C

DRIVE UNIT

Fill
Plug
Oil
Level
Check
Drain
Plug

Drain
Plug
Figure 3393

Your Crown lift truck has a drive unit centrally located in the
power unit. The drive unit is a double reduction gearbox
providing strength and efficient operation. The unit is totally
enclosed and oil filled to provide maximum lubrication to
both bearings and gears.
The drive unit has a capacity of approximately 1000 ml (3.25
pints) of 90W gear lube, 063002-003. Remove filler plug
located in the side cover, refer to Figure 3393. Add gear oil
until present at oil level check plug hole in the lower housing,
just above the idler shaft. Remove both drain plugs to
completely drain drive unit.
See Torque Value Chart at the end of this section.
Drive Tire Replacement
When replacing the drive tire, make sure the composition
and size are such that maneuverability and capacity are
maintained. The drive tire is a press-on type. To replace,
press old tire off and new tire on. The following procedure
should be followed to remove the drive tire assembly from
the drive unit. Elevate power unit and block securely. Remove the roll pin locking the castle nut to the end of the axle.
Use a 1 1/2 in. wrench and remove the castle nut from axle.
Pull axle from drive unit while stabilizing the drive tire. Refer
to Figure 3393.

Be sure the battery is disconnected before performing any maintenance operations.

Drive Motor Removal
NOTE
Removal of motor for replacement of brushes is
not necessary.
Turn the drive unit to the right or left as far as possible. Open
power unit doors and disconnect battery. For trucks not
equipped with an electric brake assembly, remove the three
screws securing the brake drum to the split bushing. Release the brake and remove the drum. Remove the retaining
ring, split bushing and woodruff key from the drive motor
shaft. For trucks built October 1, 1986 and after (equipped
with an electric brake assembly) refer to section M5.0 Brake
Maintenance for brake removal guidelines. Disconnect all
electrical connections from terminals on drive motor. Label
electrical cables if necessary to eliminate problems when
replacing motor. Remove the two motor mounting screws
located above and slightly off to the side of the motor shaft,
refer to Figure 3393. Turn the drive unit to the left as far as
possible. Support the drive motor and remove the two
screws from the bottom of motor. Pull motor straight out of
casting to prevent damage to motor shaft seal.
12592

M3.007.2015
07 Rev. 12/05

Crown 1985 PF7188-1 Rev. 12/05

DRIVE UNIT

Drive Unit Removal

NOTE
In most cases repair to the drive unit can be made
with the drive unit in the power unit. However,
should it be necessary to remove the complete
drive unit from truck, the following procedure
should be followed.
Elevate and block the power unit; the drive tire must be off
floor.
Remove steering mechanism, control handle, etc. from top
of drive unit.
SP ONLY. Disconnect brake line at base of mainframe.
Drain brake fluid into container. Unclamp and unthread
brake line from power unit. Trucks built October 1, 1986 and
after (equipped with an electric brake assembly) hydraulic
brake lines do not exist.
Disconnect motor cables from contactor panel; disconnect
brake switch leads.
Attach a hoist to support plate at top of drive unit, near the
thrust plate. Use caution not to damage brake linkage, if so
equipped in the process.
Loosen and remove the (3) screws connecting the thrust
plate to the power unit and carefully raise the drive unit until
it is clear of the power unit.

Figure 0357S-02

Remove the drive wheel axle (item 9, Figure 0357S-02).

Remove the roll pin (item 10) locking the castle nut (item 13)
to the end of the axle. Use a 1 1 /2 in. wrench and remove
castle nut from axle. Pull axle from drive unit housing while
stabilizing the drive tire.

NOTE

Unfasten the four screws (item 32 & 29) and remove the
cover (item 33) and the gasket (item 34).

The drive unit should be taken to a clean work

area if further disassembly is necessary. Make
sure the vented fill plug is to the top side of unit if
it is necessary to lay the drive unit down for
transporting, etc.

