Download PDF: Crown Forklift PR 3000 Series Pallet Service Manual

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 PR 3000 Series operator instructions, refer to Crown publication, “You and Your Crown Pallet Rider Truck” (PF-10449).

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 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 PR 3000 Series capacities, technical information and dimensional specifications, please contact your Crown dealer or write to: Crown Equipment Corporation 40-44 S. Washington Street New Bremen, OH 45869 This manual is arranged according to major sections. The first part of the page number, found at the bottom of each page, denotes the section in which a particular form will be located. The 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

DESCRIPTION

REPLACEMENT PARTS SECTION

Lubrication and Adjustments Hydraulics Drive Unit Electrical Brake Forks Cylinder Glossary

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 Structure Cylinders Accessories Specifications

5082

931206 Crown 1993 PF-10040-1 Rev. 9/96

Printed in U.S.A.

02 REV. 8/96

ITD–6730–001

ITD–6730–001

INTRODUCTION

The data plate for the PR 3000 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.

PR 3000

Serial Number

Truck Data Number

Model Number

Truck Type

Capacity Lbs. Load Tire WidthMax. Grade

%

S E R I E S

Approximate Truck Weight as Battery Type Equipped (less batt.)

Total Battery Weight Lbs. MAX Max. AMP Hr. Cap.

This truck as released conforms to the mandatory requirments of ANSI 856.1

2571

D.C. Voltage

MIN Hr. Rate

Crown Equipment Corporation, New Bremen, Ohio 45869 USA

69116

SERIAL PLATE

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

*Capacity 60 = 6000 lb. (2720 kg) 80 = 8000 lb. (3530 kg.)

Image Generator PR - Pallet Rider

PR3020-60 Series Major technical and design changes making the product a new and improved generation.

Relative Size or Performance 20 = 24 volt 40 = 24 volt with field weakening

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

Crown 1993 PF-10040-2 Rev. 9/96

Printed in U.S.A.

02 REV. 8/96

ITD–6730–002

ITD–6730–002

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.

Axle - = Single T = Tandem

TRUCK DATA NUMBER EXAMPLE Control C = Curtis Transistor S = Sevcon Transistor

Drive Tires RU = Rubber, Black-Lugged SR = Rubber, Black-Siped WR = Rubber, White-Lugged LR = Rubber, Black-Lugged F.G. PO = Poly, Black-Smooth SP = Poly, Black-Siped GP = Poly, Black-Grooved CP = Poly, Cream-Smooth ** = Special AP = 5.5" Wide Poly DP = Diamond Siped Poly HP = High Crown Poly RP = Razor Siped Poly RS = Smooth Rubber

Fork Tip - = Standard E = Extended

Fork Width 18 = 18 in. (455mm) 25 = 25 in. (635mm) 22 = 22 in. (560mm) 26 = 26 in.( 660mm) 23 = 23 in. (585mm) 27 = 27 in. (685mm) 24 = 24 in. (610mm) 28 = 28 in. (710mm) ** = Special

- 22 42 E W T - C A SR IN - A T R Standard/Special Truck - = Standard S = Special C = Custom

Casters - = Standard A = Quick Adjustment T = Quick Adjustment Casters W/Torsion Bar

Fork Length 36 = 36 in. (914mm) 60 = 60 in. (1524mm) 42 = 42 in. (1067mm) 84 = 84 in. (2134mm) 48 = 48 in. (1219mm) 93 = 93 in. (2362mm) 54 = 54 in. (1371mm) 96 = 96 in. (2438mm) ** = Special

Freezer / Corrosion - = Without Freezer Corrosion F = Freezer Corrosion

Battery Compartment W = Wide 13.19 in. (335mm) N = Narrow 6.70 in. (170mm)

Printed in U.S.A.

Crown 1993 PF-10040-3 Rev. 9/96

02 REV. 8/96

ITD–6730–003

ITD–6730–003

INTRODUCTION TRUCK DATA NUMBER EXAMPLE (continued)

Key/Toggle Switch - = Key Switch T = Toggle Switch

Storage Compartment - = Without Storage Module B = Storage Module Mounted on Load Backrest C = Storage Module Mounted On Battery Cover

Internal Hour Meter - = Without Internal Hour Meter I = Internal Hour Meter

- 22 42 E W T - C A SR IN - A T R Meter Options KE = Key Only HM = Hour Meter DM = Discharge Volt Meter HD = Hour & Discharge Volt Meter IN = Battery Interrupt IH = Battery Interrupt & Hour Meter

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

Travel Alarm - = Without Travel Alarm A = Travel Alarm

Crown 1993 PF-10040-4 Rev. 9/96

Printed in U.S.A.

02 REV. 8/96

ITD–6730–004

ITD–6730–004

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 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, review the appropriate sections in this service manual for additional procedures to be followed.

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

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

•

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

•

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

•

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

•

Ensure the battery used meets weight, size, amperage and voltage requirements of the truck (refer to the serial plate). NEVER operate the 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. If battery acid is spilled on the floor or any other surface, use Battery Spill Kit, Crown part number 300035, to neutralize and clean up the battery acid. Follow the manufacture directions for use.

•

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

•

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

•

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

•

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

Crown 2000 PF11888-1 Rev. 4/11

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

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

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

MA-6730-100 02 Rev. 4/11

3

SAFETY Control of Hazardous Energy Battery Removal CAUTION When removing the battery, move the truck to an area intended for battery care. The floor must be level. Turn the key switch or toggle switch OFF and remove the key. Disconnect the battery and lockout or tagout the truck as described in Lockout/Tagout in this section.

Never partially move the battery from the truck without a roller stand in place. Lower the load engaging means completely. If the battery is removed with the load engaging means raised, use a hoist attached to the mast to provide tip over protection. Do not allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing or transporting the battery. Use an insulator, such as plywood, to cover the top of the battery before and during removal.

Battery Installation Figure 25461

CAUTION When installing the battery, move the truck to an area intended for battery care. The floor must be level. Turn the key switch or toggle switch OFF and remove the key. Disconnect the battery and lockout or tagout truck as described in Lockout/Tagout in this section. If the battery was removed with the load engaging means raised, use a hoist attached to the mast to provide tip over protection. Do not allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing or transporting the battery. Use an insulator, such as plywood, to cover the top of the battery before and during installation.

CAUTION Ensure the battery being used meets the weight, size, amperage and voltage requirements of the truck (refer to the serial plate). NEVER operate the truck with an undersized battery.

Lockout/Tagout

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

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

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

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

2. No load on the forks.

3. Chock the wheels.

Always turn the key switch or toggle switch OFF, remove the key and apply a tag (1) to the control pod (2) with a cable tie to warn others that the truck is being serviced. Refer to Figure 25461.

MA-6730-101 02 Rev. 4/11

4

4. Disconnect the battery. Lockout or tagout the truck as described in Lockout/Tagout in this section.

5. Turn and hold the key switch or toggle switch to the start position a minimum of 10 seconds.

Crown 2000 PF11888-2 Rev. 4/11

SAFETY Control of Hazardous Energy 6. To verify the capacitors have discharged, place a volt meter across the following terminals: Curtis: B+ and B- terminals of the traction motor controller for three or more seconds.

Sevcon: B- and D1 terminals of the traction motor controller for three or more seconds.

The voltage should be less than 1 V on both traction motor controllers. Refer to Figure 25462.

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

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

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

2. No load on the forks. Completely lower the forks.

Curtis

3. Turn the key switch or toggle switch OFF and remove the key.

Sevcon Figure 25462

7. Turn the key switch or toggle switch OFF and remove the key.

Crown 2000 PF11888-3 Rev. 4/11

4. Disconnect the battery. Lockout or tagout the truck as described in Lockout/Tagout in this section.

5. Depressurize the hydraulic reservoir by momentarily opening the cap on it before disconnecting any hydraulic lines or components.

MA-6730-102 02 Rev. 4/11

5

SAFETY Control of Hazardous Energy Towing the Truck

•

Refer to the following guidelines when towing the truck.

Towing by Pulling In the Power Unit First Direction WARNING • • •

The towed truck must always maintain three contact points with the floor or towing device.

Maximum travel speed while towing the truck is 1.6 km/h (1 mph).

Do not make sharp turns when towing the truck.

Preparing the Truck for Towing

•

Attaching a Towing Device to the Truck to be Towed

•

Use the pull force requirements listed under the Towing Device Requirements section to determine the specifications of the "eye bolt" and tow strap.

•

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

•

Attach a tow strap low on the towed truck (1). Refer to Figure 25463.

The truck will be difficult to steer. Use extreme care.

•

Ensure the truck can be steered safely during towing. This may require an operator to ride in the truck during towing.

•

Ensure the truck can brake safely during towing.

•

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

•

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

•

Remove all loads from the forks before towing the truck.

•

Lower the forks to the floor before towing the truck.

Figure 25463

Towing Device Requirements

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

MA-6730-103 02 Rev. 4/11

6

Pull the truck by the power unit skirt.

NOTE

Refer to the serial plate for gross truck weight; include battery weight if it is in the truck during towing.

WARNING

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

Use a tow strap that is long enough to allow the operator time to stop safely if he or she needs to do so quickly. Towing at 1.6 km/h (1 mph) will require a 2438 mm (96 in) minimum distance between the towed truck and towing vehicle; choose a tow strap accordingly.

Crown 2000 PF11888-4 Rev. 4/11

SAFETY Control of Hazardous Energy Towing Vehicle Minimum Requirements

Preparing the Truck for Towing

•

Use the pull force requirements listed under the Towing Device Requirements section to determine traction force. This traction force must be within the towing specifications of the towing vehicle.

•

•

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

•

Always attach a tow strap as low as possible on the towing vehicle. Consult the manufacturer for more information.

Towing Operation Guidelines

•

Maximum travel speed while towing the truck is 1.6 km/h (1 mph).

•

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

Towing the Truck by Pulling in the Forks First Direction

Refer to the serial plate for gross truck weight; include battery weight if it is in the truck during towing.

WARNING The truck will be difficult to steer. Use extreme care.

•

Ensure the truck can be steered safely during towing. This may require an operator to ride in the truck during towing.

•

Ensure the truck can brake safely during towing.

•

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

•

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

•

Remove all loads from the forks before towing the truck.

•

Lower the forks to the floor before towing the truck.

Towing Device Requirements NOTE

WARNING • • •

The towed truck must always maintain three (3) contact points with the floor or towing device.

Maximum travel speed while towing the truck is 1.6 km/h (1 mph).

Do not make sharp turns when towing the truck.

Crown 2000 PF11888-5 Rev. 4/11

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

•

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

MA-6730-104 02 Rev. 4/11

7

SAFETY Control of Hazardous Energy Attaching a Towing Device to the Truck to be Towed

•

Pull the truck by its fork end.

•

Attach a tow strap to the fork end of the truck (1) and tow it in the forks first direction. The tow strap can be attached by passing through one of the load wheel openings on top side of the fork. The tow strap should not rub against the load wheel. Refer to Figure 25464.

Towing Operation Guidelines

•

Maximum travel speed while towing the truck is 1.6 km/h (1 mph).

•

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

Towing by Lifting and Towing in the Power Unit First Direction WARNING • • •

The towed truck must always maintain three (3) contact points with the floor or towing device.

Maximum travel speed while towing the truck is 1.6 km/h (1 mph).

Do not make sharp turns when towing the truck.

Preparing the Truck for Towing

• Figure 25464

•

Use a tow strap that is long enough to allow the operator time to stop safely if he or she needs to do so quickly. Towing at 1.6 km/h (1 mph) will require a 2438 mm (96 in) minimum distance between the towed truck and towing vehicle; choose a tow strap accordingly.

WARNING The truck will be difficult to steer. Use extreme care.

•

Remove the battery before lifting and towing.

•

Ensure the truck can be steered safely during towing. This may require an operator to ride in the truck during towing.

•

Ensure the truck can brake safely during towing.

•

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

•

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

Towing Vehicle Minimum Requirements

•

Use the pull force requirements listed under the Towing Device Requirements section to determine traction force. This traction force must be within the towing specifications of the towing vehicle.

•

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

•

Always attach a tow strap as low as possible on the towing vehicle. Consult the manufacturer for more information.

MA-6730-105 02 Rev. 4/11

8

Refer to the serial plate for gross truck weight; include battery weight if it is in the truck during towing.

Crown 2000 PF11888-6 Rev. 4/11

SAFETY Control of Hazardous Energy •

Remove all loads from the forks before towing the truck.

•

Lower the forks to the floor before towing the truck.

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

•

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

Towing Vehicle Minimum Requirements

•

Use the pull force requirements listed under the Towing Device Requirements section to determine traction force. This traction force must be within the towing specifications of the towing vehicle.

•

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

•

Always attach a tow strap as low as possible on the towing vehicle. Consult the manufacturer for more information.

Towing Operation Guidelines WARNING Do not lift the towed truck higher than 51 mm (2 in) off the floor.

•

This method does not require a towed truck operator.

•

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

•

The truck cannot be lifted and towed in the forks first direction.

Crown 2000 PF11888-7 Rev. 4/11

MA-6730-106 02 Rev. 4/11

9

SAFETY Control of Hazardous Energy Lifting and Blocking Refer to Figure 25465.

•

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

•

No load on the forks. Completely lower the forks.

•

Turn the key switch or toggle switch OFF and remove the key.

•

Disconnect and remove the battery. Lockout or tagout the truck as described in Lockout/Tagout in this section.

•

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

•

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

•

Jack stands: Lift the power unit end to the appropriate height, not to exceed 400 mm (16 in), and place a jack stand under the skirt. An additional four stands may be required: Two under the power unit where the power unit and lift structure join and two under the battery compartment.

•

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

•

Hydraulic jack capacity: 3620 kg (8000 lb)

•

•

–

Crown part number: 300080

–

Collapsed height minimum: 60 mm (2.25 in)

–

Raised height maximum: 400 mm (16 in)

Jack stand capacity: 6350 kg (14000 lb) –

Crown part number: 300081

–

Commercially available

Lifting straps capacity: 900 kg (2000 lb) –

Commercially available

MA-6730-107 02 Rev. 4/11

10

Figure 25465 1

Hydraulic Jack

2

Overhead Lifting Device

3

Lifting Straps

4

Hardwood Block

5

Jack Stand

Crown 2000 PF11888-8 Rev. 4/11

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

MAINTENANCE LUBRICATION AND ADJUSTMENT For regular maintenance, access to the components is accomplished by removing the two (2) screws connecting the door assemblies. Swinging open or lifting the doors off allows maintenance to be performed on the pump, motor, contactor panel, drive unit, hydraulic system, and electrical components located in the power unit.

NOTE Be sure battery connector is disconnected.

For Transistor Maintenance Instructions, see appropriate section in this manual.

All “DX” (with internal dimples), “DU” & “HTX” type bushings must have inside diametercoated with multipurpose grease (or low temp multipurpose grease in freezer applications) prior to insertion of pivot shafts.

Keep the truck clean and free from the 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. However, some operating conditions will require more frequent checks and lubrication than listed. For example, applications with much dust or moisture will require modification of the schedule to fit that particular application.

High grade lubricants and fluids should be used. Almost any of the oil companies can supply these high grade lubricants; those listed on Chart 1-1 are typical. Any lubricant with equal specifications may be used.

On trucks equipped to operate in below freezing temperatures, low temperature hydraulic oil and grease must be used. All screws, washers, nuts, roll pins, retaining rings, brake linkage, etc. need to be coated with a film of rust preventive (078882-002) to protect against corrosion. Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts.

NOTE PE, PC and PR trucks were used as examples fo r the illustrations in this section. Lubrication and adjustment procedures are applicable for PE, PC, PR and PW trucks regardless of truck shown (except as noted).

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

931206

4854 - 42068

Crown 1993 PF-9976-1 Rev. 11/95

Printed in U.S.A.

03 REV. 11/95

M1.0–6435–001

M1.0–6435–001

MAINTENANCE

L-1 L-2 L-3 L-4

L-6

L-7

L-5 L-8

ILLUSTRATION 1-3

2421S

LUBRICATION CHART LUBE TYPE

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

Steering Chain (PR) Universal Joint (1 point) PR) Door Hinges Steering Gears (PR) Hydraulic Reservoir- Power Steering (PR) Brake Reservoir (PR) Brake Pedal Pivot (PR) Hydraulic Reservoir-Lift

† - Check

Chg. - Change

F B F B D G C D

30 days 60 days QTY. 100 hr. 250 hr.

AR AR AR AR 3.5 qt.

AR AR 2 qt.

L - Lubricate

† L † † † † † †

90 days 6 months 500 hr. 1000 hr.

12 months 2000 hr.

†

†

Chg.

†

†

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.

Crown 1993 PF-9976-2 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M1.0 - 6435 - 002

M1.0 - 6435 - 002

MAINTENANCE

L-1

L2 L-3 L-7

L-4 L-5

L-8

L-6

ILLUSTRATION 1-4

3851-01

LUBRICATION CHART

INDEX COMPONENT L-1 L-2 L-3 L-4 L-5 * L-6

L-7 L-8

Parking Brake (PC) & Brake Linkage Brake Linkage Drive Unit-Level Drive Unit-Rollers (4 points) Drive Unit-Axle (2 points) Caster (4 points), Quick Adjustment Caster (12 points), Quick Adjustment Caster w/Torsion Bar (14 points) Drive Unit-Pivot (1 point) Battery Rollers

† - Check

Chg. - Change

LUBE TYPE

QTY

30 days 60 days 100 hr. 250 hr.

BB C A F F

AR AR 3.5 pt.

AR AR

L † † L L

F F C

AR AR AR

L L †

L - Lubricate

90 days 6 months 500 hr. 1000 hr.

†

†

12 months 2000 hr.

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 1993 PF-9976-3 Rev. 11/95

Printed in U.S.A.

03 REV. 11/95

M1.0–6435–003

M1.0–6435–003

MAINTENANCE

L-5 L-8

L-1

L-7

L-11 L-1

L-7 L-8

L-10 L-6 L-4 L-2

L-6

L-3

L-4 L-1

L-4

L-5

L-9 L-3

L-2 L-4

2424-01

2423

ILLUSTRATION 1-5 LUBRICATION CHART LUBE TYPE

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

Upper Lift Linkage (4 points) F Lower Linkage Pivot Pins (4 points) F Power Unit Pivot (2 points) F Tension Bars (9 in.[230mm] Fork-6 points, 7 in.[180mm] Fork-4 points) F Lift Cylinder (2 points) F Rollers (2 points) F Load Wheel Axle (4 points) F Riser Pivot (4 points) F Load Wheel Pivot Tandem) (4 points) F Torsion Springs BB Coast selector linkage, Yoke Roller Bearing and Double springs BB

† - Check

Chg - Change

30 days 60 days QTY. 100 hr. 250 hr.

AR AR AR

L L L

AR AR AR AR AR AR AR

L L L L L L L

AR

L

L - Lubricate

90 days 6 months 500 hr. 1000 hr.

12 months 2000 hr.

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 1993 PF-9976-4 Rev. 1/94

Printed in U.S.A.

