PDF Service & Parts Manual Crown Forklift RR5200S DC - 5 MB
This dual-purpose manual provides complete service and parts information for the Crown RR5200S DC forklift.
Access detailed repair procedures, electrical schematics, and hydraulic diagrams for effective troubleshooting.
The integrated parts section contains exploded views and part numbers, making it easy to identify and order the correct components.
This is the all-in-one resource for maintaining your Crown reach truck.
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--- Page 1 ---
RR 5200S DC
Service & Parts Manual
Crown PF13001-00M
--- Page 3 ---
SAFETY
General Maintenance Instructions
16. Be sure that any equipment added to the truck (ter-
minal, fan, clipboard, etc.) is positioned so that it
does not block your vision or interfere with safe and
efficient operation of the truck.
For further information pertaining to operating and
maintenance procedures:
• All trucks except Series B and Tow Tractors, refer
to current ASME B56.1.
• Series B trucks, refer to current ASME B56.10.
• Tow Tractors, refer to current ASME B56.9.
MA-04.0-002 Crown 1976 PF2821-2 Rev. 10/06
04 Rev. 10/06
--- Page 4 ---
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
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8841
Crown 2001 PF13118-9 Printed in U.S.A.
MA–1452–108 MA–1452–108
--- Page 5 ---
SAFETY
Control of Hazardous Energy
Reach Mechanism Tilt
• Move truck to a secure non-traffic maintenance • Move truck to a secure non-traffic maintenance
area with a level floor. area with a level floor.
• Chock wheels of truck (refer to Lifting and Blocking • Chock wheels of truck (refer to Lifting and Blocking
in this section). in this section).
• Extend reach assembly. • Tilt forks down so weight of carriage is not on the
tilt cylinder.
• Clamp a 50 x 100 mm (2 x 4 in) hardwood block in
either left or right channel of reach support assem- • Lockout or tagout truck as described in Lockout -
bly below the roller. Tagout in this section.
• Relieve hydraulic pressure from reach circuit by re-
tracting carriage until roller rests on block.
• If mast is staged refer to Mast in this section for
blocking instructions.
• Lockout or tagout truck as described in Lockout -
Tagout in this section.
Figure 15991-01
Figure 15992-01
a Cut Away for Clarity
b Clamp a Tilt Forks Completely Down
c Hardwood Block
MA-1452-118 Crown 2007 PF15685-10 Rev. 9/07
01 Rev. 9/07
--- Page 7 ---
COMPONENTRY
RR/RD 5200S
ALM1 BRK1
Status Alarm Drive Brake
Location: distribution panel. Location: traction motor (M1).
Purpose: draws operator attention to changing truck Purpose: provide braking force to drive motor to stop
status. truck and prevent movement of parked ve-
hicle.
Data: controlled by Access 3.
Data: Access 3 release via operator or control
Adjustment: none required. system request, spring applied.
ALM2 Adjustment: Performance menu P6.
Travel Alarm
BRK2
Location: on drive carriage in traction motor compart- Caster Brake
ment.
Location: on caster wheels.
Purpose: audible warning when travelling forward
and/or reverse direction. Purpose: provide braking force to caster wheels to
assist BRK1 in stopping truck.
Data: controlled by Access 2.
Data: Access 3 apply via operator or control sys-
Adjustment: features menu F14. tem request, spring released.
BRES1 Adjustment: Performance menu P7.
Battery Retainer Switch
BRS1
Location: below Access 3. Stand up Floor Brake Pedal Switch
Purpose: monitor switch for control system. Informs Location: under floorboard left foot pedal.
control system when battery restraints are in
place. Purpose: allows operator to operate the brakes opera-
tion through the control system.
Data: wired normally open held closed.
Data: momentary contact wired normally closed
Adjustment: slight adjustment through elongated mount- held open. Switch actuated when operator
ing holes in mounting bracket. not on pedal.
Adjustment: none required.
010328 4894
Crown 2001 PF13144-1 Rev. 2/03 Printed in U.S.A.
01 REV. 2/03
M1.0–1452–550 M1.0–1452–550
--- Page 8 ---
COMPONENTRY
RDB1 RV3
Horn Relay Driver Block Relief Valve #3
Location: near Access 2. Location: steering control unit.
Purpose: provides ground path to horn relay K2. Purpose: limit maximum inlet steering pressure.
Data: 36 volt MOSFET driver actuated upon switch Data: preset to 8275 kPa (1200 psi).
closure.
Adjustment: none recommended.
