PDF Service Manual Crown SP 42 Forklift - 2 MB
This service manual provides in-depth repair and maintenance instructions for the Crown SP 42 stockpicker forklift.
It covers diagnostics, electrical systems, hydraulics, and mechanical components.
A must-have resource for any technician responsible for keeping the Crown SP 42 in top working order.
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--- Page 1 ---
INTRODUCTION
This manual is intended for the service mechanic who is seeking information about maintenance and service replace-
ment parts. It contains a section on troubleshooting which will enable a qualified mechanic to locate and solve prob-
lems which may occur.
OPERATOR INSTRUCTIONS
This manual does not contain operation instructions. Operator Instructions in tag or booklet form are sent with each
truck. Additional copies can be ordered if required. These booklets are for you and your personnel to insure years of
safe, trouble-free operation of your Crown Lift Truck. For stockpicker operator instructions, refer to Crown publication,
"You and Your Crown Stockpicker" (PF7568).
DRIVER TRAINING
Crown has available a complete series of Driver Training programs in two parts, concerning basic safety rules and
operating characteristics of your stockpicker. To obtain this informative material, ask your Crown Dealer about "Its up to
You" and "You and Your Stockpicker".
SERVICE TRAINING
Complete Service Training is available to the lift truck mechanic covering all Crown Lift Trucks, SCR systems, wire
guidance, hydraulic and electrical systems. To obtain more information concerning service training, contact your Crown
Dealer.
When ordering replacement parts from this manual, always specify, along with the part number, the model and serial
number of the truck. This information will further enable us to give correct, fast and efficient service.
For Series SP capacities, technical information and dimensional specifications, please refer to the following
sales literature: SP Literature SF4285
SP36 Specifications SF4286
SP42 Specifications SF4287
30SP48 Specifications SF4288
15SP48 Specifications SF4289
Copies of publications can be obtained from your Crown dealer or by writing to:
Crown Equipment Corporation
44 S. Washington Street
New Bremen, OH 45869
This manual is arranged according to major sections. The first part of the page number, found at the bottom of each
page, denotes the section in which a particular form will be located. The front of the manual covers the written mainte-
nance. The back covers the replacement parts. The sectional descriptions are as follows:
MAINTENANCE REPLACEMENT PARTS
SECTION DESCRIPTION SECTION DESCRIPTION
M1 Lubrication and Adjustments 1 Basic Chassis or Power Unit
M2 Hydraulics 2 Hydraulic System and Components
M3 Drive Unit 3 Drive Unit and Components
M4 Electrical 4 Electrical Components
M5 Brake 5 Brake Assemblies and Brake Systems
M6 Steering 6 Steering System and Components
M7 Mast and Main Frame 7 Main Frame and Mast Assemblies
M8 Cylinder 8 Cylinders
M9 Platform 9 Platform Assembly
M10 Glossary 10 Accessories
11 Specifications
1894
Crown 1986 PF7569-1 Rev. 6/02 Printed in U.S.A.
03 REV. 6/02
ITD–07.2–003 ITD–07.2–003
--- Page 3 ---
CONTROL OF HAZARDOUS ENERGY
LOCKOUT/TAGOUT
SP36, SP42
In the interest of safety and to ensure compliance with the 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 the SP36, SP42. Before performing any service or maintenance on the SP36, SP42, review
the appropriate sections in this service manual for additional procedures to be followed.
In addition, Crown recommends that all mechanics wear appropriate protective items, such as safety glasses, work gloves,
and steel toed shoes, whenever performing service or maintenance work on Crown equipment.
BATTERY
SAFETY RULES BATTERY CARE
• Wear protective clothing, such as, rubber apron, gloves,
boots and full-face shield when performing any main- WARNING
tenance on batteries. Do not allow electrolyte to come Only qualified and experienced personnel should
in contact with eyes, skin, clothing or floor. If electrolyte perform maintenance and repair on batteries.
comes in contact with eyes, flush immediately and
thoroughly with clean water. Obtain medical attention • Make certain the charger being used matches the
immediately. Should electrolyte be spilled on skin, voltage and amperage of the truck battery. This voltage
rinse promptly with clean water and wash with soap. A is listed on the truck serial plate.
baking soda solution (one pound to one gallon of water) • Before disconnecting or connecting batteries to a
will neutralize acid spilled on clothing, floor or any other charger, make sure the charger is “OFF”. If an attempt
surface. Apply solution until bubbling stops and rinse is made to do this while the charger is “ON”, serious
with clean water. injury to you, the battery and charger could result.
