• Author / Uploaded
• Daniel Popescu

Citation preview

cmrnw

Model No. Serial No.

FC 4500 Series ...... A C

T r a c t io n ;

Service & Parts Manual

wuwniuu/ rri^ujOs/u/ Printed in U.S.A.

e ra uin

TABLE OF CONTENTS

crnwh

TABLE OF CONTENTS

TABLE OF CONTENTS SAFETY

PAGE

G eneral M aintenance In s tru c tio n s ................................................ 3 C leaning o f M aterial H andling E q u ip m e n t................................... 5 Cleaning M ethods......................................................................... 5 C o n trol o f Hazardous E n e rg y ........................................................ 7 Lockout/Tagout..............................................................................7 B atte ry.............................................................................................7 Safety Rules ............................................................................7 Battery C a re ..............................................................................7 Charging ..................................................................................7 Battery Removal ..................................................................... 8 Battery In sta lla tio n ................................................................... 8 Lockout - Tagout ..................................................................... 8 Capacitance ..................................................................................9 H yd ra ulic...................................................................................... 10 Lifting and B locking......................................................................11 Mast .............................................................................................12 Blocking M asts........................................................................12 Disconnect Tilt Cylinder ............................................................. 15 Removing M a s t............................................................................16 Removing C ounterw eight...........................................................17

INTRODUCTION

PAGE

In tro d u ctio n .................................................................................... 21 Operation Instructions................................................................. 21 Operator Training ....................................................................... 21 Service Training ......................................................................... 21 Replacement P a rts ..................................................................... 21

LUBRICATION & ADJUSTMENT

PAGE

L u b rica tio n and A d ju s tm e n t.........................................................27 L u b rica tio n & A d ju s tm e n t.............................................................33 Component A ccess..................................................................... 33 Battery C o ve r......................................................................... 33 Left Side Step Cover .............................................................33 Right Side Step C o v e r...........................................................33 F lo o rb oa rd s........................................................................... 33 Steering Column Covers ...................................................... 33 D ashboard..............................................................................33 Control Lever C over............................................................... 34 Contactor Assembly Cover .................................................. 34 Fan and Controller Cover .................................................... 34 Lubrication ..................................................................................34 C o m p o n e n try .................................................................................. 53 ACCPOT1 ..................................................................................53 A C S ...............................................................................................53 ACCUMULATOR ....................................................................... 53 ACCESS 1 ..................................................................................54 ACCESS 2 ..................................................................................54 ACCESS 3 ..................................................................................54

TABLE OF CONTENTS c jia u in ALM1 ............................................................................................55 A L M 2 ............................................................................................55 ALM3 (O ptional)...........................................................................55 AXS1 ............................................................................................56 AXS2 ............................................................................................56 AXS3 ............................................................................................56 B R E S ........................................................................................... 57 BREATHER ............................................................................... 57 B R K S ........................................................................................... 57 C B V ............................................................................................. 58 C YLIN D ER ................................................................................... 58 C YLIN D ER ................................................................................... 58 C YLIN D ER ................................................................................... 59 C YLIN D ER ...................................................................................59 C YLIN D ER ...................................................................................59 DIPSTICK ...................................................................................60 DISTRIBUTION P A N E L..............................................................60 ECR1 ........................................................................................... 60 E C R 2 ........................................................................................... 61 FAN1 & FAN 2...............................................................................61 FAN3 (O p tion a l).......................................................................... 61 FAN4 ........................................................................................... 62 FAN5 ........................................................................................... 62 FIL ................................................................................................62 FILTE R ......................................................................................... 63 FNS (O p tion a l)............................................................................ 63 FS ................................................................................................63 FU1 ............................................................................................. 64 FU2 ............................................................................................. 64 FU3 ............................................................................................. 64 FU4 ............................................................................................. 65 FU5 ............................................................................................. 65 FU6 ............................................................................................. 65 FU7 ............................................................................................. 66 FU8 ............................................................................................. 66 FU11 (O p tio n a l).......................................................................... 66 FU12 (O p tio n a l).......................................................................... 67 HAND P U M P ...............................................................................67 HGTS1 ......................................................................................... 67 HN1 ............................................................................................. 68 H N S ............................................................................................. 68 HR1 ............................................................................................. 68 HR2 ............................................................................................. 69 HSS ............................................................................................. 69 INFOLINK MODULE (O p tio n a l)................................................. 69 IMPACT SENSOR (O ptional)..................................................... 70 K 1 .................................................................................................. 70 K 2 .................................................................................................. 70 K11 (Optional) .............................................................................71 K12 (Optional) ............................................................................ 71 KYS ............................................................................................. 71 L .................................................................................................... 72 LGS1 (O p tion a l).......................................................................... 72 LGS2 (O ptional).......................................................................... 72

IV

ovauih

TABLE OF CONTENTS

LG T1,2, 3 (Optional) ................................................................. 73 L G T 4 .............................................................................................73 LGT5, 6 ........................................................................................ 73 M 1 .................................................................................................74 M 2 .................................................................................................74 M 3 ................................................................................................. 74 MANUAL RELIEF V A LV E ...........................................................75 M P C E .......................................................................................... 75 P ................................................................................................... 75 PRESSURE CHECK P O IN T...................................................... 76 PRK-A, PRK-B ........................................................................... 76 12V POWER SUPPLY ...............................................................76 P S 1 ...............................................................................................77 P um p............................................................................................ 77 P um p............................................................................................ 77 R A S ...............................................................................................78 RES2 (O p tio n a l)......................................................................... 78 RES3 (O p tio n a l)......................................................................... 78 R S .................................................................................................79 R V 1 ...............................................................................................79 R V 2 ...............................................................................................79 R V 3 ...............................................................................................80 S ................................................................................................... 80 SB80 (Optional) ......................................................................... 80 SCU ............................................................................................ 81 S E S ...............................................................................................81 S E S 1 .S E S 2 ................................................................................81 S tra in e r........................................................................................ 82 Suction ........................................................................................ 82 S V 1 ...............................................................................................82 S V 2 ...............................................................................................82 S V 3 ...............................................................................................83 T B S .............................................................................................. 83 THS1 (Optional) ......................................................................... 83 THS2 (Optional) ......................................................................... 84 TLMS .......................................................................................... 84 TLT .............................................................................................. 84 TMM ............................................................................................ 85 TS1 ............................................................................................... 85 T S 2 ...............................................................................................85 U L V ...............................................................................................86 V ALV E .......................................................................................... 86 V A LV E .......................................................................................... 86 Metric Torque V alu e s ..................................................................... 87 Grade .......................................................................................... 87 Torque V alues..................................................................................89 Grade .......................................................................................... 89

TABLE OF CONTENTS HYDRAULIC

cjiaum PAGE

H ydraulic System ...........................................................................93 Hydraulic Lines and F ittin g s....................................................... 93 R e s e rv o ir..................................................................................... 93 Capacity ................................................................................. 93 Filters ..................................................................................... 94 Drift T e s t....................................................................................... 95 T ilt Drift Test ...........................................................................95 Lift Drift Test .......................................................................... 95 Cylinder and Circuit B leeding..................................................... 95 Lift Circuit ...............................................................................96 Tilt Circuit ...............................................................................97 Sideshift C irc u it...................................................................... 97 Steer Cylinder Circuit ............................................................97 Service Brake Circuit ............................................................98 Park Brake C irc u it.................................................................. 98 H ydraulic C irc u itry ........................................................................ 99 Accumulator and Unloading V a lv e ...........................................103 Spring Apply/Hydraulic Release Park Brake ..........................104 H ydraulic S chem atic S y m b o ls ................................................... 119 L ift P u m p ....................................................................................... 123 Disassem bly............................................................................... 123 Mounting Flange And End C o ve r............................................. 124 A sse m b ly................................................................................... 124 C ontrol V a lv e ................................................................................. 125 Relief Valve RV1 O p e ra tio n ..................................................... 125 Relief Valve RV2 O p e ra tio n ..................................................... 125 Adjustment of RV1 & R V 2 ................................................... 126 Main Pressure Compensating Element (MPCE) Operation . 127 Control Valve Disassembly ......................................................128 Control Valve Inspection & R e p a ir...........................................129 Control Valve A ssem bly............................................................ 129 Adding 4th Spool Valve S e c tio n ............................................... 130 H ydraulic M anifold B lo c k s ..........................................................133 M a n ifo ld s ................................................................................... 133 Tilt M anifold...........................................................................133 Park Brake Release M a n ifo ld ............................................. 133 Accessory M anifold.............................................................. 133 Manifold Block Component Replacem ent.......................... 134

DRIVE UNIT

PAGE

Drive U n it....................................................................................... 137 Drive Unit Lubrication................................................................ 137 Drive Unit Oil C h a ng e ..........................................................137 Drive Unit Mounting Bolts ........................................................137 Drive Tire R eplacem ent............................................................ 138 Traction Motor (M 1 ).................................................................. 138 Traction Motor Removal ..................................................... 139 1st Reduction Pinion Installation.........................................142 Installation of Traction M o to r............................................... 142 Axle Hub and Axle In sta lla tio n ................................................. 143 Drive Unit Removal .................................................................. 144 Drive Unit Installation ..........................................................145

VI

ovaiurt ELECTRICAL

TABLE OF CONTENTS PAGE

E le c tric a l.........................................................................................149 Access 1 - Display Control Module (D C M )............................. 149 S w itc h e s .........................................................................................151 AXS1, AXS2, T L T ..................................................................... 151 R A S ............................................................................................. 152 T B S ............................................................................................. 154 H S S ............................................................................................. 155 A C S ............................................................................................. 156 HGST1 .......................................................................................156 SES1, S E S 2 .............................................................................. 157 TLMS .........................................................................................157 E lectrical S y s te m ..........................................................................159 Wiring Color C odes................................................................... 159 Power C a b le s ............................................................................159 S w itc h e s .................................................................................... 163 A ccess 1 2 3 ...S yste m ................................................................... 171 User Main Menu Level ............................................................. 171 User L e v e l.................................................................................. 171 Message Mode ................................................................... 171 H o u r...................................................................................... 172 Events .................................................................................. 173 S e rvice .................................................................................. 173 Performance ........................................................................173 Analyzer .................................................................................... 188 Analyzer Access ................................................................. 188 C alibration.................................................................................. 191 Calibration A cce ss............................................................... 191 Calibration Procedures .......................................................191 Calibration Error M essages................................................ 192 Features .................................................................................... 193 Features Access ................................................................. 193 Hour/Event/Utilities M e n u .........................................................196 Hour Meter M e n u................................................................. 196 Event M e n u ..........................................................................197 Utilities M e n u ....................................................................... 197 P erform ance.............................................................................. 198 Performance A c c e s s ....................................................... ..1 9 8 D istrib u tio n B o a rd ....................................................................... 201 Components Included On Distribution B o a rd ........................ 201 Distribution Board Jumper Configurations .............................202 P o te n tio m e te rs ..............................................................................207 Accelerator Potentiometer (POT 1 ) ..........................................207 R em oval/lnstallation................................................................. 207

VII

TABLE OF CONTENTS Contactors..................................................................................... 209 140538-001/-002 Contactor (36/48 Volt) S (S te e rin g ).........209 132084-005/-006 Contactor L (Line) & P (Pump) ................. 209 Inspection................................................................................... 209 C o n ta cts..................................................................................... 209 Steering C o n ta ctor.................................................................... 210 Coil ....................................................................................... 210 Component R eplacem ent................................................... 210 Contact R eplacem ent..........................................................210 Coil R eplacem ent................................................................210 "EE" Component R eplacem ent.........................................211 Contact R eplacem ent....................................................... 211 Coil R eplacem ent................................................................ 211 Line and Pump Contactor ....................................................... 212 C o il....................................................................................... 212 Component Replacement ....................................................... 212 Contact R eplacem ent..........................................................213 Coil R eplacem ent................................................................213 "EE" Component R eplacem ent...............................................213 Contact R eplacem ent..........................................................214 Coil R eplacem ent................................................................214 B a tte ry ............................................................................................215 Safety R u le s...............................................................................215 Checking B a tte ry ...................................................................... 215 Battery C a re ...............................................................................216 Charging Battery ...................................................................... 216 Battery Removal ...................................................................... 217 Battery In sta lla tio n .................................................................... 217 Seat Deck Cover A djustm ent................................................... 218 Seat Deck Latch A d ju stm e n t................................................... 219 Seat Deck Cylinders ................................................................220 R e m o v a l...............................................................................220 Installation.............................................................................220 Battery Cleaning ...................................................................... 222 Troubleshooting........................................................................ 222 Dual Voltage C onversion......................................................... 222 Motors ........................................................................................... 223 Event Codes .................................................................................225 Event Code 1 1 0 .............................................................................229 Event Code 111 .............................................................................231 Event Code 1 1 2 .............................................................................231 Event Code 1 1 3 .............................................................................231 Event Code 1 1 9 .............................................................................232 Event Code 123 ........................................................................... 232 Event Code 130 ........................................................................... 233 Event Code 1 3 1 .............................................................................233 Event Code 133 ........................................................................... 234 Event Code 134 ........................................................................... 234 Event Code 163 ........................................................................... 235 Event Code 164 ........................................................................... 236 Event Code 199 ........................................................................... 236 Event Code 200 ........................................................................... 237 Event Code 201 ........................................................................... 237 Event Code 202 ........................................................................... 237

VIII

CAQUJh

CAOUJh

TABLE OF CONTENTS

Event Code 203 ............................................................................238 Event Code 204 ............................................................................239 Event Code 205 ............................................................................239 Event Code 206 ............................................................................240 Event Code 207 ............................................................................240 Event Code 208 ............................................................................241 Event Code 209 ............................................................................241 Event Code 210 ............................................................................241 Event Code 214 ............................................................................242 Event Code 215 ............................................................................243 Event Code 216 ............................................................................243 Event Code 219 ............................................................................243 Event Code 220 ............................................................................243 Event Code 221 ............................................................................244 Event Code 222 ............................................................................244 Event Code 223 ............................................................................245 Event Code 224 ............................................................................245 Event Code 225 ............................................................................246 Event Code 299 ............................................................................246 Event Code 300 ............................................................................247 Event Code 301 ............................................................................247 Event Code 302 ............................................................................248 Event Code 303 ............................................................................248 Event Code 304 .............. 249 Event Code 305 ............................................................................249 Event Code 306 ............................................................................250 Event Code 307 ............................................................................250 Event Code 308 ............................................................................250 Event Code 309 ............................................................................250 Event Code 310 ............................................................................251 Event Code 311 ............................................................................251 Event Code 312 ............................................................................252 Event Code 313 ............................................................................252 Event Code 314 ............................................................................253 Event Code 315 ............................................................................253 Event Code 316 ............................................................................254 Event Code 317 ............................................................................254 Event Code 319 ............................................................................254 Event Code 320 ............................................................................254 Event Code 321 ............................................................................255 Event Code 322 ............................................................................255 Event Code 323 ............................................................................256 Event Code 324 ............................................................................256 Event Code 325 ............................................................................256 Event Code 326 ............................................................................257 Event Code 330 ............................................................................257 Event Code 399 ............................................................................257 FWD/REV ...................................................................................... 258 Creep Speed Only ....................................................................... 260 No Traction/No Lift/BDI = 0% .................................................... 260

IX

TABLE OF CONTENTS o ia m BRAKE

PAGE

Service Brake ............................................................................... 263 O p e ra tio n ................................................................................... 263 Brake P e d a l...............................................................................264 Shimming the Brake Pedal ..................................................... 265 Brake Assembly Removal ....................................................... 266 Disassembly of Brake ..............................................................266 Lining/Rotor Inner And Outer S ta to r........................................ 267 Piston, W iper and Seal R em oval.............................................267 Wiper, Seal & Piston Installation .............................................268 Service Brake Assembly ..........................................................268 Service Brake Installation ....................................................... 268 Service Brake B le e d in g ............................................................269 Drive Tire In sta lla tio n ................................................................ 269 Service Brake Adjustments ..................................................... 269 Service Brake V a lve .................................................................. 269 Parking Brake ...............................................................................271 O p e ra tio n ................................................................................... 271 Inspection................................................................................... 271 C ylin d e r.................................................................................271 Brake H u b .............................................................................272 Replacement of Brake S h o e s .............................................272 A djustm e n t.................................................................................272 Adjustments When Replacing Brake Shoes or Brake Hub . 273 Traction M o to r.......................................................................... 273 Park Brake Release Manifold ................................................. 274 Manually Releasing the Parking Brake .................................. 275 Parking Brake S o le n o id ............................................................275

STEERING

PAGE

Steering ..........................................................................................279 Hydrostatic Steering U n it......................................................... 279 Steering Column A s s e m b ly ..................................................... 280 C olum n....................................................................................... 280 Gas Cylinder .............................................................................281 Directional C o n tro l.................................................................... 282 Steering Wheel R em oval..........................................................283 Steering W h e el.......................................................................... 284 Final A ssem bly.......................................................................... 285 Steer Axle Assembly ................................................................ 285 Steer Tire .............................................................................285 Torque R equirem ents......................................................... 286 Steer Axle P ositioning..........................................................289

