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S e r v i c e M a n u a l

GENERAL MAINTENANCE WARNING TO PREVENT SERIOUS RISK OF INJURY TO YOURSELF AND OTHERS OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS These vehicles may become hazardous if adequate maintenance is neglected. Therefore, adequate maintenance facilities, trained personnel and procedures should be provided.

6. Avoid fire hazards and have fire protection equipment present. Do not use an open flame to check level, or for leakage of electrolyte and fluids or oil. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

Maintenance and inspection shall be performed in conformance with the following practices:

7. Keep shop well ventilated, clean and dry.

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

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

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

9. Capacity, operation and maintenance instruction plates or decals shall be maintained in legible condition.

3. Before leaving the vehicle—

10. All parts of lift mechanisms shall be inspected to maintain them in safe operating condition.

Stop vehicle.

Fully lower the platform.

Place directional controls in neutral.

Turn off power (Battery disconnect).

Remove key.

Block the wheels if vehicle is on an incline.

11. All hydraulic systems shall be regularly inspected and maintained in conformance with good practice. Cylinders, valves and other similar parts shall be checked to assure that “drift” has not developed to the extent that it would create a hazard.

4. Before working on vehicle — a.

Raise drive wheels free of floor or disconnect power sources.

Use chocks or other positive positioning devices.

Block load engaging means, inter masts or chassis before working under them.

Operation to check performance of vehicle or attachments shall be conducted in an authorized safe clearance area.

12. Batteries, motors, controllers, limit switches, protective devices, electrical conductors and connections shall be maintained in conformance with good practice. Special attention shall be paid to the condition of electrical insulation. 13. Vehicles shall be kept in a clean condition to minimize fire hazards and facilitate detection of loose or defective parts. 14. Modifications and additions which affect capacity and safe vehicle operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation and maintenance plates or decals shall be changed accordingly. 15. Care shall be taken to assure that all replacement parts are interchangeable with the original parts and of equal quality to that provided in the original equipment. For further information pertaining to operating and maintenance procedures refer to:

5. Before starting to operate vehicle —

• ANSI/SIA A92.6-1990 Self Propelled Elevating Work Platforms.

Be in operating position.

Place directional control in neutral.

Before operating vehicle, check functions of lift systems, directional control, speed control,

For copies send request to: Scaffold Industry Association Inc. 14039 Sherman Way Van Nuys, CA 91405-2599

Printed in Germany

01 REV. 2/98 MA-2350-001

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Printed in Germany

TABLE OF CONTENTS Title

Revision No. - Date

General Maintenance Instructions --------------- MA–2350–001

01 - 2/98

Table of Contents ------------------------------------ IDX–2350–700 thru –702 Introduction -------------------------------------------- ITD–2350–500 thru –502

01 - 2/98

LUBRICATION AND ADJUSTMENT Lubrication & Adjustment ------------------------ M1.0–2350–001 –002 Lubrication & Adjustment ------------------------ M1.0–2350–010 thru –015

01 - 2/98

Torque Values -------------------------------------- M1.9–2350–001

HYDRAULIC MAINTENANCE Hydraulic System ---------------------------------- M2.0–2350–500

01 - 2/98

DRIVE UNIT MAINTENANCE Wheels ----------------------------------------------- M3.2–2350–001 –002

01 - 2/98

ELECTRICAL MAINTENANCE Electrical --------------------------------------------- M4.0–2350–001 thru –005 Switches --------------------------------------------- M4.0–2350–020 thru –022 Potentiometers ------------------------------------- M4.0–2350–530 Fuses ------------------------------------------------- M4.0–2350–040

01 - 2/98 01 - 2/98

Codes & Symbols ---------------------------------- M4.1–2350–001 –002 System Controller ---------------------------------- M4.2–2350–500 –501

01 - 2/98

Contactor --------------------------------------------- M4.4–2350–500 –501

Printed in Germany

01 REV. 2/98 IDX-2350-700

TABLE OF CONTENTS Revision No. - Date

Title Battery ------------------------------------------------ M4.6–2350–500 thru –504 Service Panel --------------------------------------- M4.8–2350–001 –002

01 - 2/98

PLATFORM MAINTENANCE Platform ---------------------------------------------- M9.0–2350–500

GLOSSARY Glossary ----------------------------------------------- M10–2350–500 –501

WIRING DIAGRAMS Wiring Diagram Index ------------------------------- DIA–2350–500 thru –504

01 - 2/98

CHASSIS PARTS Front --------------------------------------------------- 01.0–2350–500 –501 Rear ---------------------------------------------------- 01.0–2350–550

01 - 2/98 01 - 2/98

Front Axle --------------------------------------------- 01.5–2350–550

HYDRAULIC PARTS Hydraulic System ----------------------------------- 02.0–2350–500

DRIVE UNIT PARTS Drive Wheel ------------------------------------------ 03.2–2350–001

ELECTRICAL PARTS Contactor Panel 24V ------------------------------- 04.1–2350–500

01 - 2/98

Contactor Emergency Disconnect -------------- 04.4–2350–500 Traction Pod ------------------------------------------ 04.6–2350–500 Steering Pod ----------------------------------------- 04.6–2350–550 Service Panel ---------------------------------------- 04.8–2350–500 –501 Gate Switch ------------------------------------------ 04.8–2350–550 Height Switch ---------------------------------------- 04.8–2350–650 Motor Cover ------------------------------------------ 04.8–2350–750 –751

01 - 2/98 01 - 2/98 01 - 2/98 01 - 2/98

Printed in Germany

01 REV. 2/98 IDX-2350-701

TABLE OF CONTENTS Revision No. - Date

Title

MAST PARTS Chain --------------------------------------------------- 07.2–2350–550

01 - 2/98

PLATFORM PARTS Platform ------------------------------------------------ 09.0–2350–500

02 - 10/99

Floorboard ---------------------------------------------- 09.0–2350–550

ACCESSORIES Aisle Guide ------------------------------------------- 10.0–2350–500

Printed in Germany

02 REV. 10/99 IDX-2350-702

INTRODUCTION This manual is intended for the customer or operator who is seeking information about maintenance and service replacement parts.

OPERATOR INSTRUCTIONS This manual does not contain operator instructions. Operator instructions in booklet form are sent with each vehicle. Additional copies can be ordered if required. These booklets are for you and your personnel to ensure years of safe, trouble free operation. When ordering additional copies refer to Crown publication PF12538.

DRIVER TRAINING A Drivers Training Manual and Video are both shipped with each vehicle. Additional copies of each are available through your Crown Dealer.

REPLACEMENT PARTS When ordering replacement parts from your Crown Dealer always specify, along with the part number, the model and serial number of the vehicle. This information will further enable your Crown Dealer to give correct, fast and efficient service. For capacities, technical information and dimensional specifications, please refer to the following sales literature:

Literature

CPG–12543

Specifications

CPG–12545

Copies of publications or videos can be obtained from your Crown Dealer, or from: CROWN Gabelstapler GmbH Kronstadter Straße 11 81677 München Phone: +49 (0 89) 9 30 02 - 0 Fax: +49 (0 89) 9 30 02 - 133

Printed in Germany

01 REV. 2/98 ITD-2350-500

INTRODUCTION This manual is arranged by major sections. The first part of the Control 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 sections, the later portion covers replacement parts. The section descriptions are as follows: Maintenance Section

Replacement Parts

Description

Section

Description

Lubrication and Adjustment

Chassis

Hydraulic

Drive Unit

Electrical

Not Used

Mast

Not Used

Platform

M10

Glossary

Accessories

DIA

Wiring Diagrams T001

The data plate is located on the lower rear section of the third stage mast in the operator compartment and includes a model number and a truck data number.

Load Deck Load Tray Capacity (Equally Distributed Load)

One Person Plus Tools Maximum Weight

mm Platform Lift Ht.

Max. Grade

Max. AMP Hr. Cap.

Hour Rate

Serial Number

Model Number

VDC

From these two numbers the vehicle model, series, series updates, vehicle size and specific truck data can be determined.

Minimum Total Battery Weight

The following will explain the model and vehicle data numbering system.

Vehicle Data Number

Model Year

This vehicle as released conforms to CE regulations. The user is responsible for proper operation and maintanance of this vehicle per the mandantory requirements of the country where it is operated.

Crown Lift Trucks Ltd. Fishponds Road,Wokingham, 175 Berkshire RG41 2JT CL A-E United Kingdom

Voltage

kg Approx. Weight as Equipped. with Battery

bar Hydraulic Pressure

6174E

Printed in Germany

01 REV. 2/98 ITD-2350-501

INTRODUCTION MODEL NUMBER EXAMPLE

WAV50–84 Lift Height – 70 or 84 in. 1780 or 2135 mm Version – Characteristic that distinguishes vehicle from other versions Series Update – Significant change(s) to the product that would not merit a new series number (generation) Image Generator – Work Assist Vehicle The vehicle data number provides you and your dealer with a wealth of information to ensure the selection of proper parts for your vehicle. You may simply provide this number to your dealer, or use the following breakdown if selecting your own part numbers or service information from this manual.

