001

PUMP 2855S

LIFT - 48 VOLT

1 2

†3

†15 †16

†17 †7 †9

†11 †8 *4

†12 *4

†8 *13 *14 †10

CLOCKWISE ROTATION

†7

116625 LIFT PUMP ASSEMBLY Index Part No.

Part Name

1 118622 2 118623 3† 4 * 5 * 6 * 7† 8† 9† 10 † 11 † 12 † 13 * 14 *

Screw 3/8" Flatwasher Spring Cover O-Ring Seal Back-Up Seal Bushing Bushing Bushing Body Gear Drive Gear Drive Flange Mounting Seal Ring Retaining

940502 Ultra Hydraulics Crown 1994 PF-10189

2.1 - 19 - 002

No. Req. 4 4 1 2 2 2 2 2 1 1 1 1 1 1

Index Part No.

Part Name

15 † 16 † 17 †

Valve O-Ring Cap

No. Req. 1 1 1

MISCELLANEOUS 118624

Kit Seal Includes Indexes 4, 5, 6, 13 and 14

Always Specify Model & Serial Number * Included In Seal Kit † Internal pump components are not available (except seals) due to matched set requirements. Since components must be replaced as matched sets, pump replacement is more economical. Relief valve (indexes 15 thru 17) are pre-set and not adjustable in the field

4067 - 37620 Printed in U.S.A.

2.1 - 19 - 002

PUMP MOTOR 3465S

ACCESSORY 72V

091096 ACCESSORY MOTOR Index Part No. 1 2 3

4 5 6 7 8 9 10 11 12 13 14

Part Name

No. Req.

094839 102662 078457 094841

Band Cover Band Cover F/C Cover Bearing C.E. Head Assembly C.E. Includes Index 4, 5, 6 & 7 060015-102 Screw 1/4" 094846 Stud Package Terminal 078496 Spring Set Brush 094842 Plate Assembly Brush 094843 Brush Set 094847 Washer Spring 065081-017 Bearing Ball C.E. 087153 Screw Package Pole Shoe 094840 Coil Package Field 094838 Armature 094845 Bearing Ball C.E. 094844 Head Assembly D.E. Includes Index 13 060015-010 Screw 1/4"

1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 4

Always Specify Model & Serial Number Prestolite

3749

Crown 1984 PF-5758 Rev. 11/94

Printed in U.S.A.

04 REV. 11/94

02.2–18.0–100

SERVO MOTOR 1980S

6 14 12 2 4

15 13 8

11 10 9

93137 SERVO MOTOR ASSEMBLY Index Part No. 1 2 3 4 5 6 7 8

Part Name

No. Req.

Bolt Tie 060012-021 Screw #6 060005-003 Lockwasher 100189 Bracket End (D.E) 100190 Bearing Retainer Bearing 100182 Armature Assembly 100183 Yoke and Magnet Assembly 100185 Brush (Indiana General) 116692 Brush (Leeson )

2 2 2 1 2 1 1 1 2 2

Index Part No.

Part Name

9 10 11 12

Holder Brush Clip Spring Brush Bracket End (Includes Index 8, 9, 10, & 11) Shim Washer Spring Washer Ring Retaining

13 14 15 16

100188 100187 100186 100184

No. Req. 2 2 2 1 AR 1 1 1

Always Specify Model & Serial Number 4029 Crown 1984 PF-5726 REV. 3/93

Printed in U.S.A.

01 REV. 3/93

2.2-18-200

SERVO MOTOR 6547

Index Part No. 1 2

980204 Pittman Crown 1998 PF11375

02.2–18.0–201

125648 126166

Part Name

No. Req.

Motor Asm. 1 Kit Brush Includes Brush, Spring, Terminal, Brush Cap & Brush Clip 1

5713 - 43906/44457 Printed in U.S.A.

02.2–18.0–201

PUMP MOTOR LIFT 48V - TSP 36V/48V - FP, FC

3469S

101271 PUMP MOTOR 36V/48V Index Part No. 1 2 3

4 5 6 7

105588 065081-005 105569 060015-069 105564 105565 078472 105570 105567

Part Name

No. Req.

Ring Retaining Bearing D.E. Head Assembly D.E. Includes Index 1 & 2 Screw 1/4" Armature & Fan Assembly Fan Washer Spring Stud Pkg. Terminal Field Coil Pkg.

1 1 1 4 1 1 1 1 1

Index Part No. 8 9 10 11 12 13 14

Prestolite

087153 104888 089184 103118 105571 065081-0005 105568 060015-102

Part Name

No. Req.

Screw Pkg. Pole Shoe Brush Set Spring Set Brush Brush Holder Plate Cover Plate Pkg. Bearing C.E. Head Assembly C.E. Screw 1/4"

1 1 1 1 1 1 1 4

Always Specify Model & Serial Number

3749

Crown 1988 PF-7764 Rev. 11/94

Printed in U.S.A.

02 REV. 11/94

02.2–19.0–001

PUMP MOTOR 3122-01

LIFT 020230-001 – TSP & FP/FC 020230-002 – FP/FC EE

5 19

PART OF MOTOR 18 7 16 15

20 14 13 10 17

12 10 10 9 8 11 PART OF MOTOR

1 6

Crown 1994 PF-10292 Rev. 8/96

Printed in U.S.A.

03 REV. 8/96

02.2–19.0–002

PUMP MOTOR 020230-001 PUMP MOTOR 36/48 VOLT 020230-002 PUMP MOTOR 36/48 VOLT EE Index Part No. 1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18

19 20

Part Name

No. Req.

060078-009 Screw 1/4" 060009-144 Ring Retaining 065081-054 Bearing 020242 Head Drive End 060078-007 Screw 1/4" 020231 Armature Includes Fan 119040 Kit Terminal Includes All Components For 1 Motor 065081-056 Bearing 060046-020 Washer Spring 020232-001 Frame & Field Assembly for 020230-001 020232-002 Frame & Field Assembly for 020230-002 062547 Connector BWS/Thermal 060078-008 Screw 5/16" 060032-051 Screw #8 118991 Kit Brush Spring Includes 8 Springs 118942 Kit Brush Includes 8 Brushes 060078-011 Screw 1/4" 020240-002 Brush Box Assembly 020433-001 Headband for 020230-001 020407-001 Headband EE 020421 Headband EE 020245 Head Commutator End 062547 Connector BWS/Thermal 020291 Lead BWI 020292 Lead BWI

4 1 1 1 2 1 1 1 1 1 1 1 12 4 1 1 8 1 1 1 1 1 1 1 1

Always Specify Model & Serial Number

930802

5095 Printed in U.S.A.

03 REV. 8/96

02.2–19.0–003

PUMP MOTOR 1319S

LIFT - 72 VOLT UNITS

106813 LIFT MOTOR (72 V.) Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Part Name

No. Req.

094829 107339

Band Cover Head Assembly C.E. Includes Index 3, 4 & 5 094834 Spring Set Brush 107340 Holder Brush Includes Index 3 118894 Brush Set Includes Index 8 & 9 093591 Washer Spring 065081-023 Bearing Ball – C.E. 094837 Stud Package Terminal Lead Brush 094830 Coil Package Field Includes Index 11 Insulator Backboard 094836 Screw Package Pole Shoe 107341 Armature Includes Index 14 094828 Fan Ring Retaining 065081-027 Bearing Ball – D.E. 078499 Seal 094835 Head Assembly D.E. Includes Index 15, 16 & 17

1 1 1 1 1 1 1 1 4 1 4 1 1 1 1 1 1 1

Always Specify Model & Serial Number 4362 Crown 1988 PF8094 Rev. 4/94

Printed in U.S.A.

01 REV. 4/94

02.2–19.0–050

VALVE ASSEMBLY 3593

ACCESSORY - PIVOT

A P 20

T 8

BYD

A 16

10 9

OUT

6 1 15 21 12 7

119507 VALVE ASSEMBLY Index Part No.

Part Name

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

Flatwasher Spring Plunger Spool Body Bushing Cap Includes Breather Plug Seat Poppet O-Ring Ring Retaining Flatwasher .035 in. (9mm)

100259 085738 085735 085741 100262 107368 085746 087248 102959 085749

No. Req. 1 1 1 1 1 1 1 1 1 1 2 1 AR

Index Part No. 14 15 16 17 18 19 20

950320 EATON

No. Req.

085737 Plug 085744 Spring 107364 Spring 085747 Flatwasher .015 in. (3mm) 085748 Flatwasher .010 in. (2mm) 107363 Seal Wiper 088714 Plug Assembly 064019-027 O-Ring 087251 Washer Back-Up 064019-042 O-Ring 107365 Spacer

1 1 1 AR AR 1 1 1 1 1 1

Always Specify Model & Serial Number 4624

Crown 1995 PF-10468 Rev. 6/95

02.3–19.0–002

Part Name

Printed in U.S.A.

01 REV. 6/95

02.3–19.0–002

VALVE ASSEMBLY 3594

ACCESSORY – TRAVERSE-EXTEND/RETRACT

A B

P 11

T 8 13

A 16

10 9

OUT

6 1 15 20 12 7

119508 VALVE ASSEMBLY Index Part No.

Part Name

1 2 3 4 5 6 7 8 9 10 11

Flatwasher Spring Plunger Spool Body Bushing Cap Includes Breather Plug Seat Poppet O-Ring

100259 085738 085735 085741 100262 107368 085746 087248

950320 EATON Crown 1994 PF-10469

02.3–19.0–051

No. Req. 1 1 1 1 1 1 1 1 1 1 2

Index Part No.

Part Name

12 13 14 15 16 17 18 19 20

Ring Retaining Flatwasher .035 in. (9mm) Plug Spring Spring Flatwasher .015 in. (3mm) Flatwasher .010 in. (2mm) Seal Wiper Spacer

102959 085749 085737 085744 107364 085747 085748 107363 107365

No. Req. 1 AR 1 1 1 AR AR 1 1

Always Specify Model & Serial Number 4551 - 40613 Printed in U.S.A.

02.3–19.0–051

MANIFOLD 2669

MAIN / AUXILIARY LOWER

SV3 A

RV2

SV2 C1

RV1

7 6

8 1 2

RV1

3 4

RV2

5 C1 C2 A T

SV2 SV3

14 15 16

9 11

10 12

Crown 1993 PF-10086

2.4 - 19 - 002

Printed in U.S.A.

2.4 - 19 - 002

MANIFOLD 105604-002 MANIFOLD ASSEMBLY (Includes Index 1 thru 5 & 8 thru 16) Index Part No. 1

2 3 4 5 6 7 8 9 10 11 12

13 14 15 16

Part Name

No. Req.

088097

Valve Relief Includes Index 2, 3 & 4 105476-004 Kit Seal Includes Index 2, 3 & 4 064019-045 O-Ring 064019-042 O-Ring 064074-020 Ring Back-up 101762 Block Manifold 086322 Suppressor SB66 060013-011 Screw 060005-004 Lockwasher 064091-007 Plug 064074-020 Ring Back-up 064019-042 O-Ring 064019-045 O-Ring 117304-002 Valve Solenoid Includes Index 9,10, & 11 087662-002 Coil 105476-004 Kit Seal Includes Index 9, 10 & 11 064074-022 Ring Back-up 064019-044 O-Ring 064019-076 O-Ring 117305-002 Valve Solenoid Includes Index 13, 14 & 15 094513-002 Coil 105476-006 Kit Seal Includes Index 13, 14 & 15

2 2 2 2 2 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1

Always Specify Model & Serial Number

931129

4191 - 38536 Printed in U.S.A.

2.4 - 19 - 003

MANIFOLD 6784

MAIN/AUXILIARY LOWER

SV3 A

RV2

SV2 C1

7 SB66

RV1

T 8

RV1 1 2 RV2

4 1

13 14

15 16

SV2

10 12

Crown 1994 PF10136 Rev. 8/98

02.4–19.0–004

SV3

Printed in U.S.A.

01 REV. 8/98

02.4–19.0–004

MANIFOLD 105604-002 MANIFOLD ASSEMBLY (Includes Index 1 thru 16) Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16

Part Name

No. Req.

117913-001 Valve Relief Includes Index 2, 3 & 4 RV1 & RV2 118398 Kit Seal Includes Index 2, 3 & 4 O-Ring O-Ring Ring Back-up 101762 Block Manifold 086322 Suppressor SB66 060013-011 Screw 060005-004 Lockwasher 064091-007 Plug 064074-020 Ring Back-up 064019-042 O-Ring 064019-045 O-Ring 117304-002 Valve Solenoid Includes Index 9,10 & 11 SV3 104164-009 Coil 30 V. 105476-004 Kit Seal Includes Index 9, 10 & 11 064074-022 Ring Back-up 064019-044 O-Ring 064019-076 O-Ring 117305-002 Valve Solenoid Includes Index 13, 14 & 15 SV2 104164-009 Coil 30 V. 105476-006 Kit Seal Includes Index 13, 14 & 15

2 2 2 2 2 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1

Always Specify Model, Data & Serial Numbers

940502

5845 - 44796 Printed in U.S.A.

02.4–19.0–005

01 REV. 8/98

02.4–19.0–005

MANIFOLD 2065S

TRAVERSE

Crown 1993 PF-9825

2.4 - 19 - 102

Printed in U.S.A.

2.4 - 19 - 102

MANIFOLD 112440-001 MANIFOLD ASSEMBLY (48V) 112440-002 MANIFOLD ASSEMBLY (72V) Index Part No. 1 2

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

22 23 24 25 26 27

Part Name

No. Req.

112405 Block Manifold 112404-002 Valve Solenoid 48/72V Includes Index 3 thru 7 116259 Coil 36V O-Ring O-Ring Ring Back-Up Ring Back-Up O-Ring 064091-006 Plug 064091-002 Plug 093810 Orifice 061004-012 Adhesive Thread Locking 065002-007 Ball 086322 Suppresser SB72 060013-021 Screw #8 060005-004 Lockwasher 064019-042 O-Ring 064074-028 Ring Back-Up 064019-021 O-Ring 064074-029 Ring Back-Up 064019-046 O-Ring 064074-030 Ring Back-Up 064019-045 O-Ring 101683-002 Valve Solenoid 48V Includes Index 14 thru 20 101683-001 Valve Solenoid 72V Includes Index 14 thru 20 087662-003 Coil 48V 087662-002 Coil 72V 103558 Valve Single Pilot Check Includes Indexes 23 thru 27 064019-045 O-Ring 064019-021 O-Ring 064074-021 Ring Back-Up 064074-020 Ring Back-Up 064019-042 O-Ring

1 2 2 2 2 2 2 2 6 2 2 1 1 1 2 2 1 2 1 2 1 2 1 1 1 1 1 2 2 2 2 2 2

Always Specify Model & Serial Number 114439 Kit Seal Includes Index 3 thru 7 2 105478-001 Kit Seal Includes Index 14 thru 20 1 105477-001 Kit Seal Includes Index 23 thru 27 2

901122

3200 - 35019 Printed in U.S.A.

2.4 - 19 - 103

MANIFOLD 2065S

TRAVERSE

Crown 1994 PF10134 Rev. 2/03

02.4–19.0–104

Printed in U.S.A.

01 REV. 2/03

02.4–19.0–104

MANIFOLD 112440-001 MANIFOLD ASSEMBLY (48V) 112440-002 MANIFOLD ASSEMBLY (72V) Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

22 23 24 25 26 27

Part Name

No. Req.

112405 Block Manifold 112404-002 Valve Solenoid 48/72V Includes Index 3 thru 7 104164-009 Coil 30V O-Ring O-Ring Ring Back-Up Ring Back-Up O-Ring 064091-006 Plug 064091-002 Plug 093810 Orifice 061004-012 Adhesive Thread Locking 065002-007 Ball 086322 Suppresser SB72 060013-021 Screw 060005-004 Lockwasher O-Ring Ring Back-Up O-Ring Ring Back-Up O-Ring Ring Back-Up O-Ring 117385-002 Valve Solenoid 48V Includes Index 14 thru 20 117385-001 Valve Solenoid 72V Includes Index 14 thru 20 104164-010 Coil 48V 104164-006 Coil 72V 117386 Valve Single Pilot Check Includes Indexes 23 thru 27 O-Ring O-Ring Ring Back-Up Ring Back-Up O-Ring

1 2 2 2 2 2 2 2 6 2 2 1 1 1 2 2 1 2 1 2 1 2 1 1 1 1 1 2 2 2 2 2 2

Always Specify Model, Data & Serial Numbers 114439 118469 114439

Kit Seal Includes Index 3 thru 7 Kit Seal Includes Index 14 thru 20 Kit Seal Includes Index 23 thru 27

940502

2 1 2

5016 Printed in U.S.A.

02.4–19.0–105

01 REV. 2/03

02.4–19.0–105

MANIFOLD 2063S

PIVOT

112447-001 MANIFOLD ASSEMBLY 48 VOLT 112447-002 MANIFOLD ASSEMBLY 72 VOLT (Includes Indexes 1 thru 18 & 21 thru 24) Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part Name

No. Req.

101416 Block Manifold 064091-006 Plug 117387 Valve Shuttle Includes Index 4 thru 8 O-Ring Ring Back-Up O-Ring Ring Back-Up O-Ring 112425 Valve Countrbalance Includes Index 10 thru 14 064019-045 O-Ring 064074-029 Ring Back-Up 064019-021 O-Ring 064074-028 Ring Back-Up 064019-042 O-Ring 077288-003 Valve Relief Includes Index 16 thru 18 064019-030 O-Ring 064074-019 Ring Back-Up

940502 Crown 1994 PF-10133

2.4 - 19 - 201

1 4 1 1 1 1 1 1 2 2 4 2 4 2 2 2 2

Index Part No. 18 19 20 21

22 23 24

Part Name

No. Req.

064019-028 O-Ring 085670 Suppressor SB71 060013-021 Screw #8 060005-004 Lockwasher 101682-002 Valve Solenoid 48 Volt Includes Index 22 thru 24 101682-001 Valve Solenoid 72 Volt Includes Index 22 thru 24 104164-004 Coil 48 Volt 104164-003 Coil 36 Volt 064019-030 O-Ring 064019-028 O-Ring 064074-031 Ring Back-Up

2 1 2 2 1 1 1 1 1 1 2

Always Specify Model & Serial Number 114439 Kit Seal Includes Index 4 thru 8 1 105477-002 Kit Seal Includes Index 10 thru 14 2 105476-001 Kit Seal Includes Index 16 thru 18 2 105476-002 Kit Seal Includes Index 22 thru 24 1 4213 - 39047 Printed in U.S.A.

2.4 - 19 - 201

MANIFOLD 3454

FORK - FLOW DIVIDER

9 19 C4

C3 C2

11 4

17 12

SPC

14 FDV

C4 C3

SPC

C1 1 2

7 6

112854 MANIFOLD ASSEMBLY Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12

Part Name

No. Req.

110253 Block Manifold 064091-006 Plug 103558 Valve Single Pilot Check Includes Index 4 thru 8 064019-045 O-Ring 064074-021 Ring Back-Up 064019-021 O-Ring 064074-020 Ring Back-Up 064019-042 O-Ring 060013-005 Screw #8 060005-004 Lockwasher 101441 Valve Flow Divider Includes Index 11 thru 17 064019-045 O-Ring 064074-030 Ring Back-Up

1 2 2 2 2 2 2 2 2 2

Index Part No. 13 14 15 16 17 18 19

1 1 2

891023

Part Name

No. Req.

064019-046 O-Ring 064074-029 Ring Back-Up 064019-021 O-Ring 064074-028 Ring Back-Up 064019-042 O-Ring 086360-004 Strip Marking 071909-002 Block Terminal TB705 105605-705 Label

1 2 1 2 1 1 1 1

Always Specify Model & Serial Number 105477-001 Kit Seal Includes Index 4 thru 8 2 Kits Required for Complete SPC Assembly 1 105478-001 Kit Seal Includes Index 11 thru 17 1 4415

Crown 1993 PF9810 Rev. 11/94

Printed in U.S.A.

01 REV. 11/94

02.4–19.0–301

MANIFOLD 3454

FORK - FLOW DIVIDER

9 19 C4

C3 C2

11 4

17 12

SPC

14 FDV

C4 C3

SPC

C1 1 2

7 6

112854 MANIFOLD ASSEMBLY Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12

Part Name

No. Req.

110253 Block Manifold 064091-006 Plug 117386 Valve Single Pilot Check Includes Index 4 thru 8 O-Ring Ring Back-Up O-Ring Ring Back-Up O-Ring 060013-005 Screw #8 060005-004 Lockwasher 117384 Valve Flow Divider Includes Index 11 thru 17 O-Ring Ring Back-Up

1 2 2 2 2 2 2 2 2 2

Index Part No. 13 14 15 16 17 18 19

1 1 2

940502

Part Name

No. Req.

O-Ring Ring Back-Up O-Ring Ring Back-Up O-Ring 086360-004 Strip Marking 071909-002 Block Terminal TB705 105605-705 Label

1 2 1 2 1 1 1 1

Always Specify Model & Serial Number 114439

118469

Kit Seal Includes Index 4 thru 8 2 Kits Required for Complete SPC Assembly 1 Kit Seal Includes Index 11 thru 17 1 4415

Crown 1994 PF10135 Rev. 11/94

Printed in U.S.A.

01 REV. 11/94

02.4–19.0–302

MANIFOLD 2839S

BRAKE SV7 T RV3 P SV8

SV6

SV9 C2

ACC

4 SV7 C1

28 25 RV3

10 SV9

9 8

SV6

16 15 14

31 ACC

20 19 SV8

24 23

24 22 21

Crown 1994 PF10131 Rev. 7/99

Printed in U.S.A.

01 REV. 7/99

02.4–19.0–402

MANIFOLD 107336-001 MANIFOLD ASSEMBLY (48 V) 107336-002 MANIFOLD ASSEMBLY (72 V) Index Part No. 1

2 3 4 5 6 7 8

9 10 11 12

Part Name

117382-004 Valve Solenoid 48 V Includes Index 2 thru 4 117382-003 Valve Solenoid 72. V Includes Index 2 thru 4 118398 Kit Seal Includes Index 2 thru 4 104164-010 Coil 48 V 104164-006 Coil 36 V O-Ring O-Ring Ring Back Up 064091-006 Plug 064020-002 Plug 117391 Block Manifold 117388-002 Valve Solenoid 48 V Includes Index 9 thru 11 117388-001 Valve Solenoid 72 V Includes Index 9 thru 11 118398 Kit Seal Includes Index 9 thru 11 104164-010 Coil 48 V 104164-006 Coil 36 V O-Ring O-Ring Ring Back Up 117383-002 Valve Solenoid 48 V Includes Index 13 thru 15 117383-001 Valve Solenoid 72 V Includes Index 13 thru 15 118398 Kit Seal Includes Index 13 thru 15 104164-010 Coil 48 V 104164-006 Coil 36 V

No. Req.

1 1 1 1 1 1 1 1 1 1 1

Index Part No. 13 14 15 16 17

18 19 20 21

1 1 1 1 1 1 1 1 1 1 1 1 1

22 23 24 25

26 27 28 29 30 31

Part Name

No. Req.

O-Ring O-Ring Ring Back Up 106845-001 Disc Orifice 117380 Valve Check Includes Index 18 thru 20 118398 Kit Seal Includes Index 18 thru 20 O-Ring O-Ring Ring Back Up 117381-001 Valve Solenoid 72 V Includes Index 22 thru 24 118398 Kit Seal Includes Index 22 thru 24 104164-006 Coil 36 V O-Ring O-Ring Ring Back Up 077288-004 Valve Relief Includes Index 26 thru 28 105476-001 Kit Seal Includes Index 26 thru 28 064019-030 O-Ring 064074-019 Ring Back Up 064019-028 O-Ring 086322 Suppressor SB67 086322 Suppressor SB68 060013-008 Screw 060005-004 Lockwasher

1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 4 4

Always Specify Model, Data & Serial Numbers

940502

6182 - 45822 Printed in U.S.A.

01 REV. 7/99

02.4–19.0–403

MANIFOLD 2064S

TRAVERSE CUSHION

Crown 1993 PF-9823 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

2.4 - 19 - 501

MANIFOLD 112443-001 MANIFOLD ASSEMBLY 48/72 VOLTS Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24

Part Name

No. Req.

108275-001 Valve PFR Includes Index 2 thru 6 064019-045 O-Ring 064019-021 O-Ring 064074-021 Ring Back-Up 064074-020 Ring Back-Up 064019-042 O-Ring 064091-006 Plug 108272 Block Manifold 085045 Valve Check Includes Index 10 thru 12 064019-045 O-Ring 064019-042 O-Ring 064074-020 Ring Back-Up 112404-002 Valve Solenoid 3W 2P 48/72 Volts Includes Index 14 thru 18 104164-006 Coil 36V O-Ring O-Ring Ring Back-Up Ring Back-Up O-Ring 108275-002 Valve PFR Includes Index 20 thru 24 064019-045 O-Ring 064019-021 O-Ring 064074-021 Ring Back-Up 064074-020 Ring Back-Up 064019-042 O-Ring

1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Always Specify Model & Serial Number 105477-001 Kit Seal Includes Index 2 thru 6 105476-004 Kit Seal Includes Index 10 thru 12 114439 Kit Seal Includes Index 14 thru 18 105477-001 Kit Seal Includes Index 20 thru 24

910401

1 1 1 1

4288 - 39044 Printed in U.S.A.

01 REV. 1/94

2.4 - 19 - 502

MANIFOLD 2064S

TRAVERSE CUSHION

Crown 1994 PF-10132

2.4 - 19 - 503

Printed in U.S.A.

2.4 - 19 - 503

MANIFOLD 112443-001 MANIFOLD ASSEMBLY 48/72 VOLTS Index Part No. 1 2 3 4 5 6 7 8 9

10 11 12 13

14 15 16 17 18 19

20 21 22 23 24

Part Name

No. Req.

117389-001 Valve PFR Includes Index 2 thru 6 114439 Kit Seal Includes Index 2 thru 6 O-Ring O-Ring Ring Back-Up Ring Back-Up O-Ring 064091-006 Plug 108272 Block Manifold 117380 Valve Check Includes Index 10 thru 12 118398 Kit Seal Includes Index 10 thru 12 O-Ring O-Ring Ring Back-Up 112404-002 Valve Solenoid 3W 2P 48/72 Volts Includes Index 14 thru 18 104164-009 Coil 30V 114439 Kit Seal Includes Index 14 thru 18 O-Ring O-Ring Ring Back-Up Ring Back-Up O-Ring 117389-002 Valve PFR Includes Index 20 thru 24 114439 Kit Seal Includes Index 20 thru 24 O-Ring O-Ring Ring Back-Up Ring Back-Up O-Ring

1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Always Specify Model & Serial Number

940502

4213 - 39047 Printed in U.S.A.

2.4 - 19 - 504

SERVO CONTROL VALVE 2804S

093762 SERVO CONTROL VALVE ASSEMBLY Index Part No. 1

2 3 4 5 6 7

Part Name

Motor PM See Section 2.2 063002-021 Grease Moly Kote B Threaded Shaft 060012-039 Screw #6 060005-003 Lockwasher 094041 Spacer 060012-033 Screw #6 060046-004 Washer Spring 060015-016 Screw 1/4 “ 093136 Spacer Motor

No. Req.

093137

1 AR 4 4 1 4 10 4 1

Index Part No. 8 9 10 11 12 13 14 15

Part Name

No. Req.

065007-074 Bushing 100286 Valve Control See Section 2.3 060000-048 Pin Roll 093478 Bracket 093474 LVDT Assembly 093476 Stud 061004-012 Adhesive Thread Locking 090776 Spacer 100269 Core LVDT

1 1 1 1 1 1 AR 1 1

Always Specify Model & Serial Number

Crown 1984 PF-5723 Rev. 1/94

Printed in U.S.A.

02 REV. 1/94

2.5 - 18 - 100

SERVO CONTROL VALVE 6544S

5 10 11 1

9 6 7

6 4

15 13

3 14

125654 SERVO CONTROL VALVE ASSEMBLY Index Part No. 1

2 3 4 5 6 7

Part Name

No. Req.

125648 Motor PM See Section 2.2 063002-021 Grease Moly Kote B Threaded Shaft 060012-039 Screw 060005-003 Lockwasher 094041 Spacer 060012-033 Screw 060046-004 Washer Spring 060015-016 Screw 125655 Spacer Motor

1 AR 4 4 1 4 10 4 1

Index Part No. 8 9 10 11 12 13 14 15

Part Name

No. Req.

065007-074 Bushing 1 100286 Valve Control See Section 2.3 1 060000-048 Pin Roll 1 093478 Bracket 1 093474 LVDT Assembly 1 093476 Stud 1 061004-012 Adhesive Thread Locking AR 090776 Spacer 1 100269 Core LVDT 1 Always Specify Model, Data & Serial Numbers

980204 Crown 1998 PF11374

02.5–18.0–101

5713 - 43906/44457 Printed in U.S.A.

02.5–18.0–101

CONTROL VALVE LINKAGE 3596

Crown 1994 PF-10470

02.5–19.0–003

Printed in U.S.A.

02.5–19.0–003

CONTROL VALVE LINKAGE Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Part Name

No. Req.

060014-001 Screw 1 060005-045 Lockwasher 1 106271 Cam Linkage 1 060030-021 Washer Shim AR 060030-156 Washer 4 065007-012 Bearing Sleeve 2 065007-032 Bearing Sleeve 2 106196 Arm Linkage 1 104750 Shaft Linkage 1 104744 Plate Mounting 1 102594-002 Ball Joint Rod End 4 060005-007 Lockwasher 4 060021-074 Nut 4 104760-002 Rod Adjusting 1 104760-001 Rod Adjusting 1 104760-003 Rod Adjusting 1 060021-007 Nut 2 108020 Yoke Includes Index 35 thru 39 2 060009-061 Ring Retaining 2 108018 Pin 2 102374 Rod Adjusting 1 060012-005 Screw 6 060005-048 Lockwasher 6 073624 Switch PTS 1 092143 Plate Fastening 3 073624 Switch TVSL 1 073624 Switch TVSR 1 119508 Valve Traverse See Section 2.3 1 060015-015 Screw 4 060005-007 Lockwasher 4 119507 Valve Pivot See Section 2.3 1 065004-007 Grommet 1 108273- * Manifold See Section 2.4 1 060016-073 Screw 2 060005-008 Lockwasher 2 060030-017 Washer 2 060012-027 Screw 2 060005-003 Lockwasher 2 079564-002 Block Terminal TB528 1 105605-528 Label 1 079565-002 Strip Marking 1 108019 Yoke 1 106234 Slug 1 106248 Spring Compression 1 106235 Button 1 060009-142 Ring Retaining 1 086322 Suppressor SB54 1 060013-011 Screw 2 060005-004 Lockwasher 2 Always Specify Model & Serial Number

950320

4551 - 40613 Printed in U.S.A.

02.5–19.0–004

HYDRAULIC MOTOR 7433S

15 19

13 12

7 4

tch

t 2

4 5 3 6

125714 HYDRAULIC MOTOR ASSEMBLY Index Part No.

Part Name

1 126990 2 126991 3 126992 4 126993 5 † 126994 6 † 7 126995 8 † 126996 9 126997 10 126998 11 127000 12 126999 13 127001

Screw End Cover Seal Seal Commutator & Ring Commutator & Ring Manifold Rotor Set Wear Plate Drive Link Key Woodruff Shaft Needle Bearing

971110 Taylor-Newcomb Crown 1999 PF11658

02.6–18.0–004

No. Req. 5 1 1 5 1 1 1 1 1 1 1 1 1

Index Part No.

Part Name

14 15 16 17 18 19 20

Thrust Washer Thrust Bearing Inner Seal O-Ring Housing Needle Bearing Seal

127002 127003 127004 127005 127006 127007 127008

No. Req. 1 1 1 1 1 1 1

Always Specify Model, Data & Serial Numbers †Must Be Replaced As A Complete Set. 127009

Seal Kit Includes Index 3, 4, 16, 17, 18 & Lubricant

1 6102 - 44045 Printed in U.S.A.

02.6–18.0–004

DRIVE UNIT LUBRICATION SYSTEM 5826S

19 18

TUBING IS INSTALLED THROUGH CORED HOLE IN CASTING

15 14

18 10

3 2 5

8 7 6

Crown 1993 PF-9672 Rev. 11/97

Printed in U.S.A.

03 REV. 11/97

03.0–1430–200

DRIVE UNIT LUBRICATION SYSTEM Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17 18 19 20 21

Part Name

No. Req.

085990 Housing 064019-059 O-Ring 064019-047 O-Ring 065002-003 Ball 085987 Spring 085988 Plug 065002-007 Ball 083479 Spring 085989 Piston 064169-001 Elbow 085936 Tube 100779 Fitting Lubrication 064020-003 Plug 061004-023 Adhesive Hydraulic Sealant 064198-002 Plug RR, RS, RD & SP3000 Only 061004-023 Adhesive Hydraulic Sealant 064020-002 Plug 061004-023 Adhesive Hydraulic Sealant 064168-001 Connector 085935 Tube 060015-021 Screw Set 061004-023 Adhesive Hydraulic Sealant 060015-010 Screw 061004-023 Adhesive Hydraulic Sealant 085584 Block 064170-001 Elbow

1 1 2 1 1 1 1 1 1 1 1 1 1 1

091780

Pump Assembly Oil (Includes Index 1 thru 9)

1 1 1 1 1 1 2 1 1 1 1 1

Always Specify Model, Data & Serial Numbers

930222

5215 Printed in U.S.A.

03 REV. 11/97

03.0–1430–201

DRIVE UNIT Drive Unit Lubrication System Drive Unit Lubrication System

TS, TSP, SP 3000, SP 3200, SP 3400, SP 3470, SP 3480, SP 3471, SP 3481, SP 3505, SP 3510, SP 3511, SP 3512, SP 3520, SP 3521, SP 3522, SP 3550 SP 3570, SP 3571, SP 3580 and SP 3581

(a)

Tubing is installed through cored hole in casting

Figure 21934

03.0-1452-200 05 Rev. 6/09

556

SP3500

Crown 2001 PF13029-1 Rev. 6/09

DRIVE UNIT Drive Unit Lubrication System INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 . . . . . 091780 . . . . . . . . . . . Oil Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . . . . 085990. . . . . . . . . . . . Pump Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 . . . . . . . . 064019-059 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 . . . . . . . . 064019-047 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 . . . . . . . . 065002-003 . . . . . . . . Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 . . . . . . . . 085987. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . . . . . . . . 085988. . . . . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 . . . . . . . . 065002-007 . . . . . . . . Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9 . . . . . . . . 083479. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 10 . . . . . . . . 085989. . . . . . . . . . . . Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11 . . . . . 064169-001. . . . . . . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12 . . . . . 060015-125. . . . . . . . Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 061004-005. . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 13 . . . . . 085936 . . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 14 . . . . . 064168-001. . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 15 . . . . . 064020-002. . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 061004-005. . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 16 . . . . . 076048-001. . . . . . . . Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 17 . . . . . 085935 . . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 18 . . . . . 060015-010. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 061004-005. . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 19 . . . . . 085584 . . . . . . . . . . . Spacer Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 20 . . . . . 064170-001. . . . . . . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Always Specify Model, Data & Serial Number Crown 2001 PF13029-2 Rev. 6/09

SP3500

03.0-1452-201 05 Rev. 6/09

557

DRIVE UNIT 1204S

Crown 1992 PF-9343

3 - 18 - 007

Printed in U.S.A.

3 - 18 - 007

DRIVE UNIT Index Part No. 1 2 3 4

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29

30 31 32 33 34 35 36 37

Part Name

091114 Housing Drive Unit 060017-007 Screw 3/8" 060005-009 Lockwasher 064091-005 Plug 091160 Cover 060016-031 Screw 5/16" 060005-008 Lockwasher Tire (See Section 3.2) 078885-001 Bolt Special Hub (See Section 3.2) 094288 Axle (Includes Index 19) 087412 Seal 060015-053 Screw 1/4" 060000-005 Roll Pin 087461 Retainer Seal 065005-001 Sealer Gasket 087408 Gasket 065024 Bearing Cone 065023 Bearing Cup 083513 Cam 065018 Bearing Cup 065019 Bearing Cone 094288 Hub (Includes Index 8) 089248-001 Shim (.005 in. [0.13 mm]) 089248-002 Shim (.007 in. [0.18 mm]) 089248-003 Shim (.020 in. [0.51 mm]) 089246 Gear Set Spiral Bevel (Includes Gear and Pinion) 110558 Locknut 078885-003 Bolt 061004-012 Adhesive Thread Locking 110559 Screw 089239-002 Wire Lock 065052 Bearing Cone 065051 Bearing Cup 083514 Spacer 083516-001 Shim (.008 in. [0.20 mm]) 083516-002 Shim (.010 in. [0.25 mm]) 083516-003 Shim (.013 in. [0.33 mm]) 083517 Retainer Bearing 060016-068 Screw 5/16" 060005-008 Lockwasher 083511 Washer Special 060044-006 Lockwasher 060043-006 Locknut 087386 Gear 061008-004 Key Woodruff 060044-005 Lockwasher

No. Req. 1 2 2 1 1 7 7 1 8 1 1 1 5 2 1 AR 1 1 1 1 1 1 1 AR AR AR 1 1 8 AR 2 1 2 2 1 AR AR AR 1 6 6 1 1 1 1 1 1

Index Part No. 38 39 40

41 42 43 44 45 46 47 48 49 50 51 52 53

54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73

Part Name

No. Req.

060043-005 Locknut 083501 Gasket 065005-004 Sealer Gasket 086618 Cover 060016-030 Screw 5/16" 061004-012 Adhesive Thread Locking 060005-037 Lockwasher 064020-004 Plug Vented Pipe 083531 Spacer 060009-039 Ring Retaining 065081-003 Bearing Ball 086016 Gear Idler 086015 Shaft Idler 064019-061 O-Ring 064019-033 O-Ring 085581 Retainer Bearing 085586 Shaft Pinion 065081-032 Bearing Ball 085580 Retainer Bearing 061004-012 Adhesive Thread Locking 085928-001 Shim (.008 in. [0.20 mm]) 085928-002 Shim (.010 in. [0.25 mm]) 085928-003 Shim (.013 in. [0.33 mm]) 085927 Spacer 064138-003 Seal Oil 060009-097 Ring Retaining 108116 Gear Ring 060017-066 Screw 3/8" 061004-012 Adhesive Thread Locking 065081-043 Bearing Ball 064021-003 Plug 083500 Gasket Motor (See Section 3.1) 060018-005 Screw 7/16" 060005-043 Lockwasher 065013-004 Bearing Needle 065063-003 Bearing Inner Race 085582 Seal Felt 093406 Stud R.H. 091749 Stud L.H. (Shown) 060023-010 Bolt 061004-010 Adhesive Thread Locking 061011-009 Pin Dowel 065081-004 Bearing 065015-001 Race Bearing 065014-001 Bearing Thrust 061011-020 Pin Dowel

1 1 AR 1 4 AR 4 1 2 2 2 1 1 1 2 1 1 1 1 AR AR AR AR 1 1 1 1 2 AR 1 1 1 1 4 4 1 1 1 1 1 4 AR 2 1 2 1 2

Always Specity Model & Serial Number

911105

3649-35997 Printed in U.S.A.

3 - 18 - 008

DRIVE UNIT A

26 31

8860-01

41 40

54 Traction Motor See Section 03.1

48 53

44 49

Part of Power Unit

37 35

1 69 62

A 68

17 59

20 19

65 62 67

16 15 13

3 61

12 8

Traction Tire See Section 03.2

Crown 2001 PF13148-1 Rev. 2/04

03.0–18.1–001

Printed in U.S.A.

01 REV. 2/04

03.0–18.1–001

DRIVE UNIT Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Part Name

129478 Housing Drive Unit 060017-017 Screw 060005-009 Lockwasher 064091-005 Plug 128566 Cover 060016-031 Screw 060005-008 Lockwasher 128942 Nut Preload 065005-003 Anti-Sieze 078885-001 Lug Bolt 064020-003 Plug 061004-005 Adhesive Thread Locking 127974 Axle Includes Index 19 087412 Seal 060015-053 Screw 060000-005 Roll Pin 087461 Retainer Seal 065005-001 Sealer Gasket 087408 Gasket 065024 Bearing Cone 065023 Bearing Cup 083513 Cam 065018 Bearing Cup 065019 Bearing Cone 128941 Hub Includes Index 8 089248-001 Shim 0.13 mm (.005 in.) 089248-002 Shim 0.18 mm (.007 in.) 089248-003 Shim 0.51 mm (.020 in.) 128297 Gear and Pinion Matched 128725 Locknut 078885-003 Bolt 061004-004 Adhesive Thread Locking 110559 Screw Cap 089239-001 Wire Lock Cut to Length Required 065052 Bearing Cone 065051 Bearing Cup 083514 Spacer 083516-001 Shim 0.20 mm (.008 in.) 083516-002 Shim 0.25 mm (.010 in.) 083516-003 Shim 0.33 mm (.013 in.) 083517 Retainer Bearing 060016-004 Screw 060005-008 Lockwasher 083511 Flatwasher Special 060044-006 Lockwasher 060043-006 Locknut

No. Req. 1 2 2 1 1 7 7 1 AR 8 1 AR 1 1 5 2 1 AR 1 1 1 1 1 1 1 AR AR AR 1 1 7 1 2 1 2 2 1 AR AR AR 1 6 6 1 1 1

Index Part No. 35 36 37 38 39

Part Name

No. Req.

