REACH & ATTACHMENTS
Reach Mechanism
Reach Mechanism
The reach assembly on your truck is designed to lift,
transport and deposit materials from racks where out-
riggers cannot enter into or under. Extend the reach
carriage by "rolling" the thumbwheel, located on the
multi-task control handle, away from the operator.
Reach carriage extension speed is varied by the
amount of thumbwheel rotation.
WARNING
Wear appropriate items, such as safety glasses, steel-
toed shoes, whenever performing maintenance work.
Do not place fingers, hands or arms through mast or
position them at pinch points.
In this section you may be required to lift and block the
truck, mast and reach mechanism or raise and lower
different components for removal and installation.
Make sure the lifting device and sling are sufficiently
rated to withstand the weight being lifted. Never work
under or around a truck that is not properly secured.
Refer to truck Data Plate for truck weight information.
It will be necessary to disconnect and remove the bat-
tery from the truck, disconnect tilt cylinders from the
reach mechanism, disconnect electrical connections
and hydraulic lines.
The Control of Hazardous Energy section of this man-
ual provides information for performing the above pro-
cedures along with additional information on other pro-
cedures dealing with truck maintenance. Read and
review this section prior to reach assembly removal, in-
stallation and maintenance as outlined in this section.
Reach Assembly Inspection
Reach Cylinder Inspection
Inspect the two reach cylinders on a regular basis. Re-
fer to the Planned Maintenance section of this manual
for inspection intervals and locations. Refer to Cylin-
ders - Reach Cylinders in this manual for specific infor-
mation on inspecting, adjusting and maintaining the
reach cylinders.
Crown 2010 PF17927-1 Rev. 2/12
Reach Assembly Pivot Shaft Inspection
There are 14 pivot shafts on the Reach Assembly that
require regular inspection. Inspect the pivot shafts for
excessive wear, damage and proper lubrication. Check
the roll pin that secures each pivot cylinder for proper
placement and excessive wear. Replace the parts as
needed. Refer to the Planned Maintenance section of
this manual for inspection intervals and locations.
Reach Staging Bumper Inspection
Located on the back side of the rear reach carriage are
two reach staging bumpers. Check the bumpers for ex-
cessive wear or damage. Replace the bumpers as
needed. Refer to the Planned Maintenance section of
this manual for inspection intervals and locations.
Reach Assembly Lubrication
There are lubrication fittings in multiple locations on the
RM and RMD Reach Assemblies. Use a grease gun to
pump the appropriate lubricant into the fitting until it is
full.
On RMD Reach Assemblies, there are two lubrication
fittings located on the upper inner arm pivots (6), two
fittings located on the upper mid-pivots (4), two fittings
on the lower mid-pivots (5), and two fittings on the up-
per outer arms (2). There is also a fitting located on
each reach cylinder at the rod end (1) and one at the
piston end (3). There are four lubrication fittings (7) on
the tilt cylinder. Two additional lubrication fittings are on
the fork carriage sideshift glides and two on the side-
shift cylinder pivots. Refer to Figure 24862.
Figure 24862
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REACH & ATTACHMENTS
Reach Mechanism
On RM Reach Assemblies, there are two lubrication fit-
tings located on the upper inner arm pivots (1) and two
fittings on the upper outer arms (2). There is also a fit-
ting located at the end of each reach cylinder on the rod
end (3) and one at the piston end (4). There are four
lubrication fittings (5) on the tilt cylinder. Two additional
lubrication fittings are on the fork carriage sideshift
glides and two on the sideshift cylinder pivots. Refer to
Figure 24863.
Figure 24863
In addition, use a paint brush or other suitable applica-
tion tool to lubricate the front and rear carriage chan-
nels. Apply a light coat of lubricant to the fork carriage
tilt/sideshift rail.
Refer to the Lubricants Chart in the Inspection and Lu-
brication chapter in this manual for further information
on appropriate lubricants. Refer to the Planned Mainte-
nance section for lubrication quantities and intervals.
Reach Cylinder Adjustment
RM Reach Extended Adjustment
The single reach extension distance is 590.5 mm
(23.25 in) as measured from the leveled fork or fork
carriage face between the retracted and extended po-
sitions.
The maximum extension occurs when one or both of
the front rollers contact the upper surfaces of their
tracks in the front reach carriage. The maximum exten-
sion is not adjustable.
Install the reach cylinders with the rod end cylinder
clevis roll pins to the outside of the truck to facilitate
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removal. Turn the rod to adjust the cylinder length to
synchronize the full extension of the reach cylinder with
the front roller upper surface contact. After adjusting
both cylinders, fully extend the reach mechanism. One
or both of the front rollers must contact the upper sur-
faces of their track and the rear rollers must be in con-
tact with the rear face of the channels in the rear reach.
The arms, front reach carriage, fork carriage and forks
must not lift as a unit at full reach extension and should
be free of any twisting action due to cylinder extension
differences.
Apply red thread locking adhesive to the threads of the
cylinder rod next to the clevis. Torque the jam nuts fix-
ing the cylinder adjustment to 163 ± 14 Nm (120 ±
10.3 ft lb).
RM Reach Retracted Adjustment
The single reach retracted distance is 152 ± 3 mm
(5.98 ± 0.12 in) as measured from the fork face to the
forward vertical face of the rear reach vertical channel.
RM Poly Stops
Located on the lower cross member of the back side of
the reach carriage are two poly stops. These stops pre-
vent metal to metal contact when the reach assembly
is fully retracted. Add or subtract shims to ensure the
poly stops contact the rear carriage assembly evenly
when the reach mechanism is at the desired fully re-
tracted measurement. Use blue thread locking adhe-
sive to secure the mounting screws. Torque the screws
to 10 Nm (96 in lb). Do not over-torque.
RMD Reach Extended Adjustment
The double reach extension distance is 1346 mm
(53 in) as measured from the leveled fork or fork car-
riage face to the face of the 3rd stage mast.
The maximum extension occurs when one or both of
the front rollers contact the stops in the front reach car-
riage. The maximum extension is not adjustable.
Install the reach cylinders with the rod end cylinder
clevis roll pins to the outside of the truck to facilitate
removal. Adjustment of the cylinder length is not re-
quired, but is advantageous to minimize the cylinder
length. Minimize the cylinder length by applying red
thread locking adhesive to the cylinder rod threads
near the shoulder and turning the jam nut so that it is
against the rod shoulder and turning the cylinder rod of
clevis so that the rod end clevis is against the jam nut.
Torque the jam nuts fixing the cylinder adjustment to
163 ± 14 Nm (120 ± 10.3 ft lb).
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 REACH & ATTACHMENTS
Reach Mechanism