• Keep vent plugs firmly in place at all times except when • Never use a match or lighter. Battery fumes are explo-
adding water or taking hydrometer readings. sive.
• Do not bring any type of flame, spark, etc., near the • Make certain battery used meets weight, size and
battery. Gas formed while the battery is charging, is voltage requirements of truck (refer to serial plate).
highly explosive. This gas remains in the cells long NEVER operate truck with an undersized battery.
after charging has stopped.
• Do not lay metallic or conductive objects on battery. CHARGING
Arcing will result.
• Do not allow dirt, cleaning solution or other foreign
material to enter cells. Impurities in electrolyte has a CAUTION
neutralizing effect reducing available charge.
• If battery repair is planned, follow the battery
Never smoke or bring flame near the battery. Gas
manufacturer's instructions concerning repair prac-
formed during charging is highly explosive and
tices and procedures.
can cause serious injury.
Consult the charger manufacturer’s manual covering your
charger for hints on operation and maintenance.
6853
Crown 2000 PF11869-1 Rev. 11/00 Printed in U.S.A.
01 REV. 11/00
MA–07.2–101 MA–07.2–101
--- Page 4 ---
LUBRICATION & ADJUSTMENT
Lubrication and Adjustment
The following is a list of lubricants and maintenance
products recommended when doing Planned Mainte-
nance on Crown Lift Trucks.
Lubrication Identification Chart
Type of Lubricant Part Number Package Quantity
363506-001 1 Quart
A Gear Lube 80W-90 (Typical)
363506-012 (12) 1 Quart Cans
363503-001 1 Quart
AA Automatic Transmission Fluid (Multi-Purpose)
363503-012 (12) 1 Quart
363513-001 1 Quart
AAA Universal Hydraulic & Transmission Fluid
363513-012 (12) 1 Quart
363514-001 1 Quart
AAAA Synthetic Gear Oil 75W-90
363514-012 (12) 1 Quart
063002-034 14.5 oz Cartridge
B Grease (Multi-Purpose)
063002-045 (40) 14.5 oz Cartridges
063002-017 14.5 oz Cartridge
BB(1) Grease (Low Temperature)
063002-046 (40) 14.5 oz Cartridges
363002-001 14 oz Cartridge
BBB Food Grade Grease (Multi-Purpose)
363002-030 (30) 14 oz Cartridges
063002-025 14.5 oz Cartridge
BBBB Grease (Multi-Purpose) Premium
063002-026 5 Gallon
C Oil (SAE 40)
363500-001 1 Quart
CC Engine Oil (10W30)
363500-012 (12) 1 Quart
363504-101 1 Gallon
D Hydraulic Oil
363504-106 (6) 1 Gallon
363505-101 1 Gallon
DD(1) Hydraulic Oil (Low Temp)
363505-106 (6) 1 Gallon
DDD Hydraulic Oil - DTE24 063001-021 1 Gallon
063002-024 14.5 oz Cartridge
E Channel Grease
063002-022 35 lb Pail
063002-024 14.5 oz Cartridge
F Gear Grease
063002-022 35 lb Pail
363107-001 15 oz Can
Chain & Cable Lube
363107-012 (12) 15 oz Cans
G
363115-001 12 oz Can
Premium Chain & Cable Lube
363115-012 (12) 12 oz Cans
363129-001 11 oz Can
H Final Finish - Rubber & Vinyl Dressing
363129-012 (12) 11 oz Cans
(1) Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.
M1.0-04.0-002 Crown 1987 PF7886-2 Rev. 1/11
19 Rev. 1/11
30
--- Page 5 ---
MAINTENANCE
CHART 1-5
See Illustration 1-4 & 1-6 for Index Call-outs
† - Denotes Inspect and (or) Adjust
Crown 1981 PF-6391-6 Printed in U.S.A.
M1.0 - 07.2 - 006 M1.0 - 07.2 - 006
--- Page 6 ---
INSPECTION & LUBRICATION
SAE Torque Values
SAE Torque Values
It is important to tighten fasteners to the correct torque
value. This section shows the standard torque values
for the screws and bolts used in Crown lift trucks and
vehicles. Special torque values in the maintenance and
parts sections of this manual override the standard
torque values in this section.