087386 Gear 1st Reduction 061008-004 Key Woodruff 060044-005 Lockwasher 060043-005 Locknut 083501 Gasket 065005-002 Sealer Gasket 086618 Cover 060016-030 Screw Tighten to 20 - 27 Nm (15 - 20 ft. lbs.) 061004-013 Adhesive Thread Locking 060005-037 Lockwasher 064020-004 Plug Vented Pipe 083531 Spacer 060009-039 Ring Retaining 065081-003 Bearing Ball 086016 Gear Idler 086015 Shaft Idler 064019-061 O-Ring 064019-033 O-Ring 085581 Retainer 085586 Shaft Pinion 065081-032 Bearing Ball 085580 Retainer 061004-004 Adhesive Thread Locking 085928-001 Shim 0.20 mm (.008 in.) 085928-002 Shim 0.25 mm (.010 in.) 085928-003 Shim 0.33 mm (.013 in.) 085927 Spacer 064138-003 Seal Oil 060009-097 Ring Retaining 131101 Locking Bolt 061011-020 Pin Dowel 065014-001 Bearing Thrust 064021-003 Plug 083500 Gasket 065015-001 Race Bearing 060018-005 Screw 060005-043 Lockwasher 065013-004 Bearing Needle 065063-003 Bearing Inner Race 085582 Seal Felt 061001-015 Adhesive 093406 Stud R.H. 091749 Stud L.H. (Shown) 060023-010 Bolt 061004-010 Adhesive Thread Locking 061011-009 Pin Dowel 065081-065 Bearing

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

1 1 1 1 1 AR 1 4 1 4 1 2 2 2 1 1 1 2 1 1 1 1 1 AR AR AR 1 1 1 1 2 1 1 1 2 4 4 1 1 1 1 1 1 4 AR 2 1

Always Specify Model, Data & Serial Numbers

010420

7447 - E010977

Crown 2001 PF13148-2 Rev. 2/04

Printed in U.S.A.

03.0–18.1–002

01 REV. 2/04

03.0–18.1–002

DRIVE UNIT PARTS Drive Unit Drive Unit

Traction Motor See Drive Unit

Part of Power Unit

Figure 13092

03.0-18.1-003

Crown 2007 PF15152-1

DRIVE UNIT PARTS Drive Unit INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 . . . . . 129478 . . . . . . . . . . . Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . 064020-003. . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 061004-023. . . . . . . . Thread Lock Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 . . . . . 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 . . . . . 060017-017. . . . . . . . Screw 3/8 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 . . . . . 064091-005. . . . . . . . Plug w/O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 . . . . . 083513 . . . . . . . . . . . Cam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . . . . . 065023 . . . . . . . . . . . Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 . . . . . 065024 . . . . . . . . . . . Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9 . . . . . 087408 . . . . . . . . . . . Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 065005-001 . . . . . . . . Gasket Sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 10 . . . . . 087461 . . . . . . . . . . . Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11 . . . . . 060000-005. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 12 . . . . . 060015-053. . . . . . . . Screw 1/4 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 13 . . . . . 087412 . . . . . . . . . . . Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 065005-001 . . . . . . . . Gasket Sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 14 . . . . . 061011-020 . . . . . . . . Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 15 . . . . . 065013-004. . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 16 . . . . . 065063-003. . . . . . . . Bearing Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 17 . . . . . 065015-001. . . . . . . . Bearing Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 18 . . . . . 065014-001. . . . . . . . Thread Lock Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 19 . . . . . 085582 . . . . . . . . . . . Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 061001-015 . . . . . . . . Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 20 . . . . . 093406 . . . . . . . . . . . Stud RH Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 091749 . . . . . . . . . . . Stud LH Asm Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 21 . . . . . 060023-010. . . . . . . . Screw .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 061004-010 . . . . . . . . Thread Lock Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 22 . . . . . 061011-009 . . . . . . . . Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 23 . . . . . 064019-061. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 24 . . . . . 086015 . . . . . . . . . . . Idler Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 25 . . . . . 060018-005. . . . . . . . Screw 7/16 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 26 . . . . . 060005-043. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Always Specify Model, Data & Serial Number Crown 2007 PF15152-2

03.0-18.1-004

DRIVE UNIT PARTS Drive Unit

Traction Tire See Drive Unit

Figure 13093

03.0-18.1-005

Crown 2007 PF15152-3

DRIVE UNIT PARTS Drive Unit INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

35 . . . . . 078885-001. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 36 . . . . . 127974 . . . . . . . . . . . Axle Includes Index 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 37 . . . . . 060016-031. . . . . . . . Screw 5/16 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 38 . . . . . 060005-008. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 39 . . . . . 064021-003. . . . . . . . Plug w/O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 40 . . . . . 128566 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 41 . . . . . 083500 . . . . . . . . . . . Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 42 . . . . . 110559 . . . . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 43 . . . . . 128725 . . . . . . . . . . . Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 44 . . . . . 089239-001. . . . . . . . Wire Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 45 . . . . . 131101 . . . . . . . . . . . Locking Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 46 . . . . . 078885-003. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 061004-010 . . . . . . . . Thread Lock Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 47 . . . . . 128297 . . . . . . . . . . . Matched Gear & Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 48 . . . . . 089248-001. . . . . . . . Shim 0.13mm (0.005 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 089248-002. . . . . . . . Shim 0.18 mm (0.007 in). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 089248-003. . . . . . . . Shim 0.51 mm (0.020 in). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 49 . . . . . 128941 . . . . . . . . . . . Hub Includes Index 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 065005-003 . . . . . . . . Anti-Seize. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 50 . . . . . 128942 . . . . . . . . . . . Preload Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 51 . . . . . 065019 . . . . . . . . . . . Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 52 . . . . . 065018 . . . . . . . . . . . Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 53 . . . . . 064019-033. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 54 . . . . . 085581 . . . . . . . . . . . Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 55 . . . . . 065081-065. . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 56 . . . . . 085586 . . . . . . . . . . . Pinion Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 57 . . . . . 065089-004. . . . . . . . Double Row Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 58 . . . . . 085580 . . . . . . . . . . . Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 061004-010 . . . . . . . . Thread Lock Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 59 . . . . . 085928-001. . . . . . . . Shim 0.20 mm (0.008 in). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 085928-002. . . . . . . . Shim 0.25 mm (0.010 in). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 085928-003. . . . . . . . Shim 0.33 mm (0.013 in). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 60 . . . . . 085927 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 61 . . . . . 064138-003. . . . . . . . Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 62 . . . . . 060009-097. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Always Specify Model, Data & Serial Number Crown 2007 PF15152-4

03.0-18.1-006

DRIVE UNIT PARTS Drive Unit

Torque to 20 - 27 Nm (15 - 20 ft lbs)

Figure 13094

03.0-18.1-007

Crown 2007 PF15152-5

DRIVE UNIT PARTS Drive Unit INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

70 . . . . . 083531 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 71 . . . . . 065081-003. . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 72 . . . . . 060009-039. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 73 . . . . . 086016 . . . . . . . . . . . Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 74 . . . . . 128297 . . . . . . . . . . . Matched Gear & Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 75 . . . . . 061008-004. . . . . . . . Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 76 . . . . . 065052 . . . . . . . . . . . Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 77 . . . . . 065051 . . . . . . . . . . . Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 78 . . . . . 083514 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 79 . . . . . 083516-001. . . . . . . . Shim 0.20 mm (0.008 in). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 083516-002. . . . . . . . Shim 0.25 mm (0.010 in). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 083516-003. . . . . . . . Shim 0.33 mm (0.013 in). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 80 . . . . . 083517 . . . . . . . . . . . Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 81 . . . . . 060016-004. . . . . . . . Screw 5/16 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 82 . . . . . 060005-008. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 83 . . . . . 060016-030. . . . . . . . Screw 5/16 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 061004-014 . . . . . . . . Thread Lock Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 84 . . . . . 060005-037. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 85 . . . . . 064020-004. . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 86 . . . . . 086618 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 87 . . . . . 083501 . . . . . . . . . . . Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 065005-002 . . . . . . . . Gasket Sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 88 . . . . . 060043-005. . . . . . . . Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 89 . . . . . 060044-005. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 90 . . . . . 087386 . . . . . . . . . . . 1st Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 91 . . . . . 060043-006. . . . . . . . Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 92 . . . . . 060044-006. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 93 . . . . . 083511 . . . . . . . . . . . Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Always Specify Model, Data & Serial Number Crown 2007 PF15152-6

03.0-18.1-008

DRIVE MOTOR 3470S

104078 DRIVE MOTOR 36V/48V Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12

Part Name

No. Req.

103113 Armature Includes Index 12 103115 Cover Plate pkg. 104888 Brush Set Service 105073 Field Coil Pkg. 103117 Head Assembly C.E. 060015-102 Screw 1/4" 089184 Spring Set Brush 065081-005 Bearing Ball 103118 Plate Assembly Brush 103119 Head D.E. 087239 Pole Shoe Screw Pkg. 103120 Terminal Stud Pkg. 103114 Fan

1 1 1 1 1 4 1 1 1 1 1 1 1

Always Specify Model & Serial Number

860915 Prestolite

3749

Crown 1986 PF-7648 Rev. 11/94

03.1–14.0–005

Printed in U.S.A.

02 REV. 11/94

03.1–14.0–005

DRIVE MOTOR 3473S

104121 DRIVE MOTOR 72V Index Part No. 1 2 3 4 5 6 7 8 9 10 11

Part Name

No. Req.

106142 Armature 105571 Cover Plate Pkg. 104888 Brush Set Service 106143 Field Coil Pkg. 106144 Head Assembly C.E. 060015-102 Screw 1/4" 089184 Spring Set Brush 060015-064 Screw 1/4" 065081-005 Bearing Ball 103118 Plate Assembly Brush 103119 Head D.E. 087239 Screw Pole Shoe Pkg. 106145 Terminal Stud Pkg.

1 1 1 1 1 4 1 4 1 1 1 1 1

Always Specify Model & Serial Number

870813 Prestolite

3749

Crown 1987 PF-7849 Rev. 11/94

Printed in U.S.A.

01 REV. 11/94

03.1–18.0–002

MOTOR 5491

DRIVE

Part of Commutator End Head 14

5 1

13 12 18

19 4

16 17

11 9

8 Part of Frame

14 13 12 6

Printed in U.S.A.

Crown 1994 PF-10411 Rev. 8/96

01 REV. 8/96

03.1–18.1–001

MOTOR 020334 DRIVE MOTOR (72 VOLT) Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Part Name

No. Req.

060078-007 Screw Thread Forming 1/4" 060078-009 Screw Thread Forming 1/4" 020223 Drive End Head 020433-001 Headband 020344 Commutator End Head 020335 Armature Includes Fan 065081-056 Bearing Ball 060009-144 Ring Retaining 020337 Frame and Field 060078-008 Screw Thread Forming 1/4" 020258 Terminal & Lead Includes Index 11 020281 Bracket Terminal 020196 Insulator Terminal 020197 Nut Terminal 060016-003 Screw 5/16" 060005-008 Lockwasher 020290-002 Brush Box Includes Index 16 thru 19 118466 Spring 060032-051 Screw Self Tapping #10 060078-011 Screw Thread Forming 1/4" 020277-001 Brush 12.5 x 25

4 8 1 1 1 1 1 1 1 8 2 4 2 2 4 4 1 8 4 8 8

Always Specify Model & Serial Number MISCELLANEOUS 119573

950125

Kit Brush Includes Index 16, 18 & 19

CROWN

5076 Printed in U.S.A.

01 REV. 8/96

03.1–18.1–002

TIRE ASSEMBLY 3445

HUB

TIRE

Index Part No.

Part Name

079266-030-01 079266-070-01 087880-003 087880-013

087391

No. Req.

Tire Poly Black Tire Poly Cream Tire Poly Includes Index 2 Tire Poly Non-Marking Includes Index 2 Hub

2 2 2 2 2

Always Specify Model & Serial Number

4537 - 40190 Crown 1988 PF-8103 Rev. 12/94

Printed in U.S.A.

01 REV. 12/94

03.2–19.0–001

TIRE ASSEMBLY 3445

HUB

TIRE

Index Part No. 1

079266-030-01 079266-070-01 125382-003 125382-013

087391 063000-041

Part Name

No. Req.

Tire Poly Black Tire Poly Cream Tire Poly Includes Index 2 Tire Poly Non-Marking Includes Index 2 Hub Paint Medium Gray

2 2 2 2 2 AR

Always Specify Model, Data & Serial Numbers

980727 Crown 1998 PF11495

03.2–19.0–002

5847 - 44882 Printed in U.S.A.

03.2–19.0–002

ELECTRICAL COMPONENTS - POWER UNIT 4268S

Index 1 2

Part No.

Part Name

086360-004 071909-002 105605-609 060013-005 060005-004 071909-002 105605-610 060013-005 060005-004 086360-004

Strip Marking Block Terminal TB609 Label Screw Lockwasher Block Terminal TB610 Label Screw Lockwasher Strip Marking

No. Req.

Index

2 1 1 2 2 1 1 2 2 2

Crown 1996 PF10975 Rev. 3/01

04.0–19.0–003

Part No.

Part Name

No. Req.

071909-002 105605-611 060013-005 060005-004 071909-002 105605-612 060013-005 060005-004

Block Terminal TB611 Label Screw Lockwasher Block Terminal TB612 Label Screw Lockwasher

1 1 2 2 1 1 2 2

Printed in U.S.A.

01 REV. 3/01

04.0–19.0–003

ELECTRICAL COMPONENTS - POWER UNIT Index 7

Part No.

Part Name

107075-001

Contactor Panel Assembly 72V. See Section 4.1 1 Contactor Panel Assembly 48V. See Section 4.1 1 Flatwasher 5 Lockwasher 5 Nut 5 Steering Feedback Assembly See Section 4.8 1 Screw 2 Lockwasher 2 Door Assembly Swing-Out See Section 4.0 Electrical Components Door Assembly 1 Screw 2 Flatwasher 2 Wire Guidance Components See Section 4.3 1 Screw 3 Lockwasher 3 Adhesive Thread Locking 1 Screw 4 Flatwasher 4 Lockwasher 4 Nut 4 Shim 0.065 in. (1.65 mm) Thick AR Pin Hinge 1 Hinge 1 Motor Accessory Pump 48V. M2 See Section 2.2 1 Shim Spacing 1 Motor Accessory Pump 72 V. M2 See Section 2.2 1 Shim Spacing 1 Screw 4 Lockwasher 4 Flatwasher 4 Bracket Mounting 2 Mount Vibration Pair 4 Screw 4 Flatwasher 4 Lockwasher 4 Nut 4 Guard Motor 1 Screw 2 Lockwasher 2 Clamp Harness 3 Screw 3 Lockwasher 3 Clamp Harness 4 Screw 4 Lockwasher 4 Clamp Harness 2 Screw 2 Lockwasher 2 Clamp Harness 1 Screw 1 Lockwasher 1 Strip Mounting 2 Block Terminal TB615 1

107075-002

9 10 11

13 14 15

060030-052 060005-020 060021-009 106569 060015-006 060005-007

060017-027 060030-026 060017-010 060005-009 061004-026 060017-010 060030-026 060005-009 060021-011 060030-026 077210-006 107248 104492 107852 126305

16 17 18 19

20 21 22 23 24 25 26

960521

100805 060016-003 060005-008 060030-017 107771 093786-002 060017-012 060030-080 060005-009 060021-011 123244 060017-006 060005-009 061002-012 060015-046 060005-006 061002-020 060015-046 060005-006 061002-001 060014-001 060005-005 061002-002 060014-001 060005-005 086360-004 071909-002

No. Req.

Index

28 29

31 32

33 34 35

Part No.

Part Name

105605-615 060013-005 060005-004 071909-002 105605-616 060013-005 060005-004 086360-007 071909-003 105605-618 060013-005 060005-004 093762

Label 1 Screw 2 Lockwasher 2 Block Terminal TB616 1 Label 1 Screw 2 Lockwasher 2 Strip Marking 1 Block Terminal TB618 1 Label 1 Screw 2 Lockwasher 2 Servo Control Valve SV1 See Section 2.5 1 Screw 3 Lockwasher 3 Switch Pressure 1 Screw 2 Lockwasher 2 Block Terminal TB617 1 Label 1 Screw 2 Lockwasher 2 Strip Marking 1 Grommet 1 Connector Assembly Cable 48V. Includes Housing & Contacts 1 Connector Assembly Cable 72V. Includes Housing & Contacts 2 Housing 72V. 1 Housing 48V. 1 Contact 2 Screw AR Lockwasher AR Stand-Off 1 Lockwasher 1 Flatwasher 1 Screw 1 Flashing Light Assembly LGT 16 See Section 4.9 1 Screw 4 Lockwasher 4 Flatwasher 4 Battery See Section 1.0 Power Unit AR Resistor Assembly 48V. Trucks Only 1 Screw 2 Lockwasher 2 Plate Conductive 48V. Trucks Only 1 Grease Silicone AR Alarm Travel F, R, or F & R HN3 1 Screw 1/4" w/ F or R Alarm 2 Screw 1/4" w/ F & R Alarm 2 Lockwasher 2 Nut 2 Plate Mounting w/ F & R Alarm 1 Block Double Diode DB1 w/ F & R Alarm 1 Screw 2 Lockwasher 2

060015-069 060005-006 107201 060014-024 060005-005 071909-004 105605-617 060013-005 060005-004 086360-001 065004-006 077917-001 077917-001

38 39 40 41

42 43

078723-001 078723-006 078724-001 060015-062 060005-006 078953-002 060005-026 060030-060 060015-066 060017-021 060005-009 060030-026 109815 060011-005 060005-050 109018 093983 115565 060015-048 060015-008 060005-007 060021-006 119222 075256 060013-003 060005-004

No. Req.

Always Specify Model, Data & Serial Numbers

6981

Printed in U.S.A.

04.0–19.0–004

01 REV. 3/01

04.0–19.0–004

ELECTRICAL COMPONENTS - DOOR ASSEMBLY 3991S

9 BACK VIEW DOOR IN OPEN POSITION 10 2 1 3 5

4 6 7

26 25 13 20

32 33

21 22

27 17

19 14

18 29

23 33 15

FRONT VIEW DOOR IN CLOSED POSITION 16

14 Crown 1988 PF-8102 Rev. 8/95

Printed in U.S.A.

03 REV. 8/95

04.0–19.0–100

ELECTRICAL COMPONENTS - DOOR ASSEMBLY Index Part No. 1 2 3

9 10 11 12 13

Part Name

No. Req.

078953-002 Stand Off 061004-012 Adhesive Thread Lock 078953-002 Stand Off 060015-003 Screw 1/4" 060005-007 Lockwasher 060030-012 Flatwasher 102061 Contactor ED-2 060014-006 Screw #10 060005-005 Lockwasher 060030-046 Flatwasher 102108 Suppressor SB64 060013-016 Screw #8 060005-004 Lockwasher 060030-045 Flatwasher 102061 Contactor S 060014-006 Screw #10 060005-005 Lockwasher 060030-046 Flatwasher 102108 Suppressor SB65 060013-016 Screw #8 060005-004 Lockwasher 060030-045 Flatwasher 109331-003 Steering Servo Motor Control Used on 72 volt Trucks See Section 04.2 109331-004 Steering Servo Motor Control Used on 48 volt Trucks See Section 04.2 060017-007 Screw 3/8" 060005-009 Lockwasher 106808 Panel Door 105932-* Electronic Box Power Unit See Section 04.3 065004-006 Grommet 078953-002 Stand Off 061004-012 Adhestive Thread Lock 104672 Distribution Panel 107671 Distribution Panel Assembly Includes Index 14, 16, 17, 18 & 28

Index Part No.

1 1 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2 1 2 2 2

1 2 2 1

29 30 31

1 2 7 1 1

15 16 17 18 19 20 21 22 23 24

25 26 27

32 33

Part Name

No. Req.

060021-005 Nut 060005-045 Lockwasher 060005-005 Lockwasher 060030-046 Flatwasher 060014-005 Screw #10 062299 Bar LED 104401-005 Spacer 061004-012 Adhesive Thread Lock 107667 Panel Display 069146 Label 062337-002 Relay K4 062339 Spring Hold Down 105070 Power Supply 5 volt PS601 105201 Cushion 108649 Cover 105071 Power Supply 12 volt PS602 060015-003 Screw 1/4" 060005-007 Lockwasher 060030-012 Washer 094362-001 Fuse 4 Amp FU1 094362-002 Fuse 15 Amp FU2 thru FU8 102064 Controller Curtis 060015-002 Screw 1/4" 060005-007 Lockwasher 107666 Hour Meter 060012-006 Screw #6 060005-048 Lockwasher 107657 Cover 060015-073 Screw 1/4" 069012 Label Warning Electrical Additions 103687-010 Switch EMS3 103687-011 Switch EMS4 & TES1

4 4 4 4 4 4 4 1 1 1 1 1 1 1 1 1 7 7 7 1 7 1 2 2 1 2 2 1 4 1 1 2

Always Specify Model & Serial Number

4748 - 41487 Printed in U.S.A.

03 REV. 8/95

04.0–19.0–101

ELECTRICAL COMPONENTS— PLATFORM 0660S-01

Enlarged View of R.H. Console Assembly

8 9 41 7

10 39

35 36

12 11

33 14

15 29 32 28

24 19 16

21 17 18

25 20

Part of Platform

23 26

Crown 2001 PF13200

04.0–19.0–304

Printed in U.S.A.

04.0–19.0–304

ELECTRICAL COMPONENTS— PLATFORM Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12

13 14

16 17

18 19 20 21 22 23

Part Name

No. Req.

107151-002 Key Replacement Nut Key Switch 108066 Switch Assembly Key KYS Includes Index 1 & 2 Nut Signal 092396 Signal Electronic HN-2 Includes Index 4 104125-002 Switch Toggle EMS-2 Includes Index 8 104125-002 Switch Toggle EMS-1 Includes Index 8 Nut Switch Overhead Console R.H. See Section 9.0 Overhead Console L.H. See Section 9.0 Display Panel See Section 4.8 060014-049 Screw Speed Control Assembly See Section 4.6 Speed Control Assembly End Aisle Control See Section 4.6 060017-010 Screw 060005-009 Lockwasher 104743 Card Interrupt Interface 060014-006 Screw 060005-005 Lockwasher 060030-044 Flatwasher Electronic Box - Platform See Section 4.3 060005-008 Lockwasher 060021-009 Nut 078953-003 Stand-Off 061004-026 Thread Locking Adhesive 104990 Panel Distribution Relay Includes Index 18 & 19 062337-002 Relay K1, K2 & K3 062339 Spring Hold Down 094362-002 Fuse 15 Amp FU-9 105071 Power Supply 12 V. 105070 Power Supply 5 V. 105201 Cushion 108649 Cover Power Supply 060030-060 Flatwasher 060005-026 Lockwasher 060021-033 Nut Seat Assembly See Section 9.0 060016-003 Screw 060005-008 Lockwasher 060030-119 Flatwasher Switch Assembly Chain See Section 7.6 060005-009 Lockwasher 060017-007 Screw

010517

1 1 1 1

Index Part No. 25

1 1

1 2 28 1 1

29 30

1 10 1 1 2 2 1 2 2 2 1 3 3 6 1

31 32

33 34 35

36 1 3 3 1 1 1 1 1 6 6 6 1 2 2 2

38 39 40 41

Part Name

No. Req.

Height Sensor Assembly See Section 9.0 060005-009 Lockwasher 060017-027 Screw Floor Pedal Assembly L.H. See Section 4.8 060005-009 Lockwasher 060017-006 Screw Foot Pedestal Assembly See Section 4.8 060005-008 Lockwasher 060021-009 Nut 060017-007 Screw 060030-119 Flatwasher 060005-009 Lockwasher 129244-001 Horn HN-1 129579 Suppressor SB53 060030-045 Flatwasher 060005-004 Lockwasher 060013-021 Screw 105646 Plate Mounting Control Valve Linkage See Section 2.5 060030-061 Flatwasher 060005-009 Lockwasher 060017-027 Screw Steering Control Assembly See Section 4.5 and 6.0 060005-009 Lockwasher 060017-007 Screw Switch Assembly Upper LMS-2 See Section 4.8 TF Only 060005-009 Lockwasher 060017-006 Screw Switch Assembly Lower LMS-1 See Section 4.8 060005-009 Lockwasher 060017-006 Screw Floor Pedal Assembly R. H. See Section 4.8 060005-009 Lockwasher 060017-006 Screw 108306 Switch TDSL 060012-005 Screw 060005-003 Lockwasher 108305 Adapter Switch 108306 Switch TDSR 060012-005 Screw 060005-003 Lockwasher 069046 Label Warning Override

1 2 2 2 2 2 1 2 2 1 1 1 1 1 2 2 2 1 1 3 3 3 1 2 2 1 2 2 1 2 2 1 2 2 1 4 4 2 1 4 4 1

Always Specify Model, Data & Serial Numbers 1 2 2

407 - EO5192 Printed in U.S.A.

04.0–19.0–305

CONTACTOR PANEL 1515S-01

TS, TSP SERIES To Battery Negative 55

2 6

8 7

11 13 14

47 3

12 54

14 16

50 27

7 38

26 D

B 49

C 36

28 7 37 39

27 7

31 7

30 32

7 33

20 17

23 24 44 23 43

22 7 21

28 45 28 29 7

51 29 28

52 28

Crown 1992 PF9492 Rev. 5/99

Printed in U.S.A.

05 REV. 5/99

04.1–19.0–003

CONTACTOR PANEL 107075-001 CONTACTOR PANEL ASSEMBLY (72V.—TS, TSP) 107075-002 CONTACTOR PANEL ASSEMBLY (48V.—TSP) Index Part No. 1 2 3 4

5 6 7

8 9

13 14

16 17 18 19 20 21

Part Name

No. Req.

105575 Insulator 1 105574 Heat Sink 1 093983 Grease Silicone 1 103005 Insulator 2 060014-023 Screw 2 060005-005 Lockwasher 2 060030-044 Flatwasher 2 079813 Rectifier 4A 1 107173 Bar Bus 1 060015-029 Screw 10 060005-026 Lockwasher 10 060030-060 Flatwasher 10 107122 Panel Contactor 1 102061 Contactor - 36/48V. TS/TSP - D See Section 4.4 1 060014-006 Screw 2 060005-005 Lockwasher 2 102108 Block Suppressor SB62 1 060013-016 Screw 2 060005-004 Lockwasher 2 060030-045 Flatwasher 2 102109 Block Suppressor SB63 1 060013-016 Screw 2 060005-004 Lockwasher 2 060030-045 Flatwasher 2 107258 Contactor - 48V. TSP FB-RB See Section 4.4 1 106842 Contactor - 36V. TS/TSP FB-RB See Section 4.4 1 060015-046 Screw 2 060030-012 Flatwasher 2 060005-007 Lockwasher 2 107096 Bar Bus 1 Nut Included with Index 12 3 Lockwasher Included with Index 12 3 102109 Block Suppressor SB61 1 060013-016 Screw 2 060005-004 Lockwasher 2 060030-045 Flatwasher 2 078953-002 Stand-Off 7 079774 Block Driver PMT, D, P1 & P2 4 107084 Plate Top 1 086360-006 Strip Marking 1 071909-002 Block Terminal TB614 1 105605-614 Label 1 060012-027 Screw 2 060005-003 Lockwasher 2 060030-045 Flatwasher 2

Index Part No. 22

24 25 26 27

30 31

32 33

37 38 39 40 41 42 43

Part Name

No. Req.

060014-028 Screw 060005-005 Lockwasher 060030-090 Flatwasher 105576 Block Fuse 060012-010 Screw 060005-003 Lockwasher 094362-002 Fuse FU-10, FU-11 106767 Bar Bus 079566-011 Label 107099 Bar Bus 060015-066 Screw 060005-026 Lockwasher 060030-060 Flatwasher 060016-002 Screw 060005-008 Lockwasher 060030-017 Flatwasher 060016-001 Screw 060005-008 Lockwasher 060030-017 Flatwasher 107936 Plugging Module 060012-023 Screw 060005-003 Lockwasher 060030-045 Flatwasher 106761 Bar Bus 079566-007 Label 125476 Contactor - 36/48V. TS/TSP P3 See Section 4.4 079566-009 Label 125476 Contactor - 36/48V. TS/TSP P2 See Section 4.4 079566-006 Label 125476 Contactor - 36/48V. TS/TSP P1 See Section 4.4 079566-005 Label 125476 Contactor - 36/48V. TS/TSP ED1 See Section 4.4 079566-010 Label 060014-006 Screw 060005-005 Lockwasher 106766 Bar Bus 107100 Bar Bus 107095 Bar Bus 076924-021 Fuse FU13 079566-044 Label 076924-001 Fuse FU14 079566-045 Label 076924-012 Fuse FU15 079566-046 Label

4 4 4 2 2 2 2 1 1 2 3 3 3 9 9 9 4 4 4 1 2 2 2 1 1 1 1 1 1 1 1 1 1 12 12 2 1 1 1 1 1 1 1 1

Parts Listing Continued On Next Page Printed in U.S.A.

05 REV. 5/99

04.1–19.0–004

CONTACTOR PANEL Index Part No. 44 45 46

48 49 50

52 53

Part Name

No. Req.

107098 107101 102803

Bar Bus Bar Bus SCR Panel - Pump See Section 4.2 093983 Grease Silicone 060017-038 Screw 060005-009 Lockwasher 060030-026 Flatwasher 076924-022 Fuse FU12 079566-013 Label 125494 Bar Bus 107869 SCR Panel Traction See Section 4.2 093983 Grease Silicone 103324 Screw 060005-008 Lockwasher 060030-017 Flatwasher 107652 Bar Bus 107258 Contactor - 48V. TSP FA-RA See Section 4.4 106842 Contactor - 36V. TS/TSP FA-RA See Section 4.4 060015-046 Screw 060030-012 Flatwasher 060005-007 Lockwasher 060016-002 Screw 060005-008 Lockwasher 060030-017 Flatwasher 112488 Bar Bus 060015-066 Screw 060030-060 Flatwasher 060005-026 Lockwasher 060021-006 Nut

1 2 1 AR 6 6 6 1 1 1 1 AR 3 3 3 1 1 1 2 2 2 2 2 2 1 1 1 1 1

Always Specify Model, Data & Serial Numbers

920812

6108 - 45813 Printed in U.S.A.

05 REV. 5/99

04.1–19.0–005

SCR PANEL 2356S

TRACTION

CONNECTS TO CONTACTOR PANEL

Crown 1988 PF-7767 Rev. 10/97

Printed in U.S.A.

03 REV. 10/97

04.2–19.0–050

SCR PANEL 107869 TRACTION SCR PANEL Index Part No. 1 2 3 4 5 6

7 8 9 10 11 12 13 14 15

17 18 19 20 21 22 23 24

25 26 27 28 29 30

31 32 33 34 35

103002 103011 103013 103024 103329 060005-003 060030-004 103027 103025 107342 103015 079812 103004 093983 103003 103012 103328 060005-005 060030-044 103324 060005-008 060030-017 103008 103007 103026 103018 103017 103019 103016 103325 060005-003 060030-004 103009 103006 093983 103022 103023 103021 060030-017 060005-008 103327 103326 060005-007 103005 079813 079813 116205

Part Name

No. Req.

Heatsink Base Spider Assembly With Leads Lead Snubber Screw W/Lockwasher Screw Lockwasher Flatwasher Screw W/Lockwasher Screw W/Lockwasher Card Assembly Oscillator Strap mounting Capacitor Insulator Grease Silicone Kit 1 Rectifier Includes Index 12 Thermal Protector Screw Lockwasher Flatwasher Screw Lockwasher Flatwasher SCR 5 REC SCR 2 REC Screw W/Lockwasher Bar Bus Bar Bus Bar Bus Bar Bus Screw Lockwasher Flatwasher Reactor Insulator Grease Silicone Heatsink Post Terminal Shunt & Wire Flatwasher Lockwasher Nut Screw Lockwasher Bushing Insulated Diode 3 REC Diode 4 RECB Boot Insulator

1 1 1 4 4 1 1 1 8 8 1 1 1 1 1 1 1 5 5 5 2 2 2 1 1 4 1 1 1 1 4 4 4 1 1 1 1 1 1 2 2 2 1 1 3 1 1 4

Always Specify Model, Model & Serial Numbers

103020

Wire Harness Not Shown

1 5616 Printed in U.S.A.

03 REV. 10/97

04.2–19.0–051

SCR PANEL 2357S

LIFT PUMP

Crown 1988 PF-7768 Rev. 5/96

Printed in U.S.A.

02 REV. 5/96

04.2–19.0–100

SCR PANEL 102803 PUMP SCR PANEL Index Part No. 1 2 3 4 5 6

7 8 9 10 11 12 13 14 15

17 18 19 20 21 22 23 24

25 26 27 28 29 30

32 33 34

Part Name

103002 103011 103013 103024 103329 060005-003 060030-004 103027 103025 105580 103015 079812 103004 093983 105583 103012 103328 060005-005 060030-044 103324 060005-008 060030-017 103008 103007 103026 103018 103017 103019 103016 103325 060005-003 060030-004 103009 103006 093983 103022 103023 103021 060030-017 060005-008 103327 103326 060005-007 060030-010 103005 079813 116205

Heatsink Spider Assembly With Leads Lead Snubber Screw W/Lockwasher Screw Lockwasher Flatwasher Screw W/Lockwasher Screw W/Lockwasher Card Assembly Oscillator Strap Mounting Capacitor Insulator Grease Silicone Kit 1 REC Includes Index 12 Thermal Protector Screw Lockwasher Flatwasher Screw Lockwasher Flatwasher SCR 5 REC SCR 2 REC Screw W/Lockwasher Bar Bus Bar Bus Bar Bus Bar Bus Screw Lockwasher Flatwasher Reactor Insulator Grease Silicone Heatsink Post Terminal Shunt & Wire Flatwasher Lockwasher Nut Screw Lockwasher Flatwasher Bushing Insulating Diode 3 REC Boot Insulator

No. Req. 1 1 1 3 4 1 1 1 6 8 1 2 1 1 1 1 1 5 5 5 3 3 3 1 1 4 1 1 1 1 4 4 4 1 1 1 1 1 1 2 2 2 1 1 1 3 1 4

Always Specify Model & Serial Number MISCELLANEOUS 105582

Wire Harness Not Shown

1 4998 Printed in U.S.A.

02 REV. 5/96

04.2–19.0–101

STEERING SERVO MOTOR CONTROL 0427S

109331-003 STEERING SERVO PANEL ASSEMBLY (72 V.) 109331-004 STEERING SERVO PANEL ASSEMBLY (48 V.) Index Part No. 1 2

4 5 6 7

Part Name

092653 Cover 060015-045 Screw 1/4 " 062033-015 Resistor 060011-010 Screw #4 060005-036 Lockwasher 110549 Card 060012-007 Screw #6 060005-048 Lockwasher 060015-003 Screw 1/4" 060030-012 Washer 078953-001 Stand-off 109712 Label 109276 Bar Buss

891106 Crown 1991 PF-9074

4.2 - 19 - 152

No. Req. 1 4 1 2 2 1 5 5 1 1 1 1 2

Index Part No. 8 9

10 11 12 13 14

Part Name

No. Req.

108937 Cable Assembly 1 062033-018 Resistor (Used on 72 V. Trucks) 2 062033-029 Resistor (Used on 48 V. Trucks) 2 060011-010 Screw #4 4 060005-036 Lockwasher 4 062413 Module 2 071200-002 Connector 1 060014-024 Screw #10 4 060005-005 Lockwasher 4 060015-045 Screw 1/4" 1 107977 Box Servo 1 Always Specify Model & Serial Number

33006 Printed in U.S.A.

4.2 - 19 - 152

STEERING SERVO MOTOR CONTROL 0427S

109331-003 STEERING SERVO PANEL ASSEMBLY (72 V.) 109331-004 STEERING SERVO PANEL ASSEMBLY (48 V.) Index Part No. 1 2

4 5 6 7

Part Name

092653 Cover 060015-045 Screw 1/4" 062033-015 Resistor 060011-010 Screw #4 060005-036 Lockwasher 111268 Card 062161 Jumper 060012-007 Screw #6 060005-048 Lockwasher 060015-003 Screw 1/4" 060030-012 Washer 078953-001 Stand-off 109712 Label 109276 Bar Bus

No. Req. 1 4 1 2 2 1 1 5 5 1 1 1 1 2

Index Part No. 8 9

10 11 12 13 14

920612

Part Name

No. Req.

108937 Cable Assembly 062033-018 Resistor Used on 72 V. Trucks 062033-028 Resistor Used on 48 V. Trucks 060011-010 Screw #4 060005-036 Lockwasher 062413 Module 071200-002 Connector 060014-024 Screw #10 060005-005 Lockwasher 060015-045 Screw 1/4" 107977 Box Servo

1 2 2 4 4 2 1 4 4 1 1

Always Specify Model & Serial Number

4897

Crown 1992 PF-9434 Rev. 1/96

Printed in U.S.A.

01 REV. 1/96

04.2–19.0–153

This page available for NOTES.

ELECTRONIC BOX — POWER UNIT 0658S

44 43

39 40 38

41 35

31 30

Crown 1991 PF-9138 Rev. 6/92

Printed in U.S.A.

01 REV. 6/92

4.3 - 19 - 003

ELECTRONIC BOX — POWER UNIT ELECTRONIC BOX ASSEMBLY (COMPLETE) Part No.

Equipped With

112046-001-XX 112046-002-XX 112046-003-XX 112046-004-XX

Wire Guidance with 2.2.0 Firmware Rail Guidance with 2.2.0 Firmware Wire Guidance and End Aisle Control w/2.4.0 Firmware Rail Guidance and End Aisle Control w/2.4.0 Firmware

XX = Service Terminal Language: -01 German (EEC), -02 French (EEC), -03 Spanish (EEC), -04 Dutch (EEC), -05 Italian (EEC), -06 English (EEC), -12 English (ANSI)

ELECTRONIC BOX SUB-ASSEMBLY (LESS CARDS) 112059-001 112059-002 112059-003 112059-004 Index Part No. 1 2 3 4

5 6 7 8 9 10

12 13 14 15 16 17 18 19 20 21 22 23

Part Name

WIRE GUIDANCE RAIL GUIDANCE WIRE GUIDANCE AND END AISLE CONTROL RAIL GUIDANCE AND END AISLE CONTROL No. Req.

112075 Label Card Part Number 112076 Label Card Position 104797 Label Shock 060021-006 Nut 1/4" 060005-007 Lockwasher 060030-012 Flatwasher 105435 Cover 112060 Box Electronic 102138 Bar Spacer 103966 Board Mother 102137 Bar Spacer 062265-001 Guide Card - R.H. 062265-002 Guide Card - L.H. (Shown) 060027-017 Rivet Harness Wiring (See Wiring Diagrams-Section DIA) 061003-003 Tie Cable 107665 Mount Vibration 060005-006 Lockwasher 060021-006 Nut 1/4" 062213 Cap Receptacle 060012-007 Screw #6 060005-003 Lockwasher 060011-013 Screw #4 060005-036 Lockwasher 105606-401 Label 105606-402 Label 105606-403 Label 105606-404 Label 105606-405 Label 105606-406 Label

1 1 2 2 2 2 1 1 2 1 2 11 11 44

4 4 8 8 1 40 40 8 8 1 1 1 1 1 1

Index Part No. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

910812

Part Name

No. Req.

105606-407 Label (Wire Guidance) 1 105606-408 Label (Wire Guidance) 1 105606-409 Label 1 060021-003 Nut (Rail Guidance) 8 102777 Cover (Rail Guidance) 2 112065 Cover (without End Aisle Control)1 103986 Card Quad Driver (QD-3) 1 103986 Card Ouad Driver (QD-2) 1 103986 Card Quad Driver (QD-1) 1 104367 Card Servo R/L 1 103961 Card Linear Conv. 1 103905 Card Digital 1 104636 Card Sensor Amplifier (Wire Guidance) 2 112174 Card End Aisle Control 1 103994 Card Serial Link 1 103931 Card CPU (Less ROM’s) 1 ROM (See Note) 1 062007-047 Terminal 2 094866-001 Wire (Quantity Specifies Length) 4 101497 Label 1 104742 Label 1 Label (Contact Factory Authorization Required) Always Specify Model & Serial Number Note: Use the Service Terminal to verify part number of ROM’s.