RMD Reach Retracted Adjustment 9. Use masking tape to label the two hydraulic hoses
"A" and "B" (respective to their manifold block port)
The double reach retracted distance is 275 ± 3 mm for greater ease in reassembly. Disconnect the two
(10.81 ± 0.12 in) as measured from the fork face to the hydraulic lines from the mast to the reach assem-
forward vertical face of the rear reach vertical channel. bly at the reach manifold assembly ports A and B.
Add or subtract shim(s) as needed to meet the speci- Cap the lines from the mast and the ports on the
fied retracted distance. Make sure the stops contact block.
the cross member tube of the secondary inner arm at
the same time. Apply blue thread locking adhesive to 10. Disconnect the control cables from the power unit
the screw threads before installing the stops. to the reach assembly.
11. Use the lifting device and sling to lower the reach
RMD Poly Stops assembly off the mast and set it aside.
Located on the middle cross member of the front reach
carriage are two poly stops. These stops prevent metal Reach Mechanism Disassembly
to metal contact when the reach assembly is fully re-
tracted. Add or subtract shims to ensure the poly stops 1. Move the truck to a service area on a level floor.
contact the cross member tube of the secondary inner 2. Chock the wheels. Refer to the Control of Hazard-
arm evenly when the reach mechanism is at the de- ous Energy section.
sired fully retracted distance. Use blue thread locking
adhesive to secure the mounting screws. Torque the 3. Tilt the forks down so the weight of the carriage is
screws to 10 Nm (96 in lb). Do not over-torque. not on the tilt cylinder. Do not continue to request
tilt after the weight is supported. Remove the fork
locking screw from the lower center cross member
Reach Assembly Removal of the fork carriage. Remove the forks.
1. Turn the truck OFF. Chock the drive wheels. 4. Raise and block the mast as shown in Figure
24954 with the reach support at a minimum height
2. Remove the forks and load backrest from the car-
of 1130 mm (44.5 in). Use bands to secure all
riage.
blocking to the mast. Refer to the Control of Haz-
3. Turn the truck ON. Raise the mast to a height that ardous Energy section of this manual for further in-
allows the reach assembly to be removed and ex- formation on Lifting and Blocking.
tend the reach assembly. Block the reach assem-
bly in the extended position so that it will remain
upright more easily when it is removed from the
truck. Refer to the Control of Hazardous Energy
section for blocking procedures.
4. Block the mast as shown in Control of Hazardous
Energy.
5. Turn the truck OFF and disconnect the battery.
6. Lockout/tagout the truck as described in Control of
Hazardous Energy.
7. Connect a lifting device and sling to the carriage
assembly and raise it enough to allow slack in the
chains on the primary cylinder. Make sure the lift-
ing device and sling can support the entire weight
of the reach assembly. Remove the cotter pin and
two nuts from each chain anchor on the carriage
end to disconnect them from the reach carriage.
8. Open the manual control valve (MVL) to release
hydraulic pressure. Figure 24954