01 REV. 1/94

M1.0 - 6435 - 004

M1.0 - 6435 - 004

MAINTENANCE

I-6 I-1

I-2

I-7

I-3 I-4

I-8

I-5 I-9

ILLUSTRATION 1-6

2484S

INSPECTION AND ADJUSTMENT CHART

INDEX COMPONENT I-1 I-2 I-3 I-4 I-5 I-6 I-7 I-8 I-9

Steering Chain (PR) Electrical Connections Motor Brushes-Power Steering (PR) Contactor Tips Hydraulic Lines & Fittings Torque Generator (PR) Motor Brushes-Lift Brake Operation Brake Switch

30 days 100 hr.

60 days 250 hr.

90 days 500 hr.

6 months 1000 hr.

12 months 2000 hr.

† † † † † † † † †

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

Crown 1993 PF-9976-5

M1.0 - 6435 - 005

Printed in U.S.A.

M1.0 - 6435 - 005

MAINTENANCE I-1

I-2

I-3 I-4 I-5 I-6 I-7

I-8 I-9 I-11

I-10

ILLUSTRATION 1-7

3864-01

INSPECTION AND ADJUSTMENT CHART

INDEX COMPONENT I-1 I-2 I-3 I-4 I-5 I-6 I-7 I-8 I-9 I-10 I-11

Travel Controls Brake Operation Parking Brake Battery & Connector Hydraulic Lines & Fittings Brake Switch Motor Brushes-Traction Horn Brake Lining Caster Battery Retainer Switches

30 days 100 hr.

60 days 250 hr.

90 days 500 hr.

6 months 1000 hr.

12 months 2000 hr.

† † † † † † † † † † †

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

Crown 1993 PF-9976-6 Rev. 11/95

Printed in U.S.A.

03 REV. 11/95

M1.0–6435–006

M1.0–6435–006

MAINTENANCE

I-2

I-3 I-1

I-4

I-2

ILLUSTRATION 1-8

2486

INSPECTION AND ADJUSTMENT CHART

INDEX COMPONENT I-1 I-2 I-3 I-4

Limit Switch & Lift Linkage Lift Cylinder Tires, Wheels, & Rollers Tension Bars

30 days 100 hr.

60 days 250 hr.

90 days 500 hr.

6 months 1000 hr.

12 months 2000 hr.

† † † †

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

Crown 1993 PF-9976-7

M1.0 - 6435 - 007

Printed in U.S.A.

M1.0 - 6435 - 007

C

LUBRICATION AND ADJUSTMENT

For regular maintenance, access to the components is accomplished by removing the two (2) screws connecting the door assemblies. Swinging open or lifting the doors off allows maintenance to be performed on the pump, motor, contactor panel, drive unit, hydraulic system, and electrical components located in the power unit.

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

NOTE Be sure battery connector is disconnected.

For Transistor Maintenance Instructions, see appropriate section in this manual.

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

Keep the truck clean and free from the 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.

High grade lubricants and fluids should be used. Almost any of the oil companies can supply these high grade lubricants; those listed on Chart 1-1 are typical. Any lubricant with equal specifications may be used.

On trucks equipped to operate in below freezing temperatures, low temperature hydraulic oil and grease must be used. All screws, washers, nuts, roll pins, retaining rings, brake linkage, etc. need to be coated with a film of rust preventive (078882-002) to protect against corrosion. Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts.

NOTE PE, PC and PR trucks were used as examples for the illustrations in this section. Lubrication and adjustment procedures are applicable for PE, PC, PR and PW trucks regardless of truck shown (except as noted).

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

960509

8078 - EO10974

Crown 1996 PF10954-1 Rev. 4/04

Printed in U.S.A.

04 REV. 4/04

M1.0–6435–008

M1.0–6435–008

LUBRICATION AND ADJUSTMENT

L-1 L-2 L-3 L-4

L-6

L-7

L-5 L-8

ILLUSTRATION 3

2421S

LUBRICATION CHART LUBE TYPE

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

Steering Chain (PR) Universal Joint (1 point) PR) Door Hinges Steering Gears (PR) Hydraulic Reservoir- Power Steering (PR) Brake Reservoir (PR) Brake Pedal Pivot (PR) Hydraulic Reservoir-Lift

† - Check

Chg. - Change

F B F B D G C D

30 days 60 days QTY. 100 hr. 250 hr.

AR AR AR AR 3.5 qt.

AR AR 2 qt.

L - Lubricate

† L † † † † † †

90 days 6 months 500 hr. 1000 hr.

12 months 2000 hr.

†

†

Chg.

†

†

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.

Crown 1996 PF10954-2 Rev. 4/99

Printed in U.S.A.

02 REV. 4/99

M1.0–6435–009

M1.0–6435–009

C

LUBRICATION AND ADJUSTMENT

L-1

PC 3500 "T" Handle

L2 L-3

PC 3500 Rider Handle

L-7

L-4 L-5

L-6

L-9

L-8 ILLUSTRATION 4

5397-01

LUBRICATION CHART

INDEX COMPONENT L-1 L-2 L-3 L-4 L-5 * L-6

L-7 L-8 L-9

Parking Brake (PC) & Brake Linkage Brake Linkage Drive Unit-Level Drive Unit-Rollers (4 points) Drive Unit-Axle (2 points) Caster (4 points), Quick Adjustment Caster (12 points), Quick Adjustment Caster w/Torsion Bar (14 points) Drive Unit-Pivot (1 point) Battery Rollers Handle Pivots & Torsion Springs

† - Check

Chg. - Change

LUBE TYPE

QTY

30 days 60 days 100 hr. 250 hr.

BB C A F F

AR AR 3.5 pt.

AR AR

L † † L L

F F C BB

AR AR AR AR

L L † L

L - Lubricate

90 days 6 months 500 hr. 1000 hr.

†

†

12 months 2000 hr.

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.

Printed in U.S.A.

Crown 1996 PF10954-3 Rev. 4/04

04 REV. 4/04

M1.0–6435–010

M1.0–6435–010

C

LUBRICATION AND ADJUSTMENT

L-5 L-8

L-1

L-7

L-11 L-1

L-7 L-8

L-10 L-6 L-4 L-2

L-6

L-3

L-4 L-1

L-4

L-5

L-9 L-3

L-2 L-4

2424-01

2423

ILLUSTRATION 5 LUBRICATION CHART LUBE TYPE

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

Upper Lift Linkage (4 points) F Lower Linkage Pivot Pins (4 points) F Power Unit Pivot (2 points) F Tension Bars (9 in.[230mm] Fork-6 points, 7 in.[180mm] Fork-4 points) F Lift Cylinder (2 points) F Rollers (2 points) F Load Wheel Axle (4 points) F Riser Pivot (4 points) F Load Wheel Pivot Tandem) (4 points) F Torsion Springs BB Coast selector linkage, Yoke Roller Bearing and Double springs BB

† - Check

Chg - Change

30 days 60 days QTY. 100 hr. 250 hr.

AR AR AR

L L L

AR AR AR AR AR AR AR

L L L L L L L

AR

L

L - Lubricate

90 days 6 months 500 hr. 1000 hr.

12 months 2000 hr.

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 1996 PF10954-4 Rev. 4/99

Printed in U.S.A.

02 REV. 4/99

M1.0–6435–011

M1.0–6435–011

LUBRICATION AND ADJUSTMENT

I-6 I-1

I-2

I-7

I-3 I-4

I-8

I-5 I-9

ILLUSTRATION 6

2484S

INSPECTION AND ADJUSTMENT CHART

INDEX COMPONENT I-1 I-2 I-3 I-4 I-5 I-6 I-7 I-8 I-9

Steering Chain (PR) Electrical Connections Motor Brushes-Power Steering (PR) Contactor Tips Hydraulic Lines & Fittings Torque Generator (PR) Motor Brushes-Lift Brake Operation Brake Switch

30 days 100 hr.

60 days 250 hr.

90 days 500 hr.

6 months 1000 hr.

12 months 2000 hr.

† † † † † † † † †

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

Crown 1996 PF10954-5 Rev. 4/99

Printed in U.S.A.

02 REV. 4/99

M1.0–6435–012

M1.0–6435–012

C

LUBRICATION AND ADJUSTMENT

I-1

PC 3500 "T" Handle I-2

I-3 I-4 I-5 I-6 I-7 PC 3500 Rider Handle I-8 I-9 I-10 I-11

I-13

I-12

ILLUSTRATION 7

7392-02

INSPECTION AND ADJUSTMENT CHART

INDEX COMPONENT I-1 I-2 I-3 I-4 I-5 I-6 I-7 I-8 I-9 I-10 I-11 I-12 I-13

Travel Controls Brake Operation Battery & Connector Motor Brushes - Pump Hydraulic Lines & Fittings Motor Brushes - Traction Horn Brake Switch Drive Unit Rollers & Race Brake Lining Brake Split Bushing Key Caster Battery Retainer Switches

30 days 100 hr.

60 days 250 hr.

90 days 500 hr.

6 months 1000 hr.

12 months 2000 hr.

† † † † † † † † † † †

Chg.

† †

† = Inspect and/or Adjust Chg. = Change Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

Printed in U.S.A.

Crown 1996 PF10954-6 Rev. 4/04

04 REV. 4/04

M1.0–6435–013

M1.0–6435–013

C

LUBRICATION AND ADJUSTMENT

I-2

I-3 I-1

I-4

I-2

ILLUSTRATION 8

2486

INSPECTION AND ADJUSTMENT CHART

INDEX COMPONENT I-1 I-2 I-3 I-4

Limit Switch & Lift Linkage Lift Cylinder Tires, Wheels, & Rollers Tension Bars

30 days 100 hr.

60 days 250 hr.

90 days 500 hr.

6 months 1000 hr.

12 months 2000 hr.

† † † †

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

Printed in U.S.A.

Crown 1996 PF10954-7 Rev. 4/99

02 REV. 4/99

M1.0–6435–014

M1.0–6435–014

MAINTENANCE ADJUSTMENT General Notes PART OF POWER UNIT

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

MOUNTING BRACKET

MOVE SHIMS HERE TO MOVE CASTERS DOWN (TOWARD FLOOR)

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.

• To adjust the casters up, refer to illustration and loosen mounting bolts. Move shims between mounting bracket and clamp blocks.

MOVE SHIMS HERE TO MOVE CASTERS UP (TOWARD POWER UNIT)

• To adjust the casters down, refer to illustration and loosen mounting bolts. Move shims between mounting bracket and power unit.

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.

Caster Caster Drive Tire Adjustment Load Load

CLAMP BLOCKS

2374

Traction/Brake Performance

Stability/Handling Performance

Steer Effort

UP

Decreases

Increases

Increases

Decreases

Increases

DOWN

Increases

Decreases

Decreases

Increases

Decreases

931206

4061MM - 37800

Crown 1993 PF-9968

Printed in U.S.A.

M1.5 - 6535 - 001

M1.5 - 6535 - 001

LUBRICATION & ADJUSTMENT Adjustments

Adjustments 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.

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.

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.

•

To adjust casters up or down, refer to illustration.

Loosen nut until axle can be rotated freely. With axle locater to the top, axle and wheel are at their highest setting. Rotating the axle will cause the caster wheel to move downward, thereby increasing caster load, etc. (See chart below). When axle locater is to the bottom, axle and tire are at their lowest setting.

•

Wedge washer must be assembled as shown for maximum effectiveness.

AXLE AT HIGHEST SETTING

ROTATE AXLE FOR HEIGHT ADJUSTMENT

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

Reducing caster loading reduces stability.

(1)

Axle Locator

(4)

Wedge Washer

(2)

Lancing

(5)

Wheel

(3)

Nut

(6)

Axle

Figure 16883

Quick Adjustment Chart Caster Adjustment

Caster Load

Drive Tire Load

Traction/Brake Performance

Stability/Handling Performance

Steer Effort

Up

Decreases

Increases

Increases

Decreases

Increases

Down

Increases

Decreases

Decreases

Increases

Decreases

Crown 2002 PF13305-1 Rev. 7/07

M1.5-6535-002 02 Rev. 7/07

53

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

ILLUSTRATION 1.5-1

4733 - 41486

Crown 1993 PF-10047-1 Rev. 8/95

Printed in U.S.A.

02 REV. 8/95

M1.5-6730-001

M1.5-6730-001

MAINTENANCE Trucks Equipped With Rubber Drive Tires

Trucks Equipped With Poly Drive Tires

4013

ILLUSTRATION 1.5-2 NOTE

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

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).

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

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

6. Tighten jam nut.

7. Connect battery, remove blocks and check adjustment.

Refer to Illustration 1.5-2 and set gages as shown for either rubber or poly drive tire. Gages are visable thru a hole in the power unit skirt.

Crown 1993 PF-10047-2 Rev. 8/95

Printed in U.S.A.

02 REV. 8/95

M1.5-6730-002

M1.5-6730-002

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-10047-3 Rev. 8/95

Printed in U.S.A.

02 REV. 8/95

M1.5-6730-003

M1.5-6730-003

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

MAINTENANCE GAUGES TT Hour Meter

BDI (PC 3000 & PR) Discharge Meter/Lift Interrupt

The hour meter is used to record the trucks powered travel time in hours. This instrument serves as an aid in determining a lubrication and maintenance schedule.

The battery discharge indicator/lift interrupt is used to monitor the state of charge of the trucks battery. As the state of charge (specific gravity) falls below a predetermined level, the truck’s lift contactor(s) will drop-out, permitting no further lifting operations.

V Discharge Meter The battery discharge indicator is used to monitor the lift truck’s battery voltage while the key switch is in the “on” position. Observe the operation of the gauge. During regular operation, the LED bar will move down step by step, through 10 positions. As the display bar moves down through the 8th LED to the 9th LED, (slightly below the 1/4 full mark) the LED will begin flashing, indicating an approximate 75% discharged battery. As the battery continues to be discharged, an additional warning will occur as the 9th and 10th LED flash alternatively. The 10th LED is the bottom display bar. The alternate flashing indicates a need for the battery to be charged.

The discharge/lift interrupt meter shows the state of charge of the battery. The pointer will move from “F” full charge, towards “E” discharged red zone, as the battery is discharged. As the pointer moves to the yellow zone, the warning light in the gauge will come on. This is a signal to the operator that he has approximately 5% battery capacity left before the truck’s lift contactor(s) will be locked out. If the truck continues to operate with a low battery, the pointer will move to the red zone. At this time, lift lock-out will occur, preventing battery damage caused by deep discharging.

UNIGAGE (PE, PC 3500 & PW) Discharge Meter/Lift Interupt/Hour Meter The battery discharge indicator/lift interrupt/hour meter is used to monitor and protect the battery as well as the electrical components of the truck. (See Section M4.6)

931206

4589AB - 41087

Crown 1993 PF-9989 Rev. 6/95

Printed in U.S.A.

01 REV. 6/95

M4.0–6435–080

M4.0–6435–080

ELECTRICAL WIRING WIRING COLOR CODES The following information is an explanation of terms and symbols which are being standardized on Crown wiring diagrams.

The leads used are limited to the following colors. The color of the wire is based on the function of the circuit in which it is used. Each wire is assigned a three or four digit number. The first one or two numbers identify the color of the lead. The last two numerals number the lead from one thru ninety-nine.

(See chart below) Exceptions to this can be leads supplied by vendors with components. The color of each function shall be shown on the schematic. Each wire shall be identified by a number on the wiring pictorial.

ABBR.

COLOR

NUMBER

FUNCTION

FUNCTION

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

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

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

G/W

Green Stripe/White

59 **

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

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

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

4233 Crown 1978 PF3452-1 Rev. 11/02

Printed in U.S.A.

06 REV. 11/02

M4.1–12.0–001

M4.1–12.0–001

ELECTRICAL WIRING WIRING HARNESS Shown here is a section of a pictorial wiring diagram showing a wiring harness. The wires shown coming from the wiring harness are all labeled on the diagram in such a way as to be able to tell where the other end of a particular wire is connected. Following is an example taken from this wiring diagram.

There are two wires coming from the harness which lead to HNS (Horn Switch) terminal 1 and terminal 2, labeled 2904-TB1-1 and 801-TB1-8 respectively. 2904-TB1-1 is a red stripe wire marked 2904 (see “Wiring Color Codes”), which goes through the wiring harness to Terminal Board 1 (TB1), terminal 1.

801-TB1-8 is a gray wire marked 801 which goes through the wiring harness to connect to Terminal Board 1, terminal 8.

The wires are labeled similarly at Terminal Board 1. The wire shown coming from terminal 1 of TB1 which leads to the Horn Switch is labeled on the diagram 2904-HNS-1 (Red stripe wire marked 2904 which leads to horn switch, terminal 1).

The wire leading to the horn switch, terminal 2 is labeled 801-HNS-2 on the diagram.

6011SI

POWER CABLES Power cables are designated using one of the following abbreviations, followed by a dash number.

Abbreviation PC # 1 PC # 2 PC # 4 PC # 6 PC#10 PC # 1/0 PC # 2/0 PC # 3/0

Part No. 084571 084570 084569 084568 090963 084572 084573 086749

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

Crown 1978 PF3452-2 Rev. 11/02

Printed in U.S.A.

06 REV. 11/02

M4.1–12.0–002

M4.1–12.0–002

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

Component

Abbreviation

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

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

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

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

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

Crown 1978 PF3452-3 Rev. 11/02

Printed in U.S.A.

06 REV. 11/02

M4.1–12.0–003

M4.1–12.0–003

ELECTRICAL WIRING 3804

Maintained Contact Switches Operator Actuated

Momentary Contact Switches Operator Actuated

Normally Open

Normally Open

Normally Closed

Held Open

Center Off

Normally Closed

Double Throw

Held Closed

2 Circuit

Multiple Pole Break Before Make

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

Key Switch

Momentary Contact Switches Mechanically Actuated Normally Open

Off Momentary Contact Switches Mechanically Operator Actuated

Normally Open Held Closed

Normally Open

Normally Closed Held Open

Held Closed

Normally Closed

Held Open

Normally Closed Open On Rise

Close On Rise

Double Throw

2 Circuit

Crown 1978 PF3452-4 Rev. 11/02

Printed in U.S.A.

06 REV. 11/02

M4.1–12.0–004

M4.1–12.0–004

ELECTRICAL WIRING 3805

Thermistor PM Motor

T

Rheostat

Mov or Transzorb Suppressor

Wound Motor Armature Motor Field

Current Shunt

Lamp

Zener Diode Diode

SCR

Connection Point Tach Sensor Power Termination Mast Cable

I

Encoder

Common Isolated LED

B

Battery Negative Fuse

Horn

Transformer

SIP Resistor Coil Battery Solenoid Valve or Relay With Suppression

Inductor

Normally Closed

Polarized Capacitor

Normally Open

Non-Polarized Capacitor

Plug PC

LVDT

Connector CA

Resistor

Jack JC Test Point

Potentiometer

Crown 1978 PF3452-5 Rev. 11/02

Printed in U.S.A.

06 REV. 11/02

M4.1–12.0–005

M4.1–12.0–005

ELECTRICAL SYSTEM Wiring

Wiring

Color

Wiring Color Codes

Wire colors will be limited to those in the chart. The color of the wire will be chosen based on the function of the circuit in which it is used.

The following information is an explanation of wiring color codes used.

Number Each wire is assigned a three or four digit number. The first one or two digits will identify the color of the wire and the last two digits are the sequential numbering of the wires from 01 to 99.