3769A-36603 Printed in U.S.A.

01 REV. 6/92

4.3 - 19 - 004

ELECTRONIC BOX 5672S

POWER UNIT 22 Rotated View

20 19

1 15 2

26 25 28 24

16 27

43 43

3 6 3 42 4

13 16 7 39

15 40

38 37

9 36 35 34

14 41

13 33 32

30 29

11 10

Crown 1993 PF9996 Rev. 5/02

Printed in U.S.A.

04 REV. 5/02

04.3–19.0–005

ELECTRONIC BOX ELECTRONIC BOX ASSEMBLY (COMPLETE)

Index Part No. 1 2 3 4

5 6 7 8 9 10

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Part No. 112046-001-XX 112046-002-XX 112046-003-XX 112046-004-XX 117322-001-XX 117322-002-XX 117322-003-XX 117322-004-XX

Equipped With Wire Guidance, TF Mast, 2.6.0 Firmware Rail Guidance, TF Mast, 2.6.0 Firmware Wire Guidance, End Aisle Control, TF Mast, 2.6.0 Firmware Rail Guidance, End Aisle Control, TF Mast, 2.6.0 Firmware Wire Guidance, TN Mast, 2.6.0 Firmware Rail Guidance, TN Mast, 2.6.0 Firmware Wire Guidance, End Aisle Control, TN Mast, 2.6.0 Firmware Rail Guidance, End Aisle Control, TN Mast, 2.6.0 Firmware

Part Name

No. Req.

112075 Card Part Number 1 112076 Card Position ANSI 1 801881-XXX Card Position EEC 1 069019 Danger High Voltage ANSI 2 869019-XXX Danger High Voltage EEC 2 060021-006 Nut 2 060005-007 Lockwasher 2 060030-012 Flatwasher 2 105435 Cover 1 112060 Box Electronic 1 102138 Bar Spacer 2 103966 Board Mother ANSI 1 122383 Board EEC 1 102137 Bar Spacer 2 062265-001 Guide Card R.H. 11 062265-002 Guide Card L.H. Shown 11 060027-017 Rivet 44 Harness Wiring See Wiring Diagrams-Section DIA 061003-003 Tie Cable 4 107665 Mount Vibration 4 060005-006 Lockwasher 8 060021-006 Nut 8 062213 Cap Receptacle 1 060012-007 Screw 40 060005-003 Lockwasher 40 060011-013 Screw 8 060005-036 Lockwasher 8 105606-401 Label 1 105606-402 Label 1 105606-403 Label 1 105606-404 Label 1 105606-405 Label 1 105606-406 Label 1 105606-407 Label Wire Guidance 1 105606-408 Label Wire Guidance 1 105606-409 Label 1 060021-003 Nut Rail Guidance 8 102777 Cover Rail Guidance 2 112065 Cover without End Aisle Control 1

Index Part No. 29 30 31 32 33 34 35

Part Name

No. Req.

103986 103986 103986 104367 103961 103905 104636

Card Quad Driver QD-3 Card Ouad Driver QD-2 Card Quad Driver QD-1 Card Servo R/L Card Linear Conv. Card Digital Card Sensor Amplifier Wire Guidance 112174-00S Card End Aisle Control 103994 Card Serial Link ANSI 122387 Card Serial Link EEC 103931 Card CPU Less ROM’s ANSI 123306 Card CPU Less ROM’s EEC ROM See Note 062007-047 Terminal 094866-001 Wire Quantity Specifies Length 069249 Warning Static 801363-XXX Warning Static 069012 Warning Electrical Additions ANSI 869012-XXX Warning Electrical Additions EEC

36 37 38 39 40 41 42 43

1 1 1 1 1 1 2 1 1 1 1 1 1 2 4 1 1 2 2

Always Specify Model, Data & Serial Numbers XXX or XX Choice of dash no, depends on language. When ordering, refer to the chart below and complete the part no. with the correct dash no. First Dash No.

Second Dash No.

Language

001 002 003 004 005 006

01 02 03 04 05 06

German French Spanish Dutch Italian English

Example: If index 43 with German language is required, order 869012-001.

931015

Note: Use the Service Terminal to verify part number of ROM’s. 3012 - EO7041 Printed in U.S.A.

04 REV. 5/02

04.3–19.0–006

ELECTRONIC BOX 1350S

PLATFORM

Crown 1988 PF-7784 Rev. 6/92

Printed in U.S.A.

03 REV. 6/92

4.3 - 19 - 100

ELECTRONIC BOX 102527-XXX ELECTRONIC BOX ASSEMBLY with End Aisle Control and 2.4.0 Firmware 114762-XXX ELECTRONIC BOX ASSEMBLY with 2.2.0 Firmware 102523 ELECTRONIC BOX SUB-ASSEMBLY (Less Cards) XXX = Service Terminal Language: -001 German (EEC), -002 French (EEC), -003 Spanish (EEC), -004 Dutch (EEC), -005 Italian (EEC), -006 English (EEC), -012 English (ANSI) Index Part No. 1 2

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Part Name

No. Req.

094678 Cover 060021-006 Nut 060005-007 Lockwasher 060030-012 Washer 105910 Label Card Position 105909 Label Card Part Number 102187 Box Weldment 102243 Bar Spacer 060013-013 Screw #8 105202 Pad Seal 102242 Card Resistor Pull-up 062213 Cap Receptacle 060011-003 Screw #4 060005-036 Lockwasher 105606-303 Label 105606-302 Label 105606-301 Label 105606-306 Label 105606-305 Label 105606-304 Label 102184 Bar Spacer 103963 Board Mother 102183 Bar Spacer 062265-001 Guide Card - R.H. 062265 002 Guide Card - L.H. (Shown) 060027-017 Rivet

1 2 2 2 1 1 1 2 4 1 1 1 6 6 1 1 1 1 1 1 2 1 2 9 9 36

Index Part No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Part Name

No. Req.

060012-007 Screw #6 060005-003 Lockwasher 101497 Label 104742 Label 104797 Label 105796 Harness Wiring 061003-003 Tie Cable 103986 Card Quad Driver 103982 Card Lamp Driver 103922 Card Encoder 103931 Card CPU (Less ROM's) ROM (See Note) 103994 Card Serial Link 103972 Card 32 Input 108031 Cover 104401-002 Stand-Off 060013-030 Screw 060005-033 Lockwasher 060030-045 Washer

24 24 1 1 1 1 3 1 1 1 1 2 1 1 1 4 4 8 8

Always Specify Model & Serial Number Note - Use the Service Terminal to verify part number of ROM's.

3769A-36603 Printed in U.S.A.

03 REV. 6/92

4.3 - 19 - 101

ELECTRONIC BOX 5673S

PLATFORM

36 37 38

32 6

7 5

10 11 12 13

19 23

14 15 16

31 30 29 28 27

Crown 1993 PF9997 Rev. 4/99

Printed in U.S.A.

03 REV. 4/99

04.3–19.0–102

ELECTRONIC BOX 114762-XXX ELECTRONIC BOX ASSEMBLY, TF MAST, 2.6.0 FIRMWARE 117324-XXX ELECTRONIC BOX ASSEMBLY, TN MAST, 2.6.0 FIRMWARE Index Part No. 1 2

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

21 22 23

24 25

Part Name

No. Req.

094678 Cover 060021-006 Nut 060005-007 Lockwasher 060030-012 Washer 105910 Card Position 105909 Card Part Number 102187 Box Weldment 102243 Bar Spacer 060013-013 Screw 105202 Pad Seal 102242 Card Resistor Pull-up 062213 Cap Receptacle 060011-003 Screw 060005-036 Lockwasher 105606-303 Label 105606-302 Label 105606-301 Label 105606-306 Label 105606-305 Label 105606-304 Label 102184 Bar Spacer 103963 Board Mother ANSI 122390 Board Mother EEC 102183 Bar Spacer 062265-001 Guide Card R.H. 062265 002 Guide Card L.H. Shown 060027-017 Rivet 060012-007 Screw 060005-003 Lockwasher 069249 Warning Static ANSI 801363-XXX Warning Static EEC 069012 Warning Electrical Additions ANSI 869012-XXX Warning Electrical Additions EEC 069019 Danger High Voltage ANSI 869019-XXX Danger High Voltage EEC 105796 Harness Wiring 061003-003 Tie Cable

1 2 2 2 1 1 1 2 4 1 1 1 6 6 1 1 1 1 1 1 2 1 1 2 9 9 36 24 24 1 1

Index Part No. 26 27 28 29

No. Req.

103986 103982 103922 103931 123306

Card Quad Driver Card Lamp Driver Card Encoder Card CPU Less ROM’s ANSI Card CPU Less ROM’s EEC ROM See Note 103994 Card Serial Link ANSI 122387 Card Serialk Link EEC 103972 Card 32 Input 108031 Cover 104401-002 Stand-Off 060013-030 Screw 060005-033 Lockwasher 060030-045 Washer 105606-519 Label CA 105606-520 Label CA 105606-521 Label CA 105606-522 Label CA

30 31 32 33 34

35 36 37 38

1 1 1 1 1 2 1 1 1 1 4 4 8 8 1 1 1 1

Always Specify Model, Data & Serial Numbers XXX Choice of dash no, depends on language. When ordering, refer to the chart below and complete the part no. with the correct dash no.

1 1 1 1 1 3

Part Name

First Dash No.

Language

001 002 003 004 005 006

German French Spanish Dutch Italian English

Example: If index 23 with German language is required, order 869012-001. Note - Use the Service Terminal to verify part number of ROM's.

6073 - 45613/45771 Printed in U.S.A.

03 REV. 4/99

04.3–19.0–103

ELECTRICAL SYSTEM Line Driver Line Driver

Figure 14341

04.3-19.0-550 03 Rev. 6/06

Crown 1987 PF7823-1 Rev. 6/06

ELECTRICAL SYSTEM Line Driver INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 . . . . . . . . . . . . . . . . . . . . . . Line Driver Assembly See Chart 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 . . . . . . . . 105822. . . . . . . . . . . . Panel Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . . . . 105818. . . . . . . . . . . . Lamp Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . Lockwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 . . . . . . . . 105816. . . . . . . . . . . . Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 . . . . . . . . 105817-001 . . . . . . . . Indicator Lens Amber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 . . . . . . . . 105817-002 . . . . . . . . Indicator Lens Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 . . . . . . . . 105830. . . . . . . . . . . . Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . . . . . . . . . . 106012 . . . . . . . . . . . Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 . . . . . . . . 060005-045 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9 . . . . . . . . 060014-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 10 . . . . . . . . 069454. . . . . . . . . . . . Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11 . . . . . . . . 105969. . . . . . . . . . . . Cover Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12 . . . . . . . . 092396. . . . . . . . . . . . Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHART 1 Index 0 Line Drive Assembly

Unit Voltage

Unit Frequency

105824-001

120 VAC

5.2 KHZ

105824-002

230/240 VAC

5.2 KHZ

105824-003

120 VAC

6.25 KHZ

105824-004

230/240 VAC

6.25 KHZ

105824-005

120 VAC

7.0 KHZ

105824-006

230/240 VAC

7.0 KHZ

105824-007

120 VAC

10.0 KHZ

105824-008

230/240 VAC

10.0 KHZ

Always Specify Model, Data & Serial Number Crown 1987 PF7823-2 Rev. 6/06

04.3-19.0-551 03 Rev. 6/06

ELECTRICAL SYSTEM Line Driver

Figure 14342

04.3-19.0-552 03 Rev. 6/06

Crown 1987 PF7823-3 Rev. 6/06

ELECTRICAL SYSTEM Line Driver INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

20 . . . . . . . . 111111 . . . . . . . . . . . . Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 21 . . . . . . . . 108269. . . . . . . . . . . . Battery Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 102584 . . . . . . . . . . . Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 108291 . . . . . . . . . . . Wiring Harness (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 22 . . . . . . . . 111105 . . . . . . . . . . . . Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 23 . . . . . . . . 060030-012 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 24 . . . . . . . . 060015-073 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 25 . . . . . . . . 105864. . . . . . . . . . . . Shock Hazard Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 26 . . . . . . . . 105667. . . . . . . . . . . . Line Driver Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 27 . . . . . . . . 108268. . . . . . . . . . . . Power Supply 12 V.D.C.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 108267 . . . . . . . . . . . Wiring Harness (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 28 . . . . . . . . 060005-004 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 29 . . . . . . . . 060013-005 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 30 . . . . . . . . 062488-008 . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 31 . . . . . . . . 102559. . . . . . . . . . . . Line Driver Card (Less Oscillator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 108266 . . . . . . . . . . . Wiring Harness (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 32 . . . . . . . . 060005-003 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 33 . . . . . . . . 060012-023 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 34 . . . . . . . . 062394-001 . . . . . . . . Oscillator Assembly 5.2 KHZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 062394-002 . . . . . . . . Oscillator Assembly 6.25 KHZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 062394-003 . . . . . . . . Oscillator Assembly 7.0 KHZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 062394-004 . . . . . . . . Oscillator Assembly 10.0 KHZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 35 . . . . . . . . 103687-009 . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 36 . . . . . . . . 094362-004 . . . . . . . . Fuse (Used Only on 100/120 V.A.C. Systems) . . . . . . . . . . . . . . . . . . . . 1 094362-005 . . . . . . . . Fuse (Used Only on 220/240 V.A.C. Systems) . . . . . . . . . . . . . . . . . . . . 1 37 . . . . . . . . 105821. . . . . . . . . . . . Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 38 . . . . . . . . 105866. . . . . . . . . . . . Specifications Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 39 . . . . . . . . 105867. . . . . . . . . . . . Reduce The Risk Of Fire Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . 1

Always Specify Model, Data & Serial Number Crown 1987 PF7823-4 Rev. 6/06

04.3-19.0-553 03 Rev. 6/06

SENSOR BAR 0666

END AISLE CONTROL

14 CA624

13 16 12

CA622 TB627 CA626 7 6

CA625

TB623

22 8

PART OF MAIN FRAME

Crown 1991 PF-9146 Rev. 12/93

4.3 - 19 - 600

Printed in U.S.A.

01 REV. 12/93

4.3 - 19 - 600

SENSOR BAR 112784-001-## Sensor Bar Assembly (North Sensors) 112784-002-## Sensor Bar Assembly (South Sensors) (Does Not Include Index 6, 7, 19, 20, 21 &22) Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part Name

No. Req.

112071-0## Bar Sensor See Note 060016-060 Screw 5/16 " Set 112616 Plug 060000-100 Pin Roll 104401-004 Spacer 061002-001 Clamp 060014-006 Screw #10 060005-005 Lockwasher 113231 Clamp Nylon 060012-061 Screw #6 Nylon 113008 Block Sensor 060016-003 Screw 5/16" 060005-008 Lockwasher 062512-001 Sensor North Standard B1 062512-002 Sensor South B1 062512-001 Sensor North Standard A1 062512-002 Sensor South A1 062512-001 Sensor North Standard A2 062512-002 Sensor South A2 062512-001 Sensor North Standard B2 062512-002 Sensor South B2 060014-005 Screw #10 060005-005 Lockwasher 112390 Board Printed Circuit

1 1 1 1 4 4 4 4 8 8 4 8 8 1 1 1 1 1 1 1 1 8 8 1

Index Part No. 18 19 20 21 22

Part Name

No. Req.

060012-060 Screw #6 060005-003 Lockwasher 069079 Label 113232-0## Cover See Note 060016-018 Screw 5/16 " 060005-008 Lockwasher 060030-017 Flatwasher 060019-050 Screw 1/2 " 060005-012 Lockwasher 060030-059 Flatwasher

4 4 1 1 2 2 2 4 4 4

MISCELLANEOUS 113304

Magnet Floor EAC

Always Specify Model & Serial Number ## = When ordering Index 1 or Index 20, the last two digits of the Part Number corresponds with the Truck’s Load Wheel Over All Width (in inches). Example: Order Sensor Bar 112071-060 for trucks with a Load Wheel Over All Width of 60 inches. The Truck’s Load Wheel Over All Width is stamped on the serial plate.

4239 Printed in U.S.A.

4.3 - 19 - 601

01 REV. 12/93

4.3 - 19 - 601

CONTACTOR 0664S

Crown 1988 PF7753-1 Rev. 11/04

04.4–19.0–001

Printed in U.S.A.

05 REV. 11/04

04.4–19.0–001

CONTACTOR 106842 CONTACTOR ASSEMBLY – 36V. (72 V. UNITS) 107258 CONTACTOR ASSEMBLY – 48V. (48 V. UNITS) Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

15 16 17

Part Name

No. Req.

107355 Link Bent 060059-001 Nut 060005-031 Lockwasher 060059-004 Nut 060005-020 Washer Spring 107351 Screw 107354 Link Straight 107350 Cover Top 114434 Contact Fixed 48 & 72V Units 107352 Spring Return 48V Units 107358 Spring Return 72V Units 107348 Contact Assembly Moving 48 & 72V Units 107359 Fixed Contact Double Special Includes One Connecting Screw Assembly 107360 Fixed Contact Single Includes One Connecting Screw Assembly 107356 Insulator Contact 060063-004 Screw M8 060005-031 Lockwasher 060059-001 Nut 107353 Coil and Frame Assembly 48V Units 107349 Coil and Frame Assembly 72V Units 118935 Cap Armature Spring 094711 Mounting Bracket Includes Index 17 060014-011 Screw 060005-005 Lockwasher

2 4 4 4 4 4 1 2 4 2 2 2 1 2 4 4 4 4 2 2 2 1 4 4

Always Specify Model, Data & Serial Numbers 48 & 72V UNITS 123922

Kit Contact Tip Includes Index 7, 9, 10 & 11

ALBRIGHT

9658

Crown 1988 PF7753-2 Rev. 11/04

04.4–19.0–002

Printed in U.S.A.

05 REV. 11/04

04.4–19.0–002

CONTACTOR ASSEMBLY 3005S

102061 CONTACTOR ASSEMBLY Index Part No. 1 2 3 4 5 6 7 8 9 10

Part Name

No. Req.

060059-001 Nut 060005-031 Lockwasher 060059-004 Nut Half Washer Spring 105538 Screw 105537 Cover Top 106010 Spring Return 105535 Contact Fixed Includes Index 1 thru 4 105536 Contact Assembly Moving 105541 Coil 48V.

2 2 2 2 2 1 1

Index Part No. 11 12 13

2 1 1

Albright

No. Req.

106011 Bracket Mounting 060005-004 Lockwasher 060014-011 Screw 105540 Insulator Spring

1 2 2 1

Always Specify Model & Serial Number MISCELLANEOUS 120089

Kit Contact Tip Includes Index 8 & 9

1 4565 Printed in U.S.A.

Crown 1988 PF-7754 Rev. 3/95

04.4–19.0–050

Part Name

01 REV. 3/95

04.4–19.0–050

CONTACTOR ASSEMBLY 1195S

26 8

22 25 21 20

7 18

5 12

13 4 3

11 2

1 10

Crown 1988 PF-7818 Rev. 2/92

Printed in U.S.A.

01 REV. 2/92

4.4 - 19 - 100

CONTACTOR ASSEMBLY 102063 CONTACTOR ASSEMBLY Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Part Name

No. Req.

106017 Base Frame 1 064019-038 O-Ring 1 106018 Coil (48 V. [lncludes Index 2]) 1 104553 Varistor 1 106019 Screw (w/Lockwasher) 4 106020 Frame Sub-Assembly (Includes Indexes 1 thru 7) 1 106089 Spring 1 106090 Guide 2 106091 Armature 1 106092 Insulator Lower 1 106093 Plate Mounting 1 104560 Screw 4 106094 Insulator Upper 1 106095 Contacts Fixed 2 060005-034 Lockwasher 2 060005-031 Lockwasher 2 060016-002 Screw 5/16" 2 060013-031 Screw #8 2 106097 Insulator 2 060030-096 Flatwasher 2 060054 Lockwasher 2 060013-011 Screw #8 2 060030-217 Flatwasher 2 104564 Shim AR 106098 Guide Movable Contact 1 106099 Contact Movable 1 106100 Spring 1 106101 Insulator Spring 1 104569 Flatwasher Fiber 1 060030-217 Flatwasher 1 060005-005 Lockwasher 1 104570 Locknut 1 106102 Kit Contact Replacement (Includes Indexes 14,19 & 25 thru 28 [Not Shown]) 1 Always Specify Model & Serial Number

Printed in U.S.A.

01 REV. 2/92

4.4 - 19 - 101

CONTACTOR 1513

4 5

9 10 11

2 13 14 8 3

15 7

114393 CONTACTOR ASSEMBLY Index Part No.

Part Name

1 2 3 4 5 6 7 8 9 10 11

Coil 48V Suppressor Incl. Plate Mounting Locknut Hex Screw #8 Flatwasher Bar Bus Lockwasher Ex. Tooth Spacer Bushing Bridge Spring

115632 115664 60042-015 60013-003 60030-217 115628 60005-034 115629 115627 115626 115625

No. Req. 1 1 1 4 4 2 4 2 1 1 1

Index Part No.

Part Name

No. Req.

12 13 14 15

Washer Fiber Screw 5/16" Lockwasher Screw #8

1 4 4 4

920629

115624 60016-002 60005-031 60013-013

MISCELLANEOUS 115631

Service Tip Kit Includes Index 6 thru 15

Always Specify Model & Serial Number

5187

Crown 1992 PF-9491 Rev. 10/96

Printed in U.S.A.

01 REV. 10/96

04.4–19.0–102

CONTACTOR 1513-01

TS, TSP

9 10 11

2 16

13 14 8

Model

Function

ED, P1, P2, P3

TSP

ED, P1, P2, P3

Crown 1998 PF11475 Rev. 9/03

04.4–19.0–103

Printed in U.S.A.

01 REV. 9/03

04.4–19.0–103

CONTACTOR 125476 36V CONTACTOR ASSEMBLY Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part Name

No. Req.

115632 Coil Suppressor Included 115664 Plate Mounting 060042-015 Locknut Hex 060013-003 Screw 060030-217 Flatwasher 115628 Bar Bus 060005-034 Lockwasher Ex. Tooth 115629 Spacer 115627 Bushing 115626 Bridge 115625 Spring 115624 Washer Fiber 060016-002 Screw 060005-031 Lockwasher 060013-013 Screw 131156 Spring

1 1 1 4 4 2 4 2 1 1 1 1 4 4 4 1

Always Specify Model, Data & Serial Numbers 115631

Kit Contact Includes Index 2 & 6 thru 15

970929

6518 - EO9583 Printed in U.S.A.

04.4–19.0–104

01 REV. 9/03

04.4–19.0–104

CONTROL LINKAGE - L.H. 3765S

11 A

55 10 13

Extend Override Option

Crown 1988 PF7798 Rev. 6/99

Printed in U.S.A.

07 REV. 6/99

04.5–19.0–001

CONTROL LINKAGE - L.H. Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30 31

Part Name

No. Req.

104493 Housing Control 104912 Lens 094610-004 Insert Pivot 094610-005 Insert Traverse 094610-003 Insert Raise 104622 Cover Knob 104623 Insert Side 104966 Insert Side 104975 Knob Control Lever 108693 Spring Compression 060032-038 Screw Self Tapping 060005-018 Lockwasher 104967 Switch AXS 104626 Button Switch 104760-002 Rod Adjusting 060021-007 Nut 102594-001 Ball Joint Rod End 060005-007 Lockwasher 060009-003 Ring Retaining 104488 Shaft Lever Pivot 060030-021 Flatwasher 065007-032 Bearing Sleeve 104482 Lever Control Auxiliary 107174 Lever Assembly Includes Index 9 Auxiliary 118182 Lever Assembly Includes Index 9 Extend Override 060030-021 Flatwasher 071909-002 Block Terminal TB526 105605-526 Label 071909-002 Block Terminal TB527 105605-527 Label 060013-005 Screw 060005-004 Lockwasher 086360-004 Strip Marking 060015-003 Screw 060005-022 Lockwasher 105780 Support Lever 060015-056 Screw 060005-006 Lockwasher 104760-001 Rod Adjusting

1 3 1 1 1 3 4 1 3 2 2 2 1 1 1 2 2 2 2 1 AR 5 2

Index Part No. 32 33 34

35 36 37 38 39

40 41 42 43 44 45 46 47

2 1 1 1 1 1 1 4 4 2 1 1 1 3 3 1

48 49 50 51

52 53 54 55

Part Name

No. Req.

060030-021 Flatwasher 060014-022 Screw 060005-045 Lockwasher 104437 Lever Control 107200 Lever Assembly Includes Index 9 & 35 060000-060 Pin Roll 088611-001 Collar 090400 Spring Torsion 104417 Spring Retainer 060016-004 Screw 060005-008 Lockwasher 060030-017 Flatwasher 060015-007 Screw 060005-007 Lockwasher 108109 Bar 104434 Shaft Lever Pivot 060014-053 Screw 104422 Support Lever 060015-056 Screw 060005-006 Lockwasher 065007-012 Bearing Sleeve 060015-046 Screw 060030-012 Flatwasher 060005-022 Lockwasher 104405 Bracket Alignment Nut Lockwasher 104379 Retainer 116818 Encoder ECR2 Includes Index 49 062007-065 Terminal 065003-170 Sleeving 105730 Grommet 060046-014 Washer Spring 060000-036 Pin Roll 104967 Switch Extend Override

1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 5 AR 3 2 1 1

Always Specify Model, Data & Serial Numbers

6138 - 45962 Printed in U.S.A.

07 REV. 6/99

04.5–19.0–002

SPEED CONTROLS 0420S

Crown 1988 PF-7799 Rev. 5/91

Printed in U.S.A.

03 REV. 5/91

4.6 - 19 - 001

SPEED CONTROLS 104620 SPEED CONTROL ASSEMBLY Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Part Name

No. Req.

107051 Button Palm 1 108693 Spring Compression 10 104406 Block Mounting 1 094605 Switch (DMS-1) 1 060010-008 Screw 2 060005-001 Lockwasher 2 105480 Cover 1 060012-049 Screw 7 061021-002 Bushing Snap 1 104403 Grip Assembly Hand 1 060000-004 Roll Pin 1 094605 Switch (ORS) 1 094605 Switch (HNS) 1 107048 Button Horn 1 107049 Button Override 1 071909-002 Block Terminal (TB-510) 1 105605-510 Label 1 071909-002 Block Terminal (TB-509) 1 105605-509 Label 1 060013-005 Screw 4 060005-004 Lockwasher 4 086360-004 Strip Marking 2 104478 Bracket 1 060015-003 Screw 2 060005-007 Lockwasher 2 102347 Housing Speed Control 1 107050 Button Emergency Disconnect 1 060030-145 Washer 1 105304 Bushing 1

Index Part No. 25 26 27 28 29 30 31 32 33 34 35 36 37

38 39 40 41

42 43

Part Name

No. Req.

060000-002 Roll Pin 060030-020 Washer 088611-002 Collar 108531 Spring Torsion 060030-207 Washer 105300 Shaft 060014-053 Screw Set Nut Lockwasher 104379 Retainer 104184-001 Encoder (ECR-3) [Includes Index 32] 104401-002 Spacer 061004-020 Thread Locking Adhesive 105305 Retainer 060013-004 Screw 060005-033 Lockwasher 060030-096 Washer 094605 Switch (EDS) 060010-007 Screw 060005-001 Lockwasher 105306 Bar 060015-007 Screw 060005-007 Lockwasher 060030-204 Washer 105474 Cover 108229 Bar

1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 6 2 2 2

Always Specify Model & Serial Number

32582 Printed in U.S.A.

03 REV. 5/91

4.6 - 19 - 002

SPEED CONTROLS 5380

Components Installed Inside Housing Cavity

B 2 5

7 6

39 11

47 46 17

30 31

33 34 32

22 2

35 36 37

39 38

15 18

42 21 19

Crown 1991 PF9149 Rev. 6/99

Printed in U.S.A.

05 REV. 6/99

04.6–19.0–003

SPEED CONTROLS 113026-001 SPEED CONTROL ASSEMBLY 30 TSP 113026-002 SPEED CONTROL ASSEMBLY (END AISLE CONTROL) 30 TSP 113026-003 SPEED CONTROL ASSEMBLY 1.5 TSP 113026-004 SPEED CONTROL ASSEMBLY (END AISLE CONTROL) 1.5 TSP Index Part No. 1 2

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

107051 108693 108693

Part Name

No. Req.

Button Palm 1 Spring 30 TSP 10 Spring End Aisle Control 30 TSP 12 108693 Spring 1.5 TSP 6 108693 Spring End Aisle Control 1.5 TSP 8 104406 Block Mounting 1 094605 Switch DMS-1 1 060010-008 Screw 2 060005-001 Lockwasher 2 112070 Cover 1 060012-049 Screw 7 061021-002 Bushing Snap 1 104403 Grip Assembly Hand 1 060000-004 Roll Pin 1 094605 Switch ORS 1 094605 Switch HNS 1 107048 Button Horn 1 112988 Button Override 1 071909-002 Block Terminal TB-510 1 105605-510 Label 1 071909-002 Block Terminal TB-509 1 105605-509 Label 1 060013-005 Screw 4 060005-004 Lockwasher 4 086360-004 Strip Marking 2 104478 Bracket 1 060015-003 Screw 2 060005-007 Lockwasher 2 113048 Housing Speed Control 30 TSP 1 122805 Housing Speed Control 1.5 TSP 1 107050 Button Emergency Disconnect 30 TSP 1 060030-145 Washer 1 105304 Bushing 1 060000-002 Roll Pin 1 060030-020 Washer 2 088611-002 Collar 2 108531 Spring Torsion 1

Index Part No. 29 30 31 32

Part Name

No. Req.

060030-207 Washer 1 105300 Shaft 1 060014-053 Screw Set 1 Nut 1 Lockwasher 1 104379 Retainer 1 116818 Encoder ECR-3 Includes Index 32 1 062007-065 Terminal 5 104401-002 Spacer 1 061004-020 Thread Locking Adhesive 1 105305 Retainer 1 060013-004 Screw 1 060005-033 Lockwasher 1 060030-096 Washer 1 094605 Switch EDS 30 TSP 1 060010-007 Screw 30 TSP 8 060005-001 Lockwasher 30 TSP 8 060010-007 Screw 1.5 TSP 6 060005-001 Lockwasher 1.5 TSP 6 105306 Bar 1 060015-007 Screw 2 060005-007 Lockwasher 2 060030-204 Washer 2 105474 Cover 1 108229 Bar 1 112989 Button Reset End Aisle Control 1 112990 Button Black Blank 1 094605 Switch ORS-4 End Aisle Control 1 113025 Retainer Used Instead of Switch on Truck Equipped Without End Aisle Control 1 113047 Block Retainer 1 060013-010 Screw 1 060005-004 Lockwasher 1 122803 Switch Emergency Disconnect 1.5 TSP 1 090651-008 Plug 1.5 TSP 1

33 34

35 36 37

38 39

40 41

42 43 44 45

46 47 48 49

Always Specify Model, Data & Serial Numbers

910812

6138 - 45962 Printed in U.S.A.

05 REV. 6/99

04.6–19.0–004

STEERING FEEDBACK 2672S

Crown 1988 PF8112 Rev. 6/99

Printed in U.S.A.

07 REV. 6/99

04.8–19.0–001

STEERING FEEDBACK Index Part No. 1 2

3 4 5 6

7 8 9 10 11 12 13 14

Part Name

No. Req.

065004-017 Grommet 1 060015-012 Screw 4 060005-007 Lockwasher 4 060030-012 Flatwasher 4 107232 Cover 1 116818 Encoder ECR5 Includes Index 8 1 062007-065 Terminal 5 104378 Pin Taper 1 060015-012 Screw 3 060005-007 Lockwasher 3 060030-012 Flatwasher 3 104379 Retainer 1 Lockwasher 1 Nut 1 104380 Pate pivot 1 104486 Spring Compression 1 065081-050 Bearing Ball 2 107233 Bracket Mounting 1 108027 Plate 1 060013-012 Screw 2 060005-004 Lockwasher 2 061004-020 Adhesive Thread Locking AR 109481 Pulley Timing Belt 1 060012-043 Screw Set 2

Index Part No. 16 17

Part Name

No. Req.

103601-006 Bearing Nyliner 109482 Pulley Timing Belt 060013-023 Screw Set 107228 Belt Timing 079564-003 Block Terminal TB613 105605-613 Label 060012-027 Screw 060005-003 Lockwasher 079565-003 Strip Marking 107234 Plate Mounting 065007-014 Bearing Sleeve 088611-002 Collar 083133 Spring Torsion 060030-018 Flatwasher 060009-008 Ring Retaining 109698 Shaft 060030-012 Flatwasher 060030-040 Flatwasher 108532 Spring Torsion 109697 Mica Strip Heater Freezer/Corrosion 060015-012 Screw Freezer/Corrosion 060030-012 Flatwasher Freezer/Corrosion 060005-007 Lockwasher Freezer/Corrosion

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

2 1 2 1 1 1 2 2 1 1 1 2 1 1 1 1 1 1 1 2 2 4 2

Always Specify Model, Data & Serial Numbers

6138 - 45962 Printed in U.S.A.

07 REV. 6/99

04.8–19.0–002

LIMIT SWITCH 2285

1 2

7 4

8 9 5

15 11

12 13 12

107335-001 UPPER SWITCH LMS2 107335-002 LOWER SWITCH LMS1 107335-003 UPPER FREEZER/CORROSION SWITCH (Shown) LMS2 107335-004 LOWER FREEZER/CORROSION SWITCH LMS1 Index Part No. 1 2 3 4 5 6 7 8

Part Name

No. Req.

060013-012 Screw #8 2 060005-004 Lockwasher 2 107564 Bracket Upper Shown 1 107565 Bracket Lower 1 077656 Switch Staging LMS-2 Shown TF Only 1 077656 Switch Reset LMS-1 1 102646 Plate Resistor Freezer/Corrosion1 060021-004 Nut 2 107570 Actuator 1 060005-003 Lockwasher 2

Index Part No. 9 10 11 12 13 14 15

Part Name

No. Req.

060012-023 Screw #6 060012-022 Screw #6 Freezer/Corrosion 060038-002 Pin 107571 Pin 060030-116 Flatwasher 082608-001 Roller 062033-013 Resistor RES-16 LMS-1 RES-17 LMS-2 Freezer/Corrosion 060010-004 Screw #2 060005-001 Lockwasher

2 2 1 1 2 1 1 2 2

Always Specity Model & Serial Number 4121E - 37979 Crown 1988 PF-8088 Rev. 9/93

4.8 - 19 - 100

Printed in U.S.A.

01 REV. 9/93

4.8 - 19 - 100

DISPLAY PANEL 2350S

Crown 1988 PF7788 Rev. 5/98

Printed in U.S.A.

05 REV. 5/98

04.8–19.0–200

DISPLAY PANEL Index Part No. 1 2 3 4

5 6

8 9

10 11 12 13

14 15 16

Part Name

No. Req.

105411 Cover Console Post 1 060014-049 Screw #10 10 103688 Frame Switch 5 105452 Frame Switch Used only On Units Equipped With Wire Guidance 1 105420 Cover Adjustable 1 060014-049 Screw #10 1 060005-005 Lockwasher 1 060030-044 Flatwasher 1 107678-002 Panel Display Used On Units Equipped With Wire Guidance 1 107678-004 Panel Display Used On Units Equipped With Rail Guidance 1 107679 Support Assembly Panel 1 107709 Tube Units Equipped With Wire Guidance 11 107709 Tube Units Equipped With Rail Guidance 8 107681 Support Panel 1 060015-025 Screw 1/4" 4 060042-006 Nut 2 092108 Lamp Units Equipped With Wire Guidance 11 092108 Lamp Units Equipped With Rail Guidance 8 107710 Board Assembly Printed Circuit Includes Index 17 & 18 1 062300 LED Bar 4 Position 2 062299 LED Bar 1 Position 1

Index Part No. 17 18 19 20

22 23 24 25 26 27 28 29 30 31

Part Name

No. Req.

062313-001 Socket Feed Thru 1 062172-004 Cable Ribbon 1 104401-004 Spacer 5 092106 Base Lamp Units Equipped With Wire Guidance 11 092106 Base Lamp Units Equipped With Rail Guidance 8 107711-001 Board Assembly Printed Circuit Used On Units Equipped With Wire Guidance Includes Index 27 Thru 31 1 107711-002 Board Assembly Printed Circuit Used On Units Equipped With Rail Guidance Includes Index 27 Thru 30 1 060012-014 Screw #6 8 060005-003 Lockwasher 8 060015-086 Screw 1/4" 2 109149 Block Mounting 2 108770 Cover Bottom 1 060015-073 Screw 1/4" 1 103687-004 Switch SWH1 1 103687-006 Switch FNS 1 103687-007 Switch LGS 2 103687-005 Switch BRS1 1 105532-001 Switch GUS Used Only On Units Equipped With Wire Guidance 1 069005 Label Warning Rider Trucks 1 Always Specify Model & Serial Number

931015

5731 Printed in U.S.A.

05 REV. 5/98

04.8–19.0–201

CONTROL CABLES 2029S

Crown 1991 PF-8196 Rev. 4/93

Printed in U.S.A.

02 REV. 4/93

4.8 - 19 - 500

CONTROL CABLES Index Part No.

Part Name

No. Req.

1 † 083603-001 Cable 2 † 083603-001 Cable 3 071200-002 Connector Water Tight 4 † 083603-002 Cable 5 085430 Grip Cable 6 078613 Spring 7 † 083603-002 Cable 8 † 083603-002 Cable 9 108576 Hose Asm. Gang 5 Hose 2 Cable 10 078613 Spring 11 105449 Grip Cable 12 * Cable Mast Cable #1 Serial 13 * Cable Mast Cable #2 14 * Cable Mast Cable #3 15 107951 Cable Serial 061003-003 Tie Cable

6 6 1 12 1 1 12 12 1 3 3 AR AR AR 1 AR

Always Specify Model and Serial Number †Quantity equals length (in feet) of cable *See Supplemental List

890206

2253 - 33117 Printed in U.S.A.

02 REV. 4/93

4.8 - 19 - 501

CONTROL CABLES

COLLAPSED/LIFT HEIGHT in. mm 125/208 131/220 137/232 143/244 149/256 155/268 161/280 167/292 173/304 179/316 185/328 191/340 197/352 203/364 209/376 215/388 221/400 227/412 233/424 239/436 245/448 251/460 257/472 263/484 269/496

INDEX 12 ‡Cable Assembly Part No.

3175/5285 3325/5590 3480/5890 3630/6200 3785/6500 3935/6805 4090/7110 4240/7415 4395/7720 4545/8025 4700/8330 4850/8635 5005/8940 5155/9245 5310/9550 5460/9855 5615/10160 5765/10465 5920/10770 6070/11075 6225/11380 6375/11685 6530/11990 6680/12295 6830/12600

106118-005 106118-005 106118-006 106118-006 106118-007 106118-007 106118-008 106118-008 106118-009 106118-009 106118-010 106118-010 106118-011 106118-011 106118-012 106118-012 106118-013 106118-013 106118-014 106118-014 106118-015 106118-015 106118-016 106118-017 106118-017

INDEX 12 INDEX 13 & 14 *083603-002 Cable †No. Req. †No. Req. 38.42 38.42 40.42 40.42 42.42 42.42 44.42 44.42 46.42 46.42 48.42 48.42 50.42 50.42 52.42 52.42 54.42 54.42 56.42 56.42 58.42 58.42 59.42 61.42 61.42

39.00 40.00 41.00 42.00 43.00 44.00 45.00 46.00 47.00 48.00 49.00 50.00 51.00 52.00 53.00 54.00 55.00 56.00 57.00 58.00 59.00 60.00 61.00 62.00 63.00

‡Cable Assembly includes cable and plug *This cable can also be purchasd in 250 ft. (75 m) rolls by ordering 083603-088 or 500 ft. (150 m) rolls by ordering 083603-089. †Number Required Equals Length (in Feet) of Cable.

Crown 1991 PF-8196 Rev. 6/93

Printed in U.S.A.

01 REV. 6/93

4.8 - 19 - 500 - SUP

CONTROL CABLES 2029S-02

TF CABLE ROUTING

12 13 14

6.5 in. (165mm)

Crown 1993 PF-9950 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

4.8 - 19 - 502

CONTROL CABLES Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part Name

No. Req.

