SP3500-Service-Manual
Uploaded by
Michael HunterSP3500-Service-Manual
Uploaded by
Michael HunterWIRING DIAGRAMS
Electrical Diagrams Index
Electrical Diagrams Index
This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Power Unit W/Options DIA-7335-002 03 - 11/08
Schematic - Platform W/Options DIA-7335-003 03 - 11/08
Schematic - Power Unit DIA-7335-004 01 - 6/08
Schematic - Platform DIA-7335-005 01 - 6/08
Platform Distribution Panel DIA-7335-006 01 - 6/08
Platform Distribution Panel Forks First SAA DIA-7335-007
Power Unit Distribution Panel DIA-7335-008 02 - 6/08
Platform Modules Access 1 & 4 DIA-7335-009
Platform Modules Access 1 & 4 Forks First SAA DIA-7335-010
Control Pod And Light Switches DIA-7335-011
Overhead Guard Lights/Fans DIA-7335-012 01 - 3/08
Traction Control Module Access 3 DIA-7335-013
Steering Control Module Access 5 DIA-7335-014
Hydraulics & Optional MMS DIA-7335-015
Guidance Control Module Access 6 (Optional) DIA-7335-016
Freezer Conditioning (Optional) DIA-7335-017 02 - 6/08
Freezer Conditioning SAA (Optional) DIA-7335-018 01 - 6/08
Power Cables DIA-7335-019 01 - 6/08
Wire Harnesses DIA-7335-020 01 - 3/08
Crown 2007 PF15657-1 Rev. 11/08 DIA-7335-001
05 Rev. 11/08
457
WIRING DIAGRAMS
Schematic - Power Unit w/Options
Schematic - Power Unit w/Options
142223 F 2 of 2
DIA-7335-002 Crown 2007 PF15657-2 Rev. 11/08
03 Rev. 11/08
458
WIRING DIAGRAMS
Schematic - Platform w/Options
Schematic - Platform w/Options
142223 F 1 of 2
Crown 2007 PF15657-3 Rev. 11/08 DIA-7335-003
03 Rev. 11/08
459
WIRING DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
142677 E 2 of 2
DIA-7335-004 Crown 2007 PF15657-4 Rev. 6/08
01 Rev. 6/08
460
WIRING DIAGRAMS
Schematic - Platform
Schematic - Platform
142677 E 1 of 2
Crown 2007 PF15657-5 Rev. 6/08 DIA-7335-005
01 Rev. 6/08
461
WIRING DIAGRAMS
Platform Distribution Panel
Platform Distribution Panel
142680 D
DIA-7335-006 Crown 2007 PF15657-6 Rev. 6/08
01 Rev. 6/08
462
WIRING DIAGRAMS
Platform Distribution Panel Forks First SAA
Platform Distribution Panel Forks First SAA
142696 B
Crown 2007 PF15657-7 DIA-7335-007
463
WIRING DIAGRAMS
Power Unit Distribution Panel
Power Unit Distribution Panel
142681 C
DIA-7335-008 Crown 2007 PF15657-8 Rev. 6/08
02 Rev. 6/08
464
WIRING DIAGRAMS
Platform Modules Access 1 & 4
Platform Modules Access 1 & 4
142682 C
Crown 2007 PF15657-9 DIA-7335-009
465
WIRING DIAGRAMS
Platform Modules Access 1 & 4 Forks First SAA
Platform Modules Access 1 & 4 Forks First SAA
142697 B
DIA-7335-010 Crown 2007 PF15657-10
466
WIRING DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
142683 C
Crown 2007 PF15657-11 DIA-7335-011
467
WIRING DIAGRAMS
Overhead Guard Lights/Fans
Overhead Guard Lights/Fans
142687 C
DIA-7335-012 Crown 2007 PF15657-12 Rev. 6/08
01 Rev. 3/08
468
WIRING DIAGRAMS
Traction Control Module Access 3
Traction Control Module Access 3
142684 B
Crown 2007 PF15657-13 DIA-7335-013
469
WIRING DIAGRAMS
Steering Control Module Access 5
Steering Control Module Access 5
142685 B
DIA-7335-014 Crown 2007 PF15657-14
470
WIRING DIAGRAMS
Hydraulics & Optional MMS
Hydraulics & Optional MMS
142686 A
Crown 2007 PF15657-15 DIA-7335-015
471
WIRING DIAGRAMS
Guidance Control Module Access 6 (Optional)
Guidance Control Module Access 6 (Optional)
142688 A
DIA-7335-016 Crown 2007 PF15657-16
472
WIRING DIAGRAMS
Freezer Conditioning (Optional)
Freezer Conditioning (Optional)
142689 D
Crown 2007 PF15657-17 Rev. 6/08 DIA-7335-017
02 Rev. 6/08
473
WIRING DIAGRAMS
Freezer Conditioning SAA (Optional)
Freezer Conditioning SAA (Optional)
142700 C
DIA-7335-018 Crown 2007 PF15657-18 Rev. 6/08
01 Rev. 6/08
474
WIRING DIAGRAMS
Power Cables
Power Cables
142690 B
Crown 2007 PF15657-19 Rev. 6/08 DIA-7335-019
01 Rev. 6/08
475
WIRING DIAGRAMS
Wire Harnesses
Wire Harnesses
Harness P/N Connected By:
Power Unit
140113 Power Harness: PC206, B-, B+, ED1, ED2
140333(a) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
140334(a) Wire Guidance Harness: JC602, PC603, PC604
140335(a) End Aisle Harness (EAC): JC602, PC607, PC608
141028(a) Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, PVL, RGSL, RGSR, SV1, THS2
142890 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC601, BNEG, BRES1, BRES2, BW-
P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1, THS-P2
143590 CA201, CA202, K15, PC809, HN2
Platform
134322(a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC307, PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331,
CA332, PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140107 Switch Harness: PC104, PC310, PC311, PC312, PC313, FNS, LGS1, LGS2, LGS3
140108 LH Overhead Guard Harness: JC310, JC311, PC314, PC315, PC316, PC501, LGS1, LGS2,
Platform Wall
140109 RH Overhead Guard Harness: JC312, JC313, JC314, JC315, JC316, PC338, PC503, FNS,
LGS3, Platform Wall
140290-001(a) InfoLink Harness
141029(b) Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141530-001 Height Limit Switches
thru
141530-004
141214(a) InfoLink Harness
142218 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
PC306, PC307, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335,
PC501, PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1,
GSI, GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
143589(a) Travel Alarm JC330, JC336, PC701
(a) Optional
(b) SAA Trucks
DIA-7335-020 Crown 2007 PF15657-20 Rev. 6/08
01 Rev. 3/08
476
WIRING DIAGRAMS
Electrical Diagrams Index
Electrical Diagrams Index
This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Power Unit W/Options DIA-7335-002 03 - 11/08
Schematic - Platform W/Options DIA-7335-003 03 - 11/08
Schematic - Power Unit DIA-7335-004 01 - 6/08
Schematic - Platform DIA-7335-005 01 - 6/08
Platform Distribution Panel DIA-7335-006 01 - 6/08
Platform Distribution Panel Forks First SAA DIA-7335-007
Power Unit Distribution Panel DIA-7335-008 02 - 6/08
Platform Modules Access 1 & 4 DIA-7335-009
Platform Modules Access 1 & 4 Forks First SAA DIA-7335-010
Control Pod And Light Switches DIA-7335-011
Overhead Guard Lights/Fans DIA-7335-012 01 - 3/08
Traction Control Module Access 3 DIA-7335-013
Steering Control Module Access 5 DIA-7335-014
Hydraulics & Optional MMS DIA-7335-015
Guidance Control Module Access 6 (Optional) DIA-7335-016
Freezer Conditioning (Optional) DIA-7335-017 02 - 6/08
Freezer Conditioning SAA (Optional) DIA-7335-018 01 - 6/08
Power Cables DIA-7335-019 01 - 6/08
Wire Harnesses DIA-7335-020 01 - 3/08
Crown 2007 PF15657-1 Rev. 11/08 DIA-7335-001
05 Rev. 11/08
457
WIRING DIAGRAMS
Schematic - Power Unit w/Options
Schematic - Power Unit w/Options
142223 F 2 of 2
DIA-7335-002 Crown 2007 PF15657-2 Rev. 11/08
03 Rev. 11/08
458
WIRING DIAGRAMS
Schematic - Platform w/Options
Schematic - Platform w/Options
142223 F 1 of 2
Crown 2007 PF15657-3 Rev. 11/08 DIA-7335-003
03 Rev. 11/08
459
WIRING DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
142677 E 2 of 2
DIA-7335-004 Crown 2007 PF15657-4 Rev. 6/08
01 Rev. 6/08
460
WIRING DIAGRAMS
Schematic - Platform
Schematic - Platform
142677 E 1 of 2
Crown 2007 PF15657-5 Rev. 6/08 DIA-7335-005
01 Rev. 6/08
461
WIRING DIAGRAMS
Platform Distribution Panel
Platform Distribution Panel
142680 D
DIA-7335-006 Crown 2007 PF15657-6 Rev. 6/08
01 Rev. 6/08
462
WIRING DIAGRAMS
Platform Distribution Panel Forks First SAA
Platform Distribution Panel Forks First SAA
142696 B
Crown 2007 PF15657-7 DIA-7335-007
463
WIRING DIAGRAMS
Power Unit Distribution Panel
Power Unit Distribution Panel
142681 C
DIA-7335-008 Crown 2007 PF15657-8 Rev. 6/08
02 Rev. 6/08
464
WIRING DIAGRAMS
Platform Modules Access 1 & 4
Platform Modules Access 1 & 4
142682 C
Crown 2007 PF15657-9 DIA-7335-009
465
WIRING DIAGRAMS
Platform Modules Access 1 & 4 Forks First SAA
Platform Modules Access 1 & 4 Forks First SAA
142697 B
DIA-7335-010 Crown 2007 PF15657-10
466
WIRING DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
142683 C
Crown 2007 PF15657-11 DIA-7335-011
467
WIRING DIAGRAMS
Overhead Guard Lights/Fans
Overhead Guard Lights/Fans
142687 C
DIA-7335-012 Crown 2007 PF15657-12 Rev. 6/08
01 Rev. 3/08
468
WIRING DIAGRAMS
Traction Control Module Access 3
Traction Control Module Access 3
142684 B
Crown 2007 PF15657-13 DIA-7335-013
469
WIRING DIAGRAMS
Steering Control Module Access 5
Steering Control Module Access 5
142685 B
DIA-7335-014 Crown 2007 PF15657-14
470
WIRING DIAGRAMS
Hydraulics & Optional MMS
Hydraulics & Optional MMS
142686 A
Crown 2007 PF15657-15 DIA-7335-015
471
WIRING DIAGRAMS
Guidance Control Module Access 6 (Optional)
Guidance Control Module Access 6 (Optional)
142688 A
DIA-7335-016 Crown 2007 PF15657-16
472
WIRING DIAGRAMS
Freezer Conditioning (Optional)
Freezer Conditioning (Optional)
142689 D
Crown 2007 PF15657-17 Rev. 6/08 DIA-7335-017
02 Rev. 6/08
473
WIRING DIAGRAMS
Freezer Conditioning SAA (Optional)
Freezer Conditioning SAA (Optional)
142700 C
DIA-7335-018 Crown 2007 PF15657-18 Rev. 6/08
01 Rev. 6/08
474
WIRING DIAGRAMS
Power Cables
Power Cables
142690 B
Crown 2007 PF15657-19 Rev. 6/08 DIA-7335-019
01 Rev. 6/08
475
WIRING DIAGRAMS
Wire Harnesses
Wire Harnesses
Harness P/N Connected By:
Power Unit
140113 Power Harness: PC206, B-, B+, ED1, ED2
140333(a) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
140334(a) Wire Guidance Harness: JC602, PC603, PC604
140335(a) End Aisle Harness (EAC): JC602, PC607, PC608
141028(a) Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, PVL, RGSL, RGSR, SV1, THS2
142890 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC601, BNEG, BRES1, BRES2, BW-
P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1, THS-P2
143590 CA201, CA202, K15, PC809, HN2
Platform
134322(a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC307, PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331,
CA332, PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140107 Switch Harness: PC104, PC310, PC311, PC312, PC313, FNS, LGS1, LGS2, LGS3
140108 LH Overhead Guard Harness: JC310, JC311, PC314, PC315, PC316, PC501, LGS1, LGS2,
Platform Wall
140109 RH Overhead Guard Harness: JC312, JC313, JC314, JC315, JC316, PC338, PC503, FNS,
LGS3, Platform Wall
140290-001(a) InfoLink Harness
141029(b) Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141530-001 Height Limit Switches
thru
141530-004
141214(a) InfoLink Harness
142218 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
PC306, PC307, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335,
PC501, PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1,
GSI, GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
143589(a) Travel Alarm JC330, JC336, PC701
(a) Optional
(b) SAA Trucks
DIA-7335-020 Crown 2007 PF15657-20 Rev. 6/08
01 Rev. 3/08
476
WIRING DIAGRAMS
Electrical Diagrams Index
Electrical Diagrams Index
This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Power Unit w/Options DIA-7335-022 01 - 1/10
