PDF DOWNLOAD :Crown Forklift RR 3000 Series 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 trouble shooting 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 rider reach 3000 series operator instructions, refer to Crown publication, “You and Your Crown Narrow Aisle Stand-up Rider” (PF-9659).

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 Narrow Aisle Rider”.

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

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

For Series RR capacities, technical information and dimensional specifications, please refer to the following sales literature: RR Literature SF-12109 RR Specifications SF-12118 Copies of publications can be obtained from your Crown dealer or by writing to: Crown Equipment Corporation 40-44 S. Washington Street New Bremen, OH 45869 An index for this manual is located on the following pages. The 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.

These sections are indicated by a grid bar at the right hand edge of the page. The higher the number of the section, the farther down the page it is 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 M6 M7 M8 M9 M10

DESCRIPTION

REPLACEMENT PARTS SECTION

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

1 2 3 4 5 6 7 8 9 10

930222

DESCRIPTION Basic Chassis or Power Unit Hydraulic System and Components Drive Unit and Components Electrical Components Brake Assemblies and Brake Systems Steering System and Components Main Frame and Mast Assemblies Cylinders Reach Assembly Accessories 4342 - 39280

Crown 1993 PF9724-1 Rev. 6/94

Printed in U.S.A.

01 REV. 6/94

ITD–1430–001

ITD–1430–001

INTRODUCTION

MAX.

BATTERY WEIGHT LBS. MIN.

MAX. A. H. CAP.

HR. RATE

D.C. VOLTAGE

BATT. TYPE

MAX. GRADE WITH 12 IN. MAX. FORK HEIGHT

The data plate for the RR series truck is located on the operator compartment back wall 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 two pages explain the model & truck data numbering system.

%

LOAD TIRE TREAD WIDTH 180° TRAVERSE SIDESHIFT MODEL NUMBER

FORK LENGTH

SERIAL NUMBER

MAX. TILT BACK

°

TRUCK DATA NUMBER

THIS TRUCK AS RELEASED FROM THE FACTORY CONFORMS TO THE MANDATORY REQUIREMENTS OF THE ANSI B56.1 STANDARD. CROWN EQUIPMENT CORP. NEW BREMEN, OH 45869

1952

069108 A

TRUCK DATA PLATE

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

Image Generator RR - Rider Reach

*Capacity 35 = 3500 lb. (1590 kg.)

40 = 4000 lb. (1815 kg.)

45 = 4500 lb. (2040 kg.)

RR3010-35 Series Major technical and design changes making the product a new and improved generation.

Relative Size or Performance 10 = 24 volt, 39 in. (990 mm) power unit 20 = 36 volt, 39 in. (990 mm) power unit 40 = 36 volt, 45 in. (1145 mm) power unit

The example of the model number shown above (RR3010-35) is a RR 3000 series truck. It has a 24 volt electrical system, 39 in. (990 mm) power unit and 3500 lb. (1590 kg.) capacity . *Actual rated capacity may vary, depending on special equipment or modifications. Consult capacity plate located on the power unit console.

Crown 1993 PF-9724-2

ITD - 1430 - 002

Printed in U.S.A.

ITD - 1430 - 002

INTRODUCTION The truck data number provides you and your Crown dealer with a wealth of 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 if selecting your own part numbers or service information from this manual.

TRUCK DATA NUMBER EXAMPLE Freezer Condition Option Drive Tire (-) = Standard G = Poly, Black - Center Groove F = With Freezer Condition P = Poly, Black - Smooth C = Corrosion Condition R = Rubber, Black - Smooth W = Rubber, White - Smooth Battery Compartment Size A = 12.19 in. (310 mm) Width B = 14.25 in. (360 mm) Width Steering C = 16.25 in. (410 mm) Width F = Forward D = 18.00 in. (460 mm) Width R = Reverse E = 20.75 in. (530 mm) Width

Mast Type TT = Telescopic Triple Stage TL = Telescopic Limited Free Lift TF = Telescopic Full Free Lift

High Speed Option (45" P.U.) (-) = Without High Speed Option H = With High Speed Option

-TT270C36-2PSF-HB Standard/Special Truck (-) = Standard S = Special

Bolt On Outriggers B = With Bolt On Outriggers (-) = Without Bolt On Outriggers

Lift Height TL & TF Mast TT Mast 138 in. (3505 mm) 198 in. (5025 mm) 150 in. (3810 mm) 210 in. (5335 mm) 240 in. (6100 mm) 270 in. (6860 mm) 300 in. (7620 mm) 321 in. (8155 mm) 341 in. (8660 mm) 366 in. (9300 mm) 400 in. (10160mm)

Back-up Alarm & Light Package Option (-) = Standard (Without Lights & Back-up Alarm 1 = Strobe Light (Amber) 2 = Back-up Alarm 3 = Worklights 4 = Back-up Alarm & Strobe Light (Amber) 5 = Worklights & Strobe Light (Amber) 6 = Back-up Alarm, Worklights & Strobe Light (Amber)

Inside Straddle Dimension 34 in. through 61 in.

(865 mm through 1550 mm) Load Wheel Size 1 = 4.0 x 2.88 in. (100 x 70 mm) 2 = 4.0 x 4.12 in. (100 x 105 mm) 3 = 5.0 x 2.88 in. (125 x 70 mm) 4 = 5.0 x 4.12 in. (125 x 105 mm) 5 = 10.5 x 4.0 in. (265 x 100 mm)

Sideshifter Option (-) = Without Sideshifter S = With Sideshifter

The example of the truck data number shown above is a standard truck with telescopic triple stage mast, 270 in. (5335mm) lift height, "C" size battery compartment, inside straddle dimension of 36 in. (915 mm), without freezer condition, 4.0 x 4.12 in. (100 x 105 mm) load wheels, smooth, black, poly drive tires, equipped with sideshifter, forward steering, without lights and back-up alarm, high speed option and bolt on outriggers.

Printed in U.S.A.

Crown 1993 PF9724-3 Rev. 6/94

01 REV. 6/94

ITD–1430–003

ITD–1430–003

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 rider reach 3000 series, Model 3500 operator instructions, refer to Crown publication, “You and Your Crown Narrow Aisle Stand-up Rider” (PF-12321).

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 Narrow Aisle Rider”.

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

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

For Series RR capacities, technical information and dimensional specifications, please refer to the following sales literature: RR Literature SF-12109 RR Specifications SF-12118 Copies of publications can be obtained from your Crown dealer or by writing to: Crown Equipment Corporation 40-44 S. Washington Street New Bremen, OH 45869 This manual is arranged according to major sections. The first part of the page number, found at the bottom of each page, denotes the section in which a particular form will be located. The 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 M6 M7 M8 M9 M10

DESCRIPTION

REPLACEMENT PARTS SECTION

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

1 2 3 4 5 6 7 8 9 10 11

950619 Crown 1995 PF-10573-1 Rev. 9/96

DESCRIPTION Basic Chassis or Power Unit Hydraulic System and Components Drive Unit and Components Electrical Components Brake Assemblies and Brake Systems Steering System and Components Main Frame and Mast Assemblies Cylinders Reach Assembly Accessories Specifications 5077 Printed in U.S.A.

01 REV. 8/96

ITD–1435–001

ITD–1435–001

INTRODUCTION

MAX.

BATTERY WEIGHT LBS. MIN.

MAX. A. H. CAP.

HR. RATE

D.C. VOLTAGE

BATT. TYPE

MAX. GRADE WITH 12 IN. MAX. FORK HEIGHT

The data plate for the RR series truck is located on the inside of the power unit door 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 two pages explain the model & truck data numbering system.

%

LOAD TIRE TREAD WIDTH 180° TRAVERSE SIDESHIFT MODEL NUMBER

FORK LENGTH

SERIAL NUMBER

MAX. TILT BACK

°

TRUCK DATA NUMBER

THIS TRUCK AS RELEASED FROM THE FACTORY CONFORMS TO THE MANDATORY REQUIREMENTS OF THE ANSI B56.1 STANDARD. CROWN EQUIPMENT CORP. NEW BREMEN, OH 45869

1952

069108 A

TRUCK DATA PLATE

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

Image Generator RR - Rider Reach

*Capacity 35 = 3500 lb. (1590 kg.)

40 = 4000 lb. (1815 kg.)

45 = 4500 lb. (2040 kg.)

RR3510-35 Series Major technical and design changes making the product a new and improved generation.

Relative Size or Performance 10 = 24 volt, 39 in. (990 mm) power unit 20 = 36 volt, 39 in. (990 mm) power unit 40 = 36 volt, 45 in. (1145 mm) power unit

The example of the model number shown above (RR3510-35) is a RR 3000 series Model 3500 truck. It has a 24 volt electrical system, 39 in. (990 mm) power unit and 3500 lb. (1590 kg.) capacity. *Actual rated capacity may vary, depending on special equipment or modifications. Consult capacity plate located on the power unit console.

Crown 1995 PF-10573-2 Rev. 9/96

Printed in U.S.A.

01 REV. 8/96

ITD–1435–002

ITD–1435–002

INTRODUCTION The truck data number provides you and your Crown dealer with a wealth of 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 if selecting your own part numbers or service information from this manual.

TRUCK DATA NUMBER EXAMPLE Drive Tire Freezer Condition Option P = Poly (-) = Standard F = With Freezer Condition R = Rubber C = Corrosion Condition Battery Compartment Size A = 12.19 in. (310 mm) Width B = 14.25 in. (360 mm) Width C = 16.25 in. (410 mm) Width D = 18.00 in. (460 mm) Width or C in D E = 20.75 in. (530 mm) Width

Steering F = Forward R = Reverse

High Speed Option (45" P.U.) (-) = Without High Speed Option H = With High Speed Option

Mast Type TT = Telescopic Triple Stage TL = Telescopic Limited Free Lift TF = Telescopic Full Free Lift

-TT270C36-2PSF-HB Standard/Special Truck (-) = Standard S = Special C = Custom

Bolt On Outriggers B = With Bolt On Outriggers (-) = Without Bolt On Outriggers Travel Alarm & Light Package Option (-) = Standard (Without Lights & Travel Alarm) 1 = Strobe Light (Amber) 2 = Travel Alarm 3 = Worklights 4 = Travel Alarm & Strobe Light (Amber) 5 = Worklights & Strobe Light (Amber) 6 = Travel Alarm, Worklights & Strobe Light (Amber) 7 = Travel Alarm & Worklights

Lift Height TL & TF Mast TT Mast 138 in. (3505 mm) 198 in. (5025 mm) 150 in. (3810 mm) 210 in. (5335 mm) SPC = Special 240 in. (6100 mm) Custom 270 in. (6860 mm) Ht. Pulls 300 in. (7620 mm) In Custom 321 in. (8155 mm) Value 341 in. (8660 mm) 366 in. (9300 mm) 400 in. (10160mm) Inside Straddle Dimension 34 in. through 61 in.

(865 mm through 1550 mm)

Sideshifter Option Load Wheel Size (-) = Without Sideshifter 1 = 4.0 x 2.88 in. (100 x 70 mm) S = With Sideshifter 2 = 4.0 x 4.12 in. (100 x 105 mm) 3 = 5.0 x 2.88 in. (125 x 70 mm) 4 = 5.0 x 4.12 in. (125 x 105 mm) 5 = 10.5 x 4.0 in. (265 x 100 mm) 6 = 10.5 x 4.5 in. (265 x 102 mm) The example of the truck data number shown above is a standard truck with telescopic triple stage mast, 270 in. (5335mm) lift height, "C" size battery compartment, inside straddle dimension of 36 in. (915 mm), without freezer condition, 4.0 x 4.12 in. (100 x 105 mm) load wheels, poly drive tires, equipped with sideshifter, forward steering, without lights and travel alarm, high speed option and bolt on outriggers.

Printed in U.S.A.

Crown 1995 PF-10573-3 Rev. 9/96

01 REV. 8/96

ITD–1435–003

ITD–1435–003

SAFETY

General Maintenance Instructions

General Maintenance Instructions WARNING An injury could occur.

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

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

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

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

• Fully lower the load engaging means.

• Put the directional control in neutral.

• Apply the parking brake.

• Turn off the lift truck.

• Remove the key.

• Chock the wheels of the lift truck.

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

• Use chocks or other positive positioning devices.

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

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

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

• Apply the brake.

• Put the directional control in neutral.

Crown 1976 PF2821 Rev. 6/22

•

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

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

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

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

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

Hold the steering wheel tightly and brace your feet.

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

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

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

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

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

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

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

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

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

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

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

3

SAFETY

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

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

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

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

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

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

• For tow tractors, see ASME B56.9.

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

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

MA-04.0-002 07 Rev. 6/22

4

Crown 1976 PF 2821 Rev. 6/22

SAFETY

Cleaning of Material Handling Equipment

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

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

Using a power washer

CAUTION

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

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

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

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

Material damage can occur.

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

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

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

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

Crown 2000 PF11969 Rev. 9/21

MA-1140-050 05 Rev. 9/21

5

SAFETY

Cleaning of Material Handling Equipment Crown Cleaning Products Cleaner Type

Part Number

Package Quantity

Degreaser and cleaner

363105-001 363105-012

19 oz can (12) 19 oz cans

All-purpose cleaner

363114-001 363114-012

19 oz can (12) 20 oz cans

Glass cleaner

363101-001 363101-012

19 oz can (12) 19 oz cans

Waterless hand cleaner

363111-001 363111-012

15 oz tube (12) 15 oz tubes

Pumiced and smooth hand cleaner

363112-001 363112-004

1 gal jug (4) 1 gal jugs

Wall-mounted deluxe soap dispenser

363122

Use with P/N 363112-001

Tough on grease

063009-005

1 gal jug

Citrus degreaser spray

363156-001 363156-012

32 oz spray bottle (12) 32 oz spray bottles

Citrus degreaser spray

363157-101 363158-101

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

Citra-sol degreaser

363146-001 363146-012

19 oz can (12) 19 oz cans

Battery cleaner

363124-001 363124-012

18 oz can (12) 18 oz cans

MA-1140-051 05 Rev. 9/21

6

Crown 2000 PF11969 Rev. 9/21

MAINTENANCE 5532

LIFTING & BLOCKING POINTS RR, RS, RD, & RR3000, RS3000, RD3000 SERIES TRUCKS NOTES:

Side

Move Truck to a Secure Non Traffic Maintenance Area With a Level Floor No Load on Forks Disconnect Battery Hydraulic Jack - Capacity 8000 LBS. Crown P/N: 122599 Collapsed Height Minimum: 2.25 in. (57 mm) Raised Height Maximum: 16 in. (405 mm)

Lower Forks and Move Towards Center of Truck if Required

Jack Stand - Capacity 10,000 LBS. Commercially Available

Steer Wheel Load Wheels Hard Wood Block

! WARNING Do Not Raise Load Wheels More Than 0.5 in. (13 mm) from Floor to Position Hard Wood Block.

Raise Forks 3 to 6 in.

(76 to 152 mm) From Floor

Wheel Chock Both Load Wheels Set Jack Stand Height as Required Not to Exceed 16 in. (405 mm) 961201 Crown 1996 PF-11031

MA–1430–100

5099 Printed in U.S.A.

MA–1430–100

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

Remove contactor compartment cover and caster cover (caster cover is below contactor panel cover) to access top of caster.

Remove the two screws located at the left side of the poweron pedal, remove pedal and lift brake pedal to service the brake master cylinders, switches, linkage and undercarriage pivot.

NOTE Be sure battery connectors are disconnected.

The power unit console is secured to the top of the power unit with five fasteners. Loosen fasteners and remove the console to perform maintenance to the lift pump(s) and motor(s), console display, multi-function control assembly, fault switches, lift/lower and auxiliary valves, lift/lower and auxiliary manifold, distribution panel and SCR panel.

Remove one screw and lockwasher securing the contactor panel cover and remove cover to perform maintenance to the contactors, circuit selector, and deadman switch.

Unlatching and swinging open the power unit door allows access to the power steering pump and motor, hydraulic reservoir, brake reservoir, hydraulic oil filter, drive brake and linkage, drive motor, torque generator and steering system.

To perform maintenance to certain areas of the mast or carriage assembly it may be necessary to remove the safety shield (includes safety glass and guard). The safety shield is mounted to supports and the supports are assembled to the mainframe. Remove ten screws securing supports to mainframe and four screws securing guard to supports. Remove supports, guard assembly, and safety glass carefully.

SAFETY SHIELD

POWER UNIT CONSOLE

CONTACTOR COMPARTMENT COVER

P OW E R - O N PEDAL

B R A K E P E DA L

P OW E R U N I T DOOR 1782-01

ILLUSTRATION 1-1

930222

5701

Crown 1993 PF9647-1 Rev. 4/98

Printed in U.S.A.

05 REV. 4/98

M1.0–1430–001

M1.0–1430–001

MAINTENANCE Lubrication 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.

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

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

On trucks equipped to operate in below freezing temperatures, low temperature hydraulic oil must be used. All screws, washers, nuts, roll pins, retaining rings, brake linkage, etc. need to be coated with a 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 Use Planned Maintenance Inspection Reports (PF9715) for RR and RD trucks as required to record and assure maintenance checks.

Crown 1993 PF-9647-2 Rev. 8/95

Printed in U.S.A.

03 REV. 8/95

M1.0–1430–002

M1.0–1430–002

MAINTENANCE 4333

L-1 L-2

L-3 L-4

L-14

L-5 L-15 L-6 L-7

L-13 L-8

L-12 L-7

L-9

L-11 L-10

INDEX

COMPONENT

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

Multi-function linkage Multi-function gears Brake Reservoir Steering Chain Steering Shaft Pedal Pivot Brake Linkage Undercarriage Pivot Steering Gears Drive Unit–Level Drive Unit–Pivot Door Hinge Pin Hydraulic Filter Hydraulic Reservoir Floorboard Springs

ILLUSTRATION 1-2 LUBRICATION CHART LUBE TYPE

QTY.

C B F C B C C B B A B C

AR AR AR AR AR AR AR AR AR 1.5 pt. (.7 l) AR AR

D B

‡ AR

30 da.

100 hr.

†† Pertains to Model 3500 Trucks Only 60 da.

90 da.

6 mo.

12 mo.

250 hr. 500 hr. 1000 hr. 2000 hr. † † † † L † † L † † † † † †

† 1st Chg. *Chg.

Chg. Chg. Chg.

See Chart 1-2 for Lube Type designation explanation (M1.0-04-002). Lubrication intervals for Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts. * Change first time only as noted, thereafter check at 250 hr./60 da. intervals and change at longer interval as noted. †-Check Chg.-Change L-Lubricate AR-As Required ‡ Hydraulic 39 in. (990 mm) power unit: 5 gal. (19 liters) Reservoir 45 in. (1145 mm) power unit & "A", "B", "C" & "D" size battery compartment: 6 gal. (23 liters) Capacity 45 in. (1145 mm) power unit & "E" size battery compartment: 7 gal. (27 liters) CHART 1-3 Crown 1993 PF9647-3 Rev. 4/98

Printed in U.S.A.

05 REV. 4/98

M1.0–1430–003

M1.0–1430–003

MAINTENANCE 1773-02

L-1

L-2 L-4 L-5

L-3

L-6

L-7 L-8

L-9

ILLUSTRATION 1-3

INDEX

COMPONENT

L-1 L-2 L-3 ††L-4 L-5 L-6 L-7 L-8 L-9

Mast Cylinder Stud Mast Channels Lift Chain Cylinder Wear Pad (TT Masts) Lift Cylinder Guide Caster Axle Caster Pivot Battery Rollers Load Wheel Axles

LUBRICATION CHART

†† Pertains to Model 3500 Trucks Only

LUBE TYPE

QTY.

60 da.

250 hr.

B E C B B B B B B

AR AR AR AR AR AR AR AR AR

30 da.

100 hr.

90 da.

500 hr.

6 mo.

12 mo.

1000 hr. 2000 hr.

† † † † † L L † †

See Chart 1-2 for Lube Type designation explanation (M1.0-04-002) †-Check Chg.-Change L-Lubricate AR-As Required Lubrication intervals for Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts CHART 1-4

Crown 1993 PF-9647-4 Rev. 8/95

Printed in U.S.A.

03 REV. 8/95

M1.0–1430–004

M1.0–1430–004

MAINTENANCE 1774-02

Sideshifter Assembly

RK FO ND E

L-1

L-10

L-4 L-2 L-6

L-3 L-5

L-7

L-4 L-9

ILLUSTRATION 1-4

L-2 L-8

LUBRICATION CHART INDEX L-1 L-2 L-3 L-4 L-5 L-6 L-7 L-8 L-9 L-10

COMPONENT Upper Inner Arms Pivot Areas Reach Cylinder Pivots Forks Slides Tilt Cylinder Rod End Upper Outer Arm Fork Carriage Pivots Tilt Cylinder Pivot Bearings Carriage Channel Sideshifter Slide Rail

LUBE TYPE B B L B L B L L E B

QTY. AR AR AR AR AR AR AR AR AR AR

30 da.

100 hr.

60 da.

250 hr. † † † † † †

90 da.

500 hr.

6 mo.

12 mo.

1000 hr. 2000 hr.

† † † †

See Chart 1-2 for Lube Type designation explanation (M1.0-04-002) †-Check Chg.-Change L-Lubricate AR-As Required Lubrication intervals for Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts CHART 1-5

Crown 1993 PF-9647-5 Rev. 8/95

Printed in U.S.A.

03 REV. 8/95

M1.0–1430–005

M1.0–1430–005

MAINTENANCE 1775-01

I-1 I-2 & I-3 I-4 I-5 I-6

I-9

I-7 I-8 & I-1 I-9 I-17 I-10 I-11 I-13 I-15

I-12 I-9

I-16 I-11

†† Pertains to Model 3500 Trucks Only

I-14

I-13

I-7

ILLUSTRATION 1-5

INSPECTION AND ADJUSTMENT CHART 30 da.

60 da.

90 da.

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 I-14 I-15 ††I-16 ††I-17

Electrical Connections, Cables and Wiring † † Multi-function Switches and Valve Linkage Travel Controls † Sequence Switch † Fault Switches † Horn † Steering Assembly and Chain † Contactor Tips † Motor Brushes † Deadman Switch † Brake Switches and Brake Operation † Undercarriage Articulation † Brake Linings † Stop Block, Drive Carriage † Tilt Cylinder † Battery Retainer Switches † Floorboard Springs † Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment CHART 1-6

Crown 1993 PF-9647-6 Rev. 8/95

6 mo.

12 mo.

Printed in U.S.A.

03 REV. 8/95

M1.0–1430–006

M1.0–1430–006

MAINTENANCE I-3

I-2

I-1

6068

I-1 I-6 I-20

Sideshifter Assembly

I-4 I-2

RK FO ND E I-19

I-5 I-13 I-18 I-6 I-7 I-17 I-8 I-16 I-15

I-14 I-9 I-10 I-11

I-9 I-12

ILLUSTRATION 1-6 INSPECTION AND ADJUSTMENT CHART 30 da.

60 da.

90 da.

6 mo.

12 mo.

INDEX COMPONENT 100 hr.

250 hr.

500 hr.

1000 hr.

2000 hr.

I-1 Column Rollers † I-2 Mast Limit Switches † I-3 Electrical Cables, Wiring, Switches and Lights † I-4 Lift Cylinders Guides and Slide † I-5 Lift Cylinders † I-6 Hydraulic Lines, Hoses and Electrical Cable † I-7 Lift Chain † I-8 Battery, Connector and Cable † I-9 Tires, Caster and Load Wheels † I-10 Reach Cylinder † I-11 Chain Anchors and Retainers † I-12 Forks † ††I-13 Cylinder Wear Pad (TT Masts) † ††I-14 Battery Retainer Switches † I-15 Rollers & Bushings † I-16 Slides † I-17 Lower Hangers † I-18 Sideshifter Cylinder Mounting † I-19 Sideshifter Cylinder † I-20 Lift Cylinder Mounting (Top & Bottom) † †† Pertains to Model 3500 Trucks Only Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

CHART 1-7 Crown 1993 PF-9647-7 Rev. 7/97

Printed in U.S.A.

04 REV. 7/97

M1.0–1430–007

M1.0–1430–007

INSPECTION & LUBRICATION SAE Torque Values

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

Grade

Grade Identification (on Head)

Specification

Bolt and Screw Size (in)

SAE - Grade 2

1/4 through 1-1/2

SAE - Grade 5

1/4 through 1-1/2

SAE - Grade 8

1/4 through 1-1/2

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

Fig. 1 (14916-02)

Crown 1979 PF5067 Rev. 2/16

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

71

INSPECTION & LUBRICATION SAE Torque Values

Torque Chart Bolt Diameter

Grade 5

Grade 8

Dry Torque Specification

Dry Torque Specification

in

ft Ib

kg-m

Nm

ft lb

kg-m

Nm

1/4

9±3

1.2 ± 0.4

12 ± 4

13 ± 4

1.8 ± 0.5

17.5 ± 5.5

5/16

18 ± 5

2.5 ± 0.7

24.5 ± 7

25 ± 5

3.5 ± 0.7

34 ± 7

3/8

32 ± 5

4.4 ± 0.7

43.5 ± 7

48 ± 10

6.6 ± 1.3

65 ± 13.5

7/16

50 ± 10

6.9 ± 1.4

67.5 ± 13.5

75 ± 10

10.4 ± 1.4

102 ± 13.5

1/2

75 ± 10

10.4 ± 1.4

101.5 ± 13.5

112 ± 15

15.5 ± 2.0

152 ± 20.5

9/16

110 ± 15

15.2 ± 2.0

149 ± 20.5

163 ± 20

22.5 ± 3.0

221 ± 27

5/8

150 ± 20

20.7 ± 2.8

203.5 ± 27

225 ± 30

31.1 ± 4.1

305 ± 41

3/4

265 ± 35

36.6 ± 4.8

359 ± 47.5

400 ± 50

55.2 ± 6.9

542 ± 68

7/8

420 ± 60

58.1 ± 8.3

569 ± 81

640 ± 80

88.3 ± 11.0

868 ± 108

1

640 ± 80

88.5 ± 11.1

868 ± 109

960 ± 115

132.5 ± 15.9 1300 ± 156

1 1/8

800 ± 100

110.6 ± 13.8 1085 ± 136

1 1/4

1000 ± 120

138 ± 16.6

1356 ± 163

1 3/8

1200 ± 150

166 ± 20.7

1630 ± 203

1 1/2

1500 ± 200

207 ± 27.7

2034 ± 271

Torque specifications for bolts related to hydraulic valves.

5/16

13 ± 2

1.8 ± 0.3

17.5 ± 2.5

3/8

24 ± 2

3.3 ± 0.3

32.5 ± 2.5

7/16

39 ± 2

5.4 ± 0.3

53 ± 2.5

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

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

72

Crown 1979 PF5067 Rev. 2/16

MAINTENANCE HYDRAULIC SYSTEM FILTER HYDRAULIC LINES AND FITTINGS 1. Blow air through all hose and lines to remove loose particles before installing. Any rubber hose with wire braid inner construction and any steel tube lines which have been collapsed or kinked are permanently damaged and must be replaced even if the damage is not externally visible.

2. Flexible hose shall be replaced if it collapses in its normal operating position.

3. All hoses and lines are to be clear of any surface or edge which will cause damaging wear and cuts, or on which they can become caught.

The spin on filter cartridge has been tightened by Crown.

When replacing filter, apply a film of oil 063001-001 to the seal and hand tighten until seal snugly contacts filter head.

NOTE Do not tighten filter with a wrench. A wrench should only be used for removal of the filter.

Use only a good grade of hydraulic oil such as Mobil DTE 24 (Crown No. 063001-001) or equal. On trucks equipped to operate in below freezing temperatures, Mobil Aero HFA or equal is recommended (Crown No. 063001-006).

NOTE

4. All connections are to be leak free.

Do not use hydraulic brake fluid.

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

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.

RESERVOIR With all cylinders in the retracted position and after all air has been bled from the hydraulic system, fill reservoir so that the oil level is between 0.5 in. (13 mm) to 1.0 in. (25 mm) above bottom of fill strainer. The total capacity of the hydraulic system at this level should be approximately:

• Trucks with 39 in. (990 MM) power unit:

5 gal. (20 liters)

• Trucks with 45 in. (1145 mm) power unit & “A”, “B”, “C” & “D” size battery compartment:

6 gal. (23 liters)

• Trucks with 45 in. (1145 mm) power unit & “E” size battery compartment:

7 gal. (27 liters)

5612 Crown 1993 PF9688-1 Rev. 1/98

Printed in U.S.A.

01 REV. 1/98

M2.0–1430–001

M2.0–1430–001

MAINTENANCE DRIFT TEST All drift tests should be conducted with a capacity load (refer to capacity plate for the rated capacity of your truck). The material used for the test load must be evenly stacked within the limits of a four foot square pallet and must be secured to the fork carriage with the forks spread to their maximum width.

CAUTION

Never stand or work under a suspended load.

Tilt Drift Test Cycle tilt forward and back several times before testing drift.

Elevate test load above staging height. Measure drift at the tilt cylinder rod. With the mast vertical (0 degree tilt), the mast and carriage may not drift more than 0.5 in. (13 mm) over a five minute period.

Lift Drift Test Elevate the test load above staging height and tilt mast to the full back position. After five minutes, measure the distance the forks have drifted. Drifting in excess of 2.5 in. (63 mm) over a five minute period is considered unacceptable.

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

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

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

Crown 1993 PF9688-2 Rev. 1/98

Printed in U.S.A.

01 REV. 1/98

M2.0–1430–002

M2.0–1430–002

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

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

For truck applications operating continually in temperatures at or above 40 degrees Fahrenheit, use 100% standard hydraulic oil.

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

For truck applications primarily operating in a freezer environment, use a 80/20 blend, 80% low temperature (063001-006) and 20% standard hydraulic oil (063001-021).

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

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

50 40 30 20 10 0 10 20 30 40 C

120 100 80 60 40 20 0 20 40 F

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

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

RR Models 6353

Crown 1993 PF9688-3 Rev. 1/98

Printed in U.S.A.

01 REV. 1/98

M2.0–1430–003

M2.0–1430–003

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

HYDRAULIC Pump Maintenance

Pump Maintenance

Figure 9221-01

Pump - Gear

Oil Seal Removal

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

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

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

Crown 1982 PF5372-1 Rev. 9/06

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

117

HYDRAULIC Pump Maintenance Oil Seal Replacement 1. Make sure the seal housing in the pump mounting flange is clean and free from burrs.

2. Pack the space between the lips of the seal with a high melting point, mineral based grease.

3. Seat the oil seal.

–

–

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

If the pump is assembled: Slide an "Assembly Sleeve" (available from Crown [#93170]) over the shaft splines until it comes in contact with the shaft shoulder.

Lightly grease the sleeve. Slide the oil seal, with the garter spring facing inwards, over the sleeve and start it squarely into the housing.

7. Hold the pump body vertically with the mounting flange end downward and with one hand underneath to prevent the bushings (index 5) from falling out. Tap the side of the body with a rawhide mallet to dislodge the lower bushings, and slide them carefully out of the body. Keep the bushings as a pair and place them on or near the mounting flange.

8. Invert the body and lift out the drive (index 9) and the idler (index 8) gears.

9. Remove the remaining pair of bushings as described in step 7 and place on or near the end cover.

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

4. Press the seal into the full depth of the recess.

5. Remove the Assembly Sleeve.

Pump Disassembly 1. Remove the bolts which hold the pump to the lift motor.

2. Lightly mark or scribe the end cover (index 2), the body (index 7) and the mounting flange (index 10) to ensure re-assembly in the correct relationship.

Also note the direction of rotation of the pump.

3. Loosen the bolts and lockwashers (index 1) and pull out the bolts.

4. Remove the end cover (index 2) and carefully lift out the two backing washers (index 3), the lobe seals (index 4) and the body "O" ring seals (index 6). The body seal is a moulded rubber seal on early pumps but changed to an "O" ring on newer units (Specify when ordering).

5. Fit an "Assembly Sleeve" tool (available from Crown [#93170]) over the splines on the drive shaft before withdrawing the mounting flange. Lightly tap the mounting flange clear of the two hollow dowels in the pump body and slide it squarely off of the shaft.

6. Carefully lift out the body "O" ring seal (index 6), the two backing washers (index 3) and the lobe seal (index 4).

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

118

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

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

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

Crown 1982 PF5372-2 Rev. 9/06

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

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

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

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

Lobe Seal

Backing Washers

Figure 9222-01

Crown 1982 PF5372-3 Rev. 9/06

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

119

HYDRAULIC Pump Maintenance

Clockwise Rotation Cover End

Mounting Flange End

Flat

Bushing Lobes

Bushing Lobes

Assemble Drive Gear in this Bore

Assemble Drive Gear in this Bore Cover End

Flat

Mounting Flange End

Bushing Lobes

Flat

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

Pump Reassembly Make sure that all pump components are perfectly clean and lubricated with the hydraulic oil to be used in the pump, prior to assembly.

1. Prepare the bushings (index 5) for mounting flange end of the body for assembly as follows: (Refer to Figure 9222-01) Place the bushings on the workbench with their lobes up and the flats in contact. Lubricate the lobe seal (index 4) with a mineral based grease and fit it around the bushing lobes. Fit a backing washer (index 3) inside each lobe seal. When fitted correctly, the backing washer must be level and flush with the top surface of the bushing lobes.

2. Prepare the bushings for the cover end of the body for installation into the pump in the same manner.

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

120

3. Pack the space between the lips of the oil seal (index 11) with a high melting point, mineral based grease.

4. Pick up the body and hold it with the hollow dowels up and with the fingers of one hand inside the bores of the body, ready to support the bushings.

5. Pick up the mounting flange bushing complete with lobe seal and backing washers, and slide them into the body bores with the lobes facing outwards and away from the flat at the intersection of the body bores. The bushings must be inserted squarely into the bores and must be kept square to each other. Do not use force when installing the bushings. If the bushings should cock in the bores, remove them and examine for scored body walls.

Light scoring can be stoned out with a fine grit hand stone.

Crown 1982 PF5372-4 Rev. 9/06

HYDRAULIC Pump Maintenance 6. Lubricate the body seals "O" ring (index 6) with a mineral based grease and seat it in the body.

7. Refer to Figure 9223-01to find the position of the drive gear bore for the direction of rotation you require. Lay the pump body on its side and slide the drive gear (index 9) through the drive gear bore (as called out in Figure 9223-01) so that the shaft protrudes out of the hollow dowel end of the body.

8. Slide the "Assembly Sleeve" (#93170) over the end of the splined shaft. Hold the drive gear journal with one hand and slide the mounting flange (index 10) squarely over the shaft and onto the two hollow dowels, flush against the body. The "Assembly Sleeve" provides a lead-in for the oil seal. Remove the "Sleeve" and clamp the mounting flange in a soft jawed vice with the pump body above the flange. If the sleeve is stuck on the splines it can be removed by tightening a 1/4"-28 bolt into the end of the "Assembly Sleeve".

9. Check that the bushings are flush against the mounting flange face and that the lobe seals (index 4) and backing washers (index 3) have not become dislodged. Check to see that the arrow on the body, adjacent to the word "ROTATION" is pointing in the correct pump rotation.

10. Mesh the idler gear (index 8) with the drive gear. If the original gears are being replaced on a new shaft, make sure that the marked side of the teeth are in contact so the bedded-in position of the teeth is maintained.

11. Pick up the bushings for the end cover side of the pump, complete with lobe seals and backing washers and slide them over the gear journals with the lobes facing outward and away from the flats in the bores. Again, the bushings must be installed squarely and without force.

Start Up Procedure A pump that has been re-assembled with new gears, bushings or body must be carefully broke-in before it is subjected to full load working conditions.

When test rig facilities are not available the following procedure must be carried out: 1. Install the pump on the application.

2. Where the pump speed is variable set the speed to 1500 rev/min; otherwise run the pump at its normal operating speed.

3. Run the pump at this speed for a period of 10 minutes at minimum pressure, that is, with the hydraulic system unloaded.

4. If the pump operating pressure can be directly controlled, ensure that the pressure is progressively increased up to full working requirements over the first hour of operation. In circumstances where the pressure cannot be directly controlled the same effect can be obtained by progressively increasing the work load on the machine, over the same period of time.

5. During this period make frequent checks of the pump casing temperature, or the oil temperature, if a temperature gauge is included in the system.

The temperature should not exceed that experienced under normal working conditions. If the temperature does rise excessively then it is possible that the pump has been assembled incorrectly and it must be dismantled to check this. If no fault is found then further period of running-in at low pressure, as in step 3, must be carried out.

12. Lubricate the body seal "O" ring (index 6) and seat it in the body.

13. Place the end cover in position, aligning the scribe marks made earlier.

14. Insert the bolts and lockwashers into the body and hand tighten into the tapped holes in the mounting flange. Apply a torque load of 4.7 to 5 kgm (34 to 36 ft lbs) to each bolt head.

15. Pour a small amount of hydraulic oil into the ports and check the pump for freeness and direction of rotation.

Crown 1982 PF5372-5 Rev. 9/06

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

121

HYDRAULIC SYSTEM Steer Pump

Steer Pump 19

20

18

4 2 4

3 5

3 2

17

16 22

11

15 10

A

11

12

10 21

14 13 9 8

6

7

1 Fig. 1 (11075-02)

Preparing for disassembly Pump repair must be performed in a clean, dust-free location, using clean tools and equipment. Dirt or grit damages the highly machined surfaces and results in leakage or premature failure of the pump.