083603-001 Cable 083603-001 Cable 071200-002 Connector Water Tight 083603-002 Cable 085430 Grip Cable 078613 Spring 083603-002 Cable 083603-002 Cable 108576 Hose Asm. Gang 5 Hose 2 Cable 078613 Spring 105449 Grip Cable * Cable Mast Cable #1 Serial * Cable Mast Cable #2 * Cable Mast Cable #3 107951 Cable Serial 061003-003 Tie Cable

† †

6 6 1 † 12 1 1 † 12 † 12 1 3 3 AR AR AR 1 AR

Always Specify Model and Serial Number †Number Required equals length (in feet) of cable *See the Following Supplemental List

931015

4230A - 37979 Printed in U.S.A.

01 REV. 1/94

4.8 - 19 - 503

CONTROL CABLES COLLAPSED/LIFT HEIGHT In. mm

125/208 131/220 137/232 143/244 149/256 155/268 161/280 167/292 173/304 179/316 185/328 191/340 197/352 203/364 209/376 215/388 221/400 227/412 233/424 239/436 245/448 251/460 257/472 263/484 269/496

INDEX 12 ‡ Cable Assembly Part No. Part No. TF TN 106118-005 106118-005 106118-006 106118-006 106118-007 106118-007 106118-008 106118-008 106118-009 106118-009 106118-010 106118-010 106118-011 106118-011 106118-012 106118-012 106118-013 106118-013 106118-014 106118-014 106118-015 106118-015 106118-016 106118-017 106118-017

118092-001 118092-001 118092-001 118092-001 118092-002 118092-002 118092-003 118092-003 118092-004 118092-004 118092-005 118092-005 118092-006 118092-006 118092-007 118092-007 118092-008 118092-008 118092-009 118092-009 118092-010 118092-010 118092-011 118092-012 118092-012

INDEX 12 INDEX 13 & 14 * Bulk Cable † No. Req. † No. Req. TF TN TF TN 38.42 38.42 40.42 40.42 42.42 42.42 44.42 44.42 46.42 46.42 48.42 48.42 50.42 50.42 52.42 52.42 54.42 54.42 56.42 56.42 58.42 58.42 59.42 61.42 61.42

30.50 30.50 30.50 30.50 32.50 32.50 34.50 34.50 36.50 36.50 38.50 38.50 40.50 40.50 42.50 42.50 44.50 44.50 46.50 46.50 48.50 48.50 50.50 52.50 52.50

39.00 40.00 41.00 42.00 43.00 44.00 45.00 46.00 47.00 48.00 49.00 50.00 51.00 52.00 53.00 54.00 55.00 56.00 57.00 58.00 59.00 60.00 61.00 62.00 63.00

35.00 36.00 37.00 38.00 39.00 40.00 41.00 42.00 43.00 44.00 45.00 46.00 47.00 48.00 49.00 50.00 51.00 52.00 53.00 54.00 55.00 56.00 57.00 58.00 59.00

‡Cable Assembly includes cable and plug

* This cable can also be purchased in bulk as follows: 250 ft. (75mm) Roll TF TN 083603-088 117688-002

500 ft. (150mm) Roll TF TN 083603-089 117688-003

†Number Required Equals Length (in Feet) of Cable.

Crown 1993 PF-9950 Rev. 2/94

Printed in U.S.A.

01 REV. 2/94

4.8 - 19 - 502 - SUP

CONTROL CABLES 2029S-02

TF CABLE ROUTING

12 13 14

6.5 in. (165mm)

Crown 1995 PF10473 Rev. 10/98

Printed in U.S.A.

02 REV. 10/98

04.8–19.0–504

CONTROL CABLES Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Part Name

No. Req.

119203-004 Cable 119203-004 Cable 071200-002 Connector Water Tight 119203-001 Cable 085430 Grip Cable 078613 Spring 119203-001 Cable 119203-001 Cable 108576 Hose Asm. Gang 5 Hose 2 Cable 078613 Spring 105449 Grip Cable * Cable Mast Cable #1 Serial * Cable Mast Cable #2 * Cable Mast Cable #3 107951 Cable Serial 061003-003 Tie Cable

† †

6 6 1 † 12 1 1 † 12 † 12 1 3 3 AR AR AR 1 AR

Always Specify Model, Data and Serial Numbers †Number Required equals length (in feet) of cable *See the Following Supplemental List

950508

5870 - 45114 Printed in U.S.A.

02 REV. 10/98

04.8–19.0–505

CONTROL CABLES COLLAPSED/LIFT HEIGHT In. mm

125/208 131/220 137/232 143/244 149/256 155/268 161/280 167/292 173/304 179/316 185/328 191/340 197/352 203/364 209/376 215/388 221/400 227/412 233/424 239/436 245/448 251/460 257/472 263/484 269/496 275/508 281/520 287/532

30.42 30.42 30.42 30.42 32.42 32.42 34.42 34.42 36.42 36.42 38.42 38.42 40.42 40.42 42.42 42.42 44.42 44.42 46.42 46.42 48.42 48.42 50.42 52.42 52.42 54.42 54.42 56.42

39.00 40.00 41.00 42.00 43.00 44.00 45.00 46.00 47.00 48.00 49.00 50.00 51.00 52.00 53.00 54.00 55.00 56.00 57.00 58.00 59.00 60.00 61.00 62.00 63.00 64.00 65.00 66.00

35.00 36.00 37.00 38.00 39.00 40.00 41.00 42.00 43.00 44.00 45.00 46.00 47.00 48.00 49.00 50.00 51.00 52.00 53.00 54.00 55.00 56.00 57.00 58.00 59.00 60.00 61.00 62.00

‡Cable Assembly includes cable and plug

* This cable can also be purchased in bulk as follows: 250 ft. (75mm) Roll TF TN 119203-003 117688-002

500 ft. (150mm) Roll TF TN 119203-003 117688-003

†Number Required Equals Length (in Feet) of Cable.

Crown 1995 PF10473 Rev. 10/98

Printed in U.S.A.

02 REV. 10/98

04.8–19.0–504-SUP

OVERHEAD CONSOLE - L.H. 2728S

Crown 1989 PF-8468 Rev. 1/94

4.9 - 19 - 052

Printed in U.S.A.

02 REV. 1/94

4.9 - 19 - 052

OVERHEAD CONSOLE - L.H. Index Part No. 1 2 3 4 5 6 7

8 9 10 11 12 13

Part Name

No. Req.

060021-004 Nut 060005-004 Lockwasher 060030-045 Flatwasher 104295 Guard Fan 104292 Cover Top L.H. 060016-018 Screw 5/16 " 060005-008 Lockwasher 062033-003 Resistor 25W 30 Ohms Fan 48 V. Units 062033-027 Resistor 25W 8 Ohms Fan 72 V. Units 062033-029 Resistor 25W 12 Ohms Fan 72 V. Units 063002-029 Grease Silicone 060011-011 Screw #4 060005-036 Lockwasher 060030-115 Flatwasher 060021-047 Nut 061002-015 Clamp harness 060030-017 Flatwasher 060021-009 Nut 060005-008 Lockwasher 060030-161 Flatwasher 104298 Fan 48 V. Units 108682 Fan 72 V. Units

2 2 4 2 1 4 4 1 1 1 AR 2 2 1 2 1 1 4 4 4 1 1

Index Part No. 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Part Name

No. Req.

104288 Cord Assembly 1 104297 Support Fan 1 109192 Louver 1 109193 Louver 2 012510 Washer Rubber 6 060030-091 Flatwasher 12 060030-045 Flatwasher 6 060012-011 Screw #6 6 061004-020 Adhesive Thread locking AR 060013-026 Screw #8 2 060013-008 Screw #8 2 060005-004 Lockwasher 2 107853 Block Suppresser SB51 & TB5011 108026-051 Label 1 105605-501 Label 1 086360-007 Strip Marking 1 104326 Console Overhead L.H. 1 104303 Socket Lamp 1 104296-001 Light Assembly 48 V. Units 1 104296-002 Light Assembly 72 V. Units 1 061002-011 Clamp Harness 1 060030-017 Flatwasher 1 109195-001 Spacer 6 Always Specify Model & Serial Number Miscellaneous 105704 116936 116937

890417

Harness Wiring Platform Lights 1 Harness Fan Wiring 72 V. 1 Harness Fan Wiring 48 V. 1

2494 - 31104 Printed in U.S.A.

4.9 - 19 - 053

02 REV. 1/94

4.9 - 19 - 053

OVERHEAD CONSOLE - R.H. 2725S

Crown 1988 PF7806 Rev. 10/98

Printed in U.S.A.

03 REV. 10/98

04.9–19.0–100

04.9–19–100

0VERHEAD CONSOLE - R.H. Index Part No. 1 2 3 4 5 6

7 8

9 10 11 12 13

14 15 16 17 18

Part Name

No. Req.

060016-018 Screw 060005-008 Lockwasher 105051 Cover Top R.H. 060021-047 Nut 061004-012 Adhesive Thread Locking 060030-115 Flatwasher 060011-011 Screw 48 V. Units Only 060005-036 Lockwasher 48 V. Units Only 062033-005 Resistor 48 V. Units Only, Dome Light 063002-029 Grease Silicone 061002-011 Clamp Harness 060021-009 Nut 060005-008 Lockwasher 060030-161 Flatwasher 060013-005 Screw 060005-004 Lockwasher 071909-003 Block Terminal TB502 105605-502 Label 086360-007 Strip Marking 104325 Console Overhead - R.H. 105043 Lamp Asm. Includes Bulb 48 V. Units Only 107392 Lamp Asm. Includes Bulb 36 & 72 V. Units 101957 Bulb 36 V. LGT17 105491 Bulb 48 V. LGT17 104305 Lens 060032-029 Screw Self-Tapping 104303 Socket Lamp 104296-001 Light Asm. 48 V. Units 104296-002 Light Asm. 36 & 72 V. Units 105619 Bulb 48 V. LGT20 102195 Bulb 36 & 72 V. LGT20 062007-015 Terminal 061002-011 Clamp Harness

4 4 1 2 AR 1 2 2 1 AR 1 4 4 4 2 2 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 2 1

Always Specify Model, Data & Serial Numbers 105704

Harness Wiring Not Shown

5897 - 43821 Printed in U.S.A.

03 REV. 10/98

04.9–19.0–101

BRAKE PARTS Brake System Brake System

R.H. Brake System Shown

(a)

See Brake Parts

(b)

See Drive Unit Parts

(c)

See Cylinder Parts

Figure 21014

05.0-19.0-007

Crown 2008 PF17576-1

BRAKE PARTS Brake System INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 . . . . . 060014-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2 . . . . . 060005-005. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3 . . . . . 087604 . . . . . . . . . . . Brake Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 . . . . . 081399-001. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 . . . . . 081859 . . . . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 . . . . . 104116 . . . . . . . . . . . Brake Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . . . . . 060016-058. . . . . . . . Screw 5/16” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 061004-006. . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 . . . . . 146233 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9 . . . . . 077233-012. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 10 . . . . . 060030-052. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 11 . . . . . 093266 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12 . . . . . 103160 . . . . . . . . . . . Clevis Pin - Freezer/Corrosion (Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 076470-002. . . . . . . . Clevis Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 13 . . . . . 060038-005. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 14 . . . . . 091052 . . . . . . . . . . . Connecting Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 15 . . . . . 060021-038. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 16 . . . . . 077027-006. . . . . . . . Adjusting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 17 . . . . . 065032-003. . . . . . . . Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 18 . . . . . 060005-020. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 19 . . . . . 109713 . . . . . . . . . . . Switch Actuator RH (Shown). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 110368 . . . . . . . . . . . Switch Actuator LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 20 . . . . . 093268 . . . . . . . . . . . Adjusting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 21 . . . . . 073837-001. . . . . . . . Cupped Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 22 . . . . . 074213 . . . . . . . . . . . Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 23 . . . . . 060014-033. . . . . . . . Screw - RH Assembly Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 24 . . . . . 060005-005. . . . . . . . Lockwasher - RH Assembly Only (Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . 2 060030-044. . . . . . . . Flatwasher - LH Assembly Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 25 . . . . . 105209 . . . . . . . . . . . Sensor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 26 . . . . . 107938 . . . . . . . . . . . Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 27 . . . . . 073823-001. . . . . . . . Flanged Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 28 . . . . . 102570 . . . . . . . . . . . Pivot Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 29 . . . . . 060030-041. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 30 . . . . . 060038-005. . . . . . . . Cottor Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 31 . . . . . 087373 . . . . . . . . . . . Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 32 . . . . . 105428 . . . . . . . . . . . Resistor Plate - Freezer/Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 33 . . . . . 060005-003. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 34 . . . . . 060012-032. . . . . . . . Screw - Freezer/Corrosion (Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 060012-008. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 35 . . . . . 062033-013. . . . . . . . Resistor - Freezer/Corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 36 . . . . . 060011-005 . . . . . . . . Screw - Freezer/Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 37 . . . . . 060005-036. . . . . . . . Lockwasher - Freezer/Corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 38 . . . . . 092143 . . . . . . . . . . . Fastening Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 39 . . . . . 100705 . . . . . . . . . . . Mounting Plate RH (Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 100706 . . . . . . . . . . . Mounting Plate LH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 40 . . . . . 083936-001. . . . . . . . Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Always Specify Model, Data & Serial Number Crown 2008 PF17576-2

05.0-19.0-008

BRAKE PARTS Brake Assembly Brake Assembly

Figure 21015

05.3-14.0-102

Crown 2008 PF17582-1

BRAKE PARTS Brake Assembly INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 . . . . . 146250 . . . . . . . . . . . Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 . . . . . . . . 146277. . . . . . . . . . . . Brake Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 . . . . . . . . 102898. . . . . . . . . . . . Cam Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 . . . . . . . . 102897. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 . . . . . . . . 146276. . . . . . . . . . . . Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 146278 . . . . . . . . . . . Pivot Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 146280 . . . . . . . . . . . Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 . . . . . . . . 146281. . . . . . . . . . . . Actuator Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 . . . . . . . . 102893. . . . . . . . . . . . Retaining Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Always Specify Model, Data & Serial Number Crown 2008 PF17582-2

05.3-14.0-103

STEERING Steering Gearbox Steering Gearbox

Power Unit

Figure 13077-01

06.0-7330-102 06 Rev. 6/06

Crown 1996 PF10971-1 Rev. 6/06

STEERING Steering Gearbox INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 . . . . . 084603 . . . . . . . . . . . Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . 093061 . . . . . . . . . . . Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 . . . . . 065010-005. . . . . . . . Bearing w/Snap Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 . . . . . 060009-005. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 . . . . . 060009-036. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 . . . . . 118497 . . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . . . . . 060009-037. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 . . . . . 064138-012. . . . . . . . Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9 . . . . . 060009-044. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 10 . . . . . 061009-021. . . . . . . . Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11 . . . . . 065081-032. . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12 . . . . . 060009-152. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 13 . . . . . 117782 . . . . . . . . . . . Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 14 . . . . . 060030-178. . . . . . . . Flatwasher (1.6 mm (0.062 in.) thick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060030-179. . . . . . . . Flatwasher (0.3 mm (0.010 in.) thick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060030-180. . . . . . . . Flatwasher (0.13 mm (0.005 in.) thick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060030-181. . . . . . . . Flatwasher (0.08 mm (0.003 in.) thick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060030-279. . . . . . . . Flatwasher (0.8 mm (0.031 in.) thick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 15 . . . . . 065081-044. . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 16 . . . . . 117704 . . . . . . . . . . . Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 17 . . . . . 064020-002. . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 061004-005. . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 18 . . . . . 061011-001 . . . . . . . . Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 19 . . . . . 060030-049. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 20 . . . . . 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 21 . . . . . 060017-010. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Always Specify Model, Data & Serial Number Crown 1996 PF10971-2 Rev. 6/06

06.0-7330-103 06 Rev. 6/06

STEERING Steering Gearbox

Steering Motor See Chapter 6

See page -102

Figure 13078-01

06.0-7330-104 06 Rev. 6/06

Crown 1996 PF10971-3 Rev. 6/06

STEERING Steering Gearbox INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

30 . . . . . 065081-060. . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 31 . . . . . 060030-224. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 32 . . . . . 060030-178. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 33 . . . . . 117780 . . . . . . . . . . . Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 34 . . . . . 061009-020. . . . . . . . Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 35 . . . . . 117781 . . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 36 . . . . . 060030-178. . . . . . . . Flatwasher (1.6 mm (0.062 in.) thick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060030-179. . . . . . . . Flatwasher (0.3 mm (0.010 in.) thick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060030-180. . . . . . . . Flatwasher (0.13 mm (0.005 in.) thick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060030-181. . . . . . . . Flatwasher (0.08 mm (0.003 in.) thick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 37 . . . . . 065081-044. . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 38 . . . . . 060009-002. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 39 . . . . . 065081-012. . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 40 . . . . . 060009-118 . . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 41 . . . . . 118500 . . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 42 . . . . . 061009-019. . . . . . . . Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 43 . . . . . 118502 . . . . . . . . . . . Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 44 . . . . . 130490 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 45 . . . . . 064020-004. . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 061004-005. . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 46 . . . . . 102969 . . . . . . . . . . . Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 47 . . . . . 060015-054. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 061004-006. . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 47 . . . . . 060005-008. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 49 . . . . . 060016-019. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 065005-002. . . . . . . . Gasket Sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 065031-001. . . . . . . . RTV Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

Always Specify Model, Data & Serial Number Crown 1996 PF10971-4 Rev. 6/06

06.0-7330-105 06 Rev. 6/06

STEERING CONTROLS 2678S-01

Crown 1988 PF7790 Rev. 6/99

Printed in U.S.A.

06 REV. 6/99

06.0–19.0–050

STEERING CONTROLS Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

25 26 27 28 29 30

31 32 33 34 35 36 37 38 39

Part Name

No. Req.

074846 Knob Steering 060046-013 Washer Spring 092121 Bolt 060000-040 Pin Roll 065081-040 Bearing Ball 074847-001 Sleeve 060009-048 Ring Retaining 074849-002 Spacer 102288 Handle Steering 060005-010 Lockwasher 060021-032 Nut 060038-010 Pin Cotter 060012-001 Screw Set 104581 Collar 065081-038 Bearing 102289 Spacer 060013-023 Screw Set 060009-068 Ring Retaining 102287 Sleeve 060030-082 Flatwasher 060009-005 Ring Retaining 104378 Pin Tapered Nut Lockwasher 104379 Retainer 116818 Encoder ECR1 Includes Index 22 062007-065 Terminal 065003-170 Sleeving 104493 Housing Steering Control 105726 Panel Steering Display 060011-023 Screw 060005-036 Lockwasher 104995 Card Steering Indicator 104364 Bracket Indicator 060012-044 Screw 060005-048 Lockwasher 060030-045 Flatwasher 060012-038 Screw 104321 Cover 060000-001 Pin Roll 092094 Block Friction 092115-002 Bar 060030-010 Flatwasher 075921 Spring Compression 105725 Bracket 060015-057 Screw 060005-022 Lockwasher

1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 2 1 1 AR 1 1 1 1 1 1 5 AR 1 1 2 2 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1

Always Specify Model, Data & Serial Numbers

6138 - 45962 Printed in U.S.A.

06 REV. 6/99

06.0–19.0–051

MAST 0711S

Crown 1991 PF-9155

7.1 - 19 - 005

Printed in U.S.A.

7.1 - 19 - 005

MAST Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Part Name

No. Req.

076293 Roller Carriage 2 092830 Shaft Cam 2 060017-019 Screw 3/8" 2 060005-009 Lockwasher 2 093022 Block 2 060019-019 Screw 1/2" 4 060005-012 Lockwasher 4 Cylinder (See Section 8.2) 1 060019-003 Screw 1/2" 8 060005-013 Lockwasher 8 089131 Block Stop 2 093023 Spacer 2 089132-001 Stop Poly 2 074486-002 Bushing Stop 2 060005-006 Lockwasher 2 060030-040 Washer 2 060015-016 Screw 1/4" 2 108839 Cover R.H. 1 060017-007 Screw 3/8" 1 060005-009 Lockwasher 1 060030-026 Washer 1 100180 Spacer 2 060019-027 Screw 1/2" 2 060005-012 Lockwasher 2 Main Frame (Contact Factory) 1 074668-003 Roller Column 4 060030-057 Washer AR 060030-085 Washer AR 084888 Bearing Cam Follower 6 060030-067 Washer 6 060009-005 Ring Retaining 6 Cylinder (See Section 8.2) 1 084609-003 Retainer 2 092746-003 Bracket 2 092747-003 Stop Poly 2 060015-002 Screw 1/4" 2 061004-012 Thread Locking Adhesive 1 089077 Cover Mast 1 083564-001 Stud 4 083562 Retainer 4 060014-022 Screw #10 1 060030-044 Washer 1 060005-005 Lockwasher 1 060021-005 Nut 1

Index Part No. 35 36 37 38 39 40 41 42

43 44 45 46 47

48 49 50 51 52

53 54

Part Name

No. Req.

089272 Chain 083563 Receptacle 060014-012 Screw #10 060005-028 Lockwasher 089090 Cover Mast 2nd Stage * 102892 Clamp Cable - L.H. (Shown) 091198 Clamp Cable - R.H. 060017-027 Screw 3/8" 060005-009 Lockwasher Reservoir Hydraulic (See Hydraulic System - Main Frame [Section 2.0]) 060005-009 Lockwasher 060030-061 Washer 060017-010 Screw 3/8" 060017-007 Screw 3/8" 089091 Cover 060014-006 Screw #10 060005-005 Lockwasher 089093 Cover 060014-006 Screw #10 060005-005 Lockwasher 106355 Cover L.H. 060017-007 Screw 318" 060005-009 Lockwasher 060030-026 Washer 089050 Shaft Cam 060017-019 Screw 3/8" 060005-009 Lockwasher 076293 Roller Carriage 092825 Support 060030-061 Washer 060030-119 Washer 060005-009 Lockwasher 060017-007 Screw 3/8" Load Wheel (See Section 7.4) Cover * 060017-006 Screw 3/8" 060005-009 Lockwasher 060030-026 Washer

1 4 8 8 2 1 1 2 6 6

1 4 2 2 2 2 4 4 2 6 6 1 1 1 1 2 2 2 2 2 4 4 2 2 2 1 4 4 4

Always Specify Model & Serial Number

Printed in U.S.A.

7.1 - 19 - 006

MAST

INDEX 39 - Mast 2nd Stage Part No.

109155-005 109155-006 109155-007 109155-008 109155-009 109155-010 109155-011 109155-012 109155-013 109155-014 109155-015 109155-016 109155-017 109155-018 109155-019 109155-020 109155-021 109155-022 *109155-023 *109155-024 *109155-025 *109155-026 *109155-027

INDEX 54 - Cover

Collapsed Height in. mm

Lift Height in. mm

125 131 137 143 149 155 161 167 173 179 185 191 197 203 209 215 221 227 233 239 245 251 257

208 220 232 244 256 268 280 292 304 316 328 340 352 364 376 388 400 412 424 436 448 460 472

Crown 1991 PF-9155

7.1 - 19 - 005 - SUP

3175 3330 3480 3630 3785 3935 4090 4240 4395 4545 4700 4850 5005 5150 5310 5460 5615 5765 5920 6070 6225 6375 6530

5285 5590 5890 6200 6500 6805 7110 7415 7720 8025 8330 8635 8940 9245 9550 9855 10160 10465 10770 11075 11380 11685 11990

Part No.

107275-005 107275-006 107275-007 107275-008 107275-009 107275-010 107275-011 107275-012 107275-013 107275-014 107275-015 107275-016 107275-017 107275-018 107275-019 107275-020 107275-021 107275-022 107275-023 107275-024 107275-025

Load Wheel Over All Width in. mm 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

1320 1345 1370 1395 1420 1445 1475 1500 1525 1550 1575 1600 1625 1650 1675 1700 1725 1750 1780 1805 1830

Printed in U.S.A.

7.1 - 19 - 005 - SUP

MAST 0711S-01

43 50 55

56 57

Crown 1993 PF-9796

7.1 - 19 - 007

Printed in U.S.A.

7.1 - 19 - 007

MAST Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

35 36 37 38 39 40

Part Name

No. Req.

076293 Roller Carriage 092830 Shaft Cam 060017-019 Screw 3/8" 060005-009 Lockwasher 093022 Block 060019-019 Screw 1/2" 060005-012 Lockwasher Cylinder See Section 8.2 060019-003 Screw 1/2" 060005-013 Lockwasher 089131 Block Stop 093023 Spacer 089132-001 Stop Poly 074486-002 Bushing Stop 060005-006 Lockwasher 060030-040 Washer 060015-016 Screw 1/4" 108839 Cover R.H. 060017-007 Screw 3/8" 060005-009 Lockwasher 060030-026 Washer 100180 Spacer 060019-027 Screw 1/2" 060005-012 Lockwasher Main Frame Contact Factory 074668-003 Roller Column 060030-057 Washer 060030-085 Washer 084888 Bearing Cam Follower 060030-067 Washer 060009-005 Ring Retaining Cylinder See Section 8.2 084609-003 Retainer 092746-003 Bracket 092747-003 Stop Poly 060015-002 Screw 1/4" 061004-026 Thread Locking Adhesive 089077 Cover Mast 083564-001 Stud 083562 Retainer 060014-022 Screw #10 060030-044 Washer 060005-005 Lockwasher 060021-005 Nut 089272 Chain 083563 Receptacle 060014-012 Screw #10 060005-028 Lockwasher 089090 Cover * Mast 2nd Stage 102892 Clamp Cable - L.H. Shown 091198 Clamp Cable - R.H.

920928

2 2 2 2 2 4 4 1 8 8 2 2 2 2 2 2 2 1 1 1 1 2 2 2 1 4 AR AR 6 6 6 1 2 2 2 2 1 1 4 4 1 1 1 1 1 4 8 8 2 1 1 2

Index Part No. 41 42

43 44

45 46 47

48 49 50 51 52

53 54

56 57

Part Name

No. Req.

060017-027 Screw 3/8" 6 060005-009 Lockwasher 6 Reservoir Hydraulic See Hydraulic System - Main Frame Section 2.0 1 060005-009 Lockwasher 4 060030-061 Washer 2 060017-010 Screw 3/8" 2 060017-007 Screw 3/8" 2 115592 Stud Roller L.H. - Shown 1 115593 Stud Roller R.H. 1 060017-007 Screw 3/8" 4 060005-009 Lockwasher 4 060030-044 Flatwasher 4 074020 Roller 2 060009-036 Ring Retaining 2 106355 Cover L.H. 1 060017-007 Screw 3/8" 1 060005-009 Lockwasher 1 060030-026 Washer 1 089050 Shaft Cam 2 060017-019 Screw 3/8" 2 060005-009 Lockwasher 2 076293 Roller Carriage 2 092825 Support 2 060030-061 Washer 4 060030-119 Washer 4 060005-009 Lockwasher 2 060017-007 Screw 3/8" 2 Load Wheel See Section 7.4 2 * Cover 1 060017-006 Screw 3/8" 4 060005-009 Lockwasher 4 060030-026 Washer 4 115594-001 Shim 0.090 in. (2.3 mm) Thick AR 115594-002 Shim 0.075 in. (1.9 mm) Thick AR 115594-003 Shim 0.060 in. (1.5 mm) Thick AR 115594-004 Shim 0.048 in. (1.2 mm) Thick AR 115594-005 Shim 0.030 in. (0.8 mm) Thick AR 115594-006 Shim 0.010 in. (0.3 mm) Thick AR 115594-007 Shim 0.005 in. (0.1 mm) Thick AR 115591 Cover L.H. - Shown 1 115590 Cover R.H. 1 060014-006 Screw #10 8 060005-005 Lockwasher 8 060030-044 Flatwasher 8 Always Specify Model & Serial Number * See The Following Supplemental Form

3924-36979 Printed in U.S.A.

7.1 - 19 - 008

MAST

INDEX 39 - Mast 2nd Stage Part No.

INDEX 54 - Cover

Collapsed Height in. mm

Lift Height in. mm

125 131 137 143 149 155 161 167 173 179 185 191 197 203 209 215 221 227 233 239 245 251 257

208 220 232 244 256 268 280 292 304 316 328 340 352 364 376 388 400 412 424 436 448 460 472

Crown 1993 PF-9796

7.1 - 19 - 007 - SUP

3175 3330 3480 3630 3785 3935 4090 4240 4395 4545 4700 4850 5005 5150 5310 5460 5615 5765 5920 6070 6225 6375 6530

5285 5590 5890 6200 6500 6805 7110 7415 7720 8025 8330 8635 8940 9245 9550 9855 10160 10465 10770 11075 11380 11685 11990

Part No.

Load Wheel Over All Width in. mm 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

1320 1345 1370 1395 1420 1445 1475 1500 1525 1550 1575 1600 1625 1650 1675 1700 1725 1750 1780 1805 1830

Printed in U.S.A.

7.1 - 19 - 007 - SUP

MAST - TN 2310S-01

Crown 1993 PF-9954 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

7.1 - 19 - 050

MAST - TN Index Part No. 1 2 3 4 5

6 7 8 9 10 11 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26

27 28 29 30

Part Name

No. Req.

076293 Roller Carriage 109467 Shaft Cam 060017-019 Screw 3/8" 060005-009 Lockwasher 060009-018 Ring Retaining 106151 Mast Pad 110431 Adhesive Cartridge 14.5 oz. (430ml) Cylinder See Section 8.1 060019-003 Screw 1/2" 060005-013 Lockwasher 089131 Block Stop 093023 Spacer 089132-001 Stop Poly 074486-002 Bushing Stop 060005-006 Lockwasher 060030-040 Washer 060015-016 Screw 1/4" 108839 Cover R.H. 060017-007 Screw 3/8" 060005-009 Lockwasher 060030-026 Washer 100180 Spacer 060019-027 Screw 1/2" 060005-012 Lockwasher Main Frame Contact Factory 074668-003 Roller Column 060030-057 Washer 060030-085 Washer 114964 Retainer 100441 Cover Mast 107511-002 Stud 060014-022 Screw #10 060030-044 Washer 060005-005 Lockwasher 060021-005 Nut 089272 Chain 107510 Receptacle 060014-012 Screw #10 060005-028 Lockwasher 089090 Cover

2 2 2 2 4 AR 1 1 8 8 2 2 2 2 2 2 2 1 1 1 1 2 2 2 1 4 AR AR 4 1 4 1 1 1 1 1 4 8 8 2

Index Part No.

Part Name

No. Req.

31 * Mast 2nd Stage 32 102892 Clamp Cable - L.H. Shown 091198 Clamp Cable - R.H. 33 060017-027 Screw 3/8" 060005-009 Lockwasher 34 Reservoir Hydraulic See Hydraulic System - Main Frame Section 2.0 060005-009 Lockwasher 060030-061 Washer 060017-010 Screw 3/8" 060017-007 Screw 3/8" 35 106355 Cover L.H. 060017-007 Screw 3/8" 060005-009 Lockwasher 060030-026 Washer 36 089050 Shaft Cam 37 060017-019 Screw 3/8" 060005-009 Lockwasher 38 076293 Roller Carriage 39 089091 Cover 40 060014-006 Screw #10 060005-005 Lockwasher 41 089093 Cover 42 060014-005 Screw #10 060005-005 Lockwasher 060030-044 Flatwasher 43 092825 Support 44 060030-061 Washer 060030-119 Washer 060005-009 Lockwasher 060017-007 Screw 3/8" 45 Load Wheel See Section 7.4 46 * Cover 060017-006 Screw 3/8" 060005-009 Lockwasher 060030-026 Washer

931015

1 1 2 6 6

1 4 2 2 2 1 1 1 1 2 2 2 2 2 4 4 2 4 4 4 2 4 4 2 2 2 1 4 4 4

Always Specify Model & Serial Number * See The Following Supplemental Form

4230A - 37979 Printed in U.S.A.

01 REV. 1/94

7.1 - 19 - 051

MAST - TN

INDEX 31 - Mast 2nd Stage Part No.

100435-005 100435-006 100435-007 100435-008 100435-009 100435-010 100435-011 100435-012 100435-013 100435-014 100435-015 100435-016 100435-017 100435-018 100435-019 100435-020 100435-021 100435-022 100435-023 100435-024 100435-025 100435-026 100435-027 100435-028 100435-029

INDEX 46 - Cover

Collapsed Height in. mm

Lift Height in. mm

125 131 137 143 149 155 161 167 173 179 185 191 197 203 209 215 221 227 233 239 245 251 257 263 269

208 220 232 244 256 268 280 292 304 316 328 340 352 364 376 388 400 412 424 436 448 460 472 484 496

Crown 1993 PF-9954

7.1 - 19 - 050 - SUP

3175 3330 3480 3630 3785 3935 4090 4240 4395 4545 4700 4850 5005 5150 5310 5460 5615 5765 5920 6070 6225 6375 6530 6680 6830

5285 5590 5890 6200 6500 6805 7110 7415 7720 8025 8330 8635 8940 9245 9550 9855 10160 10465 10770 11075 11380 11685 11990 12295 12600

Part No.

Load Wheel Over All Width in. mm 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

1320 1345 1370 1395 1420 1445 1475 1500 1525 1550 1575 1600 1625 1650 1675 1700 1725 1750 1780 1805 1830

Printed in U.S.A.

7.1 - 19 - 050 - SUP

LIFTING MECHANISM PARTS Mast - TF Mast - TF

Column Roller (24) Large Radius Towards Mounting Stud

Column Roller (074668-004)

Figure 6532-01

07.1-19.0-009 04 Rev. 6/07

Crown 1994 PF10401-1 Rev. 6/07

LIFTING MECHANISM PARTS Mast - TF INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 . . . . . 076293 . . . . . . . . . . . Roller Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 . . . . . 109467 . . . . . . . . . . . Shaft Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 . . . . . 060017-019. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 . . . . . 093022 . . . . . . . . . . . Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 . . . . . 060019-019. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 060005-012. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6 . . . . . . . . . . . . . . . . . . . . . . Cylinder See Section 8.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . . . . . 060019-003. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 060005-013. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8 . . . . . 089131 . . . . . . . . . . . Block Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9 . . . . . 093023 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 10 . . . . . 089132-001. . . . . . . . Stop Poly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 11 . . . . . 074486-002. . . . . . . . Bushing Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 12 . . . . . 060005-006. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 060030-040. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 13 . . . . . 060015-016. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 14 . . . . . 108839 . . . . . . . . . . . Cover R.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 15 . . . . . 060017-007. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060030-026. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 16 . . . . . 100180 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 17 . . . . . 060019-027. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 060005-012. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 061004-026. . . . . . . . Adhesive Thread Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 18 . . . . . . . . . . . . . . . . . . . . . . Load Wheel See Section 7.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 19 . . . . . 092825 . . . . . . . . . . . Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 20 . . . . . 060030-061. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 060030-119 . . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 060017-007. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 21 . . . . . 060017-027. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 22 . . . . . 102892 . . . . . . . . . . . Clamp Cable - L.H. Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 091198 . . . . . . . . . . . Clamp Cable - R.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 23 . . . . . 060009-018. . . . . . . . Ring Retaining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 24 . . . . . 074668-004. . . . . . . . Roller Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Always Specify Model, Data & Serial Number Crown 1994 PF10401-2 Rev. 6/07

07.1-19.0-010 04 Rev. 6/07

LIFTING MECHANISM PARTS Mast - TF Column Roller (24) Large Radius Towards Mounting Stud

Column Roller (074668-004)

Figure 13081

07.1-19.0-011 04 Rev. 6/07

Crown 1994 PF10401-3 Rev. 6/07

LIFTING MECHANISM PARTS Mast - TF INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

30 . . . . . 060009-005. . . . . . . . Ring Retaining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 31 . . . . . 060030-067. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 32 . . . . . 084888 . . . . . . . . . . . Bearing Cam Follower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 33 . . . . . . . . . . . . . . . . . . . . . . Cylinder See Section 8.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 34 . . . . . 084609-003. . . . . . . . Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 35 . . . . . 092746-003. . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 36 . . . . . 092747-003. . . . . . . . Stop Poly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 37 . . . . . 060015-001. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 38 . . . . . 083561 . . . . . . . . . . . Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 39 . . . . . 089077 . . . . . . . . . . . Cover Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 40 . . . . . 083564-001. . . . . . . . Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 41 . . . . . 060014-022. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 42 . . . . . 060021-005. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 43 . . . . . 086272 . . . . . . . . . . . Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 44 . . . . . 083563 . . . . . . . . . . . Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 45 . . . . . 060014-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 060005-028. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 46 . . . . . 089090 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 47 . . . . . . . . . . . . . . . . . . . . . . Reservoir Hydraulic See Hydraulic System - Main Frame Section 2.0 . . . . . 1 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 060030-061. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 060017-010. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 060017-007. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 48 . . . . . 074668-004. . . . . . . . Roller Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 49 . . . . . 060009-018. . . . . . . . Ring Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 50 . . . . . 089050 . . . . . . . . . . . Shaft Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 51 . . . . . 060017-019. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 52 . . . . . 076293 . . . . . . . . . . . Roller Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 53 . . . . . 106355 . . . . . . . . . . . Cover L.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060017-007. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 060030-026. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Always Specify Model, Data & Serial Number Crown 1994 PF10401-4 Rev. 6/07

07.1-19.0-012 04 Rev. 6/07

LIFTING MECHANISM PARTS Mast - TF Column Roller (24) Large Radius Towards Mounting Stud

Column Roller (074668-004)

Figure 13091

07.1-19.0-013 04 Rev. 6/07

Crown 1994 PF10401-5 Rev. 6/07

LIFTING MECHANISM PARTS Mast - TF INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

54 . . . . . 107275-005. . . . . . . . Cover - 1320 mm (52 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-006. . . . . . . . Cover - 1345 mm (53 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-007. . . . . . . . Cover - 1370 mm (54 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-008. . . . . . . . Cover - 1395 mm (55 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-009. . . . . . . . Cover - 1420 mm (56 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-010. . . . . . . . Cover - 1445 mm (57 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-011 . . . . . . . . Cover - 1475 mm (58 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-012. . . . . . . . Cover - 1500 mm (59 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-013. . . . . . . . Cover - 1525 mm (60 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-014. . . . . . . . Cover - 1550 mm (61 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-015. . . . . . . . Cover - 1575 mm (62 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-016. . . . . . . . Cover - 1600 mm (63 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-017. . . . . . . . Cover - 1625 mm (64 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-018. . . . . . . . Cover - 1650 mm (65 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-019. . . . . . . . Cover - 1675 mm (66 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-020. . . . . . . . Cover - 1700 mm (67 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-021. . . . . . . . Cover - 1725 mm (68 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-022. . . . . . . . Cover - 1750 mm (69 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-023. . . . . . . . Cover - 1780 mm (70 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-024. . . . . . . . Cover - 1805 mm (71 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 107275-025. . . . . . . . Cover - 1830 mm (72 in) Load Wheel Over All Width . . . . . . . . . . . . . . . . . . 1 060017-006. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 060030-026. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Always Specify Model, Data & Serial Number Crown 1994 PF10401-6 Rev. 6/07

07.1-19.0-014 04 Rev. 6/07

MAST - TN 6533S

Column Roller (19) Large Radius Towards Mounting Stud

2 3

Column Roller (074668-004)

Not Required On Collasped Height Less Than 161 in. (4090mm) 19

10 11 13

18 15

Not Required On Collasped Height 30 Less Than 209 in. (5310mm)

4 37

39 40

16 17 20

41 42

43 21

Crown 1994 PF10111 Rev. 10/98

07.1–19.0–052

Printed in U.S.A.

03 REV. 10/98

07.1–19.0–052

MAST - TN Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26

Part Name

No. Req.

076293 Roller Carriage 109467 Shaft Cam 060017-019 Screw 060005-009 Lockwasher 060009-018 Ring Retaining 106151 Mast Pad 110431 Adhesive Cartridge 14.5 oz. (430ml) Cylinder See Section 8.1 060019-003 Screw 060005-013 Lockwasher 089131 Block Stop 093023 Spacer 089132-001 Stop Poly 074486-002 Bushing Stop 060005-006 Lockwasher 060030-040 Washer 060015-016 Screw 108839 Cover R.H. 060017-007 Screw 060005-009 Lockwasher 060030-026 Washer 100180 Spacer 060019-027 Screw 060005-012 Lockwasher 061004-026 Adhesive Thread Locking Main Frame Contact Factory 074668-004 Roller Column 060030-061 Washer 060030-119 Washer 060005-009 Lockwasher 060017-007 Screw Load Wheel See Section 7.4 109304 Retainer 100441 Cover Mast 109303-001 Stud 060014-022 Screw 060030-044 Washer 060005-005 Lockwasher 060021-005 Nut

2 2 2 2 4 AR 1 1 8 8 2 2 2 2 2 2 2 1 1 1 1 2 2 2 1 1 4 4 4 2 2 2 4 1 4 1 1 1 1

Index Part No. 27 28 29 30 31 32 33

36 37 38 39 40 41 42 43

Part Name

No. Req.