Schematic - Platform w/Options DIA-7335-023
Schematic - Power Unit w/Pallet Grab DIA-7335-024 02 - 1/10
Schematic - Platform w/Pallet Grab DIA-7335-025 01 - 1/10
Schematic - Power Unit DIA-7335-026
Schematic - Platform DIA-7335-027
Platform Distribution Panel DIA-7335-028 01 - 1/10
Platform Distribution Panel Forks First SAA DIA-7335-029
Power Unit Distribution Panel DIA-7335-030
Platform Modules ACCESS 1 & 4 DIA-7335-031
Platform Modules ACCESS 1 & 4 Forks First SAA DIA-7335-032
Control Pod And Light Switches DIA-7335-033 01 - 2/10
Overhead Guard Lights/Fans DIA-7335-034 01 - 1/10
Overhead Guard Spotlights (Optional) DIA-7335-035
Traction Control Module ACCESS 3 DIA-7335-036 01 - 1/10
Steering Control Module ACCESS 5 DIA-7335-037
Hydraulics & Optional MMS DIA-7335-038
Guidance Control Module ACCESS 6 (Optional) DIA-7335-039 01 - 1/10
Travel Alarm & Freezer Conditioning (Optional) DIA-7335-040 02 - 2/10
Travel Alarm & Pallet Grab DIA-7335-041
Forks First/Lifting Forks (Optional) DIA-7335-042
Power Cables DIA-7335-043
Wire Harnesses DIA-7335-044 01 - 2/10
Crown 2009 PF17806-1 Rev. 2/10 DIA-7335-021
04 Rev. 2/10
459
WIRING DIAGRAMS
Schematic - Power Unit w/Options
Schematic - Power Unit w/Options
142223 H 2 of 4
DIA-7335-022 Crown 2009 PF17806-2 Rev. 1/10
01 Rev. 1/10
460
WIRING DIAGRAMS
Schematic - Platform w/Options
Schematic - Platform w/Options
142223 H 1 of 4
Crown 2009 PF17806-3 DIA-7335-023
461
WIRING DIAGRAMS
Schematic - Power Unit w/Pallet Grab
Schematic - Power Unit w/Pallet Grab
142223 H 4 of 4
DIA-7335-024 Crown 2009 PF17806-4 Rev. 1/10
02 Rev. 1/10
462
WIRING DIAGRAMS
Schematic - Platform w/Pallet Grab
Schematic - Platform w/Pallet Grab
142223 H 3 of 4
Crown 2009 PF17806-5 Rev. 1/10 DIA-7335-025
01 Rev. 1/10
463
WIRING DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
142677 G 2 of 2
DIA-7335-026 Crown 2009 PF17806-6
464
WIRING DIAGRAMS
Schematic - Platform
Schematic - Platform
142677 G 1 of 2
Crown 2009 PF17806-7 DIA-7335-027
465
WIRING DIAGRAMS
Platform Distribution Panel
Platform Distribution Panel
142680 F
DIA-7335-028 Crown 2009 PF17806-8 Rev. 1/10
01 Rev. 1/10
466
WIRING DIAGRAMS
Platform Distribution Panel Forks First SAA
Platform Distribution Panel Forks First SAA
142696 B
Crown 2009 PF17806-9 DIA-7335-029
467
WIRING DIAGRAMS
Power Unit Distribution Panel
Power Unit Distribution Panel
142681 E
DIA-7335-030 Crown 2009 PF17806-10
468
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4
Platform Modules ACCESS 1 & 4
142682 D
Crown 2009 PF17806-11 DIA-7335-031
469
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4 Forks First SAA
Platform Modules ACCESS 1 & 4 Forks First SAA
142697 C
DIA-7335-032 Crown 2009 PF17806-12
470
WIRING DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
142683 D
Crown 2009 PF17806-13 Rev. 2/10 DIA-7335-033
01 Rev. 2/10
471
WIRING DIAGRAMS
Overhead Guard Lights/Fans
Overhead Guard Lights/Fans
142687 D 1 of 2
DIA-7335-034 Crown 2009 PF17806-14 Rev. 1/10
01 Rev. 1/10
472
WIRING DIAGRAMS
Overhead Guard Spotlights (Optional)
Overhead Guard Spotlights (Optional)
142687 D 2 of 2
Crown 2009 PF17806-15 DIA-7335-035
473
WIRING DIAGRAMS
Traction Control Module ACCESS 3
Traction Control Module ACCESS 3
142684 B
DIA-7335-036 Crown 2009 PF17806-16 Rev. 1/10
01 Rev. 1/10
474
WIRING DIAGRAMS
Steering Control Module ACCESS 5
Steering Control Module ACCESS 5
142685 C
Crown 2009 PF17806-17 DIA-7335-037
475
WIRING DIAGRAMS
Hydraulics & Optional MMS
Hydraulics & Optional MMS
142686 A
DIA-7335-038 Crown 2009 PF17806-18
476
WIRING DIAGRAMS
Guidance Control Module ACCESS 6 (Optional)
Guidance Control Module ACCESS 6 (Optional)
142688 A
Crown 2009 PF17806-19 Rev. 1/10 DIA-7335-039
01 Rev. 1/10
477
WIRING DIAGRAMS
Travel Alarm & Freezer Conditioning (Optional)
Travel Alarm & Freezer Conditioning (Optional)
142689 F 1 of 2
DIA-7335-040 Crown 2009 PF17806-20 Rev. 2/10
02 Rev. 2/10
478
WIRING DIAGRAMS
Travel Alarm & Pallet Grab
Travel Alarm & Pallet Grab
142689 F 2 of 2
Crown 2009 PF17806-21 DIA-7335-041
479
WIRING DIAGRAMS
Forks First/Lifting Forks (Optional)
Forks First/Lifting Forks (Optional)
142700 D
DIA-7335-042 Crown 2009 PF17806-22
480
WIRING DIAGRAMS
Power Cables
Power Cables
142690 D
Crown 2009 PF17806-23 DIA-7335-043
481
WIRING DIAGRAMS
Power Cables
Wire Harnesses
Harness P/N Connected By:
Power Unit
146557 Power Harness: PC206, B-, B+, ED1, ED2
140333(a, c) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
142670(a, d) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
140334(a, c) Wire Guidance Harness: JC602, PC603, PC604
142671(a, d) Wire Guidance Harness: JC602, PC603, PC604
140335(a) End Aisle Harness (EAC): JC602, PC607, PC608
141028(a) Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, PVL, RGSL, RGSR, SV1, THS2
142890 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC601, BNEG, BRES1, BRES2, BW-
P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1, THS-P2
143590 CA201, CA202, K15, PC809, HN2
146764 ACCESS 5 to Steer Motor
Platform
134322(a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC307, PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331,
CA332, PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140107 Switch Harness: PC104, PC310, PC311, PC312, PC313, FNS, LGS1, LGS2, LGS3
140108 LH Overhead Guard Harness: JC310, JC311, PC314, PC315, PC316, PC501, LGS1, LGS2,
Platform Wall
140109 RH Overhead Guard Harness: JC312, JC313, JC314, JC315, JC316, PC338, PC503, FNS,
LGS3, Platform Wall
140170(b) CHB7, CHB8, JC331,PC331 (CA331)
140290-001(a) InfoLink Harness
141029(b) Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141530-001 Height Limit Switches
through
141530-004
141214(a) InfoLink Harness
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
DIA-7335-044 Crown 2009 PF17806-24 Rev. 2/10
01 Rev. 2/10
482
WIRING DIAGRAMS
Power Cables
Harness P/N Connected By:
142218 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
PC306, PC307, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335,
PC501, PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1,
GSI, GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
143589(a) Travel Alarm JC330, JC336, PC701
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
Crown 2009 PF17806-25 Rev. 2/10 DIA-7335-045
01 Rev. 2/10
483
WIRING DIAGRAMS
Electrical Diagrams Index
Electrical Diagrams Index
This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Power Unit w/Options DIA-7335-022 01 - 1/10
Schematic - Platform w/Options DIA-7335-023
Schematic - Power Unit w/Pallet Grab DIA-7335-024 02 - 1/10
Schematic - Platform w/Pallet Grab DIA-7335-025 01 - 1/10
Schematic - Power Unit DIA-7335-026
Schematic - Platform DIA-7335-027
Platform Distribution Panel DIA-7335-028 01 - 1/10
Platform Distribution Panel Forks First SAA DIA-7335-029
Power Unit Distribution Panel DIA-7335-030
Platform Modules ACCESS 1 & 4 DIA-7335-031
Platform Modules ACCESS 1 & 4 Forks First SAA DIA-7335-032
Control Pod And Light Switches DIA-7335-033 01 - 2/10
Overhead Guard Lights/Fans DIA-7335-034 01 - 1/10
Overhead Guard Spotlights (Optional) DIA-7335-035
Traction Control Module ACCESS 3 DIA-7335-036 01 - 1/10
Steering Control Module ACCESS 5 DIA-7335-037
Hydraulics & Optional MMS DIA-7335-038
Guidance Control Module ACCESS 6 (Optional) DIA-7335-039 01 - 1/10
Travel Alarm & Freezer Conditioning (Optional) DIA-7335-040 02 - 2/10
Travel Alarm & Pallet Grab DIA-7335-041
Forks First/Lifting Forks (Optional) DIA-7335-042
Power Cables DIA-7335-043
Wire Harnesses DIA-7335-044 01 - 2/10
Crown 2009 PF17806-1 Rev. 2/10 DIA-7335-021
04 Rev. 2/10
459
WIRING DIAGRAMS
Schematic - Power Unit w/Options
Schematic - Power Unit w/Options
142223 H 2 of 4
DIA-7335-022 Crown 2009 PF17806-2 Rev. 1/10
01 Rev. 1/10
460
WIRING DIAGRAMS
Schematic - Platform w/Options
Schematic - Platform w/Options
142223 H 1 of 4
Crown 2009 PF17806-3 DIA-7335-023
461
WIRING DIAGRAMS
Schematic - Power Unit w/Pallet Grab
Schematic - Power Unit w/Pallet Grab
142223 H 4 of 4
DIA-7335-024 Crown 2009 PF17806-4 Rev. 1/10
02 Rev. 1/10
462
WIRING DIAGRAMS
Schematic - Platform w/Pallet Grab
Schematic - Platform w/Pallet Grab
142223 H 3 of 4
Crown 2009 PF17806-5 Rev. 1/10 DIA-7335-025
01 Rev. 1/10
463
WIRING DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
142677 G 2 of 2
DIA-7335-026 Crown 2009 PF17806-6
464
WIRING DIAGRAMS
Schematic - Platform
Schematic - Platform
142677 G 1 of 2
Crown 2009 PF17806-7 DIA-7335-027
465
WIRING DIAGRAMS
Platform Distribution Panel
Platform Distribution Panel
142680 F
DIA-7335-028 Crown 2009 PF17806-8 Rev. 1/10
01 Rev. 1/10
466
WIRING DIAGRAMS
Platform Distribution Panel Forks First SAA
Platform Distribution Panel Forks First SAA
142696 B
Crown 2009 PF17806-9 DIA-7335-029
467
WIRING DIAGRAMS
Power Unit Distribution Panel
Power Unit Distribution Panel
142681 E
DIA-7335-030 Crown 2009 PF17806-10
468
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4
Platform Modules ACCESS 1 & 4
142682 D
Crown 2009 PF17806-11 DIA-7335-031
469
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4 Forks First SAA
Platform Modules ACCESS 1 & 4 Forks First SAA
142697 C
DIA-7335-032 Crown 2009 PF17806-12
470
WIRING DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
142683 D
Crown 2009 PF17806-13 Rev. 2/10 DIA-7335-033
01 Rev. 2/10
471
WIRING DIAGRAMS
Overhead Guard Lights/Fans
Overhead Guard Lights/Fans
142687 D 1 of 2
DIA-7335-034 Crown 2009 PF17806-14 Rev. 1/10
01 Rev. 1/10
472
WIRING DIAGRAMS
Overhead Guard Spotlights (Optional)
Overhead Guard Spotlights (Optional)
142687 D 2 of 2
Crown 2009 PF17806-15 DIA-7335-035
473
WIRING DIAGRAMS
Traction Control Module ACCESS 3
Traction Control Module ACCESS 3
142684 B
DIA-7335-036 Crown 2009 PF17806-16 Rev. 1/10
01 Rev. 1/10
474
WIRING DIAGRAMS
Steering Control Module ACCESS 5
Steering Control Module ACCESS 5
142685 C
Crown 2009 PF17806-17 DIA-7335-037
475
WIRING DIAGRAMS
Hydraulics & Optional MMS
Hydraulics & Optional MMS
142686 A
DIA-7335-038 Crown 2009 PF17806-18
476
WIRING DIAGRAMS
Guidance Control Module ACCESS 6 (Optional)
Guidance Control Module ACCESS 6 (Optional)
142688 A
Crown 2009 PF17806-19 Rev. 1/10 DIA-7335-039
01 Rev. 1/10
477
WIRING DIAGRAMS
Travel Alarm & Freezer Conditioning (Optional)
Travel Alarm & Freezer Conditioning (Optional)
142689 F 1 of 2
DIA-7335-040 Crown 2009 PF17806-20 Rev. 2/10
02 Rev. 2/10
478
WIRING DIAGRAMS
Travel Alarm & Pallet Grab
Travel Alarm & Pallet Grab
142689 F 2 of 2
Crown 2009 PF17806-21 DIA-7335-041
479
WIRING DIAGRAMS
Forks First/Lifting Forks (Optional)
Forks First/Lifting Forks (Optional)
142700 D
DIA-7335-042 Crown 2009 PF17806-22
480
WIRING DIAGRAMS
Power Cables
Power Cables
142690 D
Crown 2009 PF17806-23 DIA-7335-043
481
WIRING DIAGRAMS
Power Cables
Wire Harnesses
Harness P/N Connected By:
Power Unit
146557 Power Harness: PC206, B-, B+, ED1, ED2
140333(a, c) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
142670(a, d) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
140334(a, c) Wire Guidance Harness: JC602, PC603, PC604
142671(a, d) Wire Guidance Harness: JC602, PC603, PC604
140335(a) End Aisle Harness (EAC): JC602, PC607, PC608
141028(a) Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, PVL, RGSL, RGSR, SV1, THS2
142890 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC601, BNEG, BRES1, BRES2, BW-
P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1, THS-P2
143590 CA201, CA202, K15, PC809, HN2
146764 ACCESS 5 to Steer Motor
Platform
134322(a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC307, PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331,
CA332, PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140107 Switch Harness: PC104, PC310, PC311, PC312, PC313, FNS, LGS1, LGS2, LGS3
140108 LH Overhead Guard Harness: JC310, JC311, PC314, PC315, PC316, PC501, LGS1, LGS2,
Platform Wall
140109 RH Overhead Guard Harness: JC312, JC313, JC314, JC315, JC316, PC338, PC503, FNS,
LGS3, Platform Wall
140170(b) CHB7, CHB8, JC331,PC331 (CA331)
140290-001(a) InfoLink Harness
141029(b) Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141530-001 Height Limit Switches
through
141530-004
141214(a) InfoLink Harness
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
DIA-7335-044 Crown 2009 PF17806-24 Rev. 2/10
01 Rev. 2/10
482
WIRING DIAGRAMS
Power Cables
Harness P/N Connected By:
142218 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
PC306, PC307, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335,
PC501, PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1,
GSI, GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
143589(a) Travel Alarm JC330, JC336, PC701
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
Crown 2009 PF17806-25 Rev. 2/10 DIA-7335-045
01 Rev. 2/10
483
WIRING DIAGRAMS
Electrical Diagrams Index
Electrical Diagrams Index
This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Power Unit w/Options DIA-7335-047
Schematic - Platform w/Options DIA-7335-048
Schematic - Power Unit w/Pallet Grab DIA-7335-049
Schematic - Platform w/Pallet Grab DIA-7335-050
Schematic - Power Unit DIA-7335-051
Schematic - Platform DIA-7335-052
Platform Distribution Panel DIA-7335-053
Platform Distribution Panel Forks First SAA DIA-7335-054
Power Unit Distribution Panel DIA-7335-055
Platform Modules ACCESS 1 & 4 DIA-7335-056
Platform Modules ACCESS 1 & 4 Forks First SAA DIA-7335-057
Control Pod And Light Switches DIA-7335-058
Overhead Guard Lights/Fans DIA-7335-059
Overhead Guard Spotlights (Optional) DIA-7335-060
Traction Control Module ACCESS 3 DIA-7335-061
Steering Control Module ACCESS 5 DIA-7335-062
Hydraulics & Optional MMS DIA-7335-063
Guidance Control Module ACCESS 6 (Optional) DIA-7335-064
Travel Alarm & Freezer Conditioning (Optional) DIA-7335-065
Travel Alarm & Pallet Grab DIA-7335-066
Forks First/Lifting Forks (Optional) DIA-7335-067
Power Cables DIA-7335-068
Wire Harnesses DIA-7335-069
Crown 2010 PF17970-1 DIA-7335-046
507
WIRING DIAGRAMS
Schematic - Power Unit w/Options
Schematic - Power Unit w/Options
142223 H 2 of 4
DIA-7335-047 Crown 2010 PF17970-2
508
WIRING DIAGRAMS
Schematic - Platform w/Options
Schematic - Platform w/Options
142223 I 1 of 4
Crown 2010 PF17970-3 DIA-7335-048
509
WIRING DIAGRAMS
Schematic - Power Unit w/Pallet Grab
Schematic - Power Unit w/Pallet Grab
142223 H 4 of 4
DIA-7335-049 Crown 2010 PF17970-4
510
WIRING DIAGRAMS
Schematic - Platform w/Pallet Grab
Schematic - Platform w/Pallet Grab
142223 I 3 of 4
Crown 2010 PF17970-5 DIA-7335-050
511
WIRING DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
142677 G 2 of 2
DIA-7335-051 Crown 2010 PF17970-6
512
WIRING DIAGRAMS
Schematic - Platform
Schematic - Platform
142677 H 1 of 2
Crown 2010 PF17970-7 DIA-7335-052
513
WIRING DIAGRAMS
Platform Distribution Panel
Platform Distribution Panel
142680 F
DIA-7335-053 Crown 2010 PF17970-8
514
WIRING DIAGRAMS
Platform Distribution Panel Forks First SAA
Platform Distribution Panel Forks First SAA
142696 B
Crown 2010 PF17970-9 DIA-7335-054
515
WIRING DIAGRAMS
Power Unit Distribution Panel
Power Unit Distribution Panel
142681 E
DIA-7335-055 Crown 2010 PF17970-10
516
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4
Platform Modules ACCESS 1 & 4
142682 E
Crown 2010 PF17970-11 DIA-7335-056
517
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4 Forks First SAA
Platform Modules ACCESS 1 & 4 Forks First SAA
142697 D
DIA-7335-057 Crown 2010 PF17970-12
518
WIRING DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
142683 D
Crown 2010 PF17970-13 DIA-7335-058
519
WIRING DIAGRAMS
Overhead Guard Lights/Fans
Overhead Guard Lights/Fans
142687 D 1 of 2
DIA-7335-059 Crown 2010 PF17970-14
520
WIRING DIAGRAMS
Overhead Guard Spotlights (Optional)
Overhead Guard Spotlights (Optional)
142687 D 2 of 2
Crown 2010 PF17970-15 DIA-7335-060
521
WIRING DIAGRAMS
Traction Control Module ACCESS 3
Traction Control Module ACCESS 3
142684 B
DIA-7335-061 Crown 2010 PF17970-16
522
WIRING DIAGRAMS
Steering Control Module ACCESS 5
Steering Control Module ACCESS 5
142685 C
Crown 2010 PF17970-17 DIA-7335-062
523
WIRING DIAGRAMS
Hydraulics & Optional MMS
Hydraulics & Optional MMS
142686 A
DIA-7335-063 Crown 2010 PF17970-18
524
WIRING DIAGRAMS
Guidance Control Module ACCESS 6 (Optional)
Guidance Control Module ACCESS 6 (Optional)
142688 A
Crown 2010 PF17970-19 DIA-7335-064
525
WIRING DIAGRAMS
Travel Alarm & Freezer Conditioning (Optional)
Travel Alarm & Freezer Conditioning (Optional)
142689 F 1 of 2
DIA-7335-065 Crown 2010 PF17970-20
526
WIRING DIAGRAMS
Travel Alarm & Pallet Grab
Travel Alarm & Pallet Grab
142689 F 2 of 2
Crown 2010 PF17970-21 DIA-7335-066
527
WIRING DIAGRAMS
Forks First/Lifting Forks (Optional)
Forks First/Lifting Forks (Optional)
142700 D
DIA-7335-067 Crown 2010 PF17970-22
528
WIRING DIAGRAMS
Power Cables
Power Cables
142690 D
Crown 2010 PF17970-23 DIA-7335-068
529
WIRING DIAGRAMS
Wire Harnesses
Wire Harnesses
Harness P/N Connected By:
Power Unit
146557 Power Harness: PC206, B-, B+, ED1, ED2
140333(a, c) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
142670(a, d) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
140334(a, c) Wire Guidance Harness: JC602, PC603, PC604
142671(a, d) Wire Guidance Harness: JC602, PC603, PC604
140335(a) End Aisle Harness (EAC): JC602, PC607, PC608
141028(a) Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, PVL, RGSL, RGSR, SV1, THS2
142890 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC601, BNEG, BRES1, BRES2, BW-
P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1, THS-P2
143590 CA201, CA202, K15, PC809, HN2
146764 ACCESS 5 to Steer Motor
Platform
134322(a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331, CA332,
PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140107 Switch Harness: PC104, PC310, PC311, PC312, PC313, FNS, LGS1, LGS2, LGS3
140108 LH Overhead Guard Harness: JC310, JC311, PC314, PC315, PC316, PC501, LGS1, LGS2,
Platform Wall
140109 RH Overhead Guard Harness: JC312, JC313, JC314, JC315, JC316, PC338, PC503, FNS,
LGS3, Platform Wall
140170(b) CHB7, CHB8, JC331,PC331 (CA331)
140290-001(a) InfoLink Harness
141029(b) Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141530-001 Height Limit Switches
through
141530-004
141214(a) InfoLink Harness
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
DIA-7335-069 Crown 2010 PF17970-24
530
WIRING DIAGRAMS
Wire Harnesses
Harness P/N Connected By:
142218 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
PC306, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335, PC501,
PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1, GSI,
GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
143589(a) Travel Alarm JC330, JC336, PC701
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
Crown 2010 PF17970-25 DIA-7335-070
531
WIRING DIAGRAMS
Electrical Diagrams Index
Electrical Diagrams Index
This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Power Unit w/Options DIA-7335-047
Schematic - Platform w/Options DIA-7335-048
Schematic - Power Unit w/Pallet Grab DIA-7335-049
Schematic - Platform w/Pallet Grab DIA-7335-050
Schematic - Power Unit DIA-7335-051
Schematic - Platform DIA-7335-052
Platform Distribution Panel DIA-7335-053
Platform Distribution Panel Forks First SAA DIA-7335-054
Power Unit Distribution Panel DIA-7335-055
Platform Modules ACCESS 1 & 4 DIA-7335-056
Platform Modules ACCESS 1 & 4 Forks First SAA DIA-7335-057
Control Pod And Light Switches DIA-7335-058
Overhead Guard Lights/Fans DIA-7335-059
Overhead Guard Spotlights (Optional) DIA-7335-060
Traction Control Module ACCESS 3 DIA-7335-061
Steering Control Module ACCESS 5 DIA-7335-062
Hydraulics & Optional MMS DIA-7335-063
Guidance Control Module ACCESS 6 (Optional) DIA-7335-064
Travel Alarm & Freezer Conditioning (Optional) DIA-7335-065
Travel Alarm & Pallet Grab DIA-7335-066
Forks First/Lifting Forks (Optional) DIA-7335-067
Power Cables DIA-7335-068
Wire Harnesses DIA-7335-069
Crown 2010 PF17970-1 DIA-7335-046
507
WIRING DIAGRAMS
Schematic - Power Unit w/Options
Schematic - Power Unit w/Options
142223 H 2 of 4
DIA-7335-047 Crown 2010 PF17970-2
508
WIRING DIAGRAMS
Schematic - Platform w/Options
Schematic - Platform w/Options
142223 I 1 of 4
Crown 2010 PF17970-3 DIA-7335-048
509
WIRING DIAGRAMS
Schematic - Power Unit w/Pallet Grab
Schematic - Power Unit w/Pallet Grab
142223 H 4 of 4
DIA-7335-049 Crown 2010 PF17970-4
510
WIRING DIAGRAMS
Schematic - Platform w/Pallet Grab
Schematic - Platform w/Pallet Grab
142223 I 3 of 4
Crown 2010 PF17970-5 DIA-7335-050
511
WIRING DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
142677 G 2 of 2
DIA-7335-051 Crown 2010 PF17970-6
512
WIRING DIAGRAMS
Schematic - Platform
Schematic - Platform
142677 H 1 of 2
Crown 2010 PF17970-7 DIA-7335-052
513
WIRING DIAGRAMS
Platform Distribution Panel
Platform Distribution Panel
142680 F
DIA-7335-053 Crown 2010 PF17970-8
514
WIRING DIAGRAMS
Platform Distribution Panel Forks First SAA
Platform Distribution Panel Forks First SAA
142696 B
Crown 2010 PF17970-9 DIA-7335-054
515
WIRING DIAGRAMS
Power Unit Distribution Panel
Power Unit Distribution Panel
142681 E
DIA-7335-055 Crown 2010 PF17970-10
516
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4
Platform Modules ACCESS 1 & 4
142682 E
Crown 2010 PF17970-11 DIA-7335-056
517
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4 Forks First SAA
Platform Modules ACCESS 1 & 4 Forks First SAA
142697 D
DIA-7335-057 Crown 2010 PF17970-12
518
WIRING DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
142683 D
Crown 2010 PF17970-13 DIA-7335-058
519
WIRING DIAGRAMS
Overhead Guard Lights/Fans
