3, Ohlo 45869 USA Phone 419/629-2311 HOW TO ORDER SERVICE PARTS To obtain fast, efficient service when ordering repair parts for your Crown Material Handling Equipment, please follow © this simple procedure: 1. Address all orders to your local Crown dealer. 2. Specify model and serial number of truck, which is shown on the metal serial number plate. 8. List the quantity needed. 4, List the part number and description, as shown in this Service Manual. 5. Show billing and shipping address, 6. Suggest fastest routing Your authorized Crown dealer stocks a large number of standard service parts. In addition, he has a factory-irained Service Department to serve you. Our Local Crown Dealer Is a, ©” NAME. ADDRESS: city STARE oS kt ip TELEPHONE ‘The information in this manual is the latest available at the time of printing for the unit with which it was shipped. ‘Should there be any variation due to vendor changes or special options on your unit, contact your Crown Dealer (or Crown at the above address. & Printed i U.S.AWARRANTY Grown Equipment Corporation ("Crown") warrants to and for the sole benefit ofthe original Purchaser of material handling equipment sold by Crown, that such equipment is free from defects in material and workmanship under normal and proper use, operation and mainte nance. This warranty shall remain in effect for a period of one (1) year after delivery of the ‘equipment to the original purchaser with respect to: Motors (except brushes), Motor Driven Pumps and Valves ‘SOR Solid State Components, Sequence Control Cards, Contactors (except contact tips and switches) ‘Tuck Frames, Masts, Carriages, Castings and Drive Unit Gears and Bearings The above warranty will remain in effect with respect to all other parts (including brushes, contactor tips, and switches) for a period of ninety (80) days after such delivery. Grown shall provide both the labor and the parts required to repair, or, at Crown's option, Grown shall replace any part of the equipment which upon examination by Crown is deter” mined by Grown to have been defective during the applicable warranty period. Notice of any claimed defect must be promptly given by the original purchaser to Crown or to an authorized Crown dealer, and the claimed defective part prompily returned to Crown in New Bremen, Ohio, with transportation charges prepaid, Grown does not warrant and this warranty does not apply to batteries, chargers, tres or other trade accessories or attachments not manufactured by Crown which are incorporated in or Gelivered with the equipment and which are warranted by their respective manufacturers. Damage or defects from overicacing or other misuse, negligence, abuse, accident, fallure to follow instructions, or from other causes having an origin other than in the manufacture of the equipment are not within the scope of this warranty. Crown reserves the right to make changes and improvements in the design and construction of its equipment without thereby being obligated to make corresponding changes and improvements in previously manufac- tured equipment. The term “original purchaser” as used in this warranty means the customer to whom the equipment was first delivered for use. ‘The warranty set forth herein is the complete and entire warranty made by Crown, and ‘hore are no other warranties, express or implied, whether of merchantability, fitness ‘or particular purpose, or otherwise, made by Crown. No person is authorized to make any other or additional warranty on behalf of Crown. The right to repair or replacement, as set forth herein, is the sole and exclusive remedy for breach of the above warranty, ‘and Crown shall not be liable for any damages, whether direct, incidental, consequen- tial or otherwise, occasioned by any breach of this warranty, or for any charges or ‘expenses of any nature incurred without Crown's consent, even though Crown has boon negligent. In no event shall Crown's liability under any claim exceed the purchase price of the equipment in respect of which damages are claimed. New Bremen, Ohio 45809 USA Phone: 419/630-2311 SOOO S Secnown $P.3000 Revision TL TT No.-Date XX Ot 7196 x x XX 03-1201 x x XX ot- 11/00 x x SECTION M1 xX xX 44-302 XX of 85 XX 03-1204 x x XX 02-4186 SECTION M2 xX xX 03-198 x xX os-4m2 x x cee x x aes Title Introduction Intoduetion General Maintenance Lifting & Blocking Points Control of Hazardous Energy Cleaning of Material Handing Equipment LUBRICATION AND ADJUSTMENT Lubrication and Adjustment Lubrication and Adjustment = General Component Accessibiliy = Lubrication, Inspection 8 Adjustment Lubrication and Adjustment ~ General — Component Accessibiliy = Lubrication, Insgection & Adjustment Skid Inspection Torque Values, SP 3000 INDEX ‘Serial No. of Units Used For From: Page Number 1 Standard Special Date ITD-7330-001 oxor708 0401/02 ITD-7330-004 MA-04.0-001 sairroer 4201/96 —-MAL07.2-100 MA-7330-100 MA=1140-050 M1.0-04.0-001 Mt.0-7930-001 4185261 4/796 14155261 (1795 HYDRAULIC MAINTENANCE Hydraulics Hydraulic Circuits — Reservoir Hydraulic Lines and iting Filter = rit Test Hydraulics ~ Hydraulic Circuits ~ Reservoir — Hydraulic Lines and Fitings ~Fiter = it Test Hydraulic Schematic Symbols Pump Litt ~ Oil Seal Removal & Replacement = Disassembly & Assembly = Pars Inspection = Start-up Procedure Manifold LitvLower = Relet Valve Operation & Adjustment LivLower Control Valve ~ Relief Valve Operation & Adjustment Accumulator = Precharging Troubleshooting Chart oaronoe oasoroe ‘ogot/o2 0401102 M1.0-7330-001 ¥M1.0-7330-001 M1.0-7330-003, M1.0-7330-015 M1.0-7330-015 M1.0-7330-015 M1.0-7330-017 M1.5-7330-001 M13-14.0-001 M2.0-7390-001 Mz.0-7330-002 M2.0-7330-007 M2.0-7330-007 Mz.0-7390-007 Mz.0-7330-008 Mz.0-7330-010 1M2.0-7330-011 M2.0-7390-016 M2.0-7390-016 M2.0-7330-016 M2.0-7330-017 M2.1-00.0-001 M2.1-10.0-001 M2.1-10.0-001 M2.1~10.0-002 M2.1~10.0-002 M2.1—10.0-004 M2.4-7330-001 M2.4-7330-001 M2.4-7390-005, ‘Me.4-7330-005, ‘M2.6-7330-001 M2.6-7990-001 M2.¢-7330-001 IDX-7330-001 08 REV. 4/02 IDX-7330-901cCnown SP 3000 INDEX Serial No. of Units Used For '$P3000 Revision Title From: Page Number TL TT (No.-Date Te: Standard Special Date SECTION M3 DRIVE UNIT MAINTENANCE X Xo 101 rive Unit M3.0-7390-001 = Dive Tire Replacement M3.0-7330-001 = Lubrication M3.0-7330-001 — Drive Unit Removal & Installation M3.0-7330-003, XX 01-698 Devo Unit Repair/Rebuild M3.0-1490-050 = Component Ovarviaw 1M3.0-1430-050 = Removing & Installing Axle Seal M3.0-1430-051 — Drive Unit Disassembly M3.0-1430-052 = Drive Unit Assembly M3.0-1490-057, SECTION M4 ELECTRICAL MAINTENANCE XX 02-997 Electrical System M4.0-7330-001 = General 1217983) 1201198 Mé.0-7330-001 = Component Accessibiity Ma.0-7390-001 = Gomponent Location Ma.0-7330-002 XX 2-aor Electrical 14217903 szove9 —-M4.0-7330-010 = General oaioroz ——M4.0-7330-010 = Component Accessiblity Ma.0-7330-010 ~ Gamponent Lecation Ma.o-7330-011 XX 08-401 Switches M4.0-7330-020, oaioroa XX ot t00 Fuses 1M4.0-7330-040 XX 01-695 Control Cables Ma.0-7330-060 = Tension Device Mé.0-7330-060, — Routing M4.0-7330-060 XX 01-97 Encoders 1M4.0-7390-080, = Stooring Feedback Ma.0-7330-080 XX 01-895 Relays Ma.0-7330-100, 1217999) 12101199 XX 01-100 Relays 1217983, 1210199 M4.0-7390-110 oaior02 x # Electrical oaio1o2 © M4.0-7390-200 = General Ma0-7330-200, = Component Accessiblity M4.0-7390-200, = Component Location M4.0-7330-201 x x ‘Switenes M4.0-7390-220, See Relays Mao-7330-310 XX 01-595 Electrical Wiring Ma.1—1430-001 = Wiring Color Codes Ma.1—1430-001 = Power Cables Ma.t—1430-001, XX 05-497 Transistor Controller Ma.2-7330-001, — Basics of Circuit Operation Ma'2-7330-001, = Control Features Mé.2-7330-003 = General Maintananoe Instructions Ma.2-7380-005 = Gomponent Testing Ma.2-7330-005 XX 04-8100 Transistor Controler Tune-Up Ma.2-7330-200 = Service Terminal Operation osoro2 —-M4.2-7390-200 = Function Adjustments For Truck Application Ma.2-7330-202 x x ‘Transistor Controler Tune-Up oaioro2 = Ma.2-7330-210 = Service Terminal Operation Mé.2-7330-210 — Function Adjuetments For Truck Application M4.2-7930-212 XX 03-7100 Transistor Contraler Troubleshooting M4.2-7390-400 XX 01-9100 Truck Management Module (THM) 1Ma.2-7330-500 mS ‘Status Codes tazsoaa4 ogio109 ©‘ Ma.2-7330-600 ‘Toms tao PPTCaTED Rone Fawanoen 08 REV. 4/02 IDX-7330-002 IDX-7330-002cnown SP 3000 INDEX SP 3000. Revision TTT No.-Date x xX 2-497 xx e 8 KX 02-7198 x x x x et x8 xX x oe-z02 x xX o1-202 xX X — o1-1088 x xX o1-asg XX o1-298 IDX-7330-003 Serial No. of Units Used For From: Te Standard Special Date Electronic System = Power Up — Brake Fslease Traction ~ Raise ~Lower —Manval Steering ~ Automatic Guidance Steering = oltagas, Speed Limit & Braking Force Chant ElectricalElectronic System 10217993 12/01/99 Display and Steering Module Wire Guidance System 10217993 1210189 Wire Guidance System Technical Overview 1190502 ovors8 ~ Black Diagram ~ Enclosure Connector, Pin Locations, Signals ~ Quick Setup = Setup = Troubleshooting Guide = Dynamic Adjustment Matrix = Quick Reference Adjustmont Matric Wire Guidance System 1A190802 101/98 = Technical Overview 5A217993 12101169, = Block Diagram ~ Enclosure — Connector, Pin Locations, Signals = Quick Setp = Setup = Troubleshooting Guide = Dynamic Adjustment Matrix ~ Quick Reterence Adjustment Matrix Wire Guidance System 10217999, 12/0190 ‘Traction Speed & Direction Sensor 1a217993 2101/98 Line Driver Output 40217993 s2101/99 Line Driver Output 10217993 12/01/98 ‘Truck Considaratons 18217993 s2101/88 “Truck Considerations 10217993, 12/01/88 Contactor 1A. 110613-001, Pi & P2 110612003, = Inspection ~ Component Replacement Contactor F & R116784-001 = Inspection Component Replacement Contactor ED 118996 Inspection — Component Replacement Contactor (EE) 1A 118280001 14155261 0417195 —Ingpection Component Replacement Contactor (EE) F&F 118282-005 1A185261 04/1798 = Inspection Component Replacement 08 REV. 4/02 Page Number M4.3-7330-001 44.3-7330-003 M4.3-7330-008 4.3-7230-008 Ma 3-7330-008 M4.3-7330-009 M4.3-7330-010 Ma3-7990-011 Ma.3-7530-012 M4.3-7390-015 M4 3-7930-100 M4.3-7390-475 1Ma.3-7330-500 Ma.3-7390-501 IMa.3-7330-502 Ma.3-7390-503 Ma.3-7380-504 M4.3-7390-506 Ma.3-7390-608 Ma.3-7390-516 M4.3-7330-520 M4.3-7230-621 Ma.3-7330-522 Ma.3-7330-523 M4.3-7330-524 M4.3-7330-525 M4.3-7930-526 Ma.3-7330-528 Ma-3-7330-530 M4.3-7330-538 Ma.s-7390-542 M4.3-7390-543 M4.3-7390-550 M4-3-7330-600 Ma.3-7230-700 M4.3-7390-702 M4.3-7380-800 Ma.3-7330-802 M4.4-04.2-001 M4.4-04.2-001 Ma.2-04,2-002 Ma.a-6535-001 M4.4-6535-001 M4 4-6595-002 Ma.4-7390-001 Ma.2-7360-001 Ma.4-7330-002 Ma.4-7390-025 M4.4-7390-025 M4.4-7390-026 Ma.4-7380-075 M4.4-7390-075 M4.4-7300-076 IDX-7330-003SP 3000 INDEX Serial No. of Units Used For Title From: Page Number Te Standard Special Date x x Contactor (EE) ED 119784 1185261 04/17/08 M4.4-7390-100 = Inspection 1Ma.47330—100 = Component Replacement M4.4-7390-100 x x Contactor (EE) 1A,P1,P2 118260-003, -004 14145503, osiores —Ma.d-1430-200 = Inspection M4.41490-200 —Component Replacement M4.4-1430-201 a CControi Module M4.5-7300-001 = Access Ma.§-7330-001 ~ Troubleshooting Ma.5-7380-001 — Adjustments, M4.§-7380-002 — Component Replacement M4.§-7380-003 oueteae ‘Steering Feedback Assombly 1M4.5-7330~100 x x Battery Ma.e-7380-001 ~Satety Rules Ma.6-7380-001 = Checking M4.6-7380-001 = Care M4.6-7390-002 = Charging 1M4.6-7380-003 —Femoval ‘Ma.¢-7330-004 = Installation 1M4.6-7390-005 ~ Cleaning M4.