Crown Forklift RR5000 Service & Parts Manual by www.heydownloads.com

RR 5000 Service & Parts Manual

Crown PF11314-006

C RR RD

RR/RD 5000 SERIES INDEX

Revision No. - Date

Title

Serial No. of Units Used For From: January 1, 1998 To: Standard Special Date

X X X X

02 - 5/97 02 - 8/00 01 - 4/98

General Maintenance Introduction Cleaning of Material Handling Equipment Lifting and Blocking Points

01 - 11/00

Control of Hazardous Energy

Page Number

MA–04.0–001 ITD–1450–001 MA–1140–050 MA–1450–100 4/24/00

SECTION M1 X

10 - 12/00

X X X

06 - 1/01 08 - 1/01 02 - 4/88

SECTION M2 X

03 - 8/00

X X X X X

05 - 1/01 02 - 5/98 03 - 6/00

SECTION M3 X

07 - 12/00

SECTION M4 01 - 4/98

LUBRICATION AND ADJUSTMENT Lubrication and Adjustment – Lubricant & Fluid Chart – Identification Chart Lubrication and Adjustment Componentry Torque Values

M1.0–04.0–001 M1.0–04.0–002 M1.0–04.0–003 M1.0–1450–001 M1.0–1450–050 M1.9–14.0–001

HYDRAULIC MAINTENANCE Hydraulic System – Filter – Reservoir – Drift Test Hydraulic Circuits Hydraulic Schematic Symbols Hydraulic Pump Manifold Hydraulic Troubleshooting Chart

M2.0–1450–001 M2.0–1450–002 M2.0–1450–002 M2.0–1450–002 M2.0–1450–020 M2.1–00.0–001 M2.1–1450–001 M2.4–1450–001 M2.9–1450–001

DRIVE UNIT MAINTENANCE Drive Unit – Drive Tire Replacement – Drive Unit Lubrication System • Oil Pump Disassembly • Oil Pump Assembly – Undercarriage Inspections and Adjustments – Drive Unit Removal

M3.0–1450–001 M3.0–1450–001 M3.0–1450–001 M3.0–1450–003 M3.0–1450–003 M3.0–1450–004 M3.0–1450–007

ELECTRICAL MAINTENANCE

Truck Setup (software 122676-001-05)

Truck Setup (software 122676-001-06) (this section replaced by M4.3-1650-025) Access 1 (software 122676-001-03)

01 - 6/98

X X

01 - 2/98

01 - 8/98

MA–1450–101

Truck Setup (software 122676-001-03)

Access 1 (software 122676-001-05) (this section replaced by M4.3-1650-001) Calibration (software 122676-001-03) Calibration (software 122676-001-05) (this section replaced by M4.3-1650-800) Capacity Data Monitor Height Sensor

1A191154 1A193510 1A193510 1A195977 1A195977 1A201888 1A191154 1A193510 1A193510 1A195977 1A191154 1A193510 1A193510 1A195977

01/31/98 04/01/98 04/01/98 06/15/98 06/15/98 11/12/98 01/31/98 04/01/98 04/01/98 06/15/98 01/31/98 04/01/98 04/01/98 06/15/98

M4.2–1450–200 M4.2–1450–210 M4.2–1450–218 M4.3–1450–001 M4.3–1450–020 M4.3–1450–080 M4.3–1450–085 M4.3–1450–200 M4.3–1450–300

3033 Crown 1998 PF11307-1 Rev. 5/02

Printed in U.S.A.

06 REV. 5/02

IDX–1450–001

RR/RD 5000 SERIES INDEX Serial No. of Units Used For From: To: Standard Special Date

Title

RR RD

Revision No. - Date

04 - 11/98

Status Codes

03 - 9/00

X X

01 - 7/99

Status Codes (software 122676-001-09) (software 122676-001-10) (software 122676-001-11) Access 1 Display Access 1 2 3 (software 122676-001-08)

03 - 8/00

Access 1 2 3 (software 122676-001-09)

X X

01 - 9/00 01 - 6/98

X X X X X

01 - 10/93 01 - 2/98

Access 1 2 3 (software 122676-001-11) Calibration (software 122676-001-06) (this section replaced by M4.3-1650-025) Contactor Contactor 118396 24V Multi Task Control Battery Motor Chart

01 - 1/01

SECTION M5 X

04 - 1/01

SECTION M6 X X X

X X X

02 - 4/98

SECTION M7 X X

X X

04 - 5/00 05 - 1/00

01 - 1/00

SECTION M8 X

02 - 5/00

01 - 4/99

Page Number

1A191154 1A206159 1A206159

01/31/98 02/15/99 02/15/99

M4.3–1450–400

1A195977 1A201888 1A206159 1A206159 1A231690 1A231690 1A195977 1A201888

06/15/98 11/12/98 02/15/99 02/15/99 08/25/00 08/25/00 06/15/98 11/12/98

M4.3–1650–001 M4.3–1650–025

M4.3–1450–480

M4.3–1650–065 M4.3–1650–105 M4.3–1650–800 M4.4–04.2–001 M4.4–7330–001 M4.5–1450–001 M4.6–1450–001 M4.7–1450–001

BRAKE MAINTENANCE Brakes – Adjustment – Assembly – Troubleshooting

M5.0–1450–001 M5.0–1450–002 M5.0–1450–004 M5.0–1450–005

STEERING MAINTENANCE Steering System Steer Motor Steering Unit – Relief Valve – Disassembly – Assembly

M6.0–1450–001 M6.2–1450–001 M6.3–1450–001 M6.3–1450–001 M6.3–1450–001 M6.3–1450–004

MAST MAINTENANCE Mast Lift Chain – Inspection – Lubrication – Replacement – Leaf Chain Disconnect Fork Inspection

M7.0–1450–001 M7.5–18.0–001 M7.5–18.0–001 M7.5–18.0–003 M7.5–18.0–004 M7.5–18.0–005 M7.8–04.2–001

CYLINDER MAINTENANCE Cylinder Lift – Disassembly – Seal Removal – Seal Installation – Assembly – Bleeding Cylinder Tilt – Disassembly – Rod Disassembly – Seal Replacement – Assembly

M8.0–1450–001 M8.0–1450–001 M8.0–1450–001 M8.0–1450–002 M8.0–1450–004 M8.0–1450–004 M8.6–1450–001 M8.6–1450–001 M8.6–1450–002 M8.6–1450–002 M8.6–1450–002

Crown 1998 PF11307-2 Rev. 5/02

Printed in U.S.A.

06 REV. 5/02

IDX–1450–002

C RR RD

Revision No. - Date

RR/RD 5000 SERIES INDEX

SECTION M9 X

01 - 4/99

01 - 11/00

Page Number

REACH MECHANISM MAINTENANCE Reach Mechanism – Cylinder Adjustment – Disassembly – Bushing Replacement – Center Pivot Repair/Adjustment – Reassembly Reach Assembly – Cylinder Adjustment – Disassembly – Bushing Replacement – Center Pivot Repair/Adjustment – Reassembly

SECTION M10 X

Serial No. of Units Used For From: To: Standard Special Date

Title

M9.0–1450–001 M9.0–1450–001 M9.0–1450–002 M9.0–1450–003 M9.0–1450–004 M9.0–1450–004 M9.0–1650–001 M9.0–1650–001 M9.0–1650–002 M9.0–1650–004 M9.0–1650–004 M9.0–1650–005

GLOSSARY Glossary

M10–1450–001

WIRING DIAGRAMS X X

X X

07 - 6/00

Wiring Diagram Introduction Wiring Diagram Index

DIA–ITD–001 DIA–1450–001

HYDRAULIC SCHEMATICS X X

02 - 12/00 02 - 12/00

Hydraulic Schematic Hydraulic Schematic

SECTION 1

POWER UNIT PARTS

X X

08 - 9/00 02 - 4/98

Power Unit Floorboard

X X

01 - 11/00 02 - 4/99

Floorboard Undercarriage Articulation

02 - 3/01

Undercarriage Articulation

X X X X X X

01 - 3/01 02 - 11/98 02 - 11/98 03 - 12/00 06 - 3/01 02 - 3/98

Undercarriage Articulation Mast Guard 89 Mast Guard 95, 107 Mast Guard 119 thru 172 Battery & Retainers Overhead Guard

SECTION 2 X

02 - 2/99

HYD–1450–001 HYD–1450–050

01.0–1450–001 01.0–1450–050 1A207228 1A207228

04/05/99 04/05/99

1A211126 1A211126 1A234559 1A234559

07/03/99 07/03/99 10/30/00 10/30/00

1A231076 1A231076

08/16/00 08/16/00

1A197777 1A197777

08/01/98 08/01/98

01.0–1450–053 01.0–1450–100 01.0–1450–101 01.0–1450–102 01.2–1450–001 01.2–1450–025 01.2–1450–050 01.2–1450–100 01.2–1450–200

HYDRAULIC PARTS Reservoir

X X X X

01 - 12/00 03 - 12/00 02 - 12/00

Reservoir Manifold Steering Control Mast

01 - 4/99

Mast

02.0–1450–001

Crown 1998 PF11307-3 Rev. 5/02

02.0–1450–003 02.0–1450–050 02.0–1450–100 02.0–1450–400 02.0–1450–402

Printed in U.S.A.

06 REV. 5/02

IDX–1450–003

RR/RD 5000 SERIES INDEX Serial No. of Units Used For From: To: Standard Special Date

Title

RR RD

Revision No. - Date

X X X X X X

X X X

04 - 4/99 06 - 1/01 02 - 7/98 02 - 7/98 02 - 7/98 02 - 3/99

Reach - Tilt Reach - Tilt & Side Shift Pump - Lift Pump - Lift Pump - Lift Motor - Lift 36V 6.75 in. w/Sensors

X X

Motor - Lift 36V 6.75 in. w/Sensors Motor - Lift 36V 6.75 in. w/o Sensors

X X

X 01 - 5/98

Motor - Lift 36V 6.75 in. w/o Sensors Motor - Lift 24V

05 - 6/00 02 - 6/99

Motor - Lift 24V Manifold Valve Manifold Valve Reach

X X X

X X

SECTION 3 X X

X X

Drive Unit Lubrication System Drive Unit

01 - 4/98

Drive Unit Motor - Traction 36V

01 - 3/01 01 - 1/01

Motor - Traction 36V Motor - Traction 24V

04 - 2/01

Motor - Traction 24V Tire

X X X X X X X X X

X X X X X X X X

X X X X X X X X X

06 - 12/98 01 - 11/00

04 - 5/99 04 - 5/99 03 - 4/99 09 - 3/01 02 - 3/01 03 - 3/01 03 - 10/98 04 - 1/01 05 - 6/00 02 - 7/99

07 - 3/01 04 - 11/00 03 - 7/99

02.0–1450–600 02.0–1450–800 02.1–1450–001 02.1–1450–050 02.1–1450–100 02.2–1450–001 1A237825 1A237825

01/24/01 01/24/01

1A237825 1A237825

01/24/01 01/24/01

1A237825 1A237825

01/24/01 01/24/01

02.2–1450–003 02.2–1450–050 02.2–1450–052 02.2–1450–100 02.2–1450–102 02.4–1450–001 02.4–1450–050

DRIVE UNIT PARTS

03 - 11/97 01 - 2/98

SECTION 4

Page Number

03.0–1430–200 03.0–1450–001 1A230942 1A230942

08/15/00 08/15/00

1A237825 1A237825

01/24/01 01/24/01

1A237825 1A237825

01/24/01 01/24/01

03.0–1450–003 03.1–1450–001 03.1–1450–003 03.1–1450–100 03.1–1450–102 03.2–1450–001

ELECTRICAL PARTS Components

04.0–1450–001

Components Components Contactor Panel - 24V 1 Pump Contactor Panel - 36V 1 Pump Contactor Panel - 36V 2 Pumps EE Distribution Panel Contactor Contactor Contactor Multi-Task Control Multi-Task Control Display Height Sensor Connectors Control Cable Fork Tilt Switch Strobe Light Freezer/Corrosion Overhead Guard Accessories

Crown 1998 PF11307-4 Rev. 5/02

1A207228 1A207228 1A237825 1A237825

04/05/99 04/05/99 01/24/01 01/24/01

1A205705 1A205705

02/24/99 02/24/99

04.0–1450–003 04.0–1450–005 04.1–1450–001 04.1–1450–050 04.1–1450–100 04.3–1450–001 04.4–6535–050 04.4–7330–050 04.4–7330–100 04.6–1450–001 04.6–1450–003 04.8–1450–001 04.8–1450–100 04.8–1450–170 04.8–1450–200 04.8–1450–500 04.9–10.0–550 04.9–1450–001 04.9–1450–050

Printed in U.S.A.

06 REV. 5/02

IDX–1450–004

C RR RD

Revision No. - Date

RR/RD 5000 SERIES INDEX

SECTION 5 X X X

X X X

Caster 01 - 9/00 02 - 12/98

05 - 7/99

05.3–1450–050

Caster Brake - Traction Motor

Steering System

X X X

Steering System Steer Motor 121659 Steer Unit 121658

SECTION 7

X X

X X X X X X

X X

X X X X

TT - 7.25 Removable Outrigger Ends Load Wheel Yoke Load Backrest Forks

01 - 8/98 02 - 2/98

SECTION 9 X X X X

01 - 5/99 02 - 10/99 02 - 10/99 01 - 4/99

04/17/00 04/17/00

1A225525 1A225525

04/17/00 04/17/00

1A217628 1A217628

11/15/99 11/15/99

1A218548 1A218548

12/13/99 12/13/99

06.0–1450–003 06.0–1450–005 06.2–1450–001 06.3–1450–001

07.2–1450–001

01 - 1/01

01 - 10/99

1A225525 1A225525

TT - 5.5 TT - 5.5 TT - 7.25

01 - 3/98

08/16/00 08/16/00 10/30/00 10/30/00

MAST PARTS

SECTION 8 X

1A230942 1A230942 1A234559 1A234559

05.3–1450–051 05.3–1450–100

06.0–1450–001

02 - 1/01 04 - 12/99

02 - 9/98 02 - 5/00 01 - 2/01 06 - 3/01

08/16/00 08/16/00

Steering System

02 - 11/98

1A231076 1A231076

STEERING PARTS

Page Number

BRAKE PARTS

SECTION 6 X

Serial No. of Units Used For From: To: Standard Special Date

Title

07.2–1450–004 07.2–1450–100 07.2–1450–103 07.2–1450–500 07.4–1450–001 07.5–1450–250 07.8–1450–001 07.9–08.0–003

CYLINDER PARTS Lift - TT

08.3–1450–001

Lift - TT Carriage - TT Carriage - TT Reach Tilt Side Shift

08.3–1450–003 08.3–1450–050 08.3–1450–052 08.5–1450–001 08.6–1450–001 08.7–1430–050

REACH MECHANISM PARTS Tilt Tilt & Sideshift Tilt Tilt & Sideshift

09.0–1450–001 09.0–1450–100 09.0–1650–001 09.0–1650–100

Crown 1998 PF11307-5 Rev. 5/02

Printed in U.S.A.

06 REV. 5/02

IDX–1450–005

C RR RD

Revision No. - Date

SECTION 10 X

05 - 1/01

SECTION 11

RR/RD 5000 SERIES INDEX Serial No. of Units Used For From: To: Standard Special Date

Title

Page Number

ACCESSORIES Labels and Decals

10.9–1450–001

MISCELLANEOUS SERVICE INFORMATION

03 -11/01

Technical Service Bulletins - contains all service bulletins pertaining to this series.

11.0–1450–100

03 - 6/01

Kits, Instructions - contains part numbers of various service kits pertaining to this series, with instructions referenced.

11.0–1450–200

Crown 1998 PF11307-6 Rev. 5/02

Printed in U.S.A.

06 REV. 5/02

IDX–1450–006

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT RR/RD 5000/5000S In the interest of safety and to ensure compliance with the OSHA Regulations, (Standards - 29 CFR), The control of hazardous energy (lockout/tagout) - 1910.147, Crown has developed guidelines for proper energy control when performing service and maintenance on the RR/RD 5000/5000S. Before performing any service or maintenance on the RR/RD 5000/5000S, review the 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 BATTERY CARE

SAFETY RULES • Wear protective clothing, such as, rubber apron, gloves, boots and full-face shield when performing 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 lay metallic or conductive objects on battery. Arcing will result. • 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 manufacturer's instructions concerning repair practices and procedures.

CAUTION 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 connecting batteries to a charger, make sure the charger is “OFF”. If an attempt is made to do this while the charger is “ON”, serious injury to you, the battery and charger could result. • Never use a match or lighter. Battery fumes are explosive. • Make certain battery used meets weight, size and voltage requirements of truck (refer to serial plate). NEVER operate truck with an undersized battery. CHARGING

CAUTION 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.

6402 Crown 2000 PF11867-1 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–1450–101

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT BATTERY REMOVAL

BATTERY INSTALLATION CAUTION

When removing the battery, move truck to area intended for battery care. Floor must be level. Turn keyswitch or toggle switch to "off" position and remove key. Disconnect battery and lockout or tagout truck as described in Battery - 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. Don’t 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.

CAUTION When installing the battery, move truck to area intended for battery care. Floor must be level. Turn keyswitch or toggle switch to "off" position and remove key. Lockout or tagout truck as described in Battery - Lockout/Tagout in this section. If battery was removed with load engaging means raised, use hoist attached to mast to provide tip over protection. Don’t 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.

CAUTION Make certain battery used meets weight, size and voltage requirements of truck (refer to serial plate). NEVER operate truck with an undersized battery.

8251

LOCKOUT - TAGOUT Always turn key switch to "off", remove key and apply tag to multifunction control and/or steering tiller with cable tie warning others truck is being serviced.

Apply tag to multifunction control... and/or

W AR NIN G Do ba not c vehttery onne Maicle. to thi ct s bei inten an ng peance avad veh rformis opeilabl icle i ed rat e fo s no ion r t .

the steering tiller W AR NIN G Do ba not c vehttery onne Maicle. to thi ct s bei inten andng peance ava veh rformis opeilabl icle i ed rat e fo s no ion r t .

When maintenance is to be performed and the battery will be left in the truck, disconnect battery, 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 the 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.

8252

Crown 2000 PF11867-2

MA–1450–102

Printed in U.S.A.

MA–1450–102

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT CAPACITANCE Due to capacitance voltage present in the Access 2 and Access 3 modules, whenever performing maintenance which may permit contact with the bus bars and associated power cables, discharge the capacitors.

8254-01

1. Move truck to a secure non traffic maintenance area with a level floor. 2. Chock wheels of truck. Refer to Lifting and Blocking in this section. 3. Disconnect battery. Lockout or tagout truck as described in Battery - Lockout/Tagout in this section. 4. Turn and hold the keyswitch to the "start" position until the indicators on the Access 1 face first go dim - then out. 5. Turn key switch to "off", remove key.

Access 2

WA RN ING Do ba not c vehttery onne Maicle. to thi ct s beiinten an ng peance avad veh rformis opeilabl icle i ed rat e fo s no ion r t .

Access 3 0S

500

Access 1

ACCESS 3

2 T2

RV H

ACCESS 2

B SV P

C1 A SV A T1 PV P1

L MV

RV 1 SV L

s es cc

3 CV 6

s es cc

WA RN ING Do b a n ot c vehttery onne Maicle. to thi ct s b e i i nt e n an ng peance avad veh rformis opeilabl icle i ed rat e fo s no ion r t .

L-6

ACCESS 1 8253-01

Crown 2000 PF11867-3 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–1450–103

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT BRAKE The brakes can be released through the use of the Brake Release Service Tool (127373) during a maintenance situation. When using this method to release the brakes, the truck will not have brakes available for stopping from the operator compartment pedal. The truck will not have traction control and power steering will not work.

WARNING Extreme care must be taken when using the Brake Release Service Tool to release the brakes. The truck will be free-wheeling and the brake pedal in the operator compartment will have no effect on braking.

APPLYING THE BRAKES To apply the brakes, move the power switch on the Brake Release Service Tool to "off". DISCONNECTING BRAKE RELEASE SERVICE TOOL 1. Move the service tool power switch to "off". 2. Disconnect the battery connector. 3. Unplug service tool from the brake connector. 4. Connect the harness connector to the brake connector.

CONNECTING BRAKE RELEASE SERVICE TOOL 1. Lower load engaging means completely. 2. Lockout or Tagout truck as described in Battery Lockout/Tagout in this section. 3. Chock wheels or make sure truck is secured by some means to keep it from rolling away.

To prepare for towing:

WARNI NG

POWER SWITCH

Warn the towing vehicle that an accident could happen and to use extreme caution.

1. Move power switch to OFF . 2. Disconnect battery from truck and connect to brake release tool.

Truck does not have brakes, travel control or power steering when Brake Release Tool is being used.

3. Connect brake release tool to traction brake. 4. Move power switch to ON. 5. Press and release the brake release switch. Truck is ready to be towed.

BRAKE RELEASE SWITCH

To remove brake release tool: 1. Move power switch to OFF . 2. Disconnect battery from brake release tool. 3. Disconnect brake release tool from traction brake. Check to see that traction brake is applied.

4. Disconnect CA609 at the traction motor brake and connect the Brake Release Service Tool to the brake connector.

BRAKE RELEASE TOOL 286-C

5. Plug the battery connector of the Brake Release Service Tool to the battery. 6. Move the power switch on the Brake Release Service Tool to "on".

8255

7. Toggle the brake release switch to release the brakes. 8. Remove wheel chocks and move truck to area intended for maintenance. When towing the truck make sure all operators are informed of the trucks lack of braking.

Crown 2000 PF11867-4

MA–1450–104

Printed in U.S.A.

MA–1450–104

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT HYDRAULIC 1. Move truck to a secure non traffic maintenance area with a level floor.

WARNING 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 damage 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, to make sure the hydraulic system is not under pressure:

2. Retract reach mechanism all the way or, if required for maintenance, block when extended as described in Reach Mechanism of this section. 3. Completely lower load engaging means (mast and fork carriage) or, if required for maintenance, block mast sections at appropriate height as described in Mast of this section. 4. Tilt forks tips all the way down. Do not continue to tilt after fork tips are down to keep pressure from building up at the tilt cylinder. 5. Turn key switch to "off", remove key. 6. Disconnect battery. Lockout or tagout truck as described in Battery - Lockout/Tagout in this section. 7. Open manual lower valve to relieve hydraulic pressure.

Lower mast completely including fork carriage

Tilt forks completely down

W RA IN GN oD ton nocyrettab tcen ot .elcihev iaM siht b netn p gnie dna si ecna rofre evliava o dem elba si elcih ton rof.noitarep

Retract reach mechanism all the way 8256-01 Crown 2000 PF11867-5 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–1450–105

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT

LIFTING AND BLOCKING 1. RR 5000 truck shown. Information applies to RR/RD 5000 and RR/RD 5000S trucks. 2. Move truck to a secure non traffic maintenance area with a level floor.

Side

3. No load on forks. 4. Lockout or tagout truck as described in Battery Lockout/Tagout in this section. Lower forks and move towards center of truck if required

NOTES : • Hydraulic Jack - Capacity 8000 lbs. (3620 kg.) • Crown part number: 122599 • Collapsed height minimum: 2.25 in. (60 mm) • Raised height maximum: 16 in. (400 mm) • Jack Stand - capacity 10,000 lbs. (4500 kg.) Commercially available.

W RA IN GN oD ton nocyrettab tcen ot .elcihev iaM siht b netn p gnie dna si ecna rofre evliava o dem elba si elcih ton rof.noitarep

Load wheels

Hard wood block

Steer Wheel

WARNING Truck stability decreases dramatically if load wheels are raised more than 0.5 inch (13 mm). Attach sling and overhead lifting device to all cross members of the mast to prevent truck from tipping over when raising the side of the truck.

Raise forks 3 to 6 in. (70 to 150 mm) from floor

W RA IN GN oD ton nocyrettab tcen ot .elcihev iaM siht b netn p gnie dna si ecna rofre evliava o dem elba si elcih ton rof.noitarep

Chock both load wheels

8257-01

Set jack stand height as required. Not to exceed 16 in. (400 mm)

Crown 2000 PF11867-6 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–1450–106

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT MAST AND FORK CARRIAGE Blocking Masts

Third stage block

Second stage block

Use 4 inch (100 mm) by 4 inch (100 mm) or bigger hardwood blocks of the appropriate length for supporting mast channels. Block both mast rails of each stage to maintain truck stability. Remove any carriage mounted accessory (e.g. carton clamp, slip sheet, roll loader [SP only], etc.) except sideshifters before blocking masts. These accessories add significant weight to the mast. 1. Move truck to a secure non traffic maintenance area with a level floor. 2. Chock wheels of truck. Refer to Lifting and Blocking in this section. 3. Connect battery. 4. Raise forks and position block under second stage mast.

Clamp blocks together

Clamp block to mainframe

8259P

5. Using a clamp, secure block to mast channel. 6. Lower mast and position appropriate length block under third stage mast. 7. Using a clamp, secure block to mast channel or second stage block. 8. Lower fork carriage until carriage rests on stops or place block under carriage and lower until weight rests on block. 9. Lockout or tagout truck as described in Battery Lockout/Tagout in this section.

8258P

Crown 2000 PF11867-7

MA–1450–107

Printed in U.S.A.

MA–1450–107

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT REACH MECHANISM 1. Move truck to a secure non traffic maintenance area with a level floor. 2. Chock wheels of truck. Refer to Lifting and Blocking in this section. 3. Extend reach assembly. 4. Clamp a 2" x 4" (50 mm x 100 mm) hardwood block in either left or right channel of reach support assembly below the roller. 5. Relieve hydraulic pressure from reach circuit by retracting carriage until roller rests on block. 6. If mast is staged refer to Mast in this section for blocking instructions. 7. Lockout or tagout truck as described in Battery Lockout/Tagout in this section.

Cutaway for clarity

Clamp

Hardwood Block 8260

Crown 2000 PF11867-8

MA–1450–108

Printed in U.S.A.

MA–1450–108

CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT TILT 1. Move truck to a secure non traffic maintenance area with a level floor. 2. Chock wheels of truck. Refer to Lifting and Blocking in this section. 3. Tilt forks down so weight of carriage is not on the tilt cylinder. 4. Lockout or tagout truck as described in Battery Lockout/Tagout in this section.

Tilt forks completely down

W RA IN GN oD ton nocyrettab tcen ot .elcihev iaM siht b netn p gnie dna si ecna rofre evliava o dem elba si elcih ton rof.noitarep

8261-01

Crown 2000 PF11867-9 Rev. 11/00

Printed in U.S.A.

01 REV. 11/00

MA–1450–109

LUBRICATION AND ADJUSTMENT RR/RD 5000 Component Accessibility For regular maintenance, access to various truck components is accomplished by removing covers, panels or opening the power unit door. The following is a general explanation of which cover, panel, etc. that must be removed to allow for the most efficient access when performing service and/or maintenance to components. Refer to the illustrations in this section as an aid in locating parts that require attention. NOTE Be sure battery connectors are disconnected. The power unit console is secured to the top of the power unit with five clip springs. Lift and remove the console to perform maintenance to Access 3, Access 2, multi-task handle assembly, distribution panel (ALM1), key switch, hydraulic manifold block , Access 1 and key switch suppressor (SB20).

Remove four screws securing the contactor panel cover and remove cover to perform maintenance to the contactors, fuse panel and battery connector(s). Remove contactor compartment cover and floorboard cover to access top of caster. Remove floorboard to service pedals, switches ENS,BRS1 and DMS1 and connector JC607. Unlatching and swinging open the power unit door allows access to the steering control unit (SCU), traction motor (M1), traction encoder (ECR1), electric brake (BRK1), lift pump motors (M2 & M3), lift pumps (P1 & P2), hydraulic steer motor linkage, horn (HN) and travel alarm (ALM2). Remove the left hand reservoir cover(s) to gain access to the left reservoir and breather element. Remove the right hand reservoir cover(s) to gain access to the right reservoir and filter element.

Arm Pad Back Pad

Safety Shield

Access 1 Display Steering Tiller

Multi-Task Handle Reservoir Cover

Contactor Panel Cover (RR/RD 5000)

Reservoir Cover

Power On Pedal Brake Pedal

Power Unit Console Battery Compartment Battery Retainer 6267 980131

Entry Bar

Power Unit Door

Floorboard Assembly

ILLUSTRATION 1-1

Crown 1998 PF11313-1 Rev. 1/01

6910 Printed in U.S.A.

06 REV. 1/01

M1.0–1450–001

LUBRICATION AND ADJUSTMENT Lubrication The following information is intended to provide guidelines for proper lubrication intervals as called out in the lubrication chart. However, some operating conditions will require more frequent checks and lubrication than listed. For example, applications with much dust or moisture will require modification of the schedule to fit that particular application. The use of high grade lubricants and fluids should be used. Sources of these lubricants may be from almost any of the oil companies; those listed in M1.0-04.0-002 chart 1-1 are typical and any lubricant with equal specifications may be used.

For trucks running continuously at temperatures of 10 degrees Fahrenheit or below, use an 80% low temperature (063001-006) and 20% standard (063001-021) hydraulic oils. Refer to Illustration 1-2. Blending hydraulic oil as described above will ensure the best and most efficient operation of your Crown equipment All screws, washers, nuts, roll pins, retaining rings, etc. need to be coated with a rust preventive (078882) to protect against corrosion. Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts.

For truck applications operating continually in temperatures at or above 40 degrees Fahrenheit, use 100% standard hydraulic oil (063001-001). Refer to Illustration 1-2. For truck applications primarily operating in a cooler enviroment with intermittent freezer entry, use a 50/50 blend of low temperature (063001-006) and standard (063001-021) hydraulic oils. Refer to Illustration 1-2.

50/50 Blend of Low-Temp (063001-006 [50%]) & Standard Hydraulic Oil (063001-021 [50%])

6316

50 40 30 20 10 0 10 20 30 40 C

NOTE Use Planned Maintenance Inspection Reports (PF11047) for RR/RD 5000 trucks as required to record and assure maintenance checks.

120 100 80 60 40 20 0 20 40 F

Standard Hydraulic Oil (063001-001 [100%])

80/20 Blend of Low-Temp (063001-006 [80%]) & Standard Hydraulic Oil (063001-021 [20%])

ILLUSTRATION 1-2

Crown 1998 PF11313-2 Rev. 11/00

Printed in U.S.A.

05 REV. 11/00

M1.0–1450–002

LUBRICATION AND ADJUSTMENT 6475-03

L-1

L-8

L-5

B S

P C

A S

A T P

1 P

L V M

2 P

L-11

L-10

3 C

L-6

L-9

L-7 L-2

L-6 L-13 L-4 Brake Shroud Used On "EE" Trucks Only

L-12 L-3

ILLUSTRATION 1-3 See Chart 1-1

Crown 1998 PF11313-3 Rev. 1/01

Printed in U.S.A.

06 REV. 1/01

M1.0–1450–003

LUBRICATION AND ADJUSTMENT

INDEX

COMPONENT

LUBE TYPE

L-1

Mast Channels

L-2

Castor Axle & Pivot

B**

L-3

Drive Unit Pivot

L-4

Drive Unit Level

L-5

Multi-Task Handle (Ramps & Plunger) Door Hinge Pin(s)

L-6 L-7

QTY.

30 da. 100 hr.

As Required As Required As Required 1.5 pt. (0.7 Litre) As Required As Required

60 da. 250 hr.

90 da. 500 hr.

6 mo. 1000 hr.

12 mo. 2000 hr.

Check Lube Lube 1st Change

Change

Lube Check

Hydraulic Reservoir - Left (Shown) • Oil

• Breather

3.25 gal. (12.3 Litre) 1

Change Change

Hydraulic Reservoir - Right

L-8 L-9 L-10 L-11 L-12 L-13

• Oil

• 10 Micron Filter Element

• Cap Breather Element All Lift Chain(s)

D C

Load Wheel Axles (Left & Right Side) Fork Slides

Mast Staging Bumpers (Bottom 2nd Stage Mast) Steering Gears

Lower Floorboard & Entry Bar Pivot Points

3.25 gal. (12.3 Litre) 1 1 As Required As Required As Required As Required As Required As Required

Change Change Change Check Check Check Check Lube Lube

LUBRICATION CHART 1-1 See Chart 1-1 and 1-2 for Lube Type designation explanation (M1.0-04.0-001). Lubrication intervals must be changed to a frequency that will minimize wear on moving shafts and parts on vehicles used in less desirable operating conditions. Lubricaion intervals for Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving parts. * In below freezing temperatures use Dextron II, Crown part number 063001-010. ** In below freezing temperatures use low temperature, multipurpose grease, Crown part number 063002-017.

Crown 1998 PF11313-4 Rev. 8/00

Printed in U.S.A.

04 REV. 8/00

M1.0–1450–004

LUBRICATION AND ADJUSTMENT 6476-01

Sideshifter Assembly RK FO ND E

L-11

L-10 L-1 L-3 L-2

L-4

L-6

L-3 L-5

L-7

L-4 L-9

L-2 L-8

ILLUSTRATION 1-4 See Chart 1-2

Crown 1998 PF11313-5 Rev. 6/98

Printed in U.S.A.

03 REV. 6/98

M1.0–1450–005

LUBRICATION AND ADJUSTMENT

INDEX

COMPONENT

LUBE TYPE

L-1

Upper Inner Arms

As Required

Check

L-2

Reach Pivot(s)

As Required

Check

L-3

Reach Cylinder Pivot(s)

As Required

Check

L-4

Fork Slides

As Required

Check

As Required

Check

L-5

Tilt Cylinder Rod End

QTY.

L-6

Upper Outer Arm(s)

As Required

L-7

Fork Carriage Pivot(s)

As Required

30 da. 100 hr.

60 da. 250 hr.

90 da. 500 hr.

6 mo. 1000 hr.

12 mo. 2000 hr.

Check

L-8

Tilt Cylinder Pivot Bearings

As Required

Check

L-9

Carriage Channel

As Required

Check

L-10

Sideshifter Slide Rail

As Required

Check

L-11

Reach Carriage Staging Bumpers

As Required

Check

LUBRICATION CHART 1-2 See Chart 1-1 and 1-2 for Lube Type designation explanation (M1.0-04.0-001). Lubrication intervals must be changed to a frequency that will minimize wear on moving shafts and parts on vehicles used in less desirable operating conditions. Lubricaion intervals for Freezer/Corrosion trucks must be changed to a frequency that will minimize corrosion and wear on moving parts.

Crown 1998 PF11313-6 Rev. 6/98

Printed in U.S.A.

03 REV. 6/98

M1.0–1450–006

LUBRICATION AND ADJUSTMENT 6280-02

I-23

I-22

I-1 I-2

I-1 I-18

I-3 I-2 I-17

I-1

2 V R

2 T

H C P

B S V P

1 C A S V A

1 T P V A

1 P

L V M

2 P

R V 1 S V L

3 C V 6

I-1 I-1 I-14

I-3 I-1 I-15 I-1 I-16 I-15

I-4

I-2

Brake Shroud Used On "EE" Trucks Only

I-1

I-5

I-13 I-1

I-6 I-19

I-1 I-20

I-12 I-1

I-21

I-1

I-8

I-7

I-2 I-11 I-1 I-10 I-2

I-9 I-1

ILLUSTRATION 1-5 See Chart 1-3 Crown 1998 PF11313-7 Rev. 1/01

Printed in U.S.A.

06 REV. 1/01

M1.0–1450–007

LUBRICATION AND ADJUSTMENT

30 da. 100 hr.

INDEX

COMPONENT

I-1 I-2 I-3 I-4 I-5 I-6 I-7 I-8 I-9 I-10 I-10 I-11 I-12 I-13 I-14 I-15 I-16 I-17 I-18 I-19 I-20

Electrical i.e.: Connections, Cables and Wiring Hydraulic i.e.: Hoses and Fittings Padding Contactor Tips (ED & P2) Undercarriage Articulation Caster Wheel Floorboard Springs Floorboard Assembly (ENS, BRS1, DMS1) Horn Pump Motors (M2 & M3), Motor Brushes Pumps (P1 & P2) Steer Motor Traction Motor (M1) i.e: Motor Brushes Electrical Brake (BRK1 & ECR1) Distribution Panel (K1, K2, FU10 & FU11) Access 1 Display Panel Travel Alarm (Optional) Steering Control Unit (SCU) Multi-Task Control (POT1,2,3, FS, RS & EDS) Articulation Adjustment Battery Retainer (BRES1, Right & BRES2, Left Shown) Drive Unit Oil Pump Operation Overhead Guard i.e.: Secure to Truck & No Cracks Mast Dampening Screws (2nd & 3rd Stage Masts Top & Bottom [8])

I-21 I-22 I-23

60 da. 250 hr.

90 da. 500 hr.

6 mo. 1000 hr.

12 mo. 2000 hr.

Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check

INSPECTION CHART 1-3 Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.

Crown 1998 PF11313-8 Rev. 6/98

Printed in U.S.A.

03 REV. 6/98

M1.0–1450–008

LUBRICATION AND ADJUSTMENT 6282-02

Sideshifter Assembly

I-17

I-15 RK FO ND E

I-1 I-10

I-13

I-20 I-16

I-12

I-2

I-11

I-20

I-14

I-3 I-16

I-23

I-9

I-22

P C

A S

A T P

1 P

L V M

2 P

I-4

I-7

s es

3 C

I-19 I-18

I-5 I-8 Brake Shroud Used On "EE" Trucks Only

I-21

I-6 ILLUSTRATION 1-6 See Chart 1-4 Crown 1998 PF11313-9 Rev. 1/01

Printed in U.S.A.

06 REV. 1/01

M1.0–1450–009

LUBRICATION AND ADJUSTMENT

30 da. 100 hr.

INDEX

COMPONENT

I-1 I-2 I-3 I-4 I-5 I-6 I-7 I-8 I-9 I-10 I-11 I-12 I-13 I-14 I-15 I-16 I-17 I-18 I-19 I-20 I-21 I-22 I-23

Column Rollers Yoke Control Cables Forks Load Wheels Drive Tire & Lug Bolts Reach Cylinders Tilt Cylinder Free Lift Cylinder Lift Cylinders Rollers & Bearings Lower Hangers Sideshift Cylinder Mounting Slides Sideshift Cylinder & Hydraulic Connections Lift Chain Anchors Height Sensor (ECR2) - See Note 1 Free Lift Switch (FLS) Fork Switch (FKS) - Optional All Lift Chain(s) Undercarriage Pivot Point Mast & Reach Carriage Staging Bumpers Mast Mounting Screws (6) For Tightness

60 da. 250 hr.

90 da. 500 hr.

6 mo. 1000 hr.

12 mo. 2000 hr.

Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check

INSPECTION CHART 1-4 Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. Note 1: ECR2 is optional on trucks with 270 in./6860mm or less lift height and standard on trucks with greater than 270 in./6860mm lift height.

Crown 1998 PF11313-10 Rev. 6/98

Printed in U.S.A.

03 REV. 6/98

M1.0–1450–010

COMPONENTRY RR/RD 5000 ALM1 Status Alarm

BRK1 Drive Brake

Location: distribution panel.

Location: traction motor (M1).

Purpose: draws operator attention to changing truck status.

Purpose: provide braking force to drive motor to stop truck and prevent movement of parked vehicle.

Data: controlled by Access 3. Data: Access 3 release via operator or control system request, spring applied.

Adjustment: none required. ALM2 Travel Alarm

Adjustment: Service menu level P6. BRS1 Brake Pedal Switch

Location: above motors in motor compartment. Purpose: audible warning when travelling forward and/or reverse direction.

Location: under floorboard left foot pedal. Purpose: allows operator to operate the brakes operation through the control system.

Data: controlled by Access 2. Adjustment: none required.

Data: momentary contact wired normally closed. Switch actuated when operator not on pedal.

BRES1, BRES2 Battery Retainer Switches

Adjustment: none required.

Location: battery compartment wall toward operator compartment. Purpose: monitor switch for control system. Informs control system when battery restraints are in place.

BWS1, BWS2, BWS3 Motor Brush Wear Switches Location: BWS1 - traction motor, BWS2 - pump motor #1, BWS3 - pump motor #2. Purpose: informs control system when brushes are worn to replacement length.

Data: wired normally open. Adjustment: Slight adjustment through elongated mounting holes in mounting bracket.

Data: wired normally closed. Brushes worn to replacement length opens contact. Adjustment: none required.

970901

6918 - EO4277

Crown 1997 PF11063-1 Rev. 1/01

Printed in U.S.A.

08 REV. 1/01

M1.0–1450–050

COMPONENTRY CBV Counter Balance Valve

CV4 Check Valve

Location: reach carriage.

Location: hydraulic manifold.

Purpose: provide smooth motion control for reach, tilt, sideshift, control reach & tilt drift.

Purpose: prevent lift flow from P1 bypassing PVH during raise.

Data: pressure setting pre-set by vendor. Adjustment: none required. CV1 Check Valve

Data: not applicable. Adjustment: none required. CV6 Check Valve

Location: hydraulic manifold.

Purpose: allow one direction flow of hydraulic fluid from PCA to PVH.

Purpose: permit P2 pressure to be limited by RV1. Data: not applicable.

Data: not applicable. Adjustment: none required. Adjustment: none required. CV2 Check Valve

DMS1 Interlock Switch Location: under floorboard right pedal.

Location: hydraulic manifold. Purpose: prevent back flow into pump #2. Data: not applicable.

Purpose: limits truck operation when operator's foot is not in proper position. Data: wired normally closed. Switch actuated when operator's foot not on pedal.

Adjustment: none required. Adjustment: none required. CV3 Check Valve

DPS1, DPS2, DPS3, DPS4, DPS5, DPS6 Display Function Switches

Location: hydraulic manifold. Purpose: prevent lift cylinder from bypassing PVH during lower.

Location: Access 1 (display panel). DPS1 - up arrow, DPS2 - down arrow, DPS3 - enter, DPS4 performance, DPS5 - truck hours, DPS6 service codes.

Data: not applicable. Adjustment: none required.

Purpose: operator interface with control system for various truck information. Data: printed circuit board mounted push button switch wired normally open. Adjustment: none required.

Crown 1997 PF11063-2

M1.0–1450–051

Printed in U.S.A.

M1.0–1450–051

COMPONENTRY ECR1 Traction Feedback Encoder

EDS Emergency Disconnect Switch

Location: on traction motor (M1).

Location: operator compartment.

Purpose: provide ground speed and direction information for control system based on motor speed.

Purpose: resets the emergency disconnect contactor, removing battery power from control and power circuits.

Data: 5 volts D.C., 128 counts per revolution resolution.

Data: wired normally closed. Pressing switch button actuates switch.

Adjustment: none required. Adjustment: none required. ECR2 Height Sensor

ENS Operator Compartment Entry Switch

Location: side of mast. Location: under floorboard. Purpose: provide measured height of forks beyond freelift. Data: 32 counts per revolution resolution.

Purpose: signals Access 3 to remove power from traction circuit when operator’s foot is resting on the power unit skirt area along operator compartment.

Adjustment: See M4.3 section - calibration. Data: wired normally closed. Operator standing on skirt actuates switch.

ED Emergency Disconnect Contactor

Adjustment: none required. Location: contactor panel. Purpose: provide means for operator or control system to remove power from control and/or power circuits. Data: Access 3 provides battery positive to the contactor and Access 2 provides battery negative. Coil voltage 24 volts D.C., coil resistance 44 ohms. Adjustment: none required.

FAN1 Operator Compartment Fan Location: over head guard. Purpose: operator comfort. Data: 24 volt D.C. high speed, 12 volt D.C. low speed, 1 amp current draw. Adjustment: none required.

Crown 1997 PF11063-3 Rev. 9/00

Printed in U.S.A.

07 REV. 9/00

M1.0–1450–052

COMPONENTRY FKS Forks Tilted Switch

FU1 Main Control Fuse

Location: reach carriage.

Location: contactor panel.

Purpose: monitor switch for control system. Informs control system when forks are tilted full up or down.

Purpose: protect control circuitry from over current.

Data: wired normally open. Switch contacts open when forks tilted to maximum limits.

Data: see section 4. Adjustment: none required. FU2 Fan/Work Lights Fuse

Adjustment: none required. FLS Free Lift Switch

Location: contactor panel. Purpose: protect lights and associated wiring from over current.

Location: reach carriage. Purpose: monitor switch for control system. Informs control system when mast is within free lift range. Data: wired normally open. Switch is actuated when mast is in free lift range. Adjustment: none required.

Data: see section 4. Adjustment: none required. FU3 Options Fuse Location: contactor panel.

FNS Fan Switch

Purpose: protect optional components and associated wiring from over current.

Location: operator compartment panel.

Data: see section 4.

Purpose: permit operator to control operator comfort fan with OFF, LOW and HIGH selections.

Adjustment: none required. FU4 Hydraulics Fuse

Data: three position selector switch. Adjustment: none required.

Location: contactor panel.

FS Forward Switch

Purpose: protect componentry controlled by Access 2 and associated wiring from over current.

Location: pivot point of multi-task control handle. Purpose: informs control system forward travel direction is being requested by the operator.

Data: see section 4. Adjustment: none required.

Data: optic switch output 0 volts when forward travel direction selected. Output 5 volts when in neutral or reverse travel selected. Adjustment: none required.

Crown 1997 PF11063-4 Rev. 10/98

Printed in U.S.A.

03 REV. 10/98

M1.0–1450–053

COMPONENTRY FU5 Brake #1 Outer Coil Fuse

FU9 M1 Traction Motor Fuse

Location: contactor panel

Location: contactor panel.

Purpose: protect outer coil and associated wiring from over current.

Purpose: protect traction motor and associated circuitry from over current.

Data: see section 4.

Adjustment: none required.

FU6 Brake #1 Inner Coil Fuse

FU10 Access 3 Switch Common (T-COMM)

Location: contactor panel.

Location: distribution panel.

Purpose: protect BRK1 inner coil and associated wiring from over current.

Purpose: protect Access 3 input circuitry from over current.

Data: see section 4.

Adjustment: none required.

FU7 M3 Motor Fuse (pump #2)

FU11 Access 2 Switch Common (H-COMM)

Location: contactor panel.

Location: distribution panel.

Purpose: protect motor and associated wiring from over current.

Purpose: protect Access 2 input circuitry from over current.

Data: see section 4.

Adjustment: none required.

FU8 M2 Lift Motor Fuse (pump #1)

FU12 Freezer Condition Fuse

Location: contactor panel.

Location: freezer condition distribution panel.

Purpose: protect lift motor and associated circuitry from over current.

Purpose: protect freezer condition components and wiring from over current.

Data: see section 4.

Adjustment: none required.

Crown 1997 PF11063-5 Rev. 10/98

Printed in U.S.A.

03 REV. 10/98

M1.0–1450–054

COMPONENTRY FU13 Freezer Condition Fuse

HN Horn

Location: freezer condition distribution panel.

Location: motor compartment.

Purpose: protect freezer condition components and wiring from over current.

Purpose: provide operator controlled audible warning to the operating area.

Data: see section 4.

Data: 24 volt D.C. on 24 volt trucks and 36 volt D.C. on 36 volt trucks, 2 amp.

Adjustment: none required. Adjustment: none required. HGTRS Height Reset Switch

HNS Horn Switch

Location: safety shield support. Location: multi-task control handle. Purpose: resets counter in electronic system when forks are lowered.

Purpose: allows operator to sound horn.

Data: wired normally open. When mast is within freelift range switch is held closed. Adjustment: Adjust switch arm to hold switch actuated when forks are in free lift range. HGTS12 Height Switch 12 inch (305 mm)

Data: wired normally open. When pressed, relay K2 is energized and supplies battery voltage to the horn. Adjustment: none required. HSS High Speed Switch

Location: top of main frame.

Location: tilt cylinder.

Purpose: monitor switch for control system. Switch resets when forks are within 12 inches (305 mm) of full lift height to allow Access 2 to limit lift speed.

Purpose: monitor switch for control system. Informs if forks are carrying a load. Limits high speed traction and lower. Data: wired normally closed. Load on forks actuates switch by monitoring pressure in tilt cylinders.

Data: wired normally open. Actuated when forks are more than 12 inches (305 mm) from full lift height.

Adjustment: none required. Adjustment: Adjust switch arm to reset switch when forks are within 12 inches (305 mm) of full lift height.

K1 Power Up Relay Location: distribution panel. Purpose: provides power up, power down sequence interlock. Data: 24 or 36 volt D.C. coil energized upon keyswitch test position closure. Adjustment: none required.

Crown 1997 PF11063-6 Rev. 1/01

Printed in U.S.A.

08 REV. 1/01

M1.0–1450–055

COMPONENTRY K2 Horn Relay

LGS1 Light Switch Number 1 (dome)

Location: distribution panel.

Location: operator compartment (display).

Purpose: provides battery voltage path to horn.

Purpose: allows operator to turn dome light on and off.

Data: 24 or 36 volt D.C. coil energized upon horn switch closure by operator.

Data: toggle switch wired normally open. Adjustment: none required.

Adjustment: none required. LGS2 Light Switch Number 2 (work)

K3 Options Relay

Location: operator compartment (display). Location: display mounting bracket. Purpose: allows operator to turn work lights on and off. Purpose: provides electrical power for optional electrical equipment e.g. lights, fan etc. Data: 24 or 36 volt D.C. coil energized upon key switch test position closure.

Data: toggle switch wired normally open. Adjustment: none required. LGT1 Dome Light

Adjustment: none required. K4 Horn Relay Driver Block

Location: on LH mast guard. Purpose: provide light for operator compartment.

Location: above brake or optional f/c distribution board in motor compartment.

Data: 12 volt D.C., 1.5 amp, use 8 ohm resistor in series for 24 volt trucks and 16 ohm resistor in series for 36 volt trucks.

Purpose: provides ground path to horn relay K2. Data: 24 or 36 volt MOSFET driver actuated upon switch closure.

Adjustment: none required. LGT2, LGT3 Work Lights

Adjustment: none required. KYS Key Switch

Location: side of mast at over head guard. Purpose: provide work area light outside operator compartment.

Location: operator compartment. Purpose: allows operator to power up and down the truck. Data: key operated selector switch. Energizes K1 with start position and maintains K1 with ignition position.

Data: 2 amp, 24 volt D.C. for 24 volt trucks and 36 volt D.C. for 36 volt trucks. Adjustment: minimal manual directional adjustment.

Adjustment: none required.

Crown 1997 PF11063-7 Rev. 1/01

Printed in U.S.A.

08 REV. 1/01

M1.0–1450–056

COMPONENTRY LGT4 Strobe Light

M3 Lift Motor #2

Location: over head guard.

Location: in motor compartment.

Purpose: high intensity visual warning of lift truck presence.

Purpose: provide driving force for hydraulic pump supplying hydraulic pressure for high speed lift.

Data: 0.5 amp, 24 volt D.C. for 24 volt trucks, 36 volt D.C. for 36 volt trucks.

Data: on/off control provided by P2 contactor which is controlled by Access 2 via operator input (POT2).

Adjustment: none required. Adjustment: none required. LS Load Sense

MRC1 Access 3

Location: base of tilt cylinder. Location: top of power unit below console. Purpose: provide approximate weight measurement information on forks for data capacity monitor. Data: bi-directional differential pressure transducer. Adjustment: Refer to M4.3 section - calibration. M1 Traction Motor

Purpose: controls traction motor speed via operator input (POT1). Data: transistor control circuitry. Adjustment: Refer to M4.2 and M4.3 sections. MRC2 Access 2

Location: in motor compartment.

Location: top of power unit below console.

Purpose: provide driving force for traction.

Purpose: controls motor M2 speed and motor M3 on/off via operator input (POT2).

Data: Access 3 provides speed control via operator input (POT1). Adjustment: none required. M2 Lift Motor #1

Data: transistor control circuitry. Adjustment: Refer to M4.2 and M4.3 sections. MVL Manual Lowering Valve

Location: in motor compartment.

Location: hydraulic manifold.

Purpose: provide driving force for hydraulic pump supplying hydraulic pressure for lift, steering and accessory functions.

Purpose: provide emergency manual lower for lift cylinders in event of power failure.

Data: speed control provided by Access 2 via operator input (POT2).

Data: fine metering needle valve (8 turns for full open adjustment). Normally closed. Adjustment: none required.

Adjustment: none required.

Crown 1997 PF11063-8

M1.0–1450–057

Printed in U.S.A.

M1.0–1450–057

COMPONENTRY ORF5, ORF6 Orifice #5 & #6

ORF1 Orifice #1 Location: hydraulic manifold.

Location: hydraulic manifold.

Purpose: vent output for PCA when not used.

Purpose: provide controlled de-pressurization of mast hose(s) after accessory function is de-selected.

Data: nominal 0.020" orifice.

Data: nominal 0.015" orifice.

Adjustment: none required.

ORF2 Orifice #2

ORS Lift Cutout Override Switch

Location: hydraulic manifold. Purpose: vent pilot signal for PCB4 when not raising.

Location: operator compartment (display). Purpose: allows operator to override a lift cutout.

Data: nominal 0.010" orifice dia.

Data: momentary contact toggle switch wired normally open.

Adjustment: none required. ORF3 Orifice #3

Adjustment: none required. P1 Lift, Steering and Accessory Hydraulic Pump

Location: hydraulic manifold. Purpose: dampen pressure signal to PCH.

Location: in motor compartment. Data: nominal 0.015" dia. orifice Purpose: provide hydraulic flow to operate the steering, lift and accessory functions of the truck.

Adjustment: none required.

Data: not applicable.

ORF4 Orifice #4

Adjustment: none required. Location: hydraulic manifold. Purpose: dampen pressure pilot signal to PCB4. Data: nominal 0.051" dia. orifice. Adjustment: none required.

P2 High Speed Lift Hydraulic Pump Location: in motor compartment. Purpose: provide hydraulic pressure for high speed lift function. Data: 10cc (.61 cir) displacement. Adjustment: none required.

Crown 1997 PF11063-9 Rev. 9/00

Printed in U.S.A.

07 REV. 9/00

M1.0–1450–058

COMPONENTRY POT1 Traction Request Potentiometer

P2 Pump Contactor Location: contactor panel.

Location: pivot point of multi-task control handle.

Purpose: switch power to motor M3. On/off controlled by Access 2 via operator input (POT2).

Purpose: provide traction input to controller. Data: 1.7 K ohm.

Data: 24 volt D.C. Adjustment: refer to M4.3 section - calibration. Adjustment: none required. POT2 Lift Request Potentiometer

PCA Pressure Compensator

Location: pivot point of multi-task control handle. Location: hydraulic manifold. Purpose: provide lift request input to controller. Purpose: provide compensated flow control for accessory functions & bypass excess flow to lift.

Data: 1.7 K ohm. Adjustment: refer to M4.3 section - calibration.

Data: not applicable.

POT3 Accessory Request Potentiometer

Adjustment: none required. PCBy Pressure Compensator Bypass

Location: multi-task control handle. Purpose: provide accessory functions request input to controller.

Location: hydraulic manifold. Purpose: bypass excess lift and accessory flow to tank. Data: 100 psi bias at crack; nominal 10 qpm flow.

Data: 1.7 K ohms. Adjustment: refer to M4.3 section - calibration. PVA Accessory Function Electrical Proportional Valve

Adjustment: none required. PCH Pressure Compensator

Location: hydraulic manifold. Purpose: provide proportional control of accessory functions.

Location: hydraulic manifold. Purpose: provide meter-out pressure compensation for PVH flow.

Data: coil controlled by Access 2 when accessory function is selected via POT3 and SSS.

Data: not applicable. Adjustment: refer to M4.3 section - calibration. Adjustment: none required.

Crown 1997 PF11063-10 Rev. 6/99

Printed in U.S.A.

04 REV. 6/99

M1.0–1450–059

COMPONENTRY RV3 Relief Valve #3

PVH Raise/Lower Electrical Proportional Valve Location: hydraulic manifold.

Location: steering control unit.

Purpose: provide proportional control of raise and lower functions.

Purpose: limit maximum inlet steering pressure. Data: preset to 1200 psi.

Data: coil controlled by Access 2 when raise/lower function is selected via POT2.

Adjustment: none recommended. SB20 Suppressor Block

Adjustment: refer to M4.3 section - calibration. RS Reverse Switch

Location: display, mounting bracket.

Location: pivot point of multi-task control handle.

Purpose: key switch inrush current protection. Data: not applicable.

Purpose: informs control system reverse travel direction being requested by operator.

Adjustment: none required. Data: optic switch output 0 volt when reverse travel direction selected. Output 5 volt when in neutral or forward travel selected.

SB80 Suppressor Block Location: inside fan assembly (OHG).

Adjustment: none required.

Purpose: suppress electrical noise from operation of operator compartment fan (FAN1).

RV1 Relief Valve #1

Data: not applicable.

Location: hydraulic manifold.

Adjustment: none required.

Purpose: limit maximum lift pressure for raise.

SB81 Suppressor Block

Data: not applicable. Adjustment: adjusted to 3100 psi & sealed at inspection.

Location: inside strobelight assembly (OHG). RV2 Relief Valve #2

Purpose: suppress electrical noise from operation of strobe light (LGT4).

Location: hydraulic manifold. Data: not applicable. Purpose: limit maximum accessory pressure (independent of lift).

Adjustment: none required.

Data: preset to 1500 psi. Adjustment: none required.

Crown 1997 PF11063-11 Rev. 9/00

Printed in U.S.A.

07 REV. 9/00

M1.0–1450–060

COMPONENTRY SVL Lower Solenoid

SCU Steering Control Unit Location: at base of steering tiller.

Location: hydraulic manifold.

Purpose: provide steer direction & flow to steer motor.

Purpose: provide hydraulic flow path for the lower function. Data: coil energized by Access 2 when lower function selected via POT2. Coil resistance 28.8 ohms. Coil voltage 24 volts D.C. regardless of battery voltage.

Data: not applicable. Adjustment: none required. SCV6 Solenoid Check Valve

Adjustment: none required. SVP Solenoid Venting Pilot

Location: hydraulic manifold. Purpose: (24V) To maximize efficiency by bypassing all other valving when maximum lift is requested. (36v) To keep RV1 in the hydraulic circuit when P2 is running and keeps oil flow in P1 circuit from loading P2 when P2 is not running.

Location: hydraulic manifold. Purpose: open load sense pilot to PCB4 while raise function is selected. Data: coil energized by Access 2 when raise function is selected via POT2. Coil resistance 39.3 ohms. Coil voltage 24 volts D.C. regardless of battery voltage.

Data: not applicable. Adjustment: none required. SSS Side Shift Select Switch

Adjustment: none required. SVR Reach Solenoid

Location: switch in multi-task handle. Purpose: allows operator to select between reach and side shift functions. Data: printed circuit board mounted push button.

Location: manifold block on reach support. Purpose: provide hydraulic flow path for reach function.

Adjustment: none required. Data: coil energized by Access 2 when reach function is selected via POT3. Coil resistance 39.3 ohms. Coil voltage 24 volts D.C. regardless of battery voltage.

SVA Accessory Direction Location: hydraulic manifold.

Adjustment: none required. Purpose: select direction of hydraulic fluid flow for accessory function. Data: coil energized by Access 2 when accessory function selected via POT3 and TBS or TDS. Coil resistance 28.8 ohms. Coil voltage 24 volts D.C. regardless of battery voltage. Adjustment: none required.

Crown 1997 PF11063-12 Rev. 9/00

Printed in U.S.A.

07 REV. 9/00

M1.0–1450–061

COMPONENTRY TBS Tilt Back Switch

SVS Side Shift Solenoid Location: manifold block on reach carriage.

Location: multi-task control handle.

Purpose: provide hydraulic flow path for side shift function.

Purpose: allows operator to select tilt back function of hydraulic system.

Data: coil energized when side shift function selected via POT3 and SSS. Coil resistance 39.3 ohms. Coil voltage 24 volts D.C. regardless of battery voltage.

Data: printed circuit board mounted push button switch wired normally open. Adjustment: none required. TDS Tilt Down Switch

Adjustment: none required. SVT Tilt Solenoid

Location: multi-task control handle. Purpose: allows operator to select tilt down function of hydraulic system.

Location: manifold block on reach carriage. Purpose: provide hydraulic flow path for tilt function. Data: coil energized by Access 2 when tilt function is selected. Coil resistance 39.3 ohms. Coil voltage 24 volts D.C. regardless of battery voltage.

Data: printed circuit board mounted push button switch wired normally open. Adjustment: none required.

Adjustment: none required. THS1, THS2, THS3 Motor Thermal Switches Location: THS1 - traction motor, THS2 - lift motor #1, THS3 - lift motor #2 Purpose: motor over temperature monitors. Data: momentary contact thermal switch wired normally open. Over temperature condition actuates switch. Adjustment: none required.

Crown 1997 PF11063-13 Rev. 9/00

Printed in U.S.A.

07 REV. 9/00

M1.0–1450–062

COMPONENTRY Component Location Illustrations 6332-02

LGT3 LGT2

LGT4 SB81

FAN1 SB80

Multi-Task Control Hydraulic Manifold

KYS LGT1

2 V R

2 T

H C P

B S V P

1 C A S V A

Distribution Panel

Access 3

1 T P V A

1 P

L V M

2 P

R V 1 S V L

Access 2

e cc

3 C V 6

Display Access 1

Contactor Panel

BRES1 M3 P2 BWS3 THS3 ALM2 HN

Floorboard

BRES2 ECR1 M1 BWS1 THS1

Crown 1997 PF11063-14 Rev. 1/01

BRK1

M2 P1 BWS2 THS2

Printed in U.S.A.

08 REV. 1/01

M1.0–1450–063

COMPONENTRY 6333-01

K2 FU11

FU10

FU8 FU9

FU7 FU1 FU2

ED FU3 FU4 Power Unit Top FU5

FU6

Distribution Board Contactor Panel DPS1 DPS2

DPS4 Display Mounting Bracket

DPS3

DPS5 CA

CITY

NITO

LGS1

DPS6

FNS LGS2

SB20

TDS TBS SSS HNS POT3

ORS FS RS POT1 POT2

Display - Access 1

EDS

Multi-Task Control

Crown 1997 PF11063-15 Rev. 9/00

Printed in U.S.A.

07 REV. 9/00

M1.0–1450–064

COMPONENTRY 6334-01

CBV SVR

ECR2 HGTS12

Location of switches determined by lift height

HGTRS

FLS Reach Support

DMS1

BRS1 ENS

SVS SVT FU13 FU14 K11 FKS

Floorboard (bottom view) K12

HSS or LS Reach Carriage

PCH

CV3

PVA

1 C

PCby

PCA

SVA

RV2 PC2

Freezer Condition Circuit Board

P 2

2 B

V R 2 T

V P

A V

C 4

SVL

CV2

6 V

V S

C 2

V R 2 T

CV1

RV1

MVL

CV4 CV6 SCV6

PC1 SVP

MVL

PVH

Hydraulic Manifold (3 views) Crown 1997 PF11063-16 Rev. 9/00

Printed in U.S.A.

07 REV. 9/00

M1.0–1450–065

HYDRAULIC SYSTEM RR/RD 5000/5000S SERIES HYDRAULIC LINES AND FITTINGS

ADDING HYDRAULIC OIL The RR/RD 5000/5000S hydraulic system is very susceptible to dirt and contamination that could, overtime, create hydraulic malfunctions. Therefore, before adding oil to truck, filter oil with a 10 micron filter or with a 100 mesh strainer. This is especially important when the oil source is a 55 gallon drum. An example of a pneumatic pump with a 10 micron inline filter and funnel with a 100 mesh strainer is shown below. To select appropriate hydraulic oil, refer to section M1.0.

1. Blow air through all hose and lines to remove loose particles before installing. Any rubber hose with wire braid inner construction, thermoplastic hose and any steel tube lines which have been collapsed or kinked are permanently damaged and must be replaced even if the damage is not externally visible. 2. Flexible hose shall be replaced if it collapses in its normal operating position.

10 Micron Filter (Part No. 076755)

3. All hoses and lines are to be clear of any surface or edge which will cause damaging wear and cuts, or on which they can become caught.

Pneumatic Pump

4. All connections are to be leak free. 5. The beaded elbows in suction ports of all pumps must be positioned such that the suction hose retains its full volume flow, and does not collapse.

To Air Source

100 Mesh Filter (Removable)

Heavy-Duty Polyethlene Funnel 10 x 7 in. (250 x 175 mm) at Top - Part No. 126098 6459

ILLUSTRATION 1

980131

6747 - EO2475

Crown 1997 PF11297-1 Rev. 8/00

Printed in U.S.A.

03 REV. 8/00

M2.0–1450–001

HYDRAULIC SYSTEM DRIFT TEST

The internal filter is contained within the reservoir filter/fill assembly.

All drift tests should be conducted with a capacity load (refer to capacity plate for the rated capacity of your truck). The material used for the test load must be evenly stacked within the limits of a four foot square pallet and must be secured to the fork carriage with the forks spread to their maximum width.

FILTER

16-20 ft. lbs. (22-27 Nm)

CAUTION Never stand or work under a suspended load. Tilt Drift Test Cycle tilt forward and back several times before testing drift. Elevate test load 24 in. off floor. Measure drift at the load center with forks tilted up. Forks may not drift more than 0.5 in. (15 mm) over a five minute period.

ILLUSTRATION 2

8513

To access filter, rotate filter cap CCW and remove. Grasp inner support tube and remove the filter element. The filter element can be removed from the support tube and replaced. Insert filter element and support tube and replace filter cap. Torque cap to 16-20 ft. lbs. (22-27 Nm). Filter element may be incinerated for disposal.

Lift Drift Test Elevate the test load above staging height and tilt carriage to the full back position. After five minutes, measure the distance the carriage has drifted. Drifting in excess of 2.0 in. (50 mm) over a five minute period is considered unacceptable.

RESERVOIR

NOTE

With all cylinders in the retracted position and after all air has been bled from the hydraulic system, fill reservoir so that the oil level is between the "full" and "add" marks. The total capacity of the hydraulic system at this level should be approximately: • Trucks with dual reservoirs:

6.5 gal. (24.6 liters)

• Trucks with single reservoirs:

7.25 gal. (27.4 liters)

The lift measurement is to be taken from the tip of the fork to the floor. Occasionally, a slight creep of the fork assembly may occur due to internal leakage in the piston pak, but it can also be caused by leakage in the check or control valve. To seat these valves properly when this occurs, raise and lower the forks to flush out any foreign material from the valve seat. A thorough check for leaks in the system should be conducted if abnormal oil losses occur. The hydraulic system is designed to eliminate mechanical damage even if fittings become loose.

Crown 1997 PF11297-2 Rev. 8/00

Printed in U.S.A.

03 REV. 8/00

M2.0–1450–002

HYDRAULIC SYSTEM

HYDRAULIC SYSTEM CONTAMINATION Contamination in the hydraulic system can cause severe damage to the system. Any maintenance done to the hydraulic system should be done in a clean work area and the component parts should be kept as clean as possible during assembly. Any hydraulic oil put into the system should be clean and strained as described in "ADDING HYDRAULIC OIL" in this section.

Left Hand Lift Cylinder

Main Lift Cylinder and Carriage Cylinder Contamination 1. Move truck to service area, preferably under a hoist, and chock wheels.

Right Hand Lift Cylinder

Loosen Fitting Do Not Remove

2. Raise mast and block 2nd stage mast 3 ft. (915 mm) from floor. Turn key switch OFF and disconnect battery. 3. Open manual lowering valve, MVL, and slowly lower carriage.

Loosen & Remove Fitting from Bottom of Cylinder MVL - Manual Lowering Valve 7816P

ILLUSTRATION 4

5. Remove hydraulic lines from both lift cylinders, from bottom of carriage cylinder and from hydraulic hose to truck power unit. Blow air through hoses and lines to remove loose particles or contamination. Catch any hydraulic oil that may be spilled, do not reuse.

7815P

ILLUSTRATION 3

4. Refer to Illustration 4. Loosen fitting on cross over hydraulic tube leading from main supply line on left lift cylinder, as viewed facing front of truck. Loosen fitting and remove hydraulic tube from bottom of right hand lift cylinder.

6. Remove rams from both main lift cylinders. Flush both cylinders with a water based degreaser such as part number 065009-005. Thoroughly blow all degreaser and moisture from cylinder tubes making sure they are clean and totally dry. Inspect rams and cylinder tubes for damage. 7. Remove ram from carriage cylinder. Flush carriage cylinder tube with water based degreaser, part number 065009-005, and blow all degreaser and moisture from cylinder tube making sure it is clean and dry. Inspect ram and cylinder tube for damage. 8. Remove hydraulic line from port "C" on manifold block going to lift cylinder and blow air through line to remove any foreign particles. Connect hydraulic lines to cylinders but do not connect hydraulic line to manifold block. Plug line with plastic plug to prevent dirt or contamination from getting into line.

Crown 1997 PF11297-3 Rev. 8/00

Printed in U.S.A.

03 REV. 8/00

M2.0–1450–003

HYDRAULIC SYSTEM

Hydraulic Tank Contamination 9. Check condition of hydraulic filter element, breather cap element and change as required. Per the Lubrication and Adjustment chart in section M1.0-1450-001 on page -004, Crown recommends replacement of the following every 2000 hours of operation: Hydraulic Oil Filter Element 127741 Breather Element 127742 10. If contamination has reached the hydraulic reservoir(s) Crown recommends draining the hydraulic reservoir(s). Remove hydraulic lines or tubes and flush tank(s) with water based degreaser, such as part number 063009-005. Blow all degreaser and moisture from hydraulic reservoir(s), and reconnect all lines and tubes to reservoir(s). 11. Clean outside of manifold block with same water based degreaser to remove surface dirt. A decision needs to be made at this point whether to clean and flush the manifold block or replace it with a rebuilt or new assembly. A rebuilt manifold block assembly is now available from Crown, part number 123192-00R. If it is felt contamination inside the manifold block is extensive, replacement should be seriously considered. Hydraulic Manifold Block Removal and Flushing

7829P

ILLUSTRATION 5

15. Remove all solenoid coils from valves and mark coils for re-assembly.

CAUTION Do Not put hydraulic manifold or components into degreaser tank to clean. 12. Remove hydraulic lines from block, plug ports and hoses with plastic plugs to avoid oil leakage or contamination of lines or hoses. 13. Loosen accessible cartridge valves and SAE plugs while the manifold is still in the truck, do not remove any of the components at this time. 14. Remove manifold block from truck and put on a clean piece of cardboard for disassembly as shown in Illustration 5.

Printed in U.S.A.

Crown 1997 PF11297-4 Rev. 8/00

03 REV. 8/00

M2.0–1450–004

HYDRAULIC SYSTEM

16. Remove all cartridge valves from manifold block and place into a clean tub. During the entire disassembly, flushing and re-assembly it is extremely important to keep all work surfaces, equipment and parts as clean as possible to prevent contamination after assembly. Check to make sure ORF4 is removed from SVP cavity, this is the only orifice that is not screwed into the block. Do not remove any of the other orifices from the block.

Note Visible Contamination On Valve Screen

ORF4

7933P

ILLUSTRATION 6

17. Make a visual inspection of valves and valve cavities for any signs of contamination. Check operation of valve mechanisms for sticking or rough operation as seen in Illustration 7. If any valves are contaminated or do not function properly, discard valve and replace with new valve.

7832P

ILLUSTRATION 7

Printed in U.S.A.

Crown 1997 PF11297-5 Rev. 8/00

03 REV. 8/00

M2.0–1450–005

HYDRAULIC SYSTEM

18. Thoroughly clean the valves using a siphon sprayer, such as Crown part number 065174-001, and same water based degreaser as used in step 6. Do not clean valves or manifold block in degreaser tank. Do not exceed 40 PSI of air pressure to the sprayer to avoid doing any damage to the valves. Refer to Illustration 8.

Sprayer & Water Based Degreaser

7936P

21. Inspect all ports for contamination and then place manifold block in a clean container for flushing. With same sprayer and water based degreaser thoroughly flush each port on manifold block, not more than 40 PSI air pressure into sprayer. Do not clean manifold block in degreaser tank. See Illustration 10.

Air Pressure Not More Than 40 PSI 7935P

ILLUSTRATION 9

ILLUSTRATION 8

19. After cleaning, blow all liquid from valves with air nozzle, not more than 40 PSI, check valve operation again and place valves in a clean lint free location. 20. Remove SAE plugs from manifold block. It sometimes helps to tap the top of the plugs using a small hammer and a large diameter (1/4 in. [6.5 mm]) flat punch prior to loosening with a wrench. Be careful not to damage the hex hole or the plug by using excessive force. Refer to Illustration 9.

Printed in U.S.A.

Crown 1997 PF11297-6 Rev. 8/00

03 REV. 8/00

M2.0–1450–006

HYDRAULIC SYSTEM 23. Refer to Illustration 12 and look into each port with a flashlight and check for contamination that may not have been completely flushed out. If any is found flush block a second time as described in steps 21 and 22.

7939P

7937P

ILLUSTRATION 10

22. Remove manifold block from container and place into clean container on top of clean block. Use compressed air nozzle to blow air over and through manifold block to completely remove any moisture, air pressure not to exceed 40 PSI. It is very important that the inside and outside of the block be totally dry and clean. See Illustration 11.

ILLUSTRATION 12

24. Remove top o-ring seal from each valve, cover threads on valve with sleeve or tape to prevent damage to new seal, and carefully replace top o-ring seal supplied in kit. The top o-ring seal will be the one closest to the outside surface of the manifold block after the valve is installed in the manifold block. Visually inspect all other o-ring seals and back up rings, replace as required. These o-rings are not supplied in kit, but are listed on page 02.4-1450-001 of this manual, and are available through Crown. 25. Apply a light film of hydraulic oil to the o-ring and threads of all the valves and plugs before installing back into manifold block. When installing ORF4 and SVP in cavity, spread a clean light grease on FLAT side of ORF4 and stick on nose of SVP, then carefully insert into cavity. This will properly orient ORF4 and prevent it from changing position during installation. 26. Screw each valve and plug into manifold block by hand until snug.

7938P

ILLUSTRATION 11 Printed in U.S.A.

Crown 1997 PF11297-7 Rev. 8/00

03 REV. 8/00

M2.0–1450–007

HYDRAULIC SYSTEM

27. Refer to Illustration 13 for valve placement and Illustration 14 for chart of torque values for valves and plugs and torque accordingly.

PCH

RV2

#10 #6

ORF1

Part of RR/RD 5000S Power Unit

#4 1 C

ORF3

V R 2 T

ORF2

ORF5

2 B

A 1 V R

A V P

ORF6

A V S

L V S

CV6

6 V C

P V S

RV1

SVL SCV6

H V P

CV4

CV1

PVA #6

PC2

ORF4

PC1 Part of RR/RD 5000S Power Unit

SVP

PVH

PCby

SVA CV3

PCA #6 #6

CV2 by

MVL

Part of RR/RD 5000 Power Unit

MVL

C 2

7947

ILLUSTRATION 13

Printed in U.S.A.

Crown 1997 PF11297-8 Rev. 8/00

03 REV. 8/00

M2.0–1450–008

HYDRAULIC SYSTEM Recommended Torque Values for Valves

Crown Valve Identification

Vendor Identification Number

Cavity Size

Torque Valve Cartridge ft. lbs.

