Download PDF: Crown Forklift PC 3600 Series Pallet Service Manual

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INTRODUCTION

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

OPERATOR INSTRUCTIONS This manual does not contain operation instructions. Operator Instructions in tag or booklet form are sent with each truck.

Additional copies can be ordered if required. These booklets are for you and your personnel to insure years of safe, troublefree operation of your Crown Lift Truck. For PC 3600 Series operator instructions, refer to Crown publication, “You and Your Crown Pallet Rider” (PF14612).

DRIVER TRAINING Crown has available a complete series of Driver Training programs, in two parts concerning basic safety rules and operating characteristics of your truck. To obtain this information, ask your Crown Dealer about “Its up to You” and “You and Your Crown Pallet Rider”.

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

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

For PC 3600 Series capacities, technical information and dimensional specifications, please refer to the following sales literature: PC 3600 Specifications SF14580 Copies of publications can be obtained from your Crown dealer or by writing to: Crown Equipment Corporation 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 first portion of the manual covers the written maintenance.

The later portion covers replacement parts. The sectional descriptions are as follows: MAINTENANCE SECTION M1 M2 M3 M4 M5 M7 M8 M10

051206

ITD–6636–001

DESCRIPTION Lubrication and Adjustments Hydraulics Drive Unit Electrical Brake Fork Cylinder Glossary

REPLACEMENT PARTS SECTION 1 2 3 4 5 7 8 10 11

DESCRIPTION Power Unit Hydraulic System and Components Drive Unit and Components Electrical Components Brake Assemblies and Brake Systems Lift Structures Cylinders Accessories Specifications

12332 Crown 2005 PF15173-1

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INTRODUCTION

The serial plate for the PC 3600 Series truck is located on the power unit and includes a model number and truck data number. From these two numbers, you can identify the truck model, series, series updates, determine relative size or performance, capacity and specific truck data. These next three pages explain the model & truck data numbering system.

Figure 13216

Serial Plate

MODEL NUMBER EXAMPLE Series Update Significant change(s) to the product that would not merit a new series number (generation).

Image Generator PC - Center Control Pallet Rider

PC3600-60 Series Major technical and design changes making the product a new and improved generation.

*Capacity 60 = 2722 kg. (6000 lb.)

80 = 3629 kg. (8000 lb.)

*Actual rated capacity may vary, depending on special equipment or modifications. Consult capacity plate located on the power unit console.

Crown 2005 PF15173-2

ITD–6636–002

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INTRODUCTION

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

TRUCK DATA NUMBER EXAMPLE Axles - = Single T = Tandem * = Special

Fork Tip - = Standard E = Extended

Control C = Curtis Transistor

Fork Width 22 = 560mm (22 in.) 25 = 635mm (25 in.)

23 = 585mm (23 in.) 26 = 660mm (26 in.)

24 = 610mm (24 in.) 27 = 685mm (27 in.)

28 = 710mm (28 in.) ** = Special

Drive Tire RU = Rubber, Black - Lugged SR = Rubber, Black-Siped WR = Rubber, White - Lugged LR = Rubber, Black - Lugged Fiber Glass Impreg.

RS = Rubber, Black - Smooth PO = Poly, Black - Smooth SP = Poly, Black-Siped GP = Poly, Black - Grooved CP = Poly, Cream - Smooth HP = Poly, Black - High Crown DP = Poly, Black - Diamond Siped RP = Poly, Black - Razor Siped BP = Poly, Black - 13.5 in. x 5.5 in.

AP = Poly, Black - 13 in. x 5.5 in. ** = Special

- 22 36 E W T F C A RU KE - A - R W Standard/Special Truck - = Standard S = Special C = Custom

Fork Length 36 = 915mm (36 in.)

60 = 1525mm (60 in.)

42 = 1065mm (42 in.)

84 = 2135mm (84 in.)

48 = 1220mm (48 in.)

93 = 2360mm (93 in.)

54 = 1370mm (54 in.)

96 = 2440mm (96 in.) ** = Special Custom

Casters A = Quick Adjust Caster T = Quick Adjust with Torsion * = Special

Freezer Condition Option - = Without Conditioning F = Freezer Condition C = Corrosion Package * = Special

Battery Compartment Size W = Wide 335mm (13.19 in.) * = Special

ITD–6636–003

Crown 2005 PF15173-3

C

INTRODUCTION TRUCK DATA NUMBER EXAMPLE (continued)

Travel Alarm - = Without Travel Alarm A = Travel Alarm

Meter Options KE = Key Only HM = Hour Meter BD = Curtis Spyglass

Battery Rollout - = Without Battery Rollout R = Battery Rollout I = Battery Rollout & Retainer Switches

- 22 36 E W T F C A RU KE - A - R W

Internal Hour Meter - = Without Internal Hour Meter I = Internal Hour Meter * = Special Handle W = Standard T = Tee Key/Toggle Switch - = Key Switch T = Toggle Switch

Crown 2005 PF15173-4

ITD–6636–004

SAFETY

General Maintenance Instructions

General Maintenance Instructions WARNING An injury could occur.

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

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

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

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

• Fully lower the load engaging means.

• Put the directional control in neutral.

• Apply the parking brake.

• Turn off the lift truck.

• Remove the key.

• Chock the wheels of the lift truck.

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

• Use chocks or other positive positioning devices.

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

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

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

• Apply the brake.

• Put the directional control in neutral.

Crown 1976 PF2821 Rev. 6/22

•

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

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

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

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

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

Hold the steering wheel tightly and brace your feet.

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

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

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

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

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

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

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

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

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

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

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

3

SAFETY

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

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

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

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

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

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

• For tow tractors, see ASME B56.9.

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

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

MA-04.0-002 07 Rev. 6/22

4

Crown 1976 PF 2821 Rev. 6/22

SAFETY

Cleaning of Material Handling Equipment

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

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

Using a power washer

CAUTION

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

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

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

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

Material damage can occur.

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

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

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

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

Crown 2000 PF11969 Rev. 9/21

MA-1140-050 05 Rev. 9/21

5

SAFETY

Cleaning of Material Handling Equipment Crown Cleaning Products Cleaner Type

Part Number

Package Quantity

Degreaser and cleaner

363105-001 363105-012

19 oz can (12) 19 oz cans

All-purpose cleaner

363114-001 363114-012

19 oz can (12) 20 oz cans

Glass cleaner

363101-001 363101-012

19 oz can (12) 19 oz cans

Waterless hand cleaner

363111-001 363111-012

15 oz tube (12) 15 oz tubes

Pumiced and smooth hand cleaner

363112-001 363112-004

1 gal jug (4) 1 gal jugs

Wall-mounted deluxe soap dispenser

363122

Use with P/N 363112-001

Tough on grease

063009-005

1 gal jug

Citrus degreaser spray

363156-001 363156-012

32 oz spray bottle (12) 32 oz spray bottles

Citrus degreaser spray

363157-101 363158-101

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

Citra-sol degreaser

363146-001 363146-012

19 oz can (12) 19 oz cans

Battery cleaner

363124-001 363124-012

18 oz can (12) 18 oz cans

MA-1140-051 05 Rev. 9/21

6

Crown 2000 PF11969 Rev. 9/21

SAFETY Control of Hazardous Energy

Control of Hazardous Energy Lockout/Tagout In the interest of safety and to ensure compliance with the OSHA Regulations, (Standards - 29 CFR), control of hazardous energy (lockout/tagout) - 1910.147, Crown has developed guidelines for proper energy control when performing service and maintenance on the truck. Before performing any service or maintenance work, review the appropriate sections in this Service and Parts 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.

•

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 battery manufacturer's instructions concerning repair practices and procedures.

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

•

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

•

Before disconnecting or connecting batteries to a charger, make sure charger is OFF. If an attempt is made to do this while charger is ON, serious injury to you, 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.

Battery 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 battery. Gas formed while battery is charging is highly explosive. This gas remains in cells long after charging has stopped.

•

Do not lay metallic or conductive objects on battery. Arcing will result.

Crown 2005 PF15167-1 Rev. 11/09

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

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

MA-6636-100 01 Rev. 11/09

3

SAFETY Control of Hazardous Energy Battery Removal

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.

CAUTION When removing battery, move truck to area intended for battery care. Floor must be level. Turn key switch or toggle switch to OFF position and remove key. Disconnect battery and lockout/tagout truck as described in Lockout - Tagout in this section. Never move battery partially from truck without roller stand in place. Lower load engaging means completely. Do not allow any metallic object to come in contact with top of battery cells. This may cause a short circuit when removing or transporting battery. Use an insulator (i.e., plywood) to cover top of battery before and during removal.

Figure 17633

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

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

Figure 17632

Battery Installation CAUTION When installing battery, move truck to area intended for battery care. Floor must be level. Turn key switch or toggle switch to OFF position and remove key. Lockout/tagout truck as described in Lockout - Tagout in this section. Do not allow any metallic object to come in contact with top of battery cells. This may cause a short circuit when transporting or installing battery. Use an insulator (i.e., plywood) to cover top of battery 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.

MA-6636-101 01 Rev. 11/09

4

Crown 2005 PF15167-2 Rev. 11/09

SAFETY Control of Hazardous Energy Capacitance

Hydraulic

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

•

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

•

Lockout/tagout truck as described in Lockout Tagout in this section.

•

Place a minimum 100 ohm, 2 watt resistor between positive (1) and negative (2) terminals of controller for 15 or more seconds. Refer to Figure 17637.

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

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

When maintenance is to be performed on the hydraulic system, to make sure the hydraulic system is not under pressure:

Figure 17637

•

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

•

Completely lower load engaging means or, if required for maintenance, block at the appropriate height.

•

Lockout/tagout truck as described in Lockout Tagout in this section.

Completely Lower Forks

Figure 17634

Crown 2005 PF15167-3 Rev. 11/09

MA-6636-102 01 Rev. 11/09

5

SAFETY Control of Hazardous Energy Towing Truck

Towing Device Requirements:

Refer to the following guidelines when towing the truck:

Towing by Pulling in Power Unit First Direction

NOTE: Excessive acceleration by towing vehicle, or drag caused by towed vehicle (i.e., brake drag, drive unit drag, wheel drag, etc.) will greatly increase requirements to pull or push a vehicle.

•

WARNING This procedure applies only to manual steer trucks.

To calculate pull force requirement, multiply gross vehicle weight by 50% (i.e., gross vehicle weight x 0.5) for force needed to pull a vehicle on a flat level surface.

Attaching Towing Device To Lift Truck To Be Towed:

WARNING • •

Towed truck must always maintain three contact points with floor and/or towing device.

Do not make sharp turns when towing this truck.

Preparing Truck For Towing:

•

•

NOTE: Use pull force requirements listed under Towing Device Requirements (see above) to determine specifications of "eye bolt" and tow strap.

•

Attach an "eye bolt" to power unit skirt. If hole is not provided in skirt, you may need to drill a hole in center of skirt. (Contact your Crown representative for more information.) Attach a tow strap to "eye bolt" and to vehicle used for towing.

•

Attach tow strap low on the towed vehicle. Refer to Figure 17629.

Refer to data plate for gross vehicle weight; include battery weight if it is in vehicle during towing.

WARNING Truck will be difficult to steer. Use extreme care.

•

Ensure truck can be steered safely during towing.

This may require an operator to ride truck during towing.

•

Ensure truck can be braked safely during towing.

•

Ensure operator compartment has not been damaged in such a way as to inhibit operator safety during towing. If operator needs to exit vehicle quickly during towing, can it be done safely? If not, use another method to move vehicle.

•

Ensure floor is level and flat without trash or debris in towing path.

•

Remove all loads from forks before towing vehicle.

•

Lower forks to floor before towing vehicle.

•

Maximum travel speed while towing truck is 1.6 kph (1 mph).

MA-6636-103 01 Rev. 11/09

6

Pull vehicle by power unit skirt.

Tow Here To Pull In Power Unit First Direction Figure 17629

•

Use a tow strap that is long enough to allow operator time to stop safely if he or she needs to do so quickly. Towing at 1.6 kph (1 mph) will require a 2438 mm (96.0 in) minimum distance between towed and towing vehicle; choose a tow strap accordingly.

Crown 2005 PF15167-4 Rev. 11/09

SAFETY Control of Hazardous Energy Towing Vehicle Minimum Requirements:

•

Use pull force requirements calculated in Towing Device Requirements to determine traction force.

This traction force must be within towing specifications of towing vehicle.

•

Both towed and towing vehicle must be able to stop under their own power if they need to while towing.

•

Attach tow strap as low as possible on towing vehicle. Consult manufacturer for more information.

Towing Operation Guidelines:

• •

Maximum travel speed while towing truck is 1.6 kph (1 mph).

Both the towing vehicle operator and towed vehicle operator must be able to communicate clearly while towing. For example: if braking is required during towing, operators of towed and towing vehicles must clearly and quickly verbally communicate their intentions. Clear communication is also required during acceleration, turning, etc.

Towing by Pulling in Forks First Direction WARNING This procedure applies only to manual steer trucks.

WARNING • •

Towed truck must always maintain three contact points with floor and/or towing device.

Do not make sharp turns when towing this truck.

•

Ensure operator compartment has not been damaged in such a way as to inhibit operator safety during towing. If operator needs to exit vehicle quickly during towing, can it be done safely? If not, use another method to move vehicle.

•

Ensure floor is level and flat without trash or debris in towing path.

•

Remove all loads from forks before towing vehicle.

•

Lower forks to floor before towing vehicle.

•

Maximum travel speed while towing truck is 1.6 kph (1 mph).

Towing Device Requirements: NOTE: Excessive acceleration by towing vehicle, or drag caused by towed vehicle (i.e., brake drag, drive unit drag, wheel drag, etc.) will greatly increase requirements to pull or push a vehicle.

•

To calculate pull force requirement, multiply gross vehicle weight by 50% (i.e., gross vehicle weight x 0.5) for force needed to pull a vehicle on a flat level surface.

Attaching Towing Device To Lift Truck To Be Towed:

•

Pull vehicle by fork end of truck.

•

Attach a tow strap to fork end of vehicle and tow in forks first direction (see figure below). Tow strap can be attached by passing through one of the load wheel openings on top side of fork. Strap should not rub against load wheel.

Tow Here To Pull In Forks First Direction

Preparing Truck For Towing:

•

Refer to data plate for gross vehicle weight. Include battery weight if it is in vehicle during towing.

WARNING Truck will be difficult to steer. Use extreme care.

•

Ensure truck can be steered safely during towing.

This may require an operator to ride truck during towing.

•

Ensure truck can be braked safely during towing.

Crown 2005 PF15167-5 Rev. 11/09

Figure 17630

MA-6636-104 01 Rev. 11/09

7

SAFETY Control of Hazardous Energy •

Use a tow strap that is long enough to allow operator time to stop safely if he or she needs to do so quickly. Towing at 1.6 kph (1 mph) will require a 2438 mm (96.0 in) minimum distance between towed and towing vehicle; choose a tow strap accordingly.

Towing by Lifting and Towing in Power Unit First Direction NOTE: This method does not require a towed vehicle operator.

WARNING

Towing Vehicle Minimum Requirements:

•

• •

Use pull force requirements calculated in Towing Device Requirements to determine traction force.

This traction force must be within towing specifications of towing vehicle.

WARNING •

Towed truck must always maintain three contact points with floor and/or towing device.

Do not make sharp turns when lifting and towing this truck.

Both towed and towing vehicle must be able to stop under their own power if they need to while towing.

•

Attach tow strap as low as possible on towing vehicle. Consult manufacturer for more information.

Preparing Truck For Towing:

Towing Operation Guidelines:

•

Maximum travel speed while towing truck is 1.6 kph (1 mph).

•

Both the towing vehicle operator and towed vehicle operator must be able to communicate clearly while towing. For example: if braking is required during towing, operators of towed and towing vehicles must clearly and quickly verbally communicate their intentions. Clear communication is also required during acceleration, turning, etc.

MA-6636-105 01 Rev. 11/09

8

This procedure applies to trucks with power steering.

•

Refer to data plate for gross vehicle weight. Include battery weight if it is in vehicle during towing.

WARNING Truck will be difficult to steer. Use extreme care.

•

Remove battery before lifting and towing.

•

Ensure truck can be braked safely during towing.

•

Ensure operator compartment has not been damaged in such a way as to inhibit operator safety during towing. If operator needs to exit vehicle quickly during towing, can it be done safely? If not, use another method to move vehicle.

•

Ensure floor is level and flat without trash or debris in towing path.

•

Remove all loads from forks before towing vehicle.

•

Lower forks to floor before towing vehicle.

Crown 2005 PF15167-6 Rev. 11/09

SAFETY Control of Hazardous Energy Towing Device Requirements:

Towing Vehicle Minimum Requirements:

NOTE: Excessive acceleration by towing vehicle, or drag caused by towed vehicle (i.e., brake drag, drive unit drag, wheel drag, etc.) will greatly increase requirements to pull or push a vehicle.

•

Use pull force requirements calculated in Towing Device Requirements to determine traction force.

This traction force must be within towing specifications of towing vehicle.

•

•

Both towed and towing vehicle must be able to stop under their own power if they need to while towing.

•

Attach tow strap as low as possible on towing vehicle. Consult manufacturer for more information.

•

To calculate pull force requirement, multiple gross vehicle weight by 50% (i.e., gross vehicle weight x 0.5) for force needed to pull a vehicle on a flat level surface.

Towing device must hook to bottom side of truck skirt. It should provide both pulling and braking forces to towed truck. Towing device must allow pivoting of towed vehicle without damaging skirt or underside of towed vehicle.

Towing Operation Guidelines:

WARNING Do not lift towed truck higher than 51 mm (2.0 in) off floor.

•

Ensure towed vehicle does not uncouple from towing vehicle during towing or braking. Secure towed vehicle to towing vehicle with clamps or straps.

•

Truck cannot be lifted and towed in the forks first direction.

Lift and Tow from Under Skirt Here Figure 17631

Crown 2005 PF15167-7 Rev. 11/09

MA-6636-106 01 Rev. 11/09

9

SAFETY Control of Hazardous Energy Lifting and Blocking •

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

•

No load on forks.

•

Remove battery and lockout/tagout truck as described in Lockout - Tagout in this section.

•

Lift power unit end with jack and place hardwood blocks under skirt.

•

Lift forks with overhead lifting device, hardwood blocks, or jack stands. Set hydraulic jack to appropriate height, not to exceed 400 mm (16 in).

Blocking

•

Jack stands: lift power unit end to appropriate height and place jack stand under skirt. An additional 4 stands will be required: 2 under power unit at power unit/lift structure joint, 2 under battery compartment.

Hardwood blocks: place an additional hardwood block under center of battery compartment.

NOTES:

•

Hydraulic Jack Capacity: 3620 kg (8000 lb) • Crown Part Number: 122599 • Collapsed Height Minimum: 60 mm (2.25 in) • Raised Height Maximum: 400 mm (16 in)

•

Jack Stand Capacity: 4500 kg (10000 lb) • Commercially Available

•

Lifting Straps Capacity: 900 kg (2000 lb) • Commercially Available

Jack Stands Figure 17635

MA-6636-107 01 Rev. 11/09

10

Crown 2005 PF15167-8 Rev. 11/09

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

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

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

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

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

Figure 14990

Crown 1987 PF7886-1 Rev. 1/11

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

29

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

Lubrication Identification Chart Type of Lubricant

Part Number

A

Gear Lube 80W-90 (Typical)

363506-001 363506-012

1 Quart (12) 1 Quart Cans

AA

Automatic Transmission Fluid (Multi-Purpose)

363503-001 363503-012

1 Quart (12) 1 Quart

AAA

Universal Hydraulic & Transmission Fluid

363513-001 363513-012

1 Quart (12) 1 Quart

AAAA

Synthetic Gear Oil 75W-90

363514-001 363514-012

1 Quart (12) 1 Quart

Grease (Multi-Purpose)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

BB(1)

Grease (Low Temperature)

063002-017 063002-046

14.5 oz Cartridge (40) 14.5 oz Cartridges

BBB

Food Grade Grease (Multi-Purpose)

363002-001 363002-030

14 oz Cartridge (30) 14 oz Cartridges

BBBB

Grease (Multi-Purpose) Premium

063002-025 063002-026

14.5 oz Cartridge 5 Gallon

B

Package Quantity

C

Oil (SAE 40)

CC

Engine Oil (10W30)

363500-001 363500-012

1 Quart (12) 1 Quart

D

Hydraulic Oil

363504-101 363504-106

1 Gallon (6) 1 Gallon

DD(1)

Hydraulic Oil (Low Temp)

363505-101 363505-106

1 Gallon (6) 1 Gallon

DDD

Hydraulic Oil - DTE24

063001-021

1 Gallon

E

Channel Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

F

Gear Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

Chain & Cable Lube

363107-001 363107-012

15 oz Can (12) 15 oz Cans

Premium Chain & Cable Lube

363115-001 363115-012

12 oz Can (12) 12 oz Cans

Final Finish - Rubber & Vinyl Dressing

363129-001 363129-012

11 oz Can (12) 11 oz Cans

G

H

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

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

30

Crown 1987 PF7886-2 Rev. 1/11

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

Part Number

I

Grease (Lift Pump Coupling)

063002-039 127801S

1 lb 1 oz

J

Brake Fluid - Dot 5

063004-002 063004-003

12 oz 1 Gallon

K

Grease (Wheel Bearing)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

L

Metal Assembly Spray

063002-021

11 oz Spray

M

Silicone Grease (Clear)

063002-020

5.3 oz Tube

Brake & Parts Cleaner

363102-001 363102-012

14 oz Can (12) 14 oz Cans

Low VOC Brake & Parts Cleaner

363103-001 363103-012

14 oz Can (12) 14 oz Cans

Non-Flammable Brake & Parts Cleaner

363116-001 363116-012

19 oz Can (12) 19 oz Cans

O

Penetrating Lubricant

363104-001 363104-012

20 oz Can (12) 20 oz Cans

P

Premium Formula Multi-Purpose Grease

363108-001 363108-012

11 oz Can (12) 11 oz Cans

Q

White Lithium Grease

363110-001 363110-012

11 oz Can (12) 11 oz Cans

R

Choke & Carburetor Cleaner

363109-001 363109-012

15 oz Can (12) 16 oz Cans

Contact Cleaner - Non-Flammable

363106-001 363106-012

10 oz Can (12) 10 oz Cans

Contact Cleaner

363128-001 363128-012

11 oz Can (12) 11 oz Cans

T

Electrical Connector Oxidation & Corrosion Inhibitor

127189-001

30 cc

U

Battery Cleaner

363124-001 363124-012

18 oz Can (12) 18 oz Cans

V

Battery Protector

363125-001 363125-012

15 oz Can (12) 15 oz Cans

W

Food Grade Machine Lubricant

363127-001 363127-012

12 oz Can (12) 12 oz Cans

X

Food Grade Silicone Spray

363126-001 363126-012

11 oz Can (12) 11 oz Cans

Coolant

363509-101 363509-106

1 Gallon (6) 1 Gallon

Extended Life Coolant

363511-101 363511-106

1 Gallon (6) 1 Gallon

N

S

Y

Crown 1987 PF7886-3 Rev. 1/11

Package Quantity

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

31

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Alternate Lubricants & Fluids Chart Type of Lubricant

Product Name

Manufacturer/ Distributor

A

Gear Lube 80W-90 (Typical)

Crown

Crown

AA

Automatic Transmission Fluid (Multi-Purpose)

Crown

Crown

AAA Universal Hydraulic & Transmission Fluid Crown

Crown

AAAA Synthetic Gear Oil 75W-90

Crown

Crown Mobil Union 76 Co. Shell Burmah Castrol Exxon

B

Grease (Multi-Purpose)

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

BB

Grease (Low Temp) (2)

Lubriplate Alvania RA(1) Helveum O(1)

Fiske Bros Refining Co. Shell Burmah Castrol

BBB Food Grade Grease (Multi-Purpose)

Petro Canada Purity FG

Petro Canada

BBBB Grease (Multi-Purpose) Premium

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

Mobil Shell Chevron

C

Oil (SAE 40)

D

Hydraulic Oil

Crown

Crown

DD

Hydraulic Oil (Low Temp) (2)

Crown

Crown

Mobil DTE 24

Mobil

DDD Hydraulic Oil - DTE24 (3) E

Channel Grease

Factran #2

Standard Oil Co.

F

Gear, Channel & Shaft Grease

Molykote BR-2 Plus

Dow Corning

Chain & Cable Lube

Crown

Crown

Premium Chain & Cable Lube

Crown

Crown

H

Final Finish - Rubber & Vinyl Dressing

Crown

Crown

I

Grease (Lift Pump Coupling)

Nyogel 774F-MS

NYE Lubricants

J

Brake Fluid - Dot 5

Q2-1141 Silicon Brake Fluid

Dow Corning

Grease (Wheel Bearing)

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

Mobil Exxon Fiske Bros. Refining Co.

G

K

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

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

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

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

32

Crown 1987 PF7886-4 Rev. 1/11

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

Product Name

Manufacturer/ Distributor

L

Metal Assembly Spray

Dow Corning

Dow Corning

M

Silicon Grease (Clear)

Dow Corning 111 Compound

Dow Corning

Brake & Parts Cleaner

Crown

Crown

Low VOC Brake & Parts Cleaner

Crown

Crown

Non-Flammable Brake & Parts Cleaner

Crown

Crown

O

Penetrating Lubricant

Crown

Crown

P

Premium Formula Multi-Purpose Grease Crown

Crown

Q

White Lithium Grease

Crown

Crown

R

Choke & Carburetor Cleaner

Crown

Crown

S

Contact Cleaner

Crown

Crown

T

Electrical Connector Oxidation & Corrosion Inhibitor

Nye Grease

NYE Lubricants

U

Battery Cleaner

Crown

Crown

V

Battery Protector

Crown

Crown

W

Food Grade Machinery Lubricant

Crown

Crown

X

Food Grade Silicone Spray

Crown

Crown

Y

Extended Life Coolant

N

Crown 1987 PF7886-5 Rev. 1/11

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

33

Notes:

34

C

LUBRICATION AND ADJUSTMENT COMPONENT ACCESS The following is a list of covers, panels, etc. that must be removed to allow access when performing service and/or maintenance to components. Refer to the figures in this section as an aid in locating parts that require attention.

Control Module (Load Backrest) * Horn Switch (HNS2) * Fork Raise Switch (RAS2) * Fork Lower Switch (LOS2) * Freezer/Corrosion Resistors (RES4, RES5 & RES6)

NOTE Always disconnect battery before performing maintenance.