Overhead Guard Lights/Fans
142687 D 1 of 2
DIA-7335-059 Crown 2010 PF17970-14
520
WIRING DIAGRAMS
Overhead Guard Spotlights (Optional)
Overhead Guard Spotlights (Optional)
142687 D 2 of 2
Crown 2010 PF17970-15 DIA-7335-060
521
WIRING DIAGRAMS
Traction Control Module ACCESS 3
Traction Control Module ACCESS 3
142684 B
DIA-7335-061 Crown 2010 PF17970-16
522
WIRING DIAGRAMS
Steering Control Module ACCESS 5
Steering Control Module ACCESS 5
142685 C
Crown 2010 PF17970-17 DIA-7335-062
523
WIRING DIAGRAMS
Hydraulics & Optional MMS
Hydraulics & Optional MMS
142686 A
DIA-7335-063 Crown 2010 PF17970-18
524
WIRING DIAGRAMS
Guidance Control Module ACCESS 6 (Optional)
Guidance Control Module ACCESS 6 (Optional)
142688 A
Crown 2010 PF17970-19 DIA-7335-064
525
WIRING DIAGRAMS
Travel Alarm & Freezer Conditioning (Optional)
Travel Alarm & Freezer Conditioning (Optional)
142689 F 1 of 2
DIA-7335-065 Crown 2010 PF17970-20
526
WIRING DIAGRAMS
Travel Alarm & Pallet Grab
Travel Alarm & Pallet Grab
142689 F 2 of 2
Crown 2010 PF17970-21 DIA-7335-066
527
WIRING DIAGRAMS
Forks First/Lifting Forks (Optional)
Forks First/Lifting Forks (Optional)
142700 D
DIA-7335-067 Crown 2010 PF17970-22
528
WIRING DIAGRAMS
Power Cables
Power Cables
142690 D
Crown 2010 PF17970-23 DIA-7335-068
529
WIRING DIAGRAMS
Wire Harnesses
Wire Harnesses
Harness P/N Connected By:
Power Unit
146557 Power Harness: PC206, B-, B+, ED1, ED2
140333(a, c) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
142670(a, d) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
140334(a, c) Wire Guidance Harness: JC602, PC603, PC604
142671(a, d) Wire Guidance Harness: JC602, PC603, PC604
140335(a) End Aisle Harness (EAC): JC602, PC607, PC608
141028(a) Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, PVL, RGSL, RGSR, SV1, THS2
142890 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC601, BNEG, BRES1, BRES2, BW-
P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1, THS-P2
143590 CA201, CA202, K15, PC809, HN2
146764 ACCESS 5 to Steer Motor
Platform
134322(a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331, CA332,
PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140107 Switch Harness: PC104, PC310, PC311, PC312, PC313, FNS, LGS1, LGS2, LGS3
140108 LH Overhead Guard Harness: JC310, JC311, PC314, PC315, PC316, PC501, LGS1, LGS2,
Platform Wall
140109 RH Overhead Guard Harness: JC312, JC313, JC314, JC315, JC316, PC338, PC503, FNS,
LGS3, Platform Wall
140170(b) CHB7, CHB8, JC331,PC331 (CA331)
140290-001(a) InfoLink Harness
141029(b) Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141530-001 Height Limit Switches
through
141530-004
141214(a) InfoLink Harness
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
DIA-7335-069 Crown 2010 PF17970-24
530
WIRING DIAGRAMS
Wire Harnesses
Harness P/N Connected By:
142218 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
PC306, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335, PC501,
PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1, GSI,
GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
143589(a) Travel Alarm JC330, JC336, PC701
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
Crown 2010 PF17970-25 DIA-7335-070
531
WIRING DIAGRAMS
Electrical Diagrams Index
Electrical Diagrams Index
This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Power Unit w/Options DIA-7335-076
Schematic - Platform w/Options DIA-7335-077
Schematic - Power Unit w/Pallet Grab DIA-7335-078
Schematic - Platform w/Pallet Grab DIA-7335-079
Schematic - Power Unit DIA-7335-080
Schematic - Platform DIA-7335-081
Platform Distribution Panel DIA-7335-082 01 - 11/11
Platform Distribution Panel Forks First SAA DIA-7335-083
Power Unit Distribution Panel DIA-7335-084
Platform Modules ACCESS 1 & 4 DIA-7335-085
Platform Modules ACCESS 1 & 4 Forks First SAA DIA-7335-086
Control Pod And Light Switches DIA-7335-087
Overhead Guard Lights/Fans DIA-7335-088
Overhead Guard Spotlights (Optional) DIA-7335-089
Traction Control Module ACCESS 3 DIA-7335-090
Steering Control Module ACCESS 5 DIA-7335-091
Hydraulics & Optional MMS DIA-7335-092
Guidance Control Module ACCESS 6 (Optional) DIA-7335-093
Travel Alarm & Freezer Conditioning (Optional) DIA-7335-094
Travel Alarm & Pallet Grab DIA-7335-095
Forks First/Lifting Forks (Optional) DIA-7335-096
Power Cables DIA-7335-097
Wire Harnesses DIA-7335-098 01 - 11/11
Crown 2011 PF25078-1 Rev. 11/11 DIA-7335-075
01 Rev. 11/11
495
WIRING DIAGRAMS
Schematic - Power Unit w/Options
Schematic - Power Unit w/Options
142223 I 2 of 4
DIA-7335-076 Crown 2011 PF25078-2
496
WIRING DIAGRAMS
Schematic - Platform w/Options
Schematic - Platform w/Options
142223 I 1 of 4
Crown 2011 PF25078-3 DIA-7335-077
497
WIRING DIAGRAMS
Schematic - Power Unit w/Pallet Grab
Schematic - Power Unit w/Pallet Grab
142223 I 4 of 4
DIA-7335-078 Crown 2011 PF25078-4
498
WIRING DIAGRAMS
Schematic - Platform w/Pallet Grab
Schematic - Platform w/Pallet Grab
142223 I 3 of 4
Crown 2011 PF25078-5 DIA-7335-079
499
WIRING DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
142677 H 2 of 2
DIA-7335-080 Crown 2011 PF25078-6
500
WIRING DIAGRAMS
Schematic - Platform
Schematic - Platform
142677 H 1 of 2
Crown 2011 PF25078-7 DIA-7335-081
501
4
3
2
1
502
01 Rev. 11/11
DIA-7335-082
A
A
Platform Distribution Panel
(12) TP12 K1
(5) TP5 RAS2
(4) TP4 RAS1
(8) TP8 ALM1
(6) TP6 B FU2
(1) TP1 BRAKE
(2) TP2 B+ FU1
(14) TP14 CAN L
(9) TP9 ED1 FU9
(3) TP3 ED1 FU7
(15) TP15 B NEG
(13) TP13 CAN H
(11) TP11 K1 COIL
(10) TP10 ED1 FU8
(7)TP7 MODULE POWER
WIRING DIAGRAMS
CA101 CA102 CA103
Platform Distribution Panel
1 2 3 4 5 6 7 8 1 2 3 4 5 (8)
16 5917 CA302-2 ALM1 NEG
R2 CR12 15
CA107 (15) (7) R1 14 29124 JC331-1 CHAIN BREAK SWITCHES
1 VR1 ALM1 13
515 PC301-3 BNEG CAN ACCESS 29114 (RAS3) LIFTING FORK OPTION
530 CA322-1 BNEG GTS1 2 (12) 12 2937 CA304-1 +BV KYS ACCESS 4
CR4
520 (CA309) BNEG CHS1 3 C1 (11) 11 2925 CA308-4 +BV KYS CONTROL POD
521 CA320-2 BNEG HGTRS 4 CR2 K1A 10 2941 CA302-3 +BV KYS ACCESS 1
+ K1
580 CA323-2 BNEG ACCESS 1 STR POS IND 5 (6) (9) (5) (2) (1) (10) +t TR1 9 29105 CA323-1 +BV KYS STR POS IND
550 CA355-1 BNEG ZSS 6 CR3 CR1 8 2924 CA308-2 IGN
514 CA309-7 BNEG ORS1 7 7 2923 CA308-3 START
B
B
513 CA302-4 BNEG ACCESS 1 8 6 207 PC301-4 +BV FU2 CAN ACCESS
525 CA304-3 BNEG ACCESS 4 9 (3) (4)
5 5904 (CA321) BRAKE SWITCH
524 (CA321) BNEG BRS 10 4 2935 CA308-11 RAS2
522 (CA321) BNEG HN1 11 3 2932 CA308-10 RAS1
512 PC306-3 BNEG CUSTOMER ACCESSORIES 12 2 2997 (CA303) LIFTING FORKS DIODE
BNEG INFOLINK/INTERMEC OPTION 13 1 2940 PC306-2 +BV FU7 CUST ACCY
(13) CA105 2939 PC301-5 +BV ED1 FU7 CAN ACCESS
CA106 (14)
B+ INFOLINK/INTERMEC OPTION 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 205 PC306-1 BV FU1 CUST ACCY
BRAKE SWITCH BLK CA104 RED/BLK BNEG
BV FU1 WHT WHT/BLK BNEG
BV FU2 RED BLU BNEG
BV ED1 FU9 GRN ORG BNEG
BV ED1 FU8 ORG GRN BNEG
BV ED1 FU7 BLU RED CAN L
RAS1 WHT/BLK WHT CAN H
RAS2 RED/BLK BLK BV AK FROM KYS
MC1
2 MC2
001 CA303-7 CAN H ACCESS 4 1
003 CA302-8 CAN H ACCESS 1 6
005 PC301-1 CAN H ACCESS 29
031 CA323-3 CAN H ACCESS 1 STEER POSITION INDICATOR
2
002 CA303-8 CAN L ACCESS 4 1
C
C
004 CA302-9 CAN L ACCESS 1 6
006 PC301-2 CAN L ACCESS 29
032 CA323-4 CAN L ACCESS 1 STEER POSITION INDICATOR
4
3
2
1
142680 E
Crown 2011 PF25078-8 Rev. 11/11
WIRING DIAGRAMS
Platform Distribution Panel Forks First SAA
Platform Distribution Panel Forks First SAA
142696 B
Crown 2011 PF25078-9 DIA-7335-083
503
WIRING DIAGRAMS
Power Unit Distribution Panel
Power Unit Distribution Panel
142681 E
DIA-7335-084 Crown 2011 PF25078-10
504
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4
Platform Modules ACCESS 1 & 4
142682 E
Crown 2011 PF25078-11 DIA-7335-085
505
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4 Forks First SAA
Platform Modules ACCESS 1 & 4 Forks First SAA
142697 C
DIA-7335-086 Crown 2011 PF25078-12
506
WIRING DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
142683 D
Crown 2011 PF25078-13 DIA-7335-087
507
WIRING DIAGRAMS
Overhead Guard Lights/Fans
Overhead Guard Lights/Fans
142687 E 1 of 2
DIA-7335-088 Crown 2011 PF25078-14
508
WIRING DIAGRAMS
Overhead Guard Spotlights (Optional)
Overhead Guard Spotlights (Optional)
142687 E 2 of 2
Crown 2011 PF25078-15 DIA-7335-089
509
WIRING DIAGRAMS
Traction Control Module ACCESS 3
Traction Control Module ACCESS 3
142684 B
DIA-7335-090 Crown 2011 PF25078-16
510
WIRING DIAGRAMS
Steering Control Module ACCESS 5
Steering Control Module ACCESS 5
142685 C
Crown 2011 PF25078-17 DIA-7335-091
511
WIRING DIAGRAMS
Hydraulics & Optional MMS
Hydraulics & Optional MMS
142686 A
DIA-7335-092 Crown 2011 PF25078-18
512
WIRING DIAGRAMS
Guidance Control Module ACCESS 6 (Optional)
Guidance Control Module ACCESS 6 (Optional)
142688 A
Crown 2011 PF25078-19 DIA-7335-093
513
WIRING DIAGRAMS
Travel Alarm & Freezer Conditioning (Optional)
Travel Alarm & Freezer Conditioning (Optional)
142689 G 1 of 2
DIA-7335-094 Crown 2011 PF25078-20
514
WIRING DIAGRAMS
Travel Alarm & Pallet Grab
Travel Alarm & Pallet Grab
142689 G 2 of 2
Crown 2011 PF25078-21 DIA-7335-095
515
WIRING DIAGRAMS
Forks First/Lifting Forks (Optional)
Forks First/Lifting Forks (Optional)
142700 D
DIA-7335-096 Crown 2011 PF25078-22
516
WIRING DIAGRAMS
Power Cables
Power Cables
142690 D
Crown 2011 PF25078-23 DIA-7335-097
517
WIRING DIAGRAMS
Wire Harnesses
Wire Harnesses
Harness P/N Connected By:
Power Unit
146557 Power Harness: PC206, B-, B+, ED1, ED2
140333(a, c) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
142670(a, d) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
140334(a, c) Wire Guidance Harness: JC602, PC603, PC604
142671(a, d) Wire Guidance Harness: JC602, PC603, PC604
140335(a) End Aisle Harness (EAC): JC602, PC607, PC608
141028(a) Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, PVL, RGSL, RGSR, SV1, THS2
142890 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC601, BNEG, BRES1, BRES2, BW-
P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1, THS-P2
143590 CA201, CA202, K15, PC809, HN2
146764 ACCESS 5 to Steer Motor
Platform
134322(a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331, CA332,
PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140170(b) CHB7, CHB8, JC331,PC331 (CA331)
140290-001(a) InfoLink® Harness
141029(b) Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141530-001 Height Limit Switches
through
141530-004
141214(a) InfoLink Harness
142218 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
PC306, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335, PC501,
PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1, GSI,
GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
DIA-7335-098 Crown 2011 PF25078-24 Rev. 11/11
01 Rev. 11/11
518
WIRING DIAGRAMS
Wire Harnesses
Harness P/N Connected By:
142218-001 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
