craiun PLATFORM

Refer to the following w h e n maintaining and/or repairing the V T F Mast- Thrust rollers that are w o r n , not turning freely
platform o n y o u r Turret Stockpicker (TSP). a n d c h e c k roller a d j u s t m e n t . W h e n the platform is c o m -
pletely l o w e r e d , thrust rollers s h o u l d be a d j u s t e d to have
I N S P E C T I O N AND A D J U S T M E N T 0.75 m m (0.030 in.) c l e a r a n c e w i t h the I-beam flange o n
e a c h side of the 2 n d s t a g e mast.
A safe a n d efficient truck operation is d e p e n d e n t on period c
inspections. W h e n m a k i n g a routine inspection of the T S P I : i u m n roller plate pivots freely.
p l a t f o r m , c h e c k for the following:
E t h i n g s , bearings a n d shafts for wear.
Front Platform A r e a
Overhead Guard Area
% C o l u m n rollers that are w o r n , not turning freely a n d c h e c k
for proper m a s t c l e a r a n c e . R e f e r t o lllustrat on 9-" * o ' 2 - r j :
I e : - ~ a t i o n and cracks.
stage c o l u m n roller clearance m e a s - ' e ~ e ~ : s - : - ~ a s :
type installed on truck. z
: : e - s.', tch operation ( T D S L & T D S R ) .

T F M A S T (Manufactured Prior to 4/95) V O v e r h e a d shield.

Column P -oper operation of spot lights, d o m e light a n d f a n .

— Shims = : e :

Display Panel

A P r o p e r operation of s w i t c h e s a n d lights.

2nc Stage
Gates
Mast

V W e a k e n i n g of spring t e n s i o n .

_2.80mm (0.110 in.) V Proper switch operation ( G L S & G R S ) .

->i;-<-
3 . 5 5 m m (0.140 in.)
Pedestal Pedal Area
T N ( M a n u f a c t u r e d F r o m 10/93 to P r e s e n t ) &
T F ( M a n u f a c t u r e d F r o m 4/95 to P r e s e n t )
A Free m o v e m e n t of pedestal a n d service b r a k e pedals.

Large R a d i u s T o w a r d s Column P -operswitch operation (BRS-3, B R S - 4 , D M S - 2 & D M S - 3 ) .

M o u n t i n g Stud Roller No S h i m s
\ B e a r i n g s a n d shafts for wear.

Seat and Area Below

2'z Stage
Mast
\ Seat m o v e s up a n d d o w n freely.

v W o r n w e a r buttons ( m o u n t e d o n seat s u p p o r t ) .

_0.75mm (0.030 in.) >

V S h a f t s , bearings a n d b u s h i n g s for wear.
1.60mm (0.062 in.)
V P r o p e r operation of g e a r motor.
I L L U S T R A T I O N 9-1

V S h o c k a b s o r b e r b r a c k e t s pivot freely.

V S h o c k a b s o r b e r pins, b r a c k e t s , p l u n g e r s , b u m p e r s a n d
poly stops for wear.

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 CRQUJh PLATFORM

V Height s e n s o r reel turns freely. L o w e r Platform A r e a

V Control cable extension spring adjustment. Springs should
have an overall length of 150 m m (6 in.).
V Hydraulic h o s e s a n d control c a b l e s for wear a n d cracks.
V Lift chain for c r a c k e d plates, tight joints, protruding pins,
wear, etc. (refer to M 7 . 5 section for chain m a i n t e n a n c e ) .
V Hydraulic fittings for leaks.
V Free m o v e m e n t of floor pedals.
V Prcce'sv. t c h o p e r a t i o n ( B R S - 4 , B R S - 5 , D M S - 4 & D M S - 5 ) .
V Proper chain a n c h o r adjustment. Chain a n c h o r s s h o u l d
be = c . r e d so that the distance from the top of the
platform skirt to the top of the m a i n f r a m e b a s e m e a s u r e s
178 to 185 m m (7 to 7.25 in.) arc; an equal a m o u n t of
tension is on e a c h of the lift chains.

V Proper switch operation ( C H S - 1 , C H S - 2 , C H S - 3 , C H S - 4 ,

LMS-1, LMS-2, LMS-3, LMS-4 & SES).

S p e e d Control Area

V Twist grip rotates freely.

V P a l m , e m e r g e n c y d i s c o n n e c t , raise/lower cutout, over-

ride a n d horn buttons d e p r e s s a n d spring return freely.

V Proper s w i t c h operation ( D M S - 1 , E D S , E M S - 1 , E M S - 2 .
HNS & O R S ) .

V Worn bushings and bearings.

Control Linkage A s s e m b l y and Area Below

V Free m o v e m e n t of control levers.

V Steering tiller turns freely.

V Steering indicator lights f u n c t i o n properly.

V Auxiliary lift button d e p r e s s e s a n d spring returns freely.

V Proper switch operation ( A X S , P T S , T V S L & T V S R ) .

V Hydraulic fittings for leaks.

V Shaft, b u s h i n g s a n d b e a r i n g s for w e a r .

lams I L L U S T R A T I O N 9-2

Crown 1989 PF8204-2 Rev. 12/01 Printed in U S A

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 CRQUJri PLATFORM

V Lift chain for cracked plates, tight joints, protruding pins, 2. A liberal coat of C r o w n 0 6 3 0 0 2 - 0 2 4 grease or equiva-
wear, etc. Also, chain anchor for w e a r a n d c r a c k s (refer to lent to c o l u m n a n d thrust rollers contact area of the
M7.5 section for chain m a i n t e n a n c e ) . mast.

V G a n g hose and control cables for w e a r and c r a c k s . 3. Application of S A E 4 0 oil to lift c h a i n .

V Proper adjustment of gang h o s e . T h e gang h o s e should 4. S p r a y i n g a g e n e r o u s a m o u n t of solvent ( W D - 4 0 or

be adjusted so that there is 13 m m to 16 m m (0.50 in. to equivalent) o n t h e inside of t h e height sensor housing
0.63 in.) clearance between the g a n g hose loop a n d the to c l e a n , f o l l o w e d with a silicon s p r a y . Lubriplate Spray
lower bumper. L u b e or e q u i v a l e n t .

5. A p p l i c a t i o n of S A E 4 0 oil t o control valve linkage, side

gate shafts a n d b u s h i n g s , c h a i n slack pusher rods and
s h o c k a b s o r b e r pins ( c a n a l s o u s e Lubriplate Spray
Lube).

R.H.
6. A p p l i c a t i o n of 0 6 3 0 0 2 - 0 2 5 g r e a s e or equivalent to seat
LOWER
BUMPER guides.

PAD R E P L A C E M E N T

- : BE S h o u l d a floor pedal, p e d e s t a l p e d a l or brake pedal pad n e e d

replacement proceed as follows:
— u o
fa
1 3 m m to 1 6 m m 1. T h o r o u g h l y c l e a n the p e d a l s u r f a c e .
(0.50 in. to 0.63 in.1
2. A p p l y a thin coat of c e m e n t ( C r o w n 0 6 1 0 0 7 - 0 0 2 ) to the
10013S I L L U S T R A T I O N 9-3
p a d a n d p e d a l . D o not a p p l y c e m e n t to the pad if it is a
s p o n g e type s u r f a c e , i n s t e a d a p p l y a heavier coat to
V T r a y liner ( g a n g hose) for wear.
the pedal only.

LUBRICATION
3. A l l o w the c e m e n t to dry until it b e c o m e s tacky (approxi-
mately 10 to 15 m i n u t e s ) .
Regular lubrication of the platform s h o u l d include:

1. Application of C r o w n 0 6 3 0 0 2 - 0 2 5 grease o r e q - . a l e n t 4 . P l a c e the pad in position a n d a p p l y pressure to insure

to the lube fitting a s s e m b l e d onto the pivot p'a:e s~ a~. g o o d contact b e t w e e n s u r f a c e s .

I L L U S T R A T I O N 9-4
Crown 1969 PF8204-3 Rev. 12/01 Printed in U.S.A.

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 CAQUJh PLATFORM

MAST SHIELD

T o perform m a i n t e n a n c e to certain areas of the mast or

platform a s s e m b l y , it m a y be necessary to remove the mast
shield. T h e m a s t shield is m o u n t e d in rubber molding so that
it is fully s u s p e n d e d . T h e molding and safety glass should be
a s s e m b l e d as s h o w n in Illustration 9-5. T h e w e d g e locking
strip must be p r e s s e d into the o p e n groove to secure the
glass in place.

A special tool, w e d g e insertion tool, (Crown 103792) will

greatly aid in the installation of the w e d g e locking strips. T o
use the tool:

1 . Feed the strip t h r o u g h the throat of the tool h e a d (see

Illustration 9-5) leaving a p p r o x i m a t e l y 25 m m (1 in.) of
strip e x p o s e d b e n e a t h t h e h e a d .

2. I nsert the tool into the " V slot in the m a i n molding body.

3. O n c e started, with both the strip a n d body e n d s flush,

c l a m p the e n d with y o u r t h u m b a n d p u s h the tool
t h r o u g h t h e slot.

If the tool s e e m s to push relatively h a r d , apply a little heat to

the m o l d i n g . T h i s will liquefy the film which covers the
molding a n d act as a rubber lubricant.

2457S ILLUSTRAT C \ ~z

Crown 1989 PF8204-4 Rev. 12/01 Primed in U S A

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 CRQUJh PLATFORM

GATES FASTENING
SWITCH P L A T E

(GLS S H O W N )
Located on each side of the platform is a gate that c a n be SHAFT APPLY
rotated "up" to allow for entry or exit. T r u c k operation c a n n o t SPRING
FORCE
be achieved until the gates are l o w e r e d . W h e n the gates are
RELEASE
" d o w n " switch contacts are c l o s e d , providing a signal to the
electronics box allowing truck operation.

T o repair or replace the g a t e s w i t c h e s , torsion springs, lower

pivot shafts, etc., p r o c e e d a s follows:

ROLL
1. Raise the gate to t h e " u p " position allowing for the leas- COVER BUSHING GATE
PIN
a m o u n t of spring t e n s i o n .
L.H. GATE ASSEMBLY S H O W N
2. R e m o v e t w o m o u n t i n g s c r e w s from the c o v e r at the
I L L U S T R A T I O N 9-7
lower arm pivot point.
-
~ : a : : . spring t e n s i o n w h e n assembling " e pivot
3. D i s a s s e m b l e the s w i t c h actuator f r o m the shaft.
s - a ~ t : /. a-d the rear of platform (toward load handler) until
t h e roll pin can be installed t h r o u g h the lower portion of the
4. Use a s p a n n e r w r e n c h ( C r o w n 104712 [ r e f e r t o Illustra-
gate a — s~a~
tion 9-6]) that h a s t w o 5/32 i n . p i n s at a s p r e a d of 15/16
in. a n d position t h e s p a n n e r w r e n c h at the shaft e n d .
GTSL & GTSR
K e e p the gate Njp" a n d r e m o v e t h e roll pin securing the
G a t e S w i t c h e s (Illustration 9-8)
lower portion of the gate to t h e shaft.

T h e g a t e s w i t c h e s supply the signal to the electronics box

104712 w h e t h e r t h e g a t e s are o p e n or c l o s e d . T o a c c e s s these
SPANNER TOOL. SPECIAL
s w i t c h e s , r e m o v e t w o (2) m o u n t i n g s c r e w s from plastic
c o v e r at t h e l o w e r a r m pivot point.

T o adjust, c l o s e g a t e a n d l o o s e n switch mounting s c r e w s

a n d m o v e s w i t c h s o the normally o p e n contact closes and
roller o n s w i t c h is c e n t e r e d o n the actuator. Tighten mount-
ing s c r e w s . O p e n g a t e . T h e n o r m a l l y o p e n contact must
open.

2«8 I L L U S T R A T I O N 9-6

As the roll pin is r e m o v e d , the spring t e n s i o n will be

transferred to the s p a n n e r w r e n c h . Y o u will h a v e to
a s s u m e this load w i t h the s p a n n e r w r e n c h to r e m o v e
the punch u s e d to drive the roll pin out.

5. R e m o v e all n e c e s s a r y parts noting their location for

correct position w h e n a s s e m b l i n g .

GTSL (L.H.)
GTSR (R.H.)

2459s I L L U S T R A T I O N 9-8

Crown 1989 PF8204-5 Rev. 12/01 Printed in U.S.A.