Handle Control Pod To gain access to:

Power Unit Doors To gain access to: * Traction Motor * Drive Unit * Brake drum assembly and linkage * Lift motor (M2) and pump (P & SV1) * Hydraulic Reservoir * Horn (HN1) * Travel Alarm (ALM2) * Diode Block (DB1) * Lift Limit Switch (LMS) * Display * TT1 & TT2 internal/external hour meter * Key Switch (KYS) * Transistor Controller (MRC1) * Line contactor (L) * Fuses (FU1 - Traction) (FU2 - Control) & (FU3 - Accessories) * Lift Cylinder * Lubrication points

Control Module in Load Backrest (Not Shown)

* Forward Travel Switch (FS) * Reverse Travel Switch (RS) * Fork Lower Switch (LOS1) * Fork Raise Switch (RAS1) * Horn Switch (HNS1) & (HSN3 - Freezer/Corrosion) * Acceleration Potentiometer (ACCEL) * Freezer/Corrosion Resistors (RES1 & RES2) Knuckle * Brake Switch (BRS) * Lubrication points Battery Compartment * Battery Restraint Switches (BRES1 & BRES2) Roller/Load Wheels, & Tension Bars * Lubrication Points

Standard Handle & Control Pod

Meter Console & Key Switch

Knuckle Rollers, Load Wheels &Tension Bars

Traction Motor & Drive Unit Battery Restraint Switches

051206

M1.0–6636–001

Lift Pump & Motor

Caster Wheels Figure 13145

12333 Crown 2005 PF15162-1

C

LUBRICATION AND ADJUSTMENT

LUBRICATION The following information is intended to provide guidelines for proper lubrication intervals as called out in the lubrication chart. Some operating conditions will require more frequent checks and lubrication than listed.

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 in M1.0-04.0-002 chart 1-1 are typical and any lubricant with equal specifications may be used.

All "DX" (with internal dimples), "DU" & "HTX" type bushings must have inside diameter coated with multipurpose grease (or low temperature multipurpose grease in freezer applications) prior to insertion of pivot shafts.

Crown trucks may require a mixture of low temperature hydraulic oil, Crown P/N 063001-006 (3.79 litre [gal.]), blended with standard hydraulic oil, Crown P/N 063001-021 (3.79 litre [gal.]) when used in a freezer or cooler. 100% low temperature oil is too thin for most cold storage operations and therefore could shorten the life of cylinder packings and pumps if used in higher ambient temperatures.

(063001-006) and 50% standard hydraulic oil (063001-021).

The proper mixture of freezer hydraulic oil will ensure the best and most efficient operation of your Crown equipment.

Keep truck clean and free from accumulation of grease, dirt, and other possible combustible materials.

After maintenance has been performed and before operating truck, be sure all covers are in place.

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. Some operating conditions will require more frequent checks and lubrication than listed. For example, trucks operating in high dust or moisture areas will require modification of the schedule to fit that particular application.

All screws, washers, nuts, roll pins, retaining rings, etc. need to be coated with a rust preventive (078882) to protect against corrosion. Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts.

For truck applications operating continually in temperatures at or above 0° C (32° F), use 100% standard hydraulic oil (063001-001).

For truck applications primarily operating at temperatures of 0° C (32° F) or below, use a 50/50 blend, 50% low temperature

NOTE Use appropriate Planned Maintenance Inspection Reports to record and assure maintenance checks.

Standard Hydraulic Oil (063001-001 [100%]) 50/50 Mix of Low - Temp 063001-006 [50%]) & Standard Hydraulic Oil (063001-021 [50%])

PPT Models Figure 6355-01

Crown 2005 PF15162-2

M1.0–6636–002

LUBRICATION AND ADJUSTMENT

C

Figure 13146

M1.0–6636–003

Crown 2005 PF15162-3

C

LUBRICATION AND ADJUSTMENT

CHART 1 Lubrication Chart 30 da.

60 da.

90 da.

100 hr.

250 hr.

500 hr. 1000 hr. 2000 hr.

Lube Type

Qty

Caster Wheels (4 points) Quick Adjustment Caster (12 points), Quick Adjustment Caster w/Torsion Bar (14 points)

F

AR

L

* L-2

Lower Linkage Pivot Pins (4points)

F

AR

L

* L-3

Power Unit Pivot (2 points)

F

AR

L

A

1.65 ltr.

(3.5 pt.)

(a)

Index Component * L-1

* L-4

Drive Unit Level

* L-4

Drive Unit Drain Plug

L-5

Drive Unit Rollers (4 points)

F

AR

L

* L-6

Brake Linkage

C

AR

(a)

L-7

Drive Unit Pivot (1 point)

F

AR

L

L-8

Handle Torsion Springs

BB

AR

L

L-9

Upper Lift Linkage (4 points)

F

AR

L

(a)

- Check

Chg. - Change

L - Lubricate

(a)

6 mo.

(a)

12 mo.

Chg.

AR - As Required

See Lube Type Chart for explanation. Lubrication intervals for Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts. * Freezer/Corrosion Trucks - use low temperature (BB) grease on load wheels and caster wheels. Use type F grease on all other lift linkage and caster pivot points.

Crown 2005 PF15162-4

M1.0–6636–004

LUBRICATION AND ADJUSTMENT

C

Figure 13147

M1.0–6636–005

Crown 2005 PF15162-5

C

LUBRICATION AND ADJUSTMENT

CHART 2 Lubrication Chart Lube Type

Index Component

Qty

30 da.

60 da.

90 da.

100 hr.

250 hr.

500 hr. 1000 hr. 2000 hr.

L-1

Door Hinges

F

AR

(a)

* L-2

Hydraulic Reservoir-Lift

D

2.85 ltr.

(3 qt.)

(a)

* L-3

ACCEL Cam & Torsion Spring

BB

AR

L

* L-4

Upper Fork Carriage Pivot (2 points)

F

AR

L

L-5

Lift Cylinder (2 points)

F

AR

L

* L-6

Riser Pivot Points (4 points)

F

AR

L

* L-7

Load Wheel Axles (4 points)

F

AR

L

* L-7

Tandem Load Wheel Pivot (4 points)

F

AR

L

* L-8

Pallet Entry Rollers

F

AR

L

* L-9

Tension Bars (230mm [9 in.] Fork - 6 points, 180 mm [7 in.] Fork - 4points)

F

AR

L

*L-10 Battery Rollers

B

AR

(a)

L-11 Drive Unit - Axle (2 points)

F

AR

L

(a)

- Check

Chg. - Change

L - Lubricate

(a)

6 mo.

(a)

12 mo.

Chg.

AR - As Required

See Lube Type Chart for explanation. Lubrication intervals for Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts. * Freezer/Corrosion Trucks - use low temperature (BB) grease on load wheels, caster wheels and battery rollers. Use type F grease on all other lift linkage and caster pivot points.

Crown 2005 PF15162-6

M1.0–6636–006

LUBRICATION AND ADJUSTMENT

C

Figure 13148

M1.0–6636–007

Crown 2005 PF15162-7

C

LUBRICATION AND ADJUSTMENT

CHART 3 Inspection and Adjustment Chart Index Component

30 da.

60 da.

90 da.

6 mo.

12 mo.

100 hr.

250 hr.

500 hr. 1000 hr. 2000 hr.

(b)

I-1

Electrical Connections

I-2

Motor Brushes - Lift

(b)

I-3

Motor Brushes - Traction

(b)

I-4

Drive Tire

(b)

I-5

Hydraulic Lines & Fittings

(b)

I-6

Drive Unit Roller Race & Rollers

(b)

I-7

Contactor Tips

I-8

Caster Wheels

(b)

I-9

Lower Lift Linkage

(b)

I-10

Horn Switch (HN1 & HN2)

(b)

I-11

Battery & Battery Connector

(b)

(b)

(b) = Inspect and/or Adjust Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

Crown 2005 PF15162-8

M1.0–6636–008

LUBRICATION AND ADJUSTMENT

C

Figure 13149

M1.0–6636–009

Crown 2005 PF15162-9

C

LUBRICATION AND ADJUSTMENT

CHART 4 Inspection and Adjustment Chart Index Component

30 da.

60 da.

90 da.

100 hr.

250 hr.

500 hr. 1000 hr. 2000 hr.

I-1

Electrical Connections

(b)

I-2

Lift Limit Switch (LMS)

(b)

I-3

Brake Operation & Switch (BRS)

(b)

I-4

Brake Linkage & Lining

(b)

I-5

Brake Split Bushing Key

(b)

I-6

Forward & Reverse Travel Switches (FS/RS)

(b)

I-7

Stall Alarm (ALM1)

(b)

I-8

Lift Cylinder

(b)

I-9

Tension Bars & Forks

(b)

I-10

Load Wheels & Rollers

(b)

I-11

Upper Lift Linkage

(b)

I-12

Battery Retainers, Switches & Battery Rollers

(b)

I-13

Caster Wheel Adjustment

(b)

6 mo.

12 mo.

(b) = Inspect and/or Adjust Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

Crown 2005 PF15162-10

M1.0–6636–010

COMPONENTRY

C

ACCEL POT1 Traction Accelerator Potentiometer Location: handle control pod.

Purpose: provide input to MRC1 for travel speed.

Data: 5K ohm.

Adjustment: refer to section M4.5.

Figure 10727-01

ALM1 Stall Alarm Location: R.H. side of power unit.

Purpose: alert operator that traction motor is stalled for 4 seconds or longer.

Data: controlled through MRC1.

Adjustment: none required.

ALM2 (Optional) Backup Alarm / Travel

Figure 13219

Location: meter console.

Purpose: alert pedestrians of truck movement request.

Data: reverse and/or forward switch.

Adjustment: none required.

BRES1 (Optional) Battery Retainer Switch Location: right side, battery compartment floor.

Figure 10729-01

Purpose: monitor presence of battery retainer and disable travel if battery retainer is not present.

Data: wired normally open, held closed when battery retainer is in place.

Adjustment: none required.

Figure 10731-01

051206

M1.0–6636–050

12481 Crown 2005 PF15177-1

C

COMPONENTRY

BRES2 Battery Retainer Switch Location: left side, battery compartment floor.

Purpose: monitor presence of battery retainer and disable travel if battery retainer is not present.

Data: wired normally open, held closed when battery retainer is in place.

Figure 10732-01

Adjustment: none required.

BRS Brake Switch Location: knuckle, right side.

Purpose: indicate position of control handle for braking.

Data: wired normally open, held open when control handle is in drive position.

Adjustment: see section M5.0.

Figure 10730P

CYLINDER Lift Location: power unit.

Purpose: raise forks.

Data:

not applicable.

Adjustment: see section M7.0.

Cylinder

DB1 ALM2

Figure 10804-01

Location: meter console.

Purpose: electrical noise suppression.

Data: not applicable.

Adjustment: none required.

Figure 10734-01

Crown 2005 PF15177-2

M1.0–6636–051

COMPONENTRY

C

DISP Dash Display Location: meter console.

Purpose: display battery charge, hours of truck operation and fault codes.

Data: not applicable.

Adjustment: none required.

Figure 10735-01

FIL (Filter) Location: R.H. side of power unit.

Purpose: suppress electrical noise generated by operation of the horn.

Data: not applicable.

Adjustment: none required.

Figure 10738-01

FS Forward Travel Switch Location: handle control pod.

Purpose: signals MRC1 for selection of forward travel.

Data: momentary contact wired normally open, actuated when operator moves twist grip to forward travel position.

Adjustment: none required.

FU1 Traction Motor Power Fuse

Figure 13220

Location: R.H. side of power unit.

Purpose: protect traction motor and associated wiring from overcurrent.

Data: ACK - 175.

Adjustment: none required.

Figure 10739-01

M1.0–6636–052

Crown 2005 PF15177-3

C

COMPONENTRY

FU2 Control Circuitry Fuse Location: R.H. side of power unit.

Purpose: protect control circuitry from overcurrent.

Data: ABC - 15.

Adjustment: none required.

Figure 10740-01

FU3 Accessories Location: R.H. side of power unit.

Purpose: protect optional accessories and associated wiring from overcurrent.

Data: ABC - 15.

Adjustment: none required.

Figure 10741-01

HN1 Horn Location: R.H. side of power unit.

Purpose: provide operator controlled audible warning.

Data: 24 to 48 operating voltage.

Adjustment: none required.

HNS1 Horn Switch

Figure 10742-01

Location: handle control pod.

Purpose: allow operator to sound horn.

Data: wired normally open. Button w/spring return, closes when operator depresses horn button.

Adjustment: none required.

Figure 10743P

Crown 2005 PF15177-4

M1.0–6636–053

COMPONENTRY

C

HNS2 Horn Switch Location: load backrest control pod.

Purpose: allow operator to sound horn.

Data: wired normally open. Button w/spring return, closes when operator depresses horn button.

Adjustment: none required.

Figure 13222

HNS3 Horn Switch Location: handle control pod.

Purpose: allow operator to sound horn.

Data: wired normally open. Button w/spring return, closes when operator depresses horn button.

Adjustment: none required.

HNS3 Figure 10745

HSS High Speed Switch Location: floorboard.

Purpose: initiates high speed operation.

Data: wired normally open.

Adjustment: none required.

KYS Key Switch

Figure 13223

Location: meter console.

Purpose: allows operator to power truck up and shut truck down.

Data: key operated selector switch.

Adjustment: none required.

Figure 10750-01

M1.0–6636–054

Crown 2005 PF15177-5

C

COMPONENTRY

L Line Contactor Location: R.H. side of power unit.

Purpose: provide power to M1.

Data: when no faults present in MRC1, battery negative is provided through MRC1.

Adjustment: refer to section M4.4.

Figure 10758-01

LMS Lift Limit Switch Location: L.H. side of power unit.

Purpose: cuts out lift when forks reach maximum lift.

Data: activated by fork linkage.

Adjustment: adjust so lift pump cuts out when cylinder is fully exteneded approximately 150 mm (6.0 in.).

LMS Figure 10752P

LOS1 Fork Lower Switch Location: handle control pod.

Purpose: lower forks when activated.

Data: wired normally open, activated when lower button is depressed.

Adjustment: none required.

LOS1 LOS2 Fork Lower Switch

Figure 10753P

Location: load backrest control pod.

Purpose: lower forks when activated.

Data: wired normally open, activated when lower button is depressed.

Adjustment: none required.

Figure 13224

Crown 2005 PF15177-6

M1.0–6636–055

C

COMPONENTRY M1 Traction Motor Location: in drive unit.

Purpose: provides driving force for traction.

Data: MRC1 provides speed control via operator input (ACCEL).

Adjustment: none required.

M1 Figure 10755P

M2 Pump Motor Location: L.H. side of power unit.

Purpose: provide driving force for hydraulic pump supplying hydraulic oil flow for lift and accessory functions.

Data: input of RAS switch to MRC1 controls pump solenoid supplying battery voltage.

Adjustment: none required.

MRC1 Traction SCR Control

M2 Figure 10756P

Location: R.H. side of power unit.

Purpose: controls traction motor speed via operator input from accelerator (ACC1).

Data: transistor control circuitry.

Adjustment: refer to section M4.2.

P Pump Solenoid

Figure 10757-01

Location: L.H. side of power unit.

Purpose: provide power to M2.

Data: controlled by MRC1 through inputs from raise switches.

Adjustment: none required.

P Figure 10759P

M1.0–6636–056

Crown 2005 PF15177-7

C

COMPONENTRY

PUMP Lift Location: L.H. side of power unit.

Purpose: provide hydraulic flow for lift and accessory operation.

Data: not applicable.

Adjustment: none required.

Pump Figure 10760-01

RAS1 Raise Switch Location: handle control pod.

Purpose: raises forks when activated.

Data: momentary contact wired normally open, activated when raise button is depressed.

Adjustment: none required.

RAS2 Raise Switch

RAS1 Figure 10766P

Location: load backrest control pod.

Purpose: raises forks when activated.

Data: momentary contact wired normally open, activated when raise button is depressed.

Adjustment: none required.

RES1 Freezer/Corrosion Heater Location: handle control pod.

Figure 13225

Purpose: applies heat to FS switch.

Data: 120 ohms, 10 watts.

Adjustment: none required.

Figure 13226

Crown 2005 PF15177-8

M1.0–6636–057

COMPONENTRY

C

RES2 Freezer/Corrosion Heater Location: handle control pod.

Purpose: applies heat to RS switch.

Data: 120 ohms, 10 watts.

Adjustment: none required.

Figure 13227

RES3 Freezer/Corrosion Heater Location: load backrest control pod.

Purpose: applies heat to LOS2 switch.

Data: 15 ohms, 5 watts.

Adjustment: none required.

RES4 Freezer/Corrosion Heater

Figure 13228

Location: load backrest control pod.

Purpose: applies heat to RAS2 switch.

Data: 15 ohms, 5 watts.

Adjustment: none required.

RES5 Freezer/Corrosion Heater Location: load backrest control pod.

Figure 13229

Purpose: applies heat to HNS2 switch.

Data: 15 ohms, 5 watts.

Adjustment: none required.

Figure 13230

M1.0–6636–058

Crown 2005 PF15177-9

C

COMPONENTRY

RS Reverse Switch Location: handle, control pod.

Purpose: signals MRC1 for selection of reverse travel.

Data: momentary contact wired normally open, actuated when operator moves twist grip to reverse travel position.

Adjustment: none required.

Figure 13221

SV1 Lower Solenoid Location: lift pump and motor assembly L.H. side.

Purpose: lower forks by providing path for hydraulic fluid to reservoir.

Data: 24 volt coil. Coil contains internal suppression diode and is polarity sensitive.

Adjustment: none required.

Figure 10795P

On/Off Toggle Switch Location: meter console.

Purpose: allows operator to power truck up and shut truck down.

Data: 2 position, maintained contact.

Adjustment: none required.

TT2 Internal Operating Time Hour Meter Location: meter console.

On/Off Toggle Switch Figure 10796-01

Purpose: record operating time of truck.

Data: not applicable.

Adjustment: none required.

Figure 10797-01

Crown 2005 PF15177-10

M1.0–6636–059

MAINTENANCE QUICK ADJUSTMENT CASTER ADJUSTMENT General Notes The brake and caster systems are adjusted at the factory to provide nominal brake and stability performance for level, smooth, dry, concrete floors and standard tire and load conditions. Upon installation, the trucks brake and stability performance should be checked to ensure acceptability. It may be necessary to modify the factory settings to properly accommodate the particular operating conditions. When a vehicle is operating over a variety of floor and load conditions, it may be impractical to adjust the brakes and casters to perform optimally for all of the different conditions.

Caster Adjustment To optimize and maintain the trucks brake and stability performance, the caster should be adjusted periodically to account for tire wear and also when tire replacement is necessary. Adjusting the casters up or down will affect the operating characteristics of the truck as shown in chart below.

WARNING • Increasing caster loading reduces load on the drive tire and therefore reduces braking effectiveness and traction.

• Reducing caster loading reduces stability.

Drive tire wear or replacement as well as floor conditions will effect operating characteristics of the truck, mainly: • Braking/Traction • Stability/Handling • Steer Effort Floor conditions in set up area should be consistant generally with floor conditions in the overall facility. Periodic caster adjustments may be required to maintain proper balance of these characteristics and proper operation.

To adjust casters: 1. Rotate caster to a power unit first travel direction (as shown).

2. Raise forks completely.

3. Disconnect battery and block drive tire and forks.

4. Refer to illustrations and loosen the adjustment screw lock nut.

2375 931206

4733 - 41486

Crown 1993 PF-9970-1 Rev. 8/95

M1.5 - 6435 - 001

ILLUSTRATION 1.5-1

Printed in U.S.A.

02 REV. 8/95

M1.5 - 6435 - 001

MAINTENANCE Trucks Equipped With Rubber Drive Tires

Trucks Equipped With Poly Drive Tires

3928

ILLUSTRATION 1.5-2

5. Using a 1/2 in. hex key, rotate adjusting screw counterclockwise (viewed from fork end of truck) for drive tire wear and clockwise for caster wheel wear.

• Counter-clockwise rotation of adjusting screw moves caster up (toward power unit).

• Clockwise rotation of adjusting screw moves caster down (toward floor).

Refer to Illustration 1.5-2 and set gages as shown for either rubber or poly drive tire.

NOTE With new drive tire and new caster wheels the overall lengths of the compression springs are set from the factory to measure 3 in. (75 mm).

6. Tighten jam nut.

7. Connect battery, remove blocks and check adjustment.

Crown 1993 PF-9970-2 Rev. 8/95

M1.5 - 6435 - 002

Printed in U.S.A.

02 REV. 8/95

M1.5 - 6435 - 002

MAINTENANCE TORQUE REQUIREMENTS The nut used to secure the tapered roller bearing and the thrust bearing is to be torqued to 125 ft. lbs. (170 Nm). Rotate the yoke a minimum of three turns in each direction while torquing. Then loosen the nut until free. The bearing setting as adjusted must not be disturbed. Retighten the nut to 25 ft. lbs. (35 Nm) of torque. Further tighten the nut until one of the slots in the nut and the hole in the end of the spindle are aligned.

2377

ILLUSTRATION 1.5-3

The locknut on the adjusting screw is to be torqued to 60 65 ft.lbs. (82 to 88 Nm).

3929

ILLUSTRATION 1.5-4

Crown 1993 PF-9970-3 Rev. 8/95

M1.5 - 6435 - 003

Printed in U.S.A.

02 REV. 8/95

M1.5 - 6435 - 003

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 System

Hydraulic System The hydraulic system is supplied its power by a gear type pump which provides the pressure for lift to the 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 strainer is in the suction line to filter the hydraulic oil before it goes into the pump. The pump, lower solenoid, relief valve and flow control are all a part of an integral hydraulic unit.

5. Disassembly - To remove the cylinder cap, turn counterclockwise utilizing a spanner wrench with 3/16 inch pins and unscrew it from the cylinder tube. See Figure 16889. Replace packings and seals, clean and lubricate inside ram assembly and reassemble.

6. Assembly - After packings, seals, bushings, etc. are in place, install the cap. See Figure 16889. Apply thread locking adhesive (061004-005) to threads of cap. Screw the cap clockwise until the cap is tight with the top of the cylinder tube.

CAUTION

Hydraulic schematic of standard pallet truck model is shown in Figure 6357-01.

Care should be taken when inserting the cylinder cap, to prevent threads and sharp edges from damaging new seals and packings.

Hydraulic System - General

Hydraulic Seals

1. To check hydraulic fluid level, remove the breather cap from the reservoir and insert a clean dowel.

With the lift fully lowered and on a level floor, it should be no lower than one half inch from the breather hole. Approximate capacity of the hydraulic system is three quarts. Use only a good grade hydraulic oil (063001-001) or equal.

The seals used in the cylinders are made from an extremely tough, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

NOTE Do not use hydraulic brake fluid.

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

3. 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.

4. Great care and cleanliness should be exercised in the disassembly and assembly of any hydraulic cylinder. Wipe all surfaces clean of dirt and oil before attempting disassembly. Care should be taken when removing the ram as nicks will damage the packings. Whenever new packings are required, new wiper rings should also be installed.

Crown 1989 PF8295-1 Rev. 7/07

M2.0-06.4-001 03 Rev. 7/07

HYDRAULIC Hydraulic System

6357-01

General Installation Tools used to install hydraulic seals should be of soft metal or suitable plastic, free of burrs and sharp edges.

Screwdrivers and other similar tools should not be used as they may damage the sealing edges.

The area in contact with the seal should be free of burrs, sharp edges and nicks. If necessary to force seal over sharp edges, slots or undercuts, protective devices should be used. 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.

(1)

Ram

(2)

Cap

(3)

Spanner Wrench

(4)

Cylinder

Figure 16889

M2.0-06.4-002 03 Rev. 7/07

Crown 1989 PF8295-2 Rev. 7/07

HYDRAULIC Hydraulic System Rod U-Cup Installation 1. Installation Tool An installation tool made of any soft metal or hard plastic machined smooth and free of burrs with a fixed steel pin (PIN 1) and two movable pins (PINS 2 & 3) is required for this installation method.

– Withdraw pin 3 so that U-cup loop snaps into installation groove see Figure 16892.

(1)

Pin 3

(2)

Tool Body

(3)

Pin 1

(1)

Pin 3

Pin 2

(2)

Pin 1

(3)

Pin 2

(4)

Figure 16892

– Withdraw pin 2 and U-cup will completely snap into installation groove see Figure 16893.

–

Withdraw installation tool.

Figure 16890

2. Installation Procedure – Slip U-cup over the fixed pin see Figure 16890, pin 1 and bend it over pin 2 as shown.

(1)

Pin 2

(2)

Pin 3

(3)

Pin 1

– Continue bending U-cup until pin 3 can be pushed through the U-cup loop which locks U-cup in position.

– Insert installation tool with mounted U-cup into cylinder bore until aligned with U-cup installation groove. See Figure 16891.

Figure 16893

(1)

Pin 3

(2)

Pin 1

(3)

Pin 2

Figure 16891

Crown 1989 PF8295-3 Rev. 7/07

M2.0-06.4-003 03 Rev. 7/07

HYDRAULIC Hydraulic System Hydraulics Troubleshooting Chart Hydraulics Troubleshooting Chart Symptom

Probable Cause

Remedy

Noisy Pump

• Low oil supply • Oil too heavy (i.e. viscous) • Air leak on inlet line • Partially blocked inlet line

Check reservoir.

Check for proper oil viscosity.

Check plumbing.

Check for foreign object and/or clean.

Foaming hydraulic oil

• Pump cavitation • Water in oil

Check reservoir.

Check for proper oil viscosity.

Check plumbing.

Clean and fill reservoir.

Pump or oil overheating

• Oil supply too thin Drain and fill with proper oil.

• Contaminated oil Drain, clean and fill with clean oil.

• Pump cavitation Check reservoir. See Foaming oil.

• Pump drive shaft excessively Inspect for proper alignment. iimisaligned with pump driven shaft • Pump drive shaft axially loaded Check for clearance at shaft ends, iiby driving shaft (Prime Mover) misalignment or worn keys or splines.

• System relief valve bypassing Check relief valve.

Low flow

• Pump cavitation Check reservoir. See Foaming oil.

• Foaming hydraulic oil Check for proper oil viscosity.

• Relief valve leaking or set too low Check relief valve.

• Speed too low Check prime mover speed.

• Oil too hot Check temp. See Oil overheating.

Failure to build pressure

• Defective relief valve • Low oil supply

M2.0-06.4-004 03 Rev. 7/07

Check relief valve.

Fill reservoir.

Crown 1989 PF8295-4 Rev. 7/07

HYDRAULIC Hydraulic System Freezer Preparation

(32 degrees Fahrenheit), use 100% standard hydraulic oil.

Crown trucks may require a mixture of low temperature hydraulic oil, Crown P/N 063001-006 (gal), blended with standard hydraulic oil, Crown P/N 063001-021 (gal) when used in a freezer or cooler. 100% low temperature oil is too thin for most cold storage operations and therefore could shorten the life of cylinder packings and pumps if used in higher ambient temperatures.

NOTE Trucks equipped with velocity fuses may experience staging issues if an insufficient mix of low temperature oil has been used.

For Powered Pallet Truck applications operating continually in temperatures at or above 0 degrees Celcius

For truck applications operating primarily at temperatures of 0 degrees Celcius (32 degrees Fahrenheit) or below, use a 50/50 blend, 50% low temperature (063001-006) and 50% standard hydraulic oil (063001-021).