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REACH & ATTACHMENTS
Reach Mechanism

5. Extend the reach mechanism and block it in the ex-

tended position with a 75 x 75 mm (3 x 3 in) hard-
wood block (1) through the reach mechanism as
shown in Figure 24221. Make sure the block ex-
tends beyond both outer arms.

Figure 24398

11. Disconnect the two tube assemblies that run from

the tilt cylinder to the accessory manifold assembly
from the adapters (1) at the base of the accessory
manifold block. Take care not to lose the o-ring
seals between the tubes and the adapters. Refer to
Figure 24399.
Figure 24221
12. Disconnect the two hoses that run from the reach
6. Relieve the hydraulic pressure from the reach cir- manifold to the accessory manifold at the acces-
cuit by retracting the carriage until the rear rollers sory manifold adapters (2).
rest on the blocks installed in Step 4. To prevent
pressure from accumulating at the reach cylinders,
do not continue to request retract after the carriage
rollers contact the block.Key the truck OFF.
7. Turn the truck OFF.
8. Lockout/Tagout the truck as described in the Con-
trol of Hazardous Energy section.
9. Open the manual lowering valve (MVL) to relieve
hydraulic pressure.
10. Remove the two screws (1) that secure the mani-
fold guard (2) from the accessory manifold block.
Retain the guard and hardware. Refer to Figure
24398.

Figure 24399

13. Cap the tubes and adapters to prevent dust and

debris from getting into the hydraulic system.

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 REACH & ATTACHMENTS
Reach Mechanism

14. Remove the four screws that secure the tilt cylinder
and sideshift assembly (1) to the reach mecha-
nism. Remove the assembly from the mounting
pins (2). Set the assembly to the side. Refer to Fig-
ure 24400.

Figure 24397

1 Load Backrest and Reach Carriage (shown removed from

Reach Mechanism)

16. If removal of individual parts from the front of the

carriage is not necessary for the work you are com-
Figure 24400 pleting, ensure the load backrest, fork carriage and
reach carriage are properly supported with the lift-
ing device and sling as shown in Figure 24397.
WARNING
17. Remove the roll pins (1) that secure the upper front
Make sure that the lifting device and sling are suffi- pivot shafts to the top of the inner arm, and then
ciently rated to withstand the weight of the load back- remove the upper front pivot shafts. Retain the roll
rest and reach carriage. pins and pivots shafts for reassembly. Refer to Fig-
15. Use an overhead lifting device and sling to support ure 24401.
the weight of the load backrest, fork carriage and
front reach carriage when the mounting hardware
is removed. Refer to Figure 24397.
It is not necessary to remove the load backrest and
fork carriage before removing the front reach. The
three pieces can be removed as one. If it is neces-
sary to remove the load backrest separately, sup-
port it using the lifting device and sling. Remove
the four screws that secure it to the fork carriage
and remove the load backrest.
If it is necessary to remove the fork carriage sepa-
rately, support it with the lifting device and sling. Lift
the fork carriage off the front reach.

