Download PDF: Crown Forklift WP2000 Series Pallet Service Manual

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

OPERATOR INSTRUCTIONS This manual does not contain operator instructions. Operator instructions are sent with each truck, additional copies can be ordered if required. These booklets are for you and your personnel to insure years of safe, trouble free operation of your Crown Lift Truck. For operator instructions, refer to Crown publication, “Operator Manual WP2000 Series” (PF12769).

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 Walkie”.

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

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

For Series WP2000 capacities, technical information and dimensional specifications, please refer to the following sales literature: WP2000 Series Literature SF12835 WP2000 Series Specifications SF12836 Copies of publications can be obtained from your Crown dealer or by writing to: Crown Equipment Corporation 44 S. Washington Street New Bremen, OH 45869 This manual is arranged according to major sections. The first part of the page number, found at the bottom of each page, denotes the section in which a particular form will be located. The first portion of the manual covers the written maintenance.

The later portion covers replacement parts. The sectional descriptions are as follows: MAINTENANCE SECTION M1 M2 M3 M4 M5 M6 M7 M8

000601 Crown 2000 PF11838-1

ITD–2720–001

DESCRIPTION Lubrication and Adjustments Hydraulics Drive Unit Electrical Brake Steering Lift Linkage Cylinder

REPLACEMENT PARTS SECTION 1 2 3 4 5 7 8 10

DESCRIPTION Basic Chassis or Power Unit Hydraulic System and Components Drive Unit and Components Electrical Components Brake Assemblies and Brake Systems Lift Structure and Load Backrest Cylinder Accessories

6405 Printed in U.S.A.

ITD–2720–001

INTRODUCTION

The data plate for the WP 2000 series truck is located on top of the power unit cover and includes a model number. From this number, you can identify the truck model, series, series updates, determine relative size or performance and capacity.

Below is an explanation of the model numbering system.

WP 2000 SSERIES E R I E S

Capacity Lbs: (equally distributed load)

Truck Type

Truck Wt. as equipped (with max. batt.)

Battery Type

Approx. Truck Wt. as equip. (less batt.)

D.C. Voltage

Total Battery Weight Lbs.

Max. AMP Hr. Cap.

Max.

Min.

Model Number

Serial Number

Hour Rate

Year Manf.

Max. Grade %

Truck Data Number

Load Tire Tread Width

This truck as released conform to the mandatory requirements of ANSI B56.1

Crown Equipment Corporation, New Bremen, Ohio 45869 USA

TRUCK DATA PLATE

8045

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

*Capacity 45 = 4500 lb. (2040 kg)

Image Generator WP - Walkie Pallet

WP2045-45 Series Major technical and design changes making the product a new and improved generation.

Relative Size or Performance 30 = 7.8 in. (200 mm) battery compartment 35 = 7.8 in. (200 mm) battery compartment with trailer package 40 = 9.0 in. (230 mm) battery compartment 45 = 9.0 in. (230 mm) battery compartment with trailer package

The example of the model number shown above (WP2040-45) is a WP 2000 series. It has a 9.0 in. (230 mm) battery compartment, trailer package and 4500 lb. (2040 kg.) capacity. * Actual rated capacity may vary, depending on special equipment or modifications. Consult capacity plate located on the overhead guard.

Crown 2000 PF11838-2

ITD–2720–002

Printed in U.S.A.

ITD–2720–002

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

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

2. No load on forks.

3. Disconnect battery and chock wheels as needed.

NOTES : • Hydraulic Jack - Capacity 8000 lbs. (3620 kg.)

• Crown part number: 122599 • Collapsed height minimum: 2.25 in. (57 mm) • Raised height maximum: 16 in. (405 mm) • Jack Stand - capacity 10,000 lbs. (4500 kg) Commercially available Hard Wood Block One Side of Truck Only

8099

WARNING

Set Jack Stand Height as Required Not to Exceed 16 in. (405 mm)

Truck stability decreases dramatically when load wheels are raised. Attach sling and overhead lifting device to prevent truck from tipping over when raising the side of the truck.

000601 Crown 2000 PF11853

MA–2720–100

6407 Printed in U.S.A.

MA–2720–100

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT WP2000 In the interest of safety and to ensure compliance with the OSHA Regulations, (Standards - 29 CFR), The control of hazardous energy (lockout/tagout) - 1910.147, Crown has developed guidelines for proper energy control when performing service and maintenance on the WP2000. Before performing any service or maintenance on the WP2000, review the appropriate sections in this service manual for additional procedures to be followed.

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

BATTERY SAFETY RULES

BATTERY CARE

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

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

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

• Do not lay metallic or conductive objects on battery.

Arcing will result.

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

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

CAUTION

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

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

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

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

• Make certain battery used meets weight, size and voltage requirements of truck (refer to serial plate).

NEVER operate truck with an undersized battery.

CHARGING

CAUTION

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

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

6865 Crown 2000 PF11893-1 Rev. 1/01

Printed in U.S.A.

01 REV. 1/01

MA–2720–101

MA–2720–101

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT BATTERY REMOVAL

BATTERY INSTALLATION CAUTION

CAUTION

When removing the battery, move truck to area intended for battery care. Floor must be level.

Turn keyswitch or toggle switch to "off" position and remove key. Disconnect battery and lockout or tagout truck as described in Battery - Lockout/ Tagout in this section. Lower load engaging means completely. Don’t allow any metallic object to come in contact with the top of the battery cells.

This may cause a short circuit when removing, transporting the battery. Use an insulator (such as plywood, plastic caps) to cover the top of the battery posts before and during removal.

When installing the battery, move truck to area intended for battery care. Floor must be level.

Turn keyswitch or toggle switch to "off" position and remove key. Lockout or tagout truck as described in Battery - Lockout/Tagout in this section. Don’t allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when transporting or installing the battery. Use an insulator (such as plywood, plastic caps) to cover the top of the battery posts before and during installation.

CAUTION

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

Industrial Type Battery

Automotive Type Battery

8555

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

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

G

IN

RN

WA nnect t co is no to th is Dottery bahicle. ancemed t ve nten rforis no e Maiing pe hicl r bed ve e fo anailablion. av erat op

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

8448

Printed in U.S.A.

Crown 2000 PF11893-2 Rev. 1/01

01 REV. 1/01

MA–2720–102

MA–2720–102

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT HYDRAULIC WARNING

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

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

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

2. Completely lower load engaging means or, if required for maintenance, block truck at appropriate height as described in Lifting and Blocking of this section.

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

Completely lower forks

RN

IN

G

WA nnect t co s no to thi is Dottery ed bahicle. ance rm t ve inten rfo is no le Maing pe hic bed ve le for anailab n. av eratio op

8449-01

Crown 2000 PF11893-3 Rev. 1/01

Printed in U.S.A.

01 REV. 1/01

MA–2720–103

MA–2720–103

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT LIFTING AND BLOCKING 1. Move truck to a secure non traffic maintenance area with a level floor.

2. No load on forks.

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

4. Lift power unit end with jack and place hard wood blocks under skirt.

NOTES : • Hydraulic Jack - Capacity 8000 lbs. (3620 kg.)

Crown part number: 122599 Collapsed height minimum: 2.25 in. (60 mm) Raised height maximum: 16 in. (400 mm) • Jack Stand - capacity 10,000 lbs. (4500 kg.) commercially available.

• Lifting Straps - capacity 2000 lbs. (900 kg.) commercially available.

5. Lift forks with overhead lifting device for hard wood blocks or jackstands. Set jackstands to the appropriate height, not to exceed 16 inches (400 mm).

6. Jackstands: lift power unit end to appropriate height and place jackstands under skirt. Place additional 2 jackstands under lift structure next to power unit.

Hard wood blocks: place an additional hard wood block under center of battery compartment.

ING RN WA nnect co is

t no to th is Dottery . ed bahicle ance rm t ve nten rfo is no Maiing pe hicler bed ve e fo anailablion. av erat op

ING RN

WA nnect t co is no to th is Dottery . ed bahicle ance rm t ve nten rfo is no Maiing pe hicler bed ve e fo anailablion. av erat op

8451-01

JACKSTANDS

8450-01

BLOCKING Crown 2000 PF11893-4 Rev. 1/01

Printed in U.S.A.

01 REV. 1/01

MA–2720–104

MA–2720–104

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT CAPACITANCE Due to capacitance voltage present in the traction motor controller, whenever performing maintenance which may permit contact with the bus bars and associated power cables, discharge the capacitors.

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

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

3. Place a minimum 100 ohm, 2 watt resistor between the BATT+ and BATT- terminals of the controller for 3 or more seconds.

8

E

1

8134P

Crown 2000 PF11893-5 Rev. 1/01

Printed in U.S.A.

01 REV. 1/01

MA–2720–105

MA–2720–105

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

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

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

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

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

Figure 14990

Crown 1987 PF7886-1 Rev. 1/11

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

29

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

Lubrication Identification Chart Type of Lubricant

Part Number

A

Gear Lube 80W-90 (Typical)

363506-001 363506-012

1 Quart (12) 1 Quart Cans

AA

Automatic Transmission Fluid (Multi-Purpose)

363503-001 363503-012

1 Quart (12) 1 Quart

AAA

Universal Hydraulic & Transmission Fluid

363513-001 363513-012

1 Quart (12) 1 Quart

AAAA

Synthetic Gear Oil 75W-90

363514-001 363514-012

1 Quart (12) 1 Quart

Grease (Multi-Purpose)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

BB(1)

Grease (Low Temperature)

063002-017 063002-046

14.5 oz Cartridge (40) 14.5 oz Cartridges

BBB

Food Grade Grease (Multi-Purpose)

363002-001 363002-030

14 oz Cartridge (30) 14 oz Cartridges

BBBB

Grease (Multi-Purpose) Premium

063002-025 063002-026

14.5 oz Cartridge 5 Gallon

B

Package Quantity

C

Oil (SAE 40)

CC

Engine Oil (10W30)

363500-001 363500-012

1 Quart (12) 1 Quart

D

Hydraulic Oil

363504-101 363504-106

1 Gallon (6) 1 Gallon

DD(1)

Hydraulic Oil (Low Temp)

363505-101 363505-106

1 Gallon (6) 1 Gallon

DDD

Hydraulic Oil - DTE24

063001-021

1 Gallon

E

Channel Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

F

Gear Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

Chain & Cable Lube

363107-001 363107-012

15 oz Can (12) 15 oz Cans

Premium Chain & Cable Lube

363115-001 363115-012

12 oz Can (12) 12 oz Cans

Final Finish - Rubber & Vinyl Dressing

363129-001 363129-012

11 oz Can (12) 11 oz Cans

G

H

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

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

30

Crown 1987 PF7886-2 Rev. 1/11

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

Part Number

I

Grease (Lift Pump Coupling)

063002-039 127801S

1 lb 1 oz

J

Brake Fluid - Dot 5

063004-002 063004-003

12 oz 1 Gallon

K

Grease (Wheel Bearing)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

L

Metal Assembly Spray

063002-021

11 oz Spray

M

Silicone Grease (Clear)

063002-020

5.3 oz Tube

Brake & Parts Cleaner

363102-001 363102-012

14 oz Can (12) 14 oz Cans

Low VOC Brake & Parts Cleaner

363103-001 363103-012

14 oz Can (12) 14 oz Cans

Non-Flammable Brake & Parts Cleaner

363116-001 363116-012

19 oz Can (12) 19 oz Cans

O

Penetrating Lubricant

363104-001 363104-012

20 oz Can (12) 20 oz Cans

P

Premium Formula Multi-Purpose Grease

363108-001 363108-012

11 oz Can (12) 11 oz Cans

Q

White Lithium Grease

363110-001 363110-012

11 oz Can (12) 11 oz Cans

R

Choke & Carburetor Cleaner

363109-001 363109-012

15 oz Can (12) 16 oz Cans

Contact Cleaner - Non-Flammable

363106-001 363106-012

10 oz Can (12) 10 oz Cans

Contact Cleaner

363128-001 363128-012

11 oz Can (12) 11 oz Cans

T

Electrical Connector Oxidation & Corrosion Inhibitor

127189-001

30 cc

U

Battery Cleaner

363124-001 363124-012

18 oz Can (12) 18 oz Cans

V

Battery Protector

363125-001 363125-012

15 oz Can (12) 15 oz Cans

W

Food Grade Machine Lubricant

363127-001 363127-012

12 oz Can (12) 12 oz Cans

X

Food Grade Silicone Spray

363126-001 363126-012

11 oz Can (12) 11 oz Cans

Coolant

363509-101 363509-106

1 Gallon (6) 1 Gallon

Extended Life Coolant

363511-101 363511-106

1 Gallon (6) 1 Gallon

N

S

Y

Crown 1987 PF7886-3 Rev. 1/11

Package Quantity

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

31

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Alternate Lubricants & Fluids Chart Type of Lubricant

Product Name

Manufacturer/ Distributor

A

Gear Lube 80W-90 (Typical)

Crown

Crown

AA

Automatic Transmission Fluid (Multi-Purpose)

Crown

Crown

AAA Universal Hydraulic & Transmission Fluid Crown

Crown

AAAA Synthetic Gear Oil 75W-90

Crown

Crown Mobil Union 76 Co. Shell Burmah Castrol Exxon

B

Grease (Multi-Purpose)

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

BB

Grease (Low Temp) (2)

Lubriplate Alvania RA(1) Helveum O(1)

Fiske Bros Refining Co. Shell Burmah Castrol

BBB Food Grade Grease (Multi-Purpose)

Petro Canada Purity FG

Petro Canada

BBBB Grease (Multi-Purpose) Premium

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

Mobil Shell Chevron

C

Oil (SAE 40)

D

Hydraulic Oil

Crown

Crown

DD

Hydraulic Oil (Low Temp) (2)

Crown

Crown

Mobil DTE 24

Mobil

DDD Hydraulic Oil - DTE24 (3) E

Channel Grease

Factran #2

Standard Oil Co.

F

Gear, Channel & Shaft Grease

Molykote BR-2 Plus

Dow Corning

Chain & Cable Lube

Crown

Crown

Premium Chain & Cable Lube

Crown

Crown

H

Final Finish - Rubber & Vinyl Dressing

Crown

Crown

I

Grease (Lift Pump Coupling)

Nyogel 774F-MS

NYE Lubricants

J

Brake Fluid - Dot 5

Q2-1141 Silicon Brake Fluid

Dow Corning

Grease (Wheel Bearing)

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

Mobil Exxon Fiske Bros. Refining Co.

G

K

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

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

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

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

32

Crown 1987 PF7886-4 Rev. 1/11

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

Product Name

Manufacturer/ Distributor

L

Metal Assembly Spray

Dow Corning

Dow Corning

M

Silicon Grease (Clear)

Dow Corning 111 Compound

Dow Corning

Brake & Parts Cleaner

Crown

Crown

Low VOC Brake & Parts Cleaner

Crown

Crown

Non-Flammable Brake & Parts Cleaner

Crown

Crown

O

Penetrating Lubricant

Crown

Crown

P

Premium Formula Multi-Purpose Grease Crown

Crown

Q

White Lithium Grease

Crown

Crown

R

Choke & Carburetor Cleaner

Crown

Crown

S

Contact Cleaner

Crown

Crown

T

Electrical Connector Oxidation & Corrosion Inhibitor

Nye Grease

NYE Lubricants

U

Battery Cleaner

Crown

Crown

V

Battery Protector

Crown

Crown

W

Food Grade Machinery Lubricant

Crown

Crown

X

Food Grade Silicone Spray

Crown

Crown

Y

Extended Life Coolant

N

Crown 1987 PF7886-5 Rev. 1/11

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

33

Notes:

34

LUBRICATION AND ADJUSTMENT COMPONENT ACCESS

LUBRICATION

To access the drive unit, hydraulic system, contactor panel, etc., remove the power unit cover. Two screws secure the cover to the power unit. After loosening the screws, the cover can be tilted to the front and removed via the control handle.