Before disassembling the pump, scribe match marks on the stator (8) and the gear housing (19) to make sure that the pump is assembled in the same manner as it was shipped from the factory. If the stator or gear housing is replaced during repair, scribe a match mark on the new part in the same location as on the part it replaces.

Disassembling the pump See Figure 1.

1. Clean the outside of the pump with a high grade solvent and thoroughly dry.

2. Secure the pump in a vice (using light clamping pressure) at the area of the mounting flange (A).

3. Remove the eight screws (20) from the stator (8).

4. Separate the gear housing (19) from the stator (8).

It may be necessary to lightly tap the sides of the housing to facilitate the separation.

Crown 1984 PF5875 Rev. 11/21

CAUTION Never insert a screwdriver or other similar instrument between the housing and the stator for the purpose of prying the two halves apart as permanent damage may result.

5. Remove the dowel pins (18) from the gear housing (19).

6. Remove the idler gear and drive gear assemblies including the retaining rings (11), gears (12), keys, idler shaft (14) and drive shaft (15).

Technician Tips: When removing the plastic shim (9), note the color of the shim. These shims are supplied in different colors corresponding to different thicknesses.

When replacing the shim, the same color shim must be installed.

7. Disassemble the shaft assemblies.

General part inspection 1. Thoroughly wash all pump components in a good grade solvent and blow dry.

2. Lay the cleaned components on a dirt-free bench or shop-cloth and individually inspect each part.

M2.1-18.0-001 02 Rev. 11/21

225

HYDRAULIC SYSTEM Steer Pump

Inspecting the drive shaft 1. Inspect the drive shaft (15) for wear or cracking on the end of the shaft.

2. Inspect the grooving on the area of the drive shaft (15) where the oil seal (6) seats.

3. Inspect for wear or flaking on the area of the drive shaft (15) where the needle bearings (10) travel.

4. Inspect the metal distortion around the keyway or the retaining ring grooves. If any of these conditions exist, the drive shaft (15) must be replaced.

Inspecting the idler shaft 1. Inspect the idler shaft (14) for wear or flaking on the area of the shaft where the needle bearings travel.

2. Inspect the metal distortion around the keyway or the retaining ring grooves. If any of these conditions exist, the idler shaft (14) must be replaced.

Inspecting the gears 1. Inspect the gears (12) for any signs of galling or metal build-up on the side faces of the gears and on the outside diameter of the teeth. If these conditions exist, the gears must be replaced. When replacing gears, always replace both gears as a set.

Inspecting the oil seal 1. Inspect the oil seal (6) for wear, cracks, chips, or any other condition that causes the seal to leak. If any of these conditions exist, Crown recommends replacing the oil seal.

2. Remove the oil seal (6) from the stator (8). Discard the oil seal. Make sure not to damage the oil seal bore on the stator.

3. Install the new oil seal (6) in the stator (8). Make sure that the oil seal is installed evenly in the stator.

Inspecting the needle bearings 1. Check the needle bearings (10) for excessive bearing to shaft clearance in the stator bearings and the gear housing bearings. Although replacement bearings are available, Crown recommends replacing the entire stator (8) and gear housing (19) because bearing wear or damage usually damages the bearing bores.

Inspecting the stator 1. Inspect the inner-face of the stator (8) for signs of scoring, excessive wear, or metal build-up.

2. If a slight metal build-up is evident, the stator face can be lapped smooth with the use of a solvent-

M2.1-18.0-002 02 Rev. 11/21

226

soaked crocus cloth (280 or 320 grit) placed on a flat surface.

Technician Tips: Make sure to remove only enough material to clean up the build-ups. A stator having a scored or worn inner-face must be replaced.

Inspecting the gear housing 1. Inspect the gear pocket face on the gear house (19) and wall for scoring or excessive wear. If either of the conditions exist, the housing must be replaced.

Inspecting the keys 1. Inspect the keys for cracks or shear marks. Replace if necessary.

Assembling the pump See Figure 1.

1. Install the shim (9) on the inner-face of the stator (8).

Technician Tips: A thin film of hydraulic oil helps maintain the location of the shim.

Technician Tips: If a new shim is being installed, make sure that the color of the shim corresponds to the color of the shim removed during disassembly.

2. Assemble the idler and drive gear assemblies by installing the keys, gears (12), and retaining rings (17) on the respective shafts (14 and 15).

3. Install the drive shaft.

4. Put the end of the drive shaft in the sleeve bore and slide the shaft to a position where the side of the gear is in contact with the stator inner-face.

5. Insert the idler gear shaft in the respective bore after aligning and meshing the gear teeth properly.

6. After both shafts are in position, make sure that the shim is free of the gear teeth.

7. Install the two dowel pins (18) in the gear housing (19).

8. After aligning the scribed match marks, carefully slide the gear housing (19) in place and install the screws.

If the scribe marks are not visible, make sure that the assembly is as follows: • Hold the pump in a position where the outside face of the gear housing (19) is visible.

• Rotate the pump to a position where the idler shaft (14) is directly below the drive shaft (15).

• From that position, the 12.7 mm (0.5 in) NPTF port should be on the left side.

Crown 1984 PF5875 Rev. 11/21

HYDRAULIC SYSTEM Steer Pump

•

Hand-tighten the eight screws (20) and make sure that the drive shaft rotates freely. If the drive shaft rotates freely, torque the screws 10–14 N m (8–10 ft lb).

Crown 1984 PF5875 Rev. 11/21

M2.1-18.0-002 02 Rev. 11/21

227

Notes:

228

MAINTENANCE CONTROL VALVE - CESSNA

ILLUSTRATION 2-18 Disassembly 1. Plug all ports and clean outside of valve thoroughly.

2. Remove detent cap (#32). When detent cap is being removed, care should be taken not to lose spring (#29) and balls (#30).

3. Remove caps (#1). Do not remove screws (#2) and (#31) from spool assemblies unless spring (#26) needs to be replaced. The spring need not be replaced unless it is broken.

4. Remove spools (#4), (#22) and (#23) from valve body.

© Crown 1978 PF-3375-1

M2.3 - 11 - 011

NOTE Spools and bodies are matched sets. Be sure each spool is identified with the correct body bore.

5. Remove bushings (#24) and “O” Rings (#15) from spools.

6. Remove orifice plates (#9) and (#14).

CAUTION

Check position and location of orifice plates when removed to assure proper assembly.

Printed in U.S.A.

M2.3 - 11 - 011

MAINTENANCE 7. Remove relief valve plug (#16), shim (#17), spring (#19), and poppet (#20) from body.

NOTE Do not remove poppet seat. Seat has been set to predetermined depth and locked in place.

8. Remove lift check plug (#10), spring (#12), and plunger (#13) from body.

9. Remove pressure beyond plug (#5) from body.

10. Remove “O” Rings (#15) from body bores.

11. Remove all “O” Rings and back-up washers from all plugs.

Inspection 1. Remove all nicks and burrs from parts and inspect for excessive wear.

2. Inspect spool spring, relief valve spring and lift check spring for breakage.

3. Inspect relief valve poppet for breakage or wear.

4. Inspection of “O” Rings, and back-up washers is not necessary. It is recommended that they be replaced as new parts when valve is serviced.

Service of Relief Valve The pin type relief valve is serviced when disassembly of the valve is accomplished. If a higher or lower system pressure is required, shims (#17) may be added or taken out as needed, noting that adding shims increases pressure; removing shims decreases pressure. (See Illustration 2-19) Electrical Switch Adjustment To adjust the switch, shims must be added between the switch and the switch mounting plate. (See Illustration 2-19) Shim switch so that the spool travels .020″/.060″ [.51mm/1.52mm] between switch contacts (clicks). Spool travel in either direction from neutral must not be less than .010″ [.25mm] nor greater than .050″ [1.27mm] when switch contacts (clicks).

Reassembly 1. Thoroughly clean and dry all parts. Metal parts should be lightly oiled prior to assembly.

NOTE All “O” Rings and back-up washers should be replaced as new parts.

2. Position new “O” Rings (#15) in proper grooves in spool bores.

3. Install new back-up washers and “O” Rings on plugs.

RELIEF VALVE SHIMS (#17)

4. Install relief valve components (#20), (#19), (#17), and (#16).

5. Install lift check components (#13), (#12), and (#10).

6. Install pressure beyond plug into body.

7. If screws (#2) and (#31) have been removed to replace spring (#26), they should be installed with loctite and torqued 5 to 8 ft. lbs.

8. Slide bushing (#24) over spool, slide new “O” Ring (#15) over spool and position next to sleeve.

9. Dip spools in oil and install spool and spring assemblies (#4) and (#22) in proper location.

SWITCH SHIMS

10. Install balls (#30) and spring (#29) by placing index finger over bottom hole in screw (#31). Place one ball, then the spring and other ball into the hole. With the cap (#32) in other hand, assemble the two parts with bottom hole entering the cap first and at the same time sliding index finger away from the hole. Press other ball down with thumb, and slide cap on and back into detent position.

11. Install detent spool assembly into proper location.

12. Install caps (#32) and (#1) to secure spool assemblies.

ILLUSTRATION 2-19

© Crown 1978 PF-3375-2

M2.3 - 11 - 012

13. Install orifice plates.

Printed in U.S.A.

M2.3 - 11 - 012

MAINTENANCE

Trouble Shooting Guide

Crown 1978 PF-3375-3

M2.3 - 11 - 013

Printed in U.S.A.

M2.3 - 11 - 013

MAINTENANCE LIFT/LOWER CONTROL VALVE RELIEF VALVE #3 (RV3) Operation

Adjustment

The lift system is protected from excessive oil pressure by RV3. RV3 senses pressure at the valve inlet. If the pressure within the system exceeds RV3 preset level, RV3 will open and relieve pressure by directing oil to the reservoir thus maintaining a maximum pressure limit for the system.

Lift Valve Assembly

To adjust RV3, refer to Illustration 2.3-1 and proceed as follows: 1. Connect a 0-5000 psi. (0-35000kPa) pressure gauge to the test port (Quick Disconnect) between lift manifold and valve.

2. If the truck is capable of two pump operation, place a jumper between test points TP9 and TP11 on the distribution panel that is located just above the SCR panel on the power unit. This is to insure that both pumps are running when the relief valve is being set.

3. Operate the hydraulic system so that the oil temperature is 110-130 degrees F (45-55 C).

RV3 Valve Assembly

ILLUSTRATION 2.3-1

1909

4. Loosen the jam nut so that RV3 can be adjusted. Raise the fork carriage until it stops. Hold the control lever in the RAISE position and check the indication of the pressure gauge when the relief valve opens. Turn the adjustment screw to change the setting. Refer to Chart 1 for correct pressure settings.Tighten the jam nut when the adjustment is correct. Recheck setting after the jam nut has been tightened. Readjust if necessary.

Truck Voltage

Model

Set Pressure (psi)

Set Pressure (kPa)

24V

TL

2570 - 2620

17720 - 18065

TT

2410 - 2460

16615 - 16960

TF

2210 - 2260

15240- 15820

TL

2590 - 2640

17860 - 18200

TF

2385 - 2435

16445 -16790

TT30RD

2640 - 2690

18200 -18545

TT45RR

2850 - 2900

19650 - 19995

TT35RR, 40RS

2490 - 2540

17170 -17515

36V

1948 930222 Crown 1993 PF-9712-1

M2.3 - 1430 - 001

CHART 1

3684NF-37094 Printed in U.S.A.

M2.3 - 1430 - 001

MAINTENANCE TROUBLE SHOOTING Troubles

Probable Cause

Remedy

Oil leaks at either end of spool.

Defective O-rings in valve body.

Replace O-rings.

Unable to push spool in.

Oil leakage past spool seal into spool cap.

Remove cap, if it contains oil, replace spool seal O-rings.

Check O-ring retainer to see if it is flat. If it has been "belled" check for restriction from outlet to tank of valve which would cause excessive back pressure.

Spring-centered spools do not return to neutral.

Broken springs.

Bent spool.

Replace springs.

Return for FACTORY repair, or replace with new spool of same size and type.

Excessive back pressure.

Relieve condition. May be either restriction from outlet to tank or another valve is operated in series from the outlet of the valve. Either change system to work separately or use high-pressure carry-over.

Foreign particles.

Clean system and valve.

Misalignment of operating linkage.

Check linkage for binding condition.

Defect ive p u m p .

C h e ck p re ssu re .

Defe ct ive cylin d e r.

R e p a ir o r r e p la ce .

Load la r g e r t h a n ca p a cit y.

R e f e r t o u n it se ria l p l a t e f o r m a xim u m ca p a city t o b e l i f t e d .

Reli e f va lve s n o t p r o p e r ly se t .

C h e ck p re ssu re s e t t i n g s .

Reli e f va lve s d o n o t f u n ct io n prope r ly.

R e p a ir a n d r e a d jus t .

Dirt o r f o r e ig n p a rt icle s lo d g e d betw e e n re lie f va lve , p lu n g e r and se a t s.

Wea k o r b r o ke n re lie f valve sp rin g s.

D isa sse m b le , clea n a n d re a sse m b le .

No motion, slow or jerky action of hydraulic system.

1910 Crown 1993 PF-9712-2

M2.3 - 1430 - 002

R e p la ce sp r in g s.

Scor e d r e lie f va lve sp r in g s.

R e p la ce p lu n g e r s .

Valv e b o d y cra cke d in sid e .

R e p la ce va lve .

Spo o l n o t m o ve d t o f u ll st r o ke .

C h e ck t ra ve l.

C H A RT 2 Printed in U.S.A.

M2.3 - 1430 - 002

C

DRIVE UNIT

Your Crown Narrow Aisle Rider lift truck has a single drive unit located at the left rear corner of the power unit. The drive unit is a double reduction gearbox incorporated spiral bevel gears for strength, quietness and smooth operation. The unit is totally enclosed and oil is pumped throughout to give maximum lubrication to both bearings and gears. The drive motor, located on the left side of the undercarriage, directly above the drive unit, is equipped with a hydraulically released spring applied, brake system.

DRIVE UNIT BASICS LUBRICATION Normal application 32° F (0° C) and above Freezer application 32° F (0° C) and below

90 wt gear lube Automatic Transmission Fluid

Part Number 063002-003 Part Number 063001-010

Drive unit oil should be changed at the first 500 hr and then every 2000 hr thereafter.

CHECKING DRIVE UNIT LUBRICATION SYSTEM

19 18

21

20

17

TUBING IS INSTALLED THROUGH CORED HOLE IN CASTING

16

22

13 15

12

14 11

Illustration 1 shows the two check points for drive unit lubrication. Item (14) is the check level and fill plug. When filling the drive unit (1 1/2 pint/0.7 liters capacity), be sure that the oil is to this level. The other check point is found at the top of the drive unit item (15). During each PM, remove the pipe plug with a 3/16 inch hex key wrench. If oil is visible, the oil pump located at the bottom of the unit is operational. If oil is not present, operate the drive unit with the plug removed. Oil should flow from the pipe plug hole. If, after this test, oil is still not present, the oil pump must be repaired or replaced.

18 10

3 3 2 5

1

4

9

23

8 7 6

1837S

ILLUSTRATION 1 5701

Crown 1993 PF9705-1 Rev. 4/98

Printed in U.S.A.

02 REV. 4/98

M3.0–1430–001

M3.0–1430–001

C

DRIVE UNIT

GENERAL DRIVE UNIT MAINTENANCE

Retaining Screw

Axle Nut

Since the drive unit used on this model incorporates an oil pump, maintaining clean drive unit oil is essential. This can be easily accomplished through oil changes at the recommend intervals previously specified (see Lubrication).

Rotate Nut One Notch

During the oil change, remove the rear drive unit axle cover and inspect the axle nut. If the axle nut retaining screws are loose or the axle nut can be rotated between the screws, remove the retaining screws and tighten the axle nut to the next screw hole. Reinstall retaining screws (in their original position) within the hub's thread hole. Refer to Illustration 2 & 3 below.

Tightening the axle nut will compensate for any wear in the axle assembly, which if left unattended could result in excessive wear between the hub and axle spline requiring axle and hub replacement.

Retaining Screw 6493

ILLUSTRATION 2

Retaining Screw Axle Nut Hub

Axle Rear Cover

6492

ILLUSTRATION 3

Crown 1993 PF9705-2 Rev. 4/98

Printed in U.S.A.

02 REV. 4/98

M3.0–1430–002

M3.0–1430–002

C

DRIVE UNIT

DRIVE TIRE REPLACEMENT 19 18

1. When replacing the drive tire, make sure the composition and size are such that maneuverability and braking requirements are maintained. The drive tire is a “presson” type; press the old drive tire off the hub and press the new tire on. The outside of the hub must be pressed flush with outside edge of the tire.

2. Tighten lug bolts in sequences of 30 ft.lbs. (40Nm), 60 ft.lbs. (80Nm), and 90-100 ft.lbs (120-135Nm).

Refer to Illustration 4 for bolt sequence.

21

20

17

TUBING IS INSTALLED THROUGH CORED HOLE IN CASTING

16

22

13 15

12

14 11

1 4

5 8

7

18 10

3

2 6 3 3

Illustration 3-2 4 ILLUSTRATION

1899

2 9

5

OIL PUMP DISASSEMBLY (Refer to Illustration 5 & 6)

1

4

23

8 7

1. Remove drain plug (23); drain oil from drive unit.

2. Remove oil pump housing (1) from drive unit.

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

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

5. Remove piston (9), spring (8), and ball (7) from oil pump housing.

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

7. Thoroughly clean housing and all parts.

AXLE BEARING CONE

CAM

BEARING CUP PISTON(9) SPRING(8)

O- RING (3) DRIVE UNIT HOUSING

BALL(7) PLUG SPECIAL(6)

O- RING (2) OIL PUMP HOUSING

SPRING(5)

6

Illustration 3-4

1837S

ILLUSTRATION 6

OIL PUMP ASSEMBLY Inspect all component parts and drive unit casting for dirt and burrs before assembly.

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

2. Place ball (7), spring (8), and special pipe plug into piston (9). Lubricate piston with oil to aid in smooth action and install piston into oil pump housing installed in drive unit housing.

4. Install o-rings (2) and (3) onto pump body.

5. Oil pump body and port thoroughly and screw pump assembly into casting until seated.

6. Replace drain plug and fill drive unit with 1.5 pts. (0.7 liters) of gear oil.

7. To check oil pump output remove pipe plug (15) and observe oil flow from port.

BALL4) ILLUSTRATION 3-3 1895

ILLUSTRATION 5

Crown 1993 PF9705-3 Rev. 4/98

Printed in U.S.A.

02 REV. 4/98

M3.0–1430–003

M3.0–1430–003

C

DRIVE UNIT

A 50 35 25 27

A

28 21 29

50 31

33

45 40 41

32

36 37 38 39

34

21

Located on Power Unit

42 43 44

ILLUSTRATION 3-1 ILLUSTRATION 7

1896S

NOTE

CAUTION

Disconnect battery and chock load wheels before performing any maintenance procedure.

UNDER CARRIAGE INSPECTIONS AND ADJUSTMENTS Refer to Illustration 7 1. Disconnect battery and remove from compartment; pull door hinge pin up and remove door.

2. Disconnect the positive (+) cable from the power steering motor; disconnect the A-2 cable from the drive motor.

3. Replace the vent plug in the cap of the brake reservoir with a non-vented plug and remove the reservoir from the steering bracket.

Under normal maintenance operations it is recommended the undercarriage not be removed completely from the power unit.

6. Adjust the amount of undercarriage articulation to 0.25 in. (6mm) +0.00 in., -0.06 in. (+0.00mm -1.5mm) at both stop locations unless otherwise noted on a label at both locations.

7. The locknut that secures the castor mounting assembly (50) to the undercarriage must be tightened to 70-80 ft.lbs. (95-110Nm). Rotate caster assembly while tightening to insure centering of the thrust bearing with the roller bearing.

4. When removing undercarriage note the number and position of washers (41) and replace in same position at assembly.

5. The four 3/4" diameter bolts (43) that clamp pivot shaft (44) to the power unit must be tightened to 225-250 ft.Ibs. (305-340Nm).

Crown 1993 PF9705-4 Rev. 4/98

NOTE

The articulation adjustment bolts are located above point “A” as shown in Illustration 7. With the truck in a level condition, and the trailing edge of the caster turned toward the drive unit, adjust the distance between top of undercarriage and the bottom of adjusting bolt to the specified dimension and tighten jam nut.

Printed in U.S.A.

02 REV. 4/98

M3.0–1430–004

M3.0–1430–004

C

DRIVE UNIT

DRIVE UNIT REMOVAL 1. Remove the drain plug in the bottom of the drive unit casting with a 1/4" hex key wrench and allow gear oil to drain.

2. Remove the four 3/4" bolts at the undercarriage pivot, tighten to 225 - 250 ft.lbs. (305 - 340Nm) at assembly; remove the hinged floor board assembly and the contactor panel cover.

3. Disconnect the S-1, S-2, A-1, and the positive (+) power steering cable from the contactors and pull cables from guides on power unit.

4. Raise the rear of the truck with a floor jack until the four socket head bolts and the two dowel pins are below the skirt of the power unit; place jack stands beneath power unit before beginning work on undercarriage. Remove the six lug bolts and the drive tire assembly from the drive unit.

See drive unit tire replacement when assembling drive tire assembly.

5. Remove the four 3/4" socket head bolts and the two dowel pins at the left side of the undercarriage. Apply thread locking adhesive (061004-010) and tighten to 250 - 275 ft.lbs (340 - 370Nm) at assembly.

6. Lower the rear of the power unit down and install the four 3/4" bolts at the undercarriage pivot. (Tighten bolts, do not torque at this time.)

7. Stabilize the drive unit and raise the rear of the truck until the drive unit will clear the power unit.

8. Move drive unit to a clean work area if further disassembly is necessary.

9. Reverse steps 1 thru 8 to install drive unit.

Crown 1993 PF9705-5 Rev. 4/98

Printed in U.S.A.

02 REV. 4/98

M3.0–1430–005

M3.0–1430–005

MAINTENANCE DRIVE UNIT REPAIR/REBUILD The drive unit used on your Crown Lift Truck, is a double reduction gearbox incorporated spiral bevel gears for strength, quietness and smooth operation. The unit is totally enclosed and oil is pumped throughout to give maximum lubrication to both bearings and gears.

DRIVE UNIT COMPONENT OVER VIEW Shown in the illustrations below is a parts breakdown and two cross sectional views of the drive unit components. The views shown may vary slightly between the RR, RS, RD, SP 3000, TS and TSP trucks.

2910S RR, RS, & RD SHOWN

RR, RS, & RD SHOWN

1199S-02

2911S 4295MI Crown 1994 PF10344-1

Printed in U.S.A.

01 REV. 6/95

M3.0–1430–050

M3.0–1430–050

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

REMOVING AXLE SEAL

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

2876P

INSTALLING NEW AXLE SEAL

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

2875P

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

Crown 1994 PF10344-2

M3.0–1430–051

Printed in U.S.A.

M3.0–1430–051

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

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

3048P

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

3049P

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

3050P Crown 1994 PF10344-3

M3.0–1430–052

Printed in U.S.A.

M3.0–1430–052

MAINTENANCE

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

3051P

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

3052P

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

3053P

Crown 1994 PF10344-4

M3.0–1430–053

Printed in U.S.A.

M3.0–1430–053

MAINTENANCE

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

3054P

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

3055P

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

3056P

Crown 1994 PF10344-5

M3.0–1430–054

Printed in U.S.A.

M3.0–1430–054

MAINTENANCE

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

3057P

11. REMOVING LOCKNUT FROM AXLE Remove axle locknut. Due to the thread locking adhesive the locknut may need to be heated during removal.

Cut the wirelocks and remove the 8 bolts that secure the ring gear to the hub.

3058P

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

3059P

Crown 1994 PF10344-6

M3.0–1430–055

Printed in U.S.A.

M3.0–1430–055

MAINTENANCE

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

3060P

14. REMOVING HUB WITH PULLER The hub is heat press fitted to the axle. Depending on wear pulling may require the use of a puller and heat. If the hub can be removed without a puller, the hub and axle assembly should be replaced.

The axle can be removed. Do not use the seal flange for support if pressing is required to remove the axle, use the housing. Replace the seal.

3061P

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

3062P

Crown 1994 PF10344-7

M3.0–1430–056

Printed in U.S.A.

M3.0–1430–056

MAINTENANCE ASSEMBLING DRIVE UNIT

1. DRIVE UNIT COMPONENTS Shown are all the components that make up the drive unit.

Before reassembly be sure to inspect all components for wear or damage. Install the housing components which include the bearing cups and oil pump tubing.

3063P

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

3044P

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

3064P

Printed in U.S.A.

Crown 1994 PF10344-8

01 REV. 6/95

M3.0–1430–057

M3.0–1430–057

MAINTENANCE

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

3065P

5. TOOL INSTALLED The face of the tool shown has a radius of exactly 1 in.

(25mm) from the center of the axle bore.

3066P

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

3067P

Crown 1994 PF10344-9

M3.0–1430–058

Printed in U.S.A.

M3.0–1430–058

MAINTENANCE

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

3068P

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

3069P

9. AXLE CENTER TOTAL

3045P

Crown 1994 PF10344-10

M3.0–1430–059

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

Printed in U.S.A.

M3.0–1430–059

MAINTENANCE 10. AXLE INSPECTION Inspect the axle before installation to insure there are no nicks or scratches.

Before installing bearings on the axle heat each bearing and the pump cam to 250°F (120°C) for approximately 25 minutes. To insure proper heating only use a temperature controlled oven or oil bath. Heating the bearings by any other method or exceeding the 250°F (120°C) will cause bearing damage.

The hub should be heated to 450°F (232°C) for approximately 35 minutes. Heating the hub will ease installation and insure proper seating.

3070P

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

3071P

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

3072P

Crown 1994 PF10344-11

M3.0–1430–060

Printed in U.S.A.

M3.0–1430–060

MAINTENANCE

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

3073P

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

3074P

15. TIMING MARK ON PINION AND SPIRAL BEVEL GEAR

3075P

Crown 1994 PF10344-12

M3.0–1430–061

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

Printed in U.S.A.

M3.0–1430–061

MAINTENANCE

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

3076P

17. TIGHTENING NUT Tighten the nut with Crown tool part number 100253-001.

Once the nut is tight bend the tab over on the locking washer.

3077P

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

3078P

Crown 1994 PF10344-13

M3.0–1430–062

Printed in U.S.A.

M3.0–1430–062

MAINTENANCE

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

3079P

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

3080P

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

3081P

Crown 1994 PF10344-14

M3.0–1430–063

Printed in U.S.A.

M3.0–1430–063

MAINTENANCE

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

3082P

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

3083P

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

3084P

Crown 1994 PF10344-15

M3.0–1430–064

Printed in U.S.A.

M3.0–1430–064

MAINTENANCE

25. SNAP RING THICKNESS Measure the snap ring thickness. Example .095 in.

(2.4mm).

3085P

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

3046P

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

27. SPACER AND SHIM INSTALLATION Install the shims and spacer with the 2 3/8 pipe as shown.

After the spacer is seated install the snap ring.

3086P

Crown 1994 PF10344-16

Printed in U.S.A.

01 REV. 6/95

M3.0–1430–065

M3.0–1430–065

MAINTENANCE

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

3087P

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

3088P

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

3089P

Crown 1994 PF10344-17

M3.0–1430–066

Printed in U.S.A.

M3.0–1430–066

MAINTENANCE

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

3090P

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

3091P

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

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

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

3116S

Crown 1994 PF10344-18

M3.0–1430–067

Printed in U.S.A.

M3.0–1430–067

MAINTENANCE

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

3092P

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

3093P

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

3094P

Crown 1994 PF10344-19

M3.0–1430–068

Printed in U.S.A.

M3.0–1430–068

MAINTENANCE

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

3095P

Crown 1994 PF10344-20

M3.0–1430–069

Printed in U.S.A.

M3.0–1430–069

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

BMS BRAKE MONITOR SWITCH This switch is mounted to the brake mounting plate assembly on the drive motor top. To access, open the power unit door by turning the two latches at the operator compartment onequarter turn and pivoting door open.

The switch is operated by means of an actuator connected to the spring adjustment rod. Adjust by loosening the nuts on either side of the actuator and moving actuator as needed to actuate switch when the brakes are released and reset when the brake is set.

BRS BRAKE RELEASE SWITCH The brake release switch is located beneath the brake pedal in the operator compartment. To access the switch, pivot the brake pedal up, right to left. BRS is mounted with a bracket to the power unit weldment near midpoint of the pedal.

When the brake pedal is depressed, the pedal contacts a spring loaded actuator and forces it away from the switch, resetting the switch contacts. Slight adjustment of the switch is possible through undersized mounting screws for the switch. Make certain the switch is actuated when the brake pedal is released and reset when the brake pedal is depressed.

BRAKE PEDAL

BMS

BRAKE RELEASED

ACTUATOR 1853

930222 Crown 1993 PF-9682-1

M4.0 - 1430 - 001

BRS

BRS MOUNTING BRACKET

BRAKE APPLIED

ILLUSTRATION 4.0-1

BRAKE APPLIED

1854

BRAKE RELEASED ACTUATOR

ILLUSTRATION 4.0-2

3684MJ-37094 Printed in U.S.A.

M4.0 - 1430 - 001

MAINTENANCE DMS DEAD MAN SWITCH

ERS ERASE SWITCH

DMS is located in the bottom corner of the contactor panel compartment, towards the forks. Access to the electrical connections of this switch is gained by removing the contactor compartment cover. DMS must be actuated when the floorboard is released and reset when the floorboard is depressed. DMS does not require adjustment.

ERS is located along the left edge of the operator compartment when standing at the power unit, facing the forks. This switch does not require adjustment.

FNS FAN SWITCH The fan switch is located in the overhead guard console. This switch does not require adjustment.

PART OF POWER UNIT DMS

RELEASED DEPRESSED 1850

ILLUSTRATION 4.0-3

DPS DISPLAY SWITCH DPS is located along the left edge of the operator compartment when standing at the power unit, facing the forks. This switch does not require adjustment.

FORKS ERS

DPS

LGS1 1851

FNS

LGS2

ILLUSTRATION 4.0-5

FS FORWARD SWITCH FS is located in the multifunction control assembly directly below the control handle pivot point. The console assembly must be removed to perform maintenance to this switch.

Refer to the M4.5 section for adjustment procedures and specifications.

PART OF POWER UNIT 1856

ILLUSTRATION 4.0-4

Crown 1993 PF-9682-2

M4.0 - 1430 - 002

Printed in U.S.A.

M4.0 - 1430 - 002

MAINTENANCE HGTS1 FREE LIFT SPEED LIMIT

HGTS2 270" (6860 mm) SPEED LIMIT

The free lift speed limit switch is located at the top of the main frame on the right hand side of the truck when standing at the power unit facing the forks.

This switch is present only on trucks with 271" (6860 mm) or greater lift height. HGTS2 is located at the top of the main frame on the left hand side of the truck when standing at the power unit facing the forks.

Adjusting the mounting bracket of HGTS1 allows setting where the roller of the switch arm will contact the crossbrace.

To adjust when the switch actuates, loosen the switch arm clamping screw and turn switch arm so switch actuates when first stage mast is fully lowered.

HGTS1

To adjust this switch, raise the forks to a lift height of 270".

The roller of the switch arm should not be in contact with the tripper bar. Lower the forks 1" (25 mm) and loosen the switch arm clamping screw until the switch shaft can be turned with a screwdriver. Turn the switch shaft with the screwdriver until the switch actuates and tighten the clamping screw. Make certain the switch remains actuated throughout travel on the entire tripper bar. If the switch resets at anytime during the travel, adjust switch slightly so reset does not occur.

SCREWDIVER SLOT IN SWITCH SHAFT

HGTS2 HGTS3

ACTUATOR ARM CLAMPING SCREW 1857

ACTUATOR ARM CLAMPING SCREW

ILLUSTRATION 4.0-6 SCREWDIVER SLOT IN SWITCH SHAFT

1858

ILLUSTRATION 4.0-7

HGTS3 SECOND LIFT PUMP CUTOUT This switch is present only on trucks with two lift pumps.

HGTS3 is located at the top of the main frame on the left hand side of the truck when standing at the power unit facing the forks. This switch is mounted away from the first stage mast slightly more than HGTS2 so the roller on the switch arm of HGTS3 does not contact the tripper bar used by HGTS2. An actuator block welded lower on the mast contacts the roller of the switch arm on this switch to actuate the switch.

To adjust this switch, fully extend the mast. Lower the forks 1 foot (305 mm). Loosen the switch arm clamping screw and extend or retract the switch arm as necessary to actuate the switch when the mast is in this position. If moving the switch arm does not provide enough adjustment to actuate the switch, loosen the set screw securing the switch arm to the switch post and turn the switch post with a screwdriver until switch actuates.

Crown 1993 PF-9682-3

M4.0 - 1430 - 003

Printed in U.S.A.

M4.0 - 1430 - 003

MAINTENANCE HNS Horn

LGS1 & LGS2 DOME LIGHT WORK LIGHT

The horn switch is located in the multifunction control handle.

This switch does not require adjustment.

The light switches are located in the overhead guard console on trucks so equipped. These switches do not require adjustment.

HNS ILLUSTRATION 4.0-8

1849

KYS Keyswitch KYS is located on the right side of the overhead console. The keyswitch has a mechanical restriction which requires the key to be returned to “off” from the “on” position before it can be turned to the “TEST” position. This switch requires no adjustment.

LGS1 1851

FNS

LGS2

ILLUSTRATION 4.0-10

MFS1 & MFS2 MULTIFUNCTION SWITCH 1 MULTIFUNCTION SWITCH 2

TEST

The multifunction switches are located above and slightly to the right of the accessory valve on the multifunction control.

Multifunction switch 1 is the bottom switch and is actuated when the control handle is moved upwards. The console assembly must be removed to perform maintenance to this switch.

ON 1792

OFF

ILLUSTRATION 4.0-9

Multifunction switch 2 is the top switch and is actuated when the control handle is moved downwards. The console assembly must be removed to perform maintenance to this switch.

Refer to section M4.5 for adjustment instructions for these switches.

RAS RAISE The raise switch is present only on trucks with high speed raise and is located at the top and toward the center of the multifunction control mounting bracket. This switch is actuated when the control handle is moved upward to its maximum position. The console assembly must be removed to perform maintenance to this switch. Refer to section M4.5 for adjustment instructions.

Crown 1993 PF-9682-4

M4.0 - 1430 - 004

Printed in U.S.A.

M4.0 - 1430 - 004

MAINTENANCE RS REVERSE SWITCH RS is located in the multifunction control assembly directly below the control handle pivot point. The console assembly must be removed to perform maintenance to this switch.

Refer to section M4.5 for adjustment instructions.

SQS SEQUENCE SQS is located in the multifunction control handle. This switch does not require adjustment.

SQS 1852

ILLUSTRATION 4.0-11

THS1 THERMOSTAT 1 The thermostat for freezer conditioned trucks is located on the freezer condition distribution panel mounted on the left side of the multifunction control mounting bracket. The console assembly must be removed to perform maintenance to this switch. This switch requires no adjustment.

FREEZER CONDITION DISTRIBUTION BOARD

THS1

1862

ILLUSTRATION 4.0-12

Crown 1993 PF-9682-5

M4.0 - 1430 - 005

Printed in U.S.A.

M4.0 - 1430 - 005

MAINTENANCE CONTROL CABLES CONTROL CABLE TENSION DEVICE The control cables which are routed through the mast pulleys are kept properly seated in these pulleys by means of a tension device located at the base of the first stage mast. To obtain the proper cable tension, adjust the spring so there is 8.5 inches (216 mm) overall extension when measured from the inside of the top hook to the inside of the bottom hook. Fasten cable ties around the end of the cable grip to help prevent cable slippage.

Adjusting spring to this measurement applies approximately 4 pounds of pull on the cable.

TT MAST

CABLE ROUTING Cables are routed through the mast assembly as shown.

TF MAST

TL MAST

CABLE TIE

CABLE GRIP

SPRING 8.5 IN. (216 MM)

1937 930222

3684NH - 37094

Crown 1993 PF-9719

Printed in U.S.A.

M4.0 - 1430 - 080

M4.0 - 1430 - 080

MAINTENANCE TUNE UP RR, RS and RD trucks with type TC traction card (EV100) Panels are factory adjusted for a particular motor and truck and should not require adjustment. On new or mistuned cards, adjust functions to value listed in charts.

When the term “press key” or “depress key” is used, press the appropriate key on the handset keypad for approximately 1 second.

The card is adjusted by connecting the GE Handset (112209) to the “Y” receptacle on the traction SCR control card.

Depress the CONT key on the handset and hold depressed, then turn the trucks keyswitch to the “on” position. All 8’s will be displayed on the handset display to show that all LED segments of the display are operational and signifies that the control card and handset are in the adjustment ready (neutral) mode. Release the CONT key.

CAUTION

Care must be taken when replacing the EV100 control card. Installation of the wrong control card may cause misoperation. Refer to subtitle and parts breakdown for card type and part number.

WARNING

Failure to follow proper set-up instructions could result in misoperation or damage to control system. Settings must be changed by authorized personnel only. Card type selection must be made within the capabilities of the SCR control used and the supporting electromechanical devices. Failure to comply with proper application standards could result in misoperation or damage to the control and/or motors.

3415

ILLUSTRATION 2 Press the number key 2 on the handset keypad to select function 2. The handset will display U 02 as shown for a brief moment to acknowledge which key has been pressed.

HANDSET OPERATION

WARNING

Before connecting or disconnecting the handset, lift the drive wheels clear of floor and place hardwood blocks under truck frame. Turn keyswitch “OFF”, disconnect battery and discharge capacitor 1C of the traction and pump (if applicable) control.

