INTRODUCTION

RR/RD 5200/5200S
RR/RD 5200(AC)/5200S(AC)
This manual is intended for the service mechanic who is seeking information about maintenance and service replacement
parts. It contains a section on troubleshooting which will enable a qualified mechanic to locate and solve problems which
may occur.

OPERATOR INSTRUCTIONS

This manual does not contain operator instructions. Operator instructions are sent with each truck, additional copies can
be ordered if required. These booklets are for you and your personnel to insure years of safe, trouble free operation of your
Crown Lift Truck. For operator instructions, refer to Crown publications, "Operator Manual RR/RD 5200 Series" (PF12904),
"Operator Manual RR/RD 5200S Series" (PF12905).

DRIVER TRAINING

Crown has available a complete series of Driver Training programs, in two parts concerning basic safety rules and operating
characteristics of your truck. To obtain this information, ask your Crown Dealer about "Its up to You" and "You and Your
Narrow Aisle Rider".

SERVICE TRAINING

Complete Service Training is available to the lift truck mechanic covering all Crown Lift Trucks, SCR systems, wire guidance,
hydraulic and electrical systems. To obtain more information concerning service training, contact your Crown Dealer.

REPLACEMENT PARTS

When ordering replacement parts from this manual, always specify, along with the part number, the model, data and serial
number of the truck. This information will further enable us to give correct, fast and efficient service.

For Series RR/RD 5200 and RR/RD 5200S capacities, technical information and dimensional specifications, please refer
to the following sales literature:

RR/RD 5200/5200S Series Literature SF14166

RR/RD 5200(AC)/5200S(AC) Series Literature SF14166

RR 5200 Series Specifications SF12895 RR 5200S Series Specifications SF12896

RD 5200 Series Specifications SF12897 RD 5200S Series Specifications SF12898

Copies of publications can be obtained from your Crown dealer or by writing to:

Crown Equipment Corporation

44 S. Washington Street
New Bremen, OH 45869

This manual is arranged according to major sections. The first part of the page number, found at the bottom of each page,
denotes the section in which a particular form will be located. The first portion of the manual covers the written maintenance.
The later portion covers replacement parts. The sectional descriptions are as follows:

MAINTENANCE REPLACEMENT PARTS

SECTION DESCRIPTION SECTION DESCRIPTION

M1 Lubrication and Adjustments 1 Basic Chassis or Power Unit

M2 Hydraulics 2 Hydraulic System and Components
M3 Drive Unit 3 Drive Unit and Components
M4 Electrical 4 Electrical Components
M5 Brake 5 Brake Assemblies and Brake Systems
M6 Steering 6 Steering System and Components
M7 Mast and Main Frame 7 Main Frame and Mast Assemblies
M8 Cylinder 8 Cylinders
M9 Reach Assembly 9 Reach Assembly
M10 Glossary 10 Accessories
010328 11 Specifications 4160
Crown 2001 PF13063-1 Rev. 10/02 Printed in U.S.A.
04 REV. 10/02
ITD–1452–001 ITD–1452–001
 INTRODUCTION

Battery Weight Lbs. D.C. Voltage

Max. Min.
Max. A. H. Cap. HR. Rate Batt. Type

Truck Wt.
Less Batt.
Max. Grade With 12 In. %
Max. Fork Height

Load Tire Tread

Width

180° Traverse
Sideshift
Model Number Fork Length

Serial Number Max. Tilt Back

°
RR/RD 5200 Truck Data Number RR/RD 5200S
The data plate for the RR/RD 5200 series truck is
This truck as released from the factory conforms to the
located on the cover below the operator back rest/seat mandatory requirements of the ANSI B56.1 Standard.

and includes a model number and truck data number. Crown Equipment Corp. New Bremen, OH 45869 CL B

From these two numbers, you can identify the truck

8795
model, series, series updates, determine relative size or TRUCK DATA PLATE
performance, capacity and specific truck data. The
following pages explain the model & truck data number-
ing system.