CV1 CV2 CV3 CV4 CV6 SCV6 RV1 RV2 MVL PVA PCA PVH PCH PCby SVL SVP SVA PC1 PC2

CV12-20 CV12-20 CV12-20 CV16-20 CV10-20 SV10-20 RV10-22 RV10-22 NV08-21E PV70-33B EC12-4001 PV72-33A EC12-3002 EC12-S3503 SV16-2202 SV08-2012 SV10-40 PC08-30 PC08-30

C12-2 C12-2 C12-2 C16-2 C10-2 C10-2 C10-2 C10-2 C08-2 C10-3 C12-4 C12-3 C12-3 C12-3 C16-2 C08-2 C10-4 C08-3 C08-3

75 - 80 75 - 80 75 - 80 95 - 100 40 - 45 35 - 40 40 - 45 40 - 45 30 - 35 35 - 40 50 - 55 50 - 55 50 - 55 50 - 55 75 - 80 25 - 30 35 - 40 30 - 35 30 - 35

Torque Coil Nut ft. lbs.

Top O-Ring Replacement Part Number

10 - 12

064019-075 064019-075 064019-075 064019-076 064019-045 064019-045 064019-045 064019-045 064019-030 064019-045 064019-075 064019-075 064019-075 064019-075 064019-076 064019-030 064019-045 064019-030 064019-030

10 - 12

6 6 6 6

Recommended Torque Values for Plugs

7948

Plug Size

Thread Size

Torque Plugs ft. lbs.

Replacement O-Rings

#2 #4 #6 #8 #10

5/16-24 7/16-20 9/16-18 3/4-16 7/8-14

5-6 10 - 11 17 - 18 30 - 32 32 - 36

064019-074 064019-031 064019-099 064019-030 064019-045

ILLUSTRATION 14

28. Mount manifold block into power unit, remove all plastic plugs and connect all hydraulic lines and hoses previously removed to manifold block, cylinders and power unit. 29. Fill reservoir(s) with hydraulic oil using 100 micro strainer, use hydraulic oil specified in section M1.0. 30. Connect battery and turn truck ON, allow truck to run for a minute or two. Slowly elevate carriage through free lift to re-stage mast. Continue to slowly lift mast until mast block can be removed from under second stage mast. After carefully removing mast block turn truck OFF and disconnect battery, leave mast in elevated position.

Printed in U.S.A.

Crown 1997 PF11297-9 Rev. 8/00

03 REV. 8/00

M2.0–1450–009

HYDRAULIC SYSTEM

31. Slowly open bleed screw on carriage (free lift) cylinder, and bleed air from cylinder until a solid stream of hydraulic fluid flows out around bleed screw. 32. Tighten bleed screw and wipe off excess oil. 33. Slowly open bleed screw on right hand or left hand lift cylinder and bleed air from cylinder until a solid stream of hydraulic oil flows out around screw. 34. Tighten bleed screw and wipe off excess oil. 35. Bleed second lift cylinder as described above. 36. After bleeding cylinders, connect battery and turn truck ON and use multi-task control to raise carriage through free lift and into stage, stop and hold position. 37. With carriage raised, examine cylinders for any leaks. 38. Lower carriage through free lift to examine operation and staging. 39. Raise and lower carriage rapidly through complete lift/ lower cycle a minimum of 10 cycles to flush system. 40. Turn truck OFF and check hydraulic oil level, add specified hydraulic oil as required. 41. Check truck operation.

Printed in U.S.A.

Crown 1997 PF11297-10 Rev. 8/00

03 REV. 8/00

M2.0–1450–010

MANIFOLD RR/RD 5000/5000S SERIES

RELIEF VALVE #1 & #2 (RV1 & RV2) Operation

RV2

The lift circuit is protected from excessive oil pressure by RV1 and the accessory (reach, tilt, etc.) circuit is protected by RV2. If pressure within the circuit exceeds the relief valve preset level, the valve will open and relieve pressure by directing oil to the reservoir thus maintaining a maximum pressure limit for the circuit. 1 C

RV2

Test Port (Quick Disconnect)

T H

P 2

V R 2 T

RV2 is not adjustable. To check for proper operation: 1. Connect a 0 to 5000 psi. (0 to 35000 kPa) pressure gauge to the test port of the manifold. Insert thermometer in hydraulic oil. 2. Place a 6000 lb. (2750 kg) load on forks. Depress and hold tilt back switch on multi task handle. Keep mast in full tilt back position while reading gauge. Pressure reading must be taken while passing full flow over relief valve. Pressure range is:

P A

Oil Temperature F˚ C˚ 70 to 90 20 to 32 100 to 140 38 to 60

2 P

6479

RV1

Pressure PSI kPA 1690 to 1790 11650 to 12350 1650 to 1750 11400 to 12050

PROPORTIONAL VALVES PVA & PVH

ILLUSTRATION 1

If PVA and PVH are replaced, valves must be calibrated. To calibrate, refer to section M4.3.

Adjustment A fully charged battery should be installed in the truck and all truck calibration and feature configuration should be completed before attempting any measurements or adjustments.

1 C

T H

PVA

V R 2 T

RV1

A A

P A

To adjust RV1:

2 P

1. Connect a 0 to 5000 psi. (0 to 35000 kPa) pressure gauge to the test port of the manifold. Insert thermometer in hydraulic oil. 2. Place a 6000 lb. (2750 kg) load on forks. Hold control lever in the full raise position while reading gauge. Pressure reading must be taken while passing full flow over relief valve with all pumps operating. Pressure range is: Oil Temperature F˚ C˚ 70 to 90 20 to 32 100 to 140 38 to 60

PVH

6481

ILLUSTRATION 2

Pressure PSI kPa 3250 to 3300 22400 to 22750 3150 to 3200 21700 to 22050

3. If relief valve setting is not within required range, loosen jam nut on RV1 and adjust valve. 4. Tighten jam nut when adjustment is correct and recheck pressure setting. Readjust if necessary. 980131

6251

Crown 1998 PF11353-1 Rev. 6/00

Printed in U.S.A.

03 REV. 6/00

M2.4–1450–001

MANIFOLD

Manifold Block O-Ring Replacement 1. Remove console on 5000 series trucks or open side panel covering manifold block on 5000S series trucks. 2. Open Manual Lowering Valve (MVL) on manifold block to relieve system pressure. See Illustration 3.

WARNING

AVOID HIGH PRESSURE FLUIDS – Escaping fluid under high 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.

5. Remove manifold block from truck and place on a clean piece of cardboard in a clean area to avoid contamination while disassembling, as shown in Illustration 4. 7. Remove all valves from manifold block and place on a clean piece of cardboard. During the entire disassembly, replacement of o-rings, putting valves back into manifold, and proper torque of valves, it is extremely important to keep work surfaces and parts as clean as possible to avoid contamination. Check to make sure ORF4 is removed from SVP cavity, refer to Illustration 5, this is the only orifice that is not screwed into the block. Do not remove any of the other orifices or SAE plugs from the block. 8. Make a visual inspection of valves and valve cavities for any signs of contamination. Check operation of valve mechanisms for sticking or rough operation as seen in Illustration 6. If any valves are contaminated or do not function properly, discard valve and replace with new valve.

9. Remove top (cap) o-ring from each valve, cover threads on valve with sleeve or tape to prevent damage to replacement o-ring, and carefully replace top o-ring. The top o-ring (cap) will be the one closest to the outside surface of the manifold block after the valve is installed in the manifold block. Visually inspect all other o-ring and back-up rings, replace as required. Refer to Chart 1 for o-ring usage.

MVL - Manual Lowering Valve

10. Apply a light film of hydraulic oil to threads of all the valves before installing into the manifold block. When installing ORF4 and SVP in cavity, spread a clean light grease on FLAT side of ORF4 and stick on nose of SVP, then carefully insert into cavity. This will properly orient ORF4 and prevent it from changing position during installation.

7815P

11. Install each valve into manifold block by hand until snug.

ILLUSTRATION 3

3. Remove all hydraulic hoses and lines from manifold block, cap lines and hoses with plastic plugs to avoid oil leakage and contamination. Catch any oil that may be spilled. 4. Loosen accessible cartridge valves while the manifold block is still in the truck, do not remove any of the valves at this time.

12. Refer to Illustration 7 for valve and plug placement and Chart 2 for torque values of valves and plugs. Torque each valve to the value given. If using a crows foot or other extension, position it at 90° to torque wrench handle to keep torque value same as torque wrench setting.

Crown 1998 PF11353-2 Rev. 6/00

Printed in U.S.A.

03 REV. 6/00

M2.4–1450–002

MANIFOLD

7932P

ILLUSTRATION 4

Note Visible Contamination On Valve Screen

ORF4

7933P

ILLUSTRATION 5

7934P

Crown 1998 PF11353-3 Rev. 6/00

ILLUSTRATION 6

Printed in U.S.A.

03 REV. 6/00

M2.4–1450–003

MANIFOLD

PCH

RV2

#10 #6

ORF1

Part of RR/RD 5000S Power Unit

1 C

ORF3

T H

ORF5

V R 2 T

ORF2

A 1

ORF6

C 4

CV6

RV1

SVL SCV6

CV4

CV1

PVA

PC2

PC1 Part of RR/RD 5000S Power Unit

ORF4 SVP

PVH

PCby

SVA CV3

PCA #6 #6

CV2

MVL

Part of RR/RD 5000 Power Unit

MVL

7947

ILLUSTRATION 7

Crown 1998 PF11353-4 Rev. 6/00

Printed in U.S.A.

03 REV. 6/00

M2.4–1450–004

MANIFOLD

Chart 1 lists the top o-ring part number for valves and plugs installed in the lift/accessory and reach carriage manifold blocks. Refer to this chart whenever installing a top replacement o-ring. Seal kits are available to replace all o-rings on each cartridge type valve. Refer to parts section 2.0 and 2.4 for seal kit part numbers. Reference Designation

Valve/Plug Part No.

Location

O-Ring Part No.

CV1, CV2, CV3

123255-001

Lift/Acc. Manifold

064019-075

0.103

1.987

2.19

CV4

123255-002

064019-076

0.116

1.171

–

CV6

125379

064019-045

0.097

0.755

–

SCV6

117304-003

064019-045

0.097

0.755

–

RV1

117913-002

064019-045

0.097

0.755

–

CBV

121819

064019-045

0.097

0.755

–

SVR/SVS SVT

122167-001

064019-030

0.087

0.644

–

RV2

123334-002

064019-045

0.097

0.755

–

MVL

177739

064019-030

0.087

0.644

–

PVA

123257-002

064019-045

0.097

0.755

–

PCA

123259

064019-075

0.103

1.987

2.19

PVH

123257-001

064019-075

0.103

1.987

2.19

PCH

123261

064019-075

0.103

1.987

2.19

PCby

123260

064019-075

0.103

1.987

2.19

SVL

117305-003

064019-076

0.116

1.171

–

SVP

123258

064019-030

0.087

0.644

–

SVA

117385-003

064019-045

0.097

0.755

–

PC1, PC2

123256

064019-030

0.087

0.644

–

#2 Plug

064091-004

064019-074

0.064

0.239

–

#4 Plug

064091-006

064019-031

0.072

0.351

–

#6 Plug

064091-002

064019-099

0.070

0.301

0.44

#8 Plug

064091-001

064019-030

0.087

0.644

–

#10 Plug

064091-007

064019-045

0.097

0.755

–

Carriage Manifold

Lift/Acc. Manifold

Crown 1998 PF11353-5 Rev. 6/00

O-Ring Dimensions (in.) W. I.D. O.D.

Printed in U.S.A.

03 REV. 6/00

M2.4–1450–005

MANIFOLD

Chart 2 lists torque values for all cartridge type valves installed in the lift/accessory manifold block and reach carriage manifold block(s) and plugs. Refer to this chart whenever installing a replacement cartridge valve(s) and/or plugs.

Part No. 117304-003

Reference Designation

Location

Cartridge Torque Ft. Lbs. (Nm)

117305-003

SCV6 (1 Lift Pump) SVL

117385-003

SVA

35 - 40

(48 - 54)

117739

MVL

30 - 35

(41 - 48)

N/A

117913-002

RV1

40 - 45

(54 - 61)

N/A

121819

CBV

(34)

N/A

122167-001

SVR/SVS SVT

(27)

123255-001

CV1/CV2 CV3

123255-002

Lift/Acc. Manifold

35 - 40

Coil Nut Torque Ft. Lbs. (Nm)

Carriage Manifold

Lift/Acc. Manifold

(48 - 54)

N/A

75 - 80 (102 - 108)

(8.0) (8.0)

(10)

75 - 80 (102 - 108)

N/A

CV4

95 - 100 (129 - 135)

N/A

123256

PC1/PC2

30 - 35

(41 - 48)

6 (PC1)

123257-001

PVH

50 - 55

(68 - 75)

10 - 12 (14 - 16)

123257-002

PVA

35 - 40

(48 - 54)

10 - 12 (14 - 16)

123258

SVP

25 - 30

(34 - 41)

123259

PCA

50 - 55

(68 - 75)

N/A

123260

PCby

50 - 55

(68 - 75)

N/A

123261

PCH

50 - 55

(68 - 75)

N/A

123334-002

RV2

40 - 45

(54 - 61)

N/A

125379

40 - 45

(54 - 61)

N/A

064091-001

CV6 (2 Lift Pumps) #8 Plug

30 - 32

(41 - 44)

N/A

064091-002

#6 Plug

17 - 18

(23 - 24)

N/A

064091-004

#2 Plug

5-6

(7 - 8)

N/A

064091-006

#4 Plug

10 - 11

(14 - 15)

N/A

064091-007

#10 Plug

32 - 36

(44 - 49)

N/A

Crown 1998 PF11353-6 Rev. 6/00

(8.0)

Printed in U.S.A.

03 REV. 6/00

M2.4–1450–006

DRIVE UNIT RR/RD 5000/5000S SERIES CAUTION

Disconnect battery and chock load wheels before performing any maintenance procedure. DRIVE TIRE REPLACEMENT

DRIVE UNIT LUBRICATION

When replacing the drive tire, make sure the composition and size are such that maneuverability and braking requirements are maintained. The drive tire is a “press-on” type; press the old tire off the hub and press new tire on.

The drive unit has a capacity of approximately 1.5 pints (710 ml) of 80/90W gear oil Crown no. 063002-003 (063001-023, ATF for trucks operating in below freezing applications). Remove drain plug to completely drain unit. To fill, remove fill plug. Add gear oil until present at oil level check plug. Refer to Illustration 2.

1. Disconnect battery and chock wheels. 2. Raise and block the power unit so drive tire is off of the floor. Loosen and remove the 8 lug bolts and remove wheel and hub from drive unit. 3. Remove old drive tire and replace with new drive tire. The outside of the hub must be pressed flush with the outside edge of the tire.

Fill & Oil Level Check Plug

4. Mount wheel and hub onto the drive unit axle and secure with the 8 lug bolts. Apply thread locking adhesive (061004-019) and anti seize to ramp part of wheel bolt. Drain Plug

5. Tighten lug bolts in sequences of 30 ft. lbs. (40 Nm), 60 ft. lbs. (80 Nm) and 100 ft. lbs. (135 Nm). Refer to Illustration 1 for bolt sequence.

1 4

5 5977

7 3

ILLUSTRATION 2

2 6

1899

ILLUSTRATION 1

6. Remove blocks, lower power unit, connect battery and remove wheel chocks. 7. Adjust the articulation as described later in this section.

980131

6530

Crown 1997 PF11127-1 Rev. 12/00

Printed in U.S.A.

07 REV. 12/00

M3.0–1450–001

DRIVE UNIT

LUBRICATION Normal application 32° F (0° C) and above Freezer application 32° F (0° C) and below

90 wt. gear lube Automatic Transmission Fluid

Part Number 063002-003 Part Number 063001-023

Drive unit oil should be changed at the first 500 hr and then every 2000 hr thereafter. GENERAL DRIVE UNIT MAINTENANCE Since the drive unit used on this model incorporates an oil pump, maintaining clean drive unit oil is essential. This can be easily accomplished through oil changes at the recommend intervals previously specified (see Lubrication).

Rotate Nut One Notch

During the oil change, remove the rear drive unit axle cover and inspect the axle nut. If the axle nut retaining screws are loose or the axle nut can be rotated between the screws, remove the retaining screws and tighten the axle nut to the next screw hole. Reinstall retaining screws (in their original position) within the hub's threaded hole. Refer to Illustration 3 & 4. Tightening the axle nut will compensate for any wear in the axle assembly, which if left unattended could result in excessive wear between the hub and axle spline requiring axle and hub replacement.

Retaining Screw

Axle Nut

Retaining Screw

ILLUSTRATION 3

6493

Retaining Screw Axle Nut Hub

Axle Rear Cover

6497

ILLUSTRATION 4

Crown 1997 PF11127-2 Rev. 12/00

Printed in U.S.A.

07 REV. 12/00

M3.0–1450–002

DRIVE UNIT

Oil Pump Disassembly (Refer to Illustrations 5 & 6) 1. Disconnect battery and chock wheels.

3. Remove oil pump housing (1) from drive unit and move to a clean work area for further disassembly.

AXLE BEARING CONE

CAM

BEARING CUP PISTON(9) SPRING(8)

O- RING (3) DRIVE UNIT HOUSING

BALL(7) PLUG SPECIAL(6)

O- RING (2) OIL PUMP HOUSING

4. Check O-rings (2) and (3) for damage and replace if necessary. 5. Remove piston (9), spring (8) and ball (7) from oil pump housing. 6. Remove special pipe plug (6), spring (5) and ball (4) from oil pump housing. 7. Thoroughly clean housing and all parts.

SPRING(5)

Oil Pump Assembly (Refer to Illustrations 5 & 6)

BALL4)

ILLUSTRATION 5

Inspect all component parts and drive unit casting for dirt and burrs before assembly.

2. Remove drain plug (23); drain oil from drive unit.

1. Place ball (4) and spring (5) into oil pump housing (1).

1895S

19 18

2. Place ball (7), spring (8) and special pipe plug into piston (9). Lubricate piston with oil to aid in smooth action and install piston into oil pump housing installed in drive unit housing.

TUBING IS INSTALLED THROUGH CORED HOLE IN CASTING

4. Oil pump body and port thoroughly and screw pump assembly into casting until seated.

3. Install O-rings (2) and (3) onto pump body.

13 15

14 11

18 10

5. Apply hydraulic sealer (061004-023) to drain plug and replace drain plug. Fill drive unit with 1.5 pints (710 ml) of gear oil, 063002-003 (063001-023, ATF for trucks operating in below freezing applications). 6. To check oil pump output remove pipe plug (15) and observe oil flow from port.

3 3 2 9

8 7 6

1837S

ILLUSTRATION 6

Crown 1997 PF11127-3 Rev. 12/00

Printed in U.S.A.

07 REV. 12/00

M3.0–1450–003

DRIVE UNIT

UNDER CARRIAGE INSPECTIONS AND ADJUSTMENTS (Refer to Illustrations 7 & 8) 1. Disconnect battery and remove from compartment; lift up and remove power unit door. 2. Disconnect all wiring to drive motor and electrical brake. 3. Disconnect hydraulic hoses to hydraulic steering motor and cap hose ends. 4. When removing undercarriage note the number and position of washers and replace in same position at assembly. 5. The four 0.75 in. diameter bolts that clamp pivot shaft to the power unit must be tightened to 225 - 250 ft. Ibs. (305 - 340 Nm) at assembly.

Articulation Adjustment 1. Truck must be on flat level floor and the trailing edge of caster pointing towards drive tire as shown in illustrations. RR/RD 5000 Series 2. Inspect wear plug on drive tire side of undercarriage and replace as necessary. Refer to Illustration 7. 3. Adjust the amount of undercarriage articulation on the left side (drive tire) to 0.06 in. +0.00 –0.02 in. (1.5 mm +0.0 –0.5 mm) between the top of the wear plug and the bottom of adjusting bolt, and tighten jam nut. 4. On the right side adjust distance between top of undercarriage and bottom of stops to 3.5 in. +0.00 –0.04 in. (89 mm +0.0 –1.0mm). Refer to Illustration 7.

NOTE Under normal maintenance operations it is recommended the undercarriage not be removed completely from the power unit.

RR/RD 5000S Series

6. Inspect springs and mounting hardware on RR/RD 5000 Series. 7. Inspect caster and wheel assembly. 8. Inspect caster assembly bearings. The locknut that secures the caster to the undercarriage must be tightened to 22 - 32 ft. lbs. (30 - 43 Nm). Rotate caster assembly while tightening to insure centering of bearings.

5. Inspect wear plugs on both ends of undercarriage and replace as neccessary. Refer to Illustration 8. 6. Adjust right side (caster) to 0.25 in +0.00 –0.04 in. (6.4 mm +0.0 –1.0 mm) from top of wear plug to bottom of adjusting bolt, and tighten jam nut. Refer to Illustration 8. 7. Adjust left side (drive tire) to 0.25 in. +0.00 –0.04 in. (6.4 mm +0.0 –1.0 mm) for mast heights to 321 in. (8155 mm) and below. For truck heights 322 in. (8180 mm) and above adjust to 0.12 in. +0.00 –0.04 (3.0 mm +0.0 –1.0mm). Refer to Illustration 8. NOTE The articulation adjustment will change as drive and caster tires wear. The articulation adjustment affects the stability of the truck.

Crown 1997 PF11127-4 Rev. 6/99

Printed in U.S.A.

04 REV. 6/99

M3.0–1450–004

DRIVE UNIT RR/RD 5000 SERIES Articulation Adjustment Brake Right Rear Corner Of P/U

Tighten Nut to 275 - 300 ft. lbs. (375 - 405 Nm)

Tightened To 22-32 ft. lbs. (30-43 Nm)

Drive Motor Articulation Adjusting Screw

Adjust Height of Both Stops To 3.5 in. (89 mm)

Hydraulic Steering Motor

Inspect Wear Plug

Inspect Spring(s)

Adjust Articulation To 0.06 in. +0.00 –0.02 in. (1.5 mm +0.0 –0.5 mm) Note Number And Location Of Flatwashers

5938-03

Part Of Power Unit Tightened To 225-250 ft. lbs. (305-340 Nm)

Inspect Caster And Wheel

Trailing Edge Of Caster Must Be In Direction Of Arrow For Articulation Adjustment

ILLUSTRATION 7

Crown 1997 PF11127-5 Rev. 11/00

Printed in U.S.A.

05 REV. 11/00

M3.0–1450–005

DRIVE UNIT RR/RD 5000S SERIES Tighten Nut to 275 - 300 ft. lbs. (375 - 405 Nm)

Brake Adjust Articulation To 0.25 in. +0.00 –0.04 in. (6.4 mm +0.0 –1.0 mm) Inspect Wear Plug

Tighten Nut to 275 - 300 ft. lbs. (375 - 405 Nm) Drive Motor

Inspect Wear Plug

Adjust Articulation To 0.25 in. +0.00 –0.04 in. (6.4 mm +0.0 –1.0 mm) For Mast Heights 321 in. (8155mm) and Below. For Mast Heights 322 in. (8180mm) and Above Adjust to 0.12 in. + 0.0 –0.04 in. (3.0 mm +0.0 –1.0 mm) 5984-02

Tightened To 22-32 ft. lbs. (30-43Nm) Hydraulic Steering Motor Inspect Caster And Wheel

Part Of Power Unit Note Number And Location Of Flatwashers

Tightened To 225-250 ft. lbs. (305-340Nm)

Trailing Edge Of Caster Must Be In Direction Of Arrow For Articulation Adjustment

ILLUSTRATION 8

Crown 1997 PF11127-6 Rev. 11/00

Printed in U.S.A.

05 REV. 11/00

M3.0–1450–006

DRIVE UNIT

DRIVE UNIT REMOVAL (Refer to Illustration 9) 1. Chock load wheels, disconnect batterry.

CAUTION

2. Using a floor jack, raise and block rear of truck high enough to allow for drive unit removal, but not higher than 16 in. (400 mm).

Make sure truck is properly blocked and jack stands securely under the power unit before removing drive unit.

3. Remove the eight lug bolts and drive tire assembly.

6. Carefully lower drive unit using jack, refer to step 4. When drive unit is clear of power unit, remove it to a clean work area for further disassembly and repair.

4. Support and stabilize the drive unit with a floor jack or transmission jack. 5. Remove the five 0.625 in. screws and two dowel pins that secure the drive unit stud assembly to the articulation carriage.

CAUTION Drive unit may tip over when lowering it. Keep hands and feet away from pinch points.

Brake Right Rear Corner Of P/U

Drive Motor Hydraulic Steering Motor

Note Number And Location Of Flatwashers Part Of Power Unit Remove Five, 0.62 in. Bolts and Two Dowel Pins. Tighten Bolts To 225 ft.lbs. (305Nm)

Tightened To 225 - 250 ft. lbs. (305 - 340Nm) Remove 8 Lug Bolts And Drive Tire

Drive Unit Drain Plug

RR/RD 5000 Series Shown 5978-01

ILLUSTRATION 9

Crown 1997 PF11127-7 Rev. 12/00

Printed in U.S.A.

07 REV. 12/00

M3.0–1450–007

DRIVE UNIT

DRIVE UNIT REPLACEMENT 31

1. Make sure load wheels are chocked and rear of truck is securely blocked high enough to allow drive unit replacement, but not higher than 16 in. (400 mm).

30 28

2. Refer to Illustration 10. Clean all mounting surfaces on undercarriage and drive unit and check for damage.

3. Install seal (16), bearing cup (15), bearing cone (14) and seal (13) into undercarriage. 4. Install ring gear (12) to drive unit. Apply blue thread lock adhesive, 061004-026, to screws (11) and torque to 25 - 30 ft. lbs. (34 to 41 Nm).

25 24 23

22 20 18 17

5. Install dowel pin (10) and bearing stud (9) into drive unit. Use red thread lock adhesive, 061004-019, on screw (5) and torque to 225 ft. lbs. (305 Nm).

Undercarriage

21 19 16

6. Install metallic seal (8), bearing cone (7) and bearing cup (6).

7. Raise drive unit into position using floor jack.

7 6

Shim(s)

Bearing Cup Holder 4 1 3 2

Drive Unit

Fill & Oil Level Check Plug

Drain Plug Drive Tire

7474

ILLUSTRATION 10

Printed in U.S.A.

Crown 1997 PF11127-8 Rev. 12/00

07 REV. 12/00

M3.0–1450–008

DRIVE UNIT

8. If same drive unit is being re-installed back into truck, use same shims that were removed at disassembly. If a replacement drive unit is being put into the truck the amount of shims will need to be determined.

A. Locate the undercarriage factory stamp, letters A – K. Two possible locations have been used to stamp your drive unit. The first is located on the machined surface near the steering unit towards the left side of the undercarriage, see Illustration 11. The second is located on the lower left side near the bearing cup mounting surface, see Illustration 12. For all trucks with undercarriage stamps refer to Chart 1 for correct amount of shims.

The replacement drive unit will be shipped with one thick shim that will bring it to an established standard measurement determined by the factory. Five .002 shims will also be included in the kit. To determine the proper number of shims required:

B. Some trucks in service do not have an undercarriage stamp. These trucks will require use of a special tool, Crown part number 126383, to determine the correct number of shims required.

LOCATION 1

9. Thoroughly clean the mounting surface on the undercarriage. Mount Crown tool 126383 to the undercarriage using motor mounting screws, see Illustration 13. Determine the gap measurement with a feeler gauge. Use Chart 1 to determine both letter stamp and the correct number of shims to be used. Stamp appropriate letter on undercarriage in either location noted above, for future reference.

Part of Power Unit 6820P

ILLUSTRATION 11

Undercarriage

LOCATION 2

6821P

Crown tool 126383

ILLUSTRATION 12

This Gap To Be Measured With Feeler Gauge 6822

ILLUSTRATION 13

Printed in U.S.A.

Crown 1997 PF11127-9 Rev. 6/99

04 REV. 6/99

M3.0–1450–009

DRIVE UNIT

Gap Measurement

Steel Stamp

Thin Shims

.000 - .010 .010 - .011 .011 - .012 .012 - .013 .013 - .014 .014 - .015 .015 - .016 .016 - .017 .017 - .018 .018 - .019 .019 - .020

K J I H G F E D C B A

0 0 1 1 2 2 3 3 4 4 5

DRIVE UNIT DOWEL PINS (Refer to Illustration 14) Refer to the following repair procedure for for dowel pins that are missing and/or protruding out of their respective holes. 1. Raise and securely block truck so drive tire is off floor. 2. Loosen the four hex socket head screws securing cup holder (contains lower drive unit bearing). 3. Insert the two dowel pins and tighten the four socket head screws. (This ensures alignment of the dowel pin holes since they may have previously shifted.)

CHART 1 4. Remove dowel pins. 10. Install two dowel pins (1) and align bearing cup holder. Apply red thread lock adhesive, 061004-019, to screws (3) and secure bearing cup holder and drive unit to undercarriage. Torque five screws 225 ft. lbs. (305 Nm).

5. Tap dowel pin holes with special 1/2"-13 NC BH7 roll tap, Crown Part number 126105. 6. Insert dowel pins.

11. Install drive tire as described in “Drive Tire Replacement” in this section.

7. Torque hex socket head screws 225 ft. lbs. (305 Nm).

12. Apply hydraulic seal, 061004-023, to drain plug and install. Fill drive unit with 1.5 pints (710 ml) of gear oil. See “Drive Unit Lubrication” in this section for recommended gear oil. Apply hydraulic seal to fill plug and install. 13. Lower truck, remove chocks and test for proper operation. Cup Holder

Tap Dowel Pins Holes Dowel Pins

Hex Socket Head Screw

6507

ILLUSTRATION 14

Printed in U.S.A.

Crown 1997 PF11127-10 Rev. 12/00

07 REV. 12/00

M3.0–1450–010

TRUCK SETUP Software Version 122676-001-05 RR/RD 5000/5000S SERIES

The feature menu is shown on the following pages. The first level of the menu shows the different areas of setup for this truck.

• F20 Lockout • F21 Save?

• F1 • F2

Voltage Pedals

• F3

Hgt Encoder

The performance menu follows the feature menu on the following pages. The first level of the menu shows the different areas of performance for this truck. The features must be set prior to setting the performance since the features turns on and off certain performance levels.

• F4

Trk Wt

• F5

Max Load

• F6

Reach

• F7

Sideshift

• F8

Tilt

• F9

Capacity

• F10 Productive

• F11 Hi Lift • F12 Hi Travel • F13 Brush/Temp • F14 Alarm • F15 Bat Retain • F16 Speed Cut • F17 Dashboard • F18 User Perf

• F19 User Codes

980401 Crown 1998 PF11356-1

M4.2–1450–210

select truck battery voltage. select "2 pedal" for 5000 truck and "5 pedal" for 5000S truck. select "yes" if truck is equipped with height encoder. enter truck weight with battery and without load from data plate. enter maximum capacity load from data plate. select "single" for RR and "double" for RD or none. select "yes" if truck is equipped with sideshifter. select "yes" if truck is equipped with tilt. information from the capacity data plate required if truck is equipped with a capacity data monitor. select "no" if truck not equipped with productivity package. Select "switch" if truck is equipped with productivity package with pressure switch and select "capacity" on trucks equipped with CDM and pressure transducer. enables high speed option when equipped. enables high speed option when equipped. select "yes" if truck is equipped with brush wear and temperature sensors in the traction and lift motors. select travel alarm configuration required if truck is equipped with alarm 2. select "yes" if truck is equipped with battery retainer switches. traction speed cutback. Requires switch input at CA403-16. makes selected items available on operator menu. select "yes" if user performance option is desired. If yes is selected, any user can select any performance level regardless of F19 settings. enter up to 25 user codes which can be applied to various performance levels. If F18 is yes, any user can select any performance level.

disables truck operation. select "Y" if setups entered should be saved.

• P1, P2, P3

Setup P1, P2, P3 performance settings for the user performance level of the feature menu (F18 and F19). • P4 BDI adjusts the individual cell voltage that the BDI uses as the definition of 0% state of charge. • P5 Plug adjusts the plugging force. • P6 Drv Brake adjusts the drive wheel braking force. • P7 Cas Brake adjusts the caster wheel braking force. • P8 Accy>FLS adjusts hydraulic accessory speed with lift height above free lift. • P9 Accy<FLS adjusts hydraulic accessory speed below free lift. • P10 Trav>FLS adjusts traction speed with lift height above free lift. • P11 Trav>270 adjusts traction speed above 270 in. (6.9 m) of lift height. • P12 Coast adjusts distance truck will coast when multi-task handle is returned to neutral. • P13 Save? select "Y" if setups entered should be saved. Feature and Performance Access When powering up the truck, press and maintain the arrow up key on the display. This enters service level two of Access 1 operation. Navigate to the F - Features or P - Performance menu and press the enter key. The message display now displays the message shown in the menu on the following page. Setup Complete When setup procedures are complete, scroll down to the Save? (F21) (P13) menu and press the enter key. If the setup completed is necessary to save into memory for future truck operation, select the Save? Y (F21.2) (P13.2) menu and press the enter key. This process will require less than a minute to complete. Do not operate any truck controls or display keys during this process. 5364 Printed in U.S.A.

M4.2–1450–210

C Press the

TRUCK SETUP

key to move right and left in the menu and allow system to accept changes to the features. Press the

and

to move up and down. F

Features

Voltage = ___

F21 Pedals = ___

Hgt Encoder = ___

F1.1

A = 36 Volt

F1.2

b = 24 Volt

F2.1

A = 5 pedals

RR/RD 5000S

F2.2

b = 2 pedals

RR/RD 5000

F3.1

A = No

F3.2

b = Yes @ ___

Trucks equipped with CDM and lift heights greater than 270 inches.

F3.3

Modify hgt

F3.3.1

Trk Wt = ___0

(With battery - From data plate)

Max Load = ___

(From data plate)

Reach = ___

Sideshift = ___

Tilt = ___

Listed on truck data plate.

Min = ___

Truck collapsed height, check truck data plate.

F6.1

A = None

F6.2

b = Single

F6.3

c = Double

F7.1

A = No

F7.2

b = Yes

F8.1

A = No

F8.2

b = Yes

continued on next page 1

= Menu available on 36 volt trucks with enhanced display.

Crown 1998 PF11356-2

M4.2–1450–211

Printed in U.S.A.

M4.2–1450–211

C continued from previous page

TRUCK SETUP

F91 Capacity = ___

F9.1

F9.2

Yes

F9.3

Zones = ___

F9.4

Height 1 = ___

F9.5

Weight 1 = ___

F9.6

Height 2 = ___

F9.7

Weight 2 = ___

F9.8

Height 3 = ___

F9.9

Weight 3 = ___

F9.10 Height 4 = ___ F9.11

Weight 4 = ___

- number of spaces filled in on capacity data plate. - first lift height on data plate. - first capacity on data plate. - second lift height on data plate. - second capacity on data plate. - third lift height on data plate. - third lift height on data plate. - fourth lift height on data plate. - fourth capacity on data plate.

F9.12 Escape F102 Productive = ___

F113 Hi Lift = ___

F12 Hi Travel = ___

F10.1 A = No F10.2 b = Switch

trucks without CDM.

F10.3 c = Capacity

trucks with CDM.

F11.1

A = No

F11.2

b = Yes

F12.1 A = No F12.2 b = Yes

F134 Brush/Temp = ___

F13.1 A = No F13.2 b = Yes

continued on next page 1

= menu available on trucks with enhanced display and height sensor. = 36 volt trucks with productivity option and load sense switch (LS). 3 = available on 5000S only. 4 = menu available on trucks with enhanced display. 2

Crown 1998 PF11356-3

M4.2–1450–212

Printed in U.S.A.

M4.2–1450–212

C continued from previous page

TRUCK SETUP

F141 Alarm = ___

F14.1 A = Off F14.2 b = Forward

forks first direction

F14.3 c = Reverse

power unit first direction

F14.4 d = Both F15 Bat Retain = ___

F15.1 A = No F15.2 b = Yes

F16 Speed Cut = ___

- without battery retainer switch. - with battery retainer switch.

F16.1 A = No F16.2 b = Yes

F172 Dashboard = ___

F17.1 A = No F17.2 b = Timer

stop watch

F17.3 c = Ht/Wt

- view height (requires height sensor) and weight (requires CDM).

F17.4 d = Both F18 User Perf = ___

F18.1 A = No F18.2 b = Yes

enables ability for operator to select P1, P2, P3 performance levels.

continued on next page 1

= travel alarm.

= menu available on trucks with enhanced display.

Crown 1998 PF11356-4

M4.2–1450–213

Printed in U.S.A.

M4.2–1450–213

C continued from previous page

TRUCK SETUP

F19 User Codes = ___

F19.1 A = No F19.2 b = Yes F19.3 c = View F19.4 d = Add

Requires Pesonal Identification Number. Note: If F18 is "yes", at least one performance level is required and any user can select any performance level.

F19.5 e = Delete F19.6 f = Escape F20 Lockout = ___

F20.1 A = No

Truck lockout.

F20.2 b = Yes F21 Save?

F21.1 Save? N F21.2 Save? Y

Note: Do not operate vehicle during the "save" operation or values may get corrupted.

continued on next page

Crown 1998 PF11356-5

M4.2–1450–214

Printed in U.S.A.

M4.2–1450–214

C Press the

TRUCK SETUP

key to move right and left in the menu and allow system to accept changes to the performance menu. Press

the

and

Performance

to move up and down. P1

Setup P1

P1.1 Forward = __.__

P1.2 Reverse = __.__

P1.3 Accel = __.__

P1.4 Pump 2 = __.__

P1.5 Lower = __.__

P1.1.1

Std = __.__

P1.1.2

Custom __.__

P1.2.1

Std = __.__

P1.2.2

Custom __.__

P1.3.1

Std = __.__

P1.3.2

Custom __.__

P1.4.1

Std = __.__

P1.4.2

Custom __.__

P1.5.1

Std = __.__

P1.5.2

Custom __.__

P2.1.1

Std = __.__

P2.1.2

Custom __.__

P2.2.1

Std = __.__

P2.2.2

Custom __.__

P2.3.1

Std = __.__

P2.3.2

Custom __.__

P2.4.1

Std = __.__

P2.4.2

Custom __.__

P2.5.1

Std = __.__

P2.5.2

Custom __.__

P1.6 Escape P2

Setup P2

P2.1 Forward = __.__

P2.2 Reverse = __.__

P2.3 Accel = __.__

P2.4 Pump 2 = __.__

P2.5 Lower = __.__

P2.6 Escape continued on next page Crown 1998 PF11356-6

M4.2–1450–215

Printed in U.S.A.

M4.2–1450–215

C continued from previous page

TRUCK SETUP

Setup P3

P3.1 Forward = __.__

P3.2 Reverse = __.__

P3.3 Accel = __.__

P3.4 Pump 2 = __.__

P3.5 Lower = __.__

P3.1.1

Std = __.__

P3.1.2

Custom __.__

P3.2.1

Std = __.__

P3.2.2

Custom __.__

P3.3.1

Std = __.__

P3.3.2

Custom __.__

P3.4.1

Std = __.__

P3.4.2

Custom __.__

P3.5.1

Std = __.__

P3.5.2

Custom __.__

P3.6 Escape P4

BDI = ___

P4.1 Std = ___

BDI fine tuning.

P4.2 Custom = ___ P5

Plug = ___

P5.1 Std = ___ P5.2 Custom = ___

Drv Brake = ___

P6.1 Std = ___ P6.2 Custom = ___

Refer to section M4.3 calibration. Adjusts stopping distance.

continued on next page

Crown 1998 PF11356-7

M4.2–1450–216

Printed in U.S.A.

M4.2–1450–216

C continued from previous page

TRUCK SETUP

P71 Cas Brake = ___

P7.1 Std = ___ P7.2 Custom = ___

Accy > FLS = ___

P8.1 Std = ___

Controls accessory speed above and below free lift.

P8.2 Custom = ___ P9

Accy < FLS = ___

P9.1 Std = ___ P9.2 Custom = ___

P102 Trav> FLS = ___

P10.1 Speed = ___

Travel speed above freelift.

P113 Trav < 270" = ___

P11.1 Speed = ___

Travel speed above 270 inch lift height.

P12 Coast = ___

P12.1 Std = ___

Adjusts plugging during coast. (1 = soft, 9 = hard)

P12.2 Custom = ___ P13 Save?

P13.1 Save? N P13.2 Save? Y

continued on next page 1

= available on 5000S only.

= requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

= menu available on trucks equipped with height sensor only. Requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

Crown 1998 PF11356-8

M4.2–1450–217

Printed in U.S.A.

M4.2–1450–217

TRUCK SETUP Software Version 122676-001-06 RR/RD 5000/5000S SERIES

The feature menu is shown on the following pages. The first level of the menu shows the different areas of setup for this truck. • F1 • F2

Voltage Pedals

• F3

Hgt Encoder

• F4

Trk Wt

• F5

Max Load

• F6

Reach

• F7

Sideshift

• F8

Tilt

• F9

Capacity

• F10 Productive

• F11 Hi Lift • F12 Metric • F13 Brush/Temp • F14 Alarm • F15 Bat Retain • F16 Speed Cut • F17 Dashboard • F18 User Perf

• F19 User Codes

• F20 Lockout 980615 Crown 1998 PF11440-1

M4.2–1450–218

select truck battery voltage. select "2 pedal" for 5000 truck and "5 pedal" for 5000S truck. select "yes" if truck is equipped with height encoder. enter truck weight with battery and without load from data plate. enter maximum capacity load from data plate. select "single" for RR and "double" for RD or none. select "yes" if truck is equipped with sideshifter. select "yes" if truck is equipped with tilt. information from the capacity data plate required if truck is equipped with a capacity data monitor. select "no" if truck not equipped with productivity package. Select "switch" if truck is equipped with productivity package with pressure switch and select "capacity" on trucks equipped with CDM and pressure transducer. enables high speed option when equipped. enables conversion of weight, height and speed measurements to metric units. select "yes" if truck is equipped with brush wear and temperature sensors in the traction and lift motors. select travel alarm configuration required if truck is equipped with alarm 2. select "yes" if truck is equipped with battery retainer switches. traction speed cutback. Requires switch input at CA403-16. makes selected items available on operator menu. select "yes" if user performance option is desired. If yes is selected, any user can select any performance level regardless of F19 settings. enter up to 25 user codes which can be applied to various performance levels. If F18 is yes, any user can select any performance level. disables truck operation.

• F21 Language • F22 Save?

enables selection of English or German language for Level 1 display messages. select "Y" if setups entered should be saved.

Setup P1, P2, P3 performance settings for the user performance level of the feature menu (F18 and F19). • P4 BDI adjusts the individual cell voltage that the BDI uses as the definition of 0% state of charge. • P5 Plug adjusts the plugging force. • P6 Drv Brake adjusts the drive wheel braking force. • P7 Cas Brake adjusts the caster wheel braking force. • P8 Accy>FLS adjusts hydraulic accessory speed with lift height above free lift. • P9 Accy<FLS adjusts hydraulic accessory speed below free lift. • P10 Trav>FLS adjusts traction speed with lift height above free lift. • P11 Trav>270 adjusts traction speed above 270 in. (6.9 m) of lift height. • P12 Coast adjusts distance truck will coast when multi-task handle is returned to neutral. • P13 Save? select "Y" if setups entered should be saved. Feature and Performance Access When powering up the truck, press and maintain the arrow up key on the display. This enters service level two of Access 1 operation. Navigate to the F - Features or P - Performance menu and press the enter key. The message display now displays the message shown in the menu on the following page. Setup Complete When setup procedures are complete, scroll down to the Save? (F22) (P13) menu and press the enter key. If the setup completed is necessary to save into memory for future truck operation, select the Save? Y (F22.2) (P13.2) menu and press the enter key. This process will require less than a minute to complete. Do not operate any truck controls or display keys during this process. 5775 Printed in U.S.A.

M4.2–1450–218

C Press the

TRUCK SETUP

key to move right and left in the menu and allow system to accept changes to the features. Press the

and

to move up and down. F

Features

Voltage = ___

F21 Pedals = ___

Hgt Encoder = ___

F1.1

A = 36 Volt

F1.2

b = 24 Volt

F2.1

A = 5 pedals

RR/RD 5000S

F2.2

b = 2 pedals

RR/RD 5000

F3.1

A = No

F3.2

b = Yes @ ___

Trucks equipped with CDM and lift heights greater than 270 inches.

F3.3

Modify hgt

F3.3.1

Trk Wt = ___0

(With battery - From data plate)

Max Load = ___

(From data plate)

Reach = ___

Sideshift = ___

Tilt = ___

Listed on truck data plate.

Min = ___

Truck collapsed height, check truck data plate.

F6.1

A = None

F6.2

b = Single

F6.3

c = Double

F7.1

A = No

F7.2

b = Yes

F8.1

A = No

F8.2

b = Yes

continued on next page 1

= Menu available on 36 volt trucks with enhanced display.

Crown 1998 PF11440-2

M4.2–1450–219

Printed in U.S.A.

M4.2–1450–219

C continued from previous page

TRUCK SETUP

F91 Capacity = ___

F9.1

F9.2

Yes

F9.3

Zones = ___

F9.4

Height 1 = ___

F9.5

Weight 1 = ___

F9.6

Height 2 = ___

F9.7

Weight 2 = ___

F9.8

Height 3 = ___

F9.9

Weight 3 = ___

F9.10 Height 4 = ___ F9.11

Weight 4 = ___

F9.12 Escape F102 Productive = ___

F113 Hi Lift = ___

F12 Metric = ___

F10.1 A = No F10.2 b = Switch

trucks without CDM.

F10.3 c = Capacity

trucks with CDM.

F11.1

A = No

F11.2

b = Yes

F12.1 A = No F12.2 b = Yes

F134 Brush/Temp = ___

F13.1 A = No F13.2 b = Yes

continued on next page 1

Crown 1998 PF11440-3

M4.2–1450–220

Printed in U.S.A.

M4.2–1450–220

C continued from previous page

TRUCK SETUP

F141 Alarm = ___

F14.1 A = Off F14.2 b = Forward

forks first direction

F14.3 c = Reverse

power unit first direction

F14.4 d = Both F15 Bat Retain = ___

F15.1 A = No F15.2 b = Yes

F16 Speed Cut = ___

- without battery retainer switch. - with battery retainer switch.

F16.1 A = No F16.2 b = Yes

F172 Dashboard = ___

F17.1 A = No F17.2 b = Timer

stop watch

F17.3 c = Ht/Wt

- view height (requires height sensor) and weight (requires CDM).

F17.4 d = Both F18 User Perf = ___

F18.1 A = No F18.2 b = Yes

enables ability for operator to select P1, P2, P3 performance levels.

continued on next page 1

= travel alarm.

= menu available on trucks with enhanced display.

Crown 1998 PF11440-4

M4.2–1450–221

Printed in U.S.A.

M4.2–1450–221

C continued from previous page

TRUCK SETUP

F19 User Codes = ___

F19.1 A = No F19.2 b = Yes F19.3 c = View F19.4 d = Add

Requires Pesonal Identification Number. Note: If F18 is "yes", at least one performance level is required and any user can select any performance level.

F19.5 e = Delete F19.6 f = Escape F20 Lockout = ___

F20.1 A = No

Truck lockout.

F20.2 b = Yes F21 Language

F21.1 English F21.2 German

F22 Save?

F22.1 Save? N F22.2 Save? Y

Note: Do not operate vehicle during the "save" operation or values may get corrupted.

continued on next page

Crown 1998 PF11440-5

M4.2–1450–222

Printed in U.S.A.

M4.2–1450–222

C Press the

TRUCK SETUP

key to move right and left in the menu and allow system to accept changes to the performance menu. Press

the

and

Performance

to move up and down. P1

Setup P1

P1.1 Forward = __.__

P1.2 Reverse = __.__

P1.3 Accel = __.__

P1.4 Pump 2 = __.__

P1.5 Lower = __.__

P1.1.1

Std = __.__

P1.1.2

Custom __.__

P1.2.1

Std = __.__

P1.2.2

Custom __.__

P1.3.1

Std = __.__

P1.3.2

Custom __.__

P1.4.1

Std = __.__

P1.4.2

Custom __.__

P1.5.1

Std = __.__

P1.5.2

Custom __.__

P2.1.1

Std = __.__

P2.1.2

Custom __.__

P2.2.1

Std = __.__

P2.2.2

Custom __.__

P2.3.1

Std = __.__

P2.3.2

Custom __.__

P2.4.1

Std = __.__

P2.4.2

Custom __.__

P2.5.1

Std = __.__

P2.5.2

Custom __.__

P1.6 Escape P2

Setup P2

P2.1 Forward = __.__

P2.2 Reverse = __.__

P2.3 Accel = __.__

P2.4 Pump 2 = __.__

P2.5 Lower = __.__

P2.6 Escape continued on next page Crown 1998 PF11440-6

M4.2–1450–223

Printed in U.S.A.

M4.2–1450–223

C continued from previous page

TRUCK SETUP

Setup P3

P3.1 Forward = __.__

P3.2 Reverse = __.__

P3.3 Accel = __.__

P3.4 Pump 2 = __.__

P3.5 Lower = __.__

P3.1.1

Std = __.__

P3.1.2

Custom __.__

P3.2.1

Std = __.__

P3.2.2

Custom __.__

P3.3.1

Std = __.__

P3.3.2

Custom __.__

P3.4.1

Std = __.__

P3.4.2

Custom __.__

P3.5.1

Std = __.__

P3.5.2

Custom __.__

P3.6 Escape P4

BDI = ___

P4.1 Std = ___

BDI fine tuning.

P4.2 Custom = ___ P5

Plug = ___

P5.1 Std = ___ P5.2 Custom = ___

Drv Brake = ___

P6.1 Std = ___ P6.2 Custom = ___

Refer to section M4.3 calibration. Adjusts stopping distance.

continued on next page

Crown 1998 PF11440-7

M4.2–1450–224

Printed in U.S.A.

M4.2–1450–224

C continued from previous page

TRUCK SETUP

P71 Cas Brake = ___

P7.1 Std = ___ P7.2 Custom = ___

Accy > FLS = ___

P8.1 Std = ___

Controls accessory speed above and below free lift.

P8.2 Custom = ___ P9

Accy < FLS = ___

P9.1 Std = ___ P9.2 Custom = ___

P102 Trav> FLS = ___

P10.1 Speed = ___

Travel speed above freelift.

P113 Trav < 270" = ___

P11.1 Speed = ___

Travel speed above 270 inch lift height.

P12 Coast = ___

P12.1 Std = ___

Adjusts plugging during coast. (1 = soft, 9 = hard)

P12.2 Custom = ___ P13 Save?

P13.1 Save? N P13.2 Save? Y

continued on next page 1

= available on 5000S only.

= requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

= menu available on trucks equipped with height sensor only. Requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

Crown 1998 PF11440-8

M4.2–1450–225

Printed in U.S.A.

M4.2–1450–225

ACCESS 1 RR/RD 5000/5000S SERIES The Access 1 module, commonly referred to as the display, is the interface between the operator or service technician and the truck electronic system. This section will cover the control components of the Access 1 module for monitoring and testing truck operation. Controls and Indicators Standard Display Battery Discharge Indicator Power "on"

Operator Improper Sequence Error

Service Required Light Fork Height Indicator

Message Display (4 Character)

6217

Navagation Keys

Dome Work Lift Operator Light Cutout Light Compartment Override Fan

Enhanced Display

Capacity Data Monitor

Quick Reference Keys

6218 980131 Crown 1997 PF-11278-1

M4.3–1450–001

Message Display (16 Character) 5289 Printed in U.S.A.

M4.3–1450–001

ACCESS 1 These indicators on all displays: Battery Discharge Indicator • resembles fuel gauge for indication of battery state of charge. • display represents approximate battery charge. • the indicators in the corners represent a fully charged battery to the right and battery in need of charge to the left and will flash when this level is reached.

6219

Power "on" • illuminates when power is present to display.

6215

Operator Improper Sequence Error • illuminates when operator uses incorrect sequence of truck operation. • illuminates when load that is over capacity (based on 24" load center) has been picked up with forks.

6216

Service Required • illuminates when a status has been detected that requires attention. Accompanied by status code.

6248

Navagation Keys • arrow up and arrow down keys scroll display up and down through menus. Used also to enter the service modes at power up. • return or enter key moves display into and out of selected menus and allows system to accept inputs.

6222

Fork Height Indicator • illuminates when forks are above free lift. • flashes and alarm sounded when forks above free lift and travel speed greater than 1.5 mph.

6224

6250

Message Display (standard display only, requires reference material) • 4 character limited alphabet capabilities and full numeric capability display. • presents information to operator as necessary. • visual interface with truck electronic system. Options Control Switches • control switches for trucks equipped with dome light, operator comfort fan, work lights and/ or lift cutout override.

6251

Crown 1997 PF-11278-2

M4.3–1450–002

Printed in U.S.A.

M4.3–1450–002

ACCESS 1

These indicators on enhanced displays only:

Performance Menu Hour Meter Menu Log Events Menu 6221

6225

Quick Reference Keys • during truck operation, keys can be used to go directly to indicated operator menu. • pressing key while in menu returns display to normal operation.

Extended Message Display (in place of 4 character display on standard) • 16 character alpha numeric display. C • presents more comprehensive information to operator as necessary. • visual interface with truck electronic system. This indicator on enhanced display with CDM Capacity Data Monitor • fork icon indicates approximate lift height of forks. • bar left of fork icon indicates maximum recommended lift height for load on forks. • circle to the left of the bar corresponds to data plate circles. • for more information on the capacity monitor, refer to the M4.3 Capacity Monitor section of the service manual.

6223

Crown 1997 PF-11278-3

M4.3–1450–003

Printed in U.S.A.

M4.3–1450–003

USER MAIN MENU LEVEL

The truck operator has access to the following menu after inputting the required user code.

User Code Input Run or System Ready Screen Hour Hour Meters

H1 H2 H3 H4 H5

Run = ___ Travel = ___ Lift 1 = ___ Lift 2 = ___ PM Due = ___

Total truck pedal time Total time traction motor (M1) operation Total time motor (M2) operation Total time motor (M3) operation Run meter reading for next planned maintenance inspection

Log Events

LL L-1 L-2

Last = ___ Last-1 = ___ Last-2 = ___

Last service condition status code Second last service condition status code Third last service condition status code

Performance

P1 P2 P3

Performance Performance Performance

Performance level one. Programmed in service menu. Performance level two. Programmed in service menu. Performance level three. Programmed in service menu.

Elapsed Timer

Timer __:__:__ Start Stop

Stop watch.

Height & Weight

___ inch Fork height. Truck must be equipped with a height sensor. ____ lb @ ___ in Load weight and fork height. Truck must be equipped with height sensor and capacity monitor.

NOTE: Some of the above categories are not available on standard display. Based on truck configuration, some features (stop watch) may not be enabled.

Crown 1997 PF-11278-4

M4.3–1450–004

Printed in U.S.A.

M4.3–1450–004

SERVICE MAIN MENU LEVELS The service technician has access to various portions of the following menu depending on the access level selected. • Level two service menu is accessed by pressing the "up" arrow key during power up of the truck. This level allows truck operation. • Level three menu is accessed by pressing the "up" and "down" arrow keys simultaneously during truck power up.This level does not permit truck operation.

Service Code Input

Four digit code

Analyzer

• Level two (except the A4 menu level) and level three menu. • In A1 menu the truck status can be checked which will match the truck status listed with each status code. A2 menu permits checking inputs to the Access 2 and 3 modules as seen by the modules. A3 menu permits checking the outputs of the Access 2 and 3 modules as seen by the modules. A4 is the test output menu which allows the system to power the output components, without truck operation, for troubleshooting.

Calibrate

• Level two menu only. • Truck components requiring calibration to the Access 1 - 2 - 3 system are contained in this menu.

Features

• Level two and level three menu only. • In the features menu, programming is performed to set truck operation and performance to customer specifications and truck configuration.

Hour Reset

• Level two menu only. • Ability to check and reset hour meters available in this menu.

Log Events

• Level two and level three menu. • The last 16 codes in order of occurance and the accumulative count for each code can be viewed in this menu. Resetting log event counts available.

Performance

• Level two menu only. • Truck performance for operator code is set in this menu with additional overall performance adjustments available.

Utilities

Crown 1997 PF-11278-5

M4.3–1450–005

Printed in U.S.A.

M4.3–1450–005

ANALYZER MENU Press the

key to move right and left in the menu and allow

system to accept calibration values. Press the move up and down.

Analyzer

Status

Inputs

and

A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7 A1.8 A1.9 A2.1 A2.2 A2.3 A2.4 A2.5 A2.6 A2.7 A2.8 A2.9 A2.10 A2.11 A2.12 A2.13 A2.14 A2.15 A2.16 A2.17 A2.18 A2.19 A2.20 A2.21 A2.22 A2.23 A2.24 A2.25 A2.26 A2.27 A2.28 A2.29 A2.30 A2.31 A2.32 A2.33 A2.34 A2.35 A2.36

Steer = ___ Accy = ___ Lower = ___ Raise = ___ Full Trav = ___ Limp Trav = ___ ED Closed = ___ Battery = ___ Escape FS = ___ RS = ___ POT 1 = ___ POT 2 = ___ POT 3 = ___ SSS = ___ TBS = ___ TDS = ___ ED = ___ ENS = ___ DMS1/2 = ___ BRS1 = ___ BRS2 = ___ BRS3 = ___ FLS = ___ HGTRS = ___ LMS = ___ HGTS12 = ___ ECR2 = ___ HSS = ___ LS = ___ CA408-11 = ___ ECR1 = ___ BW1 = ___ THS1 = ___ BW2 = ___ THS2 = ___ BW3 = ___ THS3 = ___ DPS4 = ___ DPS5 = ___ DPS6 = ___ ORS = ___ CA407-5 = ___ BRES1/2 = ___ CA408-12 = ___

(continued on next page) Crown 1997 PF-11278-6

M4.3–1450–006

Printed in U.S.A.

M4.3–1450–006

ANALYZER MENU (continued from previous page) A3

Outputs

Test Outputs

A5 Crown 1997 PF-11278-7

M4.3–1450–007

A3.1 A3.2 A3.3 A3.4 A3.5 A3.6 A3.7 A3.8 A3.9 A3.10 A3.11 A3.12 A3.13 A3.14 A3.15 A3.16 A3.17 A3.18 A3.19 A3.20 A3.21

Lamps/ALM1 ALM2 ED SVA SVL SVP SVR SVS SVT PVA PVH BRK1-O BRK1-I BRK2 M1-A M1-F FOR M1-F REV M2 P2 GPD1 Escape

A4.1 A4.2 A4.3 A4.4 A4.5 A4.6 A4.7 A4.8 A4.9 A4.10 A4.11 A4.12 A4.13 A4.14 A4.15 A4.16 A4.17 A4.18 A4.19 A4.20 A4.21

Lamps/ALM1 ALM2 ED SVA SVL SVP SVR SVS SVT PVA PVH BRK1-O BRK1-I BRK2 M1-A M1-F FOR M1-F REV M2 P2 GPD1 Escape

Escape Printed in U.S.A.

M4.3–1450–007

CALIBRATION MENU Press the

key to move right and left in the menu and allow

system to accept calibration values. Press the move up and down.

Calibration

Trav Handle

R / L Handle

Accy Handle

Height

and

C1.1

Forward = __.__ move handle to full forward position

C1.2

Center = __.__

C1.3

Reverse = __.__ move handle to full reverse position

C2.1

Raise = __.__ move handle to full raise position

C2.2

Center = __.__ move handle to center position

C2.3

Lower = __.__ move handle to full lower position

C3.1

Reach = __.__ move thumbwheel to full reach position

C3.2

Center = __.__ move thumbwheel to center position

C3.3

Retract = __.__ move thumbwheel to full retract position

C4.1

R Cut1 = ___

C4.2

C6 C7

Crown 1997 PF-11278-8

M4.3–1450–008

Weight

Valves Save ?

R Cut2 = ___

move handle to center position

C4.1.1

None

C4.1.2

Override

C4.1.3

Stop

C4.1.4

Escape

C4.2.1

None

C4.2.2

Override

C4.2.3

Stop

C4.2.4

Escape

C4.3.1

Max Height = ___

I = ••• (ma) enter ma reading from proportional I = ••• (ma) valve

C4.3

Max Hgt = ___

C4.4

Escape

C5.1

No Load

C5.2

3500 Lbs.

C5.3

Escape

C6.1

Main = •••

C6.1.1

C6.2

Accy = •••

C6.2.1

C7.1

Save ? N

C7.2

Save ? Y

Lift to Limit

Note: Do not operate vehicle during the save operation.

Printed in U.S.A.

M4.3–1450–008

FEATURES MENU Press the

key to move right and left in the menu and allow

system to accept calibration values. Press the move up and down.

Features

and

Voltage = ___

Pedals = ___

Hgt Encoder = ___

F1.1

A = 36 Volt

F1.2

b = 24 Volt

F2.1

A = 5 Pedals

5000S with seat

F2.2

b = 2 Pedals

5000

F3.1

A = No

F3.2

b = Yes @ ___

F3.3

Modify hgt

F3.3.1

Min = ___

Trk Wt = ___0

(With Battery - From Data Plate)

Max Load = ___

(From Data Plate)

Reach = ___

Sideshift = ___

Tilt = ___

F6.1

A = None

F6.2

b = Single

F6.3

c = Double

F7.1

A = No

F7.2

b = Yes

F8.1

A = No

F8.2

b = Yes

(continued on next page) Crown 1997 PF-11278-9

M4.3–1450–009

Printed in U.S.A.

M4.3–1450–009

FEATURES MENU (continued from previous page)

F9 Capacity = • *

F10 Productive = •

F11 Hi Lift = •

F12 Hi Travel = •

F9.1

F9.2

Yes

F9.3

Zones = •

number of spaces filled in on capacity data plate.

F9.4

Height 1 = •••

first (maximum) lift height on data plate.

F9.5

Weight 1 = •••• first (maximum) capacity on data plate.

F9.6

Height 2 = •••

second lift height on data plate.

F9.7

Weight 2 = ••••

second capacity on data plate.

F9.8

Height 3 = •••

third lift height on data plate.

F9.9

Weight 3 = ••••

third capacity on data plate.

F9.10

Height 4 = •••

fourth lift height on data plate.

F9.11

Weight 4 = ••••

fourth capacity on data plate.

F9.12

Escape

F10.1

A = No

F10.2

b = Switch

trucks without CDM

F10.3

c = Capacity

trucks with CDM

F11.1

A = No

F11.2

b = Yes

F12.1

A = No

F12.2

b = Yes

(continued on next page) Crown 1997 PF-11278-10

M4.3–1450–010

Printed in U.S.A.

M4.3–1450–010

FEATURES MENU (continued from previous page)

F13 Brush / Temp = • *

F14 Alarm = *

F15 Bat Retain = •

F16 Speed Cut = •

F17 Dashboard = • *

F13.1

A = No

F13.2

b = Yes

F14.1

A = Off

F14.2

b = Forward

fork first direction.

F14.3

c = Reverse

power unit first direction.

F14.4

d = Both

F15.1

A = No

without battery retainer switch.

F15.2

b = Yes

with battery retainer switch.

F16.1

A = No

F16.2

b = Yes

F17.1

A = No

F17.2

b = Timer

F17.3

c = Ht / Wt

F17.4

d = Both

(continued on next page) Crown 1997 PF-11278-11

M4.3–1450–011

Printed in U.S.A.

M4.3–1450–011

FEATURES MENU (continued from previous page)

F18 User Perf = • *

F19 User Codes = •

F20 Lockout = •

F21 Save ?

Crown 1997 PF-11278-12

M4.3–1450–012

F18.1

A = No

F18.2

b = Yes

F19.1

A = No

F19.2

b = Yes

F19.3

c = View User •••• @ P •

F19.4

d = Add User •••• @ P •

F19.5

e = Delete User •••• @ P •

F19.6

f = Escape

F20.1

A = No

F20.2

b = Yes

F21.1

Save ?

F21.2

Save ? Y

if F18 is "yes" one of these is required.

Note: Do not operate vehicle during the save operation.

Printed in U.S.A.

M4.3–1450–012

HOUR RESET MENU Press the

key to move right and left in the menu and allow

system to accept calibration values. Press the move up and down.

Hour Reset

Run = ____

Travel = ____

Crown 1997 PF-11278-13

M4.3–1450–013

and

Lift 1 = ____

Lift 2 = ____

PM H_ @ ____

H2.1

Sure? N

H2.2

Sure? Y

H3.1

Sure? N

H3.2

Sure? Y

H4.1

Sure? N

H4.2

Sure? Y

H5.1

PM H1 = ____

H5.2

PM H2 = ____

H5.3

PM H3 = ____

H5.4

PM H4 = ____

H5.5

PM None

H5.6

Escape

Printed in U.S.A.

M4.3–1450–013

LOG EVENTS MENU Press the

key to move right and left in the menu and allow

system to accept calibration values. Press the move up and down.

Log Events

History

and

Last = ___ @ ____ L - 1 = ___ @ ____ thru L - 15 = ___ @ ____

Totals

Event ___ = ____ thru Event ___ = ____

Erase

L3.1

L3.2

L3.3 L4

Crown 1997 PF-11278-14

M4.3–1450–014

Erase Chron

Erase All

L3.1.1

Sure? N

L3.1.2

Sure? Y

L3.2.1

Sure? N

L3.2.2

Sure? Y

Escape

Printed in U.S.A.

M4.3–1450–014

PERFORMANCE MENU Press the

key to move right and left in the menu and allow

system to accept calibration values. Press the move up and down.

and

Note: Feature setups must be established prior to modifying performance setups. P

Performance

Setup P1

P1.1

P1.2

P1.3

P1.4

P1.5

Setup P2

Forward = _._

Reverse = _._

Accel = _

Pump 2 = ___

Lower = ___

P1.6

Escape

P2.1

Forward = _._

P2.2

P2.3

P2.4

P2.5

P2.6

Reverse = _._

Accel = _

Pump 2 = ___

Lower = ___

P1.1.1

Std = _._

P1.1.2

Custom = _._

P1.2.1

Std = _._

P1.2.2

Custom = _._

P1.3.1

Std = _

P1.3.2

Custom = _

P1.4.1

Pump 2 = On

P1.4.2

Pump 2 = Off

P1.5.1

Std = ___

P1.5.2

Custom = ___

P2.1.1

Std = _._

P2.1.2

Custom = _._

P2.2.1

Std = _._

P2.2.2

Custom = _._

P2.3.1

Std = _

P2.3.2

Custom = _

P2.4.1

Pump 2 = On

P2.4.2

Pump 2 = Off

P2.5.1

Std = ___

P2.5.2

Custom = ___

Escape

(continued on next page) Crown 1997 PF-11278-15

M4.3–1450–015

Printed in U.S.A.

M4.3–1450–015

PERFORMANCE MENU (continued from previous page) P3

Setup P3

P3.1

P3.2

P3.3

P3.4

P3.5

Accel = _

Pump 2 = ___

Lower = ___

Escape

P4.1

Std = _

P4.2

Custom = _

P5.1

Std = _

P5.2

Custom = _

P6.1

Std = _

P6.2

Custom = _

P7.1

Std = _

P7.2

Custom = _

P8.1

Std = _

P8.2

Custom = _

P9.1

Std = _

P9.2

Custom = _

P10 Trav > FLS = _._

P10.1

Speed = _._

P11 Trav > 270" = _._

P11.1

Speed = _._

P12 Coast = _

P12.1

Std = _

P12.2

Custom = _

P13.1

Save ? N

P13.2

Save ? Y

BDI = _

Plug = _

Drv Brake = _

Cas Brake = _

Accy > FLS = _

Accy < FLS = _

P13 Save ?

M4.3–1450–016

Reverse = _._

P3.6 P4

Crown 1997 PF-11278-16

Forward = _._

P3.1.1

Std = _._

P3.1.2

Custom = _._

P3.2.1

Std = _._

P3.2.2

Custom = _._

P3.3.1

Std = _

P3.3.2

Custom = _

P3.4.1

Pump 2 = On

P3.4.2

Pump 2 = Off

P3.5.1

Std = ___

P3.5.2

Custom = ___

Printed in U.S.A.

M4.3–1450–016

UTILITIES MENU Press the

key to move right and left in the menu and allow

system to accept calibration values. Press the move up and down.

Utilities

Crown 1997 PF-11278-17

M4.3–1450–017

Part Number

Copy Setups

and

U1.1

Access 1

______

U1.2

Access 2

______

U1.3

Access 3

______

U1.4

Software

______-___-__

U1.5

Escape

U2.1

From TCM

U2.2

From HCM

U2.3

Escape

Printed in U.S.A.

M4.3–1450–017

ACCESS 1 Software Version 122676-001-05 RR/RD 5000/5000S SERIES

The Access 1 module, commonly referred to as the display, is the interface between the operator or service technician and the truck electronic system. This section will cover the control components of the Access 1 module for monitoring and testing truck operation. Controls and Indicators Standard Display Battery Discharge Indicator Power "on"

Operator Improper Sequence Error

Service Required Light Fork Height Indicator

Message Display (4 Character)

6217

Navagation Keys

Dome Work Lift Operator Light Cutout Light Compartment Override Fan

Enhanced Display

Capacity Data Monitor

Quick Reference Keys

6218

Message Display (16 Character)

980401

5693

Crown 1998 PF11355-1 Rev. 8/98

Printed in U.S.A.

01 REV. 8/98

M4.3–1450–020

6219

Power "on" • illuminates when power is present to display.

6215

6216

Service Required • illuminates when a status has been detected that requires attention. Accompanied by status code.

6248

6222

Fork Height Indicator • illuminates when forks are above free lift. • flashes and alarm sounded when forks above free lift and travel speed greater than 1.5 mph.

6224

6250

6251

Crown 1998 PF11355-2

M4.3–1450–021

Printed in U.S.A.

M4.3–1450–021

ACCESS 1

These indicators on enhanced displays only: Performance Menu Hour Meter Menu Log Events Menu 6221

6225

Quick Reference Keys • during truck operation, keys can be used to go directly to indicated operator menu. • pressing key while in menu returns display to normal operation.

6223

Crown 1998 PF11355-3

M4.3–1450–022

Printed in U.S.A.

M4.3–1450–022

USER MAIN MENU LEVEL

The truck operator has access to the following menu after inputting the required user code.

User Access Code

qqqq

Run

System Ready

Hour Reset

H1 H2 H3 H4 H5

Run = Travel = Lift 1 = Lift 2 = PM @____H_

Total truck pedal time Total time traction motor (M1) operation Total time motor (M2) operation Total time motor (M3) operation Run meter reading for next planned maintenance inspection

LL L-1 L-2 L4

Last = ____ Last-1 = ____ Last-2 = ____ Escape

Last service condition status code Second last service condition status code Third last service condition status code

P1 P2 P3

Performance Performance Performance

Performance level one. Programmed in service menu. Performance level two. Programmed in service menu. Performance level three. Programmed in service menu.

Timer ___:___:___ Start Stop

Stop watch.

Log Events

Performance

Elapsed Timer

Height&Weight ____ inch Fork height. Truck must be equipped with a height sensor. ____lb. @ ____inch Load weight and fork height. Truck must be equipped with height sensor and capacity monitor.

not available on trucks with standard display.

Crown 1998 PF11355-4

M4.3–1450–023

Printed in U.S.A.

M4.3–1450–023

SERVICE MAIN MENU LEVELS

The service technician has access to various portions of the following menu depending on the access level selected. • Level two service menu is accessed by pressing the "up" arrow key during power up of the truck. This level allows truck operation. • Level three menu is accessed by pressing the "up" and "down" arrow keys simultaneously during truck power up.This level does not permit truck operation.

Service Access Code

qqqq

Analyzer

Calibrate

• Level two menu only. • Truck components requiring calibration to the Access 1 - 2 - 3 system are contained in this menu.

Features

• Level two and level three menu only. • In the features menu, programming is performed to set truck operation and performance to customer specifications and truck configuration.

Hour Reset

• Level two menu only. • Ability to check and reset hour meters available in this menu.

Log Events

• Level two and level three menu. • The last 16 codes in order of occurance and the accumulative count for each code can be viewed in this menu. Resetting log event counts available.

Performance

• Level two menu only. • Truck performance for operator code is set in this menu with additional overall performance adjustments available.

Utilities

Crown 1998 PF11355-5 Rev. 8/98

Printed in U.S.A.

01 REV. 8/98

M4.3–1450–024

C Press the

ANALYZER MENU

key to move right and left in the menu and allow system to perform function requested. Press the

and

to move up and down.

Service Access Code

qqqq A

Analyzer

Status

A1.1

Steer = q

A1.2

Accy = q

A1.3

Lower = q

A1.4

Raise = q

A1.5

Full Trav = q

A1.6

Limp Trav = q

A1.7

ED Closed = q

A1.8

Battery = q

A1.9

Escape

continued on next page

Crown 1998 PF11355-6

M4.3–1450–025

Printed in U.S.A.

M4.3–1450–025

C continued from previous page

continued on next page

ANALYZER MENU

Inputs

A2.1

FS = q

1=Forward selected

A2.2

RS = q

1 = Reverse selected

A2.3

POT1 = q

A2.4

POT2 = q

A2.5

POT3 = q

A2.6

SSS = q

1.4v = Full forward 4.5v = Full reverse 1.4v = Full raise 4.5v = Full lower 1.0v = Full reach 4.0v = Full retract 1 = Side shift selected

A2.7

TBS = q

1 = Tilt back selected

A2.8

TDS = q

1 = Tilt down selected

A2.9

403-11 = q

1 = Input closed

A2.10 ENS = q

1 = Entry bar pressed

A2.11 DMS1/2 = q

1 = Off pedal

A2.12 BRS1 = q

1 = Off pedal

A2.13 BRS2 = q

1 = Off pedal

A2.14 BRS3 = q

0 = Off pedal

A2.15 FLS = q

0 = Above free lift

A2.16 HGTRS = q

0 = At height reset

A2.17 LMS = q

0 = input closed

A2.18 HGTS12 = q

0 = Within 12" from top

A2.19 ECR2 = q

Increasing = raise

A2.20 HSS = q

0 = Unloaded (<500 lbs)

A2.21 ECR1 = q

Increasing = Forward

A2.22 BRES1 = q

0 = Retainer missing

A2.23 ORS = q

0 = Override not selected

A2.24 BW1 = q

0 = Brush worn

A2.25 THS1 = q

0 = Hot

A2.26 BW2 = q

0 = Brush worn

A2.27 THS2 = q

0 = Hot

A2.28 BW3 = q

0 = Brush worn

A2.29 THS3 = q

0 = Hot

A2.30 DPS4 = q

0 = Button pressed

A2.31 DPS5 = q

0 = Button pressed

A2.32 DPS6 = q

0 = Button pressed

A2.33 407-5 = q

0 = Input closed

A2.34 408-11 = q

0 = Input open

A2.35 LS = q

Increasing = More weight

A2.36

0 = Input open

Crown 1998 PF11355-7 Rev. 8/98

CA408-12 = q

Printed in U.S.A.