Power Steering equipped PR Units operating primarily at temperatures of 0 degrees Celcius (32 degrees Fahrenheit) or below, use a 50/50 blend, 50% low temperature (063001-006) and 50% standard hydraulic oil (063001-021).

The proper mixture of freezer hydraulic oil will ensure the best and most efficient operation of your Crown equipment.

PPT Models (1)

50/50 Mix of Low-Temp (063001-006 [50%]) & Standard Hydraulic Oil (063001-021 [50%])

(2)

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

Figure 16894

Crown 1989 PF8295-5 Rev. 7/07

M2.0-06.4-005 03 Rev. 7/07

HYDRAULIC Hydraulic Schematic Symbols

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

VENTED RESERVOIR with the lines below the fluid level

FILTER or STRAINER

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

PILOT or DRAIN LINE limited flow

LINES CROSSING

M

ELECTRIC MOTOR operates in one direction and speed

M

ELECTRIC MOTOR operates in one direction in a speed that changes

M

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

HYDRAULIC PUMP fixed displacement, operates in one direction

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

HYDRAULIC MOTOR operates in two opposite directions

LINES CONNECTED GAUGE pressure QUICK DISCONNECT (disconnected)

PLUGGED PORT (test port)

FLOW METER

GAUGE temperature

ACCUMULATOR gas charged, diaphragm type

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

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

169

HYDRAULIC Hydraulic Schematic Symbols

PRESSURE SWITCH

CYLINDER double-acting cylinder, unequal area

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

ACTUATOR MANUAL

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

SOLENOID one coil or winding

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

CYLINDER single-acting cylinder, with cushion SOLENOID DUAL

COMPONENT ENCLOSURE manifold block

ACTUATOR MANUAL LEVER

SOLENOID PROPORTIONAL

VALVE PILOT CHECK (pilot to open)

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

170

Crown 1979 PF5066-2 Rev. 6/12

HYDRAULIC Hydraulic Schematic Symbols

ORIFICE THROTTLE fixed

VALVE SHUTTLE

ORIFICE THROTTLE adjustable VALVE SINGLE COUNTERBALANCE in manifold

FLOW CONTROL PRESSURE COMPENSATED fixed

FLOW CONTROL PRESSURE COMPENSATED fixed with reverse flow bypass

FLOW DIVIDER/COMBINER

FUSE VELOCITY BYPASS FLOW CONTROL controlled flow, pressure adjusted

VALVE RELIEF fixed

VALVE RELIEF adjustable

VALVE CHECK

VALVE MANUAL SHUTOFF

P T

T P

TORQUE GENERATOR

L R

STEER UNIT hydrostatic

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

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

171

HYDRAULIC Hydraulic Schematic Symbols

VALVE two-way valve with two positions

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

VALVE three-way valve with two positions

VALVE four-way valve with two positions

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

VALVE four-way valve with three positions

VALVE two-way valve with all positions

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

VALVE four-way valve with all positions

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

172

Crown 1979 PF5066-4 Rev. 6/12

C

DRIVE UNIT

Fill Plug Oil Level Check Drain Plug

Drain Plug Figure 3393

Your Crown lift truck has a drive unit centrally located in the power unit. The drive unit is a double reduction gearbox providing strength and efficient operation. The unit is totally enclosed and oil filled to provide maximum lubrication to both bearings and gears.

The drive unit has a capacity of approximately 1000 ml (3.25 pints) of 90W gear lube, 063002-003. Remove filler plug located in the side cover, refer to Figure 3393. Add gear oil until present at oil level check plug hole in the lower housing, just above the idler shaft. Remove both drain plugs to completely drain drive unit.

See Torque Value Chart at the end of this section.

Drive Tire Replacement When replacing the drive tire, make sure the composition and size are such that maneuverability and capacity are maintained. The drive tire is a press-on type. To replace, press old tire off and new tire on. The following procedure should be followed to remove the drive tire assembly from the drive unit. Elevate power unit and block securely. Remove the roll pin locking the castle nut to the end of the axle.

Use a 1 1/2 in. wrench and remove the castle nut from axle.

Pull axle from drive unit while stabilizing the drive tire. Refer to Figure 3393.

Be sure the battery is disconnected before performing any maintenance operations.

Drive Motor Removal NOTE Removal of motor for replacement of brushes is not necessary.

Turn the drive unit to the right or left as far as possible. Open power unit doors and disconnect battery. For trucks not equipped with an electric brake assembly, remove the three screws securing the brake drum to the split bushing. Release the brake and remove the drum. Remove the retaining ring, split bushing and woodruff key from the drive motor shaft. For trucks built October 1, 1986 and after (equipped with an electric brake assembly) refer to section M5.0 Brake Maintenance for brake removal guidelines. Disconnect all electrical connections from terminals on drive motor. Label electrical cables if necessary to eliminate problems when replacing motor. Remove the two motor mounting screws located above and slightly off to the side of the motor shaft, refer to Figure 3393. Turn the drive unit to the left as far as possible. Support the drive motor and remove the two screws from the bottom of motor. Pull motor straight out of casting to prevent damage to motor shaft seal.

12592

M3.0–07.2–015 07 Rev. 12/05

Crown 1985 PF7188-1 Rev. 12/05

C

DRIVE UNIT

Drive Unit Removal NOTE In most cases repair to the drive unit can be made with the drive unit in the power unit. However, should it be necessary to remove the complete drive unit from truck, the following procedure should be followed.

Elevate and block the power unit; the drive tire must be off floor.

Remove steering mechanism, control handle, etc. from top of drive unit.

SP ONLY. Disconnect brake line at base of mainframe.

Drain brake fluid into container. Unclamp and unthread brake line from power unit. Trucks built October 1, 1986 and after (equipped with an electric brake assembly) hydraulic brake lines do not exist.

Disconnect motor cables from contactor panel; disconnect brake switch leads.

Figure 0357S-02

Attach a hoist to support plate at top of drive unit, near the thrust plate. Use caution not to damage brake linkage, if so equipped in the process.

Loosen and remove the (3) screws connecting the thrust plate to the power unit and carefully raise the drive unit until it is clear of the power unit.

Remove the drive wheel axle (item 9, Figure 0357S-02).

Remove the roll pin (item 10) locking the castle nut (item 13) to the end of the axle. Use a 1 1 /2 in. wrench and remove castle nut from axle. Pull axle from drive unit housing while stabilizing the drive tire.

NOTE

Unfasten the four screws (item 32 & 29) and remove the cover (item 33) and the gasket (item 34).

The drive unit should be taken to a clean work area if further disassembly is necessary. Make sure the vented fill plug is to the top side of unit if it is necessary to lay the drive unit down for transporting, etc.

Remove the retaining ring (item 27), access it through the slots in the face of the second reduction gear (item 28). Large retaining ring pliers with a locking ratchet such as a Waldes Truarc No. S-6700, Crown no. 092668, should be used (see Figure 3394).

Drive Unit Disassembly The following disassembly and assembly procedure is a complete tear down and rebuild operation. Once the problem has been diagnosed the repair procedure can be used that covers the necessary repair.

LOWER HOUSING Drain gear oil.

In order to separate the drive unit top from the drive unit bottom remove the six screws (item 17, Figure 0060S-01) securing the two drive unit sections together.

Crown 1985 PF7188-2 Rev. 12/05

Figure 3394

M3.0–07.2–016 07 Rev. 12/05

C

DRIVE UNIT Pull the gear (item 28) and the bearing (item 26) assembly from the housing. If the bearing needs replacement, remove the retaining ring (item 7) and press off the bearing.

Remove the inside oil seal (item 24).

Remove the alignment dowel pin (item 3) located directly above the idler shaft (item 18) and then remove the idler shaft.

Pick out the loose spacers (item 23) and the gear assembly (item 20, 21 & 22) from the top cavity in the lower housing.

Move to the other side of the housing and remove the bearing (item 6) and the bearing adapter (item 5) after unseating and removing the retaining ring (item 8). If this bearing needs replacement, remove the retaining ring (item 7) and press off the bearing.

Remove the roller assemblies (items 11 & 15) by removing the set screw (item 14) located in the housing and removing shaft (16 & 38).

UPPER HOUSING Refer to Figure 0060S-01. Remove the support assembly (item 1). Remove the spacers (item 2). Note the number and position for reference at assembly. Lift off the thrust plate (item 3) which contains a felt seal (item 5) and a bearing cup (item 6).

Remove bearing cone (item 8) and felt seal (item 7) from top of upper housing (item 16).

After the motor (item 11) has been removed, the oil seal (item 32) can be removed from either side of its bore.

Remove cover (item 26) and gasket (item 25) from the side of the housing.

Remove cotter pin (item 24) and unscrew the castle nut (item 23) about half way off the end of the pinion shaft (item 15).

While supporting gear (item 20), gently tap on the end of pinion shaft via the castle nut. This will unseat the gear and bearings (items 14 & 19), as well as push out the expansion plug (item 13).

Once the bearings are free, slide the pinion shaft to the left until the gear (item 20) is clear and can be removed along with the two keys (item 21).

Continue to slide the pinion shaft and catch the bearing’s (item 19) right inner race [cone] along with the inner race spacer.

When the pinion is moved far enough, remove the left inner cone and then completely remove the pinion shaft.

Remove the bearing outer races and the bearing retaining ring from housing.

NOTE The #10-24 tapped hole located directly below the retaining ring slot is to be used to help unseat the retaining ring. Use a #10-24 x 1 in. screw (060014-010).

Figure 0060S-01

M3.0–07.2–017 07 Rev. 12/05

After inspecting the housings and before reassembly, thoroughly clean in solvent and blow dry.

Crown 1985 PF7188-3 Rev. 12/05

C

DRIVE UNIT

Bearing (Item 14)

Pinion (Item 15)

Right Outer Gear Left Outer Race (Cup) (Item 20) Race (Cup) Retaining Left Inner Right Inner Washer Ring Race (Cone) Race (Cone) (Item 22) Spacer

Cover (Item 26)

Expansion Plug (Item 13)

Cotter Pin (Item 24)

Left Bore

Spacer Retaining Ring Unseating Hole

Gasket (Item 25) Middle Bore

Key (Item 21)

Castle Nut (Item 23) Figure 3395

Drive Unit Assembly NOTE If the upper or lower housings were replaced, before proceeding with assembly, check the housings for burrs or casting slag. Also, the area where the lower part of the motor mounting plate rests in the upper drive unit housing should be checked, and ground if necessary, to assure a proper fit.

After inspection and grinding, thoroughly clean the housings in solvent and blow dry.

UPPER HOUSING With the upper housing (item 16) in the same relative position as the housing in Figure 0060S-01, install the lower grommet (item 9) into the neck of the housing.

Preassemble the key (item 31) and the gear (item 30) onto the motor (item 11). After the components are in position, insert the retaining ring (item 29) into its groove on the end of the motor shaft.

Grease the motor shaft and its bore and install the oil seal (item 32). Refer to Drive Motor Shaft Seal Replacement.

With the use of an arbor press, force the left outer cup of the bearing (item 19) into the middle pinion bore (See Figure 0060S-01). This bearing includes two inner bearing cones, two outer bearing cups, a spacer and a retaining ring spacer.

After the left outer race has been pressed slightly past the groove, install the retaining ring spacer.

Slide the pinion shaft (item 15) through the left bore. Install the left inner race and spacer onto the right side of the pinion shaft prior to the shaft entering the middle bore.

Move the shaft through the middle bore to a position where the right inner race, right outer race and the gear (item 20) can be installed.

Once installed, force the pinion completely in and insert the two keys (item 21) into the gear.

Apply a light film of multi-purpose grease (063002-025) to the face of the motor and place the gasket (item 10) onto the greased mounting face. Insert the complete motor assembly into the housing and secure the fasteners.

Slide the bearing (item 14) and the expansion plug (item 13) in place on the left bore before installing the washer (item 22) and the castle nut (item 23) on the opposite end of the pinion shaft (item 15).

NOTE

Tighten the castle nut (item 23) to 203 - 271 Nm (150 to 200 ft/lbs), then insert the cotter pin (item 24). Bolt the cover (item 26) and the gasket (item 25) to the right side of the upper housing and insert the filler plug (item 28) into the cover.

Two bolts fasten from the inside of the housing and two bolts fasten from the outside. When tightening these bolts, follow a diagonal tightening procedure to insure proper motor seating.

Crown 1985 PF7188-4 Rev. 12/05

M3.0–07.2–018 07 Rev. 12/05

C

DRIVE UNIT Attach the brake assembly to the side of the upper drive unit housing. For trucks not equipped with an electric brake assembly, torque the two screws securing the brake assembly to the drive unit to 17.5 - 23 Nm (13 - 17 ft/lbs). For trucks built October 1, 1986 and after (equipped with an electric brake assembly) refer to section M5.0 Brake Maintenance for brake installation guidelines.

Apply a thin film of multi-purpose grease to the upper bearing neck on the housing and install the inner race (item 8). Once in position, thoroughly grease the rollers and roller cage of the bearing.

Spacer

Figure 3396 Figure 0357S-02

Insert the felt seal (item 7) into the groove which encircles the inner race. The felt seal ends must meet squarely to assure a good seal. The felt can be stretched or compressed to accomplish this.

Insert the retaining ring (item 27) into its mounting slot in the bore by means of snap ring pliers (see Figure 3394) inserted through the slots in the gear face.

Press the outer race (item 6) into the thrust plate (item 3) and install the grease zerk into the side of the plate.

Preassemble the gear (item 21) with its bearing (item 22) and the retaining rings (item 20).

Assemble the thrust plate assembly on top of the upper bearing neck and install the felt seal (item 5) in between the bearing neck and the thrust plate bore.

Place the gear assembly between the two spacers (item 23) and place them into their relative mounting position in the housing.

Install spacers (item 2) to fill the gap between the top of the thrust plate and the bottom of the support assembly. Refer to Figure 0060S-01.

When the gear assembly is properly positioned, insert the idler shaft (item 18) which has been preassembled with Orings (item 17 & 19). Lock the shaft in place with one of the dowel pins (item 3).

Bolt support assembly (item 1) to the upper drive unit housing.

LOWER HOUSING Position the lower housing (item 25) in the same manner as the housing is shown in Figure 0357S-02.

Lay the retaining ring (item 27) around the inside gear neck and then press the bearing (item 26) onto the neck to a position where the retaining ring (item 7) can be installed.

After greasing the outside diameter of the bearing (item 26), press the entire gear assembly into the housing.

M3.0–07.2–019 07 Rev. 12/05

Left Side

Right Side Figure 3397 Crown 1985 PF7188-5 Rev. 12/05

C Apply a film of grease to the mounting surface of the cover (item 33) and place the gasket (item 34) onto the greased cover surface. Also grease the neck of the gear (item 28) in the area where the oil seal will ride. Install the cover onto the housing and insert and tighten its fasteners evenly.

Insert bearing adaptor (item 5) into the bearing (item 6). Coat the lower right side drive axle bore with grease, press bearing assembly in position and install retaining ring (item 8).

Install oil seals. Refer to Seal Replacement in this section.

Place slinger (item 36) in position over inner axle seal.

Position the wheel assembly in the housing. Install outer slinger (item 36) onto the axle and slide the axle (item 9) through the left side bore. Align the axle splines and fully seat the axle.

Before installing axle, coat axle with anti-seize compound (065005-003). Ensure that the washers (item 40) are installed opposing each other. Torque the axle nut (item 13) to 68 Nm (50 ft/lbs). Loosen, then retorque to 108 Nm (80 ft/lbs).

FINAL ASSEMBLY After the upper and lower drive unit halves have been completely assembled, insert the dowel pins (items 37 [Qty. 2] & item 3 [Qty. 1]) into the lower housing.

Apply a coat of gasket sealer (065005-002) to the mounting surface, at the point where the housings join.

DRIVE UNIT SEAL REPLACEMENT AXLE INNER SEAL Drain gear lube from drive unit. Remove drive tire assembly per instructions located in the beginning of this section .

Remove the old seal. Be sure not to nick or scratch the sealing surfaces of housing or gear hub. Thoroughly REMOVE the old gasket sealing material from the bore.

Apply a thin coat of gasket sealer, 065005-001, to the housing bore. The seal lip should be lubricated with the fluid being retained or compatible grease.

NOTE Care must be taken not to get any gasket sealer on either the seal lip or the seal surface of the gear hub.

Position the new seal in proper alignment and gently tap with plastic mallet to start the seal into the housing bore not in excess of 1.5 mm (.06 in.).

Carefully press the new seal into position. The seal’s outer shell should not be more than 0.8 mm (.030 in.) beyond the end of the gear hub. For more information refer to Technical Service Bulletin No. 152 and 091009 tool assembly.

Replace drive tire and axle. Fill unit with proper amount and type of gear lube.

OUTER AXLE SEAL

Set the gasket (item 2) and the shims (item 1) on the mounting surface of the lower housing and then couple the two halves together. If the housings do not seat completely, rotate the drive wheel. This will help mate the gears.

Refer to steps 1 thru 4 of Axle Inner Seal replacement procedure.

Insert the six fasteners (item 17) and tighten the bolts to a torque reading of between 34 - 40 Nm (25 - 30 ft/lbs).

Carefully press the new seal into position. The seals outer shell should not be more than 2.8 mm (.110 in.) beyond the end of the gear hub. For more information refer to Technical Service Bulletin No. 152.

Insert and tighten drain plugs (item 4) and fill with gear lube.

Test the drive unit motor assembly for tight bearings by rotating the motor shaft with a torque wrench. The rotating torque should be 0.9 - 1.8 Nm (8 to 16 in/lb).

Replace drive tire and axle. Fill unit with proper amount and type of gear lube.

Reinstall the drive unit into the power unit by reversing the six steps described in Drive Unit Removal in the front of this section. The three bolts (item 4) which fasten the thrust plate (item 3) to the power unit bracket are to be tightened to a torque reading of 108 - 122 Nm (80 - 90 ft/lbs).

Crown 1985 PF7188-6 Rev. 12/05

M3.0–07.2–020 07 Rev. 12/05

C

DRIVE UNIT DRIVE MOTOR SHAFT SEAL

THRUST ROLLER REPLACEMENT

Remove brake drum, split bushing and woodruff key from drive motor shaft.

Remove set screw and remove roller shaft. Remove roller, flatwasher(s) and felt seal from lower drive housing. The roller bearings are part of the roller assembly. Do not attempt to remove bearings from the roller bore. The flatwasher and felt seal can be reused. Refer to illustration for proper position and/or location of Thrust Roller parts.

Carefully remove old seal from drive unit housing. Do not nick or scratch the sealing surfaces of the housing or motor shaft.

Thoroughly remove the old gasket sealing material from the housing bore. Inspect the motor shaft sealing surface area.

Should a groove, nick or any slight imperfection be present the new seal can be pressed slightly beyond the original position in the housing bore. An additional depth of up to 3.2 mm (.125 in.) is allowable, any seal installation with a greater depth may not provide adequate seal surface.

Apply a thin coat of gasket sealer. 065005-001, to the housing bore. The seal lip should be lubricated with the fluid being retained.

NOTE Drive units with steel thrust roller throughout cannot use poly core thrust roller.

The thrust rollers must be lubricated and maintained properly to achieve proper truck operation and obtain satisfactory service life from component parts. All thrust rollers must turn freely and smoothly during normal truck operation.

NOTE Care must be taken not to get any gasket sealer on either the seal lip or the sealing surface of the motor shaft.

Protect the seal lip from sharp edges or burrs on motor shaft.

Position seal installation sleeve on motor shaft. Use 094614 sleeve when installing 073433 seal & 094615 sleeve when installing 087795 seal. Align the seal properly and gently press into housing. Remove seal installation sleeve from motor shaft. Install woodruff key, split bushing and brake drum on drive motor shaft. For trucks not equipped with an electric brake assembly, torque the three screws that attach the brake drum and tapered bushing to the motor shaft to 11 - 13.5 Nm (8 - 10 ft/lbs). For trucks built October 1, 1986 and after (equipped with an electric brake assembly) refer to section M5.0 Brake Maintenance for brake installation guidelines.

M3.0–07.2–021 07 Rev. 12/05

Crown 1985 PF7188-7 Rev. 12/05

C

DRIVE UNIT Torque Value Chart Upper to Lower Housing Assembly Torque Values: 34 - 40 Nm (25 - 30 ft/lbs) Item 17 Brake Attachment to Drive Unit Torque Values: 17.5 - 23 Nm (13 - 17 ft/lbs) Assembling Brake Drum to Drive Motor Shaft Torque Values: 11 - 13.5 Nm (8 - 10 ft/lbs) Motor Shaft Rotating Torque Values: 0.9 - 1.8 Nm (8-16 in/lbs) Thrust Plate to Power Unit Bracket Torque Values: 108 - 122 Nm (80 - 90 ft/lbs) Item 4

Figure 0060S-01

Castle Nut on Pinion Shaft in Upper Housing Torque Values: 203 - 271 Nm (150 - 200 ft/lbs) Item 23 Castle Axle Nut Torque Values: 68 Nm (50 ft/lbs) Then Retorque to 108 Nm (80 ft/lbs) Item 13

Figure 0357S-02

Crown 1985 PF7188-8 Rev. 12/05

M3.0–07.2–022 07 Rev. 12/05

ELECTRICAL SYSTEM Electrical System

Electrical System

Wire color-codes

Wire color-codes and schematic symbols

See the Wire Color-Codes table for the applicable wire colors. The function of the circuit determines the wire color. Each wire has a three or four digit number. The first one or two digits identify the color of the lead. The last two digits identify the lead from one through 99. It is possible that some vendor component leads do not have these same numbers or colors. A wire pictorial identifies each wire by number. See the WIRING DIAGRAMS chapter for wire pictorials and electrical diagrams.

This section includes information on wire color-codes and schematic symbols that are standard on Crown electrical diagrams.

Wire Color-Codes Number

Color

Function

0xx

Black

Digital Signal (1)

1xx

Brown

Analog Signal (1)

2xx

Red

Primary positive that has not gone through a switch (2)

3xx

Orange

12 V Non-Battery Positive (3)

4xx

Yellow

Non-Battery Positive (3)

5xx

Green

Primary negative that has not gone through a switch (2)

6xx

Blue

Isolated Negative (4)

7xx

Violet

5 V Non-Battery Positive (3)

8xx

Gray

Non-Battery Positive (3)

9xx

White

Miscellaneous

29xx

Red/White

Primary positive that has gone through a switch (2)

59xx

Green/White Primary negative that has gone through a switch (2)

(1) Signal - A conductor that gives a variable input or output potential.

(2) Primary- A conductor that gives battery positive potential or battery negative potential.

(3) Non-Battery Positive - A conductor that gives a non-battery positive potential from the output of a regulated DC-to-DC converter.

(4) Isolated Negative - A conductor that gives a negative potential that is electrically isolated from battery negative.

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179

ELECTRICAL SYSTEM Electrical System Power cables To identify the power cables, see the Power Cables Abbreviations table for all lift trucks except the WP 3000 Series. For example: PC #1/0-10 is P/N 084572-010.

Fig. 3 (8117-01)

Power Cables Abbreviations Abbreviation

Part Numbers

PC#1

084571

Fig. 4 (8118-01)

PC#2

084570

Number of terminals

PC#4

084569

PC#6

084568

PC#8

124474

PC#10

090963

PC#1/0

084572

PC#2/0

084573

PC#3/0

086749

PC#4/0

137636

•

All terminals are shown even if not connected.

Momentary contact switch or maintained contact switch •

See Figures 5 and 6 for switches with a momentary contact. A momentary contact is shown as a shaded triangle.

Fig. 5 (8119-01)

Switches The switch symbols show: •

The switch type

Fig. 6 (8120-01)

•

The number of terminals

•

•

If the switch is a momentary contact switch or maintained contact switch

•

How the switch is connected

•

How the switch operates

•

How the switch functions

Switch type •

See Figures 7 and 8 for switches with a maintained contact. A maintained contact is shown as an open circle (an open circle also shows the common terminal).

Fig. 7 (8115-01)

See Figures 1 and 2 for switches with a common terminal.

Fig. 8 (8117-01)

Fig. 1 (8115-01)

Fig. 2 (8116-01)

•

See Figures 3 and 4 for switches without a common terminal.

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Crown 2010 PF17948 Rev. 2/20

ELECTRICAL SYSTEM Electrical System How the switch is connected To know how the switch is connected, look carefully at the contact symbols. An open circle shows a maintained contact, thus it is the normally closed terminal. A shaded triangle shows a momentary contact, thus it is the normally open terminal.

Switches that have more than one maintained contact do not have a normally open or normally closed terminal, although they can have a common terminal. Sym-

bols for these switches include the symbols on the actual switch.

Example: 1 2

Fig. 9 (8121-01)

Examples (All Momentary) With common (Transfer) Connected normally open, held open Connected normally open, held closed Connected normally closed, held open Connected normally closed, held closed

Fig. 10 (8119-01)

Fig. 12 (8122)

Fig. 14 (8115-01)

Fig. 16 (8124)

Without common (Double Break)

Fig. 11 (8120-01)

Fig. 13 (8123)

Fig. 15 (8117-01)

Fig. 17 (8125)

How the switch operates If it is necessary to include how the switch mechanically operates, there is a note on the electrical diagram.

Function A reference designator shows the switch function (for example: FS = forward switch). See the COMPONENTRY chapter for more information on the applicable reference designators for your lift truck.

Notes: •

On an electrical diagram, the condition of a circuit includes a note (for example: the lift truck is fully lowered with no operator on the lift truck).

•

See Figure 18 for an example of a positive action switch.

1 Fig. 18 (8126-02)

Crown 2010 PF17948-3 Rev. 2/20

M4.1-0000-003 02 Rev. 2/20

181

ELECTRICAL SYSTEM Electrical System Specialty switches

•

See Figure 19 for a pressure switch.

Fig. 19 (8127)

•

See Figure 20 for a reed switch.

Fig. 20 (8128)

•

See Figure 21 for a temperature switch.

Fig. 21 (8129)

•

See Figure 22 for a brake fluid switch.