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 CAQlUh PLATFORM

CHAIN ANCHOR ADJUSTMENT If a n excess e a ~ o u n t of c l e a r a n c e is f o u n d at a n y point r

the mast, m e I ~5 ~ m (0.030 in.) c l e a r a n c e m a y have to be
-
T h e p l a t f o r m lift c h a i n a n c h o r s l o c a t e d in the f l o o r of t h e ^ c m e - e : . : e: - e " a but never to a point that could cause
p l a t f o r m s h o u l d be a d j u s t e d s o that the d i s t a n c e f r o m the d a ~ a : e m ~ e s ce — _ s t rollers.
top of t h e m a i n f r a m e b a s e m e a s u r e s 178 to 185 m m (7 t o
7.25 in.) w h e n t h e p l a t f o r m is c o m p l e t e l y l o w e r e d . A d j u s t C O L U I » l R O L L E R ADJUSTMENT - T F MAST
c h a i n a n c h o r s so t h a t a n e q u a l a m o u n t of t e n s i o n is ( T r u c k s Umtuc+wrtl P r i o r to 4/95)
p l a c e d on e a c h of t h e lift c h a i n s .
1. C l e a n c o l u m n m l u s t a t s , if a n y paint or rust is e v i d e n t

te mease I : - I - : : 12-"25).

2 . A r t x k a n y p l a c e o n e s t a m o n e a c h s t u d a n d install
:: _ : e~

3. With t i e use of an i n s o e c a i o e r ^ a l B r t o a j s t r a t i o n ) .
~ e a s _ ' e : e " .ee e~ : ~~. em

*•:-=
: : _-- -: z.- ~ Z t ;- e - a n t e d , so
:e :e-e m a- e ~ e ~ e a s m e - e ' t cn the cor-
• e r : : - :•- y ~ e m e ' -5.~c-.est d i m e n s i o n

- e a s _ e - e : s ce :" " e 2 " c stage mast a l o n g the

-
i -i -ee "a : s - ~ n rollers will travel, using
--- : . - = :e :a : s ee : ^stration 9-10). After find-
:es" : ; - " a c t cc nt. lock the t h u m b s c r e w a n d
- -
: s:s -s :e a ; : _ s i d e calipers together a n d
ikiMiuwmmi f i e a m o u n t of s h i m to be a d d e d to (or
-
e : me c o l u m n rollers.
I L L U S T R A T I O N 9-9 OUTSIDE
CALIPER
T h e 3rd c h a i n a n c h o r should be adjusted s o t h a t t h e
_ _
distance from the washer (inclusive) to the platform .-.e o e :
is 178 m m (7 in.).

S I D E T H R U S T R O L L E R A D J U S T M E N T (TF Mast)

T h e side thrust rollers located on the back of the platform

should be adjusted to have 0.75 m m (0.030 in.) c l e a r a n c e
with I-beam flange on e a c h side of the 2nd stage mast w h e n
the platform is completely lowered. Turn the c a m shafts until
the rollers have this c l e a r a n c e . Raise the platform to assure
there is no binding of the side thrust rollers through the total
length of the 2 n d stage mast.

NOTE

W h e n s h i m m i n g c o i u m n rollers, t r y t o b a l a n c e out the n u m -

Apply a light film of multi-purpose grease to c a m
shafts prior to installation. ber of s h i m s ( e x a m p l e : 2 s h i m s right, 2 s h i m s left). If a n
u n e v e n n u m b e r of s h i m s a r e r e q u i r e d , note the side to w h i c h
the extra s h i m s w e r e a d d e d a n d install all other o d d s h i m s to
that side.

Crown 1989 PF8204-6 Rev. 12/01 Primed in U S A .

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M9.0-19.0-006 M9.0-19.0-006
 PLATFORM

NOTE 7. Divide the s u m of these t w o (2) g a p s by (2) a n d place

T h e m i n i m u m c l e a r a n c e p e r s i d e is 2 . 8 0 m m
(0.110 in.). Using shim w a s h e r s , adjust the
c l e a r a n c e to be 2 . 8 0 m m t o 3.55 m m ( 0 . 1 1 0 i n .
t o 0 . 1 4 0 in.) per s i d e . S h i m s a r e a v a i l a b l e in
t h i c k n e s s e s of 0.81 m m (0.032 i n . [ 0 6 0 0 3 0 - 0 8 5 ] )
and 1.60 m m (0.063 i n . [ 0 6 0 0 3 0 - 0 5 7 ] ) .
T F M A S T ( M a n u f a c t u r e d Prior to 4/95)
Column
i Shims Ro e-
t h i s a m o u n t o f s h i m o r g a g e , between column rollerand
w e b o n o n e side of the mast.
Example:
G a p = 1.80 m m (0.070 in.) + 2 = 0.90 m m (0.035 in.)
8. Adjust c a m on o p p o s i t e side so that the thrust roller
c o n t a c t s the f l a n g e of the " I " b e a m .
9. R e m o v e the s h i m / g a g e a n d adjust other c a m so the
thrust roller c o n t a c t s the f l a n g e of the " I " b e a m .

\ 10. M o v e t h e 2 n d stage up a n d d o w n the m a i n f r a m e . T h e

! thrust rollers s h o u l d roll a b o u t 7 5 % of the time or more,
without heavy m a r k i n g of the mast.
2 n d Stage
Mast 11. R e p e a t steps 1 t h r u 10 for top thrust rollers.

T N ( M a n u f a c t u r e d F r o m 10/93 to P r e s e n t ) &
T F ( M a n u f a c t u r e d F r o m 4/95 to P r e s e n t )
_ 2 . 8 0 m m ( 0 . 1 1 0 in.)
3 . 5 5 m m ( 0 . 1 4 0 in.) Large Radius T o w a r d s Column
M o u n t i n g Stud Roller
I L L U S T R A T I O N 9-11 No S h i m s

Distance f r o m the top of the platform skirt to the top of t h e

m a i n f r a m e base m e a s u r e s 178 m m to 185 m m (7 to 7.25 in.).
2nd Stage
Mast
COLUMN R O L L E R A D J U S T M E N T - TN & T F MAST
(TN M a n u f a c t u r e d F r o m 10/93 & T F F r o m 4/95 to P r e s e n t )

1. C l e a n c o l u m n roller studs. If a n y paint or rust is e v i d e n t

on s t u d s , r e m o v e with e m e r y cloth a n d lubricate w i t h 0 . 7 5 m m (0.030 in.) >

multi-purpose g r e a s e ( C r o w n 0 6 3 0 0 2 - 0 2 5 ) . 1.60mm (0.062 in.)

I L L U S T R A T I O N 9-12
2. Install c o l u m n rollers with large r a d i u s of roller t o w a r d s
stud shoulder. Refer to Illustration 9-12.
SIDE THRUST ROLLER ADJUSTMENT
( T F Mast M a n u f a c t u r e d Prior to 4/95)
3. Install retaining rings.

T h e 2 n d stage mast is w i d e r at the top t h a n at the b o t t o m to

4. E x t e n d 2 n d stage to the m a i n s t o p s a n d adjust c a m
minimize m o v e m e n t of the platform w h e n raising and lower-
shafts to their loosest setting.
ing. Raise the platform to the t o p of t h e 2 n d stage mast a n d
adjust side thrust rollers evenly a n d s n u g . C h e c k to be sure
5. Apply a light film of grease to both e n d s of c a m if n e e d e d .
that the c o l u m n rollers are g a p p e d e v e n l y so that the platform
m o v e s up a n d d o w n parallel to the mast. Also, lower a n d
6. At the b o t t o m of 2 n d stage m a s t , with c o l u m n rollers
raise the platform to e n s u r e no binding t h r o u g h the total
p u s h e d against the stud s h o u l d e r s a n d 2 n d s t a g e
length of the 2 n d stage mast.
forced to one side, m e a s u r e the d i s t a n c e , on b o t h
sides, b e t w e e n c o l u m n roller f a c e a n d w e b of the " I "
beam.

Crown 1989 PF8204-7 Rev. 12/01 Printed in U.S.A.

04 R E V . 12/01
M9.0-19.0-007 M9.0-19.0-007
 PLATFORM

SIDE THRUST ROLLER A D J U S T M E N T - P L A T F O R M mble the left platform c o v e r (below control

(TF M a n u f a c t u r e d F r o m 4/95 & T N F r o m 10/93 to P r e s e n t ) Ihe left platform floor cover a n d c o v e r o n the
" d l e r allowing a c c e s s to g a n g h o s e c o n n e c -
1. Insure column rollers are installed with large radius
toward stud shoulder and retaining rings a r e intact.

2. Adjust c a m shafts t o their looset setting a n d slide

platform to top of the 2 n d s t a g e . A p p l y a light film of
grease to both ends of c a m shaft if n e e d e d .

3. Force the platform to one side of t h e 2 n d stage a n d

push c o l u m n rollers against stud s h o u l d e r s .

4. Measure the gap, on both s i d e s , b e t w e e n the c o l u m n

roller face and w e b of the "I" b e a m .

5. Divide the s u m of t h e s e t w o (2) g a p s by (2) a n d place

this amount of s h i m , or g a g e , b e t w e e n c o l u m n roller
and w e b on side of platform.

Example:
Gap = 1.80 m m (0.070 in.) - 2 = 0 . 9 0 m m (0.035 in.)

6. Adjust c a m on the o p p o s i t e s i d e of s h i m / g a g e so the

thrust roller contacts the f l a n g e of t h e T b e a m .

7. Remove the s h i m / g a g e a n d adjust t h e other c a m s o the

thrust roller contacts the ' l a r g e the T b e a m .
246is ILLUSTRATION 9-'3
8. Repeat steps 1 thru 7 for t h e u p p e r set of thrust rollers.

9. Move the platform up a r d d o w n 2nd stage mast. C h e c k WARNING

to see if the thrust rollers roll a b o u t 7 5 % of the time
without heavy marking of the mast.
10. Inspect platform to see if the g a p s b e t w e e n the uprights
and 2nd stage mast are relatively e v e n . If platform rubs
on the 2 n d stage mast or d o e s net a p p e a r to sit s q u a r e
on mast, readjust side thrust no ers
GANG HOSE R E P L A C E M E N T
1. To replace the g a n g h o s e , traverse the load handler
completely to the left (this will allow for better a c c e s s
and easier d i s a s s e m b l y / a s s e m b l y of the hydraulic
gang hose c o n n e c t i o n s at the load handler).
2. Place blocks under platform a n d lower platform onto
blocks to relieve pressure in the raise/lower circuit.
6. D i s a s s e m b l e the g a n g hose c l a m p located be zt.
3. Disconnect battery, c h o c k load w h e e l s a n d actuate
pivot and traverse levers to relieve p r e s s u r e .
7. N o t e location of c o n n e c t i o n s , cut any c a b l e ties, cSs-
4. Remove floor mat f r o m platform.
A VOtD HIGH PRESSURE FL UIDS—Escaping
• _ :. -~e • cressurecan penetra:a • - :a. s-
hg serious injury. Relieve pressure before <Ms-
:: - 'as: ~g hydraulic lines. Tig~:e - a :: ~ ~s:-
-----aa-'ceapplyingpressure. <aa: ~a~:sana
bodyaway from pin holes which eject fluids under
r
- g ~: -f 5 s L e. Use a piece c*' ca ':: : a -jor caper
to search for leaks. Do not use your hand.
Any fluid injected into the skin under high pres-
sure should be considered as a serious medical
a ~a ga -cy despite an initial'normal'appearance
ofthe skin. There is a delayed onset of pain, and
serious tissue damage may occur. Medicalatten-
tion shouldbe sought immediately by a specialist
who has had experience with this type of injury.
re
platform just above the g a n g hose tray.
connect g a n g hose and r e m o v e .

Cro»n 1955 PF8204-8 Rev. 12/01

04 R E V . 12/01
M9.0-19.0-008
 CflQUJh PLATFORM

8. C h e c k c o n d i t i o n of tray liner, replace if necessary.
9. Route n e w g a n g h o s e , apply hydraulic sealant ( C r o w n
: : - - : 0 5 sealant) to fitting r - e a d s and connect
hose.
10. A s s e m b l e h o s e c l a m p to b o t t o m of platform but d o not
tighten bolt.
1. Raise the platform just high e n o u g h so that the thrust
roller c o v e r s c a n be r e m o v e d . Disconnect battery,
c h o c k load w h e e l s a n d securely block platform.
2. R e m o v e the four thrust roller c o v e r s f r o m the back of
"-e : a~orm and rotate the c a m shafts so t h a t t h e thrust
rollers will not c o n t a c t the mast w h e n r e m o v i n g the
platform.

