Crown Forklift M Series Walkie Stacker Service Manual - PDF DOWNLOAD

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

OPERATOR INSTRUCTIONS This manual does not contain operation instructions. Operator Instructions in tag or booklet form are sent with each truck. Additional copies can be ordered if required. These booklets are for you and your personnel to insure years of safe, trouble-free operation of your Crown Lift Truck. For Series M operator instructions, refer to Crown publication, “You and Your Crown Walkie” (PF-10020).

DRIVER TRAINING Crown has available a complete series of Driver Training programs; in two parts concerning basic safety rules and operating characteristics of your series M truck. To obtain this informative material, ask your Crown dealer about "Its Up to You" and "You and Your Walkie".

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

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

For Series M capacities, technical information and dimensional specifications, please refer to the following sales literature: M Literature SF-4291 M Specifications SF-4293 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 written maintenance. The back covers replacement parts. The sectional descriptions are as follows: MAINTENANCE SECTION M1 M2 M3 M4 M5 M7 M8

DESCRIPTION Lubrication and Adjustment Hydraulics Drive Unit Electrical Brake Main Frame and Mast Assemblies Cylinder

REPLACEMENT PARTS SECTION 1 2 3 4 5 7 8 10

DESCRIPTION Power Chassis Hydraulic System and Components Drive Unit and Components Battery Charger Brake System Main Frame and Mast Assemblies Cylinders Drum Rotators and Accessories

5080 Printed in U.S.A.

Crown 1976 PF-2764-1 Rev. 8/96

03 REV. 8/96

ITD–04.4–001

ITD–04.4–001

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

15 M T 2 3 * CAPACITY Pound Rated (X 100) Ex. 15 X 100 = 1500 lbs.

FORK LENGTH 1500 lb.

Dash In. (mm) 1 26 (660) 2 30 (760) 3 36 (915) 4 42 (1065) 9 45 (1145) 5 48 (1220) 8 54 (1370)

MODEL DESIGNATION M - Motorized Intermediate Walkie Stacker T - Telescopic S - Straddle

2000 lb.

Dash In. (mm) 1 30 (760) 2 36 (915) 3 42 (1065) 4 45 (1145) 5 48 (1220) 6 54 (1370)

LIFT HEIGHT M Dash In. (mm) 1 57 (1450) 2 67 (1700) 3 77 (1955)

MS Dash In. (mm) 1 54 (1370) 2 64 (1625) 3 74 (1880)

MT Dash In. (mm) 1 90 (2285) 2 110 (2795) 3 130 (3300)

EXAMPLE: A truck having amodel number 20 MT-2-3 is a 1500 lb. capacity, intermediate duty telescopic walkie stacker with 110 inch lift height and 36 inch fork length. * Actual rated capacity may vary, depending upon special equipment or modifications. Consult serial number plate.

Crown 1976 PF-2764-2 Rev. 8/96

Printed in U.S.A.

03 REV. 8/96

ITD–04.4–002

ITD–04.4–002

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.

Meter Options KE = No Meter Options HM = Hour Meter DM = Discharge Meter HD = Hour/Discharge Meter

Drive Tires 1 = Poly 2 = Rubber Handle 1 = No Raise/Lower In Handle 2 = Raise/Lower In Handle

Lift Height 057 = 57 in. (1450mm) 067 = 67 in. (1700mm) 077 = 77 in. (1955mm) 087 = 87 in. (2210mm) 090 = 90 in. (2285mm) *** = Custom SPC= Special

Maintenance Platform A = Maintenance Platform B = No Maintenance Platform

– 090 26 1 1 R 1 KE 5 B 2 –

Standard / Custom / Special – = Standard C = Custom S = Special Inside Straddle Dimension 26 = 26.5 in. (675mm) 28 = 28 in. (710mm) 30 = 30 in. (2210mm) 32 = 32.5 in. (825mm) 34 = 34 in. (865mm) 36 = 36 in. (915mm) 38 = 38.5 in. (980mm) 40 = 40 in. (2285mm) 42 = 42 in. (1065mm) 44 = 44 in. (1120mm) 46 = 46 in. (1170mm) 48 = 48 in. (1220mm) 50 = 50 in. (1270mm) ** = Custom -- = No I.D. __ = Special AD = Adjustable

Attachments – = No Attachments 1 = Drum Stacker 2 = Roll Top 3 = Snap-On Platform

Remote Control 1 = Remote Control 2 = No Remote

Load Backrest 1 = 30 in. x 36 in.

2 = 36 in. x 36 in.

3 = 42 in. x 36 in.

4 = Custom 5 = No Load Backrest Battery 1 = Standard 2 = Semi-Industrial

Wheels 1 = Steel Load Caster 2 = Poly Load Caster

Crown 1976 PF-2764-3 Rev. 8/96

Printed in U.S.A.

03 REV. 8/96

ITD–04.4–003

ITD–04.4–003

C

INTRODUCTION

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

OPERATOR INSTRUCTIONS This manual does not contain operation instructions. Operator Instructions in tag or booklet form are sent with each truck. Additional copies can be ordered if required. These booklets are for you and your personnel to insure years of safe, trouble-free operation of your Crown Lift Truck. For Series M operator instructions, refer to Crown publication, “You and Your Crown Walkie” (PF-10020).

DRIVER TRAINING Crown has available a complete series of Driver Training programs; in two parts concerning basic safety rules and operating characteristics of your series M truck. To obtain this informative material, ask your Crown dealer about "Its Up to You" and "You and Your Walkie".

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

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

For Series M capacities, technical information and dimensional specifications, please refer to the following sales literature: M Literature SF-4291 M Specifications SF-4293 Copies of publications can be obtained from your Crown dealer or by writing to: Crown Equipment Corporation 44 South 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 written maintenance. The back covers replacement parts. The sectional descriptions are as follows: MAINTENANCE SECTION M1 M2 M3 M4 M5 M7 M8

DESCRIPTION Lubrication and Adjustment Hydraulics Drive Unit Electrical Brake Main Frame and Mast Assemblies Cylinder

040601 Crown 2004 PF13848-1

ITD–04.4–004

REPLACEMENT PARTS SECTION 1 2 3 4 5 7 8 10

DESCRIPTION Power Chassis Hydraulic System and Components Drive Unit and Components Battery Charger Brake System Main Frame and Mast Assemblies Cylinders Drum Rotators and Accessories

8445 Printed in U.S.A.

ITD–04.4–004

C

INTRODUCTION

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

MODEL NUMBER SYSTEM

20 M T 2 3 * CAPACITY Pound Rated (X 100) Ex. 20 X 100 = 910 kg (2000 lbs.)

MODEL DESIGNATION M - Motorized Intermediate Walkie Stacker T - Telescopic

FORK LENGTH 910 kg (2000 lb.)

Dash mm (in.)

1 760 (30) 2 915 (36) 3 1065 (42) 4 1145 (45) 5 1220 (48) 6 1370 (54)

LIFT HEIGHT M Dash mm (in.)

2 67 (1700)

MT Dash mm (in.)

1 90 (2300) 2 110 (2800) 3 130 (3300)

EXAMPLE: A truck having amodel number 20 MT-2-3 is a 910 kg (2000 lb.) capacity, intermediate duty telescopic walkie stacker with 2800 mm (110 in.) lift height and 1065 mm (42 in.) fork length. * Actual rated capacity may vary, depending upon special equipment or modifications. Consult serial number plate.

Crown 2004 PF13848-2

ITD–04.4–005

Printed in U.S.A.

ITD–04.4–005

C

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.

Drive Tires P = Poly R = Rubber

Meter Options KE = No Meter Options HM = Hour Meter DM = Discharge Meter HD = Hour/Discharge Meter

Handle 2 = Raise/Lower In Handle

Lift Height 067 = 1700 mm (67 in.)

090 = 2285 mm (90 in.)

110 = 2800 mm (110 in.)

130 = 3300 mm (130 in.)

Maintenance Platform A = Maintenance Platform B = No Maintenance Platform

Attachments – = No Attachments 3 = Snap-On Platform

– 090 18 2 1 R 1 KE 5 B 2 –

Standard / Custom / Special – = Standard

Remote Control 1 = Remote Control 2 = No Remote

Inside Straddle Dimension 18 = 460 mm (18.12 in.)

AD = Adjustable Load Backrest 1 = 750 mm (30 in.) x 900 mm (36 in.)

2 = 900 mm (36 in.) x 900 mm (36 in.)

5 = No Load Backrest

Battery 1 = Standard 2 = Semi-Industrial

Wheels 1 = Steel Load Caster 2 = Poly Load Caster

Crown 2004 PF13848-3

ITD–04.4–006

Printed in U.S.A.

ITD–04.4–006

SAFETY

General Maintenance Instructions

General Maintenance Instructions WARNING An injury could occur.

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

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

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

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

• Fully lower the load engaging means.

• Put the directional control in neutral.

• Apply the parking brake.

• Turn off the lift truck.

• Remove the key.

• Chock the wheels of the lift truck.

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

• Use chocks or other positive positioning devices.

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

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

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

• Apply the brake.

• Put the directional control in neutral.

Crown 1976 PF2821 Rev. 6/22

•

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

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

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

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

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

Hold the steering wheel tightly and brace your feet.

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

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

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

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

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

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

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

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

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

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

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

3

SAFETY

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

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

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

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

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

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

• For tow tractors, see ASME B56.9.

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

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

MA-04.0-002 07 Rev. 6/22

4

Crown 1976 PF 2821 Rev. 6/22

MAINTENANCE

LUBRICATION To obtain maximum life of any industrial equipment, a well planned maintenance program should be followed. The following information is intended to provide guidelines for proper lubrication intervals as called out in the lubrication chart, however, some operating conditions will require more frequent checks and lubrication than listed. For example, applications with much dust or moisture will require modification of the schedule to fit that particular application.

TYPE LUBRICANT

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 below are typical and any lubricant with equal specifications may be used.

