Crown RC 5500 series Service And Parts Manual
RC
RC 5500 Series
AC Traction
Service & Parts Manual
Crown 2007 PF15343 3/07
New Bremen, Ohio 45869 USA
H
Phone 419/629-2311
crown.com
ow to Order Service Parts
To obtain fast, efficient service when ordering repair parts for your Crown Material Handling Equipment, please
follow this simple procedure:
1. Address all orders to your local Crown dealer.
2. Specify model and serial number of truck, which is shown on the serial number plate.
3. List the quantity needed.
4. List the part number and description, as shown in this Service Manual.
5. Show billing and shipping address.
6. Suggest fastest routing.
Your authorized Crown dealer stocks a large number of standard service parts. In addition, he has a factory trained Service Department to serve you.
Our Local Crown Dealer Is
NAME
ADDRESS
CITY
STATE ZIP
TELEPHONE
The information in this manual is the latest available at the time of printing for the unit with which it was shipped.
Should there be any variation due to vendor changes or special options on your unit, contact your Crown dealer
or Crown at the above address.
Crown 1986 Printed in U.S.A.
PF7609 Rev. 4/01
.
TABLE OF CONTENTS
I
Notes:
II
TABLE OF CONTENTS
SAFETY PAGE
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . .3
Control of Hazardous Energy . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lockout - Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Brake Release Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 7
Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Towing Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Towing by Pulling in
Power Unit First Direction . . . . . . . . . . . . . . . . . . . . . . . . .9
Towing by Pulling
in the Forks First Direction . . . . . . . . . . . . . . . . . . . . . . .10
Towing by Lifting Truck and
Pulling in Power Unit First Direction . . . . . . . . . . . . . . . . .10
Towing by Lifting Truck and
Pulling in the Forks First Direction . . . . . . . . . . . . . . . .10
Lifting and Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Blocking Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Disconnecting Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Removing Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cleaning of Material Handling Equipment . . . . . . . . . . . . . . . .17
Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
TABLE OF CONTENTS
INTRODUCTION PAGE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operater Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
LUBRICATION & ADJUSTMENT PAGE
Lubrication and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Lubrication and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Component Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Componentry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Access 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Access 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Access 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
ALM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
ALM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
III
TABLE OF CONTENTS
BRESL, BRESR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
BRKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
BRK1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
BRK2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CBVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CBVR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CVR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
DMS1, DMS2, DMS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
ECR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ECR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
EDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ENLS, ENSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
FNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
FAN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
FAN2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
FU4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
FU5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
FU13/FU14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
HGTS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
HGTS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
HGTS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
HGTS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
HN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
HNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
KYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
LCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
LGT1, LGT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
LGTS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
LGT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
LGT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
ORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
PCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
POT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
POT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
POT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
POT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PRVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
RPS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
RPS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
IV
RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
RVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
RVM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
SSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
SPL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
SVTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
SVTR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
SVT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
SVH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SVBy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SVA1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SVA1B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SVA2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SVA2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SVA3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
TBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
TDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
TR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
TR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
TS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
TS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
TS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Metric Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
TABLE OF CONTENTS
HYDRAULIC PAGE
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Hydraulic Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Lift Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Tilt Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Steering Slip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Freezer Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Tilt and Accessory Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Tilt Down Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Tilt Back Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Tilt Position Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Sideshift - Left Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Sideshift - Right Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Fourth Hydraulic Function (Second Accessory) . . . . . . . . . . . 91
Fifth Hydraulic Function (Third Accessory) . . . . . . . . . . . . . . . 91
V
TABLE OF CONTENTS
Accessory Clamp Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Attachment Setup - General . . . . . . . . . . . . . . . . . . . . . . . . . 93
Attachment Setup - Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Hydraulic Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . 97
Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Parts Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Pump Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
DRIVE UNIT PAGE
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Inspect Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Drive Unit Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Drive Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Traction Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . 109
Traction Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . 109