1 1 . C o n n e c t battery a n d s l o w l . • : v ;e :ne load handler

c o m p l e t e l y to the right b e i n g careful not to d a m a g e the
gang hose.

12. Adjust the gang hose s o that there is from 13 m m to 16

m m (0.50 in. to 0.63 in.) clearance between the gang
hose loop and the lower b u m p e r referto Illustration 9-14.

R.H.
LOWER
BUMPER

BOLT THRUST
HOSE ROLLER
CAM
CLAMP SHAFT

1 3 m m to 1 6 m m I L L U S T R A T I O N 9-15
(0.50 in. to 0.63 in.l
3. R e m o v e cover f r o m height cable switch (HCS) a s s e m -
I L L U S T R A T I O N 9-14
bly m o u n t e d on b a s e of m a i n f r a m e , r e f e r t o Illustration
9-16. Hold height cable securely a n d loosen cable
13. T i g h t e n h o s e c l a m p bolt a n d c a b l e tie w h e r e neces- c l a m p screw. B e i n g careful not to d a m a g e cable, pull
sary. cable t h r o u g h m a i n f r a m e . A ferrule has b e e n c r i m p e d
14. C h e c k o p e r a t i o n of load handler, recheck g a n g hose on t h e height s e n s i n g cable near the e n d , this s h o u l d
loop c l e a r a n c e a n d c h e c k for hydraulic leaks. prevent the cable f r o m being c o m p l e t e l y reeled into the
15. A s s e m b l e c o v e r s a n d floor mat. height s e n s o r h o u s i n g . Slowly allow the cable to be
reeled into the height s e n s o r housing until the ferrule
PLATFORM REMOVAL contacts the h o u s i n g .

T h e weight of t h e platform, w i t h o u t the load handler, is

a p p r o x i m a t e l y 9 0 0 Kg (2000 lbs.) a n d w i t h the load handler
is a p p r o x i m a t e l y 1450 Kg (3200 lbs.). Be sure e q u i p m e n t
u s e d to lift a n d s u p p o r t the platform is of sufficient capacity
to safely h a n d l e this load. W h e n r e m o v i n g the platform from
the 2 n d stage mast refer to the f o l l o w i n g :

Crown 1989 PFB204-9 Rev. 12/01 Printed in U.S.A.

04 R E V . 12/01
M9.0-19.0-009 M9.0-19.0-009
 PLATFORM

HEIGHT C A B L E
(3ROKEN) SWITCH HEIGHT
ASSEMBLY (HCS) SENSOR
CABLE

- F E R R L LE

4 0 0 m m (16 in.)

10009S ILLUSTRATION 9-16

4. C o n n e c t battery, r e m o v e b l o c k s f r o m p l a t f o r m a n d
lower platform.

=
Disconnect battery a n d r e m o v e the c a c - = - : e ' efer
to L o a d H a n d l e r R e m o v a l in t h e M 9 . 1 s e c t i o n of this ___5 _ : :
-~ Z\ 3-17

manual.
8. Block p l a t f c — s e c . e .
To allow for proper sling, c h a i n , etc. h o o k - u p , d i s c o n -
nect the t w o t r a v e r s e c u s h i o n s w i t c h e s ( T D S L & T D S R ) 9. R e m o v e floor m a t a n d c o s e a : : e : .•, s c e e d

m o u n t e d on the o v e r h e a d g u a r d shield a s s e m b l y a n d control and rr zz e c* : a a a c c e s s to

-

remove shield f r o m o v e r h e a d g u a r d . hydraulic r : = e a : c — e c t c " S . height

_
sensor, c h a - a " : : - s s
Attach sling, c h a i n , etc. to t o p of platform a n d raise
a p p r o x i m a t e l y 0 . 3 m (1 foot) to a l l o w s l a c k in the lift 10. To prevent
chains, hydraulic h o s e s a n d electrical c a b l e . (If u s i n g ing the p l a t f c r ~ ~z>~~ —
c h a i n , place w o o d b l o c k s a b o v e a n d below or o n u p p e r cable f r o m T B 5 2 4 ma •e "e y . se-scr.
spur rack teeth to p r e v e n t d a m a g e w h e n lifting plat- Assemble a 3/8-16UNC _~ ength
form.) of 1.25 in. ( C r o w n 06CO" t~e _
e cht s e n s o r
h o u s i n g as s h o w n i n I k 18. T h i s bolt locks
the reel in p l a c e , inset e cable d o e s not
c o m p l e t e l y reel into t h D i s a s s e m b l e the
height sensor r.cunt'r-g ; m o v e height s e n -
s o r f r o m platfcrm

Crown 1939 PF8204-10 Rev. 12/01 Printed in U S A

04 R E V . 12/01
M9.0-19.0-010 M9.0-19.0-010
 PLATFORM

15. Note a n d mark location of hydraulic h o s e s a n d discon-

SEAT nect h o s e s . Be p r e p a r e d to catch any hydraulic oil
ASSEMBLY during d i s a s s e m b l y .

HEIGHT 16. R e m o v e the t w o hose retainers located at the top of the

SENSOR mast, r e f e r t o Illustration 9-20.

LOCKING
BOLT HOSE
RETAINERS

2466S I L L U S T R A T I O N 9-18

11. Note a n d m a r k location of the three control cables,

d i s c o n n e c t c a b l e s and unhook springs from cable
grips.

12. D i s a s s e m b l e the t w o m o u n t i n g bolts from the chain :--: = = I L L U S T R A T I O N 9-20

s l a c k / b r e a k switch assembly a n d r e m o v e assembly,
refer t o Illustration 9-19.
13. T F M a s t - R e m o v e the shoe-: absorber m o u n t i n g pins
a n d r e m o v e both shock absorbers.
1 7 . Pull c a b l e s , c h a i n s a n d h o s e s free of platform a n d lay
over top of m a s t out of w a y .
18. Slowly lift the platform out of the top of the mast a n d
m o v e to a clean w o r k a r e a for repair.

PLATFORM ASSEMBLY

1 . Prior to assembling platform to 2 n d stage mast, apply a

liberal coat of multi-purpose grease (Crown 063002-024
grease) to the c o l u m n and thrust roller contact area of the
SHOCK mast.
ABSORBER CHAIN
SLACK/BREAK
SWITCH A S M . 2. Attach sling, c h a i n etc. to top of platform a n d carefully
lower the platform into t h e mast. A s the platform is
l o w e r e d into the m a s t , c h e c k the running c l e a r a n c e of
the c o l u m n a n d side thrust rollers at v a r i o u s intervals.
(Refer to C o l u m n Roller A d j u s t m e n t a n d Side T h r u s t
Roller A d j u s t m e n t . )

3. Block platform a p p r o x i m a t e l y 1 m (3 ft.) f r o m floor.

"67S I L L U S T R A T I O N 9-19
4. A s s e m b l e the t w o h o s e retainers at the top of the m a s t .
A l s o , be sure h o s e s , c a b l e s a n d c h a i n s are properly
14. D i s a s s e m b l e lift chains from a n c h o r s located in middle
routed t h r o u g h mast.
of platform floor a n d pull chains from platform.

Crown 1989 PF8204-11 Rev. 12/01 Printed in U.S.A.

0 4 R E V . 12/01
M9.0-19.0-011 M9.0-19.0-011
 CROUJh PLATFORM

5. Apply t h r e a d sealant ( C r o w n 0 6 1 0 0 4 - 0 0 5 sealant) to 13. A s s e m b l e shield onto o v e r h e a d g u a r d a n d connect

hydraulic fittings a n d c o n n e c t hydraulic h o s e s . switches.

6. A s s e m b l e lift chains to chain a n c h o r s a p p r o x i m a t i n g TDSR

the a d j u s t m e n t of the chain a n c h o r s . P r o p e r chain
a n c h o r a d j u s t m e n t will be m a d e later. N.C. C O M M

NOTE TB502
( m o u n t e d inside of t h e
R.H. o v e r h e a d c o n s o l e )
Routing chain t h r o u g h the platform can be m a d e
less difficult by attaching a w i r e t o the c h a i n , 1
pushing the wire t h r o u g h the platform first a n d
BLK ?
then pulling the chain in position for a s s e m b l y to
anchors. 3

•WHI 4 —WHI-i
7. T F M a s t - A s s e m b l e s h o c k a b s o r b e r s .
5 BLK
c
8. C h e c k to be sure p u s h rods are property located a n d
a s s e m b l e the c h a i n s l a c k / b r e a k switch a s s e m b l y onto TDSL
the p l a t f o r m .

N.C. C O M
9. C o n n e c t control c a b l e s , cable grips and springs. Proper
spring e x t e n s i o n a d j u s t m e n t s will b e m a d e after plat- I L L U S T R A T I O N 9-22
form blocks are r e m o v e d a n d lift chain a d j u s t m e n t s
have b e e n m a d e . 14. Adjust chain anchors s o that the distance from the top
of t i e platform skirt to the top of the mainframe b a s e
10. A s s e m b l e height s e n s o r to p l a t f o r m , f e e d i n g the height m e a s u r e s 178 mm to 185 mm (7 to 7.25 in.) and an
sensor cable below the platform. e c _ a =~:>_-t r te^s — s cn tne " : - = - = " ' 5 3 ' :
c h a m a n c h o r should be adjusted s o that the distance
11 C o n n e c t electrical c a b l e t o T B 5 2 4 m o u n t e d o n the from the w a s h e r (inclusive) to the platform weldment is
height sensor, refer t o Illustration 9-21 a n d r e m o v e 178 m m (7 in.).
locking bolt f r o m height s e n s o r h o u s i n g .
15. kz.-St c a r a z~zs sc : - a t there is approximately 140 m m
T552- (5.5 in.) of spring extension.
n
RED -
16. A s s e ~ c a : : . e - tc z atform floor.
ORG 2
WHI 2 17. A s s e m b l e l o a d h a n d l e r onto platform (Refer to L o a d
BLK - H a n d t e r A s s e m b l y in the M9.1 section of this m a n u a l ) .

18. C o n n e c t battery a n d raise platform high e n o u g h to

allow c o n n e c t i o n of height s e n s o r c a b l e .
!469 I L L U S T R A T I O N 9-21

19. Disconnect battery a n d block p l a t f o r m .

12. R e m o v e blocks, l o w e r platform a n d u n h o o k c h a i n ,
sling, etc. f r o m p l a t f o r m .

Crawn 1989 PF8204-12 Rev. 12/01 Printed in U S A .

04 R E V . 12/01
M9.0-19.0-012 M9.0-19.0-012
 CAQUJh PLATFORM

20. T h r e a d the height sensor cable t h r o u g h the m a i n f r a m e

to the switch a s s e m b l y . Adjust the cable so that the
distance f r o m w h e r e the cable enters the top of the
main f r a m e to the ferrule ( c r i m p e d o n t o the cable)
m e a s u r e s 4 0 0 m m (16 in.).

HEIGHT CABLE

10009S I L L U S T R A T I O N 9-23

21. S e c u r e cable to the switch lever a n d a s s e m b l e cover.

2 2 . C o n n e c t battery a n d c h e c k for hydraulic leaks, b i n d i n g ,

proper switch o p e r a t i o n , etc.

2 3 . A s s e m b l e covers a n d install floor mat.

Crown 1989 PF8204-13 Rev. 1201 Printed in U.S.A.

0 4 R E V . 12/01
M9.0-19.0-013 M9.0-19.0-013
 cnawn MAINTENANCE

LOAD HANDLER

T h e f o l l o w i n g i n f o r m a t i o n s h o u l d be u s e d w h e n m a i n t a i n -
ing and/or repairing the load h a n d l e r on y o u r T u r r e t COLUMN
Sr '.'3 ROL_E =
S t o c k p i c k e r (TSP).