Grade
Grade Identification Bolt and Screw
Specification
(on Head) Size (in)
SAE - Grade 2 1/4 through 1-1/2
SAE - Grade 5 1/4 through 1-1/2
SAE - Grade 8 1/4 through 1-1/2
NOTE: Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all its bolted assem-
blies. 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.
Fig. 1 (14916-02)
Crown 1979 PF5067 Rev. 2/16 M1.9-14.0-001
06 Rev. 2/16
71
--- Page 7 ---
MAINTENANCE
ILLUSTRATION 2.1-1
HYDRAULIC PUMP — PARKER HANNIFIN Preparation for Disassembly
Pump - Gear The pump overhauling should be performed in a clean,
dust-free location, using clean tools and equipment. Dirt
Before the pump is removed or disassembled, check the
or grit will damage the highly machined surfaces and will
following list of common troubles and remedies. It could
result in leakage or premature failure of the pump.
save time, effort and money.
Crown 1982 PF-5361-1 Rev. 4/88 Printed in U.S.A.*
02 REV. 4/88
M2.1 - 07.2 - 001 M2.1 - 07.2 - 001
--- Page 8 ---
MAINTENANCE
Next inspect the check valves (index 4 & 21). Raise If it is determined that all check valves are functioning
the platform a couple of inches, disconnect the properly, one or more of the external component
battery and loosen the hydraulic fitting from the “P1” valves are faulty. With the use of a test plug (f#92177),
port. If hydraulic oil flows out and the platform lowers remove each valve and replace it with the test plug.
the right check valve (index 21 [as shown in illus- Operate the system until the problem disappears. The
tration 2.4-1]) is faulty. A certain amount of oil will valve you have out of the manifold body at that time is
always run out. It comes from the suction line the faulty valve. The test plug will only fit the manual
between the pump and the check valve and should not valve, relief valve and the “SV2” solenoid valve
be confused with oil under pressure. If the platform cavities in the body so the test procedure will have to
does not lower, repeat the same test method on the be a process of elimination. If the test plug does not
“P2” port. If this also proves negative, test both ports alleviate the problem when inserted into the “SV2”,
for check valve “O” ring leakage. Drain out as much of manual or relief valve cavities and, as tested pre-
the hydraulic oil from the “PI” and “P2” port cavities viously, the check valves are working properly, the
as possible. Monitor the oil level for a minute or so to problem has to be in the “SV1” solenoid valve.
see if the oil level rises. If it does, lower the platform
If the problem is a slow drift of the platform, replace
and remove both check valves and replace the “O”
the smaller “O” ring and back-up ring on the faulty
rings since it is impossible to futher isolate which
valve. Re-install the valve and run operational test. If
check valve “O” ring is leaking.
the problem persists, replace the component valve.
VALVE ASSEMBLY TROUBLE SHOOTING CHART
(REFER TO ILLUSTRATION 2.4-1)
TROUBLE PROBABLE CAUSE REMEDY
1. Oil present around manifold. Defective “O” ring on the valves, Replace “O” rings (index 11, 15, 19 or
fittings or plugs. 29 [as required]) or replace “O” rings
on plugs or fittings.
2. Platform will not raise (pump runs). Relief valve stuck in the open position. Replace relief valve.
Solenoid valves or manual valve stuck Actuate the valve(s) and try to dislodge
in the open (free flow) position. the debris. Check to see that the valve
(solenoid only) is not over tightened.
(160 to 170 in. /lb. max.) If neither of
the above two remedies work, replace
valve.
3. No low speed raise, high speed Check valve (index 4) stuck in the Actuate the lift button several times
raise works properly. open position. to try to dislodge the debris. If that
doesn’t work, replace check valve.
4. Platform will not raise capacity Relief valve not adjusted correctIy. Readjust relief valve in accordance
load. with chart 2.4-2.
5. Platform drifts down (t). Defective “O” rings on check valves, Replace “O” rings (index 5, 10, 14, 18,
solenoid valves manual valve or relief 22 or 28 [as required]) or back-up rings
valve. (index 9, 13, 17 or 27). Check valve
cavity at “O” ring sealing area for nicks
or rough surfaces.
Debris caught in check valve Actuate the valve(s) and try to dislodge
(index 21) seats. the debris. If that doesn’t work, replace
valve.
