ITD - 04.2 - 001 - 02 INTRODUCTION This manual Is intended for the service mechanic who Is seeking Information about maintenance and service replacement parts. It contains a section on trouble shooting which will enable a qualified mechanic to locate and solve problems which may occur. This manual does not contain operation instructions. For operation instructions, refer to the Crown publication, "You and Your Crown Walkie,” (PF-2785) When ordering replacement parts from this manual, always specify, along with the part ‘umber, the model and serlal number of the truck. This Information will further enable us to Give correct, fast and efficient service. For capacities, technical information and dimensional specifications, please refer to the following sales literature: SeriesW SF-1111 Rev. 10/77 Serles WA SF-1626 Rev. 3/72 Copies of publications can be obtained from your Crown dealer or by writing to: crown 40-44. Washington Street New Bremen, OH 45869 ‘An index for this manual is located on the following pages. The manual Is arranged according to major sections. The first part of the page number, found at the bottom of each page, denotes the section in which a particular form will be located. These sections are Indicated by a black bar at the right hand edge of the page. The higher the number of the section, the farther down the page It Is located. The sectional breakdown is as follows: Section 1 Basic Chassis or Power Unit Section 2 Hydraulic System and Components Section 3. Drive Unit and Components Section 4 Electrical Components Section 5 Brake Assemblies and Brake Systems Section 6 Steering System and Components Section 7 Main Frame and Mast Assemblies Section 8 Cylinders Section 10 Accessories FGrown arr Pra Rew 2776__=“(NTRODUCTION . All Crown it trucks are ven a model number. This number is used as a ie} str gtion 2 bt the tuck "The folowing chart gues'a model number and, shinow i aa formed: y BoB os MODEL NUMBER SYSTE! ¥ 4 Potind Rated (x 100} : “3G 100 = 8000 Ibs. ee cee : 5, Méic Rated (x 1000) 36. 900 se 3* 2.0% 1000 = 20009 420 : ete 48 x 1180 MODEL DESIGNATION We Walkie Fl <9 Walkie Articulated we am oF sats 34 "870 = ee 36 4920 * T., Telescopic 38 * 970 Be test 40 40 otk 2 ‘som: © PAF ull Free Litt 4 sa ¥ Sra: “170 PL Limited Free Lift 2 48 soa; x, 2 (80 270s 5 TsMfriple Telescopic "beam te: ‘A tft truck having the modet ‘number 30 WrF-+- 2 would be a * 3000 ib. (809 mm) collapsed heiat ih Fk length 3 capacity walkie with telescopic ful tregtt-a 11 38" (970 mm) inside straddle, and 2 88" € * Actual rated capacity may vary. depending upon special equipment or modifications. z Consult serial number plate. COLLAPSED HEISHT : " mu ‘ mm} 460 a. (20 = } ao inden ITD 04:2 00202Revision No, - Date x 2.0w oo: aire o1-8/79 ot -e/e2 2 REE HRI BER IO OK EB I HCH IO HHO EO OO OOK OIE BES ROO RK IO A OE IO RIO I II I IK IO I RI — Ser aes Pr = (IDX 7-04.2- 208 - HEAVY.DUTY, W INDEX Tite thnfodiuétion General Maintenance Maintenance Torque Values Hycraulie Schematic Syinbote Pump, Gear Valve, Control (Parker) — Roliet Valve Adjustment — Trouble Shooling Chgrt Valve: Control (Cessna) ee ~ Relief Valve Adjustmont -Trouble Shooting Chart Hose Rost Color Codes = Wiring Harness — Power Cables — symbole & Abbreviations SCR Model 50 ~ The SCR System circuit Operation — Controi Features = Waintenance: —Tune-up ~ Component Testing = Trouble Shooting Crjart Contactors, 75Amp ‘ Contectors, 100 Amp Contactore, 160 Amp Battery Batery Interrupt Battery Interrupt Motors ‘Trouble Shooting Procedures Trouble Shooting Chart Schmatio - Electrical Pictorlal- Control Poa Pictorial - Contactor Panet Pictorlal- Main Wiring Pictorial- Power Cablee Pictorial Accessories ‘Schematic Electrical - SCR Pictorial - Control Pod - SCR Pictorial - Contactor Panel - SCR Pictorial- Main Witing- SCR Pictorial- Power Gables - SCR Plotorial - Accessories - SCA Thydraulig Schematio | °° oes Wes gs 8 GR-80-008 ‘This Index Is used for all W(H.0.) Models from Decombar, 1963, Standard Serial No, W-22219 Speclal Serial No. H-0877 70 -04.2-001 MA- 04-001 MA-04.2-001 M1.9- 14-001 Mz.1~00-001 Ma2.t-12-011 2.3-11-001 2.314 - 005 M2.3~ 11-008 2 3- 14-020 2.3 14-028 M2.3- 14-024 m2's-11-001 Mga 12-001 Ma.1-12-001 Maa 12-002 4.1 712-003 SCR-50-001 SCR 50-002 ‘SCR -50 -002 3GA- 50-009 SCR -50-004 SCR -50 005 ‘SCR-50-007 Maa 11-001 Maa t1 ott Maa 11-021 | -Ma8 11-008 Ma.8-11 - 200 M48 -11-800 Ma.7-04,2-001 ‘W48-04.2-001 Ma.9-04.2-00% DIA -04.2- 086 DIA 0412-100, Dia 042-200 DIA-04.2- 300, Di& -04.2- 400 DIA -04.2- 450 DIA 04.2 - 506 DIA 04:2-600 DIA-04:2- 700 DIA -04'2- B00 DIA- 08.2900 1a +04 2-950 HYD -04.2-007 eT eTTTY IDX - 04.2 - 208, | yp| HEAVY, DUTY. W. INDEX t & Revision Tie : Pacis Number 2 Nov bate - x Power Unit \ 8 1-04.2-008, XXX Retractable Remote Control " 141-042-001 eB BK Hycraulic System 5 r 2042-011 ok OX 7 208.214 KKK Hydraulic System w/Remote Lockout © 2-04.2-202 4 x RX KK Pump -90625 ach 2.1-07.2-001 - ay Xe KKK OK Motor, Pump - 2619 1 " 1 ty, 2.2 -07.2- 002 XX XX x awe - 92645 ere ero 23-11 -008 Lk, KX .X X 01-10/82 —Vabe-st981 sorts gurtss0 : 24-08-003, XK KX Control Linkage Bat ix 28-08-001 (XK KKK orve Unit-Top a3 as 912-000 KX x XX Drive Unit - Bottom F aet2-108 KK Xx Motor, Drive 87652 3.4 -08.2-008 Xx K Kx Tire Assembly 322-042-001 box xxx Contactor Pane! 404.9005, area ar aa oR Contactor Panet 4:1-08.2-006 ’ Kx Kx Contactor Assembly 414-042-004 i KX KX X O1-1/79: Contactor Assembly 44-11-001 KX XX x onto! Handle 45-04.2-008 i: XX KX XK Control Handie - SCR 4.6-04.2-004 Jeena Electrical Components 48-04.2-001 5 KK KX 2 Button Station 49-064.258 Seer KREME Battery Intenupt 4.9-05.1 -050 Xxx Kx Battery Interrupt a9-1t one KKK KX Brake System 5-06.2-001 KKK KX rake Assombiy 83-04-04 Souter Pear IDX - 04.2 - 200 ADX - 04.2 -,209 Spmaiien“CHEAVY DUTY W INDEX i 5 Bi i 3.3.32 tHe 223 é a's? 2 § ee sete ‘Mast Assembly (TL, TF) 74-b4.2-011 i ee Mast Assembiy (Adjustable rr-bad-s10 LN. s 2 ait ‘Mast Assembly (TL, TF) © 71-64a-s00 |e XXX XX Mast Assembly (TT) 7.2-04,2- 005, iH Kxxxx Load Backrest . 13-dez-ov2 |° XXX XK Fork Assembly 7'9-08-bo2 s 3 xx tinder, uit 74 2199, 81201 == ei-osa-o0a |S xx Cynder, it (TL 01178, e1104 ei-dutton |} N XX 01-11/78 —Oylinder, Lit (TL) 81182, 81186 etats-o [S XXX x Cylinder, it TF at173 ss sa-tiaton |E | mete ylinger, Lift (TT) 81148 24-058-001 |] we fo Mtn Cylinder, Lift (TT 81198 ea-titlon [N 7 S37 E 5 | so cuca T | ipiee Oo | x 5 x “ — a a E cone eee ieee x | ‘ oT é | c aa y |e | ora Ee NEE SB | * € : é : 5 6 N as r t o N $ . 10 € r I eteeeecee ee woccmome|O | 7 ~— a N STE ETERS" 1 x ao i “DX -04.2- 210 IDX-04.2-210 |Bem T SPE eaves raped? marge fae Wei 2, Debus Me nate RR ERIE FEE nate, en ps Las eva ~or bre catia eat os nimi oes “eet? ay 2 estes sonst Peep pe BIBVER LC oa ays se on ET Pret apirign 68 Be nero hoe vntos ae ae ua STMONAS 26 aS FE Toe Gry ate om sufadlunem wore Soy 6 BME eo od 1B RCHEIEGO oot, ATW Ure Sanity SEEPS Gio neh sass n9ceiass tie Heat ee 8 AB TEMBOE SE Te Hoga ho leecghe sift a: dauivera bs grnsage oF ga mein + horn POO AC. aMGENERAL MAINTENANCE INSTRUCTIONS WARNING TO PREVENT SERIOUS RISK OF INJURY TO YOURSELF AND OTHERS OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS Power industrial trucks may become hazardous if adequate maintenance Is neglected. Therefore, adequate maintenance facilities, trained personnel and procedures should be provided. Maintenance and inspection shall be performed in conformance with the following practices 1. A scheduled planned maintenance, lubrication. and inspection system should be followed. 