Service Manual Crown Pallet Jack
Contents
1. amp AU ns Es Service Manual Crown Pallet Jack Models PTH and PTH50 Developed by Generic Parts Service This manual is intended for basic service and maintenance of the Crown pallet jack The pallet jacks you are servicing are tools that make moving products easier Operating pallet jacks with rusty broken or worn parts makes usage and maintenance more difficult Pallet jack parts are inexpensive and easy to replace To ensure maximum life from the jack always replace the parts that are broken or worn Remember that all parts on a pallet jack depend on the adjoining parts to work properly and to perform to their full potential When used in conjunction with our catalog this service manual will explain how and when to replace a pallet jack part Remember when in doubt replace it If you have any questions just call us We make it easy 1 800 331 0839 US 19 95 Fax 1 800 366 5939 CAN 29 95 CALL 1 800 331 0839 GENERIC PARTS SERVICE GPS Inc Contents 2 Suggested Assemblies 3 Commonly Used Tools 3 Helpful Reminders 4 Axles 4 Bushings 5 Load Rollers and Load Roller Brackets 6 Steer Wheels and Axle Traverse 8 Push Rods 9 Lifting Link 10 Handle Removal and Installation Hydraulic Unit 12 Inspection 13 Service Hints 14 Removal 14 Installation 15 Diagram Copyright 1999 by GPS Inc All rights reserved Crown PTH and PTH50 pallet jacks are products of Crown Equipm2. maintenance easier CALL 1 800 331 0839 4 GENERIC PARTS SERVICE GPS Inc Load Roller and Load Roller Brackets Inspection Load rollers Load rollers should have neither flat spots nor large pieces of metal imbedded in them i e tacks nails or metal shavings Any chips in the wheel that keep it from rolling smoothly indicate the need for replacement If the wheel has cracks loose tread or does not turn freely replace both wheels Always change the wheels in pairs to reduce uneven wear New load rollers have an outside diameter of 3 PTH50 or 3 4 PTH If the diameter is is worn more than 4 from normal size replacement is necessary Load roller brackets Inspect the brackets for cracks or wear from prolonged rubbing on the floor Check for out of round axle holes and inspect the bushings closely see Bushing Inspection If any of the above conditions exist replace the brackets Removal Tip We recommend servicing one load roller assembly at a time while using the other assembly as reference PTH Load roller Pump the jack to expose the load roller brackets and then turn the jack on its side Use a hammer and pin punch to remove both of the roll pins in the load roller brackets that secure the load roller axle in place Drive the axle out with the punch and remove the load roller 10 minutes Load roller brackets Remove the load roller Drive the roll pins out of the pivot axle that hold the exit roller in
3. place as well as the roll pin that fastens the pivot axle to the frame Drive the pivot axle out pull the push rod away from the frame and pull the brackets off of the push rod 15 minutes Installation PTH Load roller brackets Slide the brackets on to the push rod Insert the pivot axle through the frame brackets and the exit roller Secure the pivot axle to the frame with the roll pin Position the exit roller between the two roll pin holes then hammer the two roll pins in to keep the exit roller in place 15 minutes Load rollers Insert the load roller axle through the brackets and load roller then secure the axle to the brackets with the two roll pins 10 minutes PTH Load Roller Axle Roll Pin Load Roller Q Z P OG Bushing x Exit Roller Push Rod Roll Pins Pivot Axle GENERIC PARTS SERVICE 5 GPS Inc PTH50 Load roller Pump the jack to expose the load roller brackets and then turn the jack on its side Use a hammer and pin punch to remove both of the roll pins in the load roller brackets that secure the load roller axle in place Drive the axle out with the punch and remove the load roller 10 minutes Load roller brackets Remove the load roller Drive the roll pin that fastens the pivot axle to the frame into the axle this is a blind roll pin hole Remove the pivot axle just enough to be able to drive the roll pin out of the axle then drive the pivot axle completely out P
