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Crown PTH50 Series Hand Pallet Truck Service Repair Manual

service repair manual

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Crown PTH50 Series Hand Pallet Truck Service Repair Manual

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  1. PTH50 SERIES SERVICE + PARTS MANUAL From Serial No. SZ_______ on M Order no.: 812570-006 Revision: A • Printed in Germany

  2. TABLE OF CONTENTS TABLE OF CONTENTS SERVICE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lubrication and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Type of Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Key to Figure 15295 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic Unit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Lift Piston Ram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pump Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cartridge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Forks Will Not Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Unit Will Not Hold Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Unit Lifts On Pump Stroke But Lowers When Handle Is Raised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Unit Leaks Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . 9 Unit Will Not Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 PAGE SERIAL NO. CUT REV. PARTS Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Load Roller Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Load Roller Single . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Load Roller Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Load Roller Tandem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Labels and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 PAGE SERIAL NO. CUT REV. PTH50 3

  3. TABLE OF CONTENTS Notes: PTH50 4

  4. SERVICE 1

  5. Notes: 2

  6. SERVICE Introduction Introduction Model Number This number is used as a brief description of the truck. Refer to the example below for the method used to de- termine the model number and its meaning. This manual is intended for the service technician. It includes information about maintenance, trouble- shooting and a list of replacement parts for the hand pallet truck PTH50. 1 2 Replacement Parts PTH50-27-48 When ordering replacement parts from this manual, al- ways specify: 4 3 – the part number 1 Image Generator (PTH = Hand Pallet Truck) – the model number of the truck 2 Fork Spread (in inches) – the serial number of the truck 3 Fork Length (in inches) The data plate with model and serial number is located on the rear of the fork carriage (see Fig. 15292). 4 Capacity* [50 = 2300 kg (5000 lbs)] *Actual rated capacity may vary, depending on special equipment or modifications. Refer to the data plate for actual cpacity rating. Lubrication The truck is designed to require minimum lubrication. Self-lubricating bushings and sealed bearings are used throughout the truck with two exceptions: – A single grease nipple is provided so the bear- ing in the traverse can occasionally be lubri- cated (use part number 063002-034). – The handle lever ball detent needs occasional lubrication (use part number 363108-001). 15292 PTH50 3

  7. SERVICE Lubrication and Inspection Lubrication and Inspection 15310 Index Component Inspect / Lubricate I-1 Handle, Actuating Lever Inspect handle; lubricate handle detent ball area. I-2 Entry Roller, Load Roll- ers Check for cuts. I-3 Risers Keep risers lubricated. Check for signs of damage or wear. I-4 Forks Inspect forks for cracks on exterior surface. I-5 Grease Nipple Ensure bearing is properly lubricated; use part number 063002-034. I-6 Steered Wheels Inspect wheels for cuts. I-7 Hydraulic Unit Make sure pump is clean. Inspect for any signs of damage or wear. I-8 Spring Check spring for wear, damage, and cleanliness. PTH50 4

  8. SERVICE Hydraulic Unit Hydraulic Unit Lower Pulling the actuating lever up to lower position (2, Fig. 15305EU) lowers the forks. This transmits the downward movement of upper check ball (24) in the cartridge valve to the tappet and unseats the lower check ball (23) in the cartridge valve opening a pas- sageway and allowing fluid to escape from the lift chamber, back into the reservoir, thus lowering the lift piston ram and the forks. Functions (Refer to Figures 15295 & 15305EU) Raise Raise function is selected by pushing actuating lever down to raise position (4, Fig. 15305EU). As the actuating lever is released, springs (5 & 22, Fig. 15305EU) and the spring in the handle return all components to their previous positions. When the handle is raised, the pump piston is actuated upward by means of spring (5, Fig. 15295) and draws fluid from reservoir through control chamber, around the upper check ball (24) in the cartridge valve, through chamber (25) and into the pump cylinder. Fluid move- ment continues in this direction until the top of the han- dle stroke is reached. 1 2 Pushing the handle downward forces fluid out of the pump cylinder and through the chamber. The upper check ball (24) in the cartridge valve blocks the control piston chamber and reservoir. This causes the fluid to continue past the lower check ball (23) in the cartridge valve and into lift chamber, moving the lift piston ram upward. The forks are raised. 3 4 When the end of the handle stroke is reached, the han- dle is raised again and the cycle repeats. As the handle is raised, the lower check ball in the car- tridge valve (23) closes, thus retaining fluid in the lift chamber. Neutral Neutral function is selected by engaging actuating le- ver in neutral position (3, Fig. 15305EU). In this posi- tion tension is applied to the pull rod and chain. The chain pulls the connector and rotates the cam shaft moving the control piston downwards. 15305EU 1 Handle 2 Actuating lever in lower position The downward movement of the control piston unseats the upper check ball (24) in the cartridge valve in the control piston chamber. 3 Actuating lever in neutral position 4 Actuating lever in raise position Fluid Level Raising the handle draws fluid from reservoir through control piston chamber around the upper check ball (24) in the cartridge valve through the control pis- ton chamber and into the pump cylinder. With the forks lowered, check hydraulic fluid by un- screwing the filler plug. Insert a clean probe. • Maximum fluid level should be 38 mm (1.5 in) from top of pump cover. • Minimum level 57 mm (2.25 in) from top of pump cover. When the handle is pushed downwards, since the up- per check ball in the cartridge valve (24) is held un- seated, fluid returns to reservoir, by the same route. PTH50 5

