Crown Sit-down Rider Lift Truck FC 4500 Series Service & Parts Manual

C

Model No.

Serial No.

FC 4500 Series

AC Traction

Service & Parts Manual

Crown 2007 PF15703 08/07

Printed in U.S.A.

New Bremen, Ohio 45869 USA

Phone 419/629-2311 crown.com

How to Order Service Parts

To obtain fast, efficient service when ordering repair parts for your Crown Material Handling Equipment, please follow this simple procedure:

1.

Address all orders to your local Crown dealer.

2.

Specify model and serial number of truck, which is shown on the serial number plate.

3.

List the quantity needed.

4.

List the part number and description, as shown in this Service Manual.

5.

Show billing and shipping address.

6.

Suggest fastest routing.

Your authorized Crown dealer stocks a large number of standard service parts. In addition, he has a factory trained Service Department to serve you.

Our Local Crown Dealer Is

NAME

ADDRESS

CITY

STATE

TELEPHONE

ZIP

The information in this manual is the latest available at the time of printing for the unit with which it was shipped.

Should there be any variation due to vendor changes or special options on your unit, contact your Crown dealer or Crown at the above address.

Crown 1986 PF7609 Rev. 4/01 Printed in U.S.A.

TABLE OF CONTENTS

I

Notes:

II

TABLE OF CONTENTS


General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . 3

Cleaning of Material Handling Equipment . . . . . . . . . . . . . . . . . 5

Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Control of Hazardous Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Lockout - Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Lifting and Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Blocking Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Disconnect Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Removing Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Removing Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

LUBRICATION & ADJUSTMENT PAGE

Lubrication and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Lubrication & Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Battery Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Left Side Step Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Right Side Step Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Floorboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Steering Column Covers . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Control Lever Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Contactor Assembly Cover . . . . . . . . . . . . . . . . . . . . . . . . 34

Fan and Controller Cover . . . . . . . . . . . . . . . . . . . . . . . . . 34

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

III


IV

Componentry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

ACC POT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

ACS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

ACCESS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

ACCESS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

ACCESS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

ALM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

ALM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

ALM3 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

AXS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

AXS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

AXS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

BRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

BRKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

CBV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

DIPSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

DISTRIBUTION PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

ECR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

FAN1 & FAN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

FAN3 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

FAN4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

FAN5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

FIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

FNS (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

FU4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

FU5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

FU6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

FU7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

FU8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

FU11 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

FU12 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

HAND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

HGTS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

HN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

HNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

HR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

HR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

HSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

INFOLINK MODULE (Optional) . . . . . . . . . . . . . . . . . . . . . . . 69

IMPACT SENSOR (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . 70

K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70


K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

K11 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

K12 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

KYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

LGS1 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

LGS2 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

LGT1, 2, 3 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

LGT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

LGT5, 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

MANUAL RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

MPCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

PRESSURE CHECK POINT . . . . . . . . . . . . . . . . . . . . . . . . . . 76

PRK-A, PRK-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

12V POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

PS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

RAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

RES2 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

RES3 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

RV1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

RV2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

RV3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

SB80 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

SES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

SES1, SES2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

SV1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

SV2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

SV3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

TBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

THS1 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

THS2 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

TLMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

TLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

TMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

TS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

TS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

ULV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Metric Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

V


Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Hydraulic Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Tilt Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Lift Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Cylinder and Circuit Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . 97

Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Sideshift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Steer Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Service Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Park Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Hydraulic Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Accumulator and Unloading Valve . . . . . . . . . . . . . . . . . . . . 105

Spring Apply/Hydraulic Release Park Brake . . . . . . . . . . . . 106

Hydraulic Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . 121

Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Mounting Flange And End Cover . . . . . . . . . . . . . . . . . . . . . 126

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Relief Valve RV1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 127

Relief Valve RV2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 127

Adjustment of RV1 & RV2 . . . . . . . . . . . . . . . . . . . . . . . . 128

Main Pressure Compensating Element (MPCE) Operation . 129

Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 130

Control Valve Inspection & Repair . . . . . . . . . . . . . . . . . . . . 131

Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Adding 4

th

Spool Valve Section . . . . . . . . . . . . . . . . . . . . . . 132

Hydraulic Manifold Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Tilt Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Park Brake Release Manifold . . . . . . . . . . . . . . . . . . . . . 135

Accessory Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Manifold Block Component Replacement . . . . . . . . . . . . 136

DRIVE UNIT PAGE

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Drive Unit Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Drive Unit Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Drive Unit Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Drive Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Traction Motor (M1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Traction Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . 141

1st Reduction Pinion Installation . . . . . . . . . . . . . . . . . . . 144

Installation of Traction Motor . . . . . . . . . . . . . . . . . . . . . . 144

Axle Hub and Axle Installation . . . . . . . . . . . . . . . . . . . . . . . 145

Drive Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Drive Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

VI


Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Access 1 - Display Control Module (DCM) . . . . . . . . . . . . . . 151

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

AXS1, AXS2, TLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

RAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

TBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

HSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

ACS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

HGTS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

SES1, SES2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

TLMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Wiring Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Access 123...System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

User Main Menu Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

User Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Analyzer Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Calibration Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Calibration Error Messages . . . . . . . . . . . . . . . . . . . . . . . 196

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Features Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Hour/Event/Utilities Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Hour Meter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Event Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Utilities Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Performance Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Components Included On Distribution Board . . . . . . . . . . . . 205

Distribution Board Jumper Configurations . . . . . . . . . . . . . . 206

Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Accelerator Potentiometer (POT1) . . . . . . . . . . . . . . . . . . . . 211

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

VII


VIII

Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

140538-001/-002 Contactor (36/48 Volt) S (Steering) . . . . . 213

132084-005/-006 Contactor L (Line) & P (Pump) . . . . . . . . 213

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Steering Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . 214

Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

"EE" Component Replacement . . . . . . . . . . . . . . . . . . . . 215



Line and Pump Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 216



"EE" Component Replacement . . . . . . . . . . . . . . . . . . . . . . 217



Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Checking Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Charging Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Seat Deck Cover Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 222

Seat Deck Latch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 223

Seat Deck Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Battery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Dual Voltage Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Battery Discharge Interrupt Performance (P4) . . . . . . . . . . . 227

Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Event Code 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Event Code 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Event Code 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Event Code 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Event Code 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Event Code 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Event Code 130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Event Code 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Event Code 133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Event Code 134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Event Code 163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Event Code 164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Event Code 165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Event Code 199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

Event Code 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244


Event Code 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Event Code 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Event Code 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Event Code 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Event Code 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Event Code 206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Event Code 207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Event Code 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Event Code 209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Event Code 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Event Code 214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Event Code 215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Event Code 216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Event Code 217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Event Code 219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Event Code 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Event Code 221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Event Code 222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Event Code 223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Event Code 224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Event Code 225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Event Code 247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Event Code 299 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Event Code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

Event Code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

Event Code 302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Event Code 303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Event Code 304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Event Code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Event Code 306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Event Code 307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Event Code 308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Event Code 309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Event Code 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Event Code 311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Event Code 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Event Code 313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Event Code 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

Event Code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

Event Code 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Event Code 317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Event Code 319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Event Code 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Event Code 321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Event Code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Event Code 323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Event Code 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Event Code 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Event Code 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Event Code 330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Event Code 399 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

FWD/REV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Creep Speed Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

No Traction/No Lift/BDI = 0% . . . . . . . . . . . . . . . . . . . . . . . . . 266

IX


Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Shimming the Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 271

Brake Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Disassembly of Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Lining/Rotor Inner And Outer Stator . . . . . . . . . . . . . . . . . . . 273

Piston, Wiper and Seal Removal . . . . . . . . . . . . . . . . . . . . . 273

Wiper, Seal & Piston Installation . . . . . . . . . . . . . . . . . . . . . 274

Service Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Service Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Service Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Drive Tire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Service Brake Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 275

Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Brake Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Replacement of Brake Shoes . . . . . . . . . . . . . . . . . . . . . 278

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Adjustments When Replacing Brake Shoes or Brake Hub . 279

Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

Park Brake Release Manifold . . . . . . . . . . . . . . . . . . . . . . . 280

Manually Releasing the Parking Brake . . . . . . . . . . . . . . . . 281

Parking Brake Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Hydrostatic Steering Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Steering Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 286

Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Gas Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

Steering Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Steer Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Steer Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

Steer Axle Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

X


LIFTING MECHANISM PAGE

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

Bearing Cap Torque Requirements . . . . . . . . . . . . . . . . . . . . 299

Mast Flaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

Mast Testing (Assembled) . . . . . . . . . . . . . . . . . . . . . . . . 300

Shim Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Shim Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Mast Column Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Carriage Column Roller Adjustments . . . . . . . . . . . . . . . . 303

Carriage Side Thrust Roller Adjustments (TL & TT Masts) . . 304

Mast Column Roller Removal - TT Mast (Inner Mast) . . . . . 305

Mast Column Rollers Removal - TL Mast . . . . . . . . . . . . . . . 306

Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Lift Cylinder Removal - TL & TT . . . . . . . . . . . . . . . . . . . . . . 306

Carriage Removal - TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . 307

Carriage Removal - TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . 307

Mast Removal (TL & TT Mast) . . . . . . . . . . . . . . . . . . . . . . . 308

Mast Assembly (TL & TT Mast) . . . . . . . . . . . . . . . . . . . . . . 309

Tilt Cylinder Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Quad (Four Stage) Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Mast Flaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Mast Testing (Assembled) . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

Carriage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

Carriage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

Lift Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Rust and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

Cracked Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

Tight Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

Protruding or Turned Pins . . . . . . . . . . . . . . . . . . . . . . . . 319

Chain Side Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

Lift Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

Chain Anchors and Pulleys . . . . . . . . . . . . . . . . . . . . . . . 321

Leaf Chain Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Disconnect Procedures: . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

Bent or Twisted Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

XI


Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Seal Installation - General . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Rod U-Cup Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Small U-Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Large U-Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Cylinder U-cup Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 333

Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

Cylinder Bleeding and Flushing . . . . . . . . . . . . . . . . . . . . . . 334

Bleeding - Free Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 334

Bleeding - Stage Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . 334

Flushing - Stage and Free Lift Cylinders . . . . . . . . . . . . . . . 334

Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Rod Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

Tilt Cylinder Flushing and Bleeding Procedures . . . . . . . . . 338

Tilt Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

Tilt Cylinder Installation and Adjustments . . . . . . . . . . . . . . 339

Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342



Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

Parking Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346



Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

XII


WIRING DIAGRAMS PAGE

Introduction to Diagram Usage . . . . . . . . . . . . . . . . . . . . . . . 357

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

Pictorials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359

Electrical Schematic - AC Traction/DC Lift . . . . . . . . . . . . . . 360

Electrical Schematic - AC Traction/AC Lift . . . . . . . . . . . . . . 361

Electrical Schematic - AC Traction/DC Lift With Options . . 362

Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

ACCESS 3 - AC Traction Controller . . . . . . . . . . . . . . . . . . . . 364

ACCESS 2 - AC Lift Controller . . . . . . . . . . . . . . . . . . . . . . . . 365

Hydraulic Switch Harness With Tilt Position Assist . . . . . . . 366

Dashboard with TMM Option . . . . . . . . . . . . . . . . . . . . . . . . . 367

ACCESS 1 - Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

Foot Operated Direction Control . . . . . . . . . . . . . . . . . . . . . . 370

Brake and Accelerator Pedals . . . . . . . . . . . . . . . . . . . . . . . . 371

Motors and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

InfoLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

Freezer Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

Freezer Condition - Jumper Harness . . . . . . . . . . . . . . . . . . . 376

Power Cables - AC Traction/DC Lift . . . . . . . . . . . . . . . . . . . . 377

Power Cables - AC Traction/AC Lift . . . . . . . . . . . . . . . . . . . . 378

Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

HYDRAULIC SCHEMATIC PAGE

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

POWER UNIT PARTS PAGE

Seat Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386

Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

Overhead Guard & Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . 394

Battery Spacers & Retainers . . . . . . . . . . . . . . . . . . . . . . . . . . 398

Static Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

Hip Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

XIII


HYDRAULIC PARTS PAGE

Suction Line Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

Lift & Tilt Line Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

Steer & Brake Line Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . 420

Pressure Line Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422

Accessory Line Hydraulics - TL/Quad . . . . . . . . . . . . . . . . . 424

Accessory Line Hydraulics - TT . . . . . . . . . . . . . . . . . . . . . . 426

Steer & Brake Line Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . 428

Return Line Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

Lift & Return Line Hydraulics - TL Mast . . . . . . . . . . . . . . . . 432

Lift & Return Line Hydraulics - TT Mast . . . . . . . . . . . . . . . . 434

Accessory Line Hydraulics - TL Mast . . . . . . . . . . . . . . . . . . 436

Accessory Line Hydraulics - TT Mast . . . . . . . . . . . . . . . . . . 438

Mast Hydraulics - Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . 440

Mast Hydraulics - Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . 442

Lift Pump - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444

Lift Pump - TL/Quad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

Lift Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

DC Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450

Directional Control Valve - 3 Spool . . . . . . . . . . . . . . . . . . . . 452

Directional Control Valve - 4 Spool . . . . . . . . . . . . . . . . . . . . 454

Manifold Crossover Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . 456

Tilt Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458

Park Brake Release Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 460

4-Position Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . 462

Lowering Flow Control Valve - TL . . . . . . . . . . . . . . . . . . . . . 464

Lowering Control Valve - TT . . . . . . . . . . . . . . . . . . . . . . . . . 466

Accessory Manifold - TL/Quad . . . . . . . . . . . . . . . . . . . . . . . 468

Accessory Manifold - TL/TT . . . . . . . . . . . . . . . . . . . . . . . . . . 472

Accessory Manifold - Quad . . . . . . . . . . . . . . . . . . . . . . . . . . 474

Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478

Control Valve Linkage - Standard No Accessories . . . . . . . 482

Control Valve Linkage - One Accessory . . . . . . . . . . . . . . . . 486

Control Valve Linkage - Two Accessories . . . . . . . . . . . . . . 490

TT Carriage Hydraulics - Single Accessory . . . . . . . . . . . . . 494

Carriage Hydraulics - TL Single Accessory . . . . . . . . . . . . . 498

Carriage Hydraulics - Quad Mast . . . . . . . . . . . . . . . . . . . . . 502

TT Carriage Hydraulics - Double Accessory . . . . . . . . . . . . 506

Carriage Hydraulics - TL Double Accessory . . . . . . . . . . . . 512

DRIVE UNIT PARTS PAGE

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520

AC Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524

Drive Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526

XIV


ELECTRICAL PARTS PAGE

Electrical Components - Power Unit . . . . . . . . . . . . . . . . . . . 534

Controller Panel - DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538

Controller Panel - AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540

Contactor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542

Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544

Freezer Condition Distribution Board . . . . . . . . . . . . . . . . . . 546

Contactor L & P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548

Contactor L & P - “EE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550

Steering Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552

Steering Contactor “EE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554

Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556

Foot Operated Directional Control . . . . . . . . . . . . . . . . . . . . . 558

Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560

Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562

Tilt Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564

Control Cable - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566

Control Cable - TL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570

Strobe Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576

Overhead Guard - Front Lights & Mirrors . . . . . . . . . . . . . . . 578

Overhead Guard - Rear Lights . . . . . . . . . . . . . . . . . . . . . . . . 580

Drive Thru Overhead Guard - Front Lights & Mirrors . . . . . . 584

Drive Thru Overhead Guard Accessories - Rear . . . . . . . . . 586

TL/TT Mast Mounted Work Lights . . . . . . . . . . . . . . . . . . . . . 590

Quad Mast Mounted Work Lights . . . . . . . . . . . . . . . . . . . . . . 592

BRAKE PARTS PAGE

Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596

Power Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598

Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600

STEERING PARTS PAGE

Steering Column - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604

Steering Column - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608

Steering Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610

Steering And Service Brake Pump . . . . . . . . . . . . . . . . . . . . . 614

Power Steering Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 616

Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618

Steer Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620

XV

LIFTING MECHANISM PARTS PAGE

TL Mast Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624

Mast - TL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626

TT Mast Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636

Mast - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638

Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648

Fork Carriage - TL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656

Fork Carriage - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658

Fork Carriage - Quad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 660

Yoke - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 662

Yoke Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666

Lift Chain - TL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668

Lift Chain TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 670

Lift Chain Quad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674

Load Backrest - TL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678

Load Backrest - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 680

Load Backrest - Quad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 682

Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686

CYLINDER PARTS PAGE

Mast Cylinder - TL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696

Mast Cylinder - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698

Quad Mast Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702

Quad Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704

Carriage Cylinder - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 706

Tilt Cylinder - TL/Quad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708

Tilt Cylinder - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 712

Sideshifter Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716

Parking Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 718

Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720

PLATFORM PARTS PAGE

Sideshifter - TL/TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724

Sideshifter - Quad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 726

LABELS AND DECALS PAGE

Work Assist Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730

InfoLink Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734

Labels and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 736

XVI

SAFETY

1

Notes:

2

SAFETY

General Maintenance Instructions


WARNING

TO PREVENT SERIOUS RISK OF INJURY TO

YOURSELF AND OTHERS OBSERVE THE FOL-

LOWING 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—

– 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.

4.

Before working on truck—

– Raise drive wheel free of floor or disconnect power sources.

– Use chocks or other positive positioning devices.

– 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 attachments shall be conducted in an authorized safe clearance area.

5.

Before starting to operate truck—

– Be in operating position.

– Apply brake.

– Place directional control in neutral.

– 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 equipment 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 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 of tipover, do not jump. Hold steering wheel tightly and brace your feet.

9.

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

– All guards must be installed to factory configuration and condition before operating truck. Do not operate truck if any guards or fasteners are damaged, improperly installed or missing.

10. Capacity, operation and maintenance instruction plates or decals shall be maintained in legible condition.

11. All parts of lift mechanisms shall be inspected to maintain them in safe operating condition.

12. 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 hazard.

13. Batteries, motors, controllers, limit switches, protective devices, electrical conductors, and connections shall be maintained in conformance with good practice. Special attention shall be paid to the condition of electrical insulation.

14. Trucks shall be kept in a clean condition to minimize fire hazards and facilitate detection of loose or defective parts.

Crown 1991 PF8971-1 Rev. 10/08 MA-11.0-002

04 Rev. 10/08

3

SAFETY


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 maintenance plates or decals shall be changed accordingly.

– Adding electrical devices (radio, terminal, lights, etc.) or changing existing components or wiring can affect truck operation and could cause an accident. Contact authorized Crown personnel before adding to or changing the electrical system in any way.

– For EE rated trucks, adding electrical devices could cause a fire or explosion, as well as void the

EE rating. Written approval must be obtained from

Crown prior to adding electrical device(s). Prior to use, inspection of installed device(s) must be performed by an appropriate nationally recognized testing laboratory (i.e. Underwriters Laboratories

Inc) or the Authority Having Jurisdiction (see NFPA

505).

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 (terminal, 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-11.0-003

04 Rev. 10/08

4

Crown 1991 PF8971-2 Rev. 10/08

SAFETY

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 pressured air. For localized degreasing, use of an appropriate 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 corrosion.

Functional integrity of contaminated components may be questionable. Nuisance fault logging, intermittent operation or immediate failure could be the resultant of power washing. For these reasons all electronic components including motors must be protected. Component removal is the best method to eliminate the risk of damage.

Power washing will also remove and/or destroy lubricants in or on the surface of shafts, unsealed bearings, hinges, exposed gears, bushings, chains, linkages, etc. These Items must also be protected or properly lubricated after cleaning.

Consideration must also be given to metal surfaces.

The cleaning process can strip away paint and protective coatings applied to components (i.e., hydraulic lines, terminal strips, linkages) for freezer/corrosion environment. Paint and/or protective coating must be reapplied to these areas to reduce the chance of oxidation and corrosion.

Before installing removed components, lubricating or returning the equipment to service it must be free of solvent residue and thoroughly dry.

Crown Cleaning Products Chart

Cleaner Type

Degreaser & Cleaner

All Purpose Cleaner

Glass Cleaner

Waterless Hand Cleaner

Pumiced & Smooth Hand Cleaner

Wall Mounted Deluxe Soap Dispenser

Tough On Grease

Part Number

363105-001

363105-012

363114-001

363114-012

363101-001

363101-012

363111-001

363111-012

363112-001

363112-004

363122

063009-005

Package Quanity

20 oz. Can

(12) 20 oz. Cans

20 oz. Can

(12) 20 oz. Cans

20 oz. Can

(12) 20 oz. Cans

15 oz. Tube

(12) 15 oz. Tubes

1 Gallon Jug

(4) 1 Gallon Jugs

Used with 363112-001

1 Gallon Jug

Crown 2000 PF11969-1 Rev. 10/06 MA-1140-050

02 Rev. 10/06

5

Notes:

6

SAFETY

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 maintenance 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 electrolyte 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 electrolyte 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 firmly in place at all times except when adding water or taking hydrometer readings.

•

Do not bring any type of flame, spark, etc., near the battery. Gas formed while the battery is charging, is highly explosive. This gas remains in the cells long after charging has stopped.

•

Do not lay metallic or conductive objects on battery. Arcing will result.

•

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

•

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

Battery Care

CAUTION

Only qualified and experienced personnel should perform maintenance and repair on batteries.

•

Make certain the charger being used matches the voltage and amperage of 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 attempt is made to do this while the charger is "ON", serious injury to you, the battery and charger could result.

•

Never use a match or lighter. Battery fumes are explosive.

•

Make certain battery used meets weight, size and voltage requirements of truck (refer to serial plate).

NEVER operate truck with an undersized battery.

Charging

CAUTION

Never smoke or bring flame near the battery. Gas formed during charging is highly explosive and can cause serious injury.

Consult the charger manufacturer's manual covering your charger for hints on operation and maintenance.

Crown 2007 PF17014-1 MA-2045-100

7

SAFETY


Battery Removal

CAUTION

When removing the battery, move truck to area intended for battery care. Floor must be level. Turn keyswitch or toggle switch to "off" position and remove key. Disconnect battery and lockout or tagout truck as described in Battery - Lockout/Tagout in this section.

Never move battery partially from truck without roller stand in place. Lower load engaging means completely. If battery is removed with load engaging means raised, use hoist attached to mast to provide tip over protection. Don’t allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing, transporting the battery.

Use an insulator (such as plywood) to cover the top of the battery before and during removal.

CAUTION

Make certain battery used meets weight, size and voltage requirements of 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.

Battery Installation

CAUTION

When installing the battery, move truck to area intended for battery care. Floor must be level. Turn keyswitch or toggle switch to "off" position and remove key. Lockout or tagout truck as described in Battery -

Lockout/Tagout in this section. If battery was removed with load engaging means raised, use hoist attached to mast to provide tip over protection. Don’t allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when transporting or installing the battery. Use an insulator (such as plywood) to cover the top of the battery before and during installation.

Figure 8251

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.

When maintenance is performed and the battery is removed 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 operation.

Crown 2007 PF17014-2 MA-2045-101

8

SAFETY


Capacitance

Due to capacitance voltage present in the traction module controller, whenever performing maintenance which may permit contact with the bus bars and associated 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.

3.

Disconnecting the battery for a minimum of 10 minutes will discharge the capacitors that are inside the Traction Control Module ACCESS 3. Two additional methods of discharging these capacitors are to disconnect the battery, place a jumper from top stud of line capacitor to fuse bus bar and then hold the key switch in the START position for 10 seconds, or disconnect the battery and connect a 100 ohm 2 watt resistor between the positive and negative terminals on the controller, ACCESS3.

Traction

Control

Module

Figure 17551

Crown 2007 PF17014-3 MA-2045-102

9

SAFETY


Hydraulic

WARNING

AVOID HIGH PRESSURE FLUIDS—Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.

Any fluid injected into the skin under high pressure should be considered as a serious medical emergency despite an initial normal appearance of the skin. There is a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately by a specialist who has had experience with this type of injury.

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

1.


2.

No load on forks.

3.

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

4.



5.

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

6.

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

Lower Forks

Completely

No Load on Forks

Figure 17552

MA-2045-103

10

Crown 2007 PF17014-4

Lifting and Blocking

1.


2.

No load on forks.

3.



SAFETY


NOTE

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 commercially available.

Steer Wheel

Side

(1)

(2)

(3)

(4)

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

Chock Both Drive Wheels

Set Jack Stand Height as Required Not to Exceed

400 mm (16 in)

Locate Jack Stands & Jack as Shown, Under Steer Axle

(1)

(2)

Lower Forks Completely

Do Not Tilt Mast After Blocked

Figure 17554

Figure 17553

NOTE

When removing the drive unit, block under counterweight to prevent truck from tipping.

Jack up one side of truck, place hard wood block directly under first stage mast, jack up opposite side of truck and place second hard wood block under other side of first stage mast.

FC Series Truck - Use 100 x 100 mm (4 x 4 in) block.

WARNING

Truck stability decreases dramatically if load wheels are raised more than required to insert hard wood block. Attach sling and overhead lifting device to all cross members of the mast to prevent truck from tipping over when raising the side of the truck.

Crown 2007 PF17014-5 MA-2045-104

11

SAFETY


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 appropriate length for supporting mast channels. Block both mast rails of 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.


2.

Chock wheels of truck. Refer to Lifting and Blocking 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 -


MA-2045-105

12

Crown 2007 PF17014-6

TT Mast

TL Mast

SAFETY


Quad Mast

(1)

(2)

(3)

(4)

(5)

(6)

Fork Carriage (Shown Raised Slightly for Clarity)

Third Stage Mast

Second Stage Mast

First Stage Mast (or Mainframe)

First Stage Mast (or Outer Mast)

Fourth Stage Mast (or Inner Mast)

Figure 17555

Crown 2007 PF17014-7 MA-2045-106

13

SAFETY


TT Mast

Quad Mast

TL Mast

(1)

(2)

(3)

(4)

(5)

(6)

First Stage Mast (or Mainframe)

Second Stage Mast

Third Stage Mast

Fork Carriage

First Stage Mast (or Outer Mast)

Fourth Stage Mast (or Inner Mast)

Figure 17556

MA-2045-107

14

Crown 2007 PF17014-8

SAFETY


Disconnect Tilt Cylinder

When the tilt cylinders are disconnected from the hydraulic system or from the mounting brackets, the mast must be secured to keep the mast from pivoting toward, or away from the truck.

1.


2.

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

3.

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

4.

Tilt forks down so weight of carriage is not on the tilt cylinder.

5.



6.

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

Attach Strap or Chain to All Top Cross Braces

Wheel Chocks

Figure 17557

Crown 2007 PF17014-9 MA-2045-108

15

SAFETY


Removing Mast

1.


2.

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

3.



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.

Support mast as described in Disconnecting Tilt

Cylinders in this section.

9.

Chain mast sections together at upper crossbraces. Chain fork carriage to lower mast crossbrace. This will keep carriage and mast sections from moving when mast is laid down.

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)

(2)

(3)

(4)

Mast Lug

Pin

Block

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.

(1)

(2)

(3)

(4)

(5)

Part of Mast

Bearing

Bearing Cap

Flatwashers

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

Figure 17559

MA-2045-109

16

Crown 2007 PF17014-10

Removing Counterweight

1.


2.

Lower load engaging means completely. No load on forks.

3.



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 connectors.

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 counter weight to the power unit.

11. Carefully move counter weight from truck and lay counter weight on floor.

SAFETY


Figure 17560

Crown 2007 PF17014-11 MA-2045-110

17

Notes:

18

INTRODUCTION

19

Notes:

20

INTRODUCTION

Introduction

Introduction

This manual is intended for the service technician who is seeking information about maintenance and service replacement parts. It contains a section on troubleshooting which will enable a qualified technician to locate and solve problems which may occur.

Service Training

Complete Service Training is available for the lift truck technician covering all Crown Lift Trucks, module systems, 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 required. These booklets are for you and your personnel to insure years of safe, trouble-free operation of your

Crown Lift Truck. For sitdown rider operator instructions, refer to Crown publication, "Operator Manual

FC 4500 Series".

Operator Training

Crown produces a complete series of 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, always specify, along with part number, model and serial number of the truck. This information will further enable us to give correct, fast and efficient service.

For current part number of 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 parts. The sectional descriptions are as follows:

MAINTENANCE REPLACEMENT PARTS

M4

M5

M6

M7

SECTION DESCRIPTION

M1 Lubrication and Adjustment

SECTION

1

DESCRIPTION

Power Unit Parts

M2

M3

Hydraulic

Drive Unit

2

3

Hydraulic Parts

Drive Unit Parts

Electrical

Brake

Steering

Lifting Mechanism

4

5

6

7

Electrical Parts

Brake Parts

Steering Parts

Lifting Mechanism Parts

M8

M9

M10

Cylinders

Platform

Glossary

8

9

10

Cylinder Parts

Platform Parts

Labels and Decals

Crown 2007 PF15999-1 ITD-2045-001

21

INTRODUCTION

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 numbers, you can identify the truck model, series, series updates, determine relative size and performance, capacity and specific truck data. The following pages explain the model & truck data numbering system.

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 Generator

FC - Four Wheel Sitdown

Rider Counterbalanced

* Capacity

40 = 1815 kg (4000 lb)

50 = 2270 kg (5000 lb)

55 = 2495 kg (5500 lb)

60 = 2720 kg (6000 lb)

FC4515-40

Series

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 located on the overhead guard.

ITD-2045-002

22

Crown 2007 PF15999-2

INTRODUCTION

Introduction

Truck data numbers provide you and your Crown dealer with a wealth of information to insure the selection of proper parts for your Crown truck. You may simply provide this number to your Crown dealer, or use the following breakdown if selecting your own part numbers or service information from this manual.

Tires

S = Smooth

M = Smooth Non-Marking

L = Lugged

G = Lugged Non-Marking

Battery Compartment Size

27 = 685 mm (27 in)

33 = 840 mm (33 in)

36 = 915 mm (36 in)

Attachments

-- = No Attachment

SS = Sideshifter

PP = Push Pull

CC = Carton Clamp

FP = Fork Positioner

PR = Paper Roll Clamp

Voltage

36 = 36 Volt

48 = 48 Volt

-- = Mast Only

EE Rating

1 = EE Rating

2 = No EE Rating

Mast Type

TL = Telescopic Limited Free Lift

TT = Telescopic Triple Stage

QD = Telescopic Four Stage

-- = Power Unit Only

Parking Brake

S = Standard

A = Automatic

Standard/Custom/Special

- = Standard

C = Custom

S = Special

Lift Height

TL Mast

118 - 2995 mm (118 in)

126 = 3200 mm (126 in)

130 = 3300 mm (130 in)‘

138 = 3505 mm (138 in)

142 = 3605 mm (142 in)

150 = 3810 mm (150 in)

TT Mast

180 = 4570 mm (180 in)

188 = 4775 mm (188 in)

198 = 5030 mm (198 in)

206 = 5230 mm (206 in)

208 = 5285 mm (208 in)

216 = 5485 mm (216 in)

223 = 5665 mm (223 in)

- TT 188 33 F S S SS 5 36 2 E - A 1

231 = 5865 mm (231 in)

238 = 6045 mm (238 in)

246 = 6250 mm (246 in)

250 = 6350 mm (250 in)

258 = 6560 mm (258 in)

276 = 7010 mm (276 in)

291 = 7390 mm (291 in)

Quad Mast

240 = 6100 mm (240 in)

258 = 7390 mm (291 in)

276 = 7010 mm (276 in)

294 = 7475 mm (294 in)

312 = 7925 mm (312 in)

Custom = Plus Custom

Height

SPC = Special Lift Height

Cold Conditioning

- = No Cold Conditioning

F = Freezer Conditioning

C = Corrosion Conditioning

Accessory Hydraulics

- = No Accessory Hydraulics

S = Single Function

D = Double Function

Fans

- = No Fans

1 = Operator Fan

2 = Compartment Fan

3 = Operator and

Compartment Fan

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, Worklights & Strobe Light

7 = Travel Alarm & Worklights

Lift System

2 = Contactor

5 = AC

Crown 2007 PF15999-3 ITD-2045-003

23

Notes:

24

LUBRICATION & ADJUSTMENT

25

Notes:

26

LUBRICATION & ADJUSTMENT

Lubrication and Adjustment


To obtain maximum life of any industrial equipment, a well planned maintenance program (PM), performed by qualified technical personnel should be followed. In conjunction with, and an integral part of, any planned maintenance program should be daily operator input.

Operator involvement can greatly reduce truck down time, assist in determining planned maintenance (PM) schedules and ultimately save money. For these reasons, Crown recommends a checklist similar to the Operators Daily Checklist shown below.

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

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

Crown 1987 PF7886-1 Rev. 6/08

Figure 14990

M1.0-04.0-001

17 Rev. 6/08

27



The following is a list of lubricants and maintenance products recommended when doing Planned Maintenance on Crown Lift Trucks.

Lubrication Identification Chart

A

AA

AAA

B

BB

(1)

BBB

Type of Lubricant

Gear Lube 80W-90 (Typical)

Automatic Transmission Fluid (Multi-Purpose)

Universal Hydraulic & Transmission Fluid

Grease (Multi-Purpose)

Grease (Low Temperature)

Food Grade Grease (Multi-Purpose)

Part Number

363506-001

363506-012

363503-001

363503-012

363513-001

363513-012

063002-034

063002-045

063002-017

063002-046

363002-001

363002-030

Package Quantity

1 Quart

(12) 1 Quart Cans

1 Quart

(12) 1 Quart

1 Quart

(12) 1 Quart

14.5 oz Cartridge

(40) 14.5 oz Cartridges

14.5 oz Cartridge


14 oz Cartridge

(30) 14 oz Cartridges

C Oil (SAE 40)

CC

D

DD

(1)

DDD

E

F

G

Engine Oil (10W30)

Hydraulic Oil

Hydraulic Oil (Low Temp)

Hydraulic Oil - DTE24

Channel Grease

Gear Grease

Chain & Cable Lube

Premium Chain & Cable Lube

363500-001

363500-012

363504-101

363504-106

1 Quart

(12) 1 Quart

1 Gallon

(6) 1 Gallon

363505-101

363505-106

1 Gallon

(6) 1 Gallon

063001-021 1 Gallon

063002-024

063002-022

063002-024

063002-022

363107-001

363107-012

363115-001

363115-012

14.5 oz Cartridge

35 lb Pail

14.5 oz Cartridge

35 lb Pail

15 oz Can

(12) 15 oz Cans

12 oz Can

(12) 12 oz Cans

H

I

Final Finish - Rubber & Vinyl Dressing

Grease (Lift Pump Coupling)

363129-001

363129-012

063002-039

127801S

11 oz Can

(12) 11 oz Cans

1 lb

1 oz

J Brake Fluid - Dot 5

063004-002

063004-003

12 oz

1 Gallon

(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



T

U

K

L

M

N

O

P

Q

R

S

V

W

X

Y

Lubrication Identification Chart

Grease (Wheel Bearing)

Metal Assembly Spray

Silicone Grease (Clear)

Brake & Parts Cleaner

Low VOC Brake & Parts Cleaner

Non-Flammable Brake & Parts Cleaner

Penetrating Lubricant

Food Grade Machine Lubricant

Food Grade Silicone Spray

Coolant

Type of Lubricant

Extended Life Coolant

Part Number

063002-034

063002-045

Package Quantity

14.5 oz Cartridge


063002-021 11 oz Spray

063002-020 5.3 oz Tube

363102-001

363102-012

363103-001

363103-012

363116-001

363116-012

363104-001

363104-012

14 oz Can

(12) 14 oz Cans

14 oz Can

(12) 14 oz Cans

19 oz Can

(12) 19 oz Cans

20 oz Can

(12) 20 oz Cans

Premium Formula Multi-Purpose Grease

White Lithium Grease

Choke & Carburetor Cleaner

Contact Cleaner - Non-Flammable

363108-001

363108-012

363110-001

363110-012

363109-001

363109-012

363106-001

363106-012

11 oz Can

(12) 11 oz Cans

11 oz Can

(12) 11 oz Cans

15 oz Can

(12) 16 oz Cans

10 oz Can

(12) 10 oz Cans

Contact Cleaner

363128-001

363128-012

11 oz Can

(12) 11 oz Cans

Electrical Connector Oxidation & Corrosion Inhibitor 127189-001 30 cc

Battery Cleaner

Battery Protector

363124-001

363124-012

363125-001

363125-012

18 oz Can

(12) 18 oz Cans

15 oz Can

(12) 15 oz Cans

363127-001

363127-012

363126-001

363126-012

363509-101

363509-106

363511-101

363511-106

12 oz Can

(12) 12 oz Cans

11 oz Can

(12) 11 oz Cans

1 Gallon

(6) 1 Gallon

1 Gallon

(6) 1 Gallon

Crown 1987 PF7886-3 Rev. 6/08 M1.0-04.0-003

17 Rev. 6/08

29



Alternate Lubricants & Fluids Chart

Type of Lubricant Product Name

Crown

Manufacturer

/ Distributor

A Gear Lube 80W-90 (Typical)

AA

Automatic Transmission Fluid

(Multi-Purpose)

Crown

Crown Crown

B

BB

Grease (Multi-Purpose)

Grease (Low Temp)

(2)

Mobilgrease XHP 222 Special

Union Unoba EP No 2

Retinax A

(1)

LM Grease

Unirex EP-2

Lubriplate

Alvania RA

(1)

Helveum O

(1)

Petro Canada Purity FG

Mobil

Union 76 Co.

Shell

Burmah Castrol

Exxon

Fiske Bros Refining Co.

Shell

Burmah Castrol

BBB Food Grade Grease (Multi-Purpose)

C Oil (SAE 40)

D Hydraulic Oil

DD

Hydraulic Oil (Low Temp)

(2)

DDD Hydraulic Oil - DTE24

(3)

E Channel Grease

F Gear, Channel & Shaft Grease

G

Chain & Cable Lube

Premium Chain & Cable Lube

H Final Finish - Rubber & Vinyl Dressing

I Grease (Lift Pump Coupling)

J Brake Fluid - Dot 5

K Grease (Wheel Bearing)

Crown

Crown

Mobil DTE 24

Factran #2

Molykote BR-2 Plus

Crown

Crown

Crown

Nyogel 774F-MS

Q2-1141 Silicon Brake Fluid

Mobilgrease XHP 222 Special

Unirex EP-2

Lubriplate No. 1242

(1)

Petro Canada

Crown

Crown

Mobil

Standard Oil Co.

Dow Corning

Crown

Crown

Crown

NYE Lubricants

Dow Corning

Mobil

Exxon

Fiske Bros. Refining Co.

L Metal Assembly Spray

M Silicon Grease (Clear)

N

Brake & Parts Cleaner

Low VOC Brake & Parts Cleaner

Dow Corning

Dow Corning 111 Compound

Crown

Crown

Dow Corning

Dow Corning

Crown

Crown

Non-Flammable Brake & Parts Cleaner Crown Crown

(1)

Denotes allowable substitutes, contact factory if unavailable.

(2)

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

(3)

Premium antiwear hydraulic oil used in blending with low temp oil.

Crown 1987 PF7886-4 Rev. 6/08 M1.0-04.0-004

17 Rev. 6/08

30



Alternate Lubricants & Fluids Chart

Type of Lubricant Product Name

O Penetrating Lubricant Crown

P Premium Formula Multi-Purpose Grease Crown

Q White Lithium Grease

R Choke & Carburetor Cleaner

Crown

Crown

S Contact Cleaner

T

Electrical Connector Oxidation &

Corrosion Inhibitor

Crown

Nye Grease

U Battery Cleaner

V Battery Protector

W Food Grade Machinery Lubricant

X Food Grade Silicone Spray

Y Extended Life Coolant

Crown

Crown

Crown

Crown

Crown

Crown

Manufacturer

/ Distributor

Crown

Crown

Crown

NYE Lubricants

Crown

Crown

Crown

Crown

Crown 1987 PF7886-5 Rev. 6/08 M1.0-04.0-005

17 Rev. 6/08

31

Notes:

32


Lubrication & Adjustment


Component Access

The following is a list of covers, panels, etc. that must be removed to allow access when performing service and/or maintenance to components. Refer to the illustrations in this section as an aid in locating parts that require attention.

NOTE

Be sure battery connectors are disconnected.

Battery Cover

Provides access to:

•

Battery

•

Lift motor and pump

•

Hydraulic reservoir and filter

To open battery cover, tilt steering wheel up and pull battery cover handle (located below and in front of seat).

Left Side Step Cover

Provides access to:

•

Distribution panel

•

•

•

Floorboards

The floorboards are in two pieces. Removing the front and rear floorboard provides access to:

•

Traction motor

•

Brake pedal, switch and linkage

•

Parking brake connections and release

•

Accelerator pedal, potentiometer and switch

•

Directional control valve

•

Hydraulic hoses, etc.

•

Tilt cylinders

Horn

Steer motor and pump

Steering Column Covers

Provides access to:

•

Key switch

Direction switches

Right Side Step Cover

•

Hydraulic dipstick

To remove covers, loosen (2) screws until cover can be removed completely.

Dashboard

Provides access to:

•

Steering control unit

•

Parking brake switch

•

Steer column tilt handle

•

Display

•

Accessory switches

Crown 2007 PF17008-1 Rev. 4/09 M1.0-2045-001

01 Rev. 4/09

33



Control Lever Cover

Provides access to:

•

Control lever linkage and switches

Contactor Assembly Cover

Provides access to:

•

Contactor panel assembly

Fan and Controller Cover

Provides access to:

•

FAN1, FAN 2 & controller panel

Lubrication

The following information is intended to provide guidelines for proper lubrication intervals as called out in the lubrication chart. However, some operating conditions will require more frequent checks and lubrication than listed. For example, applications with much dust or moisture will require modification of the schedule to fit that particular application.

Use high grade lubricants and fluids. Sources of these lubricants may be from almost any of the oil companies. Recommended lubricants are listed in the Lubrication Identification Chart and the Alternate Lubricants

& Fluids Chart in Lubrication & Adjustment Chapter.

Crown trucks may require a mixture of low temperature hydraulic oil, Crown P/N 063001-006 (gal), blended with standard hydraulic oil, Crown P/N 063001-021

(gal) when used in a freezer or cooler. 100% low temperature oil is too thin for most cold storage operations and therefore could shorten the life of cylinder packings and pumps if used in higher ambient temperatures.

NOTE

Trucks equipped with velocity fuses may experience staging issues if an insufficient mix of low temperature oil has been used.

(1)

(2)

(3)

(4)

Contactor Assembly Cover (5) Steering Column Cover

Left Side Step Cover (6) Control Lever Cover

(7) Floorboards

Dashboard (8)

Battery Cover

Fan and Controller Cover

Figure 17477

(1)

(2)

(3)

Hydraulic Oil 063001-001 (100%)

50/50 Blend of Low-Temp 063001-006 (50%) and Hydraulic Oil 063001-021 (50%)

80/20 Blend of Low-Temp 063001-006 (80%) and Hydraulic Oil 063001-021 (20%)

Figure 17478

For truck applications operating continually in temperatures at or above 4.4° C (40° F), use 100% standard hydraulic oil (063001-001).

Crown 2007 PF17008-2 M1.0-2045-002

34



For truck applications primarily operating in a cooler environment with intermittent freezer entry, use a 50/

50 blend of low temperature (063001-006) and standard hydraulic oil (063001-021).

For trucks running continuously at temperatures of

-12.2° C (10° F) or below, use an 80% low temperature

(063001-006) and 20% standard hydraulic oil

(063001-021).

The proper mixture of freezer hydraulic oil will ensure the best and most efficient operation of your Crown equipment.

All screws, washers, nuts, roll pins, retaining rings, etc.

need to be coated with a rust preventive (078882) to protect against corrosion. Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts.

NOTE

Use Planned Maintenance Inspection Reports

(PF15705) for FC 4500 trucks as required to record and assure maintenance checks.

Crown 2007 PF17008-3

Figure 17479

M1.0-2045-003

35



Figure 17480

M1.0-2045-004

36

Crown 2007 PF17008-4



Lubrication Chart 1

Index

L-1

L-2

L-3

L-4

L-5

L-6

L-7

L-8

Battery Cover Hinge and Latch

Hose Pulleys (Nylon)

Lift Chains

Mast Channels

Mast and Carriage Column Rollers

Sideshifter Slide Rail

Fork Slide and Locking Pin

Mast Pivots

Component

Lube

Type

C

H

G

E

E

B

B

B

Quantity

As Required

As Required

As Required

As Required

As Required

As Required

As Required

As Required

60 Days

250 Hrs

Check

Check

Check

Check

Check

Check

Check

Check

12 Months

2000 Hrs

See Lubrication Identification Chart and Alternate Lubricants and Fluids Chart in Lubrication and Adjustment chapter.

Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving parts for trucks operated in environments with much dust and moisture, freezer/ corrosion applications, etc.

Crown 2007 PF17008-5 M1.0-2045-005

37



Figure 17481

M1.0-2045-006

38

Crown 2007 PF17008-6




Index Component

Lube

Type

C

Quantity

60 Days

250 Hrs

Check

12 Months

2000 Hrs

L-1

L-2

L-3

Seat Slides

Steer Column Pivot and

Adjustment Latch

Parking Brake Pivot

Hydraulic reservoir

• Oil

C

C

As Required

As Required

As Required

Check

Check

L-4

L-5

• 10 Micron Filter Element

• Suction Strainer

• Cap Ventilating Element

Lift, Tilt and Accessory Lever

Linkage

D

C

32.7 Litre

(7.2 gal)

1

1

1

As Required

Check

1st Change

1st Change

Check

Change

Change

Clean

Change


Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving parts for trucks operated in environments with much dust and moisture, freezer/corrosion applications, etc.

Crown 2007 PF17008-7 M1.0-2045-007

39



Figure 17482-01

M1.0-2045-008

01 Rev. 4/09

40

Crown 2007 PF17008-8 Rev. 4/09




Index

L-1

L-2

L-3

L-4

L-5

L-6

L-7

Component

Drive Unit Oil

Tilt Cylinders Pivot

Brake Pedal Pivot

Brake Linkage

Accelerator Pedal Pivot

Accelerator Potentiometer Pivot

Steer Cylinder Pivot

Lube

Type

A*

B

B

C

B

B

B

Quantity

5.7 Litre

(6 Quarts)

As Required

As Required

As Required

As Required

As Required

As Required

60 Days

250 Hrs

Check/1st

Change

Check

Check

Check

Check

Check

Check

12 Months

2000 Hrs

Change

L-8 Steer Wheel Bearing B As Required Check Check

* In below freezing temperatures use Dextron II, Crown part number 063001-010.


Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving parts for trucks operated in environments with much dust and moisture, freezer/corrosion applications, etc.

Crown 2007 PF17008-9 Rev. 4/09 M1.0-2045-009

01 Rev. 4/09

41



Figure 17483

M1.0-2045-010

42

Crown 2007 PF17008-10



Inspection Chart 4

Index

I-1

I-2

I-3

I-4

I-5

I-6

I-7

I-8

Relief Valve

Battery Rollers

Mast Channels

Component

Mast and Carriage Column Rollers

Mast Limit Switch

Mast Electrical Connections

Lift Chains and Anchors

Mast Stops and Carriage Bumpers

I-9 Forks, Latches and Carriage

I-10 Sideshifter (Slides, Cylinder and Mounting, etc.)

I-11 Mast Pivot Bearings and Mounting Bolts

I-12 Battery Retainer Switch (BRES)

60 Days

250 Hrs

Check

Check

Check

Check

Check

Check

Check

Check

Check

Check

Check

Check

12 Months

2000 Hrs

Refer to appropriate section of Service and Parts Manual for additional information concerning inspection and/or adjustment.

Crown 2007 PF17008-11 M1.0-2045-011

43



Figure 17484

M1.0-2045-012

44

Crown 2007 PF17008-12




Index

I-1

I-2

I-3

I-4

I-5

I-6

I-7

I-8

Yoke

Horn Switch

Directional Control

Component

Lift Cylinder and Mounting

Mast Hydraulic Lines, Hoses and Fittings

Pulleys, Rollers and Bearings

Electrical Connections, Cables and Wiring

Travel Alarm - Truck Frame

I-9 Seat Belt, Retainer and Switch

I-10 Battery Connector and Contacts

60 Days

250 Hrs

Check

Check

Check

Check

Check

Check

Check

Check

Check

Check

12 Months

2000 Hrs

I-11 Battery and Cables Check


Crown 2007 PF17008-13 M1.0-2045-013

45



M1.0-2045-014

46

Figure 17485

Crown 2007 PF17008-14




Index

I-1

I-2

I-3

I-4

I-5

I-6

I-7

I-8

Contactor Tips

Control Cables

Steer Tire

Steer Cylinder

Component

Distribution Panel

Electrical Connections, Cables and Wiring

Pulleys, Rollers and Bearings

Lift Chains and Anchors

60 Days

250 Hrs

Check

Check

Check

Check

Check

Check

Check

Check

12 Months

2000 Hrs

I-9 Castle Nut Check


Crown 2007 PF17008-15 M1.0-2045-015

47



AC Lift

DC Lift

Figure 17486

M1.0-2045-016

48

Crown 2007 PF17008-16




Index

I-1

I-2

I-3

I-4

I-5

I-6

Component

Power Steering Pump

Power Steering Motor - Brushes, Mounting Secure

DC Lift Pump Motor - Brushes, Mounting Secure

AC Lift Pump Motor - Mounting Secure

Lift Pump

Control Levers, Linkage and Switches

Steer Column Pivot, Universal Joint and Adjustment

Latch

60 Days

250 Hrs

Check

Check

Check

Check

Check

Check

12 Months

2000 Hrs

I-7

I-8

Steering Control Unit

Parking Brake Switch

Check

Check

I-9 Parking Brake Connections Check


Crown 2007 PF17008-17 M1.0-2045-017

49



M1.0-2045-018

50

Figure 17487

Crown 2007 PF17008-18




Index

I-5

I-6

I-7

I-8

I-1

I-2

I-3

I-4

Horn

Component

Drive Unit

Brake Operation

Brake Adjustment and Linkage

Pads and Rotors

Hydraulic Hoses, Tubes and Fittings

Tilt Cylinders, Mounting and Mounting Hardware

Battery Retainer (Side Cover)

60 Days

250 Hrs

Check

Check

Check

Check

Check

Check

Check

12 Months

2000 Hrs

Check

I-9 Overhead Guard - Secure to Truck and No Cracks

I-10 Load Backrest

Check

Check

I-11

Accelerator - Linkage, Switch Adjustment,

Potentiometer

I-12 Drive Tires and Lug Nuts

Check

Check


Crown 2007 PF17008-19 M1.0-2045-019

51

Notes:

52


Componentry

Componentry

ACC POT1

Traction Accelerator Potentiometer

Location:

accelerator assembly.

Purpose:

provide input to controller for traction acceleration.

Data:

5K ohm.

Adjustment:

calibrated.

Diagrams:

DIA-2045-002 (C-3), DIA-2045-003 (C-3),

DIA-2045-004 (C-3), DIA-2045-013 (B-2).

Parts Breakdown:

04.6-2045-001 (20).

ACS

Accelerator Switch

Location:

accelerator assembly.

Purpose:

provide start signal for traction.

Data:

wired normally open, closed when operator pushes accelerator pedal down.

Adjustment:

refer to Electrical section.

Diagrams:

DIA-2045-002 (B-3), DIA-2045-003 (B-3),

DIA-2045-004 (B-3), DIA-2045-013 (C-1).


04.6-2045-001 (23).

ACCUMULATOR

Brake System

Location:

under battery compartment.

Purpose:

energy storage for service and parking brakehydraulic circuits.

Data:

non-serviceable, pre-charge 2760 kpa (400 psi).

Adjustment:

none required.

Diagrams:

does not apply.


02.0-2045-050 (11).

Accumulator

Figure 17747

Figure 17748

Figure 17749

Crown 2007 PF17073-1 Rev. 11/08 M1.0-2045-050

02 Rev. 11/08

53


Componentry

ACCESS 1

Display Control Module (DCM)

Location:

console next to parking brake.

Purpose:

displays pertinent truck information to operator or service technician (battery charge, hours of operation, etc.).

Data:

information received from truck control modules and sensors.

Adjustment:

none required.

Diagrams:

DIA-6745-002 (B-2), DIA-6745-003 (B-2),

DIA-2045-004 (B-2), DIA-2045-010 (C-1).


04.0-2045-001 (13).

ACCESS 2

Hydraulic Control Module (HCM)

Location:

rear of truck on controller panel.

Purpose:

controls hydraulic pump motor speed via operator or input from control levers.

Data:

information received from truck control modules and sensors.

Adjustment:

none required.

Diagrams:

DIA-6745-003 (C-1), DIA-2045-007 (C-1).


04.1-2045-050 (18).

ACCESS 3

Traction Control Module (TCM)

Location:

rear of truck on controller panel.

Purpose:

controls traction motor speed via operator input from accelerator (ACCEL).

Data:

transistor control circuitry.

Adjustment:

none required.

Diagrams:

DIA-6745-002 (C-3), DIA-6745-003 (C-3),

DIA-2045-004 (C-3), DIA-6745-006 (C-1).


04.1-2045-001 (12),

04.1-2045-050 (12).

M1.0-2045-051

54

Figure 17750

Figure 17751

Figure 17751

Crown 2007 PF17073-2


Componentry

ALM1

Status Alarm

Location:

in ACCESS 1 Display.

Purpose:

alert operator of truck status.

Data:

controlled by ACCESS 1.

Adjustment:

none required.

Diagrams:

DIA-6745-002 (B-2), DIA-6745-003 (B-2),

DIA-2045-004 (B-2).


04.0-2045-001 (13).

ALM2

Brake Pressure Alarm

Location:

mounted under front cowl.

Purpose:

audible warning when insufficient hydraulic pressure for service brake operation is present.

Data:

recieves power via PSI.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-2), DIA-2045-003 (B-2),

DIA-2045-004 (B-2), DIA-2045-013 (C-3).


04.0-2045-001 (8).

ALM3 (Optional)

Travel Alarm

Location:

front truck frame.

Purpose:

alert pedestrians of truck movement.

Data:

reverse and/or forward switch.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (C-3), DIA-2045-013 (C-4).


04.0-2045-001 (79)

Left & Right are Determined from Operator’s Perspective

Figure 17750

Figure 17752

Travel Alarm

(ALM3)

Figure 17753

Crown 2007 PF17073-3 Rev. 11/08 M1.0-2045-052

02 Rev. 11/08

55


Componentry

AXS1

Auxiliary Function Switches

Location:

control valve linkage.

Purpose:

indicates accessory hydraulic function request.

Data:

wired normally open, closed when hydraulic lever is moved.

Adjustment:

see Switches section.

Diagrams:

DIA-2045-002 (B-2), DIA-2045-003 (B-2),

DIA-2045-004 (B-2),DIA-2045-008 (C-1, B-3).


02.5-2045-050 (61),

02.5-2045-100 (61).

AXS2

Auxiliary Function Switches

Location:

control valve linkage.

Purpose:

indicates accessory hydraulic function request.

Data:

wired normally open, closed when hydraulic lever is moved.

Adjustment:

see Switches section.

Diagrams:

DIA-2045-002 (B-3), DIA-2045-003 (B-3),

DIA-2045-004 (B-3), DIA-2045-008 (C-1, B-3).


02.5-2045-050 (61),

02.5-2045-100 (61, 62).

AXS3

Additional Auxiliary Function Switch

Location:

mounted on third accessory handle.

Purpose:

actuate third accessory on carriage.

Data:

wired normally open closed when activated by operator.

Adjustment:

none required.

Diagrams:

DIA-2045-008 (C-2).


02.5-1140-250 (5).

Third Accessory Handle

Figure 17754

Figure 17754

Figure 17755

M1.0-2045-053

56

Crown 2007 PF17073-4


Componentry

BRES

Battery Retainer Switch

Location:

right side, front battery compartment wall, near reservoir breather.

Purpose:

monitor presence of battery retainer and disable travel if battery retainer is not present.

Data:

wired normally open, held closed when battery retainer is in place.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-2), DIA-2045-003 (B-2),

DIA-2045-004 (B-2), DIA-2045-009 (B-1).


01.2-2045-005 (73).

BREATHER

Reservoir

Location:

on reservoir under battery.

Purpose:

allow expansion and contraction of hydraulic fluid.

Data:

10 micron.

Adjustment:

none required.

Diagrams:

does not apply.


02.0-2040-001 (4).

BRKS

Brake Switch

Location:

brake pedal mounting bracket right side.

Purpose:

indicate position of brake pedal for lights and traction cutout option.

Data:

wired normally closed, held open when pedal is in up position.

Adjustment:

see Service Brake.

Diagrams:

DIA-2045-002 (B-4), DIA-2045-003 (B-4),

DIA-2045-004 (B-4), DIA-2045-013 (C-2).


05.0-2040-001 (37).

Breather

Figure 17756

Figure 17757

Figure 17758

Crown 2007 PF17073-5 M1.0-2045-054

57


Componentry

CBV

Counter Balance Valve

Location:

tilt manifold.

Purpose:

limits forward tilt speed and minimizes forward tilt drift.

Data:

does not apply.

Adjustment:

preset at factory.

Diagrams:

does not apply.


02.4-2040-001 (2).

CYLINDER

Parking Brake

Location:

under floorboard on traction motor.

Purpose:

actuate and release park brake.

Data:

does not apply.

Adjustment:

see Brake section.

Diagrams:

does not apply.


08.8-2040-051.

CYLINDER

Carriage

Location:

mast.

Purpose:

raise fork carriage.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

does not apply.


08.3-2045-001, 08.34-2040-050.

Figure 17759

Park Brake

Cylinder

Figure 17760

Carriage Cylinder

Figure 17761

M1.0-2045-055

02 Rev. 11/08

58

Crown 2007 PF17073-6 Rev. 11/08


Componentry

CYLINDER

Lift

Location:

mast.

Purpose:

raise fork carriage.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

does not apply.


08.1-2045-001, 08.2-2045-005,

08.34-2040-001.

CYLINDER

Steer

Location:

steer axle at rear of truck.

Purpose:

set direction of truck travel.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

does not apply.


08.8-20.0-002.

CYLINDER

Tilt

Location:

under floorboard on each side of frame.

Purpose:

tilt forks up or down.

Data:

does not apply.

Adjustment:

see Cylinders section.

Diagrams:

does not apply.


08.6-2045-001, 08.6-2045-050.

Lift Cylinder

Steer Cylinder

Figure 17762

Figure 17763

Tilt Cylinder

Figure 17764

Crown 2007 PF17073-7 Rev. 7/08 M1.0-2045-056

01 Rev. 7/08

59


Componentry

DIPSTICK

Hydraulic Reservoir

Location:

hydraulic reservoir under right side step.

Purpose:

check fluid level in hydraulic reservoir.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

does not apply.


02.0-2040-001 (3).

DISTRIBUTION PANEL

Location:

under left side step.

Purpose:

centralize wiring and troubleshooting efforts.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

DIA-2045-005.


04.3-2045-001 (13).

ECR1

Traction Motor Encoder

Location:

inside traction motor.

Purpose:

motor speed and direction.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (C-3), DIA-2045-003 (C-3),

DIA-2045-004 (C-3),DIA-2045-014 (C-1).


03.1-2045-001 (8).

Dipstick

Figure 17765

Distribution Panel

Figure 17766

Figure 17767

M1.0-2045-057

60

Crown 2007 PF17073-8


Componentry

ECR2

AC Hydraulic Motor Encoder

Location:

inside AC hydraulic motor.

Purpose:

motor speed.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

DIA-2045-003 (C-1), DIA-2045-014 (C-2).


02.2-2045-001 (22).

FAN1 & FAN2

Controller Panel

Location:

rear of truck above controller panel.

Purpose:

provide cooling for ACCESS2 and/or

ACCESS3.

Data:

36 or 48 volt.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (C-3), DIA-2045-003 (C-2,

C-4), DIA-2045-004 (C-4),DIA-2045-006 (B-3),

DIA-2045-007 (A-3).


04.0-2045-001 (22).

FAN3 (Optional)

Operator Fan

Location:

work assist tube.

Purpose:

operator comfort.

Data:

36 or 48 volt.

Adjustment:

manual directional.

Diagrams:

DIA-2045-004 (C-1), DIA-2045-009 (C-3).


04.9-2040-001 (40).

Figure 17768

Figure 17769

Figure 17770

Crown 2007 PF17073-9 Rev. 7/08 M1.0-2045-058

01 Rev. 7/08

61


Componentry

FAN4

Dock Performance Fan (Traction Motor)

Location:

right side of brake mounting bracket.

Purpose:

cool traction motor.

Data:

48 volt.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (C-2), DIA-2045-013 (C-4).


04.0-2045-001 (55).

FAN5

Lift Pump Fan

Location:

below lift pump motor.

Purpose:

cool lift pump motor.

Data:

48 volt.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (C-2), DIA-2045-013 (C-4).


04.0-2045-001 (69).

FIL

Horn Filter

Location:

under floorboard on brake pedal bracket.

Purpose:

suppress electrical noise generated by operation of horn.

Data:

does not apply.

Adjustment:

none required.

Diagrams: DIA-2045-002 (A-4), DIA-2045-003 (A-4),

DIA-2045-004 (A-4), DIA-2045-011 (B-4),

DIA-2045-012 (A-2).


04.0-2045-001 (63).

M1.0-2045-059

62

Figure 17771

Figure 17772

Figure 17773

Crown 2007 PF17073-10


Componentry

FILTER

Hydraulic Fluid Return Filter

Location:


Purpose:

remove contaminants from hydraulic fluid.

Data:

10 micron.

Diagrams:

does not apply.


02.0-2045-250 (8).

FNS (Optional)

Fan Switch

Location:

console.

Purpose:

allows operator to turn on/off operator fan and select low/high speed.

Data:

three position selector switch.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (C-1), DIA-2045-009 (B-3).


04.0-2045-001 (1).

FS

Forward Travel Switch

Location:

steering column directional control or foot operated directional control.

Purpose:

signals Access 3 (TCM) for selection of forward travel.

Data:

momentary contact wired normally open, actuated when operator moves directional control to forward travel position.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-3), DIA-2045-003 (B-3),

DIA-2045-004 (B-3),DIA-2045-011 (C-3),

DIA-2045-012 (C-2, C-3)


04.5-1140-002 (7), 04.5-2045-050

(2).

Filter

Figure 17774

Figure 17775

Steering Column

Directional Control

Foot Operated

Directional Control

Figure 17776

Crown 2007 PF17073-11 Rev. 7/08 M1.0-2045-060

01 Rev. 7/08

63


Componentry

FU1

Traction Motor Power Fuse

Location:

contactor panel.

Purpose:

protect Access 3 (TCM) and associated wiring from over current.

Data:

CNN500, ANN500.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (A-4), DIA-2045-003 (B-4),

DIA-2045-004 (A-4),DIA-2045-018 (B-1),

DIA-2045-019 (B-1).


04.2-2045-001 (25).

FU2

Lift Pump Motor Power Fuse

Location:

Contactor Panel.

Purpose:

protect ACCESS2 and associated wiring from over current.

Data:

ANN500, CNN500.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (A-1), DIA-2045-003 (B-2),

DIA-2045-004 (A-1), DIA-2045-018 (A-1),

DIA-2045-019 (A-1).


04.2-2045-001 (26).

FU3

Steering Pump Motor Power Fuse

Location:

contactor panel.

Purpose:

protect power steering pump motor and associated wiring from over current.

Data:

ANN150, CNN150.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (A-1), DIA-2045-003 (A-1),

DIA-2045-004 (A-1), DIA-2045-018 (A-1),

DIA-2045-019 (A-2).


04.2-2045-001 (25).

M1.0-2045-061

64

Figure 17777

Figure 17778

Figure 17779

Crown 2007 PF17073-12


Componentry

FU4

Main Control Fuse

Location:

distribution panel.

Purpose:

protect control circuitry from over current.

Data:

ABC 15.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (A-4), DIA-2045-003 (A-4),

DIA-2045-003 (A-4), DIA-2045-005 (B-2),

DIA-2045-016 (B-3).


04.3-2045-001 (17).

FU5

Option Fuse

Location:

distribution panel.

Purpose:

protect optional components and associated wiring from over current.

Data:

ABC 15.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (A-1), DIA-2045-005 (B-3).


04.3-2045-001 (17).

FU6

Power Supply Input Fuse

Location:

12 volt power supply.

Purpose:

protect power supply input and associated wiring from over current.

Data:

ABC 15.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (B-1), DIA-2045-005 (A-4).


04.3-2045-001 (4).

Figure 17780

Figure 17781

Figure 17782

Crown 2007 PF17073-13 Rev. 11/08 M1.0-2045-062

02 Rev. 11/08

65


Componentry

FU7

Power Supply Input Fuse

Location:

12 volt power supply.

Purpose:

protect power supply output and associated wiring from over current.

Data:

15 amp.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (B-1), DIA-2045-005 (A-4).


04.3-2045-001 (5).

FU8

ACCES2 & ACCESS3 Fuse

Location:

distribution panel.

Purpose:

protect ACCESS2 & ACCESS3 and associated wiring from over current.

Data:

6 amp.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-4), DIA-2045-003 (B-4),

DIA-2045-004 (B-4), DIA-2045-005 (B-2).


04.3-2045-001 (18).

FU11 (Optional)

Freezer/Corrosion Fuse

Location:

freezer/condition board.

Purpose:

protect heaters and associated wiring from over current.

Data:

ABC 15.

Adjustment:

none required.

Diagrams:

DIA-2045-016 (B-1, B-3).


04.3-2045-001 (17).

M1.0-2045-063

02 Rev. 11/08

66

Figure 17783

Figure 17784

Figure 17785

Crown 2007 PF17073-14 Rev. 11/08


Componentry

FU12 (Optional)

Freezer/Corrosion Fuse

Location:


Purpose:

protect heaters and associated wiring from over current.

Data:

ABC 15.

Adjustment:

none required.

Diagrams:

DIA-2045-016 (B-2).


04.3-2045-001 (17).

HAND PUMP

Location:

park brake release manifold.

Purpose:

manually pressurize parking brake hydraulic circuit to release parking brake.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

does not apply.


02.4-2040-100.

HGTS1

Height Switch

Location:

located on mast at staging.

Purpose:

lift/tilt interlock and speed reduction above mast staging.

Data:

wired normally open, closed when mast is below staging.

Adjustment:

see Electrical section.

Diagrams:

DIA-2045-002 (B-4), DIA-2045-003 (B-4),

DIA-2045-004 (B-4), DIA-2045-009 (C-2).


07.1-2040-001 (20),

07.2-2045-001 (38), 07.24-2040-001 (15).

Hand Pump

Figure 17786

Figure 17787

Figure 20081

Crown 2007 PF17073-15 Rev. 7/08 M1.0-2045-064

01 Rev. 7/08

67


Componentry

HN1

Horn

Location:

left under floorboard on brake pedal bracket.

Purpose:

provide operator controlled audible warning.

Data:

36 to 48 operating voltage.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-4), DIA-2045-003 (B-4),

DIA-2045-004 (B-4), DIA-2045-011 (B-4),

DIA-2045-012 (B-2).


04.0-2045-001 (51),

05.0-2040-001 (33).

HNS

Horn Switch

Location:

steering wheel

Purpose:

allows operator to sound horn.

Data:

wired normally open. Button with spring return, closes when operator depresses horn button in center of steering wheel.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (A-4), DIA-2045-003 (A-4),

DIA-2045-004 (A-4), DIA-2045-011 (B-3),

DIA-2045-012 (B-2).


06.0-2040-001 (4, 8).

HR1

Heater for FS Switch

Location:

FS switch on foot operated directional control.

Purpose:

applies heat to FS switch.

Data:

2 watt, 24 volt.

Adjustment:

none required.

Diagrams:

DIA-2045-017 (B-2, B-4).


04.5-2045-050.

M1.0-2045-065

68

Figure 17789

Figure 17790

Figure 17845

Crown 2007 PF17073-16


Componentry

HR2

Heater for FS Switch

Location:

RS switch on foot operated directional control.

Purpose:

applies heat to RS switch.

Data:

2 watt, 24 volt.

Adjustment:

none required.

Diagrams:

DIA-2045-017 (B-2, B-4).


04.5-2045-050.

HSS

High Speed Switch

Location:

hydraulic control valve linkage.

Purpose:

provides high speed raise, AC lift only.

Data:

wired normally open, closed when raise lever is at full limit of lift stroke (lever is pulled fully back).

Adjustment:


Diagrams:

DIA-2045-003 (B-2)), DIA-2045-008 (C-1,

B-3).


02.5-2045-001 (59)02.5-2045-050

(59), 02.5-2045-100 (59).

INFOLINK MODULE (Optional)

Location:

mounted on overhead guard.

Purpose:

monitors truck functions and impacts.

Data:

does not apply.

Adjustment:

non required.

Diagrams:

DIA-2045-004 (B-2), DIA-2045-020 (C-1).


10.0-2045-075 (1).

Figure 17845

Figure 17791

Figure 17851

Crown 2007 PF17073-17 Rev. 7/08 M1.0-2045-066

01 Rev. 7/08

69


Componentry

IMPACT SENSOR (Optional)

Location:

mounted below traction motor.

Purpose:

indicates truck impact.

Data:

does not apply.

Adjustment:

non required.

Diagrams:

DIA-2045-004 (B-2), DIA-2045-020 (A-3).


10.0-2045-075 (12).

K1

Power Up and Control Relay

Location:

distribution panel.

Purpose:

provides control circuitry power and protection from reverse battery condition.

Data:

36 and 48 volt DC coil energized upon key switch test position closure.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-4), DIA-2045-003 (B-4),

DIA-2045-004 (B-4),DIA-2045-005 (B-2),

DIA-2045-016 (B-3)


04.3-2045-001 (15).

K2

Seat Relay

Location:

distribution panel.

Purpose:

hydraulic lockout and parking brake relay.

Data:

36 and 48 volt DC coil energized upon seat switch closure.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-3, B-4), DIA-2045-003

(B-3, B-4), DIA-2045-004 (B-3, B-4), DIA-2045-005

(B-2)


04.3-2045-001 (16).

M1.0-2045-067

01 Rev. 7/08

70

Figure 17852

Figure 17792

Figure 17793

Crown 2007 PF17073-18 Rev. 7/08


Componentry

K11 (Optional)

Freezer/Corrosion Relay

Location:


Purpose:

provide power to thermostat circuits when closed.

Data:

36 and 48 volt DC coil energized when THS1 calls for heat and THS2 is within temperature range.

Adjustment:

none required.

Diagrams:

DIA-2045-016 (B-2, B-3, B-4).


04.3-2045-001 (22).

K12 (Optional)

Freezer/Corrosion Relay

Location:


Purpose:

provide power to thermostat circuits when closed.

Data:

36 and 48 volt DC coil energized when THS1 calls for heat and THS2 is within temperature range.

Adjustment:

none required.

Diagrams:

DIA-2045-016 (B-1, B-2, B-4).


04.3-2045-001 (23).

KYS

Key Switch

Location:

panel in steering column.

Purpose:

allows operator to power truck up and shut truck down.

Data:

key operated selector switch, energizes K1 relay in start position and maintains K1 relay in ignition position.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (A-3), DIA-2045-003 (A-4),

DIA-2045-003 (A-4), DIA-2045-011 (B-2),

DIA-2045-012 (B-2), DIA-2045-016 (B-3).


06.0-2040-001 (17).

Figure 17794

Figure 17795

Figure 17796

Crown 2007 PF17073-19 Rev. 7/08 M1.0-2045-068

01 Rev. 7/08

71


Componentry

L

Line Contactor

Location:

contactor panel.

Purpose:

DC lift - provides power to ACCESS3.

AC lift - provides power to ACCESS2 & ACCESS3.

Data:

24 volts DC.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (A-4, C-3), DIA-2045-003

(A-4, C-4), DIA-2045-004 (A-4, C-4), DIA-2045-014

(B-4), DIA-2045-018 (B-2), DIA-2045-019 (A-1).


04.2-2045-001 (14),

04.4-2045-001.

LGS1 (Optional)

Front Work Light Switch

Location:

console cover.

Purpose:

allows operator to turn front work lights on and off.

Data:

rocker switch, wired normally open.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (B-1), DIA-2045-009 (C-2).


04.0-2045-001 (3).

LGS2 (Optional)

Rear Work Light Switch

Location:

console cover.

Purpose:

allows operator to turn rear work light on and off.

Data:

rocker switch, wired normally open.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (B-1), DIA-2045-009 (C-2).


04.0-2045-001 (3).

M1.0-2045-069

01 Rev. 7/08

72

Figure 17797

Figure 17798

Figure 17799

Crown 2007 PF17073-20 Rev. 7/08


Componentry

LGT1, 2, 3 (Optional)

Work Lights

Location:

overhead guard.

Purpose:

provide work area light outside operator compartment.

Data:

12 volt.

Adjustment:

minimal manual directional adjustment.

Diagrams:

DIA-2045-004 (B-1), DIA-2045-015 (B-1,

C-3, C-4).


04.9-2040-050 (50),

04.9-2040-150 (1).

LGT4

Strobe Light

Location:

overhead guard.

Purpose:

visual warning of lift truck presence.

Data:

0.5 amp, 36 or 48 volt.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (C-2), DIA-2045-015 (B-1,

B-3).


04.9-2040-001 (1), 04.9-2040-050

(30), 04.9-2040-075 (1), 04.9-2040-100(14),

04.9-2040-150 (41), 04.94-2040-200 (11).

LGT5, 6

Brake lights, Tail Lights, Backup Lights

Location:

overhead guard.

Purpose:

visual indication that brake pedal is depressed.

Data:

36/48 volt.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (C-2), DIA-2045-015 (B-2).


04.9-2040-050 (2), 04.9-2040-150

(11).

Figure 17800

Figure 17801

Figure 17802

Crown 2007 PF17073-21 Rev. 7/08 M1.0-2045-070

01 Rev. 7/08

73


Componentry

M1

Traction Motor

Location:

below floorboard on top of drive unit.

Purpose:

provides driving force for traction.

Data:

Access 3 (TCM) provides speed control via operator input (ACC).

Adjustment:

none required.

Diagrams: DIA-2045-002 (C-3), DIA-2045-003 (C-3),

DIA-2045-004 (C-3), DIA-2045-014 (C-1),

DIA-2045-018 (C-1), DIA-2045-019 (C-1).


03.1-2045-001.

M2

Hydraulic Pump Motor

Location:

below battery compartment.

Purpose:

provides driving force for hydraulic pump supplying hydraulic oil flow for lift and accessory functions.

Data:

input movement of control lever closes contactor or inputs signal to ACCESS2.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-1), DIA-2045-003 (C-1),

DIA-2045-004 (B-1), DIA-2045-014 (C-2, C-3),

DIA-2045-018 B-2), DIA-2045-019 (B-1).


DC lift pump motor: 02.2-2040-001

AC lift pump motor: 02.2-2045-001.

M3

Power Steering Pump Motor

Location:

below floorboard.

Purpose:

provides driving force for steering and brake functions.

Data:

energized by "S" contactor.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-1), DIA-2045-003 (B-1),

DIA-2045-004 (B-1), DIA-2045-014 (B-2, B-3),

DIA-2045-018 (B-3), DIA-2045-019 (B-3).


06.2-1140-001.

M1.0-2045-071

74

Figure 17803

Figure 17804

Figure 17805

Crown 2007 PF17073-22


Componentry

MANUAL RELIEF VALVE

Location:

park brake release manifold.

Purpose:

manually release park brake.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

does not apply.


02.4-2040-100.

MPCE

Main Pressure Compensating Element

Location:

hydraulic function control valve.

Purpose:

controls flow and pressure for lift, tilt and accessory hydraulic circuits.

Data:

does not apply.

Adjustment:

see Hydraulic section.

Diagrams:

does not apply.


02.3-2040-001 (25),

02.3-2040-050 (26).

P

Pump Solenoid

Location:

left side of power unit.

Purpose:

provide battery volts to DC pump motor (M2) when coil is energized, not used with AC lift.

Data:

positive voltage provided by RAS, TLT, TBS

(through tilt Interlock), battery negative controlled by tilt interlock on contactor lift.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (A-1, B-2), DIA-2045-004

(A-1, B-2), DIA-2045-014 (B-4), DIA-2045-018 (A-1).


04.2-2045-001 (14).

Manual Relief Valve

Figure 17806

Figure 17807

Figure 17808

Crown 2007 PF17073-23 M1.0-2045-072

75


Componentry

PRESSURE CHECK POINT

Hydraulic Function

Location:

under floorboard near brake manifold.

Purpose:

monitor system pressure during system operation for troubleshooting.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

does not apply.


02.0-2045-050 (2).

PRK-A, PRK-B

Park Brake Switch

Location:

park brake level assembly in console.

Purpose:

PRK-A allows power to be supplied to alarm

(ALM1) if park brake is not set and operator is not in seat and applies power to SV2 to release parking brake. PRK-B prevents travel by interrupting power to

ACS when in the park position.

Data:

wired normally open, held closed when brakes are released.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-3), DIA-2045-003 (B-3),

DIA-2045-004 (B-3), DIA-2045-011 (B-4).


04.8-2040-050 (6).

12V POWER SUPPLY

Location:

distribution panel.

Purpose:

provides 12 volt power for work lights.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (B-1).


02.0-6745-001 (2).

Pressure Check Point

Figure 17809

Figure 17810

12V Power Supply

Figure 17811

M1.0-2045-073

76

Crown 2007 PF17073-24


Componentry

PS1

Brake Pressure Switch

Location:

under battery compartment, near tilt manifold.

Purpose:

applies power to ALM2 when insufficient hydraulic pressure for service brake operation is present.

Data:

wired normally open, held closed when brake pressure is sufficient.

Adjustment:

none required, preset to 4135 kpa

(60 psi).

Diagrams:

DIA-2045-002 (B-2), DIA-2045-003 (B-3),

DIA-2045-004 (B-3), DIA-2045-013 (C-3).


02.0-2045-050 (20).

Pump

Lift

Location:


Purpose:

provide hydraulic flow for lift, tilt and accessory operation.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

does not apply.


02.1-2040-001.

Pump

Steering, Service Brake & Park Brake

Location:

power steering motor.

Purpose:

provides hydraulic flow for power steering, service brake and park brake release.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

does not apply.


06.1-2045-001.

Lift Pump Mounted to End of Motor

Figure 17813

Steering & Brake Pump

Mounted on End of Motor

Figure 17812

Figure 17814

Crown 2007 PF17073-25 Rev. 11/08 M1.0-2045-074

02 Rev. 11/08

77


Componentry

RAS

Raise Switch

Location:

control lever assembly.

Purpose:

indicates raise hydraulic function request.

Data:

momentary contact wired normally open when control lever pivots, a cam activates switch.

Adjustment:


Diagrams:

DIA-2045-002 (B-2), DIA-2045-003 (B-2),

DIA-2045-004 (B-2), DIA-2045-008 (C-1, B-3).


02.5-2045-001 (45),

02.5-2045-050 (45), 02.5-2045-100 (45).

RES2 (Optional)

Freezer/Corrosion Heater

Location:

steering column, directional control.

Purpose:

applies heat to FS and RS switches.

Data:

70 ohm, 10 watt for 36 volt. 120 ohm, 10 watt for

48 volt.

Adjustment:

none required.

Diagrams:

DIA-2045-016 (C-2, B-3).


04.5-1140-002 (16).

RES3 (Optional)

Freezer/Corrosion Heater

Location:

steering column, directional control.

Purpose:

applies heat to FS and RS switches.

Data:

70 ohm, 10 watt for 36 volt. 120 ohm, 10 watt for

48 volt.

Adjustment:

none required.

Diagrams:

DIA-2045-016 (C-2, B-3).


04.5-1140-002 (14).

M1.0-2045-075

01 Rev. 7/08

78

Figure 17815

Figure 17816

Figure 17817

Crown 2007 PF17073-26 Rev. 7/08


Componentry

RS

Reverse Switch

Location:

steering column directional control or foot operated directional control.

Purpose:

for selection of reverse travel.

Data:

momentary contact wired normally open, actuated when operator moves directional control to reverse travel position.

Adjustment:

see Electrical maintenance section.

Diagrams:

DIA-2045-002 (B-3), DIA-2045-003 (B-3),

DIA-2045-004 (B-3), DIA-2045-011 (C-2),

DIA-2045-012 (C-2, C-3).


04.5-1140-002 (7), 04.5-2045-050

(2).

RV1

Main Relief Valve

Location:


Purpose:

limits operating pressure for lift and tilt circuits.

Data:

not applicable.

Adjustment:

see Hydraulic maintenance section.

Diagrams:

does not apply.


02.3-2040-001 (31),

02.3-2040-050 (32).

RV2

Secondary Relief Valve

Location:


Purpose:

limits operating pressure for accessory circuits.

Data:

not applicable.

Adjustment:

see Hydraulic maintenance section.

Diagrams:

does not apply.


02.3-2040-001 (29), 02.3-2040-

050 (30).

Steering Column

Directional Control

Foot Operated

Directional Control

Figure 17818

Figure 17819

Figure 17820

Crown 2007 PF17073-27 M1.0-2045-076

79


Componentry

RV3

Steering Relief Valve

Location:

steer and brake pump.

Purpose:

limits maximum pressure of steering hydraulic circuit.

Data:

not applicable.

Adjustment:

preset at 9655 kpa (1400 psi).

Diagrams:

does not apply.


06.1-2045-001 (8 thru 13).

S

Steer Pump Contactor

Location:

contactor panel.

Purpose:

supply battery voltage to power steering pump motor when coil energized.

Data:

positive voltage provided through KYS, battery negative controlled by ACCESS1.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (A-1, B-2), DIA-2045-003

(A-1, C-3), DIA-2045-004 (A-1, B-3),DIA-2045-014

(B-4), DIA-2045-018 (A-1), DIA-2045-019 (A-1).


04.2-2045-001 (10),

04.4-2045-050, 04.4-2045-075.

SB80 (Optional)

5th Function Suppressor Block

Location:

carriage.

Purpose:

suppress electrical noise generated by 5th function solenoid valve (SVX).

Data:

does not apply.

Adjustment:

none required.

Diagrams:

DIA-2045-008 (A-2).


04.2-2045-001 (10),

04.4-2045-050, 04.4-2045-075.

M1.0-2045-077

01 Rev. 7/08

80

Figure 17821

TT Mast

Carriage

Shown

Figure 17822

Figure 17823

Crown 2007 PF17073-28 Rev. 7/08


Componentry

SCU

Steer Control Unit

Location:

bottom of steer column.

Purpose:

provide power assist steering.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

does not apply.


06.3-1145-001.

SES

Suspension Seat Switch

Location:

suspension seat.

Purpose:

allows power to be supplied to alarm (ALM1) through K2 if parking brake is not set and driver is not in seat. Provides inputs to lift and traction circuits.

Data:

wired normally open, switch is actuated when operator sits on seat.

Adjustment:


Diagrams:

DIA-2045-011 (C-1).


