PDF Service Manual Crown SH SHR 5500 Walkie Stacker - 4 MB
The official service manual for the Crown SH/SHR 5500 series walkie stacker provides technicians with the information needed for advanced troubleshooting and repair.
It includes detailed electrical and hydraulic schematics, component overhaul procedures, and maintenance specifications.
This guide is essential for any professional servicing Crown material handling equipment.
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--- Page 1 ---
INTRODUCTION
Introduction
Introduction • Hydraulic systems
• Electrical systems
This manual is for service technicians who are ap-
proved and correctly trained to do troubleshooting and For more information on service training, consult your
maintenance procedures on the lift truck. The manual Crown dealer or go to "Training" on www.crown.com.
contains information about maintenance, troubleshoot-
ing, and replacement parts. Replacement Parts
For correct and fast service, when you consult Crown
Operator Instructions for replacement parts, always give this information:
This manual does not have operator instructions. • The part number
There are operator instructions in tag or booklet form • The lift truck model number
with each lift truck. If it is necessary, more copies can
• The lift truck serial number
be ordered. The operator instructions are to make sure
that you and your personnel know how to operate your • The lift truck data number
Crown lift truck safely. For operator instructions, see Consult your Crown dealer or go to www.crown.com
the "SHC Operator Manual". for:
• The newest service manuals
Operator Training
• The newest operator manuals
Crown has operator training programs that are avail- • Training
able through your Crown dealer. For more information
• Lift truck capacities
on operator training, consult your Crown dealer or go to
"Training" on www.crown.com. • Lift truck specifications
Service Training Manual Structure
Service training is available for: This manual contains sections that have maintenance
and replacement parts. The section descriptions are as
• All Crown lift trucks
follows:
• Module systems
Service and Parts Pages
Maintenance Replacement Parts
Section Description Section Description
MA Safety 1 Power Unit Parts
M1 Inspection and Lubrication 2 Hydraulic Parts
M1.91 Componentry 3 Drive Unit Parts
M2 Hydraulic 4 Electrical Parts
M3 Drive Unit 5 Brake Parts
M4 Electrical 6 Steering Parts
M5 Brake 7 Lifting Mechanism Parts
M6 Steering 8 Cylinder Parts
M7 Lifting Mechanism 9 Reach and Attachment Parts
M8 Cylinders 10 Accessories
M9 Reach and Attachments 12 Labels and Decals
M10 Glossary
Crown 2020 PF28319 ITD-8155-001
19
--- Page 3 ---
SAFETY
Cleaning of Material Handling Equipment
Crown Cleaning Products
Cleaner Type Part Number Package Quantity
Degreaser and cleaner 363105-001 19 oz can
363105-012 (12) 19 oz cans
All-purpose cleaner 363114-001 19 oz can
363114-012 (12) 20 oz cans
Glass cleaner 363101-001 19 oz can
363101-012 (12) 19 oz cans
Waterless hand cleaner 363111-001 15 oz tube
363111-012 (12) 15 oz tubes
Pumiced and smooth hand cleaner 363112-001 1 gal jug
363112-004 (4) 1 gal jugs
Wall-mounted deluxe soap dispenser 363122 Use with P/N 363112-001
Tough on grease 063009-005 1 gal jug
Citrus degreaser spray 363156-001 32 oz spray bottle
363156-012 (12) 32 oz spray bottles
Citrus degreaser spray 363157-101 1 gal refill (use with P/N 363134-001)
363158-101 1 gal concentrated (use with P/N 363134-001)
Citra-sol degreaser 363146-001 19 oz can
363146-012 (12) 19 oz cans
Battery cleaner 363124-001 18 oz can
363124-012 (12) 18 oz cans
MA-1140-051 Crown 2000 PF11969 Rev. 9/21
05 Rev. 9/21
6
--- Page 4 ---
SAFETY
Control of Hazardous Energy
Disconnecting the tilt cylinders
The following procedures describe how to disconnect
the tilt cylinders from the mast safely. 1
WARNING
Avoid high-pressure fluids.
