FORKLIFTS CGC35S-5, CGC40S-5, CGC45S-5, CGC50C-5, CGC55C-5. Operation and Maintenance Manual

Table of Contents

Information Section

Maintenance Section

Foreword

Jacking Information

100

Inspection, Maintenance and Repair of Lift Truck

Forks

102

Safety Section

Torque Specifications

106

Cooling System Specifications

108

Important Safety Information

Fuel Specifications

110

Safety

Lubricant Specifications

111

Lubricant Viscosities and Refill Capacities

113

Warning Signs and Labels

General Hazard Information

Maintenance Intervals

114

When Required

118

Operation Information

Maintenance Information

Every 10 Service Hours or Daily

122

First 50 - 100 Service Hours or a Week

128

Burn Prevention

Fire or Explosion Prevention

Every 250 Service Hours or Monthly

133

Operator Restraint System (If Equipped)

Every 500 Service Hours or 3 Months

134

Avoiding Lift Truck Tipovers

Every 1000 Service Hours or 6 Months

143

Safety Rules

Every 1500 Service Hours or 9 Months

148

Every 2000 Service Hours or Yearly

151

How to Survive in a Tipover (If Operator

Restraint System Equipped)

Every 2500 Service Hours or 15 Months

155

General Section

Environment Protection Section

Declaration of Conformity

Environment Protection

157

Specifications

Noise and Vibration

Capacity Chart (Not used in Australia)

Index Section

Capacity Chart (with Side Shifter) (Not used in

Australia)

Index

158

Serial Number

Operator's Warning and Identification Plate

Operation Section

Operator’s Station and Monitoring Systems

Seat Switch System (If Equipped)

Lift Truck Controls

Refueling

Before Starting the Engine

Starting the Engine

Lift Truck Operation

Mono-Ped Control System (Option)

Auto Shift Controller ASC - 206 (Standard)

Operating Techniques

Parking the Lift Truck

Lift Fork Adjustment

Storage Information

Transportation Hints

Towing Information

-1-

Information Section

Foreword

Literature Information

This manual should be stored in the operator's

Photographs or illustrations guide the operator

compartment in the literature holder or seat back

through correct procedures of checking, operation

literature storage area.

and maintenance of the CROWN operator restraint

system.

This

manual

contains

safety,

operation,

transportation,

lubrication

and maintenance

SAFE and EFFICIENT OPERATION of a lift truck

information.

depends to a great extent on the skill and alertness

on the part of the operator. To develop this skill the

Some photographs or illustrations in this publication

operator should read and understand the Safe

show details or attachments that can be different

Driving Practices contained in this manual.

from your lift truck. Guards and covers might have

been removed for illustrative purposes.

Forklift trucks seldom tipover, but in the rare event

they do, the operator may be pinned to the ground

Continuing improvement and advancement of

by the lift truck or the overhead guard. This could

product design might have caused changes to your

result in serious injury or death.

lift trucks which are not included in this publication.

Operator training and safety awareness is an

Read, study and keep this manual with the lift truck.

effective way to prevent accidents, but accidents

can still happen. The CROWN operator restraint

Whenever a question arises regarding your lift truck,

system can minimise injuries. The CROWN operator

or this publication, please consult your CROWN

restraint system keeps the operator substantially

dealer for the latest available information.

within the confines of the operator’s compartment

and the overhead guard.

This manual contains information necessary for Safe

Safety

Operation. Before operating a lift truck make sure

that the necessary instructions are available and

The Safety Section lists basic safety precautions. In

understood.

addition, this section identifies the text and locations

of warning signs and labels used on the lift truck.

Read and understand the basic precautions listed in

Operation

the Safety Section before operating or performing

The Operation Section is a reference for the new

lubrication, maintenance and repair on this lift truck.

operator and a refresher for the experienced one. This

section includes a discussion of gauges, switches, lift

truck controls, attachment controls, transportation and

towing information.

Operator Restraint System (If Equipped)

Photographs and illustrations guide the operator through

This manual contains safety, operation and

correct procedures of checking, starting, operating and

maintenance information for the CROWN operator

stopping the lift truck.

restraint system. Read, study and keep it handy.

Operating techniques outlined in this publication are

basic. Skill and techniques develop as the operator

gains knowledge of the lift truck and its capabilities.

WARNING

Your CROWN truck comes equipped with an

operator restraint system. Should it become

necessary to replace the seat for any reason, it

should only be replaced with another CROWN

operator restraint system.

-2-

Information Section

Maintenance

The Maintenance Section is a guide to equipment

care. The illustrated, step-by-step instructions are

grouped by servicing intervals. Items without specific

intervals are listed under “When Required” topics.

Items in the “Maintenance Intervals” chart are

referenced to detailed instructions that follow.

Maintenance Intervals

Use the service hour meter to determine servicing

intervals. Calendar intervals shown (daily, weekly,

monthly, etc.) can be used instead of service hour

meter intervals if they provide more convenient

servicing schedules and approximate the indicated

service hour meter reading. Recommended service

should always be performed at the interval that

occurs first.

Under extremely severe, dusty or wet operating

conditions, more frequent lubrication than is

specified in the “Maintenance Intervals” chart might

be necessary.

Perform service on items at multiples of the original

requirement. For example, at “Every 500 Service

Hours or 3 Months”, also service those items listed

under “Every 10 Service Hours or Daily”.

Environment Management

Note that the Crown internal combustion engine lift

trucks are manufactured under ISO 14001 system

which is harmonized with ISO

9001. Periodic

ENVIRONMENTAL AUDITS & ENVIRONMENTAL

PERFORMANCE EVALUATIONS have been made

by internal and external inspection entities. LIFE-

CYCLE ANALYSIS has also been made throughout

the

total

product

life.

ENVIRONMENT

MANAGEMENT SYSTEM includes DESIGN FOR

ENVIRONMENT from the initial stage of the design.

ENVIRONMENT

MANAGEMENT

SYSTEM

considers environmental laws & regulations,

reduction or elimination of resource consumption as

well as environmental emission or pollution from

industrial activities, energy saving, environment-

friendly product design (lower noise, vibration,

emission, smoke, heavy metal free, ozone depleting

substance free, etc.), recycling, material cost

reduction, and even environmentally oriented

education for the employee.

-3-

Safety Section

Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic

safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations

before an accident occurs. A person must be alert to potential hazards, and use common sense. Persons

must also have the necessary training, skills and tools before attempting to perform these functions.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could

result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read

and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard

warnings are not heeded, bodily injury or death could occur to you or other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “WARNING”

as shown below.

WARNING

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning, explaining the hazard, can be either written or pictorially presented.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

CROWN cannot anticipate every possible circumstance that might involve a potential hazard, and common sense is

always required. The warnings in this publication and on the product are therefore not all inclusive. Before any tool,

procedure, work method or operating technique not specifically recommended by CROWN is used, you must be sure

that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the

operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustration in this publication are on the basis of information available at the time it

was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can

change at any time. These changes can affect the service given to the product. Obtain the complete and most current

information before starting any job. CROWN dealers have the most current information available.

-4-

Safety Section

Warning Signs and Labels

Safety

There are several specific safety signs on your lift

The safety rules and regulations in this section are

truck. Their exact location and description of the

representative of some, but not all rules and

hazard are reviewed in this section. Please take the

regulations that apply to lift trucks. Rules and

time to familiarise yourself with these safety signs.

regulations are paraphrased without representation

that they have been reproduced verbatim.

Make sure that you can read all warning and

instruction labels. Clean or replace these labels if

These fork lift trucks are built to meet Australian

you cannot read the words or see the pictures.

Standard AS2359 for Powered Industrial Trucks,

When cleaning the labels use a cloth, water and

American National Standard, ANSI B56.1 Safety

soap. Do not use solvent, gasoline, etc.

Standard for Low Lift and High Lift Trucks. Since

You must replace a label if it is damaged, missing or

regulations vary from country to country, operate

cannot be read. If a label is on a part that is replaced,

this lift truck in accordance with local regulations.

make sure a new label is installed on the replaced

part. See your dealer for new labels.

CROWN lift trucks are manufactured in accordance

with the National Fire Protection Association (NFPA)

Training Required to Operate or Service

No.

505 and the American National Standards

Institute, Inc.

Industrial Truck Standards

Warning

Development Foundation (ANSI/ITSDF) B56.1,

Safety Standard for Low and High Lift Trucks and,

for European models, according to the regulations

and standards laid down in EU Machinery Directive

2006/42/EC and EMC directive 2014/30/EU.

The most effective method of reducing the risk of

serious injury or death to you or others is for you to

know how to properly operate this lift truck, to be

alert and to avoid actions or conditions that could

cause accidents.

Located on the OVHG.

Do not operate a lift truck if it is in need of

maintenance, repair or appears to be unsafe in any

way. Report all unsafe conditions immediately to

WARNING

your supervisor, then contact your authorised lift

truck dealer. Do not attempt any adjustments or

Improper operation or maintenance could result

repairs unless trained and authorised to do so.

in injury or death. Do not operate or work on the

lift truck unless you are properly trained. Read

and understand the Operation and Maintenance

Manual. Additional manuals are available from

CROWN Lift Truck dealers.

This label also provides allowable lift truck capacity

information.

Located on the front side of the FCU.

-5-

Safety Section

General Warnings to Operator

14. Use extreme care when handling long, high or wide

loads to ensure stability and durability of the truck.

15. Forks should be completely under load and spread

apart as far as load permits.

16. Machine should be equipped with overhead guard

or equivalent protection. Where load requires it, use

load backrest extension. Use extreme caution if

operating without these devices.

17. Parking - Lower lifting mechanism to floor. Put

directional control or shift lever in neutral. Set

parking/secondary brake. Turn “ON - OFF” switch

off. Check wheels if machine is on incline.

Located on the right side of the operator's seat.

Disconnect battery when storing electric machines.

18. Observe safety rules when handling fuel for engine

powered machine and when changing batteries for

WARNING

electric machines.

Only trained and authorised personnel may

19. Avoid overuse of the inching pedal as this may

operate this machine. For safe operation, read

cause the automatic transmission oil to overheat or

and follow the operation and maintenance

the clutch to slip. Do not use as a footrest or for long

Manual furnished with this lift truck and observe

periods of time.

the following warnings:

If user operates continuously pushing work or both

brake pedal and accelerator pedal were depressed

1. Before starting machine. Check all controls and

at the same time, it may cause the automatic

transmission oil to overheat or the clutch to slip.

warning devices for proper operation.

2. Refer to machine identification plate for allowable

machine capacity. Do not overload. Operate

machines equipped with attachments as partially

loaded machines when not handling a load.

3. Put directional control or shift lever in neutral before

“ON - OFF” switch is turned on.

4. Start, turn and brake smoothly. Slow down for turns,

slippery or uneven surfaces. Extremely poor

surfaces should be repaired. Avoid running over

loose objects or holes in the roadway surfaces. Use

extreme caution when turning on inclines.

5. Travel with load as low as possible and tilted back. If

load interferes with visibility, travel with load trailing.

6. On grade operations travel with load up grade.

7. Watch out for pedestrians and obstructions. Check

overhead clearances.

8. Do not permit riders on forks or machine at any time.

9. Do not allow anyone to stand or pass under the

elevated portion of any machine.

10. Be sure operating surface can safely support

machine.

11. Operate machine and attachments only from

operator's position.

12. Do not handle unstable or loosely stacked loads.

13. Use minimum tilt when picking up or depositing a

load.

-6-

Safety Section

Parking brake

No Riders Warning

WARNING

To avoid personal injury, allow no riders. A lift

truck is designed for only one operator and no

riders.

Pull the lever BACK to engage the parking

brake.

Push the lever FORWARD to release the

parking brake.

Located beside the operator’s station.

Applying the parking brake puts the transmission in

NEUTRAL. The parking brake must be applied when

leaving the lift truck and when starting the engine. If

Moving Fan Warning

the operator leaves the seat without applying the

parking brake, an audible alarm will sound.

WARNING

To avoid personal injury, stay clear of moving

fan.

WARNING

When leaving machine apply parking brake!

Parking brake is not automatically applied.

Alarm will sound if parking brake is not applied.

Located on the shroud and upper cover.

WARNING

Correct adjustment is necessary to provide

adequate braking. See the MAINTENANCE

section for adjustment procedures. The lift truck

may creep at engine idle and can cause damage,

injury or death. Always apply the parking brake

when leaving the lift truck. The parking brake is

NOT automatically applied.

-9-

Safety Section

Do not raise loads any higher than necessary and

General Hazard Information

never raise a load higher than 1830 mm (72 in) with

the overhead guard removed.

Always use load backrest extension when the

carriage or attachment does not fully support the

load.

The load backrest extension is intended to prevent

the load or any part of the load from falling

backwards into the operator's station.

When operation the lift truck, do not depend only on

flashing lights or back-up alarm (if equipped) to warn

pedestrians.

Always be aware of pedestrians and do not proceed

Attach a “Do Not Operate” or similar warning tag to

until the pedestrians are aware of your presence

start switch or controls before servicing or repairing

and intended actions and have moved clear of the

the lift truck.

lift truck and/or load.

Do not start or service the lift truck when a “DO NOT

Do not drive lift truck up to anyone standing in front

OPERATE” or similar warning tag is attached to the

of an object.

start switch or controls.

Obey all traffic rules and warning signs.

Wear a hard hat, protective glasses and other

protective equipment as required by job conditions.

Keep hands, feet and head inside the operator

station. Do not hold onto the overhead guard while

Know the width of your attachments so proper

operating the lift truck. Do not climb on any part of

clearance can be maintained when operating near

the mast or overhead guard or permit others to do

fences, boundary obstacles, etc.

so.

Do not wear loose clothing or jewelry that can catch

Do not allow unauthorised personnel to ride on the

on controls or other parts of the lift truck.

forks or any other part of the lift truck, at any time.

When working in a building or dock, observe floor

Keep the lift truck, especially the deck and steps,

load limits and overhead clearances.

free of foreign material such as debris, oil tools and

other items which are not part of the lift truck.

Inhaling Freon gas through a lit cigarette or other

smoking method or inhaling fumes released from a

Secure all loose items such as lunch boxes, tools

flame contacting Freon can cause bodily harm or

and other items which are not part of the lift truck.

death. Do not smoke when servicing air conditioners

or wherever Freon gas may be present.

Know the appropriate work-site hand signals and

who gives them. Accept signals from one person

Never put maintenance fluids into glass containers.

only.

Use all cleaning solutions with care.

Always use the overhead guard. The overhead

guard is intended to protect the lift truck operator

Do not use steam, solvent, or high pressure to clean

from overhead obstructions and from falling objects.

electrical components.

A truck that is used for handing small objects or

Report all needed repairs.

uneven loads must be fitted with a load backrest.

If the lift truck must be operated without the

overhead guard in place due to low overhead

clearance, use extreme care. Make sure there is no

possibility of falling objects from any adjacent

storage or work area. Make sure the load is stable

and fully supported by the carriage and the load

backrest extension (if equipped).

-10-

Safety Section

Operation Information

Mounting and Dismounting

Mount and dismount the lift truck carefully.

Clean your shoes and wipe your hands before

mounting.

Face the lift truck when mounting and dismounting.

Use both hands face the lift truck when mounting

and dismounting.

Inspect the part of the chain that is normally

Use the handgrips for mounting and dismounting.

operated over the crosshead roller. When the chain

bends over the roller, the movement of the parts

Do not try to climb on or off the lift truck when

against each other causes wears.

carrying tools or supplies.

Inspect to be sure that chain link pins do not extend

Never get on or off a moving lift truck.

outside of the bore hole.

Do not use any controls as handholds when entering

If any single link pin is extended beyond its

or leaving the operator's station.

connecting corresponding link, it should be

suspected of being broken inside of its bore hole.

Never get on or off a moving lift truck. Never jump

off the lift truck.

Inspect the chain anchor and the anchor links for

wear.

Keep hands and steering wheel free of slippery

material.

Do not change any factory set adjustment

values(including engine rpm setting) unless you

have both authorization and training. Especially

Before Starting the Lift Truck

Safety equipment and switches may not be removed

or adjusted incorrectly. Repairs, adjustments and

Perform a walk-around inspection daily and at the

maintenances that are not correct can make a

start of each shift. Refer to the topic “Walk-around

dangerous operating condition.

Inspection” in “Every 10 Service Hours or Daily”

section of this manual.

For any checkup, repair, adjustments, maintenance

and all other work concerning your forklift truck,

Adjust the seat so that full brake pedal travel can be

please contact your CROWN dealer. We would like

obtained with the operator's back against the seat

to draw your attention to the fact that any secondary

back.

damages due to improper handling, insufficient

maintenance, wrong repairs or the use of other than

Make sure the lift truck is equipped with a lighting

original CROWN spare parts waive any liability by

system as required by conditions.

CROWN.

Make sure all hydraulic controls are in the HOLD

position.

Make sure the direction control lever is in the

NEUTRAL position.

Make sure the parking brake is engaged.

-11-

Safety Section

Make sure no one is standing and/or working on,

Operating the Lift Truck

underneath or close to the lift truck before operating

the lift truck.

Always keep the lift truck under control.

Operate the lift truck and controls only from the

Obey all traffic rules and warning signs.

operator's station.

Never leave the lift truck with the engine operating,

Make sure the lift truck horn, lights, backup alarm (if

or with the parking brake disengaged.

equipped) and all other devices are working properly.

Operate the engine only in a well ventilated area.

Check for proper operation of mast and attachments.

Lower a mast, with or without load, before turning or

Pay particular attention to unusual noises or erratic

traveling. Tip over could result. Watch out for

movement which might indicate a problem.

overhead obstructions.

Make sure service and parking brakes, steering, and

Always observe floor load limits and overhead

directional controls are operational.

clearance.

Make sure all personnel are clear of lift truck and

travel path.

Start, turn, and brake smoothly, slow down for turns,

grades, slippery or uneven surfaces.

Refer to the topic “Lift Truck Operation” in the

“Operation Section” of this manual for specific

starting instructions.

Use special care when operation on grades. Do not

angle across or turn on grades. Do not use lift truck

on slippery grades. Travel with forks downgrade

when unloaded. Travel with load upgrade.

Do not start the engine or move any of the controls if

there is a “DO NOT OPERATE” or similar warning

Do not overload, or handle offset, unstable, or

tag attached to the start switch or controls.

loosely stacked loads. Refer to load capacity plate

on the lift truck. Use extreme caution when handing

suspended, long, high or wide load.

Before Operating the Lift Truck

Test brakes, steering controls, horn and other

devices for proper operation. Report faulty

performance.

Do not operate lift truck until repaired.

Learn how your lift truck operates. Know its safety

devices. Know how the attachments work.

Before moving the lift truck, look around. Start, turn

and brake smoothly.

An operator must constantly observe his lift truck for

proper operation.

-12-

Safety Section

Loading or Unloading Trucks/Trailers

Do not operate lift trucks on trucks or trailers which

are not designed or intended for that purpose. Be

certain truck or trailer brakes are applied and wheel

chocks in place (or be certain unit is locked to the

loading dock) before entering onto trucks or trailers.

If trailer is not coupled to tractor, make sure the

trailer landing gear is properly secured in place. On

some trailers, extra supports may be needed to

prevent upending or corner dipping.

Tilt elevated load forward only when directly over

Be certain dock plates are in good condition and

unloading area and with load as low as possible.

properly placed and secured. Do not exceed the

rated capacity of dock boards or bridge plates.

Do not stunt ride or indulge in horseplay.

Always look and keep a clear view of the path of

travel.

Lift Truck Parking

When leaving the operator station, park the lift truck

Travel in reverse if load or attachment obstructs

visibility.

in authorised areas only. Do not block traffic.

Use extreme caution if visibility is obstructed.

Stay in designated travel path, clear of dock edges,

ditches, other drop-offs and surfaces which cannot

safely support the lift truck.

Slow down and use extra care through doorways,

intersections and other location where visibility is

reduced.

Slow down for and avoid pedestrians, other vehicles,

obstruction, pot holes and other hazards or objects

in the path of travel.

Always use overhead guards except where

operation conditions do not permit. Do not operate

lift truck in high stacking areas without overhead

guards.



Park the lift truck level, with the forks lowered

and the mast tilted forward until the fork tips

When stacking, watch for falling objects. Use load

touch the floor.

backrest extension and overhead guard.



Move the direction control lever to NEUTRAL.



Engage the parking brake.

Refer to the topic “Operation Techniques” in the



Turn the key switch off and remove the key.

“Operation Section” of this manual.



Turn the disconnect switch to OFF and remove

the key (if equipped).



Block the drive wheels when parking on an

incline.

-13-

Safety Section

Retainer pins, when struck with force, can fly out

Maintenance Information

and injure nearby persons. Make sure the area is

clear of people when driving retainer pins.

Perform all maintenance unless otherwise specified

as follows ;

Wear protective glasses when striking a retainer pin

to avoid injury to your eyes.



Park the lift truck in authorised areas only.



Park the lift truck level, with the forks lowered and

Chips or other debris can fly off objects when struck.

the mast tilted forward until the fork tips touch the

Make sure no one can be injured by flying debris

floor.

before striking any object.



Place the transmission controls in neutral.



Engage the parking brake.



Stop the engine.

Falling Objects Protective



Remove the start switch key and turn the

Structure(FOPS)

disconnect switch OFF (if equipped).

This is an attached guard located above the



Block the drive wheels when parking on an incline.

operator's compartment and secured to the lift truck.

To avoid possible weakening of the Falling Objects

Pressure Air

Protective Structure (FOPS), consult a CROWN

Pressure air can cause personal injury. When using

dealer before altering, by adding weight to, welding

pressure air for cleaning, wear a protective face

on, or cutting or drilling holes into the structure.

shield, protective clothing and protective shoes.

The overhead guard is not intended to protect

The maximum air pressure must be below 205 kPa

against every possible impact. The overhead guard

(30 psi) for cleaning purposes.

may not protect against some objects penetrating

into the operator's station from the sides or ends of

the lift truck.

Fluid Penetration

The lift truck is equipped with an overhead guard

and FOPS as standard. If there is a possibility of

Always use a board or cardboard when checking for

overhead objects falling through the guard, the

a leak. Escaping fluid under pressure, even a

guard must be equipped with smaller holes or a

pinhole size leak, can penetrate body tissue,

Plexiglas cover.

causing serious injury, and possible death. If fluid is

injected into your skin, it must be treated by a doctor

Any altering done that is not specifically authorised

familiar with this type of injury immediately.

by CROWN invalidates CROWN's FOPS

certification.

The protection offered by this FOPS will be impaired

Crushing or Cutting Prevention

if it has been subjected to structural damage.

Support equipment and attachments properly when

Structural damage can be caused by an overturn

working beneath them. Do not depend on hydraulic

accident, by falling objects, etc.

cylinders to hold it up. Any attachment can fall if a

control is moved, or if a hydraulic line breaks.

Do not mount any item such as fire extinguishers,

first aid kits and lights by welding brackets to or

Never attempt adjustments while the lift truck is

drilling holes in any FOPS structure. See your

moving or the engine is running unless otherwise

CROWN dealer for mounting guidelines.

specified.

Where there are attachment linkages, the clearance

in the linkage area will increase or decrease with

movement of the attachment.

Stay clear of all rotating and moving parts.

Keep objects away from moving fan blades.

They will throw or cut any object or tool that falls or

is pushed into them.

Do not use a kinked or frayed wire rope cable. Wear

gloves when handling the wire rope cable.

-14-

Safety Section

Burn Prevention

Fire or Explosion Prevention

Coolant

All fuels, most lubricants and some coolant mixtures

are flammable.

At operating temperature, the engine coolant is hot

and under pressure. The radiator and all lines to

Fuel leaked or spilled onto hot surfaces or electrical

heaters or the engine contain hot water or steam.

components can cause a fire.

Any contact can cause severe burns.

Do not smoke while refueling or in a refueling area.

Steam can cause personal injury.

Do not smoke in areas where batteries are charged,

Check the coolant level only after engine has been

or where flammable materials are stored.

stopped and the filler cap is cool enough to remove

with your bare hand.

Batteries in series can be located in separate

compartments.

Remove the cooling system filter cap slowly to

relieve pressure.

When using jumper cables always connect

positive(+) cable to positive(+) terminal of battery

Cooling system additive contains alkali that can

connected to starter solenoid and negative(-) cable

cause personal injury. Avoid contact with the skin

from external source to starter negative(-) terminal.

and eyes and do not drink.

(If not equipped with starter negative(-) terminal,

Allow cooling system components to cool before

connect to engine block.)

draining.

See the Operation Section of this manual for specific

starting instructions.

Oils

Clean and tighten all electrical connections. Check

daily for loose or frayed electrical wires. Have all

Hot oil and components can cause personal injury.

loose or frayed electrical wires tightened, repaired or

Do not allow hot oil or components to contact the

replaced before operation the lift truck.

skin.

Keep all fuels and lubricants stored in properly

At operation temperature, the hydraulic tank is hot

marked containers and away from all unauthorised

and can be under pressure.

persons.

Remove the hydraulic tank filter cap only after the

Store all oily rags or other flammable material in a

engine has been stopped and the filter cap is cool

protective container, in a safe place.

enough to remove with your bare hand.

Do not weld or flame cut on pipes or tubes that

Remove the hydraulic tank filter cap slowly to relieve

contain flammable fluids. Clean them thoroughly

pressure.

with nonflammable solvent before welding or flame

cutting on them.

Relieve all pressure in air, oil fuel or cooling systems

before any lines, fittings or related items are

Remove all flammable materials such as fuel, oil

disconnected or removed.

and other debris before they accumulate on the lift

truck.

Do not expose the lift truck to flames, burning brush,

Batteries

etc., if at all possible.

Batteries give off flammable fumes which can

Shields, which protect hot exhaust components from

explode.

oil or fuel spray in the event of a line, tube or seal

Do not smoke when observing the battery electrolyte

failure, must be installed correctly.

levels.

Do not operate in areas where explosive gases exist

Electrolyte is an acid and can cause personal injury

or are suspected.

if it contacts skin or eyes.

Always wear protective glasses when working with

batteries.

-15-

Safety Section

Fire Extinguisher

Have a fire extinguisher-type BC and

1.5KG

minimum capacity-on rear overhead guard leg with

latch and know how to use it. Inspect and have it

serviced as recommended on its instruction plate.

LPG

LPG is poisonous and flammable.

Breathing LPG vapors or repeated contact of LPG

with skin can cause personal injury.

Use LPG only in well-ventilated areas.

Do not smoke while changing LPG cylinders.

Use LPG with care to avoid fires.

Do not store replacement LPG cylinders in living

areas or in the operator's compartment.

Do not store LPG cylinders in direct sunlight or at

temperatures above 39°C (102°F).

Discard cylinders in a safe place. Do not puncture or

burn cylinders.

Keep LPG cylinders out of the reach of unauthorised

personnel.

Lines, Tubes and Hoses

Do not bend or strike high pressure lines. Do not

install bent or damaged lines, tubes or hoses.

Repair any loose or damaged fuel and oil lines,

tubes and hoses. Leaks can cause fires. Contact

your CROWN dealer for repair or replacement.

Check lines, tubes and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or

cardboard to check for leaks. See Fluid Penetration

in the Safety Section for more details. Tighten all

connections to the recommended torque. Replace if

any of the following conditions are found.



End fittings damaged or leaking.



Outer covering chafed or cut and wire reinforcing

exposed.



Outer covering ballooning locally.



Evidence of kinking or crushing of the flexible part of

hose.



Armoring embedded in the outer cover.



End fittings displaced.

Make sure that all clamps, guards and heat shields

are installed correctly to prevent vibration, rubbing

against other parts, and excessive heat during

operation.

-16-

Safety Section

Operator Restraint System (If

Equipped)

Warning Signs and Labels

Your CROWN lift truck has the following tipover

warning decals.

Make sure that you can read all safety signs. Clean

or replace these if you cannot read the words or see

the pictures. When cleaning the labels use a cloth,

water and soap. Do not use solvent, gasoline, etc.

You must replace a label if it is damaged, missing or

cannot be read. If a label is on a part that is replaced,

make sure a new label is installed on the replaced

part. See you CROWN Lift Truck dealer for new

The “Survive in tipover” warning is located on the

labels.

overhead guard. It shows the proper use of the

operator restraint system.