2. Only qualified and authorized personnel shall be permitted to maintain, repair. adjust and inspect, truck 3. Before leaving the truck — a. Stop truck: ». Fully lower the toad engaging means. Cc. Place directional controls in neutral. d. Apply the parking brake. e. Turn off power (power disconnect) £. Remove key. 9. Block the wheels if truck is on an incline. 4. Before working on truck — a, Raise drive whee! tree of Hloor or disconnect power sources. b. Use chocks or other posi devices. ©. Block 1oad engaging means. inter masts, or ‘chassis before working under them. d. Operation to check performance of truck or attachments shatl be conducted In an author- ized safe clearance area, positioning Before starting to operate truck — 8. Be In operating position b. Apply Brake. . Place directional control in neutral d. Before operating truck, check functions of lift systems, directional control, speed control, steering, 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 flame to check level, or for leakage of electrolyte and fluids or oil. Do not use open pans of fuel or flammable cleaning fluids for eleaning parts. 7. Keep shop well ventilated, clean and dy. 8, Brakes, steering mechanisms, contre! mechan- isms, lift overload devices. guards, and safety devices shail be inspected regularly and main- tained in a safe operating condition. 9. Capacity, operation and maintenance instruction plates or decals shali be maintained in legible condition. 10. All parts of lift mechanisms shall be inspected to ‘maintain them in safe operating condition. 11, All hydraulic systems shall be regularly inspected and maintained in conformance with good practice. Cylinders, valves. and other similar parts shall be checked to assure that “drift” has not developed to the extent that it would create a fhazard. 12, Batteries, motors, controllers, limit switches, protective devices, electrical conductors, and connections shall be maintained in conformance with good practice. Special attention shalt be paid to the condition of electrical insulation. 19, Trucks shall be kept in a clean condition to mini mize fire hazards and facilitate detection of loose or defective parts. 14. Modifications and additions whichaffect capacity and safe truck operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation and maintenance plates or decals shail be changed accordingly 15. Care shall be taken to asaure that all replacement parts are interchangeable with the original parts and of equal quality to that provided in the original equipment, For further information pertaining 10 operating and maintenance procedures, refer to ANS! B56.1 - 1975. For copies send to: ‘American National Standards Institute 1430 Broadway New York, NY 10018 01 REV. 6/78 MA - 04-001 MA - 04-00120W-30W MAINTENANCE 41. Lubrication NOTE All bearings are lubricated for life, 4. Channel - The roller surtace of the channels should be lubricated with @ good grade of light grease. b. Drive Unit - The lube level should be checked quarterly at the lube level check plug (See Item 497 on drive unit parts breakdown). if lube level Is low, add No. 90 gear (ube to proper level. Approximate capacity of drive unit Is one-half gallon. 