C MANIFOLD

RR/RD 5200/5200S
RR/RD 5200(AC)/5200S(AC)
RELIEF VALVE #1 & #2 (RV1 & RV2)
Operation

The lift circuit is protected from excessive oil pressure by
RV1 and the accessory (reach, tilt, etc.) circuit is protected
by RV2. If pressure within the circuit exceeds the relief valve
preset level, the valve will open and relieve pressure by
directing oil to the reservoir thus maintaining a maximum
pressure limit for the circuit.
4. Tighten jam nut when adjustment is correct and re-
check pressure setting. Readjust if necessary.
RV2
RV2 is not adjustable. To check for proper operation:

C
1
1. Connect a 0 to 35 mPa/0 to 5000 psi. pressure gauge
Test Port to the test port of the manifold. Insert thermometer in
RV2 T
1

C
H
(Quick hydraulic oil.
P

2
Disconnect)
V
R
2 B
T A

V
A
2. Place a 2750 kg/6000 lb. load on forks. Depress and
P

S
V
A
hold tilt back switch on multi task handle. Keep mast in
C
C
V full tilt back position while reading gauge. Pressure
V
4
1
V
P
C
V
6
RV1
S

reading must be taken while passing full flow over relief

valve. Pressure range is:

Oil Temperature Pressure

C˚ F˚ mPa PSI
6479-02 ILLUSTRATION 1
20 to 32 70 to 90 11.65 to 12.35 1690 to 1790
38 to 60 100 to 140 11.40 to 12.05 1650 to 1750
Adjustment
PROPORTIONAL VALVES PVA & PVH
A fully charged battery should be installed in the truck and all
truck calibration and feature configuration should be com-
If PVA and PVH are replaced, valves must be calibrated. To
pleted before attempting any measurements or adjustments.
calibrate, refer to section M4.3.
RV1 1
C

1
T
To adjust RV1: H
C
P

2
V
1. Connect a 0 to 35 mPa/0 to 5000 psi. pressure gauge R
T
2 B
A

to the test port of the manifold. Insert thermometer in V

A
P
V
A

PVA
S

hydraulic oil. C
C V
V 1 6
4 V
P V
S C

2. Place a 2750 kg/6000 lb. load on forks. Hold control PVH

lever in the full raise position while reading gauge.
Pressure reading must be taken while passing full flow
over relief valve with all pumps operating. Pressure
range is:
6481-02 ILLUSTRATION 2

Oil Temperature Pressure

C˚ F˚ mPa PSI
20 to 32 70 to 90 22.40 to 22.75 3250 to 3300
38 to 60 100 to 140 21.70 to 22.05 3150 to 3200

3. If relief valve setting is not within required range, loosen

jam nut on RV1 and adjust valve.