Adjustment: none required.
SB20
RS Suppressor Block
Reverse Switch
Location: below key switch.
Location: pivot point of multi-task control handle.
Purpose: key switch inrush current protection.
Purpose: informs control system reverse travel direc-
tion being requested by operator. Data: not applicable.
Data: optic switch output 0 volt when reverse travel Adjustment: none required.
direction selected. Output 5 volt when in
neutral or forward travel selected. SB21
Suppressor Block
Adjustment: none required.
Location: near Access 2.
RV1
Relief Valve #1 Purpose: suppress electrical noise from operation of
horn.
Location: hydraulic manifold.
Data: not applicable.
Purpose: limit maximum lift pressure for raise.
Adjustment: none required.
Data: not applicable.
SB42
Adjustment: adjusted to 21,375 kPa (3100 psi) & sealed at Suppressor Block
inspection.
Location: fan wire harness
RV2
Relief Valve #2 Purpose: suppress electrical noise from operation of
compartment fan.
Location: hydraulic manifold.
Data: not applicable.
Purpose: limit maximum accessory pressure (inde-
pendent of lift). Adjustment: none required.
Data: preset to 10,340 kPa (1500 psi).
Adjustment: none required.
Crown 2001 PF13144-11 Rev. 2/03 Printed in U.S.A.
01 REV. 2/03
M1.0–1452–560 M1.0–1452–560
--- Page 9 ---
HYDRAULIC
Hydraulic System
Filter Drift Test
The internal filter is contained within the reservoir filter/ All drift tests should be conducted with a capacity load
fill assembly. (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.
Tilt Drift Test
(1) 22 - 27 Nm
(16 - 20 ft lb) Cycle tilt forward and back several times before testing
drift. Elevate test load 600 mm (24.0 in) off floor. Mea-
sure drift at the load center with forks tilted up. Forks
may not drift more than 15 mm (0.50 in) over a five
minute period.
Figure 16838
Lift Drift Test
To access filter, rotate filter cap CCW and remove. Elevate the test load above staging height and tilt car-
Grasp inner support tube and remove the filter ele- riage to the full back position. After five minutes, mea-
ment. The filter element can be removed from the sup- sure the distance the carriage has drifted. Drifting in
port tube and replaced. Insert filter element and sup- excess of 50 mm (2.0 in) over a five minute period is
port tube and replace filter cap. Torque cap to considered unacceptable.
22-27 Nm (16-20 ft lb) Dispose of filter and used oil in
accordance laws and regulations concerning the dis- NOTE
posal of hazardous waste.
The lift measurement is to be taken from the tip of the
fork to the floor.
Reservoir Occasionally, a slight creep of the fork assembly may
Check reservoir fluid level when oil is warm, if not, occur due to internal leakage in the piston pak, but it
operate lift for fifteen minutes first before checking fluid can also be caused by leakage in a check or control
level. valve. To seat these valves properly when this occurs,
raise and lower the forks to flush out any foreign mate-
With all cylinders in the retracted position and after all rial from the valve seat.
air has been bled from the hydraulic system, fill reser-
voir so that the oil level is at the "add" marks. Excess A thorough check for leaks in the system should be
oil above the "add" mark should be removed. The total conducted if abnormal oil losses occur. The hydraulic
capacity of the hydraulic system at this level should be system is designed to eliminate mechanical damage
approximately: even if fittings become loose.
• Trucks with dual reservoirs:24.6 liters (6.5 gal)
• Trucks with single reservoirs:27.4 liters (7.25 gal)
CAUTION
Never stand or work under a suspended load.
M2.0-1452-002 Crown 2001 PF13008-2 Rev. 7/07
05 Rev. 7/07
--- Page 14 ---
DRIVE UNIT
Disassembly and Assembly
RR/RD 5200S/5200S(AC) Series
DC Traction Shown
(1) Brake (8) Trailing Edge of Caster Must be in Direction of
Arrow for Articulation Adjustment
(2) Drive Motor (9) Inspect Caster and Wheel
(3) Inspect Wear Plug (10) Adjust Articulation to 6.4 mm +0.0/-1.0 mm
(0.25 in +0.0/-0.04 in)
(4) Adjust Articulation to 6.4 mm +0.0/-1.0 mm (11) 375 - 405 Nm (275 - 300 ft lb)
(0.25 in +0.0/-0.04 in) for Mast Heights
8155 mm (321 in) and Below.