6. Platform will not lower. Solenoid coil failure. Replace solenoid coil.
Electrical malfunction. Refer to “Electrical” section.
(t) = in excess of drift test.
CHART 2.4-3
Crown 1982 PF-5388-3 Printed in U.S.A.
M2.4 - 07.3 - 003 M2.4 - 07.3 - 003
--- Page 9 ---
C DRIVE UNIT
Drive Unit Removal
NOTE
In most cases repair to the drive unit can be made
with the drive unit in the power unit. However,
should it be necessary to remove the complete
drive unit from truck, the following procedure
should be followed.
Elevate and block the power unit; the drive tire must be off
floor.
Remove steering mechanism, control handle, etc. from top
of drive unit.
SP ONLY. Disconnect brake line at base of mainframe.
Drain brake fluid into container. Unclamp and unthread
brake line from power unit. Trucks built October 1, 1986 and
after (equipped with an electric brake assembly) hydraulic
brake lines do not exist.
Disconnect motor cables from contactor panel; disconnect
brake switch leads.
Figure 0357S-02
Attach a hoist to support plate at top of drive unit, near the
thrust plate. Use caution not to damage brake linkage, if so Remove the drive wheel axle (item 9, Figure 0357S-02).
equipped in the process. Remove the roll pin (item 10) locking the castle nut (item 13)
to the end of the axle. Use a 1 1 /2 in. wrench and remove
Loosen and remove the (3) screws connecting the thrust castle nut from axle. Pull axle from drive unit housing while
plate to the power unit and carefully raise the drive unit until stabilizing the drive tire.
it is clear of the power unit.
Unfasten the four screws (item 32 & 29) and remove the
NOTE cover (item 33) and the gasket (item 34).
The drive unit should be taken to a clean work Remove the retaining ring (item 27), access it through the
area if further disassembly is necessary. Make slots in the face of the second reduction gear (item 28). Large
sure the vented fill plug is to the top side of unit if retaining ring pliers with a locking ratchet such as a Waldes
it is necessary to lay the drive unit down for Truarc No. S-6700, Crown no. 092668, should be used (see
transporting, etc. Figure 3394).
Drive Unit Disassembly
The following disassembly and assembly procedure is a
complete tear down and rebuild operation. Once the prob-
lem has been diagnosed the repair procedure can be used
that covers the necessary repair.
LOWER HOUSING
Drain gear oil.
In order to separate the drive unit top from the drive unit Figure 3394
bottom remove the six screws (item 17, Figure 0060S-01)
securing the two drive unit sections together.
Crown 1985 PF7188-2 Rev. 12/05 M3.0–07.2–016
07 Rev. 12/05
--- Page 10 ---
MAINTENANCE
will cut off battery power when the disconnect handle CONTROL CABLES
is engaged. Cable tension should be checked by
inspection of the disconnect spring located between Control Cable Tension Device
the mast assembly and the rear wall of the power unit. (Refer to illustration 4-2)
The spring should be ½” [12.7 mm] from being fully
1
compressed when properly adjusted. A turn buckle is The control cables which are routed through the mast
used to adjust to this measurement, compensating pulleys are kept properly seated in these pulleys by
for wear. See section 6 “Steering” for the compression means of a tension device located at the base of the
tools to use when replacing cables. main frame. To obtain the proper cable tension,
adjust the spring so there is 8“ [203mm] of extension
GAGES on the spring (14” [356mm] overall). This will be equal
to approximately 19 Ibs. [8.6 kg.] of pull. Fasten the
Hour Meter (TT)
cable ties around the end of the cable grip to help
The hour meter is used to accurately record a lift prevent cable slippage (See illustration).
trucks “running time” in hours. This instrument
serves as an aid in determining a lubrication and
maintenance schedule.
Discharge Meter (V)
A discharge meter is used to monitor the lift trucks
battery voltage while the key switch is in the “on”
position. Observe the operation of the gage. Should
the indicator needle drop into the red area, it is
recommended that a specific gravity test be taken
with a hydrometer to more accurately determine the
battery condition. Depending on the test results, the
battery should either be recharged or exchanged with
a fully charged battery.
