RC5535-30 Event 745 - Maintenance & Troubleshooting discussion in Forkliftaction's forums

Discussion:
RC5535-30 Event 745

Crown RC5500

Hi,

We have a Crown RC5535-30. It is periodically throwing event code 745 and I am concerned i will soon be left with an inoperable forklift. We live in semi-rural BC and getting a technician here isn't easy or quick, especially at this time of year.

I have followed the reference guide for event code 745. The analyzer shows POT4 seems to be operating correctly but the ECR3 input seems inconsistent. Only showing 2 values, either -1 CNT or 0 CNT.

I have checked the power supply between CA602-1 and CA602-4 and I have a clean 5V.

I have checked continuity from CA602-3 and 602-2 to Access 7 (CA231-5 and CA231-4) and i have continuity.

The manual suggests to replace ECR3. Could someone give me some advice on how to go about this? I don't see how to get access to it?

I also tested the voltage of 602-2 and 602-3 to ground and got some unusual voltages. 2V and 21V. It does not pulse when the tiller is rotated.

When 602 is unplugged i have 12v between 602-3 and ground and 12v between 602-2 and ground.

Does this suggest a deeper fault? I can't find any shorted wires or damage.

Any advice would be greatly appreciated.

Posted 13 Dec 2025 08:11
By James_Court
joined 13 Dec'25 - 1 message
BC, Canada

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Problems like this often come down to sensors or calibration rather than a full mechanical failure.

Posted 16 Dec 2025 19:22
Modified 29 Dec 2025 22:09 by poster
By Jewel_Morris
joined 26 Dec'22 - 2 messages
Illinois, United States

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You basically have to take apart the whole tiller assembly. There should be 3 Allan bolts under that black plate if you rotate it. Once you get those apart you should have access to the bearing encoder assembly. It's not super difficult to replace, but it can be a pain to get to.

It is very likely the encoder is bad. It very rare to have an issue with the module or wiring unless you can see obvious damage to the wiring. 12v is expected but if you are getting no change on the 2v output then there is definitely something wrong with the encoder.

Posted 15 Dec 2025 22:59
Modified 15 Dec 2025 23:04 by poster
By DyslexicNerd_01
joined 13 Jun'23 - 226 messages
Wisconsin, United States

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