VEHICLE DATA NUMBER EXAMPLE The example of the vehicle data number shown below is a standard vehicle with a 70 in. (1780 mm) lift height, 160 Amp. wet cell batteries, with a 15 Amp. battery charger, vehicle color of Seafoam Green, yellow wheels, with a forward travel alarm, equipped with; an hour meter, strobe light, one (1) storage pocket, aisle guidance and system controller with a handset. Color

1 = Maui Yellow 2 = Seafoam Green 3 = Alpine White

Alarms K = Lift Lower L = Forward Reverse Lift M = Forward Reverse Lower N = Reverse Lift Lower O = Forward Lift Lower P = Forward Reverse Lift, Lower Q = None

A = Forward B = Reverse C = Lift D = Lower E = Forward Reverse F = Forward Lift H = Forward Lower I = Reverse Lift J = Reverse Lower

Batterie Charger 1 = 15 Amp. 2 = 25 Amp.

Meter KE = No Hour Meter HM = Hour Meter

Lift Height 70 = 70 in. (1.780 mm) 84 = 84 in. (2.135 mm)

Storage

- 7 0 11 2 1 A H M 1 2 3 5 1 B

Language Code

Vehicle

– = Standard C = Custom S = Special

A = French B = German C = British English D = Spanish E = Italian F = Dutch

Batteries

1 = Wet 160 Amp. 2 = Wet 205 Amp. 3 = Maintenance Free 195 Amp.

System Controller – = No Handset 1 = Handset

Wheel Color 1 = Yellow 2 = Black

– = No Storage 1 = One Pocket 2 = Two Pockets

Strobe

Aisle Guide

– = No Strobe 1= Strobe

35 = Actual Width

6202 Printed in Germany

02 REV.10/98 ITD-2350-502

LUBRICATION AND ADJUSTMENT Lubrication and Adjustment

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.

To obtain maximum life of any commercial 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. OpeThe operator´s daily checklist is a seperately attached part rator involvement can greatly reduce vehicle down time, of the operator manual, delivered with the vehicle. assist in determining planned maintenance (PM) schedules and ultimately save money. For these reasons, Crown recommends a checklist similar to the Operators Daily OPERATOR´S DAILY CHECKLIST Checklist shown below. VISUAL CHECKS DAMAGE:

No bent, dented, broken or missing par ts

LEAKS:

None inside or under vehicle

TIRES & WHEELS:

Good condition

LOAD TRAY:

Ver tical position latch, storage position latch

CHAINS:

In place, no rust

BATTERIES:

Water level, vent caps in place, leaks and cleanliness

WARNING LABELS, OPERATOR MANUAL:

In place, all readable and complete

SERVICE PANEL:

Closed

Operational Checks Hour Meter (otional):

Operating

Strobe Light(s) (otional):

Operating

Battery Charge:

No abnormal light while charging

Emergency Power Disconnect (Platform/Service Panel):

Cuts power

Horn, Display Lights, Beeper:

Operating

Alarm(s), travel, raise, lower (optional)

Sounds

Motor cover:

Display flashes, Alarm beeps when pressed downward

Steering:

Is smooth, no sticking, no excess play, travels straight

Travel:

All speed ranges, forward/reverse, no unusual noises, no sticking

Raise/Lower:

No hang up, no unusual noises

Braking:

Stops vehicle within safe distance

Parking Brake:

vehicle won´t move when pushed

Sensors:

Removing hand or foot will stop vehicle

Platform Gates:

Won´t elevate above 20" (508 mm) whith gate open. Below 20" (508 mm), speed is slower with gates closed than with open.

Travel Speed Switch:

Travels slower in tur tle position T000

Printed in Germany

M1.0-2350-001

LUBRICATION AND ADJUSTMENT Lubricates & Fluids The following is a list of lubricants and maintenance products recommended when doing Planned Maintenance on Crown vehicles.

LUBRICANT & FLUID CHART TYPE OF LUBRICANT

BRAND NAME

MANUFACTURER

A. Gear Oil

Lubriplate SPO-255

Fiske Bros. Refining Co.

B. Grease (Multipur pose)

Union Unoba EP No. 2 Retinax A* LM Grease*

Union 76 Co. Shell Burmah Castrol

C. Hydraulic Oil

Mobil DTE 24 Union Unax AW ISO 32* Tellus 32* Hyspin AWS 32* Mobil AW32 Sohio Energol HLP32

Mobil Oil Co. Union 76 Co. Shell Burmah Castrol Mobil Oil Co. Sohio

Lubriplate Chain & Steel Cable Fluid

Fiske Bros. Refining Co.

D. Chain & Steel Cable Fluid

*Denotes allowable substitutes, contact factory if unavailable. Chart 1-1

LUBE IDENTIFICATION CHART LUBE TYPE

PART NO.

PACKAGE QTY.

A. Gear Oil

063002-004

Quar ts

B. Grease (Multipur pose)

063002-024

14.5 oz. car t.

C. Hydraulic Oil

063001-001

1 Gallon

D. Chain & Steel Cable Fluid

063001-009

14 oz. spray

Chart 1-2

T002

Printed in Germany

M1.0-2350-002

LUBRICATION AND ADJUSTMENT COMPONENT ACCESSIBILITY For regular maintenance, access to various vehicle components is accomplished by removing covers or panels. 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.

To remove the service panel on front of vehicle, tilt assembly down and remove two screws and disconnect wiring harness (CA403), battery charger LED connector, and charger AC connector (CA404). Components located on service panel are; hour meter (HM) (optional), fuse (FU1), chassis emergency disconnect switch (EDS2), push/drive switch (DTS), front strobe light (CHSLF) (optional), circuit board that has LED's showing status of battery charging cycle, elevation control switch (ECS) and emergency raise/ lower switch (ERLS).

NOTE To remove MRC controller, remove two screws and tilt out controller. Remove six mounting screws, wiring harness (CA401) and power cables to remove controller from mounting bracket.

BE SURE BATTERY CONNECTORS ARE DISCONNECTED.

Chassis To remove the load deck, lift at corners. Remove the load deck to perform maintenance to the hydraulic assembly i.e.; lift pump (M3), hydraulic accumulator, solenoid valve (SV1), hydraulic reservoir and velocity fuse, batteries, controller assembly (MRC), contactor panel, battery charger, service panel, terminal boards TB201, TB202 and diode block. To remove contactor panel from vehicle, remove two nuts and lockwashers securing the contactor panel to chassis and disconnect electrical connections (CA801). Components located on contactor panel are; Emergency Disconnect Contactor (EDS), horn (HN), travel alarm (ALM) (optional), fuses FU2 & FU3, connector CA801, filter block (SB81) and suppressor blocks (SB82 & SB83).

To remove battery charger, remove the four screws and disconnect the DC & AC power cords, CA404 & CA407. Components located on battery charger are; manual reset circuit breaker, status lights and switch to select which type of battery is being charged i.e.; wet cell/sealed. To remove the rear chassis cover, raise platform and remove seven screws and lift off of vehicle. Components located under the rear chassis cover are; chain slack switches (CHSL & CHSR), lift chain anchor, left & right drive motor assemblies i.e.; motor(s) (M1 [CA601] left & M2 [CA602] right), gear box & brake (CA603 & CA604 left & CA605 & CA606 right), left front/rear motor cover switches (FRMCS & FLMCS), right front/rear motor cover switches (RRMCS & RLMCS) and terminal boards TB301 & TB302.

Load Deck Rear Cover

Service Panel

6143-01

Note: Platform shown partially elevated and service panel open for illustration purposes.

Chassis Illustration 1.0-1 Printed in Germany

02 REV.4/98 M1.0-2350-010

LUBRICATION AND ADJUSTMENT Platform/Mast 3rd Stage Remove two screws that secure mast cap to expose yoke assembly. To remove traction control pod, remove the two hex head screws & two torx head screws, disconnect CA502 & CA702. Components located on traction control pod are; traction potentiometer (POT2), emergency disconnect switch (EDS1), raise switch (RAS1), lower switch (LOS1), horn switch (HN), high speed switch (HSS), presence override switch (PORS) and right hand presence sensors (RHS). To remove steer control pod, remove the two hex head screws & two torx head screws, disconnect CA501 & CA701. Components located on steer control pod are; steering potentiometer (POT1), Curtis display CAN board, key switch (KYS) and left hand presence sensors (LHS). Remove four screws that secure access panel on front of 3rd stage mast to expose lift chain anchor point. Remove two screws that secure cover on mast height switches (RCS, HTS20 & CA304) on left side of platform near bottom of 3rd stage mast. To remove floorboard, disconnect CA303, push floorboard up and lift out. Components located on floorboard are; left & right foot brake switches (DMSL & DMSR). Remove four screws that secure two gate switch covers on the bottom of the left and right gates to expose gate switches. Components located on gates are; gate closed switch left (GCSL), gate open switch left (GOSL), gate closed switch right (GCSR) and gate open switch right (GOSR).