Discharge Meter/Lift Interrupt (BDI)
The discharge meter/lift interrupt is used to monitor
the state of charge of the trucks battery. As the state
of charge (specific gravity) falls below a predeter-
mined level, the truck’s lift contactor will drop-out,
permitting no further lifting operations,
The discharge/lift interrupt meter shows the state of
charge of the battery. The pointer will move from “F”
full charge, towards “E” discharged red zone, as the
battery is discharged. As the pointer moves to the
yellow zone, the warning light in the gage will come
on. This is a signal to the operator that ‘he has
approximately 5% battery capacity left before the
truck’s lift contactor will be locked out. If the truck
continues to operate with a low battery, the pointer
will move to the red zone. At this time, lift lock-out
will occur, preventing battery damage caused by deep
discharging.
ILLUSTRATION 4-2
Crown 1981 PF-5100-4 Printed in U.S.A.
M4.0 - 07.2 - 004 M4.0 - 07.2 - 004
--- Page 11 ---
MAINTENANCE
DISCHARGE METER/LIFT INTERRUPT (BDI) Control Cables
The Discharge Indicator shows the state-of-charge in the CONTROL CABLE TENSION DEVICE
battery. During regular operation, the pointer in the gage (Refer to Illustration 4.0-18)
will move from “F”, green zone - full charge, towards “E”,
The control cables which are routed through the mast
red zone - discharged. As the pointer moves into the solid
pulleys are kept properly seated in these pulleys by
yellow zone, the “reserve warning light”, located in the
means of a tension device located at the base of the main
discharge indicator, will begin to flash. This is a warning
frame. To obtain the proper cable tension, adjust the
to the operator to recharge or change to a fully charged
spring so there is 8“ [203 mm] of extension on the spring
battery. If the truck is continued in operation without
(14” [356 mm] overall). This will be equal to approximately
recharge or replacement of battery, the pointer will move
19 Ibs. [8.6 kg.] of pull. Fasten cable ties around the end
into the red zone of the gage. Should this occur the lift
of the cable grip to help prevent cable slippage (See
contactor will drop-out and prevent any lifting opera-
Illustration).
tions, thus preventing battery damage.
CABLE ROUTING
(Refer to Illustration 4.0-18)
Cables are routed through the mast assembly as shown.
Signals carried by each cable are listed in the Illustration.
ILLUSTRATION 4.0-17
Carries signals between SCR contactor panel
1 and platform.
Carries all miscellaneous signals between plat-
2 form and power unit.
Present on wire guide trucks only. Carries signals
3 for wire guidance systems.
ILLUSTRATION 4.0-18
Crown 1986 PF-7585-9 Rev. 10/86 Printed in U.S.A.*
01 REV. 10/86
M4.0 - 07.2 - 018 M4.0 - 07.2 - 018
--- Page 12 ---
MAINTENANCE
EMERGENCY DISCONNECT SWITCH — EDS GUIDANCE SWITCH — GUS
The Emergency Disconnect Switch is located in the con- The Guidance Switch is a toggle switch located in the
trol module assembly, above the raise and lower buttons. panel above the control module assembly of the operator
This switch is actuated by a button in the control module. compartment. This switch is present only on trucks with
Depressing the button removes power from the emergen- a wire guidance system. Placing this switch in the
cy disconnect contactor coil, which opens its contact and “MANUAL” mode will cause the steering of the truck to
the latching contacts around the switch contact. This be controlled by the operator. Placing the switch in the
removes power from the power steering, lift, traction and “AUTOMATIC” mode will, provided wire guidance is ac-
control circuit. To power the truck back up, EDS must be quired, steer the truck automatically. Refer to the Wire
released and the keyswitch cycled OFF, START and back Guidance section of the Service Manual for more detail-
to ON. This switch requires no adjustment. ed description. Adjustment of this switch is not required.
TOW SWITCH — EMS-1
This toggle switch is located on the top flange of the
power unit electrical panel on SP36 series trucks and on
the pump contactor panel of SP42 and SP48 series
trucks. When the truck becomes disabled and must be
towed to the maintenance area, the Tow Switch must be
used to release the electric brake.
When EMS-1 is in the “Tow” position, traction is disabl-
ed. Before placing truck back in service, the Tow Switch ILLUSTRATION 4.0-11
must be placed in the “DRIVE” position to allow normal
truck and brake operation. This switch requires no HORN SWITCH — HNS
adjustment. The Horn Switch is located inside the control module
assembly of the operator compartment, below the raise
and lower buttons. When the horn button is depressed,
the normally open contact of HNS closes and the horn will