4. The jack should raise now Put the control lever in the neutral position and pump the handle The jack should remain at the same height If the jack raises the barrel nut needs to be adjusted to take up the slack in the chain If it lowers the barrel nut needs to be adjusted to allow a little more slack in the chain Next place the control lever in release position The jack should now lower If not inspect the actuating pin for wear the roll pin in the actuating pin the roll pin should be tapped all the way in to the actuating pin and the release pin If the release pin is sticking your hydraulic unit needs servicing Tip It is easier to install remove the handle with the hydraulic unit removed However it can be done with the hydraulic unit still attached It is also recommended that you have a partner help you hold the handle in position during installation Hold the hand release in the up position during the chain removal and in the down position during installation See Figures 3 and 4 on page Il Newer Older Style Crown PTH Removal Disconnect the adjusting nut from the control rod and the chain connector Pull the chain clear of the connecting pin Remove the roll pin that fastens the connecting pin to the hydraulic unit Drive the connecting pin out and remove the handle 15 minutes Installation Place handle on the hydraulic unit and insert the connecting pin Insert the roll pin that fastens the pin to the hydraulic unit Pull t
5. ct the problem a complete rebuild of the malfunctioning unit may be necessary Please refer to our catalog for information about ordering the appropriate seal kit or take advantage of our hydraulic unit exchange program Jack fails to lift load e Air Lock in Pump Place the control mechanism in the release position then pump handle rapidly 10 15 times 5 minutes e Low Fluid Level With the jack in a lowered position remove filler plug Using UNI HO hydraulic oil fill the reservoir until the oil is about 1 2 below the top of the reservoir Bleed the unit see Air Lock in Pump Replace the filler plug creating a snug fit 5 minutes Note Never overfill with oil as this will blow seals and cause premature leaks and pump failure e Hand Control Out of Adjustment Newer and Older PTH Place control lever in lift position Loosen the nut above the adjusting nut and turn the adjusting nut until most of the slack on the chain is taken up Test the adjustment by pumping the handle to see if the jack raises If it does not raise readjust until the jack raises Then put the control lever into neutral and pump the handle The jack should remain at the same height If it continues to raise the chain is too loose If the jack lowers the chain is too tight and needs to be readjusted Put the control lever into the release position The jack Should lower If not inspect the actuating pin the actuating plate and the release pin to ensure they a
6. d Roll Pin GENERIC PARTS SERVICE 9 CALL 1 800 331 0839 GPS Inc Handle Removal and Installation Inspection Inspect the handle for cracks and structural integrity There should be minimal side play in the handle bracket Check for worn bushings If bushings are not replaced regularly the handle bracket holes can become worn Damaged holes cause pin failure and may require complete replacement Also inspect the handle pin and roller for flat areas and wear If any of the above parts are worn more than 1 16 replace them Newer and Older PTH Place the hand control in the lift position Loosen the nut above the adjusting nut and turn the adjusting nut until most of the slack on the chain is taken up Test the adjustment by pumping the handle to see if the jack rises If it does not raise readjust until the jack rises Put the control lever into neutral and pump the handle The jack should remain at the same height If it continues to rise the chain is too loose If the jack lowers the chain is too tight and needs to be readjusted Put the control lever into the release position The jack Should lower now If not inspect the actuating pin the actuating plate and the release pin to ensure they are not worn If the release pin is sticking your hydraulic unit needs servicing Crown PTH50 Place the control lever in the lift position and adjust the barrel nut so that there is little slack in the chain Test by pumping the handle
7. ee Steer Wheels and Axle Installation and the handle if necessary see Handle Installation Bleed the hydraulic unit see Air Lock and Pump 20 minutes PTH Lifting Link Traverse ra ED y Snap Ring K lt Shoulder Pin Roll Pin Shoulder Pin Snap Ring Roll Pin GENERIC PARTS SERVICE GPS Inc CALL 1 800 331 0839 Push Rods Inspection When inspecting the push rods look for broken or cracked welds bends and out of round holes If any of the above conditions exist replace the push rod We suggest that you work on one side of the jack at one time so you can use the other side as a reference Removal Turn the jack over so the undercarriage is facing up Remove the load roller brackets see Load Roller Brackets On the PTH remove the roll pin and pin that fastens the push rod to the lifting link On the PTH50 remove the roll pin that fastens the push rod to the lifting link 20 minutes Installation Turn the jack over so the undercarriage is facing up Set the push rods in the frame The end of the push rod connecting to the load roller brackets is angled The push rod should be positioned such that the angled side faces the ground when the jack is turned upright Slide the push rod onto the lifting link and fasten by inserting the roll pin On the PTH install the pin that connects the push rod to the lifting link and insert the roll pin Install the load roller brackets see Load Roller Brackets Instal
