SC 5300 SERIES

MAINTENANCE MANUAL

Order Number: 812594-006

Revision: A • Printed in Germany
 This master manual is subject to continual updates.
It is intended solely for companies authorized by Crown.
The transfer of the content or copies thereof to third parties is prohibited.

Crown Gabelstapler GmbH & Co. KG

– European Headquarters –
Moosacher Str. 52
80809 Munich
Germany

Phone +49 (0)89 93 00 2 – 0

Fax +49 (0)89 93 00 2 – 133

All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2012
Crown Equipment Corporation
TABLE OF CONTENTS
I
Notes:

II
 TABLE OF CONTENTS

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ordering documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Truck modifications and additions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Service personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Truck Data Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cleaning of Material Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control of Hazardous Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Lockout - Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Releasing Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Releasing Brakes by Switching Connectors and Using an External Power Source . . . . . . . . . . . . . . 15
Releasing Brakes by Switching Connectors & Using On Board Truck Battery . . . . . . . . . . . . . . . . . . 16
Releasing Brakes by Using the Crown Operator Display and Truck Battery is Present . . . . . . . . . . . 16
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lift and Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Tilt Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Sideshift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Towing Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Towing by Pulling in Power Unit First Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Towing by Lifting Truck and Pulling in Power Unit First Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lifting and Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Blocking Masts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disconnecting Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mast Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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LUBRICATION & ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operators Daily Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Lubricants, Aerosols & Service Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Seat Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Floorboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Cover Below Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Dash Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Steering Column Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control Lever Cover (Trucks with Manual Valve only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Lowering Flow Control Manifold Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Armrest Pad and Cover (Trucks with EPV only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Metric Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

COMPONENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Componentry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Audible Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ALM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ALM2 (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
HN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
BRK1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
BRK2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
L ............................................................................... 73
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ACCESS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ACCESS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ACCESS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ACCESS 7 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
DR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
DR2 (EPV Only - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
INFOLINK DISPLAY MODULE (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Carriage Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Mast Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Sideshift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Steer Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
ECR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
ECR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
FAN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
FAN3 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
FU4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
FU5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
FU6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
FU7 (Option - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
FU8 (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
FU11 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
FU12 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
DS20 (Manual Valve Only - Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LGT1 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LGT2 (Option - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LGT3 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
LGT4 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
LGT5 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
LGT6 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Carriage Relief Manifold - 1st Accessory - Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Carriage Relief Manifold - 2nd Accessory - Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
EPV Manifold (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Lowering Flow Control Manifold (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Operator Presence Manifold (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Tilt Manifold (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Two Accessories Manifold (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
PT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
POT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
POT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
POT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
POT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
POT5 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
POT6 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
POT7 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Lift, Tilt, Accessory and Steer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
K2 (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
K3 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

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K11 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

K12 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
RES1 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
RES2 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
RES3 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
RES50 (Manual Valve Only, Option - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Impact Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
PT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
THS1 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
THS2 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
TS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
TS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
TS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
SPA1 (EPV Only - Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
SPA2 (EPV Only - Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
SPL (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
SPT (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
SVA4 (EPV Only, Option - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
SV1 (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
SV3 (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
SVBy (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
SVL (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
SVLSD (EPV Only - Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
SVOP (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
SVX (Manual Valve Only, Option - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
CR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
CR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
CR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
SB80 (Option - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
TR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
ACS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
AXS1 (Manual Valve Only - Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
AXS2 (Manual Valve Only - Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
AXS3 (Option - Manual Valve Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
BRES (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
BRKS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
BRKS2 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
CLS (Option - EPV Valve Only, Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
HGTS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
HGTS2 (Option - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
HGTS3 (Option - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
HNS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
HNS2 - Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
HNS3 - Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
HNS4 - (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
KYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
LGS1 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
LGS2 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

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ORS (EPV Only - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

ORS1 (Manual Valve Only - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
ORS2 (Manual Valve Only - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
ORS3 (Manual Valve Only - Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
SBS (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
SES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
TBS (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
THS1, THS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
TLMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
TLT (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
TPAS (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
VTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
CBVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
CBVR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Control Valve (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
CVLSA1 (EPV, Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
CVLSA2 (EPV, Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
CVLSI (EPV, Two Accessories Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
CVLST (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
CVR (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Flow Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
MPCE (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
MLV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Load Sense Priority Flow Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
ORF1 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
ORF2 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
ORF3 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
ORF4 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
ORF5 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
ORF6 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
ORF7 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
PCA (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
PCA1 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
PCA2 (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
PCL (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
PCT (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Quick Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
RV1 (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
RV2 (Manual Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
RVA (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
RVM (EPV Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
SPA1, SPA2, SPL, SPT, SV1, SV3, SVBy, SVL, SVLSD, SVOP SVX . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Velocity Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

SC 5300 Series

VII
TABLE OF CONTENTS

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Hydraulic Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Reservoir and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Tilt Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Cylinder and Circuit Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Lift Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Tilt Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Sideshift Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Steer Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
AC Pump and Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Manual Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
EPV - No Demand for Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Manual Valve- No Demand for Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
EPV - Steer Left Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Manual Valve - Steer Left Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
EPV - Steer Right Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Manual Valve - Steer Right Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
EPV - Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Manual Valve - Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
EPV - Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Manual Valve - Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
EPV - Tilt and Accessory Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
EPV - Tilt Back Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Manual Valve - Tilt Back Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Tilt Position Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
EPV - Tilt Forward Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Manual Valve - Tilt Forward Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Tilt Position Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
EPV - Sideshift Left Circuit (trucks with one accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Manual Valve - Sideshift Left Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
EPV - Sideshift Right Circuit (trucks with one accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Manual Valve - Sideshift Right Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
EPV - Accessory Circuit (trucks with two accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Hydraulic Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Relief Valve, RV1 and RV2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Control Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Control Valve Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Manifold Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
To adjust RVM in the EPV manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
To prepare to adjust the pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
To adjust the pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
To adjust RVA in the EPV manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
To prepare to adjust the pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
To adjust the pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

SC 5300 Series

VIII
 TABLE OF CONTENTS

To replace the manifold block O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Prepare the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Remove the manifold block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Examine the manifold block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
To replace the O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Examine the remaining O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Adaptors and valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Manifold block installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
To remove and flush the manifold block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Disassemble the manifold block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Flush the manifold block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Manifold block assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
To identify a noise from the drive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Drive Unit Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Drive Tyre Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Drive Axle Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Drive Axle Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Drive Axle Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Drive Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Alternative 1 - Remove the Drive Unit from the Side of the Power Unit . . . . . . . . . . . . . . . . . . . . . . 234
Alternative 2 - Remove the Drive Unit from the Front of the Power Unit . . . . . . . . . . . . . . . . . . . . . 237
Drive Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Traction Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Traction Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Drive Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Removal of the Drive Unit Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Installation of the Drive Unit Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Procedure to Assemble the Drive Unit Subassembly and Install the Drive Unit . . . . . . . . . . . . . . . . 250

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
AXS1, AXS2, TLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
RAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
TBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
ACS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
BRKS1, BRKS2 (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
HGTS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
TLMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Wire Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Wiring Color Codes & Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Wiring Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

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Access 1 2 3® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Operator Main Menu Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Operator Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Direction Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Model - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Timer - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Trip - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
BDI - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Hours - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Odometer - Message Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Fuel Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Operator Level Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Service Level 2 and 3 - Features Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Service Level 2 - Performance Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Service Level 2 - Performance and Calibration Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Service Level 2 - Calibration Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Service Level 2 and 3 - Hours Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Service Level 2 and 3 - Events Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Service Level 2 and 3 - Utilities Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Analyzer Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
A1 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
A2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
A2.1 ACCESS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
A2.2 ACCESS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
A2.3 ACCESS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
A2.7 ACCESS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
A3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
A3.1 ACCESS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
A3.2 ACCESS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
A3.3 ACCESS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
A3.7 ACCESS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
A4 Test Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
A4.1 ACCESS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
A4.2 ACCESS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
A4.3 ACCESS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
A4.7 ACCESS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Features Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Performance Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Calibration Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Calibration Failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Calibration Passed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Hours Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

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Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Events Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Utilities Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
132084-003 Contactor L (Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Replacing the Battery with a Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Battery removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Battery installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Replacing the battery using a battery roller stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Battery removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
Battery installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Replacing the battery using the Battery Transfer System (BTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
BTS system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Removing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Installing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Cover Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Left Side Cover Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Right Side Cover Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
To Adjust the Seat Deck Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
To Adjust the Battery Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Battery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Checking the Battery Under Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Battery Discharge Interrupt Performance (P4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Event Code Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Event Code Group 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Event Code 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Event Code 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Event Code 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
Event Code 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Event Code 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Event Code 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Event Code 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Event code 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Event Code 108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Event Code 109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Event Code 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
Event Code 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Event Code 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

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Event Code 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

Event Code 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Event Code 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
Event Code 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Event Code 117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Event Code 118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Event Code 119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
Event Code 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Event Code 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Event Code 123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
Event Code 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Event Code 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Event Code 126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Event Code 127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
Event Code 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Event Code 130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
Event Code 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Event Code 132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Event Code 133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Event Code 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Event Code 141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Event Code 162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Event Code 191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
Event Code 199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Event Code Group 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Event Code 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Event Code 201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Event Code 202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Event Code 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Event Code 207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Event Code 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Event Code 209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Event Code 221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Event Code 222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Event Code 223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Event Code 224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Event Code 225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Event Code 226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Event Code 227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Event Code 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Event Code 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Event Code 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Event Code 231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Event Code 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Event Code 233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Event Code 234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
Event Code 235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Event Code 236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Event Code 237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Event Code 238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Event Code 239 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Event Code 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Event Code 241 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Event Code 242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

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Event Code 243 ................................................................... 367

Event Code 244 ................................................................... 368
Event Code 245 ................................................................... 369
Event Code 246 ................................................................... 369
Event Code 247 ................................................................... 370
Event Code 248 ................................................................... 370
Event Code 249 ................................................................... 371
Event Code 250 ................................................................... 372
Event Code 251 ................................................................... 372
Event Code 252 ................................................................... 372
Event Code 253 ................................................................... 372
Event Code 254 ................................................................... 372
Event Code 255 ................................................................... 372
Event Code 256 ................................................................... 373
Event Code 257 ................................................................... 374
Event Code 258 ................................................................... 374
Event Code 259 ................................................................... 374
Event Code 260 ................................................................... 374
Event Code 261 ................................................................... 374
Event Code 264 ................................................................... 374
Event Code 265 ................................................................... 375
Event Code 266 ................................................................... 375
Event Code 267 ................................................................... 375
Event Code 268 ................................................................... 375
Event Code 269 ................................................................... 375
Event Code 270 ................................................................... 376
Event Code 271 ................................................................... 376
Event Code 272 ................................................................... 376
Event Code 273 ................................................................... 376
Event Code 274 ................................................................... 376
Event Code 275 ................................................................... 376
Event Code 276 ................................................................... 376
Event Code 277 ................................................................... 376
Event Code 278 ................................................................... 376
Event Code 279 ................................................................... 376
Event Code 280 ................................................................... 376
Event Code 281 ................................................................... 376
Event Code 282 ................................................................... 376
Event Code 283 ................................................................... 376
Event Code 284 ................................................................... 376
Event Code 285 ................................................................... 377
Event Code 286 ................................................................... 377
Event Code 287 ................................................................... 377
Event Code 288 ................................................................... 377
Event Code 289 ................................................................... 377
Event Code 290 ................................................................... 377
Event Code 291 ................................................................... 377
Event Code 292 ................................................................... 377
Event Code 293 ................................................................... 377
Event Code 294 ................................................................... 377
Event Code 295 ................................................................... 377

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Event Code Group 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378

Event Code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Event Code 301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Event Code 302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Event Code 303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Event Code 304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Event Code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Event Code 306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Event Code 307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Event Code 308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Event Code 309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Event Code 310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Event Code 311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
Event Code 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Event Code 313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Event Code 314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Event Code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Event Code 316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Event Code 317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Event Code 318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Event Code 319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Event Code 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Event Code 321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Event Code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Event Code 323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Event Code 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Event Code 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Event Code 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Event Code 327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Event Code 330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Event Code 331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Event Code 332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Event Code 334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Event Code 335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Event Code 336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Event Code 337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Event Code 338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Event Code 339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
Event Code 399 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
Event Code Group 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 704 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 705 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 706 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
Event Code 707 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Event Code 708 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Event Code 709 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Event Code 710 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Event Code 713 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Event Code 715 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