The most effective method of preventing serious

injury or death to yourself or others is to familiarise

Seat Adjustment

yourself with the proper operation of the lift truck, to

be alert, and to avoid actions or conditions which

can result in an accident.

WARNING

Tipover can occur if the truck is improperly

operated. In the event of a tipover, injury or

death could result.

Move the lover, slide the seat to the desired position,

and release the lever.

Adjust the seat before operating the lift truck. After

adjusting, set the seat to make sure it is properly

locked. Do not adjust the seat while the truck is in

motion.

WARNING

Do not pace your hand or fingers under the seat.

Injury may occur as the seat moves up and

down.

-17-

Safety Section

Seat Belt

The Operator Restraint System, Prevents the

operator from jumping from the operator’s

compartment in the event of a forward or side

tipover. The system is designed to keep the operator

on the seat and in the operator’s compartment in the

event of a tipover.

3. In the event of a tipover, the seat and restraint

system should be inspected for damage and

replaced, if necessary.

NOTE: Operator restraints shall be examined at

the regular truck service intervals. It is

recommended that they be replaced if any

of the following conditions are found:

1. If the seat belt is torn, if pulling motion is interrupted

during extension of the belt, or if the belt cannot be



Cut or frayed strap

inserted into the buckle properly, replace the seat



Worn or damaged hardware including anchor

belt assembly.

points



Buckle or retractor malfunction



Loose stitching

WARNING

The seat belt may cause the operator to bend at

the waist. If you are pregnant or have suffered

from some abdominal disease, consult a doctor

before you use the seat belt.

Fasten the Seat Belt

2. Belt Maintenance - Every 500 service hours. Check

that the belt fastening works properly and that

winding device is free from run lock when jerked.

Check that the belt is suitably fastened to the seat.

Check that the seat is correctly secured to the hood

and the chassis. On visual inspection, fastenings

must be intact, otherwise, contact the safety

manager.

WARNING

1. Grip the plate (connector) of the belt and pull the

Your CROWN truck comes equipped with a

belt from the retractor. Then insert the plate into the

CROWN operator restraint system. Should it

slot of the buckle until a snap is heard. Pull on the

become necessary to replace the seat for any

belt to confirm it is latched.

reason, it should only be replaced with another

CROWN operator restraint system.

2. Make sure the belt is not twisted.

-19-

Safety Section

Avoiding Lift Truck Tipovers

The stability of the lift truck is determined by the

location of its CG; or, if the truck is loaded, the

Counterbalanced lift truck design is based on the

combined CG of the truck and load. The lift truck

balance of two weights on opposite sides of a

has moving parts and, therefore, has a CG that

fulcrum (the front axle). The load on the forks must

moves. The CG moves forward or backward as the

be balanced by the weight of the lift truck.

mast is tilted forward or backward. The CG moves

up or down as the mast moves up or down. The CG

The location of the centre of gravity of both the truck

and, therefore, the stability of the loaded lift truck, is

and the load is also a factor. This basic principle is

affected by a number of factors such as:

used for picking up a load. The ability of the lift truck

to handle a load is discussed in terms of centre of



the size, weight, shape and position of the load

gravity and both forward and sideways stability.



the height to which the load is lifted



the amount of forward or backward tilt



tyre pressure



dynamic forces created when the lift truck is

accelerated, braked or turned



condition and grade of surfaces on which the lift

truck is operated

The point within an object, at which the whole weight

of the object may be regarded as being

concentrated, is called the centre of gravity or CG. If

the object is uniform, its geometric centre will

coincide with its CG. If it is not uniform, the CG

could be at a point outside of the object. When the

lift truck picks up a load, the truck and load have a

new combined CG.

These same factors are also important for unloaded

lift trucks. They tip over sideways easier than a

loaded lift truck carrying its load in the lowered

position.

-21-

Safety Section

The location of the CG in the vertical direction is the

same as the horizontal dimension.

Remember that, unless otherwise indicated, the

capacity load shown on the nameplate is for a

standard lift truck with standard backrest, forks and

mast, and having no special-purpose attachment. In

addition, the capacity load assumes that the load

centre is no further from the top of the forks than it is

from the face of the backrest. If these conditions do

not exist, the operator may have to reduce the safe

operating load because the truck stability may be

reduced. The lift truck should not be operated if its

capacity/nameplate does not indicate capacity load.

For the lift truck to be stable (not tip over forward or

to the side), the CG must stay within the area of the

NOTE: If the load is not uniform, the heaviest

lift truck stability base - a triangular area between

portion should be placed closer to the

the front wheels and the pivot of the steer wheels. If

backrest and centreed on the forks.

the CG moves forward of the front axle, the lift truck

will tip forward. If the CG moves outside of the line

on either side of the stability base, the lift truck will

NOTICE

tip to the side.

1. Capacity/Nameplates originally attached to

forklifts sold by CROWN shall not be removed,

WARNING

altered or replaced without CROWN's approval.

Dynamic forces (braking, acceleration, turning)

2. CROWN assumes no responsibility for lift trucks

also affect stability and can produce tipover

placed in service without a valid CROWN

even when the CG is within the stability triangle.

Nameplate.

3. If necessary to change your specification,

contact your CROWN lift truck dealer.

The capacity load of the lift truck is shown on the

capacity/nameplate riveted to the truck. It is

determined by the weight and load centre. The load

centre is determined by the location of the CG of the

load.

The load centre shown on the nameplate is the

horizontal distance from the front face of the forks,

or the load face of an attachment, to the CG of the

load.

-22-

Safety Section

Safety Rules

Do not operate a lift truck unless you are in the

operator’s seat. Keep hands and feet inside the

operator’s compartment. Do not put any part of the

body outside of the operator’s compartment. Never

Only properly trained and authorised personnel

should operate forklift trucks. Wear a hard hat and

put any part of body into the mast structure or

safety shoes when operating a lift truck. Do not wear

between the mast and the truck

loose clothing.

Do not start, stop, turn or change direction suddenly

or at high speed. Sudden movement can cause the

Inspect and check the condition of your forklift truck

lift truck to tip over. Slow the speed of your truck and

using the operator's check list before starting work.

use the horn near corners, exits, entrances, and

Immediately report to your supervisor any obvious

near people.

In case of a truck with the steering knob, Do not

operate the steering knob suddenly, to prevent

accident caused by quick turning.

Do not operate your truck in unauthorised areas.

Know your forklift truck and think safety. Do not

compromise safety. Follow all safety rules and read

all warning signs.

Never operate a lift truck with wet hands or shoes.

Never hold any controls with grease on your hands.

Your hands or feet will slide off of the controls and

cause an accident.

-23-

Safety Section

Do not raise anyone on the forks of your lift truck.

Do not overload. Always handle loads within the rated

Do not let other people ride on the truck.

capacity shown on the capacity plate.

Lift trucks are designed to carry loads, not people.

Do not add extra counterweight to the truck.

An overload can cause the truck to roll over and

cause injury to personnel and damage to the lift

Do not operate your truck without the load backrest

extension and overhead guard. Keep the load

against the backrest with the mast tilted backward.

Do not drive on soft ground.

Observe all signs, especially those on maximum

permitted floor loadings, elevator capacities and

clearance heights.

Handle loads carefully and check them closely for

stability and balance.

Do not lift or move loads that are not safe. Do not

pick up an off centre load. Such a load increases the

possibility of a tipover to the side. Make sure loads

are correctly stacked and positioned across both

forks. Always use the proper size pallet. Position the

Do not drive on slippery surfaces.

forks as wide as possible under the load. Position

Sand, gravel, ice or mud can cause a tipover. If

loads evenly on the forks for proper balance. Do not

unavoidable, slow down.

lift a load with one fork.

-24-

Safety Section

Do not permit anyone to stand or walk under the

Do not elevate the load with the mast tilted forward.

load or lifting mechanism. The load can fall and

Do not tilt the elevated loads forwards.

cause injury or death to anyone standing below.

This will cause the lift truck to tip over forward.

Do not jump off if your truck starts to tip over.

Look out for overhead obstructions when raising or

Stay in your seat to survive.

stacking loads. Do not travel with a raised load. Do

not travel with the mast raised. The lift truck can roll

over and cause injury or death to you or other

personnel.

Go up ramps in forward direction and down ramps in

reverse direction when moving loads.

Never elevate a load with the forklift truck on an incline.

Do not move loose loads that are higher than the load

Go straight off and straight down. Use an assistant

backrest.

when going up or down a ramp with a bulky load.

Be alert for falling loads when stacking.

Travel with the load tilted back and the forks as low as

possible.

This will increase stability to the truck and load and

permit better visibility for you.

-25-

Safety Section

Do not stack or turn on ramps.

Do not drive in forward direction when loads restrict your

Do not attempt to pick-up or deposit a load unless the lift

visibility. Operate your lift truck in reverse to improve

truck is level. Do not turn on or drive across an incline.

visibility except when moving up a ramp.

Be careful when operating a lift truck near the edge of a

Do not go over rough terrain. If unavoidable, slow down.

loading dock or ramp. Maintain a safe distance from the

Cross railroad tracks slowly and diagonally whenever

edge of docks, ramps and platforms.

possible. A railroad crossing can give a loaded forklift

Always watch tail swing.

truck a real jolt. For smoother crossing, cross the

The truck can fall over the edge and cause injury or

railroad diagonally so one wheel crosses at a time.

death.

Do not operate on bridge plates unless they can support

Avoid running over loose objects.

the weight of the truck and load.

Look in the direction of travel. Look out for other persons

Make sure that they are correctly positioned.

or obstructions in your path of travel.

Put blocks on the vehicle you enter to keep it from

An operator must be in full control of his lift truck at all

moving.

times.

-26-

Safety Section

Do not operate your truck close to another truck.

Park your lift truck in authorised areas only. Fully lower

Always keep a safe distance from other trucks and

the forks to the floor, put direction lever in NEUTRAL

make sure there is enough distance to stop safely.

position, engage the parking brake, and turn the key to

Never overtake other vehicles.

the OFF position. Remove the key and put blocks

behind the wheels to prevent the truck from rolling. Shut

off your forklift truck when leaving it unattended.

Check the condition of your forklift truck after the day's

work.

Do not use your lift truck to push or tow another truck.

Do not let another push or tow your truck.

If a truck will not move, call a service technician.

Exhaust from all internal combustion engines

contains carbon monoxide, a colorless, odorless,

tasteless, poisonous gas. Exposure to carbon

monoxide can cause serious injury or health

problems, including death. And avoid unnecessary

idling of the engine. If nausea, dizziness or

headaches are experienced stop the truck and seek

fresh air.

Forklift trucks may only be refueled at specially reserved

locations. Switch off the engine when refueling.

Smoking and handling of naked flames during refueling

are strictly prohibited. This prohibition also applies

during the changing of the LPG (liquefied propane gas)

tank.

Mop up spilt fuel and do not forget to close the fuel tank

before restarting the engine.

-27-

Safety Section

Do not operate forklifts near flammable or

An unloaded forklift may be easier to tip over than a

combustible materials.

loaded truck.

To avoid the discoloration, deformation or

When traveling without a load, the risk of lateral

combustion of materials (such as lumber, veneer

overturn is greater.

board, paper products and other similar items),

always park at least 30 cm (12 inches) away from

them.

There are many special attachments available to

replace the forks on a lift truck.

All carry safety implications and special training in

Forklift trucks are not cars. They often have small

their operation is highly recommended.

tyres, no suspension, and are very heavy.

The forklift's centre of gravity will also change when

carrying loads.

Avoid uneven bumps, pot holes and other hazards

whenever possible.

The counterweight draw bar should not be used for

towing the forklift or for towing another forklift.

Towing is only advised in emergencies, by trained

operators and at low speed, no faster than 2 km/h,

Carrying a load suspended on a chain or a cable

to a convenient location for repair.

may unbalance a truck.

Take extra care around pedestrians with a

suspended load as it may sway or even strike them.

-28-

General Section

Declaration of Conformity

We,

Manufacturer

Doosan Corporation Industrial Vehicle BG.

468, Injung-ro, Dong-gu, Incheon, Korea 22503

Authorized Representative and Compiler of Technical File According to 2006/42/EC

Doosan Industrial Vehicle Europe N.V, Mr. Chankyo Chung

Europark Noord 36 A 9100 Sint-Niklaas BELGIUM

herewith declare

that the following equipment conforms with the appropriate requirements of the

Directives 2006/42/EC (Machinery Directive), 2000/14/EC as amended by 2005/88/EC

(Noise Emission in the environment by equipment for use outdoors), 97/68/EC amended

by 2004/24/EC (Exhaust Gas Directive) and 2014/30/EU (EMC Directive) based on its

design and type, as brought into circulation by us.

Description of the equipment:

Type

: Lift Truck, Combustion-engine driven, Counterbalanced

Function

: Lifting and Moving materials

Family

: CGC40S-5 Series

Model Name

: CGC35S-5, CGC40S-5, CGC45S-5

CGC50C-5, CGC55C-5

-30-

General Section

Specifications

CHARACTERISTICS

TIER-Ⅲ

Manufacturer

CROWN

Model

GC35S-5

GC40S-5

Capacity

at rated load center

lb (kg)

7,000 (3,500)

8,000 (4,000)

Load center

in (mm)

24 (600)

Power type

Elec, Diesel , LPG, Gasoline

LPG

Operator type

Stand-on, Driver-seated

Drider-seated

Tire type

P=Pneu, E=Solid Soft, C=Cushion

Wheels(x=driven)

number, front/rear

x2/2

DIMENSIONS

Max. Fork Height

with STD 2-Stage Mast

in (mm)

113.4 (2,880)

10 Free lift

with STD 2-Stage Mast

in (mm)

6.3 (160)

Fork carriage

ISO class

III

47.2x5.9x2.0

Length x Width x Thickness

in (mm)

(1,200x150x50)

Forks

12.2x44.6

Fork Spacing (min X Max)

in (mm)

(310 x 1,132)

Tilt of mast

Forward/Backward

deg

5/6

Length to Fork Face

in (mm)

105.6 (2,682)

105.7 (2,686)

Overall Width

in (mm)

50.0 (1,270)

Mast Lowered Height

in (mm)

84.1 (2,135)

Overall dimensions

Mast Extended Height

in (mm)

162.0 (4,115)

Overhead guard Height

in (mm)

84.8 (2,155)

Seat Height

in (mm)

44.3 (1,125)

21 Turning radius

Minimum outside

in (mm)

92.9 (2,360)

94.5 (2,400)

22 Load Moment constant

in (mm)

19.9 (505)

90° Stacking aisle

in (mm)

112.8 (2,865)

114.4 (2,905)

PERFORMANCE

11.2/12.7

Travel, loaded/unloaded

mhp(km/h)

(18/19)

98.4/108.3

94.5/108.3

Speed

Lift, loaded/unloaded

fpm(mm/s)

(500/550)

(480/550)

104.3/88.6

98.4/88.6

Lowering, loaded/unloaded

fpm(mm/s)

(530/450)

(500/450)

at 1.0 km/h, loaded

8,488 (3,850)

8,455 (3,835)

27 Drawbar pull

lb (kg)

at 1.6 km/h, loaded

8,025 (3,640)

7,981 (3,620)

at 1.0 km/h, loaded

28 Gradeability

at 1.6 km/h, loaded

WEIGHT

Total weight

Unloaded

lb (kg)

12,060 (5,470)

12,895 (5,850)

16,935/2,125

18,435/2,460

with loaded, front/rear

lb (kg)

(7,970/1,000)

(8,690/1,160)

Axle load

4,915/7,145

4,695/8,200

without loaded, front/rear

lb (kg)

(2,230/3,240)

(2,130/3,720)

CHASSIS

Number of front/rear

2/2

Tires

Size, front single

22x9x16

Size, rear

18x6x12-1/8

18x7x12-1/8

35 Wheel base

in (mm)

64.2 (1,630)

41.0/41.1

Tread

Front/Rear

in (mm)

(1,042/1,044)

loaded, at the lowest point

in (mm)

5.1 (130)

Ground clearance

loaded, at center of wheelbase

in (mm)

5.1 (130)

Service

foot/hyd

Brake

Parking

hand/mech

DRIVE

41 Battery

Voltage/Ampere-hour

V/AH

12/75

Manufacturer/Model

PSI / 4X 4.3L

Rated output (at rpm)

kW/rpm

70.0/2,500

Engine

Max. torque

lb_ft/rpm

209.4/1,800

Cycle/Cylinders/Displacement

4/6/4,294

type

Powershift

Transmission

No. of Speeds forward/reverse

2/2

2,755/2,030

3,045/2,030

Operating pressure

System/Attachment

psi (bar)

(190/140)

(210/140)

-31-

General Section

TIER-Ⅲ

CROWN

GC45S-5

GC50C-5

GC55C-5

9,000 (4,500)

10,000(5,000)

12,000 (5,500)

24 (600)

LPG

Drider-seated

x2/2

113.4 (2,880)

103.5 (2,630)

6.3 (160)

47.2x5.9x2.0

47.2x5.9x2.4

(1,200x150x50)

(1,200x150x60)

13.4x50.8

(340 x 1,290)

5/6

111.3 (2,828)

113.3 (2,878)

118.5 (3,010)

55.9 (1,420)

86.0 (2,185)

169.9 (4,315)

160.0 (4,065)

84.8 (2,155)

44.3 (1,125)

99.6 (2,530)

101.6 (2,580)

103.5 (2,630)

19.9 (505)

20.3 (515)

119.5 (3,035)

121.9 (3,095)

123.8 (3,145)

11.2/12.7

(18/19)

94.5/98.4

88.6/98.4

(480/500)

(450/500)

98.4/86.6

94.5/86.6

(500/440)

(480/440)

8,466 (3,840)

8,411 (3,815)

8,367 (3,795)

8,003 (3,630)

7,937 (2,638)

7,893 (3,580)

14,330 (6,500)

15,410 (6,990)

16,180 (7,340)

20,730/2,600

22,530/2,880

24,865/3,315

(9,775/1,225)

(10,630/1,360)

(11,330/1,510)

5,500/8,830

5,555/9,855

5,290/10,890

(2,495/4,005)

(2,520/4,470)

(2,400/4,940)

2/2

22X12X16

18X8X12.1

70.5 (1,790)

43.9/41.1

(1,116/1,044)

5.1 (130)

foot/hyd

hand/mech

12/75

PSI / 4X 4.3L

70.0/2,500

209.4/1,800

4/6/4,294

Powershift

2/2

3,045/2,030

3,335/2,030

(210/140)

(230/140)

-32-

General Section

Operator's Warning and Identification Plate

Familiarise yourself with the OPERATOR'S WARNING Plate, and IDENTIFICATION, LIFT CAPACITY and

ATTACHMENT PLATES. Do not exceed capacity as equipped load ratings.

Identification, Lift Capacity and

Operator’s Warning Plate

Attachment Plate

Located on the cowl to the right side of the steering

Located on the front side of the FCU.

column.

Lift Truck Capacity Rating

Do not exceed allowable lift truck working capacity

load ratings.

The capacity of the lift truck is given by weight and

distance to the load centre. For example, a capacity

of 1200kg (2640lb) at 600mm (24in) means that the

lift truck can lift 1200kg (2640lb) if the load centre is

600 mm (24in) from both the vertical and horizontal

faces of the forks.

Before attempting to lift any load, ensure that the

weight and load centre combination is within the

capacity of the lift truck as shown on the capacity

rating plate. To determine the load centre, measure

the distance from the face of the carriage to the

gravitational centre of the load.

The rated capacity on the plate refers to the capacity

of the lift truck as it left the factory. Subsequent

changes of any form to the equipment or battery can

alter the lift truck’s rating.

The rated capacity of the lift truck applies to

operating conditions where the lift truck is on level

ground. The capacity of the lift truck is reduced on

inclines.

Below are abbreviations that may appear on the

Identification, Lift Capacity and Attachment Plate

and their meanings.

-39-

General Section

Mast Abbreviations

Attachment Abbreviations (Includes

Special Forks)

STD - Standard Mast (single inner member, low free lift)

SC - Special Carriage-increased width, height or

FF - Full Free Lift Mast (single inner member with high

outreach

free lift duplex cylinder)

SSS - Shaft-type Sideshift Carriage

FFT - Triple Lift Mast (two inner members) with either

low or full free lift characteristics.

HSS - Hook-type Sideshift Carriage (ITA)

QUAD - Quadruple (Quad) Mast (with three inner

CW - Counterweight

members)

SF - Special Forks

NOTE : When only a mast-type is listed on the

identification plate, a standard carriage

SWS - Swing Shift, Sideshift

and forks are used.

RAM - Ram or Boom

DBCBH - Double Cube Block Handler

HFP - Hydraulic Fork Positioner

CR - Crane Arm or Crane Boom

TH - Tyre Handler

CTH - Container Handler

LPP - Load Push-Pull Device

CC - Carton Clamp

RC - Roll Clamp

LS - Load Stabiliser

PWH - Pulp Wood Handler

SS-ST - Sideshift-Side Tilt Carriage

-40-

Operation Section

1. Engine Oil Pressure Indicator Light -

(MIL) as Diagnostic Faults Codes (DFC) or flash

Indicates insufficient engine oil pressure.

codes, and viewed in detail with the use of service

The light will come on when the ignition

tool software. When the ignition key is turned ON

switch is turned to the ON position. The light should

the MIL will perform a self-test, illuminate once and

go off after the engine is started. If the light turns on

then go OFF. If a detected fault condition exists, the

while operating the lift trucks, insufficient engine oil

fault or faults will be stored in the memory of the

pressure is indicated. Park the lift truck and stop the

engine control module (ECM). Once a fault occurs

engine.

the MIL will illuminate and remain ON. This signals

the operator that a faults has been detected by the

2. Alternator Indicator Light - Indicates if

SECM.

the battery charging system is operational.

The light will come on when the ignition

9. Seat Belt Warning Light (If Equipment) -

switch is turned to the ON position.

Indicates when the seat belt does not

fastened by operator.

The light should go off after the engine is started,

indicating the alternator is producing sufficient

The light will come on when the ignition switch is

voltage to charge the battery. If the light turns on

turned to the on position. The light should go off

with the engine running, check the alternator

after engine is started.

charging system for a malfunction.

10. Service Hour Meter - Indicates the total

3. Diesel Engine Start Preheat Indicator

number of hours the engine and the lift truck

Light - The light will come ON when the

have operated. The hour meter will operate

key is turned to the ON position from the

when the ignition switch is in the ON position,

OFF position. This indicates that the glow plugs are

whether the engine is running or not. The hour

preheating the pre-combustion chambers for easier

meter is used to determine lubrication and

starting.

maintenance intervals.

The amount of time needed to preheat the pre-

11. Parking indicator light- The light will come

combustion chambers is approximately seven

ON when the parking lever is applied.

seconds, depending on the surrounding air

temperature. When the light goes OFF the

12. Front Floodlights- Push down on the

maximum pre-combustion chamber temperature has

switch(17), to the first step, to turn the front

been reached and the key can be turned to the

floodlights on.

START position to start the engine.

Front and Rear Floodlights - Push down on the

switch(17), to the second step, to turn both the front and

6. Engine Coolant Temperature

rear floodlights on. The floodlights are optional.

Gauge - Shows current temperature

of the engine coolant. If the gauge

13. Transmission Neutral Position Light -

pointer moves beyond the red band

Indicates the neutral position of transmission.

during the operation, the engine is

overheated. Park the lift truck and

14. Drive Axle Oil Indicator Light (OCDB

stop the engine.

only) - Indicates too hot drive axle oil.

The light will be ON when the ignition switch is

Check the cooling system for any defect. The

in the ON position and must go OFF when the engine is

pointer will be in the red band when the coolant

running.

temperature reaches approximately 110 °C on all

Do not continue to operate the lift truck if the light is

engines.

ON during operation.

7. Transmission Oil Temperature

15. Low Level Light of LP GAS

Gauge - Shows transmission oil

temperature If the gauge pointer

Indicates the low Level of LP GAS (LP

moves beyond the red band during

only) (If Equipped)

operation, the engine is overheated.

Park the lift truck and stop the

16. Directional Turning Indicator Light

engine.

17. Front and Rear Floodlishts Switch -

Check the system for any defect. The pointer will be

The front floodright is ON when push down

in the red band when the transmission oil

switch to the first step. The front and rear

temperature reaches approximately 125 °C.

floodlights are ON when push down switch to

the second step.

8. PSI Engine Malfunction Indicator

Lamp (MIL) -PSI engine control system

18. Brake Fluid Oil Light (If Equipped) -

The light is ON when the brake fluid oil of

are equipped with built-in fault

brake reservoir comes down to low level

diagnostics. Detected system faults can

position. Refill the proper brake fluid oil if its

be displayed by the Malfunction Indicator Lamp

light is ON.

-42-

Operation Section

Circuit Breaker

Electrical Disconnect Switch (If E

quipped)

Typical Example

LP Engine Truck

Circuit Breaker

- Protects the main

1. ON-Connects the battery for electrical

electrical circuits. To reset the circuit

power to all electrical circuits.

breaker, push the button in. Located in the

engine compartment.

2. OFF-Disconnects the battery from all

electrical circuits.

Tilt Steering Column

Seat

NOTE: Seat arrangements may vary. Basic

operation will be similar.

Seat adjustment should be checked at the beginning

of each shift and when operators change.

Lock the seat into position before operating, to

prevent an unexpected seat change.

Adjust seat to allow full brake pedal travel with

operator’s back against seat back.

To adjust the steering column, push down the kn

ob(1), and move the steering column to the desir

ed position, then release the knob(1).

NOTE: The seat can only be correctly adjusted

with the operator fully seated.

-44-

Operation Section

Seat Switch System (If Equipped)

NOTICE

Prior to operating the lift truck, be sure to

understand and check the SEAT SWITCH SYSTEM.

While in normal operation and on level ground,

select a direction with the directional lever and with

the park brake released. You will note that the truck

will move slowly in the selected direction. If you lift

yours hips off of the seat, within three seconds, the

SEAT SWITCH SYSTEM will desengage the

transmission allowing the truck to coast but not

automatically stop.

To restore the lift truck to normal operation, while

sitting in the operator's seat depress the brake pedal

The lift truck is equipped with a SEAT SWITCH

to hold the lift truck, return the directional lever to the

SYSTEM. In normal operation if the direction lever is

neutral position, and then reselect a direction of

placed in either forward or reverse, the lift truck will

travel (either forward or reverse). The transmission

move at a speed proportional to the accelerator

will then re-engage.

pedal's position. If the operator leavers the seat

without setting the parking brake, within three

If seat or seat switch replacement becomes

seconds after leaving the seat, the SEAT SWITCH

necessary, be sure to use genuine CROWN lift truck

SYSTEM will automatically disengage the

parts. Lift trucks should never be operated without

transmission. The directional lever, however, will

an operational SEAT SWITCH SYSTEM.

remain in that forward or reverse location although

internally the transmission will have shifted into

neutral.

Before exiting the lift truck, the parking brake should

always be applied.

WARNING

WHEN LEAVING MACHINE APPLY PARKING

BRAKE!

PARKING BRAKE IS NOT AUTOMATICALLY

APPLIED.

NOTE: Some trucks may be equipped (ask your

dealer if this applies to your truck) with an

alarm that will sound if the parking brake is

not applied when leaving the machine.

-45-

Operation Section

Lift Truck Controls

Direction Control Lever

Transmission Inching Control

Pedal

1. Forward - Push the lever forward for

FORWARD direction travel.

Inching Control Pedal - Pushing down on

the inching pedal, modulates the hydraulic

2. Neutral - Move the lever to centre position

pressure to the clutch packs, permitting disc

for NEUTRAL.

slippage.

3. Reverse

- Pull the lever back for

Further pushing on the pedal completely relieves

REVERSE direction travel.

clutch pack pressure and applies the service brakes

to stop and hold the lift truck.

NOTE: The purpose of the inching control pedal is

Transmission Speed Range Lever

to provide precise inching control at slow

travel speed, with high engine rpm. This is

used for fast hydraulic lift during load

approach, pickup or positioning.

1. High - Rotate the lever counterclockwise for

HIGH speed range.

2. Low - Rotate the lever clockwise for LOW speed

range.

