HYDRAULIC

Hydraulic System

Hydraulic System • Beaded elbows in suction ports of all pumps must

WARNING
Avoid High Pressure Fluids - Escaping fluid under
pressure can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic lines.
Tighten all connections before applying pressure.
Keep hands and body away from pin holes which eject
fluids under high pressure. Use a piece of cardboard or
paper to search for leaks. Do not use your hand. Any
fluid injected into the skin under high pressure should
be considered as a serious medical emergency despite
an initial normal appearance of the skin. There is a de-
layed onset of pain and serious tissue damage may oc-
cur. Medical attention should be sought immediately
from a specialist who has had experience with this type
of injury.
Hydraulic Lines and Fittings
• Blow air through all hoses and lines to remove
loose particles before installing.
• Any rubber hose with wire braid inner construction
and any steel tube lines which may have been
twisted, bent, kinked or collapsed are permanently
damaged and must be replaced even if the dam-
age is not externally visible.
be positioned such that the suction hose retains its
full volume flow and does not collapse.
Reservoir
Capacity
NOTE
Hydraulic oil level should be checked at normal operat-
ing temperature, 20° to 60° C (70° to 140° F), with the
mast and forks fully lowered and all cylinders in the re-
tracted position.
The reservoir (1) is part of the power unit frame. The oil
level on the breather/dipstick (2) should be no lower
than the lowest ADD mark and below the FULL mark
(refer to chart on next page). Hydraulic oil expands as
it heats. If the reservoir is overfilled, oil may leak from
the breather.
Hydraulic oil should be checked every 500 hours (ap-
proximately 3 months) and changed every 3000 hours
(approximately 18 months). Refer to Planned Mainte-
nance in the Lubrication & Inspection section to select
the appropriate hydraulic oil.

• Flexible hoses shall be replaced immediately if any

of the following conditions exist:
– Collapses under normal operating position
– Abraded areas
– Twists or kinks
– Leaks
– Swelling
– Cuts
– Flat spots
– Damaged couplings
– Hot-spot damage

• All hoses and lines are to be clear of any surface or

edge which will cause damaging wear and cuts, or
on which they can become caught.

• All connections are to be leak free.

Figure 19993

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Reservoir Capacity at FULL Mark

Capacity
Series
Liters Gallons
C-5 Cushion 41.6 11
C-5 Pneumatic 53.0 14

Filters
Refer to Figure 19993.

Hydraulic Tank Breather

The breather filter is part of the breather/dipstick (2).
The breather filter is located within the breather cap.
Both the breather/dipstick and foam filter (3) should be
inspected for clogging during regular planned mainte-
nance intervals. Replace the breather filter or foam fil-
ter if excessively dirty or clogged. Refer to planned
maintenance for suggested intervals.

Hydraulic Tank Suction Strainer

The suction strainer (5) should be inspected and
cleaned every 3000 hours (approximately 18 months). Figure 19993
To inspect the suction strainer, the hydraulic reservoir
(1) must first be drained by removing the drain plug (6)
on the bottom of the tank. After the tank has been
drained, remove, clean, and reinstall the suction
strainer.

Hydraulic Return Filter

The return filter element is located with the return filter
assembly (7) and should be changed every 2000 hours
(approximately 12 months).

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Drift Tests
All drift tests should be conducted with a capacity load
(refer to capacity plate for the rated capacity of your
truck). The material used for the load test must be
evenly stacked within the limits of a 1.2 m x 1.2 m (4 ft
x 4 ft) pallet and must be secured to the fork carriage
with the forks spread to their maximum width.
CAUTION
Never stand or work under a suspended load.
Lift Drift Test
NOTE
Lift drift test must be performed with the operator pres-
ence switch activated. The lift measurement is to be
taken from the heel of the fork to the floor.
1. Ensure the manual lowering valve (1) is closed.
Refer to Figure 19995.
4. Repeat the drift test. If drift still exceeds the accept-
able limit, refer to Hydraulic System Troubleshoot-
ing in this section for further instruction.
Tilt Drift Test
1. Cycle tilt forward and back several times before
testing.
2. Raise forks with maximum rated load 610 mm
(24.0 in) off the floor.
3. With the forks tilted back completely, forks may not
drift more than 16 mm (0.63 in) within five minutes
The drift measurement is to be taken on the tilt cyl-
inder rod.
4. If drift exceeds the acceptable limit, refer to Hy-
draulic System Troubleshooting in this section for
further instruction.