X

r i

cjiaum LIFTING MECHANISM

TABLE OF CONTENTS PAGE

M a s t................................................................................................. 293 Bearing Cap Torque Requirem ents......................................... 293 Mast Flaking ....................................................................... 293 Mast Testing (A ssem bled).................................................. 294 Shim Basics ..............................................................................294 Shim R em oval............................................................................296 Mast Column R o lle rs .......................................................... 296 Carriage Column Roller A djustm ents................................. 297 Carriage Side Thrust Roller A djustm e n ts............................... 298 Mast Column Roller Removal - TT Mast (Inner Mast) ..........299 Mast Column Rollers Removal - TL M a s t............................... 300 Mast A sse m b ly......................................................................... 300 Lift Cylinder Removal - TT & T L ..............................................300 Carriage Removal - TT M a st.................................................... 301 Carriage Removal - TL M a s t.................................................... 301 Mast R em oval............................................................................302 Mast A sse m b ly..........................................................................304 Tilt Cylinder Adjustments ........................................................ 306 Quad (Four Stage) M a s t...........................................................306 Mast F la k in g ..............................................................................306 Mast Testing (Assem bled)........................................................ 307 Mast Removal ..................................................................... 308 Carriage Removal ............................................................... 308 Carriage Inspection .............................................................308 Lift Chain Tension ............................................................... 308 Lift Chains...................................................................................... 311 In sp e ctio n .................................................................................. 311 W ear .................................................................................... 311 Rust and Corrosion ................................................... 312 Cracked Plates ................................................................... 312 Tight J o in ts ............................................................................313 Protruding or Turned Pins .................................................. 313 Chain Side W e a r................................................................. 313 Lift Chain Lubrication ............................................................... 314 Lift Chain Replacem ent.............................................................314 Chain Anchors and P u lle y s ................................................ 315 Leaf Chain D isconnect.........................................................315 Disconnect Procedures:...................................................... 315 Fork Inspection ............................................................................317 Abrasion .................................................................................... 317 O verloading................................................................................319 Fatigue ...................................................................................... 319 Bent or Twisted F o rk s ...............................................................320 Hanger ...................................................................................... 320

XI

TABLE OF CONTENTS o ia iu r i CYLINDERS

PAGE

C y lin d e rs ....................................................................................... 323 Lift Cylinder ............................................................................... 323 Disassem bly............................................................................... 323 Seals ..........................................................................................323 Seal R em oval.............................................................................323 Seal Installation - G e n e ra l....................................................... 324 Rod U-Cup Installation..............................................................324 Small U -C u p ........................................................................ 324 Large U -C u p ........................................................................ 324 Cylinder U-cup Insta lla tio n....................................................... 325 Cylinder A ssem bly.................................................................... 325 Cylinder Bleeding and F lu sh in g ...............................................326 Bleeding - Free Lift Cylinder ................................................... 326 Bleeding - Stage Lift C ylinders................................................. 326 Flushing - Stage and Free Lift Cylinders ................................ 326 Drift T e s t..................................................................................... 326 T ilt C y lin d e r................................................................................... 327 Cylinder Disassembly ..............................................................329 Rod D isassem bly...................................................................... 329 Seal R eplacem ent.................................................................... 330 Cylinder R eassem bly................................................................ 330 Tilt Cylinder Flushing and Bleeding Procedures ................... 330 Tilt Drift T e s t............................................................................... 331 Tilt Cylinder Installation and Adjustments .............................. 331 Steer C y lin d e r...............................................................................333 Cylinder R em oval...................................................................... 334 Cylinder Disassembly ..............................................................334 Cylinder A ssem bly.................................................................... 336 Cylinder In s ta lla tio n .................................................................. 336 P arking Brake C ylind e r ..............................................................337 Cylinder R em oval...................................................................... 338 Cylinder Disassembly ..............................................................339 Cylinder A ssem bly.................................................................... 339 Cylinder In s ta lla tio n .................................................................. 340

GLOSSARY

PAGE

G lo s s a ry ......................................................................................... 343

WIRING DIAGRAMS

PAGE

In tro d u ctio n to Diagram U s a g e ................................................. 349 Schematic .................................................................................349 Pictorials ................................................................................... 349 In d e x ................................................................................................ 351 E le ctrica l S chem atic - AC Traction/D C L if t ..............................352 E le ctrica l S chem atic - AC Traction/A C L if t .............................. 353 E le ctrica l S chem atic - AC Traction/A C L ift W ith O ptions . . 354 D istrib u tio n P a n e l.........................................................................355 ACCESS 3 - AC Traction C o n tro lle r ........................................ 356 ACCESS 2 - AC L ift C o n tro lle r................................................... 357 H ydraulic S w itch Harness W ith T ilt P osition A s s is t............. 358 Dashboard w ith TMM O p tio n ..................................................... 359 ACCESS 1 - D isplay .................................................................... 360

XII

caaiun

TABLE OF CONTENTS

S teering...........................................................................................361 Foot Operated Direction Control .............................................. 362 Brake and Accelerator Pedals .................................................. 363 Motors and Alarms ..................................................................... 364 In fo L in k...........................................................................................365 Overhead G u a rd ............................................................................366 Freezer Condition ....................................................................... 367 Freezer Condition - Jumper H arness........................................368 Power Cables - AC Traction/DC L i f t ..........................................369 Power Cables - AC Traction/AC L i f t ..........................................370 Wire Harnesses ............................................................................371

HYDRAULIC SCHEMATIC

PAGE

Hydraulic S ch em atic................................................................... 375

POWER UNIT PARTS

PAGE

Seat D e c k ...................................................................................... 378 Power Unit .................................................................................... 382 Overhead Guard & Covers .........................................................386 Battery Spacers & Retainers.......................................................390 Static S e a t...................................................................................... 396 Suspension Seat ..........................................................................400 Hip Restraint.................................................................................. 404

HYDRAULIC PARTS

PAGE

Suction Line Hydraulics .............................................................408 Lift & Tilt Line Hydraulics ...........................................................410 Steer & Brake Line H ydraulics.................................................. 412 Pressure Line Hydraulics ...........................................................414 Accessory Line Hydraulics - T L /Q u ad ..................................... 416 Accessory Line Hydraulics - T T ................................................ 418 Steer & Brake Line H ydraulics.................................................. 420 Return Line H ydraulics...............................................................422 Lift & Return Line Hydraulics - TL M a s t................................... 424 Lift & Return Line Hydraulics - TT M a s t................................... 426 Accessory Line Hydraulics - TL Mast ..................................... 428 Accessory Line Hydraulics - TT Mast ..................................... 430 Mast Hydraulics - Quad M a s t .................................................... 432 Mast Hydraulics - Quad M a s t .................................................... 434 Lift Pump - T T ................................................................................436 Lift Pump - T U Q u a d ..................................................................... 438 Lift Pump M o to r ........................................................................... 440 DC Lift Motor ................................................................................442 Directional Control Valve - 3 Spool ..........................................444 Directional Control Valve - 4 Spool ..........................................446 Manifold Crossover R elief...........................................................448 Tilt Manifold ......................................................... 450 Park Brake Release Manifold .................................................... 452 Lowering Flow Control Valve - TL ............................................454 Lowering Control Valve - T T ...................................................... 456 Accessory Manifold - T L /Q u ad .................................................. 458 Accessory Manifold - T T .............................................................462 4-Position Pressure Relief Valve .............................................. 464

XIII

TABLE OF CONTENTS

cjiauin

Control L e ve r.................................................................................466 Control Valve Linkage - Standard No A ccessories............. 470 Control Valve Linkage - One Accessory.................................. 474 Control Valve Linkage - Two Accessories ..............................478 Carriage Hydraulics - TL/Quad ................................................. 482 TT Carriage Hydraulics - Single A ccessory............................484 Carriage Hydraulics - Quad Mast .............................................488 TT Carriage Hydraulics - Double Accessory ..........................492

DRIVE UNIT PARTS

PAGE

Drive U n it....................................................................................... 500 AC Traction M o to r........................................................................ 504 Drive T i r e ....................................................................................... 506

ELECTRICAL PARTS

PAGE

Electrical Components - Power U n it.........................................514 Controller Panel - DC L i f t ............................................................518 Controller Panel - AC L i f t ............................................................520 Contactor P anel.............................................................................522 Distribution P a n e l.........................................................................524 Freezer Condition Distribution B o a rd ...................................... 526 Contactor L & P .............................................................................528 Contactor L & P - “EE” ................................................................ 530 Steering C o n ta c to r...................................................................... 532 Steering Contactor “EE” ............................................................534 Directional C o n tro l...................................................................... 536 Foot Operated Directional Control ...........................................538 Accelerator ................................................................................... 540 Park Brake S w itch.........................................................................542 Tilt Limit S w itch.............................................................................544 Control Cable - T L ........................................................................ 546 Control Cable - T T .........................................................................548 Connectors ................................................................................... 550 Strobe L ig h t................................................................................... 556 Overhead Guard - Front Lights & M irrors................................ 558 Overhead Guard - Rear Lig h ts................................................... 560 Drive Thru Overhead Guard - Front Lights & M irro rs .........564 Drive Thru Overhead Guard Accessories - R e a r ................... 566 Quad Mast Mounted Work Lights .............................................570 TT Mast Mounted Work Lights................................................... 572

BRAKE PARTS

PAGE

Brake P e d a l................................................................................... 576 Power Service Brake .................................................................. 578 Parking Brake .......................................... 580

XIV

caaum STEERING PARTS

TABLE OF CONTENTS PAGE

Steering Column - Part 1 ............................................................. 584 Steering Column - Part 2 ............................................................. 588 Steering Axle ................................................................................ 590 Steering And Service Brake P u m p ............................................ 594 Power Steering Pump M o to r.......................................................596 Steer Unit ...................................................................................... 598 Steer T ire .........................................................................................600

LIFTING MECHANISM PARTS

PAGE

TL M a s t...........................................................................................606 TL Mast A ccessories................................................................... 610 TT Mast Accessories................................................................... 612 Quad M a s t...................................................................................... 614 M a s t - T T .........................................................................................622 Fork Carriage Quad Mast ...........................................................632 Fork Carriage TL ........................... 634 Fork Carriage - T T ........................................................................636 Yoke Quad M a s t............................................................................638 Y o k e - T T .........................................................................................640 Lift Chain T L ................................................................. 644 Lift Chain Quad ............................................................................646 Lift Chain T T .................................................................................. 650 Load Backrest - TL/Quad ...........................................................654 Load Backrest - T T ......................... 658 F o r k ................................................................................................. 660

CYLINDER PARTS

PAGE

Mast Cylinder TL ..........................................................................670 Mast Cylinder - TT ........................................................................672 Quad Mast C y lin d er..................................................................... 676 Quad Carriage C ylinder............................................................... 678 Carriage Cylinder - T T ................................................................. 680 Tilt Cylinder - T U Q u a d ................................................................. 682 Tilt C y lin d e r-T T ............................................................................686 Sideshifter C y lin d er..................................................................... 690 Parking Brake C y lin d e r............................................................... 692 Steer Cylinder................................................................................ 694

PLATFORM PARTS

PAGE

Sideshift - TL/Quad ..................................................................... 698 Sideshifter - T T ..............................................................................700

LABELS AND DECALS

PAGE

Work Assist Accessories ...........................................................704 In fo L in k ...........................................................................................708 Labels and D e c a ls ....................................................................... 710

XV

cm uirv

i I I

SAFETY

SAFETY General Maintenance Instructions

C A a u ih

General Maintenance Instructions

5.

/ j \ WARNING TO PREVENT SERIOUS RISK OF INJURY TO YOURSELF AND OTHERS OBSERVE THE FOL­ LOWING SAFETY INSTRUCTIONS Power industrial trucks may become hazardous if ade­ quate maintenance is neglected. Therefore, adequate maintenance facilities, trained personnel and proce­ dures should be provided.

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

2.

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

3.

Before leaving the truck—

4.

-

Stop truck.

-

Fully lower the load engaging means.

-

Place directional controls in neutral.

-

Apply the parking brake.

-

Turn off power (power disconnect).

-

Remove key.

-

Block the wheels if truck is on an incline.

Before working on truck— - Raise drive wheel free of floor or disconnect power sources. - Use chocks or other positive positioning de­ vices. - Block load engaging means, inter masts, or chassis before working under them. When working in these areas keep hands, arms, feet and legs clear to prevent pinching or injury. - Operation to check performance of truck or at­ tachments shall be conducted in an authorized safe clearance area.

Crown 1991 PF8971-1 Rev. 10/06

-

Be in operating position.

-

Apply brake.

-

Place directional control in neutral.

- Before operating truck, check functions o f lift systems, directional control, speed control, steer­ ing, warning devices, brakes and any attachments if any used. 6.

Avoid fire hazards and have fire protection equip­ ment present. Do not use an open flam e to check level, or for leakage of electrolyte and fluids or oil. Do not use open pans of fuel or flammable clean­ ing fluids for cleaning parts.

7.

Keep shop well ventilated, clean and dry.

8.

Tipover can occur with improper use of this truck, even when unloaded. In the event o f tipover, do not jump. Hold steering wheel tightly and brace your feet.

9.

Brakes, steering mechanisms, control mecha­ nisms, lift overload devices, guards, and safety de­ vices shall be inspected regularly and maintained in a safe operating condition.

Maintenance and inspection shall be performed in con­ formance with the following practices: 1.

Before starting to operate truck—

10. Capacity, operation and maintenance instruction plates or decals shall be maintained in legible con­ dition. 11. A ll parts o f lift mechanisms shall be inspected to maintain them in safe operating condition. 12. A ll hydraulic systems shall be regularly inspected and maintained in conformance with good practice. Cylinders, valves, and other sim ilar parts shall be checked to assure that “drift” has not developed to the extent that it would create a hazard. 13. Batteries, motors, controllers, lim it switches, pro­ tective devices, electrical conductors, and connec­ tions shall be maintained in conformance with good practice. Special attention shall be paid to the condition o f electrical insulation. 14. Trucks shall be kept in a clean condition to m ini­ mize fire hazards and facilitate detection o f loose or defective parts. 15. Modifications and additions which affect capacity and safe truck operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation and mainte­ nance plates or decals shall be changed accord­ ingly.

MA-11.0-002 03 Rev. 10/06 3

SAFETY General Maintenance Instructions

c n o iu r i

16. Care shall be taken to assure that all replacement parts are interchangeable with the original parts and of equal quality to that provided in the original equipment. 17. Be sure that any equipment added to the truck (ter­ minal, fan, clipboard, etc.) is positioned so that it does not block your vision or interfere with safe and efficient operation of the truck. For further information pertaining to operating and maintenance procedures, refer to current ASME B56.1.

MA-11.0-002 03 Rev. 10/06 4

Crown 1991 PF8971-2 Rev. 10/06

SAFETY

civaiuh

Cleaning of Material Handling Equipment

Cleaning of Material Handling Equipment Cleaning Methods The preferred method of cleaning built up dirt and dust from electric material handling equipment is dry pres­ sured air. For localized degreasing, use of an appropri­ ate solvent 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 on or in components (i.e., circuit boards, contactors, encoders, switches, potentiometers, etc.) after washing is a proponent of oxidation and corro­ sion. Functional integrity of contaminated components may be questionable. Nuisance fault logging, interm ittent

operation or immediate failure could be the resultant of power washing. For these reasons all electronic com­ ponents including motors must be protected. Compo­ nent removal is the best method to eliminate the risk of damage. Power washing w ill also remove and/or destroy lubri­ cants in or on the surface o f shafts, unsealed bearings, hinges, exposed gears, bushings, chains, linkages, etc. These Items must also be protected or properly lu­ bricated after cleaning. Consideration must also be given to metal surfaces. The cleaning process can strip away paint and protec­ tive coatings applied to components (i.e., hydraulic lines, terminal strips, linkages) forfreezer/corrosion en­ vironment. Paint and/or protective coating must be re­ applied to these areas to reduce the chance of oxida­ tion and corrosion. Before installing removed components, lubricating or returning the equipment to service it must be free of solvent residue and thoroughly dry.