I N S P E C T I O N AND A D J U S T M E N T

Periodic i n s p e c t i o n of y o u r load h a n d l e r is n e c e s s a r y for

s a f e a n d efficient o p e r a t i o n . W h e n m a k i n g a routine in- AUXILIARY
s p e c t i o n of the load h a n d l e r , c h e c k for t h e f o l l o w i n g : MAST

Fork Area

• D e f o r m a t i o n a n d fatigue c r a c k s .
0.020 i n . (0.50mm)
• E l o n g a t i o n of b o r e in m o u n t i n g s u p p o r t t u b e . 0.040 i n . (1.00mm)
• H y d r a u l i c leaks from c y l i n d e r a n d fittings.
• Proper s w i t c h o p e r a t i o n , ( F H S L , F H S R , F L S , F R S ) . A0665 I L L U S T R A T I O N 9.1-2
• W o r n Bearing Slides. (--Worn poly s t o p s .
• S p r i n g pin o p e r a t i o n . • Hydraulic leaks.
• Proper f o r k h e i g h t a d j u s t m e n t , refer to illustration 9.1 -1
Auxiliary Mast A r e a
(check w i t h f o r k s pivoted to t h e right a n d left).
Distance nearest t o p of fork heal to floor should measure • H y d r a u l i c f i t t i n g s a n d lift c y l i n d e r f o r l e a k s .
2.75 i n . ( 7 0 m m ) . • Upper a n d lower b u s h i n g s a n d bearings.
Distance f r o m top of fork tip to floor s h o u l d m e a s u r e 3.00 • Hydraulic hoses a n d control cable for w e a r a n d cracks.
in. (75mm). • Control c a b l e t e n s i o n s p r i n g a d j u s t m e n t . S p r i n g s h o u l d
h a v e 5 i n c h e s ( 1 2 5 m m ) of o v e r a l l l e n g t h [1 t o 2 i n c h e s
(25 to 5 0 m m ) of e x t e n s i o n ] .
• Lift e r a - fc- : a : - a : : a:es, tight joints, p r o t r u d i n g pins,
wear, etc. A l s o , c h a i n a n c h o r for w e a r and c r a c k s (refer
to M7.5 s e c t i o n f o r c h a i n m a i n t e n a n c e ) .

Upper L o a d H a n d l e r A r e a

• Proper pivot s w i t c h ( P L S & P R S ) a n d t r a v e r s e s w i t c h

(TLS & T R S ) o p e r a t i o n .
-
• Pivc: a : c . n d e r pin s h o u l d m o v e up a n d d o w n rapidly
a n d s m o o t h l y w h e n l o c k i n g a n d r e l e a s i n g p i v o t i n g fork
carriage.
2.75 in. ^ B u s h i n g s , b e a r i n g s a n d s p r o c k e t s for w e a r .
(70mm)
• Pivot c h a i n for c r a c k e d p l a t e s , tight j o i n t s , p r o t r u d i n g
p i n s , w e a r , etc.
3.00 i n .
(75mm) • Hydraulic leaks.

A 0664 I L L U S T R A T I O N 9.1-1

Fork Carriage Area

• Fork rod wear.

• Worn and cracked chain anchor.
• S w i t c h o p e r a t i o n (AHS).
• C o l u m n rollers that a r e w o r n , not t u r n i n g freely a n d
c h e c k for p r o p e r m a s t c l e a r a n c e (refer to illustration
9.1-2).

Crown 1988 PF-8194-1 Printed in U.S.A.*

M9.1 - 19 - 001 M9.1 - 19 - 001

 MAINTENANCE

T r a v e r s e Drive A r e a
0.890 in. (22.61mm)
• B u s h i n g s , b e a r i n g s a n d s p r o c k e t s for wear.
0.895 in. (22.73mm)
• T r a v e r s e drive chain for c r a c k e d plates, tight j o i r t s : ' :-
truding p i n s , w e a r , etc.
• C a r r i a g e and c o l u m n rollers that are w o r n and do - o t t u r n r
freely.
COLUMN
• W o r n w e a r plates. ROLLER
M a x i m u m a l l o w a b l e d i s t a n c e b e t w e e n v-aa- plates a n d
c o l u m n rollers is 0.910 i n . (23.11 m r - an m u m allow-
able w e a r for w e a r plates i s 0 . 0 1 5 i n . ( 0 . 3 8 m m ) , r e f e r t o
_UPPER WEAR
illustration 9.1-3 PLATE
—| j—0J910 i n . ( 2 3 . 1 1 m m ) m a x .
0.015 i n . ( 0 . 3 8 m m ) m a x . -

COLUMN COLUMN
"] ~~ ROLLER ROLLER

LOWER WEAR
UPPER WEAR PLATE
PLATE

1 - 0.890 in. (22.61mm)

0.895 in. (22.73mm)
COLUMN I L L U S T R A T I O N 9.1-4
ROLLER
• Be s u r e s p r o c k e t s , g e a r s a n d t e e t h on rack m e s h pro-
perly a n d are c e n t e r e d .
LOWER WEAR
PLATE • Racks for w e a r .

Lower Load Handler A r e a

• A l l stops for w e a r .
• Hydraulic leaks.
•*-0.015 in. (0.38mm) max.
• Worn bushings and bearings.
— 0.910 in. (23.11mm) max.
• Proper s w i t c h o p e r a t i o n ( F H S L & F L S ) .

Aoeee ILLUSTRATION 9.1-3"

NOTE

W e a r plates w o r n more than 0.015 in. (0.38mm)

s h o u l d b e r e p l a c e d . Do not c o m p e n s a t e for
w e a r by s h i m m i n g .

W h e n r e p l a c i n g w e a r plates, the d i s t a n c e b e t w e e n col-

u m n rollers a n d w e a r plates s h o u l d m e a s u r e from 0.890
in. (22.61 m m ) to 0.895 in. (22.73mm), refer to illustration
9.1-4.

Crown 1988 PF-8194-2 Printed in U.S.A.'

M9.1 - 1 9 - 0 0 2 M9.1 - 1 9 - 0 0 2
 MAINTENANCE

LUBRICATION

Regular l u b r i c a t i o n of load handler s h o u l d i n c l u d e : c. L u b e fitting for u p p e r m a s t DX b e a r i n g .

1. A p p l i c a t i o n of C r o w n #63002-25 grease or e q u i v a l e n t
to all fittings, t h e s e i n c l u d e :
a. L u b e fittings for l o w e r b e a r i n g o n t o r q u e t u b e a n d
lower idler gear b e a r i n g .
LUBE

AO67O I L L U S T R A T I O N 9.1-7

d. Fittings for upper bearing on torque tube and up-

per idler g e a r bearing.

A0666 I L L U S T R A T I O N 9.1-5

b. Lube fittings for mast thrust b e a r i n g and lower DX

bearing.

AW, I L L U S T R A T I O N 9.1-8

2. A l i b e r a l c o a t of g r e a s e ( C r o w n = 6 3 0 0 2 - 2 4 or
e q u i v a l e n t ) to c o l u m n roller contact area of m a s t , spur
rack a n d p l a t f o r m .
3. M a s t rollers, y o k e , c o l u m n rollers and fork rod a n d
b o r e s ( C r o w n # 6 3 0 0 2 - 2 5 g r e a s e or e q u i v a l e n t ) .
4 . L u b r i c a t i o n of s p r i n g pin a s s e m b l y o n forks. Use
C r o w n # 6 3 0 0 2 - 2 oil or e q u i v a l e n t .
5. A p p l i c a t i o n of a r u b b e r lubricant s u c h as A r m o u r - A l l
b r a n d s e a l a n t a n d protectant to hose a n d cable rollers
a n d roller c o n t a c t a r e a s of hoses a n d control c a b l e .
LUBE
FITTING 6. A p p l i c a t i o n of S A E 4 0 oil to the lift, pivot a n d traverse
chain.
A0669 I L L U S T R A T I O N 9.1-6

Crown 1988 PF-8194-3 Primed in U S A ;

M9.1 - 19 - 003 M9.1 - 19 - 003

 MAINTENANCE

F H S L . F H S R , F L S , FRS
F o r k H o m e a n d D i f f e r e n t i a l S w i t c h e s (Illustration 9.1-9)
SWITCH MTG. ASM
T h e s e s w i t c h e s a r e located in a : ; - ••• - ch is bolted to the SWITCH ACTUATOR
b a c k of the fork a s s e m b l y . A n actuator pin on the fork ex-
DIFFERENTIAL SWITCH
t e n s i o n , c o n t a c t s the switch actuator w h e n the forks are FLS (L.H.), FRS (R.H.)
retracted. T h e switch a c t u a : : = : _sned back and actuates
these switches.
_
During n o r m a l o p e - a : : - : e 'orks m a y d r i f t o u t o f " h o m e " FORK HOME SWITCH
FHSL (L.H.). FHSR (R.H.)
p o s i t i o n . W h e n the • • h o m e " switch ( F H S L or F H S R ) is
reset, the e l e c t r o n i c s box ignores the input as fork out of ACCESS HOLE
" h o m e " , until t h e differential switch (FLS or FRS) resets. ACTUATOR PIN
(FORK EXTENDED POSITION)
This input is interpreted as fork out of " h o m e " position a n d
0.S in. (*2ara) O A . PIN
t h e pivot f u n c t i o n will be locked out electronically. Retract
f o r k s to clear electronics for normal operation. This allows F O R K =—--—=: =:s H O N
a p p r o x i m a t e l y 0.5 i n . ( 1 2 m m ) of fork cylinder drift. GAGE BLOCK
FORK Ex-5'.:e: =CSITION

T o a c c e s s t h e s e s w i t c h e s , remove the t w o (2) m o u n t i n g

bolts w h i c h hold the switch mounting w e l d m e n t to the fork.
o I L L U S T R A T I O N 9.1-9
Lay a s s e m b l y o n its b a c k and r e m o v e four (4) s c r e w s
holding t h e switch a s s e m b l y to t h e m o u n t i n g weld ment. A n /f\ WARNING
alternate m e t h o d of accessing switches is to extend forks,
AVOID HIGH PRESSURE FLUIDS—Escaping fluid
w h i c h allows a c c e s s to switch a s s e ~ : , ~ : _ - i : n g screws.
under pressure can penetrate the skin causing
T o a d j u s t s w i t c h e s , loosen switch m e n : - : sc-ewsslightly serious injury. Relieve pressure before disconnec-
so switches can b e moved and are still h e l : With the switch ting hydraulic lines. Tighten all connections before
a c t u a t o r in the fork e x t e n d e d position m o v e the upper (dif- applying pressure. Keep hands and body away
ferential) s w i t c h until the switch p l u n g e r only t o u c h e s the from pin holes which eject fluids under high
a c t u a t o r . T i g h t e n the t o p s c r e w to hold this sw tch in posi- pressure. Use a piece of cardboard or paper to
t i o n . Push the s w i t c h actuator away from Bh a : : e s s hole search for leaks. Do not use your hand.
a n d place a 0.5 i n . ( 1 2 m m ) d i a m e t e r pin o n top of g a g e
Any fluid injected into the skin under high pressure
b l o c k s in front of a c c e s s hole. Adjust the tower (home)
should be considered as a serious medical
s w i t c h s o s w i t c h plunger is fully d e p r e s s e : ~ anten re-
emergency despite an initial normal appearance of
m a i n i n g t w o (2) m o u n t i n g s c r e w s . Remove C.5 in. (12mm)
the skin. There is a delayed onset of pain, and
diameter pin.
serious tissue damage may occur. Medical atten-
Verify s w i t c h a d j u s t m e n t by pushing switch actuator r a c k . tion should be sought immediately by a specialist
W h e n a c t u a t o r m o v e s a p p r o x i m a t e l y 0.06 i r . ( 1 . 5 m m ) , who has had experience with this type of injury.
m e a s u r e d at c e n t e r l i n e of access hole, the differential
s w i t c h s h o u l d a c t u a t e . W h e n actuator is released, the
s w i t c h m u s t reset. Push switch actuator back 0.5 in.
( 1 2 m m ) , m e a s u r e d a: : e n : e r l i n e of access hole. T - e - : ~ e
switch should actuate.

Crown 1988 PF-8194-4 Printed in U.S.A.'

M9.1 - 19 - 004 M9.1 - 19 - 004

 MAINTENANCE

FORK REMOVAL FORK ASSEMBLY

1. To r e m o v e t h e fork a s s e m b l y , lower p l a t f o r m a n d f o r k 1. After forks have b e e n properly inspected and/or

carriage completely. -eaa-e: : : a--:-'< shaft a n d bores with grease C'C.vn
2. D i s c o n n e c t battery a n d c h o c k l o a d w h e e l s . =63002-25).