SP3580 PC306, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335, PC501,
PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1, GSI,
GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
143589(a) Travel Alarm JC330, JC336, PC701
149374 Lights/Fan Harness: PC102, PC338, PC501, PC503, LGS1, LGS3, FNS
149375 Work Lights Harness: PC102, LGS3
149720 InfoLink®/Intermec Cable Assembly
149721 InfoLink/Intermec Harness: PROX, RS232
149722 PROX Extender Harness: PROX
150354(a) Windows® InfoLink CAN Breakout Harness: ALARM, CAN, CURRENT, LOAD, PROG, PROX,
MODULE, RS232, SHOCK
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
Crown 2011 PF25078-25 Rev. 11/11 DIA-7335-099
01 Rev. 11/11
519
WIRING DIAGRAMS
Electrical Diagrams Index
Electrical Diagrams Index
This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Power Unit w/Options DIA-7335-076
Schematic - Platform w/Options DIA-7335-077
Schematic - Power Unit w/Pallet Grab DIA-7335-078
Schematic - Platform w/Pallet Grab DIA-7335-079
Schematic - Power Unit DIA-7335-080
Schematic - Platform DIA-7335-081
Platform Distribution Panel DIA-7335-082 01 - 11/11
Platform Distribution Panel Forks First SAA DIA-7335-083
Power Unit Distribution Panel DIA-7335-084
Platform Modules ACCESS 1 & 4 DIA-7335-085
Platform Modules ACCESS 1 & 4 Forks First SAA DIA-7335-086
Control Pod And Light Switches DIA-7335-087
Overhead Guard Lights/Fans DIA-7335-088
Overhead Guard Spotlights (Optional) DIA-7335-089
Traction Control Module ACCESS 3 DIA-7335-090
Steering Control Module ACCESS 5 DIA-7335-091
Hydraulics & Optional MMS DIA-7335-092
Guidance Control Module ACCESS 6 (Optional) DIA-7335-093
Travel Alarm & Freezer Conditioning (Optional) DIA-7335-094
Travel Alarm & Pallet Grab DIA-7335-095
Forks First/Lifting Forks (Optional) DIA-7335-096
Power Cables DIA-7335-097
Wire Harnesses DIA-7335-098 01 - 11/11
Crown 2011 PF25078-1 Rev. 11/11 DIA-7335-075
01 Rev. 11/11
495
WIRING DIAGRAMS
Schematic - Power Unit w/Options
Schematic - Power Unit w/Options
142223 I 2 of 4
DIA-7335-076 Crown 2011 PF25078-2
496
WIRING DIAGRAMS
Schematic - Platform w/Options
Schematic - Platform w/Options
142223 I 1 of 4
Crown 2011 PF25078-3 DIA-7335-077
497
WIRING DIAGRAMS
Schematic - Power Unit w/Pallet Grab
Schematic - Power Unit w/Pallet Grab
142223 I 4 of 4
DIA-7335-078 Crown 2011 PF25078-4
498
WIRING DIAGRAMS
Schematic - Platform w/Pallet Grab
Schematic - Platform w/Pallet Grab
142223 I 3 of 4
Crown 2011 PF25078-5 DIA-7335-079
499
WIRING DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
142677 H 2 of 2
DIA-7335-080 Crown 2011 PF25078-6
500
WIRING DIAGRAMS
Schematic - Platform
Schematic - Platform
142677 H 1 of 2
Crown 2011 PF25078-7 DIA-7335-081
501
4
3
2
1
502
01 Rev. 11/11
DIA-7335-082
A
A
Platform Distribution Panel
(12) TP12 K1
(5) TP5 RAS2
(4) TP4 RAS1
(8) TP8 ALM1
(6) TP6 B FU2
(1) TP1 BRAKE
(2) TP2 B+ FU1
(14) TP14 CAN L
(9) TP9 ED1 FU9
(3) TP3 ED1 FU7
(15) TP15 B NEG
(13) TP13 CAN H
(11) TP11 K1 COIL
(10) TP10 ED1 FU8
(7)TP7 MODULE POWER
WIRING DIAGRAMS
CA101 CA102 CA103
Platform Distribution Panel
1 2 3 4 5 6 7 8 1 2 3 4 5 (8)
16 5917 CA302-2 ALM1 NEG
R2 CR12 15
CA107 (15) (7) R1 14 29124 JC331-1 CHAIN BREAK SWITCHES
1 VR1 ALM1 13
515 PC301-3 BNEG CAN ACCESS 29114 (RAS3) LIFTING FORK OPTION
530 CA322-1 BNEG GTS1 2 (12) 12 2937 CA304-1 +BV KYS ACCESS 4
CR4
520 (CA309) BNEG CHS1 3 C1 (11) 11 2925 CA308-4 +BV KYS CONTROL POD
521 CA320-2 BNEG HGTRS 4 CR2 K1A 10 2941 CA302-3 +BV KYS ACCESS 1
+ K1
580 CA323-2 BNEG ACCESS 1 STR POS IND 5 (6) (9) (5) (2) (1) (10) +t TR1 9 29105 CA323-1 +BV KYS STR POS IND
550 CA355-1 BNEG ZSS 6 CR3 CR1 8 2924 CA308-2 IGN
514 CA309-7 BNEG ORS1 7 7 2923 CA308-3 START
B
B
513 CA302-4 BNEG ACCESS 1 8 6 207 PC301-4 +BV FU2 CAN ACCESS
525 CA304-3 BNEG ACCESS 4 9 (3) (4)
5 5904 (CA321) BRAKE SWITCH
524 (CA321) BNEG BRS 10 4 2935 CA308-11 RAS2
522 (CA321) BNEG HN1 11 3 2932 CA308-10 RAS1
512 PC306-3 BNEG CUSTOMER ACCESSORIES 12 2 2997 (CA303) LIFTING FORKS DIODE
BNEG INFOLINK/INTERMEC OPTION 13 1 2940 PC306-2 +BV FU7 CUST ACCY
(13) CA105 2939 PC301-5 +BV ED1 FU7 CAN ACCESS
CA106 (14)
B+ INFOLINK/INTERMEC OPTION 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 205 PC306-1 BV FU1 CUST ACCY
BRAKE SWITCH BLK CA104 RED/BLK BNEG
BV FU1 WHT WHT/BLK BNEG
BV FU2 RED BLU BNEG
BV ED1 FU9 GRN ORG BNEG
BV ED1 FU8 ORG GRN BNEG
BV ED1 FU7 BLU RED CAN L
RAS1 WHT/BLK WHT CAN H
RAS2 RED/BLK BLK BV AK FROM KYS
MC1
2 MC2
001 CA303-7 CAN H ACCESS 4 1
003 CA302-8 CAN H ACCESS 1 6
005 PC301-1 CAN H ACCESS 29
031 CA323-3 CAN H ACCESS 1 STEER POSITION INDICATOR
2
002 CA303-8 CAN L ACCESS 4 1
C
C
004 CA302-9 CAN L ACCESS 1 6
006 PC301-2 CAN L ACCESS 29
032 CA323-4 CAN L ACCESS 1 STEER POSITION INDICATOR
4
3
2
1
142680 E
Crown 2011 PF25078-8 Rev. 11/11
WIRING DIAGRAMS
Platform Distribution Panel Forks First SAA
Platform Distribution Panel Forks First SAA
142696 B
Crown 2011 PF25078-9 DIA-7335-083
503
WIRING DIAGRAMS
Power Unit Distribution Panel
Power Unit Distribution Panel
142681 E
DIA-7335-084 Crown 2011 PF25078-10
504
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4
Platform Modules ACCESS 1 & 4
142682 E
Crown 2011 PF25078-11 DIA-7335-085
505
WIRING DIAGRAMS
Platform Modules ACCESS 1 & 4 Forks First SAA
Platform Modules ACCESS 1 & 4 Forks First SAA
142697 C
DIA-7335-086 Crown 2011 PF25078-12
506
WIRING DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
142683 D
Crown 2011 PF25078-13 DIA-7335-087
507
WIRING DIAGRAMS
Overhead Guard Lights/Fans
Overhead Guard Lights/Fans
142687 E 1 of 2
DIA-7335-088 Crown 2011 PF25078-14
508
WIRING DIAGRAMS
Overhead Guard Spotlights (Optional)
Overhead Guard Spotlights (Optional)
142687 E 2 of 2
Crown 2011 PF25078-15 DIA-7335-089
509
WIRING DIAGRAMS
Traction Control Module ACCESS 3
Traction Control Module ACCESS 3
142684 B
DIA-7335-090 Crown 2011 PF25078-16
510
WIRING DIAGRAMS
Steering Control Module ACCESS 5
Steering Control Module ACCESS 5
142685 C
Crown 2011 PF25078-17 DIA-7335-091
511
WIRING DIAGRAMS
Hydraulics & Optional MMS
Hydraulics & Optional MMS
142686 A
DIA-7335-092 Crown 2011 PF25078-18
512
WIRING DIAGRAMS
Guidance Control Module ACCESS 6 (Optional)
Guidance Control Module ACCESS 6 (Optional)
142688 A
Crown 2011 PF25078-19 DIA-7335-093
513
WIRING DIAGRAMS
Travel Alarm & Freezer Conditioning (Optional)
Travel Alarm & Freezer Conditioning (Optional)
142689 G 1 of 2
DIA-7335-094 Crown 2011 PF25078-20
514
WIRING DIAGRAMS
Travel Alarm & Pallet Grab
Travel Alarm & Pallet Grab
142689 G 2 of 2
Crown 2011 PF25078-21 DIA-7335-095
515
WIRING DIAGRAMS
Forks First/Lifting Forks (Optional)
Forks First/Lifting Forks (Optional)
142700 D
DIA-7335-096 Crown 2011 PF25078-22
516
WIRING DIAGRAMS
Power Cables
Power Cables
142690 D
Crown 2011 PF25078-23 DIA-7335-097
517
WIRING DIAGRAMS
Wire Harnesses
Wire Harnesses
Harness P/N Connected By:
Power Unit
146557 Power Harness: PC206, B-, B+, ED1, ED2
140333(a, c) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
142670(a, d) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
140334(a, c) Wire Guidance Harness: JC602, PC603, PC604
142671(a, d) Wire Guidance Harness: JC602, PC603, PC604
140335(a) End Aisle Harness (EAC): JC602, PC607, PC608
141028(a) Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, PVL, RGSL, RGSR, SV1, THS2
142890 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC601, BNEG, BRES1, BRES2, BW-
P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1, THS-P2
143590 CA201, CA202, K15, PC809, HN2
146764 ACCESS 5 to Steer Motor
Platform
134322(a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331, CA332,
PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140170(b) CHB7, CHB8, JC331,PC331 (CA331)
140290-001(a) InfoLink® Harness
141029(b) Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141530-001 Height Limit Switches
through
141530-004
141214(a) InfoLink Harness
142218 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
PC306, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335, PC501,
PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1, GSI,
GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
DIA-7335-098 Crown 2011 PF25078-24 Rev. 11/11
01 Rev. 11/11
518
WIRING DIAGRAMS
Wire Harnesses
Harness P/N Connected By:
142218-001 Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
SP3580 PC306, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335, PC501,
PC503, PC701, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1, GSI,
GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1, RAS1,
RAS2, RS
143589(a) Travel Alarm JC330, JC336, PC701
149374 Lights/Fan Harness: PC102, PC338, PC501, PC503, LGS1, LGS3, FNS
149375 Work Lights Harness: PC102, LGS3
149720 InfoLink®/Intermec Cable Assembly
149721 InfoLink/Intermec Harness: PROX, RS232
149722 PROX Extender Harness: PROX
150354(a) Windows® InfoLink CAN Breakout Harness: ALARM, CAN, CURRENT, LOAD, PROG, PROX,
MODULE, RS232, SHOCK
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
Crown 2011 PF25078-25 Rev. 11/11 DIA-7335-099
01 Rev. 11/11
519
SCHEMATIC DIAGRAMS
Index
Index
This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Power Unit w/Options DIA-7335-106
Schematic - Platform w/Options DIA-7335-107
Schematic - Power Unit w/Pallet Grab DIA-7335-108
Schematic - Platform w/Pallet Grab DIA-7335-109
Schematic - Power Unit DIA-7335-110
Schematic - Platform DIA-7335-111
Platform Distribution Panel DIA-7335-112
Platform Distribution Panel Forks First SAA DIA-7335-113
Power Unit Distribution Panel DIA-7335-114
Platform Modules ACCESS 1 & 4 DIA-7335-115
Platform Modules ACCESS 1 & 4 Forks First SAA DIA-7335-116
Control Pod And Light Switches DIA-7335-117
Overhead Guard Lights/Fans DIA-7335-118
Overhead Guard Spotlights (Optional) DIA-7335-119
Traction Control Module ACCESS 3 DIA-7335-120
Steering Control Module ACCESS 5 DIA-7335-121
Hydraulics & Optional MMS DIA-7335-122
Guidance Control Module ACCESS 6 (Optional) DIA-7335-123
Travel Alarm & Freezer Conditioning (Optional) DIA-7335-124
Travel Alarm & Pallet Grab DIA-7335-125
Forks First Option w/Heaters DIA-7335-126
Power Cables DIA-7335-127
Wire Harnesses DIA-7335-128
Crown 2013 PF25841-1 Rev. 11/11 DIA-7335-105
63
SCHEMATIC DIAGRAMS
Schematic - Power Unit w/Options
Schematic - Power Unit w/Options
A B C
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-3 M3-4 M3-5 M3-6 M3-7 M3-8 M2-1 M2-2 M2-3 M2-4 M2-6 M2-8
MAST SPOT
1 2 3 4
BNEG
BNEG
+BV (ED1) FU9
TRAVEL ALARM
+BV (ED1) FU8
+BV (ED1) FU7
BRAKE DISCONNECT
SHOCK SENSOR
CAN_H
BV AK
BNEG
BNEG
BNEG
CAN_L
+BV FU2
B+
+BV FU1
RAS1
RAS2
+BV C/C
14 PVLF
C/C THS-3
C/C THS-3
+BV C/C
SV1
1
1 SV1 1
K15
FU8
9
PVLF
POWER UNIT
MAST 3 C/C 4
FU7 FU9
SPOTLIGHTS
7 M4
FU14 P2
LGT1 M3
FIL1 + FU13 P1
NOTE:
TRUCK SHOWN WITH PLATFORM
LOWERED, GATES DOWN, 1 LIFTING FORKS OPTION.