BRAND NAME

MANUFACTURER

A. Gear Lube 90W

Poco Purelube Code 5303 Sohio Facto Lube # 3

Union Oil Company Standard Oil Company

B. Grease Multipurpose

Union Unoba EP No. 2

Union Oil Company

D. Hydraulic Oil

Union Unax AW 150

Union Oil Company

E. Lubriplate

Factran # 2

Standard Oil Company

C. Oil SAE 40

CHART 1

© CROWN 1976 PF-2719

MA - 04.4 - 001

MA - 04.4 - 001

LUBRICATION CHART Component

Index

Lube Type

100 L-1

250

Hours 500

1000

2000

†

†

†

c

Quantity

a

Drive Unit Level

L-2

Bearing

b

AR

†

L-3

Bushing & Post

b

AR

†

L-4

Axle

b

AR

L-5

Grease Cup

b

AR AR

† †

L-6

Control Handle Pivot Points

c

L-7

Hydraulic Tank

d

L-8

Load Wheels

b

AR

†

L-9

Roller Bars

b

AR

†

L-10

Lift Chain

c

AR

†

L-11

Mast Channels

e

AR

†

L-12

Mast Rollers

b

AR

†

L-13

Disconnect Arm

e

AR

†

L-14

Raise/Lower Control Linkage

c

AR

†

L-15

Battery Terminals

AR

†

L-16

Caster Wheels

b

AR

†

L-17

Brake Linkage

c

AR

†

L-18

Hydraulic Filter

† - Check

† †

c

C - Change

†

†

c

c

c

L - Lubricate

a. Gear Lube 90W

63002-3

b. Grease Multipurpose

63002-7

c. SAE-40 d. Hydraulic Oil

63001-1

e. Lubriplate

63002-1

CHART 2 REFER TO ILLUSTRATION 1 AND 2

MA - 04.4 - 002

MA - 04.4 - 002

ILLUSTRATION 1

MA - 04.4 - 003

MA - 04.4 - 003

INSPECTION AND ADJUSTMENTS CHART Component

Index

100

250

I-1

Horn

†

I-2

Tires

†

I-3

Battery

†

I-4

Lift Chain

I-5

Emergency Power Disconnect

I-6

Motor Brushes, Traction

†

I-7

Motor Brushes, Lift

†

I-8

Contact Tips

†

I-9

Electrical Connections

†

I-10

Hoses & Hydraulic Lines

†

1-11

Brakes — Operation

†

I-12

Brakes — Lining

1-13

Travel Controls — Operational

†

I-14

Magnetic Drain Plug

†

Hours 500

1000

2000

† †

†

CHART 3 REFER TO ILLUSTRATION 1 AND 2

ILLUSTRATION 2

MA - 04.4 - 004

MA - 04.4 - 004

ELECTRICAL SYSTEM Inspection and care of the electrical components in an industrial truck are a must if long life and efficient, safe operation are to be maintained through the daily use of any powered equipment. The following information is intended to aid in keeping the electrical system in good operating condition.

CAUTION

Before making checks, disconnect batteries or jack up truck and block so drive wheel is free of floor.

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

A. Checking Battery electrolyte level should be checked before each charge of the battery. The level should be maintained at one-half inch above plates or just below the lower lip of the filler hole at all times. If low, add either approved local supply or distilled water (consult battery manufacturer) preferably at the end of charge.

Do not overfill. For maximum battery life, specific gravity readings should be taken daily and recorded on a pilot cell. The pilot cell should be changed on a monthly basis with readings taken on all cells at semi-annual or annual intervals. Do not take specific gravity readings immediately after adding water. The water and electrolyte must be thoroughly mixed by charging before a reliable reading can be taken. The normal full charge specific gravity should be between 1.265 and 1.280.

B. Cleaning Always keep vent plugs tightly in place when cleaning batteries. When properly watered and charged, the batteries will remain clean and dry.

All that is necessary is to brush or blow off any dust or dirt which may accumulate on them.

However, if electrolyte is spilled or overflows from the cell, it should be neutralized with a

MA - 04.4 - 005

solution of baking soda and water (one pound soda to a gallon of water). To do this, remove the battery from the truck and clean with the solution of soda and water brushing the soda solution to get the solution beneath the connectors and removing the grime from the covers.

Then rinse the battery with cool water from a low pressure hose to remove the soda and loosened dirt. If batteries stay wet consistently, they may be either overcharged or overfilled.

This condition should be investigated and corrected.

C. Charging Charging requirements will vary depending on use of truck. Batteries discharged by more than one-third should be charged daily. If less than one-third discharge, recharging should be delayed; however, they should be recharged at least once a week.

CAUTION

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

2. Battery Charger Your unit is equipped with a built-in charger. This charger is supplied in one of two versions; one for standard batteries, the other with a timer for semiindustrial batteries. Schematic wiring diagrams, ILLUSTRATIONS 3 and 4 are provided for reference.

A. Charging Rate The charging rate can be adjusted to compensate for line voltage variations by taps on the charger transformer primary.

B. Standard Charger The batteries should not be allowed to run down completely. Continual over-discharging will greatly decrease the life of the battery. To maintain a full charge, plug the charger cord into the correct A.C. source. The charging rate

MA - 04.4 - 005

WIRING DIAGRAM

STANDARD CHARGER

ILLUSTRATION 3

HEAVY DUTY CHARGER WITH TIMER

ILLUSTRATION 4

MA - 04.4 - 006

MA - 04.4 - 006

is controlled automatically. The ammeter will show a high rate of charge if the batteries are low and will gradually diminish to a low rate as full charge is approached. Leaving the truck on charge overnight will do no harm provided battery water level is maintained; however, do not leave the charger plugged in over weekends or holidays. Continual overcharging will also greatly decrease the battery life. To insure proper charging of the batteries, check the specific gravity of each cell with a hydrometer.

Refer then to Chart 4 for the recommended charging time, in accordance with the specific gravity readings.

C. Charger with Timer On chargers equipped with a timer, the normal setting for the timer would be in the full “ON” position. This charger is equipped with a voltage sensitive relay that will close contacts starting the timer after a voltage of 14.2 V.D.C. is obtained. The timer will give the batteries a final 3-hour charge when turned full “ON” at a finish rate to assure batteries are getting a full charge.

If charge rate is too high or low, comparing charging times with Chart 5, the taps on the charger transformers can be used to compensate for line voltage variations.

RECOMMENDED CHARGING TIME

RECOMMENDED CHARGING TIME Specific Gravity

Recharge Time

Percent of Charge

Specific Gravity

Recharge Time

Percent of Charge

1.260 1.250 1.240 1.230 1.220 1.210 1.200 1.190 1.180 1.170 1.160 1.150 1.140 1.130

0

100%

1.260 1.250 1.240 1.230 1.220 1.210 1.200 1.190 1.180 1.170 1.160 1.150 1.140 1.130 1.120

0

100%

4 5 6 7 8 9 10 11 12 13 14 15 16

75%

50%

25%

1 2 3 4 4.75 5.50 6 7 7.5 8 8.5 9 9.50 10

50%

25%

CHART 4 CHART 5

MA - 04.4 - 007

MA - 04.4 - 007

3. Travel Controls The operator can choose three speeds in either forward or reverse by turning the twist grip in the direction desired. The operator closes directional and speed switches which complete the power circuit as follows: 1st Speed — The power circuit for first speed drops the batteries’ volts (supplied by two groups of batteries in parallel 12 V.) through a resistor, the motor field, the directional contactor, motor armature to battery negative.

2nd Speed — The second speed circuit provides 12V. to the motor by bypassing the resistor.

3rd Speed — Third speed operation is obtained by the B & C contactor switching the batteries from parallel to series, providing 24 V. for the motor and high speed operation.

4. Motors CAUTION

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 covers to inspect the commutator and brushes. Check the commutator for any discoloration that may show signs of raised bars or stalls. If it is glazed or dirty, clean with a strip of No. 00 sandpaper. Blow out all dirt and grit with compressed air.

CAUTION

Do not use emery cloth to clean commutator.

It is recommended that the brushes be checked for wear at least once every 90 days or 120 hours use, whichever comes first. Check the brushes for chips, breaks, or excess oil: 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 measure 3/8 inch or less should be replaced.

MA - 04.4 - 008

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 useable length.

Check motor for shorts between terminals and motor frame by use of an ohmmeter on a high resistance scale such as RX 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 further future damage.

A. Traction Motor — For ease of turning drive unit, place truck on blocks to remove weight of truck from drive unit.

1. Disconnect batteries.

2. Remove all electrical connections from motor.

3. Remove brake drum and cone.

4. Remove four bolts accessible from motor side in drive unit.

5. Remove Motor.

B. To Replace Motor 1. Install new gasket on motor end bell (use gasket sealer as required).

2. Replace motor and secure bolts.

3. Replace brake drum and cone. Torque brake drum nut to 23 foot-pounds.

C. Brush Replacement — To Remove Brushes

1. Disconnect batteries.

2. Rotate drive unit until motor brush end is accessible.

3. Clean brush area of motor.

4. Remove screws holding brush pigtails.

5. Disconnect brush springs or move to side (varies with motor Mfg.).

6. Remove brushes.

7. Check commutator for roughness and high spots. (Turn commutator if required).

8. Install new brushes, fasten pigtails and connect or secure brush springs.

9. Check that pigtails will not interfere with brush movement as the brush wears.

MA - 04.4 - 008

D. Lift Motor and Brush Inspection 1. Disconnect battery.

2. Clean brush end cover and remove commutator end head.

3. Clean dirt and carbon dust from winding and brush holder with low pressure air. Use a clean, dry cloth to clean commutator. (Do not use emery cloth).

4. Brushes should be replaced when they reach a length of 3/8 inch or will reach that length before the next scheduled inspection.

5. Check brush springs to see they maintain tension against the commutator equally on all brushes.

5. Contactors Disconnect battery or have drive wheel jacked up and free of floor. (Use blocks to prevent accidental contact with floor). Manually actuate the movable contacts to be sure there is no mechanical binding and check contact tips for wear. Minor surface irregularities or discoloration does not necessitate contact replacement.

6. Emergency Power Disconnect The emergency power disconnect will disconnect all power for the operator’s safety, should a malfunction occur. Check disconnect operation to be sure it will disconnect battery when the lever is tripped.

If unit is equipped with a remote control on cord with power disconnect, check disconnect operation by pushing stop button to assure operation if required for operator safety.

TROUBLE SHOOTING PROCEDURES 1. Recommended Test Equipment A. Volt-Ohm Meter - Simpson 260 or equal; Sensitivity 20,000 ohms/volt D. C., 5,000 ohms/ volt A. C.; Ranges required 0-50 volts D. C., 0-240 volts A.C. B. Test jumper approximately 36” long (No. 10 wire) with an alligator clip on each end.

C. Battery cell tester or hydrometer.

2. Procedure for Checking Individual Components NOTE

Remove both 80 amp fuses before making the following checks.

MA - 04.4 - 009

A. Ammeter - Remove one wire from meter terminal and measure resistance reading across ammeter.

It should read zero ohms.

B. Contactor - Connect one end of test jumper to contactor coil terminal and the other end to the battery side of the 80 amp fuse. Be certain the other terminal of the contactor is connected to ground. The contactor should pull in.

CAUTION

Watch for moving lift.

C. Fuse - With fuse removed from the circuit, check resistance across fuse. It should read zero ohms.

D. Drive Motor - Remove both brushes from motor and examine. Carbon portion should be at least ¼ inch long. Replace brushes and disconnect wires Al, S1, and S2 from terminal block on drive unit. Connect motor wires Al and S2 together. Connect one end of test jumper to motor wire S1 and other end to 80 amp fuse in chassis. Motor should run.

CAUTION

Watch for moving lift.

E. Lift Motor - Connect one end of test jumper to power terminal connection on lift motor.

Connect the other end of test jumper to 250 amp fuse. Lift motor should run. If motor does not run, first check for proper ground.

CAUTION

Test jumper may become warm due to high motor current.

F. Resistor - Disconnect lead from one side of resistor. Resistance across resistor should read one ohm or less.

G. Lift Motor Solenoid - Connect one end of test jumper to solenoid control terminal, and the other end to the battery side of the 250 amp fuse.

The other control terminal should be connected to ground. Solenoid should pull in.

H. Switches - Disconnect lead from one side of switch. With volt-ohm meter in resistance position, place test prods across switch terminals and depress switch. Meter should read zero ohms if switch is normally open (N. O.) type.