01 REV. 8/98

M4.3–1450–026

C continued from previous page

ANALYZER MENU

Outputs

A3.1

Not Used

Not used

A3.2

ALM2 = q

On/Off

A3.3

ED = q

On/Off

A3.4

SVA = q

On/Off

A3.5

SVL = q

On/Off

A3.6

SVP = q

On/Off

A3.7

SVR = q

On/Off

A3.8

SVS = q

On/Off

A3.9

SVT = q

On/Off

A3.10 PVA = q

0-100%

A3.11 PVH = q

0-100%

A3.12 BRK1o = q

0-15 Amp

A3.13 BRK1i = q

0-5 Amp

A3.14 BRK2 = q

0-4 Amp

A3.15 M1-A= q

0-560 Amp

A3.16 M1-F For = q

0-50 Amp

A3.17 M1-F Rev = q

0-50 Amp

A3.18 M2 = q

0-100%

A3.19 P2 = q

On/Off

A3.20 GPD1 = q

On/Off

continued on next page A3.21 Escape

Crown 1998 PF11355-8 Rev. 8/98

Printed in U.S.A.

01 REV. 8/98

M4.3–1450–027

C continued from previous page

ANALYZER MENU

Test Outputs

A4.1

Lamps/ALM1

On/Off

A4.2

ALM2 = q

On/Off

A4.3

ED = q

On/Off

A4.4

SVA = q

On/Off

A4.5

SVL = q

On/Off

A4.6

SVP = q

On/Off

A4.7

SVR = q

On/Off

A4.8

SVS = q

On/Off

A4.9

SVT = q

On/Off

A4.10 PVA = q

A4.12 BRK1o = q

90% 24 V 60% 36 V 90% 24 V 60% 36 V 5 Amp

A4.13 BRK1i = q

2 Amp

A4.14 BRK2 = q

2 Amp

A4.15 M1-A= q

300 Amp

A4.16 M1-F For = q

(+) 40 Amp

A4.17 M1-F Rev = q

(-) 40 Amp

A4.18 M2 = q A4.19 P2 = q

50 Amp 36 V 90 Amp 24 V On/Off

A4.20 GPD1 = q

On/Off

A4.11 PVH = q

A4.21 Escape

Escape

continued on next page

Crown 1998 PF11355-9 Rev. 8/98

Printed in U.S.A.

01 REV. 8/98

M4.3–1450–028

CALIBRATION MENU

Press the key to move right and left in the menu and allow system to accept calibration values. Press the to move up and down. C

Calibration

C41

Trav Handle

R/L Handle

Accy Handle

Height

C1.1

Forward = q

C1.2

Center = q

C1.3

Reverse = q

C2.1

Raise = q

C2.2

Center = q

C2.3

Lower = q

C3.1

Reach = q

C3.2

Center = q

C3.3

Retract = q

C4.1

R Cut1 = q

C4.2

R Cut2 = q

C4.3

Max Hgt = q

C4.4

Escape

and

C4.1.1

None

C4.1.2

Override

C4.1.3

Stop

C4.1.4

Escape

C4.2.1

None

C4.2.2

Override

C4.2.3

Stop

C4.2.4

Escape

C4.3.1

Max Height =

continued on next page 1

= available on trucks equipped with height sensor only.

Crown 1998 PF11355-10

M4.3–1450–029

Printed in U.S.A.

M4.3–1450–029

CALIBRATION MENU

continued from previous page C51

Weight

Valves

Save?

C5.1

No Load

C5.2

3500 lbs.

C5.3

Escape

C6.1

Main I = q

C6.1.1

I = q (ma)

C6.2

Main G = q

C6.2.1

G=q

C6.3

Accy I = q

C6.3.1

I = q (ma)

C6.4

Accy G = q

C6.4.1

G=q

C6.5

Escape

C7.1

Save? N

C7.2

Save? Y

continued on next page 1

=menu available on trucks with enhanced display only. Capacity data monitor (CDM) must be enabled (F9).

Crown 1998 PF11355-11 Rev. 8/98

Printed in U.S.A.

01 REV. 8/98

M4.3–1450–030

C Press the

FEATURES MENU

key to move right and left in the menu and allow system to accept changes to the features. Press the

and

to move up and down.

Features

Voltage = ___

F21 Pedals = ___

Hgt Encoder = ___

F1.1

A = 36 Volt

F1.2

b = 24 Volt

F2.1

A = 5 pedals

RR/RD 5000S

F2.2

b = 2 pedals

RR/RD 5000

F3.1

A = No

Trucks equipped with height encoder.

F3.2

b = Yes @ ___

Trk Wt = ___0

(With battery - From data plate)

Max Load = ___

(From data plate)

Reach = ___

Sideshift = ___

Tilt = ___

Listed on truck data plate.

F6.1

A = None

F6.2

b = Single

F6.3

c = Double

F7.1

A = No

F7.2

b = Yes

F8.1

A = No

F8.2

b = Yes

continued on next page 1

= Menu available on 36 volt trucks with enhanced display.

Printed in U.S.A.

Crown 1998 PF11355-12 Rev. 8/98

01 REV. 8/98

M4.3–1450–031

C continued from previous page

FEATURES MENU

F91 Capacity = ___

F9.1

F9.2

Yes

F9.3

Zones = ___

F9.4

Height 1 = ___

F9.5

Weight 1 = ___

F9.6

Height 2 = ___

F9.7

Weight 2 = ___

F9.8

Height 3 = ___

F9.9

Weight 3 = ___

F9.10 Height 4 = ___ F9.11

Weight 4 = ___

- number of spaces filled in on capacity data plate. - first lift height on data plate. - first capacity on data plate. - second lift height on data plate. - second capacity on data plate. - third lift height on data plate. - third capacity on data plate. - fourth lift height on data plate. - fourth capacity on data plate.

F9.12 Escape F102 Productive = ___

F10.1 A = No

F113 Hi Lift = ___

F12 Hi Travel = ___

F10.2 b = Switch

trucks with productivity package.

F10.3 c = Capacity

trucks with CDM.

F11.1

A = No

F11.2

b = Yes

F12.1 A = No F12.2 b = Yes

F134 Brush/Temp = ___

F13.1 A = No F13.2 b = Yes

continued on next page 1

= menu available on trucks with enhanced display and height sensor. = 36 volt trucks with productivity package/CDM. 3 = available on 5000S only. 4 = menu available on trucks with enhanced display. 2

Printed in U.S.A.

Crown 1998 PF11355-13 Rev. 8/98

01 REV. 8/98

M4.3–1450–032

C continued from previous page

FEATURES MENU

F141 Alarm = ___

F14.1 A = Off F14.2 b = Forward

forks first direction

F14.3 c = Reverse

power unit first direction

F14.4 d = Both F15 Bat Retain = ___

F15.1 A = No F15.2 b = Yes

F16 Speed Cut = ___

- without battery retainer switch. - with battery retainer switch.

F16.1 A = No F16.2 b = Yes

F172 Dashboard = ___

F17.1 A = No F17.2 b = Timer

stop watch

F17.3 c = Ht/Wt

- view height (requires height sensor) and weight (requires CDM).

F17.4 d = Both F18 User Perf = ___

F18.1 A = No F18.2 b = Yes

enables ability for operator to select P1, P2, P3 performance levels.

continued on next page 1

= travel alarm.

= menu available on trucks with enhanced display.

Crown 1998 PF11355-14

M4.3–1450–033

Printed in U.S.A.

M4.3–1450–033

C continued from previous page

FEATURES MENU

F19 User Codes = ___

F19.1 A = No F19.2 b = Yes F19.3 c = View

If F19 is "yes", minimum of one Pesonal Identification Number is required. If F18 is "yes", any user can select any performance level.

F19.4 d = Add F19.5 e = Delete F19.6 f = Escape F20 Lockout = ___

F20.1 A = No

Truck lockout.

F20.2 b = Yes F21 Save?

F21.1 Save? N F21.2 Save? Y

Note: Do not operate vehicle during the "save" operation or values may get corrupted.

continued on next page

Printed in U.S.A.

Crown 1998 PF11355-15 Rev. 8/98

01 REV. 8/98

M4.3–1450–034

C Press the and H

HOUR METER MENU

key to move right and left in the menu and allow system to accept changes to the hour reset menu. Press the to move up and down.

Hour Reset

H1 Run = ___ H2 Travel = ___

H3 Lift 1 = ___

H4 Lift 2 = ___

H5 PM H• @ ___

H2.1

Sure? N

H2.2

Sure? Y

H3.1

Sure? N

H3.2

Sure? Y

H4.1

Sure? N

H4.2

Sure? Y

H5.1

PM H1 = ___

H5.1

PM H2 = ___

H5.1

PM H3 = ___

H5.1

PM H4 = ___

H5.1

PM None = ___

H5.1

Escape

H6 Escape

continued on next page

Crown 1998 PF11355-16

M4.3–1450–035

Printed in U.S.A.

M4.3–1450–035

C Press the and L

LOG EVENTS MENU

key to move right and left in the menu and allow system to accept changes to the log events menu. Press the to move up and down.

Log Events

L1 History

L2 Totals

L3 Erase

Last =

___ @ ____

L-1 =

L-15 =

___ @ ____ • • • • • ___ @ ____

Event ___

= ____

Event ___

= ____

L3.1

L3.2

L3.3

Erase Hist

Erase All

L3.1.1

Sure? N

L3.1.2

Sure? Y

L3.2.1

Sure? N

L3.2.2

Sure? Y

Escape

L4 Escape

continued on next page

Crown 1998 PF11355-17

M4.3–1450–036

Printed in U.S.A.

M4.3–1450–036

C Press the

PERFORMANCE MENU

key to move right and left in the menu and allow system to accept changes to the performance menu. Press

the

and

Performance

to move up and down.

Setup P1

P1.1 Forward = __.__

P1.2 Reverse = __.__

P1.3 Accel = __.__

P1.4 Pump 2 = ____

P1.5 Lower = __.__

P1.1.1

Std = __.__

P1.1.2

Custom __.__

P1.2.1

Std = __.__

P1.2.2

Custom __.__

P1.3.1

Std = __.__

P1.3.2

Custom __.__

P1.4.1

Pump 2 = On

P1.4.2

Pump 2 = Off

P1.5.1

Std = __.__

P1.5.2

Custom __.__

P2.1.1

Std = __.__

P2.1.2

Custom __.__

P2.2.1

Std = __.__

P2.2.2

Custom __.__

P2.3.1

Std = __.__

P2.3.2

Custom __.__

P2.4.1

Pump 2 = On

P2.4.2

Pump 2 = Off

P2.5.1

Std = __.__

P2.5.2

Custom __.__

P1.6 Escape P2

Setup P2

P2.1 Forward = __.__

P2.2 Reverse = __.__

P2.3 Accel = __.__

P2.4 Pump 2 = ____

P2.5 Lower = __.__

P2.6 Escape continued on next page Printed in U.S.A.

Crown 1998 PF11355-18 Rev. 8/98

01 REV. 8/98

M4.3–1450–037

C continued from previous page

PERFORMANCE MENU

Setup P3

P3.1 Forward = __.__

P3.2 Reverse = __.__

P3.3 Accel = __.__

P3.4 Pump 2 = ____

P3.5 Lower = __.__

P3.1.1

Std = __.__

P3.1.2

Custom __.__

P3.2.1

Std = __.__

P3.2.2

Custom __.__

P3.3.1

Std = __.__

P3.3.2

Custom __.__

P3.4.1

Pump 2 = On

P3.4.2

Pump 2 = Off

P3.5.1

Std = __.__

P3.5.2

Custom __.__

P3.6 Escape P4

BDI = ___

P4.1 Std = ___

BDI fine tuning.

P4.2 Custom = ___ P5

Plug = ___

P5.1 Std = ___ P5.2 Custom = ___

Drv Brake = ___

P6.1 Std = ___ P6.2 Custom = ___

Refer to section M5.0 brakes. Adjusts stopping distance.

continued on next page

Crown 1998 PF11355-19 Rev. 8/98

Printed in U.S.A.

01 REV. 8/98

M4.3–1450–038

C continued from previous page

PERFORMANCE MENU

P71 Cas Brake = ___

P7.1 Std = ___ P7.2 Custom = ___

Accy > FLS = ___

P8.1 Std = ___

Controls accessory speed above free lift.

P8.2 Custom = ___ P9

Accy > 270" = ___

P9.1 Std = ___ P9.2 Custom = ___

Controls accessory speed above 270 inch (6.9 m) lift height.

P102 Trav> FLS = ___

P10.1 Speed = ___

Travel speed above freelift.

P113 Trav < 270" = ___

P11.1 Speed = ___

Travel speed above 270 inch (6.9 m) lift height.

P12 Coast = ___

P12.1 Std = ___

Adjusts regenerative braking during coast. (9 = soft, 1 = hard)

P12.2 Custom = ___ P13 Save?

P13.1 Save? N P13.2 Save? Y

continued on next page 1

= available on 5000S only.

= requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

= menu available on trucks equipped with height sensor only. Requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

Crown 1998 PF11355-20 Rev. 8/98

Printed in U.S.A.

01 REV. 8/98

M4.3–1450–039

C U

Utilities

UTILITIES MENU

U1 Part Number

U2 Copy Setups

U1.1

Access 1

______

U1.2

Access 2

______

U1.3

Access 3

______

U1.4

Software

______.___.__

U1.5

Escape

U2.1

From TCM

U2.2

From HCM

U2.3

Escape

U3 Escape

Crown 1998 PF11355-21

M4.3–1450–040

Printed in U.S.A.

M4.3–1450–040

CALIBRATION Software Version 122676-001-05 RR/RD 5000/5000S SERIES The calibration menu is shown on the following pages. The first level of the menu shows the different areas of calibration for this truck. • C1 Trav Handle traction potentiometer (POT1) in the multi task control. • C2 R/L Handle raise/lower potentiometer (POT2) in the multi task control. • C3 Accy Handle accessory potentiometer (POT3) in the multi task control. • C4 Height raise cutouts (2 possible) and maximum height. Truck must be equipped with height sensor. • C5 Weight capacity data monitor (CDM). Truck must be equipped with enhanced display, height sensor and load sense transducer. F9 in the features menu must be enabled. • C6 Valves raise/lower (PVH) and accessory (PVA) electrical proportional valves. When to calibrate: • Access 1 replaced will require the load sense transducer (LS) to be calibrated. • Access 2 or Access 3 replaced will require the potentiometers in the multi task control to be calibrated. • any of the potentiometers or components used to mount or position potentiometers in the multi task control replaced. • the hydraulic manifold has been replaced without keeping the existing electrical proportional valves (PVH, PVA). • PVH replaced. • PVA replaced. • load sense transducer (LS) replaced. • status code instructions recommends recalibration of a specific component.

Calibration Access When powering up the truck, press and maintain the arrow up key on the display. This enters level two of Access 1 operation. Navigate to the C - Calibrate menu and press the enter key. The message display now displays the message: C1 Trav Handle (as shown in the menu on the following pages). Calibration Procedures A full explanation of calibration procedures for each menu level follows the calibration menu map. Calibration Complete When calibration procedures are complete, scroll down to the Save? (C7) menu and press the enter key. If the calibration completed is necessary to save into memory for future truck operation, select the "Save? Y" (C7.2) menu and press the enter key. This process will require less than a minute to complete. To keep calibration values from becoming unusable, do not operate any truck controls or display keys during this process.

980401

5792 Printed in U.S.A.

Crown 1998 PF11360-1 Rev. 6/98

01 REV. 6/98

M4.3–1450–085

CALIBRATION Press the key to move right and left in the menu and allow system to accept calibration values. Press the to move up and down. 1

1.1

1.2

1.3

2.1

2.2

2.3

= q

3.1

= q

3.2

3.3

4.1

1 = q

and

4.1.1 4.1.2 4.1.3 4.1.4

4.2

2 = q

4.2.1 4.2.2 4.2.3 4.2.4

4.3

= q

4.3.1

4.4

Crown 1998 PF11360-2

M4.3–1450–086

Printed in U.S.A.

M4.3–1450–086

CALIBRATION

5.1 5.2

3500

5.3 6

6.1

6.1.1

= q (

6.2

= q

6.2.1

= q

6.3

6.3.1

= q (

6.4

= q

6.4.1

= q

)

6.5

C1 Trav Handle (traction request potentiometer - POT1) C1.1 (forward) - move the multi task handle to the full speed . The menu will then forward traction position and press move to the next menu level.

C1.2 (center) - with the multi task handle in the neutral position, press . The menu will then move to the next menu level.

Crown 1998 PF11360-3

M4.3–1450–087

7.1

7.2

? (

)

( 9).

C1.3 (reverse) - move the multi task handle to the full speed reverse traction position and press . The menu will then return to the C1 menu level. If no additional calibration procedures are to be performed, and select the C7.2 scroll to the C7 menu level, press menu. Calibration is complete and truck can be returned to operation. If additional calibration procedures are to be performed, scroll to the appropriate menu level and continue.

Printed in U.S.A.

M4.3–1450–087

CALIBRATION C2 R/L Handle (raise/lower request potentiometer - POT2)

C4 Height (raise cutouts and maximum lift height)

C2.1 (raise) - move the multi task handle to the full speed raise position and press . The menu will then move to the next menu level.

C4.1 (R cut1) - this menu level permits programming a lift cutout. If more than one cutout is to be programmed, this level must be the lower lift height and must be performed at the "override" level (C4.1.2). C4.1.1 (none) select this level by pressing , if no cutouts are required. The menu will return to the C4.1 level. Next program the maximum lift height (C4.3). C4.1.2 (override) programs a lift cutout with override. Position the forks at the desired lift cutout height. Press . Programming is complete and menu will return to C4.1. C4.1.3 (stop) programs a lift cutout without override. Position the forks at the desired lift cutout height. Press . Programming is complete and menu will return to C4.1. C4.1.4 (escape) select this menu level by pressing if no changes are to be made.

C2.2 (center) - with the multi task handle in the neutral position, press . The menu will then move to the next menu level. C2.3 (lower) - move the multi task handle to the full speed lower position and press . The menu will then return to the C2 menu level. If no additional calibration procedures are to be performed, scroll to the C7 menu level, press and select the C7.2 menu. Calibration is complete and truck can be returned to operation. If additional calibration procedures are to be performed, scroll to the appropriate menu level and continue. C3 Accy Handle (multi task accessory function control thumbwheel) C3.1 (reach) - move the multi task thumbwheel to the full speed reach position and press . The menu will then move to the next menu level. C3.2 (center) - with the thumbwheel in the neutral position, . The menu will then move to the next menu level. press

C4.2 (R cut2) - this menu level permits programming a second lift cutout. This cutout must be at a higher lift height than C4.1. C4.2.1 (none) select this level by pressing , if this cutout is not required. The menu will return to the C4.2 level. Next program the maximum lift height (C4.3). C4.2.2 (override) programs a lift cutout with override. Position the forks at the desired lift cutout height. Press . Programming is complete and menu will return to C4.2. C4.2.3 (stop) programs a lift cutout without override. Position the forks at the desired lift cutout height. Press . Programming is complete and menu will return to C4.2. C4.2.4 (escape) select this menu level by pressing if no changes are to be made. C4.3 (max hgt) programs the maximum mechanical lift height of the truck (not to be used to limit lift height). C4.3.1 (max height) Raise forks until the mechanical stops are contacted and press . Programming is complete and the menu will return to the C4.3 menu level. C4.4 (escape) select this menu level by pressing return to the C4 menu level.

Printed in U.S.A.

Crown 1998 PF11360-4 Rev. 6/98

01 REV. 6/98

M4.3–1450–088

CALIBRATION C5 Weight (calibration of load sense transducer [LS])

Press

When calibrating LS, the forks must be level with an accurate load weight and load center for the truck. Make sure load is clear of the floor.

C5.1 (no load) - No load on forks. Press advance to next level.

. Menu will

C5.2 (3500 lbs) - With a 3500 pound load of the correct load center and clear of floor, press . Menu will advance to next level. C5.3 (escape) - Press

to return to the C5 menu level.

If no additional calibration procedures are to be performed, scroll to the C7 menu level, press and select the C7.2. Calibration is complete and truck can be returned to operation. If additional calibration procedures are to be performed, scroll to the appropriate menu level and continue.

and scroll to next menu level.

The target time is 6.67 seconds with the acceptable range between 6.45 and 6.90 seconds. Calculate the difference between the measured time and the target time. For every 0.08 seconds the time is less than the target time, add 2 units to the gain setting. For every 0.08 seconds the time is greater than the target time, subtract 2 units from the gain setting. Repeat test to achieve a time within the acceptable range, preferably close to the target. When complete, press

C6 Valves (calibrates PVH and PVA) PVH is termed the "Main" and PVA is termed the "Accy" valve in the menu. Setting the "main G" requires a minimum 1500 pound load on the forks. The approximate amount of current required to move the valve spools to a point that the port is about to open is the value in C6.1 "Main I" and C6.3 "Accy I" . Fine tuning of spool speed with maximum command is adjusted in C6.2 "Main G" and C6.4 "Accy G". C6.1(main I) - press . Menu advances to the submenu level. C6.1.1 (I) A current value may be etched in the hydraulic manifold or the nut on the end of the valve, shown in the illustration, which is the "main I" value. If a value is not present, enter 145. The current setting, if available, will be etched in one of these locations.

C6.3 (accy I) press . Menu advances to the submenu level. C6.3.1 (I) enter the value etched in the nut on the valve end, if present, or enter 225. Press and scroll to the next menu level. C6.4 (accy G) press . Menu advances to the submenu level. C6.4.1 (G) forks must be below freelift. Measure the time required to reach from one limit to the next. The target time is 2.5 seconds (2.3 to 2.7 seconds) for an RR and 5 seconds (4.8 to 5.2 seconds) for an RD. Calculate the difference between the measured time and the target time. For every 0.1 second the time is less than the target time, add 20 units from the set gain. For every 0.1 second the measured time is greater than the target time, subtract 20 units to the set gain. Repeat this process until the measured time is within the acceptable time limits, preferably close to the target time. When the gain is set press

. Scroll to menu level C6.5 and

press . Scroll to the C7 menu level and select the C7.2 menu level to save the calibration values into truck memory and press .

1 C

T H

and scroll to next menu level.

V R 2 T

PVA

P A

2 P

Calibration is now complete and the truck can be returned to operation.

PVH 6491

Printed in U.S.A.

Crown 1998 PF11360-5 Rev. 6/98

01 REV. 6/98

M4.3–1450–089

ACCESS 1 Software Version 122676-001-06 RR/RD 5000/5000S SERIES

Battery Discharge Indicator Power "on"

Operator Improper Sequence Error

Service Required Light Fork Height Indicator

Message Display (4 Character)

6217

Navagation Keys

Dome Work Lift Operator Light Cutout Light Compartment Override Fan

Enhanced Display Capacity Data Monitor

Quick Reference Keys

6218 980615 Crown 1998 PF11441-1

M4.3–1650–001

Message Display (16 Character) 5775 Printed in U.S.A.

M4.3–1650–001

6219

Power "on" • illuminates when power is present to display.

6215

6216

Service Required • illuminates when a status has been detected that requires attention. Accompanied by status code.

6248

6222

Fork Height Indicator • illuminates when forks are above free lift. • flashes and alarm sounded when forks above free lift and travel speed greater than 1.5 mph.

6224

C 6250

6251

Crown 1998 PF11441-2

M4.3–1650–002

Printed in U.S.A.

M4.3–1650–002

ACCESS 1

These indicators on enhanced displays only: Performance Menu Hour Meter Menu

Quick Reference Keys • during truck operation, keys can be used to go directly to indicated operator menu. • pressing key while in menu returns display to normal operation.

Log Events Menu 6221

6225

6223

Crown 1998 PF11441-3

M4.3–1650–003

Printed in U.S.A.

M4.3–1650–003

USER MAIN MENU LEVEL

The truck operator has access to the following menu after inputting the required user code.

❑❑❑❑

User Access Code

Run

System Ready

Hour Reset

H1 H2 H3 H4 H5

Run = Travel = Lift 1 = Lift 2 = PM @____H_

Total truck pedal time Total time traction motor (M1) operation Total time motor (M2) operation Total time motor (M3) operation Run meter reading for next planned maintenance inspection

LL L-1 L-2 L4

Last = ____ Last-1 = ____ Last-2 = ____ Escape

Last service condition status code Second last service condition status code Third last service condition status code

P1 P2 P3

Performance Performance Performance

Performance level one. Programmed in service menu. Performance level two. Programmed in service menu. Performance level three. Programmed in service menu.

Timer ___:___:___ Start Stop

Stop watch.

Log Events

Performance

Elapsed Timer

Height&Weight ____ inch Fork height. Truck must be equipped with a height sensor. ____lb. @ ____inch Load weight and fork height. Truck must be equipped with height sensor and capacity monitor.

not available on trucks with standard display.

Crown 1998 PF11441-4

M4.3–1650–004

Printed in U.S.A.

M4.3–1650–004

SERVICE MAIN MENU LEVELS

❑❑❑❑

User Access Code

Analyzer

Calibrate

• Level two menu only. • Truck components requiring calibration to the Access 1 - 2 - 3 system are contained in this menu.

Features

• Level two and level three menu. • In the features menu, programming is performed to set truck operation and performance to customer specifications and truck configuration.

Hour Reset

• Level two menu only. • Ability to check and reset hour meters available in this menu.

Log Events

• Level two and level three menu. • The last 16 codes in order of occurance and the accumulative count for each code can be viewed in this menu. Resetting log event counts available.

Performance

• Level two menu only. • Truck performance for operator code is set in this menu with additional overall performance adjustments available.

Utilities

Crown 1998 PF11441-5

M4.3–1650–005

Printed in U.S.A.

M4.3–1650–005

ANALYZER MENU

key to move right and left in the menu and allow system to perform function requested. Press the

Press the

and

to move up and down.

❑❑❑❑ A

Analyzer

Service Access Code A1

Status

A1.1

Steer = ❑

A1.2

Accy = ❑

A1.3

Lower = ❑

A1.4

Raise = ❑

A1.5

Full Trav = ❑

A1.6

Limp Trav = ❑

A1.7

ED Closed = ❑

A1.8

Battery = ❑

A1.9

Escape

continued on next page

Crown 1998 PF11441-6

M4.3–1650–006

Printed in U.S.A.

M4.3–1650–006

C continued from previous page

continued on next page

ANALYZER MENU

Inputs

A2.1

FS = ❑

1=Forward selected

A2.2

RS = ❑

1 = Reverse selected

A2.3

POT1 = ❑

A2.4

POT2 = ❑

A2.5

POT3 = ❑

A2.6

SSS = ❑

1.4v = Full forward 4.5v = Full reverse 1.4v = Full raise 4.5v = Full lower 1.0v = Full reach 4.0v = Full retract 1 = Side shift selected

A2.7

TBS = ❑

1 = Tilt back selected

A2.8

TDS = ❑

1 = Tilt down selected

A2.9

403-11 = ❑

1 = Input closed

A2.10 ENS = ❑

1 = Entry bar pressed

A2.11 DMS1/2 = ❑

1 = Off pedal

A2.12 BRS1 = ❑

1 = Off pedal

A2.13 BRS2 = ❑

1 = Off pedal

A2.14 BRS3 = ❑

0 = Off pedal

A2.15 FLS = ❑

0 = Above free lift

A2.16 HGTRS = ❑

0 = At height reset

A2.17 LMS = ❑

0 = input closed

A2.18 HGTS12 = ❑

0 = Within 12" from top

A2.19 ECR2 = ❑

Increasing = raise

A2.20 HSS = ❑

0 = Unloaded (<500 lbs)

A2.21 ECR1 = ❑

Increasing = Forward

A2.22 BRES1 = ❑

0 = Retainer missing

A2.23 ORS = ❑

0 = Override not selected

A2.24 Speed 0.0 MPH

0 = Brush worn

A2.25 BW1 = ❑

0 = Hot

A2.26 THS1 = ❑

0 = Brush worn

A2.27 BW2 = ❑

0 = Hot

A2.28 THS2 = ❑

0 = Brush worn

A2.29 BW3 = ❑

0 = Hot

A2.30 THS3 = ❑

0 = Button pressed

A2.31 DPS4 = ❑

0 = Button pressed

A2.32 DPS5 = ❑

0 = Button pressed

A2.33 DPS6 = ❑

0 = Input closed

A2.34 407-5 = ❑

0 = Input open

A2.35 408-11 = ❑

Increasing = More weight

A2.36 LS = ❑

0 = Input open

A2.37

CA408-12 = ❑

A2.38 Escape Crown 1998 PF11441-7

M4.3–1650–007

Printed in U.S.A.

M4.3–1650–007

C continued from previous page

ANALYZER MENU

Outputs

A3.1

Not Used

Not used

A3.2

ALM2 = ❑

On/Off

A3.3

ED = ❑

On/Off

A3.4

SVA = ❑

On/Off

A3.5

SVL = ❑

On/Off

A3.6

SVP = ❑

On/Off

A3.7

SVR = ❑

On/Off

A3.8

SVS = ❑

On/Off

A3.9

SVT = ❑

On/Off

A3.10 PVA = ❑

0-100%

A3.11 PVH = ❑

0-100%

A3.12 BRK1o = ❑

0-15 Amp

A3.13 BRK1i = ❑

0-5 Amp

A3.14 BRK2 = ❑

0-4 Amp

A3.15 M1-A= ❑

0-560 Amp

A3.16 M1-F = ❑

0-50 Amp

A3.17 M1-R = ❑

0-50 Amp

A3.18 M2 = ❑

0-100%

A3.19 P2 = ❑

On/Off

A3.20 GPD1 = ❑

On/Off

continued on next page A3.21 Escape

Crown 1998 PF11441-8

M4.3–1650–008

Printed in U.S.A.

M4.3–1650–008

C continued from previous page

ANALYZER MENU

Test Outputs

A4.1

Lamps/ALM1

On/Off

A4.2

ALM2 = ❑

On/Off

A4.3

ED = ❑

On/Off

A4.4

SVA = ❑

On/Off

A4.5

SVL = ❑

On/Off

A4.6

SVP = ❑

On/Off

A4.7

SVR = ❑

On/Off

A4.8

SVS = ❑

On/Off

A4.9

SVT = ❑

On/Off

A4.10 PVA = ❑

A4.12 BRK1o = ❑

90% 24 V 60% 36 V 90% 24 V 60% 36 V 5 Amp

A4.13 BRK1i = ❑

2 Amp

A4.14 BRK2 = ❑

2 Amp

A4.15 M1-A= ❑

300 Amp

A4.16 M1-F = ❑

(+) 40 Amp

A4.17 M1-R = ❑

(-) 40 Amp

A4.18 M2 = ❑ A4.19 P2 = ❑

50 Amp 36 V 90 Amp 24 V On/Off

A4.20 GPD1 = ❑

On/Off

A4.11 PVH = ❑

A4.21 Escape

Escape

continued on next page

Crown 1998 PF11441-9

M4.3–1650–009

Printed in U.S.A.

M4.3–1650–009

CALIBRATION MENU

key to move right and left in the menu and allow system to accept calibration values. Press the Press the to move up and down. C

Calibration

C41

Trav Handle

R/L Handle

Accy Handle

Height

C1.1

Forward = ❑

C1.2

Center = ❑

C1.3

Reverse = ❑

C2.1

Raise = ❑

C2.2

Center = ❑

C2.3

Lower = ❑

C3.1

Reach = ❑

C3.2

Center = ❑

C3.3

Retract = ❑

C4.1

R Cut1 = ❑

C4.2

C4.3

C4.4

R Cut2 = ❑

Max Hgt = ❑

and

C4.1.1

None

C4.1.2

Override

C4.1.3

Stop

C4.1.4

Escape

C4.2.1

None

C4.2.2

Override

C4.2.3

Stop

C4.2.4

Escape

C4.3.1

Max = ___ in.

C4.3.2

2nd = ___ in.

Escape

continued on next page 1

= available on trucks equipped with height sensor only.

Crown 1998 PF11441-10

M4.3–1650–010

Printed in U.S.A.

M4.3–1650–010

CALIBRATION MENU

continued from previous page C51

Weight

Valves

Save?

C5.1

No Load

C5.2

____ lbs.

C5.3

Escape

C6.1

Main 1 = ❑

C6.1.1

I = ❑ (ma)

C6.2

Main G = ❑

C6.2.1

G=❑

C6.3

Accy I = ❑

C6.3.1

I = ❑ (ma)

C6.4

Accy G = ❑

C6.4.1

G=❑

C6.5

Escape

C7.1

Save? N

C7.2

Save? Y

continued on next page 1

=menu available on trucks with enhanced display only. Capacity data monitor (CDM) must be enabled (F9).

Crown 1998 PF11441-11

M4.3–1650–011

Printed in U.S.A.

M4.3–1650–011

C Press the

FEATURES MENU

key to move right and left in the menu and allow system to accept changes to the features. Press the

and

to move up and down. F

Features

Voltage = ___

F21 Pedals = ___

Hgt Encoder = ___

A = 36 Volt

F1.2

b = 24 Volt

F2.1

A = 5 pedals

RR/RD 5000S

F2.2

b = 2 pedals

RR/RD 5000

F3.1

A = No

F3.2

b = Yes @ ___

Trucks equipped with CDM and lift heights greater than 270 inches.

F3.3

Modify hgt

F3.3.1

Trk Wt = ___0

(With battery - From data plate)

Max Load = ___

(From data plate)

Reach = ___

Sideshift = ___

Tilt = ___

Listed on truck data plate.

F1.1

Min = ___

Truck collapsed height, check truck data plate.

F6.1

A = None

F6.2

b = Single

F6.3

c = Double

F7.1

A = No

F7.2

b = Yes

F8.1

A = No

F8.2

b = Yes

continued on next page 1

= Menu available on 36 volt trucks with enhanced display.

Crown 1998 PF11441-12

M4.3–1650–012

Printed in U.S.A.

M4.3–1650–012

C continued from previous page

FEATURES MENU

F91 Capacity = ___

F9.1

F9.2

Yes

F9.3

Zones = ___

F9.4

Height 1 = ___

F9.5

Weight 1 = ___

F9.6

Height 2 = ___

F9.7

Weight 2 = ___

F9.8

Height 3 = ___

F9.9

Weight 3 = ___

F9.10 Height 4 = ___ F9.11

Weight 4 = ___

F9.12 Escape F102 Productive = ___

F113 Hi Lift = ___

F12 Metric = ___

F10.1 A = No F10.2 b = Switch

trucks without CDM.

F10.3 c = Capacity

trucks with CDM.

F11.1

A = No

F11.2

b = Yes

F12.1 A = No F12.2 b = Yes

F134 Brush/Temp = ___

F13.1 A = No F13.2 b = Yes

continued on next page 1

Crown 1998 PF11441-13

M4.3–1650–013

Printed in U.S.A.

M4.3–1650–013

C continued from previous page

FEATURES MENU

F141 Alarm = ___

F14.1 A = Off F14.2 b = Forward

forks first direction

F14.3 c = Reverse

power unit first direction

F14.4 d = Both F15 Bat Retain = ___

F15.1 A = No F15.2 b = Yes

F16 Speed Cut = ___

- without battery retainer switch. - with battery retainer switch.

F16.1 A = No F16.2 b = Yes

F172 Dashboard = ___

F17.1 A = No F17.2 b = Timer

stop watch

F17.3 c = Ht/Wt

- view height (requires height sensor) and weight (requires CDM).

F17.4 d = Both F18 User Perf = ___

F18.1 A = No F18.2 b = Yes

enables ability for operator to select P1, P2, P3 performance levels.

continued on next page 1

= travel alarm.

= menu available on trucks with enhanced display.

Crown 1998 PF11441-14

M4.3–1650–014

Printed in U.S.A.

M4.3–1650–014

C continued from previous page

FEATURES MENU

F19 User Codes = ___

F19.1 A = No F19.2 b = Yes F19.3 c = View F19.4 d = Add

Requires Pesonal Identification Number. Note: If F18 is "yes", at least one performance level is required and any user can select any performance level.

F19.5 e = Delete F19.6 f = Escape F20 Lockout = ___

F20.1 A = No

Truck lockout.

F20.2 b = Yes F21 Language = ___

F21.1 English F21.2 German

F22 Save?

F22.1 Save? N F22.2 Save? Y

Note: Do not operate vehicle during the "save" operation or values may get corrupted.

continued on next page

Crown 1998 PF11441-15

M4.3–1650–015

Printed in U.S.A.

M4.3–1650–015

C Press the and H

HOUR METER MENU

key to move right and left in the menu and allow system to accept changes to the hour reset menu. Press the to move up and down.

Hour Reset

H1 Run = ___ H2 Travel = ___

H3 Lift 1 = ___

H4 Lift 2 = ___

H5 PM H• @ ___

H2.1

Sure? N

H2.2

Sure? Y

H3.1

Sure? N

H3.2

Sure? Y

H4.1

Sure? N

H4.2

Sure? Y

H5.1

PM H1 = ___

H5.1

PM H2 = ___

H5.1

PM H3 = ___

H5.1

PM H4 = ___

H5.1

PM None = ___

H5.1

Escape

H6 Escape

continued on next page

Crown 1998 PF11441-16

M4.3–1650–016

Printed in U.S.A.

M4.3–1650–016

C Press the and L

LOG EVENTS MENU

key to move right and left in the menu and allow system to accept changes to the log events menu. Press the to move up and down.

Log Events

L1 History

L2 Totals

L3 Erase

Last =

___ @ ____

L-1 =

L-15 =

___ @ ____ • • • • • ___ @ ____

Event ___

= ____

Event ___

= ____

L3.1

L3.2

L3.3

Erase Hist

Erase All

L3.1.1

Sure? N

L3.1.2

Sure? Y

L3.2.1

Sure? N

L3.2.2

Sure? Y

Escape

L4 Escape

continued on next page

Crown 1998 PF11441-17

M4.3–1650–017

Printed in U.S.A.

M4.3–1650–017

C Press the

PERFORMANCE MENU

key to move right and left in the menu and allow system to accept changes to the performance menu. Press

the

and

Performance

to move up and down. P1

Setup P1

P1.1 Forward = __.__

P1.2 Reverse = __.__

P1.3 Accel = __.__

P1.4 Pump 2 = __.__

P1.5 Lower = __.__

P1.1.1

Std = __.__

P1.1.2

Custom __.__

P1.2.1

Std = __.__

P1.2.2

Custom __.__

P1.3.1

Std = __.__

P1.3.2

Custom __.__

P1.4.1

On = __.__

P1.4.2

Off __.__

P1.5.1

Std = __.__

P1.5.2

Custom __.__

P2.1.1

Std = __.__

P2.1.2

Custom __.__

P2.2.1

Std = __.__

P2.2.2

Custom __.__

P2.3.1

Std = __.__

P2.3.2

Custom __.__

P2.4.1

On = __.__

P2.4.2

Off __.__

P2.5.1

Std = __.__

P2.5.2

Custom __.__

P1.6 Escape P2

Setup P2

P2.1 Forward = __.__

P2.2 Reverse = __.__

P2.3 Accel = __.__

P2.4 Pump 2 = __.__

P2.5 Lower = __.__

P2.6 Escape continued on next page Crown 1998 PF11441-18

M4.3–1650–018

Printed in U.S.A.

M4.3–1650–018

C continued from previous page

PERFORMANCE MENU

Setup P3

P3.1 Forward = __.__

P3.2 Reverse = __.__

P3.3 Accel = __.__

P3.4 Pump 2 = __.__

P3.5 Lower = __.__

P3.1.1

Std = __.__

P3.1.2

Custom __.__

P3.2.1

Std = __.__

P3.2.2

Custom __.__

P3.3.1

Std = __.__

P3.3.2

Custom __.__

P3.4.1

On = __.__

P3.4.2

Off __.__

P3.5.1

Std = __.__

P3.5.2

Custom __.__

P3.6 Escape P4

BDI = ___

P4.1 Std = ___

BDI fine tuning.

P4.2 Custom = ___ P5

Plug = ___

P5.1 Std = ___ P5.2 Custom = ___

Drv Brake = ___

P6.1 Std = ___ P6.2 Custom = ___

Refer to section M4.3 calibration. Adjusts stopping distance.

continued on next page

Crown 1998 PF11441-19

M4.3–1650–019

Printed in U.S.A.

M4.3–1650–019

C continued from previous page

PERFORMANCE MENU

P71 Cas Brake = ___

P7.1 Std = ___ P7.2 Custom = ___

Accy > FLS = ___

P8.1 Std = ___

Controls accessory speed above and below free lift.

P8.2 Custom = ___ P9

Accy < FLS = ___

P9.1 Std = ___ P9.2 Custom = ___

P102 Trav> FLS = ___

P10.1 Speed = ___

Travel speed above freelift.

P113 Trav > 270" = ___

P11.1 Speed = ___

Travel speed above 270 inch lift height.

P12 Coast = ___

P12.1 Std = ___

Adjusts plugging during coast. (1 = soft, 9 = hard)

P12.2 Custom = ___ P13 Save?

P13.1 Save? N P13.2 Save? Y

continued on next page 1

= available on 5000S only.

= requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

3 = menu available on trucks equipped with height sensor only. Requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

Crown 1998 PF11441-20

M4.3–1650–020

Printed in U.S.A.

M4.3–1650–020

C U

Utilities

UTILITIES MENU

U1 Part Number

U2 Copy Setups

U1.1

Access 1

______

U1.2

Access 2

______

U1.3

Access 3

______

U1.4

Software

______.___.__

U1.5

Escape

U2.1

From TCM

U2.2

From HCM

U2.3

Escape

U3 Escape

Crown 1998 PF11441-21

M4.3–1650–021

Printed in U.S.A.

M4.3–1650–021

ACCESS 123 Software Version 122676-001-08 RR/RD 5000/5000S SERIES

Battery Discharge Indicator Power "on"

Operator Improper Sequence Error

Service Required Light Fork Height Indicator

Message Display (4 Character) 6217

Navigation Keys

Dome Work Lift Operator Light Cutout Light Compartment Override Fan

Enhanced Display Capacity Data Monitor

Quick Reference Keys

6218 980611 Crown 1998 PF11533-1

M4.3–1650–025

Message Display (16 Character) 5792 - 45380 Printed in U.S.A.

M4.3–1650–025

ACCESS 123 These indicators on all displays: Battery Discharge Indicator • resembles fuel gauge for indication of battery state of charge. • display represents approximate battery charge. • the indicators in the corners represent a fully charged battery to the right and battery in need of charge to the left and will flash when this level is reached.

6219

Power "on" • illuminates when power is present to display.

6215

Operator Improper Sequence Error • illuminates when operator uses incorrect sequence of truck operation. • on trucks equipped with CDM, illuminates when load that is over capacity (based on 24" load center) has been picked up with forks.

6216

Service Required • illuminates when a status has been detected that requires attention. Accompanied by status code.

6248

Navigation Keys • arrow up and arrow down keys scroll display up and down through menus. Used also to enter the service modes at power up. • return or enter key moves display into and out of selected menus and allows system to accept inputs.

6222

Fork Height Indicator • illuminates when forks are above free lift. • flashes and alarm sounded when forks above free lift and travel speed greater than 1.5 mph.

6224

C 6250

6251

Crown 1998 PF11533-2

M4.3–1650–026

Printed in U.S.A.

M4.3–1650–026

ACCESS 123

These indicators on enhanced displays only: Performance Menu Hour Meter Menu

Quick Reference Keys • during truck operation, keys can be used to go directly to indicated operator menu. • pressing key while in menu returns display to normal operation.

Log Events Menu 6221

6225

6223

Crown 1998 PF11533-3

M4.3–1650–027

Printed in U.S.A.

M4.3–1650–027

USER MAIN MENU LEVEL

The truck operator has access to the following menu after inputting the required user code.

❑❑❑❑

Service Access Code

Run

System Ready

Hour Reset

H1 H2 H3 H4 H5

Run = Travel = Lift 1 = Lift 2 = PM @____H_

Total truck pedal time Total time traction motor (M1) operation Total time motor (M2) operation Total time motor (M3) operation Run meter reading for next planned maintenance inspection

LL L-1 L-2 L4

Last = ____ Last-1 = ____ Last-2 = ____ Escape

Last service condition status code Second last service condition status code Third last service condition status code

P1 P2 P3

Performance Performance Performance

Performance level one. Programmed in service menu. Performance level two. Programmed in service menu. Performance level three. Programmed in service menu.

Timer ___:___:___ Start Stop

Stop watch.

Log Events

Performance

Elapsed Timer

Height&Weight ____ inch Fork height. Truck must be equipped with a height sensor. ____lb. @ ____inch Load weight and fork height. Truck must be equipped with height sensor and capacity monitor.

not available on trucks with standard display.

Crown 1998 PF11533-4

M4.3–1650–028

Printed in U.S.A.

M4.3–1650–028

SERVICE MAIN MENU LEVELS

❑❑❑❑

Service Access Code

Analyzer

Calibrate

• Level two menu only. • Truck components requiring calibration to the Access 1 - 2 - 3 system are contained in this menu.

Features

• Level two and level three menu. • In the features menu, programming is performed to set truck operation and performance to customer specifications and truck configuration.

Hour Reset

• Level two menu only. • Ability to check and reset hour meters available in this menu.

Log Events

• Level two and level three menu. • The last 16 codes in order of occurance and the accumulative count for each code can be viewed in this menu. Resetting log event counts available.

Performance

• Level two menu only. • Truck performance for operator code is set in this menu with additional overall performance adjustments available.

Utilities

Crown 1998 PF11533-5

M4.3–1650–029

Printed in U.S.A.

M4.3–1650–029

ANALYZER MENU

key to move right and left in the menu and allow system to perform function requested. Press the

Press the

and

to move up and down.

❑❑❑❑ A

Analyzer

Service Access Code A1

Status

A1.1

Steer = ❑

A1.2

Accy = ❑

A1.3

Lower = ❑

A1.4

Raise = ❑

A1.5

Full Trav = ❑

A1.6

Limp Trav = ❑

A1.7

ED Closed = ❑

A1.8

Battery = ❑

A1.9

Escape

continued on next page

Crown 1998 PF11533-6

M4.3–1650–030

Printed in U.S.A.

M4.3–1650–030

C continued from previous page

ANALYZER MENU

Inputs

A2.1

FS = ❑

1=Forward selected

A2.2

RS = ❑

1 = Reverse selected

A2.3

POT1 = ❑

A2.4

POT2 = ❑

A2.5

POT3 = ❑

A2.6

SSS = ❑

1.4v = Full forward 4.5v = Full reverse 1.4v = Full raise 4.5v = Full lower 1.0v = Full reach 4.0v = Full retract 1 = Side shift selected

A2.7

TBS = ❑

1 = Tilt back selected

A2.8

TDS = ❑

1 = Tilt down selected

A2.9

403-11 = ❑

1 = Input closed

A2.10 ENS = ❑

1 = Entry bar pressed

A2.11 DMS1/2 = ❑

1 = Off pedal

A2.12 BRS1 = ❑

1 = Off pedal

A2.13 BRS2 = ❑

1 = Off pedal

A2.14 BRS3 = ❑

0 = Off pedal

A2.15 FLS = ❑

0 = Above free lift

A2.16 HGTRS = ❑

0 = At height reset

A2.17 LMS = ❑

0 = input closed

A2.18 HGTS12 = ❑

0 = Within 12" from top

A2.19 ECR2 = ❑

Increasing = raise

A2.20 HSS = ❑

0 = Unloaded (<500 lbs)

A2.21 ECR1 = ❑

Increasing = Forward

A2.22 BRES1 = ❑

0 = Retainer missing

A2.23 ORS = ❑

0 = Override not selected

A2.24 Speed 0.0 MPH A2.25 BW1 = ❑ A2.26 THS1 = ❑ A2.27 BW2 = ❑ A2.28 THS2 = ❑ A2.29 BW3 = ❑ A2.30 THS3 = ❑ A2.31 DPS4 = ❑ A2.32 DPS5 = ❑ A2.33 DPS6 = ❑ A2.34 407-5 = ❑ A2.35 408-11 = ❑ A2.36 LS = ❑ continued on next page

Crown 1998 PF11533-7

M4.3–1650–031

A2.37

CA408-12 = ❑

0 = Brush worn 0 = Hot 0 = Brush worn 0 = Hot 0 = Brush worn 0 = Hot 0 = Button pressed 0 = Button pressed 0 = Button pressed 0 = Input closed 0 = Input open Increasing = More weight 0 = Input open

Printed in U.S.A.

M4.3–1650–031

C continued from previous page

ANALYZER MENU

Outputs

A3.1

Not Used

Not used

A3.2

ALM2 = ❑

On/Off

A3.3

ED = ❑

On/Off

A3.4

SVA = ❑

On/Off

A3.5

SVL = ❑

On/Off

A3.6

SVP = ❑

On/Off

A3.7

SVR = ❑

On/Off

A3.8

SVS = ❑

On/Off

A3.9

SVT = ❑

On/Off

A3.10 PVA = ❑

0-100%

A3.11 PVH = ❑

0-100%

A3.12 BRK1o = ❑

0-15 Amp

A3.13 BRK1i = ❑

0-5 Amp

A3.14 BRK2 = ❑

0-4 Amp

A3.15 M1-A= ❑

0-560 Amp

A3.16 M1-F For = ❑

0-50 Amp

A3.17 M1-F Rev = ❑

0-50 Amp

A3.18 M2 = ❑

0-100%

A3.19 P2 = ❑

On/Off

A3.20 GPD1 = ❑

On/Off

continued on next page A3.21 Escape

Crown 1998 PF11533-8

M4.3–1650–032

Printed in U.S.A.

M4.3–1650–032

C continued from previous page

ANALYZER MENU

Test Outputs

A4.1

Lamps/ALM1

On/Off

A4.2

ALM2 = ❑

On/Off

A4.3

ED = ❑

On/Off

A4.4

SVA = ❑

On/Off

A4.5

SVL = ❑

On/Off

A4.6

SVP = ❑

On/Off

A4.7

SVR = ❑

On/Off

A4.8

SVS = ❑

On/Off

A4.9

SVT = ❑

On/Off

A4.10 PVA = ❑

A4.12 BRK1o = ❑

90% 24 V 60% 36 V 90% 24 V 60% 36 V 5 Amp

A4.13 BRK1i = ❑

2 Amp

A4.14 BRK2 = ❑

2 Amp

A4.15 M1-A= ❑

300 Amp

A4.16 M1-F For = ❑

(+) 40 Amp

A4.17 M1-F Rev = ❑

(-) 40 Amp

A4.18 M2 = ❑ A4.19 P2 = ❑

50 Amp 36 V 90 Amp 24 V On/Off

A4.20 GPD1 = ❑

On/Off

A4.11 PVH = ❑

A4.21 Escape

Escape

continued on next page

Crown 1998 PF11533-9

M4.3–1650–033

Printed in U.S.A.

M4.3–1650–033

CALIBRATION MENU

key to move right and left in the menu and allow system to accept calibration values. Press the Press the to move up and down.

Calibration

C41

Trav Handle

R/L Handle

Accy Handle

Height

C1.1

Forward = ❑

C1.2

Center = ❑

C1.3

Reverse = ❑

C2.1

Raise = ❑

C2.2

Center = ❑

C2.3

Lower = ❑

C3.1

Reach = ❑

C3.2

Center = ❑

C3.3

Retract = ❑

C4.1

R Cut1 = ❑

C4.2

C4.3

C4.4

R Cut2 = ❑

Encoder = ❑

and

C4.1.1

None

C4.1.2

Override

C4.1.3

Stop

C4.1.4

Escape

C4.2.1

None

C4.2.2

Override

C4.2.3

Stop

C4.2.4

Escape

C4.3.1

Max = ___ in.

C4.3.2

2nd = ___ in.

Escape

continued on next page 1

= available on trucks equipped with height sensor only.

Crown 1998 PF11533-10

M4.3–1650–034

Printed in U.S.A.

M4.3–1650–034

CALIBRATION MENU

continued from previous page C51

Weight

Valves

Save?

C5.1

No Load

C5.2

____ lbs.

C5.3

Escape

C6.1

Main I = ❑

C6.1.1

I = ❑ (ma)

C6.2

Main G = ❑

C6.2.1

G=❑

C6.3

Accy I = ❑

C6.3.1

I = ❑ (ma)

C6.4

Accy G = ❑

C6.4.1

G=❑

C6.5

Escape

C7.1

Save? N

C7.2

Save? Y

continued on next page 1

=menu available on trucks with enhanced display only. Capacity data monitor (CDM) must be enabled (F9).

Crown 1998 PF11533-11

M4.3–1650–035

Printed in U.S.A.

M4.3–1650–035

C The calibration menu is shown on the following pages. The first level of the menu shows the different areas of calibration for this truck. • C1 Trav Handle traction potentiometer (POT1) in the multi task control. • C2 R/L Handle raise/lower potentiometer (POT2) in the multi task control. • C3 Accy Handle accessory potentiometer (POT3) in the multi task control. • C4 Height raise cutouts (2 possible) and maximum height. Truck must be equipped with height sensor. • C5 Weight capacity data monitor (CDM). Truck must be equipped with enhanced display, height sensor and load sense transducer. F9 in the features menu must be enabled. • C6 Valves raise/lower (PVH) and accessory (PVA) electrical proportional valves. When to calibrate: • Access 1 replaced will require the load sense transducer (LS) to be calibrated. • Access 2 or Access 3 replaced will require the potentiometers in the multi task control to be calibrated. • any of the potentiometers or components used to mount or position potentiometers in the multi task control replaced. • the hydraulic manifold has been replaced without keeping the existing electrical proportional valves (PVH, PVA). • PVH replaced. • PVA replaced. • load sense transducer (LS) replaced. • status code instructions recommends recalibration of a specific component.

Crown 1998 PF11533-12

M4.3–1650–036

CALIBRATION Calibration Access When powering up the truck, press and maintain the arrow up key on the display. This enters level two of Access 1 operation. Navigate to the C - Calibrate menu and press the enter key. The message display now displays the message: C1 Trav Handle (as shown in the menu on the preceding pages). Calibration Procedures A full explanation of calibration procedures for each menu level follows. Calibration Complete When calibration procedures are complete, scroll down to the Save? (C7) menu and press the enter key. If the calibration completed is necessary to save into memory for future truck operation, select the "Save? Y" (C7.2) menu and press the enter key. This process will require less than a minute to complete. To keep calibration values from becoming unusable, do not operate any truck controls or display keys during this process.

Printed in U.S.A.

M4.3–1650–036

C C1 Trav Handle (traction request potentiometer - POT1) C1.1 (forward) - move the multi task handle to the full speed forward traction position and press . The menu will then move to the next menu level. C1.2 (center) - with the multi task handle in the neutral . The menu will then move to the next position, press menu level.

CALIBRATION C3.3 (retract) - move the multi task thumbwheel to the full . The menu will then speed retract position and press return to the C3 menu level. If no additional calibration procedures are to be performed, and select C7.2. scroll to the C7 menu level, press Calibration is complete and truck can be returned to operation. If additional calibration procedures are to be performed, scroll to the appropriate menu level and continue.

C1.3 (reverse) - move the multi task handle to the full speed reverse traction position and press . The menu will then return to the C1 menu level.

C4 Height (raise cutouts and maximum lift height)

If no additional calibration procedures are to be perand select formed, scroll to the C7 menu level, press the C7.2 menu. Calibration is complete and truck can be returned to operation. If additional calibration procedures are to be performed, scroll to the appropriate menu level and continue.

C4.1 (R cut1) - this menu level permits programming a lift cutout. If more than one cutout is to be programmed, this level must be the lower lift height and must be performed at the "override" level (C4.1.2). C4.1.1 (none) select this level by pressing , if no cutouts are required. The menu will return to the C4.1 level. Next program the maximum lift height (C4.3). C4.1.2 (override) programs a lift cutout with override. Posi. tion the forks at the desired lift cutout height. Press Programming is complete and menu will return to C4.1. C4.1.3 (stop) programs a lift cutout without override. Posi. tion the forks at the desired lift cutout height. Press Programming is complete and menu will return to C4.1. if no C4.1.4 (escape) select this menu level by pressing changes are to be made.

C2 R/L Handle (raise/lower request potentiometer - POT2) C2.1 (raise) - move the multi task handle to the full speed . The menu will then move to the raise position and press next menu level. C2.2 (center) - with the multi task handle in the neutral position, press . The menu will then move to the next menu level. C2.3 (lower) - move the multi task handle to the full speed lower position and press . The menu will then return to the C2 menu level. If no additional calibration procedures are to be performed, scroll to the C7 menu level, press and select the C7.2 menu. Calibration is complete and truck can be returned to operation. If additional calibration procedures are to be performed, scroll to the appropriate menu level and continue. C3 Accy Handle (multi task accessory function control thumbwheel)

Fork height must be below free lift before entering this menu.

C4.2 (R cut2) - this menu level permits programming a second lift cutout. This cutout must be at a higher lift height than C4.1. , if this cutout C4.2.1 (none) select this level by pressing is not required. The menu will return to the C4.2 level. Next program the maximum lift height (C4.3). C4.2.2 (override) programs a lift cutout with override. Posi. tion the forks at the desired lift cutout height. Press Programming is complete and menu will return to C4.2. C4.2.3 (stop) programs a lift cutout without override. Posi. tion the forks at the desired lift cutout height. Press Programming is complete and menu will return to C4.2. if no C4.2.4 (escape) select this menu level by pressing changes are to be made.

C3.1 (reach) - move the multi task thumbwheel to the full speed reach position and press . The menu will then move to the next menu level. C3.2 (center) - with the thumbwheel in the neutral position, press . The menu will then move to the next menu level. Crown 1998 PF11533-13

M4.3–1650–037

Printed in U.S.A.

M4.3–1650–037

CALIBRATION

C4.3 (max hgt) programs the maximum mechanical lift height of the truck (not to be used to limit lift height). C4.3.1 (max height) Raise forks until the mechanical stops are contacted measure actual fork height from top of fork to floor and enter, to the nearest inch, in this screen. C4.3.2 (2nd = lower) lower forks until display message changes to "stop". Measure fork height from top of fork to the floor and enter measurement, to the nearest inch, in this screen. Note: If HGTRS indicates mast is below staging, the message "Invalid" will be displayed meaning a valid calibration will not occur. C4.4 (escape) select this menu level by pressing to return to the C4 menu level. Raise cutouts can now be calibrated or must be re-calibrated if cutouts exist.

The approximate amount of current required to move the valve spools to a point that the port is about to open is the value in C6.1 "Main I" and C6.3 "Accy I" . Fine tuning of spool speed with maximum command is adjusted in C6.2 "Main G" and C6.4 "Accy G". C6.1(main I) - press . Menu advances to the submenu level. C6.1.1 (I) A current value may be etched in the hydraulic manifold or the nut on the end of the valve, shown in the illustration, which is the "main I" value. If a value is not present, enter 145. The current setting, if available, will be etched in one of these locations.

1 C

T H

P 2

V R 2 T

PVA

P A

C5 Weight (calibration of load sense transducer [LS]) When calibrating LS, the forks must be level with an accurate load weight and load center for the truck. Make sure load is 12 inches above the floor. C5.1 (no load) - No load on forks. Press advance to next level.

. Menu will

C5.2 (____ lbs) - With a load greater than 1500 pounds and of the correct load center and 12 inches above floor, enter the load weight to the nearest pound, press . Menu will advance to next level. C5.3 (escape) - Press

to return to the C5 menu level.

If no additional calibration procedures are to be performed, scroll to the C7 menu level, press and select C7.2. Calibration is complete and truck can be returned to operation. If additional calibration procedures are to be performed, scroll to the appropriate menu level and continue. C6 Valves (calibrates PVH and PVA) PVH is termed the "Main" and PVA is termed the "Accy" valve in the menu.

2 P

PVH 6491

Press

and scroll to next menu level.

C6.2 (main G) - press . Menu advances to the sub menu level. C6.2.1 (G) during this procedure a measurement will be made to monitor the forks lowering 10 feet through the staged portion of mast extension with a minimum of 3 feet prior to entering the 10 foot measurement. Make the appropriate markings. Move the multi task handle to the maximum speed lower position and measure the time required to lower through the 10 foot distance marked. The target time is 6.67 seconds with the acceptable range between 6.45 and 6.90 seconds. Calculate the difference between the measured time and the target time. For every 0.08 seconds the time is less than the target time, add 2 units to the gain setting. For every 0.08 seconds the time is greater than the target time, subtract 2 units from the gain setting. Repeat test to achieve a time within the acceptable range, preferably close to the target. When complete, press

and scroll to next menu level.

Setting the "main G" requires a minimum 1500 pound load on the forks.

Crown 1998 PF11533-14

M4.3–1650–038

Printed in U.S.A.

M4.3–1650–038

CALIBRATION

. Menu advances to the sub menu C6.3 (accy I) press level. C6.3.1 (I) enter the value etched in the nut on the valve end, if present, or enter 225. Press and scroll to the next menu level. . Menu advances to the sub menu C6.4 (accy G) press level. C6.4.1 (G) forks must be below freelift. Measure the time required to reach from one limit to the next. The target time is 2.5 seconds (2.3 to 2.7 seconds) for an RR and 5 seconds (4.8 to 5.2 seconds) for an RD. Calculate the difference between the measured time and the target time. For every 0.1 second the time is less than the target time, add 20 units from the set gain. For every 0.1 second the measured time is greater than the target time, subtract 20 units to the set gain. Repeat this process until the measured time is within the acceptable time limits, preferably close to the target time. When the gain is set press

. Scroll to menu level C6.5 and

press . Scroll to the C7 menu level and select the C7.2 menu level to save the calibration values into truck memory and press . Calibration is now complete and the truck can be returned to operation.

Crown 1998 PF11533-15

M4.3–1650–039

Printed in U.S.A.

M4.3–1650–039

C Press the

FEATURES MENU

key to move right and left in the menu and allow system to accept changes to the features. Press the

and

to move up and down.

Features

Voltage = ___

F21 Pedals = ___

Hgt Encoder = ___

F1.1

A = 36 Volt

F1.2

b = 24 Volt

F2.1

A = 5 pedals

RR/RD 5000S

F2.2

b = 2 pedals

RR/RD 5000

F3.1

A = No

F3.2

b = Yes

Trk Wt = ___0

(With battery - From data plate)

Max Load = ___

(From data plate)

Reach = ___

Sideshift = ___

Tilt = ___

Listed on truck data plate.

Trucks equipped with height encoder

F6.1

A = None

F6.2

b = Single

F6.3

c = Double

F7.1

A = No

F7.2

b = Yes

F8.1

A = No

F8.2

b = Yes

continued on next page 1

= Menu available on 36 volt trucks.

Crown 1998 PF11533-16

M4.3–1650–040

Printed in U.S.A.

M4.3–1650–040

C continued from previous page

FEATURES MENU F91 Capacity = ___

F9.1

F9.2

Yes

F9.3

Zones = ___

F9.4

Height 1 = ___

F9.5

Weight 1 = ___

F9.6

Height 2 = ___

F9.7

Weight 2 = ___

F9.8

Height 3 = ___

F9.9

Weight 3 = ___

F9.10 Height 4 = ___ F9.11

Weight 4 = ___

- number of spaces filled in on capacity data plate. - first lift height on data plate. - first capacity on data plate. - second lift height on data plate. - second capacity on data plate. - third lift height on data plate. - third capacity on data plate. - fourth lift height on data plate. - fourth capacity on data plate.

F9.12 Escape F102 Productive = ___

F113 Hi Lift = ___

F12 Metric = ___

F10.1 A = No F10.2 b = Switch

trucks with productivity package.

F10.3 c = Capacity

trucks with CDM.

F11.1

A = No

F11.2

b = Yes

F12.1 A = No F12.2 b = Yes

F134 Brush/Temp = ___

F13.1 A = No F13.2 b = Yes

continued on next page 1

= menu available on trucks with enhanced display and height sensor. = 36 volt trucks with productivity package/CDM. 3 = available on 5000S only. 4 = menu available on trucks with enhanced display. 2

Crown 1998 PF11533-17

M4.3–1650–041

Printed in U.S.A.

M4.3–1650–041

C continued from previous page

FEATURES MENU

F141 Alarm = ___

F14.1 A = Off F14.2 b = Fwd

forks first direction

F14.3 c = Rev

power unit first direction

F14.4 d = Both F15 Bat Retain = ___

F15.1 A = No F15.2 b = Yes

F16 Fan = ___

- without battery retainer switch. - with battery retainer switch.

F16.1 A = No F16.2 b = Yes

F17 Speed Cut = ___

F17.1 A = No F17.2 b = Yes

F182 Dashboard = ___

F18.1 A = No F18.2 b = Timer

stop watch

F18.3 c = Wt/Ht

- view height (requires height sensor) and weight (requires CDM).

F18.4 d = Both F19 User Perf = ___

F19.1 A = No F19.2 b = Yes

enables ability for operator to select P1, P2, P3 performance levels.

continued on next page 1

= travel alarm.

= menu available on trucks with enhanced display.

Crown 1998 PF11533-18

M4.3–1650–042

Printed in U.S.A.

M4.3–1650–042

FEATURES MENU

continued from previous page

F20 User Codes = ___

F20.1 A = No F20.2 b = Yes F20.3 c = View

If F20 is "yes", then at least one Personal Identification Number is required. If F19 is "yes", any user can select any performance level.

F20.4 d = Add F20.5 e = Delete F20.6 f = Escape F21 Lockout = ___

F21.1 A = No

Truck lockout.

F21.2 b = Yes F221 Language = ___

F22.1 English F22.2 German F22.3 Italian F22.4 Spanish F22.5 French F22.6 Dutch

F23 Save?

F23.1 Save? N F23.2 Save? Y

Note: Do not operate vehicle during the "save" operation or values may get corrupted.

continued on next page

= Menu available with enhanced display only.

Crown 1998 PF11533-19

M4.3–1650–043

Printed in U.S.A.

M4.3–1650–043

C The feature menu is shown on the following pages. The first level of the menu shows the different areas of setup for the truck. Features Access

FEATURES SETUP F3.2

• F4

When powering up the truck, press and maintain on the display, then enter the service code. This enters service level two of Access 1 operation. Navigate to the F - Features menu and press . The message display now displays the message shown in the following menu. The "•" marks the highest levels of the features (F) menu. • F1

F1.1

F1.2

• F2

F2.1

F2.2

• F3

F3.1

Voltage = __ The current selected truck voltage is displayed. If voltage is correct, press to access F2. If voltage to access F1.1. displayed is incorrect, press A = 36 volts if truck has a 36 volt electrical system. Press The menu will return to F1. If truck has a 24 volt electrical system, press to access F1.2. b = 24 volts Press if truck has a 24 volt electrical system. The menu will return to F1.

Pedals = __ The current selection is displayed. "B" for 5000 truck and “A” for 5000S truck. If selection is correct press to access F3. If selection is incorrect, press to access F2.1. A = 5 pedals On 5000S trucks press at this menu level. The menu will return to F2. If truck is a 5000, press to access F2.2. b = 2 pedals On 5000 trucks, press at this menu level. The menu will return to F2. Ht Encoder = __ The current selection is displayed. If the correct message is displayed, “B” for trucks equipped with height encoder and “A” for trucks not equipped with height encoder, press to access F4. If the setting must be changed, press to access F3.1. A = No Press if truck is not equipped with height encoder. The display will return to the F3 menu. If truck is equipped with height encoder, press to access F3.2.

Crown 1998 PF11533-20

M4.3–1650–044

b = yes Press if truck is equipped with height encoder. The display will return to the F3 menu. Trk Wt = __ The current truck weight is displayed. If displayed weight is incorrect, press . Enter truck weight with battery and without load from data plate. Press to change/modify truck weight. Then use and to select the remaining digits. Note: The fifth digit (zero) is permanent and unchangable on the enhanced display. On the standard display the fifth digit (zero) is hidden from view. For example: Standard Display Enhanced Display 0879

08790

To enter a Trk Wt 13640 lbs, you would enter 1364. Standard Display Enhanced Display 1364

Press

13640

to access F5.

• F5

Max Load = __ Enter maximum capacity load from data plate. to change/modify Max Load. Then use Press the and to select the first digit. Press to move to the second digit. Use these steps to set the remaining digits. Press to access F6.

• F6

Reach = __ If the correct configuration is displayed for your truck, “B” for RR and “C” for RD, press to access F7. If necessary to change, press to access F6.1. A = None If truck is not equipped with a reach mechanism, press . Display will return to F6. If this is not the correct selection, press to access F6.2. b = Single On RR trucks, press . The display will return to the F6 menu. If truck is not an RR, press to access F6.3. c = Double On RD trucks, press . The display will return to the F6 menu.

F6.1

F6.2

F6.3

Printed in U.S.A.

M4.3–1650–044

C • F7

F7.1

F7.2

• F8

F8.1

F8.2

FEATURES SETUP F9.6

Height 2 = __ If the value displayed is not the second height listed on the capacity data plate, enter the correct value. Press . F9.7 Weight 2 = __ If the value displayed is not the second weight listed on the capacity data plate, enter the correct value. Press . F9.8 Height 3 = __ If the value displayed is not the third height listed on the capacity data plate, enter the correct value. Press . F9.9 Weight 3 = __ If the value displayed is not the third weight listed on the capacity data plate, enter the correct value. Press . F9.10 Height 4 = __ If the value displayed is not the fourth (lowest) height listed on the capacity data plate, enter the correct value. Press . F9.11 Weight 4 = __ If the value displayed is not the fourth (greatest) weight listed on the capacity data plate, enter the correct value. Press . F9.12 Escape When all values have been entered, press . The display will return to F9. • F10

• F9

F9.1

F9.2

F9.3

F9.4

F9.5

Capacity = __ If truck is equipped with a capacity data monitor the display should show “B”. Trucks not equipped with capacity data monitor should be “A”. If message is correct, press to access F10. If message needs to be changed, press . A = No If truck is not equipped with capacity data monitor, press . Display will return to F9. If this is not the correct choice press to access F9.2. B = Yes On trucks equipped with capacity data monitor, press . Display will return to F9. Zones = __ Enter the number of zones. This number is the number of spaces filled in on the capacity data plate. When entered press . Height 1 = __ If the value displayed is not the first (highest) height listed on the capacity data plate, enter the correct value. Press . Weight 1 = __ If the value displayed is not the first (lowest) weight listed on the capacity data plate, enter the correct value. Press .

Crown 1998 PF11533-21

M4.3–1650–045

Productive = __ The current selection will be displayed. Message “A” is displayed if truck is not equipped with the productivity package/capacity data monitor. Message “B” is displayed if truck is equipped with productivity package and pressure switch on the tilt cylinder. Message “C” is displayed on trucks equipped with Capacity Data Monitor and pressure transducer on the tilt cylinder. If the incorrect selection is present, press to access F10.1 F10.1 A = No If truck is not equipped with the optional Productivity Package or Capacity Data Monitor, press to select “no” and return to menu F10. If truck is equipped with one of these options press to access F10.2. F10.2 b = Switch Press at this level if truck is equipped with the Productivity Package. Display will return to menu F10. If this is not the option on the truck, press to access F10.3. F10.3 c = Capacity Press if truck is equipped with the Capacity Data Monitor. Display will return to menu F10.

Printed in U.S.A.

M4.3–1650–045

C • F11

Hi Lift = __ This menu is available only on 5000S trucks. The current selection is displayed. If selection is incorrect, press to access F11.1. F11.1 A = No Press if truck is not equipped with the high performance lift motors. If truck is equipped with this option, press . F11.2 b = Yes Press if truck is equipped with the high performance lift motors. The display will return to menu F11. Metric = __ If message is “B”, a conversion of weight, height and speed measurements to metric units will be present in messages on the display. The message “A” will display measurements in U.S. units. If selection needs to be changed, press to access F12.1. F12.1 A = No When units of measurement are to be U.S., press at this menu level. The display will return to F12. To change units of measurement, press to access F12.2. F12.2 b = Yes Press if units of measurements displayed are to be in metric units. Display will return to F12.

FEATURES SETUP • F14

F14.1

• F12

Brush/Temp = __ This menu is available only on trucks equipped with an enhanced display. If message is “B” truck must be equipped with brush wear and temperature sensors in the traction and lift motors. Without sensors, message is “A”. To change message, press to access F13.1. F13.1 A = No If truck is not equipped with brush wear and temperature sensors in the traction and lift motors, press . Display will return to menu F13. If this selection is not wanted, press to access F13.2. F13.2 b = Yes Press if truck is equipped with brush wear and temperature sensors in the traction and lift motors. The display will return to menu F13.

F14.2

F14.3

F14.4

• F13

Crown 1998 PF11533-22

M4.3–1650–046

Alarm = __ The current alarm configuration will be displayed. A travel alarm selection is required if truck is equipped with alarm 2. “A” is displayed if alarm is disabled. “B” is displayed when alarm in forward direction of travel (forks first) is enabled. “C” is displayed when alarm in reverse direction of travel (power unit first) is enabled. “Both” is displayed when both forward and reverse alarms are enabled. To change selection, press to access F14.1. A = Off Press if truck is not equipped with alarm2. Display will return to F14. To change selection, press to access F14.2. b = Fwd Pressing at this menu level will activate the travel alarm when traveling in the forward (forks first) direction. The display will return to F14. To make different selection, press to access menu F14.3. c = Rev Pressing at this menu level will activate the travel alarm when traveling in the reverse (power unit first) direction. The display will return to F14. To make different selection, press to access menu F14.4. d = Both Pressing at this menu level will activate the travel alarm when traveling in both the forward (forks first) and reverse (power unit first) direction. The display will return to F14.

• F15

Bat Retain = __ The current selection is displayed. Trucks without battery retainer switches should have the message “A” and trucks with battery retainer switches should display the message “B”. To change the setup, press . F15.1 A = No Press to make selection for trucks without battery retainer switches. The display will return to F15. Press to access F15.2. F15.2 b = Yes Press at this menu level when truck is equipped with battery retainer switches. The display will return to F15.

Printed in U.S.A.

M4.3–1650–046

C • F16

Fan = __ Used to enable thermostatically controlled drive motor compartment fan on trucks equipped with this feature "Yes" enables fan operation, "No" disables operation. Note: When enabled, the fan will only operate when motor compartment reaches predetermined temperature. The current selection is displayed. Trucks without motor compartment fan should have message "A" and trucks with motor compartment fan should display message "b". To change the setup, press .

F16.1 A = No Press to make this feature disbled. Display will return to F16. If desired to enable feature, press to access F16.2. F16.2 b = Yes Press to enable the drive motor compartment fan feature. Display will return to F16. • F17

Speed Cut = __ When current status is “B” a switch input at CA403-16 is required. To change setting, press to access F17.1. F17.1 A = No Press to make this feature disabled. Display will return to F17. If desired to enable feature, press to access F17.2. F17.2 b = Yes Press to enable the speed cut out feature. Display will return to F17.

• F18

Dashboard = __ This menu level is available on trucks with an enhanced display. The current selection is displayed. Activating makes selected items available on operator menu. Message “A” will have none of the options available. “B” makes a stopwatch type timer available to the operator. “C” requires a height encoder for height and the Capacity Data Monitor for weight. To change selection, press to access F18.1. F18.1 A = No To make none of the enhancements available to the operator, press . The display will return to F18. To enable either or both enhancements, press to access F18.2. F18.2 b = Timer Press to make a stopwatch style timer only available in the operator menu. For a different selection, press .