01.5-2040-056 (16).

SES1, SES2

Static Seat Switches

Location:

static seat.

Purpose:

allows power to be supplied to alarm (ALM1) through K2 if parking brake is not set and driver is not in seat. Provides inputs to lift and traction circuits.

Data:

wired normally open, switches are wired in parallel and actuated when operator sits on seat.

Adjustment:


Diagrams:

DIA-2045-002 (A-4), DIA-2045-003 (A-4),

DIA-2045-004 (A-4),DIA-2045-011 (C-1).


01.5-2040-007 (47).

Figure 17824

Figure 17825

Figure 17826

Crown 2007 PF17073-29 M1.0-2045-078

81


Componentry

Strainer

Suction

Location:

hydraulic reservoir.

Purpose:

remove contaminants from hydraulic fluid.

Data:

100 mesh.

Adjustment:

none required.

Diagrams:

does not apply.


02.0-2040-001 (5).

SV1

Tilt Lockout Solenoid

Location:

tilt manifold.

Purpose:

limits forward tilt above staged lift.

Data:

coil is controlled by tilt interlock module. Coil resistance for 36 volt coils is 88 ohm, for 48 volt coil 157 ohm. Coil contains internal suppression diode and is polarity sensitive.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-2), DIA-2045-003 (B-3),

DIA-2045-004 (B-3), DIA-2045-008 (B-2, B-4).


02.4-2040-001 (7).

SV2

Parking Brake Solenoid

Location:

parking brake release manifold.

Purpose:

controls hydraulic pressure in parking brake cylinder to apply or release parking brake.

Data:


Adjustment:

none required.

Diagrams:

DIA-2045-002 (B-2), DIA-2045-003 (B-3),

DIA-2045-004 (B-3), DIA-2045-013 (C-2).


02.4-2040-100 (4).

M1.0-2045-079

82

Suction

Strainer

Figure 17827

Figure 17828

Figure 17829

Crown 2007 PF17073-30


Componentry

SV3

Tilt Position Assist Solenoid

Location:

tilt manifold.

Purpose:

locks out tilt function when tilt limit is reached and mast is above free lift.

Data:


Adjustment:

none required.

Diagrams:

DIA-2045-004 (B-2), DIA-2045-008 (C-3).


02.4-2040-100 (4).

TBS

Tilt Back Switch

Location:

mounted to bracket on control valve.

Purpose:

indicates tilt back request to interlock module.

Data:

wired normally open, closed with upward movement of tilt spool valve.

Adjustment:


Diagrams:

DIA-2045-002 (B-2), DIA-2045-003 (B-2),

DIA-2045-004 (B-2), DIA-2045-008 (B-3, C-1).


02.5-2045-001 (58),

02.5-2045-050 (58), 02.5-2045-100 (58).

THS1 (Optional)

Freezer/Corrosion Thermostat

Location:

mounted on bracket located on front of overhead guard.

Purpose:

provide low temperature turn on control.

Data:

open temperature 15.5° C (60° F) and close temperature of 4° C (40° F).

Adjustment:

not required.

Diagrams:

DIA-2045-016 (C-2, B-3).


04.0-2045-001 (19).

Figure 17830

Figure 17831

Figure 17832

Crown 2007 PF17073-31 Rev. 7/08 M1.0-2045-080

01 Rev. 7/08

83


Componentry

THS2 (Optional)

Freezer/Corrosion Thermostat

Location:

mounted on key switch bracket on steering column.

Purpose:

provide high temperature turn on control.

Data:

open temperature 60° C (140° F) and close temperature of 49° C (120° F).

Adjustment:

not required.

Diagrams:

DIA-2045-016 (C-2, B-3).


06.0-2040-001 (50).

TLMS

Tilt Limit Switch

Location:

mounted on left tilt cylinder.

Purpose:

provide indication of tilt position.

Data:

wired normally open, held closed when mast is tilted back.

Adjustment:


Diagrams:

DIA-2045-002 (B-2), DIA-2045-003 (B-2),

DIA-2045-004 (B-2), DIA-2045-009 (B-1).


04.8-2040-100 (3).

TLT

Tilt Switch

Location:

tilt spool valve, lower switch.

Purpose:

indicate tilt forward or tilt back request.

Data:

wired normally open, closed with motion of tilt spool valve up or down.

Adjustment:


Diagrams:

DIA-2045-002 (B-2), DIA-2045-003 (B-2),

DIA-2045-004 (B-2), DIA-2045-008 (B-3, C-1).


02.5-2045-001 (46),

02.5-2045-050 (46), 02.5-2045-100 (46)

M1.0-2045-081

01 Rev. 7/08

84

Figure 17833

Figure 17834

Figure 17835

Crown 2007 PF17073-32 Rev. 7/08


Componentry

TMM

Truck Management Module

Location:

under left side step by distribution panel.

Purpose:

provide motor over temperature and brush wear indication.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

DIA-2045-004 (A-1), DIA-2045-009 (C-4).


04.3-2045-001 (29).

TS1

Traction Motor Temperature Sensor

Location:

in traction motor stator.

Purpose:

provide motor over temperature data.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

DIA-2045-002 (C-3), DIA-2045-003 (C-3),

DIA-2045-004 (C-3), DIA-2045-014 (C-1).


03.1-2045-001.

TS2

Lift Pump Motor Temperature Sensor

Location:

in lift pump motor stator.

Purpose:

provide motor over temperature data.

Data:

does not apply.

Adjustment:

none required.

Diagrams:

DIA-2045-003 (C-1), DIA-2045-014 (C-2).


02.2-2045-001.

Figure 17836

Figure 17837

Figure 17838

Crown 2007 PF17073-33 M1.0-2045-082

85


Componentry

ULV

Valve

Location:

steering and brake pump.

Purpose:

control pressure in the brake accumulator and limit maximum pressure in brake circuits.

Data:

does not apply.

Adjustment:

set at 7930 kpa (1150 psi).

Diagrams:

does not apply.


06.1-2040-001 (4).

VALVE

Hydraulic Function Control

Location:

right side of operator compartment.

Purpose:

manual control of hydraulic function.

Data:

does not apply.

Adjustment:

not required.

Diagrams:

does not apply.


02.3-2040-001, 02.3-2040-050.

VALVE

Service Brake

Location:

below brake pedal.

Purpose:

pressurize service brake system to apply service brake when brake pedal is pressed.

Data:

does not apply.

Adjustment:

not required.

Diagrams:

does not apply.


05.0-2040-001 (23).

Figure 17839

Hydraulic Function

Control Valve

Figure 17840

Service Brake

Valve

Figure 17841

M1.0-2045-083

02 Rev. 11/08

86

Crown 2007 PF17073-34 Rev. 11/08


Metric Torque Values


All Crown trucks are manufactured with class 8.8 or better screws and bolts. The information contained in this section will aid you when replacing any screws and bolts that are necessary when performing maintenance on your lift truck.

Grade

Grade Marking

(on Head)

Specification Material

Bolt and Screw

Size (mm)

M5 through M36

Class 5.8

Low Carbon Steel

Class 8.8

Medium Carbon Steel

Quenched and Tempered

M5 through M36

Class 10.9

Medium Carbon Alloy Steel


M5 through M36

NOTE:

Even though a bolt head is unmarked, Crown uses nothing less than class 8.8 in all of its bolted assemblies. Instances do occur when class 8.8 bolts are manufactured unmarked. When a fastener is replaced that is unmarked, replace the fastener with a class 8.8.

Figure 15048

Crown 1989 PF8514-1 Rev. 11/08 M1.9-06.6-001

02 Rev. 11/08

87



Torque Chart - Metric Hex Head Cap Screws and Nuts

Thread Diameter

& Pitch

M5 x 0.80

M6 x 1.00

M8 x 1.25

M10 x 1.50

M12 x 1.75

M14 x 2.00

M16 x 2.00

M20 x 2.50

M24 x 3.00

M30 x 3.50

Class 8.8

5 - 8 (4 - 6)

8 - 10 (6 - 7)

20 - 25 (15 - 18)

39 - 43 (29 - 32)

71 - 76 (52 - 56)

113 - 122 (83 - 90)

175 - 190 (129 - 140)

340 357 (251 - 271)

587 - 635 (433 - 468)

Tightening Torque Nm (ft lb)

Class 10.9

7 - 8 (5 - 6)

12 - 14 (9 - 10)

28 - 31 (21 - 23)

56 - 61 (41 - 45)

100 - 107 (73 - 79)

159 - 171 (117 - 126)

247 - 267 (182 - 197)

479 - 518 (353 - 382)

824 - 892 (608 - 658)

Class 12.9

8 - 10 (6 - 7)

15 - 16 (11 - 12)

34 - 37 (25 - 27)

68 - 75 (50 - 54)

119 - 127 (88 - 94)

190 - 205 (140 - 151)

296 - 320 (218 - 236)

574 - 621 (423 - 458)

990 - 1071 (730 - 790)

1175 - 1274 (867 - 940) 1654 - 1792 (1220 - 1322) 1985 - 2150 (1464 - 1586)

Note:

Torque values called out in the maintenance section of this manual will take precedence over torque values found on this page.

Torque Chart - Metric Hex Socket Countersink Head Screws

Thread Diameter

& Pitch

M5 x 0.80

M6 x 1.00

M8 x 1.25

M10 x 1.50

M12 x 1.75

M14 x 2.00

M16 x 2.00

M20 x 2.50

Class 8.8

4 - 7 (3 - 5)

7 - 10 (5 - 7)

16 - 19 (12 - 14)

31 - 34 (23 - 25)

56 - 60 (41 - 44)

124 - 146 (99 - 108)

259 - 281 (191 - 207)

416 - 451 (307 - 333)


Class 10.9

5 - 8 (4 - 6)

9 - 12 (7 - 9)

23 - 26 (17 - 19)

45 - 49 (33 - 36)

79 - 84 (58 - 62)

190 - 206 (140 - 152)

363 - 395 (268 - 291)

586 - 635 (432 - 468)

Class 12.9

7 - 10 (5 - 7)

11 - 14 (8 - 10)

27 - 30 (20 - 22)

54 - 58 (40 - 43)

94 - 102 (69 - 75)

228 - 247 (168 - 182)

437 - 473 (322 - 349)

702 - 762 (518 - 562) M24 x 3.00

M30 x 3.50

Note:


M1.9-06.6-002

02 Rev. 11/08

88

Crown 1989 PF8514-2 Rev. 11/08



Torque Chart - Metric Socket Head Cap Screws

Thread Diameter

& Pitch

M5 x 0.80

M6 x 1.00

M8 x 1.25

M10 x 1.50

M12 x 1.75

M14 x 2.00

M16 x 2.00

M20 x 2.50

M24 x 3.00

M30 x 3.50

Class 8.8

5 - 8 (4 - 6)

9 - 12 (7 - 9)

22 - 24 (16 - 18)

42 - 45 (31 - 33)

72 - 77 (53 - 57)

115 - 125 (85 - 92)

179 - 194 (132 - 143)

348 - 377 (257 - 278)

601 - 651 (443 - 480)


Class 10.9

7 - 9 (5 - 7)

12 - 15 (9 - 11)

30 - 33 (22 - 24)

58 - 64 (43 - 47)

102 - 110 (75 - 81)

161 - 175 (119 - 129)

251 - 273 (185 - 201)

489 - 530 (361 - 391)

846 - 915 (624 - 675)

Class 12.9

8 - 11 (6 - 8)

15 - 18 (11 - 13)

35 - 38 (26 - 28)

71 - 76 (52 - 56)

122 - 132 (90 - 97)

194 - 210 (143 - 155)

301 - 327 (222 - 241)

588 - 637 (434 - 470)

1014 - 1098 (748 - 810)

1196 - 1296 (882 - 956) 1681 - 1822 (1240 - 1344) 2017 - 2187 (1488 - 1613)

Note:


Torque Chart - Metric Flanged Hex Head Cap Screws and Nuts

Thread Diameter

& Pitch

M5 x 0.80

M6 x 1.00

M8 x 1.25

M10 x 1.50

M12 x 1.75

M14 x 2.00

M16 x 2.00

M20 x 2.50

Class 8.8


Class 10.9

8 - 11 (6 - 8)

14 - 16 (10 - 12)

31 - 34 (23 - 25)

62 - 68 (46 - 50)

108 - 117 (80 - 86)

174 - 187 (128 - 138)

273 - 294 (201 - 217)

Class 12.9

9 - 12 (7 - 9)

16 - 19 (12 - 14)

38 - 41 (28 - 30)

75 - 81 (55 - 60)

130 - 141 (96 - 104)

209 - 225 (154 - 166)

327 - 354 (241 - 2610

Note:


Crown 1989 PF8514-3 Rev. 11/08 M1.9-06.6-003

02 Rev. 11/08

89

Notes:

90


Torque Values

Torque Values

All Crown Trucks are manufactured with Grade 5 or better screws and bolts. The information contained in this section will aid you when replacing any screws and bolts that are necessary when performing maintenance on your lift truck.

Grade

Grade Marking

(on Head)

Specification Material

Bolt and Screw

Size (Inches)

SAE - Grade 2 Low Carbon Steel

1/4 thru 1-1/2

SAE - Grade 5

Medium Carbon Steel,


1/4 thru 1-1/2

SAE - Grade 8

Medium Carbon Alloy Steel,


1/4 thru 1-1/2

NOTE:

Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all of its bolted assemblies. Instances do occur when Grade 5 bolts are manufactured unmarked. When a fastener is replaced that is unmarked, replace the fastener with a Grade 5.

Figure 14916

Crown 1979 PF5067-1 Rev. 9/06 M1.9-14.0-001

04 Rev. 9/06

91


Torque Values

Torque Chart

Bolt

Diameter

3/4

7/8

1

1 1/8

1 1/4

1 3/8

1 1/2 in

1/4

5/16

3/8

7/16

1/2

9/16

5/8 ft Ib

9 ± 3

Grade 5

Dry Torque Requirement kgm

1.2 ± .4

Nm

12 ± 4

18 ± 5

32 ± 5

50 ± 10

75 ± 10

2.5 ± .7

4.4 ± .7

24.5 ± 7

43.5 ± 7 ft lb

Grade 8

Dry Torque Requirement

13 ± 4

25 ± 5

48 ± 10

6.9 ± 1.4

67.5 ± 13.5

75 ± 10

10.4 ± 1.4

101.5 ± 13.5

112 ± 15 kgm

1.8 ± .5

3.5 ± .7

6.6 ± 1.3

10.4 ± 1.4

15.5 ± 2.0

Nm

17.5 ± 5.5

34 ± 7

65 ± 13.5

102 ± 13.5

152 ± 20.5

110 ± 15

150 ± 20

265 ± 35

420 ± 60

15.2 ± 2.0

20.7 ± 2.8

36.6 ± 4.8

58.1 ± 8.3

149 ± 20.5

203.5 ± 27

359 ± 47.5

569 ± 81

640 ± 80 88.5 ± 11.1

868 ± 109

800 ± 100 110.6 ± 13.8

1085 ± 136

1000 ± 120 138 ± 16.6

1356 ± 163

1200 ± 150 166 ± 20.7

1630 ± 203

1500 ± 200 207 ± 27.7

2034 ± 271

Mounting bolt torque requirements involving hydraulic valves.

163 ± 20

225 ± 30

400 ± 50

640 ± 80

22.5 ± 3.0

31.1 ± 4.1

55.2 ± 6.9

88.3 ± 11.0

221 ± 27

305 ± 41

542 ± 68

868 ± 108

960 ± 115 132.5 ± 15.9

1300 ± 156

5/16

3/8

13 ± 2

24 ± 2

1.8 ± .3

3.3 ± .3

17.5 ± 2.5

32.5 ± 2.5

7/16 39 ± 2 5.4 ± .3

53 ± 2.5

NOTE:


M1.9-14.0-002

04 Rev. 9/06

92

Crown 1979 PF5067-2 Rev. 9/06

HYDRAULIC

93

Notes:

94

HYDRAULIC

Hydraulic System


Hydraulic Lines and Fittings

•

Blow air through all hoses and lines to remove loose particles before installing.

•

Any rubber hose with wire braid inner construction and any steel tube lines which may have been twisted, bent, kinked or collapsed are permanently damaged and must be replaced even if the damage is not externally visible.

•

Flexible hoses shall be replaced immediately if any of the following conditions exist:

– Collapses under normal operating position

– Abraded areas

– Twists or kinks

– Leaks

– Swelling

– Cuts

– Flat Spots

– Damaged Couplings

– Hot-spot damage

•

All hoses and lines are to be clear of any surface or edge which will cause damaging wear and cuts, or on which they can become caught.

•

All connections are to be leak free.

•

Beaded elbows in suction ports of all pumps must be positioned such that the suction hose retains its full volume flow and does not collapse.

WARNING

Avoid High Pressure Fluids-Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines.

Tighten all connections before applying pressure.

Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.

Any fluid injected into the skin under high pressure should be considered as a serious medical emergency despite an initial normal appearance of the skin. There is a delayed onset of pain and serious tissue damage may occur. Medical attention should be sought immediately by a specialist who has had experience with this type of injury.

Reservoir

Capacity

The reservoir is part of the power unit frame and capacity is:

•

32.7 litre (7.2 gal) at the "Full" mark on dipstick.

•

30.5 litre (6.7 gal) at the "Add" mark on dipstick.

If the reservoir is overfilled, oil may leak from the breather.

Hydraulic oil should be checked every 90 days or 500 hours and changed every 12 months or 2000 hours.

Refer to Lubrication and Adjustment maintenance section to select appropriate hydraulic oil.

Crown 2007 PF17005-1 Rev. 6/08 M2.0-2045-001

01 Rev. 6/08

95

HYDRAULIC


(1)

(2)

(3)

(4)

(5)

Return Filter

Breather Cap

Hydraulic Reservoir

Battery Compartment Floor

Lift Pump Motor

Figure 17439

Filters

Replace breather cap (includes 10 micron element) and return filter (10 micron element) at the initial 90 day or 500 hour point.

Every 12 months or 2000 hours:

•

Clean suction strainer (100 mesh strainer).

•

Replace breather cap.

•

Replace return filter.

When replacing return filter, do not tighten filter with the use of a wrench. A wrench should only be used for filter removal.

To install filter, apply a film of hydraulic oil to the seal and hand tighten until seal contacts filter head. Then tighten one half revolution. Check for leaks.

Breather Dipstick

Figure 17440

(5)

(6)

(7)

(1)

(2)

(3)

(4)

Breather

Dipstick

O-Ring

Suction Strainer

Reservoir - Part of Power Unit Frame

O-Ring

Plug

Figure 17441

Crown 2007 PF17005-2 Rev. 6/08 M2.0-2045-002

01 Rev. 6/08

96

HYDRAULIC


Drift Test

All drift tests should be conducted with a capacity load

(refer to capacity plate for the rated capacity of your truck). The material used for the load test must be evenly stacked within the limits of a 1.2 m x 1.2 m

(4 ft x 4 ft) pallet and must be secured to the fork carriage with the forks spread to their maximum width.

CAUTION

Never stand or work under a suspended load.

Tilt Drift Test

Cycle tilt forward and back several times before testing.

Raise the maximum rated load 610 mm (24 in) off the floor. Measure drift at the tilt cylinder rod. With the forks tilted back completely, forks may not drift forward more than 16 mm (0.63 in) within five minutes as measured on the tilt cylinder rod.

Lift Drift Test

Fully raise forks with maximum rated load. The load may not drift down more than 50 mm (2.0 in) within five minutes. The lift measurement is to be taken from the tip of the fork to the floor.

Occasionally, a slight creep of the fork assembly may occur due to internal cylinder seal leakage, but it can also be caused by leakage in the check valves, control valve, etc. To seat these valves properly when this occurs, raise and lower the forks to flush out any foreign material from the valve seat.

Cylinder and Circuit Bleeding

With all cylinders in the retracted position, verify oil level in reservoir is between "add" and "full" marks on dipstick. After all air has been bled from cylinders, hydraulic oil may need to be added to reservoir. Do not over fill reservoir.

CAUTION

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

Crown 2007 PF17005-3 Rev. 6/08 M2.0-2045-003

01 Rev. 6/08

97

HYDRAULIC


Lift Circuit

•

Slowly elevate empty carriage to approximately

1.2 m (4 ft).

•

If mast is equipped with carriage cylinder, carefully open carriage cylinder bleed screw and bleed air from cylinder until a solid stream of oil flows out of cylinder. Tighten bleed screws 7.6 Nm (90 in lb).

•

Continue raising carriage until mast cylinders extend approximately 1.2 m (4 ft).

•

Individually bleed each mast cylinder following the same procedure used for the carriage cylinder.

M2.0-2045-004

01 Rev. 6/08

98

(1)

(2)

(3)

Bleed Screws

Carriage Cylinder

Mast Cylinders

Figure 17442

Crown 2007 PF17005-4 Rev. 6/08

HYDRAULIC


Tilt Circuit

Carriage hydraulic circuits need to be flushed after repair of tilt cylinder and bled of all air. Before flushing and bleeding of system, inspect all hydraulic connections and verify that all filters are installed and hydraulic levels are adequate for test. The hydraulic system must be pressurized during the flushing and bleeding procedure.

Tilt

Cylinder

Figure 17443

Tilt Cylinder Bleeding

•

Turn truck ON, tilt mast completely forward.

•

Tilt the mast completely back.

•

Repeat this complete cycle, totally forward and then completely back, a minimum of 10 times.

•

If it is suspected that any air is still in the system, repeat the process.

Sideshift Circuit

•

Disconnect hoses on sideshift cylinder and connect together using connector 064278-006.

•

Actuate the sideshift lever fully in one direction and hold for one minute. Uncouple the hoses and reconnect to the sideshift cylinder.

•

Cycle sideshift cylinder left and right approximately

10 times.

Steer Cylinder Circuit

•

Power up the truck and rotate steering wheel from lock to lock approximately 10 times.

•

Check steering for an equal number of revolutions, lock to lock in both directions. There should be approximately three and three-fourth revolutions, no more than four revolutions.

•

If there are more than four turns, lock to lock in either direction, then repeat the procedure.

CAUTION


Crown 2007 PF17005-5 Rev. 6/08 M2.0-2045-005

01 Rev. 6/08

99

HYDRAULIC


Service Brake Circuit

•

Power up truck (steer pump motor needs to be running).

CAUTION

Brake linings are susceptible to contamination. When installing or servicing brakes, keep all oil and fluids away from linings.

•

Loosen the two bleed screws on top of each brake.

Be prepared to catch oil.

•

Slowly depress brake pedal. Allow air-oil mixture to flow until a solid stream of oil is achieved.

•

Tighten bleed screws.

Park Brake Circuit

•

Chock wheels to prevent truck from moving when park brake is released.

•


•

Release park brake.

•

Slowly open bleed screw on park brake cylinder.

Allow air-oil mixture to flow until a solid stream of oil is achieved. Tighten bleed screws 7.6 Nm

(90 in lb).

•

Apply park brake.

Figure 17444

(1)

(2)

(3)

Bleed Screws

Back of Service Brake

Left and Right Determined from Operators’s Perspective

(1)

(2)

(3)

(4)

Parking Brake

Traction Motor

Park Brake Cylinder

Bleed Screw

Figure 17445

Crown 2007 PF17005-6 Rev. 6/08 M2.0-2045-006

01 Rev. 6/08

100

Hydraulic Circuitry

These pages contain brief descriptions of hydraulic circuits for the various hydraulic functions. Figure 17192 represents a reference schematic for these descriptions and may vary depending on your truck. Refer to the Hydraulic Schematic section for appropriate schematic.

HYDRAULIC


Crown 2007 PF17006-1 Rev. 7/08 M2.0-2045-050

01 Rev. 7/08

101

HYDRAULIC


M2.0-2045-051

01 Rev. 7/08

102

1 Lift/Lower

2 Tilt

3 Accessory 1

4 Accessory 2

7

8

5

6

Return Filter

Steering

Reservoir

Breather

9 Suction

Strainer

10 Optional Tilt

Position

Assist Valve

Figure 17725-01

Crown 2007 PF17006-2 Rev. 7/08

HYDRAULIC


1.

Pressure Check Point located under floorboard and used to monitor pressure during operation for troubleshooting.

2.

For all Quad and TL Mast trucks, RV1 relief valve is set to 21375 ± 345 kPa (3100 ± 50 psi) - Lift and

Tilt Circuit. For TT Mast trucks manufactured prior to 9/2/08, RV1 relief valve is set to 21735 ±

345 kPa (3100 ± 50 psi). For TT Mast trucks manufactured on 9/2/08 and after, RV1 is set to 23440

± 345 kPa (3400 ± 50 psi) - Lift and Tilt Circuit.

3.

RV2 relief valve set to 17235 ± 345 kPa (2500 ±

50 psi) - Accessory Circuit.

4.

MPCE, Main Pressure Compensating Element.

5.

Breather Cap contains a 10 micron filter.

6.

Suction Strainer is 100 mesh.

7.

Lowering Flow Control Manifold, pressure compensated, non-adjustable regulated flow in one direction.

8.

Flow Control Regulator, maintains a constant flow rate in one direction only (lowering). Reverse (lift) flow rate is uncontrolled.

9.

CBV counter balance valve, limits tilt "forward" speed and minimizes tilt "forward" drift. Pressure setting is preset.

10. SV1 solenoid valve, limits tilt "forward" above staged lift. Controlled by tilt interlock module. Not adjustable.

11. Return Filter, 10 micron filtration.

12. Brake Valve, input pressure, 8275 kPa (1200 psi), output pressure of 5515 kPa (800 psi). Not adjustable.

13. Reservoir, capacity is 32.7 litre (7.2 gal) at full mark on dip stick.

14. RV3 relief valve, steering relief, is set at 9655 kPa

(1400 psi).

15. ULV Unloading Valve, controls pressure in the brake accumulator and limits maximum pressure in brake circuits. Preset at 7930 kPa (1150 psi).

16. PS1 Hydraulic Pressure Switch, applies power to alarm when insufficient hydraulic pressure for service brake operation or parking brake release. Preset at 4135 kPa (600 psi). Not Adjustable.

17. Accumulator is precharged to 2760 kPa (400 psi).

Accumulator is not rechargeable.

18. SV2 Solenoid Valve controls hydraulic pressure in parking brake cylinder to apply or release the parking brake. Not adjustable.

19. Manual Release Valve manually releases parking brake.

20. Hand Pump manually pressurizes the parking brake hydraulic circuit to release parking brake.

21. SV3 solenoid valve, when Tilt Position Assist Option is ON and forks reach the level position, the

VTS switch on the tilt cylinder activates the Tilt Assist Valve and hydraulic fluid passes through the valve and back to the reservoir. Forks will stay in the level position until the Tilt Position Assist Option is turned OFF.

The truck has a power disc brake and hydrostatic steering system that utilizes a gear type pump for the steer and brake circuit. Refer to Figure 17726-01.

The steering system is composed of the pump, a steering control unit (SCU) and a double rod cylinder steer axle assembly. The pump contains an internal steering circuit relief valve, RV3, set at 9655 kPa (1400 psi).

The brake system includes the pump, an accumulator, pressure switch, brake valve, park brake release valve manifold and service disc brakes. The pump contains an internal brake circuit unloading valve set to 7930 ±

345 kPa (1150 ± 50 psi).

With an operator in the seat and the truck powered up, the traction control system will energize the brake and steering motor (M3) solenoid. Hydraulic oil will be drawn from the reservoir through a 100 mesh suction strainer by the brake & steering pump and sent to the accumulator, pressure switch, SV2, port P of the brake valve and port P of the SCU.

With no demand for steering, the oil will enter port P of the SCU, pass through the open center envelope of the valve spool and exit the SCU at port T. The hydraulic oil will then be routed back to the reservoir via the return filter.

Crown 2007 PF17006-3 Rev. 7/08 M2.0-2045-052

01 Rev. 7/08

103

HYDRAULIC


1 Accumulator

2 Return Filter

3 Pressure Switch

4 Brake Valve

5 Reservoir

6 Steer and Brake Pump

7 Suction Strainer

8 Park Brake Release Valve Manifold

9 Park Brake Control Valve

Pressure Flow

Suction

Return

M2.0-2045-053

01 Rev. 7/08

104

Figure 17726-01

Crown 2007 PF17006-4 Rev. 7/08

HYDRAULIC


Accumulator and Unloading Valve

The purpose of the accumulator is energy storage. The accumulator, in addition to the pump, can be thought of as a source of flow for both service and parking brake circuits. Oil pressure in the accumulator is maintained by the pump and unloading valve. The unloading valve is a special relief valve that controls the pressure in the accumulator and limits maximum pressure in the brake circuits.

An accumulator charging cycle is as follows:

•

Assume the accumulator is in a discharged state and the oil at the accumulator port is at 0 psi. In this condition, the brake unloading valve will be closed.

The accumulator is charged with nitrogen gas to a pressure of 2760 kPa (400 psi) and includes a diaphragm that separates the nitrogen gas from the hydraulic oil.

•

When the operator is on the seat (seat switch closed) and the truck is powered-up, a pressure switch monitoring accumulator pressure activates a low pressure warning alarm. At the same time, the brake and steer motor starts and oil from the pump flows to the service and park brake valves and accumulator. The accumulator accepts any excess flow not being used by either the service or park brake circuits.

•

As hydraulic oil is pumped into the accumulator, pressure in the brake circuit increases. When pressure reaches 3240 kPa (470 psi), the park brake can be released if commanded. When pressure has increased to about 4135 kPa (600 psi), the low pressure warning alarm shuts off.

•

At 7930 ± 345 kPa (1150 ± 50 psi), the unloading valve will open and direct oil flow from the brake pump across an orifice at low pressure. Oil in the accumulator is kept from back flowing through the unloading valve by a check valve. By unloading the brake pump at low pressure, an energy savings is realized. This circuit also provides a limited number of brake applications using oil stored in the accumulator in the event the brake pump becomes disabled.

•

The accumulator is now the primary source of flow for both brake circuits. Between normal internal leakage (through brake valves) and operating service brakes or park brake, oil is taken from the accumulator and the pressure decreases. When pressure in the accumulator is down to about 90% of unloading valve set pressure or about 7135 kPa

(1035 psi), the unloading valve will close sending brake pump flow to the accumulator restoring oil pressure.

•

Should the accumulator lose its precharge, the unloading circuit will cycle more frequently than normal because of the reduced oil volume available from the accumulator. Normal braking operation will still be available as long as the truck is powered. Unpowered braking will not be available resulting in automatic application of the parking brake shortly after flow from the brake pump is lost.

Crown 2007 PF17006-5 Rev. 7/08 M2.0-2045-054

01 Rev. 7/08

105

HYDRAULIC


Spring Apply/Hydraulic Release

Park Brake

The park brake is released by energizing solenoid valve SV2. If a failure occurs resulting in a loss of pressure in the brake circuit, the park brake cylinder spring force will apply the park brake.

A manual release valve and hand pump are incorporated in the park brake release valve manifold to manually release the park brake if towing is required. The manual release valve will automatically reset when the truck is powered up and park brake release is commanded. It can also be reset manually to reapply the park brake by pulling up on its stem. See brake maintenance section for operating instructions.

To turn the truck left, the operator turns the steering wheel to the left. This action moves the lower envelope of the valve spool inside the steering control unit (SCU) into position, routing hydraulic oil that enters port P through the SCU, out port L and into the steer cylinder causing the cylinder rod & piston assembly to shift turning the steer wheels. As the cylinder rod & piston shifts, oil is forced out of the other end of the cylinder. This hydraulic oil enters the SCU at port R, passes through the lower envelope of the valve spool, exits the SCU at port T and returns to the reservoir through the return line filter. Refer to Figures 17727 and 17728-01.

There is a check ball valve across ports P and T inside the SCU. This valve permits limited manual steering of the truck in the event the steering pump motor cannot be energized.

Steer

Cylinder

M2.0-2045-055

01 Rev. 7/08

106

Figure 17727

Crown 2007 PF17006-6 Rev. 7/08

HYDRAULIC


1 Return Filter

2 Steer Cylinder

3 Reservoir


5 Suction Strainer

Pressure Flow

Suction

Return

Crown 2007 PF17006-7 Rev. 7/08

Figure 17728-01

M2.0-2045-056

01 Rev. 7/08

107

HYDRAULIC


Turning the steering wheel to the right moves the upper envelope of the steering control unit (SCU) valve spool into position, allowing the hydraulic oil that enters port

P to pass through the SCU and exit the SCU at port R.

This hydraulic oil enters the steer cylinder causing the cylinder rod & piston assembly to shift turning the steer wheels. As the cylinder rod & piston shifts, oil in the other end of the cylinder is forced out, enters the SCU at port L, passes through the lower envelope of the valve spool, exits the SCU at port T and returns to the reservoir through the return line filter. Refer to Figures

17729 and 17730-01.

There is a check ball valve across ports P and T inside the SCU. This valve permits limited manual steering of the truck in the event the steering pump motor cannot be energized.

Steer

Cylinder

Figure 17729

M2.0-2045-057

01 Rev. 7/08

108

Crown 2007 PF17006-8 Rev. 7/08

HYDRAULIC


1 Return Filter

2 Steer Cylinder

3 Reservoir


5 Suction Strainer

Pressure Flow

Suction

Return

Crown 2007 PF17006-9 Rev. 7/08

Figure 17730-01

M2.0-2045-058

01 Rev. 7/08

109

HYDRAULIC


When the brake pedal is applied, oil flows through the brake valve into ports in the service brake torque plates and against pistons within the torque plates. The pistons squeeze the inner and outer stators and lining/rotor assemblies together causing the wheels to decelerate.

Brake Valve

Brakes

Figure 17731

5

6

7

3

4

1

2

Accumulator

Pressure Switch

Brake Valve

Reservoir

Steer and Brake Pump

Suction Strainer

Park Brake Release Valve Manifold

M2.0-2045-059

01 Rev. 7/08

110

Pressure Flow

Suction

Figure 17732-01

Crown 2007 PF17006-10 Rev. 7/08

HYDRAULIC


When the brake pedal is released, the brake valve spool moves relieving oil pressure in the brake assemblies. Oil flows from the service brake torque plates and returns to the reservoir. As oil pressure is relieved, the inner and outer stators move away from the lining/rotor assemblies allowing the wheels to move freely.

Brake Valve

Brakes

Figure 17733

3

4

1

2

Brake Valve

Brakes

Reservoir

Suction Strainer

Crown 2007 PF17006-11 Rev. 7/08

Pressure Flow

Suction

Return

Figure 17734-01

M2.0-2045-060

01 Rev. 7/08

111

HYDRAULIC


When the operator pulls back on the Lift/Lower control handle, the raise switch (RAS) is closed and the Lift/

Lower spool inside the directional control valve assembly is moved into position for lift. The raise switch will energize the pump motor contactor (P1), which energizes the lift pump motor. (On trucks with optional AC lift, a high speed switch, HSS, is actuated near the end of the control lever stroke which will energize P2 contactor. Full battery voltage is then provided to the lift motor resulting in maximum lift speed). The motor turns a pump, which will draw hydraulic oil from the reservoir and route it to the directional control valve. Once inside the valve, the hydraulic oil flow is routed to a pressure check port, a main pressure compensating element

(MPCE) and the lift/lower spool. The hydraulic oil will flow across the spool, through a check valve, back across the spool, exit the directional control valve at port 1A, pass through the check valve portion of Lowering Flow Control Manifold and be routed to the carriage and mast cylinders. Refer to Figures 17735-01 and 17736-01.

Some of the hydraulic oil that flows across the lift/lower spool will flow through a pilot passage to MPCE and

RV1. MPCE is controlled by both inlet pressure and work port pressure. Its purpose is to provide constant flow to the function for a given spool position regardless of operating pressure. RV1 is the relief valve for the lift and tilt circuits and is preset from the factory.

Refer to section M2.3 for RV1 adjustment.

1

4

5

2

3

6

Figure 17735-01

Relief Valve

Quad Mast/TL Mast

TT Mast RV1 (trucks manufactured prior to 9/2/08)

21375 ± 345 kPa (3100 ± 50 psi)

TT Mast RV1 (trucks manufactured since 9/2/08)

23440 ± 345 kPa (3400 ± 50 psi)

Lift/Lower

To Lift Cylinders

Directional Control Valve

From Lift Pump

To Reservoir

M2.0-2045-061

01 Rev. 7/08

112

Crown 2007 PF17006-12 Rev. 7/08

HYDRAULIC


7

8

5

6

3

4

1

2

Pressure Check

Lift/Lower


Lowering Flow Control Manifold

Flow Control Regulator

Carriage Cylinder

Velocity Fuse

Lift Cylinders

9 Reservoir

10 Suction Strainer

11 Lift, Tilt and Accessory Hydraulic Pump

Pressure Flow

Suction

Figure 17736-01

Crown 2007 PF17006-13 Rev. 7/08 M2.0-2045-062

01 Rev. 7/08

113

HYDRAULIC


When the operator pushes the lift/lower control handle forward, the lift/lower spool is moved into position for lower. Hydraulic oil leaves the mast and carriage cylinders, passes through the lowering flow control manifold, enters the directional control valve at port 1A, passes across the spool, exits the directional control valve and returns to the reservoir. Refer to Figures

17737-01 and 17738-01. The pressure compensating flow control valve in the lowering flow control manifold, regulates the maximum lowering speeds regardless of the load on the forks.

3

4

1

2


Lift/Lower

From Lift Cylinders

To Reservoir

Figure 17737-01

M2.0-2045-063

01 Rev. 7/08

114

Return

7

8

5

6

9

3

4

1

2


Lift/Lower

Lowering Flow Control Manifold

Flow Control Regulator

Carriage Cylinder

Velocity Fuse

Lift Cylinders

Reservoir

Suction Strainer

Figure 17738-01

Crown 2007 PF17006-14 Rev. 7/08

Tilt back is accomplished when the operator pulls back on the tilt control handle. This action moves the tilt spool into position for tilt back and closes the tilt back switch (TBS) and tilt switch (TLT). The tilt switch will energize the same pump contactor (P1) and motor

(M2) as was used for the lift circuit. Hydraulic oil will be pulled from the reservoir by the pump and routed to the pressure check port, main pressure compensating element (MPCE) and the tilt spool valve. Hydraulic oil passes across the tilt spool valve, through a flow control screw, a check valve, back across the tilt spool valve and exits the directional control valve at port 2A.

This hydraulic oil will enter the tilt counterbalance manifold at port V2, pass through the check portion of the valve, exit the manifold at port C2 and be routed to the front of the tilt cylinders. MPCE will again be acted on by both inlet and work port pressure to insure constant oil flow, and RV1 will limit circuit pressure. For all Quad and TL Mast trucks, RV1 relief valve is set to 21375 ±

345 kPa (3100 ± 50 psi) - Lift and Tilt Circuit. For TT

Mast trucks manufactured prior to 9/2/08, RV1 relief valve is set to 21735 ± 345 kPa (3100 ± 50 psi). For TT

Mast trucks manufactured on 9/2/08 and after, RV1 is set to 23440 ± 345 kPa (3400 ± 50 psi) - Lift and Tilt

Circuit. Return hydraulic oil will be pushed out of the rear of the cylinders entering port C1 of the tilt CBV manifold. Hydraulic oil will enter the directional control valve at port 2B, pass across the tilt spool, exit the directional control valve and enter the reservoir. When

Tilt Position Assist Option is ON and forks reach the level position, the VTS switch on the tilt cylinder activates the Tilt Assist Valve and hydraulic fluid passes through the valve and back to the reservoir. Forks will stay in the level position until the Tilt Position Assist

Option is turned OFF. Refer to Figures 17739-01 and

17740-01.

5

6

7

3

4

1

2


Lift/Lower

Tilt

From Tilt Manifold

To Tilt Manifold

To Reservoir

From Lift Pump

HYDRAULIC


Figure 17739-01

Crown 2007 PF17006-15 Rev. 7/08 M2.0-2045-064

01 Rev. 7/08

115

HYDRAULIC


7

8

5

6

9

3

4

1

2

Optional Tilt Position Assist Valve

Pressure Check


Lift/Lower

Tilt

Tilt Cylinders

Reservoir

Suction Strainer

Lift, Tilt and Accessory Hydraulic Pump

M2.0-2045-065

01 Rev. 7/08

116

Pressure Flow

Suction

Return

Figure 17740-01

Crown 2007 PF17006-16 Rev. 7/08

Tilt forward is accomplished when the operator pushes the tilt control handle forward. This action moves the tilt spool into position for tilt forward and closes the tilt switch (TLT). Hydraulic oil will be pulled from the reservoir by the pump and routed to the pressure check port, main pressure compensating element (MPCE) and the tilt spool. Hydraulic oil will flow across the tilt spool, through the flow control screw and check valve, back across the tilt spool and exit the directional control valve at port 2B. Hydraulic oil enters the tilt counterbalance manifold at port V1 and exits the manifold at port

C1 and is routed to the rear of the tilt cylinders. The supply hydraulic oil will assist the return hydraulic oil in opening the counterbalance valve so that return hydraulic oil from both tilt cylinders can pass through the tilt counterbalance manifold. SV1 is energized to permit return oil flow from port C2 to port V2, pass across the tilt spool and return to the reservoir. Refer to Figures 17741-01 and 17742-01.

HYDRAULIC


5

6

7

3

4

1

2


Lift/Lower

Tilt

From Tilt Manifold

To Tilt Manifold

To Reservoir

From Lift Pump

Figure 17741-01

Crown 2007 PF17006-17 Rev. 7/08 M2.0-2045-066

01 Rev. 7/08

117

HYDRAULIC


7

8

5

6

9

3

4

1

2

Optional Tilt Position Assist Valve

Pressure Check


Lift/Lower

Tilt

Tilt Cylinders

Reservoir

Suction Strainer


M2.0-2045-067

01 Rev. 7/08

118

Pressure Flow

Suction

Return

Figure 17742-01

Crown 2007 PF17006-18 Rev. 7/08

HYDRAULIC


The number of accessories will vary from truck to truck, depending upon application. An accessory commonly used is sideshift.

Sideshift left is accomplished when the operator pushes the sideshift control lever forward. This action moves the sideshift spool valve into position for sideshift left and closes the sideshift switch (AXS1). The same contactor (P1), pump and motor (M2) that is used for lift and tilt functions also supplies hydraulic oil flow for sideshift. Hydraulic oil enters the directional control valve, passes across the sideshift spool valve, through a flow control screw, a check valve, back across the sideshift spool valve and exits the directional control valve at port 3B. This hydraulic oil flow is routed to the right side of the sideshift cylinder, causing it to shift to the left. Hydraulic oil from the left side of the cylinder will enter the directional control valve at port 3A, pass across the sideshift spool valve, exit the valve and return to the reservoir. RV2, is set to 17235 kPa

(2500 psi) to protect the accessory circuits from over pressurization. Refer to Figure 17743-01.

Pressure Flow

Suction

Return

Figure 17743-01

3

4

1

2

5

6

Pressure Check

Accessory 1

Sideshift Cylinder

Reservoir

Suction Strainer


Crown 2007 PF17006-19 Rev. 7/08 M2.0-2045-068

01 Rev. 7/08

119

HYDRAULIC


Sideshift right is accomplished when the operator pulls back on the sideshift control handle. This action moves the sideshift spool valve into position for sideshift left and closes the sideshift switch (AXS1). The same contactor (P1), pump and motor (M2) that is used for lift and tilt functions also supplies hydraulic oil flow for sideshift. Hydraulic oil enters the directional control valve, passes across the sideshift spool valve, through a flow control screw, a check valve, back across the sideshift spool valve and exits the directional control valve at port 3A. This hydraulic oil flow is routed to the left side of the sideshift cylinder, causing it to shift to the right. Hydraulic oil from the right side of the cylinder will enter the directional control valve at port 3B, pass across the sideshift spool valve, exit the valve and return to the reservoir. RV2, is set to 17235 kPa

(2500 psi) to protect the accessory circuits from over pressurization. Refer to Figure 17744-01.

Pressure Flow

Suction

Return

Figure 17744-01

3

4

1

2

5

6

Pressure Check

Accessory 1

Sideshift Cylinder

Reservoir

Suction Strainer


M2.0-2045-069

01 Rev. 7/08

120

Crown 2007 PF17006-20 Rev. 7/08

HYDRAULIC

Hydraulic Schematic Symbols


VENTED RESERVOIR with lines above fluid level

ELECTRIC MOTOR unidirectional single speed

VENTED RESERVOIR with lines below fluid level

ELECTRIC MOTOR unidirectional variable speed

Crown 1979 PF5066-1 Rev. 9/06

FILTER or STRAINER

HYDRAULIC LINE with full flow (plumbing - may be tubing, hose, or flow passage in manifold

PILOT or DRAIN LINE limited flow

LINES CROSSING

LINES CONNECTED

QUICK DISCONNECT

(disconnected)

PLUGGED PORT

(test port)

FLOW METER

HYDRAULIC PUMP fixed displacement unidirectional

HYDRAULIC MOTOR bi-directional

GAUGE pressure

GAUGE temperature

ACCUMULATOR gas charged diaphragm type

Figure 3559-03

M2.1-00.0-001

04 Rev 9/06

121

HYDRAULIC


PRESSURE SWITCH

CYLINDER double acting unequal area

CYLINDER double acting equal area

(steer) (double end)

CYLINDER single acting spring returned

(rod end vented)

CYLINDER single acting ram type

CYLINDER single acting with cushion

COMPONENT ENCLOSURE manifold block

ACTUATOR MANUAL LEVER

M2.1-00.0-002

04 Rev 9/06

122

ACTUATOR MANUAL

SPRING

(bias to normal de-energized position)

SOLENOID single coil or winding

HYDRAULIC PILOT

OPERATED

SOLENOID pilot operated

SOLENOID DUAL

SOLENOID PROPORTIONAL

VALVE PILOT CHECK

(pilot to open)

Figure 3560-03

Crown 1979 PF5066-2 Rev. 9/06

Crown 1979 PF5066-3 Rev. 9/06

ORIFICE THROTTLE fixed

ORIFICE THROTTLE adjustable

FLOW CONTROL

PRESSURE COMPENSATED fixed

FLOW CONTROL

PRESSURE COMPENSATED fixed with reverse flow bypass

FUSE VELOCITY

HYDRAULIC


VALVE SHUTTLE

VALVE

SINGLE COUNTERBALANCE in manifold

FLOW DIVIDER/COMBINER

VALVE RELIEF fixed setting

BYPASS FLOW CONTROL regulated flow pressure compensated

VALVE MANUAL SHUTOFF

TORQUE GENERATOR

VALVE RELIEF adjustable

VALVE CHECK

STEER UNIT hydrostatic

Figure 3561-03

M2.1-00.0-003

04 Rev 9/06

123

HYDRAULIC


VALVE

2 way 2 position

VALVE

3 way 2 position

VALVE

4 way 2 position

VALVE

4 way 3 position

VALVE

2 way infinite positions

VALVE

4 way infinite positions

VALVE

3 way 2 position spring bias, solenoid control

VALVE

4 way 3 position dual spring centered, manual lever control

NOTE: The type of valve depends on the number of spools found in the component enclosure

(Triple spool valve shown)

Figure 3562-03

Crown 1979 PF5066-4 Rev. 9/06 M2.1-00.0-004

04 Rev 9/06

124

HYDRAULIC

Lift Pump

Lift Pump

Pumps are comprised of an end cover, body housing a dual element gear set, bushes and a mounting flange bolted together with through bolts. The gear set comprises of a dual element arrangement with phased teeth to give low pressure ripple and hence overall low system noise. The gear sets are separated by a balance plate and the gear journals are supported in plain bearings within pressure balanced bushes to give high volumetric and mechanical efficiencies.

Routine maintenance consists of periodic checks for tightness of the mounting bolts and port fittings plus visual examination for oil leaks. The unit should be kept externally clean, especially in the area of the shaft seal as dirt can accelerate seal wear and cause leakage.

The direction of rotation is indicated by the word "rotate" and an arrow etched on the body adjacent to the driveshaft. Rotation is always specified as viewed on the driveshaft.

Disassembly

Disassemble the pump in a clean, dust free location, using clean tools and equipment. Dirt or grit will damage the highly polished machined surfaces and will result in leakage or premature pump failure.

Figure 17340

Before beginning disassembly, scribe matched marks on the body assembly, the end cover and mounting flange to insure that the pump will be reassembled properly. This pump can be assembled for either clockwise or counterclockwise rotation as viewed from driveshaft end. Note which direction the arrow is pointing next to the word "rotation" prior to disassembly.

•

Remove bolts and spring washers (1).

•

Remove end cover (2), body O-ring (3), bush seal

(4) and backup seal (5).

•

Turn unit over and lightly tap mounting flange (6), to disengage it from the locating dowels and slide the flange off the shaft.

•

Remove retaining ring (8) and push the shaft seal

(7) out of the mounting flange taking care not to damage any sealing surfaces.

•

Remove body O-ring (3), bush seal (4) and backup seal (5).

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HYDRAULIC

Lift Pump

Mounting Flange And End Cover

The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the regions where the body O-rings and bush seals contact, which could result in external leakage.

Check shaft seal recesses for scoring or damage that could result in oil leakage around the outer diameter of the shaft seal. Replacement shaft seal can be refitted with hydraulic sealant (061004-023) to overcome slight damage in this area.

If the driveshaft and gears are not damaged then they can be reused. If the gears are damaged they are unserviceable.

Assembly

All parts should be clean and lubricate bushes and gears with clean hydraulic oil. Make sure O-ring recess and end faces of body remain dry. This will assist assembly of components into body bores.

•

Place end cover (2) against the undowelled end of the body (9) and stand assembly on the cover so the dowels are uppermost and to the left hand side.

•

Apply a light coating of petroleum jelly into the grooves of the bushes and the body (9) O-ring groove. Also coat the O-ring (3), bush seal (4) and backup seal (5) with petroleum jelly, this will help keep the seals and O-ring in place during reassembly.

•

Install replacement body O-ring (3), bush seal and backup seal (4 & 5) ensuring the seals locate correctly on the seal grooves.

•

Install replacement shaft seal (7) into recess in the mounting flange with the garter spring facing the pump. Remember that if the seal recess was scored then hydraulic sealant (061004-023) must be applied to the outer diameter of the seal. Apply a coat of high melting point grease to the shaft seal lips. Install retaining ring (8) in its groove.

•

Install shaft seal assembly sleeve over driveshaft and carefully install mounting flange (6) ensuring that it locates squarely onto the dowels in the body, remove assembly sleeve.

•

Holding the whole unit together carefully turn it over and support it on the mounting flange, not the driveshaft.

•

Remove end cover (2) and apply a light coating of petroleum jelly into the grooves of the bushes and the body (9) O-ring groove. Also coat the O-ring

(3), bush seal (4) and backup seal (5) with petroleum jelly, this will help keep the seals and O-ring in place during reassembly.

•

Install replacement body O-ring (3), bush seal and backup seal (4 & 5) ensuring the seals locate correctly on the seal grooves.

•

Install end cover (2) and bolts and lockwashers (1).

Tighten bolts to 45 - 50 Nm (34 - 38 ft lb).

•

Pour a small amount of clean hydraulic oil into a port and check that the shaft can be rotated without undo force.

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HYDRAULIC

Control Valve

Control Valve

Depending on the number of hydraulic functions, your truck is equipped with a 3 or 4 spool control valve. The valve consists of an inlet/outlet section and hydraulic function valve sections. The inlet/outlet section contains main relief valve RV1, secondary relief valve RV2 and the main pressure compensating element, MPCE.

RV1 and RV2 are adjustable. The tilt valve section and accessory valve sections include a flow control screw restrictor. Refer to Hydraulic Section for circuit operation.

Relief Valve RV1 Operation

The Lift and Tilt circuit maximum operating pressure is limited by relief valve RV1, it senses pressure in the Lift and Tilt pilot circuits. If the pressure in either circuit exceeds RV1 preset level, it will open limiting maximum pressure that can be developed by MPCE which directs the excess flow to the reservoir. When Lift and Tilt are operating at different pressures, the higher of the two pressures is sensed by RV1.

Relief Valve RV2 Operation

The 1 st

Accessory and 2 nd

Accessory circuit maximum operating pressure is limited by relief valve RV2, it senses pressure in the 1 st

and 2 nd

Accessory pilot circuits. If the pressure in either circuit exceeds RV2 preset level, it will open limiting the maximum pressure that can be developed by MPCE which directs the excess flow to the reservoir. When the 1 st

Accessory and

2 nd

Accessory are operating at different pressures, the higher of the two pressures is sensed by RV2.

Figure 19885

3

4

1

2

5

2nd Accessory

1st Accessory

Tilt

Lift

Inlet/Outlet

If equipped with a 3 spool valve and an additional function is required, a spool section can be added for a second accessory function. See “Adding 4 th

Spool Valve

Section” located near the end of this section.

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Control Valve

Adjustment of RV1 & RV2

To adjust RV1 or RV2 refer to illustration 2 and proceed as follows:

1.

Refer to Figure 19886. Connect a 0-35000 kPa (0-

5000 psi) pressure gauge to the test port on the control valve (1). Operate the hydraulic system until the oil temperature is 45-55° C (110-130° F).

Figure 19886

2.

Refer to Figure 19885. Loosen the jam nut so that

RV1 can be adjusted. Raise the fork carriage until it stops and hold the control lever in the RAISE position and check the pressure gauge when the relief valve opens. Turn the adjustment screw, located on the bottom of the relief valve, to change the setting. Tighten the screw to increase the pressure or loosen it to lower pressure. Tighten the jam nut after setting relief valve to correct pressure.

Recheck setting after the jam nut has been tightened and re-adjust if necessary.

If adjustment is being made to RV2, follow same procedure except activate accessory instead of raising fork carriage.

Relief Valve Set Pressure Chart

FC 4500 Truck with Quad or TL Mast

Valve

RV1

RV2

Set Pressure

(kPa)

21375 ±345

17235 ±345

Set Pressure

(psi)

3100 ±50

2500 ±50

Valve

RV1

RV2


FC 4500 Truck with TT Mast

(manufactured prior to 9/2/08

Set Pressure

(kPa)

21375 ±345

17235 ±345

Set Pressure

(psi)

3100 ±50

2500 ±50

Valve

RV1

RV2


FC 4500 Trucks with TT Mast

(manufactured after 9/2/08)

Set Pressure

(kPa)

23440 ±345

17235 ±345

Set Pressure

(psi)

3400 ±50

2500 ±50

M2.3-2045-002

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Control Valve

Main Pressure Compensating Element (MPCE) Operation

The Main Pressure Compensating Element, MPCE, controls flow and pressure output for all functions. The individual flow control screws, in the tilt and accessory valve sections, work with MPCE to limit maximum output flow for each function regardless of inlet flow to the control valve.

MPCE is a movable spool acted on by a spring and is controlled by pilot pressures that act on each end of the spool. With no pilot pressure (or balanced, equal pilot pressures), the spring positions the MPCE closed, blocking oil flow through the control valve. Pilot pressure P1 acting on MPCE opposing the spring, is sensed off the inlet flow passage to MPCE and pilot pressure P2 is sensed at work port outlet passages, refer to Figure 7588-01.

When a function is actuated, oil flow passes through the control spool, across the flow control screw restriction in the tilt and accessory spools, back through the control spool and out the appropriate work port. remain constant regardless of inlet flow; MPCE shifts accordingly to bypass excess flow to maintain the pressure difference across the flow control restrictor.

Figure 7588-01

Pilot pressure P1 is sensed at the inlet to the control spool, and pilot pressure P2 is sensed on the back side of the flow control screw restriction. P1 and P2 pressures are ported to the ends of MPCE. As flow passes across the flow control screw restriction, a pressure differential is created with P1 being greater than P2. As the flow across the restriction increases, P1 pressure also increases and shifts MPCE open. Thus, MPCE is shifted sufficiently to maintain a definite pressure difference across the flow control restriction, between P1 and P2. Work port output flow will remain constant regardless of actual working pressures until relief pressure is reached. Also, the flow out the work port will

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Control Valve

Control Valve Disassembly

When performing maintenance to valve, it is recommended that the valve be removed from truck. Thoroughly clean the exterior of the valve before disassembly. All component parts of the valve are available for service replacement except the valve spool and housing. They are selectively fit and if damaged the entire valve spool section should be replaced.

WARNING

AVOID HIGH PRESSURE FLUIDS – Escaping fluid under pressure can penetrate the shin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.


7

8

5

6

3

4

1

2

Inlet/Outlet Section

Shuttle

Poppet

Lift Section

Tilt Section

Flow Control Screw

1st Accessory Section

2nd Accessory Section

Figure 19887

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HYDRAULIC

Control Valve

1.

To disassemble valve, place it in vertical position with the inlet/outlet section of valve up to prevent poppet, shuttle, etc. from falling apart when disassembling sections. Refer to Figure 19887 and remove tie rod nuts from one side of valve.

2.

Carefully slide valve sections apart to avoid losing check valve poppet and spring enclosed between valve sections. Poppets must be kept with respective valve sections and should be tagged. An Oring is also present between sections and should be removed. When separating sections, be careful not to damage machined sealing surfaces.

3.

Thoroughly clean all parts.

If it is necessary to remove spools, they should be tagged for their respective valve sections. Switching spools will result in incorrect clearances, causing binding, sticking, or excessive leakage.

Control Valve Inspection & Repair

All seats, poppets, seal counterbores, spools, etc.

should be smooth and free of nicks, scratches, or grooves. If present, remove by using fine lapping compound.

Inspect springs and replace if weak, broken, or distorted.

Inspection of O-rings and wipers is not necessary since they should be replaced when valve is disassembled.

Control Valve Assembly

Prior to assembly of valve, be sure that valve parts and tools are thoroughly clean and free from dust and foreign matter.

Coat all valve parts with hydraulic oil.

When assembling valve, finger tighten stud nuts before torquing. Check that there isn’t any spacing between sections. Any spacing between sections is an indication of incorrect assembly or spring, poppet etc. improperly positioned.

Torque tie rod nuts (1/2 in) to 19 Nm (14 ft lb). Torque tie rod nut (9/16 in) to 45 Nm (33 ft lb).

Valve should have no spacing between sections and spools should be free if pushed in and released.

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Control Valve

Adding 4 th

Spool Valve Section

The control valve is designed so that if an additional accessory function is required, a 3 spool valve can be converted to a 4 spool valve. To convert, order kit

130193 and proceed as follows:

1.

Assemble nuts to tie rods in kit. Assemble nuts to ends of rods that have the shortest thread length and bottom nuts on threads.

2.

Place 3 spool control valve on clean flat surface with port holes up.

3.

Remove nuts from one end of tie rods.

4.

Replace rods, one at a time, with pre-assembled tie rods from the accessory end of the valve.

5.

Stand valve vertically on accessory valve section end.

6.

Carefully remove inlet/outlet, lift, and tilt sections off of valve by lifting up and over tie rods.

7.

After removing, check surface of exposed section to be sure that O-ring, check valve & spring are in place.

8.

Add shuttle to 2 nd

accessory section, which was 1 st accessory (3 rd

section) of three spool valve. This section will become the 4 th

section on the 4 spool valve.

Figure 19888

3

4

1

2

Poppet & Spring

3rd Valve Section (from kit)

Shuttle

4th Valve Section

9.

Check to be sure O-ring check valve and spring are positioned properly on section to be added. Place new 1st accessory spool valve section (from kit) over tie rods with O-ring up.

10. Assemble tilt, lift, & inlet/outlet sections to valve, with inlet/outlet section being the last section assembled.

11. Finger tighten remaining nuts on tie rods.

12. Place valve in its original position with port holes up.

13. Torque (1/2 in) nuts on tie rods to 19 ±2 Nm (14

±1.5 ft lb).

14. Torque (9/16 in) nut on tie rod to 45 ±4.5 Nm (33

±3.5 ft lb).

M2.3-2045-006

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HYDRAULIC

Control Valve

No pressure

Symptom

Erratic pressure

Pressure setting not correct

Leaks

Sticking Spool(s)

Leaking seals

Unable to move spool in or out

Control Valve Cause & Solution Chart

Probable Cause Possible Solution

Check for foreign matter between poppets and their mating members

Clean or replace RV1/MPCE

Pilot poppet seat damaged or poppet sticking

Clean and/or replace poppets

Wear due to dirt or lock nut and adjustment screw loose

Excessive high oil temperature, more than 82°C (180°F) with cold valve.

Check pressure and clean or replace valve

Damaged seats, worn O-rings and parts sticking due to dirt

Check seats for scratches or nicks

Replace worn or damaged parts

Eliminate restriction in plumbing and filtering system

Dirt in oil

Pipe fittings too tight

Change oil & filter, clean system

Check torque values

Valve warped from mounting Loosen valve and check for sticking

Excessively high pressure in valve Measure pressure on inlet and cylinder lines

Spool bent

Return spring damaged

Replace spool

Replace faulty parts

Spring or detent cap binding (cap dented or shifted)

Loosen cap, center, tighten or replace

Valve not at thermal equilibrium

Paint or dirt on or under seal(s)

Let system warm up

Remove and clean seal(s)

Excessive back pressure

Scored spool

Loose seal plates

Cut or scored seal

Dirt in valve

Plunger cap full of dirt

Bind in linkage

Open or enlarge line to revervoir

Replace valve or section

Clean and tighten

Replace faulty parts

Clean and flush out

Replace seals

Free up linkage

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Control Valve

Sympton

Load will not hold

Control Valve Cause & Solution Chart

Probable Cause

Cylinder leaking or worn

Oil by-passing valve spool

Possible Solution

Check cylinders


Load lowers when spool is moved from neutral

Port relief valve noy holding

Dirt in check valve

Poor hydraulic system

Remove and clean

Disassemble and clean

Scored check valve, poppet or seat Replace poppet or lap poppet to seat

Defective pump Check pressure or replace

Dirt in relief valve, RV1 or RV2

Relief valve defective

Disassemble and clean

Replace valve

Worn cylinders

Load to heavy

Internal valve crack

Spool not at full stroke

Reservoir low on oil

System filter clogged

Lines restricted

Repair or replace

Check line pressure


Check movement and linkage

Add oil

Clean or replace filter

Check lines

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HYDRAULIC

Hydraulic Manifold Blocks


Manifolds

The manifold block contains plugs, valves and coils.

When performing maintenance to manifolds, refer to corresponding hydraulic parts section(s).

Tilt Manifold

The tilt manifold, mounted on the power unit, includes a CBV tilt counterbalance valve and a non-adjustable

SV1 solenoid valve on lift trucks with tilt or tilt lockout and lift trucks with tilt lockout/position assist. This valve limits tilt "forward" above staged lift. The SVX solenoid valve, on lift trucks with tilt or tilt lockout, provides optional 5th function.

Park Brake Release Manifold

This manifold, located under the floorboard, includes a non-adjustable SV2 solenoid valve. This valve controls hydraulic pressure in the parking brake cylinder for applying or releasing the parking brake.

Manual Release Operation

1.

Remove hand pump cap.

2.

Depress and hold manual brake release valve.

3.

Pump hand pump until parking brake is fully released

4.

Release manual brake release valve. Valve will remain in actuated position until the parking brake is reapplied.

Figure 17588

Lift trucks with tilt lockout/position assist also include an SV3 optional tilt assist valve. When the tilt position assist is turned ON, this valve stops tilt when forks are level and stops further tilt until turned OFF.

(1)

(2)

(3)

Hand Pump

Manual Brake Release Valve

Electric Brake Release Valve

Refer to the return line hydraulics section.

Figure 17590

Accessory Manifold

This manifold, located on the carriage, provides pressure for optional accessory functions.

Figure 17589

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HYDRAULIC


Manifold Block Component Replacement

1.

After removing all hydraulic hoses and lines from manifold block(s), cap lines and hoses with plastic plugs to avoid oil leakage and contamination.

Catch any oil that may be spilled.

2.

Loosen accessible cartridge valves while the manifold block is still in the truck; do not remove any of the valves at this time.

3.

Remove manifold block from truck and place on a clean piece of cardboard in a clean area to avoid contamination while disassembling.

4.

Remove all valves/components from manifold block and place on a clean piece of cardboard.

During the entire disassembly, replacement of orings, putting valves back into manifold and proper torque of valves, it is extremely important to keep work surfaces and parts as clean as possible to avoid contamination.

5.

Make a visual inspection of valves and valve cavities for any signs of contamination. Check operation of valve mechanisms for sticking or rough operation. If any valves are contaminated or do not function properly, discard valve and replace with new valve.

6.

Remove related o-ring(s) from each valve, cover threads on valve with sleeve or tape to prevent damage to replacement o-ring(s) and carefully replace o-rings. Visually inspect all other o-rings and back-up rings, replace as required.

7.

Apply a light film of hydraulic oil to threads of all the valves before installing into the manifold block.

8.

Install each valve into manifold block by hand until snug.

9.

Refer to Chart 1 for torque values of valves/plugs and/or coil nuts. Torque each component to the value given. If using a crows foot or other extension, position it at 90° to torque wrench handle to keep torque value same as torque wrench setting.

Chart 1 lists torque values for valves/plugs installed in tilt manifold block. Refer to this chart whenever installing a replacement valve(s) and/or coil nuts.

Component

Part Number

064091-001

064091-006

126944

127269-001,

-002

127269-001,

-002

Chart 1 - Tilt Manifold Valve/Coil Nut Torque Values

Reference

Designation

(plug)

(plug)

CBV

Nm

Valve Torque

54.4 - 58.5

17.7 - 20.4

40.7 - 47.4

(in lb)

(480 - 516)

(156 - 180)

(360 - 420)

Coil Nut Torque

Nm (in lb)

SV1

SV3

27.2 - 34

27.2 - 34

(240 - 300)

(240 - 300)

6.2 - 7.4

6.2 - 7.4

(55 - 65)

(55 - 65)

M2.4-2045-002

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DRIVE UNIT

137

Notes:

138

DRIVE UNIT

Drive Unit

Drive Unit

This section requires lifting and blocking the truck; using a hoist to raise and lower different components for removal and installation. It will be necessary to disconnect and remove the battery from the truck, disconnect the tilt cylinders from the power unit/mast, disconnect electrical connections and hydraulic lines.

CAUTION

The control of hazardous energy section provides information for performing the above procedures along with some additional information on other procedures addressing truck maintenance. Read this section before performing traction motor and drive unit removal, installation and maintenance.

Your truck has one drive unit and traction motor. Drive unit is totally enclosed and oil filled for maximum lubrication to bearings and gears. The drive unit is equipped on each drive tire with a hydraulic service brake. Mounted on the traction motor is a spring applied, hydraulic released parking brake.

(a)

(b)

(c)

Drain Plug

Fill Plug

Check Level Plug

Drive Unit Lubrication

The drive unit has an approximate capacity of 5.7 litre

(6 quarts) of 80-90W gear lube, Crown P/N

063002-003. For trucks operating in freezer conditions a mixture of Dextron II, Crown P/N 363503-001 and

063002-003 is needed. Refer to lubrication and adjustment section for correct mixture for your particular truck application and temperature range.

It is recommended that after the initial 250 hours of operation the drive unit oil should be changed. After the initial oil change, it should be changed every 2000 hours or 12 months of operation. Refer to lubrication and adjustment section for additional information on service intervals.

Drive Unit Oil Change

1.

Raise and block mast to gain access to drive unit.

Refer to Figure 17623 and control of hazardous energy section-lifting and blocking portion for correct jacking and blocking instructions.

Figure 17623

2.

Chock wheels and disconnect battery.

3.

Place drain pan under drive unit drain plug and remove plug.

4.

Check drive unit for leaks.

5.

Install drain plug after all oil has been drained from unit.

6.

Fill with 80-90W gear lube or appropriate mixture of gear lube and Dextron II depending upon truck application. Refer to lubrication and adjustment section for mixture ratios.

7.

Drive unit capacity is approximately 5.7 litre

(6 quarts) or until oil runs out of the check plug.

Drive Unit Mounting Bolts

•

Check mounting bolts that connect drive unit to truck frame are tight. Torque mounting bolts to

545 Nm (400 ft lb).

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DRIVE UNIT

Drive Unit

Drive Tire Replacement

When replacing the drive tires, make sure the composition and size are such that maneuverability and braking requirements are maintained. Refer to truck data plate for tire information.

Drive tires are a "press-on" type; press old tire off of the hub and press new tire on. It is recommended that both drive tires be replaced at the same time to maintain equal tire circumference.

1.

Disconnect battery and chock wheels.

2.

Raise and block drive unit so drive tire is off of the floor. Refer to control of hazardous energy sectionlifting and blocking portion for correct jacking and blocking instructions.

CAUTION

Make sure the lifting device and blocking material are sufficiently rated and strong enough to withstand the weight of the truck. Never work under or around a truck that is not properly blocked and secure.

3.

Remove six lug nuts and remove drive tire from truck. Be careful not to damage threaded studs when removing tire

4.

"Press" old tire off of hub.

5.

"Press" new tire onto hub.

6.

Apply anti-seize compound to "inside surface" of hub.

7.

Mount drive tire on truck.

8.

Torque lug nuts in sequences of 50 Nm (35 ft lb),

270 Nm (200 ft lb) and 415-440 Nm (305-

325 ft lb). Refer to Figure 17624 for torque sequence.

(a)

(b)

(c)

Drive Tire Torque Sequence

Apply Anti-Seize to this Surface

Tire and 128375 Hub Shown

Figure 17624

9.

Repeat procedures for remaining drive tire assembly.

10. Remove blocking material and lower truck, remove wheel chocks and connect battery.

11. Verify truck operation.

Traction Motor (M1)

Refer control of hazardous energy section - lifting and blocking section, including the following steps, before removing the traction motor.

•


•

Remove floor mat.

•

Remove floorboards.

M3.0-2045-002

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DRIVE UNIT

Drive Unit

Traction Motor Removal

1.

Lower forks and tilt mast completely forward. Refer to control of hazardous energy section for correct blocking procedures.

2.

Secure all sections of the mast assembly with a lifting sling at top of the mast and connect a hoist to stabilize the mast.

3.


4.

Remove floorboards.

5.

Disconnect hydraulic lines to right hand tilt cylinder. Be prepared to catch hydraulic oil and cap hoses.

6.

Remove the screw and retainer on the front of the right hand tilt cylinder and remove pin that connects cylinder to mast.

7.

Remove the mounting bolts and retaining pin on rear pivot point of right hand tilt cylinder.

8.

Remove plug in access hole on right side of power unit near the cylinder rear mounting pin.

9.

Install a M20 bolt, through the power unit frame into the cylinder mounting pin and remove pin.

10. Remove service brake valve from service brake pedal mounting bracket. Refer to Figure 17499.

NOTE

Hydraulic lines do not have to be removed from service brake valve.

11. Remove service brake pedal mounting bracket.

Refer to Figure 17499.

Remove Service

Brake Valve

Remove Service Brake

Pedal Mounting Bracket

Figure 17499

12. Remove accelerator linkage from the front cowl.


13. Disconnect and label all electrical connections to motor.

14. Disconnect CA603 ECR1.

15. Disconnect main wire harness next to service brake. Refer to Figure 17500.

16. Remove cable ties that connect wire harness to frame or any other components and lay harness to the side.

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DRIVE UNIT

Drive Unit

Disconnect Wire

Harness

Remove Accelerator

Linkage from Cowl

Figure 17500

17. Remove the rue rings and pin holding parking brake cylinder in place. Refer to Figure 17501.

18. Loosen the adjusting nuts on the parking brake assembly to remove tension from brake drum. Refer to Figure 17501.

19. Remove the nut at the rod end of the park brake cylinder. Refer to Figure 17501.

20. Remove cylinder from backing plate. Refer to Figure 17501. Hydraulic lines do not have to be removed.

21. Remove four screws that mount backing plate to the motor. Refer to Figure 17501.

(a)

(b)

(c)

(d)

(e)

(f)

Loosen Nuts

Traction Motor

Remove Nut

Park Brake Cylinder

Remove Rings and Pin

Remove Four Screws

Figure 17501

22. Attach sling to motor and bells. Refer to Figure

17502.

23. Connect lifting device to sling and support motor.

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DRIVE UNIT

Drive Unit

Lift Using End Bells

(a)

(b)

(c)

(d)

Part of LH Power Unit

Electronics Compartment

Access Hole for Traction Motor Screw Removal

Left and Right Determined from Operator’s Perspective

CAUTION

Figure 17502

The traction motor weighs approximately 113 kg

(250 lb). Use appropriately rated lifting sling and lifting device for motor removal.

24. Tilt steering column up.

25. Remove control valve cover.

26. Remove optional left side battery door if equipped.

27. Remove left hand step plate that covers the electronics compartment.

28. Remove distribution board from electronics compartment.

29. Remove access hole cap to access the 5th screw that attaches the motor to the drive unit. Refer to

Figure 17503.

Figure 17503

30. Loosen the five screws that mount traction motor to drive unit. Support the motor before removing mounting screws. Remove mounting screws.

31. Separate the motor from the drive unit housing by using a 7/16-14 x 1 in bolt inserted into a tapped hole in the drive motor flange.

CAUTION

Keep hands away from pinch points when removing motor from truck.

32. Once motor is free from the drive unit housing, use lifting device to slowly raise and remove motor from the power unit. Rotate parking brake backing plate as necessary to clear truck.

33. Insert a clean rag into the drive unit opening to keep dirt and other contaminants out of drive unit.

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DRIVE UNIT

Drive Unit

1st Reduction Pinion Installation

1.

The traction motor shaft and pinion bore is an interference fit; therefore the pinion must be heated before assembly. To assemble, heat 1st reduction pinion 205° C (400° F) maximum for 45 to 75 minutes. After assembling pinion to motor shaft, be sure pinion is fully seated on motor shaft shoulder.

2.

Using drive coupler tool (131348), torque locking nut immediately after pinion is seated and retaining ring is assembled to shaft. Torque nut 204 Nm

(150 ft lb) minimum and then rotate to the next castle lock for roll pin assembly. Refer to Figure

17504.

(c)

(d)

(e)

(f)

(a)

(b)

Locking Nut

Drive Coupler Tool (131348)

Used to Torque Locking Nut

Pinion

Roll Pin

Motor Cross Section

Torque 204 Nm (150 ft lb)

Figure 17504

Installation of Traction Motor

1.

Clean traction motor mounting surface and mating motor housing surface to remove old gasket, dirt and oil.

2.

Apply primer N, 061004-016, and gasket eliminator, 061004-015, to motor mounting surface and allow to dry one to two minutes.

3.

Apply gasket eliminator, 061004-015, to drive unit motor mounting surface in a continuous bead prior to installing traction motor. Refer to Figure 17505.

Apply Gasket Eliminator in a Continuous Bead

Figure 17505

4.

Mount motor squarely on mating surface (without lateral movement) to assure even spread of sealant across flanges.

5.

Motor should pilot onto 2nd axle pin fully prior to assembly of motor mounting screws.

6.

Allow for sufficient cure time with parts undisturbed, approximately four hours with primer.

7.

Apply thread locking primer, 061004-002 and removable thread locker, 061004-026 to the five motor mounting screws.

8.

Torque screws to 47.5 ± 6.8 Nm (35 ± 5 ft lb) using torque pattern shown in Figure 17506.

NOTE

Do not draw the motor onto pilot fasteners. This action will result in binding or burrs on pin.

Crown 2007 PF17013-6 M3.0-2045-006

144

DRIVE UNIT

Drive Unit

Drive Unit Housing

Section (RH)

Traction Motor Mounting Surface Shown

Figure 17506

9.

Reverse the above procedures for installing the remainder of components removed.

10. Refer to parking brake maintenance section for parking brake adjustments.

11. Refer to hydraulic system and service brake maintenance sections for bleeding hydraulic system and service brake bleeding procedures.

NOTE

The parking brake will need to be readjusted after assembly, verify the service brake functions properly.

12. Check for oil leaks around motor mounting.

7.

Rotate hub clockwise and counterclockwise three times (minimum) in each direction.

8.

Loosen adjusting nut.

9.

Torque adjustment nut 130 ± 14 Nm (95 ± 10 ft lb).

10. Bend lockwasher tab to secure adjusting nut. Do not bend a tab previously used (tab may break off while operating truck).

11. Clean axle flange surface and mating axle hub surface. Be sure surfaces are free of old gasket eliminator, dirt and oil.

12. Apply primer N, 061004-016, to one surface and allow to dry (approximately one to two minutes).

13. Apply gasket eliminator, 061004-015, in a continuous bead to other surface. Once applied, the bead should not be disturbed until assembly to assure proper seal.

14. Assemble axle squarely on mating surface (without lateral movement) to assure even spread of sealant across flange.

15. Torque axle mounting bolts to 61.0 ± 6.8 Nm (45 ±

5 ft lb). Refer to Figure 17625 for proper tightening sequence.

Bolt Tightening Sequence

Axle Hub and Axle Installation

1.

Prior to assembly, inspect all components for nicks, burrs or any other damage.

2.

Apply a light film of hydraulic oil to hub bearing bore and tapered bearing. Install bearing cup and cone in service brake end of hub. Be sure cone is completely seated.

3.

Apply light film of oil to hub oil seal bore and install oil seal. Be sure seal is completely seated.

4.

Assemble hub on axle housing.

5.

Apply a light film of hydraulic oil to hub bearing bore and tapered bearing. Install bearing cup and cone in axle end of hub. Also install tabbed washer, lockwasher and nut.

6.

To seat bearings, torque nut to 320 ± 30 Nm (235

± 20 ft lb).

Axle

Figure 17625

16. Allow sufficient cure time for gasket eliminator with parts undisturbed, approximately four hours with primer.

Crown 2007 PF17013-7 M3.0-2045-007

145

DRIVE UNIT

Drive Unit

Drive Unit Removal

NOTE

Removal of traction motor for drive unit removal is not necessary. The traction motor and drive unit can be removed from truck as one complete unit.

1.

A pallet will be needed to place under the drive unit assembly for removal. Refer to Figure 17626 for example.

Placement Holders

Securely Block

Counterweight

Figure 17627

6.

Remove drive tires.

Pallet for Drive Unit

2.

Remove forks, lower mast and tilt mast completely forward.

3.

Disconnect battery and chock wheels.

Figure17626

4.

Remove battery from truck. Refer to battery maintenance section for battery removal procedures.

5.

Raise and block truck under power unit, steer axle and counterweight, 330 mm (13 in) off of floor. Refer to Figure 17627 and control of hazardous energy-lifting and blocking section for proper procedures on lifting and blocking the truck.

WARNING

Once the mast and drive unit are removed the rear of the truck will be the heaviest. The counterweight must be blocked to maintain stability of truck.

NOTE

It may be necessary to connect a jumper from the battery to the truck in order to apply the service brake to prevent the drive tires from turning while removing the lug nuts.

7.

Connect a lifting strap and hoist to all sections of the mast assembly. Refer to control of hazardous energy-lifting and blocking section.

8.

Disconnect all hoses, hydraulic lines, cables and connectors that connect power unit to mast assembly. Label all connections to aid in installation of mast assembly. Cap hydraulic lines and hoses.

9.

Remove the screw and retainer on the front of the right and left hand tilt cylinders. Do not remove pins that connect tilt cylinders to mast assembly at this time.

10. Apply tension to the mast assembly using the hoist. Be sure mast is not binding at this time.

11. Remove bearing caps that connect mast pivot points to truck.

M3.0-2045-008

146

Crown 2007 PF17013-8

12. Remove tilt cylinder pins. Refer to Figure 17628.

DRIVE UNIT

Drive Unit

10. Using a brass drift punch, drive in the dowel pins on the drive unit, thru the power unit. Pins can be removed after the drive unit has been removed from the truck.

11. Loosen the eight bolts (four on each side) that connect the drive unit to the power unit.

CAUTION

Keep hands away from pinch points when removing drive unit and traction motor from truck.

12. Remove mounting bolts and remove drive unit assembly from truck using pallet to slide drive unit out.

Remove Tilt Cylinder Pins

Figure 17628

1.

Using the hoist, carefully remove the mast assembly from the truck.

2.

Tie strap tilt cylinders out of the way.

3.

Remove front and rear floorboards.

4.

Remove service brake valve from service brake pedal mounting bracket.

5.

Remove pressure and return lines from service brake valve. Be prepared to catch oil and cap lines.

6.

Remove service brake pedal mounting bracket.

7.

Disconnect all electrical and hydraulic lines to parking brake cylinder and traction motor. Label all connections to aid in installation of drive unit.

8.

If present, remove hydraulic line and clamp from bottom side of traction motor.

9.

Support the traction motor/drive unit assembly by placing a pallet under the drive unit to support assembly.

Drive Unit Installation

1.

Reverse the disassembly procedures for installing drive unit assembly.

2.

Align bolt and dowel pins holes.

3.

Install mounting bolts and snug tighten.

4.

Using a brass drift punch, drive the four dowel pins in until they are flush with the frame.

5.

Torque mounting bolts that connect drive unit to power unit frame to 545 Nm (400 ft lb).

6.

All hydraulic lines need to be bled after assembly.

Refer to hydraulic system and service brake sections for circuit bleeding procedures.

CAUTION

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

7.

All remaining screws and bolts must be torqued to proper values. Refer to torque values and drive unit repair/rebuild maintenance sections for torque values and sequences.

8.

Check for hydraulic leaks at all connections.

9.

Verify oil level in drive unit and hydraulic reservoir.

10. Verify all truck functions and options are operational.

CAUTION

The drive unit and traction motor combined weigh approximately 410 kg (905 lb) minus the drive tires. Use appropriately rated pallet for drive unit removal.

Crown 2007 PF17013-9 M3.0-2045-009

147

Notes:

148

ELECTRICAL

149

Notes:

150

ELECTRICAL

Electrical

Electrical

Access 1 - Display Control Module

(DCM)

Access 1 is mounted on the truck console to the right of the steering column. Access 1 incorporates several monitoring functions into one meter. It displays an indicator for state of battery charge, a battery retainer switch indicator, a seat belt indicator, an operator improper sequence error indicator, and a service required indicator.

Access 1 - Display Control Module (DCM)

Figure 17573

Crown 2007 PF17016-1 M4.0-2045-001

151

ELECTRICAL

Electrical

M4.0-2045-002

152

(1) Access 1 - Display Control Module (DCM)

(2) Battery Discharge Indicator

(3) Display Screen

(4) Battery Retainer Switch Indicator

(5) Seat Belt Indicator

(6) Enter or Return Key - Used to Navigate In and Out of Menus and Accept Inputs

(7) Navigation Keys - Up, Down, Left and Right Arrows;

Used to Scroll Through Menus

(8) Operator Improper Sequence Error Indicator

(9) Service Required Indicator

* NOTE: These four indicators are viewable during initial key-on, self test and indicator functioning.