Meter should read very high (infinite) resistance if switch is normally closed (N. C.) type.

MA - 04.4 - 009

TROUBLE SHOOTING ANALYSIS

E. Interlock switch on top of B contactor

1. No Travel in either direction

F. Lift solenoid

A. Check battery charge

G. Lift motor

B. Control circuit fuse (14 amp)

H. Lift switch in control handle (optional)

C. Power circuit fuses (80 amp)

I. All wiring in lift circuit

D. Brake switch

5. 80 Amp fuse blows

E. Reversing switch

A. Power cables for ground or short

F. Key switch (optional)

B. Contactors for proper operation or short

G. Directional switches

C. Motors for possible short

H. Directional contactors

6. Ammeter does not indicate charging

I. Resistor

A. Ammeter

J. Drive motor

B. Correct A.C. input to charger

K. Control harness for broken or damaged leads

C. 80 Amp fuse

L. Power cables for loose or poor connection

D. Battery charger output

M. Cam in control handle for proper alignment

E. High speed contactors (B & C Contactors)

2. No Second speed in either direction

F. Batteries for faulty cell

A. Second speed switch in handle

G. Battery water level

B. Second speed contactor (A contactor)

H. All wiring in charger circuit

C. Cam in control handle for proper alignment

BRAKE SYSTEM

D. Wiring for broken or loose connection

1.To adjust the brake (refer to ILLUSTRATION 5)

3. No Third speed in either direction A. Third speed switch in handle B. Third speed contactors (B & C Contactors) C. Third speed cutout switch in control handle D. Batteries E. Interlock switch on top of B contactor F. Cam in control handle for proper alignment G. 80 Amp fuses H. Limit switch on telescopic units I. Wiring for broken or loose connection 4. Lift motor inoperative A. Batteries B. Power circuit fuses (80 amp) C. Control circuit fuse (14 amp)

tighten the locking nut (Item 2) to increase spring tension and braking. When brake linings become worn and proper adjustments can no longer be obtained by this method, loosen nuts (Item 1) holding the wear plates and remove one or more shims (Item 3). Then readjust spring tension for proper braking.

NOTE

The braking distance should be approximately 24 inches. This is with the unit operating in top speed and empty.

2. Should the brake linings become smooth, yet a safe amount of the lining remains, the surface can be put back in good condition using a wire brush.

Clean splines of motor and brake drum before replacing drum. The drum is fastened to the motor using a tapered bushing with a nut. After the drum and bushing are mounted on the motor shaft, the nut should be torqued to 23 foot-pounds and the set screws in the nut tightened.

D. Lift switch

MA - 04.4 - 010

MA - 04.4 - 010

BRAKE ADJUSTMENT

HYDRAULIC SYSTEM The hydraulic system is supplied its power by a gear type pump which provides the pressure for lift to a piston type cylinder through a combination valve.

Pressure is limited by a relief valve to limit the maximum load that can be lifted.

Lowering is controlled by the solenoid section of the combination valve and a flow control valve to provide a controlled lowering speed.

A filter is in the suction line to filter the hydraulic oil before it goes into the pump.

Hydraulic Schematics of all standard “M” Models are at the end of the Maintenance Section.

Hydraulic System — General

1. To check hydraulic fluid level, remove the breather

ILLUSTRATION 5 3. To adjust the brake switch arm (ILLUSTRATION 6) loosen the locking nuts and adjust arm to activate switch opening the control circuit when brakes are applied.

cap from the reservoir and insert a clean dowel.

With the lift fully raised and on a level floor, it should be one-half to one inch deep. Approximate capacity of the hydraulic system is six quarts. Use only a good grade of hydraulic oil such as Union oil AW150 (Crown No. 63001-1) or equal. On trucks equipped to operate in below freezing temperatures, Petro Fluid #606 or equal is recommended.

NOTE

Do not use hydraulic brake fluid.

2. After the first 90 days of operation, it is recommended that the hydraulic filter be changed. Thereafter, the filter should be changed every 180 days depending on truck usage. Hydraulic fluid should be changed once a year, and the system flushed with a safe solvent.

3. Occasionally, a slight creep of the carriage may occur. This may be due to internal leakage in lower valve or in the piston pak. On remote control units, this can also be due to leakage in the remote lowering solenoid and check valve. To seat these valves properly when this occurs, raise and lower the carriage to flush out the valve seat of any foreign material.

ILLUSTRATION

MA - 04.4 - 011

6

4. 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.

MA - 04.4 - 011

5. Great care and cleanliness should be exercised in disassembly of the lifting piston. Wipe all surfaces clean of dirt and oil before removing cap and ram.

Care should be taken not to damage the packing on the piston end when removing ram from cylinder.

Replace wiper seals whenever replacing packings.

6. Packing I n s t r u c t i o n s — B r e a k d o w n , c l o s e l y observe end of retainer ring located in slot of cylinder assembly. Carefully rotate cap to back retainer out of cylinder housing. Remove cap, replace packings and seals, clean and lubricate inside ram assembly and reassemble.

7. Assembly — After packings and seals are in place, align the hole in the cap with the tapered slot in the cylinder assembly. (See ILLUSTRATION 7). Insert cap in cylinder assembly and apply pressure until hole is visible through cylinder assembly slot. Take wire retainer and insert hooked end into hole of cap and turn hex head cap until tapered end of retainer is flush with cylinder housing.

Hydraulic Seals 1. General Installation A. 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.

B. The area in contact with the seal should be free of burrs, sharp edges and nicks.

C. If necessary to force seal over sharp edges, slots or undercuts, protective devices should be used.

D. 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.

Lift Relief Valve Setting The relief valve should be adjusted to lift a minimum of 5% over the rated capacity of the truck. No-lift bypass should be set to 10% over rated capacity.

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 and 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.

4. All connections are to be leak free.

Miscellaneous

ILLUSTRATION 7

MA-04.4-012

Lift Chain Adjustment — Check lift chains so that both chains have as near the same tension as possible.

MA - 04.4 - 012

HYDRAULIC SCHEMATIC

MA-04.4-013

MA-04.4-013

HYDRAULIC SCHEMATIC SYMBOLS

MA - 04.4 - 014

MA - 04.4 - 014

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

6609 Crown 2000 PF11895-1 Rev. 11/00

Printed in U.S.A.

01 REV.11/00

MA–04.0–100

MA–04.0–100

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. Lower load engaging means completely. If battery is removed with load engaging means raised, use hoist attached to mast to provide tip over protection. Don’t allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing, transporting the battery. Use an insulator (such as plywood, plastic caps) to cover the top of the battery posts before and during removal.

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, plastic caps) to cover the top of the battery posts before and during installation.

CAUTION

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

8554

LOCKOUT - TAGOUT Always turn key switch to "off", remove key and apply tag to twist grip with cable tie warning others truck is being serviced.

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

CR

OW

N

WA RN IN D G ba o n tt ot veery con Mahiclto tnect in e. hi s an bein tena d g nc av veh per e ai ic fo i le rm s op labl er e is ed at fo n io r ot n.

8397

Crown 2000 PF11895-2

MA–04.0–101

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.

Printed in U.S.A.

MA–04.0–101

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.

W AR NI NG Do ba not c vehttery onne Maicle. to thi ct s bei inten an ng peance avad veh rformis opeilabl icle i ed rat e fo s no ion r t .

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

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

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

4. Operate hydraulic levers in both directions to remove any hydraulic pressure.

Completely lower forks

8458-01

Crown 2000 PF11895-3 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–04.0–102

MA–04.0–102

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT

LIFTING AND BLOCKING 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.

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.

Side

Power Unit

Position jack and hard wood block as shown

W AR NI NG Do ba not c vehttery onne Maicle. to thi ct s bei inten an ng peance avad veh rformis opeilabl icle i ed rat e fo s no ion r t .

W AR NI NG Do ba not c vehttery onne Maicle. to thi ct s bei inten an ng peance avad veh rformis opeilabl icle i ed rat e fo s no ion r t .

Raise forks 3 to 6 in.ches (70 to 150 mm) from floor

8459-01

Set jack stand height as required.

Not to exceed 16 inches (400 mm)

WARNING

Truck stability decreases dramatically if indicated location is raised more than 6.5 inch (160 mm) from the floor. Attach sling and overhead lifting device to all cross members of the mast to prevent truck from tipping over when raising the side of the truck.

8460-01

Crown 2000 PF11895-4 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–04.0–103

MA–04.0–103

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT MAST Blocking Masts

3. Connect battery.

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

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

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

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

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

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

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

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

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

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

Fork Carriage (shown raised slightly for clarity)

Third Stage Mast Second Stage Mast

First Stage Mast (or mainframe) 8269

Fork Carriage

Fork Carriage

Third Stage Second Stage

Second Stage

First Stage (or mainframe)

First Stage (or mainframe)

8270 Crown 2000 PF11895-5

MA–04.0–104

Printed in U.S.A.

MA–04.0–104

SAFETY

Cleaning of Material Handling Equipment

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

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

Using a power washer

CAUTION

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

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

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

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

Material damage can occur.

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

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

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

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

Crown 2000 PF11969 Rev. 9/21

MA-1140-050 05 Rev. 9/21

5

SAFETY

Cleaning of Material Handling Equipment Crown Cleaning Products Cleaner Type

Part Number

Package Quantity

Degreaser and cleaner

363105-001 363105-012

19 oz can (12) 19 oz cans

All-purpose cleaner

363114-001 363114-012

19 oz can (12) 20 oz cans

Glass cleaner

363101-001 363101-012

19 oz can (12) 19 oz cans

Waterless hand cleaner

363111-001 363111-012

15 oz tube (12) 15 oz tubes

Pumiced and smooth hand cleaner

363112-001 363112-004

1 gal jug (4) 1 gal jugs

Wall-mounted deluxe soap dispenser

363122

Use with P/N 363112-001

Tough on grease

063009-005

1 gal jug

Citrus degreaser spray

363156-001 363156-012

32 oz spray bottle (12) 32 oz spray bottles

Citrus degreaser spray

363157-101 363158-101

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

Citra-sol degreaser

363146-001 363146-012

19 oz can (12) 19 oz cans

Battery cleaner

363124-001 363124-012

18 oz can (12) 18 oz cans

MA-1140-051 05 Rev. 9/21

6

Crown 2000 PF11969 Rev. 9/21

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

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

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

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

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

Figure 14990

Crown 1987 PF7886-1 Rev. 1/11

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

29

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

Lubrication Identification Chart Type of Lubricant

Part Number

A

Gear Lube 80W-90 (Typical)

363506-001 363506-012

1 Quart (12) 1 Quart Cans

AA

Automatic Transmission Fluid (Multi-Purpose)

363503-001 363503-012

1 Quart (12) 1 Quart

AAA

Universal Hydraulic & Transmission Fluid

363513-001 363513-012

1 Quart (12) 1 Quart

AAAA

Synthetic Gear Oil 75W-90

363514-001 363514-012

1 Quart (12) 1 Quart

Grease (Multi-Purpose)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

BB(1)

Grease (Low Temperature)

063002-017 063002-046

14.5 oz Cartridge (40) 14.5 oz Cartridges

BBB

Food Grade Grease (Multi-Purpose)