3. R e m o v e t h e cover f r o m t h e fork c a r : age (refer t o il- 2 . L u b r i c a t e t h e s p r i n g pin a s s e m b l y on t h e fork w i t h oil

lustration 9.1-10) allowing a c c e s s to electrical c o n n e c - (Crown #63002-2).
tions a n d r e t a i n i n g r i n g s . 3. P o s i l k x i f o r k a s s e m b l y in place a n d f e e d the electrical
-
:s: e "~e : e s - - - o u g h the fork carriage.
4 . Insert fork s h a f t a n d a s s e m b l e retaining rings onto fork
-
s~ a
5. T o r e d u c e f o r k w e a r f r o m t i e f o r k s r u b b i n g t h e floor
d u r i n g n o r m a l o p e r a t i o n , m e a s u r e t h e d i s t a n c e (with
t h e f o r k c a r r i a g e p i v o t e d t o t h e right a n d left) from the
t o p o f t h e f o r k b l a d e , nearest t h e h e e l , to t h e floor. This
d i s t a n c e s h o u l d m e a s u r e 2 . 7 5 i n . ( 7 0 m m ) . r e f e r t o il-
lustration 9.1-11.

Boi7i ILLUSTRATION 9.1-10

4. T h e electrical cable will be p u l l e d t h r o u g h t h e fork car-

riage w h e n r e m o v i n g the fork a s s e m b l y so d i s c o n n e c t
!
s w i t c h leads f r o m T B 7 0 5 a n d c u t any c a b e t i e s .
5. Disconnect hydraulic h o s e s f r o m t h e b a c k of t h e forks
3.00 i n .
a n d c a b l e tie h o s e s o u t of t h e w a y . B e s u r e to c a t c h
(75mm) •
a n y h y d r a u l i c oil d u r i n g d i s a s s e m b l y .
A0664 I L L U S T R A T I O N 9.1-11
6. Slide b l o c k s u n d e r f o r k s , u s i n g b l o c k s j u s t t h i c k
e n o u g h to t a k e t h e w e i g h t of t h e f o r k s off of t h e fork If not, a d j u s t t h e c h a i n a n c h o r o n t h e b a c k of the a_ • an,
shaft. lift c y l i n d e r .
7. R e m o v e r e t a i n i n g r i n g s a n d d r i v e o u t f o r k shaft.
T h e fork tip r.eight (top f o r k tip) s h o u l d m e a s u r e 3.00 i n .
8. B e i n g careful not to d a m a g e e l e c t r i c a l c a b l e , r e m o v e ( 7 5 m m ) a b o v e t h e f l o o r . A d d or r e m o v e s h i m s located in
fork a s s e m b l y p u l l i n g t h e c a b l e t h r o u g h t h e fork :
t h e heel area : t r e fork o n t h e fork c a r r i a g e to obtain pro-
carriage. per p o s i t i o n of t h e f o r k t i p .
For m o r e i n f o r m a t i o n on fork i n s p e c t i o n , r e f e r t o t h e M 7 . 8
s e c t i o n in this m a n u a l .

Crown 1988 PF-8194-5 Primed in U.S-A

M9.1 - 19 - 005 M9.1 - 19 - 005

 MAINTENANCE

6. A s s e m b l e hydraulic hoses to b a c k of forks a n d elec- 7. D i s a s s e m b l e t h e lift c h a i n f r o m chain a n c h o r and con-

trical leads to T B 7 0 5 as s h o w n in illustration 9.1-12. trol c a b l e f r o m w a t e r t i g h t c o n n e c t o r o n back of fork
carriage.
8. C a b l e tie h y d r a u l i c h o s e s , electrical c a b l e and lift
C1 c h a i n out of w a y .
V1 i 9. Slowly lower fork c a r r i a g e o u t of the b o t t o m of the aux-
C2 iliary mast a n d m o v e to a c l e a n w o r k area for repair.
r
COLUMN R O L L E R ADJUSTMENT
1 C3 FORK E X T E N S . C N
I CYLINDERS 1. C l e a n c o l u m n roller s t u d s . If a n y p a i n t or rust is evi-
V2l d e n t o n s t u d s , r e m o v e w i t h e m e r y c l o t h a n d grease
w i t h m u l t i - p u r p o s e g r e a s e ( C r o w n #63002-25).
C4
2. A r b i t r a r i l y p l a c e o n e s h i m o n e a c h s t u d a n d install
column rollers.

FORK MANIFOLD 3. W i t h t h e u s e of a n i n s i d e c a l i p e r (refer to illustration),

m e a s u r e b e t w e e n t h e t w o rollers.

NOTE

BLK T h e c o l u m n roller s t u d s a r e c a n t e d , s o be certain

= 3-"-:=-
WHI_ • : : a k e t h e m e a s u r e m e n t o n t h e correct portion of
t h e roller ( n a r r o w e s t d i m e n s i o n p o s s i b l e ) .
BLK
4 . M e a s u r e t h e o u t s i d e of the auxiliary m a s t along the
WHI
a r e a w h e r e t h e f o r k c a r r i a g e c o l u m n rollers will travel,
u s i n g a n o u t s i d e c a l i p e r (refer to Illustration 9.1-13).
- Fter f i n d i n g t h e w i d e s t c o n t a c t point, lock t h e t h u m b
s c r e w a n d p l a c e t h e i n s i d e a n d o u t s i d e calipers
: = 3
t o g e t h e r a n d d e t e r m i n e the a m o u n t of s h i m to be add-
RED e d t o (or r e m o v e d f r o m ) t h e c o l u m n rollers.
GRN

OUTSIDE
TB705 CALIPER

Axr2 I L L U S T R A T I O N 9.1-12

7. A s s e m b l e cover to fork carriage a n d c h e c k for p r o p e r

operation.

FORK CARRIAGE REMOVAL

1. T o r e m o v e the fork c a r r i a g e , c o m p l e t e l y lower plat-

f o r m a n d forks.
2. Disconnect battery a n d c h o c k load w h e e l s .
3. R e m o v e forks (see fork r e m o v a l ) .
4. A t t a c h a c h a i n , s l i n g , etc. to t h e platform o v e r h e a d INSIDE
g u a r d ; raise approximately 3 ft. (1m) a n d block CALIPER
securely.
5. A t t a c h a c h a i n , sling, etc. to fork carriage a n d raise I L L U S T R A T I O N 9.1-13
MM
slightly to insure slack in the hydraulic hoses, c o n t r o l
c a b l e a n d lift chain.
6. D i s c o n n e c t control cable leads from T B 7 0 5 a n d
hydraulic hoses from the fork manifold block. Be sure
and catch any hydraulic oil d u r i n g d i s a s s e m b l y .

Crown 1988 PF-8194-6 Printed in U.S.A.*

M9.1 - 19 - 006 M9.1 -19 - 006

 MAINTENANCE

W h e n s h i m m i n g c o l u m n rollers, t r y t o b a l a n c e out t h e
TRAVERSE M A N I F O L D
n u m b e r of s h i m s ( e x a m p l e : 2 s h i m s right, 2 s h i m s left). If
an u n e v e n n u m b e r of s h i m s a r e r e q u i r e d , note t h e side to
w h i c h the e x t r a s h i m s w e r e a d d e d a n d install all other o d d
s h i m s to t h a t s i d e .

NOTE
FORK M A N I F O L D
T h e m i n i m u m c l e a r a n c e p e r s i d e is 0 . 0 2 0 i n . — -•- -» —
(0.51mm). Using shim washers, adjust the F2 F1
V1
c l e a r a n c e to be 0 . 0 2 0 i n . ( 0 . 5 0 m m ) t o 0 . 0 4 0 -
( 1 . 0 0 m m ) p e r s i d e , refer to illustration 9.1-14.
S h i m s a r e a v a i l a b l e in t h i c k n e s s e s of 0.03 i n .
(0.8mm (#60030-68]) and 0.06 in. ( 1 . 5 m m
[#60030-50]). V2

COLUMN
SHIMS ROLLER

AUXILIARY,
MAST
Y-
: :=g
3= \
BLU

u E_- — :
0.020 i n . (0.50mm) RED BLK — 3
0.040 in. (1.00mm)"

A066S I L L U S T R A T I O N 9.1-14 WHI — 3

FORK CARRIAGE ASSEMBLY Wh =_- —[T

-

1. A t t a c h c h a i n , s l i n g , e t c . to f o r k c a r r i a g e a n d c a r e f u l l y 3T:5
-
install t h e c a r r i a g e b a c k into t h e auxiliary m a s
10675 I L L U S T R A T I O N 9.1-15
2. C h e c k t h e r u n n i n g c l e a r a n c e of t h e c o l u m n rollers.
The m i n i m u m c l e a r a n c e per side is 0.020 in. ( 0 . 5 0 m m ) 4 . C h e c k a d j u s t m e n t of control cable e x t e n s i o n s p r i n g
and t h e m a x i m u m is 0 . 0 4 0 i n . ( 1 . 0 0 m m ) , refer to i l - so t h a t t h e r e is 1 to 2 i n . (25 to 5 0 m m ) of e x t e n s i o n ,
lustration 9 . 1 - 1 4 . 5 in. ( 1 2 5 m m ) of overall l e n g t h .

3. A t t a c h lift c h a i n to c h a i n a n c h o r , h y d r a u l i c h o s e s to 5. A p p l y a liberal coat of multi-purpose g r e a s e ( C r o w n

fork m a n i f o l d a n d c o n n e c t c o n t r o l c a b l e to T B 7 0 5 # 6 3 0 0 2 - 2 4 ) to the c o l u m n roller c o n t a c t areas of the
(refer to illustration 9.1-15). mast.
6. A s s e m b l e f o r k s (see Fork A s s e m b l y ) a n d c a b l e tie
where necessary.
7. R e m o v e b l o c k s f r o m p l a t f o r m , c o n n e c t battery a n d
c h e c k for p r o p e r o p e r a t i o n .

Crown 1988 PF-8194-7 Printed in U.S.A.*

M9.1 - 19 - 007 M9.1 - 19 - 007

 MAINTENANCE

AUXILIARY LIFT CYLINDER REMOVAL

If the cylinder packing requires r e p l a c e m e n t , the entire lift

cylinder does not have to be r e m o v e d . O n l y removal of the
cylinder r a m is r e q u i r e d . Refer to the M 8 . 4 section in this
m a n u a l for proper p r o c e d u r e s . H o w e v e r , if it b e c o m e s
n e c e s s a r y to r e m o v e the auxiliary lift cylinder for replace-
m e n t or repair, p r o c e e d as follows:
SLING
1. Raise fork carriage and p ace Dlocks under fork car-
riage to allow slack in hydraulic h o s e s , c o n t r o l cable
a n d lift c h a i n .
2. D i s c o n n e c t battery a n d c h o c k load w h e e l s .
3. R e m o v e c o v e r f r o m the front of t h e fork c a r r i a g e ex-
: : s - ; ~z~'.z and d i s c o n n e c t control cable from
TB705.
4. Disassemble w a t e r t i g h t control c a b l e c o n n e c t o r from
fork carriage a n d pull c a b l e t h r o u g h hole in f o r k car- I L L U S T R A T I O N 9.1-16
riage b r a c k e t . 15. M o v e cylinder to c l e a n w o r k area for repairs. While the
5. D i s c o n n e c t hydraulic hose c o n n e c t i o n s near top of c y l i n d e r is r e m o v e d , m a k e the f o l l o w i n g inspections:
auxiliary mast or f r o m fork m a n i f o l d block o n fork car- C h e c k the o u t e r covering of the hydraulic hoses for
riage. Be sure a n d c a t c h any hydraulic oil d u r i n g c r a c k s , s c u f f s a n d w o r n areas.
disassembly.
• I n s p e c t t h e y o k e a n d c h e c k to be sure pulleys are
6. D i s a s s e m b l e the hose retainer plate from top of y o k e turning freely.
assembly.
• I n s p e c t t h e c h a i n a n d c h a i n a n c h o r (refer to the
7. Pull h o s e s a n d control cable t h r o u g h pulleys a n d lay M 7 . 5 s e c t i o n in this m a n u a l for proper inspection).
aside.
16. R e p a i r a n d r e p l a c e w h e r e necessary.
8. R e m o v e the t w o cover plates f r o m back of m a s t ex-
p o s i n g t h e c h a i n a n c h o r a n d b o t t o m of lift cylinder. AUXILIARY LIFT CYLINDER ASSEMBLY