Printed in Germany

02 REV.4/98 M1.0-2350-011

LUBRICATION AND ADJUSTMENT 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 excessive dust or moisture will require modification of the schedule to fit that particular application. The use of high grade lubricants and fluids is recommended. 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.

Yoke Assembly Steering Pod

Traction Pod

Platform

DeadMan Switches

Load Tray

Gate Switches

Mast Height Switches Lift Chain Anchor Point Access Cover

Rear Cover

6149-01

Note: Platform shown partially elevated and service panel open for illustration purposes.

Illustration 1.0-2 Printed in Germany

02 REV.4/98 M1.0-2350-012

LUBRICATION AND ADJUSTMENT

Note: Platform shown partially elevated and service panel open for illustration purposes.

6150-01

Illustration 1.0-3 LUBRICATION CHART INDEX

L-1 L-2

COMPONENT

Drive Unit - Left Drive Unit - Right

LUBE TYPE

QTY.

90 da.

180 da.

270 da.

360 da.

150 hr.

300 hr.

450 hr.

600 hr.

1st Change

Change

(150 - 175 ml)

1st Change

Change

(150 - 175 ml)

1st Change

Change

L-3

Front Axle

As Required

Lube

L-4

Top 4.0 in. (100 mm) of Mast

As Required

Lube

L-5

Aisle Guide Rollers - Left

As Required

Lube

L-6

Aisle Guide Rollers - Right

As Required

Lube

L-7

Hydraulic Reservoir

3 Qts. (2.8 l)

L-8

Lift Chain

As Required

Lube

See chart 1-2 for Lube designation explanation (M1.0-2350-002). Lubrication intervals must be changed to a frequency that will minimize wear on moving shafts and parts on vehicles used in less desirable operating conditions. T-003

Chart 1-3 Note: Hours are based on traction hours which is accessible by using Curtis handset.

Printed in Germany

02 REV.4/98 M1.0-2350-013

LUBRICATION AND ADJUSTMENT

6151-01 Note: Platform shown partially elevated and service panel open for illustration purposes.

Illustration 1.0-4

INSPECTION & ADJUSTMENT CHART: CHASSIS FRONT INDEX

COMPONENT

90 da.

180 da.

270 da.

360 da.

150 hr

300 hr.

450 hr.

600 hr.

I-1

Electrical i.e.: Connectors, Cables and Wiring

Check

I-2

Front Axle and Casters

Check

I-3

Wheels, Front & Rear

Check

I-4

Service Panel

Check

I-5

Front Strobe Light (Optional)

Check

I-6

Load Deck

Check

I-7

Batteries i.e.; For Leakage, Cracks & Corrosion

Check

I-8

Battery Connector

Check

I-9

Contactor Panel

Check

I-10

Hydraulic Assembly i.e.; Pump, Motor (M3)

Check

I-11

Hydraulic Accumulator, and Reservoir Filler Cap

Check

I-12

Battery Charger

Check

I-13

Dynamic Cable Tension Area

Check

I-14

Chassis Side Covers

Check

I-15

MRC Controller

Check

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

Note: Hours are based on traction hours which is accessible by using Curtis handset.

T004

Printed in Germany

02 REV.4/98 M1.0-2350-014

LUBRICATION AND ADJUSTMENT

6152-01 Note: Platform shown partially elevated and service panel open for illustration purposes.

Illustration 1.0-5

INSPECTION & ADJUSTMENT CHART: CHASSIS REAR INDEX

COMPONENT

90 da.

180 da.

270 da.

360 da.

150 hr

300 hr.

450 hr.

600 hr.

I-1

Electrical i.e.: Connectors, Cables and Wiring

Check

I-2

Drive Unit - Left (Motor, Gearbox and Brake)

Check

I-3

Drive Unit - Right (Motor, Gearbox and Brake)

Check

I-4

Chain Slack Switches

Check

I-5

Lift Chain Anchor Point

Check

I-6

Motor Cover Switches (FLMCS & RLMCS)

Check

I-7

Motor Cover Switches (FRMCS & RRMCS)

Check

I-8

Rail Guidance Rollers - Left (Optional)

Check

I-9

Rail Guidance Switch Optical - Left (RGSL

Check

I-10

Rail Guidance Rollers - Right (Optional)

Check

I-11

Rail Guidance Switch Optical - Right (RGSR)

Check

I-12

Chassis Springs i.e.: Broken, Missing

Check

I-13

Lift Cylinder i.e.: For Cracks, Leakage & Secure Mounting to Vehicle

Check

I-14

Rear Chassis Cover in Place & Secure

Check

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

Note: Hours are based on traction hours which is accessible by using Curtis handset.

T005 Printed in Germany

02 REV.4/98 M1.0-2350-015

LUBRICATION AND ADJUSTMENT

6201-01

Note: Platform shown partially elevated and service panel open for illustration purposes.

Illustration 1.0-6 INSPECTION & ADJUSTMENT CHART: PLATFORM INDEX

COMPONENT

90 da.

180 da.

270 da.

360 da.

150 hr

300 hr.

450 hr.

600 hr.

I-1

Electrical i.e.: Connectors, Cables and Wiring

Check

I-2

Traction Pod (POT2, HN, RAS1, LOS1, EDS1,HSS, RHS & PORS)

Check

I-3

Steering Pod (POT1, KYS & LHS)

Check

I-4

Platform Padding For Wear & Tear

Check

I-5

Floorboard Mat For Wear, Tear & Missing

Check

I-6

Yoke For Wear & Cracks

Check

I-7

Load Tray For Damage, Secure to Vehicle

Check

I-8

3rd Stage Mast Lift Chain Anchor Point

Check

I-9

Dynamic Cable Tension Area

Check

I-10

Lift Chain For Tension, Wear & Broken/Cracked Links

Check

I-11

Lift Cylinder For Leaks & Cracks

Check

I-12

Foot Brake Switches (DMSL & DMSR)

Check

I-13

Mast Lift Height Switches (RC3 & HTS20)

Check

I-14

Left & Right Platform Gates For Operation

Check

I-15

Left & Right Platform Switches (GOSL, GCSL, GOSR & GCSR)

Check

I-16

Platform Springs For Cracked & Missing

Check

I-17

Left & Right Bolster For Cracks & Secure

Check

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

Note: Hours are based on traction hours which is accessible by using Curtis handset.

T006

Printed in Germany

02 REV.4/98 M1.0-2350-016

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Printed in Germany

TORQUE VALUES STANDARD SCREWS/BOLTS

Self locking screws/nuts

6155

Grade All Crown vehicles are manufactured with grade 5 or better screws and bolts. Instances do occur when grade 5 screws/ bolts are manufactured unmarked. Even though a fastener is unmarked, Crown uses nothing less than grade 5 fasteners. When an unmarked fastener requires replacement, replace with a grade 5 fastener. Refer to the chart below to identify grade.

Self locking screws/nuts are used to secure many components. They are one-piece, all metal and lock when seated. These screws/nuts don't require lockwashers and eliminate separate screw, lockwasher and nut combinations. Vehicles have been thoroughly tested and evaluated utilizing self locking fasteners. Do not replace a self locking screw/ nut with a standard screw/nut and lockwasher.

Grade

Grade Grade Marking

Specification

All self locking fasteners are grade 5 or better. Grade can not be determined by visual inspection. Crown replacements are recommended since quality is established and proven.

Material

SAE-Grade 2 Low Carbon Steel SAE-Grade 5

Medium Carbon Steel Quenched & Tempered

Medium CarbonAlloy SAE-Grade 8 Steel, Quenched & Tempered

Dry torque requirements are specified in the chart below.

T007

Torque Chart – Standard Screws/Bolts Dry torque requirements are specified in the chart below.Torque requirements specified in the maintenance sections of this manual take precedence over torque requirements listed in the following chart.

Screw Diameter

ft.lbs.

Torque Chart – Self Locking Srews/Nuts Torque ft.lbs.

1/4 in.

14 ± 3

19 ± 4

5/16 in.

21 ± 5

28 ± 6

3/8 in.

43 ± 5

58 ± 6

Grade 8

Torque requirements specified in the maintenance sections of this manual take precedence over torque requirements listed in the following chart.

Screw/Nut Diameter

Torque Chart - Standard Screws/Bolts Grade 5

Torque Chart – Self Locking Screws/Nuts

1/4 in.

9±3

12 ± 4

13 ± 4

18 ± 5

7/16 in.