€-7390-006 — Troubleshooting M4.6-7390-006 x 2 Motor Information Chart Ma.7-7380-001 Traction M4.7-7380-001 =Litt M4.7-7390-002 SECTION M5 BRAKE MAINTENANCE XX 03-996 Brakes 1Ms.0-7380-001 = Air Gap Adjustment 1Ms.0-7390-002 = Stopping Distance Adjustment Ms .0-7330-003 Manual Release 1Ms.0-7380-004 ~ Rotor and Brake Pad Replacement 1MS.0-7330-004 Brake Assembly 1M5.0-7380-005 = Troubleshooting 1Ms.0-7330-006 SECTION M6 STEERING MAINTENANCE XX 01-2102 Steering 1M6.0-7380-001 = Steering Direction 1M6.0-7330-001 = Steering Whee! Direction Indicator ‘M6.0-7360-001 ~ Steering Wheel Adjusiment 1Me6.0-7330-002 Steering Gearbox ‘Me.0-7330-002 SECTION M7 MAST MAINTENANCE XX 1-102 Mast M7.0-7330-001 General M7.0-7330-001 = Shim Basics M7.0-7330-001 = Roller Removal TL. M7.0-7330-003, ~Rollor Romoval TT 1M7.0-7330-004 ~ Shim Measurements (Tolerances) 1M7.0-7330-007 —Testing (Assembled) M7.0-7330-008 = Flaking M7.0-7330-008 = Shim Removal M7.0-7390-008 = Removal \a7.0-7390-009 —Reassembly M7.0-7330-010 08 REV. 4/02 IDX-7330-004 IDX-7330-004Cnown SP 3000 INDEX Serial No. of Units Used For ‘SP.3000 Revision Title Page Number TL TT No.-Date Special Date XX 06-1201 LiftChain M7-S-18.0-001 ~ Inspection M7.5-18.0-001 = Lubrication M7-5-18.0-003 — Replacement M7-5-18.0-004 x Xx Fork inspection M7.8-07 2-001 ~ Abrasion M7.8-07 2-001 ~ Overloading M7-8-07.2-008 — Fatigue 1M7.8-07.2-008 = Bent or Twisted M7.8-07 2-008 = Hanger M7.8-07 2-008 SECTION MB CYLINDER MAINTENANCE xy Cylinder Repair 'Mg.0-7330-001 = General ‘Ma.o-7330-001 = Inspection ‘Ma.0-7330-002 ~ Dieassembly ‘Ma.0-7880-p02 ~ Accossing Flod Packing 'Me.0-7830-003 = Rod Packing Replacement Ms.0-7830-003 = Mast Cylinder Removal MB.0-7830-005 = Free Lit Cylinder Removal Ma.0-7880-006 = Free Lift & Mast Cylinder Assembly Me,0-7830-006 = Frog Lift & Mast Cylinder Installation MB.0-7830-006 SECTION M9 PLATFORM MAINTENANCE x Xx Platform ‘Ma,0-7330-001 = Floormat Replacement Ma.0-7330-001 ~ Safety Shield Ropiacoment ¥Ma.0-7830-001 — Forks. Ma.0-7830-002 = Pallet Grab Ma,0-7330-003, = Operator Compartment Gates Mg.0-7330-008 = Operator Harness, Ms.0-7830-005, = Shim Basios M8,0-7830-008, x = Removal & Shimming TL 'Ma,0-7330-006 x = Removal & Shimming TT Ms,0-7830-009 SECTION M10 GLOSSARY XX 04-401 Glossary Mi0-7390-001 oaon02 me Glossary dante © Mt0-7330-010 WIRING DIAGRAMS x x Introduction DIA-TD-oo1 XX 07-6199 index DiA-7330-001 4a217903 j21019 XX 03-601 Index 40217993 1201/89 —_‘DIA-7830-025 arate x F Index balo102 © DIA-7330-050 IDX-7330-005 08 REV. 4/02 IDX-7330-005Cnown SP 3000 INDEX ‘SP 3000 sree TT Title ‘Serial No. of Units Used For From: Te Standard Special Date HYDRAULIC SCHEMATICS. Page Numb XX 044/97 Hydraulic Schematic HYD-7380-001 oarorr02 gs Hydraulic Schematic 0401102 HYD-7330-003 SECTION 1 POWER UNIT PARTS XX 02-895 Power Unit (01.0-7830-001 4A174008 os /0a/98 XX 03-6999 Power Unit 1Ai74009 09/039 —01.0-7330-008, 19217993 12101198 x x Power Unit 14217993 1210198 01.0-7330-005 XX 02-895 Battery 01.2-7980-001 41A174009 ‘ogjoaie6 ee Battory 4174008 09/03'96 _01.2-7330-008 SECTION 2 HYDRAULIC PARTS XX 01-9795 Hydraulic System Power Unit 02.0-7330-001 One Speed Lift sar7t673 6724/96 XX 03-6198 Hydraulic System Power Unit 1AI71673, 06'24'95 02.0-7330-003 ‘One Speed Lit XX 01-9195 Hydraulic System Pomer Unit 02.0-7330-050 Two Specs Litt sat7i673 6124/96 XX 03-6199. Hydraulic System Power Unit 1Ai71673, 06/24/96 020-730-052 ‘Two Speed Lit XX 01-8199 Hydraulic Systam Mast (02.0-7330-100 oaioro2 x x Hydraulic System Mast osior02 © 02,.0-7380-102 x Xx Pump itt 116078 02.1-07.3-001 1a%62700 10/16/98 Mencia Pump Lit 121201 1162700 1011695 02.1-07.3-002 XX 03-3199 Motor Pump 114330 022-073-001 XX 01-3'98 Motor (with sensors) Pump 118838 192,2-7830-050 XX 03-699 Manifold One Speed Lit 118855 (92.4-7830-001 X — X 02-5197 Manifold Two Speod Lift 118943, 02.4-7330-050 sa72282 07115106 XX 03-699 Manifold Two Speed Lit 118943, 1at72282 07/15/96 © 02.4-7330-052 SECTION 3 DRIVE UNIT PARTS XX 01-899 Drive Unit 1A186429 0901/87 03,0-7330-001 1280913, 03105/01 x Drive Unit 14239913, 3105/01 03.0-7330-008 XX 08-8986 Drive Unit 030-140-019 1196820 901/87 XX 09-1187 Drive Unt Lubrication System (03,0-1430-200 snaa092 osi2er0% None Drive Unit Lubrication System 1azaos2i 03/2601 03.0-1482-200, XX g1- 10184 Motor Drive (6.7 in. [170 mm] dia.) 20366 03.1-7380-001 XX 04-40/84 Motor Drive (7.5 in, [190 mm] da, 03.1-7330-050, with sensors) 020316 ae Tire Drive 087880-001 thru -o12 08.2-7390-001 oajorio2 x x Tire Drive 087880-001 thru -018 sio102 —03.2-7330-002 IDX-7330-006 08 REV. 4/02 IDX-7330-006chown SP 3000 INDEX Serial No. of Units Used For 'SP.3000 Revision —_Title From: Page Number TL TT No.-Date Te ‘Standard Special Date SECTION 4 ELECTRICAL PARTS XX —02-12/95 Electrical Components Power Unit 04,0-7330-001 AAt71673 osraae6 a x Electrical Components Power Unit satriers eats © 04.0-7990-008, 4a217993 12/099 uk Electrical Components Power Unit 1A217993, 1201/9 _04.0-7830-005 awe KR Electrical Components Power Unit owowoe —04.0-7590-007 ook ‘Traction Pane! 118439 (06,1-7330-001 saist977 ovs0es x x Traction Pane! 4151977 0179095 —04.1-7390-008, sA175410 40/14/96 ae ‘Traction Pane! (Never in production} 04,1-7390-005 Bees Traction Panel sar7sa10 yorraig 041-780-007 41a217993 1201/98 XX 01-401 Traction Panel 10217993 12099 © 04.1-7390-009 XX 02-587 Traction Panel sA1ss261 417/95 04.1-7350-025 4A217993 1201/98 XX 01-401 Traction Pane! 1217993 1a0v99 —_04.1-7590-027 XX 03-401 Transistor Panel 117904 (04.2-7530-001 XX 04-1700 _istrbution Panel 117861 04:3-7330-001 x xX LitvPower Panel 118061-001 8 -002 043-730-100 4a217993 savas x. x LiPower Panel 118067-001 8-002 ‘1A217093, 1a01v9e —04.3-7390-102 XX 01-585 —_LitvPower Pane! 155261 04/1795 04.3-7330-125, XX 01-55 Fuse Box 1155261 04/17/85 04'3-7330-150 1217993 12101198 x. x Fuse Box 1217993 1aovee —04.5-7590-152 XX 01-187 Wire Guide Sensors (04.3-7390-500 sa2i7eas sae ae Wire Guidance 1217993 120198 04.3-7390-502 XX 03-3186 Wire Guide Module 117848-001 04.3-7390-850 +At90502 1/098 Kx Wire Guide Module satg0502 101/98 © 04.8-7950-552 10217993 s2101a8 XX 01-1283 —_Line Driver 108824-001 thru -008 04.3-19.0-550 XX 06-1086 Contactor 1A 110613-001, 04.4-04.2-020 XX 04-892 Contactor FIR 111634 sA175410 tonai9e + 044-065-250 XX 02-895 Contactor 118280-003, -004 1145603 onows4 — 04.4-1490-200 XX 08-3101 Contactor P1, Pz 110813-003, 04.4-6595-050 XX 04-1000 Contactor FIR 116794-001 (04.4-7530-001 sat7sat0 sorare6 x x Contactor (Never in production) 04.4-7330-002 XX 02-587 Contactor (EE) 1A 118280-001, 1155261 047/95 © 04.4-7390-025 XX 02-301 Contactor ED 11806, (06.4-7390-050 XX 01-61 Contactor (EE) F & F 118282-005 1At5s261 047/95 © 04.4-7530-075 XX 03-3101 Contactor (EE) ED 119784 1A185281 0417/95 04.4-7330-100 x xX Control Module Front 04.6-7330-001 1185261, 047195 Box Control Modula Front 1A155261 0417/95 © 04.6-7590-008, x x Control Module Back (04.6-7330-020, 1155261, 0417/85 x x Control Module Back 1155261, 0417/85 | 04.6-7a30-022 + Denotes new form on this index. 08 REV. 4/02 IDX-7330-007 IDX-7330-007cnownh SP 3000 INDEX SP.3000_ Revision TL TT No.-Date x x 03- 11/00 x X 02-9196 x XX 01-1095 raner XX 01-595 xX 01-1096 XX 01-102 x x Seance xX 01-895 x * en Secret XX ot 401 X =X 07-801 SECTION 5 KX xk x Xx Saat See SECTION 6 Seay Hee xX xX 02-2100 x x xX xX 02-8100 Ra x Tite Contra! Cable TL Control Cable TL Control Gable TT Control Gable TT Control Gable TT Limit Switches Limit Switches ‘Switch Panel 118444001 thru -009 Connectors Connectors ‘Stooring Feedback Flashing Light Overhead Console Overhead Console Components FIC Power Unit Components FIC Control Module Components FIC Mast & Platform Strobe Light 112951-001 BRAKE PARTS Brake Pedal 104837 Brake 118168 Brake 121771 Brake 126361 Brake 12661 STEERING PARTS ‘Stoaring Command ‘Steering Gearbox 118503 Steering Gearbox 118503 Motor Steering Servo 118390 Steer Motor 125498 Steer Motor 128183 Serial No. of Units Used For From: To: Standard Special Date 10155261 1155261 18155261 14155261 A279 10217993 sat72282 4172282 4at69523, 1163523 10217998 4a2i7993 18217893 satroi93 1170133 sa2i7e9a 10217993 sanz91t1 1a2291t1 oart7'95 04/17/95 4795 04/17/95 4/01/02 4/01/02 oalowo2 0401/02 12/01/99 12101198, o7/15096 07/15/96 jvo895 1196/95 12/01/88 05/01/99 4201/08 12101198 05/08/86 05/08/96 12/01/99 120189 o7/t0100 7/1000 Page Number 04.8-7390-001 04.8-7390-003 04.8-7390-025, 04.8-7390-027 04.8-7390-029 04.8-7380-050 04.8-7390-054 04.8-7330-100, 04.8-7330-170, 04.8-7390-172 04.8-7390-200, 04.9-7330-001 04.3-7330-050, 04.9-7390-052 (04.8-7330-100, 04.9-7330-150 04.9-7330-200 049-100-850 05.1-7330-001 05.3-7330-001 05,3-7330-003 05.3-7330-005 05,3-7830-007 06.0-7830-001 06.0-7330-100, 06.0-7390-102 06.2-7330-001 06.2-7330-002 (08.2-7300-003 IDX-7330-008 08 REV. y02 IDX-7330-008Cnown SP 3000 INDEX Serial No. of Units Used For $P3000 Revision Title. From: Page Number TL TT No.-Date sre Standard Special Date SECTION 7 MAST PARTS x Mast TL 07.1-7330-001 1155261 Osiris x Mast TL 1155261 04/1795 07.1-7390-008 x Mast TT 07.2-7890-001 4155261 4795 X 01-1095 Mast TT 10155261 04/1795 07.2-7930-008 ‘oworo2 x Mast TT owovee —_07.2-7330-005, XX 02-6/98 Load Whee! 07.4-7330-001 ‘4/012 x ey, Load Whee! wore —_07.4-7330-002 X 01-1095 Yoke TT 118973 07.5-7330-001 1175898 ovaB/96 x Yoke TT 129178 1175898 yo/a886 © 07.8-7330-003, x 09-4998 LiftChain TL 07.6-7330-001 X 04-498 Lit Chain TT (97.6-7330-050 4/0102 % Lit Chain TT o4iovo2 —_07.6-7990-052 SECTION 8 CYLINDER PARTS XX _ 01-895 Cylinder Mast TT & TL 118568 08.1-7880-001 oaro10e me Cylinder Mast TT & TL. 118568 0401/02 —_08.1-7580-003 X 02-1000 Gylinder Free Lin TT 118574 08.3-7890-001 osioim2 x Cylinder Free Lin TT 118574 04/01/02 08.3-7390-003 SECTION 9 PLATFORM PARTS XX 02-1186 Platform Operater Side 08.0-7330-001 sacaanse o7joavot x x Platform Operator Side 1a2aee32 07/08/01 09.0-7390-003 x Platform Mast Side & Underside TL 09.0-7390-050 7A155261 osrt705 x Platform Mast Side & Underside TL 1155261 04/17/85 09.0-7390-052 azaso47 os'30V01 x Platform Mast Side & Underside TL 1A248047 08/30/01 09.0-7390-088 x Pratform Mast Side & Underside TT 09.0-7390-100 1155261 oars X 02-5/97 Platform Mast Sida & Underside TT 1A155261 04/17/95 09.0-7390-102 sa24s047 ‘98/30/01 x Platform Mast Side & Underside TT 1a246047 osao/o1 © 09.0-7330-108 ‘04/0102, x Platform Mast Side & Underside TT 0401/02 —09.0-7390-105 x X 02-996 Gate 08.0-7390-150, 1A247594 10/19/01 x x Side Gate 1247504 1018/01 09.0-7330-152 X 02-599 Pallet Grab 08.0-7330-200 40217993) 12/01/99 aes Pallet Gra 10217993, 1201/99 09.0-7390-202 x x Fork 102476 08.0-7330-250 x x Rear Gate (Australian) 10287504 tortor 09.1-7330-175, 08 REV. 4/02 IDX-7330-009 IDX-7330-009Cnhown ‘SP.3000 Revision TL TT No.