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Event Code 716 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

Event Code 717 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Event Code 720 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Event Code 722 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
Event Code 723 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Event Code 724 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Event Code 727 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Event Code 735 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Event Code 736 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
Event Code 737 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
Event Code 738 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
Event Code 743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
Event Code 799 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
No Event Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Checking Brake Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Hydrostatic Steering Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Steering Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Gas Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Steering Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Steer Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Steer Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
Housing and Yoke Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Housing, Rack, Pistons and Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Steer Cylinders Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
Circuit Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
To Examine steering drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Steer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Steering Control Unit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Steering Control Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421

LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
TT Lift Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Mast Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Carriage Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
TT Mast Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
Mast Flaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
TT Mast Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
Mast Removal from the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434

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TABLE OF CONTENTS

TT Mast Assembly - Lying Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437

Quad Mast Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Column Roller Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Mast Flaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
Carriage Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
Lift Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Rust and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Cracked Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Tight Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Protruding or Turned Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Chain Side Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
Lift Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Chain Anchors and Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Leaf Chain Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Disconnect Procedures: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Bent or Twisted Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
Sideshifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Sideshifter Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Sideshifter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
Sideshifter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
Bearing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Supply Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
Sideshift Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467

CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
Seal Installation - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
Rod U-Cup Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
Small U-Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
Large U-Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
Cylinder U-cup Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Cylinder Bleeding and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Bleeding - Free Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Bleeding - Stage Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Flushing - Stage and Free Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474

SC 5300 Series

XVI
 TABLE OF CONTENTS

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Rod Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Cylinder and Circuit Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Tilt Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
Tilt Cylinder Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477

GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481

SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 487

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
Schematic - EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491
Truck Rear - EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492
Trucks Splices - EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493
ACCESS 3 - EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
ACCESS 2 - EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495
ACCESS 1 - EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496
Armrest - EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 497
Front 1 - EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
Front 2 - EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
Hydraulics - EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Overhead Guard with Incandescent Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Overhead Guard with LED Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Freezer Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
InfoLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
Wire Harnesses - EPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
Schematic - Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
Truck Rear - Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Truck Splices - Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510
ACCESS 3 - Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
ACCESS 2 - Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
ACCESS 1 - Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513
Front 1 - Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Front 2 - Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
Hydraulics - Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 516
Overhead Guard with Incandescent Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517
Overhead Guard with LED Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518
Freezer Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519
InfoLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
Wire Harnesses - Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525

Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
EPV - Single Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 528
EPV - Double Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529

SC 5300 Series

XVII
TABLE OF CONTENTS

Notes:

SC 5300 Series

XVIII
INTRODUCTION
1
Notes:

2
 INTRODUCTION
Important Information

Important Information Manual structure

This maintenance manual applies to the following mod- The manual is divided into the following sections:
els of the SC 5300 Series trucks:
:

Section
SC 5310-1.3
SC 5320-1.3 Index
SC 5320-1.6 Safety
SC 5340-1.4
SC 5340-1.8 Inspection and Lubrication
SC 5360-1.8 Componentry
SC 5360-2.0
Hydraulic
Ordering spare parts Drive Unit
To order spare parts, use the parts manual supplied Electrical
separately. Always quote the following numbers when
ordering spare parts: Brake
• Truck data number Steering
• Serial number Lifting Mechanism
These numbers can be found on the truck data plate. Cylinders
For details of the truck's technical specifications refer to
the Technical Specifications chapter in the operator Glossary
manual. Wiring Diagrams
Note: Always use original Crown spare parts.
Hydraulic Schematic
Ordering documentation
Parts manuals, operator manuals, specification sheets
etc. can be obtained from: Truck modifications and additions
Crown Gabelstapler GmbH & Co. KG
Moosacher Str. 52 WARNING
80809 Munich
Germany Fatal accidents can be caused by modifying the
original condition of the truck.
Tel.: +49 (0)89 / 93 002 -0 Changes to the original condition of the truck when de-
Fax: +49 (0)89 / 93 002 -175 or 133 livered can lead to fatal accidents.
www.crown.com  Any necessary changes to the original condition of
the truck must be checked and approved in writing
by Crown Gabelstapler GmbH & Co. KG prior to be-
ing made.

• Modifications or additions to the truck may only be

performed with Crown’s prior written approval. In
such cases the data plate must be changed if nec-
essary.
• If at a later time Crown is no longer in business or is
not operating in your country and there is no suc-
cessor in the interest to the business, modifications
and alterations may only be performed if the follow-
ing conditions are met:

Crown 2012 PF25677-1 SC 5300 Series ITD-1153-001

3
INTRODUCTION
Important Information

– Design, test(s) and implementation to be carried

out only by an expert in industrial trucks and their
safety
– Permanent records of the design, test(s) and im-
plementation to be maintained
– Modifications must be incorporated into the truck
labelling and documentation (operator, service
and parts manuals)
– A permanent and readily visible label to be af-
fixed to the truck stating the manner in which the
truck has been modified or altered, the date and
name and address of the organisation responsi-
ble

Service personnel qualification

To maintain the safety and functionality of the
truck, maintenance and repair work must only be
performed by service engineers who have been au-
thorised by Crown.
Contact Crown if you wish to have your engineers
trained.
Details of routine inspection and maintenance work to
be performed by the customer can be found in the
Maintenance and Safety Inspection chapter of the op-
erator manual.

Truck Data Number

The truck data number is located on the data plate.
It contains important information concerning the truck's
features at the time of delivery.
The truck data number given in the example on the
next page. shows a standard truck with a TT mast and
4370 mm of lift height. The battery compartment size is
533 mm, cold conditioning is not an option and the
drive tyre is standard super elastic. The truck has a sin-
gle hydraulic accessory that is a hook on type side-
shifter. SRO is enabled. The truck has a travel alarm
and an electric proportional valve (fingertip controls).

ITD-1153-002 SC 5300 Series Crown 2012 PF25677-2

4
 INTRODUCTION
Important Information

Battery Compartment Size

425 = 425 mm
533 = 533 mm
641 = 641 mm Drive Tyre and Steer Tyre
749 = 749 mm S = Standard Super Elastic
O = Non-Standard Super Elastic

Mast Type
TT = Telescopic Triple Stage
QD = Telescopic Four Stage
TL = Telescopic Limited Free Lift
Sideshifter Type
TF = Telescopic Full Free Lift
- = No Sideshifter
H = Hook On
I = Integrated

Standard/Custom/Special
- = Standard Hydraulic Controls
C = Custom M = Manual Valve
S = Special E = Electric Proportional Valve

- TT 4370 533 - S S H 1 2 E
Travel Alarm & Light Package
Lift Height
Option
Displays Lift Height Dimension
- = No Travel Alarm & Lights
4370 = 4370 mm
1 = Strobe Light
4825 = 4825 mm
2 = Travel Alarm
5285 = 5285 mm
3 = Worklights
5740 = 5740 mm
4 = Travel Alarm and Strobe Light
6120 = 6120 mm
5 = Worklights and Strobe Light
6390 = 6390 mm
6 = Travel Alarm, Worklights, and
6925 = 6925 mm
Strobe Light
7495 = 7495 mm
7 = Travel Alarm and Worklights
789 = Custom
911 = Special
SRO(1)
1 = Enabled
2 = Disabled
Cold Conditioning
- = No Cold Conditioning
F = Freezer Conditioning Accessory Hydraulics
C = Corrosion Conditioning - = No Accessory Hydraulics (1) If SRO (Static Return to Off) is
S = Single Function enabled, you must return the di-
D = Double Function rectional lever to neutral after the
seat switch opens to enable trac-
tion

Crown 2012 PF25677-3 SC 5300 Series ITD-1153-003

5
Notes:

6
SAFETY
7
Notes:

8
 SAFETY
General Maintenance Instructions

General Maintenance Instruc- level, or for leakage of electrolyte and fluids or oil.
Do not use open pans of fuel or flammable clean-
tions ing fluids for cleaning parts.
7. Keep shop well ventilated, clean and dry.
8. Brakes, steering mechanisms, control mecha-
WARNING nisms, lift overload devices, guards, and safety de-
vices shall be inspected regularly and maintained
To prevent serious risk of injury to yourself and in a safe operating condition.
others observe the following safety instructions.
9. Capacity, operation and maintenance instruction
plates or decals shall be maintained in legible con-
Powered industrial trucks may become hazardous if dition.
adequate maintenance is neglected. Therefore, ade-
10. All parts of lift mechanisms shall be inspected to
quate maintenance facilities, trained personnel and
maintain them in safe operating condition.
procedures should be provided.
11. All hydraulic systems shall be regularly inspected
Maintenance and inspection shall be performed in con-
and maintained in conformance with good practice.
formance with the following practices:
Cylinders, valves, and other similar parts shall be
1. A scheduled planned maintenance, lubrication, checked to assure that “drift” has not developed to
and inspection system should be followed. the extent that it would create a hazard.
2. Only qualified and authorised personnel shall be 12. Batteries, motors, controllers, limit switches, pro-
permitted to maintain, repair, adjust and inspect tective devices, electrical conductors, and connec-
truck. tions shall be maintained in conformance with
3. Before leaving the truck— good practice. Special attention shall be paid to the
– Stop truck. condition of electrical insulation.
– Fully lower the load handler. 13. Trucks shall be kept in a clean condition to mini-
mise fire hazards and facilitate detection of loose
– Place control handle in neutral.
or defective parts.
– Apply the parking brake.
14. Modifications and additions which affect capacity
– Turn off power (power disconnect). and safe truck operation shall not be performed by
– Remove key. the customer or user without manufacturers prior
– Block the wheels if truck is on an incline. written approval. Capacity, operation and mainte-
nance plates or decals shall be changed accord-
4. Before working on truck—
ingly.
– Raise drive wheel free of floor or disconnect
15. Care shall be taken to assure that all replacement
power sources.
parts are interchangeable with the original parts
– Use chocks or other positive positioning devices. and of equal quality to that provided in the original
– Block load handler, inter masts, or chassis before equipment.
working under them. 16. Be sure that any equipment added to the truck (ter-
– Operation to check performance of truck or at- minal, fan, clipboard, etc.) is positioned so that it
tachments shall be conducted in an authorised does not block your vision or interfere with safe and
safe clearance area. efficient operation of the truck.
5. Before starting to operate truck— Note: For further information pertaining to operating
– Be in operating position. and maintenance procedures, refer to F.E.M. safety
code - Power Industrial Truck (section 4).
– Apply brake.
For copies send to:
– Place control handle in neutral.
F.E.M.
– Before operating truck, check functions of lift sys-
10 Avenue Hoche
tems, control handle, speed control, steering,
75382 Paris Cedex 08 France
warning devices, brakes and any attachments if
any used.
6. Avoid fire hazards and have fire protection equip-
ment present. Do not use an open flame to check

Crown 1980 PF6285-1 Rev. 10/06 SC 5300 Series MA-04.5-001

03 Rev. 10/06
9
SAFETY
Cleaning of Material Handling Equipment

Cleaning of Material Handling power washing. For these reasons all electronic com-
ponents including motors must be protected. Compo-
Equipment nent removal is the best method to eliminate the risk of
damage.
Cleaning Methods Power washing will also remove or destroy lubricants in
The preferred method of cleaning built up dirt and dust or on the surface of shafts, unsealed bearings, hinges,
from electric material handling equipment is dry pres- exposed gears, bushings, chains, linkages, etc. These
sured air. For localised degreasing, use of an appropri- items must also be protected or properly lubricated af-
ate solvent is recommended. ter cleaning.
If these methods are not effective and power washing Consideration must also be given to metal surfaces.
is the only alternative, extreme care must be exercised. The cleaning process can strip away paint and protec-
Electrical components including connectors, terminal tive coatings applied to components (i.e., hydraulic
boards and wiring can be permanently damaged from lines, terminal strips, linkages) for freezer/condition en-
water or cleaning solvents. Mineral and chemical resi- vironment. Paint or protective coating must be reap-
due left on or in components (i.e., circuit boards, con- plied to these areas to reduce the chance of oxidation
tactors, encoders, switches, potentiometers, etc.) after and corrosion.
washing is a proponent of oxidation and corrosion. Before installing removed components, lubricating or
Functional integrity of contaminated components may returning the equipment to service it must be free of
be questionable. Nuisance fault logging, intermittent solvent residue and thoroughly dry.
operation or immediate failure could be the resultant of