Remove the retaining ring (item 27), access it through the

slots in the face of the second reduction gear (item 28). Large
retaining ring pliers with a locking ratchet such as a Waldes
Truarc No. S-6700, Crown no. 092668, should be used (see
Figure 3394).

Drive Unit Disassembly

The following disassembly and assembly procedure is a
complete tear down and rebuild operation. Once the problem has been diagnosed the repair procedure can be used
that covers the necessary repair.
LOWER HOUSING
Drain gear oil.
In order to separate the drive unit top from the drive unit
bottom remove the six screws (item 17, Figure 0060S-01)
securing the two drive unit sections together.
Crown 1985 PF7188-2 Rev. 12/05

Figure 3394

M3.007.2016
07 Rev. 12/05

DRIVE UNIT
Pull the gear (item 28) and the bearing (item 26) assembly
from the housing. If the bearing needs replacement, remove
the retaining ring (item 7) and press off the bearing.
Remove the inside oil seal (item 24).
Remove the alignment dowel pin (item 3) located directly
above the idler shaft (item 18) and then remove the idler
shaft.
Pick out the loose spacers (item 23) and the gear assembly
(item 20, 21 & 22) from the top cavity in the lower housing.
Move to the other side of the housing and remove the
bearing (item 6) and the bearing adapter (item 5) after
unseating and removing the retaining ring (item 8). If this
bearing needs replacement, remove the retaining ring (item
7) and press off the bearing.
Remove the roller assemblies (items 11 & 15) by removing
the set screw (item 14) located in the housing and removing
shaft (16 & 38).

UPPER HOUSING
Refer to Figure 0060S-01. Remove the support assembly
(item 1). Remove the spacers (item 2). Note the number and
position for reference at assembly. Lift off the thrust plate
(item 3) which contains a felt seal (item 5) and a bearing cup
(item 6).
Remove bearing cone (item 8) and felt seal (item 7) from top
of upper housing (item 16).
After the motor (item 11) has been removed, the oil seal (item
32) can be removed from either side of its bore.
Remove cover (item 26) and gasket (item 25) from the side
of the housing.
Remove cotter pin (item 24) and unscrew the castle nut (item
23) about half way off the end of the pinion shaft (item 15).
While supporting gear (item 20), gently tap on the end of
pinion shaft via the castle nut. This will unseat the gear and
bearings (items 14 & 19), as well as push out the expansion
plug (item 13).
Once the bearings are free, slide the pinion shaft to the left
until the gear (item 20) is clear and can be removed along
with the two keys (item 21).
Continue to slide the pinion shaft and catch the bearings
(item 19) right inner race [cone] along with the inner race
spacer.
When the pinion is moved far enough, remove the left inner
cone and then completely remove the pinion shaft.
Remove the bearing outer races and the bearing retaining
ring from housing.
NOTE
The #10-24 tapped hole located directly below
the retaining ring slot is to be used to help unseat
the retaining ring. Use a #10-24 x 1 in. screw
(060014-010).

Figure 0060S-01

M3.007.2017
07 Rev. 12/05

After inspecting the housings and before reassembly, thoroughly clean in solvent and blow dry.

Crown 1985 PF7188-3 Rev. 12/05

DRIVE UNIT

Bearing
(Item 14)

Pinion
(Item 15)

Right Outer
Gear
Left Outer
Race
(Cup)
(Item
20)
Race (Cup) Retaining
Left Inner
Right Inner
Washer
Ring
Race (Cone)
Race (Cone)
(Item
22)
Spacer

Cover
(Item 26)

Expansion
Plug
(Item 13)

Cotter Pin
(Item 24)

Left Bore

Spacer
Retaining Ring
Unseating Hole

Gasket
(Item 25)
Middle Bore

Key
(Item 21)