Fig. 22 (8130)

•

See Figure 23 for a three position key switch

Start Acc Ign

Off

Fig. 23 (8131-01)

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Crown 2010 PF17948 Rev. 2/20

ELECTRICAL SYSTEM Electrical System Switch symbols (Switches that operate mechanically)

Switch Symbols Actuation Description

NO

Number of Terminals

SPST

2

SPDT

3

Momentary with common

without common

Fig. 24 (34385)

Fig. 25 (34386)

Fig. 26 (34387)

SPDT

Fully Maintained with common

Fig. 27 (34388)

4

Fig. 29 (34390)

Fig. 28 (34389)

DPDT

4 Fig. 30 (34391)

DPDT

Fig. 31 (34392)

6 Fig. 33 (34394)

Fig. 32 (34393)

DPDT

8 Fig. 34 (34395)

NOHC

without common

SPST

2

SPDT

3

Fig. 36 (34397)

Fig. 35 (34396)

Fig. 37 (34398)

Fig. 38 (34399)

SPDT

4 Fig. 39 (34400)

DPDT

4 Fig. 40 (34401)

DPDT

Fig. 41 (34402)

6 Fig. 42 (34403)

Crown 2010 PF17948 Rev. 2/20

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183

ELECTRICAL SYSTEM Electrical System

DPDT

8 Fig. 43 (34404)

M4.1-0000-004 02 Rev. 2/20

184

Crown 2010 PF17948 Rev. 2/20

ELECTRICAL SYSTEM Electrical System

Switch Symbols Actuation Description

No. of Terminals

Momentary w/ common

NC

SPST

without common

Fully Maintained w/ common

without common

2 Fig. 44 (34405) Fig. 45 (34406)

SPDT

3 Fig. 46 (34407)

SPDT

Fig. 47 (34408)

4 Fig. 48 (34409)

DPST

Fig. 49 (34410)

4 Fig. 50 (34411) Fig. 51 (34412)

DPDT

6

Fig. 52 (34413)

DPDT

Fig. 53 (34414)

8

Fig. 54 (34415)

NCHO

SPST

Fig. 55 (34416)

2 Fig. 56 (34417) Fig. 57 (34418)

SPDT

3 Fig. 58 (34419)

SPDT

4 Fig. 59 (34420)

DPST

4 Fig. 60 (34421) Fig. 61 (34422)

DPDT

6

Fig. 62 (34423)

Crown 2010 PF17948 Rev. 2/20

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185

ELECTRICAL SYSTEM Electrical System Switch Symbols Actuation Description DPDT

No. of Terminals

Momentary

Fully Maintained

8

Fig. 63 (34424)

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Crown 2010 PF17948 Rev. 2/20

ELECTRICAL SYSTEM Electrical System

Other Electrical Symbols Symbol

Fig. 64 (34297)

Fig. 67 (34298)

Name Signal Flow One Way

Symbol

Fig. 65 (34308)

Signal Flow Simultaneous Fig. 68 (34309)

Name Cable Unconnected

Symbol

JC

Fig. 70 (34299)

Fig. 71 (34310)

Connector Fixed/Jack

Fig. 66 (34319)

Cable PC Unconnected Insulated Fig. 69 (34320)

CA Signal Flow Alternate

Name

Junction Point

Connector Plug

1 Connector Assembly

2 Fig. 72 (34321)

Chassis Ground Fig. 73 (34300)

*

* A-Analog B-Battery L-Logic

Ground Return

Fig. 76 (34301)

Fig. 79 (34302)

1 2 3 4 5

Fig. 74 (34311)

Terminal Strip Fig. 75 (34322)

T-Connection Fig. 77 (34312)

Test Point

Fig. 82 (34303)

Cable Twisted Pair Fig. 85 (34304)

Cable MultTwisted Pairs

SIP Resistor Fig. 78 (34323)

Double Junction Fig. 80 (34313)

Cable Shielded

Resistor

Fig. 83 (34314)

Fig. 86 (34315)

Fig. 89 (34316)

Pot Fig. 81 (34324)

Mast Cable

Rheostat Fig. 84 (34325)

Power Termination

Female/ Socket

Heater Fig. 87 (34326)

T

Thermistor

Fig. 90 (34327)

Fig. 88 (34305)

Cable MultiConductor

Fig. 92 (34317)

Male/Pin

U

Mov/Transzorb

Fig. 93 (34328)

Fig. 91 (34306)

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187

ELECTRICAL SYSTEM Electrical System Other Electrical Symbols Symbol

Name

Symbol

Cable MultiConductor

Fig. 95 (34318)

Name

Socket and Pin

Symbol

Name

Fig. 96 (34329)

Capacitor Nonpolarized

Fig. 94 (34307)

+ Capacitor Polarized

N-FET With Diode Clamp

Fig. 99 (34355)

P-FET With Diode Clamp

Contactor Normally Open Fig. 102 (34356)

Battery

Fig. 97 (34330) Fig. 98 (34344)

Fig. 100 (34331)

Current Shunt Fig. 101 (34345)

Inductor Fig. 103 (34332)

Fig. 104 (34346)

LVDT Fig. 106 (34333)

Fig. 109 (34334)

Fig. 107 (34347)

M

Ferrite Bead

Motor Field, Series Fig. 105 (34357)

Motor Field, Shunt

Contactor Normally Closed

Coil Fig. 108 (34358)

Series Motor, DC Fig. 111 (34359)

Coil Suppression

Fig. 110 (34348)

M

Diode Fig. 112 (34335)

Shunt Motor, DC

Fuse-Band Shows Positive Fig. 114 (34360) Feed

Fig. 113 (34349)

LED Fig. 115 (34336)

M Fig. 116 (34350)

Zener Diode

M

Fig. 118 (34337)

Permanent Magnet Motor Separately Excited Motor, DC

Tach Sensor Fig. 117 (34361)

TT

Hour Meter Fig. 120 (34362)

Fig. 119 (34351)

SCR Fig. 121 (34338)

M4.1-0000-008 02 Rev. 2/20

188

M 3

Fig. 122 (34352)

Motor, AC

Lamp Fig. 123 (34363)

Crown 2010 PF17948 Rev. 2/20

ELECTRICAL SYSTEM Electrical System Other Electrical Symbols Symbol

Name

Symbol

Name

Transistor NPN Fig. 124 (34339)

Fig. 127 (34340)

Fig. 128 (34354)

Darlington NPN Fig. 130 (34342)

DC/DC Converter Power Supply

Suppressor

077732

Horn Fig. 126 (34364)

Fig. 131 (34366)

Encoder Fig. 129 (34365) +

+

–

Darlington PNP

–

077728, 085670, 091181

Suppressor

Fig. 132 (34367) 1

Fig. 133 (34343)

Name

Transformer Fig. 125 (34353)

Transistor PNP

Symbol

Suppressor

2 34

085484, 086755

115487

Fig. 134 (34368)

Fig. 135 (34369)

5

Dual Suppressor

+

82495, 086322, 093757

Dual Suppressor

Fig. 136 (34370)

3

1 112533

5

Filter Block

Fig. 137 (34371)

NOR Gate Fig. 139 (34373)

Schmitt Inverter

Fig. 141 (34375)

Amp/Comp Fig. 143 (34377)

NAND Gate Fig. 145 (34379)

Schmitt Neutralizer

Schmitt NAND Fig. 140 (34374)

Fig. 142 (34376)

OR Gate Fig. 138 (34372)

AND Gate Fig. 144 (34378)

X-OR Gate Fig. 146 (34380)

X-NOR Gate Fig. 147 (34381)

Integrated Circuit Fig. 148 (34382)

Crown 2010 PF17948 Rev. 2/20

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189

Notes:

190

ELECTRICAL Electrical System

Electrical System The following is an explanation of terms and symbols which are standard on Crown wiring diagrams.

Wiring Color Codes

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. Exceptions to this can be component leads supplied by vendors. Each wire is identified by a number on a wiring pictorial (refer to section DIA).

Wires are limited to the colors shown in the chart below. The color of the wire is based on the function of the Wiring Color Codes Chart Number

Color

Function

0**

Black

Traction Inputs/Outputs

1**

Brown

Analog Inputs

2**

Red

Battery Positive

3**

Orange

Non-Battery Positive

4**

Yellow

Status Inputs/Outputs

5**

Green

Battery Negative

6**

Blue

Isolated Negative

7**

Violet

Load Position Inputs/Outputs

8**

Gray

Indicators and Warning Devices

9**

White

Miscellaneous

29**

Red Stripe/White

Positive that has gone thru a switch

59**

Green Stripe/White

Negative that has gone thru a switch or resistor

Power Cables Except WP trucks, power cables are designated using one of the following abbreviations, followed by a dash number.

Power Cables Abbreviations Chart Abbreviation

Part Numbers

PC#1

084571

PC#2

084570

PC#4

084569

PC#6

084568

PC#10

090963

PC#1/0

084572

PC#2/0

084573

PC#3/0

086749

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

Crown 2000 PF11845-1 Rev. 10/06

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131

ELECTRICAL Electrical System Component Abbreviations and Designators Component Abbreviations and Designators Components 1AD

1A Bypass Driver

ALM

Alarm

ATD

Anti Tie Down Module

BATT

Battery

BDI

Battery Disch. Interrupt

BRK

Brake

CA

Connector Assembly

CAP

Capacitor

DB

Diode Block

DFR

Defrost

DMC

Dual Motor Card

DR

Driver Module

ECN

Encoder

FAN

Fan

FIL

Filter

FLS

Flasher

FU

Fuse

HF

Hash Filter

HN

Horn

HR

Heater

HSC

High Speed Card

JC

Fixed Part of Ca

LGT

Light

M

Motor

MCR

Motor Control

PC

Movable Part of Ca

PCVA

"Pressure Compensated Valve, Acc."

PCVH

"Pressure Compensated Valve, Hoist"

PMTD

Pulse Monitor Trip Driver

POT

Potentiometer

PS

Power Supply

PS

Pressure Switch

M4.1-2720-002 03 Rev. 10/06

132

REC

Rectifier

RES

Resistor

SB

Suppressor Block

SSC

Safety Switch Card

SV

Hydraulic Solenoid

SVA

Solenoid Valve - Accessory

SVL

Solenoid Valve - Lower

SVP

Solenoid Valve - Pilot

SVR

Solenoid Valve - Reach

SVS

Solenoid Valve - Sideshift

SVT

Solenoid Valve - Tilt

TB

Terminal Board

TD

Time Delay

TDR

Time Delay Relay

TMM

Truck Management Module

TP

Test Point

TT

Hour Meter (Truck Time)

V

Discharge or Volt Meter

XC

Socket for PC Board

Contactor and Relays A

Speed Contactor

B

Speed Contactor

C

Speed Contactor

D

Dual Contactor

ED

Emerg. Disc. Contactor

F

Forward Contactor

FA

Forward Contactor A

FB

Forward Contactor B

FW

Field Weakening

K

Relay

P

Pump Contactor

R

Reverse Contactor

RA

Reverse Contactor A

RB

Reverse Contactor B

Crown 2000 PF11845-2 Rev. 10/06

ELECTRICAL Electrical System Component Abbreviations and Designators

Component Abbreviations and Designators

RGB

Regen. Braking Contactor

DTS

Drive Tow Switch

S

Power Steering Contactor

ECS

Elevation Control Switch

1A

Bypass Contactor

EDS

Emergency Disconnect Switch

EIS

Extend In Switch

Switches 1AS

Traction Bypass Switch

EMS

Emergency Switch

ACC

Accessory Switch

ENS

Entry Switch

ACS

Accelerator Switch

EOS

Extend Out Switch

AHS

Aux. Height Switch

ERLS

Emergency Raise/Lower Switch

AS

Switch For A Contactor

ERS

Erase Switch

AxA

Aux. Sw. on A Contactor

EXS

Extend Switch

AxB

Aux. Sw. on B Contactor

FHS

Fork Home Switch

AxC

Aux. Sw. on C Contactor

FKS

Fork Switch

AxF

Aux. Sw. on Fwd. Contactor

FLMCS

Forward Left Motor Cover Sw

AxR

Aux. Sw. on Rev. Contactor

FLS

Fork Left Switch/Free Lift Switch

AXS

Aux. Function Switch

FNS

Fan Switch

BFS

Brake Fluid Switch

FRMCS

Forward Right Motor Cover Sw

BLS

Battery Latched Switch

FRS

Fork Right Switch

BMS

Brake Monitor Switch

FS

Forward Switch

BPS

Brake Pressure Switch

FTS

Foot Guard Switch

BRES

Battery Restraint Switch

GCSL

Gate Closed Switch Left

BRS

Brake Switch

GCSR

Gate Closed Switch Right

BS

Switch For B Contactor

GOSL

Gate Open Switch Left

CHS

Chain Switch

GOSR

Gate Open Switch Right

CHSL

Chain Switch Left

GTS

Gate Switch

CHSR

Chain Switch Right

GUS

Guidance Switch

CLS

Clamp Switch

HCS

Height Cable Switch

CS

Switch For C Contactor

HGTS

Height Switch

CTS

Cable Tension Switch

HNS

Horn Switch

DIS

Direction Switch

HSS

High Speed Switch

DMS

Dead Man Switch

HTS

Heater Switch

DMSL

Dead Man Switch Left

HTSXX

Height Switch (XX Inches)

DMSR

Dead Man Switch Right

KORS

Key Override Switch

DPS

Display Switch

KYS

Key Switch

DRS

Door Switch

LCS

Lower Cutout Switch

Crown 2000 PF11845-3 Rev. 10/06

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133

ELECTRICAL Electrical System Component Abbreviations and Designators

Component Abbreviations and Designators

LGS

Light Switch

SWH

Operator Activated Switch

LMS

Limit Switch

TBS

Tilt Back Switch

LOS

Lower Switch

TDS

Tilt Down Switch

LTS

Loadtray Switch

TES

Test Switch

MFS

Multi-funciton Switch

THS

Thermal Switch

MVS

Multi-voltage Switch

TLS

Traverse Left Switch

NUS

Null Switch

TLT

Tilt Switch

ORS

Override Switch

TRS

Traverse Right Switch

PLS

Pivot Left Switch

TUS

Tilt Up Switch

PORS

Presence Overide Switch

TVS

Traverse Switch

PRS

Pivot Right Switch

ZSS

Zone Select Switch

PS

Pressure Switch

Terms

PTS

Pivot Switch

ASM

Assembly

PUS

Pump Switch

CTRL

Control

QPS

Quick Pick Switch

CTRLR

Controller

RAS

Raise Switch

DESIG LIST Designation List

RES

Reach Extended Switch

DIST PNL

Distribution Panel

RGS

Rail Guide Switch

DSPL

Display

RGSL

Rail Guidance Switch Left

F/C

Freezer Conditioning

RGSR

Rail Guidance Switch Right

HCM

Hydraulic Control Module

RIS

Reach In Switch

HDL

Handle

RLMCS

Rear Left Motor Cover Switch

HYD

Hydraulic

ROS

Reach Out Switch

OHG

Overhead Guard

RRMCS

Rear Right Motor Cover Switch

PCB

Printed Circuit Board

RS

Reverse Switch

PICT

Pictorial

RSS

Sheet Retainer Switch

PKT

Packet

SAS

Safety Switch

PL

Platform

SCS

Sideshift Center Switch

PWR

Power

SES

Seat Switch

PWR SPLY

Power Supply

SLS

Sideshift Left Switch

SCHEM

Schematic

SQS

Sequence Switch

TCM

Traction Control Module

SRS

Sideshift Right Switch

TMM

Truck Management Module

SSS

Sideshift Switch

TRAC

Traction

STS

Power Steer Switch

M4.1-2720-004 03 Rev. 10/06

134

Crown 2000 PF11845-4 Rev. 10/06

ELECTRICAL Electrical System Switches

Momentary or Maintained Contact

Switch symbols convey:

•

Momentary contact is a shaded triangle.

1. Type of switch.

2. Number of terminals.

Figure 8119-01

3. Momentary or maintained contact. or

4. How the switch is held and wired.

5. How the switch is activated.

6. Application.

Figure 8120-01

Type of Switch

•

•

With common

Maintained is an open circle (an open circle also denotes the common terminal).

Figure 8115-01

or

Figure 8115-01

or

Figure 8117-01 Figure 8116-01

•

Without common

Figure 8117-01

How the Switch is Held and Wired To determine how the switch is held and wired, look closely at the contact symbols. An open circle denotes a maintained contact so therefore it is the normally closed terminal. A shaded triangle denotes a momentary contact, therefore it is the normally open terminal.

Switches having more than one maintained contact do not have a normally open or normally closed terminal, although they may have a common. Symbols for these switches include the markings present on the actual switch.

or

Figure 8118-01

Example:

Number of Terminals

•

All terminals are shown even if not wired.

Figure 8121-01

Crown 2000 PF11845-5 Rev. 10/06

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135

ELECTRICAL Electrical System

Examples (All Momentary) With Common (Transfer) Wired normally open, held open

Without Common (Double Break)

Figure 8119-01

Wired normally open, held closed

Figure 8122

Wired normally closed, held open

Figure 8120-01

Figure 8123

Figure 8115-01

Figure 8117-01

Figure 8124

Figure 8125

Wired normally closed, held closed How the Switch is Activated If it is necesary to include how the switch is mechanically actuated, a note will be added to the drawing (example: operator, lever or truck actuated, etc.)

Application Switch application is conveyed through the abbreviation (example: HTS = Height Switch 120 in., DTS = Drive/Tow Switch).

Notes:

•

In a schematic, the condition of a circuit is defined using a note (example: vehicle shown fully lowered with no operator on vehicle).

•

Positive action switches are marked with the following symbol:

8126-02

M4.1-2720-006 03 Rev. 10/06

136

Crown 2000 PF11845-6 Rev. 10/06

ELECTRICAL Electrical System Switch Symbols (Mechanically activated switches)

Actuation Description

No. of Terminals

Momentary w/common w/o common

Fully Maintained w/common

w/o common

Figure 8100-01

Crown 2000 PF11845-7 Rev. 10/06

M4.1-2720-007 03 Rev. 10/06

137

ELECTRICAL Electrical System Switch Symbols (Mechanically activated switches) Continued

Actuation Description

No. of Terminals

Momentary w/common w/o common

Fully Maintained w/common

w/o common

Figure 8101-02

M4.1-2720-008 03 Rev. 10/06

138

Crown 2000 PF11845-8 Rev. 10/06

ELECTRICAL Electrical System Specialty Switches Pressure Switch

Figure 8127

Reed Switch

Figure 8128

Temperature Switch

Figure 8129

Brake Fluid Switch

Figure 8130

Three Position Key Switch

Start

Off

Figure 8131-01

Crown 2000 PF11845-9 Rev. 10/06

M4.1-2720-009 03 Rev. 10/06

139

ELECTRICAL Electrical System Other Electrical Symbols

Signal Flow One Way

Terminal Strip

Heater

Signal Flow Simultaneous

T-Connection

Thermistor

Double Junction

Mov/ Transzorb

Signal Flow Alternate Chassis Ground

Mast Cable

Common Return

Power Termination

Test Point

Female/ Socket

Cable Shielded Cable Twisted Pair

Male Pin

Capacitor Nonpolarized Capacitor Polarized Current Shunt Inductor

Socket & Pin LVDT Connector Fixed/Jack

Cable MultiTwisted Pairs

Connector Moveable/ Plug

Ferrite Bead

Diode Cable MultiConductor

Connector Assembly LED

Cable MultiConductor

Resistor Zener Diode

Cable Unconnected

SIP Resistor SCR

Cable Unconnected Insulated

Pot

Junction Point

Rheostat

Transistor NPN

Figure 8132-02

M4.1-2720-010 03 Rev. 10/06

140

Crown 2000 PF11845-10 Rev. 10/06

ELECTRICAL Electrical System Other Electrical Symbols Transistor PNP

DC/DC Converter Power Supply

Darlington NPN

Battery

Darlington PNP N-FET With Diode Clamp

P-FET With Diode Clamp Motor Field, Series Motor Field, Shunt Series Motor, DC

Contactor Normally Open

Dual Suppressor

Dual Suppressor

Contactor Normally Closed

Filter Block

Coil

OR Gate

Coil Suppression

NOR Gate

Fuse - Band Shows Positive Feed

Schmitt NAND

Tach Sensor

Schmitt Buffer

Hour Meter Schmitt Inverter Lamp

Shunt Motor, DC

Amp/Comp Horn

Permanent Magnet Motor

AND Gate Encoder NAND Gate

Separately Excited Motor, DC

Suppressor X-OR Gate Suppressor

Motor, AC

Transformer

X-NOR Gate Suppressor

Integrated Circuit Figure 8133-02

Crown 2000 PF11845-11 Rev. 10/06

M4.1-2720-011 03 Rev. 10/06

141

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TUNE UP The adjustments for tuning up the controller are located under the Program menu. Plug handset (Crown P/N 130475) into the controller.

The handset plugs into the 4 - pin molex connector on the control. If the connector is already occupied, disconnect existing connector and mate handset connector.

Only one column of cursor positions initially exists, Figure 10468. Submenus will be shown when using the 4-directional Menu Navigation Key to go deeper into the Menu structure. Use the right arrow on the Menu Navigation Key to enter the Program Menu. A Sub-Menu indented to the right is displayed. See Figure 10469.

Navigating to an additional Sub-Menu using the right arrow on the Menu Navigation Key presents a screen with additional information and bar graph, Figure 10470. At this level the value of the parameter can be adjusted by using the Data Inc/Dec Key. Refer to chart on next page for setting values.

MAIN MENU Program Monitor Faults Functions Information Programmer Setup Figure 10468-01

Program MAIN C/L L/S MAIN C/L PLUG C/L L/S PLUG C/L ACCEL RATE CREEP SPEED Figure 10469-01

Use the left arrow on the Menu Navigation Key to back out of the Sub-Menus to the Main Menu.

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

Program

MAIN LIMIT

Figure 10470-01

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

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

Display Screen LCD screen capable of displaying up to 7 lines of text & graphics simultaneously.

Data INC/DEC Key Changes value of the parameter indicated by the cursor.

Figure 10466-01

051206

M4.2–6636–200

12511 Crown 2005 PF15179-1

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TUNE UP Unit of Measure

Adj. Range

Factory Setting

M1 (TURTLE) DRIVE CURRENT LIMIT

Amps

200 - 400

400

M2 (RABBIT) DRIVE CURRENT LIMIT

Amps

200 - 400

400

Current limit when in Mode 2 (rabbit) of high speed switch.

M1 (TURTLE) ACCELERATION RATE

Sec

0.5 - 5

0.5

Time to reach full drive output from zero output in Mode 1 (turtle).

M2 (RABBIT) ACCELERATION RATE

Sec

0.5 - 5

0.5

Time to reach full drive output from zero output in Mode 2 (rabbit).

M1 (TURTLE) BRAKING RATE

Sec

1.0 - 5

1

Time to reach full braking output from zero output in Mode 1 (turtle) when changing directions.

M2 (RABBIT) BRAKING RATE

Sec

1.0 - 5

1

Time to reach full braking output from zero output in Mode 2 (rabbit) when changing directions.

M1 (TURTLE) BOTH DIRECTIONS MAXIMUM SPEED LIMIT

%

Creep Speed to 100%

82%

M2 (RABBIT) POWER UNIT FIRST MAXIMUM SPEED LIMIT

%

Creep Speed to 100%

100%

M2 (RABBIT) FORKS FIRST MAXIMUM SPEED LIMIT

%

Creep Speed to 100%

100%

On/Off

OFF

Allows the controller to stay in high speed once HSS (rabbit/turtle) is pressed and released.

RESET VOLTS

200 - 300

205

Battery Cell Voltage at which the state of charge resets the BDI to 100%.

FULL VOLTS

165 - 210

205

Battery Cell Voltage considered to be 100% state of charge.

EMPTY VOLTS

90 - 200

152

Warm Res. to 510

490

Parameter

HIGH SPEED LATCH

HOT RESISTANCE WARM RESISTANCE

Amps Amps

ADS PWM THROTTLE DEADBAND

%

ANTI TIEDOWN

Maximum Mode 2 (rabbit) speed.

Maximum Reverse Mode 2 (rabbit) speed.

Battery Cell Voltage considered to be 0% state of charge.

Sets the Field Resistance that represents a Hot Motor Temperature.

0 to Hot Res.

430

Sets the Field Resistance that represents a Warm Motor Temperature.

0 - 100%

40%

Parameter used in conjunction with other ADS features to detect Abuse of the vehicle during operation.

0 - 30%

12%

Percentage of throttle movement which represents the neutral deadband.

On/Off

OFF

Prevents vehicle operation in Modes 2 or 4 if the Modes 2 or 4 are active when the brake is first released.

Amps

100 - 400

400

M2 (RABBIT) POWER UNIT FIRST BRAKING CURRENT LIMIT

Amps

100 - 400

400

M2 (RABBIT) FORKS FIRST BRAKING CURRENT LIMIT

Amps

100 - 400

400

Crown 2005 PF15179-2

Current limit when in Mode 1 (turtle).

Maximum Mode 1 (turtle) speed.

M1 (TURTLE) BRAKING CURRENT LIMIT

COAST RATE

Description

Braking current limit when in Mode 1 (turtle).

Braking current limit when in Mode 2 (rabbit).

Bit

1 - 255

12

Reverse braking current limit when in Mode 2 (rabbit).

Adjusts the braking force the truck generates when changing between Mode 2 (rabbit) and Mode 1 (turtle). A low value generates more force, a higher value (e.g. 20) generates no force.

M4.2–6636–201

ELECTRICAL SYSTEM Contactor

Contactor

Maintenance Inspection

1 2 3

5 4

6

Fig. 1 (10554-02)

7 8

General Safety

9

CAUTION The use of contactors from other manufacturers could cause damage to the truck.

The original contactors are made for Crown lift trucks.

10

 Only use original Crown contactors as replacements.

11

 Do not change the configuration of the contactors or the electrical connections.

Fig. 2 (28096)

Checking the contacts Refer to Figure 28096.

1. Check the silver coating of both fixed contacts (8) and the mobile contact (9).  If the silver layer has worn off the contact points, replace all three contacts (8, 9).

Crown 1992 PF9313-1 Rev. 4/13

M4.4-04.2-001 05 Rev. 4/13

41

ELECTRICAL SYSTEM Contactor Note: The contacts (8, 9) wear during typical operation.

This does not have an effect on typical operation. Do not clean blackened or tarnished contacts, as that could cause them to wear faster.

4. Remove the two screws (5) from the cover (6).

Checking the coil

7. Install the cover (6) on the replacement coil (11) with the two screws (5).

Refer to Figure 28096.

1. Use a digital volt-ohm multimeter (DVOM) to measure the resistance between the connections on the coil (11).

5. Remove the cover (6) from the coil (11).

6. Install the mobile contact (9) in the replacement coil (11).

8. Install the contactor on the contactor panel with the two screws.

9. Connect all electrical connections to the contactor.

Note: If there is a diode between the connections on the coil (11), desolder the diode on one side, then measure the resistance between the connections on the coil. If you do not do this, the results will be incorrect.  The resistance of the coil must be 15–19 Ω.  If the resistance is not 15–19 Ω, replace the coil.

Checking the return spring Refer to Figure 28096.

1. Check the return spring (7) for corrosion or discolor from heat.  Replace the return spring (7) if it has corrosion or discolor.

Torque Values For general torque values, refer to INSPECTION AND LUBRICATION/Metric Torque Values or INSPECTION AND LUBRICATION/SAE Torque Values.

Component Replacement Refer to Figure 28096.

Contact Replacement 1. Disconnect the electrical connections to the contactor.

Note: It is not necessary to disconnect the coil (11) for this procedure.

2. Remove the two screws (5) from the cover (6).

3. Remove the cover (6).

4. Remove and replace both fixed contacts (8) and the mobile contact (9).

5. Install the cover (6) with the two screws (5).

6. Connect the electrical connections to the contactor.

Coil Replacement 1. Disconnect all electrical connections to the contactor.