Drive Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Drive Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Drive Unit Sub-Assembly Removal . . . . . . . . . . . . . . . . . . . .111
Drive Unit Gear Assembly Replacement/Installation . . . . . . 113
ELECTRICAL PAGE
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Wiring Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
ACCESS 123...System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
ACCESS 1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Operator Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Timer - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Trip - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Bdi - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Hours - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . 135
Odometer - Message Mode . . . . . . . . . . . . . . . . . . . . . . 135
Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Level 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Bleed Quick Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . 136
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Relief Pressure Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
VI
Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Analyzer Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
A1 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
A2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
A3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
A4 Test Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Hour Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Traction Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Basics of System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 197
Control Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Power Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Hydraulic Control Module - AC/DC . . . . . . . . . . . . . . . . . . . . 199
Basics of System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 199
Accessory Control Module . . . . . . . . . . . . . . . . . . . . . . . . . .199
Basics of System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 199
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Battery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
Pump Motor and Brush Inspection . . . . . . . . . . . . . . . . . . . .209
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Event Code 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Event Code 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Event Code 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Event Code 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Event Code 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Event Code 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Event Code 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Event Code 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Event Code 108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Event Code 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Event Code 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Event Code 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
Event Code 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Event Code 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Event Code 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Event Code 199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Event Code 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Event Code 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
TABLE OF CONTENTS
VII
TABLE OF CONTENTS
Event Code 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Event Code 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Event Code 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Event Code 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Event Code 204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Event Code 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Event Code 206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Event Code 207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Event Code 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Event Code 209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Event Code 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Event Code 213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Event Code 214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Event Code 215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Event Code 216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Event Code 217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Event Code 218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Event Code 219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Event Code 220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Event Code 221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Event Code 222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Event Code 223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Event Code 224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Event Code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Event Code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Event Code 302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Event Code 303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Event Code 304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Event Code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Event Code 306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Event Code 307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Event Code 308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Event Code 309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Event Code 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Event Code 311-313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Event Code 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Event Code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Event Code 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Event Code 318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Event Code 319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Event Code 399 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Event Code 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Event Code 701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Event Code 702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Event Code 703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Event Code 704 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Event Code 705 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Event Code 706 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Event Code 707 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Event Code 708 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Event Code 709 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Event Code 710 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Event Code 711 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Event Code 712 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
VIII
Event Code 713 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Event Code 714 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Event Code 715 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Event Code 716 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Event Code 717 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Event Code 718 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Event Code 719 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Event Code 720 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Event Code 721 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Event Code 722 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Event Code 723 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Event Code 724 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Event Code 726 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Event Code 727 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Event Code 728 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Event Code 729 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Event Code 730 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Event Code 731 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Event Code 732 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Event Code 733 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Event Code 734 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Event Code 735 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Event Code 736 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Event Code 737 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Event Code 738 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Event Code 739 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