AND UNATTENDED.
FU15 ACCESS 3 2 GUIDANCE OPTION.
+ B- 3 MAST MOUNTED
12 CA401
CHB5 CHB4 B+ U U ECR6 SPOTLIGHTS OPTION.
20 V V M1 MAST 4 COLD CONDITION OPTION.
CHS4 CHS3 W W3 HEIGHT 5 PLATFORM LIGHTS/FANS
17 10 CHB FEEDBACK
OPTION.
1 11 CHA 6 BATTERY RESTRAINT
SVL 22 2 ED COIL ED2 OPTION.
2 7 DRIVER (-) 7 DUAL PUMP OPTION. 2
P2 21 TS1 TRACTION
16 TEMP 8 MOTOR MANAGEMENT
+t° TEMP
P1 18 15 14 3 +12V SYSTEM OPTION.
5 6 CHB
FAN2 8 23 7 13 4 CHA 9 TRAVEL ALARM OPTION.
ECR3
CAN_L
CAN_H
NEG TRACTION 10 SAA GATE OPTION.
8
11 EU DEADMAN SWITCH.
MMS
12 EU CHAIN BREAK SWITCHES.
M2 13 ZONE SELECT OPTION.
ED1
ACCESS 5 14 INFOLINK OPTION.
STEER A2
A1 STEER A1 A2 15 PALLET GRAB OPTION.
FU10
B+ CA403 B-
FU5 21
0+ 9 3
FU6
4
22 CR10
0+ I+ 7 19 ED COIL DRIVER (+)
I+ CA407 18 ED IN CS1
BRK I- 27 +5V
SIG CURRENT CR9
I- 0- 8 6 24 NEG SENSE
28 ECR2
0- BRK REL 17 20 13 CHA +5V STEERING
23 INDEX FEEDBACK 6 K2
PVL 11
12 14
CHB
CAN_H CA402-4
CA402-5
NEG
120 OHM
PVL 2 BRES1 BRES2
5
+BV LOGIC 10 RGSR 2 RGSL
3 B+ SENSE 25 16 3
26 BNEG SENSE
CAN_L
JC413 RES2
RES3
DTS1
9 HN2
K15
LOAD WHEEL
SENSOR BAR 2 ACCESS 6 EAC DIST PNL
DIG 1
B1
GS2 1 +12V CA608-1 2 1 BNEG 2
1 COIL 1 24 2
3
BNEG CA608-2
4 3 ANATST 34 EAC
CA604
A1 TST 1 2
2 COIL 2 25 4 A1 ANA 5 +12V 5
3 BNEG 23 5 A1 DIG 3 CA605
5 +5V 22 CA602 DIG 1
A1
6 STEST 28 6 A2 TST 4 2 1 BNEG 2
26
CA607
TR2 7 8 COIL 3 7 A2 ANA 5 3 TST 3 EAC
COIL 4 27 8 A2 DIG 6 4 5 ANA 4
+t° TR3 2 9 B1 TST 7 +12V 5
GS1 10 B1 ANA 8 CA606
FU2
+t° CR11 11 B1 DIG A2
1
COIL 4 17 9 1 BNEG
DIG 1
12 B2 TST 10 2 2
CA603
2COIL 3 18 11 3 TST 3 EAC
3 16 13 B2 ANA
CA601-2
CAN_L CA601-5
4 5 ANA
CA601-1
CA601-4
BNEG 4
FU3 2 5 15 14 B2 DIG 12 +12V 5
4 +5V
6
STEST 21 CA609 B2 4
FU1
7 8
COIL 2 19 1 DIG 1
COIL 1 20 2 BNEG 2
STEER WHEEL CA610 4 3 ANATST 34 EAC
SENSOR BAR 5 +12V 5
CAN_H
ED1 ED2
FU4
K2 24V BATT
+
A B C
149646 A 4 of 9
DIA-7335-106 Crown 2013 PF25841-2
64
SCHEMATIC DIAGRAMS
Schematic - Platform w/Options
Schematic - Platform w/Options
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS TRUCK SHOWN WITH PLATFORM LOWERED
1 GATES DOWN AND UNATTENDED.
1 1
RAS4 ACCESS 4
RAS3 CA304-2
CA303-9 CA304-7
LOS3 LMS1 CA303-1 SIG POT1
CA303-10 TRACTON
+12V CA303-4 +5V
LOS4 CA304-21 CA303-19 NEG
ECR5 CHA CA304-22
STEER CHB CA304-23 CA303-20
COMMAND NEG CA304-20 CA303-21
ECR1
+12V CA304-18
STEER CHA CA304-16 CHS2 CHS1
COMMAND
CHB CA304-17 CA304-11
NEG CA304-19 GTS2 GTS1 GTS5 GTS6
ECR4 +5V CA303-12 CA304-10
HEIGHT CHA CA303-13 10
ENCODER CHB CA303-14 CA303-6
NEG CA303-15 CA303-23 ZSSA HGTRS NOTE:
FS
CA304-9 1 LIFTING FORKS OPTION.
RS CA304-13 ZSSB
CA304-8 ZSS 13 2 GUIDANCE OPTION.
CA304-1
CAN_H CA303-7
CAN_L CA303-8
CA304-3
CA303-16 CA304-14 ZSSC
LOS1 3 MAST MOUNTED SPOTLIGHTS
CA303-17 CA304-5 OPTION.
LOS2 CA303-3
CA304-4
CA303-18 4 COLD CONDITION OPTION.
12 CHB7 CHB8
5 PLATFORM LIGHTS/FANS OPTION.
RAS1 6 BATTERY RESTRAINT OPTION.
2 2
7 RAS2 ACCESS 1
7 DUAL PUMP OPTION.
CA302-3 CA302-4 8 MOTOR MANAGEMENT SYSTEM
OPTION.
9 TRAVEL ALARM OPTION.
2
120 OHM
10 SAA GATE OPTION.
ALM1 GUS
CR12 CA302-14
11 EU DEADMAN SWITCH.
CAN_H CA302-8
CAN_L CA302-9
CA302-2 ORS1
CA302-13 12 EU CHAIN BREAK SWITCHES.
CA302-1 DMS1 13 ZONE SELECT OPTION.
11 14 INFOLINK® OPTION.
15 PALLET GRAB OPTION.
STEER POSITION INDICATOR
CA323-3
CA323-4
CA323-2
CA323-1
R1 R2
CAN_L
CAN_H
VR1
3 + C1 3
BRS
CA301 PROG CA301
CAN_H K1
CAN_L
CR1 CR2
KYS CR3
START TR1
ACC -T°
CR4
+BV (ED1) FU7 (CUSTOMER OPTIONS)
EDS IGN K1
OFF
+BV FU1 (CUSTOMER OPTIONS)
PLATFORM
LIGTHS/FAN
5
LIFTING FORK COILS
BRAKE DISCONNECT
4 5 13 251524
(FAN/SPOT LIGHTS)
MAST SPOT LIGHT
4 4
(POWER SUPPLY)
INFOLINK 14 PLATFORM
+BV (ED1) FU8
+BV (ED1) FU9
TRAVEL ALARM
6 7 8 9 C/C 4
+BV AK
CAN_H
CAN_L
+BV FU2
C/C THS-3
C/C THS-3
BNEG
BNEG
BNEG
BNEG
BNEG
1
+BV C/C
+BV C/C
RAS1
RAS2
1
PVLF
SV1
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-1 M2-3 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-2 M2-4 M2-6 M2-8
A B C
149646 A 3 of 9
Crown 2013 PF25841-3 DIA-7335-107
65
SCHEMATIC DIAGRAMS
Schematic - Power Unit w/Pallet Grab
Schematic - Power Unit w/Pallet Grab
A B C
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-4 M2-6 M2-8
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-1 M2-2 M2-3 M2-5 M2-7
MAST SPOT
1 2 3 4 15
BNEG
BNEG
TRAVEL ALARM
+BV (ED1) FU9
BNEG
BNEG
BNEG
CAN_H
+BV AK
+BV (ED1) FU8
+BV (ED1) FU7
CAN_L
PALLET
PALLET
PALLET
PALLET
B+ PVLF
BRAKE DISCONNECT
POWER UNIT
+BV FU1
+BV FU2 SHOCK SENSOR
GRAB
GRAB
GRAB
GRAB
SV1
RAS1
RAS2
14
1 1 1
SV1
K15 9
FU8
FU19 FU16
PVLF FU18 FU17
MAST
FU7 FU9 SPOTLIGHTS
3
7 M4
FU14 P2
LGT1 M3
FIL1 + FU13 P1
FU15 ACCESS 3
+ B-
12 CA401
CHB5 CHB4 B+ U U ECR6
20 V V M1 MAST NOTE:
CHS4 CHS3 W W3 HEIGHT 1 LIFTING FORKS OPTION.
17 10 CHB ENCODER
1 11 CHA 2 GUIDANCE OPTION.
SVL 22 2 ED COIL DRIVER (-) ED2 3 MAST MOUNTED
2 7
P2 21 TS1TRACTION SPOTLIGHTS OPTION. 2
16 TEMP 4 COLD CONDITION OPTION.
3 +t° TEMP
P1 18 15 10 +12V
5 6 CHA 5 PLATFORM LIGHTS/FANS
8 23 7 13 4 CHB
FAN2 ECR3 OPTION.
CAN_H
CAN_L
NEG TRACTION 6 BATTERY RESTRAINT OPTION.
8 7 DUAL PUMP OPTION.
MMS
8 MOTOR MANAGEMENT
M2 SYSTEM OPTION.
ED1 9 TRAVEL ALARM OPTION.
ACCESS 5 10 SAA GATE OPTION.
STEER A2
A1 STEER A1 A2
FU10 11 EU DEADMAN SWITCH.
B+ B-
0+ FU5 9 21
3
12 EU CHAIN BREAK SWITCHES.
4
22
ED COIL DRIVER (+) CR10 13 ZONE SELECT OPTION.
FU6 I+ 19
7 14 INFOLINK® OPTION.
0+ CA407 CA403 18 +5V ED IN
I+ 27 SIG CS1 CR9 15 PALLET GRAB OPTION.