Figure 17574

Crown 2007 PF17016-2

Switches

All switches should be checked regularly to assure safe and efficient operation. When adjustments are performed to any switch, make certain the locking devices are tightened to maintain correct adjustment. Also verify the operation of the switches before replacing covers.

AXS1, AXS2, TLT

Hydraulic Auxiliary and Tilt (without extended tilt option) Switches

1.

Loosen switch mounting screws.

2.

Position switch so roller is in the center of cam's

V-groove as shown in Figure 17372-01.

3.

Slightly tighten switch mounting screws.

4.

Rotate control lever to move cam up and down.

The switch should close as early in the stroke as possible while allowing the switch to open when the lever is released. This may require as much as

0.76 mm (0.03 in) spool movement before closing to allow the switch to open when the lever is released. Also, make sure the switch is not over depressed when closed. Switch damage may occur.

Readjust the switch as necessary.

5.

Tighten both screws to secure switch. Recheck for proper switch opening and closing.

1 AXS1, AXS2 or TLT Switch

2 Cam

3 Center of V-Groove

4 V-Groove

AXS1, AXS2 or TLT Switch

ELECTRICAL

Switches

Figure 17372-01

Crown 2008 PF17342-1 Rev. 10/08

Cam Lowered

0.76 mm (0.03 in)

Switch Closed

Figure 17373

M4.0-2045-100

01 Rev. 10/08

153

ELECTRICAL

Switches


Cam Raised

0.76 mm (0.03 in)

Switch Closed

RAS

Figure 17374

Raise Switch

1.


2.

Position switch so roller is approximately centered on lower ramp of cam's upper groove as shown in

Figure 17376-01.

3.


4.

Rotate control lever to move cam up. The switch should close as early in the stroke as possible while allowing the switch to open when the lever is released. This may require as much as 1.3 mm

(0.05 in) spool movement before closing to allow the switch to open when the lever is released. Also, make sure the switch is not over depressed when closed. Switch damage may occur. Readjust the switch as necessary.

5.

Tighten both screws to secure switch. Recheck for proper switch opening and closing.


Cam Moved to Maximum

Raised Position

Figure 17375

1 RAS Switch

2 Upper Groove

3 Roller Approximately Centered on Ramp

Figure 17376-01

M4.0-2045-101

01 Rev. 10/08

154

Crown 2008 PF17342-2 Rev. 10/08

RAS Switch

RAS Switch

ELECTRICAL

Switches

Cam Raised

1.3 mm (0.05 in)

Switch Closed

Figure 17377

RAS Switch


Lowered Position

Figure 17379


Raised Position

Figure 17378

Crown 2008 PF17342-3 Rev. 10/08 M4.0-2045-102

01 Rev. 10/08

155

ELECTRICAL

Switches

TBS

Tilt Back Switch (with extended tilt option)

1.


2.

Position switch so center of roller is in line with bottom edge of cam's upper groove as shown in Figure 17380-01.

3.


4.

Rotate control lever to move cam up. The switch should close as early in the stroke as possible while allowing the switch to open when the lever is released. This may require as much as 0.76 mm

(0.03 in) spool movement before closing to allow the switch to open when the lever is released. Also, make sure the switch is not over depressed when closed. Switch damage may occur. Readjust the switch as necessary.

5.

Tighten both screws to hold the switch secure. Recheck for proper opening and closing.

TBS Switch

Cam Raised

0.76 mm (0.03 in)

Switch Closed

Figure 17381

TBS Switch

1

2

3

Figure 17380-01

TBS Switch

Upper Groove

Center of Roller in Line with Bottom Edge of Top Groove

Cam Moved to

Maximum Raised

Position

Figure 17382

Crown 2008 PF17342-4 Rev. 10/08 M4.0-2045-103

01 Rev. 10/08

156

ELECTRICAL

Switches

HSS

High Speed Switch (AC lift only)

1.


2.

Position switch so roller is approximately 6.35 mm

(0.25 in) above the lower ramp on the upper groove as shown in Figure 17383-01.

3.


4.

Rotate control lever to move cam up. The switch should close as near to the end of the stroke as possible while allowing the switch to open when the lever is released. Also, make sure the switch is not over depressed when closed. Switch damage may occur. Readjust the switch as necessary.

5.

Tighten both screws to hold the switch secure. Recheck for proper opening and closing.

HSS Switch

Cam Raised

Switch Closed

Figure 17384

HSS Switch

Figure 17383-01

1 HSS Switch

2 Lower Ramp

3 Roller Approximately 6.35 mm (0.25 in) Above Lower Ramp

Cam Moved to

Maximum Speed

Figure 17385

Crown 2008 PF17342-5 Rev. 10/08 M4.0-2045-104

01 Rev. 10/08

157

ELECTRICAL

Switches

ACS

Accelerator Switch

1.

Place a 1.9 mm (0.1 in) thick shim between lever and buffer. Refer to Figure 17386-01.

2.

Loosen the two #6 screws so switch can be moved freely. Slide switch roller against cam as shown in

Figure 17387. The switch should be actuated.

3.

Tighten the #6 screws to secure the switch.

4.

Remove shim from between accelerator mount and buffer.

5.

Rotate accelerator lever several times to verify switch is not actuated when accelerator lever is in its neutral position (lever arm against buffer). If not, repeat previous adjustment steps.

Cam

Switch

Actuated

Figure 17387

Figure 17386-01

1 Part of Accelerator Mount

2 Buffer

3 Part of Lever

4 Place 1.9 mm (0.075 in) Thick Shim Between Lever and

Buffer

M4.0-2045-105

01 Rev. 10/08

158

Crown 2008 PF17342-6 Rev. 10/08

ELECTRICAL

Switches

HGTS1

Height Switch - TL

Switch measurement is adjustable.

1.

Gap between height switch and the block on the outer mast should be 6.0 mm (0.25 in). Gap can be adjusted when needed from 4.5 to 7.5 mm (0.19 to

0.31 in) with shims provided.

Height Switch - TT

1.

Gap between height switch and the block on the

2nd Stage Mast should measure approximately

6.35 mm (0.25 in) when mast is in lowered position.

The measurement is not adjustable.

1 HGTS1

2 Block (On 2nd Stage Mast)

Figure 19789-01

3

4

1

2

HGTS1

Top View

Shim

Gap

Crown 2008 PF17342-7 Rev. 10/08

Figure 20888

M4.0-2045-106

01 Rev. 10/08

159

ELECTRICAL

Switches

SES1, SES2 TLMS

Seat Switches

1.


2.

Adjust switch so 1.5 mm (0.060 in) to 2 mm

(0.070 in) gap is obtained between flat spring and switch actuating arm with the actuating arm resting on switch plunger.

3.

Tighten switch mounting screws.

1 Loosen Screws to Adjust Switch

2 Flat Spring in Free Position

3 1.5 mm (0.06 in) to 2 mm (0.07 in) Gap

4 Switch Plunger

Figure 17389-01


1.

Remove floorboard.

2.

With the bracket in the rearward position, the switch roller should be activated, position "A".

3.

With the bracket in the forward position, the switch roller should be deactivated, position "B".

4.

Loosen adjustment screw on switch until steps 2 and 3 can be achieved.

5.

With truck unloaded and on a flat surface, attach an inclinometer on the back of the first stage mast.

NOTE

If truck has a special attachment it also must be on truck prior to making this adjustment.

6.

Tilt the mast forward 2° ± 15'.

7.

Loosen the two adjustment screws on block and move assembly until the roller assembly on switch is deactivated. Tighten adjustment screws.

8.

Verify lift cutout by lowering the mast and tilting mast forward. Raise mast at full speed. Lift cutout should occur within 150 mm (6.0 in) of fork height staging. Any accessories on the truck (sideshift, etc.) should still be operational at this point.

NOTE

The measurement in step 8 is not adjustable.

9.

Verify tilt cutout by tilting mast back and raising mast above the lift cutout point. Tilt mast forward at full speed until tilt cutout occurs. Tilt cutout should occur at 2° ± 15'. Any accessories on the truck

(sideshift, etc.) should still be operational at this point.

10. Remove inclinometer and install floorboard cover.

M4.0-2045-107

01 Rev. 10/08

160

Crown 2008 PF17342-8 Rev. 10/08

ELECTRICAL

Switches

Figure 17390-01

1 Left Tilt Cylinder

2 Forward Adjustment

3 Rearward Adjustment

4 Clevis

5 Left and Right Determined from Operator’s Perspective

6 Bracket

7 Adjustment Screws

8 Tilt Limit Switch (TLMS) and Mounting Plate

9 Position B

10 Position A

11 Switch Adjustment Screw

Figure 17391-01

1 Left Tilt Cylinder

2 Mounted to Mast

3 Bracket

4 Tilt Limit Switch Mounting Plate

5 Switch Plate Adjustment Screws

6 Left and Right Determined from Operator’s Perspective

7 Tilt Limit Switch (TLMS)

8 Mounted to Power Unit

9 Switch Adjusting Screw

Crown 2008 PF17342-9 Rev. 10/08 M4.0-2045-108

01 Rev. 10/08

161

Notes:

162

ELECTRICAL

Electrical System


The following is an explanation of terms and symbols which are standard on Crown wiring diagrams.

Wiring Color Codes

Wires are limited to the colors shown in the chart below. The color of the wire is based on the function of the circuit in which it is used. Each wire is assigned a three or four digit number. The first one or two numbers identify the color of the lead. The last two numerals number the lead from one thru ninety-nine. Exceptions to this can be component leads supplied by vendors. Each wire is identified by a number on a wiring pictorial (refer to section DIA).

7**

8**

9**

29**

59**

3**

4**

5**

6**

Number Color

0** Black

1**

2**

Brown

Red

Orange

Yellow

Green

Blue

Violet

Gray

White

Red Stripe/White

Green Stripe/White

Wiring Color Codes Chart

Function

Traction Inputs/Outputs

Analog Inputs

Battery Positive

Non-Battery Positive

Status Inputs/Outputs

Battery Negative

Isolated Negative

Load Position Inputs/Outputs

Indicators and Warning Devices

Miscellaneous

Positive that has gone thru a switch

Negative that has gone thru a switch or resistor

Power Cables

Except WP trucks, power cables are designated using one of the following abbreviations, followed by a dash number.

Power Cables Abbreviations Chart

Abbreviation

PC#1

PC#2

PC#4

PC#6

PC#10

PC#1/0

PC#2/0

PC#3/0

Part Numbers

084571

084570

084569

084568

090963

084572

084573

086749

An example of such a cable is PC # 1/0 - 10. The part number for this cable is 084572-010.

Crown 2000 PF11845-1 Rev. 10/06 M4.1-2720-001

03 Rev. 10/06

163

ELECTRICAL


Component Abbreviations and Designators

M

MCR

PC

PCVA

PCVH

PMTD

POT

PS

PS

FLS

FU

HF

HN

HR

HSC

JC

LGT

CAP

DB

DFR

DMC

DR

ECN

FAN

FIL

Components

1AD 1A Bypass Driver

ALM

ATD

Alarm

Anti Tie Down Module

BATT

BDI

BRK

CA

Battery

Battery Disch. Interrupt

Brake

Connector Assembly

Capacitor

Diode Block

Defrost

Dual Motor Card

Driver Module

Encoder

Fan

Filter

Flasher

Fuse

Hash Filter

Horn

Heater

High Speed Card

Fixed Part of Ca

Light

Motor

Motor Control

Movable Part of Ca

"Pressure Compensated Valve, Acc."

"Pressure Compensated Valve, Hoist"

Pulse Monitor Trip Driver

Potentiometer

Power Supply

Pressure Switch


SVR

SVS

SVT

TB

TD

TDR

TMM

TP

REC

RES

SB

SSC

SV

SVA

SVL

SVP

Rectifier

Resistor

Suppressor Block

Safety Switch Card

Hydraulic Solenoid

Solenoid Valve - Accessory

Solenoid Valve - Lower

Solenoid Valve - Pilot

Solenoid Valve - Reach

Solenoid Valve - Sideshift

Solenoid Valve - Tilt

Terminal Board

Time Delay

Time Delay Relay

Truck Management Module

Test Point

P

R

FW

K

ED

F

FA

FB

RA

RB

C

D

A

B

TT

V

Hour Meter (Truck Time)

Discharge or Volt Meter

XC Socket for PC Board

Contactor and Relays

Speed Contactor

Speed Contactor

Speed Contactor

Dual Contactor

Emerg. Disc. Contactor

Forward Contactor

Forward Contactor A

Forward Contactor B

Field Weakening

Relay

Pump Contactor

Reverse Contactor

Reverse Contactor A

Reverse Contactor B

Crown 2000 PF11845-2 Rev. 10/06 M4.1-2720-002

03 Rev. 10/06

164

ELECTRICAL


RGB

S

1A

Switches

1AS

ACC

ACS

AHS

CHSR

CLS

CS

CTS

DIS

DMS

DMSL

DMSR

DPS

DRS

BLS

BMS

BPS

BRES

BRS

BS

CHS

CHSL

AS

AxA

AxB

AxC

AxF

AxR

AXS

BFS


Regen. Braking Contactor

Power Steering Contactor

Bypass Contactor

Traction Bypass Switch

Accessory Switch

Accelerator Switch

Aux. Height Switch

Switch For A Contactor

Aux. Sw. on A Contactor

Aux. Sw. on B Contactor

Aux. Sw. on C Contactor

Aux. Sw. on Fwd. Contactor

Aux. Sw. on Rev. Contactor

Aux. Function Switch

Brake Fluid Switch

Battery Latched Switch

Brake Monitor Switch

Brake Pressure Switch

Battery Restraint Switch

Brake Switch

Switch For B Contactor

Chain Switch

Chain Switch Left

Chain Switch Right

Clamp Switch

Switch For C Contactor

Cable Tension Switch

Direction Switch

Dead Man Switch

Dead Man Switch Left

Dead Man Switch Right

Display Switch

Door Switch

Crown 2000 PF11845-3 Rev. 10/06


GUS

HCS

HGTS

HNS

HSS

HTS

HTSXX

KORS

KYS

LCS

FRS

FS

FTS

GCSL

GCSR

GOSL

GOSR

GTS

ERS

EXS

FHS

FKS

FLMCS

FLS

FNS

FRMCS

DTS

ECS

EDS

EIS

EMS

ENS

EOS

ERLS

Drive Tow Switch

Elevation Control Switch

Emergency Disconnect Switch

Extend In Switch

Emergency Switch

Entry Switch

Extend Out Switch

Emergency Raise/Lower Switch

Erase Switch

Extend Switch

Fork Home Switch

Fork Switch

Forward Left Motor Cover Sw

Fork Left Switch/Free Lift Switch

Fan Switch

Forward Right Motor Cover Sw

Fork Right Switch

Forward Switch

Foot Guard Switch

Gate Closed Switch Left

Gate Closed Switch Right

Gate Open Switch Left

Gate Open Switch Right

Gate Switch

Guidance Switch

Height Cable Switch

Height Switch

Horn Switch

High Speed Switch

Heater Switch

Height Switch (XX Inches)

Key Override Switch

Key Switch

Lower Cutout Switch

M4.1-2720-003

03 Rev. 10/06

165

ELECTRICAL



RS

RSS

SAS

SCS

SES

SLS

SQS

SRS

SSS

STS

RES

RGS

RGSL

RGSR

RIS

RLMCS

ROS

RRMCS

PLS

PORS

PRS

PS

PTS

PUS

QPS

RAS

LGS

LMS

LOS

LTS

MFS

MVS

NUS

ORS

Light Switch

Limit Switch

Lower Switch

Loadtray Switch

Multi-funciton Switch

Multi-voltage Switch

Null Switch

Override Switch

Pivot Left Switch

Presence Overide Switch

Pivot Right Switch

Pressure Switch

Pivot Switch

Pump Switch

Quick Pick Switch

Raise Switch

Reach Extended Switch

Rail Guide Switch

Rail Guidance Switch Left

Rail Guidance Switch Right

Reach In Switch

Rear Left Motor Cover Switch

Reach Out Switch

Rear Right Motor Cover Switch

Reverse Switch

Sheet Retainer Switch

Safety Switch

Sideshift Center Switch

Seat Switch

Sideshift Left Switch

Sequence Switch

Sideshift Right Switch

Sideshift Switch

Power Steer Switch

M4.1-2720-004

03 Rev. 10/06

166


SWH

TBS

TDS

TES

THS

TLS

TLT

TRS

Operator Activated Switch

Tilt Back Switch

Tilt Down Switch

Test Switch

Thermal Switch

Traverse Left Switch

Tilt Switch

Traverse Right Switch

TUS

TVS

ZSS

Terms

Tilt Up Switch

Traverse Switch

Zone Select Switch

ASM

CTRL

Assembly

Control

CTRLR Controller

DESIG LIST Designation List

DIST PNL

DSPL

F / C

HCM

HDL

HYD

OHG

PCB

Distribution Panel

Display

Freezer Conditioning

Hydraulic Control Module

Handle

Hydraulic

Overhead Guard

Printed Circuit Board

PICT

PKT

PL

PWR

Pictorial

Packet

Platform

Power

PWR SPLY Power Supply

SCHEM Schematic

TCM

TMM

TRAC

Traction Control Module

Truck Management Module

Traction

Crown 2000 PF11845-4 Rev. 10/06

Switches

Switch symbols convey:

1.

Type of switch.

2.

Number of terminals.

3.

Momentary or maintained contact.

4.

How the switch is held and wired.

5.

How the switch is activated.

6.

Application.

Type of Switch

•

With common or

ELECTRICAL


Momentary or Maintained Contact

•

Momentary contact is a shaded triangle.

or

Figure 8119-01

Figure 8120-01

•

Maintained is an open circle (an open circle also denotes the common terminal).

Figure 8115-01 or

Figure 8115-01

• or

Without common

Figure 8116-01

Figure 8117-01

Figure 8117-01

How the Switch is Held and Wired

To determine how the switch is held and wired, look closely at the contact symbols. An open circle denotes a maintained contact so therefore it is the normally closed terminal. A shaded triangle denotes a momentary contact, therefore it is the normally open terminal.

Switches having more than one maintained contact do not have a normally open or normally closed terminal, although they may have a common. Symbols for these switches include the markings present on the actual switch.

Example:

Figure 8118-01

Number of Terminals

•

All terminals are shown even if not wired.

Figure 8121-01

Crown 2000 PF11845-5 Rev. 10/06 M4.1-2720-005

03 Rev. 10/06

167

ELECTRICAL


Examples (All Momentary)

With Common (Transfer)

Wired normally open, held open

Wired normally open, held closed

Wired normally closed, held open

Wired normally closed, held closed

Figure 8119-01

Figure 8122

Figure 8115-01

Figure 8124

Without Common (Double Break)

Figure 8120-01

Figure 8123

Figure 8117-01

Figure 8125

How the Switch is Activated

If it is necesary to include how the switch is mechanically actuated, a note will be added to the drawing (example: operator, lever or truck actuated, etc.)

Application

Switch application is conveyed through the abbreviation (example: HTS = Height Switch 120 in., DTS =

Drive/Tow Switch).

Notes:

•

In a schematic, the condition of a circuit is defined using a note (example: vehicle shown fully lowered with no operator on vehicle).

•

Positive action switches are marked with the following symbol:

8126-02

M4.1-2720-006

03 Rev. 10/06

168

Crown 2000 PF11845-6 Rev. 10/06

ELECTRICAL


Switch Symbols

(Mechanically activated switches)

Actuation Description

No. of

Terminals

Momentary w/common w/o common

Fully Maintained w/common w/o common

Figure 8100-01

Crown 2000 PF11845-7 Rev. 10/06 M4.1-2720-007

03 Rev. 10/06

169

ELECTRICAL


Switch Symbols

(Mechanically activated switches)

Continued

Actuation Description

No. of

Terminals

Momentary w/common w/o common

Fully Maintained w/common w/o common

M4.1-2720-008

03 Rev. 10/06

170

Figure 8101-02

Crown 2000 PF11845-8 Rev. 10/06

Specialty Switches

Pressure Switch

Reed Switch

Temperature Switch

Brake Fluid Switch

Three Position Key Switch

Start

Off

Figure 8127

Figure 8128

Figure 8129

Figure 8130

Figure 8131-01

ELECTRICAL


Crown 2000 PF11845-9 Rev. 10/06 M4.1-2720-009

03 Rev. 10/06

171

ELECTRICAL


Other Electrical Symbols

Signal Flow

One Way

Signal Flow

Simultaneous

Signal Flow

Alternate

Chassis

Ground

Common

Return

Test Point

Cable

Shielded

Cable

Twisted Pair

Cable Multi-

Twisted Pairs

Cable Multi-

Conductor

Cable Multi-

Conductor

Cable

Unconnected

Cable

Unconnected

Insulated

Junction

Point

M4.1-2720-010

03 Rev. 10/06

172

Terminal

Strip

T-Connection

Double

Junction

Mast Cable

Power

Termination

Female/

Socket

Male

Pin

Socket & Pin

Connector

Fixed/Jack

Connector

Moveable/

Plug

Connector

Assembly

Resistor

SIP Resistor

Pot

Rheostat

Heater

Thermistor

Mov/

Transzorb

Capacitor

Nonpolarized

Capacitor

Polarized

Current

Shunt

Inductor

LVDT

Ferrite Bead

Diode

LED

Zener Diode

SCR

Transistor

NPN

Figure 8132-02

Crown 2000 PF11845-10 Rev. 10/06

Other Electrical Symbols

Transistor

PNP

Darlington

NPN

Darlington

PNP

N-FET With

Diode Clamp

P-FET With

Diode Clamp

Motor Field,

Series

Motor Field,

Shunt

Series Motor,

DC

Shunt Motor,

DC

Permanent

Magnet

Motor

Separately

Excited Motor, DC

Motor, AC

Transformer

Crown 2000 PF11845-11 Rev. 10/06

ELECTRICAL


DC/DC

Converter

Power Supply

Battery

Contactor

Normally

Open

Contactor

Normally

Closed

Coil

Dual

Suppressor

Dual

Suppressor

Filter Block

OR Gate

Coil

Suppression

Fuse - Band

Shows Positive

Feed

Tach Sensor

Hour Meter

NOR Gate

Schmitt NAND

Schmitt

Buffer

Schmitt

Inverter

Lamp

Amp/Comp

Horn

AND Gate

Encoder

NAND Gate

Suppressor

Suppressor

X-OR Gate

X-NOR Gate

Suppressor

Integrated

Circuit

Figure 8133-02

M4.1-2720-011

03 Rev. 10/06

173

Notes:

174

ELECTRICAL

Access 123...System


User Main Menu Level

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 display options. The user may choose from the following options (provided a higher priority message is not active):

•

Message (for example Bdi = 70%)

•

Hour

•

Events

•

Service

•

Performance (if enabled and PIN not active)

The following messages will 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

(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 16565

5.

User selected message, per F7 setting.

If any message is more than eight characters it will be scrolled across the display from right to left.

The display will continue to show the last selected message 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 Message (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

Note:

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.

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ELECTRICAL


Bdi - Message Mode

This menu allows the operator to display the battery percent of remaining charge. 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 Bdi.

Press the enter/return button. The display will exit the

Message Mode and show (Bdi = XX%).

Hours - Message Mode

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).

Odometer - Message Mode

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

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 will 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 display will exit Message Mode and display distance traveled 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

Timer - Start

Press the enter/return button. The display will exit the

Message Mode and display; Stopwatch (00:00:00), which will be incrementing.

Timer - Stop

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 display Stop, press the enter/return button. The display will exit the Message Mode and show the Stopwatch stopped, with the amount of time accumulated (example, 01:01:32).

Timer - Reset

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 display will exit the Message Mode. The Stopwatch will be zeroed, and not counting (00:00:00).

Hour

This menu allows the user to view one of five different hour meter readings.

•

H1 (key on, operator in seat)

•

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

•

H3 (Access 1 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 will be displayed. Use the up/down arrows to view different hour meter readings. To stop the message from scrolling press the right arrow at the desired hour meter. To exit Hour menu press the left arrow until Hour is displayed.

M4.3-2045-002

176

Crown 2007 PF15956-2

ELECTRICAL


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 will 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 password 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/return 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 Service menu.

Performance

If User Performance is enabled in the Features menu

(F8), 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, balanced productivity/energy consumption)

•

P2 (performance similar to FC4000 series)

•

P3 (used where operational conditions require lowest 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

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ELECTRICAL


Operator Menus

Message Mode Menus

Allows the user to select what is displayed 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.

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)

H2 visible only if selected in Features menu continued on page -005

Figure 16548

Crown 2007 PF15956-4 M4.3-2045-004

178

continued from page -004

Operator Menus

ELECTRICAL


Crown 2007 PF15956-5

Performance menu only visible when selected in the service menu

Figure 16549

M4.3-2045-005

179

ELECTRICAL



Level 2 and 3

Service Menus

Level 2 and 3

Level 2 only

Level 3 only continued on page -007

Not available if equipped with AC lift and F6=AC

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

M4.3-2045-006

180 continued on page -015 continued on page -015 continued on page -016 continued on page -017 continued on page -017 continued on page -017

Figure 16550

Crown 2007 PF15956-6


ELECTRICAL


Service Menus

Place direction control lever in forward (forks first) position

Accel Pedal Fully Up

Continuous Hold on Accel Pedal

(Fully Depressed)

Release Pedal

Place direction control lever in reverse (power unit first) position

Accel Pedal Fully Up

Continuous Hold on Accel Pedal

(Fully Depressed) continued on page -008

Adjusts Voltage (Visible on Display)

Involving Power Cables

Crown 2007 PF15956-7

Figure 16551

M4.3-2045-007

181

ELECTRICAL



Service Menus

Only Available on DC Lift

M4.3-2045-008

182 continued on page -011 continued on page -009

Figure 16552

Crown 2007 PF15956-8


Service Menus

ELECTRICAL


continued on page -010

F11 and F12 default = Disable.

F12 only visible if F11 has been enabled.

Crown 2007 PF15956-9

F11 and F12 will provide flow adjustment for accessories from 3 to 10 gpm.

Flow control screw, located in control valve, must match setting.

Figure 16553

M4.3-2045-009

183

ELECTRICAL


continued from page

-009

Service Menus

View Codes

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

M4.3-2045-010

184

F9.5 programs a timeout when operator leaves the seat. Default = Disable.

Default time = 5 mins. and is adjustable from 1 to 99 min.

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

Delete Codes

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

Figure 16554

Crown 2007 PF15956-10


ELECTRICAL


Service Menus

Level 2: View Only/Level 3: Increase Only


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






Level 2: View Only

Enables PM

Timer continued on page -012

Crown 2007 PF15956-11

Level 2: View Only

Figure 16555

M4.3-2045-011

185

ELECTRICAL



Service Menus

Range continues

...


M4.3-2045-012

186

Figure 16556

Crown 2007 PF15956-12


Service Menus

ELECTRICAL



Crown 2007 PF15956-13 Rev. 11/08

Figure 16557-01

M4.3-2045-013

01 Rev. 11/08

187

ELECTRICAL



Level 3 Menu

Service Menus

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


M4.3-2045-014

188

Figure 16558

Crown 2007 PF15956-14


Service Menus

Access 1 Inputs

ELECTRICAL



Access 2 Inputs

Only present if option

TMM is selected (F3).

DC Lift Only.

Only if optional AC Lift

(F6) is selected.

Crown 2007 PF15956-15

Figure 16559

M4.3-2045-015

189

ELECTRICAL



Service Menus

Access 3 Inputs

M4.3-2045-016

190

Figure 16560

Crown 2007 PF15956-16

ELECTRICAL



Service Menus

Access 1 Outputs





Crown 2007 PF15956-17

Figure 16561

M4.3-2045-017

191

ELECTRICAL


Analyzer

The analyzer menu description is shown on the following pages. This menu shows the different system components 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. At 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 accept the password.

To stop scrolling display, press the right arrow. To move to the next menu level the left arrow must be pressed.

A1 Status -

View only the status of monitored truck systems. Press the right arrow to view status.

A1.1 Lift -

Press right arrow, display will show enabled or disabled. Enabled indicates lift is allowed. Disabled indicates lift is not allowed, this could be due to a system fault. Press the left arrow to return to the A1.1 submenu. 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 enabled or disabled. Enabled indicates traction is not inhibited. 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 components. 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); Off = switch open (raise not selected).

Press down arrow to continue.

A2.1.2 TLT = ___;

Tilt switch, switch is active on forward or back tilt - On = switch closed (tilt not selected);

Off = switch open (tilt selected). Press down arrow to continue.

A2.1.3 TBS =___;

Tilt Back Switch - On = switch open

(tilt back selected); Off = switch closed (tilt back not selected). 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).


A2.1.5 AXS1 = ___;

1st Accessory Switch - Features menu (F11) must be enabled to view. On = switch closed (1st accessory selected); Off = switch open (1st accessory not selected). Press down arrow to continue.

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.

M4.3-2045-018

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Crown 2007 PF15956-18

ELECTRICAL


A2.1.10 TMM =

___V; Truck Management Module -

Menu item is only available if Features menu F3 is enabled.

•

M2 (DC lift) over temperature = 0.75Vdc to

1.25Vdc

•

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.


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 continue.

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 degrees Fahrenheit if F2 = disabled or in degrees Celsius if F2 = enabled. Above 160°C (320°F) motor is hot.


A2.2.4 M2 Current =

___A; Displays the lift motor current 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 will 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.



Access 3 monitored inputs.

A2.3.1 FS =___;

Forward Switch - On = switch closed

(Forward direction selected). Off = switch open (Forward direction not selected). Press down arrow to continue.

A2.3.2 RS = ___;

Reverse Switch - On = switch closed

(Reverse direction selected). Off = switch open (Reverse direction not selected). Press down arrow to continue.

A2.3.3 BRKS =

___; Brake switch - On = switch closed

(Brake pedal depressed). Off = switch open (Brake pedal not depressed). Press down arrow to continue.

A2.3.4 SEAT =

___; Seat switch - On = switch closed

(Operator on seat). Off = switch open (Operator not on seat). Press down arrow to continue.

A2.3.5 HGTS1 ___;

Mast Height Switch - On = switch closed (mast below free-lift); Off = switch open (mast above free-lift). Press down arrow to continue.

A2.3.6 ACS ___;

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 POT1

___ V; Accelerator Potentiometer - 0.2

Vdc pedal released to 4.0 Vdc pedal fully depressed.


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 application.

A2.3.10 M1 Speed =

___RPM; Displays the traction motor (M1) speed in RPMs. Press down arrow to continue.

A2.3.11 M1 TEMP =

___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 Current =

___ A; Displays the traction motor current in amperes. Press down arrow to continue.

A2.3.13 Access3 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 will cut back to allow controller to cool. Above 100°C (212°F) traction will be disabled. Press down arrow to continue.

A2.3.14 BDI =

___%; Indicates percent of 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); Off = switch open

(2nd accessory not selected). Press down arrow to continue.

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193

ELECTRICAL


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 arrow to view outputs.

A3.1 Access 1 Outputs -


Access 1 monitored outputs.

A3.1.1 SV1 =

___; Tilt lockout solenoid - On = SV1 energized, mast is tilted greater than two degrees forward. Off = 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 energized. Press left arrow to return to A3.1.2. Press down arrow to continue.

A3.1.3 P =

___; Lift Contactor - On = lift contactor energized. Off = 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. Off = status alarm off. Press left arrow to return to A3.1 menu. Press down arrow to go to A3.2

menu.




A3.2.1 FAN2 =

___; Access 2 controller cooling fan -

On = fan running; Off = 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.





A3.3.1 L =

___; Line Contactor - On = Access 3 sending output to energize the line contactor. Off = Access

3 not sending output to energize the line contactor.


A3.3.2 M1 =

___; (OFF/ON) Displays traction motor being driven or not. Press down arrow to continue.

A3.3.3 FAN1 =

___; Access 3 controller cooling fan -

On = fan running; Off = fan not running. Press left arrow twice to return to A3 menu. Press down arrow to go to

A4 menu.

A4 Test Outputs

(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 =

___; (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:


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 limit 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/return to test Access 2 cooling fan. Press left arrow to return to

A4 menu.

Note:


AC lift and features menu (F6) = AC.

M4.3-2045-020

194

Crown 2007 PF15956-20

ELECTRICAL


Calibration

The calibration menu description is shown on the following pages. The level of the menu shows the different area of calibration for this truck. If calibration procedures are not performed correctly and/or features settings are not entered correctly, unsatisfactory truck performance may result.

•

C1 Accel Pedal - accelerator potentiometer (Pot1)

•

C2 Batt Adj - actual battery voltage level

When to calibrate:

•

Access 3 replaced, full truck calibration is required.

•

Access 1 replaced, C2 calibration required.

•

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

Calibration Access


VICE menu, press the right arrow to enter LEVEL 2.

Press the right arrow again to enter the Access password. Use the up/down arrow buttons to change number, press right arrow to move to the next number.

Once all numbers in the Access code have been entered press enter/return. Using the down arrow navigate to the CALIBRATION menu, and then press the right arrow. The message displayed will be C1 Accel

Pedal.

Calibration Procedures

A full explanation of calibration procedures for each menu level follows.

C1 Accel Pedal -

Accelerator Potentiometer (POT1).

Press right arrow.

Several steps are required for this calibration. The following are descriptions of messages displayed during calibration:

Note:

Errors during calibration will be indicated by different messages, see Calibration Error Messages at the end of this description.

1.

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

2.

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

3.

"Dir Switch FWD 0.00V" - Place the direction control 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 position, press right arrow.

6.

"Press ACCEL 0.00V" - fully depress and hold accelerator pedal, press right arrow.

7.

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

8.

"Dir Switch REV 0.00 V" - Release the accelerator pedal. Place the direction control lever in the reverse (power unit first) position, press the right arrow.

9.

"Min volts" - press the right arrow.

10. "Press ACCEL" - Fully depress and hold the accelerator 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 accelerator pedal fully depressed, press the right arrow.

13. "Save? N" - press the up arrow

14. "Save? Y" - Press enter/return to save.

15. "Calibration Accepted" - proper calibration complete.

Press enter/return to return to C1.

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Calibration Error Messages

Two messages may be displayed if required calibration criteria are not met:

•

Calibration Rejected

•

Retry

These messages may result from improper sequencing of switches to component issues. If either of these messages is displayed, press enter/return to begin calibration from the beginning.

C2 Batt Adj -

Connect digital volt meter (DVOM) across battery, record reading. Press the right arrow.

C2.1 Adj Volts -

Calibration accounts for cable and connection voltage drops between battery and controller. The following are descriptions of messages displayed during calibration:

1.

"Adj Volts" will scroll, press right arrow.

2.

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

3.

Use up and down arrows to adjust voltage measured 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 will return to C2.

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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


VICE menu, press the right arrow to enter LEVEL 2.

Press the right arrow again to enter the Access password. Use the up/down arrow buttons to change number, press right arrow to move to the next number.

Once all numbers in the Access code have been entered press the enter/return button. Using the down arrow, navigate to the FEATURES menu and then press the right arrow. The message displayed will be F1 Language =.

If changes have been made in the sub menus, pressing the left arrow at the first level menu will 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 messages will be displayed on Access 1. Factory setting is

English and can not be modified. Press down to continue.

F2 Metric = ___;

Determines the units of measure displayed. Factory setting is disabled and can not be modified. Press down arrow to continue.

F3 TMM =

___; This menu is enabled if the truck is equipped with a Truck Management Module. It is disabled if the truck is not equipped with a Truck Management Module. To Enable or Disable, press the right arrow, 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.

F4 Hour Meter =

___; 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 H1 and H2 (see hour meter description to determine monitored system item). Press the enter/return button.

Menu will return to F4, press the down arrow to continue.

F5 Battery 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 electrical maintenance section of the Service and Parts Manual for other components which may need to be replaced when changing truck voltage). Press the enter/ return button. Menu will return to F5, press the down arrow to continue.

F6 Lift System =

___; This feature determines whether the truck is equipped with DC (contactor) lift or

AC (Access 2) lift. To change the truck lift system, press the right arrow, use the up and down arrows to change between DC and AC. Press the enter/return button. Menu will return to F6, press the down arrow to continue.

Note:

Setting F6 incorrectly can affect proper lift operation.

F7 Message Mode =

___; This feature changes information displayed during operation. Press the right arrow, use the up and down arrows to change. Select from: Bdi (battery percent of charge), Hours (hour meter reading), Odometer (total distance truck has traveled in miles), Trip (total distance truck has traveled since last reset), Timer (stopwatch) or All (allows operator to determine message using display buttons).

Press enter/return. Menu will return to F7. Press the down arrow to continue.

F8 User Performance =

___; 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 performance modes. Press the right arrow, use the up and down arrows to change. Press enter/return. Menu will return to F6. Press the down arrow to continue.

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F9 User Codes =

____ Use this feature to enter up to

25 user codes which can be applied to various performance 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 performance 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 will 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 Add 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 continue.

Note:

If a PIN is already in use, "PIN Used" will be displayed. Select a different PIN.

F9.3 Modify Code

This feature will allow modification of previously entered user codes. Press the right arrow, the entry number will 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 arrow, display will show Perf Level. Press the right arrow, use the up and down arrows to select desired performance level (P1, P2 or P3). Press enter/return, menu will display Perf Level. Press left arrow, display will return to F9.3. Press 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 will display the entry number for one half second. Use the up and down arrows 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.

F9.5 Timeout

This feature allows a timer to be assigned to user codes. This timer will affect all user codes. The timer begins when the operator leaves the seat. Once the timer 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 timer value. Press the enter/return button. Press the left arrow 3 times to return to F9. Press the down arrow to continue.

F10 Auto 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 arrow, 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 Accy 1

This feature allows the operation of 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/return 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 Service and Parts Manual hydraulic section for part numbers.

F11.2

___ 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 buttons to choose between 3, 5, 7 and 10 GPM. Press enter/return to accept, menu will return to F11.2. Press the left arrow to return to F11. Press the down arrow to continue.

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F12 Accy 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 Service and Parts Manual hydraulic section for part numbers.

F12.2

___ 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 buttons 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" will 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 will return to

Features.

F13 Power Brake;

Enabled allows brake and accelerator 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.

ELECTRICAL


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Hour/Event/Utilities Menu

Hour Meter Menu

Hour meters are viewed only in the Operator Message mode and in Service Level 2 mode. Adjustment of hour meters must be performed in Service Level 3 menu.

H1 Runtime1 =

___; (5 digits) The H1 hour meter runs when the key switch is on and the operator is in the seat. H1 resides in the display. If the display is replaced, this hour meter can be increased only. To increase this hour meter, enter the Level 3 service menu.

Use the up and down arrow buttons to scroll to Hour.

Press the right arrow twice. Use the up and down arrows to modify the value. Press the enter/return button to accept and return to H1 Runtime1. Press down arrow to continue.

H2 Runtime2 =

___; (5 digits) The H2 hour meter runs when the key switch is on and the operator is in the seat. H2 incorporates a programmable timeout which will continue to increment for the timeout period after the operator has exited the seat. H2 resides in the display. If the display is replaced, this hour meter can be increased only. To increase this hour meter, enter the

Level 3 service menu. Use the up and down arrow buttons to scroll to Hour. Press the right arrow twice. Use the up and down arrows to modify the value. Press the enter/return button to accept and return to H2

Runtime2. Press down arrow to continue.

H3 Access 1 =

___; (5 digits) Total accumulated display module hours. This hour meter can not be changed.

H4 Access 2 =

___; (5 digits) Total accumulated hydraulic control module hours. H4 resides in Access 2.

This hour meter can not be changed. If Access 2 is replaced H4 will update to value in memory of new controller.


H5 Access 3 =

___; (5 digits) Total accumulated traction control module hours. H5 resides in Access 3. If the traction control module is replaced, this hour meter can not be changed. If Access 3 is replaced H5 will update to value in memory of Access 2. Press down arrow to continue.

H6 SteerMotor =

___; (5 digits) Total accumulated steer motor on hours. H6 resides in Access 1. If Access

1 is replaced, this hour meter can be increased only. To increase this hour meter, press the right arrow. H6

SteerMotor will be displayed. Press right arrow to edit.

Use up/down arrows to change hour value. Press enter/return to return to H6. Press down arrow to continue.

H7 Odometer =

___; (mile) Total accumulated miles the truck has traveled. H7 can be increased or decreased if a module has been replaced. To increase/ decrease, press the right arrow. H7 Odometer will be displayed. Press right arrow to edit. Use up/down arrows to change value. Press enter/return to return to

H7. Press down arrow to continue.

H8 PM Timer;

Sets a timer to alert the operator

Planned Maintenance is due. Press the right arrow to set up the PM Timer.

H8.1 Tag =

___; Determines which hour meter will be monitored. Press the right arrow. Use the up/down arrows to select:

•

None disables PM Timer

•

H1 Monitors H1 Runtime1

•

H2 Monitors H2 Runtime 2

•

H3 Monitors Access 1 hour meter

•


•


•

H6 Monitors Steer Motor hour meter

•

H7 Monitors Odometer

Press enter/return at desired meter. This will return to

H8.1 menu. Press the down arrow.

H8.2 Interval =

___; Sets the interval between alerts.

Press the right arrow to edit interval between alerts.

Use the up or down arrows to change value. Press enter/return to accept value and return to H8.2 menu. (Example: Interval = 250, when the monitored hour meter increases 250 hours from the current reading an alert will be given to the operator.) Press left arrow twice to return to HOUR. Press the down arrow to continue.

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Event Menu

Events are viewed only from the Operator Message

Mode. Level 2 and Level 3 allows access to view events in chronological order or accumulated and provide hour meter reading and battery state of charge when the event occurred. The following description is for Level 3 menu only.

To enter level 3:

Key up the truck. Use the up or down arrows to scroll to Service. Press the right arrow once.

Press the down arrow once. Press the right arrow and use up/down arrows to enter the first digit of the password. Press the right arrow to move to the next digit, use up/down arrows to enter next digit, continue until all digits of the password are entered. Press enter/return button to accept password. Use the up or down arrows to scroll to Events. Press the right arrow.

E1 Chron History

To view a chronological listing of the last 16 events beginning with the last event logged, press the right arrow.

E1.1 Last;

Displays last logged event. Press right arrow to view Code = ___. Press the up/down arrow to view the hour meter reading of the truck when the last event was logged. Press the up/down arrow to view the battery state of charge (SOC) when the last event was logged. Press the left arrow to return to E1.1. Press the down arrow to continue viewing the logged events from

Last to Last - 15. The hour meter and battery state of charge for each event can also be viewed. Press the left arrow to return to E1. Press the down arrow to continue.

E2 Accum History;

View the number of times a specified event has occurred. Press the right arrow.

Event ___ Occurrences = ___;

Use up/down arrows to scroll through the accumulated events. Press the left arrow to return to E2 menu. Press down arrow to continue.

E3 Clear History

This menu is used to clear logged event history. Press the right arrow.

E3.1 Clear Chronological;

Press the right arrow to clear the chronological listing of event codes. Use up/ down arrow to change to Yes. Press enter/return to clear. Press left arrow to return to E3.1 menu. Press the down arrow to continue.

E3.2 Clear All;

Press the right arrow to clear all stored event history. Press right arrow, use up/down arrow to select Yes. Press enter/return to clear to return to E3.2.

Press left arrow twice to return to Events.

Utilities Menu

Utilities are viewed only from level 2 and level 3 menus and are not available in the operator message mode.

The following description is for level 3 menu only.

To enter level 3:

Key up the truck. Use up/down arrows to scroll to Service. Press the right arrow once.

Press the down arrow once. Press the right arrow and use up/down arrows to enter the first digit of the password. Press the right arrow to move to the next digit.

Use up/down arrows to enter the next digit of the password, continue until all digits of the password are entered. Press enter/return button to accept password.

Use up/down arrows to scroll to Utilities. Press the right arrow.

U1 Part Numbers;

View module and software part numbers. Press down arrow to continue.

U1.1 Access1;

View display module part numbers.

Press right arrow to continue.

U1.1.1 Module =

___; Displays Access1 hardware part number. Press the down arrow to continue.

U1.1.2 Software =

___; Displays the software part number in Access1. Press left arrow to return to U1.1

menu. Press down arrow to continue.

U1.2 Access2;

View hydraulic control module part numbers. Press right arrow to continue.

U1.2.1 Module =

___; Displays Access 2 hardware part number. Press the down arrow to continue.


___; Displays the software part number in Access 2. Press the left arrow to return to

U1.2 menu. Press the down arrow to continue.

U1.3 Access3;

View traction control module part numbers. Press right arrow to continue.

U1.3.1 Module =

___; Displays Access 3 hardware part number. Press the down arrow to continue.


___; Displays the software part number in Access 3. Press the left arrow to return to

U1.3 menu. Press the left arrow to return to Utilities. To exit level 3 menu truck must be keyed off then back on.

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Performance

The performance menu is shown on the following pages. The features menu determines adjustable ranges for several performance items. Verification of proper features settings is recommended prior to setting up performance.

P1, P2 and P3:

Three performance levels may be selected from when in the operator mode. These settings affect forward and reverse travel speed and acceleration rate. Refer to F8 in the features menu to enable / disable.

Settings for each performance level can be higher, lower or the same as the setting under any other performance level, for example - traction speeds forward and reverse can be the same for all performance levels and the acceleration rate can be different for all performance levels.

Performance Access

Power up the truck, navigate to the SERVICE menu by pressing the down arrow button. At the SERVICE menu, press the right arrow to enter LEVEL 2. Press the right arrow again to enter the Access password.

Use the up/down arrow buttons to change number, press right arrow to move to the next number. Once all numbers in the Access code have been entered press the enter/return button. Using the down arrow navigate to the PERFORMANCE menu, and then press the right arrow. This message displayed will be P1 Setup P1.

P1 Setup P1 -

Enter the parameters for the P1 level in this sub menu. Press the right arrow to view/modify the current P1 settings.

P1.1 Forward =

___ mph; Maximum forward (forks first) traction speed. To modify press the right arrow and use up/down arrows to select desired speed.

Range is from 1 to 9.0 mph for 36V, 1 to 11.0 mph for

48V. Factory setting is 9.0 for 36V, 11.0 for 48V. Press the enter/return button to accept. The menu will return to P1.1; press the down arrow to continue.

P1.2 Rev =

___ mph; Maximum reverse (power unit first) traction speed. To modify, press the right arrow and use the up/down arrows to select desired speed.

Range is 1 to 9.0 mph for 36V, 1 to 11.0 mph for 48V.

Factory setting is 9.0 for 36V, 11.0 for 48V. Press the enter/return button to accept. The menu will return to

P1.2, press the down arrow to continue.

P1.3 Accel =

___; Acceleration rate (time for truck to go from stop to top speed). To modify press the right arrow and use the up/down arrows to select desired acceleration rate. Range is 1 for the longest acceleration time to 9 for the shortest acceleration time. Factory setting is 7. Press the enter/return button to accept.

The menu will return to P1.3.

Press the left arrow to return to P1. Press the down arrow to go to P2 or the left arrow to exit to the main menu.

P2 Setup P2 -


P2.1 Forward =


Range from 1 to 9.0 mph for 36V, 1 to 11.0 mph for

48V. Factory setting is 9.0 for 36V, 11.0 for 48V. Press the enter/return button to accept. The menu will return to P2.1, press the down arrow to continue.

P2.2 Rev =

___ mph; Maximum reverse (power unit first) traction speed. To modify press the right arrow and use the up/down arrows to select desired speed.

Range is 1 to 9.0 mph for 36V, 1 to 11.0 for 48V. Factory setting is 9.0 for 36V, 11.0 for 48V. Press the enter/ return button to accept. The menu will return to P2.2, press the down arrow to continue.

P2.3 Accel =


The menu will return to P2.3

Press the left arrow to return to P2 Setup P2. Press the down arrow to go to P3 or the left arrow to exit to the main menu.

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P3 Setup P3 -


P3.1 Forward =


Range from 1 to 9.0 mph for 36V, 1 to 11.0 mph for

48V. Factory setting is 5.0 for 36V, 5.0 for 48V. Press the enter/return button to accept. The menu will return to P3.1, press the down arrow to continue.

P3.2 Rev =

___ mph; Maximum reverse (power unit first) traction speed. To modify press the right arrow and use the up/down arrows to select desired speed.

Range is 1 to 9.0 mph for 36V, 1 to 11.0 mph for 48V.

Factory setting is 5.0 for 36V, 5.0 for 48V. Press the enter/return button to accept. The menu will return to

P3.2, press the down arrow to continue.

P3.3 Accel =


The menu will return to P3.3

Press the left arrow to return to P3 Setup P3. Press the down arrow to go to P4 or the left arrow to exit to the main menu.

P4 Bdi;

Enter the parameters for battery discharge indication. Press right arrow to view/modify the current

P4 settings.

Note:

A full description of this setting can be found in the battery section of this manual.

P4.1 Upper Voltage Threshold =

___; Adjusts the voltage level necessary for the display to transition from 100% to 90%. Press right arrow to edit. Use up/ down arrows to change the value, factory setting is 4.

Press enter/return to return to P4.1. Press down arrow to continue.

P4.2 Lower Voltage Threshold =

___; Adjusts the voltage level necessary for the display to transition from 20% (yellow bar flashing) to 10% (lift lock-out).

Press right arrow to edit. Use up/down arrows to change the value, factory setting is 7. Press enter/return to return to P4.2. Press left arrow to return to P4.

P5 Plug =

___; Setting allows the adjustment of plugging distance. The longest plugging distance will occur with the accelerator pedal near the neutral position and

P5 setting of 1. The shortest plugging distance is achieved when the accelerator pedal is fully depressed and P5 setting of 9.

Press the right arrow to modify. Range is 1 to 9. Factory setting is 6. Press the enter/return button to accept. The menu will return to P5, press the down arrow to continue.

P6 Coast =

___; Controls the amount of regenerative braking current applied to the drive motor when the operator returns the accelerator pedal to neutral while the truck is moving. The higher the setting, the lower the amount of regenerative braking current applied to the drive motor, resulting in the longest coasting distance.

The lower the setting, the higher the amount of regenerative braking current applied to the drive motor, the shorter the coasting distance.Press the right arrow to adjust. Use the up/down arrows to select desired amount of regenerative braking applied. Range is from

1 to 9, factory setting is 9. Press the Enter button to save. Display returns to P6 Coast =, press the down arrow.

P7 Perf > FL;

Affects truck performance with forks raised above free lift. Press the right arrow to modify.

P7.1 Speed FWD =

___; Affects the traction speed when the forks are above free lift and traveling in the forks first direction. Range is 1 mph for the slowest traction speed to 4 mph for the maximum traction speed. Factory setting is 4.0. Press the right arrow to adjust. Use the up/down arrows to select desired setting. Press the enter/return button to accept. The menu will return to P7.1, press the down arrow to continue.

P7.2 Speed REV =

___; Affects the traction speed when the forks are above free lift and traveling in the power unit first direction. Range is 1 mph for the slowest traction speed to 4 mph for the maximum traction speed. Factory setting is 4.0. Press the right arrow to adjust. Use the up/down arrows to select desired setting. Press the enter/return button to accept. The menu will return to P7.2, press the down arrow to continue.

P7.3 Accel FL =

___; Affects the acceleration rate when the forks are above free. Range is 1 for the longest acceleration time to 9 for the shortest acceleration time. Factory setting is 5. Press the right arrow to adjust. Use the up and down arrows to select desired setting. Press the enter/return button to accept. The menu will return to P7.3, press the down arrow to continue.

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ELECTRICAL


P7.4 Plug FL =

___; Affects plugging distance when the forks are above free lift. Press the right arrow to adjust. Use up/down arrows to select desired setting.

Range is 1 for the longest plugging distance to 9 for the shortest plugging distance, with the accelerator pedal fully depressed. Factory setting is 7. Press the enter/ return button to accept. The menu will return to P7.4.

Press the left arrow to go to P7 menu, press the down arrow button to continue.

P99 Load factory defaults -

Loads factory settings for all Performance menu levels. Press the right arrow to select this feature. Use up arrow to select "Y" to accept factory settings. Display returns to P99, press the left arrow to exit to main menu.

P3.2

P3.3

P4.1

P4.2

P5

P6

P7.1

P7.2

P7.3

P7.4

Menu

P1.1

P1.2

P1.3

P2.1

P2.2

P2.3

P3.1

Chart 1 - Factory Defaults

6

9

4.0

4.0

5.0

1

4

7

5

7

36V Setting

9.0

9.0

7

9.0

9.0

4

5.0

6

9

4.0

4.0

5.0

1

4

7

5

7

48V Setting

11.0

11.0

7

11.0

11.0

4

5.0

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ELECTRICAL

Distribution Board


The distribution board is mounted in the electronics compartment under the left side step. Access the distribution panel by removing the left side step plate that covers the electronic compartment. The board has connectors CA201 through CA207 for connections to display, accessories, key switch, truck bus bar located under battery compartment, optional power supply as well as various switches. Test points TP 1 thru 4 are located on board for troubleshooting truck system.

There are separate distribution boards used for 36 and

48 volt trucks. Refer to truck's data plate for battery voltage information.

Components Included On Distribution Board

•

Relay K1 is used for truck power-up.

•

Relay K2A seat relay is activated by seat and used for brake pressure alarm (ALM2).

•

Relay K2B is used for travel alarm (ALM3).

•

Fuse FU4 protects control circuits from overcurrent.

•

Fuse FU5 protects optional accessory circuits from overcurrent.

•

Fuse FU8 protects motor controller circuit from overcurrent.

Crown 2007 PF17000-1 Rev. 11/08

(1)

(2)

(3)

Distribution Panel Cover

Electronics Compartment

Distribution Board

Figure 17395

Figure 17396

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Distribution Board Jumper Configurations

On the distribution board are jumpers J2 and J3 to allow selection of certain truck optional features.

•

J2 can be jumpered to allow for alarm (ALM3) to sound when forward direction of travel is selected.


•

J3 can be jumpered to allow for alarm (ALM3) to sound when reverse direction of travel is selected.


•

J2 and J3 can both be jumpered to allow for alarm

(ALM3) to sound when either direction of travel is selected. Refer to Figure 17399.

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J2 Configured for ALM3 to sound when forward direction of travel is selected.

ELECTRICAL


Crown 2007 PF17000-3 Rev. 11/08

Figure 17397

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207

ELECTRICAL


J3 Configured for ALM3 to sound when reverse direction of travel is selected.

M4.3-2045-103

01 Rev. 11/08

208

Figure 17398

Crown 2007 PF17000-4 Rev. 11/08

J2 and J3 Configured for ALM3 to sound when forward or reverse direction of travel is selected.

ELECTRICAL


Crown 2007 PF17000-5 Rev. 11/08

Figure 17399

M4.3-2045-104

01 Rev. 11/08

209

Notes:

210

Potentiometers

Accelerator Potentiometer (POT1)

The accelerator potentiometer is located below the floorboard on the accelerator mechanism.

POT1

ELECTRICAL

Potentiometers

Figure 17473

This potentiometer provides accelerator position information to Access 3, which controls the speed of the truck.

Removal/Installation

1.

Turn key switch OFF, disconnect battery and remove mat and both front and rear floorboard sections.

2.

Disconnect wire harness (CA612) from potentiometer.

3.

Remove two screws holding potentiometer to the accelerator assembly.

4.

Install replacement potentiometer and secure with screws.

5.

Connect wire harness (CA612) to potentiometer.

6.

Replace floorboards and calibrate new potentiometer.

NOTE

For accelerator switch (ACS) adjustments refer to

Switches maintenance section.

Crown 2007 PF17001-1 M4.3-2045-200

211

Notes:

212

ELECTRICAL

Contactors

Contactors

140538-001/-002 Contactor

(36/48 Volt) S (Steering)

132084-005/-006 Contactor L (Line)

& P (Pump)

The purpose of these instructions is to instruct the technician on proper care and maintenance to obtain satisfactory service from these devices. Crown has tested and applied these contactors according to the requirements of our vehicle. No modifications or changes should be made in the layout, physical arrangement or electrical connections without permission from Crown.

CAUTION

Before any inspection, adjustments, servicing, parts replacement or any other act is performed requiring physical contact with the electrical working components or wiring of these contactors, disconnect battery, raise drive wheels clear of floor and place blocks under truck frame.

Inspection

The following information is intended to assist during periods of normal maintenance and to provide checks for maintaining adjustments. As these devices are tested and adjusted at the factory, they should not normally require further adjustments. However, if factory adjustments are tampered with or otherwise changed, then the checks contained in the following information may be made.

Contacts

•

In normal operation, contacts will become blackened, discolored and roughened. This condition will not interfere with proper operation and cleaning is not necessary.

•

Contacts should be replaced before the silver contact facing is completely eroded through to the backing material. The silver contact facing may transfer to the moving contact or stationary contact and cause buildup on a contact. This condition can be expected under certain conditions and does not require contact dressing or filing.

•

It is recommended that contacts always be replaced in pairs.

Crown 2007 PF17043-1 Rev. 3/08 M4.4-2045-001

01 Rev. 3/08

213

ELECTRICAL

Contactors

Steering Contactor

Coil

•

Remove all electrical connections to coil.

•

Resistance reading of the coil should be approximately 174 ohm.

•

If reading does not fall within these limits, then replace as necessary.

Component Replacement

Refer to Figure 17863 and parts breakdown in the contactor section.

Contact Replacement

1.

Remove electrical connections to contacts (coils do not have to be disconnected for this procedure).

2.

Remove two screws (Index 6) from top of contacts and lift contact assembly from truck.

3.

Disassemble and replace contacts.

4.

Install contact assembly on coils and fasten securely with two screws (Index 6).

5.

Reconnect all electrical connections.

Coil Replacement

1.

Disconnect all electrical wiring.

2.

Remove the four contactor mounting screws and remove contactor from truck.

3.

Remove two screws (Index 6) and separate contact assembly from coil assembly.

4.

Select replacement coil and transfer plunger

(Index 2) from coil being replaced to replacement coil.

5.

Reassemble contact assembly to coil assembly and secure with two screws (Index 6).

6.

Mount contactor on truck and reconnect all electrical wiring.

(a)

Torque 13.4 - 14.6 Nm

(9.9 - 10.8 ft lb)

M4.4-2045-002

01 Rev. 3/08

214

Figure 17863

Crown 2007 PF17043-2 Rev. 3/08

ELECTRICAL

Contactors

"EE" Component Replacement

Refer to Figure 17864 and parts breakdown in the contactor "EE" section.


1.


2.

Remove two screws (Index 10) from top of contacts and lift contact assembly from truck.

3.


4.

Install contact assembly on coils and fasten securely with two screws (Index 10).

5.



1.


2.


3.

Remove two screws (Index 10) and separate contact assembly from coil assembly.

4.



5.

Reassemble contact assembly to coil assembly and secure with two screws (Index 10).

6.


(a) Torque 13.4 - 14.6 Nm

(9.9 - 10.8 ft lb)

Crown 2007 PF17043-3

Figure 17864

M4.4-2045-003

215

ELECTRICAL

Contactors

Line and Pump Contactor

Coil

•

Remove all electrical connections to coil.

•

Resistance reading of the coil should be approximately 44 ohm.

•

If reading does not fall within these limits, then replace as necessary.

Component Replacement

Refer to Figure 17400 and parts breakdown in the contactor section.

M4.4-2045-004

216

(a) Torque 13.4 - 14.6 Nm

(9.9 - 10.8 ft lb)

Figure 17400

Crown 2007 PF17043-4

ELECTRICAL

Contactors


1.


2.

Remove two screws and washers (Index 2) from top of contacts and lift contact assembly from truck.

3.


4.

Install contact assembly on coils and fasten securely with two screws and washers (Index 2).

5.



1.


2.


3.

Remove two screws and washers (Index 2) and separate contact assembly from coil assembly.

4.



5.

Reassemble contact assembly to coil assembly and secure with two screws and washers (Index 2).

6.


"EE" Component Replacement

Refer to Figure 17401 and parts breakdown in the contactor "EE" section.

(a)

Torque 13.4 - 14.6 Nm

(9.9 - 10.8 ft lb)

Crown 2007 PF17043-5

Figure 17401

M4.4-2045-005

217

ELECTRICAL

Contactors


1.


2.

Remove two screws and washers (Index 4) from top of contacts and lift contact assembly from truck.

3.


4.

Install contact assembly on coils and fasten securely with two screws and washers (Index 4).

5.



1.


2.


3.

Remove two screws and washers (Index 4) and separate contact assembly from coil assembly.

4.

Select replacement coil and transfer plunger (Index 9) from coil being replaced to replacement coil.

5.

Reassemble contact assembly to coil assembly and secure with two screws and washers (Index 4).

6.


M4.4-2045-006

218

Crown 2007 PF17043-6

ELECTRICAL

Battery

Battery

The care and maintenance of the battery is very important to obtain efficient truck operation and maximum battery life.

CAUTION

Gases produced by a battery can be explosive. Do not smoke, use an open flame, create an arc or sparks in the vicinity of the battery. Ventilate an enclosed area well when charging.

Batteries contain sulfuric acid which may cause severe burns. Avoid contact with eyes, skin or clothing. In case of contact, flush immediately and thoroughly with clean water. Obtain medical attention when eyes are affected. A baking soda solution (one pound to one gallon of water) applied to spilled acid until bubbling stops, neutralizes the acid for safe handling and disposal.

Leaking voltage from battery terminals to battery case can cause misleading trouble symptoms with the truck electrical system. Since components of the truck electrical system are insulated from truck frame, leaking voltage will not normally affect truck operation unless a short circuit or breakdown of circuit wire insulation to truck frame occurs.

A voltage check from battery connector terminal to battery case should indicate near zero volts. Typically the sum of the voltages at both terminals will equal battery voltage. This leakage will discharge the battery. As battery cleanliness deteriorates, the usable charge of the battery decreases due to this self discharge.

Although a leakage voltage reading of zero volts may not be possible, a cleaner battery will have more usable charge for truck operation and not affect operation of electronic devices on the unit.

Safety Rules

•

Wear protective clothing such as, rubber apron, gloves, boots and goggles when performing any maintenance on batteries. Do not allow electrolyte to come in contact with eyes, skin, clothing or floor.

If electrolyte comes in contact with eyes, flush immediately and thoroughly clean with water. Obtain medical attention immediately. Should electrolyte be spilled on skin, rinse promptly with clean water and wash with soap and water. 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 firmly in place at all times except when adding water or taking hydrometer readings.

•

Do not bring any type of flame, spark, etc., near the battery. Gas formed while the battery is charging, is highly explosive. This gas remains in the cells long after charging has stopped.

•

Do not lay metallic or conductive objects on battery. Arcing will result.

•

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

•

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

Checking Battery

Battery electrolyte level should be checked before each charge of the battery. The level should be maintained at 13 mm (0.5 in) above plates or just below lower lip of the filler hole at all times. If low, add distilled water or approved local supply (consult battery manufacturer) at the end of a charge cycle. Do not overfill.

For maximum battery life, specific gravity readings should be taken daily on a pilot cell and recorded. A different pilot cell should be selected on a monthly basis with readings taken on all cells at semi annual or annual intervals. Do not take specific gravity readings immediately after adding water. Water and electrolyte must be thoroughly mixed by charging before a reliable reading can be taken. Normal full charged specific gravity should be between 1.265 and 1.285.

Crown 2008 PF17252-1 Rev. 11/08 M4.6-2045-001

01 Rev. 11/08

219

ELECTRICAL

Battery

Battery Care

Your Crown truck is powered by an electrical storage battery. Here are a few suggestions which will help you give the battery proper care.

The battery is located beneath the operator’s seat.

1.

Charge the battery only in areas designated for that use.

2.

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

3.

Before disconnecting or connecting batteries to a charger, make sure the charger is OFF. If you attempt any action while the charger is ON, then serious injury to you, the battery and/or the charger could result.

4.

Before charging, make sure the battery cells contain the correct amount of water. Charging the batteries with a low water level might result in damage to the cells. When checking the water levels, never use any type of open flame, battery fumes are explosive.

5.

Before connecting the battery cable to the truck’s receptacle, make sure the key switch is off, controls are in the off position and parking brake is on.

The battery cable must be fully connected before the truck is used. If the plug is not making good contact, heat will weld the two parts of the battery connector together, making it difficult to remove and necessary to replace.

6.

Battery terminals should be checked and cleaned of corrosion regularly. Good battery terminal contact is essential not only for operation, but also for proper charging of the battery.

7.

Charging requirements will vary depending on the use of the truck. The battery should be given an equalizing charge on a weekly basis. This charge should normally be an additional three hours at the finish rate.

8.

Refer to charger manufacturer's manual for specific charging procedures.

9.

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

Charging Battery

Charging requirements will vary depending on use of truck. A battery with a specific gravity of 1.160 or less should be recharged. In some applications more than one battery is required to provide ample power to the unit during the service period.

CAUTION

Never smoke or bring open flame near the battery. Gas formed during charging is highly explosive and can cause serious injury.

Consult the charger manufacturer's manual covering your charger for hints on operation and maintenance.

Some of the basic rules are as follows:

Placing battery on charge:

•

Park truck at charging station with forks lowered and key removed. Raise seat deck for venting.

•

Make certain charger control is in off position.

•

Connect battery to charger and make certain connectors are mated completely.

•

Set timer for specified time. Set for normal (Daily

Charge, except one night a week when the equalize [Weekend] Charge should be used).

•

Check ammeter to make certain it shows charge.

Removing battery from charge:

•

Make certain charger is turned off.

•

Unplug the connector, using both hands with a straight pulling motion.

•

Hang up the charger cable to prevent damage to the cable. (Broken connectors can cause poor connections and connector failures).

•

Make daily battery checks, add distilled water as needed.

•

Connect battery to truck. Make certain connections are mated completely.

M4.6-2045-002

220

Crown 2008 PF17252-2

ELECTRICAL

Battery

Battery Removal

CAUTION

Do not allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing or transporting the battery. Use an insulator (such as plywood) to cover the top of the battery before and during removal and installation.

1.

Turn key switch OFF and apply parking brake.

2.

Disconnect battery.

3.

Tilt steering wheel up and raise battery cover.

6.

If a roller stand is going to be used, then make sure the stand is the same height as the rollers in the battery compartment and is at least as long as or longer than the battery.

CAUTION

If truck has battery rollers, when removing battery retainer side panel assembly make sure battery is secured so that it does not prematurely roll out of truck.

4.

Remove battery retainer side panel assembly from truck.

5.

The overhead guard has a cut out to permit use of a lifting device to aid in battery removal. Use only an approved spreader bar and adjust width to battery size. Connect spreader bar to lifting device, and the hooks to the lifting holes in the side of the battery.

Figure 17343

7.

Remove the battery from the truck. As stated in the

CAUTION, never let anything metallic touch the top of the battery, or insulate as required.

Battery Installation

CAUTION

Do not allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing or transporting the battery. Use an insulator (such as plywood) to cover the top of the battery before and during removal and installation.

1.

Check to make sure key switch is turned OFF.

2.

Remove battery retainer side panel assembly from right side of truck.

Crown 2008 PF17252-3

Figure 17342

M4.6-2045-003

221

ELECTRICAL

Battery

3.

The overhead guard has a cutout to permit use of a lifting device to aid in battery installation. Use only an approved spreader bar and adjust width to battery size. Connect the spreader bar to the lifting device, and the hooks to the lifting holes in the side of the battery.

4.

If a roller stand is going to be used make sure the stand is the same height as the rollers in the trucks battery compartment and is at least as long as or longer than the battery.

5.

Install battery into truck.

6.

Install battery retainer side panel assembly onto truck. Remove spreader bar, if used.

Seat Deck Cover Adjustment

1.

With the seat deck down the gap between rear of the seat deck and lower tube on overhead guard should be uniform.

2.

If gap is larger or smaller, adjust gap by moving mounting bracket to a different slot and recheck for a uniform gap across back of seat deck.

3.

For side to side adjustment, place flatwashers on the RH pivot only. Flatwashers can be placed on both sides or all on the same side, depending upon the adjustment needed to center the seat deck on the truck relative to the counterweight. There should be 4 mm (0.15 in) from the seat deck flange to the outside of the counterweight on each side.

7.

Connect battery, lower and latch battery cover and return steering wheel to a comfortable position.

8.

Check truck operation.

Figure 17344

CAUTION

Make certain same battery or battery of equal weight is loaded into truck for stability. See nameplate for minimum battery weight.

Figure 17345-01

3

4

1

2

5

6

Adjustment for gap between Seat Deck and Counter

LH Side Adjustment

RH Side Adjustment

Part of Overhead Guard

Side to side

Mounting Bracket

4.

The left hand side adjustment for trucks equipped with optional full side covers should be adjusted for a uniform gap along the left side of truck using height adjustment bolt.

5.

For trucks without full side covers, this is the down stop for the left hand side of seat deck.

Crown 2008 PF17252-4 M4.6-2045-004

222

6.

The right hand hold down bracket is adjusted with the slots to engage the stub shaft in control lever assembly. The stub shaft should bottom out in groove of the hold down bracket when seat deck is completely down.

Seat Deck Latch Adjustment

1.

The handle latch bar should be adjusted with the gas cylinders disconnected from seat deck and seat deck completely down against stops. Refer to

Seat Deck Section.

2.

By adding or removing shims, adjust the latch bar to within 3 mm (0.12 in) of back of the latch slot.

3.

Adjust screw and jam nut so that the front face of the handle is aligned with the front face of the seat deck.

1

2

3

Handle

Screw and Jam Nut

Hold Down Bracket

ELECTRICAL

Battery

Figure 17347-01

7

8

5

6

3

4

1

2

Part of Seat Deck

Side view of Seat Deck Latch

Handle

Latch

Spacers

Latch Bar

Part of front battery wall

Latch Bar

Crown 2008 PF17252-5

Figure 17346-01

M4.6-2045-005

223

ELECTRICAL

Battery

Seat Deck Cylinders

Removal

1.

Raise seat deck and rest against rubber stops on overhead guard.

2.

Loosen flange nut but do not remove nut at this time.

3.

Insert a 65 mm (2.55 in) long, 8 or 10 mm (0.32 or

0.39 in) diameter rod into the removal hole.

4.

Position pry bar as shown in Figure 17348-01 and apply downward pressure on pry bar to push the cylinder down and allow it to slip into installation position for removal.

5.

Remove flange nut and washers, then remove cylinder from seat deck and overhead guard.

6.

Repeat above steps for left hand cylinder.

Installation

1.

Raise seat deck and rest against rubber stops on overhead guard.

2.

Attach lower rod end to overhead guard mounting location first as this will allow the upper rod end to be mounted into the "j" slot.

3.

Insert upper rod end into "j" slot and install washers on each side of the flange containing the "j" slot.

Also install flange nut but do not tighten nut at this time.

4.

Insert a 65 mm (2.55 in) long, 8 or 10 mm (0.32 or

0.39 in) diameter rod into the installation hole.

5.

Position pry bar as shown in Figure 17348-01 and apply downward pressure on pry bar to push the cylinder down and allow it to slip into final installation position.

6.

Torque flange nut to 45 Nm (33 ft lb).

7.

Repeat above steps for left hand cylinder.

M4.6-2045-006

224

Crown 2008 PF17252-6

ELECTRICAL

Battery

3

4

1

2

5

Removal

Removal hole

Pry bar

“J” slot

66 mm (2.55 in) length, 8 mm (0.32 in) or 10 mm (0.39 in) diameter rod

8

9

6

7

RH Cylinder

Initial installation position

Installation hole

Installed position

10 LH Cylinder

11 Lower Rod End

12 Torque to 45 mm (33 ft lb)

Crown 2008 PF17252-7

Figure 17348-01

M4.6-2045-007

225

ELECTRICAL

Battery

Battery Cleaning

Always keep vent plugs tightly in place when cleaning battery. When properly watered and charged, the battery will remain clean and dry. Brush or blow off any dust or dirt that may accumulate on battery. However, if electrolyte is spilled or overflows from a cell, it should be neutralized with a solution of baking soda and water

(one pound to one gallon of water). Remove battery from truck and clean with the solution of baking soda and water, brushing the soda solution beneath the connectors and removing grime from the covers. Then rinse the battery with cool water from a low pressure supply to remove the soda and loosen dirt. If batteries stay wet consistently, they may be either overcharged or over filled. This condition should be investigated and corrected.

Troubleshooting

Records of battery specific gravity readings, charger used, truck used, etc. can be a most effective troubleshooting aid. Contact your dealer for charts specifically for this purpose.

Voltage readings of each cell taken at the normal charger finish rate also indicate battery condition. New batteries will have cell voltages from 2.55 to 2.65 volt.

Older batteries may however range from 2.45 to 2.55

volt. These readings still indicate that the battery is in good condition.

A variation of .20 volt may be normal if certain cells are exposed to higher temperatures during discharge.

Voltage differences that cannot be attributed to battery age or operating conditions indicate a weak cell(s) and maintenance is required.

Dual Voltage Conversion

This truck is dual voltage capable. Voltage conversion requires a feature menu setting change. Make the change in ACCESS 123… System section, Features,

F5 menu, also make changes shown in Chart 1 - Dual

Voltage Conversion.

Chart 1 - Dual Voltage Conversion

Component

SV1 Coil

SV2 Coil

K1

K2

SV3 Coil

(TPA Option)

Operator Fan

Back Up Bulb

RES2

Freezer/Corrosion

RES3

Freezer/Corrosion

Foot Operated

Directional Control

Freezer/Corrosion

Harness

36 Volt

Part Number

127269-001

127269-001

062640-002

062711-001

If Present

48 Volt

Part Number

127269-002

127269-002

062640-003

062711-002

127269-001

127259-005

117993

130117-001

130117-001

130583

127269-002

127259-006

117994

130117-002

130117-002

130584

CAUTION

Only qualified and experienced personnel should perform maintenance and repair on batteries.

M4.6-2045-008

226

Crown 2008 PF17252-8

ELECTRICAL

Battery

Battery Discharge Interrupt Performance (P4)

This adjustment allows the battery discharge interrupt to accurately compensate for the actual battery being used. The factory preset value represents a typical battery for a particular compartment size and is satisfactory in most cases. However, if the indicator is showing

100% discharge, or the interrupt is locking out the lift function, at too high (greater than 1175 specific gravity) or too low (less than 1140 specific gravity), the P4 setting is not suited to the actual battery being used.

If several different batteries are used in the truck and the range in battery capacity is greater than 200 AH, the battery with the highest ampere hour rating should be used for the adjustment procedure. The factory setting for P4.1 is 0 and P4.2 is 2.

The controller performs the following to determine battery state of charge:

1.

Voltage sampling is done with the truck in standby

(traction motors not running) and occurs every

250ms.

2.

Samplings are averaged together and retained in memory.

3.

These samplings are compared with a software table determined by the combination of P4 settings and C2 values, then the level of charge is determined (see chart 2 for 48 and 36 volt batteries at factory settings) and displayed.

4.

If, after 15 minutes, the truck has not been in a standby state long enough to obtain thirty averages, the controller will decrease the discharge percentage by 5% regardless of actual state of charge.

5.

Battery discharge level can reach 100% at key-on only when the battery voltage determined by the

P4.1 setting is achieved and the percentage of change from the last time the battery was unplugged from the truck is greater than 15% (i.e. unplugged at 80% truck must reach a minimum charge of 96% to update the display; unplugged at

86% even if the battery achieves the corresponding P4.1 setting voltage it will not display 100%).

Chart 2 - Charge Level Comparison With

P4.1 and P4.2 at Factory Settings

Battery Charge % 36 V Battery 48 V Battery

100 > 37.60 V > 50.20 V

90

80

<= 37.60 V

<= 37.48 V

<= 50.20 V

<= 50.00 V

70

60

50

40

30

20 (Yellow Bar

Flashing)

10 (Lift Lock-Out)

<= 37.20 V

<= 36.93 V

<= 36.80 V

<= 36.68 V

<= 36.63 V

<= 36.13 V

<= 35.90 V

<= 49.60 V

<= 49.20 V

<= 49.00 V

<= 48.80 V

<= 48.70 V

<= 48.00 V

<= 47.70 V

Crown 2008 PF17252-9 Rev. 11/08 M4.6-2045-009

01 Rev. 11/08

227

ELECTRICAL

Battery

The following steps should be taken to optimize BDI performance:

1.

Start with a fully charged and equalized battery of the size and condition that will normally be used in the truck.

2.

Measure and record battery open circuit voltage.

3.

Complete C2 calibration procedures.

4.

Run truck through one complete battery cycle, under normal working conditions.

5.

When truck reaches 10% (lift lock-out) measure and record battery open circuit voltage.

6.

Adjust P4.1 according to Chart 3 for 48 V or 36 V batteries, based on voltage recorded in step 2.

7.

Adjust P4.2 according to Chart 3 for 48 V or 36 V batteries, based on voltage recorded in step 5.

8.

Fully charge the battery.

9.

Perform steps 2 thru 8 until desired performance is achieved.

Voltage values between 90% and 10% in the charts are modified linearly after P4.1 and P4.2 are set.

Chart 3 - Factory Setting for P4.1 and P4.2

6

7

4

5

8

9

2

3

0

1

Setting

P4.1 Settings 100% to 90% Transition

P4.2 Settings 20% to

10% Transition (Lift

Lock-out)

36 V

Battery

48 V

Battery

36 V

Battery

48 V

Battery

36.5 V

36.7 V

37.0 V

37.3 V

37.6 V

37.8 V

38.1 V

38.6 V

38.9 V

39.5 V

49.1 V

49.3 V

49.6 V

49.9 V

50.2 V

50.4 V

50.7 V

51.2 V

51.5 V

52.1 V

34.0 V

34.3 V

34.6 V

34.8 V

35.1 V

35.4 V

35.7 V

35.9 V

36.2 V

36.7 V

45.8 V

46.1 V

46.4 V

46.6 V

46.9 V

47.2 V

47.5 V

47.7 V

48.0 V

48.5 V

NOTE

Do not set P4.2 setting for higher voltage than P4.1 setting transition.

M4.6-2045-010

01 Rev. 11/08

228

Crown 2008 PF17252-10 Rev. 11/08

ELECTRICAL

Motors

Motors

This truck is equipped with an AC traction motor. The traction motor has an internal sensor, ECR1, that monitors both motor speed and position. It also contains a thermal sensor that monitors motor temperature.

The truck also has a standard DC lift pump motor, or an optional AC lift pump motor.

The AC lift pump motor has an motor over temperature sensor and an internal encoder, ECR2, that monitors motor speed and position.

Part Number

Voltage

Rated Output

RPM

Direction of Rotation

Motor Diameter

Internal Sensors

AC Motor Information Chart

AC Traction Motor

140199

36/48V

10 kW (13.4 HP)

1580

Bi-Directional

290 mm (11.4 in)

ECR1

AC Lift Pump Motor

021218

36/48V

-

-

CCW

183 mm (7.2 in)

ECR

AC Lift Pump Motor EE

021246

36/48V

-

-

CCW

183 (7.2 in)

ECR

Crown 2007 PF17093-1 M4.7-2045-001

229

ELECTRICAL

Motors

Number of Brush Holders

Number of Brush Springs

Brush Length (New)

Spring Tension (New Brushes)

Minimum Brush Length (Replacement)

Spring Tension (Replacement)

Commutator

Maximum Diameter (New)

Minimum Diameter (Reslotting)

Minimum Diameter (Replace)

Bearing Lubricant

DC Motor Information Chart

DC Lift Pump Motor

8

8

33 mm (1.30in)

1360 grams (48 oz)

16 mm (0.62 in)

907 grams (32 oz)

85.3 mm (3.36 in)

82.3 mm (3.24 in)

81 mm (3.19 in)

Hi Temp Chevron SRI-2 or Equiv. 25 - 30% fill

DC Steer Motor

4

4

28 mm (1.10 in)

1540 grams (55 oz)

15 mm (0.60 in)

980 grams (35 oz)

54 mm (2.12 in)

52 mm (2.05 in)

49 mm (1.93 in)

Hi Temp Chevron SRI-2 or Equiv. 25 - 30% fill

Condition of Performance (No Load)

Volts

Maximum Amps

RPM

Field Resistance - Each at 24° C (75° F)

Series Ohms

Shunt Ohms

Armature Resistance - Each at 24° C (75° F)

Ohms

Measured Between Bars

Frame Diameter

Direction of Rotation

12

56

2175 Minimum

0.0033

0.0033

0.0043

1 and 9

190 mm (7.5 in)

CWDE

12

4

995 Minimum

0.0152

10.1

0.1659

1 and 8

142 mm (5.59 in)

CWDE

M4.7-2045-002

230

Crown 2007 PF17093-2

ELECTRICAL

Event Codes

Event Codes

ACCESS Module Listing:

ACCESS 1: Display Control Module (DCM)

ACCESS 2: Hydraulic Control Module (HCM)

ACCESS 3: Traction Control Module (TCM)

Some Troubleshooting Basics

Statistically the majority of malfunctions occur in or at hardware components, contactors and motors. The next components to test are connectors, wiring and input devices such as switches, potentiometers or encoders. The last component to suspect is the motor control system. In all instances, you should begin your troubleshooting procedure at the driven device, proceed to inputs devices, then, and only then, move on to the control to which these devices attach.

No Event Code?

When the truck malfunctions and no event code is displayed it usually means the malfunction is not electrical.

If the truck powers up, but a code is not displayed, the malfunction is probably mechanical or hydraulic rather than electrical. Information regarding mechanical and hydraulic troubleshooting is located in the appropriate section in this Manual.

WARNING

Never key “ON” truck with any control connectors disconnected. In addition, never remove or connect any control connectors while truck is keyed “ON”.

When a Malfunction Occurs

•

Go to the display and ACCESS the Level 2: Field

Service Mode.

NOTE

Your monitoring system can be accessed at three levels of authorization:

Level 1: Operator Mode

Level 2: Field Service Mode (Full Truck Operation)

Level 3: Analyzer/Test Mode (No Truck Operation)

This section deals with the Level 2 and Level 3. For information on Level 1 see the Operators Manual. Refer to ACCESS 1 2 3…System for display information.

Crown 2007 PF15957-1 Rev. 11/08 M4.8-2045-001

02 Rev. 11/08

231

ELECTRICAL

Event Codes

Display Messages

During truck operation, messages may occur which are intended to provide visual assistance to the operator of the truck. Once the reason for the message is corrected the message will be removed. Following is a list of these messages as viewed on the display with a description of message intent.

Display

BATT LOW

FWD/REV

Return to Neutral

Lift Lockout

Brake Press LOW

Chart 1 -

MESSAGES DURING DISPLAY OPERATION

AND AFTER POWER UP

Release Accel Pedal

Description

Battery charge low. If battery is not low on charge follow procedures for Event 315.