089272 Chain 109305-001 Receptacle 060014-012 Screw 060005-028 Lockwasher 089090 Cover * Mast 2nd Stage 091198 Clamp Cable R.H. Not Shown 060017-027 Screw 060005-009 Lockwasher * Cover 060017-006 Screw 060005-009 Lockwasher 060030-026 Washer Reservoir Hydraulic See Hydraulic System Main Frame Section 2.0 060005-009 Lockwasher 060030-061 Washer 060017-010 Screw 060017-007 Screw 106355 Cover L.H. 060017-007 Screw 060005-009 Lockwasher 060030-026 Washer 089050 Shaft Cam 060017-019 Screw 060005-009 Lockwasher 076293 Roller Carriage 089091 Cover 060014-006 Screw 060005-005 Lockwasher 089093 Cover 060014-005 Screw 060005-005 Lockwasher 060030-044 Flatwasher 092825 Support

1 4 8 8 2 1 2 4 4 1 4 4 4 1 4 2 2 2 1 1 1 1 2 2 2 2 2 4 4 2 4 4 4 2

Always Specify Model, Data & Serial Numbers

940110

* See The Following Supplemental Form

5870 - 45114 Printed in U.S.A.

07.1–19.0–053

03 REV. 10/98

07.1–19.0–053

MAST - TN

INDEX 31 - Mast 2nd Stage Part No.

INDEX 33 - Cover

Collapsed Height in. mm

Lift Height in. mm

125 131 137 143 149 155 161 167 173 179 185 191 197 203 209 215 221 227 233 239 245 251 257 263 269 275 281 287

208 220 232 244 256 268 280 292 304 316 328 340 352 364 376 388 400 412 424 436 448 460 472 484 496 508 520 532

3175 3325 3480 3630 3785 3935 4090 4240 4395 4545 4700 4850 5005 5150 5310 5460 5615 5765 5920 6070 6225 6375 6530 6680 6830 6985 7140 7290

5285 5590 5890 6200 6500 6805 7110 7415 7720 8025 8330 8635 8940 9245 9550 9855 10160 10465 10770 11075 11380 11685 11990 12295 12600 12905 13210 13515

Crown 1994 PF10111 Rev. 10/98

07.1–19.0–052-SUP

Part No.

Load Wheel Over All Width in. mm 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

1320 1345 1370 1395 1420 1445 1475 1500 1525 1550 1575 1600 1625 1650 1675 1700 1725 1750 1780 1805 1830

Printed in U.S.A.

03 REV. 10/98

07.1–19.0–052-SUP

LOAD WHEEL 3566

6 7

2 3 8

6 5

Index Part No. 1 2 3 4 5 6

060019-019 060005-012 090423 060023-013 060005-023 060017-007 060005-009 109439 060009-115

Part Name Screw Lockwasher Cap Screw Lockwasher Screw Lockwasher Sleeve Ring Retaining

No. Req. 8 8 2 2 2 2 2 2 4

Index Part No. 7 8

Part Name

No. Req.

065081-043 Bearing Ball 4 090270-070-01 Tire Cream Non-Marking 2 090270-080-01 Tire Black 2 100236-001 Tire Asm. Cream Non-Marking Includes Index 7 & 9 2 100236-002 Tire Asm. Black Includes Index 7 & 9 2 100205 Hub 2

Always Specify Model, Data & Serial Numbers 6043 Crown 1984 PF5776 Rev. 3/99

Printed in U.S.A.

04 REV. 3/99

07.4–18.0–002

GUIDE WHEELS 2693S

Index 1 2 3 4 5 6 7

Part No.

Part Name

060017-010 060005-009 107766 107767-001 107767-002 107767-004 107767-003 107767-001 107767-002 060015-003 060005-007 061004-012 094542

Screw 3/8" Lockwasher Cover Shim .06 in. (1.5mm) Shim .12 in. (3.0mm) Shim .50 in. (12.7mm) Shim .25 in. (6.4mm) Shim .06 in. (1.5mm) Shim .12 in. (3.0mm) Screw 1/4" Lockwasher Adhesive Thread Locking Pin Stop Screw 5/8" Spacer Tube Guide Wheel R.H. Shown Tube Guide Wheel L.H. Screw 1/4" Lockwasher Adhesive Thread Locking Support Switch Insulator Switch R.H. RGSR Shown Switch L.H. RGSR

8 9 * 10 * 11 * * 12 060015-003 060005-007 061004-012 13 107770 14 094564 15 087373 087373

No. Req.

Index

4 4 2 AR AR 2 2 AR AR 4 4 AR 1 8 * 1 1 4 4 AR 2 2 1 1

18 19 20 21 22 23 24 25 26

27 * 28 29 30 31 32

Part No.

Part Name

060012-008 060005-003 060021-003 062033-007 060011-005 060005-036 084022-002 076048 094537 094538 094528 060030-085 065081-007 090748-030 060023-007 060005-023 060030-014

Screw #6 Lockwasher Nut Resistor Freezer/Corrosion Screw #4 Freezer/Corrosion Lockwasher Freezer/Corrosion Stop Poly Fitting Lubrication Spring Extension Axle Yoke Flatwasher Bearing Ball Wheel Guide 6 in. (150mm) Screw 3/4" Lockwasher Flatwasher Bumper Pin Roll Pin Guide Wheell Flatwasher Bearing Ball Wheel Guide 6 in. (150mm)

060000-051 109872 060030-113 065081-007 090748-030

No. Req.

Always Specify Model & Serial Number

* See the following supplemental list Crown 1988 PF-7747 Rev. 12/93

4 4 4 2 4 4 2 2 4 2 2 4 4 2 6 6 6 1 2 4 4 4 2

2732

Printed in U.S.A.

01 REV. 12/93

7.4 - 19 - 100

GUIDE WHEELS Load Wheel Overall Wldth

Gulde Wheel Spread Beyond Load Wheel O.A.W.

Index 9 Screw

Index 10 Spacer Part Number

Index 11 R.H.

L.H.

in.

52 52 52 52

1320 1320 1320 1320

1.25 1.75 4.75 2.75

30 45 120 70

060020-015 060020-010 060020-035 060020-032

None 107768-001 107768-001 & -002 107768-001

2 6&2 6

107757-001 107757-001 107757-001 107757-001

107758-001 107758-001 107758-001 107758-001

53 53 53 53

1345 1345 1345 1345

1.75 2.75 5.25 7.75

45 70 135 195

060020-015 060020-032 060020-015 060020-008

107768-001 107768-001 None 107768-001 & -002

2 6 2 ea.

107757-002 107757-002 107757-006 107757-006

107758-002 107758-002 107758-006 107758-006

54 54 54 54 54 54

1370 1370 1370 1370 1370 1370

2.75 6.25 8.75 3.75 4.75 4.75

70 160 220 90 120 120

060020-032 060020-031 060020-035 060020-008 060020-035 060020-035

107768-001 107768-001 107768-001 & -002 107768-001 & -002 107768-001 & -002 107768-001 & -002

6 4 6&2 2 ea. 6&2 6&2

107757-003 107757-007 107757-007 107757-003 107757-003 107757-006

107758-003 107758-007 107758-007 107758-003 107758-003 107758-006

1400

8.75

220

060020-035

107768-001 & -002

6&2

107757-008

107758-008

56 56 56 56 56 56 56 56

1420 1420 1420 1420 1420 1420 1420 1420

1.75 2.75 3.75 4.25 4.75 6.75 7.25 8.75

45 70 90 110 120 170 185 220

060020-010 060020-032 060020-008 060020-034 060020-035 060020-032 060020-033 060020-035

107768-001 107768-001 107768-001 & -002 107768-001 & -002 107768-001 & -002 107768-001 107768-002 107768-001 & -002

2 6 2 ea. 4&2 6&2 6 2 6&2

107757-005 107757-005 107757-005 107757-005 107757-005 107757-009 107757-009 107757-009

107758-005 107758-005 107758-005 107758-005 107758-005 107758-009 107758-009 107758-009

57 57 57 57 57 57 57 57

1450 1450 1450 1450 1450 1450 1450 1450

1.25 1.75 2.75 4.75 5.75 6.25 8.25 3.75

30 45 70 120 145 160 210 90

060020-015 060020-010 060020-032 060020-035 060020-010 060020-031 060020-034 060020-008

None 107768-001 107768-001 107768-001 & -002 107768-001 107768-001 107768-001 & -002 107768-001 & -002

2 6 6&2 2 4 4&2 2 ea.

107757-006 107757-006 107757-006 107757-006 107757-010 107757-010 107757-010 107757-006

107758-006 107758-006 107758-006 107758-006 107758-010 107758-010 107758-010 107758-006

1475

1.75

060020-010

107768-001

107757-007

107758-007

59 59 59 59 59 59 59

1500 1500 1500 1500 1500 1500 1500

1.75 2.75 3.75 4.75 6.25 7.25 7.75

45 70 95 120 160 185 195

060020-010 060020-032 060020-008 060020-035 060020-031 060020-033 060020-008

107768-001 107768-001 107768-001 &-002 107768-001 &-002 107768-001 107768-002 107768-001 & -002

2 6 2 ea. 6&2 4 2 2 ea.

107757-008 107757-008 107757-008 107757-008 107757-012 107757-012 107757-012

107758-008 107758-008 107758-008 107758-008 107758-012 107758-012 107758-012

Crown 1988 PF7747 Rev. 10/94

Qty.

Printed in U.S.A.

01 REV. 10/94

07.4–19.0–100-SUP-1

GUIDE WHEELS Load Wheel Overall Wldth

Gulde Wheel Spread Beyond Load Wheel O.A.W.

Index 9 Screw

Index 10 Spacer Part Number

Index 11 R.H.

L.H.

in.

60 60 60 60 60 60 60 60 60 60 60 60 60

1525 1525 1525 1525 1525 1525 1525 1525 1525 1525 1525 1525 1525

1.25 1.75 2.25 2.75 3.25 3.75 4.25 4.75 5.25 5.75 6.25 7.75 8.75

30 45 60 70 85 95 110 120 135 145 160 195 220

060020-015 060020-010 060020-031 060020-032 060020-033 060020-008 060020-034 060020-035 060020-015 060020-010 060020-010 060020-008 060020-035

None 107768-001 107768-001 107768-001 107768-002 107768-001 &-002 107768-001 &-002 107768-001 &-002 None 107768-001 107768-001 107768-001 & -002 107768-001 &-002

2 4 6 2 2 ea. 4&2 6&2 2 4 2 ea. 6&2

107757-009 107757-009 107757-009 107757-009 107757-009 107757-009 107757-009 107757-009 107757-013 107757-013 107757-013 107757-013 107757-013

107758-009 107758-009 107758-009 107758-009 107758-009 107758-009 107758-009 107758-009 107758-013 107758-013 107758-013 107758-013 107758-013

61 61 61 61

1550 1550 1550 1550

1.75 4.75 7.25 7.75

45 120 185 195

060020-010 060020-035 060020-033 060020-008

107768-001 107768-001 &-002 107768-002 107768-001 & -002

2 6&2 2 2 ea.

107757-010 107757-010 107757-014 107757-014

107758-010 107758-010 107758-014 107758-014

62 62 62 62 62 62 62 62 62 62 62 62 62

1575 1575 1575 1575 1575 1575 1575 1575 1575 1575 1575 1575 1575

1.25 1.75 2.25 2.75 3.25 3.75 4.25 4.75 5.25 5.75 6.25 6.75 8.75

30 45 60 70 85 95 110 120 135 145 160 170 220

060020-015 060020-010 060020-031 060020-032 060020-033 060020-008 060020-034 060020-035 060020-010 060020-010 060020-031 060020-032 060020-035

None 107768-001 107768-001 107768-001 107768-002 107768-001 &-002 107768-001 &-002 107768-001 &-002 107768-001 107768-001 107768-001 107768-001 107768-001 &-002

2 4 6 2 2 ea. 4&2 6&2 2 2 4 6 6&2

107757-011 107757-011 107757-011 107757-011 107757-011 107757-011 107757-011 107757-011 107757-015 107757-015 107757-015 107757-015 107757-015

107758-011 107758-011 107758-011 107758-011 107758-011 107758-011 107758-011 107758-011 107758-015 107758-015 107758-015 107758-015 107758-015

63 63 63 63

1600 1600 1600 1600

3.25 4.75 5.25 6.25

85 120 135 160

060020-033 060020-035 060020-015 060020-031

107768-002 107768-001 &-002 None 107768-001

2 6&2 4

107757-012 107757-012 107757-016 107757-016

107758-012 107758-012 107758-016 107758-016

64 64 64 64 64 64 64 64 64 64

1625 1625 1625 1625 1625 1625 1625 1625 1625 1625

3.75 4.25 4.75 5.25 5.75 6.25 6.75 7.75 8.25 8.75

95 110 120 135 145 160 170 195 210 220

060020-008 060020-034 060020-035 060020-015 060020-010 060020-031 060020-032 060020-008 060020-034 060020-035

107768-001 &-002 107768-001 &-002 107768-001 &-002 None 107768-001 107768-001 107768-001 107768-001 & -002 107768-001 & -002 107768-001 &-002

2 ea. 4&2 6&2 2 4 6 2 ea. 4&2 6&2

107757-013 107757-013 107757-013 107757-017 107757-017 107757-017 107757-017 107757-017 107757-017 107757-017

107758-013 107758-013 107758-013 107758-017 107758-017 107758-017 107758-017 107758-017 107758-017 107758-017

1650

5.75

145

060020-010

107768-001

107757-017

107758-017

66 66 66

1675 1675 1675

4.75 7.75 8.75

120 195 220

060020-035 060020-008 060020-035

107768-001 &-002 107768-001 & -002 107768-001 &-002

6&2 2 ea. 6&2

107757-015 107757-019 107757-019

107758-015 107758-019 107758-019

Crown 1988 PF7747 Rev. 10/94

Qty.

Printed in U.S.A.

01 REV. 10/94

07.4–19.0–100-SUP-2

GUIDE WHEELS Load Wheel Overall Wldth

Gulde Wheel Spread Beyond Load Wheel O.A.W.

Index 9 Screw

Index 10 Spacer

L.H.

in.

67 67 67

1700 1700 1700

3.75 7.75 8.75

95 195 220

060020-008 060020-008 060020-035

107768-001 & -002 107768-001 & -002 107768-001 & -002

2 ea. 2 ea. 6&2

107757-016 107757-019 107757-019

107758-016 107758-019 107758-019

70 70

1775 1775

1.25 6.25

30 160

060020-015 060020-031

None 107768-001

107757-019 107757-023

107758-019 107758-023

1805

5.75

145

060020-010

107768-001

107757-024

107758-024

72 72 72 72

1830 1830 1830 1850

3.75 5.75 7.75 8.75

95 145 195 220

060020-008 060020-010 060020-008 060020-035

107768-001 & -002 107768-001 107768-001 & -002 107768-001 & -002

2 ea. 2 2 ea. 6&2

107757-021 107757-025 107757-025 107757-025

107758-021 107758-025 107758-025 107758-025

Load Wheel Overall Wldth

Part Number

Index 11 R.H.

Gulde Wheel Spread Beyond Load Wheel O.A.W.

Qty.

Index 27 Bumper

.mm

in.

52 52 52 52 52 52 52

1320 1320 1320 1320 1320 1320 1320

1.75 2.75 4.75 5.25 5.75 7.75 8.25

45 70 120 135 145 195 210

106729-001-02 106729-001-04 106729-001-08 106729-001-09 106729-001-10 106729-001-14 106729-001-15

53 53 53 53

1345 1345 1345 1345

1.75 2.75 5.25 7.75

45 70 135 195

106729-002-02 106729-002-04 106729-002-09 106729-002-10

54 54 54 54 54 54

1370 1370 1370 1370 1370 1370

1.75 2.75 3.75 4.75 6.25 8.75

45 70 90 120 160 220

106729-003-02 106729-003-04 106729-003-06 106729-003-08 106729-003-11 106729-003-16

55 55

1400 1400

1.75 8.75

45 220

106729-004-02 106729-004-16

56 56 56 56 56 56 56 56

1420 1420 1420 1420 1420 1420 1420 1420

1.75 2.75 3.75 4.25 4.75 6.75 7.25 8.75

45 70 90 110 120 170 185 220

106729-005-02 106729-005-04 106729-005-06 106729-005-07 106729-005-08 106729-005-12 106729-005-13 106729-005-16

Crown 1988 PF7747 Rev. 10/94

Printed in U.S.A.

01 REV. 10/94

07.4–19.0–100-SUP-3

GUIDE WHEELS Load Wheel Overall Wldth

Gulde Wheel Spread Beyond Load Wheel O.A.W.

Index 27 Bumper

in.

57 57 57 57 57 57 57

1450 1450 1450 1450 1450 1450 1450

1.75 2.75 3.75 4.75 5.75 6.25 8.25

45 70 90 120 145 160 210

106729-006-02 106729-006-04 106729-006-06 106729-006-08 106729-006-10 106729-006-11 106729-006-15

58 58 58 58 58 58 58 58 58 58 58 58 59 59 59 59 59 59 59

1475 1475 1475 1475 1475 1475 1475 1475 1475 1475 1475 1475 1500 1500 1500 1500 1500 1500 1500

1.75 2.25 2.75 3.25 3.75 4.75 5.25 5.75 6.75 7.75 8.25 8.75 1.75 2.75 3.75 4.75 6.25 7.25 7.75

45 60 70 85 90 120 135 145 170 195 210 220 45 70 95 120 160 185 195

106729-007-02 106729-007-03 106729-007-04 106729-007-05 106729-007-06 106729-007-08 106729-007-09 106729-007-10 106729-007-12 106729-007-14 106729-007-15 106729-007-16 106729-008-02 106729-008-04 106729-008-06 106729-008-08 106729-008-11 106729-008-13 106729-008-14

60 60 60 60 60 60 60 60 60 60 60 60 60

1525 1525 1525 1525 1525 1525 1525 1525 1525 1525 1525 1525 1525

1.25 1.75 2.25 2.75 3.25 3.75 4.25 4.75 5.25 5.75 6.25 7.75 8.75

30 45 60 70 85 95 110 120 135 145 160 195 220

106729-009-01 106729-009-02 106729-009-03 106729-009-04 106729-009-05 106729-009-06 106729-009-07 106729-009-08 106729-009-09 106729-009-10 106729-009-11 106729-009-13 106729-009-14

61 61 61

1550 1550 1550

1.75 7.25 7.75

45 185 195

106729-010-02 106729-010-13 106729-010-14

Crown 1988 PF7747 Rev. 10/94

Printed in U.S.A.

01 REV. 10/94

07.4–19.0–100-SUP-4

GUIDE WHEELS Load Wheel Overall Wldth

Gulde Wheel Spread Beyond Load Wheel O.A.W.

Index 27 Bumper

.mm

in.

62 62 62 62 62 62 62 62 62 62 62

1575 1575 1575 1575 1575 1575 1575 1575 1575 1575 1575

1.75 2.25 2.75 3.25 3.75 4.25 4.75 5.25 5.75 6.25 6.75

45 60 70 85 95 110 120 135 145 160 170

106729-011-02 106729-011-03 106729-011-04 106729-011-05 106729-011-06 106729-011-07 106729-011-08 106729-011-09 106729-011-10 106729-011-11 106729-011-12

63 63 63 63 63 63

1600 1600 1600 1600 1600 1600

1.75 3.25 4.75 5.25 5.75 6.25

45 85 120 135 145 160

106729-012-02 106729-012-05 106729-012-08 106729-012-09 106729-012-10 106729-012-11

64 64 64 64 64 64 64 64 64 64 64

1625 1625 1625 1625 1625 1625 1625 1625 1625 1625 1625

1.75 3.75 4.25 4.75 5.25 5.75 6.25 6.75 7.75 8.25 8.75

45 95 110 120 135 145 160 170 195 210 220

106729-013-02 106729-013-06 106729-013-07 106729-013-08 106729-013-09 106729-013-10 106729-013-11 106729-013-12 106729-013-14 106729-013-15 106729-013-16

65 65

1650 1650

1.75 5.75

45 145

106729-014-02 106729-014-10

66 66 66 66

1675 1675 1675 1675

1.75 4.75 7.75 8.75

45 120 195 220

106729-015-02 106729-015-08 106729-015-14 106729-015-16

67 67

1700 1700

1.75 3.75

45 95

106729-016-02 106729-016-06

1725

1.75

106729-017-02

1750

1.75

106729-018-02

70 70

1775 1775

1.75 6.25

45 160

106729-019-02 106729-019-11

1805

5.75

145

106729-020-10

72 72 72 72 72

1830 1830 1830 1830 1830

1.75 3.75 5.75 7.75 8.75

45 95 145 195 220

106729-021-02 106729-021-06 106729-021-10 106729-021-14 106729-021-16

Crown 1988 PF7747 Rev. 10/94

Printed in U.S.A.

01 REV. 10/94

07.4–19.0–100-SUP-5

GUIDE WHEELS 2

1 3

4 6

Front Rail Guide Wheel (L.H. Side Shown) (Standard)

5640

7 8

29 10

14 15

20 21

34 35 23

20 17

Index Part No. 1 2 3 4 5 6 7

8 9 10 11 12

13 14 15 16

Rear Rail Guide Wheel (R.H. Side Shown ) (Optional) Part Name

No. Req.

Crown 1996 PF-11010

07.4–19.0–101

30 31

060017-010 Screw 3/8" 4 060005-009 Lockwasher 4 107766 Cover 2 107767-001 Shim .06 in. (1.5mm) AR 107767-002 Shim .12 in. (3.0mm) AR 107767-004 Shim .50 in. (12.7mm) 2 107767-003 Shim .25 in. (6.4mm) 2 107767-001 Shim .06 in. (1.5mm) AR 107767-002 Shim .12 in. (3.0mm) AR 060015-003 Screw 1/4" 4 060005-007 Lockwasher 4 061004-026 Adhesive Thread Lock 1 094542 Pin Stop 1 * Screw 5/8" 8 060005-014 Lockwasher 8 * Spacer Package 1 * Tube Guide Wheel R.H. Shown 1 * Tube Guide Wheel L.H. 1 060015-003 Screw 1/4" 4 060005-007 Lockwasher 4 060030-012 Flatwasher 4 061004-026 Adhesive Thread Lock 1 107770 Support Switch 2 094564 Insulator 2 087373 Switch R.H. RGSR Shown 1 087373 Switch L.H. RGSR 1 060012-008 Screw #6 4 060005-003 Lockwasher 4 060021-003 Nut 4

970203

12 16

31 30

23 Index Part No. 17

18 19 20 21 22 23 24 25 26

27 28 29 30 31 32 33 34 35 36

Part Name

No. Req.

062033-007 Resistor Freezer/Corrosion 2 060011-005 Screw #4 Freezer/Corrosion 4 060005-036 Lockwahser Freezer/Corrosion 4 084022-002 Stop Poly 2 076048-001 Fitting Lubrication 2 094537 Spring Extension 4 094538 Axle 2 094528 Yoke 2 060030-085 Flatwasher 4 065081-007 Bearing Ball 4 090748-030 Wheel Guide 6 in. (150mm) 2 060023-007 Screw 3/4" 6 060005-023 Lockwasher 6 060030-014 Flatwasher 6 * Bumper 1 109872 Pin Guide Wheel 2 060017-006 Screw 3/8" 2 060005-009 Lockwasher 2 060030-113 Flatwasher 4 065081-007 Bearing Ball 4 090748-030 Wheel Guide 6 in. (150mm) 2 * Shim AR * Support Guide Wheel 2 060005-014 Lockwasher 6 * Screw 5/8" 6 Always Specify Model & Serial No. * See the Following Supplemental List 5159 - 43027 Printed in U.S.A.

07.4–19.0–101

GUIDE WHEELS Load Wheel Overall Width In. mm 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

Bumper Index 27

1320 1350 1375 1400 1425 1450 1475 1500 1525 1550 1575 1600 1625 1650 1675 1700 1725 1750 1775 1800 1825

120769-052 120769-053 120769-054 120769-055 120769-056 120769-057 120769-058 120769-059 120769-060 120769-061 120769-062 120769-063 120769-064 120769-065 120769-066 120769-067 120769-068 120769-069 120769-070 120769-071 120769-072 FRONT RAIL GUIDE WHEEL

Front Guide Wheel Spread Beyond Load Wheel Overall Width in. mm 1.25 1.50 1.75 2.00

32 38 44 51

2.25 2.50

57 64

2.75 3.00

70 76

3.25 3.50

83 89

3.75 4.00 4.25 4.50 4.75

95 102 108 114 121

5.00 5.25

127 133

5.50

140

Crown 1996 PF-11010

07.4–19.0–101–SUP-1

Shim Index 33

Shim Quantity

Support Index 34

Screw Index 36

None 120775-002 120775-003 120775-002 120775-003 120775-003 120775-002 120775-003 120775-003 120775-002 120775-003 120775-003 120775-002 120775-003 120775-003 None 120775-002 120775-003 120775-002 120775-003 120775-003 120775-002 120775-003 120775-003

None 2 2 2 2 4 2 4 6 2 6 8 2 8 10 None 2 2 2 2 4 2 4 6

120772-001 120772-001 120772-001 120772-001

060020-015 060020-015 060020-015 060020-031

120772-001 120772-001

060020-031 060020-031

120772-001 120772-001

060020-031 060020-033

120772-001 120772-001

060020-033 060020-033

120772-001 120772-002 120772-002 120772-002 120772-002

060020-033 060020-015 060020-015 060020-015 060020-031

120772-002 120772-002

060020-031 060020-031

120772-002

060020-031 Printed in U.S.A.

07.4–19.0–101–SUP-1

GUIDE WHEELS Front Rail Guide Wheel Continued Front Guide Wheel Spread Beyond Load Wheel Overall Width in. mm 5.75

146

6.00 6.25

152 159

6.50 6.75 7.00 7.25 7.50

165 171 178 184 191

7.75 8.00

197 203

8.25 8.50

210 216

8.75

222

Shim Index 33

Shim Quantity

Support Index 34

Screw Index 36

120775-002 120775-003 120775-003 120775-002 120775-003 120775-003 None 120775-002 120775-003 120775-002 120775-003 120775-003 120775-002 120775-003 120775-003 120775-002 120775-003 120775-003

2 6 8 2 8 10 None 2 2 2 2 4 2 4 6 2 6 8

120772-002

060020-033

120772-002 120772-002

060020-033 060020-033

120772-002 120772-003 120772-003 120772-003 120772-003

060020-033 060020-015 060020-015 060020-015 060020-031

120772-003 120772-003

060020-031 060020-031

120772-003 120772-003

060020-031 060020-033

120772-003

060020-033

REAR RAIL GUIDE WHEEL NOTE: Rear Guide Wheel Spread = Load Wheel Overall Width + Front Guide Wheel Spread Beyond Load Wheel Overall Width Example: Load Wheel Overall Width is 52 in. & Front Guide Wheel Spread Beyond Load Wheel Overall Width is 1.25 in. 52.00 in. + 1.25 in. = 53.25 in. Rear Guide Wheel Spread in. mm

Screw Index 9

53.25 53.50 53.75 54.00

1353 1359 1365 1372

060020-015 060020-010 060020-010 060020-031

54.25 54.50 54.75 55.00

1378 1384 1391 1397

060020-015 060020-010 060020-010 060020-031

55.25 55.50 55.75 56.00

1403 1410 1416 1422

060020-015 060020-010 060020-010 060020-031

56.25 56.50 56.75 57.00

1429 1435 1441 1448

060020-015 060020-010 060020-010 060020-031

Crown 1996 PF-11010

07.4–19.0–101–SUP-2

Qty. Tube Guide Wheel RH Tube Guide Wheel LH Index 10 Index 11 Index 11 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4

107757-001 107757-001 107757-001 107757-001

107758-001 107758-001 107758-001 107758-001

107757-002 107757-002 107757-002 107757-002

107758-002 107758-002 107758-002 107758-002

107757-003 107757-003 107757-003 107757-003

107758-003 107758-003 107758-003 107758-003

107757-004 107757-004 107757-004 107757-004

107758-004 107758-004 107758-004 107758-004

Printed in U.S.A.

07.4–19.0–101–SUP-2

GUIDE WHEELS Rear Rail Guide Wheel Continued Rear Guide Wheel Spread in. mm

Screw Index 9

Shim Index 10 – 107768-003 107768-001 107768-001 107768-003 – 107768-003 107768-001 107768-001 107768-003 – 107768-003 107768-001 107768-001 107768-003 – 107768-003 107768-001 107768-001 107768-003 – 107768-003 107768-001 107768-001 107768-003 – 107768-003 107768-001 107768-001 107768-003 – 107768-003 107768-001 107768-001 107768-003 – 107768-003 107768-001 107768-001 107768-003 – 107768-003 107768-001 107768-001 107768-003 – 107768-003 107768-001 107768-001 107768-003

57.25 57.50 57.75 58.00

1454 1461 1467 1473

060020-015 060020-010 060020-010 060020-031

58.25 58.50 58.75 59.00

1480 1486 1492 1499

060020-015 060020-010 060020-010 060020-031

59.25 59.50 59.75 60.00

1505 1511 1518 1524

060020-015 060020-010 060020-010 060020-031

60.25 60.50 60.75 61.00

1530 1537 1543 1549

060020-015 060020-010 060020-010 060020-031

61.25 61.50 61.75 62.00

1556 1562 1568 1575

060020-015 060020-010 060020-010 060020-031

62.25 62.50 62.75 63.00

1581 1588 1594 1600

060020-015 060020-010 060020-010 060020-031

63.25 63.50 63.75 64.00

1607 1613 1619 1626

060020-015 060020-010 060020-010 060020-031

64.25 64.50 64.75 65.00

1632 1638 1645 1651

060020-015 060020-010 060020-010 060020-031

65.25 65.50 65.75 66.00

1657 1664 1671 1676

060020-015 060020-010 060020-010 060020-031

66.25 66.50 66.75 67.00

1683 1689 1695 1702

060020-015 060020-010 060020-010 060020-031

Crown 1996 PF-11010

07.4–19.0–101–SUP-3

Qty. Tube Guide Wheel RH Tube Guide Wheel LH Index 10 Index 11 Index 11 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4

107757-005 107757-005 107757-005 107757-005

107758-005 107758-005 107758-005 107758-005

107757-006 107757-006 107757-006 107757-006

107758-006 107758-006 107758-006 107758-006

107757-007 107757-007 107757-007 107757-007

107758-007 107758-007 107758-007 107758-007

107757-008 107757-008 107757-008 107757-008

107758-008 107758-008 107758-008 107758-008

107757-009 107757-009 107757-009 107757-009

107758-009 107758-009 107758-009 107758-009

107757-010 107757-010 107757-010 107757-010

107758-010 107758-010 107758-010 107758-010

107757-011 107757-011 107757-011 107757-011

107758-011 107758-011 107758-011 107758-011

107757-012 107757-012 107757-012 107757-012

107758-012 107758-012 107758-012 107758-012

107757-013 107757-013 107757-013 107757-013

107758-013 107758-013 107758-013 107758-013

107757-014 107757-014 107757-014 107757-014

107758-014 107758-014 107758-014 107758-014

Printed in U.S.A.

07.4–19.0–101–SUP-3

GUIDE WHEELS Rear Rail Guide Wheel Continued Rear Guide Wheel Spread in. mm

Screw Index 9

67.25 67.50 67.75 68.00

1708 1715 1721 1727

060020-015 060020-010 060020-010 060020-031

68.25 68.50 68.75 69.00

1734 1740 1746 1753

060020-015 060020-010 060020-010 060020-031

69.25 69.50 69.75 70.00

1759 1765 1772 1778

060020-015 060020-010 060020-010 060020-031

69.25 69.50 69.75 70.00

1759 1765 1772 1778

060020-015 060020-010 060020-010 060020-031

70.25 70.50 70.75 71.00

1784 1791 1797 1803

060020-015 060020-010 060020-010 060020-031

71.25 71.50 71.75 72.00

1810 1816 1822 1829

060020-015 060020-010 060020-010 060020-031

72.25 72.50 72.75 73.00

1835 1842 1848 1854

060020-015 060020-010 060020-010 060020-031

73.25 73.50 73.75 74.00

1861 1867 1873 1880

060020-015 060020-010 060020-010 060020-031

74.25 74.50 74.75 75.00

1886 1892 1899 1905

060020-015 060020-010 060020-010 060020-031

75.25 75.50 75.75 76.00

1911 1918 1924 1930

060020-015 060020-010 060020-010 060020-031

Crown 1996 PF-11010

07.4–19.0–101–SUP-4

Qty. Tube Guide Wheel RH Tube Guide Wheel LH Index 10 Index 11 Index 11 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4 – 4 2 2 4

107757-015 107757-015 107757-015 107757-015

107758-015 107758-015 107758-015 107758-015

107757-016 107757-016 107757-016 107757-016

107758-016 107758-016 107758-016 107758-016

107757-017 107757-017 107757-017 107757-017

107758-017 107758-017 107758-017 107758-017

107757-017 107757-017 107757-017 107757-017

107758-017 107758-017 107758-017 107758-017

107757-018 107757-018 107757-018 107757-018

107758-018 107758-018 107758-018 107758-018

107757-019 107757-019 107757-019 107757-019

107758-019 107758-019 107758-019 107758-019

107757-020 107757-020 107757-020 107757-020

107758-020 107758-020 107758-020 107758-020

107757-021 107757-021 107757-021 107757-021

107758-021 107758-021 107758-021 107758-021

107757-022 107757-022 107757-022 107757-022

107758-022 107758-022 107758-022 107758-022

107757-023 107757-023 107757-023 107757-023

107758-023 107758-023 107758-023 107758-023 Printed in U.S.A.

07.4–19.0–101–SUP-4

GUIDE WHEELS Rear Rail Guide Wheel Continued Rear Guide Wheel Spread in. mm

Screw Index 9

Shim Index 10 – 107768-003 107768-001 107768-001 107768-003 – 107768-003 107768-001 107768-001 107768-003 107768-001 107768-001 107768-003 107768-001 107768-001 107768-003 107768-002 107768-002 107768-003 107768-001 107768-002 107768-001 107768-002 107768-003 107768-001 107768-002 107768-001 107768-002 107768-003 107768-001 107768-002

76.25 76.50 76.75 77.00

1937 1943 1949 1956

060020-015 060020-010 060020-010 060020-031

77.25 77.50 77.75 78.00

1962 1969 1975 1981

060020-015 060020-010 060020-010 060020-031

78.25 78.50

1988 1994

060020-031 060020-032

78.75 79.00

2000 2006

060020-034 060020-033

79.25 79.50

2013 2019

060020-033 060020-008

79.75

2026

060020-008

80.00

2032

060020-034

80.25

2038

060020-034

80.50

2045

060020-035

80.75

2051

060020-035

Crown 1996 PF-11010

07.4–19.0–101–SUP-5

Qty. Tube Guide Wheel RH Tube Guide Wheel LH Index 10 Index 11 Index 11 – 4 2 2 4 – 4 2 2 4 4 4 4 6 6 4 2 2 4 2 2 2 2 4 4 2 4 2 4 6 2

107757-024 107757-024 107757-024 107757-024

107758-024 107758-024 107758-024 107758-024

107757-025 107757-025 107757-025 107757-025

107758-025 107758-025 107758-025 107758-025

107757-025 107757-025

107758-025 107758-025

107757-025 107757-025

107758-025 107758-025

107757-025 107757-025

107758-025 107758-025

107757-025

107758-025

107757-025

107758-025

107757-025

107758-025

107757-25

107758-025

Printed in U.S.A.

07.4–19.0–101–SUP-5

YOKE 6864S

TF MAST 2 1 3

4 5 10 5

6 9

8 7 Index Part No. 1 2 3

4 5 6 7

8 9 10

Part Name

No. Req.

109211 Pulley Mounting Plate 109207 Shaft 089157-001 Stop Bar 060015-003 Screw 060005-003 Lockwasher 089164-001 Spacer 089164-002 Spacer 065081-042 Bearing 110325 Pulley Includes Index 5 110168 Pulley 089157-002 Stop Bar 060015-003 Screw 060005-006 Lockwasher 102681 Shaft Cylinder See Section 08.2 110308 Spacer

1 1 2 4 4 2 AR 3 1 1 2 4 4 1 1 1

Always Specify Model, Data & Serial Numbers

891115

5903 - SERV.

Crown 1989 PF8549 Rev. 10/98

Printed in U.S.A.

01 REV. 10/98

07.5–18.1–001

TIP OUT - TF 2291S

Crown 1989 PF-8545 Rev. 9/93

7.5 - 18.1 - 100

Printed in U.S.A.

01 REV. 9/93

7.5 - 18.1 - 100

TIP OUT - TF Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

Part Name

No. Req.

Pulley Assembly Chain Includes Index 2 & 3 110167 Pulley Chain 065081-042 Bearing Ball 110308 Spacer 089164-001 Spacer 089164-002 Spacer 109207 Shaft 089157-002 Bar Stop 060015-003 Screw 1/4" 060005-007 Lockwasher 109199 Support Chain Pulley 060030-083 Flatwasher 089062 Pulley 089065 Pulley 109227-001 Spacer 060030-083 Flatwasher 060009-005 Ring Retaining 089058 Pulley 060030-168 Flatwasher 060030-067 Flatwasher 107692-004 Roller 107692-009 Roller 060030-067 Flatwasher 107692-008 Roller 107692-007 Roller 107692-003 Roller 060030-067 Flatwasher 107692-006 Roller 107692-005 Roller

1 1 3 1 2 AR 1 2 4 4 1 26 2 10 2 AR 10 2 2 6 3 1 AR 1 1 2 2 2 2

110324

Index Part No. 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49

891115

Part Name

No. Req.

109464 Retainer 060019-015 Screw 1/2" 060005-012 Lockwasher 060030-041 Flatwasher 092965 Sleeve 060020-026 Screw 5/8" 060005-014 Lockwasher 060009-002 Ring Retaining 060030-047 Flatwasher 094228-001 Spacer 094228-002 Spacer 092827-004 Shaft * Anchor Chain * Pin Chain Anchor * Ring Retaining * Fitting Lubrication 060017-062 Screw 3/8" 060005-009 Lockwasher 065083-001 Bearing Thrust 060030-051 Flatwasher 089108-001 Rest Button 060009-037 Ring Retaining 102651 Shaft 109221 Block Mounting 060019-001 Screw 1/2" 060005-012 Lockwasher

2 4 4 4 4 4 4 2 4 1 1 1 1 1 2 1 1 1 1 AR 2 4 2 2 8 8

* See Section 7.6 Lift Chain Always Specify Model & Serial Number

4121E - 37979 Printed in U.S.A.

7.5 - 18.1 - 101

01 REV. 9/93

7.5 - 18.1 - 101

TIP OUT - TN 2303-01

22 B

20 19

A C

B A

C A

15 B

12 17 11

29 2

25 25

RK FO ND E

D D F D

E D E

20 23

27 20 23

7 30

32 33

21 18 32 SECOND STAGE MAST

Crown 1993 PF-9946 Rev. 2/94

7.5 - 18.1 - 150

Printed in U.S.A.

01 REV. 2/94

7.5 - 18.1 - 150

TIP OUT - TN Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Part Name

No. Req.

Pulley Assembly Chain Includes Index 2 & 3 110167 Pulley Chain 065081-042 Bearing Ball 110308 Spacer 089164-001 Spacer 089164-002 Spacer 109207 Shaft 089157-002 Bar Stop 060015-003 Screw 1/4" 060005-003 Lockwasher 100440 Support Chain Pulley 060030-083 Flatwasher 089062 Pulley 089065 Pulley 060009-079 Ring Retaining 060030-083 Flatwasher 060009-005 Ring Retaining 116232 Pulley 060030-168 Flatwasher 060030-067 Flatwasher 060019-010 Screw 1/2" 060005-012 Lockwasher 107692-010 Roller 060030-268 Flatwasher 114422 Block Mounting 107692-014 Roller 060030-269 Flatwasher 060030-134 Flatwasher 107692-011 Roller 107692-013 Roller 116236 Retainer 060020-043 Screw 5/8" 060005-055 Lockwasher 060017-011 Screw 3/8" 060005-009 Lockwasher 065083-001 Bearing Thrust 060030-051 Flatwasher 060009-037 Ring Retaining 102651 Shaft

1 1 3 1 2 AR 1 2 4 4 1 21 3 15 16 AR 6 3 3 AR 8 8 9 37 2 9 2 3 9 9 4 4 4 1 1 1 AR 4 2

110324

Always Specify Model & Serial Number

931015

4230 - 38886 Printed in U.S.A.