363002-001 363002-030

14 oz Cartridge (30) 14 oz Cartridges

BBBB

Grease (Multi-Purpose) Premium

063002-025 063002-026

14.5 oz Cartridge 5 Gallon

B

Package Quantity

C

Oil (SAE 40)

CC

Engine Oil (10W30)

363500-001 363500-012

1 Quart (12) 1 Quart

D

Hydraulic Oil

363504-101 363504-106

1 Gallon (6) 1 Gallon

DD(1)

Hydraulic Oil (Low Temp)

363505-101 363505-106

1 Gallon (6) 1 Gallon

DDD

Hydraulic Oil - DTE24

063001-021

1 Gallon

E

Channel Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

F

Gear Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

Chain & Cable Lube

363107-001 363107-012

15 oz Can (12) 15 oz Cans

Premium Chain & Cable Lube

363115-001 363115-012

12 oz Can (12) 12 oz Cans

Final Finish - Rubber & Vinyl Dressing

363129-001 363129-012

11 oz Can (12) 11 oz Cans

G

H

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

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

30

Crown 1987 PF7886-2 Rev. 1/11

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

Part Number

I

Grease (Lift Pump Coupling)

063002-039 127801S

1 lb 1 oz

J

Brake Fluid - Dot 5

063004-002 063004-003

12 oz 1 Gallon

K

Grease (Wheel Bearing)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

L

Metal Assembly Spray

063002-021

11 oz Spray

M

Silicone Grease (Clear)

063002-020

5.3 oz Tube

Brake & Parts Cleaner

363102-001 363102-012

14 oz Can (12) 14 oz Cans

Low VOC Brake & Parts Cleaner

363103-001 363103-012

14 oz Can (12) 14 oz Cans

Non-Flammable Brake & Parts Cleaner

363116-001 363116-012

19 oz Can (12) 19 oz Cans

O

Penetrating Lubricant

363104-001 363104-012

20 oz Can (12) 20 oz Cans

P

Premium Formula Multi-Purpose Grease

363108-001 363108-012

11 oz Can (12) 11 oz Cans

Q

White Lithium Grease

363110-001 363110-012

11 oz Can (12) 11 oz Cans

R

Choke & Carburetor Cleaner

363109-001 363109-012

15 oz Can (12) 16 oz Cans

Contact Cleaner - Non-Flammable

363106-001 363106-012

10 oz Can (12) 10 oz Cans

Contact Cleaner

363128-001 363128-012

11 oz Can (12) 11 oz Cans

T

Electrical Connector Oxidation & Corrosion Inhibitor

127189-001

30 cc

U

Battery Cleaner

363124-001 363124-012

18 oz Can (12) 18 oz Cans

V

Battery Protector

363125-001 363125-012

15 oz Can (12) 15 oz Cans

W

Food Grade Machine Lubricant

363127-001 363127-012

12 oz Can (12) 12 oz Cans

X

Food Grade Silicone Spray

363126-001 363126-012

11 oz Can (12) 11 oz Cans

Coolant

363509-101 363509-106

1 Gallon (6) 1 Gallon

Extended Life Coolant

363511-101 363511-106

1 Gallon (6) 1 Gallon

N

S

Y

Crown 1987 PF7886-3 Rev. 1/11

Package Quantity

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

31

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Alternate Lubricants & Fluids Chart Type of Lubricant

Product Name

Manufacturer/ Distributor

A

Gear Lube 80W-90 (Typical)

Crown

Crown

AA

Automatic Transmission Fluid (Multi-Purpose)

Crown

Crown

AAA Universal Hydraulic & Transmission Fluid Crown

Crown

AAAA Synthetic Gear Oil 75W-90

Crown

Crown Mobil Union 76 Co. Shell Burmah Castrol Exxon

B

Grease (Multi-Purpose)

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

BB

Grease (Low Temp) (2)

Lubriplate Alvania RA(1) Helveum O(1)

Fiske Bros Refining Co. Shell Burmah Castrol

BBB Food Grade Grease (Multi-Purpose)

Petro Canada Purity FG

Petro Canada

BBBB Grease (Multi-Purpose) Premium

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

Mobil Shell Chevron

C

Oil (SAE 40)

D

Hydraulic Oil

Crown

Crown

DD

Hydraulic Oil (Low Temp) (2)

Crown

Crown

Mobil DTE 24

Mobil

DDD Hydraulic Oil - DTE24 (3) E

Channel Grease

Factran #2

Standard Oil Co.

F

Gear, Channel & Shaft Grease

Molykote BR-2 Plus

Dow Corning

Chain & Cable Lube

Crown

Crown

Premium Chain & Cable Lube

Crown

Crown

H

Final Finish - Rubber & Vinyl Dressing

Crown

Crown

I

Grease (Lift Pump Coupling)

Nyogel 774F-MS

NYE Lubricants

J

Brake Fluid - Dot 5

Q2-1141 Silicon Brake Fluid

Dow Corning

Grease (Wheel Bearing)

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

Mobil Exxon Fiske Bros. Refining Co.

G

K

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

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

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

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

32

Crown 1987 PF7886-4 Rev. 1/11

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

Product Name

Manufacturer/ Distributor

L

Metal Assembly Spray

Dow Corning

Dow Corning

M

Silicon Grease (Clear)

Dow Corning 111 Compound

Dow Corning

Brake & Parts Cleaner

Crown

Crown

Low VOC Brake & Parts Cleaner

Crown

Crown

Non-Flammable Brake & Parts Cleaner

Crown

Crown

O

Penetrating Lubricant

Crown

Crown

P

Premium Formula Multi-Purpose Grease Crown

Crown

Q

White Lithium Grease

Crown

Crown

R

Choke & Carburetor Cleaner

Crown

Crown

S

Contact Cleaner

Crown

Crown

T

Electrical Connector Oxidation & Corrosion Inhibitor

Nye Grease

NYE Lubricants

U

Battery Cleaner

Crown

Crown

V

Battery Protector

Crown

Crown

W

Food Grade Machinery Lubricant

Crown

Crown

X

Food Grade Silicone Spray

Crown

Crown

Y

Extended Life Coolant

N

Crown 1987 PF7886-5 Rev. 1/11

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

33

Notes:

34

LUBRICATION & ADJUSTMENT Operator’s Daily Checklist

Operator’s Daily Checklist To get the maximum life out of your equipment, approved personnel must follow a planned maintenance (PM) schedule. Operator input is an important part of a planned maintenance schedule. Operator input can decrease the time that the truck is not available, help to schedule planned maintenances, and save money. Because of this, Crown recommends an operator's daily checklist.

Before you do maintenance on the truck, you must move it to an area where there is sufficient space. This is to make sure that others are safe and that you do the correct maintenance on the truck.

This checklist (OF3772) is available through your Crown dealer.

Fig. 1 (14990)

Crown 2011 PF25239-1 Rev. 8/12

M1.0-04.0-006 01 Rev. 8/12

35

Notes:

36

INSPECTION AND LUBRICATION

Lubricants, Aerosols, and Service Supplies

Lubricants, Aerosols, and Service Supplies See the Lubrication Identification table and the Alternate Lubricants and Fluids table in this section for the recommended list of lubricants, aerosols, and service supplies. Use the tables when performing planned maintenance on Crown lift trucks.

Lubricant Identification Lubricant Identifier

Description

Part Number

Package Quantity

A

Oil, gear, 80W-90, high performance, multi-purpose

363506-001

1 qt

AA

Fluid, automatic transmission, multi-purpose

363503-001

1 qt

AAA

Fluid, universal hydraulic and transmission

363513-001

1 qt

AAAA

Oil, synthetic, 75W-90

363514-001

1 qt

363514-101

1 gal

B

Grease, multi-purpose

063002-034

14 oz cartridge

BB

Grease, multi-purpose, low temperature

063002-017

14.5 oz cartridge

063002-046

40 - 14.5 oz cartridges

BBB

Grease, food grade, multi-purpose

363002-001

14 oz cartridge

363002-030

5 gal

BBBB

Grease, multi-purpose, premium

063002-025

14.5 oz cartridge

063002-026

5 gal

063002-060

16 oz can

363500-001

1 qt

363500-101

1 gal

363504-101

1 gal

363504-005

5 gal

5B

Grease, NLGI 00

C

Oil, SAE-40

CC

Oil, engine,10W-30

D (1)

Oil, standard, hydraulic

DD

Oil, hydraulic, low temperature, used with premium hydraulic oil

363505-101

1 gal

363505-005

5 gal

Oil, premium, hydraulic, Mobil DTE 24

063001-021

1 gal

4D (3)

Oil, hydraulic, Mobil Univis HVI 13

063001-035

5 gal

E

Grease - mast channel and gears

063002-024

14.5 oz cartridge

063002-022

35 lb pail

EE

Lubricant - channel slide

363143-001

10.5 oz can

DDD (2) (4)

Crown 2011 PF25240 Rev. 1/22

M1.0-04.0-050 07 Rev. 1/22

39

INSPECTION AND LUBRICATION

Lubricants, Aerosols, and Service Supplies Lubricant Identification Lubricant Identifier

Part Number

Package Quantity

063002-024

14.5 oz cartridge

063002-022

35 lb pail

Lubricant - chain and cable

363107-001

15 oz can

Lubricant, premium - chain and cable

363115-001

12 oz can

H

Protectant - rubber and vinyl

363129-001

11 oz can

I

Grease, synthetic - motor spline connection

063002-039

1 lb

127801S

1 oz

J

Fluid, brake, DOT 5

063004-002

12 oz

063004-003

1 gal

K

Grease - wheel bearing

063002-034

14 oz cartridge

063002-045

40 - 14 oz cartridges

L

Lubricant, metal spray, break-in

063002-021

16 oz spray

LL

Lubricant, S00727 - freezer condition

063002-059

9 oz can

M

Grease, clear - O-rings

063002-020

5.3 oz tube

Cleaner, low VOC - brakes and parts

363119-001

15 oz can

Cleaner, nonflammable - brake and parts

363116-001

18 oz can

O

Lubricant, penetrating

363104-001

15 oz can

P

Grease, premium, multi-purpose

363108-001

13 oz can

Q

Grease, white, lithium

363110-001

14 oz can

R

Cleaner - carburetor and choke

363109-001

14 oz can

Cleaner, contact, nonflammable

363106-001

10 oz can

Cleaner, contact

363128-001

13.5 oz can

127189-001

55 cc

127189-002

2 oz. tube

F G

N

S

Gear grease

T

Contact lubricant

U

Cleaner - battery

363124-001

18 oz can

V

Protector - battery

363125-001

14 oz can

W

Lubricant, food grade, machine

363127-001

12 oz can

X

Lubricant, food grade, silicone spray

363126-001

11 oz can

Y

Coolant, extended lift - C-5 LP series

363535-101

1 gal

363535-005

6 - 1 gal bottles

Z

Fluid, windshield washer, protects to -29 °C (-20 °F)

300100-101

1 gal

M1.0-04.0-051 07 Rev. 1/22

40

Description

Crown 2011 PF25240 Rev. 1/22

INSPECTION AND LUBRICATION

Lubricants, Aerosols, and Service Supplies Lubricant Identification Lubricant Identifier

Description

Part Number

Package Quantity

Technician Tips: Lift trucks operated in below freezing temperatures must use low temperature hydraulic oil and grease.