2. Remove the two screws that secure the contactor to the contactor panel.

3. Remove the contactor.

M4.4-04.2-002 05 Rev. 4/13

42

Crown 1992 PF9313-2 Rev. 4/13

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CONTROL POD MAINTENANCE The control pod comes in several variations to provide the operator controls for travel, raise, lower, horn. All PE truck variations incorporate a safety reversing switch and may include Quickpick controls.

The following procedures outline adjustments of the safety reversing switch (SAS) on PE trucks, directional switches (FS/RS), and potentiometer (ACCEL/POT1). 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

Acceleration Potentiometer (ACCEL Pot 1) POT Adjustment with handset With truck turned "OFF", unplug connector PC405 from Traction Controller and plug handset, Model 1311-1101 (130475) into controller.

Turn truck "ON" and make sure THROTTLE TYPE SETTING is set at Type 2.

Scroll to THROTTLE CMD in the monitor menu.

Center the pot at 0% throttle. Note there is a dead band at the end of pot rotation that may appear as 0% (the pot is not centered in this position). The dead band can be easily detected. Slightly turn the pot gear, if the value changes slowly, the pot is centered. If the value quickly changes from 0% to 100%, the pot is in the dead band position.

Remove covers from top and bottom of control pod.

SAFETY REVERSING SWITCH (PE Truck Only)

Center the pot at 0% throttle and secure the potentiometer in position.

Turn adjusting screw counterclockwise until safety reversing switch actuates (zero ohms on meter). Turn adjusting screw clockwise one half turn for correct adjustment.

Turn truck "OFF" and remove handset.

Directional Switches

Make sure truck handle is in BRAKE POSITION, to prevent truck movement.

With twist grip in the neutral position turn adjustment screws on both directional switches, slowly, clockwise until switch actuates (zero ohms between common and normally opened terminals). Next, turn both screws counterclockwise until switches de-actuate. After switches de-actuates, continue to turn the screws an additional 1/4 turn. Secure adjustment screws with thread locking adhesive (061004-014).

Install covers.

POT Adjustment without handset

Connect positive probe of volt meter to CA404 pin 15, and the negative lead to "B-" for negative reference on the controller.

With battery connected and key switch "ON", check voltage.

If voltage reading is above .5V, adjust potentiometer until voltage drops below .5V, and then secure pot in position.

Turn key switch "OFF" and remove meter probes from controller.

Install covers.

051206

M4.5–6540–005 01 REV. 2/06

13109 Crown 2005 PF15168-1 Rev. 2/06

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CONTROL POD MAINTENANCE

COMPONENT REPLACEMENT

Lift, Lower, Horn Switches And Buttons (Lift, Lower Switches Not On TR Truck, Refer To Figure 10925)

Remove covers from top and bottom of control pod.

Directional, Speed And Actuators (Refer To Figure 0272S) 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. Remove mounting screws and replace switch. Secure in place with mounting screws and connect electrical wires as noted at disassembly. Tighten electrical connection screws to 390-460 Nmm (55-65 inch ounces).

47 46 45

LOS1

42

41

48 51

49 50

42 42 43 41

43 44

41 42

HNS1

RAS1 Figure 10925

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.

Figure 0272S

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 to 390-460 Nmm (55-65 inch ounces).

Locate actuator arm in question. Remove speed nut (39) 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.

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 (PE Truck Only, Refer To Figure 0274S) Remove mounting screws from safety reversing switch 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.

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

Perform switch adjustment procedures.

Install covers.

Crown 2005 PF16168-2 Rev. 2/06

M4.5–6540–006 01 REV. 2/06

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CONTROL POD MAINTENANCE 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

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.

19

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.

9

10

Install covers.

13

Twist Grips (Refer To Figure 1977 and Figure 13191)

8 7 6 Figure 0274S

Replace component 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.

Part of Control Pod

Potentiometer (ACCEL POT1) ( Refer To Figure 0275S) 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 Figure 1977

Figure 0275S

M4.5–6540–007

Crown 2005 PF15168-3

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CONTROL POD MAINTENANCE

On PC or TR trucks 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 pinion control pod end of twist grip.

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 Figure 0277S. Torsion Spring

Part of Control Pod

Stop

Part of Yoke

Control Pod Housing Twist Grip Figure 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 8. Insert washers between cam and control pod as required to remove any lateral movement of components on the shaft.

Roll Pins

Extension

Figure 13191

Cams, Torsion Spring, Stop (Refer To Figure 10926S and Figure 0277S) 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 physical arrangement of components on the shaft with respect to each other and the finger lobe on the left hand grip.

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.

Install covers.

Stop & Return Assembly

Spacer Cam

Flatwashers

Figure 10926S

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.

Crown 2005 PF16168-4

M4.5–6540–008

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CONTROL POD MAINTENANCE Quickpick® Controls (PE Trucks Only) (Refer To Figure 0905-01)

LOAD BACKREST POD (PC Truck Only, Refer To Figure 13192)

When replacing components, refer to illustration below.

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

The PC 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 backrest to gain access to the 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).

Cover

Switch Shoulder Screw Insulator

Button

Shoulder Screw Spring

Roll Pin Adjustment Screw

Load Backrest Pod

Button

Figure 13192 Figure 0905-01

M4.5–6540–009

Crown 2005 PF15168-5

ELECTRICAL SYSTEM Battery

Battery

Removal (Roll Out)

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

To remove a battery from a truck to a battery roller stand, park truck with brakes applied. Disconnect battery connectors- and remove battery side panels. Roll battery onto the roller stand which is the same height and as long or longer than the battery. Caution must be taken not to allow any metallic object to come in contact with the top of the cell, as this may cause a short circuit when the battery is rolled in or out of the truck.

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 semiannual 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.

Removal (Hoist) When the removal of a battery from a truck is required, park the truck with brakes applied and disconnect battery connectors. (On "SC" units the overhead guard has a chain access cutout to permit the use of an overhead crane or chain lift). Attach spreader bar to ends of battery and lift out. Caution must be taken not to allow any metallic object to come in contact with the top of the cell, as this may cause a short circuit when the battery is removed.

Crown 1978 PF3379-1 Rev. 10/06

Cleaning Always keep vent plugs tightly In place when cleaning battery. When properly watered and charged, the battery will remain clean and dry. All that is necessary Is to brush or blow off any dust or dirt which may accumulate on them. However, if electrolyte is spilled or overflows from the cell. it should be neutralized with a solution of baking soda and water (one pound soda to a gallon of water). To do this, remove 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.

M4.6-11.0-001 01 Rev. 10/06

ELECTRICAL SYSTEM Battery Charging Charging requirements will vary depending on use of truck. Batteries discharged by more than one-third should be charged daily. If tees than one-third discharge, recharging should be delayed; however, they should be recharged at least once a week. If usage of truck makes it necessary, more than one battery should be available to provide ample power to the unit at all times.

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.

Some of the basic rules are as follows: 1. Placing battery on charge: – Park truck at charging station with forks lowered and key removed.

–

Unplug battery from truck.

–

Be sure charger control is in the off position.

– Connect battery to charger and be sure connectors are mated all the way.

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

–

Check ammeter to be sure it shows charge.

2. Removing battery from charge: –

Be sure the charger is turned off.

– Break the connectors, using both hands with a straight pulling motion.

– Hang up the charger cable to prevent damage.

(Broken connectors can cause poor connections and connector failures).

–

Make daily battery checks.

– Connect battery to truck. Be sure connectors are mated all the way.

M4.6-11.0-002 01 Rev. 10/06

Crown 1978 PF3379-2 Rev. 10/06

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ELECTRICAL MAINTNENANCE SPYGLASS Maintenance Indicator (Red) Wrench and Battery Display

LCD Display (8 Alpha/Numeric Characters)

Battery Discharge Indicator LEDS (1 Red, 1 Yellow & 3 Green) Face Of Spyglass Display

Bottom of Spyglass Display Figure 10903-01

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

• BDI is displayed on LCD when handle is in operating zone (i.e. 100% charge).

The hour meter reading is displayed on the LCD when handle is in the brake zone.

• Motor controller fault codes are displayed on the LCD. NOTE: Handset does not display readings with a decimal point. A reading of 20.5 will be displayed as 205 on the Handset.

030707

M4.6–6540–001 01 Rev. 2/06

13110 Crown 2003 PF13580-1 Rev. 2/06

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ELECTRICAL MAINTNENANCE

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

• When the BDI reads < 20% charge, the control locks out lift on PE & PC Series trucks, and high speed travel on TR Series trucks. At this point the battery must be recharged or exchanged for a fully charged battery to resume truck operation.

Controller (Refer to Section M4.2-6540-200, Tune Up For Controller Settings) • Transistor Controller has 3 BDI adjustments, FULL Volts, RESET Volts and EMPTY Volts.

25 - 30% Charge

50 - 55% Charge

Figure 10904-01

• The EMPTY volts setting is how far the battery can be discharged before lift lockout or high speed travel lockout occurs. The controller comes set from the factory with EMPTY volts setting at 1.52 VPC, 23.3 volts open circuit voltage for 24 volt batteries. The specific gravity (SG) of the battery at 1.52 VPC is approximately 1150 SG with electrolyte temperature at 25° C (77° F) and battery under full current load. This setting represents the 80% discharge point of the battery and is the level that recharge is recommended.

Discharge beyond this level can cause permanent damage to the battery.

• The RESET volts setting is the amount of charge the battery must have to reset the BDI. The controller comes set from the factory with RESET volts settings of 2.05 volts per cell (VPC), 24.6 volts open circuit voltage for 24 volt batteries. The specific gravity (SG) of the battery at 2.05 VPC is approximately 1250 SG with electrolyte temperature at 25° C (77° F) and battery under full current load.

• The FULL volts setting is the amount of charge the battery must have to read 100% charge. The controller comes set from the factory with FULL volts setting of 2.05 volts per cell (VPC), 24.6 volts open circuit voltage for 24 volt batteries. The specific gravity (SG) of the battery at 2.05 VPC is approximately 1250 SG with electrolyte temperature at 25° C (77° F) and battery under full load.

100% Charge

Bottom Of Spyglass Display Figure 10905-01

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

• A battery's condition, or capacity will decline due to age and/or improper maintenance making a 2.05 VPC reading not possible. To utilize a battery in this condition it is necessary to reduce the RESET volts parameters. The DISCHARGE volts setting can also be changed to allow the battery to go deeper into discharge or not as far into discharge.

Crown 2003 PF13580-2 Rev. 2/06

M4.6–6540–002 01 Rev. 2/06

C

ELECTRICAL MAINTNENANCE CA401 Connector

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

If a battery capable of resetting the control is connected to the truck, it will take approximately 10 seconds before the meter will read properly and for reset to occur.

Bottom Of Spyglass Display Figure 10906-01

CHART 1 Connector Pin No. (CA401)

Signal

Function

1

No Connection

2

No Connection

3

B+ = 24 Volts

Optional Heater B+ = 24V (Freezer Truck Only)

4

B+ = 36 Volts

Optional Heater B+ = 36V (Freezer Truck Only)

5

Power IN +

+12V/+15V From Motor Controller

6

Receive

Communication Input

7

No Connection

8

Power In -

Common From Motor Controller CHART 2

Symptom:

Check:

Gage will not reset

Check battery state-of-charge, both voltage and specific gravity. If a battery is not able to produce reset at the RESET volts setting of 205, the battery and/or charger must be checked.

Spyglass will reset if voltage at PC404-1 on the controller is greater than 24.6 volts.

Truck comes in too soon for a battery change

Check specific gravity of battery when the BDI reads <20% charge. Do not lower the EMPTY volts setting if the specific gravity of the battery corresponds to more than 80% discharge (1150 SG for most batteries with the electrolyte temperature at 25° C [77° F] and battery under full current load). More running time can be obtained by lowering the EMPTY volts setting, providing the battery does not show 80% discharge.

Lift is not disabled when BDI displays less than 20% charge (PE, PC Only)

Check wiring

Gage resets but lift is locked out (PE, PC Only)

Check voltage between PC404-18 and battery negative on the controller PC404-18 should register 1 volt or less when the raise button is depressed.

Check pump solenoid (P). (PE, PC Only)

M4.6–6540–003 01 Rev. 2/06

Crown 2003 PF13580-3 Rev. 2/06

MOTORS

Disconnect battery before checking brushes.

Inspection of both 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 brush bands to inspect commutator and brushes.

Check 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 low pressure compressed air.

Do not use emery cloth to clean commutator.

Check brushes for chips, breaks, or oil-soaked. If any of these conditions exist, they must be replaced. If brushes are dirty, clean with a clean, dry cloth to remove loose particles of dirt. Be sure brushes slide freely in their holders and make full contact with the commutator. Brushes that are worn beyond one-half their original length should be replaced.

Inspect brush springs for signs of heating that may change tension of the brushes on the commutator. With brushes in place, be sure spring and brush pigtails do not interfere with the brushes movement through its usable length.

Check motor for shorts between terminals and motor frame by use of an ohmmeter on a high resistance scale such as R x 10,000. If a reading of less than 50,000 ohms is observed, the source of trouble should be repaired before unit is placed into operation to prevent further damage.

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

1. Disconnect battery.

2. Remove all electrical connections from motor.

3. Remove brake drum, cone and key.

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

Support motor and remove two bolts from brake side.

5. Remove motor.

051206

M4.7–6636–001 01 Rev. 2/06

C Brush Replacement - To Remove Brushes 1. Disconnect battery.

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

3. Clean brush band area of motor and remove band.

4. Remove screws holding brush pigtails.

5. Disconnect brush springs or move to side.

6. Remove brushes.

• New brush length: 33 mm (1.3 in.)

• Replacement length: 16 mm (0.62 in.)

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

• Maximum diameter of commutator: 74 mm (2.92 in.)

• Minimum diameter for resloting: 72 mm (2.85 in.)

• Replacement diameter: 70 mm (2.75 in.)

• Armature resistance @ 24° C (75° F) = .0044 ohms between bars 1 and 10 8. Check brush spring tension.

• New brush: 1360 gm (48 oz.)

• Worn brush: 907 gm (32 oz.)

9. Install new brushes, fasten pigtails, and connector secure brush springs.

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

11. Install brush band.

12. Use Hi Temp (Chevron SRI-2 or equivalent) grease for motor bearings with a 35% fill.

To Install Motor 1. Lubricate seal in drive unit housing.

2. Install new gasket on motor end bell (use gasket sealer as required).

3. Install motor and secure with mounting bolts.

4. Install brake drum, cone and key. Torque brake drum bolts to 11 to 14 Nm (8 to 10 ft. lbs.).

Lift Motor and Brush Inspection 1. Disconnect battery.

2. Clean brush band area and remove brush band.

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 10 mm (0.375 in.) 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.

13111 Crown 2005 PF15169-1 Rev. 2/06

C

MOTORS Typical Current Readings (Amps)

Amp readings should be taken under the following conditions: Travel - empty; take reading at full travel speed.

Lift - empty; take reading while raising.

Lift Relief - take reading while lift pump is at relief.

Power Steering Idle - take reading while truck is stopped and no other functions are operating.

Power Steering Relief - take readings while turning the steering tight against the stops and holding it there.

PE 4000 SERIES Capacity

Travel

Lift-Empty

Lift Relief

2720 kg (6000 lbs.)

3630 kg (8000 lbs.)

85-110

80-100

170-200

85-110

80-100

185-215

Capacity

Travel

Lift-Empty

Lift Relief

2720 kg (6000 lbs.)

3630 kg (8000 lbs.)

85-110

85-105

180-210

85-110

90-110

195-225

PC 3600 SERIES

TR 3600 SERIES Rolling Load Capacity 4536 kg (10,000 lbs.)

Crown 2005 PF15169-2 Rev. 2/06

Travel 85-110

M4.7–6636–002 01 Rev. 2/06

C

EVENT CODES PC3600 Event Codes There are several ways to view event codes on the PC3600: • Spyglass display (optional) • Blinking LED status indicator on the 1404C controller.

(Refer to troubleshooting section M4.2 of service manual for more information.)

• 1311 handheld programmer (Crown p/n 130475). (Refer to page 12 and 13 for more information.)

Check the Event Code Listing Check the event code listing in this guide for a description of the possible problem, to identify the components affected and corrective actions to be taken.

If the truck powers up but a code is not displayed... the malfunction is probably mechanical or hydraulic rather than electrical. Information regarding mechanical and hydraulic troubleshooting is located in the appropriate section of the service manual.

Crown 1404C Transistor Control LED Diagnostics During normal operation, with no faults present, the Status LED flashes a single flash at approximately 1 flash/second.

If the controller detects a fault, a 2-digit code (see Chart 1) is flashed continuously until the fault is corrected. For example, code “3,2”—welded direction contactor—appears as:

LED CODE

EXPLANATION

LED off

no power or defective controller

solid on

defective controller

single flash controller operational; no faults 1, 1

motor warm

1,2

hardware fail-safe error ADS fault

1,3

M-, current sensor or motor fault

1,4

motor hot

2,1

5k ohm - 0 or throttle wiper input fault

2, 2

static return to off (SRO) fault

2,3

high-pedal-disable fault (HPD)

3,1

contactor driver over current

3,2

welded main contactor

3, 3

precharge fault

3,4

missing contactor or main contactor did not close

4,1

low battery voltage

4, 2

over voltage

4,3

thermal cutback, due to over/under temp.

4,4

anti-tiedown fault

4,5

quick coast switch anti-tiedown

4,6

fwd/rev fault, fwd & rev switch signals high CHART 1

Figure 2619

NOTE Only one fault is indicated at a time, and faults are not queued up.

051206

M4.8–6636–400

12473 Crown 2005 PF15175-1

C

EVENT CODES

1311 Handheld Programmer Diagnostics

Menu Navigation Key Moves screen cursor up or down through Menu list (top and bottom arrows), and opens or closes Sub Menus (right and Left arrows).

Bookmark Keys Allow you to quickly go back to your favorite selections without having to navigate back through the menu.

Display Screen LCD screen capable of displaying up to 7 lines of text & graphics simultaneously.

Data INC/DEC Key Changes value of the parameter indicated by the cursor.

Figure 10466

With a programmer, diagnostics and troubleshooting is more direct than with the LED alone. The programmer presents complete diagnostic information in plain language— no codes to convert. Codes are displayed in the Faults Menu.

The following 4-step troubleshooting process is generally used for diagnosing and troubleshooting an inoperative truck: (1) visually inspect the truck for obvious problems; (2) diagnose the problem, using the programmer; (3) test the circuitry with the programmer; and (4) correct the problem.

Repeat the last three steps as necessary until the truck is operational.

Example: A truck that does not operate in “forward” is brought in for repair.

Step 1: Examine the truck and its wiring for any obvious problems, such as broken wires or loose connections.

Step 2: Connect the programmer and select the Faults Menu - Systems Faults and read the displayed information. In this example, the display shows “No Faults Present,” indicating that the controller has not detected anything out of normal.

Step 3: From the programmer's Main Menu select the Monitor Menu and observe the status of the inputs and outputs in the forward direction. For this example, the display shows that the forward switch did not close when “forward” was selected, which means the problem is either in the forward switch or the switch wiring.

Step 4: Check or replace the forward switch and wiring and repeat the test. If the programmer shows the forward switch closing and the truck now drives normally, the problem has been corrected.

Refer to the event code listing in this section for a description of the possible problem, to identify the components affected and corrective actions to be taken.

Crown 2005 PF15175-2

M4.8–6636–401

C

EVENT CODES Main Menu Use the right and left arrows to open and close the sub-menus.

Program Monitor Faults Functions Information Programmer Setup

See page M4.2-6636-403 for Program Menu.

Use the up and down arrows to scroll through the menus.

Program Monitor Faults Functions Information Programmer Setup

M4.8–6636–402

See page M4.2-6636-404 for Monitor Menu.

See page M4.2-6636-405 for Faults Menu.

See page M4.2-6636-406 for Functions Menu.

See page M4.2-6636-408 for Information Menu.

See page M4.2-6636-409 for Programmer Setup Menu.

Crown 2005 PF15175-3

C

EVENT CODES

Program Menu

From page M4.2-6636-402

Program M1 Drive C/L 400 M2 Drive C/L 400 Hot Resi 490 Warm Resi 430 M1 Brake C/L 400 M2 Brake C/L 400

Use the right and left arrows to open and close menus.

Use the up and down arrows to scroll through menu.

Program M1 Drive C/L

400 Min 200

Max 400

Use the (+) to increase setting.

Use the (–) to decrease setting.

Program sub menus are used to change truck parameter settings (ie. controller tune-up). Refer to tune-up section M4.2 of service manual for more information.

Crown 2005 PF15175-4

M4.8–6636–403

C

EVENT CODES Monitor Menu

From page M4.2-6636-402

Programmer Listing Description

Monitor Throttle 0% Arm Current Field Current Arm PWM Field PWM Batt Voltage

Use the up and down arrows to scroll through menu.

0 0 0 0 24V

THROTTLE

Accel Pot

ARM CURRENT

Traction Motor Armature Current

FIELD CURRENT

Traction Motor Field Current

ARM PWM

Traction Motor Armature PWM

FIELD PWM

Traction Motor Field PWM

BATT VOLTAGE

Battery Voltage

CAP VOLTAGE

Motor Controller Capacitor Voltage

HEATSINK TEMP

Motor Controller Heatsink Temperature

ADS TOTAL 2

Abuse Detection (Number of Times Motor was Stalled for 4 Seconds or Longer)

ADS TOTAL 1

Abuse Detection (Longest Duration of Motor Stall)

FORWARD INPUT

FS (Forward Switch)

REVERSE INPUT

RS (Reverse Switch)

MODE

HSS - (1) Turtle or (2) Rabbit

INTERLCK INPUT

BRS (Brake Switch)

LIFT INPUT

RAS (Raise Switch)

EMR REV INPUT

SAS (Reversing Switch)

MOTOR RPM

Traction Motor RPM (Not Available)

MAIN CONT

L (Line Contactor Status - ON/OFF)

LIFT DRVR

M2 (Lift Pump Contactor Status ON/OFF)

COAST DRVR

EML, LGT1 (Quick Coast Status ON/OFF)

BEEPER DRVR

ALM1 (Alarm Status - ON/OFF)

FAULT 1 OUTPUT

Not Used

FAULT 2 OUTPUT

Not Used

CONTROL STATE

Not Used

PICK INPUT

QP (Quick Pick Switches)

MODSEL 1

Not Used

MODSEL 2

Not Used

FLD RESIST

Traction Motor Field Resistance

BDI%

Battery Discharge Percentage

CHART 2

M4.8–6636–404

Crown 2005 PF15175-5

C

EVENT CODES

Faults Menu

From page M4.2-6636-402

Faults

Faults System Faults Fault History Clear Fault History Functions Information Programmer Setup

<Currently No Faults> or List of Faults

Faults

Motor Warm Faults System Faults Fault History Clear Fault History Functions Information Programmer Setup

Error Code 7

Using Chart 3, find event code that caused fault. Then use event code listing in this guide to resolve fault.

EVENT CODE

PROGRAMMER LCD DISPLAY

EVENT CODE

PROGRAMMER LCD DISPLAY

11

MOTOR WARM

31

12

HW FAILSAFE 1-3

32

MAIN CONT WELDED

ADS FAULT

33

PRECHARGE FAULT

M-SHORTED

34

13

Faults System Faults Fault History Clear Fault History Functions Information Programmer Setup

Ignore this error code, for internal use only.

FIELD OPEN

CONT DRVR OC

MISSING CONTACTOR MAIN CONT DNC

ARM SENSOR

41

LOW BATTERY VOLTAGE

FLD SENSOR

42

OVER VOLTAGE

14

MOTOR HOT

43

THERMAL CUTBACK

21

THROTTLE FAULT 1

44

ANTI-TIEDOWN

THROTTLE FAULT 2

45

QUICK COAST SWITCH

22

SRO

23

HPD

46

FWD/REV FAULT

ANTI-TIEDOWN

CHART 3 Faults You are about to clear Fault History.

Continue?

Yes (+)

Crown 2005 PF15175-6

No (–)

M4.8–6636–405

C

EVENT CODES Functions Menu

From page M4.2-6636-402

Functions Settings Get Settings From Cont...

Write Settings To Cont...

Reset All Settings Information Programmer Setup

Functions Settings Get Settings From Cont...

Write Settings To Cont...

Reset All Settings Information Programmer Setup

See page M4.2-6636-407

Functions Set all Controller Settings from Programmer.

OK (+)

Functions Set all Controller Settings in Programmer?

OK (+) Functions Settings sub menus are used for saving program settings to programmer and writing these settings to additional motor controllers.

Refer to Tune-Up section M4.2 of service manual for setting descriptions.

Abort (–)

Functions Operation Cancelled No Action Taken OK (+)

Functions All Controller Settings Saved in Programmer.

OK (+)

Abort (–) Functions Operation Cancelled No Action Taken OK (+)

Functions Functions All Controller Settings Set from Programmer.

Executing...

OK (+)

M4.8–6636–406

Crown 2005 PF15175-7

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EVENT CODES

Functions Menu (Continued)

From page M4.2-6636-406

Functions Settings Get Settings From Cont...

Write Settings To Cont...

Reset All Settings Information Programmer Setup

Functions Reset All Settings to Original Values.

Yes (+)

No (–)

Functions

Executing...

Functions Operation Cancelled No Action Taken Functions

OK (+)

All Controller Settings Reset to Original Values.

OK (+)

Crown 2005 PF15175-8

M4.8–6636–407

C

EVENT CODES Information Menu

From page M4.2-6636-402

Information Model NumberXXXX-XXXX Serial Number XXXXXX MFG Date dd-(mth)-yy Software Version XX-XX Programmer Setup

Information Model Number XXXX-XXXX

M4.8–6636–408

Crown 2005 PF15175-9

C

EVENT CODES

Programmer Setup Menu

From page M4.2-6636-402

Programmer Setup Program LCD Contrast Language Information OEM Info *Reconfigured

Programmer Setup LCD Contrast -75 – no

OEM Info ? *Reconfigured ?

Model Number ?

Serial Number ?

Manufacturing Date ?

Software Version ?

Hardware Version ?

Crown 2005 PF15175-10

Min -150

Max 150

Programmer Setup Model Number XXXX-XXXX

M4.8–6636–409

EVENT CODES

C

Event 11 is traction motor warm.

Event Code 11

Step 1:

Step 2:

Step 3:

Step 4:

Step 5:

Step 6:

Determine if truck is under a heavy-duty cycle or high ambient temperatures.

If: Truck is overheating due to these conditions and performance is degraded.

Then allow truck to cool down.

If: Performance is not degraded.

Then continue to use truck.

If: Truck is not overheating due to the above conditions.

Then proceed with step 2.

Using a current clamp or 1311 handheld programmer, check for excessive current in drive motor (check current on A2 motor cable) due to mechanical condition of drive motor, drive unit and brakes dragging.

If: With drive tire off the ground applying full throttle in walkie speed mode (not high speed), results in armature current less than 35 amps.

Then go to step 3 If: With drive tire off the ground applying full throttle in walkie speed mode (not high speed), results in armature current above 35 amps.