3416

ILLUSTRATION 3

E

CU

1 09

Next the display will switch to the actual setting for function 2.

100 V E

OL

NTR

O RC

SC

3414

ILLUSTRATION 4

1049

ILLUSTRATION 1 930222

4556

Crown 1993 PF-9698-1 Rev. 5/95

Printed in U.S.A.

06 REV. 5/95

M4.2–1430–200

M4.2–1430–200

MAINTENANCE NOTE

The handset is now ready to be disconnected.

If you do not wish to change the setting, depress the ESC key in the lower right corner of the keypad to exit the setting mode.

WARNING

Refer to the Charts on following pages. If the value displayed on the handset is not as shown in the chart, press the CONT key. This will cause the setting number to change value (number will change to adjustment knob position) and begin to flash. Turn the adjustment knob on the handset to obtain the setting listed. When the proper reading is obtained, press the CONT or STORE key. This saves the reading in the control card memory. Depress the ESC key located at the lower right corner of the key pad to exit this setting. The handset should return to the netural mode displaying all 8's.

If the 8's are not displayed depress the continue key to return to the neutral mode. Make adjustments as necessary to the remaining functions in the same manner as described.

Before connecting or disconnecting the handset, lift the drive wheels clear of floor and place hardwood blocks under truck frame. Turn keyswitch “OFF”, disconnect battery and discharge capacitor 1C of the traction and pump (if applicable) control.

After tune up procedures are complete, turn keyswitch to “off” and disconnect the battery. Unplug handset and connect plug removed to connect handset.

To access function settings greater than 15, depress the CONT key simultaneously with a number key, starting with 1 for function 16, 2 for function 17, etc.

When all settings are completed, exit the setting mode by pressing the ESC key twice. The display will show a -01 or the battery state of charge (075 for example, illustration 5).

This indicates that the adjustments were stored.

3409

3413

ILLUSTRATION 5

Crown 1993 PF-9698-2 Rev. 5/95

Printed in U.S.A.

06 REV. 5/95

M4.2–1430–201

M4.2–1430–201

MAINTENANCE FUNCTION ADJUSTMENTS FOR TRUCK APPLICATION The following function settings may be modified if necessary, to optimize truck performance to the application. Whenever modifing the function settings, the following procedures must be used.

Battery Discharge Interrupt FUNCTION 14 This adjustment allows the battery discharge interrupt to accurately compensate for the actual battery being used.

The preset value represents a typical battery for a particular compartment size and is satisfactory in most cases. However, if the indicator is showing 100% discharge, or the interrupt is locking out the lift fumction, at too high (greater than 1175) or too low (less than 1140) specific gravity, the compensation adjustment value is not suited to the actual battery being used.

If several different batteries are used in the truck and the range in capacity is greater than 200 AH, The largest battery should be used for the adjustment procedure. Normally the value for function 14 will be set between 19 and 28 for 24 volt batteries and between 12 and 19 for 36 volt batteries.

5. If the number of bars lit increased (% charge on handset increased more than 6%) after connecting the battery, the BDI is overcompensating and the truck will lock out at too high a specific gravity. The value of function 14 (IR compensation) should be lowered by 1 set point. e.g. change from 15 to 14.

6. If the number of bars lit decreased (% charge on handset decreased more than 6%), the BDI is undercompensating and will lock out at too low a specific gravity. The value of function 14 (IR compensation) should be raised by 1 set point. e.g. change from 14 to 15.

7. Repeat procedure to verify accuracy of new settings. If function 14 has been adjusted per this procedure and lock out still occurs at too high a specific gravity, the value may need to be lowered further until lockout occurs at the desired specific gravity. When this occurs, it is possible that the duty cycle discharge rate is too high for the battery size (AH capacity) being used.

It is also likely that this adjustment will cause lockout to occur at discharge levels beyond 80%.

Plug Braking FUNCTIONS 5 and 16

The truck should be operated under normal working conditions to obtain an accurate indication. While performing these steps, either observe the handset connected to the "Y" plug of the SCR traction control and reading the % charge or observe the bars in the BDI display of the overhead guard console. Start with a fully charged and equalized battery of the size and condition that will normally be used in the truck.

1. Cycle the battery by disconnecting and then reconnecting the emergency disconnect.

2. Proceed with normal duty cycle operation until the BDI shows that the battery has discharged to the point that between 2 to 5 bars are lit (22 to 61% charge if using handset).

3. This step should be completed within 5 to 10 minutes after the completion of the duty cycle. Note the number of bars lit (% charge on handset). Cycle the battery using the battery disconnect, leaving the battery disconnected for at least 30 seconds.

The braking effort by the plug braking function is dependent on plugging current limit (C/L), function 5 and pedal plug, function 16. For plug braking to function correctly, the function 16 setting must be 30 greater than function 5. e.g.

Function 5 setting is 83, function 16 setting must be 83 + 30 for a setting of 113. In certain applications it may be desirable to either increase or decrease the braking effort from plug braking.

1. Use the handset and determine the present values of functions 5 and 16. Should match settings in charts for truck model and voltage.

2. To increase the braking effect (decrease stopping distance), add 3 to both function 5 and function 16 to maintain 30 as the difference between the functions.

To decrease the braking effect (increase stopping distance), subtract 3 from both functions.

3. Operate truck and use plug braking to determine if performance is adequate. If not, adjust as necessary.

4. Connect the battery and note the number of bars lit (% charge on handset).

NOTE Operating the truck in the forks first direction, with a capacity load and too severe of a plug braking setting may result in drive tire slide. It is recommended that a setting be selected that results in no tire slide.

Crown 1993 PF-9698-3 Rev. 5/95

Printed in U.S.A.

06 REV. 5/95

M4.2–1430–202

M4.2–1430–202

MAINTENANCE CHARTS Charts 1 through 5 list the settings for the tune up functions.

FUNCTION CODE 2 3 4 5 6 7 8 11 12 13 14 15 16 17

DESCRIPTION

TRUCKS

Creep Speed * Controlled Acceleration Current Limit ** Plug Current Limit 1A Drop out Current Level Field Weakening Pick Up Field Weakening Drop Out Speed 1 (No 1A > Free Lift) Speed 2 (Forks First Limit) Speed 3 (Power Unit First Limit) Internal Resistance Compensation Battery Voltage Pedal Position Plug Card Type

RS3010-40 181 7 255 88 255 0 0 15 15 0 Chart 5 24 118 22

RR3010-35 188 7 255 95 255 0 0 15 22 0 Chart 5 24 125 22

RR3010-40 188 7 255 95 255 0 0 15 34 0 Chart 5 24 125 22

For Trucks equipped with 24 Volt Traction Motor CHART 1 * This feature can be adjusted upwards to soften acceleration. Crown does not recommend adjusting lower than 7. ** This feature can be adjusted to a lower number to increase the plugging distance. Adjusting the number higher can cause damage to the drive motor.

FUNCTION DESCRIPTION CODE

2 3 4 5 6 7 8 11 12 13 14 15 16 17

Creep Speed * Controlled Acceleration Current Limit ** Plug Current Limit 1A Drop out Current Level Field Weakening Pick Up Field Weakening Drop Out Speed 1 (No 1A > Free Lift) Speed 2 (Forks First Limit) Speed 3 (Power Unit First Limit) Internal Resistance Compensation Battery Voltage Pedal Position Plug Card Type

TRUCKS RS3020-40 RR3020-35 RR3020-35 RD3020-30 RR3020-45 TL TT “A” TT “B &C” 146 136 135 164 162 7 7 7 7 7 255 255 255 255 255 73 68 77 84 83 255 255 255 255 255 0 0 0 0 0 0 0 0 0 0 15 15 15 15 15 38 81 63 0 29 0 15 0 0 0 Chart 5 Chart 5 Chart 5 Chart 5 Chart 5 36 36 36 36 36 103 98 107 114 113 22 22 22 22 22

For Trucks equipped with Standard Duty 36 Volt Traction Motor CHART 2 * This feature can be adjusted upwards to soften acceleration. Crown does not recommend adjusting lower than 7. ** This feature can be adjusted to a lower number to increase the plugging distance. Adjusting the number higher can cause damage to the drive motor.

Crown 1993 PF-9698-4 Rev. 5/95

Printed in U.S.A.

06 REV. 5/95

M4.2–1430–203

M4.2–1430–203

MAINTENANCE FUNCTION CODE

2 3 4 5 6 7 8 11 12 13 14 15 16 17

DESCRIPTION

TRUCKS

RD3040-30 89"-119" Collapsed Hgt. Creep Speed 156 * Controlled Acceleration 7 Current Limit 255 ** Plug Current Limit 79 1A Drop out Current Level 255 Field Weakening Pick Up 0 Field Weakening Drop Out 0 Speed 1 (No 1A > Free Lift) 15 Speed 2 (Forks First Limit) 0 Speed 3 (Power Unit First Limit) 0 Internal Resistance CompensationChart 5 Battery Voltage 36 Pedal Position Plug 109 Card Type 22

RD3040-30 131"-172" Collapsed Hgt. 176 7 255 93 255 0 0 15 0 151 Chart 5 36 123 22

RR3040-45 89"-119" Collapsed Hgt. 157 7 255 79 255 0 0 15 22 0 Chart 5 36 109 22

RR3040-45 131"-172" Collapsed Hgt. 175 7 255 92 255 0 0 15 29 152 Chart 5 36 122 22

For Trucks equipped with Heavy Duty 36 Volt Traction Motor CHART 3 * This feature can be adjusted upwards to soften acceleration. Crown does not recommend adjusting lower than 7. ** This feature can be adjusted to a lower number to increase the plugging distance. Adjusting the number higher can cause damage to the drive motor.

FUNCTION CODE

2 3 4 5 6 7 8 11 12 13 14 15 16 17

DESCRIPTION

TRUCKS

RD3040-30 89"-119" Collapsed Hgt. Creep Speed 156 * Controlled Acceleration 7 Current Limit 255 ** Plug Current Limit 79 1A Drop out Current Level 255 Field Weakening Pick Up 51 Field Weakening Drop Out 58 Speed 1 (No 1A > Free Lift) 15 Speed 2 (Forks First Limit) 0 Speed 3 (Power Unit First Limit) 0 Internal Resistance CompensationChart 5 Battery Voltage 36 Pedal Position Plug 109 Card Type 22

RD3040-30 131"-172" Collapsed Hgt. 176 7 255 93 255 59 66 15 0 151 Chart 5 36 123 22

RR3040-45 89"-119" Collapsed Hgt. 157 7 255 79 255 51 58 15 22 0 Chart 5 36 109 22

RR3040-45 131"-172" Collapsed Hgt. 175 7 255 92 255 59 66 15 28 152 Chart 5 36 122 22

For Trucks equipped with Heavy Duty 36 Volt Traction Motor and High Speed Option CHART 4 * This feature can be adjusted upwards to soften acceleration. Crown does not recommend adjusting lower than 7. ** This feature can be adjusted to a lower number to increase the plugging distance. Adjusting the number higher can cause damage to the drive motor.

Crown 1993 PF-9698-5 Rev. 5/95

Printed in U.S.A.

06 REV. 5/95

M4.2–1430–204

M4.2–1430–204

MAINTENANCE Compartment Size A B C A B C D E

Function 14 Setting 19 23 28 10 12 15 17 19

Voltage 24 24 24 36 36 36 36 36

Internal Resistance Compensation (Function 14) Setting CHART 5

Refer to the following chart to identify what is available for each specific model.

Direction Of Travel:

Power Unit First

Maximum Speed Limited By:

FW

RR3000 & RD3000 With 45 in. (1145mm) Power Unit

RR Hi Speed

*X

RD Hi Speed

*X

RR3000, RD3000 & RS3000 With 39 in. (990mm) Compartment

1A

SL

Forks First FW

1A

SL X

X

RD Standard

X

RR Standard

X

X X

RR3020-35 TL & TF

X

X

RR3020-35 TT Power Unit With “A” Battery

X

X

RD3020-30

X

All Other

X

FW = FIELD WEAKENING CONTACTOR

X X SL = SPEED LIMITED

* Trucks Equipped With The High Speed Option, The Field Weakening Contactor Will Pull In Shortly After The 1A Contactor.

NOTE: On all units when the mast is raised above the staging point, travel speeds will be limited due to SCR card settings.

On all units with lift heights greater than 270 in. (6860mm) travel speeds will be limited to 1 MPH (1KPH).

CHART 6

Crown 1993 PF-9698-6 Rev. 5/95

Printed in U.S.A.

06 REV. 5/95

M4.2–1430–205

M4.2–1430–205

MAINTENANCE TUNE UP RR, RS and RD trucks with type TC traction card (EV100) Panels are factory adjusted for a particular motor and truck and should not require adjustment. On new or mistuned cards, adjust functions to value listed in charts.

When the term “press key” or “depress key” is used, press the appropriate key on the handset keypad for approximately 1 second.

The card is adjusted by connecting the GE Handset (112209) to the “Y” receptacle on the traction SCR control card.

Depress the CONT key on the handset and hold depressed, then turn the trucks keyswitch to the “on” position. All 8’s will be displayed on the handset display to show that all LED segments of the display are operational and signifies that the control card and handset are in the adjustment ready (neutral) mode. Release the CONT key.

CAUTION

Care must be taken when replacing the EV100 control card. Installation of the wrong control card may cause misoperation. Refer to subtitle and parts breakdown for card type and part number.

WARNING

Failure to follow proper set-up instructions could result in misoperation or damage to control system. Settings must be changed by authorized personnel only. Card type selection must be made within the capabilities of the SCR control used and the supporting electromechanical devices. Failure to comply with proper application standards could result in misoperation or damage to the control and/or motors.

3415

ILLUSTRATION 2 Press the number key 2 on the handset keypad to select function 2. The handset will display U 02 as shown for a brief moment to acknowledge which key has been pressed.

HANDSET OPERATION WARNING

Before connecting or disconnecting the handset, lift the drive wheels clear of floor and place hardwood blocks under truck frame. Turn keyswitch “OFF”, disconnect battery and discharge capacitor 1C of the traction and pump (if applicable) control.

3416

09

1C

U

E

ILLUSTRATION 3 Next the display will switch to the actual setting for function 2.

OL

NTR

O RC

SC

3414

ILLUSTRATION 4

1049

ILLUSTRATION 1 950619

5106

Crown 1995 PF-10667-1 Rev. 8/96

Printed in U.S.A.

01 REV. 8/96

M4.2–1435–200

M4.2–1435–200

MAINTENANCE NOTE If you do not wish to change the setting, depress the ESC key in the lower right corner of the keypad to exit the setting mode.

Refer to the Charts on following pages. If the value displayed on the handset is not as shown in the chart, press the CONT key. This will cause the setting number to change value (number will change to adjustment knob position) and begin to flash. Turn the adjustment knob on the handset to obtain the setting listed. When the proper reading is obtained, press the CONT or STORE key. This saves the reading in the control card memory. Depress the ESC key located at the lower right corner of the key pad to exit this setting. The handset should return to the netural mode displaying all 8's.

If the 8's are not displayed depress the continue key to return to the neutral mode. Make adjustments as necessary to the remaining functions in the same manner as described.

The handset is now ready to be disconnected.

WARNING

Before connecting or disconnecting the handset, lift the drive wheels clear of floor and place hardwood blocks under truck frame. Turn keyswitch “OFF”, disconnect battery and discharge capacitor 1C of the traction and pump (if applicable) control.

After tune up procedures are complete, turn keyswitch to “off” and disconnect the battery. Unplug handset and connect plug removed to connect handset.

To access function settings greater than 15, depress the CONT key simultaneously with a number key, starting with 1 for function 16, 2 for function 17, etc.

When all settings are completed, exit the setting mode by pressing the ESC key twice. The display will show a -01 or the battery state of charge (075 for example, illustration 5).

This indicates that the adjustments were stored.

3409

3413

ILLUSTRATION 5

Crown 1995 PF-10667-2

M4.2–1435–201

Printed in U.S.A.

M4.2–1435–201

MAINTENANCE FUNCTION ADJUSTMENTS FOR TRUCK APPLICATION The following function settings may be modified if necessary, to optimize truck performance to the application. Whenever modifing the function settings, the following procedures must be used.

Battery Discharge Interrupt FUNCTION 14 This adjustment allows the battery discharge interrupt to accurately compensate for the actual battery being used.

The preset value represents a typical battery for a particular compartment size and is satisfactory in most cases. However, if the indicator is showing 100% discharge, or the interrupt is locking out the lift fumction, at too high (greater than 1175) or too low (less than 1140) specific gravity, the compensation adjustment value is not suited to the actual battery being used.

If several different batteries are used in the truck and the range in capacity is greater than 200 AH, The largest battery should be used for the adjustment procedure. Normally the value for function 14 will be set between 19 and 28 for 24 volt batteries and between 12 and 19 for 36 volt batteries.

5. If the number of bars lit increased (% charge on handset increased more than 6%) after connecting the battery, the BDI is overcompensating and the truck will lock out at too high a specific gravity. The value of function 14 (IR compensation) should be lowered by 1 set point. e.g. change from 15 to 14.

6. If the number of bars lit decreased (% charge on handset decreased more than 6%), the BDI is undercompensating and will lock out at too low a specific gravity. The value of function 14 (IR compensation) should be raised by 1 set point. e.g. change from 14 to 15.

7. Repeat procedure to verify accuracy of new settings. If function 14 has been adjusted per this procedure and lock out still occurs at too high a specific gravity, the value may need to be lowered further until lockout occurs at the desired specific gravity. When this occurs, it is possible that the duty cycle discharge rate is too high for the battery size (AH capacity) being used.

It is also likely that this adjustment will cause lockout to occur at discharge levels beyond 80%.

Plug Braking FUNCTIONS 5 and 16

The truck should be operated under normal working conditions to obtain an accurate indication. While performing these steps, either observe the handset connected to the "Y" plug of the SCR traction control and reading the % charge or observe the bars in the BDI display of the overhead guard console. Start with a fully charged and equalized battery of the size and condition that will normally be used in the truck.

1. Cycle the battery by disconnecting and then reconnecting the emergency disconnect.

2. Proceed with normal duty cycle operation until the BDI shows that the battery has discharged to the point that between 2 to 5 bars are lit (22 to 61% charge if using handset).

3. This step should be completed within 5 to 10 minutes after the completion of the duty cycle. Note the number of bars lit (% charge on handset). Cycle the battery using the battery disconnect, leaving the battery disconnected for at least 30 seconds.

4. Connect the battery and note the number of bars lit (% charge on handset).

The braking effort by the plug braking function is dependent on plugging current limit (C/L), function 5 and pedal plug, function 16. For plug braking to function correctly, the function 16 setting must be 30 greater than function 5. e.g.

Function 5 setting is 83, function 16 setting must be 83 + 30 for a setting of 113. In certain applications it may be desirable to either increase or decrease the braking effort from plug braking.

1. Use the handset and determine the present values of functions 5 and 16. Should match settings in charts for truck model and voltage.

2. To increase the braking effect (decrease stopping distance), add 3 to both function 5 and function 16 to maintain 30 as the difference between the functions.

To decrease the braking effect (increase stopping distance), subtract 3 from both functions.

3. Operate truck and use plug braking to determine if performance is adequate. If not, adjust as necessary.

NOTE Operating the truck in the forks first direction, with a capacity load and too severe of a plug braking setting may result in drive tire slide. It is recommended that a setting be selected that results in no tire slide.

Crown 1995 PF-10667-3

M4.2–1435–202

Printed in U.S.A.

M4.2–1435–202

MAINTENANCE CHARTS Charts 1 through 5 list the settings for the tune up functions.

FUNCTION CODE 2 3 4 5 6 7 8 11 12 13 14 15 16 17

DESCRIPTION

TRUCKS

Creep Speed * Controlled Acceleration Current Limit ** Plug Current Limit 1A Drop out Current Level Field Weakening Pick Up Field Weakening Drop Out Speed 1 (No 1A > Free Lift) Speed 2 (Forks First Limit) Speed 3 (Power Unit First Limit) Internal Resistance Compensation Battery Voltage Pedal Position Plug Card Type

RS3510-40 181 7 255 88 255 0 0 15 15 0 Chart 5 24 118 22

RR3510-35 188 7 255 95 255 0 0 15 22 0 Chart 5 24 125 22

RR3510-40 188 7 255 95 255 0 0 15 34 0 Chart 5 24 125 22

For Trucks equipped with 24 Volt Traction Motor CHART 1 * This feature can be adjusted upwards to soften acceleration. Crown does not recommend adjusting lower than 7. ** This feature can be adjusted to a lower number to increase the plugging distance. Adjusting the number higher can cause damage to the drive motor.

FUNCTION DESCRIPTION CODE

2 3 4 5 6 7 8 11 12 13 14 15 16 17

Creep Speed * Controlled Acceleration Current Limit ** Plug Current Limit 1A Drop out Current Level Field Weakening Pick Up Field Weakening Drop Out Speed 1 (No 1A > Free Lift) Speed 2 (Forks First Limit) Speed 3 (Power Unit First Limit) Internal Resistance Compensation Battery Voltage Pedal Position Plug Card Type

TRUCKS RS3520-40 RR3520-35 RR3520-35 RD3520-30 RR3520-45 TL TT “A” TT “B &C” 146 136 135 164 162 7 7 7 7 7 255 255 255 255 255 73 68 77 84 83 255 255 255 255 255 0 0 0 0 0 0 0 0 0 0 15 15 15 15 15 38 81 63 0 29 0 15 0 0 0 Chart 5 Chart 5 Chart 5 Chart 5 Chart 5 36 36 36 36 36 103 98 107 114 113 22 22 22 22 22

For Trucks equipped with Standard Duty 36 Volt Traction Motor CHART 2 * This feature can be adjusted upwards to soften acceleration. Crown does not recommend adjusting lower than 7. ** This feature can be adjusted to a lower number to increase the plugging distance. Adjusting the number higher can cause damage to the drive motor.

Crown 1995 PF-10667-4

M4.2–1435–203

Printed in U.S.A.

M4.2–1435–203

MAINTENANCE FUNCTION CODE

2 3 4 5 6 7 8 11 12 13 14 15 16 17

DESCRIPTION

TRUCKS

RD3540-30 89"-119" Collapsed Hgt. Creep Speed 156 * Controlled Acceleration 7 Current Limit 255 ** Plug Current Limit 79 1A Drop out Current Level 255 Field Weakening Pick Up 0 Field Weakening Drop Out 0 Speed 1 (No 1A > Free Lift) 15 Speed 2 (Forks First Limit) 0 Speed 3 (Above 270" Both Directions) 0 Internal Resistance Compensation Chart 5 Battery Voltage 36 Pedal Position Plug 109 Card Type 22

RD3540-30 131"-172" Collapsed Hgt. 176 7 255 93 255 0 0 15 0 151 Chart 5 36 123 22

RR3540-45 89"-119" Collapsed Hgt. 157 7 255 79 255 0 0 15 22 0 Chart 5 36 109 22

RR3540-45 131"-172" Collapsed Hgt. 175 7 255 92 255 0 0 15 29 152 Chart 5 36 122 22

For Trucks equipped with Heavy Duty 36 Volt Traction Motor CHART 3 * This feature can be adjusted upwards to soften acceleration. Crown does not recommend adjusting lower than 7. ** This feature can be adjusted to a lower number to increase the plugging distance. Adjusting the number higher can cause damage to the drive motor.

FUNCTION CODE

2 3 4 5 6 7 8 11 12 13 14 15 16 17

DESCRIPTION

TRUCKS

RR3540-45 89"-119" Collapsed Hgt. Creep Speed 157 * Controlled Acceleration 7 Current Limit 255 ** Plug Current Limit 79 1A Drop out Current Level 255 Field Weakening Pick Up 51 Field Weakening Drop Out 58 Speed 1 (No 1A > Free Lift) 15 Speed 2 (Forks First Limit) 22 Speed 3 (Above 270" Both Directions) 0 Internal Resistance Compensation Chart 5 Battery Voltage 36 Pedal Position Plug 109 Card Type 22

RR3540-45 131"-172" Collapsed Hgt. 175 7 255 92 255 59 66 15 29 152 Chart 5 36 122 22

RR3520-45 “C” Batt. Comp.

Collapsed Hgt. 89"-119" 162 7 255 83 255 40 50 15 29 0 Chart 5 36 113 22

For Trucks equipped with Heavy Duty 36 Volt Traction Motor and High Speed Option CHART 4 * This feature can be adjusted upwards to soften acceleration. Crown does not recommend adjusting lower than 7. ** This feature can be adjusted to a lower number to increase the plugging distance. Adjusting the number higher can cause damage to the drive motor.

Crown 1995 PF-10667-5 Rev. 8/96

Printed in U.S.A.

01 REV. 8/96

M4.2–1435–204

M4.2–1435–204

MAINTENANCE FUNCTION CODE

2 3 4 5 6 7 8 11 12 13 14 15 16 17

DESCRIPTION

TRUCKS

RD3540-30 89"-119" Collapsed Hgt. Creep Speed 156 * Controlled Acceleration 7 Current Limit 255 ** Plug Current Limit 79 1A Drop out Current Level 255 Field Weakening Pick Up 51 Field Weakening Drop Out 58 Speed 1 (No 1A > Free Lift) 15 Speed 2 (Forks First Limit) 0 Speed 3 (Power Unit First Limit) 0 Internal Resistance Compensation Chart 5 Battery Voltage 36 Pedal Position Plug 109 Card Type 22

RD3540-30 131"-172" Collapsed Hgt. 176 7 255 93 255 59 66 15 0 151 Chart 5 36 123 22

RD3520-30 “B & C” Batt. Comp.

Collapsed Hgt. 89"-119" 164 7 255 84 255 42 52 15 0 0 Chart 5 36 114 22

For Trucks equipped with Heavy Duty 36 Volt Traction Motor and High Speed Option CHART 4 (Continued) * This feature can be adjusted upwards to soften acceleration. Crown does not recommend adjusting lower than 7. ** This feature can be adjusted to a lower number to increase the plugging distance. Adjusting the number higher can cause damage to the drive motor.

Compartment Size A B C A B C D E

Voltage 24 24 24 36 36 36 36 36

Function 14 Setting 19 23 28 10 12 15 17 19

Internal Resistance Compensation (Function 14) Setting CHART 5

Crown 1995 PF-10667-6

M4.2–1435–205

Printed in U.S.A.

M4.2–1435–205

MAINTENANCE Refer to the following chart to identify what is available for each specific model.

Direction Of Travel:

Power Unit First

Maximum Speed Limited By:

FW

RR3500 & RD3500 With 45 in. (1145mm) Power Unit

RR Hi Speed

*X

RD Hi Speed

*X

RR3500, RD3500 & RS3500 With 39 in. (990mm) Power Unit

1A

SL

Forks First FW

1A

SL X

X

RD Standard

X

RR Standard

X

X X

RR3520-35 TL & TF

X

X

RR3520-35 TT Power Unit With “A” Battery Comp.

X

X

RR3520-45 “C”

X

RD3520-30 “B & C”

X

All Other

X X

FW = FIELD WEAKENING CONTACTOR

X SL = SPEED LIMITED

* Trucks Equipped With The High Speed Option, The Field Weakening Contactor Will Pull In Shortly After The 1A Contactor.

NOTE: On all units when the mast is raised above the staging point, travel speeds will be limited due to SCR card settings.

On all units with lift heights greater than 270 in. (6860mm) travel speeds will be limited to 1 MPH (1KPH).

CHART 6

Crown 1995 PF-10667-7

M4.2–1435–206

Printed in U.S.A.

M4.2–1435–206

MAINTENANCE SEQUENCE CONTROL

POWER UNIT WALL

DC

-D

C

Co

nv

er

te

r

JC601 JC602

JC603 1864

SEQUENCE CONTROL PRINTED CIRCUIT BOARD

The sequence control printed circuit board is mounted in the box located in the contactor panel compartment directly above the contactor panel. Also located in the box is a DC to DC converter which supplies the 12 and 5 volt power for the sequence control electronics.

COMPONENT REPLACEMENT After the sequence control printed circuit board is accessed, disengage the connectors and remove four (4) screws securing circuit board to the box lid.

ACCESSING Remove the cover over the contactor panel compartment.

The sequence control box is located directly above the contactor panel. Remove screw at top edge of box and pivot lid down. The sequence control printed circuit board is mounted on the lid. In the back of the box is the DC to DC converter.

930222

4573 - 37094

Crown 1993 PF-9683-1 Rev. 2/95

Printed in U.S.A.

01 REV. 2/95

M4.3–1430–001

M4.3–1430–001

MAINTENANCE STATIC ELECTRICITY PRECAUTIONS Certain electronic components within the sequence control and the overhead guard display are susceptible to static electricity charges. Boards within the assemblies as well as the connector pins should not be touched or handled without using static grounding devices.

Crown has available a Static Field Service Kit (101491). The kit includes a work mat, 15 foot (4.5 m) ground cord, large and small wrist straps with coiled ground cord.

When working with these components, place the work mat on a convenient, flat surface. Attach one end of the ground cord to the work mat and the other end to a reliable ground on the truck frame. Slip on a wrist band that is comfortable, but contacts the entire circumference of the wrist. Connect one end of the coiled ground cord to the wrist band and the other end to a reliable ground on the truck frame.

0703P

0704S

It is now safe to touch and handle static sensitive components. When a board is removed it should be placed immediately into a static shielding bag or onto the work mat. If a static shielding bag is not available, the board can be wrapped up in the work mat and transported safely.

If static grounding devices are not used, components within the controls may be damaged or degraded.

Crown 1993 PF-9683-2

M4.3 - 1430 - 002

Printed in U.S.A.

M4.3 - 1430 - 002

MAINTENANCE TROUBLESHOOTING

FLOWCHARTS

A malfunction with the sequence control will be noticeable by either the function indicator lights or truck hydraulic functions not operating or both.

Troubleshooting flowcharts, based on the failure symptom are provided. Whenever any malfunction with the display is encountered, first perform the checks in the first flowchart, Initial Power Input and Battery Negative Checks, to eliminate lack of supply voltage as the malfunction. When power and battery negative have been confirmed, refer to the flowchart that matches the symptom being experienced.

Connectors interconnecting the sequence control to the truck electrical system have screws at the top which provide an excellent location to make voltage checks. By placing the meter probe on the screw, an electrical connection is made between the meter and connector terminal.

SCREW LOCATIONS

12

METER PROBE

34

56

78

1. Initial power input and battery negative checks.

2. Low speed lift does not operate.

3. High speed lift does not operate.

4. Lower does not operate.

5. Second Function will not operate.

6. Third function will not operate.

7. Fourth function will not operate.

8. Control will not sequence.

9. Function operates, indicator light does not illuminate.

WIRE LOCATIONS

1865

Equipment Required: Digital meter and common hand tools.

Crown 1993 PF-9683-3

M4.3 - 1430 - 003

Printed in U.S.A.

M4.3 - 1430 - 003

MAINTENANCE 1866

1. Initial Power Input and Battery Negative Checks.

Does display go through the TEST sequence.

Yes

Check 12 volt battery input.

CA601-7 negative, CA601-10 positive. Should be 12 volts when battery is connected, regardless of KYS position.

No

Do lift and auxiliary function indicators illuminate when KYS is in "test" position?

No voltage.

Check 12 volt output of DC to DC converter at CA604-8.

Yes.

12 volts.

12 volts.

Check 5 volt battery input. CA601-7 negative, CA601-8 positive. Should be 5 volts when battery is connected, regardless of KYS position.

5 volts.

0 volts.

Check for battery voltage from CA801-2 to ground while KYS is in "test" position.

Repair wiring between CA604-8 and CA601-10.

Check for battery voltage to DC-DC converter at CA604-4 and battery negative at CA604-5.

No voltage.

Voltage.

Check condition of FU8.

Check for battery negative at CA602-6. Solenoids use this negative connection.

Check KYS wiring and FU5.

Repair and replace as necessary.

0 volts.

Yes

K3 operates.

Check sequence control voltages.

Check wiring between CA203-11 and overhead display and repair.

Fuse blown.

Fuse okay.

Does relay K2 operate when keyswitch is in "on" position?

No

No

Replace.

Check for +5 volts (CA801-8), +12 volts (CA801-9) and negative (CA801-10) at overhead display.

Check for battery voltage from TP3 to TP8 while KYS is in "test" position.

Voltages present.

Check K3 operation. If K1 energizes, K3 is operational.

K3 does not operate.

A

No voltage.

Replace overhead display.

Battery volts.

Check overhead guard display voltages.

No voltage.

Check DC-DC converter and wiring to overhead gaurd display. Repair and replace as necessary.

Replace K3.

B Continued on next page

Crown 1993 PF-9683-4

M4.3 - 1430 - 004

Printed in U.S.A.

M4.3 - 1430 - 004

MAINTENANCE 1867

Continued from previous page A

Check for battery volts between CA601-9 of the sequence control and battery negative at CA602-6 with KYS in "test" position.

0 volts.

B

Check for battery volts at the overhead guard display between CA801-2 and battery negative CA801-14 with KYS in "test" position.

Battery volts.

Check condition of wiring between sequence control CA601-9 and distribution board CA203-12. Repair as necessary.

Battery volts.

0 volts.

Check wiring from distribution board CA203-11 to overhead guard. Repair as necessary.

Check for +5 volts (CA801-8), +12 volts (CA801-9) and negative (CA801-10) at overhead display.

No voltage.

Voltages present.

Check for +5 volts (CA601-8), +12 volts (CA601-10) and negative (CA601-7) at sequence control printed circuit board.

Replace overhead display.

Voltages present.

Replace sequence control printed circuit board.

Crown 1993 PF-9683-5

M4.3 - 1430 - 005

Voltages absent.

Check DC-DC converter and wiring to overhead gaurd display. Repair and replace as necessary.

Check condition of wiring between the distribution board and sequence control printed circuit board. Repair as necessary.

Printed in U.S.A.

M4.3 - 1430 - 005

MAINTENANCE 1868-01

2. Low Speed Lift Does Not Operate.

Make initial checks for supply voltages and battery negative.

Is input present at CA601-2? Should be 0 volts when requesting lift.

No

Check condition and connections of wiring between CA601-2 and battery negative.

Yes

Check output at CA603-1. Should be 0 volts when contactor is energized.

Condition requires attention.

Repair.

Condition okay.

Battery volts.

0 volts.

Check condition of MFS1.

Faulty. Repair.

Is truck in lift lockout? Check voltage at CA601-6. Should be 10 volts.

Check condition and connections of wiring between KYS and CA603-2.

Condition requires attention.

Repair.

Condition okay.

Check battery condition and charge.

Check condition of P1 contactor coil and suppressor.

10 volts.

0 volts.

Replace sequence control circuit board.

Battery discharged.

Battery condition okay.

Faulty. Repair.

Charge or replace battery.

Crown 1993 PF-9683-6 Rev. 2/95

Check wiring from CA401-2 to CA601-6.

Repair as necessary.

Printed in U.S.A.

01 REV. 2/95

M4.3–1430–006

M4.3–1430–006

MAINTENANCE 1869

3. High Speed Lift Does Not Operate.

Make initial checks for supply voltages and battery negative.

No

Does low speed lift operate?

Use the Low Speed Lift Does Not Operate flow chart to check condition of the low speed lift circuit.

Voltage changes.

Yes

With operator floor plate depressed, check voltage at TP9 on the distribution printed circuit board.

Should be battery volts dropping to zero volts when high speed raise is requested.

Voltage does not change.

Check condition of P2 contactor coil and suppressor.

No voltage.

Check wiring between P2 contactor and sequence control printed circuit board.

Condition requires attention.

Repair.

Condition okay.

Wiring faulty. Repair.

Wiring okay.

Check connections and condition of pump motor 2.

With operator floor plate depressed, check voltage at TP11 on the distribution printed circuit board.

Should be battery volts dropping to zero volts when high speed raise is requested.

Replace sequence control circuit board.

Repair as necessary.

Voltage as described.

No voltage.

Check for battery volts on supply side of raise switch (RAS).

Battery volts.

0 volts.

Check condition, adjustment and wiring of HGTS3.

Check condition and connections of wiring between RAS and KYS. Condition requires attention.

Repair.

Check condition, adjustment and wiring of raise switch (RAS).

Condition requires attention.

Repair.

Crown 1993 PF-9683-7

M4.3 - 1430 - 007

Printed in U.S.A.

M4.3 - 1430 - 007

MAINTENANCE 1870

4. Lower Does Not Operate.

Make initial checks for supply voltages and battery negative.

Is battery negative present at CA601-3 when MFS2 is closed?

No

Check condition and connections of wiring for MFS2 circuit between CA601-3 and battery negative.

Yes

Condition requires attention.

Repair.

Monitor voltage at CA602-4. Should be battery volts dropping to zero volts when lower is requested.

Condition okay.

Voltage as described.

Check condition and adjustment of MFS2.

Condition requires attention or adjustment. Repair or adjust as necessary.

Voltage does not change.

Replace sequence control circuit board.

Check condition of lower solenoid (SVD).

Condition okay.

Does not operate. Replace.

Problem does not appear to be electrical in nature. Troubleshoot the hydraulic system.

Crown 1993 PF-9683-8

M4.3 - 1430 - 008

Printed in U.S.A.

M4.3 - 1430 - 008

MAINTENANCE 1871

5. Second Function Will Not Operate.

Make initial checks for supply voltages and battery negative.

Is input present at CA601-2? Should be 0 volts when requesting second function operation.

No

Check condition and connections of wiring between CA601-2 and battery negative.

Condition requires attention.