-Date SECTION 10 XX 04-1205 x x KX 02-1096 sex SECTION 11 xe x x XX 09-1201 XX 03-1201 Sorial No. of Units Used For Title From: To: Standard Special Date ACCESSORIES Aisle Guide Wheels 401/02 Aisle Guide Wheels, oarori02 Labels and Decals 1285270, 4717/00 Labels and Decals 14235270 41117100 SPECIFICATIONS Service Specifications oaiorio2 Service Specifications oaioro2 Technical Service Bulletins - contain all service bullatine pertaining fo this series. Kits, Instructions - contains part numbers of various service kts pertaining to this series, with instructions referenced. Page Number 10.0-7830-001 10.0-7390-008 10.9-7330-001 10.9-7390-003 11.0-7330-001 11,0-7390-004 11.0-7330-100 11.0-7390-200 IDX-7330-010 08 REV. 4/02 IDX-7330-010cnownh INTRODUCTION ‘This manual is intended for the service mechanic who is seeking information about maintenance and service replacement parts. OPERATOR INSTRUCTIONS ‘This manual does not contain operation instructions. Operator Instructions in tag or bookiet form are sent with each truck. ‘Additional copies can be ordered if required. These booklets are for you and your personnel to insure years of safe, trouble- ‘ree operation of your Crown Lift Truck. For SP 3000 Series operator instructions, refer to Crown publication, “You and Your Grown Stockpicker* (PF10243). DRIVER TRAINING Crown has available a complete series of Driver Training programs, intwo parts concerning basic safety rules and operating characteristics of your truck. To obtain this information ask your Grown Dealer about “Its up to You" and “You and Your Stockpicker’. SERVICE TRAINING Complete Service Training is available to the lift ruck mechanie covering all Crown Lift Trucks, wire guidance, hydraulicand electrical systems. To obtain more information conceming service training, contact your Crown Dealer. REPLACEMENT PARTS When ordering replacement parts from this manual, always specify, along with the part number, the model, serial number and data number of the truck. This information will further enable us to give correct, fast and efficient service. For SP 3000 Series capacities, technical information and dimensional specifications, please refer to the following sales literature: SP 8000 Series Literature SF-12254 SP 3000 Series Specifications SF-12226 Copies of publications can be obtained from your Crown dealer or by writing to: Crown Equipment Corporation 40-44 S. Washington Street New Bremen, OH 45869 ‘This manual is arranged according to major sections and covers maintenance and replacement parts. The descriptions are as follows: MAINTENANCE REPLACEMENT PARTS SECTION DESCRIPTION SECTION DESCRIPTION ut Lubrication and Adjustments 1 Power Unit M2 Hydraulics 2 Hydraulic System and Components M3 Drive Unit 3 Drive Unit and Components ma Electrical 4 Electrical Components Ms Brake 5 Brake Assemblies and Brake Systems ue Steering 6 Steering System and Components M7 Mast and Main Frame 7 Main Frame and Mast Assemblies ws Cylinder 8 Cylinders Ma Platform 9 Platform Assembly Mio Glossary 10 Accessories 01 REV. 7/96 ITD-7330-001 ITD-7330-001Cnown INTRODUCTION The data plate for the SP 3000 Series truck is located on the platform and icludes a model number and truck data number. From these two num- bers, you can identity the truck model, series, series updates, determine per- formance, capacity and specific truck data. The next two pages explain the ‘model & truck data numbering system. Series Update ‘Significant change(s) to the product that would not merit a new series number (generation). Image Generator SP - Stockpicker TYPICAL DATA PLATE ity 3000 Ib. (1360 kg.) SP 3010-30 Series alt jE Performance Major technical and design changes making the product a new and im- proved generation. 10 = Single speed raise & lower, 8.5 hp drive motor Je speed raise & lower, 4.0 hp drive motor 20 = Two speed raise & lower, 8.5 hp drive motor 40 = Two speed raise & lower, 4.0 hp drive motor 18 ‘The example of the mode! number shown above (SP 3010-30) is a SP 3000 Series truck. I's equipped with single speed raise & lower, 3.5 hp drive motor and. 3000 Ib. (1360 kg.) capacity. “Actual rated capacity may vary, depending on special equipment or modifications. Consult capacity plate located on the overhead guard. 01 REV. 7/96 ITD-7330-002 ITD-7330-002CnOown INTRODUCTION ‘The truck data number provides you and your Grown dealer with a wealth of information to insure the selection of proper parts for your Crown truck. You may simply provide this number to your Crown dealer, or use the following breakdown if selecting your own part numbers or service information from this manual. Drive Tires NM = Non-Marking Cream Color CG = Genter Groove DS = Diagonal Siped Wire Guidance No Wire Guidance Wire Guidance —=Poly 10 Straddle Width Poy 40 422 = 42 in, (1O6smm) : 7 48 = 48 in. (1220mm) didelbeedicon 52 = 62 in. (1920mm) 54 = 54 in. (1370mm) : 58 = 86 in. (1420mm) Switch Pane! 60 = 60 in. (1525mm) iecaee eames asses 3 = Fotk Override, Zone Select fad yal isa 4= Workiight, Dome Light, Fan Sapo 5 = Fork Override, Worklght, Dome Light, Fan 6 = Fork Overrode, Zone Select, aT Workiight, Dome Light, Fan ‘TT = Telescopic Triple Slage een a ae TL = Telescopic Limited Free Lift 8 = Fork Override, worklight Dome Light, Fan, Spotight 9 = Fork Override, Zone Select, CTT 240 42 ----—F NM 421 workiight, Dome Light, Fan, Spotlight Platform Width 42 = 42 in, (108mm) 48 = 48 in, (1220mm) 54= 54 in. (1370mm) 60 = 60 in, (825mm) 64 = 64 in, (1625mm) 196 = 126 in. (3455mm) 148 in. (3760mm) 172 in. (4370mm) 194 in, (4830mm) 195 = 198 in. (495mm) 210 = 210 in, (6335mm) 214 = 214 in, (5435mm) Cold Condition 240 = 240 in. (6095mm) = = No Cold Condition 276 = 276 in. (700mm) C=Corrosion 312= 312 In, (796mm) F = Freezer Custom Pulls In Custom Height Value SPC= Special Aisle Guide Wheel Width No Fail Guidance 47.75 thru 65.25 (1220 thru 166mm) v7 Feainuea 01 REV. 7/96 ITD-7330-003 ITD-7330-003cnown INTRODUCTION This manual is intended for the service mechanic who is seeking information about maintenance and service replacement parts. OPERATOR INSTRUCTIONS ‘This manual does not contain operation instructions. Operator Instructions in tag or booklet form are sent with each truck. Additional copies can be ordered if required. These booklets are for you and your personnel to insure years of safe, trouble- {ree operation of your Crown Lift Truck. For SP 3000 Series operator instructions, refer to Crown publication, "You and Your Crown Stockpicker” (PF10243). DRIVER TRAINING Crown has available a complete series of Driver Training programs, intwo parts concerning basic safety rules and operating Characteristics of your truck. To obtain this information ask your Crown Dealer about “ts up to You" and "You and Your Stockpicker’ SERVICE TRAINING Complete Service Training is available tothe lifttruck mechanic covering all Crown Lift Trucks, wire guidance, hydraulic and electrical systems. To obtain more information concerning service training, contact your Grown Dealer. REPLACEMENT PARTS When ordering replacement parts from this manual, always specify, along with the part number, the model, serial number and data number of the truck. This information will further enable us to give correct, fast and elficient service. For SP 3000 Series capacities, technical information and dimensional specifications, please refer to the following sales literature: SP 3000 Series Literature F-12254 SP 3000 Series Specifications SF-12226 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 manualis arranged according to major sections and covers maintenance and replacement parts. The descriptions are as follows: MAINTENANCE REPLACEMENT PARTS SECTION DESCRIPTION SECTION DESCRIPTION mt Lubrication and Adjustments 1 Power Unit m2 Hydraulics 2 Hydraulic System and Components Ms Drive Unit 3 Drive Unit and Components ma Electrical 4 Electrical Components M5 Brake 5 Brake Assemblies and Brake Systems M6 Steering 6 Steering System and Components M7 Mast and Main Frame zi Main Frame and Mast Assemblies Ms Cylinder 8 Cylinders mg Platform 9 Platform Assembly M10 Glossary 10 Accessories 01 REV. 6/02 ITD-7330-004 ITD-7330-004cCnown The data plate for the SP 3000 Series truck is located on the platform and includes a model number and truck data number. From these two num- bers, you can identify the truck model, series, series updates, determine per- formance, capacity and specific truck INTRODUCTION TYPICAL DATA PLATE — Lower Right Corner of data. The next two pages explain the Mast Side of Platform model & truck data numbering system. MODEL NUMBER EXAMPLE Series Update Significant change(s) to the product that would not merit a new series number (generation). “Capacity 30 = 1360 kg. (3000 Ib.) Image Generator SP - Stockpicker SP 3010-30 L Performance = Single speed raise & lower, 3.5 hp drive motor Series Major technical and design changes making the product a new and im proved generation. 18 = Single speed raise & lower, 4.0 ho drive motor 20 = Two speed raise & lower, 3.5 hp drive motor 40 = Two speed raise & lower, 4.0 hp drive motor ‘The example af the model number shown above (SP 3010-30) is a SP 3000 Series truck. Its equipped with single speed raise & lower, 3.5 hp drive motor and 1360 kg. (3000 Ib.) capacity “Actual rated capacity may vary, depending on special equipment or modifications. Consult capacity plate located on the overhead guard. ITD-7330-005 ITD-7330-005 01 REV. 6/02Cnown INTRODUCTION The truck data number provides you and your Crown dealer with a wealth of information to insure the selection of proper parts for your Crown truck. You may simply provide this number to your Crown dealer, or use the following breakdown if selecting your own part numbers or service information from this manual. Straddle Width a 48 = 1220 mm (48 in.) 52 = 1320 mm (52 in.) 54 = 1370 mm (54 in.) 56 = 1420 mm (56 in.) 60 = 1525 mm (60 in.) 64 = 1625 mm (64 in.) 68 = 1725 mm (68 in.) 72 = 1830 mm (72 in.) ** = Special Wire Guidance No Wire Guidance W = Wire Guidance 1065 mm (42 in.) Mast Type TT = Telescopic Triple Stage TL = Telescopic Limited Free Litt larking Cream Color CG = Center Groove DS = Diagonal Siped 40 = Poly 40 RS = Razor Siped 2 = Fork Override 3 = Fork Override, Zone Select 4-= Worklight, Dome Light, Fan 5 = Fork Override, Workiight, Dome Light, Fan 6 = Fork Override, Zone Select, Workight, Dome Light, Fan 7 = Workiight, Dome Light, Fan, Spotlight 8 = Fork Override, Workiight Dome Light, Fan, Spotlight CTT 240 42 --- Lift Height 136 = 3455 mm (136 In) 148 = 3760 mm (148 in.) 172 = 4370 mm (172 in) 4194 = 4980 mm (194 in.) 195 = 4955 mm (195 in.) 210 = 5335 mm (210 in) 214 = 5435 mm (214 in.) 240 = 6095 mm (240 in.) 7010 mm (276 in) 7570 mm (294 in.) 7925 mm (312 in.) 8380 mm (330 in.) 3840 mm (348 in.) 3295 mm (366 in.) Custom Pulls In Custom Height Value SPC= Special ~-- — F NM 421 9 = Fork Override, Zone Select, Worklght, Dome Light, Fan, Spotlight Platform Width 42 = 1065 mm (42 in.) 48 = 1220 mm (48 in.) 54 = 1370 mm (54 in.) 60 = 1525 mm (60 in.) 64 = 1625 mm (64 in.) Cold Condition — = No Cold Condition C= Corrosion Freezer Aisle Guide Wheel Width io Rall Guidance 4245 thru 1810 mm (47.75 thru 71.00) ITD-7330-006 01 REV. 6/02 ITD-7330-006GENERAL MAINTENANCE INSTRUCTIONS WARNING TO PREVENT SERIOUS RISK OF INJURY TO YOURSELF AND OTHERS OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS 8. Brakes, steering mechanisms, control mechanisms, Cnown Power industrial trucks may become hazardous if adequate maintenance is neglected. Therefore, adequate mainte- nance facilities, rained personnel and procedures shouldbe provided, Maintenance and inspection shall be performed in conform- ance with the following practices: lift overload devices, guards, and safety devices shall be inspected regularly and maintained in a safe oper- ating condition, Capacity, operation and maintenance instruction plates or decals shall be maintained in legible condition. 1. A scheduled planned maintenance, lubrication, and 10. All parts of lit mechanisms shall be inspected to inspection system should be followed maintain them in safe operating condition. 2. Only qualified and authorized personnel shall be per- 11. All hydraulic systems shall be regularly inspected and mitted to maintain, repair, adjust and inspect truck. maintained in conformance with good practice. Cylin- ders, valves, and other similar parts shall be checked 8. Before leaving the truck — to assure that “drift” has not developed to the extent a. Stop truck. that it would create a hazard b. Fully lower the load engaging means. «. Place directional controls in neutral 12, Batteries, motors, controllers, limit switches, protective <. Apply the parking brake, devices, electrical conductors, and connections shall @. Tum off power (power disconnect). be maintained in conformance with good practice. 