Then problem is with mechanical condition of drive motor, drive unit, brakes, etc.

Repair as necessary.

Check appropriate controller output voltage and current to the field.

If: With drive tire off the ground applying full throttle in walkie speed mode (not high speed), results in field voltage from F1 to F2 terminals greater than 6.5 volts or field current less than 14 amps or greater than 16 amps.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

If: Field voltage and current is OK. Then proceed with step 4.

Determine if control parameters are set to the right values under Program menu using 1311 programmer.

If: WARM RESISTANCE is not adjusted to 430 and HOT RESISTANCE is not adjusted to 490 then set parameters to these values.

If: Parameters are adjusted correctly, in Monitor menu with motor at or near ambient temperature, observe FIELD RESISTANCE while lowering handle into operating position. Leave throttle in neutral position.

If the value is between 300 and 400.

Proceed to step 5.

If value is not between 300 and 400.

Proceed to step 6.

Check for loose or bad connections in field and armature power cables.

If: Connections are loose.

Then tighten.

If: Connection terminals are bad.

Then replace cables.

If: Terminals are OK. Then proceed with step 7.

Check for high resistance field at motor.

If: Field resistance from F1 to F2 terminal with one of the field cables removed is between 0.30 and 0.50 ohms with motor at or near ambient temperature.

Proceed to step 7.

If: Field resistance from F1 to F2 terminal with one of the field cables removed is greater than 0.50 ohms with motor at or near ambient temperature.

Replace motor with known good.

M4.8–6636–410

Crown 2005 PF15175-11

C Step 7:

Step 8:

Step 9:

EVENT CODES

Check for various contactor event codes that could cause nuisance WARM and HOT events.

If: There are event codes 31, 32, 33 or 34 associated with event 11 (see fault history).

Then proceed to that event code for trouble shooting directions.

If: There are no event codes 31, 32, 33 or 34 associated with event 11.

Then proceed to step 8.

Determine if motor is really overheating. Field temperatures should be above 110°C/230°F immediately after truck-overheating event is logged.

If: Field temperatures on outside of motor near data label are far cooler than specified.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section.

If: Field temperatures are as hot or hotter than specified.

Then proceed with step 9.

Event code is persistent and performance is degraded.

If: Condition is persistent and performance is degraded.

Then contact Crown service department.

Traction Controller MRC1 CA404-1 B+

F1

F2

M-

B-

M1 FIELD

KYS

M1 A1

FU2 24V

A2

TRACTION

+

Figure 10986

Crown 2005 PF15175-12

M4.8–6636–411

EVENT CODES

C

Event 12 is logged if the 1404C module detects an ADS (Abuse Detection System) event or an internal failsafe condition.

Event Code 12

Step 1:

Step 2:

Step 3:

Step 4:

Step 5:

If a 1311 handheld programmer is available, then check fault code history.

If: ADS fault .

Then proceed with step 2.

If: HW failsafe fault.

Then proceed with step 5.

If: No 1311 handheld programmer is available.

Then proceed with steps 2 – 5.

Determine if the operator is holding the truck in a stall for more than 4 seconds (for example, bulldozing a load). The ALM1 beeper should have sounded at a fast rate (4 beeps per second).

If: The operator has stalled the truck.

Instruct operator in proper operation of the truck. If a motor is held in stall for more than 4 seconds, damage can occur such as raised motor bars.

If: The operator has not stalled the truck.

Then proceed to step 3.

Determine if control parameters are set to the right values under Program menu using 1311 handheld programmer.

If: ADS PWM is not adjusted to the values in M4 tune up section of the service manual.

Then set parameters to these values.

If: ADS PWM is set correctly.

Then proceed with step 4.

Using a current clamp, check for excessive current in drive motor (check current on A2 motor cable) due to mechanical condition of drive motor, drive unit and brakes dragging.

If: With drive tire off ground applying full throttle in walkie speed mode (not high speed), results in armature current less than 35 amps.

Then go to step 5.

If: With drive tire off ground applying full throttle in walkie speed mode (not high speed), results in armature current above 35 amps Then problem is with mechanical condition of drive motor, drive unit, brakes, etc.

Repair as necessary.

Key the truck off then back on.

If: Event is persistent.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

If: Problem is not persistent.

Then monitor closely.

M4.8–6636–412

Crown 2005 PF15175-13

C

EVENT CODES

Event 13 is a collection of events dealing with traction motor field and armature.

Step 1:

Step 2:

Step 3:

Step 4:

Step 5:

Event Code 13

If a 1311 handheld programmer is available, then check the event under the fault menu.

If: Field open.

Then proceed with Step 2-3.

If: M- shorted.

Then proceed with step 4.

If: ARM Sensor.

Then proceed with Step 5 If: Field sensor.

Then proceed with Step 5 If: No 1311 handheld programmer is available.

Then proceed with steps 2 – 5.

Check motor field cables for loose connections at controller and motor or for miswiring.

If: Field wires are loose.

Then tighten field terminal screws and nuts.

If: Terminals are miswired.

Then connect power cables correctly.

If: Terminals are wired OK. Then proceed with step 3.

Check motor field winding resistance by removing the field cables at the controller. Using a multimeter, measure the resistance of the field at the field terminals leads.

If: Motor field resistance is greater than 0.50 ohms.

Then replace motor or power cables.

If: Motor field resistance is less than 0.50 ohms.

Then proceed with step 4.

Disconnect motor cable going to M- on controller. Check voltage at M- on controller using B- on the controller for negative reference. Truck should be keyed on with handle up.

If: Voltage is greater than 2.5 volts.

Then look for a shorted arm winding or a short to frame on motor.

If: Voltage is less than 2.5 volts.

Then proceed with step 5.

Replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

Traction Controller MRC1 CA404-1 B+

F1

F2

M-

B-

M1 FIELD

KYS

M1 A1

FU2 24V

A2

TRACTION

+

Figure 10986

Crown 2005 PF15175-14

M4.8–6636–413

EVENT CODES

C

Event 14 is traction motor hot.

Event Code 14

Step 1:

Step 2:

Step 3:

Step 4:

Step 5:

Step 6:

Determine if truck is under a heavy-duty cycle or high ambient temperatures.

If: Truck is overheating due to these conditions and performance is degraded.

Then allow truck to cool down.

If: Performance is not degraded.

Then continue to use truck.

If: Truck is not overheating due to the above conditions.

Then proceed with step 2.

Using a current clamp or 1311 handheld programmer, check for excessive current in drive motor (check current on A2 motor cable) due to mechanical condition of drive motor, drive unit and brakes dragging.

If: With drive tire off the ground applying full throttle in walkie speed mode (not high speed), results in armature current less than 35 amps.

Then go to step 3.

If: With drive tire off the ground applying full throttle in walkie speed mode (not high speed), results in armature current above 35 amps.

Then problem is with mechanical condition of drive motor, drive unit, brakes, etc.

Repair as necessary.

Check appropriate controller output voltage and current to the field.

If: With drive tire off ground applying full throttle in walkie speed mode (not high speed), results in field voltage from F1 to F2 terminals greater than 6.5 volts or field current less than 14 amps or greater than 16 amps.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

If: Field voltage and current is OK. Then proceed with step 4.

Determine if control parameters are set to the right values under Program menu using 1311 programmer.

If: WARM RESISTANCE is not adjusted to 430 and HOT RESISTANCE is not adjusted to 490 then set parameters to these values.

If: Parameters are adjusted correctly, in Monitor menu with motor at or near ambient temperature, observe FIELD RESISTANCE while lowering handle into operating position. Leave throttle in neutral position.

If the value is between 300 and 400.

Proceed to step 5.

If value is not between 300 and 400.

Proceed to step 6.

Check for loose or bad connections in field and armature power cables.

If: Connections are loose.

Then tighten.

If: Connection terminals are bad.

Then replace cables.

If: Terminals are OK. Then proceed with step 7.

Check for high resistance field.

If: Field resistance from F1 to F2 terminal with one of the field cables removed is between 0.30 and 0.50 ohms with motor at or near ambient temperature.

Proceed to step 7.

If: Field resistance from F1 to F2 terminal with one of the field cables removed is greater than 0.50 ohms with motor at or near ambient temperature.

Replace motor with known good.

M4.8–6636–414

Crown 2005 PF15175-15

C Step 7:

Step 8:

Step 9:

EVENT CODES

Check for various contactor event codes that could cause nuisance WARM and HOT events.

If: There are event codes 31, 32, 33 or 34 associated with event 11 (see fault history).

Then proceed to that event code for trouble shooting directions.

If: There are no event codes 31, 32, 33 or 34 associated with event 11.

Then proceed to step 8.

Determine if motor is really overheating. Field temperatures should be above 110°C/230°F immediately after truck-overheating event is logged.

If: Field temperatures on outside of motor near data label are far cooler than specified.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

If: Field temperatures are as hot or hotter than specified.

Then proceed with step 9.

Event code is persistent and performance is degraded.

If: Condition is persistent and performance is degraded.

Then contact Crown service department.

Traction Controller MRC1 CA404-1 B+

F1

F2

M-

B-

M1 FIELD

KYS

M1 A1

FU2 24V

A2

TRACTION

+

Figure 10986

Crown 2005 PF15175-16

M4.8–6636–415

EVENT CODES

C

EVENT 21 is a collection of events dealing with the potentiometer.

Event Code 21

Step 1:

Step 2:

Step 3:

If a 1311 handheld programmer is available, then check fault code history.

If: Throttle fault 1.

Then proceed with step 2.

If: Throttle fault 2.

Then proceed to step 3.

If: The 1311 handheld programmer is not available.

Then proceed with step 2 and 3.

With the battery connected and key switch on, check the voltage at pin 15 of CA404 (probe with connector in place at controller) using B- on the controller for the negative reference. (Caution: leave the handle in braked position to prevent truck movement). Readings taken in neutral unless stated otherwise.

If: The wiper voltage (brown wire) is greater than .7V. Then adjust pot to read near .5V while throttle is in neutral.

If: The wiper voltage does not change linearly with rotation of throttle to a voltage near 4.4V - 5V. Then proceed with step 3.

If: Pot is reading correctly and intermittent event code 21 occurs.

Then check wiring and connectors for opens occurring due to vibration.

With the battery connected and key switch on, check the voltage at pin 13 of CA404 (probe with connector in place at controller) using B- on the controller for the negative reference. (Caution: leave the handle in braked position to prevent truck movement). Readings taken in neutral unless stated otherwise.

If: The voltage at the pot high (violet wire) CA404-13 is not between 4.4V and 5.5V. Then remove the violet wire from connector and check voltage at the controller with the connector in place.

If: The voltage is not between 4.4V and 5.5V. Then replace controller.

If: The voltage at CA404-14 pot low (blue wire) is greater than 2.5V. Then check for pinched wires.

If: The voltage at pot high is OK and wiper voltage does not change linearly with rotation of throttle and pot low is near .5V. Then check wiring and connectors to the pot for opens.

If: Wiring is OK. Then replace potentiometer.

Figure 13031

M4.8–6636–416

Crown 2005 PF15175-17

C

EVENT CODES

EVENT 22 is a SRO (Static Return to Off). This event code is shown only by the 1404C Control Module status light blinking a 22 or the wrench light on the Spyglass blinking.

Event Code 22

Step 1:

Determine if the operator is operating the truck out of sequence such as turning the throttle before handle is in operating position.

If: SRO event.

Then instruct operator in proper sequence of the truck.

If: The truck is going into an improper SRO. Then proceed to step 2.

Step 2:

With truck in neutral determine if FS and RS switches are closed improperly. Read 1311 handheld program or check voltage at CA404-10/CA404-11.

If: Switches are closed while throttle is in neutral.

Then repair switch or locate the wiring error.

If: FS and RS switches are OK. Then check connection to the controller or replace controller.

Figure 13032

Crown 2005 PF15175-18

M4.8–6636–417

EVENT CODES

C

EVENT 23 is an HPD (High Throttle Pot. Disable). This event code is shown only by the 1404C Control Module status light blinking a 23 or the wrench light on the Spyglass blinking. The HPD event looks and acts like a SRO.

Event Code 23

Step 1:

Step 2:

Determine if the operator is operating the truck out of sequence such as turning the throttle before truck is keyed ON. If: HPD event.

Then instruct operator in proper sequence of the truck.

If: The truck is going into an improper HPD. Then proceed to step 2.

With battery connected and key switch on, check the voltage at pin 15 of CA404 (controller) using B- on the controller for negative reference. (Caution leave the handle in brake position to prevent truck movement). Readings taken in neutral unless stated otherwise.

If: Voltage is greater than .5V. Then adjust potentiometer.

If: Voltage is less than .5V. Then check wiring for a shorted or pinched wire causing an improper input to CA404-21. (Wire not used on PC3600 but could become shorted giving an improper signal).

Figure 13065

M4.8–6636–418

Crown 2005 PF15175-19

C

EVENT CODES

Event 31 is a contactor driver over-current event.

Step 1:

Step 2:

Step 3:

Event Code 31

Check resistance of the line contactor (L) coil by probing CA404-9 and CA404-17 with key off.

If: The resistance is greater than 10 ohms.

Then proceed to step 2.

If: The resistance is less than 10 ohms.

Then remove wires from main contactor coil. Again check coil resistance.

If: Less than 10 ohms. then coil is shorted, replace main contactor.

If: Greater than 10 ohms.

Then check harness wiring for shorted wires to each other and short to frame.

Check resistance of the pump (P) coil by probing CA404-18 and CA404-9 with key off.

If: The resistance is greater than 10 ohms.

Then proceed to step 3.

If: The resistance is less than 10 ohms.

Then remove wires from pump contactor coil. Again check coil resistance.

If: Less than 10 ohms.

Then coil is shorted, replace pump contactor.

If: Greater than 10 ohms.

Then check harness wiring for shorted wires to each other and short to frame.

Check resistance of the alarm (ALM1) by probing CA404-20 and CA404-9 with key off.

If: The resistance is greater than 10 ohms.

Then check harness for shorts and short to frame. Re-key truck and monitor this code. If problem persists replace controller with known good.

If: The resistance is less than 10 ohms.

Then disconnect alarm at CA409. Again check coil resistance.

If: Less than 10 ohms.

Then alarm is shorted, replace main alarm.

If: Greater than 10 ohms.

Then check harness wiring for shorted wires to each other and short to frame.

Figure 13066

Crown 2005 PF15175-20

M4.8–6636–419

EVENT CODES

C

Event 32 is the line contactor not opening due to bad driver or welded tips.

Event Code 32

Step 1:

Step 2:

Step 3:

Check line (L) contactor tips to ensure that tips are not welded and will not release.

If: Tips are welded.

Then replace tips or main contactor.

If: Tips are not welded.

Then proceed with step 2.

Check voltage of the main coil by probing CA404-17 with the battery connected and key switch on, using B- on the controller for the negative reference. Handle should be up.

If: The voltage is less than 20 volts with handle up.

Then check harness for shorted wire to battery negative or short to frame on wire 5904.

If: Wire is shorted.

Then fix or replace harness.

If: Harness is OK. Then proceed with step 3.

Check the line contactor to ensure that the contactor is not stuck shut. Tips should be in good working order.

If: Contactor is stuck shut.

Then repair or replace contactor.

If: Contactor is in good working order and condition is persistent.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

2908 L

2961

5904 CA404-17

CA404-9

Traction Controller MRC1

KYS

B+

F1

F2

FU2

M-

B-

M1 FIELD FU1

M1 A1 L

A2

TRACTION 24V +

Figure 10992

M4.8–6636–420

Crown 2005 PF15175-21

C Event 33 is the precharge circuit not working.

Step 1:

EVENT CODES Event Code 33

Connect voltmeter across the main controller battery terminals (B+, B-). With the key switch on, pull handle down to close brake switch. Monitor voltage.

If: Voltage goes above 20 volts and module still gives event code.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

If: Voltage goes above 20 volts and module does not give event code.

Then monitor the truck to see if event is persistent. If so, then replace controller with known good.

Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

If: Voltage does not go above 20 volts.

Then check the power cables to the controller for proper connections.

If: Power cables are connected wrong or bad crimp.

Then replace or fix cables.

If: Power cables are correct.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

Crown 2005 PF15175-22

M4.8–6636–421

EVENT CODES

C

Event 34 is the line contactor missing or not connected.

Event Code 34

Step 1:

Check resistance of the line contactor coil by probing CA404-17 and CA404-9 with the battery disconnected.

If: The resistance is greater than 60 ohms.

Then check harness for open wire on 2961,2908, 5904 and check pins 9 and 17 in PC404 to ensure they are making good contact.

If: Wire is damaged or bad crimp.

Then fix or replace harness.

If: Wire is OK. Then ensure that the leads are tight on the contactor coil and ensure that the coil resistance is less than 60 ohms by measuring directly across coil with battery disconnected.

If: Coil resistance is greater than 60 ohms.

Then replace or repair contactor.

If: The resistance is less than 60 ohms.

Then go to step 2.

Step 2:

Check contactor driver at CA404-17. Ensure that the voltage is above 20 volts when the handle is in brake position.

If: The voltage is below 20 volts.

Then check wires at CA404-17 for pinched wires or loose connections.

If: Wires are not pinched or loose.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

If: Wires are pinched or loose.

Then repair or replace harness.

If: The voltage is above 20 volts.

Then proceed with step 3.

Check FU1 for open fuse. Ensure that the fuse is not blown nor has loose power connections.

If: Fuse is bad or connections are loose.

Then replace fuse or tighten connections.

If: Fuse is good and connections tight.

Then proceed with step 4.

Check line contactor for good tips to ensure that the contactor is closing OK. If: Contactor tips are worn badly.

Then repair or replace contactor.

If: Tips are in good shape and condition is persistent.

Then replace controller with known good. Ensure that the controller is Programmed for the truck as described in the M4 Tune up section of the service manual.

Step 3:

Step 4:

2908

2961

L

CA404-9

CA404-17

5904

Traction Controller MRC1

KYS

B+

F1

F2

FU2

M-

B-

M1 FIELD FU1

M1 A1 L

A2

TRACTION 24V +

Figure 10992

M4.8–6636–422

Crown 2005 PF15175-23

C

EVENT CODES

Event 41 is the low battery voltage at controller.

Step 1:

Step 2:

Step 3:

Event Code 41

Check voltage of battery with battery disconnected.

If: The voltage is less than 17 volts.

Then recharge or replace battery.

If problem persists.

Then check condition of battery or readjust BDI/lift lockout setting if equipped. Refer to Tune-Up section M4.2 of service manual.

If: The voltage is above 17 volts.

Then proceed with step 2.

Check the condition of the battery terminals.

If: The connections are loose or corroded.

Then replace the terminals.

If: The connections are tight.

Then proceed with step 3.

Check the condition of FU2, key switch and CA404-1 terminal to ensure good connections. The battery voltage is measured on pin 1 of CA404.

If: The connections are loose or corroded.

Then replace the terminals or FU2.

If: The connections are tight.

Then replace battery with known good battery.

CA404-1 KYS

FU2

Traction Controller MRC1 B-

24V +

Figure 10993

Crown 2005 PF15175-24

M4.8–6636–423

EVENT CODES

C

Event 42 is the battery voltage too high at controller.

Event Code 42

Step 1:

Step 2:

Step 3:

Step 4:

Step 5:

Check voltage of battery with battery disconnected.

If: The voltage is greater than 27 and less than 28 volts immediately after the battery is disconnected from the charger.

Then battery is fully charged to maximum and should drop to around 24 volts within a few minutes with normal use.

If: The voltage is above 28 volts.

Then ensure battery is in good condition, proper voltage battery for truck (24 volts), and charger is in good working order.

If: Voltage is below 27 volts.

Then proceed with step 2.

See if the line contactor has opened during a regen brake with the battery at full charge. If the battery has recently come off of the charger, the battery can temporary go over the limit with a harsh regen brake.

If: Truck has just come off of the charge and regen braked.

Then battery is fully charged to maximum and should drop in voltage within a few minutes with normal use.

If: Truck has not been charged recently.

Then proceed with step 3.

See if the line contactor has opened during a regen brake. Determine if the contactor is in good working order with good tips and a good return spring. (See if the line contactor could have opened during a regen).

If: The contactor tips or spring is bad.

Then repair or replace contactor.

If: The contactor is functioning properly.

Then check the wiring going to the contactor coil.

If: Wire terminals are loose or wires damaged.

Then repair or replace harness.

If: Harness is OK. Then proceed with step 4.

Check the power conditions of the line contactor.

If: The connections are loose or corroded.

Then replace the terminals.

If: The connections are tight.

Then proceed with step 5.

Check the condition FU1 and battery terminals for good connections.

If: The connections are loose or corroded.

Then replace the terminals or FU1.

If: The connections are tight.

Then replace battery to ensure that battery is not defective.

2908 L

2961

5904 CA404-17

CA404-9

Traction Controller MRC1

KYS

B+

F1

F2

FU2

M-

B-

M1 FIELD FU1

M1 A1 L

A2

TRACTION 24V +

Figure 10992

M4.8–6636–424

Crown 2005 PF15175-25

C

EVENT CODES

Event 43 is controller is too warm or too cold. Caused by high duty cycles or high/low ambient temperatures.

Step 1:

Step 2:

Step 3:

Step 4:

Step 5:

Event Code 43

Determine if truck is under a heavy-duty cycle or high ambient temperatures.

If: Truck is overheating due to these conditions and performance is degraded.

Then allow truck to cool down.

If: Performance is not degraded.

Then continue to use truck.

If: Condition is persistent.

Then contact Crown customer service.

If: Truck is not overheating due to the above conditions.

Then proceed with step 2.

Determine if truck is too cold (less than -25½C [-13½ F]).

If: Truck is too cold due to these conditions.

Then allow truck to heat up and do not store truck in freezer.

If: Truck is above -25½C (-13½ F).

Then proceed with step 3.

Using a current clamp, check for excessive current in drive motor (check current on A2 motor cable) due to mechanical condition of drive motor, drive unit and brakes dragging.

If: With drive tire off ground applying full throttle in walkie speed mode (not high speed), results in armature current less than 35 amps.

Then go to step 4.

If: With drive tire off ground applying full throttle in walkie speed mode (not high speed), results in armature current above 35 amps.

Then problem is with mechanical condition of drive motor, drive unit, brakes, etc. Repair as necessary.

Check for loose or bad connections in field and armature power cables.

If: Connections are loose.

Then tighten.

If: Connection terminals are bad.

Then replace cables.

If: Connections are OK. Then proceed with step 5.

Determine if controller is mounted correctly. Module should sit flush to battery wall with no gap between it and battery wall. Ensure all mounting bolts are tight.

If: Module is not mounted correctly.

Then mount the module correctly and ensure bolts are tight.

If: Module is mounted correctly.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

Traction Controller MRC1 CA404-1 B+

F1

F2

M-

B-

M1 FIELD

KYS

M1 A1

FU2 24V

A2

TRACTION

+

Figure 10986

Crown 2005 PF15175-26

M4.8–6636–425

EVENT CODES

C

Event 44 is HSS Anti-Tiedown. (Standard truck should have the anti-tiedown feature turned off and this event should only appear if feature is turned on.)

Event Code 44

Step 1:

Step 2:

Step 3:

Step 4:

Determine if HSS is being pressed before throttle is requested.

If: Switch is being pressed.

Instruct operator in proper sequence of the truck.

If: Switch is not being pressed before throttle is requested.

Then proceed with step 2.

Determine if HSS switch is tied down.

If: Switch is tied down.

Then remove restraint. Explain to operator the importance of the failsafe condition.

If: Switch is not tied down.

Then proceed with step 3.

Determine if HSS switch is stuck.

If: Switch is stuck.

Then readjust or replace switch.

If: Switch is not stuck.

Then proceed with step 4.

Check harness for short or pinched wires.

If: Wires are damaged.

Then repair or replace harness.

Figure 13067

M4.8–6636–426

Crown 2005 PF15175-27

C

EVENT CODES

Event 45 is HSS closed. An event 45 will not be logged in the model 1404C module memory.

Step 1:

Step 2:

Event Code 45

Determine if the HSS is tied down.

If: Switch is tied down.

Then remove restraint. Explain to operator the importance of the failsafe condition.

If: Switch is are not tied down.

Then proceed with step 2.

Check harness for short or pinched wires going to CA403-6.

If: Wires are damaged.

Then repair or replace harness.

Figure 13067

Crown 2005 PF15175-28

M4.8–6636–427

EVENT CODES

C

Event 46 is Forward (FS) and Reverse (RS) switches simultaneously closed.

Event Code 46

Step 1:

Step 2:

Determine if FS and RS are misadjusted so both are closed simultaneously.

If: Switches are misadjusted.

Then readjust switch. See section M4.5 of the service manual for direction switch adjustment.

If: Switches are not misadjusted.

Then ensure that the switches are in good working order.

If: Switches are worn or damaged Then replace switches.

If: Switches are OK. Then proceed with step 2.

Determine if FS or RS wires are shorted.

If: Wires are shorted to one switch.

Then fix or replace harness.

Figure 13068

M4.8–6636–428

Crown 2005 PF15175-29

C

EVENT CODES

No event code, truck does not function.

Step 1:

Step 2:

Step 3:

Step 4:

Determine if Status LED on controller is blinking.

If: Status LED is blinking at an even rate Then module has power and no events. Proceed with step 4.

If: Status LED is blinking out a 2 digit code when the truck is trying to be run.

Then proceed with the event diagnostics code that is being blinked out.

If: Status LED is not on.

Then check to see if FU2 is good.

If: FU2 is not functional.

Then replace FU2 with known good fuse.

If: Fuse blows again after keying up.

Then check harness for shorts or pinch wires.

If: FU2 is good.

Then proceed with Step 2.

If: Status LED is on continuously and not blinking.

Then rekey truck.

If: LED comes on steady again and is persistent.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

If: LED then comes up at a normal rate.

Then check power terminals and CA404 connector for loose connections.

Check voltage on key input CA404-1 with the battery connected and key switch on, using B- on the controller for the negative reference. Handle should be up.

If: The voltage is greater than 20 volts with handle up.

Then proceed with step 3.

If: The voltage is less than 20 volts.

Then check key switch and wires in between controller and key switch for opens.

If: Wiring or key switch is OK. Then replace battery with known good battery.

If: Wiring or key switch is fault.

Then repair or replace.

Ensure that CA404-1 has a good crimp and that battery terminals are connected OK. If: A problem with crimps or connectors is found.

Then fix the problem.

If: Crimps are good and power cables are OK. Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

Ensure that all inputs and connector are tight and that controller has all the correct settings. See M4 tune up section of the service manual.

CA404-1 KYS

FU2

Traction Controller MRC1 B-

24V +

Figure 10993

Crown 2005 PF15175-30

M4.8–6636–429

EVENT CODES

C

No event code, truck does not travel.

Step 1:

Step 2:

Step 3:

If line contactor closes go to step 2.

If: Line contactor does not close when handle is moved to the operating position.

Then verify BRS switch input at CA404-2 is near battery volts when handle is moved to operating position.

If: BRS switch input voltage is not correct.