Both directional switches closed. Return directional lever to neutral. If message does not clear, follow NO

EVENT FWD/REV.

Need to place directional control in neutral. If directional control is in the neutral position mechanically, follow NO

EVENT FWD/REV.

Need to place accelerator pedal in full up position. If accelerator pedal is in full up position mechanically, follow procedures for Event 326.

Indicated battery level is at lift interrupt percentage.

Operator has 3 raise attempts left.

Service brake pressure is low.

M4.8-2045-002

02 Rev. 11/08

232

Crown 2007 PF15957-2 Rev. 11/08

Display

EV = 222

EV = 223

EV = 225

EV = 229

EV = 318

EV = 322

EV = 323

EV = 325

EV = 329

Chart 2 -

MESSAGES DURING TRUCK OPEATION

NOT LOGGED IN EVENT HISTORY

Description

ACCESS 2 over temperature, follow procedures for Event 222.

Lift motor over temperature, follow procedures for Event 223.

Lift motor temperature sensor not functioning, refer to Events 222, 223 and 225 for additional information.

Lift motor current sensor not functioning, refer to Events 201, 202, 204, 205 and 208 for additional information.

ACCESS 3 memory read error. Monitor message frequency, if frequency increases for no apparent reason replace ACCESS 3.

ACCESS 3 over temperature, follow procedures for Event 322.

Traction motor over temperature, follow procedures for Event 323.

Traction motor temperature sensor not functioning, refer to Events 322, 323 and 325 for additional information.

Traction motor current sensor not functioning, refer to Events 301, 302, 304, 305 and 308 for additional information.

ELECTRICAL

Event Codes

Crown 2007 PF15957-3 Rev. 11/08 M4.8-2045-003

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233

ELECTRICAL

Event Codes

To Locate Malfunctioning Components

Component and wiring location maps are provided at strategic locations to help you quickly determine the physical location of items in question.

All components are clearly marked at the connection points.

Test Points

Test points referenced in the event code descriptions are located on the distribution panel.

Power Cable Connections.

CAUTION

Due to capacitance voltage present on the motor control panel, whenever performing maintenance which may permit contact with the bus bars and associated power cables, discharge capacitor on the traction control panel by placing a minimum 100 ohm, 2 watt resistor (062033-030) between positive (+) and negative (-) of capacitor for 3 or more seconds.

ACCESS 1

Display Control Module (DCM)

(1)

(2)

(3)

(4)

(6)

(7)

(8)

(5)

Display Screen

Battery Retainer Switch Indicator

Seat Belt Indicator

Enter or Return Key Used to Navigate in and out of menus and to accept inputs

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

Right Arrow) used to scroll through menus

Operator Improper Sequence Error Indicator

Service Required Indicator

Battery Discharge Indicator

*Note: These four indicators are viewable during:

1. Initial key-on

2. Self test

3. Indicator functioning

DCM - ACCESS 1 Display Control Module

HCM - ACCESS 2 Hydraulic Control Module

TCM - ACCESS 3 Traction Control Module

Figure 16569

Crown 2007 PF15957-4 Rev. 11/08 M4.8-2045-004

02 Rev. 11/08

234

Event Code 110

Communication between ACCESS 1, ACCESS 2

(AC lift option) and ACCESS 3 not established at power up.

Step 1:

Check CAN communication path. With key off, battery unplugged and CA204 connected to distribution panel; check resistance between CA204-7 and

CA204-8; CA204-10 & 11 and CA204-16 & 11 on the distribution panel.

•

If: 58 to 62 ohm.

– Then re-key and monitor event frequency.

•

If: 0 ohm.

– Then perform CAN Short Test.

•

If: Greater than 62 ohm or O/L.

– Then perform CAN Open Test.

ELECTRICAL

Event Code 110

Chart 3 - CAN Short Test

1.

Disconnect CA204 from the distribution panel.

2.

Check resistance between PC204-7 and 8 AND PC204-10 and 11.

3.

All resistance values should be approximately 120 ohm.

4.

If either resistance check is less than

115 ohm, check wiring between

ACCESS and distribution panel.

5.

If wiring is correct, then perform CAN terminating resistor test.

Chart 4 - CAN Open Test

1.

Disconnect CA204 from the distribution panel.

2.

Check resistance between PC204-7 and 8 AND PC204-10 and 11.

3.

All resistance values should be approximately 120 ohm.

4.

If either resistance check is Open (O/

L), check wiring between ACCESS and distribution panel.

5.

If wiring is correct, then perform CAN terminating resistor test.

Crown 2007 PF15957-5 Rev. 11/08 M4.8-2045-005

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ELECTRICAL

Event Code 110

Chart 5 - CAN Terminating Resistor Test

1.

Disconnect CA630 from ACCESS 1 and CA402 from ACCESS 3.

2.

Check resistance between CA630-5 and 6 on ACCESS 1.

3.

Check resistance between CA402-17 and 19 on ACCESS 3.

4.

Resistance should be approximately 120 ohm.

5.

Replace ACCESS with resistance less than 115 or greater than 125 ohm.

M4.8-2045-006

02 Rev. 11/08

236

Figure 16570

Crown 2007 PF15957-6 Rev. 11/08

Event Code 111

ACCESS 1 communication with ACCESS 3 time out

Step 1:

Follow Event 110 procedures.

Event Code 112

ACCESS 1 communication with ACCESS 2 time out

Step 1:


Event Code 113

Step 1:

Check voltage at ACCESS 1 CA630-17 (+) and CA630-4 (-), with key on and seat switch closed.

•

If: Less than 34 Vdc (36 volt truck)/46 Vdc (48 volt truck).

– Then check wiring and connections between

FU4 and ACCESS 1.

•

If: 34 to 38 Vdc (36 volt truck) or 46 to 50 Vdc (48 volt truck).

– Then re-key truck, replace ACCESS 1 if event returns.

NOTE

If truck operates this could be a random nuisance code.

Monitor code frequency. If frequency gradually increases for no apparent reason, replace ACCESS 1.

ELECTRICAL

Event Code 111

Figure 16571

Crown 2007 PF15957-7 Rev. 11/08 M4.8-2045-007

02 Rev. 11/08

237

ELECTRICAL

Event Code 119

Event Code 119

ACCESS 1 detects Pump contactor (P) driver shorted (DC lift option)

NOTE

If this event occurs on trucks with AC lift option, verify

Features menu F6 setting is correct; if F6 set to AC, then replace ACCESS 1.

Step 1:

Disconnect wires 2937 and 5913 from pump contactor (P1) and re-key the truck.

•

If: Event clears or changes.

– Then replace pump contactor.

•

If: Event does not clear.

– Then proceed to Step 2.

Step 2:

Disconnect CA630 at ACCESS 1. Check resistance between CA630-1 and CA630-16 with coil wires connected.

•

If: Less than 51 or greater than 57 ohm.

– Then check wiring between CA630 and pump contactor coil.

•

If: 51 to 57 ohm.

– Then replace ACCESS 1.

Event Code 123

Truck Management Module indicates Lift motor

(M2) over temperature (DC lift option)

NOTE

If event occurs on trucks with AC lift option or TMM option not present, then verify Features F6 and F3 are set properly. If F6 set to AC and F3 set to Disabled, then replace ACCESS 1.

Step 1:

Check TMM input voltage to ACCESS 1, enter

Analyzer menu A2.1.10.

•

If: 0.75 to 1.25 Vdc.


•

If: Less than 0.75 Vdc or greater than 1.25 Vdc.


Step 2:

Check voltage between CA208-1 (-) and TP1

(+) at the distribution panel.

•


– Then replace TMM.

•

If: Less than 33 Vdc.

– Then check wiring between CA208 and THS-P

(M2). If wiring correct, replace THS-P.

M4.8-2045-008

02 Rev. 11/08

238

Figure 16572

Crown 2007 PF15957-8 Rev. 11/08

ELECTRICAL

Event Code 130

Event Code 131

ACCESS 1 detects steering contactor (S) coil shorted

Step 1:

Disconnect wires 2954 and 525 from steering contactor (S); re-key truck.

•

If: Event clears or changes to 134.

– Then replace steering contactor.

•



Step 2:

Disconnect CA630 at ACCESS 1 and CA201 at Distribution panel. Check resistance between

CA630-23 and CA201-13.

•

If: Less than 170 or greater than 180 ohm.

– Then check wiring between CA630 and pump contactor coil.

•

If: 170 to 180 ohm.


Figure 16573

Event Code 130

ACCESS 1 detects Lift Pump Contactor (P) Coil

Shorted (DC lift option)

NOTE


Features menu F6 setting is correct; if F6 set to AC, then replace ACCESS 1.

Step1:


Crown 2007 PF15957-9 Rev. 11/08

Figure 16574

M4.8-2045-009

02 Rev. 11/08

239

ELECTRICAL

Event Code 133

Event Code 133

ACCESS 1 detects Lift contactor (P) driver open

(DC lift option)

NOTE


Features menu F6 is set correctly. If F6 set to AC, then replace ACCESS 1.

Step 1:

Connect DVOM to wires 2937 (+) and 5913 (-) at the pump contactor (P1). Enter the Analyzer A4.3

menu; press enter/return to drive the Pump contactor.

•

If: 17 to 22 Vdc (36 volt truck)/23 to 28 Vdc (48 volt truck).

– Then replace pump contactor (P1).

•



Step 2:

Connect DVOM to CA630-16 (+) and CA630-1

(-) on ACCESS 1. Power up truck and enter Analyzer menu A4.3; press enter/return to drive the component.

•



CA630 and pump contactor (P1) coil.

•



Event Code 134

ACCESS 1 detects steering contactor (S) driver open

Step 1:

Connect DVOM to wires 2954 (+) and 525 (-) at the steering contactor (S). Power up truck and enter

Analyzer menu A4.4; press enter/return to drive the

Steer contactor.

•


– Then replace steering contactor (S).

•



Step 2:

Connect DVOM to CA630-23 (+) on

ACCESS 1 and CA201-13 on the Distribution panel.

Enter Analyzer A4.3 menu; press enter/return to drive the component.

•



CA630, CA201 and steering contactor (S) coil.

•



M4.8-2045-010

02 Rev. 11/08

240

Figure 16572

Crown 2007 PF15957-10 Rev. 11/08

ELECTRICAL

Event Code 163

Step 3:



•



•


– Then check wiring between CA208 and BW-P

(M2). If wiring correct, replace BW-P.

Figure 16574

Event Code 163

Truck Management Module indicates Lift motor

(M2) brushes worn (DC lift option)

NOTE

If event occurs on trucks with AC lift option or TMM option not present, then verify Features F6 and F3 are set properly. If F6 = AC and F3 = Disabled, then replace

ACCESS 1.

Step 1:

Inspect lift motor (M2) brushes.

•

If: Brushes correct.


Step 2:



•

If: 1.75 to 2.25 Vdc.


•



Crown 2007 PF15957-11 Rev. 11/08

Figure 16573

M4.8-2045-011

02 Rev. 11/08

241

ELECTRICAL

Event Code 164

Event Code 164

Truck Management Module indicates Steer motor

(M3) brushes worn

NOTE

If event occurs on trucks with AC lift option or TMM option not present, then verify Features F6 and F3 are set properly. If F6 = AC and F3 = Disabled, then replace

ACCESS 1.

Step 1:



•

If: 2.75 to 3.25 Vdc.


•



Step 2:

Inspect steer motor (M3) brushes.

•

If: Brushes OK.


Step 3:



•



•


– Then check wiring between CA208 and BW-S

(M3). If wiring correct, replace BW-S.

Event Code 165

Truck Management Module (TMM) not detected by

ACCESS 1

NOTE

If event occurs on trucks without TMM option present, then verify Feature F3 is set correctly. If F3 set to Disabled, then replace ACCESS 1.

Step 1:

Connect DVOM to wires CA630-4 (-) and

CA630-20 (+) on ACCESS 1 and power up truck.

•


– Then check wiring between CA208 and

ACCESS 1.

•

If: Wiring correct.


•

If: Greater than 1 Vdc.


M4.8-2045-012

02 Rev. 11/08

242

Figure 16576

Figure 20917

Crown 2007 PF15957-12 Rev. 11/08

Event Code 199

Step 1:

Re-key truck

•



ELECTRICAL

Event Code 199

Crown 2007 PF15957-13 Rev. 11/08 M4.8-2045-013

02 Rev. 11/08

243

ELECTRICAL

Event Code 200

Event Code 200

Step 1:

Verify line contactor (L) is closed. Key must be on and operator present in seat.

•

If: Line contactor closed.

– Then follow Event 203 procedures.

•

If: Line contactor open.


NOTE


Monitor code frequency. If it gradually increases for no apparent reason, replace ACCESS 2.

Event Code 201

ACCESS 2 detects internal current overload

Step 1:

Check for loose power cable connections, lift motor (M2) power cables shorted to each other and verify power cables are connected to the correct terminals on lift motor and ACCESS 2.

•

If: Connections and routing correct.


Event Code 202

ACCESS 2 detects M2 voltage feedback circuit out of range

Step 1:

Verify motor power cables are connected to the proper terminals of the Lift motor (M2) and ACCESS 2.

•

If: Cables properly connected.


Step 2:

Check for traction motor short to frame. Remove power cables from U, V and W of Lift motor.

Check the resistance from each motor terminal to the frame of the truck.

•

If: Short detected.

– Then replace lift motor (M2).

•

If: Open (O/L).


Figure 16577

M4.8-2045-014

02 Rev. 11/08

244

Crown 2007 PF15957-14 Rev. 11/08

Event Code 203

ACCESS 2 has detected an under or over voltage condition at key switch (KYS) input

NOTE

Overvoltage threshold is 65 Vdc; undervoltage threshold is 15 Vdc. If this event occurs during power up, idle or traction request, then an undervoltage condition is likely. If this event occurs during motor plugging, then an overvoltage condition is likely. Battery condition and state of charge should be taken into consideration.

Step 1:

Check voltage between (B-) terminal and

CA404-33 on ACCESS 2, with the key on and operator in the seat.

•

If: Less than 15 Vdc or greater than 65 Vdc.


•

If: Between 15 Vdc and 64 Vdc.

– Then replace ACCESS 2 (see note).

Step 2:

Check voltage between CA202-8 (+) and TP4

(-) on the distribution panel.

•


– Then check wiring between battery B+ and

CA202-8.

•

If: 15 Vdc to 65 Vdc.

– Then check wiring between CA202-8 and

CA404-33.

ELECTRICAL

Event Code 203

Figure 16578

Crown 2007 PF15957-15 Rev. 11/08 M4.8-2045-015

02 Rev. 11/08

245

ELECTRICAL

Event Code 204

Event Code 204

Low voltage on Lift motor (M2) terminal outputs

NOTE

Event may be logged if line contactor tips open during truck operation.

Step 1:

Enter Events menu E1 Chron History.

•

If: Event 204 is preceded by Event 317.

– Then follow event 317 procedures.

•

If: Event 204 not preceded by Event 317.


Step 2:

Check line contactor coil wire connections, line contactor tip condition, FU2 condition and cable connections between line contactor and ACCESS 2.

•

If: Connections, FU2 and contactor tips correct.


Step 3:

Check for Lift motor short to frame. Remove power cables from U, V and W of M2. Check the resistance from each motor terminal to the frame of the truck.

•

If: Short detected.

– Then replace Lift motor (M2).

•

If: Open (O/L).


Event Code 205

High voltage on motor terminal outputs

Step 1:

Check for loose power cable connections, lift motor power cables shorted to each other and verify power cables are connected to the correct terminals on

Lift motor and ACCESS 2.

•

If: Cables correct.


Step 2:

Check for Lift motor short to frame. Remove power cables from U, V and W of M2. Check the resistance from each motor terminal to the frame of the truck.

•

If: Short detected.


•

If: Open (O/L).


Figure 16580

M4.8-2045-016

02 Rev. 11/08

246

Figure 16580

Crown 2007 PF15957-16 Rev. 11/08

ELECTRICAL

Event Code 206

Event Code 206

Voltage present at ACCESS 2 (B+) terminal prior to power up.

Step 1:

Check line contactor tip condition.

•

If: Tips correct.


Step 2:

Check voltage between (B+) and (B-) terminals on ACCESS 2, with key off.

NOTE

ACCESS 2 internal capacitors charge when the key is turned on. Voltage may be present between B+ and B- on the module for approximately 10 minutes after key is turned off.

•


– Then short exists between battery and (B+) terminal on ACCESS 2.

•

If: Voltage steadily dropping toward 0 Vdc or at 0

Vdc.


Event Code 207

B+ from Line Contactor not present at ACCESS 2 after power up

Step 1:

Using the service manual, perform C2 calibration. Re-key the truck.

•

If: Event clears.

– Then return truck to service.

•



Step 2:

Check voltage between (B+) and (B-) terminals on ACCESS 2, with key on and operator present in seat.

NOTE


•


– Then check (FU2), line contactor (L) tip condition and power cable connections between battery connector and ACCESS 2.

•



Crown 2007 PF15957-17 Rev. 11/08

Figure 16580

Figure 16580

M4.8-2045-017

02 Rev. 11/08

247

ELECTRICAL

Event Code 208

Event Code 208

ACCESS 2 detects current in Lift motor (M2) prior to lift request

Step 1:

Check for loose power cable connections, lift motor power cables shorted to each other and verify power cables are connected to the correct terminals on lift motor and ACCESS 2.

•

If: Connections correct.


Step 2:

Check for Lift motor short to frame. Remove power cables from U, V and W of M2. Check the resistance from motor terminal to the frame of the truck.

•

If: Short detected.


•

If: Open (O/L).


Event Code 209

ACCESS 2 capacitor not charging after power up

Step 1:

Follow Event Code 203 procedures.

Event Code 210

ACCESS 2 CAN not receiving from ACCESS 3 and

ACCESS 1

Step 1:


Figure 16580

M4.8-2045-018

02 Rev. 11/08

248

Crown 2007 PF15957-18 Rev. 11/08

ELECTRICAL

Event Code 214

Event Code 214

ACCESS 2 detects M2 speed not matching request

NOTE

Event is logged when ECR2 counts change abruptly.

Step 1:

Power up truck, enter Analyzer menu A2.2.2

and request lift.

•

If: 0 RPM.


•

If: RPM increases as lift hydraulic lever.

– Then check wiring condition and connections between CA606 and CA404.

Step 2:

Check ECR2 voltage between CA606-1 (+) and CA606-2 (-).

•

If: 11.3 to 12.3 Vdc.


•

If: Less than 11.3 Vdc.


Step 3:

Check wiring condition and connections between CA606-3 & 4 (ECR2) and CA404-13 & 14 on

ACCESS 2.

•

If: Connections correct


Step 4:

Check ECR2 voltage between CA404-1 (+) and CA404-2 (-) on ACCESS 2.

•

If: 11.3 to 12.3 Vdc.

– Then check wiring condition and connections between CA606-1 & 2 and CA404-1 & 2.

•

If: Less than or greater than 11.3 to 12.3 Vdc.


Figure 16585

Crown 2007 PF15957-19 Rev. 11/08 M4.8-2045-019

02 Rev. 11/08

249

ELECTRICAL

Event Code 215

Event Code 215

Incorrect battery voltage detected at ACCESS 2

Step 1:

Verify correct battery is installed and charged.

•

If: Correct battery installed and charge correct.


Step 2:

Enter Features Menu F5, verify setting 36 (36 volt truck) or 48 (48 volt truck).

•

If: Setting correct.


Step 3:

Enter Calibration Menu (C2), perform BATT

ADJ calibration (refer to Calibration section) and re-key the truck.

•

If: Event clears.


•



Event Code 217

ACCESS 2 detects low current on power bridge

NOTE

Event may be followed by Event 304 when a traction function is selected.

Step 1:

Check line contactor (L) tip are in good condition and contactor is not binding.

Step 2:

Check B+ cable condition and connections between line contactor (L), FU2 and ACCESS 2.

•

If: Cable condition and connections are correct.


•

If: Cable condition and connections are not correct.

– Then correct as needed.

Event Code 216

Step 1:

Re-key the truck.

•



NOTE



Figure 20918

M4.8-2045-020

02 Rev. 11/08

250

Crown 2007 PF15957-20 Rev. 11/08

Event Code 219

ACCESS 2 internal memory revert to factory settings

NOTE

Truck will function using factory default settings.

Step 1:

Re-key truck.

•

If: Event clears.

– Then verify Features & Performance settings are correct for application and perform C1 & C2 calibrations.

•



NOTE

If truck operates this could be a random nuisance event. Monitor event frequency. If it gradually increases for no apparent reason, replace ACCESS 2.

Event Code 220

NOTE


Step 1:

Re-key truck.

•

If: Event clears.


•



NOTE


ELECTRICAL

Event Code 219

Event Code 221

ACCESS 2 FAN 2 inoperable

NOTE

Truck will continue to operate; performance may at times be reduced to manage controller thermal limits.

Restricted air flow in FAN2 duct may cause this event.

Step 1:

Connect DVOM to fan wires 2907 (+) and 5915

(-). Enter Analyzer menu A4.10; press enter/return to drive FAN2. Seat switch must be closed.

•

If: Fan operates.

– Then check fan duct for restrictions.

•

If: Fan does not operate and 32 to 37 Vdc.

– Then replace FAN2.

•

If: Fan does not operate and 0 Vdc.


Step 2:

Connect DVOM between CA404-29 (+) and

CA404-28 (-). Enter Analyzer menu A4.10; press enter/ return to drive FAN2. Seat switch must be closed.

•

If: 32 to 37 Vdc.


CA404-28 & 29 and FAN2.

•

If: 0 Vdc.


Figure 16586

Crown 2007 PF15957-21 Rev. 11/08 M4.8-2045-021

02 Rev. 11/08

251

ELECTRICAL

Event Code 222

Event Code 222

ACCESS 2 temperature out of range

NOTE



Step 1:

Check controller temperature using Analyzer menu A2.2.5.

•

If: 75° C (167° F) or greater.


•

If: Less than 75° C (167° F).


Step 2:

Drive Fan 2 using Analyzer menu A4.10 and check for air flow restrictions. Seat switch must be closed.

•

If: Fan operates and duct is clear.


•

If: Fan does not operate.

– Then follow Event code 221 procedures.

Step 3:

Re-key truck.

•



Event Code 223

Lift motor (M2) over temperature

Step 1:

Check M2 thermal sensor (TS2) using Analyzer menu A2.2.3 (M2 Temp).

•



•

If: Temperature less than 160° C (320° F).

– Then re-key truck and monitor event frequency.

Step 2:

Determine if truck is under extreme duty cycles or high ambient temperatures.

•

If: Extreme duty cycles or high ambient temperatures.

– Then continue to use truck.

NOTE

If extreme duty cycles are normal for application, consider installing Lift Motor cooling fan (see PF16775).

•

If: Duty cycles and ambient temperature normal.


Step 3:

Check TS2 voltage between B- and CA606-6.

•

If: 0.2 Vdc.

– Then go to Step 4.

•

If: Greater than 0.2 Vdc.


Step 4:

Check wiring between at CA606-5 and

CA404-25.

•

If: Wiring correct.


Step 5:

Disconnect CA606. Check resistance of TS2 between PC606-5 and PC606-6.

•

If: Greater than 1.8K ohm.

– Then replace Traction motor (M2).

•

If: 0.5K to 1.8K ohm.


M4.8-2045-022

02 Rev. 11/08

252

Crown 2007 PF15957-22 Rev. 11/08

ELECTRICAL

Event Code 224

Step 6:

Check voltage between B- terminal on

ACCESS 2 and CA404-24.

•

If: 0.2 Vdc.


CA606-6.

•



Event Code 225

Step 1:

Re-key the truck.

•



NOTE


Event Code 247

ACCESS 2 detects lift motor (M2) stalled

Step 1:


Event Code 299

Step 1:

Re-key truck.

•



Figure 16587

Event Code 224

Step 1:

Re-key the truck.

•



NOTE


Crown 2007 PF15957-23 Rev. 11/08 M4.8-2045-023

02 Rev. 11/08

253

ELECTRICAL

Event Code 300

Event Code 300

Step 1:


•



•



NOTE



Event Code 301

ACCESS 3 detects internal current overload

Step 1:

Block drive wheels off of floor (refer to Control of Hazardous Energy Section in Service and Parts

Manual for proper blocking procedures). Release the parking brake (refer to Parking Brake Section in Service and Parts Manual).

Step 2:

Turn drive tires manually to verify the traction motor is not locked.

•

If: Motor does not turn freely.

– Then check for possible issues internal to the traction motor, drive unit or brakes.

•

If: Motor turns freely.


Step 3:

Check for loose power cable connections, motor power cables shorted to each other and verify power cables are connected to the correct terminals on traction motor and ACCESS 3.

•

If: Connections and routing correct.


Figure 16588

Crown 2007 PF15957-24 Rev. 11/08 M4.8-2045-024

02 Rev. 11/08

254

ELECTRICAL

Event Code 302

Event Code 302

ACCESS 3 detects M1 voltage feedback circuit out of range

Step 1:

Verify motor power cables are connected to the proper terminals of the traction motor (M1) and

ACCESS 3.

•

If: Cables properly connected.


Step 2:

Check for traction motor short to frame. Remove power cables from U, V and W of traction motor.

Check the resistance from each motor terminal to the frame of the truck.

•

If: Short detected.

– Then replace traction motor (M1).

•

If: Open (O/L).


Step 1:

Check voltage between (B-) terminal and

CA402-33 on ACCESS 3, with the key on and operator in the seat.

•



•

If: Between 15 Vdc and 65 Vdc.

– Then replace ACCESS 3 (see Note).

Step 2:

Check voltage between CA202-8 (+) and TP4

(-) on the distribution panel.

•


– Then check wiring between battery B+ and

CA202-8.

•

If: 15 Vdc to 65 Vdc.


CA402-33.

Figure 16588

Event Code 303

ACCESS 3 has detected an under or over voltage condition at key switch (KYS) input

NOTE

Overvoltage threshold is 65 Vdc; undervoltage threshold is 15 Vdc. If this event occurs during power up, idle or traction request an undervoltage condition is likely.

If this event occurs during motor plugging an overvoltage condition is likely. Battery condition and state of charge should be taken into consideration.

Crown 2007 PF15957-25 Rev. 11/08

Figure 16589

M4.8-2045-025

02 Rev. 11/08

255

ELECTRICAL

Event Code 304

Event Code 304

Low voltage on traction motor (M1) terminal outputs

NOTE

Event may be logged if line contactor tips open during truck operation.

Step 1:

Enter Events menu E1 Chron History.

•

If: Event 304 is preceded by Event 217.

– Then follow event 217 procedures.

•

If: Event 304 not preceded by Event 217.


Step 2:

Check line contactor coil wire connections, line contactor tip condition, FU1 condition and cable connections between line contactor and ACCESS 3.

•

If: Connections, FU1 and contactor tips correct.


Step 3:

Check for Traction motor short to frame. Remove power cables from U, V and W of M1. Check the resistance from each motor terminal to the frame of the truck.

•

If: Short detected.


•

If: Open (O/L).


Figure 16590

Event Code 305

High voltage on motor terminal outputs

NOTE

A symptom of this event is FU1 blowing during plugging.

Step 1:

Check for loose power cable connections, motor power cables shorted to each other and verify power cables are connected to the correct terminals on traction motor and ACCESS 3.

•

If: Cables correct.


Step 2:

Check for traction motor short to frame. Remove power cables from U, V and W of M1. Check the resistance from each motor terminal to the frame of the truck.

•

If: Short detected.


•

If: Open (O/L).


M4.8-2045-026

02 Rev. 11/08

256

Crown 2007 PF15957-26 Rev. 11/08

ELECTRICAL

Event Code 306

Event Code 306

Voltage present at ACCESS 3 (B+) terminal prior to power up.

Step 1:

Check line contactor tip condition.

•

If: Tips correct.


Step 2:

Check voltage between (B+) and (B-) terminals on ACCESS 3, with key off.

NOTE


•


– Then short exists between battery and (B+) terminal on ACCESS 3.

•

If: Voltage steadily dropping toward 0 Vdc or at 0

Vdc.


•


– Then check (FU1), line contactor (L) tip condition and power cable connections between battery connector and ACCESS 3.

•



Event Code 308

ACCESS 3 detects current in traction motor (M1) prior to traction request

Step 1:

Check for loose power cable connections, traction motor power cables shorted to each other and verify power cables are connected to the correct terminals on traction motor and ACCESS 3.

•



Step 2:

Check for traction motor short to frame. Remove power cables from U, V and W of traction motor.

Check the resistance from motor terminal to the frame of the truck.

•

If: Short detected.


•

If: Open (O/L).


Event Code 307

B+ from Line Contactor not present at ACCESS 3 after power up

Step 1:

Using the service manual, perform C2 calibration. Re-key the truck.

•

If: Event clears.


•



Step 2:

Check voltage between (B+) and (B-) terminals on ACCESS 3, with key on and operator present in seat.

NOTE


Event Code 309

ACCESS 3 capacitor not charging after power up

Step 1:


Crown 2007 PF15957-27 Rev. 11/08 M4.8-2045-027

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257

ELECTRICAL

Event Code 310

Event Code 310

Step 1:


•



•



NOTE



Event Code 311

Line contactor (L) driver shorted

Step 1:

With the key off and battery unplugged, disconnect wires 2915 and 5914 from the line contactor coil.

Connect the battery and power up the truck.

•

If: Event changes.

– Then replace line contactor coil.

•

If: Event 311 returns.


Step 2:

Disconnect CA402 at ACCESS 3. With line contactor coil wires (2915 & 5914) disconnected, check resistance between CA402-26 and CA402-27.

•

If: Resistance detected.

– Then repair shorted wiring between CA402 and line contactor coil.

•

If: Open circuit (O/L).


Figure 16591

M4.8-2045-028

02 Rev. 11/08

258

Crown 2007 PF15957-28 Rev. 11/08

ELECTRICAL

Event Code 312

Event Code 312

Line contactor (L) driver open

Step 1:

Connect DVOM to wires 2915 (+) and 5914 (-) at the line contactor (L). Enter Analyzer menu A4.6; press enter/return to drive the line contactor.

•


– Then replace line contactor (L).

•

If: Less than 17 Vdc (36 volt truck) or 23 Vdc (48 volt truck).


Step 2:

Connect DVOM to CA402-27 (+) and

CA402-26 (-) on ACCESS 3. Enter the Analyzer A4.6

menu; press enter/return to drive the component.

•



CA402 and line contactor (L) coil.

•

If: Less than 17 Vdc (36 volt truck) or 23 Vdc (48 volt truck).


Event Code 313

Line contactor coil shorted

Step 1:


Figure 16591

Crown 2007 PF15957-29 Rev. 11/08 M4.8-2045-029

02 Rev. 11/08

259

ELECTRICAL

Event Code 314

Event Code 314

ACCESS 3 detects M1 speed not matching request

NOTE

Event is logged when ECR1 counts change abruptly.

Step 1:

Block drive wheels off of floor (refer to Control of Hazardous Energy Section in Service and Parts

Manual for proper blocking procedures). Power up truck, enter Analyzer menu A2.3.10, release brakes and request forward travel.

•

If: 0 RPM.


•

If: RPM increases as accelerator pedal is depressed.


Step 2:

Check ECR1 voltage between CA603-1 (+) and CA603-2 (-).

•

If: 11.3 to 12.3 Vdc.


•

If: Less than 11.3 Vdc


Step 3:

Check wiring condition and connections between CA603-3 & 4 (ECR1) and CA402-13 & 14 on

ACCESS 3.

•



Step 4:

Check ECR1 voltage between CA402-1 (+) and CA402-2 (-) on ACCESS 3.

•

If: 11.3 to 12.3 Vdc.

– Then check wiring condition and connections between CA603-1 & 2 and CA402-1 & 2.

•

If: Less than or greater than 11.3 to 12.3 Vdc.


Figure 16592

Event Code 315

Incorrect battery voltage detected at ACCESS 3

Step 1:

Verify correct battery is installed and charged.

•

If: Correct battery installed and charged correctly.


Step 2:

Enter Features Menu F5, verify setting 36 (36 volt truck) or 48 (48 volt truck).

•

If: Setting correct.


Step 3:

Enter Calibration Menu (C2), perform BATT

ADJ calibration (refer to calibration section of service manual) and re-key the truck.

•

If: Event clears.


•



M4.8-2045-030

02 Rev. 11/08

260

Crown 2007 PF15957-30 Rev. 11/08

ELECTRICAL

Event Code 316

Event Code 316

Step 1:


•



•



NOTE



Event Code 317

ACCESS 3 detects low current on power bridge

NOTE

Event may be followed by Event 204 when a hydraulic function is selected.

Step 1:

Check line contactor (L) tip condition and contactor for binding.

•

If: Tips correct and contactor not binding.


Step 2:

Check B+ cable condition and connections between line contactor (L) and ACCESS 3.

•

If: Cable condition and connections correct.


Event Code 319

ACCESS 3 internal memory revert to factory settings

NOTE


Step 1:

Re-key truck.

•

If: Event clears.


•



NOTE


Event Code 320

NOTE


Step 1:

Re-key truck.

•

If: Event clears.


•



NOTE


Crown 2007 PF15957-31 Rev. 11/08 M4.8-2045-031

02 Rev. 11/08

261

ELECTRICAL

Event Code 321

Event Code 321

ACCESS 3 FAN1 inoperable

NOTE



Step 1:

Connect DVOM to fan wires 2968 (+) and 5902

(-). Enter Analyzer menu A4.3, press enter/return to drive FAN1. Seat switch must be closed.

•

If: Fan operates.

– Then check fan duct for restrictions.

•

If: Fan does not operate and 32 to 37 Vdc.

– Then replace FAN1.

•

If: Fan does not operate and 0 Vdc.


Step 2:

Connect DVOM between CA402-29 (+) and

CA402-28 (-). Enter Analyzer menu A4.3, press enter/ return to drive FAN1. Seat switch must be closed.

•

If: 32 to 37 Vdc.


CA402-28 & 29 and FAN1.

•

If: 0 Vdc.


Event Code 322

ACCESS 3 temperature out of range

NOTE



Step 1:

Check controller temperature using Analyzer menu A2.3.13.

•



•

If: Less than 75° C (167° F).


Step 2:

Drive Fan 1 using Analyzer menu A4.8 and check for air flow restrictions. Seat switch must be closed.

•

If: Fan operates and duct is clear.


•

If: Fan does not operate.

– Then follow Event code 321 procedures.

Step 3:

Re-key truck.

•



Figure 16593

M4.8-2045-032

02 Rev. 11/08

262

Crown 2007 PF15957-32 Rev. 11/08

ELECTRICAL

Event Code 323

Event Code 323

Traction motor (M1) over temperature

Step 1:

Check M1 thermal sensor (TS1) using Analyzer menu A2.3.11 (M1 Temp).

•



•

If: Temperature less than 160° C (320° F).

– Then re-key truck and monitor event frequency.

Step 2:

Determine if truck is under extreme duty cycles or high ambient temperatures.

•

If: Extreme duty cycles or high ambient temperatures.

– Then continue to use truck.

Note: If extreme duty cycles are normal for application,

consider installing Traction Motor Cooling Fan Kit (see

PF16772).

•

If: Duty cycles and ambient temperature normal.


Step 3:

Check TS1 voltage between B- and CA603-6.

•

If: 0.2 Vdc.


•



Step 4:

Check wiring between at CA603-5 and

CA402-25.

•

If: Wiring correct.


Step 5:

Disconnect CA603. Check resistance of TS1 between PC603-5 and PC603-6.

•

If: Greater than 1.8K ohm.

– Then replace Traction motor (M1).

•

If: 0.5K to 1.8K ohm.


Step 6:

Check voltage between B- terminal on

ACCESS 3 and CA402-24.

•

If: 0.2 Vdc.


CA603-6.

•



Figure 16594

Event Code 324

Step 1:

Re-key the truck.

•



Note: If truck operates this could be a random nui-

sance event. Monitor event frequency. If it gradually increases for no apparent reason, replace ACCESS 3.

Event Code 325

Step 1:

Re-key the truck.

•



Note: If truck operates this could be a random nui-

sance event. Monitor event frequency. If it gradually increases for no apparent reason, replace ACCESS 3.

Crown 2007 PF15957-33 Rev. 11/08 M4.8-2045-033

02 Rev. 11/08

263

ELECTRICAL

Event Code 326

Event Code 326

Traction POT 1 out of electrical limit

Step 1:

Check accelerator potentiometer (POT1) voltage using Analyzer menu A2.3.8.

•

If: 0.2 V pedal released to 4.5 V pedal fully depressed.

– Then calibrate accelerator potentiometer

(POT1) using Calibration menu C1.

•

If: 4.8 V or greater.


Step 2:

Check voltage with DVOM between CA612-A

(+) and CA612-C (-).

•

If: 10.8 to 11.3 Vdc.


•



Step 3:

Check voltage between CA612-B (+) and

CA612-C (-).

•

If: 0.2 Vdc pedal released to 4.8 Vdc pedal fully depressed.


•

If: Greater than 4.8 Vdc or voltage doe not change as pedal is depressed.

– Then replace Pot 1.

Step 4:

Check voltage between CA402-16 (+) and

CA402-15 (-).

•

If: Voltage does not change as pedal is depressed.


CA612-B.

•

If: 0.2 Vdc pedal released to 4.8 Vdc pedal fully depressed.


Step 5:

Check voltage with DVOM between CA402-3

(+) and CA402-15 (-).

•

If: 10.8 to 11.3 Vdc.

– Then check connections and wiring between

CA402 and CA612.

•



Event Code 330

Step 1:

Re-key truck.

•



Event Code 399

Step 1:

Re-key truck

•



FWD/REV

Figure 16595

ACCESS 3 sees both directional switches closed at the same time

Note

:

If the message only occurs when a direction is selected, then check wiring between directional switches and ACCESS 3.

M4.8-2045-034

02 Rev. 11/08

264

Crown 2007 PF15957-34 Rev. 11/08

ELECTRICAL

FWD/REV

Step 1:

Check switch inputs using Analyzer menu

A2.3.1 for forward switch (FS) and A2.3.2 for reverse switch (RS) with key on, seat switch closed and direction control in neutral. ON indicates direction requested

(switch closed), OFF indicates direction not selected

(switch open).

•

If: FS, RS or both switches indicate ON with direction control lever in neutral.


•

If: Both switches do not indicate ON with direction control lever in neutral.

– Then re-key truck.

Step 2:

Check voltage between wires 2925 (+) and

2926 (-) at (RS) and between wires 2924 (+) and 2927

(-) at (FS) with key on, seat switch closed and direction control in neutral.

•

If: 33 to 38 Vdc (36 volt) or 45 to 52 Vdc (48 volt) for both.

– Then switches open - proceed to Step 4.

•

If: Less than 33 Vdc (36 volt) or 45 Vdc (48 volt) on either.

– Then replace switch with low voltage reading.

•

If: Less than 33 Vdc (36 volt) or 45 Vdc (48 volt) for both.


Step 3:

Check voltage between B- and CA402-5 and 6 on ACCESS 3, with key on, seat switch closed and direction control in neutral. Step 1:

•

If: 33 to 38 Vdc (36 volt) or 45 to 52 Vdc (48 volt) on both connections.

– Then check wiring between directional switches and ACCESS 3.

•

If: Less than 33 Vdc (36 volt) or 45 Vdc (48 volt) on either.


Step 4:

Check voltage between B- and CA402-5 & 6 on

ACCESS 3, with key on, seat switch closed and direction control in neutral.

•

If: 33 to 38 Vdc present at either or both test points.

– Then a short to (B+) exist in circuit between FS and CA402-5 or RS and CA402-6. Repair/replace as necessary.

•

If: Less than 33 Vdc at both test points.


Figure 16626

Crown 2007 PF15957-35 Rev. 11/08 M4.8-2045-035

02 Rev. 11/08

265

ELECTRICAL

Creep Speed Only

Creep Speed Only

Symptom indicates ECR1 component or circuit open at power up, refer to Events 314 and 326 for additional information.

No Traction/No Lift/BDI = 0%

Symptom indicates line contactor tips closed prior to request, follow Event 306 procedures.

M4.8-2045-036

02 Rev. 11/08

266

Crown 2007 PF15957-36 Rev. 11/08

BRAKE

267

Notes:

268

BRAKE

Service Brake

Service Brake

Operation

The service brake is actuated by hydraulic oil entering an inlet port located on the back of the torque plate. Oil pressure is applied to four pistons through passages within the torque plate. The pistons squeeze the lining/ rotor between the inner stator and outer stator.

Left and Right is Determined from the Operator’s Perspective

(1) Lining/Rotor Assembly (5) Seal

(2) (6)

(3)

Inner Stator

Torque Plate Right Hand (Shown) (7)

Wiper

Piston

(4) Bleed Screw (8) Outer Stator

Figure 17341

Crown 2001 PF13245-1 Rev. 8/07 M5.0-2040-001

03 Rev. 8/07

269

BRAKE

Service Brake

Brake Pedal

(Refer to Figure 17470)

Inspect brake pedal for worn or damaged parts and replace as needed.

Mounted on the brake pedal bracket is switch (BRS1) to activate the brake lights when the brake pedal is depressed.

Mounted on the brake pedal bracket is filter block

(FIL1) for the horn (HN1).

Mounted on the brake pedal bracket is horn (HN1) for sounding an audible alarm.

Mounted to the brake pedal bracket is the service brake valve.

All fittings have an o-ring face seal. If these lines are opened, the o-ring must be replaced.

(5)

(6)

(7)

(8)

(1)

(2)

(3)

(4)

(9)

(10)

(11)

(12)

Right Hand Brake Assembly

To Hydraulic Reservoir

To Steer and Brake Pump

Cooling Fan

BRS1

FIL1

Brake Pedal

Brake Pedal Mounting

Bracket

Horn (HN1)

Part of Power Unit

Brake Valve

Left Hand Brake Assembly

NOTE

All lines contain an O-Ring Face Seal Fitting. If any of the line are opened the O-Ring must be replaced to prevent oil leakage at the connection.

M5.0-2040-002

03 Rev. 8/07

270

Figure 17470

Crown 2001 PF13245-2 Rev. 8/07

BRAKE

Service Brake

Shimming the Brake Pedal

(Refer To Figure 17471)

Brake pedal should be in the normal operating position

(pedal resting atop the brake arm).

Measure the gap between the "upstop" and brake arm.

Refer to the following chart to determine the number of shims needed. Example: If gap measurement =

3.50 mm (0.14 in) then 2 shims will need to be added to plunger.

Pedal in Normal Operating Position (Pedal Resting on

Arm with No Pressure Applied to Pedal)

(1) (4)

(2)

Brake Plunger

Measure Gap (5)

Upstop

Brake Valve

(3) Brake Arm

Figure 17471

Disconnect brake arm and plunger from brake valve.

Install appropriate number of shims, refer to Chart 1, onto the brake valve plunger and secure with retaining ring.

Chart 1 Gap Measurement - Shims

Gap Measurement mm (in)

0.00 - 1.78

(0.00 - 0.07)

1.79 - 3.35

(0.07 - 0.13)

3.36 - 4.93

(0.13 - 0.19)

4.94 - 6.50

(0.19 - 0.25)

6.51 - 8.08

(0.25 - 0.31)

8.09 - 9.65

(0.31 - 0.38)

9.66 - 11.23

(0.38 - 0.44)

11.24 - 12.80 (0.44 - 0.50)

12.81 - 14.38 (0.50 - 0.56)

Number of

Shims

6

7

4

5

8

2

3

0

1

Crown 2001 PF13245-3 Rev. 8/07 M5.0-2040-003

03 Rev. 8/07

271

BRAKE

Service Brake

Connect brake arm and plunger.

With brake pedal in the normal operating position, verify the brake arm is against the "upstop". If not, additional shim(s) will need to be added until it is.

Verify service brake operation by pressing on the brake pedal several times to see if it returns to the "upstop".

If not, it may be necessary to add a shim(s) to the plunger.

Verify that brakes are not dragging (noticeable when coasting to a stop). If brakes are dragging then remove a shim from the plunger and recheck.

Verify service brake and truck operation after shimming is complete.

Brake Assembly Removal

(Following Is For One Service Brake Assembly)

Lower forks, disconnect and remove battery. Elevate and securely block truck so drive tires are off floor. Refer to Control Of Hazardous Energy section, "Lifting and Blocking" in service manual for lifting and blocking procedures.

WARNING

Wear appropriate items, such as safety glasses and steel-toed shoes whenever performing maintenance work. Do not place fingers, hands or arms through mast or position them at pinch points.

In this section you may be required to lift and block the truck and mast or raise and lower different components for removal and installation. Make sure lifting device and sling are sufficiently rated to withstand the weight being lifted. Never work under or around a truck that is not properly secured. Refer to truck Data Plate for truck weight information.

It will be necessary to disconnect and remove the battery from the truck, disconnect tilt cylinders from the mast, disconnect electrical connections and hydraulic lines. "Control of Hazardous Energy" section provides information for performing the above procedures along with some additional information on other procedures dealing with truck maintenance. This section should be read and reviewed prior to mast removal, installation and maintenance as outlined in this section.

Remove drive tire. Refer to Chapter M3.0 for drive tire removal.

Remove differential axle. Refer to Chapter M3.0 for axle removal procedures. Be prepared to catch oil.

WARNING

AVOID HIGH PRESSURE FLUIDS-Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.


Remove locknut, lockwasher and tabbed washer and remove axle hub assembly. Refer to Chapter M3.0 for axle hub assembly removal procedures. Be prepared to catch oil.

Disconnect hose from service brake assembly. Be prepared to catch oil.

Remove 10 screws and flatwashers that mount service brake assembly to axle mount.

NOTE

Screws that mount the Left hand and Right hand brake assemblies are different lengths.

Keep mounting screws with there respective brake assembly.

Remove service brake assembly from axle mount and place on a clean work surface for disassembly.

Disassembly of Brake

Brake linings are susceptible to contamination. When installing or servicing brakes, keep all oil, fluids and any other contaminants away from linings.

Remove screws and nuts and remove outer stator.

Remove lining/rotor assembly and inner stator.

M5.0-2040-004

03 Rev. 8/07

272

Crown 2001 PF13245-4 Rev. 8/07

12.7 mm

(0.50 in)

BRAKE

Service Brake

Lining/Rotor Inner And Outer Stator

The minimum overall thickness of lining/rotor pads (lining) is 8 mm (0.030 in) on either side. Refer to Figure

17337. Replace lining/rotor if thickness is 8 mm

(0.030 in) or less.

Outer Stator

8 mm (0.030 in)

Measurement Taken from Either Side

Lining/Rotor Assembly

Figure 17337

The minimum thickness of the inner stator is 12.7 mm

(0.50 in). To check for wear, measure the depth of the stator grooves created by the lining. Refer to Figure

17338. Replace stator if thickness is 12.7 mm (0.50 in) or less.

Inner Stator

12.7 mm

(0.50 in)

Figure 17338

The minimum thickness for the outer stator is 12.7 mm

(0.50 in). To check for wear, measure the depth of the stator grooves created by the lining. Refer to Figure

17339. Replace stator if thickness is 12.7 mm (0.50 in) or less.

Figure 17339

Piston, Wiper and Seal Removal

If any indication of fluid leakage appears around piston areas, replace seal and wiper.

NOTE

Service brake assembly should be removed from truck before disassembling pistons, wipers or seals.

Wipers and seals should not be reused. Leakage may result if brakes are reassembled with used or damaged components. Take caution not to scratch or nick piston bores or outside piston surface when removing pistons, wipers and seals.

To remove piston, insert a 40 mm (1.5 in) diameter, expandable, piston removal tool, Crown Part Number

126431, into piston bore and tighten until secure. Pull piston out of torque plate with a slight rocking motion.

Refer to Figure 17468 for a cross sectional view of plug and piston.

NOTE

When removing piston, the bleeder plug or hydraulic inlet port must be open. If not open, a vacuum will be created making piston removal difficult.

Crown 2001 PF13245-5 Rev. 8/07 M5.0-2040-005

03 Rev. 8/07

273

BRAKE

Service Brake

Install outer stator using six screws, flatwashers and nuts. Torque screws 45-55 Nm (35 - 40 ft lb). Refer to

Figure 17336 for torque sequence.

(1)

(2)

Expandable Rubber Plug Piston

Removal Tool Part Number 126431

Piston

Figure 17468

Remove wiper by sliding a small, flatblade screwdriver under the bottom of the wiper. With small hammer, strike screwdriver and drive wiper out of bore.

Remove seal with seal pick.

Wiper, Seal & Piston Installation

Clean all metal parts prior to assembly. Using low pressure air, blow excess cleaning solution off of all parts and out of all fluid passages.

Apply a thin coat of hydraulic oil to seals prior to installation.

Install piston seal first in seal grooves in piston bore.

Install wiper in piston bore groove with wiper facing out.

After installing wiper in bore, seat wiper by placing a cylindrical object, such as a 19 mm (0.75 in) drive socket on wiper and tapping lightly. Cylindrical object's diameter must be slightly larger than the piston outside diameter and less than the wiper outside diameter.

Install piston in piston bore.

Service Brake Assembly

If piston seal replacement is not necessary. Clean the exposed portion of piston with clean rag.

Install inner stator and lining/rotor assembly in torque plate. Refer to Figure 17341.

Figure 17336

Service Brake Installation

Left and right hand service brakes assemblies are determined by location of the hydraulic port on back of the torque plate. When installing service brakes, be sure the hydraulic port on back of the service brake is on side closest to the operator compartment (away from forks) and aligned with axle mount through hole.

Install service brake assembly on axle mount.

Secure with ten screws and flatwashers. Torque screws to 271.2 ± 27.1 Nm (200 ± 20 ft lb)

NOTE

Screws that mount the Left hand and Right hand service brake assemblies are different lengths. Use correct length screws for mounting service brake assemblies.

Connect hydraulic line to back of service brake assembly. Hold connector located on back of torque plate with wrench to prevent overtightening.

Install axle hub assembly and differential axle assembly. Refer to Chapter M3.0 for installation procedures and torque values.

NOTE

The oil seal for axle hub assembly must be replaced each time the service brakes are removed and reinstalled to prevent oil leakage.

M5.0-2040-006

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274

Crown 2001 PF13245-6 Rev. 8/07

BRAKE

Service Brake

Service Brake Bleeding

Connect battery and power up truck (steer pump motor must be running).

Brake linings are susceptible to contamination. When installing and/or servicing brakes, keep all fluids from contacting Brake Linings.

Loosen the two bleed screws on top of each brake. Be prepared to catch oil.

Slowly depress brake pedal. Allow air-oil mixture to flow until a solid stream of oil is achieved.

Torque bleed screws 17-23 Nm (150-200 in lb).

Bleed Screws

Drive Tire Installation

Turn truck off and disconnect battery.

Install drive tire. Refer to Chapter M3.0 for lug nut installation.

Repeat procedures for remaining service brake assembly.

Lower truck onto floor and remove jack stands and blocking. Chock drive wheels. Disconnect lifting devise and remove jack.

Install and connect battery.

Check oil level in hydraulic reservoir and check for oil leaks.

Remove chocks and verify service brake and truck operation.

Check for unusual noises, clicking, grinding etc. coming from brake assembly.

Service Brake Adjustments

No adjustments required.

Figure 17469

Service Brake Valve

No adjustments required.

Input pressure 8274 kPa (1200 psi).

Output pressure 5516 kPa (800 psi).

Plunger travel 8.8 mm (0.346 in).

Plunger force 139 kg (306 lb).

Crown 2001 PF13245-7 Rev. 8/07 M5.0-2040-007

03 Rev. 8/07

275

Notes:

276

BRAKE

Parking Brake

Parking Brake

Operation

The parking brake is applied with a switch (PRKA, B) mounted on the console, to the right of the steering column, refer to Figure 17531, or the optional seat activation of the parking brake whenever the operator leaves the seat.

Parking Brake Switch (PRKA, B) shown in “APPLIED” position

Crown 2007 PF17011-1

Figure 17531

(1)

(2)

(3)

(4)

(5)


Brake Cylinder

Brake Shoe

Brake Hub

Springs

Figure 17532

When the parking brake switch is depressed (set) the cylinder pulls the shoes against the brake hub mounted on the traction motor. Refer to Figure 17532.

Inspection

During each planned maintenance inspection, check brakes for any damaged parts and free movement of the brake mechanism.

Cylinder

Inspect the cylinder for any leakage around seals and fittings. Refer to Cylinder sections for maintenance and parts breakdown of cylinder and seal kit part number.

Brake linings are bonded to the shoe. It is important to observe the minimum allowable thickness.

Minimum lining thickness at the point of greatest wear is 2.0 mm (0.079 in). Refer to Figure 17533.

M5.0-2045-100

277

BRAKE

Parking Brake

Brake Hub

Inspection of the brake hub is required during each planned maintenance inspection. If any scoring of the drum occurs, a new brake hub must be installed.

CAUTION

Brake linings are susceptible to contamination. When installing or servicing the brakes. Keep all oil, fluids or any other contaminants away from linings.

Replacement of Brake Shoes

Brake shoes that show excessive dirt, uneven wear, or improper braking should be replaced. Refer to Brake

Shoe Inspection.

NOTE

To avoid uneven braking both brake shoes should be replaced at the same time.

Adjustment

Adjustment of the park brake is necessary after:

•

Installation of new brake shoes

•

Replacement of brake hub

•

Repair and or replacement of the traction motor

(1)

(2)

Brake Shoe Lining

Minimum Thickness

Figure 17533

M5.0-2045-101

278

Crown 2007 PF17011-2

BRAKE

Parking Brake

Adjustments When Replacing Brake

Shoes or Brake Hub

Raise drive tires - block and secure. Refer to "Lifting and Blocking" in “Control of Hazardous Energy” section for procedures on lifting, blocking and securing truck.

Remove floor mat and floor board covers in operator compartment.

To center the brake shoes to the brake hub, loosen the four backing plate screws. Tighten the clamp rod unit until the shoes firmly contact the drum. Tighten the four backing plate screws. Refer to Figure 17534.

CAUTION

Truck must be turned on and seat switch activated for the parking brake to be released. Make sure the drive tires are off of the ground and the vehicle is blocked and secure. Refer to Control of Hazardous Energy section.

Release the parking brake by placing the key switch in the "on" position, place the park brake switch (PRKA,

B) in the released position and place approximately

7.5 kg (20 lb) on the operator seat. The truck must be turned on and seat switch activated for the parking brake to be released. Make sure the drive tires are off of the ground and the vehicle is blocked and secure.

Place 0.38 mm (0.015 in) thick shims between brake shoe and brake hub at top of brake shoes to set running clearance. Refer to Figure 17535.

Tighten clamp rod nut until snug.

Remove shims and tighten lock nut on clamp rod.

Refer to Figure 17536 and Chart 1 for correct torque values.

Traction Motor


(1) Clamping Rod

(2) Backing Plate Screws

Figure 17534

Crown 2007 PF17011-3


(1) Clamping Rod

(2) Running Clearance

Figure 17535

M5.0-2045-102

279

BRAKE

Parking Brake


When hydraulic pressure is lost the parking brake will be automatically set. In order to move the truck to an area for maintenance, the parking brake must be released using the manual release valve on the park brake release manifold block. It's located under the floorboard, to the right of the hydraulic pump motor

(M2). Refer to Figures 17537 and 17538.

Traction Motor

M5.0-2045-103

280

Chart 1 Torque Table

(1) Backing Plate Mounting Screws

(2) Brake Shoes to Backing Plate Mounting Screws

(3) Brake Hub to Motor Mounting Bolt

(4) Locking Nuts for Adjustment Rod

24.5 ± 7 Nm (18 ± 5 ft lb)

24.5 ± 7 Nm (18 ± 5 ft lb)

101.5 ± 13.5 Nm (75 ± 10 ft lb)

43.5 ± 7 Nm (32 ± 5 ft lb)

(5) Pivot Arm to Ball Joint Nut

(6) Ball Joint to Cylinder Rod

43.5 ± 7 Nm (32 ± 5 ft lb)

43.5 ± 7 Nm (32 ± 5 ft lb)

Figure 17536

Crown 2007 PF17011-4

BRAKE

Parking Brake

Manually Releasing the Parking

Brake


Remove cap covering the hand pump.

Depress and hold the manual release valve in the depressed position.

Operate the hand pump by pushing down and pulling up while keeping the manual release valve depressed.

Continue until the parking brake is fully released.

NOTE

The manual release valve will be held in the depressed position by the pressure releasing the parking brake.

Manually Applying the Parking Brake

Pull up on the manual release valve to release the pressure holding the parking brake released.

Parking Brake Solenoid

Parking brake solenoid, SV2, removes pressure from the parking brake cylinder to apply the parking brake.

Coil voltage is 36 volts and coil resistance is 90 ohms.

SV2 requires no adjustments. Refer to Figures 17537 and 17538.

(1)

(2)

(3)

Hand Pump

Manual Release Valve

SV2 Parking Brake Solenoid

Figure 17537

Crown 2007 PF17011-5

(1)

(2)

(3)

(4)

Park Brake Release Manifold Block

Hand Pump

Manual Release Valve

SV2 Park Brake Solenoid

Figure 17538

M5.0-2045-104

281

Notes:

282

STEERING

283

Notes:

284

STEERING

Steering

Steering

Your truck is equipped with a hydraulic steering system. A hydrostatic steering control unit, located in the control column, is coupled via hydraulic tubes and hoses to the steering axle, mounted near the back of the power unit, used to actuate the steering.

SCU

Figure 17349

Hydrostatic Steering Unit

The hydrostatic steering unit (open center non-reaction) mounts in the control column below the steering wheel. The non-reaction unit maintains the steered position when the operator releases the steering wheel.

The cylinder ports are blocked in the neutral valve position. The operator must steer the drive wheel back to the straight ahead position.

The steering unit meters a proportional amount of oil to the steering motor when the wheel is rotated. This pressurized oil is supplied by the PS pump, and is supplied to the appropriate side of the steering motor by the direction of rotation of the steer control unit via the steering wheel. When the steering wheel rotation is stopped, the steer motor ports are blocked to hold the steering in that position. In the event that pump flow is stopped, the steer unit can be manually rotated to pump flow to the appropriate steer actuator port by turning the steering wheel in the desired direction, thus allowing emergency steering.

Steer circuit relief pressure is non-adjusting and preset to 9655 kPa (1400 psi). Normal steering pressures are

2758 - 5516 kPa (400 - 800 psi).

NOTE

The clamps shown at the right secure steer unit hydraulic tubes to the power unit and must be securely in place to prevent fluid leakage.

1

2

3

Clamp

Tube Clamp

Part of Power Unit

Figure 17350-01

WARNING

The truck steering can be reversed by incorrectly connecting the hydraulic hoses. Care should be exercised when maintenance is performed on the steering system. Prior to disassembly, mark hose and tube locations so they can be properly assembled.

After completing maintenance, always check to be sure steering system is functioning properly.

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285

STEERING

Steering

Steering Column Assembly

Refer to the following procedures and specifications when assembling or disassembling the steering column.

Column

Before removing shaft assembly from column, remove brush holder and brushes or they will be damaged. Refer to Figure 17353-01.

Refer to Figure 17352-01. Apply 1.5 to 2 turns of black electrical tape around the upper shaft at positions where wires enter tube, covering solder area on contact ring and wire entering tube.

5

6

7

3

4

1

2

Steer Unit

Mounting Bracket

Steering Column

Steering Wheel

Directional Control

Release Lever

Gas Cylinder

Figure 17351-01

3

4

1

2

5

Electrical Tape

Solder Area

Upper Shaft

Insulator

Contact Ring

Figure 17352-01

M6.0-2045-002

01 Rev. 12/08

286

Crown 2007 PF17169-2 Rev. 12/08

Apply a small amount of oil (063001-002) to outside of o-ring at bottom of lower shaft. Refer to Figure

17353-01.

Gas Cylinder

STEERING

Steering

3

4

1

2

5

6

Column Assembly

Brush

Brush Holder

Upper Shaft

Lower Shaft

O-Ring

Figure 17353-01

5

6

7

3

4

1

2

Part of Column

Release Head

Retaining Ring

Release Lever

Roll Pin

Gas Cylinder

Part of Power Unit

Figure 17354-01

Crown 2007 PF17169-3 Rev. 12/08 M6.0-2045-003

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287

STEERING

Steering

Screw gas cylinder threaded shaft into threaded hole in release head until plunger pin on gas cylinder contacts bottom edge of release lever. Refer to Figure

17355-01.

Figure 17355-01

3

4

1

2

5

6

Release Head

Roll Pin

Release Lever

Jam Nut

Gas Cylinder

Pin Contacts Release Lever

Continue to screw the gas cylinder into head until release lever moves to its maximum position and lever is not loose within head. Screw gas cylinder another 1/4 rotation and lock in position by tightening jam nut.

Rotate gas cylinder body until lower mounting tab is parallel with release head.

Figure 17356-01

3

4

1

2

Bracket

Cam Lever

Forward Switch

Reverse Switch

When installing the cam lever into bracket, be sure to orient handle in correct position. Refer to 17357-01.

Directional Control

Apply a small amount of grease (063002-007) to cam lever mounting bracket bores. Refer to Figure

17356-01.

1

2

3

Figure 17357-01

Orient cam lever as shown for North American trucks. Orient cam lever on other side (rotate 180°) for European trucks.

Cam Lever

Bracket

M6.0-2045-004

01 Rev. 12/08

288

Crown 2007 PF17169-4 Rev. 12/08

STEERING

Steering

Steering Wheel Removal

1.

Disconnect battery and chock drive wheels.

2.

Position steering column in convenient position to allow for steering wheel removal.

3.

Remove Horn Button. Refer to Figure 17358.

5.

Remove jam nut. Refer to Figure 17359-01.

Horn Button

Figure 17358

4.

Disconnect wires from horn contact rings.

NOTE

Horn contact rings do not need to be removed from the steering wheel.

1

2

Jam Nut

Horn Wires

Figure 17359-01

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STEERING

Steering

6.

Position horn wires in wheel puller, Part Number

129253, notch. Refer to Figure 17360-01.

NOTE

Wires must be positioned inside of puller as they could be pinched during the removal of the steering wheel.

7.

Use M8 x 85 mm long bolts, part number

060063-009, with wheel puller, part number

129253. Refer to Figure 17360-01.

8.

Turn each bolt equally to prevent steering wheel from binding.

9.

Remove steering wheel from steering shaft.

NOTE

The use of a rubber mallet may be needed to initially loosen the steering wheel from the steering shaft by striking upwards on bottom of the steering wheel base.

Steering Wheel

The two notches on the upper horn switch contact, which are directly opposite of each other, must be aligned with the two brass inserts in the steering wheel.

3

4

1

2

Figure 17361-01

Notches in Upper Contact Must Align with Inserts

Upper Contact

Steering Wheel

Brass Insert

1

2

3

Figure 17360-01

Insert Horn Wires Here to Prevent Pinching of Wires

Bolt 060063-009

Wheel Puller 129256

M6.0-2045-006

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290

Crown 2007 PF17169-6 Rev. 12/08

STEERING

Steering

Final Assembly

1.

Apply a small amount of anti-seize compound part number (065005-003) on tapered area of steering shaft prior to installing steering wheel. Do not get any on the threaded portion of the shaft. This will make wheel removal easier.

2.

When installing steering wheel on shaft, align splines and push down until taper in steering wheel seats with taper on shaft. Secure with jam nut. Do not over tighten - torque to 36 Nm (27 ft lb).

3.

Apply a small amount of grease (063002-007) on the outside diameter of tilt pin and install release head (with gas cylinder included). Secure with retaining ring. Release head (with gas cylinder) must rotate freely on the tilt pin, without excessive free movement; 0.025 mm (0.001 in) maximum movement.

4.

Apply a small amount of grease part number

(063002-007) to gas cylinder lower end mounting pin (included with power unit frame) and position gas cylinder and column assembly onto frame. The fit of the gas cylinder to its mounting pin must be held and must not have excessive free movement

0.050 mm (0.002 in) maximum.

5.

After steering column assembly is mounted to frame, check tilting and locking functions for proper operation. Check the

full up

and

axle back

positions. The full up (forward) position should be 16° ±

2° and the full back should be 40° ± 2° from vertical.

Steer Axle Assembly

Figure 17846-01

1

2

3

Steer Cylinder Assembly

Steer Tire Assembly

Battery Compartment

NOTE

Orientation of cover shown is for truck with 840 and

915 mm (33 and 36 in) Battery Compartment. Refer to

Figure 17846-01.

Your truck has an articulated steering axel. There are no adjustments required. Forged spindles pivot on each end of the axle. A steering link is connected to the spindle and steering cylinder. There are six lubrication fittings on the axel assembly: one on each spindle and one on each steering link pin.

Steer Tire

When replacing the steer tire, make sure the composition and size are such that maneuverability, stability and braking requirements are maintained. Both steer tires should be replaced at the same time to maintain equal tire circumference.

Refer to the maintenance ITD chapter for tire information.

The steer tire is a press-on type; press the old tire off the hub and press new tire on. The outside of the hub must be pressed flush with the outside edge of the tire.

Crown 2007 PF17169-7 Rev. 12/08 M6.0-2045-007

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STEERING

Steering

Torque Requirements

1

2

3

Figure 17847-01

King Pin

Spindle

Torque to 50 - 60 Nm (37 - 44 ft lb). Then rotate spindle three times through its full range of movement, loosen nut until free and torque to 130 - 140 Nm (96 - 103 ft lb)

M6.0-2045-008

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292

Crown 2007 PF17169-8 Rev. 12/08

STEERING

Steering

Crown 2007 PF17169-9 Rev. 3/09

1 Tapered Roller Spindle Bearing

2 Spindle

3 Tapered Roller Wheel Bearing

4 Wheel and Hub

5 Wheel Hub Oil Seal

6 King Pin

7 Torque 114 - 128 Nm (84 - 94 ft lb)

8 Torque to 50 - 60 Nm (37 - 44 ft lb). Then rotate spindle three times through its full range of movement, loosen nut until free and torque to 130 - 140 Nm (96 - 103 ft lb)

Figure 17871-02

M6.0-2045-009

02 Rev. 3/09

293

STEERING

Steering

The tapered roller spindle bearings, index 1, on the steer wheel spindle, must be packed with grease,

Crown Part Number (063002-034) or equivalent prior to assembly. The cavity with in the wheel hub, index 2, should be filled with grease, Crown Part Number

(063002-034). Refer to Figure 17871-01.

The castle nut on the king pin, index 6, should be tightened 50 - 60 Nm (37 - 44 ft lb). Rotate hubs stop to stop a minimum of three times. Loosen nut until free.

Re-tighten nuts to 130 - 140 Nm (96 - 103 ft lb). If necessary (to install cotter pin), tighten nut to the next nearest slot to align with hole in spindle. Refer to Figures 17847-01 and 17871-01.

The tapered roller wheel bearings, index 3, on the steer wheel spindle, must be packed with grease, Crown

Part Number (063002-034) or equivalent prior to assembly. The cavity within the wheel hub, index 4, should be filled with grease, Crown Part Number

(063002-034). The wheel hub oil seal, index 5, has two sealing lips. The seal should be installed with the spring loaded lip toward the bearing side. Refer to Figure 17871-01.

Torque the steering cylinder cap screws, index 7, 114

- 128 Nm (84 - 94 ft lb). For all remaining screws and nuts refer to Lubrication and Adjustment for torque values and procedures. Refer to Figure 17871-01.

Torque the mounting clamp screw nuts, index 4, to secure to Steer Axle mounting point 200 - 220 Nm (147.5

- 162 ft lb). Refer to Figure 17872-02.

3

4

1

2

Figure 17872-02

Part of Power Unit

Mounting Clamp

Steer Axle Beam

Nut Torque to 200 - 220 Nm (147.5 - 162 ft lb)

M6.0-2045-010

02 Rev. 3/09

294

Crown 2007 PF17169-10 Rev. 3/09

STEERING

Steering

Steer Axle Positioning

Your truck has one of three battery compartment sizes

685, 840 or 915 mm (27, 33 or 36 in) and two wheelbases. The 685 mm (27 in) battery compartment has a

1270 mm (50.0 in) wheelbase and the 840 and

915 mm (33 and 36 in) utilize a 1400 mm (55.0 in) wheelbase. Refer to truck Data Plate for battery compartment size.

Refer to the Maintenance ITD chapter for tire information.

The steer axle mounted with the four-hole bolt pattern closest to the fork end of truck for trucks with 840 or

915 mm (33 or 36 in) battery compartment and

1400 mm (55.0 in) wheelbase. Refer to Figure

17849-01.

WARNING

Incorrect mounting of articulation casting and/or steer axel mount can result in the handling characteristics of the truck to be altered. Proper positioning of the articulation casting and steer axle mount, is important for safe operation of the truck.

When assembling the articulation casting, be sure to note the position. When mounting the articulation casting, the long end of the casting should always face towards the fork end of truck regardless of battery compartment size or wheelbase. Refer to Figure 17848-01.

Figure 17849-01

1

2

Steer Axle Mount

133 mm (5.25 in)

The steer axle mount is mounted with four bolt-hole pattern closest to the rear of the truck for trucks with

685 mm (27 in) battery compartment and 1270 mm

(50.0 in) wheelbase. Refer to Figure 17850-01.

1

2

Figure 17848-01

Articulation Casting

Long End Mounted Towards Fork End, Front of Truck

1

2

Figure 17850-01

Steering Axle Mounting Position of 1270 mm (50.0 in)

Wheelbase Truck

133 mm (5.25 in)

Crown 2007 PF17169-11 Rev. 3/09 M6.0-2045-011

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295

Notes:

296

C

LIFTING MECHANISM

297

Notes:

298

LIFTING MECHANISM

Mast

Mast

In this section you will be required to lift and block the truck and mast, use a hoist to raise and lower different components for removal and installation. It will be necessary to disconnect and remove the battery from the truck, disconnect tilt cylinders from the mast, disconnect electrical connections and hydraulic lines. Section

MA, "Control of Hazardous Energy" provides information for performing the above procedures along with some additional information on other procedures dealing with truck maintenance. This section should be read and reviewed prior to mast removal, installation and maintenance as outlined in this section.

Bearing Cap Torque Requirements

Torque the four bolts securing the bearing caps to the mast and drive unit to 70 - 80 Nm (52 - 59 ft lb). Refer to Figure 17405-01. Flatwashers are required under the bolt heads to obtain the correct torque value.

WARNING

Wear appropriate protective items such as safety glasses, work gloves, and steel-toed shoes, whenever performing maintenance work on Crown equipment.

The mast is constructed of hot rolled carbon steel and the sections telescope on steel alloy column rollers.

Two lift cylinders, two tilt cylinders and one carriage cylinder (TT and Quad Mast Only) are used for all lift/ lower and tilt operations. Lift chains, control cables and hydraulic lines are routed throughout the mast assembly.

Figure 17405-01

3

4

1

2

5

Flatwasher

Bearing Cap

Part of Mast

Bearing

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

Mast Flaking

It is not uncommon for a new mast to appear as if it is flaking or peeling. This appearance is an indication that the rollers are seating to the mast channel and is considered normal.

Eventually, this condition will disappear. Grease applied to the channel will retain these particles. If flaking continues, column rollers should be checked to see if they need to be re-shimmed.

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Mast

Mast Testing (Assembled)

With the mast assembled, there are some tests that can be made to verify that column rollers are riding correctly.

Inspect each channel for roller tracking path. The only area that should show wear is the flange of the channel where the roller rides, refer to Figure 16947. The channel should not show signs of any cutting or grooving. If grooving or cutting is evident, it will normally take place at the side of the roller, 10 mm (0.375 in) from the channel flange. If this type of wear is evident, remove a shim. Full surface scuffing is also a sign that too many shims are installed.

Once an adjustment has been made by removing or adding shims, recheck of the mast channel. To see the new wear pattern, clean the channel with a solvent that will remove the lubricant and wipe with a cloth. Spray the channel with a thin coat of paint. This will allow a visible indication of where the rollers are riding. Repeat as required.

Shim Basics

The mast is designed to be at its tightest point when fully extended and its loosest when completely lowered. This allows column rollers to move freely as the mast extends while providing maximum stability with mast fully extended.

Each mast is designed to be wider at the bottom than the top. If the mast was shimmed so it was tight when fully lowered, it would not fully extend because of mast channel to roller binding at about 75% of lift height causing detrimental effects to the mast. The mast should only be checked for tightness when near full extension.

To add shims behind a column roller, the roller must be removed and the shim(s) placed behind the column roller on the stud, refer to Figure 17406-02.

Channel Should Only Show Wear Here

Figure 16947

Once mast meets requirements, lubricate mast with grease, part number (063002-024) for standard applications or (063002-017) for freezer/corrosion applications. When the mast is raised near full extension, it should not lean right or left; instead it should appear straight. If a leaning condition exists, it is a sign that the shimming is too loose or unbalanced and will need to be adjusted, or lift chains require adjustment.

3

4

1

2

5

Part of First Stage Mast - TT

Part of Outer Mast - TL

Column Roller Stud

Column Roller

Shim 0.8 mm (0.031 in) Thick

Figure 17406-02

Crown 2008 PF17343-2 Rev. 10/08 M7.0-2045-002

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300

Shim size is 0.8 mm (0.031 in) thick. When shims are installed, it is always ideal to have an equal number of shims on each column roller stud. Often times this is not possible. If an unequal number of shims are required it is very important that an equal distribution of shims per side be followed. An example would be two shims on each stud for the left column rollers and one on each right side roller stud. If shims are not installed in this manner, mast tilting will occur. Refer to Figure

16950-01.

7

8

6

2

4

5

1

3

Correct

2 Shims (Mast)

1 Shim (Carriage)

2 Shims (Carriage)

1 Shim (Mast)

Incorrect

1 Shim (Mast)

2 Shims (Mast)

9 1 Shim (Carriage)

10 2 Shims (Carriage)

11 1 Shim (Carriage)

12 2 Shims (Carriage)

13 1 Shim (Mast)

14 2 Shims (Mast)


Mast

Crown 2008 PF17343-3 Rev. 10/08

Figure 16950-01

M7.0-2045-003

01 Rev. 10/08

301


Mast

Shim Removal

Under certain circumstances it may be necessary to remove shims with the mast assembled. When necessary, refer to the following procedures.

WARNING




Mast Column Rollers

1.

To access column rollers at top of the mast, completely lower the mast.

To access column rollers at bottom of the mast, raise mast to a position where the column roller that requires adjustment is accessible.

2.

Securely block the mast. Refer to section MA,

"Control of Hazardous Energy", for mast blocking procedures.

3.

To access shims behind column roller, use a pry bar to push column roller out.

4.

Locate the thinnest shim and push it away to isolate it from the rest. Refer to Figure 17407.

5.

Using a hammer and chisel, break and remove the thinnest shim.

Never remove the thickest shim. Its removal will cause the mast to be loose.

Isolate Thinnest Shim

Figure 17407

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Mast

Carriage Column Roller Adjustments

Refer to Figures 17408-01, 17409-01 and 17410-01.

TL carriage has six column rollers on the fork carriage.

Each roller rides the inner channel of the second stage mast. TT trucks have four column rollers that ride the inner channel of the third stage mast.

The top two rollers on the TL carriage are designed to extend above the mast channel. These rollers are retained with a snap ring and require no adjustment. The remaining four carriage rollers will require adjustment.

1.

Extend the carriage until it meets the carriage stops. The top two rollers on the TL carriage will extend above the mast channel.

2.

Lower carriage slightly below stop to free carriage.

Figure 17409-01

1

0-0.76 mm (0-0.030 in) Clearance Between Mast and Roller

1 Prybar Position

2 Feeler Gage Position

4.

Measure the distance between the channel and shoulder of the column roller. Always measure the side the column rollers are canted toward. A clearance of 0 - 0.76 mm (0 - 0.030 in) should be obtained between mast and roller. If the dimension is greater than 0.76 mm (0.030 in), add a shim behind the column roller. A maximum of 6 shims

5 mm (0.2 in) per stud can be used between the stud shoulder and roller bearing. If dimension is 0 and it does not appear to be tight, proceed to check the remaining column rollers. The test procedure after assembly will determine if the column rollers with zero clearance will require shim removal.

Figure 17408-01

1

2

Adjustable Column Rollers

Non-Adjustable Column Rollers

3.

Check each column roller with the carriage extended and using a prybar to shift the carriage to one side. This will force the opposite side tight against the mast channel. This is necessary to seat each column roller against the roller stud shoulder to allow for an accurate roller to channel clearance measurement. Once the carriage has shifted, retain slight pressure to hold the carriage in position.

Figure 17410-01

1 Shim Thickness 0.8 mm (0.030 in)

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Mast

NOTE

Accurate measurements can be checked from one side only. Once the previously described measurements are obtained the column rollers will be within tolerance. When shim adjustments are required, try to even out the number of shims per side. Refer to Figure

16950-01.

WARNING




Carriage Side Thrust Roller Adjustments (TL & TT Masts)

(Refer to Figures 17411-01 and 17412-01)

To adjust the side thrust rollers, proceed as follows:

Side Thrust Rollers

Figure 17411-01

1.

Raise carriage approximately midway in the mast channel it rides in. Securely block the carriage and mast, refer to section MA, "Control of Hazardous

Energy" for blocking procedures.

2.

Loosen cap screw, (4) pull side thrust roller, (1) clear of dowel pin (5) and pivot roller toward the mast channel.

3.

Turn roller cam (3) until side thrust roller (1) is snug against the mast. Align roller cam (3) to dowel pin

(5) and tighten capscrew (4).

4.

Repeat for remaining side thrust roller.

5.

Verify carriage will lower completely and the side thrust rollers are tight against mast during the final

1/3 of lowering.

Figure 17412-01

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Mast

Mast Column Roller Removal - TT

Mast (Inner Mast)

WARNING




1.

Refer to "Shim Basics" and "Mast Testing" to determine shim requirements.

2.

Remove forks and load backrest.

3.

Disconnect hydraulic lines to carriage assembly if present.

4.

Remove carriage, refer to carriage removal in this section and section MA, "Control of Hazardous Energy".

5.

Chock wheels, disconnect and remove battery.

Refer to MA “Control of Hazardous Energy.”

6.

Disconnect hydraulic line to carriage cylinder. Be prepared to catch oil.

7.

Disconnect lift chain anchor from carriage cylinder.

8.

Remove any hoses or control cables that maybe present on yoke.

9.

Place a lifting sling around the carriage cylinder just below the chain anchor and connect to lifting device.

10. Remove clamp that secures carriage cylinder to third stage mast.

11. Using the lifting device, remove carriage cylinder from third stage mast. Place a lifting sling around the third stage mast.

12. Using a lifting device, raise inner mast approximately 50 mm (2.0 in) to allow for slack in the lift chains.

13. Disconnect lift chains from lift cylinders at back of the first stage mast by removing chain pins or anchors. Be sure chains do not obstruct mast when raising or lowering and secure with tie straps.

14. Disconnect lower hose guide bracket and move out of the way (if equipped with optional accessory hoses).

15. Using a lifting device, raise inner mast until it is out of intermediate mast. Lay mast flat on the floor.

16. Remove column rollers and note number of shims on each stud. Remove column rollers carefully as the shims will cling to the back of column rollers and fall off after removal.

•

Refer to "Shim Basics", “Shim Removal” and "Mast

Testing" to determine shim requirements.

17. Raise and securely block truck 130 mm (5.0 in) off of the floor. Refer to section MA, "Control of Hazardous Energy" for lifting and blocking procedures.

18. Place a lifting sling around the intermediate mast.

19. Remove hoses, chains or control cables that maybe present on intermediate mast.

20. Remove clevis pin that secures lift cylinder to outer mast.

21. Remove pins at top of both lift cylinder rams.

22. Using a lifting device, raise the intermediate mast high enough to release the lift cylinders.

23. Tilt lift cylinders inward towards center of mast.

24. Using a lifting device, lower intermediate mast until column rollers on outer and intermediate masts are accessible.


26. Refer to shimming procedures.

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Mast

Mast Column Rollers Removal - TL

Mast

WARNING




1.

Refer to "Shim Basics", “Shim Removal” and "Mast

Testing" to determine shim requirements.

2.

Remove forks and load backrest.

3.

Disconnect hydraulic lines to carriage assembly if present.

4.

Remove carriage, refer to carriage removal in this section and section MA, "Control of Hazardous Energy".

5.


Refer to MA, “Control of Hazardous Energy.”

6.

Disconnect hydraulic tubes to lift cylinders. Be prepared to catch oil and cap lines.

7.

Raise and securely block truck 150 mm (6.0 in) off of the floor. Refer to section MA, "Control Of Hazardous Energy" for lifting and blocking procedures.

8.

Place a lifting sling around the second stage mast.

9.

Remove clevis pin that secures lift cylinder to outer mast.

10. Remove pins at top of both lift cylinder rams.

11. Using a lifting device, raise the second stage mast high enough to release the lift cylinders.

12. Tilt lift cylinders inward towards center of mast.

13. Using a lifting device, lower second stage mast to gain access to column rollers on first and second stage masts.


15. Refer to shimming procedures.

Mast Assembly

Reverse the above procedures for the TT and TL masts.

Lift Cylinder Removal - TL & TT

NOTE

Most repairs can be made without removing the lift cylinders from the truck.

1.

Disconnect hydraulic tubes to both lift cylinders. Be prepared to catch oil.

2.

Connect lifting strap to second stage mast.

NOTE

It maybe necessary to loosen lift chains, hoses and cables to allow the second stage mast to be raised enough to free the lift cylinders for removal.

3.

Remove clevis pin that secures lift cylinder to truck.

4.

Remove screw at top of the ram.

5.

Raise second stage mast and tilt lift cylinders in towards the center of mast.

6.

Using a lifting device, remove lift cylinder from truck.

7.

Repeat above procedure for remaining lift cylinder.

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Mast

Carriage Removal - TL Mast Carriage Removal - TT Mast

WARNING




1.

Raise carriage.

2.

Place hardwood blocks under each side of carriage and lower carriage until carriage chains are slack. Refer to MA, “Control of Hazardous Energy.”

3.

Disconnect battery and chock wheels. Refer to

MA, “Control of Hazardous Energy.”

4.

Disconnect lift chain from either the carriage cylinder or the carriage. Disconnect accessory hoses and control cables if equipped and lay out of the way. Be prepared to catch oil and cap hydraulic lines.

5.

Raise inner mast with a lifting device until the carriage can be pulled forward and out of the mast.

6.

Lower mast to collapsed height.

WARNING




1.

Raise carriage.

2.