Crown Cleaning Products Chart

Cleaner Type Part Number Package Quantity

Degreaser & Cleaner 363105-001 20 oz Can
363105-012 (12) 20 oz Cans
All Purpose Cleaner 363114-001 20 oz Can
363114-012 (12) 20 oz Cans
Glass Cleaner 363101-001 20 oz Can
363101-012 (12) 20 oz Cans
Waterless Hand Cleaner 363111-001 15 oz Tube
363111-012 (12) 15 oz Tubes
Pumiced & Smooth Hand Cleaner 363112-001 1 Gallon Jug
363112-004 (4) 1 Gallon Jugs
Wall Mounted Deluxe Soap Dispenser 363122 Used with 363112-001
Tough On Grease 063009-005 1 Gallon Jug
Citrus Degreaser Spray 363134-001 32 oz spray bottle
363134-012 (12) 32 oz spray bottles
Citrus Degreaser Spray 36135-001 1 Gallon refill used with 363134-001
363140-101 1 Gallon concentrated used with 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-1140-050 SC 5300 Series Crown 2000 PF11969-1 Rev. 6/10

03 Rev. 6/10
10
 SAFETY
Control of Hazardous Energy

Control of Hazardous Energy Battery Care

Lockout/Tagout
In the interest of safety and to ensure compliance with CAUTION
EU Machinery Directives, Crown has developed guide- Only qualified and experienced personnel should per-
lines for proper energy control when performing ser- form maintenance and repair on batteries.
vice and maintenance on the truck. Before performing
 Make certain the charger being used matches the
any service or maintenance on the truck, review the ap-
voltage and amperage of the truck battery. This
propriate sections in this service manual for additional
voltage is listed on the truck serial plate.
procedures to be followed.
 Before disconnecting or connecting batteries to a
In addition, Crown recommends that all mechanics
charger, make sure charger is OFF. If an attempt is
wear appropriate protective items, such as safety
made to do this while charger is ON, serious injury
glasses, work gloves, and steel-toed shoes, whenever
to you, the battery and charger could result.
performing service or maintenance work on Crown
equipment.  Never use a match or lighter. Battery fumes are ex-
plosive.
Battery  Make certain battery used meets weight, size, am-
perage and voltage requirements of truck (refer to
Safety Rules serial plate). NEVER operate truck with an under-
• Wear protective clothing, such as, rubber apron, sized battery.
gloves, boots and full-face shield when performing
any maintenance on batteries. Do not allow electro-
lyte to come in contact with eyes, skin, clothing or Charging
floor. If electrolyte comes in contact with eyes, flush
immediately and thoroughly with clean water. Ob-
tain medical attention immediately. Should electro- CAUTION
lyte be spilled on skin, rinse promptly with clean
water and wash with soap. If battery acid is spilled Gas formed during charging is highly explosive and
on the floor or any other surface, use Battery Spill can cause serious injury.
Kit, part no 300035 to neutralise and clean-up the  Never smoke or bring flame near the battery.
battery acid. Follow the manufacture directions for
use. Consult the charger manufacturer's manual covering
• Keep vent plugs firmly in place at all times except your charger for hints on operation and maintenance.
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 man-
ufacturer's instructions concerning repair practices
and procedures.

Crown 2011 PF25412-1 SC 5300 Series MA-1153-100

11
SAFETY
Control of Hazardous Energy

Battery Removal Battery Installation

CAUTION CAUTION
When removing the battery, move truck to area in- When installing the battery, move truck to area in-
tended for battery care. Floor must be level. tended for battery care. Floor must be level.
 Turn key switch or toggle switch to OFF position  Turn key switch or toggle switch to OFF position
and remove key. and remove key.
 Disconnect battery and lockout or tagout truck as  Lockout or tagout truck as described in Lockout -
described in Lockout - Tagout in this section. Never Tagout in this section.
move battery partially from truck without roller stand  If battery was removed with load handler raised,
in place. use hoist attached to mast to provide tip over pro-
 Lower load handler completely. tection.
 If battery is removed with load handler raised, use  Do not allow any metallic object to come in contact
hoist attached to mast to provide tip over protection. with the top of the battery cells. This may cause a
 Do not allow any metallic object to come in contact short circuit when transporting or installing the bat-
with the top of the battery cells. This may cause a tery. Use an insulator (such as plywood) to cover
short circuit when removing, transporting the bat- the top of the battery before and during installation.
tery. Use an insulator (such as plywood) to cover
the top of the battery before and during removal.

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

Lockout - Tagout
Always turn key switch to OFF, remove key and apply
tag to steering wheel with cable tie warning others truck
is being serviced.

CAUTION
Figure 8251 A Lockout - Tagout Kit (part number 300037) is availa-
ble. Refer to the One Source Catalog.

Figure 8346
When maintenance is to be performed and the battery
will be left in the truck, disconnect battery, remove the

MA-1153-101 SC 5300 Series Crown 2011 PF25412-2

12
 SAFETY
Control of Hazardous Energy

main power fuses and install a lockout device on the

battery connector. Refer to Figure 24312.

Figure 24312
1 Lockout device on battery connector (Lockout Tagout Kit,
part no. 300037)

When maintenance is performed and the battery is re-

moved from the truck, remove main power fuses, install
a lockout device on the trucks battery connector if pos-
sible, 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.

Capacitance
Due to capacitance voltage present in the ACCESS 2
and ACCESS 3 modules, whenever performing main-
tenance which may permit contact with the bus bars
and associated power cables, discharge the capaci-
tors.
1. Move truck to a secure non-traffic maintenance
area with a level floor.
2. Chock truck wheels. Refer to Lifting and Blocking
in this chapter.
3. Disconnect battery. Lockout/Tagout truck as de-
scribed in Lockout/Tagout in this chapter.
4. Turn and hold the key switch to the start position a
minimum of 10 seconds.
5. To verify the capacitors have discharged, place a
volt meter across the B+ and B- terminals of
ACCESS 2 and ACCESS 3 module.
6. Turn key switch to OFF and remove key.

Crown 2011 PF25412-3 SC 5300 Series MA-1153-103

13
SAFETY
Control of Hazardous Energy

Figure 25879
1 ACCESS 3
2 Negative (B-) Terminal
3 Positive (B+) Terminal
4 ACCESS 2

MA-1153-103 SC 5300 Series Crown 2011 PF25412-4

14
 SAFETY
Control of Hazardous Energy

Brake
It is necessary to release the electric brakes before
towing the truck

WARNING
Extreme care must be taken when using any of the fol-
lowing procedures to release the truck brakes. The
brake pedal in the operator compartment and the truck
brakes will not function when using any of the following
procedures. The brakes can only be applied when the
truck is returned to its original configuration.
 During any procedure, lockout and tagout the truck
as described in Lockout - Tagout in this section.
 Remove load from truck before releasing the
brakes and towing.
 Always perform brake release procedure on a level
surface to prevent the truck from rolling. Chock
drive wheels or make sure truck is secure before
releasing brakes.
 When towing the truck, make sure all operators
know that truck does not have braking capability.
 Move truck to a maintenance area and secure on a Figure 24313
level surface. 1 Tow
 If the truck is not returned to normal braking config- 2 Drive
uration after towing, it must remain in a Lockout -
Tagout condition. 3. Raise seat deck, locate and disconnect JC405
from PC405. They are the Drive/Tow connectors
and are located near the ACCESS 3 module.
Releasing Brakes Route the female end of the plug between the seat
deck and rear counterweight, so it can be ac-
When releasing the truck brakes, use extreme caution
cessed from the rear of the truck. Be careful not to
and follow one of the following procedures. Choose the
pinch the wires.
procedure that best fits the situation.
4. Using brake release harness (139956-002), con-
Releasing Brakes by Switching Connec- nect an auxiliary power source to the plug. This will
tors and Using an External Power Source release the brakes.
1. Turn key switch to OFF position, disconnect the 5. Tow truck to maintenance area, secure truck in po-
battery (if present), and remove left side operator sition, disconnect power supply, and return the
floorboard. connectors to original configuration.
2. Refer to Figure 24313. Disconnect plug JC605
from PC605 (labeled Drive). Connect plug JC605
and PC606 (labeled Tow). Install floorboard. CAUTION
Leaving a power source ON and connected to the truck
brake coils could over heat and damage the brakes. If
the truck is not returned to normal braking configuration
then it must remain in Lockout - Tagout condition.

Crown 2011 PF25412-5 SC 5300 Series MA-1153-104

15
SAFETY
Control of Hazardous Energy

Releasing Brakes by Switching Connec- Releasing Brakes by Using the Crown Op-
tors & Using On Board Truck Battery erator Display and Truck Battery is Pre-
1. With truck key switch turned OFF, disconnect bat- sent
tery and remove left side operator floor plate. 1. Turn key switch ON.
2. Refer to Figure 24313. Disconnect plug JC605
from PC605 (labeled Drive). Connect plug JC605
and PC606 (labeled Tow). Install floor plate. WARNING
3. If brakes do not release, locate Drive/Tow connec-
tors JC405 and PC405 in the rear of the truck near After enabling tow mode, the truck will be difficult to
the traction control module and make sure that steer because the truck will not have power steering.
they are connected.
4. Tow truck to maintenance area, secure truck in po- 2. Navigate to Access 1 2 3 Service Level 2 (pass-
sition, and return connectors to original configura- word is required) menu, then to Utilities menu, then
tion. to U2 tow mode. Enable tow mode. For more infor-
mation concerning Access 1 2 3 menus, refer to
Access 1 2 3 section of this service manual.
CAUTION 3. When in tow mode, there is a five minute window
that the brakes are in the released state. If addi-
Leaving this power source connected to the truck brake tional time is required the release can be reacti-
coils could overheat and damage the brakes. If the vated for additional five minute periods.
truck is not returned to normal braking configuration, 4. If the brakes are released in tow mode, and need
then it must remain in the Lockout - Tagout condition. to be applied, disable tow mode.
5. When in tow mode, if operator is not present (out
of seat) and either drive wheel moves, an audible
alarm will sound.
6. When in tow mode, if operator is present (in the
seat) and either drive wheel moves, there is no au-
dible alarm.
7. Tow the truck to maintenance area, disable tow
mode and turn truck OFF. If truck is not returned to
normal braking configuration then it must remain in
the Lockout - Tagout condition.

MA-1153-105 SC 5300 Series Crown 2011 PF25412-6

16
 SAFETY
Control of Hazardous Energy

Hydraulic 4. Lower the forks to floor.

5. Turn the truck OFF.
6. Lockout or tagout the truck described in this man-
WARNING ual section.
7. On a SC 5300 with a manual valve operate the tilt
Avoid high pressure fluids. control lever to release hydraulic pressure in the tilt
Escaping fluid under pressure can penetrate the skin circuit.
causing serious injury. On a SC 5300 with EPV place a catch pan or oil
 Relieve pressure before disconnecting hydraulic absorbent pad below the cylinder fittings.
lines. 8. Place a shop rag over the fittings to lessen the
 Tighten all connections before applying pressure. chance of spray and slowly loosen both hydraulic
 Keep hands and body away from pinholes which fittings in one of the tilt cylinders to relieve pressure
eject fluids under high-pressure. in the tilt circuit.
 Use a piece of cardboard or paper to search for Steering Circuit
leaks. Do not use your hand.
1. Move the truck to a secure, no traffic maintenance
Consider any fluid injected into the skin under high-
area with a level floor.
pressure as a serious medical emergency despite an
initial normal appearance of the skin. There is a de- 2. Lockout or tagout the truck described in this man-
layed onset of pain, and serious tissue damage may ual section.
occur. Seek medical attention immediately by a spe- 3. Turn the steering wheel to the left or right all the
cialist who has experience with this type of injury. way and hold for 10-20 seconds.