Crown 1998 PF11533-23

M4.3–1650–047

FEATURES SETUP F18.3 c = Wt/Ht To view the fork height in the operator menu, the height sensor must be installed on the truck. To view the load weight in the operator menu, the capacity data monitor must be installed. To make this enhancement active, press . The display will return to F18. To make all enhancements active, press to access F18.4. F18.4 d = Both Pressing will make all enhancements in F18 active. The display will return to F18. • F19

User Perf = __ The current selection is displayed. If “b” is message displayed, any user can select any performance level (P1, P2, P3) regardless of F20 settings. If message displayed is “A”, operator user code will enable only the performance level assigned to the code. To change the current setting, press to access F19.1. F19.1 A = No Press to make the performance levels accessible only through use of a user code. To make all performance levels available to all operators, press to access F19.2. F19.2 b = yes Press to make performance levels available to all operators. Display will return to F19.

• F20

User Codes = __ Use this menu level to enter up to 25 user codes which can be applied to various performance levels. If F20 is b, any user can select any performance level. If it is desired to enable this feature and enter user codes, press to access F20.1. F20.1 A = No Pressing at this menu level will disable the user code option and return the display to F20. To continue, press to access F20.2 F20.2 b = Yes To enable this feature, press . Dislpay will to advance to the F20.3 return to F20. Press menu. F20.3 c = View To view all codes entered in the system, press . To move forward and backward through the codes, press and . To advance to F20.4, press to return to F20.3 and then use the down arrow key to access F20.4.

Printed in U.S.A.

M4.3–1650–047

C F20.4 d = Add To add user codes, press . A prompt (User _ _ _ _ @ P _) for entering a four digit number and the assigned performance level will appear. Enter the desired code and performance level and press . The display will return to F20.4. If additional codes are to be added, repeat process described. Press to access F20.5. F20.5 e = Delete To delete any of the user codes, press . The available codes can be scrolled through with and until the desired code is displayed. To delete, press . The display will return to F20.5. To delete additional codes repeat process described. Press to access F20.6. F20.6 f = escape When done in the user code sub menu, press to return to F20. • F21

Lockout = __ Current status of truck operation lockout displayed. Message “A” indicates truck is not disabled. Message “B” indicates truck operation is disabled. To change status of this feature press to access F21.1. F21.1 A = No If truck is disabled and it is desired to enable operation, press . The display will return to menu F21. If it is desired to disable truck operation, press to access F21.2. F21.2 b = Yes To disable truck operation, press . Display will return to menu F21.

• F22

F22.1

F22.2

F22.3

F22.4

FEATURES SETUP F22.5 French To select, press . Display will return to F22. For different language, press to access F22.6. F22.6 Dutch To select, press . Display will return to F22. • F23

Save? Entering this menu level permits saving the changes made or discarding changes and returning to the previously saved feature parameters. Press to access F23.1. F23.1 Save? N Press at this menu level to discard any changes made and return to previously saved feature parameters. Press to access the F23.2 menu. F23.2 Save? Y Press at this menu level to save changes made. During the save process, do not operate any truck controls to avoid corrupting data being saved. When data is saved, the system will return to the F menu.

Features Complete When setup procedures are complete, scroll down to the Save? (F23) menu and press . If the setup completed is necessary to save into memory for future truck operation, select the Save? Y (F23.2) menu and press . This process will require less than a minute to complete. Do not operate any truck controls or display keys during this process.

Language = __ Not available on standard dislpay. This menu level enables selection of desired language for Level 1 display messages. If language change is desired, press to access F22.1. English To select, press . Display will return to F22. For different language, press to access F22.2. German To select, press . Display will return to F22. For to access F22.3. different language, press Italian To select, press . Display will return to F22. For different language, press to access F22.4. Spanish To select, press . Display will return to F22. For different language, press to access F22.5.

Crown 1998 PF11533-24

M4.3–1650–048

Printed in U.S.A.

M4.3–1650–048

C Press the and H

HOUR METER MENU

key to move right and left in the menu and allow system to accept changes to the hour reset menu. Press the to move up and down.

Hour Reset

H1 Run = ___ H2 Travel = ___

H3 Lift 1 = ___

H4 Lift 2 = ___

H5 PM H• @ ___

H2.1

Sure? N

H2.2

Sure? Y

H3.1

Sure? N

H3.2

Sure? Y

H4.1

Sure? N

H4.2

Sure? Y

H5.1

PM H1 = ___

H5.2

PM H2 = ___

H5.3

PM H3 = ___

H5.4

PM H4 = ___

H5.5

PM None = ___

H5.6

Escape

H6 Escape

continued on next page

Crown 1998 PF11533-25

M4.3–1650–049

Printed in U.S.A.

M4.3–1650–049

C Press the and L

LOG EVENTS MENU

key to move right and left in the menu and allow system to accept changes to the log events menu. Press the to move up and down.

Log Events

L1 History

L2 Totals

L3 Erase

Last =

___ @ ____

L-1 =

L-15 =

___ @ ____ • • • • • ___ @ ____

Event ___

= ____

Event ___

= ____

L3.1

L3.2

L3.3

Erase Hist

Erase All

L3.1.1

Sure? N

L3.1.2

Sure? Y

L3.2.1

Sure? N

L3.2.2

Sure? Y

Escape

L4 Escape

continued on next page

Crown 1998 PF11533-26

M4.3–1650–050

Printed in U.S.A.

M4.3–1650–050

C Press the

PERFORMANCE MENU

key to move right and left in the menu and allow system to accept changes to the performance menu. Press

the

and

Performance

to move up and down.

Setup P1

P1.1 Forward = __.__

P1.2 Reverse = __.__

P1.3 Accel = __.__

P1.4 Pump 2 = ____

P1.5 Lower = __.__

P1.1.1

Std = __.__

P1.1.2

Custom __.__

P1.2.1

Std = __.__

P1.2.2

Custom __.__

P1.3.1

Std = __.__

P1.3.2

Custom __.__

P1.4.1

Pump 2 = On

P1.4.2

Pump 2 = Off

P1.5.1

Std = __.__

P1.5.2

Custom __.__

P2.1.1

Std = __.__

P2.1.2

Custom __.__

P2.2.1

Std = __.__

P2.2.2

Custom __.__

P2.3.1

Std = __.__

P2.3.2

Custom __.__

P2.4.1

Pump 2 = On

P2.4.2

Pump 2 = Off

P2.5.1

Std = __.__

P2.5.2

Custom __.__

P1.6 Escape P2

Setup P2

P2.1 Forward = __.__

P2.2 Reverse = __.__

P2.3 Accel = __.__

P2.4 Pump 2 = ____

P2.5 Lower = __.__

P2.6 Escape continued on next page Crown 1998 PF11533-27

M4.3–1650–051

Printed in U.S.A.

M4.3–1650–051

C continued from previous page

PERFORMANCE MENU

Setup P3

P3.1 Forward = __.__

P3.2 Reverse = __.__

P3.3 Accel = __.__

P3.4 Pump 2 = ____

P3.5 Lower = __.__

P3.1.1

Std = __.__

P3.1.2

Custom __.__

P3.2.1

Std = __.__

P3.2.2

Custom __.__

P3.3.1

Std = __.__

P3.3.2

Custom __.__

P3.4.1

Pump 2 = On

P3.4.2

Pump 2 = Off

P3.5.1

Std = __.__

P3.5.2

Custom __.__

P3.6 Escape P4

BDI = ___

P4.1 Std = ___

BDI fine tuning.

P4.2 Custom = ___ P5

Plug = ___

P5.1 Std = ___ P5.2 Custom = ___

Drv Brake = ___

P6.1 Std = ___ P6.2 Custom = ___

Refer to section M5.0 brakes. Adjusts stopping distance.

continued on next page

Crown 1998 PF11533-28

M4.3–1650–052

Printed in U.S.A.

M4.3–1650–052

C continued from previous page

PERFORMANCE MENU

P71 Cas Brake = ___

P7.1 Std = ___ P7.2 Custom = ___

Accy > FLS = ___

P8.1 Std = ___

Controls accessory speed above free lift.

P8.2 Custom = ___ P9

Accy > 270" = ___

P9.1 Std = ___ P9.2 Custom = ___

Controls accessory speed above 270 inch (6.9 m) lift height.

P102 Trav> FLS = ___

P10.1 Speed = ___

Travel speed above freelift.

P113 Trav > 270" = ___

P11.1 Speed = ___

Travel speed above 270 inch (6.9 m) lift height.

P12 Coast = ___

P12.1 Std = ___

Adjusts regenerative braking during coast. (9 = soft, 1 = hard)

P12.2 Custom = ___ P13 Save?

P13.1 Save? N P13.2 Save? Y

continued on next page 1

= available on 5000S only.

= requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

3 = menu available on trucks equipped with height sensor only. Requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

Crown 1998 PF11533-29

M4.3–1650–053

Printed in U.S.A.

M4.3–1650–053

C The first level of the menu shows the different areas of performance for this truck. The Features must be set prior to setting Performance since Features turns on and off certain Performance levels. Performance Access When powering up the truck, press and maintain on the display, then enter the service code. This enters service level two of Access 1 operation. Navigate to the P - Performance menu and press . The "•" marks the highest levels of the Performance (P) menu. • P1, P2, P3 performance: These represent three performance levels that may be selected when in the operator mode. When a PIN code is used (Personal Identification Number) any one of the three performance levels can be assigned to 25 different PIN codes. Performance settings affect truck performance. Refer to F18 and F19 in the features menu to activate. Any adjustment under each performance level can be higher, lower or the same as the adjustment under any other performance level e.g. traction speeds forward and reverse can be the same for all performance levels and the lower speed can be different for all performance levels. The factory set performance levels of P1, P2 and P3 are as follows: P1: set for the maximum achievable performance level. P2: reduced performance from the maximum level and is similar to the performance of the Model RR3500. P3: lowest performance setting of the three levels. • P1

P1.1

Setup P1 Enter the parameters for the P1 performance level in this sub menu. Press to view/change the current P1 settings. Press to go to P2 setups. Fwd.= ________ The set traction speed in the forks first direction of travel in effect will be displayed. To change/ modify this speed press . Press to go to P1.2 Reverse. Note: Trucks with productivity package or capacity data monitor option, this setting represents the travel speed with a capacity load. The unloaded travel speed will be faster.

Crown 1998 PF11533-30

M4.3–1650–054

PERFORMANCE SETUP P1.1.1 Std ________ The maximum allowable traction speed in the forks first direction of travel is displayed. If this is the desired setting and is the setting displayed in P1.1, press to return to P1.1. If a setting other than that displayed is desired, press to access P1.1.2. P1.1.2 Cust = If a maximum traction speed in the forks first direction of travel less than the standard is desired, press . Then use and to display the speed required. Once the desired speed is displayed, press to return to P1.1. P1.2 Rev. = ________ The set traction speed in the power unit first direction of travel in effect will be displayed. To change/modify this speed press to go to P1.2.1. Note: Trucks with productivity package or capacity data monitor option, this setting represents the travel speed with a capacity load. The unloaded travel speed will be faster. P1.2.1 Std = _______ The maximum allowable traction speed in the power unit first direction of travel is displayed. If this is the desired setting and is the setting displayed in P1.2, press to return to P1.2. If a setting other than that displayed is desired, press to access P1.2.2. P1.2.2 Cust = If a maximum traction speed in the power unit first direction of travel less than the standard is desired, press . Then use and to display the speed required. Once the desired speed is displayed, press to return to P1.2. P1.3 Accel = ______ The setting of the acceleration rate (time for truck to go from stop the top speed) is displayed here. The adjustment range is 1 for the longest acceleration time to 9 for the shortest acceleration time. If this setting is okay, press to go to P1.4. To change/modify the acceleration rate press to go to P1.3.1. P1.3.1 Std = ______ The maximum allowable acceleration setting is displayed. If this is the desired setting and is the to return to setting displayed in P1.3, press P1.3. If a setting other than that displayed is desired, press to access P1.3.2. P1.3.2 Custm = If an acceleration rate other than the standard is desired, press . Then use and to obtain the desired setting. When set, press to return to P1.3.

Printed in U.S.A.

M4.3–1650–054

C P1.4

Pump 2 = ______ If pump 2 is enabled for high speed lift, “on” will be displayed. If pump 2 is disabled, “off” will be displayed. To change/modify the status of pump 2 press . Press to go to P1.5 Lower. P1.4.1 Pump 2 = On If it is necessary to have pump 2 enabled, press in this screen to select “on” and return to P1.4. If pump is to be disabled, press to access P1.4.2. P1.4.2 Pump 2 = Off If it is necessary to have pump 2 disabled, press in this screen to select “off” and return to P1.4. P1.5 Lower = ______ The set lower speed of the forks in feet per minute will be displayed in this screen. The adjustment range is 70 to 90 feet per minute. Note: Trucks with productivity package or capacity data monitor option, this setting represents the lowering speed with a capacity load. The fork empty lowering speed will be faster. To change/ modify the lowering speed press . Press to go to P1.6 Escape. P1.5.1 Std = ______ The set allowable lower speed is displayed. If this is the desired setting and is the setting displayed in P1.5, press to return to P1.5. If a setting to other than that displayed is desired, press access P1.5.2. P1.5.2 Cusm = If a lower speed other than the standard is desired, press . Then use and to obtain the desired setting. When set, press to return to P1.5. Then press to go to the P1.6 Escape menu. P1.6 Escape In this menu press to exit the P1 performance sub menus and return to P1. • P2

P2.1

Setup P2 Enter the parameters for the P2 performance level in this sub menu. Press to change the current P2 performance settings. Press to go to P3 setups. Fwd. = ______ The set traction speed in the forks first direction of travel in effect will be displayed. To change/ modify this speed press . Press to go to P2.2 Reverse.

Crown 1998 PF11533-31

M4.3–1650–055

PERFORMANCE SETUP P2.1.1 Std = ______ The set allowable traction speed in the forks first direction of travel is displayed. If this is the desired setting and is the setting displayed in P2.1, press to return to P2.1. If a setting other than that displayed is desired, press to access P2.1.2. P2.1.2 Custm = If a maximum traction speed in the forks first direction of travel different than the standard is desired, press . Then use and to display the speed required. Once the desired speed is displayed, press to return to P2.1. P2.2 Rev. = ______ The set traction speed in the power unit first direction of travel in effect will be displayed. To change/modify this speed press . Press to go to P2.3 Accel. P2.2.1 Std ______ The set allowable traction speed in the power unit first direction of travel is displayed. If this is the desired setting and is the setting displayed in P2.2, press to return to P2.2. If a setting other than that displayed is desired, press to access P2.2.2. P2.2.2 Custm = If a maximum traction speed in the power unit first direction of travel different than the standard is desired, press . Then use and to display the speed required. Once the desired speed is displayed, press to return to P2.2. P2.3 Accel = ______ The setting of the acceleration rate (time for truck to go from stop the top speed) is displayed here. The adjustment range is 1 for the longest acceleration time to 9 for the shortest acceleration time. To change/modify the status of acceleration rate press . Press to go to P2.4 Pump 2. P2.3.1 Std = ______ The current allowable acceleration setting is displayed. If this is the desired setting and is the setting displayed in P2.3, press to return to P2.3. If a setting other than that displayed is desired, press to access P2.3.2. P2.3.2 Custm = If an acceleration rate other than the current is and to obtain desired, press . Then use the desired setting. When set, press to return to P2.3.

Printed in U.S.A.

M4.3–1650–055

C P2.4

Pump 2 = ______ If pump 2 is enabled for high speed lift, “on” will be displayed. If pump 2 is disabled, “off” will be displayed. To change/modify the status of pump 2 press . Press to go to P2.5 Lower. P2.4.1 Pump 2 - On If it is necessary to have pump 2 enabled, press in this screen to select “on” and return to P2.4. If pump is to be disabled, press to access P2.4.2. P2.4.2 Pump 2 = Off If it is necessary to have pump 2 disabled, press in this screen to select “off” and return to P2.4. P2.5 Lower = ______ The set lower speed of the forks in feet per minute will be displayed in this screen. The adjustment range is 70 to 90 feet per minute. Note: Trucks with productivity package or capacity data monitor option, this setting represents the lowering speed with a capacity load. The fork empty lowering speed will be faster. P2.5.1 Std = ______ The current allowable lower speed is displayed. If this is the desired setting and is the setting to return to P2.5. If a displayed in P2.5, press setting other than that displayed is desired, press to access P2.5.2. P2.5.2 Custm = If a lower speed other than the standard is desired, Press . Then use and to obtain the desired setting. When set, press to return to P2.5. Then Press to go to the P2.6 escape menu. P2.6 Escape In this menu Press to exit the P2 performance sub menus and return to P2.

• P3

P3.1

Setup P3 Enter the parameters for the P3 performance to view/change level in this sub menu. Press the current P3 performance settings. Press to go to P4 BDI. Fwd. = ______ The set traction speed in the forks first direction of travel in effect will be displayed. Note: Trucks with productivity package or capacity data monitor option, this setting represents the travel speed with a capacity load. The unloaded travel speed will be faster.

Crown 1998 PF11533-32

M4.3–1650–056

PERFORMANCE SETUP P3.1.1 Std ______ The set allowable traction speed in the forks first direction of travel is displayed. If this is the desired setting and is the setting displayed in P3.1, press to return to P3. If a setting other than that displayed is desired, press to access P3.1.2. P3.1.2 Custm = If maximum traction speed in the forks first direction of travel different than the standard is desired, press . Then use and to display the speed required. Once the desired speed is displayed, press to return to P3.1. P3.2 Rev. = ______ The set traction speed in the power unit first direction of travel in effect will be displayed. To change/modify this speed press . Press to go to P3.3 Accel. Note: Trucks with productivity package or capacity data monitor option, this setting represents the travel speed with a capacity load. The unloaded travel speed will be faster. P3.2.1 Std ______ The maximum allowable traction speed in the power unit first direction of travel is displayed. If this is the desired setting and is the setting displayed in P3.2, press to return to P3.2. If a setting other than that displayed is desired, press to access P3.2.2. P3.2.2 Custm = If a maximum traction speed in the power unit first direction of travel different than the standard is desired, press . Then use and to display the speed required. Once the desired speed is displayed, press to return to P3.2. P3.3 Accel = ______ The setting of the acceleration rate (time for truck to go from stop to top speed) is displayed here. The adjustment range is 1 for the longest acceleration time to 9 for the shortest acceleration time. To change/modify the acceleration rate press , Press to go to P3.4 Pump 2. P3.3.1 Std = ______ The maximum allowable acceleration setting is displayed. If this is the desired setting and is the setting displayed in P3.3, press to return to P3.3. If a setting other than that displayed is desired, press to access P3.3.2. P3.3.2 Custm = If an acceleration rate other than the standard is and to obtain desired, Press . Then use the desired setting. When set, press to return to P3.3.

Printed in U.S.A.

M4.3–1650–056

C Pump 2 = ______ If pump 2 is enabled for high speed lift, “on” will be displayed. If pump 2 is disabled, “off” will be displayed. To change/modify the status of Pump 2 press . Press to go to P3.5 Lower. P3.4.1 Pump 2 = On If it is necessary to have pump 2 enabled, press in this screen to select “on” and return to P3.4. If pump is to be disabled, press to access P3.4.2. P3.4.2 Pump 2 = Off If it is necessary to have pump 2 disabled, press in this screen to select “off” and return to P3.4. P3.5 Lower = ______ The set lower speed of the forks in feet per minute will be displayed in this screen. The adjustment range is 70 to 90 feet per minute. Note: Trucks with productivity package or capacity data monitor option, this setting represents the lowering speed with a capacity load. The fork empty lowering speed will be faster. To change/ modify the lowering speed press . Press to go to P3.6 Escape. P3.5.1 Std = ______ The maximum allowable lower speed is displayed. If this is the desired setting and is the to return to setting displayed in P3.5, press P3.5. If a setting other than that displayed is desired, press to access P3.5.2. P3.5.2 Custm = If a lower speed other than the standard is desired, Press . Then use and to obtain the desired setting. When set, press to return to P3.5. Then Press to go to the P3.6 escape menu. P3.6 Escape In this menu Press to exit the P3 performance sub menus and return to P3.

PERFORMANCE SETUP

P3.4

• P4

P4.1

P4.2

• P5

P5.1

P5.2

• P6

P6.1

Decreasing the P4 setting will reduce the volts per cell monitor level allowing the battery to go into deeper discharge prior to lift lockout. Increasing the P4 setting will increase the volts per cell monitor level disabling the lift function earlier in the discharge cycle.

P6.2

Crown 1998 PF11533-33

M4.3–1650–057

The current setting will be displayed. Adjustment range for the BDI is 1 to 9. 1 is the deepest battery discharge setting with lift cutout occurring at 1.9 volts per cell and 9 is the least battery discharge setting with lift cutout occurring at 1.98 volts per cell. Make BDI lockout and discharge indication changes in this sub menu. To change/modify the BDI press . Press to go to P5 Plug. Std = ______ This setting is the factory recommended setting. If this is the desired setting and the setting displayed in P4, press to return to P4. If a setting other than the displayed is desired, press to access P4.2. Custm = Press . Then use and to obtain the desired setting. When set, press to return to P4. Plug = ______ This affects the plugging force. The current setting will be displayed. Adjustment range for Plug is 1 to 9. 9 will provide the shortest plugging (stopping) distance and 1 the longest. To change/ modify Plugging press . Press to go to P6 Drive brake. Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P5, press to return to P5. If a value different than this is desired, press to access P5.2. Custm = Press . Then use and to obtain the desired setting. When set, press to return to P5. Drv Brake = ______ This affects the drive motor brake’s braking effort. The current setting will be displayed. Adjustment range is 1 to 9. 9 will provide the most braking power and 1 the least. To change/modify the braking effort press . Press to go to P7 (RR/ RD 5000 "S" trucks only) or P8 (RR/RD 5000). Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P6, press to return to P6. If a value different than this is desired, press to access P6.2. Custm = Refer to section M5 in this manual for adjustment procedures. Press . Then use and to obtain the desired setting. When set, press to return to P6. Printed in U.S.A.

M4.3–1650–057

C • P7

P7.1

P7.2

• P8

P8.1

P8.2

PERFORMANCE SETUP

Cas Brake = ______ (RR/RD 5000S trucks only) This affects the caster brake’s braking effort. The current setting will be displayed. Adjustment range is 1 to 9. 9 will provide the most braking power and 1 the least. . To change/modify the braking effort press Press to go to P8 Accy > FLS. Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P7, press to return to P7. If a value different than this is desired, press to access P7.2. Custm = Refer to section M5 in this manual for adjustment procedures. Press . Then use and to obtain the desired setting. When set, press to return to P7.

• P9

Accy>FLS = ______ This affects the hydraulic accessory speed when the forks are above free lift. The current setting will be displayed. Adjustment range is 1 to 9. 9 will provide the greatest speed and 1 the least. To change/modify the accessory speed above free to go to P9 Accy > 270". lift press . Press Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P8, press to return to P8. If a value different than this is desired, press to access P8.2. Custm = Press . Then use and to obtain the desired setting. When set, press to return to P8.

• P10

Crown 1998 PF11533-34

M4.3–1650–058

P9.1

P9.2

Accy>270 = _______ This affects the hydraulic accessory speed when the forks are above 270 inches (6.9 m). The current setting will be displayed. Adjustment range is 1 to 9. 9 will provide the greatest speed and 1 the least. To change/modify the accessory speed above 270 inches (6.9m) press . Press to go to P10 Travel > FLS. Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P9, press to return to P9. If a value different than this is desired, press to access P9.2. Custm = Press . Then use and to obtain the desired setting. When set, press to return to P9.

Trav>FLS = ______ This affects the traction speed when the forks are above free lift. The current setting will be displayed. Adjustment range is dependant on the truck configuration. To change/modify travel to go to speed above free lift press . Press P11 Travel > 270". P10.1 Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P10, press to return to P10. If a value different than this is desired, press to access P10.2. P10.2 Custm = Press . Then use and to obtain the desired setting. When set, press to return to P10.

Printed in U.S.A.

M4.3–1650–058

C • P11

Trav>270 = _______ This affects traction speed when the forks are above 270 inches (6.9 m). The current setting will be displayed. Adjustment range is dependant on the truck configuration. To change/modify travel speed above 270 inches (6.9m) press . Press to go to P12 Coast. P11.1 Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P11, press to return to P11. If a value different than this is desired, press to access P11.2. P11.2 Custm = Press . Then use and to obtain the to return to desired setting. When set, press P11.

• P12

Coast = ______ This affects the coasting effort of the truck when the operator returns the multi-task handle to neutral while the truck is in motion. The current setting will be displayed. Adjustment range is 1 to 9. 9 will provide the longest coast distance and 1 the shortest. To change/modify coasting effort press . Press to go to P13 Save. P12.1 Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P12, press to return to P12. If a value different than this is desired, press to access P12.2. P12.2 Custm = Press . Then use and to obtain the desired setting. When set, press to return to P12.

Crown 1998 PF11533-35

M4.3–1650–059

PERFORMANCE SETUP • P13

Save? Entering this menu level permits saving the changes made or discarding changes and returning to the previously saved performance parameters. Press to access P13.1. P13.1 Save? N Press at this menu level to discard any changes made and return to previously saved performance parameters. Press to access the P13.2 menu. P13.2 Save? Y Press at this menu level to save changes made. During the save process, do not operate any truck controls to avoid corrupting data being saved. When data is saved, the system will return to the P Performance menu.

Setup Complete When setup procedures are complete, scroll down to the Save? (P13) menu and press . If the setup completed is necessary to save into memory for future truck operation, select the Save? Y (P13.2) menu and press . This process will require less than a minute to complete. Do not operate any truck controls or display keys during this process.

Printed in U.S.A.

M4.3–1650–059

C U

Utilities

UTILITIES MENU

U1 Part Number

U2 Copy Setups

U1.1

Access 1

______

U1.2

Access 2

______

U1.3

Access 3

______

U1.4

Software

______.___.__

U1.5

Escape

U2.1

From TCM

U2.2

From HCM

U2.3

Escape

U3 Escape

Crown 1998 PF11533-36

M4.3–1650–060

Printed in U.S.A.

M4.3–1650–060

ACCESS 123 Software Version 122676-001-09 RR/RD 5000/5000S SERIES

Battery Discharge Indicator Power "on"

Operator Improper Sequence Error

Service Required Light Fork Height Indicator

Message Display (4 Character) 6217

Navigation Keys

Dome Work Lift Operator Light Cutout Light Compartment Override Fan

Enhanced Display Capacity Data Monitor

Quick Reference Keys

6218

Message Display (16 Character)

990215

6385

Crown 1999 PF11597-1 Rev. 8/00

Printed in U.S.A.

03 REV. 8/00

M4.3–1650–065

6219

Power "on" • illuminates when power is present to display.

6215

6216

Service Required • illuminates when a status has been detected that requires attention. Accompanied by status code.

6248

6222

Fork Height Indicator • illuminates when forks are above free lift. • flashes and alarm sounded when forks above free lift and travel speed greater than 1.5 mph.

6224

C 6250

6251

Crown 1999 PF11597-2

M4.3–1650–066

Printed in U.S.A.

M4.3–1650–066

ACCESS 123

These indicators on enhanced displays only: Performance Menu Hour Meter Menu

Quick Reference Keys • during truck operation, keys can be used to go directly to indicated operator menu. • pressing key while in menu returns display to normal operation.

Log Events Menu 6221

6225

6223

Crown 1999 PF11597-3

M4.3–1650–067

Printed in U.S.A.

M4.3–1650–067

USER MAIN MENU LEVEL

The truck operator has access to the following menu after inputting the required user code.

❑❑❑❑

Service Access Code

Run

System Ready

Hour Reset

H1 H2 H3 H4 H5

Run = Travel = Lift 1 = Lift 2 = PM @____H_

Total truck pedal time Total time traction motor (M1) operation Total time motor (M2) operation Total time motor (M3) operation Run meter reading for next planned maintenance inspection

LL L-1 L-2 L4

Last = ____ Last-1 = ____ Last-2 = ____ Escape

Last service condition status code Second last service condition status code Third last service condition status code

P1 P2 P3

Performance Performance Performance

Performance level one. Programmed in service menu. Performance level two. Programmed in service menu. Performance level three. Programmed in service menu.

Timer ___:___:___

Stop watch. Resets timer to zero. Starts and Stops the timer.

Log Events

Performance

Elapsed Timer

Height&Weight ____ inch Fork height. Truck must be equipped with a height sensor. ____lb. @ ____inch Load weight and fork height. Truck must be equipped with height sensor and capacity monitor.

not available on trucks with standard display.

Crown 1999 PF11597-4 Rev. 8/00

Printed in U.S.A.

01 REV. 8/00

M4.3–1650–068

SERVICE MAIN MENU LEVELS

❑❑❑❑

Service Access Code

Analyzer

Calibrate

• Level two menu only. • Truck components requiring calibration to the Access 1 - 2 - 3 system are contained in this menu.

Features

• Level two and level three menu. • In the features menu, programming is performed to set truck operation and performance to customer specifications and truck configuration.

Hour Reset

• Level two menu only. • Ability to check and reset hour meters available in this menu.

Log Events

• Level two and level three menu. • The last 16 codes in order of occurance and the accumulative count for each code can be viewed in this menu. Resetting log event counts available.

Performance

• Level two menu only. • Truck performance for operator code is set in this menu with additional overall performance adjustments available.

Utilities

Crown 1999 PF11597-5

M4.3–1650–069

Printed in U.S.A.

M4.3–1650–069

ANALYZER MENU

key to move right and left in the menu and allow system to perform function requested. Press the

Press the

and

to move up and down.

❑❑❑❑ A

Analyzer

Service Access Code A1

Status

A1.1

Steer = ❑

A1.2

Accy = ❑

A1.3

Lower = ❑

A1.4

Raise = ❑

A1.5

Full Trav = ❑

A1.6

Limp Trav = ❑

A1.7

ED Closed = ❑

A1.8

Battery = ❑

A1.9

Escape

continued on next page

Crown 1999 PF11597-6

M4.3–1650–070

Printed in U.S.A.

M4.3–1650–070

C continued from previous page

ANALYZER MENU

Inputs

A2.1

FS = ❑

1=Forward selected

A2.2

RS = ❑

1 = Reverse selected

A2.3

POT1 = ❑

A2.4

POT2 = ❑

A2.5

POT3 = ❑

A2.6

SSS = ❑

1.4v = Full forward 4.5v = Full reverse 1.4v = Full raise 4.5v = Full lower 1.0v = Full reach 4.0v = Full retract 1 = Side shift selected

A2.7

TBS = ❑

1 = Tilt back selected

A2.8

TDS = ❑

1 = Tilt down selected

A2.9

403-11 = ❑

1 = Input closed

A2.10 ENS = ❑

1 = Entry bar pressed

A2.11 DMS1/2 = ❑

1 = Off pedal

A2.12 BRS1 = ❑

1 = Off pedal

A2.13 BRS2 = ❑

1 = Off pedal

A2.14 BRS3 = ❑

0 = Off pedal

A2.15 FLS = ❑

0 = Above free lift

A2.16 HGTRS = ❑

0 = At height reset

A2.17 LMS = ❑

0 = input closed

A2.18 HGTS12 = ❑

0 = Within 12" from top

A2.19 ECR2 = ❑

Increasing = raise

A2.20 HSS = ❑

0 = Unloaded (<500 lbs)

A2.21 ECR1 = ❑

Increasing = Forward

A2.22 BRES1 = ❑

0 = Retainer missing

A2.23 ORS = ❑

0 = Override not selected

Crown 1999 PF11597-7

M4.3–1650–071

A2.37

CA408-12 = ❑

0 = Brush worn 0 = Hot 0 = Brush worn 0 = Hot 0 = Brush worn 0 = Hot 0 = Button pressed 0 = Button pressed 0 = Button pressed 0 = Input closed 0 = Input open Increasing = More weight 0 = Input open

Printed in U.S.A.

M4.3–1650–071

C continued from previous page

ANALYZER MENU

Outputs

A3.1

Not Used

Not used

A3.2

ALM2 = ❑

On/Off

A3.3

ED = ❑

On/Off

A3.4

SVA = ❑

On/Off

A3.5

SVL = ❑

On/Off

A3.6

SVP = ❑

On/Off

A3.7

SVR = ❑

On/Off

A3.8

SVS = ❑

On/Off

A3.9

SVT = ❑

On/Off

A3.10 PVA = ❑

0-100%

A3.11 PVH = ❑

0-100%

A3.12 BRK1o = ❑

0-15 Amp

A3.13 BRK1i = ❑

0-5 Amp

A3.14 BRK2 = ❑

0-4 Amp

A3.15 M1-A= ❑

0-560 Amp

A3.16 M1-F For = ❑

0-50 Amp

A3.17 M1-F Rev = ❑

0-50 Amp

A3.18 M2 = ❑

0-100%

A3.19 P2 = ❑

On/Off

A3.20 PU fan

On/Off

continued on next page A3.21 Escape

Crown 1999 PF11597-8

M4.3–1650–072

Printed in U.S.A.

M4.3–1650–072

C continued from previous page

ANALYZER MENU

Test Outputs

A4.1

Lamps/ALM1

On/Off

A4.2

ALM2 = ❑

On/Off

A4.3

ED = ❑

On/Off

A4.4

SVA = ❑

On/Off

A4.5

SVL = ❑

On/Off

A4.6

SVP = ❑

On/Off

A4.7

SVR = ❑

On/Off

A4.8

SVS = ❑

On/Off

A4.9

SVT = ❑

On/Off

A4.10 PVA = ❑

A4.12 BRK1o = ❑

90% 24 V 60% 36 V 90% 24 V 60% 36 V 5 Amp

A4.13 BRK1i = ❑

2 Amp

A4.14 BRK2 = ❑

2 Amp

A4.15 M1-A= ❑

300 Amp

A4.16 M1-F For = ❑

(+) 40 Amp

A4.17 M1-F Rev = ❑

(-) 40 Amp

A4.18 M2 = ❑ A4.19 P2 = ❑

50 Amp 36 V 90 Amp 24 V On/Off

A4.20 PU fan

On/Off

A4.11 PVH = ❑

A4.21 Escape

Escape

continued on next page

Crown 1999 PF11597-9

M4.3–1650–073

Printed in U.S.A.

M4.3–1650–073

CALIBRATION MENU

key to move right and left in the menu and allow system to accept calibration values. Press the Press the to move up and down.

Calibration

C41

Trav Handle

R/L Handle

Accy Handle

Height

C1.1

Forward = ❑

C1.2

Center = ❑

C1.3

Reverse = ❑

C2.1

Raise = ❑

C2.2

Center = ❑

C2.3

Lower = ❑

C3.1

Reach = ❑

C3.2

Center = ❑

C3.3

Retract = ❑

C4.1

R Cut1 = ❑

C4.2

C4.3

C4.4

R Cut2 = ❑

Encoder = ❑

and

C4.1.1

None

C4.1.2

Override

C4.1.3

Stop

C4.1.4

Escape

C4.2.1

None

C4.2.2

Override

C4.2.3

Stop

C4.2.4

Escape

C4.3.1

Max = ___ in.

C4.3.2

2nd = ___ in.

Escape

continued on next page 1

= available on trucks equipped with height sensor only.

Crown 1999 PF11597-10

M4.3–1650–074

Printed in U.S.A.

M4.3–1650–074

CALIBRATION MENU

continued from previous page C51

Weight

Valves

Save?

C5.1

No Load

C5.2

____ lbs.

C5.3

Escape

C6.1

Main I = ❑

C6.1.1

I = ❑ (ma)

C6.2

Main G = ❑

C6.2.1

G=❑

C6.3

Accy I = ❑

C6.3.1

I = ❑ (ma)

C6.4

Accy G = ❑

C6.4.1

G=❑

C6.5

Escape

C7.1

Save? N

C7.2

Save? Y

continued on next page 1

=menu available on trucks with enhanced display only. Capacity data monitor (CDM) must be enabled (F9).

Crown 1999 PF11597-11

M4.3–1650–075

Printed in U.S.A.

M4.3–1650–075

Crown 1999 PF11597-12

M4.3–1650–076

Printed in U.S.A.

M4.3–1650–076

C1.3 (reverse) - move the multi task handle to the full speed reverse traction position and press . The menu will then return to the C1 menu level.

C4 Height (raise cutouts and maximum lift height)

C4.1 (R cut1) - this menu level permits programming a lift cutout. If more than one cutout is to be programmed, this level must be the lower lift height and must be performed at the "override" level (C4.1.2). C4.1.1 (none) select this level by pressing , if no cutouts are required. The menu will return to the C4.1 level. Next program the maximum lift height (C4.3). C4.1.2 (override) programs a lift cutout with override. Posi. tion the forks at the desired lift cutout height. Press Programming is complete and menu will return to C4.1. C4.1.3 (stop) programs a lift cutout without override. Posi. tion the forks at the desired lift cutout height. Press Programming is complete and menu will return to C4.1. if no C4.1.4 (escape) select this menu level by pressing changes are to be made.

Fork height must be below free lift before entering this menu.

M4.3–1650–077

Printed in U.S.A.

M4.3–1650–077

CALIBRATION

The approximate amount of current required to move the valve spools to a point that the port is about to open is the value in C6.1 "Main I" and C6.3 "Accy I" . Fine tuning of spool speed with maximum command is adjusted in C6.2 "Main G" and C6.4 "Accy G". . Menu advances to the submenu level. C6.1(main I) - press C6.1.1 (I) A current value may be etched in the hydraulic manifold or the nut on the end of the valve, shown in the illustration, which is the "main I" value. If a value is not present, enter 145. The current setting, if available, will be etched in one of these locations.

1 C

T H

P 2

V R 2 T

PVA

P A

2 P

PVH

. Menu will

to return to the C5 menu level.

6491

Press

and scroll to next menu level.

C6.2 (main G) - press . Menu advances to the sub menu level. C6.2.1 (G) Before beginning with the raise lower calibration procedure, operate the lift/lower function until the hydraulic oil reaches approximately 100 degrees F. This typically takes 10 to 15 minutes of operation. The lower speed setting should be set so that the fork carriage passes through a 10 foot distance within 6.4 to 6.9 seconds. To measure this, either mark an adjacent rack or the mast for 10 feet of fork carriage movement. (Note: On a TT mast, each channel moves at a rate of approximately 2:1 ratio, or 1/2 speed of carriage movement.) With a minimum 1500 lb. load weight raise the mast to the full extended position without contacting the mast stops. Select maximum speed lower and time the rate of descent through the previously marked 10 foot distance. The target time is 6.67 seconds with the acceptable range between 6.45 and 6.90 seconds. Calculate the difference between the measured time and the target time. For every 0.08 seconds the time is less than the target time, add 2 units to the gain setting. For every 0.08 seconds the time is greater than the target time, subtract 2 units from the gain setting. Repeat test to achieve a time within the acceptable range, preferably close to the target. When complete, press

Crown 1999 PF11597-14

M4.3–1650–078

and scroll to next menu level. Printed in U.S.A.

M4.3–1650–078

CALIBRATION

. Menu advances to the sub menu C6.3 (accy I) press level. C6.3.1 (I) enter the value etched in the nut on the valve end, if present, or enter 225. Press and scroll to the next menu level. Navigate to the A3.18 menu and monitor the steering/lift motor amperage (M2) while standing on the operator compartment pedals. Rotate the steering tiller and release. After the steering tiller is neutral, watch the display for at least 5 - 10 seconds and determine if the pump motor current stays above or below the steer idle threshold current level. Scroll to the C7 menu level and select the C7.2 menu level to save . the calibration values into truck memory and press

Model RR5010 RR5020, RR5060, RR5080 RR5060, RR5080 with 7.5" lift motors

Approximate Steer Idle Current Threshold 110 65 95

If the current does not stay above the threshold level, increase the setting of Accy I (C6.3.1) by 20 unit increments and repeat previous steps until the current stays above the threshold level. After the pump motor current has been seen to stay above the steer idle current threshold, begin to reduce the setting of Accy I (C6.3.1) by 10 unit increments and repeat previous steps until the pump motor current drops below the steer idle current threshold, approximately 10 - 15 Amps. When the correct setting is accomplished, you will notice a decrease in M2 motor (steering/lift) speed approximately 5 - 10 seconds after the tiller is released. Verify the amperage is consistent with the above chart.

Measure the speed of the reach function with the empty forks below the free lift switch. . Menu advances to the sub menu C6.4 (accy G) press level. C6.4.1 (G) forks must be below freelift. Measure the time required to reach from one limit to the next. The target time is 2.5 seconds (2.3 to 2.7 seconds) for an RR and 5 seconds (4.8 to 5.2 seconds) for an RD. Calculate the difference between the measured time and the target time. For every 0.1 second the time is less than the target time, add 20 units from the set gain. For every 0.1 second the measured time is greater than the target time, subtract 20 units to the set gain. Repeat this process until the measured time is within the acceptable time limits, preferably close to the target time. NOTE: The C6.4 (accy G) adjustment is integral to the C6.3 (accy I) adjustment parameter. Therefore, adjustment made outside of the ranges called out in the service manual may result in unsatisfactory performance. After adjusting C6.4 (accy G) some fine adjustment of C6.3 (accy I) will be required if the steering/lift pump does not decrease in speed after approximately 5 - 10 seconds since the last steering or accessory command. When the gain is set press

. Scroll to menu level C6.5 and

. Scroll to the C7 menu level and select the C7.2 press menu level to save the calibration values into truck memory . and press Calibration is now complete and the truck can be returned to operation.

Printed in U.S.A.

Crown 1999 PF11597-15 Rev. 3/99

01 REV. 3/99

M4.3–1650–079

C Press the

FEATURES MENU

key to move right and left in the menu and allow system to accept changes to the features. Press the

and

to move up and down.

Features

Voltage = ___

F21 Pedals = ___

Hgt Encoder = ___

F1.1

A = 36 Volt

F1.2

b = 24 Volt

F2.1

A = 5 pedals

RR/RD 5000S

F2.2

b = 2 pedals

RR/RD 5000

F3.1

A = No

F3.2

b = Yes

Trk Wt = ___0

(With battery - From data plate)

Max Load = ___

(From data plate)

Reach = ___

Sideshift = ___

Tilt = ___

Listed on truck data plate.

Trucks equipped with height encoder

F6.1

A = None

F6.2

b = Single

F6.3

c = Double

F7.1

A = No

F7.2

b = Yes

F8.1

A = No

F8.2

b = Yes

continued on next page 1

= Menu available on 36 volt trucks.

Crown 1999 PF11597-16

M4.3–1650–080

Printed in U.S.A.

M4.3–1650–080

C continued from previous page

FEATURES MENU F91 Capacity = ___

F9.1

F9.2

Yes

F9.3

Zones = ___

F9.4

Height 1 = ___

F9.5

Weight 1 = ___

F9.6

Height 2 = ___

F9.7

Weight 2 = ___

F9.8

Height 3 = ___

F9.9

Weight 3 = ___

F9.10 Height 4 = ___ F9.11

Weight 4 = ___

- number of spaces filled in on capacity data plate. - first lift height on data plate. - first capacity on data plate. - second lift height on data plate. - second capacity on data plate. - third lift height on data plate. - third capacity on data plate. - fourth lift height on data plate. - fourth capacity on data plate.

F9.12 Escape F102 Productive = ___

F113 Hi Lift = ___

F12 Metric = ___

F10.1 A = No F10.2 b = Switch

trucks with productivity package.

F10.3 c = Capacity

trucks with CDM.

F11.1

A = No

F11.2

b = Yes

F12.1 A = No F12.2 b = Yes

F134 Brush/Temp = ___

F13.1 A = No F13.2 b = Yes

continued on next page 1

= menu available on trucks with enhanced display and height sensor. = 36 volt trucks with productivity package/CDM. 3 = available on 5000S only. 4 = menu available on trucks with enhanced display. 2

Crown 1999 PF11597-17

M4.3–1650–081

Printed in U.S.A.

M4.3–1650–081

C continued from previous page

FEATURES MENU

F141 Alarm = ___

F14.1 A = Off F14.2 b = Fwd

forks first direction

F14.3 c = Rev

power unit first direction

F14.4 d = Both F15 Bat Retain = ___

F15.1 A = No F15.2 b = Yes

F16 Fan = ___

- without battery retainer switch. - with battery retainer switch.

F16.1 A = No F16.2 b = Yes

F17 Speed Cut = ___

F17.1 A = No F17.2 b = Yes

F182 Dashboard = ___

F18.1 A = No F18.2 b = Timer

stop watch

F18.3 c = Wt/Ht

- view height (requires height sensor) and weight (requires CDM).

F18.4 d = Both F19 User Perf = ___

F19.1 A = No F19.2 b = Yes

enables ability for operator to select P1, P2, P3 performance levels.

continued on next page 1

= travel alarm.

= menu available on trucks with enhanced display.

Crown 1999 PF11597-18

M4.3–1650–082

Printed in U.S.A.

M4.3–1650–082

FEATURES MENU

continued from previous page

F20 User Codes = ___

F20.1 A = No F20.2 b = Yes F20.3 c = View

If F20 is "yes", then at least one Personal Identification Number is required. If F19 is "yes", any user can select any performance level.

F20.4 d = Add F20.5 e = Delete F20.6 f = Escape F21 Lockout = ___

F21.1 A = No

Truck lockout.

F21.2 b = Yes F221 Language = ___

F22.1 English F22.2 German F22.3 Italian F22.4 Spanish F22.5 French F22.6 Dutch

F23 Save?

F23.1 Save? N F23.2 Save? Y

Note: Do not operate vehicle during the "save" operation or values may get corrupted.

continued on next page

= Menu available with enhanced display only.

Crown 1999 PF11597-19

M4.3–1650–083

Printed in U.S.A.

M4.3–1650–083

C The feature menu is shown on the following pages. The first level of the menu shows the different areas of setup for the truck. Features Access

FEATURES SETUP F3.2

• F4

F1.1

F1.2

• F2

F2.1

F2.2

• F3

F3.1

Crown 1999 PF11597-20

M4.3–1650–084

08790

To enter a Trk Wt 13640 lbs, you would enter 1364. Standard Display Enhanced Display 1364

Press

13640

to access F5.

• F5

• F6

F6.1

F6.2

F6.3

Printed in U.S.A.

M4.3–1650–084

C • F7

F7.1

F7.2

• F8

F8.1

F8.2

FEATURES SETUP F9.6

• F9

F9.1

F9.2

F9.3

F9.4

F9.5

Crown 1998 PF11443-21

M4.3–1650–085

Printed in U.S.A.

M4.3–1650–085

C • F11

FEATURES SETUP • F14

F14.1

• F12

F14.2

F14.3

F14.4

• F13

Crown 1999 PF11597-22

M4.3–1650–086

• F15

Printed in U.S.A.

M4.3–1650–086

C • F16

FEATURES SETUP

• F18

F18.3 c = Wt/Ht To view the fork height in the operator menu, the height sensor must be installed on the truck. To view the load weight in the operator menu, the capacity data monitor must be installed. To make this enhancement active, press . The display will return to F18. To make all enhancements active, press to access F18.4. F18.4 d = Both Pressing will make all enhancements in F18 active. The display will return to F18. • F19

• F20

User Codes = __ Use this menu level to enter up to 25 user codes which can be applied to various performance levels. If F19 is b, any user can select any performance level. If it is desired to enable this feature and enter user codes, press to access F20.1. F20.1 A = No Pressing at this menu level will disable the user code option and return the display to F20. To continue, press to access F20.2 F20.2 b = Yes To enable this feature, press . Dislpay will to advance to the F20.3 return to F20. Press menu. F20.3 c = View To view all codes entered in the system, press . To move forward and backward through the codes, press and . To advance to F20.4, press to return to F20.3 and then use the down arrow key to access F20.4.

Crown 1999 PF11597-23 Rev. 8/00

Printed in U.S.A.

01 REV. 8/00

M4.3–1650–087

• F22

F22.1

F22.2

F22.3

F22.4

FEATURES SETUP F22.5 French To select, press . Display will return to F22. For different language, press to access F22.6. F22.6 Dutch To select, press . Display will return to F22. • F23

Crown 1999 PF11597-24

M4.3–1650–088

Printed in U.S.A.

M4.3–1650–088

C Press the and H

HOUR METER MENU

key to move right and left in the menu and allow system to accept changes to the hour reset menu. Press the to move up and down.

Hour Reset

H1 Run = ___ H2 Travel = ___

H3 Lift 1 = ___

H4 Lift 2 = ___

H5 PM H• @ ___

H2.1

Sure? N

H2.2

Sure? Y

H3.1

Sure? N

H3.2

Sure? Y

H4.1

Sure? N

H4.2

Sure? Y

H5.1

PM H1 = ___

H5.2

PM H2 = ___

H5.3

PM H3 = ___

H5.4

PM H4 = ___

H5.5

PM None = ___

H5.6

Escape

H6 Escape

continued on next page

Crown 1999 PF11597-25

M4.3–1650–089

Printed in U.S.A.

M4.3–1650–089

C Press the and L

LOG EVENTS MENU

key to move right and left in the menu and allow system to accept changes to the log events menu. Press the to move up and down.

Log Events

L1 History

L2 Totals

L3 Erase

Last =

___ @ ____

L-1 =

L-15 =

___ @ ____ • • • • • ___ @ ____

Event ___

= ____

Event ___

= ____

L3.1

L3.2

L3.3

Erase Hist

Erase All

L3.1.1

Sure? N

L3.1.2

Sure? Y

L3.2.1

Sure? N

L3.2.2

Sure? Y

Escape

L4 Escape

continued on next page

Crown 1999 PF11597-26

M4.3–1650–090

Printed in U.S.A.

M4.3–1650–090

C Press the

PERFORMANCE MENU

key to move right and left in the menu and allow system to accept changes to the performance menu. Press

the

and

Performance

to move up and down.

Setup P1

P1.1 Forward = __.__

P1.2 Reverse = __.__

P1.3 Accel = __.__

P1.4 Pump 2 = ____

P1.5 Lower = __.__

P1.1.1

Std = __.__

P1.1.2

Custom __.__

P1.2.1

Std = __.__

P1.2.2

Custom __.__

P1.3.1

Std = __.__

P1.3.2

Custom __.__

P1.4.1

Pump 2 = On

P1.4.2

Pump 2 = Off

P1.5.1

Std = __.__

P1.5.2

Custom __.__

P2.1.1

Std = __.__

P2.1.2

Custom __.__

P2.2.1

Std = __.__

P2.2.2

Custom __.__

P2.3.1

Std = __.__

P2.3.2

Custom __.__

P2.4.1

Pump 2 = On

P2.4.2

Pump 2 = Off

P2.5.1

Std = __.__

P2.5.2

Custom __.__

P1.6 Escape P2

Setup P2

P2.1 Forward = __.__

P2.2 Reverse = __.__

P2.3 Accel = __.__

P2.4 Pump 2 = ____

P2.5 Lower = __.__

P2.6 Escape continued on next page Crown 1999 PF11597-27

M4.3–1650–091

Printed in U.S.A.

M4.3–1650–091

C continued from previous page

PERFORMANCE MENU

Setup P3

P3.1 Forward = __.__

P3.2 Reverse = __.__

P3.3 Accel = __.__

P3.4 Pump 2 = ____

P3.5 Lower = __.__

P3.1.1

Std = __.__

P3.1.2

Custom __.__

P3.2.1

Std = __.__

P3.2.2

Custom __.__

P3.3.1

Std = __.__

P3.3.2

Custom __.__

P3.4.1

Pump 2 = On

P3.4.2

Pump 2 = Off

P3.5.1

Std = __.__

P3.5.2

Custom __.__

P3.6 Escape P4

BDI = ___

P4.1 Std = ___

BDI fine tuning.

P4.2 Custom = ___ P5

Plug = ___

P5.1 Std = ___ P5.2 Custom = ___

Drv Brake = ___

P6.1 Std = ___ P6.2 Custom = ___

Refer to section M5.0 brakes. Adjusts stopping distance.

continued on next page

Crown 1999 PF11597-28

M4.3–1650–092

Printed in U.S.A.

M4.3–1650–092

C continued from previous page

PERFORMANCE MENU

P71 Cas Brake = ___

P7.1 Std = ___ P7.2 Custom = ___

Accy > FLS = ___

P8.1 Std = ___

Controls accessory speed above free lift.

P8.2 Custom = ___ P9

Accy > 270" = ___

P9.1 Std = ___ P9.2 Custom = ___

Controls accessory speed above 270 inch (6.9 m) lift height.

P102 Trav> FLS = ___

P10.1 Speed = ___

Travel speed above freelift.

P113 Trav > 270" = ___

P11.1 Speed = ___

Travel speed above 270 inch (6.9 m) lift height.

P12 Coast = ___

P12.1 Std = ___

Adjusts regenerative braking during coast. (9 = soft, 1 = hard)

P12.2 Custom = ___ P13 Acc Ramp

P13.1 Std = ___ P13.2 Custom = ___

P14 Save?

P14.1 Save? N P14.2 Save? Y

continued on next page 1

= available on 5000S only.

= requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

= menu available on trucks equipped with height sensor only. Requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

Crown 1999 PF11597-29

M4.3–1650–093

Printed in U.S.A.

M4.3–1650–093

C The first level of the menu shows the different areas of performance for this truck. The Features must be set prior to setting Performance since Features turns on and off certain Performance levels. Performance Access When powering up the truck, press and maintain on the display, then enter the service code. This enters service level two of Access 1 operation. Navigate to the P - Performance menu and press . The "•" marks the highest levels of the Performance (P) menu. • P1, P2, P3 performance: These represent three performance levels that may be selected when in the operator mode. When a PIN code is used (Personal Identification Number) any one of the three performance levels can be assigned to 25 different PIN codes. Performance settings affect truck performance. Refer to F18 and F19 in the features menu to activate. Any adjustment under each performance level can be higher, lower or the same as the adjustment under any other performance level e.g. traction speeds forward and reverse can be the same for all performance levels and the lower speed can be different for all performance levels. The factory set performance levels of P1, P2 and P3 are as follows: NOTE: Travel speed displayed does not account for the boosted speed when equipped with the productivity or CDM option. Therefore maximum travel speed for all speed settings can be up to .7 mph faster than displayed if the truck is equipped with these options and the right conditions exist. P1: set for the maximum achievable performance level. P2: reduced performance from the maximum level and is similar to the performance of the Model RR3500. P3: lowest performance setting of the three levels. • P1

Setup P1 Enter the parameters for the P1 performance level in this sub menu. Press to view/change the current P1 settings. Press to go to P2 setups.

Crown 1999 PF11597-30

M4.3–1650–094

PERFORMANCE SETUP P1.1

Fwd.= ________ The set traction speed in the forks first direction of travel in effect will be displayed. To change/ modify this speed press . Press to go to P1.2 Reverse. Note: Trucks with productivity package or capacity data monitor option, this setting represents the travel speed with a capacity load. The unloaded travel speed will be faster. P1.1.1 Std ________ The maximum allowable traction speed in the forks first direction of travel is displayed. If this is the desired setting and is the setting displayed in P1.1, press to return to P1.1. If a setting other than that displayed is desired, press to access P1.1.2. P1.1.2 Cust = If a maximum traction speed in the forks first direction of travel less than the standard is desired, press . Then use and to display the speed required. Once the desired speed is displayed, press to return to P1.1. P1.2 Rev. = ________ The set traction speed in the power unit first direction of travel in effect will be displayed. To change/modify this speed press to go to P1.2.1. Note: Trucks with productivity package or capacity data monitor option, this setting represents the travel speed with a capacity load. The unloaded travel speed will be faster. P1.2.1 Std = _______ The maximum allowable traction speed in the power unit first direction of travel is displayed. If this is the desired setting and is the setting displayed in P1.2, press to return to P1.2. If a setting other than that displayed is desired, press to access P1.2.2. P1.2.2 Cust = If a maximum traction speed in the power unit first direction of travel less than the standard is desired, press . Then use and to display the speed required. Once the desired speed is displayed, press to return to P1.2. P1.3 Accel = ______ The setting of the acceleration rate (time for truck to go from stop the top speed) is displayed here. The adjustment range is 1 for the longest acceleration time to 9 for the shortest acceleration time. If this setting is okay, press to go to P1.4. To change/modify the acceleration rate press to go to P1.3.1.

Printed in U.S.A.

M4.3–1650–094

C P1.3.1 Std = ______ The maximum allowable acceleration setting is displayed. If this is the desired setting and is the to return to setting displayed in P1.3, press P1.3. If a setting other than that displayed is desired, press to access P1.3.2. P1.3.2 Custm = If an acceleration rate other than the standard is desired, press . Then use and to obtain the desired setting. When set, press to return to P1.3. P1.4 Pump 2 = ______ If pump 2 is enabled for high speed lift, “on” will be displayed. If pump 2 is disabled, “off” will be displayed. To change/modify the status of pump 2 press . Press to go to P1.5 Lower. P1.4.1 Pump 2 = On If it is necessary to have pump 2 enabled, press in this screen to select “on” and return to P1.4. to access If pump is to be disabled, press P1.4.2. P1.4.2 Pump 2 = Off If it is necessary to have pump 2 disabled, press in this screen to select “off” and return to P1.4. P1.5 Lower = ______ The set lower speed of the forks in feet per minute will be displayed in this screen. The adjustment range is 70 to 90 feet per minute. Note: Trucks with productivity package or capacity data monitor option, this setting represents the lowering speed with a capacity load. The fork empty lowering speed will be faster. To change/ modify the lowering speed press . Press to go to P1.6 Escape. P1.5.1 Std = ______ The set allowable lower speed is displayed. If this is the desired setting and is the setting displayed in P1.5, press to return to P1.5. If a setting other than that displayed is desired, press to access P1.5.2. P1.5.2 Cusm = If a lower speed other than the standard is desired, press . Then use and to obtain the to return to desired setting. When set, press P1.5. Then press to go to the P1.6 Escape menu. P1.6 Escape In this menu press to exit the P1 performance sub menus and return to P1.

Crown 1999 PF11597-31

M4.3–1650–095

PERFORMANCE SETUP • P2

Setup P2 Enter the parameters for the P2 performance level in this sub menu. Press to change the current P2 performance settings. Press to go to P3 setups. P2.1 Fwd. = ______ The set traction speed in the forks first direction of travel in effect will be displayed. To change/ modify this speed press . Press to go to P2.2 Reverse. P2.1.1 Std = ______ The set allowable traction speed in the forks first direction of travel is displayed. If this is the desired setting and is the setting displayed in P2.1, press to return to P2.1. If a setting other than that displayed is desired, press to access P2.1.2. P2.1.2 Custm = If a maximum traction speed in the forks first direction of travel different than the standard is desired, press . Then use and to display the speed required. Once the desired speed is to return to P2.1. displayed, press P2.2 Rev. = ______ The set traction speed in the power unit first direction of travel in effect will be displayed. To change/modify this speed press . Press to go to P2.3 Accel. P2.2.1 Std ______ The set allowable traction speed in the power unit first direction of travel is displayed. If this is the desired setting and is the setting displayed in P2.2, press to return to P2.2. If a setting other than that displayed is desired, press to access P2.2.2. P2.2.2 Custm = If a maximum traction speed in the power unit first direction of travel different than the standard is desired, press . Then use and to display the speed required. Once the desired speed is to return to P2.2. displayed, press P2.3 Accel = ______ The setting of the acceleration rate (time for truck to go from stop the top speed) is displayed here. The adjustment range is 1 for the longest acceleration time to 9 for the shortest acceleration time. To change/modify the status of acceleration rate press . Press to go to P2.4 Pump 2. P2.3.1 Std = ______ The current allowable acceleration setting is displayed. If this is the desired setting and is the setting displayed in P2.3, press to return to P2.3. If a setting other than that displayed is desired, press to access P2.3.2. Printed in U.S.A.

M4.3–1650–095

C P2.3.2 Custm = If an acceleration rate other than the current is desired, press . Then use and to obtain the desired setting. When set, press to return to P2.3. P2.4 Pump 2 = ______ If pump 2 is enabled for high speed lift, “on” will be displayed. If pump 2 is disabled, “off” will be displayed. To change/modify the status of pump 2 press . Press to go to P2.5 Lower. P2.4.1 Pump 2 - On If it is necessary to have pump 2 enabled, press in this screen to select “on” and return to P2.4. to access If pump is to be disabled, press P2.4.2. P2.4.2 Pump 2 = Off If it is necessary to have pump 2 disabled, press in this screen to select “off” and return to P2.4. P2.5 Lower = ______ The set lower speed of the forks in feet per minute will be displayed in this screen. The adjustment range is 70 to 90 feet per minute. Note: Trucks with productivity package or capacity data monitor option, this setting represents the lowering speed with a capacity load. The fork empty lowering speed will be faster. P2.5.1 Std = ______ The current allowable lower speed is displayed. If this is the desired setting and is the setting displayed in P2.5, press to return to P2.5. If a setting other than that displayed is desired, press to access P2.5.2. P2.5.2 Custm = If a lower speed other than the standard is desired, Press . Then use and to obtain the to return to desired setting. When set, press P2.5. Then Press to go to the P2.6 escape menu. P2.6 Escape In this menu Press to exit the P2 performance sub menus and return to P2. • P3

P3.1

Setup P3 Enter the parameters for the P3 performance level in this sub menu. Press to view/change the current P3 performance settings. Press to go to P4 BDI. Fwd. = ______ The set traction speed in the forks first direction of travel in effect will be displayed. Note: Trucks with productivity package or capacity data monitor option, this setting represents the travel speed with a capacity load. The unloaded travel speed will be faster.

Crown 1999 PF11597-32

M4.3–1650–096

Printed in U.S.A.

M4.3–1650–096

PERFORMANCE SETUP

P3.4

Pump 2 = ______ If pump 2 is enabled for high speed lift, “on” will be displayed. If pump 2 is disabled, “off” will be displayed. To change/modify the status of Pump 2 press . Press to go to P3.5 Lower. P3.4.1 Pump 2 = On If it is necessary to have pump 2 enabled, press in this screen to select “on” and return to P3.4. If pump is to be disabled, press to access P3.4.2. P3.4.2 Pump 2 = Off If it is necessary to have pump 2 disabled, press in this screen to select “off” and return to P3.4. P3.5 Lower = ______ The set lower speed of the forks in feet per minute will be displayed in this screen. The adjustment range is 70 to 90 feet per minute. Note: Trucks with productivity package or capacity data monitor option, this setting represents the lowering speed with a capacity load. The fork empty lowering speed will be faster. To change/ modify the lowering speed press . Press to go to P3.6 Escape. P3.5.1 Std = ______ The maximum allowable lower speed is displayed. If this is the desired setting and is the to return to setting displayed in P3.5, press P3.5. If a setting other than that displayed is desired, press to access P3.5.2. P3.5.2 Custm = If a lower speed other than the standard is desired, Press . Then use and to obtain the desired setting. When set, press to return to P3.5. Then Press to go to the P3.6 escape menu. P3.6 Escape In this menu Press to exit the P3 performance sub menus and return to P3. • P4

The current settings will be displayed. Adjustment range for the BDI is 1-9. A setting of 1 will take the battery to its deepest discharge. A setting of 9 will decrease the level of discharge. To change/modify press . Press to go to P5 Plug. NOTE: If this adjustment is set incorrectly, a fault code 832, indicating low battery voltage may result. P4.1

P4.2

• P5

P5.1

P5.2

• P6

P6.1

Decreasing the P4 setting will reduce the volts per cell monitor level allowing the battery to go into deeper discharge prior to lift lockout. If the P4 setting is adjusted to a level that will permit battery discharge that is too deep, fault code 832 will be registered. (See fault code 832 description.) Increasing the P4 setting will increase the volts per cell monitor level disabling the lift function earlier in the discharge cycle. Crown 1999 PF11597-33 Rev. 7/99

Std = ______ This setting is the factory recommended setting. If this is the desired setting and the setting displayed in P4, press to return to P4. If a setting other than the displayed is desired, press to access P4.2. Custm = Press . Then use and to obtain the desired setting. When set, press to return to P4. Plug = ______ This affects the plugging force. The current setting will be displayed. Adjustment range for Plug is 1 to 9. 9 will provide the shortest plugging (stopping) distance and 1 the longest. To change/ modify Plugging press . Press to go to P6 Drive brake. Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P5, press to return to P5. If a value different than this is desired, press to access P5.2. Custm = Press . Then use and to obtain the desired setting. When set, press to return to P5. Drv Brake = ______ This affects the drive motor brake’s braking effort. The current setting will be displayed. Adjustment range is 1 to 9. 9 will provide the most braking power and 1 the least. To change/modify the braking effort press . Press to go to P7 (RR/ RD 5000 "S" trucks only) or P8 (RR/RD 5000). Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P6, press to return to P6. If a value different than this is desired, press to access P6.2.

Printed in U.S.A.

02 REV. 7/99

M4.3–1650–097

C P6.2

• P7

P7.1

P7.2

• P8

P8.1

P8.2

Custm = Refer to section M5 in this manual for adjustment procedures. Press . Then use and to obtain the desired setting. When set, press to return to P6. Cas Brake = ______ (RR/RD 5000S trucks only) This affects the caster brake’s braking effort. The current setting will be displayed. Adjustment range is 1 to 9. 9 will provide the most braking power and 1 the least. To change/modify the braking effort press . Press to go to P8 Accy > FLS. Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P7, press to return to P7. If a value to access different than this is desired, press P7.2. Custm = Refer to section M5 in this manual for adjustment procedures. Press . Then use and to obtain the desired setting. When set, press to return to P7. Accy>FLS = ______ This affects the hydraulic accessory speed when the forks are above free lift. The current setting will be displayed. Adjustment range is 1 to 9. 9 will provide the greatest speed and 1 the least. To change/modify the accessory speed above free lift press . Press to go to P9 Accy > 270". Std = ______ The value displayed is a setting that is acceptable for optimum truck and installation conditions. If this setting is the desired setting and is the value displayed in P8, press to return to P8. If a value different than this is desired, press to access P8.2. Custm = Press . Then use and to obtain the to return to desired setting. When set, press P8.

Crown 1999 PF11597-34

M4.3–1650–098

PERFORMANCE SETUP • P9

P9.1

P9.2

• P10

Printed in U.S.A.

M4.3–1650–098

PERFORMANCE SETUP

• P11

• P12

• P13

Acc Ramp This adjustment effects the ramp time of the accessory valve. Increasing this setting numerically makes the accessory hydraulic functions more reactive. A setting of 1 will provide smoother reaction, while a setting of 9 will be more reactive.

NOTE: Unsatisfactory accessory hydraulic performance could be the result of air trapped in the accessory circuit. Refer to section M2 for more information. • P14

Save? Entering this menu level permits saving the changes made or discarding changes and returning to the previously saved performance parameters. Press to access P14.1. P14.1 Save? N Press at this menu level to discard any changes made and return to previously saved performance parameters. Press to access the P14.2 menu. P14.2 Save? Y Press at this menu level to save changes made. During the save process, do not operate any truck controls to avoid corrupting data being saved. When data is saved, the system will return to the P Performance menu.

Setup Complete When setup procedures are complete, scroll down to the Save? (P14) menu and press . If the setup completed is necessary to save into memory for future truck operation, select the Save? Y (P14.2) menu and press . This process will require less than a minute to complete. Do not operate any truck controls or display keys during this process.

Crown 1999 PF11597-35 Rev. 8/00

Printed in U.S.A.

01 REV. 8/00

M4.3–1650–099

C U

Utilities

UTILITIES MENU

U1 Part Number

U2 Copy Setups

U1.1

Access 1

______

U1.2

Access 2

______

U1.3

Access 3

______

U1.4

Software

______.___.__

U1.5

Escape

U2.1

From TCM

U2.2

From HCM

U2.3

Escape

U3 Escape

Crown 1999 PF11597-36

M4.3–1650–100

Printed in U.S.A.

M4.3–1650–100

ACCESS 123 Software Version 122676-001-11 RR/RD 5000/5000S SERIES

Battery Discharge Indicator Power "on"

Operator Improper Sequence Error

Service Required Light Fork Height Indicator

Message Display (4 Character) 6217

Navigation Keys

Dome Work Lift Operator Light Cutout Light Compartment Override Fan

Enhanced Display Capacity Data Monitor

Quick Reference Keys

6218

Message Display (16 Character)

000828

6760

Crown 2000 PF11923-1 Rev. 9/00

M4.3–1650–105

Printed in U.S.A.

01 Rev. 9/00

M4.3–1650–105

6219

Power "on" • illuminates when power is present to display.

6215

6216

Service Required • illuminates when a status has been detected that requires attention. Accompanied by status code.

6248

6222

Fork Height Indicator • illuminates when forks are above free lift. • flashes and alarm sounded when forks above free lift and travel speed greater than 1.5 mph.

6224

6250

6251

Crown 2000 PF11923-2

M4.3–1650–106

Printed in U.S.A.

M4.3–1650–106

ACCESS 123

These indicators on enhanced displays only: Performance Menu Hour Meter Menu 6221

Log Events Menu

6225

Quick Reference Keys • during truck operation, keys can be used to go directly to indicated operator menu. • pressing key while in menu returns display to normal operation.

6223

Crown 2000 PF11923-3

M4.3–1650–107

Printed in U.S.A.

M4.3–1650–107

USER MAIN MENU LEVEL

The truck operator has access to the following menu after inputting the required user code.

❑❑❑❑

Service Access Code

Run

System Ready

Hours

H1 H2 H3 H4 H5

Run = Travel = Lift 1 = Lift 2 = PM @____H_

Total truck pedal time Total time traction motor (M1) operation Total time motor (M2) operation Total time motor (M3) operation Run meter reading for next planned maintenance inspection

LL L-1 L-2 L4

Last = ____ Last-1 = ____ Last-2 = ____ Escape

Last service condition status code Second last service condition status code Third last service condition status code

P1 P2 P3

Performance Performance Performance

Performance level one. Programmed in service menu. Performance level two. Programmed in service menu. Performance level three. Programmed in service menu.

Timer ___:___:___ Start Stop

Stop watch.

Log Events

Performance

Elapsed Timer

Height&Weight ____ inch Fork height. Truck must be equipped with a height sensor. ____lb. @ ____inch Load weight and fork height. Truck must be equipped with height sensor and capacity monitor.

not available on trucks with standard display.

Crown 2000 PF11923-4

M4.3–1650–108

Printed in U.S.A.

M4.3–1650–108

SERVICE MAIN MENU LEVELS

❑❑❑❑

Service Access Code

Analyzer

Calibrate

• Level two menu only. • Truck components requiring calibration to the Access 1 - 2 - 3 system are contained in this menu.

Features

• Level two and level three menu. • In the features menu, programming is performed to set truck operation and performance to customer specifications and truck configuration.

Hours

• Level two menu only. • Ability to check hour meters available in this menu.

Log Events

• Level two and level three menu. • The last 16 codes in order of occurance and the accumulative count for each code can be viewed in this menu. Resetting log event counts available.

Performance

• Level two menu only. • Truck performance for operator code is set in this menu with additional overall performance adjustments available.

Utilities

• Level two and level three menu. • Part numbers of the Access 1, Access 2 and Access 3 modules and software version number accessable in U1 menu. The U2 menu provides the tool for copying setup values from one module to the other. The U3 menu provides the capability to enter hour meter readings when Access 3 is replaced and to reset the travel, lift 1 or lift 2 hour meter after corresponding motor replacement.

Crown 2000PF11923-5

M4.3–1650–109

Printed in U.S.A.

M4.3–1650–109

ANALYZER MENU

key to move right and left in the menu and allow system to perform function requested. Press the

Press the

and

to move up and down.

❑❑❑❑ A

Analyzer

Service Access Code A1

Status

A1.1

Steer = ❑

A1.2

Accy = ❑

A1.3

Lower = ❑

A1.4

Raise = ❑

A1.5

Full Trav = ❑

A1.6

Limp Trav = ❑

A1.7

ED Closed = ❑

A1.8

Battery = ❑

A1.9

Escape

continued on next page

Crown 2000 PF11923-6

M4.3–1650–110

Printed in U.S.A.

M4.3–1650–110

C continued from previous page

ANALYZER MENU

Inputs

A2.1

FS = ❑

1=Forward selected

A2.2

RS = ❑

1 = Reverse selected

A2.3

POT1 = ❑

A2.4

POT2 = ❑

A2.5

POT3 = ❑

A2.6

SSS = ❑

1.4v = Full forward 4.5v = Full reverse 1.4v = Full raise 4.5v = Full lower 1.0v = Full reach 4.0v = Full retract 1 = Side shift selected

A2.7

TBS = ❑

1 = Tilt back selected

A2.8

TDS = ❑

1 = Tilt down selected

A2.9

403-11 = ❑

1 = Input closed

A2.10 ENS = ❑

1 = Entry bar pressed

A2.11 DMS1/2 = ❑

1 = Off pedal

A2.12 BRS1 = ❑

1 = Off pedal

A2.13 BRS2 = ❑

1 = Off pedal

A2.14 BRS3 = ❑

0 = Off pedal

A2.15 FLS = ❑

0 = Above free lift

A2.16 HGTRS = ❑

0 = At height reset

A2.17 LMS = ❑

0 = input closed

A2.18 HGTS12 = ❑

0 = Within 12" from top

A2.19 ECR2 = ❑

Increasing = raise

A2.20 HSS = ❑

0 = Unloaded (<500 lbs)

A2.21 ECR1 = ❑

Increasing = Forward

A2.22 BRES1 = ❑

0 = Retainer missing

A2.23 ORS = ❑

0 = Override not selected

Crown 2000 PF11923-7

M4.3–1650–111

A2.37

CA408-12 = ❑

0 = Brush worn 0 = Hot 0 = Brush worn 0 = Hot 0 = Brush worn 0 = Hot 0 = Button pressed 0 = Button pressed 0 = Button pressed 0 = Input closed 0 = Input open Increasing = More weight 0 = Input open

Printed in U.S.A.

M4.3–1650–111

C continued from previous page

ANALYZER MENU

Outputs

A3.1

Not Used

Not used

A3.2

ALM2 = ❑

On/Off

A3.3

ED = ❑

On/Off

A3.4

SVA = ❑

On/Off

A3.5

SVL = ❑

On/Off

A3.6

SVP = ❑

On/Off

A3.7

SVR = ❑

On/Off

A3.8

SVS = ❑

On/Off

A3.9

SVT = ❑

On/Off

A3.10 PVA = ❑

0-100%

A3.11 PVH = ❑

0-100%

A3.12 BRK1o = ❑

0-15 Amp

A3.13 BRK1i = ❑

0-5 Amp

A3.14 BRK2 = ❑

0-4 Amp

A3.15 M1-A= ❑

0-560 Amp

A3.16 M1-F For = ❑

0-50 Amp

A3.17 M1-F Rev = ❑

0-50 Amp

A3.18 M2 = ❑

0-100%

A3.19 P2 = ❑

On/Off

A3.20 PU fan

On/Off

continued on next page A3.21 Escape

Crown 2000 PF11923-8

M4.3–1650–112

Printed in U.S.A.