The following information is intended to provide guidelines for proper lubrication intervals as called out in the lubrication chart. However, some operating conditions will require more frequent checks and lubrication than listed. For example, applications with much dust or moisture will require modification of the schedule to fit that particular application.

NOTE Be sure the battery connector is disconnected.

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

Sources of these lubricants may be from almost any of the oil companies; those listed in M1.0-04.0-002 chart 1-1 are typical and any lubricant with equal specifications may be used.

On trucks equipped to operate in freezer and cooler applications, a mixture of low temperature hydraulic oil and standard hydraulic oil may be required. Refer to section M2.0 for proper mixtures.

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

NOTE Use Planned Maintenance Inspection Reports (PF11827) for WP 2000 trucks as required to record and assure maintenance checks.

8018P

ILLUSTRATION 1

000601

3850

Crown 2000 PF11828-1 Rev. 9/02

Printed in U.S.A.

03 REV. 9/02

M1.0–2720–001

M1.0–2720–001

LUBRICATION AND ADJUSTMENT

L-6

L-7

L-1 L-7

L-1 L-5

L-2

L-3

L-4 ILLUSTRATION 2

8019-01

INDEX L-1 L-2 L-3 L-4 L-5

L-6 L-7

COMPONENT

LUBE TYPE

QTY.

Lift Cylinder Attachment (Top and Bottom) Steer Bearing Load Wheel Bearings Drive Unit Oil

B B B A

AR AR AR 1 quart (0.75 Liter)

Hydraulic Reservoir • Oil

D

1 quart (0.75 Liter) 1 each AR AR

• Return & Suction Filters Control Handle Coil Springs Lift Linkage & Risers (Two Upper Link Fittings, in Power Unit, Not Shown)

B B

30 da.

100 hr.

60 da.

250 hr.

90 da.

500 hr.

6 mo.

1000 hr.

12 mo.

2000 hr.

Check Check Check Check/ 1st Chg. Check

Change

1st Chg. 1st Chg. Check Check

Change Check

Change

CHART 3 See Chart 1-1 and 1-2 for Lube Type designation explanation (M1.0-04.0-001).

Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving parts for trucks operated in environments with much dust & moisture, freezer/corrosion applications, etc.

Crown 2000 PF11828-2 Rev. 9/02

Printed in U.S.A.

03 REV. 9/02

M1.0–2720–002

M1.0–2720–002

LUBRICATION AND ADJUSTMENT

I-1 I-2 I-10 I-9

I-3

I-11

I-4

I-11

I-4 I-5

I-8

I-12

I-6

I-7

I-6

ILLUSTRATION 3

8020

30 da.

100 hr.

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

Travel Controls Battery & Connector Lift Limit Switch Lift Cylinder Seals Charger Caster Wheels and Bearings Drive Tire Hydraulic Lines, Hoses, Connections, etc.

Contactor Tips Transistor Controller Lift Linkage, Risers & Tension Bars Load Wheels and Bearings

60 da.

250 hr.

90 da.

500 hr.

6 mo.

1000 hr.

12 mo.

2000 hr.

Check Check Check Check Check Check Check Check Check Check Check Check

CHART 6 Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

Crown 2000 PF11828-3 Rev. 9/02

Printed in U.S.A.

03 REV. 9/02

M1.0–2720–003

M1.0–2720–003

LUBRICATION AND ADJUSTMENT

I-10

I-1

I-2 I-8 I-9 I-3 I-4 I-5

I-7

I-6

ILLUSTRATION 4

8021

30 da.

100 hr.

INDEX

COMPONENT

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

Control Handle Operation Brake & Override Switches Brake Operation, Adjustment & Mounting Brake Rotors and Friction Plate Brake Hub Key Fork Height Horn Pump & Drive Motor Brushes Pump and Drive Motor Commutator Electrical Connections

60 da.

250 hr.

90 da.

500 hr.

6 mo.

1000 hr.

12 mo.

2000 hr.

Check Check Check Check Check

Change

Check Check Check Check Check CHART 6

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

Crown 2000 PF11828-4 Rev. 9/02

Printed in U.S.A.

03 REV. 9/02

M1.0–2720–004

M1.0–2720–004

C

LIFT LINKAGE

Tension Bar Assembly Removal (Refer to Illustration 1) • With the use of a lifting device, raise and securely block truck to allow access to the tension bars. Refer to lifting and blocking section in this manual.

WARNING

Fork Assembly

Ensure lifting device and blocking equipment has a sufficiently rated capacity for the weight of the truck. Never work under a suspended truck.

WARNING 1

If the truck is placed on its side, the battery must be removed. Also, the vented plug in the drive unit and the hydraulic fluid fill cap on the hydraulic fluid reservoir must be capped to prevent fluid leakage.

Connects To Power Unit

4

• Remove the roll pin (1) from top of the forks and drive out the riser pivot shaft.

2

3 6

• Remove roll pin (2) and drive out pivot shaft (2).

5

4

• Remove the tension bar assembly (3) from the truck.

1 1

Tension Bar Replacement (Refer to Illustration 1) • Remove the tension bar ends (4) from the tension bar (3). To assure proper reinstallation of the tension bar into the tension bar ends, count the number of turns it takes to remove each end.

• Thread the new tension bar into the tension bar ends.

If the number of turns taken vary considerably from one end to the other, compensate to even the thread engagement while maintaining the original center distance between the tension bar ends.

NOTE Item 4 has a R.H. and L.H. designation. Make sure the correct one is placed in its correct location at assembly.

Bottom View Of Tension Bars

ILLUSTRATION 1

8048

Tension Bar Assembly Installation (Refer to Illustration 1) • Connect the tension bar assembly to the riser assembly (1) with the riser shaft (1). When in position, insert roll pin (1).

• Connect the other end of the tension bar assembly to the lower link assembly using shaft (2) and roll pin (2).

• Lubricate all grease fittings.

000601

4764

Crown 2000 PF11839-1 Rev. 1/03

Printed in U.S.A.

01 REV. 1/03

M7.0–2720–001

M7.0–2720–001

C

LIFT LINKAGE

Fork Height • Lower the fork completely. The riser stops should contact the fork ends evenly for both the right and left fork ends. Refer to Illustration 2.

Fork Lift Heights

Height Above Riser Pivot 83mm + 2.0mm (3.25 in. + 0.08 in.)

Part Of Fork Assembly

Forks Completely Lowered

Riser Stop Riser Stops Should Contact Both Sides When Lowered.

Riser Stop

Standard Lift Height 150mm (6.0 in.)

ILLUSTRATION 2

8049

Heel Height 85mm +/– 3.0mm (3.35 in. +/– 0.1 in.)

Floor Surface

Fork Height Adjustment • With the use of a lifting device, raise and securely block truck to allow access to the tension bars. Refer to lifting and blocking section in this manual.

Floor Surface

CAUTION

Ensure lifting device and blocking equipment has a sufficiently rated capacity for the weight of the truck. Never work under a suspended truck.

Trailer Fork Lift Height 130mm (5.0 in.)

• Loosen jam nut on tension bar. Refer to Illustration 1.

8047-01

• Rotate the tension bar using the welded nut (6). Refer to Illustration 1.

• Lower truck and verify fork height at riser pivot point is 83 mm + 2.0 mm (3.25 in. + 0.08 in.) and heel height is 85 mm +/–3.0 mm (3.35 in. +/–0.10 in.). Refer to Illustration 3.

• Repeat the above steps until the riser stops contact the fork ends evenly.

ILLUSTRATION 3

• After adjustments are completed and dimensions are verified, torque the locking jam nut on tension bar to 203 Nm (150 ft. lbs.).

• Repeat the above procedure for the other fork.

• Verify fork lift height. Standard forks lift height should be 150 mm (6.0 in.) and trailer fork should be 130 mm (5.0 in.). Refer to Illustration 3.

NOTE The above procedure focuses on the adjustments of just one tension bar. The height relationship between the right and left forks should be considered when replacing either one or both.

Crown 2000 PF11839-2

Printed in U.S.A.

01 REV. 1/03

M7.0–2720–002

M7.0–2720–002

INSPECTION AND LUBRICATION Caster

Caster

Adjust the casters

The brake and caster systems are adjusted at the factory to supply nominal brake and stable performance for level, smooth, and dry floors, and standard tire and load conditions. After you install the casters, make sure that the truck brake and performance are stable. It could be necessary to change the factory adjustments for the applicable operation conditions. When a truck operates in many conditions, it is not possible to adjust the brakes and casters to operate best for all of the conditions.

Caster Adjustment To make sure that the truck brake and performance are stable, you must adjust the caster for tire wear and tire replacement. Refer to the Caster Adjustment Chart.

Refer to Figure 11.

8. Remove the jam nut (2) from the caster.

9. Remove the adjustment screw (1) from the caster.

10. With your hand, tighten the adjustment screw (1) into the caster. Continue to tighten the adjustment screw 1/2 turn with a wrench.

11. Fully remove the adjustment screw (1) from the caster again.

12. With your hand, tighten the adjustment screw (1) into the caster again. Continue to tighten the adjustment screw three 3/4 turn with a wrench.

13. Tighten the jam nut (2).

WARNING A truck that is not stable can cause an injury.

The adjustment of the casters has an effect on the performance of the truck, which can cause an injury.  If you increase the caster load, you decrease the load on the drive tire and decrease the truck brake and traction operation.  If you decrease the caster load, you decrease how stable the truck is.  Drive tire wear or replacement and floor conditions have an effect on how the truck operates.  Floor conditions in a set up area must agree with floor conditions in the environment.

1 2

Prepare the truck for maintenance Refer to Figure 11.

1. Move the truck to a maintenance area with a level floor.

2. Turn the caster to get access to the adjustment screw (1).

3. Lower the forks fully.

4. Turn the truck OFF. 5. Disconnect the battery.

Fig. 11 (25657-01)

6. Put the chocks against the wheels to prevent the movement of the truck. Refer to SAFETY > Control of Hazardous Energy > Lifting and Blocking.

7. Complete the lockout/tagout procedures for the truck. Refer to SAFETY > Control of Hazardous Energy > Lockout/Tagout Procedures.

Crown 2000 PF11834-1 Rev. 7/12

M1.5-2720-001 02 Rev. 7/12

45

INSPECTION AND LUBRICATION Caster Prepare the truck for operation 14. Remove the wheel chocks.

15. Remove the lockout/tagout tag to operate the truck.

17. Turn the truck ON and make sure that the adjustment is correct. The force of each caster must be approximately 489 N (110 lb), the equivalent of a 50 kg (110 lb) load.

16. Connect the battery.

Caster Adjustment Chart Caster Adjustment

Caster Load

Drive Tire Load

Traction and Brake Performance

How Stable the Truck is and How the Truck Controls

Steer Force

Up

Decreases

Increases

Increases

Decreases

Increases

Down

Increases

Decreases

Decreases

Increases

Decreases

M1.5-2720-002 02 Rev. 7/12

46

Crown 2000 PF11834-2 Rev. 7/12

INSPECTION AND LUBRICATION Metric Torque Values

Metric 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 (mm)

5.8

Class 5.8

M5 through M36

8.8

Class 8.8

M5 through M36

10.9

Class 10.9

M5 through M36

12.9

Class 12.9

M5 through M36

NOTE: Even though a bolt head is unmarked, Crown uses nothing less than class 8.8 in all its bolted assemblies. Instances do occur when class 8.8 bolts are manufactured unmarked. When a fastener is replaced that is unmarked, replace the fastener with a class 8.8.

Fig. 1 (15048-01)

Crown 1989 PF8514 Rev. 2/16

M1.9-06.6-001 05 Rev. 2/16

67

INSPECTION AND LUBRICATION Metric Torque Values

Torque Chart–Metric Hex Head Cap Screws and Nuts Thread Diameter and Pitch

Torque Nm (ft lb) Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

5–8 (4–6)

7–8 (5–6)

8–10 (6–7)

M6 x 1.00

8–10 (6–7)

12–14 (9–10)

15–16 (11–12)

M8 x 1.25

20–25 (15–18)

28–31 (21–23)

34–37 (25–27)

M10 x 1.50

39–43 (29–32)

56–61 (41–45)

68–75 (50–54)

M12 x 1.75

71–76 (52–56)

100–107 (73–79)

119–127 (88–94)

M14 x 2.00

113–122 (83–90)

159–171 (117–126)

190–205 (140–151)

M16 x 2.00

175–190 (129–140)

247–267 (182–197)

296–320 (218–236)

M20 x 2.50

340 357 (251–271)

479–518 (353–382)

574–621 (423–458)

M24 x 3.00

587–635 (433–468)

824–892 (608–658)

990–1071 (730–790)

M30 x 3.50

1175–1274 (867–940)

1654–1792 (1220–1322)

1985–2150 (1464–1586)

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

Torque Chart–Metric Hex Socket Countersink Head Screws Thread Diameter and Pitch

Torque Nm (ft lb) Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

4–7 (3–5)

5–8 (4–6)

7–10 (5–7)

M6 x 1.00

7–10 (5–7)

9–12 (7–9)

11–14 (8–10)

M8 x 1.25

16–19 (12–14)

23–26 (17–19)

27–30 (20–22)

M10 x 1.50

31–34 (23–25)

45–49 (33–36)

54–58 (40–43)

M12 x 1.75

56–60 (41–44)

79–84 (58–62)

94–102 (69–75)

M16 x 2.00

124–146 (99–108)

190–206 (140–152)

228–247 (168–182)

M20 x 2.50

259–281 (191–207)

363–395 (268–291)

437–473 (322–349)

M24 x 3.00

416–451 (307–333)

586–635 (432–468)

702–762 (518–562)

M14 x 2.00

M30 x 3.50 Note: Special torque values in the maintenance and parts sections of this manual override the standard torque values in this section.

M1.9-06.6-002 05 Rev. 2/16

68

Crown 1989 PF8514 Rev. 2/16

INSPECTION AND LUBRICATION Metric Torque Values

Torque Chart–Metric Socket Head Cap Screws Thread Diameter and Pitch

Torque Nm (ft lb) Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

5–8 (4–6)

7–9 (5–7)

8–11 (6–8)

M6 x 1.00

9–12 (7–9)

12–15 (9–11)

15–18 (11–13)

M8 x 1.25

22–24 (16–18)

30–33 (22–24)

35–38 (26–28)

M10 x 1.50

42–45 (31–33)

58–64 (43–47)

71–76 (52–56)

M12 x 1.75

72–77 (53–57)

102–110 (75–81)

122–132 (90–97)

M14 x 2.00

115–125 (85–92)

161–175 (119–129)

194–210 (143–155)

M16 x 2.00

179–194 (132–143)

251–273 (185–201)

301–327 (222–241)

M20 x 2.50

348–377 (257–278)

489–530 (361–391)

588–637 (434–470)

M24 x 3.00

601–651 (443–480)

846–915 (624–675)

1014–1098 (748–810)

M30 x 3.50

1196–1296 (882–956)

1681–1822 (1240–1344)

2017–2187 (1488–1613)

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

Torque Chart–Metric Flanged Hex Head Cap Screws and Nuts Thread Diameter and Pitch

Torque Nm (ft lb) Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

5–8 (4–6)

8–11 (6–8)

9–12 (7–9)

M6 x 1.00

9–12 (7–9)

14–16 (10–12)

16–19 (12–14)

M8 x 1.25

22–24 (16–18)

31–34 (23–25)

38–41 (28–30)

M10 x 1.50

44–48 (33–35)

62–68 (46–50)

75–81 (55–60)

M12 x 1.75

77–83 (57–61)

108–117 (80–86)

130–141 (96–104)

M14 x 2.00

123–134 (91–98)

174–187 (128–138)

209–225 (154–166)

M16 x 2.00

193–210 (143–155)

273–294 (201–217)

327–354 (241–2610)

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

Crown 1989 PF8514 Rev. 2/16

M1.9-06.6-003 05 Rev. 2/16

69

Notes:

70

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

C

HYDRAULIC SYSTEM

CIRCUIT OPERATION

RESERVOIR (See Illustration 2 on the following page)

Lift

With cylinders in the retracted position and after all air has been bled from the system, the oil level in the reservoir is to be approximately 20 mm/0.75 in. below the bottom of the vent cap. The capacity of the reservoir is approximately 0.75 liter/1 quart.