(1) Usual operation (temperatures of 0.6 °C [33 °F] and above) (2) Used on TSP lift trucks. Standard temperature freezers (-18 to 4 °C [0 to 39 °F]). Do not mix with different oil.

(3) Used on TSP lift trucks. Low temperature freezers (-40 to -12 °C [-40 to 10 °F]). Do not mix with different oil.

(4) Premium antiwear hydraulic oil used in mixing with low temperature oil

Crown 2011 PF25240 Rev. 1/22

M1.0-04.0-051 07 Rev. 1/22

41

INSPECTION AND LUBRICATION

Lubricants, Aerosols, and Service Supplies Alternate Lubricants and Fluids Type of Lubricant

Product Name

Manufacturer/ Distributor

A

Oil, 80W-90, high performance, multipurpose - gear

Crown

Crown

AA

Fluid, multi-purpose - Automatic transmission

Crown

Crown

AAA

Fluid, universal - hydraulic and transmis- Crown sion

Crown

AAAA

Oil, synthetic, 75W-90 - gear

Crown

Crown

Mobilgrease XHP 222 Special

Mobil

Union Unoba EP No 2

Union 76 Co.

Retinax A (1)

Shell

LM Grease

Burmah Castrol

Unirex EP-2

Exxon

Lubriplate

Fiske Bros Refining Co.

Alvania RA (1)

Shell

Helveum O (1)

Burmah Castrol

Petro Canada Purity FG

Petro Canada

Mobilux EP2 64127-4

Mobil

Retinax AM 71119

Shell

B

BB

BBB

BBBB

Grease, multi-purpose

Grease, low temperature Grease, multi-purpose, food grade

Grease, multi-purpose, premium

Chevron RPM Heavy-Duty LC Chevron Grease EP

5B

Grease NLGI 00

Mobilgrease XHP 005

Mobil

C

Oil, SAE 40

CC

Oil, 10W-30 - engine

Crown

Crown

D (2)

Oil, hydraulic

Crown

Crown

DD

Oil, hydraulic, low temperature

Crown

Crown

Mobil DTE 24

Mobil

Oil, hydraulic - Mobil Univis HVI 13

Mobil Univis AVI 13

Mobil

E

Grease - channel

Factran #2

Standard Oil Co.

EE

Lubricant - channel slide

Crown

Crown

F

Grease - gear channel and shaft

Molykote BR-2 Plus

Dow Corning

Lubricant - chain and cable

Crown

Crown

Lubricant, premium - chain and cable

Crown

Crown

DDD (3) (5) Oil, hydraulic - Mobil DTE24 4D (4)

G

M1.0-04.0-053 07 Rev. 1/22

42

Crown 2011 PF25240 Rev. 1/22

INSPECTION AND LUBRICATION

Lubricants, Aerosols, and Service Supplies Alternate Lubricants and Fluids Type of Lubricant

Product Name

Manufacturer/ Distributor

H

Protectant, rubber and vinyl

Crown

Crown

I

Grease - lift pump coupling

Nyogel 774F-MS

NYE Lubricants

J

Fluid, DOT 5 - brake

Q2-1141 Silicone Brake Fluid

Dow Corning

Mobilgrease XHP 222 Special

Mobil

Unirex EP-2

Exxon

Lubriplate No. 1242 (1)

Fiske Bros. Refining Co. Dow Corning

K

Grease - wheel bearing

L

Spray - metal assembly

Dow Corning

LL

Lubricant, spray on S00727, PTFE freezer lubricant

Spray on S00727

M

Grease, silicone, clear

Dow Corning 111 Compound

Dow Corning

Cleaner, low VOC - brake and parts

Crown

Crown

Cleaner, nonflammable - brake and parts Crown

Crown

O

Lubricant, penetrating

Crown

Crown

P

Grease, premium, multi-purpose

Crown

Crown

Q

Grease, white, lithium

Crown

Crown

R

Cleaner - choke and carburetor

Crown

Crown

S

Cleaner - contact

Crown

Crown

T

Inhibitor - electrical connector oxidation and corrosion

NYE Grease

NYE Lubricants

U

Cleaner - battery

Crown

Crown

V

Protector - battery

Crown

Crown

W

Lubricant, food grade, machine

Crown

Crown

X

Lubricant, food grade, silicone spray

Crown

Crown

Mobil Delvac ELC

Mobil

Shell Rotella Ultra ELC

Shell

Zerex ELC HD Coolant

Zerex

N

Y Z

Coolant, extended life

Sherwin Williams

Fluid, windshield washer

Crown 2011 PF25240 Rev. 1/22

M1.0-04.0-054 07 Rev. 1/22

43

INSPECTION AND LUBRICATION

Lubricants, Aerosols, and Service Supplies Alternate Lubricants and Fluids Type of Lubricant

Product Name

Manufacturer/ Distributor

Technician Tips: Lift trucks operated in below freezing temperatures must use low temperature hydraulic oil and grease.

(1) Permitted alternative, consult the factory if unavailable (2) Usual operation (temperatures of 0.6 °C (33 °F) and above) (3) Used on TSP lift trucks. Standard temperature freezers (-18 to 4 °C (0–39 °F). Do not mix with different oil (4) Used on TSP lift trucks. Low temperature freezers (-40 to -12 °C (-40 to 10 °F). Do not mix with different oil (5) Premium antiwear hydraulic oil used in mixing with low temperature oil

M1.0-04.0-055 07 Rev. 1/22

44

Crown 2011 PF25240 Rev. 1/22

INSPECTION & LUBRICATION SAE Torque Values

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

Grade

Grade Identification (on Head)

Specification

Bolt and Screw Size (in)

SAE - Grade 2

1/4 through 1-1/2

SAE - Grade 5

1/4 through 1-1/2

SAE - Grade 8

1/4 through 1-1/2

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

Fig. 1 (14916-02)

Crown 1979 PF5067 Rev. 2/16

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

71

INSPECTION & LUBRICATION SAE Torque Values

Torque Chart Bolt Diameter

Grade 5

Grade 8

Dry Torque Specification

Dry Torque Specification

in

ft Ib

kg-m

Nm

ft lb

kg-m

Nm

1/4

9±3

1.2 ± 0.4

12 ± 4

13 ± 4

1.8 ± 0.5

17.5 ± 5.5

5/16

18 ± 5

2.5 ± 0.7

24.5 ± 7

25 ± 5

3.5 ± 0.7

34 ± 7

3/8

32 ± 5

4.4 ± 0.7

43.5 ± 7

48 ± 10

6.6 ± 1.3

65 ± 13.5

7/16

50 ± 10

6.9 ± 1.4

67.5 ± 13.5

75 ± 10

10.4 ± 1.4

102 ± 13.5

1/2

75 ± 10

10.4 ± 1.4

101.5 ± 13.5

112 ± 15

15.5 ± 2.0

152 ± 20.5

9/16

110 ± 15

15.2 ± 2.0

149 ± 20.5

163 ± 20

22.5 ± 3.0

221 ± 27

5/8

150 ± 20

20.7 ± 2.8

203.5 ± 27

225 ± 30

31.1 ± 4.1

305 ± 41

3/4

265 ± 35

36.6 ± 4.8

359 ± 47.5

400 ± 50

55.2 ± 6.9

542 ± 68

7/8

420 ± 60

58.1 ± 8.3

569 ± 81

640 ± 80

88.3 ± 11.0

868 ± 108

1

640 ± 80

88.5 ± 11.1

868 ± 109

960 ± 115

132.5 ± 15.9 1300 ± 156

1 1/8

800 ± 100

110.6 ± 13.8 1085 ± 136

1 1/4

1000 ± 120

138 ± 16.6

1356 ± 163

1 3/8

1200 ± 150

166 ± 20.7

1630 ± 203

1 1/2

1500 ± 200

207 ± 27.7

2034 ± 271

Torque specifications for bolts related to hydraulic valves.

5/16

13 ± 2

1.8 ± 0.3

17.5 ± 2.5

3/8

24 ± 2

3.3 ± 0.3

32.5 ± 2.5

7/16

39 ± 2

5.4 ± 0.3

53 ± 2.5

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

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

72

Crown 1979 PF5067 Rev. 2/16

HYDRAULIC Hydraulic Schematic Symbols

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

VENTED RESERVOIR with the lines below the fluid level

FILTER or STRAINER

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

PILOT or DRAIN LINE limited flow

LINES CROSSING

M

ELECTRIC MOTOR operates in one direction and speed

M

ELECTRIC MOTOR operates in one direction in a speed that changes

M

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

HYDRAULIC PUMP fixed displacement, operates in one direction

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

HYDRAULIC MOTOR operates in two opposite directions

LINES CONNECTED GAUGE pressure QUICK DISCONNECT (disconnected)

PLUGGED PORT (test port)

FLOW METER

GAUGE temperature

ACCUMULATOR gas charged, diaphragm type

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

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

169

HYDRAULIC Hydraulic Schematic Symbols

PRESSURE SWITCH

CYLINDER double-acting cylinder, unequal area

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

ACTUATOR MANUAL

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

SOLENOID one coil or winding

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

CYLINDER single-acting cylinder, with cushion SOLENOID DUAL

COMPONENT ENCLOSURE manifold block

ACTUATOR MANUAL LEVER

SOLENOID PROPORTIONAL

VALVE PILOT CHECK (pilot to open)

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

170

Crown 1979 PF5066-2 Rev. 6/12

HYDRAULIC Hydraulic Schematic Symbols

ORIFICE THROTTLE fixed

VALVE SHUTTLE

ORIFICE THROTTLE adjustable VALVE SINGLE COUNTERBALANCE in manifold

FLOW CONTROL PRESSURE COMPENSATED fixed

FLOW CONTROL PRESSURE COMPENSATED fixed with reverse flow bypass

FLOW DIVIDER/COMBINER

FUSE VELOCITY BYPASS FLOW CONTROL controlled flow, pressure adjusted

VALVE RELIEF fixed

VALVE RELIEF adjustable

VALVE CHECK

VALVE MANUAL SHUTOFF

P T

T P

TORQUE GENERATOR

L R

STEER UNIT hydrostatic

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

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

171

HYDRAULIC Hydraulic Schematic Symbols

VALVE two-way valve with two positions

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

VALVE three-way valve with two positions

VALVE four-way valve with two positions

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

VALVE four-way valve with three positions

VALVE two-way valve with all positions

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

VALVE four-way valve with all positions

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

172

Crown 1979 PF5066-4 Rev. 6/12

MAINTENANCE CONTACTORS 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.

NOTE Before any adjustments, servicing, parts replacement or any other act is performed requiring physical contact with the electrical working components or wiring of this contactor, disconnect battery, discharge capacitor(s) and have drive wheels jacked up and free of the floor.

75- AMPERE CONTACTORS

ILLUSTRATION 4-10 Voltage Spike Suppression

When these contactors are used in conjunction with static control, it is often necessary to suppress the voltage spike which results when coil current is interrupted. This is done to prevent damage to static components such as silicon controlled rectifiers, transistors, etc.