Sideshift Circuit
Before performing maintenance on the hydraulic sys-
tem, relieve the hydraulic pressure. To relieve pres- 1. Move the truck to a secure, no traffic maintenance
sure, refer to the following: area with a level floor.
2. Lockout or tagout the truck described in this man-
Lift and Lower Circuit ual section.
1. Move the truck to a secure, no traffic maintenance 3. Check to be sure nothing is pushing against the
area with a level floor. sideshift carriage or cylinder ram.
2. Tilt forks level. 4. On a SC 5300 with a manual valve operate the
3. With no load on the forks, lower the forks or block sideshift control lever to release hydraulic pressure
the mast sections at a suitable height. Refer to in the tilt circuit.
Mast in this manual section. On a SC 5300 with EPV wait 10-20 seconds after
4. Turn the truck OFF. sideshifting to relieve the hydraulic pressure in the
sideshift circuit.
5. Lockout or tagout the truck described in this man-
ual section.
6. Remove the floorboards.
7. Slowly open the manual lower valve to remove hy-
draulic pressure from the lift and lower circuit.

Tilt Circuit
1. Move the truck to a secure, no traffic maintenance
area with a level floor. If truck has an attachment,
remove attachment.
2. With no load on the forks, raise the forks high
enough so you can tilt the mast completely forward
(about 0.3 meter).
3. Tilt the mast completely forward. As soon as the
mast reaches full forward tilt, release the tilt lever
so the pressure doesn't increase in the tilt circuit.

Crown 2011 PF25412-7 SC 5300 Series MA-1153-106

17
SAFETY
Control of Hazardous Energy

Towing Truck 7. Towing device/vehicle must have pulling/braking

capacity greater than the pulling force found in the
Refer to the following guidelines when towing the truck: previous step.
Towing by Pulling in Power Unit First Di- Note: Excessive acceleration by the towing vehicle, or
rection drag caused by the towed vehicle (i.e., brake drag,
drive unit drag, wheel drag, etc.), will greatly increase
the requirements to pull or push a vehicle.

WARNING Attaching Towing Device To Lift Truck To Be

Towed
 Towed truck must always maintain three contact 8. Pull vehicle by overhead guard.
points with floor and/or towing device. Note: Use pull force requirements listed under Towing
 Maximum travel speed while towing truck is 3.2 km/ Device Requirements (see previous column) to deter-
h (2 mph). mine specifications of tow strap.
 Do not make sharp turns when towing this truck. 9. Attach towing strap around both rear overhead
 Towed vehicle forks should be empty and no more guard uprights. Refer to Figure 26733.
than 305 mm off floor. If possible, tilt forks back and
center sideshifter.
 Provide a safe distance for truck to coast to stop.

Preparing Truck For Towing

1. Refer to the data plate for the gross vehicle weight.
Include the battery weight if it is in the vehicle dur-
ing towing.

WARNING
Truck will be difficult to steer. Use extreme care.

2. Ensure truck can be steered safely during towing.

3. Reference the service manuals SAFETY Control of
Hazardous Energy BRAKE section for information
on releasing the electric brakes before towing.
4. Ensure operator compartment has not been dam-
aged in such a way as to inhibit operator safety
during towing. If operator needs to exit vehicle
quickly during towing, can it be done safely? If not,
use another method to move vehicle.
5. Ensure floor is level and flat without trash or debris Figure 26733
in towing path. 1 Route tow strap around both rear overhead guard uprights
2 Lower forks completely, no load on forks
Towing Device Requirements
6. The pull force required to tow the vehicle on a flat 10. Use a tow strap that is long enough to allow the
level surface can be found by multiplying the gross operator time to stop safely if he or she needs to do
vehicle weight of the truck by 0.20 (i.e., GVW x so quickly. Towing at 1.6 km/h (1 mph) will require
0.20).The gross vehicle weight of the towed truck a 2438 mm minimum distance between towed and
can be found on the data tag. Include the battery towing vehicle; choose a tow strap accordingly.
weight if it is in the vehicle during towing. Towing Vehicle Minimum Requirements:
11. Use pull force requirements calculated in Towing
Device Requirements to determine traction force.

MA-1153-107 SC 5300 Series Crown 2011 PF25412-8

18
 SAFETY
Control of Hazardous Energy

This traction force must be within towing specifica- Preparing Truck For Towing
tions of towing vehicle.
12. Both towed and towing vehicle must be able to stop
under their own power if they need to while towing. CAUTION
13. Attach tow strap as low as possible on towing ve-
hicle. Consult manufacturer for more information. • When removing the battery, move truck to area in-
tended for battery care. Floor must be level.
Towing Guidelines
• Turn key switch or toggle switch to OFF position
• Maximum travel speed while towing truck is 3.2 km/ and remove key.
h (2 mph).
• Disconnect battery and lockout or tagout truck as
• Both the towing vehicle operator and towed vehicle described in Lockout - Tagout in this section.
operator must be able to communicate clearly while
• Never move battery partially from truck without
towing. For example: if braking is required during
roller stand in place. Lower load handler com-
towing, operators of towed and towing vehicles
pletely. If battery is removed with load handler
must clearly and quickly verbally communicate their
raised, use hoist attached to mast to provide tip
intentions. Clear communication is also required
over protection.
during acceleration, turning, etc.
• Do not allow any metallic object to come in contact
Towing by Lifting Truck and Pulling in with the top of battery cells. This may cause a short
Power Unit First Direction circuit when removing, transporting the battery. Use
an insulator (such as plywood) to cover top of bat-
tery before and during removal.
WARNING
1. Remove battery from vehicle.
 Towed truck must always maintain three contact 2. Release parking brake. Refer to Brake in this sec-
points with floor and/or towing device. tion for proper procedure.
 Maximum travel speed while towing truck is
3.2 km/h.
 Do not make sharp turns when towing this truck.
 Towed vehicle forks should be empty and no more
than 305 mm off floor. If possible, tilt forks back and
center sideshifter.
 Provide a safe distance for truck to coast to stop.
 Excessive acceleration by towing vehicle, or drag
caused by towed vehicle (i.e., brake drag, drive unit
drag, wheel drag, etc.) will greatly increase require-
ments to pull or push a vehicle.

Crown 2011 PF25412-9 SC 5300 Series MA-1153-108

19
SAFETY
Control of Hazardous Energy

3. Lift and tow from power unit end of vehicle. Refer • Towing device must not damage underside of
to Figure 26734. towed vehicle or steer wheels.

Lifting and Blocking

Side View

Figure 24318
Figure 26734 1 Lower forks (not shown)
2 Hardwood block
1 Lift from this location
3 Height not to exceed 400 mm (16 in)
2 Lower forks completely, no load on forks
1. Move truck to a secure non-traffic maintenance
4. Ensure towed vehicle does not uncouple from tow-
area with a level floor.
ing vehicle during towing.
2. No load on forks.
5. Towing device must not damage underside of
towed vehicle. 3. Lockout or tagout truck as described in Lockout -
Tagout in this section.
Lifting Vehicle Requirement
Note:
6. Make sure all lifting vehicle capacities are not ex-
• Hydraulic Jack Capacity: 3991 kg
ceeded while lifting, travelling, accelerating, or
• Crown Part Number: 300083
braking. Refer to manufacturer if there is any doubt
• Collapsed Height Minimum: 60 mm
this vehicle can carry disabled vehicle.
• Raised Height Maximum: 400 mm
7. Use pull force requirements calculated in Towing
• Jack Stand Capacity: 6350 kg
Device Requirements to determine traction force.
• Crown Part Number: 300081
This traction force must be within towing specifica-
tions of towing vehicle.
8. Both towed and towing vehicle must be able to stop
under their own power if they need to while towing. CAUTION
Lifting and Towing Guidelines When raising rear of truck, raise one side 25-40 mm
• Lift and tow from power unit end of vehicle. and block. Raise opposite side 25-40 mm and block.
Continue alternating sides until reaching required
• Ensure towed vehicle does not uncouple from tow- height (not to exceed 400 mm).
ing vehicle during towing. Secure with straps or
clamps.

MA-1153-109 SC 5300 Series Crown 2011 PF25412-10

20
 SAFETY
Control of Hazardous Energy

WARNING
Truck stability decreases dramatically if truck skirt is
raised more than 140 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.

Steer Wheel

Figure 24317
1 Raise forks 75 - 150 mm from floor (not shown)
2 Chock both drive wheels
3 Hardwood block
4 Height not to exceed 400 mm - refer to note

Crown 2011 PF25412-11 SC 5300 Series MA-1153-109

21
SAFETY
Control of Hazardous Energy

Mast 5. Using a clamp or ratchet tie down, secure blocks to

mast channel as shown.
Blocking Masts 6. Lower mast and position appropriate length blocks
Use 100 x 100 mm or larger hardwood blocks of appro- under third stage mast as shown.
priate length for supporting mast channels. Block both 7. Lower mast and position appropriate length blocks
mast rails of each stage to maintain stability. under fourth stage mast (or inner) on quad mast
Remove any carriage mounted accessory (i.e., carton trucks as shown.
clamp, etc.) except sideshifters before blocking masts. 8. Using a clamp or ratchet tie down, secure blocks to
These accessories add significant weight to the mast. mast channel or second stage block as shown.
1. Move truck to a secure non-traffic maintenance 9. Lower fork carriage until carriage rests on stops or
area with a level floor. place blocks under carriage and lower until weight
2. Chock wheels of truck (refer to Lifting and Blocking rests on blocks.
in this section). 10. Lockout or tagout truck as described in Lockout -
3. Connect battery. Tagout in this section.
4. Raise forks and position blocks under second
stage mast as shown.

Figure 16959-01
a TT Mast e Second Stage Mast
b Quad Mast f First Stage Mast (or Mainframe)
c Fork Carriage (Shown Slightly Raised for Clarity) g First Stage Mast (or Outer Mast)
d Third Stage Mast h Fourth Stage Mast (or Inner)

MA-1153-110 SC 5300 Series Crown 2011 PF25412-12

22
 SAFETY
Control of Hazardous Energy

Figure 16960-01
a TT Mast
b Quad Mast
c Fork Carriage
d Third Stage
e Second Stage
f First Stage (or Mainframe)
g First Stage (or Outer Mast)
h Fourth Stage (or Inner Mast)

Crown 2011 PF25412-13 SC 5300 Series MA-1153-112

23
SAFETY
Control of Hazardous Energy

Disconnecting Tilt Cylinder

When the tilt cylinders are disconnected from the hy-
draulic system or from the mounting brackets, the mast
must be secured to keep the mast from pivoting to-
ward, or away from the truck.
1. Move truck to a secure non-traffic maintenance
area with a level floor.
2. Lower forks and mast (load handler) completely.
No load on forks.
3. Lockout or tagout truck as described in Lockout -
Tagout in this section.
4. Chock wheels (refer to Lifting and Blocking in this
section).
5. Attach a sling and lifting device to all mast top
cross braces so movement will be minimal when tilt
cylinders are disconnected.

Figure 16961-01
a Attach Lifting Device to All Top Cross Braces and Center to
Maintain Balance
b Wheel Chocks

MA-1153-113 SC 5300 Series Crown 2011 PF25412-14

24
 SAFETY
Control of Hazardous Energy

Mast Removal
1. Move truck to a secure non-traffic maintenance
area with a level floor.
2. Lockout or tagout truck as described in Lockout -
Tagout in this section.
3. Remove battery.
4. Remove forks.
5. Remove hydraulic pressure from the lift, tilt and
sideshift (accessory) circuits. Refer to “Hydraulic”
in this manual section.
6. Disconnect lift cylinder hydraulic lines, accessory
cables and accessory hydraulic lines between
power unit and mast if present. Use catch pan or oil
absorbent pads to catch hydraulic oil.
7. Disconnect wiring between mast and power unit.
8. Support mast as described in Disconnecting Tilt
Cylinders in this section.
9. Chain mast sections together at the upper cross- Figure 26735
braces. Chain fork carriage to lower mast cross- a Part of Mast
brace. This will keep carriage and mast sections
b Shim
from moving when the mast is laid down.
c To Power Unit
10. Remove pins connecting tilt cylinders to the mast.

Figure 8351
11. Remove pivot block mounting bolts. If pivot blocks
are to be removed, note number and location of
shims between pivot blocks and mast.
12. Move mast away from truck and lay mast on level
floor with the truck side of the mast on the floor.

Crown 2011 PF25412-15 SC 5300 Series MA-1153-114

25
SAFETY
Control of Hazardous Energy

Counterweight Removal
1. Move truck to a secure non-traffic maintenance
area with a level floor.
2. Lockout or tagout truck described in Lockout -
Tagout in this section.
3. Remove battery.
4. Attach a sling and lifting device to all top cross
braces of the mast, to prevent tipover.
5. Attach a sling and lifting device to the rear of the
overhead guard to support the guard when the
guard mounting bolts are removed.