Place hardwood blocks under each side of carriage and lower carriage until carriage chains are slack. Refer to MA, “Control of Hazardous Energy.”

3.

Disconnect battery and chock wheels. Refer to

MA, “Control of Hazardous Energy.”

4.

Disconnect lift chain from either the main lift cylinders or the carriage. Disconnect accessory hoses and control cables, if equipped, and lay out of the way. Be prepared to catch oil and cap hydraulic lines.

5.

On TL mast, remove mast stops fastened to the inner mast top. Remove chain pulleys mounted to the outer mast top, so the carriage moves freely.

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Mast

Mast Removal (TL & TT Mast)

Refer to Figures 17413, 17414-01 and 17415-01.

WARNING




If the amount of overhead clearance will not allow the mast sections to be raised enough for removal then the mast assembly will need to be removed from the truck and laid down for disassembly. Refer to section MA,

"Control of Hazardous Energy".

1.

Remove forks and tilt mast completely forward.

2.


Refer to MA, “Control of Hazardous Energy.”

Remove front and rear floorboards.

3.

Cycle control levers a few times to assure hydraulic pressure is relieved from system.

4.

At the top of the mast, connect lifting sling around all mast sections.

WARNING

Make sure lifting device and sling are sufficiently rated to withstand the weigh being lifted. Never work under or around a truck that is not properly secured. Refer to truck Data Plate for truck weight information.

5.

Connect a lifting device to sling on mast assembly.

6.

Disconnect all hydraulic lines and hoses that connect power unit to mast assembly. Be prepared to catch oil and cap all lines.

7.

Disconnect all electrical and cable connections between power unit and mast assembly.

8.

Remove screws that mount retaining clips on tilt cylinder mounting pins (1). Do not remove tilt cylinder pins (2) that connect the tilt cylinder to mast at this time. Refer to Figure 17414-01.

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Securely Block

Counterweight

Figure 17413

Figure 17414-01

9.

Apply tension to the mast assembly using a lifting device. Be sure mast is not binding at this time.

10. Remove bearing caps that connect mast to pivot points on truck.

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Mast

11. Carefully remove both tilt cylinder pins (1) that connect tilt cylinders to mast. Refer to Figure

17415-01.

Mast Assembly (TL & TT Mast)

Refer to Figure 17416-01.

1.

Place lifting sling at top of mast around all sections of mast assembly and attach lifting device to sling.

2.

Carefully raise and position mast on truck. Disconnect battery.

3.

Install bearing caps that mount pivot point of mast to truck, apply thread locking adhesive

(061004-019) to mounting screws and torque to 70

- 80 Nm (52 - 59 ft lb).

4.

Attach tilt cylinders to mast assembly using mounting pins.

5.

Install tilt cylinder mounting pin retainer clips and screws.

Figure 17415-01

12. Tie strap tilt cylinders out of the way.

13. Using a lifting device, carefully remove mast assembly from truck.

14. Place mast assembly on flat surface with side of the mast that faces the operator down.

NOTE

With mast assembly laid down, the cylinders and mast assemblies must be removed by making all hookups with lifting sling and lifting device as near the center of the assembly as possible to maintain balance.

15. Follow the procedures outlined earlier in this section for column roller removal and shimming.

CAUTION

All hydraulic lines, hoses have an o-ring face seal to prevent hydraulic fluid leakage. These o-ring face seals must be replaced to prevent hydraulic fluid leakage whenever the lines are disconnected.

6.

Hoses must not be twisted after assembling. A twisted hose will move from side to side of pulley and/or rise out of pulley(s) when carriage or mast is raised or lowered.

7.

Make sure hoses aren't twisted or snagged on sharp edges when routing hoses through mast.

8.

If truck is equipped with a hydraulic accessory, assemble accessory parts (clamps, guides, etc.) to mast and hydraulic hoses in clamp nearest the manifold block. Refer to Figure 17416-02, 20922 and Mast Accessory Hose Chart to determine the length of hose (3) to be left below the lower clamp

(2).

Mast Accessory Hose Length

(measured from bottom of lower clamp to top of hydraulic fitting)

TT Mast TL Mast

Accessory

Hose

1st Hose (3A)

2nd hose (3B)

3rd hose (4A)

4th hose (4B) mm

90.0

279.0

141.0

333.0

in

3.5

11.0

5.6

13.1

mm

379.0

359.0

277.0

289.0

in

14.9

14.1

10.9

11.4

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Mast

1 Accessory Hoses - TT

2 Lower Clamp (Nearest Manifold Block)

3 Measure from Clamp Bottom to Fitting Top

Figure 17416-02 Figure 20922

1

2

3

Accessory Hoses - TL

Lower Clamp (Nearest Manifold Block)

Measure from Clamp Bottom to Fitting Top

9.

Assemble hose accessory parts (guide(s), clamps, etc.) to mast.

10. Leave top clamp loose and route hoses through clamp(s) and mast.

11. Align the bulkhead fittings with the corresponding hose position in the clamp (refer to mast pages as needed).

12. Remove slack between the upper and lower clamps allowing the hose to bend smoothly below the clamp and maintaining the dimensions (measured from clamp bottom to fitting top) as shown in table.

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Mast

TT Mast

Connect hoses to the carriage bulkheads. Lubricate the hose guide at the bottom of the 3rd stage mast with a suitable substance, such as Armorial protectant or rubber lubricant, allowing the hoses to slide obtaining equal tension on both sides of the guide. Assemble roll pins in the yoke to retain the hose(s) with the slot in the pins away from the hose(s) and flush with the outer side of the pulley(s).

TL Mast

NOTE

Hose guides at top of inner mast must be within

3.0 mm (0.1 in) of hoses.

•

Hoses 3A and 3B - Assemble the hoses into the clamp mounted to the fork carriage with mast and carriage completely lowered. Connect the hose ends to the bulkhead fittings. Remove hose slack between the bulkhead fittings and the clamp. The inside bend radius of the hose must not be less than 50.0 mm (2.0 in).

•

Hoses 4A and 4B - Assemble the hoses into the clamp mounted to the fork carriage with mast and carriage completely lowered. Adjust the hose length below the clamp as shown in the table.

13. Assemble hoses to carriage connections.

14. Tighten clamps. Torque (bulkhead) nuts to 11 Nm

(8 ft lb).

15. Connect all hydraulic hoses and fittings.

16. Assemble all electrical connections. If truck is equipped with accessory control cable, adjust cable grip so extension spring measures 230 mm

(9.0 in). Refer to Figure 17417-02. Be sure cable is not twisted.

Figure 17417-02

1 Extended Working Length 230 mm (9.0 in)

17. Once mast is secured to truck, remove lifting device and sling from mast assembly.

18. Verify all mast stop blocks are in place. When assembling mast stop blocks to outer mast, apply thread locking adhesive (blue) 061004-006 to mounting bolts. Torque bolts 170 - 190 Nm (125 -

140 ft lb).

19. Connect battery.

20. Run operational check on mast assembly. Verify mast operates smoothly and does not bind.

21. Check for oil leaks.

22. Lubricate all grease fittings on mast.

23. Lubricate mast channels as needed.

Refer to Lubrication and Adjustment section for additional information on lubrication points and intervals.

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Mast

Tilt Cylinder Adjustments

Refer to the Electrical and Cylinder service sections for adjustments.

WARNING




In this section you will be required to lift and block the truck and mast, use a lifting device to raise and lower different components for removal and installation. It will be necessary to disconnect and remove the battery from the truck, disconnect tilt cylinders from the mast, disconnect electrical connections and hydraulic lines.

Section MA, "Control of Hazardous Energy" provides information for performing the above procedures along with some additional information on other procedures dealing with truck maintenance. This section should be read and reviewed prior to mast removal, installation and maintenance as outlined in this section.

pair of lift chains are attached to the bottom of the 3rd stage and to the top of the outer mast. These lift chains are routed through pulley assemblies mounted in the top of the 2nd and 3rd stage masts.

The carriage cylinder (or free lift cylinder) is mounted to the inner stage mast with mounting hardware at the base and to the center cross-brace on the inner mast.

Lift chains are routed from the back of the cylinder through a yoke assembly to the back of the carriage assembly. Two tilt cylinders are used for all tilt operations and are attached to the power unit and outer mast.

Mast Flaking

It is not uncommon for a new mast to appear as if it is flaking or peeling. This appearance is an indication that the rollers are seating to the mast channel and is considered normal. Eventually, this condition will disappear. The grease applied to the channel will retain these particles. If flaking continues, column rollers should be checked to see if they need to be reshimmed.

Quad (Four Stage) Mast

The quad is a four stage mast assembly providing a high lift height while maintaining a low collapsed height.

The quad incorporates two lift cylinders and a one carriage (free lift) cylinder. The fork carriage assembly ascends completely to the top of the mast as the carriage cylinder is completely extended. As the carriage reaches the top of the mast, it contacts a pair of stops.

At this time the two lift cylinders begin to extend and the inner, 3rd and 2nd stage masts begin to ascend. A pair of lift chains are attached to the bottom of the inner stage and to the top of the 2nd stage mast. Another

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Mast

Mast Testing (Assembled)

With the mast assembled, there are some tests that can be made to verify that column rollers are riding correctly.

Inspect each channel on outer mast for roller tracking path. The only area that should show wear is the flange of the channel where the roller rides, refer to Figure

16947. The channel should not show signs of any cutting or grooving. If grooving or cutting is evident, it will normally take place at the side of the roller, 10 mm

(0.375 in) from the channel flange. If this type of wear is evident, a shim will have to be removed. Full surface scuffing is also a sign that too many shims are installed.

Roller tracking is different on 2nd, 3rd and inner mast of quad mast. Rollers are mounted parallel to web and rubbing on small raised portion of web is normal.

Channel Should Only Show Wear Here

Figure 16947

Once an adjustment has been made by removing or adding shims, a recheck of the mast channel will be required. To see the new wear pattern, clean the channel with a solvent that will remove the lubricant and wipe with a cloth. Spray the channel with a thin coat of paint. This will allow a visible indication of where the rollers are riding. Repeat as required.

WARNING

Wear appropriate items, such as safety glasses and steel- toed shoes whenever performing maintenance work. Do not place fingers, hands or arms through mast or position them at pinch points.



•

Verify lift chains are of equal tension by raising the fork carriage approximately 75 mm (3.0 in) off of ground.

•

Verify lift chains are properly lubricated. Refer to

Lift Chains section for chain lubrication and inspection procedures.

•

Extend mast to the full lift height and verify mast and carriage extend fully without binding and mast does not skew.

•

Inspect mast rails for lubrication. Lubricate as needed. Refer to Lubrication and Adjustment section for lubrication types and recommended intervals.

•

Verify hydraulic hoses travel evenly in hose guides.

•

Verify hoses are not twisted or kinked.

•

Check for hose connection leaks and tighten loose fittings.

•

Lower mast and inspect wear blocks at top of outer, 2nd and 3rd stage masts for wear and lubrication. Shim and or replace as needed.

•

Inspect all column rollers for flat spots and look for broken or missing shims. Replace as needed.

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Mast

Mast Removal

WARNING

Wear appropriate items, such as safety glasses and steel toe shoes whenever performing maintenance work. Do not place fingers, hands or arms through mast or position them at pinch points.



1.

Move truck to an area set aside for lift truck maintenance that has access to an overhead lifting device sufficiently rated to lift the mast assembly.

2.

Lower mast completely and remove load backrest.

3.

Raise carriage and remove forks.

4.

Lower mast completely.

5.

Connect a lifting device to carriage and raise carriage to get slack in lift chains and any accessory hoses. Disconnect lift chains and hydraulic hoses/ lines from back of carriage. Cap all hydraulic hose/ line connections.

6.

Disconnect hydraulic hose from truck to mast. Cap all hydraulic hose lines.

7.

Attach lifting device to top of the mast assembly and take slack out of lift chain attached to mast.

8.

Disconnect tilt cylinders from mast.

9.

Disconnect mast lower mounting bracket.

10. Remove mast assembly from truck.

11. Reverse the above procedures for installing the mast assembly on the truck.

Carriage Removal

1.

Raise mast high enough to place two 100 x 100 x

510 mm (4 x 4 x 20 in) hardwood blocks under the inner mast. Refer to MA, “Control of Hazardous

Energy.”

2.

Attach an overhead lifting device to the carriage and raise it slightly to get slack in carriage lift chains.

3.

Disconnect carriage lift chains.

4.

Disconnect hydraulic hoses/lines from carriage.

Cap all hydraulic hose/lines.

5.

Remove inner mast stops located at bottom of inner mast.

6.

Using overhead lifting device lower carriage and remove through bottom of inner mast.

7.

Reverse the above steps to install the carriage.

Carriage Inspection

•

Inspect column rollers for excessive wear or damage. Replace rollers with visible flat spots or cracks.

•

Inspect load roller bearings by turning rollers on their shafts. Rollers with roughness or noticeable restrictions to turning should be replaced.

•

Inspect all carriage weldments for cracks. Replace carriage if cracks are visible.

•

Inspect chain anchors for wear or damage. Replace as needed.

•

Inspect side thrust rollers and adjustment.

Lift Chain Tension

Refer to Figure 17419-01.

Lift chains for the quad mast have been pre-stretched to help reduce the amount of chain stretch which will help reduce the amount of adjustments needed. The following is a guideline to use when verifying lift chain tension on quad mast trucks. Lift chains should be inspected every 250 hours or 60 days.

•

Completely lower mast.

•

Raise fork heel 25 mm (1.0 in) off of floor.

•

The top of the outer and 2nd stage masts should be even with each other.

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•

The 3rd stage mast should be about 2 - 3 mm

(0.079 - 0.12 in) above the outer and 2nd stage masts.

•

The inner stage mast should be about 2 - 3 mm

(0.079 - 0.12 in) above the 3rd stage mast. Refer to Figure 17419-01.

•

Any variation in these measurements indicates the lift chain tensions are incorrect and need to be adjusted to achieve the above measurements. Another indication the mast lift chains need adjustment is if the masts are resting on the mast stop bolts at the bottom of the 2nd stage, a stop bar welded to the bottom of the 3rd stage mast and/or the bracket mounted to the bottom of the inner mast. If any of the stages are resting on these locations then the lift chains need to be adjusted to the above listed dimensions. Refer to Figure

17420-01.

•

Always replace lift chains in pairs whenever replacement is indicated.


Mast

Floor

Figure 17419-01

Outer and 2nd Stage Mast Should be Level

(1)

25 mm (1.0 in)

(2)

(3)

2 - 3 mm (0.079 - 0.12 in) Above Outer and 2nd Stage Mast

2 - 3 mm (0.079 - 0.12 in) Above 3rd Stage Mast

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Mast

1

2

3

Part of 2nd, 3rd and Inner Masts

2nd Stage Mast Stop Bolts

Inner Mast Stop Bracket

3rd Stage Mast Stop Bar

Figure 17420-01

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Crown 2008 PF17343-18 Rev. 10/08


Lift Chains

Lift Chains

Lift chains are highly important components on fork lift trucks. The chain system on your mast was designed for efficient, reliable transmission of lifting force from hydraulic cylinder(s) to the mast, platform (if present) and forks. Safe, uninterrupted use of your lift truck depends on the proper care and maintenance of the lift chains.

Most complaints of unsatisfactory chain performance can be traced directly to inadequate maintenance.

Highly stressed precision chains require periodic maintenance to deliver maximum service life.

Roller and Leaf

Chain Wear Scale

Inspection

After every 100 hours of truck operation, lift chains should be inspected and lubricated. When used in an extremely corrosive environment, inspect chains every

50 working hours. During inspection, check for the following:

Wear

As the chain flexes on and off pulleys, the joints gradually wear.

The "stretch" a chain develops during usage is due to material being worn off of pin outside diameter and pin hole inside diameter on the inside plates.

Figure 16844

Chain wear can be measured by using a 106440 wear scale or a steel tape (Refer to Figure 16844). When chains have elongated 3%, as represented on scale

"A" (19 mm [0.75 in] or 25 mm [1.0 in] pitch chain) or scale "B" (16 mm [0.625 in] pitch chain) of the wear scale, they should be discarded. On chain with 19 mm

(0.75 in) between pins, for example, 305 mm (12.0 in) of chain contains 16 pitches or links. When 16 pitches measure 314 mm (12.375 in) the chain should be replaced. On chain with 16 mm (0.625 in) between pins,

20 pitches or links equal 318 mm (12.5 in). When 20 pitches measure 327 mm (12.875 in) the chain should be replaced. Crown currently uses 16 mm (0.625 in) pitch (20 links in 318 mm [12.5 in]), 19 mm (0.75 in) pitch (16 links in 305 mm [12.0 in]) and 25 mm (1.0 in) pitch (12 links in 305 mm [12.0 in]) chain. When checking chain wear, be sure to measure a segment of chain that operates over a pulley. Do not repair chain(s) by cutting out the worn section and splicing in a new piece. If part of a chain is worn, replace lift chain(s). If truck has a matched set of lift chains replace both chains at same time.

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Lift Chains

With Forks Lowered

Check Either Front or Rear Pulley for

Chain Wear

Corroded Chain

(with Stress-Corrosion Cracks)

Figure 16846

Heavy motor oil serves both as a joint lubricant and corrosion inhibitor. During inspection, carefully examine external chain surfaces for the presence of an oily film. Under certain operating or environmental conditions it may be necessary to oil chains more frequently than 100 hour intervals. In all cases, the external surface of the chain must be protected with a film of oil.

Corroded chains should be inspected for cracked plates. Outside plates are particularly susceptible to stress corrosion cracking. If chains are heavily rusted or corroded they should be removed from the mast for a thorough inspection for cracked plates. If plates are cracked, both chains on the truck must be replaced. Oil chains when they are reinstalled on the mast.

Figure 16845

Rust and Corrosion

Chains used on lift trucks are highly stressed precision components. It is very important that "as-manufactured" ultimate strength and fatigue strength be maintained throughout the chain service life.

Corrosion will cause a major reduction in the load-carrying capacity of lift chain or roller chain because corrosion causes side plate cracking.

It is extremely important to protect lift chains from corrosion, whether in service or in storage. The initial factory lubrication on chains is an excellent rust and corrosion inhibitor. Factory lube is applied in a hot dip tank to insure complete penetration into the joint. Do not steam clean or degrease new chains. After the chain has been placed in service, factory lube must be supplemented by a maintenance lubrication program.

Refer to applicable lubrication and adjustment section for your particular truck series and/or the lubrication information later in this section.

Cracked Plates

The most common cause of plate cracking is fatigue failure. Fatigue is a phenomenon that affects most metals and many plastics. After many repeated heavy loads the plates may crack and the chains will eventually break.

Fatigue Cracks

Figure 16847

Fatigue cracks are almost always found through the pin holes perpendicular to the pitch line. (Refer to Figure

16847) Contrast this failure mode to the random failures caused by stress-corrosion cracking. (Refer to

Figure 16846) If any fatigue cracks are discovered during planned maintenance (PM) inspections, both lift chains should be replaced. Many apparently sound plates will be on the verge of cracking, making chain failure very likely.

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Lift Chains

Tight Joints

All joints in lift chain should flex freely. Tight joints resist flexure, increase internal friction, thus increasing chain tension required to lift a given load. Increased tension accelerates wear and fatigue problems. Refer to Figure

16848.

Tight Joints

Protruding & Turned Pin

Figure 16848

Tight joints in lift chains can be caused by:

1.

Bent pins or plates,

2.

Rusty joints,

3.

Peened plate edges.

Oil rusty chains and replace chains that appear bent or peened. Peening of plate edges may be caused by worn pulleys, unusually heavy loads, or chain sliding past a guide or obstruction in the mast.

Protruding or Turned Pins

Heavily loaded chains operating with little lube generate tremendous friction between pin and plates (pin and bushing in roller chain). In extreme cases, the frictional torque in the joint can actually turn pins in the press-fit outside plates.

If chain is allowed to operate in this condition, the pins slowly work out of the chain, causing chain failure.

Turned pins can be quickly spotted because the flats on the "V" heads are no longer in line. Refer to Figure

16849, pin has turned 45 degrees. Chains with turned or protruding pins should be replaced immediately.

Never attempt to repair the chain by driving pins back into the chain.

Figure 16849

Chain Side Wear

A continuous wear pattern on pin heads and outside plates indicates misalignment. Misalignment can be caused by two different factors: unequal chain tension or nonalignment between pulleys and chain anchors.

•

Unequal Chain Tension

- When a lift chain is installed or adjusted, care should be taken to "load" the chains evenly. When changing fork heel height or platform height for example, the chain anchors should be loosened until both forks come in contact with the floor. At this point both chains should display the same tension or slack. The chain anchor nuts should be tightened an equal number of revolutions on both chain anchors to put equal tension on chains. When the desired height setting is achieved the locking nut should be tightened to secure setting.

•

Non Alignment of Lifting Components

- Non alignment of the pulley and chain due to incorrect shimming of the mast or bent or damaged mast or cylinder components can also contribute to chain side wear. A check for this condition is to place the truck on a level area in your maintenance area. After supporting the fork carriage, disconnect each end of the lift chain at the chain anchor and visually inspect its alignment with the anchor slots.

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Lift Chains

Lift Chain Lubrication

The most important consideration in field maintenance of lift chains is LUBRICATION. Hard working, heavily loaded chains cannot be expected to give satisfactory wear life without scheduled periodic lubrication. Like all bearing surfaces, the precision-manufactured, hardened-steel, joint-wearing surfaces require a film of oil between mating parts to prevent rapid wear.

Maintaining an oil film on all chain surfaces will:

•

Minimize joint wear (chain stretch).

•

Prevent corrosion.

•

Reduce the possibility of pin turning.

•

Minimize tight joints in roller chain.

•

Promote smooth, quiet chain action.

•

Lower chain tension by reducing internal friction in the chain system.

Heavy motor oil is an excellent chain lubricant-even used motor oil is adequate to lubricate exposed lift chains.

Laboratory wear tests show SAE 40 oil to have greater ability to prevent wear than SAE 10 oil. Also, SAE 40 oil is superior to hydraulic fluid or automatic transmission fluid. Generally, the heaviest (highest viscosity) oil that will penetrate the joint works best.

Laboratory wear testing shows dry film lubes to be less effective in preventing joint wear than fluid petroleum based products.

Some aerosol spray lubes, such as Crown part number

063001-009, are effective, more convenient and less messy than applying motor oils.

Whatever method is used, the oil must penetrate the chain joint to prevent wear. Applying oil to external surfaces will prevent rust, but oil must flow into the live bearing surfaces for maximum wear life. (Refer to Figure 16850).

Apply oil to chains with a narrow paint brush. A plastic liquid detergent bottle makes a handy lube applicator.

Flood the chain with oil over its entire length every lube-inspection period.

Frequency of lubrication will vary with operating conditions and environment. The best estimate of lube period is 100 hours actual operating truck time. Trucks parked outdoors, used in freezers or trucks in extremely severe service, may require more frequent lubrication to maintain an oil film on all chain surfaces.

In dusty operating conditions, lubed chains will gather dust. Even under these conditions wear life will be greatly improved by periodic lubrication. Joints may acquire a "paste" made up of oil and dirt, but joint wear will still be much less than if the chain is allowed to run dry with metal-to-metal contact between pins and plates.

At 100 hour intervals, clean chains to remove accumulation of dirt-and lubricate immediately. (Do not steam clean chains.)

Lubricant

Figure 16850

Lift Chain Replacement

The first step in chain replacement is to find the chain part number in your service manual parts list.

An important factor in ordering replacement chain from the truck manufacturer is that special chains may be specified for your truck with certified minimum ultimate strength.

If the unit is equipped with two strands, replace chains as a pair. It will be virtually impossible to maintain uniform loading between the strands if a new chain is put into service opposite an old chain. The joints in the old chain will have worn through the hardest layer of the case-hardened pin. Therefore, the wear rate on the old chain will be greater than that on the new chain, greatly complicating the problem of maintaining equal chain tension.

The new chain will wear more slowly, causing it to bear the major portion of the load, resulting in premature wear and fatigue failure.

M7.5-18.0-004

08 Rev. 7/07

320

Crown 1984 PF5856-4 Rev. 7/07


Lift Chains

Never steam clean or degrease new chains. The manufacturer's grease is effective in reducing wear and corrosion. If the original factory lube is dried out or wiped off, soak the new chain in heavy engine oil for at least 0.5 hour prior to installing on truck.

After the existing chains have been removed from the mast, very carefully inspect chain anchors and sheaves. Broken, cracked, or worn anchors must be replaced. Replace worn sheaves, and check sheave bearings for wear. Do not paint the replacement chain before or after it has been installed. Paint will help prevent corrosion, but will prevent oil from reaching the pin surface for good joint lubrication.

Install the new chains, using new anchor pins. Existing pins may contain invisible fatigue cracks that could lead to pin failure. After chains have been connected to the anchors, adjust chain tension to obtain proper fork or platform height.

Correct chain installation and mast adjustment will increase chain service life.

Chain Anchors and Pulleys

An inspection of the chain system should include a close examination of chain anchors, anchor tension devices and pulleys.

Check chain anchors for wear, breakage, and radial misalignment. Anchors with worn or broken fingers should be replaced. Anchors should be adjusted to eliminate twisting or other misalignment in the chain.

When chain is misaligned, the load is not distributed uniformly between the plates-prolonged operation will result in premature fatigue failure.

Pulleys with badly worn flanges and outside diameter should be replaced. Heavy flange wear indicates chain misalignment. Investigate cause by checking chain tension and mast shimming.

Leaf Chain Disconnect

To minimize the risk of damaging (cracking, etc.) the chain, refer to the following when disconnecting leaf chain.

Tools Required:

1.

A sturdy work surface with an opening slightly greater than the pin diameter, and should be thick enough to allow the pin to extend beneath the work surface as it is driven through the bottom pin link plate.

2.

A support ring (flatwasher) with an inside diameter slightly greater than the pin diameter and a height equal to the head height of the pin.

3.

Grinding wheel.

4.

Pin punch with a diameter slightly less than the pin diameter, hammer or pressing equipment.

Disconnect Procedures:


1.

Grind the top head of the pin flush with the pin link plate. Be careful not to grind or damage the pin link plate.

2.

Position the support ring over opening of the work surface. The support ring serves to support the bottom pin link plate and avoids damage to chain components while driving the pin through the chain.

3.

Stand the chain on its side and seat pin in the support ring.

4.

Remove the pin from the chain through the top pin link plate.

(1)

(2)

(3)

(4)

(5)

Support Ring

Grind Pin Flush with Link Plate

Grinding Wheel

Pin Link Plate

Work Surface Knock Out Aperture

Figure 16851

Crown 1984 PF5856-5 Rev. 7/07 M7.5-18.0-005

08 Rev. 7/07

321

Notes:

322


Fork Inspection

Fork Inspection

WARNING

The following causes of fork failure may mean loss of equipment, damaged materials, bodily injury or loss of life. Make an inspection and measurement of the forks at each planned maintenance interval to check for wear, overload, fatigue, bends, etc. Refer to “Lubrication and Adjustment” chapter.

Allowable Wear Thickness Chart 1

Standard Fork

Thickness mm

31.5

in

1.25

38.0

44.5

51.0

57.0

63.5

1.50

1.75

2.00

2.25

2.50

Allowable 10% Wear

Fork Thickness mm

28.5

35.0

39.5

46.0

51.0

57.0

in

1.12

1.38

1.56

1.81

2.00

2.25

WARNING

• Use the proper fork for how it was designed to be used.

• Avoid using fork extensions.

• Do not modify forks.

• Only qualified personnel should make repairs.

• Visually inspect forks each work day.

Abrasion

Abrasion gradually reduces the thickness of the fork.

Be sure the fork thickness is within specifications. Do not allow forks to rub the floor during normal operation.

If forks rub floor, check lift chain adjustment. Fork wear at the heel must not exceed 10 percent of the original thickness. At this point forks are adequate for approximately 80 percent of rated capacity. Refer to Chart 2.

Use fork wear calipers, part no. 107330, or a measuring instrument such as a vernier or good 160 mm

(6.0 in) scale. For allowable fork wear thickness, refer to Chart 1.

If using the fork wear calipers, refer to the following:

Refer to Figure 16854-01. The fork wear calipers have two measuring points or jaws. The inside jaws (2) measure 10% less than the outside jaws (1).

Figure 16854-01

1

2

Outside Jaws 100% (Fork Shank)

Inside Jaws 90% (Fork Blade)

Refer to Figure 16855-01. To set the outside jaws, measure the thickness of the middle of the shank (this point receives almost no wear). Set the calipers to the

“feel” of the shank by lightly tapping on them with a metal object.

NOTE

Care should be taken when using the calipers to hold them square across the shank or an incorrect reading will result.

Crown 1988 PF7393-1 Rev. 11/08 M7.8-04.2-001

05 Rev. 11/08

323


Fork Inspection

1

2

3

Fork Blade

Fork Shank

Measure Here to Set Outside Jaws

Figure 16855-01

Figure 16856-01

1 Fork Shank Cross Section

Once the outside jaws are set, check to see if the inside jaws of the calipers pass over the flanks of the fork blade at any point between the end of the taper and the heel of the fork blade. After checking the blade, recheck the caliper setting by measuring the shank again making sure the setting was not inadvertently changed.

1 Fork Blade Cross Section

Figure 16857-01

M7.8-04.2-002

05 Rev. 11/08

324

Crown 1988 PF7393-2 Rev. 11/08


Fork Inspection

Figure 16858-01

1

2

3

Chart 2 - Wear vs. Capacity

Percentage Reduction in Fork Blade Thickness

Percentage Remaining of Specified Fork Capacity

Overloading

Know the capacity of the forks and truck. Fork capacity and load center is stamped on the fork. Refer to Figure

16859-01. Overloading can cause permanent deformation or serious fatigue conditions.

1

Figure 16859-01

Location of Capacity and Load Center Rating

Crown 1988 PF7393-3 Rev. 11/08 M7.8-04.2-003

05 Rev. 11/08

325


Fork Inspection

Fatigue

A fatigue crack will normally start in the heel area of the fork. Cracks can usually be detected in the early stages by inspection of the heel area. Check for cracks that transverse the fork in an area up to 130 mm (5.0 in) either side of the outer heel radius. These cracks are a sign that the area has weakened and the fork needs to be replaced. Make a visual inspection for cracks each work day. If a more accurate inspection is necessary, use dye penetrants or magnaflux fork.

Figure 16860-01

Figure 16861-01

1 93° Maximum

Use a carpenter’s square to check the fork. Refer to

Figure 16862-01. Hold the square against the shank staying above the radius of the heel as shown. Measure the distance closest to the radius of the heel of the fork blade and square (2). Add 31.8 mm (1.25 in) to this measurement and record. If the distance between the end of the square and blade (3) is greater than this calculation, replace blade (fork is deformed more than

93°).

1

2

130 mm (5.0 in)

130 mm (5.0 in)

Bent or Twisted Forks

Overloading, glancing blows against solid objects or picking up loads unevenly can bend or twist a fork, making fork replacement necessary. The maximum allowable difference in fork tip elevation from one fork to another is 3% of the fork length.

The angle between the top of the fork (blade) to the back surface of the vertical leg (shank) shall be less than 93°. Any angle greater will require fork repair or replacement. The fork manufacturer or service technician with the expertise of equal competence are the only parties that should attempt to make such repairs.

1

2

3

609 mm (2.0 ft)

“x”

“x” + 31.8 mm (1.25 in)

Figure 16862-01

M7.8-04.2-004

05 Rev. 11/08

326

Crown 1988 PF7393-4 Rev. 11/08

Hanger

Check for cracks or damage to the fork pins and the area of fork attachment. Check carriage for excessive wear or cracks. Repair or replace parts if necessary.

Check condition of fork locking pin, spring, cam, etc. for proper operation (if forks are so equipped).


Fork Inspection

1

2

Check Locking Pin, Spring, etc.

Check for Cracks Under Hanger

Figure 16863

Crown 1988 PF7393-5 Rev. 11/08 M7.8-04.2-005

05 Rev. 11/08

327

Notes:

328

CYLINDERS

329

Notes:

330

CYLINDERS

Cylinders

Cylinders

Great care and cleanliness should be exercised in disassembly and assembly of any hydraulic cylinders.

Wipe all surfaces clean of dirt and oil before attempting disassembly. Care should be taken when removing the ram from the cylinder to prevent damage to the packing on the piston end. After ram and wipers are removed, thoroughly wash all metallic parts in solvent and blow dry with compressed air. Carefully inspect the ram assembly and cylinder bore. Replace if scored, grooved, pitted, or worn. Minor damage to the cylinder bore can be removed with the use of a cylindrical honing tool.

Place washed components in a clean container until assembly. Whenever new packing’s are required, new wiper rings should also be installed.

Lift Cylinder

Cap

Seal Removal

When an excessive amount of hydraulic oil is evident on the cylinder, where the ram exits from the cap, the rod packing is probably bad and should be replaced.

Replacement of the packing can be accomplished without removing the ram assembly from the cylinder tube or truck.

Remove the cap as explained in “Disassembly”. If the packing is seated in the cap itself, a hooked tool should be used to remove the packing. If the packing is located below the cap and remains in the cylinder bore after the cap is removed, a pair of special tools can be used to facilitate packing removal (Refer to Figure

12850). To make these tools, weld or braze a headless

4.0 mm self-tapping (No. 8 metal) screw to the end of a screwdriver. The screwdriver must have at least

150 mm (6.0 in) of shank length with no larger than

4.0 mm (0.156 in) shank diameter. After attaching the screw to the screwdriver, grind off excess weld to a diameter of 4.0 mm (0.156 n). Wrap the shank with electrical tape from the tip of the screw to the screwdriver handle. This will prevent scratching of the cylinder bore or the ram.

Cylinder

Tube

Screwdriver

152 mm (6 in) Shaft Length (Min.)

4 mm (0.156 in) Shaft Diameter (Max.)

No. 8 Metal Screw

Headless

(4 mm Self-Tapping)

Bleed

Screw

Figure 14795

Disassembly

Turn the cap counterclockwise and unscrew it from the cylinder tube. Remove the cap and carefully remove the ram assembly from the cylinder bore, never allowing the ram to come in contact with any sharp edges.

Seals

Seals used in the cylinders are made of an extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

Tape

Weld (Grind Off Excess)

To A Max. Dia. of 4 mm (0.156 in)

Figure 12850

Insert the tools between the ram and the cylinder walls,

180 degrees apart, and screw into the face of the packing (Refer to Figure 12851). After the threads are sufficiently secured into the packing, evenly pull on the screwdriver handles until the packing is removed.

NOTE

Extreme care should be taken to prevent damage to cylinder wall and ram assembly.

Crown 1999 PF11695-1 Rev. 9/06 M8.0-1140-001

03 Rev. 9/06

331

CYLINDERS

Cylinders

Seal Pulling Tool

Cylinder Tube

Rod U-Cup Installation

Small U-Cup

•

Installation Tools

– A groove alignment plug (Refer to Figure

12892) is needed which should be flush with groove edge. Any metal or plastic material which is smooth and lubricated may be used.

Pusher Rod

Ram

Seal

Figure 12851

At this time, the wiper ring should also be removed since packings and wiper rings should always be replaced in pairs. Thoroughly clean the area where the seals seat. Any burrs, dirt or seal debris must be removed before re-installing new seals.

Critical

Seal

Seating

Area

Groove

Alignment

Plug

CAUTION

Close inspection of seal seating critical areas should be made before the new seal is installed (Refer to

Figures12892 and 12852). Your seal failure may not have been caused by a worn seal, but rather, by burrs, nicks and dirt located on the seal seating area, causing the seal to deform and lose its sealing ability.

Figure 12892

– A soft metal or plastic pusher rod is needed.

•

Squeeze U-cup together and insert end into bore first. When lower end is engaged in installation groove, release U-cup and force upper end downward using pusher rod until U-cup snaps into groove.

Seal Installation - General

Tools used to install hydraulic seals should be of soft metal or suitable plastic, free of burrs and sharp edges.

Screwdrivers and other similar tools should not be used as they may damage the sealing edges.

The area in contact with the seal should be free of burrs, sharp edges and nicks.

If necessary to force seal over sharp edges, slots or undercuts, protective devices such as a Poly-Pak tool should be used.

Light lubrication should be applied to the seal and installation groove prior to installation. The same oil as will be used later in the cylinder should be applied.

Large U-Cup

•

Installation Tool

– An installation tool made of any soft metal or hard plastic machined smooth and free of burrs with a fixed steel pin (PIN 1) and two movable pins (PINS 2 & 3) is required for this installation method. (Refer to Figure 14796).

M8.0-1140-002

03 Rev. 9/06

332

Crown 1999 PF11695-2 Rev. 9/06

CYLINDERS

Cylinders

Pin 3

Tool Body

Pin 3

Pin 1

Pin 1

Pin 2

Pin 2

Figure 14799

– Withdraw installation tool.

Figure 14796

•

Installation Procedure

– Slip U-cup over the fixed pin (Refer to Figure

14796, PIN 1) and bend it over PIN-2 as shown.

– Continue bending U-cup until PIN 3 can be pushed through the U-cup loop which locks Ucup in position.

– Insert installation tool with mounted U-cup into cylinder bore until aligned with U-cup installation groove (Refer to Figure 14797).

Cylinder U-cup Installation

For “lip first” installation, a sleeve similar to that shown in Figure 12852 should be used to protect the seal from damage on the threads and shoulders.

Cylinder Tube

Sleeve

Forging

Tool

Pin 3

Pin 1

Pin 2

Collar

Seal

Critical Seal

Seating Area

Figure 14797

– Withdraw PIN 3 so that U-cup loop snaps into installation groove (Figure14798).

Pin 3

Figure 12852

Cylinder Assembly

After packings and seals are in place and the ram assembly has been installed, reattach the cap.

Pin 1

Pin 2

CAUTION

Care should be taken when inserting the cylinder cap, to prevent threads and sharp edges from damaging new seals and packings.

Figure 14798

– Withdraw PIN 2 and U-cup will completely snap into installation groove (Figure 14799).

Crown 1999 PF11695-3 Rev. 9/06 M8.0-1140-003

03 Rev. 9/06

333

CYLINDERS

Cylinders

Cylinder Bleeding and Flushing

WARNING

AVOID HIGH PRESSURE FLUIDS—Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.


Mast hydraulic circuits need to be flushed after repair of lift cylinders and bled of all air. Before flushing and bleeding of system inspect all hydraulic connections and verify that all filters are installed and hydraulic fluid levels are adequate for test. Hydraulic system must be pressurized during the flushing and bleeding procedures.

•

Slowly open stage lift cylinder bleed screw and bleed air from cylinder until a solid stream of hydraulic fluid flows out of bleed screw.

•

Tighten bleed screw.

•

Repeat above steps for remaining stage lift cylinder.

Flushing - Stage and Free Lift Cylinders

•

After bleeding cylinders, actuate control valve to raise carriage through free and stage lift and stop to hold in position.

•

With carriage raised, examine cylinders for any leaks.

•

Actuate control valve to lower carriage through stage and free lift to examine operation and staging.

•

Raise and lower carriage rapidly for a minimum of

10 cycles to flush system.

CAUTION


Drift Test


(refer to capacity plate for the rated capacity of your truck). The material used for the load test must be evenly stacked within the limits of a 1 220 x 1 220 mm

(48.0 x 48.0 in) square pallet and must be secured to the fork carriage with the forks spread set to their maximum width.

Bleeding - Free Lift Cylinder

•

Slowly elevate carriage in free lift to approximately

1 220 mm (48.0 in).

•

Slowly open free lift cylinder bleed screw and bleed air from cylinder until a solid stream of hydraulic fluid flows out of bleed screw.

•

Tighten bleed screw.

Bleeding - Stage Lift Cylinders

•

Slowly raise forks to approximately 1 220 mm

(48.0 in).

CAUTION


Fully extend the mast with maximum rated load. The load may not drift down more than 50 mm (2.0 in) within five minutes.

Occasionally, a slight creep of the fork assembly may occur due to internal cylinder seal leakage, but it can also be caused by leakage in the check valves, control valve, etc. To seat these valves properly when this occurs, raise and lower the forks to flush out any foreign material from the valve seat.

M8.0-1140-004

03 Rev. 9/06

334

Crown 1999 PF11695-4 Rev. 9/06

Tilt Cylinder

The tilt cylinders are mounted to the power unit and mast and are double acting piston type cylinders. Extreme care should be taken when performing any type of repair.

CYLINDERS

Tilt Cylinder

Crown 2001 PF13261-1 Rev. 8/07 M8.6-2040-001

02 Rev. 8/07

335

CYLINDERS

Tilt Cylinder

M8.6-2040-002

02 Rev. 8/07

336

(2)

(3)

(4)

(5)

(1) Left and Right is Determined from the

Operator’s Perspective

Part of Mast

Torque to 102 Nm (75 ft lb)

Torque to 270 - 340 Nm (200 - 250 ft lb)

Part of Main Frame

Figure 17745

Crown 2001 PF13261-2 Rev. 8/07

CYLINDERS

Tilt Cylinder

WARNING



Cylinder Cap

Assembly

(1)

(2)

(3)

(4)

(5)

Rod Packing

Wiper Ring

Cylinder Cap

Back-up Ring

O-Ring

Figure 17431

Next, carefully remove rod assembly from cylinder tube.

Cylinder Disassembly

Before proceeding with disassembly, thoroughly clean outside of cylinder to remove grease and dirt buildup.

Place cylinder in a vise. Be careful not to over-tighten vise, because cylinder tube can be easily damaged. An adjustable spanner wrench, similar to the one shown in

Figure 17430, is required for disassembly. A face spanner wrench with 4.75 mm (0.1875 in) pins and a spread of at least 70 mm (2.625 in) is sufficient.

Rod Assembly

(5)

(6)

(7)

(8)

(1)

(2)

(3)

(4)

Roll Pin

O-Ring

Wrench Flat

Rod

Back-up Ring

Piston

Piston Seal

Castle Nut

Figure 17342

Inspect cylinder tube for any signs of scoring. If scoring is evident, tube must be replaced. The cylinder tube should be honed to remove any remaining burrs.

Figure 17430

Using spanner wrench, remove cylinder cap assembly.

Rod Disassembly

Remove roll pin and castle nut (wrench flats on rod are provided to loosen and tighten castle nut). Slide all components off end of rod. Inspect rod for scoring or other damage. If damage or scoring is evident, replace rod.

Crown 2001 PF13261-3 Rev. 8/07 M8.6-2040-003

02 Rev. 8/07

337

CYLINDERS

Tilt Cylinder

Seal Replacement

Using a small hooked tool, carefully pull the seals from their mounting grooves.

CAUTION

Never use a screwdriver to remove seals, components could be damaged causing cylinder leakage.

After removing all seals, inspect contact surfaces on both piston and cylinder cap. If slight scoring is evident, sand with fine emery paper until all high surfaces have been removed. Heavily scored components must be replaced. After all parts have been disassembled and inspected, wash all cylinder components in a good grade solvent, such as Crown part number

065009-005 and dry with low air pressure.

WARNING

When cleaning piston and cylinder cap, be sure to clean seal seating areas. Protect eyes and face when using compressed air. After all parts have been thoroughly cleaned, place in a dirt free area until ready for reassembly.

Cylinder Reassembly

Apply a coating of hydraulic oil part number

(063001-001) to all seals before they are assembled.

Install all seals by hand. After seals have been installed, install piston, castle nut and roll pin on rod; be sure piston is seated properly against rod shoulder. After installing rod assembly into cylinder tube, carefully assemble cylinder cap into tube and torque to 270 -

340 Nm (200 - 250 ft lb).

Tilt Cylinder Flushing and Bleeding

Procedures

With all cylinders in the retracted position, verify oil level in reservoir is between "add" and "full" marks on dipstick. After all air has been bled from cylinders, hydraulic oil may need to be added to reservoir. Do not over fill reservoir.

CAUTION


Carriage hydraulic circuits need to be flushed after repair of tilt cylinder and bled of all air. Before flushing and bleeding of system, inspect all hydraulic connections and verify that all filters are installed and hydraulic levels are adequate for test. The hydraulic system must be pressurized during the flushing and bleeding procedure.

•

Turn truck ON, tilt mast completely forward.

•

Tilt the mast completely back.

•

Repeat this complete cycle, totally forward and then completely back, a minimum of 10 times.

•

If it is suspected that any air is still in the system, repeat the process.

Tilt Cylinder

CAUTION

Care should be taken when inserting the cylinder cap to prevent sharp edges from damaging the new seals and packings.

Figure 17433

M8.6-2040-004

02 Rev. 8/07

338

Crown 2001 PF13261-4 Rev. 8/07

CYLINDERS

Tilt Cylinder

Tilt Drift Test


(refer to capacity plate for truck's rated capacity). Material used for load test must be evenly stacked within the limits of a 1.2 x 1.2 m (4 x 4 ft) pallet and must be secured to fork carriage with forks spread to their maximum width.

CAUTION


Cycle tilt forward and back several times before testing.

Raise maximum rated load 610 mm (24.0 in) off floor.

Measure drift at tilt cylinder rod. With forks tilted back completely, forks may not drift forward more than

16 mm (0.63 in) within 5 minutes as measured on tilt cylinder rod.

Tilt Cylinder Installation and Adjustments

Check to be sure correct cylinder clevises and spacers are used for required tilt. Refer to Chart 1 for part and dash numbers.

Chart 1 Tilt Range

Tilt Range

Back/Forward

Adjustable

Spacer Dash

Number

Non-Adjustable

Spacer Dash

Number

Clevis

Dash

Number

3°/3°

3°/5°

-015

-014

-020

-019

-001

-002

5°/5°

3°/10°

5°/10°

-013

-016

Not Used

-018

-021

Not Used

-002

-003

-003

Position adjustable spacer so side with stamped dash number faces clevis. Install adjustable spacer on right cylinder. Assemble adjusting ring on spacer so it is flush with spacer. Refer to Figure 17435.

Crown 2001 PF13261-5 Rev. 8/07

(1)

(2)

(3)


Left Cylinder

Right Cylinder

Figure 17434

(1)

(2)

(3)

(4)

(5)

(6)

Adjustable Spacer

Clevis

Non-Adjustable Spacer

Wrench Flats

43 mm (1.7 in)

Adjusting Ring

Figure 17435

M8.6-2040-005

02 Rev. 8/07

339

CYLINDERS

Tilt Cylinder

Install non-adjustable spacer on left cylinder.

Assemble clevises on both cylinder rods so that 43 mm

(1.7 in) 20.3 revolutions of the rod is threaded into clevis. Tighten bolts that clamp clevises to cylinder rods.

Connect left clevis to mast with pivot pin (right side will be connected and adjusted later).

NOTE

Truck must be empty and on a level floor to perform the following adjustments.

Extend left cylinder to full forward position. Refer to Figure 17436 and Chart 2 to determine the degree of forward tilt.

Clevis Symbols

Located Here

Figure 17436

Chart 2 Clevis Symbols

Clevis Symbols

3FC

5FC

10FC

Degree of Forward Tilt

3°±15 Minutes

5°±15 Minutes

10°±15 Minutes

Loosen clamping bolt just enough to enable cylinder rod to be rotated. Measure first stage tilt mast. If degree of tilt is not within the ± 15 minute tolerance specified in

Chart 2, rotate cylinder rod until desired degree of tilt is within tolerance range. (Mast may need tilted back to allow access to wrench flats on cylinder rod). Refer to

Chart 3 to determine how much to rotate rod.

Chart 3 Cylinder Rod Rotation

Cylinder Rod

Rotation

180°

360°

Distance Clevis moves

Approximate

Degree of Mast

Tilt

1.1 mm (0.043 in) 0°±9Minutes

2.1 mm (0.083 in) 0°±18 Minutes

When all adjustments are completed, torque clamping bolt on clevis 102 Nm (75 ft lb).

Extend both cylinders to full forward tilt position and measure how far the remaining (right) clevis needs to be adjusted to engage tilt lug on mast.

Adjust right cylinder. Torque clamp bolt on clevis

102 Nm (75 ft lb).

Attach clevis to mast using pivot pin.

Tilt mast back until left cylinder spacer is snug and cannot be rotated freely. Don't attempt to tilt back any farther.

There should now be a gap between the right adjustable spacer and cylinder. Turn the outer ring until there is no gap on the right side.

Tilt mast forward and back to check adjustment. Both cylinders should contact spacers at the same time. If not, rotate adjusting ring.

Secure adjustment by tightening the adjusting ring set screws.

M8.6-2040-006

02 Rev. 8/07

340

Crown 2001 PF13261-6 Rev. 8/07

CYLINDERS

Steer Cylinder

Steer Cylinder

(1)

(2)

(3)

(4)

(5)

Lubrication Fitting

Retaining Ring

Rod Packing

Rod Cylinder

Piston Seal

(6)

(7)

(8)

(9)

(10)

O-Ring

Cap

Spherical Bearing

Wiper Ring

Backup Ring

Figure 17474

The steer cylinder is a double acting, piston type cylinder. When the steering wheel is rotated, pressurized oil is ported to the side of the cylinder in the direction of the rotation. Oil is forced out of the opposite side of the cylinder and returns to the reservoir.

When an excessive amount of hydraulic oil is present at the rod ends of the cylinder, the rod packing or wiper ring located on the inside diameter. of endcaps are probably faulty and should be replaced. If the area around the outside of the cylinder has oil present, the o-ring or backup ring located on the outside diameter of the endcaps are probably faulty and should be replaced. If the cylinder is slow to react when turning, the piston seal is probably faulty and should be replaced.

A seal kit, part number (113744), is available for this cylinder. When replacing rod packing, wiper rings, etc., install all parts contained in seal kit.

Care and cleanliness should be exercised in the removal and/or repair of hydraulic cylinders. Wipe all surfaces clean of oil and dirt before attempting cylinder removal from truck or cylinder disassembly.

WARNING

Wear appropriate items, such as safety glasses and steel-toe shoes whenever performing maintenance work. Do not place fingers, hands or arms through mast or position them at pinch points.



Crown 1992 PF9341-1 Rev. 8/07 M8.8-20.0-010

01 Rev. 8/07

341

CYLINDERS

Steer Cylinder

Cylinder Removal

Disconnect battery and chock drive tires.

Raise and block rear of truck to access cylinder and cylinder hydraulic hoses.

Be prepared to catch hydraulic oil and disconnect hydraulic hoses. Note position of hoses for assembly.

Disassemble the four cylinder mounting bolts.

To remove cylinder from link assembly, pull cylinder away from steering frame.

Access link bolt nuts by removing caps located below each end of cylinder rod.

To prevent damage to link bolt threads when disassembling, remove cotter pins and loosen link bolt nuts so that they are flush to end of bolt.

Using rubber mallet, tap link bolts to free from cylinder rod bearings (be careful not to damage bolt threads).

Remove nuts, link bolts and cylinder.


Place cylinder in a vise. Be careful not to overtighten vise to avoid tube damage.

A retaining ring secures the endcaps to the cylinder tube, refer to Figure 17320. Using a pipe wrench, rotate one endcap so that the end of the retaining ring rotates out of the cylinder tube slot. Refer to Figure 17320 item

4. Remove retaining ring and endcap.

M8.8-20.0-011

01 Rev. 8/07

342

Crown 1992 PF9341-2 Rev. 8/07

CYLINDERS

Steer Cylinder

(1)

(2)

(3)

(4)

(5)

(6)

Wiper Ring

Rod Packing

Endcap

Retaining Ring

Backup Ring

O-Ring

(7)

(8)

(9)

(10)

(11

(12)

Tube

Bearing

Retaining Ring

Rod

Piston Seal

Lubrication Fitting

Carefully remove cylinder rod from tube. Never allow rod to contact any sharp edges and avoid contacting inside of tube with rod.

Remove remaining endcap.

CAUTION

Remove seals and thoroughly clean seal seating area.

Any burrs, dirt or seal debris must be removed before installing new seals. Close inspection of the seal seating areas should be made before new seal is installed.

Your seal failure may not have been caused by a worn

Figure 17320

seal, but rather by burrs, nicks and dirt located on the seal seating area causing the seal to deform and lose its sealing ability.

Inspect the cylinder tube, rod and endcaps for scoring and burrs. Remove with fine emery cloth. Heavily scored components must be replaced. Inspect bearings located on each end of rod and replace if necessary.

After all components are inspected, thoroughly clean all components and place in a clean area until ready for assembly.

Crown 1992 PF9341-3 Rev. 8/07 M8.8-20.0-012

01 Rev. 8/07

343

CYLINDERS

Steer Cylinder


Before assembling cylinder, all seals should be replaced.

Lightly coat seals and inside the cylinder tube with hydraulic oil. Assemble seals to endcaps and rod.

Place cylinder tube in vise. Be careful not to overtighten vise to avoid tube damage.

Align hole in one endcap with tapered slot in tube and insert cap in tube so hole is visible through slot.

Insert hooked end of retaining ring into hole in end cap and rotate endcap until end of retaining ring is flush with tube. Avoid turning end of retaining ring too far into tube making removal difficult. Endcap mounting hole tabs should be perpendicular to steering link bearing holes.

Insert rod into cylinder being careful not to damage piston rod seal or seals in endcap.

Assemble remaining endcap and retaining ring. Endcap mounting hole tabs should be perpendicular to steering link bearing holes. Be sure lube fittings at each end of the cylinder rod accept grease.

Cylinder Installation

Assemble cylinder to steering links. Be sure orientation of cupped washer is correct, refer to Figure 17475.

Torque the castle nuts 65 - 70 Nm (48 - 52 ft lb). Install cotter pin and check link for free movement.

(1)

(2)

(3)

Steering Link Bolt

Cupped Washer

Castle Nut Torque

65 - 70 Nm (48 - 52 ft lb)

Figure 17475

Assemble cylinder to steering frame with the four mounting bolts and secure.

Connect hydraulic hoses to cylinder.

Remove blocks, connect battery and check operation.

M8.8-20.0-013

01 Rev. 8/07

344

Crown 1992 PF9341-4 Rev. 8/07

Parking Brake Cylinder

CYLINDERS


(5)

(6)

(7)

(1)

(2)

(3)

(4)

Label

Ball Joint

Bearing Sleeve

Cylinder Cap

Spring

Spring

Washer

(8)

(9)

(10)

(11)

(12)

(13)

Wiper Ring

Packing Rod

Rod

Cylinder Bottom

Bleed Screw

Seal

Care and cleanliness should be exercised in the disassembly and assembly of hydraulic cylinders. Wipe all surfaces clean of dirt and oil before attempting cylinder removal from truck and/or cylinder disassembly.

Figure 17489

Three 7 mm (0.25 in) holes evenly spaced around the cylinder cap allow for any oil drainage that may be present when the packing rod seal or wiper ring becomes worn and should be replaced. Replace the wiper ring when replacing the packing rod seal.

Crown 2007 PF17017-1 M8.8-2045-001

345

CYLINDERS


Cylinder Removal

Chock load wheels, disconnect battery and remove floorboard.

Release hydraulic pressure to cylinder. To release pressure:

Remove contactor panel cover from left side of truck and remove steering pump motor power fuse, FU3, from fuse panel. Refer to Figure 17490.

(1)

(2)

FU3

Fuse Panel

(1)

(2)

(3)

(4)

Backing Plate

Parking Brake

Pivot Arm

Traction Motor

(5)

(6)

(7)

(8)

Park Brake Cylinder

Ball Joint

Cotter Pin Ring

Pin

Figure 17491

Remove cotter pin rings and pin securing bottom of cylinder to backing plate.

Make sure hydraulic pressure has been released and carefully disconnect hydraulic hose from cylinder.

Figure 17490

Connect battery and release parking brake.

Actuate seat switches and pump the service brake pedal until parking brake applies. Cycle the parking brake switch, on and off, two times (minimum) to completely relieve pressure from circuit.

Disconnect battery.

Disassemble ball joint located at top of cylinder from parking brake pivot arm. Refer to Figure 17491.

WARNING



If further disassembly is required, move cylinder to a clean, well lit work area.

Crown 2007 PF17017-2 M8.8-2045-002

346

CYLINDERS



WARNING

The cylinder assembly contains compressed coil springs that apply approximately 535 N (120 lb) of force on the cap. Take precautions during cap removal to prevent uncontrolled disassembly and prevent possible injury to yourself and others. Observe the following procedures carefully.

The cylinder cap can be removed by placing the bottom end of the cylinder in a vise; use a spanner wrench with a 7 mm (0.25 in) pin and 57 mm (2.25 in) diameter to turn the cylinder cap. Three holes are drilled in the cap to accommodate spanner wrench. Carefully turn cap counter-clockwise until disassembled from bottom of cylinder.

The packing rod seal and wiper ring are contained in the cylinder bottom. A hooked tool should be used to remove seals. Tool should be constructed of aluminum or brass so surfaces are not scratched or nicked. Thoroughly clean the area where the seals seat. Any burrs, dirt or seal debris must be removed before installing new seals.

Inspect rod, cylinder cap, springs, etc. If all appears satisfactory, no further disassembly is necessary.

If signs of scoring to the rod and/or cap, replace components. After all parts are inspected, wash all cylinder components in a good grade solvent and blow dry with low pressure air.


Install bearing sleeve to rod end of cylinder cap.

Lightly lubricate seals and installation grooves with truck hydraulic oil. Install packing rod seal and wiper ring in cylinder bottom.

Insert cylinder rod in cylinder bottom. Carefully guide rod through packing rod seal and wiper ring.

Install washer and springs on cylinder rod and position rod into cylinder cap. Assemble cap to cylinder bottom.

CAUTION

Care should be taken when installing cylinder cap to prevent damage to threads. The springs will become slightly compressed when installing cap. Clamp cylinder bottom in vise carefully to allow for more control when installing cap. Do not tighten vise too tight causing cylinder bottom damage.

Assemble ball joint to rod.

Make sure "Warning" label is affixed to cylinder assembly and is readable.

CAUTION

When cleaning piston, be sure to clean seal seating areas. Protect eyes and face when using compressed air.

After all parts are thoroughly cleaned, place in a clean area until ready for assembly.

Crown 2007 PF17017-3 M8.8-2045-003

347

CYLINDERS


Cylinder Installation

Connect hydraulic hose to cylinder.

Using cotter pin rings and pin, secure bottom of cylinder to backing plate.

Assemble ball joint to parking brake pivot arm.

Assemble steering pump motor power fuse, FU3, to fuse panel. Install contactor panel in truck.

Connect battery.


Release parking brake.

Slowly open bleed screw on park brake cylinder. Allow air-oil mixture to flow until a solid stream of oil is achieved. Tighten bleed screw 7.6 Nm (90 in lb).

(1)

(2)

(3)

(4)

Parking Brake

Traction Motor

Park Brake Cylinder

Bleed Screw

Apply parking brake.

Install floorboard.

Remove chocks and check operation.

Figure 17493

M8.8-2045-004

348

Crown 2007 PF17017-4

GLOSSARY

349

Notes:

350

GLOSSARY

Glossary

Glossary

Components have been listed in chart form to assist the service technician in locating these components on the Electrical Diagrams and Parts Breakdown forms.

The chart is in columns:

Component

;

Location

;

Function

;

Diagram

;

Parts Breakdown

. The

Component

column contains the abbreviation of the component as it appears on the Diagrams in the Maintenance Section. The

Location

column gives the general location

BATTERY

Location

Battery Power Unit Battery

Compartment

Function

Power Supply on the truck such as on platform or in power unit. The

Function

column then explains the function or circuit of that device. The

Diagram

column gives the page number of the diagram on which the component can be found. The callout in parenthesis following the page number corresponds to the grid callouts on that diagram, locating that component. The

Parts Breakdown

column includes the parts breakdown page number on which the component is located along with the index number, in parenthesis, if applicable.

Diagram

DIA-2045-002 (B-4)

DIA-2045-003 (B-4)

DIA-2045-004 (B-4)

DIA-2045-017 (A-4)

DIA-2045-019 (A-3)

DIA-2045-020 (A-3)

Parts Breakdown

01.2-2045-001

CONNECTIONS

Location

CA201 Distribution Panel







CA208 Temperature

Management Module

CA401 Access 3

CA402 ACCESS 3

CA403 ACCESS 2

CA404 ACCESS 2

CA409 Close to ACCESS 2

CA410 Seat

Function Diagram Parts Breakdown

B-, BV(FU4), Steer Solenoid DIA-2045-005 (A-2) 04.3-2045-001 (13)

FAN4, ACCESS 3, HGTS1 DIA-2045-005 (B-1) 04.3-2045-001 (13)

SES, FS, RS, Steer K1 & K2 DIA-2045-005 (C-2) 04.3-2045-001 (13)

K2, FS, RS, CAN

FU4, ALM2, FAN3, ACCY

DIA-2045-005 (C-3) 04.3-2045-001 (13)

DIA-2045-005 (C-4) 04.3-2045-001 (13)

12V Power Supply DIA-2045-005 (B-4) 04.3-2045-001 (13)

ALM3, LGTS1, LHTS2, LGTS3 DIA-2045-005 (A-3) 04.3-2045-001 (13)

Lift Pump & Steer Motor Brush

Wear & Temperature

DIA-2045-009 (B-4) 02.2-2045-050,

06.2-1140-001

Handset

Serial Communication

DIA-2045-006 (C-1) 04.1-2045-001

04.1-2045-050

DIA-2045-006 (B-2) 04.1-2045-001

04.1-2045-050

Handset

Main Plug Traction Module

+BV, TS2 Signal, CAN H,

CAN L, HSS, ECR2

SES or SES1 & SES2

DIA-2045-007 (B-1) 04.1-2045-050

DIA-2045-007 (B-1) 04.1-2045-050

DIA-2045-007 (B-2) 02.2-2045-001 (22)

02.5-2045-001 (59)

02.5-2045-050 (59)

02.5-2045-100 (59)

DIA-2045-002 (A-4)

DIA-2045-003 (A-4)

DIA-2045-004 (A-4)

DIA-2045-011 (B-1)

01.5-2040-007 (47)

01.5-2040-056 (16)

Crown 2007 PF17082-1 M10-2045-001

351

GLOSSARY

Glossary

CONNECTIONS (Continued)

CA601

CA602 Front Cowl

CA603 Power Unit Left Side

CA604 Power Unit Left Side

CA605 Contactor Panel

CA606

CA607

CA611

CA612

CA613

CA614

CA615

CA625

CA626

CA627

Location

Steer Column

Lift Pump Motor

Lift Pump Motor

Main Harness

Close to Accelerator

Front Wall

Height Switch Mast

Front Wall

Front Battery Wall

Front Cowl

Truck Frame

Function

KYS, FS, RS, HNS, FODC

PRK-A, PRK-B, Auto Park

Brake Option

ECR1, TS1

ECR2, TS2 Signal

L, P, S Contactors

Lift Pump Motor

ECR2 Interconnect DTM)

ACS

ACC Potentiometer

HGTS1/ Main Harness

Interconnect

HGTS1/Cond. Cable

Interconnect

5th Function Interconnect

PS1

ALM2 (Brake Alarm)

ALM3 (Travel Alarm)

Diagram Parts Breakdown

DIA-2045-011 (B-2) 06.0-2040-001 (17)

04.5-1140-002 (7)

04.5-2045-050 (2)

DIA-2045-011 (B-4) 04.8-2040-050 (6)

DIA-2045-014 (B-1) 03.1-2045-001 (16)

DIA-2045-014 (B-2,

B-3)

02.2-2045-001

DIA-2045-002 (B-2,

C-3)

DIA-2045-003 (C-3)

DIA-2045-004 (B-2,

B-3, C-4)

DIA-2045-014 (B-4)

04.2-2045-001 (10,

14)

DIA-2045-014 (B-1) 02.2-2045-001 (22)

DIA-2045-014 (B-2) 02.2-2045-001 (7)

DIA-2045-002 (B-3)

DIA-2045-003 (B-3)

DIA-2045-004 (B-3)

DIA-2045-013 (B-1)

04.6-2045-001 (23)

DIA-2045-013 (B-1) 04.6-2045-001 (20)

DIA-2045-002 (B-3)

DIA-2045-003 (B-3)

DIA-2045-004 (B-3)

DIA-2045-009 (B-2)

DIA-2045-009 (B-2) 07.1-2040-001 (20)

07.2-2040-001 (20)

07.24-2040-001

(15)

DIA-2045-008 (B-2))

07.1-2040-001 (20)

07.2-2040-001 (20)

07.24-2040-001

(15)

02.0-2045-050 (20) DIA-2045- 002 (B-3)

DIA-2045-003 (B-3)

DIA-2045-004 (B-3)

DIA-2045-013 (B-3)

DIA-2045- 002 (B-2)

DIA-2045-003 (B-3)

DIA-2045-004 (B-3)

DIA-2045-013 (B-3)

DIA-2045-004 (C-3)

DIA-2045-013 (B-4)

04.0-2045-001 (8)

04.0-2045-001 (77)

M10-2045-002

352

Crown 2007 PF17082-2

GLOSSARY

Glossary


CA630

CA631

CA632

CA633

CA634

CA641 Front Cowl FU5, K1, LGS1, LGS2

CA642 Front Cowl Accessory Cable

CA651 Power Unit Right Side OHG Harness to Main (FU5,

K1, LGS1, LGS2, RS)

CA661 Fan

CA662 Fan

CA663 Fan

CA664 Fan

FNS

Diode

Diode

Diode

CA665 Fan

CA666 Fan

CA667 Fan

CA801 OHG

Operator Fan

Low Speed

High Speed

+BV Rear Work Light

CA802

CA803

CA804

CA805

CA806

CA807

CA808

CA809

Location

ACCESS 1

Below Hydraulic Levers

Front Cowl

Front Cowl

Steer Column

OHG

OHG

OHG

OHG

OHG

OHG

OHG

OHG

Function

Display

Hydraulic Switches/Tilt

Interlock

ACCESS1(Display)

ACCESS 1 (Display)

CAN Access

B- Rear Work Light

Tail Distribution Panel

+BV Strobe Light


B- Strobe Light






Diagram

DIA-2045-002 (B-2)

DIA-2045-003 (B-2)

DIA-2045-004 (B-2)

DIA-2045-010 (B-2)

DIA-2045-008 (B-1,

A-3)

Parts Breakdown

04.0-2045-001 (13)

02.5-2045-001

02.5-2045-050

02.5-2045-100

DIA-2045-010 (B-2) 04.0-2045-001 (13)

DIA-2045-010 (B-3) 04.0-2045-001 (13)

DIA-2045-010 (B-4)

DIA-2045-015 (B-1)

DIA-2045-002 (B-4)

DIA-2045-003 (B-4)

DIA-2045-004 (B-1,

B-4)

DIA-2045-009 (B-2)

DIA-2045-009 (C-2)

DIA-2045-016 (B-2,

B-3)

DIA-2045-009 (B-3) 04.0-2045-001 (1)

DIA-2045-009 (B-3) 4.9-2040-001 (40)

DIA-2045-009 (B-3) 4.9-2040-001 (40)

DIA-2045-009 (B-3) 4.9-2040-001 (40)

DIA-2045-009 (B-3) 4.9-2040-001 (40)

DIA-2045-009 (C-3) 4.9-2040-001 (40)

DIA-2045-009 (C-3) 4.9-2040-001 (40)

DIA-2045-016 (B-1,

B-3)

04.9-2040-050 (30)

04.9-2040-050 (30) DIA-2045-016 (B-1,

B-3)

DIA-2045-016 (B-1,

B-3)

DIA-2045-016 (B-2,

B-4)

04.9-2040-050 (1,

13)

04.9-2040-050 (1,

13)

DIA-2045-016 (B-2) 04.9-2040-050 (13)

DIA-2045-016 (B-2) 04.9-2040-050 (13)

DIA-2045-016 (C-1) 04.9-2040-050 (13)

DIA-2045-016 (C-1) 04.9-2040-050 (13)

DIA-2045-016 (C-2) 04.9-2040-050 (13)

Crown 2007 PF17082-3 M10-2045-003

353

GLOSSARY

Glossary


Location

CA810 OHG

CA811 DIstribution Panel


Function


Freezer Corrosion Board

Freezer Condition Board

CA813 F/C Distribution Panel I/O Heaters & Thermostats

CA814 In Foot Operated Direc-

CA817

CA818

CA819

CA820

CA821

CA822 tion Control Harness

OHG

OHG

OHG

OHG

OHG

OHG

Power for Patch Heaters

+B Front Left Worklight

B- Front Left Worklight

+B Front Right Worklight

B- Front Right Worklight

+B Strobe Light

B- Strobe Light

Diagram Parts Breakdown

DIA-2045-016 (C-2) 04.9-2040-050 (13)

DIA-2045-017 (B-1) 04.3-2045-001 (21)

DIA-2045-017 (B-1) 04.3-2045-001 (21)

DIA-2045-017 (C-2)

DIA-2045-018 (B-2,

B-4)

04.3-2045-001 (21)

DIA-2045-018 (B-2,

B-4)

DIA-2045-016 (C-3,

C-4)

DIA-2045-016 (C-3,

C-4)

DIA-2045-016 (C-3,

C-4)

DIA-2045-016 (C-3,

C-4)

04.9-2040-001 (1)

04.9-2040-075 (1)

04.9-2040-100 (14)

04.9-2040-001 (1)

04.9-2040-075 (1)

04.9-2040-100 (14)

04.9-2040-001 (1)

04.9-2040-075 (1)

04.9-2040-100 (14)

04.9-2040-001 (1)

04.9-2040-075 (1)

04.9-2040-100 (14)

DIA-2045-016 (B-1) 04.9-2045-050 (1)

DIA-2045-016 (B-1) 04.9-2045-050 (1)

M10-2045-004

354

Crown 2007 PF17082-4

WIRING DIAGRAMS

355

Notes:

356

WIRING DIAGRAMS

Introduction to Diagram Usage

Introduction to Diagram Usage

Schematic

•

Power up diagram. Illustrates the circuitry involved in getting the truck system to an operating mode

(Can Interface, Access 1,2,3, Controller, Contactor, ect.).

•

Circuitry which stands alone and is separate from truck operation is shown in block form with the pictorials detailing the circuitry (e.g. light package, displays, wire guidance, freezer condition).

•

The truck has been sectioned with one page covering each section. When options affect the wiring in a section, an additional page is added which duplicates wiring that is identical and adds the option wiring. In this way only one page of the truck section is required for the applicable truck configuration.

•

Wiring that is identified by color rather than number will typically be a cable or wires with vendor componentry.

•

Page titles, listed at the beginning of the electrical diagrams, indicate the subsystem or section of truck wiring that is covered by each page.

Pictorials

•

Terminal board and connector numbering on the pictorials are in two classes; power unit and platform. Power unit TB's and CA's are even 100's

(200, 400, 600 etc.) and platform TB's and CA's are odd 100's (100, 300, 500 etc.). On manup trucks

(SP, TS, TSP etc.), odd and even 100's will be present on the wiring diagrams. Man-down trucks, which don't have a platform (stand-up rider, pallet etc.), only even 100's will be present.

•

Wiring starts at a central location (e.g. distribution board) and wiring connection points are numbered with the lowest number odd or even. The next wiring connection point from the distribution board are then numbered with the next group of 100's and so on for each connection point removed from the central location.

•

Terminal board and connector numbering is sequential on each consecutive page. In this way a wiring address giving a connector number or terminal board number will indicate which direction to look in the diagrams for the other end of the wire.

When wiring goes to a component and not a terminal board or connector, a reference terminal board is used and is shown with a dashed line box with the reference terminal board number in parenthesis. This terminal board will not appear on the truck and only present as a wiring directory.

•

Input/Output arrows may appear at terminal boards and connectors. These indicate whether what the wire is carrying is incoming or outgoing.

This is helpful when tracing the origin of the signal or voltage.

Crown 1991 PF8974-1 Rev. 6/08 DIA-ITD-001

02 Rev. 6/08

357

Notes:

358

WIRING DIAGRAMS

Index

Index

This electrical diagram index lists the diagrams with portion of truck covered by each diagram.

Title Page Number

Electrical Schematic - AC Traction DC Lift

Electrical Schematic - AC Traction AC Lift

DIA-2045-002

DIA-2045-003

Electrical Schematic - AC Traction AC Lift With Options DIA-2045-004

Distribution Panel DIA-2045-005

Access 3, AC Traction Controller

Access 2, AC Lift Controller

Hydraulic Switch Harness With Tilt Position Assist

Dashboard With TMM Option

DIA-2045-006

DIA-2045-007

DIA-2045-008

DIA-2045-009

Access 1, Display

Steering

Foot Operated Direction Control

Brake and Accelerator Pedals

Motors and Alarms

InfoLink

Overhead Guard

Freezer Condition

Freezer Condition - Jumper Harness

Power Cables - AC Traction DC Lift

Power Cables - AC Traction AC Lift

Wire Harnesses

DIA-2045-010

DIA-2045-011

DIA-2045-012

DIA-2045-013

DIA-2045-014

DIA-2045-015

DIA-2045-016

DIA-2045-017

DIA-2045-018

DIA-2045-019

DIA 2045-020

DIA-2045-021

Revision

01 - 11/08

01 - 11/08

01 - 11/08

01 - 11/08

01 - 11/08

01 - 11/08

01 - 11/08

01 - 11/08

01 - 11/08

01 - 11/08

01 - 11/08

01 - 11/08

01 - 11/08

01 - 11/08

01 - 10/07

01 - 11/08

01 - 11/08

02 - 11/08

Crown 2007 PF15723-1 Rev. 11/08 DIA-2045-001

03 Rev. 11/08

359

WIRING DIAGRAMS

Electrical Schematic - AC Traction/DC Lift

Electrical Schematic - AC Traction/DC Lift

DIA-2045-002

01 Rev. 11/08

360

140580 B 1 of 3

Crown 2007 PF15723-2 Rev. 11/08

Electrical Schematic - AC Traction/AC Lift

WIRING DIAGRAMS

Electrical Schematic - AC Traction/AC Lift

Crown 2007 PF15723-3 Rev. 11/08

140580 B 2 of 3

DIA-2045-003

01 Rev. 11/08

361

WIRING DIAGRAMS

Electrical Schematic - AC Traction/DC Lift With Options

Electrical Schematic - AC Traction/DC Lift With Options

DIA-2045-004

01 Rev. 11/08

362

140580 B 3 of 3

Crown 2007 PF15723-4 Rev. 11/08

Distribution Panel

WIRING DIAGRAMS


Crown 2007 PF15723-5 Rev. 11/08

140581 B

DIA-2045-005

01 Rev. 11/08

363

WIRING DIAGRAMS

ACCESS 3 - AC Traction Controller

ACCESS 3 - AC Traction Controller

DIA-2045-006

01 Rev. 11/08

364

140586 B 1 of 2

Crown 2007 PF15723-6 Rev. 11/08

ACCESS 2 - AC Lift Controller

WIRING DIAGRAMS

ACCESS 2 - AC Lift Controller

Crown 2007 PF15723-7 Rev. 11/08

140586 B 2 of 2

DIA-2045-007

01 Rev. 11/08

365

WIRING DIAGRAMS

Hydraulic Switch Harness With Tilt Position Assist

Hydraulic Switch Harness With Tilt Position Assist

DIA-2045-008

01 Rev. 11/08

366

140584 B

Crown 2007 PF15723-8 Rev. 11/08

Dashboard with TMM Option

WIRING DIAGRAMS

Dashboard with TMM Option

Crown 2007 PF15723-9 Rev. 11/08

140588 C

DIA-2045-009

01 Rev. 11/08

367

WIRING DIAGRAMS

ACCESS 1 - Display

ACCESS 1 - Display

DIA-2045-010

01 Rev. 11/08

368

140585 B

Crown 2007 PF15723-10 Rev. 11/08

Steering

WIRING DIAGRAMS

Steering

Crown 2007 PF15723-11 Rev. 11/08

140582 C

DIA-2045-011

01 Rev. 11/08

369

WIRING DIAGRAMS

Foot Operated Direction Control

Foot Operated Direction Control

DIA-2045-012

01 Rev. 11/08

370

140589 B

Crown 2007 PF15723-12 Rev. 11/08

Brake and Accelerator Pedals

WIRING DIAGRAMS

Brake and Accelerator Pedals

Crown 2007 PF15723-13 Rev. 11/08

140583 C

DIA-2045-013

01 Rev. 11/08

371

WIRING DIAGRAMS

Motors and Alarms

Motors and Alarms

DIA-2045-014

01 Rev. 11/08

372

140587 B

Crown 2007 PF15723-14 Rev. 11/08

InfoLink

WIRING DIAGRAMS

InfoLink

Crown 2007 PF15723-15 Rev. 11/08

143463 B

DIA-2045-015

01 Rev. 11/08

373

WIRING DIAGRAMS

Overhead Guard

Overhead Guard

DIA-2045-016

01 Rev. 10/07

374

140590 A

Crown 2007 PF15723-16 Rev. 10/07

Freezer Condition

WIRING DIAGRAMS

Freezer Condition

Crown 2007 PF15723-17 Rev. 11/08

141820 B 1 of 2

DIA-2045-017

01 Rev. 11/08

375

WIRING DIAGRAMS

Freezer Condition - Jumper Harness

Freezer Condition - Jumper Harness

DIA-2045-018

01 Rev. 11/08

376

141820 B 2of 2

Crown 2007 PF15723-18 Rev. 11/08

Power Cables - AC Traction/DC Lift

WIRING DIAGRAMS

Power Cables - AC Traction/DC Lift

Crown 2007 PF15723-19

140593 A 1 of 2

DIA-2045-019

377

WIRING DIAGRAMS

Power Cables - AC Traction/AC Lift

Power Cables - AC Traction/AC Lift

DIA-2045-020

378

140593 A 2 of 2

Crown 2007 PF15723-20

WIRING DIAGRAMS

Wire Harnesses

Wire Harnesses

The chart below lists the wire harness part number and also indicates the components connected by each wire harness.

Wire Harness Chart

124540

124575

127272

127342

127445-002 thru -009

127511

127515

128273

128340

Accelerator: CA611, ACS

Seat: CA410, SES1, SES2

Height Switch: JC613, PC614

(1)

Accessory: JC642, Accessory.

Mast Mounted Work Lights

(1)

5th Function: AXS3, Mast Control Cable PC615

5th Function: Mast Control Cable JC615

Tail Lights: +BV(K1), Batt Neg, +BV(RS), +BV(BRKS)

Overhead Guard: JC651, PC801, PC802, PC803, PC804, PC805, PC806, PC816, PC817,

PC818, PC819, PC820

128343

128344

128345

128720

Park Brake: JC602, PRK-A, PRK-B

Light Switch: JC641, PC642, LGS1, LGS2

Brake Alarm: JC626, ALM2

Freezer Condition Front: JC813, RES2, RES3, THS1, THS2

128721

128722

Freezer Condition Rear: PC811, PC812, PC813, Batt Neg, +BV, +BV(K1), RES1

12V Power supply: PC206, Batt Neg in, +12V, Batt Neg out, +BV in

129901 Operator Fan: JC661, Diode, FNS, FAN3

130117-001 Freezer/Corrosion Wire Harness RES 36V Trucks

130117-002 Freezer/Corosion Wire Harness RES 48V Trucks

130557

130583

Drive Thru Overhead Guard Light Wire Harness: JC651, PC 801, PC802, PC803, PC804,

PC805, PC806, PC816, PC817, PC818, PC819, PC820

Foot Operated Direction Control F/C 36V Truck: JC813, PC813, PC814, RES4, RES5

130584

132789

133529

139686

140557

141044

Foot Operated Direction Control F/C 48V Truck: JC813, PC813, PC814, RES4, RES5, RES6,

RES7

Travel Alarm (ALM3) CA627

Tilt Position Assist Harness to 141600

Accelerator: CA611, ACS

Impact Sensor Harness: JC902, PC902

Main Harness: PC611, PC612, PC632, PC633, PC601, PC634, PC602, PC661, HN1, BRKS,

FAN5, PC641, PC613, PC626, PC651, TLMS, PC603, PC631, PC625, SV2, BRES, PC201,

PC207, PC202, PC204, PC205, PC203, PC208, FAN 1, B-, PC402, PC410, PC409, PC627,

FAN4, PC604, PC605, JC634

Crown 2007 PF15723-21 Rev. 11/08 DIA-2045-021

02 Rev. 11/08

379

WIRING DIAGRAMS

Wire Harnesses

Wire Harness Chart

141045

141046

141047

141050

141051

141054

141600

141601

141624

142299

142717

143502

Steering: JC601, FIL, FS, HN1, HNS, KYS, RS

TMM DC Lift: JC604, Lift Motor M2 Temperature & Brush Wear, Steer Motor M3 Brush Wear

Hydraulic Switch Harness: CA636, JC631, AXS1, AXS2, AXS3, HSS, RAS, SV1, TBS, TLT

ACCESS 2 Hydraulic Controller: JC409, PC404, FAN2

DC Contactor Lift Harness: JC605, +BV, L, P, S

ACCESS 1 Display: JC632, JC633, PC630

Lower Tilt Position Assist Harness: SV3, TBS, TLT, VTS

Foot Operated Directional Control: JC601, PC601, FS, RS

Foot Operated Directional Control F/C: JC601, JC813, PC601, FS, HR1, HR2, RS

TMM AC Lift: JC604, Lift Motor ECR2, Steer M3 Brush Wear, TS2

InfoLink Harness: JC634, MODULE, PROX, PROG, SHOCK

Auto Park Brake: JC602

(1)

Choice of dash number depends on collapsed or lift height. To determine dash number, refer to the following chart.