Figure 24401

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REACH & ATTACHMENTS
Reach Mechanism

18. Lift the load backrest and reach carriage off the
rollers and away from the truck. Set in a secure
area until reassembly.
19. Use the lifting device and sling to support the inner
arm as it is still attached to the truck. Refer to Fig-
ure 24402.
21. Remove the cover from the top of the rear reach
carriage.
22. Remove the screw (1) that secures the manifold
assembly (2) on the top of the reach carriage. It is
not necessary to disconnect the hoses from the
manifold block. Move the manifold block to access
the roll pin (3). Retain the hardware for reassem-
bly. Refer to Figure 24404.
23. Remove the screw (4) that secures the clamp body
(6) and cover plate (5) to the top of the rear reach
carriage. Move the hoses aside to access the roll
pin underneath. Retain the hardware for reassem-
bly.

Figure 24402

20. Remove the roll pin (1) from the cylinder pivot shaft
(2) at the rod end of each reach cylinder (3). Re-
move the cylinder pivot shafts. Retain the hard-
ware for reassembly. Refer to Figure 24403.
Figure 24404

Figure 24403

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 REACH & ATTACHMENTS
Reach Mechanism

24. Remove the three screws that secure the magnet 26. Remove the roll pins that secure pivot shafts at the
carrier assembly to the rear reach carriage. Re- top of the rear reach carriage. Remove the pivot
move the magnet carrier. Retain the carrier and shafts. At this point, the outer arms will be con-
mounting hardware. Refer to Figure 24405. nected to the inner arms at the mid-pivots only. Re-
fer to Figure 24406.
25. Remove the two screws, the reach assist sensor
(RPS3) and shim(s), if necessary from the rear
reach carriage. Retain the sensor, shim(s) and
hardware for reassembly.

Figure 24406

27. Remove the three screws, two o-rings and cap that
secure the outer right hand arm to the inner arm at
the mid-pivot. Retain the hardware for reassembly.
Refer to Figure 24407.
28. Remove the right hand arm.

Figure 24405

Figure 24407

29. Remove the three screws, two o-rings and cap that
secure the outer left hand arm to the inner arm at
the mid-pivot.
30. Remove the left hand arm.

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REACH & ATTACHMENTS
Reach Mechanism

31. With the lifting device and sling supporting the A bushing installation tool, as shown in Figure
reach mechanism weight, remove the blocking that 17055-01, will greatly aid in the correct installation of
supports the cam follower rollers installed in Step replacement bushings.
4. Use the lifting device and sling to lower the inner
arm assembly so that it rolls off the bottom of the
reach carriage.

Figure 17055-01

1 Bushing Installation Tool

2 0.13 mm (0.005 in) Smaller than the Bushing Outside Diam-
eter
3 1.6 mm (0.062 in) Chamfer
4 0.13 mm (0.005 in) Smaller than the Bushing
5 Equal to the Length of the Bushing

NOTE
To ensure the wear surfaces are intact, closely inspect
all replacement bushings after installation.

Figure 24411

32. Inspect and replace parts as needed.

Reach Assembly Bushing Replacement

When removing an old bushing, be sure the seating
area of the bushing is not damaged in any manner. If
damage has occurred, remove all burrs and rough
edges completely before replacing the bushing.
When installing the replacement bushings in a lubri-
cated area, ensure the hole in the bushing is in proper
alignment with the lubrication fitting to allow proper lu-
bricant flow.
Apply a light coat of grease to the bushing seat to ease
installation and reduce the possibility of damage to the
replacement bushing.

NOTE
An installation tool can be used to remove worn or
damaged bushings. Various sizes of bushings will ne-
cessitate the use of various sizes of installation tools.

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 REACH & ATTACHMENTS
Reach Mechanism

Reach Assembly Shimming 2. Install the cam follower roller (21) on the right hand
side of the inner arm without using any shims (22).
Install the cap (23) using one screw (24).
Rear Roller Shimming - RM & RMD
1. Install the column roller (19) on the left hand side
of the inner arm without using any shims (20). Re-
fer to Figure 24410-01.