Castle Nut
(Item 23)
Figure 3395

Drive Unit Assembly

NOTE
If the upper or lower housings were replaced,
before proceeding with assembly, check the housings for burrs or casting slag. Also, the area where
the lower part of the motor mounting plate rests in
the upper drive unit housing should be checked,
and ground if necessary, to assure a proper fit.
After inspection and grinding, thoroughly clean
the housings in solvent and blow dry.
UPPER HOUSING
With the upper housing (item 16) in the same relative
position as the housing in Figure 0060S-01, install the lower
grommet (item 9) into the neck of the housing.
Preassemble the key (item 31) and the gear (item 30) onto
the motor (item 11). After the components are in position,
insert the retaining ring (item 29) into its groove on the end
of the motor shaft.

Grease the motor shaft and its bore and install the oil seal
(item 32). Refer to Drive Motor Shaft Seal Replacement.
With the use of an arbor press, force the left outer cup of the
bearing (item 19) into the middle pinion bore (See Figure
0060S-01). This bearing includes two inner bearing cones,
two outer bearing cups, a spacer and a retaining ring spacer.
After the left outer race has been pressed slightly past the
groove, install the retaining ring spacer.
Slide the pinion shaft (item 15) through the left bore. Install
the left inner race and spacer onto the right side of the pinion
shaft prior to the shaft entering the middle bore.
Move the shaft through the middle bore to a position where
the right inner race, right outer race and the gear (item 20)
can be installed.
Once installed, force the pinion completely in and insert the
two keys (item 21) into the gear.

Apply a light film of multi-purpose grease (063002-025) to

the face of the motor and place the gasket (item 10) onto the
greased mounting face. Insert the complete motor assembly
into the housing and secure the fasteners.

Slide the bearing (item 14) and the expansion plug (item 13)
in place on the left bore before installing the washer (item 22)
and the castle nut (item 23) on the opposite end of the pinion
shaft (item 15).

NOTE

Tighten the castle nut (item 23) to 203 - 271 Nm (150 to 200
ft/lbs), then insert the cotter pin (item 24). Bolt the cover (item
26) and the gasket (item 25) to the right side of the upper
housing and insert the filler plug (item 28) into the cover.

Two bolts fasten from the inside of the housing

and two bolts fasten from the outside. When
tightening these bolts, follow a diagonal tightening procedure to insure proper motor seating.
Crown 1985 PF7188-4 Rev. 12/05

M3.007.2018
07 Rev. 12/05

DRIVE UNIT
Attach the brake assembly to the side of the upper drive unit
housing. For trucks not equipped with an electric brake
assembly, torque the two screws securing the brake assembly to the drive unit to 17.5 - 23 Nm (13 - 17 ft/lbs). For trucks
built October 1, 1986 and after (equipped with an electric
brake assembly) refer to section M5.0 Brake Maintenance
for brake installation guidelines.
Apply a thin film of multi-purpose grease to the upper bearing
neck on the housing and install the inner race (item 8). Once
in position, thoroughly grease the rollers and roller cage of
the bearing.
Spacer

Figure 3396
Figure 0357S-02

Insert the felt seal (item 7) into the groove which encircles the
inner race. The felt seal ends must meet squarely to assure
a good seal. The felt can be stretched or compressed to
accomplish this.

Insert the retaining ring (item 27) into its mounting slot in the
bore by means of snap ring pliers (see Figure 3394) inserted
through the slots in the gear face.

Press the outer race (item 6) into the thrust plate (item 3) and
install the grease zerk into the side of the plate.

Preassemble the gear (item 21) with its bearing (item 22) and
the retaining rings (item 20).

Assemble the thrust plate assembly on top of the upper

bearing neck and install the felt seal (item 5) in between the
bearing neck and the thrust plate bore.

Place the gear assembly between the two spacers (item 23)
and place them into their relative mounting position in the
housing.

Install spacers (item 2) to fill the gap between the top of the
thrust plate and the bottom of the support assembly. Refer
to Figure 0060S-01.