65 ± 10

88 ± 13

5/16 in.

18 ± 5

24 ± 6

25 ± 5

34 ± 7

1/2 in.

95 ± 10

129 ± 13

3/8 in.

32 ± 5

43 ± 6

48 ± 10

65 ± 13

7/16 in.

50 ± 10

67 ± 13

75 ± 10

102 ±13

1/2 in.

75 ± 10

101 ± 13

112 ± 15

152 ± 20

T009

T008

Printed in Germany

M1.9-2350-001

HYDRAULIC SYSTEM

Fill Cap

6101

6100

MANUAL LOWERING VALVE

HYDRAULIC SYSTEM The hydraulic system is powered by a pump and motor assembly incorporating a gear type pump. This pump supplies oil flow for the lift function. The maximum pressure is limited by an integral relief valve. The following is a general description of the system shown above. When the "lift" button is pressed, the pump motor is energized which in turn drives the lift pump. The pump draws hydraulic oil from the reservoir and directs pressurized oil through an internal check valve to the lift cylinder. When the lift cylinder is fully extended, the lift limit switch is actuated shutting off the lift motor.

In the event of an electrical malfunction, solenoid coil failure, etc., the platform can be lowered using the manual lowering valve.

WARNING! To Lower BEFORE USING THE MANUAL LOWERING VALVE, MAKE CERTAIN ALL PEOPLE, INCLUDING YOURSELF, ARE CLEAR OF THE PLATFORM AND LOAD TRAY. WARN THE To Stop OPERATOR TO STAY Lowering COMPLETELY INSIDE THE PLATFORM RAILS. STOP LOWERING IMMEDIATELY IF THE CHAINS BECOME SLACK, OR ANY PART OF THE PLATFORM GETS CAUGHT.

When the "lower" button is pressed, the pump solenoid valve is energized. This allows the flow of hydraulic oil to travel from the lift cylinder through the flow control valve, or velocity fuse, back to the resevoir.

RESERVOIR With the lift cylinder in the fully lowered position and after all air has been bled from the hydraulic system, fill reservoir so that the oil level is at the "full" mark on the reservoir sight gauge. The total capacity of the hydraulic system at this level should be approximately 3 quarts (2.85 litres).

Manual Lower Valve

To lower the platform, push button in, twist counterclockwise 180° and release. In this position the valve will remain open. To stop lowering the platform or return to normal operation, push button in, twist clockwise 180° and release.

HYDRAULIC OILS Use a good grade of hydraulic oil as recommended in the Lubricant and Fluid Chart located in the M1.0 section of this manual. Vehicles equipped to operate in below freezing temperatures must use low temperature fluids also recommended in the M1.0 section of this manual.

Printed in Germany

01 REV.2/98 M2.0-2350-500

WHEELS

4 x 4 x 14 in. 100 x 100 x 355 mm

2 x 4 x 12 in. 50 x 100 x 305 mm

122599

203 Nm 6120-01

Illustration 3.2-1

DRIVE WHEEL REPLACEMENT 1.

Lower platform completely, turn key switch off, remove load deck and disconnect batteries.

Refer to Illustration 3.2-1. Place jack, 122599, at position "A" making sure that it is under frame. Do not try to lift vehicle if jack is under plastic side panel, it will damage the side panel. Place a 2 x 4 x 12 in. (50 x 100 x 305 mm) wood block under the rear frame and lower jack. Vehicle will rest on wood block with wheel about 1/4 in. (6 mm) off of floor.

CAUTION! DO NOT PUT ANY PART OF YOUR BODY UNDER THE VEHICLE DURING THIS PROCEDURE! 3.

Remove hub cap, index 3.

Remove flange nut, index 2 in center of hub.

Remove wheel, index 1 and woodruff key, index 4. If key is damaged replace it. A pry bar may be required to work around the backside of the drive hub to remove from tapered shaft of gearbox.

Install replacement wheel.

Install flange nut, and tighten to 150 ft. lbs. (203 Nm).

Replace hub cap. Jack vehicle up as before, remove wood block, lower and remove jack.

Connect batteries and replace load deck.

Printed in Germany

01 REV.2/98 M3.2-2350-001

WHEELS CASTER WHEEL REPLACEMENT 1.

Lower platform completely, turn key switch off, remove load deck and disconnect batteries.

Refer to Illustration 3.2-1. Place jack, 122599, at position "B" making sure that it is under frame. Do not try to lift vehicle if jack is under plastic side panel, it will damage the side panel. Place a 4 x 4 x 14 in. (100 x 100 x 355 mm) wood block under the frame between jack and caster wheel and lower jack. Vehicle will rest on wood block.

Remove hub cap, index 8, with a screwdriver by prying behind the half circles located around outside edge of hub cap.

Remove retaining ring, index 7.

Remove wheel, index 6 and inspect bearings, index 5. If they are ok, remove from wheel and press into new caster wheel. Do not put pressure on inside bearing race, only on outside bearing race.

Put new caster wheel back on spindle and replace retaining ring.

Replace hub cap. Jack vehicle up as before, remove wood block, lower and remove jack.

Connect batteries and replace load deck.

Printed in Germany

01 REV.2/98 M3.2-2350-002

ELECTRICAL MAINTENANCE Before performing maintenance to the vehicle, move the vehicle to an area set aside for maintenance or where there is adequate space to perform the required work. This is a must to insure the safety of others and to insure that proper maintenance is performed.

CAUTION! BE SURE ALL WHEELS ARE CHOCKED BEFORE PROCEEDING, BATTERY IS TO BE DISCONNECTED WHENEVER REMOVING COMPONENTS FROM THE TRUCK AND PROPER GROUNDING AND ANTI-STATIC MEASURES SHOULD BE OBSERVED TO PREVENT STATIC DAMAGE TO ELECTRONIC COMPONENTS. IF NECESSARY TO WORK ON THE VEHICLE WITH THE BATTERY CONNECTED ALL JEWELRY SHOULD BE REMOVED I.E.: RINGS AND WATCHES, AS TO PREVENT POSSIBLE SHOCK FROM METAL CONTACTING ELECTRICAL CIRCUITS.

l l l l l l l l

switch with a push button actuator. Each time the push button is pressed, the switch contacts change condition (open, closed), resetting and energizing the contactor

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The control, drive and lift electrical circuits are individually protected by fuses. Control system troubleshooting is through service codes which are displayed on a handset which is plugged into the electrical system. Service codes are also displayed in code through the display Battery Discharge Indicator lights.

Vehicle is powered by 24 volt electrical system through 4 wet or sealed cell 6 volt batteries connected in series. Operator and vehicle interface to the control system is through switches, sensors and potentiometers. Control system is microprocessor based with program to provide specific outputs with predetermined inputs from interface components. Individually controlled dual drive motors provide forward and reverse travel, steering along with service braking. Steering input to control system is provided through left hand controlled rocker mechanism coupled to a potentiometer. Travel direction and speed is provided by a right hand controlled twist grip coupled to a potentiometer. Raise, lower and horn input is through right hand controlled push buttons. Emergency electrical disconnect is accomplished through an emergency disconnect contactor (ED). The power tips of this contactor provide the power path between the battery and vehicle electrical system. ED coil is controlled by a maintained contact

Printed in Germany

01 REV.2/98 M4.0-2350-001

ELECTRICAL MAINTENANCE Component Accessability Chassis (under load deck) Components

Lift load deck from vehicle.

Load Deck

Suppressor (SB83)

Battery Disconnect

Emergency Disconnect Contactor (ED)

Travel Alarm (ALM)

Fuses FU-2 & FU-3 Filter Block (SB81)

Batteries

Horn (HN) & Suppressor Block (SB82)

MRC Controller

Fuse (FU1)

Pump Motor (M3)

Battery Charging Status Lights

Pump Contactor (P1)

Emergency Disconnect Switch (EDS2) Elevation Control (ECS) Emergency Raise/Lower Switch (ERLS) 6153-01

Battery Charger

Hour Meter (HM)

Suppressor Block (SB21)

MRC1 DB22 Push/Drive Switch (DTS) Note: Platform shown partially elevated and service panel open for illustration purposes.

ILLUSTRATION 4.0-1 Printed in Germany

01 REV.2/98 M4.0-2350-002

ELECTRICAL MAINTENANCE Chassis (under platform) Components

l l

Raise platform to height that would provide a comfortable working area and use hardwood blocks to support platform at this height. Remove mounting screws securing access covers in place and lift from vehicle.

Rear Chassis Cover(s)

Traction Motor (M1)

Front/Rear Left Motor Cover Switchs (FLMCS & RLMCS)

Electric Park Brake(s)

Traction Motor (M2)

Chain Slack Switches (CHSL &CHSR)

Front/Rear Right Motor Cover Switches (FRMCS & RRMCS) Actuator Bar For Left/Right, Front/Rear Motor Cover Switches

6158-01

ILLUSTRATION 4.0-2 Printed in Germany

01 REV.2/98 M4.0-2350-003

ELECTRICAL MAINTENANCE Steering Control Pod

Remove rail pad.