Figure 24410-01

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REACH & ATTACHMENTS
Reach Mechanism
3. Place a 25 mm (1 in) thick magnet (Crown part
number 113304) (1) in the roller channel on each
side of the rear reach carriage. Attach a steel rule
from a combination square (2) to each magnet.
Measure the distance between the metal strips.
Subtract 50 mm (2 in) to the distance to account
for the magnets in the channels. (If a thicker or thin-
ner magnet is used, use the actual width of the
magnet to account for the magnet and channel.)
Refer to Figure 24408.
4. Repeat the measurement at each spot (3) marked
by an "X" in Figure 24408. The largest of these
measurements is represented by the letter G (in
mm) in the equations below.
Figure 24408
5. Measure between the cap (1) on the right hand
side of the replacement inner arm assembly and
the face of the roller (2) on the left hand side. The
measurement is represented by the letter H (in
mm) in the equations below. Refer to Figure
24409-01.
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6. Use the equations below to determine the appro-
priate number of shims.
H-G-1=K
To determine the number of 060030-130 shims (Z)
needed on the right hand side of the inner arm be-
tween the cap and the roller complete the following
equation, then round down to the whole number of
shims needed on the left hand side.
(K x 0.6)/0.8 = Z
To determine the number of 060030-317 shims (Y)
needed on the left hand side of the inner arm be-
tween the roller and the stud, complete the follow-
ing equation, then round down to the whole num-
ber of shims needed on the right hand side.
(K x 0.4)/0.8 = Y
Install the shims as determined by the equations.
Refer to Figure 24410 for proper order of assem-
bly.
Figure 24409-01
RM Inner Arm 142344
RMD Primary Inner Arm 145097
7. After shimming, install the inner arm assembly on
the rear reach carriage. The rollers must not rub on
the inner channel at any point along their travel.
Adjust the shims as needed to achieve the appro-
priate clearances.
8. Once appropriate shimming is achieved, remove
the inner arm assembly and the screw that secures
the cap to the roller on the right hand side. Place a
drop of blue thread locking adhesive on the screw
and secure it in place. Install the inner arm assem-
bly on the rear reach carriage.
Crown 2010 PF17927-10 Rev. 2/12
 REACH & ATTACHMENTS
Reach Mechanism

RMD Outer Arm Lateral Adjustment arm widths. The following instructions and charts will
allow you to figure out the correct shimming for your
Shimming is required for the outer arms at the middle truck. Refer to Figure 24412 for shimming locations.
pivot joints to allow for variations in the welded inner

Figure 24412

1 Primary LH Outer Arm

2 Upper Mid-Pivots
3 Secondary LH Outer Arm
4 Secondary Inner Arm
5 Secondary RH Outer Arm
6 Lower Mid-Pivots
7 Primary RH Outer Arm
8 Primary Inner Arm

Pre-assemble all pivot bearings, bushings, snap rings

and spacers in the inner and outer arms.

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REACH & ATTACHMENTS
Reach Mechanism

To determine the lower mid-pivot shims, obtain the pri-
mary pivot shaft measurement (A1). Measure the be-
tween the bearing outer face and shaft face of the pri-
mary inner arm (1) as shown in Figure 24413. Place
this measurement in cell A1 in Chart 1 below. To obtain
the secondary inner arm mid-pivot measurement (B1),
measure between the faces of the washers (2) installed
on the studs of the secondary inner arm (3). Place this
measurement in cell B1.

Figure 24413

To determine the upper mid-pivot shims measure the between the outer face of the bearing and face of the
distance (C1) between the outsides of the bushings (1) shaft on the secondary inner arm (3). Place this mea-
on the primary inner arm (2). Place this measurement surement in cell D1. Refer to Figure 24414.
in cell C1 of Chart 1. Then measure the distance (D1)

Figure 24414

Complete the equations in Chart 1, using the measure-

ments taken above to determine the values for Chart 2.

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 REACH & ATTACHMENTS
Reach Mechanism

Chart 1

A B C D

2 517.6-A1=A2 519.6-B1=B2 511.5-Ca=C2 517.3-D1=D2

3 NONE (A2+B2+3.2)/8=B3 (C2+D2+3.2)/0.8=C3 NONE

Chart 2

B2 & C3 Values 060030-387 060030-317 060030-316

(1) (0.4 mm Shim) (0.8 mm Shim) (1.6 mm Shim)
0 - 0.49 mm No Shims No Shims No Shims
0.5 - 1.49 mm 1 0 0
1.50 - 2.49 mm 0 1 0
2.50 - 3.49 mm 1 1 0
3.50 - 4.49 mm 0 0 1
4.50 - 5.49 mm 1 0 1
5.50 - 6.49 mm 0 1 1
6.50 - 7.49 mm 1 1 1
7.50 - 8.49 mm 0 0 2
8.50 - 9.49 mm 1 0 2
9.50 - 10.49 mm 0 1 2
(1) Use the Chart 1 B3 value (in mm) to determine the appropriate shims for the LH and RH lower mid-
pivot joints. Use the Chart 1 C3 value (in mm) to determine the shims to use for the LH and RH
upper mid-pivot joints.