When the lift button is pressed, the pump motor is energized which drives the lift pump. The pump draws oil through a filter mounted inside the pump and motor assembly and directs pressurized oil through an internal check valve to the lift cylinders. When the lift cylinder is fully extended, the lift limit switch (LMS) is actuated shutting off the lift motor. An integral relief valve limits maximum pressure.

Lower When the lower button is pressed, the lowering solenoid valve is energized, shifting the spool. This allows oil to flow from the lift cylinder, through the flow control and return filter, back to the reservoir.

Oil Change The reservoir does not have an oil drain plug. The used oil must therefore be suctioned off or poured from the oil reservoir.

Dispose of used oil via approved disposal methods only.

Suction Pressure Lift Cylinders

Return Lift Cylinders

Lift Circuit

Filter

Lowering Solenoid Valve

Filter

Filter

Filter

Check Valve

Check Valve

Relief Valve

Flow Control

Reservoir

Lowering Solenoid Valve

Flow Control

Relief Valve

M Motor

Lower Circuit

M Pump

Suction Filter

8023-01

170 Bar/ 2465 PSI Return Filter

Vent Cap Motor

Reservoir

Pump

Suction Filter

Vent Cap

170 Bar/ 2465 PSI Return Filter

ILLUSTRATION 1

000601

4557

Crown 2000 PF11836-1 Rev. 12/02

Printed in U.S.A.

01 REV. 12/02

M2.0–2720–001

M2.0–2720–001

C

HYDRAULIC SYSTEM

PUMP & MOTOR ASSEMBLY The pump and motor assembly is mounted near the right lift cylinder and includes the pump, motor, reservoir, filters and valves. See section M2.1 for information concerning pump & motor assembly removal, filters, etc.

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.

Pump and Motor Assembly

4. All connections are to be leak free.

Filler Neck and Vent Cap

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 pump if used in higher ambient temperatures.

Reservoir

ILLUSTRATION 2

8036

For trucks operating continually in temperatures at or above 0 degrees Celsius/32 degrees Fahrenheit, use 100% standard hydraulic oil.

HYDRAULIC LINES AND FITTINGS

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.

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

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

50 40 30 20 10 0 10 20 30 40 C

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.

8037

Crown 2000 PF11836-2 Rev. 12/02

120 100 80 60 40 20 0 20 40 F

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

ILLUSTRATION 3

Printed in U.S.A.

01 REV. 12/02

M2.0–2720–002

M2.0–2720–002

C

HYDRAULIC SYSTEM

CIRCUIT BLEEDING Remove air from the hydraulic system by raising and lowering forks (cycling cylinders) several times. Air present in the system may create foam and because of the foam, oil could spill over from the filler neck. Be prepared to catch oil.

To allow air bubbles to dissipate from oil, don't use pump for approximately 10 minutes after cycling cylinders. Be sure to check oil level after letting oil settle.

DRIFT TEST Fully raise forks with capacity rated load. The load may not drift down for 5 minutes.

Occasionally, a slight creep of the forks may occur due to internal leakage of cylinder seals. However, this can also be caused by foreign material in the system. Raise and lower forks to flush out any foreign material.

Crown 2000 PF11836-3 Rev. 12/02

Printed in U.S.A.

01 REV. 12/02

M2.0–2720–003

M2.0–2720–003

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

C

LIFT PUMP

REMOVAL 1. Lower forks completely, disconnect battery and chock drive tire.

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.

2. Be prepared to catch hydraulic oil by placing pan, cardboard, etc. under truck and on work surface if pump and motor will be disassembled.

3. Disconnect solenoid valve leads.

4. Disconnect motor power cables.

5. Disconnect pressure connection.

6. Support pump and motor and remove unit by disassembling the two mounting screws from power unit.

MOTOR For motor maintenance, refer to section M4.7.

Motor

Power Cables

Relief Valve (Rear of Assembly)

Mounting Screws (Behind Bracket)

Pressure Connection and Check Valve Filler Neck and Vent Cap Lowering Valve Reservoir

8043P-01

ILLUSTRATION 1

000601

8214

Crown 2000 PF11837-1 Rev. 5/04

M2.1–2720–001

Printed in U.S.A.

01 REV. 5/04

M2.1–2720–001

C

LIFT PUMP

FILTERS

PUMP

Pressure Filter

The hydraulic pump is not serviceable and can only be replaced as an assembly. Before replacing pump, be sure the pump is clean.

The pressure filter (150 micron) is integrated within the pressure connection. When disassembling the pressure port, be sure the check valve ball is not lost.

Suction and Return Filters To access suction and return filters (450 micron), the reservoir must be disassembled from the pump connection plate.

To disassemble, remove the four screws from the flange.

After replacing pump: • Use clean, filtered (10 micron minimum) oil to replenish reservoir.

• Start pump without load and let run for a few seconds without pressure to ensure sufficient lubrication.

• Never let pump run without oil.

• If after approximately 20 seconds oil is still foaming, check system (see troubleshooting chart on next page).

• When system has reached operating temperature, check to be sure connections are sealed.

Pump Connection Plate

Pump

Reservoir Check Valve Ball

Flange Pressure Filter

Solenoid Valve

SV

8044

Suction Filter Return Filter

ILLUSTRATION 2

Crown 2000 PF11837-2 Rev. 5/04

M2.1–2720–002

26 26

Printed in U.S.A.

01 REV. 5/04

M2.1–2720–002

C

LIFT PUMP

HYDRAULIC TROUBLESHOOTING CHART Symptom

Probable Cause

Remedy

Noisy Pump

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

Check reservoir.

Check for proper oil viscosity.

Check plumbing.

Check for foreign object and/or clean.

Foaming hydraulic oil

• Pump cavitation • Water in oil

Check reservoir.

Check for proper oil viscosity.

Check plumbing.

Clean and fill reservoir.

Pump or oil overheating

• Oil supply too thin • Contaminated oil • Pump cavitation • System relief valve bypassing

Drain and fill with proper oil.

Drain, clean and fill with clean oil.

Check reservoir. See Foaming oil.

Check relief valve.

Low flow

• Pump cavitation • Foaming hydraulic oil • Relief valve leaking or set too low • Oil too hot

Check reservoir. See Foaming oil.

Check for proper oil viscosity.

Check relief valve.

Check temp. See Oil overheating.

Failure to build pressure

• Defective relief valve • Low oil supply

Check relief valve.

Fill reservoir.

CHART 1

Crown 2000 PF11837-3 Rev. 5/04

M2.1–2720–003

Printed in U.S.A.

01 REV. 5/04

M2.1–2720–003

C

DRIVE UNIT

Drive Unit Attachment To Knuckle Flange

Drive Unit Lubrication Drive unit capacity is approximately 0.95 litres (1 quart). The drive unit lubrication level should be at the oil filler opening.

Refer to Illustration 2.

Filter Vent Drive Unit Cover Drive Motor (Drive Pinion Disassembled)

Drive Tire

Gear Lube Fill And Check Plug

Gear Lube Level

Drive Shaft And Gear

ILLUSTRATION 1

8024P

Pinion Shaft And Gear

50 40 30 20 10 0 10 20 30 40 C 8155

120 100 80 60 40 20 0 20 40 F

Gear Lube (063002-003)

Low Temp Gear Lube (063001-021)

ILLUSTRATION 3

Gear Lube Drain Plug 8025P

ILLUSTRATION 2

000601

4926

Crown 2000 PF11829-1 Rev. 4/03

Printed in U.S.A.

02 REV. 4/03

M3.0–2720–001

M3.0–2720–001

C

DRIVE UNIT

0

Traction Motor See Section M3.1 27

86Nm (63 ft. lbs.)

38

28 29 30

36 35

31

32

33 34

0

26 22B

24

10Nm (7 ft. lbs.)

17 38

22A

23 21

35

20

6 5A

19

9

7

8

18

0

25

4

37 10

0

11

10Nm (7 ft. lbs.)

16

14

122 - 135Nm (90 - 100 ft. lbs.)

1

35 13

38 12

0

2 15 25Nm (18 ft. lbs.)

3 5B

8034-01

ILLUSTRATION 4

Crown 2000 PF11829-2 Rev. 4/03

Printed in U.S.A.

02 REV. 4/03

M3.0–2720–002

M3.0–2720–002

C

DRIVE UNIT Drive Shaft Disassembly (3) (Refer to Illustration 4)

Drive Unit Removal • Lockout and tagout truck. Refer to section MA.

• Remove retaining ring (13) and shim rings (11 & 12).

• Raise and block truck.

• Remove drive shaft (3).

• Remove retaining ring (37) and bearing (8).

CAUTION

Ensure lifting device and blocking equipment has a sufficiently rated capacity for the weight of the truck. Never work under a suspended truck.

• Remove retaining ring (6) and bearing (5A & B).

• Remove shaft seal (4).

Drive Shaft Assembly (3) (Refer to Illustration 4)

• Remove the covers.

• Disconnect electrical connections on the brake and drive motor.

• Remove screws (38). Remove drive unit from knuckle flange.

• Install shaft seal (4) in drive unit housing (9).

• Press bearing (8) into drive unit housing (9) and secure with retaining ring (37).

NOTE

• Drain drive unit oil.

Pack bearing 5A & B with multipurpose grease, 063002-024 or 063002-017 for freezer conditioning trucks.

Drive Motor Disassembly (Refer to Illustration 4) • Remove screws (16,17) to remove drive motor and drive pinion from housing.

• Install bearing cone (5B) on shaft (3).

• Press bearing race (5A) into drive unit housing (9) and secure with retaining ring (6).

• Remove retaining ring (34).

• Remove pinion (33) and bushing (30).

NOTE • Remove shaft seal (31).

Put a thin coat of multipurpose grease, 063002-024 or 063002-017 for freezer conditioning trucks on shaft before installing in drive unit housing.

• Remove bearing (27) and ring (32).

Pinion Shaft Disassembly (23) (Refer to Illustration 4) • Remove screws (15) and remove cover (14).

• Carefully insert shaft (3) from seal side while installing bushing (7).

• Remove retaining ring (18) and support ring (19).

• Install gear (10) on spline end of shaft (3).

• Remove gear (20).

• Position gear (10) between shim rings (11 & 12) so there is no play.

• Remove retaining ring (21).

• Secure with retaining ring (13).

• Remove cover (26) and pinion shaft (23).

• Remove bearings (22A & B and 25) from pinion shaft.

Crown 2000 PF11829-3 Rev. 4/03

Printed in U.S.A.

02 REV. 4/03

M3.0–2720–003

M3.0–2720–003

C

DRIVE UNIT

Pinion Shaft Assembly (23) (Refer to Illustration 4)

Drive Unit Cover

• Press bearing (25) into drive unit housing (9).

• Clean the drive unit cover (14) and drive housing (9) surfaces and apply form-a-gasket, 053050-020. Allow the gasket material to cure for two hours before filling with lubricant.

NOTE Pack bearing 22A & B with multipurpose grease, 063002-024 or 063002-017 for freezer conditioning trucks.

• Secure cover with screws (15) and torque to 25 Nm (18 ft. lbs.).

• Press bearing cone (22B) on pinion shaft (23).

Drive Motor Assembly

• Press bearing race (22A) into drive unit housing (9) and secure with retaining ring (21).

Install the drive motor and drive pinion into the drive unit housing and secure with bolts (16,17) and torque to 10 Nm (7 ft. lbs.).

NOTE Drive Unit Assembly Put a thin coat of multipurpose grease, 063002-024 or 063002-017 for freezer conditioning trucks on shaft before installing in drive unit housing.

• Install pinion shaft (23) while holding bearing (25).

The entire drive unit is fastened to the knuckle flange using screws (38) torqued to 86 Nm (63 ft. lbs.). The drive wheel must be aligned with the multi-task handle with the drive unit cover pointing to the right.

• Secure with retaining ring (21).

Drive Motor

• Install key (24) in pinion shaft (23) and press on gear (20).

Refer to section M4.7 for drive motor maintenance.

Drive Tire

• Locate supporting ring (19) and secure with retaining ring (18).

Torque drive tire lug bolts to 122 - 135 Nm (90 - 100 ft. lbs.) in sequence 1, 3, 2, 4. Refer to Illustration 5.

• Install cap (26) on pinion shaft (23).

Drive Motor Pre-Assembly • Press bearing (27) onto the motor shaft while holding the shaft end on the brake side.

• Apply form-a-gasket, 053050-003 to inner ring (32).

1

• Install O-ring (29) in bushing (30).

4

2

• Press shaft seal (31) into bushing and insert ball bearing compensating disk (28).

3

• Mount complete bushing on motor shaft.

• Press pinion gear (33) onto the motor shaft. Ensure that the key is inserted.

• Install retaining ring (34).

Torque Sequence 8046

Crown 2000 PF11829-4 Rev. 4/03

ILLUSTRATION 5 Printed in U.S.A.

02 REV. 4/03

M3.0–2720–004

M3.0–2720–004

ELECTRICAL SYSTEM Electrical System

Electrical System

Wire color-codes

Wire color-codes and schematic symbols

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

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

Wire Color-Codes Number

Color

Function

0xx

Black

Digital Signal (1)

1xx

Brown

Analog Signal (1)

2xx

Red

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

3xx

Orange

12 V Non-Battery Positive (3)

4xx

Yellow

Non-Battery Positive (3)

5xx

Green

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

6xx

Blue

Isolated Negative (4)

7xx

Violet

5 V Non-Battery Positive (3)

8xx

Gray

Non-Battery Positive (3)

9xx

White

Miscellaneous

29xx

Red/White

Primary positive that has gone through a switch (2)

59xx

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

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

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

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

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

Crown 2010 PF17948 Rev. 2/20

M4.1-0000-001 02 Rev. 2/20

179

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

Fig. 3 (8117-01)

Power Cables Abbreviations Abbreviation

Part Numbers

PC#1

084571

Fig. 4 (8118-01)

PC#2

084570

Number of terminals

PC#4

084569

PC#6

084568

PC#8

124474

PC#10

090963

PC#1/0

084572

PC#2/0

084573

PC#3/0

086749

PC#4/0

137636

•

All terminals are shown even if not connected.

Momentary contact switch or maintained contact switch •

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

Fig. 5 (8119-01)

Switches The switch symbols show: •

The switch type

Fig. 6 (8120-01)

•

The number of terminals

•

•

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

•

How the switch is connected

•

How the switch operates

•

How the switch functions

Switch type •

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

Fig. 7 (8115-01)

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

Fig. 8 (8117-01)

Fig. 1 (8115-01)

Fig. 2 (8116-01)

•

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

M4.1-0000-002 02 Rev. 2/20

180

Crown 2010 PF17948 Rev. 2/20

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

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

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

Example: 1 2

Fig. 9 (8121-01)

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

Fig. 10 (8119-01)

Fig. 12 (8122)

Fig. 14 (8115-01)

Fig. 16 (8124)

Without common (Double Break)

Fig. 11 (8120-01)

Fig. 13 (8123)

Fig. 15 (8117-01)

Fig. 17 (8125)

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

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

Notes: •

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

•

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

1 Fig. 18 (8126-02)

Crown 2010 PF17948-3 Rev. 2/20

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

181

ELECTRICAL SYSTEM Electrical System Specialty switches

•

See Figure 19 for a pressure switch.