M4.3–1650–112

C continued from previous page

ANALYZER MENU

Test Outputs

A4.1

Lamps/ALM1

On/Off

A4.2

ALM2 = ❑

On/Off

A4.3

ED = ❑

On/Off

A4.4

SVA = ❑

On/Off

A4.5

SVL = ❑

On/Off

A4.6

SVP = ❑

On/Off

A4.7

SVR = ❑

On/Off

A4.8

SVS = ❑

On/Off

A4.9

SVT = ❑

On/Off

A4.10 PVA = ❑

A4.12 BRK1o = ❑

90% 24 V 60% 36 V 90% 24 V 60% 36 V 5 Amp

A4.13 BRK1i = ❑

2 Amp

A4.14 BRK2 = ❑

2 Amp

A4.15 M1-A= ❑

300 Amp

A4.16 M1-F For = ❑

(+) 40 Amp

A4.17 M1-F Rev = ❑

(-) 40 Amp

A4.18 M2 = ❑ A4.19 P2 = ❑

50 Amp 36 V 90 Amp 24 V On/Off

A4.20 PU fan

On/Off

A4.11 PVH = ❑

A4.21 Escape

Escape

continued on next page

Crown 2000 PF11923-9

M4.3–1650–113

Printed in U.S.A.

M4.3–1650–113

CALIBRATION MENU

key to move right and left in the menu and allow system to accept calibration values. Press the Press the to move up and down. C

Calibration

C41

Trav Handle

R/L Handle

Accy Handle

Height

C1.1

Forward = ❑

C1.2

Center = ❑

C1.3

Reverse = ❑

C2.1

Raise = ❑

C2.2

Center = ❑

C2.3

Lower = ❑

C3.1

Reach = ❑

C3.2

Center = ❑

C3.3

Retract = ❑

C4.1

R Cut1 = ❑

C4.2

C4.3

R Cut2 = ❑

Encoder = ❑

and

C4.1.1

None

C4.1.2

Override

C4.1.3

Stop

C4.1.4

Escape

C4.2.1

None

C4.2.2

Override

C4.2.3

Stop

C4.2.4

Escape

C4.3.1

Max = ___ in.

C4.3.2

2nd = ___ in.

continued on next page C4.4 1

Escape

= available on trucks equipped with height sensor only.

Crown 2000 PF11923-10 Rev. 9/00

M4.3–1650–114

Printed in U.S.A.

01 Rev. 9/00

M4.3–1650–114

CALIBRATION MENU

continued from previous page C51

Weight

Valves

Save?

C5.1

No Load

C5.2

____ lbs.

C5.3

Escape

C6.1

Main I = ❑

C6.1.1

I = ❑ (ma)

C6.2

Main G = ❑

C6.2.1

G=❑

C6.3

Accy I = ❑

C6.3.1

I = ❑ (ma)

C6.4

Accy G = ❑

C6.4.1

G=❑

C6.5

Escape

C7.1

Save? N

C7.2

Save? Y

continued on next page 1

=menu available on trucks with enhanced display only. Capacity data monitor (CDM) must be enabled (F9).

Crown 2000 PF11923-11 Rev. 9/00

M4.3–1650–115

Printed in U.S.A.

01 Rev. 9/00

M4.3–1650–115

Crown 2000 PF11923-12

M4.3–1650–116

Printed in U.S.A.

M4.3–1650–116

C1.3 (reverse) - move the multi task handle to the full speed reverse traction position and press . The menu will then return to the C1 menu level.

C4 Height (raise cutouts and maximum lift height)

C4.1 (R cut1) - this menu level permits programming a lift cutout. If more than one cutout is to be programmed, this level must be the lower lift height and must be performed at the "override" level (C4.1.2). C4.1.1 (none) select this level by pressing , if no cutouts are required. The menu will return to the C4.1 level. Next program the maximum lift height (C4.3). C4.1.2 (override) programs a lift cutout with override. Posi. tion the forks at the desired lift cutout height. Press Programming is complete and menu will return to C4.1. C4.1.3 (stop) programs a lift cutout without override. Posi. tion the forks at the desired lift cutout height. Press Programming is complete and menu will return to C4.1. if no C4.1.4 (escape) select this menu level by pressing changes are to be made.

Fork height must be below free lift before entering this menu.

M4.3–1650–117

Printed in U.S.A.

M4.3–1650–117

CALIBRATION

The approximate amount of current required to move the valve spools to a point that the port is about to open is the value in C6.1 "Main I" and C6.3 "Accy I" . Fine tuning of spool speed with maximum command is adjusted in C6.2 "Main G" and C6.4 "Accy G". . Menu advances to the submenu level. C6.1(main I) - press C6.1.1 (I) A current value may be etched in the hydraulic manifold or the nut on the end of the valve, shown in the illustration, which is the "main I" value. If a value is not present, enter 145. The current setting, if available, will be etched in one of these locations.

1 C

P V R 2 T

2 B

PVA

P C

C 4

A V

2 P

PVH

. Menu will

to return to the C5 menu level.

6491

Press

and scroll to next menu level.

Crown 2000 PF11923-14

M4.3–1650–118

and scroll to next menu level. Printed in U.S.A.

M4.3–1650–118

CALIBRATION

. Menu advances to the sub menu C6.3 (accy I) press level. C6.3.1 (I) enter the value etched in the nut on the valve end, if present, or enter 225. Press and scroll to the next menu level. Navigate to the A3.18 menu and monitor the steering/lift motor amperage (M2) while standing on the operator compartment pedals. Rotate the steering tiller and release. After the steering tiller is neutral, watch the display for at least 5 - 10 seconds and determine if the pump motor current stays above or below the steer idle threshold current level. Scroll to the C7 menu level and select the C7.2 menu level to save . the calibration values into truck memory and press

Model RR5010 RR5020, RR5060, RR5080 RR5060, RR5080 with 7.5" lift motors

Approximate Steer Idle Current Threshold 110 65 95

Crown 2000 PF11923-15

M4.3–1650–119

. Scroll to menu level C6.5 and

. Scroll to the C7 menu level and select the C7.2 press menu level to save the calibration values into truck memory . and press Calibration is now complete and the truck can be returned to operation.

Printed in U.S.A.

M4.3–1650–119

C Press the

FEATURES MENU

key to move right and left in the menu and allow system to accept changes to the features. Press the

and

to move up and down.

Features

Voltage = ___

F21 Pedals = ___

Hgt Encoder = ___

F1.1

A = 36 Volt

F1.2

b = 24 Volt

F2.1

A = 5 pedals

RR/RD 5000S

F2.2

b = 2 pedals

RR/RD 5000

F3.1

A = No

F3.2

b = Yes

Trk Wt = ___0

(With battery - From data plate)

Max Load = ___

(From data plate)

Reach = ___

Sideshift = ___

Tilt = ___

Listed on truck data plate.

Trucks equipped with height encoder

F6.1

A = None

F6.2

b = Single

F6.3

c = Double

F7.1

A = No

F7.2

b = Yes

F8.1

A = No

F8.2

b = Yes

continued on next page 1

= Menu available on 36 volt trucks.

Crown 2000 PF11923-16

M4.3–1650–120

Printed in U.S.A.

M4.3–1650–120

C continued from previous page

FEATURES MENU F91 Capacity = ___

F9.1

F9.2

Yes

F9.3

Zones = ___

F9.4

Height 1 = ___

F9.5

Weight 1 = ___

F9.6

Height 2 = ___

F9.7

Weight 2 = ___

F9.8

Height 3 = ___

F9.9

Weight 3 = ___

F9.10 Height 4 = ___ F9.11

Weight 4 = ___

- number of spaces filled in on capacity data plate. - first lift height on data plate. - first capacity on data plate. - second lift height on data plate. - second capacity on data plate. - third lift height on data plate. - third capacity on data plate. - fourth lift height on data plate. - fourth capacity on data plate.

F9.12 Escape F102 Productive = ___

F113 Hi Lift = ___

F12 Metric = ___

F10.1 A = No F10.2 b = Switch

trucks with productivity package.

F10.3 c = Capacity

trucks with CDM.

F11.1

A = No

F11.2

b = Yes

F12.1 A = No F12.2 b = Yes

F134 Brush/Temp = ___

F13.1 A = No F13.2 b = Yes

continued on next page 1

= menu available on trucks with enhanced display and height sensor. = 36 volt trucks with productivity package/CDM. 3 = available on 5000S only. 4 = menu available on trucks with enhanced display. 2

Crown 2000 PF11923-17

M4.3–1650–121

Printed in U.S.A.

M4.3–1650–121

C continued from previous page

FEATURES MENU

F141 Alarm = ___

F14.1 A = Off F14.2 b = Fwd

forks first direction

F14.3 c = Rev

power unit first direction

F14.4 d = Both F15 Bat Retain = ___

F15.1 A = No F15.2 b = Yes

F16 Fan = ___

- without battery retainer switch. - with battery retainer switch.

F16.1 A = No F16.2 b = Yes

F17 Speed Cut = ___

F17.1 A = No F17.2 b = Yes

F182 Dashboard = ___

F18.1 A = No F18.2 b = Timer

stop watch

F18.3 c = Wt/Ht

- view height (requires height sensor) and weight (requires CDM).

F18.4 d = Both F19 User Perf = ___

F19.1 A = No F19.2 b = Yes

enables ability for operator to select P1, P2, P3 performance levels.

continued on next page 1

= travel alarm.

= menu available on trucks with enhanced display.

Crown 2000 PF11923-18

M4.3–1650–122

Printed in U.S.A.

M4.3–1650–122

FEATURES MENU

continued from previous page

F20 User Codes = ___

F20.1 A = No F20.2 b = Yes F20.3 c = View

If F20 is "yes", then at least one Personal Identification Number is required. If F19 is "yes", any user can select any performance level.

F20.4 d = Add F20.5 e = Delete F20.6 f = Escape F21 Lockout = ___

F21.1 A = No

Truck lockout.

F21.2 b = Yes F221 Language = ___

F22.1 English F22.2 German F22.3 Italian F22.4 Spanish F22.5 French F22.6 Dutch

F23 Save?

F23.1 Save? N F23.2 Save? Y

Note: Do not operate vehicle during the "save" operation or values may get corrupted.

continued on next page

= Menu available with enhanced display only.

Crown 2000 PF11923-19

M4.3–1650–123

Printed in U.S.A.

M4.3–1650–123

C The feature menu is shown on the following pages. The first level of the menu shows the different areas of setup for the truck. Features Access

FEATURES SETUP F3.2

• F4

F1.1

F1.2

• F2

F2.1

F2.2

• F3

F3.1

Crown 2000 PF11923-20

M4.3–1650–124

08790

To enter a Trk Wt 13640 lbs, you would enter 1364. Standard Display Enhanced Display 1364

Press

13640

to access F5.

• F5

• F6

F6.1

F6.2

F6.3

Printed in U.S.A.

M4.3–1650–124

C • F7

F7.1

F7.2

• F8

F8.1

F8.2

• F9

F9.1

F9.2

F9.3

F9.4

F9.5

Sideshift = __ The current selection is displayed (“B” for trucks equipped with sideshifter, “A” for trucks not equipped with sideshifter). If selection is correct for truck, press to access F8. If selection is not correct, press to access F7.1. A = No On trucks not equipped with sideshifter, press . The display will return to the F7 menu. If truck is equipped with sideshifter, press to access F7.2. b = Yes Trucks equipped with sideshifter, press . The display will return to F7. Tilt = __ The current selection is displayed (“B” for trucks equipped with tilt, “A” for trucks not equipped with to tilt). If selection is correct for truck, press access F9. If selection is not correct, press to access F8.1. A = No On trucks not equipped with tilt, press . The display will return to the F8 menu. If truck is equipped with tilt, press to access F8.2. b = Yes Trucks equipped with tilt, press . The display will return to F8. Capacity = __ If truck is equipped with a capacity data monitor the display should show “B”. Trucks not equipped with capacity data monitor should be “A”. If message is correct, press to access F10. If message needs to be changed, press . A = No If truck is not equipped with capacity data monitor, press . Display will return to F9. If this is not the correct choice press to access F9.2. B = Yes On trucks equipped with capacity data monitor, press . Display will return to F9. Zones = __ Enter the number of zones. This number is the number of spaces filled in on the capacity data plate. When entered press . Height 1 = __ If the value displayed is not the first (highest) height listed on the capacity data plate, enter the correct value. Press . Weight 1 = __ If the value displayed is not the first (lowest) weight listed on the capacity data plate, enter the correct value. Press .

Crown 2000 PF11923-21

M4.3–1650–125

FEATURES SETUP F9.6

Printed in U.S.A.

M4.3–1650–125

C • F11

FEATURES SETUP • F14

F14.1

• F12

Metric = __ If message is “B”, a conversion of weight, height and speed measurements to metric units will be present in messages on the display. The message “A” will display measurements in U.S. units. If selection needs to be changed, press to access F12.1. F12.1 A = No When units of measurement are to be U.S., press at this menu level. The display will return to F12. To change units of measurement, press to access F12.2. F12.2 b = Yes Press if units of measurements displayed are to be in metric units. Display will return to F12.

F14.2

F14.3

F14.4

• F13

Crown 2000 PF11923-22

M4.3–1650–126

• F15

Printed in U.S.A.

M4.3–1650–126

C • F16

• F18

Crown 2000 PF11923-23

M4.3–1650–127

• F20

Printed in U.S.A.

M4.3–1650–127

• F22

F22.1

F22.2

F22.3

F22.4

FEATURES SETUP F22.5 French To select, press . Display will return to F22. For different language, press to access F22.6. F22.6 Dutch To select, press . Display will return to F22. • F23

Crown 2000 PF11923-24

M4.3–1650–128

Printed in U.S.A.

M4.3–1650–128

C Press the and H

HOUR METER MENU

key to move right and left in the menu and allow system to accept changes to the hour reset menu. Press the to move up and down. Hour

H1 Run = ___ H2 Travel = ___

H3 Lift 1 = ___

H4 Lift 2 = ___

H5 PM H• @ ___

H5.1

PM H1 = ___

H5.2

PM H2 = ___

H5.3

PM H3 = ___

H5.4

PM H4 = ___

H5.5

PM None = ___

H5.6

Escape

H6 Escape

continued on next page

Printed in U.S.A.

Crown 2000 PF11923-25 Rev. 9/00

M4.3–1650–129

01 Rev. 9/00

M4.3–1650–129

C Press the and L

LOG EVENTS MENU

key to move right and left in the menu and allow system to accept changes to the log events menu. Press the to move up and down.

Log Events

L1 History

L2 Totals

L3 Erase

Last =

___ @ ____

L-1 =

L-15 =

___ @ ____ • • • • • ___ @ ____

Event ___

= ____

Event ___

= ____

L3.1

L3.2

L3.3

Erase Hist

Erase All

L3.1.1

Sure? N

L3.1.2

Sure? Y

L3.2.1

Sure? N

L3.2.2

Sure? Y

Escape

L4 Escape

continued on next page

Crown 2000 PF11923-26

M4.3–1650–130

Printed in U.S.A.

M4.3–1650–130

C Press the

PERFORMANCE MENU

key to move right and left in the menu and allow system to accept changes to the performance menu. Press

the

and

Performance

to move up and down.

Setup P1

P1.1 Forward = __.__

P1.2 Reverse = __.__

P1.3 Accel = __.__

P1.4 Pump 2 = ____

P1.5 Lower = __.__

P1.1.1

Std = __.__

P1.1.2

Custom __.__

P1.2.1

Std = __.__

P1.2.2

Custom __.__

P1.3.1

Std = __.__

P1.3.2

Custom __.__

P1.4.1

Pump 2 = On

P1.4.2

Pump 2 = Off

P1.5.1

Std = __.__

P1.5.2

Custom __.__

P2.1.1

Std = __.__

P2.1.2

Custom __.__

P2.2.1

Std = __.__

P2.2.2

Custom __.__

P2.3.1

Std = __.__

P2.3.2

Custom __.__

P2.4.1

Pump 2 = On

P2.4.2

Pump 2 = Off

P2.5.1

Std = __.__

P2.5.2

Custom __.__

P1.6 Escape P2

Setup P2

P2.1 Forward = __.__

P2.2 Reverse = __.__

P2.3 Accel = __.__

P2.4 Pump 2 = ____

P2.5 Lower = __.__

P2.6 Escape continued on next page Crown 2000 PF11923-27

M4.3–1650–131

Printed in U.S.A.

M4.3–1650–131

C continued from previous page

PERFORMANCE MENU

Setup P3

P3.1 Forward = __.__

P3.2 Reverse = __.__

P3.3 Accel = __.__

P3.4 Pump 2 = ____

P3.5 Lower = __.__

P3.1.1

Std = __.__

P3.1.2

Custom __.__

P3.2.1

Std = __.__

P3.2.2

Custom __.__

P3.3.1

Std = __.__

P3.3.2

Custom __.__

P3.4.1

Pump 2 = On

P3.4.2

Pump 2 = Off

P3.5.1

Std = __.__

P3.5.2

Custom __.__

P3.6 Escape P4

BDI = ___

P4.1 Std = ___

BDI fine tuning.

P4.2 Custom = ___ P5

Plug = ___

P5.1 Std = ___ P5.2 Custom = ___

Drv Brake = ___

P6.1 Std = ___ P6.2 Custom = ___

Refer to section M5.0 brakes. Adjusts stopping distance.

continued on next page

Crown 2000 PF11923-28

M4.3–1650–132

Printed in U.S.A.

M4.3–1650–132

C continued from previous page

PERFORMANCE MENU

P71 Cas Brake = ___

P7.1 Std = ___ P7.2 Custom = ___

Accy > FLS = ___

P8.1 Std = ___

Controls accessory speed above free lift.

P8.2 Custom = ___ P9

Accy > 270" = ___

P9.1 Std = ___ P9.2 Custom = ___

Controls accessory speed above 270 inch (6.9 m) lift height.

P102 Trav> FLS = ___

P10.1 Speed = ___

Travel speed above freelift.

P113 Trav > 270" = ___

P11.1 Speed = ___

Travel speed above 270 inch (6.9 m) lift height.

P12 Coast = ___

P12.1 Std = ___

Adjusts regenerative braking during coast. (9 = soft, 1 = hard)

P12.2 Custom = ___ P13 Acc Ramp

P13.1 Std = ___ P13.2 Custom = ___

P14 Save?

P14.1 Save? N P14.2 Save? Y

continued on next page 1

= available on 5000S only.

= requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

= menu available on trucks equipped with height sensor only. Requires P1, P2 and P3 setups. Cannot be set higher than the lowest forward and reverse speed setting in P1, P2, P3 setups.

Crown 2000 PF11923-29

M4.3–1650–133

Printed in U.S.A.

M4.3–1650–133

C The first level of the menu shows the different areas of performance for this truck. The Features must be set prior to setting Performance since Features turns on and off certain Performance levels. Performance Access When powering up the truck, press and maintain on the display, then enter the service code. This enters service level two of Access 1 operation. Navigate to the P - Performance menu and press . The "•" marks the highest levels of the Performance (P) menu. • P1, P2, P3 performance: These represent three performance levels that may be selected when in the operator mode. When a PIN code is used (Personal Identification Number) any one of the three performance levels can be assigned to 25 different PIN codes. Performance settings affect truck performance. Refer to F18 and F19 in the features menu to activate. Any adjustment under each performance level can be higher, lower or the same as the adjustment under any other performance level e.g. traction speeds forward and reverse can be the same for all performance levels and the lower speed can be different for all performance levels. The factory set performance levels of P1, P2 and P3 are as follows: NOTE: Travel speed displayed does not account for the boosted speed when equipped with the productivity or CDM option. Therefore maximum travel speed for all speed settings can be up to .7 mph faster than displayed if the truck is equipped with these options and the right conditions exist. P1: set for the maximum achievable performance level. P2: reduced performance from the maximum level and is similar to the performance of the Model RR3500. P3: lowest performance setting of the three levels. • P1

Setup P1 Enter the parameters for the P1 performance level in this sub menu. Press to view/change the current P1 settings. Press to go to P2 setups.

Crown 2000 PF11923-30

M4.3–1650–134

PERFORMANCE SETUP P1.1

Printed in U.S.A.

M4.3–1650–134

Crown 2000 PF11923-31

M4.3–1650–135

PERFORMANCE SETUP • P2

M4.3–1650–135

P3.1

Crown 2000 PF11923-32

M4.3–1650–136

Printed in U.S.A.

M4.3–1650–136

PERFORMANCE SETUP The current settings will be displayed. Adjustment range for the BDI is 1-9. A setting of 1 will take the battery to its deepest discharge. A setting of 9 will decrease the level of discharge. To change/modify press . Press to go to P5 Plug.

P3.4

• P4

BDI = ______ This adjusts the electronic system incorporated in Access 1-2-3 that monitors the battery’s state of charge. Changing this setting will effect the battery discharge lift lockout level, which disables the lift circuit when the battery is discharged. Decreasing the P4 setting will reduce the volts per cell monitor level allowing the battery to go into deeper discharge prior to lift lockout. If the P4 setting is adjusted to a level that will permit battery discharge that is too deep, fault code 832 will be registered. (See fault code 832 description.) Increasing the P4 setting will increase the volts per cell monitor level disabling the lift function earlier in the discharge cycle.

Crown 2000 PF11923-33

M4.3–1650–137

NOTE: If this adjustment is set incorrectly, a fault code 832, indicating low battery voltage may result. P4.1

P4.2

• P5

P5.1

P5.2

• P6

P6.1

Printed in U.S.A.

M4.3–1650–137

C P6.2

• P7

P7.1

P7.2

• P8

P8.1

P8.2

Crown 2000 PF11923-34

M4.3–1650–138

PERFORMANCE SETUP • P9

P9.1

P9.2

• P10

Printed in U.S.A.

M4.3–1650–138

C • P11

• P12

Crown 2000 PF11923-35

M4.3–1650–139

PERFORMANCE SETUP • P13

Acc Pump This adjustment effects the ramp time of the accessory valve. Increasing this setting numerically makes the accessory hydraulic functions more reactive. A setting of 1 will provide smoother reaction, while a setting of 9 will be more reactive.

NOTE: Unsatisfactory accessory hydraulic performance could be the result of air trapped in the accessory circuit. Refer to section M2 for more information. • P14

Printed in U.S.A.

M4.3–1650–139

C U

Utilities

UTILITIES MENU

U1 Part Number

U2 Copy Setups

U3 Hour Set

U1.1

Access 1

______

U1.2

Access 2

______

U1.3

Access 3

______

U1.4

Software

______.___.__

U1.5

Escape

U2.1

From TCM

U2.2

From HCM

U2.3

Escape

U3.1

Run

U3.2

Travel

U3.3

Lift1

U3.4

Lift2

U3.5

Escape

U3.5.1

Save? N

U3.5.2

Save? Y

U4 Escape

Crown 2000 PF11923-36

M4.3–1650–140

Printed in U.S.A.

M4.3–1650–140

CALIBRATION Software Version 122676-001-06 RR/RD 5000/5000S SERIES The calibration menu is shown on the following pages. The first level of the menu shows the different areas of calibration for this truck. • C1 Trav Handle traction potentiometer (POT1) in the multi task control. • C2 R/L Handle raise/lower potentiometer (POT2) in the multi task control. • C3 Accy Handle accessory potentiometer (POT3) in the multi task control. • C4 Height raise cutouts (2 possible) and maximum height. Truck must be equipped with height sensor. • C5 Weight capacity data monitor (CDM). Truck must be equipped with enhanced display, height sensor and load sense transducer. F9 in the features menu must be enabled. • C6 Valves raise/lower (PVH) and accessory (PVA) electrical proportional valves. When to calibrate: • Access 1 replaced will require the load sense transducer (LS) to be calibrated. • Access 2 or Access 3 replaced will require the potentiometers in the multi task control to be calibrated. • any of the potentiometers or components used to mount or position potentiometers in the multi task control replaced. • the hydraulic manifold has been replaced without keeping the existing electrical proportional valves (PVH, PVA). • PVH replaced. • PVA replaced. • load sense transducer (LS) replaced. • status code instructions recommends recalibration of a specific component.

980615

5792 Printed in U.S.A.

Crown 1998 PF11442-1 Rev. 6/98

01 REV. 6/98

M4.3–1650–800

CALIBRATION Press the key to move right and left in the menu and allow system to accept calibration values. Press the to move up and down. 1

1.1

1.2

1.3

2.1

2.2

2.3

= q

3.1

= q

3.2

3.3

4.1

1 = q

and

4.1.1 4.1.2 4.1.3 4.1.4

4.2

2 = q

4.2.1 4.2.2 4.2.3 4.2.4

4.3

= q

4.3.1 4.3.2

= ___ 2

= ___

. .

4.4

Printed in U.S.A.

Crown 1998 PF11442-2 Rev. 6/98

01 REV. 6/98

M4.3–1650–801

CALIBRATION

5.1 5.2

____

5.3 6

6.1

6.1.1

= q (

6.2

= q

6.2.1

= q

6.3

6.3.1

= q (

6.4

= q

6.4.1

= q

)

6.5

7.1

7.2

C1.2 (center) - with the multi task handle in the neutral position, press . The menu will then move to the next menu level.

(

)

( 9).

Printed in U.S.A.

Crown 1998 PF11442-3 Rev. 6/98

01 REV. 6/98

M4.3–1650–802

CALIBRATION C2 R/L Handle (raise/lower request potentiometer - POT2) C2.1 (raise) - move the multi task handle to the full speed raise position and press . The menu will then move to the next menu level. C2.2 (center) - with the multi task handle in the neutral position, press . The menu will then move to the next menu level. C2.3 (lower) - move the multi task handle to the full speed lower position and press . The menu will then return to the C2 menu level. If no additional calibration procedures are to be performed, scroll to the C7 menu level, press and select the C7.2 menu. Calibration is complete and truck can be returned to operation. If additional calibration procedures are to be performed, scroll to the appropriate menu level and continue. C3 Accy Handle (multi task accessory function control thumbwheel) C3.1 (reach) - move the multi task thumbwheel to the full speed reach position and press . The menu will then move to the next menu level. C3.2 (center) - with the thumbwheel in the neutral position, . The menu will then move to the next menu level. press

C3.3 (retract) - move the multi task thumbwheel to the full speed retract position and press . The menu will then return to the C3 menu level. If no additional calibration procedures are to be performed, scroll to the C7 menu level, press and select the C7.2. Calibration is complete and truck can be returned to operation. If additional calibration procedures are to be performed, scroll to the appropriate menu level and continue. C4 Height (raise cutouts and maximum lift height) Fork height must be below free lift before entering this menu. C4.1 (R cut1) - this menu level permits programming a lift cutout. If more than one cutout is to be programmed, this level must be the lower lift height and must be performed at the "override" level (C4.1.2). , if no cutouts C4.1.1 (none) select this level by pressing are required. The menu will return to the C4.1 level. Next program the maximum lift height (C4.3).

C4.1.2 (override) programs a lift cutout with override. Position the forks at the desired lift cutout height. Press . Programming is complete and menu will return to C4.1. C4.1.3 (stop) programs a lift cutout without override. Position the forks at the desired lift cutout height. Press . Programming is complete and menu will return to C4.1. C4.1.4 (escape) select this menu level by pressing if no changes are to be made. C4.2 (R cut2) - this menu level permits programming a second lift cutout. This cutout must be at a higher lift height than C4.1. C4.2.1 (none) select this level by pressing , if this cutout is not required. The menu will return to the C4.2 level. Next program the maximum lift height (C4.3). C4.2.2 (override) programs a lift cutout with override. Position the forks at the desired lift cutout height. Press . Programming is complete and menu will return to C4.2. C4.2.3 (stop) programs a lift cutout without override. Position the forks at the desired lift cutout height. Press . Programming is complete and menu will return to C4.2. C4.2.4 (escape) select this menu level by pressing if no changes are to be made. C4.3 (max hgt) programs the maximum mechanical lift height of the truck (not to be used to limit lift height). C4.3.1 (max height) Raise forks until the mechanical stops are contacted measure actual fork height from top of fork to floor and enter, to the nearest inch, in this screen. C4.3.2 (2nd = lower) lower forks until display message changes to "stop". Measure fork height from top of fork to the floor and enter measurement, to the nearest inch, in this screen. Note: If HGTRS indicates mast is below staging, the message "Invalid" will be displayed meaning a valid calibration will not occur. C4.4 (escape) select this menu level by pressing to return to the C4 menu level. Raise cutouts can now be calibrated or must be re-calibrated if cutouts exist. If no additional calibration procedures are to be performed, scroll to the C7 menu level, press and select C7.2. Calibration is complete and truck can be returned to operation. If additional calibration procedures are to be performed, scroll to the appropriate menu level and continue.

Printed in U.S.A.

Crown 1998 PF11442-4 Rev. 6/98

01 REV. 6/98

M4.3–1650–803

CALIBRATION C5 Weight (calibration of load sense transducer [LS])

Press

When calibrating LS, the forks must be level with an accurate load weight and load center for the truck. Make sure load is 12 inches above the floor.

C5.1 (no load) - No load on forks. Press advance to next level.

. Menu will

to return to the C5 menu level.

and scroll to next menu level.

The current setting, if available, will be etched in one of these locations.

. Scroll to menu level C6.5 and

press . Scroll to the C7 menu level and select the C7.2 menu level to save the calibration values into truck memory and press .

1 C

T H

P 2

V R 2 T

PVA

P A

2 P

Calibration is now complete and the truck can be returned to operation.

PVH 6491

Printed in U.S.A.

Crown 1998 PF11442-5 Rev. 6/98

01 REV. 6/98

M4.3–1650–804

CONTACTOR

10554

The purpose of this information is to instruct the technician on proper care and maintenance to obtain satisfactory service from these devices. Crown has tested and applied these contactors according to the requirements of our vehicle. No modifications or changes should be made in the layout, physical arrangement or electrical connections without permission from Crown. CAUTION

Before any inspection, adjustments, servicing, parts replacement or any other act is performed requiring physical contact with the electrical working components or wiring of these contactors, disconnect battery, raise drive wheels clear of floor and place blocks under truck frame. Inspection

CONTACTS • In normal operation, the contacts will become blackened, discolored, and roughened. This will not interfere with proper operation and cleaning is not necessary. • The contacts should be replaced before the silver contact facing is completely eroded through to the backing material. The silver contact facing may transfer to either the moving or stationary contact and cause buildup on one contact. This can be expected under certain conditions and does not require contact dressing or filing. • It is recommended that contacts always be replaced in mating pairs. COIL

The following information is intended to assist during periods of normal maintenance and to provide checks for maintaining adjustments. As these devices are tested and adjusted at the factory, they should not normally require further adjustments. However, if factory adjustments are tampered with or otherwise changed, the checks contained in the following information may be made.

• Remove all electrical connections. • Resistance reading of the coil should be between 15 19 ohms. • If reading does not fall within the limits, replace.

Curtis-Albright

4236

Crown 1992 PF9313-1 Rev. 11/02

Printed in U.S.A.

02 REV. 11/02

M4.4–04.2–001

CONTACTOR CONTACT REPLACEMENT

Component Replacement Refer to Illustration 4.4-1 and parts breakdown in Parts Section of manual when replacing components. 4 1

1. Remove electrical connections to contacts (coils do not have to be disconnected for this procedure). 2. Remove two (2) screws (Index 4) from top of contacts and lift contact assembly from truck. 3. Disassemble and replace contacts.

4. Place contact assembly on coils and fasten securely with two (2) screws (Index 4). 5. Connect cables.

COIL REPLACEMENT 1. Disconnect all electrical wiring.

2. Remove four (4) mounting bolts from mounting bracket and lift entire contactor from truck.

3. Remove two (2) screws (Index 4) and separate contact assembly from coil assembly.

9 6

4. Select replacement coil and transfer plunger (Index 2) from coil being replaced to replacement coil. 5. Reassemble contact assembly to coil assembly and secure with two (2) screws (Index 4).

1158-01

6. Mount contactor on truck and reconnect all electrical wiring.

ILLUSTRATION 4.4-2

Crown 1992 PF9313-2 Rev. 11/02

Printed in U.S.A.

02 REV. 11/02

M4.4–04.2–002

MAINTENANCE 118396 CONTACTOR 24 Volt Emergency Disconnect ED The purpose of these instructions is to instruct the user on proper care and maintenance to obtain satisfactory service from these devices. Crown has tested and applied these contactors according to the requirements of our vehicle. No modifications or changes should be made in the layout, physical arrangement or electrical connections without permission from Crown.

DANGER Before any inspection, adjustments, servicing, parts replacement or any other act is performed requiring physical contact with the electrical working components or wiring of these contactors; disconnect battery, raise drive wheels clear of floor and place blocks under truck frame.

Inspection The following information is intended to assist during periods of normal maintenance and to provide checks for maintaining adjustments. As these devices are tested and adjusted at the factory, they should not normally require further adjustments. However, if factory adjustments are tampered with or otherwise changed, the checks contained in the following information may be made. CONTACTS In normal operation, the contacts will become blackened, discolored, and roughened. This will not interfere with proper operation and cleaning is not necessary. The contacts should be replaced before the silver contact facing is completely eroded through to the backing material. The silver contact facing may transfer to either the moving or stationary contact and cause buildup on one contact. This can be expected under certain conditions and does not require contact dressing or filing. It is recommended that contacts always be replaced in mating pairs. To inspect the normally closed (N.C.) contacts, manually push the contacts apart. Use an inspection mirror to inspect the contacts to the rear of the contactors. COILS

6079

ILLUSTRATION 4.4-1

Remove all electrical connections from coils. Resistance reading of the coils should be between 41.8 - 46.2 ohms. If reading does not fall within the limits, replace.

941031 Curtis - Albright

5662

Crown 1994 PF10321-1 Rev. 2/98

Printed in U.S.A.

01 REV. 2/98

M4.4–7330–001

MULTI TASK CONTROL RR/RD 5000 SERIES

The RR/RD 5000 utilizes a sequential multi task control handle that eliminates multiple hydraulic levers. The multi task control, for the right hand, gives the operator complete control of travel speed, direction, lift, lower, reach, side shift, tilt and horn functions. The multi task control is located at the top and in the center of the power unit; the console must be removed to perform maintenance on the multi task control. Four micro switches, two optic sensors, and three potentiometers are used in the multi task control on the RR/RD 5000 trucks.

Lubrication Refer to Illustration 1. Remove multi task cover and console. Tilt multi task handle down, and lubricate base as shown using silicon grease Crown part number 063002-020. The multi task handle should be lubricated every 500 hrs. or 90 days, whichever comes first.

4 3

5 35 7 EDS 6

34 10

19 20 POT 1

9 13

Lubricate

22 POT 2

11 CA611 17

12 CA612

15 14

21 19

16 FS

16 RS

Part of Power Unit Top Section

Black Yellow

24 27 SSS

27 TBS, TDS 29 26 25

27 HNS

30 POT 3

32 33 6835

ILLUSTRATION 1 5877

Crown 1998 PF11527-1

M4.5–1450–001

Printed in U.S.A.

M4.5–1450–001

C Replacement of Wire Harness in Handle Containing SSS, TBS, TDS, & HNS, or POT 3 1. Lower forks completely, turn key switch off and disconnect battery.

MULTI TASK CONTROL Replacement of POT 1 or POT 2 1. Lower forks completely, turn key switch off and disconnect battery. 2. Remove multi task control cover and console.

2. Remove multi task control cover and console. 3. Refer to Illustration 1. Remove four screws, index 33, and remove lower portion of handle, index 32. 4. Remove cable ties from dust cover as required if harnesses in handle are being replaced.

3. Refer to Illustration 1. Remove four screws, index 2 & 3 noting their positions. 4. Remove cable ties as required and use extraction tool 118993 to remove wires from connectors CA611 and CA612 noting their positions.

5. The wire harness containing HNS, SSS, TBS, & TDS, index 27, or POT 3 index 30, can now be removed from the handle and dust cover, depending on part(s) requiring replacement.

5. Replace POT 1 or POT 2 and route wiring as shown in Illustration 2.

6. Use extraction tool 118993 to remove wires from connectors CA611 or CA612, noting position of all wires removed.

7. Insert wires into connectors in proper positions.

7. Refer to Illustration 2. Route harness thru handle and dust cover as shown. Secure as indicated with cable ties part number 061003-002.

9. Connect battery and check multi task handle operation. If operating correctly, replace console and cover.

6. Use cable tie 061003-002 to secure wires as shown.

8. Reassemble handle to support.

8. Insert wires into connectors in proper positions. 9. Assemble and secure bottom section of handle. 10. Connect battery and check operation of multi task handle. If operating correctly, replace console and cover.

Crown 1998 PF11527-2

M4.5–1450–002

Printed in U.S.A.

M4.5–1450–002

MULTI TASK CONTROL 6828

Position Pot 3 With Terminal Side In Toward Upper Handle

Cable tie

1/4 in. 6 mm 1/8 in. (3 mm) Dia. Hole

Cable tie

Position Pot 3 With Terminal Side In Toward Upper Handle

3/16 in. 5 mm

Cable tie

Routing Original Handle Harness

Routing Shorter Handle Harness

Cable Tie Optic Sensor Black Wire Harness POT1 & POT2 Optic Sensor Yellow Wire Note: Keep Optic Sensor Wires Between Board and Support Routing Wiring for Resistors, Pot 1 & Pot 2, and Optic Sensors ILLUSTRATION 2 Crown 1998 PF11527-3

M4.5–1450–003

Printed in U.S.A.

M4.5–1450–003

BATTERY RR/RD 5000 SERIES The care and maintenance of the battery is very important to obtain efficient truck operation and maximum battery life. CAUTION

Gases produced by a battery can be explosive. Do not smoke, use an open flame, create an arc or sparks in the vicinity of the battery. Ventilate an enclosed area well when charging. Batteries contain sulfuric acid which may cause severe burns. Avoid contact with eyes, skin or clothing. In case of contact, flush immediately and thoroughly with clean water. Obtain medical attention when eyes are affected. A baking soda solution (one pound to one gallon of water) applied to spilled acid until bubbling stops, neutralizes the acid for safe handling and disposal. Leakage voltage from battery terminals to battery case can cause misleading trouble symptoms with the truck electrical system. Since components of the truck electrical system are insulated from truck frame, leakage voltage will not normally affect truck operation unless a short circuit or breakdown of circuit wire insulation to truck frame occurs. A voltage check from battery connector terminal to battery case should indicate near zero volts. Typically, however, the sum of the voltages at both terminals will equal battery volts. This leakage voltage will discharge the battery. As battery cleanliness deteriorates, the usable charge of the battery decreases due to this self discharge. Although a leakage voltage reading of zero volts may not be possible, a cleaner battery will have more usable charge for truck operation and not affect operation of electronic devices on the unit.

980131 Crown 1998 PF-11311-1

M4.6–1450–001

Safety Rules • Wear protective clothing, such as, rubber apron, gloves, boots and goggles when performing 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 lay metallic or conductive objects on battery. Arcing will result. • 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 manufacturer's instructions concerning repair practices and procedures. Checking Battery electrolyte level should be checked before each charge of the battery. The level should be maintained at onehalf inch above plates or just below the lower lip of the filler hole at all times. If low, add distilled water or approved local supply (consult battery manufacturer) at the end of a charge cycle. Do not overfill. For maximum battery life, specific gravity readings should be taken daily on a pilot cell and recorded. A different pilot cell should be selected on a monthly basis with readings taken on all cells at semi annual or annual intervals. Do not take specific gravity readings immediately after adding water. Water and electrolyte must be thoroughly mixed by charging before a reliable reading can be taken. Normal full charged specific gravity should be between 1.265 and 1.285.

5296 Printed in U.S.A.

M4.6–1450–001

BATTERY BATTERY CARE

CHARGING

Your Crown truck is powered by an electrical storage battery. Here are a few suggestions which will help you give the battery proper care.

Charging requirements will vary depending on use of truck. A battery with a specific gravity of 1.160 should be recharged. In some applications more than one battery is required to provide ample power to the unit during the service period.

The battery on your Narrow Aisle Stand-up Rider is located in front of the operator’s compartment.

CAUTION 1. Charge the battery only in areas designated for that use. 2. Make certain the charger being used matches the voltage and amperage of the truck battery. This voltage is listed on the truck serial plate. 3. Before disconnecting or connecting batteries to a charger, make sure the charger is “OFF”. If an attempt is made to do this while the charger is “ON”, serious injury to you, the battery and charger could result. 4. Before charging, make sure the battery cells contain the correct amount of water. Charging batteries with a low water level might result in damage to the cells. When checking water levels, never use a match or lighter. Battery fumes are explosive. 5. Before connecting the battery cable to the truck’s receptacle, make sure the key switch is off and all controls are in the off position and the brakes are locked. The battery cable must be fully connected before the truck is used. If the plug is not making good contact, heat will weld the two parts of the battery connector together, making it difficult to remove and necessary to replace. 6. Battery terminals should be checked and cleaned of corrosion regularly. Good battery terminal contact is essential not only for operation, but also for proper charging of the battery. 7. The charging requirements will vary depending on the use of the truck. The battery should be given an equalizing charge on a weekly basis. This charge should normally be an additional three hours at the finish rate. 8. Refer to charger manufacturer’s instruction for specific charging procedures. 9. Make certain battery used meets weight and size requirements of truck (refer to serial plate). NEVER operate truck with an undersized battery.

Crown 1998 PF-11311-2

M4.6–1450–002

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. Some of the basic rules are as follows: Placing battery on charge: — Park truck at charging station with forks lowered and key removed. — Make certain charger control is in the off position. — Connect battery to charger and make certain connectors are mated completely. — Set timer for specified time. Set for Normal (Daily Charge, except one night a week when the Equalize [Weekend] Charge should be used). — Check ammeter to make certain it shows charge. Removing battery from charge: — Make certain charger is turned off. — Unplug the connector, using both hands with a straight pulling motion. — Hang up the charger cable to prevent damage to the cable. (Broken connectors can cause poor connections and connector failures). — Make daily battery checks, add water as needed. — Connect battery to truck. Make certain connectors are mated completely.

Printed in U.S.A.

M4.6–1450–002

BATTERY BATTERY REMOVAL & INSTALLATION BATTERY REMOVAL

4. Position battery roller stand next to truck. Align stand with battery. Battery roller stand should be the same height as the truck’s battery compartment rollers and as long or longer than battery.

CAUTION

Don’t allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing, installing or transporting the battery. Use an insulator (such as plywood) to cover the top of the battery before and during removal and installation. 1. Turn key switch off. 2. Disconnect battery.

Roller Stand

Disconnect Battery 6256

5. Roll battery onto stand. Using approved spreader bar, lift and move battery to charging area. Spreader Bar

6220

3. Remove battery retainer (one side only).

Lift to Remove Retainer

6255 Crown 1998 PF-11311-3

M4.6–1450–003

Roll onto Stand

6257 Printed in U.S.A.

M4.6–1450–003

BATTERY BATTERY INSTALLATION

4. Using approved spreader bar, move battery onto roller stand and push battery into battery compartment.

CAUTION Spreader Bar

Push into Compartment

Lift to Remove Retainer

6260

5. Remove roller stand and install battery retainer.

6258

3. Position battery roller stand next to truck. Align stand with battery compartment. Battery roller stand should be the same height as the truck’s battery compartment rollers and as long as or longer than battery.

Install Battery Retainer

6261

6. Connect battery.

Roller Stand

Connect Battery

6259

6262 Crown 1998 PF-11311-4

M4.6–1450–004

Printed in U.S.A.

M4.6–1450–004

BATTERY 7. Turn key switch on and check truck operation. CAUTION

Make certain same battery or battery of equal weight is loaded into truck for truck stability. See nameplate for minimum battery weight. BATTERY CLEANING Always keep vent plugs tightly in place when cleaning battery. When properly watered and charged, the battery will remain clean and dry. All that is necessary is to brush or blow off any dust or dirt which may accumulate on them. However, if electrolyte is spilled or overflows from a cell, it should be neutralized with a solution of baking soda and water (one pound soda to a gallon of water). To do this, remove battery from truck and clean with the solution of soda and water, brushing the soda solution beneath the connectors and removing grime from the covers. Then rinse the battery with cool water from a low pressure supply to remove the soda and loosened dirt. If batteries stay wet consistently, they may be either overcharge or overfilled. This condition should be investigated and corrected. TROUBLESHOOTING Records of battery specific gravity readings, charger used, truck used, etc. can be the most effective troubleshooting aid. Contact your dealer for charts designed specifically for this purpose. Voltage readings of each cell taken at the normal charger finish rate also indicate battery condition. New batteries will have cell voltages ranging from 2.55 volts to 2.65 volts. Older batteries may however range from 2.45 volts to 2.55 volts. These readings still indicate a battery in good condition. A variation of .20 volts may be normal if certain cells are exposed to higher temperatures during discharge. Voltage differences that cannot be attributed to battery age or operating conditions indicate a weak cell(s) and maintenance is required. CAUTION

Only qualified and experienced personnel should perform maintenance and repair on batteries.

Crown 1998 PF-11311-5

M4.6–1450–005

Printed in U.S.A.

M4.6–1450–005

BRAKE SYSTEM There are two sources of drive wheel braking on the 5000 and 5000S series, a 3-step, spring applied, electromagnetically released, friction disc brake on the drive motor armature shaft and dynamic motor braking, typically called regenerative braking. The 5000S has additional braking in two, electromagnetically applied, friction disc brakes in the caster wheels. When a brake request is made by the operator (by releasing either of the two "left pedals" or by applying the "center pedal"), the "Access 3" microprocessor determines the amount of braking effort to be applied based on the known truck weight (includes battery and maximum allowable fork load) and the maximum allowable speed for the particular travel direction and fork height. The total braking effort is shared between the drive tire and caster tire (5000S only) based on the known weight distribution. The drive tire portion is further split between the motor regenerative braking and the 3-step friction brake. The motor regenerative portion is made as large as practical in order to reduce wear on the 3-step friction brake. The drive tire and caster tire brake effort can be further electronically adjusted through the performance menu (P6 and P7) in order to address tire slide for the particular floor condition in the application. STOPPING DISTANCE Before making changes in stopping distance, verify the actual truck stop distance as listed in chart 1. If it is determined that the truck no longer meets the required stopping distance, complete the following adjustments prior to programing the P6 and P7 functions of Access 1: • Articulation adjustment, refer to section M3.0. • Truck weight & maximum load, refer to F4 and F5 in section M4.3. Compare to data tag. • Drive brake torque gap adjustment, this section.

Model

RR5010 & RR5020 RR5020 with productivity package RR5060 & RR5080 RD5020 RD5020 with productivity package RD5060 & RD5080

CAUTION

The customer shall verify that the stopping distance in any part of the application doesn't prevent the operator from performing a specific task safely, or result in braking characteristics that are significantly different from other similar vehicles being used in the facility. An alternative is for the customer to train the operator to reduce travel speed and/or allow for longer stopping distances. To check stopping distance 1. Set the drive and caster brake performance values (Access 1), P6 and P7, to their default values of 6. 2. Travel with no load, on a level, smooth, dry, concrete surface, at maximum acceleration from zero to top speed in the forks first direction and apply brakes. Use Access 1 input menu, A2.24, to monitor truck speed in mph. 3. Verify the truck stops within the distance and from the maximum speed listed in the following chart with no caster tire slide and minimal drive tire slide. 4. To address tire slide for the floor condition in the application, Access 1 performance menu brake adjustments, P6 (drive brake) and P7 (caster brake) provide individual adjustment of the two brakes. These settings may be reduced if the standard setting results in tire slide in the application. If the floor conditions will accommodate a more aggressive braking force then these settings may be increased. These adjustments affect the brake force in both travel directions when the forks are below the free lift height.

Forks First Max. Speed mph kmh (+0.0/-0.1) (+0.0/-0.1) 5.7 9.2 6.5 10.5 6.7 10.8 5.7 9.2 6.5 10.5 6.7 10.8

Max. Stopping Distance feet meters 7.0 9.0 9.0 7.5 9.5 9.5

2.1 2.7 2.7 2.3 2.9 2.9

CHART 1

980131

7450

Crown 1998 PF11312-1 Rev. 2/04

M5.0–1450–001

Printed in U.S.A.

06 REV. 2/04

M5.0–1450–001

BRAKE SYSTEM DRIVE BRAKE Air Gap Adjustment The “air gap”, referred to on this truck, is the distance between the brake armature and the electromagnet body with brakes applied (see Illustration1). As the brake pads and rotor wear normally, the air gap will increase and should be readjusted, or parts checked and replaced, when it exceeds 0.040 in. (1.0 mm). NOTE If the air gap measures more than 0.040 in. (1.0 mm), the brake may not release properly. If the brake pad thickness is less than .110 in. (2.8 mm), the brake pads and rotor should be replaced.

3. To minimize the risk of possible damage to the encoder, remove encoder. 4. Loosen the 7/8" locknut. 5. Turn the 1-1/8" hex nut down until the air gap is .010 in. (.25 mm) at its tightest location. One complete turn of the nut will change the gap 0.056 in. (1.4 mm) or a 1/6 (60 deg.) turn will change the gap 0.009 in. (0.235 mm). 6. Torque the 7/8" locknut to 90 ft. lbs. (122 Nm).

1. Chock load wheels. Open power unit doors to access brake assembly. 2. Using low pressure air, remove any dirt between armatures and magnet body.

7. Install encoder. Apply blue thread locking adhesive (061004-026) to set screw. 8. After adjustment has been completed, remove chocks and check for proper operation.

3217

ILLUSTRATION 1

Crown 1998 PF11312-2 Rev. 6/98

M5.0–1450–002

Printed in U.S.A.

02 REV. 6/98

M5.0–1450–002

BRAKE SYSTEM Torque Gap Adjustment The “torque gap”, referred to on this truck, is the distance between the torque adjuster plate and the electromagnet (see Illustration 2). The torque plate is factory preset and no adjustment is required, however, through routine maintenance it may be necessary to replace components and the gap may need to be reset to factory specifications. The torque gap will vary with each trucks GVW. NOTE Refer to the capacity plate for truck GVW as equipped with maximum battery and capacity load.

3217

TORQUE GAP inch mm 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20

greater than 15350 lbs. 14650 - 15349 lbs. 13950 - 14649 lbs. 13200 - 13949 lbs. 12500 - 13199 lbs. 11800 - 12499 lbs. 11050 - 11799 lbs. 10350 - 11049 lbs. 9650 - 10349 lbs. 8900 - 9649 lbs. less than 8900 lbs.

ILLUSTRATION 2

Crown 1998 PF11312-3 Rev. 6/98

M5.0–1450–003

0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00

GVW (capacity load and max battery)

Printed in U.S.A.

02 REV. 6/98

M5.0–1450–003

BRAKE SYSTEM Brake Assembly Retaining Ring

Before assembling brake, inspect all components for wear, grooves, nicks or other damage. If any abnormal wear or damage appears that may affect brake operation, replace with new parts. Assemble brake as follows:

Flatwashers 1 1/8" Hex Nut

1. Turn torque adjuster plate down as far as possible to reduce spring force.

Brake Pad Plate Assembly

2. Apply a light coat of multipurpose grease (063002-024) to the motor end cap threads and on top of the torque adjuster plate. 3. Position the magnet body on the motor so the coil wires are positioned as shown in Illustration 3. Apply blue thread locking adhesive (061004-026) to the three 5/16 in. screws and secure magnet to motor with screws.

Outer Armature

4. Assemble springs, inner and outer armatures to magnet body. Apply a light coat of multipurpose grease (063002-024) to entire bottom of 119046 brake pad plate assembly. Be careful not to contaminate brake pads with grease. 5. Slip rotor on motor shaft, hub first. Thread 1-1/8" hex nut onto motor shaft. Turn the nut down until the rotor moves down and almost touches the brake pads. Proper air gap adjustment will be made later. 6. Thread the 7/8" hex nut onto motor shaft. Add flatwasher(s) and place retaining ring on motor shaft.

24 Volt Wire Position

7/8" Locknut

Rotor

Compression Spring

Inner Armature

Springs

36 Volt Wire Position

Magnet Body Torque Plate

7. Set torque adjuster gap to its original factory setting. See TORQUE GAP ADJUSTMENT procedures. 8. Connect wire harness to brake assembly. 9. Adjust air gap. See AIR GAP ADJUSTMENT procedures. 10. Check brake operation and stopping distance. See adjustment procedures in truck settings section of this manual.

6207-03

Crown 1998 PF11312-4 Rev. 1/99

M5.0–1450–004

ILLUSTRATION 3

Printed in U.S.A.

03 REV. 1/99

M5.0–1450–004

BRAKE SYSTEM Fan Shroud Installation ("EE" Trucks Only)

spacer inserted to mount rear shroud

After completion of brake installation and adjustment, install fan shroud as follows:

rear shroud

1. Temporarily place a 0.13 to 0.14 in. (3.3 to 3.5 mm) thick spacer plate on top of rotor fins to allow for proper clearence. drive motor

2. Mount back half of shroud with top inner face of shroud resting on spacer plate and make certain it rests evenly against spacer plate so shroud face is parallel with top of rotor fins. Refer to Illustration 4. 3. Tighten the shroud-to-motor mounting screws. 4. Remove the spacer from between the shroud and rotor. 6550

ILLUSTRATION 4

CAUTION

Failure to remove spacer can cause serious damage to the shroud and brake rotor assembly.

front shroud cover

5. Place the outer half of the shroud on the motor, routing the brake wire harness through grommet in shroud. Refer to Illustration 5. 6. Place a straight edge across top of both shroud halves and position outer shroud half so straight edge is flat across top of both halves when placed in any position. 7. Refer to Illustration 6 and check for a 1/32 in. (0.032 in./ 0.8 mm) maximum gap on top of shroud (between the two halves). 8. Tighten the shroud-to-motor and shroud-to-shroud mounting screws and recheck top gap.

6550

ILLUSTRATION 5

straight edge 0-0.032 in. (0-0.8mm)

6550

Crown 1998 PF11312-5 Rev. 1/01

M5.0–1450–005

ILLUSTRATION 6 Printed in U.S.A.

04 REV. 1/01

M5.0–1450–005

BRAKE SYSTEM Caster Brake

Friction Plate

Two Electromagnetically applied friction brakes are located in the caster wheel assembly. Caster brakes on all RR/RD 5000S Models are factory preset and no adjustments to componetry can be made. Refer to Stopping Distance in this section for detailed instructions on adjusting braking via Access 1.

Electromagnetic Brake Coil

Should a status code for the caster brake be shown, check for the minimum component thickness (Illustration 7). If the caster brake dimension falls below the minimum thickness of 1.1 inch (28 mm), replacement of both the friction plate and electromagnetic coil is required. 1.1 inch (28mm) Minimum Thickness 6684

ILLUSTRATION 7

Friction Plate

Electromagnetic Brake Coil

RR/RD 5000S Caster Wheel and Brake Assembly

6684

Printed in U.S.A.

Crown 1998 PF11312-6 Rev. 6/98

M5.0–1450–006

02 REV. 6/98

M5.0–1450–006

BRAKE SYSTEM Troubleshooting Problem

Probable Cause

Remedy

Brakes will not release

• Air gap more than 0.040 in. (1.0 mm)

Adjust

• Open circuit in brake circuitry or wiring

Check floorboard switches and all associated wiring

• Armatures movement restricted by dirt, foreign material

Clean with low pressure air

• Air gap less than 0.010 in. (0.25 mm)

Adjust

• Brake pad mounting plate or rotor distorted

Replace

• Armatures movement restricted by dirt, foreign material

Clean with low pressure air

• Incorrect stopping distance adjustment

Adjust(see P6/P7 Section M4.3)

• Brake pad mounting plates or rotor distorted

Replace

• Incorrect stopping distance adjustment

Adjust(see P6/P7 Section M4.3)

• Brake pads loose or soiled with grease

Replace

• Brake pad mounting plate or rotor distorted

Replace

• Brake pads worn out, loose, soiled with grease, foreign material embedded

Replace

• Rotor thin, cracked or spline worn

Replace

• Open circuit in brake circuitry or wiring

Check all switches and associated wiring

Brakes drag

Brakes grab

Stopping distance too long

Abnormal noise and chatter when brakes applied

Abnormal braking force for lift height or brakes applied without request

CHART 2

Printed in U.S.A.

Crown 1998 PF11312-7 Rev. 6/02

M5.0–1450–007

05 REV. 6/02

M5.0–1450–007

STEERING RR/RD 5000 SERIES Your truck is equipped with a hydraulic steering system. A hydrostatic steering control unit, located in the power unit, is coupled via hydraulic hoses to the steering motor, mounted on the drive carriage, used to actuate the steering.

Tiller

HYDROSTATIC STEERING UNIT The hydrostatic steering unit (open center non-reaction) mounts in the power unit below the steering tiller. The nonreaction unit maintains the steered position when the operator releases the steering tiller. The cylinder ports are blocked in the neutral valve position. The operator must steer the drive wheel back to the straight ahead position.

To Reservoir

The steering unit meters a proportional amount of oil to the steering motor when the tiller is rotated. This pressurized oil is supplied by the P1 pump, and is supplied to the appropriate side of the steering motor by the direction of rotation of the steer control unit via the steering tiller. When the steering tiller rotation is stopped the steer motor ports are blocked to hold the steering in that position. In the event that pump flow is stopped, the steer unit can be manually rotated to "pump" flow to the appropriate motor port by turning the steering tiller in the desired direction, thus allowing emergency steering.

Steering Control Unit

Part of Power Unit HYDRAULIC MOTOR - SEE SECTION 06.2

Steering Motor

Steer circuit relief pressure is non-adjusting and pre-set to 1,250 psi. Normal steering pressures are 400-600 psi.

P1 Lift Pump

FORWARD AND REVERSE STEERING The steering on your truck can be changed from forward steering to reverse steering by reversing the hydraulic lines at the steering motor. Care should be exercised when maintenance is performed on the steering system to return the truck to the proper steering mode upon completion.

Undercarriage

NOTE Prior to disassembly the service technician should determine the steer direction of the truck, upon completion of the maintenance, steer direction should be checked to insure that it is set for the desired direction and functioning properly.

6478 980131

Drive Unit 5662

Crown 1998 PF11319 Rev. 4/98

Printed in U.S.A.

02 REV. 4/98

M6.0–1450–001

STEER MOTOR RR/RD 5000/5000S SERIES

DISASSEMBLY Cleanliness is extremely important when repairing hydraulic motors. Work in a clean area. Before disconnecting hydraulic lines, clean port area of motor. Before disassembly, drain oil from motor. Then plug ports and thoroughly clean exterior of motor. Check output shaft, remove any burrs, nicks, or sharp edges.

End Cap Seal Geroler Cap Screw

Seal Spacer Plate Seal

Drive

6836S

ILLUSTRATION 1

TOOLS REQUIRED • Torque wrench, 300 in. lb. (34 Nm) capacity • Ratchet wrench • 5/16 in. – 12 point heavy duty socket, 500 in. lb. (56 Nm) capacity • 5/16 in. – 6 point/torx (E10) heavy duty socket, 500 in. lb. (56 Nm) capacity • Small flat blade screwdriver • 3/16 in. hex key • Rubber hammer

3. Unclamp motor and remove output shaft, thrust needle bearing, and thrust bearing race. See Illustration 2.

Output Shaft Thrust Bearing Race

1. Clamp motor in a vise so shaft is vertical and end cap is on top. Clamp on mounting flange, using just enough clamping force to securely hold motor. Use protective material on vise jaws.

Thrust Needle Bearing

2. Remove cap screws (7) from end cap and disassemble motor as shown in Illustration 1. Do not disassemble geroler. 6837S 981007 Crown 1998 PF11516-1

M6.2–1450–001

ILLUSTRATION 2 5416 Printed in U.S.A.

M6.2–1450–001

STEER MOTOR

4. Clamp motor in vise so mounting flange is on top. Clamp across port area. Do not clamp on motor housing. Use just enough clamping force to hold motor securely. 5. Remove cap screws (4) securing mounting flange to motor housing.

6. Remove mounting flange from motor housing. 7. Carefully remove exclusion seal, pressure seal and backup ring from mounting flange. A seal removal tool may be fabricated by bending and rounding the end of a small flat blade screwdriver, see Illustration 4. Be careful to not damage the mounting flange shaft bore.

Pressure Seal

CAUTION

Back-up Ring

Thread locking adhesive was applied to cap screws (4) during assembly. Do not exceed 500 in. lb. (56 Nm) of removal torque. Since thread locking adhesive was applied to screws, heat may have to be applied to motor housing to loosen screws. Refer to Illustration 3. Use propane torch and apply just enough heat to remove screws. Do not overheat motor housing or mounting flange.

Mounting Flange

Seal Removal Tool

Exclusion Seal

ILLUSTRATION 4

6839S

ASSEMBLY

Heat with a Propane Torch

Cap Screw

Pressure Seal

NOTE Always use new seals when assembling hydraulic motors. Lubricate new seals with clean petroleum jelly. Also, lubricate machined surfaces and bearings with clean hydraulic fluid.

Seal Back-Up Ring Exclusion Seal 6838S

Crown 1998 PF11516-2

M6.2–1450–002

Check all mating surfaces. Replace any parts with scratches or burrs that could cause leakage. Wash all metal parts in clean solvent. Blow dry with low pressure air. Do not wipe parts dry with paper towels or cloth. Lint in a hydraulic system will cause damage. Check spline and chamfered area of output shaft; remove any nicks, burrs, or sharp edges that could damage shaft seals during assembly.

Mounting Flange

1. Remove all thread locking adhesive from mounting flange cap screws and their threaded holes. Threads must be clean and dry before applying new thread locking adhesive. 2. Lubricate and install output shaft, needle thrust bearing, and bearing race into housing. Do not allow oil to enter cap screw threaded holes.

ILLUSTRATION 3

Printed in U.S.A.

M6.2–1450–002

STEER MOTOR

3. Lubricate exclusion seal and install in mounting flange. Illustration 5 shows correct seal orientation. Pressure Seal

Motor Timing 12. Align shaft timing dot with any bolt hole. Bolt hole will be used for timing reference.

Back-up Ring Mounting Flange

Geroler

Star Point Exclusion Seal

Timing Dot

Spacer Plate

ILLUSTRATION 5

6840S

Threaded Hole for Timing Dot Reference

4. Lubricate and install backup ring and pressure seal. Be sure exclusion seal and pressure seal are undamaged and properly seated. 5. Apply thread locking adhesive (061004-019) to mounting flange cap screw threaded holes in motor housing. NOTE Thread locking adhesive must cure completely before motor is put into service. Using primer reduces curing time. For curing time, refer to thread locking adhesive manufacturer instructions. 6. Install a protective sleeve over output shaft. Lubricate inner edges of exclusion and pressure seals. Lubricate and install the 1 15/16 in. (49 mm) diameter o-ring seal on mounting flange. Slide mounting flange over shaft. 7. Remove protective sleeve and install the four cap screws. Torque cap screws, in a crisscross pattern, to 250 in. lb. (28 Nm). Be sure output shaft remains in housing.

6841S

ILLUSTRATION 6

13. Install spacer plate, and note position of threaded hole in housing (aligned with timing dot on shaft). Be sure slots in spacer plate provide passage for hydraulic fluid as well as cap screws. If spacer plate is improperly installed (wrong-side-up), the motor will not operate. 14. Lightly stretch, lubricate and install the second of three large diameter seals in geroler. 15. Install geroler. 16. Align any star point with threaded hole (noted for location of timing dot), refer to Illustration 6.

8. Securely clamp motor in vise so output shaft is vertical and down. Clamp on mounting flange.

17. Rotate the geroler to align the screw holes.

9. Pour clean hydraulic fluid into motor to provide start-up lubrication.

18. Lubricate and install the last of the three large diameter seals in end cap groove.

10. Lubricate and install one of the three largest diameter seals in motor housing groove.

19. Install end cap and secure with cap screws (7). Torque cap screws, in a crisscross pattern, to 300 in. lb. (34 Nm).

11. Install drive. If splined ends of drive are different lengths, install longer end into shaft.

Crown 1998 PF11516-3

M6.2–1450–003

Printed in U.S.A.

M6.2–1450–003

STEER UNIT RR/RD 5000/5000S SERIES 1. Clamp unit in vise, gerotor end up. Clamp lightly on edges of mounting area, see Illustration 6.3-3. Use protective material on vise jaws. Housing distortion could result if jaws are overtightened.

Steer Unit

Gerotor End Relief Valve

ILLUSTRATION 6.3-1

5976S

RELIEF VALVE The steer unit includes a relief valve. This valve is preset to 1200 psi/8.27 MPa and is non-serviceable. For your reference, a sectional view of this valve is shown below. Backup Ring

Ball Spring Pin

O-Ring

5951S

ILLUSTRATION 6.3-3

2. Refer to Illustration 6.3-4 and remove end cap screws. Plug

Spring

Seat Poppet

3. Remove end cap.

Spring

ILLUSTRATION 6.3-2

5979

End Cap

DISASSEMBLY

Seal

Cleanliness is extremely important when repairing a steering control unit. Work in a clean area. Before disconnecting lines, clean port area of unit thoroughly. Remove foreign material and debris from around exterior joints of the unit.

Cap Screw

Although not all the following drawings show the steer unit in a vise, Crown recommends that you keep the unit in the vise during disassembly. Gerotor

TOOLS REQUIRED • Flat blade screwdriver • Ratchet wrench & 5/16 in. 6 point/torx (E10) drive socket • Torque wrench, 275 in. lb. (30 Nm) capacity • Plastic/rubber hammer • 1/4 in. hex key • #10-24 machine screw, 1.5 in. (40 mm) long • Needle nose pliers

5952S

ILLUSTRATION 6.3-4

The following tool is not necessary for disassembly and assembly, but is extremely helpful. • 125200 spring installation tool 980131 Crown 1997 PF-11130-1

M6.3–1450–001

5415 Printed in U.S.A.

M6.3–1450–001

STEER UNIT 4. Remove seal from gerotor. 5. Remove gerotor. Be careful not to drop star.

10. Remove housing from vise. Place housing on a clean soft cloth to protect surface finish. Remove retaining ring from housing, as shown in Illustration 6.3-7.

Gerotor Seal

Star Spacer Plate

5953S

ILLUSTRATION 6.3-5

6. Remove seal from spacer plate. 7. Remove drive.

ILLUSTRATION 6.3-7

5955S

11. Rotate spool and sleeve until pin is horizontal. Push spool and sleeve assembly forward with your thumbs just far enough to free gland bushing from housing, see Illustration 6.3-8. Remove bushing.

Spacer Plate Seal

Seal Gland Bushing

Drive Housing

5954S

ILLUSTRATION 6.3-6

Pin 8. Remove spacer plate. 5956S

ILLUSTRATION 6.3-8

9. Remove seal from housing.

Crown 1997 PF-11130-2

M6.3–1450–002

Printed in U.S.A.

M6.3–1450–002

STEER UNIT 12. Remove quad ring seal from seal gland bushing.

15. Remove spool and sleeve assembly from housing, see Illustration 6.3-11.

Quad Ring Seal Dust Seal Seal Gland Bushing

ILLUSTRATION 6.3-9

5957S

Spool & Sleeve Assembly

13. Remove dust seal from seal gland bushing. Do not damage bushing. 14. Remove both bearing races and the needle thrust bearing from spool and sleeve assembly.

5959S

Needle Thrust Bearing

ILLUSTRATION 6.3-11

CAUTION Do not bind spool and sleeve in housing. Rotate spool and sleeve assembly slowly when removing from housing.

Bearing Race

16. Push pin from spool and sleeve assembly.

Bearing Race 5958S

ILLUSTRATION 6.3-10

17. Push spool partially from control end of sleeve, then remove centering springs and spacers from spool carefully by hand, see Illustration 6.3-12. Springs & Spacers

5960S

Crown 1997 PF-11130-3

M6.3–1450–003

ILLUSTRATION 6.3-12

Printed in U.S.A.

M6.3–1450–003

STEER UNIT 18. Push spool back through and out of sleeve, see Illustration 6.3-12. Rotate spool slowly when removing from sleeve. 19. Remove seal from housing, see Illustration 6.3-13.

ASSEMBLY Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage. Clean all metal parts in clean solvent. Blow dry with low pressure air. Do not wipe dry with cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage. Do not use a coarse grit or try to file or grind these parts. NOTE

Seal

Lubricate all seals with clean petroleum jelly. Do not use excessive lubricant on seals for gerotor section. Refer to section 06.3 when ordering replacement parts.

5961S

ILLUSTRATION 6.3-13

1. Assemble spool and sleeve carefully so that the spring slots line up at the same end. Rotate spool while sliding parts together. Some spool and sleeve sets have identification marks, align these marks as shown in Illustration 6.3-14. Test for free rotation. Spool should rotate smoothly in sleeve with finger tip force applied at splined end. Spring Slot Sleeve Spring Slot Spool Identification Marks 5963S

Crown 1997 PF-11130-4

M6.3–1450–004

ILLUSTRATION 6.3-14

Printed in U.S.A.

M6.3–1450–004

STEER UNIT 2. Bring spring slots of both parts in line and stand parts on end of bench. Insert spring installation tool (part no. 125200) through spring slots of both parts. Insert one pair of spring spacers between two pairs of centering springs, refer to Illustration 6.3-15. Position springs and spacers on bench so that extended edge is down. In this position, insert one end of entire spring/spacer set into spring installation tool, as shown in Illustration 6.3-16, with spring and spacer notches facing sleeve.

4. Center the spring/spacer set in the parts so that they push down evenly and flush with the upper surface of the spool and sleeve. 5. Install pin through spool and sleeve assembly until pin becomes flush at both sides of sleeve.

Spring Spacers (2)

Pin 5966S

6. Position the spool and sleeve assembly so that the splined end of the spool enters the 14 hole end of housing first, see Illustration 6.3-18.

Springs (4) 5964S

ILLUSTRATION 6.3-17

ILLUSTRATION 6.3-15

125200 Installation Tool

5967SI

ILLUSTRATION 6.3-18

CAUTION

5965S

ILLUSTRATION 6.3-16

3. Compress extended end of centering spring/spacer set and push into spool sleeve assembly withdrawing installation tool at the same time.

Crown 1997 PF-11130-5

M6.3–1450–005

Be extremely careful that the parts do not tilt out of position while inserting. Push parts gently in place with slight rotating action, keep pin nearly horizontal. Bring the spool assembly entirely within the housing bore until the parts are flush at the 14 hole end of housing. Do not pull the spool assembly beyond this point to prevent the cross pin from dropping into the discharge groove of the housing. With the spool assembly in this flush position, check for free rotation within the housing by turning with light finger tip force at the splined end.

Printed in U.S.A.

M6.3–1450–005

STEER UNIT 7. Place housing on clean lint free cloth. Refer to Illustration 6.3-19 and install seal in housing.

Needle Thrust Bearing

9. Install dust seal in seal gland bushing, flat side must face down towards bushing, see Illustration 6.3-20.

Seal Gland Bushing

Bearing Race

Retaining Ring

Seal

ILLUSTRATION 6.3-20

5969S 5968S

ILLUSTRATION 6.3-19

8. Install 2 bearing races and the needle thrust bearing in the order shown in Illustration 6.3-19.

10. Install the quad ring seal in seal gland bushing. Smooth seal in place with your finger. Do not use any seal that falls freely into pocket of bushing. 11. Install seal gland bushing over the spool end with a twisting motion. Tap the bushing in place with a plastic/ rubber hammer. Make sure the bushing is flush against the bearing race. 12. Install retaining ring in housing. After installing ring, tap on ring end around entire circumference of ring to properly seat ring in groove. Screwdriver Retaining Ring

Dust Seal Seal Gland Bushing

Seal

Quad Ring Seal

5970S

Crown 1997 PF-11130-6

M6.3–1450–006

ILLUSTRATION 6.3-21

Printed in U.S.A.

M6.3–1450–006

STEER UNIT 13. Clamp housing in vise, as shown in Illustration 6.3-22. Clamp lightly on edges of mounting area. Do not over tighten jaws.

16. Rotate spool and sleeve assembly until pin is parallel with port face, see Illustration 6.3-24. Install drive, be sure you engage drive with pin. To assure proper alignment, mark drive as shown in Illustration 6.3-26. Note relationship between slotted end of drive to splined end of drive when marking.

Port Face

Drive

Pin Parallel with Port Face

ILLUSTRATION 6.3-22

5971SI

Pin NOTE Check to insure that the spool and sleeve are flush or slightly below the 14 hole surface of the housing.

5973SI

ILLUSTRATION 6.3-24

17. Install seal in spacer plate.

Seal CAUTION Clean the upper surface of the housing by wiping with the palm of clean hand. Clean each of the flat surfaces of the meter section parts in a similar way when ready for reassembly. Do not use cloth or paper to clean surfaces. Spacer Plate

14. See Illustration 6.3-23. Install seal in housing.

Spacer Plate 5974S

ILLUSTRATION 6.3-25

Seal

5972S

ILLUSTRATION 6.3-23

15. Install spacer plate. Align bolt holes in spacer plate with tapped holes in housing.

Crown 1997 PF-11130-7

M6.3–1450–007

Printed in U.S.A.

M6.3–1450–007

STEER UNIT 18. With seal groove side of gerotor facing up (opposite spacer plate), align star valleys (ref. A) on drive (ref. B). Note the parallel relationship of reference lines A, B, C, and D - Illustration 6.3-26. Align bolt holes without disengaging gerotor from drive. Star Valley

19. Install seal in gerotor. End Cap Seal

Cap Screw

Drive (Marked)

Gerotor C D 5952S

ILLUSTRATION 6.3-27

20. Install end cap on gerotor, align holes. 21. Install 7 dry cap screws in end cap. Torque all screws to 100 to 150 in. lb. (11 to 17 Nm) evenly, then final torque to 235 in. lb. in sequence shown below.

6 1

Pin 5975S

2 3

Port Face

7 5

ILLUSTRATION 6.3-26 5917S

Crown 1997 PF-11130-8

M6.3–1450–008

ILLUSTRATION 6.3-28

Printed in U.S.A.

M6.3–1450–008

MAST RR/RD 5000/5000S SERIES

TORQUE REQUIREMENTS • The four 3/4 in. diameter bolts that fasten the lower portion of the power unit to the main frame base plate must be tightened to 225 - 250 ft. lbs. (305 - 340 Nm). • The two 5/8 in. diameter bolts that fasten the upper portion of the power unit to the main frame must be tightened to 165 - 185 ft. lbs. (225 - 250 Nm). • The four 5/8 in. diameter bolts that secure the removable load wheel assemblies to the main frame outriggers must be tightened to 165 - 185 ft. lbs. (225 - 250 Nm). 0337P

FORK ADJUSTMENTS

I-BEAM SHOULD ONLY SHOW WEAR HERE

• With the forks completely lowered and level, adjust so that the top surface of the fork tip is a maximum of 2.5 in. (65 mm) from the floor. • The maximum fork height (raised) is to be within +/– 1.00 in. (+/– 25 mm) of the fork height specified on the truck data plate. MAST TESTING (ASSEMBLED) 1. Inspect each channel for the roller tracking path. The only area that should show wear is the back portion of the I-beam where the roller rides. See Illustration 7-1. The I-beam should not show signs of any cutting or grooving. If grooving or cutting is evident, it will normally take place at the side of the roller; .375 in. (10 mm) from the channel face. If this type of wear is evident, a shim will have to be removed. 2. Once a readjustment has been made by removing or adding shims, a recheck of the mast channel will be required. To see the new wear pattern, clean the channel with a solvent that will remove the lubricant and then wipe with a cloth. Spray the channel with a thin coat of paint. This will allow a visible indication of where the rollers are riding. Repeat as required. 3. Once the mast meets requirements, lubricate mast with grease, Crown No. 063002-024 for standard or 063002-017 for freezer/corrosion application. When the mast is raised near full extension, it should not lean right or left; instead it should appear even and straight. If a leaning condition exists, it is a sign that the shimming is to loose or unbalanced and will need to be adjusted.