Remove mounting screws.

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Steering (POT1)

Pull pod towards yourself to allow connector to be disconnected. Steering Pod Pull pod to exit restraint rail.

Display

Remove Mounting Hardware

Key Switch (KYS)

6154-01

Remove Rail Pad

Traction Control Pod

Remove rail pad.

Remove mounting screws.

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Steering Pod ILLUSTRATION 4.0-3

Pull pod towards yourself to allow connectors to be disconnected. Pull pod to exit restraint rail.

Lower Switch (LOS1)

Raise Switch (RAS1)

Emergency Disconnect (EDS1)

High Speed Switch (HSS)

Presence Overide Switch (PORS)

Horn Switch (HNS)

Traction Forward/Reverse (Pot2)

Remove Mounting Hardware 6157-01

Remove Rail Pad

Traction Pod ILLUSTRATION 4.0-4 Printed in Germany

01 REV.2/98 M4.0-2350-004

ELECTRICAL MAINTENANCE Platform Floor Components

l l

Lift floorboard to allow connector to be disconnected then lift from platform. Remove screws holding cover around mast in place then lift from platform. Raise Cutout Switch (RCS) & Traction Cutout Switch (HTS20)

Gate Open/Closed Switches (GOLS/GCLS)

Terminal Board (TB301)

Gate Switch Cover Diode Block (DB11)

Floorboard Mat Terminal Board (TB302)

Gate Open/Closed Switches (GOLS/GCLS)

Gate Switch Cover

Foot Brake Switch Left (DMSL) Platform Strobe Lights (PLSLL & PLSLR) Foot Brake Switch Right (DMSR)

Floorboard

6159-01

ILLUSTRATION 4.0-5 Printed in Germany

01 REV.2/98 M4.0-2350-005

SWITCHES CHSL & CHSR Chain Slack Switch

EDS2 Emergency Disconnect Switch

(See Illustration 4.0-7)

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(Illustration 4.0-1)

Located in the base of the vehicle under the platform. Used to detect slack lift chain. No adjustment required, however, correct chain adjustment is required for proper operation.

Located on the service panel.

Pushing button disconnects vehicle power.

No adjustment required.

ERLS Emergency Raise/Lower Switch (Illustration 4.0-1)

DMSL & DMSR Foot Brake Switch

(See Illustration 4.0-4)

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Located in floorboard of the platform.

Used to detect operators position on the vehicle.

Located on the service panel. Allows for maintenance or emergency raise and lower when switch ECS is in the base position. No adjustment required.

No adjustment required.

DTS Push/Drive Switch (See Illustration 4.0-1)

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Located on the service panel. Push position releases brake and disables drive functions. No adjustment required.

ECS Elevation Control Switch (See Illustration 4.0-1)

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Located on the service panel. Used for emergency raise and lower functionsin the base position. (also see ERLS). No adjustment required.

EDS1 Emergency Disconnect Switch (See Illustration 4.0-6)

Located on the traction control pod.

Pushing button disconnects vehicle power.

No adjustment required.

Printed in Germany

01 REV.2/98 M4.0-2350-020

SWITCHES Part Of Service Panel

Replace With Type ABC-15

WARNING Vehicle does not have brakes, steering or travel control when switch in Push position

Push/Drive Switch - DTS

PUSH

Do not push vehicle when operator is on platform. Pushing speed must not exceed 2MPH to prevent damage to vehicle

Elevation Control Switch-ECS

DRIVE PLATFORM

RAISE

BASE

LOWER

Emergency Disconnect Switch - EDS2

EmergencyRaise/Lower Switch - ERLS

Wave Service Product Line 1-888-

6162

ILLUSTRATION 4.0-1

Part Of Platform

Raise Cutout Switch - RCS

Adjusting Screw(s) Height Switch HTS20

Gate Closed Switch Left (GCSL)

6163-01

ILLUSTRATION 4.0-2 Gate Open Switch Left (GOSL)

Gate Closed Switch Right (GCSR)

Gate Open Switch Right (GOSR) 6164-01

ILLUSTRATION 4.0-3

Printed in Germany

01 REV.2/98 M4.0-2350-021

SWITCHES GCSL/GOSL Gate Closed/Open Switch Left

KYS Key Switch

(See Illustration 4.0-3)

(See Illustration 4.0-5)

Located at lower left of platform gate.

Located on steering pod.

lIndicates open or closed safety gate.

Used to energize vehicle.

No adjustment required.

Adjustment required to ensure switch actuates in proper gate position.

FLMCS/RLMCS Front/Rear Left Motor Cover Switch GCSR/GOSR Gate Closed/Open Switch Right (See Illustration 4.0-7) (See Illustration 4.0-3)

Located at lower right of platform gate.

Indicates open or closed gate.

Adjustment required to ensure switch actuates in proper gate position.

HNS Horn Switch

Located at front and rear left of chassis under platform. Disables lift/lower/travel functions when activated. No adjustment required.

LOS1 Lower Switch

(See Illustration 4.0-6)

Located on the traction control pod.

Used to sound horn.

Used to lower platform.

No adjustment required.

HSS High Speed Switch (See Illustration 4.0-6)

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Located on the traction control pod. Used to switch from limited speed to normal speed operation. No adjustment required.

HTS20 20" Height Switch (See Illustration 4.0-2)

Located on lower left side of mast in platform.

Used to determine 20 inch platform height.

No adjustment required.

Printed in Germany

01 REV.2/98 M4.0-2350-022

SWITCHES Part Of Floorboard

Foot Brake Switch DMSL

Foot Brake Switch DMSR Left Hand Presence Senor - LHS

6165-01

ILLUSTRATION 4.0-4

Right Hand Presence Senor - RHS

Main Key Switch - KYS

Emergency Disconnect Switch - EDS1

High Speed Switch - HSS

Presence Over Ride Switch - PORS

6166-01

ILLUSTRATION 4.0-5

Raise Switch - RAS1 Lower Switch - LOS1 Horn Switch - HNS

6167-01

ILLUSTRATION 4.0-6 Printed in Germany

SWITCHES PORS Presence Override Switch

RCS Raise Cutout Switch

(See Illustration 4.0-6)

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(See Illustration 4.0-2)

Located on the traction control pod. Used to override presence sensors and limit performance. No adjustment required.

(See Illustration 4.0-6) Located on the traction control pod.

Used to raise platform.

No adjustment required.

Located on lower left side of mast.

Used to stop lift pump at full extended height.

No adjustment required.

FRMCS/RRMCS Front/Rear Right Motor Cover Switch

RAS1 Raise Switch

(See Illustration 4.0-7)

l l l

LHS/RHS Left/Right Hand Presence Sensor

Located at front and rear right of chassis under platform. Disables lift/lower/travel functions when activated. No adjustment required.

(See Illustration 4.0-5/4.0-6)

LHS located on the steer control pod.

RHS located on the traction control pod.

Senses hand presence.

No adjustment required. Front Right Motor Cover Switch - FRMCS

Front Left Motor Cover Switch - FLMCS

Rear Left Motor Cover Switch - RLMCS

Chain Slack Switch CHSL Chain Slack Switch CHSR

Part Of Chassis

6168

Rear Right Motor Cover Switch - RRMCS ILLUSTRATION 4.0-7 Printed in Germany

01 REV.2/98 M4.0-2350-024

FUSES FUSES When a fuse fails, the associated circuitry should be checked for short circuits before a new fuse is installed. Never jumper a fuse. Attempting to bypass a fuse could seriously damage associated circuitry. Always replace fuse with the same type and rating as specified. Fuse

Location

Circuit

Type & Size

Part Number

Service Panel FU1

6083

ILLUSTRATION 4.0-1 FU1

Service Panel

Control

ABC-15 A

094362-002

FU2 FU3 Contactor Panel

6086

ILLUSTRATION 4.0-2

FU2

Contactor Panel

Traction

ACK-40 A ECK-40 A

076924-011

FU3

Contactor Panel

Lift

ACK-40 A ECK-40 A

076924-011

Printed in Germany

M4.0-2350-040

POTENTIOMETERS

Steering POT1 Traction POT2

6176-01

POT1 Steering Potentiometer

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Located in steering control pod. Provides command signal to system controller for steering function. When replaced or instructed by service codes, potentiometer requires calibration. Reference Controller Settings in this manual and perform Calibration 4, 5 and 6.

6365

POT2 Traction Potentiometer

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Located in traction control pod. Provides command signal to system controller for traction function. When replaced or instructed by service codes, potentiometer requires calibration. Reference Controller Settings in this manual and perform Calibration 1, 2 and 3.