4. Remove key. Special attention shall be paid to the condition of 9. Block the wheels if ruck is on an incine. electrical insulation 4, Before working on truck — 13, Trucks shall bekeptin clean conditionto minimizefire a. Raise drive wheel free of floor or disconnect power hazards and facilitate detection of loose or defective sources. parts. b, Use chocks or other positive positioning devices. €c, Block load engaging means, inter masts, orchassis 14. Modifications and additions which affect capacity and before working under them. safe truck operation shall not be performed by the 4. Operation to check performance of truck or attach- customer or user without manufacturers prior written ments shall be conducted in an authorized safe approval. Capacity, operation and maintenance plates clearance area. or decals shall be changed accordingly 5, Before starting to operate truck — 15. Care shall be taken o assure thatall replacement parts a. Be in operating position. are interchangeable with the original parts and of equal b. Apply brake. Quality to that provided in the original equipment. ©. Place directional contro in neutral. 4. Before operatingtruck, checktunctionsofliftsystems, 16: Be sure that any equipment added to the truck (termi- Ghecishal conkeh speed contol, stecttig, warring nal, fan, clipboard, etc.) is positioned so that itdoes not ‘evidea, brakes ately citzckndnts Wary’ used block your vision or interfere with safe and efficient operation of the truck. 6. Avoid fire hazards and have fre protection equipment : present. Do notuse anopen iameto checklevel,orfor Fo" further information pertaining to operating and mainte- leakage of electrolyte and luids or oll. Donctuse open "ace procedures: pars Of fue or flammable cleaning fulds for cleaning i tyes except Series B and Tow Tractors, refer to current ASME B56.1 7. Keep shop well ventilated, clean and dry. * Series B trucks, refer to current ASME 856.10. * Tow Tractors, refer to current ASME B56.9. ‘Senn re Pre Fe 1a ee FimanUSA MA-04.0-001 MA-04.0-001cnown MAINTENANCE LIFTING & BLOCKING POINTS ‘SP36, SP42 & SP3000 SERIES TRUCKS NOTES: © Move Truck to a Secure Non Traffic Maintenance Area With a Level Floor © No Load on Forks © Hydraulic Jack - Capacity 8000 LBS. Crown P/N: 122599 Collapsed Height Minimum: 2.25 in. (57 mm) Raised Height Maximum: 16 in. (405 mm) © Jack Stand - Capacity 10,000 LBS. ‘Commercially Available ES alee) A warninc ‘Do Not Raise Platform ‘More Than 6.0 in. (152 mm) From Floor Raise Platform 30 6 in, (76 to 152 mm) From Floor A warninc Do Not Raise Load Wheels More Than 0.5 in. (13mm) from Floor to Position Wheel Chock Hard Wood Block caee Both Load Wheels Set Jack Stand Height as Reguired Not to Exceed Ad warnine 18in. (405 mm) Before Raising Rear of Truck Check That Locate Jack Stands Jack Does Not Interfere With and Jack on Truck Skirt Wire Guidance Sensors MA-07.2-100 MA-07.2-100CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT cCnown 'SP3000 Inthe interest of safety and to ensure compliance with the OSHA Regulations, (Standards - 29 CFR), The control of hazardous energy (lockou/tagout) - 191.147, Crown has developed guidelines for proper energy control when performing service and maintenance on the SP3000. Before performing any service or maintenance on the SP3000, 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 ZA\ caution (Only qualified and experienced personnel should perform maintenance and repair on batteries. + Wearprotectiveciothing, suchas, rubberapron, gloves, boots and full-face shield when performing any main. tenance on batteries. Do not allow electrolyte to come jincontactwith eyes, skin, clothing or floor. If electrolyte comes in contact with eyes, flush immediately and Make certain the charger being used matches the ‘horoughly with clean water. Obtain medical attention —__yeltage and amperageo' the truck battery. Thisvotage immediately. Should electrolyte be spilled on skin, rinse promptly with clean water and wash with soap. A baking soda solution (one poundto one gallon of water) will neutralize acid spilled on clothing, loororany other surface. Apply solution until bubbling stops and rinse with clean water. + Keep vent plugs firmly in place atalltimes exceptwhen 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 ettect reducing available charge. + If battery repair is planned, follow the battery manufacturer's instructions concerning repair prac- tices and procedures. is listed on the truck serial plate. Before disconnecting or connecting batteries to a charger, make sure the charger is “OFF”. fan 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 explo- sive. Make certain battery used meets weight, size and voltage requirements of truck (refer to serial plate). NEVER operate truck with an undersized battery. CHARGING AY CAUTION Neversmoke or bring flame nearthe 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. 01 REV. 11/00, MA-~7330-100 MA-~7330-100CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT chown BATTERY REMOVAL BATTERY INSTALLATION Ay 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. Never move battery par- tially from truck without roller stand in place. Lower load engaging means completely. If bat- teryis removed with load engaging means raised, use hoist attached to mast to provide tip over protection. 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, AN CAUTION When installing the battery, move truck to area intended for battery care. Floor must be level. Turn keyswitch or toggle switch to “oft” position ‘and remove key. Lockout or tagout truck as described in Battery - Lockout/Tagout in this section. Ifbattery was removed with load engag- jing means raised, use hoist attached to mast to provide tip over protection. Don’ tallow any metal- lic 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) to cover the top of the battery before and during installation. transporting the battery. Use an insulator (such as plywood) to cover the top of the battery before and during removal. Make certain battery used meets weight, sizeand voltage requirements of truck (refer to serial plate). NEVER operate truck with an undersized battery. LOCKOUT - TAGOUT ‘Always turn key switch to "oft", remove key and apply tag to steering wheel or twist grip with cable tie warning others truck is being serviced, \When maintenane is tobe performed and the battery willbe \ left inthe truck, lsconnect battery, remove the main power te fuses and installa commercially available lockout device on the battery connector. When maintenance is performed and the battery is removed fromthe truck, remove the main power fuses, installa 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. MA-7330-101 MA~7330-101Cnown CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT BRAKE The brakes canbe released through theuse ofthe Drive/Tow switch (DTS1) during a maintenance situation. When using this method to release the brakes, the truck will not have brakes available for stopping. The truck willnothave traction control and the power steering system will not work AY WARNING Extreme care must be taken when using the Drive/Tow switch to release the brakes. The truck will be free-wheeling and the brake pedal in the operator compartment wil have no effect on braking. Brakes will only be applied when DTS1 is moved from the Tow to the Drive position. 1. Lockout or tagout truck as described in Battery - Lockout/Tagout in this section. 2. Chock wheels or make sure truck is secured by some means to keep it from rolling away. 3. When towing the truck make sure all operators are informed of the trucks lack of braking. 4, Connect battery. Move switch DTS1 from the Drive position to the Tow position. 5. Move truck to area intended for maintenanee. 6. Move DTS1 fromthe Towto the Drive position. Discon- nect battery. MA~7330-102 MA~7330~102CONTROL OF HAZARDOUS ENERGY chown 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. 4. 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. Placea minimum 100 ohm, 2 wattresistor betweenthe positive and negative terminals of the capacitors for 3 or more seconds. MA-~7330—103 MA-7330-103cnown CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT HYDRAULIC A\ warns AVOID HIGH PRESSURE FLUIDS—Escaping fluid under pressure can penetrate the skin caus- ing serious injury. Relieve pressure before dis- connecting hydraulic tines. Tighten all connec- tions before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure. Use apiece of cardboard or paper to search for leaks. Do not use your hand. Any fiuid injected into the skin under high pres- sure 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. Mecicalatten- tion should be soughtimmediately 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. No load on forks, ‘Completely lower load engaging means (mast) or, if required for maintenance, block mast sections at ap- propriate height as described in Mast ofthis section. Lockout or tagout truck as described in Battery - Lockout/Tagout in this section. ‘Open power unit doors and locate the lift manifold. Open the manual lower valve to remove hydraulic pressure. Manual Lower Valve ex litfLower Manifold ACCUMULATOR The accumulator (hydraulic system shock absorber) con- tains a charge of inert gas such as dry nitrogen. Do not ‘tamper with the gas vaive on the accumulator in an attempt to reduce the amount of this charge. Use an accumulator charging equipment and procedures as described in the M2.6 section of this manual. Accumulator ‘Accumulator Gas Valve za Hydraulic Line Connection MA-7330—104 MA-7330-104CONTROL OF HAZARDOUS ENERGY cnown LOCKOUT/TAGOUT LIFTING AND BLOCKING 1. Move truck to a secure non traffic maintenance area with 2 level floor. 2. No load on forks. 3. Lockout or tagout truck as described in Battery - Lockout!Tagout in this section. NOTES * Hydraulic Jack - Capacity 8000 Ibs. (3620 kg.) Ad warnins + Crown part number: 122599 Do not raise platform * Collapsed height minimum: 2.25 in. (60 mm) more than 6.0 in. + Raised height maximum: 16 in. (400 mm) Jack Stand - capacity 10,000 Ibs. (4500 kg.) Commer- cially available. eer c (152 mm) trom floor = Load Wheels Wood Raise platform Block 3106 in (70 to 150 mm) from floor A warnine Da not raise load wheels more than 0.5 in, (13mm) from floor to position hard wood block A\warnina } Truck stability decreases dramat- y caly if oad wheels are raised more Wheel chock than 0.5 inch (13 mm). Attach sling y both load wheels and overhead liting device to all cross members of the mast to pre- Set jack stand vent truck trom tipping over when height as required raising the side of the truck not to exceed Ad warninc 16 in. (400 mm) Before raising rear of truck check that Locate jack stands Jack does not interfere with and jack on truck skirt wire guidance sensors MA-7330-105 MA-7330—105,chown CONTROL OF HAZARDOUS ENERGY MAST Blocking Masts Use 4 inch (100mm) by 4 inch (100 mm) ar bigger hardwood blocks of the appropriate length for supporting mast chan- nels. Block both mast rails of each stage to maintain truck stability Remove any carriage mounted accessory (e.g. roll loader, etc.) before blocking masts. These accessories add signiti- cant weight to the mast. 1. Move truck to a secure non traffic maintenance area with a level floor. 2. Chock wheels of truck. Refer to Lifting and Blocking in this section. 3. Connect battery. 4. LOCKOUT/TAGOUT Raise forks and position blocks under first stage mast of appropriate length. Do not block the first stage mast, when workat the main frame base is to be performed. Set blocks under the platform only, as described in step 6. 5. Using clamps, secure blocks to mast channel 6. Using the manual lowering valve, lower platform and Position appropriate length blacks under platform frame inmast channels. Using clamps, secure blocks to mast channel or first stage block, Continue to lower platform until platform frame rests on blocks. Lockout or tagout truck as described in Battery - Lockout/Tagout in this section. 