Event Code 740 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Event Code 741 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Event Code 742 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Event Code 743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Event Code 744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
Event Code 745 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Event Code 746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Event Code 747 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Event Code 748 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Event Code 749 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Event Code 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Event Code 751 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Event Code 752 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Event Code 753 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Event Code 754 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Event Code 755 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Event Code 799 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
TABLE OF CONTENTS
IX
TABLE OF CONTENTS
BRAKE PAGE
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Plugging Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Stopping Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Parking Brake Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Electric Parking Brake Release Procedures . . . . . . . . . . . . 301
Releasing Parking Brake Using Operator Display . . . . . . . . 301
Releasing Parking Brake Using Truck Battery . . . . . . . . . . . 302
Releasing Parking Brake Using External Power Source . . . 302
Brake Switch Adjustment (BRKS) . . . . . . . . . . . . . . . . . . . . 303
Parking Brake Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
STEERING PAGE
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Hydrostatic Steering Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Forward and Reverse Steering . . . . . . . . . . . . . . . . . . . . . . 309
Steer Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
Steer Command Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 310
Housing to Yoke Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 311
Steer Motor to Axle Housing Assembly . . . . . . . . . . . . . . . . 312
Wheel Assemblies to Steer Axle (Metallic Shield) . . . . . . . . 313
Wheel Assemblies to Steel Axle (Oil Seal) . . . . . . . . . . . . . 314
Hydraulic Steer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Steer Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Motor Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
LIFTING MECHANISM PAGE
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Fork Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Mast Flaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
TT (Triple Telescopic Full Free Lift) Mast . . . . . . . . . . . . . . . 321
Mast Testing (Assembled) . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Mast Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Mast Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Removal From Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Mast Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Quad (Four Stage) Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Mast Flaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Mast Testing (Assembled) . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Mast Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Carriage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Carriage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Lift Chain Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
X
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333
Rust and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334
Cracked Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334
Tight Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Protruding or Turned Pins . . . . . . . . . . . . . . . . . . . . . . . .335
Chain Side Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335
Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336
Lift Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Chain Anchors and Pulleys . . . . . . . . . . . . . . . . . . . . . . . 337
Leaf Chain Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . .337
Disconnect Procedures: . . . . . . . . . . . . . . . . . . . . . . . . . .337
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
Overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341
Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Bent or Twisted Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343
TABLE OF CONTENTS
CYLINDERS PAGE
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
Mast Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Mast Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . .349
Mast Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . 349
Mast Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . .349
Mast Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . .351
Mast Cylinder Bleeding and Flushing Procedures . . . . . .351
Mast Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Mast Cylinder Flushing . . . . . . . . . . . . . . . . . . . . . . . . . .352
Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
Carriage Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . 354
Carriage Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . .354
Carriage Cylinder Reassembly . . . . . . . . . . . . . . . . . . . .356
Carriage Cylinder Bleeding and Flushing Procedures . . . 356
Carriage Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . 356
Carriage Cylinder Flushing . . . . . . . . . . . . . . . . . . . . . . .356
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Tilt Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .357
Tilt Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .358
Rod Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .358
Tilt Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Tilt Cylinder and Rod Reassembly . . . . . . . . . . . . . . . . . .358
Tilt Cylinder Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .359
Tilt Cylinder Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . .359
Tilt Cylinder Bleeding and Flushing Procedures . . . . . . .360
Tilt Cylinder Bleeding and Flushing . . . . . . . . . . . . . . . . .361
Sideshifter Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Sideshifter Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . 363
Sideshifter Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . 364
Sideshifter Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . 365
Sideshifter Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . 366
XI
TABLE OF CONTENTS
PLATFORM PAGE
Sideshifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Sideshifter Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
Sideshifter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Sideshifter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Bearing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Supply Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Sideshift Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
GLOSSARY PAGE
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
WIRING DIAGRAMS PAGE
Introduction to Diagram Usage . . . . . . . . . . . . . . . . . . . . . . . 391
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Pictorials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Electrical Diagrams Index . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Electrical Schematic - AC Lift . . . . . . . . . . . . . . . . . . . . . . . . 394
Electrical Schematic - DC Lift . . . . . . . . . . . . . . . . . . . . . . . . 395
Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
Multi-Task Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
Accessory Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Traction Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
Hydraulic Control Module - AC Lift . . . . . . . . . . . . . . . . . . . . 401
Hydraulic Control Module - DC Lift . . . . . . . . . . . . . . . . . . . . 402
Motors and Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Console and Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . 404
Floorboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Hydraulics, Height & Load Sense . . . . . . . . . . . . . . . . . . . . . 406
Freezer Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Power Cables - AC Lift (ANSI Trucks) . . . . . . . . . . . . . . . . . . 408
Power Cable - AC Lift w/Rapid Charge . . . . . . . . . . . . . . . . . 409
Power Cable - AC Lift (Euro Trucks) . . . . . . . . . . . . . . . . . . . 410
Power Cables - DC Lift (ANSI Trucks) . . . . . . . . . . . . . . . . . . 411
Power Cable - DC Lift w/Rapid Charge . . . . . . . . . . . . . . . . . 412
Power Cable - DC Lift (Euro Trucks) . . . . . . . . . . . . . . . . . . . 413
InfoLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
HYDRAULIC SCHEMATIC PAGE
Entire Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
XII
POWER UNIT PARTS PAGE
Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Suspended Floorboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .434
FlexRide Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438
Entry Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 444
Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446
Overhead Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .448
Battery Retainers, Spacers, Rollers . . . . . . . . . . . . . . . . . . . .454
HYDRAULIC PARTS PAGE
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Plumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
Mast Plumbing - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464
Mast Plumbing - Quad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
DC Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474
Pump Motor - AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
Pump Motor - DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478
Pump Motor - AC “EE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Valve Assembly 1 Low Flow Accessory . . . . . . . . . . . . . . . . 482
Valve Assembly W/2 High Flow Accessories . . . . . . . . . . . . 486
Chain Slack Valve - Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . 490
Manifold Crossover Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . .492
Carriage Hydraulics - TT/Quad . . . . . . . . . . . . . . . . . . . . . . . .494
TABLE OF CONTENTS
DRIVE UNIT PARTS PAGE
Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500
AC Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
AC Traction Motor - EE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .504
Drive Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
ELECTRICAL PARTS PAGE
Electrical Components - Power Unit . . . . . . . . . . . . . . . . . . .510
Contactor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
Contactor Panel - EE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524
Distribution Panel - Freezer/Corrosion . . . . . . . . . . . . . . . . .526
Distribution Panel - EE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .530
Multi-T ask Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 532
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
Battery Retainer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
Tilt Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546
Access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
Control Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
Overhead Guard - Strobe Light . . . . . . . . . . . . . . . . . . . . . . . .552
Overhead Guard - Worklights . . . . . . . . . . . . . . . . . . . . . . . . . 554
Work Lights - TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
Work Lights - Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
Strobe Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
XIII
TABLE OF CONTENTS
BRAKE PARTS PAGE
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564
STEERING PARTS PAGE
Steering Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
Steer Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 570
Steer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576
Steer Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
LIFTING MECHANISM PARTS PAGE
Mast - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
Mast - Quad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
Fork Carriage - TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
Fork Carriage - Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Yoke - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
5th Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
Yoke Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608
Lift Chain - TT Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610
Lift Chain - Quad Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
Load Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
CYLINDER PARTS PAGE
Mast Cylinder - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
Carriage Cylinder - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 626
Mast Cylinder - Quad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 628
Carriage Cylinder - Quad . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
Sideshifter Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 636
PLATFORM PARTS PAGE
Sideshifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
LABELS AND DECALS PAGE
Work Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
Work Assist Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
InfoLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
Labels & Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656
Labels & Decals Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 662
Labels & Decals InfoPoint/Access . . . . . . . . . . . . . . . . . . . . 666
Labels & Decals RC 5500C . . . . . . . . . . . . . . . . . . . . . . . . . . . 670
XIV
SAFETY
1
Notes:
2
SAFETY
WARNING
General Maintenance Instructions
General Maintenance Instructions
TO PREVENT SERIOUS RISK OF INJURY TO
YOURSELF AND OTHERS OBSERVE THE FOLLOWING SAFETY INSTRUCTIONS
Power industrial trucks may become hazardous if adequate maintenance is neglected. Therefore, adequate
maintenance facilities, trained personnel and procedures should be provided.
Maintenance and inspection shall be performed in conformance with the following practices:
1. A scheduled planned maintenance, lubr ica tio n,
and inspection system should be followed.
2. Only qualified and authorized personnel shall be
permitted to maintain, repair, adjust and inspect
truck.
3. Before leaving the truck—
– Stop truck.
– Fully lower the load engaging means.
– Place directional controls in neutral.
– Apply the parking brake.
– Turn off power (power disconnect).
– Remove key.
– Block the wheels if truck is on an incline.
4. Before working on truck—
– Raise drive wheel free of floor or disconnect
power sources.
– Use chocks or other positive positioning de-
vices.
– Block load engaging means, inter masts, or
chassis before working under them.
– Operation to check performance of truck or at-
tachments shall be conducted in an authorized
safe clearance area.
5. Before starting to operate truck—
– Be in operating position.
– Apply brake.
– Place directional control in neutral.
– Before operating truck, check functions of lift
systems, directional control, speed control, steering, warning devices, brakes and any attachments
if any used.
6. Avoid fire hazards and have fire protection equipment present. Do not use an open flame to check
level, or for leakage of electrolyte and fluids or oil.
Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.
7. Keep shop well ventilated, clean and dry.
8. Brakes, steering mechanisms, control mechanisms, lift overload devices, guards, and safety devices shall be inspected regularly and maintained
in a safe operating condition.
– All guards must be installed to factory configuration and condition before operating truck. Do not
operate truck if any guards or fasteners are damaged, improperly installed or missing.
9. Capacity, operation and maintenance instruction
plates or decals shall be maintained in legible condition.
10. All parts of lift mechanisms shall be inspected to
maintain them in safe operating condition.
11. All hydraulic systems shall be regularly inspected
and maintained in conformance with good practice.
Cylinders, valves, and other similar parts shall be
checked to assure that “drift” has not developed to
the extent that it would create a hazard.
12. Batteries, motors, controllers, limit switches, protective devices, electrical conductors, and connections shall be maintained in conformance with
good practice. Special attention shall be paid to the
condition of electrical insulation.
13. Trucks shall be kept in a clean condition to minimize fire hazards and facilitate detection of loose
or defective parts.