8. ent Corp GENERIC PARTS SERVICE CALL 1 800 331 0839 GPS Inc Suggested Assemblies to Save Repair Time PTH50 Handle Assembly Rod and Chain Assembly Chain Connector Release Pin Roller Roll Pin Connecting Pin e CR 44506 001 D SUPER Super Ultra Poly Load Roller Assembly e CR 44495 001 Ultra Poly Steer Wheel Assembly CR 44648 SUPER Super Seal Kit e CR 44521 012 Handle Assembly e CR 44527 A Rod and Chain Assembly e CR 44533 A Chain Assembly CR RPK50 Roll Pin Kit CALL 1 800 331 0839 PTH Rod and Chain Adjusting Assembly Nut Chain Connector Roller Roll Pin Connecting Pin CR 82283 1 D SUPER Super Ultra Poly Load Roller Assembly CR 41275 1 D Ultra Poly Steer Wheel Assembly CR 43023 SUPER Super Seal Kit CR 41293 Handle Assembly CR 41295 A Rod and Chain Assembly CR 79904 A Chain Assembly CR RPK Roll Pin Kit GENERIC PARTS SERVICE GPS Inc Commonly Used Tools e Hammer e Jack stand e 45 Snap ring pliers large and small e 13 mm Wrench for entry rollers e 3 mm Allen wrench e 3 16 Pin punch e 3 8 Pin punch e Crown Bushing extractor this custom tool is available only through us e Soft hammer nylon mallet e Anti seize compound e Lubricant i e WD40 may be necessary to remove rusted parts PIN BUSHING SNAP RING PUNCH EXTRACTOR PLIERS Helpful Reminders e Never hammer directly on an axle always use a p
9. f the ram PTH50 only and pull the hydraulic unit out of the traverse Remove the handle and handle bracket if necessary see Handle Removal 45 minutes Installation Slide the stem of the hydraulic unit into the traverse with the washer and traverse bearing already in place on the stem Insert the ram into the A Frame with the ball positioned on the top of the ram PTH50 only and secure the ram to the A Frame with the roll pin Carefully turn the jack onto its side keeping the hydraulic unit in the traverse and frame Attach the snap ring to the stem of the hydraulic unit under the traverse Install the steer wheel assembly see Steer Wheel and Axle Installation and the handle if necessary see Handle Installation Bleed the hydraulic unit see Air Lock and Pump 45 minutes CALL 1 800 331 0839 14 GENERIC PARTS SERVICE GPS Inc Hydraulic Unit Diagram PTH PTH 50 Control lever Ran lever H Control rod Barrel nut i Control rod __Washer cer Spring Spring Nut A Washer ED sage Adjusting Nut ie connector og Chain D Chain connector so 4 d _ Master link Pin Washer Traverse Bearing Snap ring Traverse GENERIC PARTS SERVICE 15 CALL 1 800 331 0839 GPS Inc
10. he chain connector through the pin attach the adjusting nut and screw on to the control rod Have a partner hold the handle down to allow easier access to the adjusting nut and chain 25 minutes See Diagram on page 15 CALL 1 800 331 0839 10 Crown PTH50 Removal Using a 3mm allen wrench remove the screw from the chain connector There is an access slot in the hydraulic unit to reach the screw Pull the chain clear from all pins Remove the roll pin that fastens the pin to the hydraulic unit Punch the connecting pin out and remove the handle 15 minutes Installation Place the handle on the hydraulic unit and insert the connecting pin Insert the roll pin that fastens the pin to the hydraulic unit Lower the chain connector through the pin using a 3mm allen wrench Fasten the chain to the release pin with the screw using the access slot in the hydraulic unit 25 minutes GENERIC PARTS SERVICE GPS Inc Removal of lifting link Page 9 Figure Figure 2 Handle adjustments Page 10 Figure 3 Figure 4 GENERIC PARTS SERVICE 11 CALL 1 800 331 0839 GPS Inc Hydraulic Unit Inspection Inspect the outside of the pump for oil leaks Test the unit under a load to determine if there is a problem This can be done by lifting a heavy pallet and letting it stand for 15 20 minutes Below are symptoms and solutions to common hydraulic unit failures If the following solutions fail to corre