010328 3952 - EO4538

Crown 2001 PF13007-1 Rev. 10/02 Printed in U.S.A.
01 REV. 10/02
M2.4–1452–001 M2.4–1452–001
 C MANIFOLD
Manifold Block O-Ring Replacement
1. Remove console on 5200 series trucks or open side
panel covering manifold block on 5200S series trucks.
2. Open Manual Lowering Valve (MVL) on manifold block
to relieve system pressure. See Illustration 3.
WARNING
AVOID HIGH PRESSURE FLUIDS – Escaping
fluid under high pressure can penetrate the skin
causing serious injury. Relieve pressure before
disconnecting hydraulic lines. Tighten all con-
nections before applying pressure. Keep hands
and body away from pin holes which eject fluids
under high pressure. Use a piece of cardboard or
paper to search for leaks. Do not use your hand.
Any fluid injected into the skin under high pres-
sure should be considered as a serious medical
emergency despite an initial normal appearance
of the skin. There is a delayed onset of pain and
serious damage may occur. Medical attention
should be sought immediately by a specialist who
has had experience with this type of injury.
MVL - Manual Lowering Valve
10. Apply a light film of hydraulic oil to threads of all the
11. Install each valve into manifold block by hand until
7815P ILLUSTRATION 3
12. Refer to Illustration 7 for valve and plug placement and
3. Remove all hydraulic hoses and lines from manifold
block, cap lines and hoses with plastic plugs to avoid oil
leakage and contamination. Catch any oil that may be
spilled.
4. Loosen accessible cartridge valves while the manifold
block is still in the truck, do not remove any of the valves
at this time.
Crown 2001 PF13007-2
M2.4–1452–002
5. Remove manifold block from truck and place on a clean
piece of cardboard in a clean area to avoid contamina-
tion while disassembling, as shown in Illustration 4.
7. Remove all valves from manifold block and place on a
clean piece of cardboard. During the entire disassem-
bly, replacement of o-rings, putting valves back into
manifold, and proper torque of valves, it is extremely
important to keep work surfaces and parts as clean as
possible to avoid contamination. Check to make sure
ORF4 is removed from SVP cavity, refer to Illustration
5, this is the only orifice that is not screwed into the
block. Do not remove any of the other orifices or SAE
plugs from the block.
8. Make a visual inspection of valves and valve cavities
for any signs of contamination. Check operation of
valve mechanisms for sticking or rough operation as
seen in Illustration 6. If any valves are contaminated or
do not function properly, discard valve and replace with
new valve.
9. Remove top (cap) o-ring from each valve, cover threads
on valve with sleeve or tape to prevent damage to
replacement o-ring, and carefully replace top o-ring.
The top o-ring (cap) will be the one closest to the
outside surface of the manifold block after the valve is
installed in the manifold block. Visually inspect all other
o-ring and back-up rings, replace as required. Refer to
Chart 1 for o-ring usage.
valves before installing into the manifold block. When
installing ORF4 and SVP in cavity, spread a clean light
grease on FLAT side of ORF4 and stick on nose of
SVP, then carefully insert into cavity. This will properly
orient ORF4 and prevent it from changing position
during installation.
snug.
Chart 2 for torque values of valves and plugs. Torque
each valve to the value given. If using a crows foot or
other extension, position it at 90° to torque wrench
handle to keep torque value same as torque wrench
setting.
Printed in U.S.A.
M2.4–1452–002
 C MANIFOLD

Note Visible Contamination

On Valve Screen

7932P
ILLUSTRATION 4

7934P
ILLUSTRATION 6

ORF4

7933P
ILLUSTRATION 5

Crown 2001 PF13007-3 Printed in U.S.A.

M2.4–1452–003 M2.4–1452–003
 C MANIFOLD

RV2 PCH

#10
#6 #4
#4
Part of ORF1 C
1

Power Unit #6 1
T
ORF3
H
C
P G RV1
V
2
#6
R
2 B
T A
ORF2 1

P
V
A
R
V
#6
#2 S
V
A

S
V
L

C CV6
C
V
4
V
1
S
V
P
C
V
6 SVL
#6
P
V
H
SCV6
CV4
#4 #6
CV1 PVA
#6 #8
ORF4
PC1
SVP
#6 PVH
Part of PCby
SVA
Power Unit
PCA CV3
#6
#6
CV2

by
C
A P
C
P

C
V
3
#8
MVL

2
V
C

MVL
P1

Part of
Power Unit
P2

#6
#8

7947-02
ILLUSTRATION 7

Crown 2001 PF13007-4 Rev. 10/02 Printed in U.S.A.

01 REV. 10/02
M2.4–1452–004 M2.4–1452–004
 C MANIFOLD

Chart 1 lists the top o-ring part number for valves and plugs installed in the lift/accessory and reach carriage manifold blocks.
Refer to this chart whenever installing a top replacement o-ring. Seal kits are available to replace all o-rings on each cartridge
type valve. Refer to parts section 2.0 and 2.4 for seal kit part numbers.

Reference Valve/Plug O-Ring O-Ring Dim. (mm) O-Ring Dim. (in.)

Designation Part No. Location Part No. W. I.D. O.D. W. I.D. O.D.