When the gear assembly is properly positioned, insert the

idler shaft (item 18) which has been preassembled with Orings (item 17 & 19). Lock the shaft in place with one of the
dowel pins (item 3).

Bolt support assembly (item 1) to the upper drive unit

housing.
LOWER HOUSING
Position the lower housing (item 25) in the same manner as
the housing is shown in Figure 0357S-02.
Lay the retaining ring (item 27) around the inside gear neck
and then press the bearing (item 26) onto the neck to a
position where the retaining ring (item 7) can be installed.
After greasing the outside diameter of the bearing (item 26),
press the entire gear assembly into the housing.
M3.007.2019
07 Rev. 12/05

Left Side

Right Side
Figure 3397
Crown 1985 PF7188-5 Rev. 12/05

C
Apply a film of grease to the mounting surface of the cover
(item 33) and place the gasket (item 34) onto the greased
cover surface. Also grease the neck of the gear (item 28) in
the area where the oil seal will ride. Install the cover onto the
housing and insert and tighten its fasteners evenly.
Insert bearing adaptor (item 5) into the bearing (item 6). Coat
the lower right side drive axle bore with grease, press
bearing assembly in position and install retaining ring (item
8).
Install oil seals. Refer to Seal Replacement in this section.
Place slinger (item 36) in position over inner axle seal.
Position the wheel assembly in the housing. Install outer
slinger (item 36) onto the axle and slide the axle (item 9)
through the left side bore. Align the axle splines and fully seat
the axle.
Before installing axle, coat axle with anti-seize compound
(065005-003). Ensure that the washers (item 40) are installed opposing each other. Torque the axle nut (item 13)
to 68 Nm (50 ft/lbs). Loosen, then retorque to 108 Nm (80
ft/lbs).
FINAL ASSEMBLY
After the upper and lower drive unit halves have been
completely assembled, insert the dowel pins (items 37 [Qty.
2] & item 3 [Qty. 1]) into the lower housing.
Apply a coat of gasket sealer (065005-002) to the mounting
surface, at the point where the housings join.

DRIVE UNIT
SEAL REPLACEMENT
AXLE INNER SEAL
Drain gear lube from drive unit. Remove drive tire assembly
per instructions located in the beginning of this section .
Remove the old seal. Be sure not to nick or scratch the
sealing surfaces of housing or gear hub. Thoroughly REMOVE the old gasket sealing material from the bore.
Apply a thin coat of gasket sealer, 065005-001, to the
housing bore. The seal lip should be lubricated with the fluid
being retained or compatible grease.
NOTE
Care must be taken not to get any gasket sealer
on either the seal lip or the seal surface of the
gear hub.
Position the new seal in proper alignment and gently tap with
plastic mallet to start the seal into the housing bore not in
excess of 1.5 mm (.06 in.).
Carefully press the new seal into position. The seals outer
shell should not be more than 0.8 mm (.030 in.) beyond the
end of the gear hub. For more information refer to Technical
Service Bulletin No. 152 and 091009 tool assembly.
Replace drive tire and axle. Fill unit with proper amount and
type of gear lube.
OUTER AXLE SEAL

Set the gasket (item 2) and the shims (item 1) on the

mounting surface of the lower housing and then couple the
two halves together. If the housings do not seat completely,
rotate the drive wheel. This will help mate the gears.

Refer to steps 1 thru 4 of Axle Inner Seal replacement

procedure.

Insert the six fasteners (item 17) and tighten the bolts to a
torque reading of between 34 - 40 Nm (25 - 30 ft/lbs).

Carefully press the new seal into position. The seals outer
shell should not be more than 2.8 mm (.110 in.) beyond the
end of the gear hub. For more information refer to Technical
Service Bulletin No. 152.

Insert and tighten drain plugs (item 4) and fill with gear lube.
Test the drive unit motor assembly for tight bearings by
rotating the motor shaft with a torque wrench. The rotating
torque should be 0.9 - 1.8 Nm (8 to 16 in/lb).