-46-

Operation Section

Refueling

Changing LP Tanks

WARNING

Only trained, authorised personnel should fill or

exchange LP tanks.

Personnel engaged in filling of LP containers

should wear protective clothing such as face

shield, long sleeves and gauntlet gloves.

Do not refuel or store LP powered lift trucks near

any underground entrance, elevator shafts or

any other place where LP could collect in a

Close the fuel inlet valve at the LP tank. Run the

pocket causing a potentially dangerous

condition.

engine until it stops, then turn off the ignition switch

and the electrical disconnect switch (if equipped).

Examine all LP containers before filling and

Disconnect the fuel supply line.

again before reuse, for damage to various valves,

liquid gauge, fittings and hand valve wheels.

All defective or damaged LP containers must be

removed from service.

Explosive fumes may be present during

refueling.

Do not smoke in refueling areas.

Lift truck should be refueled only at designated

safe locations. Safe outdoor locations are

preferable to indoor locations.

Stop the engine and get off the lift truck during

refueling.

Loosen the retaining clamps and remove the tank.

The careless handling of LP containers can

Check the mounting to be sure the locating pin

result in a serious accident.

(dowel) is not missing or broken.

Use extreme care when transporting containers

to prevent damage to them.

NOTICE

If the location pin (dowel) is missing or broken, be

1. Park the lift truck on level ground, with the parking

sure the pin is replaced.

brake applied, the transmission in NEUTRAL, the

forks lowered and the engine running at low idle.

-49-

Operation Section

WARNING

The LP tank must not extend past the

counterweight.

12. Clamp the tank securely.

13. Connect the fuel supply line.

14. Open the fuel valve by slowly turning the valve

counterclockwise. If the fuel valve is opened too

quickly, a back pressure check valve will shut off the

fuel supply. If this happens, close the fuel valve

completely. Wait five seconds and then open the

6. Check to be sure that the LP warning plate is in

fuel valve very slowly.

position on the lift truck, and is legible.

15. Inspect the LP fuel lines and fittings with a soap

7. Check to be sure the replacement tank is of the

solution after filling the tank or when looking for

correct type.

leaks.

8. Inspect the replacement tank for damage such as

dents, scrapes or gouges and for indication of

leakage at valves or threaded connections.

9. Check for debris in the relief valve, for damage to

various valves and liquid level gauge.

10. Inspect the quick-disconnect couplings for

deterioration, damage or missing flexible seals.

11. Position the replacement tank so that the locating

pin (dowel) is in place.

-50-

Operation Section

Before Starting the Engine

Walk - Around Inspection

Make a thorough walk-around inspection before

mounting the lift truck or starting the engine. Look

for such items as loose bolts, debris buildup, oil or

coolant leaks. Check condition of tyres, mast,

carriage, forks or attachments. Have repairs made

as needed and all debris removed.

7. Inspect the overhead guard and cabin for damage

and loose or missing mounting bolts.

8. Inspect the hydraulic system for leaks, worn hoses

or damaged lines.

9. Look for transmission and drive axle leaks on the lift

truck and on the ground.

1. Inspect the operator's compartment for loose items

and cleanliness.

2. Inspect the instrument panel for broken or damaged

indicator lights or gauges.

3. Test the horn and other safety devices for proper

operation.

Typical Example

LP Engine Truck

10. Inspect the engine compartment for oil, coolant and

fuel leaks.

11. Inspect common parts and drive axle, mast etc for

grounded, loosen or missing mounting bolts.

4. Inspect the mast and lift chains for wear, broken

links, pins and loose rollers.

5. Inspect the carriage, forks or attachments for wear,

damage and loose or missing bolts.

6. Inspect the tyres and wheels for cuts, gouges,

foreign objects, inflation pressure and loose or

missing bolts.

12. Measure the engine crankcase oil level with the dip

stick. Maintain the oil level between the MAX. and

MIN., (or FULL and ADD) notches on the dip stick.

-51-

Operation Section

Starting the Engine

Prestart Conditions

LP Engine

NOTE: The engine will not start unless the

WARNING

transmission directional control lever is in

the NEUTRAL position.

LP fuel is flammable and can cause personal

injury.

Inspect LP fuel lines and fitting for leaks.

Inspect tank for secure mounting.

1. Engage the parking brake, if not already engaged.

Place the transmission directional control lever in the

NEUTRAL position.

1. Open the tank fuel valve by slowly turning the valve

counterclockwise. Observe the LP gauge(if

equipped).

2. Turn the engine ignition switch to the START

position. Release it when the engine starts.

3. If the engine does not start, do not press on the

accelerator pedal. Turn the starter switch to OFF

position, then repeat step 2 and depress the

accelerator pedal slightly during cranking.

4. Allow the engine to warm up slowly.

2. If Lift trucks are equipped with electrical disconnect

switches, the engine will not start unless the

disconnect switch is in the ON (closed) position.

Before starting, turn the disconnect switch to the

OFF(open) position.

NOTICE

When you restart the engine after turning off it, wait

4 to 5 seconds and restart it to protect the starter.

-53-

Operation Section

Electronic Controlled Spark-Ignition Engines

PSI 4.3L LP Engine

The primary components of the fuel system are the fuel supply, direct electronic pressure regulator (DEPR),

fuel mixer, electronic throttle control (ETC) device, 2-Stage convertor, engine control module (ECM), and a

catalytic converter. The system operates on a slightly positive fuel pressure. Primary fuel pressure can be

measured at the LD 2-Stage convertor. Secondary fuel pressure command and actual fuel pressure is

monitored by the ECM.

To obtain maximum effect from the catalyst and accurate control of the air fuel ratio, the emission certified

engine is equipped with an onboard computer or Engine Control Module (ECM). The ECM is a 32 bit

controller which receives input data from sensors mounted to the engine and fuel system and then outputs

various signals to control engine operation.

One specific function of the controller is to maintain a closed loop fuel control which is accomplished by use of

the Heated Exhaust Gas Oxygen sensor (HEGO) mounted in the exhaust system. The HEGO sensor sends a

voltage signal to the controller which then outputs signals to the EPR to change the amount of fuel being

delivered from the regulator or mixer to the engine.

The controller also performs diagnostic functions on the fuel system and notifies the operator of engine

malfunctions by turning on a Malfunction Indicator Light (MIL) mounted in the dash. Malfunctions in the

system are identified by a Diagnostic Trouble Code (DTC) number. In addition to notifying the operator of the

malfunction in the system, the controller also stores the information about the malfunction in its memory. A

technician can than utilize a computerized diagnostic scan tool to retrieve the stored diagnostic code and by

using the diagnostic charts in this manual to determine the cause of the malfunction. In the event a technician

does not have the computerized diagnostic tool, the MIL light can be used to identify the diagnostic code to

activate the “blink” feature and count the number of blinks to determine the diagnostic code number to locate

the fault in the system.

The primary components of the Gasoline Multi Point Fuel Injection (MPFI) fuel system are the gasoline fuel

tank, electric fuel pump, fuel pressure and temperature sensor manifold, fuel filter and fuel rail.

This engine is equipped with a fuel injector rail that does not have a pressure regulator or a return circuit to

the fuel tank. Fuel pressure for this engine is regulated by the engine’s ECM. The ECM receives fuel

pressure and temperature feedback from the gasoline fuel sensor manifold and uses this information to

control the ground side of the fuel pump. Fuel pressure is regulated by the ECM pulse width modulating

(PWM) the fuel pump. The fuel pressure and temperature sensor manifold has a return or “bleed” circuit that

connects back to the equipment fuel tank. This circuit is used to bleed off any vapor that develops in the line

and returns a small amount of fuel to the tank. The fuel comes from the fuel tank and passes through the fuel

pump. Fuel exits the fuel pump, passes through the filter and then enters the fuel pressure and temperature

manifold assembly. Fuel flows through the feed circuit and is delivered to the fuel injector rail. Fuel that enters

the bleed circuits through the by-pass valve in the manifold is returned to the fuel tank.

-55-

Operation Section

Basic Troubleshooting(LP)

The PSI 4.3L fuel systems are equipped with built-in fault diagnostics. Detected system faults can be

displayed by the Malfunction Indicator Lamp (MIL) and are covered in the Advanced Diagnostics section.

Items such as fuel level, plugged fuel lines, clogged fuel filters and malfunctioning pressure regulators may

not set a fault code by the Engine Control Module (ECM).

Below are basic checks that should be made before referring to the Advanced Diagnostics section, if engine

or drivability problems are encountered.

Locating a problem in a propane engine is done exactly the same way as with a gasoline engine.

Consider all parts of the ignition and mechanical systems as well as the fuel system.

FUEL SYSTEM SYMPTOM DIAGNOSTICS

Checks

Action

Before using this section, you should have performed On Board Diagnostic (OBD)

Check and determined that:

1. The ECM and MIL are operating correctly.

Before Using

2. There are no Diagnostic Trouble Codes (DTCs) stored, or a DTC exists but

This Section

without a MIL.

Several of the following symptom procedures call for a careful visual and physical

check. These checks are very important as they can lead to prompt diagnosis and

correction of a problem.

1. Verify the customer complaint.

2. Locate the correct symptom table.

3. Check the items indicated under that symptom.

4. Operate the equipment under the conditions the symptom occurs. Verify HEGO

Fuel System Check

switching between lean and rich. IMPORTANT! Normal HEGO switching

indicates the fuel system is in closed loop and operating correctly at that

time.

5. Take a data snapshot using the DST under the condition that the symptom

occurs to review at a later time.

• Check all ECM system fuses and circuit breakers.

• Check the ECM ground for being clean, tight and in its proper location.

• Check the vacuum hoses for splits, kinks and proper connections.

• Check thoroughly for any type of leak or restriction.

• Check for air leaks at all the mounting areas of the intake manifold sealing

surfaces.

• Check for proper installation of the mixer assembly.

• Check for air leaks at the mixer assembly.

Check the ignition wires for the following conditions:

Visual and Physical

• Cracking

Checks

• Hardening

• Proper routing

• Carbon tracking.

Check the wiring for the following items: proper connections, pinches or cuts.

The following symptom tables contain groups of possible causes for each symptom.

The order of these procedures is not important. If the DST readings do not indicate a

problem, then proceed in a logical order, easiest to check or most likely to cause the

problem.

-57-

Operation Section

INTERMITTENT

Checks

Action

DEFINITION: The problem may or may not turn ON the (MIL) or store a Diagnostic Trouble Code (DTC).

Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables

Preliminary Checks

with this condition may result in the replacement of good parts.

Faulty electrical connections or wiring can cause most intermittent problems.

Check the suspected circuit for the following conditions:

• Faulty fuse or circuit breaker, connectors poorly mated, terminals not fully seated

in the connector (backed out). Terminals not properly formed or damaged.

• Wire terminals poorly connected.

Faulty Electrical

• Terminal tension is insufficient.

Connections

• Carefully remove all the connector terminals in the problem circuit in order to

or Wiring

ensure the proper contact tension.

• If necessary, replace all the connector terminals in the problem circuit in order to

ensure the proper contact tension (except those noted as “Not Serviceable”). See

section Wiring Schematics.

• Checking for poor terminal to wire connections requires removing the terminal

from the connector body.

If a visual and physical check does not locate the cause of the problem, operate the

Operational Test

vehicle with the DST connected. When the problem occurs, an abnormal voltage or

scan reading indicates a problem circuit.

The following components can cause intermittent MIL and no DTC(s):

• A defective relay.

• Switch that can cause electrical system interference. Normally, the problem will

Intermittent MIL

occur when the faulty component is operating.

Illumination

• The improper installation of add on electrical devices, such as lights, 2-way

radios, electric motors, etc.

• The ignition secondary voltage shorted to a ground.

• The MIL circuit or the Diagnostic Test Terminal intermittently shorted to ground.

• The MIL wire grounds.

To check for the loss of the DTC Memory:

1. Disconnect the TMAP sensor.

Loss of DTC

2. Idle the engine until the MIL illuminates.

Memory

3. The ECM should store a TMAP DTC which should remain in the memory when

the ignition is turned OFF. If the TMAP DTC does not store and remain, the ECM

is faulty.

-58-

Operation Section

NO START

Checks

Action

DEFINITION: The engine cranks OK but does not start.

Preliminary Checks

None

Use the DST to :

• Check for proper communication with both the ECM

ECM Checks

• Check all system fuses engine fuse holder. Refer to Engine Controls Schematics.

• Check battery power, ignition power and ground circuits to the ECM. Refer to

Engine Control Schematics. Verify voltage and/or continuity for each.

• Check the TMAP sensor.

Sensor Checks

• Check the cam angle sensor for output (RPM).

Important: A closed LPG manual fuel shut off valve will create a no start condition.

• Check for air intake system leakage between the mixer and the throttle body.

Fuel System

Verify proper operation of the low pressure lock-off solenoids.

Checks

• Verify proper operation of the fuel control solenoids.

• Check the fuel system pressures.

• Refer to the LPG Fuel System Diagnosis.

• Check for proper mixer air valve operation.

Note: LPG being a gaseous fuel requires higher secondary ignition system voltages

for the equivalent gasoline operating conditions.

1. Check for the proper ignition voltage output with J 26792 or the equivalent.

2. Verify that the spark plugs are correct for use with LPG.

Check the spark plugs for the following conditions:

Ignition System

• Wet plugs.

Checks

• Cracks.

• Wear.

• Improper gap.

• Burned electrodes.

• Heavy deposits.

• Check for bare or shorted ignition wires.

• Check for loose ignition coil connections at the coil.

-59-

Operation Section

HARD START

Checks

Action

DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or

may start but immediately dies.

Preliminary Checks

Make sure the vehicle’s operator is using the correct starting procedure.

• Check the Engine Coolant Temperature sensor with the DST. Compare the

engine coolant temperature with the ambient air temperature on a cold engine. If

the coolant temperature reading is more than 10 degrees greater or less than the

Sensor Checks

ambient air temperature on a cold engine, check for high resistance in the

coolant sensor circuit. Check the cam angle sensor.

• Check the Throttle Position (TPS) and Foot Pedal Position (FPP) sensor

connections.

Important: A closed LPG manual fuel shut off valve will create an extended crank

OR no start condition.

• Verify the excess flow valve is not tripped or that the manual shut-off valve is not

closed.

Fuel System

Checks

Check mixer assembly for proper installation and leakage.

• Verify proper operation of the low pressure lock-off solenoid.

• Verify proper operation of the EPR.

• Check for air intake system leakage between the mixer and the throttle body.

Check the fuel system pressures. Refer to the Fuel System Diagnosis.

Note: LPG being a gaseous fuel requires higher secondary ignition system voltages

for the equivalent gasoline operating conditions.

• Check for the proper ignition voltage output with J 26792 or the equivalent.

• Verify that the spark plugs are the correct type and properly gapped.

Check the spark plugs for the following conditions:

• Wet plugs.

• Cracks.

Ignition System

• Wear.

Checks

• Burned electrodes.

• Heavy deposits

• Check for bare or shorted ignition wires.

• Check for moisture in the distributor cap.

• Check for loose ignition coil connections.

Important:

1. If the engine starts but then immediately stalls, check the cam angle sensor.

2. Check for improper gap, debris or faulty connections.

-61-

Operation Section

CUTS OUT, MISSES

Checks

Action

DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load

increases, but normally felt below 1500 RPM. The exhaust has a steady spitting sound at idle, low speed,

or hard acceleration for the fuel starvation that can cause the engine to cut-out.

Preliminary Checks

None

1. Start the engine.

2. Check for proper ignition output voltage with spark tester J 26792.

3. Check for a cylinder misfire.

4. Verify that the spark plugs are the correct type and properly gapped.

Remove the spark plugs and check for the following conditions:

• Insulation cracks.

Ignition System

• Wear.

Checks

• Improper gap.

• Burned electrodes.

• Heavy deposits.

Visually/Physically inspect the secondary ignition for the following:

• Ignition wires for arcing and proper routing.

• Cross- ring.

• Ignition coils for cracks or carbon tracking

Perform a cylinder compression check. Check the engine for the following:

• Improper valve timing.

Engine Mechanical

• Improper valve clearance.

Checks

• Worn rocker arms.

• Worn camshaft lobes.

• Broken or weak valve springs.

• Check the intake and exhaust manifold passages for casting ash.

Check the fuel system:

Fuel System

• Plugged fuel filter.

Checks

• Low fuel pressure, etc. Refer to LPG Fuel System Diagnosis.

• Check the condition of the wiring to the low pressure lock-off solenoid.

Check for Electromagnetic Interference (EMI), which may cause a misfire condition.

Using the DST, monitor the engine RPM and note sudden increases in rpms

Additional Check

displayed on the scan tool but with little change in the actual engine rpm.

If this condition exists, EMI may be present. Check the routing of the secondary

wires and the ground circuit.

-63-

Operation Section

HESITATION, SAG, STUMBLE

Checks

Action

DEFINITION: The engine has a momentary lack of response when putting it under load. The condition can

occur at any engine speed. The condition may cause the engine to stall if it’s severe enough.

Preliminary Checks

None

• Check the fuel pressure. Refer to LPG Fuel System Diagnosis.

• Check for low fuel pressure during a moderate or full throttle acceleration. If the

fuel pressure drops below specification, there is possibly a faulty low pressure

Fuel System

regulator or a restriction in the fuel system.

Checks

• Check the TMAP sensor response and accuracy.

• Check Shut-Off electrical connection.

• Check the mixer air valve for sticking or binding.

• Check the mixer assembly for proper installation and leakage. Check the EPR.

Note: LPG being a gaseous fuel requires higher secondary ignition system voltages

for the equivalent gasoline operating conditions. If a problem is reported on LPG and

not gasoline, do not discount the possibility of a LPG only ignition system failure and

test the system accordingly.

Ignition System

Checks

• Check for the proper ignition voltage output with J 26792 or the equivalent. Verify

that the spark plugs are the correct type and properly gapped.

• Check for faulty spark plug wires.

• Check for fouled spark plugs.

• Check for manifold vacuum or air induction system leaks.

Additional Check

• Check the alternator output voltage.

-64-

Operation Section

BACKFIRE

Checks

Action

DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping

noise.

Preliminary Checks

None

Important! LPG, being a gaseous fuel, requires higher secondary ignition

system voltages for the equivalent gasoline operating conditions. The ignition

system must be maintained in peak condition to prevent backfire.

• Check for the proper ignition coil output voltage using the spark tester J26792 or

the equivalent.

• Check the spark plug wires by connecting an ohmmeter to the ends of each wire

in question. If the meter reads over 30,000 ohms, replace the wires.

Ignition System

• Check the connection at ignition coil.

Checks

• Check for deteriorated spark plug wire insulation.

Remove the plugs and inspect them for the following conditions:

• Wet plugs.

• Cracks.

• Wear.

• Improper gap.

• Burned electrodes.

• Heavy deposits.

Important! The LPG Fuel system is more sensitive to intake manifold leakage

than a gasoline fuel supply system.

Check the engine for the following:

• Improper valve timing.

Engine Mechanical

• Engine compression.

Check

• Manifold vacuum leaks.

• Intake manifold gaskets.

• Sticking or leaking valves.

• Exhaust system leakage.

• Check the intake and exhaust system for casting flash or other restrictions.

Fuel System

Perform a fuel system diagnosis. Refer to LPG Fuel System Diagnosis.

Checks

-65-

Operation Section

LACK OF POWER, SLUGGISHNESS, OR SPONGINESS

Checks

Action

DEFINITION: The engine delivers less than expected power.

• Refer to the LPG Fuel system OBD System Check.

• Compare the customer’s vehicle with a similar unit to verify customer has an

actual problem. Do not compare the power output of the vehicle operating on

LPG to a vehicle operating on gasoline as the fuels do have different drive feel

Preliminary Checks

characteristics.

• Remove the air filter and check for dirt or restriction.

• Check the vehicle transmission.

• Refer to the OEM transmission diagnostics.

• Check for a restricted fuel filter, contaminated fuel, or improper fuel pressure.

Refer to LPG Fuel System Diagnosis.

• Check for the proper ignition output voltage with the spark tester J 26792 or the

equivalent.

Fuel System

• Check for proper installation of the mixer assembly. Check all air inlet ducts for

Checks

condition and proper installation.

• Check for fuel leaks between the EPR and the mixer.

• Verify that the LPG tank manual shut-off valve is fully open.

• Verify that liquid fuel (not vapor) is being delivered to the EPR.

• Check the Heated Exhaust Gas Oxygen Sensors (HEGO) for contamination and

Sensor Checks

performance. Check for proper operation of the TMAP sensor.

• Check for proper operation of the TPS and FPP sensors.

Check the exhaust system for a possible restriction:

Exhaust System

• Inspect the exhaust system for damaged or collapsed pipes.

Checks

• Inspect the muffler for signs of heat distress or for possible internal failure.

• Check for possible plugged catalytic converter.

Check the engine for the following:

• Engine compression.

Engine Mechanical

• Valve timing.

Check

• Improper or worn camshaft.

• Refer to Engine Mechanical in the Service Manual.

• Check the ECM grounds for being clean, tight, and in their proper locations.

• Check the alternator output voltage.

If all procedures have been completed and no malfunction has been found, review

Additional Check

and inspect the following items:

• Visually and physically, inspect all electrical connections within the suspected

circuit and/or systems.

• Check the DST data.

-66-

Operation Section

ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING

Checks

Action

DEFINITION: The engine runs unevenly at idle. If severe enough, the engine may shake.

Preliminary Checks

None.

Check the Heated Exhaust Gas Oxygen Sensors (HEGO) performance:

• Check for silicone contamination from fuel or improperly used sealant. If

contaminated, the sensor may have a white powdery coating result in a high but

false signal voltage (rich exhaust indication). The ECM will reduce the amount of

Sensor Checks

fuel delivered to the engine causing a severe driveability problem.

Check the Temperature Manifold Absolute Pressure (TMAP) sensor response and

accuracy.

• Check for rich or lean symptom that causes the condition.

• Drive the vehicle at the speed of the complaint.

• Monitoring the oxygen sensors will help identify the problem.

• Check for a sticking mixer air valve.

Fuel System

• Verify proper operation of the EPR.

Checks

• Perform a cylinder compression test. Refer to Engine Mechanical in the Service

Manual.

• Check the EPR fuel pressure. Refer to the LPG Fuel System Diagnosis.

• Check mixer assembly for proper installation and connection.

• Check for the proper ignition output voltage using the spark tester J26792 or the

equivalent.

• Verify that the spark plugs are the correct type and properly gapped.

Remove the plugs and inspect them for the following conditions:

• Wet plugs.

• Cracks.

Ignition System

• Wear.

Checks

• Improper gap.

• Burned electrodes.

• Blistered insulators.

• Heavy deposits.

Check the spark plug wires by connecting an ohmmeter to the ends of each wire in

question. If the meter reads over 30,000 ohms, replace the wires.

Important: The LPG Fuel system is more sensitive to intake manifold leakage than

the gasoline fuel supply system.

• Check for vacuum leaks. Vacuum leaks can cause a higher than normal idle and

Additional Checks

low throttle angle control command.

• Check the ECM grounds for being clean, tight, and in their proper locations.

Check the battery cables and ground straps. They should be clean and secure.

Erratic voltage may cause all sensor readings to be skewed resulting in poor idle

quality.

-67-

Operation Section

Advanced Diagnostics(PSI 4.3L LP Engine)

The Fuel system has built-in diagnostics for system trouble shooting. The system has a dash mounted

malfunction indicator lamp (MIL) that provides indications of engine or fuel system related problem. Most

engine control system related problems that affect emissions or driveability of the vehicle will set a (DTC)

diagnostic trouble code and illuminate the MIL.

The MIL serves as notification to the operator of a problem related to the emission control system so the

driver can arrange for service as soon as possible. It will also display DTCs that have been stored due to a

system malfunction.

The MIL should illuminate when the key is in the ON position and the engine is not running. This feature

verifies that the lamp is in proper working order. If the MIL does not illuminate with the vehicle key

ON/engine OFF, repair it as soon as possible. Once the engine is in start or run mode, the MIL should turn

off. If the lamp remains on while the engine is in the start or run mode a diagnostic trouble code may be set.

The MIL will be turned OFF after three (3) consecutive run cycles or by clearing the active code with the

Diagnostic Scan Tool (DST).

Diagnostic Trouble Codes are set when the GCP (Electronic Control Module) runs a diagnostic self test and

the test fails. When a DTC is set, the ECM will illuminate the MIL on the instrument panel and also save the

DTC in memory. The ECM will continue to run the self test. If the system continues to fail the test, the lamp

will stay illuminated and the DTC is stored as an active DTC. If the self test runs and passes, the DTC will be

stored as historic DTC. All DTCs are stored as historic faults until they are cleared. Most DTCs will

automatically clear from memory if the DTC does not reset within 50 to 100 consecutive engine run cycles.

While a Diagnostic Trouble Code is current for a sensor, the ECM may assign a default “limp home” value and

use that value in its control algorithms. All of the system diagnostic self-tests run continuously during normal

vehicle operation.

The Diagnostic Trouble Codes can be read by using either the MIL lamp or a laptop computer. Diagnostic

Trouble Codes can be cleared from memory with a laptop computer, or by turning the ignition key to the OFF

position and removing the ECM power fuse or battery cable for at least 15 seconds.

If more than one DTC is detected, start the diagnostic repair with the lowest DTC number set. Diagnose

each problem to correction unless directed to do otherwise by the diagnostic chart. The DTCs are numbered

in order of importance. Both DTC 112 and DTC122 pertain to the oxygen sensor, so it is possible that a

repair that corrects DTC 112 may also correct the problem causing the DTC 122.

Diagnostic test charts contained in this manual refer to the DST to be connected and in the “System Data

Mode.” This simply means that the DST is connected and communicating with the PC. In some instances

the chart will call out a special test mode. An example of this would be instructions for the DST to be

connected and in the DBW (drive by wire) mode. Always be sure to follow the special instructions to avoid a

false diagnosis of fuel system components.

-69-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes)

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

NONE

None, used as end of the fault list

Signifies the end of one pass

NONE

identification

through the fault list

Check ECT sensor connector and

wiring for a short to GND

ECTRangeLow

SECM (Signal) Pin B15 To ECT Pin 3

141

Coolant Sensor failure or

TurnOnMil

SECM (Sensor GND) Pin B1 to ECT

(14)

shorted to GND

Pin 1

SECM (System GND) Pin A16, B17

Check if ECT sensor connector is

(1) TurnOnMil

ECTRangeHigh

disconnected or for an open ECT circuit

151

(2) DelayedEngine

Coolant sensor disconnected

SECM (Signal) Pin B15 to ECT Pin 3

(15)

Shutdown

or open circuit

SECM (Sensor GND) Pin B1 to

(3) CheckEngineLight

ECT Pin 1

Check coolant system for radiator

blockage, proper coolant level and for

ECTOverTempFault

leaks in the system.

Engine coolant temperature

(1) TurnOnMil

Possible ECT short to GND, check

is high. The sensor has

161

(2) DelayedEngine

ECT signal wiring

measured an excessive

(16)

Shutdown

SECM (Signal) Pin B15 to ECT Pin 3

coolant temperature typically

(3) CheckEngineLight

SECM (Sensor GND) Pin B1 to

due to the engine

ECT Pin 1

overheating.

SECM (System GND) Pin A16, B17

Check regulator for coolant leaks

ECT_IR_Fault

Check for coolant system problems,

171

Engine coolant temperature

None

e.g. defective or stuck thermostat

not changing as expected

FuelSelectConflict

Check fuel select switch connection for

Conflict in fuel select signals,

a short to GND

181

normally set if both of the

TurnOnMil

SECM (SIGNAL) Pin A12

fuel select signals are

SECM (SIGNAL) Pin A15

shorted to ground

SECM (Sensor GND) Pin B1

Check Crankshaft sensor connections

CrankEdgesFault

SECM (SIGNAL) Pin B5 to Crank

No crankshaft signal when

sensor Pin 3

engine is known to be

193

None

SECM (Sensor GND) PIN B1 to Crank

rotating, broken crankshaft

sensor Pin 2

sensor leads or defective

Switched 12V to Crank sensor Pin 1

crank sensor

Check for defective Crank sensor

(*) Fault actions shown are default values specified by the OEM.