For Mast Heights 8180 mm (322 in) and
Above, Adjust to 3.0 mm +0.0/-1.0 mm
(0.12 in +0.0/-0.04 in)
(5) Hydraulic Steering Motor (12) 305 - 340 Nm (225 - 250 ft lb)
(6) Note Number and Location of Flatwashers (13) 375 - 405 Nm (275 - 300 ft lb)
(7) Part of Power Unit (14) 30 - 43 Nm (22 - 32 ft lb)
Figure 16872
M3.0-1452-008 Crown 2001 PF13030-8 Rev. 7/07
06 Rev. 7/07
--- Page 15 ---
ELECTRICAL SYSTEM
Electrical System
Component Abbreviations and Designators Component Abbreviations and Designators
LGS Light Switch SWH Operator Activated Switch
LMS Limit Switch TBS Tilt Back Switch
LOS Lower Switch TDS Tilt Down Switch
LTS Loadtray Switch TES Test Switch
MFS Multi-funciton Switch THS Thermal Switch
MVS Multi-voltage Switch TLS Traverse Left Switch
NUS Null Switch TLT Tilt Switch
ORS Override Switch TRS Traverse Right Switch
PLS Pivot Left Switch TUS Tilt Up Switch
PORS Presence Overide Switch TVS Traverse Switch
PRS Pivot Right Switch ZSS Zone Select Switch
PS Pressure Switch Terms
PTS Pivot Switch ASM Assembly
PUS Pump Switch CTRL Control
QPS Quick Pick Switch CTRLR Controller
RAS Raise Switch DESIG LIST Designation List
RES Reach Extended Switch DIST PNL Distribution Panel
RGS Rail Guide Switch DSPL Display
RGSL Rail Guidance Switch Left F/C Freezer Conditioning
RGSR Rail Guidance Switch Right HCM Hydraulic Control Module
RIS Reach In Switch HDL Handle
RLMCS Rear Left Motor Cover Switch HYD Hydraulic
ROS Reach Out Switch OHG Overhead Guard
RRMCS Rear Right Motor Cover Switch PCB Printed Circuit Board
RS Reverse Switch PICT Pictorial
RSS Sheet Retainer Switch PKT Packet
SAS Safety Switch PL Platform
SCS Sideshift Center Switch PWR Power
SES Seat Switch PWR SPLY Power Supply
SLS Sideshift Left Switch SCHEM Schematic
SQS Sequence Switch TCM Traction Control Module
SRS Sideshift Right Switch TMM Truck Management Module
SSS Sideshift Switch TRAC Traction
STS Power Steer Switch
M4.1-2720-004 Crown 2000 PF11845-4 Rev. 10/06
03 Rev. 10/06
--- Page 16 ---
C ACCESS 1 2 3®
These indicators on enhanced displays only:
Performance Menu
Quick Reference Keys
Hour Meter Menu • 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
Extended Message Display (in place of 4 character display on standard)
• 16 character alpha numeric display.
• presents more comprehensive information to operator as necessary.
6225
• 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 data monitor, refer to the M4.3 Capacity Data Monitor
section of the service manual.
6223
TRUCK SOFTWARE TOOLS RR/RD5000/5000S, RR/RD5200/5200S, RR/RD5200(AC)/5200S(AC)
PF12937-PRO is a CD-ROM based software utility program created to assist the service technician in configuring truck
setups. A PC, with requirements specified below, Down Load Cable (126456), and Isolator Connector (062785-001) are also
required. With this software utility the technician can:
• Configure, save or print truck setups.
• View or modify service password.
• View or erase fault code history.
• View or modify hour meters.
• Save or print hour meter and log history (via Data Dump).
Truck System Requirements:
• DC traction models with version 12 through 14 Software.
• AC traction models with version 01 through 04 Software (Data Dump feature not available on version 01 and 02
Software).
Computer System Requirements:
Before using the Crown Programming Tool, PF12937-PRO, the following minimum requirements for the personal computer
being used are needed:
• Minimum 1.5 mb of available hard drive disk space.
• Operating system Windows 95, 98, 2000, ME, XP or NT.
• An available COM (communications) port.
• CD-ROM drive
11183-01
Crown 2001 PF13062-3 Rev. 6/04 Printed in U.S.A.