High-pressure fluids can go through the skin and cause
severe injury. High-pressure fluid that goes into the
skin can become a severe medical emergency even
when the skin looks normal. There is a delayed start of
pain and severe tissue damage may occur.
Release the pressure before you disconnect the hy-
draulic plumbing.
Tighten all connections before you apply hydraulic
pressure.
Keep your hands away from pin-holes which eject
high-pressure fluids.
Use a piece of cardboard or paper to examine for
leaks. Do not use your hand.
You must immediately get medical aid from a spe-
cialist experienced with this type of injury. 2
1. Move the lift truck to a maintenance area on a level
floor. Fig. 8 (34437)
2. Fully lower the mast and forks.
3. Make sure that the forks are empty.
4. Turn off the lift truck.
5. Lockout/tagout the lift truck.
6. See Figure 8. Put the chocks (2) against the 2
wheels.
7. Attach a sling and an overhead lifting device (1) to
all cross members of the mast to prevent move-
ment of the mast when the tilt cylinders are discon- 1
nected.
8. See Figure 9. Remove the screws (1) and the pins
(2) that connect the tilt cylinders to the mast. Fig. 9 (34438)
MA-8155-107 Crown 2020 PF28307
14
--- Page 5 ---
INSPECTION AND LUBRICATION
Lubrication and Adjustment
I-9
I-19
I-18
I-22
I-17 I-8
I-1
I-25
I-11
I-2
L-14
I-13
L-2
L-1
I-24
L-11 I-24
I-10
I-6 L-6 I-5
I-7
I-3
I-4
I-14
L-7
L-7 L-3
Fig. 1
M1.0-8155-002 Crown 2020 PF28344
36
--- Page 6 ---
INSPECTION & LUBRICATION
SAE Torque Values
Torque Chart
Bolt Grade 5 Grade 8
Diameter
Dry Torque Specification Dry Torque Specification
in ft Ib kg-m Nm ft lb kg-m Nm
1/4 9±3 1.2 ± 0.4 12 ± 4 13 ± 4 1.8 ± 0.5 17.5 ± 5.5
5/16 18 ± 5 2.5 ± 0.7 24.5 ± 7 25 ± 5 3.5 ± 0.7 34 ± 7
3/8 32 ± 5 4.4 ± 0.7 43.5 ± 7 48 ± 10 6.6 ± 1.3 65 ± 13.5
7/16 50 ± 10 6.9 ± 1.4 67.5 ± 13.5 75 ± 10 10.4 ± 1.4 102 ± 13.5
1/2 75 ± 10 10.4 ± 1.4 101.5 ± 13.5 112 ± 15 15.5 ± 2.0 152 ± 20.5
9/16 110 ± 15 15.2 ± 2.0 149 ± 20.5 163 ± 20 22.5 ± 3.0 221 ± 27
5/8 150 ± 20 20.7 ± 2.8 203.5 ± 27 225 ± 30 31.1 ± 4.1 305 ± 41
3/4 265 ± 35 36.6 ± 4.8 359 ± 47.5 400 ± 50 55.2 ± 6.9 542 ± 68
7/8 420 ± 60 58.1 ± 8.3 569 ± 81 640 ± 80 88.3 ± 11.0 868 ± 108
1 640 ± 80 88.5 ± 11.1 868 ± 109 960 ± 115 132.5 ± 15.9 1300 ± 156
1 1/8 800 ± 100 110.6 ± 13.8 1085 ± 136
1 1/4 1000 ± 120 138 ± 16.6 1356 ± 163
1 3/8 1200 ± 150 166 ± 20.7 1630 ± 203
1 1/2 1500 ± 200 207 ± 27.7 2034 ± 271
Torque specifications for bolts related to
hydraulic valves.