01 REV. 11/00 MA-7330-106 MA-7330-106Chowh CLEANING OF MATERIAL HANDLING EQUIPMENT Electric Lift Truck Procedures ‘The preferred method of cleaning built up dirt and dust from electric material handling equipment is dry pressured air. For localized degreasing use of an appropriate solvent such as "TOUGH ON GREASE” (Crown P/N 063009-005) is recommended. If these methods are not effective and power washing is the only alternative, extreme care must be exercised. Electrical components including connectors, terminal boards and wiring can be permanently damaged from water and/or cleaning solvents. Mineral and chemical residue left an or in components (i.e. circuit boards, contactors, encoders, switches, potentiometers, etc.) after washing is a proponent of oxidation and corrosion. Functional integrity of contaminated components may be questionable. Nuisance fault logging, intermittent operation or immediate failure could be the resultant of power washing. For these reasons all electronic components including motors ‘must be protected. Component removal is the best method to eliminate the risk of damage. Power washing will also remove and/or destroy lubricants in or on the surface of shafts, unsealed bearings, hinges, exposed gears, bushings, chains, linkages, etc. These Items must also be protected or properly lubricated after cleaning. Consideration must also be given to metal surfaces. The cleaning process can strip away paint and protective coatings, applied to components (i.e. hydraulic lines, terminal strips, linkages) for freezer/corrosion environment. Paint and/or protective coating must be reapplied to these areas to reduce the chance of oxidation and corrosion. Before installing removed components, lubricating or returning the equipment to service it must be free of solvent residue and thoroughly dry. MA-1140-050 MA-1140-050chown 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, assistin determining planned maintenance (PM) schedules and ultimately save money. For these reasons, Grown recommends a checklist similarto 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 mustto insure the safety of others andito insure that proper maintenance is performed to the unit. If desired, padded packs of this checklist (OF-8772) are available through your Crown dealer. cnown Serato (ttt ana een och Operators Daily Checklist Wek bainning ‘0K [ok ox) 0K ag oK|_loK OK 0K [ok ox ‘0K [oK ok klk lok’ oF * oK'_[oK Q OK ok) OK lox lok _jok KO ox (ox _lox,_loK OK _|ok ok! (ok (0K ox [ok) [ow =e OK ok 0K’ [ot SE sone ween OK [oK_(oK, ox [ok _/ox|_ [ox Senne cece OK OK OK OK OK OK OK, OK [OK OK _oK_[ox’_|ox ‘OK [oki OK’ ok lok OK 4 OK OK OK OK OK OK. 8 (OK_‘OK' OK! 3 ox 0K OK : OK,_OK| ok | dl emermewnnwmwe OK OK OK OK! Saxe DK ok’ oK| 0K, —— DK OK OK! _OK' = fel reese T 1 ft corse 12 REV. 4/02 M1.0-04.0-001 M1.0-04.0-001Cnown LUBRICATION AND ADJUSTMENT ‘The following is a list of lubricants and maintenance products recommended when doing Planned Maintenance on Crown Lift Trucks. LUBRICANT & FLUID CHART TYPE OF LUBRICANT BRAND NAME. MANUFACTURER ‘A. Gear Lube 80W-90 (Typical) [~ Union MP Gear Lube LS) | Union 76 Co. Code 51 63 ‘Mobilube HD 80W-90" Mobil Oil Co. Dubois EGO-75 & 90" Deusol EP 90° Dubois Chem., Div of Chemed Corp. Burmah Castrol GX s0W-90 Exxon Mobil Co. ‘AA. Automatic Transmission Fluid | Multi Purpose ATF Mobile Oil Co. Freezer Application 32° F Donax TG. Shell (0° C) and Below ‘Super Flo Exxon. B. Grease (Multipurpose) FF Union Unoba EP No. 2 Union 76 Co. Retinax A” Shell LM Grease" Burmah Castrol Mobile Grease XHP 222 Special) Mobil Oil Co. Unirex EP-2 Exxon Mobil Co, BB. Grease (Low Temp)t Lubriplate Fiske Bros. Refining Co. AWvania RA* Shell Helveur O* Burmah Castrol C07 (SAE 40) D. Hydraulic Oi Union Unax AW ISO 32° Union 76 Co. Tellus 32° Shell Hyspin AWS 32" Burmah Castrol Hydraulic AW-32 Mobil Oil Co. ‘Sohio Energol HLP32 Sohio Nuto H 32 Exxon Mobil Co. DD. Hydraulic O1 (Low Temp.)t | Mobil Aero HFA Mobil Oil Co. Tellus T-15° Shell Hyspin AWH-15* Burmah Castrol Univis J-13 Exxon Mobil Co. LT Hydraulic Oil Castrol HDL ine. DDD. Hydraulic Ot Mobil DTE 24 Mobil Oil. E_ Grease Channel Factran #2 Tt ‘Standard Oil Co. F. Grease Gear, Channel, Shaft | Molykote BR-2 Plus Tf ‘Dow Corning G. Chain & Stee! Cable Fiuid Lubripiate Chain & Steet Fiske Bros. Refining Co. Cable Fluid Hi Rubber & Vinyl Dressing ‘Armoral Protectant MeKesson Corp. Clear Guard” Turtle Wax Inc. T_ Grease (Lift Pump Coupling)_|_Darmex Darmex Brake Fluid (02-1141 Silicon Brake Fluid |~Dow Coming K. Grease (Wheel Bearing) Mobiigrease XHP 222 Mobil Oil Corp. Unirex EP-2 Exxon Mobil Co. Lubriplate No. 1242* Fiske Bros. Refining Co. L__Metal Assembly Spray ‘Dow Corning [Dow Coming M. Silicon Grease (Clear) Dow Corning 111 Compound | Dow Coming * Denotes allowable substitutes, contact factory if unavailable. +t Trucks operated in below freezing temperatures must use Low Temp. Hydraulic Oil & Grease. ‘tt Same as B. tit Used in blending with low temp oil CHART 1-1 M1.0-04.0-002 12 REV. 4/02 M1.0-04.0-002Cnown LUBRICATION AND ADJUSTMENT LUBE IDENTIFICATION CHART LUBE TYPE PART NO. PACKAGE QTY. A. Gear Lube 963002-003 | Quarts AA. Automatic Transmission Fluid 063001-010, Quarts Freezer Application 32° F (0° C) and Below B. Grease, Multipurpose 063002-024 14.5 02. cart * BB. Grease, Multipurpose (Low Temp.)[Cream] | 063002-017 1455 oz. cart. ©. SAE 40 D. Hydraulic Oil 063001-001 1 Gallon *DD. Hydraulic Gil (Low Temp.) 063001-008 4 Gallon DDD. Hydraulic Oil (Standard for Blending) 063001-021 1 Gallon E, Channel Grease Multipurpose Same as B 14.5 02. cart. F. Gear Grease Multipurpose Same as B 14.5 02. cart G. Chain & Steel Cable Lube 063001-008 1402. spray H. Rubber & Vinyl Dressing |. Grease Special for Lift Pump Coupling 063002-039 4 tb. jar 063002-040 102. J. Brake Fluid ‘068004-002 12.02. (063004003 + Gallon K. Grease (Wheel Bearing) 068002-034 14.5 0z. cart L. Metal Assembly Spray ‘063002-021 1102, spray M._Grease Clear Silicon 1063002-020 5.3 02. tube * Trucks operated in below freezing temperatures must use Low Temp. Hydraulic Oil & Grease. CHART 1-2 12 REV. 4/02 M1.0-04.0-003 M1.0-04.0-003chown MAINTENANCE LUBRICATION AND ADJUSTMENT GENERAL Before performing maintenance to the truck, move truck to an area set aside for maintenance or where there is ad- equate space to perform the required work. This is a must to insure the safety of others and to insure that proper mainte- nance is performed, A CAUTION Besure battery connectorsare disconnectedand all wheels are chocked before proceeding. To obtain maximum life of any industrial equipment, a well planned maintenance program should be followed. The {following information is intended to provide guidelines for proper lubrication intervals, and are according to hours of ‘ruck operation and/or a specific number of days or months. ‘These recommended figures should be used as an aid in ‘maintaining safe and efficient truck operation. Some operat- ing conditions will require more frequent checks and lubrica- tion than listed. Applications with much dust or moisture will require modification of the schedule to fit that particular. application. ‘Only high grade lubricants and fluids shouldbe used. Sources of these lubricants may be from almost any of the oll companies; those listed below are typical and any lubricant with equal specifications may be used. (See Chart 1-1 on page M1.0-04-002) (On trucks equipped to operate in below freezing tempera- tures, low temperature hydraulic oil must be used. _ ‘Component Accessibility For regular maintenance, access to various truck compo- nents is accomplished by removing covers, panels and/or doors. The following is a general explanation of what cover, panel, etc. must be removed to allow for the most efficient ‘access when performing service and/or maintenance to ‘components. Refertotheillustrationsin this section asan aid inlocating parts that require attention. More details are given in following sections on hydraulics, electrical, brakes, etc. The top cover can be opened to allow access to battery connector, battery cell caps, check battery condition, strobe light, additional mechanical and electrical components. ‘The battery side covers can be removed to service and/or remove battery. ‘The power unit doors can be opened to allow access to the following: drive unit, traction panel, lit/power panel, drive motor, electric brake and related components, steer motor/ ‘encoder and related components, lft pump(s) and motor(s), hydraulic reservoir fiter, strainer and related components. Located under the piatformarethe hom, pallet grab, fork pins and associated parts. ‘The console on the platform when removed will allow access to side-gate switches, steering command encoder, display panel, terminal boards and associated platiorm electrical wiring, Located on the frontside of the platform are the chain slack switches, pallet grab linkage and limit switch(s). The control module must be removed to gain access to directional and lift switches, various control switches and linkages. Refer to the illustrations and charts in this section asa guide {or inspection and adjustment that may be necessary. This information used with a Planned Maintenance Inspection Report for Stockpickers available from your Crown deaier will be very helpful to a good maintenance program. Panam sn 01 REV. 6/95 M1.0-7330-001 M1.0-7330-001Gown MAINTENANCE GTs2 2 GTS4 ‘SHOWN ONLY PLATFORM FLOORBOARD \ os ILLUSTRATION 1-1 01 REV. 6/95 M1.0-7330-002 M1.0-7330-002chown MAINTENANCE LUBRICATION CHART | LUBE 60da. | 90a. |_6mo.| 12 mo. | INDEX | COMPONENT TYPE | Ty. [250hr. | 500 hr. | 7000 hr} 2000 hr, L1 | Brake Pedel Guides G | an] + L2 | Platform Gates, c | an] t Ls _| Battery Cover Hinge cj aR | ot | L4 | Power Unit Door Hinges Poe AR LS | Battery Rollers B | an | t+ Le | Battery Restraint Threads B | aR | + | | L7 | Aisle Guide Wheels B | aR] oo L8 | Load Wheel Axles BOAR L L= Lubricate + =Check Chg. = Change AR = As Required ‘See Chart 1-2 on page M1.0-04-008 for Lube Type explanation and capacity. See Illustration 1-1 for Lubrication locations. INSPECTION AND ADJUSTMENT CHART [soda | 90da.| 6mo. | 12mo. 250 hr. | 500 hr. | 7000 hr 2000 hr. INDEX | COMPONENT | 141 | Brake Pedal Switch leat 1-2 | Brake Pedal Mechanism leet 1-3 | Platform Gates and Switches [eat h4 | Load Wheels Neer 15 | Aisle Guide Wheels and Switches t 16 | Skids + 17_| Aisle Guide Skids + + = Inspect andior Adjust. See Illustration 1-1 for component locations. Refer to appropriate section of service manual for adcitional information concerning inspection and/or adjustment. CHART 1-3 Grom eon Pri0oe Rev BSE Fnesn0sn 01 REV. 6/95 M1.0-7830-003 M1.0-7330-003Chown MAINTENANCE te Mt ie He M4 L, G- x r - - fRaeeea 10 Lo hs : He ur JA f 8 PART POWER DRIVE ur MGTOR PUMP aed S el MOTOR STEER < MOTOR (@ , & 7001 ILLUSTRATION 1-2 01 REV. 6/95 M1.0-7330-004 Mi-O=rs30-00%Gown MAINTENANCE LUBRICATION CHART LUBE 60da. | 90da.| 6mo.| 12 mo. INDEX | COMPONENT TYPE | ary. [250hr. | 00 hr. | 1000 hr] 2000 hr. L-9 | Mast Channels, Collumn Rollers © | | + | | L-19_| Hose and Pulley (Plastic) H Lara] ¢t | L= Lubricate = Check ” Chg. = Change AR = As Required ‘See Chart 1-2 on page M1.0-04-003 for Lube Type explanation and capacity. See Illustration 1-2 for Lubrication locations. INSPECTION AND ADJUSTMENT CHART e0da.| 90da.|_6mo.| 12 mo. INDEX| COMPONENT 260 nr. | 500 h.| 1000 hy, 2000 hr. 18 | Battery Connector + to. | Battery t | 0 | Strobe Light/Fiashing Light t (eit | Lift Cyinders and Restraints t 1-12 | Column Rollers - Mast 2 3 | column Rollers ~ Platform + 44 | Operator Harness + | 15 | Forks t |S | Motor ruses t | I-17 | Motor Brushes - Drive | t | I-48 | Motor Brushes - Power Steering | +] 1419 | Hydraulic Lines, Fitings, Hoses + 1-20 | Power Unit to Mast Bolts t += Inspect and/or Adjust. See Ilustration 1-2 for component locations. Refer to appropriate section of service manual for additional information conceming inspection and/or adjustment. CHART 1-4 01 REV. 6/95 M1.0-7330-005 M1.0-7330-005cCnown MAINTENANCE M1.0-7330-006 M1.0-7330-006Cnownh MAINTENANCE ‘See Chart 1-2 on page M1.0-04-003 for Lube Type explanation and capacity. See Illustration 1-3 for Lubrication locations. INSPECTION AND ADJUSTMENT CHART LUBRICATION CHART LUBE soda. | 90da.