Figure 19995

2. Fully raise forks with maximum rated load. The

load may not drift down more than 50 mm (2.0 in)
within five minutes. The lift measurement is to be
taken from the heel of the fork to the floor.
3. Occasionally, a slight creep of the fork assembly
may occur due to internal cylinder seal leakage,
but it can also be caused by leakage in the check
valves, control valve, etc. To seat these valves
properly when this occurs, raise and lower the
forks to flush out any foreign material from the
valve seat.

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Cylinder and Circuit Bleeding

NOTE
Hydraulic oil level should be checked at normal operat-
ing temperature, 20° to 60° C (70° to 140° F), with the
mast and forks fully lowered and all cylinders in the re-
tracted position.
After all air has been bled from cylinders, verify oil level
in hydraulic reservoir is between ADD and FULL marks
on the hydraulic breather/dipstick. Hydraulic oil may
need to be added to reservoir. Hydraulic oil expands as
it heats. If the reservoir is overfilled, oil may leak from
the breather. Do not overfill.

CAUTION
Do not attempt to bleed a line by cracking an o-ring
face seal fitting. This will result in damaging the o-ring
which then must be replaced to prevent hydraulic fluid
leakage.

Lift Circuit
Refer to Figure 19994.
1. Slowly elevate empty carriage to approximately
1.2 m (4 ft).
2. Be prepared to catch hydraulic oil.
3. If mast is equipped with carriage cylinder, carefully
open carriage cylinder bleed screw (2) and bleed
air from cylinder until a solid stream of oil flows out
of cylinder.
4. Tighten the bleed screw to 7.6 Nm (5.6 ft lb).
5. Continue raising carriage until mast cylinders ex-
tend approximately 1.2 m (4 ft).
6. Carefully open each mast cylinder bleed screw (1)
and bleed air from cylinder until a solid stream of oil
flows out of cylinder.
7. Tighten the bleed screws to 7.6 Nm (5.6 ft lb).
Figure 19994
Tilt Circuit
Carriage hydraulic circuits need to be flushed after re-
pair of tilt cylinder and bled of all air. Before flushing
and bleeding of system, inspect all hydraulic connec-
tions, verify all filters are installed and hydraulic levels
are correct. The hydraulic system must be pressurized
during the flushing and bleeding procedure.
Tilt Cylinder Bleeding
1. Start the truck.
2. Tilt the mast completely forward.
3. Tilt the mast completely back.
4. Repeat this complete cycle, totally forward and
then completely back, a minimum of 10 times.
5. If it is suspected that any air is still in the system,
repeat the process.
Refer to Cylinders section for addition information on
tilt cylinders.

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CAUTION
Do not attempt to bleed a line by cracking an o-ring
face seal fitting. This will result in damaging the o-ring
which then must be replaced to prevent hydraulic fluid
leakage.

Sideshift Circuit
1. Actuate the sideshift lever fully in one direction and
hold for one minute.
2. Cycle the sideshift cylinder left and right approxi-
mately 10 times.

Steer Cylinder Circuit

1. Start the truck.
2. Rotate the steering wheel from lock to lock approx-
imately 10 times.
3. Check steering for an equal number of revolutions,
lock to lock in both directions. There should be ap-
proximately three and three-quarter revolutions, no
more than four revolutions.
4. If there are more than four revolutions, lock to lock,
in either direction, then repeat the procedure until
the correct number of rotations is obtained.

