Crown RR/RD 5700 Series AC Traction Service & Parts Manual – PDF Download

Description

File Details

• Manual Type: Service & Parts Manual
• Brand: Crown
• Series: RR/RD 5700 AC Traction
• Language: English
• Page Count: 813 pages
• File Format: PDF
• Document Number: PF17419-00C
• Revision: REV. A
• Publication Date: December 2009

Chapters Covered

• Safety – General maintenance instructions, cleaning, lockout/tagout, battery safety and care, capacitance discharge, releasing the brakes (tow mode, brake release service tool, mechanical method), towing procedures, hydraulic safety, lifting and blocking, mast and fork carriage blocking, reach mechanism blocking, tilt
• Lubrication & Adjustment – Planned maintenance overview, component access, power unit console, contactor panel cover, floorboard, power unit door, reservoir covers, lubrication identification charts, planned maintenance inspection charts
• Componentry – Audible indicators (ALM1, ALM2, HN), contactors (ED1, ED2, P2), encoders (ECR1 through ECR7), fans (FAN1 through FAN5), fuses (FU1 through FU14), lights (LGT1 through LGT4), brake (BRK1), load sense (LS), voltage drop resistors, thermostats, temperature sensors, motors (M1 through M4), potentiometers (POT1 through POT4), relays (K1, K2, K11, K12), solenoids (PVA, PVL, SCV, SVA, SVBY, SVL, SVR, SVS, SVT), switches (BRES1, BRES2, BRS1, DMS1, EDS, ENS, FLS, FNS, FS, HGTRS2, HNS, KYS, LGS1, LGS2, ORS, RS, SSS, TBS, TDS)
• Hydraulic – Hydraulic system operation, adding hydraulic oil, hydraulic lines and fittings, filter service, reservoir service, secondary lift pump cutout, lift speed testing, hoist drift and tilt drift, system contamination procedures, main lift cylinder and carriage cylinder contamination, hydraulic tank contamination, manifold block removal and flushing, hydraulic circuits (oil flow for hydraulic steering, hoist raise dual pumps, hoist raise single pump, hoist raise stopped, hoist lower, accessory hydraulics), hydraulic schematic symbols, DC lift pump disassembly and assembly, load sensing flow control valve, AC lift pump service, manifold block service, relief valves (RV1 and RV2) operation and adjustment, proportional valves (PVA and PVL), manifold block O-ring replacement, hydraulic troubleshooting
• Drive Unit – Disassembly and assembly, drive tire replacement, drive unit lubrication, oil pump disassembly and assembly, undercarriage inspections and adjustments, articulation adjustment for RR/RD 5700 and RR/RD 5700S series, drive unit removal, drive unit replacement, drive unit dowel pins
• Electrical – Electrical system overview, wiring color codes, power cables, switches, height sensor removal and installation, ACCESS 123 menus (Quick Reference Guide, Operator Menus, Info Screen, Timer, Trip, Height, Hours, Odometer, Speed, Weight & Height, Model, Hour Meters, Event Codes, Service Menus, Analyzer, Analyzer Menu Descriptions, Calibration, Features, Hours, Events, Performance, Utilities, Capacity Data Monitor), keyboard operation, standby mode, horizontal bars, locking the keyboard, language and default settings, AC traction drive operation, contactor inspection and component replacement, multi-task control handle service, POT1 and POT2 replacement, battery safety and charging, battery removal and installation, battery cleaning, battery troubleshooting, motors (traction motor, AC lift pump motor, DC lift pump motor, steer motor), DC motor and brush inspection
• Brake – Brake system overview, stopping distance verification, drive brake (BRK1) air gap adjustment, torque gap adjustment, brake assembly procedures, caster brake (BRK2) service, caster wheel and brake removal, caster wheel and brake inspection, drum and bearing assembly, caster wheel and brake installation
• Steering – Hydraulic steering system, hydrostatic steer control unit, forward and reverse steering, steer tiller disassembly and assembly, removing steer motor from carriage, assembly of steer motor to carriage, steering feedback gear and wheel position sensor (RPS1), steering feedback gear alignment, traction/steer tire alignment and RPS1 calibration, electronic power steering system, steer tiller service for EPS, steering feedback gear alignment for EPS, traction/steer tire alignment and RPS1 calibration for EPS, hydraulic steer motor disassembly and assembly, motor timing
• Cylinders – Lift cylinders (removal, replacement, disassembly, seal removal and installation, cylinder assembly, cylinder bleeding and flushing), tilt cylinder (disassembly, rod disassembly, seal replacement, cylinder reassembly, flushing and bleeding procedures)
• Platform / Reach Assembly – Reach inspection, poly stop, reach cylinder adjustment, disassembly, bushing replacement, center pivot repair and adjustment, reassembly, reach cylinder flushing and bleeding procedures
• Glossary – Component abbreviations and designators
• Wiring Diagrams – Electrical schematic (all trucks, AC traction and hydraulics, DC hydraulics), distribution panel, multi-task control handle, ACCESS 3 (TCM and motors), ACCESS 2 (HCM), fuse panel, ACCESS 1 (DM and key switch), freezer/corrosion packages, ACCESS 4 (VCM), mast cable and options, brakes and floorboard, power unit hydraulics, electronic power steering control, power cables for 42-inch and 48-inch configurations, thermo assist, InfoLink, mast camera, wire harnesses
• Hydraulic Schematic – Complete hydraulic schematics for AC and DC hydraulics in 42-inch and 48-inch configurations
• Parts Sections – Power unit, floorboard, undercarriage articulation, mast guard, battery retainers and spacers, overhead guard, AC/DC hydraulic reservoirs, manifold block hydraulics, steering control, reach hydraulics, mast hydraulics, drive unit, traction motor, traction tire, electrical components (AC and DC), contactors and fuses, distribution panel, multi-task control handle, ACCESS 1 display, height sensor, control cable, connectors, strobe light, freezer corrosion, overhead guard accessories, caster, brake, steering system components, lifting mechanism (outrigger ends, mast channels, load wheel, yoke, load backrest, fork), cylinders (TT lift, TT carriage, reach, tilt, sideshift), platform components (reach with tilt, reach with tilt and sideshift), labels and decals