| 6mo. | 12mo. INDEX | COMPONENT | TPE | ary. [260 hr. [500 hr. | 7000 hr| 2000 hr. L+10 | Lift Chain el an) ¢t L-11_ | Pallet Grab Linkage jc | aR] t = Lubricate ‘t=Check ~ hg. = Change [eoda. | g0da.|_¢6mo.| 12mo. INDEX | COMPONENT [250 hr. | 500 hr. | 1000 hr] 2000 hr. +21 | Lift Chains ani 1-22 | Ghain Anchors and Retainers i 123 | Chain Slack Linkage + | | +24 | Brake Friction Plates and Operation | teeta | £25 | Pallet Grab Linkage and Operation + | | +26 |Hom | ¢ | + = Inspect and/or Adjust. See Illustration 1-3 for component locations, Refer to appropriate section of service manual for additional information conceming inspection and/or adjustment. CHART 1-5 tomer 007 Fan OE M1.0-7330-007 01 REV. 6/95 Frees USA M1.0-7330-007MAINTENANCE 7 A\ ILLUSTRATION 1-4 Cnown 01 REV. 6/95 M1.0-7330-008 Goer norrerena oh ORE M1.0-7330-008CGhowh MAINTENANCE LUBRICATION CHART wee] [soda, | 20aa.| emo] temo INDEX | COMPONENT TYPE | aT. [250 hr. | 600 hr. | 1000 hr] 2000 hr. L412 | Steering Gearbox Oil Level A | 2pts.| *Chg. Chg. L413 | Steering Gears Fan! t Lie | yeas tor . | chp. hg. L415. | Hydraulic Reservoir - Single Pump “DO tae) t Chg. | Hydraulic Reservoir - Dual Pump D i1esa| + Chg. L46 | Hydraulic Strainer | Chg L417 | Drive Unit Thrust Bearing B | ar] oc L-18_| Drive Unit Fluid Level A |15pts| + Chg. L = Lubricate += Check Chg. = Change AR = As Required ‘See Chart 1-2 on page M1.0-04-003 for Lube Type explanation and capacity. See Illustration 1-4 for Lubrication locations. * Change first time only as noted, thereafter check at 250 hr./60 da. intervals and change at longer interval as. noted. INSPECTION AND ADJUSTMENT CHART ~ [eo da. | 90 da. | 6mo. | 12 mo. INDEX | COMPONENT 250 pr. | 00 hr. 7000 hr} 2000 +27 | Contactor Tips ‘i 1-28 | Steering Gears and Sprockets t 1-28 | Chain Slack Switch + 1-30 | Stop Blocks + 131 | Drive Tire t | 1-82 | All Electrical Termination Points t | ‘t= Inspect and/or Adjust. See Illustration 1-4 for component locations. Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment, CHART 1-6 M1.0-7330-009 01 REV. 6/95 M1.0-7330-009cnown MAINTENANCE 7 ILLUSTRATION 1-5 omens Pro Re parte PineinUSh M1.0-7330-010 M1.0-7330-010Cnown MAINTENANCE LUBRICATION CHART LUBE oda. | 90da.| émo. | 12mo. INDEX | COMPONENT TyPE | ary. [250 hr. | 500 hr. |7000 hr| 2000 hr. L-20__| Control Cables and Pulleys (Plastic) H | aR] t | L= Lubricate + =Check (Chg. = Change AR = As Required INSPECTION AND ADJUSTMENT CHART e0da. | 90da.| 6mo.| 12 mo. INDEX | COMPONENT 250 hr. | 500 hr. | 7000 hr] 2000 hr. 1-83 | Limit Switches - Mast and Platform t 1-34 | Travel and Lift Controls t | 1-35 | Power Disconnect t 1-36 | Panel Indicator Lights [oat 1-37 | Panel Switches fay | 1-38 | Cable Tension Devices. t | 1-39 | Control Cables and Pulleys t 140 | Mast Cushion Mechanisms chee b41 | Tow Switch tL ‘t= Inspect and/or Adjust. See Illustration 1-5 for component locations. Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. CHART 1-7 M1.0-7330-011 01 REV. 6/95, Pamean sn M1.0-7330-011Cnown MAINTENANCE LUBRICATION AND ADJUSTMENT GENERAL Before performing maintenance to the truck, move truck to an area set aside for maintenance or where there is ad- equate space to perform the required work. This is a mustto insure the safety of others and to insure that proper mainte- nance is performed Z\ caution Be sure battery connectors are disconnectedand all wheels are chocked before proceeding. To obtain maximum life of any industrial equipment, a well planned maintenance program should be followed. The following information is intended to provide guidelines for proper lubrication intervals, and are according to hours of, truck operation andior a specific number of days or months. These recommended figures should be used as an aid in maintaining safe and efficient ruck operation. Some operat- ing conditions will require more frequent checks and lubrica- tion than listed. Applications with much dust or moisture will require modification of the schedule to fit that particular application. (Only high grade lubricants and fluids should be used. Sources of these lubricants may be from almost any of the oil companies; those listed below are typical and any lubricant with equal specifications may be used. (See Chart 1-1 on page M1.0-04-002). On trucks equipped to operate in below freezing tempera- tures, low temperature hydraulic oil must be used. ‘Component Accessibility For regular maintenance, access to various truck compo- nents is accomplished by removing covers, panels and/or doors. The following is a general explanation of what cover, Panel, etc. must be removed to allow for the most efficient access when performing service andior maintenance to components. Refertothe illustrations in this section as an aid inlocating parts that require attention. More details are given in following sections on hydraulics, electrical, brakes, etc. ‘The top cover can be opened to allow access to battery connector, battery cell caps, check battery condition, strobe light, additional mechanical and electrical components. ‘The battery side covers can be removed to service and/or remove battery. ‘The power unit doors can be opened to allow access to the following: drive unit, traction panel, lit/power panel, drive motor, electric brake and related components, steer motor! encoder and related components, lit pump(s) and mator(s), hydraulic reservoir, iter, stainer and related components. Located under the platformare the horn, pallet grab, fork pins and associated parts. ‘The console on the platform when removed will allow access to side-gate switches, steering command encoder, display panel, terminal boards and associated platform electrical wiring. Located on the frant side of the platform are the chain slack switches, pallet grab linkage and limit switch(s). ‘The control module must be removed to gain access to irectional and lift switches, various control switches and linkages. Refer to the illustrations and charts in this section as a guide for inspection and adjustment that may be necessary. This information used with a Planned Maintenance inspection Report for Stockpickers available from your Crown dealer will be very helpful to @ good maintenance program. 03 REV. 12/01 M1.0-7330-015 M1.0-7330-015Chowh MAINTENANCE gTs2a.GTs4 ‘SHOWN ONLY PLATFORM FLOORBOARD Le a1 ILLUSTRATION 1-1 ‘Go on Pea 01 REV. 6/95 M1.0-7330-016 M1.0-7330-016Cnown MAINTENANCE LUBRICATION AND ADJUSTMENT GENERAL Before performing maintenance to the truck, move truck to an area set aside for maintenance or where there is ad- equate space to perform the required work. This is @ must to insure the safety of others and to insure that proper mainte- nance is performed. Ay cauron Be surebatiery connectors are disconnected and all wheels are chocked betore proceeding. To obtain maximum life of any industrial equipment, a well planned maintenance program should be followed. The following information is intended to provide guidelines for proper lubrication intervals, and are according to hours of truck operation and/or a specific number of days or months. ‘These recommended figures should be used as an aid in ‘maintaining safe and efficient ruck operation. Some operat- ing conditions will require more frequent checks and lubrica- tion than listed. Applications with much dust or moisture will require modification of the schedule to fit that particular application. Only high grade lubricants and fluids shouldbe used. Sources of these lubricants may be from almost any of the oil companies; those listed below are typical and any lubricant with equal specifications may be used. (See Chart 1-1 on Page M1.0-04-002). (On trucks equipped to operate in below freezing tempera tures, low temperature hydraulic oll must be used. Component Accessibility For regular maintenance, access to various truck compo- nents is accomplished by removing covers, panels and/or doors. The following is a general explanation of what cover, panel, etc. must be removed to allow for the most efficient ‘access when performing service and/or maintenance to components. Referto the illustrations inthis section as anaid inlocating parts that require attention. More details are given in following sections on hydraulics, electrical, brakes, etc. ‘The top cover can be opened to allow access to battery connector, battery cell caps, check battery condition, strobe light, additional mechanical and electrical components. ‘The battery side covers can be removed to service and/or remove battery. ‘The power unit doors can be opened to allow access to the following: drive unit, traction panel, lftpower panel, drive motor, electric brake and related components, steer motor! encoder and related components, lift pump(s) and motor(s), hydraulic reservoir, filter, strainer and related components. Located under the piatformare the horn, palletgrab, forkpins and associated parts. The console on the platform when removed will allow access to side-gate switches, steering command encoder, display panel, terminal boards and associated platform electrical wiring Located on the front side of the platform are the chain slack switches, pallet grab linkage and limit switch(s). The control module must be removed to gain access to directional and lift switches, various control switches and linkages. Refer to the illustrations and charts in this section as a quide for inspection and adjustment that may be necessary. This information used with a Planned Maintenance inspection Report for Stockpickers available from your Crown dealer will be very helpful to a good maintenance program. 03 REV. 12101 M1.0-7330-015 M1.0-7330-015cnown MAINTENANCE Le GTS2.a.GTS4 ‘SHOWN ONLY 4 Fl PLATFORM FLOORBOARD sus ILLUSTRATION 1-1 01 REV. 6/95 M1.0-7330-016 M1.0-7330-016cCnown MAINTENANCE LUBRICATION CHART LUBE 60da._| e0da.| 6mo.| 12mo INDEX | COMPONENT TyPE | Qty. | 250 hr. | 800 hr. | 1000 hr] 2000 hr. L1_ | Brake Pedal Guides c | ar| + | L2 | Platform Gates @ | anf ¢ | 13 | Battery Cover Hinge Che Ana [ails | La | Power Unit Door Hinges c | an} ¢ | 15 | Battery Rollers B | ar] t US | Battery Restraint Threads B | aR| t+ | L7 | Aisle Guide Wheels B AR L | 18 | Load Whee! Axles a | an] oe | L = Lubricate t= Check Chg. = Change AR = As Required ‘See Chart 1-2 on page M1.0-04-0083 for Lube Type explanation and capacity See Illustration 1-1 for Lubrication locations. INSPECTION AND ADJUSTMENT CHART oda. | o0da.| 6mo. | 12 mo. INDEX | COMPONENT 250 hr. | 500 hr. | 1000 hr] 2000 hr. I-41 | Brake Pedal Switch 12 Brake Pedal Mechanism | 1:3. _| Platform Gates and Switches 14 | Load Wheels | 15 | Aisle Guide Wheels and Switches 6 | Skids 17_| Aisle Guide Skids + ; + ; + t +.= Inspect and/or Adjust. See Illustration 1-1 for component locations, Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. CHART 1-3 01 REV. 6/95 M1.0-7330-017 M1.0-7330-017MAINTENANCE cnown ILLUSTRATION 1-2 01 REV. 6/95 M1.0-7330-018 M1.0-7330-018cnown MAINTENANCE LUBRICATION CHART | LUBE 6oda. | 90da.| 6mo. | 12mo | INDEX | COMPONENT TYPE | QTY. [250 hr. | 500 hr. | 1000 hr.| 2000 hr. L9. | Mast Channels, Collumn Rollers —e | an] t+ | L19_ [Hose and Pulley (Plastic) Har] ¢ | L = Lubricate += Check Cha. = Change AR = As Required See Chart 1-2 on page M1.0-04-003 for Lube Type explanation and capacity. See Illustration 1-2 for Lubrication locations. INSPECTION AND ADJUSTMENT CHART e0da._| soda. |_6mo. | 12mo. INDEX | COMPONENT 250 hr. | 500 hr. | 1000 hnr| 2000 hr. | 8 | Battery Connector +9 | Battery I-10 | Strobe LightFlashing Light l-11_ | Lift Cylinders and Restraints 1-42 | Column Rollers - Mast [43 | Column Rollers - Platform l-14 | Operator Harness L415. | Forks I-46 | Motor Brushes - Lift I-47 | Motor Brushes - Drive 1-18 | Motor Brushes - Powor Steering I-49 | Hydraulic Lines, Fittings, Hoses 1-20 | Power nit to Mast Bolts 444444444444 ‘f=Inspect and/or Adjust. See Illustration 1-2 for component locations. Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. CHART 1-4 01 REV. 6/95 M1.0-7330-019 M1.0-7330-019Chowh MAINTENANCE sees ILLUSTRATION 1-3 ‘Gown oan Rev BOS ania Pomonose M1.0-7330-020 M1.0-7330-020Cnown MAINTENANCE LUBRICATION CHART LUBE 90 da. | 6 mo. | 12m. | INDEX | COMPONENT TYPE | aTy. [250 hr | 500 hr. 1000 fr] 2000 n.| Lo | Litt chain co | an] + | Ltt | Pallet Grab Linkage c fan | + LL = Lubricate + =-Cheok Cho. = Change ‘See Chart 1-2 on page M1.0-04-003 for Lube Type explanation and capacity. See Illustration 1-3 for Lubrication locations. INSPECTION AND ADJUSTMENT CHART INDEX Lt 122 123 Lea 125 128 COMPONENT Litt Chains Chain Anchors and Retainers Chain Slack Linkage Brake Friction Plates and Operation Pallet Grab Linkage and Operation Horn |eoda._| soda. | 6mo. | 12 mo. | 250 hr. | 500 hr. | 1000 hr] 2000 hr. } + | t | | | ‘ | leas | | [ens | t = Inspect andior Adjust. See Illustration 1-3 for component locations. Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. CHART 1-5 M1.0-7330-021 01 REV. 6/95 M1.0-7330-021chown MAINTENANCE ue ILLUSTRATION 1-4 ‘Sen SPE nIE on aE ane Pamon use M1.0-7330-022 M1.0-7330-022cnown MAINTENANCE LUBRICATION CHART | Lupe soda. | s0da.| 6mo.| 12 mo. | INDEX | COMPONENT TYPE | Ty. | 250 hr. | 500 hr. | 1000 hr} 2000 hr. L412 | Steering Gearbox Oil Level | #000 | 2pts. | *Chg. Chg. L413 | Steering Gears JF | an] + L414 | Hydraulic Filter t | ‘cng. Chg. L415 | Hydraulic Reservoir - Single Pump D | 14a} t Cho. | Hydraulic Reservoir - Dual Pump D |rasat} + Chg. L46 | Hydraulic Strainer Cha. LA7 | Drive Unit Thrust Bearing Basan dc L418 | Drive Unit Fluid Level A [1 Spits} t | Cho. L = Lubricate t= Check Chg. = Change AR = As Required See Chart 1-2 on page M1 .0-04-008 for Lube Type explanation and capacity. See Illustration 1-4 for Lubrication locations. * Change first time only as noted, thereafter check at 250 hr,/60 da. intervals and change at longer interval as noted. + Use "DDD" (see page M1.0-04.0-003) hydraulic ol in steering gearbox for both normal and low temperature applications. INSPECTION AND ADJUSTMENT CHART [60da. | 90da. | 6mo. | 12 mo. | INDEX | COMPONENT [250 hr | 500 fr. 7000 fr} 2000 Fr. | | | 1 127 | Contactor Tips | 1-28 | Steering Gears and Sprockets | 1-28 | Chain Slack Switch | 1-30 | Stop Blocks | 131 | Drive Tire 1-32 | All Electrical Termination Points +t = Inspect and/or Adjust. See Illustration 1-4 for component locations. Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. CHART 1-6 03 REV. 1201 M1.0-7330-023 M1.0-7330-023own MAINTENANCE DISTRIBUTION’ PANEL PART OF MAIN FRAME, wm ILLUSTRATION 1-5 02 REV. 2/96 Famanvan M1.0-7330-024 M1.0-7330-024CnOown MAINTENANCE LUBRICATION CHART LUBE e0da._| 90da. | mo. | 12:mo. INDEX |COMPONENT TYPE | QTY. [250 hr. | 00 hr. [7000 ihr.) 2000 hr. L-20_| Controt Cables and Pulleys (Plastic) Hw | arn] + L= Lubricate t= Check Chg. = Change AR = As Required INSPECTION AND ADJUSTMENT CHART 90 da. |_6 mo. ‘500 hr. | 1000 hr 2000 hr. | INDEX | COMPONENT | 33 | Limit Switches - Mast and Platform 134 | Travel and Lift Controls 1-85 | Power Disconnect 1-36 | Panel indicator Lights 1-37 | Panel Switches 1-38 . | Cable Tension Devices 1-89 | Control Cables and Guides 1-40 | Mast Cushion Mechanisms 141 | Tow Switch +f = Inspect andlor Adjust. See Illustration 1-5 for component locations. Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. CHART 1-7 01 REV. 6/95 M1.0-7330-025 M1.0-7330-025Cnhown MAINTENANCE SKID INSPECTION cn Wks aquppsdl wnt sis gus weet, asa aa Toca in the lower lt and ight comer of he power unt AX caution skirt. ‘These skids are used to maintain truck stability and should be periodically inspected. «Unie Check to be sure skid mounting bolts are secure and oe measure the distance from the bottom of skid to level flor. ~ ‘The maximum allowable distance from skid to level floor is 1.00 in, (25.4mm). POWER UNIT Skid SKIRT SKID sx ILLUSTRATION 1.5-1 x | ,00 in, (25.4mm) FLOOR MAXIMUM ALLOWABLE On trucks equipped with aisle guide wheels; skids are Se ‘mounted on the bottom of the front (power unit end) aisle... USTRATON I= guide wheel supports. Power Unit Skirt Aisle Guide Wheels Skid lf measurement exceeds 1.00 in. (25.4mm), replace skids. on ILLUSTRATION 1.5-2 rm Te PrTODSE riieshUSA M1.5-7330-001 M1.5-7330-001 SEcnownh MAINTENANCE TORQUE VALUES All Crown Trucks are manufactured with Grade 5 or better screws and bolts. The information contained in this section will aid you when replacing any screws and bolts that are necessary when performing maintenance on your lift truck. GRADE GRADE MARKING ] BOLT AND SCREW | (ON HEAD) SPECIFICATION | MATERIAL SIZE, IN. ° ‘SAE — Grade 2 Low Carbon Steel 1/4 through 1 1/72 | a meet | pecem cnt Sit | vatmough 172 | as © | ste —oatee | Mosur caren mene |e aug | | i NOTE — Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in al of its bolted assemblies. Instances do occur when Grade 5 bolts are manufactured unmarked. When a fastener is replaced that is un- marked, replace the fastener with a Grade 5. TORQUE CHART ] GRADE 5 | GRADE 8 BOLT DIAMETER |___DRY TORQUE REQUIREMENT DRY TORQUE REQUIREMENT 7b ke New toy | ERS a | RDO 114" 923 i224 | 24 | 44 | 1825 | 175455 5/16" 1625 | 2547 | 2547 | 545 | 3547 | S447 38" s245 | 4427 | 43547 | 48+10 | 66413 | 054135 76" Sox 10 | 69214 [6754135] 75410 | 1044 1.4 | 102 4 195 172" 75 +10 | 104414 |1015 + 135| 112415 | 155+ 20 | 1524 205 oie" 110 + 15 | 152420 | 149 + 20.5 | 1634 20 | 225430 | 2214 27 5/8” 150 + 20 | 20.7428 | 2035 427| 225+ 90) 311441 | 9054 41 3/4 265435 | 6.6248 | 359 4 47.5 | 400450 | 552469 | 542 2 68 { 718” 420+ 60 | 58.1283 | 569+ 81 | 64080 | 883+ 11.0 | 868 + 108 a [640 + 80 | 88.54 11.1 | 868 + 109 | 960 + 115 | 1925 + 15.9] 1300 + 156 11/6" [00 + 100 | 110.6 + 13.8 | 1085 + 196 118" 1000 + 120| 138 + 166 | 1356 + 163 13/8" 1200 + 150| 166 + 207 | 1690 + 203 4412" 1500 + 200| 207 + 27.7 | 2034 » 271 Mounting bolt torque requirements involving hydraulic valves. 5/16" Wr2 | 1823 | 175225) 3/8" 222 | 3343 | 925225) 716" goe2 | 5423 | 53425 | NOTE: Torque values called out in the maintenance section of this manual will take precedence over torque values found con this page. Sve Pe Re vas 02 REV. 4/88 M19 - 14-001 M19 - 14-001cnown MAINTENANCE HYDRAULIC SYSTEM ‘The hydraulic system in your truck is powered by gear type pumps. These pumps, P1 & P2, supply oil flow for lift and accessory functions. Maximum pressure is limited by an adjustable reliet valve, RV1, (refer to section M2.4). The setting for RV1 is noted on ‘TWO SPEED LIFT the hydraulic schematics. Refer to the service manual index for pump, valve and manifold information. ‘The illustration below shows hydraulic component location in the power unit. ONE SPEED LIFT Quick Disconnect Manual Release cules ee Valve MV svi ‘Solenoid Valve Filter Sight Gauge Reservoir Pump Motor M3 Pump Motor Ma Pump Pt Pump P2 Strainer ‘Accumulator Quick Disconnect Manual Release ioe Valve MV ee svi ILLUSTRATION 1 sez ss own se PFTOSTOT Re TaD Frees USA 03 REV. 1/98 M2.0-7330-001 M2.0-7330-001chown MAINTENANCE Hydraulic Circuits Relief Valve Operation These pages contain a brief description of the hydraulic During the lit function, relief valve RV1 monitors hydraulic circuits for SP trucks which are typical of current standard pressure. If ll pressure exceeds the relief pressure setting, units. Your unit may vary. Refer to section HYD in this the relief valve is forced open, allowing the pressurized oilto manual for appropriate schematic. bypass the lift circuit. From the relief valve, oil exits from the manifold block through port T. From port T, oil passes Lift Cireuit- One Speed LiftLower ‘through the return line filter then back to the reservoir. When itis selected, cilis drawn fromthe hydraulic reservair , Accumulator Operation to hydraulic pump P'1. P1 supplies pressurized oil to the lif lower manifold block. The oil enters the manifold block The accumulator is used as a shock absorber for the lif! through port P1 and goes directly to check valve CV1. Oil lower hydraulic system. If the platform is stopped suddenly, passes through the manifold block until it exits port C. the change in oll flow exerts pressure on the hydraulic Pressurized oil enters the lft cylinders and begins to extend system. The accumulator absorbs this oll pressure change the mast. by using the gas pressurized bladder located within the accumulator. The bladder acts as a pillow to the pressurized cil, cushioning the applied pressure within the hydraulic circuit. The typical symptom of a bad or de-pressurized accumulator is abrupt starting and stopping of the platform during lift or lower. Accumulator ‘SUCTION $00 PS BRESSURE ee Precharge RETURN TL 2340/2365 Ps! aaa TF 27102728 PSI Reservoir a stainor | eae Velocity Fuse en ILLUSTRATION 2 Som inea reson Rn a Pinean OBA 01 REV. 4/97 M2.0-7330-002 M2.0-7330-002Cnown MAINTENANCE Lower Circuit - One Speed Lift/Lower When lower is selected, oil begins to exit the lift cylinder. Oil leaving the cylinder is monitored by the internal velocity fuse in each cylinder. Velocity fuses are designed to preventthe sudden release of hydraulic oil from the cylinder under such conditions as a rupture. If cylinder line ruptured, the oil exiting the cylinder ‘would create pressure on the velocity fuse forcing the fuse to, close. This blocks the oil from exiting the oylinder. Not: Te 2se0r23e6 Pst TF 27102738 PSI Pump & Motor During normal operation, oil exting the tit cylinders enters the liviower manifold block through the open envelope (envelope without a check valve) of solenoid valve SV which isinthe energized position. lis directed from SV tothe flow control valve FC. FC limits the maximum oll rate to 5 gpm. The cil exits the flow control valve and out of the manifold through port T. From port, the oil enters the return line fitter then back tothe reservoir. For accumulator operation, see previous page. === sucTION Free Lit Cylinder Mast Gylindor ILLUSTRATION 3 01 REV. 4/97 M2.0-7330-003 M2.0-7330-003Cnown MAINTENANCE Lift Circuit - Two Speed Lift/Lower LOW SPEED LIFT When the lift button is depressed to the first detent, oil is drawn from the hydraulic reservoir to hydraulic pump P1 ‘The hydraulic pump supplies pressurized oil to the lifvlower manifold block. The oil enters the manifold block through the port P1 and goes directly to check valve CV2. The ollpasses through the manifold block untiitexits portC. Pressurizedoll ‘enters the lift cylinders and begins to extend the mast. HIGH SPEED LIFT ‘When the lift button is completely depressed, pump P2tums ‘on simultaneously with pump P1. The hydraulic pump P2 supplies pressurized oi to the liftlower manifold block. The il enters the manifold block through port P2 and goes directly to check valve CV4. This oil passes through the manifold block where it joins the oil supplied from the pump P1 out to the lift cylinders. ‘SUCTION PRESSURE |ETURN ~ RELIEF ne ‘Accumulator Te 234012365 Psi SOFs! TF 27102798 PSI Precharge Relief Valve Operation During the fit function, relief valve V1 monitors hydraulic pressure. Oil pressure exceeding the relief pressure setting will force RV1 open, allowing the pressurized oil to bypass the lift citcult. Oil exits the manifold block through port T. From por T, cilpasses through the return lie fitter then back to the reservoir. Accumulator Operation The accumulator is used as a shock absorber for the lit! lower hydraulic system. Ifthe platform is stopped suddenly, the change in oil flow exerts pressure on the hydraulic system, The accumulator absorbs this oil pressure change by using the gas pressurized bladder located within the accumulator. The bladder acts as a pillow