Power Brake Circuit

Refer to Power Brake System chapter.

Park Brake Circuit

Refer to Power Brake System chapter.

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Hydraulic System Troubleshooting

NOTE
Regardless of symptom, conduct Basic Hydraulic In-
spection before proceeding with any specific trouble-
shooting steps. If the recommended actions do not cor-
rect the issue, consult Crown Service Department for
additional support.

Basic Hydraulic Inspection

WARNING
Avoid High Pressure Fluids - Escaping fluid under
pressure can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic lines.
Tighten all connections before applying pressure.
Keep hands and body away from pin holes which eject
fluids under high pressure. Use a piece of cardboard or
paper to search for leaks. Do not use your hand. Any
fluid injected into the skin under high pressure should
be considered as a serious medical emergency despite
an initial normal appearance of the skin. There is a de-
layed onset of pain and serious tissue damage may oc-
cur. Medical attention should be sought immediately
from a specialist who has had experience with this type
of injury. Figure 19993

NOTE Hydraulic Oil Symptoms

Hydraulic oil level should be checked at normal operat-
Abnormal Hydraulic Oil Usage
ing temperature, 20° to 60° C (70° to 140° F), with the
mast and forks fully lowered and all cylinders in the re- Refer to Figure 19993.
tracted position.
If hydraulic oil is leaking from the hydraulic tank
Refer to Figure 19993. breather, complete the following steps:
1. Check the oil level in the hydraulic reservoir tank, 1. Complete Basic Hydraulic Inspection.
add oil as needed.
2. Clean any dirt or debris from the top of the tank.
2. The oil level on the breather/dipstick (2) should be
3. Remove the filter plate (8) from the tank.
no lower than the lowest ADD mark and below the
FULL mark. Hydraulic oil expands as it heats. If the 4. Ensure the baffles (10) are in place. Reposition if
reservoir is overfilled, oil may leak from the necessary.
breather.
5. Reinstall the filter plate.
3. Inspect the hydraulic tank breather filter within the
6. Check for leaks.
breather/dipstick (2) and the foam filter (3). Re-
place the breather/dipstick or foam filter if exces-
Foaming Hydraulic Oil/Overheating
sively dirty or clogged.
Refer to Figure 20078-02.
4. Inspect the hydraulic system for loose fasteners/
hose clamps/leaks or obvious damage. Replace or If the hydraulic pump, motor or oil is overheating, or if
repair components as necessary. hydraulic oil is foaming, complete the following steps:

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1. Complete Basic Hydraulic Inspection. – If the correct pressure cannot be obtained, re-
lieve hydraulic pressure and replace the sec-
2. Check hydraulic oil.
ondary relief valve.
– Ensure oil is of correct type and viscosity. Refer
– With the engine OFF, open the manual lower-
to Lubrication and Adjustment maintenance
ing valve.
section to select appropriate hydraulic oil.
– Disconnect the pressure gauge.
– Check oil for contamination by water or other
substances. – Close the manual lowering valve.
3. Check load.
– Ensure load being carried is within truck capac- Relief Valve Pressure Setting Chart
ity. Refer to capacity plate for the rated capacity
of your truck. Pressure Setting
Truck
4. Inspect primary relief valve (2). Capacity Primary Relief Secondary
Valve Relief Valve
– Turn the engine OFF.
1814 kg
– Open the manual lowering valve. (4000 lb) 21.4 MPa 17.9 MPa
– Connect a 34.5 MPa (5000 psi) gauge to the 2268 kg (3100 psi) (2600 psi)
diagnostic nipple (4). (5000 lb)
– Close the manual lowering valve. 2722 kg
– Start the engine. (6000 lb) 24.1 MPa 21.4 MPa
2948 kg (3500 psi) (3100 psi)
– With the seat switch ON (operator present), op-
erate the lift function. Raise the mast to its full (6500 lb)
extension and continue to command the lift
function.
– Make note of the pressure reading obtained.
– Adjust the primary relief valve (clockwise to in-
crease pressure) to correct pressure reading.
Repeat step 4 until the correct pressure is ob-
tained.
– If correct pressure cannot be obtained, turn en-
gine OFF, relieve hydraulic pressure and re-
place primary relief valve.
5. Inspect secondary relief valve (3).
– Ensure the manual lowering valve is closed.
– Start the engine.
– With the seat switch ON (operator present), op-
erate the tilt function. Continue to command the Figure 20078-02
tilt function after the cylinders have reached full
stroke. 6. For trucks with power brakes only, refer to Power
Brakes section to ensure that the priority flow di-
– Make note of the pressure reading obtained. vider and the accumulator charge valve are both
Turn engine OFF. working properly.
– Adjust the secondary relief valve (clockwise to
increase pressure) as necessary to correct the
pressure reading. Repeat step 5 until the cor-
rect pressure is obtained.