Fig. 19 (8127)

•

See Figure 20 for a reed switch.

Fig. 20 (8128)

•

See Figure 21 for a temperature switch.

Fig. 21 (8129)

•

See Figure 22 for a brake fluid switch.

Fig. 22 (8130)

•

See Figure 23 for a three position key switch

Start Acc Ign

Off

Fig. 23 (8131-01)

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

182

Crown 2010 PF17948 Rev. 2/20

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

Switch Symbols Actuation Description

NO

Number of Terminals

SPST

2

SPDT

3

Momentary with common

without common

Fig. 24 (34385)

Fig. 25 (34386)

Fig. 26 (34387)

SPDT

Fully Maintained with common

Fig. 27 (34388)

4

Fig. 29 (34390)

Fig. 28 (34389)

DPDT

4 Fig. 30 (34391)

DPDT

Fig. 31 (34392)

6 Fig. 33 (34394)

Fig. 32 (34393)

DPDT

8 Fig. 34 (34395)

NOHC

without common

SPST

2

SPDT

3

Fig. 36 (34397)

Fig. 35 (34396)

Fig. 37 (34398)

Fig. 38 (34399)

SPDT

4 Fig. 39 (34400)

DPDT

4 Fig. 40 (34401)

DPDT

Fig. 41 (34402)

6 Fig. 42 (34403)

Crown 2010 PF17948 Rev. 2/20

M4.1-0000-005 02 Rev. 2/20

183

ELECTRICAL SYSTEM Electrical System

DPDT

8 Fig. 43 (34404)

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

184

Crown 2010 PF17948 Rev. 2/20

ELECTRICAL SYSTEM Electrical System

Switch Symbols Actuation Description

No. of Terminals

Momentary w/ common

NC

SPST

without common

Fully Maintained w/ common

without common

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

SPDT

3 Fig. 46 (34407)

SPDT

Fig. 47 (34408)

4 Fig. 48 (34409)

DPST

Fig. 49 (34410)

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

DPDT

6

Fig. 52 (34413)

DPDT

Fig. 53 (34414)

8

Fig. 54 (34415)

NCHO

SPST

Fig. 55 (34416)

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

SPDT

3 Fig. 58 (34419)

SPDT

4 Fig. 59 (34420)

DPST

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

DPDT

6

Fig. 62 (34423)

Crown 2010 PF17948 Rev. 2/20

M4.1-0000-006 02 Rev. 2/20

185

ELECTRICAL SYSTEM Electrical System Switch Symbols Actuation Description DPDT

No. of Terminals

Momentary

Fully Maintained

8

Fig. 63 (34424)

M4.1-0000-005 02 Rev. 2/20

186

Crown 2010 PF17948 Rev. 2/20

ELECTRICAL SYSTEM Electrical System

Other Electrical Symbols Symbol

Fig. 64 (34297)

Fig. 67 (34298)

Name Signal Flow One Way

Symbol

Fig. 65 (34308)

Signal Flow Simultaneous Fig. 68 (34309)

Name Cable Unconnected

Symbol

JC

Fig. 70 (34299)

Fig. 71 (34310)

Connector Fixed/Jack

Fig. 66 (34319)

Cable PC Unconnected Insulated Fig. 69 (34320)

CA Signal Flow Alternate

Name

Junction Point

Connector Plug

1 Connector Assembly

2 Fig. 72 (34321)

Chassis Ground Fig. 73 (34300)

*

* A-Analog B-Battery L-Logic

Ground Return

Fig. 76 (34301)

Fig. 79 (34302)

1 2 3 4 5

Fig. 74 (34311)

Terminal Strip Fig. 75 (34322)

T-Connection Fig. 77 (34312)

Test Point

Fig. 82 (34303)

Cable Twisted Pair Fig. 85 (34304)

Cable MultTwisted Pairs

SIP Resistor Fig. 78 (34323)

Double Junction Fig. 80 (34313)

Cable Shielded

Resistor

Fig. 83 (34314)

Fig. 86 (34315)

Fig. 89 (34316)

Pot Fig. 81 (34324)

Mast Cable

Rheostat Fig. 84 (34325)

Power Termination

Female/ Socket

Heater Fig. 87 (34326)

T

Thermistor

Fig. 90 (34327)

Fig. 88 (34305)

Cable MultiConductor

Fig. 92 (34317)

Male/Pin

U

Mov/Transzorb

Fig. 93 (34328)

Fig. 91 (34306)

Crown 2010 PF17948 Rev. 2/20

M4.1-0000-007 02 Rev. 2/20

187

ELECTRICAL SYSTEM Electrical System Other Electrical Symbols Symbol

Name

Symbol

Cable MultiConductor

Fig. 95 (34318)

Name

Socket and Pin

Symbol

Name

Fig. 96 (34329)

Capacitor Nonpolarized

Fig. 94 (34307)

+ Capacitor Polarized

N-FET With Diode Clamp

Fig. 99 (34355)

P-FET With Diode Clamp

Contactor Normally Open Fig. 102 (34356)

Battery

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

Fig. 100 (34331)

Current Shunt Fig. 101 (34345)

Inductor Fig. 103 (34332)

Fig. 104 (34346)

LVDT Fig. 106 (34333)

Fig. 109 (34334)

Fig. 107 (34347)

M

Ferrite Bead

Motor Field, Series Fig. 105 (34357)

Motor Field, Shunt

Contactor Normally Closed

Coil Fig. 108 (34358)

Series Motor, DC Fig. 111 (34359)

Coil Suppression

Fig. 110 (34348)

M

Diode Fig. 112 (34335)

Shunt Motor, DC

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

Fig. 113 (34349)

LED Fig. 115 (34336)

M Fig. 116 (34350)

Zener Diode

M

Fig. 118 (34337)

Permanent Magnet Motor Separately Excited Motor, DC

Tach Sensor Fig. 117 (34361)

TT

Hour Meter Fig. 120 (34362)

Fig. 119 (34351)

SCR Fig. 121 (34338)

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

188

M 3

Fig. 122 (34352)

Motor, AC

Lamp Fig. 123 (34363)

Crown 2010 PF17948 Rev. 2/20

ELECTRICAL SYSTEM Electrical System Other Electrical Symbols Symbol

Name

Symbol

Name

Transistor NPN Fig. 124 (34339)

Fig. 127 (34340)

Fig. 128 (34354)

Darlington NPN Fig. 130 (34342)

DC/DC Converter Power Supply

Suppressor

077732

Horn Fig. 126 (34364)

Fig. 131 (34366)

Encoder Fig. 129 (34365) +

+

–

Darlington PNP

–

077728, 085670, 091181

Suppressor

Fig. 132 (34367) 1

Fig. 133 (34343)

Name

Transformer Fig. 125 (34353)

Transistor PNP

Symbol

Suppressor

2 34

085484, 086755

115487

Fig. 134 (34368)

Fig. 135 (34369)

5

Dual Suppressor

+

82495, 086322, 093757

Dual Suppressor

Fig. 136 (34370)

3

1 112533

5

Filter Block

Fig. 137 (34371)

NOR Gate Fig. 139 (34373)

Schmitt Inverter

Fig. 141 (34375)

Amp/Comp Fig. 143 (34377)

NAND Gate Fig. 145 (34379)

Schmitt Neutralizer

Schmitt NAND Fig. 140 (34374)

Fig. 142 (34376)

OR Gate Fig. 138 (34372)

AND Gate Fig. 144 (34378)

X-OR Gate Fig. 146 (34380)

X-NOR Gate Fig. 147 (34381)

Integrated Circuit Fig. 148 (34382)

Crown 2010 PF17948 Rev. 2/20

M4.1-0000-009 02 Rev. 2/20

189

Notes:

190

ELECTRICAL Electrical System

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

Wiring Color Codes

circuit in which it is used. Each wire is assigned a three or four digit number. The first one or two numbers identify the color of the lead. The last two numerals number the lead from one thru ninety-nine. Exceptions to this can be component leads supplied by vendors. Each wire is identified by a number on a wiring pictorial (refer to section DIA).

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

Color

Function

0**

Black

Traction Inputs/Outputs

1**

Brown

Analog Inputs

2**

Red

Battery Positive

3**

Orange

Non-Battery Positive

4**

Yellow

Status Inputs/Outputs

5**

Green

Battery Negative

6**

Blue

Isolated Negative

7**

Violet

Load Position Inputs/Outputs

8**

Gray

Indicators and Warning Devices

9**

White

Miscellaneous

29**

Red Stripe/White

Positive that has gone thru a switch

59**

Green Stripe/White

Negative that has gone thru a switch or resistor

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

Power Cables Abbreviations Chart Abbreviation

Part Numbers

PC#1

084571

PC#2

084570

PC#4

084569

PC#6

084568

PC#10

090963

PC#1/0

084572

PC#2/0

084573

PC#3/0

086749

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

Crown 2000 PF11845-1 Rev. 10/06

M4.1-2720-001 03 Rev. 10/06

131

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

1A Bypass Driver

ALM

Alarm

ATD

Anti Tie Down Module

BATT

Battery

BDI

Battery Disch. Interrupt

BRK

Brake

CA

Connector Assembly

CAP

Capacitor

DB

Diode Block

DFR

Defrost

DMC

Dual Motor Card

DR

Driver Module

ECN

Encoder

FAN

Fan

FIL

Filter

FLS

Flasher

FU

Fuse

HF

Hash Filter

HN

Horn

HR

Heater

HSC

High Speed Card

JC

Fixed Part of Ca

LGT

Light

M

Motor

MCR

Motor Control

PC

Movable Part of Ca

PCVA

"Pressure Compensated Valve, Acc."

PCVH

"Pressure Compensated Valve, Hoist"

PMTD

Pulse Monitor Trip Driver

POT

Potentiometer

PS

Power Supply

PS

Pressure Switch

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

132

REC

Rectifier

RES

Resistor

SB

Suppressor Block

SSC

Safety Switch Card

SV

Hydraulic Solenoid

SVA

Solenoid Valve - Accessory

SVL

Solenoid Valve - Lower

SVP

Solenoid Valve - Pilot

SVR

Solenoid Valve - Reach

SVS

Solenoid Valve - Sideshift

SVT

Solenoid Valve - Tilt

TB

Terminal Board

TD

Time Delay

TDR

Time Delay Relay

TMM

Truck Management Module

TP

Test Point

TT

Hour Meter (Truck Time)

V

Discharge or Volt Meter

XC

Socket for PC Board

Contactor and Relays A

Speed Contactor

B

Speed Contactor

C

Speed Contactor

D

Dual Contactor

ED

Emerg. Disc. Contactor

F

Forward Contactor

FA

Forward Contactor A

FB

Forward Contactor B

FW

Field Weakening

K

Relay

P

Pump Contactor

R

Reverse Contactor

RA

Reverse Contactor A

RB

Reverse Contactor B

Crown 2000 PF11845-2 Rev. 10/06

ELECTRICAL Electrical System Component Abbreviations and Designators

Component Abbreviations and Designators

RGB

Regen. Braking Contactor

DTS

Drive Tow Switch

S

Power Steering Contactor

ECS

Elevation Control Switch

1A

Bypass Contactor

EDS

Emergency Disconnect Switch

EIS

Extend In Switch

Switches 1AS

Traction Bypass Switch

EMS

Emergency Switch

ACC

Accessory Switch

ENS

Entry Switch

ACS

Accelerator Switch

EOS

Extend Out Switch

AHS

Aux. Height Switch

ERLS

Emergency Raise/Lower Switch

AS

Switch For A Contactor

ERS

Erase Switch

AxA

Aux. Sw. on A Contactor

EXS

Extend Switch

AxB

Aux. Sw. on B Contactor

FHS

Fork Home Switch

AxC

Aux. Sw. on C Contactor

FKS

Fork Switch

AxF

Aux. Sw. on Fwd. Contactor

FLMCS

Forward Left Motor Cover Sw

AxR

Aux. Sw. on Rev. Contactor

FLS

Fork Left Switch/Free Lift Switch

AXS

Aux. Function Switch

FNS

Fan Switch

BFS

Brake Fluid Switch

FRMCS

Forward Right Motor Cover Sw

BLS

Battery Latched Switch

FRS

Fork Right Switch

BMS

Brake Monitor Switch

FS

Forward Switch

BPS

Brake Pressure Switch

FTS

Foot Guard Switch

BRES

Battery Restraint Switch

GCSL

Gate Closed Switch Left

BRS

Brake Switch

GCSR

Gate Closed Switch Right

BS

Switch For B Contactor

GOSL

Gate Open Switch Left

CHS

Chain Switch

GOSR

Gate Open Switch Right

CHSL

Chain Switch Left

GTS

Gate Switch

CHSR

Chain Switch Right

GUS

Guidance Switch

CLS

Clamp Switch

HCS

Height Cable Switch

CS

Switch For C Contactor

HGTS

Height Switch

CTS

Cable Tension Switch

HNS

Horn Switch

DIS

Direction Switch

HSS

High Speed Switch

DMS

Dead Man Switch

HTS

Heater Switch

DMSL

Dead Man Switch Left

HTSXX

Height Switch (XX Inches)

DMSR

Dead Man Switch Right

KORS

Key Override Switch

DPS

Display Switch

KYS

Key Switch

DRS

Door Switch

LCS

Lower Cutout Switch

Crown 2000 PF11845-3 Rev. 10/06

M4.1-2720-003 03 Rev. 10/06

133

ELECTRICAL Electrical System Component Abbreviations and Designators

Component Abbreviations and Designators

LGS

Light Switch

SWH

Operator Activated Switch

LMS

Limit Switch

TBS

Tilt Back Switch

LOS

Lower Switch

TDS

Tilt Down Switch

LTS

Loadtray Switch

TES

Test Switch

MFS

Multi-funciton Switch

THS

Thermal Switch

MVS

Multi-voltage Switch

TLS

Traverse Left Switch

NUS

Null Switch

TLT

Tilt Switch

ORS

Override Switch

TRS

Traverse Right Switch

PLS

Pivot Left Switch

TUS

Tilt Up Switch

PORS

Presence Overide Switch

TVS

Traverse Switch

PRS

Pivot Right Switch

ZSS

Zone Select Switch

PS

Pressure Switch

Terms

PTS

Pivot Switch

ASM

Assembly

PUS

Pump Switch

CTRL

Control

QPS

Quick Pick Switch

CTRLR

Controller

RAS

Raise Switch

DESIG LIST Designation List

RES

Reach Extended Switch

DIST PNL

Distribution Panel

RGS

Rail Guide Switch

DSPL

Display

RGSL

Rail Guidance Switch Left

F/C

Freezer Conditioning

RGSR

Rail Guidance Switch Right

HCM

Hydraulic Control Module

RIS

Reach In Switch

HDL

Handle

RLMCS

Rear Left Motor Cover Switch

HYD

Hydraulic

ROS

Reach Out Switch

OHG

Overhead Guard

RRMCS

Rear Right Motor Cover Switch

PCB

Printed Circuit Board

RS

Reverse Switch

PICT

Pictorial

RSS

Sheet Retainer Switch

PKT

Packet

SAS

Safety Switch

PL

Platform

SCS

Sideshift Center Switch

PWR

Power

SES

Seat Switch

PWR SPLY

Power Supply

SLS

Sideshift Left Switch

SCHEM

Schematic

SQS

Sequence Switch

TCM

Traction Control Module

SRS

Sideshift Right Switch

TMM

Truck Management Module

SSS

Sideshift Switch

TRAC

Traction

STS

Power Steer Switch

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

134

Crown 2000 PF11845-4 Rev. 10/06

ELECTRICAL Electrical System Switches

Momentary or Maintained Contact

Switch symbols convey:

•

Momentary contact is a shaded triangle.