Collapsed Height mm

2110

2260

2415

2565

2718

2870

3025

3175 in

83

89

95

101

107

113

119

125

Dash Number Chart

Lift Height mm

2995 & 3200 in

118 & 126

4570 & 4775

3300 & 3505

5030 & 5230

3605 & 3810

180 & 188

130 & 138

198 & 206

142 & 150

5285 & 5485

5665 & 5865

6045 & 6250

6350 & 6555

6805 & 7010

7190 & 7390

208 & 216

223 & 231

238 & 246

250 & 258

268 & 276

283 & 291

Dash Number

P/N 127272

-011

-001

-002

-003

-004

-005

-006

-007

Dash Number

P/N 127445

-002

-003

-004

-005

-006

-007

-008

-009

DIA-2045-022

02 Rev. 11/08

380

Crown 2007 PF15723-22 Rev. 11/08

HYDRAULIC SCHEMATIC

381

Notes:

382

Hydraulic Schematic

HYDRAULIC SCHEMATIC

Hydraulic Schematic

Crown 2007 PF17012-1 a Lift/Lower b Tilt c Accessory 1 d Accessory 2 i f e Return Filter

Steering g Reservoir h Breather

Suction Strainer

Figure 17562

HYD-2045-001

383

Notes:

384

POWER UNIT PARTS

385

POWER UNIT PARTS

Seat Deck

Seat Deck

01.0-2040-054

03 Rev. 10/07

386

(a)

(b)

(c)

(d)

“EE” Trucks Only

See Power Unit Parts

Part of Front Left Corner on Power Unit

Only on Trucks without Battery Doors

Figure 16338-01

Crown 2004 PF13809-1 Rev. 10/07


Seat Deck

INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 . . . . . 129988 . . . . . . . . . . . Storage Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 129992 . . . . . . . . . . . Spring Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060012-014. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

061004-026. . . . . . . . Thread Lock Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 132715 . . . . . . . . . . . Magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 132618 . . . . . . . . . . . Mounting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 050006-032. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 050068-003. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 142797-004-01 . . . . . Seat Deck

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

142797-004-02 . . . . . Seat Deck

(1)

with Storage Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

142797-004-03 . . . . . Seat Deck

(1)

Drive Thru Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . . . 1

142797-004-04 . . . . . Seat Deck

(1)

Drive Thru Overhead Guard and Storage Tray . . . . . . . . . . . . 1

142802-005-01 . . . . . Seat Deck

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

142802-005-02 . . . . . Seat Deck

(2)


142803-006-01 . . . . . Seat Deck

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

142803-006-02 . . . . . Seat Deck

(3)


9 . . . . . 065004-029. . . . . . . . Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 129226-001* . . . . . . . Battery Insulator

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129226-002* . . . . . . . Battery Insulator

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129226-003* . . . . . . . Battery Insulator

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 060062-001* . . . . . . . Screw

(1 & 2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

060062-001* . . . . . . . Screw

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

12 . . . . . 060030-141* . . . . . . . Flatwasher

(1 & 2)

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

060030-141* . . . . . . . Flatwasher

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

13 . . . . . 062488-008* . . . . . . . Spacer

(1 & 2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

062488-008* . . . . . . . Spacer

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

14 . . . . . 060059-011* . . . . . . . Nut

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 . . . . . 060102-002* . . . . . . . U-Nut

(3)

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

16 . . . . . 128953 . . . . . . . . . . . Seat Deck Support Without Battery Doors . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 050025-010. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 050068-004. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

685 mm (27 in) Battery Compartment

(2)


(3)


*

To select appropriate part number, refer to truck data number.

The truck data number represents truck features.

Refer to Introduction.

Crown 2004 PF13809-2 Rev. 10/07

Always Specify Model, Data & Serial Number

01.0-2040-055

03 Rev. 10/07

387


Seat Deck

01.0-2040-056

03 Rev. 10/07

388

(a)

(b)

(c)

(d)

(e)

“EE” Trucks Only

Seat Deck


Part of Front Wall

45 Nm (33 ft lb)

Figure 16339-01

Crown 2004 PF13809-3 Rev. 10/07


Seat Deck


30 . . . . . 050067-023* . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

050067-024* . . . . . . . Screw, "EE" Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

31 . . . . . 130083* . . . . . . . . . . Eye Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

32 . . . . . 124887 . . . . . . . . . . . Hold Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

33 . . . . . 124407 . . . . . . . . . . . Latch Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . 124409 . . . . . . . . . . . Torsion Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35 . . . . . 060100-003. . . . . . . . Ring Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

36 . . . . . 124836 . . . . . . . . . . . Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

37 . . . . . 060030-017. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

38 . . . . . 050006-036. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

39 . . . . . 060030-177. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

40 . . . . . 124962* . . . . . . . . . . Gas Spring, 685 mm (27 in) Battery Compartment . . . . . . . . . . . . . . . . . . . . 2

124412* . . . . . . . . . . Gas Spring, 840 & 915 mm (33 & 36 in) Battery Compartment . . . . . . . . . . 2

41 . . . . . 050009-025. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

42 . . . . . 050008-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

43 . . . . . 124411*. . . . . . . . . . . Latch Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

130081* . . . . . . . . . . Latch Bar, "EE" Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

44 . . . . . 127366 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

45 . . . . . 050068-004. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

46 . . . . . 050025-010. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

47 . . . . . 127341-002. . . . . . . . Edging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

48 . . . . . 130525 . . . . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

49 . . . . . 050008-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

50 . . . . . 140142 . . . . . . . . . . . Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

51 . . . . . 127383 . . . . . . . . . . . Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

52 . . . . . 050003-020. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

*




Crown 2004 PF13809-4 Rev. 10/07


01.0-2040-057

03 Rev. 10/07

389


Power Unit

Power Unit

(a) For Compartment Fans (FAN1, FAN2) -

See Electrical Components - Power Unit

(b) Counterweight Section (Truck Rear)

(c) Part of Control Valve Linkage - See

Control Valve Linkage

01.0-2045-001

02 Rev. 11/08

390

Figure 16320-01

Crown 2007 PF15742-1 Rev. 11/08


Power Unit


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



2 . . . . . 129297 . . . . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 . . . . . 126260 . . . . . . . . . . . Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 060063-015. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

061004-012. . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

5 . . . . . 060102-004. . . . . . . . U-Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 126261 . . . . . . . . . . . Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 126297 . . . . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

8 . . . . . 128583 . . . . . . . . . . . Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 060032-063. . . . . . . . Self Tapping Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

10 . . . . . 060099-003. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

11 . . . . . 060030-066. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 . . . . . 111594 . . . . . . . . . . . Foam Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

13 . . . . . 127774 . . . . . . . . . . . Tow Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 139606 . . . . . . . . . . . Door With Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 060115-002 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

*




Crown 2007 PF15742-2 Rev. 11/08


01.0-2045-002

02 Rev. 11/08

391


Power Unit

01.0-2045-003

02 Rev. 11/08

392

Figure 16321

Crown 2007 PF15742-3 Rev. 11/08


Power Unit


20 . . . . . 128289 . . . . . . . . . . . Floor Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 128160 . . . . . . . . . . . Rear Floor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 128159 . . . . . . . . . . . Front Floor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . 128245 . . . . . . . . . . . Lift Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 128173 . . . . . . . . . . . Floor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . 050025-010. . . . . . . . Carriage Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

26 . . . . . 050068-004. . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

27 . . . . . 129995 . . . . . . . . . . . Steer Motor Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

28 . . . . . 050025-010. . . . . . . . Carriage Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

29 . . . . . 050068-004. . . . . . . . Flanged Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

30 . . . . . 128604 . . . . . . . . . . . LH Fender Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . 128588 . . . . . . . . . . . LH Step Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

32 . . . . . 128246 . . . . . . . . . . . RH Fender Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

33 . . . . . 128248 . . . . . . . . . . . RH Step Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . 060063-016. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

35 . . . . . 060102-004. . . . . . . . U-Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

36

. . . . . . (1)

. . . . . . . . . . . . . . . Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

37

. . . . . . (1)

. . . . . . . . . . . . . . . LH Auxiliary Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

38

. . . . . . (1)

. . . . . . . . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

39

. . . . . . (1)

. . . . . . . . . . . . . . . RH Auxiliary Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

40

. . . . . . (1)

. . . . . . . . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

41 . . . . . 060059-017. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(1)

See Counterweight Chart

Counterweight Chart

Truck

Model

Numbers

4510-40,4520-40,

4520-50, 4540-50,

4510-2.0, 4520-2.0,

4520-2.5 & 4540-2.5

Index 36

Counterweight

Index 37

LH Auxillary

Counterweight

126886 -

4510-50, 4520-55,

4520-60, 4540-55,

4540-60, 4510-2.5,

4520-3.0 & 4540-3.0

4520-50, 4520-60,

4520-2.5 & 4520-3.0

4510-40, 4510-50,

4540-50, 4520-55,

4510-2.0, 4510-2.5,

& 4540-2.5

126887

126886

126887

-

Contact

Factory

Contact

Factory

Index 38

Screw

-

-

060099-004

060099-005

Index 39

RH Auxillary

Counterweight

-

-

Contact

Factory

Contact

Factory

Index 40

Screw

-

-

060099-004

060099-005

Crown 2007 PF15742-4 Rev. 11/08


01.0-2045-004

02 Rev. 11/08

393


Overhead Guard & Covers


Part of

Power

Unit

Part of

Power Unit

01.1-2045-001

394

Figure 16346

Crown 2007 PF15795-1




1 . . . . . 124029 . . . . . . . . . . . Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060061-015. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 . . . . . 060061-010. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 124030 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 124269 . . . . . . . . . . . Stand Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 124031 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 124034 . . . . . . . . . . . Console Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 124033 . . . . . . . . . . . Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 050067-012. . . . . . . . Locking Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

10 . . . . . 050067-014. . . . . . . . Flanged Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 060102-002. . . . . . . . U-Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 124036-001. . . . . . . . Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 129549 . . . . . . . . . . . Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 050006-024. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 . . . . . 060115-003 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

16 . . . . . 060075-008. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 050067-044. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

18 . . . . . 060059-010. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

19 . . . . . 065004-050. . . . . . . . Grommet 25 mm (1.0 in) Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 065004-035. . . . . . . . Grommet 19 mm (0.75 in) Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 124993 . . . . . . . . . . . Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

22 . . . . . 124530 . . . . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

129332* . . . . . . . . . . Rectangular Plug, Drive Thru Overhead Guard, Not Shown . . . . . . . . . . . . 8

23 . . . . . 132582-002* . . . . . . . Pad, Drive Thru Overhead Guard, Not Shown . . . . . . . . . . . . . . . . . . . . . . . 2

*




Crown 2007 PF15795-2


01.1-2045-002

395

0



1.1-2045-003

396

Figure 16349

Crown 2007 PF15795-3



Battery Compartment Size mm (in)

685

685

(27)

(27)

685

840

840

840

(27)

(33)

(33)

(33)

915

915

915

685

840

915

(36)

(36)

(36)

(27)

(33)

(36)

Overhead Guard Chart

2250

2120

2185

2250

2185

2185

2185 mm

2120

Height

(in)

(83.5)

2185

2250

2120

2185

(86.0)

(88.5)

(83.5)

(86.0)

(88.5)

(83.5)

(86.0)

(88.5)

(86.0)

(86.0)

(86.0)

Overhead

Guard Style

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Drive-Thru

Drive-Thru

Drive-Thru

Overhead Guard

Index 25

127011-001

127011-002

127011-003

126635-001

126635-002

126635-003

127012-001

127012-002

127012-003

128650-001

128650-002

128650-003

Crown 2007 PF15795-4 01.1-2045-004

397


Battery Spacers & Retainers


See Labels and

Decals

01.2-2045-001

01 Rev. 1/08

398

Figure 16366

Crown 2007 PF15804-1 Rev. 1/08




0 . . . . . 138522-003* . . . . . . . Roller Assembly

(1)

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

138522-001* . . . . . . . Roller Assembly

(2 & 3)

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

1 . . . . . . . . 138523-003* . . . . . . . Roller

(1)

, Quantity for One Roller Assembly . . . . . . . . . . . . . . . . . . . . . . 1

138523-001* . . . . . . . Roller

(2 & 3)

, Quantity for One Roller Assembly. . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 138524-003* . . . . . . . Shaft

(1)

, Quantity for One Roller Assembly. . . . . . . . . . . . . . . . . . . . . . . 1

138524-001* . . . . . . . Shaft

(2 & 3)

, Quantity for One Roller Assembly . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 065081-018 . . . . . . . . Bearing, Quantity for One Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . 060009-065 . . . . . . . . Retaining Ring, Quantity for One Roller Assembly . . . . . . . . . . . . . . . . . 2

5 . . . . . 127571 . . . . . . . . . . . Disconnect Handle (Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129353 . . . . . . . . . . . Disconnect Handle International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 050005-059. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3


7 . . . . . 078723-001. . . . . . . . Connector Gray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

078723-003. . . . . . . . Connector Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

078723-006. . . . . . . . Connector Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

078723-009. . . . . . . . Connector Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

078724-001. . . . . . . . Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

108801-001. . . . . . . . Connector Gray International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

108801-003. . . . . . . . Connector Red International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

108801-006. . . . . . . . Connector Blue International. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

108801-008. . . . . . . . Connector Yellow International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

108802-001. . . . . . . . Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 050007-014. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 050008-015. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 050025-010. . . . . . . . Carriage Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 128511 . . . . . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 050009-025. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 050068-004. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 128613 . . . . . . . . . . . Battery Adjustment Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 060063-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 119218 . . . . . . . . . . . Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 128642 . . . . . . . . . . . Battery Adjustment Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 060063-024. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)


(2)


(3)


*




Crown 2007 PF15804-2 Rev. 1/08


01.2-2045-002

01 Rev. 1/08

399



Optional

Battery

Doors

01.2-2045-003

01 Rev. 1/08

400

Figure 16367-01

Crown 2007 PF15804-3 Rev. 1/08




30 . . . . . 130264 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . 050025-010. . . . . . . . Carriage Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

32 . . . . . 050068-004. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

33 . . . . . 128180 . . . . . . . . . . . LH Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . 128178 . . . . . . . . . . . RH Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

35 . . . . . 141991-001* . . . . . . . LH Cover

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

141991-002* . . . . . . . LH Cover

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

141991-003* . . . . . . . LH Cover

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

36 . . . . . 128475-001* . . . . . . . LH Lower Strip

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

128475-002* . . . . . . . LH Lower Strip

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

128475-003* . . . . . . . LH Lower Strip

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

37 . . . . . 141990-001* . . . . . . . RH Cover

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

141990-002* . . . . . . . RH Cover

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

141990-003* . . . . . . . RH Cover

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

38 . . . . . 128472-001* . . . . . . . RH Retainer

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

128472-002* . . . . . . . RH Retainer

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

128472-003* . . . . . . . RH Retainer

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

39 . . . . . 050006-050. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40 . . . . . 050009-026. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

41 . . . . . 050068-004. . . . . . . . Flanged Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

42 . . . . . 060063-022. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

43 . . . . . 128945-001* . . . . . . . Battery Door

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

128945-002* . . . . . . . Battery Door

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

128945-003* . . . . . . . Battery Door

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

44 . . . . . 128966 . . . . . . . . . . . Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

45 . . . . . 128967 . . . . . . . . . . . Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

46 . . . . . 060120-001. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

47 . . . . . 130153 . . . . . . . . . . . Compression Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

48 . . . . . 060009-136. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)


(2)


(3)


*




Crown 2007 PF15804-4 Rev. 1/08


01.2-2045-004

01 Rev. 1/08

401



01.2-2045-005

01 Rev. 1/08

402

Figure 16368

Crown 2007 PF15804-5 Rev. 1/08




60 . . . . . * . . . . . . . . . . . . . . . . Spacer, See Spacer Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

61 . . . . . 060075-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

62 . . . . . 050068-004. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

63 . . . . . 060099-002. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


64 . . . . . 050008-068. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

65 . . . . . 130465 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

66 . . . . . 060061-001. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

67 . . . . . 062488-004. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

68 . . . . . 060059-002. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

69 . . . . . 130464 . . . . . . . . . . . Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

70 . . . . . 050068-002. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

71 . . . . . 050008-025. . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

72 . . . . . 060030-252. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

73 . . . . . 062752-005. . . . . . . . Sealed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

74 . . . . . 126046 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

75 . . . . . 050004-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

76 . . . . . 060059-014. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

*




Battery Compartment Size mm (in)

685

840

840

840

840

915

915

(27)

(33)

(33)

(33)

(33)

(36)

(36)

Spacer Chart

mm

Battery Width

(in)

Spacer Kit

Includes

Hardware

Spacer

Index 60

675 to 690 (26.50 to 27.25) Not Required Not Required

740 to 760 (29.13 to 30.00) 129503 128669

795 to 810 (31.37 to 32.00) 129501 128667


750 to 760 (29.68 to 30.00)

855 to 870 (33.59 to 34.13)

130705

129502

130703

128668


Crown 2007 PF15804-6 Rev. 1/08


01.2-2045-006

01 Rev. 1/08

403


Static Seat

Static Seat

01.5-2040-009

404

Figure 16387-01

Crown 2008 PF17607-1


Static Seat


1 . . . . . 122001 . . . . . . . . . . . Fabric Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

122002 . . . . . . . . . . . Vinyl Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 122029 . . . . . . . . . . . Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 060017-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 060017-035. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5 . . . . . 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6 . . . . . 122044 . . . . . . . . . . . Foam Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 124022 . . . . . . . . . . . Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 060032-062. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 122003 . . . . . . . . . . . Anti-Cinch Black Seat Belt Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

122003-002. . . . . . . . Anti-Cinch Orange Seat Belt Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 060018-001 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

061004-026 . . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 060021-052 . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 060019-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


13 . . . . . . . . 060019-050 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


14 . . . . . 060019-010. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 060030-187. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 130006* . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 060016-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 811145 . . . . . . . . . . . Arm Rest RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . . . . 811147 . . . . . . . . . . . . Fixing Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . . . . 811149 . . . . . . . . . . . . Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2008 PF17607-2


01.5-2040-010

405


Static Seat

01.5-2040-011

406

Part of Seat Deck


Figure 16388-01

Crown 2008 PF17607-3


Static Seat


30 . . . . . 112262 . . . . . . . . . . . Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . 112261 . . . . . . . . . . . Locking Slide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

32 . . . . . 112299 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

33 . . . . . 060016-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

34 . . . . . 107898 . . . . . . . . . . . Cupped Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

35 . . . . . 122033 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

36 . . . . . 060016-004. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

37 . . . . . 060030-232. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

38 . . . . . 060005-020. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

39 . . . . . 060021-009. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

40 . . . . . 115556 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

41 . . . . . 060015-037. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

42 . . . . . 060005-007. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

43 . . . . . 115559 . . . . . . . . . . . Flat Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

44 . . . . . 060013-002. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

45 . . . . . 060005-004. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

46 . . . . . 093603 . . . . . . . . . . . Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

47 . . . . . 062933 . . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

062752-003* . . . . . . . Switch (Freezer/Corrosion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

061002-014* . . . . . . . Harness Clamp (Freezer/Corrosion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

48 . . . . . 115557*. . . . . . . . . . . Heater Bracket (Freezer/Corrosion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

49 . . . . . 060011-013 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

50 . . . . . 060030-005. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

51 . . . . . 060005-049. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

52 . . . . . 060021-023. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

*




Crown 2008 PF17607-4


01.5-2040-012

407


Suspension Seat

Suspension Seat

01.5-2040-056

05 Rev. 6/09

408

(a) In order to mount Index 24 to Seat Back using Index 21, the Rear Cover on Seat must be unlatched by lifting up on Seat Back Cushion.

(b) Part of Suspension Seat

(c) Optional Arm Rest

(d) Part of Seat Deck, See Power Unit Parts

Figure 17900-01

Crown 2004 PF13803-1 Rev. 6/09


Suspension Seat


1 . . . . . 137973 . . . . . . . . . . . Fabric Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

130987 . . . . . . . . . . . Vinyl Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 133706. . . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 129632. . . . . . . . . . . . Locking Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 129631. . . . . . . . . . . . Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 060059-001. . . . . . . . Thin Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 137975 . . . . . . . . . . . Suspension Seat Back Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 050008-026. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 050009-020. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 060032-005. . . . . . . . Self-Tapping Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 060030-046. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 137974 . . . . . . . . . . . Suspension Seat Cover Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 060032-047. . . . . . . . Self-Tapping Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 060063-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

14 . . . . . 060030-242. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

16 . . . . . 122031 . . . . . . . . . . . Restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 122016 . . . . . . . . . . . Anti-Cinch Black Seat Belt Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

122016-002. . . . . . . . Anti-Cinch Orange Seat Belt Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 050003-059. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

19 . . . . . 050008-060. . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

20 . . . . . 050073-003. . . . . . . . Spring Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

21 . . . . . 060063-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 050009-020. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 136776 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . 050067-035. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

26 . . . . . 050068-004. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

27 . . . . . 811145 . . . . . . . . . . . RH Arm Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

28 . . . . . . . . 811147 . . . . . . . . . . . . Fixing Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

29 . . . . . . . . 811149 . . . . . . . . . . . . Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2004 PF13803-2 Rev. 6/09


01.5-2040-057

05 Rev. 6/09

409


Suspension Seat

01.5-2040-058

05 Rev. 6/09

410

Figure 17901

Crown 2004 PF13803-3 Rev. 6/09


Suspension Seat


50 . . . . . 137974 . . . . . . . . . . . Fabric Cushion Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129629 . . . . . . . . . . . Vinyl Cushion Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

131220 . . . . . . . . . . . Wide Vinyl Cushion Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

51 . . . . . 137975 . . . . . . . . . . . Fabric Support Seat Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129630 . . . . . . . . . . . Vinyl Support Seat Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

131219 . . . . . . . . . . . Vinyl Wide Support Seat Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

52 . . . . . 131200 . . . . . . . . . . . Seat Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

53 . . . . . 131198 . . . . . . . . . . . Backrest Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

54 . . . . . 131197 . . . . . . . . . . . Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

55 . . . . . 131217 . . . . . . . . . . . Switch Repair Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

56 . . . . . 131204 . . . . . . . . . . . Seat Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

57 . . . . . 131205 . . . . . . . . . . . Set of Wear Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

58 . . . . . 131203 . . . . . . . . . . . Repair Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

59 . . . . . 131199 . . . . . . . . . . . Adjustment Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

60 . . . . . 131202 . . . . . . . . . . . Suspension Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

61 . . . . . 131201 . . . . . . . . . . . Repair Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

62 . . . . . 131208 . . . . . . . . . . . Outer Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

63 . . . . . 131207 . . . . . . . . . . . Inner Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

64 . . . . . 131206 . . . . . . . . . . . Bumper Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

65 . . . . . 131209 . . . . . . . . . . . Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

66 . . . . . 131214 . . . . . . . . . . . Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

67 . . . . . 131210 . . . . . . . . . . . Tension Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

68 . . . . . 131211 . . . . . . . . . . . Weight Adjustment Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

69 . . . . . 131213 . . . . . . . . . . . Handle Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

70 . . . . . 131212 . . . . . . . . . . . Handle Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2004 PF13803-4 Rev. 6/09


01.5-2040-059

05 Rev. 6/09

411

COVERS

Hip Restraint

Hip Restraint

(a) Static Seat, See Power Unit Parts

(b) Seat Belts are mounted so they are between Hip Restraints and Seat

(c) Suspension Seat, See Power Unit Parts

(d) Seat Belts are mounted so they are between Hip Restraints and Seat

01.5-2040-150

02 Rev. 3/08

412

Figure 11518-02

Crown 2004 PF13804-1 Rev. 3/08

COVERS

Hip Restraint


1 . . . . . 060017-110 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 . . . . . 060030-119 . . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 . . . . . 132584 . . . . . . . . . . . Hip Restraint Static Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

132387 . . . . . . . . . . . Foam Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 132257 . . . . . . . . . . . Seat Belt Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 060018-001. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 060021-052. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

061004-026. . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 060019-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


8 . . . . . 132586 . . . . . . . . . . . Hip Restraint Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

132387 . . . . . . . . . . . Foam Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 060063-024. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

10 . . . . . 132252 . . . . . . . . . . . Black Seat Belt Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

132252-002. . . . . . . . Orange Seat Belt Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2004 PF13804-2 Rev. 3/08


01.5-2040-151

02 Rev. 3/08

413

Notes:

414

HYDRAULIC PARTS

415

HYDRAULIC PARTS

Suction Line Hydraulics


Lift Pump

See Hydraulic Parts

Steer & Brake Pump

See Steer Parts

02.0-2040-001

01 Rev. 5/07

416

Reservoir - Part of

Power Unit Frame

Figure 16412

Crown 2001 PF13204-1 Rev. 5/07

HYDRAULIC PARTS



1 . . . . . 064091-002. . . . . . . . Plug Includes Index 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 064019-029. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 128313 . . . . . . . . . . . Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 129045 . . . . . . . . . . . Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 124351-001. . . . . . . . Suction Strainer Includes Index 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 064019-026. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 061022-009. . . . . . . . Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 124709 . . . . . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 064297 . . . . . . . . . . . Tee Includes Index 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 064019-075. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 061022-015. . . . . . . . Hose Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 128870 . . . . . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 064143-002. . . . . . . . Nipple Includes Index 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 064019-030. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2001 PF13204-2 Rev. 5/07


02.0-2040-002

01 Rev. 5/07

417

HYDRAULIC PARTS

Lift & Tilt Line Hydraulics


Control Valve

See Hydraulic Parts

2nd

Acc.

1st

Acc.

Tilt

Lift/Lower

Tilt Cylinders

See Cylinder Parts

Right

Left

02.0-2040-100

01 Rev. 5/07

418

Tilt Manifold

See Hydraulic Parts

To Lowering Flow Control

Manifold Mounted on Mast

See Hydraulic Parts

Figure 16416

Crown 2001 PF13206-1 Rev. 5/07

HYDRAULIC PARTS



1 . . . . . 064280-006. . . . . . . . Adapter 90°

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 . . . . . 064019-029. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 . . . . . 064019-101. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 . . . . . 064337-001. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 064322-001. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 064327-006. . . . . . . . Elbow

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 064279-007. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 064019-030. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 064296-006. . . . . . . . Elbow

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 064280-002. . . . . . . . Elbow

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 130254 . . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 130253 . . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 064281-003. . . . . . . . Adapter 45°

(1)

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

14 . . . . . 128194 . . . . . . . . . . . Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 050006-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 050068-003. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 064319-006. . . . . . . . Tee

(1)

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

18 . . . . . 064323-001. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 064338-001. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 127341-003. . . . . . . . Edging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 127341-004. . . . . . . . Edging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 064279-001. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . 064019-045. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 064019-102. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . 064321-001. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064281-006* . . . . . . . Adapter

(1)

, Quad Mast, Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Includes O-Rings

*




Crown 2001 PF13206-2 Rev. 5/07


02.0-2040-101

01 Rev. 5/07

419

HYDRAULIC PARTS

Steer & Brake Line Hydraulics


See Section 02.0

Pressure Line Hydraulics

Steer Unit

See Section 06.3

Steer Cylinder

See Section 08.8

Parking Brake Cylinder

See Section 08.8

RH Brake

See Section 05.3

Brake Valve

See Section 05.0

Note:

= Steer Right

= Steer Left

= Pressure

= Return

LH Brake

See Section 05.3

Figure 15464

Crown 2007 PF15619-1 02.0-2040-202

420

HYDRAULIC PARTS



1 . . . . . 050007-014. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 050068-002. . . . . . . . Flanged Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 . . . . . 064019-029. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 064249-005. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 064019-099. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . 064019-021. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 064074-021. . . . . . . . Back Up Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 138304 . . . . . . . . . . . Left Steer Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 138305 . . . . . . . . . . . Right Steer Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 064309-007* . . . . . . . Hose 685 mm (27 in) Battery Compartment . . . . . . . . . . . . . . . . . . . . . . . . . 1

064309-028* . . . . . . . Hose 685 mm (27 in) Battery Compartment

(2)

. . . . . . . . . . . . . . . . . . . . . . . 1

064309-008* . . . . . . . Hose 840 & 915 mm (33 & 36 in) Battery Compartment. . . . . . . . . . . . . . . . 1

064309-029* . . . . . . . Hose 840 & 915 mm (33 & 36 in) Battery Compartment

(2)

. . . . . . . . . . . . . . 1


064309-030* . . . . . . . Hose 685 mm (27 in) Battery Compartment

(2)

. . . . . . . . . . . . . . . . . . . . . . . 1


064309-031* . . . . . . . Hose 840 & 915 mm (33 & 36 in) Battery Compartment

(2)

. . . . . . . . . . . . . . 1

12 . . . . . 064019-1014. . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

13 . . . . . 128106 . . . . . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 050025-002. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 . . . . . 124481-001. . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 064319-006. . . . . . . . Tee

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 064307-003. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 061002-003. . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 060061-006. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 064280-004. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 064019-031. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

22 . . . . . 064279-004. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . 064280-004. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 064289-002. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . 065060-014. . . . . . . . Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Includes O-Ring(s)

(2)

Side Service Pump Motor

*




Crown 2007 PF15619-2


02.0-2040-203

421

HYDRAULIC PARTS

Pressure Line Hydraulics


(1) Left and Right Are Determined From Operator’s Perspective

(2) Steer Unit - See Steering Parts

(3) Control Valve - See Hydraulic Parts

(4) Lift Pump - See Hydraulic Parts

(5) Brake Valve - See Brake Parts

(6) Steer & Brake Pump - See Steering Parts

(7) Park Brake Release Manifold - See Hydraulic Parts

Note:

= Steer Right

= Steer Left

= Pressure

= Return

02.0-2045-050

422

Figure 16414

Crown 2007 PF15857-1

HYDRAULIC PARTS



1 . . . . . 060063-015. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 . . . . . 130876 . . . . . . . . . . . Nipple

(1)

Test Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 064019-029. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 . . . . . 064280-010. . . . . . . . Adapter 90°

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 064019-045. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 064019-102. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 064324-001. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 064279-001. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 060017-054. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 060030-177. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 130920 . . . . . . . . . . . Pre-charged Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 061022-017. . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 127341-005. . . . . . . . Edging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 064317-008. . . . . . . . Union

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 064019-030. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16 . . . . . 127945 . . . . . . . . . . . Tee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 064279-004. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 064019-031. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

19 . . . . . 064019-099. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

20 . . . . . 128446 . . . . . . . . . . . Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 128030 . . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 064319-006. . . . . . . . Tee

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . 064019-101. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

24 . . . . . 130051 . . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . 064318-004. . . . . . . . Tee

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

26 . . . . . 064289-002. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

27 . . . . . 064279-005. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

28 . . . . . 060016-003. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

29 . . . . . 064298-010. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

30 . . . . . 064279-007. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . 138302 . . . . . . . . . . . Pressure Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

32 . . . . . 064074-021. . . . . . . . Back-up Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

33 . . . . . 064019-021. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . 138306 . . . . . . . . . . . Retainer Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

35 . . . . . 060075-070. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

Includes O-Rings

Crown 2007 PF15857-2


02.0-2045-051

423

HYDRAULIC PARTS

Accessory Line Hydraulics - TL/Quad


(a) Control Valve, See Hydraulic Parts

(b) Lift/Lower

(c) Tilt

(d) 1st Accessory

(e) 2nd Accessory

(f) Connected to Mast Accessory Hoses,

See Accessory Line Hydraulics - Mast

02.0-2045-150

424

Figure 16419-01

Crown 2008 PF17296-1

HYDRAULIC PARTS



1 . . . . . 064279-007* . . . . . . . Adapter

(1)(3)

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

064279-007* . . . . . . . Adapter

(2)(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 . . . . . 064019-030* . . . . . . . O-Ring

(1)

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

064019-030* . . . . . . . O-Ring

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . . . . . 064019-101* . . . . . . . O-Ring

(1)

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

064019-101* . . . . . . . O-Ring

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 . . . . . 064291-004* . . . . . . . Hose TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064309-005* . . . . . . . Hose Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 064330-002* . . . . . . . Hose TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064323-006* . . . . . . . Hose Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 064291-005* . . . . . . . Hose TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064322-003* . . . . . . . Hose Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 064330-001* . . . . . . . Hose TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064323-002* . . . . . . . Hose Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

One Accessory

(2)

Two Accessories

(3)

Includes O-Rings

*




Crown 2008 PF17296-2


02.0-2045-151

425

HYDRAULIC PARTS

Accessory Line Hydraulics - TT


02.0-2045-175

426

(a) Control Valve, See Hydraulic Parts

(b) Lift/Lower

(c) Tilt

(d) 1st Accessory

(e) 2nd Accessory

(f) Connected to Mast Accessory Hoses,

See Accessory Line Hydraulics - Mast

Figure 16419-01

Crown 2008 PF17305-1

HYDRAULIC PARTS



1 . . . . . 064279-007* . . . . . . . Adapter

(1)(3)

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

064279-007* . . . . . . . Adapter

(2)(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 . . . . . 064019-030* . . . . . . . O-Ring

(1)

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

064019-030* . . . . . . . O-Ring

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . . . . . 064019-101* . . . . . . . O-Ring

(1)

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

064019-101* . . . . . . . O-Ring

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 . . . . . 064291-008* . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 064330-005* . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 064291-009* . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 064330-004* . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

One Accessory

(2)

Two Accessories

(3)

Includes O-Rings

*




Crown 2008 PF17305-2


02.0-2045-176

427

HYDRAULIC PARTS



Park Brake Release Manifold

See Hydraulic Parts

See Hydraulic Parts

Pressure Line Hydraulics

Steer Unit

See Steering Parts

Steer Cylinder

See Cylinder Parts

Parking Brake Cylinder

See Cylinder Parts

Brake Valve

See Brake Parts

RH Brake

See Brake Parts

Note:

= Steer Right

= Steer Left

= Pressure

= Return

LH Brake

See Brake Parts

Figure 16435

Crown 2007 PF15885-1 02.0-2045-200

428

HYDRAULIC PARTS



1 . . . . . 050007-014. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 050068-002. . . . . . . . Flanged Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 . . . . . 064019-029. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 064279-005. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 064019-099. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . 064019-021. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 064074-021. . . . . . . . Back Up Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 138304 . . . . . . . . . . . Left Steer Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 138305 . . . . . . . . . . . Right Steer Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1





12 . . . . . 064019-101. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

13 . . . . . 128106 . . . . . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 050025-002. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 . . . . . 124481-001. . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 064319-006. . . . . . . . Tee

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 064307-003. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 061002-004. . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 060061-006. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 064280-004. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 064019-031. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

22 . . . . . 064279-004. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . 064280-004. . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 064289-002. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . 065060-014. . . . . . . . Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Includes O-Ring(s)

*




Crown 2007 PF15885-2


02.0-2045-201

429

HYDRAULIC PARTS

Return Line Hydraulics


Note:

= Steer Right

= Steer Left

= Pressure

= Return

Control Valve

See Hydraulic Parts

Steer Unit

See Hydraulics Parts

Park Brake Release Manifold

See Hydraulic Parts

Brake Valve

See Brake Parts

02.0-2045-250

430

Part of Reservoir

Figure 16432

Crown 2007 PF15884-1

HYDRAULIC PARTS



1 . . . . . 064019-029. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 . . . . . 064091-002. . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 061022-014. . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 064100-130. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 064100-124. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 064356 . . . . . . . . . . . Adapter

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 064019-076. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 127965 . . . . . . . . . . . Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

077145 . . . . . . . . . . . Filter Replacement Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 050006-026. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 061022-014. . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 064143-016. . . . . . . . Nipple

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 127341-005. . . . . . . . Edging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 138303 . . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 064019-021. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 064074-021. . . . . . . . Back-up Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 064100-125. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 064083-014. . . . . . . . Beaded Insert

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

18 . . . . . 061091-001. . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

19 . . . . . 064100-126. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 064100-127. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 064143-009. . . . . . . . Hose Nipple

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 061022-015. . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

23 . . . . . 127958 . . . . . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 064357 . . . . . . . . . . . Beaded Tee

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . 064316-001. . . . . . . . “Y” Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Includes O-Ring(s)

Crown 2007 PF15884-2


02.0-2045-251

431

HYDRAULIC PARTS

Lift & Return Line Hydraulics - TL Mast


02.0-2045-302

432

(a) Outer Mast

(b) Left and Right Determined from


(c) See Lowering Flow Control

Valve - TL

Figure 20659

Crown 2008 PF17510-1

HYDRAULIC PARTS



1 . . . . . 142181 . . . . . . . . . . . RH Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 142182 . . . . . . . . . . . LH Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 064279-001. . . . . . . . Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . 064019-045 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . . . . 064019-102 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 060063-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2008 PF17510-2


02.0-2045-303

433

HYDRAULIC PARTS

Lift & Return Line Hydraulics - TT Mast


02.0-2045-325

434

(a) Lower Flow Control Valve - TT

Figure 19745

Crown 2008 PF17307-1

HYDRAULIC PARTS



1

. . . . . . (1)

. . . . . . . . . . . . . . . Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 064280-010. . . . . . . . 90° Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 064019-045 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 064019-102 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 130032 . . . . . . . . . . . Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 060063-006. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 060063-023. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 060030-017. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 064279-001. . . . . . . . Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . . . . 064019-045 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . . . . 064019-102 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 142182 . . . . . . . . . . . LH Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 142181 . . . . . . . . . . . RH Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

See Chart

Truck

Capacity*

Lift Height*

1815 kg,

(4000 lb),

2270 kg

(5000 lb), or

2495 kg

(5500 lb) mm

4775

5230

5485

5865

6250

6555

7010

7390

231

246

258

276

291 in

188

206

216

Index 1 – Hose Assembly

Index 1

Hose Assembly

Truck

Capacity*

064359-032

064359-033

064359-034

064359-035

064359-036

064359-037

064359-038

064359-039

2720 kg

(6000 lb)

Lift Height* mm

4570

5030

5285

5665

6045

6550 in

180

198

208

223

238

250

Index 1

Hose Assembly

064359-032

064359-033

064359-034

064359-035

064359-036

064359-037

*




Crown 2008 PF17307-2


02.0-2045-326

435

HYDRAULIC PARTS

Accessory Line Hydraulics - TL Mast


02.0-2045-352

01 Rev. 12/08

436

Accessory Hose

Control Valve Connections

To Top Port of

1st Accy Section

To Bottom Port of

1st Accy Section

To Top Port of

2nd Accy Section

To Bottom Port of

2nd Accy Section

To Carriage Hydraulics - TL

Figure 20699-01

Crown 2008 PF17350-1 Rev. 12/08

HYDRAULIC PARTS



1 . . . . . * . . . . . . . . . . . . . . . . Hose

(1)

, See Accessory Hose Chart - TL Mast . . . . . . . . . . . . . . . . . . . . . . 2

* . . . . . . . . . . . . . . . . Hose

(2)

, See Accessory Hose Chart - TL Mast . . . . . . . . . . . . . . . . . . . . . . 4

2 . . . . . 128449 . . . . . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . . . . . 129265 . . . . . . . . . . . Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 060063-023. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 129284-001. . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 123281 . . . . . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 060062-002. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


9 . . . . . 143910 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 060075-013. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 064506-008. . . . . . . . Bulkhead Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 064325-008. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 064019-100. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

(1)

One Accessory

(2)

Two Accessories

*




Truck

Capacity*

1815 kg

(4000 lb),

2270 kg

(5000 lb), or

2495 kg

(5500 lb)

Lift Height* mm

3200

3505

3810 in

126

138

150

Index 1 – Hose Assembly

Index 1

Hose Assembly

Truck

Capacity*

064362-041

064362-042

2720 kg

(6000 lb)

Lift Height* mm

2995

3300 in

118

130

064362-043 3605 142

Index 1

Hose Assembly

064362-041

064362-042

064362-043

Crown 2008 PF17350-2 Rev. 12/08


02.0-2045-353

01 Rev. 12/08

437

HYDRAULIC PARTS

Accessory Line Hydraulics - TT Mast


View “A”

View “B”

(a) See View “A”

(b) See View “B”

(c) See Carriage Hydraulics - TT Mast

02.0-2045-400

438

Accessory Hose Control Valve Connections, See

Accessory Line Hydraulics - TT

To Top Port of 1 st

Accessory Section

To Bottom Port of 1 st

Accessory Section

To Top Port of 2 nd

Accessory Section

To Bottom Port of 2 nd

Accessory Section

Figure 19676

Crown 2008 PF17309-1

HYDRAULIC PARTS



1

. . . . . . (1)

. . . . . . . . . . . . . . . Hose Assembly (Single Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . Hose Assembly (Double Accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 . . . . . 123281 . . . . . . . . . . . Clamp (Single Accessory). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . Clamp (Double Accessories). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060062-022. . . . . . . . Screw (Single Accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . Screw (Double Accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 143800 . . . . . . . . . . . Hose Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 137748 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 060030-017. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 . . . . . 060009-074. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 060063-038. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 129284 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 128449 . . . . . . . . . . . Clamp Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 129265 . . . . . . . . . . . Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 060063-023. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 142226 . . . . . . . . . . . Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 060063-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

See Chart 1

Truck

Capacity*

Lift Height*

1815 kg

(4000 lb),

2270 kg

(5000 lb),

2495 kg

(5500 lb) mm

4775

5230

5485

5865

6250

6555

7010

7390

231

246

258

276

291 in

188

206

216

Chart 1 – Hose Assembly Index 1

Index 1

Hose Assembly

Truck

Capacity*

064362-031

064362-032

064362-033

064362-034

064362-035

064362-036

064362-037

064362-038

2722 kg

(6000 lb)

Lift Height* mm

4572

5030

5283

5665

6046

6350 in

180

198

208

223

238

250

Index 1

Hose Assembly

064362-031

064362-032

064362-033

064362-034

064362-035

064362-036

Crown 2008 PF17309-2

*





02.0-2045-401

439

HYDRAULIC PARTS

Mast Hydraulics - Quad Mast


RH & LH Lift Cylinders

See Cylinder Parts

Carriage Cylinder

See Cylinder Parts

02.04-2040-300

02 Rev. 5/07

440

Figuree 16454

Crown 2004 PF13810-1 Rev. 5/07

HYDRAULIC PARTS



1 . . . . . 131786 . . . . . . . . . . . U Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060059-010. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 131666-001. . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . * . . . . . . . . . . . . . . . . Hose, See Quad Mast Hose Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 132178 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 064279-001. . . . . . . . Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7 . . . . . 064325-010. . . . . . . . Bulkhead Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 064280-013. . . . . . . . 90° Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 132549 . . . . . . . . . . . Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 060063-018. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 128716-002. . . . . . . . Flow Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 064296-010. . . . . . . . 90° Swivel Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 064280-010. . . . . . . . 90° Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 133882 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 133883 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 128130-003. . . . . . . . Flow Limiter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 133871 . . . . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*




Hose

Index 4

064359-203

064359-218

064359-233

064359-248

064359-263

Quad Mast Hose Chart

Collapsed Height mm (in)

2110

2260

(83)

(89)

2410

2560

2710

(95)

(101)

(107)

Lift Height mm

6100

6560

7010

7475

7925

(in)

(240)

(258)

(276)

(294)

(312)

Hose Length mm (in)

1905

2050

(75)

(81)

2195

2340

2485

(86)

(92)

(98)

Crown 2004 PF13810-2 Rev. 5/07


02.04-2040-301

02 Rev. 5/07

441

HYDRAULIC PARTS



02.04-2040-500

03 Rev. 7/08

442

(a) To Power Unit Hydraulics

(b) Mounted To Outer Mast

(c) On 2nd Stage Mast

(d) Around Bracket On Inner Mast

(e) To Attachments

Figure 16461-01

Crown 2004 PF13887-1 Rev. 7/08

HYDRAULIC PARTS



1 . . . . . 060063-015. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 060059-020. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 . . . . . * . . . . . . . . . . . . . . . . Bracket, See Chart 1 - Quad Mast Accessory Parts . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 060063-023. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 131704 . . . . . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . 131705 . . . . . . . . . . . Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 123281 . . . . . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 060062-022. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . * . . . . . . . . . . . . . . . . Hose, See Chart 1 - Quad Mast Accessory Parts. . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 064325-006. . . . . . . . Bulkhead Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


12 . . . . . 060120-003. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 060062-002. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 060030-092. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 060059-011 . . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

16 . . . . . * . . . . . . . . . . . . . . . . Channel, See Chart 1 - Quad Mast Accessory Parts . . . . . . . . . . . . . . . . . . 1

17 . . . . . 060075-009. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 060059-024. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

19 . . . . . 060063-027. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

20 . . . . . 060030-294. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

21 . . . . . 060030-375. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

22 . . . . . 060030-285. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Note: All Quantities Shown Are For Trucks With One Accessory,

Double Amount For Trucks With Two Accessories.

*




Collapsed Height mm in

2110

2260

83

89

2410

2560

2710

95

101

107

Chart 1 - Quad Mast Accessory Parts

mm

Lift Height in

6100

6560

240

258

7010

7475

7925

276

294

312

Bracket

Index 3

Hose

Index 9

Channel

Index 16

131811-203 064360-204 131808-203

131811-218 064360-219 131808-218

131811-233 064360-234 131808-233

131811-248 064360-248 131808-248

131811-263 064360-263 131808-263

Crown 2004 PF13887-2 Rev. 7/08


02.04-2040-501

03 Rev. 7/08

443

HYDRAULIC PARTS

Lift Pump - TT

Lift Pump - TT

02.1-2045-001

444

Figure 19770

Crown 2008 PF17310-1

HYDRAULIC PARTS

Lift Pump - TT


1 . . . . . 145424 . . . . . . . . . . . Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060017-054. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060030-177. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

063002-040. . . . . . . . Spline Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

134319 . . . . . . . . . . . Seal Pump Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Note: When internal lift pump components require replacement (except seals), Crown recommends pump replacement.

Crown 2008 PF17310-2


02.1-2045-002

445

HYDRAULIC PARTS

Lift Pump - TL/Quad


02.1-2045-100

446

Figure 16464-01

Crown 2008 PF17315-1

HYDRAULIC PARTS



1 . . . . . 134167 . . . . . . . . . . . Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060017-054. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060030-177. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

063002-040. . . . . . . . Spline Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

134319 . . . . . . . . . . . Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Note: When internal lift pump components require replacement (except seals), Crown recommends pump replacement.

Crown 2008 PF17315-2


02.1-2045-101

447

HYDRAULIC PARTS

Lift Pump Motor

Lift Pump Motor

02.2-2045-001

01 Rev. 11/07

448

(a)

(b)

(c)

“EE” Motor Only

Torque 32 - 36 Nm (24 - 27 ft lb)

Torque 23 - 24 Nm (17 - 18 ft lb)

Figure 16496-01

Crown 2007 PF15939-1 Rev. 11/07

HYDRAULIC PARTS

Lift Pump Motor


0 . . . . . 021218* . . . . . . . . . . 36V/48V AC Lift Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

021246* . . . . . . . . . . 36V/48V AC Lift Motor Assembly EE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 021220* . . . . . . . . . . . Drive End Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

021242* . . . . . . . . . . . Drive End Head EE Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 021079-007 . . . . . . . . Tie Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . . . . . . . . 060059-020 . . . . . . . . Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 . . . . . . . . 060030-336 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 . . . . . . . . 021138 . . . . . . . . . . . . Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

021278. . . . . . . . . . . . Terminal Block “EE” Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 060061-013 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . . . . 062756. . . . . . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062798-001 . . . . . . . . Connector Insert, Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

065003-258 . . . . . . . . Sleeving, Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 021212-001 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

9 . . . . . . . . 020986. . . . . . . . . . . . Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 060125-001 . . . . . . . . Spring Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

11 . . . . . . . . 060059-028 . . . . . . . . Flange Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

12 . . . . . . . . 021178* . . . . . . . . . . . Gasket “EE” Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 021179* . . . . . . . . . . . Grommet “EE” Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

14 . . . . . . . . 060046-020 . . . . . . . . Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . . . . 065081-054 . . . . . . . . Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . . . . 021229. . . . . . . . . . . . Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . . . . 021227. . . . . . . . . . . . Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . . . . 021236* . . . . . . . . . . . Fan End Head Assembly, Includes Index 18 - 24 . . . . . . . . . . . . . . . . . . 1

021247* . . . . . . . . . . . Fan End Head Assembly, EE Motor, Includes Index 12, 13 & 18 - 24 . . 1

021222* . . . . . . . . . . . Fan End Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

021244* . . . . . . . . . . . Fan End Head EE Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . . . . 062749-001 . . . . . . . . Attachment Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

20 . . . . . . . . 060061-032 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

21 . . . . . . . . 060046-020 . . . . . . . . Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . . . . 021235-001 . . . . . . . . Sensor Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . . . . 021223. . . . . . . . . . . . Bearing Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . . . . 060063-046 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

25 . . . . . . . . 060059-019 . . . . . . . . Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

26 . . . . . . . . 060032-081 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

*




Crown 2007 PF15939-2 Rev. 11/07


02.2-2045-002

01 Rev. 11/07

449

HYDRAULIC PARTS

DC Lift Motor

DC Lift Motor

(a)

(b)

Part of Commutator End Head

Torque to 16 - 17 Nm (140 - 150 in lb)

02.2-2045-050

01 Rev. 2/08

450

Figure 17935-01

Crown 2007 PF17078-1 Rev. 2/08

HYDRAULIC PARTS

DC Lift Motor


0 . . . . . 020726-001. . . . . . . . DC Lift Motor 36V/48V With Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 060078-009 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 . . . . . . . . 020245. . . . . . . . . . . . Commutator End Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 062547. . . . . . . . . . . . Brush Wear Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

020291 . . . . . . . . . . . Lead BWI 190 mm (7.5 in) Long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

020292 . . . . . . . . . . . Lead BWI 310 mm (12.25 in) Long . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 119040 . . . . . . . . . . . . Terminal Stud Kit Includes Components For One Motor . . . . . . . . . . . . . 1

5 . . . . . . . . 020240-002 . . . . . . . . Brush Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . . . 118991 . . . . . . . . . . . Spring Kit Includes 8 Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 060078-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

8 . . . . . . . . 020252-001 . . . . . . . . Brush 16 x 25 mm (0.625 x 1.0 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

118942 . . . . . . . . . . . . Brush Kit Includes 8 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 060032-051 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

10 . . . . . . . . 060046-020 . . . . . . . . Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 065081-056 . . . . . . . . Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 020749-002 . . . . . . . . Frame & Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 060078-003 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

14 . . . . . . . . 062547. . . . . . . . . . . . Connector Over Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . . . . 020727. . . . . . . . . . . . Armature Includes Fan (Fan Not Serviceable). . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . . . . 020241. . . . . . . . . . . . Drive End Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

020242 . . . . . . . . . . . Drive End Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . . . . . . 065081-054 . . . . . . . Ball Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . . . . . . 060009-144 . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . . . . 060078-007 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Crown 2007 PF17078-2 Rev. 2/08


02.2-2045-051

01 Rev. 2/08

451

HYDRAULIC PARTS

Directional Control Valve - 3 Spool


(a) Accessory

(b) Tilt

(c) Lift

(d) Inlet

(e) Test Port

(f) Outlet

(g) Torque to 9.5 ± 1.5 Nm (7 ± 1 ft lb)

(h) Torque to 5.4 ± 1.5 Nm (4 ± 1 ft lb)

(i)

(j)

Torque to 19 ± 2 Nm (14 ± 1.5 ft lb)

Torque to 45 ± 4.5 Nm (33 ± 3.5 ft lb)

(k) Torque to 65 ± 7 Nm (48 ± 5 ft lb)

(l) Torque to 2.7 ± 0.3 Nm (24 ± 2 ft lb)

02.3-2045-001

01 Rev. 10/08

452

Figure 19883

Crown 2008 PF17369-1 Rev. 10/08

HYDRAULIC PARTS



0 . . . . . 142886* . . . . . . . . . . Directional Control Valve

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

145634* . . . . . . . . . . Directional Control Valve

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 127564. . . . . . . . . . . . Spool End Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 . . . . . . . . 130157. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 . . . . . . . . 112671 . . . . . . . . . . . . Seal Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 . . . . . . . . 060015-002 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5 . . . . . . . . 130161. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

6 . . . . . . . . 112676 . . . . . . . . . . . . Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7 . . . . . . . . 112660 . . . . . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . . . . 112658 . . . . . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . . . . 127566-006 . . . . . . . . Flow Control Screw - 11.4 lpm (3.0 gpm). . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 112670 . . . . . . . . . . . . Poppet C.V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

11 . . . . . . . . 127555. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

12 . . . . . . . . 112690 . . . . . . . . . . . . Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . . . . 130163. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . . . . 112672 . . . . . . . . . . . . Spring Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

15 . . . . . . . . 112673 . . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16 . . . . . . . . 112674 . . . . . . . . . . . . End Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

17 . . . . . . . . 112675 . . . . . . . . . . . . Cap Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

18 . . . . . . . . 060015-016 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

19 . . . . . . . . 145885. . . . . . . . . . . . Inlet Section Assembly

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . . . . 127566-005 . . . . . . . . Flow Control Screw - 10.2 lpm (2.7 gpm) . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . . . . 064091-007 . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . . . . 130160. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . . . . 130162. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . . . . 127563. . . . . . . . . . . . Orifice Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

25 . . . . . . . . 130171. . . . . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

26 . . . . . . . . 130158. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

27 . . . . . . . . 127556. . . . . . . . . . . . Tie Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

28 . . . . . . . . 127558. . . . . . . . . . . . Tie Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

29 . . . . . . . . 130165. . . . . . . . . . . . Secondary Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

30 . . . . . . . . 142888. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . . . . 130164* . . . . . . . . . . . Main Relief Valve

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

127565* . . . . . . . . . . . Main Relief Valve

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

32 . . . . . . . . 127554. . . . . . . . . . . . Spool Section Assembly

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

130170 . . . . . . . . . . . Seal Kit Includes Index 2, 5, 6, 13, 22, 23 & 26 . . . . . . . . . . . . . . . . . . . . . . 1

127562 . . . . . . . . . . . Conversion Kit From 3 Spool To 4 Spool Valve. . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Quad Mast

(2)

TL & TT Mast

(3)

Housing and spool are matched, if damaged replace complete spool or inlet section assembly.

*




Crown 2008 PF17369-2 Rev. 10/08


02.3-2045-002

01 Rev. 10/08

453

HYDRAULIC PARTS



(a) Two Accessories

(b) One Accessory

(c) Tilt

(d) Lift

(e) Inlet

(f) Test Port

(g) Outlet

(h) Torque to 8 - 11 Nm (6 - 8 ft lb)

(i)

(j)

Torque to 3.9 - 6.9 Nm (3 - 5 ft lb)

Torque to 17 - 21 Nm (12.5 - 15.5 ft lb)

(k) Torque to 40.5 - 49.5 Nm (29.5 - 36.5 ft lb)

(l) Torque to 58 - 72 Nm (43 - 53 ft lb)

(m) Torque to 2.4 - 3.0 Nm (22 - 26 ft lb)

02.3-2045-050

02 Rev. 5/09

454

Figure 19884-01

Crown 2008 PF17370-1 Rev. 5/09

HYDRAULIC PARTS



0 . . . . . 142887* . . . . . . . . . . Directional Control Valve Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

145635* . . . . . . . . . . Directional Control Valve TL & TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 127564. . . . . . . . . . . . Adapter Spool End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 . . . . . . . . 130157. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 . . . . . . . . 112671 . . . . . . . . . . . . Plate Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 . . . . . . . . 060015-002 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 . . . . . . . . 130161. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 . . . . . . . . 112676 . . . . . . . . . . . . Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7 . . . . . . . . 112660 . . . . . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . . . . 112658 . . . . . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


10 . . . . . . . . 112670 . . . . . . . . . . . . Poppet C.V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

11 . . . . . . . . 127555. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 . . . . . . . . 112690 . . . . . . . . . . . . Shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

13 . . . . . . . . 130163. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

14 . . . . . . . . 112672 . . . . . . . . . . . . Seat Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

15 . . . . . . . . 112673 . . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

16 . . . . . . . . 112674 . . . . . . . . . . . . End Spool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

17 . . . . . . . . 112675 . . . . . . . . . . . . Cap Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

18 . . . . . . . . 060015-016 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

19 . . . . . . . . 127566-006 . . . . . . . . Flow Control Screw - 11.4 lpm (3.0 gpm). . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . . . . 145885. . . . . . . . . . . . Inlet Section Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


22 . . . . . . . . 064091-007 . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . . . . 130160. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . . . . 130162. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . . . . 127563. . . . . . . . . . . . Orifice Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

26 . . . . . . . . 130171. . . . . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

27 . . . . . . . . 130158. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

28 . . . . . . . . 127557. . . . . . . . . . . . Tie Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

29 . . . . . . . . 127559. . . . . . . . . . . . Tie Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

30 . . . . . . . . 130165. . . . . . . . . . . . Secondary Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . . . . 142888. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

32 . . . . . . . . 130164* . . . . . . . . . . . Main Relief Valve Quad & TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

127565* . . . . . . . . . . . Main Relief Valve TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

130170 . . . . . . . . . . . Seal Kit Includes Index 2, 5, 6, 13, 23, 24 and 27. . . . . . . . . . . . . . . . . . . . . 1

(1)

Housing and spool are matched. If damaged, replace complete spool or inlet section assembly.

*




Crown 2008 PF17370-2 Rev. 5/09


02.3-2045-051

02 Rev. 5/09

455

HYDRAULIC PARTS

Manifold Crossover Relief


Model Function

RC 3000 Carriage Hydraulics

RC 5500 Carriage Hydraulics

SC 4000 Carriage Hydraulics



FC 4000 Carriage Hydraulics

FC 4500 Carriage Hydraulics

02.4-1140-050

05 Rev. 12/07

456

(a)

(b)

Pressure Pre-Set To 138 ± 3.5 Bar (2000 ± 50 PSI)

Torque to 20 - 23 Nm (15 - 17 ft lb)

Figure 15738-01

Crown 2000 PF11793-1 Rev. 12/07

HYDRAULIC PARTS



0 . . . . . 124821* . . . . . . . . . . Crossover Relief Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 124822. . . . . . . . . . . . Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 064091-002 . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 064019-029 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 . . . . . . . . 064279-010 . . . . . . . . Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . . . . 064019-045 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 126233. . . . . . . . . . . . Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*




Crown 2000 PF11793-2 Rev. 12/07


02.4-1140-051

05 Rev. 12/07

457

HYDRAULIC PARTS

Tilt Manifold

Tilt Manifold

02.4-2040-001

04 Rev. 9/07

458

(1) Trucks With Tilt Lockout/

Position Assist

(2) Trucks With Tilt or Tilt Lockout

(3) Trucks With Tilt Lockout

(4) Trucks Without Tilt Lockout

(5) Torque to 27.2 - 34 Nm

(240 - 300 in lb)

(6) Troque to 6.2 - 7.4 Nm

(55 - 65 in lb)

(7) Torque to 54.4 - 58.5 Nm

(480 - 516 in lb)

(8) Torque to 17.7 - 20.4 Nm

(156 - 180 in lb)

(9) Torque to 40.7 - 47.4 Nm

(360 - 420 in lb)

Figure 10156-03

Crown 2002 PF13340-1 Rev. 9/07

HYDRAULIC PARTS

Tilt Manifold


0 . . . . . 130124* . . . . . . . . . . Valve Counterbalance Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

0 . . . . . 130123* . . . . . . . . . . Valve Counterbalance Tilt Interlock Assembly Includes Indexes 1-6 . . . . . . 1

0 . . . . . 133095* . . . . . . . . . . Valve CB Tilt Interlock/Assist Assembly Includes Indexes 1-6, 8-9. . . . . . . . 1

0 . . . . . 133301* . . . . . . . . . . Valve Tilt Assist Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 130118* . . . . . . . . . . . Block Manifold Tilt and Tilt Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

133090* . . . . . . . . . . . Block Manifold Tilt Lockout/Position Assist . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 126944. . . . . . . . . . . . Valve Counterbalance Includes Index 3. . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 111791 . . . . . . . . . . . . Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 064091-006 . . . . . . . . Plug Includes O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

064019-031 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5 . . . . . . . . 130122* . . . . . . . . . . . Solenoid Valve Tilt Lockout Includes Index 6 . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 111790-016*. . . . . . . . Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 127269-001* . . . . . . . Solenoid Coil Suppressed 36 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

127269-002* . . . . . . . Solenoid Coil Suppressed 48 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 064091-001* . . . . . . . Plug Includes O-Ring

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064019-030* . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 127269-001* . . . . . . . Solenoid Coil Suppressed 36 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

127269-002* . . . . . . . Solenoid Coil Suppressed 48 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 133181* . . . . . . . . . . . Solenoid Valve Tilt Lockout/Position Assist Includes Index 11. . . . . . . . . 1

11 . . . . . . . . 111790-005*. . . . . . . . Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Includes Indexes 1-4, 7 for SC 4000/4500 Trucks

(2)

Includes Indexes 1-4, 7-9 for SC 4000/4500 Trucks

(3)

For Trucks Without Tilt Lockout or Tilt Lockout/Position Assist

*




Crown 2002 PF13340-2 Rev. 9/07


02.4-2040-002

04 Rev. 9/07

459

HYDRAULIC PARTS



02.4-2040-100

01 Rev. 6/07

460

Figure 16515

Crown 2001 PF13173-1 Rev. 6/07

HYDRAULIC PARTS



0 . . . . . 126727 . . . . . . . . . . . Manifold Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 129723. . . . . . . . . . . . Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129724. . . . . . . . . . . . Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 129725. . . . . . . . . . . . Manual Brake Release Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129726. . . . . . . . . . . . Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 129740. . . . . . . . . . . . Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

111790-015 . . . . . . . . Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 127269-001* . . . . . . . Coil 36V SV2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

127269-002* . . . . . . . Coil 48V SV2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Does not include Index 4.

*




Crown 2001 PF13173-2 Rev. 6/07


02.4-2040-101

01 Rev. 6/07

461

HYDRAULIC PARTS

4-Position Pressure Relief Valve


02.4-2040-400

03 Rev. 6/07

462

(1)

(2)

(3)


To Lowering Flow Control Manifold

To Control Valve

Figure 16528

Crown 2002 PF13345-1 Rev. 6/07

HYDRAULIC PARTS



1 . . . . . 129429 . . . . . . . . . . . 4-Position Pressure Relief Valve Assembly Includes Relief Valve Cartridge 1

2 . . . . . . . . 130764. . . . . . . . . . . . Relief Valve Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 130765. . . . . . . . . . . . Seal Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 129430 . . . . . . . . . . . Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 129298 . . . . . . . . . . . Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 050005-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 . . . . . 128362 . . . . . . . . . . . Upper Clamp Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 127697 . . . . . . . . . . . Lower Clamp Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 060062-012. . . . . . . . Screw M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 060062-009. . . . . . . . Screw M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

11 . . . . . 064280-008. . . . . . . . Elbow Includes O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 064327-008. . . . . . . . Long Elbow Includes O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 064298-015. . . . . . . . Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 064285-003. . . . . . . . Tee Includes O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . . . . 064019-101 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

*




Crown 2002 PF13345-2 Rev. 6/07


02.4-2040-401

03 Rev. 6/07

463

HYDRAULIC PARTS

Lowering Flow Control Valve - TL


(a) Torque to 69 to 76 Nm (51 to 56 ft lb)

(b) Torque to 92 to 100 Nm (68 to 74 ft lb)

(c) Torque to 62 to 68 Nm (46 to 50 ft lb)

(d) Torque to 43 to 49 Nm (32 to 36 ft lb)

02.4-2045-202

464

Figure 20667

Crown 2008 PF17523-1

HYDRAULIC PARTS



0 . . . . . 137936-002. . . . . . . . Manifold Block Assembly - TL Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 064091-005 . . . . . . . . Plug Includes O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . . . 064019-075 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 137935. . . . . . . . . . . . Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 128716-001 . . . . . . . . Regulator Flow Includes O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . . . 064019-112. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . . . 064019-102 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 064311-010 . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 064319-010 . . . . . . . . Tee Includes O-Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . . . 064019-045 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . . . 064019-102 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2008 PF17523-2


02.4-2045-203

465

HYDRAULIC PARTS

Lowering Control Valve - TT


02.4-2045-250

466

(a) Torque 69-76 Nm (51-56 ft lb)

(b) Torque 92-100 Nm (68-74 ft lb)

(c) Torque 62-68 Nm (46-50 ft lb)

(d) Torque 43-49 Nm (32-36 ft lb)

Figure 19674

Crown 2008 PF17312-1

HYDRAULIC PARTS



0 . . . . . 137936-001. . . . . . . . Manifold Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 137935. . . . . . . . . . . . Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . . . 064279-013 . . . . . . . Adapter (Includes O-Rings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . . . 064019-102 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . . . 064019-075 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . . . 128716-001 . . . . . . . Regulator (Includes O-Rings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . . . 064019-112. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . . . 064019-102 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . . . 064311-010. . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . . . 064319-010 . . . . . . . Tee (Includes O-Rings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . . . 064019-045 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . . . 064019-102 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2008 PF17312-2


02.4-2045-251

467

HYDRAULIC PARTS

Accessory Manifold - TL/Quad


02.4-2045-300

468

(a) 129425-001, -002, -003 and -004

Accessory Manifold Block

(b) 129425-005 Accessory Manifold Block

(c) 129425-006 Accessory Manifold Block

Figure 16521-01

Crown 2008 PF17313-1

HYDRAULIC PARTS



0 . . . . . 129425-001* . . . . . . . Accessory Manifold Block - TT/TL Mast with Quick Disconnect . . . . . . . . . . 1

129425-002* . . . . . . . Accessory Manifold Block - TT/TL Mast without Quick Disconnect . . . . . . . 1

129425-003* . . . . . . . Accessory Manifold Block - Quad Mast with Quick Disconnect . . . . . . . . . . 1

129425-004* . . . . . . . Accessory Manifold Block - Quad Mast without Quick Disconnect . . . . . . . . 1

129425-005* . . . . . . . Accessory Manifold Block

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129425-006* . . . . . . . Accessory Manifold Block - Quad Mast with Quick Disconnect & Sideshift . 1

1 . . . . . . . . 129213. . . . . . . . . . . . Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 126233. . . . . . . . . . . . Crossover Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . . . 064019-045 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4

. . . . . . . . . (2)

. . . . . . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5

. . . . . . . . . (2)

. . . . . . . . . . . . . . . . Adapter Includes O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6

. . . . . . . . . (2)

. . . . . . . . . . . . . . . . O-Ring

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2)

7

. . . . . . . . . (2)

. . . . . . . . . . . . . . . . Connector Includes O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . . . . 064004-001 . . . . . . . . Connector Includes Index 6 O-Rings

(1)

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

9 . . . . . . . . 064231-001 . . . . . . . . Dust Cap

(1)

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

10 . . . . . . . . 064333-003 . . . . . . . . Nipple

(1)

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

11 . . . . . . . . 064232-001 . . . . . . . . Dust Plug

(1)

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

12 . . . . . . . . 064334-003 . . . . . . . . Coupler

(1)

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

13 . . . . . . . . 064019-030 . . . . . . . . O-Ring

(1)

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

14

. . . . . . . . . (2)


15

. . . . . . . . . (2)

. . . . . . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16

. . . . . . . . . (2)


17

. . . . . . . . . (2)

. . . . . . . . . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18

. . . . . . . . . (2)

. . . . . . . . . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

Quick Disconnect Parts

(2)

See Chart 1

(3)

TT and TL Mast with Quick Disconnect & Sideshift

*




Crown 2008 PF17313-2


02.4-2045-301

469

HYDRAULIC PARTS


02.4-2045-302

470

(a) 129425-001, -002, -003 and -004



(c) 129425-006 Accessory Manifold Block

Figure 16521-01

Crown 2008 PF17313-3

HYDRAULIC PARTS


Accessory

Manifold Block

129425-001

129425-002

129425-003

129425-004

129425-005

129425-006

Index 4 -

O-Ring

064019-100

X

X

X

X

Chart 1 - Accessory Manifold

Index 5 -

Adapter Includes O-Rings

064279-008

X

X

X

X

X

X

Index 6 -

O-Ring

064019-030

X (6)

X (4)

X (6)

X (4)

X (8)

X (8)

Index 7 -

Connector

Includes O-Rings

064004-001

X

X

X

X

Accessory

Manifold Block

Index 14 -

Connector

Includes O-Rings

064280-009

129425-001

129425-002

129425-003

129425-004

129425-005

129425-006

X

Index 15 -

O-Ring

064019-100

X

Index 16 -

Connector

Includes O-Rings

064061-003

Index 17 -

Cap

064128-001

X

X

X

X

X X

Index 18 -

Cap

064311-008

X

Crown 2008 PF17313-4 02.4-2045-303

471

HYDRAULIC PARTS

Accessory Manifold - TL/TT


02.4-2045-350

02 Rev. 4/09

472

(a) Torque 41 - 43 Nm (30 - 31.7 ft lb)

(b) Torque 23 - 24 Nm (17 - 17.7 ft lb)

(c) Torque 43 - 49 Nm (31.7 - 36 ft lb)

Figure 19744

Crown 2008 PF17314-1 Rev. 10/08

HYDRAULIC PARTS



0 . . . . . 137938 . . . . . . . . . . . Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 137939. . . . . . . . . . . . Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 064091-002 . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . . . 064019-029 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . 064279-008 . . . . . . . . Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5 . . . . . . . . . . 064019-030 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . . . . . . 064019-100 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


8 . . . . . . . . . . 064019-045 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2008 PF17314-2 Rev. 10/08


02.4-2045-351

02 Rev. 4/09

473

HYDRAULIC PARTS

Accessory Manifold - Quad


02.44-2045-304

474

(a) 129425-003 and -004 Accessory Manifold Block


Figure 20150

Crown 2008 PF17543-1

HYDRAULIC PARTS



0 . . . . . 129425-003* . . . . . . . Accessory Manifold Block - Quad Mast with Quick Disconnect . . . . . . . . . . 1

129425-004* . . . . . . . Accessory Manifold Block - Quad Mast without Quick Disconnect . . . . . . . . 1

129425-006* . . . . . . . Accessory Manifold Block - Quad Mast with Quick Disconnect & Sideshift . 1

1 . . . . . . . . 129213. . . . . . . . . . . . Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


3 . . . . . . . . . . 064019-045 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . .

5 . . . . . . . .

(2)

. . . . . . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(2)

. . . . . . . . . . . . . . . . Adapter Includes O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(2)

. . . . . . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(2)

6 . . . . . . . .

7 . . . . . . . .

(2)


8 . . . . . . . . 064004-001 . . . . . . . . Connector Includes Index 6 O-Rings

(1)

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

9 . . . . . . . . 064231-001 . . . . . . . . Dust Cap

(1)

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

10 . . . . . . . . 064333-003 . . . . . . . . Nipple

(1)

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

11 . . . . . . . . 064232-001 . . . . . . . . Dust Plug

(1)

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

12 . . . . . . . . 064334-003 . . . . . . . . Coupler

(1)

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

13 . . . . . . . . 064019-030 . . . . . . . . O-Ring

(1)

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

14 . . . . . . . .

(2)


15 . . . . . . . .

(2)

. . . . . . . . . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

Quick Disconnect Parts

(2)

See Chart 1

*




Crown 2008 PF17543-2


02.44-2045-305

475

HYDRAULIC PARTS


02.44-2045-306

476

(a) 129425-003 and -004 Accessory Manifold Block


Figure 20150

Crown 2008 PF17543-3

HYDRAULIC PARTS


Accessory

Manifold Block

129425-003

129425-004

129425-006

Chart 1 - Accessory Manifold

Index 4

O-Ring

064019-100

X

Index 5

Adapter Includes

O-Rings

064279-008

X

X

X

Index 6

O-Ring

064019-030

X (6)

X (4)

X (8)

Accessory

Manifold Block

129425-003

129425-004

129425-006

Index 7

Connector

Includes O-Rings

064004-001

X

X

Index 14

Connector Includes

O-Rings

064061-003

X

Index 15

Cap

064128-001

X

X

X

Crown 2008 PF17543-4 02.44-2045-307

477

HYDRAULIC PARTS

Control Lever

Control Lever

1st Accessory

Insert Symbols - Index 2

(a) Lift 129714-001

(b) Tilt - 129714-002

(c) Sideshift 129714-003

(d) Fork Spread 129714-004

(e) Load Stabilizer 129714-005

(f) Push/Pull 129714-006

(g) Clamp 129714-007

(h) Rotate 129714-008

(i) Upender 129714-009

(j) Plain, Grey 129714-010

(k) Plain, Blue 129714-011

02.5-1140-250

06 Rev. 3/08

478

Insert Tactile - Index 3

(l) Lift 129716

(m) Tilt 129715-004

(n) One Accessory 129715-001

Figure 19225

Crown 1999 PF11640-1 Rev. 3/08

HYDRAULIC PARTS

Control Lever

Function

Lift/Lower

Tilt

1st Accessory

1st Accessory

1st Accessory

1st Accessory

1st Accessory

1st Accessory

1st Accessory

Control Lever Assembly - Lift/Lower, Tilt, 1st Accessory

Lever Assembly

(Includes Index 1, 2 and 3)

129721-001

129721-002

129721-003

129721-004

129721-005

129721-006

129721-007

129721-008

129721-009

Index 1

Handle

124514

124514

124514

124514

124514

124514

124514

124514

124514

Index 2

Symbol

Index 3

Tactile

129714-001 129716

129714-002 129715-004

129714-003 129715-001

129714-004 129715-001

129714-005 129715-001

129714-006 129715-001

129714-007 129715-001

129714-08 129715-001

129714-009 129715-001

Crown 1999 PF11640-2 Rev. 3/08 02.5-1140-251

06 Rev. 3/08

479

HYDRAULIC PARTS

Control Lever

2 nd

and 3 rd

Accessory

Insert Symbols - Index 2

(a) Tilt 118596

(b) Fork Spread 129714-004

(c) Load Stabilizer 129714-005

(d) Push/Pull 129714-006

(e) Clamp 129714-007

(f) Rotate 129714-008

(g) Upender 129714-009

(h) Tilt Assist (FC4) 133182-001

(I) Tilt Assist (SC4, SC5) 133182-002

02.5-1140-252

06 Rev. 3/08

480

Insert Tactile - Index 3

(j) Two Accessories 129715-002

(k) Three Accessories Tilt Assist 129715-003

(l) Three Accessories Tilt Assist 133113

Figure 19226

Crown 1999 PF11640-3 Rev. 3/08

HYDRAULIC PARTS

Control Lever


4 . . . . . 129717 . . . . . . . . . . . Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 077133-001. . . . . . . . Switch, 3rd Accessory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

133192-001. . . . . . . . Switch, Tilt Position Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 060011-022 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 062605-001. . . . . . . . Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 062606 . . . . . . . . . . . Lens Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 062609-002. . . . . . . . LED High Intensity Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

061001-020. . . . . . . . Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062791-002. . . . . . . . Inline Resistor Assembly Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

065003-004. . . . . . . . Sleeving 40 mm (1.5 in) Long, Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . 4

133190 . . . . . . . . . . . Inline Diode Assembly Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

133559 . . . . . . . . . . . Upper SC Tilt Assist Harness Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

133529 . . . . . . . . . . . Upper FC Tilt Assist Harness Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Function

Control Lever Assembly - 2nd and 3rd Accessory, Tilt Position Assist

2nd Accessory

2nd Accessory

2nd Accessory

2nd Accessory

2nd Accessory

2nd Accessory

2nd Accessory

2rd Accessory

3rd Accessory

Tilt Position Assist

Tilt Position Assist

Lever Assembly

(Includes Index 1, 2 and 3)

129721-011

129721-012

129721-013

129721-044

129721-015

129721-016

129721-017

129721-008

133182-001

133182-002

Index 1

Handle

124514

124514

124514

124514

124514

124514

124514

124514

127436

127436

127436

Index 2

Symbol

129714-007

129714-009

118596-019

118596-019

Index 3

Tactile

129714-001 129715-002

129714-002 129715-002

129714-003 129715-002

129714-004 129715-002

129714-005 129715-002

129714-006 129715-002

129715-002

129715-002

129715-003

129715-003

129715-003

Index 7

Insert

AR

133113

133113

Crown 1999 PF11640-4 Rev. 3/08


02.5-1140-253

06 Rev. 3/08

481

HYDRAULIC PARTS

Control Valve Linkage - Standard No Accessories


02.5-2045-001

482

(1)

(2)

(3)

(4)

See Control Valve Linkage

Part of Power Unit

AC Lift Only

See Control Valve Section

Figure 16536

Crown 2007 PF15950-1

HYDRAULIC PARTS



1 . . . . . 050006-026. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 . . . . . 076470-011 . . . . . . . . Clevis Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060100-001. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 065007-027. . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5 . . . . . 060046-013. . . . . . . . Spring Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . 060030-067. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 124265-002. . . . . . . . Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 124265-003. . . . . . . . Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 124268-003. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 050000-068. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 124137 . . . . . . . . . . . Pivot Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 050005-024. . . . . . . . Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 124205 . . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 060046-010. . . . . . . . Spring Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 124133 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 050025-010. . . . . . . . Carriage Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

18 . . . . . 050008-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

19 . . . . . 060046-012. . . . . . . . Spring Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 060030-221. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 124369 . . . . . . . . . . . Torsion Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2007 PF15950-2


02.5-2045-002

483

HYDRAULIC PARTS


02.5-2045-003

484

(1)

(2)

(3)

(4)


Part of Power Unit

AC Lift Only


Figure 16541

Crown 2007 PF15950-3

HYDRAULIC PARTS



40 . . . . . 124204-001. . . . . . . . Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

41 . . . . . 076470-011 . . . . . . . . Clevis Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

42 . . . . . 060100-001. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

43 . . . . . 124725 . . . . . . . . . . . Cam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

44 . . . . . 060015-068. . . . . . . . Screw Included With Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

45 . . . . . 062714* . . . . . . . . . . Switch With DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062752-005* . . . . . . . Sealed Switch Freezer/Corrosion With DC Lift . . . . . . . . . . . . . . . . . . . . . . . 1

46 . . . . . 062715* . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062752-004* . . . . . . . Sealed Switch With Freezer/Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

47 . . . . . 125504* . . . . . . . . . . Switch Plate With DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

125504* . . . . . . . . . . Switch Plate With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

48 . . . . . 060011-013* . . . . . . . Screw With DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

060011-013* . . . . . . . Screw With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

49 . . . . . 060005-049* . . . . . . . Lockwasher With DC Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

060005-049* . . . . . . . Lockwasher With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

50 . . . . . 093603* . . . . . . . . . . Insulator With DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

129001* . . . . . . . . . . Insulator Freezer/Corrosion With DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

093603* . . . . . . . . . . Insulator With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5


51 . . . . . 124721* . . . . . . . . . . Switch Bracket With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

52 . . . . . 124722* . . . . . . . . . . Switch Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

53 . . . . . 102471* . . . . . . . . . . Retainer With DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

54 . . . . . 124933* . . . . . . . . . . Actuator Switch With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

55 . . . . . 060011-022* . . . . . . . Screw With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

56 . . . . . 060005-049* . . . . . . . Lockwasher With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

57 . . . . . 124723* . . . . . . . . . . Bracket With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

58 . . . . . 062715* . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


59 . . . . . 062715* . . . . . . . . . . Switch With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062752-004* . . . . . . . Sealed Switch With Freezer/Corrosion and AC Lift . . . . . . . . . . . . . . . . . . . 1



*




Crown 2007 PF15950-4


02.5-2045-004

485

HYDRAULIC PARTS

Control Valve Linkage - One Accessory


02.5-2045-050

486

(1)

(2)

(3)

(4)


Part of Power Unit

AC Lift Only


Figure 16629

Crown 2007 PF15963-1

HYDRAULIC PARTS



1 . . . . . 050006-026. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 . . . . . 076470-011 . . . . . . . . Clevis Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 . . . . . 060100-001. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 . . . . . 065007-027. . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 . . . . . 060046-013. . . . . . . . Spring Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6 . . . . . 060030-067. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 124265-002. . . . . . . . Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 124265-003. . . . . . . . Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 124265-004. . . . . . . . Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 124268-002. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 050000-068. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 124137 . . . . . . . . . . . Pivot Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 050005-024. . . . . . . . Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 124205 . . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 060046-010. . . . . . . . Spring Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 124133 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 050025-010. . . . . . . . Carriage Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

19 . . . . . 050008-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

20 . . . . . 060046-012. . . . . . . . Spring Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 060030-221. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 124369 . . . . . . . . . . . Torsion Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2007 PF15963-2


02.5-2045-051

487

HYDRAULIC PARTS


02.5-2045-052

488

(1)

(2)

(3)

(4)


Part of Power Unit

AC Lift Only


Figure 16630

Crown 2007 PF15963-3

HYDRAULIC PARTS



40 . . . . . 124204-001. . . . . . . . Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

41 . . . . . 076470-011 . . . . . . . . Clevis Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

42 . . . . . 060100-001. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

43 . . . . . 124725 . . . . . . . . . . . Cam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4




46 . . . . . 062715* . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1




48 . . . . . 060011-013* . . . . . . . Screw With DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

060011-013* . . . . . . . Screw With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

49 . . . . . 060005-049* . . . . . . . Lockwasher With DC Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

060005-049* . . . . . . . Lockwasher With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10






52 . . . . . 124722* . . . . . . . . . . Switch Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1






58 . . . . . 062715* . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1






61 . . . . . 062715* . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


*




Crown 2007 PF15963-4


02.5-2045-053

489

HYDRAULIC PARTS

Control Valve Linkage - Two Accessories


02.5-2045-100

490

(1)

(2)

(3)

(4)


Part of Power Unit

AC Lift Only


Figure 16631

Crown 2007 PF15964-1

HYDRAULIC PARTS



1 . . . . . 050006-026. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 . . . . . 076470-011 . . . . . . . . Clevis Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . . . . . 060100-001. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 . . . . . 065007-027. . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 . . . . . 060046-013. . . . . . . . Spring Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

6 . . . . . 060030-067. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 124265-001. . . . . . . . Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 124265-002. . . . . . . . Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 124265-003. . . . . . . . Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 124265-004. . . . . . . . Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 124268-001. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 050000-068. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 124137 . . . . . . . . . . . Pivot Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 050005-024. . . . . . . . Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 124205 . . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 060046-010. . . . . . . . Spring Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 124133 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 050025-010. . . . . . . . Carriage Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

20 . . . . . 050008-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

21 . . . . . 060046-012. . . . . . . . Spring Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 060030-221. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . 124369 . . . . . . . . . . . Torsion Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2007 PF15964-2


02.5-2045-101

491

HYDRAULIC PARTS


02.5-2045-102

492

(1)

(2)

(3)

(4)


Part of Power Unit

AC Lift Only


Figure 16632

Crown 2007 PF15964-3

HYDRAULIC PARTS



40 . . . . . 124204-001. . . . . . . . Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

41 . . . . . 076470-011 . . . . . . . . Clevis Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

42 . . . . . 060100-001. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

43 . . . . . 124725 . . . . . . . . . . . Cam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4




46 . . . . . 062715* . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1




48 . . . . . 060011-013* . . . . . . . Screw With DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

060011-013* . . . . . . . Screw With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

49 . . . . . 060005-049* . . . . . . . Lockwasher With DC Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

060005-049* . . . . . . . Lockwasher With AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12






52 . . . . . 124722* . . . . . . . . . . Switch Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1






58 . . . . . 062715* . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1






61 . . . . . 062715* . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


62 . . . . . 062715* . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


*




Crown 2007 PF15964-4


02.5-2045-103

493

HYDRAULIC PARTS

TT Carriage Hydraulics - Single Accessory


Trucks without Sideshifter

(a) Trucks with Quick Disconnect

(b) Trucks without Quick Disconnect

(c) See Accessory Manifold - TT

(d) See Accessory Line Hydraulics - TT Mast

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

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

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

(h) Torque 54 - 58 Nm (40-43 ft lb)

02.7-2045-100

01 Rev. 8/09

494

Figure 19694

Crown 2008 PF17318-1 Rev. 8/09

HYDRAULIC PARTS



1 . . . . . 060063-026. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 137899 . . . . . . . . . . . Mounting Bracket LH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 064325-008. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 139178-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139178-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 139180-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139180-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 060063-045. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


7 . . . . . 139174 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 139176 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 064296-008. . . . . . . . 90° Swivel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


12 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 064325-008. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 064128-001. . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 064004-001. . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 064334-003. . . . . . . . Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 064232-001. . . . . . . . Dust Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

19 . . . . . 064333-003. . . . . . . . Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

20 . . . . . 064231-001. . . . . . . . Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

21 . . . . . 064462-008. . . . . . . . Bulkhead Straight Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

22 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

23 . . . . . . . . 064019--100 . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

24 . . . . . 064128-001. . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

25 . . . . . 064468-008. . . . . . . . 37° Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


27 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

28 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

1815 kg (4000 lb), 2270 kg (5000 lb), and 2495 kg (5500 lb) Truck Capacities

(2)

2720 kg (6000 lb) Truck Capacity

*




Crown 2008 PF17318-2 Rev. 8/09


02.7-2045-101

01 Rev. 8/09

495

HYDRAULIC PARTS


Trucks with Quick Disconnect Sideshifter

02.7-2045-102

01 Rev. 8/09

496



(c) Sideshifter See Platforms Parts

(d) Torque 47 - 54 Nm (35 - 40 ft lb)

(e) Torque 54 - 58 Nm (40 - 43 ft lb)

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

Figure 19695-01

Crown 2008 PF17318-3 Rev. 8/09

HYDRAULIC PARTS



35 . . . . . 064279-008. . . . . . . . Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

36 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

37 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

38 . . . . . 064334-003. . . . . . . . Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

39 . . . . . 064232-001. . . . . . . . Dust Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40 . . . . . 064333-003. . . . . . . . Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

41 . . . . . 064231-001. . . . . . . . Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


43 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

44 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


46 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

47 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

48 . . . . . 142916-001. . . . . . . . Hose Guide LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

49 . . . . . 060021-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

50 . . . . . 064280-006. . . . . . . . 90° Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

51 . . . . . . . . 064019-101 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

52 . . . . . . . . 064109-029 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

53 . . . . . 064327-006. . . . . . . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

54 . . . . . . . . 064019-029 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

55 . . . . . . . . 064019-101 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

56 . . . . . 064499-001* . . . . . . . Hose Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064487-001* . . . . . . . Hose Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-011* . . . . . . . Hose Assembly

(1) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-031* . . . . . . Hose Assembly

(2) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

57 . . . . . 064298-029. . . . . . . . Hose Assembly

(1) (2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-012* . . . . . . . Hose Assembly

(1) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-032* . . . . . . . Hose Assembly

(2) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)


(2)


(3)

Trucks without Accessory Manifold

Crown 2008 PF17318-4 Rev. 8/09


02.7-2045-103

01 Rev. 8/09

497

HYDRAULIC PARTS

Carriage Hydraulics - TL Single Accessory


Trucks with Quick Disconnect and Without Sideshifter



(c) 145048-038 shown

(d) See Accessory Manifold - TL/TT

(e) See Accessory Line Hydraulics - TL Mast

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

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

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

(i) Torque 54 - 58 Nm (40 - 43 ft lb)

02.7-2045-200

498

Figure 20797

Crown 2008 PF15746-1

HYDRAULIC PARTS



1 . . . . . 060063-026. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


3 . . . . . 064325-008. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 139178-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139178-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 139180-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139180-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 060063-035. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


7 . . . . . 139174 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 139176 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 064296-008. . . . . . . . 90° Swivel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


12 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 064325-008. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 064128-001. . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 064004-001. . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 064334-003. . . . . . . . Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 064232-001. . . . . . . . Dust Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

19 . . . . . 064333-003. . . . . . . . Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

20 . . . . . 064231-001. . . . . . . . Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


22 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

23 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

24 . . . . . 064128-001. . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

25 . . . . . 064468-008. . . . . . . . 37° Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


27 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

28 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)


(2)


*




Crown 2008 PF15746-2


02.7-2045-201

499

HYDRAULIC PARTS


Trucks with Quick Disconnect and Sideshifter

02.7-2045-202

500



(c) Sideshifter See Platform Parts

(d) Torque 47 - 54 Nm (35 - 40 ft lb)

(e) Torque 54 - 58 Nm (40 - 43 ft lb)

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

Figure 19695

Crown 2008 PF15746-3

HYDRAULIC PARTS



35 . . . . . 064279-008. . . . . . . . Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

36 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

37 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

38 . . . . . 064334-003. . . . . . . . Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

39 . . . . . 064232-001. . . . . . . . Dust Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40 . . . . . 064333-003. . . . . . . . Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

41 . . . . . 064231-001. . . . . . . . Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


43 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

44 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


46 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

47 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

48 . . . . . 142916-001. . . . . . . . Hose Guide LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

49 . . . . . 060021-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

50 . . . . . 064280-006. . . . . . . . 90° Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

51 . . . . . . . . 064019-101 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

52 . . . . . . . . 064109-029 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

53 . . . . . 064327-006. . . . . . . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

54 . . . . . . . . 064019-029 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

55 . . . . . . . . 064019-101 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

56 . . . . . 064499-001* . . . . . . . Hose Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064487-001* . . . . . . . Hose Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-011* . . . . . . . Hose Assembly

(1) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-031* . . . . . . Hose Assembly

(2) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

57 . . . . . 064298-029. . . . . . . . Hose Assembly

(1) (2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-012* . . . . . . . Hose Assembly

(1) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-032* . . . . . . . Hose Assembly

(2) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)


(2)


(3)


*




Crown 2008 PF15746-4


02.7-2045-203

501

HYDRAULIC PARTS

Carriage Hydraulics - Quad Mast


Trucks With Sideshift

Single Hydraulic Accessory

And No Accessory

Manifold Blocks.

