HYDRAULIC

Manifold Blocks

Manifold Blocks

CAUTION
Contamination in the hydraulic system can cause se-
vere damage to the system. Do all hydraulic system
maintenance in a clean work area. Keep the compo-
nents as clean as possible during maintenance. Hy-
draulic oil added to the system must be clean and
strained as described in Adding Hydraulic Oil in the Hy- 1
draulic System section.

NOTE
In this section, there are circumstances which require
the collection of hydraulic oil that may leak or be re-
moved from components. Be prepared to catch hy-
draulic oil with a catch pan or absorbent material. Do
not reuse hydraulic oil. Obey applicable laws and envi-
ronmental standards when disposing of used hydraulic
oil.

Hoist Manifold
Refer to Figure 26569.
The hoist manifold (1) is installed in the traction motor
compartment. This manifold directs oil flow from port P
across SVL to the lift cylinders. Refer to the Hydraulic
Circuits section for data on the hoist raise and lower Figure 26569
circuit.
Other components found on the hoist manifold are as
follows:

• Port G1 contains a male quick-disconnect fitting to

connect a pressure gauge. Use this port to read the
pressure in the hoist circuit to adjust RV1.

• Use MVL to manually lower the hoist only in the

event of an emergency or during service when it is
necessary.

• LS is a load pressure transducer which supplies an

analog signal to ACCESS 4 to calculate the weight
on the forks.

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Relief Valve (RV1) 2. Install a device to measure the oil temperature or

RV1 gives protection to the hoist circuit from too much
oil pressure. If pressure in the system is more than the
set value for the relief valve, the valve opens. It sends
oil to the reservoir to release pressure, and holds the
maximum pressure for the circuit.
RV1 is set at the factory.
To measure for correct operation do the steps that fol-
low:
1. Connect a 0-15 bar (0-5000 psi) pressure gauge to
the G1 test port of the hoist manifold.
use an infrared thermometer.
3. Operate the hoist function to the full mast exten-
sion for full flow oil to go through the relief valve.
Record the RV1 pressure.
4. When the oil temperature is in the specified tem-
perature range, the pressure value must fall in the
range supplied in the RV1 Pressure Range chart.
5. If the pressure is not in the correct range, adjust
RV1.
6. If the adjustment of RV1 does not correct the pres-
sure, replace RV1.

RV1 Pressure Range

Oil Temperature Pressure

Hydraulic Fluid
C° F° mPa psi
Standard 27 - 60 80 - 140 21.96 - 22.17 3185-3215
Freezer/Corrosion 21 - 38 70 - 100 21.96-22.17 3185-3215

Accessory Manifold
Refer to Figure 26442.
The accessory manifold (1) is located near the acces-
sory pump motor under the console cover. This mani-
fold directs oil flow from port P2 across SVA to the ac-
cessory hydraulic system. Refer to the Hydraulic 1
Circuits section for detailed information on the acces-
sory manifold circuit.
Other components located on the accessory manifold
block are as follows:

• Port G2 contains a male quick disconnect fitting so

that a pressure gauge can be connected to read
the pressure in the accessory system to adjust
RV2. Figure 26442

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Relief Valve (RV2) 2. Install oil temperature measuring instrumentation

A relief valve (RV2) protects the accessory circuit
(reach, tilt, sideshift) from excessive oil pressure. If
pressure in the system exceeds the relief valve preset
level, the valve opens and relieves pressure by direct-
ing oil to the reservoir thus maintaining the maximum
pressure limit for the circuit.
RV2 is adjustable and factory preset.
To check relief valve (RV2) operation complete these
steps:
1. Connect a 0-15 bar (0-5000 psi) pressure gauge to
the G2 test port of the accessory manifold block.
or use an infrared thermometer.
3. Record the RV2 pressure when passing full flow
over the relief by operating the reach function into
the reach extend limit.
4. When the oil temperature is within the specified
temperature range, the pressure reading should
fall in the range given in the RV2 Pressure Range
chart.
5. If the pressure falls outside of this range, adjust
RV2.
6. If the adjustment of RV2 does not result in the cor-
rect pressure, replace RV2.

RV2 Pressure Range

Oil Temperature Pressure

Hydraulic Fluid
C° F° mPa psi
Standard 27 - 60 80 - 140 11.72 - 12.41 1700 - 1800
Freezer/Corrosion 21 - 38 70 - 100 11.72 - 12.41 1700 - 1800

Reach Manifold Assembly

Refer to Figure 24715-01.
1 2
The reach manifold assembly is (1) is located on the
lower-right side of the rear reach carriage. This mani-
fold directs oil from the accessory manifold through
SVR, and then to and from the reach cylinders. Two
counterbalance valves are installed in the manifold.
The counterbalance valves prevent the reach mecha-
nism from moving faster than it should in relation to the
SVR
amount of oil flowing through the circuit.