Crown 1976 PF2821-1 Rev. 10/08
MA-04.0-001
05 Rev. 10/08
3
SAFETY
General Maintenance Instructions
14. Modifications and additions which affe ct cap a city
and safe truck operation shall not be performed b y
the customer or user without manufacturers prior
written approval. Capacity, operation and maintenance plates or decals shall be changed accordingly.
– Adding electrical devices (radio, terminal,
lights, etc.) or changing existing components or
wiring can affect truck operation and could cause
an accident. Contact authorized Crown personnel
before adding to or changing the electrical system
in any way.
– For EE rated trucks, adding electrical devices
could cause a fire or explosion, as well as void the
EE rating. Written approval must be obtained from
Crown prior to adding electrical device(s). Prior to
use, inspection of installed device(s) must be performed by an appropriate nationally recognized
testing laboratory (i.e. Underwriters Laboratories
Inc) or the Authority Having Jurisdiction (see NFPA
505).
15. Care shall be taken to assure that all replacement
parts are interchangeable with the original parts
and of equal quality to that provided in the original
equipment.
16. Be sure that any equipment added to the truck (terminal, fan, clipboard, etc.) is positioned so that it
does not block your vision or interfere with safe and
efficient operation of the truck.
For further information pertaining to operating and
maintenance procedures:
• All trucks except Series B and Tow Tractors, refer
to current ASME B56.1.
• Series B trucks, refer to current ASME B56.10.
• Tow Tractors, refer to current ASME B56.9.
05 Rev. 10/08
4
MA-04.0-002
Crown 1976 PF 2821-2 Rev. 10/08
SAFETY
CAUTION
CAUTION
Control of Hazardous Energy
Control of Hazardous Energy
Lockout/Tagout
In the interest of safety and to ensure compliance with
OSHA Regulations, (Standards - 29 CFR), control of
hazardous energy (lockout/tagout) - 1910.147, Crown
has developed guidelines for proper energy control
when performing service and maintenance on the
truck. Before performing any service or maintenance,
review appropriate sections in this service manual for
additional procedures to be followed.
In addition, Crown recommends that all mechanics
wear appropriate protective items, such as safety
glasses, work gloves, and steel-toed shoes, whenever
performing service or maintenance work on Crown
equipment.
Battery
Safety Rules
• Wear protective clothing, such as, rubber apron,
gloves, boots and full-face shield when per forming
any maintenance on batteries. Do not allow electrolyte to come in contact with eyes, skin, clothing
or floor. If electrolyte comes in contact with eyes,
flush immediately and thoroughly with clean water .
Obtain medical attention immediately. Should electrolyte be spilled on skin, rinse promptly with clean
water and wash with soap. A baking soda solution
(one pound to one gallon of water) will neutralize
acid spilled on clothing, floor or any other surface.
Apply solution until bubbling stops and rinse with
clean water.
• Keep vent plugs firmly in place at all times except
when adding water or taking hydrometer readings.
• Do not bring any type of flame, spark, etc., near the
battery. Gas formed while the battery is charging,
is highly explosive. This gas remains in the cells
long after charging has stopped.
• Do not allow dirt, cleaning solution or other foreign
material to enter cells. Impurities in electrolyte has
a neutralizing effect reducing available charge.
• If battery repair is planned, follow the battery man-
ufacturer's instructions concerning repair practices
and procedures.
Battery Care
Only qualified and experienced personnel should perform maintenance and repair on batteries.
• Make certain the charger being used matches the
voltage and amperage of the truck battery. This
voltage is listed on the truck serial plate.
• Before disconnecting or connectin g batte r i es to a
charger , make sure charger is "OFF". If an attempt
is made to do this while charger is "ON", serious
injury to you, the battery and charger could result.
• Never use a match or lighter. Battery fumes are ex-
plosive.
• Make certain battery used meets weight, size and
voltage requirements of truck (refer to seria l plate).
NEVER operate truck with an undersized battery.
Charging
Never smoke or bring flame near the battery. Gas
formed during charging is highly explosive and can
cause serious injury.
Consult the charger manufacturer's manual covering
your charger for hints on operation and maintenance.
• Do not lay metallic or conductive objects on bat-
tery. Arcing will result.