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Mast Functions
Mast Functions - General
If lift function or all mast functions do not operate prop-
erly, complete the following procedures:
1. Complete Basic Hydraulic Inspection.
2. Check load and application.
– Ensure load being carried is within truck capac-
ity. Refer to capacity plate for the rated capacity
of your truck.
– Check to see that operator request is within the
Lift/Tilt interlock envelope.
3. Inspect the mast.
– Check for debris, damage, binding, misalign-
ment (i.e. shimming), etc. Correct if necessary.
4. Check main interlock valve (MAIN_SOL).
– Enter Field Service Mode, Analyzer Menu, A3
Outputs submenu. Navigate to MAIN_SOL.
Check to see that the coil is ON when an oper-
ator is in the seat, the forks are below free lift
and tilt is level. If not, refer to Wiring Diagrams
to troubleshoot and diagnose the issue.
– Turn the engine OFF.
– Open the manual lowering valve.
– Connect a 689 kPa (100 psi) gauge to the diag-
nostic port (4).
– Close the manual lowering valve.
– Start the engine.
– Ensure seat switch is ON (operator present).
NOTE
Do not actuate any hydraulic functions. If all functions
are working properly, pressure could spike up to
24.1 MPa (3500 psi) in this circuit.
– The pressure gauge should read 6.9 to
276 kPa (1 to 40 psi).
– Turn the engine OFF.
– Open the manual lowering valve.
– Remove pressure gauge, diagnostic nipple and
adapter. Reinstall hex head plug.
– Close the manual lowering valve.
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– If correct pressure was not obtained, then re-
lieve hydraulic pressure and replace main in-
terlock valve and/or coil as necessary.
5. Check the lift interlock valve (LIFT_SOL).
– Enter Field Service Mode, Analyzer Menu, A3
outputs submenu. Navigate to LIFT_SOL.
Check to see that the coil is ON when an oper-
ator is in the seat, the forks are below free lift
and tilt is level. If not, refer to Wiring Diagrams
to troubleshoot and diagnose the issue.
– Replace the lift interlock valve and/or coil as
necessary.
6. Check the control valve operation.
– Ensure each control valve spool moves
smoothly and returns to the center position
when the handle is released.
– Inspect the control valve spools for leakage,
bad seals, or other obvious damage; replace
seals, valve section or entire control valve as
necessary.
7. Check primary relief valve and hydraulic pump.
– Turn the engine OFF.
– Open the manual lowering valve.
– Connect a 34.5 MPa (5000 psi) gauge to the
diagnostic port (4).
– Close the manual lowering valve.
– Start the engine.
– With the seat switch ON (operator present), op-
erate the lift function. Raise the mast to its full
extension and continue to command the lift
function.
– Make note of the pressure reading obtained.
For 1814 kg (4000 lb) and 2268 kg (5000 lb)
trucks, the gauge pressure should be
21.4 MPa (3100 psi) at relief. For 2722 kg
(6000 lb) and 2948 kg (6500 lb) trucks, the
gauge pressure should be 24.1 MPa
(3500 psi) at relief.
– Continue through step 8 before taking action.
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 HYDRAULIC
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8. Check the brake accumulator pressure.
– Turn the engine OFF.
– Relieve pressure in the accumulator by press-
10. Check hydraulic tank suction strainer and pump.
ing the brake pedal a minimum of 10 times.
– Connect a 20.7 MPa (3000 psi) pressure
gauge to the quick disconnect port (1) located
on top of the accumulator. Refer to Figure
19998-01.
– If the correct pressures cannot be obtained in
either step 7or 8, even after replacing the pri-
mary relief valve, continue to step 10.
Refer to Figure 19993.
– Be prepared to catch oil.
– Remove the drain plug (6) from the bottom of
the reservoir tank (1). Drain hydraulic oil from
reservoir tank and check for debris.
– Remove and inspect suction strainer (6). If it
appears to be clogged or is retaining excessive
debris, clean the tank out, replace the suction
strainer and fill the tank with clean hydraulic oil.
Refer to Lubrication and Adjustment mainte-
nance section to select appropriate hydraulic
oil.
– Repeat steps 7 and 8.
– If the suction strainer and oil appear to be fine,
remove the hydraulic pump from the transmis-
sion and inspect the pump and shaft coupling,
replace if necessary.