Replace drive tire and axle. Fill unit with proper amount and
type of gear lube.

Reinstall the drive unit into the power unit by reversing the six
steps described in Drive Unit Removal in the front of this
section. The three bolts (item 4) which fasten the thrust plate
(item 3) to the power unit bracket are to be tightened to a
torque reading of 108 - 122 Nm (80 - 90 ft/lbs).

Crown 1985 PF7188-6 Rev. 12/05

M3.007.2020
07 Rev. 12/05

DRIVE UNIT
DRIVE MOTOR SHAFT SEAL

THRUST ROLLER REPLACEMENT

Remove brake drum, split bushing and woodruff key from

drive motor shaft.

Remove set screw and remove roller shaft. Remove roller,

flatwasher(s) and felt seal from lower drive housing. The
roller bearings are part of the roller assembly. Do not attempt
to remove bearings from the roller bore. The flatwasher and
felt seal can be reused. Refer to illustration for proper
position and/or location of Thrust Roller parts.

Carefully remove old seal from drive unit housing. Do not

nick or scratch the sealing surfaces of the housing or motor
shaft.
Thoroughly remove the old gasket sealing material from the
housing bore. Inspect the motor shaft sealing surface area.
Should a groove, nick or any slight imperfection be present
the new seal can be pressed slightly beyond the original
position in the housing bore. An additional depth of up to 3.2
mm (.125 in.) is allowable, any seal installation with a greater
depth may not provide adequate seal surface.
Apply a thin coat of gasket sealer. 065005-001, to the
housing bore. The seal lip should be lubricated with the fluid
being retained.

NOTE
Drive units with steel thrust roller throughout
cannot use poly core thrust roller.
The thrust rollers must be lubricated and maintained properly to achieve proper truck operation and obtain satisfactory
service life from component parts. All thrust rollers must turn
freely and smoothly during normal truck operation.

NOTE
Care must be taken not to get any gasket sealer
on either the seal lip or the sealing surface of the
motor shaft.
Protect the seal lip from sharp edges or burrs on motor shaft.
Position seal installation sleeve on motor shaft. Use 094614
sleeve when installing 073433 seal & 094615 sleeve when
installing 087795 seal. Align the seal properly and gently
press into housing. Remove seal installation sleeve from
motor shaft. Install woodruff key, split bushing and brake
drum on drive motor shaft. For trucks not equipped with an
electric brake assembly, torque the three screws that attach
the brake drum and tapered bushing to the motor shaft to 11
- 13.5 Nm (8 - 10 ft/lbs). For trucks built October 1, 1986 and
after (equipped with an electric brake assembly) refer to
section M5.0 Brake Maintenance for brake installation guidelines.

M3.007.2021
07 Rev. 12/05

Crown 1985 PF7188-7 Rev. 12/05

DRIVE UNIT
Torque Value Chart
Upper to Lower Housing Assembly
Torque Values:
34 - 40 Nm (25 - 30 ft/lbs)
Item 17
Brake Attachment to Drive Unit
Torque Values:
17.5 - 23 Nm (13 - 17 ft/lbs)
Assembling Brake Drum to Drive Motor Shaft
Torque Values:
11 - 13.5 Nm (8 - 10 ft/lbs)
Motor Shaft Rotating Torque Values:
0.9 - 1.8 Nm (8-16 in/lbs)
Thrust Plate to Power Unit Bracket Torque Values:
108 - 122 Nm (80 - 90 ft/lbs)
Item 4

Figure 0060S-01

Castle Nut on Pinion Shaft in Upper Housing Torque Values:

203 - 271 Nm (150 - 200 ft/lbs)
Item 23
Castle Axle Nut Torque Values:
68 Nm (50 ft/lbs) Then
Retorque to 108 Nm (80 ft/lbs)
Item 13

Figure 0357S-02

Crown 1985 PF7188-8 Rev. 12/05

M3.007.2022
07 Rev. 12/05