7.5 - 18.1 - 151

01 REV. 02/94

7.5 - 18.1 - 151

MAST PULLEYS 2069S

REAR

Index 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 891115

Part No.

Part Name

No. Req.

060030-067 107692-005 107692-006 060009-005 060030-168 089065 060030-083 089058 109227-001 104722 109227-002 093448 089081 065081-038 060030-134 100652 089080

Flatwasher 35 Roller 2 Roller 2 Ring Retaining 16 Flatwasher 6 Pulley 10 Flatwasher 6 Pulley 2 Spacer 2 Spacer 4 Spacer 2 Pulley Assembly Includes Index 13 5 Pulley 5 Bearing Ball 9 Flatwasher 3 Pulley Assembly Includes Index 13 1 Bearing Ball 1

Index 16 17 18 19 20 21 22 23

Crown 1989 PF-8546 Rev. 5/93

7.5 - 18.1 - 200

Part No.

Part Name

No. Req.

107692-002 109233 060019-025 060005-012 089062 100653 089082 107692-003 107692-004 109232 060019-025 060005-012 060030-067 060030-083

Roller 2 Plate Mounting R.H. 1 Screw 1/2" 3 Lockwasher 3 Pulley 2 Pulley Assembly Includes Index 13 1 Pulley 1 Roller 2 Roller 2 Plate Mounting L.H. 1 Screw 1/2" 3 Lockwasher 3 Flatwasher 0.063 in. (1.60mm) AR Flatwasher 0.031 in. (0.79mm) AR

Always Specify Model & Serial Number 3950 - 32158 Printed in U.S.A.

01 REV. 5/93

7.5 - 18.1 - 200

HOSE TAKE UP 6857S

TF MAST

1 2 3

5 A 6

8 9

7 A

11 12 Mounted To Top Cross Brace Of C Free Lift Cylinder

13 15 38 37 18

22 30 76

C 29

33 32 26 B

35 7

16 8

27 6

21 22

8 Mounted To Top Of Main Frame

Crown 1989 PF8550 Rev. 10/98

Mounted In "V" Slot On Bottom Of Free Lift Cylinder

Printed in U.S.A.

02 REV. 10/98

07.5–18.1–300

HOSE TAKE UP Index Part No. 1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17

Part Name

No. Req.

092914 Stop Block 084609-001 Retainer 092746-001 Bracket 092747-001 Poly Stop 060015-004 Screw 01004-012 Adhesive Thread Locking 060009-005 Retaining Ring 060030-067 Flatwasher 089262-001 Pulley Asm. Includes Index 9 089076-001 Pulley 083191 Compression Fitting 083190 Thimble Wire 065081-038 Bearing 089028 Plate 060017-019 Screw 060005-009 Lockwasher 060017-014 Screw 060005-009 Lockwasher 060021-011 Nut 060030-026 Flatwasher 109454 Guide 094189 Spring 109459 Bracket 060017-007 Screw 060005-009 Lockwasher 077656 Switch CTS 109461 Bracket 060012-022 Screw 060012-008 Screw Freezer/Corrosion 060030-045 Flatwasher 060005-003 Lockwasher

1 1 1 1 1 AR 4 5 3 3 3 AR 3 1 2 2 2 2 2 1 1 1 1 2 2 1 1 2 2 2 2

Index Part No.

Part Name

No. Req.

19 109462 Yoke 1 20 070558 Pin 1 21 060038-005 Cotter Pin 1 22 * Cable AR 23 * Plate 1 24 060015-012 Screw 2 060030-012 Flatwasher 2 060005-007 Lockwasher 2 25 100985 Cover 1 060014-006 Screw 3 060030-044 Flatwasher 3 060005-007 Lockwasher 3 26 100955 Pulley 1 27 060017-007 Screw 1 060005-009 Lockwasher 1 28 109235 Cover 1 29 061011-003 Pin 1 30 100954 Clamp Block 1 31 060017-010 Screw 1 060005-009 Lockwasher 1 32 060015-077 Set Screw 1 33 074757 Compression Fitting 1 34 Hose Take Up Pulleys See Section 07.5 1 35 060017-011 Screw 1 060005-009 Lockwasher 1 36 073805-004 Strain Relief Not Shown 1 37 109786 Resistor Plate Freezer/Corrosion 1 38 062033-007 Resistor Freezer/Corrosion 1 060010-004 Screw Freezer/Corrosion 2 060005-018 Lockwasher Freezer/Corrosion 2 Always Specify Model, Data & Serial Numbers *See Following Supplemental Page

5870 - 45114 Printed in U.S.A.

02 REV. 10/98

07.5–18.1–301

HOSE TAKE UP

TS Collapsed/Lift Height in. mm

TSP Collapsed/Lift Height in. mm

125/220 131/232 137/244 143/256 149/268 155/280 161/292 167/304 173/316 179/328 185/340 191/352 197/364 203/376 209/388 215/400 221/412 227/424 233/436 239/448 245/460 251/472 257/484 263/496 269/508 275/520 281/532 287/544

3175/5590 3325/5890 3480/6200 3630/6500 3785/6805 3935/7110 4090/7415 4240/7720 4395/8025 4545/8330 4700/8635 4850/8940 5005/9245 5155/9550 5310/9855 5460/10160 5615/10465 5765/10770 5920/11075 6070/11380 6225/11685 6375/11990 6530/12295 6680/12600 6830/12905 6985/13210 7140/13515 7290/13820

INDEX 22 083189-137 Cable Amount Required ft.

INDEX 23 Pulley Plate

24 26 27 28 29 31 32 33 34 36 37 38 39 41 42 43 44 46 47 48 49 51 52 53 54 55 57 58

109251-005 109251-006 109251-007 109251-008 109251-009 109251-010 109251-011 109251-012 109251-013 109251-014 109251-015 109251-016 109251-017 109251-018 109251-019 109251-020 109251-021 109251-022 109251-023 109251-024 109251-025 109251-026 109251-027 109251-028 109251-029 109251-030 109251-031 109251-032

When ordering Index 22, order the number of feet (ft.) required of cable P/N 083189-137. The appropriate quanity is listed in the above chart. This cable can also be ordered in bulk rolls of 250 ft., P/N 083189-128 or 500 ft., P/N 083189-129. Two (2) compression fittings, 074757 and 083191 and thimble wire rope, 083190 should be ordered. To make the cable, refer to the Illustration below. Use the appropriate crimping tool to secure the compression fitting. Crown recommends a No. 1 crimp tool (Crown P/N 090526).

WIRE ROPE THIMBLE COMPRESSION FITTING (074757)

CABLE

COMPRESSION FITTING (083191)

2131S

Crown 1989 PF8550 Rev. 10/98

Printed in U.S.A.

02 REV. 10/98

07.5–18.1–300-SUP

LIFT CHAIN 30 TSP

6041S

Crown 1993 PF9962 Rev. 10/98

Printed in U.S.A.

03 REV. 10/98

07.6–19.0–003

LIFT CHAIN Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Part Name

No. Req.

109444 Plate Weldment 087373 Switch CHS1 087373 Switch CHS4 060012-008 Screw 060005-003 Lockwasher 087373 Switch CHS5 087373 Switch CHS2 092143 Plate Fastening * Chain TF 060017-007 Screw 079908 Spring 060030-149 Flatwasher 101935 Rod Pusher 060005-009 Lockwasher 060000-045 Pin Roll 102683 Pin Chain 091266-003 Anchor Chain 103881-002 Anchor Chain 060038-003 Pin Cotter 060021-019 Nut Jam 060005-030 Lockwasher 060000-045 Pin Roll 109205 Anchor Chain TF 109250 Pin Chain 109151 Tube 109152 Spring 060030-241 Flatwasher 060021-054 Nut 089073-002 Pin Chain * Chain TN * Chain TN 109204 Anchor Chain TN 060009-037 Ring Retaining TN 076048 Fitting Lubrication TN 109203 Pin Anchor * Chain TF

1 1 1 8 8 1 1 4 2 3 2 2 2 3 4 2 2 1 3 3 2 2 1 1 1 1 1 3 1 2 1 1 2 1 1 1

Always Specify Model, Data & Serial Numbers * See The Following Supplemental List.

931015

5870 - 45114 Printed in U.S.A.

03 REV. 10/98

07.6–19.0–004

LIFT CHAIN Chain COLLAPSED/LIFT HEIGHT in. mm

Index 9 TF

Index 36 TF

Index 30 TN

Index 31 TN

125/208 131/220 137/232 143/244 149/256 155/268 161/280 167/292 173/304 179/316 185/328 191/340 197/352 203/364 209/376 215/388 221/400 227/414 233/424 239/436 245/448 251/460 257/472 263/484 269/496 275/508 281/520 287/532

089260-006 089260-007 089260-008 089260-009 089260-010 089260-011 089260-012 089260-013 089260-014 089260-015 089260-016 089260-017 089260-018 089260-019 089260-020 089260-021 089260-022 089260-023 089260-024 089260-025 089260-026 089260-027 089260-038 089260-039 089260-028 089260-029 089260-071 089260-072

089260-007 089260-008 089260-009 089260-010 089260-011 089260-012 089260-013 089260-014 089260-015 089260-016 089260-017 089260-018 089260-019 089260-020 089260-021 089260-022 089260-023 089260-024 089260-025 089260-026 089260-027 089260-038 089260-039 089260-028 089260-029 089260-071 089260-072 089260-073

089260-045 089260-046 089260-047 089260-048 089260-049 089260-050 089260-051 089260-052 089260-053 089260-054 089260-055 089260-056 089260-057 089260-058 089260-059 089260-060 089260-061 089260-062 089260-063 089260-064 089260-065 089260-066 089260-067 089260-068 089260-069 089260-070 089260-074 089260-075

089260-046 089260-047 089260-048 089260-049 089260-050 089260-051 089260-052 089260-053 089260-054 089260-055 089260-056 089260-057 089260-058 089260-059 089260-060 089260-061 089260-062 089260-063 089260-064 089260-065 089260-066 089260-067 089260-068 089260-069 089260-070 089260-074 089260-075 089260-076

Crown 1993 PF9962 Rev. 10/98

Printed in U.S.A.

03 REV. 10/98

07.6–19.0–003-SUP

LIFT CHAIN 5358-01

1.5 TSP 46

TF Top of Mast

TN Top of Mast

41 42 40 39 38

41 44

41 40 42

B C

Part of Mainframe

TB529 21

A C B

Platform Chain Switch

CH5 25 CH2

20 18

24 17

28 27

35 CH1, CH2 Chain Slack

Part of Platform 1 6

CH4 25 CN1

26 37

33 32

36 35 CH4, CH5 Chain Break

12 9

8 10

9 6 11 4 9 11

Crown 1996 PF10940 Rev. 10/98

07.6–19.0–050

Chain Routing On Platform

Printed in U.S.A.

02 REV. 10/98

07.6–19.0–050

LIFT CHAIN Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Part Name

109151 Tube 109152 Spring 060030-241 Flatwasher 060021-019 Nut Jam 060021-054 Nut 060038-003 Pin Cotter 103881-002 Anchor Chain 089073-002 Pin Cotter 060000-045 Pin Roll 060005-030 Lockwasher 091266-003 Anchor Chain 102683 Pin Chain 122518 Rod Pusher 122795 Actuator 079908 Spring 122519 Bracket 060017-007 Screw 060005-009 Lockwasher 060000-079 Pin Roll 060013-030 Screw 060005-004 Lockwasher 061002-004 Clamp Harness 071909-003 Block Terminal 105605-529 Label 060012-006 Screw 060005-003 Lockwasher 086360-007 Strip Marking 060015-003 Screw 060005-007 Lockwasher 060030-012 Flatwasher

No. Req. 1 1 1 3 3 3 1 1 4 2 2 2 2 2 2 1 3 3 2 1 1 1 1 1 2 2 1 4 4 4

Index Part No. 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Part Name

No. Req.

122796 Platform Chain Switch 122413 Box Platform 060009-003 Ring Retaining 122415 Plunger 115830 Spring Compression 105450-003 Bearing Nyliner 105450-002 Bearing Nyliner 060009-001 Ring Retaining 073805-001 Bushing Strain Relief 122794 Lead 3 Conductor 062657 Switch CH1, CH2, CH4, CH5 122418 Insulator 060011-003 Screw 061004-019 Adhesive Thread Lock .5 cc 109250 Pin Chain 060000-045 Pin Roll 109203 Pin Anchor 060009-037 Ring Retaining 076048 Fitting Lubrication 109204 Anchor Chain TN Mast * Chain TN Mast * Chain TN Mast 109205 Anchor Chain TF Mast * Chain TF Mast * Chain TF Mast

2 1 1 1 1 1 1 1 1 1 2 1 4 1 1 2 1 2 1 1 2 1 1 2 1

Always Specify Model, Data & Serial Numbers

960201

*See The Following Supplemental List

5870 - 45114 Printed in U.S.A.

07.6–19.0–051

02 REV. 10/98

07.6–19.0–051

LIFT CHAIN Chain COLLAPSED/LIFT HEIGHT in. mm

Index 44 TN

Index 45 TN

Index 47 TF

Index 48 TF

Crown 1996 PF10940 Rev. 10/98

07.6–19.0–050-SUP

Printed in U.S.A.

02 REV. 10/98

07.6–19.0–050-SUP

MAST 2023S-01

AUXILIARY 31 30 36

35 34 38

38 Indexes 4,5,6,9,10,11 and 29 with telescopic forks only.

11 6

10 11

4 32

18 17

7 20

9 15 14

10 21

21 16

9 29

12 13

14 15

24 25

19 24

27 26

28 Crown 1993 PF-9799 Rev. 4/94

07.7-19.0-003

Printed in U.S.A.

01 REV. 4/94

07.7-19.0-003

MAST Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Part Name

No. Req.

109425 Mast Auxiliary 100929 Guide Hose 060021-009 Nut 060005-008 Lockwasher 060030-017 Flatwasher 103878 Plate Hose Retainer 060015-086 Screw 1/4" 060005-007 Lockwasher 060030-012 Flatwasher 108030-001 Bar Wear 109273 Yoke Telescopic Forks 108505 Yoke Non-Telescopic Forks 060009-044 Ring Retaining 060030-188 Flatwasher 108029 Pulley 060009-002 Ring Retaining 100907 Pulley 065081-027 Bearing 060009-053 Ring Retaining 101005 Spacer 100906 Shaft 100904 Pulley 060009-003 Ring Retaining 100942 Plate Cover 060015-033 Screw 1/4" 089260-034 Chain See Note A 060000-045 Roll Pin 089073-002 Pin Chain 103881-001 Chain Anchor 060021-054 Nut

1 1 1 1 1 1 2 2 2 1 1 1 1 4 3 4 1 2 2 2 1 3 2 2 2 5 2 1 1 2

Index Part No. 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Part Name

No. Req.

060005-030 Lockwasher 1 060038-003 Pin Cotter 1 Cylinder Auxiliary See Index 8.4 1 060017-050 Screw 3/8" 1 060005-009 Lockwaher 1 108030-002 Bar Wear 1 108079 Bushing 2 060000-092 Roll Pin 2 109272 Poly Stop 1 * 108589 Cover Switch 1 * 060014-023 Screw #10 2 * 060005-045 Lockwasher 2 * 077656 Switch AHS1 1 * 060012-022 Screw #6 2 * 060005-003 Lockwasher 2 * 083193 Insulator 1 * 113579 Plate Mounting 1 * 113577 Switch Lever 1 * 060017-043 Screw 3/8" 1 * 060005-010 Lockwasher 1 * 060021-012 Nut 1 * 108586-002 Spring 1 Always Specify Model & Serial Number

Note: Cut Chain to 49 in. (1244mm [49 Links]) in Length * This switch assembly only used on fixed fork trucks. For EEC trucks order Index 33 thru 39 for AHS2.

890525

4232 - 38214 Printed in U.S.A.

07.7-19.0-004

01 REV. 4/94

07.7-19.0-004

FORK 2046S

TELESCOPIC

Crown 1993 PF-8466 Rev. 5/97

Printed in U.S.A.

02 REV. 5/97

07.9–19.0–003

FORK Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Part Name

No. Req.

Fork Cylinder See Section 8.7 089898 Pin 104329 Spring 060000-079 Pin Roll 103981 Cover Switch R.H. 103980 Cover Switch L.H. 060015-033 Screw 061002-011 Clamp Harness 060015-046 Screw 060005-007 Lockwasher 105523 Actuator 060013-002 Screw 060005-004 Lockwasher 060021-003 Nut 060005-003 Lockwasher 060030-032 Flatwasher 106024 Holder Switch R.H. 106023 Holder Switch L.H. 060015-033 Screw 105524 Insulator 105530 Spacer 082605 Switch Lower R.H. FRS 082605 Switch Lower L.H. FLS 082605 Switch Upper R.H. FHS-R 082605 Switch Upper L.H. FHS-L 060012-024 Screw 060012-032 Screw 100499 Bearing Slide 109474-001 Fork Movable R.H. 36 in. (915mm) Fork 109473-001 Fork Movable L.H. 36 in. (915mm) Fork 109474-002 Fork Movable R.H. 37.4 in. (950mm) Fork 109473-002 Fork Movable L.H. 37.4 in. (950mm) Fork 109474-003 Fork Movable R.H. 42 in. (1067mm) Fork 109473-003 Fork Movable L.H. 42 in. (1067mm) Fork 109474-004 Fork Movable R.H. 45.28 in. (1150) Fork 109473-004 Fork Movable L.H. 45.28 in. (1150) Fork 109474-005 Fork Movable R.H. 48 in. (1220mm) Fork 109473-005 Fork Movable L.H. 48 in. (1220mm) Fork 060045-016 Screw Shoulder 061004-012 Adhesive Thread Locking

2 1 1 1 1 1 2 1 1 1 1 2 2 3 3 2 1 1 4 1 1 1 1 1 1 2 1 8 1 1 1 1 1 1 1 1 1 1 1 1

Always Specify Model, Data & Serial Numbers 890807

Quantities Listed Are For One Fork Assembly.

5463 Printed in U.S.A.

02 REV. 5/97

07.9–19.0–004

CYLINDER 2284

MAIN LIFT - TN

5 5

8 3 9 8 4

15 10 16 11 17 12 18 13

Crown 1993 PF-9943

8.1 - 18.1 - 001

Printed in U.S.A.

8.1 - 18.1 - 001

CYLINDER *100432 MAIN CYLINDER Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Part Name

No. Req.

064135-015 Ring Wiper 100430 Cap 061004-025 Adhesive Thread Locking 064132-023 Packing Rod 081161-014 Collar 074240 Seal 060015-078 Screw 1/4" * Ram 060009-126 Ring Retaining 100434 Bushing 116489 Retainer Spring 116490 Spring 116491 Cushion Piston 060009-125 Ring Retaining * Tube Cylinder 089152-001 Piston 081349 Spring 064019-068 O-Ring 100428 Cap 061004-025 Adhesive Thread Locking 060015-069 Screw 1/4"

1 1 AR 1 1 2 2 1 2 1 1 1 1 2 1 1 1 1 1 AR 4

Always Specify Model & Serial Number MISCELLANEOUS 117308

Kit Seal Includes Index 1, 3, 5 & 17 091240-015 Packing Sleeve 117318 Socket Cap

1 1 1

*See Following Supplemental List.

931015

4121C - 37979 Printed in U.S.A.

8.1 - 18.1 - 002

CYLINDER

TS Collapsed/Lift Height in. mm

TSP Collapsed/Lift Height in. mm

*Cylinder Assembly

*INDEX 7 Ram

*INDEX 14 Cylinder

125/220 131/232 137/244 143/256 149/268 155/280 161/292 167/304 173/316 179/328 185/340 191/352 197/364 203/376 209/388 215/400 221/412 227/424 233/436 239/448 245/460 251/472 257/484 263/496 269/508

125/208 131/220 137/232 143/244 149/256 155/268 161/280 167/292 173/304 179/316 185/328 191/340 197/352 203/364 209/376 215/388 221/400 227/412 233/424 239/436 245/448 251/460 257/472 263/484 269/496

100432-005 100432-006 100432-007 100432-008 100432-009 100432-010 100432-011 100432-012 100432-013 100432-014 100432-015 100432-016 100432-017 100432-018 100432-019 100432-020 100432-021 100432-022 100432-023 100432-024 100432-025 100432-026 100432-027 100432-028 100432-029

100425-005 100425-006 100425-007 100425-008 100425-009 100425-010 100425-011 100425-012 100425-013 100425-014 100425-015 100425-016 100425-017 100425-018 100425-019 100425-020 100425-021 100425-022 100425-023 100425-024 100425-025 100425-026 100425-027 100425-028 100425-029

100419-005 100419-006 100419-007 100419-008 100419-009 100419-010 100419-011 100419-012 100419-013 100419-014 100419-015 100419-016 100419-017 100419-018 100419-019 100419-020 100419-021 100419-022 100419-023 100419-024 100419-025 100419-026 100419-027 100419-028 100419-029

Printed in U.S.A.

8.1 - 18.1 - 001 - SUP

CYLINDER 2284

MAIN LIFT - TN

5 5

8 3 9 8 4

15 10 16 11 17 12 18 13

Crown 1998 PF11494 Rev. 10/98

Printed in U.S.A.

01 REV. 10/98

08.1–18.1–003

CYLINDER *126163 MAIN CYLINDER Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Part Name

No. Req.

064135-015 Ring Wiper 100430 Cap 061004-025 Adhesive Thread Locking 064132-023 Packing Rod 081161-014 Collar 074240 Seal 060015-078 Screw * Ram 060009-126 Ring Retaining 100434 Bushing 116489 Retainer Spring 116490 Spring 126164 Cushion Piston 060009-125 Ring Retaining * Tube Cylinder 089152-001 Piston 081349 Spring 064019-068 O-Ring 100428 Cap 061004-025 Adhesive Thread Locking 060015-069 Screw

1 1 AR 1 1 2 2 1 2 1 1 1 1 2 1 1 1 1 1 AR 4

Always Specify Model, Data & Serial Numbers 117308 091240-015 117318

Kit Seal Includes Index 1, 3, 5 & 17 Packing Sleeve Socket Cap

1 1 1

*See Following Supplemental List

980727

5870 - 45114 Printed in U.S.A.

01 REV. 10/98

08.1–18.1–004

CYLINDER

TS Collapsed/Lift Height in. mm

TSP Collapsed/Lift Height in. mm

*Cylinder Assembly

*INDEX 7 Ram

*INDEX 14 Cylinder

126163-005 126163-006 126163-007 126163-008 126163-009 126163-010 126163-011 126163-012 126163-013 126163-014 126163-015 126163-016 126163-017 126163-018 126163-019 126163-020 126163-021 126163-022 126163-023 126163-024 126163-025 126163-026 126163-027 126163-028 126163-029 126163-030 126163-031 126163-032

126165-005 126165-006 126165-007 126165-008 126165-009 126165-010 126165-011 126165-012 126165-013 126165-014 126165-015 126165-016 126165-017 126165-018 126165-019 126165-020 126165-021 126165-022 126165-023 126165-024 126165-025 126165-026 126165-027 126165-028 126165-029 126165-030 126165-031 126165-032

Crown 1998 PF11494 Rev. 10/98

Printed in U.S.A.

01 REV. 10/98

08.1–18.1–003-SUP

CYLINDER 6825

MAIN LIFT TF MAST

9 16

2 17 11 4 18 5

12 10

9 13

8 3 14

15 6

Crown 1985 PF7108 Rev. 10/98

Printed in U.S.A.

03 REV. 10/98

08.2–18.0–003

CYLINDER * 089346 FREE LIFT CYLINDER ASSEMBLY Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Part Name

No. Req.

064135-010 Ring Wiper 102149 Cap 061004-011 Adhesive Thread Locking 089172 Cap 061004-011 Adhesive Thread Locking 064132-018 Packing Rod 081161-011 Collar 060015-063 Screw 092898 Cap 061004-011 Adhesive Thread Locking 064019-068 O-Ring 081349 Spring 089152-001 Piston * Ram 060009-096 Ring Retaining 092900-001 Bushing 092897 Sleeve 060009-114 Ring Retaining 074240 Seal 060015-078 Screw * Tube Cylinder

1 1 AR 1 AR 1 1 8 1 AR 1 2 2 1 2 1 1 1 1 1 1

Always Specify Model, Data & Serial Numbers 094476

Kit Seal Includes 1, 4, 8 & 16 2 Kits Required for Complete Cylinder Assembly

*See Following Supplemental Page

5870 - 45114 Printed in U.S.A.

03 REV. 10/98

08.2–18.0–004

CYLINDER

TS Collapsed/Lift Height in. mm

TSP Collapsed/Lift Height in. mm

Cylinder Assembly

INDEX 11 Ram

INDEX18 Cylinder

089346-005 089346-006 089346-007 089346-008 089346-009 089346-010 089346-011 089346-012 089346-013 089346-014 089346-015 089346-016 089346-017 089346-018 089346-019 089346-020 089346-021 089346-022 089346-023 089346-024 089346-025 089346-026 089346-027 089346-028 089346-029 089346-030 089346-031 089346-032

089169-005 089169-006 089169-007 089169-008 089169-009 089169-010 089169-011 089169-012 089169-013 089169-014 089169-015 089169-016 089169-017 089169-018 089169-019 089169-020 089169-021 089169-022 089169-023 089169-024 089169-025 089169-026 089169-027 089169-028 089169-029 089169-030 089169-031 089169-032

089165-005 089165-006 089165-007 089165-008 089165-009 089165-010 089165-011 089165-012 089165-013 089165-014 089165-015 089165-016 089165-017 089165-018 089165-019 089165-020 089165-021 089165-022 089165-023 089165-024 089165-025 089165-026 089165-027 089165-028 089165-029 089165-030 089165-031 089165-032

Crown 1985 PF7108 Rev. 10/98

Printed in U.S.A.

03 REV. 10/98

08.2–18.0–003-SUP

CYLINDER

TS Collapsed/Lift Height in. mm

TSP Collapsed/Lift Height in. mm

Cylinder Assembly

INDEX 11 Ram

INDEX18 Cylinder

125/220 131/232 137/244 143/256 149/268 155/280 161/292 167/304 173/316 179/328 185/340 191/352 197/364 203/376 209/388 215/400 221/412 227/424 233/436 239/448 245/460 251/472 257/484 263/496 269/508

125/208 131/220 137/232 143/244 149/256 155/268 161/280 167/292 173/304 179/316 185/328 191/340 197/352 203/364 209/376 215/388 221/400 227/412 233/424 239/436 245/448 251/460 257/472 263/484 269/496

109271-005 109271-006 109271-007 109271-008 109271-009 109271-010 109271-011 109271-012 109271-013 109271-014 109271-015 109271-016 109271-017 109271-018 109271-019 109271-020 109271-021 109271-022 109271-023 109271-024 109271-025 109271-026 109271-027 109271-028 109271-029

089149-005 089149-006 089149-007 089149-008 089149-009 089149-010 089149-011 089149-012 089149-013 089149-014 089149-015 089149-016 089149-017 089149-018 089149-019 089149-020 089149-021 089149-022 089149-023 089149-024 089149-025 089149-026 089149-027 089149-028 089149-029

109267-005 109267-006 109267-007 109267-008 109267-009 109267-010 109267-011 109267-012 109267-013 109267-014 109267-015 109267-016 109267-017 109267-018 109267-019 109267-020 109267-021 109267-022 109267-023 109267-024 109267-025 109267-026 109267-027 109267-028 109267-029

3849 - 36563 Crown 1989 PF-8493 Rev. 6/93

Printed in U.S.A.

01 REV. 6/93

8.2 - 18.1 - 100 - SUP

CYLINDER 3407

FREE LIFT

9 10 16 2

17 11

5 18

12 6 13 12

Crown 1994 PF10398 Rev. 10/98

Printed in U.S.A.

01 REV. 10/98

08.2–18.1–102

CYLINDER * 119010 FREE LIFT CYLINDER ASSEMBLY Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Part Name

No. Req.

064135-010 Ring Wiper 102149 Cap 061004-011 Adhesive Thread Locking 089108-001 Rest Button 064132-018 Packing Rod 081161-011 Collar 060015-063 Screw 089153 Cap 061004-011 Adhesive Thread Locking 064019-068 O-Ring 081349 Spring 089152-002 Piston * Ram 060009-096 Ring Retaining 092900-001 Bushing 092897 Sleeve 060009-114 Ring Retaining 074240 Seal 060015-078 Screw * Tube Cylinder

2 2 AR 2 2 2 8 2 AR 2 2 2 2 4 2 2 2 2 2 1

Always Specify Model, Data & Serial Numbers 094476

Kit Seal Includes 1, 4, 8 & 16 2 Kits Required for Complete Cylinder Assembly

*See Following Supplemental Page

5870 - 45114 Printed in U.S.A.

01 REV. 10/98

08.2–18.1–103

CYLINDER

TS Collapsed/Lift Height in. mm

TSP Collapsed/Lift Height in. mm

Cylinder Assembly

INDEX 11 Ram

INDEX18 Cylinder

119010-005 119010-006 119010-007 119010-008 119010-009 119010-010 119010-011 119010-012 119010-013 119010-014 119010-015 119010-016 119010-017 119010-018 119010-019 119010-020 119010-021 119010-022 119010-023 119010-024 119010-025 119010-026 119010-027 119010-028 119010-029 119010-030 119010-031 119010-032

119012-005 119012-006 119012-007 119012-008 119012-009 119012-010 119012-011 119012-012 119012-013 119012-014 119012-015 119012-016 119012-017 119012-018 119012-019 119012-020 119012-021 119012-022 119012-023 119012-024 119012-025 119012-026 119012-027 119012-028 119012-029 119012-030 119012-031 119012-032

Crown 1994 PF10398 Rev. 10/98

Printed in U.S.A.

01 REV. 10/98

08.2–18.1–102-SUP

CYLINDER 1582

FORK

Index Part No. 1

2 3 4 5 6 7 8 9

Part Name

No. Req.

100675-001 Fork R.H. (36.00 in. & 37.40 in. [915mm & 950mm] Fork Length) 1 100675-002 Fork R.H. (42.00 in. & 45.28 in. [1067mm & 1150mm] Fork Length)1 100675-003 Fork R.H. (48.00 in. [1220mm] Fork Length) 1 100676-001 Fork L.H. (36.00 in. & 37.40 in. [915mm & 950mm] Fork Length) 1 100676-002 Fork L.H. (42.00 in. & 45.28 in. [1067mm & 1150mm] Fork Length)1 100676-003 Fork L.H. (48.00 in. [1220mm] Fork Length) 1 064091-006 Plug 1 061004-026 Thread Locking Adhesive 1 104019 Block Clamp 2 060017-007 Screw 3/8 in. 2 060005-009 Lockwasher 2 060021-072 Nut 1 061004-011 Thread Locking Adhesive 1 064216-003 Seal Piston 1 100666 Piston 1 064019-028 O-Ring 1 104044-018 Spacer (3.0 in. [76mm] Fork Extension) 1 104044-017 Spacer (3.5 in. [89mm] Fork Extension) 1

Index Part No.

10 11 12 13 14 15

890807

Part Name

No. Req.

104044-016 Spacer (4.0 in. [102mm] Fork Extension) 104044-015 Spacer (4.5 in. [115mm] Fork Extension) 104044-014 Spacer (5.0 in. [127mm] Fork Extension) 104044-013 Spacer (5.5 in. [140mm] Fork Extension) 104044-012 Spacer (6.0 in. [152mm] Fork Extension) 104044-011 Spacer (6.5 in. [165mm] Fork Extension) 104044-010 Spacer (7.0 in. [178mm] Fork Extension) 104044-001 Spacer (7.5 in. [190mm] Fork Extension) 064132-029 Packing Rod 100668 Cap End 064019-044 O-Ring 064074-022 Ring Back-Up 064135-013 Ring Wiper 109471 Rod Piston

1 1 1 1 1 1 1 1 1 1 1 1 1 1

MISCELLANEOUS 115992

Kit Seal (Includes Index 6, 8, 10, 12, 13 & 14)

1 3927-32073

Crown 1989 PF-8467 Rev. 9/92

Printed in U.S.A.

01 REV. 9/92

8.7 - 19 - 002

CYLINDER 1582-01

FORK - TELESCOPIC

112853-XXX ASSEMBLY Index Part No. 1

2 3 4 5 6 7 8 9

Part Name

No. Req.

110305-001 Fork R.H. 36.00 in. & 37.40 in. (915mm & 950mm) Fork Length 1 110305-002 Fork R.H. 42.00 in. & 45.28 in. (1067mm & 1150mm) Fork Length1 110305-003 Fork R.H. 48.00 in. (1220mm) Fork Length 1 110306-001 Fork L.H. 36.00 in. & 37.40 in. (915mm & 950mm) Fork Length 1 110306-002 Fork L.H. 42.00 in. & 45.28 in. (1067mm & 1150mm) Fork Length1 110306-003 Fork L.H. 48.00 in. (1220mm) Fork Length 1 060015-078 Screw 1/4" 2 074240 Seal 2 061004-026 Adhesive Thread Locking 1 104019 Block Clamp 2 060017-007 Screw 3/8 in. 2 060005-009 Lockwasher 2 061004-026 Adhesive Thread Locking 1 060021-072 Nut 1 061004-011 Thread Locking Adhesive 1 064216-003 Seal Piston 1 100666 Piston 1 064019-028 O-Ring 1 104044-018 Spacer 3.0 in. (76mm) Fork Extension 1

910814 Crown 1993 PF-9824

8.7 - 19 - 003

Index Part No.

10 11 12 13 14 15

Part Name

No. Req.

104044-017 Spacer 3.5 in. (89mm) Fork Extension 104044-016 Spacer 4.0 in. (102mm) Fork Extension 104044-015 Spacer 4.5 in. (115mm) Fork Extension 104044-014 Spacer 5.0 in. (127mm) Fork Extension 104044-013 Spacer 5.5 in. (140mm) Fork Extension 104044-012 Spacer 6.0 in. (152mm) Fork Extension 104044-011 Spacer 6.5 in. (165mm) Fork Extension 104044-010 Spacer 7.0 in. (178mm) Fork Extension 104044-001 Spacer 7.5 in. (190mm) Fork Extension 064132-029 Packing Rod 100668 Cap End 064019-044 O-Ring 064074-022 Ring Back-Up 064135-013 Ring Wiper 109471 Rod Piston

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

MISCELLANEOUS 116931

Kit Seal Includes Index 2, 6, 8, 10, 12, 13 & 14

3367 - 35306 Printed in U.S.A.

8.7 - 19 - 003

CYLINDER FORK CYLINDER - 112853 (Includes Index 1 thru 15) R.H. FORK DASH NUMBERS Fork Length Extension

36.00" (915mm) 37.40" (950mm)

42.00" (1067mm) 45.28" (1150mm)

48.00" (1220mm)

3.0" (76mm) 3.5" (89mm) 4.0" (102mm) 4.5" (115mm) 5.0" (127mm) 5.5" (140mm) 6.0" (152mm) 6.5" (165mm) 7.0" (178mm) 7.5" (190mm)

-130 -135 -140 -145 -150 -155 -160 -165 -170 -175

-330 -335 -340 -345 -350 -355 -360 -365 -370 -375

-530 -535 -540 -545 -550 -555 -560 -565 -570 -575

L.H. FORK DASH NUMBERS Fork Length Extension

36.00" (915mm) 37.40" (950mm)

42.00" (1067mm) 45.28" (1150mm)

48.00" (1220mm)

3.0" (76mm) 3.5" (89mm) 4.0" (102mm) 4.5" (115mm) 5.0" (127mm) 5.5" (140mm) 6.0" (152mm) 6.5" (165mm) 7.0" (178mm) 7.5" (190mm)

-230 -235 -240 -245 -250 -255 -260 -265 -270 -275

-430 -435 -440 -445 -450 -455 -460 -465 -470 -475

-630 -635 -640 -645 -650 -655 -660 -665 -670 -675

Crown 1993 PF-9824

8.7 - 19 - 003 - SUP

Printed in U.S.A.

8.7 - 19 - 003 - SUP

CYLINDER 1581

LOAD WHEEL BRAKE

100256 CYLINDER ASSEMBLY Index Part No. 1 2 3 4 5 6 7 8 9 10 11

Part Name

100233 Cap 074240 Seal 060015-078 Screw 1/4" 064132-015 Packing Rod 075677 Adjustor Seal 064069-011 Ring Wiper 060009-134 Ring Retaining 060030-198 Washer 100255 Spring Compression 100222 Rod Piston 100232 Cylinder 094976 Label Cylinder

No. Req. 1 1 1 1 1 1 1 1 1 1 1 1

Index Part No. 12

Crown 1984 PF-5777 Rev. 9/92

Part Name

No. Req.

065007-034 Bearing Sleeve

MISCELLANEOUS 065012-004 Bushing Ball 060009-101 Ring Retaining 115991 Kit Seal (Includes Index 2, 3, 4, & 6)

1 1 1

Always Specify Model & Serial Number 3927-24019 Printed in U.S.A.

04 REV. 9/92

8.8 - 18 - 050

CYLINDER 1471S-01

PIVOT

19 14 9

20 18 8

7 6

16 12

5 4

Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Part Name

064194-002 Vent Breather 114562 Cap End 073981-009 Retainer 060000-045 Pin Roll 060021-051 Nut Castle 061004-010 Adhesive Thread Lock 060030-135 Flatwasher 064074-001 Ring Back Up 064019-022 O-Ring 114561 Piston 064133-005 U-Cup Piston 092861 Cushion Piston * 114566 Rod Piston 114558 Screw needle 064074-034 Ring Back Up 064019-089 O-Ring 060021-091 Nut

*114568 CYLINDER Index Part No.

No. Req. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

14 15 16 17 18 19 20

Part Name

No. Req.

114563 Tube Cylinder 064132-022 Packing Rod 089840 Cap Cylinder 064069-008 Ring Wiper 065002-002 Ball 114557 Spring 114559 Plug Drilled

115604

1 1 1 1 1 1 1

Kit Seal (Includes Index 3, 7, 8, 10, 13, 15 & 17)

Always Specify Model, Data & Serial Numbers

940531

* See the following supplemental list

5709

Crown 1994 PF10219 Rev. 5/98

Printed in U.S.A.

01 REV. 5/98

08.8–19.0–102

CYLINDER LOAD HANDLER LENGTH inches mm

23" 584

27" 686

30" 762

33" 838

36" 914

39" 990

42" 1067

45" 1143

48" 1219

51" 1295

54" 1372

114568-

002

003

030

033

036

039

042

045

048

051

054

Dimension "A" inches mm

15.91

19.91 404

22.91 506

25.91 658

28.91 734

31.91 811

34.91 887

37.91 963

40.91 1039

43.91 1115

46.91 1192

INDEX 12

002

003

030

033

036

039

042

045

048

051

054

Cylinder

114566-

1472S

Crown 1994 PF10219 Rev. 5/98

Printed in U.S.A.

01 REV. 5/98

08.8–19.0–102-SUP

PLATFORM - VIEW 1 2050S

Crown 1993 PF-8510 Rev. 1/95

Printed in U.S.A.

01 REV. 1/95

09.0–19.0–003

PLATFORM - VIEW 1 Index 1 2 3 4 5 6 7 8 9 10

Part No.

Part Name

060014-050 108382 105163 060013-020 060005-033 060021-024 060005-024 060014-002 104514 060015-046 060005-007 105641-001 105641-002 060030-017 060005-031 060021-009 102026 101958

Screw #10 3 Cover Console - R.H. 1 Cover 1 Screw #8 2 Lockwasher 2 Nut 2 Lockwasher 2 Screw #10 2 Hinge Console Cover 1 Screw 1/4" 2 Lockwasher 2 Panel Key 52 in. (1320mm) Platform 1 Panel Key 58 in. (1470mm) Platform 1 Flatwasher 2 Lockwasher 2 Nut 2 Platform 52 in. (1320mm) Width 1 Platform 58 in. (1470mm) Width 1 Bumper Upper - R.H. 1 Rack Spur 131 Tooth 52 in. (1320mm) Platform 1 Rack Spur 147 Tooth 58 in. (1470mm) Platform 1 Screw 3/8" 52 in. (1320mm) Platform 9 Screw 3/8" 58 in. (1470mm) Platform11 Flatwasher 52 in. (1320mm) Platform 9 Flatwasher 58 in. (1470mm) Platform11 Screw 5/16" 8 Cover Platform - R.H. 52 in. (1320mm) 1 Cover Platform - R.H. 58 in. (1470mm) 1 Screw 3/8" 4 Lockwasher 4 Block Stop 2 Bracket 2 Stop Poly 2 Screw 1/4" 2 Adhesive Thread Locking 1 Bumper Lower - R.H. 1 Nut Speed 4 Cover Upper Center 1 Cover Lower Center 1 Cover Platform - L.H. 52 in. (1320mm) 1 Cover Platform - L.H. 58 in. (1470mm) 1 Rack Spur 129 Tooth 52 in. (1320mm) Platform 1 Rack Spur 145 Tooth 58 in. (1470mm) Platform 1 Screw 3/8" 52 in. (1320mm) Platform 9 Screw 3/8" 58 in. (1470mm) Platform11 Flatwasher 52 in. (1320mm) Platform 9 Flatwasher 58 in. (1470mm) Platform11 Bumper Lower - L.H. 1 Screw 3/8" 16

12 * 13 * * 060017-071 060017-071 060030-216 060030-216 060016-038 105713-001

14 15

105713-002 16

060017-037 060005-009 103828 092746-003 092747-003 060015-068 061004-012

17 18 19 20

21 * 22 060031-012 23 104645 24 104649 25 105713-003 105713-004 26 * * 060017-070 060017-070 060030-216 060030-216 27 * 28 *

No. Req.