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REACH & ATTACHMENTS
Reach Mechanism

Use the values obtained in Chart 1 to determine the

appropriate size and quantity of shims as listed in Chart
2. Use a minimum number of 0.4 mm (0.015 in) shims
by replacing two 0.4 mm (0.015 in) shims with one
0.8 mm (0.031 in) shim. Likewise, use one 1.6 mm
(0.063 in) shim as opposed to two 0.8 mm (0.031 in)
shims. Refer to Figure 24415 for shim pack (1) place-
ment between the mid-pivot spacer (2) and the outer
arm (3). Torque the nut (4) to a minimum of 162.70 Nm
(120 ft lb), then continue to tighten to allow installation
of the cotter pin (5). Refer to Figure 22415.

Figure 24411

2. Install the carriage roller (25) on the right hand

Figure 22415
Assembly of Reach Mechanism
WARNING
Make sure that the lifting device and sling are suffi-
ciently rated to withstand the weight of the load back-
rest and reach carriage.
1. Refer to Figure 24411. With the rear reach carriage
installed on the mast, use a lifting device and sling
to position the shimmed rollers in the channels on
the rear reach carriage. Slide the inner arm assem-
bly up into the channels. Block the rollers as de-
scribed in the Control of Hazardous Energy - Lifting
and Blocking section of this manual.
outer arm as shown. Secure it with the cap (26)
and one screw (27). Refer to Figure 24410-01.
3. Install the carriage roller (28) on the left hand outer
arm as shown. Secure is with the cap (29) and one
screw (30).
4. Install the larger o-ring (6). Slide the bearing (3)
that is assembled with two retaining rings (4) in the
right hand arm (1) onto the stud of the inner arm
(2).
5. Install the smaller o-ring (5) as shown in Figure
24410-01.
6. Install the cap (7) on the outside of the assembled
parts and secure the cap with three screws (8) from
the inside of the inner arm at the mid-pivot point.
Finger tighten the screws, but do not torque them
at this time. Repeat the procedure with the left
hand outer arm assembly.

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 REACH & ATTACHMENTS
Reach Mechanism

Figure 24410-01

7. Align the top of the right hand outer arm (9) with the Repeat the procedure with the left hand outer arm
rear reach carriage. Insert the pivot shaft (11) into assembly.
the bushing (10) that is already installed in the
9. Tighten each of the six screws (8) at the reach cen-
outer arm. Take care to line up the hole in the pivot
ter pivot joints to 20-23 Nm (15-17 ft lb). Then
shaft with the roll pin (12) hole that secures the
torque the bolts to 32-35 Nm (24-26 ft lb). Check
pivot shaft. Install the roll pin. Repeat the proce-
the first screw tightened on each side for proper
dure with the left hand outer arm assembly. Refer
torque. If the first screw is no longer at proper
to Figure 24410.
torque, retighten all three screws until all are within
8. Align the right hand outer arm (1) with the end of the specified torque range. Repeat this procedure
the right hand reach cylinder (13). Insert the cylin- for the remaining center pivot joints.
der pivot shaft (14) into the bushing (15) on the
outer arm. Install the roll pin (16) that secures it.

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Reach Mechanism

10. Ensure the reach mechanism is properly blocked

on the mast. Remove the lifting device and sling
from the inner arm assembly.
11. Use the lifting device and sling to slide the front
reach carriage onto the rollers of the outer arms.
12. Align the bushings (16) in the tops of the inner arm
(2) with the holes on the front reach carriage.
13. Insert the pivot shafts (17) through the front reach
carriage and the bushings in each side of the inner
arm. Take care to line up the holes to install the roll
pins (18) that secure the pivot shafts. Install the roll
pins.
14. If the fork carriage and load backrest were re-
moved from the front reach carriage, use a lifting
device and sling to install the fork carriage on the
reach carriage and then install the load backrest on
the fork carriage using four screws as previously
removed.
15. On the top of the rear reach carriage, reposition
and secure the manifold block with the screw pre-
viously removed. On the opposite side, reassem-
ble the clamp body and cover plate with a screw as
previously removed.
16. Install the rear reach top cover. Torque the screws
to 6 Nm (60 in lb). Figure 24405
17. Install the reach sensor (RPS3) and applicable
spacer(s) using two screws. The sensor must be
installed with the potted side toward the rear reach
weldment.
18. Use three screws to install the magnet carrier. The
gap between the reach sensor and the magnet car-
rier should be 4 mm ± 0.5 mm (0.16 in ± 0.02 in).
Install spacer(s), as necessary, between the reach
sensor and the carriage. Refer to Figure 24405.