Figure 25380

WARNING
After mounting bolts holding the counterweight to the
truck are removed, the counterweight will be balanced
on the pallet truck forks. Use extreme care when mov-
ing counterweight to maintain balance.

7. Remove counterweight mounting bolts.

8. Carefully move the counterweight away from truck.

Figure 25379
6. Position a pallet truck or other similar lifting device
under the counterweight from the rear of the truck
and raise to support the weight of the counter-
weight when the mounting bolts are removed.

MA-1153-115 SC 5300 Series Crown 2011 PF25412-16

26
 SAFETY
Control of Hazardous Energy

Hose Reel
Hose reels have a minimum of 3 revolutions of prewind
and up to 16 revolutions maximum. When performing
maintenance to these units, use the following steps to
remove the spring prewind.
1. Move truck to a secure non-traffic maintenance
area with a level floor.
2. Position the forks to provide the shortest distance
between the carriage mounted junction block and
the hose reel. Block the carriage at this height as
described in Mast of this section.
3. Lockout or tagout truck as described in Lockout -
Tagout in this section.
4. Remove battery.
5. Remove any hydraulic pressure that may be pre-
sent. Refer to the Hydraulic section in this chapter
of the manual.
6. Clean oil and residue from hose(s) exterior.
7. Disconnect the hose(s) from the carriage mounted
junction block while maintaining a tight grip on the
hose(s).
8. Slowly allow hose(s) to coil up on the reel and care-
fully remove prewind by grasping reel and slowly
allowing the reel to rotate.

Figure 8320

Crown 2011 PF25412-17 SC 5300 Series MA-1153-116

27
Notes:

28
LUBRICATION & ADJUSTMENT
29
Notes:

30
 LUBRICATION & ADJUSTMENT
Operators Daily Checklist

Operators Daily Checklist sons, Crown recommends a checklist similar to the Op-
erators Daily Checklist shown below.
To obtain maximum life of any industrial equipment, a
Before performing maintenance to any unit, it should
well planned maintenance program (PM), performed
be taken to an area set aside for maintenance or a sec-
by qualified technical personnel should be followed. In
tion where there is adequate space to perform required
conjunction with, and an integral part of, any planned
work. This is a must to insure the safety of others and
maintenance program should be daily operator input.
to insure that proper maintenance is performed to the
Operator involvement can greatly reduce truck down
unit.
time, assist in determining planned maintenance (PM)
schedules and ultimately save money. For these rea- If desired, padded packs of this checklist (OF3772) are
available through your Crown dealer.

Figure 14990

Crown 2011 PF25239-1 SC 5300 Series M1.0-04.0-006

31
LUBRICATION & ADJUSTMENT
Lubricants, Aerosols & Service Supplies

Lubricants, Aerosols & Service

Supplies
The following is a list of lubricants and maintenance
products recommended when doing Planned Mainte-
nance on Crown Lift Trucks.

Lubrication Identification Chart

Type of Lubricant Part Number Package Quantity

363506-001 1 Quart
A Gear Lube 80W-90 (Typical)
363506-012 (12) 1 Quart Cans
363503-001 1 Quart
AA Automatic Transmission Fluid (Multi-Purpose)
363503-012 (12) 1 Quart
363513-001 1 Quart
AAA Universal Hydraulic & Transmission Fluid
363513-012 (12) 1 Quart
363514-001 1 Quart
AAAA Synthetic Gear Oil 75W-90
363514-012 (12) 1 Quart
063002-034 14.5 oz Cartridge
B Grease (Multi-Purpose)
063002-045 (40) 14.5 oz Cartridges
063002-017 14.5 oz Cartridge
BB(1) Grease (Low Temperature)
063002-046 (40) 14.5 oz Cartridges
363002-001 14 oz Cartridge
BBB Food Grade Grease (Multi-Purpose)
363002-030 (30) 14 oz Cartridges
063002-025 14.5 oz Cartridge
BBBB Grease (Multi-Purpose) Premium
063002-026 5 Gallon
C Oil (SAE 40)
363500-001 1 Quart
Engine Oil (10W30)
363500-012 (12) 1 Quart
CC
063041-001 1 Quart
JD Turf Guard (10W30)
063041-012 (12) 1 Quart Cans
363504-101 1 Gallon
D Hydraulic Oil
363504-106 (6) 1 Gallon
363505-101 1 Gallon
DD(1) Hydraulic Oil (Low Temp)
363505-106 (6) 1 Gallon
DDD Hydraulic Oil - DTE24 063001-021 1 Gallon
063002-024 14.5 oz Cartridge
E Channel Grease
063002-022 35 lb Pail
063002-024 14.5 oz Cartridge
F Gear Grease
063002-022 35 lb Pail
(1) Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.

M1.0-04.0-050 SC 5300 Series Crown 2011 PF25240-1

32
 LUBRICATION & ADJUSTMENT
Lubricants, Aerosols & Service Supplies

Lubrication Identification Chart

Type of Lubricant Part Number Package Quantity

363107-001 15 oz Can
Chain & Cable Lube
363107-012 (12) 15 oz Cans
G
363115-001 12 oz Can
Premium Chain & Cable Lube
363115-012 (12) 12 oz Cans
363129-001 11 oz Can
H Final Finish - Rubber & Vinyl Dressing
363129-012 (12) 11 oz Cans
063002-039 1 lb
I Grease (Lift Pump Coupling)
127801S 1 oz
063004-002 12 oz
J Brake Fluid - Dot 5
063004-003 1 Gallon
063002-034 14.5 oz Cartridge
K Grease (Wheel Bearing)
063002-045 (40) 14.5 oz Cartridges
L Metal Assembly Spray 063002-021 11 oz Spray
M Silicone Grease (Clear) 063002-020 5.3 oz Tube
363102-001 14 oz Can
Brake & Parts Cleaner
363102-012 (12) 14 oz Cans
363103-001 14 oz Can
N Low VOC Brake & Parts Cleaner
363103-012 (12) 14 oz Cans
363116-001 19 oz Can
Non-Flammable Brake & Parts Cleaner
363116-012 (12) 19 oz Cans
363104-001 20 oz Can
O Penetrating Lubricant
363104-012 (12) 20 oz Cans
363108-001 11 oz Can
P Premium Formula Multi-Purpose Grease
363108-012 (12) 11 oz Cans
363110-001 11 oz Can
Q White Lithium Grease
363110-012 (12) 11 oz Cans
363109-001 15 oz Can
R Choke & Carburetor Cleaner
363109-012 (12) 16 oz Cans
363106-001 10 oz Can
Contact Cleaner - Non-Flammable
363106-012 (12) 10 oz Cans
S
363128-001 11 oz Can
Contact Cleaner
363128-012 (12) 11 oz Cans
T Electrical Connector Oxidation & Corrosion Inhibitor 127189-001 30 cc
363124-001 18 oz Can
U Battery Cleaner
363124-012 (12) 18 oz Cans
363125-001 15 oz Can
V Battery Protector
363125-012 (12) 15 oz Cans
363127-001 12 oz Can
W Food Grade Machine Lubricant
363127-012 (12) 12 oz Cans

Crown 2011 PF25240-2 SC 5300 Series M1.0-04.0-051

33
LUBRICATION & ADJUSTMENT
Lubricants, Aerosols & Service Supplies

Lubrication Identification Chart

Type of Lubricant Part Number Package Quantity

363126-001 11 oz Can
X Food Grade Silicone Spray
363126-012 (12) 11 oz Cans
363509-101 1 Gallon
Coolant
363509-106 (6) 1 Gallon
Y
363511-101 1 Gallon
Extended Life Coolant
363511-106 (6) 1 Gallon

M1.0-04.0-052 SC 5300 Series Crown 2011 PF25240-3

34
 LUBRICATION & ADJUSTMENT
Lubricants, Aerosols & Service Supplies

Alternate Lubricants & Fluids Chart

Manufacturer/ Distribu-
Type of Lubricant Product Name
tor
A Gear Lube 80W-90 (Typical) Crown Crown
Automatic Transmission Fluid
AA Crown Crown
(Multi-Purpose)
AAA Universal Hydraulic & Transmission Fluid Crown Crown
AAAA Synthetic Gear Oil 75W-90 Crown Crown
Mobilgrease XHP 222 Special Mobil
Union Unoba EP No 2 Union 76 Co.
B Grease (Multi-Purpose) Retinax A(1) Shell
LM Grease Burmah Castrol
Unirex EP-2 Exxon
Lubriplate Fiske Bros Refining Co.
BB Grease (Low Temp) (2) Alvania RA(1) Shell
Helveum O(1) Burmah Castrol

BBB Food Grade Grease (Multi-Purpose) Petro Canada Purity FG Petro Canada
Mobilux EP2 64127-4 Mobil
Retinax AM 71119 Shell
BBBB Grease (Multi-Purpose) Premium
Chevron RPM Heavy Duty LC Chevron
Grease EP
C Oil (SAE 40)
D Hydraulic Oil Crown Crown
DD Hydraulic Oil (Low Temp) (2) Crown Crown

DDD Hydraulic Oil - DTE24 (3) Mobil DTE 24 Mobil

E Channel Grease Factran #2 Standard Oil Co.
F Gear, Channel & Shaft Grease Molykote BR-2 Plus Dow Corning
Chain & Cable Lube Crown Crown
G
Premium Chain & Cable Lube Crown Crown
H Final Finish - Rubber & Vinyl Dressing Crown Crown
I Grease (Lift Pump Coupling) Nyogel 774F-MS NYE Lubricants
J Brake Fluid - Dot 5 Q2-1141 Silicon Brake Fluid Dow Corning
Mobilgrease XHP 222 Special Mobil
K Grease (Wheel Bearing) Unirex EP-2 Exxon
Lubriplate No. 1242(1) Fiske Bros. Refining Co.
(1) Denotes allowable substitutes, contact factory if unavailable.
(2) Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.
(3) Premium antiwear hydraulic oil used in blending with low temp oil.

Crown 2011 PF25240-4 SC 5300 Series M1.0-04.0-053

35
LUBRICATION & ADJUSTMENT
Lubricants, Aerosols & Service Supplies

Alternate Lubricants & Fluids Chart

Manufacturer/ Distribu-
Type of Lubricant Product Name
tor
L Metal Assembly Spray Dow Corning Dow Corning
M Silicon Grease (Clear) Dow Corning 111 Compound Dow Corning
Brake & Parts Cleaner Crown Crown
N Low VOC Brake & Parts Cleaner Crown Crown
Non-Flammable Brake & Parts Cleaner Crown Crown
O Penetrating Lubricant Crown Crown
P Premium Formula Multi-Purpose Grease Crown Crown
Q White Lithium Grease Crown Crown
R Choke & Carburetor Cleaner Crown Crown
S Contact Cleaner Crown Crown
Electrical Connector Oxidation &
T Nye Grease NYE Lubricants
Corrosion Inhibitor
U Battery Cleaner Crown Crown
V Battery Protector Crown Crown
W Food Grade Machinery Lubricant Crown Crown
X Food Grade Silicone Spray Crown Crown
Y Extended Life Coolant

M1.0-04.0-054 SC 5300 Series Crown 2011 PF25240-5

36
 LUBRICATION & ADJUSTMENT
Planned Maintenance

Planned Maintenance
Overview
CAUTION
Lift trucks are designed to move products safely, effi-
ciently and economically. In order to perform this func-  If the truck is found in need of repair or is, in any
tion day after day, lift trucks must be properly way, unsafe or contributes to an unsafe condition,
maintained. The planned maintenance (PM) section of the matter shall be reported immediately to the des-
this manual is designed to assist you in keeping your ignated authority, and the truck shall not be oper-
lift truck operating as it was designed. Proper planned ated until it has been restored to safe operating
maintenance will reduce downtime and operating cost. condition.
A good PM starts with an operational and visual in-  If, during operation, the truck becomes unsafe in
spection of the truck. Begin by performing all the in- any way, the matter shall be reported to the desig-
spections on the Operators Daily Checklist (shown nated authority, and the truck shall not be operated
previously in this section of the service manual). Next: until it has been restored to safe operating condi-
1. Move the truck to a secure, non-traffic mainte- tion.
nance area with a level floor.  Do no make repairs or adjustments unless specifi-
2. Lockout and tagout the truck, chock the drive tyres cally authorised to do so.
and discharge the capacitance voltage in
ACCESS 2 and ACCESS 3. Refer to the Control of
Hazardous Energy section for proper procedures.
3. Blow off the truck with low pressure air, including CAUTION
motors, electrical panels, fans, mast, etc. Lubrication and inspection intervals must be changed
4. Look for debris such as shrink wrap, banding or to a frequency that will minimise corrosion and wear on
other debris that may be lodged in or around mov- moving parts for trucks operated in extremely dusty or
ing or rotating components. corrosive environments.
5. Look for damaged components.
6. Look for loose or missing fasteners.
Component Access
7. Look for damaged electrical wiring or connectors.
The following is a list of covers, panels, etc. that must
Next, based upon the truck's accumulated hours, per-
be opened/removed to allow access when performing
form planned maintenance as indicated in the proper
maintenance to components identified in this section.
interval chart located in this chapter.
• 60 Day/250 Hour
• 12 Month/2000 Hour
CAUTION
Lockout and tagout the truck, chock the drive tyres and
discharge the capacitance voltage in ACCESS 2 and
ACCESS 3. Refer to the Control of Hazardous Energy
section for proper procedures.