Index 29

Part No.

Part Name

104908-001

Mat Rubber 52 in. (1320mm) Platform Mat Rubber 58 in. (1470mm) Platform Adhesive Bumper Bracket Bracket Screw 5/16" Lockwasher Nut Receptacle Retainer Cover Console - L.H. 52 in. (1320mm) Platform Cover Console - L.H. 58 in. (1470mm) Platform Stud Bumper Upper - R.H. Extension Platform - R.H. 2 in. (50mm) Extension Platform - L.H. 2 in. (50mm) Shown Extension Platform - R.H. 4 in. (100mm) Extension Platform - L.H. 4 in. (100mm) Bumper Screw 1/2" Lockwasher Flatwasher Label Strap Safety Belt Safety Medium 36 in. - 44 in. (914mm - 118mm) Belt Safety Small 32 in. - 40 in. (812mm - 1016mm) Belt Safety Large 40 in. - 48 in. (1016mm - 1220mm) Belt Safety X-Large 48 in. - 56 in. (1220mm - 1420mm)

104908-002

30 31 32 33

34 35 36

061007-002 104436 102151 102152 060016-003 060005-008 060021-009 109305-001 109304 109306 109307

37 109303-001 38 * 39 107926 107927 107928 107929 40 † 41 060019-019 060005-012 060030-059 42 105074 43 077455 44 077456-001 077456-002 077456-003 077456-004

No. Req.

1 1 1 2 1 1 4 4 2 4 4 1 1 4 1 1 1 1 1 4 4 4 4 1 1 1 1 1 1

Always Specify Model & Serial Number † 104033-005 [Index 12], 104034-005 [Index 38], 104035-005 [Index 21] and 104036-005 [Index 27] bumpers and associated hardware must be used with 2 in. (50mm) platform extensions on all traverse frame widths except 57 in. (1448mm) & 63 in. (1600mm) widths. 104033-006 [Index 12], 104034-006 [Index 38], 104035-006 [Index 21] and 104036-006 [Index 27] bumpers and associated hardware must be used with a 2 in. (50mm) platform extensions on 57 in. (1448mm) & 63 in. (1600mm) traverse frame widths and all trucks using 4 in. (100mm) platform extensions.

890424

* See The Following Supplemental List

4554 Printed in U.S.A.

01 REV. 1/95

09.0–19.0–004

PLATFORM - VIEW 1

TRAVERSE FRAME WIDTH INDEX 12

INDEX 13

INDEX 21

INDEX 26

INDEX 27

INDEX 28

INDEX 38

52in (1320mm) 104033-001

101408-001

104035-001

101408-007

104036-001

060017-069

104034-001

53in (1345mm) 104033-002

101408-002

104035-002

101408-008

104036-002

060017-020

104034-002

54in (1370mm) 104033-003

101408-003

104035-003

101408-009

104036-003

060017-073

104034-003

55in (1400mm) 104033-004

101408-004

104035-004

101408-010

104036-004

060017-072

104034-004

56in (1420mm) 104033-005

101408-005

104035-005

101408-011

104036-005

060017-072

104034-005

57in (1450mm) 104033-006

101408-006

104035-006

101408-012

104036-006

060017-074

104034-006

58in (1475mm) 104033-001

101409-001

104035-001

101409-007

104036-001

060017-069

104034-001

59in (1500mm) 104033-002

101409-002

104035-002

101409-008

104036-002

060017-020

104034-002

60in (1525mm) 104033-003

101409-003

104035-003

101409-009

104036-003

060017-073

104034-003

61in (1550mm) 104033-004

101409-004

104035-004

101409-010

104036-004

060017-072

104034-004

62in (1575mm) 104033-005

101409-005

104035-005

101409-011

104036-005

060017-072

104034-005

63in (1600mm) 104033-006

101409-006

104035-006

101409-012

104036-006

060017-074

104034-006

Crown 1989 PF-8510

9 - 19 - 003 - SUP

Printed in U.S.A.

9 - 19 - 003 - SUP

PLATFORM - VIEW 1 2050S-01

Crown 1993 PF-9958 Rev. 1/95

Printed in U.S.A.

02 REV. 1/95

09.0–19.0–005

PLATFORM - VIEW 1 Index 1 2 3 4 5 6 7 8 9 10

Part No.

Part Name

060014-050 108382 105163 060013-020 060005-033 060021-024 060005-005 060014-002 104514 060015-046 060005-007 105641-001 105641-002 060030-017 060005-031 060021-009 109496-001

Screw #10 3 Cover Console - R.H. 1 Cover 1 Screw #8 2 Lockwasher 2 Nut 2 Lockwasher 2 Screw #10 2 Hinge Console Cover 1 Screw 1/4" 2 Lockwasher 2 Panel Key 52 in. (1320mm) Platform 1 Panel Key 58 in. (1470mm) Platform 1 Flatwasher 2 Lockwasher 2 Nut 2 Platform 52"/1320mm Wide TF 36"/910mm Rail Height 1 Platform 52"/1320mm Wide TF 1000mm Rail Height 1 Platform 58"/1470mm Wide TF 36"/910mm Rail Height 1 Platform 58"/1470mm Wide TF 1000mm Rail Height 1 Platform 52"/1320mm Wide TN 36"/910mm Rail Height 1 Platform 52"/1320mm Wide TN 1000mm Rail Height 1 Platform 58"/1470mm Wide TN 36"/910mm Rail Height 1 Platform 58"/1470mm Wide TN 1000mm Rail Height 1 Bumper Upper - R.H. 1 Rack Spur 131 Tooth 52 in. (1320mm) Platform 1 Rack Spur 147 Tooth 58 in. (1470mm) Platform 1 Screw 3/8" 52 in. (1320mm) Platform 9 Screw 3/8" 58 in. (1470mm) Platform11 Flatwasher 52 in. (1320mm) Platform 9 Flatwasher 58 in. (1470mm) Platform11 Screw 5/16" 8 Cover Platform - R.H. 52 in. (1320mm)1 Cover Platform - R.H. 58 in. (1470mm)1 Screw 3/8" 4 Lockwasher 4 Block Stop 2 Bracket 2 Stop Poly 2 Screw 1/4" 2 Adhesive Thread Locking 1 Bumper Lower - R.H. 1 Nut Speed 4 Cover Upper Center 1 Cover Lower Center 1 Cover Platform - L.H. 52 in. (1320mm)1 Cover Platform - L.H. 58 in. (1470mm)1

109496-002 109497-001 109497-002 116501-001 116501-002 116502-001 116502-002 12 * 13 * *

14 15 16 17 18 19 20

060017-071 060017-071 060030-216 060030-216 060016-038 105713-001 105713-002 060017-037 060005-009 103828 092746-003 092747-003 060015-068 061004-012

21 * 22 060031-012 23 104645 24 104649 25 105713-003 105713-004

No. Req.

Index

Part No.

26 * * 060017-070 060017-070 060030-216 060030-216 27 * 28 * 29 104908-001 104908-002

30 31 32 33

34 35 36

061007-002 104436 102151 102152 060016-003 060005-008 060021-009 109305-001 109304 109306 109307

37 109303-001 38 * 39 107926 107927 107928 107929 40 * 41 060019-019 060005-012 060030-059 42 105074 43 077455 44 077456-001 077456-002 077456-003 077456-004 45

117094 060016-035 060005-031

Part Name

No. Req.

Rack Spur 129 Tooth 52 in. (1320mm) Platform 1 Rack Spur 145 Tooth 58 in. (1470mm) Platform 1 Screw 3/8" 52 in. (1320mm) Platform 9 Screw 3/8" 58 in. (1470mm) Platform11 Flatwasher 52 in. (1320mm) Platform 9 Flatwasher 58 in. (1470mm) Platform11 Bumper Lower - L.H. 1 Screw 3/8" 16 Mat Rubber 52 in. (1320mm) Platform 1 Mat Rubber 58 in. (1470mm) Platform 1 Adhesive 1 Bumper 2 Bracket 1 Bracket 1 Screw 5/16" 4 Lockwasher 4 Nut 2 Receptacle 4 Retainer 4 Cover Console - L.H. 52 in. (1320mm) Platform 1 Cover Console - L.H. 58 in. (1470mm) Platform 1 Stud 4 Bumper Upper - R.H. 1 Extension Platform - R.H. 2 in. (50mm) 1 Extension Platform - L.H. 2 in. (50mm) Shown 1 Extension Platform - R.H. 4 in. (100mm) 1 Extension Platform - L.H. 4 in. (100mm) 1 Bumper 4 Screw 1/2" 4 Lockwasher 4 Flatwasher 4 Label 1 Strap Safety 1 Belt Safety Medium 36 in. - 44 in. (914mm - 118mm) 1 Belt Safety Small 32 in. - 40 in. (812mm - 1016mm) 1 Belt Safety Large 40 in. - 48 in. (1016mm - 1220mm) 1 Belt Safety X-Large 48 in. - 56 in. (1220mm - 1420mm) 1 Plate CRT Mounting 1 Screw 5/16" 4 Lockwasher 4

Always Specify Model & Serial Number * See The Following Supplemental List

931015

4554 Printed in U.S.A.

02 REV. 1/95

09.0–19.0–006

PLATFORM - VIEW 1

TRAVERSE FRAME WIDTH INDEX 12

INDEX 13

INDEX 21

INDEX 26

INDEX 27

INDEX 28

INDEX 38

52in (1320mm) 104033-001

101408-001

104035-001

101408-007

104036-001

060017-069

104034-001

53in (1345mm) 104033-002

101408-002

104035-002

101408-008

104036-002

060017-020

104034-002

54in (1370mm) 104033-003

101408-003

104035-003

101408-009

104036-003

060017-073

104034-003

55in (1400mm) 104033-004

101408-004

104035-004

101408-010

104036-004

060017-072

104034-004

* 56in (1420mm) 104033-005

101408-005

104035-005

101408-011

104036-005

060017-072

104034-005

* 57in (1450mm) 104033-006

101408-006

104035-006

101408-012

104036-006

060017-074

104034-006

58in (1475mm) 104033-001

101409-001

104035-001

101409-007

104036-001

060017-069

104034-001

59in (1500mm) 104033-002

101409-002

104035-002

101409-008

104036-002

060017-020

104034-002

60in (1525mm) 104033-003

101409-003

104035-003

101409-009

104036-003

060017-073

104034-003

61in (1550mm) 104033-004

101409-004

104035-004

101409-010

104036-004

060017-072

104034-004

62in (1575mm) 104033-005

101409-005

104035-005

101409-011

104036-005

060017-072

104034-005

63in (1600mm) 104033-006

101409-006

104035-006

101409-012

104036-006

060017-074

104034-006

*Index 40 - Use 56"/1420mm indexes 12, 21, 27, 28 and 38 with 2 in./50mm platform extensions on all traverse frame widths except 57"/1450mm and 63"/1600mm widths. Use 57"/1420mm indexes 12, 21, 27, 28 and 38 with 2 in./50mm platform extensions on 57"/1450mm and 63"/1600mm traverse frame widths and all trucks using 4"/100mm platform extensions.

Crown 1993 PF-9958

9 - 19 - 005 - SUP

Printed in U.S.A.

9 - 19 - 005 - SUP

PLATFORM - VIEW 1 2050S-03

Platform Extensions

A 26

Crown 1994 PF10404-1 Rev. 11/03

09.0–19.0–007

Printed in U.S.A.

05 REV. 11/03

09.0–19.0–007

PLATFORM - VIEW 1 Index Part No. 1 2 3 4 5 6 7 8 9

10 11

Part Name

No. Req.

060014-050 Screw 3 108382 R.H. Console Cover 1 105163 Cover 1 060013-020 Screw 2 060005-033 Lockwasher 2 060021-024 Nut 2 060005-005 Lockwasher 2 060014-002 Screw 2 104514 Console Cover Hinge 1 060015-046 Screw 2 060005-007 Lockwasher 2 105641-001 Panel Key 1320 mm (52 in.) Platform 1 105641-002 Panel Key 1470 & 1625 mm (58 & 64 in.) Platform 1 060030-017 Flatwasher 2 060005-031 Lockwasher 2 060021-009 Nut 2 119006-001 Platform 1320 mm (52 in.) Wide TF 910 mm (36 in.) Rail Height 1 119006-002 Platform 1320 mm (52 in.) Wide TF 1000 mm (39 in.) Rail Height 1 119007-001 Platform 1470 mm (58 in.) Wide TF 910 mm (36 in.) Rail Height 1 119007-002 Platform 1470 mm (58 in.) Wide TF 1000 mm (39 in.) Rail Height 1 118908-001 Platform 1625 mm (64 in.) Wide TF 910 mm (36 in.) Rail Height 1 118908-002 Platform 1625 mm (64 in.) Wide TF 1000 mm (39 in.) Rail Height 1 119289-001 Platform 1320 mm (52 in.) Wide TN 910 mm (36 in.) Rail Height 1 119289-002 Platform 1320 mm (52 in.) Wide TN 1000 mm (39 in.) Rail Height 1 119290-001 Platform 1470 mm (58 in.) Wide TN 910 mm (36 in.) Rail Height 1 119290-002 Platform 1470 mm (58 in.) Wide TN 1000 mm (39 in.) Rail Height 1 118910-001 Platform 1625 mm (64 in.) Wide TN 910 mm (36 in.) Rail Height 1 118910-002 Platform 1625 mm (64 in.) Wide TN 1000 mm (39 in.) Rail Height 1 * R.H. Upper Bumper 1

Index Part No.

No. Req.

13 *

14 15

16 17 18 19 20 21 22 23 24 25

27 28

Rack Spur 131 Tooth Top & Bottom 1320 mm (52 in.) Platform * Rack Spur 147 Tooth Top & Bottom 1470 mm (58 in.) Platform * Rack Spur 161 Tooth Top & Bottom 1470 mm (58 in.) Platform 060017-071 Screw 1320 mm (52 in.) Platform Top 060017-071 Screw 1470 & 1625 mm (58 & 64 in.) Platform Top 060017-070 Screw 1320 mm (52 in.) Platform Bottom 060017-070 Screw 1470 & 1625 mm (58 & 64 in.) Platform Bottom 060030-216 Flatwasher 1320 mm (52 in.) Platform 060030-216 Flatwasher 1470 & 1625 mm (58 & 64 in.) Platform 060016-038 Screw 105713-001 R.H. Platform Cover 1320 mm (52 in.) 105713-002 R.H. Platform Cover 1470 & 1625 mm (58 & 64 in.) 060017-037 Screw 060005-009 Lockwasher 103828 Stop Block 092746-003 Bracket 092747-003 Poly Stop 060015-068 Screw 061004-012 Adhesive Thread Locking * R.H. Lower Bumper 060031-012 Speed Nut 104645 Upper Center Cover 119300 Lower Center Cover 105713-003 L.H. Platform Cover 1320 mm (52 in.) 105713-004 L.H. Platform Cover 1470 & 1625 mm (58 & 64 in.) 079528 Fire Extinguisher 060014-022 Screw 060005-005 Lockwasher 060021-005 Nut * L.H. Lower Bumper * Screw

Crown 1994 PF10404-2 Rev. 11/03

09.0–19.0–008

Part Name

2 2 2 9 11 9 11 9 11 8 1 1 4 4 2 2 2 2 1 1 4 1 1 1 1 1 4 4 4 1 16

Printed in U.S.A.

05 REV. 11/03

09.0–19.0–008

PLATFORM - VIEW 1 Index Part No. 29

30 31 32 33 34 35 36

37 38 39

40 41 42 43 44

Part Name

No. Req.

104908-001 Rubber Mat 1320 mm (52 in.) Platform 104908-002 Rubber Mat 1470 & 1625 mm (58 & 64 in.) Platform 061007-002 Adhesive 104436 Bumper 102151 Bracket 102152 Bracket 060016-003 Screw 060005-008 Lockwasher 060021-009 Nut 109305-001 Receptacle 109304 Retainer 109306 L.H. Console Cover 1320 mm (52 in.) Platform 109307 L.H. Console Cover 1470 & 1625 mm (58 & 64 in.) Platform 109303-001 Stud * L.H. Upper Bumper 107926 R.H. Platform Extension 50 mm (2 in.) 107927 L.H. Platform Extension 50 mm (2 in.) Shown 107928 R.H. Platform Extension 100 mm (4 in.) 107929 L.H. Platform Extension 100 mm (4 in.) * Bumper 060019-019 Screw 060005-012 Lockwasher 060030-059 Flatwasher 069046 Label Warning Override 077455 Safety Strap 077456-001 Safety Belt Medium 915 - 1120 mm (36 - 44 in.) 077456-002 Safety Belt Small 815 - 1015 mm (32 - 40 in.) 077456-003 Safety Belt Large 1015 - 1220 mm (40 - 48 in.) 077456-004 Safety Belt X-Large 1220 - 1420 mm (48 - 56 in.) 117094 CRT Mounting Plate 060016-035 Screw 060005-031 Lockwasher

1 1 1 2 1 1 4 4 2 4 4 1 1 4 1 1 1 1 1 4 4 4 4 1 1 1 1 1 1 1 4 4

Always Specify Model, Data & Serial Numbers * See The Following Supplemental List

6967 - EO1549 Crown 1994 PF10404-3 Rev. 11/03

09.0–19.0–009

Printed in U.S.A.

05 REV. 11/03

09.0–19.0–009

PLATFORM - VIEW 1

TRAVERSE FRAME WIDTH

INDEX 12 R.H.

INDEX 13

INDEX 21 R.H.

INDEX 27 L.H.

INDEX 28

INDEX 38 L.H.

1320 mm (52 in.) 104033-001 119757-001 104035-001 104036-001 060017-069 104034-001 1345 mm (53 in.) 104033-002 119757-002 104035-002 104036-002 060017-020 104034-002 1370 mm (54 in.) 104033-003 119757-003 104035-003 104036-003 060017-073 104034-003 1400 mm (55 in.) 104033-004 119757-004 104035-004 104036-004 060017-072 104034-004 *1420 mm (56 in.) 104033-005 119757-005 104035-005 104036-005 060017-072 104034-005 *1450 mm (57 in.) 104033-006 119757-006 104035-006 104036-006 060017-074 104034-006 1475 mm (58 in.) 104033-001 119757-007 104035-001 104036-001 060017-069 104034-001 1500 mm (59 in.) 104033-002 119757-008 104035-002 104036-002 060017-020 104034-002 1525 mm (60 in.) 104033-003 119757-009 104035-003 104036-003 060017-073 104034-003 1550 mm (61 in.) 104033-004 119757-010 104035-004 104036-004 060017-072 104034-004 1575 mm (62 in.) 104033-005

119757-011 104035-005 104036-005 060017-072 104034-005

1600 mm (63 in.) 104033-006 119757-012 104035-006 104036-006 060017-074 104034-006 1625 mm (64 in.) 109589-001 119757-013 104035-001 104036-001 060017-069 109587-001 1650 mm (65 in.) 109589-002 119757-014 104035-002 104036-002 060017-020 109587-002 1675 mm (66 in.) 109589-003 119757-015 104035-003 104036-003 060017-073 109587-003 1700 mm (67 in.) 109589-004 119757-016 104035-004 104036-004 060017-072 109587-004 1725 mm (68 in.) 109589-005 119757-017 104035-005 104036-005 060017-072 109587-005 1750 mm (69 in.) 109589-006 119757-018 104035-006 104036-006 060017-074 109587-006 *Index 40 - Use 1420 mm (56 in.) indexes 12, 21, 27, 28 and 38 with 50 mm (2 in.) platform extensions on all traverse frame widths except 1450 mm (57 in.) and 1600 mm (63 in.) widths. Use 1420 mm (56 in.) indexes 12, 21, 27, 28 and 38 with 50 mm (2 in.) platform extensions on 1450 mm (57 in.) and 1600 mm (63 in.) traverse frame widths and all trucks using 100 mm (4 in.) platform extensions. Does not pertain to 64 - 67 in. traverse frame widths.

Crown 1994 PF10404-4 Rev. 11/03

09.0–19.0–007-SUP

Printed in U.S.A.

05 REV. 11/03

09.0–19.0–007-SUP

PLATFORM - VIEW 2 2311S

Crown 1993 PF-9960

9 - 19 - 052

Printed in U.S.A.

9 - 19 - 052

PLATFORM - VIEW 2 Index Part No. 1 2 3 4 5 6

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Part Name

No. Req.

090498-006 Molding Insert 1 090461-006 Molding 1 103935-002 Shield Mast 1 108122 Retainer Shield - L.H. 1 065113-002 Grommeting 2 105640-001 Shield Overhead Guard 52 in. (1320mm) Platform 1 105640-002 Shield Overhead Guard 58 in. (1470mm) Platform 1 074042 Bumper Rubber 52 in. (1320mm) Platforms 4 074042 Bumper Rubber 58 in. (1470mm) Platforms 6 105036 Mirror 1 060015-023 Screw 1/4" 1 060005-007 Lockwasher 1 074668-001 Roller Column 4 090025 Shaft Cam 4 060017-006 Screw 3/8" 4 060005-009 Lockwasher 4 060030-085 Flatwasher 0.31 in. (8mm) AR 060030-057 Flatwasher 0.63 in. (16mm) AR 074668-003 Roller Column 4 060009-018 Ring Retaining 4 106332 Cover 2 102048 Cover R.H. 1 102028 Cover L.H. 1 060016-039 Screw 5/16" 16 060030-199 Flatwasher AR 060030-240 Flatwasher AR 101521 Plate Roller - TF 1 116485 Plate Roller - TN 1 065007-041 Bearing Sleeve 1 060031-012 Nut Speed 16 102029 Bracket Cover 2 060017-016 Screw 3/8" 2 060005-009 Lockwasher 2 101512 Shaft Pivot 1 060017-006 Screw 3/8" 3 060005-009 Lockwasher 3 076048 Fitting Lubrication 1 106714-001 Tray Hose 52 in. (1320mm) Platform 1 106714-002 Tray Hose 58 in. (1470mm) Platform 1 060017-036 Screw 3/8" 4 060005-009 Lockwasher 4 060030-167 Flatwasher 4 060021-011 Nut 4

Index Part No. 30 31 32

37 38

41 42 43

Part Name

No. Req

104624 Cover Floor Outside Shown 2 108023 Cover Floor Center 1 060015-033 Screw 1/4" 6 105639-001 Shield Lower 52 in. (1320mm) Platform 2 105639-002 Shield Lower 58 in. (1470mm) Platform 2 105643-001 Retainer Channel 52 in. (1320mm) Platform 2 105643-002 Retainer Channel 58 in. (1470mm) Platform 2 065114-002 Grommeting 52 in. (1320mm) Platform 4 065114-003 Grommeting 58 in. (1470mm) Platform 060015-087 Screw 1/4" 4 060005-007 Lockwasher 4 060030-012 Flatwasher 4 105506-001 Support Shield 52 in. (1320mm) Platform 2 105506-002 Support Shield 58 in. (1470mm) Platform 2 060016-018 Screw 7/16" 4 060005-008 Lockwasher 4 107590 Pad Poly 2 110431 Adhesive Cartridge 14.5 oz. (430ml) 1 107499-001 Liner Tray 52 in. (1320mm) Platform 1 107499-002 Liner Tray 58 in. (1470mm) Platform 1 060012-042 Screw 5/8" 9 061004-020 Adhesive Thread Locking 1 108265-001 Rail Front 52 in. (1320mm) Platform 36 in. (915mm) Rail Height 1 108265-002 Rail Front 52 in. (1320mm) Platform 40 in. (1000mm) Rail Height 1 108265-003 Rail Front 58 in. (1470mm) Platform 36 in. (915mm) Rail Height 1 108265-004 Rail Front 58 in. (1470mm) Platform 40 in. (1000mm) Rail Height 1 060017-027 Screw 3/8" 4 061004-026 Adhesive Thread Locking 1 090651-001 Plug 4 108123 Retainer Shield - R.H. 1 Always Specify Model & Serial Number

931015

4121K - 37979 Printed in U.S.A.

9 - 19 - 053

PLATFORM - VIEW 2 6536S

Column Roller (14) Large Radius Towards Mounting Stud 13

1 2 4

37 5

5 7

3 Column Roller (074668-004)

8 38 9 38 10 38 40

11 12

14 32

31 34

24 23

29 30

17 25 26

22 19

14 20

Crown 1994 PF10407 Rev. 5/98

Printed in U.S.A.

03 REV. 5/98

09.0–19.0–054

PLATFORM - VIEW 2 Index Part No. 1 2 3 4

5 6

8 9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26 27

Part Name

No. Req.

090498-006 Molding Insert 1 090461-006 Molding 1 103935-002 Shield Mast 1 108122 Retainer Shield L.H. 1 109559 Retainer Shield L.H. 64 in. (1625mm) Platform 1 065113-002 Grommeting 2 105640-001 Shield Overhead Guard 52 in. (1320mm) Platform 1 105640-002 Shield Overhead Guard 58 in. (1470mm) & 64 in. (1625mm) Platform 1 074042 Bumper Rubber 52 in. (1320mm) Platforms 4 074042 Bumper Rubber 58 in. (1470mm) & 64 in. (1625mm) Platforms 6 105036 Mirror 1 060015-023 Screw 1 060005-007 Lockwasher 1 074668-001 Roller Column 4 090025 Shaft Cam 4 060017-006 Screw 4 060005-009 Lockwasher 4 108123 Retainer Shield R.H. 1 109558 Retainer Shield R.H. 64 in. (1625mm) Platform 1 074668-004 Roller Column 4 060009-018 Ring Retaining 4 106332 Cover 2 102048 Cover R.H. 1 102028 Cover L.H. 1 060016-039 Screw 16 060030-199 Flatwasher AR 060030-240 Flatwasher AR 116485 Plate Roller 1 065007-041 Bearing Sleeve 1 060031-012 Nut Speed 16 102029 Bracket Cover 2 060017-016 Screw 2 060005-009 Lockwasher 2 101512 Shaft Pivot 1 060017-006 Screw 3 060005-009 Lockwasher 3 076048 Fitting Lubrication 1

Index Part No. 28

Part Name

No. Req

106714-001 Tray Hose 52 in. (1320mm) Platform 1 106714-002 Tray Hose 58 in. (1470mm) Platform 1 106714-003 Tray Hose 64 in. (1625mm) Platform 1 060017-036 Screw 4 060005-009 Lockwasher 4 060030-167 Flatwasher 4 060021-011 Nut 4 119304 Cover Floor Outside Shown 2 119303 Cover Floor Center 1 060015-033 Screw 6 105639-001 Shield Lower 52 in. (1320mm) Platform 2 105639-002 Shield Lower 58 in. (1470mm) & 64 in. (1625mm) Platform 2 105643-001 Retainer Channel 52 in. (1320mm) Platform 2 105643-002 Retainer Channel 58 in. (1470mm) & 64 in. (1625mm) Platform 2 065114-002 Grommeting 52 in. (1320mm) Platform 4 065114-003 Grommeting 58 in. (1470mm) & 64 in. (1625mm) Platform 060015-087 Screw 4 060005-007 Lockwasher 4 060030-012 Flatwasher 4 105506-001 Support Shield 52 in. (1320mm) Platform 2 105506-002 Support Shield 58 in. (1470mm) & 64 in. (1625mm) Platform 2 060016-018 Screw 4 060005-008 Lockwasher 4 107590 Pad Poly 2 110431 Adhesive Cartridge 14.5 oz. (430ml) 1 107499-001 Liner Tray 52 in. (1320mm) Platform 1 107499-002 Liner Tray 58 in. (1470mm) Platform 1 107499-003 Liner Tray 64 in. (1625mm) Platform 1 060012-042 Screw 9 061004-020 Adhesive Thread Locking 1 090651-001 Plug 4

30 31 32

37 38

Always Specify Model, Data & Serial Numbers

950428

5714 - 43635/44315 Printed in U.S.A.

03 REV. 5/98

09.0–19.0–055

SHOCK ABSORBER 2306, 2308

TF 7

1 2

5 4

PART OF PLATFORM

1 2

PART OF PLATFORM

Crown 1993 PF9952 Rev. 4/94

Printed in U.S.A.

01 REV. 4/94

09.0-19.0-151

SHOCK ABSORBER TF SHOCK ABSORBER 105078 Includes Index 1 Thru 8 Index Part No. 1 2 3 4

5 6 7 8

Part Name

No. Req.

060015-068 Screw 1/4" 061004-026 Adhesive Thread Locking 104865 Stop Poly 104864 Bracket 060015-027 Screw 1/4" 060030-012 Flatwasher 061004-026 Adhesive Thread Locking 104866 Bumper Mast 104858 Plunger 105502 Bracket Shock 104856 Pin 060017-021 Screw 3/8" 060005-009 Lockwasher 104856 Pin 060017-021 Screw 3/8" 060005-009 Lockwasher

2 1 2 2 2 2 1 2 2 2 2 2 2 2 2 2

Always Specify Model & Serial Number

TN Index Part No. 1 2 3 4 5

Part Name

No. Req.

060015-068 Screw 1/4" 061004-026 Adhesive Thread Locking 104865 Stop Poly 104864 Bracket 116492 Support Stop 060020-031 Screw 5/8" 060005-014 Lockwasher

2 1 2 2 2 4 4

Always Specify Model & Serial Number

931015

4232 - 38214 Printed in U.S.A.

01 REV. 4/94

09.0-19.0-152

HEIGHT SENSOR 2679S

HEIGHT SENSOR ASSEMBLY - 105077 (Includes Indexes 1 Thru 22) Index Part No. 1 2 3 4 5 6 7

8 9 10 11 12 13 14 15

Part Name

060014-031 Screw #10 060005-005 Lockwasher 104226 Cover 100502 Spacer 063002-021 Lubricant 094356 Arbor 107203 Spring Motor 094983 Spacer 063002-021 Lubricant 107202 Retainer 060012-010 Screw #6 060005-003 Lockwasher 104253 Reel Cable 094422-002 Cable 065081-038 Bearing Ball 104252 Housing Sensor 065081-001 Bearing Ball 060030-021 Flatwasher 060009-003 Ring Retaining Nut Lockwasher

No. Req. 4 4 1 1 AR 1 1 1 AR 1 2 2 1 1 1 1 1 AR 1 1 1

Index Part No. 16 17 18

19 20 21 22 23 24 25 26 27

Crown 1988 PF-7779 Rev. 12/93

Part Name

No. Req.

Retainer Pin Taper Encoder ECR4 Includes Index 15 062007-065 Terminals 060013-001 Screw Set #8 104398 Case 060013-002 Screw #8 060005-004 Lockwasher 107208 Sleeve Stop 105531 Bracket 079565-003 Strip Marking 079564-003 Board Terminal TB524 105605-524 Label 060012-006 Screw #6 060005-003 Lockwasher 060017-027 Screw 3/8 " 060005-009 Lockwasher

1 1

104379 104378 116818

1 5 1 1 4 4 1 1 1 1 1 2 2 3 3

Always Specify Model & Serial Number 4226 Printed in U.S.A.

02 REV. 12/93

9 - 19 - 200

HEIGHT SENSOR 2679S

HEIGHT SENSOR ASSEMBLY - 125552-001 (Includes Index 1 Thru 22) Index Part No. 1 2 3 4 5 6 7

8 9 10 11 12 13 14 15

Part Name

060014-031 Screw 060005-005 Lockwasher 104226 Cover 100502 Spacer 063002-021 Lubricant 094356 Arbor 107203 Spring Motor 094983 Spacer 063002-021 Lubricant 107202 Retainer 060012-016 Screw 060005-003 Lockwasher 125551 Reel Cable 094422-002 Cable 065081-038 Bearing Ball 125550 Housing Sensor 065081-001 Bearing Ball 060030-021 Flatwasher 060009-003 Ring Retaining Nut Lockwasher

No. Req. 4 4 1 1 AR 1 1 1 AR 1 2 2 1 1 1 1 1 AR 1 1 1

Index Part No. 16 17 18

Part Name

No. Req.

Retainer Pin Taper Encoder ECR4 Includes Index 15 062007-015 Terminals 060013-001 Screw Set 104398 Case 060013-002 Screw 060005-004 Lockwasher 107208 Sleeve Stop 105531 Bracket 079565-003 Strip Marking 079564-003 Board Terminal TB524 105605-524 Label 060012-006 Screw 060005-003 Lockwasher 060017-027 Screw 060005-009 Lockwasher 060017-031 Screw 060017-014 Screw

1 1

104379 104378 116818

19 20 21 22 23 24 25 26 27

1 5 1 1 4 4 1 1 1 1 1 2 2 1 2 1 1

Always Specify Model, Data & Serial Numbers

971003

6138 - 45962

Crown 1998 PF11377 Rev. 6/99

Printed in U.S.A.

02 REV. 6/99

09.0–19.0–201

GATE 3252S

L.H. GATE SHOWN

3 PART OF PLATFORM

16 2

16 18

PART OF PLATFORM

17 5 20

7 14

2 16 1

21 16

6 12 9

8 10

16 2

3 21

11 16 21

Crown 1994 PF-10280 REV. 9/95

09.0–19.0–251

Printed in U.S.A.

01 REV. 9/95

09.0–19.0–251

GATE Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Part Name

No. Req.

101532 Shaft Upper 104347-001 Bearing Nylon 060000-051 Roll Pin 118922-001 Gate Arm 060016-072 Screw 5/16" 061004-026 Ahesive Thread Locking 060030-040 Flatwasher 101535-001 Shaft Lower 105376 Bumper Gate 074909 Spring 101542-001 Actuator Switch 060014-006 Screw #10 060005-005 Lockwasher 060015-073 Screw 1/4" 101543 Cover 060012-022 Screw #6 060005-003 Lockwasher 087373 Switch GTSL Shown 087373 Switch GTSR 092143 Plate Fastening 060017-099 Screw 3/8" 060046-021 Washer 061004-019 Adhesive Thread Locking 090651-002 Plug 118364 Shaft 107005-001 Handle 065038-015 Bearing Oilite 108250 Gate Upright 060030-075 Flatwasher

2 6 3 3 2 1 2 1 1 1 1 2 2 2 1 2 2 1 1 1 6 6 1 2 3 1 1 1 4

Quantities listed are for one assembly only Always Specify Model & Serial Number

940815

4817 - 41859 Printed in U.S.A.

09.0–19.0–252

01 REV. 9/95

09.0–19.0–252

TRAVERSE DRIVE 0646S-01

Crown 1988 PF7728 Rev. 8/98

Printed in U.S.A.

06 REV. 8/98

09.1–19.0–100

TRAVERSE DRIVE Index Part No. 1 2 3 4 5

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Part Name

No. Req.

125714 Motor Hydraulic 061008-006 Key Woodruff 060017-021 Screw 060005-009 Lockwasher 103812 Weldment Support 060017-010 Screw 060030-167 Washer 060005-009 Lockwasher 060030-059 Washer 060019-016 Screw 061004-012 Thread Locking Adhesive 089912-002 Washer Thrust 101400 Sprocket 15 T. 101392 Cap Retaining 060015-037 Screw 060005-007 Lockwasher 078833-003 Chain Roller 076902-003 Link Connecting 060017-006 Screw 060005-009 Lockwasher 101393 Weldment Idler Shaft 076048 Fitting Lubrication 060009-037 Ring Retaining 060030-079 Washer 060030-093 Washer 061009-014 Key 101391 Sprocket 13 T. 060017-007 Screw 060005-009 Lockwasher 101397 Weldment Hub 065084-005 Bearing DX 060030-215 Washer Shim 060030-227 Washer Shim 103725 Gear Idler 076293 Roller Carriage 076143 Cap 060016-022 Screw 061004-012 Thread Locking Adhesive 103762 Extension Fitting 061004-012 Thread Locking Adhesive 105252 Weldment Torque Tube 060009-044 Ring Retaining 060038-006 Pin Cotter 060021-011 Nut 060005-009 Lockwasher 060017-007 Screw 060005-009 Lockwasher 101410 Plate Retainer 105237 Gasket 101678 Bolt Drilled 074668-001 Roller Column 060009-018 Ring Retaining

1 1 4 4 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 AR AR 1 1 2 2 1 6 AR AR 2 4 2 2 1 2 1 1 2 1 1 1 2 2 1 1 1 1 1

Index Part No. 40 41 42 43 44

Part Name

No. Req.

060030-215 Washer Shim AR 060030-227 Washer Shim AR 108113 Bar Support 1 060019-053 Screw 5 109147-001 Shim .024 in. (0.6mm) AR 109147-002 Shim .015 in. (0.4mm) AR 109147-003 Shim .005 in. (0.125mm) AR 111399 Bar 1 060017-056 Screw 2 060005-009 Lockwasher 2 061004-012 Thread Locking Adhesive 1 103859 Bracket Hose 2 060013-014 Screw 2 060005-004 Lockwasher 2 060021-004 Nut 2 103827 Actuator 2 060014-002 Screw 4 060005-005 Lockwasher 4 060030-044 Washer 4 103818 Bracket Switch - L.H. Shown 1 103815 Bracket Switch - R.H. 1 082605 Switch TLS Shown 1 082605 Switch TRS 1 060012-023 Screw 4 060005-003 Lockwasher 4 104081 Switch - L.H. Shown lncludes 48, 49, 51 & 52 1 104080 Switch - R.H. Includes 48, 49, 51 & 52 1 111398 Wear Strip 2 108115-001 Shim .005 in. (0.125mm) AR 108115-002 Shim .015 in. (0.4mm) AR 108115-003 Shim .030 in. (0.75mm) AR 060015-053 Screw 4 061004-012 Thread Locking Adhesive 1 108119-001 Actuator 52 & 58 in. (1320mm & 1475mm) Traverse Frame Width 1 108119-002 Actuator 53 & 59 in. (1350mm & 1500mm) Traverse Frame Width 1 108119-003 Actuator 54 & 60 in. (1375mm & 1525mm) Traverse Frame Width 1 108119-004 Actuator 55 & 61 in. (1400mm & 1550mm) Traverse Frame Width 1 108119-005 Actuator 56 & 62 in. (1425mm & 1575mm) Traverse Frame Width 1 108119-006 Actuator 57 & 63 in. (1450mm & 1600mm) Traverse Frame Width 1 060014-042 Screw 4 061004-020 Thread Locking Adhesive 1

45 46

47 48

49 50

51 52

54 55

56 57

Always Specify Model, Data & Serial Numbers 5844 Printed in U.S.A.

06 REV. 8/98

09.1–19.0–101

PIVOT MECHANISM 15

14 1

1495S-01

12 54

11 9

2 21 23

24 17

29 20

29 26

27 34

25 26 51

36 48 38 50

41 39

45 42 43

43 46

Crown 1992 PF-9475 Rev. 11/93

41 Printed in U.S.A.

01 REV. 11/93

9.1 - 19 - 202

PIVOT MECHANISM Index Part No. 1

3 4 5 6 7 8 9

11 12 13

14 15 16 17 18 19 20 21 22 23 24 25

Part Name

No. Req.