1. Type of switch.

2. Number of terminals.

Figure 8119-01

3. Momentary or maintained contact. or

4. How the switch is held and wired.

5. How the switch is activated.

6. Application.

Figure 8120-01

Type of Switch

•

•

With common

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

Figure 8115-01

or

Figure 8115-01

or

Figure 8117-01 Figure 8116-01

•

Without common

Figure 8117-01

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

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

or

Figure 8118-01

Example:

Number of Terminals

•

All terminals are shown even if not wired.

Figure 8121-01

Crown 2000 PF11845-5 Rev. 10/06

M4.1-2720-005 03 Rev. 10/06

135

ELECTRICAL Electrical System

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

Without Common (Double Break)

Figure 8119-01

Wired normally open, held closed

Figure 8122

Wired normally closed, held open

Figure 8120-01

Figure 8123

Figure 8115-01

Figure 8117-01

Figure 8124

Figure 8125

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

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

Notes:

•

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

•

Positive action switches are marked with the following symbol:

8126-02

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

136

Crown 2000 PF11845-6 Rev. 10/06

ELECTRICAL Electrical System Switch Symbols (Mechanically activated switches)

Actuation Description

No. of Terminals

Momentary w/common w/o common

Fully Maintained w/common

w/o common

Figure 8100-01

Crown 2000 PF11845-7 Rev. 10/06

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

137

ELECTRICAL Electrical System Switch Symbols (Mechanically activated switches) Continued

Actuation Description

No. of Terminals

Momentary w/common w/o common

Fully Maintained w/common

w/o common

Figure 8101-02

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

138

Crown 2000 PF11845-8 Rev. 10/06

ELECTRICAL Electrical System Specialty Switches Pressure Switch

Figure 8127

Reed Switch

Figure 8128

Temperature Switch

Figure 8129

Brake Fluid Switch

Figure 8130

Three Position Key Switch

Start

Off

Figure 8131-01

Crown 2000 PF11845-9 Rev. 10/06

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

139

ELECTRICAL Electrical System Other Electrical Symbols

Signal Flow One Way

Terminal Strip

Heater

Signal Flow Simultaneous

T-Connection

Thermistor

Double Junction

Mov/ Transzorb

Signal Flow Alternate Chassis Ground

Mast Cable

Common Return

Power Termination

Test Point

Female/ Socket

Cable Shielded Cable Twisted Pair

Male Pin

Capacitor Nonpolarized Capacitor Polarized Current Shunt Inductor

Socket & Pin LVDT Connector Fixed/Jack

Cable MultiTwisted Pairs

Connector Moveable/ Plug

Ferrite Bead

Diode Cable MultiConductor

Connector Assembly LED

Cable MultiConductor

Resistor Zener Diode

Cable Unconnected

SIP Resistor SCR

Cable Unconnected Insulated

Pot

Junction Point

Rheostat

Transistor NPN

Figure 8132-02

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

140

Crown 2000 PF11845-10 Rev. 10/06

ELECTRICAL Electrical System Other Electrical Symbols Transistor PNP

DC/DC Converter Power Supply

Darlington NPN

Battery

Darlington PNP N-FET With Diode Clamp

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

Contactor Normally Open

Dual Suppressor

Dual Suppressor

Contactor Normally Closed

Filter Block

Coil

OR Gate

Coil Suppression

NOR Gate

Fuse - Band Shows Positive Feed

Schmitt NAND

Tach Sensor

Schmitt Buffer

Hour Meter Schmitt Inverter Lamp

Shunt Motor, DC

Amp/Comp Horn

Permanent Magnet Motor

AND Gate Encoder NAND Gate

Separately Excited Motor, DC

Suppressor X-OR Gate Suppressor

Motor, AC

Transformer

X-NOR Gate Suppressor

Integrated Circuit Figure 8133-02

Crown 2000 PF11845-11 Rev. 10/06

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

141

C

TRANSISTOR CONTROL

The SEM zero Transistor Control uses separately excited DC motors. In most applications, by independently controlling the field and armature currents in the separately excited motor, it is possible to produce high levels of torque at low speeds efficiently.

In a shunt motor, the field is connected directly across the voltage source and is therefore independent of variations in load size and armature current. If field strength is held constant, the torque developed will vary directly with the armature current. If the mechanical load on the motor increases, the motor slows down, reducing the back EMF (which depends on the speed, as well as the constant field strength). This reduced back EMF allows the armature current to increase, providing the greater torque needed to drive the increased mechanical load. If the mechanical load is decreased, the process reverses.

In the separately excited motor, the motor is operated as a fixed field shunt motor in the normal running range. However, when additional torque is required, for example, to climb non-level terrain, such as ramps and the like, the field current is increased to provide an even higher level of torque.

Solid-State Reversing The direction of armature rotation on a shunt motor is determined by the direction in which current flows through the field windings. Because the shunt motor field typically only requires about 10% of the armature current at full torque, it is possible to replace the double-pole, doublethrow reversing contactor with a low power transistor HBridge circuit as shown in Illustration 1 with Q2, Q3, Q4 and Q5.

By energizing the transistors in pairs (eg. Q2 and Q5 or Q3 and Q4), current can be made to flow in either direction in the field. The field control circuit typically operates at 1kHz and armature control circuit typically operates at 16kHz. The line contactor is normally the only contactor required for the separately excited traction circuit. This contactor is used for emergency shut down of the motor circuit, in case of problems that would cause abnormal operation.

Field weakening with a series wound motor is accomplished by placing a resistor in parallel with the field winding of the motor. Bypassing some of the current flowing in the field into the resistor causes the field current to be less, or weakened.

With the field weakened, the motor speed will increase, giving the effect of “overdrive”. To change the “overdrive speed”, it is necessary to change the resistor value. In a separately excited motor, independent control of the field current provides for infinite adjustments of “overdrive” levels, between the motor base speed and maximum weak field speed.

The sep-ex traction system will try to maintain a constant speed downhill. This characteristic can be enhanced by increasing the field strength with the control. Overhauling load control works in just the opposite way of field weakening, as armature rotation slows with the increase of current in the field.

Regenerative braking (braking energy returned to the battery) may be accomplished completely with solid-state technology. The main advantage of regenerative braking is increased motor life. Solid state regenerative braking eliminates a power diode and contactor from the circuit.

Positive

Line Fuse

Q2

Battery

Q6

Motor Armature

F1

Motor Field

Q3

F2

VMN Capacitor

Q4

Q5

Q1

Negative = Controller power connections 8139

ILLUSTRATION 1

000601

6421

Crown 2000 PF11848-1 Rev. 9/00

Printed in U.S.A.

02 REV. 9/00

M4.2–2720–001

M4.2–2720–001

C

TRANSISTOR CONTROL

OPERATIONAL FEATURES Anti-Roll Down Function This function prevents the truck from rolling down a slope uncontrolled. When the key switch is on, the controller monitors the motor speed.

8

E

If the truck starts to move, the controller will brake the truck after a short period of time. If the truck stops, the brake is released allowing the truck to move again followed by additional braking. If the brake is not applied by control handle movement, the truck will move down the slope very slowly.

1

Self Test

8134P

The traction controller self-test system lists up to five different error messages which can be called up via the handset.

The type of fault as well as the frequency, number of service hours, and controller temperature at the time of the error are stored and displayed.

ILLUSTRATION 2

Hour Meter An hour meter is integrated within the traction controller and can be set using the handset either to "KEY ON" (hour meter activated when key switch is on) or "RUNNING" (hour meter activated only during travel).

In addition, a red LED on the controller flashes a code for the most recent error.

PROTECTION FEATURES Polarity

Reduced Speed Ranges Two reduced speed ranges are available: slow (via switch HSS) and brake override (via switch ORS).

Downhill Motor Braking When travelling downhill, the controller controls speed according to the command from the potentiometer.

Most inputs are protected against connection errors.

Temperature If the controller baseplate exceeds 176°F / 80°C, the maximum current reduces in proportion to the thermal increase.

The temperature can never exceed 194°F / 90°C. Below 14°F / -10°C, the current is reduced to 80%.

Regenerative Braking

Low Voltage

Three levels of regenerative braking are available: • Release braking (travel switch or control handle return to neutral).

• Plugging or inverse braking (travel switch is moved from one direction to the other).

• Braking by reducing speed on a slope: the controller constantly regulates the motor speed according to the set value of the traction potentiometer. Slowdown is automatically activated when the set value is exceeded.

Batteries under load, particularly if undersized or more than 80 percent discharged, will produce low voltages at the control terminals. The controller is designed for use down to 50 percent of nominal battery voltage.

Static Return to Off The control handle and travel switches must be returned to neutral before closing key switch. If not, travel will not be allowed.

Crown 2000 PF11848-2 Rev. 9/00

Printed in U.S.A.

02 REV. 9/00

M4.2–2720–002

M4.2–2720–002

C

TRANSISTOR CONTROL

GENERAL MAINTENANCE INSTRUCTIONS

Installation

The transistor control, like all electrical apparatus, does have some thermal losses. The semiconductor junctions have finite temperature limits above which these devices may be damaged. For these reasons, normal maintenance should guard against any action which will expose the components to excessive heat, such as steam cleaning; or which will reduce heat dissipating ability of the control, such as restricting air flow.

Carefully clean the mounting area on the baseplate with isopropyl alcohol and inspect to ensure it is free from nicks and burrs.

The following DOS and DON’TS should be observed: Do not connect the controller to a battery with a different rated voltage than the controller (24V). A higher voltage battery may destroy the controller and a lower voltage battery may cause system failure.

Apply a thin coating of thermal grease (Crown P/N 063002-029) to the bottom of the controller to permit better heat dissipation.

Grease should be uniformly applied then a straight edge should be used to scape excess grease off. The grease is only useful to fill microscopic gaps in the mounting surfaces. Too much grease can be worse than none at all.

The suppression for the line contactor, horn, pump contactor and lower solenoid is within the controller. Do not add external suppression.

When replacing controller, jack-up truck (reference "Lifting and Blocking", section MA) so drive tire is off floor to prevent truck from suddenly traveling in the event of an installation error.

CAUTION

The truck should not be plugged when the vehicle is jacked up and the drive wheels are in a free wheeling position. This can create excessive volt ages that can be harmful to the control.

When the key switch has been turned off, the internal capacitors may remain charged for a few minutes. When performing maintenance to the controller, disconnect battery and short circuit the controller's battery positive and battery negative power terminals using a 10 to 100 ohm (minimum 5W) resistor.

The control should not be steam cleaned. In dusty areas, use low-pressure air to blow off the control. In oily or greasy areas, a mild solution of detergent or denatured alcohol can be used to wash off the control and then blow completely dry with low-pressure air.

Control wire plugs and other exposed transistor control parts should be kept free of dirt and paint that might change the effective resistance between points.

Crown 2000 PF11848-3 Rev. 9/00

Printed in U.S.A.

02 REV. 9/00

M4.2–2720–003

M4.2–2720–003

TROUBLESHOOTING This section provides troubleshooting aids to facilitate analysis of truck event codes. By using the appropriate troubleshooting aids (based on event codes displayed through the use of the red LED on the transistor controller and handset), truck wiring diagrams and information provided in this manual, events are easily detected and corrected.

A handset must be used with the Transistor Controller. The handset with cable is part number 793548.

The Transistor Controller microprocessor continually monitors the traction controller and truck electronics. The controller also carries out diagnostic procedures on all main functions.

The controller is adjusted by connecting the Handset to the "E" connector on the controller. Refer to Illustrations 1 and 2.

Diagnostic indications are given via the red LED that is connected to port "E" which will flash a given number of times to indicate an event code or the optional handset may be used to view the event code. The red LED on port "E" will only indicate the latest event code. The transistor controller will store up to 5 events. To obtain all of the event codes, the handset must be used.

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

When the handset is connected to the controller and the controller is turned on a "self test" routine is performed.

When the "self test" is complete, use the "roll forward/back" and "enter" keys to select the required menu.

Plug In Handset

HANDSET OPERATION

WARNING

8

E

1

Before connecting or disconnecting the handset, lift the drive wheel clear of the floor and place hardwood blocks under truck frame. Turn keyswitch "OFF".

Red LED

8104P

ILLUSTRATION 2 NOTE

8

8105P

E

Controllers are factory adjusted for a particular motor and truck and should not require adjustment. On replacement or mistuned controllers, adjust functions to values listed in charts in Transistor Controller Tune-Up, section M4.2.

1

ILLUSTRATION 1

000601

4560

Crown 2000 PF11855-1 Rev. 1/03

Printed in U.S.A.

02 REV. 1/03

M4.2–2720–400

M4.2–2720–400

TROUBLESHOOTING The following Troubleshooting Chart contains general information necessary to effectively solve the more common truck electrical problems. Know the system to the best of your ability. Understand the components and their function within the system. Develop a systematic pattern to locate and solve the various problems that occur. The ability to identify problems and proceed in solving the problem grows with experience. The following chart contains problems, probable causes and suggested solutions. The information is general in nature and a remedy may simply lead you to a maintenance section that has more complete troubleshoot-

ing information. Use the chart carefully and completely. Do not make the system more complicated than necessary. Do not overlook the simplest reason(s) for an electrical problem.

NOTE Many components are monitored by the controller. If failures occur in the monitored components, a fault or event code will be recorded in the Controller. The handset can be used with the flashing LED to interpret event codes.

Handset Display

LED Flash

Test Function

Possible causes and solution

1

LOGIC FAILURE #1 (Traction Controller)

1

This test is conducted during each start-up.

Logic board failure. Replace traction controller.

2

WATCH DOG (Traction Controller)

1

This test is conducted when the key switch is turned on.

Watch dog (traction controller) faulty. Replace traction controller.

3

EEPROM KO (Traction Controller)

1

Checked at start-up. Indicates a memory fault where the truck parameters are stored.

Memory lost. Recycle key switch.

If fault continues replace controller. If fault disappears check parameters.

4

Incorrect Start

2

Checked at start-up. Alarm generated by an incorrect start-up sequence.

The key switch has failed, operator procedure error or wiring. Recycle key, check switch and wiring.

5

FORW + BACK

2

This test is conducted continuously.

Alarm is indicated when fwd and rvrs are requested simultaneously.

Wiring error, bad or faulty switch.

Check switches and wiring.

6

CAPACITOR CHARGE

3

Checked at start-up. Alarm is indicated if capacitors are not charged within 500 ms after key switch is closed.

Internal power block failure. Check all fuses and wiring. Including the VMN and battery positive termination.

7

VMN NOT OK

3

VMN checked continuously w/contactor Shorted motor windings or incorrect closed during operation. VMN monitors wiring of AB or AZ connections. the drive motor negative lead.

Possible defect in power unit. Check line contactor, battery positive termination and motor windings.

8

VFIELD NOT OK

3

Test done while key is on w/contactor open. Mainly used to check motor windings.

Open winding on motor, incorrect wiring.

Traction controller failure. Check motor windings, control cables and controller.

9

VACC NOT OK

4

Alarm is generated if accelerator output differs more than 2V from the minimum recorded at start-up.

Potentiometer is open, B2 connection wired incorrectly or defective. Check potentiometer. Recycle key.

CHART 1 Crown 2000 PF11855-2 Rev. 9/00

Printed in U.S.A.