11. in punch e Always replace old roll pins The PTH 50 has blind roll pin holes in the pivot axle and in the shoulder pins It is very important to use the correct roll pin in these locations to prevent damage to the mating parts e Replace accessible bushings whenever the jack is disassembled Our custom designed bushing extractor makes it quick and easy to remove all bushings on the Crown jack e Serial numbers can be found on the A Frame Crown PTH Serial numbers are 3 118400 to 3 999999 Crown PTH50 Serial numbers are 7 000000 and higher GENERIC PARTS SERVICE 5 CALL 1 800 331 0839 GPS Inc Axles Inspection If the axle is bent out of round or shows signs of wear replace it Check for worn roll pin holes If these are damaged or worn replace the axle Bushings Bushings are designed to wear out sooner than the mating parts They are made of softer material and are expendable It is recommended that anytime the jack is torn down to a point where the bushings are accessible they be replaced This will ensure longer life of the jack and will reduce the amount of downtime Bushings are very inexpensive and it is cost effective to change them regularly Inspection If bushings are cracked broken egg shaped or worn more than 16 from the original size replace them Remember f the jack is already disassembled replace all accessible bushings Tip Coating axles and bushings with anti seize compound before installation makes
12. ing pin connecting the steer wheel axle to the bottom of the hydraulic unit The axle will slide out 15 minutes Installation PTH Steer wheels Slide the wheel onto the axle and attach the snap ring 10 minutes Steer wheel axle Slide the axle into the bottom of the hydraulic unit and secure with the fastening pin and its roll pins Then slide the steer wheels on to the axle and attach snap rings 15 minutes Hydraulic Unit Steer Wheel Fastening Pin Snap Ring Roll Pin CALL 1 800 331 0839 PTH50 Steer wheels Remove the hubcap and then the snap ring The Wheel is now free and may be removed 10 minutes Steer wheel axle Turn the jack onto its side Remove the hub cap and the snap ring and slide the steer wheel off of the axle Remove the roll pin holding the axle to the hydraulic unit stem and drive the axle out with a soft hammer 15 minutes PTH50 Steer wheels Slide the wheel onto the axle and attach the snap ring 10 Minutes Steer wheel axle Slide the axle into the bottom of the hydraulic unit and fasten with the roll pin Then secure the steer wheels 15 Minutes PTH50 Hydraulic Unit Roll Pin Snap Ring GENERIC PARTS SERVICE GPS Inc Traverse Inspection There are few things that can be wrong with the traverse Wear can occur on the bearing shoulder or where the Shoulder bolts attach to the lifting link If these areas are egg shaped or out of round rep
13. lace the traverse Removal Pump the jack to maximum height and turn the jack onto its side Remove the steer wheels and axle see Steer Wheels and Axle Removal and the snap ring under the traverse on the stem of the hydraulic unit Turn the jack upright be careful no to damage the stem of the hydraulic unit while lowering Remove the roll pin that fastens the top of the ram to the frame Lift the frame off of the ram tip the handle and hydraulic unit away from the frame and rest both pieces on the ground Remove the ball on top of the ram PTH50 only and pull the hydraulic unit out of the traverse On the PTH remove the roll pins holding the shoulder pins in the traverse Remove the shoulder pins and the traverse On the PTH50 use a pin punch and hammer to drive the shoulder pins roll pins into the shoulder pins until they are flush Remove the shoulder pins and the traverse 20 minutes Installation Attach the traverse to the lifting link with the shoulder pins and secure the shoulder pins with the roll pins Slide the Stem of the hydraulic unit into the traverse with the traverse bearing already in place on the stem Insert the ram into the A Frame with the ball positioned on the top of the ram and secure the ram to the A Frame with the screw Carefully turn the jack onto its side keeping the hydraulic unit in the traverse and frame Attach the snap ring to the stem of the hydraulic unit under the traverse Install the steer wheel assembly s
14. lation 20 minutes Pin Load Roller Bracket UT Q i PTH Load Roller Lifting Link Push Rod Bracket Roll Pin Push Rod Pin Roll Pin CALL 1 800 331 0839 8 GENERIC PARTS SERVICE GPS Inc Lifting Link Inspection Check the lifting link for out of round holes cracks in welds or bent ears If any of these conditions exist replace the lifting link Also check the integrity of the bushings shoulder pins lifting link pins or the roll pins that fasten these parts to their mating parts Removal First remove the hydraulic unit see Hydraulic Unit Remove the traverse see Traverse Remove load roller brackets see Load Roller Brackets and both of the push rods see Push Rods Remove the roll pins that fasten the lifting link pins to the frame Extract the lifting link pins from the frame and then the lifting link 35 minutes See Figures 1 and 2 on page Il Installation Place the lifting link in position and insert the lifting link pins Insert the roll pins that fasten the lifting link pins to the frame Install the push rods see Push Rods Install the load roller brackets see Load Roller Brackets Install the traverse see Traverse Install the hydraulic unit see Hydraulic Unit 40 minutes PTH50 Hydraulic Unit P Lifting Link Pin Ss Q Roll Pin x Load Roller Bracket L a Traverse Shoulder Pin Push Rod Load Roller Bracket Roll Pin Lifting Link Push Ro