Figure 19998-01

– Start the engine.

– Ensure the steer wheels are pointing in an ap-
proximate straight direction.
– Make note of pressure gauge reading. Pres-
sure should be 6.2 to 9.5 MPa (900 to
1385 psi).
– Shut the engine OFF.
– Remove the pressure gauge.
9. Take corrective action.
– If the pressure at the accumulator (step 8) is
correct, but the pressure at the control valve di-
agnostic port (step 7) is not, adjust the primary
relief valve on the control valve (clockwise to
increase pressure) and repeat step 7 until cor-
rect pressure is obtained. If correct pressure
cannot be obtained, turn engine OFF, relieve
hydraulic pressure and replace the primary re-
lief valve.
– If the pressure at the accumulator (step 8) and Figure 19993
at the control valve diagnostic port (step 7) are
both within range and all hydraulic functions
work, but at a slower rate, continue to step 10.

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Mast/Forks Drift Down

Refer to Figure 20078-01.
1. Complete Basic Hydraulic Inspection.
2. Ensure manual lowering valve is closed.
3. Complete Lift Drift Test. Refer to Lift Drift Test in
Hydraulic System. If unacceptable drift is noted,
continue to step 4.
4. Inspect the lift interlock coil and valve.
– Lower the mast completely.
– Turn the engine OFF.
– Open the manual lowering valve.
– Remove the lift interlock coil and valve.
– Inspect the valve and replace if necessary. Figure 20078-02

– Continue on to step 5 as more than one issue

may be present.
5. Inspect the lift spool (5) on the hydraulic control
valve.
– Complete Lift Drift Test again. Refer to Lift Drift
Test in Hydraulic System.
– If unacceptable drift is noted, ensure the con-
trol valve lift spool (5) is being returned to cen-
ter position.
– Inspect control valve for bad seals or other
damage. Replace seals, valve section or con-
trol valve as necessary.
– Continue to step 6 as more than one issue may
exist.
6. Inspect lift cylinders. Refer to Cylinders section for
more information on cylinders.
– Check cylinder rams for scratches or scoring.
– Check tops of cylinders for leakage past the
packing or worn packings.
Tilt Functions
Refer to Figure 20078-02.
Tilt Cylinders Drift
1. Complete Basic Hydraulic Inspection.
2. Inspect the tilt spool (6) on control valve.
3. Ensure the control valve tilt spool (6) is being re-
turned to the center position.
4. Inspect the control valve for bad seals or other
damage.
– Even without visual signs of damage, the coun-
terbalance valve located inside the control
valve tilt spool may be damaged. Proceed to
step 5.
5. Inspect tilt cylinders. Refer to Cylinders section for
more information.
– Disassemble the tilt cylinders.
– Inspect inside of cylinder housing. Look for
scratches or scoring.
– Replace the piston packings.
– Reassemble the tilt cylinders.