-70-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION*

FIRST CHECK

CrankSyncFault

Check Crankshaft sensor connections

Loss of synchronization on

SECM (SIGNAL) Pin B5 to Crank

the crankshaft sensor,

sensor Pin 3

194

normally due to noise on the

None

SECM (Sensor GND) Pin B1 to Crank

signal or an intermittent

sensor Pin 2

connection on the crankshaft

Switched 12V to Crank sensor Pin 1

sensor

Check for defective Crank sensor

Check throttle connector connection

TPS1RangeLow

and TPS1 sensor for an open circuit or

TPS1 sensor voltage out of

short to GND

221

range low, normally set if the

TurnOnMil

SECM Pin B23 (signal) to ETC Pin 6

(22)

TPS1 signal has shorted to

SECM Pin B1 (sensor GND) to

ground, circuit has opened or

ETC Pin 2

sensor has failed

SECM (system GND) Pin A16, B17

Check throttle connector connection

TPS2RangeLow

and TPS2 sensor for an open circuit or

TPS2 sensor voltage out of

short to GND

range low, normally set if the

222

TurnOnMil

SECM Pin B4 (signal) to ETC Pin 5

TPS2 signal has shorted to

SECM Pin B1 (sensor GND) to

ground, circuit has opened or

ETC Pin 2

sensor has failed

SECM (system GND) Pin A16, B17

TPS1RangeHigh

Check throttle connector and TPS1

TPS1 sensor voltage out of

sensor wiring for a shorted circuit

231

range high, normally set if

TurnOnMil

SECM Pin B23 (signal) to ETC Pin 6

(23)

the TPS1 signal has shorted

SECM Pin B1 (sensor GND) to

to power or the ground for

ETC Pin 2

the sensor has opened

TPS2RangeHigh

Check throttle connector and TPS1

TPS2 sensor voltage out of

sensor wiring for a shorted circuit

range high, normally set if

SECM Pin B4 (signal) to ETC

232

TurnOnMil

the TPS2 signal has shorted

Pin 5

to power or the ground for

SECM pin B1 (sensor GND) to

the sensor has opened

ETC Pin 2

Check the throttle connector and pins

for corrosion.

To check the TPS disconnect the

TPS1AdaptLoMin

throttle connector and measure the

241

Learned closed throttle end

None

resistance from:

(24)

of TPS1 sensor range lower

TPS Pin 2 (GND) to Pin 6 (TPS1

than expected

SIGNAL)

(0.7  ± 30%)

TPS Pin 3 (PWR) to Pin 6 (TPS1

SIGNAL)

(1.4  ± 30%)

(*) Fault actions shown are default values specified by the OEM.

-71-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

Check the throttle connector and pins

for corrosion.

To check the TPS disconnect the

TPS2AdaptLoMin

throttle connector and measure the

Learned closed throttle end

242

None

resistance from:

of TPS2 sensor range lower

TPS Pin 2 (GND) to Pin 5 (TPS2

than expected

SIGNAL) (1.3K  ± 30%)

TPS PIN 3 (PWR) to PIN 5 (TPS2

SIGNAL) (0.6K  ± 30%)

TPS1AdaptHiMax

251

Learned WOT end of TPS1

N/A

None

(25)

sensor range higher than

expected

TPS2AdaptHiMax

Learned WOT end of TPS2

N/A

252

None

sensor range higher than

expected

TPS1AdaptHiMin

Learned WOT end of TPS1

N/A

271

None

sensor range lower than

expected

TPS2AdaptHiMin

Learned WOT end of TPS2

N/A

272

None

sensor range lower than

expected

TPS1AdaptLoMax

Learned closed throttle end

N/A

281

None

of TPS1 sensor range higher

than expected

TPS2AdaptLoMax

Learned closed throttle end

N/A

282

None

of TPS2 sensor range higher

than expected

TPS_Sensors_Conflict

TPS sensors differ by more

than expected amount

NOTE: The TPS is not a

(1) TurnOnMil

291

Perform checks for DFCs 241 & 242

serviceable item and can

(2) Engine Shutdown

only be repaired by

replacing the DV-EV

throttle assembly.

(*) Fault actions shown are default values specified by the OEM.

-72-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

Check TMAP connector and MAP

signal wiring for an open circuit

TMAP Pin 4 to SECM Pin B18 (signal)

MAPTimeRangeLow

TMAP Pin 1 to SECM Pin B1

Manifold Absolute Pressure

(sensor GND)

sensor input is low, normally

TMAP Pin 3 to SECM Pin B24

331

set if the TMAP pressure

(XDRP +5 Vdc)

None

(33)

signal wire has been

Check the MAP sensor by

disconnected or shorted to

disconnecting the TMAP connector and

ground or the circuit has

measuring at the sensor

opened to the SECM

TMAP Pin 1(GND) to Pin 4 (pressure

signal KPA) (2.4k - 8.2k)

TMAP Pin 3 (power) to Pin 4 (pressure

signal KPA) (3.4k - 8.2k)

Check TMAP connector and MAP

signal wiring for an open circuit

TMAP Pin 4 to SECM Pin B18 (signal)

MAPRangeLow

TMAP Pin 1 to SECM Pin B1

Manifold Absolute Pressure

(sensor GND)

sensor input is low, normally

TMAP Pin 3 to SECM Pin B24

set if the TMAP pressure

(1) TurnOnMil

(XDRP +5 Vdc)

332

signal wire has been

(2) CutThrottle

Check the MAP sensor by

disconnected or shorted to

disconnecting the TMAP connector and

ground or the circuit has

measuring at the sensor:

opened to the SECM

TMAP Pin 1(GND) to Pin 4 (pressure

signal KPA) (2.4k - 8.2k)

TMAP Pin 3 (power) to Pin 4 (pressure

signal KPA) (3.4k - 8.2k)

MAPTimeRangeHigh

Check TMAP connector and MAP

Manifold Absolute Pressure

signal wiring for a shorted circuit

Sensor Input is High,

TMAP Pin 4 to SECM Pin B18 (signal)

normally set if the TMAP

TMAP Pin 1 to SECM Pin B1

pressure signal wire has

(sensor GND)

become shorted to power,

TMAP Pin 3 to SECM Pin B24

341

shorted to the IAT signal, the

(XDRP +5 Vdc)

None

(34)

TMAP has failed or the

Check the MAP sensor by

SECM has failed.

disconnecting the TMAP connector and

measuring at the sensor

TMAP Pin 1(GND) to Pin 4 (pressure

signal KPA) (2.4k - 8.2k)

TMAP Pin 3 (power) to Pin 4 (pressure

signal KPA) (3.4k - 8.2k)

-73-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

MAPRangeHigh

Check TMAP connector and MAP

Manifold Absolute Pressure

signal wiring for a shorted circuit

Sensor Input is High,

TMAP Pin 4 to SECM Pin B18 (signal)

normally set if the TMAP

TMAP Pin 1 to SECM Pin B1

pressure signal wire has

(sensor GND)

become shorted to power,

TMAP Pin 3 to SECM Pin B24

shorted to the IAT signal, the

(1) TurnOnMil

(XDRP +5 Vdc)

342

TMAP has failed or the

(2) CutThrottle

Check the MAP sensor by

SECM has failed

disconnecting the TMAP connector

and measuring at the sensor:

TMAP Pin 1(GND) to Pin 4 (pressure

signal KPA) (2.4k - 8.2k)

TMAP Pin 3 (power) to Pin 4 (pressure

signal KPA) (3.4k - 8.2k)

MAP_IR_HI

Check for vacuum leaks. Check that

351

MAP sensor indicates higher

None

TMAP sensor is mounted properly.

pressure than expected

Possible defective TMAP sensor.

MAP_IR_LO

352

MAP sensor indicates lower

None

Possible defective TMAP sensor.

pressure than expected

MAP_STICKING

Check that TMAP sensor is mounted

353

MAP sensor not changing as

None

properly. Possible defective TMAP

expected

sensor.

Check TMAP connector and IAT signal

wiring for a shorted circuit

IATRangeLow

TMAP Pin 2 to SECM Pin B12 (signal)

Intake Air Temperature

TMAP Pin 1 to SECM Pin B1

Sensor Input is Low normally

371

(sensor GND)

set if the IAT temperature

TurnOnMil

(37)

To check the IAT sensor of the TMAP

sensor wire has shorted to

disconnect the TMAP connector and

chassis ground or the sensor

measure the IAT resistance

has failed.

Resistance is approx 2400 ohms at

room temperature.

Check TMAP connector and IAT signal

IATRangeHigh

wiring for a shorted circuit

Intake Air Temperature

TMAP Pin 2 to SECM Pin B12 (signal)

Sensor Input is High

TMAP Pin 1 to SECM Pin B1

381

normally set if the IAT

(sensor GND)

TurnOnMil

(38)

temperature sensor wire has

To check the IAT sensor of the TMAP

been disconnected or the

disconnect the TMAP connector and

circuit has opened to the

measure the IAT resistance

SECM.

Resistance is approx 2400 ohms at

room temperature.

IAT_IR_Fault

Check connections to TMAP sensor.

391

Intake Air Temperature not

None

Check that TMAP sensor is properly

changing as expected

mounted to manifold.

(*) Fault actions shown are default values specified by the OEM.

-74-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

Check coil driver wiring and connector

for open circuit

SECM Pin A9 (EST1) to OEM ignition

EST1_Open

system. See application note.

EST1 output open, possibly

Verify GND on ignition module Pin A

421

TurnOnMil

open EST1 signal or

(of both connectors)

defective spark module

Verify +12 Vdc on ignition module Pin

B (of both connectors)

Refer to application manual for specific

engine details.

Check coil driver wiring and connector

for shorts

SECM Pin A9 (EST1) to ignition

EST1_Short

module Pin D (4-pin connector)

EST1 output shorted high or

Verify GND on ignition module Pin A

431

low, EST1 signal shorted to

TurnOnMil

(of both connectors)

ground or power or defective

Verify +12 Vdc on ignition module Pin

spark module

B (of both connectors)

Refer to application manual for specific

engine details.

ETC_Sticking

Check for debris or obstructions inside

Electronic Throttle Control is

the throttle body

sticking. This can occur if the

Perform the throttle test using the

throttle plate (butterfly valve)

Service Tool and re-check for fault

inside the throttle bore is

Check throttle-plate shaft for bearing

sticking. The plate sticking

wear

can be due to some type of

Check the ETC driver wiring for an

(1) TurnOnMil

461

obstruction, a loose throttle

open circuit

(2) EngineShutdown

(26)

plate, or worn components

SECM Pin A17 to ETC + Pin 1

(3) CutThrottle

shaft bearings.

SECM Pin A18 to ETC - Pin 4

NOTE: The throttle

Check the ETC internal motor drive by

assembly is not a

disconnecting the throttle connector

serviceable item and can

and measuring the motor drive

only be repaired by

resistance at the throttle

replacing the DV-EV

TPS Pin 1 (+DRIVER) to

throttle assembly.

Pin 4 (-DRIVER) ~3.0-4.0

Check the ETC driver wiring for an

ETC_Open_Fault

open circuit

Electronic Throttle Control

SECM Pin A17 to ETC + Pin 1

Driver has failed, normally

SECM Pin A18 to ETC - Pin 4

set if either of the ETC driver

Check the ETC internal motor drive by

471

None

signals have opened or

disconnecting the throttle connector

become disconnected,

and measuring the motor drive

electronic throttle or SECM is

resistance at the throttle

defective.

TPS Pin 1 (+DRIVER) to

Pin 4 (-DRIVER) ~3.0-4.0

(*) Fault actions shown are default values specified by the OEM.

-75-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

ETCSpringTest

Electronic Throttle Control

Spring Return Test has

failed. The SECM will

perform a safety test of the

throttle return spring

following engine shutdown. If

(1) TurnOnMil

481

this spring has become weak

Perform throttle spring test by cycling

(2) EngineShutdown

(28)

the throttle will fail the test

the ignition key and re-check for fault

and set the fault.

NOTE: The throttle

assembly is not a

serviceable item and can

only be repaired by

replacing the DV-EV

throttle assembly.

Check ETC driver wiring for a shorted

circuit

HbridgeFault_ETC

SECM Pin A17 to ETC + Pin 1

Electronic Throttle Control

SECM Pin A18 to ETC - Pin 4

Driver has failed.

Perform the throttle test using the

Indeterminate fault on

491

Service Tool and re-check for fault

Hbridge driver for electronic

TurnOnMil

(29)

Check the ETC internal motor drive by

throttle control. Possibly

disconnecting the throttle connector

either ETC+ or ETC- driver

and measuring the motor drive

signals have been shorted to

resistance at the throttle

ground

TPS Pin 1 (+DRIVER) to

Pin 4 (-DRIVER) ~3.0-4.0

(1) TurnOnMil

Check engine oil level

521

LowOilPressureFault

(2) DelayedEngine

Check electrical connection to the oil

(52)

pressure switch

Low engine oil pressure

Shutdown

SECM Pin B9 to Oil Pressure Switch

(3) CheckEngine Light

Check battery voltage

Perform maintenance check on

electrical connections to the battery

and chassis ground

Check battery voltage during starting

and with the engine running to verify

531

SysVoltRangeLow

charging system and alternator

TurnOnMil

(53)

System voltage too low

function

Measure battery power at SECM with a

multimeter (with key on)

SECM Pin A23 (DRVP) to

SECM Pin A16 (DRVG)

SECM Pin A23 (DRVP) to

SECM Pin B17 (DRVG)

(*) Fault actions shown are default values specified by the OEM.

-76-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

Check battery and charging system

voltage

Check battery voltage during starting

and with the engine running

Check voltage regulator, alternator,

and charging system

541

SysVoltRangeHigh

Check battery and wiring for

TurnOnMil

(54)

System voltage too high

overheating and damage

Measure battery power at SECM with a

multimeter (with key on)

SECM Pin A23 (DRVP) to

SECM Pin A16 (DRVG)

SECM Pin A23 (DRVP) to

SECM Pin B17 (DRVG)

Measure transducer power at the

TMAP connector with a multimeter

TMAP Pin 3 XDRP +5 Vdc to TMAP

Pin 1 XDRG GND

Verify transducer power at the SECM

with a multimeter

SensVoltRangeLow

(1) TurnOnMil

551

SECM Pin B24 +5 Vdc to SECM Pin

Sensor reference voltage

(2) EngineShutdown

(55)

B1 XDRG GND

XDRP too low

Verify transducer power at ETC with a

multimeter

ETC Pin 3 XDRP PWR to ETC Pin 2

XDRG GND

Verify transducer power to the foot

pedal with a multimeter.

Measure transducer power at the

TMAP connector with a multimeter

TMAP Pin 3 XDRP +5 Vdc to TMAP

Pin 1 XDRG GND

Verify transducer power at the SECM

with a multimeter

SensVoltRangeHigh

(1) TurnOnMil

561

SECM Pin B24 +5 Vdc to SECM Pin

Sensor reference voltage

(2) EngineShutdown

(56)

B1 XDRG GND

XDRP too high

Verify transducer power at ETC with a

multimeter

ETC Pin 3 XDRP PWR to ETC Pin 2

XDRG GND

Verify transducer power to the foot

pedal with a multimeter.

Usually associated with additional ETC

HardOverspeed

faults

(1) TurnOnMil

571

Engine speed has exceeded

Check for ETC Sticking or other ETC

(2) HardRevLimit

(57)

the third level (3 of 3) of

faults

overspeed protection

Verify if the lift truck was motored down

a steep grade

(*) Fault actions shown are default values specified by the OEM.

-77-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

Usually associated with additional ETC

MediumOverspeed

faults

(1) TurnOnMil

Engine speed has exceeded

Check for ETC Sticking or other ETC

572

(2) MediumRevLimit

the second level (2 of 3) of

faults

overspeed protection

Verify if the lift truck was motored down

a steep grade

Usually associated with additional ETC

SoftOverspeed

faults

(1) TurnOnMil

Engine speed has exceeded

Check for ETC Sticking or other ETC

573

(2) SoftRevLimit

the first level (1 of 3) of

faults

overspeed protection

Verify if the lift truck was motored down

a steep grade

APP1RangeLow

APP1 sensor voltage out of

(1) TurnOnMil

611

range low, normally set if the

Check foot pedal connector

(2) CheckEngine Light

(61)

APP1 signal has shorted to

Check APP1 signal at SECM PIN B7

ground, circuit has opened or

sensor has failed

APP2RangeLow

APP2 sensor voltage out of

612

range low, normally set if the

Check foot pedal connector

TurnOnMil

(65)

APP2 signal has shorted to

Check APP2 signal at SECM PIN B16

ground, circuit has opened or

sensor has failed

APP1RangeHigh

APP1 sensor voltage out of

621

range high, normally set if

1) TurnOnMil

Check foot pedal connector

(62)

the APP1 signal has shorted

(2) CheckEngine Light

Check APP1 signal at SECM PIN B7

to power or the ground for

the sensor has opened

APP2RangeHigh

APP2 sensor voltage out of

622

range high, normally set if

Check foot pedal connector

TurnOnMil

(66)

the APP2 signal has shorted

Check APP2 signal at SECM PIN B16

to power or the ground for

the sensor has opened

APP1AdaptLoMin

Check APP connector and pins for

631

Learned idle end of APP1

corrosion

None

(63)

sensor range lower than

Cycle the pedal several times and

expected

check APP1 signal at SECM Pin B7

APP2AdaptLoMin

Check APP connector and pins for

632

Learned idle end of APP2

corrosion

None

(67)

sensor range lower than

Cycle the pedal several times and

expected

check APP2 signal at SECM Pin B16

APP1AdaptHiMax

641

Learned full pedal end of

None

N/A

(64)

APP1 sensor range higher

than expected

APP2AdaptHiMax

642

Learned full pedal end of

None

N/A

(68)

APP2 sensor range higher

than expected

(*) Fault actions shown are default values specified by the OEM.

-78-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

APP1AdaptHiMin

Learned full pedal end of

651

None

N/A

APP1 sensor range lower

than expected

APP2AdaptHiMin

Learned full pedal end of

652

None

N/A

APP2 sensor range lower

than expected

APP1AdaptLoMax

Learned idle end of APP1

661

None

N/A

sensor range higher than

expected

APP2AdaptLoMax

Learned idle end of APP2

662

None

N/A

sensor range higher than

expected

Check APP connector and pins for

APP_Sensors_Conflict

corrosion

APP position sensors do no

691

1) TurnOnMil

Cycle the pedal several times and

not track well, intermittent

(69)

(2) Level1PowerLimit

check APP1 signal at SECM Pin B7

connections to APP or

Cycle the pedal several times and

defective pedal assembly

check APP2 signal at SECM Pin B16

Check FTV1 for an open wire or FTV

connector being disconnected

LSDFault_Dither1

FTV1 Pin 1 (signal) to SECM Pin A1

Dither Valve 1 Fault, signal

711

FTV1 Pin 2 (power) to SECM (DRVP)

has opened or shorted to

TurnOnMil

(71)

Pin A23

ground or power or defective

Check FTV1 for an open coil by

dither 1 valve

disconnecting the FTV connector and

measuring the resistance (~26 ± 2 )

Check FTV1 for an open wire or FTV

connector being disconnected or signal

LSDFault_Dither2

shorted to GND

Dither Valve 2 Fault, signal

FTV2 Pin 1 (signal) to SECM Pin A2

712

has opened or shorted to

TurnOnMil

FTV2 Pin 2 (power) to SECM (DRVP)

ground or power or defective

Pin A23

dither 2 valve

Check FTV1 for an open coil by

disconnecting the FTV connector and

measuring the resistance (~26 ± 2 )

LSDFault_CheckEngine

Check Engine Lamp Fault,

Check ‘Check Engine Lamp’ for an

714

signal has opened or shorted

None

open wire or shorted to GND

to ground or power or

defective check engine lamp

(*) Fault actions shown are default values specified by the OEM.

-79-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

LSDFault_CrankDisable

Crank Disable Fault, signal

715

has opened or shorted to

None

N/A

ground or power or defective

crank disable relay

Check fuel lock off valve for an open

wire or connector being disconnected

LSDFault_LockOff

or signal shorted to GND

Fuel lock off Valve Fault,

Lockoff Pin B (signal) to SECM Pin A11

717

signal has opened or shorted

TurnOnMil

Lockoff Pin A (power) to SECM (DRVP)

to ground or power or

Pin A23

defective Fuel lock off valve

Check CSV for an open coil by

disconnecting the CSV connector and

measuring the resistance (~26 ± 3)

LSDFault_MIL

Malfunction Indicator Lamp

Check MIL lamp for an open wire or

718

Fault, signal has opened or

None

short to GND.

shorted to ground or power

or defective MIL lamp

GasFuelAdaptRangeLo

Check for vacuum leaks.

721

In LPG mode, system had to

Check fuel trim valves, e.g. leaking

TurnOnMil

(72)

adapt rich more than

valve or hose

expected

Check for missing orifice(s).

GasFuelAdaptRangeHi

Check fuel trim valves, e.g. plugged

731

In LPG mode, system had to

valve or hose.

TurnOnMil

(73)

adapt lean more than

Check for plugged orifice(s).

expected

Check that Pre-catalyst O2 sensor

connections are OK.

O2 (signal) Pin 3 to SECM Pin B13

O2 Pin 2 (HEATER GND) to SECM

GasO2NotActive

(DRVG GNG) Pins A16, B17

Pre-catalyst O2 sensor

O2 Pin 1 (HEATER PWR) to SECM

741

(1) TurnOnMil

inactive on LPG, open O2

(DRVP + 12V) Pin A23

(74)

(2) DisableGas O2Ctrl

sensor signal or heater

Verify O2 sensor heater circuit is

leads, defective O2 sensor

operating by measuring heater

resistance

(2.1 ± 0.4)

O2 Pin 2 (HEATER GND) to Pin 1

(HEATER PWR)

(*) Fault actions shown are default values specified by the OEM.

-80-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

Check that Post-catalyst O2 sensor

connections are OK.

O2 (signal) Pin 3 to SECM Pin B19

O2 Pin 2 (HEATER GND) to SECM

(DRVG GNG) Pins A16, B17

O2 Pin 1 (HEATER PWR) to Post O2

Heater Relay. Relay pin 87. This relay

turns on only after engine has been

running for some time and SECM has

GasPostO2NotActive

calculated that water condensation in

Post-catalyst O2 sensor

(1) TurnOnMil

exhaust has been removed by exhaust

742

inactive on LPG, open O2

(2) DisableGas

heat. Post O2 Heater Relay has SECM

sensor signal or heater

Post O2Ctrl

(DRVP + 12V) applied to the relay coil

leads, defective O2 sensor.

power. The relay coil ground is

controlled by SECM Pin A20 to activate

the relay to flow current through the

post O2 heater.

Verify O2 sensor heater circuit is

operating by measuring heater

resistance (2.1 ± 0.4)

O2 Pin 2 (HEATER GND) to Pin 1

(HEATER PWR)

743

Reserved

GasO2FailedLean

Check for vacuum leaks.

Pre-catalyst O2 sensor

(1) TurnOnMil

Check fuel trim valves, e.g. leaking

751

indicates extended lean

(2) DisableGas O2Ctrl

valve or hose.

operation on LPG

Check for missing orifice(s).

Correct other faults that may contribute

to 752 (e.g. faults pertaining to fuel trim

valves, Pre-Cat O2, Post Cat O2

GasPostO2FailedLean

(1) TurnOnMil

sensor)

Pre-catalyst O2 sensor

752

(2) DisableGas

Check for vacuum leaks

indicates extended lean

Post O2Ctrl

Check for leaks in exhaust, catalytic

operation on LPG

converter, HEGO sensors; repair leaks.

Check all sensor connections (see fault

742 corrective actions).

GasO2FailedRich

Check fuel trim valves, e.g. plugged

771

Pre-catalyst O2 sensor

(1) TurnOnMil

valve or hose.

(77)

indicates extended rich

(2) DisableGas O2Ctrl

Check for plugged orifice(s).

operation on LPG

(*) Fault actions shown are default values specified by the OEM.

-81-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

Correct other faults that may contribute

to 772 (e.g. faults pertaining to FTVs,

GasPostO2FailedRich

(1) TurnOnMil

Pre-Cat O2, Post Cat O2 sensor)

Pre-catalyst O2 sensor

772

(2) DisableGas

Look for leaks in exhaust, catalytic

indicates extended rich

PostO2Ctrl

converter, HEGO sensors; repair leaks.

operation on LPG

Check all sensor connections (see fault

742 corrective actions).

843

Reserved

Check if O2 sensor installed before the

O2RangeLow

catalyst is shorted to GND or sensor

Pre-catalyst O2 sensor

(1) TurnOnMil

GND.

911

voltage out of range low,

(2) DisableGas O2Ctrl

O2 (signal) Pin 3 to SECM Pin B13

sensor signal shorted to

SECM (DRVG GND) Pins A16, B17

ground

SECM (XDRG sensor GND) Pin B1

Check if O2 installed after the catalyst

O2_PostCatRangeLow

sensor is shorted to GND or sensor

Post-catalyst O2 sensor

(1) TurnOnMil

GND.

912

voltage out of range low,

(2) Disable LPG

O2 (signal) Pin 3 to SECM Pin B19

sensor signal shorted to

Post-catalyst O2Ctrl

Possible sources: SECM (DRVG GND)

ground

Pins A16, B17 and SECM (XDRG

sensor GND) Pin B1

O2RangeHigh

Check if O2 sensor installed before

Pre-catalyst O2 sensor

catalyst is shorted to +5Vdc or battery.

(1) TurnOnMil

921

voltage out of range high,

O2 (signal) Pin 3 to SECM Pin B13

(2) DisableGas O2Ctrl

sensor signal shorted to

SECM (XDRP + 5V) Pin B24

power

SECM (DRVP + 12V) Pin A23

Check if O2 sensor installed after

O2_PostCatRangeHigh

catalyst is shorted to +5Vdc or battery.

Post-catalyst O2 sensor

(1) TurnOnMil

O2 (signal) Pin 3 to SECM Pin B19

922

voltage out of range low,

(2) Disable LPG

Possible voltage sources: SECM

sensor signal shorted to

Post-catalyst O2Ctrl

(XDRP + 5V) Pin B24 and SECM

ground

(DRVP + 12V) Pin A23

(*) Fault actions shown are default values specified by the OEM.

-82-

Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION

DFC

PROBABLE FAULT

FAULT ACTION *

FIRST CHECK

FuelTempRangeLow

Check fuel temp sensor connector and

Fuel Temperature Sensor

wiring for a short to GND

Input is Low normally set if

SECM (signal) Pin B14 to FTS Pin 1

931

the fuel temperature sensor

TurnOnMil

SECM (sensor GND) Pin B1 to

wire has shorted to chassis

FTS Pin 2

ground or the sensor has

SECM (system GND) Pin A16, B17

failed.

FuelTempRangeHigh

Check if fuel temp sensor connector is

Fuel Temperature Sensor

disconnected or for an open FTS circuit

Input is High normally set if

SECM (signal) Pin B14 to FTS Pin 1

932

the fuel temperature sensor

TurnOnMil

SECM (sensor GND) Pin B1 to

wire has been disconnected

FTS Pin 2

or the circuit has opened to

the SECM.

TransOilTemp

(1) TurnOnMil

Refer to drivetrain manufacturer’s

933

Excessive transmission oil

(2) Delayed

transmission service procedures.

temperature

EngineShutdown

ServiceFault1

Perform service procedure related to

991

Service Interval 1 has been

None

Service Interval 1

reached

(determined by OEM)

ServiceFault2

Perform service procedure related to

992

Service Interval 2 has been

None

Service Interval 2

reached

(determined by OEM)

ServiceFault3

Perform service procedure related to

993

Service Interval 3 has been

None

Service Interval 3

reached

(determined by OEM)

ServiceFault4

Service Interval 4 has been

Replace Pre-catalyst HEGO sensor

994

TurnOnMil

reached-replace HEGO

Replace Post-catlyst HEGO sensor

sensors

ServiceFault5

995

Service Interval 5 has been

TurnOnMil

Replace engine timing belt

reached-replace timing belt

(*) Fault actions shown are default values specified by the OEM.

-83-

Operation Section

Lift Truck Operation

Power Shift Transaxle

1. Start the engine. See topic “Starting the Engine.”

5. Release the service brake.

6. Push down on the accelerator pedal to obtain the

desired travel speed. Release the pedal to decrease

travel speed.