Repair.

Condition okay.

Yes

Check output at CA602-1, CA602-3 and CA602-5. Should be 0 volts when corresponding solenoids (SVA, SVC1, SVC2 and SVE) are energized.

Battery volts.

Check condition and associated wiring of MFS1.

0 volts.

Faulty. Repair.

Check condition and connections of wiring between KYS and CA602-1, CA602-3 and CA602-5.

Condition okay.

Replace sequence control circuit board.

Condition requires attention.

Repair.

Check condition of solenoids (SVA, SVC1, SVC2, SVE) and suppressors.

Faulty. Repair.

Crown 1993 PF-9683-9

M4.3 - 1430 - 009

Printed in U.S.A.

M4.3 - 1430 - 009

MAINTENANCE 1872

6. Third Function Will Not Operate.

Make initial checks for supply voltages and battery negative.

Is input present at CA601-2? Should be 0 volts when requesting third function operation.

No

Check condition and connections of wiring between CA601-2 and battery negative.

Yes

Check output at CA602-1 and CA602-5. Should be 0 volts when corresponding solenoids (SVA, and SVE) are energized.

Condition requires attention.

Repair.

Condition okay.

Battery volts.

Check condition and associated wiring of MFS1.

0 volts.

Faulty. Repair.

Check condition and connections of wiring between KYS and CA602-1 and CA602-5.

Condition okay.

Replace sequence control circuit board.

Condition requires attention.

Repair.

Check condition of solenoids (SVA, SVE) and suppressors.

Faulty. Repair.

Crown 1993 PF-9683-10

M4.3 - 1430 - 010

Printed in U.S.A.

M4.3 - 1430 - 010

MAINTENANCE 1873

7. Fourth Function Will Not Operate.

Make initial checks for supply voltages and battery negative.

Is input present at CA601-2? Should be 0 volts when requesting fourth function operation.

No

Check condition and connections of wiring between CA601-2 and battery negative.

Condition requires attention.

Repair.

Condition okay.

Yes

Check output at CA602-1, CA602-2 and CA602-5. Should be 0 volts when corresponding solenoids (SVA, SVB1, SVB2 and SVE) are energized.

Battery volts.

Check condition and associated wiring of switch MFS1.

0 volts.

Faulty. Repair.

Check condition and connections of wiring between KYS and CA602-1, CA602-2 and CA602-5.

Condition okay.

Replace sequence control circuit board.

Condition requires attention.

Repair.

Check condition of solenoids (SVA, SVB1, SVB2, SVE) and suppressors.

Faulty. Repair.

Crown 1993 PF-9683-11

M4.3 - 1430 - 011

Printed in U.S.A.

M4.3 - 1430 - 011

MAINTENANCE 1874

8. Control Will Not Sequence.

Make initial checks for supply voltages and battery negative.

No

Is input present at CA601-1? Should be 0 volts when depressing the sequence switch (SQS).

Check condition and connections of wiring between CA601-1 and battery negative.

Condition okay.

Yes

Replace sequence control circuit board.

Condition requires attention.

Repair.

Check condition of SQS and associated wiring.

Faulty. Repair.

Crown 1993 PF-9683-12

M4.3 - 1430 - 012

Printed in U.S.A.

M4.3 - 1430 - 012

MAINTENANCE 1875

9. Function Operates, Indicator Light Does Not Illuminate.

Make initial checks for supply voltages and battery negative.

Does indicator light on either panel illuminate?

No

If an indicator light illuminates on one console but not the other, the light will likely be burned out. If, after replacement, the light still does not illuminate check the wiring between terminal board TB405 and the suspect light.

Check for 12 volts at indicator light output of sequence control.

CA602-7 - Lift LED CA602-8 - Second Function LED CA602-9 - Third Function LED CA602-10 - Fourth Function LED

Voltage not present.

Replace sequence control circuit board.

Voltage present.

Check for 12 volts at terminal board TB405.

TB405-1 - Lift LED TB405-2 - Second Function LED TB405-3 - Third Function LED TB405-4 - Fourth Function LED

Voltage not present.

Check wiring condition and connections between terminal board TB405 and sequence control printed circuit board connector CA602.

Repair as necessary.

Crown 1993 PF-9683-13

M4.3 - 1430 - 013

Yes

Voltage present.

Check wiring condition and connections between terminal board TB405 and indicator light panels.

Repair as necessary.

Printed in U.S.A.

M4.3 - 1430 - 013

MAINTENANCE SEQUENCE CONTROL CARD PROGRAMMING The sequence control card can be programmed, with switches located on the card, for use on all trucks regardless of the number and type of truck functions. Refer to the chart and illustration to determine switch settings required for truck configuration.

Required Truck Functions 1

2

Lift Lift Lift Lift Lift Lift Lift Lift Lift Lift Lift

Reach Reach Reach None Tilt Tilt SS SS SS FS Tilt

3 Tilt Tilt Tilt None None SS Tilt None FS None FS

Switch Settings 4

SWI-1

SWI-2

SWI-3

None SS FS None None None FS None None None None

Open Open Open Closed Open Open Open Closed Closed Closed Open

Closed Closed Closed Open Open Open Closed Open Closed Open Open

Open Closed Closed Open Open Closed Closed Closed Closed Closed Closed

FS= Fork Spread SS= Sideshift

CLOSE O N

OPEN

1960

1 2 3

SW1-1 = Closed SW1-2 = Open SW1-3 = Open This switch setting illustrates a truck with no auxiliary functions.

ILLUSTRATION 4.3-1

930222

3684NK-37094

Crown 1993 PF-9740

Printed in U.S.A.

M4.3 - 1430 - 050

M4.3 - 1430 - 050

MAINTENANCE OVERHEAD GUARD DISPLAY MESSAGE DISPLAY

SHIFT

TILT

REACH

WRENCH INDICATOR 1893

BATTERY STATE-OF-CHARGE DISPLAY

The overhead guard display: • displays messages to the operator when an improper sequence is used to perform a truck function.

• displays a numeric code, accompanied by wrench light, which relates to service required conditions in the SCR troubleshooting maintenance information.

• stores the last eight service codes which occurred and are accessed by using the DISP switch. This memory can also be erased by using the ERS switch.

• displays the truck, traction motor and main pump motor hours at power down.

• is used to select language the display will deliver messages in.

• indicates battery state-of-charge.

POWER UP

WRENCH INDICATOR

The display is mounted in the overhead guard area of the operator compartment and provides a visual indication of various truck monitors. When the keyswitch is turned from “off” to “on” the display will show the word KEY.

The “wrench” indicator will glow red when a service required condition exists. This indication is always accompanied by a service number on the message display. When the indicators are “flashing”, full truck operation may be possible. This indicator “solid on” may be accompanied by limited truck operation.

1795

HOUR METERS

After the keyswitch is turned to the “test” position all indicators present are turned “on”. The four segment LED matrix display goes through a graphic sequence and ends with the word TEST when the display self test is complete.

During power down, the truck power “on” time with operator in position is displayed for 4 seconds, followed by a 4 second display of the traction motor usage time and a 4 second display of the main pump motor usage time.

BATTERY STATE OF CHARGE DISPLAY

1796

If the keyswitch is held in the “test” position, all LED’s in the matrix will be illuminated. This power up sequence is performed to allow for a visual test of all indicators.

The bar graph is used to display battery state-of-charge.

When all segments are glowing, the battery is fully charged.

As the battery discharges, segments of the display are turned “off”. When the battery is at 20% or less charge, the yellow LED will flash. When 10% or less charge remains, lift lockout will occur. The battery discharge interrupt is a function of the traction SCR control card and uses the display as a visual indicator.

930222

4493

Crown 1993 PF-9697-1 Rev. 12/94

Printed in U.S.A.

02 REV. 12/94

M4.3–1430–100

M4.3–1430–100

MAINTENANCE ADDITIONAL MESSAGES

LANGUAGE SELECTION

When the operator is not standing on the power on pedal and the truck is “powered up”, the display will show the message PWR.

The display is a multilingual device capable of six languages.

Language selection is made through the use of the display and clear switches located under a ledge below the steering tiller. After the hour meters are displayed during truck power down, actuate the display and clear switches simultaneously and release. The message ENGL will be displayed. This is not necessarily the language that is active in the display module. Within four seconds, actuate the display switch to scroll through the available languages in the order listed.

1797

After power up, if the operator is not standing on the brake pedal and selects a direction of travel, the display will show the message BRAK.

1798

LANGUAGE

DISPLAY

English Spanish German Italian Dutch French

ENGL SPAN GERM ITAL DUTC FREN

When the language that is wanted is displayed, actuate the clear switch within four seconds of the last switch actuation.

This action will make the selected language active. If the display goes blank before a selection is made, the language that was active before the inquiry will still be the active language.

MULTILINGUAL MESSAGES MESSAGE

BRAKE NONE CLEAR TEST KEY POWER

ENGLISH

SPANISH

LANGUAGE GERMAN ITALIAN

DUTCH

FRENCH

BRAK NONE CLR? TEST KEY PWR

FRNO NADA CANC PRBA LLAV POT

BREM KEIN LSEN TEST SCHL ANTR

REM GEEN WIS TEST SLEV STRM

FRN RIEN EFFC TEST CLE ALIM

FRNO ZERO CANC TEST KEY ENER

NOTES: 1. LLAV is short for LLAVE. 2. The Italian word for key is CHIAVE. The abbreviation of this word either does not make sense or could give the impression that the translation is incorrect. The word would be best understood if it is left in English.

Crown 1993 PF-9697-2

M4.3 - 1430 - 101

Printed in U.S.A.

M4.3 - 1430 - 101

MAINTENANCE TROUBLESHOOTING A problem with the display module will be noticed visually. It is used as a monitor and has no effect on the operation of the truck.

When the keyswitch is placed in the “test” position, all LED’s are illuminated as a test of the individual LED’s. If any fail to illuminate, they should be replaced.

CONNECTORS The plug portion of connectors CA801 and CA802 require extraction tool part number 118993. Terminals in these connectors are part number 062536-001.

FLOWCHARTS Troubleshooting flowcharts, based on the failure symptom are provided in this section. Whenever any problem with the display is encountered, first perform the checks in the first flowchart, DC - DC Converter Testing, to eliminate the DC - DC Converter as the source of the problem. If the DC- DC Converter checks okay, refer to the flowchart that matches the symptom.

1. DC-DC Converter Testing.

2. No LED’s turn “on” when keyswitch is in “test” or “on” position.

3. LED’s do not turn on with keyswitch in “on” position or hourmeters displayed when switching from “test” to “on”.

4. KEY displayed when keyswitch is in “test” or “on” position.

5. Display remains in test mode.

6. Display remains in “on” mode when truck is powered down.

7. Half or all of one or more message display matrix LED’s do not illuminate when keyswitch is in “test” or “on” position.

8. One or more message display matrix LED segments do not illuminate when keyswitch is in “test” or “on” position.

9. Fault display/clear mode and/or language selection mode does not work.

10. No information displayed on display and battery discharge indicator not functioning.

11. Hour meters do not increment.

12. Fault codes not saved. Hour meters or language version not saved.

13. Display not showing rational information. LED’s illuminating sporadically.

Crown 1993 PF-9697-3 Rev. 12/94

Printed in U.S.A.

02 REV. 12/94

M4.3–1430–102

M4.3–1430–102

MAINTENANCE STATIC ELECTRICITY PRECAUTIONS Certain electronic components within the sequence control and the overhead guard display are susceptible to static electricity charges. Boards within the assemblies as well as the connector pins should not be touched or handled without using static grounding devices.

Crown has available a Static Field Service Kit (101491). The kit includes a work mat, 15 foot (4.5 m) ground cord, large and small wrist straps with coiled ground cord.

When working with these components, place the work mat on a convenient, flat surface. Attach one end of the ground cord to the work mat and the other end to a reliable ground on the truck frame. Slip on a wrist band that is comfortable, but contacts the entire circumference of the wrist. Connect one end of the coiled ground cord to the wrist band and the other end to a reliable ground on the truck frame.

0703P

0704S

It is now safe to touch and handle static sensitive components. When a board is removed it should be placed immediately into a static shielding bag or onto the work mat. If a static shielding bag is not available, the board can be wrapped up in the work mat and transported safely.

If static grounding devices are not used, components within the controls may be damaged or degraded.

Crown 1993 PF-9697-4

M4.3 - 1430 - 103

Printed in U.S.A.

M4.3 - 1430 - 103

MAINTENANCE 1. DC - DC CONVERTER

Disconnect connector CA801 at display board. Check supply voltages on harness portion of connector. +5 volts between CA801-10 negative and CA801-8 positive. +12 volts between CA801-10 negative and CA801-9 positive.

Voltages as described.

Voltages not as described.

Continue troubleshooting using the failure symptom to select flowchart to use.

Check voltages at connector of DC-DC converter CA604.

CA604-3 battery negative.

CA604-1 +5 volts.

CA604-2 +12 volts.

Voltages not as described.

Voltages as described.

Check for battery volts input to the DC-DC converter between CA604-5 negative and CA604-4 positive.

Check condition of wiring and connections between DC-DC converter and overhead guard connector.

Battery volts not present.

Repair as necessary.

Battery volts present.

Check condition of FU8 on the distribution board.

Replace DC-DC converter.

Fuse blown.

Replace.

Crown 1993 PF-9697-5

M4.3 - 1430 - 104

Fuse okay.

Check condition of wiring between distribution board and DC-DC converter.

Repair as necessary.

Printed in U.S.A.

M4.3 - 1430 - 104

MAINTENANCE 1879

2. SYMPTOM: No LED's turn on when key is in "test" or "on" position.

Battery volts present

With keyswitch in "test" position measure voltage between PC801-10 negative and PC801-2 positive. Should measure battery volts.

With keyswitch in "on" position, measure voltage between PC801-10 negative and PC801-3.

Should measure battery volts.

Battery volts present

No voltage

Check wiring and keyswitch condition.

Repair or replace as necessary.

Change display board with known good board.

No voltage

Check wiring and keyswitch condition.

Repair or replace as necessary.

1880

3. SYMPTOM: LED's do not turn on with keyswitch in "on" position or hourmeters displayed when switching from "test" to "on".

Battery volts present

With keyswitch in "test" position measure voltage between PC801-10 negative and PC801-2 positive. Should measure battery volts.

With keyswitch in "on" position, measure voltage between PC801-10 negative and PC801-3.

Should measure battery volts.

No voltage

Battery volts present

No voltage

Check wiring and keyswitch condition.

Repair or replace as necessary.

Substitute display board with known good board.

Check wiring and keyswitch condition.

Repair or replace as necessary.

Crown 1993 PF-9697-6

M4.3 - 1430 - 105

Printed in U.S.A.

M4.3 - 1430 - 105

MAINTENANCE 1881

4. SYMPTOM: KEY displayed when keyswitch is in "test" or "on" position.

Battery volts present

With keyswitch in "on" position, measure voltage between PC801-10 negative and PC801-3.

Should measure battery volts.

No voltage

With keyswitch in "test" position measure voltage between PC801-10 negative and PC801-2 positive. Should measure battery volts.

Battery volts present

No voltage

Check wiring and keyswitch condition.

Repair or replace as necessary.

Substitute display board with known good board.

Check wiring and keyswitch condition.

Repair or replace as necessary.

1882

5. SYMPTOM: Display remains in test mode.

Battery volts present

Substitute distribution board with known good board.

With keyswitch in "test" position measure voltage between PC801-10 negative and PC801-2 positive. Should measure battery volts.

Problem still exists.

No voltage

Check wiring and keyswitch condition.

Repair or replace as necessary.

Substitute display board with known good board.

Crown 1993 PF-9697-7

M4.3 - 1430 - 106

Printed in U.S.A.

M4.3 - 1430 - 106

MAINTENANCE 1883

6. SYMPTOM: Display remains in on mode when truck is powered down.

Zero volts

With keyswitch in "off" position, measure voltage between PC801-10 negative and PC801-3.

Should measure zero volts.

Battery volts present

Check wiring and keyswitch condition.

Repair or replace as necessary.

Substitute display board with known good board.

1884

7. SYMPTOM: Half or all of one or more message display matrix LED's do not illuminate when keyswitch is in "test" or "on" position.

Yes

Is half of the LED matrix operational?

Replace LED segment No. Entire matrix LED segment does not illuminate

Replace

Problem still exists

Substitute display board with known good board

Crown 1993 PF-9697-8

M4.3 - 1430 - 107

Printed in U.S.A.

M4.3 - 1430 - 107

MAINTENANCE

1885

8. SYMPTOM: One or more message display matrix LED segments do not illuminate when keyswitch is in "test" or "on" position.

Replace LED segment

Problem still exists.

Substitute display board with known good board.

Crown 1993 PF-9697-9

M4.3 - 1430 - 108

Printed in U.S.A.

M4.3 - 1430 - 108

MAINTENANCE 1886-01

9. SYMPTOM: Fault display/clear mode and/or language selection mode does not work.

With keyswitch in "off" position, battery connector connected and battery disconnect engaged, measure voltage between PC801-10 negative and PC801-1 positive then PC801-11 positive.

Should measure 5 volts.

5 volts present

Measure voltage between PC801-10 negative and PC801-1 positive with the display switch actuated. Should measure zero volts.

No voltage

Measure voltage between PC801-10 negative and PC801-8 positive. Should measure 5 volts.

5 volts present

Substitute display board with known good board.

No voltage

5 volts

Zero volts

Check DC - DC converter as described in DC - DC converter testing.

Check condition of wiring and display switch.

Repair or replace as necessary.

Measure voltage between PC801-10 negative and PC801-11 positive with the erase switch actuated. Should measure zero volts.

Zero volts

5 volts

Check condition of wiring and display switch.

Repair or replace as necessary.

Substitute display board with known good board.

Crown 1993 PF-9697-10 Rev. 3/93

Printed in U.S.A.

01 REV. 3/93

M4.3 - 1430 - 109

M4.3 - 1430 - 109

MAINTENANCE 1887

10. SYMPTOM: No information displayed on display and battery discharge indicator not functioning.

Connect GE handheld unit to "Y" receptacle of the traction SCR control card. Information should be displayed on the handheld.

Information displayed on handheld unit

Check continuity of wiring between traction SCR control card and display.

No continuity

No information displayed on handheld unit

Continuity

Troubleshoot SCR system as described in Section M 4.2.

Substitute display board with known good board

Repair open circuit

1888-01

11. SYMPTOM: Hour meters do not increment.

Zero volts

Measure voltage between PC801-10 negative and PC801-14 positive. Should measure zero volts with operator on truck.

5 volts

Check Wiring

Substitute display board with known good board

Crown 1993 PF-9697-11 Rev. 3/93

Printed in U.S.A.

01 REV. 3/93

M4.3 - 1430 - 110

M4.3 - 1430 - 110

MAINTENANCE

1889

12. SYMPTOM: Fault codes not saved. Hour meter or language version not saved.

Substitute display board with known good board

1890

13. SYMPTOM: Display not showing rational information. LED's illuminating sporadically.

Disconnect battery and reconnect.

No Help

Substitute display board with known good board

Crown 1993 PF-9697-12

M4.3 - 1430 - 111

Printed in U.S.A.

M4.3 - 1430 - 111

MAINTENANCE 118280-003 CONTACTOR (24 VOLT) ELECTRICALLY ENCLOSED (EE) 118280-004 CONTACTOR (36/48 VOLT) ELECTRICALLY ENCLOSED (EE) Traction (1A) Single Lift Pump (P1) Dual Lift Pump (P1, P2) The purpose of these instructions is to instruct the user on proper care and maintenance to obtain satisfactory service from these devices. Crown has tested and applied these contactors according to the requirements of our vehicle. No modifications or changes should be made in the layout, physical arrangement or electrical connections without permission from Crown.

CAUTION

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

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

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

COIL Remove all electrical connections. Resistance reading of the coil should be between 16-18 ohms (24v. coils), 42-46 ohms (36v. coils), or 69-77 ohms (48v. coils). If reading does not fall within the limits, replace.

940801 Crown 1994 PF10314-1

M4.4–1430–200

4325C - 39607 Printed in U.S.A.

M4.4–1430–200

MAINTENANCE Component Replacement

CONTACT REPLACEMENT

Refer to parts breakdown in Illustration 4.4-1 and parts list in Parts Section of manual when replacing components.

Disconnect elctrical wiring to contactor. Remove two mounting bolts from bracket and remove contactor from truck.

Remove shroud (Index 1) by removing four screws (Index 2).

Remove two screws (Index 4) from top of contactor and lift contact assembly from coil assembly. Disassemble and replace contacts as necessary.

1

2

3 5 4

6

7

6

5

Reassemble contacts. Place contact assembly on coils and fasten securely with two screws (Index 4), replace shroud & screws (Index 1 & 2). Install contactor in truck and connect wiring.

COIL REPLACEMENT Disconnect all electrical wiring from contactor. Remove two mounting bolts from mounting bracket and remove contactor from truck. Remove shroud (Index 1) by removing four screws (Index 2). Remove two screws (Index 4) and separate contact assembly from coil assembly. Remove mounting bracket from coil.

8

9

10

3134S

Reconnect mounting bracket to replacement coil. Transfer plunger (Index 9) from coil being replaced to replacement coil. Reassemble contact assembly to coil assembly and secure with two screws (Index 4), replace shroud & screws (Index 1 & 2). Mount contactor on truck and reconnect all electrical wiring.

ILLUSTRATION 4.4-1

ALBRIGHT Crown 1994 PF10314-2

M4.4–1430–201

Printed in U.S.A.

M4.4–1430–201

MAINTENANCE 118282-002 CONTACTOR (24 VOLT) ELECTRICALLY ENCLOSED (EE) Directional F&R

Inspection

The purpose of these instructions is to instruct the user on proper care and maintenance to obtain satisfactory service from these devices. Crown has tested and appiied these contactors according to the requirements of our vehicle. No modifications or changes should be made in the layout, physical arrangement or electrical connections without permission from Crown.

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

CONTACTS

CAUTION

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

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

COILS Remove all electrical connections. Resistance reading of the coils should be between 16-18 ohms (24v coils). If reading does not fall within the limits, replace.

940801 Crown 1994 PF10315-1

M4.4–1430–225

4325C - 39607 Printed in U.S.A.

M4.4–1430–225

MAINTENANCE Component Replacement

CONTACT REPLACEMENT

Refer to parts breakdown in Illustration 4.4-1 and parts list in Parts Section of manual when replacing components.

Disconnect electrical wiring to contactor. Remove two mounting bolts from bracket and remove contactor from truck.

Remove shroud (Index 1) by removing four screws (Index 2).

Remove three screws from top of contactor and lift contact assembly from coil. Disassemble and replace contacts as necessary.

3 1

Reassemble contacts. Place contact assembly on coils and fasten securely with three screws (Index 4). Reconnect shroud and screws (Index 1 & 2). Install contactor in truck and connect wiring.

2

4

5

COIL REPLACEMENT

6

7

Disconnect all electrical wiring from contactor. Remove two mounting bolts from mounting bracket and remove contactor from truck. Remove shroud (Index 1) by removing four screws (Index 2). Remove three screws (Index 4) and lift contact assembly from coils. Remove bracket from coil being replaced.

8 9

10 11 12

13

14

Reconnect bracket to replacement coil. Transfer plunger (Index 8) from coil being replaced to replacement coil.

Position contact assembly on coils and secure in place with screws (Index 4). Reconnect shroud and screws (Index 1 & 2). Install contactor in truck and connect wiring.

15

3133S

ILLUSTRATION 4.4-1

Crown 1994 PF10315-2

M4.4–1430–226

Printed in U.S.A.

M4.4–1430–226

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

CAUTION

Gases produced by a battery can be explosive.

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

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

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

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

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

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

930222 Crown 1993 PF-9654-1

M4.6 - 1430 - 001

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

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

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

• Do not lay metallic or conductive objects on battery.

Arcing will result.

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

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

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

3684MI-37094 Printed in U.S.A.

M4.6 - 1430 - 001

MAINTENANCE BATTERY CARE

CHARGING

Your Crown truck is powered by an electrical storage battery.

Here are a few suggestions which will help you give the battery proper care.

Charging requirements will vary depending on use of truck.

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

The battery on your Narrow Aisle Stand-up Rider is located in front of the operator’s compartment.

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

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

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

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

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

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

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

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

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

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

Crown 1993 PF-9654-2

M4.6 - 1430 - 002

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

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

— Make certain charger control is in the off position.

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

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

— Check ammeter to make certain it shows charge.

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

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

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

— Make daily battery checks, add water as needed.

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

Printed in U.S.A.

M4.6 - 1430 - 002

MAINTENANCE BATTERY REMOVAL & INSTALLATION BATTERY REMOVAL

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

CAUTION

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

ROLLER STAND

1. Turn key switch off.

2. Disconnect battery.

1765

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

SPREADER BAR

DISCONNECT BATTERY 1763

3. Remove battery retainer (one side only).

ROLL ONTO STAND

LIFT TO REMOVE RETAINER

1770

1764

Crown 1993 PF-9654-3

M4.6 - 1430 - 003

Printed in U.S.A.

M4.6 - 1430 - 003

MAINTENANCE BATTERY INSTALLATION

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

CAUTION SPREADER BAR

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

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

PUSH INTO COMPARTMENT

2. Remove battery retainer (one side only).

LIFT TO REMOVE RETAINER

1769

5. Remove roller stand and install battery retainer.

INSTALL BATTERY RETAINER

1766

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

1762

6. Connect battery.

ROLLER STAND

1767

CONNECT BATTERY 1768

Crown 1993 PF-9654-4

M4.6 - 1430 - 004

Printed in U.S.A.

M4.6 - 1430 - 004

MAINTENANCE 7. Turn key switch on and check truck operation.

CAUTION

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

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

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

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

These readings still indicate a battery in good condition.

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

CAUTION

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

Crown 1993 PF-9654-5

M4.6 - 1430 - 005

Printed in U.S.A.

M4.6 - 1430 - 005

MAINTENANCE MOTOR INFORMATION CHART TRACTION (24V) 020357-001 020357-002 Brushes: No. of Brush Holders No. of Brush Assemblies No. of Brush Springs Brush Length - New Spring Tension on New Brushes Min. Brush Length Replace Spring Tension Before Replacement Commutator: Max. Diameter - New Min. Diameter - Reslotting Min. Diameter - Replace Bearings: Lubricant

Cond. of Performance: (No Load) Volts Max. Amperes RPM Lb./Ft.

TRACTION (36V) 020260-001 020260-002

8 8 8 1.3 in.

8 8 8 1.3 in.

3.0 lb/in sq.

3.0 lb/in sq.

.62 in.

.62 in.

2.0 lb/in sq.

2.0 lb/in sq.

3.36 3.24 3.19

3.36 3.24 3.19

Hi Temp Chevron SRI-2 or Equiv. 35% Fill

12 35 2500

12 26 2215

.0035

.0047

Armature Resistance: (each at 75° F [24° C]) Ohms Measured Between Bars

.0038 1&9

.0074 1 & 12

Frame Diameter:

7.30 in. nominal

7.45 in.

Wound in:

Series

Series

Direction of Rotation:

Reversing

Reversing

Field Resistance: (each at 75° F [24° C]) Series Ohms Shunt Ohms

930222

4549AG - 40721

Crown 1993 PF-9709-1 Rev. 6/95

Printed in U.S.A.

01 REV. 6/95

M4.7–1430–001

M4.7–1430–001

MAINTENANCE MOTOR INFORMATION CHART

Brushes: No. of Brush Holders No. of Brush Assemblies No. of Brush Springs Brush Length - New Spring Tension on New Brushes Min. Brush Length Replace Spring Tension Before Replacement Commutator: Max. Diameter - New Min. Diameter - Reslotting Min. Diameter - Replace Bearings: Lubricant

Cond. of Performance: (No Load) Volts Max. Amperes RPM Lb./Ft.

LIFT (36V) 020113-001 020113-002

LIFT (24V) 110564

4 4 4 1.30 in.

4 4 4 1.30 in.

48 oz.

65 oz.

.62 in.

.62 in.

32 oz.

40 oz.

2.92 in.

2.80 in.

2.75 in.

2.92 in.

2.80 in.

2.75 in.

Hi Temp Chevron SRI-2 or equiv. 35% fill

Hi Temp Grease SRI-2

12 30 3700 min.

12 43 3500 min.

(Load [@Stall]) Volts Max. Amperes RPM Lb./Ft. Field Resistance: (each at 75° F [24° C]) Series Ohms Shunt Ohms

10.6 450 69.0

.0064 .0015

Armature Resistance: (each at 75° F [24° C]) Ohms Measured Between Bars

.0044 1 and 10

.0044 1 - 10

Frame Diameter:

6.7 in.

6.7 in.

CWDE

CWDE

Wound in: Direction of Rotation: Crown 1993 PF-9709-2 Rev. 6/95

Printed in U.S.A.

01 REV. 6/95

M4.7–1430–002

M4.7–1430–002

MAINTENANCE MOTOR INFORMATION CHART POWER STEERING (24V) 115826 Brushes: No. of Brush Holders No. of Brush Assemblies No. of Brush Springs Brush Length - New Spring Tension on New Brushes Min. Brush Length Replace Spring Tension Before Replacement

POWER STEERING (36V) 115105

4 4 4 1.13 in.

4 4 4 1.13 in.

1.92 lb.

1.92 lb.

0.50 in.

0.50 in.

0.72 lb.

0.72 lb.

Commutator: Max. Diameter - New Min. Diameter - Reslotting Min. Diameter - Replace

1.99 in.

1.985 in.

1.97 in.

1.99 in.

1.985 in.

1.97 in.

Bearings: Lubricant

Shell Dolium R

Shell Dolium R

Cond. of Performance: (No Load) Volts Max. Amperes RPM Lb./Ft.

24 5.0 2075 +/- 5% 2.62

36 4.95 1850 +/-5% 5.3

(Load [@Stall]) Volts Max. Amperes RPM Lb./Ft.

24 35 1800 2.62

6 41 1490 5.3

Armature Resistance: (each at 77° F [25° C]) Ohms Measured Between Bars

.047

.135

Frame Diameter:

5.68 in.

5.68 in.

CW

CW

Field Resistance: (each at 77° F [25° C]) Series Ohms Shunt Ohms

Wound in: Direction of Rotation:

Printed in U.S.A.

Crown 1993 PF-9709-3 Rev. 6/95

01 REV. 6/95

M4.7–1430–003

M4.7–1430–003

MAINTENANCE

TRUCK TROUBLESHOOTING FLOWCHART SYMPTOM INDEX Symptom

Page

(1)

Truck completely inoperative

M4.9-1430-002

(2)

No traction (No Lift, Accessory Hydraulic functions operate)

M4.9-1430-003

(3)

No power steering (Power steering pump does not run)

M4.9-1430-004

(4)

No lift

M4.9-1430-005

(5)

High speed lift does not operate. Normal lift okay.

(36 volt truck with dual lift pump)

M4.9-1430-006

(6)

No lowering

M4.9-1430-007

(7)

Wrong function operating. Lights sequence properly.

M4.9-1430-007

(8)

No hydraulic functions operate, no function lights illuminate.

(Traction okay, steering okay)

M4.9-1430-007

One or more lights malfunction. Hydraulic functions operate properly.

M4.9-1430-008

(9)

(10) Power fuses blown (FU1, FU2, FU3, FU4)

M4.9-1430-009

(11) Control fuse blown (FU5)

M4.9-1430-009

930222

Revision

01 - 7/95

4743

Crown 1993 PF-9714-1 Rev. 7/95

Printed in U.S.A.

01 REV. 7/95

M4.9–1430–001

M4.9–1430–001

MAINTENANCE 1912

(1) TRUCK COMPLETELY INOPERATIVE.

Poor Condition.

Check battery disconnect.

Repair or replace.

Disconnected.

Engage.

Okay.

Check battery state - of - charge.

Low.

Okay.

Charge.

Blown. (Check cause).

Check condition of control fuse (FU5).

Replace.

Battery volts.

Okay.

Check for battery voltage at CA205-1, CA205-2 and CA205-3 on the distribution board.

0 volts.

Check wiring from positive bus to distribution board.

Check keyswitch and associated wiring.

Open circuit. Repair.

Okay.

Defective or in poor condition.

Repair or replace as necessary.

Crown 1993 PF-9714-2

M4.9–1430–002

Check switch DMS condition and adjustment.

Repair or adjust as necessary.

Printed in U.S.A.

M4.9–1430–002

MAINTENANCE 1913-01

(2) NO TRACTION. (No Lift, Accessory Hydraulic Functions Operate)

Fuse blown.

(Check cause and repair.)

Okay.

Check condition of FU1.

Replace fuse.

Check BRS & BMS condition and adjustment.

Requires attention. Repair or adjust as necessary.

Okay.

Check for battery volts at FS and RS when KYS, DMS, BMS and BRS are closed.

Battery volts.

0 volts.

Check condition and adjustment of FS and RS.

Check interconnecting wiring, connections, switch condition and adjustments.

Requires attention. Repair, replace and adjust as necessary.

Repair, replace and adjust as necessary.

Okay.

Troubleshoot the Traction SCR system as described in section M4.2.

Printed in U.S.A.

Crown 1993 PF-9714-3 Rev. 7/95

01 REV. 7/95

M4.9–1430–003

M4.9–1430–003

MAINTENANCE

1914

(3) NO POWER STEERING. (Power steering pump does not run.)

Does steering solenoid operate?

Yes.

Check FU2.

Blown.

(Check cause)

No.

Check steering solenoid and suppressor.

Okay.

Replace.

Okay.

Shorted or open.

Replace.

Connect jumper across solenoid power cable connections. Does motor run?

Check for battery volts at steering solenoid coil with KYS "on" and floorboard depressed.

Yes.

No.

Battery volts.

Replace solenoid.

Check motor.

Replace solenoid.

Crown 1993 PF-9714-4

M4.9–1430–004

0 volts.

Check switches and associated wiring.

Printed in U.S.A.

M4.9–1430–004

MAINTENANCE 1915

(4) NO LIFT

Does pump motor run?

Yes.

Check hydraulic fluid level and associated valves, tubing, etc.

No.

Is lift interrupt operated?

No.

Yes.

Charge battery.

Okay.

Does P1 contactor operate?

No.

Check sequence control as described in section M4.3.

Check FU3.

Yes.

Blown.

(Check cause)

Replace.

Check contactor tips.

Poor condition.

Okay.

Repair or replace as necessary.

Check pump motor.

Crown 1993 PF-9714-5

M4.9–1430–005

Printed in U.S.A.

M4.9–1430–005

MAINTENANCE 1916

(5) HIGH SPEED LIFT DOES NOT OPERATE. NORMAL LIFT OKAY. (36 volt truck with dual lift pump)

No.

Does P2 operate?

Check sequence control as described in section M4.3.

Yes.

Yes.

Does pump motor run?

Check hydraulic fluid level and associated valves, tubing, etc.

No.

Okay.

Check FU4.

Poor condition.

Check P2 contactor tips.

Blown.

(Check cause)

Repair or replace as necessary.

Okay.

Replace.

Check pump motor.

Crown 1993 PF-9714-6

M4.9–1430–006

Printed in U.S.A.

M4.9–1430–006

MAINTENANCE 1917

(6) No Lowering

Check operation of sequence control as described in section M4.3.

1918

(7) WRONG FUNCTION OPERATING. LIGHTS SEQUENCE PROPERLY.

Check all interconnecting wiring and connections.

Wiring and connections okay.

Requires attention.

Check operation of sequence control as described in section M4.3.

Repair or replace as necessary.

1919

(8) NO HYDRAULIC FUNCTIONS OPERATE, NO FUNCTION INDICATORS ILLUMINATE. (Traction okay, steering okay)

Check operation of sequence control as described in section M4.3.

Crown 1993 PF-9714-7

M4.9–1430–007

Printed in U.S.A.

M4.9–1430–007

MAINTENANCE 1920

(9) ONE OR MORE INDICATORS MALFUNCTION ON EITHER OR BOTH INDICATOR PANELS. HYDRAULIC FUNCTIONS OPERATE PROPERLY.

Do any indicators illuminate?

No.

Make initial checks for voltage and battery negative to sequence control as described in section M4.3.

Yes.

Okay.

Check condition of LED's.

Burnt out.

Check signal path from the sequence control to the displays using the chart below. +12 volts should be present on corresponding paths when function is selected.

Replace.

+12 volts not present at a connection after sequence control connector.

+12 volts not present at CA602 (sequence control printed circuit board).

Repair wiring or connection.

Replace sequence control printed circuit board.

CIRCUIT INDICATOR

SEQUENCE CONTROL CA602

Lift First Position Second Position Third Position

-7 -8 -9 -10

Crown 1993 PF-9714-8

M4.9–1430–008

CONNECTION TERMINAL POWER UNIT OVERHEAD GUARD TB405 CA801 -1 -2 -3 -4

-20 -19 -18 -17

DASH CA408 -1 -2 -3 -4

Printed in U.S.A.

M4.9–1430–008

MAINTENANCE

1921

(10) POWER FUSES BLOWN. (FU1, FU2, FU3, FU4)

Check power cables for shorts.

Check contactor operation (Welded tips).

Check motors for short circuits.

1922

(11) CONTROL FUSE BLOWN. (FU5)

Check control wiring and components for damage and short circuits.

Crown 1993 PF-9714-9

M4.9–1430–009

Printed in U.S.A.

M4.9–1430–009

MAINTENANCE BRAKES BRAKE BLEEDING It may become necessary to bleed the brake system to remove air trapped in the lines. Best results are obtained if the system is bled by using a pressure bleeder such as United BT-3000 or equal. The following procedure should be used to bleed the system if a pressure bleeder is used: 1. Unlatch and open door; fill brake reservoir with brake fluid.