2. Hycraulic System a. To check hydraulic ofl level, remove oll reservoir filler cap. Oi} should be visibie at the bottom of the screen with the forks lowered to the floor. Approximate capacity of hydraulic is four and ‘one quarter gallons. Use good grade of hydrau- lic olf such as Pure Oil Puropale RX light oll or ‘an equal. DO NOT USE HYDRAULIC BRAKE FLUID. b. Occasionally, a slight creep of the carriage may occur. This may be due to internal leakage in the raise-lower valve or in the piston pak, On remote control raise and lower units, this can be ‘due to leakage in the remote lowering solenoid land the check valve. To seat these valves properly when this occurs, raise and lower the cartiage to flush out valve seat of any foreign material ©. Should a leak develop In one of the hydraulic lines, the oil reservoir can be unbolted and moved without disconnecting the hydraulic hose line. The reservolr will slide out of the way and provide access to hydraulle components, 3. Brake Adjustment To adjust brake, (refer to Drive Unit Parts Page) foosen lock nut #20 and tum adjusting aut #21 ‘clockwise to increase braking. When brake bands are worn so that adjustment can no longer be obtained by this method, remove cater pin from collar assembly #19 and turn counterclockwise several turns, Then proceed to adjust spring to get proper braking. NOTE Brake should be adjusted to stop an empty truck in ot fess than 13 inches when traveling in 3rd speed toward the operator Electrical System 1a. The pump and motor tilts back by removing one bolt to give easy access fo the contactor panel bb. Periodically check wiring for loose or broken connections and worn or damaged cables, © Motos - Occasionally, dirt and carbon. dust should be cleaned out of windings and off brush holders. A clean, dry cloth should be used when cleaning the commutator. (Do not use emery cloth). Never use oll or other lubricants on the ‘commutator or brushes. tis recommended that the brushes be checked for wear at least once every 90 days. Replace- ment brushes may be secured from local dealer service departments d. Tips - Check the silver contact tips for wear, Minor surface irregularities er discoloration does not necessitate contact tle replacement, Battery and Charging a. The battery water level should be checked before charging battery. Keep battery con- ectors clean to assure a good connection for charging and truck operation. b. The battery is mounted on rollers tor easy removal and speedy change over for multi-shitt operations, ©. See charger manufacturer's operation and service information for charger maintenance ‘and charging recommendations for your specific battery, Seaton cnn Simmer seer an rac campeneets. On enor and ute Rrnpestoopen otf te Se nro sem B Grown 190 Pres Ree 7? MA - 04.2-001 Frees se MA - 04.2- 001MAINTENA\ NCE GENERAL Before performing maintenance tothe truck, it should be taken toan area set aside for maintenance or where there is adequate space to perform the requiced work. This is ‘a must fo insure the safety of others and to insure that pro- er maintenance is performed to the unit, NOTE Bo suro battery connectors are disconnected. For regular maintenance, access to the component is accomplished by removing the two (2) screws connecting the door assemblies. Swinging the doors open allows maintenance to be performed on the pump, motor, con- tactor panel, drive unit, hydraulic system, and electrical ‘components located in the power unit. For SCR Maintenance Instructions, see appropriate sec tion in this manual ‘Some of the hydraulic components are located beneath the power unit, below the battery, To perform ‘maintenance on any of these components, the battory will have to be removed. To perform maintenance to certain areas ofthe mast it may be necessary to remove the sale- ty shield. Maintenance to the directional switches and raise-lower switches is accomplished by removing the four (4) screws which secure the cover plate to the con- ‘rol pod in the handle. TYPE OF LUBRICANT [BRAND NAME A. Gear Lube 80W-90 (Typical) | Union MP Gear Lube LS | Code 5163 