2. Push down on the service brake pedal to hold the lift

truck until ready to move it.

WARNING

3. Release the parking brake.

Sudden reversal of a loaded lift truck traveling

forward can cause the load to fall or the lift truck

NOTE: The parking brake must be released before

to tip.

the directional control can be used.

Stop the loaded lift truck completely, before

shifting to reverse.

Failure to comply could result in personal injury.

NOTE: Where conditions permit, directional

changes can be made under full power at

speeds up to 6 km/h (3.73mph). A speed of

6 km/h (3.73mph) is a fast walk. Directional

shift changes at speeds above 6 km/h

(3.73mph) are considered abusive.

Bring the lift truck to a complete stop where load

4. Select the direction of travel by pushing the

stability or other factors prevent safe operation

directional lever FORWARD for forward direction or

under full power shifts.

by pulling the lever BACK for reverse direction.

WARNING

A lift truck with the engine running but without

an operator can move slowly (creep) if the

transmission is engaged.

This could result in personal injury.

Always place the transmission control lever in

the NEUTRAL (centre) position and apply the

parking brake before dismounting the lift truck.

-84-

Operation Section

7. To change the lift truck direction of travel, release

Inching

the accelerator pedal.

NOTE: The purpose of the inching pedal is to

8. Push down on the service brake pedal to reduce the

provide precise lift truck inching control at

lift truck speed as necessary.

very slow travel speed and high engine rpm.

This is used for fast hydraulic lift, during

load approach, pick up or load positioning.

9. Move the directional lever to the desired direction of

travel. Slowly push down on the accelerator pedal

as the lift truck changes direction.

1. To inch (creep) in either direction, slowly push down

10. When the direction change is completed, continue

on the inching pedal. This will start to apply the

to push down on the accelerator pedal to obtain the

service brakes and allow the transmission clutch

desired travel speed.

discs to slip.

2. Vary the position of the inching pedal and the

accelerator pedal to control the inching speed and

distance.

3. Pushing down further on the inching pedal will

disengage the transmission completely and apply

the service brakes fully to stop and hold the lift truck.

This will provide full engine power for fast hydraulic

lift.

4. Avoid overuse of the inching pedal as this may cause

the automatic transmission oil to overheat or the

clutch to slip. Do not use as a footrest or for long

11. To stop the lift truck when traveling in either

periods of time.

direction, release the accelerator pedal.

5. If user operates continuously pushing work or both

12. Push down on the service brake pedal and bring the

brake pedal and accelerator pedal were depressed

lift truck to a smooth stop.

at the same time, it may cause the automatic

transmission oil to overheat or the clutch to slip.

-85-

Operation Section

Steering Knob (If Equipped)

Mono-Ped Control System

There is a steering knob available for inclusion with

(Option)

new truck deliveries. This option is solely intended

for slow travel situations when two handed steering

is not possible due to hydraulic operations.

Forward-Push the left side (2) of the pedal

for FORWARD direction travel.

WARNING

Loss of stability can occur when a lift truck

Neutral-The lift truck should not move when

steering wheel is rotated quickly while the truck

the Mono-Ped pedal is released..

is in motion. A steering knob will assist with

easy rotation of the steering wheel, but if a

Reverse-Push the right side (1) of the pedal

steering knob is improperly used (e.g., rotating

for REVERSE direction travel.

the steering wheel quickly while the truck is in

motion), this can contribute to truck instability

and a tip over. A steering knob is intended for

The MONO-PED pedal controls the speed and

slow travel maneuverability ONLY.

direction of the lift truck. Pushing on the right side of

the pedal

(1) causes the lift truck to move in

REVERSE. The optional reverse lights and optional

back-up alarm will be ON in the REVERSE position.

Pushing on the left side of the pedal (2) causes the

lift truck to move in FORWARD.

The speed of the truck increases as the pedal is

depressed

-86-

Operation Section

Auto Shift Controller ASC - 206 (Standard)

Adjustments

Product Description

SW1

SW2

The Autoshift controller is an electrical control system,

( Low-High Shift Point ) ( Direction Inhibit Point )

specially designed for use on forklift trucks with internal

NOTCH

Vehicle Speed

NOTCH

Vehicle Speed

combustion engines.

2.5 km/h (1.55 mph)

3.3 km/h (2.05 mph)

Its primary purpose is to prevent the operator from

3.0 km/h (1.86 mph)

3.6 km/h (2.24 mph)

operating the truck outside of the design parameters,

3.5 km/h (2.17 mph)

3.9 km/h (2.42 mph)

e.g. selecting the reverse gear when traveling in

4.0 km/h (2.49 mph)

4.2 km/h (2.61 mph)

excess of 6.0 km/h ( 3.73mph ) in a forward direction,

4.5 km/h (2.80 mph)

and vice versa.

5.0 km/h (3.11 mph)

4.8 km/h (2.98 mph)

5.5 km/h (3.42 mph)

5.1 km/h (3.17 mph)

The Autoshift controller is mounted on a convenient

6.0 km/h (3.73 mph)

5.4 km/h (3.36 mph)

position away from excessive heat sources and

6.5 km/h (4.04 mph)

5.7 km/h (3.54 mph)

retrofits into the truck’s electrical system. An

7.0 km/h (4.35 mph)

6.0 km/h (3.73 mph)

inductive speed sensor is mounted on the

transmission case where it will pick up a pulse from

a gear tooth pattern. This pulse is used to monitor

the truck in motion and its travel speed. To enable

the system to change gears smoothly, the shift

points for offset speed are adjustable.

An operator no longer has to change gears with his

hands, therefore he can be more productive.

The Autoshift controller prevents strain and abuse to

the transmission by changing gears up and down

automatically. It also prevents damage to the half

shaft, excessive tyre wear and heat to the

transmission.

Adjustment Switch

Features

Low-High Shift Point (SW1)

1. 2 - speed auto shift control

ASC-206 allows you to set the 2 speed Auto Gear Shift

Point, the maximum travel speed at which the Auto Shift

2. Prevent downshifting at high speed

Controller up-shift or down-shift the transmission

automatically according to the vehicle speed. For

3. Inhibit selecting direction at high speed outside of

adjustment of 2 speed Auto Gear Shift speed, the SW1

the design parameters.

switch is used on the printed circuit board.

For example if SW1 put to 5th notch, the 2 Speed

Auto Gear Shift speed will be 5.0 km/h(3.11 mph),

which is factory setting value as a default.

Direction Inhibit Point (SW2)

Auto Shift allows you to set the Direction Inhibit Speed,

the maximum travel speed at which the transmission

can be reversed. For adjustment of direction inhibit

speed, the SW2 switch is used on the printed circuit

board.

For example SW2 is put to 7rd notch, the Direction

Inhibit Speed will be 5.4 km/h (3.36 mph), which is

factory setting value as a default.

-87-

Operation Section

Diagnostics Features

Display for Troubleshooting

Display

Description

Remark

Automatic operation

High speed s/w input

Lever input test

Forward s/w input

Lever input test

Reverse s/w input

Lever input test

This information is input for signal diagnostics.

This test is used to verify operation of direction

control lever.

Operation

ASC-206 has internal indicator on the right side of

This system can be basically operated in two

the controller for displaying the selected gear and

preselected modes, automatic mode and manual mode.

the abnormal condition.

Automatic Mode is selected in factory-setting controller

as a default.

Manual Mode (Fail-Safe Mode) is selected to

operate the truck manually in case of emergency.

WARNING

Do not diagnose or repair Auto Shift Controller

Faults unless trained and authorised to do so.

Automatic mode

Improper

performance

maintenance

Direction Inhibit

procedures is dangerous and could result in

personal injury or death.

1. Start the engine with the direction control lever in

NEUTRAL and the parking brake engaged.

Below is a description applicable for many ASC-500

2. Press down on the service brake pedal, disengage

implementations.

the parking brake and move the direction control

lever to FORWARD.

Display for Operator

NOTE: Release the parking brake before using the

directional control lever.

Display

Description

Remark

3. Observe the LED on the Auto Shift Controller. The

Automatic operation

LED should indicate “A” while the direction control

High speed

At 2nd shift gear

lever is in FORWARD, NEUTRAL and REVERSE.

Low speed

At 1st shift gear

Report Auto Shift as faulty if the LED indicates

T/M Speed sensor open

Flashing

anything other than “A”.

E/G Speed sensor open

Flashing

Controller fault

Flashing

4. Keep the service brake pushed down until ready to

FWD 2 Sol. Short

move the truck.

Flashing

5. To change directions of a traveling lift truck when

REV 2 Sol. Short

the Auto Shift Controller LED displays “A”, shift the

FWD 1 Sol. Short

Flashing

direction control lever to the opposite direction and

REV 1 Sol. Short

Flashing

wait for the lift truck to change direction.

This information is given during normal operating when

6. If however, your travel speed is higher than the pre-

something special happens.

selected direction change speed as direction inhibit

For example, on ASC-500’s with the speed sensor,

point in the controller, Auto Shift will shift the

one of the indicators is used to indicate a sensor

transmission to NEUTRAL until the lift truck’s travel

problem.

speed slows to the pre-selected direction change

speed, and then shift the transmission to the

direction selected.

7. You should be prepared to help slow the lift truck to

the pre-selected direction change speed by

pressing down on the service brake pedal.

-88-

Operation Section

Manual Mode (Fail-Safe mode)

WARNING

In case that the controller is broken down or you

When you want to change the travel direction,

don’t want to use the functions of the Auto Shift

you must press down on the service brake

Controller, you can select Manual Mode. In Manual

pedal to reduce the travel speed. Be cautious

Mode, you can operate your lift truck in the same

that the lift truck’s stopping distance may be

manner as any lift truck without Auto Shift

longer than in manual mode because the lift

Controller. You can select the Manual mode or the

truck continues to travel forward regardless of

Automatic mode by doing following procedures.

the selection of reverse with the direction

control lever until the vehicle speed is

sufficiently reduced.

WARNING

8. The direction of travel will change automatically

when the vehicle speed is reduced as much as the

In the manual mode, direction inhibition

pre-selected speed in the controller.

function can not be operated normally. The

sudden reversal of a loaded lift truck traveling

forward can cause the load to fall or the lift

WARNING

truck to tip over.

Bring the loaded lift truck to a complete stop

before changing travel direction.

An operator can operate the truck manually by

Changing travel direction while traveling may

selecting the Manual mode with the Fail-Safe mode

cause the lift truck to lose the load or tip over.

switches on the PCB (Printed Circuit Board).

With the switch (1) in “MANUAL” position, direction

inhibit function is disable.

9. When the direction change is completed, continue

If an operator moves the switch (2) from “AUTO”

to push down on the accelerator pedal to obtain the

position to “MANUAL” position, then 2-speed auto shift

desired travel speed.

function will become disabled.

Move the switches as indicated, up of Automatic

NOTICE

(AUTO) operation or down for Manual (MANUAL)

operation.

The transmission of your lift truck may be reversed

under full power up to a travel of 6.0 km/h (3.73 mph).

But the Inhibit Speed of Auto Shift is set by the factory at

NOTE: In the factory-setting controller, AUTO

5.4 km/h (3.36 mph) because reversing the transmission

mode is selected as a default on the PCB

at lower travel speeds prolongs the lift of the

(Printed Circuit Board) as shown below.

transmission, axle shafts and tyres.

Two-Speed Auto Shift Control

While traveling forward with the high speed gear,

that is, 2nd gear selected, the ASC-206 can up-shift

or down-shift the transmission automatically

according to the vehicle speed by its own speed

ratio control so that the appropriate gear may be

engaged in every situation.

NOTICE

Two-Speed Auto Shift Control function can be

accomplished only when the direction control lever is

NOTE: After operating the truck manually by

placed in the high speed (2nd gear) position.

selecting the Manual Mode switch on

PCB(Printed Circuit Board), the position of

mode must be checked before operating

the truck automatically.

-89-

Operation Section

Parking the Lift Truck

Park the lift truck level, with the forks lowered and the

mast tilted forward until the fork tips touch the floor.

Block the drive wheels when parking on an incline.

5. Turn the key in the ignition switch to the OFF

position and remove the key.

1. Park in an authorised area only. Do not block traffic.

If LP equipped, do not park near elevator shafts or

any other area where LP could collect in a pocket

(low area), causing a potentially dangerous

condition.

NOTE: If a LP equipped lift truck is stopped or

parked for an indefinite or prolonged period

of time, close the fuel shutoff valve on the

LP tank. Run the engine until fuel in the line

runs out and the engine stops. Turn off the

ignition switch and disconnect switch (if

equipped).

6. Actuate each loading lever several times to remove

2. Place the transmission controls in NEUTRAL.

the residual pressure in the respective cylinders and

hoses.

3. Engage the parking brake.

7. Block the drive wheels if parking on an incline.

4. Lower the forks to the ground.

WARNING

Blocking the wheels will prevent unexpected lift

truck movement, which could cause personal

injury.

-94-

Operation Section

Storage Information

Before Storage

To Operate the Lift Truck After a

Before storing your lift truck, clean and inspect as

Long Time Storage

the following procedures.



Remove covers and antirust from each of the



Wipe away grease, oil, etc. adhering to the body of

components and exposed parts.

the truck with waste cloth, and use water, if needed.



Drain the engine crankcase, transmission (clutch



While cleaning the truck, check general condition of

type machine), differential and final reduction gear,

the truck. Especially check the truck body for dents

clean the inside of them and add new oil.

or damage and tyres for wear or nails or stones in



Drain off foreign matter and water from the

the tread.

hydraulic oil tank and fuel tank.



Fill the fuel tank with fuel specified.



Remove the head cover from the engine cylinder.



Check for leakage of hydraulic oil, engine oil, fuel, or

Oil valves and rocker shaft and check each valve

coolant, etc.

for proper operation.



Apply grease, where needed.



Add cooling water to the specified level.



Charge the battery and mount it on the machine.



Check for looseness of nuts and bolts, especially

hub nuts.

Connect the cables.



Check mast rollers to see that they rotate smoothly.



Perform pre-operational checks carefully. (refer to

“Before Starting the Engine”)



Prime the oil into the lift cylinders by actuating the lift

lever all the way several times.



Warm up the machine.



Drain off coolant completely in cold weather, if

antifreeze is not used.

Long Time Storage

Perform the following service and checks in addition

to the “Parking the lift truck” services.



Taking the rainy season into consideration, park the

machine at a higher and hard ground.



Avoid parking on soft grounds such as asphalt

ground in summer.



Dismount the battery from the machine. Even

though the machine is parked indoors, if the place is

hot or humid, the battery should be kept in a dry,

cool place. Charge the battery once a month.



Apply antirust to the exposed parts which tend to

rust.



Cover components such as the breather and air

cleaner which may be caught with humidity.



The machine should be operated at least once a

week. Fill the cooling system, if cooling water is

discharged, and mount the battery. Start the engine

and warm up thoroughly. Move the machine a little

forwards and backwards. Operate the hydraulic

controls several times.

-96-

Operation Section

Transportation Hints

Machine Lifting and Tiedown

Lift Truck Shipping

Information

Check travel route for overpass clearances. Make

sure there is adequate clearance if the lift truck

being transported is equipped with a high mast,

NOTICE

overhead guard or cab.

Improper lifting or tiedowns can allow load to shift

To prevent the lift truck from slipping while loading,

and cause injury and/or damage.

or shifting in transit, remove ice, snow or other

slippery material from the loading dock and the truck

1. Weight and instructions given herein apply to lift

bed before loading.

trucks as manufactured by CROWN.

2. Use proper rated cables and slings for lifting.

NOTICE

Position the crane for level lift truck lift.

Obey all state and local laws governing the height,

3. Spreader bar widths should be sufficient to prevent

weight, width and length of a load.

contact with the lift truck.

Observe all regulations governing wide loads.

4. Use the tiedown locations provided for lift truck

tiedown.

Check the state and local laws governing weight,

NOTICE

width and length of a load.

Remove ice, snow or other slippery material from

Contact your CROWN Lift Truck dealer for shipping

the shipping vehicle and the loading dock.

instructions for your lift truck.

Always block the trailer or the rail car wheels before

loading the lift truck.

Position the lift truck on the truck bed or the rail car.

Apply the parking brake and place the transmission

control in NEUTRAL.

Turn the ignition switch to the OFF position and

remove the key. If LP equipped, shut off the LP fuel

tank.

Block the wheels and secure the lift truck with

tiedowns.

-97-

Operation Section

How to Fix Forklift to a Carrier

Lifting a Forklift using a Crane

1. The rope/chain must have sufficient length for

fixing.

WARNING

2. Park the vehicle on a level ground.

1. If lifting rope breaks, serious injury/damage

3. Set the mast vertically. Lower the fork or

may occur.

attachment to the lowest position.

2. The lifting wire rope and stay must be long

4. Set all the operating devices to Neutral Position.

enough to avoid contact with the forklift. Short

Turn OFF the start switch.

rope/stay can damage the vehicle. If it's too long,

it may cause interference.

5. Apply the parking brake. Stop the tyres with

blocks (C).

If sling and LP tank contact happens during

refloatation operation, you should get rid of tank

6. Connect towing hooks to the mast top B (if

of vehicle with LP tank first, and then proceed.

without mast, front drive axle fix frame or front

fender bottom fixing hole D) and rear tow pin A, as

Cover the rope/chain with rubber or cloth to

shown in the figure below.

prevent damage to the vehicle, as necessary.

3. Rope/chain and other lifting tools must have

sufficient strength, and free of any defect or

wear.

4. Avoid impact load to the lifting devices/tools.

1. Check the weight, length, width and height of the

vehicle before lifting.

2. Park the crane at an appropriate position.

3. Connect the rope/chain to the points A and B of

the figure below.

4. If the wire rope/chain contacts the vehicle, insert a

rubber plate between the rope/chain and the vehicle

to protect the vehicle.

5. Lift up the vehicle slowly.

-98-

Operation Section

Towing Information

The different situation requirements cannot be given

WARNING

as minimal towing lift truck capacity is required on

smooth level surfaces to maximum on inclines or

Personal injury or death could result when

poor surface conditions.

towing a disabled lift truck incorrectly.

Consult your CROWN Lift Tuck dealer for towing a

Block the lift truck wheels to prevent movement

disabled lift truck.

before releasing the brakes. The lift truck can

roll free if it is not blocked.

Follow the recommendations below, to properly

perform the towing procedure.

These towing instructions are for moving a disabled

lift truck a short distance, at low speed, no faster

than 2 km/h (1.2 mph), to a convenient location for

repair. These instructions are for emergencies only.

Always haul the lift truck if long distance moving is

required.

Shield must be provided on the towing lift truck to

protect the operator if the tow line or bar should

break.

Do not allow riders on the lift truck being towed

1. Release the parking brake.

unless the operator can control the steering and/or

braking.

NOTICE

Before towing, make sure the tow line or bar is in

good condition and has enough strength for the

Release the parking brake to prevent excessive

towing situation involved. Use a towing line or bar

wear and damage to the parking brake system.

with a strength of at least 1.5 times the gross weight

of the towing lift truck for a disabled lift truck stuck in

2. Check that the service brake pedal is released.

the mud or when towing on a grade.

3. Key switch is in the OFF position.

Keep the tow line angle to a minimum. Do not

exceed a 30°angle from the straight ahead position.

4. Direction control lever is in neutral.

Connect the tow line as low as possible on the lift

5. Fasten the tow bar to the lift truck.

truck that is being towed.

6. Remove the wheel blocks. Tow the lift truck slowly.

Quick lift truck movement could overload the tow

Do not tow any faster than 2 km/h (1.2 mph).

line or bar and cause it to break. Gradual and

smooth lift truck movement will work better.

WARNING

Normally, the towing lift truck should be as large as

Be sure all necessary repairs and adjustments

the disabled lift truck. Satisfy yourself that the towing

have been made before a lift truck that has been

lift truck has enough brake capacity, weight and

towed to a service area is put back into

power, to control both lift trucks for the grade and

operation.

the distance involved.

To provide sufficient control and braking when

moving a disabled lift truck downhill, a larger towing

lift truck or additional lift trucks connected to the rear

could be required. This will prevent uncontrolled

rolling.

-99-

Maintenance Section

Jacking Information

WARNING

Hydraulic Jack & Jack Stand

Capacity

Jacking up Truck can be dangerous and should

be done only by trained personnel using proper

Hydraulic Jack Capacity

tools and procedures.

Height

Minimum

Model

Block the lift truck wheels to prevent movement

Minimum*

Requirement

while lifting the wheels. The lift truck can roll

CGC15/18S-5,

free if it is not blocked.

CGC15/18S-5,

100mm

CGC20SC-5

Follow the recommendations below, to properly

1 ton

CD15/18S-5,

2000Kg

4400Ibs

class

perform the jacking procedure.

CD20SC-5,

150mm

CG15/18S-5,

CG20SC-5

CD20/25/

NOTICE

30/33S-5,

Move Trucks to a Secure Non Traffic Maintenance

CD35C-5,

Area with a Level Floor. No Load on Forks.

CG20/25/30E-5,

150mm

Remove key from ignition switch.

CG20/25

2 ton

/30/33P-5,

3000Kg

6600Ibs

class

CG35C-5

CGC20/25/30/

33E-5,

120mm

CGC20/25/30/

33P-5

CD35/40/45S-5,

CD50/55C-5,

CD40/45/50/

3 ton

55SC-5,

180mm

3900Kg

8600Ibs

class

CG35/40/45S-5,

CG50/55C-5,

CG40/45/50/

55SC-5

CD50/60/70/

5 ton

80/90S-5,

250mm

5800Kg

12800Ibs

class

CG50/60/70S-5

11 ton

CD110/130

10000

300mm

22050Ibs

class

/160S-5

18/20

14000

ton

CDV180/200S-7

350 mm

30900Ibs

class

25 ton

19000

CDV250S-7

400 mm

42000lbs

class

• The height of lift truck with a flat tyre is lower than with an

inflated tyre. So Height Minimum of Jack must be less than the

value of the above chart.

Stand Capacity should be more than the minimum

requirement of Hydraulic Jack Capacity.

Hydraulic Jack & Jack Stand are commercially

available and should be especially designed for

forklift trucks.

-100-

Maintenance Section

Jacking Procedure

Steering Wheel

1. Raise Forks 3 to 6 in (76 to 152 mm) from Floor.

8. Do Not Tilt Mast after Blocked.

2. Place Wheel Chocks under Both Drive Wheels.

3. Locate Hydraulic Jack under Steering Axle as

Shown in Figure A.

4. Jack Up Truck with Hydraulic Jack.

5. Set Jack Stand Height as Required Not to Exceed

16 in (405mm).

WARNING

Locate Hydraulic Jack under Frame. Do NOT

locate on side panel. Do NOT raise side of truck

any more than required to insert hard wood

block.

Side

1. Lower Forks Completely.

WARNING

2. Locate Hydraulic Jack under Frame as Shown in

Figure B.

Locate Hydraulic Jack and Jack Stands under

3. Jack Up One Side of Truck.

steer axle. Do NOT locate Hydraulic Jack or

Jack Stands on Counter Weight.

4. Place Hard Wood Block directly under First Stage

Mast.

5. 1ton/2ton class - Use 6X6 in (150X150mm) Block

3ton/5ton class - Use 8X8 in (200X200mm) Block

11ton class - Use 12X12 in (300X300mm) Block

6. Jack Up Opposite Side of Truck.

7. Place Second Hard Wood Block under Other Side

of First Stage Mast.

-101-

Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks

The following section gives practical guidelines for

Users may also refer to the International

inspection, maintenance and repair of lift truck forks.

Organization For Standardization - ISO Technical

It also provides general information on the design

Report 5057 - Inspection and Repair of Fork Arms

and application of forks and the common cause of

and ISO Standard

2330

- Fork Arms-Technical

fork failures.

Characteristics and Testing.

Lift truck forks can be dangerously weakened by

Users should be familiar with the requirements for

improper repair or modification. They can also be

inspection and maintenance of lift trucks as provided

damaged by the cumulative effects of age, abrasion,

by Australian Standard AS2359.

corrosion, overloading and misuse.

A fork failure during use can cause damage to the

equipment and the load. A fork failure can also

Environment Protection

cause serious injury.

When servicing this lift truck, use an authorised

A good fork inspection and maintenance program

servicing area and an approved container to collect

along with the proper application can be very

coolant, oil, fuel, grease, electrolyte and any other

effective in preventing sudden failures on the job.

potential environmental pollutant before any lines,

fittings or related items are disconnected or removed.

Repairs and modifications should be done only by

After servicing, dispose of those materials in an

the fork manufacturer or a qualified technician who

authorised place and container. When cleaning the

knows the material used and the required welding

lift truck, be sure to use an authorised area.

and heat treatment process.

Users should evaluate the economics of returning

the forks to the manufacturer for repairs or

purchasing new forks. This will vary depending on

many factors including the size and type of fork.

Forks should be properly sized to the weight and

length of the loads, and to the size of the machine

on which they are used. The general practice is to

use a fork size such that the combined rated

capacity of the number of forks used is equal to or

greater than the “Standard(or rated) Capacity” of the

lift truck.

The individual load rating, in most cases, will be

stamped on the fork in a readily visible area. This is

generally on the top or side of the fork shank.



A fork rated at 1500 pounds at 24 inch load

centre will be stamped 1500X24.



A fork rated at 2000 kg at 600 mm load centre

will be stamped 2000X600.

The manufacturer identification and year and date of

manufacture is also usually shown.

Some countries have standards or regulations which

apply specifically to the inspection and repair of

forks.

-102-

Maintenance Section

Causes of Fork Failure



Repetitive Overloading

Repetitive cycling of loads which exceeds the

Improper Modification or Repair

fatigue strength of the material can lead to fatigue

failure. The overload could be caused by loads in

Fork failure can occur as a result of a field

excess of the rated fork capacity and by use of the

modification involving welding, flame cutting or other

forks tips as pry bars. Also, by handling loads in a

similar processes which affect the heat treatment

manner which causes the fork tips to spread and the

and reduces the strength of the fork.

forks to twist laterally about their mountings.

In most cases, specific processes and techniques



Wear

are also required to achieve proper welding of the

Forks are constantly subjected to abrasion as they

particular alloy steels involved. Critical areas most

slide on floors and loads. The thickness of the fork

likely to be affected by improper processing are the

blade is gradually reduced to the point where it may

heel section, the mounting components and the fork

not be capable of handling the load for which it was

tip.

designed.

Bent or Twisted Forks



Stress Risers

Forks can be bent out of shape by extreme

Scratches, nicks and corrosion are points of high

overloading, glancing blows against walls or other

stress concentration where cracks can develop.

solid objects or using the fork tip as a pry bar.

These cracks can progress under repetitive loading

in a typical mode of fatigue failure.

Bent or twisted forks are much more likely to break

and cause damage or injury. They should be

Overloading

removed from service immediately.

Extreme overloading can cause permanent bending

or immediate failure of the forks. Using forks of less

Fatigue

capacity than the load or lift truck when lifting loads

Parts which are subjected to repeated or fluctuating

and using forks in a manner for which they were not

loads can fail after a large number of loading cycles

designed are some common causes of overloading.

even though the maximum stress was below the

static strength of the part.

The first sign of a fatigue failure is usually a crack

which starts in an area of high stress concentration

This is usually in the heel section or on the fork

mounting.

As the crack progresses under repetitive load

cycling, the load bearing cross section of the

remaining metal is decreased in size until it

becomes insufficient to support the load and

complete failure occurs.

Fatigue failure is the most common mode of fork

failure. It is also one which can be anticipated and

prevented by recognizing the conditions which lead

up to the failure and by removing the fork service

prior to failing.

-103-

Maintenance Section

Fork Inspection

First Installation

1. Inspect forks to ensure they are the correct size for

the truck on which they will be used. Make sure they

are the correct length and type for the loads to be

handled.

If the forks have been previously used, perform

the “12 Month Inspection”.

If the forks are rusted, see “Maintenance and

Repair”.

2. Make sure fork blades are level to each other within

acceptable tolerances. See “Forks, Step 4,” in the

“2000 Service Hours or Yearly” in “Maintenance

Intervals”

Establish a daily and 12 month inspection routine by

keeping a record for the forks on each lift truck.