ILLUSTRATION 7-1 FLAKING It is not uncommon for a new mast to appear as if it is flaking or peeling. This appearance is an indication that the rollers are seating to the mast channel and is considered normal. Eventually, this condition will disappear. The grease applied to the channel will retain these particles. MAST STAGING BUMPER REPLACEMENT 1. Reference Illustration 7-2. 2. Raise mast and replace bumper, index 53. 3. Lower mast and check to be sure mast bumpers contact their stops at the same time. Adjust by adding or removing shims as required. Use shim 060030-277 (0.031 in. 0.8 mm thick). 4. Apply thread lock adhesive to bumper screws and tighten. MAST DAMPENING SCREWS The mast dampening screws are located at the bottom of the main frame, top and bottom of the second stage mast and at the top of the third stage mast. ADJUSTMENT: 1. Refer to Illustration 7-2. Lower mast completely. 2. Adjust mast dampening screws, index 56, in until they just touch the mast roller directly behind each screw. Apply thread lock adhesive to the screws.

980131

6564

Crown 1998 PF11327-1 Rev. 5/00

Printed in U.S.A.

04 REV. 5/00

M7.0–1450–001

MAST 64 56 24

25 24 21

14 15

18 17

22 22 19 13

C 79

42 ECR2 40 78 41 13

13 13

24 34 35 36

65 35

36 84

38 39

62 55

24 33 25 26 30 32 23

21 28

16 20

8 10 9 11 12

44 7

34 35 36

82 81 HGTS12 2

3 5000S Series

3 56

3 5000 Series

Part of Power Unit 3 1

13 63

38 39

48 49 50

58 51

60 72 73

52 53

Cover Used on Trucks With a Collapsed Height of 131 in. 3325mm or More

69 FLS

76 13

B For Switch HGTRS - See Section 01.2

8138

71 36

ILLUSTRATION 7-2

Crown 1998 PF11327-2 Rev. 5/00

Printed in U.S.A.

04 REV. 5/00

M7.0–1450–002

MAST

DISASSEMBLY 1. Extend reach assembly, disconnect and remove battery.

12. Remove height sensor, cable, spring and bracket, index 59, 78, 79 & 83. Or remove height switch, index 81.

2. Remove load backrest and forks from carriage.

13. Connect hoist to top cross brace of second stage mast. Raise slightly, remove screw and nut, index 46 & 47, that secure lift cylinder rams to second stage mast. The seals at the top of the lift cylinders can be replaced if required.

3. Remove safety shield. 4. Refer to Illustration 7-2. Connect hoist to carriage assembly and raise to get slack in chains. Remove yoke and chains, index 64 & 65, from free lift cylinder. The seals at the top of the free lift cylinder can be replaced if required.

14. Raise second stage mast until stop block on main frame can be accessed thru hole at bottom of second stage mast. Remove stop block, index 7 thru 12, from main frame.

NOTE 15. Raise and remove second stage mast from top of main frame. Lay second stage mast on floor.

The reach assembly can be kept in an upright position much easier if it is extended. Block pantograph to prevent premature retraction. 5. Unhook chains, control cables and hydraulic lines from carriage assembly and lower carriage to floor. 6. Connect hoist to top crossbrace of third stage mast and raise until reach assembly can be slid forward to clear mast. Lower mast to collapsed position.

16. Most repairs can be completed without removing the lift cylinders, however if their removal is required remove cross tube from left lift cylinder and from right hydraulic tube on right lift cylinder. Use container to catch oil. 17. Remove right hydraulic tube from right lift cylinder and from main frame. Use container to catch oil. 18. Use cylinder clamp or braided strap around left lift cylinder just below anchor block and connect to hoist.

7. Removal of free lift cylinder. a. Remove guard, index 60.

19. Remove cotter pin and clevis pin, index 43 & 44.

b. Remove hydraulic tube from free lift cylinder. Have container in position to catch oil from cylinder.

20. Remove left lift cylinder from main frame.

c. Use cylinder clamp or braided strap around cylinder just below chain anchor and connect to hoist. d. Remove clamps, index 62, holding free lift cylinder and remove cylinder. 8. Secure hoist to third stage mast and raise to obtain slack in chains.

21. Repeat procedure, steps 20 thru 22, to remove right lift cylinder. If the amount of overhead room will not allow the masts to be raised enough for removal, the mast assembly will need to be unbolted from the power unit and laid down. The following procedure should be followed if removal from the power unit is necessary. 1. Refer to Illustration 7-2, disconnect and remove battery.

9. Remove guides, index 14, 15, 40, 41 & 57, from lift cylinders, right and left hand sides. 10. Remove control cables, hydraulic lines, chains and pulleys from top of second stage mast and bottom of third stage mast. Note position of all components, right and left hand sides are different. 11. Use hoist to lift third stage mast out top of second stage mast. Lay third stage mast on floor.

2. Remove load backrest, forks and carriage assembly. Refer to previous disassembly procedure. 3. Remove safety shield and overhead guard. 4. Disconnect cables and hydraulic lines from power unit to mast assembly. Use container to catch hydraulic fluid.

Crown 1998 PF11327-3 Rev. 6/98

Printed in U.S.A.

02 REV. 6/98

M7.0–1450–003

MAST

5. Raise the rear of the truck enough to get a 4x4x36 in. (100x100x900 mm) hardwood block under the base plate of the power unit and the base plate of the mast assembly. This block should carry the weight of the power unit and the mast assembly when the mounting bolts are removed. The block is positioned parallel with the base plates.

1. Refer to Illustration 7-2. Use cylinder clamp or braided strap around right lift cylinder just below anchor block and connect to hoist.

6. Loosen the four 3/4 in. bolts at the base plate.

3. Using hoist lift and position left lift cylinder in main frame. Secure to main frame with clevis pin and cotter pin, index 43 & 44.

7. Attach hoist to the top of the main frame: raise just enough to take the weight off of the hardwood block.

2. Lift and position right lift cylinder in main frame. Secure to main frame with clevis pin and cotter pin, index 43 & 44.

4. Connect right hydraulic tube to right lift cylinder. 8. Remove the two 5/8 in. bolts at the top of the power unit. The weight of the power unit and mast assembly should be on the hardwood block at this time. 9. Remove the four 3/4 in. bolts across the base of the power unit. 10. Roll the mast assembly away from the power unit. 11. Move the mast assembly to an area large enough to allow the mast to be laid down and disassembled. 12. Lower the mast assembly, with the outriggers up, very carefully. Keep the hoist directly over the top of the main frame while lowering to prevent the base plate from sliding on the floor. 13. Refer to the disassembly procedures in this section at this time if further disassembly is required. NOTE With the mast assembly laid down, the cylinder and mast assemblies must be removed by making all hook ups with the hoist as near the center of the assembly as possible to maintain balance. ASSEMBLY NOTE Before assembly, refer to torque requirements, fork adjustment and mast staging procedures located in the first part of this section.

5. Install left cross tube to left lift cylinder and right tube. 6. Clean column roller studs at the top of the main frame and bottom of second stage mast. If any paint or rust is evident on the studs, remove with emery cloth and lubricate with grease, Crown No. 063002-024 for standard or 063002-017 for freezer/corrosion application. 7. Put two (2) shims on each of the four studs, two at the top of the main frame and two at the bottom of the second stage mast. Use shim 060030-085 on RR 3500 lb. capacity mast, or shim 060030-130 on RR 4500 lb. and RD 3000 lb. capacity masts. Place one roller on each stud. 8. Attach hoist to top cross member of second stage mast, lift and assemble second stage into main frame. 9. Once the mast has been reassembled, the column rollers ride and clearance should be checked. 10. Use hoist to raise second stage mast so that the rollers are about 6 to 8 in. (150 to 200 mm) below the mounting holes for the stop block, index 8, in the main frame. 11. Use a pry bar to shift the mast channels to one side, then pry on the opposite side to shift it against the other side, then go back and pry on the original side to shift it back again. This will seat the rollers and force the opposite side tight against the mast channel. This is necessary to allow for accurate roller to channel clearance measurement. Once the mast has shifted, retain light pressure to hold the mast from slipping back.

WARNING

CAUTION

Wear appropriate safety items, such as safety glasses and shoes, whenever performing maintenance work. To avoid injury, do not place fingers, hands, arms or feet through mast or position them at pinch points.

Always block masts when working on masts in an elevated position, even though connected to a hoist.

Crown 1998 PF11327-4 Rev. 6/98

Printed in U.S.A.

02 REV. 6/98

M7.0–1450–004

MAST

12. Measure the distance between the channel and the roller, about 3/8 in. (10 mm) from channel face. Always measure from the side the rollers are canted toward. If the dimension is greater than .031 in. (0.79 mm) add another shim behind the roller. If the dimension is less than .030 in. ( 0.76 mm) and it does not appear to be tight, proceed in checking the remaining channel rollers. Lower the second stage and check running clearance. If shims need to be added, remove second stage mast, add shims as required, and install second stage mast back into main frame.

22. Use a pry bar to shift the third stage mast channels to one side, then pry on the opposite side to shift it against the other side, then go back and pry on the original side to shift it back one more time. This will seat the rollers and force the opposite side tight against the second stage mast channel. Once the mast has been shifted, retain light pressure to hold the mast from slipping back.

13. Accurate measurements can only be checked from one side. Once the previously described dimensions are obtained, the mast channel rollers for the second stage to main frame will be within tolerance. When shims are installed it is always ideal to have an equal number of shims on each column roller stud. If an unequal number of shims is required, it is very important that an equal distribution of shims per side be followed. Example, see Illustration 7-3.

1 Shim (Carriage)

2 Shims (Carriage)

1 Shim (Mast)

2 Shims (Mast)

14. Brush grease on main frame and second stage rails, use Crown No. 063002-024 for standard or 063002-017 for freezer/corrosion application. 15. Raise second stage mast until access hole in mast channel is aligned with stop block mounting holes.

CORRECT

16. Refer to Illustration 7-2. Assemble stop blocks, index 7 thru 12 , to main frame, apply thread lock adhesive to screws.

1 Shim (Carriage)

2 Shims (Carriage)

17. Secure tops of the cylinders to the brackets on the second stage mast using the 1/4 in. screw and nut, index 46 and 47. 18. Assemble height switch, index 81, or height sensor, cable, spring and bracket, index 59, 78, 79 & 83, to mast.

2 Shims (Carriage)

2 Shims (Mast)

1 Shim (Mast) T

EC RR CO IN

19. Put two (2) shims on each of the four studs, two studs at the top of the second stage and two studs at the bottom of the third stage mast. Use appropriate shims as indicated in step 7 of Assembly. Place one roller on each stud.

1 Shim (Carriage)

2 Shims (Mast)

1 Shim (Mast)

20. Attach hoist to top cross member of third stage mast, lift and assemble third stage mast into second stage mast. 21. Use a hoist to raise third stage mast so that rollers are about 12 to 16 in. (300 to 400 mm) below the rollers at the top of the second stage mast.

INCORRECT 6534

Crown 1998 PF11327-5 Rev. 3/99

ILLUSTRATION 7-3 Printed in U.S.A.

03 REV. 3/99

M7.0–1450–005

MAST

23. Measure the distance between the channel and the roller as described in step 12. If shims need to be added, remove third stage mast and install shims as required. Install third stage mast back into second stage mast and check running clearances. 24. Brush grease, Crown No. 063002-024 for standard or 063002-017 for freezer/corrosion application, on second and third stage rails. 25. Assemble lift chains and chain pulleys to the second stage mast.

12 6 13

26. Connect lift chains to third stage mast.

27. Refer to Illustration 7-4. Assemble hydraulic hoses and pulleys, index 6 & 7, to second stage mast.

NOTE: Index 8 Thru 13 - Used Only When Truck is Equipped With Load Sensing & Freezer Condition Options

16 6329

6 7

11 12 13

BA To Ports A&B On Manifold

To Port C1 On Manifold

A B

To Ports 13 A & B On 14 15 Reach Manifold

ILLUSTRATION 7-5

30. Refer to Illustration 7-2. Lower mast completely. Use cylinder clamp or braided strap and put just below chain anchor bracket on free lift cylinder, connect to hoist.

A A

31. Install free lift cylinder to third stage mast, make hydraulic connections and secure using two “U” bolts, index 62. 32. Install two (2) shims and one roller on each of the four studs on the reach assembly. Use appropriate shims as indicated in step 7 of Assembly. 33. Attach hoist to top cross brace of third stage mast. Raise mast and position reach assembly under third stage mast and lower mast over reach assembly.

2 6328

ILLUSTRATION 7-4

28. Refer to Illustration 7-2. Assemble hose guides, index 14, 15, 40, 41 & 57, to lift cylinders, right and left hand sides.

34. Attach hoist to reach assembly and raise reach assembly up mast about 60 in. (1525 mm). Check fit of reach assembly in third stage mast with pry bar to determine if it is tight. Continue to raise the reach assembly up the mast and check fit two or three more times as it is raised.

29. Refer to Illustration 7-5. Install control cable(s) and pulley(s) on second stage mast.

Crown 1998 PF11327-6 Rev. 3/99

Printed in U.S.A.

03 REV. 3/99

M7.0–1450–006

MAST

35. Raise until the top roller of the reach assembly is about 12 in. (300 mm) below the top of the third stage mast. Use a pry bar to shift the reach assembly to one side, then pry on the opposite side to shift it against the other side, then go back and pry on the original side to shift it one more time. This will seat the rollers and force the opposite side tight against the third stage mast channel. Once the reach assembly has been shifted, retain light pressure to hold the reach assembly from slipping back. 36. Measure the distance between the channel and the roller as described in step 12. Lower the reach assembly and remove from mast if shims need to be changed. Install reach assembly back into third stage mast and check clearances. 37. Brush grease, Crown No. 063002-024 for standard or 063002-017 for freezer/corrosion application, on third stage rails. 38. Attach free lift chains to reach assembly. 39. Install yoke on top of free lift cylinder, route free lift chain back to mast, connect to mast. 40. Refer to Illustration 7-4. Make connections of reach hoses to third stage mast, route thru yoke and make connections to reach assembly. 41. Refer to Illustration 7-5. Install control cable grip springs and harness clamps to third stage mast, route control cable(s) thru yoke and make connections to reach assembly. 42. Refer to Illustration 7-2. Assemble guard, index 60, over hydraulic tubes. 43. Install load backrest and forks to carriage. 44. Install safety shield 45. Remove hoist, install battery and check truck operation.

CAUTION

Be sure all stops and safety devices are in place before cycling mast to check for proper operation.

Crown 1998 PF11327-7 Rev. 3/99

Printed in U.S.A.

03 REV. 3/99

M7.0–1450–007

CYLINDERS RR/RD 5000/5000S SERIES CYLINDER REMOVAL Right & Left Hand Lift

WARNING

The right or left hand lift cylinder can be removed from the truck and replaced as described below. DO NOT try to remove both cylinders at the same time, one cylinder should be removed and replaced completely before the second cylinder removal is started. 1. Move truck to service area on level floor below hoist, if available, chock wheels and remove forks.

WARNING

Make sure the platform the maintenance person rides on is secure and the individual is using an operator harness 5. Connect battery, turn key switch ON, raise mast and remove blocking. 6. Raise mast sufficiently to block at 4 ft. ( 1220 mm) if the truck has a collapsed height of 89 or 95 in. (2260 or 2413 mm), or at 6 ft. (1830 mm) if the trucks collapsed height is 107 in. (2720 mm) or above. Use hardwood blocks, one beneath each I-beam of the second stage mast, resting on the lower main frame cross brace, securely clamp both blocks in place. See Illustration 2. Lower mast completely. The right and left hand lift cylinders will be defined as viewed from in front of the forks.

Make sure lifting device is sufficiently rated to lift various parts of the mast sections either individually or as a group. Make sure that the blocking material is strong enough to withstand the weight. Never work under or around a truck that is not properly blocked.

Left Lift Cylinder

Right Lift Cylinder

2. Using two 4 x 4 x 12 in. (100 x 100 x 305 mm) hardwood blocks, raise and block second stage mast 12 in. (305 mm) above bottom cross brace of main frame. Lower mast completely. 3. Turn key switch OFF and disconnect battery. 4. Remove screw holding ram to mount at top of 2nd stage mast. Do not remove screw from both cylinders, only the one that is going to be removed from truck. Refer to Illustration 1.

Main Frame Cross Brace

2nd Stage Cross Brace

Remove Screw

3rd Stage Cross Brace

8161P 980131

ILLUSTRATION 1

8162P

6577 Printed in U.S.A.

Crown 1997 PF11305-1 Rev. 5/00

M8.0–1450–001

ILLUSTRATION 2

02 REV. 5/00

M8.0–1450–001

CYLINDERS 7. Wrap and secure a large chain around the 2nd stage cross brace and the third stage cross brace as shown in Illustration 2 as a safety precaution. When removing a lift cylinder, one of the two mast chains must also be disconnected, leaving the remaining mast chain holding the third stage mast in position.

10. Unplug height sensor and move wires to side. Remove chain anchor from main frame mount and drape over cross brace. See Illustration 4.

Height Sensor

8. Turn key switch OFF and disconnect battery. Remove console and open Manual Lowering Valve (MVL) on manifold block to relieve system pressure, see Illustration 3.

Chain Anchor

MVL - Manual Lowering Valve

Chain Anchor ILLUSTRATION 3

7815P

WARNING

AVOID HIGH PRESSURE FLUIDS—Escaping fluid under high 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 could eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.

8163P

11. Remove hose guide at top of lift cylinder. See Illustration 5.

Hose Guide

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 damage may occur. Medical attention should be sought immediately by a specialist who has had experience with this type of injury. 9. Place a shallow pan beneath the main frame and below the cylinder to be removed. Remove hydraulic line from bottom of cylinder. Cap cylinder fitting and line fitting to prevent contamination of hydraulic fluid, to protect fittings from damage, and to help contain hydraulic fluid.

8164P

ILLUSTRATION 5 Printed in U.S.A.

Crown 1997 PF11305-2 Rev. 5/00

M8.0–1450–002

ILLUSTRATION 4

02 REV. 5/00

M8.0–1450–002

CYLINDERS 12. Remove hydraulic lines, hoses and spring (if removing left lift cylinder) from mounting bracket approximately 33 in. (840 mm) from bottom of cylinder. Cap all hydraulic lines and hoses that were removed. Clean up any spilled hydraulic oil from truck. Left Lift Cylinder

Remove Height Sensor and Move to Side

Fittings & Spring

Pin Right Lift Cylinder

Mounting Bracket

8166P

Fittings

8165P

14. Remove pin holding top of cylinder to main frame. 15. Put nylon strap around top of cylinder just below mounting bracket as shown in Illustration 8.

ILLUSTRATION 6

13. Remove two screws holding height sensor and move height sensor to side. See Illustration 7.

16. Connect hoist to strap and carefully lift cylinder above 2nd stage cross brace. Be very careful when lifting cylinder not to catch hydraulic hose mount on 2nd stage cross brace.

Crown 1997 PF11305-3 Rev. 5/00

M8.0–1450–003

ILLUSTRATION 7

Printed in U.S.A.

02 REV. 5/00

M8.0–1450–003

CYLINDERS CYLINDER REPLACEMENT 18. Put cap on fitting at bottom of lift cylinder, if one is not already present.

Mounting Bracket

19. Put nylon strap around top of cylinder just below mounting bracket and connect to hoist.

WARNING

Nylon Strap

Hydraulic Hose Mount

2nd Stage Lower Cross Brace

WARNING

Make sure the platform the maintenance person rides on is secure and the individual is using an operator harness.

ILLUSTRATION 8

8167P

17. Once cylinder base is above 2nd stage cross brace bring cylinder out front, fork side, of mast.

21. Put pin back through main frame and cylinder mounting bracket. Install cotter pin through bottom of pin to secure in place. See Illustration 7 in Cylinder Removal. Then remove strap from cylinder. 22. Using two screws removed at disassembly remount height sensor back in position.

Cylinder

23. Remove cap and reattach hydraulic line to bottom of cylinder. 24. Put hose guide, at top of cylinder, and hoses back in position and secure using screw previously removed.

2nd Stage Lower Cross Brace 8168P

25. Connect hydraulic hoses, lines and spring (if left lift cylinder was removed) to bracket on cylinder. See Illustration 6 in Cylinder Removal.

ILLUSTRATION 9

Printed in U.S.A.

Crown 1997 PF11305-4 Rev. 5/00

M8.0–1450–004

02 REV. 5/00

M8.0–1450–004

CYLINDERS 26. Put chain anchor back in position and replace both nuts. Try to put about same amount of tension on chain anchor as before so that mast will remain straight. 27. Connect plugs on height sensor and harness. 28. Close Manual Lowering Valve (MVL), connect battery, turn key switch ON, and very slowly raise mast. Guide cylinder ram back into position in top of 2nd stage mast making sure hole in ram and hole in bracket will line up.

WARNING

Great care and cleanliness should be exercised in disassembly and assembly of any hydraulic cylinders. Wipe all surfaces clean of dirt and oil before attempting disassembly. Care should be taken when removing the ram from the cylinder to prevent damage to the packing on the piston end. After cylinder and wipers are removed, thoroughly wash all metallic parts in solvent and blow dry with compressed air. Carefully inspect the ram assembly and cylinder bore. Replace if scored, grooved, pitted, or worn. Minor damage to the cylinder bore can be removed with the use of a cylindrical honing tool. Place washed components in a clean container until assembly. Whenever new packings are required, new wiper rings should also be installed. Lift Cylinder Material covered in this section applies to all TT lift cylinders.

CAP

CYLINDER TUBE

29. Put screw through hole in mast and ram as seen in Illustration 1 in Cylinder Removal. 30. Raise mast enough to remove mast blocking, remove blocking, then lower mast completely and bleed right and left stage cylinders and free lift cylinder as described in section M8.0 of this manual. 31. Raise mast and check to be sure mast is straight when raised. If not, adjust chain anchor tension to correct. Put cotter pin back into chain anchor to secure in position. 32. Lower mast completely, turn key switch OFF. Check hydraulic fluid level and fill as required. Replace console, forks and remove wheel chocks. 33. Restart truck and check operation.

SEAL

0388S

Disassembly Turn the cap counterclockwise and unscrew it from the cylinder tube. Remove the cap and carefully extract the ram assembly from the cylinder bore, never allowing the ram to come in contact with any sharp edges.

Printed in U.S.A.

Crown 1997 PF11305-5 Rev. 5/00

M8.0–1450–005

ILLUSTRATION 10

02 REV. 5/00

M8.0–1450–005

CYLINDERS Seals The seals used in the cylinders are made of an extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

Insert the tools between the ram and the cylinder walls, 180 degrees apart, and screw into the face of the packing (See Illustration 12). After the threads are sufficiently secured into the packing, evenly pull on the screwdriver handles until the packing is removed.

Seal Removal

SEAL PULLING TOOL

When an excessive amount of hydraulic oil is evident on the cylinder, where the ram exits from the cap, the rod packing is probably bad and should be replaced. The replacement of the packing can be accomplished without removing the ram assembly from the cylinder tube or truck.

CYLINDER TUBE

SCREWDRIVER 6 in. (150 mm ) SHAFT LENGTH (MIN.) 5/32 in. (4 mm) SHAFT DIAMETER (MAX.) RAM

NO. 8 METAL SCREW HEADLESS (4 mm SELF-TAPPING)

SEAL 0390S

TAPE

ILLUSTRATION 12 NOTE

0389S

Extreme care should be taken to prevent damage to cylinder wall and ram assembly.

ILLUSTRATION 11

Unfasten and remove the cap as explained in “Disassembly”. If the packing is seated in the cap itself, a hooked tool should be used to remove the packing. If the packing is located below the cap and remains in the cylinder bore after the cap is removed, a pair of special tools can be used to facilitate packing removal (See Illustration 11). To make these tools, weld or braze a headless No. 8 metal (4 mm self-tapping) screw to the end of a screwdriver. The screwdriver must have at least 6 in. (150 mm) of shank length with no larger than 5/32 in. (4 mm) shank diameter. After attaching the screw to the screwdriver, grind off excess weld to a diameter of 5/32 in. (4 mm) Wrap the shank with electrical tape from the tip of the screw to the screwdriver handle. This will prevent scratching of the cylinder bore or the ram.

Crown 1997 PF11305-6 Rev. 5/00

M8.0–1450–006

At this time, the wiper ring should also be removed since packings and wiper rings should always be replaced in pairs. Thoroughly clean the area where the seals seat. Any burrs, dirt or seal debris must be removed before reinstalling new seals.

Printed in U.S.A.

02 REV. 5/00

M8.0–1450–006

CYLINDERS 2. Squeeze U-cup together and insert end into bore first. When lower end is engaged in installation groove, release U-cup and force upper end downward using pusher rod until U-cup snaps into groove.

CAUTION

Close inspection of seal seating critical areas should be made before the new seal is installed (See Illustration 13 AND 18). Your seal failure may not have been caused by a worn seal, but rather, by burrs, nicks and dirt located on the seal seating area, causing the seal to deform and lose its sealing ability.

B. LARGE U-CUP 1. Installation Tool An installation tool made of any soft metal or hard plastic machined smooth and free of burrs with a fixed steel pin (PIN 1) and two movable pins (PINS 2 & 3) is required for this installation method. (See Illustration 14).

Seal Installation - General Tools used to install hydraulic seals should be of soft metal or suitable plastic, free of burrs and sharp edges. Screwdrivers and other similar tools should not be used as they may damage the sealing edges.

PIN 3

TOOL BODY

The area in contact with the seal should be free of burrs, sharp edges and nicks.

PIN 1

If necessary to force seal over sharp edges, slots or undercuts, protective devices should be used. Light lubrication should be applied to the seal and installation groove prior to installation. The same oil as will be used later in the cylinder should be applied.

PIN 2

1902S

Rod U-Cup Installation

ILLUSTRATION 14 2. Installation Procedure

A. SMALL U-CUP

a. Slip the U-cup over the fixed pin (See Illustration 14, PIN 1) and bend it over PIN-2 as shown.

1. Installation Tools

b. Continue bending U-cup until PIN 3 can be pushed through the U-cup loop which locks U-cup in position.

a. A groove alignment plug (See Illustration 13) is needed which should be flush with groove edge. Any metal or plastic material which is smooth and lubricated may be used.

c. Insert installation tool with mounted U-cup into cylinder bore until aligned with U-cup installation groove (See Illustration 15).

PUSHER ROD

CRITICAL SEAL SEATING AREA

PIN 3 PIN 1 PIN 2

GROOVE ALIGNMENT PLUG 1901S

ILLUSTRATION 13

1903S

ILLUSTRATION 15

b. A soft metal or plastic pusher rod is needed.

Printed in U.S.A.

Crown 1997 PF11305-7 Rev. 5/00

M8.0–1450–007

02 REV. 5/00

M8.0–1450–007

CYLINDERS d. Withdraw PIN 3 so that U-cup loop snaps into installation groove (Illustration 16). PIN 3

Cylinder Assembly After packings and seals are in place and the ram assembly has been installed, reattach the cap. CAUTION

PIN 1 PIN 2

Care should be taken when inserting the cylinder cap, to prevent threads and sharp edges from damaging new seals and packings. Cylinder - Summary

ILLUSTRATION 16

1904S

e. Withdraw PIN 2 and U-cup will completely snap into installation groove (Illustration 17). PIN 3 PIN 1 PIN 2

Occasionally, a slight creep of the fork assembly may occur. This may be due to internal leakage in the piston pak but it can also be caused by leakage in the solenoid or check valve. To seat these valves properly when this occurs, raise and lower the forks to flush out any foreign material from the valve seat. A thorough check of the system for leaks should be conducted if abnormal oil losses occur. The hydraulic system is designed to eliminate mechanical damage even if fittings become loose. Cylinder Bleeding and Flushing Mast hydraulic circuits need to be flushed after repair of lift cylinders and bled of all air. Before flushing and bleeding of system inspect all hydraulic connections and verify that all filters are installed and hydraulic fluid levels are adequate for test. Hydraulic system must be pressurized during the flushing and bleeding procedures.

ILLUSTRATION 17

1905S

f. Withdraw installation tool. Cylinder U-cup Installation For “lip first” installation, a sleeve similar to that shown in Illustration 18 should be used to protect the seal from damage on the threads and shoulders. CYLINDER TUBE

SLEEVE SEAL FORCING TOOL

CRITICAL SEAL SEATING AREA

COLLAR

1906S

WARNING

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 damage may occur. Medical attention should be sought immediately by a specialist who has had experience with this type of injury.

ILLUSTRATION 18

Crown 1997 PF11305-8 Rev. 5/00

M8.0–1450–008

Printed in U.S.A.

02 REV. 5/00

M8.0–1450–008

CYLINDERS Bleeding - Free Lift Cylinder • Slowly elevate carriage in free lift to approximately 4 ft. (1220 mm). • Slowly open free lift cylinder bleed screw and bleed air from cylinder until a solid stream of hydraulic fluid flows out of bleed screw. • Tighten bleed screw. Bleeding - Stage Lift Cylinders • Slowly elevate carriage in free lift to approximately 4 ft. (1220 mm). • Slowly open stage lift cylinder bleed screw and bleed air from cylinder until a solid stream of hydraulic fluid flows out of bleed screw. • Tighten bleed screw. • Repeat above steps for the other stage lift cylinder. Flushing - Stage and Free Lift Cylinders • After bleeding cylinders, actuate manual valve to raise carriage through free and stage lift and stop to hold in position. • With carriage raised, examine cylinders for any leaks. • Actuate manual valve to lower carriage through stage and free lift to examine operation and staging. • Raise and lower carriage rapidly for a minimum of 10 cycles to flush system.

Crown 1997 PF11305-9 Rev. 5/00

M8.0–1450–009

Printed in U.S.A.

02 REV. 5/00

M8.0–1450–009

GLOSSARY RR/RD SERIES 5000 Components of the RR/RD Series 5000 truck have been listed in chart form to assist the maintenance mechanic in locating these components on the Electrical Diagrams and Exploded Parts pages. The chart is in columns: COMPONENT; LOCATION; FUNCTION; DIAGRAM; PARTS PAGE. The COMPONENT column contains the abbreviation of the component as it appears on the Diagrams in the Maintenance Section. The LOCATION column gives the general location on the truck

such as on platform or in power unit. the FUNCTION column then explains the function or circuit of that device. The DIAGRAM column gives the page number of the diagram on which the component can be found. The callout in parenthesis following the page number corresponds to the grid callouts on that diagram, locating that component. The PARTS PAGE column includes the exploded parts page number on which the component is located along with the index number, in parenthesis, if applicable.

AUDIBLE INDICATORS Location

Function

Diagram

Parts Page

ALM1

Distribution Panel

Status Alarm

04.3–1450–001

ALM2

Traction Motor Compartment

Travel Alarm

DIA–1450–002 (B-3) DIA–1450–003 (B-3) DIA–1450–005 (B-3)

Traction Motor Compartment

Horn

Location

Function

Diagram

Parts Page

Power Unit

Power

DIA–1450–002 (B-4) DIA–1450–003 (B-4) DIA–1450–006 (C-1) DIA–1450–007 (C-1) DIA–1450–016 (C-3) DIA–1450–018 (A-4)

01.2–1450–100 (20)

CONNECTORS Location

Function

Diagram

Parts Page

CA201 CA202 CA203 CA204 CA205 CA206 CA207 CA208 CA209 CA210 CA211 NB213

TMM Switches & Thermostats Override Switch Battery Restraint Switch (es) Access 2 Travel Alarm ALM 2 Access 3 Truck-KYS, EDS, HN, etc. CAN Connection Mast Cable Load Sense II KYS Suppressor Block Battery Negative Bus

DIA–1450–005 (A-3) DIA–1450–005 (A-3) DIA–1450–005 (A-3) DIA–1450–005 (A-2) DIA–1450–005 (A-2) DIA–1450–005 (C-3) DIA–1450–005 (C-2) DIA–1450–005 (B-3) DIA–1450–005 (A-1) DIA–1450–005 (B-1) DIA–1450–005 (C-2) DIA–1450–006 (B-1)

04.3–1450–001 04.3–1450–001 04.3–1450–001 04.3–1450–001 04.3–1450–001 04.3–1450–001 04.3–1450–001 04.3–1450–001 04.3–1450–001 04.3–1450–001 04.0–1450–001 04.0–1450–001 (7)

DIA–1450–002 (A-2) DIA–1450–003 (A-2) DIA–1450–005 (A-2) DIA–1450–002 (B-4) DIA–1450–003 (B-4) DIA–1450–005 (C-2)

04.0–1450–001 (25)

04.0–1450–001 (23)

BATTERY Battery

Distribution Panel Distribution Panel Distribution Panel Distribution Panel Distribution Panel Distribution Panel Distribution Panel Distribution Panel Distribution Panel Distribution Panel Access 1 Mtg Brkt Bus Bar Access 2 & 3

980131

6847

Crown 1998 PF11322-1 Rev. 11/00

M10–1450–001

Printed in U.S.A.

01 REV. 11.00

M10–1450–001

GLOSSARY CONNECTORS (Continued) Location

Function

Diagram

CA401 CA402 CA403 CA404 CA405 TB406

Key Switch Access 3 Access 3 Access 2 Access 2 Fork Carriage

Key Switch Inputs & Outputs Inputs & Outputs Inputs & Outputs Inputs & Outputs SVR, SVS, SVT, & FLS

CA407

Diaplay CAN, Pwr/Sw Inputs

CA408 CA409

Access 1 Std & Enhanced Access 1 Enhanced Contactor Panel

Display Load Sense/Sw Input Contactor Panel Connector

CA410 CA601

Access 1 Mtg Brkt Access 1 Mtg Brkt

Dome Light Resistor RES1 PC Service Terminal

CA602 CA603

Access 3 Power Unit Top

CA604

Access 1 RH Side

Access 3 ECR1 HGTS12 or HGTRS & Height Encoder Display Sw Brd Connector

DIA–1450–005 (C-2) 04.0–1450–001 (13, 17) DIA 1450-006 (B-2) 04.0–1450–001 DIA–1450–006 (C-1, B-3) 04.0–1450–001 DIA–1450–007 (B-2) 04.0–1450–001 DIA–1450–007 (C-2, B-3) 04.0–1450–001 DIA–1450–008 (B-1) 09.0–1450–001 (58) 09.0–1450–100 (70) 09.0–1650–001 (2) 09.0–1650–100 (2) DIA–1450–009 (B-2) 04.8–1450–001 DIA–1450–010 (B-1) DIA–1450–010 (B-2) 04.8–1450–001 DIA–1450–011 (B-1) 04.1–1450–001 04.1–1450–051 DIA–1450–011 (B-2) 04.8–1450–001 DIA–1450–002 (B-3) 04.8–1450–001 DIA–1450–003 (B-3) DIA–1450–006 (A-2) DIA–1450–006 (A-4) 04.0–1450–001

CA605 CA607 CA609 CA611

Access 1 LH Side Under Floorboard Traction Motor Brake Multi-Task Brkt

Display Sw Brd Connector Floorboard Switches Traction Brake Connector POT1, POT2 & Direction Sw

CA612

Multi-Task Brkt

POT3 & Handle Sw

CA615 CA616 CA617

Access 1 Brkt Power Unit Frt Wall Fork Carriage

Operator Fan Resistors Worklights Connector FKS/HSS or Load Sense Opt

CA618

Fork Carriage

FKS/HSS or Load Sense Opt

CA619

Fork Carriage

FKS/HSS or Load Sense Opt

CA620

Fork Carriage

FKS Heater

CA621

Fork Carriage

FKS Heater

CA622

Reach Carriage

Reach Solenoid

CA623

Reach Carriage

Reach Solenoid

CA624 CA625 CA626

Reach Carriage Reach Carriage Reach Carriage

Tilt/Side Shift Solenoid Side Shift Solenoid Tilt Solenoid

Crown 1998 PF11322-2

M10–1450–002

Parts Page

DIA–1450–008 (B-3) 04.0–1450–001 DIA–1450–009 (B-2) 04.8–1450–001 DIA–1450–010 (B-1) DIA–1450–010 (A-2) 04.8–1450–001 DIA–1450–013 (B-1) 01.0–1450–050 DIA–1450–013 (B-3) 05.3–1450–100 DIA–1450–015 (B-1) 04.6–1450–001 DIA–1450–018 (C-1) DIA–1450–015 (B-2) 04.6–1450–001 DIA–1450–018 (C-2) DIA–1450–011 (C-3) 04.8–1450–001 (30, 31) DIA–1450–011 (B-4) DIA–1450–008 (C-1, C-2) 02.0–1450–600 04.8–1450–500 DIA–1450–008 (C-1, C-2) 02.0–1450–600 04.8–1450–500 DIA–1450–008 (C-1, C-2) 02.0–1450–600 04.8–1450–500 DIA–1450–008(C-2) 04.8–1450–500 DIA–1450–018 (C-1) DIA–1450–008 (C-2) 04.8–1450–500 DIA–1450–018 (C-2) DIA–1450–008 (B-1) 02.0–1450–600 02.0–1450–800 DIA–1450–008 (B-1) 02.0–1450–600 02.0–1450–800 DIA–1450–008 (C-1) 02.0–1450–800 DIA–1450–008 (C-1) 02.0–1450–800 DIA–1450–008 (C-1) 02.0–1450–600 02.0–1450–800

Printed in U.S.A.

M10–1450–002

GLOSSARY CONNECTORS (Continued) Location

Function

Diagram

CA801 CA802 CA803 CA804 CA805 CA806 CA807 CA808 CA809

Mast Top LH Side Power Unit Top Batt Restraint Sw LH Batt Restraint Sw LH Batt Restraint Sw RH Batt Restraint Sw RH Freezer Dist Board Freezer Dist Board Dist Panel

Height Encoder ECR2 Oper Fan/Strobe Lgt Conn Heater BRES2 Heater BRES2 Heater BRES1 Heater BRES1 Output to Heaters Battery Input Heater FLS/FKS

CA810

Dist Panel

Heater FLS/FKS

CA812 CA813 CA814 CA815 CA816 CA819 CA820 CA823

Multi-Task Base Multi-Task Base Power Unit Top Power Unit Top Floorboard Mast Top LH Mast Top LH Contactor Panel

Heater EDS Heater EDS Heater HGTS12 or HGTRS Heater HGTS12 or HGTRS Floorboard Heater/THS5 Heater Height Encoder Heater Height Encoder Fuses F/C

DIA–1450–008 (B-3) 04.9–1450–001 DIA–1450–011 (B-3) 04.9–1450–050 DIA–1450–018 (C-1) 04.9–1450–001 DIA–1450–018 (C-1) 04.9–1450–001 DIA–1450–018 (C-1) 04.9–1450–001 DIA–1450–018 (C-1) 04.9–1450–001 DIA–1450–018 (B-2) 04.9–1450–002 DIA–1450–018 (A-2) 04.9–1450–002 DIA–1450–005 (B-1) 04.9–1450–001 DIA–1450–018 (C-1, B-2) 07.2–1450–001 07.2–1450–100 DIA–1450–005 (B-1) 04.9–1450–001 DIA–1450–018 (C-1, B-2) 07.2–1450–001 07.2–1450–100 DIA–1450–018 (B-2) 04.6–1450–001 DIA–1450–018 (C-2) 04.6–1450–001 DIA–1450–018 (B-2) 04.9–1450–001 DIA–1450–018 (B-2) 04.9–1450–001 DIA–1450–018 (B-3) 04.9–1450–001 DIA–1450–018 (B-1) 04.9–1450–001 DIA–1450–018 (B-1) 04.9–1450–001 DIA–1450–018 (A-2) 04.1–1450–001 04.1–1450–050

Parts Page

CONTACTORS Location

Function

Diagram

Contactor Panel

Emergency Disconnect

Contactor Panel

Pump 2 Contactor

DIA–1450–002 (A-3, B-2) 04.1–1450–001 (16) DIA–1450–003 (A-3, B-2) 04.1–1450–050 (16) DIA–1450–006 (C-1) DIA–1450–007 (B-1) DIA–1450–011 (B-1) DIA–1450–016 (C-2) DIA–1450–002 (A-1, A-2) 04.1–1450–050 (37) DIA–1450–003 (A-1, A-2) DIA–1450–007 (B-1) DIA–1450–011 (B-1) DIA–1450–016 (B-2)

Crown 1998 PF11322-3

M10–1450–003

Parts Page

Printed in U.S.A.

M10–1450–003

GLOSSARY FUSES Location

Function

FU1

Contactor Panel

Control HN, Access 1,2,3 Pwr & Precharge

FU2

Contactor Panel

Accessory Cable

FU3

Contactor Panel

Fan/Strobe Lgt/Work Lgts

FU4

Contactor Panel

ALM2/P2/Solenoid Valve

FU5

Contactor Panel

Traction Brk Outer Coil

FU6

Contactor Panel

Traction Brk Inner Coil

FU7

Contactor Panel

P2 Lift Pump

FU8

Contactor Panel

Access 2

FU9

Contactor Panel

Access 3

FU10

Distribution Panel

Access 3 Logic Common

FU11

Distribution Panel

Access 2 Logic Common

FU12

Freezer Dist Board

FU13 FU14

Freezer Dist Board Freezer Dist Board

Crown 1998 PF11322-4

M10–1450–004

Diagram

Parts Page

DIA–1450–002 (A-4) DIA–1450–003 (A-4) DIA–1450–011 (C-1) DIA–1450–018 (A-4) DIA–1450–002 (A-1) DIA–1450–003 (A-1) DIA–1450–011 (C-1) DIA–1450–002 (A-1) DIA–1450–003 (A-1) DIA–1450–011 (C-1) DIA–1450–002 (A-2) DIA–1450–003 (A-2) DIA–1450–011 (C-1) DIA–1450–002 (A-3) DIA–1450–003 (A-3) DIA–1450–011 (C-1) DIA–1450–002 (A-3) DIA–1450–003 (A-3) DIA–1450–011 (C-1) DIA–1450–002 (A-1) DIA–1450–003 (A-1) DIA–1450–007 (B-1) DIA–1450–016 (C-2) DIA–1450–002 (A-1) DIA–1450–003 (A-1) DIA–1450–007 (C-1) DIA–1450–016 (C-2) DIA–1450–002 (A-3) DIA–1450–003 (A-3) DIA–1450–006 (C-1) DIA–1450–016 (C-2) DIA–1450–002 (B-3) DIA–1450–003 (B-3) DIA–1450–005 (B-3) DIA–1450–002 (B-1) DIA–1450–003 (B-1) DIA–1450–005 (B-2) DIA–1450–002 (A-1) DIA–1450–003 (A-1) DIA–1450–018 (A-2, A-3) DIA–1450–018 (A-3, B-1) DIA–1450–018 (A-3, B-2)

04.1–1450–001 (25) 04.1–1450–050 (25) 04.1–1450–001 (26) 04.1–1450–050 (26) 04.1–1450–001 (27) 04.1–1450–050 (27) 04.1–1450–001 (28) 04.1–1450–050 (28) 04.1–1450–001 (29) 04.1–1450–050 (29) 04.1–1450–001 (30) 04.1–1450–050 (30) 04.1–1450–050 (34)

04.1–1450–001 (12) 04.1–1450–050 (12) 04.1–1450–001 (11) 04.1–1450–050 (11) 04.3–1450–001 (2) 04.3–1450–001 (3) 04.9–1450–001 (49) 04.9–1450–001 (34) 04.9–1450–001 (34)

Printed in U.S.A.

M10–1450–004

GLOSSARY LIGHTS Location

Function

Diagram

Parts Page

LGT1

Lower Mast LH Side

Dome Light

04.9–1450–050 (24)

LGT2 LGT3 LGT4

Mast LH Side Mast RH Side Overhead Guard

Left Worklight Right Worklight Strobe Light

DIA–1450–002 (C-3) DIA–1450–003 (C-3) DIA–1450–011 (C-2) DIA–1450–011 (C-4) DIA–1450–011 (C-4) DIA–1450–011 (C-4)

04.9–1450–050 (31) 04.9–1450–050 (31) 04.9–1450–050 (17)

MISCELLANEOUS Location

Function

Diagram

Parts Page

Access 1

Power Unit Top

Display

04.8–1450–001

Access 2

Power Unit Top

Control Hyd Functions

Access 3

Power Unit Top

Control Traction

BRK1

Traction Mtr Compt

Traction Brake

ECR1

Traction Mtr Compt

Traction Encoder

ECR2

Height Sensor

Height Encoder

Overhead Guard

Operator Fan

DIA–1450–002 (C-4) DIA–1450–003 (C-3) DIA–1450–009 DIA–1450–010 DIA–1450–002 (B-1) DIA–1450–003 (B-1) DIA–1450–007 DIA–1450–016 ((A-1) DIA–1450–002 (B-3) DIA–1450–003 (B-3) DIA–1450–006 DIA–1450–016 (C-1) DIA–1450–002 (A-3) DIA–1450–003 (B-3) DIA–1450–013 (C-2) DIA–1450–002 (B-4) DIA–1450–003 (B-4) DIA–1450–006 (A-4) DIA–1450–002 (B-3) DIA–1450–003 (B-3) DIA–1450–008 (C-3) DIA–1450–011 (C-3)

Location

Function

Diagram

Parts Page

Drive Unit

Traction Motor

03.1–1450–001 03.1–1450–050 03.1–1450–100

Power Unit

Lift Pump 1 Motor

Power Unit

Lift Pump 2 Motor

DIA–1450–002 (B-3) DIA–1450–003 (B-3) DIA–1450–006 (B-1) DIA–1450–010 (B-3) DIA–1450–016 (B-3) DIA–1450–002 (B-1) DIA–1450–003 (B-1) DIA–1450–007 (C-1) DIA–1450–010 (B-3) DIA–1450–016 (B-2 DIA–1450–002 (B-1) DIA–1450–003 (B-1) DIA–1450–007 (B-1) DIA–1450–010 (A-3) DIA–1450–016 (B-2)

04.0–1450–001 (10)

04.0–1450–001 (1)

05.3–1450–100 04.0–1450–001 (34) 04.8–1450–100 (1) 04.9–1450–050 (7)

MOTORS

Crown 1998 PF11322-5

M10–1450–005

02.2–1450–001 02.2–1450–050 02.2–1450–100 02.2–1450–001 02.2–1450–050

Printed in U.S.A.

M10–1450–005

GLOSSARY POTENTIOMETERS Location

Function

Diagram

Parts Page

POT1

Multi-Task Control

Traction Pot

04.6–1450–001 (20)

POT2

Multi-Task Control

Raise/Lower

POT3

Multi-Task Control

Accessory Pot

DIA–1450–002 (B-4) DIA–1450–003 (B-4) DIA–1450–015 (C-1) DIA–1450–002 (B-2) DIA–1450–003 (B-2) DIA–1450–015 (C-1) DIA–1450–002 (B-2) DIA–1450–003 (B-2) DIA–1450–015 (C-2)

Location

Function

Diagram

Distribution Panel

Power Up

Distribution Panel

Horn

Access 1 Brkt

OptionsFan/Strobe/Wk Lgt Accy Cable

DIA–1450–002 (A-4, B-4) 04.3–1450–001 (4) DIA–1450–003 (A-4, B-4) DIA–1450–005 (B-2, B-3) DIA–1450–018 (A-4) DIA–1450–002 (B-4) 04.3–1450–001 (5) DIA–1450–003 (B-4) DIA–1450–005 (B-2)

K11 K12

Freezer Dist Board Freezer Dist Board

Control for K12 Energizes Heaters

DIA–1450–002 (A-1, B-4) 04.8–1450–001 (27) DIA–1450–003 (A-1, B-4) DIA–1450–011 (B-2, B-3) DIA–1450–018 (A-4, B-2) 04.9–1450–001 (32) DIA–1450–018 (A-3, B-2) 04.9–1450–001 (33)

Function

Diagram

04.6–1450–001 (22) 04.6–1450–001 (30)

RELAYS

RESISTORS/HEATERS Location RES1 RES2 RES3 RES4 RES5 RES6 RES7 RES8 RES9 RES10 RES11 RES12 RES13 RES14 RES15 RES19 RES20 RES21 RES22 RES23 RES24

Access 1 Mtg Brkt Volt Drop Res Dome Lt Access 1 Mtg Brkt Volt Drop Res Fan Access 1 Mtg Brkt Volt Drop Res Fan LH Battery Gate Heater for BRES2 RH Battery Gate Heater for BRES1 Fork Carriage Heater for FLS Fork Carriage Heater for FKS Multi-Task Control Brkt Heater for EDS Multi-Task Control Brkt Volt Drop Res for RES10 Multi-Task Control Brkt Patch Heater POT3 Multi-Task Control Brkt Patch Heater for POT1 Main Frame Bottom Heater for HGTRS Floorboard Heater for DMS1 Floorboard Heater for BRS1 Floorboard Heater for ENS Height Sensor Heater for ECR2 Height Sensor Heater for ECR2 Height Sensor Heater for ECR2 Multi-Task Control Brkt Patch Heater for POT2 Multi-Task Control Brkt Volt Drop Res for RES11 Multi-Task Control Brkt Volt Drop Res for RES22

Crown 1998 PF11322-6

M10–1450–006

Parts Page

DIA–1450–011 (B-2) 04.8–1450–001 (29) DIA–1450–011 (B-3) 04.8–1450–001 (30) DIA–1450–011 (B-3) 04.8–1450–001 (31) DIA–1450–018 (B-3, C-1) 04.9–1450–002 (36) DIA–1450–018 (B-3, C-1) 04.9–1450–002 (36) DIA–1450–018 (B-4, C-1) 04.9–1450–001 (21) DIA–1450–018 (B-4, C-2) 04.9–1450–001 (26) DIA–1450–018 (B-4, C-2) 04.9–1450–002 (46) DIA–1450–018 (B-3, C-2) 04.9–1450–002 (38) DIA–1450–018 (B-3, C-2) 04.9–1450–002 (40) DIA–1450–018 (B-3, C-2) 04.9–1450–002 (43) DIA–1450–018 (B-4, C-2) 04.9–1450–001 (14) DIA–1450–018 (B-3, C-3) 04.9–1450–001 (2) DIA–1450–018 (B-3, C-3) 04.9–1450–001 (2) DIA–1450–018 (B-3, C-3) 04.9–1450–001 (2) DIA–1450–018 (A-1,B-4) 04.9–1450–001 (11) DIA–1450–018 (A-1, B-4) 04.9–1450–001 (11) DIA–1450–018 (A-1, B-4) 04.9–1450–001 (11) DIA–1450–018 (B-3, C-2) 04.9–1450–002 (43) DIA–1450–018 (B-3, C-2) 04.9–1450–002 (38) DIA–1450–018 (B-4, C-2) 04.9–1450–002 (38) Printed in U.S.A.

M10–1450–006

GLOSSARY SOLENOIDS/TANSDUCER/PROPORTIONAL VALVES Location Function LS PVA PVH SVA SCV6 SVL SVP SVR SVS SVT

Diagram

Fork Carriage Manifold Pres Transducer Load Sense II DIA–1450–003 (B-4) DIA–1450–008 (C-2) Manifold Prop Valve Accy DIA–1450–002 (A-2) DIA–1450–003 (A-2) DIA–1450–008 (C-3) Manifold Prop Valve Raise/Lower DIA–1450–002 (A-2) DIA–1450–003 (A-2) DIA–1450–008 (B-3) Manifold Ctl Direction Accy Functions DIA–1450–002 (A-2) DIA–1450–003 (A-2) DIA–1450–008 (C-3) Manifold Bypass Valve DIA–1450–002 (A-2) DIA–1450–003 (A-2) DIA–1450–008 (B-3) Manifold Allows Lowering Along w/PVH DIA–1450–002 (A-2) DIA–1450–003 (A-2) DIA–1450–008 (C-3) Manifold Pilot Valve DIA–1450–002 (A-2) DIA–1450–003 (A-2) DIA–1450–008 (C-2) Fork Carriage Reach DIA–1450–002 (A-1) DIA–1450–003 (A-1) DIA–1450–008 (B-1) Fork Carriage Side Shift DIA–1450–002 (A-1) DIA–1450–003 (A-1) DIA–1450–008 (C-1) Fork Carriage Tilt DIA–1450–002 (A-1) DIA–1450–003 (A-1) DIA–1450–008 (C-1)

Parts Page 02.0–1450–600 (15) 02.0–1450–800 (18) 02.4–1450–001 (18) 02.4–1450–001 (15) 02.4–1450–001 (17) 02.4–1450–001 (20) 02.4–1450–001 (19) 02.4–1450–001 (14) 02.4–1450–050 (1) 02.4–1450–050 (6) 02.4–1450–050 (6, 8)

SUPPRESSOR BLOCKS Location

Function

Diagram

Parts Page

SB20

Below Access 1

Key Sw Inrush Current Prot

04.0–1450–001 (36)

SB40

ED Contactor Coil

Coil Suppressor

DIA–1450–002 (A-4) DIA–1450–003 (A-4) DIA–1450–005 (C-2) DIA–1450–011 (B-1)

SB80 SB81

Overhead Guard Overhead Guard

Fan Suppressor Strobe Light Suppressor

DIA–1450–011 (C-3) DIA–1450–011 (C-4)

Crown 1998 PF11322-7 Rev. 11/00

M10–1450–007

04.1–1450–001 (17) 04.1–1450–050 (17) 04.9–1450–050 (5) 04.9–1450–050 (22)

Printed in U.S.A.

01 REV. 11.00

M10–1450–007

GLOSSARY SWITCHES Location

Function

Diagram

BRES1

Battery Compartment

RH Battery Gate In Place

BRES2

Battery Compartment

LH Battery Gate In Place

BRS1

Floorboard

Brake Switch 1

BWS1

Brush Wear

BWS2

Brush Wear

BWS3

Brush Wear

DMS1

Floorboard

Foot Break

DPS1

Access 1

Up Arrow

DPS2

Access 1

Down Arrow

DPS3

Access 1

Enter

DPS4

Access 1

Performance

DPS5

Access 1

Truck Hours

DPS6

Access 1

Service Codes

EDS

RH Side of Multi-Task Brkt

Emergency Disconnect

ENS

Floorboard

Oper Comp Entry Switch

FKS

Fork Carriage

Forks Tilted Up/Down

FLS

Fork Carriage

Free Lift Switch

FNS

Access 1

Operator Fan Switch

DIA–1450–002 (B-1) 01.2–1450–100 (9) DIA–1450–003 (B-1) DIA–1450–005 (A-3) DIA–1450–002 (B-1) 01.2–1450–100 (9) DIA–1450–003 (B-1) DIA–1450–005 (A-3) DIA–1450–002 (B-3) 01.0–1450–050 (23) DIA–1450–003 (B-3) DIA–1450–013 (C-1) DIA–1450–003 (C-3) DIA–1450–010 (B-3) DIA–1450–003 (C-3) DIA–1450–010 (B-3) DIA–1450–003 (C-3) DIA–1450–010 (A-3) DIA–1450–002 (B-3) 01.0–1450–050 (23) DIA–1450–003 (B-3) DIA–1450–013 (C-1) DIA–1450–002 (C-4) 04.8–1450–001 (9) DIA–1450–003 (C-4) DIA–1450–009 (A-2) DIA–1450–010 (A-1) DIA–1450–002 (C-4) 04.8–1450–001 (9) DIA–1450–003 (C-4) DIA–1450–009 (A-2) DIA–1450–010 (A-1) DIA–1450–002 (C-4) 04.8–1450–001 (9) DIA–1450–003 (C-4) DIA–1450–009 (A-2) DIA–1450–010 (A-1) DIA–1450–003 (C-4) 04.8–1450–001 (9) DIA–1450–010 (A-2) DIA–1450–003 (C-4) 04.8–1450–001 (9) DIA–1450–010 (A-2) DIA–1450–003 (C-4) 04.8–1450–001 (9) DIA–1450–010 (A-2) DIA–1450–002 (A-4) 04.6–1450–001(7) DIA–1450–003 (B-4) DIA–1450–005 (C-2) DIA–1450–018 (A-4) DIA–1450–002 (B-3) 01.0–1450–050 (10) DIA–1450–003 (b-3) DIA–1450–013 (C-1) DIA–1450–002 (B-2) 04.8–1450–500 (7) DIA–1450–003 (B-2) DIA–1450–008 (C-1, C-2) DIA–1450–002 (B-2) 07.2–1450–001 (69) DIA–1450–003 (B-2) 07.2–1450–100 (69) DIA–1450–008 (B-1) DIA–1450–011 (B-3) 04.8–1450–001 (3)

Crown 1998 PF11322-8

M10–1450–008

Parts Page

Printed in U.S.A.

M10–1450–008

GLOSSARY SWITCHES (Continued) Location

Function

Multi-Task Control

Forward Travel Optical Switch

HGTS12

Main Frame Mast

HGTRS

Main Frame Mast

HNS

Multi-Task Control

HSS

Tilt Cylinder

KYS

Power Unit Top

LGS1

Access 1

LGS2 ORS

Access 1 Access 1

Multi-Task Control

SSS

Multi-Task Control

TBS

Multi-Task Control

TDS

Multi-Task Control

THS1

Traction Motor

THS2

Lift Pump Motor M2

THS3

Lift Pump Motor M3

THS4 THS5

Power Unit Top Front Floorboard

Crown 1998 PF11322-9

M10–1450–009

Diagram

Parts Page

DIA–1450–002 (B-1) 04.6–1450–001 (16) DIA–1450–003 (B-1) DIA–1450–015 (C-1) 12 In from Top (P2 Cutout) DIA–1450–002 (A-3) 07.2–1450–001 (81) DIA–1450–003 (A-3) 07.2–1450–100 (81) DIA–1450–008 (C-3) Mast Staging Switch DIA–1450–002 (B-3) 07.2–1450–001 (87) DIA–1450–003 (B-3) 07.2–1450–100 (87) DIA–1450–008 (B-4) Horn Switch DIA–1450–002 (B-4) 04.6–1450–001 (27) DIA–1450–003 (B-4) DIA–1450–015 (C-3) Pressure Sw to Limit High Spd DIA–1450–002 (B-2) 02.0–1450–600 (15) DIA–1450–003 (B-2) 02.0–1450–800 (18) DIA–1450–008 (C-1) Key Switch DIA–1450–002 (A-4) 04.0–1450–001 (12, 17) DIA–1450–003 (A-4) DIA–1450–005 (C-2) DIA–1450–018 (A-4) Dome Lgt Switch DIA–1450–002 (B-2) 04.8–1450–001 (2) DIA–1450–003 (B-2) DIA–1450–011 (B-2) Worklight Switch DIA–1450–011 (B-4) 04.8–1450–001 (4) Lift Cutout Override Switch DIA–1450–002 (B-1) 04.8–1450–001 (5) DIA–1450–003 (B-1) DIA–1450–005 (A-3) Reverse Travel Optical Switch DIA–1450–002 (B-1) DIA–1450–003 (B-1) DIA–1450–015 (C-2) Sideshift Select Switch DIA–1450–002 (B-2) 04.6–1450–001 (27) DIA–1450–003 (B-2) DIA–1450–015 (C-3) Tilt Forks Back Switch DIA–1450–002 (B-2) 04.6–1450–001 (27) DIA–1450–003 (B-2) DIA–1450–015 (C-3) Tilt Forks Down Switch DIA–1450–002 (B-2) 04.6–1450–001 (27) DIA–1450–003 (B-2) DIA–1450–015 (C-3) Traction Mtr Over Temp Sw DIA–1450–003 (C-3) DIA–1450–010 (B-3) Over Temp Switch M2 DIA–1450–003 (C-3) DIA–1450–010 (B-3) Over Temp Switch M3 DIA–1450–003 (C-3) DIA–1450–010 (A-3) Ambient Temp for Htr Relay DIA–1450–018 (A-4, C-3) 04.9–1450–001 (47) Control Thermostat Heaters DIA–1450–018 (A-4, C-3) 04.9–1450–001 (2)

Printed in U.S.A.

M10–1450–009

UNDERCARRIAGE ARTICULATION 6212-01

RR/RD 5000 SERIES 2 3 4

6 7 14

Index 14 & 15 Used on Electrically Enclosed (EE) Trucks Only

13 15 14

Index Part No. 1

2 3 4 5 6 7 8 9

Part Name

No. Req.

060020-043 Screw 060021-063 Locknut 123876 Wear Plug 060019-029 Screw 060005-012 Lockwasher 060021-049 Nut 122462 Stop 122459 Stop Bolt 122457 Spring 3500 lb. Capacity 122456 Spring 4500 lb. Capacity 060019-065 Screw 122458 Spacer 065007-092 Bushing 060030-311 Flatwasher .06 in. (1.5 mm) Thick 060030-324 Flatwasher .03 in. (.76 mm) Thick

1 1 1 3 3 2 1 2 2 2 2 2 2

Index Part No. 10 11 12 13 14

Part Name

No. Req.

060023-028 Screw 060005-046 Lockwasher 125679 Block Mounting Rear 086991 Block Mounting Front 121709 Shaft 121764 Shaft Freezer Corrosion 125321 Drive Carriage 060017-014 Screw 060005-009 Lockwasher 060030-019 Flatwasher 060021-011 Nut 102126-002 Grounding Strap

4 4 1 1 1 1 1 1 1 2 1 1

Always Specify Model, Data & Serial Numbers AR AR

980131

6076

Crown 1997 PF11277 Rev. 4/99

Printed in U.S.A.

02 REV. 4/99

01.0–1450–100

UNDERCARRIAGE ARTICULATION 7421-01

RR/RD 5000 SERIES 16 14 15 14

13 12 11 9

Index 8 & 9 Used on Electrically Enclosed (EE) Trucks Only

3 8 7

6 4

Index Part No. 1 2 3 4 5 6 7

Part Name

No. Req.

060020-043 Screw 060021-063 Lockwasher 123876 Wear Plug 125321 Drive Carriage 125679 Block Mounting Rear 086991 Block Mounting Front 060023-028 Screw 060005-046 Lockwasher 121709 Shaft 121764 Shaft Freezer Corrosion 065007-092 Bushing 060030-311 Flatwasher 1.5 mm (.06 in.) Thick 060030-324 Flatwasher .75 mm (.03 in.) Thick 102126-002 Grounding Strap

1 1 1 1 1 1 4 4 1 1 2 AR

Index Part No. 9

10 11 12 13 14 15 16

AR 1

990809

Part Name

No. Req.

060017-014 Screw 060005-009 Lockwasher 060030-019 Flatwasher 060021-011 Nut 126781 Spacer 060019-072 Screw 061004-019 Thread Locking Adhesive 126780-001 Cap Spacer 122457 Spring 1585 kg. (3500 lb.) Cap. 122456 Spring 2040 kg. (4500 lb.) Cap. 126784 Bolt Stop 060021-034 Nut 126787 Stop 060019-029 Screw 060005-012 Lockwasher

1 1 2 1 4 4 1 2 2 2 2 2 1 3 3 3431

Crown 1999 PF11634 Rev. 7/02

Printed in U.S.A.

03 REV. 7/02

01.0–1450–101

UNDERCARRIAGE ARTICULATION 7421-01

RR/RD 5000 SERIES 16 14 15 14 1

13 12 11

Index 8 & 9 Used on Electrically Enclosed (EE) Trucks Only

8 7

Index Part No. 1 2 3 4 5 6 7

Part Name

No. Req.

060041-002 Screw 060021-034 Nut 127792 Wear Plug 128209 Drive Carriage 125679 Block Mounting Rear 086991 Block Mounting Front 060023-028 Screw 060005-046 Lockwasher 121709 Shaft 121764 Shaft Freezer Corrosion 065007-092 Bushing 060030-311 Flatwasher 1.5 mm (.06 in.) Thick 060030-324 Flatwasher .75 mm (.03 in.) Thick 102126-002 Grounding Strap

1 1 1 1 1 1 4 4 1 1 2

001030

AR AR 1

Index Part No. 9

Part Name

No. Req.

10 11 12 13 14 15 16

1 1 2 1 4 4 1 2 2 2 2 2 1 3 3

Always Specify Model, Data & Serial Numbers 7061

Crown 2000 PF11938 Rev. 3/01

01.0–1450–102

Printed in U.S.A.

01 REV. 3/01

01.0–1450–102

BATTERY, RETAINERS, SPACERS 8850

RR/RD 5000 SERIES 23 (EE)

RK FO ND E

24 (EE) Part of

Power Unit

8 2 3

A 6 5

9 BRES1

1 Right Rear

19 (EE)

23 (EE)

19 25 26

(EE) Parts Used On Electrically Enclosed Trucks Only

Part of Power Unit

FO EN RK D

24 (EE)

21 (EE)

22 (EE) 20

12 (EE)

Left Rear

11 12

8 2 9 BRES2

6 7

5 1

Crown 1997 PF11117 Rev. 3/01

Printed in U.S.A.

06 REV. 3/01

01.2–1450–100

BATTERY, RETAINERS, SPACERS Index Part No. 1

Part Name

060015-012 Screw 060005-007 Lockwasher 060030-097 Flatwasher 2 060011-021 Screw 060005-049 Lockwasher 3 ‡ 119274-002 Resistor 24V ‡ 119274-003 Resistor 36V ‡ 060011-001 Screw ‡ 060005-036 Lockwasher 4 123900 Bracket L.H. 5 123901 Spring Lever 6 060010-004 Screw 060005-001 Lockwasher 7 123898 Lever 8 060000-046 Pin Roll 9 062683 Switch 10 123899 Retainer 11 ‡ 123978 Insulator 12 * Retainer L.H 13 * Screw * Lockwasher * Nut 14 123897 Bracket R.H. 15 * Spacer 16 065081-018 Bearing 17 121618-001 Roller "A" Batt. 121618-002 Roller "B" Batt. 121618-003 Roller "C" Batt. 121618-004 Roller "D" Batt. 121618-005 Roller "E" Batt.

No. Req. 4 4 4 4 4 2 2 4 4 1 2 4 4 2 4 2 2 2 1 2 2 2 1 1 †2 †1 †1 †1 †1 †1

Index Part No. 18

Part Name

No. Req.

121619-001 Shaft "A" Batt. 121619-002 Shaft "B" Batt. 121619-003 Shaft "C" Batt. 121619-004 Shaft "D" Batt. 121619-005 Shaft "E" Batt. 121620-001 Roller Asm. Includes 16, 17 & 18 "A" Batt. 121620-002 Roller Asm. Includes 16, 17 & 18 "B" Batt. 121620-003 Roller Asm. Includes 16, 17 & 18 "C" Batt. 121620-004 Roller Asm. Includes 16, 17 & 18 "D" Batt. 121620-005 Roller Asm. Includes 16, 17 & 18 "E" Batt. * Retainer R.H. * Battery 126296-002 Insulation "B" Battery Comp. 126053-003 Insulation "C" Battery Comp. 060098-001 Rivet 126100 Lock 126253 Key 126174 Cam 060016-004 Screw 119218 Block 119219-002 Screw Battery Adj.

19 20 21 22 23 24 25 26 27

†1 †1 †1 †1 †1 †1 †1 †1 †1 †1 1 1 1 1 5 2 1 2 1 1 1

Always Specify Model, Data & Serial Numbers * See The Following Supplemental Forms † No. Req. are for one (1) battery roller assembly. "A" "B", "C", "D" & "E" Size Battery compartments require four (4) battery roller assemblies. ‡ Only on Trucks Equipped With Freezer/Corrsion "A" Battery Compartment = 12.19 in. (310 mm) "B" Battery Compartment = 14.25 in. (360 mm) "C" Battery Compartment = 16.25 in. (415 mm) "D" Battery Compartment = 18.00 in. (455 mm) "E" Battery Compartment = 20.75 in. (525 mm)

980131

7047 - EO2463 Printed in U.S.A.

06 REV. 3/01

01.2–1450–101

BATTERY, RETAINERS, SPACERS ‡‡Code No. INDEX 12 Retainer L.H.

INDEX 19 Retainer R.H.

INDEX 15 •Spacer

Screw

**INDEX 13 Lockwasher

Nut

Models: RR 5010-35, 5010-40, 5020-35, & 5020-45 & RD 5020-30 42 in. (1065mm) P/U 01 02 03 04 05 06 07 07 (EE) 08 09 09 (EE) 10 10 (EE) 11 12 13 14 14 (EE) 15 15 (EE) 24 25 26 27 28 29 30 31 32

122288-001 122288-001 122288-001 122288-001 122288-002 122288-002 122288-002 126300 122288-002 122288-002 126300 122288-003 126051 122288-003 122288-003 122288-003 122288-003 126051 122288-003 126051 122288-004 122288-004 122288-004 122288-004 122288-005 122288-005 122288-005 122288-005 122288-005

127733-001 127733-006 127733-006 127733-001 127733-002 127733-007 127733-002 126301-001 127733-007 127733-002 126301-001 127733-003 126052-001 127733-008 127733-008 127733-003 127733-003 126052-001 127733-003 126052-001 127733-004 127733-004 127733-004 127733-004 127733-005 127733-005 127733-005 127733-005 127733-005

Not Required 123168-002 123168-006 123168-006 Not Required Not Required 123168-004 123168-004 123168-005 123168-005 123168-005 Not Required Not Required Not Required 123168-004 123168-007 123168-002 123168-002 123168-004 123168-004 Not Required 123168-001 Not Required 123168-001 Not Required 123168-001 123168-003 123168-001 123168-003

060017-041 060017-020 060017-020

060017-041 060017-041 060017-020 060017-020 060017-041

060017-041 060017-020 060017-041 060017-041 060017-041 060017-041 060017-069 060017-069 060017-069 060017-041 060017-069 060017-041

Not Required 060005-009 060005-009 060005-009 Not Required Not Required 060005-009 060005-009 060005-009 060005-009 060005-009 Not Required Not Required Not Required 060005-009 060005-009 060005-009 060005-009 060005-009 060005-009 Not Required 060005-009 Not Required 060005-009 Not Required 060005-009 060005-009 060005-009 060005-009

060021-011 060021-011 060021-011

060021-011 060021-011 060021-011 060021-011 060021-011

060021-011 060021-011 060021-011 060021-011 060021-011 060021-011 060021-011 060021-011 060021-011 060021-011 060021-011 060021-011

** Quantity of 2 required. ‡‡Index 12 & 19, Retainer and Index 15, Spacer Part No. Dependent on Battery Code No.

• 123168-001 1.25 x 37.0 x 0.25 in. (31.75 x 940 x 6.3 mm) • 123168-002 1.25 x 37.0 x 0.38 in. (31.75 x 940 x 9.6 mm) • 123168-003 1.25 x 37.0 x 0.50 in. (31.75 x 940 x 12.7 mm) • 123168-004 1.25 x 37.0 x 0.62 in. (31.75 x 940 x 15.7 mm) • 123168-005 1.25 x 37.0 x 0.88 in. (31.75 x 940 x 22.4 mm) • 123168-006 1.25 x 37.0 x 1.00 in. (31.75 x 940 x 25 mm) • 123168-007 1.25 x 37.0 x 1.12 in. (31.75 x 940 x 28.5 mm)

SUPPLEMENTAL LIST CONTINUED ON FOLLOWING PAGE

Crown 1997 PF11117 Rev. 3/01

Printed in U.S.A.

06 REV. 3/01

01.2–1450–100-SUP-1

BATTERY, RETAINERS, SPACERS INDEX 20 – Battery - 24V Part No.

‡‡Code No.

Battery Comp. Size

Max. Battery Size (+.00/-.25 in.)

Amp Hour Range

Battery Wgt. (lbs.) Min. - Max.

087214-001 087214-002 087214-003 087215-001 087215-002 087215-003 087216-001 087216-002 087216-003

01 02 03 06 07 08 11 12 13

A A A B B B C C C

12.19 x 38.38 x 31.00 11.75 x 36.38 x 31.00 11.12 x 35.38 x 31.00 14.25 x 36.38 x 31.00 13.62 x 38.38 x 31.00 13.38 x 35.38 x 31.00 16.25 x 36.38 x 31.00 15.62 x 35.38 x 31.00 15.12 x 38.38 x 31.00

700 - 840 520 - 680 580 - 640 650 - 850 880 725 - 875 780 - 1020 870 - 960 990 - 1080

1240 - 1870 1240 - 1870 1240 - 1870 1410 - 2110 1410 - 2110 1410 - 2110 1710 - 2400 1710 - 2400 1710 - 2400

A B B C C C D D D D E E E E E

11.12 x 38.38 x 31.00 14.25 x 38.38 x 31.00 14.25 x 38.38 x 31.00 16.25 x 38.38 x 31.00 15.88 x 38.38 x 31.00 15.62 x 38.38 x 31.00 18.00 x 38.69 x 31.00 17.75 x 38.69 x 31.00 18.00 x 38.44 x 31.00 17.75 x 38.44 x 31.00 20.75 x 38.69 x 31.00 20.50 x 38.69 x 31.00 20.25 x 38.69 x 31.00 20.50 x 38.44 x 31.00 20.25 x 38.44 x 31.00

400 - 480 500 - 550 550 - 600 600 - 720 600 - 660 660 - 720 700 - 1000 770 - 875 770 - 1085 770 - 875 880 - 1120 840 - 1120 800 - 1000 880 - 1000 880 - 1000

1305 - 1725 1595 - 2090 1595 - 2090 1880 - 2490 1880 - 2585 1880 - 2490 2120 - 2980 2120 - 2800 2120 - 2980 2120 - 2800 2400 - 3070 2400 - 3070 2400 - 3070 2400 - 3070 2400 - 3070

Battery - 36V 087217-001 087218-001 087218-002 087219-001 087219-002 087219-003 094072-001 094072-002 094072-003 094072-004 102823-001 102823-002 102823-003 102823-004 102823-005

04 07 09 10 14 15 24 25 26 27 28 29 30 31 32

Battery Connectors Part No.

Description

Qty.

078723-001 078723-002 078723-003 078723-004 078723-006 078723-007 078723-008 078723-009 078724-001 108801-001 108801-003 108801-006 108801-008 108802-001

SB-350 Connector Gray SB-175 Connector Gray SB-350 Connector Red SB-175 Connector Yellow SB-350 Connector Blue SB-175 Connector Red SB-175 Connector Blue SB-350 Connector Yellow Contacts SBE-320 EEC Connector Gray SBE-320 EEC Connector Red SBE-320 EEC Connector Blue SBE-320 EEC Connector Yellow EEC Contacts

1 1 1 1 1 1 1 1 2 1 1 1 1 2

‡‡ Retainer and Spacers Part No. Dependent on Battery Code No.

Crown 1997 PF11117 Rev. 3/01

Printed in U.S.A.

06 REV. 3/01

01.2–1450–100-SUP-2

OVERHEAD GUARD 5713

RR/RD 5000/5000S SERIES

2 1 Part of Main Frame

See Section 04.9 for Overhead Guard Accessories

Index 1 – Overhead Guard Overhead Guard

Guard with Center Spotlight

Guard with Wire Mesh Cover

Guard with Third Post

Battery Size

RR/RD 5000 Series 122870-001 122870-002 122870-003 122870-004 112870-005

N01551-001 N01551-002 N01551-003 N01551-004 N01551-005

N01553-001 N01553-002 N01553-003 N01553-004 N01553-005

N01554-001 N01554-002 N01554-003 N01554-004 N01554-005

A B C D E

12.19 in. 14.25 in. 16.25 in. 18.00 in. 20.75 in.