Wire Numbering Abbreviation

Color

Number Circuit Function

BLK

Black

0**

Digital Signal

BRN

Brown

1**

Analog Signal

RED

Red

2**

Battery Positive

ORG

Orange

3**

+12 volts (DC - DC converter)

YEL

Yellow

4**

Third DC - DC converter

GRE

Green

5**

Battery Negative

BLU

Blue

6**

Isolated Negative

VIO

Violet

7**

+5 volts (DC - DC converter)

GRAY

Gray

8**

Fourth DC - DC converter

WHT

White

9**

Miscellaneous

R/W

Red Stripe on White

29**

Battery Positive after a switch

G/W

Green Stripe on White

59**

Battery Negative after a switch or resistor

** - Sequential number from 01 to 99

Crown 1993 PF9710-1 Rev. 8/06

M4.1-1430-001 02 Rev. 8/06

ELECTRICAL SYSTEM Wiring Power Cables Power cables are designated using the initials PC which stands for power cable, #- is the AWG size of the cable and the dash number. This designation also represents the part number to be ordered. e.g. PC#1/0-10 is a power cable that is size 1/0 AWG and is part number 084572-010. Refer to the following chart for the base part number of all cable sizes used.

Power Cables

M4.1-1430-002 02 Rev. 8/06

Abbreviation

Part No.

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

Crown 1993 PF9710-2 Rev. 8/06

ELECTRICAL SYSTEM Wiring Maintained Contact Switches Operator Actuated

Momentary Contact Switches Operator Actuated

Normally Open

Normally Open

Normally Closed Held Open Center Off Normally Closed Double Throw Held Closed Multiple Pole Break Before Make

2 Circuit

Center Off

Multiple Pole Make Before Break

Double Throw Start ACC IGN

Key Switch

Momentary Contact Switches Mechanically Actuated Normally Open

Off

Normally Open Held Closed

Maintained Contact Switches Mechanically Actuated Normally Open

Normally Closed Held Closed

Held Closed

Normally Closed

Held Open

Normally Closed Open On Rise

Close On Rise

Double Throw 2 Circuit Figure 3804-01

Crown 1993 PF9710-3 Rev. 8/06

M4.1-1430-003 02 Rev. 8/06

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

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

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

The MOSFET is a three terminal device (Illustration 4.2-1).

The two main terminals which are called the SOURCE and the DRAIN, carry the working current. The third electrode, known as the GATE, is the switching electrode.

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

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

During the transistor “on” times, the current flowing in the motor windings sets up a magnetic field. During the “off” times, the magnetic field set up by the motor windings, collapses and induces a voltage in the windings. This voltage would be wasted under normal conditions, however, a diode (flyback diode, Illustration 4.2-2) is placed around the motor which routes the induced voltage of the collapsing magnetic field back through the motor.

TRANSISTOR (MOSFET)

DRAIN

MOTOR

FLYBACK CURRENT

BATTERY CURRENT

GATE

SOURCE 0285-01

FLYBACK DIODE

ILLUSTRATION 4.2-2

MOSFET METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (MOSFET) 0284

ILLUSTRATION 4.2-1

Crown 1991 PF-9023-1 Rev. 4/91

Printed in U.S.A.

01 REV. 4/91

M4.2 - 06.5 - 150

M4.2 - 06.5 - 150

MAINTENANCE This “flyback” current causes current flow in the motor during the transistor “off” times. This makes the average motor current greater than the average battery current. Illustration 4.2-3 is a graphic comparison of the battery current, flyback current and motor current.

The accelerator shaping circuit takes the voltage feed from the accelerator potentiometer and shapes it to feed the desired voltage to the "on" and "off" oscillators. A delay circuit is incorporated in this circuit block so that smooth acceleration is obtained even if the accelerator control is suddenly fully actuated. The range of accelerator delay is adjustable over the range of 0.5 to 5 seconds.

OFF

2 1 BATTERY CURRENT

FLYBACK CURRENT

Over-temperature Protection

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

This built-in feature provides smooth transition from transistor to 1 A bypass. This is accomplished by the transistor continuing to pulse after 1A contactor power tips close.

Controlled Acceleration (C/A)

TRANSISTOR SWITCHING ON

3

Full Power Transition

The controller incorporates a thermal switch which measures the temperature of the transistors. At 80° C the switch comes into the circuit to linearly reduce the current limit value. At 90° C the control will shut down.

ILLUSTRATION 4.2-3

FEATURE DESCRIPTION 1A Plugging Holdoff Current Limit (C/L) A current limit circuit is included and the setting is pre-set by means of a potentiometer or calibrator. The current limit should never be increased above the rating specified for the controller or motor.

This built-in feature is designed to prevent 1A closure anytime during plugging.

Fault Detector Circuit

Plugging is pre-set at the factory. However, this feature is adjustable. The controller is designed to operate in the plugging mode, i.e., one can change direction with the accelerator and the plugging effort is independent upon the accelerator control (twist grip) position.

The fault detector circuit is designed to cause the direction contactors to de-energize if the transistor has not been turned off within a pre-set period of time. The fault detector circuit is always operational. The fault detector circuit will also detect any condition which creates a short circuit across the transistor including a welded bypass contactor, and in these conditions the forward and reverse contactor are prevented from closing.

Contactor Arc less Switching

Contactor Coil Suppression

The equipment is designed to ensure that under normal operating conditions, the making and breaking of the direction and 1A contactors occur at zero current conditions thereby eliminating arcing. Under fault conditions, and in some cases when reversing with the safety reversing switch, arcing can occur. Arcing can occur with the 1A contactor if the motor current is above the current limit setting.

Coil suppression circuits for the forward and reverse contactors are included in the logic circuit of the Sevcon control.

External suppression is used with the Curtis control. Additional suppression should not be fitted to the contactors.

Optional contactors such as pump and bypass are suppressed externally to the logic unit.

Plugging (PLUG)

Reverse Battery Protection Ramp Start Ramp start allows full power to restart a vehicle from an incline without roll back when same direction is reselected.

Reverse connection of the battery when using Sevcon transistor control will not damage the controller and the directional contactors will not energize.

Crown 1991 PF-9023-2 Rev. 4/91

Printed in U.S.A.

01 REV. 4/91

M4.2 - 06.5 - 151

M4.2 - 06.5 - 151

C

TUNE-UP SEVCON TRANSISTOR CONTROL

The Sevcon Transistor Control can be tuned up using two different units. One unit is a set of potentiometers (110769).

This unit is plugged into the controller and the corresponding features adjusted by turning the potentiometers.

DISPLAY

C/L

C/L PLUG C/A CREEP BYPASS

AMP AMP SEC %

SPEED1 SPEED2 F/W

% % AMP

BATT. MOTOR MOTOR TEMP. TEST

VOLT VOLT AMP °C

ADJUSTING CONTROLS

PLUG

SELECT

C/A CREEP

SELECTED FUNCTION INDICATOR FUNCTION SELECTOR

SPEED LIMIT

0287

POTENTIOMETER UNIT 110769 ILLUSTRATION 1

0288-01

The second unit is a hand held calibrator (111930). This unit is also plugged into the controller and the corresponding features adjusted by incrementing or decrementing the value with keys on the hand held. Once settings are made, the units can be disconnected. The calibration values are saved by the controller as changes are made.

HAND HELD UNIT 111930 ILLUSTRATION 2

With either unit, the values set are stored immediately by the controller and the controller monitors the input for any changes. With the potentiometers, any time this unit is plugged in, the values of the potentiometers are stored immediately. So the control cannot be tuned up with the hand held and then the potentiometers plugged back in without losing the values set by the hand held unless the potentiometer settings are identical to the changes made by the hand held.

When the hand held is plugged in and a feature selected, the value of that function will be displayed. If the value is not changed with the hand held, no change to the setting will occur.

930125

7164 - EO10973

Crown 1991 PF9025-1 Rev. 1/04

Printed in U.S.A.

07 REV. 1/04

M4.2–06.5–200

M4.2–06.5–200

C

TUNE-UP

HAND HELD UNIT The controller is factory preset. When a controller is replaced verify the settings to the chart. Plug the hand held unit into the connector on the bottom of the controller. Use the SELECT button to select the functions listed in the chart. If any of the settings do not aggree with the chart, use the ADJUSTING CONTROLS to adjust the setting up or down as necessary.

The functions listed below are for a nominal truck and should take into account variations in state of battery charge, battery condition, and whether or not the motor and gearbox are warmed up.

Function

*PE w/High Speed Option PE w/170 mm PE w/335 mm & 335 mm (6.62 in.)

(13.12 in.)

(13.12 in.)

Battery Comp. Battery Comp. Battery Comp.

PC

PR

TR

Current limit (C/L)

400 amps

400 amps

400 amps

400 amps 400 amps 400 amps

Plug

300 amps

330 amps

400 amps

350 amps 320 amps 320 amps

Controlled Acceleration (C/A)

0.5 sec.

0.5 sec.

0.5 sec.

0.5 sec.

1.5 sec.

1.5 sec.

Creep Speed (CREEP)

8%

8%

8%

8%

8%

8%

800 amps

800 amps

800 amps

52%

55%

45%

Bypass Dropout Speed Limit 1 (Turtle) Speed Limit 2 (Rabbit)

100%

100%

76%

Field Weakening Pickup

130 amps

130 amps

130 amps

800 amps 800 amps 800 amps 55%

57%

57%

100%

100%

100%

130 amps 130 amps 130 amps

When settings are completed, do not plug in the potentiometer unit as prompted by the note on the bottom of the label on the distribution board cover. See Illustration 3. * To verify truck has the High Speed Travel Option, look on drive unit for label/steel stamp. Tiller may have to be rotated to see label/steel stamp on drive unit.

LED code: 2 Flashes

procedure fault

3 Flashes

1A welded or shorted MOSFET

4 Flashes

directional contactor welded or shorted diode.

5 Flashes

directional contactor not closed or motor has open circuit.

6 Flashes

faulty accelerator

7 Flashes

low battery

8 Flashes

control overheated

No Light

no power to controller or defective unit

Steady Light

ready for operation

Note: If the controller is adjusted with a calibrator, do not replug the potentiometer module into the controller.

As soon as the potentiometer module is plugged in, the values in the module will override the values that have been put into the controller with the calibrator.

The calibrator values will be lost.

30

0283

ILLUSTRATION 3

Crown 1991 PF9025-2 Rev. 1/04

Printed in U.S.A.

07 REV. 1/04

M4.2–06.5–201

M4.2–06.5–201

C

TUNE-UP

POTENTIOMETER UNIT

Current Limit (C/L)

The controller is factory preset. When a controller is replaced and truck performance as described under the function is not obtained, the following procedures must be adhered to when readjusting. Plug the potentiometer unit into the connector on the bottom of the controller if not already connected.

Current limit is set at a current high enough to ensure sufficient torque for the truck to operate under maximum safe load conditions yet low enough to prevent motor “burnout”.

To adjust the current limit set C/L fully clockwise which will give maximum current limit. Connect shunt in series with motor and connect meter. Place truck against obstacle, jumper brake switch terminals and place insulating material between 1A contactor tips. Leave brake applied and turn twist grip to maximum speed. On PE and PC model trucks, depress the high speed switch also. Observing the ammeter, turn adjustment clockwise until 400 amps is obtained. Do not stall motor more than 5 seconds at a time and allow to cool between tests.

Creep Speed (Creep) The creep speed adjustment sets the minimum traction speed of the truck and is adjustable between 0 - 25% of maximum speed.

PE, PC, TR series trucks. Run truck with high speed switch depressed and with twist-grip control moved just enough so that truck moves. With twist-grip control in same position release high speed switch and adjust for same speed. Turn adjustment clockwise to increase speed.

CAUTION

Under no circumstances should the panel current limit rating be exceeded or permanent damage to the unit will result. In order for the test to be valid, ensure that traction wheel remains locked and does not turn during this test.

PR series truck. Turn twist grip to just energize directional contactor. Adjust creep speed so truck moves 51mm (2 inches) per second. Turn adjustment clockwise to increase speed.

When set, remove jumper on brake switch and remove insulating material from 1A contactor.

Controlled Acceleration (C/A) This adjustment is a delay to maximum speed when full accelerator demand is suddenly applied.

PE, PC series trucks. Depress high speed switch and move twist grip control rapidly to maximum speed. Adjust so a smooth, jerk-free increase in speed is demonstrated (approx. .5 - 1 seconds).

TR, PR series trucks. Depress high speed switch and move twist grip control rapidly to maximum speed. Adjust so a smooth, jerk-free increase in speed is demonstrated (approx.

1 to 1.5 seconds).

Turn C/A counterclockwise to increase rate of acceleration.

(Adjustable between 0.5 to 3.5 seconds.)

Plugging (Plug)

Limit (Walkie) Speed (Not applicable to TR and PC trucks) Speed limit is used to limit the maximum speed the unit will travel in the transistor range when used as a walkie and is bypassed by the high speed switch when used as a rider truck.

This adjustment is to be made with no load on the forks. The test track is to be 12.2 meters (40 feet) long with a 12.2 meters (40 feet) acceleration track. Operate truck in acceleration track 6 passes at maximum speed using plug braking at each end. To adjust, drive truck at maximum speed, high speed switch “off”.

PE series trucks. Adjust so truck travels 12.2 meters (40 feet) in 6.2 to 7.6 seconds (5.8 to 7.0 kph [3.6 to 4.4 mph]).

Plugging is the term used to describe a method of bringing the vehicle to a complete standstill and reverse the direction, in a controlled safe manner. Various factors affect the type of plugging response required, e.g. size of truck, environment, type of load to be carried, etc., and is best set under actual driving conditions. With high speed switch depressed on PE, PC, TR trucks, run truck with 1A contactor pulled in for maximum speed. Move twist grip rapidly to the maximum reverse direction. Adjust so that truck stops in 3 to 4 meters (10 to 12 feet). When turning the adjustment clockwise, plugging distance will decrease.

PR series trucks. Adjust so truck travels 12.2 meters (40 feet) in 7.4 to 9.1 seconds (4.8 to 6.0 kph [3.0 to 3.7 mph]).

Turn adjustment clockwise to increase speed.

Crown 1991 PF9025-3 Rev. 10/02

Printed in U.S.A.

07 REV. 1/04

M4.2–06.5–202

M4.2–06.5–202

C

TUNE UP CURTIS TRANSISTOR CONTROL

Adjustment potentiometers of the Curtis Transistor controller are single turn potentiometers and require a tuning tool (available from electronic supply stores). Screws in the right and left sides of the control housing must be removed with an 1/8 inch hex key to make adjustment potentiometers accessable.

The uppermost opening on the right contains the controlled acceleration C/A potentiometer. This feature controls the rate of acceleration. The middle opening on the right contains the current limit C/L adjustment potentiometer. Current limit sets the maximum current that can be drawn by the motor and control. The plug adjustment potentiometer is the adjustment available in the lowest opening on the right. This adjustment sets the distance needed to reverse the direction of travel during plugging.

Creep Speed (Creep) The creep speed adjustment sets the minimum traction speed of the truck and is adjustable between 0 - 25% of maximum speed.

PE, PC, TR series trucks. Run truck with high speed switch depressed and with twist-grip control moved just enough so that truck moves. With twist-grip control in same position release high speed switch and adjust for same speed. Turn adjustment clockwise to increase speed.

PR series truck. Turn twist grip to just energize directional contactor. Adjust creep speed so truck moves 51mm (2 in.) per second. Turn adjustment clockwise to increase speed.

Controlled Acceleration (C/A)

On the left side of the controller, the uppermost adjustment potentiometer is the creep speed adjustment. This adjustment sets the minimum speed the truck will travel. The lower adjustment potentiometer on the left side sets the speed limit. Speed limit is the speed the truck will travel when used as a walkie.

The controllers are factory preset, however, if truck performance is not as described under the function with the factory settings, the following procedures must be adhered to when readjusting.

This adjustment is a delay to maximum speed when full accelerator demand is suddenly applied.

PE, PC series trucks. Depress high speed switch and move twist grip control rapidly to maximum speed. Adjust so a smooth, jerk-free increase in speed is demonstrated (approx. .5 - 1 seconds).

TR, PR series trucks. Depress high speed switch and move twist grip control rapidly to maximum speed. Adjust so a smooth, jerk-free increase in speed is demonstrated (approx.

1 - 1.5 seconds).

Turn adjustment counter-clockwise to increase rate of acceleration. (Adjustable between 0.5 to 3.5 seconds.)

+

-

+ Limeed it C/A Ra te

+ eed Sp + g Plurrent Cu

-

-

No

be . ust eep it m cr lim efore d pee ed b : S st ote adju

29

te:

C/L Plu Cu g rre nt

Sp ad eed l jus im ted it m be ust for be ec ree p

-

+

C/L

+

+

+

- Limit

N

Plugging (Plug Current)

- Sp

+

- Creep

C/Ate Ra

C

+ reep

-

.

29

Plugging is the term used to describe a method of bringing the vehicle to a complete standstill and reverse the direction, in a controlled safe manner. Various factors affect the type of plugging response required, e.g. size of truck, environment, type of load to be carried, etc., and is best set under actual driving conditions. With high speed switch depressed on PE, PC, TR trucks, run truck with bypass contactor pulled in for maximum speed. Move control handle rapidly to the maximum reverse direction. Adjust so that truck stops in 3 to 4 meters (10 to 12 feet). When turning the adjustment clockwise, plugging distance will decrease.

ADJUSTMENT LOCATIONS 0374

ILLUSTRATION 1

7174 - EO10973 Crown 1991 PF9027-1 Rev. 1/04

Printed in U.S.A.

03 REV. 1/04

M4.2–06.5–210

M4.2–06.5–210

C

TUNE UP

Current Limit (C/L)

Speed Limit

Current limit is set at a current high enough to ensure sufficient torque for the truck to operate under maximum safe load conditions yet low enough to prevent motor “burnout”.

To adjust the current limit, set C/L fully clockwise which will give maximum current limit. Connect shunt in series with motor and connect meter. Place truck against obstacle, jumper brake switch terminals and place insulating material between 1A contactor tips. Leave brake applied and turn twist grip to maximum speed. On PE and PC model trucks, depress the high speed switch also. Observing the ammeter, turn adjustment clockwise until 400 amps is obtained. Do not stall motor more than 5 seconds at a time and allow to cool between tests.

Speed limit is used to limit the maximum speed the unit will travel in the transistor range when used as a walkie and is bypassed by the high speed switch when used as a rider truck.

CAUTION

This adjustment is to be made with no load on the forks. The test track is to be 12.2 meter (40 feet) long with a 12.2 meter (40 foot) acceleration track. Operate truck in acceleration track 6 passes at maximum speed using plug braking at each end. To adjust, drive truck at maximum speed, high speed switch “off”.

PE, PC series trucks. Adjust so truck travels 12.2 meters (40 feet) in 6.2 to 7.6 seconds (5.8 to 7.0 kph/3.6 to 4.4 mph).

TR, PR series trucks. Adjust so truck travels 12.2 meters (40 feet) in 7.4 to 9.1 seconds (4.8 to 6.0 kph/3.0 to 3.7 mph).

Under no circumstances should the panel current limit rating be exceeded or permanent damage to the unit will result. In order for the test to be valid, ensure that traction wheel remains locked and does not turn during this test.