Crown 2012 PF25680-1 SC 5300 Series M1.0-1153-001

37
LUBRICATION & ADJUSTMENT
Planned Maintenance

Figure 26902
1 Seat Deck
2 Right Side Cover
3 Floorboards
4 Dash Cover
5 Steering Column Covers
6 Lowering Flow Control Manifold Cover

Seat Deck
Provides access to:
• Seat deck latch, gas struts and hinges
• Tow Connector
• Rear electrical panels
• Steer axle and potentiometer
To open the seat deck, tilt the steering wheel up and
pull the seat deck handle (located below and in front of
the seat).

M1.0-1153-002 SC 5300 Series Crown 2012 PF25680-2

38
 LUBRICATION & ADJUSTMENT
Planned Maintenance

Left Side Cover • Steer command encoder

Provides access to: Steering Column Covers

• ACCESS 3 and ACCESS 2 Fan
Provides access to:
With the seat deck open, remove the left side cover by
• Key switch
loosening the nut on the upper left corner and lifting the
cover up. • Travel directional switches

Right Side Cover Control Lever Cover (Trucks with

Provides access to: Manual Valve only)
• Hydraulic motor and pump Provides access to:
• Battery restraint switch • Control lever linkage
The right side cover lifts out and is also a battery re-
tainer.
Lowering Flow Control Manifold
Cover
Floorboards Provides access to:
The floorboards are in two pieces. Sliding the left and • Pressure transducer
right floorboard out provides access to:
• Traction motors and brakes Armrest Pad and Cover (Trucks with
• Brake pedal, switch and potentiometer EPV only)
• Accelerator pedal, switch and potentiometer • Potentiometers, directional control switches
• Hydraulic directional control valve (trucks with man-
ual valve only)
• Hydraulic function switches and lift potentiometer
(trucks with manual valve)
• Tilt cylinders and switches
• Tilt manifold
• Horn
• Tow connectors
• Optional traction motor fan
• Hydraulic reservoir, filter, breather hoses, etc.
• Impact sensor and travel alarm
• EPV manifold (trucks with EPV only)
• Two accessories manifold (trucks with EPV only)
• ACCESS 7 (trucks with EPV and two accessories
only)
• Operator presence manifold (manual valve only)

Cover Below Dash

Provides access to:
• Steer unit
• ACCESS 1 connections
• Optional fan and work light switches

Dash Cover
Provides access to:

Crown 2012 PF25680-3 SC 5300 Series M1.0-1153-003

39
LUBRICATION & ADJUSTMENT
Planned Maintenance

Lubrication For truck applications primarily operating in a cooler

environment with intermittent freezer entry, use a 50/50
The following information is intended to provide guide- blend of low temperature (063001-006) and standard
lines for proper lubrication intervals as called out in the hydraulic oil (063001-021). For trucks running continu-
lubrication chart. However, some operating conditions ously at temperatures of -12° C (10° F) or below, use
will require more frequent checks and lubrication than an 80% low temperature (063001-006) and 20% stand-
listed. For example, applications with much dust or ard hydraulic oil (063001-021). The proper mixture of
moisture will require modification of the schedule to fit freezer hydraulic oil will ensure the best and most effi-
that particular application. Use high grade lubricants cient operation of your Crown equipment. All screws,
and fluids. Sources of these lubricants may be from al- washers, nuts, roll pins, retaining rings, etc. need to be
most any of the oil companies. Recommended lubri- coated with a rust preventive (078882) to protect
cants are listed in the Lubrication Identification Chart against corrosion. Lubrication intervals must be
and the Alternate Lubricants & Fluids Chart in Lubrica- changed to a frequency that will minimise corrosion
tion & Adjustment Chapter. Crown trucks may require and wear on moving shafts and parts.
a mixture of low temperature hydraulic oil, Crown P/
N363505-101 (gal), blended with standard hydraulic
oil, Crown P/N 063001-021 (gal) when used in a
freezer or cooler. 100% low temperature oil is too thin
for most cold storage operations and therefore could
shorten the life of cylinder packings and pumps if used
in higher ambient temperatures.

CAUTION
Trucks equipped with velocity fuses may experience
staging issues if an insufficient mix of low temperature
oil has been used.

Figure 17478-01
1 Hydraulic Oil 063001-001 (100%)
2 50/50 Blend of Low-Temp 063001-006 (50%) and Hydraulic
Oil 063001-021 (50%)
3 80/20 Blend of Low-Temp 063001-006 (80%) and Hydraulic
OIl 063001-021 (20%)

For truck applications operating continually in temper-

atures at or above 4° C (40° F), use 100% standard hy-
draulic oil (063001-001).

M1.0-1153-004 SC 5300 Series Crown 2012 PF25680-4

40
 LUBRICATION & ADJUSTMENT
Planned Maintenance

Figure 26903

Crown 2012 PF25680-6 SC 5300 Series M1.0-1153-006

41
LUBRICATION & ADJUSTMENT
Planned Maintenance

Chart 1 - Planned Maintenance Lubrication

Index Component Lube Type Quantity 60 Days 12 Months

250 Hrs 2000 Hrs
L-1 Lift, Tilt and Accessory Lever O As Required Check
Linkage and Pivots (Trucks with
Manual Valve only)
L-2 Brake Pedal Pivot B As Required Check
L-3 Hydraulic Reservoir
Oil D 16.6 Liter (4.4 gal) Check Change
10 micron Filter Element 1 1st Change Change
Suction Strainer 1 Clean
Breather Cap 1 1st Change Change
L-4 Accelerator Potentiometer Pivot O As Required Check
L-5 Accelerator Pedal Pivot O As Required Check
L-6 Brake Potentiometer Pivot O As Required Check
L-7 Tilt Cylinder Pivot B As Required Check
L-8 Armrest Adjustment Pin and Spring B As Required Check
(trucks with EPV only)
L-9 Directional Control Rollers (Trucks B As Required Check
with EPV only)
See Lubrication Identification Chart and Alternate Lubricants & Fluids Chart for lube type designation explana-
tion. Lubrication intervals must be changed to a frequency that will minimise wear on moving shafts and parts
on vehicles used in less desirable operation conditions.
Lubrication intervals for freezer/corrosion trucks must be changed to a frequency that will minimise corrosion
and wear on moving parts.

M1.0-1153-007 SC 5300 Series Crown 2012 PF25680-7

42
 LUBRICATION & ADJUSTMENT
Planned Maintenance

1 Pry cap off to access bearing

Figure 269041

Crown 2012 PF25680-8 SC 5300 Series M1.0-1153-008

43
LUBRICATION & ADJUSTMENT
Planned Maintenance

Chart 2 - Planned Maintenance Lubrication

Index Component Lube Quantity 60 Days 12 Months

Type 250 Hrs 2000 Hrs
L-1 Seat Deck Hinges Q As Required Check
L-2 Adjustment Latch Q As Required Check
L-3 Seat Deck Latch Q As Required Check
L-4 Seat Slides Q As Required Check
L-5 Steer Wheel Bearing B As Required Check
L-6 Drive Unit Oil AAAA 775 mL Check Change
(0.8 quart)
See Lubrication Identification Chart and Alternate Lubricants & Fluids Chart for lube type designation ex-
planation. Lubrication intervals must be changed to a frequency that will minimise wear on moving shafts
and parts on vehicles used in less desirable operation conditions.
Lubrication intervals for freezer/corrosion trucks must be changed to a frequency that will minimise corro-
sion and wear on moving parts.

M1.0-1153-009 SC 5300 Series Crown 2012 PF25680-9

44
 LUBRICATION & ADJUSTMENT
Planned Maintenance

Figure 26905

Crown 2012 PF25680-10 SC 5300 Series M1.0-1153-010

45
LUBRICATION & ADJUSTMENT
Planned Maintenance

Chart 3 - Planned Maintenance Lubrication

Index Component Lube Quantity 60 Days 12 Months

Type 250 Hrs 2000 Hrs
L-1 Lift Chains G As Required Check
L-2 Mast Pulleys H As Required Check
L-3 Mast and Carriage Column Rollers B/E As Required Check
L-4 Mast Channels E As Required Check
L-5 Sideshifter Slide Rail B/E As Required Check
L-6 Fork Locking Pins P As Required Check
L-7 Fork Slide P As Required Check
L-8 Mast Pivots B As Required Check
See Lubrication Identification Chart and Alternate Lubricants & Fluids Chart for lube type designation
explanation. Lubrication intervals must be changed to a frequency that will minimise wear on moving
shafts and parts on vehicles used in less desirable operation conditions.
Lubrication intervals for freezer/corrosion trucks must be changed to a frequency that will minimise
corrosion and wear on moving parts.

M1.0-1153-011 SC 5300 Series Crown 2012 PF25680-11

46
 LUBRICATION & ADJUSTMENT
Planned Maintenance

Figure 25013

Crown 2012 PF25680-12 SC 5300 Series M1.0-1153-012

47
LUBRICATION & ADJUSTMENT
Planned Maintenance

Chart 4 - Planned Maintenance Inspection

Index Component 60 Days

250 Hrs
I-1 Overhead Guard, Secure and No Cracks Check
I-2 Seat Belt, Retainer and Switch Check
I-3 Seat Deck Latch Check
I-4 Gas Struts, Hinges and Mounting Hardware Check
I-5 Battery Connector and Contacts Check
I-6 Battery Retainer Condition Check
I-7 Battery Rollers and Spacers Check
I-8 Battery Restraint Switch (BRES) Check
l-9 Battery Stop Adjustment Check
Refer to the appropriate chapter of service manual for additional information concern-
ing inspection or adjustment.

M1.0-1153-013 SC 5300 Series Crown 2012 PF25680-13

48
 LUBRICATION & ADJUSTMENT
Planned Maintenance

Figure 26907

Crown 2012 PF25680-14 SC 5300 Series M1.0-1153-014

49
LUBRICATION & ADJUSTMENT
Planned Maintenance

Chart 5 - Planned Maintenance Inspection

Index Component 60 Days

250 Hrs
l-1 Strobe, Tail and Work Lights Check
I-2 Horn Switch, Horn and Operation Check
I-3 Travel Alarm and Impact Sensor Check
Refer to the appropriate chapter of service manual for additional information con-
cerning inspection or adjustment.

M1.0-1153-015 SC 5300 Series Crown 2012 PF25680-15

50
 LUBRICATION & ADJUSTMENT
Planned Maintenance

Figure 26908

Crown 2012 PF25680-16 SC 5300 Series M1.0-1153-016

51
LUBRICATION & ADJUSTMENT
Planned Maintenance

Chart 6 - Planned Maintenance Inspection

Index Component 60 Days

250 Hrs
I-1 Control Handle and Switches Check
I-2 Key Switch Check
I-3 Steer Column Pivot, Universal and Adjustment Latch Check
I-4 Steer Command Encoder and Gears Check
I-5 Steer Unit Check
I-6 Armrest Potentiometers, Directional Control, Connections and Wiring Check
(Trucks with EPV only)
l-7 Armrest Horn Switch, Horn and Operation (Trucks with EPV only) Check
1-8 Armrest Adjustment, Pin and Spring (Trucks with EPV only) Check
1-9 EPV Manifold Valves (Trucks with EPV only) Check
1-10 Main and Accessories Relief Valves (RVM and RVA) Operation Check
(Trucks with EPV only)
Refer to the appropriate section of service manual for additional information concerning inspec-
tion or adjustment.