to the pressurized oll, cushioning the applied pressure within the hydraulic Circuit. The typical symptom of a bad or de-pressurized ‘accumulator is abrupt starting and stopping of the platform during lift or lower. ThMast Free ut Cylinder ILLUSTRATION 4 Grom ieee rneaTea Ren aa 01 REV. 4/97 M2.0-7330-004 M2.0-7330-004chown MAINTENANCE Lower Circuit - Two Speed LiftvLower When lower is selected, cil begins to exit the lft cylinder. Oil leaving the cylinder is monitored by the internal velocity fuse in each cylinder. Velocity fuses are designed to prevent sudden release of hydraulicollfromthe cylinder underacondition suchasalline rupture. Ifa cylinder line ruptures, the ol exiting the cylinder ‘would create pressure on the velocity fuse, forcing the fuse to close. This will block the ol from exiting the cylinder. LOW SPEED LOWER, When the lower button is depressed to the first detent, oil exits the lit cylinders and enters the lifvlower manifold block through port C. The oil passes through the open envelope (envelope without a check valve) of the solenoid valve SV1 Which isin the energized position. Oilis directed from SV1 to the flow control valve FC1. FC1 limits the maximum oil rate to 5 gpm. Once the oil exits FC1, itis directed out of the manifold through port T. Frompor’T, the oilentersthe return line iter then back to the reservoir. = SUCTION PRESSURE | RETURN | RELIEF | Note ‘Te 34012365 PSI Tr27102738 PSI HIGH SPEED LOWER) When the lower switch is completely depressed, solenoid valve SV2 energizes simultaneously with solenoid SV1. The hydraulic flow rateisnow doubled. Oilis directed through the ‘open envelope of solenoid valves, SV1 and SV2 to the flow control valves, FC1 and FC2. These valves limit the maxi- mum oil rate for high speed lower to 5 gpm. SV1 and SV2 energize simuttaneously permitting a flow rate of 10 gpm to retum back totank. Once the oil exits the flow control valves, itis directed out of the manifold through port T. From port T, oil enters the return line filter then back to the reservoir. For accumulator operation, see previous page. Free Litt Cylinder Cylinder ILLUSTRATION 5 01 REV. 4/97 M2.0-7330-005 M2.0-7330-005GQnowh MAINTENANCE MANUAL LOWER CIRCUITS Themanualloweringfeatureisusedtolowerthemastduring is directed to the manual lowering valve's open envelope truck down situations. The manual lowering valve MV1 is _ (envelope without check valve). Oilexits the manifold through located on the raise/lower manifold block. When MV1 is port T. From port, the oil enters the return line fiter then actuated. oiltrapped inthe cylinderis released. Oilentersthe back to the reservoir. raise/lower manifold through port C. From port C the cil flow ‘Manual Lower - One Speed Lift/Lower ‘Accumulator 500 Pst Precharge ow ». Now: Te za402965 Pst TF 271012735 PS! LivLower Manifold? ace Pump & Motor i Me Lower-Two Speed LifyLower ‘Accumulator Note: S00 ps1 ‘TL 2340/2365 Ps! Trario2735 PSI Precharge se ILLUSTRATION 6 01 REV. 4/97 M2.0-7330-006 M2.0-7330-006MAINTENANCE With allcylinders in the retracted position andatterallairhas been bled from the hydraulic system, il resenvoirsothatthe cillevel is at the high mark on the reservoir sight gauge. The total capacity of the hydraulic system at this level should be approximately 3.5 gallons (13 litres) for trucks with one speedlift, and 4.5 gallons (17 litres) for trucks with wo speed it, ILLUSTRATION 7 Hydraulic Lines and Fittings 1. Blow air through all hose and lines to remove loose particles before installing. Any rubber hose with wire braid inner construction and any steel tube lines which have been collapsed or kinked are permanently dam- aged and must be replaced even if the damage is not externally visible, 2. Flexible hose must be replaced fit collapses in normal operating position. 3. All hoses and lines are to be clear of any suriace or edge which will cause damaging wear and cuts, or on which they can become caught. 4, All;connections are to be leak free. 5. The beaded elbows in suction ports of all pumps must. be positioned such that the suction hose retains its full volume flow and does not collapse. Som oa proneT Raa A\warnina AVOID HIGH PRESSURE FLUIDS—Escaping fluid under pressure can penetrate the skin caus- ing serious injury. Relieve pressure before dis- connecting hydraulic lines. Tighten all connec- tions before applying pressure. Keep hands and ‘bodyaway from pin holes which eject fluids under . ». high pressure. Useapiece of cardboard or paper 10 search for leaks. Do not use your hand. Any fiuid injected into the skin under high pres- ‘sure should be considered as a serious medical ‘emergency despite an initial normal appearance ofthe skin. There is a delayed onset of pain, and Serious tissue damage may occur. Medical atten- tion should be soughtimmesiately by a specialist who has had experience with this type of injury. Filter The spin on fiter cartridge has been tightened by Crown. ‘When replacing fiter, apply a film of oi! 063001-001 to the ‘seal and hand tighten until seal snugly contacts filter head. NOTE Do not tighten fiter with the use of a wrench. A wrench should only be used for removal of the fiter. Use only a good grade of hydraulic oll such as Mobil DTE 24 (Crown No. 063001-001) or equal. On trucks equipped to operate in below freezing temperatures, Mobil Aero HFA or ‘equal is recommended (Crown No. 063001-006) in a 50/50 blend with standard hydraulic oi NOTE Do not use hydraulic brake fluid. 01 REV. 4/97 M2.0-7330-007 M2.0-7330-007Cnown MAINTENANCE DRIFT TEST All drift tests should be conducted with a capacity load (refer to serial plate for the rated capacity of your truck). The material used forthe test load must be evenly stacked within the limits of a four foot square pallet and must be secured to the fork carriage with the forks spread to their maximum width, Ay CAUTION Never stand or work under a suspended load. Lift Drift Test Elevate the test load above staging height. After five min- utes, measure the distance the forks have drifted. Drifting in excess of 0.5 inches (12.5mm) over a five minute period is considered unacceptable. NOTE The lift measurementis to be taken from the tip of the fork to the floor. ‘Occasionally, a slight creep of the fork assembly may occur {due to internal leakage in the piston pack, but it can also be ‘caused by leakage in check or manifold valves. To seat these valves properly when this occurs, lft and lower the forks to flush out any foreign material from the valve seat. ‘A thorough check for leaks in the system should be con- ducted if abnormal oil losses occur. The hydraulic system is designed to eliminate mechanical damage even it fittings become loose. oun toe PEIOHE a Ran ABT 01 REV. 4197 M2.0-7330-008 Freeh vea M2.0-7330-008cqnown MAINTENANCE FREEZER PREPARATION Crown trucks may requite a mixture of low temperature hydraulic oil, Crown P/N 063001-006 (gal.), blended with standard hydraulic oil, Crown P/N 083001-021 (gal.) when used in a freezer or cooler. 100% low temperature oil is too thin for most cold storage operations and therefore could shorten the life of cylinder packings and pumps if used in higher ambient temperatures. NOTE Trucks equipped with velocity fuses may experi- ence staging issues if an insufficient mix of low temperature oil has been used. For truck applications operating continually in temperatures at or above 40 degrees Fahrenheit, use 100% standard hydraulic oll Fortruck applications primarily operating inacooler environ- ment with intermittent freezer entry, use a 50/50 blend, 50% low temperature (068001-006) and 50% standard hydraulic oil (063001-021). For truck applications primarily operating in a freezer environ- ‘ment, use an 80/20 blend, 80% low temperature (063001-006) and 20% standard hydraulic oll (063001-021). ‘The proper mixture of freezer hydraulic oil will ensure the best and most efficient operation of your Crown equipment. 50/50 Mix of Low-Temp (063001-006 (50%) & Standard Hydraultc Oi (063001-021 [50%)) Standard Hydraulic Oil (063001-001 [100%}) 80/20 Mix of Low-Temp (083001-006 [80%] & ‘Standard Hydraulic (063001-021 [20%)) SP Models = ILLUSTRATION 8 Som na Pranea Ra me Frmanven 03 REV. 1/98 M2.0-7330-009 M2.0-7330-009cCnown HYDRAULIC SYSTEM The hydraulic system in your truck is powered by gear type pumps. These pumps, P1 & P2, supply cil flow for lift and accessory functions. Maximum pressure is limited by an adjustable relief vaive, RV1, (refer to section M2.4). The setting for RV1 is noted on TWO SPEED LIFT Manual Release Quick Disconnect, Valve MV Test Point Manifold Pump Mot Pump P1 Pump P2 Strainer Valve MV4 oy eS) LitvLower ; Sight Gauge Reservoir Pump Motor M3 ‘Accumulator the hydraulic schematics. Refer to the service manual index for pump, valve and manifold information. The illustration below shows hydraulic component location in the power unit. ONE SPEED LIFT ‘Quick Disconnect Manual Release Test Point for Ma san ILLUSTRATION 1 M2.0-7330-010 M2.0-7330-010chown HYDRAULIC SYSTEM Hydraulic Circuits ‘These pages contain a brief description of the hydraulic circuits for SP trucks which are typical of current standard units. Your unit may vary. Refer to section HYD in this manual for appropriate schematic. Lift Circuit - One Speed Litt/Lower ‘When liftis selected, oils drawn from the hydraulic reservoir to hydraulic pump P1. P1 supplies pressurized oil to the lift! lower manifold block. The oll enters the manifold block through port P1 and goes directly to check valve CV1. Oil passes through the manifold block until it exits port C Pressurized oil enters the lift cylinders and begins to extend the mast. SAV1 Setting: TL 161310 1631 MPa ‘Accumulator Relief Valve Operation During the lit function, relief valve RV1 monitors hydraulic, pressure. Ici pressure exceeds the relief pressure setting, the relief valve is forced open, allowing the pressurized oil to, bypass the lft circuit. From the relief valve, oil exits from the manifold block through port T. From port T, oll passes through the return tine fter then back to the reservoir. ‘Accumulator Operation The accumulator is used as a shock absorber for the lift! lower hydraulic system. If the platform is stopped suddenly, the change in oil flow exerts pressure on the hydraulic system. The accumulator absorbs this oil pressure change by using the gas pressurized bladder located within the accumulator. The bladder acts as a pillow to the pressurized cil, cushioning the applied pressure within the hydraulic citcuit. The typical symptom of a bad or de-pressurized accumulator is abrupt starting and stopping of the platform during lit or lower. SUCTION PRESSURE RETURN AEUEF ILLUSTRATION 2 M2.0-7330-011 M2.0-7330-011Cnown HYDRAULIC SYSTEM Lower Circuit - One Speed LiftLower ‘When lower is selected, oil begins to exit the lft cylinder. Oil leaving the cylinder is monitored by the internal velocity fuse in each cylinder. Velocity fuses are designed to prevent the sudden release of hydraulic oil from the cylinder under such conditions as a rupture. Ifa cylinder line ruptured, the oil exiting the cylinder would create pressure on the velocity fuse forcing the fuse to close. This blocks the oil from exiting the cylinder. “AV Setting: aa Teese Accumulate RElier sr {92910 oar 8 Peres) resi deo pen ic “stories Ta During normal operation, ol exting the lit cyinders enters the lfvlower manifold block through the open envelope (envelope without a check valve) of solenoid valve SV which is in the energized position. Oilis directed from SV to the flow control valve FC. FC limits the maximum ollrate to 191m ( gpm). The oil exits the low control valve and out of the manifold through port T. From por, the oil enters the return line fiter then back fo the reservoir For accumulator operation, see previous page. ILLUSTRATION 3 M2.0-7330-012 M2.0-7330-012