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Tilt Function not working properly
If lift function is also not working properly, refer to Mast
Functions - General in Hydraulic System section.
1. Inspect tilt cylinders. Refer to Cylinders section for
more information.
– Look for excessive scoring on cylinder rod or
hydraulic fluid leaking from front of cylinder dur-
ing tilt back.
– Look for mechanical obstruction of tilt cylinders
during tilt down and tilt back.
2. Inspect the tilt spool (6) on control valve.
– Ensure control valve tilt spool (6) is being re-
turned to the center position.
– Inspect control valve for bad seals or other
damage.
3. Check the secondary relief valve (3) located on the
hydraulic control valve.
– Ensure the manual lowering valve is closed.
– Turn the engine OFF.
– Connect a 34.5 kPa (5000 psi) gauge to the di-
agnostic nipple (4).
– Start the engine.
– With the seat switch ON (operator present), op-
erate the tilt function. Continue to command the
tilt function after the cylinders have reached full
stroke.
– Make note of the pressure reading obtained.
For 1814 kg (4000 lb) and 2268 kg (5000 lb)
trucks, the gauge pressure should be
17.6 MPa (2600 psi) at relief. For 2 722 kg
(6000 lb) and 2948 kg (6500 lb) trucks, the
gauge pressure should be 21.74 MPa
(3100 psi) at relief.
– Turn the engine OFF.
– If the pressure is not correct, adjust secondary
relief valve (clockwise to increase pressure) as
necessary to correct pressure reading. Repeat
step 3 until correct pressure is obtained.
– If correct pressure cannot be obtained, turn en-
gine OFF, relieve hydraulic pressure and re-
place secondary relief valve.
– Disconnect the pressure gauge.
– Close the manual lowering valve.
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HYDRAULIC
Hydraulic System
Carriage Functions
Refer to Figure 20078-02.
Carriage lowers too fast
1. Complete Basic Hydraulic Inspection.
2. Inspect the control valve.
3. Ensure the control valve lift spool (5) is being re-
turned to the center position.
– Inspect control valve for bad seals or other
damage.
4. Inspect lowering flow control valves.
– Block fork carriage in raised position. Refer to
Control of Hazardous Energy section.
– Turn the engine OFF.
– Open the manual lowering valve.
– Remove and inspect flow control valve located
in the carriage cylinder.
– Remove and inspect the lift interlock coil and
valve.
– Replace valves as necessary.
Accessory Functions
Refer to Figure 20078-02.
If lift and tilt functions are also not working properly, re-
fer to Mast Functions - General in this section.
If tilt function doesn’t operate properly, but the lift func-
tion operates correctly, go to Tilt Functions in this sec-
tion.
1. Complete Basic Hydraulic Inspection.
2. Inspect the appropriate accessory spools (7, 8) on
the control valve.
3. Ensure the control valve accessory spools (7, 8)
are being returned to the center position.
– Inspect control valve for bad seals or other
damage.
4. Check individual accessory attachments.
– Look for mechanical binding during operation.
– Look for hydraulic leakage during operation.
– Adjust accessory attachments per manufac-
turer’s specifications. Refer to Access 1 2 3®
section.
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Hydraulic System Checks & Adjustments LSPFD Relief Valve Adjustment

The following pressure checks and adjustments apply
only to trucks equipped with Power Brakes. Perform
these checks if power brakes (service and/or parking)
are not working properly, if steering is hard or jerky, or
to verify proper truck operation.
Check Steering Relief Pressure
NOTE
Adjustment location is dependant upon the truck ca-
pacity/type of pump. The pump for an 1814 & 2268 kg
(4000 & 5000 lb) truck is physically smaller than the
pump for a 2721 & 2948 kg (6000 & 6500 lb) truck. The
relief valve adjusting screws are also different for each
pump. The smaller pump has a flush mounted hex-
head adjusting screw (1). The larger pump has a pro-
truding hex-head adjusting screw with a jam nut (2).
Refer to Figure 23760.