(1) Left and Right Are

Determined From


(2) To Sideshift Cylinder

(3) To Accessory Hoses

02.74-2040-100

01 Rev. 8/07

502

Trucks With One


And Quick Disconnect

See Lifting Mechanism Parts

For Fork Carriage


(5) See Hydraulic Parts

Trucks With Two

Accessory Manifold Blocks

And No Quick Disconnect



Figure 17210

Crown 2004 PF13943-1 Rev. 8/07

HYDRAULIC PARTS



1 . . . . . 064279-010. . . . . . . . Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 064337-002. . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 064325-006. . . . . . . . Bulkhead Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


5 . . . . . 060016-088. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 060005-008. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 064128-001* . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 064004-001* . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 064232-001* . . . . . . . Dust Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 064334-003* . . . . . . . Female Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 064019-030* . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 064231-001* . . . . . . . Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 064333-003* . . . . . . . Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 064004-004* . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 064019-029* . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 132487* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 132490* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


19 . . . . . 064325-006. . . . . . . . Bulkhead Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

20 . . . . . 060016-088. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

21 . . . . . 060005-008. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

22 . . . . . 064091-002. . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

23 . . . . . 132491* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 132490* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . 064325-006. . . . . . . . Bulkhead Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


27 . . . . . 132488* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

28 . . . . . 132489* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*




Crown 2004 PF13943-2 Rev. 8/07


02.74-2040-101

01 Rev. 8/07

503

HYDRAULIC PARTS


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





02.74-2040-102

01 Rev. 8/07

504

Trucks With Two

Accessory Manifold Blocks,

Sideshift And Quick Disconnect


For Fork Carriage



Figure 17211

Crown 2004 PF13943-3 Rev. 8/07

HYDRAULIC PARTS



35 . . . . . 060016-088. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

36 . . . . . 060005-008. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

37 . . . . . 064279-010* . . . . . . . Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

38 . . . . . 064337-002* . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

39 . . . . . 064325-006. . . . . . . . Bulkhead Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


41 . . . . . 064280-006* . . . . . . . Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

42 . . . . . 064019-101* . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

43 . . . . . 064337-003* . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

44 . . . . . 132489* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

45 . . . . . 132488* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

46 . . . . . 064019-029. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

47 . . . . . 064004-004. . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

48 . . . . . 064333-003* . . . . . . . Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

49 . . . . . 064231-001* . . . . . . . Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

50 . . . . . 064019-030* . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

51 . . . . . 064334-003* . . . . . . . Female Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

52 . . . . . 064232-001* . . . . . . . Dust Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

53 . . . . . 064004-001* . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

54 . . . . . 064128-001* . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

55 . . . . . 060016-088. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

56 . . . . . 060005-008. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

57 . . . . . 132491* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

58 . . . . . 132490* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

59 . . . . . 064325-006. . . . . . . . Bulkhead Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


61 . . . . . 064280-002* . . . . . . . Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

62 . . . . . 064019-101* . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

63 . . . . . 064232-001* . . . . . . . Dust Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

64 . . . . . 064334-003* . . . . . . . Female Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

65 . . . . . 064019-030* . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

66 . . . . . 064231-001* . . . . . . . Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

67 . . . . . 064333-003* . . . . . . . Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

68 . . . . . 064004-004* . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

69 . . . . . 064019-029* . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

70 . . . . . 064308-003* . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

061003-005* . . . . . . . Cable Tie, Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

71 . . . . . 064308-002* . . . . . . . Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

72 . . . . . 064280-006* . . . . . . . Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

73 . . . . . 132488* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

74 . . . . . 132489* . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

75 . . . . . 064004-001* . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

76 . . . . . 064128-001. . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

*




Crown 2004 PF13943-4 Rev. 807


02.74-2040-103

01 Rev. 8/07

505

HYDRAULIC PARTS

TT Carriage Hydraulics - Double Accessory


Trucks without Quick Disconnect

(a) See Accessory Line Hydraulics - TT Mast

(b) Sideshifter

(c) See 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)

02.8-2045-100

506

Figure 19696

HYDRAULIC PARTS




137898 . . . . . . . . . . . Mounting Bracket RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060063-026. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


4 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . 064325-008. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 . . . . . 064468-008. . . . . . . . 37° Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 064128-001. . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

9 . . . . . 139178-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139178-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 139180-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139180-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 139177-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139177-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 139179-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139179-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 139174 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 139176 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 139175 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 064296-008. . . . . . . . 90° Swivel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

17 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8


19 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

20 . . . . . 064325-008. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

21 . . . . . 060063-045. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


(1)

1815 kg (4000 lb), 2270 kg (5000 lb) and 2495 kg (5500 lb) Truck Capacities

(2)


*

To select appropriate part number, use the data number to determine truck features. Refer to Introduction.


02.8-2045-101

507

HYDRAULIC PARTS


(a) Sideshifter See Platform Parts

(b) Torque 47-54 Nm (35-40 ft lb)

02.8-2045-102

508

Figure 19742

HYDRAULIC PARTS



30 . . . . . 142916-001. . . . . . . . Hose Guide LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . 060021-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

32 . . . . . 064327-006. . . . . . . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

33 . . . . . . . . 064019-029 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . . . . 064019-101 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

35 . . . . . 064280-006. . . . . . . . 90° Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

36 . . . . . . . . 064019-101 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

37 . . . . . . . . 064019-029 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

38 . . . . . 064499-001* . . . . . . . Hose Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064487-001* . . . . . . . Hose Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-011* . . . . . . . Hose Assembly

(1) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-031* . . . . . . . Hose Assembly

(2) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

39 . . . . . 064298-029. . . . . . . . Hose Assembly

(1) (2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-012* . . . . . . . Hose Assembly

(1) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-032* . . . . . . . Hose Assembly

(2) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)


(2)


(3)


*



02.8-2045-103

509

HYDRAULIC PARTS


Trucks with Quick Disconnect

(a) See Accessory Line Hydraulics - TT Mast

(b) Sideshifter

(c) Torque 54-58 Nm (40-43 ft lb)

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

02.8-2045-104

510

Figure 19743

HYDRAULIC PARTS




51 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

52 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

53 . . . . . 064231-001. . . . . . . . Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

54 . . . . . 064333-003. . . . . . . . Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

55 . . . . . 064232-001. . . . . . . . Dust Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

56 . . . . . 064334-003. . . . . . . . Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

57 . . . . . 064004-001. . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

58 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

59 . . . . . 064128-001. . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


02.8-2045-105

511

HYDRAULIC PARTS

Carriage Hydraulics - TL Double Accessory


Trucks without Quick Disconnect

(a) Sideshifter

(b) 145048-038 Shown

(c) Accessory Hose Closest to Forks Conndcts to Top Manifold Port

(d) Dee Accessory Line Hydraulics - TL Mast

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

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

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

(h) See Accessory Manifold

02.8-2045-200

512

Figure 20798

Crown 2008 PF17547-1

HYDRAULIC PARTS




137898 . . . . . . . . . . . Mounting Bracket RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060063-026. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


4 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . 064325-008. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 . . . . . 064468-008. . . . . . . . 37° Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 064128-001. . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

9 . . . . . 139178-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139178-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 139180-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139180-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 139177-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139177-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 139179-001* . . . . . . . Tube Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

139179-002* . . . . . . . Tube Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 139174 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 139176 . . . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 064296-008. . . . . . . . 90° Swivel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

17 . . . . . 064325-008. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


19 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

20 . . . . . 060063-045. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . . . 061004-004. . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

(1)


(2)


*




Crown 2008 PF17547-2


02.8-2045-201

513

F

HYDRAULIC PARTS


Trucks with Sideshifter

02.8-2045-202

514

(a) Sideshifter - See Sideshift - TL/TT

(b) Torque 47 - 54 Nm (35 - 40 ft lb)

Figure 20799

Crown 2008 PF17547-3

HYDRAULIC PARTS



30 . . . . . 142916-001. . . . . . . . Hose Guide LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . 060021-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

32 . . . . . 064327-006. . . . . . . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

33 . . . . . . . . 064019-029 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . . . . 064019-101 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

35 . . . . . 064280-006. . . . . . . . 90° Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

36 . . . . . . . . 064019-101 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

37 . . . . . . . . 064019-029 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

38 . . . . . 064499-001* . . . . . . . Hose Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064487-001* . . . . . . . Hose Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-011* . . . . . . . Hose Assembly

(1) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-031* . . . . . . . Hose Assembly

(2) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

39 . . . . . 064298-029. . . . . . . . Hose Assembly

(1) (2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-012* . . . . . . . Hose Assembly

(1) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

064298-032* . . . . . . . Hose Assembly

(2) (3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)


(2)


(3)


*




Crown 2008 PF17547-4


02.8-2045-203

515

HYDRAULIC PARTS


Trucks with Quick Disconnect

(a) See Accessory Line Hydraulics - TL Mast

(b) Sideshifter

(c) Torque 54 - 58 Nm (40 - 43 ft lb)

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

02.8-2045-204

516

Figure 20800

Crown 2008 PF17547-5

HYDRAULIC PARTS




51 . . . . . . . . 064019-100 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

52 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

53 . . . . . 064231-001. . . . . . . . Dust Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

54 . . . . . 064333-003. . . . . . . . Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

55 . . . . . 064232-001. . . . . . . . Dust Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

56 . . . . . 064334-003. . . . . . . . Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

57 . . . . . 064004-001. . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

58 . . . . . . . . 064019-030 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

59 . . . . . 064128-001. . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Crown 2008 PF17547-6


02.8-2045-205

517

Notes:

518

DRIVE UNIT PARTS

519

DRIVE UNIT PARTS

Drive Unit

Drive Unit

03.0-2045-001

02 Rev. 3/08

520

(a) Traction Motor, See Drive Unit Parts

(b) See Drive Unit Maintenance For

Torque Values and Patterns

Figure 17990-01

Crown 2007 PF17079-1 Rev. 3/08


Drive Unit


1 . . . . . 121908 . . . . . . . . . . . Drive Unit Housing RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 064329-001. . . . . . . . Magnetic Plug with O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 064019-031. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 064091-006. . . . . . . . Plug With O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 064091-001. . . . . . . . Plug With O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 064019-030. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 060015-051. . . . . . . . Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 126497-002. . . . . . . . Adjusting Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 126497-001. . . . . . . . Adjusting Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 064019-103. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 065023 . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 . . . . . 065024 . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

13 . . . . . 125530 . . . . . . . . . . . Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 060017-100. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

15 . . . . . 129980 . . . . . . . . . . . 3 rd

Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 060019-075. . . . . . . . Set Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 126752 . . . . . . . . . . . 2 nd

Reduction Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 061011-006 . . . . . . . . Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

19 . . . . . 133765 . . . . . . . . . . . Drive Unit Housing LH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

061004-016. . . . . . . . Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

061004-015. . . . . . . . Gasket Eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 064194-001. . . . . . . . Breather Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

061004-016. . . . . . . . Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

061004-005. . . . . . . . Hydraulic Thread Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 078885-006. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

22 . . . . . 060017-047. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

061004-002. . . . . . . . Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


23 . . . . . 060018-009. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

061004-002. . . . . . . . Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


24 . . . . . 064019-065. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . 121912 . . . . . . . . . . . Thrust Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

26 . . . . . 065159 . . . . . . . . . . . Needle Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

27 . . . . . 133764 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

28 . . . . . 121910 . . . . . . . . . . . Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

29 . . . . . 121915 . . . . . . . . . . . 1 st

Reduction Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

30 . . . . . 060009-067. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . 126498 . . . . . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

32 . . . . . 060000-076. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2007 PF17079-2 Rev. 3/08


03.0-2045-002

02 Rev. 3/08

521


Drive Unit

03.0-2045-003

02 Rev. 3/08

522

(a) Part of Power Unit

(b) LH Brake Assembly

(c) RH Brake Assembly

(d) See Drive Unit Maintenance for Torque Values and Patterns

(e) Torque To 545 Nm (400 ft lb)

Figure 17991-02

Crown 2007 PF17079-3 Rev. 3/08


Drive Unit


40 . . . . . 060099-006. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

41 . . . . . 060030-339. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

42 . . . . . 060059-017. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


43 . . . . . 129296 . . . . . . . . . . . Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

060106-001. . . . . . . . Roll Pin LH Side Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

44 . . . . . 121917 . . . . . . . . . . . Axle Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

45 . . . . . 121923 . . . . . . . . . . . Axle Housing RH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

46 . . . . . 060020-051. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

061004-016. . . . . . . . Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


47 . . . . . 121922 . . . . . . . . . . . Axle Housing LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

48 . . . . . 060019-070. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

061004-016. . . . . . . . Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


49 . . . . . 060020-051. . . . . . . . Screw RH Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

061004-002. . . . . . . . Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


50 . . . . . 060030-330. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

51 . . . . . 060020-050. . . . . . . . Screw LH Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

061004-002. . . . . . . . Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


52 . . . . . 064138-017. . . . . . . . Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

53 . . . . . 065157 . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

54 . . . . . 065158 . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

55 . . . . . 125531 . . . . . . . . . . . Axle Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

121920. . . . . . . . . . . . Axle Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

56 . . . . . . . . 129130. . . . . . . . . . . . Stud 6 per Axle Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

57 . . . . . 065162 . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

58 . . . . . 065161 . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

59 . . . . . 060051-005. . . . . . . . Tabbed Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

60 . . . . . 060044-011 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

61 . . . . . 060043-010. . . . . . . . Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

62 . . . . . 121921 . . . . . . . . . . . Differential Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

63 . . . . . 060017-070. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

061004-016. . . . . . . . Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


Crown 2007 PF17079-4 Rev. 3/08


03.0-2045-004

02 Rev. 3/08

523


AC Traction Motor


(a) Torque to 120 Nm (88 ft lb)

(b) Torque to 16 Nm (12 ft lb)

(c) Torque to 10 Nm (7 ft lb)

03.1-2045-001

01 Rev. 9/08

524

Figure 17066-01

Crown 2007 PF15979-1 Rev. 9/08




0 . . . . . 143574 . . . . . . . . . . . AC Traction Motor Includes 1st Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 142243. . . . . . . . . . . . Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 050012-056 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 142239. . . . . . . . . . . . Drive End Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 142250. . . . . . . . . . . . Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 142240. . . . . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 142249. . . . . . . . . . . . Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 142248. . . . . . . . . . . . Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 142252. . . . . . . . . . . . Sensor Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 142242. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 142244. . . . . . . . . . . . Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 142245. . . . . . . . . . . . Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 142241. . . . . . . . . . . . End Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 142251. . . . . . . . . . . . Tie Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

14 . . . . . . . . 062749-001 . . . . . . . . Connector Clip Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . . . . 060065-023 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . . . . 062756-004 . . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062798-007 . . . . . . . . Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062797-007 . . . . . . . . Contact Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

17 . . . . . . . . 142100. . . . . . . . . . . . Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . . . . 060062-005 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

19 . . . . . . . . 060059-015 . . . . . . . . Jam Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

20 . . . . . . . . 060030-309 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

21 . . . . . . . . 060059-006 . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Crown 2007 PF15979-2 Rev. 9/08


03.1-2045-002

01 Rev. 9/08

525


Drive Tire

Drive Tire

(a) See Drive Unit Maintenance for

Torque Values & Drive Tire Torque Sequence

(b) Standard Tread Hub

(c) Wide Tread Hub

(d) Smooth Tread Tire

(e) Lugged Tread Tire

03.2-2040-001

01 Rev. 8/07

526

Figure 17198

Crown 2001 PF13152-1 Rev. 8/07


Drive Tire


1 . . . . . 127091 . . . . . . . . . . . Lug Nut, Quantity Per Drive Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

065005-003. . . . . . . . Anti-Seize, 0.62 Liter (1.5 Pint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tire & Hub

Assembly

136020-301-51

136020-311-51

136020-301-52

136020-311-52

*1815 kg (4000 lb) Capacity

Tire Size - 535 x 180 x 380 mm (21 x 7 x 15 in) Standard Tread

Tire Hub

Tread Design Composition/Color

136019-301-41

136019-311-41

136019-301-42

136019-311-42

121973

121973

121973

121973

Smooth

Smooth

Lugged

Lugged

Rubber/Black

Rubber/Gray

Rubber/Black

Rubber/Gray

Tire & Hub

Assembly

136020-301-61

136020-311-61

136020-301-62

136020-311-62


Tire Size - 535 x 180 x 380 mm (21 x 7 x 15 in) Wide Tread

Tire Hub


136019-301-41

136019-311-41

136019-301-42

136019-311-42

128375

128375

128375

128375

Smooth

Smooth

Lugged

Lugged

Rubber/Black

Rubber/Gray

Rubber/Black

Rubber/Gray

Crown 2001 PF13152-2 Rev. 8/07


03.2-2040-002

01 Rev. 8/07

527


Drive Tire

03.2-2040-003

01 Rev. 8/07

528




(c) Wide Tread Hub



Figure 17198

Crown 2001 PF13152-3 Rev. 8/07


Drive Tire




Tire & Hub

Assembly

137212-301-51

137212-311-51

137212-301-52

137212-311-52



Tire Hub


137210-301-41

137210-311-41

137210-301-42

137210-311-42

121973

121973

121973

121973

Smooth

Smooth

Lugged

Lugged

Rubber/Black

Rubber/Gray

Rubber/Black

Rubber/Gray

Tire & Hub

Assembly

137212-301-61

137212-311-61

137212-301-62

137212-311-62



Tire Hub


137210-301-41

137210-311-41

137210-301-42

137210-311-42

128375

128375

128375

128375

Smooth

Smooth

Lugged

Lugged

Rubber/Black

Rubber/Gray

Rubber/Black

Rubber/Gray

Crown 2001 PF13152-4 Rev. 8/07


03.2-2040-004

01 Rev. 8/07

529


Drive Tire

03.2-2040-005

01 Rev. 8/07

530




(c) Wide Tread Hub



Figure 17198

Crown 2001 PF13152-5 Rev. 8/07


Drive Tire




Tire & Hub

Assembly

137213-301-51

137213-311-51

137213-301-52

137213-311-52

*2495/2720 kg (5500/6000 lb) Capacity


Tire Hub


137211-301-41

137211-311-41

137211-301-42

137211-311-42

121973

121973

121973

121973

Smooth

Smooth

Lugged

Lugged

Rubber/Black

Rubber/Gray

Rubber/Black

Rubber/Gray

Tire & Hub

Assembly

137213-301-61

137213-311-61

137213-301-62

137213-311-62

*2495/2720 kg (5500/6000 lb) Capacity


Tire Hub


137211-301-41

137211-311-41

137211-301-42

137211-311-42

128375

128375

128375

Smooth

Smooth

Lugged

128375 Lugged

Rubber/Black

Rubber/Gray

Rubber/Black

Rubber/Gray

Crown 2001 PF13152-6 Rev. 8/07


03.2-2040-006

01 Rev. 8/07

531

Notes:

532

ELECTRICAL PARTS

533

ELECTRICAL PARTS

Electrical Components - Power Unit


(a)

(b)

(c)

(d)

(e)

(f)

Distribution Panel, See Electrical Parts

Part of Power Unit


Console Cover, See Power Unit Parts

Contactor Assembly, See Electrical Parts

Controller Panel, See Electrical Parts

04.0-2045-001

01 Rev. 2/08

534

Figure 16517

Crown 2007 PF15944-1 Rev. 2/08




1 . . . . . 062595-001. . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129925-003. . . . . . . . Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 062595-002. . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129925-002. . . . . . . . Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 062595-002. . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129925-001. . . . . . . . Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 124503 . . . . . . . . . . . Switch Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

5 . . . . . 127103 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 050067-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 050008-015. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 128229 . . . . . . . . . . . Brake Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 124339 . . . . . . . . . . . LH Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 124340 . . . . . . . . . . . RH Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 050025-008. . . . . . . . Carriage Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

13 . . . . . 140128-201-0S . . . . . ACCESS1 Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 060062-004. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 050067-014. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 050004-013* . . . . . . . Screw (Freezer/Corrosion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 050008-001* . . . . . . . Nut (Freezer/Corrosion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 127417* . . . . . . . . . . Thermostat Bracket (Freezer/Corrosion) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 062783-001* . . . . . . . Thermostat (Freezer/Corrosion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 050004-025* . . . . . . . Screw (Freezer/Corrosion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

21 . . . . . 050008-004* . . . . . . . Nut (Freezer/Corrosion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

22 . . . . . 130376* . . . . . . . . . . Fan DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

130376* . . . . . . . . . . Fan AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

23 . . . . . 140180-001* . . . . . . . Fan Shroud Small Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

140180-002* . . . . . . . Fan Shroud Large Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 060021-003. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

25 . . . . . 060102-003. . . . . . . . U-Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

26 . . . . . 140312 . . . . . . . . . . . Perforated Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

27 . . . . . 050004-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

28 . . . . . 140153 . . . . . . . . . . . Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

29 . . . . . 050070-002. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

30 . . . . . 050068-004. . . . . . . . Flanged Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

31 . . . . . 060075-072. . . . . . . . Flanged Head Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

32 . . . . . 065004-035. . . . . . . . Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

33 . . . . . 060086-002. . . . . . . . Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . 060087 . . . . . . . . . . . Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

35 . . . . . 109305-001. . . . . . . . Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*




Crown 2007 PF15944-2 Rev. 2/08


04.0-2045-002

01 Rev. 2/08

535



(a)

(b)

(c)

(d)

(e)

(f)

AC Lift, See Hydraulic Parts

DC Lift, See Hydraulic Parts

Part of Power Unit

Traction Motor, See Drive Unit Parts

Brake Mounting Bracket

Steer and Brake Pump Motor, See

Steering Parts

04.0-2045-003

01 Rev. 2/08

536

Figure 16518

Crown 2007 PF15944-3 Rev. 2/08





41 . . . . . 060063-047. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

42 . . . . . 060030-365. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

43 . . . . . 060059-020. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

44 . . . . . 060075-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

45 . . . . . 060030-340. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

46 . . . . . 093786-001. . . . . . . . Vibration Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

47 . . . . . 102126-001. . . . . . . . Grounding Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

48 . . . . . 050025-010. . . . . . . . Carriage Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

49 . . . . . 050073-004. . . . . . . . Spring Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

50 . . . . . 050008-034. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

51 . . . . . 129244-001. . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

52 . . . . . 050067-023. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

53 . . . . . 050068-003. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

54 . . . . . 128458 . . . . . . . . . . . Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

55 . . . . . 126489 . . . . . . . . . . . Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

56 . . . . . 135068 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

57 . . . . . 135069 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

58 . . . . . 050006-037. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

59 . . . . . 050009-018. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

60 . . . . . 050068-003. . . . . . . . Flanged Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

61 . . . . . 060065-022. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

62 . . . . . 050008-005. . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

63 . . . . . 129579 . . . . . . . . . . . Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

64 . . . . . 050004-015. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

65 . . . . . 050008-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

66 . . . . . 129995 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

67 . . . . . 050025-010. . . . . . . . Carriage Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

68 . . . . . 050068-004. . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

69 . . . . . 130376 . . . . . . . . . . . Fan 48V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

70 . . . . . 130390 . . . . . . . . . . . Fan Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

71 . . . . . 060012-035. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

72 . . . . . 060005-003. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

73 . . . . . 060021-003. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

74 . . . . . 130025 . . . . . . . . . . . Fan Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

75 . . . . . 050006-036. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

76 . . . . . 060102-001. . . . . . . . U-Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

77 . . . . . 115565 . . . . . . . . . . . Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

78 . . . . . 060062-003. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

79 . . . . . 060030-132. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

80 . . . . . 060059-011 . . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


82 . . . . . 060062-015. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

*




Crown 2007 PF15944-4 Rev. 2/08


04.0-2045-004

01 Rev. 2/08

537


Controller Panel - DC Lift


See Electrical Parts

04.1-2045-001

01 Rev. 3/08

538

Figure 16532-01

Crown 2007 PF15948-1 Rev. 3/08




0 . . . . . 140448-002* . . . . . . . Controller Panel Assembly DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 139605. . . . . . . . . . . . Controller Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 140211 . . . . . . . . . . . . Fan Shroud Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 060062-003 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 050009-012 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 139809. . . . . . . . . . . . Fan Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 060062-004 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7 . . . . . . . . 060065-006 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . . . . 050009-003 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . . . . 050008-001 . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . . . . 141860. . . . . . . . . . . . Fan Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 050006-001 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 . . . . . . . . 140025-00S . . . . . . . . AC Traction Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 050006-037 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

14 . . . . . . . . 050010-021 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

15 . . . . . . . . 060030-265 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

16 . . . . . . . . 060063-072 . . . . . . . . Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

17 . . . . . . . . 140257. . . . . . . . . . . . Fan Shroud Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*




Crown 2007 PF15948-2 Rev. 3/08


04.1-2045-002

01 Rev. 3/08

539


Controller Panel - AC Lift


See Electrical Parts

04.1-2045-050

01 Rev. 3/08

540

Figure 16533-01

Crown 2007 PF15949-1 Rev. 3/08




0 . . . . . 140448-001* . . . . . . . Controller Panel Assembly AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 139605. . . . . . . . . . . . Controller Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 140211 . . . . . . . . . . . . Fan Shroud Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 060062-003 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . 050009-012 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . . . . 139809. . . . . . . . . . . . Fan Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . . . . 060062-004 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7 . . . . . . . . 060065-006 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . . . . 050009-003 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

9 . . . . . . . . 050008-001 . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

10 . . . . . . . . 141860. . . . . . . . . . . . Fan Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . . . . 050006-001 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

12 . . . . . . . . 140025-00S . . . . . . . . AC Traction Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 050006-037 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

14 . . . . . . . . 050010-021 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

15 . . . . . . . . 060030-265 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

16 . . . . . . . . 060063-072 . . . . . . . . Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

17 . . . . . . . . 140025-00S . . . . . . . . AC Lift Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*




Crown 2007 PF15949-2 Rev. 3/08


04.1-2045-051

01 Rev. 3/08

541


Contactor Panel

Contactor Panel

04.2-2045-001

01 Rev. 12/07

542

Figure 16638-01

Crown 2007 PF15966-1 Rev. 12/07


Contactor Panel


0 . . . . . 140345-001* . . . . . . . Contactor Panel Assembly DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

140345-002* . . . . . . . Contactor Panel Assembly AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

140345-003* . . . . . . . Contactor Panel Assembly AC Lift EE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 139646. . . . . . . . . . . . Contactor Mounting Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 060000-025 . . . . . . . . Roll Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 139645. . . . . . . . . . . . Contactor Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 060062-003 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5 . . . . . . . . 062749-002 . . . . . . . . Attachment Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 050003-013 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 050008-008 . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 139669. . . . . . . . . . . . Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 060061-006* . . . . . . . Screw DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

060061-006* . . . . . . . Screw

(1)

AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

10 . . . . . . . . 140538-002* . . . . . . . Contactor 36/48V DC/AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

140538-001* . . . . . . . Contactor 36/48V

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 060065-007 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 . . . . . . . . 084568-069* . . . . . . . Power Cable

(1)

AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 119975* . . . . . . . . . . . Insulator

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . . . . 132084-003* . . . . . . . Contactor DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

132084-003* . . . . . . . Contactor AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

132084-004* . . . . . . . Contactor

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . . . . 060030-044* . . . . . . . Flatwasher DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

060030-044* . . . . . . . Flatwasher

(1)

AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

16 . . . . . . . . 140013. . . . . . . . . . . . Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . . . . 139670* . . . . . . . . . . . Bus Bar DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

139670* . . . . . . . . . . . Bus Bar

(1)

DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . . . . 141824* . . . . . . . . . . . Bus Bar

(1)

AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . . . . 060063-006 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

20 . . . . . . . . 060005-008 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

21 . . . . . . . . 060063-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . . . . 119976* . . . . . . . . . . . Insulator

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . . . . 139671. . . . . . . . . . . . Bus Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . . . . 139672* . . . . . . . . . . . Bus Bar DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . . . . 132083-003 . . . . . . . . Fuse 500 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

113279-021 . . . . . . . . Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

26 . . . . . . . . 132083-007 . . . . . . . . Fuse 150 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

113279-038 . . . . . . . . Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

27 . . . . . . . . 139649* . . . . . . . . . . . Fuse Cover

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

28 . . . . . . . . 060061-001 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

29 . . . . . . . . 079566-008* . . . . . . . Label FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

30 . . . . . . . . 079566-002* . . . . . . . Label FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . . . . 079566-001* . . . . . . . Label FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

AC Lift "EE" (Electrically Enclosed) Option

*




Crown 2007 PF15966-2 Rev. 12/07


04.2-2045-002

01 Rev. 12/07

543




04.3-2045-001

01 Rev. 2/08

544


Figure 16646-01

Crown 2007 PF15969-1 Rev. 2/08




1 . . . . . 128540 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 124960-001. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 128652 . . . . . . . . . . . 12 V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 094362-002 . . . . . . . . Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

094362-009* . . . . . . . Fuse Shorting Bar EE Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 062765-001 . . . . . . . . Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 050008-015. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 . . . . . 060005-007. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 065004-035. . . . . . . . Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 141231 . . . . . . . . . . . Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 109305-001. . . . . . . . Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 060086-002. . . . . . . . Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 060087 . . . . . . . . . . . Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 124960-002. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

14 . . . . . 141352-001* . . . . . . . Distribution Board 36 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

141352-002* . . . . . . . Distribution Board 48 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . . . . 062640-002* . . . . . . . Relay 36 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062640-003* . . . . . . . Relay 48 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . . . . 062711-001* . . . . . . . Relay 36 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062711-002* . . . . . . . Relay 48 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . . . . 094362-002 . . . . . . . . Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . . . . 094362-012 . . . . . . . . Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 140458* . . . . . . . . . . Fuse Enclosure EE Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 050004-015* . . . . . . . Screw EE Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

21 . . . . . 140273 . . . . . . . . . . . Temperature Management Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 061003-005. . . . . . . . Cable Tie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*




Crown 2007 PF15969-2 Rev. 2/08


04.3-2045-002

01 Rev. 2/08

545


Freezer Condition Distribution Board


04.3-2045-050

546

Figure 19021

Crown 2008 PF17142-1




1 . . . . . 113628-001 . . . . . . . . Freezer Condition Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 091362-002 . . . . . . . . Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 062496-003 . . . . . . . . Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 062339. . . . . . . . . . . . Relay Hold Down Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 060021-078 . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . . . . 060005-052 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . . . . 062337-006 . . . . . . . . Relay 36 V or 48 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 060012-064 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 050004-010. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Crown 2008 PF17142-2


04.3-2045-051

547


Contactor L & P

Contactor L & P

(a) Torque 13.4 - 14.6 Nm

(9.9 - 10.8 ft lb)

04.4-2045-001

01 Rev. 12/07

548

Figure 16650

Crown 2007 PF15972-1 Rev. 12/07


Contactor L & P


0 . . . . . 132084-003. . . . . . . . Contactor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 136748. . . . . . . . . . . . Fixed Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . . . . 136753. . . . . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 136750. . . . . . . . . . . . Cover With Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 144002. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 136749. . . . . . . . . . . . Moving Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 144003. . . . . . . . . . . . Frame & Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 136755. . . . . . . . . . . . End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

136751 . . . . . . . . . . . Top Cover Assembly Includes Index 3 & 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2007 PF15972-2 Rev. 12/07


04.4-2045-002

01 Rev. 12/07

549


Contactor L & P - “EE”


(a) Torque 13.4 - 14.6 Nm

(9.9 - 10.8 ft lb)

04.4-2045-025

01 Rev. 12/07

550

Figure 16658

Crown 2007 PF15973-1 Rev. 12/07





1 . . . . . . . . 136759. . . . . . . . . . . . Steel Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 136758. . . . . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 136757. . . . . . . . . . . . Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . 136753. . . . . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . . . . 136748. . . . . . . . . . . . Fixed Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . . . . 136760. . . . . . . . . . . . Arc Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . . . . 136750. . . . . . . . . . . . Top Cover With Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 136752. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 136749. . . . . . . . . . . . Moving Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 136756. . . . . . . . . . . . Coil & Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 136761. . . . . . . . . . . . End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

136751 . . . . . . . . . . . Top Cover Assembly Includes Index 7 & 9 . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2007 PF15973-2 Rev. 12/07


04.4-2045-026

01 Rev. 12/07

551




(a) Torque 13.4 - 14.6 Nm

(9.9 - 10.8 ft lb)

Model

FC 4500

Function

S

04.4-2045-050

552

Figure 17568

Crown 2007 PF17015-1





1 . . . . . . . . 105535. . . . . . . . . . . . Fixed Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . . . . 105536. . . . . . . . . . . . Moving Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 143424. . . . . . . . . . . . Frame and Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 143422. . . . . . . . . . . . Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 105537. . . . . . . . . . . . Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 105538. . . . . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2007 PF17015-2


04.4-2045-051

553


Steering Contactor “EE”


(a) Torque 13.4 - 14.6 Nm

(9.9 - 10.8 ft lb)

Model

FC 4500 EE

Function

S

04.4-2045-075

554

Figure 17569

Crown 2007 PF17018-1




0 . . . . . 140538-001. . . . . . . . "EE" Contactor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 120111 . . . . . . . . . . . . Upper Shroud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 136758. . . . . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 119126 . . . . . . . . . . . . Main Terminal Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . 105535. . . . . . . . . . . . Fixed Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . . . . 105536. . . . . . . . . . . . Moving Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 143431. . . . . . . . . . . . Frame and Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 143422. . . . . . . . . . . . Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 105537. . . . . . . . . . . . Top Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 143432. . . . . . . . . . . . Arc Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . . . . 105538. . . . . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2007 PF17018-2


04.4-2045-076

555




Freezer/Corrosion

04.5-1140-002

05 Rev. 3/08

556

Figure 16693

Crown 2001 PF13223-1 Rev. 3/08




1 . . . . . 129720 . . . . . . . . . . . Cam/Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 105802 . . . . . . . . . . . Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060037-008. . . . . . . . Eyelet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 122109 . . . . . . . . . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 074334-007. . . . . . . . Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 074334-006. . . . . . . . Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 062766 . . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 105801 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 060031-020. . . . . . . . Speed Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 060009-005. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 121990* . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

121991* . . . . . . . . . . Bracket Freezer/Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 122020* . . . . . . . . . . Heater Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 060065-007* . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

14 . . . . . 115666*. . . . . . . . . . . Harness Includes Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062033-007* . . . . . . . Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 050004-025* . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 115666*. . . . . . . . . . . Harness Includes Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062033-007* . . . . . . . Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 050004-025* . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

*




Crown 2001 PF13223-2 Rev. 3/08


04.5-1140-003

05 Rev. 3/08

557




04.5-2045-050

02 Rev. 11/08

558

(a)

(b)

See Electrical Parts for Accelerator

Torque 8 - 11 Nm (6 - 8 ft lb)

Figure 16700-01

Crown 2007 PF15759-1 Rev. 11/08




0 . . . . . 141986* . . . . . . . . . . FODC Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

141989* . . . . . . . . . . FODC Assembly Freezer / Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 143308. . . . . . . . . . . . Pedal Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 089362. . . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 060011-021 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 . . . . . . . . 060021-023 . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5 . . . . . . . . 129739. . . . . . . . . . . . Compression Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . . . . 129596. . . . . . . . . . . . Base Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 060014-076 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8 . . . . . . . . 060005-036 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

9 . . . . . . . . 060030-027 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

10 . . . . . . . . 060030-044 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

11 . . . . . . . . 129584. . . . . . . . . . . . Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 060062-003 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . . . . 050009-013 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . . . . 129581. . . . . . . . . . . . Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . . . . 050003-020 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . . . . 124894. . . . . . . . . . . . Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . . . . 050008-015 . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . . . . 124929-001 . . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

19 . . . . . 060038-005. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 124811 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

141601* . . . . . . . . . . Harness FODC (Includes Index 2, Harness is Included in Index 0) . . . . . . . 1

141624* . . . . . . . . . . Harness Assembly Freezer/Corrosion

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . 1

112863 . . . . . . . . . . . . FS Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

113429 . . . . . . . . . . . . RS Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

130583* . . . . . . . . . . Harness Assembly 36V Freezer /Corrosion Includes Resistors . . . . . . . . . . 1

062032-004 . . . . . . . . Resistor 3W 150 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

130584* . . . . . . . . . . Harness Assembly 48V Freezer/Corrosion Includes Resistors . . . . . . . . . . 1

062032-004 . . . . . . . . Resistor 3W 150 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(1)

Includes Index 2 & Silicon Heaters (Harness Included in Index 0)

*




Crown 2007 PF15759-2 Rev. 11/08


04.5-2045-051

02 Rev. 11/08

559


Accelerator

Accelerator

(a) See Electrical Parts for Foot

Operated Directional Control

(b) Power Unit Section

(c) Freezer / Corrosion

04.6-2045-001

01 Rev. 11/08

560

Figure 16739-01

Crown 2007 PF15977-1 Rev. 11/08


Accelerator


1 . . . . . 124477* . . . . . . . . . . Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060062-003. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 050009-013. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 128665 . . . . . . . . . . . Accelerator Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 124894 . . . . . . . . . . . Buffer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 050008-015. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 124811 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 060038-005. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 124929-001. . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 124322* . . . . . . . . . . Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129582* . . . . . . . . . . Lever, Foot Operated Direction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 124929-004. . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 124895 . . . . . . . . . . . Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 050012-030. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 124934 . . . . . . . . . . . Torsion Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 124929-002. . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 124373 . . . . . . . . . . . Accelerator Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 060063-015. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 060009-075. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 124470 . . . . . . . . . . . Cam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 062708 . . . . . . . . . . . Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 060061-001. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

22 . . . . . 140439 . . . . . . . . . . . Switch Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . 087373* . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062752-002* . . . . . . . Sealed Switch

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 803310* . . . . . . . . . . Switch Actuator

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . 093523 . . . . . . . . . . . Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

26 . . . . . 092143* . . . . . . . . . . Fastening Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

130717* . . . . . . . . . . Fastening Plate

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

27 . . . . . 060012-008* . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

050006-001* . . . . . . . Screw

(1)

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

(1)

Freezer / Corrosion

*




Crown 2007 PF15977-2 Rev. 11/08


04.6-2045-002

01 Rev. 11/08

561




Console Cover


04.8-2040-050

01 Rev. 7/07

562

Figure 16757

Crown 2001 PF13184-1 Rev. 7/07




1 . . . . . 060062-017. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 . . . . . 129185* . . . . . . . . . . Console Plug, Trucks Without Console Parking Brake Switch . . . . . . . . . . . 1

3 . . . . . 128752* . . . . . . . . . . Actuator Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 060011-020 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 129001 . . . . . . . . . . . Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 062752-005. . . . . . . . Sealed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 102471 . . . . . . . . . . . Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 060037-008. . . . . . . . Eyelet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


063002-020. . . . . . . . Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 129171 . . . . . . . . . . . Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2001 PF13184-2 Rev. 7/07


04.8-2040-051

01 Rev. 7/07

563




Left Tilt Cylinder Shown

04.8-2040-100

02 Rev. 7/07

564

(1) Left and Right Are Determined

From Operator’s Perspective

(2) Tilt Cylinder - See Cylinder Parts

Figure 16953

Crown 2001 PF13212-1 Rev. 7/07




1 . . . . . 060064-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 125504 . . . . . . . . . . . Switch Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 062752-005. . . . . . . . Sealed Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 128456 . . . . . . . . . . . Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 107703 . . . . . . . . . . . Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 060064-011* . . . . . . . Screw

( 1)

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

7 . . . . . 125504* . . . . . . . . . . Switch

(1)

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

8 . . . . . 062752-005* . . . . . . . Sealed Switch

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 050008-005* . . . . . . . Nut

(1)

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

10 . . . . . 050009-003* . . . . . . . Flatwasher

(1)

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

11 . . . . . 132995* . . . . . . . . . . Slot Bracket

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 060062-029* . . . . . . . Full Thread Screw

( 1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 050008-015* . . . . . . . Nut

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 060065-019. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 050009-003. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 132994* . . . . . . . . . . Slide Bracket

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 060065-006* . . . . . . . Bolt

(1)

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

18 . . . . . 133389* . . . . . . . . . . Retainer

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 124732 . . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 060038-013. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 127204* . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

132675* . . . . . . . . . . Bracket

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 050067-022. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

Tilt Position Assist Option

*




Crown 2001 PF13212-2 Rev. 7/07


04.8-2040-101

02 Rev. 7/07

565


Control Cable - TT


04.8-2045-250

566

(a) Extended Working Length - Index 3

(b) See Electrical Parts

(c) See Lifting Mechansim Parts

Figure 19780

Crown 2008 PF17319-1




1 . . . . . 119203-007 . . . . . . . . Control Cable Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 107204 . . . . . . . . . . . Cable Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 089544 . . . . . . . . . . . Extension Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 137749 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 060063-004. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 060063-038. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 060030-017. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 061002-026. . . . . . . . Harness Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 060063-082. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 073805-004. . . . . . . . Strain Relief Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 128839 . . . . . . . . . . . Bulkhead Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 112533 . . . . . . . . . . . Filter Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062007-005 . . . . . . . . Spade Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 060065-002. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

Refer to chart for Control Cable length

Index 1 – Control Cable Length

Truck

Capacity

1815 kg

(4000 lb),

2270 kg

(5000 lb),

2495kg

(5500 lb) mm

4775

5230

5485

5865

6250

6555

7010

7390

Lift Height in

188

206

216

Index 1

Control Cable

Length mm

7239 in

285

231

246

7747

8128

8636

9144

258 9525 375

276 10033 395

291 10414 410

305

320

340

360

Truck

Capacity

2720 kg

(6000 lb)

Lift Height mm

4570

5030

5285

5665

6045

6350 in

180

198

208

223

238

250

Index 1

Control Cable

Length mm

7239 in

285

7747

8128

8636

9144

9525

305

320

340

360

375

Crown 2008 PF17319-2


04.8-2045-251

567


Control Cable - TL


04.8-2045-300

568

(a) See Connectors

(b) Extend Working Length Index 4

(c) See Mast - TL

(d) See Fork Carriage - TL

(e) Rotated View

Figure 20633

Crown 2008 PF17512-1




1 . . . . . 127515-008

(1)

. . . . . Cable Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 089544 . . . . . . . . . . . Extension Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 107204 . . . . . . . . . . . Cable Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 142226 . . . . . . . . . . . Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 060063-023. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7 . . . . . 061002-026. . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 060063-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

Includes Connectors

Crown 2008 PF17512-2


04.8-2045-301

569


Connectors

Connectors

04.8-2045-500

570

(a)

(b)

(c)

(d)

(e)

(f)

Front

Rear

Female Terminal

Male Terminal

062706 Extraction Tool

062737-002 Crimping Tool

Figure 17220

Crown 2007 PF15989-1

Crown 2007 PF15989-2


Connectors

Connector Chart - Index 1

Designation

CA208

CA409

CA410

CA601

CA602

CA603

CA604

CA605

CA606

CA607

CA611

CA613

CA614

CA615

CA625

CA626

CA627

CA631

CA632

CA633

CA634

CA641

CA642

CA651

CA661

CA813

Numer of

Terminals

8

12

3

2

3

3

6

12

4

6

12

8

4

2

2

2

2

12

12

6

6

6

2

12

3

6

Kit Number

130197-008

130197-012

130197-006

130197-012

130197-004

131237-006

130197-012

130197-008

131237-004

131237-002

130197-003

130197-002

130197-002

130197-002

130197-003

130197-003

130197-002

130197-012

130197-012

130197-006

130197-006

130197-006

130197-002

130197-012

130197-003

130197-006

CA814 4 130197-004

Kits, Index 1, Include connector receptacle, plug, contacts, seals, inserts and instructions on how to use 062706 Extraction Tool, and

062737-002 Crimp Tool

04.8-2045-501

571


Connectors

04.8-2045-502

572

(a)

(b)

(c)

(d)

(e)

(f)

Front

Rear

Female Terminal

Male Terminal



Figure 17220

Crown 2007 PF15989-3


Connectors

Designation

PC404

PC612

CA636

PC630

PC807

PC808

PC809

PC810

PC811

PC812

PC201

PC202

PC203

PC204

PC205

PC206

PC207

PC402

2

2

2

2

3

3

-

5

5

4

2

5

2

2

2

2

2

2

Connector Chart - Index 2 Through 5

Index

5

7

-

3

7

35

35

3

Number of

Terminals

16

13

8

5

7

16

5

5

12

5

Connector

Part Number

062717-001

062717-005

062717-006

062717-013

062717-008

062717-004

062717-012

062720-002

062720-002

062728-001

-

062720-001

062717-004

062717-012

062717-004

062717-004

062379-010

062379-002

Terminal Seal Plug

-

-

-

-

-

-

-

-

-

-

-

-

-

062721-001 062822-001

062721-001 062822-001

062738-003 062730-001

062020-002 -

062721-002 062822-001

-

-

-

-

-

-

-

-

-

Crown 2007 PF15989-4 04.8-2045-503

573


Connectors

04.8-2045-504

574

(a)

(b)

(c)

(d)

(e)

(f)

Front

Rear

Female Terminal

Male Terminal



Figure 17220

Crown 2007 PF15989-5


Connectors

CA817

CA818

CA819

CA820

CA821

CA822

CA662

CA663

Connector

CA801

CA802

CA803

CA804

CA805

CA806

CA816

CA664

CA665

CA666

CA667

Connector Chart - Index 6

Female Terminal Male Terminal

062007-050 062007-063

062007-050

062007-050

062007-063

062007-063

062007-050

062007-050

062007-050

062007-050

062007-063

062007-063

062007-063

-

062007-076

062007-076

062007-050

062007-050

062007-050

062007-050

062007-095

062007-076

062007-076

062007-050

062007-050

062007-050

062007-063

062007-063

062007-063

062007-063

062007-063

062007-063

062007-064

062007-063

062007-063

062007-063

062007-063

062007-063

Crown 2007 PF15989-6 04.8-2045-505

575


Strobe Light

Strobe Light

04.9-1140-001

02 Rev. 1/07

576

Figure 8336-02

Crown 2002 PF11874-1 Rev. 1/07


Strobe Light


0 . . . . . 127651-001. . . . . . . . Strobe Light Amber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

0 . . . . . 127651-002. . . . . . . . Strobe Light Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

0 . . . . . 127651-003. . . . . . . . Strobe Light Blue (Does Not Include Index 3) . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . * . . . . . . . . . . . . . . . . Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 113615 . . . . . . . . . . . Strobe Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 113620 . . . . . . . . . . . Blackout Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 113614 . . . . . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 113611 . . . . . . . . . . . Amber Lens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

113612 . . . . . . . . . . . Blue Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

113613 . . . . . . . . . . . Red Lens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

* Strobe Light Replacement is More Economical

Crown 2002 PF11874-2 Rev. 1/07


04.9-1140-002

02 Rev. 1/07

577


Overhead Guard - Front Lights & Mirrors


04.9-2040-001

06 Rev. 2/08

578

Figure 19039

Crown 2001 PF13215-1 Rev. 2/08




1 . . . . . 128653 . . . . . . . . . . . 12 V Worklight Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

125672. . . . . . . . . . . . 12 V Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

135180. . . . . . . . . . . . Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 050008-021. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060030-119 . . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 107726 . . . . . . . . . . . Rubber Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5 . . . . . 050006-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 050008-021. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 128591-002. . . . . . . . Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 127627 . . . . . . . . . . . Light Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 060061-013. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

10 . . . . . 128362 . . . . . . . . . . . Upper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 050007-021. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 127697 . . . . . . . . . . . Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 060062-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

14 . . . . . 125018-001. . . . . . . . Cable Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 060063-015. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

16 . . . . . 086609 . . . . . . . . . . . Clip Trucks With Front Worklights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 111976 . . . . . . . . . . . Mirror & English Label Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

111481 . . . . . . . . . . . . Mirror Requires Convex Mirror Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 128417 . . . . . . . . . . . RH Mirror Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

128418 . . . . . . . . . . . LH Mirror Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 060021-006. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

20 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

21 . . . . . 060030-119 . . . . . . . . Flatwasher Trucks With Front Worklights & No Mirrors . . . . . . . . . . . . . . . . 1

Crown 2001 PF13215-2 Rev. 2/08


04.9-2040-002

06 Rev. 2/08

579


Overhead Guard - Rear Lights


(a) See Strobe Light

04.9-2040-050

05 Rev. 2/08

580

Figure 17212-02

Crown 2001 PF13218-1 Rev. 2/08




1 . . . . . 125318 . . . . . . . . . . . Taillight Assembly Includes Brake & Taillights. . . . . . . . . . . . . . . . . . . . . . . . 2

120717. . . . . . . . . . . . Small Red Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

120718. . . . . . . . . . . . Center Red Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

120719. . . . . . . . . . . . Clear Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

117993* . . . . . . . . . . . Bulb Backup (36V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

117994

*

. . . . . . . . . . . Bulb Backup (48V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 060061-004. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

060061-005. . . . . . . . Screw Trucks W/Strobe Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060030-044. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 060005-005. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5 . . . . . 060014-067. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . 127908 . . . . . . . . . . . Taillight Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 050025-010. . . . . . . . Carriage Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 061021-002. . . . . . . . Snap Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 127843 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 127910-001. . . . . . . . Taillight Cover Trucks W/Taillights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

127911 . . . . . . . . . . . Taillight Cover Trucks W/Taillights & Strobe Light . . . . . . . . . . . . . . . . . . . . . 1

127906 . . . . . . . . . . . Strobe Cover Trucks W/Strobe Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 060063-016. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 126768 . . . . . . . . . . . Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 060102-001. . . . . . . . U-Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 050008-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

15 . . . . . 050008-010. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 060013-025. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

17 . . . . . 121900 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 050006-051. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*




Crown 2001 PF13218-2 Rev. 2/08


04.9-2040-051

05 Rev. 2/08

581



04.9-2040-052

05 Rev. 2/08

582

Figure 17215-02

Crown 2001 PF13218-3 Rev. 2/08




30 . . . . . 128653 . . . . . . . . . . . Worklight Assembly 12 Volt

Includes Connector

. . . . . . . . . . . . . . . . . . . . . . . 1

125672. . . . . . . . . . . . Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . 128591-002. . . . . . . . Light Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

32 . . . . . 050008-021. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

33 . . . . . 050006-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . 050008-021. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

35 . . . . . 060030-119 . . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

36 . . . . . 060102-001. . . . . . . . U-Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

37 . . . . . 107726 . . . . . . . . . . . Rubber Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

38 . . . . . 050005-010. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

39 . . . . . 124017 . . . . . . . . . . . Rear Light Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

40 . . . . . 127627 . . . . . . . . . . . Bracket Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

41 . . . . . 060059-002. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

42 . . . . . 130540 . . . . . . . . . . . Angle Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

43 . . . . . 050006-024. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

44 . . . . . 050008-015. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

45 . . . . . 050005-028. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

46 . . . . . 060061-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2001 PF13218-4 Rev. 2/08


04.9-2040-053

05 Rev. 2/08

583


Drive Thru Overhead Guard - Front Lights & Mirrors


04.9-2040-100

04 Rev. 2/08

584

Figure 19053

Crown 2002 PF13233-1 Rev. 2/08




1 . . . . . 127363 . . . . . . . . . . . Mirror Bracket LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060021-006. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060063-015* . . . . . . . Screw With Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

050006-036* . . . . . . . Screw With Worklights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

050006-037* . . . . . . . Screw With Mirrors & Worklights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 . . . . . 111976 . . . . . . . . . . . Mirror & English Label Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

111481 . . . . . . . . . . . . Mirror Requires Convex Mirror Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 050008-021. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 065004-008. . . . . . . . Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 050008-021. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 061021-002. . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 060030-119 . . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 128851-002. . . . . . . . Light Bracket LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 107726 . . . . . . . . . . . Rubber Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 . . . . . 128852 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 050006-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 050006-038. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 128653 . . . . . . . . . . . 12 V Worklight Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

125672. . . . . . . . . . . . 12 V Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

135180. . . . . . . . . . . . Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 050008-021. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 125018-002. . . . . . . . Cable Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 128851-001. . . . . . . . Light Bracket RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 127364 . . . . . . . . . . . Mirror Bracket RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 060013-020. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

21 . . . . . 127488 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 104401-017. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

23 . . . . . 060021-006. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

24 . . . . . 129332 . . . . . . . . . . . Rectangular Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

25 . . . . . 124530 . . . . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2002 PF13233-2 Rev. 2/08


04.9-2040-101

04 Rev. 2/08

585


Drive Thru Overhead Guard Accessories - Rear


04.9-2040-150

02 Rev. 8/07

586

(1) Drive Thru Overhead Guard

With Tailights and Strobe

Light

(2) See Overhead Guard and Covers Section

(3) Part Of Drive Thru

Overhead Guard

(4) Left and Right Determined


(5) See Drive thru Overhead

Guard Accessories-Front

Section


With Only A Strobe Light

Figure 17224

Crown 2002 PF13327-1 Rev. 8/07




1 . . . . . 127651-001

*

. . . . . . . Strobe Light Assembly

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060061-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 050008-010. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 127501 . . . . . . . . . . . Bracket

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 050006-036. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 060030-017. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 050068-003 . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 090651-007. . . . . . . . Plug

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

090651-007. . . . . . . . Plug

(4)

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

090651-007. . . . . . . . Plug

(5)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

065004-008. . . . . . . . Grommet

(6)

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

065004-008. . . . . . . . Grommet

(5)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 125318 . . . . . . . . . . . LED Brake Light Assembly LGT5 (LH) and LGT6 (RH) . . . . . . . . . . . . . . . . 2

10 . . . . . 060014-067. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

11 . . . . . 060005-005. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

120717

(7)

. . . . . . . . . Small Red Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

120718

(7)

. . . . . . . . . Large Red Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

120719

(7)

. . . . . . . . . White Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

117993

(7)

. . . . . . . . . 36V Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

117994

(7)

. . . . . . . . . 48V Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 127398 . . . . . . . . . . . Taillight Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 050006-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 060030-017. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 126768 . . . . . . . . . . . Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 060013-025. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(1)

Includes Bulb and Lens – See Strobe Light Section

(2)

Equipped With Strobe Light Only

(3)

Without Strobe Light

(4)

Strobe or Rear Worklight Not Included

(5)

Strobe or Rear Worklight

(6)

Strobe and Rear Worklight

(7)

Quantities Listed for One Light Assembly

*




Crown 2002 PF13327-2 Rev. 8/07


04.9-2040-151

02 Rev. 8/07

587



04.9-2040-152

02 Rev. 8/07

588


With Tailights and Strobe Light

(2) See Overhead Guard and Covers Section

(3) Part Of Drive Thru

Overhead Guard

(4) Left and Right Determined


(5) See Drive Thru Overhead

Guard Accessories-Front

Section


With Only A Strobe Light

Figure 17239

Crown 2002 PF13327-3 Rev. 8/07




30 . . . . . 127568 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . 060102-001. . . . . . . . U-Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

32 . . . . . 065004-008. . . . . . . . Grommet

(8)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

090651-007. . . . . . . . Plug

(9)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062007-063. . . . . . . . Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

33 . . . . . 130541 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . 050006-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

35 . . . . . 050068-003. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

36 . . . . . 127627 . . . . . . . . . . . Bracket Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

37 . . . . . 050005-066. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

38 . . . . . 107726 . . . . . . . . . . . Rubber Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

39 . . . . . 060030-119 . . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

40 . . . . . 050008-060. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

41 . . . . . 128653 . . . . . . . . . . . 12V Worklight Assembly LGT3

(10)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

125672. . . . . . . . . . . . 12V Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

42 . . . . . 128591-002. . . . . . . . Light Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

43 . . . . . 050006-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

44 . . . . . 050008-021. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

45 . . . . . 060061-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

46 . . . . . 060059-002. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(8)

With Rear Worklight

(9)

Without Rear Worklight

(10)

Includes Bulb and Connector

Crown 2002 PF13327-4 Rev. 8/07


04.9-2040-153

02 Rev. 8/07

589


TL/TT Mast Mounted Work Lights


04.9-2045-075

01 Rev. 11/08

590

TT Outer Mast Shown

Figure 20188-01

Crown 2008 PF17439-1 Rev. 11/08




1 . . . . . 128653* . . . . . . . . . . Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

125672. . . . . . . . . . . . Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

135180. . . . . . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 128852 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 050006-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 050008-021. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 050006-038. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 107726 . . . . . . . . . . . Rubber Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 . . . . . 060030-119 . . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 050008-021 . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 144905-002. . . . . . . . Light Bracket RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 144905-001. . . . . . . . Light Bracket LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 050007-022. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 . . . . . 050009-018. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

13 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

14 . . . . . 125018-002. . . . . . . . Cable Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

061090-001. . . . . . . . Cable Tie (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

061003-004. . . . . . . . Cable Tie (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

061003-005. . . . . . . . Cable Tie Mount (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

*




Crown 2008 PF17439-2 Rev. 11/08


04.9-2045-076

01 Rev. 11/08

591


Quad Mast Mounted Work Lights


04.94-2040-200

03 Rev. 9/07

592

(1) Left and Right Determined from Operator’s Perspective

(2) Part of Outer Mast

Figure 17246-01

Crown 2004 PF13907-1 Rev. 9/07




1 . . . . . 130092 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060075-017. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060059-024. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 060063-002. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 060030-119 . . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 107726 . . . . . . . . . . . Rubber Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 . . . . . 060059-020. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 128852 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 050006-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 060059-020. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 128653 . . . . . . . . . . . 12V Work Light Assembly

(1)

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

125672. . . . . . . . . . . . 12V Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

135180. . . . . . . . . . . . Connector Assembly 12V Work Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 130094 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 060075-017. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 060059-024. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 125018-004. . . . . . . . Cable Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 061090-001. . . . . . . . Cable Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

17 . . . . . 061003-004. . . . . . . . Cable Tie

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(1)

Includes Bulb and Connector LGT1 (LH) and LGT2 (RH)

(2)

Not Shown

*




Crown 2004 PF13907-2 Rev. 9/07


04.94-2040-201

03 Rev. 9/07

593

Notes:

594

BRAKE PARTS

595

BRAKE PARTS

Brake Pedal

Brake Pedal

(a)

(b)

(c)

Part of Power Unit

Brake Valve Hydraulic Schematic

See Brake Maintenance for Shimming Procedure

05.0-2040-001

04 Rev. 2/08

596

Figure 17223-02

Crown 2001 PF13174-1 Rev. 2/08

BRAKE PARTS

Brake Pedal


1 . . . . . 128386 . . . . . . . . . . . Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

063002-024. . . . . . . . Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 065007-079. . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . . . . . 128391 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 050067-014. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 050068-002. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 129579 . . . . . . . . . . . Suppressor Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 050004-015. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 050008-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 128458 . . . . . . . . . . . Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 126489 . . . . . . . . . . . Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

104287. . . . . . . . . . . . Plug & Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062007-111 . . . . . . . . Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 060065-022. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 . . . . . 050008-005. . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

13 . . . . . 135068 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 135069 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 050006-037. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 050009-018. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 050068-003. . . . . . . . Flanged Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 076902-005. . . . . . . . Connecting Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 128390 . . . . . . . . . . . Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 065007-084. . . . . . . . Bearing Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

063002-024. . . . . . . . Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 060030-083. . . . . . . . Flatwasher 0.78 mm (0.031 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

22 . . . . . 060009-170. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . 128524 . . . . . . . . . . . Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 050067-024. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

25 . . . . . 050068-003. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

26 . . . . . 128396 . . . . . . . . . . . Brake Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

27 . . . . . 050025-010. . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

28 . . . . . 050009-026. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

29 . . . . . 050008-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

30 . . . . . 128437 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

31 . . . . . 050067-014. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

32 . . . . . 050068-002. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

33 . . . . . 132198-001. . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . 050006-036. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

35 . . . . . 050009-020. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

36 . . . . . 050068-003. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

37 . . . . . 062714 . . . . . . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062752-005. . . . . . . . Sealed Switch (Freezer/Corrosion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

38 . . . . . 093603 . . . . . . . . . . . Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

39 . . . . . 060060-002. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

40 . . . . . 050008-003. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

41 . . . . . 128534 . . . . . . . . . . . Arm Assembly Includes Bearing & Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

42 . . . . . 065007-084. . . . . . . . Bearing Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

43 . . . . . 129801 . . . . . . . . . . . Torsion Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2001 PF13174-2 Rev. 2/08


05.0-2040-002

04 Rev. 2/08

597

BRAKE PARTS

Power Service Brake


(a) Left and Right are Determined from Operator’s Perspective

(b) Mounts to Drive Unit - See Drive Unit Parts

(c) Torque to 45 - 55 Nm (35 - 40 ft lb)

(d) Torque to 17 - 23 Nm (150 - 200 in lb)

05.3-2045-050

598

Figure 20596

Crown 2008 PF17508-1

BRAKE PARTS



0 . . . . . 143709 . . . . . . . . . . . RH Brake Assembly - Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

143710 . . . . . . . . . . . LH Brake Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 130013. . . . . . . . . . . . Hardware Kit

(1)

- Includes Index 1, 2 & 3 . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 130013. . . . . . . . . . . . Hardware Kit

(1)

- Includes Index 1, 2 & 3 . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 130013. . . . . . . . . . . . Hardware Kit

(1)

- Includes Index 1, 2 & 3 . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 126323. . . . . . . . . . . . Outer Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 130012. . . . . . . . . . . . Lining & Rotor Kit

(1),

Includes Lining, Rotor & Oil Seal . . . . . . . . . . . . . . 1

6 . . . . . . . . 126324. . . . . . . . . . . . Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 126326. . . . . . . . . . . . Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

126431. . . . . . . . . . . . Piston Removal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 126319. . . . . . . . . . . . Seal & Wiper Kit - Includes Index 8 & 9, Supplies Both Brakes. . . . . . . . 1

9 . . . . . . . . 126319. . . . . . . . . . . . Seal & Wiper Kit - Includes Index 8 & 9, Supplies Both Brakes. . . . . . . . 1

10 . . . . . . . . 143293. . . . . . . . . . . . LH Rebuild Kit - Includes Index 7 Thru 11, Oil Seal & Gasket Eliminator 1

143292. . . . . . . . . . . . RH Rebuild Kit - Includes Index 7 Thru 11, Oil Seal &Gasket Eliminator 1

061004-030 . . . . . . . . Gasket Eliminator, 50 ml Tube – Used to Seal Axles

11 . . . . . . . . 126325. . . . . . . . . . . . Bleeder Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

Supplies Parts For Both Brakes

Note: When brake is assembled to truck, use hydraulic port closest to operator compartment and align with axle mount through hole.

Crown 2008 PF17508-2


05.3-2045-051

599

BRAKE PARTS

Parking Brake

Parking Brake

05.3-2045-100

600

Figure 17305

Crown 2007 PF15992-1

BRAKE PARTS

Parking Brake


1 . . . . . 060021-012. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 060030-039. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 106244 . . . . . . . . . . . Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


5 . . . . . 106273 . . . . . . . . . . . Brake Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 106113 . . . . . . . . . . . Brake Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 060016-003. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 060005-008. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 060030-242. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 111120. . . . . . . . . . . . Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 081859 . . . . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 073988-007. . . . . . . . Spacer 10 mm (0.427 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 127208 . . . . . . . . . . . Backing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 060016-003. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 . . . . . 060005-008. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

16 . . . . . 060038-017. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 060030-318. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 103160 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

19 . . . . . 128172 . . . . . . . . . . . Pivot Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 060021-012. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 128171 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . 060100-004. . . . . . . . Cotter Pin Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2007 PF15992-2


05.3-2045-101

601

Notes:

602

STEERING PARTS

603

STEERING PARTS

Steering Column - Part 1


(1) Replaces Steering

Column Directional Control on Trucks Equipped with Foot


(2) Only Available on International Trucks


(4) See Directional Control Section

(5) Freezer/Corrosion

(6) Part of Power Unit

(7) See Steering Column - Part 2 Section

(8) See Drive Unit Section

(9) Torque to 36 Nm (27 ft lb)

06.0-2040-001

02 Rev. 8/07

604

Figure 17257

Crown 2001 PF13211-1 Rev. 8/07

STEERING PARTS



1 . . . . . 129718 . . . . . . . . . . . Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060032-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 . . . . . 060030-045. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 . . . . . 121975 . . . . . . . . . . . Contact Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 050004-025. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 122041 . . . . . . . . . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

7 . . . . . 060032-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 121976 . . . . . . . . . . . Contact Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 060021-099. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

065005-003 . . . . . . . . Anti-Seize Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

10 . . . . . 124024 . . . . . . . . . . . Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 129719 . . . . . . . . . . . Release Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 050000-070. . . . . . . . Pin Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 125090-002. . . . . . . . Spring Locking Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 124504 . . . . . . . . . . . Head Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 060009-002. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 060061-010. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

17 . . . . . 108066

(1)

. . . . . . . . . Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

107151-002 . . . . . . . . Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

107763. . . . . . . . . . . . Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062623

(2)

. . . . . . . . . Keyless Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 050004-019. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


124924. . . . . . . . . . . . Mounting Bracket Keyless Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 050005-032. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 050008-030. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 050005-032. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

23 . . . . . 050005-068. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Includes Key and Ring

(2)

Not Shown

Crown 2001 PF13211-2 Rev. 8/07


06.0-2040-002

02 Rev. 8/07

605

STEERING PARTS


(1) Replaces Steering

Column Directional Control on Trucks Equipped with Foot


(2) Only Available on International Trucks


(4) See Directional Control Section

(5) Freezer/Corrosion

(6) Part of Power Unit

(7) See Steering Column - Part 2 Section

(8) See Drive Unit Section

(9) Torque to 36 Nm (27 ft lb)

06.0-2040-003

02 Rev. 8/07

606

Figure 17261

Crown 2001 PF13211-3 Rev. 8/07

STEERING PARTS



40 . . . . . 122357 . . . . . . . . . . . Knob

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

41 . . . . . 114279-001 . . . . . . . . Bearing Sleeve

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

42 . . . . . 060009-146. . . . . . . . Retaining Ring

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

43 . . . . . 060000-002. . . . . . . . Roll Pin

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

44 . . . . . 060009-133. . . . . . . . Retaining Ring

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

45 . . . . . 123680 . . . . . . . . . . . Shaft

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

46 . . . . . 060016-088. . . . . . . . Screw

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

47 . . . . . 124726 . . . . . . . . . . . Steering Wheel

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

48 . . . . . 060061-006* . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

49 . . . . . 129776* . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

50 . . . . . 062695* . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062783-002* . . . . . . . Thermostat Assembly

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

51 . . . . . 050004-025* . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

52 . . . . . 050004-021* . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

53 . . . . . 127484* . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

54 . . . . . 050008-004* . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

55 . . . . . 129256 . . . . . . . . . . . Wheel Puller

(3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

56 . . . . . 050007-022. . . . . . . . Bolt

(3)

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

(1)

Only Available on International Trucks

(2)

Includes Thermostat, Leads and Terminals

(3)

Not Shown

*




Crown 2001 PF13211-4 Rev. 8/07


06.0-2040-004

02 Rev. 8/07

607

STEERING PARTS



06.0-2040-025

07 Rev. 3/09

608

Figure 12115-02

Crown 2004 PF13922-1 Rev. 3/09

STEERING PARTS



0 . . . . . 140568 . . . . . . . . . . . Steer Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 060009-037 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 121978. . . . . . . . . . . . Brush Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 050004-019 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . 121970. . . . . . . . . . . . Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 050004-021 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . . . . 124670. . . . . . . . . . . . Contact Ring Red/White . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

124671. . . . . . . . . . . . Contact Ring Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

061000-020 . . . . . . . . Electrical Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

7 . . . . . . . . 127442. . . . . . . . . . . . Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . . . . 139962

(1)

. . . . . . . . . . Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 131024

(1)

. . . . . . . . . . Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 060000-035 . . . . . . . . Roll Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 121951. . . . . . . . . . . . Tilt Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Individual parts that make up these assemblies are not available as service parts.

Crown 2004 PF13922-2 Rev. 3/09


06.0-2040-026

07 Rev. 3/09

609

STEERING PARTS

Steering Axle

Steering Axle

06.0-2045-100

03 Rev. 12/08

610

(a) See Steering Parts

(b) Refer to Steering Maintenance for Torque Sequence

(c) See Hydraulic Parts and Cylinder Parts Sections

(d) Torque to 114 - 128 Nm (84 - 94 ft lb)

(e) Torque to 50 - 60 Nm (37 - 44 ft lb), rotate spindle three times through its full range of movement, loosen nut until free and torque to 130 - 140 Nm (96 - 103 ft lb)

Figure 17866-03

Crown 2007 PF17075-1 Rev. 12/08

STEERING PARTS

Steering Axle


0 . . . . . 141754-001* . . . . . . . Steer Axle Assembly

(1)

Includes Index 1-8, 9-24, 43-60 & 70 . . . . . . . . . . . 1

141754-002* . . . . . . . Steer Axle Assembly

(2)

Includes Index 1-8, 9-24, 43-60 & 70 . . . . . . . . . . . 1

1 . . . . . . . . 134589-002 . . . . . . . . Axle Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 134614. . . . . . . . . . . . Pin Assembly Includes Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . 2

134615 . . . . . . . . . . . Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

064332-001 . . . . . . . Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 140706-001 . . . . . . . . Steering Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

140567 . . . . . . . . . . . Steer Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

134612 . . . . . . . . . . . Spherical Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . 060106-004 . . . . . . . . Roll Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5 . . . . . . . . 134602. . . . . . . . . . . . Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 134605. . . . . . . . . . . . Nilos Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . . . . 134610. . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . . . . 134599. . . . . . . . . . . . Spindle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

134600 . . . . . . . . . . . Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

134609 . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


9 . . . . . . . . 060038-004 . . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 064211-002 . . . . . . . . Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 065108. . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 065107. . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 065105. . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . . . . 060051-002 . . . . . . . . Tabbed Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . . . . 060038-001 . . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . . . . 138097. . . . . . . . . . . . Axle Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . . . . 107629. . . . . . . . . . . . Special Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . . . . 065106. . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . . . . 060115-029 . . . . . . . . Screw M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

20 . . . . . . . . 135328. . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

21 . . . . . . . . 134608. . . . . . . . . . . . King Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . . . . 134603. . . . . . . . . . . . Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . . . . 134607. . . . . . . . . . . . Castle Nut M20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Trucks with 840 - 915 mm (33 - 36 in) Battery Compartment

(2)

Trucks with 685 mm (27 in) Battery Compartment

*




Crown 2007 PF17075-2 Rev. 12/08


06.0-2045-101

03 Rev. 12/08

611

STEERING PARTS

Steering Axle

06.0-2045-102

03 Rev. 12/08

612


(b) For Trucks with 840 mm (33 in) and 915 mm (36 in)

Battery Compartment - See Steer Unit Maintenance

(c) See Steering Parts

(d) See Steering Maintenance for Torque Sequence

(e) Torque to 200 - 220 Nm (147.5 - 162 ft lb)

(f) Torque to 50 - 60 Nm (37 - 44 ft lb), rotate spindle three times through its full range of movement, loosen nut until free and Torque to 130 - 140 Nm (96 - 103 ft lb)

Figure 17867-02

Crown 2007 PF17075-3 Rev. 12/08

STEERING PARTS

Steering Axle


40 . . . . . 060117-001 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

41 . . . . . 060089-008. . . . . . . . Wedge Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

42 . . . . . 792268 . . . . . . . . . . . Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

43 . . . . . . . . 060117-019 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

44 . . . . . . . . 126848. . . . . . . . . . . . Steer Axle Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

45 . . . . . . . . 061009-018 . . . . . . . . Square Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

46 . . . . . . . . 114571 . . . . . . . . . . . . Pivot Isolation Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

47 . . . . . . . . 126851. . . . . . . . . . . . Mounting Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

48 . . . . . . . . 050068-006 . . . . . . . . Duralock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

49 . . . . . . . . 060021-030 . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

50 . . . . . . . . 060005-012 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

51 . . . . . . . . 134603. . . . . . . . . . . . Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

52 . . . . . . . . 134608. . . . . . . . . . . . King Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

53 . . . . . . . . 134605. . . . . . . . . . . . Nilos Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

54 . . . . . . . . 134610. . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

55 . . . . . . . . 060106-004 . . . . . . . . Roll Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

56 . . . . . . . . 134599. . . . . . . . . . . . Spindle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

134600 . . . . . . . . . . . Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

134609 . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


57 . . . . . . . . 134602. . . . . . . . . . . . Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

58 . . . . . . . . 134614. . . . . . . . . . . . Pin Assembly Includes Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . 2

134615 . . . . . . . . . . . Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


59 . . . . . . . . 134607. . . . . . . . . . . . Castle Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

60 . . . . . . . . 060038-004 . . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

61 . . . . . 064211-002 . . . . . . . . Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

62 . . . . . 065108 . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

63 . . . . . 065107 . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

64 . . . . . 065105 . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

65 . . . . . 065106 . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

66 . . . . . 060051-002. . . . . . . . Tabbed Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

67 . . . . . 107629 . . . . . . . . . . . Special Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

68 . . . . . 060038-001. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

69 . . . . . 117442 . . . . . . . . . . . Axle Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

70 . . . . . . . . 140706-001 . . . . . . . . Steer Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

140567 . . . . . . . . . . . Steer Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

134612 . . . . . . . . . . . Spherical Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2007 PF17075-4 Rev. 12/08


06.0-2045-103

03 Rev. 12/08

613

STEERING PARTS

Steering And Service Brake Pump


06.1-2040-003

614

Figure 17306-01

Crown 2007 PF17071-1

STEERING PARTS



0 . . . . . 130921 . . . . . . . . . . . Pump (Doesn’t Include Items 1 and 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 087703. . . . . . . . . . . . Flexible Coupling (Includes Rubber Insert) . . . . . . . . . . . . . . . . . . . . . . . 1

087705 . . . . . . . . . . . Rubber Insert (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 060016-003 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . . . . . . . . 094558. . . . . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 130963. . . . . . . . . . . . Unloading Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

. . . . . . . . . . . . . . . . Unloading Valve Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 126327. . . . . . . . . . . . Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

. . . . . . . . . . . . . . . . Check Valve Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 072021. . . . . . . . . . . . Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 093962. . . . . . . . . . . . Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 127426. . . . . . . . . . . . Plunger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 087126. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 127425. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 127424. . . . . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 072012. . . . . . . . . . . . Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 072011 . . . . . . . . . . . . Hex Cap Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

More economical to replace valve.

Note: When internal pump components require replacement, Crown recommends pump replacement.

Crown 2007 PF17071-2


06.1-2040-004

615

STEERING PARTS



06.2-1140-001

03 Rev. 4/08

616

Figure 19553

Crown 2000 PF11790-1 Rev. 4/08

STEERING PARTS



0 . . . . . 120706 . . . . . . . . . . . Power Steering Motor (36V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 126180. . . . . . . . . . . . Drive Endhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 116705 . . . . . . . . . . . . Bearing Drive Endhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 126181. . . . . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . . . . . . . . . . . . . . . . . . . Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 126183. . . . . . . . . . . . Field Coil Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 126182. . . . . . . . . . . . Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 125020. . . . . . . . . . . . Brush Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 126185. . . . . . . . . . . . Brush Box and Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 126184. . . . . . . . . . . . Spring Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

10 . . . . . . . . 116705 . . . . . . . . . . . . Bearing Commutator Endhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 116706 . . . . . . . . . . . . Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 126188. . . . . . . . . . . . Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

13 . . . . . . . . 126187. . . . . . . . . . . . Commutator Endhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

126186. . . . . . . . . . . . Lead Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . . . . . . . . . . . . . . . . . . . . . . Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 145045 . . . . . . . . . . . Band Kit EE Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2000 PF11790-2 Rev. 4/08


06.2-1140-002

03 Rev. 4/08

617

STEERING PARTS

Steer Unit

Steer Unit

06.3-1145-001

01 Rev. 8/07

618

Figure 17325

Crown 2006 PF15495-1 Rev. 8/07

STEERING PARTS

Steer Unit


0 . . . . . 138296 . . . . . . . . . . . Steer Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 140268. . . . . . . . . . . . Dust Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 140269. . . . . . . . . . . . Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 140270. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 140271. . . . . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . . . . 140272. . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

140267 . . . . . . . . . . . Seal Kit Includes Index 1 - 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Note: When non-serviceable components require replacement, Crown recommends steer unit assembly replacement.