Crown C leaning P roducts Chart Cleaner Type

Part Number

Package Quanity

Degreaser & Cleaner

363105-001 363105-012

20 oz. Can (12) 20 oz. Cans

All Purpose Cleaner

363114-001 363114-012

20 oz. Can (12) 20 oz. Cans

Glass Cleaner

363101-001 363101-012

20 oz. Can (12) 20 oz. Cans

W aterless Hand Cleaner

363111-001 363111-012

15 oz. Tube (12) 15oz. Tubes

Pumiced & Smooth Hand Cleaner

363112-001 363112-004

1 Gallon Jug (4) 1 Gallon Jugs

363122

Used with 363112-001

063009-005

1 Gallon Jug

Wall Mounted Deluxe Soap Dispenser Tough On Grease

Crown 2000 PF11969-1 Rev. 10/06

MA-1140-050 02 Rev. 10/06 5

SAFETY

CAQUJn Control of Hazardous Energy

Control of Hazardous Energy *

Lockout/Tagout In the interest of safety and to ensure compliance with OSHA Regulations, (Standards - 29 CFR), The control of hazardous energy (lockout/tagout) - 1910.147, Crown has developed guidelines for proper energy control when performing service and maintenance on your truck. Before performing any service or mainte­ nance on the this truck, 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 toe shoes, whenever performing service or maintenance work on Crown equipment.

Battery Safety Rules •

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

•

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

•

Do not bring any type o f flame, spark, etc., nearthe 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 bat­ tery. Arcing will result.

•

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

Crown 2007 PF17014-1

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

Battery Care / f \ CAUTION Only qualified and experienced personnel should per­ form maintenance and repair on batteries. *

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

*

Before disconnecting or connecting batteries to a charger, make sure the charger is "OFF". If an at­ tempt 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 Iighter. Battery fumes are ex­ plosive.

*

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

Charging / f \ CAUTION Never smoke orbrin g flame nearthe battery. Gas formed during charging is highly explosive andean cause serious injury. Consult the charger manufacturer's manual covering your charger fo r hints on operation and maintenance.

MA-2045-100

7

SAFETY Control of Hazardous Energy Battery Removal / f \ CAUTION When removing the battery, move truck to area in­ tended fo r battery care. Floor must be level. Turn keyswitch o r toggle switch to "ofT position and remove key. Disconnect battery and lockout o r tagout truck as described in Battery - Lockout/Tagout in this section. Never move battery partially from truck without roller stand in place. Lower load engaging means com­ pletely. If battery is removed with load engaging means raised, use hoist attached to mast to provide tip over protection. Don’t allow any m etallic object to come in contact with the top o f the battery cells. This m ay cause a short circuit when removing, transporting the battery. Use an insulator (such as plywood) to cover the top o f the battery before and during removal.

c jia u m /K

CAUTION

Make certain battery used meets weight, size and volt­ age requirements o f truck (refer to serial plate). NEVER operate truck with an undersized battery.

Lockout - Tagout Always turn key switch to "off", remove key and apply tag to steering wheel with cable tie warning others truck is being serviced.

Figure 17550

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

Battery Installation

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

/ f \ CAUTION When installing the battery, move truck to area in­ tended for battery care. Floor must be level. Turn keyswitch or toggle switch to "off" position and remove key. Lockout o r tagout truck as described in Battery Lockout/Tagout in this section. I f battery was removed with load engaging means raised, use hoist attached to mast to provide tip over protection. Don’t allow any me­ tallic object to come in contact with the top o f the bat­ tery cells. This may cause a short circuit when trans­ porting o r installing the battery. Use an insulator (such as plywood) to cover the top o f the battery before and during installation.

MA-2045-101

8

Crown 2007 PF17014-2

SAFETY

eaaiun Capacitance Due to capacitance voltage present in the traction mod­ ule controller, whenever performing maintenance which may permit contact with the bus bars and asso­ ciated power cables, discharge the capacitors. 1.

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

2.

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

Control of Hazardous Energy 3.

Disconnecting the battery for a minimum o f 10 min­ utes w ill discharge the capacitors that are inside the Traction Control Module ACCESS 3. Two addi­ tional methods of discharging these capacitors are to disconnect the battery, place a jum per from top stud o f line capacitor to fuse bus bar and then hold the key switch in the START position fo r 10 sec­ onds, or disconnect the battery and connect a 100 ohm 2 w att resistor between the positive and neg­ ative term inals on the controller, ACCESS3.

Figure 17551

Crown 2007 PF17014-3

M A-2045-102

9

SAFETY

CAOUJh

Control of Hazardous Energy Hydraulic

A

When maintenance is to be performed on the hydraulic system, make certain the hydraulic system is not under pressure.

WARNING

AVOID HIGH PRESSURE FLUIDS— Escaping fluid underpressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten a ll connections before applying pres­ sure. Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece o f card­ board o r paper to search fo r leaks. Do not use your hand. A ny fluid injected into the skin under high pressure should be considered as a serious m edical emergency despite an in itia l normal appearance o f the skin. There is a delayed onset o f pain, and serious tissue damage may occur. Medical attention should be sought imme­ diately by a specialist who has had experience with this type o f injury.

1.

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

2.

No load on forks.

3.

Completely lower load engaging means (mast) or, if required fo r maintenance, block mast sections at appropriate height as described in Mast of this sec­ tion.

4.

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

5.

Operate the hydraulic levers to remove any hy­ draulic pressure that may be present.

6.

Pump brake pedal approximately 20 times to re­ lease pressure stored in the accumulator before working on service brakes.

Figure 17552

MA-2045-103

10

Crown 2007 PF17014-4

SAFETY c jia m

Control of Hazardous Energy

n

Lifting and Blocking

NOTE

1.

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

2.

No load on forks.

3.

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

Steer Wheel

Hydraulic Jack and Jack Stand Specifications: • Hydraulic Jack Capacity: 3620 kg (8000 lb) • Minimum Collapsed Height: 60 mm (2.25 in) • Maximum Raised Height: 400 mm (16 in) • Jack Stand Capacity: 4500 kg (10,000 lb) Crown has available a hydraulic jack (122599) that meets the above specifications. Jack stands are com­ mercially available.

Side

(1)

Raise Forks 70 to 150 mm (3 to 6 in) from Floor

(2)

Chock Both Drive Wheels

(3)

Set Jack Stand Height as Required Not to Exceed 400 mm (16 in)

(4 )

Locate Jack Stands & Jack as Shown, Under Steer Axle

(1)

Lower Forks Completely

(2)

Do Not Tilt Mast After Blocked

Figure 17554

/ j \ WARNING Figure 17553

NOTE When removing the drive unit, block under counter­ weight to prevent truck from tipping.

Truck stability decreases dramatically if load wheels are raised more than required to insert hard wood block. Attach sling and overhead lifting device to a ll cross members o f the m ast to prevent truck from tip­ ping over when raising the side o f the truck.

Jack up one side of truck, place hard wood block di­ rectly under first stage mast, jack up opposite side of truck and place second hard wood block under other side o f first stage mast. FC Series Truck - Use 100 x 100 mm ( 4 x 4 in) block.

Crown 2007 PF17014-5

MA-2045-104

11

SAFETY Control of Hazardous Energy

CJVGUJh

Mast Blocking Masts Use 100 mm (4 in) by 100 mm (4 in), 50 mm (2 in) by 100 mm (4 in) or bigger hardwood blocks of appropri­ ate length for supporting mast channels. Block both mast rails o f each stage to maintain truck stability. Remove any carriage mounted accessory (e.g. carton clamp, slip sheet, roll loader [SP only], etc.) except sideshifters before blocking masts. These accessories add significant 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 Block­ ing in this section.

3.

Connect battery.

4.

Raise forks and position blocks under second stage mast as shown.

5.

Using a clamp or ratchet tie down, secure blocks to mast channel as shown.

6.

Lower mast and position appropriate length blocks under third stage mast as shown.

7.

Lower mast and position appropriate length blocks under fourth stage (or inner) for quad mast as shown.

8.

Using a clamp or ratchet tie down, secure blocks to mast channel or second stage block as shown.

9.

Lower fork carriage until carriage rests on stops or place blocks under carriage and lower until weight rests on blocks.

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

MA-2045-105

12

Crown 2007 PF17014-6

SAFETY Control of Hazardous Energy

c jia u jn

Quad Mast

TT Mast

(2)

Third Stage Mast

(3)

Second Stage Mast

(4)

First Stage Mast (or Mainframe)

(5)

First Stage Mast (or Outer Mast)

(6)

Fourth Stage Mast (or Inner Mast)

Figure 17555

Crown 2007 PF17014-7

MA-2045-106

13

SAFETY Control of Hazardous Energy TT Mast

(1)

First Stage Mast (or Mainframe)

(2)

Second Stage Mast

(3)

Third Stage Mast

(4)

Fork Carriage

(5)

First Stage Mast (or Outer Mast)

(6)

Fourth Stage Mast (or Inner Mast)

MA-2045-107

14

c iia u m

TL Mast

Crown 2007 PF17014-8

SAFETY

cnoujh Disconnect Tilt Cylinder When the tilt cylinders are disconnected from the hy­ draulic system or from the mounting brackets, the mast must be secured to keep the mast from pivoting to­ ward, or away from the truck. 1. 2.

Move truck to a secure non traffic maintenance area with a level floor. Lower load engaging means (mast) completely. No load on forks.

Control of Hazardous Energy 3.

Chock wheels of truck. Refer to Lifting and Block­ ing in this section.

4.

T ilt forks down so weight of carriage is noton the tilt cylinder.

5.

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

6.

Attach a sling and lifting device to all mast top cross braces so movement w ill be minimal when tilt cylinders are disconnected.

Figure 17557

Crown 2007 PF17014-9

MA-2045-108

15

SAFETY

ovaurn

Control of Hazardous Energy Removing Mast 1.

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

2.

Lower load engaging means (mast) completely. No load on forks.

3.

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

4.

Lift truck so drive wheels are 25 mm (1 in) clear of floor. Refer to Lifting and Blocking in this section.

5.

Remove load backrest, if slip on type.

6.

Remove forks.

7.

Cycle all hydraulic levers to remove any hydraulic pressure in the system.

8. 9.

Support mast as described in Disconnecting Tilt Cylinders in this section. Chain mast sections together at upper cross­ braces. Chain fork carriage to lower mast cross­ brace. This w ill keep carriage and mast sections from moving when mast is laid down.

(1)

Part of Mast

(2)

Bearing

(3)

Bearing Cap

(4)

Flatwashers

(5)

Bolts - Torque to 70 - 80 Nm (52 - 59 ft lb)

Figure 17559

10. Disconnect lift cylinder hydraulic lines, accessory cables and accessory hydraulic lines between power unit and mast if present. Use container to catch hydraulic oil. 11. Disconnect wiring between mast and power unit.

(1)

Mast Lug

(2)

Pin

(3)

Block

(4)

Tilt Cylinder

Figure 17558

12. Remove pins connecting tilt cylinders to the mast. 13. Remove drive wheels to allow access to the mast pivot bearing caps. 14. Remove bearing cap mounting bolts. 15. Move mast away from truck and lay mast on level floor with the truck side of the mast on the floor.

MA-2045-109

16

Crown 2007 PF17014-10

CAQUJh

SAFETY Control of Hazardous Energy

Removing Counterweight 1.

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

2.

Lower load engaging means completely. No load on forks.

3.

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

4.

Remove battery.

5.

Attach a sling and lifting device to all top cross braces of the mast to prevent tipover.

6.

Disconnect all wiring to overhead guard at connec­ tors.

7.

Remove overhead guard mounting bolts and lift guard from truck.

8.

Remove contactor panel compartment cover on the counter weight.

9.

Attach sling and overhead lifting device to the top of the counter weight through the contactor panel compartment opening. Raise lifting device so the weight of the counter weight is supported when mounting bolts are removed.

10. Remove (4) mounting bolts holding counterweight to the power unit. 11. Carefully move counter weight from truck and lay counter weight on floor.

Crown 2007 PF17014-11

MA-2045-110

17

CROUJh

t

INTRODUCTION

INTRODUCTION

cnaum

Introduction

Introduction

Service Training

This manual is intended for the service technician who is seeking information about maintenance and service replacement parte. It contains a section on trouble­ shooting which w ill enable a qualified technician to lo­ cate and solve problems which may occur.

Complete Service Training is available for the lift truck technician covering all Crown Lift Trucks, module sys­ tems, wire guidance, hydraulic and electrical systems. To obtain more information concerning service training, contact your Crown Dealer or under "Training" on www.crown.com.

Operation Instructions This manual does not contain operator instructions. Operator Instructions in tag or booklet form are sent with each truck. Additional copies can be ordered if re­ quired. These booklets are for you and your personnel to insure years o f safe, trouble-free operation of your Crown Lift Truck. For sitdown rider operator instruc­ tions, refer to Crown publication, "Operator Manual FC 4500 Series".

Operator Training Crown produces a complete series o f operator training programs available through your local Crown dealer. A complete listing of these and other available programs can also be found under "Training" on www.crown.com.

Replacement Parts When ordering replacement parts form this manual, al­ ways specify, along with part number, model and serial number of the truck. This information w ill further enable us to give correct, fast and efficient service. For current part number o f service manuals, operator manuals, operator training programs, truck capacities and technical specifications, contact your local dealer or at www.crown.com. This manual is arranged according to major sections which covers maintenance and replacement parte. The sectional descriptions are as follows:

MAINTENANCE

REPLACEMENT PARTS

SECTION

DESCRIPTION

SECTION

DESCRIPTION

M1

Lubrication and Adjustment

1

Power Unit Parte

M2

Hydraulic

2

Hydraulic Parts

M3

Drive Unit

3

Drive Unit Parts

M4

Electrical

4

Electrical Parts

M5

Brake

5

Brake Parte

M6

Steering

6

Steering Parts

M7

Lifting Mechanism

7

Lifting Mechanism Parte

M8

Cylinders

8

Cylinder Parts

M9

Platform

9

Platform Parts

M10

Glossary

10

Labels and Decals

Crown 2007 PF15999-1

ITD-2045-001

21

INTRODUCTION

cnouin

Introduction The data plate for the FC 4500 series truck is located on the battery compartment wall and includes a model number and truck data number. From these two num­ bers, you can identify the truck model, series, series updates, determine relative size and performance, ca­ pacity and specific truck data. The following pages explain the model & truck data numbering system.

U nits o f m easu re, kg/m m (Ib /in ) B attery W eig h t M ax. T ru ck W t. Less B attery

B attery T yp e

M in.

1 5%

D .C . V o ltag e

H our R ate

M a x. A .H . C ap .

M a x. G ra d e W ith 3 0 5 (1 2 ) M a x. Fo rk H eight

%

Load T ire T read W idth 1 8 0 “ T raverse S id eshift M od el N um ber

M a x. T ilt B ack O

S e ria l N um ber

Fo rk Length

T ru ck D a ta N um ber

This truck as released from the factory conforms to the mandatory requirem ents o f the ANSI B56.1 standard. Crown Equipment Corp. New Bremen, OH 45869 3 14 .1c

\_________________________ ) Figure 17370

Model Number Example Series Update --------------------------Significant change(s) to the product that would not merit a new series number (generation).

Hydraulics System 0= DC Hydraulics 5 = AC Hydraulics

Image G enerator--------------------------------FC - Four Wheel Sitdown Rider Counterbalanced

* Capacity 40 = 1815 kg 50 = 2270 kg 55 = 2495 kg 60 = 2720 kg

(4000 (5000 (5500 (6000

lb) lb) lb) lb)

FC4515-40 Series -------------------------------------- -f" 1 -------Major technical and design changes making the product a new and improved generation.

Relative Size or Performance 1 = 685 mm (27 in) Battery Compartment 2 = 840 mm (33 in) Battery Compartment 4 = 915 mm (36 in) BatteryCompartment

The example of the model number shown above (FC4515-40) is a FC 4500 series. It has an AC traction motor with a 685 mm (27 in) battery compartment. It also has AC hydraulics and has a capacity of 1815 kg (4000 lbs). *Actual rated capacity may vary, depending on special equipment or modifications. Consult capacity plate lo­ cated on the overhead guard.

ITD-2045-002

22

Crown 2007 PF15999-2

INTRODUCTION Introduction

c n o u in Truck data numbers provide you and your Crown dealer with a wealth o f information to insure the selec­ tion o f proper parts for your Crown truck. You may sim­

ply provide this number to your Crown dealer, or use the following breakdown if selecting your own part numbers or service information from this manual.