MODEL NUMBER EXAMPLE

Series Update S = 1220 mm (48 in.) Power Unit Width

Significant change(s) to the product
that would not merit a new series
number (generation). †Capacity
30 = 1360 kg. (3000 lb.)
35 = 1585 kg. (3500 lb.)
Image Generator 40 = 1815 kg. (4000 lb.)
RR - Rider Reach 45 = 2040 kg. (4500 lb.)
RD - Rider Double Reach

RR5210S-35

Series Relative Size or Performance

Major technical and design changes 10 = 24 v, Lift height up to 6860 mm (270 in.)
making the product a new and im- 20 = 36 v, DC Drive, Lift height up to 10160 mm (400 in.)
proved generation. 25 = 36 v, AC Drive, Lift height up to 10160 mm (400 in.)
60 = 36 v, DC Drive, Lift height up to 10695 mm
(421 in.), upper footrest area
65 = 36 v, AC Drive, Lift height up to 10695 mm
(421 in.), upper footrest area
80 = 36 v, DC Drive, Lift height up to 10695 mm
(421 in.), upper footrest area,
adjusable seat
85 = 36 v, AC Drive, Lift height up to 10695 mm
The example of the model number shown above (RR5210-35) is (421 in.), upper footrest area,
a RR 5200 series. It has a 24 volt electrical system and 1585 kg. adjustable seat
(3500 lb.) capacity.
† Actual rated capacity may vary, depending on special equipment or
modifications. Consult capacity plate located on the power unit console.
Crown 2001 PF13063-2 Rev. 10/02 Printed in U.S.A.
04 REV. 10/02
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 INTRODUCTION
The truck data number provides you and your Crown dealer with a wealth of information to ensure the selection of proper
parts for your Crown truck. You may simply provide this number to your Crown dealer, or use the following breakdown if
selecting your own part numbers or service information from this manual.
TRUCK DATA NUMBER EXAMPLE
Freezer Condition Option Drive Tire
– Standard P Poly DC Traction Drive
F Freezer S Special DC Traction Drive
C Corrosion A Poly AC Traction Drive
E EE C Special AC Traction Drive
D EE with Corrosion
Steering
Battery Compartment F Forward
A 310 mm (12.19 in.) R Reverse
B 360 mm (14.25 in.)
C 415 mm (16.25 in.) Outriggers
D 455 mm (18.00 in.) – Stardard
E 525 mm (20.75 in.) B Bolt On
* Special T Taper
O Bolt On Taper
Mast Type
TT Telescopic Triple Stage Productivity Package
** Special – No Productivity Package
DT Drive In Rack P Productivity Package
- TT 270 C 36 - 2 P S F - B S - Q - -
Type Third Post
– Standard – No Third Post
S Special T Third Post
C Custom

Lift Height
5030mm (198 in.)
5335mm (210 in.)
6095mm (240 in.) Brush Wear/Over Temperature Indicator
6860mm (270 in.) – Without Indicator
7620mm (300 in.) B With Indicator
8155mm (321 in.)
8660mm (341 in.) Lift Motor
9295mm (366 in.) Q 170 mm (6.6 in.) Diameter
10160mm (400 in.) S 190 mm (7.5 in.) Diameter
10695 mm (421 in.)
SPC Special Display
S Standard
Inside Straddle Dimension E Enhanced
865 mm thru 1550 mm (34 in. thru 61 in.) C Enhanced with CDM
** Special
Travel Alarm/Light Package
– Standard 4 Strobe Light & Travel Alarm
Load Wheel Size
1 Strobe Light 5 Worklights & Strobe Light
1 100 mm x 75 mm (4 in. x 2.88 in.)
2 Travel Alarm 6 All
2 100 mm x 105 mm (4 in. x 4.12 in.) 7 Travel & Worklights
3 Worklights
3 125 mm x 75 mm (5 in. x 2.88 in.)
4 125 mm x 105 mm (5 in. x 4.19 in.) Sideshift
5 265 mm x 100 mm (10.5 in. x 4 in.) – Without Sideshift
6 265 mm x 115 mm (10.5 in. x 4.5 in.) S With Sideshift
7 150 mm x 75 mm (6 in. x 2.88 in.)
6319-04 8 150 mm x 105 mm (6 in. x 4.12 in.)

The example of the truck data number shown above is a DC traction drive truck with telescopic triple stage mast, 6860 mm (270
in.) lift height, "C" size battery compartment, inside straddle dimension of 915 mm (36 in.), without freezer condition, 100 mm
x 105 mm (4 in. x 4.12 in.) load wheels, poly drive tire, sideshift, forward steering, without lights and travel alarm, bolt on outriggers,
standard display, no productivity package, standard lift pump and without brush wear/over temperature indicator.
Crown 2001 PF13063-3 Rev. 10/02 Printed in U.S.A.
04 REV. 10/02
ITD–1452–003 ITD–1452–003