CV1, CV2, 123255-001 Lift/Acc. 064019-075 0.62 59.50 55.65 0.103 1.987 2.19
CV3 Manifold

CV4 123255-002 064019-076 2.95 29.75 – 0.116 1.171 –

CV6 125379 064019-045 2.45 19.20 – 0.097 0.755 –

SCV6 117304-003 064019-045 2.45 19.20 – 0.097 0.755 –

RV1 117913-002 064019-045 2.45 19.20 – 0.097 0.755 –

CBV 121819 Carriage 064019-045 2.45 19.20 – 0.097 0.755 –

Manifold
SVR/SVS 122167-001 064019-030 2.20 16.35 – 0.087 0.644 –
SVT

RV2 123334-002 Lift/Acc. 064019-045 2.45 19.20 – 0.097 0.755 –

Manifold
MVL 177739 064019-030 2.20 16.35 – 0.087 0.644 –

PVA 123257-002 064019-045 2.45 19.20 – 0.097 0.755 –

PCA 123259 064019-075 0.62 59.50 55.65 0.103 1.987 2.19

PVH 123257-001 064019-075 0.62 59.50 55.65 0.103 1.987 2.19

PCH 123261 064019-075 0.62 59.50 55.65 0.103 1.987 2.19

PCby 123260 064019-075 0.62 59.50 55.65 0.103 1.987 2.19

SVL 117305-003 064019-076 2.95 29.75 – 0.116 1.171 –

SVP 123258 064019-030 2.20 16.35 – 0.087 0.644 –

SVA 117385-003 064019-045 2.45 19.20 – 0.097 0.755 –

#2 Plug 064091-004 064019-074 1.65 6.10 – 0.064 0.239 –

#4 Plug 064091-006 064019-031 1.85 8.90 – 0.072 0.351 –

#6 Plug 064091-002 064019-099 1.80 7.65 11.20 0.070 0.301 0.44

#8 Plug 064091-001 064019-030 2.20 16.35 – 0.087 0.644 –

#10 Plug 064091-007 064019-045 2.45 19.20 – 0.097 0.755 –

Crown 2001 PF13007-5 Printed in U.S.A.

M2.4–1452–005 M2.4–1452–005
 C MANIFOLD

Chart 2 lists torque values for all cartridge type valves installed in the lift/accessory manifold block and reach carriage
manifold block(s) and plugs. Refer to this chart whenever installing a replacement cartridge valve(s) and/or plugs.

Reference Cartridge Torque Coil Nut Torque

Part No. Designation Location Nm (Ft. Lbs.) Nm (Ft. Lbs.)

117304-003 SCV6 Lift/Acc. Manifold 48 - 54 (35 - 40) N/A

(1 Lift Pump)
117305-003 SVL 102 - 108 (75 - 80) 8.0 (6.0)

117385-003 SVA 48 - 54 (35 - 40) 8.0 (6.0)

117739 MVL 41 - 48 (30 - 35) N/A

117913-002 RV1 54 - 61 (40 - 45) N/A

121819 CBV Carriage Manifold 34 (25) N/A

122167-001 SVR/SVS
SVT 27 (20) 10 (7.0)

123255-001 CV1/CV2 Lift/Acc. Manifold 102 - 108 (75 - 80) N/A

CV3

123255-002 CV4 129 - 135 (95 - 100) N/A

123257-001 PVH 68 - 75 (50 - 55) 14 - 16 (10 - 12)

123257-002 PVA 48 - 54 (35 - 40) 14 - 16 (10 - 12)

123258 SVP 34 - 41 (25 - 30) 8.0 (6.0)

123259 PCA 68 - 75 (50 - 55) N/A

123260 PCby 68 - 75 (50 - 55)) N/A

123261 PCH 68 - 75 (50 - 55) N/A

123334-002 RV2 54 - 61 (40 - 45) N/A

125379 CV6 54 - 61 (40 - 45) N/A

(2 Lift Pumps)
064091-001 #8 Plug 41 - 44 (30 - 32) N/A

064091-002 #6 Plug 23 - 24 (17 - 18) N/A

064091-004 #2 Plug 7-8 (5 - 6) N/A

064091-006 #4 Plug 14 - 15 (10 - 11) N/A

064091-007 #10 Plug 44 - 49 (32 - 36) N/A

Crown 2001 PF13007-6 Printed in U.S.A.

M2.4–1452–006 M2.4–1452–006