07 REV. 6/04
M4.3–1452–003 M4.3–1452–003
--- Page 17 ---
C CALIBRATION MENU
continued from previous page
C5 Valves C5.1 Lift Min C5.1.1 Raise
Invalid/Fail
or
Accepted Cal/Good
C5.2 Lower Max C5.2.1 Lower
Invalid/Fail
or
Accepted Cal/Good
C5.3 Accessory C5.3.1 Reach
Invalid/Fail
or
Accepted Cal/Good
C5.4 escape
C6 Hydr Idle C6.1 Idle _______A
Invalid/Fail
or
Accepted Cal/Good
C71 Fork Positn C7.1 Fork DN = ___
Invalid/Fail
Accepted Cal/Good
C7.2 Fork Rf = ___
Invalid/Fail
Accepted Cal/Good
C7.3 Fork UP = ___
Invalid/Fail
Accepted Cal/Good
go to next page C9 Save?
continued on next page
1
= TPA (Tilt Position Assist)
Crown 2001 PF13062-13 Rev. 6/01 Printed in U.S.A.
01 REV. 6/01
M4.3–1452–013 M4.3–1452–013
--- Page 18 ---
C FEATURES MENU
continued from previous page F205 User Codes = ___ F20.1 A = No
F20.2 b = Yes
F20.3 View
F20.4 Add User 01____ @ P_
F20.5 Delete User 01____ @ P_
User 02____ @ P_
User 25____ @ P_
F20.6 Escape
F21 Lockout = ___ F21.1 A = No Truck lockout.
F21.2 b = Yes
F221 Language = ___ F22.1 English
F22.2 German
F22.3 French
F22.4 Spanish
F22.5 Dutch
F22.6 Italian
F232 Rack Sel = ___ F23.1 A = No
F23.2 b = Yes
F243 Usr Rack = ___ F24.1 A = No
F24.2 b = Yes
F254 12" Switch = ___ F25.1 A = No
F25.2 b = Yes
continued on next page
1
= Menu available with enhanced display only.
2
= Menu available with height encoder and enhanced display only. F9 CDM must be Yes.
3
= F23 must be Yes.
4
= Menu available only if F3 is No.
5
= If F20 is "yes", then at least one Personal Identification Number (PIN) is required. If F19 is "yes", any user can select any performance
level. The vehicle PIN timeout feature is adjustable from 2 to 20 minutes, in 1 minute increments, through F31 menu.
Crown 2001 PF13062-23 Rev. 12/03 Printed in U.S.A.
06 REV. 12/03
M4.3–1452–023 M4.3–1452–023
--- Page 19 ---
C LOG EVENTS MENU
Press the key to move right and left in the menu and allow system to accept changes to the log events menu. Press the
and to move up and down.
L Log Events L1 History Last = ___ @ ____
L-1 = ___ @ ____
1 •
•
•
•
•
L-15 = ___ @ ____
L2 Totals Event ___ = ____
Event ___ = ____
L3 Erase L3.1 Erase Hist L3.1.1 Sure? N
1 L3.1.2 Sure? Y
L3.2 Erase All L3.2.1 Sure? N
1 L3.2.2 Sure? Y
L3.3 escape
L4 escape
continued on next page
Crown 2001 PF13062-33 Rev. 12/03 Printed in U.S.A.
06 REV. 12/03
M4.3–1452–033 M4.3–1452–033
--- Page 20 ---
C PERFORMANCE SETUP
P12.1 Std = ______
• P11 Trav>270 = _______ The value displayed is a setting that is acceptable
This affects traction speed when the forks are for optimum truck and installation conditions. If
above 6.9 m/270 inches. The current setting will this setting is the desired setting and is the value
be displayed. Adjustment range is between 0.1 to displayed in P12, press to return to P12. If a
2.4 Kph (0.1 to 1.5 MPH). To change/modify value different than this is desired, press to
travel speed above 6.9 m/270 inches press . access P12.2.
Press to go to P12 Coast. P12.2 Cust = ______
P11.1 Std = ______ Press . Then use and to obtain the
The value displayed is a setting that is acceptable desired setting. When set, press to return to
for optimum truck and installation conditions. If
P12.
this setting is the desired setting and is the value
displayed in P11, press to return to P11. If a • P13 Accy Rmp
value different than this is desired, press to This adjustment affects the ramp time of the
access P11.2. accessory valve. Increasing this setting numeri-
P11.2 Cust = ______ cally makes the accessory hydraulic functions
Press . Then use and to obtain the more reactive. A setting of 1 will provide smoother
reaction, while a setting of 9 will be more reactive.
desired setting. When set, press to return to
P11.
• P12 Coast = ______
The current setting will be displayed. Adjustment
range is 1 to 9.
8832