3. Make sure positioning lock is in place and working

Lock forks in position before using truck. See “Forks,

Initial information should include the machine serial

Step 7” in the “2000 Service Hours or Yearly” in

number on each the forks are used, the fork

“Maintenance Intervals”.

manufacturer, type, original section size, original

length and capacity. Also list any special

characteristics specified in the fork design.

Daily Inspection

Record the date and results of each inspection,

making sure the following information is included.

1. Visually inspect forks for cracks, especially in the

heel section, around the mounting brackets, and all



Actual wear conditions, such as percent of

weld areas. Inspect for broken or jagged fork tips,

original blade thickness remaining.

bent or twisted blades and shanks.



Any damage, failure or deformation which might

2. Make sure positioning lock is in place and working.

impair the use of the truck.

Lock the forks in position before using the truck.



Note any repairs or maintenance.

See

“2000 Service Hours or Yearly” in

An ongoing record of this information will help in

“Maintenance Intervals”.

identifying proper inspection intervals for each

3. Remove all defective forks from service.

operation, in identifying and solving problem areas

and in anticipating time for replacement of the forks.

-104-

Maintenance Section

12 Months Inspection

fatigue life of the fork. Always grind or polish in the

direction of the blade and shank length.

Forks should be inspected, at a minimum, every 12



Repair or replace the positioning locks on hook type

months. If the truck is being used in a multi-shift or

forks.

heavy duty operation, they should be checked every

six months. See “Forks” in the “2000 Service Hours



Repair or replace most fork retention devices used

or Yearly” in “Maintenance Intervals.”

with other fork types.

A fork should be load tested before being returned

to service on completion of repairs authorised and

Maintenance and Repair

done in accordance with the manufacturer’s

recommendations.

1. Repair forks only in accordance with the

manufacturer’s recommendations.

Most manufacturers and standards require the

repaired fork to be tested with a load 2.5 times

Most repairs or modifications should be done

the specified capacity and at the load centre

only by the original manufacturer of the forks or

marked on the fork arm.

an expert knowledgeable of the materials,

design, welding and heat treatment process.

With the fork restrained in the same manner as

its mounting on the lift truck, apply the test load

2. The following repairs or modifications SHOULD

twice, gradually and without shock. Maintain the

NOT be attempted.

test for 30 seconds each time.



Flame cutting holes or cutouts in fork blades.



Welding on brackets or new mounting hangers.

Check the fork arm before and after the second



Repairing cracks or other damage by welding.

application of the test load. It shall not show any

permanent deformation.



Bending or resetting.

Consult the fork manufacturer for further

3. The following repairs MAY be performed.

information as may be applicable to the specific



Forks may be sanded or lightly ground, to remove

fork involved.

rust, corrosion or minor defects from the surfaces.

Testing is not required for repairs to the



Heel sections may be ground with a carbon stone

positioning lock or the markings.

to remove minor surface cracks or defects. Polish

the inside radius of the heel section to increase the

-105-

Maintenance Section

Torque Specifications

Metric Hardware

Torque for Standard Bolts, Nuts,

Most of the nuts, bolts, studs, and threaded holes in

and Taperlock Studs

your lift truck are metric. In this manual we provide

specifications in both metric and U.S. customary

NOTICE

measurement. Always replace metric hardware with

metric hardware. See the parts books for proper

The two charts below give general torques for bolts,

replacement.

nuts, and taperlock studs of SAE Grade 5 or better

quality.

NOTE: For proper fit, use only metric tools on

metric hardware. Non-metric tools might

slip and cause injury.

Torques for Bolts and Nuts With

Standard Threads

Torque for Standard Hose Clamps

Thread Size

Standard Nut and Bolt Torque

- Worm Drive

Inch

N∙m¹

lb∙ft

NOTICE

1/4

12 ± 4

9 ± 3

The chart below gives the torques for initial

5/16

25 ± 7

18 ± 5

installation of hose clamps on new hose and for

3/8

45 ± 7

33 ± 5

reassembly or retightening of hose clamps on

existing hose.

7/16

70 ± 15

50 ± 11

1/2

100 ± 15

75 ± 11

Initial Installation

9/16

150 ± 20

110 ± 15

Clamp Width

Torque On New Hose

5/8

200 ± 25

150 ± 18

N∙m¹

lb∙in

3/4

360 ± 50

270 ± 37

16 mm (.625 in)

7.5 ± 0.5

65 ± 5

7/8

570 ± 80

420 ± 60

13.5 mm (.531 in)

4.5 ± 0.5

40 ± 5

875 ± 100

640 ± 75

8 mm (.312 in)

0.9 ± 0.2

8 ± 2

1 1/8

1100 ± 150

820 ± 110

1 1/4

1350 ± 175

1000 ± 130

Reassembly Or

1 3/8

1600 ± 200

1180 ± 150

Clamp Width

Retightening Torque

1 1/2

2000 ± 275

1480 ± 200

N∙m¹

lb∙in

¹ 1 Newton meter (N∙m) is approximately the same as 0.1

16 mm (.625 in)

4.5 ± 0.5

40 ± 5

kg∙m.

13.5 mm (.531 in)

3.0 ± 0.5

25 ± 5

8 mm (.312 in)

0.7 ± 0.2

6 ± 2

¹ 1 Newton meter (N∙m) is approximately the same as 0.1

kg∙m.

-106-

Maintenance Section

Torques for Taperlock Studs

Torque for Metric Fasteners

NOTICE

Thread Size

Standard Taperlock Stud Torque

Be very careful never to mix metric with U.S.

Inch

customary (standard) fasteners. Mismatched or

N∙m¹

lb∙ft

incorrect fasteners will cause lift truck damage or

malfunction and may even result in personal injury.

1/4

8 ± 3

6 ± 2

5/16

17 ± 5

13 ± 4

Original fasteners removed from the lift truck should

3/8

35 ± 5

26 ± 4

be checked for any damages and kept for

reassembly whenever possible. If new fasteners are

7/16

45 ± 10

33 ± 7

needed, they must be of the same size and grade as

1/2

65 ± 10

48 ± 7

the ones that are being replaced.

5/8

110 ± 20

80 ± 15

The material strength identification is usually shown

on the bolt head by numbers (8.8, 10.9, etc.). This

3/4

170 ± 30

125 ± 22

chart gives standard torques for bolts and nuts with

7/8

260 ± 40

190 ± 30

Grade 8.8.

400 ± 60

300 ± 45

For mounting torques of main parts , Please refer to

1 1/8

500 ± 700

370 ± 50

Service manual for detail.

1 1/4

650 ± 80

480 ± 60

NOTE: Metric hardware must be replaced with

1 3/8

750 ± 90

550 ± 65

metric hardware. Check parts book.

1 1/2

870 ± 100

640 ± 75

¹ 1 Newton meter (N∙m) is approximately the same as 0.1

Metric ISO² Thread

kg∙m.

Thread Size

Standard Torque

Metric

N∙m¹

lb∙ft

12 ± 4

9 ± 3

25 ± 7

18 ± 5

M10

55 ± 10

41 ± 7

M12

95 ± 15

70 ± 11

M14

150 ± 20

110 ± 15

M16

220 ± 30

160 ± 22

M20

450 ± 70

330 ± 50

M24

775 ± 100

570 ± 75

M30

1600 ± 200

1180 ± 150

M36

2700 ± 400

2000 ± 300

¹ 1 Newton meter (N∙m) is approximately the same as 0.1

kg∙m.

² ISO - International Standards Organization.

-107-

Maintenance Section

Cooling System Specifications

Filling at over 20 liters (5 U.S. gallons) per minute

Coolant Information

can cause air pockets in the cooling system.

NOTE: The following information is generic and

After draining and refilling the cooling system,

valid for lift trucks.

operate the engine with the radiator cap removed

until the coolant reaches normal operating

Engine operating temperatures have increased to

temperature and the coolant level stabilises. Add

improve engine efficiency. This means proper

coolant as necessary to fill the system to the proper

cooling system maintenance is especially important.

level.

Overheating, overcooling, pitting, cavitation erosion,

cracked heads, piston seizures, and plugged

Never operate without a thermostat in the cooling

radiators are classic cooling system failures. In fact,

system. Cooling system problems can arise without

coolant is as important as the quality of fuel and

a thermostat.

lubricating oil.

NOTICE

CROWN recommends that the coolant mixture

contain

50% commercially available automotive

antifreeze, and 50% water.

The coolant mix with concentration of antifreeze

smaller than

30% does not provide sufficient

corrosion protection. Concentrations over

60%

adversely affect freeze protection and heat transfer

rates.

Never add coolant to an overheated engine, engine

damage can result. Allow the engine to cool first.

If the machine is to be stored in, or shipped to, an

area with freezing temperatures, the cooling system

must be protected to the lowest expected outside

(ambient) temperature.

The engine cooling system is normally protected to -

28°C(-20°F) with antifreeze, when shipped from the

factory unless special requirements are defined.

Check the specific gravity of the coolant solution

frequently in cold weather to ensure adequate

protection.

Clean the cooling system if it is contaminated, the

engine overheats or foaming is observed in the

radiator.

Old coolant should be drained, the system cleaned

and new coolant added every 2000 service hours or

yearly.

Refer to topic, “Cooling System - Clean, Change” in

Every 2000 Service Hours or Yearly section.

-108-

Maintenance Section

Coolant Water

Antifreeze

Hard water, or water with high levels of calcium and

magnesium ions, encourages the formation of

NOTICE

insoluble chemical compounds by combining with

cooling system additives such as silicates and

CROWN recommends using automotive antifreeze

phosphates.

suitable for gasoline engines having aluminum alloy

parts. Antifreeze of poor quality will cause corrosion

The tendency of silicates and phosphates to

of the cooling system, and thus always use

precipitate out-of-solution increases with increasing

automotive antifreeze prepared by a reliable maker,

water hardness. Hard water, or water with high

and never use it mixed with antifreeze of different

levels of calcium and magnesium ions encourages

brand.

the formation of insoluble chemicals, especially after

CROWN recommends that the coolant mix contain

a number of heating and cooling cycles.

50% commercially available automotive antifreeze,

CROWN prefers the use of distilled water or

or equivalent and acceptable water to maintain and

deionized water to reduce the potential and severity

adequate water pump cavitation temperature for

of chemical insolubility.

efficient water pump performance.

Premix coolant solution to provide protection to the

Acceptable Water

lowest expected outside (ambient) temperature.

Water Content

Limits (PPM)

Pure undiluted antifreeze will freeze at -23°C (-

10°F).

Chlorides (Cl)

50 maximum

Sulfates (SO4)

50 maximum

Use a greater concentration (above

50%) of

Total hardness

80mg/l

commercially available automotive antifreeze only

Total solids

250 maximum

as needed for anticipated outside (ambient)

6.0 to 8.0

temperatures. Do not exceed the recommendations,

provided with the commercially available automotive

ppm = parts per million

antifreezes, regarding the coolant mixture of

antifreeze to water.

Using water that meets the minimum acceptable

water requirement may not prevent drop-out of

these chemical compounds totally, but should

Make proper antifreeze additions.

minimise the rate to acceptable levels.

Adding pure antifreeze as a makeup solution for

cooling system top-up is an unacceptable practice. It

increases the concentration of antifreeze in the

cooling system which increase the concentration of

dissolved solids and undissolved chemical inhibitors

in the cooling system. Add antifreeze mixed with

water to the same freeze protection as your cooling

system.

Use the chart below to assist in determining the

concentration of antifreeze to use.

Antifreeze Concentrations

Protection Temperature

Concentration

30% antifreeze and 70%

Protection to -15°C (5°F)

water

40% antifreeze and 60%

Protection to -23°C (-10°F)

water

50% antifreeze and 50%

Protection to -37°C (-34°F)

water

60% antifreeze and 40%

Protection to -51°C (-60°F)

water

-109-

Maintenance Section

Fuel Specifications

General Fuel Information

Use only fuel as recommended in this section.

NOTICE

Fill the fuel tank at the end of each day of operation

to drive out moisture laden air and to prevent

condensation. Maintain a constant level near the top

of the day tank to avoid drawing moisture into the

tank as the level decreases. Do not fill the tank to

the top. Fuel expands as it gets warm and can

overflow.

Do not fill the fuel filters with fuel before installing

them. Contaminated fuel will cause accelerated

wear to the fuel system parts.

Drain the water and sediment from main fuel storage

tank before it is refilled. This will help prevent water

and/or sediment from being pumped from the fuel

storage tank into the engine fuel tank.

LP Specifications

LP is “Liquefied Petroleum Gas”. The exact

composition of LP varies slightly between different

parts of the country and different refineries.

HD5 is recommended for CROWN forklift trucks.

Remember LP is heavier than air and will sink to the

lowest spot possible. Avoid areas near floor drains

or lubrication pits where escaped fuel may collect.

Composition of HD5

Propane (C3H8)

90.0 %

Propylene

up to 5 %

Butane (C4H10)

2.0 %

iso-Butane

1.5 %

Methane (CH4)

1.5 %

Total

100 %

-110-

Maintenance Section

Lubricant Specifications

Lubricant Information

Hydraulic Oil (HYDO)

Certain abbreviations follow Society of Automotive

The following commercial classifications can be

Engineers (SAE) J754 nomenclature and some

used in the hydraulic system.

classifications follow SAE J183 abbreviations.



ISO 6743/4

The MIL specifications are U.S.A. Military

Specifications.



AFNOR NFE 48-603

The recommended oil viscosities can be found in the

Lubricant Viscosities chart in this publication.



DIN 51524 TEIL 2

H-LP



HAGGLUNDS DENISON

HFO-

Grease is classified by the National Lubricating

HF2

Grease Institute (NLGI) based on ASTM D217-68



CINCINNATI

Worked Penetration characteristics which are given

a defined consistency number.

P68,69,70

Viscosity : ISO VG 32

Engine Oil (DEO and EO)

Industrial premium hydraulic oils that have passed

the Vickers vane pump test (35VQ25). These oils

The following oil specifications provide guidelines for

should have antiwear, antifoam, antirust and

the selection of commercial products :

antioxidation additives for heavy duty use as stated

by the oil supplier. ISO viscosity grade of 32 would

normally be selected.

• Gasoline/LP Engine : API SJ or higher

NOTE: Engine Oil Service hours can be extended to

NOTICE

500 hours by using CROWN supplied specific oil.

Please consult CROWN dealer about it.

Make-up oil added to the hydraulic tanks must mix

with the oil already in the systems. Use only

petroleum products unless the systems are

NOTICE

equipped for use with special products. If the

Failure to follow the oil recommendations can cause

hydraulic oil becomes cloudy, water or air is entering

shortened engine lift due to carbon deposits or

the system. Water or air in the system will cause

excessive wear.

pump failure. Drain the fluid, retighten all hydraulic

suction line clamps, purge and refill the system.

Consult your CROWN Lift Truck dealer for purging

Consult the EMA Lubricating Oils Data Book for a

instructions.

listing of oil brands.

NOTE: The percentage of sulphur in the fuel will

affect the engine oil recommendations. For

fuel sulphur effects, the Infrared Analysis or

the ASTM D2896 procedure can be used to

evaluate the residual neutralization

properties of an engine oil. The sulphur

products formation depends on the fuel

sulphur content, oil formulation, crankcase

blowby, engine operating conditions and

ambient temperature.

-111-

Maintenance Section

Transmission Oil (TDTO)

Brake Fluid

NOTICE

This oil is formulated for transmissions and drive

trains only, and should not be used in engines.

Shortened engine life will result.

NOTE: MuIti-grade oils are not blended by

CROWN for use in transmissions. Multi-

grade oils which use high molecular weight

polymers as viscosity index improvers lose

their viscosity effectiveness by permanent

and temporary shear of the viscosity index

improver and therefore, are

not

recommended for transmission and drive

train compartments.

Oil Cooled Disc Brake Only

Use heavy duty hydraulic brake fluid certified by oil

NOTE: Failure to follow this recommendation can

supplier to meet the latest version of following

cause shortened transmission life due to

classifications.

material

incompatibility,

inadequate

frictional requirements for disk materials



ISO 6743/4

and/or excessive gear wear.



AFNOR NFE 48-603

Select the oil that meets the following specification.



DIN 51524 TEIL 2

H-LP



HAGGLUNDS DENISON

HFO-HF2



GM DEXRON III



CINCINNATI

P68,69,70



FORD MERCON V

Viscosity : ISO VG32

Drive Axle Oil

Brake reservoir oils that have passed the Vickers

NOTE: Failure to follow the recommendation will

vane pump test (35VQ25). These oils should have

cause shortened life due to excessive gear

antiwear, antifoam, antirust and antioxidation

wear.

additives for heavy duty use as stated by the oil

supplier. ISO viscosity grade of 32 would normally

Oil Cooled Disc Brake (OCDB)

be selected.

Select oil that meets below specifications.

The following products are authorised for use.

: Universal Transmission Tractor Oil (UTTO)

Supplier

Product Name

The following UTTO products are authorised for use.

TOTAL

AZOLLAZS

SHELL

TELLUS

Supplier

Product Name

MOBIL

DTE20S’

TOTAL

TRANSMISSION MP

CALTEX

RANDO HD

MOBIL

MOBILFLUID 424

ESS

NOTO H

CASTROL

HYSPIN AWS

Lubricating Grease (MPGM)

Use Multipurpose Molybdenum Grease (MPGM) for

all lubrication points. If MPGM grease can not be

used, a multipurpose type grease which contains

3% to 5% molybdenum disulfide can be used.

NLGI No.2 grade is suitable for most temperatures.

Use NLGI No.1 or No.0 grade for extremely low

temperature.

-112-

Maintenance Section

Lubricant Viscosities and Refill Capacities

Refill Capacities

Lubricant Viscosities

Refill Capacities-(Approximate)

for Ambient (Outside) Temperatures

U.S.

Compartment

Oil

°C

°F

Compartment or System

Liters

Gal.

or System

Viscosities

Min

Max

Min

Max

SAE

Engine Crankcase

-30

+30

-22

+86

4.3

1.1

5W30

w/Filter LP

Engine

SAE 10W30

-20

+30

-4

+86

Crankcase

SAE 5W40

-30

+40

-22

+104

Cooling System

(LP) and

w/Coolant Recovery

19.0

5.0

SAE 10W40

-20

+40

-4

+104

Lift Chains

Bottle LP

SAE 15W40

-10

+40

+14

+104

API SJ

SAE 15W50

-10

+50

+14

+122

SAE 20W50

-5

+50

+23

+122

Power Shift Transmission

13.0

3.4

Power Shift

Hydraulic & Power

Transmission

DEXRON III

-20

+50

-4

+122

73.0

19.3

Steering System

DEXRON III

ISO VG32

-20

+30

-4

+86

Drive Axle

Disc Brake (OCDB)

14.0

3.7

Hydraulic and

Power Steering

Brake Reservoir (Only for OCDB)

0.6

0.16

ISO VG46

-10

+40

+14

+104

System

ISO 6743/4 HM

ISO VG68

+50

+32

+122

Disc

Drive

Brake

Axle

UTTO

-20

+80

-4

+176

(OCDB)

Housing

UTTO

ISO VG32

-20

+30

-4

+86

Brake Reservoir

(Only for OCDB)

ISO VG46

-10

+40

+14

+104

ISO 6743/4HM

ISO VG68

+50

+32

+122

The SAE grade number indicates the viscosity of oil.

A proper SAE grade number should be selected

according to ambient temperature.

-113-

Maintenance Section

Transmission Oil Level - Check

125

Maintenance Intervals

Hydraulic Oil Level - Check

126

Drive Axle Oil Level - Check

126

Brake Oil Level - Check

126

NOTICE

Users should be familiar with the requirements for

First 50 - 100 Service Hours or a Week

inspection and maintenance of lift trucks as provided

by Australian Standard AS2359.

Transmission Oil, Oil Filter & Strainer - Clean,

Change

128

Drive Axle Oil - Check, Clean, Change

130

Parking Brake - Test, Adjust

131

NOTICE

Never exceed the Maintenance Intervals specified in

Every 250 Service Hours or Monthly

the manual. Defects and/or damage to the important

functional components may be resulted in.

Engine Oil & Filter - Change

133

Every 500 Service Hours or 3 Months

NOTICE

Air Intake System - Check, Clean

134

All maintenance and repair, except Every 10 Service

Tilt Cylinders - Check, Adjust, Lubricate

136

Hours or Daily, on the lift truck must be performed

Mast Hinge Pins - Lubricate

137

by qualified and authorised personnel only.

Crosshead Rollers - Inspect

137

Carriage Side Rollers Thrust (If Equipped) -

Lubricate

137

Carriage Sideshifter (If Equipped) - Lubricate

137

NOTICE

Mast, Carriage, Lift Chains, & Attachments - Check,

Careless disposal of waste oil can harm the

Lubricate

138

environment and can be dangerous to persons.

Carriage Side Rollers - Lubricate

138

Always dispose of waste oil to authorised personnel

Parking Brake - Test, Adjust

139

only.

Circulation Pump Belt (OCDB & LP Engine Only. If

Eguipped) - Check, Adjust

139

Drive Axle Oil & Strainer (OCDB Only) - Check,

Clean, Change

139

When Required

Horn & Lights (If Equipped) - Check

140

Inspect Vacuum Lines and Fittings (LP Engine only)

Test Fuel System for Leaks (LP Engine Only)

118

................................................................................. 140

Seat, Hood Latch & Support Cylinder - Check,

Fuel Trim Valve(FTV) Inspection (PSI Engine only)

Lubricate

118

................................................................................. 141

Fuses, Bulbs & Circuit Breaker - Change, Reset

Inspect Electrical System (LP Engine only)

141

.................................................................................119

Overhead Guard - Inspect

141

Fuse & Relay (LP Engine Only)

120

Steer Suspension - Inspect

141

Circuit Breaker

120

Steering Mechanism - Check, Lubricate

142

Carriage Roller Extrusion - Check, Adjust

121

Wheel Bolts and Nuts - Inspect

142

Battery Terminal - Clean, Inspect

121

Every 1000 Service Hours or 6 Months

Every 10 Service Hours or Daily

Air Intake System - Change

143

Inspect Engine for Fluid Leaks

122

Inspect Coolant Hoses (LP Engines Only)

143

Engine Oil Level - Check

122

LP Regulator/Converter Inspection (LP Engine Only)

Coolant Level - Check, Clean

122

................................................................................. 143

Air Cleaner Indicator - Check

123

Fuel Lines & Fittings - Check

144

Walk - Around Inspection - Inspect

124

Inspect Mixer Assembly (LP Engine Only)

144

Mast Channels - Lubricate

125

Inspect Throttle Assembly (LP Engine Only)

144

-114-

Maintenance Section

Hydraulic Return Filter - Change

144

Air Breather - Change

144

Transmission Oil, Oil Filter & Strainer - Clean,

Change

144

Lift Chains - Test, Check, Adjust

145

Universal Joint - Inspect

147

Every 1500 Service Hours or 9 Months

Drive Axle Oil (Shoe Brake Only) - Check, Clean,

Change

148

Inspect Ignition System (LP Engine Only)

148

Replace Spark Plugs (LP Engine Only)

148

Replace LP Fuel Filter Element (LP Engine Only)

.................................................................................149

Fuel Filter (LP Engine Only)

149

Testing Fuel Lock-off Operation (LP Engine Only)

.................................................................................150

Every 2000 Service Hours or Yearly

Steer Wheel Bearings -Reassemble

151

Cooling System - Clean, Change

152

Fork - Inspect

153

Every 2500 Service Hours or 15 Months

Hydraulic Oil - Check, Clean, Change

155

Inspect Battery System

155

Checking the TMAP Sensor (LP Engine Only)

156

Inspect for Intake Leaks (LP Engine Only)

156

Replace PCV Valve and breather element - Change

(LP Engine Only)

156

Replace Oxygen Sensor (PSI Engine)

156

Environment Protection

157

-115-

Maintenance Section

Quick Reference to Maintenance Schedule

FIRST

EVERY

ITEMS

SERVICES

PAGE

Air Breather

Change

144

Air Cleaner Indicator

Check

123

Air Intake System

Change

143

Air Intake System

Check, Clean

134

Battery Terminal

Clean, Inspect

121

Brake Oil Level

Check

126

Carriage Roller Extrusion

Check, Adjust

121

Carriage Side Rollers

Lubricate

138

Carriage Side Rollers Thrust (If Equipped)

Lubricate

137

Carriage Sideshifter (If Equipped)

Lubricate

137

Checking the TMAP Sensor (LP Engine

156

Only)

Circuit Breaker

120

Circulation Pump Belt (OCDB & LP Engine

Check, Adjust

139

Only. If Eguipped)

Coolant Level

Check, Clean

122

Cooling System

Clean, Change

152

Crosshead Rollers

Inspect

137

Check, Clean,

Drive Axle Oil

130

Change

Check, Clean,

Drive Axle Oil & Strainer (OCDB Only)

139

Change

Check, Clean,

Drive Axle Oil (Shoe Brake Only)

148

Change

Drive Axle Oil Level

Check

126

Engine Oil & Filter

Change

133

Engine Oil Level

Check

122

Fork

Inspect

153

Fuel Filter (LP Engine Only)

149

Fuel Lines & Fittings

Check

144

Fuel Trim Valve(FTV) Inspection (PSI

141

Engine only)

Fuse & Relay (LP Engine Only)

120

Fuses, Bulbs & Circuit Breaker

Change, Reset

119

Horn & Lights (If Equipped)

Check

140

Check, Clean,

Hydraulic Oil

155

Change

Hydraulic Oil Level

Check

126

Hydraulic Return Filter

Change

144

Inspect Battery System

155

Inspect Coolant Hoses (LP Engines Only)

143

-116-

Maintenance Section

Quick Reference to Maintenance Schedule

FIRST

EVERY

ITEMS

SERVICES

PAGE

Inspect Electrical System (LP Engine only)

141

Inspect Engine for Fluid Leaks

122

Inspect for Intake Leaks (LP Engine Only)

156

Inspect Ignition System (LP Engine Only)

148

Inspect Mixer Assembly (LP Engine Only)

144

Inspect Throttle Assembly (LP Engine Only)

144

Inspect Vacuum Lines and Fittings (LP Engine

140

only)

Test, Check,

Lift Chains

145

Adjust

LP Regulator/Converter Inspection (LP Engine

143

Only)

Mast Channels

Lubricate

125

Mast Hinge Pins

Lubricate

137

Check,

Mast, Carriage, Lift Chains, & Attachments

138

Lubricate

Overhead Guard

Inspect

141

Parking Brake

Test, Adjust

131,139

Replace LP Fuel Filter Element (LP Engine

149

Only)

Replace Oxygen Sensor (PSI Engine Only)

156

Change (LP

Replace PCV Valve and breather element

156

Engine Only)

Replace Spark Plugs (LP Engine Only)

148

Check,

Seat, Hood Latch & Support Cylinder

118

Lubricate

Steer Suspension

Inspect

141

Steer Wheel Bearings

Reassemble

151

Check,

Steering Mechanism

142

Lubricate

Test Fuel System for Leaks (LP Engine Only)

118

Testing Fuel Lock-off Operation (LP Engine

150

Only)

Check, Adjust,

Tilt Cylinders

136

Lubricate

Transmission Oil Level

Check

125

Transmission Oil, Oil Filter & Strainer

Clean, Change

128,144

Universal Joint

Inspect

147

Walk - Around Inspection

Inspect

124

Wheel Bolts and Nuts

Inspect

142

-117-

Maintenance Section

When Required

You must read and understand the warnings and instructions contained in the Safety section of this manual,

before performing any operation or maintenance procedures.

Test Fuel System for Leaks (LP

Seat, Hood Latch & Support

Engine Only)

Cylinder - Check, Lubricate

Check

Points

1. Check the operation of the seat adjuster rod. Make

sure that the seat slides freely on its track. Lightly oil

1. Obtain a leak check squirt bottle or pump spray

the seat slider tracks if necessary.

bottle.

2. Fill the bottle with an approved leak check solution.

3. Spray a generous amount of the solution on the fuel

system fuel lines and connections, starting at the

storage container.

4. Wait approximately 15-60 seconds then perform a

visual inspection of the fuel system. Leaks will

cause the solution to bubble.