Crown 2006 PF15396-1 Rev. 9/07
MA-1055-100
03 Rev. 9/07
5
SAFETY
CAUTION
CAUTION
CAUTION
Control of Hazardous Energy
Battery Removal
When removing the battery, move truck to area intended for battery care. Floor must be level. Turn key
switch or toggle switch to "OFF" position and remove
key. Disconnect battery and lockout or tagout truck as
described in Lockout - Tagout in this section. Never
move battery partially from truck without roller stand in
place. Lower load engaging means completely. If battery is removed with load engaging means raised, use
hoist attached to mast to provide tip over protection. Do
not allow any metallic object to come in contact with the
top of the battery cells. This may cause a short circuit
when removing, transporting the battery. Use an insulator (such as plywood) to cover the top of the battery
before and during removal.
Make certain same battery or battery of equal weight is
loaded into truck for truck stability. See nameplate for
minimum battery weight.
Lockout - Tagout
Always turn key switch to "OFF", remove key and apply
tag to multi-function control handle Item 1 and/or steering tiller Item 2 with cable tie warning others truck is
being serviced.
Figure 8251
Battery Installation
When installing the battery, move truck to area intended for battery care. Floor must be level. Turn key
switch or toggle switch to "OFF" position and remove
key. Lockout or tagout truck as described in Lockout Tagout in this section. If battery was removed with load
engaging means raised, use hoist attached to mast to
provide tip over protection. Do not allow any metallic
object to come in contact with the top of the battery
cells. This may cause a short circuit when transporting
or installing the battery. Use an insulator (such as plywood) to cover the top of the battery before and during
installation.
Figure 16925-01
a
Multi-function Control Handle
b
Steering Tiller
When maintenance is to be performed and th e bat tery
will be left in the truck, remove the main power fuses
and install a commercially available lockout device on
the battery connector.
When maintenance is performed and the battery is removed from the truck, remove main power fuses, install
a lockout device on the trucks battery connector if possible, or if possible install a tag with a cable tie on the
trucks battery connector so it cannot be removed easily
warning that the truck is not available for operation.
03 Rev. 9/07
6
MA-1055-101
Crown 2006 PF15396-2 Rev. 9/07
Brake Release Instructions
WARNING
CAUTION
Tow Condition Note:
- Disconnect PC210 From JC210
- Connect PC211 Into JC210
RC 5500 series trucks ship with sprin g applied/e lectrically released brakes. Power m ust be applied to the
brake circuit to release brakes for towing/unloading.
Equipment required: Crown wire harness part number
139956-001 or equivalent.
Extreme care must be taken when using this method to
release the brakes. With brakes released on uneven
surfaces, vehicle will roll.
No battery installed method
1. Open vehicle "desktop" cover and disconnect harness connector CA210 (near power fuses).
2. Plug harness (139956-001) into harness plug
JC210.
SAFETY
Control of Hazardous Energy
3. Apply 18-24 volts (DC) to harness to release
brakes.
4. Once vehicle has been moved, remove power to
harness and reconnect CA210.
Do not apply more than 28 volts (DC) to brake release
harness. Brake coil damage will occur.
Battery installed method
1. With battery unplugged from vehicle, unplug harness connector CA210 (located under desktop
cover).
2. Plug JC210 into PC211 (located in same area) on
vehicle.
3. Plug battery into vehicle battery connector to release brakes.
4. Once vehicle has been moved, disconnect battery
and reconnect CA210.
Figure 16926
Crown 2006 PF15396-3 Rev. 9/07
MA-1055-102
03 Rev. 9/07
7
SAFETY
WARNING
Truck Modules
Control of Hazardous Energy
Capacitance
Due to capacitance voltage present in the traction motor controller and lift motor controller, whenever performing maintenance which may permit contact with
the bus bars and associated power cables, discharge
the capacitors.
• Move truck to a secure non-traffic maintenance
area with a level floor.
• Lockout or tagout truck as described in Lockout -
Tagout in this section.
• Disconnecting the battery will discharge the capac-
itors. Once the dash display flashes, the capacitors
are discharged. T wo alternative methods of discharging these capacitors are to disconnect the
battery and hold the key switch in the "start" position for 10 seconds or disconnect the battery and
connect a 200 ohm, 2 watt resistor betw ee n th e
positive and negative terminals on the controller.
• Turn key switch to "OFF", remove key.