2. A bleed valve is located at the end of the slave cylinder (index 23) mounted on the drive brake mounting plate (See 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 line.

10

11

3

3. Attach pressure bleeder to the brake reservoir.

CAUTION BLEED VALVE (1)

Do not apply more than 30 to 40 p.s.i.(206.8 to 275.8 kPa) to avoid damage and possible rupture of reservoir.

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

5. Close bleed valve after all air has been forced out of the system and there is a steady flow out of the drain line.

6. Remove guard (index 15) from caster assembly. (See Illustration 5-2) Attach drain hoses to the bleed valves (index 34).

7. With the brake pedal depressed, open one bleed valve at a time, approximately 1/2 turn counterclockwise.

Close bleed valve after all air has been forced out of the system and there is a steady flow out of the drain line.

1924S

ILLUSTRATION 5-1

If a pressure bleeder is not available, the following procedure can be used: 1. Check brake reservoir for proper fluid level and inspect system to be sure all connections are tight.

8. Disconnect drain lines and pressure bleeder.

9. Check and fill reservoir if necessary.

10. Install guard on caster assembly.

2. A bleed valve is located at the end of the slave cylinder (index 23) mounted on the drive brake mounting plate (See Illustration 5-1). Attach a hose to the bleed valve and place the other end into the brake reservoir.

3. Pump the brake pedal then hold pedal down, open bleed valve approximately 1/2 turn counterclockwise to let air escape, then close valve. Repeat until a steady stream flows, without entrapped air.

930222

3684NP-37094

Crown 1993 PF-9716-1 Rev. 3/93

Printed in U.S.A.

01 REV. 3/93

M5.0 - 1430 - 001

M5.0 - 1430 - 001

MAINTENANCE 54 2

53

B 31

35

55

35

BLEED VALVE (2) 55

ILLUSTRATION 5-2

1925S

5. Pump the brake pedal, with pedal in up position, open bleed valve approximately 1/2 turn counterclockwise to let air escape, then close valve. Repeat until a steady stream flows, without entrapped air.

CAUTION

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

4. Remove guard (index 15) from caster assembly. Attach drain hoses to the bleed valves (index 34). (See Illustration 5-2)

6. Disconnect drain lines and install guard on caster assembly.

7. Check brake reservoir and fill to recommended level.

Printed in U.S.A.

Crown 1993 PF-9716-2 Rev. 3/93

01 REV. 3/93

M5.0 - 1430 - 002

M5.0 - 1430 - 002

MAINTENANCE FLUID LEVEL "A"

Brake fluid is added to the reservoir mounted on the steering bracket to the right of the oil filter. Use Dow Corning Q2-1141 Silicone Brake Fluid. The silicone brake fluid currently being used in all brake systems and available from Crown is compatible with all other types, non-corrosive and doesn’t react with painted surfaces. Order 063004-002 for 12 ounces (0.35 liter) of brake fluid or 063004-003 for 1 gallon (3.8 liter).

90°

Cutaway View of Slave Cylinder Push Rod Assembly

Pivot Block Pivot Rod Weldment

BMS

Boot Slave Cylinder Piston

Stop

• The reservoir level should be 1/2 to 3/4 in. (15 to 20 mm) from the top.

Actuator .02"(0.5mm)

BRAKE LINES

Bracket Drive Brake Spring

• Use care to avoid kinking any brake lines. Permanent damage to the line will result if this occurs.

Spring Rod

BRAKE ADJUSTMENT and LINING REPLACEMENT

Part of Under Carriage

.12" min.

(3mm)

Drive Brake

Assembly Shown With Brake Off

NOTE 1976

Drive brakes must be readjusted when braking is insufficient, or linings are wore to the extent that the return "off" stroke of slave cylinder does not actuate the switch to permit truck operation.

Readjust drive brake by repositioning the switch actuator and drive brake spring.

If linings are worn to the extent that the distance between the end of the spring rod and the undercarriage decreases to .12 inch (3 mm) (illustration 5-3) when brakes are applied, the lever arm on the drive brake must be repositioned clockwise one notch (approximately 26° or 0.69 inch [17 mm]) on serrated pin (illustration 5-4) or new shoes should be installed.

ILLUSTRATION 5-3

PREPARATION 1. Raise the rear of the truck until the drive wheel and caster are off floor, approximately 6 inches. Place a hardwood block under the center pivot of the undercarriage and lower truck onto block.

2. Unlatch door, remove hinge pin and set door aside.

3. Remove the fan (index 17) from brake drum (index 32).

(See Illustration 5-1) 4. Remove bolt (index 16) and lockwasher (index 33) located in the center of the brake drum; depress brake pedal and remove brake drum.

5. Inspect condition of drum, especially for grooves worn in the inside by worn linings.

LINING INSPECTION and REPLACEMENT 1. Inspect linings and replace if necessary.

2. Remove the two springs connecting the brake shoes and remove the two nuts, lockwashers and flatwashers holding the shoes to the backing plate.

3. Place new linings in position and secure to the backing plate. Attach springs connecting the linings.

Printed in U.S.A.

Crown 1993 PF-9716-3 Rev. 3/93

01 REV. 3/93

M5.0 - 1430 - 003

M5.0 - 1430 - 003

MAINTENANCE DRIVE BRAKE PLATE ADJUSTMENT 1. With the drive brake in its centered and fully released "off" position, assemble the brake lever arm to the cam assembly on the centerline or slightly clockwise of the centerline. Rotate the brake lever arm on serrated pin, or turn it around 180° to get most centered to slightly clockwise position.

LUBRICATE ALL CONTACT SURFACES

6. Set the initial overall length across drive brake compression spring and cupped washers (illustration 5-3) at approximately 5 inches (127 mm).

7. With brake pedal down, in the brake off position, set the drive brake shoe clearance by lengthening the push rod assembly until the brake drum can be rotated freely. Slave cylinder should be fully extended.

8. Set the switch bar to actuate the switch when pedal is down and brake is off. Leave a small gap, approximately .02 inches (0.5 mm) between the switch bar and fixed stop.

Caster Brake NOTE

SERRATED PIN

As brake linings wear, periodic brake shoe readjustment (every 250 hours on PM’s) will maintain minimum shoe clearance and wheel cylinder travel. Excessive wheel cylinder travel can cause uneven piston and manifold bore wear resulting in cylinder leakage.

Brake Plate Assembly 1932S

ILLUSTRATION 5-4

2. Lubricate pivot points and contact surfaces of back plate and brake shoes.

PREPARATION 1. Raise and block the rear of the truck in such a manner that the caster is off the floor.

NOTE When spraying the pivot areas of the drive brake shoes, washers, & axle with dry lubricant, Crown part no. 063002-021 (Refer To Illustration 5-4), do not allow any lubricant to come in contact with the lining material or braking surfaces of the brake assembly.

2. Remove four lug bolts (index 48) on each caster wheel and remove caster wheel (index 47). (See Illustration 5-2).

3. Depress brake pedal and install brake drum. Put lockwasher with tab, in place on top of brake drum and tighten the bolt securing the brake drum to the drive motor shaft to 55 ft. lbs. (75 Nm).

3. Depress brake pedal and keep depressed while performing maintenance on caster brake. A 50 Ib. (22.5 kg) weight, approximately, will be needed to keep the pedal depressed.

NOTE If brake pedal is not kept depressed while the caster brake drums are removed, both pistons in manifold block will be forced from manifold.

4. Install fan on brake drum.

5. When attaching pivot rod weldment to brake lever arm, adjust length "A" (illustration 5-3) such that pivot block is at 90° when brake is in the "on" position.

4. Remove retaining ring (index 46) and pull brake drum (index 45) from axle assembly (index 19). Inspect condition of drum, especially for grooves worn in the inside by worn lining.

Printed in U.S.A.

Crown 1993 PF-9716-4 Rev. 3/93

01 REV. 3/93

M5.0 - 1430 - 004

M5.0 - 1430 - 004

MAINTENANCE 4. Turn adjustors (index 23, illustration 5-2) to obtain shortest possible length. Position adjustor at top of shoes.

LINING INSPECTION AND REPLACEMENT 1. Inspect linings and replace if necessary.

2. Remove adjustor spring (index 27) and piston spring (index 28). Remove adjusting screw with components (index 22, 23, 24). Remove bolt (index 30) securing linings to axle assembly and remove secondary brake shoe (index 26) and primary brake shoe (index 25).

NOTE The adjustor on each side must be positioned as shown in Illustration 5-2, or proper adjustment cannot be made.

3. Place new linings in position and bolt to axle assembly (backing plate). The primary and secondary shoes will only fit properly if positioned to the correct side of the manifold block (index 36). The primary shoe will mate with the plunger (index 41) and the secondary shoe will mate with the end cap (index 55).

Install springs (index 27, 28) on brake shoes.

5. Place brake drum on axle assembly and attach retaining ring to axle end. Bolt caster wheel to brake drum (45 to 55 ft. lbs. [61 to 75 Nm]).

SHOE CLEARANCE ADJUSTMENT

NOTE 1. To adjust brake shoe clearance, align the access hole in the caster wheel and brake drum with the adjusting screw (star adjuster). Insert brake adjusting spoon and rotate (downward) star adjuster to expand shoes until they contact drum and then back off 3 to 4 clicks.

When spraying the pivot areas of the caster secondary brake shoes, washers, & axle with dry lubricant, Crown part no. 063002-021, (Refer To Illustration 5-6) do not allow any lubricant to come in contact with the lining material or braking surfaces of the brake assembly.

STAR ADJUSTER

COLLAPSE SHOES

EXPAND SHOES 1927S

2.

1926S

ILLUSTRATION 5-7 Release the brake pedal and remove the blocks from under the rear of the truck.

ILLUSTRATION 5-6

Printed in U.S.A.

Crown 1993 PF-9716-5 Rev. 3/93

01 REV. 3/93

M5.0 - 1430 - 005

M5.0 - 1430 - 005

MAINTENANCE STOPPING DISTANCE ADJUSTMENT

Mounting Bracket

General Notes

Threaded End of Clevis

The brake system is adjusted at the factory to provide optimal braking performance for smooth dry concrete floors and standard tire conditions. Upon installation, the brake adjustment should be checked by following the stopping distance procedure. It may be necessary to modify the factory setting to properly accomodate the particular floor conditions. When a vehicle is being operated over a variety of floor conditions it may be impractical to adjust the brake to perform optimally for all of the different floor conditions.

See Chart

CAUTION TRUCK MODEL

The customer shall verify that the stopping distance in any part of the application doesn't prevent the operator from performing a specific task safely, or result in braking characteristics that are significantly different from other similar vehicles being used in the facility. An alternative is for the customer to train the operator to reduce travel speed and/or allow for longer stopping distances.

RD3020-30 RD3040-30 RR3010-35 RR3020-35 RR3010-40 RR3020-45 RR3040-45 RS3010-40 RS3020-40

Caster Brake Adjustment With the brake pedal in the "up" (brake "on") position, adjust the spring at the caster brake master cylinder to the overall length given in illustration 5-8. This spring length will typically produce the maximum braking force without sliding the caster wheels. Verify that the caster wheels do not slide during the drive brake adjustment. If caster wheel slide is experienced, this length should be increased just enough to prevent slide and subsequent flat spotting of the caster wheel.

OVERALL LENGTH inches (mm) 5 3/8 (137) 5 1/8 (130) 5 5/8 (143) 5 1/2 (140) 5 5/8 (143) 5 3/8 (137) 5 3/16 (132) 5 1/2 (140) 5 1/2 (140)

CASTER BRAKE SPRING ADJUSTMENT 1965

ILLUSTRATION 5-8

Drive Brake Adjustment Adjust the brake spring on the drive motor so the truck, when traveling in the forks first direction, will stop in the shortest possible distance with a minimal amount of drive tire slide.

Making the spring overall length shorter will shorten the stopping distance. If the stop is too abrupt, the overall spring length should be increased.

Stopping Distance Procedure Check stopping distance with the truck empty, on a level, surface typical for the application. Travel at maximum acceleration from 0 to 50 feet (15 m) in the forks first direction .

Apply the brakes and measure the stopping distance. Approximate stopping distances for smooth, dry concrete are as listed.

RD3000-30 RR3000-35 RR3000-40 RR3000-45 RS3000-40

4 1/2 - 6 1/2 feet (1.4 - 2.0 m) 4 - 6 feet (1.2 - 1.8 m) 3 1/2 - 5 1/2 feet (1.1 - 1.7 m) 4 - 6 feet (1.2 - 1.8 m) 4 - 6 feet (1.2 - 1.8 m)

Printed in U.S.A.

Crown 1993 PF-9716-6 Rev. 3/93

01 REV. 3/93

M5.0 - 1430 - 006

M5.0 - 1430 - 006

MAINTENANCE MASTER CYLINDER REMOVAL

NOTE

1. Remove floorboard from operator compartment. Two self-locking bolts at the left side of the floorboard secure it to the power unit.

It is recommended that any maintenance performed on the master cylinders should be as a pair instead of individually.

2. Unlatch and open door. Attach a drain line to the bleeder screw of the slave cylinder on the drive brake mounting bracket or caster bleed screws. Open bleed screw approximately 1/2 turn and force out the fluid by pumping the brake pedal. Discard the fluid properly.

4. To remove the caster brake master cylinder turn adjusting nut (index 17) CCW until it is even with the end of threads on clevis assembly (index 12). Push down on pivot arm (index 1) to compress spring (index 15) and insert punch in hole of clevis assembly (index 12).

3. Disconnect all flexible lines to master cylinder (index 31). The master cylinder for the drive brake uses a double spring (index 25 & 26) on the push rod. The single spring (index 15) is used on the master cylinder for the caster brake. (Refer to Illustration 5-9)

5. Disconnect ball joint (index 2) from pivot arm assembly (index 1). Remove bolts (index 14) and (index 32) that secure master cylinder assembly to the power unit.

Remove bolt (index 9) and pull out shaft.

6. Remove master cylinder assembly from truck and take to clean work area for any further disassembly.

68

67

63 65

64

57

70

56

1928S

ILLUSTRATION 5-9 Printed in U.S.A.

Crown 1993 PF-9716-7 Rev. 3/93

01 REV. 3/93

M5.0 - 1430 - 007

M5.0 - 1430 - 007

MAINTENANCE BRAKE PEDAL ADJUSTMENT

Drive Brake

Caster Brake

Adjust the drive brake ball joint under the brake pedal to set pedal height at 4.43 inches (112 mm) from stop (floor support) to under side of brake pedal in the brake on (pedal up)position.

Adjust the caster brake ball joint under the brake pedal so that the pedal will hit its stop (floor support) just before the push rod in the master cylinder would be pulled against the cupped washer and retaining ring. Start with long adjustment and decrease by 1 turn increments of the ball joint, until pedal hits its stop.

Floorboard 4.43"

NOTE The piston in the master cylinder must fully retract in the brake off (pedal down) position, to enable the brake fluid reservoir to replenish brake fluid supply if needed.

Adjust to Get 4.43" Height

Floorboard

Drive Brake Master Cylinder 1975

ILLUSTRATION 5-11

Adjust to Get Pedal to Hit Floor Support & Master Cylinder Piston to be Fully Retracted

Caster Master Cylinder 1974

ILLUSTRATION 5-10

Crown 1993 PF-9716-8 Rev. 3/93

Printed in U.S.A.

01 REV. 3/93

M5.0 - 1430 - 008

M5.0 - 1430 - 008

MAINTENANCE BRAKES BRAKE BLEEDING It may become necessary to bleed the brake system to remove air trapped in the lines. Best results are obtained if the system is bled by using a pressure bleeder such as United BT-3000 or equal. The following procedure should be used to bleed the system if a pressure bleeder is used: 1. Unlatch and open door; fill brake reservoir with brake fluid.

2. A bleed valve is located at the end of the slave cylinder (index 23) mounted on the drive brake mounting plate (See 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 line.

10

11

3

3. Attach pressure bleeder to the brake reservoir.

34

CAUTION

Do not apply more than 30 to 40 p.s.i.(206.8 to 275.8 kPa) to avoid damage and possible rupture of reservoir.

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

5. Close bleed valve after all air has been forced out of the system and there is a steady flow out of the drain line.

6. Remove guard (index 15) from caster assembly. (See Illustration 5-2) Attach drain hoses to the bleed valves (index 34).

7. With the brake pedal depressed, open one bleed valve at a time, approximately 1/2 turn counterclockwise.

Close bleed valve after all air has been forced out of the system and there is a steady flow out of the drain line.

1708S-01

ILLUSTRATION 5-1

If a pressure bleeder is not available, the following procedure can be used: 1. Check brake reservoir for proper fluid level and inspect system to be sure all connections are tight.

8. Disconnect drain lines and pressure bleeder.

9. Check and fill reservoir if necessary.

10. Install guard on caster assembly.

2. A bleed valve is located at the end of the slave cylinder (index 23) mounted on the drive brake mounting plate (See Illustration 5-1). Attach a hose to the bleed valve and place the other end into the brake reservoir.

3. Pump the brake pedal then hold pedal down, open bleed valve approximately 1/2 turn counterclockwise to let air escape, then close valve. Repeat until a steady stream flows, without entrapped air.

950619

6076

Crown 1995 PF10585-1 Rev. 4/99

Printed in U.S.A.

01 REV. 4/99

M5.0–1435–001

M5.0–1435–001

MAINTENANCE 54 2

53

B 31

35

55

35

BLEED VALVE (2) 55

ILLUSTRATION 5-2

1925S

CAUTION

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

4. Remove guard (index 15) from caster assembly. Attach drain hoses to the bleed valves (index 34). (See Illustration 5-2)

Crown 1995 PF-10585-2

M5.0–1435–002

5. Pump the brake pedal, with pedal in up position, open bleed valve approximately 1/2 turn counterclockwise to let air escape, then close valve. Repeat until a steady stream flows, without entrapped air.

6. Disconnect drain lines and install guard on caster assembly.

7. Check brake reservoir and fill to recommended level.

Printed in U.S.A.

M5.0–1435–002

MAINTENANCE FLUID LEVEL "A"

Brake fluid is added to the reservoir mounted on the steering bracket to the right of the oil filter. Use Dow Corning Q2-1141 Silicone Brake Fluid. The silicone brake fluid currently being used in all brake systems and available from Crown is compatible with all other types, non-corrosive and doesn’t react with painted surfaces. Order 063004-002 for 12 ounces (0.35 liter) of brake fluid or 063004-003 for 1 gallon (3.8 liter).

90°

Cutaway View of Slave Cylinder Push Rod Assembly

Pivot Block Pivot Rod Weldment

BMS

Boot Slave Cylinder Piston

Stop

• The reservoir level should be 1/2 to 3/4 in. (15 to 20 mm) from the top.

Actuator .02"(0.5mm)

BRAKE LINES

Bracket Drive Brake Spring

• Use care to avoid kinking any brake lines. Permanent damage to the line will result if this occurs.

Spring Rod

BRAKE ADJUSTMENT and LINING REPLACEMENT

Part of Under Carriage

.12" min.

(3mm)

Drive Brake

Assembly Shown With Brake Off

NOTE 1976

Drive brakes must be readjusted when braking is insufficient, or linings are wore to the extent that the return "off" stroke of slave cylinder does not actuate the switch to permit truck operation.

Readjust drive brake by repositioning the switch actuator and drive brake spring.

If linings are worn to the extent that the distance between the end of the spring rod and the undercarriage decreases to .12 inch (3 mm) (illustration 5-3) when brakes are applied, the lever arm on the drive brake must be repositioned clockwise one notch (approximately 26° or 0.69 inch [17 mm]) on serrated pin (illustration 5-4) or new shoes should be installed.

ILLUSTRATION 5-3

PREPARATION 1. Raise the rear of the truck until the drive wheel and caster are off floor, approximately 6 inches. Place a hardwood block under the center pivot of the undercarriage and lower truck onto block.

2. Unlatch door, remove hinge pin and set door aside.

3. Remove the fan (index 17) from brake drum (index 32).

(See Illustration 5-1) 4. Remove bolt (index 16) and lockwasher (index 33) located in the center of the brake drum; depress brake pedal and remove brake drum.

5. Inspect condition of drum, especially for grooves worn in the inside by worn linings.

LINING INSPECTION and REPLACEMENT 1. Inspect linings and replace if necessary.

2. Remove the two springs connecting the brake shoes and remove the two nuts, lockwashers and flatwashers holding the shoes to the backing plate.

3. Place new linings in position and secure to the backing plate. Attach springs connecting the linings.

Crown 1995 PF-10585-3

M5.0–1435–003

Printed in U.S.A.

M5.0–1435–003

MAINTENANCE DRIVE BRAKE PLATE ADJUSTMENT 1. With the drive brake in its centered and fully released "off" position, assemble the brake lever arm to the cam assembly on the centerline or slightly clockwise of the centerline. Rotate the brake lever arm on serrated pin, or turn it around 180° to get most centered to slightly clockwise position.

LUBRICATE ALL CONTACT SURFACES

SERRATED PIN

6. Set the initial overall length across drive brake compression spring and cupped washers (illustration 5-3) at approximately 5 inches (127 mm).

7. With brake pedal down, in the brake off position, set the drive brake shoe clearance by lengthening the push rod assembly until the brake drum can be rotated freely. Slave cylinder should be fully extended. Slave rod should be adjusted until the brake shoes drag, then backed off until they just release.

8. Set the switch bar to actuate the switch when pedal is down and brake is off. Leave a small gap, approximately .02 inches (0.5 mm) between the switch bar and fixed stop.

Caster Brake NOTE As brake linings wear, periodic brake shoe readjustment (every 250 hours on PM’s) will maintain minimum shoe clearance and wheel cylinder travel. Excessive wheel cylinder travel can cause uneven piston and manifold bore wear resulting in cylinder leakage.

Brake Plate Assembly 1932S

ILLUSTRATION 5-4

2. Lubricate pivot points and contact surfaces of back plate and brake shoes.

PREPARATION

NOTE When spraying the pivot areas of the drive brake shoes, washers, & axle with dry lubricant, Crown part no. 063002-021 (Refer To Illustration 5-4), do not allow any lubricant to come in contact with the lining material or braking surfaces of the brake assembly.

1. Raise and block the rear of the truck in such a manner that the caster is off the floor.

3. Depress brake pedal and install brake drum. Put lockwasher with tab, in place on top of brake drum and tighten the bolt securing the brake drum to the drive motor shaft to 55 ft. lbs. (75 Nm).

3. Depress brake pedal and keep depressed while performing maintenance on caster brake. A 50 Ib. (22.5 kg) weight, approximately, will be needed to keep the pedal depressed.

2. Remove four lug bolts (index 48) on each caster wheel and remove caster wheel (index 47). (See Illustration 5-2).

NOTE

4. Install fan on brake drum.

If brake pedal is not kept depressed while the caster brake drums are removed, both pistons in manifold block will be forced from manifold.

5. When attaching pivot rod weldment to brake lever arm, adjust length "A" (illustration 5-3) such that pivot block is at 90° when brake is in the "off" position.

4. Remove retaining ring (index 46) and pull brake drum (index 45) from axle assembly (index 19). Inspect condition of drum, especially for grooves worn in the inside by worn lining.

Printed in U.S.A.

Crown 1995 PF10585-4 Rev. 4/99

01 REV. 4/99

M5.0–1435–004

M5.0–1435–004

MAINTENANCE 4. Turn adjustors (index 23, illustration 5-2) to obtain shortest possible length. Position adjustor at top of shoes.

LINING INSPECTION AND REPLACEMENT 1. Inspect linings and replace if necessary.

2. Remove adjustor spring (index 27) and piston spring (index 28). Remove adjusting screw with components (index 22, 23, 24). Remove bolt (index 30) securing linings to axle assembly and remove secondary brake shoe (index 26) and primary brake shoe (index 25).

NOTE The adjustor on each side must be positioned as shown in Illustration 5-2, or proper adjustment cannot be made.

3. Place new linings in position and bolt to axle assembly (backing plate). The primary and secondary shoes will only fit properly if positioned to the correct side of the manifold block (index 36). The primary shoe will mate with the plunger (index 41) and the secondary shoe will mate with the end cap (index 55).

Install springs (index 27, 28) on brake shoes.

5. Place brake drum on axle assembly and attach retaining ring to axle end. Bolt caster wheel to brake drum (45 to 55 ft. lbs. [61 to 75 Nm]).

SHOE CLEARANCE ADJUSTMENT

NOTE 1. To adjust brake shoe clearance, align the access hole in the caster wheel and brake drum with the adjusting screw (star adjuster). Insert brake adjusting spoon and rotate (downward) star adjuster to expand shoes until they contact drum and then back off 3 to 4 clicks.

When spraying the pivot areas of the caster secondary brake shoes, washers, & axle with dry lubricant, Crown part no. 063002-021, (Refer To Illustration 5-6) do not allow any lubricant to come in contact with the lining material or braking surfaces of the brake assembly.

STAR ADJUSTER

COLLAPSE SHOES

EXPAND SHOES 1927S

2.

1926S

ILLUSTRATION 5-7 Release the brake pedal and remove the blocks from under the rear of the truck.

ILLUSTRATION 5-6

Crown 1995 PF-10585-5

M5.0–1435–005

Printed in U.S.A.

M5.0–1435–005

MAINTENANCE STOPPING DISTANCE ADJUSTMENT

Floorboard

General Notes The brake system is adjusted at the factory to provide optimal braking performance for smooth dry concrete floors and standard tire conditions. Upon installation, the brake adjustment should be checked by following the stopping distance procedure. It may be necessary to modify the factory setting to properly accomodate the particular floor conditions. When a vehicle is being operated over a variety of floor conditions it may be impractical to adjust the brake to perform optimally for all of the different floor conditions.

Adjust to Get Pedal to Hit Floor Support & Master Cylinder Piston to be Fully Retracted

Caster Master Cylinder

CAUTION 1974-01

The customer shall verify that the stopping distance in any part of the application doesn't prevent the operator from performing a specific task safely, or result in braking characteristics that are significantly different from other similar vehicles being used in the facility. An alternative is for the customer to train the operator to reduce travel speed and/or allow for longer stopping distances.

ILLUSTRATION 5-8

Drive Brake Adjust the drive brake ball joint under the brake pedal to set pedal height at 4.43 inches (112 mm) from stop (floor support) to under side of brake pedal in the brake on (pedal up)position.

Floorboard

BRAKE PEDAL ADJUSTMENT

4.43 in.

(115mm)

Caster Brake Adjust to Get 4.43 in.(115mm) Height

Adjust the caster brake ball joint under the brake pedal so that the pedal will hit its stop (floor support) just before the push rod in the master cylinder would be pulled against the cupped washer and retaining ring. Start with long adjustment and decrease by 1 turn increments of the ball joint, until pedal hits its stop.

NOTE The piston in the master cylinder must fully retract in the brake off (pedal down) position, to enable the brake fluid reservoir to replenish brake fluid supply if needed.

Crown 1995 PF-10585-6

M5.0–1435–006

Drive Brake Master Cylinder 1975-01

ILLUSTRATION 5-9

Printed in U.S.A.

M5.0–1435–006

MAINTENANCE Drive Brake Adjustment

Caster Brake Adjustment

Adjust the brake spring on the drive motor so the truck, when traveling in the forks first direction, will stop in the shortest possible distance with a minimal amount of drive tire slide.

Making the spring overall length shorter will shorten the stopping distance. If the stop is too abrupt, the overall spring length should be increased.

With the brake pedal in the "up" (brake "on") position, adjust the spring at the caster brake master cylinder to the overall length given in illustration 5-10. This spring length will typically produce the maximum braking force without sliding the caster wheels. Verify that the caster wheels do not slide during the drive brake adjustment. If caster wheel slide is experienced, this length should be increased just enough to prevent slide and subsequent flat spotting of the caster wheel.

Mounting Bracket Threaded End of Clevis

Stopping Distance Procedure Check stopping distance with the truck empty, on a level, surface typical for the application. Travel at maximum acceleration from 0 to 50 feet (15 m) in the forks first direction .

Apply the brakes and measure the stopping distance. Approximate stopping distances for smooth, dry concrete are as listed.

See Chart

TRUCK MODEL RD3520-30 RD3540-30 RR3510-35 RR3520-35 RR3510-40 RR3520-45 RR3540-45 RS3510-40 RS3520-40

OVERALL LENGTH inches (mm) 5 3/8 (137) 5 1/8 (130) 5 5/8 (143) 5 1/2 (140) 5 5/8 (143) 5 3/8 (137) 5 3/16 (132) 5 1/2 (140) 5 1/2 (140)

RD3000-30 RR3000-35 RR3000-40 RR3000-45 RS3000-40

4 1/2 - 6 1/2 feet (1.4 - 2.0 m) 4 - 6 feet (1.2 - 1.8 m) 3 1/2 - 5 1/2 feet (1.1 - 1.7 m) 4 - 6 feet (1.2 - 1.8 m) 4 - 6 feet (1.2 - 1.8 m)

CASTER BRAKE SPRING ADJUSTMENT 1965

ILLUSTRATION 5-10

Crown 1995 PF-10585-7

M5.0–1435–007

Printed in U.S.A.

M5.0–1435–007

MAINTENANCE MASTER CYLINDER REMOVAL

NOTE

1. Remove floorboard from operator compartment. Two self-locking bolts at the left side of the floorboard secure it to the power unit.

It is recommended that any maintenance performed on the master cylinders should be as a pair instead of individually.

2. Unlatch and open door. Attach a drain line to the bleeder screw of the slave cylinder on the drive brake mounting bracket or caster bleed screws. Open bleed screw approximately 1/2 turn and force out the fluid by pumping the brake pedal. Discard the fluid properly.

4. To remove the caster brake master cylinder turn adjusting nut (index 17) CCW until it is even with the end of threads on clevis assembly (index 12). Push down on pivot arm (index 1) to compress spring (index 15) and insert punch in hole of clevis assembly (index 12).

3. Disconnect all flexible lines to master cylinder (index 31). The master cylinder for the drive brake uses a double spring (index 25 & 26) on the push rod. The single spring (index 15) is used on the master cylinder for the caster brake. (Refer to Illustration 5-11)

5. Disconnect ball joint (index 2) from pivot arm assembly (index 1). Remove bolts (index 14) and (index 32) that secure master cylinder assembly to the power unit.

Remove bolt (index 9) and pull out shaft.

6. Remove master cylinder assembly from truck and take to clean work area for any further disassembly.

69 68

MOUNTED TO POWER UNIT 67

63 65

71

64 70

57

70

56

1707S-01 Crown 1995 PF-10585-8

M5.0–1435–008

ILLUSTRATION 5-11 Printed in U.S.A.

M5.0–1435–008

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 STEERING SYSTEM DIRECTION OF TRAVEL

DIRECTION OF TRAVEL

FORWARD STEERING

REVERSE STEERING 1900

ILLUSTRATION 6-10

The narrow aisle Rider Reach/Rider Straddle is equipped with a power assisted steering system. Steering in your truck is accomplished with the use of a steering handle connected to the top of a torque generator. A steering sprocket connected to the bottom of the torque generator, transfers the steering force by means of a roller chain. The roller chain is routed around the “outside” of a sprocket assembly (083333), adjusting sprocket, and the steering sprocket. The routing of the roller chain in this manner is “reverse” steering, which is standard equipment. To obtain “forward” steering, an idler sprocket assembly is added. The roller chain is routed on the “inside” of the steering sprocket and on the “outside” of the idler sprocket, adjusting sprocket, and sprocket assembly (083333). Connecting the steering assembly to the carriage assembly is a shaft assembly and a universal joint assembly.

In the carriage assembly, a pinion gear, connected to the universal joint assembly, is meshed with an idler gear located on the underside of the carriage assembly. The idler gear transfers the steering force to the drive unit through a ring gear that is mounted to the top of the drive unit.

Reverse Steering (Standard) (SEE ILLUSTRATION 6-10) By rotating the steering handle clockwise, the truck will turn to the left when traveling in the forward direction. When the steering handle is turned counterclockwise, the truck will turn to the right.

Forward Steering (Optional) By rotating the steering handle clockwise, the truck will turn to the right when traveling in the forward direction. When the steering handle is turned counterclockwise, the truck will turn to the left.

To convert your truck from “reverse” steering to “forward” steering, an idler sprocket is added to the steering bracket assembly. With a longer roller chain, the chain is routed to the “inside” of the steering sprocket, instead of the “outside” as for reverse steering. The chain is routed to “outside” of the remaining sprockets; idler, adjusting, and sprocket assembly (083333).

930222

3684NC-37094

Crown 1993 PF-9707-1

Printed in U.S.A.

M6.0 - 1430 - 001

M6.0 - 1430 - 001

MAINTENANCE Chain Adjustment (SEE ILLUSTRATION 6-11) The steering chain, located in the steering bracket assembly is to be adjusted until 1/8 in. (3 mm) to 3/16 in. (5 mm) bow (in or out) is possible on slack side of the chain. To determine amount of slack, pull one side of chain tight allowing excess chain to accumulate on slack side. Should the chain become loose, loosen the jam nut on the adjustment screw in the adjustment yoke assembly and turn the adjustment screw to obtain correct chain adjustment. Once setting is obtained tighten jam nut to lock assembly.

While making chain adjustment, check all sprockets, sprocket bearings, and roller chain for wear and lubrication.

NOTE The steering handle spinner should be positioned between 7 and 9 o’clock with the drive wheel positioned for straight travel.

Threading Diagram for Steering

ADJUSTING SPROCKET ADJUSTING STEERING SPROCKET SCREW

ADJUSTING SPROCKET ADJUSTING STEERING SPROCKET SCREW IDLER SPROCKET

JAM NUT

JAM NUT CHAIN

CHAIN

STEERING BRACKET ASSEMBLY

STEERING BRACKET ASSEMBLY

SPROCKET ASSEMBLY 083333

SPROCKET ASSEMBLY 083333

Reverse Steering

Forward Steering

1907S

Crown 1993 PF-9707-2

M6.0 - 1430 - 002

ILLUSTRATION 6-11

Printed in U.S.A.

M6.0 - 1430 - 002

MAINTENANCE

48 47

46 32 3

27

B

9

26 25

46

24

13

5 9

23

30

45

31

7

40 22

40 22 15

53 57

16

58

51

52

50 21

54

56 55

19 18

PART OF POWER UNIT 14

A A

2 20

33 36

41

35

43

16

42 49

15

33

4 16 1 15

39

38

19

36

35

3

31

9

30 3

33

33

20

44

43

34

37

12

7

29

28

59

34

9 40

8

49 B

17

3

1 PART OF POWER UNIT

1690

6

3

FOR LOAD WHEELS SEE SECTION 7.4

13

9 11 10

FOR REMOVABLE OUTRIGGER ENDS SEE SECTION 7.2

3 5

9

ILLUSTRATION 7-1 FORK ADJUSTMENTS

TORQUE REQUIREMENTS • The four 3/4 in. diameter bolts that fasten the lower portion of the power unit to the main frame base plate must be tightened to 225 - 250 ft. lbs. (305 - 340 Nm).

• The four 1/2 in. diameter bolts that fasten the upper portion of the power unit to the main frame must be tightened to 77 - 94 ft. lbs. (105 - 130 Nm).

• The four 5/8 in. diameter bolts that secure the removable load wheel assemblies to the main frame outriggers must be tightened to 165 - 185 ft. lbs. (225 - 250 Nm).

RS Trucks • With the forks completely lowered and level, adjust the forks so that the top surface of the fork tip is a maximum of 3 in. (75 mm) from the floor.

RR & RD Trucks • With the forks completely lowered and level, adjust the forks so that the top surface of the fork tip is a maximum of 2.5 in. (65 mm) from the floor.

RR, RS & RD Trucks

• The 1/2 in. nut assembled to the lift cylinder mounting stud located at the top of mast (TF and TT only) must be torqued to 50 ft. lbs. (70 Nm).

• The maximum fork height (raised) is to be within +/- 1.00 in. (+/- 25 mm) of the fork height specified on the truck data plate.

930222

4501 Printed in U.S.A.

Crown 1993 PF-9711-1 Rev. 1/95

01 REV. 1/95

M7.0–1430–001

M7.0–1430–001

MAINTENANCE MAST STAGING BUMPER REPLACEMENT (TT Only) 1. Reference Illustration 7-1.

Steps 7 thru 15 cover TT Mast 7. Remove cylinder (Cluster Cylinder, TT)

2. Prior to bumper installation (item 49), lower mast and measure any gap at the meeting of mast and mainframe.

A. Remove flow control valve with connector (Have container in position to catch oil from cylinder at this time).

3. To fill the gap determine the proper shim combination using shims 060030-266 (0.063 in. [1.6mm] thick) and/ or 060030-277 (0.031 in. [0.8mm] thick). Raise mast and assemble shims and bumper.

B. Connect hoist to top crossbrace on third stage mast; raise mast high enough to disconnect hydraulic lines and cables from the base of the third stage mast. Block mast. Disconnect the hydraulic line connecting the two center cylinders; do not disconnect at base of the single cylinder.

4. Lower mast and check to be sure all mast bumpers contact their stops at the same time. Re-adjust if necessary.

C. Remove the lift chains from the side cylinders.

5. Apply thread locking adhesive to bumper screws and torque screws to 28 - 32 in. lbs. (3.16 - 3.62 Nm).

D. Remove the nut and stud holding the cylinder cluster to the top of the third stage mast; loosen, do not remove at this time, the two 3/8 in. bolts holding the cylinder cluster at the base of the second stage.