01 REV. 9/00

M4.2–2720–401

M4.2–2720–401

TROUBLESHOOTING Handset Display

LED Flash

Test Function

Possible causes and solution

10

PEDAL WIRE KO

4

Test is conducted continuously for open or faulty potentiometers.

NPOT or PPOT are open or faulty.

Check potentiometers and wiring of all B connections.

11

STBY I HIGH

5

This test is conducted during start-up and standby. Test verifies current = 0.

Defective current sensor, controller faulty. Replace traction controller.

12

I = 0 EVER

5

This test is conducted during operation. Faulty controller, or brushes in motor.

Check motor brushes and armature.

If fault continues replace controller.

13

HIGH FIELD CUR or NO FIELD CUR

5

Test is conducted continuously. Shows problem with drive motor.

Motor not wired correctly, drive unit failure. Check motor, cables and windings. Replace drive unit.

14

CONTACTOR DRIVER COIL SHORTED DRIVER SHORTED

6

These alarms are generated when a problem with the line contactor is detected.

Contactor coil open, shorted or not connected. Check wiring, if fault continues replace contactor.

15

CONTACTOR CLOSED

6

This check is made at start-up. With contactor de-energized, the capacitors should not be charged.

The line contactor tips have welded.

Check contactor, if fault continues replace controller.

16

TH. PROTECTION

7

Test is conducted continuously. Tests for controller temperatures that exceed 80°C or are less than -10°C. At temps above 90°C truck is disabled, below -10°C, truck is limited to 80% power.

If the alarm is displayed when the temperature of the controller is equal to the ambient temp., then check for defective temp. sensor or wiring.

If fault continues replace controller.

17

BATTERY LOW

32

Test is conducted continuously. Alarm is generated when the battery reaches 50% of the nominal value.

Recharge battery.

18

NONE

NONE No operation.

Wire conditions and connections.

A connections.

19

NONE

NONE No forward/reverse.

Wire conditions and connections. Battery negative termination and connection A8.

20

NONE

NONE No forks.

Wire conditions and connections.

Battery neg./contactor termination, connections A6 and all of D.

21

NONE

NONE Runs in speed reduction. Slower full operation.

Wire conditions and connections.

Connection B1 and all of C.

22

NONE

NONE No forward.

Wire conditions and connections.

Connection B4.

23

NONE

NONE No reverse.

Wire conditions and connections.

Connection B6.

24

NONE

NONE No horn.

Wire conditions and connections.

All of D connections.

CHART 1

Crown 2000 PF11855-3 Rev. 9/00

Printed in U.S.A.

01 REV. 9/00

M4.2–2720–402

M4.2–2720–402

TROUBLESHOOTING Controller Test

Controller Diagnostics

This traction controller test takes the form of a Pulse Monitor Trip Test (PMT). A test lead of 18 gauge wire and a 10 Amp fuse is required to perform this test. Refer to Illustration 3 for the following:

The following Chart contains general information necessary to effectively evaluate the controller. Pin numbers and voltages are based on the truck being placed in a neutral condition with the key switch turned to "on" unless otherwise noted. Pins E1 thru E8 are used to connect the handset, therefore no voltages are given.

10 A Fuse 1

2

3

Traction Control Module F1

VMN

+ BATT

A1

M

Voltage Reading

A1 A2 A3

+BV +BV 40% +BV +BV +BV 0 +BV 0 0V +BV 0 +BV

F1

M

LINE

A4 M P

A5

FU1 BD - 1

8143

24V BATT

Key On, With Condition Noted

– BATT

F2

F2

A2

Pin Number

BD - 2

A6 A7 A8

ILLUSTRATION 3

1. Turn key to "off". Lift and block truck.

3. Connect test lead to VMN (Item 1 in Illustration 3).

B1 B2 B3 B4

4. Connect the handset to the traction controller.

B5

5. Turn key switch to "on". The handset should display CAPACITOR CHARGE. Activating traction (FS, RS) should have no effect.

B6

2. Connect one end of test lead to the -BATT.

6. Turn key to "off". Move test lead to F1 (Item 2).

7. Turn key switch to "on". The handset should display VFIELD NOT OK. Activating traction (FS, RS) should have no effect.

8. Turn key to "off". Move test lead to F2 (Item 3).

9. Turn key switch to "on". The handset should display VFIELD NOT OK. Activating traction (FS, RS) should have no effect.

C1 C2 C3

D1 D2 D3 D4 D5 D6

10. Turn key to "off". Remove the test leads and handset.

11. Turn key switch to "on". Activating traction (FS, RS) should start the traction motor.

E1-8

Line Contactor Closed Line Contactor Open Control Handle in Travel Zone Control Handle in Brake Zone Control Handle in Travel Zone Control Handle in Brake Zone

Control Handle in Travel Zone Control Handle in Brake Zone

ACC V 0.5V 12V +BV 0V +BV 0V +BV 0V

Pot Wiper Pot Low Pot High Reverse Switch Closed Reverse Switch Open Safety (SAS) Switch Closed Safety (SAS) Switch Open Forward Switch Closed Forward Switch Open

+BV +BV +BV 0V

Jumpered to C2 Jumpered to C1 HSS (R/T) Switch Closed HSS (R/T) Switch Open

+BV Batt. Neg. +BV 0V Batt. Neg. +BV 0V

Not Used HNS Closed RAS and LMS Closed RAS and LMS Open LOS Switch Closed LOS Switch Open Do not measure, handset only.

CHART 2

If any steps did not perform as outlined in this procedure, or this test was unsuccessful, replace the traction controller.

Crown 2000 PF11855-4 Rev. 1/03

Printed in U.S.A.

02 REV. 1/03

M4.2–2720–403

M4.2–2720–403

ELECTRICAL SYSTEM Contactor

Contactor

Maintenance Inspection

1 2 3

5 4

6

Fig. 1 (10554-02)

7 8

General Safety

9

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

The original contactors are made for Crown lift trucks.

10

 Only use original Crown contactors as replacements.

11

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

Fig. 2 (28096)

Checking the contacts Refer to Figure 28096.

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

Crown 1992 PF9313-1 Rev. 4/13

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

41

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

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

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

Checking the coil

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

Refer to Figure 28096.

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

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

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

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

9. Connect all electrical connections to the contactor.

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

Checking the return spring Refer to Figure 28096.

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

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

Component Replacement Refer to Figure 28096.

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

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

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

3. Remove the cover (6).

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

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

6. Connect the electrical connections to the contactor.

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

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

3. Remove the contactor.

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

42

Crown 1992 PF9313-2 Rev. 4/13

C

BATTERY

GENERAL

Safety Rules

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.

• 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.

• If truck is equipped with wet cell batteries, keep vent plugs firmly in place at all times except when adding water or taking hydrometer readings. Do not allow dirt, cleaning solution or other foreign material to enter cells. Impurities in electrolyte has a neutralizing effect reducing available charge.

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.

• 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 cells long after charging has stopped.

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.

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

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 effect operation of electronic devices on the unit.

• Do not lay metallic or conductive objects on battery.

Arcing will result.

• De-energize all AC and DC power connections before servicing battery.

• Do not charge a frozen battery.

• Onboard charger is NOT for outdoor use. Do not expose charger to rain or snow.

• Onboard charger is designed to charge flooded, lead acid and maintenance free 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.

000601

4562

Crown 2000 PF11850-1 Rev. 12/02

Printed in U.S.A.

01 REV. 12/02

M4.6–2720–001

M4.6–2720–001

C

BATTERY

BATTERY CARE AND CHARGING

Battery Cleaning

CAUTION

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

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 data 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 the charger could result.

4. Before charging wet cell batteries, 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 any type of open flame, battery fumes are explosive.

5. Before connecting the battery cable to the trucks receptacle, make sure the key switch is off, controls are in the off position and parking brake is on. 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.

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 that 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 to one gallon of water). To do this, remove battery from truck and clean with the solution of baking 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 loosen dirt. If batteries stay wet consistently, they may be either overcharged or over filled. This condition should be investigated and corrected.

MAINTENANCE FREE BATTERIES Some trucks may be equipped with maintenance free batteries. These batteries are completely sealed, will not require any watering and have a full 80% discharge available.

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

CAUTION

Do not try to open this battery or remove the pressure release valve.

Only under severe overcharging, such as connected to an improperly sized charger, will any significant amount of gasses be released from the battery. Also, being a valve regulated battery, it never requires watering.

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

Crown 2000 PF11850-2 Rev. 12/02

Printed in U.S.A.

01 REV. 12/02

M4.6–2720–002

M4.6–2720–002

C

BATTERY

ONBOARD CHARGER

What the LEDs Mean:

An 8 position switch is located on the bottom panel (fan side): • Position 1 is for maintenance free batteries.

• A steady yellow light means there is power to the charger. If the LED does not come on, check circuit breaker, extension cord & connection. If circuits are complete with good connections, replace charger.

• Position 2 is for flooded, lead acid batteries.

Charger AC Inlet • Position 0 and position 3 to 7: charger will not work. The switch on new chargers will be set to position 0.

AC Inlet

Charger LEDs

Yellow Green (Charging LEDs) 8095P

• A flashing yellow light means something is wrong with batteries or charger. Check FU1, battery connections and batteries. If circuits are complete with good connections and batteries are in good condition, replace charger.

Charger 8091P-01

ILLUSTRATION 2

ILLUSTRATION 1

Charging requirements will vary depending on battery capacity. Time required to charge an 80% discharged battery is: • 15 hours for 300 Amp Hour Batteries (Industrial) • 8 to 10 hours for 160 to 195 Amp Hour Batteries (Battery Pack) The onboard charger is not serviceable.

• A flashing green light means the charger is working.

The green light will flash quickly at the beginning of charge and flash slowly near the end of charge.

• A steady green light means charging is finished.

• For any light condition not listed, check LEDs. If LEDs and their connection are in good condition, replace charger.

To charge batteries: • The charger is fully automatic. Turn truck off (don't disconnect battery).

• Use an extension cord less than 7.5 m/25 ft. long with wire size of 16 AWG or heavier and plug charger into any 125V, 15 amp AC outlet.

• Check charging LEDs on console.

Crown 2000 PF11850-3 Rev. 12/02

Printed in U.S.A.

01 REV. 12/02

M4.6–2720–003

M4.6–2720–003

C

BATTERY

TROUBLESHOOTING

Industrial Battery

CAUTION

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

Onboard Charger Measure open circuit battery voltage. If the voltage at the battery terminals is less than 10 volts, the charger will not start. This measurement should be made when the AC input is disconnected.

Check the LED display, if the yellow LED is illuminated, this means there is AC power to the charger. If the yellow LED is not illuminated, check the AC connection and the circuit breaker.

Check the position of the profile selector. Verify that the switch is in the correct position. Position 1 is for maintenance free batteries and position 2 is for open lead acid batteries.

If the switch is in any other position, the charger will not function.

To check the DC fuses, select the diode check function on a digital VOM. Place the red lead of the meter on the red charger lead. Place the black meter lead on the black charger lead. The meter should read 1.8 volts if the fuses are good. The meter will read open if the fuses are blown. If the fuses are blown (fuses are not serviceable), check for proper polarity at the battery connections.

With the AC connected, listen for the operation of the cooling fan. This fan will operate when the charger is delivering current to the batteries. A variation in the speed of the fan is considered normal.

Crown 2000 PF11850-4

M4.6–2720–004

Records of battery specific gravity readings, charger used, truck used, etc. can be a most effective troubleshooting aid.

Contact your dealer for charts 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 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.

Battery Pack 1. Fully charge battery pack: allow 8 to 10 hours for full charge.

2. After charge is complete, again place battery pack on charge. Measure the overall battery voltage while on charge. Should be greater than 28.4 volts.

3. Turn charger "off" and measure the open circuit voltage of the battery pack. Should be 25.3 volts to 26.0 volts.

4. Measure and record the voltage across each battery while lifting empty forks and also with key switch "off".

Each battery should be between 6.3 volts and 6.5 volts.

5. Replace any battery that measures less than 6.0 volts.

If there are batteries which are 0.3 volts lower than associated batteries, the battery pack could be showing signs of under charging.

Printed in U.S.A.

M4.6–2720–004

C

BATTERY

INSTALLING OR CHANGING INDUSTRIAL BATTERIES

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 or transporting the battery. Use an insulator (such as plywood) to cover the top of the battery before and during removal and installation.

Make certain you use the correct size and weight battery. Never operate a truck that has an underweight or undersized battery installed.

• Turn the key switch "OFF" and disconnect battery.

• Use an approved spreader bar to place a battery in, or remove from, the battery compartment. Make sure you adjust the spreader bar hooks to fit the battery.

• Connect battery and check truck operation.

8096

Crown 2000 PF11850-5

M4.6–2720–005

ILLUSTRATION 3

Printed in U.S.A.

M4.6–2720–005

ELECTRICAL Unigage

Unigage

Operation

The upper portion of the Unigage is a battery discharge indicator with lift interrupt and the lower portion is an hour meter.

The green and yellow LED's on the battery discharge indicator show how much charge is left in the battery. A flashing red LED is a warning the battery is getting low.

When two red LED's flash, the meter locks out lift and, at this point, the battery must be recharged or exchanged for a fully charged battery to resume full truck operation.

Adjustment The standard factory setting for the battery discharge indicator is "N". Refer to Figure 22767 for selector setting location. The indicator must be set according to the battery type.

Figure 22766

The purpose of the lift interrupt is to monitor and protect the battery as well as electrical components of the truck. To protect the battery, the discharge cycle must not exceed 80% discharge under full current load. For wet cell batteries, an 80% discharge equals 1.73 volts per cell (VPC) with electrolyte temperature at 25°C (77°F) and for maintenance free batteries, an 80% discharge equals 1.86 VPC under load or 2.02 VPC (open circuit).

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

Figure 22767 1

Setting selector

2

Back of meter

A new battery requires between 5 to 10 discharge cycles before it reaches its full capacity.

Crown 2000 PF11852-1 Rev. 10/09

M4.6-2720-100 05 Rev. 10/09

ELECTRICAL Unigage When maintenance free batteries are being used, set the selector to "P". No further adjustment is necessary.

When wet cell batteries are being used, adjust the setting following the procedure outlined below.

•

Measure the electrolyte density on a fully charged battery.

The density should be measured on three different battery cells and should be at least 1.27 to 1.28 or 1.29 to 1.30 for high density batteries (consult battery manufacturer for exact values).

•

Measure the electrolyte density again as soon as the two red LED's on the battery discharge indicator flash and lift is locked out. It should not measure less than 1.12 to 1.13.

For a higher reading change the indicator setting to "K", for lower reading change to "U".

• •

Troubleshooting

Figure 22768

Connector Terminal - 824819

Check the setting by measuring the electrolyte density with the battery charged and discharged.

Pin No.

Relay Option K

1

No Connection

The reset is the amount of charge the battery must have to reset the control. The control comes set from the factory. The setting equals 2.09 VPC, 25.2 V open circuit voltage for 24 V batteries. The specific gravity (SG) of the battery at 2.09 VPC is approximately 1250 SG with electrolyte temperature at 25°C (77°F) and the battery under full current load.

2

+Keyswitch

3

Relay Arm (+) Lockout

4

Relay N.C (-) Lockout

5

Common (BNEG)

6

Truck Hours

7

B+ Low (24 V)

8

B+ High (48 V)

Connector Terminal - 130997

M4.6-2720-101 05 Rev. 10/09

Pin No.

Relay Option K

1

No Connection

2

+Keyswitch

3

N.C. Holding FET Switch + (Lockout)

4

N.C. Holding FET Switch - (Lockout)

5

Common

6

Traction Hours

7

Low Voltage + (12 V)

8

High Voltage + (24 V)

Crown 2000 PF11852-2 Rev. 10/09

ELECTRICAL Unigage

SYMPTOM

CHECK

Gauges will not reset.