9. L e a v i n g t h e lift c h a i n a t t a c h e d to t h e c h a i n a n c h o r , After all c o m p o n e n t s h a v e b e e n i n s p e c t e d , repaired or

d i s a s s e m b l e t h e c h a i n a n c h o r f r o m the lift cylinder. r e p l a c e d a n d l u b r i c a t e d w h e r e necessary, refer to the
10. Lift a n d r e m o v e t h e y o k e from t h e t o p of the cylinder f o l l o w i n g p r o c e d u r e s for auxiliary lift cylinder assembly:
a l o n g w i t h t h e lift c h a i n ( a n c h o r a t t a c h e d ) a n d lay 1. A t t a c h a s l i n g t o t h e cylinder just below the stops
aside. w e l d e d t o t h e s i d e of the cylinder near the t o p .
1 1 . At the b o t t o m of t h e i f t c y f n d e r , d i s a s s e m b l e the 2. S l o w l y l o w e r a n d g u i d e t h e cylinder into the mast. Be
; - -
hydraulic hose, v e l c c r . j s e a : '~.~z a . e za~ s u r e t h e b o t t o m of t h e cylinder slides onto the pin
ready to c a t c h hydraulic oil). l o c a t e d at t h e b o t t o m of the mast.
12. W i t h alien w r e n c h , remove s c r e w located o n t h e front
of t h e m a s t , near the b o t t o m , h o l d i n g the cylinder in
place.
13. Using a pry bar, raise the b o t t o m of the lift cylinder ap-
proximately 6 i n . ( 1 5 0 m m ) a n d p l a c e b l o c k u n d e r
cylinder. T h i s will allow for p r o p e r sling h o o k - u p .
PIN
14. Attach a sling a r o u n d cylinder just below the t w o stops
w e l d e d near the t o p of c y l i n d e r (refer to illustration
9.1-16) and lift a n d g u i d e c y l i n d e r out of m a s t .

A069? I L L U S T R A T I O N 9.1-17

Crown 1988 PF-813i-S printed in U.S.A.*

M9.1 - 19 - 008 M9.1 - 19 - 008

 MAINTENANCE

3. At the front of the m a s t , near the b o t t o m , a s s e m b l e the

s c r e w a n d l o c k w a s h e r to t h e b o t t o m of t h e cylinder. RED
4. A p p l y h y d r a u l i c s e a l a n t ( C r o w n 6 1 0 0 4 - 5 sealant) to ORG
threads and assemble fitting, velocity fuse and
GRN •
h y d r a u l i c h o s e to b o t t o m of c y l i n d e r .
5. A s s e m b l e t h e y o k e to the t o p of c y l i n d e r , f e e d i n g the BLU-
lift c h a i n a n d a t t a c h e d a n c h o r to b a c k of cylinder. BLK-
6. A s s e m b l e the chain anchor to cylinder, approximating RED/BLK-
c h a i n a d j u s t m e n t . P r o p e r lift c h a i n a d j u s t m e n t will be
m a d e later.
7. Route hydraulic hoses a n d control cable t h r o u g h y o k e WHI • 8
assembly. WHI/BLK —j_9
8. A p p l y a r u b b e r l u b r i c a n t s u c h as A r m o u r - A l l b r a n d TB705
s e a l a n t a n d p r o t e c t a n t (or e q u a l ) to h o s e a n d cable
rollers a n d roller c o n t a c t a r e a s of h o s e s a n d c a b l e to I L L U S T R A T I O N 9.1-19
m i n i m i z e f r i c t i o n . A l s o a p p l y l u b r i c a n t to w a t e r tight
cable connectors and control cable. 13. Attach s l i n g , c h a i n etc. t o f o r k c a r r i a g e a n d r e m o v e
blocks.
9. A s s e m b l e h o s e r e t a i n i n g plate to top of y o k e .
14. R e m o v e s l i n g , c h a i n etc. f r c m fork c a r r i a g e a n d ad-
10. A s s e m b l e w a t e r t i g h t c o n n e c t o r to fork c a r r i a g e .
just the c h a i n a n c h o r on b a c k of c y l i n d e r s o t h a t t h e
1 1 . A p p l y t h r e a d s e a l a n t ( C r o w n # 6 1 0 0 4 - 5 sealant) t o distance from the top of t h e f c r k o'ade nearest the heel
h y d r a u l i c fittings a n d a s s e m b l e , refer to illustration to the floor m e a s u r e s 2.75 i n 7 0 m m ) r e f e r t o illustra-
9.1-18. tion 9.1-20.

TRAVERSE MANIFOLD

FORK M A \ FCC
-II «» '
F2 F1
VI j
I
1
2.75 in.
i
(70mm)

V2 3.00 i n .
(75mm)

,40675 I L L U S T R A T I O N 9.1-18 I L L U S T R A T I O N 9.1-20

12. C o n n e c t control c a b l e leads to T B 7 0 5 refer to illustra- Also m e a s u r e t o p of fork tip to floor. T h i s s h o u l d

tion 9.1-19. m e a s u r e 3.00 i n . ( 7 5 m m ) . If not, a d d or r e m o v e s h i m s
b e h i n d fork heel l o c a t e d o n fork c a r r i a g e a s r e q u i r e d .
(After c o n n e c t i n g battery, c h e c k m e a s u r e m e n t w i t h
forks p i v o t e d to t h e right a n d left).

Crown 1988 PF-8194-9 Primed in U S A . -

M9.1 - 19 - 009 M9.1 - 19 - 009

 CAQUJh MAINTENANCE

15. C o n n e c t battery. C h e c k operation for h y d r a u l i c l e a k s 6. T o p r e v e n t m o v e m e n t of the fork carriage w h e n

a n d cylinder seal leakage. T o c h e c k for c y l i n d e r seal d i s a s s e m b l i n g m a s t , s e c u r e l y c l a m p fork carriage to
l e a k a g e , p r o c e e d as follows with no l o a d : m a s t , r e f e r t o illustration 9 . 1 - 2 1 .
a. A c t u a t e cylinder (full stroke;; t h r e e t i m e s a n d w i p e
e x c e s s oil, dust etc. off of r a m .
b. A c t u a t e cylinder ten more t rnes.
c. Oil should a d h e r e to the r a m in a ring s h a p e d f o r m
but not actually a c c u n u ate. W i d t h of t h e r i n g
should be b e t w e e n 0.020 i n . (0.5mm) a n d 0.040 in.
(1.0mm).
16. Bleed all air out of cylinder.
17. A s s e m b l e covers to back o* mast a n d to front of fork
carriage.

AUXILIARY MAST REMOVAL

If auxiliary mast removal is n e c e s s a - , to replace b e a r i n g s ,

- ;
bushings, shafts e : : - : - : a - e : = - s , refer to the follow-
ing p r o c e d u r e s :

NOTE

To r e m o v e the auxiliary mast, fre fork carriage a n d

a u x i l i a r y lift c y l i n d e r d o e s not h a v e t o b e
d i s a s s e m b l e d . H o w e v e ' . if repairs n e c e s s i t a t e
their r e m o v a l , refer to p r e v i o u s d i s a s s e m b l y
procedures.

1. Pivot the forks to the front l o a d i n g p o s i t i o n (straight

ahead) and chock wheels.
2. R e m o v e the loc" - ; : - • ; ~ t - e pivot latch c y l i n d e r .
NOTE
T h r e a d locking a d h e s i v e is a p p l i e d to t h e pivot
latch l o c k i n g p i n b e f o r e a s s e m b l y , t h e r e f o r e
h e a t i n g m a y be n e c e s s a r y t o d i s a s s e m b l e p i n .
3. Pivot f o r k s c o m p l e t e l y t o t h e right or left s o t h a t t h e
mast rests against the s t o p s . T h i s p r o c e d u r e is per-
formed so that when assembling the mast, the timing
of t h e pivot cylinder c h a i n is m u c h easier.
I L L U S T R A T I O N 9.1-21
7. D i s c o n n e c t h y d r a u l i c hoses a n d control c a b l e routed
t h r o u g h the f r o n t of mast. ( D i s c o n n e c t control cable
f r o m T B 7 0 3 l o c a t e d o n t o p of load handler.)
8. R e m o v e h o s e g u i d e f r o m t o p of mast.
9. D i s a s s e m b l e c h a i n f r o m the fully e x t e n d e d pivot
cylinder only, r e m o v e f r o m s p r o c k e t o n top of mast
a n d lay a s i d e .
1 0 . Pivot m a s t by h a n d to front l o a d i n g position for proper
hook-up.

4. D i s c o n n e c t battery a n d c h o c k load w h e e l s .
5. Refer to f o r k r e m o v a l a n d c i s a s s e m b l e f o r k s f r o m
carriage.

-
Crown 198« PF-8194-10 Printed in U.S.A.

M9.1 - 19 - 010 M9.1 -19 - 010

 MAINTENANCE

1 1 . A t t a c h c h a i n , s l i n g , etc. to top of mast and apply just 8. A p p l y t h r e a d s e a l a n t (Crown #61004-5 sealant) to hy-
e n o u g h t e n s i o n t o keep the m a s t in place before draulic f i t t i n g s a n d c o n n e c t hydraulic hoses. Refer to
d i s a s s e m b l i n g further, refer to illustration 9.1-22. illustration 9.1 -23 w h e n c o n n e c t i n g t h e t w o h y d r a u l i c
- o s e s f r o m t h e t r a v e r s e manifold to the fork m a n i f o l d .

TRAVERSE M A N I F O L D

FORK MANIFOLD
F2 F1
V1

V2l

I L L U S T R A T I O N 9.1-23

9. Route control c a b l e and c c " - e : t eads t o T B 7 0 3 (refer

to illustration 9 . 1 - 2 4 ) .

RED
A0700 I L L U S T R A T I O N 9.1-22
ORG
12. D i s a s s e m b l e w a s h e r f r o m b o t t o m of mast a n d l o a d GRN
handler.
BLU
13. D i s a s s e m b l e b e a r i n g p l a t e f r o m t o p of toad h a n d l e r
a n d mast. BLK

14. Carefully lift the mast f r o m the load handler a n d m o v e

to a c l e a n w o r k a r e a for repair. RED/BLK

AUXILIARY MAST A S S E M B L Y
1. Before a s s e m b l i n g m a s t , p a c k g r e a s e in the thrust
b e a r i n g located o n the b o t t o m of mast.
2. Attach c h a i n , sling, etc. to top of mast, assemble bear-
ings to b o t t o m of mast a n d slowly lower the mast o n -
to the load handler b e i n g c a r e f u l not to d a m a g e shaft
or b e a r i n g s .
3. A s s e m b l e the b e a r i n g plate to the top of the load
handler a n d mast. T o r q u e bolts 120 to 140 ft. lb. (163
to 190 N m ) .
4. A s s e m b l e w a s h e r to b o t t o m of load handler and mast.
T o r q u e bolts 25 to 30 ft. lb. (34 to 41 Nm).
5. R e m o v e c h a i n , s l i n g , etc. f r o m mast a n d pivot mast
by h a n d so that it rests a g a i n s t stops.
6. T h r e a d c h a i n a r o u n d s p r o c k e t a n d attach to pivot
cylinder.
7. A s s e m b l e h o s e g u i d e to t o p of mast.
Crown 1988 PF-8194-11
WHI
TB703
WHI/BLK
,0702 I L L U S T R A T I O N 9.1-24
10. C h e c k a d j u s t m e n t of control c a b l e e x t e n s i o n s p r i n g .
Overall length of s p r i n g should measure 5 in. (125mm)
[1 to 2 i n . (25 to 5 0 m m ) of e x t e n s i o n ] .
1 1 . A s s e m b l e f o r k s (refer to Fork A s s e m b l y ) but d o not
c h e c k for p r o p e r fork height adjustment at this time u n -
til b a t t e r y is c o n n e c t e d .
12 A p p l y t h r e a d l o c k i n g a d h e s i v e (Crown #61004-12) to
pivot l o c k i n g p i n t h r e a d s a n d a s s e m b l e .
13. A p p l y g r e a s e ( C r o w n #63002-25) to all lube fittings u n -
til c a v i t i e s a r e full a n d a liberal coat of g r e a s e ( C r o w n
# 6 3 0 0 2 - 2 4 ) t o t h e c o l u m n rollers c o n t a c t area of t h e
m a s t . A l s o a p p l y a r u b b e r lubricant s u c h as A r m o u r -
All b r a n d s e a l a n t a n d protectant to hose a n d c a b l e
rollers a n d roller c o n t a c t areas of hoses a n d control
cable.
Printed-in U.S.A."