Hydraulic
AVOID HIGH PRESSURE FLUIDS – Escaping fluid
under pressure can penetrate the skin causing serious
injury. Relieve pressure before disconnecting hydraulic
lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which
eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your
hand.
Any fluid injected into the skin under high pressure
should be considered as a serious medical emergency
despite an initial normal appearance of the skin. There
is a delayed onset of pain, and serious tissue d amage
may occur. Medical attention should be sought immediately by a specialist who has had experience with this
type of injury.
When maintenance is to be performed on the hydraulic
system, make certain the hydraulic system is not under
pressure by:
• Move truck to a secure non-traffic maintenance
area with a level floor.
• No load on forks.
• Completely lower load engaging means (mast) or,
if required for maintenance, block mast sections at
the appropriate height as described in Mast of this
section.
• Lockout or tagout truck as described in Lockout -
Tagout in this section.
• Depressurize hydraulic reservoir by momentarily
opening cap on reservoir before disconnecting any
hydraulic lines or components.
• Operate hydraulic levers to remove any hydraulic
pressure that may be present.
Figure 16927
03 Rev. 9/07
8
MA-1055-103
Crown 2006 PF15396-4 Rev. 9/07
SAFETY
WARNING
WARNING
WARNING
WARNING
Control of Hazardous Energy
Towing Truck
Refer to the following guidelines when towing the truck:
Towing by Pulling in
Power Unit First Direction
• Towed truck must always maintain three contact
points with floor and/or towing device.
• Do not make sharp turns when lifting/towing truck.
• Towed vehicle forks should be empty and no more
than 305 mm (12.0 in) off floor. If possible, tilt forks
back and center sideshifter.
• Extreme care must be taken when using this
method to release the brakes. With brakes released on uneven surfaces, vehicle will roll.
• Provide a safe distance for truck to coast to stop.
• Excessive acceleration by towing vehicle, or drag
caused by towed vehicle (i.e., brake drag, drive
unit drag, wheel drag, etc.) will greatly increase requirements to pull or push a vehicle.
Preparing Truck For Towing:
• When attaching towing device to lift truck to be
towed, a slotted hole has been provided on rear
bottom side of power unit. Firmly attach tow device
in this area. Fasten so as not to loosen or disengage during towing.
• Power must be applied to the brake circuit to re-
lease brakes for towing. Refer to Brake Release
Instructions in this section.
• Turn power OFF.
Truck will be difficult to steer. Use extreme caution.
• Driver will be required to steer truck, as there is no
power assist from hydraulics. Truck will coast to
stop.
Towing Device Requirements:
• Towing device/vehicle must have pulling/braking
capacity greater than 3600 kg (8000 lb).
• Brakes on towed truck will not operate.
Towing mechanism attachment must not intrude more
than 40 mm (1.6 in) into floorboard cavity. Failure to
observe this WARNING could result in damage to floorboard components.
Figure 18645
a
Floorboard (cutout to show slotted hole)
b
Slotted Hole
Towing Guidelines:
• Maximum travel speed while towing truck is
3.2 kph (2 mph).
Truck will be difficult to steer. Use extreme caution.
• Driver will be required to steer truck, as there is no
power assist from hydraulics.
• Truck will coast to stop.
• Operator actions: see WARNINGS above.
Crown 2006 PF15396-5 Rev. 9/07
MA-1055-104
03 Rev. 9/07
9
SAFETY
WARNING
WARNING
WARNING
WARNING
Control of Hazardous Energy
Towing by Pulling
in the Forks First Direction
Towing by pulling in the forks first direction is not
recommended.
Towing by Lifting Truck and
Pulling in Power Unit First Direction
• Do not lift towed truck higher than 51 mm (2.0 in)
off floor.
• Towed truck must always maintain three contact
points with floor and/or towing device.
• Do not make sharp turns when lifting/towing truck.
• Towed vehicle forks should be empty and no more
than 305 mm (12.0 in) off floor. If possible, tilt forks
back and center sideshifter.
• Extreme care must be taken when using this
method to release the brakes. With brakes released on uneven surfaces, vehicle will roll.
Towing Guidelines:
• Maximum travel speed while towing truck is
3.2 kph (2 mph).
Truck will be difficult to steer. Use extreme caution.
• No operator should be on lifted and towed truck.
• Operator actions: see WARNINGS above.
