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Crown
Forklifts
RC 5500 series
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DRIVE UNIT
Drive Unit
11
2
M3.0-1055-006
07 Rev
. 10
/09
Figure 15454-03
(a)
T
orque 522 - 562 Nm (385
- 415 ft lb)
(b)
T
orque 1
1.6 - 13.2 Nm (103 - 1
17 in lb)
(c)
T
orque 32 - 38 Nm (24 - 28 ft lb)
(d)
T
orque 53.3 - 58.7 Nm (12.
5 - 16.5 ft lb)
(e)
T
orque 17.6 - 20.4 Nm (13
- 15 ft lb)
(f)
T
orque 7
1 - 79 Nm (52 - 58 ft lb)
Crown 200
7 PF15706
-6 Rev
. 10/09
128
130
Table of Contents
Main Page
Default Chapter
6
Table of Contents
6
Safety
20
General Maintenance Instructions
20
Control of Hazardous Energy
22
Lockout/Tagout
22
Battery
22
Safety Rules
22
Battery Care
22
Charging
22
Battery Removal
23
Battery Installation
23
Lockout - Tagout
23
Brake Release Instructions
24
Capacitance
25
Hydraulic
25
Towing Truck
26
Towing by Pulling in Power Unit First Direction
26
Towing by Pulling in the Forks First Direction
27
Towing by Lifting Truck and Pulling in Power Unit First Direction
27
Towing by Lifting Truck and Pulling in the Forks First Direction
27
Lifting and Blocking
28
Mast
29
Blocking Masts
29
Disconnecting Tilt Cylinder
31
Removing Mast
32
Cleaning of Material Handling Equipment
34
Cleaning Methods
34
Introduction
38
Operation Instructions
38
Operater Training
38
Service Training
38
Replacement Parts
38
Lubrication & Adjustment Page
42
Lubrication and Adjustment
44
Lubrication and Adjustment
50
Component Accessibility
50
Lubrication
52
Componentry
62
Access 1
62
Access 2
62
Access 3
62
Access 7
63
Alm1
63
Alm2
63
Bresl, Bresr
63
Brk1
64
Brk2
64
Brks
64
Cbve
65
Cbvr
65
Cvr
66
Dls
66
Dms1, Dms2, Dms3
66
Ecr1
67
Ecr2
67
Ecr3
67
Ecr4
68
Eds
68
Enls, Ensr
69
Fan1
69
Fns
69
Fan2
70
Fu1
70
Fu2
71
Fu3
71
Fu4
71
Fu13/Fu14
72
Fu5
72
Hgts1
72
Hgts2
73
Hgts3
73
Hgts4
73
Hn1
74
Hns
74
Kys
75
Lcv
76
Lgt1, Lgt2
76
Lgt3
77
Lgt4
77
Lgts1
77
Ors
79
Pca
79
Pot1
79
Pot2
80
Pot3
80
Pot4
80
Prva
81
Pt1
81
Rps1
82
Rps2
82
Rva
83
Rvm
83
Sss
83
Spl
84
Spa
84
Svte
84
Svtr
85
Svt
85
Svh
85
Svby
86
Sva1A
86
Sva1B
86
Sva2A
87
Sva2B
87
Sva3
87
Tbs
87
Tds
88
Tr1
88
Tr2
88
Ts1
89
Ts2
89
Ts3
89
Metric Torque Values
90
Grade
90
Torque Values
94
Grade
94
General Information
98
Hydraulic Lines and Fittings
98
Reservoir
98
Filter
98
Drift Test
98
Lift Drift Test
99
Tilt Drift Test
99
Steering Slip
99
Freezer Preparation
99
Circuit Operation
99
Hydraulic Circuits
101
Steering Circuit
101
Hoist
102
Lift Circuit
102
Lower Circuit
103
Tilt and Accessory Flow
104
Tilt
104
Tilt down Circuit
105
Tilt Back Circuit
106
Tilt Position Assist
107
Sideshift - Left Circuit
107
Sideshift - Right Circuit
108
Fourth Hydraulic Function (Second Accessory)
108
Fifth Hydraulic Function (Third Accessory)
108
Accessory Clamp Set-Up
110
Attachment Setup - General
110
Attachment Setup - Clamp
110
Hydraulic Schematic Symbols
114
Pump Maintenance
118
General
118
Pump Disassembly
118
Parts Inspection
118
Body
118
Priority Valve
118
Pump Reassembly
119
Start up Procedure
119
Drive Unit
124
Inspect Drive Unit
124
Drive Unit Lubrication
124
Drive Tire Replacement
125
Traction Motor
126
Traction Motor Removal
126
Traction Motor Installation
126
Drive Unit Removal
127
Drive Unit Installation
127
Drive Unit Sub-Assembly Removal
128
Drive Unit Gear Assembly Replacement/Installation
130
Electrical
134
Electrical System
138
Wiring Color Codes
138
Power Cables
138
Switches
142
Access 123
150
ACCESS 1 Display
150
Operator Level