M9.1 - 19-011 M9.1 - 19 - 011

 MAINTENANCE

14. C o n n e c t battery a n d c h e c k o p e r a t i o n . 4. R e m o v e t h e t w o s c r e w s f r o m the s w i t c h a n d terminal

15. Pivot fork carriage to the right a n d left. C h e c k fork board m o u n t i n g b r a c k e t a n d carefully lay a s i d e .
height a d j u s t m e n t ( r e f e r t o Fork A s s e m b l y ) a n d p • 5. Disconnect h y d r a u l i c hose f r o m pivot latch cylinder.
s w i t c h a d j u s t m e n t (see Pivot F u n c t i o n Limit S w i t c - 6. R e m o v e t w o m o u n t i n g bolts f r o m the pivot latch
16. C h e c k for hydraulic leaks and b l e e d cylinders unti a cylinder and lift c y l i n d e r f r o m load handler. Refer to
air is o u t of s y s t e m . M8.8 section in this m a n u a l for m a i n t e n a n c e pro-
c e d u r e s to the pivot latch cylinder.
17. A s s e m b l y c o v e r s to t o p of load h a n d l e r .
PIVOT LATCH CYLINDER R E A S S E M B L Y
PLS & PRS
Pivot F u n c t i o n Limit S w i t c h e s (Illustration 9.1-25) 1. Bolt the pivot latch cylinder in p l a c e .
PLS & P R S are located un z e • E : over o n t o p of the load 2. Apply t h r e a d s e a l a n t ( C r o w n #61004-5) t o hydraulic
handler. T h e s e s w i t c h e s verify t h e m e c h a n i c a l limit of the fitting a n d c o n n e c t hydraulic hose to cylinder.
pivot f u n c t i o n . A c t u a t o r s or. the hose g u i d e , w h i c h is 3. A s s e m b l e s w i t c h a n d t e r m i n a l board mounting
m o u n t e d to the t o p of the pivot s y o c k e t assembly, contacts bracket to t o p of load handler.
the s w i t c h e s w h e n at the m e c h a n i c a l limit left a n d right.
4. C o n n e c t leads t o t e r m i n a l b o a r d T B 7 0 3 or T B 7 0 4 ,
A d j u s t t h e c o r r e s p o n d i n g s w i t c h to a c t u a t e w h e n t h e fork refer to illustration 9.1-26.
carriage a s s e m b l y c o n t a c t s the poty s t o p s .
TB703 TB705
(UPPER)
-RED— -RED-
PIVOT LATCH -ORG- [j ORG-
CYLINDER -GRN- "—GRN-
-BLU- "|—BLU-
-BLK — -BLK-
RED/BLK-
-RED/BLK-
-GRN/WHI
-WHI
TB703 TB704 -GRN/WHI
-WHIiBLK- WHI^
WHI/BLK
GRN

rss :
U-PLS TLS
N.C COM
TRS
PRS N.C. COM.
THRU
AUX TRAVERSE
'.' AST

ACTUATOR
TB704
•-CA: :
(UPPER)

-RED SB72
-ORG RED/WHI-
-GRN RED/WHI -
-BLU i—RED/WHI -
-BLK :GRN:
- RED BOC- -GRN/WHI -
eoT77 I L L U S T R A T I O N 9.1-25 -WHI -GRN/WHI-
- ELK-
PIVOT L A T C H CYLINDER R E M O V A L

1 . D i s c o n n e c t battery a n d c h o c k w h e e l s .
1 -GRN-

PLS
2. R e m o v e b o t h c o v e r s from top of load handler. COM. . N.O.
<y^z- PRS
COM. N.O.
3. Located in the front, top portion of the load handler are SB71
PIVOT
two terminal boards, TB703 and TB704, disconnect
leads f r o m o n e of t h e s e two t e r m i n a l b o a r d s , refer to I L L U S T R A T I O N 9.1-26
illustration 9.1-25.

Crown 1988 PF-819412 Printed in U.S.A."

M9.1 - 19 - 012 M9.1 -19 - 012

 2I\QlDh MAINTENANCE

5. C o n n e c t b a t t e r y , operate and c h e c k the f o l l o w i n g :

0.25 in. to 0.37 in.
s W h e n a c t u a t e d , the latch pin s h o u l d m o v e up a n d S.'. ~ C H (6 to 9mm) SWITCH
_

d o w n rapidly and s m o o t h l y to lock a n d release AC-.- 0R\_^ J_ / A C T U A T O R

p i v o t i n g fork c a " sae
s For h y d r a u l i c leaks.
TRAVERSE
v' For p r o p e r pivot s w i t c h a d j u s t m e n t (see Pivot STOP
F u n c t i o n Limit Switch).

PIVOT CYLINDERS R E M O V A L
T_= TRS
1. Pivot fork carriage completely to the right or left so that
the pivot latch cylinder pin locks in p l a c e . T h i s pro-
c e d u r e will m a k e t i m i n g t h e pivot c h a i n m u c h easier
since o n e of t h e cylinders is completely e x t e n d e d a n d
one c o m p l e t e l y retracted.
2. D i s c o n n e c t battery a n d c h o c k w h e e l s .
3. R e m o v e t o p cover from load handler.
LATION 9.1-27
4 . D i s a s s e m b l e hydraulic h o s e s f r o m c y l i n d e r s .
LOAD H A N D L E R REMOVAi
5. D i s a s s e m b l e c h a i n f r o m pivot cyfinders.
r
6. R e m o v e bolts and pins from c y : - - c e s and lift cylinders T h e n f r c " . of the l o a d h a n s a p p r o x i m a t e l y 1200 lbs.
f r o m l o a d handler. (550kg). B e s u r e lifting e q i ent is of sufficient c a p a c i t y
to safer-, h a n d l e this l o a d .
r
For pivot c y l i n d e r m a i n t e n a n c e procedures eferto M8.8
section in t h i s m a n u a l . 1 T o r e m o v e t h e l o a d handier, r a i s e p l a t f o r m approx-
imate . 2 ft. ( 0 . 5 m i , c o m p e t e , t - a . e - s e r e caa
PIVOT CYLINDER R E A S S E M B L Y h a n d l e r to t h e left, pivot fork c a r r i a g e c l o c k w i s e and
l o w e r f o r k s . (Traversing t h e load h a n d l e r to the left will
1. Fully e x t e n d one cylinder a n d retract the other a n d
a ; e : : e r access and easier d i s a s s e m b l y / a s -
lower c y l i n d e r s in place.
s e m b l y of t h e hydraulic g a n g hose a n d control cables.)
2. A s s e m b l e pins, bolts, pivot chain a n d hydraulic h o s e s
to c y l i n d e r s . 2 . D i s c o n n e c t b a t t e r y , c h o c k load w h e e l s a n d block
platform.
3. C o n n e c t battery and c h e c k operation of load handler,
for leakage f r o m cylinder seals and fittings. Also bleed 3. R e m o v e c o v e r s on lower portion of load handler allow-

c y l i n d e r s until all air is r e m o v e d f r o m the s y s t e m . ing a c c e s s to t h e hydraulic g a n g h o s e a n d control

cable connections.
4. A s s e m b l e cover to top of load handler.
4 . D i s c o n nect t h e hydraulic g a n g h o s e a n d t h e two c o n -
TLS & TRS trol c a b l e s t h a t are routed f r o m b e n e a t h t h e platform
T r a v e r s e F u n c t i o n Limit S w i t c h e s (Illustration 9.1-27) to the ioad handler. Disconnenct c a b l e s at T B 7 0 1 and

T h e traverse limit s w i t c h e s are located below the u p p e r T B 7 0 2 . refer to illustration 9.1-28.

traverse driver. T L S and T R S verify t h e m e c h a n i c a l limit

TB701
of the traverse m e c h a n i s m for the electronic system. W h e n
TB702
the traverse mechanism nears the poly s t o p at its
m e c h a n i c a l limit, the switch actuator is m o v e d a w a y f r o m
the switch by t h e poly stop. T h i s action closes t h e n o r m a l -
ly c l o s e d s w i t c h contact. D e p e n d i n g on the direction of t h e
forks tips, this input change is interpreted by the electronics
box as " h o m e " or " f o r k e x t e n d " .

T o adjust t h e s e s w i t c h e s , center the load handler o n t h e

traverse r a c k . L o o s e n the adjusting b r a c k e t mounting
s c r e w s a n d a d j u s t a s s e m b l y so end of s w i t c h a c t u a t o r is
0.25 in. to 0.37 i n . (6 to 9 m m ) past the e d g e of t h e t r a v e r s e
stop.

I L L U S T R A T I O N 9.1-28

Crown 1988 PF-8194-13 Printed in U.S.A.*

M9.1 - 19 - 013 M9.1 - 19 - 013

cuaiur. MAINTENANCE

A t t a c h s l i n g t o t o p of load handler and apply just T R A V E R S E DRIVE A S S E M B L Y

e n o u g h t e n s i o n in sling to s u p p o r t the weight of the r
T h e t a v e r s e drive portion of the load handler includes the
load h a n d l e r .
hydraulic motor, u p p e r a n d lower idler gears, t o r q u e shaft,
v.ea- p ales and c o l u m n rollers. Refer to the following w h e n
a s s e - o i i n g these c o m p o n e n t s :

1. Assemble t h e c a r r i a g e roller (rolls on t h e I-beam

/.elded to t h e front of the platform) o n t o t h e b o t t o m of
the load handler. Also, assemble the c o l u m n roller that
is located b e h i n d t h e lower idler gear.
2. A s s e m b l e t h e lower t o r q u e shaft b e a r i n g , gasket and
retaining p l a t e to b o t t o m of load h a n d l e r .
3. Install lower idler g e a r a n d shaft.
4. M e a s u r e t h e d i s t a n c e b e t w e e n the b o t t o m of the car-
riage roller a n d the t o p of the idler gear. T h i s distance
s h o u l d m e a s u r e 1.38 in. + 0.06 in. ( 3 5 . 0 m m ±
1.5mm), refer to illustration 9.1-30. S h i m idler gear at
point Y as r e q u i r e d .

POINT X CARRIAGE
ROLLER

0.03 in. (0.8mm)

0.12 in. (3.0mm)

1.38 i n . ± 0.06 in.

(35.0mm ± 1.5mm)
POINT Y

L O W E R IDLER
GEAR

I L L U S T R A T I O N 9.1-30

K>f7s I L L U S T R A T I O N 9.1-29

6. D i s a s s e m b l e t h e upper stop a n d lower b u m p e r on the

side of t h e p l a t f o r m .
7. C a r e f u l l y p u s h the load handler off of the platform.
8. Set t h e l o a d h a n d l e r o n t o the floor and stabilize with
a n o t h e r lift t r u c k or set near support b e a m , block w a l l ,
etc. t o p r e v e n t tip-over.
9. T o d i s a s s e m b l e , re-attach s l i n g , rotate load handler
in a h o r i z o n t a l position a n d place on metal table
c a p a b l e of s u p p o r t i n g its weight or o n clean f loor.-

Crown 1988 PF-8194-14 Printed in U.S.A."