DISASSEMBLY (REFER TO ILLUSTRATION 7-1)

E. Raise the third stage mast approximately 6 inches (13mm) and place a hardwood block below the third stage, place the block under the channel of the third stage, support the cylinder cluster while blocking the mast.

1. Unplug and remove battery.

2. Remove load backrest and forks from carriage.

3. Remove safety shield.

F. Install a forged 5/8 in.-18 eye-bolt in the top of the center cylinder cluster; connect a hoist to the eyebolt and support the cylinder in an upright position.

Remove the two 3/8 in. bolts holding the ram of the center cylinder to the bottom of the second stage.

4. Connect a hoist to the carriage assembly and raise to get slack in chains and remove yoke assemblies from side cylinders, TF or TT; remove the roller bar if TL. NOTE

G. With a pry bar positioned under the ram of the center cylinder, pry up and out at the same time. As the ram clears the base of the second stage gently lower the ram and cylinder cluster assembly. As the cylinder cluster is lowered the guides at the top of the center cylinders will disengage allowing the cylinder cluster to be moved to a clean work area if cylinder disassembly is necessary.

If your unit is equipped with a reach assembly, extend the reach when removing from the mast assembly. The reach assembly can be kept in an upright position much easier if it is extended.

Block pantograph to prevent premature retraction. If your unit is not equipped with a reach assembly, use a hardwood block under the fork plate to keep the carriage upright.

CAUTION

Be sure to avoid any damage to rams or hydraulic lines during cylinder removal.

5. Unhook chains and hydraulic lines on carriage assembly, and lower carriage to the floor.

6. Connect a hoist to the top crossbrace of the mast and raise the mast until the reach assembly or forkplate can be slid forward to clear the mast, then lower to collapsed position.

8. Connect a hoist to the top of the third stage and raise, remove hardwood block under the channel of the third stage. Remove the two retaining bolts at the bottom of the third stage mast; disconnect lift chains and hydraulic lines from the base of the third stage.

Crown 1993 PF-9711-2 Rev. 1/95

Printed in U.S.A.

01 REV. 1/95

M7.0–1430–002

M7.0–1430–002

MAINTENANCE 9. Raise the third stage until it can be pulled out of the second stage, remove column rollers and be sure at this point to record the number and position of all shims for reference at reassembly.

10. Remove column rollers from the top of the second stage, record the number and position of all shims.

11. Remove the cam follower bearing from the stud at the top of the single center cylinder.

12. Remove cylinder (Rear Single Cylinder, TT) A. Connect a cylinder clamp around the top of the cylinder below the cam bearing block; connect hoist to the cylinder clamp.

B. Support the cylinder assembly with the hoist while removing the two bolts securing the cylinder to the crossbrace of the second stage; remove the two bolts securing the ram to the base of the main frame.

C. Lift the cylinder assembly clear of the main frame and move to a clean area if cylinder disassembly is necessary.

13. Remove lift chains, hydraulic lines, and cables from the pulleys at the base of the second stage mast.

14. Connect a hoist to the top of the second stage mast and raise until the stops (Item 22) can be removed from the top of the channels in the main frame.

15. Raise the second stage mast until it can be removed from the main frame; remove the column rollers from the bottom of the second stage and the top of the main frame. (Record the number and position of all spacers when removing column rollers for reference at reassembly)

Steps 18 thru 20 Cover TF Mast 18. Remove the nut and stud connecting the top of the cylinder assembly to the second stage; attach a hoist to the top crossbrace of the second stage and raise enough to place a 8 in. (200 mm) (Approx.) hardwood block under the second stage.

19. Install a forged eye-bolt, 5/8 in.-18, to the top of the cylinder assembly; attach hoist to eye-bolt and support the cylinder while the two 3/8 in. bolts are removed from the bottom of ram.

20. Lift the cylinder assembly clear of the mast assembly and move to a clean work area if further disassembly is necessary.

NOTE To remove second stage mast from main frame see step 15.

NOTE Cylinder removal is not a recommended practice, “most” repairs can be accomplished with the cylinder assembly remaining in the truck.

If the amount of room overhead will not allow the masts to be raised enough for removal, the mast assembly will need to be unbolted from the power unit and laid down. The following procedure should be followed if removal from the power unit is necessary; 1. Remove battery, flow control valve with connector.

2. Remove load backrest, forks, and carriage assembly.

3. Remove safety shield and overhead guard.

Steps 16 and 17 Cover TL Mast 16. Attach cylinder clamp near the top of the cylinder assembly, attach hoist to the clamp and support the cylinder assembly while the nut is removed from the stud assembly at the top of the second stage.

17. Remove the two 3/8 in. bolts securing the ram to the base of the main frame; lift the cylinder assembly and remove to a clean work area if further disassembly is required.

4. Disconnect cables and hydraulic lines from power unit to mast assembly.

5. Raise the rear of the truck enough to get a 4x4x36 in.

(100x100x900 mm) hardwood block under the base plate of the power unit and the base plate of the mast assembly. This block should carry the weight of power unit and the mast assembly when the mounting bolts are removed. The block is positioned parallel with the base plates.

NOTE To remove second stage mast from main frame see step 15.

Crown 1993 PF-9711-3

M7.0 - 1430 - 003

Printed in U.S.A.

M7.0 - 1430 - 003

MAINTENANCE 6. Loosen the four bolts at the base plate; remove the four bolts, two on the left - two on the right, at the top of the power unit. The weight of the power unit and mast assembly should be solid on the hardwood block at this point.

REASSEMBLY (REFER TO ILLUSTRATION 7-1) (MAINFRAME UPRIGHT AND MOUNTED TO POWER UNIT)

7. Remove the four bolts across the base of the power unit.

NOTE Before reassembly, refer to torque requirements, fork adjustments and mast staging bumper replacement located on the first page of this section.

8. Attach a hoist to the top of the main frame; raise just enough to take weight off the block; roll the mast assembly away from the power unit.

CAUTION

9. Move the mast assembly to an area large enough to allow the mast to be laid down and the second stage mast extended fully.

10. Lower the mast assembly, with outriggers up, very carefully. Keep the hoist directly over the top of the main frame while lowering to prevent the base plate from sliding on the floor.

11. Refer to disassembly procedure in this section at this time if further disassembly is required.

NOTE With the mast assembly laid down, the cylinder and mast assemblies must be removed by making all hook ups with hoist as near the center of the assembly as possible to maintain balance.

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

1. Clean both column roller studs at the top of the mainframe. If any paint or rust is evident on the studs, remove with emery cloth and grease with multi-purpose grease (Crown No. 63002-007).

2. Arbitrarily place one shim on each stud and install column rollers. With the use of an inside caliper (SEE ILLUSTRATION 7-2), measure between the two rollers.

OUTSIDE CALIPER

INSIDE CALIPER 1908S

ILLUSTRATION 7-2 NOTE The column roller studs are canted, so be certain to take the measurement on the correct portion of the roller (narrowest dimension possible).

Crown 1993 PF-9711-4

M7.0 - 1430 - 004

Printed in U.S.A.

M7.0 - 1430 - 004

MAINTENANCE

3. Measure the outside of the second stage mast, along the area where the first stage column rollers will travel, with an outside caliper (SEE ILLUSTRATION 7-2).

4. After finding the widest contact point, lock the thumb screws and place the inside and outside calipers together and determine the amount of shim to be added to (or removed from) the column rollers. When shimming column rollers, try to balance out the number of shims (Example: 2 shims right, 2 shims left). If an uneven number of shims are required, note the side to which the extra shim was added and install all other odd shims to that side.

5. Follow the above procedure for measuring the second stage, lower column rollers and the inside of the first stage channels at the rollers contact point. After measurements, shim accordingly.

Steps 10 thru 25 are for TT Models Only 10. Attach a cylinder clamp to the top of the single center cylinder just below the cam bearing mounting block; position cylinder in mast and bolt ram to bottom of main frame with two 3/8 in. bolts.

NOTE Be sure bottom rest is positioned correctly under ram.

THIS HYDRAULIC SYSTEM IS USED ONLY ON "TT" MAST ASSEMBLY TO CARRIAGE HYDRAULICS

USED ONLY ON TT MAST ASSEMBLY. 6 3

A

9

3

A

6. Connect a hoist to the top crossbrace of the second stage mast; raise the second stage until it will engage the main frame at the top. Lower the second stage into the main frame and check running clearance.

POWER UNIT 12 2

9

7 8

4

10 2

7 11 10

NOTE

5

When the column rollers are properly adjusted, they should leave a slight paint scrape on the inside rails of the first stage mast and the outside rails of the second stage.

7. Apply a small amount of multi-purpose grease to the contact areas of the masts.

8. Attach lift chains to the top of the main frame(TT only); bolt bumpers to the base of the main frame.

9. Bolt bumpers to the bottom of the second stage (TT only); raise the second stage mast until the internal stops can be installed through the second stage eyebeam and bolted to the main frame.

1

A

FO

RK

S

1

A

11

TO POWER UNIT HYDRAULICS

1705S

ILLUSTRATION 7-3 11. Bolt flange on the cylinder tube to crossbrace at bottom of second stage; disconnect cylinder clamp.

12. Measure the area of the second stage where the column rollers on the third stage will travel with an inside caliper.

13. Prepare the third stage mast in the same manner as the second stage; (See steps 1 thru 7 for installing third stage into second stage mast assembly). Install retaining bolts (item 44) at base of third stage.

14. Plumb hydraulic fitting, (item 7) hydraulic tube assembly, (item 8) and hydraulic hose assembly, (item 9) to the ram of the center cylinder in the cylinder cluster.

(SEE ILLUSTRATION 7-3) 15. Install cam follower bearings to the top of the single center cylinder. (SEE ILLUSTRATION 7-1 ITEMS 46 AND 47)

Crown 1993 PF-9711-5

M7.0 - 1430 - 005

Printed in U.S.A.

M7.0 - 1430 - 005

MAINTENANCE position.

16. Block the third stage mast 6 to 8 in. (150 to 200 mm) above the second stage with a hardwood block, 2x4x8 in. (50x100x200 mm) approximate size. Place hardwood block under channel of third stage.

17. Install a 5/8 in.-18 forged eye-bolt in the top of the center cylinder cluster, connect to hoist and raise cylinder cluster to a vertical position.

18. Engage the cam follower bearings at the top of the single center cylinder with the support channel at the rear of the main cylinder of the cluster assembly; the channel must engage the bearings from the bottom.

Pull the bottom of the cylinder cluster away from the base of the mast to get the channel low enough to engage the bearings from the bottom.

19. Guide the cylinder cluster, while raising, and bring the ram of the center cylinder into position at the base of the second stage; position the button rest under the ram and with two 3/8 in. bolts, bolt ram loosely to second stage.

20. Lower cylinder cluster and align the hydraulic line from the ram of center cylinder in the cluster; connection of the hydraulic line to the single main cylinder will be made later, (See step 24).

21. Remove the eye-bolt in top of cylinder cluster; attach hoist to the top crossbrace of the third stage; raise third stage and remove hardwood block.

22. Lower third stage mast and guide the roll pin in top of center cylinder into the hole in the mounting bracket on third stage; assemble the cylinder cluster assembly to the top of third stage with a stud and nut. Thread locking adhesive should be applied to the stud at assembly.

Tighten the two 3/8 in. bolts at the bottom of the cylinder cluster.

23. Connect hoist to top of both the second and third stage, raise until the pulley assemblies, (ITEM 34 AND 38, ILLUSTRATION 7-1) can be installed near the base of the second stage; route the lift chains from top of main frame through pulleys and connect to third stage; route the hydraulic lines (ITEM 3, ILLUSTRATION 7-3) through pulleys and connect to bulkheads on third stage.

24. Connect the hydraulic line from front center cylinder ram to rear cylinder tube.

25. Lower the second and third stage masts to collapsed Crown 1993 PF-9711-6

M7.0 - 1430 - 006

26. Attach lift chains to the two side cylinders; an access hole is provided through the battery compartment wall.

(TF and TT Models only) 27. Connect hoist to the top crossbrace of third stage; raise mast and connect hydraulic lines to bulkheads near base of third stage; lower third stage mast to its home position. (TT Models only) 28. Install yoke assemblies on rams of both side cylinders; route lift chains, hydraulic lines, and cable through yokes. (TF and TT Models only) 29. Prepare carriage assembly in the same manner as used to install a mast. (See steps 1 thru 4) 30. Connect hoist to top crossbrace of second stage (TF, TL) or third stage (TT), and raise mast. Position carriage assembly beneath the mast assembly; lower mast and guide the column rollers on carriage into mast assembly.

31. Connect the hoist to the carriage assembly; raise carriage assembly in mast assembly; remove the yoke assemblies from the side cylinders (TF, TT, only), lay the yokes on top of power unit, continue to raise carriage until the lift chains, hydraulic lines, and cables can be connected to the carriage assembly.

32. Lower carriage assembly and replace yoke assemblies on side cylinders (TF, TT only).

If the amount of room overhead will not allow the masts to be raised enough for assembly into the mainframe, lay the mainframe down. The preceding reassembly procedure can be used as such. Hook-ups should be made at the center of the mast and cylinder assemblies for balance.

When bolting the mainframe to power unit refer to disassembly procedure in this section and reverse the steps.

33. Install flow control valve with connector; connect all hydraulic lines and cables to power unit from mast assembly.

34. Bolt on overhead guard, install safety shield.

35. Secure forks and load backrest on carriage assembly.

36. Place battery in compartment and run operational check.

CAUTION

Be sure all stops and safety devices are in place before cycling mast to check for proper operation.

Printed in U.S.A.

M7.0 - 1430 - 006

MAINTENANCE 48

46

32 3

27

B

9

26 25

13

24

5

3 9

23

30

31

45

61 60

7

40

47

22

40 22 15

53 57

16

58

29

28

51

52

59

54

56 55

19

PART OF POWER UNIT 14

A A

2 20

33 36

41

35

43

16

42 49

15

33

4 16 1 15

39

38

19

36

35

3

31

9

30 3

33

33

20

44

43

34

37

12

7

61

50 21

18

6

34

9 40

8

49 B

17

3

1 PART OF POWER UNIT

1690-02

FOR LOAD WHEELS SEE SECTION 7.4

13

9 11 10

FOR REMOVABLE OUTRIGGER ENDS SEE SECTION 7.2

3 5

9

ILLUSTRATION 7-1

TORQUE REQUIREMENTS • The four 3/4 in. diameter bolts that fasten the lower portion of the power unit to the main frame base plate must be tightened to 225 - 250 ft. lbs. (305 - 340 Nm).

• The four 1/2 in. diameter bolts that fasten the upper portion of the power unit to the main frame must be tightened to 77 - 94 ft. lbs. (105 - 130 Nm).

• The four 5/8 in. diameter bolts that secure the removable load wheel assemblies to the main frame outriggers must be tightened to 165 - 185 ft. lbs. (225 - 250 Nm).

FORK ADJUSTMENTS RS Trucks • With the forks completely lowered and level, adjust the forks so that the top surface of the fork tip is a maximum of 3 in. (75 mm) from the floor.

RR & RD Trucks • With the forks completely lowered and level, adjust the forks so that the top surface of the fork tip is a maximum of 2.5 in. (65 mm) from the floor.

RR, RS & RD Trucks

• The 1/2 in. nut assembled to the lift cylinder mounting stud located at the top of mast (TF and TT only) must be torqued to 50 ft. lbs. (70 Nm).

• The maximum fork height (raised) is to be within +/- 1.00 in. (+/- 25 mm) of the fork height specified on the truck data plate.

950619

4549AJ - 40721

Crown 1995 PF-10581-1

Printed in U.S.A.

M7.0–1435–001

M7.0–1435–001

MAINTENANCE MAST STAGING BUMPER REPLACEMENT (TT Only) 1. Reference Illustration 7-1.

Steps 7 thru 15 cover TT Mast 7. Remove cylinder (Cluster Cylinder, TT)

2. Prior to bumper installation (item 49), lower mast and measure any gap at the meeting of mast and mainframe.

A. Remove flow control valve with connector (Have container in position to catch oil from cylinder at this time).

3. To fill the gap determine the proper shim combination using shims 060030-266 (0.063 in. [1.6mm] thick) and/ or 060030-277 (0.031 in. [0.8mm] thick). Raise mast and assemble shims and bumper.

B. Connect hoist to top crossbrace on third stage mast; raise mast high enough to disconnect hydraulic lines and cables from the base of the third stage mast. Block mast. Disconnect the hydraulic line connecting the two center cylinders; do not disconnect at base of the single cylinder.

4. Lower mast and check to be sure all mast bumpers contact their stops at the same time. Re-adjust if necessary.

5. Apply thread locking adhesive to bumper screws and torque screws to 28 - 32 in. lbs. (3.16 - 3.62 Nm).

DISASSEMBLY (REFER TO ILLUSTRATION 7-1) 1. Unplug and remove battery.

2. Remove load backrest and forks from carriage.

3. Remove safety shield.

4. Connect a hoist to the carriage assembly and raise to get slack in chains and remove yoke assemblies from side cylinders, TF or TT; remove the roller bar if TL. NOTE If your unit is equipped with a reach assembly, extend the reach when removing from the mast assembly. The reach assembly can be kept in an upright position much easier if it is extended.

Block pantograph to prevent premature retraction. If your unit is not equipped with a reach assembly, use a hardwood block under the fork plate to keep the carriage upright.

5. Unhook chains and hydraulic lines on carriage assembly, and lower carriage to the floor.

6. Connect a hoist to the top crossbrace of the mast and raise the mast until the reach assembly or forkplate can be slid forward to clear the mast, then lower to collapsed position.

Crown 1995 PF-10581-2

M7.0–1435–002

C. Remove the lift chains from the side cylinders.

D. Remove the nut and stud holding the cylinder cluster to the top of the third stage mast; loosen, do not remove at this time, the two 3/8 in. bolts holding the cylinder cluster at the base of the second stage.

E. Raise the third stage mast approximately 6 inches (13mm) and place a hardwood block below the third stage, place the block under the channel of the third stage, support the cylinder cluster while blocking the mast.

F. Install a forged 5/8 in.-18 eye-bolt in the top of the center cylinder cluster; connect a hoist to the eyebolt and support the cylinder in an upright position.

Remove the two 3/8 in. bolts holding the ram of the center cylinder to the bottom of the second stage.

G. With a pry bar positioned under the ram of the center cylinder, pry up and out at the same time. As the ram clears the base of the second stage gently lower the ram and cylinder cluster assembly. As the cylinder cluster is lowered the guides at the top of the center cylinders will disengage allowing the cylinder cluster to be moved to a clean work area if cylinder disassembly is necessary.

CAUTION

Be sure to avoid any damage to rams or hydraulic lines during cylinder removal.

8. Connect a hoist to the top of the third stage and raise, remove hardwood block under the channel of the third stage. Remove the two retaining bolts at the bottom of the third stage mast; disconnect lift chains and hydraulic lines from the base of the third stage.

Printed in U.S.A.

M7.0–1435–002

MAINTENANCE 9. Raise the third stage until it can be pulled out of the second stage, remove column rollers and be sure at this point to record the number and position of all shims for reference at reassembly.

10. Remove column rollers from the top of the second stage, record the number and position of all shims.

11. Remove the cylinder wear pad from the mounting block at the top of the single center cylinder.

12. Remove cylinder (Rear Single Cylinder, TT) A. Connect a cylinder clamp around the top of the cylinder below the cam bearing block; connect hoist to the cylinder clamp.

B. Support the cylinder assembly with the hoist while removing the two bolts securing the cylinder to the crossbrace of the second stage; remove the two bolts securing the ram to the base of the main frame.

C. Lift the cylinder assembly clear of the main frame and move to a clean area if cylinder disassembly is necessary.

13. Remove lift chains, hydraulic lines, and cables from the pulleys at the base of the second stage mast.

14. Connect a hoist to the top of the second stage mast and raise until the stops (Item 22) can be removed from the top of the channels in the main frame.

15. Raise the second stage mast until it can be removed from the main frame; remove the column rollers from the bottom of the second stage and the top of the main frame. (Record the number and position of all spacers when removing column rollers for reference at reassembly)

Steps 18 thru 20 Cover TF Mast 18. Remove the nut and stud connecting the top of the cylinder assembly to the second stage; attach a hoist to the top crossbrace of the second stage and raise enough to place a 8 in. (200 mm) (Approx.) hardwood block under the second stage.

19. Install a forged eye-bolt, 5/8 in.-18, to the top of the cylinder assembly; attach hoist to eye-bolt and support the cylinder while the two 3/8 in. bolts are removed from the bottom of ram.

20. Lift the cylinder assembly clear of the mast assembly and move to a clean work area if further disassembly is necessary.

NOTE To remove second stage mast from main frame see step 15.

NOTE Cylinder removal is not a recommended practice, “most” repairs can be accomplished with the cylinder assembly remaining in the truck.

If the amount of room overhead will not allow the masts to be raised enough for removal, the mast assembly will need to be unbolted from the power unit and laid down. The following procedure should be followed if removal from the power unit is necessary; 1. Remove battery, flow control valve with connector.

2. Remove load backrest, forks, and carriage assembly.

3. Remove safety shield and overhead guard.

Steps 16 and 17 Cover TL Mast 16. Attach cylinder clamp near the top of the cylinder assembly, attach hoist to the clamp and support the cylinder assembly while the nut is removed from the stud assembly at the top of the second stage.

17. Remove the two 3/8 in. bolts securing the ram to the base of the main frame; lift the cylinder assembly and remove to a clean work area if further disassembly is required.

4. Disconnect cables and hydraulic lines from power unit to mast assembly.

5. Raise the rear of the truck enough to get a 4x4x36 in.

(100x100x900 mm) hardwood block under the base plate of the power unit and the base plate of the mast assembly. This block should carry the weight of power unit and the mast assembly when the mounting bolts are removed. The block is positioned parallel with the base plates.

NOTE To remove second stage mast from main frame see step 15.

Crown 1995 PF-10581-3

M7.0–1435–003

Printed in U.S.A.

M7.0–1435–003

MAINTENANCE 6. Loosen the four bolts at the base plate; remove the four bolts, two on the left - two on the right, at the top of the power unit. The weight of the power unit and mast assembly should be solid on the hardwood block at this point.

REASSEMBLY (REFER TO ILLUSTRATION 7-1) (MAINFRAME UPRIGHT AND MOUNTED TO POWER UNIT)

7. Remove the four bolts across the base of the power unit.

NOTE Before reassembly, refer to torque requirements, fork adjustments and mast staging bumper replacement located on the first page of this section.

8. Attach a hoist to the top of the main frame; raise just enough to take weight off the block; roll the mast assembly away from the power unit.

CAUTION

9. Move the mast assembly to an area large enough to allow the mast to be laid down and the second stage mast extended fully.

10. Lower the mast assembly, with outriggers up, very carefully. Keep the hoist directly over the top of the main frame while lowering to prevent the base plate from sliding on the floor.

11. Refer to disassembly procedure in this section at this time if further disassembly is required.

NOTE With the mast assembly laid down, the cylinder and mast assemblies must be removed by making all hook ups with hoist as near the center of the assembly as possible to maintain balance.

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

1. Clean both column roller studs at the top of the mainframe. If any paint or rust is evident on the studs, remove with emery cloth and grease with multi-purpose grease (Crown No. 63002-007).

2. Arbitrarily place one shim on each stud and install column rollers. With the use of an inside caliper (SEE ILLUSTRATION 7-2), measure between the two rollers.

OUTSIDE CALIPER

INSIDE CALIPER 1908S

ILLUSTRATION 7-2 NOTE The column roller studs are canted, so be certain to take the measurement on the correct portion of the roller (narrowest dimension possible).

Crown 1995 PF-10581-4

M7.0–1435–004

Printed in U.S.A.

M7.0–1435–004

MAINTENANCE 3. Measure the outside of the second stage mast, along the area where the first stage column rollers will travel, with an outside caliper (SEE ILLUSTRATION 7-2).

4. After finding the widest contact point, lock the thumb screws and place the inside and outside calipers together and determine the amount of shim to be added to (or removed from) the column rollers. When shimming column rollers, try to balance out the number of shims (Example: 2 shims right, 2 shims left). If an uneven number of shims are required, note the side to which the extra shim was added and install all other odd shims to that side.

Steps 10 thru 25 are for TT Models Only 10. Attach a cylinder clamp to the top of the single center cylinder just below the cylinder wear pad mounting block; position cylinder in mast and bolt ram to bottom of main frame with two 3/8 in. bolts.

NOTE Be sure bottom rest is positioned correctly under ram.

To Carriage Hydraulics

5. Follow the above procedure for measuring the second stage, lower column rollers and the inside of the first stage channels at the rollers contact point. After measurements, shim accordingly.

6. Connect a hoist to the top crossbrace of the second stage mast; raise the second stage until it will engage the main frame at the top. Lower the second stage into the main frame and check running clearance.

6 3

A 9

A

3

12 2

9 7

10

4 2

7

NOTE

11

8 5

10

A 1

11

When the column rollers are properly adjusted, they should leave a slight paint scrape on the inside rails of the first stage mast and the outside rails of the second stage.

7. Apply a small amount of multi-purpose grease to the contact areas of the masts.

8. Attach lift chains to the top of the main frame(TT only); bolt bumpers to the base of the main frame.

9. Bolt bumpers to the bottom of the second stage (TT only); raise the second stage mast until the internal stops can be installed through the second stage eyebeam and bolted to the main frame.

Part of Power Unit A

1

FO

RK

S

1705-01

To Power Unit Hydraulics

ILLUSTRATION 7-3

11. Bolt flange on the cylinder tube to crossbrace at bottom of second stage; disconnect cylinder clamp.

12. Measure the area of the second stage where the column rollers on the third stage will travel with an inside caliper.

13. Prepare the third stage mast in the same manner as the second stage; (See steps 1 thru 7 for installing third stage into second stage mast assembly). Install retaining bolts (item 44) at base of third stage.

14. Plumb hydraulic fitting, (item 7) hydraulic tube assembly, (item 8) and hydraulic hose assembly, (item 9) to the ram of the center cylinder in the cylinder cluster.

(SEE ILLUSTRATION 7-3) 15. Install cylinder wear pad to the top of the single center cylinder. (SEE ILLUSTRATION 7-1 ITEM 46)

Crown 1995 PF-10581-5

M7.0–1435–005

Printed in U.S.A.

M7.0–1435–005

MAINTENANCE 16. Block the third stage mast 6 to 8 in. (150 to 200 mm) above the second stage with a hardwood block, 2x4x8 in. (50x100x200 mm) approximate size. Place hardwood block under channel of third stage.

27. Connect hoist to the top crossbrace of third stage; raise mast and connect hydraulic lines to bulkheads near base of third stage; lower third stage mast to its home position. (TT Models only)

17. Install a 5/8 in.-18 forged eye-bolt in the top of the center cylinder cluster, connect to hoist and raise cylinder cluster to a vertical position.

28. Install yoke assemblies on rams of both side cylinders; route lift chains, hydraulic lines, and cable through yokes. (TF and TT Models only)

18. Engage the cylinder wear pad at the top of the single center cylinder with the support channel at the rear of the main cylinder of the cluster assembly.

29. Prepare carriage assembly in the same manner as used to install a mast. (See steps 1 thru 4)

19. Guide the cylinder cluster, while raising, and bring the ram of the center cylinder into position at the base of the second stage; position the button rest under the ram and with two 3/8 in. bolts, bolt ram loosely to second stage.

20. Lower cylinder cluster and align the hydraulic line from the ram of center cylinder in the cluster; connection of the hydraulic line to the single main cylinder will be made later, (See step 24).

21. Remove the eye-bolt in top of cylinder cluster; attach hoist to the top crossbrace of the third stage; raise third stage and remove hardwood block.

22. Lower third stage mast and guide the roll pin in top of center cylinder into the hole in the mounting bracket on third stage; assemble the cylinder cluster assembly to the top of third stage with a stud and nut. Thread locking adhesive should be applied to the stud at assembly.

Tighten the two 3/8 in. bolts at the bottom of the cylinder cluster.

23. Connect hoist to top of both the second and third stage, raise until the pulley assemblies, (ITEM 34 AND 38, ILLUSTRATION 7-1) can be installed near the base of the second stage; route the lift chains from top of main frame through pulleys and connect to third stage; route the hydraulic lines (ITEM 3, ILLUSTRATION 7-3) through pulleys and connect to bulkheads on third stage.

24. Connect the hydraulic line from front center cylinder ram to rear cylinder tube.

25. Lower the second and third stage masts to collapsed position.

30. Connect hoist to top crossbrace of second stage (TF, TL) or third stage (TT), and raise mast. Position carriage assembly beneath the mast assembly; lower mast and guide the column rollers on carriage into mast assembly.

31. Connect the hoist to the carriage assembly; raise carriage assembly in mast assembly; remove the yoke assemblies from the side cylinders (TF, TT, only), lay the yokes on top of power unit, continue to raise carriage until the lift chains, hydraulic lines, and cables can be connected to the carriage assembly.

32. Lower carriage assembly and replace yoke assemblies on side cylinders (TF, TT only).

If the amount of room overhead will not allow the masts to be raised enough for assembly into the mainframe, lay the mainframe down. The preceding reassembly procedure can be used as such. Hook-ups should be made at the center of the mast and cylinder assemblies for balance.

When bolting the mainframe to power unit refer to disassembly procedure in this section and reverse the steps.

33. Install flow control valve with connector; connect all hydraulic lines and cables to power unit from mast assembly.

34. Bolt on overhead guard, install safety shield.

35. Secure forks and load backrest on carriage assembly.

36. Place battery in compartment and run operational check.

CAUTION

Be sure all stops and safety devices are in place before cycling mast to check for proper operation.

26. Attach lift chains to the two side cylinders; an access hole is provided through the battery compartment wall.

(TF and TT Models only) Crown 1995 PF-10581-6

M7.0–1435–006

Printed in U.S.A.

M7.0–1435–006

LIFTING MECHANISM Lift Chain

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

WARNING Falling loads can cause injury.

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

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

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

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

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

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

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

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

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

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

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

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

Crown 2020 PF5856 Rev. 2/20

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

147

LIFTING MECHANISM Lift Chain

1

1

Fig. 1 (33490)

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

Checking the lift chains for wear

Fig. 2 (33491)

Special tools and equipment:

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

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

Measuring the lift chains for wear with a chain wear scale

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

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

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

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

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

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

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

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

148

Crown 2020 PF5856 Rev. 2/20

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

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

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

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

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

Note: The pitch is the distance between the pins.

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

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

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

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

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

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

Fig. 3 (33492)

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

Lift Chain Wear Pitch

Chain Links

mm

in

25.4

1.0

19.05

New Length

Wear Limit

mm

in

mm

in

12

305

12.0

314

12.375

0.75

16

305

12.0

314

12.375

15.88 0.625

20

318

12.5

327

12.875

Crown 2020 PF5856 Rev. 2/20

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

149

LIFTING MECHANISM Lift Chain Checking the lift chains for damage Lift Chain Inspection Damage Example

Damage and Symptom Noise •

•

Mild squeaking or loud creaking during opera- • tion

Joint corrosion •

Cause

•

Red or brown color (1) • in the joint area

1

Surface corrosion •

2

Red or brown color (2) on the connecting plates

•

Insufficient lubrication in the lift chain joints

Solution 1. Check the lift chain elongation.

When the lift chain goes • over the pulley the movement in the joints causes friction.

If the lift chain is within the tolerance level, clean and lubricate the lift chain.

•

If the lift chain elongation is out of the tolerance level, replace the lift chain.

Insufficient lubrication

1. Replace the lift chain.

Grease or oils that do not 2. Lubricate the lift chain. go into the joint 3. Increase the frequency of the planned maintenance intervals.

Insufficient lubrication or anti-corrosion

1. Remove the corrosion from the lift chain with the correct cleaning agent.

•

If it is not possible to remove the corrosion, replace the lift chain.

2. Check the lift chain for pitting and other corrosion.

•

If other pitting is found or corrosion, replace the lift chain.

3. Increased frequency for planned maintenance intervals is necessary because of the conditions in the operating environment.

Images and technical information provided with the permission of Rexnord Kette GmbH • www.rexnord.com Figures 28009, 28010, 28011, 28012, 28013, 28014, 28015, 28016, 28017, 28018, 28019, and 28020 are used in this table.

M7.5-18.0-004 10 Rev. 2/20

150

Crown 2020 PF5856 Rev. 2/20

LIFTING MECHANISM Lift Chain Lift Chain Inspection Damage Example

Damage and Symptom Rigid joints •

3

4

•

Cause

Solution

Insufficient lubrication

1. Replace the lift chain.

The lift chain joints do not return to the extended position easily.

2. Increase the frequency of the planned maintenance intervals.

Turned lift chain pins

•

•

Note: Turned chain pins are 2. Increase the frequency a result of rigid joints. of the planned maintenance intervals.

One or more chain pins (4) turned.

Loose lift chain pins •

5

•

The lift chain is not aligned correctly and is operating against mast sections or at the side of the pulley.

•

The lift chains tension is not equal.

The outer plates (6) are worn down.

6

Nicks or distortion •

Insufficient lubrication

1. Replace the lift chain.

1. Replace the lift chain.

One or more chain Note: Loose chain pins are a 2. Increase the frequency pins (5) are protruding. result of rigid joints. of the planned maintenance intervals.

Too much outer wear •

•

Insufficient lubrication

Parts of the lift chain have nicks (7) or are distorted.

•

1. Measure the width of the wear zone and calculate the percentage of wear in relation to the overall width of the plate.

•

If the wear is greater than or equal to 5% of the full width, replace the lift chain. Correct the alignment of the lift components and pulleys after replacing.

•

If the wear is less than 5% of the full width, correct the alignment of the lift components and the pulleys.

The lift chain hits against 1. Remove the cause of parts of the mast. the nicks or distortion.

2. Replace the lift chain.

7 Images and technical information provided with the permission of Rexnord Kette GmbH • www.rexnord.com Figures 28009, 28010, 28011, 28012, 28013, 28014, 28015, 28016, 28017, 28018, 28019, and 28020 are used in this table.

Crown 2020 PF5856 Rev. 2/20

M7.5-18.0-005 10 Rev. 2/20

151

LIFTING MECHANISM Lift Chain Lift Chain Inspection Damage Example

Damage and Symptom Broken plates •

8

9

•

The head section of the plate is missing or • the crack is protruding.

Broken pins •

Cause

•

The outer plate (9) is lifted out a small distance

Solution

Fatigue crack because of 1. Find and correct the overload cause of the overload.

Corrosion

2. Replace the lift chain.

Pitting on the pins because of corrosion. Pitting permanently damages the pin.

1. Replace the lift chain.

1. Clean the lift chain and check for damage.

2. Increase the frequency of the planned maintenance intervals.

Note: These defects are not easy to see in the initial stages of inspection.

10

Contamination

•

Incorrect lubricant used.

•

•

The lift chain was not cleaned before lubrication.

A thick layer of dirt mixed with oil or grease (10) is on the lift chain.

•

If the lift chain is not damaged, lubricate it with the correct lubricant.

•

Replace the lift chain if it is damaged.

2. Increase the frequency of the planned maintenance intervals.

11

Hydrogen absorption

•

•

2.

Note: Electrolysis always makes hydrogen. Solvents made with chlorine also emit 3. hydrogen.

Non-distorting brittle fracture (11), only on the outer plate

Lift chain elongation •

•

The lift chain came into contact with hydrogen.

Wear caused by movement in the joints.

1. Replace the lift chain.

Check the operating conditions for sources of hydrogen.

See the cleaning the lift chains for instructions.

1. Replace the lift chain.

The lift chain elongaNote: Check if increasing tion check found the lift Note: This type of wear is the frequency of the chain to be out of the typical. planned maintenance intertolerance level. vals can increase the life of the lift chain.

Images and technical information provided with the permission of Rexnord Kette GmbH • www.rexnord.com Figures 28009, 28010, 28011, 28012, 28013, 28014, 28015, 28016, 28017, 28018, 28019, and 28020 are used in this table.

M7.5-18.0-006 10 Rev. 2/20

152

Crown 2020 PF5856 Rev. 2/20

LIFTING MECHANISM Lift Chain Replacing the lift chain 1. Find the part number for the lift chain in the service and parts manual. Make sure that the replacement lift chain is applicable to the lift truck.

Note: The lift chains must be replaced as a pair. Equal lift chain tension cannot easily be kept between the new lift chain and the existing lift chain.

2. If the lubricant dried or there is no lubricant, soak the new lift chains in heavy engine oil for a minimum of 30 min before installing.

3. After removing the existing lift chains from the mast, carefully examine the chain anchors and pulleys.

1. Use the grinding wheel to remove the top head of the pin (4) flush with the pin link plate (1). Be careful not to damage the pin link plate.

2. Put the flat washer (2) above the opening of the work surface.

– The flat washer holds the bottom pin link plate (1) and prevents damage to the lift chain components while pushing the pin through the lift chain.

3. Put the lift chain on its side and seat the pin in the flat washer (2).

4. Remove the pin from the lift chain through the top pin link plate (1).

4. Replace the chain anchors that are broken, cracked, or are worn.

3

5. Replace the pulleys that are worn and examine the pulley bearings for wear.

4

1

6. Do not paint the new lift chains.

7. Install the new lift chains with new pins. Do not use the existing pins.

8. After connecting the new lift chains to the chain anchors, adjust the lift chain tension for the correct fork or platform height.

– The correct lift chain installation and mast adjustment increase the service life.

Disconnecting a chain leaf

2 Fig. 4 (33505)

See Figure 4.