150
Message Mode
151
Timer - Message Mode
151
Trip - Message Mode
151
Bdi - Message Mode
151
Hours - Message Mode
152
Odometer - Message Mode
152
Hour
152
Pressure
152
Events
152
Service
153
Level 2
153
Level 3
153
Bleed Quick Disconnect
153
Performance
154
Relief Pressure Setup
154
Analyzer
191
Analyzer Access
191
A1 Status
191
A2 Inputs
192
A3 Outputs
196
A4 Test Outputs
198
Calibration
199
Features
205
Hours
209
Hour Access
209
Events
209
Performance
210
Utilities
213
Control Modules
214
Traction Drive Module
214
Basics of System Operation
214
Control Circuit Operation
214
Power Circuit Operation
215
Hydraulic Control Module - AC/DC
216
Basics of System Operation
216
Accessory Control Module
216
Contactor
218
Battery
220
Safety Rules
220
Checking
220
Battery Care
221
Charging
221
Battery Cleaning
222
Troubleshooting
222
Battery Removal
222
Battery Installation
224
Motors
226
Pump Motor and Brush Inspection
226
Event Codes
228
Capacitance
229
Event Code 100
231
Event Code 101
231
Event Code 102
232
Event Code 103
232
Event Code 104
233
Event Code 105
233
Event Code 106
234
Event Code 107
235
Event Code 108
236
Event Code 109
237
Event Code 110
238
Event Code 111
239
Event Code 112
240
Event Code 113
241
Event Code 114
242
Event Code 199
242
Event Code 200
243
Event Code 201
244
Event Code 202
245
Event Code 203
247
Event Code 203
248
Event Code 204
249
Event Code 205
250
Event Code 206
251
Event Code 207
253
Event Code 208
254
Event Code 209
255
Event Code 213
256
Event Code 214
257
Event Code 217
258
Event Code 218
259
Event Code 219
260
Event Code 221
261
Event Code 224
262
Event Code 300
263
Event Code 301
264
Event Code 302
265
Event Code 303
266
Event Code 304
267
Event Code 306
268
Event Code 308
269
Event Code 311-313
270
Event Code 314
271
Event Code 315
272
Event Code 318
273
Event Code 319
274
Event Code 399
275
Event Code 700
276
Event Code 702
277
Event Code 703
278
Event Code 704
279
Event Code 705
280
Event Code 706
281
Event Code 707
282
Event Code 708
283
Event Code 709
284
Event Code 710
285
Event Code 711
286
Event Code 713
287
Event Code 715
288
Event Code 717
289
Event Code 719
290
Event Code 721
291
Event Code 722
292
Event Code 723
293
Event Code 724
294
Event Code 726
295
Event Code 728
296
Event Code 729
297
Event Code 730
298
Event Code 731
299
Event Code 733
300
Event Code 734
301
Event Code 736
302
Event Code 737
303
Event Code 740
304
Event Code 741
305
Event Code 745
307
Event Code 746
309
Event Code 747
310
Event Code 749
311
Event Code 751
312
Brake
316
Brake
317
Brake
317
Service Brake
317
Electric Parking Brake Release Procedures
318
Releasing Parking Brake Using Truck Battery
319
Brake Switch Adjustment (BRKS)
320
Steering
326
Steer Command Assembly
327
Housing to Yoke Assembly
328
Steer Motor to Axle Housing Assembly
329
Wheel Assemblies to Steer Axle (Metallic Shield)
330
Wheel Assemblies to Steel Axle (Oil Seal)
331
Hydraulic Steer Motor
332
Steer Motor Assembly
333
Motor Timing
334
Lifting Mechanism Parts
338
Mast
338
Mast Testing (Assembled)
339
Mast Disassembly
340
Removal from Power Unit
341
Mast Reassembly
342
Quad (Four Stage) Mast
345
Mast Inspection
346
Carriage Removal
347
Lift Chains
350
Rust and Corrosion
351
Tight Joints
352
Lift Chain Lubrication
353
Chain Anchors and Pulleys
354
Fork Inspection
356
Overloading
358
Fatigue
359
Hanger
360
Cylinders
364
Cylinder Parts
365
Mast Cylinder
365
Mast Cylinder Inspection
366
Mast Cylinder Reassembly