Printed in Germany

M4.0-2350-530

CODES & SYMBOLS WIRING COLOR CODES The following information is an explanation of wiring color codes used.

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

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

WIRING COLOR CODE

ABBREVIATION

COLOUR

NUMBER

FUNCTION

BLK

Black

0 **

Digital Signal

BRN

Brown

1 **

Analog Signal

RED

Re d

2 **

Battery Positive

ORG

Orange

3 **

+12 volts (DC - DC conver ter)

YEL

Yellow

4 **

Third DC- DC conver ter

GRN

Green

5 **

Battery Negative

BLU

Blue

6 **

Isolated Negative

VIO

Violet

7 **

+5 volts (DC - DC conver ter)

GRAY

Gray

8 **

Four th DC - DC conver ter

WH T

White

9 **

Miscellaneous

R/W

Red - White

29 **

Battery Positive after a switch

G/W

Green - White

59 **

Battery Negative after a switch or resistor

** Sequential number from 01 to 99

T010

Printed in Germany

M4.1-2350-001

CODES & SYMBOLS SYMBOLS Momentary Contact Switches Mechanically Operator Actuated Normally Open

Basic Symbols Cont'd ConnectionPoint Mast Cable

Held Closed Horn Held Open

Normally Closed

Momentary Contact Switches Mechanically Actuated

Diode

Solenoide Valve or Relay With Suppression

Normally Open Normally Open Held Closed Normally Closed Held Open Normally Closed

Normally Closed

Normally Open Plug PC Connector CA

Basic Symbols

Jack JC Fuse PM Motor Battery Inductor

Wound Motor Armature

Non-Polarized Capacitor Motor Field Potentiometer Lamp Mov or Transzorb

Power Terminator

Suppressor Remote Negative 6160 Printed in Germany

M4.1-2350-002

SYSTEM CONTROLLER limited to: proper training, wearing eye protection, avoiding loose clothing and jewelry, and using insulated wrenches.

CURTIS 1703 The System Controller is a solid state electronic control for vehicle operation. All vehicle functions are controlled by this unit except for brake release when the Push/Drive switch is in the Push position.

l l l l l

As a vehicle control, the 1703 Controller processes inputs from operator controls and vehicle monitoring devices to provide the desired vehicle action.

Cleaning Although the 1703 controller requires virtually no maintenance if properly installed, the following minor maintenance is recommended in certain applications: 1.

Remove power by disconnecting the battery.

Discharge the capacitors in the controller by connecting a load (such as a contactor coil or a horn) across the controller’s B+ and Bterminals.

As a speed control, the 1703 enables the energy from the batteries to be fed to the electric motors smoothly through the use of power transistors.

Remove dirt or corrosion from the bus bar area. The controller should be wiped clean with a moist rag. Allow it to dry before reconnecting the battery.

Specific functions of the speed control are adjustable by using a plug-in handset.

Make sure the connections to the bus bars are tight. Use two well insulated wrenches for this task in order to avoid stressing the bus bars.

During power up of the vehicle, a system selftest is performed by the controller to make sure system integrity is present for operation.

The speed control portion of the control is also the steering control of the vehicle. By powering the drive motors at different levels, the vehicle will steer in the direction requested by the operator input. The controller also contains the ability of performing diagnostics on the vehicle. Through the status code interface (display or handset), status codes will be displayed and by using the status code descriptions in this manual, the maintenance technician will be directed to the problem area for repair. More information on this feature is located in the Electrical Troubleshooting section of this manual.

MAINTENANCE There are no user-serviceable parts inside the Curtis PMC 1703 controller. No attempt should be made to open the controller. Opening the controller may damage it and will void the warranty. However, it is recommended that the controller exterior be cleaned periodically, and - if a handset is available - this periodic cleaning provides a good opportunity to check the controller’s diagnostic history file.

Safety The 1703 controller is inherently a high power device. When working around any battery powered vehicle, proper safety precautions should be taken. These include, but are not Printed in Germany

01 REV.2/98 M4.2-2350-500

SYSTEM CONTROLLER SPECIAL TOOLS

Curtis Handset

Mini Fit Connector The connector required to connect the control to the vehicle circuitry requires special extraction tool and crimping tool. These tools are available from Crown.

The handset is used to input calibration settings, monitor inputs and outputs, and as a diagnostic aid for troubleshooting.

2621

117615 EXTRACTION TOOL ILLUSTRATION 1

6093P-01

117617 CURTIS HANDSET 804695 REPLACEMENT CORD 2644-1P

ILLUSTRATION 3

117636 CRIMPING TOOL ILLUSTRATION 2

Printed in Germany

01 REV.2/98 M4.2-2350-501

CONTACTOR

ILLUSTRATION 4.4-1 6079

CONTACTOR ED (EMERGENCY DISCONNECT) 24 VOLT 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.

Contacts

l l

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 vehicle frame.

In normal operation, the contacts will become blackened, discolored and roughened. This will not interfere with proper operation and cleaning is not necessary. Check the condition of each contact tip. Look for excessive pitting or deformities that could cause intermittent operation. Silver contact facing may transfer to either the moving or fixed contact and cause buildup on one contact. The contacts should be replaced before the silver contact facing is completely eroded through to the backing material. Do not file tips. Filing will effect proper operation by deforming the convex shape of the tip. Refer to the illustration below. Contact Tip

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. 6091

ILLUSTRATION 4.4-2

Contacts should always be replaced in pairs.

Printed in Germany

M4.4-2350-500

CONTACTOR Contact Replacement 1.

Remove electrical connections to contacts (coils do not have to be disconnected for this procedure).

Remove two (2) screws from top of cover and lift cover assembly from vehicle.

6087

ILLUSTRATION 4.4-3 3.

Disassemble and replace contacts.

Place cover assembly on coils and fasten securely.

Connect cables.

Printed in Germany

M4.4-2350-501

BATTERY BATTERY DISCHARGE INDICATOR/LIFT INTERRUPT The battery discharge indicator/lift interrupt shows the stateof-charge of the battery. When the battery is at "FULL" charge, all segments will be "ON". The battery symbol is yellow in color and all other segments are green. As the battery discharges, one segment at a time will turn "OFF". Eventually, only the battery symbol will be "ON" indicating an approximate 20% charge remaining. The battery symbol will also flash when an approximate 20% charge remains. This is a warning to the operator to recharge batteries. If the truck is continued in operation without recharging batteries, the electronic control will not allow the platform to be raised.

Battery Discharge Indicator/Lift Interrupt

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 (APPROX. 120 G TO ONE LITER OF WATER) APPLIED TO SPILLED ACID UNTIL BUBBLING STOPS, NEUTRALIZES THE ACID FOR SAFE HANDLING AND DISPOSAL.

Safety Rules

Steering Pad 6099-01

ILLUSTRATION 4.6-1

BATTERY WAVE vehicles may be equipped with 6 volt, standard wet cell batteries or with optional maintenance free batteries. Wet Cell Battery

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Maintenance Free Battery

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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 (approx. 120 g to one liter 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 charging the battery, is highly explosive. This gas remains in cells long after charging has stopped. Do not lay metallic or conductive objects on battery. Arcing could result. Do not allow dirt, cleaning solution or other foreign material to enter cells. Impurities in electrolyte has a neutralizing effect reducing available charge.

6113

ILLUSTRATION 4.6-2 Printed in Germany

M4.6-2350-500

BATTERY l l l l l l

Do not touch non-insulated parts of DC output connector or battery terminals to avoid possible electrical shock.

Cleaning Disconnect all AC and DC power connections before servicing the charger. Charger is NOT for outdoor use. Do not expose charger to rain or snow or charge a frozen battery. Charger is designed to charge lead acid batteries ONLY. Attempting to charge dry-cell batteries may cause them to burst and result in personal injuries and property damage. Do not use charger if it has been dropped or otherwise damaged. If battery repair is planned, follow the battery manufacturer's instructions concerning repair practices and procedures.

Inspection

l l l

full charged specific gravity should be between 1.265 and 1.285.

Check for corroded terminals, cracks and inter-tier cable connections.

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 in order 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 (approx. 120 g to one liter 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 overcharged or overfilled. This condition should be investigated and corrected.

Maintenance Free Batteries Sealed Maintenance Free Batteries contain a pressure release valve and under normal operating conditions do not require any special ventilation.

CAUTION!

Inspect battery for lifted cells, loose or broken cell connections or excessive moisture.

DO NOT TRY TO OPEN THIS BATTERY OR REMOVE THE PRESSURE RELEASE VALVE.

Check the electrolyte level before each charge (disregard if vehicle is equipped with maintenance free batteries).

In these batteries, the sulfuric acid is absorbed within a glass separator, which acts like a sponge, and the gases generated while on charge are recombined. Only under severe overcharging, such as connected to an improperly sized charger, will any significant amount of gases be released from the battery. Also, being a valve regulated battery, it never requires watering.