5. Repair any leaks before continuing.

6. Crank the engine through several revolutions. This

will energize the fuel lock-off and allow fuel to flow to

the pressure regulator/converter. Apply additional

leak check solution to the regulator/converter fuel

connections and housing. Repeat leak inspection as

2. Push the lever down to raise the hood and seat

listed above.

assembly. Make certain the support cylinder will

hold the hood open.

7. Repair any fuel leaks before continuing.

WARNING

Prior to any service or maintenance activity, Test

Fuel System for Leaks

3. Lightly oil the hood latch mechanism and the rod for

the hood support cylinder.

-118-

Maintenance Section

Fuses, Bulbs & Circuit Breaker -

Change, Reset

Gas

Fuses

NOTE: If a fuse filament separates, use only the

same type and size fuses for replacement.

If the filament in a new fuse separates,

have the circuits and instruments checked.

NOTICE

Always replace fuses with ones of the correct

ampere rating.

Fuse Box (Close)

Remove the front cover from the fuse box. The

fuses are located under the air cleaner.

Fuse - Protects an electrical circuit from an

overload. Opens (filament separates) if an

overload occurs.

Typical Example

Fuse Box (Open)

Fuses are identified as follows :

1. Horn - 10 A

2. Head Lamp ,Clearance Lamp, Tail Lamp - 15 A

3. Lamp Relay Coil, Fwd/Rev. Solenoid, Rear Lamp

Relay & Back-up Lamp/Alarm - 15 A

4. Instrument Panel, Hour Meter, Preheat Controller,

Fuel Shut off Solenoid - 15 A

5. Stop Lamp, Turn Signal Lamp, Strobe Lamp - 15 A

6. Starter Relay - 10 A

Typical Example

-119-

Maintenance Section

Carriage Roller Extrusion - Check,

Battery Terminal - Clean, Inspect

Adjust

WARNING

1. Set the mast vertical.

2. Lower the carriage completely.

Batteries give off flammable fumes that can

explode.

3. On full free lift and full free triple lift models, the

bottom of the inner mast must be flush with the

Do not smoke when observing the battery

electrolyte levels.

Electrolyte is an acid and can cause personal

injury if it contacts skin or eyes.

Always wear protective glasses when working

with batteries.

LP Engine - 12V X 1

5. Measure the distance from the bottom of the inner

upright to the bottom of carriage bearing.

6. The measurement (A) must be as follows in Chart

below.

Height of carriage roller extrusion (A) [unit : mm]

STD mast

FF mast

FFT mast

-7

Typical Example

LP Engine Truck

1. Clean the top of the battery and terminals.

2. Check terminals for corrosion. Coat terminals with

heavy grease.

3. Ensure the battery terminal is firmly tightened and

rubber cap is installed.

-121-

Maintenance Section

Every 10 Service Hours or Daily

You must read and understand the warnings and instructions contained in the Safety section of this manual,

before performing any operation or maintenance procedures.

Coolant Level - Check, Clean

Inspect Engine for Fluid Leaks

1. Start the engine and allow it to reach operating

Check Coolant Level

temperatures.

WARNING

2. Turn the engine off.

3. Inspect the entire engine for oil and/or coolant leaks.

At operating temperature, the engine coolant is

hot and under pressure.

4. Repair as necessary before continuing.

Steam can cause personal injury.

Engine Oil Level - Check

Check the coolant level only after the engine has

been stopped and the filter cap is cool enough

WARNING

to touch with your bare hand.

Hot oil and components can cause personal

Remove the filter cap slowly to relieve pressure.

injury. Do not allow hot oil or components to

contact skin.

Cooling system conditioner contains alkali.

Avoid contact with the skin and eyes to prevent

personal injury.

Park the lift truck level, with the forks lowered,

parking brake applied, transmission in NEUTRAL

and the engine stopped.

1. Observe the coolant level with engine cold. Maintain

1. Raise the hood and seat assembly. Make certain

coolant level to the proper line on expansion bottle.

the support cylinder securely holds the hood open.

If the expansion bottle has no coolant, it will be

necessary to check coolant at the radiator filter neck.

2. Remove the radiator cap. Fill radiator to the top of

the filter neck. Inspect radiator cap. Replace if

damaged. Install the radiator cap.

2. The oil level should be close as possible to upper

point of the oil dip stick. Do not refill more than

upper point.

-122-

Maintenance Section

Air Cleaner Indicator - Check

Checking Service Indicator

3. Start and run the engine to stabilise the coolant level

in the filter neck. If low add coolant until it reaches

the top of the filter neck. Install the radiator cap.

Observe coolant level in the expansion bottle. If

necessary, add coolant to bring the coolant to the

Typical Example

LP Engine Truck

appropriate line on the expansion bottle.

4. Stop the engine.

1. Observe the air cleaner service indicator.

5. Inspect the cooling system for leaks, hose cracks or

2. Service the air cleaner when the RED band in the

loose connections.

service indicator, lock in the visible position. See

topic, “Air Intake System - Check, Clean” in “Every

WARNING

250 Service Hours or Monthly”.

NOTE: Service the element more frequently, as

Pressure air can cause personal injury.

required, in severe dust or lint conditions.

Also, service it more frequently where the

When using pressure air for cleaning, wear a

protective face shield, protective clothing and

operator is required to wear a respirator.

protective shoes.

3. Close hood and seat assembly.

Maximum air pressure must be less than 205

kPa (30 psi) for cleaning purposes.

Inspect Acceleration Pedal

6. Blow any dust and lint from the radiator fins.

Operation(PSI Engine)

1. Verify foot pedal travel is smooth without sticking.

WARNING

When the acceleration pedal harness is

connected or disconnected, should be worked

key OFF condition.

If not, occurred malfunction, can cause the

personal injury.

Inspect Engine for Exhaust Leaks

1. Start the engine and allow it to reach operating

temperatures.

2. Perform visual inspection of exhaust system.

3. Repair any/all leaks found.

-123-

Maintenance Section

Walk - Around Inspection - Inspect

For maximum service life of the lift truck, make a

thorough walk-around inspection.

Look around and under the truck for such items as

loose or missing bolts, debris or dirt buildup, fuel, oil

or coolant leaks and cut gouged tyres.

Have any repairs made and debris removed, as

needed.

Typical Example

LP Engine Truck

8. Inspect the cooling system for leaks, worn hoses

and debris buildup.

9. Inspect engine compartment for oil, coolant and fuel

leaks.

10. Inspect the forks.



Visually inspect forks for cracks, especially in the

heel section, around the mounting brackets, and all

weld areas.

1. Inspect the tyres and wheels for cuts, gouges,



Inspect for broken or jagged fork tips, bent or

foreign objects, inflation pressure and loose or

twisted blades and shanks.

missing bolts.



Make sure positioning lock is in place and working.

Lock the forks in position before using the truck.

2. Inspect the mast and lift chains for wear, broken

See Step 7 of “ Forks ” in “ Every 2000 Service

links, pins and loose rollers.

Hours or Yearly ”

3. Inspect the hydraulic system for leaks, worn hoses



Remove all defective forks from service.

or damaged lines.

4. Look for transmission and differential leaks on the lift

truck and on the ground.

5. Inspect the operator’s compartment for loose items

and cleanliness.

6. Inspect the instrument panel for broken gauges and

indicator lights.

7. Test the horn and other safety devices for proper

operation.

-124-

Maintenance Section

Mast Channels - Lubricate

Transmission Oil Level - Check

WARNING

Hot oil and components can cause personal

injury. Do not allow hot oil or components to

contact skin.

1. Start and operate the lift truck until the engine

reaches normal operating temperature.

2. Park the lift truck level with the forks lowered,

parking brake applied and the transmission controls

in NEUTRAL.

The channels on the roller-type mast require a

3. With the brake applied and the engine at low idle,

break-in period. Apply a light film of lubricant on the

shift the directional control lever to forward and then

channels where the rollers ride. This will prevent

to reverse, to fill the clutches.

metal peel until the rollers set a pattern.

4. Shift the direction control lever to the NEUTRAL

position.

5. Open the access door in floor plate.

6. Remove the dipstick/filter cap. Observe the oil level.

7. Maintain the oil level between the Min and Max

marks on the dipstick/filter cap.

When the oil temperature is 40°C approximately,

the cold side mark on the dipstick is applicable.

When the oil temperature is 80°C approximately,

the hot side mark on the dipstick is applicable.

8. Close the access door in floor plate.

9. Stop the engine.

-125-

Maintenance Section

Drive Axle Oil Level - Check

Hydraulic Oil Level - Check

WARNING

Hot oil and components can cause personal

At operating temperature, the hydraulic tank is

injury. Do not allow hot oil or components to

hot and under pressure.

contact skin.

Hot oil can cause burns.

Park the lift truck on a level surface. Apply the

Remove the filter cap only when the engine is

parking brake. The engine is at the low idle. Place

stopped, and the cap is cool enough to touch

with your bare hand. Remove the filter cap

the directional control level in NEUTRAL.

slowly to relieve pressure.

1. Operate the lift truck for a few minutes to warm the

oil. Park the lift truck on a level surface, with the

forks lowered, mast tilted back, parking brake

engaged, transmission in NEUTRAL and the engine

stopped.

2. Raise the hood and seat assembly. Make sure the

air lift cylinder securely holds the hood open.

1. Lift the carriage high enough to access the drive

axle housing oil level plug and fill plug.

2. Put blocks under the carriage.

Brake Oil Level - Check

3. Remove the dipstick/ filter cap. Maintain the oil level

to the FULL mark on the breather/dip stick.

The brake reservoir is located on the left side of the

steering column.

1. Remove the filler cap.

2. Maintain the brake fluid level to the fluid level mark

on the brake system reservoir.

3. Clean and install the filler cap

-126-

Maintenance Section

First 50 - 100 Service Hours or a Week

You must read and understand the warnings and instructions contained in the Safety section of this manual,

before performing any operation or maintenance procedures.

Transmission Oil, Oil Filter &

Strainer - Clean, Change

WARNING

Hot oil and components can cause personal

injury. Do not allow hot oil or components to

contact skin.

Park the lift truck level, with the forks lowered,

parking brake engaged, transmission in NEUTRAL

2. Wash the strainer (screen) ①, spring ② and drain

and the engine stopped.

plug ③ in clean, nonflammable solvent. Dry and

install the strainer, spring and drain plug.

3. Raise the hood and seat assembly.

1. Remove the drain plug, spring and strainer. Allow

the oil to drain.

4. Remove and discard the oil filter. Wipe off the filter

NOTICE

base. Make sure all of the old seal is removed.

Careless disposal of waste oil can harm the

5. Put a small amount of clean oil on the seal on the

environment and can be dangerous to persons.

new filter. Install the filter by hand. When the filter

contacts the base, tighten it an additional 3/4 turn.

Always dispose of waste oil to authorised and

licensed personnel only.

6. Close the hood and seat assembly.

-128-

Maintenance Section

Oil Cooled Disc Brake (OCDB) Type

Drive Axle Oil - Check, Clean,

Change

Park the lift truck on a level surface, parking brake

applied, transmission in neutral.

WARNING

Hot oil and components can cause personal

injury. Do not allow hot oil or components to

contact skin.

1. Remove drain plug. Allow the oil to drain into a

suitable container. Clean the magnetic drain plug.

Check O-ring seal and replace if necessary.

2. Install the drain plug.

1. Lift the carriage high enough to access the drive

axle housing fill plug with breather.

2. Block the bottom of the mast with a block of wood to

hold the carriage in the raised position.

3. Turn the ignition switch OFF.

3. Remove the dip stick/filter cap. Fill the drive axle

housing with oil. See “Lubricant Specification - Drive

Axle Oil” and “Refill Capacity”

4. Start the lift truck. With the engine at low idle, place

the directional control lever to the NEUTRAL.

5. Maintain the oil level between lower mark and upper

mark on the dip stick/filter cap.

6. Install the dip stick/filter cap.

-130-

Maintenance Section

Parking Brake - Test, Adjust

WARNING

Parking Brake Testing

To prevent personal injury, the operator MUST

NOTICE

be ready to use the service brake if the parking

OSHA requires the parking brake to hold the lift

brake is not adjusted correctly and the lift truck

truck, with capacity load, on a 15% grade.

starts to move.

Testing requires a test load equal to the capacity of

the truck and a 15% grade.

Parking Brake Adjusting

If the maximum grade in the workplace is less than

its capacity, use the Parking Brake inspection

1. Park the lift truck on a level surface, lowered the

procedure covered in ‘Inspection from Operator’s

forks, shift the transmission to NEUTRAL and

Seat, Engine On’ in “Every 10 Service Hours or

shut OFF the engine and block the wheels

Daily” section.

securely.

1. Pick up capacity load and drive over to a 15%

2. Chock the lift truck's tyres to prevent unintentional

grade.

movement.

2. Drive forward up the 15% grade. Halfway up the

grade, stop the lift truck with its service brakes.

3. Engage the parking brake and slowly release the

service brake.

3. Remove the floor mat and floor plate.

4. Make sure the parking brake lever is released.

4. Engage the parking brake and shift the

transmission to NEUTRAL. Slowly release the

service brakes.

5. The parking brake adjustment is proper if it holds

the lift truck on the grade. The parking brake

needs adjusting if it does not hold the lift truck on

the grade.

6. If the lift truck starts to move in reverse down the

grade with the parking brake engaged, stop it with

the service brakes, disengage the parking brake

5. Make sure the brake lever (1) is held against stop

and reverse slowly down the grade controlling

pin (2). If the brake lever (1) is held against the

your speed with the service brakes.

stop pin (2), go to step 7. If the brake lever (1) is

NOT held against the stop pin (2), go to step 6.

-131-

Maintenance Section

6. Remove the pin (3) and the cotter pin (4). Tighten

the nut (6) to compress the spring (7) further and

pull downward and turn the clevis (5) until the pin

(3) fits into the brake lever when the lever (1) is

held against the stop pin (2). Then install the pin

(3) and the cotter pin (4) and return the nut (6) to

the clevis (5).

7. Loosen lock nut (5). Tighten screw (6) to 6 to 7

N•m (50 to 60 lb•in). Loosen the screw (6) 1 1/6

turns and tighten the lock nut (5).

NOTICE

Turn the adjustment screw (6) clockwise to tighten.

Turning the screw (6) too far counterclockwise could

allow parts to fall into the bottom of the transmission.

The transmission would than require disassembly to

remove the parts.

8. Reinstall the floor plate and floor mat.

9. Engage the parking brake, remove the tyre

chocks and test the parking brake. Refer to

‘Parking Brake Testing’ in the preceding section.

To Adjust

Park the lift truck level, with the forks lowered,

transmission in NEUTRAL, the engine stopped and

the wheels securely blocked.

1. Release the parking brake.

2. Turn the adjustment knob, clockwise to tighten the

brake.

3. Test the parking brake adjustment. Repeat the

adjustment procedure, if necessary.

-132-

Maintenance Section

Every 250 Service Hours or Monthly

You must read and understand the warnings and instructions contained in the Safety section of this manual,

before performing any operation or maintenance procedures.

Engine Oil & Filter - Change

LP Engine Crankcase

1. Operate lift truck a few minutes to warm oil. Park the

lift truck with the forks lowered, parking brake

applied, transmission in neutral and the engine

stopped.

2. Raise rear of lift truck off ground and block securely.

WARNING

Hot oil and components can cause personal

injury. Do not allow hot oil or components to

contact skin.

13. Stop the engine and measure the oil level. Maintain

the oil level to the FULL mark on the dip stick.

14. Close hood and seat assembly.

NOTICE

Engine Oil Service hours can be extended to 500

hours by using CROWN supplied specific oil. Please

consult CROWN dealer about it.

3. Remove the crankcase drain plug and allow oil to

drain. Clean and install drain plug.

4. Raise the hood and seat assembly.

5. Remove and discard oil filter element.

6. Wipe sealing surface of oil filter element mounting

base. Make sure the entire old gasket is removed.

7. Before installing a new filter element, apply a small

amount of clean engine oil to the filter element

gasket.

8. Install the new filter element. When the gasket

contacts the base, tighten it 3/4 of a turn more. Do

not overtighten.

9. Raise the lift truck, remove the blocking and lower

the lift truck.

10. Fill the crankcase. See “Refill Capacities ”.

11. Start the engine and allow the oil to fill the filter and

passages.

12. Check for oil leaks.

-133-

Maintenance Section

Every 500 Service Hours or 3 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,

before performing any operation or maintenance procedures.

cleaner and engine. Check intake hose for cracks,

Air Intake System - Check, Clean

damage and loose clamps. Tighten or replace parts

as necessary to prevent leakage.

Servicing Filter Element

NOTICE

Never service precleaner with the engine running.

Do not allow dirty air to enter the intake hose when

cleaning the inside of the air cleaner housing.

5. Check the air cleaner housing for loose latches.

6. Reset the air cleaner service indicator.

7. Install the air filter element.

8. Install the cover and tighten the cover latches.

9. Start the engine and observe the position of the

indicator. If the indicator shows RED after the

installation of the primary element, install another

clean or a new element or, replace the secondary

element. See topic, “Air Intake System - Change” in

Every 1000 Service Hours or 6 months section.

10. Stop the engine and close the hood and seat

Typical Example

LP Engine Truck

assembly.

Service the air cleaner when the red target in the

service indicator stays locked in the visible position

with the engine stopped.

1. To service the air cleaner, loosen the cover latches

and remove the cover.

Typical Example

LP Engine Truck

2. Rotate the element slightly to separate it from its

base and remove it from the air cleaner housing.

3. Clean and inspect the element or replace with a

new element. See topic, “Cleaning Primary Filter

Element”.

4. Clean the inside of air cleaner housing and the

cover. Inspect all connections between the air

-134-

Maintenance Section

Cleaning Primary Filter Elements

Water-280 kPa (40 psi) Maximum

WARNING

Pressure air can cause personal injury.

When using pressure air for cleaning, wear a

protective face shield, protective clothing and

protective shoes.

The maximum air pressure must be below 205

kPa (30 psi) for cleaning purposes.

Direct water on the inside and outside of the

element along the length of the pleats. Air dry it

NOTICE

thoroughly and then examine it.

Do not clean the elements by bumping or tapping

them.

Detergent

Inspect filter elements after cleaning. Do not use a

1. Wash the element in warm water and mild

filter with damaged pleats, gaskets or seals.

household detergent.

When cleaning with pressure air, use 205 kPa (30

2. Rinse the element with clean water. See

psi) maximum pressure to prevent filter element

instructions in preceding topic for cleaning with

damage.

water.

When cleaning with pressure water, use 280 kPa

3. Air dry it thoroughly, and then examine it.

(40 psi) maximum pressure to prevent filter element

damage.

Have spare elements on hand to use while cleaning

used elements.

The primary element should be replaced after a

year’s service or after cleaning no more than 6 times.

1. Insert a light inside the clean dry element and

examine it. Discard the element if tears, rips or

damage are found.

2. Wrap and store good elements in a clean, dry place.

Direct air on the inside and outside of the element

along the length of the pleats. Check the element for

any tears, rips or damage.

-135-

Maintenance Section

Tilt Cylinders - Check, Adjust,

Cylinder Rod Extension

Lubricate

NOTE: The following description is for forward tilt.

For cylinder rod back tilt, the collar should

Chassis Pivot Eyebolts

be stationary by the tilt eye. If it is not, the

O-ring inside the collar may need to be

replaced. To adjust back tilt, spacers must

be added or removed.

Typical Example

1. Lubricate two fittings for the pivot eyebolts, one on

Typical Example

each tilt cylinder.

2. Check the pivot eye pins for loose retainer bolts and

1. Check to make sure the tilt cylinders extend and

wear.

retract evenly.

2. If one cylinder continues to move after the other

cylinder has stopped in full forward or backward tilt,

Mast Pivot Eyes

an adjustment must be made to one cylinder.

Typical Example

3. Lubricate two fittings for the mast pivot eyes, one on

3. To adjust the cylinder rod extension, move the

each side of the mast.

spacer to the rear and loosen the pinch bolt on the

4. Check the pivot eye pins for loose retainer bolts and

clevis.

wear.

4. Turn the cylinder rod in or out of the clevis to obtain

the proper adjustment. Turning the rod into the

clevis shortens the stroke. Turning the rod out of the

clevis lengthens the stroke. When turning for

extending rod, the overlapped length between

clevis’s thread and cylinder rod must be minimum

32 mm

5. Tighten the pinch bolts to a torque of 95 ± 15 N•m

(70 ± 10 lb•ft). Check the cylinder rods again for

even travel.

-136-

Maintenance Section

Mast Hinge Pins - Lubricate

Carriage Side Rollers Thrust (If

Equipped) - Lubricate

Typical Example

1. Lower the forks and tilt the mast forward.

1. Raise the carriage high enough to gain access to

the side thrust rollers on the back side of the

2. Lubricate the two fittings for the mast hinge pins,

carriage. Block the carriage in this position.

3. one on each side of the mast.

Crosshead Rollers - Inspect

1. Operate the mast through a lift cycle. Watch the

chains move over the crosshead rollers. Make sure

the chain is tracking over the rollers properly.

2. Lubricate 2 side thrust roller fittings, one on each

side of the mast.

3. Raise the carriage, remove the blocking. Lower the

carriage to the floor.

Carriage Sideshifter (If Equipped)

- Lubricate

Typical Example

2. Check for damaged crosshead rollers, guards and

retainer rings.

1. Lubricate 4 (6) fittings. The forks may have to be

moved to gain access to all of the fittings.

2. Operate the sideshifter carriage through several

complete cycles to distribute the grease the carriage

to the floor.

-137-

Maintenance Section

Mast, Carriage, Lift Chains, &

Attachments - Check, Lubricate

1. Operate the lift, tilt and attachment controls. Listen

for unusual noises. These may indicate a need for

repair.

2. Inspect for loose bolts and nuts on the carriage.

Remove any debris from the carriage and mast.

3. Inspect the forks and attachments for free operation

and damage. Have repairs made if necessary.

7. In case of Full Free Lift Mast, Extend the primary

cylinder to full length and then check the clearance

and over lapped dimension between carriage

stopper bolt or block (1) and Inner mast stopper

block (2). Adjust the chain anchor bolt (3) so that

clearance should be 14 ± 2 mm.

8. And adjust the overlapped dimension to be 10 ± 2

mm by moving or inserting washer.

Carriage Side Rollers - Lubricate

4. Brush a film of oil on all links of the chain.

5. Raise and lower the carriage a few times to work

lubricant into the chain links.

NOTICE

Lubricate chains more frequently than normal in

applications where the lift truck is operating in a

atmosphere which could cause corrosion of

components or when lift truck must work in rapid lift

cycles.

GC35S-5, GC40S-5, GC45S-5

6. Inspect the chain anchors and individual links for

wear, loose pins or cracked leaves.

GC50C-5, GC55C-5

Lubricate 2 side roller fittings, one on each side of

the carriage

-138-

Maintenance Section

Drive Axle Oil & Strainer (OCDB

Parking Brake - Test, Adjust

Only) - Check, Clean, Change

See topic, “Parking Brake - Test, Adjust” in “First 50-

100 Service Hours.”

WARNING

Hot oil and components can cause personal

Circulation Pump Belt (OCDB & LP

injury. Do not allow hot oil or components to

contact skin.

Engine Only. If Eguipped) - Check,

Adjust

Park the lift truck on a level surface. Apply the

parking brake. Place the directional control level in

NEUTRAL and stop the engine.

1. Check the condition and adjustment of the belt (1).

Correct adjustment allows

10 mm

(3/8 inch)

deflection under 45 N of force.

2. To adjust the circulation pump belt, loosen the

1. Remove drain plug. Allow the oil to drain into a

mounting bolts (2) and adjust the adjusting inner nut

suitable container. Clean the magnetic drain plug.

(3). Tighten the adjusting outer nut (4).

Check O-ring seal and replace if necessary.

3. Lower the hood and seat assembly.

2. Install the drain plug.

3. Remove strainer assembly.

4. Washer the strainer assembly in clean,

nonflammable solvent and dry it.

5. Install the strainer assembly and reconnect the hose

and harness.

-139-

Maintenance Section

Horn & Lights (If Equipped) -

Check

6. Remove the dip stick/filter cap. Fill the drive axle

housing with oil. See “Lubricant Specification - Drive

Axle Oil” and “Refill Capacity”.

1. Press horn button, to determine if horn is

7. Start the lift truck. With the engine at low idle, place

operational.

the directional control lever to the NEUTRAL.

2. Check and replace all defective gauges.

8. Maintain the oil level between lower mark and upper

3. Check all lights such as warning, directional, backup,

mark on the dip stick/filter cap.

driving and flood lights for correct operation.

9. Install the dip stick/filter cap.

Replace all burned out bulbs. Have repairs made if

needed.

Inspect Vacuum Lines and Fittings

(LP Engine only)

1. Visually inspect vacuum lines and fittings for

physical damage such as brittleness, cracks and

kinks. Repair/replace as required.

2. Solvent or oil damage may cause vacuum lines to

become soft resulting in a collapsed line while the

engine is running.

3. If abnormally soft lines are detected, replace as

necessary.

(1) LP fuel lock-off, (2) LP regulator/converter,

(3) Fuel Trim Valve,

(4) LP mixer, (5) Vacuum lines,

(6) Coolant lines, (7) LP fuel line

-140-

Maintenance Section

Overhead Guard - Inspect

Fuel Trim Valve(FTV) Inspection

(PSI Engine only)

1. Visually inspect the Fuel trim valve(3) for abrasions

or cracking. Replace as necessary.

2. To ensure the valve is not leaking a blow-by test

can be performed.

3. With the engine off, disconnect the electrical

connector to the FTV.

4. Disconnect the vacuum line from the FTV to the

pressure regulator/converter, at the converter’s tee

connection.

5. Lightly blow through the vacuum line connected to

1. Check tightness of overhead guard mounting bolts

the FTV. Air should not pass through the FTV when

at 95 N·m (70 lb·ft).

de-energized. If air leaks past the FTV when de-

energized, replace the FTV.

2. Check overhead guard for bent or cracked sections.

Have repairs made if needed.

Inspect Electrical System (LP

Steer Suspension - Inspect

Engine only)

1. Check for loose, dirty or damaged connectors and

wires on the harness including: Fuel lock-off, TMAP

sensor, O2 sensor, Electronic throttle, Control

Relays, Fuel Trim Valve, Foot Pedal, and Distributor

sensor.

2. Repair and/or replace as necessary.

1. Inspect the suspension mounting bolts. Tighten

suspension mounting bolts, if necessary, to 240+30

N·m (180+20 lb·ft).

2. Look for leaks at the power steering hose

connections.

3. Remove any trash buildup on the suspension or the

steer axle.

-141-

Maintenance Section

Steering Mechanism - Check,

Wheel Bolts and Nuts - Inspect

Lubricate

Inspect Tightness

NOTICE

Do not lubricate ball seas of wheels or ball faces of

wheel nuts.

Be sure mounting faces of hub, wheel nuts and flat

mounting surfaces are clean.

Tighten wheel nuts again after 24 hours of operation.

NOTE: Always tighten wheel lug nuts in a

sequence opposite (180°) each other.

1. Lubricate the steer axle king pins, total of four fittings.

If equipped with dual wheels, follow the same nut

Two on the right side and two on the left side.

tightening sequence for both wheels.

2. Lubricate the steering link bearings, total of four

fittings. Two on the right side and two on the left

side.

Drive Wheels

3. Check for any worn or loose components of the

steering mechanism. Remove any debris or trash

as required.

Install drive wheel. Put two nuts opposite (180°)

each other. Tighten both.

Install the remaining nuts. Tighten all nuts in a

sequence opposite (180°) each other. Tighten to

600+90 N•m (440+60 lb•ft).

-142-

Maintenance Section

Every 1000 Service Hours or 6 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,

before performing any operation or maintenance procedures.

Air Intake System - Change

Inspect Coolant Hoses (LP

Engines Only)

Changing Primary Element

See topic, “Air Intake System - Check, Clean” in

1. Visually inspect coolant hoses and clamps.

“Every

500 Service Hours or Monthly”.

Remember to check the two coolant lines that

connect to the pressure regulator/converter.

2. Replace any hose that shows signs of swelling,

cracking, abrasion or deterioration.