368
Mast Cylinder Bleeding
369
Carriage Cylinder
370
Carriage Cylinder Disassembly
371
Carriage Cylinder Reassembly
373
Tilt Cylinder
374
Tilt Cylinder Disassembly
375
Tilt Cylinder Adjustment
376
Tilt Cylinder Bleeding and Flushing Procedures
377
Tilt Cylinder Bleeding and Flushing
378
Sideshifter Cylinder
380
Sideshifter Cylinder
381
Sideshifter Cylinder Removal
381
Sideshifter Cylinder Disassembly
382
Sideshifter Cylinder Reassembly
383
Platform Parts
386
Sideshifter
386
Sideshifter Removal
387
Sideshifter Installation
388
Bearings
390
Troubleshooting
392
Sideshift Circuit Test
393
Glossary
396
Wiring Diagrams
408
Introduction to Diagram Usage
408
Electrical Diagrams Index
410
Electrical Schematic - AC Lift
411
Electrical Schematic - DC Lift
412
Distribution Panel
413
Distribution Panel
414
Display Module
414
Multi-Task Handle
415
Accessory Control Module
416
Accessory Control Module
417
Multi-Task Handle
417
Traction Control Module
417
Hydraulic Control Module - AC Lift
418
Hydraulic Control Module - DC Lift
419
Motors and Brakes
420
Console and Overhead Guard
421
Floorboard
422
Hydraulics, Height & Load Sense
423
Hydraulics, Height & Load Sense
424
Freezer Condition
424
Power Cables - AC Lift (ANSI Trucks)
425
Power Cable - AC Lift W/Rapid Charge
426
Power Cable - AC Lift (Euro Trucks)
427
Power Cables - DC Lift (ANSI Trucks)
428
Power Cable - DC Lift W/Rapid Charge
429
Power Cable - DC Lift (Euro Trucks)
430
Infolink
431
Infolink
432
Wire Harnesses
432
Hydraulic Schematic
436
Entire Truck
436
Power Unit
439
Power Unit Parts
447
Armrest
447
Suspended Floorboard
451
Flexride Suspension
455
Entry Bar
461
Counterweight
463
Overhead Guard
465
Battery Retainers, Spacers, Rollers
471
Reservoir
475
Reservoir
477
Hydraulic Parts
477
Plumbing
477
Mast Plumbing - TT
481
Mast Plumbing - Quad
483
DC Lift Pump
491
Pump Motor - AC
493
Pump Motor - DC
495
Pump Motor - AC "EE
497
Valve Assembly 1 Low Flow Accessory
499
Valve Assembly W/2 High Flow Accessories
503
Chain Slack Valve - Quad Mast
507
Manifold Crossover Relief
509
Carriage Hydraulics - Tt/Quad
511
Drive Unit
517
Drive Unit
519
Drive Unit Parts
519
AC Traction Motor
519
AC Traction Motor - EE
521
Drive Tire
523
Electrical Parts
527
Drive Tire
527
Electrical Components - Power Unit
527
Contactor Panel
535
Contactor Panel - EE
537
Distribution Panel
541
Distribution Panel - Freezer/Corrosion
543
Distribution Panel - EE
545
Contactor
547
Multi-Task Handle
549
Connectors
555
Battery Retainer Switches
561
Tilt Limit Switch
563
Access 1
565
Control Cable
567
Overhead Guard - Strobe Light
569
Overhead Guard - Worklights
571
Work Lights - TT Mast
573
Work Lights - Quad Mast
575
Strobe Light
577
Brake Parts
581
Brake
581
Steering Parts
585
Steering Command
585
Steer Axle
587
Steer Motor
591
Steer Unit
593
Steer Tire
595
Mast - Quad
607
Fork Carriage - TT Mast
617
Fork Carriage - Quad Mast
619
Yoke - TT
623
Th Function
623
Yoke Quad Mast
625
Lift Chain - TT Mast
627
Lift Chain - Quad Mast
629
Load Backrest
633
Fork
635
Mast Cylinder - TT
641
Carriage Cylinder - TT
643
Mast Cylinder - Quad
645
Carriage Cylinder - Quad
647
Tilt Cylinder
649
Sideshifter Cylinder
653
Sideshifter
657
Platform
657
Sideshifter
657
Labels and Decals
663
Work Assist
663
Work Assist Accessories
665
Infolink
669
Labels & Decals
673
Labels & Decals Power Unit
679
Labels & Decals Infopoint/Access
683
Labels & Decals RC 5500C
687
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