The electrolyte level in wet cell batteries should be maintained at 0.5 inch (12 mm) 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 semiannual 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

Printed in Germany

M4.6-2350-501

BATTERY CHARGER

Charging

The battery charger features an automatic start/stop charge cycle which will cause less battery damage resulting from over/under charging.

To monitor charging status, refer to the 3 LED's on the service panel and/or the 5 LED's on charger.

Before charging, remove deck and be sure charger is set to the correct type of battery; wet or sealed (maintenance free). Sealed (Maintenance Free) Batteries

Service Panel Wet Cell Batteries LED

COLOR Red Yellow Green

INDICATES Abnormal Charging Charge Complete

LED

COLOR Green Yellow Red

INDICATES Charge Complete 80% Charge Incomplete (See Note)

Yellow Red

Charger On Abnormal Cycle

Charger 6114-01

ILLUSTRATION 4.6-3

CAUTION! IMPROPER CHARGER BATTERY SETTING MAY DAMAGE BATTERIES.

Charging Requirements Charging requirements will vary depending on vehicle use. The chart below lists the approximate charging time required to fully charge a battery after discharging battery to 80% of full capacity, assuming a 6 hour discharge rate. BATTERY

15 AMP CHARGER

205 Amp Hour, Wet Cell

17.0 Hours

160 Amp Hour, Wet Cell

13.5 Hours

195 Amp Hour, Maintenance Free

14.0 Hours

BATTERY

25 AMP CHARGER

205 Amp Hour, Wet Cell

10.5 Hours

160 Amp Hour, Wet Cell

8.0 Hours

195 Amp Hour, Maintenance Free

10 Hours

6115-01

ILLUSTRATION 4.6-4

Note: This LED Also Flashes when Sealed/ Maintenance Free Battery is Selected.

Printed in Germany

M4.6-2350-502

BATTERY To charge batteries, plug charger into a 220 V, 15 amp (minimum) AC outlet.

Following is a testing procedure for verifying the integrity of the batteries.

CAUTION! NEVER SMOKE OR BRING FLAME NEAR THE BATTERY. GAS FORMED DURING CHARGING IS HIGHLY EXPLOSIVE AND CAN CAUSE SERIOUS INJURY.

l l

BATTERY TESTING

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Charger will go through a diagnostic self-test. All LED's will flash 3 times, then each LED will flash individually. After a 3 to 5 second delay the charger will turn on. Both the yellow "Charger On" and red "Incomplete" LED will illuminate. A flashing red "Incomplete" LED prior to the yellow "80% Charge" LED illuminating indicates sealed (maintenance free) batteries have been selected. Be sure this is the correct selection. When battery voltages reach 2.35 to 2.38 volts per cell, the yellow LED "80% Charge" will illuminate. When a charge cycle is terminated, both the yellow "80% Charge" and the yellow "Charger On" LED will turn off. The green "Complete" LED will then illuminate.

To stop the charger at anytime during charging, unplug charger.

Abnormal Charge Sequence

Fully charge batteries. After charge is complete, again, plug-in charger. The 80% charge light on the battery charger should come "on" within 5 minutes. Measure the overall battery voltage while charger is "on". Should be greater than 28.2 volts. If the 80% charge light does not come "on",continue charging until light comes "on". If the abnormal light comes "on", the charger is malfunctioning and should be replaced.

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Turn charger "off" and measure the battery voltage. Should be 25.3 volts to 26.0 volts. Measure and record the voltage across each battery. Each battery should be between 6.3 volts and 6.5 volts. Replace any battery that measures less than 6.0 volts.If there are batteries which are 0.3 volts lower than associated batteries, the batteries could be showing signs of undercharging. Return vehicle to service.

If for any reason charging is not complete within 16 to 20 hours or if an over-current condition occurs, the "red" LED will illuminate. Unplug charger to clear and plug-in charger again to restart. If shorted battery cells are detected during a charge cycle, the "red" LED will flash on for 2 seconds and off for 1 second.

Printed in Germany

M4.6-2350-503

BATTERY TROUBLESHOOTING SYMPTOM

PROBABLE CAUSE

REMEDY

Charger will not turn "ON" Does not go thru self-test

AC circut breaker is open at circuit breaker panel.

Check for AC voltage, close.

AC circut breaker is open on charger. Reset circuit breaker. Charger will not turn "ON" after self-test

Charger is not connected to battery.

Connect battery to charger.

Incorrect plug polarity between charger and battery.

Connect plugs according to polarity.

AC Voltage to charger is low.

Check for proper AC voltage.

Low charging current.

Battery and charger voltage do not match. Battery voltage is too high. Make sure charger and battery voltage are properly matched. Reconnect battery to charger to reset voltage readings.

Red abnormal LED flashes

Output current is too high due to sudden shor t at charger.

Remove short circuit condition. Unplug charger to clear flashing LED and plug-in charger again to restart.

RED abnormal LED stays “ON”

Battery not fully charged.

- Battery disconnected from charger before charge cycle was complete.

Battery and charger voltage don’t match.

Match correct battery voltage to charger voltage.

Shor ted battery cell(s).

Check battery for open or shor ted battery cells.

Broken or loose battery and charger connection.

Check for continuity. Tighten battery to charger connections and restar t charge cycle.

Battery failure.

Test batteries as described in Battery Testing.

Insufficient charge time.

Allow enough charging time (see Charging Requirements) for batteries to reach full charge.

Charger cycling between "ON" and "OFF"

Decreased run time

T011

Printed in Germany

M4.6-2350-504

SERVICE PANEL Fuse

Abnormal Charge

Charger LEDs

Charging

US E

FUSE F US E

Charge Complete

WARNING WARNING!

Push/Drive Switch - DTS

ElevationControl Switch - ECS

Replace Fuse With Type ABC-15

Vehicle does not have brakes, steering or travel control when switch in Push position Do not push vehicle when operator is on platform. Pushing speed must not exceed 2MPH to prevent damage to vehicle

PUSH 1/10

Hour Meter - HM (Optional) EmergencyRaise/Lower Switch-EDS2

DRIVE

PLATFORM

RAISE

A.C. Inlet Connector - CA405

Emergency Disconnect Switch - EDS2 BASE

LOWER

Wave Service Product Line 1-888-

4304

ILLUSTRATION 1

A.C. Inlet Connector - CA405 Provided so charger can be plugged into a 220 V, 15 amp (minimum) AC outlet. Locate cord so it will not be stepped on, tripped over, or otherwise subject to damage or stress. Check extension cord:

The extension cord plug pins must be the same number, size and shape as the charger inlet plug.

Check extension cord wiring and condition.

Be sure wire size can safely handle load.

A.C. Cord Reel, Retractable (Optional) - CA405 Provided so charger can be plugged into a 120V, 15 amp (minimum) AC outlet. Locate cord so it will not be stepped on, tripped over, or otherwise subject to damage or stress. Check for cuts and other damage. Verify reel retracts freely.

Charger LEDs Three LED's are provided to monitor charging status. When the charger is initially "plugged-in", it will perform a diagnostic self-test. All three LED's will flash 3 times, then each LED will flash individually. After a 3 to 5 second delay, the charger will turn "ON" and the yellow, charging LED will illuminate. After charging is complete the yellow, charging LED will turn "OFF" and the green, charge complete LED will turn "ON".

mal LED will illuminate. Unplug charger to clear and plug-in charger again to restart. If shorted battery cells are detected during a charge cycle, the red, abnormal LED will flash on for 2 seconds and off for 1 second. For additional information, see Battery, section M4.2.

Push/Drive Switch - DTS When this switch is in the Drive position, normal operation of steering and traction is possible. If the vehicle must be pushed or towed, place switch in the Push position to electrically release brakes. Traction, steering and lift/lower is disabled at this time. Pushing or towing speed must not exceed 2 MPH to prevent damage to the controller. The drive motors are permanent magnet motors and when the vehicle is pushed or towed will act as generators. If vehicle is pushed or towed in excess of 2 MPH, enough current may be generated to destroy the controller. If pushing or towing is to exceed 2 MPH, disconnect motor connectors CA601 and CA602. For normal operation, the switch must be returned to the Drive position. This switch does not require adjustment.

WARNING! VEHICLE DOES NOT HAVE BRAKES, STEERING OR TRAVEL CONTROL WHEN SWITCH IS IN PUSH POSITION! Do not push vehicle while operator is on platform.

If for any reason charging is not complete within 16 to 20 hours or if an over-current condition occurs, the red, abnor-

If drive motors are connected to electrical circuit pushing speed must not exceed 2 mph to prevent damage to vehicle. Printed in Germany

01 REV. 2/98 M4.8-2350-001

SERVICE PANEL Elevation Control Switch - ECS Place this switch in the Base position and the emergency raise/lower switch (ERLS) on the service panel is active. Platform raise, lower switches and steer/traction pots are disabled at this time. Traction, steering, lifting and lowering is not possible with switch at base position. For normal operation, return switch to the Platform position. This switch does not require adjustment.