310 mm 360 mm 415 mm 455 mm 525 mm

RR/RD 5000S Series 122870-006 122870-008

N01551-006 N01551-008

N01553-006 N01553-008

N01554-006 N01554-008

C E

16.25 in. 20.75 in.

415 mm 525 mm

Index Part No. 2

Part Name

No. Req.

060023-026 Screw 061004-019 Adhesive Thread Lock

4 1

Compartment Width

Always Specify Model, Data & Serial Numbers

980131

5199

Crown 1997 PF11036 Rev. 3/98

Printed in U.S.A.

02 REV. 3/98

01.2–1450–200

HYDRAULIC RESERVOIR 5824-01

RR/RD 5000 SERIES 6 16

6 13 6

To Port "T2"on Manifold Block

To Port "T1"on Manifold Block

15 6 10

Connect to Power Unit 12

6 9

6 27

To Port "T" on Steering Control Unit

5 6

RK FO ND E

7 6

28 11

25 11

20 B

To Pump "P2" 28

17 To Pump "P1"

11 C

18 23

Part of Power Unit

11 26 11

Crown 1997 PF11067 Rev. 2/99

Printed in U.S.A.

02 REV. 2/99

02.0–1450–001

HYDRAULIC RESERVOIR Index Part No. 1

3 4 5 6 7 8 9

10 11 12 13

Part Name

No. Req.

060016-081 Screw 2 060005-008 Lockwasher 2 060030-017 Flatwasher 2 121748 Filter Asm. 1 123531 Element Filter 1 123533 Support Tube Includes O-Ring 1 064019-047 O-Ring Support Tube 1 123532 Cap Asm. 1 123534 Cap Breather Element 1 064273 Hose Nipple 1 122339 Tube Drop 1 064100-101 Hose “A” Battery 1 064100-103 Hose “B, C, D & E” Battery 1 061022-003 Clamp Hose 12 122338 Tube 1 121872 Reservoir LH 1 064100-107 Hose “A” Battery 1 064100-108 Hose “B” Battery 1 064100-110 Hose “C” Battery 1 064100-110 Hose “D” Battery 1 064100-111 Hose “E” Battery 1 064100-104 Hose “A” Battery 1 064100-106 Hose “B, C, D & E” Battery 1 061022-001 Clamp Hose AR 064270-002 Tee 1 064100-098 Hose “A” Battery 1 064100-114 Hose “B” Battery 1 064100-115 Hose “C” Battery 1 064100-116 Hose “D” Battery 1 064100-117 Hose “E” Battery 1 064270-001 Tee 1

Index Part No. 15 16 17 18 19 20 21

Part Name

No. Req.

125078 Breather 1 122338 Tube 1 121873 Reservoir RH 1 123283 Hose 1 123327 Hose RH 1 123284 Hose LH 1 123285 Tube Suction 2 Pumps Shown 1 123286 Tube Suction 1 Pump 1 060015-004 Screw 2 060005-007 Lockwasher 2 060030-012 Flatwasher 2 060091-001 Nut Insert 1 122341 Tee 1 064173-024 Hose Suction 1 Pump 1 064173-022 Hose Suction 2 Pumps 1 064173-025 Hose 2 Pumps Only 1 064173-022 Hose “A, B & C” Battery 1 064173-026 Hose “D & E” Battery 1 064100-112 Hose “A” Battery 1 064100-113 Hose “B, C, D & E” Battery 1 064143-003 Fitting Beaded AR 064100-099 Hose “A” Battery 1 064100-100 Hose “B, C, D & E” Battery 1 085653-340 Wire Ground 1

23 24 25 26 27 28 29 30

Always Specify Model, Data & Serial Numbers “A” Battery Compartment = 11.12 in. (280mm) “B” Battery Compartment = 14.25 in. (360mm) “C” Battery Compartment = 16.25 in. (415mm) “D” Battery Compartment = 18.11 in. (460mm) “E” Battery Compartment = 20.75 in. (530mm)

980131

6019 - 45632 Printed in U.S.A.

02 REV. 2/99

02.0–1450–002

HYDRAULIC RESERVOIR 5824-03

RR/RD 5000 SERIES 30 28

6 13 6

To Port "T2"on Manifold Block

6 5

To Port "T1"on Manifold Block

Connect to Power Unit

10 12

6 26 8

To Port "T" on Steering Control Unit

6 A

30 31

RK FO ND E

31 27 11 32

To Pump "P2" 27

23 To Pump "P1"

11 C B

17 22

20 11 Part of Power Unit

25 11 Crown 2000 PF11912 Rev. 12/00

Printed in U.S.A.

01 REV. 12/00

02.0–1450–003

HYDRAULIC RESERVOIR Index Part No. 1 2

3 4 5 6 7 8 9

10 11 12 13

14 15 16 17

Part Name

No. Req.

060014-089 Screw 127740 Filter 127741 Element Filter 128005 O-Ring Kit 128292 Cap 128293 By-Pass 064143-001 Hose Nipple 127915 Tube Drop 064100-101 Hose “A” Battery 064100-103 Hose “B, C, D & E” Battery 061022-003 Clamp Hose 122338 Tube 121872 Reservoir LH 064100-107 Hose “A” Battery 064100-108 Hose “B” Battery 064100-110 Hose “C” Battery 064100-110 Hose “D” Battery 064100-111 Hose “E” Battery 064100-104 Hose “A” Battery 064100-106 Hose “B, C, D & E” Battery 061022-001 Clamp Hose 064270-002 Tee 064100-098 Hose “A” Battery 064100-114 Hose “B” Battery 064100-115 Hose “C” Battery 064100-116 Hose “D” Battery 064100-117 Hose “E” Battery 064270-001 Tee 127742 Breather 127901 Reservoir RH 123283 Hose

4 1 1 1 1 1 1 1 1 1 AR 2 1 1 1 1 1 1 1 1 AR 1 1 1 1 1 1 1 2 1 1

Index Part No. 18 19 20

Part Name

No. Req.

123327 Hose RH 1 123284 Hose LH 1 123285 Tube Suction 2 Pumps Shown 1 123286 Tube Suction 1 Pump 1 060015-004 Screw 2 060005-007 Lockwasher 2 060030-012 Flatwasher 2 060091-001 Nut Insert 1 122341 Tee 1 064173-024 Hose Suction 1 Pump 1 064173-022 Hose Suction 2 Pumps 1 064173-025 Hose 2 Pumps Only 1 064173-022 Hose “A, B & C” Battery 1 064173-026 Hose “D & E” Battery 1 064100-112 Hose “A” Battery 1 064100-113 Hose “B, C, D & E” Battery 1 064143-003 Fitting Beaded AR 064100-099 Hose “A” Battery 1 064100-100 Hose “B, C, D & E” Battery 1 085653-347 Wire Ground 1 127706 Tube 2 061022-010 Clamp Hose AR 128903 Strainer 2

22 23 24 25 26 27 28 29 30 31 32

Always Specify Model, Data & Serial Numbers "A" Battery Compartment = 280 mm (11.12 in.) "B" Battery Compartment = 360 mm (14.25 in.) "C" Battery Compartment = 415 mm (16.25 in.) "D" Battery Compartment = 460 mm (18.11 in.) "E" Battery Compartment = 530 mm (20.75 in.)

000816

6894 - EO4081 Printed in U.S.A.

01 REV. 12/00

02.0–1450–004

HYDRAULIC - MANIFOLD 5825-03

RR/RD 5000 SERIES

To Reach Carriage Hydraulics Left Fitting, Located on Left Lift Cylinder

To Reach Carriage Hydraulics Right Fitting, Located on Left Lift Cylinder 11

RK FO ND E

12 To Lift Cylinders 11

To R.H. Hydraulic Reservoir

To L.H. Hydraulic Reservoir

19 12

10 13

4 8 16

To Pump P1 Port EF

B R T

To Pump P2

1 P

1 C V

Manifold Block See Section 02.4

C 2

Top of Power Unit

18 Only Used on Trucks Equipped With One (1) Lift Pump

Crown 1997 PF11068 Rev. 12/00

Printed in U.S.A.

03 REV. 12/00

02.0–1450–050

HYDRAULIC - MANIFOLD Index Part No. 1 2 3 4 5

6 7 8 9

10 11

13 14 15 16 17 18 19

Part Name

No. Req.

064061-006 Elbow Includes O-Ring 064272-002 Hose 064272-001 Hose 064061-006 Elbow Includes O-Ring 122485-001 Tube "A" Battery 122485-002 Tube "B" Battery 122485-003 Tube "C" Battery 122485-004 Tube "D" Battery 122485-005 Tube "E" Battery 064061-016 Elbow Includes O-Ring 064143-009 Elbow Beaded 061022-003 Clamp Hose 064100-098 Hose "A" Battery 064100-114 Hose "B" Battery 064100-115 Hose "C" Battery 064100-116 Hose "D" Battery 064100-117 Hose "E" Battery 064061-002 Elbow Includes O-Ring 122486-001 Tube "A" Battery 064254-102 Hose "B" Battery 064254-268 Hose "C" Battery 064254-268 Hose "D" Battery 064254-271 Hose "E" Battery 122487-001 Tube "A" Battery 064254-267 Hose "B" Battery 064254-269 Hose "C" Battery 064254-270 Hose "D" Battery 064254-272 Hose "E" Battery 064100-104 Hose "A" Battery 064100-106 Hose "B, C, D & E" Battery 064004-014 Connector 064103-058 Hose 064143-001 Elbow Beaded 064128-002 Cap 064091-007 Plug Only On Trucks With 1 Pump 061022-009 Clamp Hose

2 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2

Always Specify Model, Data & Serial Numbers "A" Battery Compartment = 11.12 in. (280 mm) "B" Battery Compartment = 14.25 in. (360 mm) "C" Battery Compartment = 16.25 in. (415 mm) "D" Battery Compartment = 18.00 in. (460 mm) "E" Battery Compartment = 20.75 in. (530 mm)

980131

6656 - EO2497 Printed in U.S.A.

03 REV. 12/00

02.0–1450–051

STEERING CONTROL 5830-01

RR/RD 5000/5000S SERIES R

TL L

T LS P

R PR

Surface "A" T

Integral Relief Valve Pre-Set @ 1250 PSI

Steering Control Unit (SCU) See Section 6.0

1 Surface "A"

5000 Series Shown

1 5 6 12 Connects to Tee Joining Hose From T2 on Manifold Block Then to L.H. Reservoir 4

11 To P Port On Pump P1

10 9 To L.S. Port On Pump P1

Shown is Reverse Steering. Switch Hoses at Ports A & B For Forward Steering.

FO EN RK D

To LSHT Motor Port A Crown 1997 PF11075 Rev. 12/00

To LSHT Motor Port B Printed in U.S.A.

02 REV. 12/00

02.0–1450–100

STEERING CONTROL Index Part No. 1 2

3 4 5 6 7 8 9 10

11 12 13

Part Name

No. Req.

061022-003 Clamp 064100-112 Hose “A” Battery 064100-113 Hose “B, C, D, E” Battery 064100-118 Hose 5000S 064143-012 Elbow Beaded 064143-013 Elbow Beaded 5000S 064061-002 Elbow 064254-257 Hose 064103-070 Hose 5000S 064004-007 Connector 064004-004 Connector 064061-009 Elbow 5000S 064252-038 Hose 064103-071 Hose 5000S 064061-004 Elbow 064254-256 Hose 064254-256 Hose “L” 5000S 064254-259 Hose “R” 5000S 064061-002 Elbow 064061-002 Elbow 5000S 064065-003 Elbow Swivel 064098-002 Elbow 064061-002 Elbow 5000S

2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 2

Always Specify Model, Data & Serial Numbers “A” Battery Compartment = 11.12 in. (280 mm) “B” Battery Compartment = 14.25 in. (360 mm) “C” Battery Compartment = 16.25 in. (415 mm) “D” Battery Compartment = 18.00 in. (460 mm) “E” Battery Compartment = 20.75 in. (530 mm)

980131

6871 Printed in U.S.A.

02 REV. 12/00

02.0–1450–101

MAST HYDRAULICS 6773

RR/RD 5000/5000S SERIES

See Section 08.3 "TT Lift Cylinder"

A A

See Section 08.3 "TT Carriage Cylinder"

6 7

11 12

8 B A

A B

Connects To Hydraulic Tubes Connected To Ports A & B On Reach Manifold 14

3 3

C1 Connects To Hydraulic Tubes Connected To Port C1 On Manifold

Connects To Hydraulic Tubes Connected To Ports A & B On Manifold

Crown 1998 PF11489 Rev. 4/99

Printed in U.S.A.

01 REV. 4/99

02.0–1450–402

MAST HYDRAULICS Index Part No.

Part Name

No. Req.

1 126130 Tube 2 121856 Tube 3 064090-004 Connector Long 4 064034-002 Fitting Bulkhead 5 064030-003 Nut Bulkhead 6 * Hose 061004-023 Sealant Hydraulic 10cc 7 * Hose 061004-023 Sealant Hydraulic 10cc 8 064030-010 Nut Bulkhead 9 123281 Clamp 10 060015-048 Screw 060005-007 Lockwasher 11 121729 Tube 12 121728 Tube 13 064097-004 Union Elbow 14 121737 Tube 15 064061-016 Elbow 90° 16 * Hose 061004-023 Sealant Hydraulic 10cc 17 060015-049 Screw 060042-006 Nut Self Locking 18 126129 Tube

1 1 2 2 2 2 1 1 1 3 2 1 1 1 1 1 1 1 2 1 1 1 1

* See The Following Supplemental List Always Specify Model, Data & Serial Numbers

980801

6076 Printed in U.S.A.

01 REV. 4/99

02.0–1450–403

MAST HYDRAULICS INDEX 6 - HOSE ASSEMBLY Part No.

064254-204 064254-205 064254-206 064254-207 064254-208 064254-209 064254-210 064254-211 064254-212

Collapsed Height/Lift Height in. mm

No. Req.

89/198 95/210 107/240 119/270 131/300 140/321 149/341 160/366 172/400

2260/5025 2415/5335 2720/6100 3025/6860 3325/7620 3555/8155 3785/8660 4065/9300 4370/10160

2 2 2 2 2 2 2 2 2

89/198 95/210 107/240 119/270 131/300 140/321 149/341 160/366 172/400

2260/5025 2415/5335 2720/6100 3025/6860 3325/7620 3555/8155 3785/8660 4065/9300 4370/10160

1 1 1 1 1 1 1 1 1

89/198 95/210 107/240 119/270 131/300 140/321 149/341 160/366 172/400

2260/5025 2415/5335 2720/6100 3025/6860 3325/7620 3555/8155 3785/8660 4065/9300 4370/10160

2 2 2 2 2 2 2 2 2

INDEX 7 - HOSE ASSEMBLY 064263-001 064263-002 064263-003 064263-004 064263-005 064263-006 064263-007 064263-008 064263-009 INDEX 16 - HOSE ASSEMBLY 064254-214 064254-215 064254-216 064254-217 064254-218 064254-219 064254-220 064254-221 064254-222

Crown 1998 PF11489 Rev. 4/99

Printed in U.S.A.

01 REV. 4/99

02.0–1450–402-SUP

REACH HYDRAULICS 5899-01

TILT RR/RD 5000/5000S SERIES Top of Reach Support

FO EN RK D

Reach Manifold See Section 2.4

SVR

1 R

B 2 3

7 C

SVT

9 5

Top of Reach Carriage

T2 1

Left & Right Reach Cylinders Attached to Reach Support See Section 8.5

Tilt Manifold See Section 2.4

11 12

A See Section 2.0

13 15 HSS LS

Free Flow

Part of 1st Stage Mast

Connects To Hydraulic Tubes Connected To Ports A & B On Manifold Block

Tilt Cylinder Mounted to Bottom of Carriage See Section 8.6 Bottom of Reach Support

Crown 1997 PF11110 Rev. 4/99

Printed in U.S.A.

04 REV. 4/99

02.0–1450–600

REACH HYDRAULICS Index Part No.

Part Name

No. Req.

1 2

064061-004 Elbow 6 064252-042 Hose RR 1 064252-044 Hose RD 1 3 064252-041 Hose RR 1 064252-043 Hose RD 1 4 064061-001 Elbow 2 5 077389-003 Tube RR 2 077389-004 Tube RD 2 061002-001 Clamp 2 060013-002 Screw 2 060005-004 Lockwasher 2 6 064171-004 Elbow 2 7 064253-079 Hose RR 2 064253-080 Hose RD 2 8 122277 Tube L.H. 3500 lbs. (1588kg) Capacity RR 1 122242 Tube L.H. 4500 lbs. (2040kg) Capacity RD 1 9 122276 Tube R.H. 3500 lbs. (1588kg) Capacity RR 1 122241 Tube R.H. 4500 lbs. (2040kg) Capacity RD 1 10 † 064253-071 Hose RR 1 † 064253-072 Hose RD 1 11 064004-007 Connector 2 12 064253-081 Hose RR/RD 2 13 064033-002 Bulkhead Connector 2 064030-003 Nut 2 14 † 122493 Check Valve CV 5 PSI (.345 bar) Crack Pressure 1 064091-002 Plug Not Shown 1 15 † 123888 Pressure Switch HSS Pre-Set to 225 PSI (15.5 bar) Torque to 32 ft. lbs. (44 Nm) 1 126512 Sensor Pressure Transducer Assembly LS 1 † 126491 Sensor Pressure Transducer LS 1 062007-050 Terminal 1 062007-063 Terminal 1 064091-006 Plug Not Shown 1 124000-001 Harness (Tilt, SS, LS) RR 1 124000-002 Harness (Tilt, SS, LS) RD 1 Always Specify Model, Data & Serial Numbers †Present on Trucks Equipped With Optional Productivity Packages.

980131

6076 Printed in U.S.A.

04 REV. 4/99

02.0–1450–601

HYDRAULIC PARTS Reach Hydraulics - Tilt & Sideshift Reach Hydraulics - Tilt & Sideshift

(a)

Refer to Hydraulic Parts

(b)

Left and Right Reach Cylinders attached to Reach Support, refer to Cylinder Parts

(c)

Tilt Cylinder mounted to bottom of Carriage, refer to Cylinder Parts

(d)

Sideshift Cylinder, refer to Cylinder Parts

(e)

Crack Pressure 0.345 bar (5 psi)

(f)

Torque To 44 Nm (32 ft lb) Pre-Set to 15 bar (225 psi)

Figure 19554-01

02.0-1450-800 08 Rev. 7/09

Crown 1997 PF11108-1 Rev. 7/09

HYDRAULIC PARTS Reach Hydraulics - Tilt & Sideshift INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

1 . . . . . 064061-004. . . . . . . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 064019-031 . . . . . . . . O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2 . . . . . 064252-042. . . . . . . . Hose RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 064252-044. . . . . . . . Hose RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 . . . . . 064252-041. . . . . . . . Hose RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 064252-043. . . . . . . . Hose RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 . . . . . 064061-001. . . . . . . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 064019-031 . . . . . . . . O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 . . . . . 077389-003. . . . . . . . Tube RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 077389-004. . . . . . . . Tube RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 6 . . . . . 061002-001. . . . . . . . Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 7 . . . . . 060013-002. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 8 . . . . . 060005-004. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9 . . . . . 064171-004. . . . . . . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 064019-031 . . . . . . . . O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 10 . . . . . 064253-079. . . . . . . . Hose RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 064253-080. . . . . . . . Hose RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 11 . . . . . 122277 . . . . . . . . . . . Left Hand Tube Capacity 1588 kg (3500 lb) RR . . . . . . . . . . . . . . . . . . . . . . 1 122242 . . . . . . . . . . . Left Hand Tube Capacity 2040 kg (4500 lb) RR, 1360 kg (3000 lb) RD . . . . 1 12 . . . . . 122276 . . . . . . . . . . . Right Hand Tube Capacity 1588 kg (3500 lb) RR . . . . . . . . . . . . . . . . . . . . . 1 122241 . . . . . . . . . . . Right Hand Tube Capacity 2040 kg (4500 lb) RR, 1360 kg (3000 lb) RD. . . 1 13 . . . . . 064253-071* . . . . . . . Hose RR (with Load Sense Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 064253-072* . . . . . . . Hose RD (with Load Sense Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 14 . . . . . 064004-007. . . . . . . . Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 064019-031 . . . . . . . . O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 15 . . . . . 064253-081. . . . . . . . Hose RR or RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 16 . . . . . 064061-004. . . . . . . . Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 064019-031 . . . . . . . . O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 17 . . . . . 064253-009. . . . . . . . Hose RR or RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 18 . . . . . 064253-010. . . . . . . . Hose RR and RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 19 . . . . . 064033-002. . . . . . . . Bulkhead Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 20 . . . . . 064030-003. . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 21 . . . . . 122493* . . . . . . . . . . Check Valve (used with load sense option) . . . . . . . . . . . . . . . . . . . . . . . . . 1 064091-002* . . . . . . . Plug (used without load sense option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 064019-029 . . . . . . . . O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 22 . . . . . 123888* . . . . . . . . . . Pressure Switch (without capacity data monitor) . . . . . . . . . . . . . . . . . . . . . 1 126512* . . . . . . . . . . Pressure Sensor Transducer (with capacity data monitor) . . . . . . . . . . . . . . 1 126491* . . . . . . . . . . Pressure Sensor Transducer LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 062007-050. . . . . . . . Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 062007-063. . . . . . . . Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 064091-006. . . . . . . . Plug (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 064019-031 . . . . . . . . O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 124000-001. . . . . . . . Harness (Tilt, SS, LS) RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 124000-002. . . . . . . . Harness (Tilt, SS, LS) RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

* To select appropriate part number, use the data number to determine truck features. Refer to Introduction.

Always Specify Model, Data & Serial Number Crown 1997 PF11108-2 Rev. 7/09

02.0-1450-801 08 Rev. 7/09

LIFT MOTOR 5816-02

RR/RD 5000/5000S SERIES 36V - 6.75 in. DIA. Standard Performance With Sensors 21 EE Headband

17 6 15

14 Brush Sensor

13 11 12 9 10 9

19 Thermal Sensor

8 7

4 20 EE Headband

Crown 1997 PF11053 Rev. 3/99

Printed in U.S.A.

02 REV. 3/99

02.2–1450–001

LIFT MOTOR 020575-001 LIFT MOTOR 36V WITH SENSORS 020575-002 LIFT MOTOR 36V WITH SENSORS EE Index Part No.

Part Name

No. Req.

1 † 060078-006 Screw Thread Forming 2 060009-144 Ring Retaining 3 065081-054 Bearing Ball 4 020131 Head Drive End 020143 Head Drive End Includes 2 & 3 5 020135 Armature Includes 18 6 113653 Kit Terminal Stud 7 065081-051 Bearing Ball 8 060046-016 Washer Spring 9 020578 Frame & Field 062547 Connector BWS/Thermal 10 020577 Brush Box Includes 11 11 113329 Kit Spring Brush Includes 4 Springs 12 060032-033 Screw Self-Tapping 13 113652 Kit Brush Includes 4 Brushes 16 x 32mm 14 060078-011 Screw Thread Rolling 15 020597 Head Commutator End 062547 Connector BWS/Thermal 020591 Head Commutator End Includes 10 thru 14 16 † 060078-004 Screw Thread Forming 17 020427-001 Headband 18 * Fan 19 060078-003 Screw Thread Forming 20 020425 Headband EE 21 020423 Headband EE

4 1 1 1 1 1 1 1 1 1 1 1 1 4 1 4 1 1 1 2 1 1 8 1 1

Always Specify Model, Data & Serial Numbers *Not Servicable † Torque Screws to 140 - 150 in. lbs. (16 - 17 Nm)

980131

6010 Printed in U.S.A.

02 REV. 3/99

02.2–1450–002

LIFT MOTOR 8694

RR/RD 5000/5000S SERIES 36V - 6.75 in. DIA. Standard Performance With Sensors

16 EE Headband 15

6 15

14 Brush Sensor

13 11 12 9 10 9

19 Thermal Sensor

8 7

3 2

4 20 EE Headband

Crown 2000 PF11985

02.2–1450–003

Printed in U.S.A.

02.2–1450–003

LIFT MOTOR 020575-003 LIFT MOTOR 36V WITH SENSORS 020575-002 LIFT MOTOR 36V WITH SENSORS EE Index Part No.

Part Name

No. Req.

1 † 060078-006 Screw Thread Forming 2 060009-144 Ring Retaining 3 065081-054 Bearing Ball 4 020131 Head Drive End 020143 Head Drive End Includes 2 & 3 5 020135 Armature Includes 18 6 113653 Kit Terminal Stud 7 065081-051 Bearing Ball 8 060046-016 Washer Spring 9 020578 Frame & Field 062547 Connector BWS/Thermal 10 020577 Brush Box Includes 11 11 113329 Kit Spring Brush Includes 4 Springs 12 060032-033 Screw Self-Tapping 13 113652 Kit Brush Includes 4 Brushes 16 x 32 mm 14 060078-011 Screw Thread Rolling 15 020597 Head Commutator End 062547 Connector BWS/Thermal 020591 Head Commutator End Includes 10 thru 14 16 † 060078-004 Screw Thread Forming 17 020423 Headband EE 18 * Fan 19 060078-003 Screw Thread Forming 20 020425 Headband EE

4 1 1 1 1 1 1 1 1 1 1 1 1 4 1 4 1 1 1 2 1 1 8 1

Always Specify Model, Data & Serial Numbers *Not Servicable † Torque Screws to 16 - 17 Nm (140 - 150 in. lbs.)

010124

6902 - EO4148 Printed in U.S.A.

02.2–1450–004

LIFT MOTOR 5820

36V - 6.75 in. DIA. RR/RD 5000/5000S SERIES STANDARD PERFORMANCE W/O SENSORS

16 15

17 6 14 13 11 12 9 10 9 19 9 8 7

2 Crown 1997 PF-11059

02.2–1450–050

Printed in U.S.A.

02.2–1450–050

LIFT MOTOR 020614 LIFT MOTOR 36V STANDARD PERFORMANCE W/O SENSORS Index Part No.

Part Name

No. Req.

1 † 060078-006 Screw Thread Forming 2 060009-144 Ring Retaining 3 065081-054 Bearing Ball 4 020131 Head Drive End 020143 Head Drive End Includes 2 & 3 5 020135 Armature Includes 18 6 113653 Kit Terminal Stud 7 065081-051 Bearing Ball 8 060046-016 Washer Spring 9 020617 Frame & Field 10 020018 Brush Box Includes 11 11 113329 Kit Spring Brush Includes 4 Springs 12 060032-033 Screw Self Tapping 13 113652 Kit Brush Includes 4 Brushes 16 x 32mm 14 060078-011 Screw Thread Rolling 15 020081 Head Commutator End 020072 Head Commutator End Includes 10 thru 14 16 † 060078-004 Screw Thread Forming 17 020427-001 Headband 18 * Fan 19 060078-003 Screw Thread Forming

4 1 1 1 1 1 1 1 1 1 1 1 4 1 4 1 1 2 1 1 8

Always Specify Model, Data & Serial Numbers * Not Serviceable † Torque Screws to 140 - 150 in. lbs. (16 - 17 Nm)

980131

5211 Printed in U.S.A.

02.2–1450–051

LIFT MOTOR 8695

36V - 6.75 in. DIA. RR/RD 5000/5000S SERIES STANDARD PERFORMANCE W/O SENSORS

16 15

6 14 13 11 12 9 10 9

17 9

8 7

2 Crown 2000 PF11986

02.2–1450–052

Printed in U.S.A.

02.2–1450–052

LIFT MOTOR 020614-002 LIFT MOTOR 36V STANDARD PERFORMANCE W/O SENSORS Index Part No.

Part Name

No. Req.

1 † 060078-006 Screw Thread Forming 2 060009-144 Ring Retaining 3 065081-054 Bearing Ball 4 020131 Head Drive End 020143 Head Drive End Includes 2 & 3 5 020135 Armature Includes 18 6 113653 Kit Terminal Stud 7 065081-051 Bearing Ball 8 060046-016 Washer Spring 9 020617 Frame & Field 10 020018 Brush Box Includes 11 11 113329 Kit Spring Brush Includes 4 Springs 12 060032-033 Screw Self Tapping 13 113652 Kit Brush Includes 4 Brushes 16 x 32 mm 14 060078-011 Screw Thread Rolling 15 020081 Head Commutator End 020072 Head Commutator End Includes 10 thru 14 16 † 060078-004 Screw Thread Forming 17 060078-003 Screw Thread Forming 18 * Fan

4 1 1 1 1 1 1 1 1 1 1 1 4 1 4 1 1 2 8 1

Always Specify Model, Data & Serial Numbers * Not Serviceable † Torque Screws to 16 - 17 Nm (140 - 150 in. lbs.)

010124

6903 - EO4148 Printed in U.S.A.

02.2–1450–053

LIFT MOTOR 6640

RR 5000 - 24 VOLT Standard Performance No Sensors 21 22

19 16 15 17

13 11 12 9

10 9

9 8 7

1 5

Crown 1997 PF11061 Rev. 5/98

Printed in U.S.A.

01 REV. 5/98

02.2–1450–100

LIFT MOTOR 020603 - 24 Volt STANDARD PERFORMANCE NO SENSORS Index Part No.

Part Name

No. Req.

1 † 060078-009 Screw Thread Forming 4 2 060009-144 Ring Retaining 1 3 065081-054 Bearing Ball 1 4 020131 Head Drive End 1 020143 Head Drive End Includes Index 2 & 3 1 5 020631 Armature Includes Index 18 1 6 125782 Kit Terminal Stud Includes Index 12 1 7 065081-051 Bearing Ball 1 8 060046-016 Washer Spring 1 9 020604 Frame & Field 1 060078-003 Screw Thread Forming 8 10 020018 Brush Box Includes Index 11 1 11 113329 Kit Spring Brush Includes 4 Springs 1 12 060032-033 Screw Self-Tapping 4 13 120860 Kit Brush Includes 4 Brushes 16 x 32mm 1 14 060078-011 Screw Thread Rolling 4 15 020619 Head Commutator End 1 020592 Head Commutator End Includes Index 10, 11, 12, 13 & 14 1 16 † 060078-007 Screw Thread Forming 2 17 020427-001 Headband 1 18 020536-001 Fan 1 19 060032-061 Screw 4 20 020622-001 Blower 1 21 020621 Shroud 1 22 060017-045 Screw 1 060005-009 Lockwasher 1 060030-232 Flatwasher 1 Always Specify Model, Data & Serial Numbers † Torque Screws to 140 - 150 in. lbs. (15.8 - 16.9Nm)

970901

5725 Printed in U.S.A.

01 REV. 5/98

02.2–1450–101

LIFT MOTOR 8695

RR 5000 - 24 VOLT Standard Performance No Sensors

16 15

6 14 13 11 12 9 10 9

17 9

8 7

2 Crown 2000 PF11987

02.2–1450–102

Printed in U.S.A.

02.2–1450–102

LIFT MOTOR 020893 - 24 Volt STANDARD PERFORMANCE NO SENSORS Index Part No.

Part Name

No. Req.

1 † 060078-006 Screw Thread Forming 4 2 060009-144 Ring Retaining 1 3 065081-054 Bearing Ball 1 4 020131 Head Drive End 1 020143 Head Drive End Includes Index 2 & 3 1 5 020135 Armature Includes Index 18 1 6 125782 Kit Terminal Stud Includes Index 12 1 7 065081-051 Bearing Ball 1 8 060046-016 Washer Spring 1 9 020604 Frame & Field 1 060078-003 Screw Thread Forming 8 10 020018 Brush Box Includes Index 11 1 11 113329 Kit Spring Brush Includes 4 Springs 1 12 060032-033 Screw Self-Tapping 4 13 120860 Kit Brush Includes 4 Brushes 16 x 32 mm 1 14 060078-011 Screw Thread Rolling 4 15 020081 Head Commutator End 1 020419 Head Commutator End Includes Index 10, 11, 12, 13 & 14 1 16 † 060078-004 Screw Thread Forming 2 17 060032-061 Screw 4 18 020536-001 Fan 1 Always Specify Model, Data & Serial Numbers † Torque Screws to 15.8 - 16.9 Nm (140 - 150 in. lbs.)

010124

6904 - EO4144 Printed in U.S.A.

02.2–1450–103

MANIFOLD 5753-04

RR/RD 5000/5000S SERIES PCH 5

RV2 4

6 2

ORF1

Part of RR/RD 5000S Power Unit

1 C

P V R 2 T

ORF2

A 1

ORF6

RV1 21

ORF5

ORF3

CV4 10

CV6 20 SVL 19

CV1 11 13 PC2

12 PC1

Part of RR/RD 5000S Power Unit

14 SVP

PCby 23

PCA 24

SCV6 20

PVA 18 ORF4

PVH 15

SVA 17

CV3 22

CV2 25

MVL

Part of RR/RD 5000 Power Unit

MVL 26

Crown 1997 PF11043 Rev. 2/00

Printed in U.S.A.

04 REV. 2/00

02.4–1450–001

MANIFOLD 123192 MANIFOLD BLOCK ASSEMBLY (Does Not Include Index 2, 20, 27, 28 & 29) Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

16 17

Part Name

No. Req.

Block Manifold Not Serviceable 1 064091-002 Plug Port #6 15 064091-006 Plug Port #4 2 123270-001 Orifice 2 122334-002 Valve Relief Accessory 1 111790-003 Kit Seal 1 123261 Compensator Hoist 1 111790-010 Kit Seal 1 064091-007 Plug Port #10 1 064091-001 Plug Port #8 3 123887 Nipple Quick Disconnect 1 064091-004 Plug Port #2 1 123270-004 Orifice 1 123255-002 Valve Check 1 111790-012 Kit Seal 1 123255-001 Valve Check 1 111790-009 Kit Seal 1 123256 Pilot Check Valve 1 111790-008 Kit Seal 1 123256 Pilot Check Valve 1 111790-008 Kit Seal 1 123258 Valve Solenoid Pilot 1 104164-002 Coil Solenoid 1 111790-001 Kit Seal 1 123270-003 Orifice 1 123257-001 Valve Proportional Solenoid Hoist 1 104164-012 Coil Solenoid 1 111790-014 Kit Seal 1 123270-005 Orifice 2 117385-003 Valve Solenoid 1 104164-005 Coil Solenoid 1 111790-007 Kit Seal 1

Index Part No. 18

Part Name

No. Req.

123257-002 Valve Solenoid Proportional 104164-012 Coil Solenoid 111790-013 Kit Seal 117305-003 Valve Solenoid 104164-005 Coil Solenoid 111790-012 Kit Seal 117304-003 Valve Solenoid Used with 1 Lift Pump 104164-005 Coil Solenoid 111790-003 Kit Seal 125379 Valve Check Used with 2 Lift Pumps 111790-003 Kit Seal 117913-002 Valve Relief Hoist 111790-003 Kit Seal 123255-001 Valve Check 111790-009 Kit Seal 123260 Valve Compensator By-Pass 111790-010 Kit Seal 123259 Valve Compensator 4-Way Accessory 111790-011 Kit Seal 123255-001 Valve Check 111790-009 Kit Seal 117739 Valve Manual Lower 111790-005 Kit Seal 060017-033 Screw 060017-047 Screw 060017-007 Screw 060005-009 Lockwasher 060030-026 Flatwasher

21 22 23 24

25 26 27 28 29

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 2 2 2 2

Always Specify Model, Data & Serial Numbers

980131

6477 Printed in U.S.A.

04 REV. 2/00

02.4–1450–002

REACH ASSEMBLY - MANIFOLDS 5860-01

RR/RD 5000/5000S SERIES Top of Reach Support

Torque into Cavity to 20 ft. lbs. (27.1Nm)

Reach

CBV

FO EN RK D

R2 1 R1 Torque into Cavity to 25 ft. lbs. (34.0Nm)

Torque into Cavity to 25 ft. lbs. (34.0Nm)

CBV

SVR

Torque to 7 ft. lbs. (9.5Nm)

Torque into Cavity to 20 ft. lbs. (27.1Nm)

Torque to 7 ft. lbs. (9.5Nm)

Top of Reach Carriage 10 7

Tilt & Sideshift

SVT

6 S

T2 T1

FO EN RK D

Torque to 7 ft. lbs. (9.5Nm) SVS

SS1 SS2 Torque into Cavity to 20 ft. lbs. (27.1Nm)

Torque to 7 ft. lbs. (9.5Nm) Torque into Cavity to 20 ft. lbs. (27.1Nm)

Top of Reach Carriage

FO EN RK D

SVT

Tilt

T2 9

Crown 1997 PF11091 Rev. 6/99

T1 Printed in U.S.A.

02 REV. 6/99

02.4–1450–050

REACH ASSEMBLY - MANIFOLDS Index Part No. 1

2 3 4 5 6

7 8

9 10

Part Name

No. Req.

122167-001 Valve Soleniod 1 104164-015 Coil 24V 1 123977 Kit Seal 1 121819 Check Valve 2 111790-002 Seal Kit 1 060016-088 Screw 2 060005-008 Lockwasher 2 125928 Block Includes Expansion Plugs 1 060015-064 Screw 1.0 in. (25 mm) Length 1 060015-069 Screw 1.5 in. (40 mm) Length 1 122167-001 Valve Soleniod 2 104164-015 Coil 24V 1 123977 Kit Seal 1 125929 Block Includes Expansion Plugs 1 122167-001 Valve Soleniod 1 104164-015 Coil 24V 1 123977 Kit Seal 1 122172 Block 1 064091-006 Plug 1 Always Specify Model, Data & Serial Numbers

Note: Regardless of truck battery voltage, the Access 1, 2, 3 system powers solenoids with 24 volts.

980131

6149 Printed in U.S.A.

02 REV. 6/99

02.4–1450–051

DRIVE UNIT PARTS Drive Unit Drive Unit

Figure 18445

03.0-1450-005 02 Rev. 7/09

Crown 2008 PF17162-1 Rev. 7/09

DRIVE UNIT PARTS Drive Unit INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

0 . . . . . 134468 . . . . . . . . . . . Drive Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 . . . . . . . . 131877. . . . . . . . . . . . Housing Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . 060017-007. . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 . . . . . 060005-009. . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 . . . . . . . . 064091-005 . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 061004-005 . . . . . . . . Hydraulic Sealant Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 . . . . . . . . 064020-003 . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 061004-005 . . . . . . . . Hydraulic Sealant Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 . . . . . . . . 064198-002 . . . . . . . . Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 061004-005 . . . . . . . . Hydraulic Sealant Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . . . . . 061011-020 . . . . . . . . Pin Dowel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 8 . . . . . . . . 064019-033 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9 . . . . . . . . 127413. . . . . . . . . . . . Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 10 . . . . . . . . 065081-065 . . . . . . . . Bearing Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11 . . . . . . . . 085586. . . . . . . . . . . . Shaft Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12 . . . . . . . . 065089-004 . . . . . . . . Bearing Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 13 . . . . . . . . 085580. . . . . . . . . . . . Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 061004-026 . . . . . . . . Adhesive Thread Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 14 . . . . . . . . 085928-001 . . . . . . . . Shim 0.20 mm (0.008 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 085928-002 . . . . . . . . Shim 0.25 mm (0.010 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 085928-003 . . . . . . . . Shim 0.36 mm (0.014 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 085928-004 . . . . . . . . Shim 1.02 mm (0.040 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 15 . . . . . . . . 085927. . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 16 . . . . . . . . 064138-003 . . . . . . . . Seal Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 17 . . . . . . . . 060009-097 . . . . . . . . Ring Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 18 . . . . . . . . 086015. . . . . . . . . . . . Shaft Idler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 19 . . . . . . . . 064019-061 . . . . . . . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Always Specify Model, Data & Serial Number Crown 2008 PF17162-2 Rev. 7/09

03.0-1450-006 02 Rev. 7/09

DRIVE UNIT PARTS Drive Unit

(a)

Torque to 18.9 Nm (14 ft lb)

(b)

Torque to 610 Nm (450 ft lb)

(c)

Torque to 135.6 Nm (100 ft lb)

Figure 18446-01

03.0-1450-007 02 Rev. 7/09

Crown 2008 PF17162-3 Rev. 7/09

DRIVE UNIT PARTS Drive Unit INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

30 . . . . . . . . 078885-001 . . . . . . . . Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 31 . . . . . . . . 127974(2) . . . . . . . . . . Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 065005-003 . . . . . . . . Anti-seize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 32 . . . . . . . . 087412. . . . . . . . . . . . Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 065005-001 . . . . . . . . Gasket Sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 33 . . . . . . . . 065024. . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 34 . . . . . . . . 065023. . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 35 . . . . . . . . 083513. . . . . . . . . . . . Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 36 . . . . . . . . 065018. . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 37 . . . . . . . . 065019. . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 38 . . . . . . . . 128942. . . . . . . . . . . . Nut Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 39 . . . . . . . . 128941(2) . . . . . . . . . . Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 40 . . . . . . . . 085928-001 . . . . . . . . Shim 0.20 mm (0.008 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 085928-002 . . . . . . . . Shim 0.25 mm (0.010 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 085928-002 . . . . . . . . Shim 0.33 mm (0.013 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 41 . . . . . . . . 128297(2) . . . . . . . . . . Matched Gear & Pinion(1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 42 . . . . . . . . 131101 . . . . . . . . . . . . Locking Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 43 . . . . . . . . 078885-003 . . . . . . . . Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 061004-026 . . . . . . . . Adhesive Thread Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 44 . . . . . . . . 089239-001 . . . . . . . . Wire Lock Cut to Length Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 45 . . . . . . . . 128725. . . . . . . . . . . . Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 46 . . . . . . . . 110559 . . . . . . . . . . . . Screw Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 47 . . . . . . . . 083500. . . . . . . . . . . . Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 48 . . . . . . . . 128447-001 . . . . . . . . Cover Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 49 . . . . . . . . 060005-008 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 50 . . . . . . . . 060016-031 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 (1) Gear and Pinion are a matched set (2) Parts are not serviceable

Always Specify Model, Data & Serial Number Crown 2008 PF17162-4 Rev. 7/09

03.0-1450-008 02 Rev. 7/09

DRIVE UNIT PARTS Drive Unit

(a)

Torque to 20 - 27 Nm (15 - 20 ft lb)

Figure 18447-01

03.0-1450-009 02 Rev. 7/09

Crown 2008 PF17162-5 Rev. 7/09

DRIVE UNIT PARTS Drive Unit INDEX

PART NUMBER

PART NAME

NUMBER REQUIRED

60 . . . . . . . . 061008-004 . . . . . . . . Key Woodruff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 61 . . . . . . . . 065052. . . . . . . . . . . . Bearing Cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 62 . . . . . . . . 065051. . . . . . . . . . . . Bearing Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 63 . . . . . . . . 083516-001 . . . . . . . . Shim 0.20 mm (0.008 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 083516-002 . . . . . . . . Shim 0.25 mm (0.010 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 083516-003 . . . . . . . . Shim 0.33 mm (0.013 in) Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 64 . . . . . . . . 134258. . . . . . . . . . . . Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 65 . . . . . . . . 060005-008 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 66 . . . . . . . . 060016-004 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 67 . . . . . . . . 083531. . . . . . . . . . . . Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 68 . . . . . . . . 065081-003 . . . . . . . . Bearing Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 69 . . . . . . . . 060009-039 . . . . . . . . Ring Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 70 . . . . . . . . 086016. . . . . . . . . . . . Gear Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 71 . . . . . . . . 083511 . . . . . . . . . . . . Flatwasher Special. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 72 . . . . . . . . 060044-006 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 73 . . . . . . . . 060043-006 . . . . . . . . Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 74 . . . . . . . . 087386. . . . . . . . . . . . Gear 1st Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 75 . . . . . . . . 060044-005 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 76 . . . . . . . . 060043-005 . . . . . . . . Locknut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 77 . . . . . . . . 083501. . . . . . . . . . . . Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 065005-001 . . . . . . . . Gasket Sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 78 . . . . . . . . 086618. . . . . . . . . . . . Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 79 . . . . . . . . 064020-004 . . . . . . . . Plug Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 80 . . . . . . . . 060005-037 . . . . . . . . Lockwasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 81 . . . . . . . . 060016-030 . . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 061004-006 . . . . . . . . Thread Locking Adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 82 . . . . . . . . 128297(2) . . . . . . . . . . Matched Gear & Pinion(1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 134469 . . . . . . . . . . . Drive Unit Replacement Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 (1) Gear and Pinion are a matched set (2) Parts are not serviceable

Always Specify Model, Data & Serial Number Crown 2008 PF17162-6 Rev. 7/09

03.0-1450-010 02 Rev. 7/09

TRACTION TIRE 5827

POLY TIRES - Size: 13 x 5.5 x 9.5 in./330 x 140 x 240mm Tire Assembly (Includes Hub)

Tire

Hub

Tread

Color

Durometer

121500-001 121500-005 121500-006 121500-008 121500-010 121500-011 121500-012 121500-013 121500-014 121500-015 121500-016 121500-017

121501-010-01 121501-010-02 121501-010-03 121501-011-01 121501-027-01 121501-027-02 121501-027-03 121501-028-01 121501-037-01 121501-037-02 121501-037-03 121501-038-01

121502 121502 121502 121502 121502 121502 121502 121502 121502 121502 121502 121502

Smooth Center Groove 22 Degree Siped Smooth Smooth Center Groove 22 Degree Siped Smooth Smooth Center Groove 22 Degree Siped Smooth

Black Black Black Cream Black Black Black Cream Black Black Black Cream

80-86 80-86 80-86 80-86 89-93 89-93 89-93 89-93 88-92 88-92 88-92 88-92

Always Specify Model, Data & Serial Numbers

980131

6972 - EO4398

Crown 1997 PF11066 Rev. 2/01

Printed in U.S.A.

04 REV. 2/01

03.2–1450–001

CONTACTOR PANEL 7438

RR 5000 SERIES - 24 VOLT, 1 PUMP

1 2

3 5 4 9

TR40 39

9 12 FU8

11 FU9

34 ED2

15 9

33 SB41

38 37 14

18 20

16 ED

17 SB40

24 32

25 FU1 26 FU2 27 FU3 28 FU4 29 FU5 30 FU6

Crown 1997 PF11038 Rev. 5/99

Printed in U.S.A.

04 REV. 5/99

04.1–1450–001

CONTACTOR PANEL 123198-001 CONTACTOR PANEL 126216-001 CONTACTOR PANEL (EEC) (Does Not Include Index 21 & 22) Index Part No.

Part Name

No. Req.

123851 Plate 060030-119 Flatwasher 060005-009 Lockwasher 060021-011 Nut 3 123208 Panel Bus Fuse 4 060015-037 Screw 060005-006 Lockwasher 5 113729-017 Label ACK/ECK-250 6 079566-051 Label 7 113729-018 Label AOK/ALS-250 8 079566-065 Label 9 060015-089 Screw 060005-026 Lockwasher 10 060015-066 Screw 060005-026 Lockwasher 11 076924-020 Fuse ACK/ECK-250 12 076924-010 Fuse AOK/ALS-300 † 076924-009 Fuse AOK/ALS-250 13 123088 Bar Bus 14 060059-003 Nut M8 15 123083 Bar Bus 16 118396 Contactor See Section 04.4 17 114285 Suppressor Diode 18 123084 Bracket Mounting 19 060061-007 Screw M5 060005-005 Lockwasher 20 060015-003 Screw 060005-007 Lockwasher 21 078723-001 SB-350 Connector Gray 078723-002 SB-175 Connector Gray 078723-003 SB-350 Connector Red 078723-004 SB-175 Connector Yellow 078723-006 SB-350 Connector Blue 078723-007 SB-175 Connector Red 078723-008 SB-175 Connector Blue 078723-009 SB-350 Connector Yellow 078724-001 Contacts † 108801-001 SBE-320 Connector Gray † 108801-003 SBE-320 Connector Red † 108801-006 SBE-320 Connector Blue † 108801-008 SBE-320 Connector Yellow † 108802-001 Contacts

1 3 3 3 1 2 2 1 1 1 1 3 3 1 1 1 1 1 1 4 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 1 2 1 1 1 1 2

1 2

Index Part No.

Part Name

No. Req.

060015-008 Screw 060005-007 Lockwasher 060030-037 Flatwasher 23 104401-014 Spacer 060005-004 Lockwasher 24 060013-040 Screw 25 094362-002 Fuse 15A, ABC-15 26 094362-002 Fuse 15A, ABC-15 27 094362-002 Fuse 15A, ABC-15 28 094362-002 Fuse 15A, ABC-15 29 094362-002 Fuse 15A, ABC-15 30 094362-002 Fuse 15A, ABC-15 31 113729-001 Label, ABC-15 32 123524 Panel Fuse 33 † 114285 Suppressor Diode 34 † 126175-001 Contactor See Section 04.4 35 † 060059-003 Nut M8 36 † 123084 Bracket Mounting 37 † 060061-007 Screw M5 † 060005-005 Lockwasher 38 † 060015-003 Screw † 060005-007 Lockwasher 39 † 062627-001 Thermistor

2 2 2 4 4 4 1 1 1 1 1 1 1 1 1 1 4 1 2 2 2 2 1

Always Specify Model, Data & Serial Numbers †Only Used On EEC Trucks 061003-005 125588-001 † 126222 062020-001

980131

Cable Tie Boot Harness Connector Wire

4 2 1 2

6115 - 44932/45100 Printed in U.S.A.

04 REV. 5/99

04.1–1450–002

CONTACTOR PANEL 7439

RR/RD 5000 SERIES - 36 VOLT, 2 PUMPS

2 5 4

9 7

TR40 31 42

12 FU8

11 FU9 40 ED2

34 FU7

43 38 44

9 14 36

14 SB40 17

37 P2 32

39 SB41 35

25 FU1 26 FU2 27 FU3 28 FU4 29 FU5

18 19

16 ED

30 FU6

Crown 1997 PF11040 Rev. 5/99

Printed in U.S.A.

04 REV. 5/99

04.1–1450–050

CONTACTOR PANEL 123198-003 CONTACTOR PANEL 126216-002 CONTACTOR PANEL (EEC) (Does Not Include Index 21 & 22) Index Part No.

Part Name

No. Req.

123851 Plate 060030-119 Flatwasher 060005-009 Lockwasher 060021-011 Nut 3 123208 Panel 4 060015-037 Screw 060005-006 Lockwasher 5 113729-017 Label ACK/ECK-250 6 079566-051 Label 7 113729-018 Label AOK/ALS-250 8 079566-065 Label 9 060015-089 Screw 060005-026 Lockwasher 10 060015-066 Screw 060005-026 Lockwasher 11 076924-020 Fuse ACK/ECK-250 12 076924-009 Fuse AOK/ALS-250 13 123086 Bar Bus 14 060059-003 Nut M8 15 123083 Bar Bus 16 118396 Contactor See Section 04.4 17 114285 Suppressor Diode 18 123084 Bracket 19 060061-007 Screw M5 060005-005 Lockwasher 20 060015-003 Screw 060005-007 Lockwasher 21 078723-001 SB-350 Connector Gray 078723-002 SB-175 Connector Gray 078723-003 SB-350 Connector Red 078723-004 SB-175 Connector Yellow 078723-006 SB-350 Connector Blue 078723-007 SB-175 Connector Red 078723-008 SB-175 Connector Blue 078723-009 SB-350 Connector Yellow 078724-001 Contacts † 108801-001 SBE-320 Connector Gray † 108801-003 SBE-320 Connector Red † 108801-006 SBE-320 Connector Blue † 108801-008 SBE-320 Connector Yellow † 108802-001 Contacts

1 3 3 3 1 2 2 1 1 2 1 5 5 1 1 1 1 1 8 1 1 1 2 4 4 4 4 1 1 1 1 1 1 1 1 2 1 1 1 1 2

1 2

Index Part No.

Part Name

No. Req.

060015-008 Screw 060005-007 Lockwasher 060030-037 Flatwasher 23 104401-014 Spacer 060005-004 Lockwasher 24 060013-040 Screw 25 094362-002 Fuse 15A, ABC-15 26 094362-002 Fuse 15A, ABC-15 27 094362-002 Fuse 15A, ABC-15 28 094362-002 Fuse 15A, ABC-15 29 094362-002 Fuse 15A, ABC-15 30 094362-002 Fuse 15A, ABC-15 31 113729-001 Label, ABC-15 32 123524 Panel 33 079566-064 Label 34 076924-009 Fuse AOK/ALS-250 35 123087 Bar Bus 065003-175 Sleeving 36 123088 Bar Bus 37 110613-003 Contactor See Section 04.4 38 † 060015-003 Screw † 060005-007 Lockwasher 39 † 114285 Suppressor Diode 40 † 126175-001 Contactor See Section 04.4 41 † 060059-003 Nut M8 42 † 062627-001 Thermistor 43 † 123084 Bracket 44 † 060061-007 Screw M5 060005-005 Lockwasher

2 2 2 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 4 1 1 2 2

Always Specify Model, Data & Serial Numbers †Only Used On EEC Trucks 125588-001 061003-005 † 126222

Boot Tie Cable Harness

2 4 1

6115 - 44932/45100

980131

Printed in U.S.A.

04 REV. 5/99

04.1–1450–051

CONTACTOR PANEL RR/RD 5000 SERIES - 36 VOLT, 2 PUMPS ELECTRICALLY ENCLOSED (EE) 5

6 8

6657

9 10

19 10

FU9

14 FU8

11 16 9

8 12

7 21

12 15 FU7 19

19 22

23 ED

28 P2

24 SB40

26 27

Label Location

34 FU1 35 FU2 36 FU3 37 FU4 38 FU5

41 42 45

39 FU6

43 44

32 Crown 1998 PF11448

04.1–1450–100

Printed in U.S.A.

04.1–1450–100

CONTACTOR PANEL

126096 CONTACTOR PANEL ASSEMBLY ELECTRICALLY ENCLOSED (EE) 36 VOLT 2 PUMPS Index Part No. 1 2

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Part Name

123851 Plate 060030-119 Flatwasher 060005-009 Lockwasher 060021-011 Nut 123090 Box 060015-003 Screw 060005-007 Lockwasher 060021-043 Nut 060005-031 Lockwasher 126176 Bus Bar 123050 Stud 060030-017 Flatwasher 119323 Insulator 126104 Bus Bar 076924-020 Fuse ACK/ECK-250 060015-089 Screw 060005-026 Lockwasher 060015-066 Screw 060005-026 Lockwasher 076924-009 Fuse AOK/ALS-250 076924-009 Fuse AOK/ALS-250 123089 Cover 060015-003 Screw 060005-007 Lockwasher 060091-001 Insert Nut 060059-003 Nut M8 126047 Bus Bar 065003-175 Sleeving 123095 Bus Bar 123096 Bus Bar

No. Req. 1 3 3 3 1 2 2 6 6 2 6 6 12 6 1 5 5 1 1 1 1 1 4 4 4 6 1 1 1 1

Index Part No. 23 24 25 26 27 28 29 30 31 32

33 34 35 36 37 38 39 40 41 42 43 44 45

Part Name

No. Req.

119784 Contactor See Section 04.4 114285 Suppressor Diode 060061-007 Screw M5 060005-005 Lockwasher 123084 Bracket 060015-003 Screw 060005-007 Lockwasher 118280-003 Contactor See Section 04.4 123524 Panel 060013-040 Screw 104401-014 Spacer 060005-004 Lockwasher 060013-011 Screw 060005-004 Lockwasher 060030-096 Flatwasher 125713 Enclosure 094362-002 Fuse 15A, ABC-15 094362-002 Fuse 15A, ABC-15 094362-002 Fuse 15A, ABC-15 094362-002 Fuse 15A, ABC-15 094362-002 Fuse 15A, ABC-15 094362-002 Fuse 15A, ABC-15 113729-001 Label ABC-15 113729-017 Label ACK/ECK-250 079566-051 Label 079566-065 Label 079566-064 Label 113729-018 Label ALS/AOK-250

1 1 4 4 2 4 4 1 1 2 6 6 4 4 4 1 1 1 1 1 1 1 1 1 1 1 1 2

Always Specify Model, Data & Serial Numbers 125588-001 061003-005

980514

Boot Cable Tie

1 4

5769 - 44789 Printed in U.S.A.

04.1–1450–101

DISTRIBUTION PANEL 5736-01

RR/RD 5000/5000S SERIES 7 Index 13, 14, 15, & 16 Used on Electrically Enclosed (EE) Trucks Only

13 14 6

4 K1

3 FU11

5 K2

2 FU10

CA205 CA209

CA204 CA202

CA210

CA203

CA201

8 ALM1 CA207 CA206 12

CA208 1

Index Part No. 1

2 3 4 5 6 7

Part Name

122179-001 Panel Distribution 24 V Includes 1 thru 6 122179-002 Panel Distribution 36 V Includes 1 thru 6 094362-008 Fuse 3 Amp 094362-004 Fuse 3/4 Amp 062640-001 Relay 24 V 062640-002 Relay 36 V 062640-001 Relay 24 V 062640-002 Relay 36 V 061003-004 Tie Cable 060013-040 Screw

No. Req.

1 1 1 1 1 1 1 1 1 4

Index Part No. 8 9 10 11 12 13

Part Name

Part of Power Unit Top Section

No. Req.

104401-017 Standoff 060005-006 Lockwasher 104401-019 Standoff 123822 Cover 060091-001 Nut Insert 060013-011 Screw 060005-004 Lockwasher 060030-096 Flatwasher 123098 Cover 104401-017 Spacer 060005-006 Lockwasher 060091-001 Insert Nut

14 15 16

4 4 4 1 4 4 4 4 1 4 4 4

Always Specify Model, Data & Serial Numbers 980131

6064

Crown 1997 PF11052 Rev. 4/99

Printed in U.S.A.

03 REV. 4/99

04.3–1450–001

MULTI-TASK CONTROL 5926-01

RR/RD 5000 SERIES

4 3

5 35 7 EDS 6

34 10

19 20 POT 1

9 13

22 POT 2

11 CA611 17

12 CA612

15 14

21 19

16 FS

16 RS

Part of Power Unit Top Section

Black Yellow

25 31

28 27

27 29 26 25

30 POT 3

32 33 Crown 1997 PF11152 Rev. 10/98

Printed in U.S.A.

03 REV. 10/98

04.6–1450–001

MULTI-TASK CONTROL Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Part Name

No. Req.

123746-001 Support 123746-002 Support F/C 060014-019 Screw 060014-061 Screw 123747 Button 094606 Spring 060009-002 Ring Retaining 062692 Switch 060011-003 Screw 060005-049 Lockwasher 060077-001 Pin Roll 093603 Insulator Connector See Section 04.8 Connector See Section 04.8 123750 Mount 060012-020 Screw 060005-003 Lockwasher 060017-079 Screw 060005-009 Lockwasher 060021-011 Nut 123775 Directional Optic Switches & Board 060012-070 Screw 060011-026 Screw 122322 Base 123081-001 Potentiometer Traction 123081-002 Potentiometer F/C Traction 060045-030 Screw 123080-001 Potentiometer Raise/Lower 123080-002 Potentiometer F/C Raise/Lower 123673 Cover Dust 060032-057 Screw 060012-075 Screw 122255 Mount Tie 061003-002 Tie Wire 125055 Harness Contains HNS, TBS,TDS & SSS 122592 Handle Right 123471 Spring 123079-001 Potentiometer Accessory 123079-002 Potentiotmeter F/C Accessory 060000-115 Pin Roll 122593 Handle Left 060013-039 Screw 124006 Cover "A" Batt. 123751 Cover "B, C, D & E" Batt. 060015-100 Screw 126027 Plate Cover "A" Batt. 060012-074 Screw "A" Batt.

1 1 3 1 1 2 1 1 1 1 1 1 1 1 1 4 4 4 4 4 1 2 2 1 1 1 2 1 1 1 3 2 2 4 1 1 1 1 1 1 1 4 1 1 3 1 2

Always Specify Model, Data & Serial Numbers 980131

5881 Printed in U.S.A.

03 REV. 10/98

04.6–1450–002

MULTI-TASK CONTROL 7315-04

RR/RD 5000 SERIES 29

2 1

5 35 7 EDS 6

34 10

28 20 POT 1

9 3 13

11 CA611

28 22 POT 2

12 CA612

16 17

15 14

21 37 19

16 FS

16 RS Black Yellow

Part of Power Unit Top Section 31

32 27

27 26 25 27

30 POT 3

32 33 Crown 1999 PF11618 Rev. 1/01

Printed in U.S.A.

04 REV. 1/01

04.6–1450–003

C Index Part No.

MULTI-TASK CONTROL Part Name

No. Req.

Index Part No.

Part Name

1 123746-001 123746-002 2 060014-086 3 060031-017 4 123747 5 094606 6 060009-002 7 062753 8 060011-003 060005-049 9 060077-008 10 093603 11 105606-611 12 105606-612 13 123750 14 060012-020 060005-003 15 060017-079 060005-009 060021-011 16 126583-00S

23 24 25 26

17 18

33 060013-039 34 124006 123751 35 060015-100 36 126027 37 122255 060012-075 061003-002

Cover Dust 1 Screw 3 Screw 1 Mount Tie 1 Tie Wire 4 Includes Thumbwheel Harness Assembly (POT3,HNS, TBS, TDS & SSS), Raised Poly Grip Thumbwheel, Index 30 And Instructions 1 Freezer/Corrosion Includes Thumbwheel Harness Assembly (POT3,HNS, TBS,TDS & SSS), Raised Poly Grip Thumbwheel, Index 30 And Instructions 1 Yoke 2 Screw "A" Batt. 2 Potentiometer Accessory See Index 27 1 Potentiometer F/C Accessory See Index 27 1 Pin Roll 1 Pin Roll 1 Handle Includes Both Handle Halves & Index 31 1 Screw 4 Cover "A" Batt. 1 Cover "B, C, D & E" Batt. 1 Screw 3 Plate Cover "A" Batt. 1 Mount Cable Tie 2 Screw 2 Tie Cable 2

19 20

21 22

Support 1 Support F/C 1 Screw 4 Speed Nut 1 Button 1 Spring 2 Ring Retaining 1 Switch 1 Screw 1 Lockwasher 1 Pin Roll 1 Insulator 1 Connector See Section 04.8 1 Label 1 Connector See Section 04.8 1 Label 1 Mount 1 Screw 4 Lockwasher 4 Screw 4 Lockwasher 4 Nut 4 Includes FWD/REV Optic Switches, Board & Harness Assembly And Instructions 1 060012-070 Screw 2 060011-026 Screw 2 061004-028 Adhesive Thread Locking 1 122322 Base Includes Index 28 1 126575-001-0S Includes POT1 Traction Potentiometer Assembly And Instructions 1 126575-002-0S Freezer/Corrosion Includes POT1 Traction Potentiometer Assembly And Instructions 1 060045-030 Screw 2 126574-001-0S Includes POT2 Hydraulic Potentiometer Assembly And Instructions 1 126574-002-0S Freezer/Corrosion Includes POT2 Hydraulic Potentiometer Assembly And Instructions 1

123673 060032-057 060012-075 122255 061003-002 27 128654-00S

128655-00S

28 122969 29 060012-074 30

31 060000-117 060000-118 32 126725

No. Req.

Always Specify Model, Data & Serial Numbers "A" Battery Compartment = 310 mm (12.19 in.) "B" Battery Compartment = 360 mm (14.25 in.) "C" Battery Compartment = 415 mm (16.25 in.) "D" Battery Compartment = 455 mm (18.00 in.) "E" Battery Compartment = 525 mm (20.75 in.)

990224

6896 - EO3894 Printed in U.S.A.

04 REV. 1/01

04.6–1450–004

DISPLAY 5747-01

RR/RD 5000/5000S SERIES

19 11

Enhanced & Enhanced With CDM 18 Enhanced &

18 Standard

Enhanced With CDM 12

16 14

17 15 13

12 Standard Enhanced With CDM 1

11 10 9 7

ITO

ITY

DAT

CAP

28 21

28 22

29 RES1

2 LGS1

3 4 FNS 5 LGS2 ORS

27 K3

Part of RR/RD 5000 Power Unit

33 30 RES2 31 RES3

Part of Main Wire Harness

Tab on Cover Index 18

1 Standard

23 26

Part of RR/RD 5000S Power Unit

1 Enhanced

24 24

Crown 1997 PF11042 Rev. 7/99

Part of RR/RD 5000S Power Unit

Printed in U.S.A.

04 REV. 7/99

04.8–1450–001

DISPLAY 122315 STANDARD DISPLAY ASSEMBLY (Includes Index 1, 6 thru 10, 12, 17, 18 & 19) 122316 ENHANCED DISPLAY ASSEMBLY (Includes Index 1, 6 thru 10, 12, 15, 16, 18 & 19) 123337 ENHANCED DISPLAY W/CDM ASSEMBLY (Includes Index 1, 6 thru 10, 12, 15, 16, 18 & 19) Index Part No. 1

2 3 4 5 6

7 8 9

11 12

13 14 15 16 17 18

Part Name

No. Req.

122858 Overlay Standard 1 122860 Overlay Enhanced 1 123338 Overlay Enhanced with CDM 1 062595-002 Switch Dome Light 1 062595-001 Switch Fan 1 062595-002 Switch Work Lights 1 062595-003 Switch Lift Cutout Override 1 122855-001 Panel Interface Standard 1 122855-002 Panel Interface Enhanced & Enhanced with CDM 1 123151 Mount Cushion 2 060021-086 Nut 2 125416 Board PCB Switch Standard Display 1 125416 Board PCB Switch Enhanced & Enhanced with CDM 2 060012-074 Screw Standard 2 060012-074 Screw Enhanced & Enhanced with CDM 4 060012-074 Screw 8 124014 Board Display Standard 1 124015 Board Display Enhanced & Enhanced with CDM 1 062666-001 Post Support Enhanced & Enhanced with CDM 5 060012-020 Screw Enhanced & Enhanced with CDM 2 117774-003 Retainer Enhanced & Enhanced with CDM 1 062580-004 Strap Grounding Enhanced & Enhanced with CDM 1 062686-001 Tape Conductive Foil Enhanced & Enhanced with CDM 1 122856-001 Cover Standard 1 122859 Cover Enhanced & Enhanced with CDM 1 065004-042 Grommet 1

Index Part No. 20

Part Name

No. Req.

123191

Bracket Display Mounting 5000 Series 060015-006 Screw 060030-012 Flatwasher 060031-026 Nut 060017-014 Screw 060030-080 Flatwasher 060005-009 Lockwasher 060021-011 Nut 122246 Bracket Display Mounting 5000S Series 060015-006 Screw 060030-012 Flatwasher 060031-026 Nut Speed 060017-019 Screw 060005-009 Lockwasher 060030-026 Flatwasher 060017-014 Screw 060005-009 Lockwasher 060030-026 Flatwahser 060021-011 Nut 062337-008 Relay 24V 062337-009 Relay 36V 060012-016 Screw 060005-048 Lockwasher 060021-003 Nut 062033-049 Resistor 24V 062033-050 Resistor 36V 062033-032 Resistor 36V Only 062033-032 Resistor 24V 062033-034 Resistor 36V 060011-012 Screw 060005-036 Lockwasher 060021-031 Nut 104401-018 Spacer

23 24

27 28

29 30 31 32

1 2 4 2 2 2 2 2 1 2 2 2 2 2 2 2 2 2 2 1 1 2 2 2 1 1 1 1 1 6 6 6 2

Always Specify Model, Data & Serial Numbers

980131

6174 Printed in U.S.A.

04 REV. 7/99

04.8–1450–002

CONTROL CABLE 5861

RR/RD 5000/5000S SERIES

Yoke See Section 07.5

8 12 11

6 13 7

5 6

9.0 in. 230 mm

Extended Working Length

21.5 in. 545 mm

Extended Working Length

Crown 1997 PF-11094

04.8–1450–200

9.0 in. 230 mm

Extended Working Length

13.5 in. 345 mm

Extended Working Length

NOTE: Index 8 Thru 13 - Used Only When Truck is Equipped With Load Sensing & Freezer Condition Options Printed in U.S.A.

04.8–1450–200

OVERHEAD GUARD ACCESSORIES 6460-02

RR/RD 5000/5000S SERIES Part Of Overhead Guard

1 4 3 9 2

21 17 LGT4

5 SB80 6

7 FN

3 18 20

12 11

19 13

22 SB81

23 14

Part of L.H. Mast Guard

15 16

25 29

Part of Overhead Guard LGT3 Right Worklight LGT2 Left Worklight

28 24 LGT1 27

33 31 LGT3 33

35 Mast Mounted Worklights

31 LGT2

34 36 Part of Main Frame Assembly

Crown 1997 PF11291 Rev. 6/02

Overhead Guard Mounted Worklights Printed in U.S.A.

04 REV. 6/02

04.9–1450–050

OVERHEAD GUARD ACCESSORIES Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Part Name

No. Req.

060015-037 Screw 061004-026 Adhesive Thread Lock 123787 Support 128458 Guard 060042-015 Nut 061004-026 Thread Locking Adhesive 107853 Suppressor 108026-080 Label 060013-008 Screw 060005-004 Lockwasher 108682 Fan 060013-044 Screw 123795 Support 123958 Duct Cable 123786 Console 060015-031 Screw 123794 Console 123793 Louver 060012-076 Screw 012510 Washer Strobe Light LGT 4 See Section 04.9 123884 Console 060014-043 Screw 123880 Bracket

4 1 1 2 4 AR 1 1 2 2 1 4 1 AR 1 4 1 2 4 4 1 1 3 1

Index Part No. 21 22 23 24

25 26 27 28 29 30 31

32 33 34 35 36

Part Name

No. Req.

060015-037 Screw 112533 Filter 060013-008 Screw 060005-004 Lockwasher 123683 Dome Light LGT1 Includes Index 24 thru 27 123782 Housing 123783 Lens Black 123781 Lens Clear 116364 Bulb 060015-023 Screw 060091-001 Insert 061021-002 Bushing 104296-002 Spotlight 36V LGT2, LGT3 102195 Bulb Sealed Beam 36V 104296-003 Spotlight 24V 087195-001 Bulb Sealed Beam 24V 060045-026 Screw 123980 Spacer 123962 Housing 060017-086 Screw 104303 Spacer 060030-115 Flatwasher 060021-047 Nut 060030-161 Flatwasher

3 1 2 2 1 1 1 1 1 2 2 1 2 2 2 2 2 4 2 4 2 2 2 4

Always Specify Model, Data & Serial Numbers

980131

1742 Printed in U.S.A.

04 REV. 6/02

04.9–1450–051

TRACTION MOTOR BRAKE 6868

RR/RD 5000/5000S SERIES 6 16

15 14

3 12 2

1 7

Index Part No. 1 2 3 4 5 6 7 8 9 10 11

Part Name

No. Req.

Traction Motor See Section 3.1 1 118167 Adjuster 1 125807 Magnet & Coil Body 1 119042 Spring Compression 15 119044 Armature Inner 1 060016-058 Screw 3 061004-026 Adhesive Thread Locking 1 119043 Armature Outer 1 119677 Spring Compression 1 Rivet 12 119046 Brake Pad Assembly Includes Index 9 and 11 1 Brake Pad 6

Index Part No. 12 13 14 15 16

Part Name

No. Req.

125808 Brake Rotor 118166-001 Nut 118166-002 Nut 060030-082 Flatwasher 060009-153 Ring Retaining

121592 062037-012 062036-003 105606-609

1 1 1 AR 1

Brake 2 Step Includes Index 3, 4, 5, 7, 10 & 12 Connector Contact Pin Label

1 1 4 1

Always Specify Model, Data & Serial Numbers

980131

5975

Crown 1997 PF11265 Rev. 12/98

Printed in U.S.A.

02 REV. 12/98

05.3–1450–100

STEERING SYSTEM 6827

RR/RD 5000 SERIES

29 25

47 30

31 32 33 35 36 37

24 23

18 17

RR/RD 5000 Undercarriage

14 41

7 5

Drive Unit See Section 03.0

Part of Power Unit

46 1

2 47

Crown 1997 PF11120 Rev. 7/99

Printed in U.S.A.

05 REV. 7/99

06.0–1450–001

STEERING SYSTEM Index Part No. 1 2 3 4 5

6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23

Part Name

No. Req.

060020-052 Screw 5 061004-026 Adhesive Thread Locking 1 125845-001 Pin Pull Dowel 2 060020-027 Screw 1 125362 Cup Holder 1 125475-088 Shim 0.084 in. (2 mm) Thick AR 125475-092 Shim 0.088 in. (2.2 mm) Thick AR 125475-096 Shim 0.096 in. (2.4 mm) Thick AR 125475-100 Shim 0.100 in. (2.5 mm) Thick AR 125475-104 Shim 0.104 in. (2.6 mm) Thick AR 125475-108 Shim 0.108 in. (2.7 mm) Thick AR 125475-112 Shim 0.112 in. (2.8 mm) Thick AR 065127 Bearing Cup 1 065128 Bearing Cone 1 065129-002 Seal Metallic 1 125305 Stud 1 060000-049 Pin Roll 1 060017-066 Screw Tighten to 25 - 30 ft. lbs. 2 061004-026 Adhesive Thread Locking 1 060017-007 Screw Tighten to 25 - 30 ft. lbs. 2 060005-009 Lockwasher 2 125304 Gear Ring 1 065129-001 Seal Metallic 1 065126 Bearing Cone 1 065125 Bearing Cup 1 064214-002 Seal 1 060009-036 Ring Retaining 1 060009-095 Ring Retaining 1 092157 Gear Idler Includes 18 & 20 1 084586 Gear Idler 1 065010-005 Bearing Ball 1 060009-018 Ring Retaining 1 121710 Gear Pinion 1 060009-035 Ring Retaining 1

Index Part No. 24 25

Part Name

No. Req.

065081-033 Bearing Ball 121835 Spacer 121836 Spacer 121837 Spring 121711 Stud 060045-003 Screw Shoulder Hydraulic Motor Section 06.2 123678 Knob 060000-002 Pin Roll 123674 Tiller 060016-019 Screw 060005-008 Lockwasher 060016-091 Screw 123675 Mount 060009-036 Ring Retaining 065081-063 Bearing Ball 060009-156 Ring Retaining 060017-102 Screw 123574 Support 060017-032 Screw 060030-119 Flatwasher 123694 Brace Steering Unit Section 06.3 060017-077 Screw 060030-119 Flatwasher 060005-009 Lockwasher 060021-011 Nut 060030-119 Flatwasher 060005-009 Lockwasher 060021-011 Nut 060016-076 Screw 061004-026 Adhesive Thread Locking 100779 Lubrication Fitting 060017-010 Screw 060030-119 Flatwasher

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

46 47 48

1 2 2 2 1 2 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 2 1 1 1 2 2 2 4 1 2 1 1

Always Specify Model, Data & Serial Numbers

980131

6170 Printed in U.S.A.

05 REV. 7/99

06.0–1450–002

STEERING SYSTEM 6827

RR/RD 5000 SERIES

29 25

47 30

31 32 33 35 36 37

24 23

18 17

RR/RD 5000 Undercarriage

14 41

7 6

Drive Unit See Section 03.0

3 4

45 Part of Power Unit

46 1

2 47

Crown 2000 PF11917

06.0–1450–003

Printed in U.S.A.

06.0–1450–003

STEERING SYSTEM Index Part No. 1 2 3 4 5

6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23

Part Name

No. Req.