5/16 13 ± 2 1.8 ± 0.3 17.5 ± 2.5
3/8 24 ± 2 3.3 ± 0.3 32.5 ± 2.5
7/16 39 ± 2 5.4 ± 0.3 53 ± 2.5
NOTE: Special torque values in the maintenance and parts sections of this manual over-
ride the standard torque values in this section.
M1.9-14.0-002 Crown 1979 PF5067 Rev. 2/16
06 Rev. 2/16
72
--- Page 7 ---
COMPONENTRY
FU_EWS (Not Shown, Optional)
FU_EWS (Not Shown, Optional) Data: information received from operator input via
switches and controls on the X10® Handle
Early Warning System Fuse Adjustments: not applicable
Location: on the EWS wiring harness Diagrams: not applicable
Purpose: protects EWS components and associated Parts Breakdown: 04.5-8155-100
wiring from over current
04.5-8155-125
Data: 2 A
04.5-8155-150
Adjustments: not applicable
04.5-8155-175
Diagrams: not applicable
Parts Breakdown: not shown K1
HGTS1 (See LMS1) accessory Relay
Location: on the control panel bracket inside the
HN power unit
Purpose: provides power to optional Work Assist®
Horn components (i.e. worklights, strobe lights, operator fan)
Location: on the power unit, mounted next to M1 Adjustments: not applicable
Purpose: audible alarm actuated by the operator to Diagrams: not applicable
warn of lift truck movement
Parts Breakdown: 04.1-8155-001
Data: information is received from operator input via
HNS1 or HNS2 on the control handle
K_EWS (Optional)
Adjustments: not applicable
Diagrams: not applicable Early Warning System Relay
Parts Breakdown: 04.0-8155-001 Location: on the power unit above the fuse panel
Purpose: provides the EWS signal to the ACCESS 1
HNS1 / HNS2 Adjustments: not applicable
Horn Switch Diagrams: not applicable
Location: on the control handle Parts Breakdown: not shown
Purpose: allows the operator to sound HN
KYS
Data: wired normally open. Circuit closes and sounds
HN when horn switch button on handgrip is depressed Key Switch
Adjustments: not applicable Location: ACCESS 1 display panel
Diagrams: not applicable Purpose: allows the operator to power up ans shut
Parts Breakdown: 04.5-8155-001 down the lift truck
Data: key–operated selector switch, energizes control
HSS circuitry in the ignition position
Adjustments: not applicable
High Speed Switch
Diagrams: not applicable
Location: control handle cap
Parts Breakdown: not shown
Purpose: controls traction speed
M1.91-8155-010 Crown 2020 PF28334
88
--- Page 8 ---
COMPONENTRY
SAS
SAS SRS
Safety Reverse Switch Sideshift Right Switch (Lift Trucks with Optional
Sideshift Function)
Location: control handle cap
Location: control handle cap
Purpose: moves the lift truck in direction of forks when
actuated Purpose: indicates the sideshift right request
Data: momentary contact switch wired normally open, Data: wired normally closed, held open. when the side-
held closed by the button on end of the control handle shift button is pressed in correct direction, the switch
cap closes and activates the function
Adjustment: not applicable Adjustment: adjustments can be made in perfor-
mance menus to determine the desired pump speed
Diagrams: not applicable
Diagrams: not applicable
Parts Breakdown: 04.5-8155-100
Parts Breakdown: 04.5-8155-152
04.5-8155-125
04.5-8155-177
04.5-8155-150
04.5-8155-175 SVCV
SVA1 / SVA2 Solenoid Check Valve
Location: manifold block with accessories Location: on the manifold block with accessories
Purpose: selects the direction of hydraulic flow for ac- Purpose: prevents the back flow of hydraulic fluid to
cessory functions allow proper lift
Data: not applicable Data: not applicable
Adjustment: not applicable Adjustment: not applicable
Diagrams: not applicable Diagrams: HYD-8155-001
Parts Breakdown: 02.4-8155-001 Parts Breakdown: 02.4-8155-001
SLS
Sideshift Left Switch (Lift Trucks with Optional
Sideshift Function)
Location: control handle cap
Purpose: indicates the sideshift left request
Data: wired normally closed, held open. when the side-
shift button is pressed in correct direction, the switch
closes and activates the function
Adjustment: adjustments can be made in perfor-
mance menus to determine the desired pump speed
Diagrams: not applicable
Parts Breakdown: 04.5-8155-152
04.5-8155-177
M1.91-8155-020 Crown 2020 PF28334
98
--- Page 9 ---
HYDRAULIC SYSTEM
Hydraulic System
Hydraulic lines and fittings control valve. To seat these valves properly when this
occurs, raise and lower the forks to flush out any for-
Blow air through all hoses and lines to remove loose eign material from the valve seat. Check the system for
particles before installing. Any rubber hose with wire leaks if there is any abnormal loss of oil.