Hydraulic oil temperature should be at least 21° C

(70° F).
1. Complete Basic Hydraulic Inspection.
2. With the engine OFF, discharge the brake accu-
mulator by pumping the brake pedal until pressure
is depleted. Pressing (and releasing) the brake
pedal five to ten times will accomplish this. An al-
ternative method is; turn KYS to the IGN (ON) po-
sition and release/apply the parking brake to re-
lieve accumulator pressure.
3. Connect pressure gauge (Crown p/n 300098 or
equivalent) to the quick disconnect port on the
brake accumulator.
4. Start the engine, let it achieve idle speed then turn
the steering wheel (in either direction) until it stops Figure 23760
and hold it in that position (steering relief).
When the pump is installed in the transmission, the ad-
5. Pressure on the gauge should be 9.9 to 10.6 MPa justing screw (1) for the smaller pump is located on the
(1435 to 1535 psi) (1485 psi is optimal). right-hand side of the pump, towards the transmission.
6. If pressure is low or high, the relief valve for the The adjusting screw (2) for the larger pump is located
Load Sensing Priority Flow Divider spool inside the on the left-hand side of the pump, towards the truck
pump needs to be adjusted. power unit. Refer to Figure 23761.

Figure 23761

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A modified 4mm L-handle hex wrench is used to ac-
cess the adjusting screw on the smaller pump. Refer to
Figure 23762.
The transmission filter can be removed if necessary to
make it easier to insert the wrench into the screw. Use
shop towels to catch spilled transmission oil and be
certain to reinstall the filter tightly before starting the
engine. Refer to Figure 23764.

Figure 23764

With the pressure gauge still connected to the accumu-

lator, start the engine. Then turn steering to the limit
(steer relief) and hold it there. Use the hex wrench to
adjust the LSPFD relief valve for a pressure of 9.9 to
10.6 MPa (1435 to 1535 psi) (1485 psi is optimal). Re-
Figure 23762 fer to Figure 23765.
Figure 23763 shows the hex wrench inserted into the
adjusting screw. NOTE
Hydraulic oil temperature should be at least 70° F be-
fore making any adjustment.

Figure 23763

Figure 23765

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Clockwise adjustment increases pressure and counter another or there is not 689 kPa (100 psi) pressure dif-
clockwise adjustment decreases pressure. If a pres- ference between low and high, then adjustment of the
sure of 9.9 to 10.6 MPa (1435 to 1535 psi) cannot be Power Brake Pressure Unloading Valve is necessary.
achieved through adjustment, the pump will need to be
replaced. Power Brake Pressure
Unloading Valve Adjustment
Once the LSPFD relief valve is adjusted, the hex
wrench can be carefully removed from the pump with- If the power brake recharge start point is 6.2 MPa
out removing the transmission filter. (900 psi) or less, or if the recharge stop point is either
greater than 9.5 MPa (1385 psi) or not 689 kPa
Power Brake Unloading Valve Pressures Check (100 psi) different than the recharge start point, then
the Pressure Unloading Valve on the Brake Manifold
With the LSPFD relief valve now adjusted to the proper
must be adjusted.
pressure, the Power Brake Unloading Valve pressures
should be checked. This check verifies the minimum
pressure at which the power brake system starts the NOTE
recharge cycle and the maximum pressure that it stops Steering Relief Pressure should be checked and
the recharge cycle. When this occurs engine idle speed LSPFD Valve Adjustment should be performed (as
will drop slightly, then rev up slightly, then return to nor- necessary) before adjusting the Pressure Unloading
mal idle rpm. Valve.
With the pressure gauge still connected to the accumu- The Brake Manifold is located on the right-hand side of
lator, the engine running at idle speed, and steering the engine and the Pressure Unloading Valve is on the
NOT turned into either stop; pump the brake pedal with rearward facing side of that manifold. Refer to Figure
your hand while watching the pressure gauge. Optimal 23766-01.
pressures are 6.6 MPa (950 psi) (engine idle drops
slightly) and 9.5 MPa (1385 psi) (engine idle recovers).
However, this can vary from truck to truck. The main
thing is that the pressures stay consistently within the
6.6 to 9.5 MPa (950 to 1385 psi) range and the low and
high readings are at least 689 kPa (100 psi) apart. For
example: 7.6 MPa (1100 psi) (engine idle drops
slightly) and 8.3 MPa (1200 psi) (engine idle recovers)
pressures are ok because they are within the 6.6 to
9.5 MPa (950 to 1385 psi) range and they are at least
689 kPa (100 psi) apart.