Attachments ------------— = No Attachment SS = Sideshifter PP = Push Pull CC = Carton Clamp FP = Fork Positioner PR = Paper Roll Clamp

T ire s ---------------------------5 = Smooth M = Smooth Non-Marking L = Lugged 6 = Lugged Non-Marking

Voltage 36 = 36 Volt 48 = 48 Volt -- = Mast Only EE Rating 1 = EE Rating 2 = No EE Rating

Battery Compartment Size 27 = 685 mm (27 in) 33 = 840 mm (33 in) 36 = 915 mm (36 in)

Parking Brake S = Standard A = Automatic

Mast Type ----------------------TL = Telescopic Limited Free Lift TT = Telescopic Triple Stage QD = Telescopic Four Stage - = Power Unit Only Standard/Custom/Special ~ L - = Standard - TT C = Custom S = Special

188 33 F S S SS 5 36 2 E - A 1 T— Fans - = No Fans 1 = Operator Fan 2 = Compartment Fan 3 = Operator and Compartment Fan

Lift H eight----------------TL Mast

231 = 5865 mm (231 in)

1 1 8 -2 9 9 5 mm (118 in)

238 = 6045 mm (238 in)

126 = 3200 mm (126 in)

246 = 6250 mm (246 in)

130 = 3300 mm (130 in)‘

250 = 6350 mm (250 in)

138 = 3505 mm (138 in)

258 = 6560 mm (258 in)

142 = 3605 mm (142 in)

276 = 7010 mm (276 in)

150 = 3810 mm (150 in)

291 = 7390 mm (291 in)

TT Mast

Quad Mast

1 8 0 = 4 5 7 0 mm (180 in)

240 = 6100 mm (240 in)

188 = 4775 mm (188 In)

258 = 7390 mm (291 in)

198 = 5030 mm (198 in)

276 = 7010 mm (276 in)

206 = 5230 mm (206 in)

294 = 7475 mm (294 in)

2 08 = 5285 mm (208 in)

312 = 7925 mm (312 in)

216 = 5485 mm (216 in) 223 = 5665 mm (223 in)

Custom = Plus Custom Height

Foot Operated Directional Control - = No Foot Operated Dir. Control 1 = Foot Operated Dir. Control Travel Alarm & Light Package Option - = No Travel Alarm & Lights 1 = Strobe Light 2 = Travel Alarm 3 = Worklights 4 = Travel Alarm & Strobe Light 5 = Worklights & Strobe Light 6 = Travel Alarm, W orklights & Strobe Light 7 = Travel Alarm & W orklights

SPC = Special Lift Height

Cold Conditioning ---------- = No Cold Conditioning F = Freezer Conditioning C = Corrosion Conditioning

Crown 2007 PF15999-3

Accessory Hydraulics - = No Accessory Hydraulics S = Single Function D = Double Function

L ift System 2 = Contactor 5 = AC

ITD-2045-003

23

c m u jh

LUBRICATION & ADJUSTMENT

25

LUBRICATION & ADJUSTMENT

C R O U Jh

Lubrication and Adjustment

Lubrication and Adjustment

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

To obtain maximum life o f any industrial equipment, a well planned maintenance program (PM), performed by qualified technical personnel should be followed. In conjunction with, and an integral part of, any planned maintenance program should be daily operator input. Operator involvement can greatly reduce truck down time, assist in determining planned maintenance (PM) schedules and ultim ately save money. For these rea­ sons, Crown recommends a checklist sim ilar to the Op­ erators Daily Checklist shown below.

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

cnouin

Operators Daily Checklist

Model ---------------------------------------------

Serial No_________________________ W eek beginning

Thie check mustbe made by the truck operator dally atthe start of the s tift Certain Hemslisted are notIncluded on eomemodels.Check a l Items applicable to unit noted above.

Check ( * / ) appropriate box

____

____

| Q 1C] O K

[

.. ,

..

2 0 ______

onlT T INO. — ■

Truck No. -

] N eeds repair or adjustm ents (give details in com m ents section) TUESDAY W HNESQtf THURSDAY

FRIDAY

SATURDAY

SUNDAY

VISUALCHECKS

|

MONDAY DAMME bent, dented or broken parts

OK

LEAKS drive unit, brake*, hydraulcs

OK

OK OK

IDES (WHEELS drive wheats, load wheete, eastern FORKS in place, property secured

OK OK

OK OK

CHAINS, CABLES(HOSES inpiaee

OK

H0URMEIBI operating

OK

BATTERY water level, vent cape in place, ctanfineea

OK OK OK OK OK OK OK OK OK OK OK OK OK OK

OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK

BATTERY CONNECTOR cracked, burnt, Nght Ming GUARDS overhead, feed beckreet, battery retainer

|

SAFETY DEVICES fle * t*« l^ .ln 4 c a lo rM *. safetyalM d operator hameee,warning terete, ate. in condUon a* equipped HORN eounde

tmm

nobM ng, no areasshe play TRAVEL CONTROLS speed ranges,forward » reverse, no unusual noise HYDRAULIC CONTROLS iteee&levnttitfarew d&raaN m d teeth In a ow l tideehM right A felt, etc* no taweual noise BRAKES elepbuckwllh ln required dbtance,workernoolHy, brake override funeticne P A N R IG BRAKE seat, hand,foot lA TT B tY CHARGE tfecharge meter total green or 7$% charge aierratahg forks POWER DISCONNECT cuts off ad electric power ATTAUM Om hmedon properly, no unusual nolee U W T SWITCHES M usi limit, M ta r*. * t M l, etc.

OK OK OK OK OK

OK

OK

OK OK OK OK

OK OK

OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK

OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK

OK

OK OK OK OK OK OK OK OK OK OK OX OK OK OK OK OK

OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK

OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK

HOURM ETBtREADRtfi O P B M nfrS M T lIU SUPERVISOR'S OX

• Hthe truck Is lound M b* in need of repair or in any way unsafe, o< contributes to an unaafecondition, the matter shal be reported immecSately to the designated authority, and f ie truck *haa not be operated until it has been restored » safe opening condWon. if during cperetton, the truck becomes unsate many w ^ , the matter trial b e reponMbnmeaaMy to the designated auth ors and the huckshai not be operated until itftas boon restored 1o safe operating condGon. Do not make repairs or acjustmente unless specifically auttorized to do so. OF3772 Rev. SCO

Printed lnU .fiA

Figure 14990

Crown 1987 PF7886-1 Rev. 6/08

M1.0-04.0-001 17 Rev. 6/08

27

LUBRICATION & ADJUSTMENT

crauin

Lubrication and Adjustment The following is a list of lubricants and maintenance products recommended when doing Planned Mainte­ nance on Crown Lift Trucks. Lubrication Ide n tificatio n Chart Type of Lubricant

Part Number

Package Quantity

Gear Lube 80W-90 (Typical)

363506-001 363506-012

1 Quart (12) 1 Quart Cans

Automatic Transmission Fluid (Multi-Purpose)

363503-001 363503-012

1 Quart (12) 1 Quart

Universal Hydraulic & Transmission Fluid

363513-001 363513-012

1 Quart (12) 1 Quart

Grease (Multi-Purpose)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

BB

Hydraulic Oil (Low Temp)

363505-101 363505-106

1 Gallon (6) 1 Gallon

DDD

Hydraulic Oil - DTE24

063001-021

1 Gallon

E

Channel Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

F

Gear Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

Chain & Cable Lube

363107-001 363107-012

15ozC an (12) 15ozC ans

Premium Chain & Cable Lube

363115-001 363115-012

12ozC an (12) 12 oz Cans

H

Final Finish - Rubber & Vinyl Dressing

363129-001 363129-012

11 oz Can (12) 11 ozC ans

I

Grease (Lift Pump Coupling)

063002-039 127801S

1 lb 1 oz

J

Brake Fluid - Dot 5

063004-002 063004-003

12 oz 1 Gallon

A AA AAA B

C CC D

Oil (SAE 40)

G

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

M1.0-04.0-002 17 Rev. 6/08

28

Crown 1987 PF7886-2 Rev. 6/08

LUBRICATION & ADJUSTMENT

CJlOUJh

Lubrication and Adjustment Lubrication Id entification C hart

Type of Lubricant

Part Number

Package Quantity

K

Grease (Wheel Bearing)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

L

Metal Assembly Spray

063002-021

11 oz Spray

M

Silicone Grease (Clear)

063002-020

5.3 oz Tube

Brake & Parts Cleaner

363102-001 363102-012

14 oz Can (12) 14 oz Cans

Low VOC Brake & Parts Cleaner

363103-001 363103-012

14 oz Can (12) 14 oz Cans

Non-Flammable Brake & Parts Cleaner

363116-001 363116-012

19 oz Can (12) 19 oz Cans

O

Penetrating Lubricant

363104-001 363104-012

20 oz Can (12) 20 oz Cans

P

Premium Formula Multi-Purpose Grease

363108-001 363108-012

11 oz Can (12) 11 oz Cans

Q

White Lithium Grease

363110-001 363110-012

11ozC an (12) 11 oz Cans

R

Choke & Carburetor Cleaner

363109-001 363109-012

15 oz Can (12) 16 oz Cans

Contact Cleaner - Non-Flammable

363106-001 363106-012

10ozC an (12) 10 oz Cans

Contact Cleaner

363128-001 363128-012

11ozC an (12)11 oz Cans

T

Electrical Connector Oxidation & Corrosion Inhibitor

127189-001

30 cc

U

Battery Cleaner

363124-001 363124-012

18ozC an (12) 18 oz Cans

V

Battery Protector

363125-001 363125-012

15 oz Can (12) 15 oz Cans

w

Food Grade Machine Lubricant

363127-001 363127-012

12ozC an (12) 12 oz Cans

X

Food Grade Silicone Spray

363126-001 363126-012

11 oz Can (12) 11 oz Cans

Coolant

363509-101 363509-106

1 Gallon (6) 1 Gallon

Extended Life Coolant

363511-101 363511-106

1 Gallon (6) 1 Gallon

N

s

Y

Crown 1987 PF7886-3 Rev. 6/08

M 1.0-04.0-003 17 Rev. 6/08

29

LUBRICATION & ADJUSTMENT

CR O UIh

Lubrication and Adjustment

A lternate Lubricants & Fluids Chart

Type o f Lubricant

Manufacturer / Distributor

Product Name

A

Gear Lube 80W-90 (Typical)

Crown

Crown

AA

Automatic Transmission Fluid (Multi-Purpose)

Crown

Crown

Grease (Multi-Purpose)

Mobilgrease XHP 222 Special Union Unoba EP No 2 Retinax AO) LM Grease Unirex EP-2

Mobil Union 76 Co. Shell Burmah Castrol Exxon

Grease (Low Temp) (2)

Lubriplate Alvania RA^) Helveum OO)

Fiske Bros Refining Co. Shell Burmah Castrol

Food Grade Grease (Multi-Purpose)

Petro Canada Purity FG

Petro Canada

B

BB BBB C

Oil (SAE 40)

D

Hydraulic Oil

Crown

Crown

Hydraulic Oil (Low Temp) (2)

Crown

Crown

Hydraulic Oil - DTE24 -

X-NORGate

Suppressor

077 7 2 8, 085670, 091181

Transformer

= $ > -

Integrated Circuit Figure 8133-02

Crown 2000 PF11845-11 Rev. 10/06

M 4.1-2720-011 03 Rev. 10/06

169

ELECTRICAL Access 123...System

c n o u ih Access 123...System User Main Menu Level (1)

(2)*

(8)

(7)*

(3)*

(6)*

(4)

(5)

(1)

Display Screen

(2)

Battery Retainer Switch indicator

(3)

Seat Belt Indicator

(4)

Enter or Return Key used to navigate in and out of menus and to accept inputs

(5)

Navigation Keys (Up Arrow, Down Arrow, Left Arrow, Right Arrow)

(6)

Operator Improper Sequence Error Indicator

(7)

Service Required Indicator

(8)

Battery Discharge Indicator

‘ NOTE: These four indicators are viewable during: 1. Initial key-on 2. Self test 3. Indicator functioning Figure 16S65

Typical navigation button usage: up and down arrows will scroll through menu choices, right arrow will enter a menu and left arrow will exit the current menu. The enter/return button is used to select a function or choice.

User Level The following pages describe operator controlled dis­ play options. The user may choose from the following options (provided a higher priority message is not ac­ tive): •

Message (for example Bdi = 70%)

•

Hour

•

Events

•

Service

•

Performance (if enabled and PIN not active)

The following messages w ill be displayed in order of priority (if enabled), regardless of user selection: 1.

Event Code

2.

PM Due

3.

User Code

4.

Return throttle to neutral

Crown 2007 PF15956-1

5.

User selected message, per F7 setting.

If any message is more than eight characters it w ill be scrolled across the display from right to left. The display w ill continue to show the last selected mes­ sage even if the truck is turned OFF and back ON. To change the message displayed, enter the Message Mode and select one of the other choices.

Message Mode To enter the Message Mode, key up truck. With a Mes­ sage (for example Bdi = 70%) present on the display, press the right arrow to enter this menu. Press the up/ down arrows to scroll through menu choices: •

BDI

•

Hours

•

Odometer

•

Trip

•

Timer

N ote: Message Mode is controlled by the Features menu (F7). F7 allows one of the message choices (in which case you would not be able to scroll through any choices) or ALL.

M4.3-2045-001

171

ELECTRICAL

ciiaiun

Access 123...System Bdl - Message Mode

Tim er - Start

This menu allows the operator to display the battery percent o f remaining charge. To select this message, key up the truck. Press the right arrow to enter the Mes­ sage Mode. Use the up/down arrows to scroll to Bdi. Press the enter/return button. The display will exit the Message Mode and show (Bdi = XX%).

Press the enter/return button. The display will exit the Message Mode and display; Stopwatch (00:00:00), which will be incrementing. Tim er - Stop

This menu allows the operator to display accumulated seat hours. To select this message, key up the truck. Press the right arrow. Use the up/down arrows, scroll to Hours. Press the enter/return button. The display will exit the Message Mode and show (H1=XX).

Use the up/down arrows to display Stopwatch. Press the right arrow to enter the Message Mode. Use the up/ down arrows to display Timer. Press the right arrow to enter the Timer menu. Use the up/down arrows to dis­ play Stop, press the enter/return button. The display w ill exit the Message Mode and show the Stopwatch stopped, with the amount o f time accumulated (exam­ ple, 01:01:32).

Odometer - Message Mode

Tim er - Reset

Press the right arrow. Use the up/down arrows to scroll to Odometer. Press the enter/return button. The dis­ play w ill exit the Message Mode and show the distance the truck has traveled, in miles (mi=XX).

Use the up/down arrows to display the Stopwatch. Press the right arrow to enter the Message Mode. Use the up/down arrows to display Timer. Press the right arrow to enter Timer menu. Use the up/down arrows to display Reset. Press the enter/return button. The dis­ play w ill exit the Message Mode. The Stopwatch will be zeroed, and not counting (00 :00 :00 ).

Hours - Message Mode

Trip - Message Mode This menu allows the operator to display the distance traveled in either direction since the last reset, in feet. To select this message, key up the truck. Press the right arrow to enter the Message Mode. Use the up/ down arrows to scroll to Trip. Press the enter/return button and the display w ill exit the Message Mode. The display will show ft=00000. (Metric is not available) Trip - Reset Press the right arrow to enter Message Mode. Use the up/down arrows to display Trip. Press the right arrow to display Reset. Press the enter/return button. The dis­ play will exit Message Mode and display distance trav­ eled reset (ft= 00000 ). Timer - Message Mode This menu allows the operator to display a stopwatch. To select this message, key up the truck. Press the right arrow, use up/down arrows to display Timer. Press the right arrow to enter the Timer menu. Use the up/down arrows to scroll through choices: •

Stop

•

Start

•

Reset

M4.3-2045-002

172

Hour This menu allows the user to view one o f five different hour meter readings. •

H 1 (key on, operator in seat)

•

H2 (key on, operator in seat plus programmable time out)

•

H3 (Access 1 on-time)

•

H4 (Access 2 on-time)

•

H5 (Access 3 on-time)

•

H6 Steer motor on-time

•

H7 Odometer

To enter this menu, key up the truck. Press the down arrow to display Hour. Press the right arrow, H1 w ill be displayed. Use the up/down arrows to view different hour meter readings. To stop the message from scroll­ ing press the right arrow at the desired hour meter. To exit Hour menu press the left arrow until Hour is dis­ played.

Crown 2007 PF15956-2

cjiaiun

ELECTRICAL Access 123„.System

Events This menu allows the user to view stored event codes, up to 16. To enter this menu, key up the truck. Press the down arrow until Events is displayed. Press the right arrow, "Last" will briefly be displayed. The last event code stored w ill then be displayed (EV=XXX). Use the up/down arrows to scroll through stored event codes (Last to Last-15). Press the left arrow button to return to the main menu at Events. Note: Event codes can not be cleared from the User level menu.

Service This menu enters maintenance levels 2 and 3. A pass­ word is required to enter maintenance levels. To enter this menu, key up the truck. Press the down arrow until Service is displayed. Press the right arrow, Level 2 will be displayed. Press the down arrow to go to Level 3, if desired. From either level, press the right arrow, four blank boxes will be displayed. Use the up/ down arrows to enter the first digit of the password. Press the right arrow to move to the next digit, continue until the final digit is entered. Press the enter/retum button to accept the password, Note: Once maintenance Levels 2 or 3 are entered the truck must be turned OFF then back ON to exit the Ser­ vice menu.