Emergency Disconnect Switch - EDS2 Pushing the button depresses the EDS2 switch plunger. Power is removed from the emergency disconnect contactor coil which opens its contact and removes power from the lift, lower and traction circuit. To power the truck backup, push button again to release EDS2 switch plunger. The keyswitch must then be cycled OFF and back to ON. This switch requires no adjustment. Also see Switches, section M4.0.

Emergency Raise/Lower Switch - ERLS When the elevation control switch is in the Base position, platform raise and lower can be controlled by this switch. This switch does not require adjustment.

Fuse - FU1 FU1 is the control fuse. If it fails, the truck can not be powered-up. Replace with an ABC-15A fuse. Also see Fuses, section M4.0.

Hour Meter (Optional) - HM The Hour Meter is used to accurately record the operatorin-position time (feet on brake release pedals). This instrument serves as an aid in determining a lubrication and maintenance schedule.

Printed in Germany

01 REV.2/98 M4.8-2350-002

PLATFORM LOAD TRAY 1.The load tray is designed to carry a maximum load of 45 kg (Models whose Serial-No. is starting with 10A), or 90 kg (Models whose Serial-No. is starting with 9A). 2.The load tray can be adjusted up or down to four different positions. 3.The load tray can be locked in the full vertical position for better access to the load deck. Load Tray

Load Tray Locking Pin

Locking Pin

70°

Carriage

Track

6095

Load Tray in Locked Position

Operation

Load Tray in Un-Locked Position

ILLUSTRATION 9-1

1.To move the load tray to a different position, rotate it up approximately 70° to release the locking pin as shown in Illustration 9-1 and move it up or down as desired. To lock the load tray in position rotate it back to the horizontal position. Push down at the rear of the tray to insure that the locking pin is at the bottom of the retaining slot. 2.To lock the load tray in the full vertical position. Rotate it up as far as it will go, lower until it comes in contact with the spring cushion, and then push it down to compress the spring cushion. Push the load tray under the lip on top of the track and allow it to spring back up slightly to lock in position.

Printed in Germany

02 REV.10/99 M9.0-2350-500

GLOSSARY Components, shown on the Electrical Diagrams, are listed in the following chart to assist the maintenance mechanic in locating these components on Parts Breakdown forms. The chart is in columns: COMPONENT; LOCATION; FUNCTION; PARTS BREAKDOWN.The COMPONENT (first) 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 PARTS BREAKDOWN column includes the parts breakdown page number on which the component is located along with the index number, in parenthesis, if applicable.

COMPONENTS

AUDIBLE INDICATORS Location

Function

Parts Breakdown

ALM

Contactor Panel

Warning Alarm

04.1–2350–001 (3)

Contactor Panel

Horn

Chassis

Power

01.0–2350–001 (2)

Contactor Panel

Emergency Disconnect

04.1–2350–001 (1)

FU1

Service Panel

Control

04.8–2350–001 (10)

FU2

Contactor Panel

Traction

04.1–2350–001 (2)

FU3

Contactor Panel

Raise

04.1–2350–001 (2)

CHSLF

Service Panel

Front Strobe

04.6–2350–050 (15)

PLSLL

Platform

Left Rear Strobe

09.0–2350–003 (9)

PLSLR

Platform

Right Rear Strobe

09.0–2350–003 (9)

Truck Hour Meter

04.6–2350–050 (14)

04.1–2350–001 (4)

BATTERY Battery

CONTACTORS ED

FUSES

LIGHTS

MISCELLANEOUS HM

Service Panel

T013

Printed in Germany

01 REV.2/98 M10.0-2350-500

GLOSSARY COMPONENTS

SWITCHES Location

Function

Parts Breakdown

CHSL

Chassis (Below Platform)

Left Chain Slack

07.2–2350–550 (4)

CHSR

Chassis (Below Platform)

Right Chain Slack

07.2–2350–550 (3)

DMSL

Platform (Left Floorboard Pedal)

Brake

09.0–2350–550 (2)

DMSR

Platform (Right Floorboard Pedal)

Brake

09.0–2350–550 (2)

DTS

Ser vice Panel

Push/Drive

04.8–2350–500 (8)

ECS

Ser vice Panel

Elevation Control

04.8–2350–500 (8)

EDS1

Traction Pod

EDS2

Ser vice Panel

ERLS

Ser vice Panel

Emergency Raise/Lower

04.8–2350–500 (7)

FLMCS

Chassis (Below Platform)

Front Left Motor Cover

04.8–2350–750 (2)

FRMCS

Chassis (Below Platform)

Front Right Motor Cover

04.8–2350–750 (2)

GCSL

Platform (Below Left Gate)

Gate Closed Switch Left

04.8–2350–500 (4)

GCSR

Platform (Below Right Gate)

Gate Closed Switch Right

04.8–2350–500 (3)

GOSL

Platform (Below Left Gate)

Gate Open Switch Left

04.8–2350–500 (3)

GOSR

Platform (Below Right Gate)

Gate Open Switch Right

04.8–2350–500 (4)

HNS

Contactor Panel

Horn

04.6–2350–500 (5)

HTS20

Platform (Directly Above Floorboard on Mast)

20 in. (510 mm) Sense for Traction Cutout

04.8–2350–650 (3)

KYS

Steering Pod

Main Key

04.6–2350–550 (2)

LOS1

Traction Pod

Lower

04.6–2350–500 (4)

RAS1

Traction Pod

Raise

04.6–2350–500 (2)

RCS

Platform (Directly Above Floorboard on Mast)

Raise Cutout

04.8–2350–650 (2)

RGSL

Chassis

Rail Guidance Switch Left

RGSR

Chassis

Rail Guidance Switch Right

RLMCS

Chassis (Below Platform)

Rear Left Motor Cover

04.8–2350–750 (1)

RRMCS

Chassis (Below Platform)

Rear Right Motor Cover

04.8–2350–750 (1)

Platform Emergency Disconnect Chassis Emergency Disconnect

04.6–2350–500 (1) 04.8–2350–500 (9)

Printed in Germany

01 REV.2/98 M10.0-2350-501

T012

ELECTRICAL DIAGRAMS This electrical diagram index lists the diagrams with the portion of the vehicle covered by each diagram. Title

Page Number

Block Diagram

DIA–2350–501

Schematic

DIA–2350–502

Wet Cell Batteries

DIA–2350–503

Maintenance Free Batteries

DIA–2350–504

Revision

01 - 2/98

Printed in Germany

01 REV.2/98 DIA-2350-500

BLOCK DIAGRAM

Left Hand Control

(Presence Senors)

CAN Display

Platform

(Presence Senors)

Right Hand Control

Platform Termination

Platform Chassis

Chassis Termination

Battery

Battery Charger

Service Panel

System Controller

120129

NOTES: 1. OPTIONS ARE SHOWN IN DASHED BOXES

Printed in Germany

DIA-2350-501

PC/ Handset

SCHEMATIC

(x4 in Series)

MRC1 Controller

Tilt Sensor

RT Tract Motor Out

Platform NEG

LT TRAC Motor Out

POT1 (Steer)

120130

Battery Charger

Chassis NEG

Display

POT2 (Traction)

NOTES: 1. VEHICLE SHOWN FULLY LOWERED WITH NO OPERATOR PRESENT, GATES FULLY OPEN, CONTROL IN PLATFORM NOT CHARGING, OUT OF RAIL, LEVEL FLOOR, IN HIGH PERF MODE, HAND SENSOR ACTIVE 2. CIRCUT OPENS UPON CHARGING, DE-ENERGING ED COIL. 3. OPTIONS ARE SHOWN IN DASHED BOXES

Printed in Germany

DIA-2350-502

POWER CABLES WET CELL BATTERIES Service Panel

Battery Charger

Battery Connector CA802

Hydraulic Unit

120133

NOTES: 1. ED-B AND COIL APPEAR ON CONTACTOR PANEL PICTORIAL 2. P1 COIL APPEARS ON CHASSIS PICTORIAL 3. CIRCUT OPENS UPON CHARGING, DE-ENERGIZING ED COIL 4: ALL POWER CABLES (84568) ARE #6 Printed in Germany

01 REV.2/98 DIA-2350-503

POWER CABLES MAINTENANCE FREE BATTERIES Service Panel

Battery Charger

Hydraulic Unit

Battery Connector CA802

120144

Printed in Germany

DIA-2350-504

Crown Commercial Products Group Molly Millars Lane l Wokingham Berkshire RG41 2QW United Kingdom Phone: +44 (0) 118 989-8888 Fax: +44 (0) 118 989-8889 www.crown.com 812546-006 • Printed in Germany