Special tools and equipment: – A stable work surface with an opening that is larger than the pin diameter. The work surface must be of sufficient thickness to let the pin (4) extend below the work surface to push it through the pin link plate (1) on the bottom.

– A flat washer (2) with an inside diameter more than the pin diameter and a height that is equal to the head height of the pin.

– A grinding wheel (3).

– A punch with a diameter that is less than the pin diameter.

– A hammer or press.

Crown 2020 PF5856 Rev. 2/20

M7.5-18.0-007 10 Rev. 2/20

153

Notes:

154

LIFTING MECHANISM Fork Inspection

Fork Inspection

WARNING If the fork locking pin is not fully engaged, the fork could become unintentionally disengaged.

DANGER This section shows causes of fork failure. Fork failure causes loss of equipment, damaged materials, bodily injury, and loss of life. Inspect and measure the forks at each planned maintenance interval to check for wear, overload, fatigue, bends, and so on.

WARNING

Abrasion See Figure 1.

Abrasion gradually reduces the thickness of the fork.

Make sure that the fork thickness is within the specifications. Do not allow the forks to rub against the floor during operation. If the forks rub the floor when the mast is vertical, then check the lift chain adjustment.

 Use the proper fork for how it was designed to be used.  Avoid using fork extensions.  Do not modify the forks.  Only qualified personnel can make repairs.  Visually inspect the forks each work day.

(a)

100 90 80 70 60 (b)

50 40 30 20 10 0

0

10

20

30

40

50

60

70

80

90

100

(c)

Fig. 1 (16858-02) (a)

Fork wear versus load capacity

(b)

Percentage remaining of specified fork load capacity

Fork wear at the fork heel must not exceed 10% of the original thickness. When the fork heel has worn 10% of the original thickness, 80% of rated capacity is the Crown 1988 PF7393 Rev. 10/21

(c)

Percentage reduction in fork blade thickness

maximum load that the forks can support. The rated capacity of the fork decreases exponentially as the fork wears. Use the fork wear calipers, a measuring instruM7.8-04.2-001 07 Rev. 10/21

329

LIFTING MECHANISM Fork Inspection

ment such as a vernier, or a quality 160 mm (6.0 in) scale. For allowable fork wear thickness, see the Allowable Fork Wear table.

2

Allowable Fork Wear Standard Fork Thickness

1

Allowable 10% Wear Fork Thickness

mm

in

mm

in

31.5

1.25

28.5

1.12

38.0

1.50

35.0

1.38

44.5

1.75

39.5

1.56

51.0

2.00

46.0

1.81

57.0

2.25

51.0

2.00

63.5

2.50

57.0

2.25

3

Fig. 3 (16855-02)

1. See Figure 4. To set the outside jaws, hold the calipers square across the shank and measure the thickness of the middle of the shank (1).

Measuring fork wear with the fork wear calipers Special tools and equipment: • Fork wear calipers, P/N 107330 See Figure 2. The fork wear calipers have two measuring points or jaws. The inside jaws (2) measure 10% less than the outside jaws (1).

1 Fig. 4 (16856-02)

1

2

2. See Figure 5. Check if the inside jaws of the calipers pass over the flanks of the fork blade at any point between the end of the taper and the heel of the fork blade (1).

Fig. 2 (16854-02)

See Figure 3. The fork wear calipers are used to measure the area (3) on the shank (2) to measure the fork blade (1). This area (3) on the shank (2) receives almost no wear.

1 Fig. 5 (16857-02)

3. Check the caliper setting again by measuring the shank. Make sure that the caliper setting did not change.

M7.8-04.2-002 07 Rev. 10/21

330

Crown 1988 PF7393 Rev. 10/21

LIFTING MECHANISM Fork Inspection

Overloading WARNING 1

Fork damage.

Overloading can cause permanent damage to the forks.  Know the load capacity of the forks and lift truck.

See Figure 6.

Fork load capacity and load center are stamped (1) on the fork.

2 Fig. 7 (16860-02)

1

2. Make a visual inspection for cracks during daily operator checks. When a more accurate inspection is necessary, use dye penetrants or Magnaflux.

3. Replace the forks when cracks are found.

Fig. 6 (16859-02)

Fatigue See Figure 7.

A fatigue crack starts in the fork heel area of the fork.

Cracks can be detected in the early stages by inspecting the fork heel area.

Inspecting the fork for fatigue 1. Check for cracks that go across the fork in an area up to 130 mm (5.0 in) either side of the outer fork heel radius (1) and (2). The cracks indicate that an area is weakened or damaged.

Crown 1988 PF7393 Rev. 10/21

M7.8-04.2-003 07 Rev. 10/21

331

LIFTING MECHANISM Fork Inspection

Bent or Twisted Forks Overloading, hitting solid objects, or picking up loads that are uneven can bend or twist the fork, resulting in replacing the fork. The maximum allowable difference in fork tip height from one fork to another is 3% of the fork length.

See Figure 8. The angle (1) between the top of the fork blade to the back surface of the shank must be less than 93°. Replace the fork if the angle is greater than 93°. Contact a Crown Equipment Corporation representative for additional information on repairing the forks.

the result in step 3, replace the fork. The dimension indicates that the fork is bent more than 93°.

Hanger See Figure 10.

1. Check for cracks or damage to the fork pins, spring, handle, and roll pin (1).

2. Check for cracks or damage to the area of fork attachment (2).

3. Check the fork carriage for excessive wear or cracks. Repair or replace parts if necessary.

WARNING If the fork locking pin is not fully engaged, the fork could become unintentionally disengaged.

1

4. Check the condition of the fork locking pin, spring, handle, and roll pin for proper operation, if the forks have these parts installed.

1

Fig. 8 (16861-02)

Using a carpenters square to check the fork 1. See Figure 9. Hold the square (1) against the shank above the radius of the fork heel.

1

2 Fig. 10 (16863-02)

2

3

Fig. 9 (16862-02)

2. Measure the distance (2) closest to the radius of the fork heel of the fork blade and square.

3. Add 31.8 mm (1.25 in) to this measurement and note the dimension.

4. Measure the distance (3) between the end of the square and blade. If the distance is greater than

M7.8-04.2-004 07 Rev. 10/21

332

Crown 1988 PF7393 Rev. 10/21

MAINTENANCE CYLINDERS Great care and cleanliness should be exercised in the disassembly and assembly of any hydraulic cylinders. Wipe all surfaces clean of dirt and oil before attempting disassembly. Care should be taken when removing the ram from the cylinder to prevent damage to the packing on the piston end. After cylinder and wipers are removed, thoroughly wash all metallic parts in solvent and blow dry with compressed air. Carefully inspect the ram assembly and cylinder bore. Replace if scored, grooved, pitted, or worn.

Minor damage to the cylinder bore can be removed with the use of a cylindrical honing tool. Place washed components in a clean container until assembly. Whenever new packings are required, new wiper rings should also be installed.

Lift Cylinder

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

Seal Removal When an excessive amount of hydraulic oil is evident on the top of the cylinder (or bottom in the case of the middle cylinder on “TF” and “TT” cylinder clusters), where the ram exits from the cap, the rod packing is probably bad and should be replaced. The replacement of the packing can be accomplished without removing the ram assembly from the cylinder tube or truck.

The material covered in this section applies to all TL, TF, and TT lift cylinders.

0389S

0388S

ILLUSTRATION 8-1

Disassembly

ILLUSTRATION 8-2

Unfasten and remove the cap as explained in “Disassembly”. If the packing is seated in the cap itself, a hooked tool should be used to remove the packing. If the packing is located below the cap and remains in the cylinder bore after the cap is removed, a pair of special tools can be used to facilitate packing removal (See Illustration 8-2). To make these tools, weld or braze a headless No. 8 metal (4mm self-tapping) screw to the end of a screwdriver. The screwdriver must have at least 6 in. (150mm) of shank length with no larger than 5/32 in. (4mm) shank diameter.

After attaching the screw to the screwdriver, grind off excess weld to a diameter of 5/32 in. (4mm). Wrap the shank with electrical tape from the tip of the screw to the screwdriver handle. This will prevent scratching of the cylinder bore or the ram.

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.

930222

3684ND-37094

Crown 1993 PF-9708-1

Printed in U.S.A.*

M8.0 - 1430 - 001

M8.0 - 1430 - 001

MAINTENANCE Insert the tools between the ram and the cylinder walls, 180 degrees apart, and screw into the face of the packing (See Illustration 8-3). After the threads are sufficiently secured into the packing, evenly pull on the screwdriver handles until the packing is removed.

CAUTION

Close inspection of seal seating critical areas should be made before the new seal is installed (See Illustration 8-4 AND 8-9). 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.

Seal Installation - General 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.

ILLUSTRATION 8-3

0390S

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.

NOTE Extreme care should be taken to prevent damage to cylinder wall and ram assembly.

At this time, the wiper ring should also be removed since packings and wiper rings should always be replaced in pairs. Thoroughly clean the area where the seals seat. Any burrs, dirt or seal debris must be removed before re-installing new seals.

Crown 1993 PF-9708-2

M8.0 - 1430 - 002

Printed in U.S.A.

M8.0 - 1430 - 002

MAINTENANCE Rod U-Cup Installation

2. Installation Procedure a. Slip the U-cup over the fixed pin (See Illustration 8-5, PIN 1) and bend it over PIN-2 as shown.

A. SMALL U-CUP 1. Installation Tools

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

a. A groove alignment plug (See Illustration 8-4) is needed which should be flush with groove edge. Any metal or plastic material which is smooth and lubricated may be used.

c. Insert installation tool with mounted U-cup into cylinder bore until aligned with U-cup installation groove (See Illustration 8-6).

1903

d. Withdraw PIN 3 so that U-cup loop snaps into installation groove (Illustration 8-7).

ILLUSTRATION 8-4

1901

ILLUSTRATION 8-6

b. A soft metal or plastic pusher rod is needed.

2. Squeeze U-cup together and insert end into bore first.

When lower end is engaged in installation groove, release U-cup and force upper end downward using pusher rod until U-cup snaps into groove.

B. LARGE U-CUP 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 Illustration 8-5).

1904

e. Withdraw PIN 2 and U-cup will completely snap into installation groove (Illustration 8-8).

1905 1902

ILLUSTRATION 8-5

Crown 1993 PF-9708-3

M8.0 - 1430 - 003

ILLUSTRATION 8-7

ILLUSTRATION 8-8 f. Withdraw installation tool.

Printed in U.S.A.

M8.0 - 1430 - 003

MAINTENANCE Cylinder U-cup Installation

Cylinder Assembly

For “lip first” installation, a sleeve similar to that shown in illustration 8-9 should be used to protect the seal from damage on the threads and shoulders.

After packings and seals are in place and the ram assembly 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 Bleeding

1906

ILLUSTRATION 8-9

After the cylinder is re-installed on the truck, but before the truck is put back into operation, air must be bled from the hydraulic system. Without a load on the forks, raise and lower the mast through one complete cycle. With the mast fully lowered, check the hydraulic reservoir and add fluid if necessary. Raise and lower the mast through the complete cycle at least five more times. This action will force any air that may be trapped in the system to the top of the cylinder(s). Loosen the small bleeding screw, located at the top of the cylinder(s) until all air escapes and only oil continues to flow from the screw. Tighten the screw and wipe off excess oil.

Cylinder - Summary Occasionally, a slight creep of the fork assembly may occur. This may be due to internal leakage in the piston pak but it can also be caused by leakage in the solenoid or check valve. To seat these valves properly when this occurs, raise and lower the forks to flush out any foreign material from the valve seat. A thorough check of the system for leaks should be conducted if abnormal oil losses occur. The hydraulic system is designed to eliminate mechanical damage even if fittings become loose.

Crown 1993 PF-9708-4

M8.0 - 1430 - 004

Printed in U.S.A.

M8.0 - 1430 - 004

MAINTENANCE

ILLUSTRATION 8-23 TILT CYLINDER (OPTIONAL) The tilt cylinder is mounted at the base of the carriage assembly.

The tilt cylinder is a double acting piston type cylinder. Extreme care should be taken when performing any type of repair. In event of excessive oil leakage around the cap end of the cylinder or its inability to tilt the load, the cylinder will have to be removed from the truck and repaired.

NOTE Check the wire retaining ring to determine correct turning direction for removal. If the cap is turned the wrong direction, and the end of the retaining ring is allowed to slip inside the cylinder, removal of ring is very difficult.

Disassembly Before proceeding with disassembly, thoroughly clean the outside of the cylinder to remove all dirt and grease build-up. Place the cylinder in a vise. Care should be taken to avoid over tightening, as tube assembly (Item 14) damage may result. With the use of an adjustable spanner wrench, similar to the one shown in Illustration 8-24, a face spanner wrench with 3/16″ pins and a pin spread of 2.625 inches is needed. Rotate the gland until the wire retaining ring (Item 13) is completely unwound from the inside of the cylinder.

ILLUSTRATION 8-24

Crown 1979 PF-5023-1

Printed in U.S.A.

M8.6 - 14 - 001

M8.6 - 14 - 001

MAINTENANCE Before removing the rod assembly, push the gland,(Item 3), down into the cylinder, away from the retaining ring grove area.

Using a scraper or similar tool, remove any raised material or burrs from the edge of the grove. If burrs, etc., are not removed, piston removal may be difficult.

Carefully remove the rod assembly which includes the gland (Item 3), the rod (Item 1), the piston (Item 9), the locknut (Item 2), and lockwasher (Item 11), out the end of the tube assembly.

Inspect the tube assembly for any signs of scoring. If scoring is evident, the tube assembly must be replaced. The tube assembly should be honed to remove any remaining burrs.

Rod Disassembly Clamp the end of the rod containing the ball bushing in a vise.

Unlock and remove locknut with appropriate size spanner wrench. Slide all components off of the rod. Inspect the rod for scoring. If scoring is evident, the rod must be replaced.

NOTE When cleaning piston and gland, be sure to clean seal seating areas. Protect eyes and face when using compressed air.

After all parts are thoroughly cleaned, place in a dirt free area until ready for reassembly.

Cylinder Reassembly Apply a coat of hydraulic oil (Crown No. 63001-1) to all seals before they are assembled. Install all seals by hand. After the seals are installed, slide the gland onto the piston end of the rod.

Install piston and fasten locknut; be sure piston is seated properly against the rod shoulder. After installing the rod assembly into the tube assembly, align the hole in the gland with the slot in the cylinder wall and carefully press the gland into position.

CAUTION

Seal Replacement With the use of a small hooked tool, carefully pull the seals from their mounting grooves.

CAUTION

Never use a screwdriver to remove seals, as damage and leakage may result.

Care should be taken when inserting the gland to prevent sharp edges from damaging new seals and packings.

Once the gland is in place and the positioning hole is visible through the cylinder slot, insert the hooked end of the wire retaining ring into the positioning hole. Turn the gland clockwise until the tapered end of the retainer is flush with the cylinder tube.

After all seals are removed, inspect the contact surfaces on the piston and the gland for scoring. If slight scoring is evident, sand with a fine emery paper until high areas are removed. Heavily scored components must be replaced. After all parts are inspected, wash all cylinder components in a good grade solvent and dry with air pressure.

Crown 1979 PF-5023-2

Printed in U.S.A.

M8.6 - 14 - 002

M8.6 - 14 - 002

REACH ASSEMBLY REACH ASSEMBLY

Reach Cylinder Adjustment

The reach assembly on your Narrow Aisle Rider Reach Truck is designed to lift, transport, and deposit materials from racks where outriggers cannot enter into or under. After the truck is positioned in front of the load, the reach sequence is selected, and the carriage extended to the proper lifting position. Speed of extending can be controlled by the amount of movement at the control handle. The handle is raised to extend and lowered to retract, providing the reach sequence has been selected. (See sequence section of maintenance for in-depth operation of sequence control). After extending to engage forks under the load properly, the load is lifted, fully retracted, and lowered to a safe travel height.

Extend mechanism completely. From retracted position, the distance to the top front edge of fork carriage assembly should be 23.50 in. (600mm). (The measurement must be taken at the top of the reach mechanism). With reach cylinders fully extended, the cylinder rod can be turned to obtain the correct dimension. Refer to illustration 9-1.

23.5 in. 600mm

WARNING

Wear appropriate protective items, such as safety glasses, steel toe shoes, etc. whenever performing maintenance work. To avoid injury, do not place fingers, hands, or arms through mast or position them at a pinch point at any time.

INSPECTION CHECKS Poly Stop Located at bottom/center of the support assembly is a poly stop. The poly stop prevents metal to metal contact when the reach assembly is fully retracted. The poly stop should be shimmed to make contact with the carriage assembly as reach cylinders are fully retracted.

3626

ILLUSTRATION 9-1

The poly stop at top of the inner arm uses spacers for correct position. Draw socket head screw snug, do not over tighten.

The number of washers can be determined with the truck operational. The poly stop bumper should compress 0.25 in.

(6 mm) to 0.50 in. (13mm) when fully retracted with a 2000 Ib. (905 Kg) load. Use thread locking adhesive to secure the screw into position. Torque screw 28-32 in.lbs. (3.2-3.6 Nm).

Crown 1995 PF-10504-1

M9.0–1430–001

Printed in U.S.A.

M9.0–1430–001

REACH ASSEMBLY 58 Reach Assembly With Tilt 11

29

47

10 1112

12

7

26

8

42

53

54 55

49

25

56

42

40

8

9

52

27

51

33 28

30

41 45

28 38

31 32

29

SB64 3

8

39

4 1

43

57

44 16 15

46

14

45

13 50

5

16 37

34 31 30

2 51 25 2

32 30

19

6 36

35 13 23

33 32 22 33

17 18 48 20

24

21

31 2

ILLUSTRATION 9-2

3629S

Disassembly (SEE ILLUSTRATION 9-2 ) 1. Remove four screws holding load backrest (not shown) to fork plate (53) and remove load backrest.

2. (Disregard if truck is not equipped with tilt). Remove screw (57) in bottom cross member of fork plate.

3. Remove forks (Not shown) from fork plate.

4. Extend reach assembly and place a 2" x 4" x 8" hardwood block in either left or right channel of support assembly (1).

5. Retract reach assembly until column roller (21) on outer arm (13) is resting on hardwood block. The hardwood block will not allow assembly to retract when the reach cylinders are removed.

NOTE

6. ( Disregard if truck is not equipped with tilt). Remove roll pin (55) from tilt cylinder shaft (52) with brass punch or other soft material rod.

Remove two roll pins (54) from pivot shafts (56) at top of fork plate. Use hoist or other suitable means to support fork plate, and remove pivot shafts.

Remove hydraulic lines from tilt cylinder (43) to manifold block (not shown) on support assembly. (Allow hydraulic pressure to bleed off slowly). Remove four screws holding tilt cylinder in carriage assembly (40).

Remove tilt cylinder, if further disassembly is required take to a clean working area. Consult cylinder section of this manual for proper disassembly procedure.

If ball bushing (46) in tilt cylinder rod end requires replacement, remove retaining rings (45) and use an arbor press to remove and replace it.

[Disconnect battery]. If complete disassembly of reach assembly is required, removal of entire reach assembly from mast assembly will ease disassembly procedure.

Crown 1995 PF-10504-2

M9.0–1430–002

Printed in U.S.A.

M9.0–1430–002

REACH ASSEMBLY 7. Attach hoist to top cross bar of carriage assembly.

Remove roll pins (29) in pivot shafts (25) which connect outer arms to carriage assembly. Remove pivot shafts and raise carriage assembly to clear carriage rollers (22) on inner arm assembly (6).

8. Remove roll pin (37) from pivot shaft (36) at rod end of reach cylinders (34). Remove pivot shafts (36) at rod end. Disconnect hydraulic lines from bulkhead located near top of reach cylinders. Remove roll pin (51) from upper pivot shafts (50) and remove pivot shafts. Reach cylinders should be replaced on support assembly in same position as they were removed.

9. Connect hoist to inner arm assembly cross brace and lift until column rollers on outer arm assemblies can be rotated out of support assembly channel.

BUSHING INSTALLATION TOOL EQUAL TO THE LENGTH OF THE BUSHING .005 IN. .13MM SMALLER THAN THE BUSHING O. D. .062 IN. 1.6MM CHAMFER 3627

12. Remove outer arm and thrust washers. Record location of thrust washers for reference during reassembly.

ILLUSTRATION 9-3 NOTE The installation tool can also be used effectively to remove worn or damaged bushings. Various sizes of bushings will necessitate use of various sizes of installation tools.

10. Remove column rollers from outer arms. Record number and position of all spacers for reference during reassembly.

11. Remove roll pin (19) and retaining ring (48) from locknut (18) at pivot center. Remove locknut with a hook type spanner wrench.

Ball bushings are removed and installed with greater ease when using an installation tool similar to the one shown in illustration 9-4.

NOTE Close inspection of all new bushings after installation is necessary to be sure wear surfaces are intact.

13. Remove roll pins (29) in pivot shafts (25) of inner arm assembly.

BALL BUSHING INSTALLATION TOOL

Bushing Replacement (Reach Assembly Components)

.005 IN. .13MM SMALLER THAN THE BALL BUSHING O. D.

When removing old bushing be sure seating area of bushing is not damaged in any manner. If damage does occur remove all burrs and rough edges completely.

.19 IN. 5MM

When installing new bushings in a lubricated area be sure hole in the bushing is in proper alignment with the lubrication fitting to allow proper lubrication flow.

BALL BUSHING

Apply a light coat of grease to bushing seat to ease installation and reduce possibility of damage to new bushings.

CUT-AWAY VIEW OF THE COUNTERBORE

A bushing installation tool, shown in illustration 9-3, will aid greatly in proper installation of new bushings.

.125 IN. 3.2MM 3628

Crown 1995 PF-10504-3

M9.0–1430–003

.005 IN. .13MM SMALLER THAN THE BUSHING I. D.

ILLUSTRATION 9-4

Printed in U.S.A.

M9.0–1430–003

REACH ASSEMBLY Center Pivot Repair and Adjustment When replacing thrust washers (16) on both sides of the outer arm assembly, apply a light coat of grease to all surfaces.

NOTE Be sure all areas of contact are thoroughly cleaned and free of any burrs or debris that could damage new thrust washers.

To properly adjust, tighten the nut on the center pivot assembly snug to eliminate any abnormal drag. Loosen nut and retighten to 65 in. lbs., then continue to tighten to next nearest groove pin location.

5. Install column rollers to outer arms. Measure distance between column rollers with an outside caliper. Subtract this dimension from deminsion obtained in step 4 to determine the amount of shims required. Balance out the number of shims (Example: 2 shims right, 2 shims left). If an uneven number of shims are required, note to which side the extra shim was added and install all other odd shims to that side.

6. Measure the distance between outer arms at top. (TLTF is 17.25 inches 434.98mm, TT is 13.25 inches 336.55mm). Measure distance between pivot blocks welded on fork carriage assembly (40). These dimensions should indicate that the outer arms will fit properly in the fork carriage assembly.

NOTE

Reassembly NOTE Before proceeding with reassembly, all parts should be clean and free of any burrs or rough edges which could damage new bushings or other parts during assembly. Apply a thin coat of grease to all bushings, thrust washers, and pivot shafts.

1. Install inner arm assembly (6) into support assembly (1).

2. Install pivot shafts (25) simultaneously, rather than one at a time. Pivot shafts are slotted on the end to obtain proper alignment for installation of roll pin (29).

3. Install thrust washer (16) at center pivot. Slide outer arms (13) onto center pivot stud. Install thrust washer, locknut (18) and roll pin (19).

NOTE Refer to Center Pivot Repair and Adjustment, (located in this section) for proper adjustment information of center pivot.

4. Use an inside caliper to measure area of support assembly where column roller (21) on outer arm will travel, record measurement.

Crown 1995 PF-10504-4

M9.0–1430–004

Failure of the outer arms to fit into carriage assembly properly indicates inner arm assembly, carriage assembly, or outer arm assembly is bent or deformed in some way.

7. Attach carriage rollers (22) to inner arm assembly studs.

8. Raise inner arm assembly until column rollers on outer arms can be fitted into channels of support assembly.

Place 2" x 4"x 8" (approx. length) hardwood block in either channel beneath column roller. Lower inner arm assembly until weight of arm assembly is on hardwood block.

9. Guide fork carriage assembly onto inner arm carriage rollers.

10. Install pivot shafts (25) and roll pins (29).

11. Install reach cylinders. a. Install pivot shafts (50) and roll pins (51). b. Extend cylinder manually and install pivot shafts (36) and roll pins (37). c. Connect hydraulic lines from reach cylinders to bulkheads near top of reach cylinders.

NOTE Disregard steps 12, 13, 14, and 15 of reassembly procedure if truck is not equipped with tilt function.

Printed in U.S.A.

M9.0–1430–004

REACH ASSEMBLY 12. Place bushings (44) on tilt cylinder (43) pivot studs and install tilt cylinder assembly in carriage assembly.

(Check serial number plate to obtain capacity of truck to obtain proper tilt cylinder assembly. This information is also needed to obtain proper fork plate assembly (53) and tilt cylinder shaft (52).

13. Connect all hydraulic lines from tilt cylinder to manifold block at top of support assembly.

14. Position fork plate assembly (53) with a hoist and install pivot shafts (56) and pins (54).

15. Extend tilt cylinder piston rod and install tilt cylinder shaft (52) and pin (55).

16. Run an operational check. (Refer to Reach Cylinder Adjustment in this section for adjustment procedure).

17. Install forks and load backrest. Add bolt (57).

Crown 1995 PF-10504-5

M9.0–1430–005

Printed in U.S.A.

M9.0–1430–005

MAINTENANCE GLOSSARY - Model 3500 Components of the RR 3000 Series, Model 3500 truck have been listed in chart form to assist the maintenance mechanic in locating these components on the Electrical Diagrams and Exploded Parts pages.

The chart is in columns: COMPONENT; LOCATION; FUNCTION; DIAGRAM; PARTS PAGE. The COMPONENT column contains the abbreviation of the component as it appears on the Diagrams in the Maintenance Section. The LOCATION column gives the general location on the truck

such as on platform or in power unit. the FUNCTION column then explains the function or circuit of that device. The DIAGRAM column gives the page number of the diagram on which the component can be found. The callout in parenthesis following the page number corresponds to the grid callouts on that diagram, locating that component. The PARTS PAGE column includes the exploded parts page number on which the component is located along with the index number, in parenthesis, if applicable.

AUDIBLE INDICATORS Location

Function

Diagram

Parts Page

HN1 HN2

Power Unit Power Unit

Horn Travel Alarm

DIA–1435–009 (B-3) DIA–1435–009 (B-4)

04.0–1435–001 (23) 04.0–1435–001 (25)

Location

Function

Diagram

Parts Page

Power Unit

Power

DIA–1435–012 (B-1)

01.2 –1435–100 (9)

CONNECTIONS Location

Function

Diagram

Parts Page

CA201

Distribution Panel

OverHead Guard

04.3–1430–100 (8)

CA202

Distribution Panel

Hour Meter Signal

CA203

Distribution Panel

Sequence Control

CA204

Distribution Panel

Multifunction Control

CA205

Distribution Panel

Contactor Panel

CA206

Distribution Panel

SCR Control Card

CA207

Distribution Panel

HGT Switches

PC401 PC402 TB403 PC404

Traction Logic Card Traction Logic Card Traction Logic Card Traction Logic Card

Speed Limit Inputs Contactor Coil Inputs Switch/Power Inputs (TB11T) Communications

DIA–1435–004 (A-3) DIA–1435–013 (A-3) DIA–1435–014 (A-3) DIA–1435–004 (A-3) DIA–1435–013 (A-3) DIA–1435–014 (A-3) DIA–1435–004 (A-2) DIA–1435–013 (A-2) DIA–1435–014 (A-2) DIA–1435–004 (A-1) DIA–1435–013 (A-1) DIA–1435–014 (A-1) DIA–1435–004 (B-3) DIA–1435–013 (B-3) DIA–1435–014 (B-3) DIA–1435–004 (B-2) DIA–1435–013 (B-2) DIA–1435–014 (B-2) DIA–1435–004 (B-1) DIA–1435–013 (B-1) DIA–1435–014 (B-1) DIA–1435–005 (B-1) DIA–1435–005 (B-2) DIA–1435–005 (B-2) DIA–1435–005 (B-2)

BATTERY

Battery

950619

04.3–1430–100 (8)

04.3–1430–100 (8)

04.3–1430–100 (8)

04.3–1430–100 (8)

04.3–1430–100 (8)

04.3–1430–100 (8)

5024

Crown 1995 PF-10597-1 Rev. 7/96

Printed in U.S.A.

01 REV. 7/96

M10–1435–001

M10–1435–001

MAINTENANCE CONNECTIONS (Continued) Location TB405 CA406 CA407 CA408 CA409 CA410 CA411 CA412 CA413 CA414 CA415 CA416 CA417 CA418 CA419 CA420 CA421 CA422 CA423 CA424 CA425 CA426 CA427 CA428 CA601 CA602 CA603 CA604 PB605

Power Unit Right Wall Power Unit Power Unit Power Unit Back Wall Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Sequence Control Sequence Control Sequence Control Sequence Control Contactor Panel

NB606

SCR Panel

CA801 CA802 CA803 CA804 CA805 CA806 CA807 CA808 CA809 CA810 CA811 CA812 CA813 CA814

Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard

Function

Diagram

Parts Page

ACC. Function LEDS Over Head Guard Power Key Switch/Hour Meters Console Display F/C Distribution Panel (1) F/C Distribution Panel (1) Multifunction Heater + Multifunction Heater Brake Monitor SW Heater + Brake Monitor SW Heater Brake Pedal SW Heater + Brake Pedal SW Heater F/C Distribution Panel (2) F/C Distribution Panel (2) BV + HGTS1 Heater + HGTS1 Heater HGTS2 Heater + HGTS2 Heater BV + BRES1 Heater + BRES1 Heater BRES2 Heater + BRES2 Heater Sequence Control Inputs Auxiliary Outputs Pump Coil Outputs DC-DC Converter Positive Bus For F/C Distribution Panel 1 & 2 Negative Bus For F/C Distribution Panel 1 & 2 Display Inputs Light/Fan Strobe Light + (LGT4) Strobe Light - (LGT4) Left Work Light + (LGT3) Left Work Light - (LGT3) Fan High Speed + (FNS) Fan Low Speed + (FNS) Fan - (Operator) Dome Light RES + (RES12) Dome Light + (LGT1) Dome Light - (LGT1) Right Work Light + (LGT2) Right Work Light - (LGT2)

DIA–1435–006 (B-1) DIA–1435–006 (B-2) DIA–1435–006 (B-3) DIA–1435–006 (B-4) DIA–1435–007 (B-1) DIA–1435–007 (B-1) DIA–1435–007 (C-1) DIA–1435–007 (B-1) DIA–1435–007 (C-1) DIA–1435–007 (C-1) DIA–1435–007 (C-2) DIA–1435–007 (C-2) DIA–1435–007 (B-2) DIA–1435–007 (B-2) DIA–1435–007 (B-3) DIA–1435–007 (C-2) DIA–1435–007 (C-2) DIA–1435–007 (C-2) DIA–1435–007 (C-2) DIA–1435–007 (B-2) DIA–1435–007 (C-1) DIA–1435–007 (C-1) DIA–1435–007 (C-1) DIA–1435–007 (C-1) DIA–1435–008 (B-1) DIA–1435–008 (B-2) DIA–1435–008 (B-3) DIA–1435–009 (C-1)

04.9–1430–004 (20) 04.9–1430–004 (20) 04.9–1430–004 (29) 04.9–1430–004 (29) 04.9–1430–004 (4) 04.9–1430–004 (4) 04.9–1430–004 (2) 04.9–1430–004 (2) 04.9–1430–004 (32) 04.9–1430–004 (32) 04.9–1430–004 (18) 04.9–1430–004 (10) 04.9–1430–004 (10) 04.9–1430–004 (8) 04.9–1430–004 (8) 04.9–1430–004 (18) 01.2–1435–200 (17) 01.2–1435–200 (17) 01.2–1435–200 (17) 01.2–1435–200 (17) 04.3–1430–001 04.3–1430–001 04.3–1430–001 04.3–1430–001 (4)

Crown 1995 PF-10597-2 Rev. 7/96

DIA–1435–009 (C-2) DIA–1435–009 (C-4) DIA–1435–010 (B-1) DIA–1435–011 (B-1) DIA–1435–011 (B-1) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-3) DIA–1435–011 (B-3) DIA–1435–011 (B-3) DIA–1435–011 (B-3)

04.2–20.0–001 04.9–1435–050 04.9–10.0–550 04.9–10.0–550 04.9–1435–050 (8) 04.9–1435–050 (8) 04.9–1435–050 (20) 04.9–1435–050 (20) 04.9–1435–050 (20) 04.9–1435–200 (3) 04.9–1435–200 (3) 04.9–1435–200 (3) 04.9–1435–200 (8) 04.9–1435–200 (8)

Printed in U.S.A.

01 REV. 7/96

M10–1435–002

M10–1435–002

MAINTENANCE CONTACTORS Location

Function

Diagram

Parts Page

F

Contactor Panel

Forward Travel (24V)

R

Contactor Panel

Reverse Travel (24V)

S

Contactor Panel

Steering (24 & 36V)

DIA–1435–005 (B-2) DIA–1435–012 (B-3) DIA–1435–005 (B-2) DIA–1435–012 (B-3) DIA–1435–005 (B-1) DIA–1435–008 (A-3) DIA–1435–012 (B-1)

P1

Contactor Panel

Pump 1 (24V)

DIA–1435–008 (B-3) DIA–1435–012 (B-1)

P2

Contactor Panel

Pump 2 (36/48V)

DIA–1435–008 (B-3) DIA–1435–012 (A-1)

1A

Contactor Panel

Bypass Contactor (24 & 36V) DIA–1435–005 (B-1) (Works in Conjunction with DIA–1435–012 (B-2) SCR Card Settings to Increase Travel Speeds)

FW

Contactor Panel

Field Weakening Coil (Works in Conjunction with 1A & SCR Card Settings to Increase Travel Speeds)

DIA–1435–005 (B-1) DIA–1435–012 (B-2)

04.4–6535–001 04.4–1430–225 (EE) 04.4–6535–001 04.4–1430–225 (EE) 04.1–1430–003 (25) 04.1–1430–052 (25) 04.1–1430–102 (25) 04.1–1430–200 (19) 04.1–1430–225 (24) 04.1–1430–003 (17) 04.1–1430–052 (17) 04.1–1430–102 (17) 04.1–1430–200 (15) 04.1–1430–225 (19) 04.4–1430–002 04.1–1430–052 (31) 04.1–1430–102 (31) 04.1–1430–225 (16) 04.4–1430–002 04.1–1430– 003 (4) 04.1–1430–052 (4) 04.1–1430–102 (4) 04.1–1430–200 (4) 04.1–1430–225 (4) 04.4–6535–050 04.4–1430–002 04.4–1430–200 (EE) 04.1–1430–102 (37) 04.4–6535–050

Location

Function

Diagram

Parts Page

FU1

Contactor Panel

Traction Motor

DIA–1435–012 (B-2)

FU2

Contactor Panel

Power Steering Motor

DIA–1435–012 (B-2)

FU3

Contactor Panel

Pump 1 Motor

DIA–1435–012 (B-2)

04.1–1430–003 (9) 04.1–1430–052 (9) 04.1–1430–102 (9) 04.1–1430–200 (41) 04.1–1430–225 (48) 04.1–1430–003 (26) 04.1–1430–052 (26) 04.1–1430–102 (26) 04.1–1430–200 (37) 04.1–1430–225 (44) 04.1–1430–003 (12) 04.1–1430–052 (12) 04.1–1430–102 (12) 04.1–1430–200 (39) 04.1–1430– 225 (45)

FUSES

Crown 1995 PF-10597-3 Rev. 7/96

Printed in U.S.A.

01 REV. 7/96

M10–1435–003

M10–1435–003

MAINTENANCE FUSES (continued) Location

Function

Diagram

Parts Page

FU4

Contactor Panel

Pump 2 Motor

DIA–1435–012 (B-2)

FU5

Distribution Panel

Key Switch

04.1–1430–052 (35) 04.1–1430–102 (35) 04.1–1430–225 (47) 04.3–1430–100 (13)

FU6

FU7

FU8

FU9 FU10 FU11 FU12 FU13 FU14

DIA–1435–004 (B-4) DIA–1435–013 (B-4) DIA–1435–014 (B-4) Distribution Panel Lights/Fan (K2A) DIA–1435–004 (B-4) DIA–1435–013 (B-4) DIA–1435–014 (B-4) Distribution Panel Options (K2B) DIA–1435–004 (B-3) DIA–1435–013 (B-4) DIA–1435–014 (B-4) Distribution Panel Test Relay (K3) DIA–1435–004 (B-2) DIA–1435–013 (B-2) DIA–1435–014 (B-2) F/C Power Panel (2) BV + From Pos. Bus, K5 F/C DIA–1435–007 (B-3) F/C Distribution Panel K4, Multi-Function SW F/C DIA–1435–007 (B-1) F/C Distribution Panel K4, BMS, BRS, HGTS1 F/C DIA–1435–007 (B-1) F/C Distribution Panel K5, Strip Heater 1 F/C DIA–1435–007 (B-2) F/C Distribution Panel K5, Strip Heater 2, DMS F/C DIA–1435–007 (B-2) F/C Power Panel (1) BV +, K4, Multi-Function SW DIA–1435–007 (A-2)

04.9–1430–004 (18) 04.9–1430–004 (22) 04.9–1430–004 (23) 04.9–1430–004 (33) 04.9–1430–004 (34) 04.9–1430–004 (18)

Location

Function

Diagram

Parts Page

Over Head Guard Main Frame Main Frame Over Head Guard

Dome Light Right Work Light Left Work Light Strobe Light

DIA–1435–011 (B-1) DIA–1435–011 (C-1) DIA–1435–011 (C-2) DIA–1435–011 (C-2)

04.9–1435–200 (3) 04.9–1435–050 (8) 04.9–1435–050 (8) 04.9–1435–050 (18)

04.3–1430–100 (14)

04.3–1430–100 (15)

04.3–1430–100 (16)

LIGHTS

LGT1 LGT2 LGT3 LGT4

MOTORS Location

Function

Batt.Volt.