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19. Use the mounting pins (2) to install the tilt cylinder
and sideshift assembly (1) on the truck. Refer to
Figure 24400.
20. Secure the tilt cylinder and sideshift assembly (1)
with four screws. Apply one drop of blue thread
locking adhesive to each screw. Torque the screws
to 80 Nm (60 ft lb).
Figure 24400
21. Remove the dust caps, if necessary, and attach
the two hose assemblies from the reach manifold
to the accessory manifold. Ensure the o-rings are
in place between the adapters (2) and hoses. Re-
fer to Figure 24399.
22. Remove the dust caps, if necessary, and attach
the tube assemblies from the tilt cylinder to the ac-
cessory manifold. Ensure the o-rings are in place
between the adapters (1) and hoses.
Crown 2010 PF17927-17 Rev. 2/12
REACH & ATTACHMENTS
Reach Mechanism
Figure 24399
23. Connect all electronics that were previously dis-
connected.
24. Replace the manifold guard on the accessory man-
ifold block (tilt/sideshift) using two screws. Torque
the screws to 6 Nm (60 in lb).
25. Close the MLV.
26. Key the truck ON.
27. Remove lifting device and sling, blocks and wheel
chocks.
28. Verify proper truck operation.
Reach Sensor Air Gap
Place shims between the reach sensor (RPS3) and the
rear reach carriage to adjust the air gap between the
sensor and the magnet carrier to 4 ± 0.5 mm (0.16 in ±
0.02 in). Ensure that the potted side of the sensor faces
inward toward the rear reach.
Reach Assembly Hose Positioning
& Adjustment
It is important to properly position and secure all hoses
and cables on the reach assembly to prevent damage
or binding during operation.
M9.0-1960-017
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REACH & ATTACHMENTS
Reach Mechanism

RM Hoses and Control Cable • Secure the hoses to the cylinder with a cable tie (2)
as shown in Figure 24865. Position the cable tie so
RM Cable Clamp Locations the head (3) is towards the inside of the reach cyl-
Position the cable clamps on the hoses and cable as inder.
shown in Figure 24864. • No hose adjustments are necessary on the right-
• Position one clamp 254 ± 25 mm (10 ± 1 in) from hand side.
each end of the hoses (1).

• Center the third clamp (2) equally between the

hose ends.

Figure 24865

RM Sideshift Cylinder Hoses

Figure 24864
• Adjust both 90° elbow fittings so that they are par-
RM Reach Cylinder Hoses allel to the ground.
Refer to Figure 24865. • Route the hoses parallel to one another in a
• Adjust the 90° elbow fitting (1) on the piston end of smooth arc to the tilt/sideshift manifold.
each reach cylinder so that it runs parallel to the
cylinder tube.

• Adjust the 90° elbow fitting (2) on the rod end of the
reach cylinder to point slightly toward the outside of
the truck to allow the hose to clear the piston end
fitting.

• On the left-hand side, with the reach fully ex-

tended, loosen the hose clamp on top of the rear
reach assembly. Adjust the piston end hose to al-
low as much hose as possible to run between the
clamp and the 90° fitting without the hose rubbing
on the mainframe when the forks are fully lowered.

• Adjust the rod end hose so that it just touches (3)

the top brace casting or the reach cylinder when
fully extended. Tighten the hose clamp.

M9.0-1960-018 Crown 2010 PF17927-18 Rev. 2/12

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 REACH & ATTACHMENTS
Reach Mechanism

RM Reach Assembly Hoses & Control Cable RM Reach Harness

• Induce a slight twist where the hoses attach to the • Route the reach harness (1) between the connec-
manifolds so that the hoses lean away from and do tors on the rear of the reach manifold. Use a wire
not rub on the reach sensor. Refer to Figure 24867. tie to secure the harness to the left-hand reach
manifold tube. Refer to Figure 24873.