Then check wiring from BRS to CA404-2.

Controller supplies 5 volts output for throttle potentiometer. (Pot hi-broken wire will not result in an event code). In the control pod, verify pot hi on potentiometer is receiving this voltage. Reading the voltage between violet wire pot hi and blue pot low wire.

If: Voltage is not nominal 5V. Then check wiring for open or possible shorts.

If: Wiring is OK. Then go to step 3.

Remove CA404-13 wire pot hi from Molex connector. Measure voltage from BNEG reference to controller CA404-13 where wire was removed.

If: Voltage at controller is not nominal 5.5V. Then replace controller.

M4.8–6636–430

Crown 2005 PF15175-31

C

EVENT CODES

No event code, lift engages without raise switch activation.

Step 1:

Step 2:

Step 3:

Step 4:

Look to see if RAS1 or RAS2 switch is stuck by checking voltage at CA404-8 using B- on the controller for the negative reference. Handle should be up.

If: The voltage is less than 20 volts with handle up.

Then proceed with step 2.

If: The voltage is greater than 20 volts.

Then check raise switches to ensure that raise switches are not stuck.

If: Raise switches are stuck.

Then replace or readjust switches.

If: Raise switches are OK. Then check wiring for shorted or pinched wires.

Measure continuity across pump contactor power terminals with battery disconnected.

If: Resistance measured is less than 10 ohms.

Then replace contactor.

If: Resistance measured is greater than 10 ohms.

Then proceed with step 3.

Check the lift contactor coil driver by checking voltage at CA404-18 using B- on the controller for the negative reference. Handle should be up.

If: The voltage is less than 5 volts without a raise input on CA404-8.

Then check wiring for pinched or shorted wires.

If: Wires are shorted or pinched.

Then repair or replace wires.

If: Wires are OK. Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section.

If: The voltage is greater than 5 but less than 20 volts.

Then check wires for short to frame.

If: Wires are shorted to frame.

Then repair or replace harness.

If: Wires are not shorted to frame.

Then proceed with step 4.

If: Voltages are above 20 volts and pump motor continues to run.

Then look for short to frame or miswire.

Check the input to the brake switch. Ensure that wires 2911, 2909, 2910 are not broken going to the brake switch.

If: Wires are broken.

P CA404-18 2910 Then repair or replace harness.

EML 2909 CA404-19 RAS1 Traction If: Wires are OK. Controller Then replace controller with known good.

RAS2 LMS CA404-8 MRC1 Ensure that the controller is programmed for the truck as described in the M4 Tune BRES1 BRES2 CA404-2 2911 Bup section.

BRS KYS

FU2 FU1

P

M2 FIELD

M2

24V

PUMP

+

Figure 10995

Crown 2005 PF15175-32

M4.8–6636–431

EVENT CODES

C

No event code, lift does not engage.

Step 1:

Step 2:

Step 3:

Step 4:

Step 5:

Determine if truck has lift interrupt by determining if it has a Spyglass display. Refer to section M4.6 of service manual for spyglass illustration.

If: Truck has a spyglass, that means it has lift interrupt.

Then proceed with step 2.

If: Truck has no spyglass.

Then proceed with step 7.

Look at the spyglass BDI reading. Determine the BDI reading of the gauge.

If: The BDI is less than 20% state of charge.

Then recharge or replace battery.

If: The BDI is greater than 20% state of charge.

Then proceed with step 3.

Look to see if RAS1 or RAS2 switch is stuck open by checking voltage at CA404-8 using B- on the controller for the negative reference. Handle should be up.

If: The voltage is less than 20 volts with the switches pressed.

Then proceed with step 4.

If: The voltage is greater than 20 volts.

Then proceed with step 5.

Look at the raise switches to ensure that they are being activated.

If: Switches are not being activated.

Then repair or replace switches.

If: Switches are being activated.

Then check to see if horn operates (horn uses same positive feed as the raise switches).

If: Horn operates.

Then check the wires from the raise switch to the controller including the limit switch.

If: The horn does not operate.

Then check the wires from the raise switch back to the FU2 fuse for open or pinched wires. Check FU2 for an open fuse.

Listen for the pump contactor to close contacts.

If: Contactor is not closing.

Then proceed with step 6.

If: Contactor is closing.

Then measure voltage across pump contactor power terminals with battery connected and raise switch engaged.

If: Voltage is greater than 1 volt.

Then replace contactor.

If: Voltage is less than 1 volt.

Then check pump motor for proper voltage across the terminals.

If: Motor has battery voltage going to it.

Then repair or replace motor.

If: Motor does not have voltage going to it.

Then replace FU1 if open and check motor cables for good connections.

M4.8–6636–432

Crown 2005 PF15175-33

C Step 6:

Step 7:

Step 8:

Step 9:

EVENT CODES

Check the lift contactor coil driver by checking voltage at CA404-18 using B- on the controller for the negative reference. Handle should be up.

If: The voltage is less than 5 volts with a raise input on CA404-8.

Then check wiring for open wires on 5901.

If: Wires or connections are open.

Then repair or replace wires.

If: Wires are OK. Then replace the pump contactor.

If: The voltage is greater than 5 volts.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the M4 Tune up section of the service manual.

Check the voltage across the Pump contactor coil.

If: Voltage is greater than 16 volts.

Then proceed with step 8.

If: Voltage is less than 16 volts.

Then proceed with step 9.

Listen for the pump contactor to close contact.

If: Contactor is not closing.

Then repair or replace contactor after ensuring that the connections are tight.

If: Contactor is closing.

Then measure voltage across pump contactor power terminals with battery connected and raise switch engaged.

If: Voltage is greater than 1 volt.

Then replace contactor.

If: Voltage is less than 1 volt.

Then check pump motor for proper voltage across the terminals.

If: Motor has battery voltage going to it.

Then repair or replace motor.

If: Motor does not have voltage going to it.

Then replace FU1 if open and check motor cables for good connections.

Look at the raise switches to ensure that they are being activated.

If: Switches are not being activated.

Then repair or replace switches.

If: Switches are being activated.

Then check to see if horn operates (horn uses same positive feed as the raise switches).

If: Horn operates.

Then check the wires from the raise HNS1 switch to the controller including the limit HN1 HNS2 switch. Also check the negative wire for HNS3 the pump.

If: The horn does not operate.

5901 P CA404-18 Then check the wires from the raise Traction switch back to the FU2 fuse for open or RAS1 Controller pinched wires. Check FU2 for an open RAS2 MRC1 LMS CA404-8 fuse.

B-

P

M2 FIELD

FU1 KYS

FU2

M2 PUMP 24V

+

Figure 10996

Crown 2005 PF15175-34

M4.8–6636–433

C

EVENT CODES No event code, BDI (battery discharge indicator) does not reset.

Step 1:

Step 2:

Step 3:

Determine if control parameters are set to the right values under the Program menu using 1311 programmer. RESET VOLTS sets the reset value for the battery (voltage = RESET VOLTS multiplied by 0.12). It should be defaulted to 205 (205 multiplied by 0.12 = 24.6 volts). Check voltage of battery with battery disconnected.

If: The voltage is less than RESET VOLTS multiplied by 0.12 volts.

Then battery is not fully charged. Place battery back onto charger and set for a full charge.

If: Battery does not read full voltage after being on charger.

Then check condition of battery or charger.

If: The voltage is greater then RESET VOLTS multiplied by 0.12.

Then proceed with step 2.

Measure the voltage drop of the key switch input CA404-1 from the battery by placing the positive lead of the volt meter onto the input of FU2 and the negative lead into CA404-1 with the module plugged in and key on. (CA404-1 is the input for voltage for the BDI measurements, as well as the module KYS input).

If: The voltage drop is greater than 0.2 volts.

Then proceed with step 3.

If: The voltage drop is less than 0.2 volts.

Then try a different fully charged battery and rekey.

If: The BDI then resets.

Then check condition of the original battery.

If: The BDI does not reset.

Then replace controller with known good. Ensure that the controller is programmed for the truck as described in the Tune-up section M4.2 of the service manual.

Measure the voltage drop of the KYS and FU2 fuse.

If: Either has a drop over 0.2 volts.

Then replace that component.

If: Neither has a drop of 0.2 volts.

Then check the wiring for a bad crimp or a shorted or pinched wire.

CA404-1 KYS

FU2

Traction Controller MRC1 B-

24V +

Figure 10993

M4.8–6636–434

Crown 2005 PF15175-35

C

BRAKES "T" HANDLE The brake system used on your Rider pallet truck consists of a traction motor mounted brake which is activated by pulling on the brake lever or by setting the parking brake. Refer to Figure 5401-01.

Parking Brake Lever

Brake Lever

Brake Switch

Brake & Parking Brake Released

Brake & Parking Brake Applied Figure 5401-01

The brake will be activated when the operator pulls the brake lever.

The mechanical brake is internal expanding type with drum and bonded brake linings. A brake switch is incorporated to cut-off power to the control circuit preventing drive motor 051206

M5.0–6636–001 01 Rev. 2/06

overload during braking. When the brake lever is pulled the linkage forces the brake shoes against the drum. The brake lever is spring loaded and will return to released position when the operator releases it. Releasing the brake will permit forward or reverse travel.

13117 Crown 2005 PF15170-1 Rev. 2/06

C

BRAKES

Parking Brake

Brake Lining Replacement

To actuate the parking brake raise the parking brake lever to up right position as shown in Figure 5401-01. The parking brake should be actuated when truck is unattended, with or without a load, or is parked on an incline. The parking brake is spring actuated and does not require adjustment.

Raise the rear of the truck until the drive wheel is off the floor.

Place hardwood blocks under power unit frame and lower truck onto blocks. Be sure drive tire does not contact floor in this position. Remove two screws securing the power unit doors together and open doors to a position that will not obstruct the work to be performed.

Brake Handle Chain Adjustment Release brakes and refer to Figure 5402-01. Check distance between stop and brake arm. It should be .8±.5 mm (.031±.020 in.). If the measurement does not fall within the .3/1.3 mm (.011/.051 in.) range then remove the screw and nut that holds the block to the brake arm. Rotate the block on the adjustment rod until the .8±.5 mm (.031±.020 in.) spacing is obtained. Reassemble the block to the brake arm using the screw and nut and recheck the measurement.

Refer to Figure 2299. and remove the three screws and lockwashers (1) located in the center of the brake drum.

Make sure brakes are released and remove the brake drum (2). Inspect the condition of the drum, especially for groves on the inside of the drum caused by worn linings.

Brake Arm

Adjustment Rod Block

Traction Motor

Figure 2299

Screw & Nut

Remove the two springs (12) connecting the brake shoes (10).

Stop

Replace linings and attach springs.

NOTE Position the brake springs so that the long hooks are not connected to the same shoe.

Figure 5402-01

Install brake drum and tighten fastening screws.

Torque these screws 11-14 Nm (8-10 ft. lb.).

Crown 2005 PF15170-2

M5.0–6636–002

C

BRAKES Brake Shoe Adjustment Before adjusting shoes, be sure shoes/drums aren’t worn excessively and require replacement. To adjust: • Disconnect battery, block power unit off floor and release brakes by placing the control handle in the travel position.

• Refer to Figure 5403-01. Loosen nuts securing collar to tie rod.

Periodic adjustment of the brake lever may be required if the collar/nuts are near the end of the tie rod and have reached maximum adjustment. Increasing the angle of the brake lever will permit additional shoe adjustment.

• To adjust brake lever, remove retaining clip securing brake lever to the cam shaft. Remove lever and rotate so when lever is assembled to shaft, lever has moved one notch/spline. Assemble lever and secure with retaining clip.

• Adjust collar so shoes merely contact drum then back-off slightly. Shoes should be close to drum, but not touching when brake is released. Tighten nuts to secure collar.

• Place control handle in the braking position, connect battery and check brake operation. The brake shoes should contact the drum after the brake switch has been actuated. Adjust collar to compensate for shoe wear during normal truck operation.

Jam Nuts

Tie Rod

Collar Brake Lever

Figure 5403-01

M5.0–6636–003

Crown 2005 PF15170-3

C

BRAKES

Brake Lever Adjustment

Brake Switch Adjustment

Refer to Figure 5404-01. The brake lever should travel 5 mm (.25 in.) but not more than 10 mm (.50 in.) from the brake released to the brake applied position. Adjust the collar on the tie rod, that connects to the brake plate lever, as described in Brake Shoe Adjustment.

Refer to Figure 5405-01. Adjust the switch actuating screw in brake arm to have .8 to 1.6 mm (.031 in. to .062 in.) over travel after switch actuation to reduce possible switch damage. Tighten jam nuts to secure setting.

Brake Released 5 mm (.25 in.)

Not More Than 10 mm (.50 in.)

Brake Applied

Brake Arm Jam Nuts Brake Switch Actuator Brake Switch

Figure 5405-01

Jam Nuts

Tie Rod

Collar Brake Lever

Figure 5404-01

Crown 2005 PF15170-4

M5.0–6636–004

C

BRAKES General Notes

Stopping Distance Procedure

The brake system is adjusted at the factory to provide optimal braking performance for smooth dry concrete floors and standard tire conditions. Upon installation, the brake adjustment should be checked by following the stopping distance procedure. It may be necessary to modify the factory setting to properly accommodate the particular floor conditions. When a vehicle is being operated over a variety of floor conditions it may be impractical to adjust the brake to perform optimally for all of the different floor conditions.

Check stopping distance with the truck empty on a level surface typical for the application. Travel at maximum acceleration for 15 M (50 feet) in the power unit first direction.

Apply the brakes and measure the stopping distance.

TYPICAL STOPPING DISTANCE MODEL

METERS

FEET

PC 3600

1.2

4

TR 3600

2.13

7

• Increasing caster loading reduces load on the drive tire and therefore reduces braking effectiveness and traction.

• Reducing caster loading reduces stability. Drive tire wear or replacement as well as floor conditions will effect operating characteristics of the truck, mainly: • Braking/Traction • Stability/Handling • Steer Effort Floor conditions in set up area should be consistent generally with floor conditions in the overall facility.

Periodic caster adjustments may be required to maintain proper balance of these characteristics and proper operation.

M5.0–6636–005 01 Rev. 2/06

Crown 2005 PF15170-5 Rev. 2/06

C

BRAKES

Parking Brake Compression Spring Replacement Refer to Figure 5394. Open power unit doors. Remove screw and nut (54) holding block (58) to brake arm (48).

Unscrew block from adjustment rod (59) noting the approximate number of turns required to remove. Take cover (32) off and unplug wire harness. Remove cover (28) from control pod (1). Disconnect parking brake handle (2) from Bracket (7) by removing set screw and pin (8). Remove control pod (1) by removing two nuts (16). Remove two handle cams by removing roll pins (24), remove brake levers (13) noting position of springs (23) and bearings (17). Remove lever plate (18) and roll pin (21). Replace springs (19 & 20) in lever plate. Compress springs and replace roll pin (21). Put lever

plate back into control pod. Install brake levers making sure bearings (17) are all in place. Install handle cams (22), springs (23), and bearings (25) using two roll pins (24).

Attach bracket (7) to parking brake handle (2) using pin and set screw (8). Feed chain (27) and adjustment rod (59) through control handle (30). Reattach control pod using two washers & nuts (16). Reconnect harness at plug. Put block (58) back on adjustment rod and connect to brake arm (48) with screw and nut (54). Make chain adjustment as described in Brake Handle Chain Adjustment paragraph. Check handle and brake operation and replace all covers.

Figure 5394 Crown 2005 PF15170-6

M5.0–6636–006

C

BRAKES BRAKE INSTALLATION The lever arm must be properly positioned before installing new brake assembly, shoes and/or drums. To position: Remove the retaining clip securing the lever arm to the cam shaft and remove lever arm. Refer to Figure 6213 for proper mounting holes and align brake assembly on housing.

Replace lever arm and position arm as shown. Install retaining clip to secure lever arm to cam shaft.

After the shoes have worn, the angle of the lever arm may have to be increased. For more information, refer to Brake Shoe Adjustment.

12 Degrees Lever Alignment Hole

Mounting Holes

Figure 6213

M5.0–6636–007

Crown 2005 PF15170-7

C

BRAKES STANDARD HANDLE

The brake system used on your pallet truck consists of a traction motor mounted brake which is activated by raising it to the vertical position thru the horizontal position. Refer to Figure 13209.

The mechanical brake is internal expanding type brake with drum and bonded brake linings. The brake is mechanically released and spring applied. A brake switch is incorporated to cut-off power to the control circuit preventing drive motor overload during braking. The brake is applied when the control handle is in the vertical (up) position thru the horizon-

tal (down) position. The area of control handle travel beyond the vertical (up) position is referred to as the operating (travel) range of the handle. Refer to Figure 13209.

In the vertical position the cam will allow the spring to apply the brake by forcing the brake shoes against the drum.

Moving the control handle into the operating range rotates the cam and will mechanically release the brake and allow forward or reverse travel. The brake remains released until the handle is in the braking position and the cam allows the spring to apply the brake. Refer to Figure 13210.

Brake Applied

Brake Released

Figure 13209

Brake Applied

Brake Released Figure 13210

Crown 2005 PF15170-8

M5.0–6636–008

C

BRAKES Parking Brake To engage parking brake, move the brake lever toward the steering arm. To disengage the parking brake, move the brake lever away from the steering arm. Refer to Figure 2564-01. The parking brake should be engaged when truck is unattended, with or without a load or is parked on an incline.

Brake Engaged (Lever Toward Steering Arm)

Brake Disengaged (Lever Away from Steering Arm)

Traction Motor

Figure 2564-01 Figure 2299

Brake Lining Replacement Raise the rear of the truck until the drive wheel is off the floor.

Place hardwood blocks under power unit frame and lower truck onto blocks. Be sure drive tire does not contact the floor in this position. Remove the two screws securing the power unit doors together and open doors to a position that will not obstruct the work to be performed.

Remove the three screws and lockwashers (item 1) located in the center of the brake drum. Refer to Figure 2299.

Release brakes and remove the brake drum (item 2). Inspect the condition of the drum, especially for grooves on the inside of the drum caused by worn linings.

M5.0–6636–009

Remove the two springs (item 12) connecting the brake shoes (item 10).

Place new linings in position and attach springs.

NOTE Position the brake springs so that the long hooks are not connected to the same shoe.

Install brake drum and tighten fastening screws. These screws are to be torqued to 11 - 14 Nm (8 - 10 ft. lb.).

Crown 2005 PF15170-9

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BRAKES

Brake Shoe Adjustment

Brake Switch Adjustment

Before adjusting shoes, be sure shoes/drums aren’t worn excessively and require replacement. To adjust:

Adjust the screw which actuates the brake switch to a length that will actuate the switch at a point when the horizontal center line of the twist grips is 1125 mm (44.35 in.) at walking position approximately, from the floor.

• Disconnect battery, block power unit off floor and release brakes by placing the control handle in the travel position.

• Refer to Figure 2584-01. Loosen nuts securing collar to tie rod.

• Adjust collar so shoes merely contact drum then back-off slightly. Shoes should be close to drum, but not touching when brake is released. Tighten nuts to secure collar.

• Place control handle in the braking position, connect battery and check brake operation. The brake shoes should contact the drum after the brake switch has been actuated. Readjust the collar to compensate for shoe wear during normal truck operation.

Periodic adjustment of the brake lever may be required if the collar/nuts are near the end of the tie rod and have reached maximum adjustment. Increasing the angle of the brake lever will permit additional shoe adjustment.

• To adjust brake lever, remove retaining clip securing brake lever to the cam shaft. Remove lever and rotate so when lever is assembled to shaft, lever has moved one notch/spline. Assemble lever and secure with retaining clip.

Brake Switch Actuator Jam Nut

Brake Switch

Brake Arm

Collar

Tie Rod Bolt Brake Lever

Tighten the jam nut to lock the position of the switch actuator.

General Notes The brake system is adjusted at the factory to provide optimal braking performance for smooth dry concrete floors and standard tire conditions. Upon installation, the brake adjustment should be checked by following the stopping distance procedure. It may be necessary to modify the factory setting to properly accommodate the particular floor conditions. When a vehicle is being operated over a variety of floor conditions it may be impractical to adjust the brake to perform optimally for all of the different floor conditions.

• Increasing caster loading reduces load on the drive tire and therefore reduces braking effectiveness and traction.

• Reducing caster loading reduces stability.

Drive tire wear or replacement as well as floor conditions will effect operating characteristics of the truck, mainly: • Braking/Traction • Stability/Handling • Steer Effort Floor conditions in set up area should be consistent generally with floor conditions in the overall facility.

Periodic caster adjustments may be required to maintain proper balance of these characteristics and proper operation.

Rotate Clockwise

Figure 2584-01

Crown 2005 PF15170-10

M5.0–6636–010

C

BRAKES Stopping Distance Procedure Check stopping distance with the truck empty, on a level surface typical for the application. Travel at maximum acceleration for 15 m (50 feet) in the power unit first direction.

Apply the brakes and measure the stopping distance. Approximate stopping distances for smooth, dry concrete are as listed. Refer to the Stopping Distance Chart for required stopping distance. Adjust the distance by lengthening the spring overall length to increase the stopping distance or by shortening the spring overall length to decrease the stopping distance.

TYPICAL STOPPING DISTANCE MODEL

METERS

FEET

PC 3600

1.2

4

TR 3600

2.13

7

Torsion Spring Replacement Three torsion springs located at the pivot point of the control handle keep the control handle in the vertical position when not in use. A brake cam and spacer are also located in this

area that allow for proper brake operation and the routing of necessary electrical wires.

The following procedure should be used when replacing a broken spring: Remove either end cap. Release spring tension and remove the other end cap. The pivot shaft can now be removed. Use a brass rod and mallet to remove shaft. Note spacer, spring and cam position for assembly purposes. The spacer is used to allow a path for electrical wiring to be routed from control pod to contactor panel. The cam, located to the side of the handle above the brake switch area must be secured properly to the control handle with roll pins. Any parts not properly installed will not effectively keep the handle in the vertical position when not in use.

Position spring, spacer, spring, spring as shown in Figure 2591. Install pivot shaft. Install roll pins to end of shaft. Install end cap. Spring tension will be applied in order to secure end cap to knuckle. Secure other end cap. Handle should move smoothly from vertical to horizontal. Be sure brake cam is actuating brake switch properly. Make sure electrical wires are routed over spacer properly. Any abnormal handle functions must be corrected to insure proper truck operation.

NOTE

End Cap

Torsion Springs Brake Cam

Spacer

Pivot Shaft Cam Roller Jam Nut

All torsion springs should be completely greased to eliminate friction. 45° of shaft rotation is needed to install end cap, which in turn puts upward spring tension on handle.

Roller Arm Pivot Shaft

Roller Arm Ass'y.

Brake Switch Actuator

Brake Switch Tie Rod Bolt Collar

Brake Lever

Figure 2591

M5.0–6636–011 01 Rev. 2/06

Crown 2005 PF15170-11 Rev. 2/06

C

BRAKES

BRAKE INSTALLATION The lever arm must be properly positioned before installing new brake assembly, shoes and/or drums. To position: Remove the retaining clip securing the lever arm to the cam shaft and remove lever arm. Refer to Figure 6213 for proper mounting holes and align brake assembly on housing.

Replace lever arm and position arm as shown. Install retaining clip to secure lever arm to cam shaft.

After the shoes have worn, the angle of the lever arm may have to be increased. For more information, refer to Brake Shoe Adjustment.

12 Degrees Lever Alignment Hole

Mounting Holes

Figure 6213

Crown 2005 PF15170-12

M5.0–6636–012

FORK MAINTENANCE FORKS - 9 in. & 10 in. (230mm & 255mm) FORK INSPECTION Forks Lowered: • With the battery in the truck, the fork heel height should measure 3.62 to 3.75 in. (90 to 95 mm) for forks 60 in.

(1525 mm) and shorter, 3.75 to 3.88 in. (95 to 100 mm) for forks longer than 60 in. (1525 mm).

• The fork tip height at the load wheel centerline should not exceed 3.38 in. (85 mm).

3.38 in.

(85mm)

• The risers must contact one stop each.

Forks Raised: • The fork height, measured at the load wheel cut out, should be 9.12 in. (230 mm) minimum.

9.12 in. (230mm) MINIMUM

3.62 in. to 3.75 in. (90 to 95mm) for 60in. (1525mm) or Shorter Forks 3.75 in. to 3.88 in. (95 to 100mm) for Forks Longer Than 60in. (1525mm) ILLUSTRATION 1

2320

STOP BLOCKS

LIFT LINKAGE ADJUSTMENT Tension Bar Length and Cylinder Adjustment

FORWARD NUT

After completely lowering the forks (the cylinder should be bottomed out), loosen the four nuts on each tension bar end.

The riser should be completely lowered so that it contacts the stop blocks in the fork tip.

With the battery in place, adjust the lift cylinder length so the fork heel height measures: • 3.62 to 3.75 in. (90 to 95 mm) for 60 in. (1525 mm) and shorter.

JAM NUTS TENSION BAR

• 3.75 to 3.88 in. (95 to 100 mm) for forks longer than 60 in.

(1525 mm).

2351

931206

ILLUSTRATION 2

6268

Crown 1993 PF9963-1 Rev. 11/99

Printed in U.S.A.

02 REV. 11/99

M7.0–6435–001

M7.0–6435–001

FORK MAINTENANCE The cylinder length is adjusted by loosening the jam nut on top of the fork cross bar and turning the hex head on top of the rod end. Rotating the hex clockwise one revolution increases the fork heel height approximately 0.125 in. (3 mm) and one revolution counter-clockwise lowers the heel height approximately 0.125 in. (3 mm). Refer to Illustration 3.

TENSION BAR Refer to Illustration 5 for proper assembled length of the threaded rod located on end of tension bar. Apply anti-seize compound (065005-003) to threads at installation.

CAUTION

Align the rod end pin parallel to the fork cross bar.

This will prevent damage to the rod end if the power unit is separated from the fork assembly for maintenance.

5.12 in. (130mm) FOR: 6.62 in. (170mm) BATTERY COMPARTMENT 7.88 in. ( 200mm) BATTERY COMPARTMENT

Tighten the jam nut on top of the cross bar.

Apply thread locking adhesive to the tension bar threaded rod and tighten the forward nut just until the riser begins to leave the stop blocks. Tighten the back nut and then tighten remaining nuts.

CYLINDER ROD HEX

5.62 in. (140mm) FOR: 13.12 in. (330mm) BATTERY COMPARTMENT

JAM NUT 2366

FORK CROSS BAR

ROD END

2322

ILLUSTRATION 5

JAM NUTS When assembling jam nuts to the tension bars, position the jam nut between the standard hex nut and riser. This will allow the standard hex nut to carry the load rather than the jam nut.

ROD END PIN

ILLUSTRATION 3

BELLEVILLE WASHER

RISER INBOARD WASHER

The belleville washer should be up, as shown in illustration 4 for correct installation.