079564-004 Board Terminal TB703 1 105605-703 Label 1 079565-004 Strip Marking 1 060012-027 Screw #6 2 060005-003 Lockwasher 2 079564-004 Board Terminal TB704 1 105605-704 Label 1 079565-004 Strip Marking 1 060012-027 Screw #6 2 060005-003 Lockwasher 2 103823 Bracket 1 060016-016 Screw 5/16" 2 Nut Switch 4 077656 Switch PRS Includes Index 4 1 077656 Switch PLS Includes Index 4 1 060017-007 Screw 3/8" 2 060005-009 Lockwasher 2 101288 Cylinder Pivot Latch See Section 8.8 1 101295 Pin Locking 1 061004-012 Thread Locking Adhesive 1 060030-083 Flatwasher .031 in. (.8mm) AR 060030-134 Flatwasher .218 in. (5.5mm) AR 060030-167 Flatwasher .125 in. (3.2mm) AR 060030-168 Flatwasher .125 in. (3.2mm) AR 114568-002 Cylinder Pivot 23" Load Handler See Section 8.8 2 114568-003 Cylinder Pivot 27" Load Handler See Section 8.8 2 065012-001 Bushing Ball 2 101718 Pin 2 060015-004 Screw 1/4" 2 060005-007 Lockwasher 2 060030-106 Flatwasher 2 060015-033 Screw 1/4" 2 103865 Bracket Mounting 1 105603-001 Manifold 48 Volt See Section 2.41 105603-002 Manifold 72 Volt See Section 2.41 060015-007 Screw 1/4" 1 060005-007 Lockwasher 1 101993 Clamp Hose 1 060016-003 Screw 5/16" 4 060005-008 Lockwasher 4 103831 Bracket 1 060017-034 Screw 3/8" 2 060005-009 Lockwasher 2 060038-005 Pin Cotter 2 060021-015 Nut 2 060030-189 Flatwasher 2 101570 Shim 0.06" (1.5mm) Thickness AR 111638 Shim 0.03" (.8mm) Thickness AR

Index Part No. 26 27

28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

49 50

51 52 53 54

Part Name

No. Req.

101161-001 Stop Poly 060015-012 Screw 1/4" 060005-007 Lockwasher 060030-012 Flatwasher 074486-001 Bushing Stop 093262-001 Chain Roller See Note A 076902-005 Link Connecting 065084-002 Bushing DX 101406 Plate Bearing 101679 Bolt Drilled 076048 Fitting Lubrication 060015-033 Screw 1/4" 101992 Clamp Hose 060016-016 Screw 5/16" 101989 Guide Hose 101994 Clamp Hose 060016-003 Screw 5/16" 060005-008 Lockwasher 104047 Cover 060015-004 Screw 1/4" 061004-012 Thread Locking Adhesive 092747-003 Stop Poly 092746-003 Bracket 065087 Bearing Thrust 076048 Fitting Lubrication 065084-004 Bearing DX 103877 Flatwasher 060017-007 Screw 060005-009 Lockwasher 079564-004 Board Terminal TB701 105605-701 Label 079565-004 Strip Marking 060012-030 Screw #6 060005-003 Lockwasher 105019 Plate Mounting 079564-004 Board Terminal TB702 105605-702 Label 079565-004 Strip Marking 060012-027 Screw #6 060005-003 Lockwasher 065004-007 Grommet 108714 Clamp Hose 060015-007 Screw 1/4" 060005-007 Lockwasher 060019-040 Screw 1/2" 060030-154 Flatwasher

2 2 2 2 2 1 2 1 1 2 2 2 1 1 1 1 2 2 1 2 1 2 2 1 1 1 1 2 2 1 1 1 2 2 1 1 1 1 2 2 2 1 1 1 1 1

Always Specify Model & Serial Number (Note “A” = Cut Chain to 13" [13 links] Length)

3856-36593 Printed in U.S.A.

01 REV. 11/93

9.1 - 19 - 203

PIVOT MECHANISM 15

1495S-01

12 54

21 23

24 17

29 20 19

Indexes 14 thru 20 with telescopic forks only.

35 36

26 51

48 38

45 42

43 46

Crown 1994 PF-10215 Rev. 5/97

09.1–19.0–204

41 Printed in U.S.A.

01 REV. 5/97

09.1–19.0–204

PIVOT MECHANISM Index Part No. 1

3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20

22 23

Part Name

No. Req.

079564-004 Board Terminal TB703 1 105605-703 Label 1 079565-004 Strip Marking 1 060012-027 Screw 2 060005-003 Lockwasher 2 079564-004 Board Terminal TB704 1 105605-704 Label 1 079565-004 Strip Marking 1 060012-027 Screw 2 060005-003 Lockwasher 2 103823 Bracket 1 060016-016 Screw 2 Nut Switch 4 077656 Switch PRS Includes 4 1 077656 Switch PLS Includes 4 1 060017-007 Screw 2 060005-009 Lockwasher 2 101288 Cylinder Pivot Latch See Section 8.8 1 101295 Pin Locking 1 061004-012 Thread Locking Adhesive 1 060030-083 Flatwasher .031 in. (.8mm) AR 060030-134 Flatwasher .218 in. (5.5mm) AR 060030-167 Flatwasher .125 in. (3.2mm) AR 060030-168 Flatwasher .125 in. (3.2mm) AR Cylinder Pivot See Section 8.8 2 065012-001 Bushing Ball 2 101718 Pin 2 060015-004 Screw 2 060005-007 Lockwasher 2 060030-106 Flatwasher 2 060015-033 Screw 2 103865 Bracket Mounting 1 Manifold Traverse See Section 2.4 1 060015-007 Screw 1 060005-007 Lockwasher 1 101993 Clamp Hose 1 060016-003 Screw 4 060005-008 Lockwasher 4 103831 Bracket 23" (585mm) to 30" (760mm) Load Handler 1 117072 Bracket 33" (840mm) to 54" (1370mm) Load Handler 1 060017-034 Screw 4 060017-034 Screw 33" (840mm) to 54" (1370mm) Load Handler 8 060005-009 Lockwasher 4 060005-009 Lockwasher 33" (840mm) to 54" (1370mm) Load Handler 8 060038-005 Pin Cotter 2 060021-015 Nut 2

Index Part No. 24 25

Part Name

No. Req.

060030-189 Flatwasher 2 101570 Shim 0.06" (1.5mm) Thickness AR 111638 Shim 0.03" (.8mm) Thickness AR 101161-001 Stop Poly 2 060015-012 Screw 2 060005-007 Lockwasher 2 060030-012 Flatwasher 2 074486-001 Bushing Stop 2 093262-001 Chain Roller See Note A 1 076902-005 Link Connecting 2 065084-002 Bushing DX 1 101406 Plate Bearing 1 101679 Bolt Drilled 2 076048 Fitting Lubrication 2 060015-033 Screw 2 101992 Clamp Hose 1 060016-016 Screw 1 108943 Guide Hose 1 101994 Clamp Hose 1 060016-003 Screw 2 060005-008 Lockwasher 2 104047 Cover 1 060015-004 Screw 2 061004-012 Thread Locking Adhesive 1 092747-003 Stop Poly 2 092746-003 Bracket 2 065087 Bearing Thrust 1 076048 Fitting Lubrication 1 065084-004 Bearing DX 1 103877 Flatwasher 1 060017-007 Screw 2 060005-009 Lockwasher 2 079564-004 Board Terminal TB701 1 105605-701 Label 1 079565-004 Strip Marking 1 060012-030 Screw 2 060005-003 Lockwasher 2 105019 Plate Mounting 1 079564-004 Board Terminal TB702 1 105605-702 Label 1 079565-004 Strip Marking 1 060012-027 Screw 2 060005-003 Lockwasher 2 065004-007 Grommet 2 108714 Clamp Hose 1 060015-007 Screw 1 060005-007 Lockwasher 1 060019-040 Screw 1 060030-154 Flatwasher 1

26 27

28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

49 50

51 52 53 54

Always Specify Model, Data & Serial Numbers (Note “A” = Cut Chain to 13" [13 links] Length)

940531

5430 Printed in U.S.A.

09.1–19.0–205

01 REV. 5/97

09.1–19.0–205

FORK CARRIAGE 2024

TELESCOPIC

TO AUXILIARY MAST 33

3 1

31 6

8 STOP LOCATION FOR TRUCKS WITH A 27in.(685mm) LOAD HANDLER HEAD LENGTH

12 15 16 19

26 20

27 29

23 17

9.1 - 19 - 301

30 22

24 25

Crown 1993 PF-9813

STOP LOCATION FOR TRUCKS WITH A 23in.(580mm) LOAD HANDLER HEAD LENGTH

Printed in U.S.A.

9.1 - 19 - 301

FORK CARRIAGE Index Part No.

Part Name

No. Req.

1 110042 Rod Fork 2 110046 Weldment Fork Carriage 3 060000-045 Pin Roll 4 * 089260-030 Chain 5 089073-002 Pin Chain 6 060000-045 Pin Roll 7 060030-050 Flatwasher .06 in. (1.5mm) 060030-068 Flatwasher .03 in. (.7mm) 8 074020 Roller Column 9 060015-006 Screw 1/4" 060005-007 Lockwasher 060030-012 Flatwasher 10 074486-001 Bushing Stop 11 108112 Stop Poly 12 060009-017 Ring Retaining 13 Fork Assembly Telescopic See Section 7.9 14 071977-003 Clamp 15 060015-019 Screw 1/4" 060005-007 Lockwasher 16 110044 Cover 17 060015-053 Screw 1/4" 18 060015-053 Screw 1/4" 19 110713 Spacer 20 110712 Shim 21 077656 Switch AHS 22 060012-022 Screw #6 060005-003 Lockwasher 23 092143 Plate Fastening 24 105438 Bracket Switch 25 060015-003 Screw 1/4" 060005-007 Lockwasher 26 060030-116 Flatwasher 27 082608-005 Roller 28 082609 Pin 29 104894 Actuator 30 060012-014 Screw #6 060005-003 Lockwasher 31 089132-002 Stop Poly 32 074486-002 Bushing Stop 33 060015-016 Screw 1/4" 060005-006 Lockwasher 060030-040 Flatwasher

2 1 1 5 1 1 AR AR 4 4 4 4 4 2 4 2 2 2 2 1 4 4 2 AR 1 2 2 1 1 2 2 2 1 1 1 2 2 2 2 2 2 2

Always Specify Model & Serial Number * Cut Chain to 49 in. (1245mm) [49 Links] in Length.

891023

2598 - 33232 Printed in U.S.A.

9.1 - 19 - 302

TELESCOPIC FORK CARRIAGE 2024-02

To Auxiliary Mast 4

3 6

32 31 7

Stop Location For Trucks With A 580 mm (23 in.) Load Handler Head Length 10 9 11

13 12 15 18 19

20 Stop Location For Trucks With A 685 mm (27 in.) Load Handler Head Length

†26 †27 †26

14 †29 17

†28

†23

†30 †22

†24 †25 †Indicates Mounting Location Of Switch AHS For North American Trucks. For International Trucks Switch AHS Mounts On Opposite Side Of Fork Carriage.

†21 AHS

Crown 1994 PF10216 Rev. 3/02

Printed in U.S.A.

03 REV. 3/02

09.1–19.0–303

TELESCOPIC FORK CARRIAGE Index Part No. 1 2

3 4 5 6 7

8 9

10 11

12 13 14 15 16 17 18

110042 110046

Part Name

No. Req.

Fork Rod Fork Carriage 760 mm (30 in.) Width** 117148-001 Fork Carriage 1070 mm (42 in.) Width** 117148-002 Fork Carriage 1370 mm (54 in.) Width** 060000-045 Roll Pin * 089260-030 Chain 089073-002 Chain Pin 060000-045 Roll Pin 060030-050 Flatwasher 1.5 mm (.06 in.) 060030-068 Flatwasher 0.7 mm (.03 in.) 060030-297 Flatwasher 0.4 mm (.016 in.) 074020 Column Roller 060015-006 Screw 060005-007 Lockwasher 060030-012 Flatwasher 074486-001 Bushing 108112 Poly Stop 123456-001 Shim 3.0 mm (.12 in.) 123456-002 Shim 1.5 mm (.06 in.) 060009-017 Retaining Ring Telescopic Fork Assembly See Section 7.9 071977-003 Clamp 060015-019 Screw 060005-007 Lockwasher 110044 Cover 060015-053 Screw 060015-053 Screw

2 1

Index Part No. 19 20 21 22

1 1 1 5 1 1 AR AR AR 4 4 4 4 4 2 AR AR 4 2 2 2 2 1 4 4

23 24

25 26 27 28 29 30 31 32 33

Part Name

No. Req.

110713 Spacer 110712 Shim 077656 Switch AHS 060012-022 Screw 060005-003 Lockwasher 092143 Fastening Plate 108765 L.H.Switch Bracket North American Trucks (Shown) 108764 R.H. Switch Bracket International Trucks 060015-003 Screw 060005-007 Lockwasher 060030-116 Flatwasher 082608-005 Roller 082609 Pin 104894 Actuator 060012-014 Screw 060005-003 Lockwasher 089132-002 Poly Stop 074486-002 Bushing 060015-016 Screw 060005-006 Lockwasher 060030-040 Flatwasher

2 AR 1 2 2 1 1 1 2 2 2 1 1 1 2 2 2 2 2 2 2

Always Specify Model, Data & Serial Numbers 105703 108849

Wire Harness North American Trucks Wire Harness International Trucks

1 1

* Cut Chain to 1245 mm (49 in.) [49 Links] in Length. ** Measured Across Forks

940531

2667 SERV. Printed in U.S.A.

03 REV. 3/02

09.1–19.0–304

FORK CARRIAGE 2021

FIXED TO AUXILIARY MAST 4 2 3

10 9

13 14

12 Index Part No. 1 2

3 4 5 6 7 8

16 Part Name

No. Req.

108573 Rod Fork 2 110526-001 Fork Carriage With 4 in. (100mm) Extension 1 110526-002 Fork Carriage With 5 in. (125mm) Extension 1 110526-003 Fork Carriage With 6 in. (150mm) Extension 1 060000-045 Pin Roll 1 * 089260-030 Chain 5 089073 Pin Chain 1 060000-045 Pin Roll 1 060030-050 Flatwasher .06 in. (1.5mm) AR 060030-068 Flatwasher .03 in. (.7mm) AR 074020 Roller Column 4

Index Part No. 9 10 11 12 13 14 15 16

Part Name

No. Req.

060009-043 Ring Retaining Fork Assembly Fixed See Section 7.9 108497 Cover 060015-053 Screw 1/4" 108554-001 Spacer 109194 Spacer 060015-053 Screw 1/4" 079564-004 Block Terminal 060012-027 Screw #6 060005-003 Lockwasher

4 2 1 4 2 AR 4 1 4 4

Always Specify Model & Serial Number *Cut Chain To 49 in. (1245mm) [49 Links]) in Length.

891023 Crown 1993 PF-9814

9.1 - 19 - 350

2253 - 33117 Printed in U.S.A.

9.1 - 19 - 350

FORK CARRIAGE 2021-02

FIXED

TO AUXILIARY MAST 4 2 3 1

5 6

18 19

Stop Location 27 in.(685mm) Load Handler Head Length

11 13 15

Crown 1994 PF-10214 Rev. 8/96

Stop Location 23 in.(580mm) Load Handler Head Length

Printed in U.S.A.

02 REV. 8/96

09.1–19.0–351

FORK CARRIAGE Index Part No.

Part Name

No. Req.

108573-001 Rod Fork 30 in. (760mm) Wide Fork Carriage 2 108573-002 Rod Fork 42 in. (1060mm) & 54 in. (1370mm) Wide Fork Carriage 2 2 ** Fork Carriage 1 3 060000-045 Pin Roll 1 4 * 089260-030 Chain 5 5 089073 Pin Chain 1 6 060000-045 Pin Roll 1 7 060030-050 Flatwasher .06 in. (1.5mm) AR 060030-068 Flatwasher .03 in. (0.7mm) AR 060030-297 Flatwasher .016 in. (0.4mm) AR 8 074020 Roller Column 4 9 060009-043 Ring Retaining 4 10 Fork Assembly Fixed See Section 7.9 2 11 108497 Cover 1 12 060015-053 Screw 1/4" 4 13 108554-001 Spacer 30 in. (760mm) Wide Fork Carriage 2 108554-002 Spacer 42 in. (1060mm) & 54 in. (1370mm) Wide Fork Carriage 2 14 109194-001 Spacer 30 in. (760mm) Wide Fork Carriage AR 109194-002 Spacer 42 in. (1060mm) & 54 in. (1370mm) Wide Fork Carriage 2 15 060015-053 Screw 1/4" 4 16 079564-004 Block Terminal 1 060012-027 Screw #6 4 060005-003 Lockwasher 4 17 108112 Stop Poly 2 123456-001 Shim .12 in. (3.0mm) AR 123456-002 Shim .06 in. (1.5mm) AR 18 074486-001 Bushing Stop 4 19 060015-006 Screw 1/4" 4 060005-007 Lockwasher 4 060030-012 Flatwasher 4 Always Specify Model & Serial Number *Cut Chain To 49 in. (1245mm) [49 Links]) in Length. **See Following Supplemental List.

940531

5103 - 43001 Printed in U.S.A.

02 REV. 8/96

09.1–19.0–352

FORK CARRIAGE INDEX 2 FORK CARRIAGE

Overtravel (Extension)

Fork Carriage Width Across Forks 30 in. 42 in. 54 in. (760mm) 1060mm) (1370mm)

4 in. (100mm)

117128-001

117128-002

117128-003

5 in. (130mm)

117126-001

117126-002

117126-003

6 in. (150mm)

117115-001

117115-002

117115-003

Crown 1994 PF-10214 Rev. 8/96

Printed in U.S.A.

02 REV. 8/96

09.1–19.0–351-SUP

LABELS AND DECALS 4029S

21 16 0.75 in. 19 mm

18 15 22 5 13 0.81 in. 21 mm

5 5

STAMPED SERIAL NUMBER

13 29

2.75 in. 70 mm

DATE OF MANUFACTURE 0.75 in. 19 mm

0.75 in. 19 mm

24 9

7 26

Crown 1988 PF-8146-1 Rev. 8/95

Printed in U.S.A.

01 REV. 8/95

10.9–19.0–001

LABELS AND DECALS 3948S

9.0 in. 230 mm 0.75 in. 19 mm

6 11

8 2.75 in. 70 mm 12 10

Crown 1988 PF-8146-2 Rev. 8/95

Printed in U.S.A.

01 REV. 8/95

10.9–19.0–002

LABELS AND DECALS 3949S

17 1.5 in. 38 mm

4 25

14 20

6 5

Crown 1988 PF-8146-3 Rev. 8/95

Printed in U.S.A.

01 REV. 8/95

10.9–19.0–003

LABELS AND DECALS Index Part No.

Part Name

No. Req.

1 106290-002 Decal Crown Banner 2 106290-001 Decal Crown Banner 3 107166 Warning Manual Lowering 4 105074 Warning Override 5 087062 Warning Hands Off 6 086740 Caution Do Not Stand Under 7 104797 Warning Electrical Hazard 8 106158-006 Decal Crown Heavy 9 094171 Warning No Hook 10 094976 Warning Spring Loaded 11 106158-012 Decal Crown Heavy 12 094412 Tread Outrigger 13 104742 Warning Electrical Additions 14 094731 Warning Rider Trucks 15 073768 Decal Patent Pending 16 094938 Warning Load Hazard 17 106158-004 Decal Crown Heavy 18 * Nameplate Serial 060027-014 Rivet 19 087617 Warning Do Not Stand On 20 086279 Envelope Manual Holder 113280 Bag Poly 086608 Ring 086609 Clip 21 077607-002 Nameplate Used Only On California Trucks 22 069135 Label Patent

1 1 1 1 14 4 3 3 1 3 1 2 5 1 1 1 1 1 4 1 1 1 1, 1 1 1

Index Part No. 23

24 25 26 27

28 29

Part Name

No. Req.

104798-047 Warning Battery Size 17.88 x 38.31 in. (455 x 975 mm)1 104798-049 Warning Battery Size 17.88 x 38.06 in. (455 x 967 mm)1 104798-052 Warning Battery Size 13.25 x 38.06 in. (337 x 967 mm)1 104798-053 Warning Battery Size 13.25 x 37.81 in. (337 x 960 mm)1 104798-054 Warning Battery Size 13.12 x 37.69 in. (333 x 957 mm)1 104798-055 Warning Battery Size 15.62 x 38.06 in. (397 x 967 mm)1 104798-056 Warning Battery Size 15.50 x 37.81 in. (394 x 960 mm)1 104798-057 Warning Battery Size 15.50 x 37.69 in. (394 x 957 mm)1 104798-058 Warning Battery Size 17.88 x 37.81 in. (455 x 960 mm)1 104798-059 Warning Battery Size 26.88 x 38.31 in. (683 x 975 mm)1 104798-060 Warning Battery Size 26.88 x 38.06 in. (683 x 967 mm)1 104798-061 Warning Battery Size 32.75 x 38.31 in. (831 x 975 mm)1 104798-062 Warning Battery Size 32.75 x 38.06 in. (831 x 967 mm)1 104484 Caution Do Not Push 1 108512 Warning Mirror 1 108481 Warning Moving Linkage 1 110938 Danger High Pressure 1 110941 Tag 1 086608 Ring 1 069088 Warning End of Aisle 1 107668 Warning Tow Drive 1 Always Specify Model & Serial No. MISCELLANEOUS 107373

Kit Decal Includes Index 3 thru 7, 9, 10, 13, 14, 16, 19, & 24 thru 29

2899 - 40532 Crown 1988 PF-8146-4 Rev. 8/95

Printed in U.S.A.

01 REV. 8/95

10.9–19.0–004

LABELS AND DECALS 5441S

16 0.75 in. 19 mm

5 2

18 15

5 0.81 in. 21 mm

5 5

Stamped Serial Number

29 13 2.75 in. 70 mm

Date of Manufacture 0.75 in. 19 mm

0.75 in. 19 mm 24 3

7 26

950828

5036 - 42717

Crown 1995 PF-10707-1 Rev. 7/96

Printed in U.S.A.

02 REV. 7/96

10.9–19.0–005

LABELS AND DECALS 5442S

On Filler Breather Cap 22

9.0 in. 230 mm 6 11

0.75 in. 19 mm

8 2.75 in. 70 mm 12

Crown 1995 PF-10707-2 Rev. 7/96

Printed in U.S.A.

02 REV. 7/96

10.9–19.0–006

LABELS AND DECALS 5443S

17 1.5 in. 38 mm

25 28

14 20

6 5

Crown 1995 PF-10707-3 Rev. 7/96

Printed in U.S.A.

02 REV. 7/96

10.9–19.0–007

LABELS AND DECALS DOMESTIC Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

19 20

21 22

Part Name

No. Req.

106290-002 Decal Crown Banner 106290-001 Decal Crown Banner 069158 Warning Lowering Valve 069046 Label Override 069006 Warning Hands Off 069010 Warning Stand Under 069019 Danger High Voltage 106158-006 Decal Crown 069043 Caution No Hook 069042 Danger Spring Loaded 106158-012 Decal Crown 094412 Tread Outrigger 069012 Warning Electrical Additions 069005 Warning Rider Trucks 069135 Label Patent 069044 Warning Load Hazard 106158-004 Decal Crown Nameplate Serial Contact Factory 060027-014 Rivet 069009 Warning Stand On 086608 Ring 086609 Clip 086279 Envelpoe Manual 113280 Bag Poly 069088 Warning End of Aisle 069154 Label Hydraulic Oil

1 1 1 1 14 4 1 3 1 3 1 2 5 1 1 1 1 1 4 1 1 1 1 1 1 1

Index Part No. 23

24 25 26 27

28 29

950828

Part Name

No. Req.

069014-020 Label Battery 17.88 x 38.31 in. 069014-050 Label Battery 17.88 x 38.06 in. 069014-052 Label Battery 13.25 x 38.06 in. 069014-053 Label Battery 13.25 x 37.81 in. 069014-054 Label Battery 13.12 x 37.69 in. 069014-055 Label Battery 15.62 x 38.06 in. 069014-056 Label Battery 15.50 x 37.81 in. 069014-057 Label Battery 15.50 x 37.69 in. 069014-058 Label Battery 17.88 x 37.81 in. 069014-059 Label Battery 26.88 x 38.31 in. 069014-060 Label Battery 26.88 x 38.06 in. 069014-061 Label Battery 32.75 x 38.31 in. 069014-062 Label Battery 32.75 x 38.06 in. 069022 Caution Don’t Push 069041 Warning Blind Spots 069040 Warning Steering Linkage 069039 Danger Pressurized Fluid 086608 Ring 110941 Tag 069077 Warning No Passengers 107668 Warning Tow Switch/Driver

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Always Specify Model & Serial Number MISCELLANEOUS 121354

Kit Decal Includes Index 3, 5, 6, 7, 9, 10, 13, 14, 16, 19, 21, & 24 thru 29

5036 - 42717

Crown 1995 PF-10707-4 Rev. 7/96

Printed in U.S.A.

02 REV. 7/96

10.9–19.0–008

LABELS AND DECALS INTERNATIONAL Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

19 20

21 22 23

Part Name

No. Req.

106290-002 Decal Crown Banner 1 106290-001 Decal Crown Banner 1 869158-* Warning Lowering Valve 1 869046-* Label Override 1 869006-* Warning Hands Off 14 869010-* Warning Stand Under 4 869019-* Danger High Voltage 1 106158-006 Decal Crown 3 869043-* Caution No Hook 1 869042-* Danger Spring Loaded 3 106158-012 Decal Crown 1 094412 Tread Outrigger 2 869012-* Warning Electrical Additions 5 869004-* Warning Moving Vehicle 1 869005-* Warning Rider Trucks 1 069135 Label Patent 1 869044-* Warning Load Hazard 1 106158-004 Decal Crown 1 Nameplate Serial Contact Factory 1 060027-014 Rivet 4 869009-* Warning Stand On 1 086608 Ring 1 086609 Clip 1 086279 Envelpoe Manual 1 113280 Bag Poly 1 869088-* Warning End of Aisle 1 069154 Label Hydraulic Oil 1 069014-020 Label Battery 17.88 x 38.31 in. 1 069014-050 Label Battery 17.88 x 38.06 in. 1 069014-052 Label Battery 13.25 x 38.06 in. 1 069014-053 Label Battery 13.25 x 37.81 in. 1 069014-054 Label Battery 13.12 x 37.69 in. 1 069014-055 Label Battery 15.62 x 38.06 in. 1 069014-056 Label Battery 15.50 x 37.81 in. 1 069014-057 Label Battery 15.50 x 37.69 in. 1 069014-058 Label Battery 17.88 x 37.81 in. 1 069014-059 Label Battery 26.88 x 38.31 in. 1 069014-060 Label Battery 26.88 x 38.06 in. 1 069014-061 Label Battery 32.75 x 38.31 in. 1 069014-062 Label Battery 32.75 x 38.06 in. 1

Index Part No.

Part Name

24 25 26 27

Caution Don’t Push Warning Blind Spots Warning Steering Linkage Danger Pressurized Fluid Ring Tag Warning No Passengers Warning Tow Switch/Driver

28 29

869022-* 869041-* 869028-* 869039-* 086608 110941 869077-* 869146-*

No. Req. 1 1 1 1 1 1 1 1

Always Specify Model & Serial Number MISCELLANEOUS 123347

Kit Decal Includes Index 3, 5, 6, 7, 9, 10, 13, 14, 16, 19, 21, & 24 thru 29

* Choice of dash no. depends on language. When ordering, refer to the chart below and complete the part no. with the correct dash no. Dash No.

Language

001 002 003 004 005 006

German French Spanish Dutch Italian English

Example: If index 5 with German language is required, order 869012-001.

950828

5036 - 42717

Crown 1995 PF-10707-5 Rev. 7/96

Printed in U.S.A.

02 REV. 7/96

10.9–19.0–009

LABELS AND DECALS 5441S-02

22mm (.85 in) TN Mast 390mm (15.34 in) TF Mast 17mm (.66 in) 72mm (2.83 in)

103mm (4.04 in)

8 Centered from Side to Side

5 21

22mm (.85 in) TN Mast 186mm (7.31 in) TF Mast

15 18mm (.71 in)

7 5

13 Stamped Serial Number

7 17 56mm (2.20 in)

127mm (5.00 in) 13

212mm (8.36 in) 17mm (.66 in)

6mm (.24 in)

Date of Manufacture

17 27

9 26

Crown 2000 PF11968-1 Rev. 10/02

Printed in U.S.A.

01 REV. 10/02

10.9–19.0–010

LABELS AND DECALS 5442S-02

17mm (.66 in) 21mm (.81 in) TN Mast 224mm (8.83 in) TF Mast 103mm (4.04 in)

17 1

123mm (4.86 in) TN Mast 336mm (13.22 in) TF Mast

On Filler Breather Cap 22 2

Centered on Mast 17

180mm (7.07 in)

6 17mm (.66 in)

17 56mm (2.20 in)

Crown 2000 PF11968-2 Rev. 10/02

Printed in U.S.A.

01 REV. 10/02

10.9–19.0–011

LABELS AND DECALS 5443S-02

28 20

11 17

101mm (3.97 in)

19 132mm (5.21 in)

187mm (7.35 in) 1

6 291mm (11.46 in)

Crown 2000 PF11968-3 Rev. 10/02

Printed in U.S.A.

01 REV. 10/02

10.9–19.0–012

LABELS AND DECALS DOMESTIC Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

19 20

21 22

Part Name

No. Req.

069372-022 Decal Momentum TSP 069020 Danger Battery 069013 Warning Lowering Valve 069046 Label Override 069006 Warning Hands Off 069010 Warning Stand Under 069019 Danger High Voltage 069374-001 Decal crown.com 069043 Caution No Hook 069042 Danger Spring Loaded Plate Data - Contact Factory 122857 Bezel 094412 Tread Outrigger 069012 Warning Electrical Additions 069264 Warning Rider Trucks 069004 Warning Moving Vehicle 069135 Label Patent 069044 Warning Load Hazard 106158-001 Decal Crown Heavy Nameplate Serial Contact Factory 122857 Bezel 060027-014 Rivet 069009 Warning Stand On 086608 Ring 086609 Clip 121257-001 Envelope Manual 113280 Bag Poly 069088 Warning End of Aisle 069154 Label Hydraulic Oil

4 1 1 1 14 4 3 3 1 3 1 1 2 5 1 1 1 1 7 1 1 4 1 1 1 1 1 1 1

Index Part No. 23

Part Name

No. Req.

069112-020 Label Battery 454 x 973 mm (17.88 x 38.31 in.) 069112-050 Label Battery 454 x 967 mm (17.88 x 38.06 in.) 069112-085 Label Battery 337 x 967 mm (13.25 x 38.06 in.) 069112-086 Label Battery 337 x 960 mm (13.25 x 37.81 in.) 069112-087 Label Battery 334 x 957 mm (13.12 x 37.69 in.) 069112-088 Label Battery 397 x 967 mm (15.62 x 38.06 in.) 069112-089 Label Battery 394 x 960 mm (15.50 x 37.81 in.) 069112-090 Label Battery 394 x 957 mm (15.50 x 37.69 in.) 069112-091 Label Battery 454 x 960 mm (17.88 x 37.81 in.) 069112-081 Label Battery 683 x 973 mm (26.88 x 38.31 in.) 069112-082 Label Battery 683 x 967 mm (26.88 x 38.06 in.) 069112-083 Label Battery 832 x 973 mm (32.75 x 38.31 in.) 069112-084 Label Battery 832 x 967 mm (32.75 x 38.06 in.) 069022 Caution Don’t Push 069041 Warning Blind Spots 069040 Warning Steering Linkage 069039 Danger Pressurized Fluid 086608 Ring 110941 Tag 069077 Warning No Passengers 069146 Label 069176 Danger Harness

24 25 26 27

28 29 30

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Always Specify Model, Data & Serial Numbers 121354

Kit Decal Includes Index 2, 3, 5, 6, 7, 9, 10, 13, 14, 16, 19, 21, 23, & 25 thru 30

001117

3978 - EO8722

Crown 2000 PF11968-4 Rev. 10/02

Printed in U.S.A.

01 REV. 10/02

10.9–19.0–013

LABELS AND DECALS INTERNATIONAL Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

19 20

21 22 23

Part Name

No. Req.

069372-022 Decal Momentum TSP 869020-* Danger Battery 869013-* Warning Lowering Valve 869046-* Label Override 869006-* Warning Hands Off 869010-* Warning Stand Under 869019-* Danger High Voltage 069374-001 Decal crown.com 869043-* Caution No Hook 869042-* Danger Spring Loaded Plate Data - Contact Factory 122857 Bezel 094412 Tread Outrigger 869012-* Warning Electrical Additions 869004-* Warning Moving Vehicle 869264-* Warning Rider Trucks 069135 Label Patent 869044-* Warning Load Hazard 106158-001 Decal Crown Heavy Nameplate Serial Contact Factory 122857 Bezel 060027-014 Rivet 869009-* Warning Stand On 086608 Ring 086609 Clip 121257-001 Envelope Manual 113280 Bag Poly 869088-* Warning End of Aisle 069154 Label Hydraulic Oil 069112-020 Label Battery 454 x 973 mm (17.88 x 38.31 in.) 069112-050 Label Battery 454 x 967 mm (17.88 x 38.06 in.) 069112-085 Label Battery 337 x 967 mm (13.25 x 38.06 in.) 069112-086 Label Battery 337 x 960 mm (13.25 x 37.81 in.) 069112-087 Label Battery 334 x 957 mm (13.12 x 37.69 in.) 069112-088 Label Battery 397 x 967 mm (15.62 x 38.06 in.)

4 1 1 1 14 4 3 3 1 3 1 1 2 5 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1

Index Part No.

Part Name

No. Req.

069112-089 Label Battery 394 x 960 mm (15.50 x 37.81 in.) 069112-090 Label Battery 394 x 957 mm (15.50 x 37.69 in.) 069112-091 Label Battery 454 x 960 mm (17.88 x 37.81 in.) 069112-081 Label Battery 683 x 973 mm (26.88 x 38.31 in.) 069112-082 Label Battery 683 x 967 mm (26.88 x 38.06 in.) 069112-083 Label Battery 832 x 973 mm (32.75 x 38.31 in.) 069112-084 Label Battery 832 x 967 mm (32.75 x 38.06 in.) 869022-* Caution Don’t Push 869041-* Warning Blind Spots 869028-* Warning Steering Linkage 869039-* Danger Pressurized Fluid 086608 Ring 110941 Tag 869077-* Warning No Passengers 869146-* Warning Tow Switch/Driver

24 25 26 27

28 29

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Always Specify Model, Data & Serial Numbers 123347-*

Kit Decal Includes Index 3, 5, 6, 7, 9, 10, 13, 14, 16, 19, 21, & 24 thru 29

* Choice of dash no. depends on language. When ordering, refer to the chart below and complete the part no. with the correct dash no.

1 Dash No.

Language

001 002 003 004 005 006

German French Spanish Dutch Italian English

1 1 1 1 1

Example: If index 5 with German language is required, order 869006-001.

001117

3978 - EO8722

Crown 2000 PF11968-5 Rev. 10/02

Printed in U.S.A.

01 REV. 10/02

10.9–19.0–014

TECHNICAL SERVICE BULLETINS - TSP The following information covers pertinent technical service bulletins pertaining to the Turret Sideloader (TSP) lift truck. TECHNICAL SERVICE BULLETIN NO.

DESCRIPTION

TSB-251

Preparation of Trucks for Freezer Installations.

TSB-255

Meters and troubleshooting.

TSB-263

Transistor 062227 no longer available.

TSB-275

Frame or component mounting bore repair.

TSB-276

SCR card and wire guidance board “pot” adjusting tool 107369.

TSB-280

Load wheels.

TSB-281

EV100 PMT condition during plug braking.

TSB-291

EV100 SCR Panel Wiring Change.

TSB-309

Turret Truck Software.

TSB-310

Drive Unit Lubricant for Freezer applications.

TSB-312

Curtis Battery Discharge Interrupt (BDI).

TSB-317

Field Strength Meter.

TSB-318

Pivot Cylinder.

TSB-325

Mast Stabilizer Rollers.

TSB-331

Switch 089362 Polarity.

TSB-336

Improved Spur Racks (119757-).

TSB-337

Accumulators.

TSB-347

Crown Manufactured Motors and Head Bands.

TSB-367

Accessory Pump Motor Hydraulic Hose Routing.

TSB-368

Cylinder Weld Leaks.

TSB-376

Spline Insert Kits.

Crown 1990 PF8809 Rev. 7/98

(Previously page number 11 - 19 - 001)

Printed in U.S.A.

06 Rev. 7/98

11.0–19.0–100

KITS, INSTRUCTIONS - TSP The following information covers part numbers of various service kits pertaining to the Turret Stockpicker (TSP) lift truck, with instructions referenced. Service Kits Part No.

Description

107373

Decal Kit (Ref. PF6924)

109768 Transistor Replacement Kit (Ref. PF6675) 110032-001-0S Upgrade Ansi 2.2.0 Software Kit (Ref. PF6680) 110032-002-0S Upgrade TSP EEC 2.1.0 Kit (Ref. PF6680, PF6709) 110209-001 110209-002 110209-003

Fork Extension Kit (Right Hand) (Ref. PF6681) Fork Extension Kit (Right Hand) (Ref. PF6681) Fork Extension Kit (Right Hand) (Ref. PF6681)

110210-001 110210-002 110210-003

Fork Extension Kit (Left Hand) (Ref. PF6681) Fork Extension Kit (Left Hand) (Ref. PF6681) Fork Extension Kit (Left Hand) (Ref. PF6681)

110224 110568 111268-00S

Pump Assembly Kit Fork Carriage Guide Kit (Ref. PF6694) Servo Circuit Board Kit (Ref. PF6764)

111997 113045-BAS 113321-BAS

Anchor Chain Kit Eac W/G Kit (Ref. PF 6721) Eac TSP R/G (Ref. PF6721)

113322-BAS Eac Kit (Ref. PF6724) 114887-001-0S Ansi 2.4.0 Software w/o Eac Kit (Ref. PF6762) 114887-002-0S EEC 2.4.0 Software w/o Eac Kit (Ref. PF6762) 114911-001 114911-002 115023

Kit TS ANSE 4.2.0 w/o Eac (Ref. PF6704, PF6763) Kit TS EES 4.2.0 w/o Eac (Ref. PF6704, PF6763) Timing Belt Pulley Kit

115654-001 115654-002 116113

Pivot Cyl. 23" Load Handler Kit (Ref. PF6770) Pivot Cyl. 27" Load Handler Kit (Ref. PF6770) Seat Kit

116207 116841 117338

Pinion Asm. Shim Hght Tool Kit (Ref. PF6771) Mast Stabilizing Roller Kit (Ref. PF6783) FM0918 Ansi 2.6.0 Kit (Ref. FM0918)

117340 118920-001 118921-001

FM0924 EEC 2.6.0 Firmware Kit (Ref. FM0924) Gate Upper Kit (Ref. PF6841) Gate Lower Kit (Ref. PF6842)

118996-001 118996-002 118998-001

Accumulator Kit (Ref. PF6845) Obsolete - Replaced by 118996-002 Accumulator Kit (Ref. PF6845) Accumulator TSP Load Handler Kit (Ref. PF6845) Obsolete - Replaced by 118998-002

118998-002

Accumulator TSP Load Handler Kit (Ref. PF6845)

Crown 1994 PF10359-1 Rev. 9/98

11.0–19.0–200

(Previously page number 11 - 19 - 100)

05 REV. 9/98

Printed in U.S.A.

11.0–19.0–200

KITS, INSTRUCTIONS - TSP Service Kits (Continued) Part No.

Description

119057 121354 123655

72V Drive Motor Kit (Ref. PF6846) Decal TSP Kit (Ref. PF6924) Hose Accy Pump 72V Kit (Ref. PF6925)

123656 125794 125850

Hose Accy Pump 48V Kit (Ref. PF6925) Drive Unit Shipping Kit Lift Motor Insert Service 6.7 Kit (Ref. PF6951)

125851

Lift Motor Insert Service 7.5 Kit (Ref. PF6951)

Crown 1994 PF10359-2 Rev. 9/98

11.0–19.0–201

(Previously page number 11 - 19 - 100)

05 REV. 9/98

Printed in U.S.A.

11.0–19.0–201

REMANUFACTURED PARTS - TSP The following information covers pertinent remanufactured components pertaining to the Turret Stockpicker (TSP) lift truck. Remanufactured Components Part No.

Description

103905-00R 103922-00R 103931-00R

Digital Card Encoder Card CPU Card

103961-00R 103972-00R 103982-00R

Linear Conv. Card 32-Input Card Lamp Driver Card

103986-00R 103994-00R 104367-00R

Quad Driver Card Serial Link Card Servo R & L Card

104636-00R 104672-00R 104990-00R

Amplifier Sensor Distribution Panel Assembly Distribution Relay Panel Assembly

105580-00R Oscillator Card 107342-00R Oscillator Card 107711-001-0R PC Switch Board Assembly 107711-002-0R PC Switch Board Assembly 107740-00R PC Lamp Board Assembly

Crown 1994 PF10360

11.0–19.0–300

(Previously page number 11 - 19 - 101)

Printed in U.S.A.

11.0–19.0–300

mfg 20090807