15. nk lifting link pin and traverse shoulder pin e Pushrod Load roller bracket pivot axle Service Hints e Tampering and abuse are two of the most common problems In most cases minor repairs become major when inexperienced people attempt to rebuild a hydraulic unit If you come across a unit that looks like it has been tampered with or modified inspect the unit carefully to be sure it can be rebuilt or call Generic Parts Service for technical assistance e The pump piston and ram are polished to a fine finish for maximum seal life and minimum oil leakage If you see these surfaces nicked or pitted this will cause the unit to fail in a short time Replace any rusty or damaged parts that will cause premature wear on their mating parts or the body of the hydraulic unit e Use UNI HO hydraulic oil Do not use automotive oil or hydraulic brake fluid GENERIC PARTS SERVICE 13 CALL 1 800 331 0839 GPS Inc Hydraulic Unit Removal Pump the jack to its maximum height and turn the jack onto its side Remove the steer wheels and axle see Steer Wheels and Axle Removal and the snap ring under the traverse on the stem of the hydraulic unit Turn the jack upright be careful no to damage the stem of the hydraulic unit while lowering Remove the roll pin that fastens the top of the ram to the frame Lift the frame off of the ram tip the handle and hydraulic unit away from the frame and rest both pieces on the ground Remove the ball on top o
16. re not worn If the release pin is sticking your hydraulic unit needs servicing 15 minutes Crown PTH50 Place control lever in lift position and adjust the barrel nut so that there is little slack in the chain Test by pumping the handle The jack should raise Put the control lever in the neutral position and pump the handle the jack should remain at the same height If the jack raises the barrel nut needs to be adjusted to take up the slack in the chain If it lowers the barrel nut needs to be adjusted to allow a little more slack in the chain Next place the control lever in the release position The jack should lower If not inspect the actuating pin for wear the roll pin in the actuating pin the roll pin should be tapped all the way in to the actuating pin and the release pin If the release pin is sticking your hydraulic unit needs servicing 10 minutes CALL 1 800 331 0839 12 GENERIC PARTS SERVICE GPS Inc Jack fails to lower Look for any bent or damaged frame parts lifting link push rod etc Bent or damaged frame parts should be replaced e Hand control is out of adjustment see Hand Control Out of Adjustment e Debris blocking an oil channel in the hydraulic unit Contact us for our hydraulic core exchange program Jack lifts in short increments Lack of oil pressure see Low Fluid Level One fork lifts the other does not Check for damage in the following areas and their attached parts e Lifting li
17. ull the push rod away from the frame and pull the brackets off of the push rod 15 minutes PTH50 Load roller brackets Slide the brackets on to the push rod Insert the pivot axle through the frame exit roller and brackets Line up the roll pin hole and secure the pivot axle to the frame with the roll pin 15 minutes Load rollers Insert the load roller axle through the brackets and load roller then secure the axle to the brackets with the two roll pins 10 minutes PTH50 Roll Pin ped Load Roller X Bearing Exit Roller SC Exit Roller Bracket Ge Pivot Axle Bracket Bushing Push Rod Roll Pin CALL 1 800 331 0839 Steer Wheels and Axle Inspection Steer wheels should have neither flat spots nor large pieces of metal imbedded in them i e tacks nails or metal shavings Chips in the wheel which keep it from rolling smoothly indicate replacement Steer wheels should turn freely They should not rub the bottom of the traverse If they do check for the correct installation of the snap ring under the traverse The PTH50 uses 7 wheels and the PTH uses 8 wheels If the diameter is worn more than 1 4 from the normal size replacement is necessary Removal PTH Steer wheels Turn the jack onto its side remove the snap ring attaching the wheel to the axle and the wheel may be removed 10 minutes Steer wheel axle Turn the jack onto its side Remove the steer wheels the roll pins and fasten
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