Performance If User Performance is enabled in the Features menu (F 8 ), this menu allows the operator to choose one of three performance modes to operate the truck. When using factory defaults: •

P1 (maximum achievable performance level, bal­ anced productivity/energy consumption)

•

P2 (performance sim ilar to FC4000 series)

•

P3 (used where operational conditions require low­ est truck performance)

To enter Performance menu, key up the truck. Use the up/down arrows to scroll to Performance. Press the right arrow P1, P2 or P3 will be displayed. Use the up/ down arrows to display a different performance level. Once the desired level is displayed, press the enter/ return button to select. Press the left arrow button to return to the main menu at Performance.

Crown 2007 PF15956-3

M4.3-2045-003

173

ELECTRICAL Access 123...System

c jia u in

Operator Menus

Message Mode Menus Allows the user to select what is dis­ played in message mode if no higher priority items are active. Also allows the user to control the trip meter and timer. Only the appropriate menus will be made visible based on the “Default Message” feature item.

User Code

Message Mode

© 1©

©i©

@ lHours"

Odometer

or

)©

J

@ 1©

Message Mode Priority 1 Event Code 2 PM Due (if enabled) 3 User Code (if enabled) 4 Return throttle to neutral 5 Default message (per feature selected)

@|©

| Timer"

© 1®

© I® D@

@ [" L

3©

Start

© 1© 3©

Reset

H1

j Runtime1=_

HsT

] Runtime2=

@

[

©

r ^ lA c e e s s f

D@ @ C

ZZ©@[

Value

3 -s

Value

H2 visible only if selected in Features menu

© © Value

3

Value

3

Value

3

Q © N v *g

3

@ 0

3

© I® © ) | H 4 ~ ] Access2=C

o continued on page -005

© ) | H5~

o

= ] Access3=

© j© © ) | H6*

] Steer Motor=~

© I© ©

[ H7

) Odometer=_

X X X ml

Figure 16548

M4.3-2045-004

174

Crown 2007 PF15956-4

ELECTRICAL Access 123...System

c a a u jh

continued from page -004

O perator Menus

Events

Last

©

Ev=

I Lastj |

~ lE v = -

@ |L a s t|

I

©

l LasM

@

| Last-15

Value

D

Value

3

ooc

evT

Value

D

J iv T

Value

3

)| Ev=_

Value

D

© 1®

Service

@O

Level 2 z m


continued on page-015

inputs

D® #- continuecIon page-016

Outputsy

m

m

O IO [a ^2

®

}

continued on

w

Access2 O u t p u t s ) @ ^ S ) - »

017

continued on page-017

■A c c ^ o t ^ - O - O -

)© ( © [

m

Lamp Test

) @ » @ H On/Off

)

@ 1® @

| A4.2

o ^ r —— W IM *

Not available if equipped with AC lift and F6=AC

)[ALM 1

UK

o @ fA 4 i

o

o J

o

o

o

@ )[ m

o Fan 2 only visible when optional AC Lift is enabled and F6 =AC

^

A4.8

i------I A4~1-

On/Off

)

flM B N

On/Off

)

fM S N

on/off K

mm

o ^p ff~ )

o

@ [m 7

continued on page-007

fp jS N

SV1

^ Q H O r w o fT )

~yj Fan 1

Fan 2

y m m

o n /o ff)

ymmt

On/Off )

Figure 16550

M4.3-2045-006

176

Crown 2007 PF15956-6

ELECTRICAL

eaouin

Access 123...System

S ervice M enus

continued from page -006

Place direction control lever in forward (forks first) position

© I® Calibration

)@

@ C 1

] Accel Pedal

)@

@ C 1 .1

fo irS w itc h F W P)n j@ W ji| Min Volts/Pot Volts

Continuous Hold on Accel Pedal (Fully Depressed)

Accel Pedal Fully Up >

Pot V

) 0 to 0.5 V

®®

Press ACCEL

Release Pedal Pot V

3.8 to 4 2 V

)@

-------- -----------------w

@ |@

Max Volts/Pot Volts ~) V a lu e ~ )(^ )— |

m

I

\ Dir Switch R E V ) P la c e d ir e c tio n CO ntral L0 V 9 ! ®

------------ ------- in reverse (power unit first) position

Accel Pedal Fully Up - > | Min Volts/Pot Volts ~)@

| Pot V

.

Continuous Hold on Accel Pedal (Fully Depressed)

] 0 to 0.5 V ) | ^ | Press ACCEL

----------------

D®

Save? Y

® |® » | Max Volts/Pot Volts ) | Value )@

|P o tV

) 3.8 to 4 .2 V )@

fs a v e ? N )@

Save? Y

e C2

) |B a t A c O @

@

| C2.1

^Adj Volts ) @

@

T— v

_ @ i®

] Value D O O t Value @ f S a v e ? K I ) ^ l

Adjusts Voltage (Visible on Display) Involving Power Cables

continued on page -008

Figure 16551

Crown 2007 PF15956-7

M4.3-2045-007

177

ELECTRICAL

CR Q UIh

Access 123...System

,, continued from page-008

ole Features

S ervice Menus

O0{

FI

I Language*

• o o

*| English

DO

© 1©

O

O

( Q ) | F6..

] Lift System=^

DO

DC

© (© O O

O lAC

DO

continued on page -011

continued on page -009

Figure 16552

M4.3-2045-008

178

Crown 2007 PF15956-8

ELECTRICAL

cjiauih continued from page -008

Crown 2007 PF15956-9

Access 123...System

Service Menus

M4.3-2045-009

179

ELECTRICAL e n a u jn

Access 123...System

Service Menus

continued from page -009

] view

^ 1111

C o d e 7 ~ )i j Q @ ( Entry

B W @

| Entry 2

O

lE r« y 3

View Codes “Entry XX” is displayed on _ screen fo r the initial 0.5 J ) © seconds. Then the code and performance level are

pi

. ) 2222 P2~

1 » r a f ) Add C o d e Q © N © fPIN~y© © (

3333 P3

0001

) @ ) displayed. 3

Perf Level

P1

O IO Q l

_

)«B>

01#

OtHZZZDO @ ) | F9.3

Modify Code

o @

© o

o @

1Entry 2~")

| Perf Level

>© @ 1

PI

) ®

o o ® r w D -----------

o

F9.4 I Delete Code

Modify Codes “Entry XX” is displayed on screen for the initial 0.5 seconds. Then the code and performance level are displayed as shown below: 1234 P1 ) 1111 P1

Entry 1

0 ©

OIO ' 2222 P2

I Entry 2

@

\

F9.5 programs a timeout when operator leaves the seat. Default = Disable. Default time = 5 mins, and is adjustable from 1 to 99 min.

m

CO

w

a.

Timeout=

)

CO CO CO CO

© [reT

delete Codes “Entry XX” is displayed on . screen for the initial 0.5 ' seconds. Then the code and performance level are

/

OIO | Entry 25

O ld

Disable

l Enable

O O l|Value=MirT

Value ) Save? NAT ) Q

Figure 16554

M4.3-2045-010

180

Crown 2007 PF15956-10

ELECTRICAL

C A O U Jh

Access 123...System Service Menus

continued from page -008

Level 2: View Only/Level 3: Increase Only

o |o Hour

m

m

HI

Edit Value

]Runtim e1=XXXXX

@ 1© @

[ H2

D©@@

Level 2: View Only/Level 3: increase Only H2.1 Runtime2= _)

1 R untim e2-XXXXX

eie

H2.2 Timeout=_ D

@ @ @ )

@

@

In Level 3, after changes are made, answer Y/N

@

Level 2: View Only/Level 3: Increase Only @

J Level 2: View Only/Level 3: Increase Only

@

I H3~

] Accessl = X X X X X ~ ) @

J Value

Q

I hT

[A cce882=X X X )oO @ @ | Edtt Value

) @ @ @

Level 2: View Only/Level 3: Increase Only

® [ H5 Access3=XXXXX @ 1® o r * Steer Motor=

® |® @

Edit Value

D@ ©@

Level 2: View Only/Level 3: Increase Only Edit Value

) @

@

)@ @ @

4 r -

Level 2: View Only

® i® I H8

@

Level 2: View Only/Level 3: Increase Only

j:tS|@fNone

] PM Timer

) m > Enables PM

O IO H1

“ Timer )©

@ 1® @ N

)Q

© i© ©

IH 3

O

lw

*

)&

l

© |@

continued on page -012

_

)©

@ 1©

. .)© ® i®

rH5

@ | h6

...

*

)Q

@ 1®

@ iH7

>a

Level 2: View Only H8.2

lnterval=

m

m

Edit Value

)

Figure 16555

Crown 2007 PF15956-11

M 4.3-2045-011

181

ELECTRICAL c n a u m

Access 123...System

continued from page -011

S ervice Menus

Figure 16556

M4.3-2045-012

182

Crown 2007 PF15956-12

ELECTRICAL c m

u

Access 123...System

i w

continued from page -012

Crown 2007 PF15956-13

S ervice Menus

M4.3-2045-013

183

ELECTRICAL c jia u in

Access 123...System

S ervice Menus

continued from page -013 Level 3 Menu Utilities

mm

U1 Part Numbers

U1.1 Accessl

ID#©

U 1.1.1 Module=

oo

Value

)

1Value

)

O 0 P O

U 1.1.2 Software

^@

@

Only show Access2 when feature is selected for AC lift and F6 =AC.

#1#

continued on page -006

Figure 16558

M4.3-2045-014

184

Crown 2007 PF15956-14

ELECTRICAL

CJlOUJh

Access 123... System

Service Menus A ccess 1 Inputs A2.1.1 1 RAS=

o o ljOn/Off

)

@ 1 ® @ |A2!l.2 ] TLT^

On/Off

)

e fo rto ff

)

continued from page -006

# ,§ > @

| A2.1.3 ] T B S = _

iQ

A2.1.4 ] TLMS=

o

o

lj On/Off

)

O

O

l| On/Off

)

@ 1® @

| A 2.1.5 ] AXS1=_

@ _@ @ | A 2 /I.8 ] BR E S=_

mm

On/Off

)

^ On/Off

)

@ 1® @ | A2.1.9 ] HGTS1=

@ | a 2.1.10]

tmm=

_

m

m

QX6 N - - V

Only present if option TMM is selected (F3). DC Lift Only.

)

A ccess 2 Inputs continued from * @ @ (

page -006

a 2.2.i

]

hss=

® f ® _____________ ( 8 ) l A2.2.2 ] M2SpeedRPM=

mm

Only if optional AC Lift (F6 ) is selected.

Value

__________ R p iv T )

@ '@ @ | A2.2.3 ] M2 Temp=

0 F/cT)

® " ® ______________ @

l A2-2.4 ] M2 Current=

A

)

@ ;@ ( ^ ) | A2.2.5 ] Access2 Temp=

°F/C ~)

Figure 16559

Crown 2007 PF15956-15

M4.3-2045-015

185

ELECTRICAL c n a iim

Access 123...System

Service Menus Access 3 Inputs continued from page -006

A2.3.1 J F S ^

@

@

PlO ale

D

I N

M

Value

l A 2 j . 2 )| RS=

[

m

D

BRKS=

J ]

o lo @

| A2^.4~]( SEAT=____ ~

@ |@ @

r*2 y H

HGTS1=

@ |@ @

| A2.3.6 ) ACS=

ala

p q ti=

@ i@ © ) l A2.3.9 j~Travel S p e e d = _

@

©

@

ala____ ala ala

_m

ph

)

|A2.3.10)| M1SpeedRPM=_

[A 2 g /v T | M1 Temp=

_° F /c)

[ A Z a i F j M1 Current=

I

a

D

______________ (Q j) [a 2.3. 13 f~Access 3 Tem p=_ ) © } g © l

m

_° F/C)

®

©

] A 2 j. 1 4 ) Bdi=

©

[A 2.3.15] Batt V=

□ D

® a® @

| A2.3.16] AXS2=_

aia

@ |A 2 . 3 . 1 8 ] | PS1=

Figure 16560

M4.3-2045-016

186

Crown 2007 PF15956-16

ELECTRICAL

ciiaujh

Access 123...System

Service Menus Access 1 Outputs continued from page -006

mm

A3.1.1 j : SV1 =

o:o

@

A3.1.2

@

I A3.1.3

m

On/Off

m

f s=

J

p=

3

| On/Off

o

o

c

On/Off

3

#

[

On/Off

3

o o @ lA 3 -1 .4 lALM1 =

#

Access 2 Outputs continued from page -006

@

@

I A3-2-1 ) Fan2=_

3

o A3.3.2 J M2=

3

Access 3 Outputs continued page -006

A3.3.1

@

L=

|A3.3.2 ) M1=__

Q

Q

Value

| Value

mm @

| A3 3.3 ] Fan1 =

Value

Figure 16561

Crown 2007 PF15956-17

M4.3-2045-017

187

ELECTRICAL Access 123...System Analyzer The analyzer menu description is shown on the follow­ ing pages. This menu shows the different system com­ ponents which can be viewed or tested. Note: There must be an operator present in the seat in order to view any Analyzer menu items. Level 2: •

A1 (truck status, view only)

•

A2 (module inputs)

•

A3 (module outputs)

•

A4 (not available in this level)

Truck functions are enabled in this level with operator present in seat. Level 3: •

A1 (truck status, view only)

•

A2 (module inputs)

•

A3 (not available in this level)

•

A4 (module output tests)

Truck functions are disabled in this level.

Analyzer Access After powering up the truck, navigate to the SERVICE menu by pressing the down arrow button. A t the SER­ VICE menu, press the right arrow to enter Level 2. If this choice is the desired menu press the right arrow. Use the up/down arrow to enter the first digit of the password. Press the right arrow to move to the next digit, use the up/down arrow to enter the next digit. Continue until the last digit has been entered, press the enter/return button to accept the password. If level 3 is desired, press the down arrow from Level 2 on the display. Press the right arrow, use the up/down arrow to enter the first digit of the password. Press the right arrow to move to the next digit, use the up/down arrow to enter the next digit. Continue until the last digit has been entered, press the enter/return button to ac­ cept the password. To stop scrolling display, press the right arrow. To move to the next menu level the left arrow must be pressed.

M4.3-2045-018

188

CRQUJh A1 Status - View only the status of monitored truck systems. Press the right arrow to view status. A1.1 Lift - Press right arrow, display w ill show enabled or disabled. Enabled indicates lift is allowed. Disabled indicates lift is not allowed, this could be due to a sys­ tem fault. Press the left arrow to return to the A1.1 sub­ menu. Press the down arrow to continue or press the left arrow to return to the A1 menu. A1.2 Traction - Press right arrow, display will show en­ abled or disabled. Enabled indicates traction is not in­ hibited. Disabled indicates traction is not available; this could be due to a system fault. Press the left arrow to return to the A1.2 submenu. Press the down arrow to continue or press the left arrow to return to the A1 menu. A2 Inputs - View the inputs of monitored truck compo­ nents. From the A1 menu, press the down arrow. Press the right arrow to view inputs. A2.1 Access 1 Inputs - Press the right arrow to view Access 1 monitored inputs. A2.1.1 RAS = ___ ; Raise Switch - On = switch closed (raise selected); O ff = switch open (raise not selected). Press down arrow to continue. A2.1.2 TLT = ___ ; Tilt switch, switch is active on for­ ward or back tilt - On = switch closed (tilt not selected); Off = switch open (tilt selected). Press down arrow to continue. A2.1.3 TBS =___ ; T ilt Back Switch - On = switch open (tilt back selected); Off = switch closed (tilt back not se­ lected). Press down arrow to continue. A2.1.4 TLMS = ___; Tilt Limit Switch - On = switch closed (less than 2 degrees forward mast tilt); Off = switch open (greater than 2 degrees forward mast tilt). Press down arrow to continue. A2.1.5 AXS1 = ___ ; 1st Accessory Switch - Features menu (F11) must be enabled to view. On = switch closed (1st accessory selected); O ff = switch open (1st accessory not selected). Press down arrow to con­ tinue. A2.1.8 BRES ■___ ; Battery Restraint Switch - On = switch closed (battery retainer in place); Off = switch open (battery retainer not installed). Press down arrow to continue. A2.1.9 HGTS1 = ___ ; Mast Height Switch - On = switch closed (mast below free-lift); Off = switch open (mast above free-lift). Press down arrow to continue.

Crown 2007 PF15956-18

ELECTRICAL

CJVOWh

Access 123...System

A2.1.10 TMM ■ ___ V; Truck Management Module Menu item is only available if Features menu F3 is en­ abled.

A2.3.3 BRKS = ___ ; Brake switch - On = switch closed (Brake pedal depressed). Off = switch open (Brake pedal not depressed). Press down arrow to continue.

•

M2 (DC lift) over temperature = 0.75Vdc to 1.25Vdc

A2.3.4 SEAT ■ ___ ; Seat switch - On = switch closed (Operator on seat). O ff = switch open (Operator not on seat). Press down arrow to continue.