Towing by Lifting Truck and
Pulling in the Forks First Direction
Towing by lifting truck and pulling in the forks first
direction is not recommended.
Preparing Truck For Towing:
• Power must be applied to the brake circuit to re-
lease brakes for towing. Refer to Brake Release
Instructions in this section.
• Turn power OFF.
Towing Device Requirements:
• Towing device must have lifting capacity of
2268 kg (5000 lb) at load position at slot opening in
bottom of power unit.
• Towing device must have pulling/pushing/braking
capacity greater than 3600 kg (8000 lb).
• Ensure that a stem or ball capable of stated pulling/
pushing/braking capacity, and of such a design as
to prevent disengagement during towing oper ation,
is used.
• When attaching towing device to lift truck to be
towed, engage in slot located in rear , lower portion
of power unit skirt.
03 Rev. 9/07
10
MA-1055-105
Crown 2006 PF15396-6 Rev. 9/07
SAFETY
WARNING
NOTE
Side
Steer
Wheel
Control of Hazardous Energy
Lifting and Blocking
Move truck to a secure non-traffic maintenance
•
area with a level floor.
• No load on forks.
• Lockout or tagout truck as described in Lockout -
Tagout in this section.
NOTES:
• Hydraulic Jack Capacity: 3620 kg (8000 lb)
• Crown Part Number: 122599
• Collapsed Height Minimum: 60 mm (2.25 in)
• Raised Height Maximum: 400 mm (16 in)
Figure 16928-01
a
Use Serated Pads on Jack and Position Jack 75 mm (3.0 in)
Inward on a Flat Surface
b
Hardwood Block One Side of Truck Only to Height as
Required – Not to Exceed 162 mm (8.0 in)
c Do Not Raise Forks More than 380 mm (15 in) from Floor
Truck stability decreases dramatically if truck skirt is
raised more than 140 mm (5.5 in) or 15°. Attach sling
and overhead lifting device to all cross members of the
mast to prevent truck from tipping over when raising
one side of the truck.
Figure 16929-01
a
Use Hardwood Blocks to Set Height as Required – Not to
Exceed 162 mm (8.0 in)
b
Wheel Chock Both Drive Wheels
c Do Not Raise Forks More than 380 mm (15 in) from Floor
Position hardwood blocks as shown when lifting and
blocking the truck.
Crown 2006 PF15396-7 Rev. 9/07
MA-1055-106
03 Rev. 9/07
11
SAFETY
Control of Hazardous Energy
Mast
Blocking Masts
Use 100 x 100 mm (4 x 4 in) or bigger hardwood blocks
of appropriate length for supporting mast channels.
Block both mast rails of each stage to maintain stability .
Remove any carriage mounted accessory (i.e., carton
clamp, etc.) except sideshifters before blocking masts.
These accessories add significant weight to the mast.
• Move truck to a secure non-traffic maintenance
area with a level floor.
• Chock wheels (refer to Lifting and Blocking in this
section).
• Connect battery.
• Raise forks and position blocks under second
stage mast as shown.
• Using a clamp or ratchet tie down, secure blocks to
mast channel as shown.
• Lower mast and position appropriate length blocks
under third stage mast as shown.
• Lower mast and position appropriate length block
under fourth stage mast (or inner) on quad ma st as
shown.
• Using a clamp or ratchet tie down, secure blocks to
mast channel or second stage block as shown.
• Lower fork carriage until carriage rests on stops or
place blocks under carriage and lower until weight
rests on blocks.
• Lockout or tagout truck as described in Lockout -
Tagout in this section.
a
TT Mast e Third Stage Mast
b
Quad Mast f Fork Carriage (Shown Raised Slightly for Clarity)
c Second Stage Mast g Fourth Stage Mast (or Inner)
d First Stage Mast (Mainframe or Outer Mast)
MA-1055-107
03 Rev. 9/07
12
Figure 16930-01
Crown 2006 PF15396-8 Rev. 9/07
SAFETY
Control of Hazardous Energy
a
TT Mast e Third Stage
b
Quad Mast f Fourth Stage (or Inner Mast)
c First Stage (Mainframe or Outer Mast) g Fork Carriage
d Second Stage
Figure 16931-01
Crown 2006 PF15396-9 Rev. 9/07
MA-1055-108
03 Rev. 9/07
13
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