M1.0-1153-017 SC 5300 Series Crown 2012 PF25680-17

52
 LUBRICATION & ADJUSTMENT
Planned Maintenance

Figure 26909

Crown 2012 PF25680-18 SC 5300 Series M1.0-1153-018

53
LUBRICATION & ADJUSTMENT
Planned Maintenance

Chart 7 - Planned Maintenance Inspection

Index Component 60 Days

250 Hrs
I-1 Lift and Accessory Relief Valves (RV1 and RV2) Operation (Trucks with Manual Check
Valve only)
I-2 Tilt Restriction Solenoid Valve (SV1) and Tilt Position Assist Solenoid Valve [(SV3) Check
Trucks with Manual Valve only]
I-3 Accelerator Linkage, Switch Adjustment & Potentiometer Check
I-4 Tilt Cylinders, Mounting & Mounting Hardware Check
I-5 Brake Linkage, Mounting, Potentiometer and Operation Check
I-6 Traction Motors, Mounting Secure Check
I-7 Drive Units Mounting Secure Check
I-8 Drive Tires and Lug Nuts Check
l-9 Operator Presence Manifold Valves (Trucks with Manual Valve Only) Check
1-10 Two Accessories Manifold Valve (Trucks with EPV and Two Accessories only) Check
I-11 Traction Motor Compartment and Steer Column Electrical Connections Cables and Check
Wiring (not shown)
I-12 Traction Motor Compartment Hydraulic Hoses, Tubes and Fittings (not shown) Check
Refer to the appropriate section of service manual for additional information concerning inspection or
adjustment.

M1.0-1153-019 SC 5300 Series Crown 2012 PF25680-19

54
 LUBRICATION & ADJUSTMENT
Planned Maintenance

1 - Pry cap off to access tabbed washers and nut

Figure 26910

Crown 2012 PF25680-20 SC 5300 Series M1.0-1153-020

55
LUBRICATION & ADJUSTMENT
Planned Maintenance

Chart 8 - Planned Maintenance Inspection

Index Component 60 Days

250 Hrs
I-1 Fan Check
I-2 Contactor Tips Check
I-3 Distribution/Relay Panels Check
I-4 Hydraulic Motor, Mounting Secure Check
I-5 Hydraulic Pump Check
I-6 Steer Angle Potentiometer Check
I-7 Steer Axle/Cylinder Check
I-8 Steer Tire, Mounting Secure Check
I-9 Rear Compartment Electrical Connections, Cables and Wiring (not Check
shown)
I-10 Rear Compartment Hydraulic Hoses, Tubes and Fittings (not shown) Check
Refer to the appropriate chapter of service manual for additional information concerning inspec-
tion or adjustment.

M1.0-1153-021 SC 5300 Series Crown 2012 PF25680-21

56
 LUBRICATION & ADJUSTMENT
Planned Maintenance

Figure 26911

Crown 2012 PF25680-22 SC 5300 Series M1.0-1153-022

57
LUBRICATION & ADJUSTMENT
Planned Maintenance

Chart 9 - Planned Maintenance Inspection

Index Component 60 Days

250 Hrs
I-1 Mast and Carriage Column Rollers Check
I-2 Mast Limit Switch (HGST1) Check
I-3 Lift Chains and Anchors Check
I-4 Mast Pulleys Rollers and Bearings Check
I-5 Yoke Check
I-6 Pressure Transducer (PT1) Check
I-7 Brake Air Gap Check
I-8 Mast Channels Check
I-9 Lift Cylinders and Mounting Check
I-10 Mast Stops and Carriage Bumpers Check
Refer to the appropriate chapter of service manual for additional information con-
cerning inspection or adjustment.

M1.0-1153-023 SC 5300 Series Crown 2012 PF25680-23

58
 LUBRICATION & ADJUSTMENT
Planned Maintenance

Figure 26912

Crown 2012 PF25680-24 SC 5300 Series M1.0-1153-024

59
LUBRICATION & ADJUSTMENT
Planned Maintenance

Chart 10 - Planned Maintenance Inspection

Index Component 60 Days

250 Hrs
I-1 Load Backrest Check
I-2 Carriage Check
I-3 Forks Check
I-4 Fork Latches Check
I-5 Sideshifter (Slide, Cylinder, Mounting Hardware, etc) Check
I-6 Mast Pivot Bearings and Mounting Bolts Check
l-7 Control Levers Linkage, Switches and Lift Potentiometer (trucks with
Manual Valve only)
I-8 Mast Hydraulic Lines, Hoses and Fittings (not shown) Check
I-9 Mast Cable and Wiring (not shown) Check
Refer to the appropriate chapter of service manual for additional information concerning inspec-
tion or adjustment.

M1.0-1153-025 SC 5300 Series Crown 2012 PF25680-25

60
 LUBRICATION & ADJUSTMENT
METRIC TORQUE VALUES

Metric Torque Values

All Crown trucks are manufactured with class 8.8 or
better screws and bolts. The information contained in
this section will aid you when replacing any screws and
bolts that are necessary when performing maintenance
on your lift truck.

Grade

Grade Marking Bolt and Screw

Specification Material
(on Head) Size (mm)

Class 5.8 Low Carbon Steel M5 through M36

Medium Carbon Steel

Class 8.8 M5 through M36
Quenched and Tempered

Medium Carbon Alloy Steel

Class 10.9 M5 through M36
Quenched and Tempered

Note: Even though a bolt head is unmarked, Crown uses nothing less than class 8.8 in all of its bolted assem-
blies. Instances do occur when class 8.8 bolts are manufactured unmarked. When a fastener is replaced that
is unmarked, replace the fastener with a class 8.8.

Figure 15048

Crown 1989 PF8514-1 Rev. 12/11 SC 5300 Series M1.9-06.6-001

03 Rev. 12/11
61
LUBRICATION & ADJUSTMENT
METRIC TORQUE VALUES

Torque Chart - Metric Hex Head Cap Screws and Nuts

Thread Diameter Tightening Torque Nm

& Pitch Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 5-8 7-8 8 - 10
M6 x 1.00 8 - 10 12 - 14 15 - 16
M8 x 1.25 20 - 25 28 - 31 34 - 37
M10 x 1.50 39 - 43 56 - 61 68 - 75
M12 x 1.75 71 - 76 100 - 107 119 - 127
M14 x 2.00 113 - 122 159 - 171 190 - 205
M16 x 2.00 175 - 190 247 - 267 296 - 320
M20 x 2.50 340 357 479 - 518 574 - 621
M24 x 3.00 587 - 635 824 - 892 990 - 1071
M30 x 3.50 1175 - 1274 1654 - 1792 1985 - 2150
Note: Torque values called out in the maintenance section of this manual will take precedence over torque
values found on this page.

Torque Chart - Metric Hex Socket Countersink Head Screws

Thread Diameter Tightening Torque Nm (ft lb)

& Pitch Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 4-7 5-8 7 - 10
M6 x 1.00 7 - 10 9 - 12 11 - 14
M8 x 1.25 16 - 19 23 - 26 27 - 30
M10 x 1.50 31 - 34 45 - 49 54 - 58
M12 x 1.75 56 - 60 79 - 84 94 - 102
M14 x 2.00
M16 x 2.00 124 - 146 190 - 206 228 - 247
M20 x 2.50 259 - 281 363 - 395 437 - 473
M24 x 3.00 416 - 451 586 - 635 702 - 762
M30 x 3.50
Note: Torque values called out in the maintenance section of this manual will take precedence over torque
values found on this page.

M1.9-06.6-002 SC 5300 Series Crown 1989 PF8514-2 Rev. 12/11

03 Rev. 12/11
62
 LUBRICATION & ADJUSTMENT
METRIC TORQUE VALUES

Torque Chart - Metric Socket Head Cap Screws

Thread Diameter Tightening Torque Nm

& Pitch Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 5-8 7-9 8 - 11
M6 x 1.00 9 - 12 12 - 15 15 - 18
M8 x 1.25 22 - 24 30 - 33 35 - 38
M10 x 1.50 42 - 45 58 - 64 71 - 76
M12 x 1.75 72 - 77 102 - 110 122 - 132
M14 x 2.00 115 - 125 161 - 175 194 - 210
M16 x 2.00 179 - 194 251 - 273 301 - 327
M20 x 2.50 348 - 377 489 - 530 588 - 637
M24 x 3.00 601 - 651 846 - 915 1014 - 1098
M30 x 3.50 1196 - 1296 1681 - 1822 2017 - 2187
Note: Torque values called out in the maintenance section of this manual will take precedence over torque
values found on this page.

Torque Chart - Metric Flanged Hex Head Cap Screws and Nuts

Thread Diameter Tightening Torque Nm

& Pitch Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 5-8 8 - 11 9 - 12
M6 x 1.00 9 - 12 14 - 16 16 - 19
M8 x 1.25 22 - 24 31 - 34 38 - 41
M10 x 1.50 44 - 48 62 - 68 75 - 81
M12 x 1.75 77 - 83 108 - 117 130 - 141
M14 x 2.00 123 - 134 174 - 187 209 - 225
M16 x 2.00 193 - 210 273 - 294 327 - 354
Note: Torque values called out in the maintenance section of this manual will take precedence over torque
values found on this page.

Crown 1989 PF8514-3 Rev. 12/11 SC 5300 Series M1.9-06.6-003

03 Rev. 12/11
63
LUBRICATION & ADJUSTMENT
Torque Values

Torque Values
All Crown Trucks are manufactured with Grade 5 or
better screws and bolts. The information contained in
this section will aid you when replacing any screws and
bolts that are necessary when performing maintenance
on your lift truck.

Grade

Grade Marking Bolt and Screw Size

Specification Material
(on Head) (Inches)

SAE - Grade 2 Low Carbon Steel 1/4 thru 1-1/2

Medium Carbon Steel,

SAE - Grade 5 1/4 thru 1-1/2
Quenched and Tempered

Medium Carbon Alloy Steel,

SAE - Grade 8 1/4 thru 1-1/2
Quenched and Tempered

Note: Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all of its bolted assem-
blies. Instances do occur when Grade 5 bolts are manufactured unmarked. When a fastener is replaced that is
unmarked, replace the fastener with a Grade 5.

Figure 14916

M1.9-14.0-001 SC 5300 Series Crown 1979 PF5067-1 Rev. 9/06

04 Rev. 9/06
64
 LUBRICATION & ADJUSTMENT
Torque Values

Torque Chart

Bolt Grade 5 Grade 8

Diameter Dry Torque Requirement Dry Torque Requirement
in ft Ib kgm Nm ft lb kgm Nm
1/4 9±3 1.2 ± 4 12 ± 4 13 ± 4 1.8 ± 5 17.5 ± 5.5
5/16 18 ± 5 2.5 ± 7 24.5 ± 7 25 ± 5 3.5 ± 7 34 ± 7
3/8 32 ± 5 4.4 ± 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
Mounting bolt torque requirements in-
volving hydraulic valves.

5/16 13 ± 2 1.8 ± 3 17.5 ± 2.5

3/8 24 ± 2 3.3 ± 3 32.5 ± 2.5
7/16 39 ± 2 5.4 ± 3 53 ± 2.5
Note: Torque values called out in the maintenance section of this manual will take precedence over
torque values found on this page.

Crown 1979 PF5067-2 Rev. 9/06 SC 5300 Series M1.9-14.0-001

04 Rev. 9/06
65
Notes:

66
COMPONENTRY
67
Notes:

68
 COMPONENTRY
Componentry

Componentry
The electrical and hydraulic components in this section
are listed alphabetically and include the information be-
low:
• Component designator (i.e., ALM2) that is on the
wiring diagram, hydraulic schematic,
Access 1 2 3® menu and parts pages.
• Description
• Location of the component on the truck
• Purpose of the component
• Technical data
• Adjustments, if applicable
• Wiring diagram or hydraulic schematic page(s) the
component appears.
• Parts page that the component appears. One addi-
tional number immediately follows the parts page
number. This number (in parenthesis) is the index
number of the (i.e., 04.0-1153-050 (9)).