Turn adjustment clockwise to increase speed.

When set, remove jumper on brake switch and remove insulating material from 1A contactor.

Crown 1991 PF9027-2 Rev. 1/04

Printed in U.S.A.

03 REV. 1/04

M4.2–06.5–211

M4.2–06.5–211

MAINTENANCE TROUBLESHOOTING SEVCON TRANSISTOR CONTROLLER This section provides troubleshooting aids to facilitate analysis of truck failures.

By using the appropriate troubleshooting aids (based on self diagnostics system), truck wiring diagram, and information provided in this manual; most problems should be easily detected and corrected.

WARNING

Traction wheel must be clear of the floor and free to rotate during all of the following checks unless otherwise specified. Care must be taken whenever doing “live” checks to prevent possible personal injury. At all other times disconnect the battery.

Certain troubleshooting functions can be performed using the Sevcon calibrator unit 111930. Use of the calibrator permits the service technician to access the status of switch inputs to the control. Connect the calibrator to the jack at the bottom of the controller.

WARNING

Truck is fully operational with the calibrator unit connected to the controller.

Use the SELECT button on the calibrator to access the TEST function (Illustration 4.2-1).

0288-01

Use of the + and - keys steps the calibrator through the tests available as listed by Chart 1.

Sequence No. 1 2 3 4 5 6 7 8 9 10

Test

Display

Accelerator Input Reverse Switch (RS) Forward Switch (FS) Brake Switch (BRS) Speed 1 Switch (HSS) Speed 2 Switch (not used) Safety Reversing Switch (SAS) Low Voltage Anti-Tie Down (HSS) not used not used

0-100% CL/OP CL/OP CL/OP CL/OP *CL/OP **CL/OP -

* CL indicates battery low, OP indicates battery okay. ** CL indicates HSS tied down, OP indicates HSS not tied down.

CHART 1 The first test is the accelerator input. The display shows the percent of full speed that is being requested. The tests from sequence 1 to 7 displays the associated switch condition as seen by the controller. CL indicates switch closed and OP indicates switch open. The Test under sequence 8 is the anti-tie down test of switch HSS.

111930 CALIBRATOR UNIT ILLUSTRATION 4.2-1

Crown 1991 PF-9026-1 Rev. 10/91

M4.2 - 06.5 - 420

Printed in U.S.A.

02 REV. 10/91

M4.2 - 06.5 - 420

MAINTENANCE The Sevcon transistor controller incorporates self-diagnostics utilizing a LED fault indicator. The LED is located on the top side of the controller near the A2 terminal. At battery connection, the LED should not illuminate. At key ON, the LED should illuminate steadily. If the LED illuminates and remains steady, but forward or reverse cannot be selected, check the controller wiring harness. If the LED flashes, refer to the charts included in this section for code, probable cause and remedy. LED codes are listed on the controller label as shown in illustration 4.2.-2.

0283

ILLUSTRATION 4.2-2

Crown 1991 PF-9026-2 Rev. 10/91

M4.2 - 06.5 - 421

Printed in U.S.A.

02 REV. 10/91

M4.2 - 06.5 - 421

MAINTENANCE 2 FLASHES – PROCEDURE FAULT

3 FLASHES – 1A WELDED OR SHORTED CONTROLLER

Crown 1991 PF-9026-3 Rev. 10/91

M4.2 - 06.5 - 422

Printed in U.S.A.

02 REV. 10/91

M4.2 - 06.5 - 422

MAINTENANCE 4 FLASHES – DIRECTIONAL CONTACTOR WELDED

5 FLASHES – DIRECTIONAL CONTACTOR NOT CLOSED OR MOTOR HAS OPEN CIRCUIT

Crown 1991 PF-9026-4 Rev. 10/91

M4.2 - 06.5 - 423

Printed in U.S.A.

02 REV. 10/91

M4.2 - 06.5 - 423

MAINTENANCE 6 FLASHES – FAULTY ACCELERATOR

7 FLASHES – LOW BATTERY

Crown 1991 PF-9026-5 Rev. 10/91

M4.2 - 06.5 - 424

Printed in U.S.A.

02 REV. 10/91

M4.2 - 06.5 - 424

MAINTENANCE 8 FLASHES – CONTROL OVERHEATED

FUSE BLOWN The following procedure should be adopted when checking out both blown power fuses or control fuses.

Disconnect battery.

Using a suitable meter reading resistance, check for short circuits between fuse connection and negative.

By isolating the various parts of the circuit connected to the blown fuse, trace the short circuit and correct.

Certain faults e.g. short field or armature, may also have damaged power components. Be careful when switching on.

Crown 1991 PF-9026-6 Rev. 10/91

M4.2 - 06.5 - 425

Printed in U.S.A.

02 REV. 10/91

M4.2 - 06.5 - 425

MAINTENANCE SEVCON/CURTIS TRANSISTOR FIELD WEAKENING

FUSE F

MOTOR FIELD

Three (3) conditions are monitored by the Sevcon traction controller/Curtis field weakening module to determine when to pull in the field weakening contactor; - 1A contactor energized, - motor current below predetermined level and - traveling in the power unit first direction.

CURRENT (AMPS)

Field Weakening is a method of obtaining increased traction speeds by decreasing current flow in the motor field while maintaining the current flow in the motor armature (increasing speed by this method is inherent to DC motor design).

Weakening the motor field current is accomplished by placing a resistor in parallel with the motor field (illustration 4.21). In this mode of operation the ability of the motor to operate at high torque is decreased. To avoid constant decreased motor torque, a contactor tip is placed in series with the resistor and is opened during times of increased torque requirements.

FW CONTACTOR PULL IN NOMINAL 130 AMPS

FW CONTACTOR DROP OUT NOMINAL 230 AMPS

ACCELERATION CURVE

R

DISTANCE TRAVELED

FW RES 1497

BATTERY

FW R

F

MOTOR ARMATURE CURRENT SENSOR

ILLUSTRATION 4.2-2 Current draw by the traction motor climbs rapidly during acceleration, peaks, and drops off when traction speed is constant (illustration 4.2-2). 1A contactor actuation is part of the acceleration curve. Provided the truck is being operated in the power unit first direction of travel, the 1A contactor is energized and motor current is at the field weakening pull in level, the traction control energizes the field weakening contactor. The field weakening resistor is now in parallel with the motor field (illustration 4.2-1).

1A MOSFET 1496

ILLUSTRATION 4.2-1

When the input to the traction controller from the 1A contactor changes, the motor current exceeds a value preset by the controller (illustration 4.2-2) or the fork first direction of travel is selected, the traction controller removes power from the field weakening contactor. This increase in motor current could be due to the truck encountering a grade.

931201

4061MN - 37800

Crown 1993 PF-10043

Printed in U.S.A.

M4.2 - 6535 - 300

M4.2 - 6535 - 300

MAINTENANCE CONTACTORS Crown has tested and applied these contactors according to the requirements of our vehicle. No modifications or changes should be made in the layout, physical arrangement or electrical connections without written permission from Crown.

The information contained in this section pertains to the contactors listed below.

Contactor

Voltage

Model Usage

104140

24

SP36,42 & 48,TWR/TR, RR,RS,RD SP36,42 & 48, TWR/TR, RR,RS,RD,FC PE,PC,TWR/TR RC,SC,RR,RS,RD RC,SC,RR,RS,RD,FC RC,SC,RR,RS,RD PE,PC,PR,TWR/TR PE,PC,PR,TWR/TR FC FC RR,RS,RD RR,RS,RD

104483 105706 106109 109740 109747 111634 111635 112218 112220 116001 116002

24 24 36 24 24 24 24 36/48 36/48 24 36

Inspection The following information is intended to assist during periods of normal maintenance and to provide checks for maintaining adjustments. As these devices are tested and adjusted at the factory, they should normally not require further adjustments. However, if factory adjustments are tampered with or otherwise changed, the checks contained in the following information may be made.

CONTACTS In normal operation, the contacts may become blackened, discolored, and roughened. This will not interfere with proper operation and cleaning is not necessary. The contacts should be replaced if the silver contact facing is completely eroded through to the backing material. The silver contact facing may transfer to either the moving or stationary contact and cause buildup on one contact. This can be expected under certain conditions and does not require contact dressing or filing. It is recommended that contacts always be replaced in mating pairs.

COILS Remove coil from circuit by removing wires from terminals, including suppressor. Coil resistance should be as follows:

1737PS

ILLUSTRATION 4.4-1

Coil

Voltage

Resistance

104438 104496 106446 109764 112222 112268

24 24 36 24 36/48 24

11.5 to 14.1 ohms 11.5 to 14.1 ohms 21 to 27 ohms 10.5 to 13.5 ohms 28.2 to 36.2 ohms 14 to 18 ohms

CONTACT AND SPIRAL RETURN SPRINGS

WARNING

Before any inspection, adjustments, servicing, parts replacement or any other act is performed requiring physical contact with the electrical working components or wiring of these contactors; disconnect battery, raise traction wheels clear of floor and place hardwood blocks under truck frame.

These springs should be replaced if signs of corrosion or discoloration from overheating are present.

SPIRAL RETURN SPRING 0282

CONTACT SPRING

ILLUSTRATION 4.4-2

3966 Crown 1991 PF-9022-1 Rev. 8/95

Printed in U.S.A.

03 REV. 8/95

M4.4–11.0–040

M4.4–11.0–040

MAINTENANCE SUPPRESSORS 104141 & 109738 Suppressors: A visual inspection of this suppressor is necessary. Remove from coil. A faulty suppressor will be cracked or broken.

104496 & 104497 Suppressor: This suppressor is a resistordiode network. When meter, on R x 10K scale, is attached with polarity shown in Illustration 4.4-3, a meter reading of less than 5,000 ohms should be realized. Reverse meter leads. Meter should indicate infinite resistance.

0280

ILLUSTRATION 4.4-3

109636 Suppressors: This suppressor contains a diode.

When meter, on R x 10K scale, is attached with polarity shown in Illustration 4.4-4, a meter reading of near 0 ohms should be realized. Reverse meter leads. Meter should indicate infinite resistance.

0281

ILLUSTRATION 4.4-4

7. Assemble stationary tips (Index 14, 15, 16) and bus clamps (Index 25).

8. Assemble stationary tips (Index 27, 28).

9. Assemble clamps (Index 24) and screws (Index 29).

10. Position stationary contact (lndex 14) on bus clamps.

11. Assemble covers and long screws. Start screws in tapped holes of base plate. Tighten screws in one turn increments, using a diagonal pattern. Tighten screws to 14-18 inch-pounds torque (1.6 - 2.0 Newton meters).

COILS (Refer to Illustration 4.4-6) 1. Loosen eight (8) screws (Index 33).

2. Lift contact assembly, including bus base (Index 13), from frame (Index 4) as an assembly.

3. Remove frame (Index 4).

4. Lift coil (Index 3) from post on base plate (Index 1).

Note position of coil terminals in relation to base plate for assembly.

5. Position replacement coil on base plate, as noted at disassembly, and locate projections on base plate in indentations of coil.

6. Position frame (Index 4) over coil and locate projections on magnet frame in indentation of coil.

7. Make certain small end of spiral spring (Index 5) is forced over small diameter of plunger (Index 7) as shown in Illustration 4.4-5.

Component Replacement 104483, 105706, 109747, 111634 Contactors CONTACTS (Refer to Illustration 4.4-6) 1. Loosen eight (8) long screws (Index 33). Lift covers (Index 31) and screws from contactor.

2. Remove stationary tip (Index 14). Loosen and remove screws (Index 29) and clamps (Index 24).

3. Remove stationary tips (Index 27, 28) and bus clamps (Index 25). Turn movable tips 90 degrees and remove stationary tips (Index 14, 15, 16).

4. Loosen and remove 10-32 nut (Index 23) from armature and movable contact tip assembly with 3/8 inch socket or nut driver.

5. Replace contacts.

6. Assemble movable contacts on armature shaft and tighten nut (Index 23) to 14-18 inch-pounds torque (1.6 - 2.0 Newton meters).

1738PS

ILLUSTRATION 4.4-5

8. Position contact assembly on frame.

9. Assemble covers and long screws. Start screws in tapped holes of base plate. Tighten screws in one turn increments, using a diagonal pattern. Tighten screws to 14-18 inch-pounds torque (1.6 - 2.0 Newton meters).

Crown 1991 PF-9022-2 Rev. 8/95

Printed in U.S.A.

03 REV. 8/95

M4.4–11.0–041

M4.4–11.0–041

MAINTENANCE 0052

1 2 18

4

19

3

17

19 21

20

23

26

22

2

6

26 13

5

7

9

4

11 25

24

14

15

10

8

12 6

29 14 16

30

18

27

25 28

21

Index 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

20

23

29

33

17

19 30

32

19

24

31

26 ASSEMBLED VIEW

22

26

Part Name

Index

Plate Magnetic Base Screw M4 Coil Frame Spring Armature Assembly (Includes Index 7 Thru 12) Plunger Washer Washer Guide Lockwasher Nut Stud Base Bus Tip Stationary Tip Stationary Tip Stationary Bushing Plunger Carrier Movable Tip Washer Spring Guide

20 21 22 23 24 25 26 27 28 29

30

31 32 33

Part Name Spring Bus Insulation Upper Flatwasher Locknut #10 Clamp Clamp Bus Tip Movable Tip Stationary Tip Stationary Screw M8 Lockwasher Flatwasher Screw M8 Lockwasher Flatwasher Cover Lockwasher Screw #10

ILLUSTRATION 4.4-6 Crown 1991 PF-9022-3 Rev. 8/95

Printed in U.S.A.

03 REV. 8/95

M4.4–11.0–042

M4.4–11.0–042

MAINTENANCE 104140, 106109, 109740, 111635, 112218, 112220, 116001, 116002 Contactors COIL (Refer to Illustration 4.4-7)

CONTACTS (Refer to Illustration 4.4-7) 1. Remove nut (Index 25) from armature. Lift washer, spring retainer, spring and spring guide washer (Index 24, 23, 22, 21) from armature.

2. Lift movable contact (Index 20) from armature. Install replacement contact.

3. Assemble spring guide washer, spring, spring retainer and washer on armature.

4. Install nut on armature and tighten to 14-18 inchpounds torque (1.6 - 2.0 Newton meters).

5. Remove four (4) long screws (Index 17) and remove the stationary tip clamps (Index 15) from contactor assembly.

6. Remove stationary contacts.

7. Install replacement contacts and secure in place with stationary tip clamps. Tighten four screws, in one turn increments, using a diagonal pattern. Tighten screws to 14-18 inch-pounds torque (1.6 - 2.0 Newton meters).

1. Remove four (4) long screws (Index 17) and stationary tip clamps (Index 15).

2. Remove stationary contacts.

3. Lift stationary tip carrier (Index 13) with the armature assembly (Index 26) from the contactor assembly.

4. Remove magnet frame (Index 5).

5. Lift coil (Index 14) from post on base plate (Index 1).

Note position of coil terminals in relation to base plate for assembly.

6. Position replacement coil on base plate, as noted at disassembly, and locate projections on base plate in indentations of coil.

7. Position magnet frame over coil and locate projections on magnet frame in indentation of coil.

8. Make certain the small end of spiral spring (Index 6) is forced over small diameter of plunger (Index 7) as shown in Illustration 4.4-5. Assemble armature assembly and stationary tip carrier on top of magnet frame.

9. Install stationary contacts and stationary tip clamps.

10. Start four (4) screws in tapped holes of base plate.

Tighten screws, in one turn increments, using a diagonal pattern. Tighten to 14-18 inch-pounds torque (1.6 - 2.0 Newton meters).

Crown 1991 PF-9022-4 Rev. 8/95

Printed in U.S.A.

03 REV. 8/95

M4.4–11.0–043

M4.4–11.0–043

MAINTENANCE 0053

1

2 3

4

18 20 22

19

6

24 26

21

8 10

5

23

7

25

12 9

14

11

13 ASSEMBLED VIEW

15

17 16

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

Part Name

Index

Plate Magnetic Base Suppressor Screw M4 Coil Frame Spring Plunger Washer Washer Guide Lockwasher Nut Stud Carrier Stationary Tip

14 15 16 17 18 19 20 21 22 23 24 25 26

Part Name Tip Stationary Clamp Stationary Tip Lockwasher Screw #10 Bushing Plunger Carrier Movable Tip Tip Movable Washer Spring Guide Spring Retainer Spring Flatwasher Locknut #10 Armature Assembly (Includes Index 7 Thru 12)

ILLUSTRATION 4.4-7 Crown 1991 PF-9022-5 Rev. 8/95

Printed in U.S.A.

03 REV. 8/95

M4.4–11.0–044

M4.4–11.0–044

CONTACTORS Crown has tested and applied these contactors according to the requirements of our vehicle. No modifications or changes should be made in the layout, physical arrangement or electrical connections without written permission from Crown.

The information contained in this section pertains to the contactors listed below.

Contactor

Voltage

Series Usage

104140 104483 106109 111634 111635 112220 125707 126209-002

24 24 36 24 24 36/48 36/48 36

W, WR, SP36 & 48 SP36 & 48, FC 4000 SC 4000 PR 3000, SP 3200 PR 3000 FC 4000 FC/FP, FC 4000 SC 4000

Inspection The following information is intended to assist during periods of normal maintenance and to provide checks for maintaining adjustments. As these devices are tested and adjusted at the factory, they should normally not require further adjustments. However, if factory adjustments are tampered with or otherwise changed, the checks contained in the following information may be made.

CONTACTS In normal operation, the contacts may become blackened, discolored, and roughened. This will not interfere with proper operation and cleaning is not necessary. The contacts should be replaced if the silver contact facing is completely eroded through to the backing material. The silver contact facing may transfer to either the moving or stationary contact and cause buildup on one contact. This can be expected under certain conditions and does not require contact dressing or filing. It is recommended that contacts always be replaced in mating pairs.

COILS Remove coil from circuit by removing wires from terminals, including suppressor. Coil resistance should be as follows:

ILLUSTRATION 1

1737PS

WARNING

Before any inspection, adjustments, servicing, parts replacement or any other act is performed requiring physical contact with the electrical working components or wiring of these contactors; disconnect battery, raise traction wheels clear of floor and place hardwood blocks under truck frame.

Coil

Voltage

Resistance

104438 112222 112268 126240

24 36/48 24 36

11.5 to 14.1 ohms 28.2 to 36.2 ohms 14 to 18 ohms 55 to 65 ohms

SUPPRESSORS CONTACT AND SPIRAL RETURN SPRINGS These springs should be replaced if signs of corrosion or discoloration from overheating are present.

SPIRAL RETURN SPRING 0282

020201

CONTACT SPRING

ILLUSTRATION 2

4306

Crown 2001 PF13175-1 Rev. 11/02

Printed in U.S.A.

02 REV. 11/02

M4.4–1140–010

M4.4–1140–010

CONTACTORS 109738 Suppressor: A visual inspection of this suppressor is necessary. Remove from coil. A faulty suppressor will be cracked or broken.

8. Assemble stationary tips (Index 27, 28).

104496 & 104497 Suppressor: This suppressor is a resistordiode network. When meter, on R x 10K scale, is attached with polarity shown in Illustration 3, a meter reading of less than 5,000 ohms should be realized. Reverse meter leads.