Diagram

Parts Page

Traction

Power Unit

Traction

Pump1

Power Unit

Lift

24V 36V 24V

DIA–1435–012 (A-2) DIA–1435–012 (A-2) DIA–1435–008 (B-3) DIA–1435–012 (B-2) DIA–1435–008 (B-3) DIA–1435–012 (B-2) DIA–1435–008 (B-3) DIA–1435–012 (A-2) DIA–1435–008 (B-3) DIA–1435–012 (B-1) DIA–1435–012 (A-2) DIA–1435–012 (A-2)

03.1–1430–050 03.1–1430–002 02.2–14.0–003

06.2–1430–001 06.2–1430–050

36V Pump2

Power Unit

Lift

24V 36V

Steering

Power Unit

Power Steering 24V 36V

02.2–10.0–006 02.2–14.0–003 02.2–10.0–006

POTENTIOMETERS Location

Function

Diagram

Parts Page

POT-1

Acceleration

DIA–1435–005 (B-2)

04.6–1435–001 (22)

Multi-Function Control

Crown 1995 PF-10597-4 Rev. 7/96

Printed in U.S.A.

01 REV. 7/96

M10–1435–004

M10–1435–004

MAINTENANCE RELAYS Location

Function

Diagram

Parts Page

K1

Distribution Panel

Power Up

04.3–1430–100 (9)

K2

Distribution Panel

Light/Fan Option

K3

Distribution Panel

Test

K4

F/C Distribution Panel

04.9–1430–004 (21)

K5

F/C Distribution Panel

BMS, BRS, HGTS1 Multi-Function SW F/C Strip Heater 1, DMS, Strip Heater 2, THS2 F/C

DIA–1435–004 (B-3) DIA–1435–013 (B-3) DIA–1435–014 (B-3) DIA–1435–004 (B-3) DIA–1435–013 (B-3) DIA–1435–014 (B-3) DIA–1435–004 (B-3) DIA–1435–013 (B-3) DIA–1435–014 (B-3) DIA–1435–007 (B-1) DIA–1435–007 (B-3)

04.9–1430–004 (35)

04.3–1430–100 (10)

04.3–1430–100 (18)

SOLENOID VALVES Location

Function

Diagram

Parts Page

SVA

Power Unit

Torque Generator

DIA–1435–008 (B-2)

SVB1 SVB2 SVC1 SVC2 SVD

Fork Carriage Fork Carriage Fork Carriage Fork Carriage Power Unit

Side Shift Side Shift Reach Reach Lift/Lower

DIA–1435–008 (C-3) DIA–1435–008 (C-3) DIA–1435–008 (C-3) DIA–1435–008 (C-3) DIA–1435–008 (B-2)

SVE

Power Unit

Lift/Lower

DIA–1435–008 (A-2)

02.0–1430–001 (23) 02.0–1430–050 (22) 02.0–1430–100 (23) 02.0–1430–800 (1) 02.0–1430–800 (1) 02.0–1430–600 (1) 02.0–1430–600 (1) 02.4–1430–003 (6) 02.4–1430–102 (6) 02.4–1430–003 (2) 02.4–1430–102 (2)

SUPPRESSOR BLOCKS Location

Function

Diagram

Parts Page

SB61 SB62

Power Unit Carriage

A Solenoid D & E Solenoid

DIA–1435–008 (B-2) DIA–1435–008 (B-2)

DB63

Power Unit

Power St.Solenoid

DIA–1435–008 (B-3)

SB64

Main Frame

SVC1 & SVC2 Sol.

DIA–1435–008 (B-3)

SB65 SB66 SB67 SB68 SB69 SB70

Carriage Power Unit Overhead Guard Power Unit Overhead Guard Power Unit

SVB1 & SVB2 Sol. Horn (HN1) Fan Operator (FNS) Travel Alarm (HN2) Flashing Light (LGT4) Fan Compartment

DIA–1435–008 (B-3) DIA–1435–009 (B-3) DIA–1435–011 (C-2) DIA–1435–008 (B-4) DIA–1435–011 (C-1) DIA–1435–011 (C-4)

04.0–1435–001 (7) 02.4–1430–003 (16) 02.4–1430–102 (14) 04.1–1430–003 (31) 04.1–1430–052 (30) 04.1–1430–102 (30) 04.1–1430–200 (30) 04.1–1430–225 (34) 09.0–1430–100 (3) 09.0–1430–300 (3) 09.0–1430–300 (3) 04.0–1435–001 (23) 04.9–1435–050 (20) 04.0–1435–001 (25) 04.9–1435–050 (17) 01.0–1435–001 01.0–1435–100

Crown 1995 PF-10597-5 Rev. 7/96

Printed in U.S.A.

01 REV. 7/96

M10–1435–005

M10–1430–005

MAINTENANCE SWITCHES Location

Function

Diagram

Parts Page

BMS

Traction Motor

Brake Monitor

05.0–1430–252 (9)

BRS

Below Brake Pedal

Brake Release

DMS

Contactor Panel Comp.

(Towards Forks)

Deadman SW (Power On/Off)

DPS ERS FNS FS

Power Unit Left Side Power Unit Left Side Overhead Console Multi-Function Control

Display Faults Erase Faults Fan High/Low/Off Forward Direction

HGTS1

Main Frame Right Side

Free Lift SPD Limit

07.2–1435–001 (22)

HGTS2

Main Frame Left Side

270 in. (6860mm) Speed Limit

HGTS3

Main Frame Left Side

2nd Pump Cutout

HGTS4

Main Frame Right Side

Raise Cutout

HNS1 KYS LGT1 LGT2 LGT3 LGT4

Power Unit Overhead Console Overhead Console Overhead Guard Overhead Guard Overhead Guard

Horn On/Off/Test Dome Light Work Light (R.H.) Work Light (L.H.) Strobe Light

DIA–1435–004 (C-3) DIA–1435–007 (C-1) DIA–1435–013 (C-3) DIA–1435–014 (C-3) DIA–1435–004 (C-3) DIA–1435–007 (C-2) DIA–1435–013 (C-3) DIA–1435–014 (C-3) DIA–1435–004 (C-2) DIA–1435–007 (C-3) DIA–1435–013 (C-3) DIA–1435–014 (C-3) DIA–1435–006 (B-2) DIA–1435–006 (B-2) DIA–1435–011 (C-1) DIA–1435–004 (A-1) DIA–1435–013 (A-1) DIA–1435–014 (A-1) DIA–1435–004 (C-1) DIA–1435–007 (C-2) DIA–1435–013 (C-1) DIA–1435–014 (C-1) DIA–1435–004 (C-1) DIA–1435–007 (C-2) DIA–1435–013 (C-1) DIA–1435–014 (C-1) DIA–1435–004 (C-1) DIA–1435–013 (C-1) DIA–1435–014 (C-1) DIA–1435–013 (C-1) DIA–1435–014 (C-1) DIA–1435–009 (B-3) DIA–1435–006 (C-3) DIA–1435–011 (C-3) DIA–1435–011 (C-3) DIA–1435–011 (C-2) DIA–1435–011 (C-1)

MFS1

Multi-Function Control

Multifunction SW1 (Actuates Prior to Primary Raise SW)

MFS2

Multi-Function Control

Multifunction SW2

04.6–1435–001 (43)

ORS

Console

Raise Override

DIA–1435–004 (A-1) DIA–1435–007 (C-1) DIA–1435–013 (A-1) DIA–1435–014 (A-1) DIA–1435–004 (A-1) DIA–1435–007 (C-1) DIA–1435–013 (A-1) DIA–1435–014 (A-1) DIA–1435–014 (C-1)

Crown 1995 PF-10597-6 Rev. 7/96

05.0–1435–001 (50)

04.0–1435–001 (4)

04.0–1435–001 (12) 04.0–1435–001 (12) 04.9–1435–200 (13) 04.6–1435–001 (32)

07.2–1435–100 (55)

07.2–1435–100 (58)

07.2–1435–100 (60) 04.6–1435–001 (49) 04.9–1435–200 (14) 04.9–1435–200 (3) 04.9–1435–050 (8) 04.9–1435–050 (8) 04.9–1435–050 (18) 04.9–10.0–550 04.6–1435–001 (39)

01.0–1435–001 (55) 01.0–1435–100 (56)

Printed in U.S.A.

01 REV. 7/96

M10.0–1435–006

M10.0–1435–006

MAINTENANCE SWITCHES (continued) Location

Function

Diagram

RAS

Multi-Function Control

RS

Multi-Function Control

SQS

Multi-Function Handle

THS1 THS2 THS3

F/C Distribution Panel (1) F/C Distribution Panel (2) Power Unit (P/U Door)

High Speed Raise DIA–1435–004 (A-1) (Trucks W/2 Lift Pumps) DIA–1435–013 (A-1) DIA–1435–014 (A-1) Reverse DIA–1435–004 (A-1) DIA–1435–007 (B-2) DIA–1435–013 (A-1) DIA–1435–014 (A-1) Sequence DIA–1435–004 (A-1) DIA–1435–013 (A-1) DIA–1435–014 (A-1) F/C Thermostat DIA–1435–007 (B-2) F/C Thermostat DIA–1435–007 (C-3) Fan Thermostat DIA–1435–011 (B-4)

BRES1

Power Unit

Battery Retainer Alarm

BRES2

Power Unit

Battery Retainer Alarm

DIA–1435–004 (C-3) DIA–1435–006 (B-1) DIA–1435–007 (C-1) DIA–1435–004 (C-3) DIA–1435–006 (B-1) DIA–1435–007 (C-2)

RESISTORS Location

Function

FW RES RES1 RES2 RES3 RES4 RES5 RES6 RES7 RES8 RES9 RES10 RES11 RES12 RES13 RES14 RES15

Contactor Panel Under Brake Pedal Under Brake Pedal Power Unit Left Side Multi-Function Controls Multi-Function Controls Multi-Function Controls Multi-Function Controls Main Frame Upper Left Main Frame Upper Right Contactor Panel Contactor Panel Overhead Guard Overhead Guard Overhead Guard Power Unit Door

Field Weakening DIA–1435–012 (B-2) DMS SW Heater DIA–1435–007 (B-4) Brake Release Switch Heater DIA–1435–007 (C-2) Brake Monitor Switch Heater DIA–1435–007 (C-1) Multifunction Heater DIA–1435–007 (C-1) Multifunction Heater DIA–1435–007 (C-1) Multifunction Heater DIA–1435–007 (C-1) Multifunction Heater DIA–1435–007 (C-1) HGTS2 Heater DIA–1435–007 (C-2) HGTS1 Heater DIA–1435–007 (C-2) Contactor Heater (Vertical) DIA–1435–007 (C-3) Contactor Heater (Horizontal) DIA–1435–007 (C-3) Dome Light (LGT1) DIA–1435–011 (B-3) Fan Operator (24 V.) DIA–1435–011 (B-2) Fan Operator (36 V.) DIA–1435–011 (B-3) Fan Compartment DIA–1435–011 (C-4)

RES16 RES17

Power Unit R.H. Power Unit L.H.

BRES2 SW Heater BRES1 SW Heater

Diagram

Crown 1995 PF-10597-7 Rev. 7/96

DIA–1435–007 (C-1) DIA–1435–007 (C-2)

Parts Page 04.6–1435–001 (64)

04.6–1435–001 (32)

04.6–1435–001 (57)

04.9–1430–004 (24) 04.9–1430–004 (13) 01.0–1435–001 (5) 01.0–1435–100 (5) 01.2–1435–100

01.2–1435–100

Parts Page 04.1–1430–102 (42) 04.9–1430–004 (6) 04.9–1430–004 (2) 04.9–1430–004 (4) 04.9–1430–004 (29) 04.9–1430–004 (29) 04.9–1430–004 (29) 04.9–1430–004 (29) 04.9–1430–004 (10) 04.9–1430–004 (8) 04.9–1430–004 (14) 04.9–1430–004 (14) 04.9–1435–200 04.9–1435–200 (25) 04.9–1435–200 (25) 01.0–1435–001 01.0–1435–100 01.2–1435–200 (17) 01.2–1435–200 (17)

Printed in U.S.A.

01 REV. 7/96

M10.0–1435–007

M10.0–1435-007

MAINTENANCE GLOSSARY - Model 3500 Components of the RR 3000 Series, Model 3500 truck have been listed in chart form to assist the maintenance mechanic in locating these components on the Electrical Diagrams and Exploded Parts pages.

The chart is in columns: COMPONENT; LOCATION; FUNCTION; DIAGRAM; PARTS PAGE. The COMPONENT column contains the abbreviation of the component as it appears on the Diagrams in the Maintenance Section. The LOCATION column gives the general location on the truck

such as on platform or in power unit. the FUNCTION column then explains the function or circuit of that device. The DIAGRAM column gives the page number of the diagram on which the component can be found. The callout in parenthesis following the page number corresponds to the grid callouts on that diagram, locating that component. The PARTS PAGE column includes the exploded parts page number on which the component is located along with the index number, in parenthesis, if applicable.

AUDIBLE INDICATORS Location

Function

Diagram

Parts Page

HN1 HN2

Power Unit Power Unit

Horn Travel Alarm

DIA–1435–009 (B-3) DIA–1435–009 (B-4)

04.0–1435–001 (23) 04.0–1435–001 (25)

Location

Function

Diagram

Parts Page

Power Unit

Power

DIA–1435–012 (B-1)

01.2 –1435–100 (9)

CONNECTIONS Location

Function

Diagram

Parts Page

CA201

Distribution Panel

OverHead Guard

04.3–1430–100 (8)

CA202

Distribution Panel

Hour Meter Signal

CA203

Distribution Panel

Sequence Control

CA204

Distribution Panel

Multifunction Control

CA205

Distribution Panel

Contactor Panel

CA206

Distribution Panel

SCR Control Card

CA207

Distribution Panel

HGT Switches

PC401 PC402 TB403 PC404

Traction Logic Card Traction Logic Card Traction Logic Card Traction Logic Card

Speed Limit Inputs Contactor Coil Inputs Switch/Power Inputs (TB11T) Communications

DIA–1435–004 (A-3) DIA–1435–013 (A-3) DIA–1435–014 (A-3) DIA–1435–004 (A-3) DIA–1435–013 (A-3) DIA–1435–014 (A-3) DIA–1435–004 (A-2) DIA–1435–013 (A-2) DIA–1435–014 (A-2) DIA–1435–004 (A-1) DIA–1435–013 (A-1) DIA–1435–014 (A-1) DIA–1435–004 (B-3) DIA–1435–013 (B-3) DIA–1435–014 (B-3) DIA–1435–004 (B-2) DIA–1435–013 (B-2) DIA–1435–014 (B-2) DIA–1435–004 (B-1) DIA–1435–013 (B-1) DIA–1435–014 (B-1) DIA–1435–005 (B-1) DIA–1435–005 (B-2) DIA–1435–005 (B-2) DIA–1435–005 (B-2)

BATTERY

Battery

950619

04.3–1430–100 (8)

04.3–1430–100 (8)

04.3–1430–100 (8)

04.3–1430–100 (8)

04.3–1430–100 (8)

04.3–1430–100 (8)

5024

Crown 1995 PF-10597-1 Rev. 7/96

Printed in U.S.A.

01 REV. 7/96

M10–1435–001

M10–1435–001

MAINTENANCE CONNECTIONS (Continued) Location TB405 CA406 CA407 CA408 CA409 CA410 CA411 CA412 CA413 CA414 CA415 CA416 CA417 CA418 CA419 CA420 CA421 CA422 CA423 CA424 CA425 CA426 CA427 CA428 CA601 CA602 CA603 CA604 PB605

Power Unit Right Wall Power Unit Power Unit Power Unit Back Wall Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Power Unit Sequence Control Sequence Control Sequence Control Sequence Control Contactor Panel

NB606

SCR Panel

CA801 CA802 CA803 CA804 CA805 CA806 CA807 CA808 CA809 CA810 CA811 CA812 CA813 CA814

Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard Over Head Guard

Function

Diagram

Parts Page

ACC. Function LEDS Over Head Guard Power Key Switch/Hour Meters Console Display F/C Distribution Panel (1) F/C Distribution Panel (1) Multifunction Heater + Multifunction Heater Brake Monitor SW Heater + Brake Monitor SW Heater Brake Pedal SW Heater + Brake Pedal SW Heater F/C Distribution Panel (2) F/C Distribution Panel (2) BV + HGTS1 Heater + HGTS1 Heater HGTS2 Heater + HGTS2 Heater BV + BRES1 Heater + BRES1 Heater BRES2 Heater + BRES2 Heater Sequence Control Inputs Auxiliary Outputs Pump Coil Outputs DC-DC Converter Positive Bus For F/C Distribution Panel 1 & 2 Negative Bus For F/C Distribution Panel 1 & 2 Display Inputs Light/Fan Strobe Light + (LGT4) Strobe Light - (LGT4) Left Work Light + (LGT3) Left Work Light - (LGT3) Fan High Speed + (FNS) Fan Low Speed + (FNS) Fan - (Operator) Dome Light RES + (RES12) Dome Light + (LGT1) Dome Light - (LGT1) Right Work Light + (LGT2) Right Work Light - (LGT2)

DIA–1435–006 (B-1) DIA–1435–006 (B-2) DIA–1435–006 (B-3) DIA–1435–006 (B-4) DIA–1435–007 (B-1) DIA–1435–007 (B-1) DIA–1435–007 (C-1) DIA–1435–007 (B-1) DIA–1435–007 (C-1) DIA–1435–007 (C-1) DIA–1435–007 (C-2) DIA–1435–007 (C-2) DIA–1435–007 (B-2) DIA–1435–007 (B-2) DIA–1435–007 (B-3) DIA–1435–007 (C-2) DIA–1435–007 (C-2) DIA–1435–007 (C-2) DIA–1435–007 (C-2) DIA–1435–007 (B-2) DIA–1435–007 (C-1) DIA–1435–007 (C-1) DIA–1435–007 (C-1) DIA–1435–007 (C-1) DIA–1435–008 (B-1) DIA–1435–008 (B-2) DIA–1435–008 (B-3) DIA–1435–009 (C-1)

04.9–1430–004 (20) 04.9–1430–004 (20) 04.9–1430–004 (29) 04.9–1430–004 (29) 04.9–1430–004 (4) 04.9–1430–004 (4) 04.9–1430–004 (2) 04.9–1430–004 (2) 04.9–1430–004 (32) 04.9–1430–004 (32) 04.9–1430–004 (18) 04.9–1430–004 (10) 04.9–1430–004 (10) 04.9–1430–004 (8) 04.9–1430–004 (8) 04.9–1430–004 (18) 01.2–1435–200 (17) 01.2–1435–200 (17) 01.2–1435–200 (17) 01.2–1435–200 (17) 04.3–1430–001 04.3–1430–001 04.3–1430–001 04.3–1430–001 (4)

Crown 1995 PF-10597-2 Rev. 7/96

DIA–1435–009 (C-2) DIA–1435–009 (C-4) DIA–1435–010 (B-1) DIA–1435–011 (B-1) DIA–1435–011 (B-1) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-2) DIA–1435–011 (B-3) DIA–1435–011 (B-3) DIA–1435–011 (B-3) DIA–1435–011 (B-3)

04.2–20.0–001 04.9–1435–050 04.9–10.0–550 04.9–10.0–550 04.9–1435–050 (8) 04.9–1435–050 (8) 04.9–1435–050 (20) 04.9–1435–050 (20) 04.9–1435–050 (20) 04.9–1435–200 (3) 04.9–1435–200 (3) 04.9–1435–200 (3) 04.9–1435–200 (8) 04.9–1435–200 (8)

Printed in U.S.A.

01 REV. 7/96

M10–1435–002

M10–1435–002

MAINTENANCE CONTACTORS Location

Function

Diagram

Parts Page

F

Contactor Panel

Forward Travel (24V)

R

Contactor Panel

Reverse Travel (24V)

S

Contactor Panel

Steering (24 & 36V)

DIA–1435–005 (B-2) DIA–1435–012 (B-3) DIA–1435–005 (B-2) DIA–1435–012 (B-3) DIA–1435–005 (B-1) DIA–1435–008 (A-3) DIA–1435–012 (B-1)

P1

Contactor Panel

Pump 1 (24V)

DIA–1435–008 (B-3) DIA–1435–012 (B-1)

P2

Contactor Panel

Pump 2 (36/48V)

DIA–1435–008 (B-3) DIA–1435–012 (A-1)

1A

Contactor Panel

Bypass Contactor (24 & 36V) DIA–1435–005 (B-1) (Works in Conjunction with DIA–1435–012 (B-2) SCR Card Settings to Increase Travel Speeds)

FW

Contactor Panel

Field Weakening Coil (Works in Conjunction with 1A & SCR Card Settings to Increase Travel Speeds)

DIA–1435–005 (B-1) DIA–1435–012 (B-2)

04.4–6535–001 04.4–1430–225 (EE) 04.4–6535–001 04.4–1430–225 (EE) 04.1–1430–003 (25) 04.1–1430–052 (25) 04.1–1430–102 (25) 04.1–1430–200 (19) 04.1–1430–225 (24) 04.1–1430–003 (17) 04.1–1430–052 (17) 04.1–1430–102 (17) 04.1–1430–200 (15) 04.1–1430–225 (19) 04.4–1430–002 04.1–1430–052 (31) 04.1–1430–102 (31) 04.1–1430–225 (16) 04.4–1430–002 04.1–1430– 003 (4) 04.1–1430–052 (4) 04.1–1430–102 (4) 04.1–1430–200 (4) 04.1–1430–225 (4) 04.4–6535–050 04.4–1430–002 04.4–1430–200 (EE) 04.1–1430–102 (37) 04.4–6535–050

Location

Function

Diagram

Parts Page

FU1

Contactor Panel

Traction Motor

DIA–1435–012 (B-2)

FU2

Contactor Panel

Power Steering Motor

DIA–1435–012 (B-2)

FU3

Contactor Panel

Pump 1 Motor

DIA–1435–012 (B-2)

04.1–1430–003 (9) 04.1–1430–052 (9) 04.1–1430–102 (9) 04.1–1430–200 (41) 04.1–1430–225 (48) 04.1–1430–003 (26) 04.1–1430–052 (26) 04.1–1430–102 (26) 04.1–1430–200 (37) 04.1–1430–225 (44) 04.1–1430–003 (12) 04.1–1430–052 (12) 04.1–1430–102 (12) 04.1–1430–200 (39) 04.1–1430– 225 (45)

FUSES

Crown 1995 PF-10597-3 Rev. 7/96

Printed in U.S.A.

01 REV. 7/96

M10–1435–003

M10–1435–003

MAINTENANCE FUSES (continued) Location

Function

Diagram

Parts Page

FU4

Contactor Panel

Pump 2 Motor

DIA–1435–012 (B-2)

FU5

Distribution Panel

Key Switch

04.1–1430–052 (35) 04.1–1430–102 (35) 04.1–1430–225 (47) 04.3–1430–100 (13)

FU6

FU7

FU8

FU9 FU10 FU11 FU12 FU13 FU14

DIA–1435–004 (B-4) DIA–1435–013 (B-4) DIA–1435–014 (B-4) Distribution Panel Lights/Fan (K2A) DIA–1435–004 (B-4) DIA–1435–013 (B-4) DIA–1435–014 (B-4) Distribution Panel Options (K2B) DIA–1435–004 (B-3) DIA–1435–013 (B-4) DIA–1435–014 (B-4) Distribution Panel Test Relay (K3) DIA–1435–004 (B-2) DIA–1435–013 (B-2) DIA–1435–014 (B-2) F/C Power Panel (2) BV + From Pos. Bus, K5 F/C DIA–1435–007 (B-3) F/C Distribution Panel K4, Multi-Function SW F/C DIA–1435–007 (B-1) F/C Distribution Panel K4, BMS, BRS, HGTS1 F/C DIA–1435–007 (B-1) F/C Distribution Panel K5, Strip Heater 1 F/C DIA–1435–007 (B-2) F/C Distribution Panel K5, Strip Heater 2, DMS F/C DIA–1435–007 (B-2) F/C Power Panel (1) BV +, K4, Multi-Function SW DIA–1435–007 (A-2)

04.9–1430–004 (18) 04.9–1430–004 (22) 04.9–1430–004 (23) 04.9–1430–004 (33) 04.9–1430–004 (34) 04.9–1430–004 (18)

Location

Function

Diagram

Parts Page

Over Head Guard Main Frame Main Frame Over Head Guard

Dome Light Right Work Light Left Work Light Strobe Light

DIA–1435–011 (B-1) DIA–1435–011 (C-1) DIA–1435–011 (C-2) DIA–1435–011 (C-2)

04.9–1435–200 (3) 04.9–1435–050 (8) 04.9–1435–050 (8) 04.9–1435–050 (18)

04.3–1430–100 (14)

04.3–1430–100 (15)

04.3–1430–100 (16)

LIGHTS

LGT1 LGT2 LGT3 LGT4

MOTORS Location

Function

Batt.Volt.

Diagram

Parts Page

Traction

Power Unit

Traction

Pump1

Power Unit

Lift

24V 36V 24V

DIA–1435–012 (A-2) DIA–1435–012 (A-2) DIA–1435–008 (B-3) DIA–1435–012 (B-2) DIA–1435–008 (B-3) DIA–1435–012 (B-2) DIA–1435–008 (B-3) DIA–1435–012 (A-2) DIA–1435–008 (B-3) DIA–1435–012 (B-1) DIA–1435–012 (A-2) DIA–1435–012 (A-2)

03.1–1430–050 03.1–1430–002 02.2–14.0–003

06.2–1430–001 06.2–1430–050

36V Pump2

Power Unit

Lift

24V 36V

Steering

Power Unit

Power Steering 24V 36V

02.2–10.0–006 02.2–14.0–003 02.2–10.0–006

POTENTIOMETERS Location

Function

Diagram

Parts Page

POT-1

Acceleration

DIA–1435–005 (B-2)

04.6–1435–001 (22)

Multi-Function Control

Crown 1995 PF-10597-4 Rev. 7/96

Printed in U.S.A.

01 REV. 7/96

M10–1435–004

M10–1435–004

MAINTENANCE RELAYS Location

Function

Diagram

Parts Page

K1

Distribution Panel

Power Up

04.3–1430–100 (9)

K2

Distribution Panel

Light/Fan Option

K3

Distribution Panel

Test

K4

F/C Distribution Panel

04.9–1430–004 (21)

K5

F/C Distribution Panel

BMS, BRS, HGTS1 Multi-Function SW F/C Strip Heater 1, DMS, Strip Heater 2, THS2 F/C

DIA–1435–004 (B-3) DIA–1435–013 (B-3) DIA–1435–014 (B-3) DIA–1435–004 (B-3) DIA–1435–013 (B-3) DIA–1435–014 (B-3) DIA–1435–004 (B-3) DIA–1435–013 (B-3) DIA–1435–014 (B-3) DIA–1435–007 (B-1) DIA–1435–007 (B-3)

04.9–1430–004 (35)

04.3–1430–100 (10)

04.3–1430–100 (18)

SOLENOID VALVES Location

Function

Diagram

Parts Page

SVA

Power Unit

Torque Generator

DIA–1435–008 (B-2)

SVB1 SVB2 SVC1 SVC2 SVD

Fork Carriage Fork Carriage Fork Carriage Fork Carriage Power Unit

Side Shift Side Shift Reach Reach Lift/Lower

DIA–1435–008 (C-3) DIA–1435–008 (C-3) DIA–1435–008 (C-3) DIA–1435–008 (C-3) DIA–1435–008 (B-2)

SVE

Power Unit

Lift/Lower

DIA–1435–008 (A-2)

02.0–1430–001 (23) 02.0–1430–050 (22) 02.0–1430–100 (23) 02.0–1430–800 (1) 02.0–1430–800 (1) 02.0–1430–600 (1) 02.0–1430–600 (1) 02.4–1430–003 (6) 02.4–1430–102 (6) 02.4–1430–003 (2) 02.4–1430–102 (2)

SUPPRESSOR BLOCKS Location

Function

Diagram

Parts Page

SB61 SB62

Power Unit Carriage

A Solenoid D & E Solenoid

DIA–1435–008 (B-2) DIA–1435–008 (B-2)

DB63

Power Unit

Power St.Solenoid

DIA–1435–008 (B-3)

SB64

Main Frame

SVC1 & SVC2 Sol.

DIA–1435–008 (B-3)

SB65 SB66 SB67 SB68 SB69 SB70

Carriage Power Unit Overhead Guard Power Unit Overhead Guard Power Unit

SVB1 & SVB2 Sol. Horn (HN1) Fan Operator (FNS) Travel Alarm (HN2) Flashing Light (LGT4) Fan Compartment

DIA–1435–008 (B-3) DIA–1435–009 (B-3) DIA–1435–011 (C-2) DIA–1435–008 (B-4) DIA–1435–011 (C-1) DIA–1435–011 (C-4)

04.0–1435–001 (7) 02.4–1430–003 (16) 02.4–1430–102 (14) 04.1–1430–003 (31) 04.1–1430–052 (30) 04.1–1430–102 (30) 04.1–1430–200 (30) 04.1–1430–225 (34) 09.0–1430–100 (3) 09.0–1430–300 (3) 09.0–1430–300 (3) 04.0–1435–001 (23) 04.9–1435–050 (20) 04.0–1435–001 (25) 04.9–1435–050 (17) 01.0–1435–001 01.0–1435–100

Crown 1995 PF-10597-5 Rev. 7/96

Printed in U.S.A.

01 REV. 7/96

M10–1435–005

M10–1430–005

MAINTENANCE SWITCHES Location

Function

Diagram

Parts Page

BMS

Traction Motor

Brake Monitor

05.0–1430–252 (9)

BRS

Below Brake Pedal

Brake Release

DMS

Contactor Panel Comp.

(Towards Forks)

Deadman SW (Power On/Off)

DPS ERS FNS FS

Power Unit Left Side Power Unit Left Side Overhead Console Multi-Function Control

Display Faults Erase Faults Fan High/Low/Off Forward Direction

HGTS1

Main Frame Right Side

Free Lift SPD Limit

HGTS2

Main Frame Left Side

270 in. (6860mm) Speed Limit

HGTS3

Main Frame Left Side

2nd Pump Cutout

HGTS4

Main Frame Right Side

Raise Cutout

HNS1 KYS LGT1 LGT2 LGT3 LGT4

Power Unit Overhead Console Overhead Console Overhead Guard Overhead Guard Overhead Guard

Horn On/Off/Test Dome Light Work Light (R.H.) Work Light (L.H.) Strobe Light

DIA–1435–004 (C-3) DIA–1435–007 (C-1) DIA–1435–013 (C-3) DIA–1435–014 (C-3) DIA–1435–004 (C-3) DIA–1435–007 (C-2) DIA–1435–013 (C-3) DIA–1435–014 (C-3) DIA–1435–004 (C-2) DIA–1435–007 (C-3) DIA–1435–013 (C-3) DIA–1435–014 (C-3) DIA–1435–006 (B-2) DIA–1435–006 (B-2) DIA–1435–011 (C-1) DIA–1435–004 (A-1) DIA–1435–013 (A-1) DIA–1435–014 (A-1) DIA–1435–004 (C-1) DIA–1435–007 (C-2) DIA–1435–013 (C-1) DIA–1435–014 (C-1) DIA–1435–004 (C-1) DIA–1435–007 (C-2) DIA–1435–013 (C-1) DIA–1435–014 (C-1) DIA–1435–004 (C-1) DIA–1435–013 (C-1) DIA–1435–014 (C-1) DIA–1435–013 (C-1) DIA–1435–014 (C-1) DIA–1435–009 (B-3) DIA–1435–006 (C-3) DIA–1435–011 (C-3) DIA–1435–011 (C-3) DIA–1435–011 (C-2) DIA–1435–011 (C-1)

MFS1

Multi-Function Control

Multifunction SW1 (Actuates Prior to Primary Raise SW)

MFS2

Multi-Function Control

Multifunction SW2

ORS

Console

Raise Override

Crown 1995 PF-10597-6 Rev. 7/96

DIA–1435–004 (A-1) DIA–1435–007 (C-1) DIA–1435–013 (A-1) DIA–1435–014 (A-1) DIA–1435–004 (A-1) DIA–1435–007 (C-1) DIA–1435–013 (A-1) DIA–1435–014 (A-1) DIA–1435–014 (C-1)

05.0–1435–001 (50)

04.0–1435–001 (4)

04.0–1435–001 (12) 04.0–1435–001 (12) 04.9–1435–200 (13) 04.6–1435–001 (32)

07.2–1435–001 (22)

07.2–1435–100 (55)

07.2–1435–100 (58)

07.2–1435–100 (60) 04.6–1435–001 (49) 04.9–1435–200 (14) 04.9–1435–200 (3) 04.9–1435–050 (8) 04.9–1435–050 (8) 04.9–1435–050 (18) 04.9–10.0–550 04.6–1435–001 (39)

04.6–1435–001 (43)

01.0–1435–001 (55) 01.0–1435–100 (56)

Printed in U.S.A.

01 REV. 7/96

M10.0–1435–006

M10.0–1435–006

MAINTENANCE SWITCHES (continued) Location

Function

Diagram

RAS

Multi-Function Control

RS

Multi-Function Control

SQS

Multi-Function Handle

THS1 THS2 THS3

F/C Distribution Panel (1) F/C Distribution Panel (2) Power Unit (P/U Door)

High Speed Raise DIA–1435–004 (A-1) (Trucks W/2 Lift Pumps) DIA–1435–013 (A-1) DIA–1435–014 (A-1) Reverse DIA–1435–004 (A-1) DIA–1435–007 (B-2) DIA–1435–013 (A-1) DIA–1435–014 (A-1) Sequence DIA–1435–004 (A-1) DIA–1435–013 (A-1) DIA–1435–014 (A-1) F/C Thermostat DIA–1435–007 (B-2) F/C Thermostat DIA–1435–007 (C-3) Fan Thermostat DIA–1435–011 (B-4)

BRES1

Power Unit

Battery Retainer Alarm

BRES2

Power Unit

Battery Retainer Alarm

DIA–1435–004 (C-3) DIA–1435–006 (B-1) DIA–1435–007 (C-1) DIA–1435–004 (C-3) DIA–1435–006 (B-1) DIA–1435–007 (C-2)

RESISTORS Location

Function

FW RES RES1 RES2 RES3 RES4 RES5 RES6 RES7 RES8 RES9 RES10 RES11 RES12 RES13 RES14 RES15

Contactor Panel Under Brake Pedal Under Brake Pedal Power Unit Left Side Multi-Function Controls Multi-Function Controls Multi-Function Controls Multi-Function Controls Main Frame Upper Left Main Frame Upper Right Contactor Panel Contactor Panel Overhead Guard Overhead Guard Overhead Guard Power Unit Door

Field Weakening DIA–1435–012 (B-2) DMS SW Heater DIA–1435–007 (B-4) Brake Release Switch Heater DIA–1435–007 (C-2) Brake Monitor Switch Heater DIA–1435–007 (C-1) Multifunction Heater DIA–1435–007 (C-1) Multifunction Heater DIA–1435–007 (C-1) Multifunction Heater DIA–1435–007 (C-1) Multifunction Heater DIA–1435–007 (C-1) HGTS2 Heater DIA–1435–007 (C-2) HGTS1 Heater DIA–1435–007 (C-2) Contactor Heater (Vertical) DIA–1435–007 (C-3) Contactor Heater (Horizontal) DIA–1435–007 (C-3) Dome Light (LGT1) DIA–1435–011 (B-3) Fan Operator (24 V.) DIA–1435–011 (B-2) Fan Operator (36 V.) DIA–1435–011 (B-3) Fan Compartment DIA–1435–011 (C-4)

RES16 RES17

Power Unit R.H. Power Unit L.H.

BRES2 SW Heater BRES1 SW Heater

Diagram

Crown 1995 PF-10597-7 Rev. 7/96

DIA–1435–007 (C-1) DIA–1435–007 (C-2)

Parts Page 04.6–1435–001 (64)

04.6–1435–001 (32)

04.6–1435–001 (57)

04.9–1430–004 (24) 04.9–1430–004 (13) 01.0–1435–001 (5) 01.0–1435–100 (5) 01.2–1435–100

01.2–1435–100

Parts Page 04.1–1430–102 (42) 04.9–1430–004 (6) 04.9–1430–004 (2) 04.9–1430–004 (4) 04.9–1430–004 (29) 04.9–1430–004 (29) 04.9–1430–004 (29) 04.9–1430–004 (29) 04.9–1430–004 (10) 04.9–1430–004 (8) 04.9–1430–004 (14) 04.9–1430–004 (14) 04.9–1435–200 04.9–1435–200 (25) 04.9–1435–200 (25) 01.0–1435–001 01.0–1435–100 01.2–1435–200 (17) 01.2–1435–200 (17)

Printed in U.S.A.

01 REV. 7/96

M10.0–1435–007

M10.0–1435-007

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