Check battery state-of-charge, both voltage and specific gravity. The setting equals 2.09 VPC. Batteries charged to 1250 SG with the electrolyte temperature at 25°C (77°F) and battery under full current load or better will have this voltage. If a battery is not able to produce a reset, the battery and charger must be checked.

Truck comes in too soon Check the specific gravity of the battery when the meter’s red LED’s flash. for a battery change.

Do not turn the DISCHARGE setting towards “K” if the specific gravity of the battery corresponds to more than 80% discharge (1150 SG for most batteries with electrolyte temperature at 25°C (77°F) and under full current load). More running time can be obtained by turning the DISCHARGE setting from “N” towards “K”, providing the battery does not show 80% discharge.

Lift is not disabled when red LED’s are flashing.

Check wiring, relay and meter.

High speed travel is not Check wiring, relay and meter. disabled when red LED’s are flashing.

WARNING Tow tractors must use the 824819 battery indicator. Installing the 130997 battery indicator in tow tractors could result in damage to the gage.

Crown 2000 PF11852-3 Rev. 10/09

M4.6-2720-102 05 Rev. 10/09

C

MOTORS

BRUSHES Access

Replacement

1. Disconnect battery and chock drive tire.

1. Replace all brushes at the same time. When brushes are replaced, spring replacement is also recommended.

2. To access brushes: • Traction motor: minimum brush length is 16 mm/ 0.63 in. (5/8 in.).

• Traction motor: remove headband.

• Pump motor: remove the two hydraulic unit mounting bolts and tilt unit just enough to access top of motor.

Remove commutator end head and insulator.

Traction Motor Brush ILLUSTRATION 2

8086P

• Pump motor: minimum brush length is 10 mm/0.40 in.

(13/32 in.).

Pump Motor Brushes

Traction Motor Head Band

8085P-01

Hydraulic Unit Mounting Bolts

Pump Motor Commutator Endhead

ILLUSTRATION 1

8087P

ILLUSTRATION 3

2. Blow dust from motor using low pressure air.

3. Rotate armature and check for irregularities or other damage. An evenly distributed carbon layer on the brush contact surface is normal.

4. Be sure all brushes exert uniform pressure on the armature.

000601

4563

Crown 2000 PF11844 Rev. 12/02

Printed in U.S.A.

01 REV. 12/02

M4.7–2720–001

M4.7–2720–001

BRAKE 0

The brake system consists of a traction motor mounted brake which is activated by lowering the spring loaded steering arm in the horizontal (down) position or by raising it to the vertical (up) position. The handle or steering arm is spring loaded to return to the vertical position when it is released by the operator, applying the brake. The area of control handle travel between these two positions is referred to as the operating (travel) range of the handle. See section M4.2 for additional information.

6.0Nm (4.5 ft. lbs.)

Adjusting Nut

Mounting Screw

This brake is spring applied and electrically released. The WP is designed so that when de-energized the brake will be applied. Should it become necessary to move the truck while de-energized, the brake is equipped with two hex socket head screws that may be manually loosened to release the brake.

Magnet Body

Hub

Spring

Rotor Plate

WARNING

Before returning truck to operation be sure to return the brake release screws to their original position and check for proper braking function.

Failure to return screws to their original position results in truck having no braking ability.

Rotor

Rubber Cover

Friction Plate

Woodruff Key

Brake Mounting Screws 8050

Hex socket head screws used for releasing brake

ILLUSTRATION 1

Part of Drive Motor 8051-01

000601

ILLUSTRATION 2

4564 Printed in U.S.A.

Crown 2000 PF11840-1 Rev. 12/02

02 REV. 12/02

M5.0–2720–001

M5.0–2720–001

BRAKE Brake Disassembly (Refer to Illustrations 1 & 2)

3. Tighten mounting screws to 6 Nm (4.5 ft. lbs.).

Should it become necessary to remove the brake, replace brake pads and/or rotor, or make repairs to the drive motor.

The following steps should be followed:

4. Set up brake torque and verify brakes work properly.

Brake Adjustment

1. Lift and block truck as needed, and disconnect battery.

AIR GAP ADJUSTMENT

2. Remove covers.

The "air gap" is the distance between the magnet body and the rotor plate with the brake applied. As the brake pads and rotor wear normally, the air gap will increase and should be readjusted when it measures more than 0.2 mm (0.008 in.).

3. Disconnect the brake electrical connector and remove the rubber outer cover ring.

4. Remove the three brake mounting screws, refer to Illustration 1.

NOTE If the air gap measures more than 0.2 mm (0.008 in.), the brake may not release properly.

5. Remove magnet body from the motor.

6. Carefully remove the rotor from the splined hub. A Woodruff Key is located between the motor shaft and hub. Replace the Woodruff Key each time brake is removed. Care should be taken while removing assembly to avoid damage to the machined surfaces.

Air gap adjustment can be performed as long as the brake pads and rotor function properly or until the adjustable spacer threads are fully engaged (adjustment limit reached).

To adjust gap (brake applied) refer to Illustration 3: 1. Chock load wheels and open power unit doors to access brake assembly.

7. Remove the friction plate.

2. Using low pressure air, remove any dirt between armatures and magnet body.

8. Remove the Allen head cap screws and nuts.

9. Remove the screws from the magnetic body.

3. Loosen (only) the brake assembly screws.

10. Remove the rotor plate.

11. Thoroughly clean all brake components and inspect rotor plate, friction plate, and rotor for uneven wear, grooves or cracks. If necessary replace any components at this time.

4. Rotate adjustable spacers evenly and adjust air gap to 0.2 mm (0.008 in.). Check gap near each spacer.

5. Tighten the brake assembly screws 6 Nm (4.5 ft. lbs.).

6. Remove chocks and check operation.

Replace the rotor if the minimum thickness of 5.5 mm (0.22 in.) has been exceeded. Replacement of the rotor plate, friction plate and woodruff key should be accomplished at this time also.

0.2mm (0.008 in.)

Air Gap

Brake Assembly (Refer to Illustrations 1 & 2) Before assembling brake, inspect all components for wear, grooves, nicks or other damage. If any abnormal wear or damage appears that creates any doubt that brake operation may be affected, replace with new parts. Assemble brake as follows:

Magnet Body Adjustable Spacer

1. Reverse steps 1 thru 11.

Feeler Gauge

Armature

2. Set brake Air Gap. 6739-01

ILLUSTRATION 3 Printed in U.S.A.

Crown 2000 PF11840-2 Rev. 12/02

02 REV. 12/02

M5.0–2720–002

M5.0–2720–002

BRAKE STOPPING DISTANCE ADJUSTMENT

General Notes

The stopping distance of the truck should require minimal adjustment. However, this distance should be checked with each planned maintenance.

The braking system and caster system are adjusted at the factory to provide nominal brake and stability performance for level, smooth, dry, concrete floors and standard tire and load conditions. Upon installation, the trucks brake and stability performance should be checked to ensure acceptability. It may be necessary to modify the factory settings to properly accommodate the particular operating conditions.

When a vehicle is operating over a variety of floor and load conditions, it may be impractical to adjust the brakes and casters to perform optimally for all of the different conditions.

Using an unloaded truck, run truck to it's top speed on an even dry concrete surface. Move control handle into the lower braking position. Measure length of braking path from the actuation point of the brakes until the truck has stopped.

The actual length of the braking path should be between approximately 0.5 - 0.7 m (1 ft. 8 in. to 2 ft. 4 in.).

To adjust stopping distance, proceed as follows:

WARNING

1. Chock wheels. Remove power unit door to access brake assembly.

2. Rotate the spring adjusting nut clockwise to SHORTEN the stopping distance or counterclockwise to LENGTHEN the stopping distance.

3. Remove wheel chocks and check operation.

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

• Reducing caster loading reduces stability.

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

Printed in U.S.A.

Crown 2000 PF11840-3 Rev. 12/02

02 REV. 12/02

M5.0–2720–003

M5.0–2720–003

BRAKE Troubleshooting Symptom

Probable Cause

Remedy

Brakes will not release

• Air gap more than 0.2 mm (0.008 in.)

Adjust

• Brake temperature above 140° C/280° F

Allow to cool and check air gap

• Open circuit in brake module circuitry or wiring

Make voltage checks at test points of the brake module

• Air gap less than 0.2 mm (0.008 in.)

Adjust

• Brake pad mounting plates or rotor distorted

Replace

• Armatures movement restricted by dirt, foreign material

Clean with low pressure air

• Pads soiled with grease

Replace

• Incorrect stopping distance adjustment

Adjust

• Brake pad mounting plates or rotor distorted

Replace

• Brake pads loose or soiled with grease

Replace

• Brake pad mounting plates or rotor distorted

Replace

• Brake pads worn out, loose, soiled with grease, foreign material embedded

Replace

• Rotor thin, cracked, or spline worn

Replace

Brakes drag

Brakes grab

Abnormal noise and chatter when brakes applied

CHART 1

Printed in U.S.A.

Crown 2000 PF11840-4 Rev. 12/02

02 REV. 12/02

M5.0–2720–004

M5.0–2720–004

STEERING The steering system consists of a control handle attached to the steering knuckle which is directly connected to the drive unit. The handle or steering arm is spring loaded, at the knuckle, to return to the vertical position when it is released by the operator. The handle also interacts with the brake switches to apply the brakes in both the full upright position and the fully lowered position. The area of control handle travel between these two positions is referred to as the operating or travel range of the handle. The operator may apply a force over the entire operating range of the control handle to affect the steering.

Assemble the control handle and springs as follows:

The springs are located on the rotary shaft of the control handle at the knuckle. The inner spring tabs fit into the machined groove or keyway in the shaft. The outer tabs fit into the control handle and when properly tensioned, exert an upward force on the handle.

4. Check for proper operation.

CAUTION

Do not place hands inside the control handle near the rotary axle while the springs are tensioned.

1. Reverse steps 1 thru 5 above.

2. With control handle in its full upright position, tension the rotary shaft by using a face spanner wrench and turning approximately 20° clockwise or until the roll pin holes align with the knuckle.

3. Drive a roll pin into position to hold shaft and spring assembly in place.

Spring Adjustment (Refer to Illustration 1) The rotary shaft is fixed on the left side at the knuckle with a roll pin. If the spring pressure reduces over time or the handle no longer returns to the upright position, the springs can be re-tensioned as follows: 1. Lift and block truck as needed, and disconnect battery.

Handle and Knuckle Disassembly (Refer to Illustration 1)

2. Raise control handle to its full upright position.

Should it become necessary to remove the control handle from the knuckle to replace springs and/or shaft, or make repairs to the assembly. The following steps should be followed:

3. Drive out roll pin holding left side of shaft. Using a face spanner wrench rotate the shaft clockwise until the offset roll pin hole on the right side aligns with the knuckle and drive in new roll pin.

1. Lift and block truck as needed, and disconnect battery.

4. Check for proper operation.

2. Raise control handle to its full upright position.

Part of Control Handle

3. Drive out roll pin holding left side of shaft. The shaft should turn counterclockwise approximately 20°. If the shaft does not rotate a face spanner wrench may be used to rotate the shaft and relieve the spring tension.

Roll Pin

Shaft

4. Drive the shaft toward the right side as needed to remove springs.

Left Hand Side of Knuckle

5. Thoroughly clean all steer components and inspect springs, shaft and knuckle for uneven wear or cracks.

If necessary replace any components at this time.

Handle and Knuckle Assembly (Refer to Illustration 1)

Springs 8092

ILLUSTRATION 1

Before assembling handle, springs, and knuckle, inspect all components for uneven wear, cracks, or other damage. If any abnormal wear or damage appears that creates any doubt that steering may be affected, replace with new parts.

000601

4565 Printed in U.S.A.

Crown 2000 PF11851-1 Rev. 12/02

01 REV. 12/02

M6.0–2720–001

M6.0–2720–001

STEERING Roller Bearing (Refer to Illustration 2) The control handle is connected to the drive unit via the knuckle and a flange. The twin conical roller bearings are located between the flange and the truck chassis. They are lubricated and are considered maintenance free. Illustration 2 shows a cross section of the roller bearing with the drive unit disassembled.

6. Remove the lower conical roller bearing together with the inner ring and the seal from the flange.

7. Remove the upper conical roller bearing, inner ring, and seal.

8. Drive out the outer rings of both bearings from the chassis.

Disassembly (Refer to Illustration 2) Should it become necessary to replace the roller bearings, or make repairs to the assembly. The following steps should be followed: 1. Lift and block truck as needed, and disconnect battery.

Assembly (Refer to Illustration 2) Before assembling bearings in chassis, inspect all components for wear, cracks, or other damage. If any abnormal wear or damage appears that creates any doubt that steering may be affected, replace with new parts.

2. Remove the front panel and knuckle panels.

1. Reverse the disassembly procedures in steps 1 - 8.

3. Remove 6 mounting screws located in the knuckle and remove the control handle and its support. Care should be used to insure no control wires are damaged.

2. Thoroughly grease all bearings prior to final assembly and connect all wires to the control handle insuring that all wires are free from twists.

4. Disconnect the drive unit wiring.

3. Torque the knuckle mounting screws to 49 Nm/36 ft. lb.

5. Using a rubber mallet gently knock the flange and drive unit down and out of the chassis. The lower conical roller bearing together with the inner ring and seal will remain on the flange.

4. Test for proper operation and return to service.

Control Handle

Knuckle Screw

Seal Upper Conical Roller Bearing and Ring

Lower Conical Roller Bearing and Ring 8093S

Truck Chassis Flange

ILLUSTRATION 2

Crown 2000 PF11851-2 Rev. 12/02

Printed in U.S.A.

01 REV. 12/02

M6.0–2720–002

M6.0–2720–002

C

LIFT LINKAGE

Tension Bar Assembly Removal (Refer to Illustration 1) • With the use of a lifting device, raise and securely block truck to allow access to the tension bars. Refer to lifting and blocking section in this manual.

WARNING

Fork Assembly

Ensure lifting device and blocking equipment has a sufficiently rated capacity for the weight of the truck. Never work under a suspended truck.

WARNING 1

If the truck is placed on its side, the battery must be removed. Also, the vented plug in the drive unit and the hydraulic fluid fill cap on the hydraulic fluid reservoir must be capped to prevent fluid leakage.

Connects To Power Unit

4

• Remove the roll pin (1) from top of the forks and drive out the riser pivot shaft.

2

3 6

• Remove roll pin (2) and drive out pivot shaft (2).

5

4

• Remove the tension bar assembly (3) from the truck.

1 1

Tension Bar Replacement (Refer to Illustration 1) • Remove the tension bar ends (4) from the tension bar (3). To assure proper reinstallation of the tension bar into the tension bar ends, count the number of turns it takes to remove each end.

• Thread the new tension bar into the tension bar ends.

If the number of turns taken vary considerably from one end to the other, compensate to even the thread engagement while maintaining the original center distance between the tension bar ends.

NOTE Item 4 has a R.H. and L.H. designation. Make sure the correct one is placed in its correct location at assembly.

Bottom View Of Tension Bars

ILLUSTRATION 1

8048

Tension Bar Assembly Installation (Refer to Illustration 1) • Connect the tension bar assembly to the riser assembly (1) with the riser shaft (1). When in position, insert roll pin (1).

• Connect the other end of the tension bar assembly to the lower link assembly using shaft (2) and roll pin (2).

• Lubricate all grease fittings.

000601

4764

Crown 2000 PF11839-1 Rev. 1/03

Printed in U.S.A.

01 REV. 1/03

M7.0–2720–001

M7.0–2720–001

C

LIFT LINKAGE

Fork Height • Lower the fork completely. The riser stops should contact the fork ends evenly for both the right and left fork ends. Refer to Illustration 2.