Mobilube HD 80W-90° | Dubois EGO-75 & 90" Deuso! EPSO™ T Union Unaba EP No.2 | Retinax A* tM Lubripate B. Grease (Multipurpose) BB. Grease (Low Temp.)t Alvania RA” i Helveum 07 [COil (SAE 40) ane a Hydraulic ‘Mobi Union Unax AW ISO 92° Tallus 27° jee : Hysoin AWS 92° DD. Hydraulic Oil (Low Temp.)t | Mobil Aero HFA Tellus 118" fe | Hvepin AW 15° = i Grease (Masi Charnal) Chain & Cable Lube Grease (Lit Pump Cougiing), * Denotes allowable substitues, contact factory if unavailable +f Trucks used in below freezing lemperatures must use Low CHART LUBRICATION To obtain maximum life of any industrial equifsment, awell planned maintenance pragram should be followed, The following informations intended to provide guidelines for proper lubrication intervals as called out in the lubrica - tion chart, however, some operating conditions will re quire more frequent checks and lubrication than listed For example, applications with much dust or moisture will require modification of the schedule to fit that perticular application ‘The use of high grade lubricants and tluids should be us- led, Sources of these lubricants may be from almost any of the oll companies; those listed below are typical and any lubricant with equal specifications may be used. (See Chart 1-1) On trucks equipped to operate in delow freezing temperatures, low temperature hycraulic ol and grease must be used. Union 76 Co. Mobil Oil Co. Dubois Chem., Div of Chemed Corp, Burmah Castrol Union 76 Co. Shell Fiske Bros. Refining Co. Shelt Burimah Castrol Mobil Git Union 76 Co. Shell Burmah Castrol Mobil Oil Co. Shell Burman Castrol see stant eon T she Bros. Reining Go. F Darmex Temp. Hydraulic Oil & Grease. 1 M1.0 - 04.2 - 001 M1.0 - 04.2 - 001MAINTENANCE LUBE IDENTIFICATION CHART [uBe Wee” ~ [CAPR PART, ‘A. Gear Lube (90) 3.5 pts. (1600m) | 630023 B. Grease (Multipurpose) | ar 6302-25 88, Grease (Low Temp.)t AR 63002-17 ©." Oil (SAE 40) AR D. Hydraulic O11 | Sal. (2255 litres) | 6301-1 DD. Hydraulic Oil (Low Temp.)t S gal (22.5 litres) | 630016 Grease (Mast Channel) E F, Chain & Cable Lube g i a Quarts: out oa 14x Seay + Trucks used in below freezing temperatures must use low Temp. Hydraulic Oil & Grease, j CHART 1-2 LUBRICATION CHART [tise | COMPONENT Layee | ory. 1 tt [eatery Aoters ARS Le | Brake Linkage | ¢ | an 3 | Door Hinges: jo | an 4 | Drive Unit Levet A US | Drive Unit- Pivot BAR Lé | Drive Unit- Rollers BAR 7 | Drive Unit Axle BAR Le | Drive Tie - Hub se |e U9 | Free Lift Stud (TL), BAR U0 | Free Litt Latches (TT) BAR Lt | Fork Slides | 8 | aA U2 | Hydraulic Reservoir D 1a | Lit Chains F | AR 14 | Lit Motor Pump Coupling c | an 15 | Load Wheel Axles BAR U6 | Mast Channels } e& | ar aoe L417 | Mast Rollers | Bo] AR a 2 | Mechanica Disconnect Linkage | CAR | Le | Roller Bar c_| an = Lubricate += Check GC = Change AR= As Required ‘See Chart 1 -2 for Lube Type explanation and capacity. See lilustration 1 - 1 for Index Cal-outs CHART 1-3 M1.0 - 04.2 - 002 M1.0 - 04.2 - 002MAINTENANCE esata e \\ be ' Ba MLLUSTRATION 1-1 oan a Peer Tinwano ea M1.0 - 04.2 - 003 M1.9 - 04.2 - 003MAINTENANCE INSPECTION AND ADJUSTMENT CHART [INDEX| COMBONENT a [tt Battery and Connector | 42 [Brake Lining 13 | Brake Operation | 1 |Beake Switch [6 |Column Rollers 17 |Contact Tips 18. | Control Valve Switches 19. | Electrical Connections | 10. | Emecgency Disconnect Lit | Forks’ 142 |Horn 1413 | Hydraulic Lines & Fittings 1414 | Lit Chains 148 | Lit Cylinder 146 | Limit Switch, Mast 17 | Motor Brushes «Lift Motor Brushes - Traction Stop Blocks & Mast Latches Tires, Load Wheels & Guide Wheels | 15. | Chain Anchors & Retainers + = Inspect andfor Adjust See Ilustration 1-1 for Index Calkouts. CHART 1-4 M1.0 - 04.2 - 004 M1.0-04.2- 004