Meter should indicate infinite resistance.

10. Position stationary contact (Index 14) on bus clamps.

9. Assemble clamps (Index 24) and screws (Index 29).

11. Assemble covers and long screws. Start screws in tapped holes of base plate. Tighten screws in one turn increments, using a diagonal pattern. Tighten screws to 1.6 to 2.0 Nm (14 to 18 in.lbs.) torque.

COILS (Refer to Illustration 6)

0280

ILLUSTRATION 3

109636 Suppressors: This suppressor contains a diode.

When meter, on R x 10K scale, is attached with polarity shown in Illustration 4, a meter reading of near 0 ohms should be realized. Reverse meter leads. Meter should indicate infinite resistance.

1. Loosen eight (8) screws (Index 33).

2. Lift contact assembly, including bus base (Index 13), from frame (Index 4) as an assembly.

3. Remove frame (Index 4).

4. Lift coil (Index 3) from post on base plate (Index 1).

Note position of coil terminals in relation to base plate for assembly.

0281

ILLUSTRATION 4

Component Replacement

5. Position replacement coil on base plate, as noted at disassembly, and locate projections on base plate in indentations of coil.

104483, 111634 Contactors CONTACTS (Refer to Illustration 6) 1. Loosen eight (8) long screws (Index 33). Lift covers (Index 31) and screws from contactor.

6. Position frame (Index 4) over coil and locate projections on magnet frame in indentation of coil.

7. Make certain small end of spiral spring (Index 5) is forced over small diameter of plunger (Index 7) as shown in Illustration 5.

2. Remove stationary tip (Index 14). Loosen and remove screws (Index 29) and clamps (Index 24).

3. Remove stationary tips (Index 27, 28) and bus clamps (Index 25). Turn movable tips 90 degrees and remove stationary tips (Index 14, 15, 16).

4. Loosen and remove 10-32 nut (Index 23) from armature and movable contact tip assembly with 3/8 inch socket or nut driver.

5. Replace contacts.

6. Assemble movable contacts on armature shaft and tighten nut (Index 23) to 1.6 to 2.0 Nm (14 to 18 in.lbs.) torque.

7. Assemble stationary tips (Index 14, 15, 16) and bus clamps (Index 25).

Crown 2001 PF13175-2

M4.4–1140–011

1738PS

ILLUSTRATION 5

8. Position contact assembly on frame.

9. Assemble covers and long screws. Start screws in tapped holes of base plate. Tighten screws in one turn increments, using a diagonal pattern. Tighten screws to 1.6 to 2.0 Nm (14 to 18 in.lbs.) torque.

Printed in U.S.A.

M4.4–1140–011

CONTACTORS 0052

1 2 18

4

19

3

17

19 21

20

23

26

22

2

6

26

9

13

5

7

4

11 25

24

14

15

10

8

12 6

29 14 16

30

18

27

25 28

21

Index 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

20

23

29

33

17

19 30

32

19

24

31

26 ASSEMBLED VIEW

22

26

Part Name

Index

Plate Magnetic Base Screw M4 Coil Frame Spring Armature Assembly (Includes Index 7 Thru 12) Plunger Washer Washer Guide Lockwasher Nut Stud Base Bus Tip Stationary Tip Stationary Tip Stationary Bushing Plunger Carrier Movable Tip Washer Spring Guide

20 21 22 23 24 25 26 27 28 29

30

31 32 33

Part Name Spring Bus Insulation Upper Flatwasher Locknut #10 Clamp Clamp Bus Tip Movable Tip Stationary Tip Stationary Screw M8 Lockwasher Flatwasher Screw M8 Lockwasher Flatwasher Cover Lockwasher Screw #10

ILLUSTRATION 6 Crown 2001 PF13175-3

M4.4–1140–012

Printed in U.S.A.

M4.4–1140–012

CONTACTORS 104140, 106109, 111635, 112220, 125707, 126209 Contactors COIL (Refer to Illustration 7)

CONTACTS (Refer to Illustration 7) 1. Remove nut (Index 25) from armature. Lift washer, spring retainer, spring and spring guide washer (Index 24, 23, 22, 21) from armature.

1. Remove four (4) long screws (Index 17) and stationary tip clamps (Index 15).

2. Remove stationary contacts.

2. Lift movable contact (Index 20) from armature. Install replacement contact.

3. Assemble spring guide washer, spring, spring retainer and washer on armature.

4. Install nut on armature and tighten to 1.6 to 2.0 Nm (14 to 18 in.lbs.) torque.

5. Remove four (4) long screws (Index 17) and remove the stationary tip clamps (Index 15) from contactor assembly.

3. Lift stationary tip carrier (Index 13) with the armature assembly (Index 26) from the contactor assembly.

4. Remove magnet frame (Index 5).

5. Lift coil (Index 14) from post on base plate (Index 1).

Note position of coil terminals in relation to base plate for assembly.

6. Position replacement coil on base plate, as noted at disassembly, and locate projections on base plate in indentations of coil.

6. Remove stationary contacts.

7. Install replacement contacts and secure in place with stationary tip clamps. Tighten four screws, in one turn increments, using a diagonal pattern. Tighten screws to 1.6 to 2.0 Nm (14 to 18 in.lbs.) torque.

7. Position magnet frame over coil and locate projections on magnet frame in indentation of coil.

8. Make certain the small end of spiral spring (Index 6) is forced over small diameter of plunger (Index 7) as shown in Illustration 5. Assemble armature assembly and stationary tip carrier on top of magnet frame.

9. Install stationary contacts and stationary tip clamps.

10. Start four (4) screws in tapped holes of base plate.

Tighten screws, in one turn increments, using a diagonal pattern. Tighten to 1.6 to 2.0 Nm (14 to 18 in.lbs.) torque.

Crown 2001 PF13175-4 Rev. 5/02

Printed in U.S.A.

01 REV. 5/02

M4.4–1140–013

M4.4–1140–013

CONTACTORS 8920

1

2 3

4 18 20 6

22

19

24

26 8

21 10

5

7

23

12 9

25 14

11

Assembled View 13 15

17 16

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

Part Name

Index

Plate Magnetic Base Suppressor Screw M4 Coil Frame Spring Plunger Washer Washer Guide Lockwasher Nut Stud Carrier Stationary Tip

14 15 16 17 18 19 20 21 22 23 24 25 26

Part Name Tip Stationary Clamp Stationary Tip Lockwasher Screw #10 Bushing Plunger Carrier Movable Tip Tip Movable Washer Spring Guide Spring Retainer Spring Flatwasher Locknut #10 Armature Assembly (Includes Index 7 Thru 12)

ILLUSTRATION 7 Crown 2001 PF13175-5

M4.4–1140–014

Printed in U.S.A.

M4.4–1140–014

C

CONTROL POD

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

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

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

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

Adjustments

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

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

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

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

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

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

Remove covers from top and bottom of control pod.

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

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

Install covers.

930415

7188 - EO10973

Crown 1993 PF9758-1 Rev. 1/04

Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–010

M4.5–04.2–010

C

CONTROL POD

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

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

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

Install covers.

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

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

0271S

ILLUSTRATION 1

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

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

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

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

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

Perform potentiometer adjustment procedures.

Install covers.

Crown 1993 PF9758-2 Rev. 1/04

Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–011

M4.5–04.2–011

C

CONTROL POD

Component Replacement

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

Remove covers from top and bottom of control pod.

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

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

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

47 46

48

45

42 41

43 41 42 44 41

0273

49 50

42 42

43

0272S

51

52 53

ILLUSTRATION 3

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

ILLUSTRATION 2

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

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

Install speed nut.

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

Perform switch adjustment procedures.

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

Install covers.

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

Install covers.

Crown 1993 PF9758-3 Rev. 1/04

Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–012

M4.5–04.2–012

C

CONTROL POD

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

20 14

12 11

11 10

19 9

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

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

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

10

Install covers.

13 8

TWIST GRIPS

7 64 ILLUSTRATION 0274

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

Install covers.

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

POTENTIOMETER (Illustration 5) PART OF CONTROL POD

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

PART OF YOKE TWIST GRIP

EXTENSION ROLL PINS 1977

0275S

ILLUSTRATION 6

ILLUSTRATION 5

Crown 1993 PF9758-4 Rev. 1/04

Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–013

M4.5–04.2–013

C

CONTROL POD

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

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

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

Part of Control Pod Part of Yoke Twist Grip

0277S

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

Roll Pins

Extension ILLUSTRATION 7

3871

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

Remove extension from grip and remove grip from yoke.

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

STOP & RETURN ASSEMBLY (TRANSISTOR & SCR CONTROL)

SPACER (TRANSISTOR & SCR CONTROL)

0276S-01

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

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

WASHERS CAM

STOP (RESISTOR CONTROL)

ILLUSTRATION 9

Install covers.

SPEED CAM (RESISTOR CONTROL)

ILLUSTRATION 8

Crown 1993 PF9758-5 Rev. 1/04

Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–014

M4.5–04.2–014

C

CONTROL POD

DETENT ARM AND SPRING

COVER

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

SWITCH SHOULDER SCREW INSULATOR SHOULDER SCREW

BUTTON SPRING ROLL PIN

BUTTON

0278S

ILLUSTRATION 10

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

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

Install covers.

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

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

0905-01

ILLUSTRATION 11

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

Adjustment Screw

3873 Crown 1993 PF9758-6 Rev. 1/04

Load Backrest Pod

ILLUSTRATION 12 Printed in U.S.A.

02 REV. 1/04

M4.5–04.2–015

M4.5–04.2–015

MAINTENANCE CURTIS MODEL 933/3 BATTERY DISCHARGE INTERRUPT (BDI) DISCHARGE N

1 2 3 4 5 6 7 8

O

P

M L C

K D

BATTERY

F INDICATOR

+

–

E 1/2

B

E

A

1/10

RESET

CURTIS 933 CURTIS CONTROLS DIVISION Manufactured in The USA

MODEL 933/3 Made in the USA Patent Pending This is a Static Sensitive Device Only Authorized Service Technicians

METER WITH POINTER

TWO WIRE METER (Red LEDs)

THREE WIRE METER (Red LEDs)

BDI/HOUR METER w/ 10 LED'S (Green & Yellow)

CONTROLLER 4245-01

ILLUSTRATION 4.6-1

The CURTIS MODEL 933/3 consists of two (2) components: the meter and the controller. Refer to Illustration 1.

The purpose of the Battery Discharge Interrupt (BDI), is to monitor and protect the battery and other electrical components of the lift truck. When the battery is not replaced or recharged at the correct time, generally at 80% discharge or 1.74 volts per cell (VPC), the battery will experience high current draws that will damage battery and electrical components. To avoid continued discharge at this level, a contact in the controller of the BDI which is placed in the lift pump circuit, opens and inhibits the lift function until the battery is recharged or a freshly charged battery is installed in the truck.

Meter Operation Your meter may have either an indicator pointer or LED levels.

The indicator pointer meter shows the state-of-charge of the battery. The pointer will move from the green ball (full charge zone) to the red ball (discharged zone) as the battery is discharged. As the pointer moves to the solid yellow area, a reserve warning light will begin to flash. This flashing light indicates approximately 5% battery capacity available before the lift contactors will be locked out. If the battery continues to be discharged, the pointer will move to the red ball zone. The red ball zone indicates lift lockout to prevent deep discharge of the battery and electrical component damage. When the battery is recharged or replaced with a fully charged battery, the meter will reset to the level of the recharged or replaced battery.

charged battery. If the battery continues to be discharged, the last LED will be turned on and the last two LEDs will flash alternately. Lift lockout will then occur until battery exchange or recharge takes place.

Controller Operation/Adjustment The controller, designed especially for lift trucks, has been adjusted at the factory to settings of "B" for reset and "N", for discharge. These settings have been found to be satisfactory in most industrial applications.

The reset setting of "B" equals 2.1 volts per cell (VPC), 25.2 open circuit voltage for a 24 volt battery, 37.8 open circuit voltage for a 36 volt battery. The specific gravity (SG) of the battey at 2.1 VPC is approximately 1250. As a battery charged to this level is connected to the truck the instrument will reset. A battery charged to less than 2.1 VPC will not cause reset. A battery's condition, or capacity, will decline due to age and/or improper maintenance and a 2.1 VPC reading is not possible. To utilize a battery in this condition it is necessary to make a reset adjustment toward "A". On the other hand, new batteries and batteries in better condition may necessitate a reset adjustment from "B" to "E". This adjustment will increase the VPC that are needed to reset the instrument; 2.125 VPC for example. Battery condition, battery size, and the truck's duty cycle must be considered before making any adjustment from the "B" setting.

Example: A 24 volt battery with a shorted cell may only read 23.1 open circuit volts; 2.1 VPC x 11 = 23.1.

NOTE

The LED meter also monitors the battery. When the battery is at full charge, the 1st LED is illuminated. As the battery discharges, the illuminated LED is turned off and the next LED is turned on. When the next to last is illuminated, the battery should be recharged or exchanged with a fully Crown 1982 PF-5315-1 Rev. 7/96

This adjustment should only be done to allow time to make necessary repairs to the battery.

Continued use could cause permanent damage to battery, charger and truck.

Printed in U.S.A.

03 REV. 7/96

M4.6–11.0–200

M4.6–11.0–200

MAINTENANCE A lower reset adjustment may be necessary. Remove the potentiometer protector by hand turning in a CCW direction.

Turn the shaft, with arrow on top, toward the "A" setting to lower or decrease the VPC necessary to allow reset to occur.

This decrease may be 2.08 VPC for example. Refer to Chart 1 for discharge and reset VPC settings.

DISCHARGE O P

INCREASE

N

M

L

K

The discharge setting of "N" equals 1.74 VPC, 20.9 open circuit voltage for a 24 volt battery, 31.32 open circuit voltage for a 36 volt battery. As the battery is discharged to 1.74 VPC, the discharge alarm will activate causing the truck's lift contactor(s) to be locked out. Lockout prevents deep-discharge of the battery causing battery damage and possible truck electrical component damage. The "N" setting, 1.74 VPC, represents 80% battery discharge; 1.70 VPC equals a 100% discharged battery. The 80% discharge point is the recommended point for battery recharge or replacement.

The specific gravity (SG) at 1.74 VPC is approximately 1150.

To change the discharge setting, remove the potentiometer protector by hand turning in a CCW direction. Turn shaft, with arrow on top, from "N" toward "K" to lower or decrease the VPC necessary to activate the discharge alarm and cause lift lockout. Adjustments made fron "N" toward "P" will increase the VPC needed to cause lift lockout. Consider the battery condition, battery size, and the truck's duty cycle before making any adjustments from the "N" setting.

CAUTION

D E

INCREASE

C

Should a battery capable of reset be connected to the truck it will take approximately 10 seconds before the meter will read properly and reset to occur. If the discharged battery is then reconnected to the truck it will take 20 to 30 minutes before lockout will occur. this additional discharge to the battery can cause severe component and battery damage due to deep discharge

B

A

WIRING DIAGRAM

RESET

Battery Positive 4055

ILLUSTRATION 4.6-2

Discharge Pot Setting VPC P O * N M L K Beyond K

1.82 1.78 1.73 1.68 1.63 1.57 1.56

Existing Lift Switch

RESET Pot Setting VPC E D C * B A Beyond A

Existing Lift Contactor Coil

Fast Test Input 4 5 3

Panel

2.18 2.15 2.12 2.09 2.06 2.00

Meter

Battery Connector Break Existing Connection

1 2 3 4 5 6 7 8

933/3 + Battery – Meter + Battery Led – Lift – Battery – Battery

Battery Negative 4054

ILLUSTRATION 4.6-3

* Factory Setting CHART 4.6-1

Crown 1982 PF-5315-2 Rev. 9/95

Printed in U.S.A.

01 REV. 9/95

M4.6–11.0–201

M4.6–11.0–201

MAINTENANCE To Battery Positive (+)

Controller Tester "1141"

"1142" Tester

DISCHARGE N

Button 1 2 3 4 5 6 7 8

2

8

O

P

M L C

K D

E

B A

RESET

CURTIS 933 CURTIS CONTROLS DIVISION Manufactured in The USA

MODEL 933/3 Made in the USA Patent Pending This is a Static Sensitive Device Only Authorized Service Technicians

Controller 4056

ILLUSTRATION 4.6-4

Operational Test Should a unit fail to function properly or be replaced by a new unit, a fast-run-down controller tester "1141", when used with "1142" tester, will cause the meter to go from "full" to "lockout" in approximately one (1) minute. The "1142" tester can be used alone and will cause the meter to go from "full" to "lock-out in approxomately 30 minutes. The following procedure should be followed when using the "1141" and/or "1142" testers: (A) Disconnect trucks' battery.

(E) If battery is completely charged the meter will go to "full". Check that the truck's lift mode is functional.

(F) Move the "1142" switch to RUN position, starting the normal 30 minute discharge. Push button on "1142" tester, speeding up the rate of discharge.

(G) As the pointer goes into the solid yellow zone the "reserve warning" light flashes. When the pointer reaches the red ball lift lockout takes place. Check truck's lift mode.

Refer to Illustration 4.6-4 For B & C. NOTE (B) Connect "FasTest 1141" to controller (black lead to terminal #8 of controller and blue lead to terminal #2 of controller).

(C) Disconnect the battery positive lead from terminal #1 of controller. Connect spade terminal of "1142" tester to terminal #1. Connect battery positive to screw terminal of "1142".

"1142" tester used by itself will necessitate an approximate 30 minute discharge time.

NOTE If the operational test checks okay on a unit it may be benificial to use an ampere-hour meter to determine ampere-hours used at interrupt.

(D) Move "1142" switch to RESET position. Wait ten seconds and connect battery to truck.

Crown 1982 PF-5315-3 Rev. 9/95

Printed in U.S.A.

01 REV. 9/95

M4.6–11.0–202

M4.6–11.0–202

MAINTENANCE Ampere-Hour Meter

Function

An "Ampere-Hour" meter monitors and displays current draw as it occurs and records the accumulated total amperehours used. The ampere-hour meter connects between the battery and the truck. With a properly charged battery in the truck, the truck is put through a duty cycle which represents the work it is required to perform during its shift. The elasped time is recorded with a stop watch. From these figures it can be computed to determine when lockout should occur. Refer to Chart 2.

A fully charged battery has a capacity rating by the battery manufacture; this is called ampere-hour rating. The amount of time it takes to discharge a battery depends on how hard the battery is worked. High current rates or hard work cut down the discharge time. Example: a 226 ampere-hour (A.H.) battery is worked at a 452 amperes per hour rate. This battery will reach 100% discharge in 30 minutes. A 600 A.H. battery doing work at 100 ampere-hour will reach 100% discharge in 6 hours. Low battery voltage causes contactors to chatter, sluggish motor starts and causes internal heating of the battery which shortens its life. Refer to Illustration 6.

Time (seconds)

Accumulated Ampere-Hours

Run Lift 15 in. (380mm) Place Back Out Turn Run Turn Run Lift 1 in. (25mm) Run Lift 10 in. (255mm) Sideshift Stack Load

10 12 1 3 1 11 1 5 1 30 8 2 2

0.347 1.114 1.156 1.281 1.308 1.919 1.956 2.130 2.194 3.444 3.955 4.094 4.177

Totals

87

4.200

CHART 4.6-2 1.265 S.G. 180.8 A.H. 1.245 S.G. 246 A.H. 1.220 S.G. 355 A.H. 1.195 S.G. 408 A.H. 1.180 S.G. 480 A.H. 1.169 S.G. 525 A.H.