Figure 24715-01

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Manifold Blocks
Tilt/Sideshift Manifold Assembly
Refer to Figure 24715-01.
The tilt/sideshift manifold assembly (2) is located under
a cover on the front of the reach carriage. The tilt/side-
shift manifold assembly contains SVS and SVT. This
manifold directs oil from the reach manifold assembly
through the tilt/sideshift manifold to the tilt and sideshift
cylinders.
Manifold Block O-Ring Replacement
This section is applicable to various manifold blocks on
the truck.
Prepare the truck
1. Lower the carriage to the floor.
2. Open MVL to relieve hydraulic pressure.
3. Lockout/Tagout the truck.
Remove the manifold block
NOTE
During the entire procedure it is extremely important to
keep work surfaces and parts as clean as possible to
avoid contamination.
4. Remove all hydraulic hoses and lines from the
manifold block.
5. Cap the lines and hoses with plugs to avoid oil
leakage and contamination.
6. Remove the manifold block from the truck and
place it on a clean piece of cardboard in a clean
work area.
Check the manifold block
7. Remove all valves from the manifold block and
place them on a clean piece of cardboard.
8. Visually check the adapters, valves, valve seals,
and valve cavities for any signs of defects or con-
tamination.
9. Check the operation of each valve mechanism for
sticking or rough operation.
10. If any valves are contaminated or do not function
properly, discard the valve and replace with a new
valve. If contamination is found in the manifold, re-
fer to Manifold Block Removal and Flushing for fur-
ther information.
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O-Ring replacement in seal kits
11. O-ring seal kits are available from Crown for the
RV2, MVL, CV4 and SVA. Remove the top (cap)
O-ring seal from each valve. The top O-ring (cap)
seal will be the one closest to the outside surface
of the manifold block after the valve is installed in
the manifold block.
12. Cover the threads on each valve with a sleeve or
tape to prevent damage to the new seal.
13. Carefully replace the top O-ring seals as supplied
in the seal kits.
Check remaining O-Rings
14. Visually check all other O-ring seals and back-up
rings. Replace as needed. These O-rings are not
part of seal kits, but are available from Crown. Re-
fer to the appropriate parts page for part numbers.
Adaptors and valves
15. Apply a light film of hydraulic oil to the O-ring and
threads of each adapter and valve before installing
it into the manifold block.
16. Install each valve into the manifold block by hand
until snug. Refer to the applicable parts page for
valve placement diagrams. Refer to the Torque
Values chart for the torque values of individual
valves and plugs.
Manifold block installation
17. Install the manifold block on the truck.
18. Remove all plastic plugs and caps and connect all
hydraulic lines and hoses as removed from the
manifold block.
19. Check the oil level in the hydraulic reservoir. Add
hydraulic oil as necessary.
20. Follow the steps in Hydraulic Systems - Mast Ac-
cessory Hose Bleeding and Reach Carriage
Bleeding to flush any air from the system.
21. Check for leaks and verify proper truck operation
before you return the truck to service.
Crown 2011 PF25592-4

Manifold Block Removal and
Flushing
If contamination inside the accessory manifold block is
extensive, replace the manifold block. Complete infor-
mation on Hydraulic System Contamination is located
in Hydraulic System - Hydraulic System Contamina-
tion.
This section is applicable to the various manifold
blocks on the truck.
CAUTION
Do not put the manifold block or components into a de-
greaser tank to clean. Do not reuse spilled or contami-
nated oil.
1. If you have already completed the steps in Hydrau-
lic System - Hydraulic System Flushing, skip to
Step 5. Otherwise, fully lower the carriage to the
floor.
Prepare the truck
2. Lower the carriage to the floor.
3. Open MVL to relieve hydraulic pressure.
4. Lockout/Tagout the truck.
Remove the manifold block
NOTE
During the entire procedure it is extremely important to
keep work surfaces and parts as clean as possible to
avoid contamination.
5. Remove all hydraulic hoses and lines from the
manifold block.
6. Cap the lines and hoses with plugs to avoid oil
leakage and contamination.
Check the manifold components
7. Remove all valves from the manifold block and
place them on a clean piece of cardboard.
8. Make a visual inspection of the adapters, valves,
valve seals, and valve cavities for any signs of de-
fects or contamination.
9. Check the operation of each valve mechanism for
sticking or rough operation. If any valves are con-
taminated or do not function properly, discard the
valve and replace with a new valve.
Crown 2011 PF25592-5
HYDRAULIC
Manifold Blocks
NOTE
To avoid damage when using a siphon sprayer to clean
the valves and ports, or a compressed air nozzle to
remove moisture from the manifold block, do not ex-
ceed 2.75 bar (40 psi).
10. Thoroughly clean each adapter and valve using a
siphon sprayer, Crown part number 065174-001,
and a water based degreaser, Crown part number
063009-005.
11. After cleaning a valve, blow all liquid from the valve
with an air nozzle. Check the valve operation and
place the valve in a clean, lint free location.
NOTE
Be careful not to damage the hex hole or the plug by
using excessive force.
12. Remove any SAE plugs from the manifold block. It
sometimes helps to tap the top of the plugs using a
small hammer and a large diameter (6.5 mm
[0.25 in]) flat punch prior to loosening them with a
wrench.
13. Check each port for contamination.
Flush the manifold block
14. Place the manifold block in a clean container for
flushing.
15. Use the sprayer and water based degreaser to
thoroughly flush each port on the manifold block.
16. Remove the manifold block from the wet container.
17. Place the manifold block into a clean, dry con-
tainer.
18. Use a compressed air nozzle to blow air over and
through the manifold block to completely remove
all moisture. It is very important that the inside and
outside of the manifold block is thoroughly dry and
clean.
19. Check each port on the manifold block with a flash-
light for any remaining contamination. If contami-
nation is found, flush and dry the manifold block a
second time as described above.
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Manifold Blocks