Fork Lift Heights

Height Above Riser Pivot 83mm + 2.0mm (3.25 in. + 0.08 in.)

Part Of Fork Assembly

Forks Completely Lowered

Riser Stop Riser Stops Should Contact Both Sides When Lowered.

Riser Stop

Standard Lift Height 150mm (6.0 in.)

ILLUSTRATION 2

8049

Heel Height 85mm +/– 3.0mm (3.35 in. +/– 0.1 in.)

Floor Surface

Fork Height Adjustment • With the use of a lifting device, raise and securely block truck to allow access to the tension bars. Refer to lifting and blocking section in this manual.

Floor Surface

CAUTION

Ensure lifting device and blocking equipment has a sufficiently rated capacity for the weight of the truck. Never work under a suspended truck.

Trailer Fork Lift Height 130mm (5.0 in.)

• Loosen jam nut on tension bar. Refer to Illustration 1.

8047-01

• Rotate the tension bar using the welded nut (6). Refer to Illustration 1.

• Lower truck and verify fork height at riser pivot point is 83 mm + 2.0 mm (3.25 in. + 0.08 in.) and heel height is 85 mm +/–3.0 mm (3.35 in. +/–0.10 in.). Refer to Illustration 3.

• Repeat the above steps until the riser stops contact the fork ends evenly.

ILLUSTRATION 3

• After adjustments are completed and dimensions are verified, torque the locking jam nut on tension bar to 203 Nm (150 ft. lbs.).

• Repeat the above procedure for the other fork.

• Verify fork lift height. Standard forks lift height should be 150 mm (6.0 in.) and trailer fork should be 130 mm (5.0 in.). Refer to Illustration 3.

NOTE The above procedure focuses on the adjustments of just one tension bar. The height relationship between the right and left forks should be considered when replacing either one or both.

Crown 2000 PF11839-2

Printed in U.S.A.

01 REV. 1/03

M7.0–2720–002

M7.0–2720–002

GLOSSARY Components of the WP 2000 truck have been listed in chart form to assist the maintenance mechanic in locating these components on the Electrical Diagrams and Parts Breakdown forms.

The chart is in columns: COMPONENT; LOCATION; FUNCTION; DIAGRAM; PARTS BREAKDOWN. The COMPONENT column contains the abbreviation of the component as it appears on the Diagrams and in the Maintenance Section. The LOCATION column gives the general location

on the truck such as on mast 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 the component. The PARTS BREAKDOWN column includes the parts breakdown page number on which the component is located along with the index number, in parenthesis, if applicable.

AUDIBLE INDICATORS Location

Function

Diagram

Parts Breakdown

HN1

Power Unit (Near Pump)

Truck Horn

DIA–2720–004 (C3) DIA–2720–009 (C3)

04.0–2720–001 (28)

Location

Function

Diagram

Parts Breakdown

Power Unit (Batt. Comp.)

Power Supply

DIA–2720–003 (A2) DIA–2720–003 (A2) DIA–2720–012 (A1)

04.8–2720–100 (18) 04.8–2720–200 (9)

Function

Diagram DIA–2720–004 (B1) DIA–2720–009 (B1) DIA–2720–004 (B2) DIA–2720–009 (B2) DIA–2720–004 (C3) DIA–2720–009 (C3) DIA–2720–005 (B1) DIA–2720–010 (B1) DIA–2720–005 (B2) DIA–2720–010 (B2) DIA–2720–005 (B3) DIA–2720–010 (B3) DIA–2720–006 (B1) DIA–2720–011 (B1) DIA–2720–006 (B2) DIA–2720–011 (B2)

BATTERY

Battery

CONNECTIONS Location A

Traction Control Module

B

Traction Control Module

TT, KYS, ORS, BRS, Brake, Line Contactor POT, RS, SAS, FS

C

Traction Control Module

HSS

CA202

Power Unit

CA404

Power Unit

CA406

Power Unit

LMS, SV, Line Contactor HN, Optional THS TT, KYS, LMS, P, Optional BDI BRS, ORS

CA410

Control Handle

RAS, LOS, HNS, HSS

CA411

Control Handle

CA412

Control Handle

Pot/Switch Module, Optional Freezer Components SAS

D

Traction Control Module

HN, P, SV

E

Traction Control Module

Handset

000601

DIA–2720–006 (B4) DIA–2720–011 (B4) DIA–2720–004 (B3) DIA–2720–009 (B3) DIA–2720–003 (C4) DIA–2720–008 (C4)

6642

Crown 2000 PF11861-1 Rev. 8/00

Printed in U.S.A.

02 REV. 8/00

M10–2720–001

M10–2720–001

GLOSSARY

CONTACTORS Location

Function

Diagram

Parts Breakdown

DIA–2720–003 (B1) DIA–2720–004 (C1) DIA–2720–008 (B1) DIA–2720–009 (C1) DIA–2720–012 (A2) DIA–2720–004 (C4) DIA–2720–009 (C4) DIA–2720–012 (C2)

04.0–2720–001 04.4–2720–001

L

Power Unit (Below Controller)

Line Contactor For Traction Control Module

P

Power Unit (Below Controller)

Lift Pump Contactor

CONTROLLERS Location

Diagram

Parts Breakdown

Power Unit (Side Opposite Traction Control Battery Disconnect)

DIA–2720–003 (C1) DIA–2720–004 (A1) DIA–2720–008 (C1) DIA–2720–009 (A1) DIA–2720–012 (B4)

04.0–2720–001 (19)

Location

Function

Diagram

Parts Breakdown

FU1

Above Traction Control Module

Main Power Fuse

04.0–2720–001 (16)

FU2

Instrument Panel

Control Circuit

FU3

Instrument Panel

Freezer Components

DIA–2720–003 (A1) DIA–2720–008 (A1) DIA–2720–012 (A2) DIA–2720–003 (B1) DIA–2720–008 (B1) DIA–2720–008 (A1)

Location

Function

Diagram

Parts Breakdown

Battery Discharge Meter

DIA–2720–010 (C2)

04.8–2720–300 (6)

Hour Meter Battery Discharge, Hour Meter & Lift Interrupt

DIA–2720–010 (C2) DIA–2720–010 (B3)

04.8–2720–300 (6) 04.8–2720–300 (6)

Location

Function

Diagram

Parts Breakdown

M1

Drive Unit

Traction

03.1–2720–001

M2

Power Unit (Below Controller)

Lift

DIA–2720–003 (B2) DIA–2720–008 (B2) DIA–2720–012 (B3) DIA–2720–012 (B2)

Traction Control Module

Function

04.0–2720–001 04.4–2720–001

FUSES

04.8–2720–300 (8) 04.8–2720–300 (11)

METERS

Discharge Instrument Panel Meter Hour Meter Instrument Panel Unigage Instrument Panel

MOTORS

Crown 2000 PF11861-2 Rev. 6/00

02.1–2720–001

Printed in U.S.A.

02 REV. 8/00

M10–2720–002

M10–2720–002

GLOSSARY POTENTIOMETERS Location

Function

Diagram

Parts Breakdown

Acceleration

DIA–2720–006 (C3)

04.5–2720–100 (14) DIA–2720–011 (C3)

SOLENOID VALVES Location

Function

Diagram

Parts Breakdown

SV

Pump and Motor Assembly

Lowering

DIA–2720–004 (C4) DIA–2720–009 (C4) HYD–2720–001 (B2)

02.1–2720–001 (18)

Location

Function

Diagram

Parts Breakdown

DIA–2720–005 (C3) DIA–2720–010 (C3) DIA–2720–006 (C2) DIA–2720–011 (C2) DIA–2720–006 (C1) DIA–2720–011 (C1) DIA–2720–006 (C2) DIA–2720–011 (C2) DIA–2720–004 (C1) DIA–2720–009 (C1) DIA–2720–005 (C1) DIA–2720–010 (C1) DIA–2720–006 (C1) DIA–2720–011 (C1) DIA–2720–005 (C3) DIA–2720–010 (C3) DIA–2720–006 (C1) DIA–2720–011 (C1) DIA–2720–006 (C2) DIA–2720–011 (C2) DIA–2720–006 (A4) DIA–2720–011 (A4) DIA–2720–010 (C1)

03.3–2720–001 (7)

POT/Switch Control Pod Module

SWITCHES

BRS FS

Knuckle (Side Opposite Brake Battery Disconnect) POT/Switch Module Foward Traction

HNS

Control Pod

Horn

HSS

Control Pod

High Speed Traction

KYS

Instument Panel

Key

LMS

Power Unit (Battery Lift Limit Disconnect Side of Truck) Control Pod Lower

LOS ORS RAS

Knuckle (Battery Brake Override Disconnect Side of Truck) Control Pod Raise

RS

POT/Switch Module

Reverse Traction

SAS

Control Handle

Safety Reverse Traction

THS

Instument Panel

Freezer/Corrosion

Crown 2000 PF11861-3 Rev. 6/00

04.5–2720–100 (14) 04.5–2720–100 (29) 04.5–2720–100 (7) 04.8–2720–300 (5, 12) 04.0–2720–001 (6) 04.5–2720–100 (27) 03.3–2720–001 (7) 04.5–2720–100 (27) 04.5–2720–100 (14) 04.5–2720–001 (9) 04.8–2720–300 (9)

Printed in U.S.A.

02 REV. 8/00

M10–2720–003

M10–2720–003

CYLINDERS Lift Cylinders

Lift Cylinders

Lift Cylinder Removal Refer to Figure 26136.

Lift Cylinder Operation The lift cylinders are single-acting. The piston rods are raised by the hydraulic fluid pressure and lowered by the weight of the raised load. Figure 26135 shows a lift cylinder cross section.

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

2. Remove the top cover and the main cover.

3. Extend the piston rods until the left-hand piston rod attachment is next to the contactors so the roll pin can be removed.

4. Block the fork carriage to prevent it from lowering and to take the fork weight off of the lift cylinders.

5. Press and hold the lower switch for at least 10 seconds to depressurize the hydraulic system.

1

WARNING

2

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 that 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 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.

3 4

3 5

6

6. Turn the truck OFF. 7. Disconnect the battery. Lockout/Tagout the truck as described in Lockout/Tagout in the Control of Hazardous Energy section.

8. Remove the roll pin (1) from the left-hand piston rod attachment (2).

Figure 26135

9. Disconnect the electrical connections to the lift pump motor.

10. Remove the roll pin from the right-hand piston rod attachment.

1

Piston Rod

2

Wiper

3

Guide Ring

4

Seal

11. Lower the piston rods (3) into the cylinder tubes (4).

5

Hydraulic Fluid Inlet/Outlet

12. Disconnect the hydraulic lines.

6

Cylinder Tube

13. Remove the cylinder clamp (5) at the base of the lift cylinder.

Crown 2000 PF11843-1 Rev. 10/11

M8.0-2720-001 01 Rev. 10/11

213

CYLINDERS Lift Cylinders Lift Cylinder Disassembly

NOTE Protect the piston rods (3) from scratches when removing them through the chassis hole (6) by using cardboard or paper.

To disassemble the lift cylinder and carefully extract the ram assembly from the cylinder bore, never allow the ram assembly to contact any sharp edges.

14. Remove the lift cylinder from the truck.

Seals The seals used in the lift cylinder are made from an extremely durable, hard polyurethane material that can be deformed temporarily to allow for installation without permanent damage.

Seal Removal CAUTION When an excessive amount of hydraulic fluid is evident around the area where the ram assembly exits from the cylinder tube, the seal is damaged and must be replaced.

CAUTION Never use a screwdriver to remove seals, as damage and leakage may result.

CAUTION The hooked tool must be constructed of aluminum or brass to not scratch or nick any surfaces. The hooked tool is not available through Crown.

The lift cylinder must be removed from the truck to perform seal replacement. The seal is seated inside the cylinder tube so a hooked tool should be used to remove the seal. Refer to Figure 16733.

127 mm (5 in)

Figure 26136

Figure 16733

1. Remove the wiper. The seal and the wiper should always be replaced in pairs.

M8.0-2720-002 01 Rev. 10/11

214

Crown 2000 PF11843-2 Rev. 10/11

CYLINDERS Lift Cylinders 2. Thoroughly clean the area where the seal seats.

Any burrs, dirt, or seal debris must be removed before installing new seals.

NOTE Lubricate all replacement parts with a thin coat of hydraulic fluid before installing them.

Lift Cylinder Inspection 1. Check the piston rods for signs of nicks, scratches, or other damage to the surface.

2. Check the wiper for wear and fluid leakage.

NOTE An installation tool made of soft material or suitable plastic that is smooth and free of burrs with a fixed steel pin and two movable pins is required for this installation. Refer to Figure 16735-02.

3. Check the piston rod seal for damage or excess wear that can cause hydraulic fluid leakage.

4 3

CAUTION Close inspection of seal seating critical areas should be made before the new seal is installed.

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.

1

4. When repairing the lift cylinder, check the condition of the guide rings. Ideally, all seal components should be replaced, not just worn or damaged seals.

5. Minor irregularities on the cylinder tube surface or the piston rod can be removed with an aluminium oxide cloth or a honing tool.

6. After inspection, clean all lift cylinder components with a high grade solvent and dry with low pressure compressed air.

Seal Installation CAUTION

2 Figure 16735-02 1

Pin 1

2

Pin 2

3

Pin 3

4

Tool Body

1. Slip the seal over the fixed pin. Refer to Figure 16735-02 and bend it over pin 2 as shown.

2. Continue bending the seal until pin 3 can be pushed through the seal loop which locks the seal in position. Refer to Figure 16735-02.

Tools used to install seals must be made of soft material or suitable plastic, free of burrs and sharp edges.

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

CAUTION The area in contact with the seal should be free of burrs, sharp edges, and nicks. If a new seal must be installed over sharp edges, slots, or corners, take the appropriate protective measures.

Crown 2000 PF11843-3 Rev. 10/11

M8.0-2720-003 01 Rev. 10/11

215

CYLINDERS Lift Cylinders 3. Insert the installation tool with the mounted seal into the lift cylinder bore until aligned with the seal installation groove. Refer to Figure 16736-01.

3

3

1 2 1

Figure 16738-01

2 Figure 16736-01 1

Pin 1

2

Pin 2

3

Pin 3

1

Pin 1

2

Pin 2

3

Pin 3

6. Remove the installation tool.

Lift Cylinder Assembly

4. Remove pin 3 so the seal loop snaps into the seal installation groove. Refer to Figure 16737-01.

CAUTION Occasionally, a slight creep of the fork assembly may occur. This may be due to internal leakage in the seals but it also may indicate hydraulic fluid leakage in other areas of the hydraulic system. Refer to the Hydraulic System section for circuit bleeding and drift test guidelines.

3

1

Apply a thin coat of hydraulic fluid to the ram assembly and install it into the cylinder tube.

2 Figure 16737-01 1

Pin 1

2

Pin 2

3

Pin 3

5. Remove pin 2 and the seal will completely snap into the seal installation groove. Refer to Figure 16738-01.

M8.0-2720-004 01 Rev. 10/11

216

Crown 2000 PF11843-4 Rev. 10/11

HYDRAULIC SCHEMATIC Hydraulic Schematic Hydraulic Schematic

1

Lift Cylinders

2

Solenoid Valve (SV)

3

Filter

4

Check Valve (CV)

5

Lift Pump Motor (M2)

6

Lift Pump

7

Reservoir

8

Suction Filter

9

Return Filter

10

Vent Cap

11

Relief Valve (RV) (2465 psi/170 bar)

12

Flow Control

Figure 25656

Crown 2000 PF11835-1 Rev. 7/11

HYD-2720-001 01 Rev. 7/11

55