Recommended Max. Discharge 80% Specific Gravity

% of Total Capacity at Given Rate to 6 Hr. Rate

1.300 1/2 Hr., 226 A.H., 452 Amps.

1.0 Hr., 330 A.H., 330 Amps.

1.270

2.0 Hr., 444 A.H., 222 Amps.

37.5%

3.0 Hr., 510 A.H., 170 Amps.

1.240

6.0 Hr., 600 A.H., 100 Amps.

49%

10.0 Hr., 656 A.H., 65.6 Amps.

1.210

74% 1.180 85% 1.150

0

10

20

30

40

50

60

70

80

90

100

100% 109%

% of Rated Ampere-Hour Capacity 4057

ILLUSTRATION 4.6-5

Crown 1982 PF-5315-4 Rev. 9/95

Printed in U.S.A.

01 REV. 9/95

M4.6–11.0–203

M4.6–11.0–203

MAINTENANCE Only 80% of the rated capacity is available for actual work.

At about 80% discharged, the voltage drops off quickly causing high current draws that are harmful to the truck and battery. Batteries should be changed at 80% discharged.

Open circuit voltage and specific gravity are related as how hard a battery is worked. Open circuit voltage and specific gravity will vary with different current rates. SG readings taken immediately after using a battery will change depending on the stabilization of the acid throughout the electrolyte, which can take up to 24 hours. This reading can drop as much as 20 points. However, the open circuit voltage may rise up to a tenth of a volt per cell. Refer to Illustration 6.

To determine the approximate worktime of a battery at the average current rate use the following procedure:

(B) Divide the ampere-hours available by 6 to obtain average current. Example: 600 ÷ 6 = 100 amperes.

(C) Divide the average current needed in the example used earlier, 174 amperes, by the 6 hour discharge current, 100, to obtain the ratio of the average current required to the 6 hour discharge current.

Example: 174 = 1.7 ratio 100 (D) Use the graph in Illustration 6 and 1.7 ratio equals 3 hours to reach 100% discharge and 2 1/2 hours of work time until 80% discharge is reached.

Lockout should occur at approximately the time when the battery reaches 80% discharge. If the instrument is doing this it is operating correctly.

(A) Refer to the battery's identification plate for the number of ampere-hours available. Example: 600 A.H. at the 6 hour rate.

To compute average current use the following formula: Accumulated ampere-hours x

(Example)

4.2 x

3600 sec./hr Total Time 3600 sec./hr 87

= Average current

= 173.8

Ratio of Current Drain to 6.0 Hr. Discharge Current

5

4

3

Capacity to 100% Discharge

2 Capacity to 80% Discharge (Work Time) 1

0 4058

1

2

3

4

5

6

7

Hours ILLUSTRATION 6

Crown 1982 PF-5315-5 Rev. 9/95

Printed in U.S.A.

01 REV. 9/95

M4.6–11.0–204

M4.6–11.0–204

MAINTENANCE Troubleshooting Symptom:

Remedy:

Gage will not reset.

Check battery state-of-charge, both voltage and specific gravity (SG). The "B" setting equals 2.12 volts per cell (VPC). Batteries charged to 1250 or better will have this voltage. The "A" setting equals 2.055 VPC equaling 1210 SG. If a battery is not able to produce reset at the "A" setting, the battery and/or charger must be checked.

Truck comes in too soon for battery recharge/change.

Check specific gravity (SG) of battery when the meter light comes on. Do not turn the SG alarm towards "K" if the SG of the battery corresponds to more than 80% discharge (1150 for most batteries). More running time can be obtained by turning the SG alarm from "N" setting towards "K", providing the battery does not show 80% discharge. Under no circumstances should the adjustment be made if the SG corresponds to more than 80% discharge at the 6 hour rate.

Gage sticking.

Disconnect battery. Connect ohmeter to pin 4 and then tapping pin 3 with the other lead. DO NOT slip onto pin 3, you might burn out the 1 millampere meter movement.

As you tap pin 3 the gage pointer will jump, if not, the meter should be replaced.

Gage moves erratically or bounces.

Probable cause is noise pickup from unsurpressed contactor coil(s). Check suppression circuits on all contactor coils and replace defective circuits. If all suppressor circuits are operational, the controller and or gage could be defective.

Reserve Warning Light does not illuminate.

Check meter wiring and/or battery voltage. Meter defective.

Reserve Warning Light illuminate continuously.

Check meter wiring and/or battery voltage. Meter defective.

Lift not locked out when gage pointer enters red area of gage

Remove wire from pin 6 on the controller and try to lift. If lift is functional problem is in truck wiring. If lift is not functional reconnect wire to pin 6. Connect either tester 1141 or 1142 or both to controller. Run gage to red ball. Verify gage light is blinking. Lift should not work. If lift does work, replace controller and gage.

Lift lockout occurring unusually early.

Run the lift motor and check the voltage directly across the (This condition only pertinent after the truck has been battery terminals. Repeat this check at terminals 1 and 8 on operating successfully for serval months with the fuel gage) the controller. The readings should be within 0.5 volts of each other. Possible causes: high resistance in truck to battery connector.

Specific gravity (SG) is very low at lockout.

This can occur with a lightly worked truck where there is very little lifting and a lot of travel. Make a course adjustment by turning the discharge pot from "N" to "P" and measure SG after several cycles of operation. Fine tune by turning back towards "O" if SG is to high.

Crown 1982 PF-5315-6 Rev. 9/95

Printed in U.S.A.

01 REV. 9/95

M4.6–11.0–205

M4.6–11.0–205

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

C

MOTORS CAUTION

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.

CAUTION

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.

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: 75 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.

931201

5671

Crown 1993 PF9985-1Rev. 5/03

Printed in U.S.A.

02 REV. 5/03

M4.7–6435–001

M4.7–6435–001

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.

PW 3000 SERIES Capacity

Travel

Lift-Empty

Lift Relief

2720 kg 40-50 75-95 165-195 (6000 lbs.)

3630 kg 40-50 75-95 180-210 (8000 lbs.)

-------------------------------------------------------------------PW 3520-3.0 40-50 75-95 165-195 PE 3000/4000 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.)

75-95

85-105

180-210

75-95

90-110

195-225

Travel

Lift-Empty

Lift Relief

PC 3000 SERIES

PR 3000 SERIES Capacity

Power Steering Idle 15-20

Power Steering Relief 65-75

2720 kg 100-120 80-100 170-200 (6000 lbs.)

3630 kg 100-120 80-100 170-200 15-20 65-75 (8000 lbs.)

-------------------------------------------------------------------------------------------------------------------PR 3520-3.0 100-120 80-100 170-200 15-20 65-75

Crown 1993 PF9985-2 Rev. 5/03

Printed in U.S.A.

02 REV. 5/03

M4.7–6435–002

M4.7–6435–002

MAINTENANCE TROUBLESHOOTING PROCEDURES RECOMMENDED TEST EQUIPMENT

Switches

Volt-ohm meter — Simpson 260 or equal; sensitivity 20,000 ohm/volt D.C., 5,000 ohm/volt A.C.; ranges required 0-50 volts D.C., 0-250 volts A.C.

Disconnect lead from one side of switch. With volt-ohm meter on resistance scale, place test prods across switch terminals. If normally open (N.O.) type contacts are being checked, the meter should read a very high (infinite) resistance. Meter should read zero ohms if normally closed (N.C.) contacts are checked. When the switch is depressed the resistance reading should be opposite.

Test jumper approximately 36 in.(900mm) long (No. 10 wire) with clips on both ends (2 required).

Battery cell tester on hydrometer.

Diode For SCR controlled units, see SCR Operation and Maintenance section of manual for additional test equipment.

For transistor controlled units, see Transistor Operation and Maintenance section of manual for additional test equipment.

To check the diode, disconnect the leads and check resistance between the terminals. Resistance should be 7-12 ohms in the conducting direction, and 50,000 ohms or higher in the non-conducting direction.

CONDUCTING

+

—

—

+

PROCEDURE FOR CHECKING INDIVIDUAL COMPONENTS NON-CONDUCTING

Battery Cell tester operation will vary with different models. See manufacturer’s instructions supplied with your instrument.

When using a hydrometer, the specific gravity of a fully charged battery should be 1.280. Check each cell. All cells should have close to same reading.

0848

Discharge Indicator Connect one end of test jumper to the positive terminal, the other end to battery positive. Meter should show reading.

Check leads to key switch and control fuse.

Charger Fuses Consult charger manufacturer’s instructions for his recommended test procedures.

CAUTION

Power circuit. Remove power fuses, jack truck so drive wheels are clear of floor and place blocks under truck frame before making following checks.

Disconnect battery before making resistance checks.

Some blown fuses can be detected by a visual inspection; however, others will require checking with a volt-ohm meter.

Remove fuse from circuit, place meter in the R x 1 position, place test prod on each end of fuse. Meter should read zero ohms. Be sure to investigate cause of blown fuse.

Horn

Contactor Connect one end of test jumper to coil positive terminal.

Make sure other coil terminal is connected to battery negative. Connect other end of test jumper to control side of control circuit fuse. The contactor should pull in. See contactor information elsewhere in this section for additional checks.

To check, use jumper lead from battery positive to positive terminal on horn. Horn should sound. On SCR controlled units, remove lead from positive horn terminal to hash filter to eliminate hash filter as a cause of malfunction. Retest and if it does not sound, place a jumper from negative horn terminal to battery negative to check the negative leads.

5846 Crown 1982 PF5396-1 Rev. 8/98

Printed in U.S.A.

04 REV. 8/98

M4.8–04.2–001

M4.8–04.2–001

MAINTENANCE Hour meter

Key Switch

Connect one end of jumper to positive hour meter terminal and the other end to battery side of power fuses. Meter should run. If not, check continuity from negative terminal to battery negative. If meter still does not run, remove lead from positive hour meter terminal to hash filter to eliminate hash filter as a possible cause of the malfunction and retest.

Check with jumper from terminal wire to discharge indicator.

Drive Motor Remove brushes from motor and check for chips, cracks, and wear. Brushes that are worn beyond one-half the length of a new brush should be replaced. Replace brushes, if required, and disconnect cables A1, A2, S1 and S2 from contactors.

Time Delay Relay Remove positive (blue) leads and one lead from contact terminals. (Green stripe is contact terminal lead.) Connect Volt-ohm meter leads across contact terminals. Connect one end of test jumper to positive terminal and other end to battery side of power fuse. Meter should read zero ohms within one-half second.

SCR Components Consult the SCR section of the manual for procedures on checking components associated with the SCR control system, as well as suppressors, hash filters and potentiometer.

CAUTION Transistor Components

Watch for moving lift.

Connect cables A1 and S2 together. Connect one end of test jumper to cable S1 and connect the other end of test jumper to battery side of 100A fuse. Connect A2 lead to battery negative. Motor should run. If not, check cables for good connection at motor. Check for continuity between cables, S1, S2 and A1, A2.

Pump Motor Connect test jumper across power terminals on pump contactor. Motor should run.

CAUTION

Consult the transistor section of the manual for procedures on checking components associated with the transistor control system.

Power Solenoid Typically used on pump motors. Remove power fuse from circuit. Connect a volt-ohm meter on the resistance scale across the solenoid power contacts. Meter should read a high resistance (infinite). Connect test jumper between the coil positive terminal and the control side of control circuit fuse. The solenoid should actuate, indicated by a meter reading of zero ohms.

Double Diode Block 075256

Test jumper may become warm because of high motor current.

+

1

—

2

3

+

If motor does not run, remove motor brushes and check for chips, cracks, and wear. Brushes that are worn beyond onehalf the length of a new brush should be replaced. Also check continuity in armature and motor field windings.

0849

Solenoids To check solenoids, connect jumper lead to positive lead of solenoid. Connect other end of jumper to positive battery terminal. Solenoid should activate. If solenoid still does not activate, disconnect lead from positive terminal of solenoid to varistor to eliminate varistor as the cause of the malfunction and retest.

To check a double diode block, connect the negative meter lead to terminal 2 and the positive meter lead to terminal 1 then terminal 3. The meter indication should be a short circuit. Connect the positive meter lead to terminal 2 and the negative lead to terminal 1 then terminal 3. The meter indication should be open circuit.

Crown 1982 PF5396-2 Rev. 8/98

Printed in U.S.A.

04 REV. 8/98

M4.8–04.2–002

M4.8–04.2–002

MAINTENANCE Single Suppressor Block 077728, 085670 & 091181

Switch Suppressor Block 085484 & 086755

—

+ RED

GREEN

V

0850

A conclusive test cannot be performed on this style filter with a conventional analog meter. A meter should indicate an open circuit, on the R x 10,000 ohm scale, in both directions.

If this suppressor is the suspected problem, replace with a known good component.

Dual Suppressor Block 082495, 086322 & 093757 —

+

0852

To check this style filter, connect the negative meter lead to one terminal and the positive meter lead to the other terminal for approximately 5 seconds. Reverse the meter leads. The VOM needle should deflect and return to infinity when on the Rx10,000 ohm scale.

Hash Filter 077732

+

0851 0853

This style filter is checked in the same manner as the single suppressor block. If this suppressor is the suspected problem, replace with known good component.

This style filter is checked in the same manner as the switch suppressor block.

Dual Suppressor Block 115487

Diode Block 113511

1

2

3

4

5

1

2

3

4

5

3809 3810

This style filter is checked in the same manner as the single suppressor block. If this suppressor is the suspected problem, replace with known good component.

To check this diode block, connect the negative meter lead to terminal 1 and the positive meter lead to terminal 2. Meter should indicate short circuit. Reverse meter leads. The meter should indicate open circuit. Connect the negative meter lead to terminal 3 and the positive meter lead to terminal 4. Meter should indicate short circuit. Reverse meter leads. The meter should indicate open circuit. Move positive meter lead to terminal 5. Meter should indicate open circuit. Reverse meter leads. Meter should indicate short circuit.

Crown 1982 PF-5396-3 Rev. 5/95

Printed in U.S.A.

03 REV. 5/95

M4.8–04.2–003

M4.8–04.2–003

MAINTENANCE Regulator 113741

1

2

3

3811

A conclusive test cannot be performed on this component with a conventional analog meter. To check this regulator, set meter to R x 1,000 ohm scale and connect meter leads to terminals 1 and 2. Meter should read 4.5k to 5k ohms. If resistance checks OK and regulator is suspected faulty, replace with known good component.

Diode Block 113587

1

2

3

4

0904

To check this diode block, connect the negative meter lead to terminal 1 and the positive meter lead to terminal 2. Meter should indicate short circuit. Move the negative meter lead to terminal 3. The meter should again indicate short circuit.

Connect the positive meter lead to terminal 1 and the negative meter lead to terminal 2. The meter should indicate open circuit. Move the positive meter lead to terminal 3. The meter should again indicate short circuit. Connect the negative meter lead to terminal 3 and the positive meter lead to terminal 4. Meter should indicate short circuit. Reverse the meter leads. The meter should indicate open circuit.

Crown 1982 PF-5396-4 Rev. 5/95

Printed in U.S.A.

03 REV. 5/95

M4.8–04.2–004

M4.8–04.2–004

MAINTENANCE TROUBLESHOOTING CHART The following charts contain simple and easy-to-follow tables that outline the various symptoms and the corrective action required.

Reconnect the battery as needed for the specific check, and be familiar with both component testing and replacement procedures before proceeding.

Before proceeding, visually check for loose wiring, signs of overheating of components, etc.

A check for leakage from battery positive to frame and battery negative to frame should be checked as part of normal maintenance. Check resistance on R x 1000 scale from frame to battery positive; a reading of less than 20,000 ohms can cause misleading symptoms. The same readings can be applied when checking from frame to battery negative. A resistance of less than 20,000 ohms should be corrected before proceeding.

CAUTION

Before touching any electrical components disconnect battery and jack the drive wheel off the floor.

ALL TESTING SHOULD BE DONE WITH TRUCK JACKED UP Symptom

Probable Cause

1.

a. b. c. d. e. f. g. h.

No travel in either direction.

i. j. k. l. m. n.

Check battery for charge.

Control circuit fuse.

Power circuit fuse.

Key switch.

Brake switch.

Reversing switch (forward direction only).

Directional switches.

Check control harness for broken or damaged leads.

Directional contactors.

Resistor (resistor control units only).

Power cables loose or poor connections.

Drive motor.

On SCR controlled units consult the SCR information in this manual.

On transistor controlled units consult the transistor information in this manual.

2.

No second speed in either direction (resistor control units only).

a. b. c. d.

Second speed switch in handle.

Second speed (A) contactor.

Resistor.

Check control wiring and power leads from (A) contactor.

3.

No third speed in either direction (resistor control units only).

a. b. c. d. e. f.

Third speed switch in handle.

Third speed cutout switch in handle.

High speed switch.

Time delay relay.

Third speed (B) contactor.

Brown, brown stripe, green, green stripe leads and blue lead to time delay relay in the control circuit and power leads from (B) contactor to resistor.

Crown 1989 PF-8924-1 Rev. 10/91

Printed in U.S.A.

01 REV. 10/91

M4.9 - 06.5 - 001

M4.9 - 06.5 - 001

MAINTENANCE Symptom

Probable Cause

4.

No lift (motor doesn’t run).

Check on all units: a. Battery. b. Power circuit fuse. c. Control circuit fuse. d. Lift solenoid. e. Power leads to pump motor. f. Lift motor. g. Lift switch in handle. h. Diode on contactor panel. i. Raise solenoid. j. Check control wiring to lift solenoid.

5.

No lift but motor runs.

Check on all units: a. Low hydraulic fluid in reservoir. b. Seals and wear plate in pump. c. Coupling between pump and motor. d. Raise solenoid not activating. e. Lower solenoid (stuck open).

6.

Unit doesn’t lower.

a. Lower switch in handle. b. Lower solenoid. c. Check control wiring in handle and to lower solenoid.

7.

Load creeps down.

a. b. c. d. e.

8.

Power circuit fuse blows.

a. Check all power cables for shorts. b. Check contactors for proper operation. c. Check motors for shorts.

9.

Control circuit fuse blows. possible shorts.

Check control leads for damaged leads and

Leaks in hydraulic lines.

Cylinder packing.

Internal leakage in raise-lower valve.

Check valve.

Lower solenoid valve.

10. SCR malfunctions.

See the SCR information in this manual.

11. Transistor malfunctions.

See the transistor information in this manual.

Crown 1989 PF-8924-2 Rev. 10/91

Printed in U.S.A.

01 REV. 10/91

M4.9 - 06.5 - 002

M4.9 - 06.5 - 002

MAINTENANCE

2611S

ILLUSTRATION 5-1

BRAKE SYSTEM

Brake Bleeding

The brake system used on your Pallet Rider consists of a motor mounted brake which is released as the operator depresses the brake pedal. The pedal movement is transferred into hydraulic pressure by means of a master cylinder which is attached to the pedal beneath the platform. The master cylinder is connected to the slave cylinder, located on the drive unit, by brake lines. The slave cylinder, in turn, changes the hydraulic pressure into linear motion and mechanically activates the brake linkage which releases the brake. As the operator lets up on the brake pedal, a spring applies the brake by expanding the brake shoes inside the brake drum.