Figure 24867
• Use a wire tie (1) to secure the control cable to the
right hand accessory hose fitting at the reach man-
ifold as shown in Figure 24868.
Figure 24873
• On trucks with ACCESS 7, use a wire tie (1) to se-
cure the FLS wiring to the lower left-hand hole of
the reach manifold mounting plate. Refer to Figure
24874.

Figure 24874

Figure 24868

Crown 2010 PF17927-19 Rev. 2/12 M9.0-1960-019

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REACH & ATTACHMENTS
Reach Mechanism

RMD Reach Hoses and Cables

RMD Cable Securing Locations

Secure the RMD control cable to the outer accessory
hose using wire ties (1) at the locations shown in Figure
24871. These locations prevent the cable ties from
traveling over any pulleys.

Figure 24871

RMD Reach Cylinder Hoses

Refer to Figure 24872.
• Adjust the 90° elbow fitting (1) on the piston end of
each reach cylinder so that it runs parallel to the
cylinder tube.
Figure 24872
RMD Sideshift Cylinder Hoses
• Adjust both 90° elbow fittings on top of the sideshift
cylinder so that they are parallel to the ground.

• Adjust the 90° elbow fitting (2) on the rod end of the • Route the hoses parallel to one another in a
reach cylinder to point slightly toward the outside of smooth arc from the sideshift cylinder to the tilt/
the truck to allow the hose to clear the piston end sideshift manifold.
fitting.

• On the left-hand side, with the reach fully ex-

tended, loosen the hose clamp on top of the rear
reach assembly. Adjust the hoses (3) so that they
smoothly wrap around the casting and reach cylin-
der as shown in Figure 24872. Tighten the hose
clamp.

• Secure the hoses to the cylinder with a cable tie (4)

as shown in Figure 24872. Position the cable tie so
the head (5) is towards the inside of the reach cyl-
inder.

• No hose adjustments are necessary for the right-

hand side.

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RMD Reach Harness
• Route the reach harness (1) between the connec-
tors on the rear of the reach manifold. Use a wire
tie (2) to secure the harness to the left-hand reach
manifold tube. Refer to Figure 24873.
Figure 24873
• On trucks with ACCESS 7, use a wire tie (1) to se-
cure the FLS wiring to the lower left-hand hole of
the reach manifold mounting plate. Refer to Figure
24874.
Figure 24874
Crown 2010 PF17927-21 Rev. 2/12
REACH & ATTACHMENTS
Reach Mechanism
Reach Cam Roller Adjustment
Refer to Figure 26656.
The rear reach carriage must be vertically parallel to
the 3rd stage of the mast. Make the adjustments for 3rd
stage mast. The top right cam roller is not adjustable.
1. Raise the forks 1219 mm (48 in).
2. Put blocks in position to correctly hold the reach
carriage. Refer to the Control of Hazardous Energy
chapter.
3. Lockout/Tagout the truck. Refer to the Control of
Hazardous Energy chapter.
4. Turn the bottom left cam roller (1) until the right
side of the vertical channel of the rear reach is par-
allel with the 3rd stage I-beam of the mast. If it is
necessary, use a pry bar between the rear reach
and the 3rd stage I-beam to put the reach mecha-
nism in the correct position.
NOTE
• If more adjustment is necessary, turn the cam plate
(2) over. This gives 40 degrees more adjustment.
• The gap between the vertical channel of the rear
reach and the third stage I-beam cannot change by
more than 3 mm from the top of the reach channel
to the bottom.
5. Use blue thread-locking adhesive on the joint of
the screw (3) that attaches the cam plate to the ec-
centric shaft.
6. Install the second screw (4) to hold the cam in po-
sition.
7. Turn the top left (5) and bottom right (6) rollers to
get the rollers as near the I-beam flange as possi-
ble. Leave enough room to install the bolts (7) that
hold the cam plates (8) in position.
8. Tighten the bolts (4, 7) and raise the forks through
the full primary lift travel.
M9.0-1460-021
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REACH & ATTACHMENTS
Reach Mechanism

9. Make sure that the top left (5) and the bottom right
(6) cam rollers only lightly touch or do not touch the
third stage through this travel. Move the position of
the cam plate one hole at a time until there is no
load on the rollers.

5
8
3
1 6
4

8
2
7

Figure 26656

M9.0-1460-022 Crown 2010 PF17927-22 Rev. 2/12

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