Changing Secondary Element

Replace the secondary element after the primary

element has been cleaned three times or yearly.

1. Remove the primary air cleaner element. See topic

“Servicing Filter Element”. Clean the inside of the air

cleaner housing and cover.

(1) LP fuel lock-off, (2) LP regulator/converter

(3) Fuel Trim Valve(FTV), (4) LP mixer

(5) Vacuum lines, (6) Coolant lines, (7) LP fuel line

LP Regulator/Converter Inspection

2. Remove the secondary element. Inspect the gasket

between the air cleaner housing and the engine

(LP Engine Only)

inlet. Replace the gasket if it is damaged.

1. Visually inspect the pressure regulator/converter

housing(2) for coolant leaks and detect the fuel pipe

NOTICE

joints, LP mixer and regulator/converter for LP fuel

leaks.

Always replace the secondary element. Do not

attempt to reuse it by cleaning.

To detect the LP fuel leaks, smear detected parts

with suds, visually inspect whether there are

bubbles after the engine start.

3. Install a new secondary element. Install a new or

cleaned primary element. Install the cover. Tighten

NOTE: For pressure testing and internal inspection

the latches.

of the pressure regulator/converter, contact

to the CROWN service.

4. Start the engine and observe the air cleaner service

indicator. If the indicator shows RED after installing

a new secondary element and a cleaned primary

(outer) element, replace the cleaned primary filter

with a new element.

5. Stop the engine. Close the hood and seat assembly.

-143-

Maintenance Section

Fuel Lines & Fittings - Check

Visually inspect fuel lines and fittings for physical

damage. Replace as required.

Inspect Mixer Assembly (LP

Engine Only)

Refer to the LP mixer section of the engine service

manual for procedures.

2. Remove filter assembly from the hydraulic tank

cover.

Inspect Throttle Assembly (LP

3. Install new filter assembly in the hydraulic tank

Engine Only)

cover.

1. Visually inspect the throttle assembly motor housing

4. Inspect cover gasket for damage, replace it if

for coking, cracks and missing cover-retaining clips.

necessary.

Repair and/or replace as necessary.

5. Clean and Install the cover and tighten retaining

NOTE: Refer to the LP mixer and throttle section of

bolts.

the service manual for procedures on

6. Lower the hood and seat assembly.

removing the mixer and inspecting the

throttle plate.

Air Breather - Change

Park the lift trucks level, with the forks lowered,

Hydraulic Return Filter - Change

parking brake engaged, transmission in NEUTRAL

and the engine stopped.

WARNING

1. Raise the hood and seat assembly.

Hot oil and components can cause personal

2. Remove and discard the air breather.

injury. Do not allow hot oil or components to

contact skin.

Park the lift truck level with the forks lowered,

parking brake engaged, transmission in NEUTRAL

and the engine stopped.

3. Install a new air breather.

4. Lower the hood and seat assembly.

Transmission Oil, Oil Filter &

1. Raise the hood and seat assembly. Loosen the

Strainer - Clean, Change

bolts of the hydraulic tank cover, and remove the

See topic, “Transmission Oil, Oil Filter & Strainer -

hydraulic tank cover with filter assembly.

Clean, Change” in “First 50 - 100 Service Hours or a

Week”.

-144-

Maintenance Section

Lift Chains - Test, Check, Adjust

Check for Equal Tension

Lift Chain Wear Test

Inspect the part of the chain that is normally

operated over the cross head roller. When the chain

bends over the roller, the movement of the parts

against each other causes wears.

Inspect to be sure that chain link pins do not extend

outside of the link hole. If any single link pin is

extended beyond its connecting corresponding link,

it should be suspected of being broken inside of its

link hole. Lift chains are required to check for wear

about every 1,000 service hours or 6 months.

Chain wear test is a measurement of wear of the

Typical example

chain links and pins. Take the following steps to

check chain wear.

Lift the carriage and the mast high enough for

getting tension on lift chains. Check the chains, and

1. Lift the mast and carriage enough for getting tension

make sure the tension is the same. Lift chains are

on lift chains.

required to check for equal tension about every

1,000 service hours or 6 months.

WARNING

Personal injury can be caused by sudden

movement of the mast and carriage.

Keep hands and feet clear of any parts that can

move.

Lift Chain Adjustment

Typical example

2. Measure precisely ten links of chain distance at the

centre of pins in millimeter.

3. Calculate chain wear rate*.

4. If the chain wear rate is 2% or more, replace the lift

chain.

*Chain wear rate (%)

Actual measurement - Pitch** X 10

X 100

Typical example for carriage equal tension

Pitch** X 10

If the tension is not the same on both chains, take

the procedure as follows.

**Chain Pitch for GC35/40/45S-5, GC50/55C-5

NOTE: If carriage height is not correct, make

= 25.40 mm(1.0 in)

adjustments by following procedures.

-145-

Maintenance Section

Carriage Chain Adjustment

Mast Chain Adjustment - FF, FFT Mast

Make sure that carriage height is correct. If correct,

adjust the chain for equal tension. If not, adjust the

chain for correct carriage height by adjusting anchor

nuts(1),(2).

NOTE: See the previous section, “Carriage Roller

Extrusion” in “When Required” for proper

height of carriage.

1. Fully lower the carriage and tilt mast forward or lift

the carriage and put blocks under the carriage to

release the tension from the lift chains.

2. Loosen nut(1) and adjust nut(2) to get proper

distance from bottom of inner upright to the bottom

Typical example for FF mast

of carriage bearing.

Typical example for FFT mast

Typical example for carriage chain of STD mast

Make sure that mast height is correct. If correct,

adjust chain for equal tension. If not, adjust mast

chain for correct mast height by adjusting anchor

nuts (3), (4).

NOTE: See the previous section, “Carriage Roller

Extrusion” in “When Required” for proper

inner mast height.

1. Lift the inner mast and put blocks under the inner

mast to release the tension from the lift chains.

2. Loosen nut(3) and adjust nut(4) to make inner mast

rail flush with outer mast rail bottom.

Typical example for carriage chain of FF,FFT mast

3. Make adjustment anchor nuts(3),(4) for equal chain

tension.

3. Make adjustment anchor nut(1),(2) for equal chain

tension.

4. Raise the inner mast and check equal chain tension.

If not equal, repeat the same procedure as step 1

4. Set the mast vertical and raise the carriage and

through step 3.

check equal chain tension. If not equal, repeat the

same procedure as step 1 through step 3.

5. Put LOCTITE No. 242 tread lock on the threads of

the anchor nuts(3),(4) after the adjustment is

5. Put LOCTITE No. 242 Tread lock on the threads of

completed.

the anchor nuts(1),(2) after the adjustment is

completed.

-146-

Maintenance Section

Every 1500 Service Hours or 9 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,

before performing any operation or maintenance procedures.

Drive Axle Oil (Shoe Brake Only) -

Replace Spark Plugs (LP Engine

Check, Clean, Change

Only)

See topic, “Drive Axle Oil - Check, Clean, Change”

1. Disconnect Battery Cables.

in “First 50-100 Service Hours or a Week”.

2. Using a gentle twisting motion remove the high

voltage cables from the spark plugs. Replace any

damaged cables.

Inspect Ignition System (LP

3. Remove the spark plugs.

Engine Only)

4. Gap the new spark plugs to the proper

specifications.

1. Disconnect Battery Cables.

PSI Engine : 0.9 mm (0.035 inch)

2. Remove and inspect the spark plugs. Replace as

required.

5. Apply anti-seize compound to the spark plug

3. Test secondary cables with an Ohmmeter. If

threads and install.

maximum resistance is higher than 25 kOhms,

repair and/or replace.

PSI Engine : 30 N·m (22 lb·ft)

4. Remove distributor cap and perform visual

inspection. Replace cap and rotor if corrosion is

WARNING

found on the contacts.

Do not overtighten the spark plugs.

5. Inspect the ignition coil for cracks and heat

deterioration. Visually inspect the coil heat sink fins.

If any fins are broken replace as required.

6. Re-install the high voltage cables.

-148-

Maintenance Section

Replace LP Fuel Filter Element (LP

Fuel Filter (LP Engine Only)

Engine Only)

Disassembly

Park the lift truck in an authorised refueling area with

the forks lowered, parking brake applied and the

transmission in Neutral.

1. Close the fuel shutoff valve on the LP-Fuel tank.

Run the engine until the fuel in the system runs out

and the engine stops.

2. Turn off the ignition switch.

3. Scribe a line across the filter housing covers, which

will be used for alignment purposes when re-

installing the filter cover.

1. Remove top cover (2), magnet (3), spring (4), and

Filter

filter element (7) from bottom cover (5).

Housing

2. Replace the filter element (7).

Scribe

Point

3. Check bottom cover O-ring seal (6) for damage.

Replace if necessary.

4. Re-assemble the filter assembly aligning the scribe

lines on the top and bottom covers.

5. Install the cover retaining screws, tightening the

screws in an opposite sequence across the cover.

6. Open the fuel valve by slowly turning the valve

4. Remove the cover retaining screws (1)

counterclockwise.

7. Crank the engine several revolutions to open the

fuel lock-off. DO NOT START THE ENGINE. Turn

the ignition key switch to the off position.

8. Check the filter housing, fuel lines and fittings for

leaks. Repair as necessary.

-149-

Maintenance Section

Every 2000 Service Hours or Yearly

You must read and understand the warnings and instructions contained in the Safety section of this manual,

before performing any operation or maintenance procedures.

4. Remove the castle nut and washer.

Steer Wheel Bearings -

5. Remove the wheel assembly. Examine the seal for

Reassemble

damage and wear. Replace the seal if necessary.

Park the lift truck level with the forks lowered,

6. Remove the inner bearing. Clean and lubricate the

parking brake engaged, transmission in NEUTRAL

and the engine stopped.

steering knuckle. Reassemble both the inner and

outer bearing cones.

7. Install the inner bearing. Lubricate the seal and

install the wheel assembly on the knuckle.

8. Install the outer wheel bearing and the outer washer.

Install a new lock washer and fit the locknut.

Typical Example

1. Lift the steer wheels off the ground. Place stands or

blocking under the frame and steer axle to support

the lift truck.

2. Remove the hub cap.

Typical Example

9. Tighten the locknut to 135 N•m (100 lb•ft), while

turning wheel hub to seat the bearing.

10. Loosen the locknut. Retorque it to 50 ± 5 N•m (37 ±

4 lb•ft). Bend the lockwasher tang to secure locknut.

11. Install the hub cap.

12. Raise the lift truck and remove the blocking Lower

the lift truck to the ground.

Typical Example

3. Remove the cotter pin.

-151-

Maintenance Section

4. Close radiator drain valve and install block drain

Cooling System - Clean, Change

plug. Fill the cooling system with 1 kg (2 lb) sodium

bisulphate per 40 liters (10 gallons) of water. Most

WARNING

commercial cooling system cleaners can be used.

5. Start and run the engine for 30 minutes.

At operating temperature, the engine coolant is

hot and under pressure.

6. Stop the engine and drain the cleaning solution.

Steam can cause personal injury.

7. Flush the system with clean water, until draining

water is clear.

Check the coolant level only after the engine has

been stopped and the filter cap is cool enough

8. Close the drain valve and install the block drain plug.

to touch with your bare hand.

Fill the system with neutralizing solution, 250g (1/2

lb) sodium carbonate per 40 liters (10 gallons) of

Remove the filter cap slowly to relieve pressure.

water.

Cooling system conditioner contains alkali.

9. Start and run the engine for 10 minutes.

Avoid contact with the skin and eyes to prevent

10. Stop the engine and drain the neutralizing solution.

personal injury.

11. Flush the system with clean water until draining

Use all cleaning solutions with care.

water is clear.

12. Close the drain valve and install the block drain plug.

The lift truck must be level, the forks lowered, the

Add coolant to the top of the filter neck.

parking brake engaged, the transmission in

13. Start and run the engine to stabilise the coolant level.

NEUTRAL and the engine stopped and cool.

See “Every 10 Service hours or Daily”, “Coolant

Level-Check”, in this manual.

1. Turn the radiator cap slowly to relieve the pressure,

then remove the cap.

2. Remove the block drain plug.

Typical Example

3. Open radiator drain valve. Allow the coolant to drain.

Drain the recovery bottle.

-152-

Maintenance Section

Fork - Inspect

Check the straightness of the upper face of blade

(D) and the front face of shank (E) with a straight

Forks should be inspected, at a minimum, every 12

edge.

months. If the truck is being used in a multi-shift or

heavy duty operation, they should be checked every

The fork should be withdrawn from service if the

six months.

deviation from straightness exceeds 0.5 percent

of the length of the blade and/or the height of the

1. Inspect the forks carefully for cracks. Special

shank respectively 5 mm/1000 mm (0.18"/36").

attention should be given to the heel section (A), all

weld areas and mounting brackets (B). Inspect the

top and bottom hooks on forks used on hook type

carriages and tubes on shaft mounted forks.

Forks with cracks should be removed from

service. "Wet Test" magnetic particle inspection

is generally preferred due to its sensitivity and

the ease of interpreting the results. Portable

equipment is usually recommended so it can be

moved to the lift truck.

Inspectors should be trained and qualified in

accordance with The American Society for Non

Destructive Testing, Level II Qualifications.

Check the difference in height of one fork tip to the

other when mounted on the fork carrier. A difference

in fork tip height can result in uneven support of the

load and cause problems with entering loads.

The maximum recommended difference in fork

tip elevation (F) is 6.5 mm (0.25") for pallet forks

and 3 mm (0.125") for fully tapered forks. The

maximum allowable difference in fork tip

elevation between the two or more forks is 3

percent of blade length (L).

Replace one or both forks when the difference in

fork tip height exceeds the maximum allowable

difference. Contact your local CROWN Lift Truck

2. Check the angle between the upper face of the

Dealer for further information.

blade and the front face of the shank. The fork

should be withdrawn from service if angle (C)

exceeds 93 degrees or deviates by more than 3

degrees from an original angle other than

degrees, as may be found in some special

application forks.

-153-

Maintenance Section

8. Check fork markings (N) for legibility. Renew

Check the fork blade (J) and shank (H) for wear with

markings as required to retain legibility.

special attention to the heel (G). The fork should be

withdrawn from service if the thickness is reduced to

9. a. Lift the mast and operate the tilt control lever, until

90 percent or less of the original thickness.

the top surface of the forks is parallel with the floor.

Place two straight bars that are the same width as

Fork blade length may also be reduced by wear,

the carriage, across the forks as shown.

especially on tapered forks and platens. Remove

the forks from service when the blade length is

b. Measure the distance from the bottom of

no longer adequate for the intended loads.

each end of the two bars to the floor. The

forks must be parallel within 3 mm (.12 in) for

Full Tapered and Polished (FTP) forks, all

other forks 6.4 mm (.25 in), for their complete

length.

c. Put one fork, one third from the tip, under a

fixture that will not move. Then operate the tilt

control with caution until the rear of the truck

lifts just off the floor. Follow the same

procedure with the second fork. Repeat Step

Check the fork mountings (K) for wear, crushing and

other local deformation, which can cause excessive

side to side wobble of the forks. Excessive

clearance on hook type forks may allow them to fall

from the carrier. Forks which show visible signs of

such damage should be removed from service.

Check the positioning lock and other fork retention

devices to make sure they are in place and working.

Hook type forks use a spring loaded pin (M),

located in the top hook, to engage notches in the

top carriage bar to hold the fork in place.

When adjusting the fork spacing, the forks are

prevented from sliding off the end of the carriage by

stop blocks. These stop blocks are at both ends of

the carriage and in the path of the bottom fork hook.

The load backrest extension may be used in place

of the stop blocks in some cases.

Shaft mounted forks may use set collars or spacers

on the shaft to either side of the fork. They may also

use U bolts, pins, or similar devices which engage

the fork through the top structure of the carriage.

-154-

Maintenance Section

Every 2500 Service Hours or 15 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,

before performing any operation or maintenance procedures.

FULL mark on the dipstick.

Hydraulic Oil - Check, Clean,

Change

Inspect Battery System

1. Clean battery outer surfaces with a mixture of

WARNING

baking soda and water.

Hot oil and components can cause personal

2. Inspect battery outer surfaces for damage and

injury. Do not allow hot oil or components to

replace as necessary.

contact skin.

3. Remove battery cable and clean, repair and/or

replace as necessary.

Park the lift truck level with the forks lowered, mast

tilted back (all cylinders retracted), parking brake

engaged, transmission in NEUTRAL and the engine

stopped.

1. Remove the hydraulic tank drain plug. Allow the oil

to drain. Clean and install the plug.

2. Raise the hood and seat assembly.

3. Remove dipstick/filter cap. Fill the hydraulic tank.

See “Refill Capacities.” Install the breather/dipstick.

4. Lower the hood and seat assembly.

5. Start the engine and operate the hydraulic controls,

and the steering system, through a few cycles to fill

the lines. Look for oil leaks.

6. Stop the engine and check the oil level. With all

cylinders retracted, maintain the oil level to the

-155-

Maintenance Section

Checking the TMAP Sensor (LP

Replace Oxygen Sensor (PSI

Engine Only)

Engine)

1. Verify that the TMAP sensor (2) is mounted tightly

into the manifold adapter (3), with no leakage.

2. If the TMAP is found to be loose, remove the TMAP

retaining screw and the TMAP sensor from the

manifold adapter.

3. Visually inspect the TMAP O-ring seal for damage.

Replace as necessary.

4. Apply a thin coat of an approved silicon lubricant to

the TMAP o-ring seal.

5. Re-install the TMAP sensor into the manifold

adapter and securely tighten the retaining screw.

Exhaust Tube

(1) Adapter-Throttle body, (2) TMAP sensor,

(3) Adapter-Manifold, (4) Throttle body

Muffler Ass’y

Inspect for Intake Leaks (LP

When indicated by MIL, replace oxygen sensors on

Engine Only)

the exhaust tube and muffler assembly.

1. Visually inspect the intake manifold, throttle

assembly

(4), and manifold adapters

(3), for

1. Stop engine and wait until the exhaust pipe and

looseness and leaks. Repair as necessary.

exhaust pipe is cooled.

Replace PCV Valve and breather

2. Disconnect the electrical connector of oxygen

sensor.

element - Change (LP Engine

3. Remove oxygen sensor.

Only)

4. Assemble new oxygen sensor Tightening torque :

2. Loosen the hose clamps and remove the PCV valve.

45 N·m (32.5 lb·ft)

3. Assemble new PCV valve and hose.

5. Connect the electrical connector of oxygen sensor.

4. Tighten the hose clamps

-156-

Index Section

Chassis Pivot Eyebolts

136

Index

Check Coolant Level

122

Check for Equal Tension

145

Checking Element

135

Checking Service Indicator

123

Checking the TMAP Sensor (LP Engine Only)

156

12 Months Inspection

105

Circuit Breaker

44,120

Circulation Pump Belt (OCDB & LP Engine Only. If

Eguipped) - Check, Adjust

139

Cleaning Primary Filter Elements

135

Coolant Information

108

Accelerator Pedal

Coolant Level - Check, Clean

122

Adjustments

Coolant Water

109

Air-205 kPa (30 psi) Maximum Pressure

135

Coolant

Air Breather - Change

144

Cooling System - Clean, Change

152

Air Cleaner Indicator - Check

123

Cooling System Specifications

108

Air Intake System - Change

143

Crosshead Rollers - Inspect

137

Air Intake System - Check, Clean

134

Crushing or Cutting Prevention

Antifreeze

109

Cylinder Rod Extension

136

Attachment Abbreviations (Includes Special Forks)

...................................................................................40

Auto Shift Controller ASC - 206 (Standard)

Avoiding Lift Truck Tipovers

Daily Inspection

104

Declaration of Conformity

Detergent

135

Direction Control Lever

Batteries

Disassembly

149

Battery Terminal - Clean, Inspect

121

Drive Axle Oil - Check, Clean, Change

130

Before Operating the Lift Truck

Drive Axle Oil & Strainer (OCDB Only) - Check,

Before Starting the Engine

Clean, Change

139

Before Starting the Lift Truck

Drive Axle Oil (Shoe Brake Only) - Check, Clean,

Before Storage

Change

148

Bent or Twisted Forks

103

Drive Axle Oil Level - Check

126

Brake Fluid

112

Drive Axle Oil

112

Brake Oil Level - Check

126

Drive Wheels

142

Brake Pedal Adjustment Warning

Bulbs

120

Burn Prevention

Electrical Disconnect Switch (If Equipped)

Electronic Controlled Spark-Ignition Engines

Engine Compartment

Capacity Chart (Not used in Australia)

34,36

Engine Oil & Filter - Change

133

Capacity Chart (with Side Shifter) (Not used in

Engine Oil (DEO and EO)

111

Australia)

35,37

Engine Oil Level - Check

122

Carriage Chain Adjustment

146

Environment Management

Carriage Roller Extrusion - Check, Adjust

121

Environment Protection

102,157

Carriage Side Rollers - Lubricate

138

Every 10 Service Hours or Daily

122

Carriage Side Rollers Thrust (If Equipped) -

Every 1000 Service Hours or 6 Months

143

Lubricate

137

Every 1500 Service Hours or 9 Months

148

Carriage Sideshifter (If Equipped) - Lubricate

137

Every 2000 Service Hours or Yearly

151

Causes of Fork Failure

103

Every 250 Service Hours or Monthly

133

Centre of Gravity (CG)

Every 2500 Service Hours or 15 Months

155

Changing LP Tanks

Every 500 Service Hours or 3 Months

134

Changing Primary Element

143

Changing Secondary Element

143

-158-

Index Section

Inspect Electrical System (LP Engine only)

141

Inspect Engine for Exhaust Leaks

123

Falling Objects Protective Structure(FOPS)

Inspect Engine for Fluid Leaks

122

Fatigue

103

Inspect for Intake Leaks (LP Engine Only)

156

Fire or Explosion Prevention

Inspect Ignition System (LP Engine Only)

148

First 50 - 100 Service Hours or a Week

128

Inspect Mixer Assembly (LP Engine Only)

144

First Installation

104

Inspect Throttle Assembly (LP Engine Only)

144

Fluid Penetration

Inspect Tightness

142

Foreword

Inspect Vacuum Lines and Fittings (LP Engine only)

Fork - Inspect

153

................................................................................. 140

Fork Inspection

104

Inspection, Maintenance and Repair of Lift Truck

Fuel Filter (LP Engine Only)

149

Forks

102

Fuel Lines & Fittings - Check

144

Instrument Panel

Fuel Specifications

110

Fuel Trim Valve(FTV) Inspection (PSI Engine only)

.................................................................................141

Fuse & Relay (LP Engine Only)

120

Fuses

119

Jacking Information

100

Fuses, Bulbs & Circuit Breaker - Change, Reset

Jacking Procedure

101

.................................................................................119

Lift Chain Adjustment

145

General Fuel Information

110

Lift Chain Wear Test

145

General Hazard Information

Lift Chains - Test, Check, Adjust

145

Lift Control

Lift Fork Adjustment

Lift Truck Capacity Rating

Lift Truck Controls

Hook - on type Fork

Lift Truck Operation

Horn & Lights (If Equipped) - Check

140

Lift Truck Parking

How to Fix Forklift to a Carrier

Lift Truck Shipping

How to Survive in a Tipover (If Operator Restraint

Lift Truck Stability Base

System Equipped)

Lift Truck Stability

Hydraulic Jack & Jack Stand Capacity

100

Lifting a Forklift using a Crane

Hydraulic Oil - Check, Clean, Change

155

Lifting Drums or Round Objects

Hydraulic Oil (HYDO)

111

Lifting the Load

Hydraulic Oil Level - Check

126

Literature Information

Hydraulic Return Filter - Change

144

Load Backrest Must Be In Place Warning

Loading or Unloading Trucks/Trailers

Long Time Storage

LP Engine Crankcase

133

LP Engine

LP Regulator/Converter Inspection (LP Engine Only)

Identification, Lift Capacity and Attachment Plate

................................................................................. 143

...................................................................................39

LP Specifications

110

If Optional Suspension Seat (weight adjusting type)

Lubricant Information

111

Equipped

Lubricant Specifications

111

Important Safety Information

Lubricant Viscosities and Refill Capacities

113

Improper Modification or Repair

103

Lubricant Viscosities

113

Inching into Loads

Lubricating Grease (MPGM)

112

Inching

Index

158

Inspect Acceleration Pedal Operation(PSI Engine)

.................................................................................123

Inspect Battery System

155

Inspect Coolant Hoses (LP Engines Only)

143

Machine Lifting and Tiedown Information

-159-

Index Section

Maintenance and Repair

105

Pressure Air

Maintenance Information

Pressure Warning

Maintenance Intervals

114

Prestart Conditions

Maintenance

Product Description

Make proper antifreeze additions

109

Mast Abbreviations

Mast Chain Adjustment - FF, FFT Mast

146

Mast Channels - Lubricate

125

Mast Hinge Pins - Lubricate

137

Refill Capacities

113

Mast Pivot Eyes

136

Refueling

Mast, Carriage, Lift Chains, & Attachments - Check,

Replace LP Fuel Filter Element (LP Engine Only)

Lubricate

138

................................................................................. 149

Metric Hardware

106

Replace Oxygen Sensor (PSI Engine)

156

Metric ISO² Thread

107

Replace PCV Valve and breather element - Change

Mono-Ped Control System (Option)

(LP Engine Only)

156

Mounting and Dismounting

Replace Spark Plugs (LP Engine Only)

148

Moving Fan Warning

Safety Rules

No Riders Warning

Safety

2,5

No Standing On Forks Warning, No Standing Under

Seat Adjustment

Forks Warning

Seat Belt

Noise and Vibration

Seat Switch System (If Equipped)

Noise

Seat

Seat, Hood Latch & Support Cylinder - Check,

Lubricate

118

Serial Number Locations

Serial Number

Oil Cooled Disc Brake (OCDB) Type

127,130

Service Brake Pedal

Oil Cooled Disc Brake (OCDB)

112

Servicing Filter Element

134

Oil Cooled Disc Brake Only

112

Sideshift Attachment Control (If Equipped)

Oils

Specifications

Operating in hot weather

Stability and Centre of Gravity

Operating Techniques

Starting From a 12 Volt External Source

Operating the Lift Truck

Starting the Engine

Operation Information

Starting the Lift Truck

Operation

2,88

Steer Suspension - Inspect

141

Operator's Warning and Identification Plate

Steer Wheel Bearings -Reassemble

151

Operator Restraint System (If Equipped)

Steering Knob (If Equipped)

Operator’s Station and Monitoring Systems

Steering Mechanism - Check, Lubricate

142

Operator’s Warning Plate

Storage Information

Overhead Guard - Inspect

141

Overhead Guard Must Be In Place Warning

Overloading

103

Table of Contents

Test Fuel System for Leaks (LP Engine Only)

118

Testing Fuel Lock-off Operation (LP Engine Only)

Parking Brake - Test, Adjust

131,139

................................................................................. 150

Parking Brake Adjusting

131

Tilt Control

Parking Brake Lever

Tilt Cylinders - Check, Adjust, Lubricate

136

Parking Brake Testing

131

Tilt Steering Column

Parking brake

To Adjust

132

Parking the Lift Truck

To Operate the Lift Truck After a Long Time Storage

Power Shift Transaxle

................................................................................... 96

-160-

Index Section

Torque for Metric Fasteners

107

Torque for Standard Bolts, Nuts, and Taperlock

Studs

106

Torque for Standard Hose Clamps - Worm Drive106

Torque Specifications

106

Torques for Bolts and Nuts With Standard Threads

.................................................................................106

Torques for Taperlock Studs

107

Towing Information

Training Required to Operate or Service Warning... 5

Transmission Inching Control Pedal

Transmission Oil (TDTO)

112

Transmission Oil Level - Check

125

Transmission Oil, Oil Filter & Strainer - Clean,

Change

128,144

Transmission Speed Range Lever

Transportation Hints

Traveling With the Load

Turning

Universal Joint - Inspect

147

Unloading

Vibration(weighted overall value)

Walk - Around Inspection

Walk - Around Inspection - Inspect

124

Warning Signs and Labels

5,17

Water-280 kPa (40 psi) Maximum Pressure

135

Wheel Bolts and Nuts - Inspect

142

When Required

118

-161-