It may become necessary to bleed the brake system to remove any air that has been trapped in the lines. Best results are obtained if the system is bled by using a pressure bleeder such as KD tools #255 or Wagner Lockheed #FL444 Fluid Ball or the equivalent. The following procedure should be used to bleed the system if a pressure bleeder is used.

1. Lower the forks to floor level and fill the brake reservoir with brake fluid.

931201

4061MQ - 38700

Crown 1993 PF-10044-1

Printed in U.S.A.

M5.0 - 6730 - 001

M5.0 - 6730 - 001

MAINTENANCE Dow Corning Q2-1141 Silicone Brake Fluid or equal.

2. A bleed valve is located at the end of the slave cylinder (index 43) mounted on the drive unit, refer to illustration 5-1. Attach a drain hose to the bleed valve for the purpose of catching and reusing the excess fluid. A clear line is preferred so you can see air bubbles flow through the line.

Brake Lines

3. Attach the pressure bleeder to the brake reservoir.

Lining Replacement

CAUTION

Exercise care to avoid kinking any brake lines. Permanent damage to the line will result if this occurs ILLUSTRATION 5-2

(Refer to illustration 5-2)

Do not apply more than 50 P.S.I. to avoid damage and possible rupture of the reservoir.

4. With the brake pedal in the raised position, open the valve on the pressure bleeder. Open the bleed valve on the slave cylinder approximately 1/2 turn counterclockwise.

5. Close the bleed valve after all of the air has been forced out of the system and there is a steady flow of brake fluid out of the drain line, (this may take between 2 and 3 minutes).

2612S

6. Check and refill the brake reservoir if necessary.

1. Raise the rear of the truck until the drive wheel is off the floor. Place hardwood blocks below the deck skirts to maintain the elevation.

If a pressure bleeder is not available, the following procedure can be used:

2. Unlatch and open the door assemblies to a position where they will not obstruct the work to be performed.

1. Check the brake reservoir for proper fluid level and inspect the system to be sure all connections are tight.

3. Unfasten the screws (index 91) and remove the retaining ring (index 90) from the brake drum. Depress the brake pedal and remove the brake drum (index 87).

2. A bleed valve is located at the end of the slave cylinder (index 43) mounted on the drive unit, refer to illustration 5-1. Attach a drain hose to the bleed valve for the purpose of catching and reusing excess fluid.

3. Open the bleed valve on the slave cylinder approximately 1/2 turn counterclockwise.

4. Pump the brake pedal, open the bleed valve until the pedal stops at the bottom of its travel, then close the valve. Repeat this procedure until a steady stream of brake fluid flows out of the drain line without any signs of entrapped air, (this may take between 2 and 3 minutes).

CAUTION

Do not allow the fluid in the brake reservoir to drain so low as to draw air into the system.

Fluid Level Brake fluid is added to the reservoir mounted on the steering box, on the back side of the platform. The reservoir should be filled to 1/2 in. (12.7mm) to 3/4 in. (19mm) from the top. Use Crown 1993 PF-10044-2

M5.0 - 6730 - 002

4. Inspect the condition of the drum, especially for grooves on the inside of the drum caused by worn linings.

5. Remove the two springs (index 84) which connects the brake shoes (index 83) together. Next, remove the two springs (index 79) which holds the shoes to the backing plate (index 82) and remove the old shoes.

6. Place the new linings in position and attach the springs (index 84 & 79).

NOTE Position the brake springs (index 84) so that the long hooks are not connected to the same shoe.

7. Depress the brake pedal and reinstall the brake drum.

Attach the retaining ring and secure the screws. These screws are to be tightened to a torque reading of between 8 to 10 ft.lbs. (11 to 14Nm).

Printed in U.S.A.

M5.0 - 6730 - 002

MAINTENANCE

COMPRESSION SPRINGS

LOCKING NUTS PIVOT BLOCK

BRAKE ARM

2613S

ILLUSTRATION 5-3 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.

Crown 1993 PF-10044-3

M5.0 - 6730 - 003

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 consistent generally with floor conditions in the overall facility.

Periodic caster adjustments may be required to maintain proper balance of these charateristics and proper operation.

Printed in U.S.A.

M5.0 - 6730 - 003

MAINTENANCE Brake Adjustments There are two types of brake adjustments; brake force and switch & shoes adjustment. Braking force adjustment alone can be performed if proper stopping distances can be obtained. If the stopping distance criteria (see “A” below) cannot be met, proceed with the switch and shoe adjustment (“B”).

NOTE When replacing shoes, always use both methods.

A. BRAKE FORCE ADJUSTMENT (Refer to illustration 5-2 & 5-3) To obtain the correct braking force setting, adjust the brake spring tension by either turning the adjustor nut (index 23) in or out. Spring adjustment tests are to be made on an empty truck, traveling at maximum forward speed on a dry, level surface. The allowable stopping distance for a Rider Pallet is from 40 to 52 inches (1016mm to 1320mm).

B. SWITCH AND SHOE ADJUSTMENT (Refer to illustration 5-2 & 5-3) Place the switch actuator (index 44) located on the slave cylinder rod assembly (index 46) against the button of the cut-out limit switch (index 54) but do not activate the switch. Rotate the brake arm (index 78) clockwise until the brake shoes contact the brake drum. Adjust the pivot block (index 75), by turning the locking nuts (index 76), to align with the hole in the brake arm. Rotate the brake drum to make sure the shoes are not dragging. When satisfied with adjustment, tighten the set screw in the switch actuator.

Crown 1993 PF-10044-4

M5.0 - 6730 - 004

Printed in U.S.A.

M5.0 - 6730 - 004

MAINTENANCE

ILLUSTRATION 5-12 MASTER CYLINDER

Master Cylinder Disassembly

Operation

1. Pull back the rubber dust cover (5) and remove the circlip (6) with a pair of long-nosed pliers. (REFER TO ILLUSTRATION 5-12

When the brake pedal is depressed the push rod (2) contacts the plunger (3) and forces it up the bore of the cylinder (1). (REFER TO ILLUSTRATION 5-12).

During the first 1/32 inch (0.8 mm) of push rod travel, the spring washer (4) under the valve head is allowed to resume its natural “bowed” shape and closes the port to the reservoir. As the plunger continues to move up the bore, fluid is forced through the brake lines to the slave cylinders.

When the brake pedal is released the plunger moves back with the return of the fluid and the final movement of the plunger compresses the spring washer, lifting the valve seal off its seat and opening the supply tank port. The fluid can now move unrestricted between cylinder and reservoir.

2. Remove the plunger either by shaking the cylinder or by compressed air pressure.

If seals are loose on the plunger and appear oversize, the system is probably contaminated. Compare the old seals with new seals from rebuild kit, DO NOT ALLOW NEW SEALS TO COME IN CONTACT WITH OLD. If the old seals are considerably larger, contamination is again likely and the system should be thoroughly flushed. All seals and hoses should be changed at this time.

3. Inspect the surface of the plunger for any damage of any kind.

If plunger shows any damage at all, the master cylinder must be replaced.

Crown 1979 PF-5027-1

Printed in U.S.A.

M5.4 - 14 - 001

M5.4 - 14 - 001

MAINTENANCE 4. Clean all parts thoroughly that will be reused. Compare parts of assembly with parts in the rebuild kit to determine which parts will be reused.

5. Place the cleaned parts onto a very clean work area.

6. Inspect the plunger and cylinder bore for visible score marks, ridges, and corrosion. Check the bore for smoothness to touch. Very minor imperfections may be eliminated. The use of a very fine emery cloth in the cylinder bore should be the only type of repair attempted to remove any roughness in the cylinder bore.

CAUTION

Removal of any material or anodizing from the cylinder bore during any attempted clean-up operation will cause the cylinder to malfunction.

7. If there is doubt as to the condition of the parts then replace master cylinder. Inspect all remaining parts to be sure they are in good working order.

Master Cylinder Reassembly 1. Use the new parts obtained from Rebuild Kit during reassembly. Lubricate the inner diameter of the new plunger seal with unused brake fluid and fit the seal to the plunger.

2. Fit the valve seal, smallest diameter leading, onto the valve head. Position the spring washer on the valve stem to that it “flares” away from the valve stem shoulder. (SEE ILLUSTRATION 5-13)

6. Smear the sealing areas of the rubber dust cover with grease and fit to the push rod. Position the dust cover on the cylinder body.

NOTE When connecting the push rod it is necessary to maintain the 1/32 inch (0.8 mm) gap between the push rod and the plunger when the push rod is fully returned. In applications where the pedal returns until stopped by the cylinder there is no danger, but when a pedal stop is used care must be taken to maintain proper gap.

7. Install master cylinders in truck, connect lines, and bleed system.

Slave Cylinder At such time when the master cylinders and the brake system require maintenance it is recommended the slave cylinder(s) be included in such maintenance. Providing the working surfaces of the cylinder bore and piston are in good condition, new seals from a Crown Service Kit may be used. If score marks, ridges or corrosion appear on plunger or in cylinder bore, the slave cylinder should be replaced. Slight imperfections may be eliminated with the use of very fine emery cloth. If there is any doubt as to condition of slave cylinder it should be replaced.

CAUTION

Removal of any material or anodizing from the cylinder bore during any attempted clean-up operation will cause the cylinder to malfunction.

Disassembly 1. Remove slave cylinder from truck and disassemble on a clean work area (REFER TO ILLUSTRATION 5-14

ILLUSTRATION 5-13 3. Connect the spring retainer to the spring and compress the spring until the valve stem passes through the keyhole in the spring retainer and engages in the center. Fit the spring subassembly the plunger and press the leaf of the spring retainer to secure. (SEE ILLUSTRATION 5-13) 4. Lubricate the plunger seal and the cylinder bore with unused brake fluid.

5. Insert the plunger assembly fully into the cylinder bore, valve end first, easing the entrance of the plunger seal. Position the push rod and retaining washer and fit the circlip into groove.

ILLUSTRATION 5-14

Crown 1979 PF-5027-2

Printed in U.S.A.

M5.4 - 14 - 002

M5.4 - 14 - 002

MAINTENANCE 2. The new parts in the service kit will indicate which used parts can be discarded. Clean all remaining parts and the cylinder with unused brake fluid. Inspect all other parts to be sure all other parts are in good working condition.

Chart Listing Master Cylinder, Slave Cylinder, & Rebuild Kit.

Assembly 1. Place the new seal on the piston with the flat back of the seal against the shoulder.

2. Lubricate the seal and the cylinder bore with new brake fluid and reassemble the cylinder. Smear the dust cover and the sealing areas with grease to help protect the internal parts.

3. Install slave cylinder to truck and bleed system.

Crown 1979 PF-5027-3

Printed in U.S.A.

M5.4 - 14 - 003

M5.4 - 14 - 003

MAINTENANCE TORQUE GENERATOR The torque generator used in this unit consists of two elements in one housing; the gerotor (hydraulic motor) and the companion control valve. The two elements are interconnected by drive links to provide an emergency direct through drive in the event of a hydraulic failure.

The turning effort, (torque) is provided by the gerotor mechanism which consists of an inner star and outer ring.

The inner star has six teeth which orbit in a fixed outer ring with seven lobes. The orbiting effect is created by hydraulic pressure from the control valve to the chambers between the inner star and outer ring lobes and is transformed into a steady circular shaft motion through a double ended splined drive to the power end shaft. This creates a high torque at low R.P.M. The control shaft operates at the same speed as the output shaft. The control valve consists of three basic components: the valvebody, control sleeve, and control spool. There are no external lubrication points on the torque generator. The hydraulic motor and valve mechanism are lubricated on the inside by the hydraulic fluid passing through it.

Repairs to be made on the torque generator should be done in a clean area, and during disassembly the parts should be laid out and inspected, then assembled without any foreign material entering unit. All parts should be cleaned with a degreasing solution and air dried before assembly. Do not wipe any parts with rag or shop towel. A small piece of lint could cause a malfunction of the gerotor or valve mechanism.

Disassembly Before loosening cap bolts scribe a line parallel to the center line of the unit from the power end housing to the control end cap to assist in orientating the parts for reassembly. Note position of power end and control end shaft keyways. Drain oil from unit by rotating the control shaft several times. Place unit in a soft jawed vise with the power end shaft up. Remove the key from the keyway.

Now remove the seven socket head cap screws that secure the power end housing to the control housing. Lift off the power end housing and shaft assembly from the upper wear plate. Slide the power end shaft out of the housing and discard the shaft “O” Ring seal. Note position of the seal washer. Remove the power end drive from the gerotor set. Then remove the gerotor set and wear plates from the control housing and lay these parts out on the bench for inspection. Lift out the control end drive from the center of the control spool in the control housing. Now relocate the unit in the vise to a horizontal position and remove the key from the shaft keyway. Inspect and clean the control end shaft. Carefully remove the four socket head cap screws that secure the control end cap to the

© Crown 1978 PF-3389-1

M6.3–11–001

control housing. Slip off the control end cap and remove the static “O” Ring, shaft “O” Ring seal and seal washer from the control end cap. Now pull the control spool and sleeve out of the control housing. Carefully note the position of the centering springs and push the cross pin from the sleeve. Slide the control spool out of the control sleeve and remove the centering springs. If spool and sleeve are frozen in the control housing, discard the entire control valve assembly and replace. DO NOT replace or interchange control spool, control sleeve or control housing separately as these parts should be replaced in matched assemblies.

Careful inspection of all parts is essential for proper operation after assembly. The centering springs should be checked for abnormal wear or deformation. Check the gerotor wear plates for wear or scoring. A certain amount of polishing due to the rubbing action on the wear plates may occur and should not be taken for wear. If heavy wear is evident, wear plates should be replaced. These parts are precision matched to a fine finish and flatness which prevents high pressure leakage in this area. Inspect the control spool, control sleeve and control housing for scoring or uneven wear. These three pieces are select fit during original assembly and any undue wear or damage to any one part makes it mandatory that they all be replaced as a matched set. Inspect edges of cross pin holes in control sleeve and tapered holes in the control spool for burns or interruptions. These must be removed for proper valve operation. Check cross pin for snug fit in control sleeve, if not, replace. Inspect the stub shafts of the power end shaft and control spool for coupling wear and broken-out keyways. If wear is severe replace part.

Severe coupling wear generally indicates misalignment.

Assembly Insert the control spool into the control sleeve so that the spring slots will line up. DO NOT force these two together.

Due to a very close fit, it may be necessary to insert the spool from the opposite end. Install the two sets of centering springs back-to-back in the spring slots with the notched ends of the springs away from the shoulder of the spool. Center springs in slot so they do not stick out beyond the sleeve. Now insert cross pin. Carefully insert the control sleeve into the bore of the control housing the same procedure used to assemble the spool and sleeve.

Place new “O” Ring seals in the static “O” Ring seal groove and the shaft “O” Ring seal counter- bore of the control end cap. You will notice that the proper size “O” Ring appears to be too large and must be pushed in place. Place the seal washer in the counterbore adjacent to the seal. Install the control end cap over the shaft of the control spool with a twisting motion to prevent damage to the seal. Care should be taken to prevent the control spool and

Printed in U.S.A.

M6.3–11–001

MAINTENANCE sleeve assembly from sliding out of the control housing during assembly procedures. Align the control end cap with the previously scribed line and loosely secure the assembly with four socket head cap screws. Using the original scribed line to aid in relative position of these parts, place the wear plate on the lapped surface of the control housing aligning the larger holes of the wear plate with the tapped holes of the control housing. Observe the control end drive and note the slot in its spline. Insert the spline in control spool and rotate slightly until the slot drops on the cross pin through the spool. With this in place, assemble the gerotor inner star and outer ring and place them on the wear plate. Engage the splined end of the control end drive with the splined hole of the gerotor inner star. Note that it is important that the two teeth of the drive gear be directly in line with the valley between any two points of the inner star. If this alignment is not correct, unit will attempt to operate in reverse when operated with hydraulic pressure. Insert one end of the double ended splined power end drive into the gerotor inner star splined hole. Now place the other wear plate over the gerotor set.

Check power end housing to be sure it is clean. Lubricate shaft “O” Ring seal with clean oil and insert in power end housing “O” Ring counterbore groove. This “O” Ring will appear to be too large for its counterbore and must be pushed in place. Insert the seal washer in the counterbore. Insert the power end shaft into the power end housing with a twisting motion to prevent damage to the seal.

Place the power end housing and shaft over the power end drive splined end and rotate until splined joint is engaged. Check and align power end housing with scribed line. Clean and inspect the seven cap screws.

Apply a drop of grade C-Loctite to each screw, insert and thread them into the seven holes of the power end housing. Slowly tighten the seven cap screws evenly to a torque of 12 to 14 ft./lbs. If power end shaft does not turn freely after cap screws have been tightened, back off tension and retighten screw more even. Turn the unit over and tighten the four cap screws that secure the control end cap.

TROUBLE SHOOTING CHART FOR TORQUE GENERATOR 1. Slow Speed

2. Lack of Power a. Worn pump not delivering sufficient power—repair or replace torque generator. b. Low oil supply—fill reservoir to recommended level. c. Faulty relief valve—check pressure reading.

Replace relief valve.

3. Binding or Locking a. Misalignment of input or output shaft of steering unit—correct misalignment.

4. Oil Fluid Overheating a. Relief valve partially stuck open causing continuous bypass—repair valve. b. Insufficient oil supply—refill reservoir. c. Steering unit not recentering to neutral position.

Check and correct alignment of input shaft.

5. Input Wheel Creep or “Motoring” a. Broken or weak centering springs. Disassemble control end of unit and check springs by placing it on a flat surface and pressing it down to 1/16 inch, release and it should return to 7/32 inch when released. If spring is completely broken, disassemble complete unit and thoroughly clean all parts and reassemble. b. “Sticky” control spool and sleeve. Disassemble control end of unit and inspect for foreign matter or burns between spool and sleeve. Control spool must rotate freely in sleeve.

6. Oil Leaks a. Tighten all cap screws and replace shaft “O” Rings.

7. Output shaft attempting to operate in reverse of input shaft rotation or extreme chatter of input wheel after unit has been repaired. a. Incorrect reassembly of control sleeve and gerotor inner star orientation. Disassemble unit and reposition inner star one splined tooth on control end drive spline.

a. Worn pump—repair or replace pump. b. Pressure relief valve partially stuck in open position.

Disassemble, clean and repair pump. c. Kink or flattened hydraulic line to steering unit— replace line. d. Worn gerotor mechanism in torque booster— disassemble and replace part.

© Crown 1978 PF-3389-2

M6.3–11–002

Printed in U.S.A.

M6.3–11–002

FORK MAINTENANCE FORKS - 7 IN. (180 MM) FORK INSPECTION Forks Lowered: • With the battery in the truck, the fork heel height should measure 3.75 to 3.88 in. (95 to 100 mm).

• The fork tip height at the load wheel centerline should not exceed 3.50 in. (90 mm).

3.5 in.

(90mm)

• The risers must contact one stop each.

Forks Raised: • The fork height, measured at the load wheel cut out, should be 9.25 in. (235 mm) minimum.

9.25 in. (235mm) MINIMUM

3.75 in. to 3.88 in.