Use only those voltage spike suppressors which are factory specified and supplied by the truck manufacturer.

When connecting the suppressors across the coil, polarity must be maintained in accordance with Illustration 4-11.

ILLUSTRATION 4-11 MAINTENANCE AND ADJUSTMENTS

The following information is intended to assist during periods of normal maintenance and to provide checks to determine if the contactors are in proper operating condition.

ILLUSTRATION 4-9 Connections

The power connections are ¼ - 20 screws which should be tightened to 45 to 60 inch-pounds (5.1 to 6.8 newton meters [N•m]). It is recommended that this tightening be done with a screwdriver, spin tight, or a socket on a shaft extension. If a wrench is used, take care that the head or body of the wrench does not come in contact with the molded side plate (See lllustration 4-10).That is, do not use the molded side plate as a pivot point.

As these devices are adjusted, inspected, and tested at the factory, they should not normally require further adjustments. However, any time a part has been replaced, the following checks should be made.

Power 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-alloy contact facing is completely eroded through to the backing material, or before the wipe is

© Crown 1978 PF-3282-1

Printed in U.S.A.

M4.4 - 11 - 001

M4.4 - 11 - 001

MAINTENANCE reduced to zero. The siIver alloy may transfer from one contact and cause buildup on the mating contact.

This can be expected under certain conditions and does not require contact dressing or filing. When replacing only one contact of a mating pair, remove any high peaks or beads of material on the contact that is not replaced.

MEASURE NORMALLY OPEN WIPE WITH .040" (1.0 mm) DIA. ROD AT THIS END; THE DISTANCE BETWEEN THE MOLDED MOVABLE CONTACT ASSEMBLY AND THE ARMATURE

Power Contacts Adjustments With the contactor mounted or held in its normal operating position, check the contact wipes and gaps. These checks are most easily made with small rods or drills of a diameter equal to the dimensions given below. These contractors are double break (two sets of contacts per circuit) and the gaps must be measured on both sets of contacts.

Normally open gap

— 0.050 inches (1.27 mm) minimum each side

Normally closed gap — 0.050 inches (1.27 mm) minimum each side Normally open wipe

— 0.040 inches (1.0 mm) minimum

ILLUSTRATION 4-13

Normally closed wipe — no check NOTE The normally open wipe measurement given is with new contacts and will decrease as the contacts wear.

Illustrations 4-12 and 4-13 show de-energized and energized positions, and where to measure.

The only means of adjusting to obtain these measurements is by moving the side plates in or out on the frame. If adjustment is necessary, make sure that the side plates are relatively square with respect to each other and with the U-frame. Recheck the electrical interlock adjustments and, if necessary, re-adjust per “Electrical Interlocks” in this section.

Replacement of Parts It is necessary to disassemble these devices in order to replace any part except the electrical interlock or its operator. For this reason, you may find it to your advantage to replace the entire contactor whenever a complete set of contacts or a new coil is needed.

However, if you desire to replace a part, use the following procedures: 1. Disconnect the contactor and remove it from the vehicle.

2. To replace the coil, first unsolder the coil leads from the coiI terminal strips; then remove the screws which fasten the molded side plates to the frame.

ILLUSTRATION 4-12

© Crown 1978 PF-3382-2

M4.4 - 11- 002

3. Now, slide the frame and coil out from between the molded side plates. If the core does not have a head, it is now possible to remove the coil without disassembling the core and the frame. If the core does have a head, you must remove the screw which holds the core to the frame. It may be necessary to hold the core with a pair of pliers.

Printed in U.S.A.

M4.4 - 11- 002

MAINTENANCE 4. Replace the coil, and reassemble the core to the

frame. Be sure the special conical Iockwasher is in place and that the screw is tightened.

5. Slide the frame and coil assembly back between the molded side plates with the armature spring positioned as shown in Illustration 4-14.

ELECTRICAL INTERLOCKS An auxiliary snap-action electrical interlock can be mounted on most forms of these contactors (See Illustration 4-15). This electrical interlock has one normally open pole and one normally closed pole. It must be adjusted to operate in the following manner.

6. Replace the screws in the side plates, making sure the stationary contacts and the coil terminal strips are positioned in their respective slots in the side plates.

7. Check the power contact gaps and wipes per the Power Contact Adjustments section of this instruction publication. Make sure the armature spring is properly seated as shown in Illustration 4-14.

ILLUSTRATION 4-15 1. With a 0.010-inch (0.25 mm) thick shim or rod between the armature and the U-frame at the top, the interlock must operate when the coil is energized or when the armature is manually operated.

ILLUSTRATION 4-14 8. The side plates can be moved by the amount the holes are larger than the screws. Try to align the side plates as squarely as possible with the frame.

9. To replace a worn contact or set of contacts, first disconnect the contactor and remove it from the vehicle.

2. With a 0.030-inch (0.76 mm) thick shim or rod, using the same procedure, the interlock should not operate. The interlock mounting bracket has slotted mounting holes and can be moved in or out to obtain these requirements. If it is necessary to do this, recheck the contact adjustments per this section.

a. Remove the bottom molded side plate. Note that by leaving the top molded side plate attached to the frame, the normally open contact adjustments will not be changed. b. Replace the worn contacts and reassemble the contactor, taking care that the stationary contact strips, the coil terminal strips, and the armature tongues are all properly positioned in their respective slots in the side plates. Make sure the armature spring is positioned as shown in Illustration 4-14. c. Check the contact gaps and wipes and if necessary, re-adjust per the description in this section.

© Crown 1978 PF-3382-3

Printed in U.S.A.

M4.4 - 11- 003

M4.4 - 11- 003

MAINTENANCE CONTROL POD The control pod comes in several variations to provide the operator controls for travel, raise, lower, horn and high speed cutout. All variations incorporate a safety reversing switch.

PE trucks may include Quickpick controls.

Adjustments Remove covers from top and bottom of control pod.

SAFETY REVERSING SWITCH Turn adjusting screw counter-clockwise until safety reversing switch actuates (zero ohms on meter). Turn adjusting screw clockwise one half turn for correct adjustment.

DIRECTIONAL AND SPEED SWITCHES (resistor speed control)

ILLUSTRATION 4.5-1 Depending on the model, control pods will have two (2) speed switches or a potentiometer; with or without a 1A switch; with or without a high speed cutout switch. When a 1A switch other than in the control pod is used, e.g. a cross bar mounted 1A switch on PE series trucks, a high speed cutout switch is not required.

The following instructions outline the adjustment of the safety reversing switch, directional switches, speed switches (resistor speed control trucks) and potentiometer (Transistor and SCR speed control trucks). Replacement procedures are also included for all components in the control pod.

To verify when switches are actuated, connect a volt-ohm meter, on the R x 10,000 ohm scale, across the N.O. contacts. Meter indication should be zero ohms. When switch is not actuated, meter should indicate infinite resistance.

On resistor speed control trucks, a detent arm drops into various detents as the twist grip is rotated in either direction.

Switches actuate when in the corresponding detents and remain actuated until twist grip passes the corresponding detent toward the neutral position.

Turn the twist grip toward operator until detent arm drops in bottom of first detent. Turn adjusting screw on appropriate directional switch actuating arm slowly clockwise until switch actuates (zero ohms on meter). Secure with thread locking adhesive (Crown no. 061004-014).

Advance twist grip to second detent and hold. Turn adjusting screw on “A” speed (second speed) switch slowly clockwise until switch actuates (zero ohms on meter). Secure adjustment with thread locking adhesive (Crown no. 061004-014).

Advance twist grip to third detent and hold. Turn adjusting screw on “B” speed (third speed) switch slowly clockwise until switch actuates (zero ohms on meter). Secure adjustment with thread locking adhesive (Crown no. 061004-014).

RESISTOR CONTROL ILLUSTRATION 4.5-2

TRANSISTOR AND SCR CONTROL ILLUSTRATION 4.5-3

Crown 1985 PF-7198-1 Rev. 10/91

Printed in U.S.A.

02 REV. 10/91

M4.5 - 04.2 - 001

M4.5 - 04.2 - 001

MAINTENANCE Return twist grip to neutral and turn in opposite direction to first detent and hold. Turn adjusting screw on opposite directional switch slowly clockwise until switch actuates (zero ohms on meter). Secure adjustment with thread locking adhesive (Crown no. 061004-014).

Return twist grip to neutral and check that all switches reset (infinite resistance on meter). If a switch does not reset, turn adjusting screw counter-clockwise, in quarter-turn increments, until switch resets. Check that switch actuates when twist grip is rotated to corresponding detent.

Install covers.

0271S

DIRECTIONAL AND 1A SWITCHES (Transistor and SCR speed control) With the twist grip in the neutral position turn the adjustment screws on both directional switches, slowly, clockwise until switch actuates (zero ohms on meter). Turn both screws 1/ 2 turn counter-clockwise. Place an ohm meter across the potentiometer and turn twist grip slowly until a directional switch actuates. Record reading shown on meter. Turn twist grip in opposite direction slowly until other directional switch actuates. Record reading shown on meter.

Compare the two readings. The values should be within 250 ohms of each other. If the difference is in excess of 250 ohms, turn adjusting screw on actuator arm of directional switch which corresponds to the highest reading, counterclockwise in quarter-turn increments until readings at actuation are within 250 ohms. Secure adjustments with thread locking adhesive (Crown no. 061004-014).

Set the 1A switch (on units which incorporate the 1A switch in the control pod) to actuate when the reading from the potentiometer is less than 200 ohms. Check in both directions of twist grip rotation. Secure adjustment with thread locking adhesive (Crown no. 061004-014).

Install covers.

POTENTIOMETER (Transistor and SCR speed control) When a new potentiometer is being installed, the potentiometer can be approximately adjusted outside the assembly.

Attach a jumper between the outside terminals of the potentiometer and connect leads of ohm meter between either outside terminal and center terminal of the potentiometer.

ILLUSTRATION 4.5-4

Rotate the shaft of the potentiometer to obtain the highest ohm meter reading (approximately 5000 ohms). Disconnect meter and jumper. Install potentiometer as outlined in Replacement.

To fine adjust the potentiometer in the assembly, proceed with the following instructions.

With the twist grip in the neutral position, connect an ohm meter between the center terminal and either end terminal (disconnect one wire from potentiometer at terminal board to assure correct reading). Loosen potentiometer locknut and rotate potentiometer back and forth to obtain the highest resistance reading (approximately 5000 ohms). Secure adjustment with locknut. Rotate twist grip from stop to stop.

Resistance reading must not jump from zero ohms to infinite resistance throughout entire rotation. If resistance does jump, adjust potentiometer slightly.

When potentiometer is adjusted, make certain potentiometer terminals will not contact the cover when installed. If terminals will contact the cover, loosen the adjustable potentiometer mounting bracket and move pinion gear away from teeth on stop. Loosen locknut on potentiometer mounting post and turn potentiometer so terminals will not touch the cover and secure. Move pinion gear on potentiometer toward gear teeth on stop until teeth mesh completely and tighten adjustable mounting bracket screws.

Perform potentiometer adjustment procedures.

Install covers.

Crown 1985 PF-7198-2 Rev. 10/91

Printed in U.S.A.