braid inner construction and any steel tube lines that
are collapsed or kinked are permanently damaged. Tilt test
Damaged hoses must be replaced even if the damage
is not externally visible. Raise the test load approximately 600 mm (24.0 in) and
tilt the mast fully back. Turn off the lift truck. Measure
Flexible hoses must be replaced if they collapse in the the drift on the tilt cylinder rod. The mast must not drift
normal operating position. forward more than 20 mm (0.75 in) in five minutes
All hoses must be away from any surface or edge caus- when measured on the tilt cylinder rod.
ing wear, damage, or cuts. Occasionally, a slight creep of the mast assembly can
All connections must be free of leaks. occur due to internal leakage in the tilt cylinder piston
pack. A slight creep can also be caused by leakage in
Beaded elbows in suction ports of all pumps must be the check valve or the control valve. To seat these
positioned so that the suction hose retains its full vol- valves properly when this occurs, tilt the mast forward
ume flow and does not collapse. and back to flush out any foreign material from valve
seat.
Hydraulic oils
Check the system for leaks if there is any abnormal
Use only a high grade of hydraulic oil. See the Lubrica- loss of oil.
tion section. For freezer condition lift trucks, use low
temperature hydraulic oil.
Note: Do not use hydraulic brake fluid.
Drift test
All drift tests must be conducted with a capacity load
(see the lift truck serial plate for the rated capacity). Ma-
terial used for test load must be evenly stacked within
limits of a four foot square pallet. The material must be
secured to the fork carriage with the forks spread to the
maximum width.
Note: The lift measurement is taken from the tip of the
fork to the floor. The tilt measurement is taken on the
tilt cylinder rod.
WARNING
Never stand or work under a suspended load.
Lift drift test
Raise the test load approximately 600 mm (24.0 in)
and turn off the lift truck. After five minutes, measure
the distance the forks have drifted. Drifting must not be
more than 63.5 mm (2.5 in). A five-minute duration of
this test is necessary due to the centering time required
for the control valve spool.
Occasionally, a slight creep of the fork assembly can
occur due to internal leakage in the check valve or the
M2.0-8155-004 Crown 2020 PF28348
74
--- Page 10 ---
HYDRAULIC SYSTEM
Relief Valves
Pressure Settings
Valve Set Pressure (MPa) Set Pressure (psi)
RV 21.37 MPa 3100 psi
RVA 10.34 MPa 1500 psi
Troubleshooting
Symptom Probable Cause Possible Solution
Oil leaks around Defective o-rings in the cartridge Replace the o-rings.
manifold. valve or port connector fittings.
Carriage does not raise RV is stuck in the open position. Replace the relief valve.
(M2 runs).
SVCV is not opening. Actuate the valves and try to dislodge the de-
bris. Check to see that the valve (solenoid only)
is not over-tightened. If neither remedy works,
replace the valve.
Carriage does not raise Relief valve not adjusted correctly. Readjust the relief valve in accordance with the
a capacity load. Pressure Settings Table.