•

M2 brushes worn = 1.75Vdc to 2.25Vdc

•

M3 motor brushes worn = 2.75Vdc to 3.25Vdc.

•

TMM not present < 0.025Vdc

Press the left arrow to return to A2.1 menu. Press down arrow to go to A2.2. A2.2 Access 2 Inputs - This menu is only available if the truck is equipped with optional AC lift and AC is selected in Features menu F6 . Press the right arrow to view Access 2 monitored inputs. A2.2.1 HSS = ___ ; High Speed Switch - On = switch closed (high speed lift selected); Off = switch open (high speed lift not selected). Press down arrow to con­ tinue. A2.2.2 M2Speed = ___ RPM; Displays the lift motor (M2) speed in RPMs. Press left arrow to return to A2.2 menu. Press down arrow to continue. A2.2.3 M2 Temp = ___ F; Lift motor temperature in de­ grees Fahrenheit if F2 = disabled or in degrees Celsius if F2 = enabled. Above 160°C (320°F) motor is hot. Press down arrow to continue. A2.2.4 M2 Current =___A; Displays the lift motor cur­ rent in amperes. Press down arrow to continue. A2.2.5 Access2 Temp =___ F; Lift motor controller temperature in degrees Fahrenheit if F2 disabled or in degrees Celsius if F2 enabled. Above 75°C (167°F) truck performance w ill cut back to allow controller to cool. Above 100°C (212°F) lift will be disabled. Press left arrow to return to A2.2 menu. Press down arrow to continue to A2.3 menu. A2.3 Access 3 Inputs - Press the right arrow to view Access 3 monitored inputs. A2.3.1 FS =___ ; Forward Switch - On = switch closed (Forward direction selected). Off = switch open (For­ ward direction not selected). Press down arrow to con­ tinue. A2.3.2 RS = ___; Reverse Switch - On = switch closed (Reverse direction selected). Off = switch open (Re­ verse direction not selected). Press down arrow to con­ tinue.

Crown 2007 PF15956-19

A2.3.5 HGTS1___; Mast Height Switch - On = switch closed (mast below free-lift); O ff = switch open (mast above free-lift). Press down arrow to continue. A2.3.6 A C S ___; Accelerator Switch - On = switch closed (accelerator pedal depressed and parking brake released). Off = switch open (accelerator pedal not depressed or parking brake not released). Press down arrow to continue. A2.3.8 P O T1___ V; Accelerator Potentiometer - 0.2 Vdc pedal released to 4.0 Vdc pedal fully depressed. Press down arrow to continue. A2.3.9 Travel Speed = ___ MPH; Truck travel speed in miles per hour. Press down arrow to continue. Note: Maximum speed based on performance and features (F5) settings, battery condition and applica­ tion. A2.3.10 M1 Speed = ___ RPM; Displays the traction motor (M1) speed in RPMs. Press down arrow to con­ tinue. A2.3.11 M1 TEM P= ___ F; Traction motor temperature in degrees Fahrenheit if F2 = disabled or in degrees Celsius if F2 = enabled. Above 160°C (320°F) motor is hot. Press down arrow to continue. A2.3.12 M1 C urrent = ___ A; Displays the traction mo­ tor current in amperes. Press down arrow to continue. A2.3.13 A ccess3 TEMP = F/C: Traction motor controller temperature in degrees Fahrenheit if F2 = disabled or in degrees Celsius if F2 = enabled. Above 75°C (167°F) truck performance w ill cut back to allow controller to cool. Above 100°C (212°F) traction w ill be disabled. Press down arrow to continue. A2.3.14 BDI ■ ___ %; Indicates percent o f battery charge left. Press down arrow to continue. A2.3.15 Bat V =___ V; Current battery voltage. Press down arrow to continue. A2.3.16 AXS2 = ___ ; 2nd Accessory Switch - Features menu (F12) must be enabled to view. On = switch closed (2nd accessory selected); O ff = switch open (2nd accessory not selected). Press down arrow to continue.

M4.3-2045-019

189

ELECTRICAL Access 123...System A2.3.18 PS1 =___; Brake Pressure Switch - On = switch open (greater than 600 psi present in service brake system); Off = Switch closed (less than 600 psi present in service brake system). Press left arrow twice to return to A2 menu. Press down arrow to go to A3 menu. A3 Outputs (not available in level 3 service menu) View outputs from Access modules. Press the right ar­ row to view outputs. A3.1 Access 1 Outputs - Press the right arrow to view Access 1 monitored outputs. A3.1.1 SV1 ■ ___ ; Tilt lockout solenoid - On = SV1 en­ ergized, mast is tilted greater than two degrees for­ ward. O ff = SV1 not energized, mast is tilted less than 2 degrees forward. Press down arrow to continue. A3.1.2 S = ___; Steering Contactor - On = steering contactor energized. Off = steering contactor not ener­ gized. Press left arrow to return to A3.1.2. Press down arrow to continue. A3.1.3 P = ___ ; Lift Contactor - On = lift contactor en­ ergized. O ff = lift contactor not energized. Press down arrow to continue. Note: Menu item not available if truck is equipped with AC lift and features menu (F6 ) = AC. A3.1.4 ALM1 = ___; Status Alarm - On = status alarm activated. O ff = status alarm off. Press left arrow to re­ turn to A3.1 menu. Press down arrow to go to A3.2 menu. A3.2 Access 2 Outputs - Press the right arrow to view Access 2 monitored outputs.

CJlOUJh A3.3.3 FAN1 = ___ ; Access 3 controller cooling fan On = fan running; O ff= fan not running. Press left arrow twice to return to A3 menu. Press down arrow to go to A4 menu. A 4 Test O utputs (only available in level 3 service menu) Test specific components controlled by Access 1 ,2 or 3. Press right arrow to continue. A4.1 LAMPTEST = _ _ j (OFF/ON) Press enter/return to test display lights. Press down arrow to continue. A4.2 ALM1 = ___ ; (OFF/ON) Press enter/return to test status alarm. Press down arrow to continue. A4.3 P = ___ ; (OFF/ON) Press enter/return to test lift pump contactor. Press down arrow to continue. Note: Menu item not available if truck is equipped with AC lift and F6 = AC. A4.4 S = ___ ; (OFF/ON) Press enter/return to test steering contactor. Press down arrow to continue. A4.5 SV1 = ___ ; (OFF/ON) Press enter/return to test tilt lim it solenoid. Press down arrow to continue. A4.6 L = ___ ; (OFF/ON) Press enter/return to test line contactor. Press down arrow to continue. A4.8 FAN1 = ___ ; (OFF/ON) Press enter/return to test Access 3 cooling fan. Press down arrow to continue. A4.10 FAN2 = ___ ; (OFF/ON) Press enter/retum to test Access 2 cooling fan. Press left arrow to return to A4 menu. Note: Menu item not available if truck is equipped with AC lift and features menu (F6 ) = AC.

A3.2.1 FAN2 = ___ ; Access 2 controller cooling fan On = fan running; O ff = fan not running. Press down arrow to continue. A3.2.2 M2 = ___ ; (OFF/ON) Displays lift motor being driven or not. Press left arrow to return to A3.2 menu. Press down arrow to continue. A3.3 Access 3 Outputs - Press the right arrow to view Access 3 monitored outputs. A3.3.1 L = ___ ; Line Contactor - On = Access 3 send­ ing output to energize the line contactor. O ff = Access 3 not sending output to energize the line contactor. Press down arrow to continue. A3.3.2 M1 = ___ ; (OFF/ON) Displays traction motor being driven or not. Press down arrow to continue.

M4.3-2045-020

190

Crown 2007 PF15956-20

ELECTRICAL

cjvauin

Access 123...Sy$tem

Calibration

Calibration Procedures

The calibration menu description is shown on the fol­ lowing pages. The level of the menu shows the differ­ ent area of calibration for this truck. If calibration proce­ dures are not performed correctly and/or features settings are not entered correctly, unsatisfactory truck performance may result.

A fu ll explanation of calibration procedures for each menu level follows.

*

C1 Accel Pedal - accelerator potentiometer (Pot1)

*

C2 Batt Adj - actual battery voltage level

C1 Accel Pedal - Accelerator Potentiometer (POT1). Press right arrow. Several steps are required for this calibration. The fol­ lowing are descriptions o f messages displayed during calibration:

When to calibrate:

Note: Errors during calibration w ill be indicated by dif­ ferent messages, see Calibration Error Messages at the end o f this description.

*

Access 3 replaced, full truck calibration is required.

1.

"Close Seat SW" - check that seat switch is closed, press right arrow.

*

Access 1 replaced, C2 calibration required.

2.

*

The potentiometer or components used to mount or position the potentiometer is replaced.

"Release PARK Brake" - release parking brake, press right arrow.

3.

"D ir Switch FWD 0 .0 0 V - Place the direction con­ trol lever in the forward (forks first) position, press right arrow.

4.

"0.00 V" - potentiometer voltage at current pedal position.

5.

"Min volts" - place accelerator pedal in full up posi­ tion, press right arrow.

Calibration Access After powering up the truck, navigate to the SERVICE menu by pressing the down arrow button. At the SER­ VICE menu, press the right arrow to enter LEVEL 2. Press the right arrow again to enter the Access pass­ word. Use the up/down arrow buttons to change num­ ber, press right arrow to move to the next number. Once all numbers in the Access code have been en­ tered press enter/return. Using the down arrow navi­ gate to the CALIBRATION menu, and then press the right arrow. The message displayed will be C1 Accel Pedal.

6 . "Press ACCEL 0.00V” - fully depress and hold ac­ celerator pedal, press right arrow. 7.

"MAX volts" - while continuing to hold the acceler­ ator pedal fully depressed, press right arrow.

8 . "D ir Switch REV 0.00 V" - Release the accelerator pedal. Place the direction control lever in the re­ verse (power unit first) position, press the right ar­ row. 9.

"Min volts" - press the right arrow.

10. "Press ACCEL" - Fully depress and hold the accel­ erator pedal, press the right arrow. 11. "4.50 V" - potentiometer voltage at current pedal position, hold accelerator pedal fully depressed, press right arrow. 12. "Max volts" - while continuing to hold the accelera­ tor pedal fully depressed, press the right arrow. 13. "Save? N" - press the up arrow 14. "Save? Y" - Press enter/retum to save. 15. "Calibration Accepted" - proper calibration com­ plete. Press enter/return to return to C1.

Crown 2007 PF15956-21

M4.3-2045-021

191

ELECTRICAL Access 123...System

CJiauih

Calibration Error Messages Two messages may be displayed if required calibration criteria are not met: •

Calibration Rejected

•

Retry

These messages may result from improper sequenc­ ing of switches to component issues. If either of these messages is displayed, press enter/return to begin cal­ ibration from the beginning. C2 B att A d j - Connect digital volt meter (DVOM) across battery, record reading. Press the right arrow. C2.1 A d j V olts - Calibration accounts for cable and connection voltage drops between battery and control­ ler. The following are descriptions of messages dis­ played during calibration: 1. "Adj Volts" will scroll, press right arrow. 2.

"Volt" and voltage measured by the truck will alter­ nate, press the right arrow.

3.

Use up and down arrows to adjust voltage mea­ sured by the truck to match reading recorded by DVOM, press enter/return.

4.

"Save? N" will be shown, press the up arrow.

5.

"Save? Y" will be shown, press enter/return to save.

6 . Menu w ill return to C2.

M4.3-2045-022

192

Crown 2007 PF15956-22

Cl\OUJh Features The feature menu is shown on the following pages. The first level of the menu shows the different areas of setup for the truck.

Features Access After powering up the truck, navigate to the SERVICE menu by pressing the down arrow button. A t the SER­ VICE menu, press the right arrow to enter LEVEL 2. Press the right arrow again to enter the Access pass­ word. Use the up/down arrow buttons to change num­ ber, press right arrow to move to the next number. Once ail numbers in the Access code have been en­ tered press the enter/return button. Using the down ar­ row, navigate to the FEATURES menu and then press the right arrow. The message displayed w ill be F1 Lan­ guage =. If changes have been made in the sub menus, pressing the left arrow at the first level menu w ill prompt Save? N the settings. Use the up and down arrows to select Save? Y then press enter/return to save settings. F1 Language = ___ ; Determines the language mes­ sages will be displayed on Access 1. Factory setting is English and can not be modified. Press down to con­ tinue. F2 M etric = ___; Determines the units of measure dis­ played. Factory setting is disabled and can not be mod­ ified. Press down arrow to continue. F3 TMM a ___ ; This menu is enabled if the truck is equipped with a Truck Management Module. It is dis­ abled if the truck is not equipped with a Truck Manage­ ment Module. To Enable or Disable, press the right ar­ row, use the up and down arrows to change between Enabled/Disabled. Press the enter/return button. Menu will return to F3. Press the down arrow to continue.

ELECTRICAL Access 123...System F5 B attery Type ■ ___V; This feature determines the truck battery voltage. To change the truck voltage, press the right arrow, use the up and down arrows to change between 36Vdc and 48Vdc (refer to the electri­ cal maintenance section of the Service and Parts Man­ ual for other components which may need to be re­ placed when changing truck voltage). Press the enter/ return button. Menu w ill return to F5, press the down arrow to continue. F6 L ift S yste m = __ ; This feature determines whether the truck is equipped with DC (contactor) lift or AC (Ac­ cess 2) lift. To change the truck lift system, press the right arrow, use the up and down arrows to change be­ tween DC and AC. Press the enter/return button. Menu w ill return to F6 , press the down arrow to continue. N ote: Setting F6 incorrectly can affect proper lift oper­ ation. F7 M essage Mode = ___ ; This feature changes infor­ mation displayed during operation. Press the right ar­ row, use the up and down arrows to change. Select from : Bdi (battery percent o f charge), Hours (hour m eter reading), Odometer (total distance truck has traveled in miles), Trip (total distance truck has traveled since last reset), Timer (stopwatch) or All (allows oper­ ator to determine message using display buttons). Press enter/return. Menu will return to F7. Press the down arrow to continue. F8 U ser Perform ance = ___ ; This feature determines whether the operator has the ability to select different truck performance levels. If enabled and F9 is disabled, any user can select any performance level (P1, P2, P3). If disabled, the operator can not change truck per­ formance modes. Press the right arrow, use the up and down arrows to change. Press enter/retum . Menu w ill return to F6 . Press the down arrow to continue.

F4 H our M e te r= __ ; This feature determines the hour meter that will be displayed during operation. To change the displayed hour meter, press the right arrow, use the up and down arrows to change between H 1 and H2 (see hour meter description to determine mon­ itored system item). Press the enter/return button. Menu will return to F4, press the down arrow to con­ tinue.

Crown 2007 PF15956-23

M4.3-2045-023

193

ELECTRICAL Access 123...System F9 U ser C odes = ____ Use this feature to enter up to 25 user codes which can be applied to various perfor­ mance levels. To modify, press the right arrow. Use the up and down arrows to enable or disable. Press the right arrow to continue. Note: If F9 is enabled, operators can not change per­ formance levels regardless of F8 setting. Truck will be limited to the performance level assigned to the User Code. F9.1 View Codes This feature will display the (entry number 1 - 25) for one half second then the user code and performance level selected for that entry will be displayed. A user code must be present in list to view codes. If no user code has been entered F9.1 w ill be disabled. Press enter/return, then use the up and down arrows to view stored entry numbers and user codes. Press the left arrow to return to F9.1. Press the down arrow to continue. F9.2 A dd Codes This feature will allow the addition of user codes. Press the right arrow PIN will be displayed. Press the right arrow and use the up and down arrows to enter a 4 digit PIN (Personal Identification Number). Press the enter/return button to accept the PIN. Menu will display Perf Level, press the right arrow and use the up and down arrows to select the performance level (P1, P2 or P3) desired for this user code. Press enter/ return to return to F9.2. Press the down arrow to con­ tinue. Note: If a PIN is already in use, "PIN Used" will be dis­ played. Select a different PIN. F9.3 M o d ify Code This feature w ill allow modification of previously entered user codes. Press the right arrow, the entry number w ill be displayed for one half second. Use the up and down arrows to select the entry number to change. Press the right arrow, menu will display PIN. Press the right arrow, use the up and down arrows to change the PIN (Personal Identification Number). Press enter/return to accept new PIN. If performance level desired also needs changed press the down ar­ row, display w ill show Perf Level. Press the right arrow, use the up and down arrows to select desired perfor­ mance level (P1, P2 or P3). Press enter/retum, menu will display Perf Level. Press left arrow, display will re­ turn to F9.3. Press down arrow to continue.

enaum F9.5 Tim eout This feature allows a tim er to be as­ signed to user codes. This tim er w ill affect all user codes. The tim er begins when the operator leaves the seat. Once the tim er has timed out the user code will need to be entered to return the truck to operation. Press the right arrow to enable or disable this feature. If feature is enabled press the right arrow to view the current timeout setting. Press the right arrow to change the tim er value. Press the enter/return button. Press the left arrow 3 times to return to F9. Press the down arrow to continue. F10 A uto Park Brake This feature allows the operation of the optional Auto Park Brake. The truck must be equipped with this feature. To modify press the right ar­ row, use the up and down arrows to change between enable/disable. Press enter/return to accept change. Press left arrow to return to F10. Press the down arrow to continue. F11 A ccy 1 This feature allows the operation o f a first hydraulic accessory. To modify, press the right arrow to continue. F11.1 Use the up and down arrows to enable or disable Accy 1. If disabled, press enter/retum to return to F11. If enabled, press the right arrow to continue. Note: The proper flow control screw must be installed in the spool to achieve selected flow rate. See the Ser­ vice and Parts Manual hydraulic section for part num­ bers. F 11.2___ GPM; The current flow rate in gallons per minute w ill be displayed. To select different flow rates press the right arrow. Use the up and down arrow but­ tons to choose between 3, 5, 7 and 10 GPM. Press enter/retum to accept, menu w ill return to F11.2. Press the left arrow to return to F11. Press the down arrow to continue.