  9. SERVICE Hydraulic Unit Capacity of the hydraulic unit is: • 46 mL (15.4 US fl oz) minimum • 58 mL (19.7 US fl oz) maximum cles attracted to the magnet can be cleaned off. The hydraulic unit must be partially removed to remove the ram. Hydraulic Unit Removal (Refer to page 12) 1. Raise forks completely and securely block rear of truck approximately 100 mm (4.0 in). 2. Remove roll pin from frame. 3. Drive out roll pin. Remove hub caps & retaining rings. Remove wheels from axle. Remove retain- ing ring - not necessary for removal of ram to clean magnet. Hydraulic Fluid Fill/Check Plug 4. Pull actuating lever to lower position, while press- ing lift piston ram into cylinder. The hydraulic unit can now be lifted out. Cartridge Valve Torque to 50 Nm (36.8 ft lbs) 15283 Type of Fluid When operating in temperatures above freezing, use Crown anti-wear hydraulic fluid, part number 363504-101, or equal. For units being operated in tem- peratures below freezing, use Crown low temperature hydraulic fluid, part number 363505-101, or equal. Do not use brake fluid. To obtain maximum life from the hydraulic unit, a mag- net is located at the base of the ram to attract and hold any metal particles that could cause damage to seals, valve seats and other parts. Approximately every three months, the ram should be removed so that any parti- PTH50 6

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  11. SERVICE Hydraulic Unit 15295 PTH50 7

  12. SERVICE Hydraulic Unit Key to Figure 15295 Cartridge Valve Torque to 50 Nm (36.8 ft lbs) Handle Shaft Control Spring (1) (11) (22) Piston Boss Camshaft Lower Check Ball (2) (12) (23) Rod Seal Seal Upper Check Ball (3) (13) (24) Seal Circlip Control Piston (4) (14) (25) Compression Spring Cylinder Ram Chamber (5) (15) (26) Washer Pump Casting Handle Roll Pin (6) (16) (27) Piston Retainer Rod Seal O-Ring (7) (17) (28) CirClip Ram Piston Wiper (8) (18) (29) Pump Piston Magnetic End Oil Plug (9) (19) (30) Camshaft Roll Pin Back Ring Washer (10) (20) (31) O-Ring Handle Pin (21) (32) The entire handle assembly can now be removed. Ro- tate cam shaft so roll pin is parallel to control piston. Drive out roll pin from cam shaft. Remove control pis- ton spring and O-ring. Finally, remove cam shaft. Hydraulic Unit Disassembly (Refer to Figure 15295) Lift Piston Ram Remove by pulling through the top of unit out of cylin- der. Seal (13) is then removed followed by circlip (14) which allows removal of the bushing, seal (17) and spacer. Once the ram is removed, the magnet (19) should be cleaned. Pump Piston Circlip (8) is removed allowing pump cylinder to be re- moved with O-rings (21), back-up ring, spring (22), pump piston, washer and retaining ring (14). Seals (13) and (17) may be removed at this time. If pump piston and cylinder cannot be easily removed (due to seals "sticking"), use gentle downward pres- sure on the handle to push them out. Be careful not to compress the spring too much since this may cause the entire assembly to be released in a hazardous manner. Cartridge Valve The cartridge valve controls the lift/lower functions. In- ternally it has an upper and lower check ball and spring that controls the flow of hydraulic fluid. Inspect seals on cartridge valve, if needed, replace all seals on cartridge valve. Disassemble cap screw from chain connector and remove chain, link and connector through hole in handle pin. Drive out roll pin and remove handle pin. PTH50 8

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