Carriage drifts down Defective o-rings on check valves, Replace the o-rings or back-up rings. Check the
more than the amount solenoid valves, or proportional valve capacity at the o-ring sealing area for
specified in the drift test. valve. nicks or rough surfaces.
Debris caught in check valve Actuate the valves and try to dislodge the de-
seats. bris. If that does not work, replace valve.
Carriage will not lower. Solenoid coil failure. Replace the solenoid coil.
Cylinder malfunction. Refer to Cylinders.
Electrical malfunction. Refer to Electrical.
M2.4-8155-002 Crown 2020 PF28350
84
--- Page 11 ---
DRIVE UNIT
Drive Unit
24. See Figure 5. Press the bearing (49) onto the
bevel gear (48). Use the two holes in the bevel
gear. Remove the washers (43) adjust the thick-
ness:
– To reduce the clearance: Increase the number of
shims (43).
– To increase the clearance: Reduce the number
of shims (43).
25. Install the washers (43) with the adjusted size.
26. See Figure 5. Press the roller bearing (49).
27. Install the shaft and check the clearance again.
Keep adjusting if necessary until the clearance is
within the tolerance range of 0.2–0.5 mm (0.008–
0.020 in).
28. See Figure 8. Press the shaft seal (54) over the
holes in the flange on the shaft in the correct posi-
tion.
Note: For gearboxes with screw-on cover (43):
• See Figure 5. Clean the contact surface of the
housing (57) and cover (46) with a suitable solvent.
Fig. 9 (19164)
• Install the O-ring (58) to the cover (46).
• Attach the cover (46) with the screws (45). Torque
to 10 N m (7 ft lb).
Note: Before adding oil, check the hardening times re-
quired for the sealing compound used.
For gearboxes with a press-on cover (46).
– Install O-ring (58) to a new cover (46) with the
sealed side facing out.
– Using a plastic hammer strike the cover evenly
without damaging the cover (46).
29. Install the drive gear cover (26) into the correct po-
sition.
30. See Figure 4. Install the O-ring (22), shim (23),
supporting ring (24), and retaining ring (27) into the
correct position and fasten the screws (15). Torque
to 25 N m (18 ft lb).
31. See Figure 4. Install the bleeder valve (25).
32. Install and tighten the drain plug.
33. See Figure 4. Install the intermediate flange (16)
and torque to 35 N m (26 ft lb).
Note: Before adding oil, check the hardening times re-
quiring for each sealing compound used.
34. Add oil. See Lubrication and Adjustment for recom-
mended oil.
M3.0-8055-010 Crown 2008 PF15863 Rev. 11/18
02 Rev. 11/18
96
--- Page 12 ---
ELECTRICAL SYSTEM
Access 1 2 3®
Access 5 Inputs continued from page -005 A2.4.1 TEMP Access 5 = Value °C
A2.4.2 TS3 = Value °C
A2.4.3 Steer Motor Current = Value A
A2.4.4 RPM Steer Motor = Value Value
A2.4.5 Steer POT1 = Value Value
A2.4.6 Steer POT2 = Value Value
A2.4.7 ECR3 = Value Value
A2.4.8 Feedback POT = Value Value
A2.4.9 Steer Angle = Value Value
Fig. 7 (34706)
M4.3-8155-008 Crown 2020 PF28343
40
--- Page 13 ---
ELECTRICAL SYSTEM
Access 1 2 3®
Events menus
continued from the previous page
Events E1 Chron History E1.1 Last Code = ____
Hour = ____
Temp = ____
Displayed if F11.2 =
SOC = ____
Level 1
E1.2 Last–1 Code = ____
Hour = ____
Temp = ____
SOC = ____ Displayed if F11.2 =
Level 1
E1.16 Last–15 Code = ____
Hour = ____
Temp = ____
Displayed if F11.2 =
SOC = ____ Level 1
continued on the next page
continued on page -020
Fig. 17 (34713)
M4.3-8155-018 Crown 2020 PF28343
50
--- Page 14 ---
ELECTRICAL SYSTEM
Contactor
Note: The contacts (8, 9) wear during typical operation. 4. Remove the two screws (5) from the cover (6).