NOTE
If the LSPFD relief valve pressure is not set high
enough (pressure is too close to the pressure for the
Power Brake Unloading Valve), brake circuit pressure
would not drop when the pedal was pressed and you
may not notice engine idle speed dropping down at the
beginning of the brake recharge cycle. This situation is Figure 23766-01
caused by the LSPFD relief valve inside the pump stay-
ing "open" and loading the engine. This is why the first Pressure Unloading Valve adjustment is similar to the
check and adjustment to be made is Steering Relief relief pressure adjustment performed on the pump's
pressure and LSPFD relief valve adjustment. LSPFD Valve. Adjust the Pressure Unloading Valve so
It takes a minimum of 6.2 to 6.6 MPa (900 to 950 psi) that brake recharge starts (engine idle drops slightly) at
in the Power Brake system to keep the parking brakes no less than 6.6 MPa (950 psi) and the recharge stops
released. 6.6 MPa (950 psi) is good number to shoot (idle speed recovers) at no more than 9.5 MPa
for. Anything less could result in the parking brakes (1385 psi) (but at least 689 kPa (100 psi) more than
dragging. when brake recharge started).
If either the low (charge start) or the high (charge stop)
pressures are inconsistent (different) from one cycle to

M2.0-2510-014 Crown 2008 PF17392-14 Rev. 8/10

04 Rev. 8/10
114
 HYDRAULIC
Hydraulic System

If the Pressure Unloading Valve adjustment fails to

achieve consistent low and high pressures (or the
689 kPa (100 psi) pressure difference between low
and high), then the brake manifold (including the Pres-
sure Unloading Valve) should be replaced.

Pedal Pump Check

With the pressure gauge still connected to the accumu-
lator and the engine running at idle speed turn the
steering wheel into relief and hold it there, then shut
engine off. While watching the pressure gauge, count
the number of brake pedal pumps it takes to drop the
brake system to the low (charge start) pressure. You
should get at least 3 full pedal pumps before the pres-
sure drops to that point.
If you cannot achieve 3 full pumps before the brake
system pressure drops to less than 6.6 MPa (950 psi)
it could be a sign that the accumulator is not holding a
proper charge. A faulty accumulator is usually accom-
panied by a rapid charging cycle (occurs more often)
and a clicking sound.
If the accumulator tests okay, but the system cannot
achieve 9.5 MPa (1385 psi) without running the engine
and going over steer relief, then the brake manifold is
likely bad and needs replaced. There could be so much
internal leakage inside the brake manifold that the
pressure cannot turn the Pressure Unloading Valve off.
When this occurs, the brake system will charge con-
stantly, placing a load on the engine, robbing power
and potentially overheating the hydraulic oil.

Crown 2008 PF17392-15 Rev. 8/10 M2.0-2510-015

04 Rev. 8/10
115
Notes:

116