CYLINDER ROD END BELLEVILLE WASHER

INBOARD WASHER

JAM NUT

STANDARD HEX NUT

FORK TIP

TENSION BAR END

LIFT CYLINDER

FORK CROSS BAR 2353

2605

JAM NUT

ILLUSTRATION 6

ILLUSTRATION 4

Crown 1993 PF9963-2 Rev. 11/99

Printed in U.S.A.

02 REV. 11/99

M7.0–6435–002

M7.0–6435–002

FORK MAINTENANCE Riser Assembly

Bushing Installation When new bushings are pressed into inboard/outboard link assemblies, risers, tension bar ends, tension bars and link assemblies, the position of the hole in the bushing must be aligned per the following illustrations. This is important to insure that bushing/shaft is properly greased. If bushing holes are not positioned as shown, the entire bushing/shaft will not receive grease and will cause premature wear.

Check alignment of holes by greasing before assembling.

Refer to the following illustrations 7 thru 10.

Lubrication Fitting Hole

Lubrication Hole In Bushing 2608

Lubrication Fitting Hole

Link Assembly

ILLUSTRATION 9 Lubrication Fitting Hole

Lubrication Hole In Bushing

Lubrication Hole In Bushing End Tension Bar Assembly 2609 2606

ILLUSTRATION 10

ILLUSTRATION 7

Inboard / Outboard Link Assembly

Lubrication Hole In Bushing

Lubrication Fitting Hole

2607

ILLUSTRATION 8

Crown 1993 PF9963-3 Rev. 11/99

Printed in U.S.A.

02 REV. 11/99

M7.0–6435–003

M7.0–6435–003

FORK MAINTENANCE ASSEMBLY: Inboard Link Bend Tabs Up On The Flat Side Of Hex Head Screw

Part Of Fork

0

The flatwashers shown in Illustration 12 keep the linkage components from rubbing together. The position of these flatwashers depends on fork spread.

Apply Thread Locking Adhesive

32 ft. lbs.

(43Nm)

When mounting pivot shaft to inboard link using screw and retainer clip, apply threadlocking adhesive to screw. Torque screw to 32 ft. lbs. (43Nm) and turn until screw head flats align with the retainer clip wings. Bend retainer clip wings up against screw head flats. Refer to Illustration 11.

Clip Tension Bar

NOTE

Part Of Power Unit

Retainer clips are only to be used once. It is recommended that they be replaced every time they are removed from the truck.

Clip Part Of Fork

‡Flatwasher

‡Position Of Flatwasher Depends Upon Fork Spread

7740

ILLUSTRATION 11

Flatwashers

Flatwashers

28 in.(711mm) 27 in.(685mm) 26 in.(660mm)

Flatwashers

Flatwashers

25 in.(635mm) 24 in.(610mm) 23 in.(584mm)

Flatwashers

7742S

Flatwashers ILLUSTRATION 12

Crown 1993 PF9963-4 Rev. 11/99

Printed in U.S.A.

02 REV. 11/99

M7.0–6435–004

M7.0–6435–004

CYLINDERS Cylinder

1. Raise truck & block truck under battery compartment and between riser assemblies and fork tips using approximately 100 x 100 mm (4 x 4 in) blocks and lower truck onto blocks. Turn key switch off and disconnect battery.

Great care and cleanliness should be exercised in the disassembly and assembly of any hydraulic cylinder.

Wipe all surfaces clean of dirt and oil before attempting disassembly. Care should be taken when removing the ram as nicks will damage the packings. After the cylinder components are disassembled and seals, O-rings and wipers are removed, thoroughly wash all metallic parts in solvent and blow dry with compressed air.

Carefully inspect the ram assembly and cylinder bore.

Replace if scored, grooved, pitted or worn. Minor damage to the cylinder bore can be removed with the use of a cylinder honing tool. Place washed components in a clean container until reassembly. Whenever new packings are required, new wiper rings should also be installed.

5. Remove roll pin and pivot shaft noting that there is one spacer on each side between the rod end and the cylinder ram.

Removal

6. Remove the four cylinder mounting screws and tilt the lift cylinder into the battery compartment.

2. Loosen and rotate large jam nut to top of threads on rod end. Do not remove jam nut from rod end.

3. Rotate rod end clockwise into lift structure until jam nut contacts belleville washer.

4. Connect battery, turn key switch on and lower truck back onto blocks. Turn key switch off, disconnnect and remove battery from truck.

7. Remove hydraulic line from bottom of lift cylinder and attempt to catch any hydraulic oil that may escape. Remove the cylinder and mounting blocks from the truck.

Refer to Figure 16730 and 16731.

CAUTION Be sure all hydraulic pressure is removed from lift cylinder before performing any maintenance on hydraulic system.

1

Rod End

2

Lift Structure

3

Cylinder

4

Cylinder Fitting

5

Hydraulic Hose

6

Bolt

7

Mounting Block

NOTE Fork height adjustment should be checked after cylinder installation. See Forks for adjustment.

CAUTION When reassembling lift cylinder to truck, align the rod end pivot shaft parallel to the fork cross bar. This will prevent damage to the rod end if the power unit is seperated from the fork assembly for maintenance.

1

Locknut

2

Cylinder Rod End

3

Belleville Washer

4

Pivot Shaft

5

Ram

6

Lift Structure

7

Ram must be lowered to access Pivot Shaft. See steps 2 & 3.

Figure 16730 Figure 16731

Crown 1993 PF9945-1 Rev. 7/07

M8.0-6435-001 02 Rev. 7/07

CYLINDERS Disassembly

burrs, dirt or seal debris must be removed before installing new seals.

To disassemble the cylinder, use spanner wrench or an adjustable wrench, depending on cap, and simply turn the cap counterclockwise and unscrew it from the cylinder tube. Remove the cap and carefully extract the ram assembly from the cylinder bore, never allowing the ram to come in contact with any sharp edges.

CAUTION Never use a screwdriver to remove seals, as damage and leakage may result.

Figure 16733 1

Cylinder

2

Spanner Wrench

3

Cap

4

Flats

5

Ram

CAUTION Close inspection of seal seating critical areas should be made before the new seal is installed (See Figure 16734). Your seal failure may not have been caused by a worn seal, but rather, by burrs, nicks and dirt located on the seal seating area, causing the seal to deform and lose its sealing ability.

Figure 16732

Hydraulic Seals The seals used in the cylinder are made from an extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

Seal Removal When an excessive amount of hydraulic oil is evident around the area where the ram exits from the cap, the rod seal is probably damaged and should be replaced.

The cylinder must be removed from the truck to perform seal replacement. Unfasten and remove the cap as explained in Disassembly. The rod seal is seated inside the cap so a hooked tool should be used to remove the seal (Refer to Figure 16733). At this time the rod wiper ring should also be removed since the rod seal and the wiper should always be replaced in pairs.

Thoroughly clean the area where the seal seats. Any

1

Critical Seal Seating Area

2

Pusher Rod

3

Groove Alignment Plug

Figure 16734

M8.0-6435-002 02 Rev. 7/07

Crown 1993 PF9945-2 Rev. 7/07

CYLINDERS Seal Installation Tools used to install hydraulic seals should be of soft metal or suitable plastic, free of burrs and sharp edges.

Screwdrivers and other similar tools should not be used as they may damage the sealing edges.

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

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

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.

1

Pin 1

2

Pin 2

3

Pin 3

Figure 16736

Rod U-Cup Installation

– Withdraw pin 3 so that U-cup loop snaps into installation groove (Figure 16737).

1. Installation Tool An installation tool made of any soft metal or hard plastic machined smooth and free of burrs with a fixed steel pin (PIN 1) and two movable pins (PINS 2 & 3) is required for this installation method. See Figure 16735.)

1

Tool Body

2

Pin 1

3

Pin 2

4

Pin 3

1

Pin 1

2

Pin 2

3

Pin 3

Figure 16737

– Withdraw pin 2 and U-cup will completely snap into installation groove (Figure 16738).

Figure 16735

2. Installation Procedure – Slip U-cup over the fixed pin (See Figure 16735, Pin 1) and bend it over pin 2 as shown.

– Continue bending U-cup until pin 3 can be pushed through the U-cup loop which locks U-cup in position.

– Insert installation tool with mounted U-cup into cylinder bore until aligned with U-cup installation groove (See Figure 16736).

Crown 1993 PF9945-3 Rev. 7/07

1

Pin 1

2

Pin 2

3

Pin 3 Figure 16738

–

Withdraw installation tool.

M8.0-6435-003 02 Rev. 7/07

CYLINDERS Cylinder Assembly After packings and seal are in place and the ram has been installed, reattach the cap.

CAUTION Care should be taken when inserting the cylinder cap, to prevent threads and sharp edges from damaging new seals and packings.

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

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

M8.0-6435-004 02 Rev. 7/07

Crown 1993 PF9945-4 Rev. 7/07

C

GLOSSARY Components have been listed in chart form to assist the service technician in locating these components on the Electrical Diagrams and Parts Breakdown forms.

The chart is in columns: COMPONENT; LOCATION; FUNCTION; DIAGRAM; PARTS BREAKDOWN. The COMPONENT column contains the abbreviation of the component as it appears on the Diagrams in the Maintenance Section.

The LOCATION column gives the general location on the truck such as on platform or in power unit. The FUNCTION

column then explains the function or circuit of that device.

The DIAGRAM column gives the page number of the diagram on which the component can be found. The callout in parenthesis following the page number corresponds to the grid callouts on that diagram, locating that component. The PARTS BREAKDOWN column includes the parts breakdown page number on which the component is located along with the index number, in parenthesis, if applicable.

AUDIBLE INDICATORS Location

Function

Diagram

Parts Breakdown

ALM1

Power Unit

Stall Alarm

04.0–6636–001(17)

ALM2

Power Unit

Travel Alarm

HN1

Power Unit

Truck Horn

DIA–6636–004 (B-4) DIA–6636–005 (B-4) DIA–6636–002 (C-1) DIA–6636–003 (C-1) DIA–6636–007 (C-4) DIA–6636–008 (C-4) DIA–6636–002 (B-1) DIA–6636–003 (B-1) DIA–6636–007 (C-3) DIA–6636–008 (C-3)

Location

Function

Diagram

Parts Breakdown

Lift Structure

Truck Power

DIA–6636–002 (B-4) DIA–6636–003 (B-4) DIA–6636–004 (C-3) DIA–6636–005 (C-3) DIA–6636–009 (A-1, C-1)

07.7–6435–003(1)

CONNECTORS Location

Function

Diagram

Parts Breakdown

CA401

Console

Display

CA402 CA403 CA404

Handle Power Unit Power Unit

CA405

Power Unit

04.8–6540–001(12)

04.0–6636–001(19)

BATTERY

Battery

051206

M10–6636–001

DIA–6636–007 (C-1) DIA–6636–008 (B-1) Display to Main Harness DIA–6636–006 (A-1) Load Backrest to Main Harness DIA–6636–006 (A-4) Traction Controller DIA–6636–002 (B-3, C-3) DIA–6636–003 (B-3, C-3) DIA–6636–004 (B-1) DIA–6636–005 (B-1) Traction Controller DIA–6636–004 (B-2) DIA–6636–005 (B-2)

11877 Crown 2005 PF15126-1

C

GLOSSARY

CONNECTORS (Continued) Location

Function

Diagram

CA407

Battery Restraints

Battery Restraint Switches

DIA–6636–004 (B-3) DIA–6636–005 (B-3)

CA408 CA409

Power Unit Power Unit

ACC Stall Alarm

CA601 CA602

Control Pod Control Pod

CA604

Control Pod

ACCEL FS, RS, RES1, RES2, RAS1, LOS1, HNS1, HNS2 RAS2, HNS2, LOS2, RES3, RES4, RES5

Parts Breakdown

DIA–6636–004 (B-4) DIA–6636–005 (B-4) DIA–6636–006 (B-1) DIA–6636–006 (B-2) DIA–6636–006 (B-4)

CONTACTORS Location

Function

Diagram

Parts Breakdown

L

Power Unit

Line

04.0–6636–001(23) 04.4–6540–001

P

Pump Motor

Pump

DIA–6636–002 (B-2, B-4) DIA–6636–003 (B-2, B-4) DIA–6636–004 (B-3) DIA–6636–005 (B-3) DIA–6636–009 (B-2) DIA–6636–002 (B-2, B-4) DIA–6636–003 (B-2, B-4) DIA–6636–004 (B-3) DIA–6636–005 (B-3) DIA–6636–007 (C-2) DIA–6636–008 (C-2) DIA–6636–009 (A-1)

02.1–6540–001 (29) 02.0–6540–001 (6)

Location

Function

Diagram

Parts Breakdown

FU1

Power Unit R.H. Side

Traction

04.0–6636–003 (42)

FU2

Power Unit R.H. Side

Control

FU3

Power Unit R.H. Side

Options

DIA–6636–002 (A-4) DIA–6636–003 (A-4) DIA–6636–004 (B-3, C-4) DIA–6636–005 (B-3, C-4) DIA–6636–009 (C-2) DIA–6636–002 (A-4) DIA–6636–003 (A-4) DIA–6636–004 (B-3, C-4) DIA–6636–005 (B-3, C-4) DIA–6636–002 (A-4) DIA–6636–003 (A-4) DIA–6636–004 (B-3, C-4) DIA–6636–005 (B-3, C-4)

Fuses

Crown 2005 PF15126-2

04.0–6636–003 (31)

04.0–6636–003 (32)

M10–6636–002

C

GLOSSARY METERS Location

Function

Diagram

Parts Breakdown

DISP

Console

Display (BDI)

04.8–6540–001 (8)

TT1

Console

Register Operating Time

TT2

Console

Register Internal Operating Time

DIA–6636–002 (C-2) DIA–6636–007 (C-1) DIA–6636–003 (C-1) DIA–6636–008 (C-1) DIA–6636–002 (C-2) DIA–6636–003 (C-1) DIA–6636–007 (C-1) DIA–6636–008 (C-1)

Location

Function

Diagram

Parts Breakdown

M1

Drive Unit

Traction

03.1–6540–003

M2

Power Unit L.H. Side

Lift

DIA–6636–002 (B-4) DIA–6636–003 (B-3) DIA–6636–004 (B-3) DIA–6636–005 (B-3) DIA–6636–009 (A-3) DIA–6636–002 (B-4) DIA–6636–003 (B-4) DIA–6636–004 (C-3) DIA–6636–005 (C-3) DIA–6636–009 (A-2)

04.8–6540–001 (8) 04.8–6540–001 (11)

MOTORS

02.0–6540–001 (3) 02.1–6540–001

MOTORS CONTROLLERS Location

Function

Diagram

Parts Breakdown

MRC1

Traction Controls & Display

DIA–6636–002 (B-2) DIA–6636–003 (B-2) DIA–6636–004 (C-1) DIA–6636–005 (C-1)

04.0–6636–001 (34)

POTENTIOMETERS Location

Function

Diagram

Parts Breakdown

ACCEL POT1 Control Pod

Traction Accelerator

DIA–6636–002 (C-3) DIA–6636–003 (C-3) DIA–6636–006 (C-1)

04.6–6636–001 (29) 04.6–6636–100 (29) 04.6–6636–200 (30) 04.6–6636–250 (30)

Power Unit R.H. Side

M10–6636–003

Crown 2005 PF15126-3

C

GLOSSARY

RESISTORS Location

Function

Diagram

Parts Breakdown

RES1

Control Pod

Freezer Condition

DIA–6636–006 (C-2)

RES2

Control Pod

Freezer Condition

DIA–6636–006 (C-2)

RES3 RES4 RES5

Load Backrest Load Backrest Load Backrest

Freezer Condition Freezer Condition Freezer Condition

DIA–6636–006 (C-3) DIA–6636–006 (C-4) DIA–6636–006 (C-4)

04.6–6636–102 (53) 04.6–6636–252 (55) 04.6–6636–102 (53) 04.6–6636–252 (55) 07.9–6636–003 (31) 07.9–6636–003 (31) 07.9–6636–003 (31)

SOLENOID VALVES Location

Function

Diagram

Parts Breakdown

SV1

Lower

DIA–6636–002 (B-1) DIA–6636–003 (B-1) DIA–6636–007 (C-3) DIA–6636–008 (C-3)

02.1–6540–001 (11)

Diagram

Parts Breakdown

Pump

SUPPRESSORS/DIODE BLOCKS Location Function CR1

Power Unit

Polarity

DIA–6636–002 (B-3) DIA–6636–003 (B-3) DIA–6636–004 (C-3) DIA–6636–005 (C-3) DIA–6636–002 (C-1) DIA–6636–003 (C-1) DIA–6636–007 (C-4) DIA–6636–008 (C-3) DIA–6636–007 (C-3) DIA–6636–008 (C-3)

DB1

Console

Alarm2

FIL1

Power Unit R.H. Side

HN1

Location

Function

Diagram

Parts Breakdown

BRES1

Battery Comp.

R.H. Side

Battery Restraint

07.7–6435–104 (6)

BRES2

Battery Comp.

L.H. Side

Battery Restraint

BRS

Knuckle Support

Brake

DIA–6636–002 (B-3) DIA–6636–003 (B-3) DIA–6636–004 (B-3) DIA–6636–005 (B-3) DIA–6636–002 (B-3) DIA–6636–003 (B-3) DIA–6636–004 (C-3) DIA–6636–005 (C-3) DIA–6636–002 (A-3) DIA–6636–003 (A-3) DIA–6636–006 (B-3)

04.8–6540–001 (18)

04.0–6636–001 (11)

SWITCHES

Crown 2005 PF15126-4

07.7–6435–104 (6)

05.0–6636–003 (65) 05.0–6635–104 (36)

M10–6636–004

C

GLOSSARY SWITCHES (Continued) Location

Function

Diagram

Parts Breakdown

FS

Control Pod

Forward Traction

DIA–6636–002 (B-3) DIA–6636–003 (B-3) DIA–6636–006 (C-1)

HNS1

Control Pod

Horn (Travel)

DIA–6636–002 (A-1) DIA–6636–003 (A-1) DIA–6636–006 (C-2)

HNS2

Load Backrest Pod Horn (Travel)

HNS3

Control Pod

Horn (Travel)

HSS

Power Unit

High Speed Foot Switch

KYS

Console

Truck Power ON/OFF

LMS

Power Unit

Lift Limit

LOS1

Control Pod

Lower

DIA–6636–002 (A-1) DIA–6636–003 (A-1) DIA–6636–006 (C-4) DIA–6636–002 (A-1) DIA–6636–003 (A-1) DIA–6636–006 (C-2) DIA–6636–002 (A-3) DIA–6636–003 (A-3) DIA–6636–006 (C-4) DIA–6636–002 (A-3) DIA–6636–003 (A-3) DIA–6636–007 (B-2) DIA–6636–008 (B-2) DIA–6636–002 (B-3) DIA–6636–003 (B-2) DIA–6636–007 (C-2) DIA–6636–008 (B-2) DIA–6636–002 (A-1) DIA–6636–003 (A-1) DIA–6636–006 (C-2)

04.6–6636–003 (45) 04.6–6636–102 (45) 04.6–6636–202 (40) 04.6–6636–252 (45) 04.6–6636–003 (45) 04.6–6636–102 (59) 04.6–6636–202 (40) 04.6–6636–252 (59) 07.9–6636–003 (29)

LOS2

Load Backrest Pod Lower

RAS1

Control Pod

RAS2

Load Backrest Pod Raise

RS

Control Pod

Reverse Traction

Toggle

Console

Truck Power ON/OFF

M10–6636–005

Raise

DIA–6636–002 (A-1) DIA–6636–003 (A-1) DIA–6636–006 (C-4) DIA–6636–002 (A-3) DIA–6636–003 (A-2) DIA–6636–006 (C-2) DIA–6636–002 (A-3) DIA–6636–003 (A-2) DIA–6636–006 (C-3) DIA–6636–002 (B-3) DIA–6636–003 (B-3) DIA–6636–006 (C-1) DIA–6636–002 (A-3) DIA–6636–003 (A-3) DIA–6636–007 (B-2) DIA–6636–008 (B-2)

04.6–6636–102 (59) 04.6–6636–252 (59) 07.9–6635–005 (47)

04.8–6540–001 (1)

01.0–6636–001 (22) 04.0–6636–001 (2)

04.6–6636–003 (45) 04.6–6636–102 (56) 04.6–6636–202 (40) 04.6–6636–252 (56) 07.9–6635–003 (29)

04.6–6636–003 (45) 04.6–6636–102 (56) 04.6–6636–202 (40) 04.6–6636–252 (56) 07.9–6636–003 (29)

04.6–6636–003 (45) 04.6–6636–102 (45) 04.6–6636–202 (40) 04.6–6636–252 (45) 04.8–6540–001 (14)

Crown 2005 PF15126-5

C

ELECTRICAL DIAGRAMS INDEX

This electrical diagram index for the PC 3600 Transistor Control lists the diagrams with portion of truck covered by each diagram.

Title

Page Number

Schematic with Battery Lift Interrupt

DIA–6636–002

Schematic without Battery Lift Interrupt

DIA–6636–003

Traction Controller with Battery Lift Interrupt

DIA–6636–004

Traction Controller without Battery Lift Interrupt

DIA–6636–005

Handle Control Pod, Load Back Rest

DIA–6636–006

Console, Hydraulics & Horn with Battery Lift Interrupt

DIA–6636–007

Console, Hydraulics & Horn without Battery Lift Interrupt

DIA–6636–008

Power Cables

DIA–6636–009

Wire Harnesses

DIA–6636–010

051206

DIA–6636–001

Revision

11789 Crown 2005 PF15115-1

C A

SCHEMATIC B

C

With Battery Lift Interrupt

1

1

2

2

3

3

4

4

051206 Crown 2005 PF15115-2

A

B

C

11789 133368 B 1 of 2

DIA–6636–002

C

SCHEMATIC A

B

C

Without Battery Lift Interrupt

1

1

2

2

3

3

4

4

11789 133368 B 2 A of 2

DIA–6636–003

B

C

051206 Crown 2005 PF15115-3

C A

TRACTION CONTROLLER B

C

With Battery Lift Interrupt

1

1

2

2

3

3

4

4

051206 Crown 2005 PF15115-4

A

B

C

11789 133371 B 1 of 2

DIA–6636–004

C

TRACTION CONTROLLER A

B

C

Without Battery Lift Interrupt

1

1

2

2

3

3

4

4

11789 133371 B 2 A of 2

DIA–6636–005

B

C

051206 Crown 2005 PF15115-5

C A

HANDLE CONTROL POD, LOAD BACK REST B

C

1

1

2

2

3

3

4

4

051206 Crown 2005 PF15115-6

A

B

C

11789 133370 B

DIA–6636–006

C

CONSOLE, HYDRAULICS & HORN A

B

C

With Battery Lift Interrupt

1

1

2

2

3

3

4

4

11789 133369 A 1 A of 2

DIA–6636–007

B

C

051206 Crown 2005 PF15115-7

C A

CONSOLE, HYDRAULICS & HORN B

C

Without Battery Lift Interrupt

1

1

2

2

3

3

4

4

051206 Crown 2005 PF15115-8

A

B

C

11789 133369 A 2 of 2

DIA–6636–008

C

POWER CABLES A

B

C

1

1

2

2

3

3

4

4

11789 133372 B

DIA–6636–009

A

B

C

051206 Crown 2005 PF15115-9

C Harness

WIRE HARNESSES Components Connected By:

133452-003 Control Pod Harness (Standard and F/C Models) - PC602, FS, RS, RAS1, LOS1 HNS1, HNS3, Freezer Condition Harness.

133412

Control Pod Heater Harness F/C - RES1, RES2

133453

Handle Harness (Standard and F/C Models) - PC402, JC601, JC602

133454

Main Harness No Lift Interrupt - JC402, JC403, PC404, JC407, PC407, PC408, PC409, PC603, LMS, LOS1, LOS2, RAS1, RAS2, TT2, DB1, ALM2, EML, BRS, B-, L, Fuse Panel, HN1, Hour Meter, KSW, BRES

133455

Main Harness With Lift Lockout - PC401, JC402, JC403, PC404, PC405, JC407, PC407, PC408, PC409, PC603, LOS1, LOS2, RAS1, RAS2, TT2, DB1, ALM2, EML, BRS, B-, L, Fuse Panel, ALM1, HN1, KWS, LMS

131335

Diode Harness Assembly (CR1)

085650-131 Red Lead Assembly 131109

Battery Restraint Switch Harness - PC407, JC407

118817

Load Backrest Switch Harness - PC604, LOS2, RAS2, HNS3, RES6 (Freezer Condition Option)

133413

Load Backrest Pod Harness - PC403, JC604

118765

Load Backrest Pod F/C - RES4, RES5, RES6

120662-003 Floorboard High Speed Switch Harness - HSS

051001 Crown 2005 PF15115-10

DIA–6636–010

SCHEMATIC DIAGRAMS

Introduction to Diagram Use

Introduction to Diagram Use Electrical schematics Schematics are designed to provide a high-level view of the complete lift truck electrical system. They can be used to diagnose and understand the electrical path of major components in a specific circuit.

Pictorials Pictorials are designed to provide a detailed view of the lift truck electrical system. The circuits are shown across multiple pages. Components, connectors, and wire are all part of pictorials. Each circuit always begins on the left side of the page and has its connecting page identified also.

The terminal board and connector numbers on the pictorials are in two groups: power unit and platform. The power unit terminal boards and connectors are as follows: • 200s • 400s • 600s • 800s The platform terminal boards and connectors are as follows: • 100s • 300s • 500s • 700s • 900s

of the lift truck section is necessary for the applicable lift truck setup.

The page titles show the section of the lift truck wires on each page.

Components Components such as solenoids, valves, encodes, or switches in schematics and pictorials are identified by symbols and reference designators. See the Electrical System section for more information. Reference designators are a short form of the component name.

Connectors A connector can be a single connection, a plug indicated by PC, a jack indicated by JC. A combination of a plug and a jack together are indicated by CA in the diagrams. Connectors that have multiple connections are indicated by pin numbers. For example, PC120-2 indicates that the -2 is the pin number in connector PC120.

Wiring Wiring identifies the conductor connecting the components. Standard circuits are indicated by a solid line representing the wire. Optional features are indicated by dashed lines representing the wire. Each wire has a color, number, and arrow associated with it. Wires identified by color are from a different manufacturer.

The wire arrows indicate whether the component is receiving or sending the signal. This helps identify the source of the signal or voltage.

The wires start at a specified location such as the distribution board. The connection points start from the lowest number. The next connection point from the distribution panel is with the next group of 100s and continue for each connection point away from the specified location.

The terminal board and connector numbers are in sequence on each page. A wire address with a connector number or terminal board number shows which direction to look in the electrical diagrams for the other end of the wire. When the wire goes to a component and not a terminal board or connector, the pictorial shows a terminal board to refer to. This terminal board is not a solid line and has the terminal board number in parentheses. This terminal board is not on the lift truck.

Each page includes a section of the lift truck. When a feature on the lift truck is not standard, a new page includes the standard and feature wires. Only one page Crown 1991 PF8974 Rev. 3/22

DIA-ITD-001 04 Rev. 3/22

787

Notes:

788