This does not have an effect on typical operation. Do 5. Remove the cover (6) from the coil (11).
not clean blackened or tarnished contacts, as that
6. Install the mobile contact (9) in the replacement
could cause them to wear faster.
coil (11).
Checking the coil 7. Install the cover (6) on the replacement coil (11)
Refer to Figure 28096. with the two screws (5).
1. Use a digital volt-ohm multimeter (DVOM) to mea- 8. Install the contactor on the contactor panel with the
sure the resistance between the connections on two screws.
the coil (11). 9. Connect all electrical connections to the contactor.
Note: If there is a diode between the connections on
the coil (11), desolder the diode on one side, then mea-
sure the resistance between the connections on the
coil. If you do not do this, the results will be incorrect.
The resistance of the coil must be 15–19 Ω.
If the resistance is not 15–19 Ω, replace the coil.
Checking the return spring
Refer to Figure 28096.
1. Check the return spring (7) for corrosion or discolor
from heat.
Replace the return spring (7) if it has corrosion
or discolor.
Torque Values
For general torque values, refer to INSPECTION AND
LUBRICATION/Metric Torque Values or INSPECTION
AND LUBRICATION/SAE Torque Values.
Component Replacement
Refer to Figure 28096.
Contact Replacement
1. Disconnect the electrical connections to the con-
tactor.
Note: It is not necessary to disconnect the coil (11) for
this procedure.
2. Remove the two screws (5) from the cover (6).
3. Remove the cover (6).
4. Remove and replace both fixed contacts (8) and
the mobile contact (9).
5. Install the cover (6) with the two screws (5).
6. Connect the electrical connections to the contac-
tor.
Coil Replacement
1. Disconnect all electrical connections to the contac-
tor.
2. Remove the two screws that secure the contactor
to the contactor panel.
3. Remove the contactor.
M4.4-04.2-002 Crown 1992 PF9313-2 Rev. 4/13
05 Rev. 4/13
42
--- Page 16 ---
ELECTRICAL SYSTEM
Control Modules
Servicing Control Modules
WARNING
There are fire risks from short circuits. Control modules
operate at high currents. Please note:
• You must be trained to perform this work.
• Use fatigue-free eye protection.
• Wear close-fitting clothing.
• Do not wear jewelry.
• Always use insulated tools.
2
3
5
WARNING
6
There is a risk of serious injury, avoid accidents by:
4
• Switching the lift truck off.
1 • Disconnecting the battery.
• Preventing the lift truck from being switched on
again. See the SAFETY / Control of Hazardous En-
ergy section.
Discharging Capacitors
Fig. 6 (34754) The lift truck must be de-energized and secured. See
the SAFETY / Control of Hazardous Energy.
1. Discharge the capacitors.
2. Make sure that the control modules are clean and
dry.
3. Make sure that the nuts attaching the power cables
are tight.
Replacing Control Modules
Removing
The lift truck must be de-energized and secured. See
th SAFETY / Control of Hazardous Energy section.
1. Discharge the capacitors.
2. Disconnect all wires (mark the wires if necessary).
Remove the bus bars if present.
3. Remove the control module mounting screws.
4. Remove the control module.
5. Check the tooth pattern left by back plate of the
control module on the assembly plate. The full sur-
Crown 2020 PF28351 M4.5-8155-003
133
--- Page 17 ---
ELECTRICAL
Event Codes
Power Cable Connections
Due to capacitance voltage present on the motor con-
trol panel, whenever performing maintenance which
may permit contact with the bus bars and associated
power cables, discharge capacitor on the traction con-
trol panel by placing a minimum 100 ohm, two watt
resistor (062033-030) between positive (+) and nega-
tive (-) of capacitor for three or more seconds.