Manifold block assembly

20. Replace the O-rings as described in Manifold
Block O-Ring Replacement.
21. Install each valve into the manifold block by hand
until snug. Refer to the applicable parts page for
valve placement diagrams. Refer to the Torque
Values chart for the torque values of individual
valves and plugs.

Manifold block installation

22. Install the manifold block on the truck.
23. Remove all plastic plugs and caps and connect all
hydraulic lines and hoses as removed from the
manifold block.
24. Check the oil level in the hydraulic reservoir. Add
hydraulic oil as necessary.
25. Follow the steps in Hydraulic Systems - Mast Ac-
cessory Hose Bleeding and Reach Carriage
Bleeding to flush any air from the system.
26. Check for leaks and verify proper truck operation
before you return the truck to service.

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Manifold Blocks

Manifold Block Torque Values

Cartridge Torque Coil Nut Torque

Reference Designator Location
Nm ft lb Nm ft lb
5/16 Plug Manifold on Top of Reach Carriage 7-8 5-6 N/A N/A
7/16 Plug Tilt/Sideshift, Hoist, & Accessory Manifold 14 - 15 10 - 11 N/A N/A
9/16 Plug Hoist Manifold 23 - 24 17 - 18 N/A N/A
CBV Reach Manifold 41 - 47 30 - 35 N/A N/A
CV4 Accessory Manifold 27.12 20 N/A N/A
LS Hoist Manifold 18 - 22 13 - 16 N/A N/A
MVL Hoist Manifold 27.12 20 N/A N/A
Port A1 & B1 Adapters Reach Manifold 23 - 24 17 - 18 N/A N/A
Port A1 & B1 Adapters Tilt/Sideshift Manifold 14 - 15 10 - 11 N/A N/A
Port A & B Adapters Reach & Accessory Manifold 23 - 24 17 - 18 N/A N/A
Port C Tee Hoist Manifold 69 - 76 51 - 56 N/A N/A
Port G1 Nipple Hoist Manifold 14 - 15 10 - 11 N/A N/A
Port P Adapter Hoist Manifold 69 - 76 51 - 56 N/A N/A
Port P2 Adapter Accessory Manifold 23 - 24 17 - 18 N/A N/A
Port R1 & R2 Adapters Manifold on Top of Reach Carriage 18 - 20 13 - 15 N/A N/A
Port RA Adapter Manifold on Top of Reach Carriage 23 - 24 17 - 18 N/A N/A
Port RA Adapter Reach Manifold 14 - 15 10 - 11 N/A N/A
Port RB Adapter Manifold on Top of Reach Carriage 23 - 24 17 - 18 N/A N/A
Port RB Adapter Reach Manifold 14 - 15 10 - 11 N/A N/A
Port SS1 Adapters Tilt/Sideshift Manifold 14 - 15 10 - 11 N/A N/A
Port SS2 Adapter Tilt/Sideshift Manifold 14 - 15 10 - 11 N/A N/A
Port T Adapter Hoist Manifold 41 - 43 30 - 32 N/A N/A
Port T1 Adapter Tilt/Sideshift Manifold 14 - 15 10 - 11 N/A N/A
Port T2 Adapter Tilt/Sideshift Manifold 14 - 15 10 - 11 N/A N/A
RV1 Hoist Manifold 62 - 73 46 - 54 N/A N/A
RV2 Accessory Manifold 27.12 20 N/A N/A
SVA Accessory Manifold 27.12 20 6.80 5
SVL Hoist Manifold 68 50 6.80 5
SVR Reach Manifold 26 - 28 19 - 21 5-8 4-6
SVS Tilt/Sideshift Manifold 20 - 23 15 - 17 5-8 4-6
SVT Tilt/Sideshift Manifold 20 - 23 15 - 17 5-8 4-6

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