060020-052 Screw 5 061004-026 Adhesive Thread Locking 1 125845-001 Pin Pull Dowel 2 060020-027 Screw 1 125362 Cup Holder 1 125475-088 Shim 0.084 in. (2 mm) Thick AR 125475-092 Shim 0.088 in. (2.2 mm) Thick AR 125475-096 Shim 0.096 in. (2.4 mm) Thick AR 125475-100 Shim 0.100 in. (2.5 mm) Thick AR 125475-104 Shim 0.104 in. (2.6 mm) Thick AR 125475-108 Shim 0.108 in. (2.7 mm) Thick AR 125475-112 Shim 0.112 in. (2.8 mm) Thick AR 065127 Bearing Cup 1 065128 Bearing Cone 1 065129-002 Seal Metallic 1 127412 Stud 1 060000-049 Pin Roll 1 060017-066 Screw Tighten to 25 - 30 ft. lbs. 2 061004-026 Adhesive Thread Locking 1 060017-007 Screw Tighten to 25 - 30 ft. lbs. 2 060005-009 Lockwasher 2 125304 Gear Ring 1 065129-001 Seal Metallic 1 065126 Bearing Cone 1 065125 Bearing Cup 1 064214-002 Seal 1 060009-036 Ring Retaining 1 060009-095 Ring Retaining 1 092157 Gear Idler Includes 18 & 20 1 084586 Gear Idler 1 065010-005 Bearing Ball 1 060009-018 Ring Retaining 1 121710 Gear Pinion 1 060009-035 Ring Retaining 1

Index Part No. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Part Name

No. Req.

1 2 2 2 1 2 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 2 1 1 1 2 2 2 4 1 2 1 1

Always Specify Model, Data & Serial Numbers

000815

6753 - EO-3277 Printed in U.S.A.

06.0–1450–004

STEERING SYSTEM 8505

RR/RD 5000 SERIES 27 25

28 29 26

47 32

33 35 36 37

24 23

18 17

RR/RD 5000 Undercarriage

40 16

10 9

42 13 12

Drive Unit See Section 03.0 3

45 Part of Power Unit

46 1

2 47

Crown 2000 PF11977

06.0–1450–005

Printed in U.S.A.

06.0–1450–005

STEERING SYSTEM Index Part No. 1 2 3 4 5

6 7 8 9 10 11

12 13 14 15 16 17 18 19 20 21 22 23

Part Name

No. Req.

060020-052 Screw 5 061004-026 Adhesive Thread Locking 1 125845-001 Pin Pull Dowel 2 060017-024 Screw 4 125362 Cup Holder 1 125475-088 Shim 0.084 in. (2 mm) Thick AR 125475-092 Shim 0.088 in. (2.2 mm) Thick AR 125475-096 Shim 0.096 in. (2.4 mm) Thick AR 125475-100 Shim 0.100 in. (2.5 mm) Thick AR 125475-104 Shim 0.104 in. (2.6 mm) Thick AR 125475-108 Shim 0.108 in. (2.7 mm) Thick AR 125475-112 Shim 0.112 in. (2.8 mm) Thick AR 065127 Bearing Cup 1 065128 Bearing Cone 1 065129-002 Seal Metallic 1 127412 Stud 1 060000-049 Pin Roll 1 060017-066 Screw Tighten to 25 - 30 ft. lbs. 2 061004-026 Adhesive Thread Locking 1 060017-007 Screw Tighten to 25 - 30 ft. lbs. 2 060005-009 Lockwasher 2 125304 Gear Ring 1 065129-001 Seal Metallic 1 065126 Bearing Cone 1 065125 Bearing Cup 1 064214-002 Seal 1 060009-036 Ring Retaining 1 060009-095 Ring Retaining 1 092157 Gear Idler Includes 18 & 20 1 084586 Gear Idler 1 065010-005 Bearing Ball 1 060009-018 Ring Retaining 1 121710 Gear Pinion 1 060009-035 Ring Retaining 1

Index Part No. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

46 47 48

Part Name

No. Req.

065081-033 Bearing Ball 128134 Shaft Threaded 121837 Spring Compression 121711 Stud 060030-288 Flatwasher 060042-020 Nut Self-Locking Hydraulic Motor Section 06.2 123678 Knob 060000-002 Pin Roll 123674 Tiller 060016-019 Screw 060005-008 Lockwasher 060016-091 Screw 123675 Mount 060009-036 Ring Retaining 065081-063 Bearing Ball 060009-156 Ring Retaining 060017-102 Screw 123574 Support 060017-032 Screw 060030-119 Flatwasher 123694 Brace Steering Unit Section 06.3 060017-077 Screw 060030-119 Flatwasher 060005-009 Lockwasher 060021-011 Nut 060030-119 Flatwasher 060005-009 Lockwasher 060021-011 Nut 060016-076 Screw 061004-026 Adhesive Thread Locking 100779 Lubrication Fitting 060017-010 Screw 060030-119 Flatwasher

1 2 2 1 2 2 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 2 1 1 1 2 2 2 4 1 2 1 1

Always Specify Model, Data & Serial Numbers

001030

6813C - EO-4178 Printed in U.S.A.

06.0–1450–006

MAST 5714-03

RR 5000 SERIES 1588kg (3500 lb) 140mm (5.5 in) CHANNEL

3 5000S Series 3 5000 Series

Part of Power Unit

For Switch HGTRS - See Section 01.2

Crown 1997 PF11037-1 Rev. 4/06

07.2–1450–001

03 REV. 4/06

Printed in U.S.A.

07.2–1450–001

C Index Part No. 1 2 3

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

MAST Part Name

No. Req.

060023-009 Screw 060005-046 Lockwasher 060021-049 Nut 121681-006 Shim 1.5mm (.060 in) Thick 121681-012 Shim 3mm (.120 in) Thick 060020-048 Screw 190mm (7.50 in) Long 5000 Series 060020-042 Screw 255mm (10.0 in) Long 5000S Series (RH Side) 060020-048 Screw 190mm (7.50 in) Long 5000S Series (LH Side) 060030-260 Flatwasher 060042-019 Nut Self Locking * Main Frame Cylinder Lift RH See Section 08.0 Cylinder Lift LH See Section 08.0 060020-015 Screw 060005-014 Lockwasher 080069 Block Stop 074481-001 Shim Stop 107563-001 Bracket 092747-001 Stop Poly 060015-004 Screw 061004-026 Adhesive Thread Lock 074668-001 Roller Column 060030-085 Shim .78mm (.031 in) Thick 121679 Guide 123281 Clamp 060015-015 Screw 060042-006 Nut Self Locking 060017-059 Screw 060017-094 Screw Load Sensor & F/C 061004-019 Adhesive Thread Lock 060005-009 Lockwasher 060030-078 Flatwasher 121624-001 Shaft 121624-003 Shaft Load Sensor & F/C 119655-001 Pulley 060030-192 Flatwasher 060009-043 Ring Retaining 060009-062 Ring Retaining 065081-045 Bearing Ball 117556-001 Pulley Chain Includes Index 24 & 25 117557-001 Pulley Chain 060017-059 Screw 061004-019 Adhesive Thread Lock

Crown 1997 PF11037-2 Rev. 4/06

07.2–1450–002

4 4 4 AR AR 2 1 1 2 2 1 1 1 4 4 2 AR 2 2 2 1 12 AR 1 1 1 1 1 1 1 1 1 1 1 2 2 2 4 2 2 2 1 1

Index Part No.

Part Name

No. Req.

28 060005-009 Lockwasher 29 060030-078 Flatwasher 30 121624-002 Shaft 31 118197-002 Pulley Cable 32 060030-192 Flatwasher 33 121623 Pulley Hose 34 * Chain Mast 35 086499 Pin 36 060000-055 Pin Roll 37 075385-001 Anchor Chain 38 060021-028 Nut 39 060038-003 Pin Cotter 40 121667 Guide 41 121679 Guide 42 060015-015 Screw 060042-006 Nut Self Locking 43 076470-025 Pin Clevis 060030-191 Flatwasher 44 060038-017 Pin Cotter 45 * Mast 2nd Stage 46 060015-043 Screw 47 060042-006 Nut Self Locking 48 * Spring 49 121621 Ram Spring 50 060009-101 Ring Retaining 51 121622 Stop Lower 52 060030-277 Flatwasher .78mm (.031 in) Thick 53 124019 Bumper 54 060017-056 Screw 061004-026 Adhesive Thread Lock 55 * Mast 3rd Stage 56 118197-002 Pulley Load Sensor & F/C 57 124010 Guide Load Sensor & F/C 58 060015-033 Screw 061004-020 Adhesive Thread Lock 59 123231-001 Spring 60 121738 Guard 61 060017-032 Screw 060005-009 Lockwasher 060021-011 Nut 62 121795 Clamp 63 060042-018 Nut Self Locking 64 Yoke See Section 07.5 65 * Chain Carriage 66 Cylinder Free Lift See Section 08.0 67 075385-004 Anchor Chain 68 Carriage Reach See Section 09.0

03 REV. 4/06

1 1 1 1 1 1 2 6 14 2 12 6 1 1 1 1 2 2 2 1 2 2 2 2 2 2 AR 2 2 1 1 1 1 1 1 1 1 2 2 2 2 4 1 2 1 2 1

Printed in U.S.A.

07.2–1450–002

MAST Index Part No.

Part Name

No. Req.

69 † 123316-003 Switch Includes Switch, Leads, Terminals & JC Label 1 † 108306 Switch 1 060061-005 Screw 2 70 060061-005 Screw 2 060005-005 Lockwasher 2 061003-004 Tie Cable 3 060030-012 Flatwasher 2 71 084985 Pin 2 72 060017-050 Screw 2 061004-019 Adhesive Thread Lock 1 73 124018 Stop Poly 2 74 119047 Ram Spring 2 75 060000-028 Pin Roll 4 76 119048 Rod 2 77 * Spring 2 78 Height Sensor See Section 04.8 1 79 * Cable 1 80 060015-064 Screw 2 060005-007 Lockwasher 2 81 † 123316-004 Switch 2260, 2415 & 2720mm (89, 95 & 107 in) Collapsed Height Includes Switch, Leads, Terminals & JC Label 1 † 123316-005 Switch 3025mm (119 in) Collapsed Height Includes Switch, Leads, Terminals & JC Label 1 060013-020 Screw 1 060013-021 Screw 1 061004-026 Adhesive Thread Locking 1 † 108306 Switch 1 82 060061-008 Screw 2 061004-019 Adhesive Thread Lock 1 83 123174 Bracket 1 84 060095-001 Set Screw 8 061004-026 Adhesive Thread Locking 1 85 075385-003 Anchor Chain 2 061003-005

Tie Cable (Hoses to Mast Cylinder)

* See The Following Supplemental Form † Internal switch replacement is not economical. Should internal switch require replacement, replace entire switch. Switch arm is not available. Always Specify Model, Data & Serial Numbers

980131 Crown 1997 PF11037-3 Rev. 4/06

07.2–1450–003

13851

03 REV. 4/06

Printed in U.S.A.

07.2–1450–003

MAST Load Wheel Size

1st Dash No. Collapsed Height/Lift Height

* 2nd Dash No.

2260/5030mm 89/198 in

100 x 75mm (4.0 x 2.88 in) 100 x 105mm (4.0 x 4.12 in)

2415/5335mm 95/210 in 2720/6095mm 107/240 in

125 x 75mm (5.0 x 2.88 in)

3025/6860mm 119/270 in

125 x 105mm (5.0 x 4.12 in) 265 x 100mm (10.5 x 4.0 in) Index

Part No.

Non-removable Outrigger Ends 123403123403123403123403123403Non-removable Outrigger Ends (Tapered) 123403123403123403123403Removable Outrigger Ends 123405123405123405123405Removable Outrigger Ends (Tapered) 123405123405123405123405-

34 thru 61

104 304 204 404 504

105 305 205 405 505

106 306 206 406 506

107 307 207 407 507

604 804 704 904

605 805 705 905

606 806 706 906

607 807 707 907

104 304 204 404

105 305 205 405

106 306 206 406

107 307 207 407

604 804 704 904

605 805 705 905

606 806 706 906

607 807 707 907

X X X X X

X X X

121890-

004

005

006

007

121891-

004

005

006

007

123233-

004

005

006

007

* The 2nd dash number is the same as the truck's inside straddle dimension in inches.

Crown 1997 PF11037-4 Rev. 4/06

07.2–1450–001-SUP-1

03 REV. 4/06

Printed in U.S.A.

07.2–1450–001-SUP-1

MAST

INDEX 34 CHAIN — MAST Collapsed Height mm in 2260 2415 2720 3025

89 95 107 119

Lift Height mm in

Length Required in Iinks

ORDER NUMBER

5030 5335 6095 6860

83.25 89.25 113.25 113.25

073991-067 073991-067 073991-067 073991-067

198 210 240 270

111 119 151 151

MINIMUM ORDER QUANTITY EACH PER TRUCK 7 8 10 10

14 15 19 19

INDEX 65 CHAIN — CARRIAGE Collapsed Height mm in 2260 2415 2720 3025

89 95 107 119

Lift Height mm in

Length Required in Iinks

ORDER NUMBER

5030 5335 6095 6860

54.75 57.75 63.75 69.75

073991-067 073991-067 073991-067 073991-067

198 210 240 270

73 77 85 93

MINIMUM ORDER QUANTITY EACH PER TRUCK 5 5 6 6

10 10 11 12

When ordering Chain, order the number of feet required for your particular truck. The appropriate minimum order quantity is listed in the above chart. Cut the chain to the length required for your truck. INDEX 48 SPRING - MAST Collapsed Height mm in 2260 2415 2720 3025 3325

89 95 107 119 131

Lift Height mm in 5030 5335 6095 6860 7620

198 210 240 270 300

ONE EACH REQUIRED Spring Spring 122399 (Bronze) 122399 (Bronze) 122399 (Bronze) 119031 (Gray) 119031 (Gray)

128011 (Red) 122399 (Bronze) 119031 (Gray) 119031 (Gray) 119031 (Gray)

INDEZ 77 SPRING - CARRIAGE Collapsed Height mm in 2260 2415 2720 3025 3325

89 95 107 119 131

Lift Height mm in 5030 5335 6095 6860 7620

Crown 1997 PF11037-5 Rev. 4/06

07.2–1450–001-SUP-2

198 210 240 270 300

ONE EACH REQUIRED Spring Spring 128012 (Red) 128012 (Red) 119049 (Gray) 119049 (Gray) 119049 (Gray)

119049 (Gray) 119049 (Gray) 119049 (Gray) 119049 (Gray) 119049 (Gray)

03 REV. 4/06

Printed in U.S.A.

07.2–1450–001-SUP-2

MAST 8137

RR 5000 SERIES 3500 lb. (1588 kg) 5.5 in. (140 mm) CHANNEL 84

24 16 14 15 57

23 22

22 19

78 13

24 34 35 36

42 ECR2

23 25 30 32 33 24 26

65 35

21 56

18 17

B C

25 24 21

38 39

40 41

D 80

39 8 10 9 11 12

44 7

34 35

45 63

63 61

HGTS12

84 2

3 5000S Series

3 5000 Series 3 1

58 Part of Power Unit

51 54

49 50

72 73

52 53

1 13

B For Switch HGTRS - See Section 01.2

69 FLS

13 71 36

Crown 2000 PF11857 Rev. 1/01

Printed in U.S.A.

02 REV. 1/01

07.2–1450–004

MAST Index Part No. 1

2 3

4 5 6 7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26

27 28

Part Name

No. Req.

060023-009 Screw 4 060005-046 Lockwasher 4 060021-049 Nut 4 121681-006 Shim 1.5 mm (.060 in.) Thick AR 121681-012 Shim 3 mm (.120 in.) Thick AR 060020-048 Screw 190 mm (7.50 in.) Long 5000 Series 2 060020-042 Screw 255 mm (10.0 in.) Long 5000S Series (RH Side) 1 060020-048 Screw 190 mm (7.50 in.) Long 5000S Series (LH Side) 1 060030-260 Flatwasher 2 060042-019 Nut Self Locking 2 * Main Frame 1 Cylinder Lift RH See Section 08.0 1 Cylinder Lift LH See Section 08.0 1 060020-015 Screw 4 060005-014 Lockwasher 4 080069 Block Stop 2 074481-001 Shim Stop AR 107563-001 Bracket 2 092747-001 Stop Poly 2 060015-004 Screw 2 061004-026 Adhesive Thread Lock 1 074668-001 Roller Column 12 060030-085 Shim .78 mm (.031 in.) Thick AR 121679 Guide 1 123281 Clamp 1 060015-015 Screw 1 060042-006 Nut Self Locking 1 060017-059 Screw 1 060017-094 Screw Load Sensor & F/C 1 061004-019 Adhesive Thread Lock 1 060005-009 Lockwasher 1 060030-078 Flatwasher 1 121624-001 Shaft 1 121624-003 Shaft Load Sensor & F/C 1 119655-001 Pulley 2 060030-192 Flatwasher 2 060009-043 Ring Retaining 2 060009-062 Ring Retaining 4 065081-045 Bearing Ball 2 117556-001 Pulley Chain Includes Index 24 & 25 2 117557-001 Pulley Chain 2 060019-071 Screw 1 075385-003 Anchor Chain 2

Index Part No.

Part Name

No. Req.

29 060030-332 Flatwasher 30 127874-001 Shaft 31 127513-001 Pulley Cable 32 060030-192 Flatwasher 33 121623 Pulley Hose 34 * Chain Mast 35 086499 Pin 36 060000-055 Pin Roll 37 075385-001 Anchor Chain 38 060021-028 Nut 39 060038-003 Pin Cotter 40 121667 Guide 41 121679 Guide 42 060015-015 Screw 060042-006 Nut Self Locking 43 076470-025 Pin Clevis 060030-191 Flatwasher 44 060038-017 Pin Cotter 45 * Mast 2nd Stage 46 060015-043 Screw 47 060042-006 Nut Self Locking 48 * Spring 49 128014 Ram Spring 50 060009-101 Ring Retaining 51 121622 Stop Lower 52 060030-277 Flatwasher .78 mm (.031 in.) Thick 53 124019 Bumper 54 060017-056 Screw 061004-026 Adhesive Thread Lock 55 * Mast 3rd Stage 56 127513-001 Pulley Load Sensor & F/C 57 124010 Guide Load Sensor & F/C 58 060015-033 Screw 061004-020 Adhesive Thread Lock 59 123231-001 Spring 60 121738 Guard 61 060017-032 Screw 060005-009 Lockwasher 060021-011 Nut 62 121795 Clamp 63 060042-018 Nut Self Locking 64 Yoke See Section 07.5 65 * Chain Carriage 66 Cylinder Free Lift See Section 08.0 67 075385-004 Anchor Chain 68 Carriage Reach See Section 09.0

2 1 1 1 1 2 6 14 2 12 6 1 1 1 1 2 2 2 1 2 2 2 2 2 2 AR 2 2 1 1 1 1 1 1 1 1 2 2 2 2 4 1 2 1 2 1

Printed in U.S.A.

02 REV. 1/01

07.2–1450–005

MAST Index Part No.

Part Name

No. Req.

69 † 123316-003 Switch Includes Switch, Leads, Terminals & JC Label 1 † 108306 Switch 1 060061-005 Screw 2 70 060061-005 Screw 2 060005-005 Lockwasher 2 061003-004 Tie Cable 3 060030-012 Flatwasher 2 71 084985 Pin 2 72 060017-050 Screw 2 061004-019 Adhesive Thread Lock 1 73 124018 Stop Poly 2 74 128015 Ram Spring 2 75 060000-028 Pin Roll 4 76 119048 Rod 2 77 * Spring 2 78 Height Sensor See Section 04.8 1 79 * Cable 1 80 060015-064 Screw 2 060005-007 Lockwasher 2 81 † 123316-004 Switch 2260, 2415 & 2720 mm (89, 95 & 107 in.) Collapsed Height Includes Switch, Leads, Terminals & JC Label 1 † 123316-005 Switch 3025 mm (119 in.) Collapsed Height Includes Switch, Leads, Terminals & JC Label 1 060013-020 Screw 1 060013-021 Screw 1 061004-026 Adhesive Thread Locking 1 † 108306 Switch 1 82 060061-008 Screw 2 061004-019 Adhesive Thread Lock 1 83 123174 Bracket 1 84 060095-001 Set Screw 8 061004-026 Adhesive Thread Locking 1 Always Specify Model, Data & Serial Numbers 061003-005

Tie Cable (Hoses to Mast Cylinder)

* See The Following Supplemental Form † Internal switch replacement is not economical. Should internal switch require replacement, replace entire switch. Switch arm is not available.

000417

6897 - EO4082 Printed in U.S.A.

02 REV. 1/01

07.2–1450–006

MAST

Load Wheel Size

1st Dash No. Collapsed Height/Lift Height

100 x 75mm (4.0 x 2.88 in.)

2260/5030mm (89/198 in.)

100 x 105mm (4.0 x 4.12 in.)

2415/5335mm (95/210 in.) 2720/6095mm (107/240 in.)

125 x 75mm (5.0 x 2.88 in.) 125 x 105mm (5.0 x 4.12 in.)

3025/6860mm (119/270 in.)

265 x 100mm (10.5 x 4.0 in.)

Index

Part No.

* 2nd Dash No.

3325/7620mm (131/300 in.) 34 thru 61

104 304 204 404 504

105 305 205 405 505

106 306 206 406 506

107 307 207 407 507

108 308 208 408 508

604 804 704 904

605 805 705 905

606 806 706 906

607 807 707 907

608 808 708 908

104 304 204 404

105 305 205 405

106 306 206 406

107 307 207 407

108 308 208 408

604 804 704 904

605 805 705 905

606 806 706 906

607 807 707 907

608 808 708 908 008

X X X X

X X X

127876-

004

005

006

007

121891-

004

005

006

007

123233-

004

005

006

007

* The 2nd dash number is the same as the truck's inside straddle dimension in inches. Crown 2000 PF11857 Rev. 1/01

Printed in U.S.A.

02 REV. 1/01

07.2–1450–004-SUP-1

MAST INDEX 34 CHAIN — MAST Collapsed Height mm in.

Lift Height mm in.

Length Required in. Iinks

ORDER NUMBER

2260 2415 2720 3025 3325

5030 5335 6095 6860 7620

83.25 89.25 113.25 113.25 125.25

073991-067 073991-067 073991-067 073991-067 073991-067

89 95 107 119 131

198 210 240 270 300

111 119 151 151 167

MINIMUM ORDER QUANTITY EACH PER TRUCK 7 8 10 10 11

14 15 19 19 21

INDEX 65 CHAIN — CARRIAGE Collapsed Height mm in.

Lift Height mm in.

Length Required in. Iinks

ORDER NUMBER

2260 2415 2720 3025 3325

5030 5335 6095 6860 7620

54.75 57.75 63.75 69.75 75.75

073991-067 073991-067 073991-067 073991-067 073991-067

89 95 107 119 131

198 210 240 270 300

73 77 85 93 101

MINIMUM ORDER QUANTITY EACH PER TRUCK 5 5 6 6 7

10 10 11 12 13

Lift Height mm in.

2260 2415 2720 3025 3325

5030 5335 6095 6860 7620

89 95 107 119 131

198 210 240 270 300

ONE EACH REQUIRED SPRING SPRING 122399 (Bronze) 122399 (Bronze) 122399 (Bronze) 119031 (Gray) 119031 (Gray)

128011 (Red) 122399 (Bronze) 119031 (Gray) 119031 (Gray) 119031 (Gray)

INDEX 77 SPRING — CARRIAGE Collapsed Height mm in.

Lift Height mm in.

2260 2415 2720 3025 3325

5030 5335 6095 6860 7620

89 95 107 119 131

198 210 240 270 300

ONE EACH REQUIRED SPRING SPRING 128012 (Red) 128012 (Red) 119049 (Gray) 119049 (Gray) 119049 (Gray)

119049 (Gray) 119049 (Gray) 119049 (Gray) 119049 (Gray) 119049 (Gray)

Crown 2000 PF11857 Rev. 1/01

Printed in U.S.A.

02 REV. 1/01

07.2–1450–004-SUP-2

MAST RR 5000/5000S 2040kg (4500 lb.) CAPACITY RD 5000/5000S 1360kg (3000 lb.) CAPACITY 185mm (7.25 in.) CHANNEL

5821-03

3 5000S Series Part of Power Unit

For Switch HGTRS - See Section 01.2

Crown 1997 PF11062-1 Rev. 4/06

07.2–1450–100

3 5000 Series

Cover Used on Trucks With a Collapsed Height of 3325 mm 131 in or More

05 REV. 4/06

Printed in U.S.A.

07.2–1450–100

C Index Part No. 1 2 3

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

MAST Part Name

No. Req.

060023-009 Screw 060005-046 Lockwasher 060021-049 Nut 121681-006 Shim 121681-012 Shim 060020-048 Screw 190 mm (7.50 in) Long 5000 Series 060020-042 Screw 255 mm (10.0 in) Long 5000S Series RH Side 060020-048 Screw 190 mm (7.50 in) Long 5000S Series LH Side 060030-260 Flatwasher 060042-019 Nut Self Locking * Main Frame Cylinder Lift RH See Section 08.0 Cylinder Lift LH See Section 08.0 060020-015 Screw 060005-014 Lockwasher 080069 Block Stop 074481-001 Shim Stop 107563-001 Bracket 092747-001 Stop Poly 060015-004 Screw 061004-026 Adhesive Thread Lock 123400 Roller Column 060030-130 Shim .79 mm (.031 in) Thick 121679 Guide 123281 Clamp 060015-015 Screw 060042-006 Nut Self Locking 060017-059 Screw 060017-094 Screw Load Sensor & F/C 061004-019 Adhesive Thread Lock 060005-009 Lockwasher 060030-078 Flatwasher 121624-001 Shaft 121624-003 Shaft Load Sensor & F/C 119655-001 Pulley 060030-192 Flatwasher 060009-043 Ring Retaining 060009-062 Ring Retaining 065081-045 Bearing Ball 117556-001 Pulley Chain Includes Index 24 & 25 117557-001 Pulley Chain 060017-059 Screw 061004-019 Adhesive Thread Lock

Crown 1997 PF11062-2 Rev. 4/06

07.2–1450–101

4 4 4 AR AR 2 1 1 2 2 1 1 1 4 4 2 AR 2 2 2 1 12 AR 1 1 1 1 1 1 1 1 1 1 1 2 1 2 4 2 2 2 1 1

Index Part No.

Part Name

No. Req.

28 060005-009 Lockwasher 1 29 060030-078 Flatwasher 1 30 121624-002 Shaft 1 31 127513-001 Pulley Cable 1 32 060030-192 Flatwasher 1 33 121623 Pulley Hose 1 34 * Chain Mast 2 35 086499 Pin 8 36 060000-055 Pin Roll 16 37 075385-001 Anchor Chain 2 38 060021-028 Nut 12 39 060038-003 Pin Cotter 6 40 121667 Guide 1 41 121679 Guide 1 42 060015-015 Screw 1 060042-006 Nut Self Locking 1 43 076470-025 Pin Clevis 2 060030-191 Flatwasher 2 44 060038-017 Pin Cotter 2 45 * Mast 2nd Stage 1 46 060015-043 Screw 2 47 060042-006 Nut Self Locking 2 48 * Spring 2 063002-007 Lubricant AR 49 121621 Ram Spring 2260 to 3025 mm (89 to 119 in) Collapsed Height 2 121627 Ram Spring 3325 to 4370 mm (131 to 149 in) Collapsed Height 1 121627 Spring 4065 to 4370 mm (160 to 172 in) Collapsed Height 2 50 060009-101 Ring Retaining 2260 to 3025 mm (89 to 119 in) Collapsed Height 2 060009-045 Ring Retaining 3325 to 4370 mm (131 to 149 in.) Collapsed Height 1 060009-045 Ring Retaining 4065 to 4370 mm (160 to 172 in) Collapsed Height 2 51 121622 Stop Lower 2260 to 3025 mm (89 to 119 in) Collapsed Height 2 121622 Stop Lower 3325 to 4370 mm (131 to 149 in) Collapsed Height 1 121622 Stop Lower 4065 to 4370 mm (160 to 172 in) Collapsed Height 2 52 060030-277 Flatwasher .78 mm (.031 in.) Thick AR

05 REV. 4/06

Printed in U.S.A.

07.2–1450–101

C Index Part No. 53

124019

MAST Part Name

No. Req.

Bumper 2260 to 3025 mm (89 to 119 in) Collapsed Height 2 124019 Bumper 3325 to 4370 mm (131 to 149 in) Collapsed Height 1 124019 Bumper 4065 to 4370 mm (160 to 172 in) Collapsed Height 2 54 060017-056 Screw 2260 to 3025 mm (89 to 119 in. ) Collapsed Height 2 060017-056 Screw 3325 to 4370 mm (131 to 149 in) Collapsed Height 1 060017-056 Screw 4065 to 4370 mm (160 to 172 in) Collapsed Height 2 061004-026 Adhesive Thread Lock 1 55 * Mast 3rd Stage 1 56 060095-001 Set Screw 8 061004-026 Adhesive Thread Locking 1 57 124010 Guide Load Sensor & F/C 1 58 060015-033 Screw 1 061004-020 Adhesive Thread Lock 1 59 123231-001 Spring 1 60 121738 Guard 1 61 060017-032 Screw 2 060005-009 Lockwasher 2 060021-011 Nut 2 62 121795 Clamp 2 63 060042-018 Nut Self Locking 4 64 Yoke See Section 07.5 1 65 * Chain Carriage 2 66 Cylinder Free Lift See Section 08.0 1 67 075385-004 Anchor Chain 2 68 Carriage Reach See Section 09.0 1 69 † 123316-003 Switch Includes Switch, Leads, Terminals & JC Label 1 † 108306 Switch 1

Index Part No.

Part Name

No. Req.

060061-005 Screw 2 060030-012 Flatwasher 2 060005-005 Lockwasher 2 061003-004 Tie Cable 3 71 084985 Pin 2 72 060017-050 Screw 2 061004-019 Adhesive Thread Lock 1 73 103270 Stop Poly 2 74 122918 Ram Spring 2 75 060000-080 Pin Roll 4 76 122919 Rod 2 77 * Spring 2 78 Height Sensor See Section 04.8 1 79 * Cable 1 80 060015-064 Screw 2 060005-007 Lockwasher 2 81 † 123316-001 Switch 2260 & 2415mm (89 & 95 in) Collapsed Height Includes Switch, Leads, Terminals & JC Label 1 † 123316-002 Switch 2720 & 3025mm (107 & 119 in) Collapsed Height Includes Switch, Leads, Terminals & JC Label 1 † 108306 Switch 1 82 060061-008 Screw 2 061004-019 Adhesive Thread Lock 1 83 123174 Bracket 1 84 075385-003 Anchor Chain 2 85 118197-002 Pulley Load Sensor & F/C 1 061003-005

Tie Cable (Hoses to Mast Cylinder)

980131 Crown 1997 PF11062-3 Rev. 4/06

07.2–1450–102

13876

05 REV. 4/06

Printed in U.S.A.

07.2–1450–102

MAST RR5000/5000S 4500 LB. (2040kg) CAPACITY

265 x 115mm (10.5 x 4.5 in)

2260/5025mm 89/198 in

2415/5335mm 95/210 in

2720/6100mm 107/240 in

3025/6860mm 119/270 in

3325/7620mm 131/300 in

3555/8155mm 140/321 in

150 x 105mm (6.0 x 4.12 in)

150 x 70mm (6.0 x 2.88 in)

125 x 105mm (5.0 x 4.12 in)

305 205 405 505

306 206 406 506

307 207 407 507

308 208 408 508

309 209 409 509

X X X X

804 704 904

X X X

805 705 905

806 706 906

807 707 907

808 708 908

304 204 404

X X

305 205 405

306 206 406

307 207 407

308 208 408

804 704 904

X X

805 705 905

806 706 906

807 707 907

808 708 908

111 211

112 212

310 410

311 411

312 412

510 610

511 611

512 612

810 910

811 911

812 912

309 209 409

110 210

34 thru 61

809 709 909

4370/10160mm 172/400 in

Removable Outrigger Ends (Tapered w/side shift only) 123406123406123406125056125056-

304 204 404 504

*2nd Dash No. 4065/9300mm 160/366 in

Removable Outrigger Ends 123406123406123406125056125056-

1st Dash No. Collapsed Height/Lift Height 3785/8660mm 149/341 in

Non-removable Outrigger Ends (Tapered w/side shift only) 123404123404123404125056125056-

125 x 70mm (5.0 x 2.88 in)

Index Part No. 4 Non-removable Outrigger Ends 123404123404123404123404125056125056-

100 x 105mm (4.0 x 4.12 in)

Load Wheel Size

809 709 909

X X

121761-

004

005

006

007

008

009

010

011

012

121762-

004

005

006

007

008

009

010

011

012

123233-

004

005

006

007

008

009

010

011

012

* The 2nd dash number is the same as the truck's inside straddle dimension in inches. Crown 1997 PF11062-4 Rev. 4/06

07.2–1450–100-SUP-1

05 REV. 4/06

Printed in U.S.A.

07.2–1450–100-SUP-1

MAST RD5000/5000S 3000 LB. (1360kg) CAPACITY

105 305 205 405

106 306 206 406

107 307 207 407

108 308 208 408

109 309 209 409

X X

604 804 704 904

X X X X

605 805 705 905

606 806 706 906

607 807 707 907

608 808 708 908

4370mm/10160mm 172 in./400 in.

3555mm/8155mm 140 in./321 in.

104 304 204 404

*2nd Dash No.

4065mm/9300mm 160 in./366 in.

3325mm/7620mm 131 in./300 in.

3025mm/6860mm 119 in./270 in.

2720mm/6100mm 107 in./240 in.

2415mm/5335mm 95 in./210 in.

2260mm/5025mm 89 in./198 in.

150 x 105mm (6.0 x 4.12 in)

150 x 70mm (6.0 x 2.88 in)

125 x 105mm (5.0 x 4.12 in)

125 x 70mm (5.0 x 2.88 in)

1st Dash No. Collapsed Height/Lift Height

3785mm/8660mm 149 in./341 in.

Removable Outrigger Ends (Tapered) 123407123407123407123407125057125057-

100 x 105mm (4.0 x 4.12 in)

Index Part No. 4 Non-removable Outrigger Ends (Tapered) 123407123407123407123407125057125057-

100 x 70mm (4.0 x 2.88 in)

Load Wheel Size

310 410

311 411

312 412

810 910

811 911

812 912

34 thru 61

609 809 709 909

X X

121761-

004

005

006

007

008

009

010

011

012

121762-

004

005

006

007

008

009

010

011

012

123233-

004

005

006

007

008

009

010

011

012

* The 2nd dash number is the same as the truck's inside straddle dimension in inches.

Crown 1997 PF11062-5 Rev. 4/06

07.2–1450–100-SUP-2

05 REV. 4/06

Printed in U.S.A.

07.2–1450–100-SUP-2

MAST

INDEX 34 073991-067 CHAIN — MAST Lift Height mm in

Length Required in. Iinks

ORDER NUMBER

5025 5335 6100 6860 7620 8155 8660 9300 10160

83.25 89.25 113.25 113.25 125.25 134.25 143.25 155.25 167.25

073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067

Collapsed Height mm in 2260 2415 2720 3025 3325 3555 3785 4065 4370

89 95 107 119 131 140 149 160 172

198 210 240 270 300 321 341 366 400

111 119 151 151 167 179 191 207 223

MINIMUM ORDER QUANTITY EACH PER TRUCK 7 8 10 10 11 12 12 13 14

14 15 19 19 21 23 24 26 28

INDEX 65 073991-067 CHAIN — CARRIAGE Lift Height mm in

Length Required in. Iinks

ORDER NUMBER

5025 5335 6100 6860 7620 8155 8660 9300 10160

54.75 57.75 63.75 69.75 75.75 80.25 84.75 90.75 96.75

073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067

Collapsed Height mm in 2260 2415 2720 3025 3325 3555 3785 4065 4370

89 95 107 119 131 140 149 160 172

198 210 240 270 300 321 341 366 400

73 77 85 93 101 107 113 121 129

MINIMUM ORDER QUANTITY EACH PER TRUCK 5 5 6 6 7 7 8 8 9

10 10 11 12 13 14 15 16 17

89 95 107 119 131 140 149 160 172

Lift Height mm in 5030 5335 6100 6860 7620 8155 8660 9300 10160

198 210 240 270 300 321 341 366 400

ONE EACH REQUIRED Spring Spring 122399 (Bronze) 119031 (Gray) 119031 (Gray) 119031 (Gray) 128010 (Bronze) 128010 (Bronze) 122422 (Green) 122422 (Green) 122422 (Green)

119031 (Gray) 119031 (Gray) 119031 (Gray) 119031(Gray) 122422 (Green) 122422 (Green) 122422 (Green) 122422 (Green) 122422 (Green)

INDEZ 77 SPRING - CARRIAGE Collapsed Height mm in 2260 2415 2720 3025 3325 3555 3785 4065 4370

89 95 107 119 131 140 149 160 172

Lift Height mm in 5025 5335 6100 6860 7620 8155 8660 9300 10160

Crown 1997 PF11062-6 Rev. 4/06

07.2–1450–100-SUP-3

198 210 240 270 300 321 341 366 400

ONE EACH REQUIRED Spring Spring 122398 (Red) 122398 (Red) 122398 (Red) 122398 (Red) 122398 (Red) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze)

122398 (Red) 122398 (Red) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze)

05 REV. 4/06

Printed in U.S.A.

07.2–1450–100-SUP-3

MAST 8138

RR 5000/5000S 4500 lb. (2040 kg) CAPACITY RD 5000/5000S 3000 lb. (1360 kg) CAPACITY 7.25 in. (185 mm) CHANNEL 24

14 15 57

18 17

24 33 25 26 30 32 23

22 22

C 79

42 ECR2 40 78 41 13

36 84

38 39

24 34 35 36

37 43

62 55

65 35

26 23

16 20

B 56

21 28

25 24 21

8 10 9 11 12

44 7

34 35 36

82 13 63

81 HGTS12

3 5000S Series

3 56

3 5000 Series 3

Part of Power Unit

48 49 50

60 72 73

52 53

56 68

1 For Switch HGTRS - See Section 01.2

Cover Used on Trucks With a Collapsed Height of 131 in. 3325mm or More

69 FLS

13 71

36 Printed in U.S.A.

Crown 2000 PF11858 Rev. 1/01

01 REV. 1/01

07.2–1450–103

MAST Index Part No. 1

2 3

4 5 6 7 8 9 10 11 12 13 14 15 16 17

18 19 20 21 22 23 24 25 26

27 28 29

Part Name

No. Req.

060023-009 Screw 4 060005-046 Lockwasher 4 060021-049 Nut 4 121681-006 Shim AR 121681-012 Shim AR 060020-048 Screw 190 mm (7.50 in.) Long 5000 Series 2 060020-042 Screw 255 mm (10.0 in.) Long 5000S Series RH Side 1 060020-048 Screw 190 mm (7.50 in.) Long 5000S Series LH Side 1 060030-260 Flatwasher 2 060042-019 Nut Self Locking 2 * Main Frame 1 Cylinder Lift RH See Section 08.0 1 Cylinder Lift LH See Section 08.0 1 060020-015 Screw 4 060005-014 Lockwasher 4 080069 Block Stop 2 074481-001 Shim Stop AR 107563-001 Bracket 2 092747-001 Stop Poly 2 060015-004 Screw 2 061004-026 Adhesive Thread Lock 1 123400 Roller Column 12 060030-130 Shim .79 mm (.031 in.) Thick AR 121679 Guide 1 123281 Clamp 1 060015-015 Screw 1 060042-006 Nut Self Locking 1 060017-059 Screw 1 060017-094 Screw Load Sensor & F/C 1 061004-019 Adhesive Thread Lock 1 060005-009 Lockwasher 1 060030-078 Flatwasher 1 121624-001 Shaft 1 121624-003 Shaft Load Sensor & F/C 1 119655-001 Pulley 2 060030-192 Flatwasher 1 060009-043 Ring Retaining 2 060009-062 Ring Retaining 4 065081-045 Bearing Ball 2 117556-001 Pulley Chain Includes Index 24 & 25 2 117557-001 Pulley Chain 2 060019-071 Screw 1 127513-001 Pulley Load Sensor & F/C 1 060030-332 Flatwasher 2

Index Part No.

Part Name

No. Req.

30 127874-001 Shaft 1 31 127513-001 Pulley Cable 1 32 060030-192 Flatwasher 1 33 121623 Pulley Hose 1 34 * Chain Mast 2 35 086499 Pin 8 36 060000-055 Pin Roll 16 37 075385-001 Anchor Chain 2 38 060021-028 Nut 12 39 060038-003 Pin Cotter 6 40 121667 Guide 1 41 121679 Guide 1 42 060015-015 Screw 1 060042-006 Nut Self Locking 1 43 076470-025 Pin Clevis 2 060030-191 Flatwasher 2 44 060038-017 Pin Cotter 2 45 * Mast 2nd Stage 1 46 060015-043 Screw 2 47 060042-006 Nut Self Locking 2 48 * Spring 2 063002-007 Lubricant AR 49 128014 Ram Spring 2260 to 3025 mm (89 to 119 in.) Collapsed Height 2 128013 Ram Spring 3325 to 4370 mm (131 to 172 in.) Collapsed Height 2 50 060009-101 Ring Retaining 2260 to 3025 mm (89 to 119 in.) Collapsed Height 2 060009-045 Ring Retaining 3325 to 4370 mm (131 to 172 in.) Collapsed Height 2 51 121622 Stop Lower 2 52 060030-277 Flatwasher .78 mm (.031 in.) Thick AR 53 124019 Bumper 89 2 54 060017-056 Screw 2 061004-026 Adhesive Thread Lock 1 55 * Mast 3rd Stage 1 56 060095-001 Set Screw 8 061004-026 Adhesive Thread Locking 1 57 124010 Guide Load Sensor & F/C 1 58 060015-033 Screw 1 061004-020 Adhesive Thread Lock 1 59 123231-001 Spring 1 60 121738 Guard 1 61 060017-032 Screw 2 060005-009 Lockwasher 2 060021-011 Nut 2 62 121795 Clamp 2 63 060042-018 Nut Self Locking 4

Printed in U.S.A.

01 REV. 1/01

07.2–1450–104

MAST Index Part No.

Part Name

No. Req.

64 65 * 66

Yoke See Section 07.5 1 Chain Carriage 2 Cylinder Free Lift See Section 08.0 1 67 075385-004 Anchor Chain 2 68 Carriage Reach See Section 09.0 1 69 † 123316-003 Switch Includes Switch, Leads, Terminals & JC Label 1 † 108306 Switch 1 70 060061-005 Screw 2 060030-012 Flatwasher 2 060005-005 Lockwasher 2 061003-004 Tie Cable 3 71 084985 Pin 2 72 060017-050 Screw 2 061004-019 Adhesive Thread Lock 1 73 103270 Stop Poly 2 74 128016 Ram Spring 2 75 060000-080 Pin Roll 4 76 122919 Rod 2 77 * Spring 2 78 Height Sensor See Section 04.8 1 79 * Cable 1 80 060015-064 Screw 2 060005-007 Lockwasher 2 81 † 123316-001 Switch 2260 & 2415 mm (89 & 95 in.) Collapsed Height Includes Switch, Leads, Terminals & JC Label 1 † 123316-002 Switch 2720 & 3025 mm (107 & 119 in.) Collapsed Height Includes Switch, Leads, Terminals & JC Label 1 † 108306 Switch 1 82 060061-008 Screw 2 061004-019 Adhesive Thread Lock 1 83 123174 Bracket 1 84 075385-003 Anchor Chain 2 Always Specify Model, Data & Serial Numbers 061003-005

Tie Cable (Hoses to Mast Cylinder)

* See The Following Supplemental Form † Internal switch replacement is not economical. Should internal switch require replacement, replace entire switch. Switch arm is not available.

000417

6897 - EO4082 Printed in U.S.A.

01 REV. 1/01

07.2–1450–105

MAST RR5000/5000S 4500 LB. (2040kg) CAPACITY

10.5 x 4.5 in. (265 x 115mm)

89/198 in. 2260/5025mm

95/210 in. 2415/5335mm

107/240 in. 2720/6100mm

119/270 in. 3025/6860mm

131/300 in. 3325/7620mm

140/321 in. 3555/8155mm

6.0 x 4.12 in. (150 x 105mm)

5.0 x 4.12 in. (125 x 105mm)

6.0 x 2.88 in. (150 x 70mm)

305 205 405 505

306 206 406 506

307 207 407 507

308 208 408 508

309 209 409 509

X X X X

804 704 904

X X

805 705 905

806 706 906

807 707 907

808 708 908

304 204 404

X X

305 205 405

306 206 406

307 207 407

308 208 408

804 704 904

X X

805 705 905

806 706 906

807 707 907

808 708 908

111 211

112 212

310 410

311 411

312 412

510 610

511 611

512 612

810 910

811 911

812 912

309 209 409

110 210

34 thru 61

809 709 909

172/400 in. 4370/10160mm

Removable Outrigger Ends (Tapered w/side shift only) 123406123406123406125056125056-

304 204 404 504

*2nd Dash No.

160/366 in. 4065/9300mm

Removable Outrigger Ends 123406123406123406125056125056-

1st Dash No. Collapsed Height/Lift Height

149/341 in. 3785/8660mm

Non-removable Outrigger Ends (Tapered w/side shift only) 123404123404123404125056125056-

5.0 x 2.88 in. (125 x 70mm)

Index Part No. 4 Non-removable Outrigger Ends 123404123404123404123404125056125056-

4.0 x 4.12 in. (100 x 105mm)

Load Wheel Size

809 709 909

X X

127877-

004

005

006

007

008

009

010

011

012

121762-

004

005

006

007

008

009

010

011

012

123233-

004

005

006

007

008

009

010

011

012

* The 2nd dash number is the same as the truck's inside straddle dimension in inches. Crown 2000 PF11858 Rev. 1/01

Printed in U.S.A.

01 REV. 1/01

07.2–1450–103-SUP-1

MAST RD5000/5000S 3000 LB. (1360kg) CAPACITY

105 305 205 405

106 306 206 406

107 307 207 407

108 308 208 408

109 309 209 409

X X

604 804 704 904

X X X

605 805 705 905

606 806 706 906

607 807 707 907

608 808 708 908

172 in./400 in. 4370mm/10160mm

140 in./321 in. 3555mm/8155mm

104 304 204 404

*2nd Dash No.

160 in./366 in. 4065mm/9300mm

131 in./300 in. 3325mm/7620mm

119 in./270 in. 3025mm/6860mm

107 in./240 in. 2720mm/6100mm

95 in./210 in. 2415mm/5335mm

89 in./198 in. 2260mm/5025mm

6.0 x 4.12 in. (150 x 105mm)

6.0 x 2.88 in. (150 x 70mm)

5.0 x 4.12 in. (125 x 105mm)

5.0 x 2.88 in. (125 x 70mm)

1st Dash No. Collapsed Height/Lift Height

149 in./341 in. 3785mm/8660mm

Removable Outrigger Ends (Tapered) 123407123407123407123407125057125057-

4.0 x 4.12 in. (100 x 105mm)

Index Part No. 4 Non-removable Outrigger Ends (Tapered) 123407123407123407123407125057125057-

4.0 x 2.88 in. (100 x 70mm)

Load Wheel Size

310 410

311 411

312 412

810 910

811 911

812 912

34 thru 61

609 809 709 909

X X

121761-

004

005

006

007

008

009

010

011

012

121762-

004

005

006

007

008

009

010

011

012

123233-

004

005

006

007

008

009

010

011

012

* The 2nd dash number is the same as the truck's inside straddle dimension in inches.

Crown 2000 PF11858 Rev. 1/01

Printed in U.S.A.

01 REV. 1/01

07.2–1450–103-SUP-2

MAST INDEX 34 073991-067 CHAIN — MAST Collapsed Height in. mm 89 95 107 119 131 140 149 160 172

2260 2415 2720 3025 3325 3555 3785 4065 4370

Lift Height in. mm

Length Required in. Iinks

ORDER NUMBER

198 210 240 270 300 321 341 366 400

83.25 89.25 113.25 113.25 125.25 134.25 143.25 155.25 167.25

111 119 151 151 167 179 191 207 223

073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067

7 8 10 10 11 12 12 13 14

14 15 19 19 21 23 24 26 28

73 77 85 93 101 107 113 121 129

073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067 073991-067

5 5 6 6 7 7 8 8 9

10 10 11 12 13 14 15 16 17

5025 5335 6100 6860 7620 8155 8660 9300 10160

MINIMUM ORDER QUANTITY EACH PER TRUCK

INDEX 65 073991-067 CHAIN — CARRIAGE 89 95 107 119 131 140 149 160 172

2260 2415 2720 3025 3325 3555 3785 4065 4370

198 210 240 270 300 321 341 366 400

5025 5335 6100 6860 7620 8155 8660 9300 10160

54.75 57.75 63.75 69.75 75.75 80.25 84.75 90.75 96.75

Lift Height in. mm

89 95 107 119 131 140 149 160 172

198 210 240 270 300 321 341 366 400

2260 2415 2720 3025 3325 3555 3785 4065 4370

5025 5335 6100 6860 7620 8155 8660 9300 10160

ONE EACH REQUIRED SPRING SPRING 122399 (Bronze) 119031 (Gray) 119031 (Gray) 119031 (Gray) 128010 (Bronze) 128010 (Bronze) 122422 (Green) 122422 (Green) 122422 (Green)

119031 (Gray) 119031 (Gray) 119031 (Gray) 119031 (Gray) 122422 (Green) 122422 (Green) 122422 (Green) 122422 (Green) 122422 (Green)

122398 (Red) 122398 (Red)) 122398 (Red) 122398 (Red) 122398 (Red) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze)

122398 (Red) 122398 (Red) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze) 122421 (Bronze)

INDEX 77 SPRING — CARRIAGE 89 95 107 119 131 140 149 160 172

2260 2415 2720 3025 3325 3555 3785 4065 4370

198 210 240 270 300 321 341 366 400

5025 5335 6100 6860 7620 8155 8660 9300 10160

Crown 2000 PF11858 Rev. 1/01

Printed in U.S.A.

01 REV. 1/01

07.2–1450–103-SUP-3

REMOVABLE OUTRIGGER ENDS 1

5693

RR/RD 5000/5000S SERIES 3 5 2 3 4

PART OF MAIN FRAME LOAD WHEEL SIZE - 4 x 4.12 in. (100 x 105 mm)

LOAD WHEEL SIZE 4 x 2.88 in. (100 x 75 mm) Index Part No. 1

Part Name

†No. Req.

123415-001 End Outrigger 123425-001 End Outrigger With Tip 115003-002 Pin Location 060009-059 Ring Retaining 060020-041 Screw 060030-279 Flatwasher 060021-092 Nut

2 3 4 5

2 2 4 4 4 4 4

LOAD WHEEL SIZE - 5 x 2.88 in. (125 x 75 mm) Index Part No. 1

Part Name

2 3 4 5

2 2 4 4 4 4 4

1 2 3 4 5

Part Name

123415-005 End Outrigger 123425-005 End Outrigger With Tip 115004-001 Pin Location 060009-011 Ring Retaining 060020-039 Screw 060030-279 Flatwasher 060021-092 Nut †Quanity Listed is Per Truck

980131 Crown 1997 PF-11022

07.2–1450–500

2 3 4 5

†No. Req.

123415-003 End Outrigger 123425-003 End Outrigger With Tip 115004-001 Pin Location 060009-011 Ring Retaining 060020-039 Screw 060030-279 Flatwasher 060021-092 Nut

2 2 4 4 4 4 4

Index Part No. 1 2 3 4 5

Part Name

†No. Req.

123415-004 End Outrigger 123425-004 End Outrigger With Tip 115004-001 Pin Location 060009-011 Ring Retaining 060020-039 Screw 060030-279 Flatwasher 060021-092 Nut

2 2 4 4 4 4 4

LOAD WHEEL SIZE - 6 x 4.12 in. (150 x 105 mm)

LOAD WHEEL SIZE - 6 x 2.88 in. (150 x 75 mm) Index Part No.

Part Name

LOAD WHEEL SIZE - 5 x 4.12 in. (125 x 105 mm)

†No. Req.

123415-002 End Outrigger 123425-002 End Outrigger With Tip 115003-002 Pin Location 060009-059 Ring Retaining 060020-041 Screw 060030-279 Flatwasher 060021-092 Nut

Index Part No.

†No. Req. 2 2 4 4 4 4 4

Index Part No. 1 2 3 4 5

Part Name

†No. Req.

123415-006 End Outrigger 123425-006 End Outrigger With Tip 115004-001 Pin Location 060009-011 Ring Retaining 060020-039 Screw 060030-279 Flatwasher 060021-092 Nut

2 2 4 4 4 4 4

Always Specify Model, Data & Serial Numbers 5253 Printed in U.S.A.

07.2–1450–500

LOAD WHEEL 5698-01

RR/RD 5000/5000S SERIES 4 in. (100 mm) O.D. Tandem Load Wheels 2 1

3 4

31 33

19 21

38 39 40

41 42

35 28 27 26

39 38 37

32 10.5 in. (265mm) O.D. Load Wheels

6 in. (150 mm) O.D. Tandem Load Wheels

Index Part No.

25 26 27

2 21

14 16 15 17

6 11

5 in. (125 mm) O.D. Tandem Load Wheels

Part Name

No. Req.

Index Part No.

Part Name

No. Req.

4 in. (102mm) O.D. Tandem Load Wheels 1

2 3 4 5

073962-006 Axle 2.88 in. (75mm) Load Wheel Width 073962-003 Axle 4.12 in. (105mm) Load Wheel Width 076048-001 Fitting Lubrication 060030-068 Flatwasher .03 in. (0.8mm) Thick, 1.62 in. (41mm) O.D. 060030-109 Flatwasher .12 in. (3.0mm) Thick, 2.25 in. (57mm) O.D. 060030-110 Flatwasher .06 in. (1.5mm) Thick, 1.19 in. (30mm) O.D. 065081-021 Bearing Ball

6 4 4 4

7 8

AR 8 AR 8

9 10 11

083585-*

Wheel Poly 4 in. x 2.88 in. (100mm x 75mm) 088628-* Wheel Poly 4 in. x 4.12 in. (100mm x 105mm) 060000-030 Pin Roll 122451-001 Plate Pivot Includes 9, 2.88 in. (75mm) & 4.12 in. (105mm) 065084-013 Bearing 111859-002 Sleeve 061004-027 Adhesive 122451-002 Plate Pivot Includes 9, 2.88 in. (75mm) & 4.12 in. (105mm)

4 4 4 2 4 4 1 2 5859

Crown 1997 PF11023 Rev. 9/98

Printed in U.S.A.

02 REV. 9/98

07.4–1450–001

LOAD WHEEL Index Part No.

Part Name

No. Req.

Index Part No.

13 14 15 16 17 18

19 20 21 22 23

No. Req.

6 in. (150mm) O.D. Load Wheels

5 in. (125mm) O.D. Load Wheels 12

Part Name

073962-006 Axle 2.88 in. (75mm) Load Wheel Width 4 073962-003 Axle 4.12 in. (105mm) Load Wheel Width 4 076048-001 Fitting Lubrication 4 060030-127 Flatwasher .03 in. (0.8mm) Thick, 2.00 in. (50mm) O.D. 8 060030-278 Flatwasher .12 in. (3.0mm) Thick, 3.00 in. (76mm) O.D. 8 060030-093 Flatwasher 0.6 in. (1.5mm) Thick, 1.50 in. (38mm) O.D. 8 060030-289 Flatwasher .03 in. (0.8mm) Thick, 1.50 in. (38mm) O.D. AR 065081-057 Bearing Ball 8 115032-* Wheel Poly 5.0 in. x 2.88 in. (125mm x 73mm) 4 115033-* Wheel Poly 5.0 in. x 4.12 in. (125mm x 105mm) 4 060000-030 Pin Roll 4 121786-002 Plate Pivot Includes 21, 2.88 in. (75mm) & 4.12 in. (105mm) 2 065084-015 Bearing 4 111858-002 Sleeve 4 061004-027 Adhesive 1 121786-001 Plate Pivot Includes 21, 2.88 in. (75mm) & 4.12 in. (105mm) 2

25 26 27 28 29

30 31 32 33 34

074659-006 Axle 2.88 in. (75mm) Load Wheel Width 4 074659-004 Axle 4.12 in. (105mm) Load Wheel Width 4 076048-001 Fitting Lubrication 4 060030-317 Flatwasher .03 in. (0.8mm) Thick, 1.87 in. (47mm) O.D. AR 060030-315 Flatwasher .16 in. (4.1mm) Thick, 3.75 in. (95mm) O.D. 8 060030-316 Flatwasher .06 in. (1.5mm) Thick, 1.87 in. (47mm) O.D. 8 065081-008 Bearing Ball 8 125069-* Wheel Poly 6.0 in. x 2.88 in. (150mm x 75mm) 4 125070-* Wheel Poly 6.0 in. x 4.12 in. (150mm x 105mm) 4 060000-051 Pin Roll 4 061004-027 Adhesive 1 125205 Pivot Plate Includes 32, 2.88 in. (75mm) & 4.12 in. (105mm) 2 065084-015 Bearing 4 111858-002 Sleeve 2 125204 Pivot Plate Includes 32, 2.88 in. (75mm) & 4.12 in. (105mm) 2

Printed in U.S.A.

02 REV. 9/98

07.4–1450–002

LOAD WHEEL Index Part No.

Part Name

No. Req.

10.5 in. (265mm) O.D. Load Wheels 35

36 37 38 39 40 41

074659-002 Axle 4.0 in. (100mm) Load Wheel Width 074659-005 Axle 4.5 in. (115mm) Load Wheel Width 076048-001 Fitting Lubrication 060030-111 Flatwasher .12 in. (3.2mm) Thick, 3.00 in. (76mm) O.D. 060030-113 Flatwasher .09 in. (2.4mm) Thick, 1.75 in. (44mm) O.D. 060030-112 Flatwasher .06 in. (1.5mm) Thick, 1.75 in. (44mm) O.D. 060030-085 Flatwasher .03 in (0.8mm) Thick, 2.00 in. (50mm) O.D. 065081-008 Bearing Ball 105088-060 Tire 10.5 in. x 4.0 in. (265mm x 100mm) 105089-060 Tire 10.5 in x 4.5 in (265mm x 115mm) 105090-060 Tire 10.5 in. x 4.0 in. (265mm x 100mm) Includes 39 & 41 105091-060 Tire 10.5 in. x 4.5 in. (265mm x 115mm) Includes 39 & 41 105086 Hub 10.5 in. x 4.0 in. (265mm x 100mm) 105087 Hub 10.5 in. x 4.5 in. (265mm x 115mm) 060000-051 Pin Roll

2 2 2

* Choice of dash no. depends on load wheel application. When ordering load wheels, refer to the chart below and complete the part no. with the correct dash no. Example: If a dash 010 tire is required for index 6, order 083585-010.

Dash No.

010

85A durometer — Better cut and tear resistance, good for heavy loads and long runs. Excellent for docking, rough floors, floor debris and traction.

025

90A durometer — Excellent performance for high capacity transport operations, easy riding. Good for freezer, traction, resistant to flat spotting, best cut and tear resistance.

030

95A durometer — Good cut and tear resistance, high capacity. Exceptional performance in high capacity transport operations. Use where others “burn Off” or bond fail. Not available for 6.0 in. wheels.

035

95A durometer — Excellent performance for high capacity transport operations, good cut and tear resistance. Resistance to flat spotting and best for freezer use.

040

95A durometer — Excellent cut and tear resistance and high capacity transport operations. Use where nothing else works.

AR AR 4 2 2

2 2 2 2

Application

Always Specify Model, Data & Serial Numbers

980131

5859 Printed in U.S.A.

02 REV. 9/98

07.4–1450–003

YOKE 5851

RR/RD 5000/5000S SERIES

12 11

13 11

17 16

15 1 6 RK FO ND E

4 14

4 5

8 7

10 9 8

Crown 1997 PF11088 Rev. 5/00

Printed in U.S.A.

02 REV. 5/00

07.5–1450–250

YOKE Index Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part Name

No. Req.

121628 Yoke 060000-112 Pin Roll 123183-002 Shaft 060009-011 Ring Retaining 123181-003 Shaft 060009-018 Ring Retaining 123401-001 Shaft Load Sensing With F/C 060030-057 Flatwasher 065081-027 Bearing Ball 117575-003 Pulley Includes 9 117576-003 Pulley 060030-329 Flatwasher 119655-002 Pulley Hose 127583-001 Pulley Wire 060000-067 Pin Roll Load Sensing With F/C 127513-002 Pulley Wire Load Sensing With F/C 060030-192 Flatwasher Load Sensing With F/C 060009-011 Ring Retaining Load Sensing

1 1 1 2 1 2 1 2 2 1 1 4 2 1 1 1 1 1

Always Specify Model, Data & Serial Numbers

980201

6564 Printed in U.S.A.

02 REV. 5/00

07.5–1450–251

LOAD BACKREST 5925-01

Dimension "C"

1 Dimension "A"

Fastened to Fork Plate 1

Dimension "B"

. (

Top Of Fork Index Part No. 1 2

Part Name

82 5

)

2 No. Req.

060019-019 Screw 060005-012 Lockwasher 060019-031 Screw 060005-029 Lockwasher

2 2 2 2

INDEX 3: Load Backrest Model

Part No.

RR & RD RR & RD RR & RD RR & RD W/S.S. RR & RD W/S.S. RR & RD W/S.S.

125608-048 125608-036 125608-042 125367-048 125367-036 125367-042

980131

Overall Dimension in. mm 32.5 x 48 32.5 x 36 32.5 x 42 32.5 x 48 32.5 x 36 32.5 x 42

Dimension A in. mm

Dimension B in. mm

20.5 8.5 14.5 20.5 8.5 14.5

43.88 31.88 37.88 43.88 31.88 37.88

825 x 1220 825 x 915 825 x 1070 825 x 1220 825 x 915 825 x 1070

520 215 370 520 215 370

Always Specify Model, Data & Serial Numbers

Crown 1997 PF11124 Rev. 2/01

1115 810 960 1115 810 960

Dimension C in. mm 48 36 42 48 36 42

1220 915 1070 1220 915 1070 7013 Printed in U.S.A.

01 REV. 2/01

07.8–1450–001

TT LIFT CYLINDER 5823-01

RR/RD 5000/5000S SERIES

8 1

7 1

8 7

2 Left Hand Lift Cylinder

7 6

10 Right Hand Lift Cylinder

RK FO ND E

2 5

3 11 11

Crown 1997 PF11064 Rev. 6/02

Printed in U.S.A.

02 REV. 6/02

08.3–1450–001

TT LIFT CYLINDER 121676-See Below CYLINDER ASSEMBLY LEFT HAND (Does Not Include Index 10) 121663-See Below CYLINDER ASSEMBLY RIGHT HAND (Does Not Include Index 2 & 11) Index Part No. 1

2 3 4 5 6 7 8 9 10 11

Part Name

No. Req.

074240 Seal 1 060015-078 Screw 1 061004-026 Adhesive Thread Lock 1 See Below Cylinder Tube Left Hand 1 060009-067 Ring Retaining 2 073975-004 Bushing 1 See Below Ram 50mm (1.875 in.) Diameter 1 081161-018 Collar 1 064132-046 Rod Packing 1 100512 Cap 1 064135-003 Ring Wiper 1 See Below Cylinder Tube Right Hand 1 121674-056 Fuse Velocity Cartridge Left Hand Cylinder Only 1 Always Specify Model, Data & Serial Numbers

123868 Kit Seal (Includes Index 1, 7 & 9) 1 091240-004 Poly Pak Tool (Used for Seal Installation) 1

Collapsed Height in. mm

Lift Height in. mm

LH Cylinder Assembly

RH Cylinder Assembly

Index 2

Index 5

Index 10

89 95 107 119 131 140 149 160 172

198 210 240 270 300 321 341 366 400

121676-004 121676-005 121676-006 121676-007 121676-008 121676-009 121676-010 121676-011 121676-012

121663-004 121663-005 121663-006 121663-007 121663-008 121663-009 121663-010 121663-011 121663-012

121677-004 121677-005 121677-006 121677-007 121677-008 121677-009 121677-010 121677-011 121677-012

121672-004 121672-005 121672-006 121672-007 121672-008 121672-009 121672-010 121672-011 121672-012

121664-004 121664-005 121664-006 121664-007 121664-008 121664-009 121664-010 121664-011 121664-012

2260 2415 2720 3025 3325 3555 3785 4065 4370

5025 5335 6100 6860 7620 8155 8660 9300 10160

980131

3200 Printed in U.S.A.

02 REV. 6/02

08.3–1450–002

TT LIFT CYLINDER 5823-01

RR/RD 5000/5000S SERIES

8 1

7 1

8 7

2 Left Hand Lift Cylinder

7 6

10 Right Hand Lift Cylinder

RK FO ND E

2 5

3 11 11

Crown 1999 PF11786 Rev. 6/02

Printed in U.S.A.

01 REV. 6/02

08.3–1450–003

TT LIFT CYLINDER 121676-See Below CYLINDER ASSEMBLY LEFT HAND (Does Not Include Index 10) 121663-See Below CYLINDER ASSEMBLY RIGHT HAND (Does Not Include Index 2 & 11) Index Part No. 1

2 3 4 5 6 7 8 9 10 11

Part Name

No. Req.

074240 Seal 1 060015-078 Screw 1 061004-026 Adhesive Thread Lock 1 See Below Cylinder Tube Left Hand 1 060009-067 Ring Retaining 2 073975-004 Bushing 1 See Below Ram 50mm (1.875 in.) Diameter 1 081161-018 Collar 1 064132-046 Rod Packing 1 100512 Cap 1 064135-003 Ring Wiper 1 See Below Cylinder Tube Right Hand 1 124251-003 Fuse Velocity Cartridge Left Hand Cylinder Only 1 Always Specify Model, Data & Serial Numbers

123868 Kit Seal (Includes Index 1, 7 & 9) 1 091240-004 Poly Pak Tool (Used for Seal Installation) 1

Collapsed Height in. mm

Lift Height in. mm

LH Cylinder Assembly

RH Cylinder Assembly

Index 2

Index 5

Index 10

89 95 107 119 131 140 149 160 172

198 210 240 270 300 321 341 366 400

121676-004 121676-005 121676-006 121676-007 121676-008 121676-009 121676-010 121676-011 121676-012

121663-004 121663-005 121663-006 121663-007 121663-008 121663-009 121663-010 121663-011 121663-012

121677-004 121677-005 121677-006 121677-007 121677-008 121677-009 121677-010 121677-011 121677-012

121672-004 121672-005 121672-006 121672-007 121672-008 121672-009 121672-010 121672-011 121672-012

121664-004 121664-005 121664-006 121664-007 121664-008 121664-009 121664-010 121664-011 121664-012

2260 2415 2720 3025 3325 3555 3785 4065 4370

5025 5335 6100 6860 7620 8155 8660 9300 10160

991115

3201 Printed in U.S.A.

01 REV. 6/02

08.3–1450–004

TT CARRIAGE CYLINDER 5829

RR/RD 5000/5000S SERIES 6 12 13 14

1 7

11 3 4

12 13 14 15

3 4 5

7 8 9 10 9 11

Crown 1997 PF11069 Rev. 10/99

Printed in U.S.A.

01 REV. 1099

08.3–1450–050

TT CARRIAGE CYLINDER *121717- CYLINDER ASSEMBLY Index Part No.

Part Name

No. Req.

1 * Cylinder Tube 2 060015-078 Screw 074240 Seal 3 125233 Valve Flow Control 4 125232 Spacer 5 064091-008 Plug Internal Hex with O-Ring 061004-026 Adhesive Thread Lock .5cc 6 * Ram 2.625 in. (65 mm) O.D. 7 087025 Spring Compression 8 117537-004 Piston Shutoff 9 060009-096 Ring Retaining 10 084882-001 Bushing 11 060009-100 Ring Retaining 12 064135-007 Ring Wiper 13 121727 Cap 14 064132-042 Seal Rod 15 081161-020 Collar

1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1

123894 Kit Seal (Includes Index 2, 12 & 14) 1 091240-009 Poly Pack Tool (Used for Seal Installation) 1 * See Below Always Specify Model, Data & Serial Numbers

Collapsed Height in. mm

Lift Height in. mm

Cylinder Assembly

Index 1

Index 6

89 95 107 119 131 140 149 160 172

198 210 240 270 300 321 341 366 400

121717-004 121717-005 121717-006 121717-007 121717-008 121717-009 121717-010 121717-011 121717-012

121718-004 121718-005 121718-006 121718-007 121718-008 121718-009 121718-010 121718-011 121718-012

121725-004 121725-005 121725-006 121725-007 121725-008 121725-009 121725-010 121725-011 121725-012

2260 2415 2720 3025 3325 3555 3785 4065 4370

5025 5335 6100 6860 7620 8155 8660 9300 10160

980131

6245 Printed in U.S.A.

01 REV. 1099

08.3–1450–051

TT CARRIAGE CYLINDER 5829

RR/RD 5000/5000S SERIES 6 12 13 14

1 7

11 3 4

12 13 14 15

3 4 5

7 8 9 10 9 11

Crown 1999 PF11785

08.3–1450–052

Printed in U.S.A.

08.3–1450–052

TT CARRIAGE CYLINDER *121717- CYLINDER ASSEMBLY Index Part No.

Part Name

No. Req.

1 * Cylinder Tube 2 060015-078 Screw 074240 Seal 3 125233 Valve Flow Control 4 125232 Spacer 5 064091-008 Plug Internal Hex with O-Ring 061004-026 Adhesive Thread Lock .5cc 6 * Ram 2.625 in. (65 mm) O.D. 7 103487 Spring Compression 8 127489-002 Piston Shutoff 9 060009-096 Ring Retaining 10 084882-001 Bushing 11 060009-100 Ring Retaining 12 064135-007 Ring Wiper 13 121727 Cap 14 064132-042 Seal Rod 15 081161-020 Collar

1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1

123894 Kit Seal (Includes Index 2, 12 & 14) 1 091240-009 Poly Pack Tool (Used for Seal Installation) 1 * See Below Always Specify Model, Data & Serial Numbers

Collapsed Height in. mm

Lift Height in. mm

Cylinder Assembly

Index 1

Index 6

89 95 107 119 131 140 149 160 172

198 210 240 270 300 321 341 366 400

121717-004 121717-005 121717-006 121717-007 121717-008 121717-009 121717-010 121717-011 121717-012

121718-004 121718-005 121718-006 121718-007 121718-008 121718-009 121718-010 121718-011 121718-012

121725-004 121725-005 121725-006 121725-007 121725-008 121725-009 121725-010 121725-011 121725-012

991213

2260 2415 2720 3025 3325 3555 3785 4065 4370

5025 5335 6100 6860 7620 8155 8660 9300 10160

6304 Printed in U.S.A.

08.3–1450–053

REACH CYLINDER 5831

RR/RD 5000/5000S SERIES 1 2

12 13

112987 RD REACH CYLINDER ASSEMBLY 122298-001 RR REACH CYLINDER ASSEMBLY RH (Shown) 122298-002 RR REACH CYLINDER ASSEMBLY LH Index Part No. 1 2

3 4 5 6 7 8 9

Part Name

No. Req.

065012-001 Bushing Ball 112974 RD Tube 122299 RR Tube RH 122300 RR Tube LH Not Shown 060042-001 Nut 111924 Piston 064216-005 Seal Piston 064074-020 Ring Backup 064019-042 O-Ring 111923-001 RR Rod Piston 111923-002 RD Rod Piston 064019-015 O-Ring

1 1 1 1 1 1 1 2 1 1 1 1

Index Part No. 10 11 12 13 14 15 16 17

Part Name

No. Req.

064074-005 Ring Backup 111927-001 Rod End 064132-037 Packing Rod 064135-009 Ring Wiper 111936 Retainer Wire 111937 Nut End Rod 060021-040 Nut 082469 Rod End

113745

1 1 1 1 1 1 1 1

Kit Seal (Includes Index 5, 6, 7, 9, 10, 12, 13, & 14)

Always Specify Model, Data & Serial Numbers

980131

5856

Crown 1997 PF11072 Rev. 8/98

Printed in U.S.A.

01 REV. 8/98

08.5–1450–001

TILT CYLINDER 5914

RR/RD 5000/5000S SERIES 6 5 4 3 2

1 14 13

123399-001 TILT CYLINDER Index Part No. 1 2 3 4 5 6 7 8 9 10

Part Name

088579 Rod Piston 064135-002 Ring Wiper 082305 Cap 064074-012 Ring Backup 064019-040 O-Ring 064132-010 Rod Packing 064074-013 Ring Backup 064019-041 O-Ring 105206 Piston 064216-002 Seal Piston

980131 Crown 1997 PF-11116

08.6–1450–001

No. Req. 1 1 1 1 1 1 1 1 1 1

Index Part No. 11 12 13 14

Part Name

No. Req.

060044-004 Lockwasher 060043-004 Lockwasher 073981-003 Retainer Square Wire 122492-001 Cylinder Tube

1 1 1 1

089178

Kit Seal (Includes Index 2, 4, 5, 6, 7, 8, & 10)

Always Specify Model, Data & Serial Numbers

5262 Printed in U.S.A.

08.6–1450–001

SIDESHIFT CYLINDER 5835

3 17

4 17 5

12 13 14 15

9 8 6 10

2 7

093559-001 CYLINDER - 4 in. (100 mm) SIDESHIFT (TF & TL) 093559-002 CYLINDER - 4 in. (100 mm) SIDESHIFT (TT) 093559-003 CYLINDER - 2 in. (50 mm) SIDESHIFT (TF & TL) 093559-004 CYLINDER - 2 in. (50 mm) SIDESHIFT (TT) Index Part No. 1

2 3 4 5 6 7 8

Part Name

No. Req.

085130-001 Rod 4 in. (100 mm) Sideshift TF & TL 1 085130-002 Rod 4 in. (100 mm) Sideshift TT 1 085130-003 Rod 2 in. (50 mm) Sideshift TF & TL 1 085130-004 Rod 2 in. (50 mm) Sideshift TT 1 060038-005 Pin Cotter 1 064069-007 Ring Wiper 1 083397 Adjustor Seal 1 061004-023 Adhesive Thread Lock 1 064132-011 Packing Rod 1 085262 Tube Cylinder 1 073981-009 Ring Retaining 1 064074-004 Ring Back-Up 2

Index Part No. 9 10 11 12 13 14 15 16 17

Part Name

No. Req.

064019-025 O-Ring 064133-005 U-Cup Piston 085132 Piston 060030-041 Flatwasher 060021-044 Nut Slotted Hex 064019-006 O-Ring 064074-018 Ring Back-Up 093558 Chamber Cushion 088587 Spacer 2 in. (50mm) Sideshift Only

101343

1 2 1 1 1 1 1 1 2

Kit Seal (Includes Index 2, 3, 5, 7, 8, 9, 10, 14, & 15)

Always Specify Model, Data & Serial Numbers 930222

5662 Printed in U.S.A.

Crown 1993 PF9675 Rev. 2/98

02 REV. 2/98

08.7–1430–050

mfg 091109