(95mm to 100mm) ILLUSTRATION 1

2529

LIFT LINKAGE ADJUSTMENT (Tension Bar Length and Cylinder Adjustment) After completely lowering the forks (the cylinder should be bottomed out), remove the cover plates in the fork tips.

Loosen the nut on each tension bar and turn special nut until the riser comes in contact with the stop blocks in the fork tips.

Refer to Illustration 2.

STOP BLOCKS NUT LOCKWASHER SPECIAL NUT

With the battery in place, adjust the lift cylinder so the fork heel height measures: • 3.75 to 3.88 in. (95 to 100 mm).

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 0.125 in. (3 mm) and one revolution counterclockwise lowers the heel height 0.125 in. (3 mm). Refer to Illustration 3 on the following page.

GUIDE SCREW

TENSION BAR 2321

ILLUSTRATION 2

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.

931206

6268

Crown 1993 PF9964-1 Rev. 11/99

Printed in U.S.A.

01 REV. 11/99

M7.0–6435–050

M7.0–6435–050

FORK MAINTENANCE Check to make sure the cylinder and risers stop together.

This is checked by standing on the forks while the forks are lowered. Repeat the adjustment procedure until you feel the cylinder and risers stop together. Tighten the cylinder and tension bar jam nuts and install covers in the fork tips.

LIFT LINKAGE REMOVAL CAUTION

If the truck must be split (forks separated from power unit) for maintenance, be sure the lift cylinder rod end pin is parallel with the fork cross bar. This will prevent the rod end from damage.

CYLINDER ROD HEX JAM NUT

FORK CROSS BAR

Depending on the extent of disassembly required, the removal of the lift linkage can be accomplished using one of two methods. The first method, "forks-up", allows replacement/repair riser components. The "elevated" method allows replacement of the complete tension bar assembly or component replacement on the front (power unit) end of the lift linkage.

CAUTION

ROD END

2322

ROD END PIN

ILLUSTRATION 3

A pallet truck without the battery weighs approximately 2000 lbs. (910 kg.). Always use lifting and blocking equipment with equal or greater capacity. Extreme care should be taken whenever trucks are raised and lowered to prevent personal injury.

Belleville Washer The belleville washer should be up as shown in illustration 4 for correct installation.

CYLINDER ROD END BELLEVILLE WASHER

JAM NUT FORK CROSS BAR

LIFT CYLINDER

2605

ILLUSTRATION 4

Crown 1993 PF9964-2 Rev. 11/99

Printed in U.S.A.

01 REV. 11/99

M7.0–6435–051

M7.0–6435–051

FORK MAINTENANCE Forks-up Method

Elevated Method

Remove the battery and place hardwood blocks under the outboard ends of the front (power unit) skirt as shown in Illustration 5. With the use of an overhead lifting device equipped with barrel hooks [having a capacity of 2000 lbs.

(910 kg.) each], raise the fork tips until they are elevated approximately 16 in. (400 mm) above the floor. Securely block the fork tips while leaving the lifting mechanism attached. If the lifting mechanism must be removed, additional blocks should be placed beneath the battery compartment.

Refer to Illustration 6 and remove the riser pivot shaft (index 2) after extracting the roll pin (index 1). Support the riser assembly by hand before completely removing the shaft, then lower the riser assembly.

1

2 4 A

A

B B 3

8 2000 lbs.

(910 kg.)

CAPACITY

A 5

9

7 B

6 B A

2325

16 in.

(400mm)

ILLUSTRATION 6

If the tension bar (index 3) must be replaced, the roll pin (index 8) will have to be removed. Access to the top of the tension bar end (index 7) is best gained through the back wall of the battery compartment. The tension bar nuts on the riser end should be loosened and removed. The old tension bar can then be unscrewed from the bar end (index 7). After the tension bar is replaced, the fork height must be adjusted.

FORKS - UP Remove the battery and attach an overhead lifting device to the center of the front (power unit) end of your truck. Raise the truck and place jack stands [having a capacity of 2000 lbs. (910 kg.) each] under the outboard ends of the front skirt (as shown in Illustration 5). Before unhooking the lifting device, securely block the load wheels. Move the lifting device to the fork tips and raise forks so jack stands can be positioned at the fork tips. Four more jack stands must be positioned beneath the truck for it to be stable. Two stands should be located on the sides beneath the battery compartment and two on the side skirts directly below the door hinges. The placement of these stands are critical because any power unit to lift structure shifting after the tension bar assembly is removed will make pin replacement difficult.

2323

2000 lbs.

(910 kgs.)

CAPACITY ELEVATED 2324

ILLUSTRATION 5

When securely elevated, remove the roll pin (index 1 ) and support the riser while extracting the pivot shaft (index 2).

Lower the riser assembly. Move to the other end of the tension bar assembly and remove the linkage pivot pins (index 4 & 5). Support the tension bar end before completely removing these pins. Remove links (index 6 & 9) and slide tension bar out from fork. The removal of only one tension bar assembly at a time is recommended to help maintain power unit to lift structure alignment.

Crown 1993 PF9964-3 Rev. 11/99

Printed in U.S.A.

01 REV. 11/99

M7.0–6435–052

M7.0–6435–052

FORK MAINTENANCE Riser Assembly

When removing any tension bar linkage, all bearings, pins and links should be inspected and replaced as necessary.

The shaft attached to the link (index 6) with a roll pin should not be disassembled unless shaft damage warrants replacement. If it must be replaced, the shaft should be driven out of the link, shearing the roll pin. The upper portion of the broken roll pin must be removed before installing the new roll pin.

Lubrication Fitting Hole

BUSHING INSTALLATION

Lubrication Hole In Bushing

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 as shown in the following illustrations 7 thru 10.

2608

ILLUSTRATION 9 Lubrication Fitting Hole

Lubrication Hole In Bushing

Lubrication Fitting Hole

Link Assembly End Tension Bar Assembly 2609

ILLUSTRATION 10

Lubrication Hole In Bushing ILLUSTRATION 7

2606

Inboard / Outboard Link Assembly

Lubrication Hole In Bushing

Lubrication Fitting Hole 2607

ILLUSTRATION 8

Crown 1993 PF9964-4 Rev. 11/99

Printed in U.S.A.

01 REV. 11/99

M7.0–6435–053

M7.0–6435–053

FORK MAINTENANCE ASSEMBLY: The flatwashers shown in illustration 12 keep the linkage components from rubbing together. The position of these flatwashers depends on fork spread.

Inboard Link

Apply Thread Locking Adhesive

Bend Tabs Up On The Flat Side Of Hex Head Screw

Part Of Fork 0

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.

32 ft. lbs.

(43Nm) Clip

Tension Bar

NOTE Clip

Part Of Power Unit

Retainer clips are only to be used once. It is recommended that they be replaced every time the pivot shaft is removed from the inboard link.

Part Of Fork ‡Flatwasher

‡Position Of Flatwasher Depends Upon Fork Spread 7741

ILLUSTRATION 11

FLATWASHER

FLATWASHER

27 in. (686mm)

FLATWASHER

FLATWASHER

18 in. (457mm) 22 in. (559mm)

FLATWASHER

FLATWASHER

2327S

ILLUSTRATION 12

Crown 1993 PF9964-5 Rev. 11/99

Printed in U.S.A.

01 REV. 11/99

M7.0–6435–054

M7.0–6435–054

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

GLOSSARY GLOSSARY Components of the PR truck have been listed in chart form to assist the maintenance mechanic in locating these components on the Electrical Diagrams and Parts Breakdown forms.

The chart is in columns COMPONENT; LOCATION; FUNCTlON; CONTROL; DIAGRAM; PARTS BREAKDOWN. The COMPONENT column contains the abbreviation of the component as it appears on the Diagrams and in the Maintenance Section. The LOCATION column 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 CONTROL column relates to the diagram and list the type of traction control. 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 the component. The PARTS BREAKDOWN column includes the parts breakdown page number on which the component is located along with the index number, in parentheses, if applicable.

AUDIBLE INDICATORS Location

Function

Control

Diagram

Parts Breakdown

HN1

Power Unit

Truck Horn

Meter Console

Travel Alarm

DIA - 6730 - 202 (C-3) DIA - 6730 - 208 (C-3) DIA - 6730 - 202 (A-4) DIA - 6730 - 208 (A-4)

1 - 6730 - 001 (25)

HN2

*Transistor **Transistor *Transistor **Transistor

4.5 - 6730 - 001 (13)

BATTERY

Battery

Location

Function

Control

Diagram

Parts Breakdown

Lift Structure

Power

*Transistor **Transistor

DIA - 6730 - 205 (C-2) DIA - 6730 - 211 (C-2)

7.7 - 6435 - 001 (1)

CONNECTORS (PLUG IN) Location

Function

Control

Diagram

Parts Breakdown

CA201

Distribution Panel

Contactors

Distribution Panel

Grab Bar

CA203

Distribution Panel

Options

CA204

Distribution Panel

Meters

CA205

Distribution Panel

Traction

CA206

Distribution Panel

Control Handle

CA207

Distribution Panel

Control Handle

CA208

Distribution Panel

Lift

CA209

Battery Comp.

Battery Restraints

CA401

Traction Ctrl

Traction

DIA - 6730 - 202 (A-1) DIA - 6730 - 208 (A-1) DIA - 6730 - 202 (A-3) DIA - 6730 - 208 (A-2) DIA - 6730 - 202 (A-2) DIA - 6730 - 208 (A-2) DIA - 6730 - 202 (A-3) DIA - 6730 - 208 (A-3) DIA - 6730 - 202 (A-1) DIA - 6730 - 208 (A-4) DIA - 6730 - 202 (C-3) DIA - 6730 - 208 (C-1) DIA - 6730 - 202 (C-3) DIA - 6730 - 208 (C-2) DIA - 6730 - 202 (C-2) DIA - 6730 - 208 (C-2) DIA - 6730 - 202 (C-2) DIA - 6730 - 208 (C-3) DIA - 6730 - 203 (B-1) DIA - 6730 - 209 (B-1) DIA - 6730 - 215 (B-2)

4.1 - 6630 - 100 (10)

CA202

*Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor

CA404

Field Weakening

4.1 - 6630 - 100 (10) 4.1 - 6630 - 100 (10) 4.1 - 6630 - 100 (10) 4.1 - 6630 - 100 (10) 4.1 - 6630 - 100 (10) 4.1 - 6630 - 100 (10) 4.1 - 6630 - 100 (10) 4.1 - 6630 - 100 (10)

* Transistor Denotes Curtis Transistor Controller ** Transistor Denotes Sevcon Transistor Controller Crown 1993 PF-10069-1

M10 - 6730 - 001

Printed in U.S.A.

M10 - 6730 - 001

GLOSSARY CONTACTORS Location

Function

Control

Diagram

Parts Breakdown

1A Contactor Panel

Bypass Traction

F

Forward Traction

*Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor

DIA - 6730 - 203 (C-3) DIA - 6730 - 209 (B-4) DIA - 6730 - 203 (C-4) DIA - 6730 - 209 (B-4) DIA - 6730 - 215 (B-3) DIA - 6730 - 221 (B-3) DIA - 6730 - 204 (C-1) DIA - 6730 - 206 (C-1) DIA - 6730 - 203 (C-3) DIA - 6730 - 209 (B-4)

4.1 - 6630 - 001 (23) 4.1 - 6630 - 100 (23) 4.1 - 6630 - 001 (26) 4.1 - 6630 - 100 (26) 4.1 - 6630 - 001 (30) 4.1 - 6630 - 100 (32) 2.1 - 06.4 - 013 (58)

Parts Breakdown

Traction Controller

FW Contactor Panel

Field Weakening

P

Pump Motor

Pump

R

Traction Controller

Reverse Traction

4.1 - 6630 - 001 (26) 4.1 - 6630 - 100 (26)

DIODE BLOCK Location

Function

Control

Diagram

DB43

Field Weakening

*Transistor

DIA - 6730 - 215 (B-2) 1 - 6730 - 001 (45)

Contactor Panel

FUSES Location

Function

Control

Diagram

Parts Breakdown

FU1

Contactor Panel

Traction

FU2

Contactor Panel

Traction

Contactor Panel

Steering

DIA - 6730 - 203 (B-2) DIA - 6730 - 209 (B-2) DIA - 6730 - 203 (B-3) DIA - 6730 - 209 (B-3) DIA - 6730 - 204 (C-1) DIA - 6730 - 205 (B-3)

4.1 - 6630 - 001 (28) 4.1 - 6630 - 100 (28) 4.1 - 6630 - 001 (Misc) 4.1 - 6630 - 100 (Misc)

FU3

*Transistor **Transistor *Transistor **Transistor *Transistor **Transistor Control

Diagram

Parts Breakdown

DIA - 6730 - 202 (A-3) DIA - 6730 - 208 (A-3) DIA - 6730 - 203 (A-3) DIA - 6730 - 208 (C-2) DIA - 6730 - 202 (A-3) DIA - 6730 - 208 (A-2) DIA - 6730 - 202 (A-3) DIA - 6730 - 208 (A-3)

4.9 - 05.1 - 051

METERS Location

Function

BDI

Column

TT1 TT2

Control Handle Power Unit

V

Power Unit

Battery Discharge Interrupt *Transistor **Transistor Register Operating Time *Transistor **Transistor Internal Time Register *Transistor **Transistor Discharge Indicator *Transistor **Transistor

4.5 - 6730 - 001 (3) 4.5 - 6730 - 001 (15) 4.5 - 6730 - 001 (2)

MOTORS Location

Function

Pump

Power Unit

Lift

Steering

Power Unit

Traction

Drive Unit

Control

*Transistor **Transistor Power Steering *Transistor **Transistor Traction *Transistor **Transistor

Diagram

Parts Breakdown

DIA - 6730 - 204 (C-1) DIA - 6730 - 206 (C-1) DIA - 6730 - 204 (B-1) DIA - 6730 - 206 (B-1) DIA - 6730 - 205 (C-2) DIA - 6730 - 211 (C-2)

2.1 - 06.4 - 013 (76)

3.1 - 07.3 - 006

* Transistor Denotes Curtis Transistor Controller ** Transistor Denotes Sevcon Transistor Controller Crown 1993 PF-10069-2

M10 - 6730 - 002

Printed in U.S.A.

M10 - 6730 - 002

GLOSSARY MOTOR CONTROLLERS Location

Function

Control

Diagram

MRC1

Traction & Lift

*Transistor **Transistor

DIA - 6730 - 205 (B-2) 4.1 - 6630 - 001 (6) DIA - 6730 - 211 (B-2) 4.1 - 6630 - 100 (6)

Transistor Panel

Parts Breakdown

POTENTIOMETERS Location

Function

Control

Diagram

ACCEL

Traction Accelerator

*Transistor **Transistor

DIA - 6730 - 204 (B-3) 4.6 - 06.7 - 005 (41) DIA - 6730 - 206 (B-3)

Control Pod

Parts Breakdown

RESISTORS Location

Function

Control

Diagram

RES1 Control Pod

Freezer/Condition

*Transistor **Transistor

DIA - 6730 - 204 (B-4) 4.6 - 06.7 - 005 (25) DIA - 6730 - 206 (B-4)

SOLENOID VALVES Location

Function

Control

Diagram

Parts Breakdown

SV

Lower

*Transistor **Transistor

DIA - 6730 - 202 (C-2) DIA - 6730 - 208 (C-2)

2.1 - 06.4 - 013 (44)

Control

Diagram

Parts Breakdown

*Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor

DIA - 6730 - 202 (C-3) DIA - 6730 - 208 (C-3) DIA - 6730 - 202 (C-2) DIA - 6730 - 208 (C-2) DIA - 6730 - 202 (C-1) DIA - 6730 - 208 (C-1) DIA - 6730 - 204 (B-1) DIA - 6730 - 206 (B-1)

1 - 6730 - 001 (32)

Pump

SUPPRESSOR BLOCKS Location Function SB21

Power Unit

Horn

SB40

Power Unit

Pump Solenoid Valve

SB41

Power Unit

Pump Solenoid Coil

SB42

Power Unit

Steering

Parts Breakdown

SWITCHES Location

Function

Control

Diagram

Parts Breakdown

BRES1

Battery Comp.

Battery Restraint

Battery Comp.

Battery Restraint

BRS

Knuckle Support

Brake

FS

Control Pod

Forward Traction

HNS1

Control Pod

Horn

KYS

Column Control Pod

Key

DIA - 6730 - 202 (C-2) DIA - 6730 - 208 (C-3) DIA - 6730 - 202 (C-2) DIA - 6730 - 208 (C-3) DIA - 6730 - 204 (C-2) DIA - 6730 - 206 (C-2) DIA - 6730 - 204 (B-2) DIA - 6730 - 206 (B-2) DIA - 6730 - 204 (B-4) DIA - 6730 - 206 (B-4) DIA - 6730 - 204 (B-3) DIA - 6730 - 206 (B-3)

7.7 - 6435 - 100 (6)

BRES2

*Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor

7.7 - 6435 - 100 (6) 5 - 06.7 - 104 (34) 4.6 - 06.7 - 005 (31) 4.6 - 6730 - 001 (41) 4.5 - 6730 - 001 (7) 4.6 - 06.7 - 005 (23)

* Transistor Denotes Curtis Transistor Controller ** Transistor Denotes Sevcon Transistor Controller Crown 1993 PF-10069-3

M10 - 6730 - 003

Printed in U.S.A.

M10 - 6730 - 003

GLOSSARY SWITCHES (Continued) Location

Function

Control

Diagram

Parts Breakdown

LMS

Power Unit

Lift Limit

Control Pod

Lower

RAS1

Control Pod

Raise

RS

Control Pod

Reverse Traction

STS

Control Handle

Steering

Toggle

Column

Key

DIA - 6730 - 204 (C-2) DIA - 6730 - 206 (C-2) DIA - 6730 - 204 (B-2) DIA - 6730 - 206 (B-2) DIA - 6730 - 204 (B-2) DIA - 6730 - 206 (B-2) DIA - 6730 - 204 (B-2) DIA - 6730 - 206 (B-2) DIA - 6730 - 204 (C-2) DIA - 6730 - 206 (C-2) DIA - 6730 - 204 (B-3) DIA - 6730 - 206 (B-3)

1 - 6730 - 001 (6)

LOS1

*Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor *Transistor **Transistor

4.5 - 6730 - 001 (7) 4.6 - 06.7 - 005 (23)

Parts Breakdown

4.6 - 06.7 - 005 (18) 4.6 - 06.7 - 005 (18) 4.6 - 06.7 - 005 (31) 1 - 6730 - 001 (12)

TERMINAL BOARDS Location

Function

Control

Diagram

TB403

Switches

*Transistor **Transistor

DIA - 6730 - 204 (C-2) 4 - 6535 - 001 (12) DIA - 6730 - 206 (C-2)

Control Handle

MISCELLANEOUS Location

Function

Control

Diagram

Parts Breakdown

FW MOD Power Unit

Field Weakening

*Transistor

DIA - 6730 - 215 (B-2)

1 - 6730 - 001 (43)

* Transistor Denotes Curtis Transistor Controller ** Transistor Denotes Sevcon Transistor Controller Crown 1993 PF-10069-4

M10 - 6730 - 004

Printed in U.S.A.

M10 - 6730 - 004

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