02 REV. 10/91

M4.5 - 04.2 - 002

M4.5 - 04.2 - 002

MAINTENANCE Component Replacement

LIFT, LOWER, HIGH SPEED CUTOUT, HORN SWITCHES AND BUTTONS

Remove covers from top and bottom of control pod.

DIRECTIONAL, SPEED, 1A SWITCHES AND ACTUATORS Remove three mounting screws from switch and bracket assembly. Arrange wires in control pod to permit switch and bracket assembly to be moved out from under cam through top of control pod.

Locate switch to be replaced and disconnect electrical wires, noting location for proper installation (Illustration 4.5-6).

Remove mounting screws and replace switch. Secure in place with mounting screws and connect electrical wires as noted at disassembly. Tighten electrical connection screws 55-65 inch ounces (390-460 Nmm).

0273S

0272S

ILLUSTRATION 4.5-5

Locate switch to be replaced and disconnect wires, noting location for proper installation. Remove appropriate mounting screws and slide switch from assembly. Position replacement switch and slide into assembly, securing in place with mounting screws. Connect wires as noted at disassembly and tighten electrical connection screws 55-65 inch ounces (390-460 Nmm).

Locate actuator arm in question. Remove speed nut (39) (Illustration 4.5-5) and slide rod (33) out until actuator in question can be removed. Remove adjusting screw from arm being replaced and install in replacement arm. Slide rod into switch bracket, aligning actuators so rod goes through pivot point. Install speed nut.

Slide switch and bracket assembly onto mounting posts in control pod and secure in place with mounting screws.

Perform switch adjustment procedures.

ILLUSTRATION 4.5-6

Locate button to be replaced and remove two spring retaining screws (51). Work springs out of assembly. Remove corresponding switch mounting screws and move switch aside. Remove button from cover. Position replacement button so symbol on button is correct and insert in cover.

Compress springs and insert in spring recess in back of button and under bracket for spring retaining screw. Install spring retaining screws. Position switch and secure in place with mounting screws.

Install covers.

SAFETY REVERSING SWITCH AND BUTTON ASSEMBLY Remove mounting screws from safety reversing switch (Illustration 4.5-7) and lift from control pod. Disconnect electrical wires and install on replacement switch. Position replacement switch in control pod and secure in place with mounting screws.

Install covers.

Crown 1985 PF-7198-3 Rev. 10/91

Printed in U.S.A.

02 REV. 10/91

M4.5 - 04.2 - 003

M4.5 - 04.2 - 003

MAINTENANCE Remove two retaining screws (13) and pull button assembly from control pod. Remove four screws (10) and separate all components of assembly.

Connect wires to replacement potentiometer. Place insulator (55) on potentiometer aligning tab on potentiometer with notch in insulator. Slide potentiometer through hole in mounting bracket and assemble insulator (59), lockwasher (60) and locknut (62). Before tightening locknut, turn potentiometer so terminals will not touch the cover when assembled.

Slide pinion gear (63) on potentiometer shaft and approximately adjust the potentiometer as outlined in Potentiometer Adjustment.

Move potentiometer toward the stop so pinion gear teeth and teeth on stop mesh completely. Tighten screws on mounting plate. Perform the Potentiometer Adjustment procedures.

Install covers.

TWIST GRIPS

Replace component in question and reassemble (6) (7) (8) and (9) using screws (10). Make certain springs are in position and insert button assembly in pod. Secure in place with retaining screws (13). Make certain edge of switch bellows (8) is positioned in recess in control pod. Perform Safety Reversing Switch Adjustment Procedure.

If truck (PE) is equipped with Quickpick controls, remove button located on the side of twist grip. Drive roll pin from twist grip being replaced (Illustration 4.5-9). Slide grip out through hole in yoke. Remove bushing from old grip and install on replacement grip. Position replacement grip with arrows upward when handle is in operating position and slide grip through hole in yoke. Align square hole in grip with square shaft and slide together. Align hole in grip with hole in shaft and drive in roll pin.

Install covers.

CAMS, TORSION SPRING, STOP

POTENTIOMETER (Illustration 4.5-8)

Drive roll pin from right hand twist grip and remove grip through hole in yoke. Slowly slide the square shaft with grip from assembly. Make note of the physical arrangement of components on the shaft with respect to each other and the arrows on the left hand grip.

SPACER STOP & RETURN (TRANSISTOR & ASSEMBLY SCR CONTROL) (TRANSISTOR & ARROWS SCR CONTROL) WASHERS CAM

0274S

ILLUSTRATION 4.5-7

Loosen screws on adjustable mounting bracket. Move potentiometer away from stop so gear teeth unmesh. Slide pinion gear off potentiometer shaft. Remove locknut (62), star lockwasher (60) and insulator (59). Pull potentiometer from mounting bracket, remove insulator (55) and disconnect wires, noting location for proper installation.

TWIST GRIP

ROLL PIN

SPEED CAM (RESISTOR CONTROL)

STOP (RESISTOR CONTROL) 0276S 0275S

ILLUSTRATION 4.5-8

Crown 1985 PF-7198-4 Rev. 10/91

ILLUSTRATION 4.5-9 Printed in U.S.A.

02 REV. 10/91

M4.5 - 04.2 - 004

M4.5 - 04.2 - 004

MAINTENANCE Replace component in question. When assembling, make certain the arrows on the twist grip will be toward the top of the control pod when control handle is in operating position.

Apply grease (Crown no. 063002-025) to the inside of the torsion spring and assemble the stop, spring, collars and plate. Make certain the torsion spring is assembled on spring arm of the stop as shown in Illustration 4.5-10.

Select new component and assemble in reverse order, making certain sleeving is on spring.

Apply grease (Crown no. 063002-025) to outside diameter of detent roller.

Install covers.

QUICKPICK CONTROLS (PE Trucks Only) When replacing components, refer to illustration below.

Switches require no adjustment. Tighten switch electrical connection screws 55-65 inch ounces (390-460 Nmm).

COVER 0277S

ILLUSTRATION 4.5-10

SWITCH Assemble components on shaft in control pod as noted at disassembly and shown in Illustration 4.5-9. Make certain torsion spring is over tab in control pod housing as shown in Illustration 4.5-10. Insert washers between cam and control pod as required to remove any lateral movement of components on the shaft.

Insert right hand twist grip through hole in yoke, arrows up, and secure in place with roll pin. Perform switch and potentiometer adjustment procedures as necessary.

SHOULDER SCREW INSULATOR SHOULDER SCREW

BUTTON SPRING ROLL PIN

Apply grease (Crown no. 063002-025) to entire torsion spring.

BUTTON

Install covers.

DETENT ARM AND SPRING Using a pin punch, drive the roll pin from the detent arm pivot point (Illustration 4.5-11). Unhook spring in bottom of control pod and remove detent arm and spring. Disassemble spring and detent arm.

0278S

0905

ILLUSTRATION 4.5-12

ILLUSTRATION 4.5-11

Crown 1985 PF-7198-5 Rev. 10/91

Printed in U.S.A.

02 REV. 10/91

M4.5 - 04.2 - 005

M4.5 - 04.2 - 005

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

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

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

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

M4.1–12.0–003

ELECTRICAL WIRING 3804

Maintained Contact Switches Operator Actuated

Momentary Contact Switches Operator Actuated

Normally Open

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

M4.1–12.0–004

ELECTRICAL WIRING 3805

Thermistor PM Motor

T

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

I

Encoder

Common Isolated LED

B

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

M4.1–12.0–005

C

CONTROL POD

The control pod comes in several variations to provide the operator controls for travel, raise, lower, horn and high speed cutout. All variations, except the PC 3500, incorporate a safety reversing switch. PE trucks may include Quickpick controls.

Depending on the model, control pods will have two (2) speed switches or a potentiometer; with or without a 1A switch; with or without a high speed cutout switch. When a 1A switch other than in the control pod is used, e.g. a cross bar mounted 1A switch on PE series trucks, a high speed cutout switch is not required.

The following instructions outline the adjustment of the safety reversing switch, directional switches, speed switches (resistor speed control trucks) and potentiometer (Transistor and SCR speed control trucks). Replacement procedures are also included for all components in the control pod.

To verify when switches are actuated, connect a volt-ohm meter, on the R x 10,000 ohm scale, across the N.O. contacts. Meter indication should be zero ohms. When switch is not actuated, meter should indicate infinite resistance.

Adjustments

DIRECTIONAL AND SPEED SWITCHES (resistor speed control) On resistor speed control trucks, a detent arm drops into various detents as the twist grip is rotated in either direction.

Switches actuate when in the corresponding detents and remain actuated until twist grip passes the corresponding detent toward the neutral position.

Turn the twist grip toward operator until detent arm drops in bottom of first detent. Turn adjusting screw on appropriate directional switch actuating arm slowly clockwise until switch actuates (zero ohms on meter). Secure with thread locking adhesive (Crown no. 061004-014).

Advance twist grip to second detent and hold. Turn adjusting screw on “A” speed (second speed) switch slowly clockwise until switch actuates (zero ohms on meter). Secure adjustment with thread locking adhesive (Crown no. 061004-014).

Advance twist grip to third detent and hold. Turn adjusting screw on “B” speed (third speed) switch slowly clockwise until switch actuates (zero ohms on meter). Secure adjustment with thread locking adhesive (Crown no. 061004-014).

Return twist grip to neutral and turn in opposite direction to first detent and hold. Turn adjusting screw on opposite directional switch slowly clockwise until switch actuates (zero ohms on meter). Secure adjustment with thread locking adhesive (Crown no. 061004-014).

Remove covers from top and bottom of control pod.

SAFETY REVERSING SWITCH (Not Applicable on PC, TR Trucks) Turn adjusting screw counter-clockwise until safety reversing switch actuates (zero ohms on meter). Turn adjusting screw clockwise one half turn for correct adjustment.

Return twist grip to neutral and check that all switches reset (infinite resistance on meter). If a switch does not reset, turn adjusting screw counter-clockwise, in quarter-turn increments, until switch resets. Check that switch actuates when twist grip is rotated to corresponding detent.

Install covers.

930415

7188 - EO10973

Crown 1993 PF9758-1 Rev. 1/04

Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–010

M4.5–04.2–010

C

CONTROL POD

DIRECTIONAL AND 1A SWITCHES (Transistor and SCR speed control) With the twist grip in the neutral position turn the adjustment screws on both directional switches, slowly, clockwise until switch actuates (zero ohms on meter). Turn both screws 1/ 2 turn counter-clockwise. Place an ohm meter across the potentiometer and turn twist grip slowly until a directional switch actuates. Record reading shown on meter. Turn twist grip in opposite direction slowly until other directional switch actuates. Record reading shown on meter.

Compare the two readings. The values should be within 250 ohms of each other. If the difference is in excess of 250 ohms, turn adjusting screw on actuator arm of directional switch which corresponds to the highest reading, counterclockwise in quarter-turn increments until readings at actuation are within 250 ohms. Secure adjustments with thread locking adhesive (Crown no. 061004-014).

Set the 1A switch (on units which incorporate the 1A switch in the control pod) to actuate when the reading from the potentiometer is less than 200 ohms. Check in both directions of twist grip rotation. Secure adjustment with thread locking adhesive (Crown no. 061004-014).