M9.1 - 19 - 014 M9.1 - 19 - 014

 MAINTENANCE

5. Add a p p r o p r i a t e quantity of s h i m w a s h e r s to t o p of 10. A s s e m b l e l u b r i c a t i o n fitting a n d e x t e n s i o n to idler

idler gear, point X, to m a i n t a i n a g a p of 0.03 i n . shaft.
(0.8mm) to 0.12 in. ( 3 . 0 m m ) . 1 1 . Slide the torque shaft into the lower bearing of the load
NOTE handler. S h i m torque shaft at point Z so that the torque
s h a " : - : - ; e a - s are visually c e n t e r e d on both d er
The following s h i m w a s h e r s a r e available f r o m ;
gears. r e e - : -
- s t a t i o n 9.1-32.
Crown for s h i m m i n g idler g e a r s a n d t o r q u e shaft
# 6 0 0 3 0 - 2 3 9 [ 0 . 0 6 2 in. ( 1 . 5 7 m m ) thick].
# 6 0 0 3 0 - 2 2 7 [ 0 . 1 2 5 in. ( 3 , 1 8 m m ) t h i c k ] a n d
TORQUE
#60030-215 [0.188 in. ( 4 . 7 8 m m ) thick]. i f
SHAFT
6. A s s e m b l e lubrication fitting a n d e x t e n s i o n to idler
shaft. Also, be sure to a s s e m b l e cotter pin to idler shaft
screw.
7. Install u p p e r idler gear a n d shaft.
8. Measure the distance b e t w e e n t h e b o t t o m s u r f a c e of DLER
the upper idler gear a n d the t o p s u r f a c e of the lower
idler gear. Distance s h o u l d m e a s u r e 87.38 in. + 0 06
in. ( 2 2 1 9 m m ± 1.5mm), refer t o illustration 9 . 1 - 3 1 .
Shim u p p e r idler gear at point W as r e q u i r e d .
0.03 in. (0.8mm)
0.12 in. (3.0mm) POINT Z

1 POINT V
ILLUSTRATION 3

12. A s s e m b l e t h e h u b , hose bracket a - a r e a r i n g to top

UPPER IDLER of t o r q u e shaft.
GEAR 13. M e a s u r e a n d a d d s h i m w a s h e r s at p o n t T (refer to il-
lustration 9.1-33) to maintain a g a p of 0.12 i n . (3.1mm)
to 0.25 i n . ( 6 . 3 m m ) .

POINT W 0.12 in. (3.1mm)

: I f n. (6.3mm)
87.38 in. + 0.06 in.
(2219mm ± 1.5mm)

L O W E R IDLER
GEAR
POINT T
III UK
I J—I

TORQUE
EE SHAFT

LOWER IDLER
GEAR I L L U S T R A T I O N 9.1-33

.ova I L L U S T R A T I O N 9.1-31

9. Add s h i m w a s h e r s to t o p of idler gear at point V t o

maintain a gap of 0.03 in. (0.8mm) to 0.12 in. (3.0mm).

Ctown T9S8 F-F-8194-15 Printed in U.S.A.'

M9.1 - 19 - 015 M9.1 - 19 - 015

 CRQUJh MAINTENANCE

14. Install h y d r a u l i c motor a n d m e a s u r e the distance be-

0.890 in. (22.61mm)
t w e e n t h e b o t t o m of t h e I c e - sprocket and the top
s u r f a c e of t h e upper h e a d plate (dimension A ) , refer 0.895 in. (22.73mm)
to illustration 9.1-34.
15. A s s e m b l e s p r o c k e t o n t o torque shaft and s h i m to
d i m e n s i o n A + 0.03 i n . ( 0 . 8 m m ) . For this p u r p o s e ,
C r o w n h a s available s h i m w a s h e r s #60030-79 [0.125 COLUMN
in. (3.18mm) thick] and #60030-93 [0.062 in. (1.57mm) ROLLER
thick].

\ WEAR
HYDRAULIC PLATE
MOTOR

COLUMN
ROLLER

WEAR
PLATE

I L L U S T R A T I O N 9.1-34 _ 0.890 in. (22.61mm)

0.895 in. (22.73mm)
16. A s s e m b l e remaining c o l u m n rollers onto load handler.
17. Install u p p e r a n d lower wear plates. M e a s u r e the » 7,7
0 I L L U S T R A T I O N 9.1-35
d i s t a n c e b e t w e e n the c o l u m n rollers and wear plates.
18. Lubricate c h a i n , gears, bearings etc.
A d d s h i m s to m a i n t a i n a g a p of 0.890 in. (22.61 m m )
to 0 . 8 9 5 i n . ( 2 2 . 7 3 m m ) , refer to illustration 9.1-35.
( S h i m s for upper wear plate: C r o w n # 1 0 5 3 9 8 - 1 ; 0.024
in. [0.61 m m ] thick a n d #105398-2; 0.015 in. [ 0 . 3 8 m m ]
t h i c k . S h i m s for lower w e a r plate: C r o w n # 1 0 8 1 1 5 - 1 :
0.005 i n . [ 0 . 1 3 m m ] t h i c k , # 1 0 8 1 1 5 - 2 ; 0.015 i n .
[ 0 . 3 8 m m ] t h i c k and 108115-3; 0.030 in. [ 0 . 7 6 m m ]
thick.)

Crown 1988 PF-8194-16 Pnnted in U.S.A.*

M9.1 - 19 - 016 M9.1 - 19 - 016

 GAOUJh MAINTENANCE

SPUR RACK REPLACEMENT

W h e n r e p l a c i n g s p u r racks, refer t o t h e following:

NOTE

A l t h o u g h t h e lower spur rack c a n n o t be adjusted

horizontally, if r e p l a c i n g t h e l o w e r s p u r rack only,
follow t h e s p u r rack a l i g n m e n t p r o c e d u r e s below.

1. C h o c k load w h e e l s , d i s c o n n e c t battery and r e m o v e

load h a n d l e r (refer to L o a d H a n d l e r Removal).

2. R e m o v e old s p u r r a c k s .

3. A s s e m b l e lower spur rack onto platform. Torque bolts

f r o m 3 5 t o 4 0 ft. lbs. (48 to 5 4 N m ) .

4. Arbitrarily position the u p p e r s p u r rack onto the plat-

f o r m a n d hold in place b y finger t i g h t e n i n g a bolt on
e a c h e n d of t h e rack.

5. Place a level o n top of t h e u p p e r spur rack (refer

lustration 9.1-35) t o c h e c k l e v e l n e s s o f pJatfBBB.lhe)
rack m u s t b e level w i t h i n 0.015 i n . per f o o t f L Z S n r
per meter) or 1/16 in. o n a 4 ft. leveL If necessary am
a hydraulic jack under a n outside e d g e zf r e s a e t a o B
to level a s required.

I L L U S T R A T I O N 9.1-36

8 . If necessary, horizontally adjust the u p p e r spur rack

I L L U S T R A T I O N 9.1-35
6. D r o p a p l u m b - l i n e t h r o u g h the valley of a gear tooth
o n the upper spur rack extending below the lower spur
rack teeth (refer to illustration 9.1-36).
7. Place a s q u a r e against the t e e t h of the lower rack t o
verify t h e position of t h e p l u m b - l i n e relative to t h e
t e e t h . T h e p l u m b line m u s t be w i t h i n 1/16 in. (0.06 i n .
[ 1 . 5 m m ] ) of the s a m e position o n the upper and lower
gear teeth.
so that the valley of a tooth o n t h e u p p e r a n d lower
spur rack a r e a l i g n e d .
9. A s s e m b l e all u p p e r spur rack bolts a n d t o r q u e f r o m
35 to 40 ft. l b s . (48 t o 54 N m ) .
NOTE
After the load h a n d l e r has been a s s e m b l e d onto
the p l a t f o r m , a n additional check for p r o p e r spur
rack a l i g n m e n t c a n be m a d e by p l a c i n g a level o n
the torque shaft b e t w e e n the gears. If the p l a t f o r m
is level a n d t h e s p u r racks properly a l i g n e d , t h e
t o r q u e shaft will b e p l u m b .

-
Crown 1988 PF-8194-17 Printed In U.S.A.

M9.1 - 19 - 017 M9.1 - 19 - 017

 MAINTENANCE

SPUR RACK REPLACEMENT

W h e n r e p l a c i n g s p u r r a c k s , refer to t h e following:

NOTE

A l t h o u g h t h e lower spur rack c a n n o t be adjusted

h o r i z o n t a l l y , if r e p t a c i n g t h e l o w e r s p u r rack only,
follow t h e s p u r rack a l i g n m e n t p r o c e d u r e s below.

1. C h o c k load w h e e l s , d i s c o n n e c t battery and r e m o v e

load h a n d l e r (refer to L o a d H a n d l e r Removal).

2. R e m o v e o l d s p u r r a c k s .

3. A s s e m b l e lower spur rack onto platform. Torque bolts

f r o m 35 to 4 0 ft. lbs. (48 to 54 N m ) .

4. A r b i t r a r i l y p o s i t i o n the u p p e r s p u r rack onto the plat-

f o r m a n d hold in place by finger t i g h t e n i n g a bolt on
e a c h e n d of the rack.

5. P l a c e a level o n top of t h e u p p e r s p u r rack (refer to il-

l u s t r a t i o n 9.1-35) to c h e c k l e v e l n e s s of platform. T h e
rack m u s t b e level w i t h i n 0.015 i n . per foot ( 1 . 2 5 m m
p e r m e t e r ) or 1/16 in. o n a 4 f t . level. If necessary, use
a hydraulic j a c k under a n outside e d g e of the platform
to level a s r e q u i r e d .

I L L U S T R A T I O N 9.1-36

8. If necessary, horizontally adjust the u p p e r s p u r rack

ma I L L U S T R A T I O N 9.1-35
6. D r o p a p l u m b - l i n e t h r o u g h the v a l l e y of a gear tooth
o n the upper spur rack extending below the lower spur
rack t e e t h (refer to illustration 9.1-36).
7. P l a c e a s q u a r e a g a i n s t the t e e t h of the lower rack to
verify t h e p o s i t i o n of t h e p l u m b - l i n e relative to the
t e e t h . T h e p l u m b line m u s t be w i t h i n 1/16 in. (0.06 i n .
[ 1 . 5 m m ] ) of t h e s a m e position o n the upper and lower
gear teeth.
so that the valley of a tooth o n t h e u p p e r a n d lower
spur rack a r e a l i g n e d .
9. A s s e m b l e all u p p e r spur rack bolts a n d t o r q u e f r o m
35 to 4 0 ft. lbs. (48 to 54 N m ) .
NOTE
After the load h a n d l e r has been a s s e m b l e d onto
the p l a t f o r m , a n additional c h e c k for p r o p e r s p u r
rack a l i g n m e n t c a n be made by p l a c i n g a level o n
the torque shaft b e t w e e n the gears. If the p l a t f o r m
is level a n d t h e s p u r racks properly a l i g n e d , the
t o r q u e shaft will be p l u m b .

Crown 1988 PF-8194-17 Primed in U.S.A.*

M9.1 - 19 - 017 M9.1 - 19 - 017

CAOUJh MAINTENANCE

LOAD HANDLER ASSEMBLY

1 . A t t a c h a s l i n g to t h e t o p of t h e l o a d h a n d l e r a n d p o s i -
t i o n t h e l o a d h a n d l e r in p l a c e o n t h e left side of t h e
platform.

2. C a r e f u l l y i n s t a l l the l o a d h a n d l e r b a c k o n t o t h e plat-
f o r m j u s t f a r e n o u g h t o a s s e m b l e t h e s t o p block a n d
b u m p e r . B e s u r e t h e u p p e r a n d lower idler g e a r s
e n g a g e t h e s p u r r a c k s at t h e s a m e t i m e .

3. A s s e m b l e t h e u p p e r stop block a n d lower b u m p e r onto

t h e p l a t f o r m . T o r q u e u p p e r s t o p b l o c k bolts 30 to 3 5
ft. l b s . (41 t o 4 7 N m ) .

4 . C o n n e c t t h e h y d r a u l i c g a n g h o s e fittings t o their re-

s p e c t i v e l o a d h a n d l e r fittings. F i t t i n g s a r e n u m b e r e d .

5. C o n n e c t c o n t r o l c a b l e s to T B 7 0 1 a n d T B 7 0 2 , refer to
illustration 9.1-37.

TB528 TB701
PLATFORM LOAD HANDLER

-RED-
-ORG-
-GRN-
-BLU-
-BLK-
-RED/BLK-
WHI —
-WHI/BLK-
— R E D —
10 —ORG—
11 -GRN —
12 -BLU—
13 - B L K —
14 RED/BLK
15 -WHI—i
16
7
17 WHI/BLK
18
19
20
21
TB702
LOAD H A N D L E R

Aon? I L L U S T R A T I O N 9.1-37

6. L u b r i c a t e s p u r r a c k s a n d g e a r s ( C r o w n # 6 3 0 0 2 - 2 4 ) .

7. A s s e m b l e c o v e r s to load h a n d l e r .

8. C o n n e c t b a t t e r y a n d c h e c k o p e r a t i o n .

Crown 1988 PF-8194-18 Printed in U.S.A."

M9.1 -19 - 018 M9.1 - 19 - 018