The Crown RR/RD 5700 Series AC Traction Service & Parts Manual is a complete workshop reference for Crown RR and RD 5700 series lift trucks equipped with AC traction drive. It covers the RR5715, RR5725, RR5795, RD5725, and RD5795 model configurations across their various lift heights, battery compartment sizes, and mast types. The manual is organized into maintenance chapters followed by illustrated parts breakdowns, giving technicians both the procedures and the part numbers needed for repair and overhaul work.

Every major system on the truck is documented. The hydraulic section explains oil flow through the steering, hoist, lower, and accessory circuits with schematic diagrams and step-by-step valve service. The electrical section covers the ACCESS 123 control system in depth, including how to navigate the analyzer menus, perform calibrations, configure features, and interpret event codes. The drive unit chapter provides procedures for articulation adjustment, tire replacement, and drive unit removal, along with torque values and shimming requirements. The brake section covers both the traction motor brake and the caster brake found on S series trucks.

Safety procedures are integrated throughout the manual, with specific guidance on lockout/tagout, capacitance discharge, brake release methods, and proper lifting and blocking. These procedures matter because the truck systems operate under high pressure and store electrical energy. Following the documented sequences protects the technician and prevents damage to components.

For parts ordering, the manual includes exploded-view illustrations with index numbers that correspond to parts lists. The parts sections cover the power unit, hydraulic reservoirs and manifold, drive unit, traction motor, electrical components, contactors, fuses, distribution panel, multi-task control handle, ACCESS modules, brakes, steering components, lifting mechanism, cylinders, and platform assemblies. Labels and decals are also documented, which is useful when restoring a truck to its original configuration.

The wiring diagrams are extensive. Separate schematics are provided for all trucks, AC traction and hydraulics, and DC hydraulics. Additional diagrams cover the distribution panel, multi-task control handle, ACCESS modules, fuse panel, mast cable options, brakes and floorboard, power unit hydraulics, electronic power steering, and power cable routing for both 42-inch and 48-inch power units. The hydraulic schematics show the complete circuit for AC and DC hydraulic systems in both power unit sizes.

Why Technicians and Fleet Operators Use This Manual

Correct service information reduces downtime and prevents repeat repairs. The Crown RR/RD 5700 Series AC Traction Service & Parts Manual provides the specifications that matter: torque values for critical fasteners, hydraulic pressure ranges for relief valves, air gap and torque gap settings for the brake, articulation adjustment dimensions, chain wear limits, and calibration procedures for the height sensor, load sensor, and steer wheel position sensor.

When a fault occurs, the troubleshooting charts in the hydraulic section help isolate the cause. When a component needs replacement, the parts breakdowns identify the exact part number. When the truck needs planned maintenance, the lubrication charts specify the intervals and lubricant types. This manual supports all of those tasks and more.

IMAGES PREVIEW

Instant PDF Delivery

The manual is delivered as a PDF download immediately after purchase. There is no physical shipment and no waiting. Open the file on any device, search for the section you need, and print pages for use in the shop. Whether you are servicing one truck or maintaining an entire fleet of Crown RR/RD 5700 series lift trucks, this manual provides the technical depth and parts information to keep the equipment operating correctly.