BRK I- I- 6 24 28 NEG CURRENT
SENSE ECR2
0- 0- 8 20 13 CHA +5V
BRK REL 17 STEERING K2
23 INDEX FEEDBACK
11 12 14
PVL CHB 6
CAN_H CA402-4
CAN_L CA402-5
NEG BRES1
120 OHM
PVL 2 5
+BV LOGIC 10 RGSR 2 RGSL BRES2
3 +B SENSE 25 16
26
3
BNEG SENSE
JC413 RES2
RES3
DTS1
9 HN2
K15
LOAD WHEEL 2 EAC DIST PNL
SENSOR BAR 2 ACCESS 6 DIG 1
B1
GS2 +12V CA608-1 2 1
2 1
BNEG 2
COIL 1 24 BNEG CA608-2 3 TST 3 EAC
1 3 A1 TST 1 2 4 5 ANA 4
CA604
2 COIL 2 25 +12V 5
3 BNEG 23
4 A1 ANA
3 CA605
5 +5V 22 CA602 6 5 A1 DIG
DIG
A1
4 2 1
A2 TST 1
6 STEST 28 BNEG
CA607
2
TR2 7 8 COIL 3 26 7 A2 ANA 5 3 TST 3 EAC
COIL 4 27 8 A2 DIG 6 4 5 ANA 4
+t° TR3 9 B1 TST 7 +12V 5
GS1 2 10 B1 ANA 8 CA606 A2
+t° CR11 11 B1 DIG 9 1 DIG 1
1 COIL 4 17 12 B2 TST 10 2 BNEG 2
EAC
3
CA603
3
2 COIL 3 18 13 B2 ANA 11 4 5 ANA
TST
4
CA601-4
CA601-2
CA601-1
3 BNEG 16
CA601-5
FU3 B2 DIG 12 +12V 5
4 5 +5V
6 STEST 21
15 14
CA609 B2
4
FU1
FU2
COIL 2
7 8 COIL 19 1 DIG 1
1 20 2 BNEG 2
EAC
STEER WHEEL
CA610 4 3 ANA
TST 3
4
SENSOR BAR 5 +12V 5
CAN_L
CAN_H
ED1 ED2
FU4
K2 24V BATT
+
A B C
149646 A 6 of 9
DIA-7335-108 Crown 2013 PF25841-4
66
SCHEMATIC DIAGRAMS
Schematic - Platform w/Pallet Grab
Schematic - Platform w/Pallet Grab
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS TRUCK SHOWN WITH PLATFORM LOWERED
1 1 GATES DOWN AND UNATTENDED. 1
RAS4 ACCESS 4
RAS3 CA304-2
CA303-9 CA304-7
LOS3 LMS1 CA303-1 SIG POT1
CA303-10 CA303-4 +5V TRACTON
LOS4 +12V CA304-21
ECR5 CHA CA304-22 CA303-19 NEG
STEER CHB CA304-23 CA303-20
COMMAND NEG CA304-20 CA303-21
ECR1 +12V CA304-18
STEER CHA CA304-16 CHS2 CHS1
COMMAND CHB CA304-17 CA304-11 NOTE:
NEG CA304-19 GTS2 GTS1 GTS5 GTS6 1 LIFTING FORKS OPTION.
ECR4 +5V CA303-12 CA304-10
HEIGHT CHA CA303-13 HGTRS 10 2 GUIDANCE OPTION.
ENCODER CHB CA303-14 CA303-6
NEG CA303-15 CA303-23 ZSSA 3 MAST MOUNTED
FS SPOTLIGHTS OPTION.
CA304-9
RS CA304-13 ZSSB 4 COLD CONDITION OPTION.
CA304-8 ZSS 13 CLAMP 16
CA303-16 CA304-14 ZSSC 5 PLATFORM LIGHTS/FANS OPTION.
CAN_H CA303-7
CAN_L CA303-8
CA304-3
CA304-1
LOS1 CA303-22
CA303-17 6 BATTERY RESTRAINT OPTION.
LOS2 CA303-3 CA304-5 DETECT
CA303-18 7 DUAL PUMP OPTION.
12 CHB7 CHB8 CA304-4
8 MOTOR MANAGEMENT
SYSTEM OPTION.
2 RAS1 9 TRAVEL ALARM OPTION. 2
7 RAS2 ACCESS 1
10 SAA GATE OPTION.
CA302-3 11 EU DEADMAN SWITCH.
CA302-4
12 EU CHAIN BREAK SWITCHES.
2
13 ZONE SELECT OPTION.
120 OHM
ALM1 GUS 14 INFOLINK® OPTION.
CA302-14
ORS1
CAN_H CA302-8
CAN_L CA302-9
CA302-2 15 PALLET GRAB OPTION.
CR12 CA302-13
DMS1 16 PALLET CLAMP
CA302-1 & DETECT OPTION.
11
STEER POSITION INDICATOR
CA323-3
CAN_L CA323-4
CA323-2
CA323-1
R2
R1
CAN_H
VR1
3 + C1 3
BRS
CA301 PROG CA301 CAN_H K1
CAN_L
CR1 CR2
KYS CR3
START TR1
-T°
ACC
EDS CR4
IGN K1
OFF
PLATFORM
LIGTHS/FAN
5
(CUSTOMER OPTIONS)
(CUSTOMER OPTIONS)
LIFTING FORK COILS
BRAKE DISCONNECT
(FAN/SPOT LIGHTS)
4 5 13 251524
4 4
+BV (ED1) FU7
(POWER SUPPLY)
+BV (ED1) FU8
INFOLINK 14
TRAVEL ALARM
+BV (ED1) FU9
+BV (FU1)
PALLET GRAB
6 7 8 9
MAST SPOT
CAN_H
15
CAN_L
+BV FU2
1
+BV AK
BNEG
BNEG
BNEG
BNEG
BNEG
RAS1
RAS2
PVLF 1
B-
B-
B-
B-
SV1
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-1 M2-2 M2-3 M2-4 M2-6 M2-8
A B C
149646 A 5 of 9
Crown 2013 PF25841-5 DIA-7335-109
67
SCHEMATIC DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
A B C
M1-6 M1-4 M1-8 M1-1 M2-2 M2-4 M2-6 M2-8
M1-2 M1-5 M1-7 M1-3 M2-1 M2-3 M2-5 M2-7
+BV (ED1) FU9
BNEG
BNEG
+BV (ED1) FU7
BNEG
BNEG
BNEG
+BV (ED1) FU8
BRAKE DISCONNECT
+BV AK
+BV FU2
RAS1
+BV FU1
CAN_H
CAN_L
RAS2
TRUCK SHOWN WITH PLATFORM
1 LOWERED GATES DOWN 1
AND UNATTENDED.
FU7 FU9
FU8
LGT1 P1
M3
FIL1 + FU13
ACCESS 3
+ B-
FU15 B+ U U
CA401-20 V V M1 ECR6
CHS4 CHS3 W3 MAST HEIGHT
W ENCODER
CA401-17 CA401-10 CHB
CA401-1 CA401-11 CHA
SVL CA401-22 CA401-2 ED COIL DRIVER (-) ED2
2 TS1 2
CAN_H CA401-23
CA401-15
CA401-16 TRACTION TEMP
CA401-3 +12V +t•‹
P1 CA401-18
CA401-5 CHB
CA401-8 CA401-6 CHA
CA401-4 NEG
CAN_L
ECR3
TRACTION
FAN2
M2
ED1
ACCESS 5
STEER A2
A1 STEER A1 A2
FU10
B+ B-
FU5 CA403-21
0+ CA403-9 CA403-3
CA403-4
FU6 CA403-22
I+ CA403-7 CA403-19 ED COIL DRIVER (+)
0+ CA407 CA403-18 ED IN CR10
I+ CA403-27 +5V CS1 CR9
BRK CA403-24 SIG CURRENT
I- I- 0- CA403-6
CA403-8 CA403-28 NEG SENSE
0- BRK REL CA403-17
CA403-20
CA403-13 CHA
+5V ECR2
K2
CA403-23 INDEX STEERING
CA403-11 FEEDBACK
CA403-14 CHB
120 OHM
CAN_H CA402-4
PVL CA403-2 CA403-12 NEG
CAN_L CA402-5
CA403-5
3 B+ SENSE
+BV LOGIC CA403-10
CA403-25
CA403-16 3
CA403-26 BNEG SENSE
JC413 RES3
DTS1 RES2
TR2
+t° TR3
FU1
+t° CR11
FU3
4 4
FU2
FU4
ED1 ED2
K2 24V BATT
+
A B C
149646 A 2 of 9
DIA-7335-110 Crown 2013 PF25841-6
68
SCHEMATIC DIAGRAMS
Schematic - Platform
Schematic - Platform
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS
1 TRUCK SHOWN WITH PLATFORM LOWERED 1
ACCESS 4 GATES DOWN AND UNATTENDED.
+12V CA304-21
ECR5 CHA CA304-22
STEER CHB CA304-23 CA303-1 SIG POT1
COMMAND NEG CA304-20 TRACTON
CA303-4 +5V
+12V CA304-18 CA303-19 NEG
ECR1 CHA CA304-16
STEER CHB CA304-17
COMMAND NEG CA304-19
+5V CA303-12 CHS2 CHS1
ECR4 CA304-11
HEIGHT CHA CA303-13
ENCODER CHB CA303-14 GTS2 GTS1
NEG CA303-15 CA304-10
FS
CA304-9
RS CA303-6
CA304-8 HGTRS
RAS1
CA304-1
CA303-7
CA303-8
CA304-3
CA303-16
LOS1
CA303-17
LOS2 CA303-18
2 2
CAN_H
CAN_L
ACCESS 1
CA302-3 CA302-4
ALM1
120 OHM
CAN_H CA302-8
CAN_L CA302-9
CA302-2
CR12 CA302-13
ORS1
STEER POSITION INDICATOR
CA323-3
CA323-4
CA323-2
CA323-1
R2
R1
3 3
CAN_L
CAN_H
VR1
+ C1
BRS
CA301 CAN_H K1
CR1 CR2
CAN_L
KYS CR3
START TR1
-t°
ACC
BRAKE DISCONNECT
EDS IGN CR4
(CUSTOMER OPTIONS)
K1
OFF
(FAN/SPOT LIGHTS)
+BV (ED1) FU7
(POWER SUPPLY)
+BV (ED1) FU8
+BV (ED1) FU9
4 4
+BV (FU1)
CAN_H
CAN_L
+BV AK
+BV FU2
RAS2
BNEG
BNEG
BNEG
BNEG
BNEG
RAS1
M1-6 M1-4 M1-8 M1-1 M2-1 M2-3 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M2-2 M2-4 M2-6 M2-8
A B C
149646 A 1 of 9
Crown 2013 PF25841-7 DIA-7335-111
69
70
DIA-7335-112
Platform Distribution Panel
Platform Distribution Panel
SCHEMATIC DIAGRAMS
4
1
TP16 B NEG
TP14 CAN L
TP13 CAN H
TP12 K1
TP11 K1 COIL
TP10 ED1 FU8
TP9 ED1 FU9
TP8 ALM1
TP7 MODULE POWER
TP6 B+ FU2
TP5 RAS2
TP4 RAS1
TP3 ED1 FU7
TP2 B+ FU1
TP1 BRAKE
A
A
CA101
K1A
16 151413 12 11 10 9 8 7 6 5 4 3 2 1
CA102
CA107 1 2 3 4 5 6 7 8 9 10111213
1
2
3
4
5
5917 CA302-2 ALARM 1 NEG
1
2
3
4
5
6
7
8
TP8
R2
CR12
TP16
R1
ALM1
TP7
VR1
29124 JC331-1 CHAIN BREAK SWITCHES
515 PC301-3 B- CAN ACCESS 29114 (RAS3) LIFTING FORK OPTION
TP12 K1A
530 CA322-1 B- GTS1 CR4 2937 CA304-1 +BV KYS ACCESS 4
C1
521 (CA309) B- CHS1 2925 CA308-4 +BV KYS CONTROL POD
TP11 CR2
TP10
520 CA320-2 B- HGTRS 2941 CA302-3 +BV KYS ACCESS 1
TP2
TP1
K1
TP6
TP9
580 CA323-2 B- ACCESS 1 STR POS INDICATOR
TR1
29105 CA323-1 +BV KYS STR POS IND
+t
TP5
550 CA335-1 B- ZSS CR3 CR1 2924 CA308-2 IGN
514 CA309-7 B- ORS1 2923 CA308-3 START
513 CA302-4 B- ACCESS 1 207 PC301-4 +BV FU2 CAN ACCESS
TP4
525 CA304-3 B- ACCESS 4 5904 (CA321) BRAKE SWITCH
TP3
524 (CA321) B- BRS 2932 CA308-11 RAS2
522 (CA321) B- HN1 2935 CA308-10 RAS1
512 PC306-3 B- CUSTOMER ACCESSORIES 2997 (CA303) LIFTING FORKS DIODE
2940 PC306-2 +BV ED1 FU7 CUSTOMER ACCY
B
B
CA103
CA106
TP13 2939 PC301-5 +BV ED1 FU7 CAN ACCESS
MC1
205 PC306-1 +BV FU1 CUSTOMER ACCY
10
11
12
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
CA105
CA104
TP14
BRAKE SWITCH BLK RED/BLK BNEG
B+ FU1 WHT WHT/BLK BNEG
B+ FU2 RED BLU BNEG
B+ ED1 FU9 GRN ORG BNEG
B+ ED1 FU8 ORG GRN BNEG
B+ ED1 FU7 BLU RED CAN L
RAS1 WHT/BLK WHT CAN H
RAS2 RED/BLK BLK +BV AK FROM KYS