Install covers.

POTENTIOMETER (Transistor and SCR speed control) When a new potentiometer is being installed, the potentiometer can be approximately adjusted outside the assembly.

Attach a jumper between the outside terminals of the potentiometer and connect leads of ohm meter between either outside terminal and center terminal of the potentiometer.

0271S

ILLUSTRATION 1

Rotate the shaft of the potentiometer to obtain the highest ohm meter reading (approximately 5000 ohms). Disconnect meter and jumper. Install potentiometer as outlined in Replacement.

To fine adjust the potentiometer in the assembly, proceed with the following instructions.

With the twist grip in the neutral position, connect an ohm meter between the center terminal and either end terminal (disconnect one wire from potentiometer at terminal board to assure correct reading). Loosen potentiometer locknut and rotate potentiometer back and forth to obtain the highest resistance reading (approximately 5000 ohms). Secure adjustment with locknut. Rotate twist grip from stop to stop.

Resistance reading must not jump from zero ohms to infinite resistance throughout entire rotation. If resistance does jump, adjust potentiometer slightly.

When potentiometer is adjusted, make certain potentiometer terminals will not contact the cover when installed. If terminals will contact the cover, loosen the adjustable potentiometer mounting bracket and move pinion gear away from teeth on stop. Loosen locknut on potentiometer mounting post and turn potentiometer so terminals will not touch the cover and secure. Move pinion gear on potentiometer toward gear teeth on stop until teeth mesh completely and tighten adjustable mounting bracket screws.

Perform potentiometer adjustment procedures.

Install covers.

Crown 1993 PF9758-2 Rev. 1/04

Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–011

M4.5–04.2–011

C

CONTROL POD

Component Replacement

LIFT, LOWER, HIGH SPEED CUTOUT, HORN SWITCHES AND BUTTONS

Remove covers from top and bottom of control pod.

DIRECTIONAL, SPEED, 1A SWITCHES AND ACTUATORS Remove three mounting screws from switch and bracket assembly. Arrange wires in control pod to permit switch and bracket assembly to be moved out from under cam through top of control pod.

Locate switch to be replaced and disconnect electrical wires, noting location for proper installation (Illustration 3).

Remove mounting screws and replace switch. Secure in place with mounting screws and connect electrical wires as noted at disassembly. Tighten electrical connection screws 390-460 Nmm (55-65 inch ounces).

47 46

48

45

42 41

43 41 42 44 41

0273

49 50

42 42

43

0272S

51

52 53

ILLUSTRATION 3

Locate button to be replaced and remove two spring retaining screws (51). Work springs out of assembly. Remove corresponding switch mounting screws and move switch aside. Remove button from cover. Position replacement button so symbol on button is correct and insert in cover.

ILLUSTRATION 2

Locate switch to be replaced and disconnect wires, noting location for proper installation. Remove appropriate mounting screws and slide switch from assembly. Position replacement switch and slide into assembly, securing in place with mounting screws. Connect wires as noted at disassembly and tighten electrical connection screws 390-460 Nmm (55-65 inch ounces).

Locate actuator arm in question. Remove speed nut (39) (Illustration 2) and slide rod (33) out until actuator in question can be removed. Remove adjusting screw from arm being replaced and install in replacement arm. Slide rod into switch bracket, aligning actuators so rod goes through pivot point.

Install speed nut.

Slide switch and bracket assembly onto mounting posts in control pod and secure in place with mounting screws.

Perform switch adjustment procedures.

Compress springs and insert in spring recess in back of button and under bracket for spring retaining screw. Install spring retaining screws. Position switch and secure in place with mounting screws.

Install covers.

SAFETY REVERSING SWITCH AND BUTTON ASSEMBLY (Not Applicable on PC, TR Trucks) Remove mounting screws from safety reversing switch (Illustration 4) and lift from control pod. Disconnect electrical wires and install on replacement switch. Position replacement switch in control pod and secure in place with mounting screws.

Install covers.

Crown 1993 PF9758-3 Rev. 1/04

Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–012

M4.5–04.2–012

C

CONTROL POD

Remove two retaining screws (13) and pull button assembly from control pod. Remove four screws (10) and separate all components of assembly.

20 14

12 11

11 10

19 9

Connect wires to replacement potentiometer. Place insulator (55) on potentiometer aligning tab on potentiometer with notch in insulator. Slide potentiometer through hole in mounting bracket and assemble insulator (59), lockwasher (60) and locknut (62). Before tightening locknut, turn potentiometer so terminals will not touch the cover when assembled.

Slide pinion gear (63) on potentiometer shaft and approximately adjust the potentiometer as outlined in Potentiometer Adjustment.

Move potentiometer toward the stop so pinion gear teeth and teeth on stop mesh completely. Tighten screws on mounting plate. Perform the Potentiometer Adjustment procedures.

10

Install covers.

13 8

TWIST GRIPS

7 64 ILLUSTRATION 0274

Replace component in question and reassemble (6) (7) (8) and (9) using screws (10). Make certain springs are in position and insert button assembly in pod. Secure in place with retaining screws (13). Make certain edge of switch bellows (8) is positioned in recess in control pod. Perform Safety Reversing Switch Adjustment Procedure.

Install covers.

If truck (PE) is equipped with Quickpick controls, remove button located on side of twist grip. Drive roll pins from each end of twist grip being replaced. Slide grip in hole of yoke to access extension on end of twist grip. Remove extension from grip and remove grip from yoke. Depending on operator preference, position replacement grip with lobe toward yoke or away from yoke (trucks are manufactured with lobe toward yoke), with arrows up and install grip in yoke. Align key on extension with slot in grip and assemble extension to grip. Align square hole in grip with square shaft and slide together. Assemble roll pins in each end of grip.

POTENTIOMETER (Illustration 5) PART OF CONTROL POD

Loosen screws on adjustable mounting bracket. Move potentiometer away from stop so gear teeth unmesh. Slide pinion gear off potentiometer shaft. Remove locknut (62), star lockwasher (60) and insulator (59). Pull potentiometer from mounting bracket, remove insulator (55) and disconnect wires, noting location for proper installation.

PART OF YOKE TWIST GRIP

EXTENSION ROLL PINS 1977

0275S

ILLUSTRATION 6

ILLUSTRATION 5

Crown 1993 PF9758-4 Rev. 1/04

Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–013

M4.5–04.2–013

C

CONTROL POD

On PC 3500 truck remove roll pin closest to control pod. Slide twist grip from shaft and out of yoke. Remove roll pin and extension from grip. Align key on extension with twist grip and assemble extension into grip, attach with roll pin. Slide extension into yoke, with lobe toward yoke, and handle onto square shaft on side of control pod. Assemble roll pin in control pod end of twist grip.

Replace component in question. When assembling, make certain the arrows on the twist grip will be toward the top of the control pod when control handle is in operating position.

Apply grease (Crown no. 063002-025) to the inside of the torsion spring and assemble the stop, spring, collars and plate. Make certain the torsion spring is assembled on spring arm of the stop as shown in Illustration 9.

Part of Control Pod Part of Yoke Twist Grip

0277S

Assemble components on shaft in control pod as noted at disassembly. Make certain torsion spring is over tab in control pod housing as shown in Illustration 9. Insert washers between cam and control pod as required to remove any lateral movement of components on the shaft.

Roll Pins

Extension ILLUSTRATION 7

3871

CAMS, TORSION SPRING, STOP Drive roll pins from each end of right hand twist grip. Slide grip in hole of yoke to access extension on end of twist grip.

Remove extension from grip and remove grip from yoke.

Slowly slide the square shaft from assembly. Make note of the physical arrangement of components on the shaft with respect to each other and the finger lobe on the left hand grip.

STOP & RETURN ASSEMBLY (TRANSISTOR & SCR CONTROL)

SPACER (TRANSISTOR & SCR CONTROL)

0276S-01

Depending on operator preference, position right hand grip with lobe toward yoke or away from yoke (trucks are manufactured with lobe toward yoke), with arrows up and install grip in yoke. Align key on extension with slot in grip and assemble extension to grip. Align square hole in grip with square shaft and slide together. Assemble roll pins in each end of grip. Perform switch and potentiometer adjustment procedures as necessary.

Apply grease (Crown no. 063002-025) to entire torsion spring.

WASHERS CAM

STOP (RESISTOR CONTROL)

ILLUSTRATION 9

Install covers.

SPEED CAM (RESISTOR CONTROL)

ILLUSTRATION 8

Crown 1993 PF9758-5 Rev. 1/04

Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–014

M4.5–04.2–014

C

CONTROL POD

DETENT ARM AND SPRING

COVER

Using a pin punch, drive the roll pin from the detent arm pivot point (Illustration 10). Unhook spring in bottom of control pod and remove detent arm and spring. Disassemble spring and detent arm.

SWITCH SHOULDER SCREW INSULATOR SHOULDER SCREW

BUTTON SPRING ROLL PIN

BUTTON

0278S

ILLUSTRATION 10

Select new component and assemble in reverse order, making certain sleeving is on spring.

Apply grease (Crown no. 063002-025) to outside diameter of detent roller.

Install covers.

QUICKPICK CONTROLS (PE Trucks Only) When replacing components, refer to illustration below.

Switches require no adjustment. Tighten switch electrical connection screws 390-460 Nmm (55-65 inch ounces).

0905-01

ILLUSTRATION 11

LOAD BACKREST POD (PC 3500 Truck Only) The PC 3500 Truck can have a load backrest control pod on it. The pod will contain raise and lower switches, which do not require adjustment, and a horn switch. To adjust the horn switch, remove cushion and control pod from load backrest to gain access to adjustment screw. Connect meter to switch and fully depress horn button. Turn adjustment screw in until switch activates, zero ohms on meter, continue to turn in until switch plunger is almost fully depressed making sure it is not bottomed out. Secure screw with thread locking adhesive (Crown no. 061004-014).

Adjustment Screw

3873 Crown 1993 PF9758-6 Rev. 1/04

Load Backrest Pod

ILLUSTRATION 12 Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–015

M4.5–04.2–015

MAINTENANCE MAST Outrigger Adjustment

CAUTION

Only perform this adjustment procedure on one outrigger at a time to prevent possible tipping of unit. Before altering outriggers, raise truck and block so applicable load wheel is free of floor.

1. Locate and mark the center point between both outriggers to be used as the reference point in determining the proper amount of adjustment.

2. Remove the 3 bolts securing outrigger to the frame of the truck.

CAUTION

3. Make proper adjustment to outrigger in reference to your center point. The design of the outrigger and attachment points allow for standard adjustments from 26.5 inches to 50 inches. The standard adjustment points require all three (3) bolts to be used.

CAUTION

Equal adjustments from the center point must be made to each outrigger to insure truck stability 4. Attach outrigger and torque mounting bolts to 265 ft.lbs. Repeat steps 2 thru 4 for adjustment of opposite outrigger.

5. Remove blocking and check for proper operation.

Outrigger and load wheel assembly weigh in excess of 50 lbs. Extreme care should be taken to avoid injury.

OUTRIGGER BOLTS

5809

Crown 1997 PF-11049

M7.0–04.4–001

Printed in U.S.A.

M7.0–04.4–001