F9.4 Delete Code This feature will allow the removal of currently entered user codes. To delete a user code, press the right arrow. The menu w ill display the entry number for one half second. Use the up and down ar­ rows to select the entry number to delete. Press enter/ return to delete the user code. Press the left arrow to return to F9.4. Press the down arrow to continue. M4.3-2045-024

194

Crown 2007 PF15956-24

oiauin

ELECTRICAL Access 123...System

F12 A ccy 2 This feature allows the operation of a first hydraulic accessory. To modify, press the right arrow to continue. Note: F11 must be enabled. F12.1 Use the up and down arrows to enable or disable Accy 2. If disabled, press enter/return to return to F12. If enabled, press the right arrow to continue. Note: The proper flow control screw must be installed in the spool to achieve selected flow rate. See the Ser­ vice and Parts Manual hydraulic section for part num­ bers. F 1 2.2 ___ GPM; The current flow rate in gallons per minute will be displayed. To select different flow rates press the right arrow. Use the up and down arrow but­ tons to choose between 3, 5, 7 and 10 GPM. Press enter/return to accept, menu will return to F12.2. Press the left arrow to return to F12. Press the left arrow, "Save? N" w ill be displayed. To ignore changes press the enter/return button to continue. To accept changes use the up arrow, "Save? Y" will be displayed. Press enter/return button to save. The display w ill return to Features. F13 Power Brake; Enabled allows brake and acceler­ ator pedals to be depressed for four seconds. After four seconds traction is cut out and "Return to Neutral" is displayed. Disabling this feature cuts out traction when the brake pedal is depressed.

Crown 2007 PF15956-25

M4.3-2045-025

195

ELECTRICAL

2940 CA661-2 FAN3 +BV(FU4)------ )

Seat Deck

(c)

Part of Overhead Guard

(d)

Part of Front Wall

(e)

45 Nm (33 ft lb)

Figure 16339-01

01.0-2040-056 03 Rev. 10/07

380

Crown 2004 PF13809-3 Rev. 10/07

POWER UNIT PARTS

cjiatun INDEX 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

Seat Deck

PART NUMBER . 050067-023* 050067-024* . 130083* . .. . 124887 . 124407 . 124409 . 060100-003. . 124836 . 060030-017. . 050006-036. . 060030-177. . 124962* . . . 124412* . . . . 050009-025. . 050008-030. . 124411*. . . . 130081* . . . . 127366 . 050068-004. . 050025-010. . 127341-002. . 130525 .. .. . 050008-030. . 140142 . 127383 . 050003-020.

PART NAME

NUMBER REQUIRED

S c re w ...................................................................................................................2 Screw, "EE" Only.................................................................................................. 2 Eye Plate...............................................................................................................1 Hold Down.............................................................................................................1 Latch P in.............................................................................................................1 Torsion S pring...................................................................................................... 2 Ring Cotter P in .................................................................................................... 4 P la te .................................................................... 1 Flatwasher.............................................................................................................2 S c re w ................................................................................................................... 2 Flatwasher............................................................................................................. 6 Gas Spring, 685 mm (27 in) Battery Compartment...........................................2 Gas Spring, 840 & 915 mm (33 & 36 in) Battery C om partm ent..................... 2 Flatwasher............................................................................................................ 4 Nut..................................................................................... 2 Latch Bar...............................................................................................................1 Latch Bar, "EE" O nly........................................ 1 Spacer............................................................................................................... AR Nut......................................................................................................................... 2 B o lt....................................................................................................................... 2 Edging.............................................................................................................. 1 S c re w ................................................................................................................... 1 Nut......................................................................................................................... 1 L atch ..................................................................................................................... 1 Handle................................................................................................................... 1 S c re w ...................................................................................................................4

* To select appropnatr- part number refer tn trunk data number. The truck data number represents truck features. Refer to Introduction

Always Specify Model, Data & Serial Number Crown 2004 P F13809-4 Rev. 10/07

Q1.0-2040-057 03 Rev. 10/07

381

POWER UNIT PARTS Power Unit

cr

aum

Figure 16320

01.0-2045-001 01 Rev. 3/08

382

Crown 2007 PF15742-1 Rev. 3/08

POWER UNIT PARTS

cnawh INDEX

Power Unit

PART NUMBER

PART NAME

NUMBER REQUIRED

1 ........ . 139604-001*......... . . Frame 685 mm (27 in) Battery Compartment, Domestic . .............................1 139604-002*......... . . Frame 840 mm (33 in) Battery Compartment, Domestic ,..............................1 139604-003*......... . . Frame 915 mm (36 in) Battery Compartment, Domestic ,............................. 1 139604-004*......... . . Frame 685 mm (27 in) Battery Compartment, European . ............................ 1 139604-005*......... . . Frame 840 mm (33 in) Battery Compartment, European . ............................ 1 139604-006*......... . . Frame 915 mm (36 in) Battery Compartment, European . ............................ 1 2 ........ . 129297 ................. ■■ P lug................. ............................. 3 3 ........ . 126260 ................. . . Front Cover. . . ............................. 1 4 ........ . 060063-015........... . . S c re w ............. ............................. 2 5 ........ . 060102-004........... . . U-Nut............... ............................. 2 6 ........ . 126261 ................. . . Rear Cover . . . ............................. 1 7 ........ . 8 ........ . 9 ........ . 1 0 ........ . 1 1 ........ . 1 2 ........ . 13 ........ . 14 ........ . 15 ........ .

126297 ................. 128583 ................. 060032-063........... 060099-003........... 060030-066........... 111594 ................. 127774 ................. 139606 ................. 060115-002...........

■■ P lug................. .. H o o k............... . . Self Tapping S crew ........................................... . . S c re w ............. . . Flatw asher.. . . . . Foam Tape . . . . . Tow P in ........... . . Door W ith Fans . . S c re w .............

........................... AR ............................. 1 ..............................4 ..............................4 ..............................4 ........................... AR ..............................1 ..............................1 .............................. 2

* To select appropriate part number, refer to truck data number. The truck data number represents truck features.

Refer to Introduction.

Always Specify Model, Data & Serial Number Crown 2007 PF15742-2 Rev. 3/08

01.0-2045-002 01 Rev. 3/08

383

POWER UNIT PARTS Power Unit

o v a u in

Figure 16321

01.0-2045-003 01 Rev. 3/08

384

Crown 2007 PF15742-3 Rev. 3/08

POWER UNIT PARTS

cjiauin INDEX 20

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

PART NUMBER

Power Unit PART NAME

NUMBER REQUIRED

128289 ..................... Floor M at................................ 128160 ..................... Rear Floor Cover................... 128159 ..................... Front Floor C o ve r................. 128245 ..................... Lift Motor Cover..................... 128173 ..................... Floor Bracket......................... 050025-010...............Carriage B o lt......................... 050068-004...............Lock N u t................................ 129995 ..................... Steer Motor Mount................. 050025-010...............Carriage B o lt......................... 050068-004...............Flanged Nut........................... 128604 ..................... LH Fender M a t..................... 128588 ..................... LH Step M a t......................... 128246 ..................... RH Fender M a t..................... 128248 ..................... RH Step M a t......................... 060063-016...............S c re w .................................... 060102-004...............U-Nut...................................... C ) ..............................Counterweight ..................... ..............................LH Auxiliary Counterweight (1) ..............................S c re w .................................... ..............................RH Auxiliary Counterweight (1> ..............................S c re w .................................... 060059-017...............Nut.......................................... 0) See Counterweight Chart

1 1

1 1 1 2 2 1 3 3

1 1 1 1 4 4

1 1 2 1 2 4

C ounterw eight Chart Truck Model Numbers

Index 36 Counterweight

Index 37 LH Auxiliary Counterweight

Index 38 Screw

Index 39 RH Auxiliary Counterweight

Index 40 Screw

4510-40,4520-40, 4520-50, 4540-50, 4510-2.0, 4520-2.0, 4520-2.5 & 4540-2.5

126886

-

-

-

-

4510-50,4520-55, 4520-60,4540-55, 4540-60,4510-2.5, 4520-3.0 & 4540-3.0

126887

-

-

-

-

4520-50, 4520-60, 4520-2.5 & 4520-3.0

126886

Contact Factory

060099-004

Contact Factory

060099-004

4510-40,4510-50, 4540-50, 4520-55, 4510-2.0, 4510-2.5, & 4540-2.5

126887

Contact Factory

060099-005

Contact Factory

060099-005

Always Specify Model, Data & Serial Number Crown 2007 PF15742-4 Rev. 3/08

01.0-2045-004 01 Rev. 3/08

385

POWER UNIT PARTS Overhead Guard & Covers

cnauin

Figure 16346

01.1-2045-001

386

Crown 2007 PF15795-1

POWER UNIT PARTS

CSKDUIh INDEX

Overhead Guard & Covers

PART NUMBER

PART NAME

1 2 3 4 5

NUMBER REQUIRED

............. 124029 ......Top C o ve r................................................................................. 060061-015............... S c re w ........................................................................................ 060061-010............... S c re w ........................................................................................ 124030......................Cover........................................................................................... 124269 ..................... S ta n d O ff..................................................................................... 124031 ..................... Cover........................................................................................... 124034 ..................... Console C o v e r........................................................................ . 124033 ......................Front C over.............................................................................. 050067-012............... Locking Bolt................................................................................ 050067-014............... Flanged S c re w ........................................................................ 060102-002............... U-Nut........................................................................................... 124036-001............... Rear C o ve r................................................................................ 129549 ..................... G u a rd ......................................................................................... 050006-024............... S c re w ......................................................................................... 060115-003............... S c re w ......................................................................................... 060075-008............... S c re w .......................................................................... .............. 050067-044............... S c re w ......................................................................................... 060059-010............... Nut............................................................................................... 065004-050............... Grommet 25 mm (1.0 in) D iam eter........................................ . 065004-035............... Grommet 19 mm (0.75 in) D iam eter........................................ 124993 ..................... B um per....................................................................................... 124530 ..................... P lug............................................................................................. 1 2 9 3 3 2 *................... Rectangular Plug, Drive Thru Overhead Guard, Not Shown 2 3 ...... 132582-002*............. Pad, Drive Thru Overhead Guard, Not S how n....................... ...... ...... ...... ...... 6 ...... 7 ...... 8 ......... 9 ......... 10 ......... 11 ...... 12 ......... 13 ...... 14 ......... 15 ......... 16 ......... 17 ......... 18 ...... 19 ......... 20 ......... 2 1 ...... 2 2 ......

1 7

2 1 2 1 1 1 9

2 2 1 2 4 4

2 4 4

1 1 2 2 8 2

* To select appropriate part number, refer to truck data number. The truck data number represents truck features.

Refer to Introduction. I

Always Specify Model, Data & Serial Number Crown 2007 PF15795-2

01.1-2045-002

387

POWER UNIT PARTS Overhead Guard & Covers

CRQUJh

Figure 16349

1.1-2045-003

388

Crown 2007 PF15795-3

POWER UNIT PARTS

ejiaiuh

Overhead Guard & Covers

Overhead Guard Chart Battery Compartment Size

Crown 2007 PF15795-4

Height

mm

(in)

mm

(in)

Overhead Guard Style

Overhead Guard Index 25

685

(27)

2120

(83.5)

Standard

127011-001

685

(27)

2185

(86 .0 )

Standard

127011-002

685

(27)

2250

(88.5)

Standard

127011-003

840

(33)

2120

(83.5)

Standard

126635-001

840

(33)

2185

(86 .0 )

Standard

126635-002

840

(33)

2250

(88.5)

Standard

126635-003

915

(36)

2120

(83.5)

Standard

127012-001

915

(36)

2185

(86 .0 )

Standard

127012-002

915

(36)

2250

(88.5)

Standard

127012-003

685

(27)

2185

(86 .0 )

Drive-Thru

128650-001

840

(33)

2185

(86 .0 )

Drive-Thru

128650-002

915

(36)

2185

(86 .0 )

Drive-Thru

128650-003

01.1-2045-004

389

POWER UNIT PARTS

cjiauin

Battery Spacers & Retainers

4

i

Figure 16366

01.2-2045-001 01 Rev. 1/08

390

Crown 2007 PF15804-1 Rev. 1/08

POWER UNIT PARTS

ciiaiuh INDEX

Battery Spacers & Retainers

PART NUMBER

PART NAME

0

............. 138522-003*.. Roller Assembly (1) ..................................................... 138522-001*.............Roller Assembly (2 & 3>..................................................... 1 ............ 138523-003*.............. Roller (1), Quantity for One Roller A ssem bly.......... 138523- 0 0 1 *......... Roller (2&3), Quantity for One Roller A ssem bly.. . 2 .............138524-003*.............. Shaft W, Quantity for One Roller Assem bly........... 138524- 0 0 1 * ......... Shaft . . 128475-003*............. LH Lower Strip *3) . . 141990-001*.............RH C over*1) ............. 141990-002*............. RH Cover*2) ............. 141990-003*............. RH Cover*3) ............. 128472-001*.............RH Retainer *1) . . . . 128472-002*.............RH Retainer *2) . . . . 128472-003*.............RH Retainer *3) . . . . 050006-050............... S c re w ..................... 050009-026............... Flatwasher............... 050068-004............... Flanged Nut............... 060063-022............... Nut............................ 128945-001*.............Battery Door *1) . . . . 128945-002*.............Battery Door *2) . . . . 128945-003*.............Battery Door *3) . . . . 128966 ..................... Handle..................... 128967 ..................... L atch........................ 060120-001............... S c re w ..................... 130153 ..................... Compression Spring 060009-136............... Retaining Ring.........

36

37

38

39 40 41 42 43

44 45 46 47 48

PART NAME

NUMBER REQUIRED ........................... 1 ............................. 4 ..............................4

.......................1 ........................... 1 ........................... 1 ........................... 1 ........................... 1 ........................... 1 ........................... 1 ........................... 1 ........................... 1 ........................... 1 ........................... 1 ........................... 1 .......................1 ........................... 1 .........................2 .........................2 .........................2 .........................2 ........................... 1 ........................... 1 .......................1 ........................... 1 ........................... 1 ........................... 1 ........................... 1 ........................... 1

*1) 685 mm (27 in) Battery Compartment *2) 840 mm (33 in) Battery Compartment *3) 915 mm (36 in) Battery Compartment

' To select appropnate parr number, refer to truck data number. The truck data number represents truck features. 'A; Refer to Introduction.

Always Specify Model, Data & Serial Number Crown 2007 PF15804-4 Rev. 1/08

01.2-2045-004 01 Rev. 1/08

393

POWER UNIT PARTS Battery Spacers & Retainers

ewauih

63

BRES

Figure 16368

01.2-2045-005 01 Rev. 1/08

394

Crown 2007 PF15804-5 Rev. 1/08

POWER UNIT PARTS < 2 j\a u m INDEX

Battery Spacers & Retainers

PART NUMBER

PART NAME

NUMBER REQUIRED

1

6 0 ......* .................................. Spacer, See Spacer Chart 6 1 ...... 060075-005............... S c re w ............................... 62 ......... 050068-004............... Nut...................................... 63 ......... 060099-002............... S c re w ............................... 061004-026............... Thread Lock Adhesive . . 64 ......... 050008-068............... Nut...................................... 6 5 ...... 130465 ......................B ra cke t.............................. 66 ......... 060061-001............... S c re w ............................... 67 ......... 062488-004............... Spacer............................... 6 8 ...... 060059-002............... Nut...................................... 6 9 ...... 130464 ..................... A ctuator............................. 7 0 ...... 050068-002............... Nut...................................... 7 1 ...... 050008-025............... Lock N u t............................ 7 2 ...... 060030-252............... Flatwasher......................... 7 3 ...... 062752-005............... Sealed S w itch................... 7 4 ...... 126046 ..................... S pa ce r.............................. 7 5 ...... 050004-005............... S c re w ............................... 7 6 ...... 060059-014............... Nut......................................