Crown 2006 PF15495-2 Rev. 8/07


06.3-1145-002

01 Rev. 8/07

619

STEERING PARTS

Steer Tire

Steer Tire

06.4-2040-001

04 Rev. 10/08

620

Figure 17308-01

Crown 2001 PF13153-1 Rev. 10/08

STEERING PARTS

Steer Tire

NUMBER REQUIRED INDEX PART NUMBER PART NAME

0

. . . . . . (1)

. . . . . . . . . . . . . . . Tire Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1

. . . . . . . . . (1)

. . . . . . . . . . . . . . . . Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2

. . . . . . . . . (1)

. . . . . . . . . . . . . . . . Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 065105. . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 065107. . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 065106 . . . . . . . . . . . Bearing Cone (Refer to Steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 065108 . . . . . . . . . . . Bearing Cone (Refer to Steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 117442 . . . . . . . . . . . Axle Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Quantities Listed are for 1 Steer Tire

(1)

See Chart 1

Index 0

Tire Assembly

Index 1

Tire

Index 2

Hub

136163-301-52 136162-301-42 117444

136163-311-52

136163-311-51

136163-301-51

137215-301-52

137215-311-52

137215-311-51

137215-301-51

136162-311-42

136162-311-41

136162-301-41

135906-301-42

135906-311-42

135906-311-41

135906-301-41

Chart 1 - Steer Tire Assembly

117444

117444

117444

117444

117444

117444

117444

Tire Size Compound Tread

Truck

Capacity

405 x 150 x 265 mm

(16 x 6 x 10.5 in)

405 x 150 x 265 mm

(16 x 6 x 10.5 in)

405 x 150 x 265 mm

(16 x 6 x 10.5 in)

405 x 150 x 265 mm

(16 x 6 x 10.5 in)

105 x 180 x 265 mm

(16 x 7 x 10.5 in)

105 x 180 x 265 mm

(16 x 7 x 10.5 in)

105 x 180 x 265 mm

(16 x 7 x 10.5 in)

105 x 180 x 265 mm

(16 x 7 x 10.5 in)

Black Rubber Lugged

Gray Rubber

Gray Rubber

Lugged

Smooth

Black Rubber Smooth

Black Rubber Lugged

Gray Rubber

Gray Rubber

Lugged

Smooth

Black Rubber Smooth

1815 kg,

2270 kg

(4000 lb,

5000 lb)

2495 kg,

2720 kg

(5500lb,

6000 lb)

Crown 2001 PF13153-2 Rev. 10/08


06.4-2040-001

04 Rev. 10/08

621

Notes:

622

LIFTING MECHANISM PARTS

623

LIFTING MECHANISM PARTS

TL Mast Accessories


2

Accessories

1

Accessory

2nd Stage

Mast

07.1-2040-100

01 Rev. 8/07

624

Figure 17213

Crown 2001 PF13276-1 Rev. 8/07




1 . . . . . 074674 . . . . . . . . . . . Pulley Control Cable includes Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 103348-003. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 060019-054. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . 060059-012. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 060030-067. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . 105939 . . . . . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

7 . . . . . 129263-002* . . . . . . . Shaft, Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 129263-001* . . . . . . . Shaft, One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 060009 . . . . . . . . . . . Ring Retaining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

*




Crown 2001 PF13276-2 Rev. 8/07


07.1-2040-101

01 Rev. 8/07

625


Mast - TL

Mast - TL

Outer Mast

(a) See Mast Cylinder - TL

(b) See Lift Chain - TL

(c) Torque 71 - 80 Nm

(52 - 59 ft lb)

07.1-2045-001

01 Rev. 6/09

626

Figure 20573-01

Crown 2008 PF17490-1 Rev. 6/09


Mast - TL


1 . . . . . *

(1)

. . . . . . . . . . . . . . . Outer Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 064332-001. . . . . . . . Lube Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060030-085. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

4 . . . . . 074668-001. . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 060121-001. . . . . . . . Clevis Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 060038-003. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 . . . . . 060122-001. . . . . . . . Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 128509 . . . . . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

9 . . . . . 064019-049. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

10 . . . . . 128508 . . . . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 064332-002. . . . . . . . 90° Lube Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 060030-187. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

13 . . . . . 060115-004 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

14 . . . . . 131854-190. . . . . . . . Chain Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 060059-022. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 060059-025. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 042906 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 060000-055. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(1)

See Chart 1

*




Truck

Capacity*

1815 kg

(4000 lb),

2270 kg

(5000 lb), or

2495 kg

(5500 lb)

Lift Height* mm

3200

3505

3810 in

126

138

150

Chart 1 – Outer Mast Index 1

Index 1

Outer Mast

Truck

Capacity*

Lift Height*

141479-211-52

141479-226-52

2720 kg

(6000 lb)

141479-241-52 mm

2995

3300

3605 in

118

130

142

Index 1

Outer Mast

141479-211-62

141479-226-62

141479-241-62

Crown 2008 PF17490-2 Rev. 6/09


07.1-2045-002

01 Rev. 6/09

627


Mast - TL

Outer Mast

(a) Wire Harness See Electrical Diagrams

(b) Torque to 170 - 190 Nm (125 - 140 ft lb)

07.1-2045-003

01 Rev. 6/09

628

Figure 20574

Crown 2008 PF17490-3 Rev. 6/09


Mast - TL


30 . . . . . 129252 . . . . . . . . . . . Stop Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

31 . . . . . 074481-001. . . . . . . . Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

32 . . . . . 107563-001. . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

33 . . . . . 092747-001. . . . . . . . Poly Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

34 . . . . . 060062-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


35 . . . . . 060117-005 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


36 . . . . . 060061-013. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

37 . . . . . 060061-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

38 . . . . . 062749-001. . . . . . . . Attachment Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

39 . . . . . 144023 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

40 . . . . . 144024 . . . . . . . . . . . Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

41 . . . . . 060030-217. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

42 . . . . . 062874 . . . . . . . . . . . Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

43 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

44 . . . . . 061002-026. . . . . . . . Harness Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

45 . . . . . 060063-030. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

46 . . . . . 060030-052. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

061003-005

(1)

. . . . . . Tie Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Not Shown

Crown 2008 PF17490-4 Rev. 6/09


07.1-2045-004

01 Rev. 6/09

629


Mast - TL

Inner Mast

(a) See Mast Cylinder - TL

07.1-2045-005

01 Rev. 6/09

630

Figure 20575

Crown 2008 PF17490-5 Rev. 6/09


Mast - TL


60 . . . . . *

(1)

. . . . . . . . . . . . . . . Inner Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

61 . . . . . 060106-007. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

62 . . . . . 103284-001. . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

63 . . . . . 060030-231. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

64 . . . . . 124223-001. . . . . . . . Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

65 . . . . . . . . 124224-001 . . . . . . . . Chain Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

66 . . . . . . . . 065081-045 . . . . . . . . Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

67 . . . . . . . . 060009-062 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

68 . . . . . 060009-043. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

See Chart 2

*




Chart 2 – Inner Mast Index 60

Lift Height* mm in

2995

3200

118

126

3300

3505

3605

3810

130

138

142

150

Index 60

Inner Mast

143811-211

143811-226

143811-241

Crown 2008 PF17490-6 Rev. 6/09


07.1-2045-006

01 Rev. 6/09

631


Mast - TL

Inner Mast

(a) Two Accessories Shown

(b) With 5th Function

07.1-2045-007

01 Rev. 6/09

632

Figure 20576

Crown 2008 PF17490-7 Rev. 6/09


Mast - TL


85 . . . . . 060059-012. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

86 . . . . . 129263-001. . . . . . . . Shaft

(1)

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

129263-002. . . . . . . . Shaft

(2)

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

87 . . . . . 060030-168. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

88 . . . . . 105939 . . . . . . . . . . . Pulley

(1)

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

105939 . . . . . . . . . . . Pulley

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

89 . . . . . 060030-067. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

90 . . . . . 060009-005. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

91 . . . . . 060030-255. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

92 . . . . . 103418-032. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

93 . . . . . 074674 . . . . . . . . . . . Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

94 . . . . . 074675 . . . . . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

95 . . . . . 065081-036. . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

96 . . . . . 060115-033 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Truck With One Accessory

(2)

Truck With Two Accessories

Crown 2008 PF17490-8 Rev. 6/09


07.1-2045-008

01 Rev. 6/09

633


Mast - TL

Inner Mast

07.1-2045-009

01 Rev. 6/09

634

(a) See Lift Chain - TL

(b) See Fork Carriage - TL

Figure 20577

Crown 2008 PF17490-9 Rev. 6/09


Mast - TL


115 . . . . 060030-085. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

116 . . . . 074668-001. . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

117 . . . . 131854-150. . . . . . . . Chain Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

118 . . . . 060059-022. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


119 . . . . 060038-003. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

120 . . . . 042906 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

121 . . . . 060000-055. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Crown 2008 PF17490-10 Rev. 6/09


07.1-2045-010

01 Rev. 6/09

635


TT Mast Accessories


07.2-2040-100

03 Rev. 6/09

636

(a)

(b)

(c)

(d)

One Accessory

Two Accessories

Second Stage Mast

Third Stage Mast

Figure 17216-01

Crown 2001 PF13240-1 Rev. 6/09




1 . . . . . 128489 . . . . . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 . . . . . 128488-001. . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 060009-038. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 128485 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 060063-006. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


6 . . . . . 060059 . . . . . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 060030-067. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 105939 . . . . . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

9 . . . . . 129263-002* . . . . . . . Shaft Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 060009-005. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 129263-001* . . . . . . . Shaft One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 129231 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

13 . . . . . 060063-004. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

14 . . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

15 . . . . . 129564-002. . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 060063-015. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 060030-052. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 128488-002. . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 060009-038. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

20 . . . . . 060063-016. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

21 . . . . . 060030-052. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 060059 . . . . . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

23 . . . . . 074674 . . . . . . . . . . . Pulley Control Cable Includes Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . . . . 065081-036 . . . . . . . . Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

25 . . . . . 103348 . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

26 . . . . . 060019-054. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*




Crown 2001 PF13240-2 Rev. 6/09


07.2-2040-101

03 Rev. 6/09

637


Mast - TT

Mast - TT

Outer Mast

(a) See Tilt Cylinder - TT

(b) See Mast Cylinder - TT

(c) See Lift Chain - TT

(d) Part of Power Unit

(e) Torque 71 - 80 Nm (52.4 - 59 ft lb)

07.2-2045-001

01 Rev. 8/09

638

Figure 19661

Crown 2008 PF17297-1 Rev. 8/09


Mast - TT

INDEX PART NUMBER DESCRIPTION QUANTITY

1 . . . . . *

(1)

. . . . . . . . . . . . . . . Outer Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 064332-001. . . . . . . . Lube Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060030-085. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

4 . . . . . 074668-001. . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 060121-001. . . . . . . . Clevis Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 060038-003. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 . . . . . 060122-001. . . . . . . . Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 128509 . . . . . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

9 . . . . . 064019-049. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

10 . . . . . 128508 . . . . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 064332-002. . . . . . . . 90° Lube Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 060030-187. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

13 . . . . . 060115-004 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

14 . . . . . 131854-190. . . . . . . . Chain Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 060059-022. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 060059-025. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 042906 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 060000-055. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

19 . . . . . 065012-002. . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

20 . . . . . 141665 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

21 . . . . . 060009-037. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(1)

See Chart 1

Truck

Capacity*

Lift Height*

1815 kg

(4000 lb),

2270 kg

(5000 lb), or

2495kg

(5500 lb) mm

4775

5230

5485

5865

6250

6555

7010

7390

231

246

258

276

291 in

188

206

216

Chart 1 – Outer Mast Index 1

Index 1

Outer Mast

Truck

Capacity*

Lift Height*

141479-211-53

141479-226-53

141479-241-53

141479-256-53

141479-272-53

141479-287-53

141479-302-53

141479-317-53

2720 kg

(6000 lb) mm

4572

5030

5285

5665

6045

6350 in

180

198

208

223

238

250

Index 1

Outer Mast

141479-211-63

141479-226-63

141479-241-63

141479-256-63

141479-272-63

141479-287-63

*


Crown 2008 PF17297-2 Rev. 8/09


07.2-2045-002

01 Rev. 8/09

639


Mast - TT

Outer Mast

07.2-2045-003

01 Rev. 8/09

640

(a) Wire Harness See Electrical Diagrams

Figure 19918

Crown 2008 PF17297-3 Rev. 8/09


Mast - TT


30 . . . . . 129252 . . . . . . . . . . . Stop Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

31 . . . . . 074481-001. . . . . . . . Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

32 . . . . . 107563-001. . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

33 . . . . . 092747-001. . . . . . . . Poly Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

34 . . . . . 060062-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


35 . . . . . 060117-005 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


36 . . . . . 062749-001. . . . . . . . Attachment Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

37 . . . . . 060061-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

38 . . . . . 062874 . . . . . . . . . . . Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

39 . . . . . 060030-217. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

40 . . . . . 061002-026. . . . . . . . Harness Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

41 . . . . . 060030-052. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

42 . . . . . 060063-083. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Crown 2008 PF17297-4 Rev. 8/09


07.2-2045-004

01 Rev. 8/09

641


Mast - TT

Intermediate Mast

07.2-2045-005

01 Rev. 8/09

642

(a) See Mast Cylinder - TT

Figure 16485-01

Crown 2008 PF17297-5 Rev. 8/09


Mast - TT


50 . . . . . *

(1)

. . . . . . . . . . . . . . . Intermediate Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

51 . . . . . 060030-085. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

52 . . . . . 103284-001. . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

53 . . . . . 074668-001. . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

54 . . . . . 127874-002. . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

55 . . . . . 060030-332. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

56 . . . . . 121623 . . . . . . . . . . . Hose Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

57 . . . . . 060115-001 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

58 . . . . . 124223-001. . . . . . . . Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

59 . . . . . . . . 124224-001 . . . . . . . . Chain Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

60 . . . . . . . . 065081-045 . . . . . . . . Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

61 . . . . . . . . 060009-062 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

62 . . . . . 060009-043. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

63 . . . . . 060106-007. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

64 . . . . . 060030-085. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

(1)

See Chart 2

Lift Height* mm in

4775

5233

188

206

5486

5868

216

231

Chart 2 – Intermediate Mast Index 50

Index 50

Intermediate Mast

141528-211

141528-226

141528-241

141528-256

Lift Height* mm in

6249

6553

246

258

7010

7390

276

291

Index 50

Intermediate Mast

141528-272

141528-287

141528-302

141528-317

*


Crown 2008 PF17297-6 Rev. 8/09


07.2-2045-006

01 Rev. 8/09

643


Mast - TT

Intermediate Mast

07.2-2045-007

01 Rev. 8/09

644

(a) With 5th Function

Figure 19159

Crown 2008 PF17297-7 Rev. 8/09


Mast - TT


75 . . . . . 060059-012. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

76 . . . . . 129263-001. . . . . . . . Shaft

(1)

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

129263-002. . . . . . . . Shaft

(2)

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

77 . . . . . 060030-168. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

78 . . . . . 105939 . . . . . . . . . . . Pulley

(1)

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

105939 . . . . . . . . . . . Pulley

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

79 . . . . . 060030-067. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

80 . . . . . 060009-005. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

81 . . . . . 128485 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

82 . . . . . 060063-006. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


83 . . . . . 128489 . . . . . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84 . . . . . 128488-001. . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

85 . . . . . 060009-038. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

86 . . . . . 060030-255. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

87 . . . . . 103418-032. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

88 . . . . . 074674 . . . . . . . . . . . Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

89 . . . . . . . . 074675. . . . . . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

90 . . . . . . . . 065081-036 . . . . . . . . Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

91 . . . . . 060115-033 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

1 Accessory

(2)

2 Accessories

Crown 2008 PF17297-8 Rev. 8/09


07.2-2045-008

01 Rev. 8/09

645


Mast - TT

Inner Mast

(a) See Lift Chain - TT

(b) See Yoke - TT

(c) See Carriage Cylinder - TT

07.2-2045-009

01 Rev. 8/09

646

Figure 19662

Crown 2008 PF17297-9 Rev. 8/09


Mast - TT


100 . . . . *

(1)

. . . . . . . . . . . . . . . Inner Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

101 . . . . 060030-085. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

102 . . . . 074668-001. . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

103 . . . . 131854-150. . . . . . . . Chain Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

104 . . . . 060059-022. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


105 . . . . 060038-003. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

106 . . . . 042906 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

107 . . . . 060000-055. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

108 . . . . 137750 . . . . . . . . . . . U-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

109 . . . . 060059-010. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

110 . . . . 131857-230. . . . . . . . Chain Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

111 . . . . 060059-023. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

112 . . . . 113303 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

113 . . . . 060000-045. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

114 . . . . 136360 . . . . . . . . . . . Hose Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

See Chart 3

Lift Height* mm in

4775

5233

188

206

5486

5868

216

231

Chart 3 – Inner Mast Index 100

Index 100

Inner Mast

142103-211

142103-226

142103-241

142103-256

Lift Height* mm in

6249

6553

246

258

7010

7390

276

291

*


Index 100

Inner Mast

142103-272

142103-287

142103-302

142103-317

Crown 2008 PF17297-10 Rev. 8/09


07.2-2045-010

01 Rev. 8/09

647


Quad Mast

Quad Mast

07.24-2040-001

09 Rev. 7/09

648

(a)

(b)

(c)

(d)

Mounted to Power Unit

See Cylinder Parts


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

Figure 17218-03

Crown 2004 PF13860-1 Rev. 7/09


Quad Mast


1 . . . . . 076470-025 . . . . . . . Clevis Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 060030-191. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060038-017. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 060009-036. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 060000-045. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . 131857-195. . . . . . . . Chain Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 113303 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 131664-002. . . . . . . . Wear Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 131964 . . . . . . . . . . . Wear Block Shim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

10 . . . . . 131787-100. . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

11 . . . . . 060030-231. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

12 . . . . . 060059-023. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

13 . . . . . 060059-026. . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

14 . . . . . 060038-003. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 . . . . . 127311 . . . . . . . . . . . Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 060030-217. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 060061-006. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


18 . . . . . 062749-001. . . . . . . . Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 060061-008. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

20 . . . . . 064332-002. . . . . . . . Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

21 . . . . . 065012-002. . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

22 . . . . . 129480 . . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

23 . . . . . 129481 . . . . . . . . . . . Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 060063-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

25 . . . . . 060089-005. . . . . . . . Wedge Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


27 . . . . . 128508 . . . . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

28 . . . . . 060115-004 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

29 . . . . . 060030-187. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

30 . . . . . 064019-049. . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


31 . . . . . 128509 . . . . . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

32 . . . . . 060122-001. . . . . . . . Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

33 . . . . . 129252 . . . . . . . . . . . Mast Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

34 . . . . . 107563-001. . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2004 PF13860-2 Rev. 7/09


07.24-2040-002

09 Rev. 7/09

649

3


Quad Mast

07.24-2040-003

09 Rev. 7/09

650

(a) See Lifting Mechanism Parts

Figure 17392-03

Crown 2004 PF13860-3 Rev. 7/09


Quad Mast


45 . . . . . 092747-001. . . . . . . . Poly Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

46 . . . . . 074481-001. . . . . . . . Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

47 . . . . . 060062-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


48 . . . . . 060117-005 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


49 . . . . .

(1)

. . . . . . . . . . . . . . . Outer Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

50 . . . . . 131667-003. . . . . . . . Chain Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

51 . . . . . . . . 131668-003 . . . . . . . . Chain Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

52 . . . . . . . . 065081-045 . . . . . . . . Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

53 . . . . . . . . 060009-062 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

54 . . . . . 060009-043. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

55 . . . . . 131663 . . . . . . . . . . . Wear Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


57 . . . . .

(1)

. . . . . . . . . . . . . . . Second Stage Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

58 . . . . . 060117-004 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

59 . . . . . 123400 . . . . . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

60 . . . . . 060030-342. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

61 . . . . . 131854-150. . . . . . . . Chain Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

62 . . . . . 042906 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

63 . . . . . 060000-055. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

64 . . . . . 060059-022. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

65 . . . . . 060059-025. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

Contact Factory

Crown 2004 PF13860-4 Rev. 7/09


07.24-2040-004

09 Rev. 7/09

651


Quad Mast

07.24-2040-005

09 Rev. 7/09

652

(a)

(b)


See Cylinder Parts

Figure 17219-02

Crown 2004 PF13860-5 Rev. 7/09


Quad Mast


70 . . . . . 131668-001. . . . . . . . Chain Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

71 . . . . . 065081-045. . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

72 . . . . . 060009-062. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

73 . . . . . 131667-001. . . . . . . . Chain Pulley Assembly Includes Pulley, Bearing and Retaining Rings. . . . . 2

74 . . . . . 060030-342. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

75 . . . . . 131922-002. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

76 . . . . . 131670 . . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

77 . . . . . 131922.001 . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

78 . . . . . 131666-001. . . . . . . . Hose Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

79 . . . . . 060009-130. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

80 . . . . . 131663 . . . . . . . . . . . Wear Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


82 . . . . . 131787-100. . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

83 . . . . . 060030-231. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

84 . . . . .

(1)

. . . . . . . . . . . . . . . Third Stage Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

85 . . . . . 131665* . . . . . . . . . . Shaft One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

86 . . . . . 131665* . . . . . . . . . . Shaft Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

061004-019* . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

87 . . . . . 060030-067* . . . . . . . Flatwasher Shaft One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

88 . . . . . 060030-067* . . . . . . . Flatwasher Shaft Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

89 . . . . . 131671-001* . . . . . . . Hose Pulley Shaft One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

90 . . . . . 131671-001* . . . . . . . Hose Pulley Shaft Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

91 . . . . . 060009-005* . . . . . . . Retaining Ring Shaft One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

92 . . . . . 060009-005* . . . . . . . Retaining Ring Shaft Two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

93 . . . . . 060000-055. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

94 . . . . . 131854-150. . . . . . . . Chain Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

95 . . . . . 042906 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

96 . . . . . 060059-022. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

97 . . . . . 060059-025. . . . . . . . Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

98 . . . . . 060038-003. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

99 . . . . . 131659 . . . . . . . . . . . Hose Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

100 . . . . 060063-023. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

101 . . . . 060059-001. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

102 . . . . 137750-002. . . . . . . . U-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

103 . . . . 060059-010. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

104 . . . . 060106-003. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

105 . . . . 060117-003 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

Contact Factory

*




Crown 2004 PF13860-6 Rev. 7/09


07.24-2040-006

09 Rev. 7/09

653

2


Quad Mast

(a)

(b)


See Cylinder Parts

07.24-2040-007

09 Rev. 7/09

654

Figure 17393-02

Crown 2004 PF13860-7 Rev. 7/09


Quad Mast


116 . . . .

(1)

. . . . . . . . . . . . . . . Inner Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

117 . . . . 131805 . . . . . . . . . . . Accessory Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

118 . . . . 050000-039. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

119 . . . . 132086 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

120 . . . . 060063-029. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

121 . . . . 131854-100. . . . . . . . Chain Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

122 . . . . 042906 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

123 . . . . 131857-195. . . . . . . . Chain Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

124 . . . . 113303 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

125 . . . . 060059-023. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

126 . . . . 060059-026. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

127 . . . . 060000-045. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

Contact Factory

Crown 2004 PF13860-8 Rev. 7/09


07.24-2040-008

09 Rev. 7/09

655


Fork Carriage - TL


(a) 145048-038 Shown

(b) See Lift Chain - TL

07.3-2045-003

656

Figure 20692

Crown 2008 PF17529-1




1

. . . . . . (1)

. . . . . . . . . . . . . . . Fork Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060063-006. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 129261 . . . . . . . . . . . Cam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 074020 . . . . . . . . . . . Side Thrust Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 060009-036. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 060117-003 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 060122-001. . . . . . . . Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 060030-085. . . . . . . . Flatwasher 0.8 mm (0.031 in) thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

9 . . . . . 074668-001. . . . . . . . Roller Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

10 . . . . . 060009-018. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

See Chart

Truck

Capacity*

1815 kg (4000 lb)

2270 kg (5000 lb)

2495 kg (5500 lb)

2720 kg (6000 lb)


Carriage Width mm in

965

38

1120

44

965

1120

38

44

Index 1

Fork Carriage

145048-038

145048-044

145058-038

145058-044

*




Crown 2008 PF17529-2


07.3-2045-004

657


Fork Carriage - TT


See Lift Chain - TT Mast

07.3-2045-025

658

Figure 19664

Crown 2008 PF17320-1




1 . . . . . *

(1)

. . . . . . . . . . . . . . . Fork Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060030-085. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

3 . . . . . 074668-001. . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 . . . . . 124018 . . . . . . . . . . . Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 060017-050. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


6 . . . . . 131857-135. . . . . . . . Chain Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 113303 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 060000-045. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 060122-001. . . . . . . . Dowel Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 129261 . . . . . . . . . . . Cam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 060117-003 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 074020 . . . . . . . . . . . Side Thrust Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 060009-036. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(1)

See Chart


Truck

Capacity*

1815 kg (4000 lb)

2270 kg (5000 lb)

2495 kg (5500 lb)

Carriage Width

mm in

965

38

Index 1

Fork Carriage

137860-038

1118

44 137860-044

965

38 137864-038

2720 kg (6000 lb)

1118

44 137864-044

*


Crown 2008 PF17320-2


07.3-2045-026

659


Fork Carriage - Quad


07.34-2045-050

660

Figure 21438

Crown 2009 PF17628-1




1 . . . . . *

(1)

. . . . . . . . . . . . . . Fork Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 124018 . . . . . . . . . . . Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . 060017-050. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


4 . . . . . 065177 . . . . . . . . . . . Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5 . . . . . 060115-003 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . 060030-231. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

7 . . . . . 131787-100. . . . . . . . Column Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 060009-130. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 060063-006. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . 131854-100. . . . . . . . Chain Anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 060059-022. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

12 . . . . . 060059-025. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 060038-003. . . . . . . . Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 042906 . . . . . . . . . . . Chain Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 . . . . . 060000-055. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(1)

See Chart

AR - As Required


Truck

Capacity*

1815 kg (4000 lb)

2270 kg (5000 lb)

2495 kg (5500 lb)

Carriage Width

mm in

965

38

Index 1

Fork Carriage

142992-038

1118

44 142992-044

965

38 142992-038

2720 kg (6000 lb)

1118

44 142992-044

*


Crown 2009 PF17628-2


07.34-2045-051

661


Yoke - TT

Yoke - TT

Standard (All Trucks)

One Accessory

07.5-2045-001

662

Figure 18339-01

Crown 2008 PF17300-1


Yoke - TT


1 . . . . . 128450 . . . . . . . . . . . Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 103281 . . . . . . . . . . . Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 103280. . . . . . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 065081-045 . . . . . . . . Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . 081161-017 . . . . . . . . Collar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 128757-001. . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 060009-100. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 060009-105. . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 060030-041. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 060030-330. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

11 . . . . . 105967 . . . . . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 060045-031. . . . . . . . Shoulder Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

13 . . . . . 050000-039. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 124264-001. . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2008 PF17300-2


07.5-2045-002

663


Yoke - TT

Two Accessories

Two Accessories

With Control Cable

07.5-2045-003

664

Figure 19158-01

Crown 2008 PF17300-3


Yoke - TT


25 . . . . . 050000-039. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

26 . . . . . 060030-041. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

27 . . . . . 060030-330. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

28 . . . . . 124264-001. . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

29 . . . . . 060045-031. . . . . . . . Shoulder Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

30 . . . . . 105967 . . . . . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

31 . . . . . 050000-042. . . . . . . . Roll Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

32 . . . . . 128758 . . . . . . . . . . . Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

33 . . . . . 079332 . . . . . . . . . . . Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . . . . 079331. . . . . . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

35 . . . . . . . . 065081-038 . . . . . . . . Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

36 . . . . . 060045-007. . . . . . . . Shoulder Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2008 PF17300-4


07.5-2045-004

665


Yoke Quad Mast

Yoke Quad Mast

(1)

(2)

(3)

Refer to Cylinders for Carriage Cylinder

One Accessory

Two Accessory

07.54-1055-001

01 Rev. 8/07

666

Figure 17260

Crown 2007 PF15635-1 Rev. 8/07


Yoke Quad Mast


1 . . . . . 136560 . . . . . . . . . . . Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060009 . . . . . . . . . . . Retaining Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 136562 . . . . . . . . . . . Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 136563. . . . . . . . . . . . Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 065081-045 . . . . . . . . Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 131677 . . . . . . . . . . . Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 060030-288. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 060063-008. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


9 . . . . . 131671-001. . . . . . . . Hose Pulley

(1) (2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

131671-001. . . . . . . . Hose Pulley

(1) (3)

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

10 . . . . . 138363-001. . . . . . . . Spacer

(1) (2)

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

11 . . . . . 131803 . . . . . . . . . . . Shaft

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 131804 . . . . . . . . . . . Cover

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 060063-015. . . . . . . . Screw

(1)

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

(1)

Used with Accessory Hoses only

(2)

One Accessory only

(3)

Two Accessory only

*




Crown 2007 PF15635-2 Rev. 8/07


07.54-1055-002

01 Rev. 8/07

667


Lift Chain - TL

Lift Chain - TL

See Mast - TL and Fork Carriage - TL for Chain

Anchors, Pins, etc.

07.6-2045-001

668

(a) Outer Mast

(b) Inner Mast

(c) Fork Carriage

Figure 20647

Crown 2008 PF17511-1


Lift Chain - TL


1 . . . . . *

(1)

. . . . . . . . . . . . . . . Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

See Chart 1

*




Chart 1 – Chain Index 1

Lift Height* mm (in)

2995

3200

118

126

Length Required mm

1962

(in)

(77.25)

Links

103

Part Number

073991-067

Minimum Order Required (ft)

Each

7

Per Truck

14

3300

3505

3605

3810

130

138

142

150

2115

2267

(83.25)

(89.25)

111

119

073991-067

073991-067

7

8

14

16

When ordering chain, order the number of inches of 073991-067 for your particular truck. The appropriate minimum order quantity is listed in the charts. Cut chain to length required for your truck.

Replace both chains at the same time.

Crown 2008 PF17511-2


07.6-2045-002

669


Lift Chain TT

Lift Chain TT

See Mast - TT and Fork Carriage for Chain Anchors and Pins

07.6-2045-050

670

(a) Outer Mast

(b) Intermediate Mast

(c) Inner Mast

(d) Fork Carriage

Figure 19655

Crown 2008 PF17301-1


Lift Chain TT


1

. . . . . . (1)

* . . . . . . . . . . . . . . . Mast Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2

. . . . . . (2)

* . . . . . . . . . . . . . . . Carriage Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

See Chart 1

(2)

See Chart 2

Chart 1 – Mast Chain Index 1

Lift Height* mm in

4775

5230

5485

5865

6250

6555

188

206

216

231

246

258

Length Required mm

2038

2191

2343

2496 in

80.25

86.25

92.25

98.25

2648 104.25

2800 110.25

Links

107

115

123

131

139

147

Part Number

073991-067

073991-067

073991-067

073991-067

073991-067

073991-067


Each Per Truck

7

8

8

9

9

10

14

16

16

18

18

20

7010

7390

276

291

2953

3105

116.25

122.25

155

163

073991-067

073991-067

10

11

20

22


Replace both chains at the same time.

*




Crown 2008 PF17301-2


07.6-2045-051

671


Lift Chain TT

See Mast - TT and Fork Carriage for Chain Anchors and Pins

07.6-2045-052

672

(a) Outer Mast

(b) Intermediate Mast

(c) Inner Mast

(d) Fork Carriage

Figure 19655

Crown 2008 PF17301-3


Lift Chain TT

Chart 2 – Carriage Chain Index 2

Lift Height* mm in

4775

5230

5485

5865

6250

6555

188

206

216

231

246

258

Length Required mm in

1194

1296

1346

1448

1499

1600

47.00

51.00

53.00

57.00

59.00

63.00

Links

47

51

53

57

59

63

Part Number

089260-030

089260-030

089260-030

089260-030

089260-030

089260-030


Each Per Truck

4

5

5

6

5

5

4

5

5

5

5

6

7010

7390

276

291

1651

1753

65.00

69.00

65

69

089260-030

089260-030

6

6

6

6


*




Crown 2008 PF17301-4 07.6-2045-053

673


Lift Chain Quad

Lift Chain Quad

07.64-2040-001

01 Rev. 8/07

674

Refer to Chapter 7 for Chain Anchors and Pins

(1) Outer Mast

(2) Second Stage Mast

(3) Third Stage Mast

(4) Inner Mast

Figure 17262

Crown 2004 PF13871-1 Rev. 8/07


Lift Chain Quad


1 . . . . . * . . . . . . . . . . . . . . . . Chain BL844 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . * . . . . . . . . . . . . . . . . Chain BL634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . * . . . . . . . . . . . . . . . . Chain BL634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

When ordering chain (1, 2 and 3) order the number of inches of 089260-030 or 073991-067 for your particular truck. The appropriate minimum order quantity listed is in these charts. Cut chain to length required for your truck.

(1)

Replace both chains at the same time.

*




(1)

Index 1 - Chain (Outer Mast TO 3rd Stage Mast)

Lift Height mm

6100

6560

7010

(in)

(240)

(258)

(276)

7475

7925

(294)

(312)

089260-030 Bulk Chain

Length Required

(When cutting from bulk) mm

1855

(in)

(73)

Links

73

2005

2160

2310

2465

(79)

(85)

(91)

(97)

79

85

91

97

Chain (Mast)

Part Number

089260-086

089260-087

089260-088

089260-089

089260-090

Crown 2004 PF13871-2 Rev. 8/07


07.64-2040-002

01 Rev. 8/07

675


Lift Chain Quad

07.64-2040-003

01 Rev. 8/07

676

Refer to Chapter 7 for Chain Anchors and Pins

(1) Outer Mast

(2) Second Stage Mast

(3) Third Stage Mast

(4) Inner Mast

Figure 17262

Crown 2004 PF13871-3 Rev. 8/07


Lift Chain Quad

Lift Height mm

6100

6560

7010

7475

7925

(in)

(240)

(258)

(276)

(294)

(312)

(1)

Index 2- Chain (2nd Stage TO Inner Mast)

Length Required


1850

(in)

(72.75)

Links

97

2000

2155

2305

2460

(78.75)

(84.75)

(90.75)

(96.75)

105

113

121

129

Chain (Mast)

Part Number

073391-028

073391-018

073391-120

073391-019

073391-116

Lift Height mm

6100

6560

7010

(in)

(240)

(258)

(276)

7475

7925

(294)

(312)

073991-067 Bulk Chain

(1)

Index 3- Chain (Carriage)

Length Required


1275

(in)

(50.25)

Links

67

1430

1580

1735

1885

(56.25)

(62.25)

(68.25)

(74.25)

75

83

91

99

Chain (Carriage)

Part Number

073991-042

073991-029

073991-043

073991-037

073991-048

Crown 2004 PF13871-4 Rev. 8/07 07.64-2040-004

01 Rev. 8/07

677


Load Backrest - TL


(a) Fork Carriage

(b) Torque to 102 Nm (75 ft lb

(c) 138382-003 Shown

07.8-2045-005

01 Rev. 1/09

678

Figure 20704-01

Crown 2008 PF17531-1 Rev. 1/09




1 . . . . . *

(1)

. . . . . . . . . . . . . . Load Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060115-025 . . . . . . . . Screw (Sideshift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

060115-027 . . . . . . . . Screw (No Sideshift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . . . . . 060059-010. . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(1)

See Chart

*




Load Backrest Chart

Index 1

Load

Backrest

138382-002

138382-003 mm

991

991

Width

138382-004 991

138393-002 1143 in

39

39

39

45

138393-003 1143

138393-004 1143

137871-036

137871-042

991

991

45

45

39

39

137871-048 991

137872-036 1143

137872-042 1143

137872-048 1143

39

45

45

45

Height mm in

914

1067

1219

914

1067

1219

914

1067

1219

914

1067

1219

42

48

36

42

36

42

48

36

48

36

42

48

Truck

Capacity*

1815 kg

(4000lb),

2270 kg

(5000 lb), or

2495 kg

(5500 lb)

2720 kg

(6000 lb)

Crown 2008 PF17531-2 Rev. 1/09


07.8-2045-006

01 Rev. 1/09

679


Load Backrest - TT


07.8-2045-050

01 Rev. 1/09

680

(a) Fork Carriage

(b) Torque 102 Nm (75 ft lb)

Figure 16076-02

Crown 2008 PF17322-1 Rev. 1/09




1 . . . . . *

(1)

. . . . . . . . . . . . . . . Load Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060115-025 . . . . . . . . Screw (Sideshift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


3 . . . . . 060059-010. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(1)

See Chart

Load Backrest Chart

Index 1

Load

Backrest

138382-002

138382-004 mm

991

991

Width

138382-005 991

138393-002 1143 in

39

39

39

45

138393-004 1143

138393-005 1143

137871-036

137871-042

991

991

45

45

39

39

137871-048

137871-060

991

991

137872-036 1143

137872-042 1143

137872-048 1143

137872-060 1143

39

39

45

45

45

45

Height mm

1219

1524

914

1067

1219

1524

914

1219

1524

914

1219

1524

914

1067 in

48

60

36

42

48

60

48

60

36

42

36

48

60

36

Truck

Capacity*

1815 kg

(4000lb),

2270 kg

(5000 lb), or

2495 kg

(5500 lb)

2720 kg

(6000 lb)

*


Crown 2008 PF17322-2 Rev. 1/09


07.8-2045-051

01 Rev. 1/09

681


Load Backrest - Quad


(a) Fork Carriage

(b) Torque 99 - 128 Nm (73 - 94.4 ft lb)

07.84-2045-104

682

Figure 21488

Crown 2009 PF17629-1




1

. . . . . . (1)

. . . . . . . . . . . . . . . Load Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 060115-025 . . . . . . . . Screw (Sideshift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4


3 . . . . . 060059-010. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(1)

Refer to applicable Load Backrest Chart

Crown 2009 PF17629-2


07.84-2045-105

683



(a) Fork Carriage

(b) Torque 99 - 128 Nm (73 - 94.4 ft lb)

07.84-2045-106

684

Figure 21488

Crown 2009 PF17629-3




Index 1

Load

Backrest

Width mm in

Height mm in

Index 1

Load

Backrest

Width mm in

Height mm in

138382-002 991 39 914 36 138393-002 1143 45 914 36

138382-003 991 39 1067 42 138393-003 1143 45 1067 42

138382-004 991 39 1219 48 138393-004 1143 45 1219 48

Truck Capacity*

1815 kg (4000 lb)

2270 kg (5000 lb)

2495 kg (5500 lb)

*


Index 1

Load Backrest

129711-001

129711-002

129711-003

129711-004

129711-005

129711-006

129711-007

129711-008

129711-009

129711-010

129711-011

129711-012

129711-013

129711-014

129711-015

Load Backrest for 129710-001 thru -005 Cascade Fork Positioner (Not Shown)

914

1219

1524

914

1219

1524

914

1219

1524

Load Backrest Height mm in

914

1219

36

48

1524

914

1219

1524

60

36

48

60

48

60

36

48

60

36

48

60

36

Fork Positioner Width mm in

940

940

940

1041

1041

1041

1245

1245

1245

1041

1041

1041

1245

1245

1245

37

37

37

41

41

41

49

49

49

41

41

41

49

49

49

Truck

Capacity*

1815 kg (4000 lb)

2270 kg (5000 lb)

2495 kg (5500 lb)

2720 kg (6000 lb)

Crown 2009 PF17629-4 07.84-2045-107

685


Fork

Fork

07.9-2040-001

02 Rev. 12/08

686

Figure 17265-01

Crown 2001 PF13190-1 Rev. 12/08


Fork


1815, 2270 and 2495 kg (4000, 5000 and 5500 lb) Capacity

1 . . . . . 103442* . . . . . . . . . . Pin Bundle includes Items 2 thru 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 103443. . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 104329. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 075248. . . . . . . . . . . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 060000-061 . . . . . . . . Roll Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2720 kg (6000 lb)

1 . . . . . 111582* . . . . . . . . . . . Pin Bundle includes Items 2 thru 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 106207. . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 107685. . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 075248. . . . . . . . . . . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 0600000-061 . . . . . . . Roll Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*




Crown 2001 PF13190-2 Rev. 12/08


07.9-2040-002

02 Rev. 12/08

687


Fork

07.9-2040-003

02 Rev. 12/08

688

Figure 17265-01

Crown 2001 PF13190-3 Rev. 12/08


Fork

1815, 2270 and 2495 kg (4000, 5000 and 5500 lb)

Polished Finished, Full Taper - 100 mm (4 in) Width

Dimensions Part Number mm (in)

45 x 100 x 800 (1.75 x 4 x 31.50) 088228-009

45 x 100 x 915

45 x 100 x 990

(1.75 x 4 x 36)

(1.75 x 4 x 39)

088228-002

088228-006

45 x 100 x 1065 (1.75 x 4 x 42) 088228-003

45 x 100 x 1100 (1.75 x 4 x 43.31) 088228-010

45 x 100 x 1145 (1.75 x 4 x 45)

45 x 100 x 1220 (1.75 x 4 x 48)

45 x 100 x 1370 (1.75 x 4 x 54)

45 x 100 x 1525 (1.75 x 4 x 60)

088228-005

088228-004

088228-007

088228-008

Standard Finish, Partial Taper - 100 mm (4 in) Width

45 x 100 x 800 (1.75 x 4 x 31.50) 094182-009

45 x 100 x 915

45 x 100 x 990

(1.75 x 4 x 36)

(1.75 x 4 x 39)

094182-002

094182-006

45 x 100 x 1065 (1.75 x 4 x 42) 094182-003

45 x 100 x 1100 (1.75 x 4 x 43.31) 094182-010

45 x 100 x 1145 (1.75 x 4 x 45)

45 x 100 x 1220 (1.75 x 4 x 48)

094182-005

094182-004

45 x 100 x 1370 (1.75 x 4 x 54)

45 x 100 x 1525 (1.75 x 4 x 60)

094182-007

094182-008

Crown 2001 PF13190-4 Rev. 12/08 07.9-2040-004

02 Rev. 12/08

689


Fork

07.9-2040-005

02 Rev. 12/08

690

Figure 21019

Crown 2001 PF13190-5 Rev. 12/08


Fork

1815, 2270 and 2495 kg (4000, 5000 and 5500 lb)



45 x 130 x 800 (1.75 x 5 x 31.50)

45 x 130 x 915 (1.75 x 5 x 36)

45 x 130 x 990 (1.75 x 5 x 39)

45 x 130 x 1065 (1.75 x 5 x 42)

45 x 130 x 1100 (1.75 x 5 x 43.31)

45 x 130 x 1145 (1.75 x 5 x 45)

45 x 130 x 1220 (1.75 x 5 x 48)

45 x 130 x 1370 (1.75 x 5 x 54)

45 x 130 x 1525 (1.75 x 5 x 60)

106211-009

106211-002

106211-007

106211-003

106211-010

106211-008

106211-004

106211-005

106211-006


45 x 130 x 800 (1.75 x 5 x 31.50) 106212-009

45 x 130 x915 (1.75 x 5 x 36)

45 x 130 x 990 (1.75 x 5 x 39)

106212-002

106212-007

45 x 130 x 1065 (1.75 x 5 x 42) 106212-003

45 x 130 x 1100 (1.75 x 5 x 43.31) 106212-010

45 x 130 x 1145 (1.75 x 5 x 45)

45 x 130 x 1220 (1.75 x 5 x 48)

106212-008

106212-004

45 x 130 x 1370 (1.75 x 5 x 54)

45 x 130 x 1525 (1.75 x 5 x 60)

106212-005

106212-006

Crown 2001 PF13190-6 Rev. 12/08 07.9-2040-006

02 Rev. 12/08

691


Fork

07.9-2040-007

02 Rev. 12/08

692

Figure 21020

Crown 2001 PF13190-7 Rev. 12/08


Fork

2720 kg (6000 lb) Capacity



45 x 130 x 800 (1.75 x 5 x 31.50) 106213-009

45 x 130 x 915 (1.75 x 5 x 36)

45 x 130 x 990 (1.75 x 5 x 39)

106213-002

106213-007

45 x 130 x 1065 (1.75 x 5 x 42) 106213-003

45 x 130 x 1100 (1.75 x 5 x 43.31) 106213-010

45 x 130 x 1145 (1.75 x 5 x 45)

45 x 130 x 1220 (1.75 x 5 x 48)

45 x 130 x 1370 (1.75 x 5 x 54)

45 x 130 x 1525 (1.75 x 5 x 60)

106213-008

106213-004

106213-005

106213-006


45 x 130 x 800 (1.75 x 5 x 31.50) 106214-009

45 x 130 x915 (1.75 x 5 x 36)

45 x 130 x 990 (1.75 x 5 x 39)

106214-002

106214-007

45 x 130 x 1065 (1.75 x 5 x 42) 106214-003

45 x 130 x 1100 (1.75 x 5 x 43.31) 106214-010

45 x 130 x 1145 (1.75 x 5 x 45)

45 x 130 x 1220 (1.75 x 5 x 48)

106214-008

106214-004

45 x 130 x 1370 (1.75 x 5 x 54)

45 x 130 x 1525 (1.75 x 5 x 60)

106214-005

106214-006

Crown 2001 PF13190-8 Rev. 12/08 07.9-2040-008

02 Rev. 12/08

693

Notes:

694

CYLINDER PARTS

695

CYLINDER PARTS

Mast Cylinder - TL


(a) RH Cylinder Only

(b) Torque to 25.7 - 28.5 Nm (18.9 - 21.0 ft lb)

08.1-2045-003

01 Rev. 12/08

696

Figure 20672-01

Crown 2008 PF17524-1 Rev12/08

CYLINDER PARTS



0 . . . . . *

(1)

. . . . . . . . . . . . . . Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 064135-003 . . . . . . . . Ring Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 133157. . . . . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 064132-046 . . . . . . . . Rod Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 081161-018 . . . . . . . . Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . *

(1)

. . . . . . . . . . . . . . . Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


7 . . . . . . . . 117537-005 . . . . . . . . Shutoff Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 060009-151 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 128185-006 . . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 060009-047 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . *

(1)

. . . . . . . . . . . . . . . Cylinder Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 074240. . . . . . . . . . . . Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 060015-078 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . . . . 146168-001 . . . . . . . . Valve Flow Limiter (RH Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

111574 . . . . . . . . . . . Seal Kit (Includes Items 1, 3 and 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

091240-004. . . . . . . . Poly Pak Tool (Used for Seal Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

See Chart

*




Lift Height* mm in

2995

3200

3300

3505

3605

3810

118

126

130

138

142

150

Index 0

RH Cylinder

Assembly

146167-211-02

TL Mast Lift Cylinder Chart

Index 0

LH Cylinder

Assembly

Index 5

Ram

146179-211-02 140281-211-02

Index 11

RH Cylinder

Tube

136341-211

Index 11

LH Cylinder

Tube

144200-211

146167-226-02

146167-241-02

146179-226-02

146179-241-02

140281-226-02

140281-241-02

136341-226

136341-241

142200-226

142200-241

Crown 2008 PF17524-2 Rev. 12/08


08.1-2045-004

01 Rev. 12/08

697

CYLINDER PARTS

Mast Cylinder - TT



(b) Torque Value 25.7 - 28.5 Nm (18.9 - 21.0 ft lb)

08.2-2045-005

01 Rev. 12/08

698

Figure 16091-02

Crown 2008 PF17324-1 Rev. 12/08

CYLINDER PARTS



0 . . . . .

(1)

. . . . . . . . . . . . . . . RH Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

. . . . . . . . . . . . . . . LH Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . .

(1)

. . . . . . . . . . . . . . . . RH Cylinder Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

. . . . . . . . . . . . . . . . LH Cylinder Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . .

(1)

. . . . . . . . . . . . . . . . Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


4 . . . . . . . . 117537-005 . . . . . . . . Shutoff Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 060009-151 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 128185-006 . . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 060009-047 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 081161-018 . . . . . . . . Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 064132-046 . . . . . . . . Packing Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 133157. . . . . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 064135-003 . . . . . . . . Wiper Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 074240. . . . . . . . . . . . Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 060015-078 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . . . . 142026-002 . . . . . . . . Velocity Fuse (RH Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

123868 . . . . . . . . . . . Seal Kit (Includes Index 9, 11, 12 & 13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


(1)

See Chart

Crown 2008 PF17324-2 Rev. 12/08


08.2-2045-006

01 Rev. 12/08

699

CYLINDER PARTS



(b) Torque Value 25.7 - 28.5 Nm (18.9 - 21.0 ft lb)

08.2-2045-007

01 Rev. 12/08

700

Figure 16091-02

Crown 2008 PF17324-3 Rev. 12/08

CYLINDER PARTS


Mast Cylinder - TT Parts

Truck

Capacity*

1815 kg

(4000 lb),

2270kg

(5000 lb),

2495 kg

(5500 lb)

2722 kg

(6000 lb)

4570

5030

5285

5665

6045

6350

Lift Height* mm

4775

5230 in

188

206

Cylinder Assembly

RH

Index 0

136340-211

136340-226

LH

142199-211

142199-226

RH

Index 1

Cylinder Tube

136341-211

136341-226

Index 2

Ram

LH

142200-211 140281-211

142200-226 140281-226

5485

5865

216

231

136340-241

136340-256

142199-241

142199-256

136341-241

136341-256

142200-241

142200-256

140281-241

140281-256

6250

6555

7010

7390

246

258

276

291

136340-272

136340-287

136340-302

136340-317

142199-272

142199-287

142199-302

142199-317

136341-272

136341-287

136341-302

136341-317

142200-272

142200-287

142200-302

142200-317

140281-272

140281-287

140281-302

140281-317

180

198

208

223

238

250

136340-211

136340-226

136340-241

136340-256

136340-272

136340-287

142199-211

142199-226

142199-241

142199-256

142199-272

142199-287

136341-211

136341-226

136341-241

136341-256

136341-272

136341-287

142200-211

142200-226

142200-241

142200-256

142200-272

142200-287

140281-211

140281-226

140281-241

140281-256

140281-272

140281-287

*


Crown 2008 PF17324-4 Rev. 12/08 08.2-2045-008

01 Rev. 12/08

701

CYLINDER PARTS

Quad Mast Cylinder


08.34-2040-001

05 Rev. 1/09

702

Figure 17300-01

Crown 2004 PF13759-1 Rev. 1/09

CYLINDER PARTS



0 . . . . .

(1)

. . . . . . . . . . . . . . . Left Hand Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

. . . . . . . . . . . . . . . Right Hand Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . .

(1)

. . . . . . . . . . . . . . . Left Hand Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 074240. . . . . . . . . . . . Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 060015-078 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 060009-046 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 128185-003 . . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . .

(1)

. . . . . . . . . . . . . . . . Left Hand Ram 57.1 mm (2.25 in) Diameter . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 131890. . . . . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 064135-005 . . . . . . . . Wiper Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 064132-053 . . . . . . . . Rod Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 081161-026 . . . . . . . . Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . .

(1)

. . . . . . . . . . . . . . . . Right Hand Ram 57.1 mm (2.25 in) Diameter . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . .

(1)

. . . . . . . . . . . . . . . . Right Hand Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

132633 . . . . . . . . . . . Seal Kit (Includes Index 2, 3, 8 and 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

091240-017. . . . . . . . Poly Pack Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

See Quad Mast Cylinder Chart

Quantity listed for one cylinder

6100

6560

7010

7475

7925

Lift Height* mm in

240

258

276

294

312

Quad Mast Cylinder Chart

Index 0

Left Hand

Cylinder

Assembly

Right Hand

Cylinder

Assembly

131878-203

131878-218

131878-233

131878-248

131878-263

131881-203

131881-218

131881-233

131881-248

131881-263

Index 1

Right Hand

Tube

131880-203

131880-218

131880-233

131880-248

131880-263

Index 6

Left Hand

Ram

131879-203

131879-218

131879-233

131879-248

131879-263

Index 11

Right Hand

Ram

131882-203

131882-218

131882-233

131882-248

131882-263

Index 12

Left Hand

Tube

131885-203

131885-218

131885-233

131885-248

131885-263

*




Crown 2004 PF13759-2 Rev. 1/09


08.34-2040-002

05 Rev. 1/09

703

CYLINDER PARTS

Quad Carriage Cylinder


Flow Control Valve

Item 4

08.34-2040-050

02 Rev. 3/08

704

Figure 17302

Crown 2004 PF13757-1 Rev. 3/08

CYLINDER PARTS



0 . . . . .

(1)

. . . . . . . . . . . . . . . Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . .

(1)

. . . . . . . . . . . . . . . . Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 074240. . . . . . . . . . . . Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 060015-078 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . .

(1)

. . . . . . . . . . . . . . . . Flow Control Valve 62.8 lpm (16.6 gpm) . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 060009-096 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 128185-050 . . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . .

(1)

. . . . . . . . . . . . . . . . Ram 66.6 mm (2.625 in) Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 131852. . . . . . . . . . . . Cap M80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 064135-007 . . . . . . . . Wiper Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 064132-042 . . . . . . . . Rod Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 081161-020 . . . . . . . . Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


091240-009. . . . . . . . Poly Pack Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

See Quad Carriage Cylinder Chart

6100

6560

7010

7475

7925

Lift Height* mm in

240

258

276

294

312

Quad Carriage Cylinder Chart

Index 0

Cylinder

Assembly

Index 1

Tube

Index 7

Ram

131846-203 131847-203 131851-203

131846-218 131847-218 131851-218

131846-233 131847-233 131851-233

131846-248 131847-248 131851-248

131846-263 131847-263 131851-263

*




Crown 2004 PF13757-2 Rev. 3/08


08.34-2040-051

02 Rev. 3/08

705

CYLINDER PARTS

Carriage Cylinder - TT


08.3-2045-001

01 Rev. 12/08

706

(a) Torque to 33.5 - 36.3 Nm(24.7 - 26.8 ft lb)

Figure 19657-02

Crown 2008 PF17325-1 Rev. 12/08

CYLINDER PARTS



0 . . . . .

(1)

. . . . . . . . . . . . . . . Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . .

(1)

. . . . . . . . . . . . . . . . Cylinder Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . .

(1)

. . . . . . . . . . . . . . . . Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 128185-050 . . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 060009-096 . . . . . . . . Retaining Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 081161-020 . . . . . . . . Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 064132-042 . . . . . . . . Rod Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 131852. . . . . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 064135-007 . . . . . . . . Wiper Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 074240. . . . . . . . . . . . Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 060015-078 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 131983-042 . . . . . . . . Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 064091-005 . . . . . . . . Hex Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . . . 064019-075 . . . . . . . O-Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

123894 . . . . . . . . . . . Seal Kit (Includes Index 6, 8, 9 & 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


(1)

See Chart

Carriage Cylinder - TT Parts

5485

5665

5865

6045

6250

6350

6555

7010

7390 mm

4570

Lift

Height in

180

4775

5030

5230

5285

188

198

206

208

246

250

258

276

291

216

223

231

238

Index 0

Cylinder

Assembly

142171-211 142172-211

142171-226 142172-226 136338-226

142171-241 142172-241 136338-241

142171-256 142172-256 136338-256

142171-272 142172-272 136338-272

142171-287

Index 1

Cylinder Tube

142172-287

Index 2

Ram

136338-211

136338-287

142171-302 142172-302 136338-302

142171-317 142172-317 136338-317

Crown 2008 PF17325-2 Rev. 12/08


08.3-2045-002

01 Rev. 12/08

707

CYLINDER PARTS

Tilt Cylinder - TL/Quad


08.6-2045-001

03 Rev. 6/09

708

(a) Left & Right Determined From Operator’s

Perspective

(b) Part of Mast

(c) Part of Power Unit

(d) Torque to 102 Nm (75 ft lb)

(e) Torque to 270 - 340 Nm (200 - 250 ft lb)

Figure 17310-05

Crown 2008 PF17327-1 Rev. 6/09

CYLINDER PARTS



0 . . . . . 130101-001. . . . . . . . Left Hand Tilt Cylinder (Includes Index 1 thru 13) . . . . . . . . . . . . . . . . . . . . . 1

0 . . . . . 130101-002. . . . . . . . Right Hand Tilt Cylinder (Shown, Includes Index 1 thru 13) . . . . . . . . . . . . . 1

1 . . . . . . . . 130102-001 . . . . . . . . Left Hand Cylinder Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

130102-002 . . . . . . . . Right Hand Cylinder Tube (Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 060000-022 . . . . . . . . Roll Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 060021-103 . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 064216-012 . . . . . . . . Piston Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 130104. . . . . . . . . . . . Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 064074-035 . . . . . . . . Backup Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . . . . 064019-016 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 128434. . . . . . . . . . . . Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 064132-041 . . . . . . . . Packing Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 064019-114 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 064074-044 . . . . . . . . Backup Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 130103. . . . . . . . . . . . Cylinder Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 064135-017 . . . . . . . . Wiper Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 050067-022. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 . . . . . 050009-018. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

16 . . . . . 128467 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 128490 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 054011-006 . . . . . . . . Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

19 . . . . . 065012-002. . . . . . . . Ball Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

20 . . . . . 116439 . . . . . . . . . . . Nut Adjuster (Used with Adjustable Spacer, Index 25) . . . . . . . . . . . . . . . . . 1

21 . . . . . 060015-021. . . . . . . . Screw (Used with Adjustable Spacer, Index 25) . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 064019-016. . . . . . . . O-Ring (Used with Index 25). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

23

. . . . . . (1)

. . . . . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 050007-043. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

25 . . . . . 060059-010. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

26

. . . . . . (1)

. . . . . . . . . . . . . . . Clevis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

27 . . . . . 129481 . . . . . . . . . . . Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

28 . . . . . 060063-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

29 . . . . . 060089-005. . . . . . . . Wedge Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

30 . . . . . 142212 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


129229 . . . . . . . . . . . Seal Kit (Includes Index 2, 4, 6, 7, 9, 10, 11 and 13) . . . . . . . . . . . . . . . . . . 1

(1)

See Chart

*




Crown 2008 PF17327-2 Rev. 6/09


08.6-2045-002

03 Rev. 6/09

709

CYLINDER PARTS


08.6-2045-003

03 Rev. 6/09

710

(a) Left & Right Determined From Operator’s

Perspective

(b) Part of Mast

(c) Part of Power Unit

(d) Torque to 102 Nm (75 ft lb)

(e) Torque to 270 - 340 Nm (200 - 250 ft lb)

Figure 17310-05

Crown 2008 PF17327-3 Rev. 6/09

CYLINDER PARTS


Chart 1 Tilt Cylinder

Tilt Range

Backward - Forward

3° - 3°

3° - 5°

5° - 5°

3° - 10°

5° - 10°

Index 23

RH Cylinder

Adjustable Spacer

LH Cylinder

Spacer

116438-015

116438-014

116438-013

116438-016

Not Used

116437-020

116437-019

116437-018

116437-021

Not Used

Index 26

Clevis

128457-001

128457-002

128457-002

128457-003

128457-003

Crown 2008 PF17327-4 Rev. 6/09 08.6-2045-004

03 Rev. 6/09

711

CYLINDER PARTS

Tilt Cylinder - TT


(a) Part of Mast

(b) Part of Power Unit



08.6-2045-050

01 Rev. 8/09

712

Figure 19919

Crown 2008 PF17328-1 Rev. 8/09

CYLINDER PARTS



0 . . . . . 130101-001. . . . . . . . Left Hand Tilt Cylinder (Includes Index 1 - 13) . . . . . . . . . . . . . . . . . . . . . . . 1

0 . . . . . 130101-002. . . . . . . . Right Hand Tilt Cylinder (Shown, Includes Index 1 - 13) . . . . . . . . . . . . . . . 1

1 . . . . . . . . 130102-001 . . . . . . . . Left Hand Cylinder Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

130102-002 . . . . . . . . Right Hand Cylinder Tube (Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 060000-022 . . . . . . . . Roll Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 060021-103 . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 064216-012 . . . . . . . . Piston Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . . . . 130104. . . . . . . . . . . . Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . . . . 064074-035 . . . . . . . . Backup Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . . . . 064019-016 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 128434. . . . . . . . . . . . Piston Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 064132-041 . . . . . . . . Packing Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 064019-114 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 064074-044 . . . . . . . . Backup Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 130103. . . . . . . . . . . . Cylinder Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 064135-017 . . . . . . . . Wiper Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 050067-022. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 . . . . . 050009-018. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

16 . . . . . 128467 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

17 . . . . . 128490 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 054011-006 . . . . . . . . Lubrication Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

19 . . . . . 065012-002. . . . . . . . Ball Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

20 . . . . . 116439 . . . . . . . . . . . Nut Adjuster (Used with Adjustable Spacer, Index 25) . . . . . . . . . . . . . . . . . 1

21 . . . . . 060015-021. . . . . . . . Screw (Used with Adjustable Spacer, Index 25) . . . . . . . . . . . . . . . . . . . . . . 1

22 . . . . . 064019-016. . . . . . . . O-Ring (Used with Adjustable Spacer, Index 25) . . . . . . . . . . . . . . . . . . . . . 4

23

. . . . . . (1)

. . . . . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

24 . . . . . 050007-043. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

25 . . . . . 060059-010. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

26

. . . . . . (1)

. . . . . . . . . . . . . . . Clevis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

27 . . . . . 129481 . . . . . . . . . . . Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

28 . . . . . 060063-011 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

29 . . . . . 060089-005. . . . . . . . Wedge Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

30 . . . . . 142212 . . . . . . . . . . . Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


129229 . . . . . . . . . . . Seal Kit (Includes Index 2, 4, 6, 7, 9, 10, 11 and 13) . . . . . . . . . . . . . . . . . . 1

(1)

See Chart 1

*


Crown 2008 PF17328-2 Rev. 8/09


08.6-2045-051

01 Rev. 8/09

713

CYLINDER PARTS


(a) Part of Mast

(b) Part of Power Unit



08.6-2045-052

01 Rev. 8/09

714

Figure 19919

Crown 2008 PF17328-3 Rev. 8/09

CYLINDER PARTS


Chart 1 Tilt Cylinder

Index 23

Tilt Range

Backward - Forward

Right Cylinder

Adjustable Spacer

Left Cylinder

Spacer

3° - 3°

3° - 5°

116438-015

116438-014

116437-020

116437-019

5° - 5°

3° - 10°

5° - 10°

116438-013

116438-016

Not Used

116437-018

116437-021

Not Used

Index 26

Clevis

128457-001

128457-002

128457-002

128457-003

128457-003

Crown 2008 PF17328-4 Rev. 8/09 08.6-2045-053

01 Rev. 8/09

715

CYLINDER PARTS

Sideshifter Cylinder


08.7-1030-001

07 Rev. 5/08

716

Internal Components

Not Available

Model

FC/FP

FC/FP

Sideshifter Width

880 mm (34.5 in)

1120 mm (44.0 in)

FC 4000 965 mm (38.0 in)

FC 4000 1120 mm (44.0 in)

FC 4500 880 mm (34.5 in)

FC 4500 965 mm (38.0 in)

FC 4500 1120 mm (44.0 in)

RC 3000 880 mm (34.5 in)

RC 5500 880 mm (34.5 in)

RC 5500 965 mm (38.0 in)

SC 880 mm (34.5 in)

SC 4000 880 mm (34.5 in)

SC 4200 965 mm (38.0 in)

SC 4500 880 mm (34.5 in)

Figure 17319

Crown 1999 PF11650-1 Rev. 5/08

CYLINDER PARTS



0 . . . . . 126841-001. . . . . . . . Sideshift Cylinder 880 and 965 mm (34.5 and 38 in) . . . . . . . . . . . . . . . . . . 1

126841-002. . . . . . . . Sideshift Cylinder 1120 mm (44 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 116865 . . . . . . . . . . . . Rod Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . . . . . . . . . . . . . . . . . . . . . . O-Ring 70 Duro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 116860 . . . . . . . . . . . . Rod Wiper Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . 126902. . . . . . . . . . . . Carrier Retainer Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

126903 . . . . . . . . . . . Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 1999 PF11650-2 Rev. 5/08


08.7-1030-002

07 Rev. 5/08

717

CYLINDER PARTS



08.8-2040-051

01 Rev. 8/07

718

Figure 17323

Crown 2003 PF13543-1 Rev. 8/07

CYLINDER PARTS



0 . . . . . 131136 . . . . . . . . . . . Parking Brake Cylinder Assembly (Includes Items 1 and 3 thru 13) . . . . . . . 1

1 . . . . . . . . 069042. . . . . . . . . . . . Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . . 078067. . . . . . . . . . . . End Rod Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . . . . 065007-032 . . . . . . . . Bearing Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . 131135 . . . . . . . . . . . . Cylinder Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1



7 . . . . . . . . 060030-292 . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 064135-019 . . . . . . . . Wiper Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 064132-050 . . . . . . . . Rod Packing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

10 . . . . . . . . 130996. . . . . . . . . . . . Cylinder Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . . . . 128167. . . . . . . . . . . . Cylinder Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . . . . 060015-078 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . . . . 074240. . . . . . . . . . . . Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


Crown 2003 PF13543-2 Rev. 8/07


08.8-2040-052

01 Rev. 8/07

719

CYLINDER PARTS

Steer Cylinder

Steer Cylinder

08.8-2045-003

720

Figure 18194-01

Crown 2008 PF17124-1

CYLINDER PARTS

Steer Cylinder


0 . . . . . 143471 . . . . . . . . . . . Steer Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 064017-015 . . . . . . . . Wiper Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . . . . 064132-057 . . . . . . . . Packing Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3 . . . . . . . . 143480. . . . . . . . . . . . End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . 064074-027 . . . . . . . . Backup Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . . . . 064019-081 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . . . . 134585. . . . . . . . . . . . Cylinder Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . . . . 073981-012 . . . . . . . . Square Wiper Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . . . . 064216-013 . . . . . . . . Rod Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . . . . 134583. . . . . . . . . . . . Cylinder Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

144542 . . . . . . . . . . . Seal Kit, Includes Index 1, 2, 4, 5, 7 & 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Crown 2008 PF17124-2


08.8-2045-004

721

Notes:

722

PLATFORM PARTS

723

PLATFORM PARTS

Sideshifter - TL/TT


09.0-2045-050

01 Rev. 9/08

724

(a)

(b)

(c)

See sideshifter Cylinder

See Hydraulic Parts

Torque Value 163 Nm

(120 ft lb)

Figure 19667

Crown 2008 PF17330-1 Rev. 9/08

PLATFORM PARTS



0

. . . . . . (1)

* . . . . . . . . . . . . . . . Sideshifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 131989. . . . . . . . . . . . Upper Bearing (Includes Lube Fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . . . . 094004. . . . . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . . . . . . . . 126843. . . . . . . . . . . . Lower Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . . . . . . . . . . . . . . . . . . . Fork Stop

(2)

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

5 . . . . . . . . 116876 . . . . . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . . . . 060020-019 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 . . . . . . . . 131990. . . . . . . . . . . . Lower Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . . . . 060000-020 . . . . . . . . Roll Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . . . . . . . . . . . . . . . . . . . . . . Faceplate

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Refer to Sideshifter Chart

(2)

Not serviceable, replace Sideshifter when Faceplate or Fork Stop is needed.

Truck Capacity* kg lb

1815

2270

2495

4000

5000

5500

2720 6000

Sideshifter Chart

Carriage Width mm in

965 38

1118

965

1118

44

38

44

Index 0

Sideshifter

136579-002

136579-003

136579-004

136579-005

*




Crown 2008 PF17330-2 Rev. 9/08


09.0-2045-051

01 Rev. 9/08

725

PLATFORM PARTS

Sideshifter - Quad


09.04-2045-100

726

(a) Refer to Cylinder Parts

(b) Refer to Hydraulic Parts

(c) Torque Value 163 Nm (120 ft lb)

Figure 17324-02

Crown 2008 PF17532-1

PLATFORM PARTS



0 . . . . . 129709-002* . . . . . . . Sideshifter 965 mm (38 in) Class II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129709-003* . . . . . . . Sideshifter 1120 mm (44 in) Class II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129709-004* . . . . . . . Sideshifter 965 mm (38 in) Class III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

129709-005* . . . . . . . Sideshifter 1120 mm (44 in) Class III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 . . . . . . . . 131989. . . . . . . . . . . . Upper Bearing (Includes lubrication fitting) . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . . . . 094004. . . . . . . . . . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . . . . . . . . 126843. . . . . . . . . . . . Lower Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . . . . 131990. . . . . . . . . . . . Lower Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5 . . . . . . . . 116876 . . . . . . . . . . . . Flatwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 . . . . . . . . 060020-019 . . . . . . . . Capscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

7 . . . . . . . . . . . . . . . . . . . . . . . . . . Faceplate

(1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . . . . 060000-030 . . . . . . . . Roll Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . . . . 126844. . . . . . . . . . . . Fork Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 . . . . . 069865 . . . . . . . . . . . Service Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Not Serviceable, Replace Sideshifter when Faceplate is Required.

*




Crown 2008 PF17532-2


09.04-2045-101

727

Notes:

728

LABELS AND DECALS

729

LABELS AND DECALS

Work Assist Accessories


10.0-2045-025

730

(1)

(2)

Left and Right Determined from Operator’s Perspective

Part of Drive Thru Overhead Guard

Figure 17336

Crown 2007 PF15995-1




1 . . . . . 127237 . . . . . . . . . . . Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . 129287 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 060062-013. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 128362 . . . . . . . . . . . Upper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 127697 . . . . . . . . . . . Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 060062-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 050004-019. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

8 . . . . . 127259-005* . . . . . . . 36 Volt Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

127259-006* . . . . . . . 48 Volt Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062007-064 . . . . . . . . Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 050005-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

10 . . . . . 129286 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 128362 . . . . . . . . . . . Upper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 127697 . . . . . . . . . . . Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 060062-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

14 . . . . . 050008-008. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

15 . . . . . 127237 . . . . . . . . . . . Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 050005-062. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

17 . . . . . 127419 . . . . . . . . . . . U-Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 . . . . . 127234 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

19 . . . . . 050004-019. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

20 . . . . . 127259-005* . . . . . . . 36V Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

127259-006* . . . . . . . 48V Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

062007-064 . . . . . . . . Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

21 . . . . . 050068-002. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

22 . . . . . 050005-005. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

23 . . . . . 050005-062. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

24 . . . . . 050008-008. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

25 . . . . . 065004-005. . . . . . . . Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*




Crown 2007 PF15995-2


10.0-2045-026

731



10.0-2045-027

732


Figure 17337

Crown 2007 PF15995-3




40 . . . . . 130050-002. . . . . . . . Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

41 . . . . . 060062-038. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

42 . . . . . 128362 . . . . . . . . . . . Upper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

43 . . . . . 130071 . . . . . . . . . . . Wire Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

44 . . . . . 130060 . . . . . . . . . . . Clamp Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

45 . . . . . 060062-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

46 . . . . . 130125 . . . . . . . . . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

47 . . . . . 127697 . . . . . . . . . . . Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

48 . . . . . 060062-060. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

49 . . . . . 130008 . . . . . . . . . . . Clip Pad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

50 . . . . . 816658 . . . . . . . . . . . Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

51 . . . . . 814594 . . . . . . . . . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

52 . . . . . 060062-003. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

53 . . . . . 060030-078. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

54 . . . . . 130064 . . . . . . . . . . . Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

55 . . . . . 090670-008. . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

063002-020. . . . . . . . Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR

56 . . . . . 050008-034. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

57 . . . . . 131403 . . . . . . . . . . . Clip Pad Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

58 . . . . . 128362 . . . . . . . . . . . Upper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

59 . . . . . 060062-038. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

60 . . . . . 127697 . . . . . . . . . . . Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

61 . . . . . 060062-060. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

62 . . . . . 130147 . . . . . . . . . . . Accessory Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

63 . . . . . 050003-014. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

64 . . . . . 128362 . . . . . . . . . . . Upper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

65 . . . . . 127697 . . . . . . . . . . . Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

66 . . . . . 060062-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

67 . . . . . 128362 . . . . . . . . . . . Upper Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

68 . . . . . 060061-013. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

69 . . . . . 127697 . . . . . . . . . . . Lower Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

70 . . . . . 060062-012. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2007 PF15995-4


10.0-2045-028

733


InfoLink Accessories


(a)

(b)

(c)

(d)

Part of Drive Thru Overhead Guard


Part of FC 4500 Power Unit

Part of SC 4500 Power Unit

10.0-2045-075

03 Rev. 8/08

734

Figure 17341-02

Crown 2007 PF15997-1 Rev. 8/08




0 . . . . . 140253-001. . . . . . . . InfoLink Kit With Proximity Reader Includes Index 1 - 4 . . . . . . . . . . . . . . . . 1

140253-002. . . . . . . . InfoLink Kit Without Proximity Reader Includes Index 1 - 4 . . . . . . . . . . . . . 1

1 . . . . . . . . 134791-001 . . . . . . . . InfoLink Module With Proximity Reader Included in -001 Kit . . . . . . . . . . 1

134791-002 . . . . . . . . InfoLink Module Without Proximity Reader Included in -002 Kit . . . . . . . 1

2 . . . . . . . . 060061-006 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . . . . . . . . 060005-005 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 . . . . . . . . 139899. . . . . . . . . . . . Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 141482-001. . . . . . . . Bracket Drive Thru Overhead Guard RH . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

141482-002. . . . . . . . Bracket Drive Thru Overhead Guard LH, Shown . . . . . . . . . . . . . . . . . . . . . 1

6 . . . . . 060062-040. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

7 . . . . . 050068-002. . . . . . . . Flange Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

8 . . . . . 127419 . . . . . . . . . . . U - Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

9 . . . . . 060062-016. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

10 . . . . . 140245 . . . . . . . . . . . Bracket 15° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 060061-013. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 . . . . . 140382 . . . . . . . . . . . Impact Sensor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 140557 . . . . . . . . . . . Impact Sensor Harness Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . 145969 . . . . . . . . . . . Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 060030-074. . . . . . . . Flatwasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

16 . . . . . 060042-016. . . . . . . . Locking Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Crown 2007 PF15997-2 Rev. 8/08


10.0-2045-076

03 Rev. 8/08

735


Labels and Decals


(a)

(b)

(c)

(d)

(e)

Centered

Align

Inside of Contactor Panel

Underside of Seat Deck

Steel Stamp Serial Number, Date & Country of Manufacture

10.9-2045-001

03 Rev. 8/09

736

Figure 17859-01

Crown 2007 PF17074-1 Rev. 8/09




1 . . . . . 106158-001. . . . . . . . Crown Decal Heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 . . . . . 106158-022. . . . . . . . Crown Decal Heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . . . . . 069372-005. . . . . . . . Momentum FC Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4 . . . . . 069374-001. . . . . . . . crown.com Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5 . . . . . 069023 . . . . . . . . . . . Convex Mirror Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

869023-

(1)

. . . . . . . . Convex Mirror Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

6 . . . . . 069372-004. . . . . . . . Momentum FC Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

7 . . . . . 069775 . . . . . . . . . . . InfoPoint Overview Map AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869775-

(1)

. . . . . . . . InfoPoint Overview Map AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

069780 . . . . . . . . . . . InfoPoint Overview Map DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869780-

(1)

. . . . . . . . InfoPoint Overview Map DC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

8 . . . . . 069020 . . . . . . . . . . . Danger Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869020-

(1)

. . . . . . . . Danger Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

9 . . . . . 069112-061 . . . . . . . . Warning Battery Size 739 x 972 mm (29.10 x 38.25 in) . . . . . . . . . . . . . . . . 1

069112-064 . . . . . . . . Warning Battery Size 796 x 972 mm (31.25 x 38.25 in) . . . . . . . . . . . . . . . . 1





10 . . . . . 069259 . . . . . . . . . . . Warning Passenger English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

069392 . . . . . . . . . . . Warning Passenger Australian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

11 . . . . . 069366 . . . . . . . . . . . Park Brake Release Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869366-

(1)

. . . . . . . . Park Brake Release Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

12 . . . . . 069154 . . . . . . . . . . . Hydraulic Oil Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

13 . . . . . 127573 . . . . . . . . . . . Battery Disconnect Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

14 . . . . . . . . . . . . . . . . . . . . . . Data Plate

(2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

15 . . . . . 069047 . . . . . . . . . . . Caution Charger Hook Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869047-

(1)

. . . . . . . . Caution Charger Hook Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

16 . . . . . 069320-004. . . . . . . . Danger Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

17 . . . . . 069778 . . . . . . . . . . . InfoPoint Rear View Dual Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869778-

(1)

. . . . . . . . InfoPoint Rear View Dual Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

069779 . . . . . . . . . . . InfoPoint Rear View Single Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869779-

(1)

. . . . . . . . InfoPoint Rear View Single Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

18 . . . . . 069111 . . . . . . . . . . . UL Label, EE Trucks Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(1)

Choice of dash number depends on language. When ordering, refer to Language Chart and complete the part number with the correct dash number. Australia will use -006 (English) label unless noted.

(2)

Contact Factory

Dash Number

001

002

003

Language Dash Number Chart

Language

German

French

Spanish

Dash Number

004

005

006

Language

Dutch

Italian

English

Crown 2007 PF17074-2 Rev. 8/09


10.9-2045-002

03 Rev. 8/09

737



10.9-2045-003

03 Rev. 8/09

738

(i)

(j)

(k)

(e)

(f)

(g)

(h)

(a)

(b)

(c)

(d)

Align Edge of Label with Cutout in OHG

Trucks without Attachments

Trucks with Attachments

If Labels will not Fit on OHG, in the Case of Multiple

Attachment Capacity Plates or Drive Thru Rack Option,

Move Item 20 onto Seat Deck Near Control Levers

Center Label on Flats of OHG

Position Label Against Weld

LH Battery Door Shown

Distribution Panel Cover

Front View of OHG Cowl Plate

Center Label on Operator Side

Counterweight

Figure 17860

Crown 2007 PF17074-3 Rev. 8/09




25 . . . . . 069016 . . . . . . . . . . . Warning Tilt Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869016-

(3)

. . . . . . . . Warning Tilt Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

26 . . . . . 069017 . . . . . . . . . . . Warning Slow Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869017-

(3)

. . . . . . . . Warning Slow Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

27 . . . . . 069018 . . . . . . . . . . . Danger Tip Over, Trucks With Shoulder Restraint . . . . . . . . . . . . . . . . . . . . 1

869018-

(3)

. . . . . . . . Danger Tip Over, Trucks With Shoulder Restraint . . . . . . . . . . . . . . . . . . . . 1

069094 . . . . . . . . . . . Danger Tip Over, Trucks With Hip Restraint . . . . . . . . . . . . . . . . . . . . . . . . . 1

869094-

(3)

. . . . . . . . Danger Tip Over, Trucks With Hip Restraint . . . . . . . . . . . . . . . . . . . . . . . . . 1

28 . . . . . . . . . . . . . . . . . . . . . . Capacity Plate

(4)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

29 . . . . . 069093 . . . . . . . . . . . "EE" Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

30 . . . . . 069010 . . . . . . . . . . . Warning Stand Under . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

869010-

(3)

. . . . . . . . Warning Stand Under . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

31 . . . . . 069009 . . . . . . . . . . . Warning Stand On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

869009-

(3)

. . . . . . . . Warning Stand On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

32 . . . . . 069012 . . . . . . . . . . . Warning Electrical Additions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

869012-

(3)

. . . . . . . . Warning Electrical Additions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

33 . . . . . 069777 . . . . . . . . . . . InfoPoint Distribution Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

34 . . . . . . . . . . . . . . . . . . . . . . Capacity Plate Attachment

(4)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

35 . . . . . 069011 . . . . . . . . . . . Warning SCR Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869011-

(3)

. . . . . . . . Warning SCR Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(3)


(4)

Contact Factory


Dash Number

001

002

003

004

005

006

Language

German

French

Spanish

Dutch

Italian

English

Crown 2007 PF17074-4 Rev. 8/09


10.9-2045-004

03 Rev. 8/09

739



(d)

(e)

(f)

(g)

(h)

(i)

(a)

(b)

(c)

1st Stage Mast

Manufacturing Project Steel Stamp

Distance from Floor, if Collapsed Height is

2260 mm (89 in) or Greater then Dimension from Floor will be 1800 mm (70.87 in)

2nd Stage Mast

Front View of Mast

From Bottom of Cylinder

3rd Stage Mast

Center Label on Cross Brace

Center Label on Cylinder Horizontally

10.9-2045-005

03 Rev. 8/09

740

Figure 17861

Crown 2007 PF17074-5 Rev. 8/09




40 . . . . . 069259 . . . . . . . . . . . Warning Passenger English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

069392 . . . . . . . . . . . Warning Passenger Australian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

41 . . . . . 069007 . . . . . . . . . . . Warning Hands Off/Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

869007-

(5)

. . . . . . . . Warning Hands Off/Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

42 . . . . . 069262 . . . . . . . . . . . Warning Operator English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869262-

(5)

. . . . . . . . Warning Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

069348 . . . . . . . . . . . Warning Operator Australian. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

43 . . . . . 069010 . . . . . . . . . . . Warning Stand Under . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

869010-

(5)

. . . . . . . . Warning Stand Under . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

44 . . . . . 069006 . . . . . . . . . . . Warning Hands Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869006-

(5)

. . . . . . . . Warning Hands Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

45 . . . . . 069105 . . . . . . . . . . . Warning Hands Off/Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869105-

(5)

. . . . . . . . Warning Hands Off/Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(5)



Dash Number

001

002

003

004

005

006

Language

German

French

Spanish

Dutch

Italian

English

Crown 2007 PF17074-6 Rev. 8/09


10.9-2045-006

03 Rev. 8/09

741



10.9-2045-007

03 Rev. 8/09

742

(a)

(b)

(c)

Centered

Inside of Access Door

Underside of Floorboard

Figure 17862

Crown 2007 PF17074-7 Rev. 8/09




50 . . . . . 069785 . . . . . . . . . . . ACCESS 3 Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

51 . . . . . 069784 . . . . . . . . . . . ACCESS 2 Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

52 . . . . . 069782 . . . . . . . . . . . InfoPoint Contactor Sub AC Lift Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869782-

(6)

. . . . . . . . InfoPoint Contactor Sub AC Lift Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

069783 . . . . . . . . . . . InfoPoint Contactor Sub DC Lift Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869783-

(6)

. . . . . . . . InfoPoint Contactor Sub DC Lift Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

53 . . . . . 069776 . . . . . . . . . . . InfoPoint Drive Compartment Map AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 1

869776-

(6)

. . . . . . . . InfoPoint Drive Compartment Map AC Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 1

143674-001-0S . . . . . Labels & Decals Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

143676-001. . . . . . . . InfoPoint Labels Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

(6)



Dash Number

001

002

003

004

005

006

Language

German

French

Spanish

Dutch

Italian

English

Crown 2007 PF17074-8 Rev. 8/09


10.9-2045-008

03 Rev. 8/09

743

Notes:

744

mfg

20090818

FC 4500 AC Series

PF15703-00

6

REV. C

Crown Sit-down Rider Lift Truck FC 4500 Series Service & Parts Manual

Model No.

Serial No.

FC 4500 Series

AC Traction

Service & Parts Manual

How to Order Service Parts

Our Local Crown Dealer Is

TABLE OF CONTENTS

SAFETY

INTRODUCTION

LUBRICATION & ADJUSTMENT

HYDRAULIC

DRIVE UNIT

ELECTRICAL

BRAKE

STEERING

LIFTING MECHANISM

CYLINDERS

GLOSSARY

WIRING DIAGRAMS

HYDRAULIC SCHEMATIC

POWER UNIT PARTS

HYDRAULIC PARTS

DRIVE UNIT PARTS

ELECTRICAL PARTS

BRAKE PARTS

STEERING PARTS

LIFTING MECHANISM PARTS

CYLINDER PARTS

PLATFORM PARTS

LABELS AND DECALS

Key Features

Related manuals

Frequently Answers and Questions

How do I order service parts for my Crown FC 4500 Series lift truck?

What kind of safety features are included in the FC 4500 Series?

How do I adjust the seat deck cover on my FC 4500 Series?

Table of contents

Crown Sit-down Rider Lift Truck FC 4500 Series Service & Parts Manual

Model No.

Serial No.

FC 4500 Series

AC Traction

Service & Parts Manual

How to Order Service Parts

Our Local Crown Dealer Is

TABLE OF CONTENTS

SAFETY

INTRODUCTION

LUBRICATION & ADJUSTMENT

HYDRAULIC

DRIVE UNIT

ELECTRICAL

BRAKE

STEERING

LIFTING MECHANISM

CYLINDERS

GLOSSARY

WIRING DIAGRAMS

HYDRAULIC SCHEMATIC

POWER UNIT PARTS

HYDRAULIC PARTS

DRIVE UNIT PARTS

ELECTRICAL PARTS

BRAKE PARTS

STEERING PARTS

LIFTING MECHANISM PARTS

CYLINDER PARTS

PLATFORM PARTS

LABELS AND DECALS

Key Features

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Frequently Answers and Questions

How do I order service parts for my Crown FC 4500 Series lift truck?

What kind of safety features are included in the FC 4500 Series?

How do I adjust the seat deck cover on my FC 4500 Series?

Table of contents