Crown 2012 PF25671-1 SC 5300 Series M1.91-1153-001

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COMPONENTRY
Audible Indicators

Audible Indicators EPV Diagrams: DIA-1153-003

DIA-1153-012
ALM1 Manual Valve Diagrams: DIA-1153-009
DIA-1153-026
Status Alarm Parts Breakdown: 04.0-1153-050 (13)
Location: internal to ACCESS 1 04.0-1153-100 (13)
Purpose: alerts the operator of improper operator se-
quence or when the display logs an Event. The alarm
will sound briefly when the truck is turned ON.
Data: controlled by ACCESS 1. View ALM1 status from
ANALYZER, A3.1.1 menu. Test ALM1 from ANA-
LYZER, A4.1.2 menu.
Adjustment: N/A
EPV Diagrams: DIA-1153-003
DIA-1153-008
Manual Valve Diagrams: DIA-1153-020
DIA-1153-025
Parts Breakdown: not available

ALM2 (optional)
Travel Alarm
Location: traction motor compartment, mounted on
the right side of power unit below the traction motor
Purpose: alerts pedestrians of truck movement
Data: controlled by ACCESS 3. ACCESS 3 provides
+BV and negative to ALM2. View ACCESS 3 output to
ALM2 from ANALYZER, A3.3.3 menu. Test ACCESS 3
output to ALM2 from ANALYZER, A4.3.3 menu.
Adjustment: can be set from FEATURES, F20.2 menu
to sound during forward travel, reverse travel or all
travel. Alarm can also be disabled in F20.2.
EPV Diagrams: DIA-1153-010

Manual Valve Diagrams: DIA-1153-026

Parts Breakdown: 04.0-1153-050 (9)

04.0-1153-100 (9)

HN1
Horn
Location: traction motor compartment. The horn
mounts near where the brake pedal pivots.
Purpose: provide operator controlled audible warning
Data: receives +BV from battery when horn switch
HNS is closed. BNEG is supplied to horn when the bat-
tery is connected.
Adjustment: N/A

M1.91-1153-002 SC 5300 Series Crown 2012 PF25671-2

70
 COMPONENTRY
Audible Indicators

1 The Figure shows ACCESS 1.

ALM is internal ACCESS 1.

FIgure 26829

Crown 2012 PF25671-3 SC 5300 Series M1.91-1153-003

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COMPONENTRY
Brakes

Brakes
BRK1
Right Brake
Location: right traction motor
Purpose: provide braking force to right traction motor
to stop the truck during a hard brake application. The
brake prevents movement when the truck is parked.
Data: coil resistance is 7 to 10 Ω at 22 °C. Electrically
released and spring applied. ACCESS 1 controls the
brake. ACCESS 1 supplies positive and negative to
BRK1. View ACCESS 1 outputs to BRK1 from ANA-
LYZER, A3.1.2. Test ACCESS 1 output to BRK1 from
ANALYZER, A4.1.3 menu.
Adjustment: refer to Brake section of service manual
EPV Diagrams: DIA-1153-003
DIA-1153-008
Manual Valve Diagrams: DIA-019
DIA-1153-025
Parts Breakdown: 05.3-1152-001

BRK2
Left Brake
Location: left traction motor
Purpose: provide braking force to left traction motor to
stop the truck during a hard brake application. The
brake prevents movement when the truck is parked.
Data: coil resistance is 7 to 10 Ω at 22 °C.Electrically
released and spring applied. ACCESS 1 controls the
brake. ACCESS 1 supplies positive and negative to
BRK2. View ACCESS 1 outputs to BRK2 from ANA-
LYZER, A3.1.3. Test ACCESS 1 output to BRK2 from
ANALYZER, A4.1.4 menu.
EPV Diagrams: DIA-1153-003
DIA-1153-008
Manual Valve Diagrams: DIA-1153-020
DIA-1153-025
Parts Breakdown: 05.3-1152-001(661)

M1.91-1153-004 SC 5300 Series Crown 2012 PF25671-4

72
 COMPONENTRY
Contactors

Contactors
L
Line Contactor
Location: rear truck compartment, controller panel
Purpose: line contactor tips provide +BV to
ACCESS 3 and ACCESS 2 power circuit
Data: controlled by ACCESS 3. ACCESS 3 provides
24 V and negative to L contactor coil. Coil is sup-
pressed internally to absorb voltage from collapsing
magnetic field when de-energizing and is polarity sen-
sitive. Coil resistance is approximately 55 Ω. View
ACCESS 3 output to L contactor coil from ANALYZER,
A3.3.1 menu. Test ACCESS 3 output to L coil from AN-
ALYZER, A4.3.1 menu.
Adjustment: N/A
EPV Diagrams:
Coil: DIA-1153-003
DIA-1153-004
Contacts: DIA-1153-003
DIA-1153-017

Manual Valve Diagrams:

Coil: DIA-1153-020
DIA-1153-021
Contacts: DIA-1153-020
DIA-1153-033

Parts Breakdown: 04.1-1153-050 (19)

04.4-2045-001

Crown 2012 PF25671-5 SC 5300 Series M1.91-1153-005

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COMPONENTRY
Contactors

Figure 26830

M1.91-1153-005 SC 5300 Series Crown 2012 PF25671-6

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 COMPONENTRY
Control Modules

Control Modules ACCESS 3

Traction Control Module
ACCESS 1
Location: rear truck compartment, controller panel
Display Control Module Purpose: controls the traction system, line contactor,
Location: truck dash ACCESS 3 cooling fan and travel alarm (option) oper-
Purpose: display pertinent truck information to opera- ation
tor or service technician, allows technician to modify Data: N/A
truck settings, calibrate components and troubleshoot. Adjustment: if module is replaced, complete truck cal-
During truck operation ACCESS 1 energises the brake ibration is recommended to prevent nuisance codes.
coils, floorboard fan, pressure transducer, steer com- Also if replacement module includes updated software,
mand encoder, solenoid valve lower (EPV only) and the software in the remaining modules must be up-
solenoid valve bypass (EPV only). dated so all software is compatible.
Data: N/A EPV Diagrams: DIA-1153-003
Adjustment: if module is replaced, complete truck cal- DIA-1153-006
ibration is recommended to prevent nuisance codes. DIA-1153-017
Also if replacement module includes updated software,
the software in the remaining modules must be up- Manual Valve Diagrams: DIA-1153-020
dated so all software is compatible. DIA-1153-023
EPV Diagrams: DIA-1153-003 DIA-1153-033
DIA-1153-008
Parts Breakdown: 04.1-1153-050 (26)
Manual Valve Diagrams: DIA-1153-020
DIA-1153-025 ACCESS 7 (EPV Only)
Accessory Control Module
Parts Breakdown: 04.0-1153-001 (7)
Location: traction motor compartment, mounts above
ACCESS 2 the double accessory manifold
Purpose: during truck operation, ACCESS 7 ener-
Hydraulic Control Module gises the 2nd accessory solenoid proportional valves
Location: rear truck compartment, controller panel and solenoid valve load sense dump
Purpose: controls the hydraulic system operation ex- Data: N/A
cept the 2nd accessory solenoid proportional valves Adjustment: if module is replaced, complete truck cal-
(EPV only) and solenoid valve load sense dump (EPV ibration is recommended to prevent nuisance codes.
only) Also if replacement module includes updated software,
Data: N/A the software in the remaining modules must be up-
Adjustment: if module is replaced, complete truck cal- dated so all software is compatible.
ibration is recommended to prevent nuisance codes. Diagrams: DIA-1153-003
Also if replacement module includes updated software, DIA-1153-009
the software in the remaining modules must be up- Parts Breakdown: 04.0-1153-100 (26)
dated so all software is compatible.
EPV Diagrams: DIA-1153-003
DIA-1153-007
DIA-1153-0017

Manual Valve Diagrams: DIA-1153-020

DIA-1153-024
DIA-1153-033
Parts Breakdown: 04.1-1153-050 (2)

Crown 2012 PF25671-7 SC 5300 Series M1.91-1153-006

75
COMPONENTRY
Control Modules

FIgure 26831

M1.91-1153-007 SC 5300 Series Crown 2012 PF25671-8

76
 COMPONENTRY
Control Modules

DR1
Parts Breakdown: 10.0-1152-050 (1)
Rear Light Driver
Location: tie strapped to the wire harness located
above the left traction motor
Purpose: rear light and switch interface, provides
power to rear light
Data: +BV is provided from the battery when the rear
light switch LGS2 is closed. BNEG is supplied when
the battery is connected.
Adjustment: N/A
EPV Diagrams: DIA-1153-013
DIA-1153-014

Manual Valve Diagrams: DIA-1153-029

DIA-1153-030

Parts Breakdown: 04.0-1153-050 (see end of parts

list)

DR2 (EPV Only - Not Shown)

Floorboard Fan Driver
Location: tie strapped to the floorboard fan (FAN3)
wire harness
Purpose: floorboard fan and switch interface, provides
power to fan
Data: controlled by ACCESS 1. ACCESS 1 provides
positive to DR2 when traction motor(s) temperature is
greater than 100 °C, positive is removed when traction
motor(s) temperature is less than 80 °C. BNEG is pro-
vided to DR2 when the battery is connected.
Adjustment: N/A
EPV Diagrams: DIA-1153-001

Parts Breakdown: 04.0-1152-050 (see end of parts

list)

INFOLINK DISPLAY MODULE (Op-

tion)
Location: overhead guard
Purpose: monitors truck functions and impacts, re-
quires pre-operational truck check; if equipped with
proximity reader requires operator login authorization
Data: N/A
Adjustment: N/A
EPV Diagrams: DIA-1153-016

Manual Valve Diagrams: DIA-1153-032

Crown 2012 PF25671-9 SC 5300 Series M1.91-1153-009

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COMPONENTRY
Control Modules

1 InfoLink display module

Figure 26832

M1.91-1153-009 SC 5300 Series Crown 2012 PF25671-10

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 COMPONENTRY
Cylinders

Cylinders Sideshift Cylinder

Location: sideshift carriage
Carriage Cylinder Purpose: sideshift forks (carriage)
Location: inner TT, TF and Quad mast Data: N/A
Purpose: raise fork carriage Adjustment: N/A
Data: N/A EPV Diagrams: HYD-1153-002 (12)
Adjustment: N/A
EPV Diagrams: HYD-1153-002 (15) Manual Valve Diagrams: HYD-1153-001 (11)
HYD-1153-003 (15)
Parts Breakdown: 08.7-1030-001
Manual Valve Diagrams: HYD-1153-001 (16)
Steer Actuator
Parts Breakdown: 08.3-1153-050 Location: steer axle
08.34-1030-052 Purpose: rotate steer axle
Mast Cylinder Data: N/A
Adjustment: N/A
Location: outer (1st stage) mast
EPV Diagrams: HYD-1153-002 (8)
Purpose: raise inner mast stages
HYD-1153-003 (8)
Data: N/A
Adjustment: N/A Manual Valve Diagrams: HYD-1153-001 (8)
EPV Diagrams: HYD-1153-002 (13, 14)
HYD-1153-003 (13, 14) Parts Breakdown: 06.0-1140-052 (7 through 12, 22,
23)
Manual Valve Diagrams: HYD-1153-001 (14, 15)
Tilt Cylinder
Parts Breakdown: 08.3-1153-001 Location: traction motor compartment
08.3-1153-100 Purpose: tilt mast and forks
08.34-1030-001
Data: N/A
Adjustment: N/A
EPV Diagrams: HYD-1153-002 (10, 11)
HYD-1153-003 (10, 11)

Manual Valve Diagrams: HYD-1153-001 (9, 10)

Parts Breakdown: 08.6-1152-001

Crown 2012 PF25671-11 SC 5300 Series M1.91-1153-010

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COMPONENTRY
Cylinders

1 Carriage cylinder
2 Mast cylinder
3 Sideshift cylinder
4 Steer cylinder
5 Tilt cylinder

Figure 26833

M1.91-1153-011 SC 5300 Series Crown 2012 PF25671-12

80