2

2 1

1 1 1 1 1 1 1

2 2 2 1 1

2 2

* t 0 select appropriate pad number, refer to truck data number. The truck data number represents truck features. Refer to Introduction.

Spacer C hart Battery Width

Battery Compartment Size mm

(in)

mm

(in)

Spacer Kit Includes Hardware

685

(27)

675 to 690

(26.50 to 27.25)

Not Required

Not Required

840

(33)

740 to 760

(29.13 to 30.00)

129503

128669

840

(33)

795 to 810

(31.37 to 32.00)

129501

128667

840

(33)

825 to 835

(32.50 to 32.94)

Not Required

Not Required

840

(33)

750 to 760

(29.68 to 30.00)

130705

130703

915

(36)

855 to 870

(33.59 to 34.13)

129502

128668

915

(36)

900 to 925

(35.50 to 36.38)

Not Required

i

Spacer Index 60

Not Required

Always Specify Model, Data & Serial Number Crown 2007 PF15804-6 Rev. 1/08

01.2-2045-006 01 Rev. 1/08

395

POWER UNIT PARTS Static Seat

cjiauin

Figure 16387-01

01.5-2040-005 03 Rev. 3/08

396

Crown 2004 PF13808-1 Rev. 3/08

POWER UNIT PARTS

cnaiim INDEX

1 2 3 4 5

6 7

8 9

10

11 12 13 14 15 16 17 18 19

20

PART NUMBER

Static Seat PART NAME

122001 ..................... Fabric S e a t.................................. 122002 ..................... Vinyl S e a t.................................... 122029 ..................... R estraint...................................... 060017-011............... S c re w .......................................... 060017-035............... S c re w .......................................... 060005-009.................Lockwasher................................ 122044 ..................... Foam C o v e r................................ 124022 ..................... Back C o ve r.................................. 060032-062............... S c re w .......................................... 122003 ..................... Anti-Cinch Black Seat Belt K it.. 122003-002............... Anti-Cinch Orange Seat Belt Kit . . .060018-001 ................Screw ..................................... 061004-026............... Thread Locking Adhesive .. ...0 6 0 0 2 1 -0 5 2 ............... N u t....................................... .. . . .060019-011 ................Screw..................................... 061004-026............... Thread Locking Adhesive .. . . . 060019-050................Screw .................................... 061004-026............... Thread Locking Adhesive .. 060019-010............... S c re w .......................................... 060030-187............... Flatwasher.................................... 1 3 0 0 0 6 *................... B ra cke t........................................ 060016-012............... S c re w ........................................... 8 11145..................... Arm Rest R H ................................ . . . 811147........................Fixing S c re w ......................... .. .811149........................ C over.....................................

NUMBER REQUIRED

1 1

1 2 3 5

2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1

Always Specify Model, Data & Serial Number Crown 2004 PF13808-2 Rev. 3/08

01.5-2040-006 03 Rev. 3/08

397

POWER UNIT PARTS Static Seat

crquin

i

i

Figure 16388-01

01.5-2040-007 03 Rev. 3/08

398

Crown 2004 PF13808-3 Rev. 3/08

POWER UNIT PARTS

cilauin

Static Seat

INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

3 0 ........ . 3 1 ........ . 3 2 ........ . 3 3 ........ . 3 4 ........ . 3 5 ... . . 3 6 ........ . 3 7 ........ . 38. . . . . 39. . . . . 4 0 ........ . 4 1 .... . 4 2 .... . 4 3 ........ . 4 4 .... . 4 5 ___ . 4 6 .... . 4 7 ___ .

112262 ..................... 112261 ..................... 112299 ..................... 060016-012............... 107898 ..................... 122033 ..................... 060016-004............... 060030-232............... 060005-020............... 060021-009............... 115556 ..................... 060015-037............... 060005-007............... 115559 ..................... 060013-002............... 060005-004............... 093603 ..................... 062933 ..................... 062752-003*............. 061002-003*............. 060065-007*............. 050008-001*............. 115557*..................... 060011-013............... 060030-005............... 060005-049............... 060021-023...............

S lid e ................................................. Locking Slide.................................... B ra cke t............................................. S c re w ............................................... Cupped W a sh e r.............................. Spacer............................................... S c re w ............................................... Flatwasher......................................... Lockwasher...................................... Nut..................................................... B ra cke t............................................. S c re w ............................................... Lockwasher...................................... Flat Spring......................................... S c re w ............................................... Lockwasher...................................... In s u la to r........................................... S w itch............................................... Switch (Freezer/Corrosion)............. Harness Clamp (Freezer/Corrosion) Screw (Freezer/Corrosion)............. Nut (Freezer/C orrosion)................. Heater Bracket (Freezer/Corrosion) S c re w ............................................... Flatwasher......................................... Lockwasher...................................... Nut.....................................................

........................... 1 .........................1 ............ ............. 2 .......................... 2 ..........................2 ..........................2 .......................... 2 ..........................2

4 8 .... 4 9 .... 50. . .. 5 1 ... . 5 2 ....

. . . . .

..............................4 ..............................4 .............................. 1

.......................... 2 .......................... 2 .......................... 2 .......................... 2 .......................... 2 ..............................4

.......................... 2 .......................... 2

.........................1 ............................1 .......................... ... 1 .........................1 ..............................4

.......................... 2 ..............................4 ..............................4

* To select appropriate pa it number, refer to truck data number. The truck data number represents truck features. Refer to Introduction.

Always Specify Model, Data & Serial Number Crown 2004 P F13808-4 Rev. 3/08

01.5-2040-008 03 Rev. 3/08

399

POWER UNIT PARTS CJlO UJh

Suspension Seat

15 /•

26

(a)

In order to mount Index 24 to S eat Back using Index 21, the R ear Cover on S eat must be unlatched by lifting up on Seat Back Cushion.

(b)

Part o f Suspension Seat

(c)

Optional Arm Rest

(d)

Part o f S eat Deck, S ee Power Unit Parts

^ 1 7 25

Figure 17900-01

01.5-2040-056 04 Rev. 3/08

400

Crown 2004 PF13803-1 Rev. 3/08

POWER UNIT PARTS C A Q U Jh INDEX

1 2 3 4 5

6 7

8 9

10 11 12 13 14 15 16 17 18 19

20 21 22 23 24 25 26 27 28 29

PART NUMBER

Suspension Seat PART NAME

137973 ..................... Fabric Suspension S e a t............. 130987 ..................... Vinyl Suspension S e a t............... . . . 133706........................S w itc h ................................... . . . 129632........................Locking S lid e ......................... . . .129631........................S lide ....................................... 060059-001............... Thin Nut........................................ 137975 ..................... Suspension Seat Back C o v e r.. 050008026..Nut.............................................. 050009-020............... Flatwasher................................. 0 6 0 0 3 2 - 0 0 5 . . . . . . . . Self-Tapping Screw ................... 060030-046............... Flatwasher................................. 137974 ......................Suspension Seat Cover B ack.. 060032-047............... Self-Tapping S crew ..................... 060063-011............... S c re w ........................................ 060030-242............... Flatwasher................................. 060059-001............... Nut.............................................. 122031 ..................... R estraint.................................... 122016 ..................... Anti-Cinch Black Seat Belt K i t . . 122016-002............... Anti-Cinch Orange Seat Belt Kit 050003-059............... S c re w ........................................ 050008-060............... Lock N u t...................................... 050073-003............... Spring N u t.................................... 060063-011............... S c re w ........................................ 050009020..Flatwasher................................. 060059-001............... Nut.............................................. 810736 ..................... B ra cke t...................................... 050067035..S c re w ........................................ 050068004..Nut.............................................. 8 11145......................RH Arm Rest ............................. . . .811147....................... Fixing S c re w ......................... . . .811149....................... C over.....................................

NUMBER REQUIRED

1 1 1 1 1 2 1 2 2 1 1 1 2 4 4 4

1 1 1 5 3 4

1 1 1

1 1 1 1 1 1

Always Specify Model, Data & Serial Number Crown 2004 PF13803-2 Rev. 3/08

01.5-2040-057 04 Rev. 3/08

401

POWER UNIT PARTS Suspension Seat

CRQUIh

Figure 17901

01.5-2040-058 04 Rev. 3/08

402

Crown 2004 PF13803-3 Rev. 3/08

POWER UNIT PARTS

.. 064298-032*............. Hose Assembly (4>(5> ..

NUMBER REQUIRED

2 2 2 2 2 2

2 2 2 2 2 2 2 1 2 1 1 1 1 1 1

1 1

1 1 1 1 1

(3) 1815 kg (4000 lb), 2270 kg (5000 lb), and 2495 kg (5500 lb) Truck Capacities (4) 2720 kg (6000 lb) Truck Capacity Trucks without Accessory Manifold

Always Specify Model, Data & Serial Number Crown 2008 PF17318-4

02.7-2045-103

487

HYDRAULIC PARTS Carriage Hydraulics - Quad Mast

annum

Trucks With Sideshift

Crown 2004 PF13943-1 Rev. 8/07

02.74-2040-100 01 Rev. 8/07

488

HYDRAULIC PARTS

CJVQUJh INDEX

PART NUMBER

1 2 3 4 5

6 7

20 21 22 23 24 25 26 27 28

PART NAME

............. 064279-010..A dapter............. ............. 064337-002. H . o s e ................. ............. 064325-006..Bulkhead Nut . .. ............. 064326-006..Bulkhead Fitting ............. 060016-088. S . c re w ............... ............. 060005-008..Lockwasher.. . . ............. 064128-001* C a p ................... 064004-001*. Connector........ 064232-001*. Dust Plug.......... 064334-003*. Female Coupler. 064019-030*. O-Ring............... Dust C ap.......... 064231-001*. 064333-003*. N ip p le ............... 064004-004*. Connector........ 064019-029*. O-Ring............... 132487* T u b e ................. 132490* T u b e ................. 064326-006. . Bulkhead Fitting 064325-006. . Bulkhead Nut . .. 060016-088. . S c re w ............... 060005-008. , Lockwasher.. . . 064091-002. , Plug................... 132491* T u b e ................. 132490* T u b e ................. 064325-006. . Bulkhead N u t... Bulkhead Fitting 064326-006.. T u b e ................. 132488* . . . T u b e ................. 132489*

.

8 ......... . .

9 10 11 12 13 14 15 16 17 18 19

Carriage Hydraulics - Quad Mast

. . . . . . . . . . . . . . . . .

NUMBER REQUIRED

2 2 2

2 2 2 2 2 2 2 2 2 2 2 2 1 1 2 2 4 4 4

1 1 4 4

1 1

* To select appropriate part number, refer to truck data number. The truck data number represents truck features.

Refer to Introduction.

Always Specify Model, Data & Serial Number Crown 2004 PF13943-2 Rev. 8/07

02.74-2040-101 01 Rev. 8/07

489

HYDRAULIC PARTS

caauih

Carriage Hydraulics - Quad Mast

Trucks With Sideshift, Double Hydraulic Accessory And One Accessory Manifold Block Mounted On Right Side Of Quick Disconnect (1)

Right And Left Are Determined From Operator’s Perspective

(2)

To Sideshift Cylinder

(3)

To Accessory Hoses

(4)

S ee Hydraulic Parts

- ' Trucks With Two Accessory Manifold Blocks, Sideshift And Quick Disconnect See Lifting Mechanism Parts For Fork Carriage (5)

See Hydraulic Parts

(6)

To Sideshift Cylinder

Figure 17211

02.74-2040-102 01 Rev. 8/07

490

Crown 2004 PF13943-3 Rev. 8/07

HYDRAULIC PARTS

£RGUIh INDEX

Carriage Hydraulics - Quad Mast

PART NUMBER

35 . 060016-088. . . . 36 . 060005-008... . 37 . 064279-010*... 38 . 064337-002*... 39 . 064325-006. .. . 40 ......... 064 3 26 -0 0 6.... 41 .064280-006*... 42 ......... 064019-101*... 43 ......... 064337-003*... 44 . 1 32 4 8 9 *........... 45 . 1 3 2 4 8 8 *........... 46 ......... 0 64 0 19 -0 2 9.... 47 ......... 064 0 04 -0 0 4.... 48 ......... 064333-003*... 49 ......... 064231-001*... 50 ......... 064019-030*... 51 . 064334-003*... 52 ......... 064232-001*... 53 ......... 064004-001*... 54 . 064128-001*.. . 55 . 060016-088.... 56 . 060005-008. . . . 57 . 1 32 4 9 1 *........... 58 . 1 32 4 9 0 *........... 59 . 064325-006. .. . 60 . 064326-006. .. . 61 . 064280-002*. . . 62 . 064019-101*... 63 . 064232-001*.. . 64 . 064334-003* . . . 65 . 064019-030*... 66 . 064231-001*... 67 . 064333-003*.. . 68 . 064004-004*.. . 69 . 064019-029*. . . 70 . 064308-003*... 061003-005*.. . 71 . 064308-002*.. . 72 . 064280-006*... 73 . 1 32 4 8 8 *........... 74 . 1 32 4 89 *........... 75 ......... 064004-001*... 76 ......... 064128-001. . . .

PART NAME S c re w ....................... Lockwasher............... Adapter..................... H o se .......................... Bulkhead Nut............. Bulkhead Fitting . . . . Adapter..................... O-Ring........................ H o se .......................... T u b e .......................... T u b e .......................... O-Ring........................ Connector................. N ip p le ........................ Dust Cap................... O-Ring........................ Female Coupler......... Dust Plug................... Connector................. C a p ............................ S c re w ........................ Lockwasher............... T u b e .......................... T u b e .......................... Bulkhead Nut............. Bulkhead Fitting . . . . Adapter..................... O-Ring....................... Dust Plug................... Female Coupler......... O-Ring....................... Dust C ap................... N ip p le ....................... Connector................. O-Ring........................ H o se .......................... Cable Tie, Not Shown H o se .......................... Adapter..................... T u b e .......................... T u b e .......................... Connector................. C a p ............................

NUMBER REQUIRED

.........................2 .......................... 2

.........................1 .........................1 ..............................4 ..............................4

.........................1 .........................1 .........................1 .........................1 .........................1 .......................... 2 .......................... 2 .............. ........... 2 .......................... 2 .......................... 2 .......................... 2 .......................... 2 .......................... 2 .......................... 2 ..............................4 ..............................4

.........................1 .........................1 ..............................4 ..............................4

...................... .. 2 ..............................4 ..............................4 ..............................4 ..............................4 ..............................4 ..............................4 ..............................4 ..............................4

.........................1 .........................1 .........................1 .......................... 2 .........................1 .........................1 .......................... 2 .......................... 2

* To select appropriate part number, refer to truck data number. The truck data number represents truck features. Refer to Introduction.

Always Specify Model, Data & Serial Number Crown 2004 PF13943-4 Rev. 807

02.74-2040-103 01 Rev. 8/07

491

HYDRAULIC PARTS

cjiaiun

TT Carriage Hydraulics - Double Accessory

Trucks without Quick Disconnect

(a)

S ee Accessory Line Hydraulics - W Mast

(b)

Sideshifter

(c)

S ee Accessory Manifold - TT

(d)

Torque 43-47 Nm (32-35 ft lb)

(e)

Torque 23-26 Nm (17-19 ft lb)

(f)

Torque 16-18 Nm (12-13 ft lb)

(C)

Figure 19696

02.8-2045-100

492

Crown 2008 PF17338-1

HYDRAULIC PARTS

CAQUIh INDEX

TT Carriage Hydraulics - Double Accessory

PART NUMBER

PART NAME

1

............. 137899 ......Mounting Bracket LH___ 137898 ..................... Mounting Bracket RH . . . 2 ...... 060063-026............... S c re w ............................... 3 ...... 064355-008............... Bulkhead Straight Fitting. 4 ............... 064019-100................O -R ing........................ 5 ............... 064019-030............... O -R ing........................ 6 . . . . . 064325-008......... . .. Nut.......................... 7. . . . . 0 6 4 4 6 8 -0 0 8 ..... . . . 37° Adapter........... 8 . . . . . 064128-001........ . . . C a p ....................... 9. . . . . 1 39 1 78 -0 0 1*.... . . . Tube Assembly 0). 139178-002*.. .. 1 0 . .. . . 139180-001*.. .. . . . Tube Assembly C). 139180-002*.. .. . . . Tube Assembly (2). 1 1 . . . . . 139177-001*.. .. . . . Tube Assembly C). 1 39 1 77 -0 0 2*....___Tube Assembly (2). 1 2 . .. . . 139179-001*.. ..___Tube Assembly (1). 1 39 1 79-002*.... . . . Tube Assembly 064298-031*.............Hose Assembly (2) (3) 3 9 ...... 064298-029...............Hose Assembly (1M2) 064298-012*.............Hose Assembly