MC2
2
001 CA303-7 CAN H ACCESS 4
1
003 CA302-8 CAN H ACCESS 1
6
005 PC301-1 CAN H CAN ACCESS
031 CA323-3 CAN H ACCESS 1 STR POS IND 29
2
002 CA303-7 CAN L ACCESS 4
1
004 CA302-9 CAN L ACCESS 1
6
006 PC301-2 CAN L CAN ACCESS
032 CA323-4 CAN L ACCESS 1 STR POS IND 29
C
C
Crown 2013 PF25841-8
142680 E
1
Crown 2013 PF25841-9
Platform Distribution Panel Forks First SAA
4
2 (2) TP2 B+ FU1
1
(16) TP16 B NEG
(14) TP14 CAN L
(13) TP13 CAN H
(12) TP12 K1
(11) TP11 K1 COIL
(10) TP10 ED1 FU8
(9) TP9 ED1 FU9
(8) TP8 ALM1
(7)TP7 MODULE POWER
(6) TP6 B FU2
(5) TP5 RAS2
(4) TP4 RAS1
(3) TP3 ED1 FU7
(1) TP1 BRAKE
A
A
CA101 CA102 CA103
1 2 3 4 5 6 7 8 1 2 3 4 5
R2 (8)
16 5917 CA302-2 ALM1 NEG
CR12 15
CA107 (7) R1
VR1 14 29111 (CA304) CHAIN BREAK SWITCHES
515 PC301-3 BNEG CAN ACCESS 1 ALM1 13 29114 (CA701) CABIN DOW SWITCHES
530 CA322-1 BNEG GTS1 2 CR4 (12) 12 2937 CA304-1 BV KYS ACCESS 4
520 (CA309) BNEG CHS1 3 C1 (11) 11 2925 CA308-4 BV KYS CONTROL POD
521 CA320-2 BNEG HGTRS 4 CR2 K1A 10 2941 CA302-3 BV_KYS ACCESS 1
+ K1
580 CA323-2 BNEG ACCESS 1 STR POS IND 5 (6) (9) (5) (2) (1) (10) 9 29105 CA323-1 BV KYS STR POS IND
550 CA335-1 BNEG ZSS 6 CR3 CR1 +t TR1 8 2924 CA308-2 IGN
Platform Distribution Panel Forks First SAA
514 CA309-7 BNEG ORS1 7 7 2923 CA308-3 START
513 CA302-4 BNEG ACCESS 1 8 6 207 PC301-4 BV FU1 CAN ACCESS
525 CA304-3 BNEG ACCESS 4 9 (3) (4) 5 5904 (CA321) BRAKE SWITCH
524 (CA321) BNEG BRS 10 4 2935 CA308-11 RAS2
522 (CA321) BNEG HN1 11 3 2932 CA308-10 RAS1
512 PC306-3 BNEG CUSTOMER ACCESSORIES 12 2
B
B
13 1 2940 PC306-2 BV FU7 CUST ACCY
562 CA320-2 PDS CDS (13) CA105 2939 PC301-5 BV ED1 FU7 CAN ACCESS
(14)
CA106
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 205 PC306-1 BV FU1 CUST ACCY
BRAKE SWITCH BLK CA104 RED/BLK BNEG
BV FU1 WHT WHT/BLK BNEG
BV FU2 RED BLU BNEG
BV ED1 FU9 GRN ORG BNEG
BV ED1 FU8 ORG GRN BNEG
BV ED1 FU7 BLU RED CAN L
RAS1 WHT/BLK WHT CAN H
RAS2 RED/BLK BLK BV AK FROM KYS
SCHEMATIC DIAGRAMS
MC1
2 MC2
001 CA303-7 CAN H ACCESS 4 1
003 CA302-8 CAN H ACCESS 1 6
005 PC301-1 CAN H CAN ACCESS 29
031 CA323-3 CAN H ACCESS 1 STR POS IND
002 CA303-8 CAN L ACCESS 4 2
004 CA302-9 CAN L ACCESS 1 1
006 PC301-2 CAN L CAN ACCESS 6
032 CA323-4 CAN L ACCESS 1 STR POS IND 29
C
C
DIA-7335-113
142696 B
1
71
72
DIA-7335-114
Power Unit Distribution Panel
Power Unit Distribution Panel
SCHEMATIC DIAGRAMS
4
1
121 (CA412) NEGATIVE BRUSH BRUSHWEAR M3
TP19 MMS
TP18 RAS2
TP17 RAS1
TP16 CAN_L
TP15 CAN_H
TP14 INNER BRAKE
TP13 OUTER BRAKE
TP12 BATT SENSE
TP11 K1 OUT
TP10 FU9
TP9 FU8
TP8 FU7
TP7 FU2
TP6 FU1
TP5 ED2
TP4 K2
TP3 BNEG
TP2 ED1
TP1 B+
108 (CA412) POSITIVE BRUSH BRUSHWEAR M3
POSITION 1 AND 2 ARE CLOSED.
5 AND 4 ARE CLOSED, IN THE TOP
NOTE: ON DTS1 IN THE CENTER POSITION
107 (CA412) NEGATIVE BRUSH BRUSHWEAR M4
106 (CA412) POSITIVE BRUSH BRUSHWEAR M4
122 CA401-7 BRUSHWEAR
5930 CA407-5 BRAKE SWITCH
29129 (CA808) +BV_K2 FU3 PVLF AND SV1 LIFTING FORK OPTION
A
A
2959 (CA412) +BV_K2 FU3 SVL
2960 (CA412) +BV_K2 FU3 PVL
2955 PC417-1 +BV_K2 FU3 CHB5
29122 (CA401) +BV_K2 FU3 FAN2 1 2968 CA407-1 BRAKE COIL OUTER
2970 (CA412) +BV_K2 FU3 THS P1 1 2957 CA403-9 BRAKE OUTER
2954 PC415-1 +BV_K2 FU3 CHAIN SLACK 2 2956 CA403-7 BRAKE COIL INNER
2972 CA601-1 +BV_K2 FU3 ACCESS 6 2 2969 CA407-2 BRAKE INNER
2966 CA403-10 +BV_K2 FU3 ACCESS 5 3 208 K15-7 +BV HN2
2953 CA401-1 +BV_K2 FU3 ACCESS 3 3 206 CA403-25 BATTERY SENSE ACCESS 5
29107 CA413-4 DRIVE/TOW FU4 POWER 4 2964 (CA412) +BV_ED1 LGT1
578 CA413-3 DRIVE/TOW BNEG 5 2963 (CA412) ED1 COIL
5109 +BV HN2 6 2961 (CA412) P1 COIL
7 2962 (CA412) P2 COIL
4
29108 CA413-1 BRAKE RESIST 2996 8 2967 CA403-18 CR9 SUPPRESION
29125 CA413-2 BRAKE RESIST 2995
3
585 (CA401) BNEG BB
10
12
13
14
15
16
11
1
4
4
5
8
9
1
2
2
5
7
8
3
6
7
3
6
CA201
CA202
CA418
1
4
5
2
6
3
CR7
CR8
CR6
CR5 R3
29127
R4
29123
DTS1
TP19
6 4 3 1
29124
CR9
5 2
TP12
586
FU4
TP11
TP6 TP7 TP8 TP9 TP10
FU1
R5
TP14
RES2
RES3
B
B
TP13
K2
TP1
FU2
CA206 1 2 3 4 5 6
FU5
FU7
TP2
FU6
FU8
TP18
TP17
201 (CA401) +BV
TP13
202 (CA401) +BV TR2 TP5
FU9
2901 (CA401) +BV_ED1 +t
2902 (CA401) +BV_ED2
501 (CA401) BNEG BB
TP4
FU3
TP16
502 (CA401) BNEG BB
K2
CA203
TR3 CR11
CA205
CA204
+t TP15 MAST MOUNTED
GRN SPOT LIGHTS (OPTION)
12
10
11
MC2
4
5
1
6
7
8
1
1
4
5
8
9
2
3
4
5
6
7
2
3
6
7
3
9 RED/BLK BNEG
017 CA401-23 CAN_H ACCESS 3 WHT/BLK BNEG
019 CA402-4 CAN_H ACCESS 5 15 BLU BNEG
021 CA601-4 CAN_H ACCESS 6 14 ORG BNEG
018 CA401-15 CAN_L ACCESS 3 9 GRN BNEG
020 CA402-5 CAN_L ACCESS 5 15 RED CAN_L
14
MC1
022 CA601-5 CAN_L ACCESS 6 WHT CAN_H
BLK +BV_AK FROM KYS
RED/BLK RAS2
C
C
WHT/BLK RAS1
BLU +BV_ED1 FU7
ORG +BV_ED1 FU8
GRN +BV_ED1 FU9
Crown 2013 PF25841-10
RED +BV FU2
WHT +BV FU1
BLK BRAKE SWITCH
142681 E
1
SCHEMATIC DIAGRAMS
Platform Modules ACCESS 1 & 4
Platform Modules ACCESS 1 & 4
A B C
6 CA301 JC301
005 CA105-3 CAN_H 1 CAN 1 4 6 BLK
006 CA105-9 CAN_L 6 2 ACCESS 2 5
515 CA107-1 DISTRIBUTION BNEG 3 3 13 7 WHT MAST
CABLE
207 CA103-6 DISTRIBUTION +BV FU1 4 4 25 8 RED 4
2939 CA103-2 DISTRIBUTION +BV ED1 FU7 5 210 5 15 9 GRN
203 CA308-1 EDS 6 6 24
1 CA302 INFOLINK 1
5902 CA309-5 DMS1 1 SW AL ACCESS 1
5917 CA103-16 ALARM 1 2 GPD
2941 CA103-10 DISTRIBUTION +BV KYS 3 +BV (DCM)
513 CA107-8 DISTRIBUTION BNEG 4 BNEG
5 NEG
6 N/A
1 7 N/A SP 3500
003 CA105-2 CAN_H 1 8 CAN_H
004 CA105-8 CAN_L 9 CAN_L
10N/A CA302
11N/A 1 5
12SW AH/ANA 6 9
5901 CA309-4 ORS1 13SW AL
5903 CA309-6 GUS 14SW AL 10 14
CA323
29105 CA103-9 DISTRIBUTION +BV KYS 1 ACCESS 1
580 CA107-5 DISTRIBUTION BNEG 29 2
031 CA105-4 CAN_H 3 (DCM)
29 4
032 CA105-10 CAN_L GUIDANCE AND
(1) HEIGHT ENCODER (ECR4) 32 PULSE/REV STEER INDICATOR
(2) STEER SENSE ENCODER (ECR1) 32 PULSE/REV
(3) STEER SENSE ENCODER (ECR5) 32 PULSE/REV
CA303
7
2 101 CA309-1 POT1 SIGNAL 1 AN1
2 AN2 ACCESS 4 2
29123 PC331-1 CHAIN BREAK SWITCH 7 3 SW2 / AN1SP (VCM)
701 CA309-2 POT1 +5V 4 +5V
2997 CA103-3 LIFTING FORKS DIODE 2989 2 5 +5V
5912 CA320-1 HGTRS NO 2 6 SW7
001 CA105-1 CAN_H 2 7 CAN_H
002 CA105-7 CAN_L CA327 1 29139 8 CAN_L
29112 (CA701) LMS1 LIFTING FORK OPTION 9 SW1 / AN2SP CA303
29113 (CA701) LOS4 LIFTING FORK OPTION 1 29140 10 SW0 / AN3SP
CA328 5 11+5V 1 8
(1) CH A
WHT 1 CH A 703 5 12+5V
9 15
ECR4 CH B BLU 2 CH B 007 5 13ECR1 A
+12V 16
NEG RED 3 +5V 008 5
14ECR1 B 23
BLK 4 NEG 516 15LOGIC NEG
2930 CA308-9 RAS1 CA317 16SW8 / AN4SP
2928 CA308-7 LOS1 17SW9 / AN5SP
2929 CA308-8 LOS2 18SW10 / AN6SP
506 CA309-2 LOGIC NEG POT1 7 581 19RS-232 COM
20RS-232 TX
21RS-232 RX
22SW / INDEX
59136 CA332-1 ZSSA 23SW6
CA304
2937 CA103-12 +BV KYS CA330 1 1 MODULE POWER
29145 CA701-1 +BV 29128 2 DRIVER B+
3 525 CA107-9 DISTRIBUTION B- 3 B- 3
5936 CA701-3 OPTION PVLF COIL DRIVER SUBHARNESS CA325 1 5941 4 PWM1
5935 CA701-4 OPTION SV1 COIL DRIVER SUBHARNESS 1 5942 5 PWM2
CA326 6 PWM3
5980 CA701-2 OPTION TRAVEL ALARM HARNESS CA336 1 5915 7 PWM4 23 16
2927 CA308-6 REVERSE SWITCH 8 SW12 15 9
2926 CA308-5 FORWARD SWITCH 9 SW11 8 1
5916 (CA321) GATE SWITCHES 10SW5
5911 (CA309) CHAIN SLACK SWITCHES 11SW4
12SW3 CA304
59139 CA333-1 ZSSB 13SW15
59138 CA334-1 ZSSC 14SW14
3 15SW13
(2) CH A
WHT 1 CH A 009 3 16ECR2 A
ECR1 CH B
+12V
BLU 2 CH B 010 3 17ECR2 B
NEG RED 3 +12V 312 3 18+12V
BLK 4 NEG 517 4 19LOGIC NEG
(3) CH A
WHT 5 CH A 518 4 20LOGIC NEG
ECR5 CH B BLU 6 CH B 313 4 21+12V
+12V
NEG RED 7 +12V 011 4 22ECR3 A
BLK 8 NEG 012 23ECR3 B
CA318
29123 CA303-3 CHAIN BREAK OPTION
29124 PC103-14 B+ DISTRIBUTION BOARD EU CHAIN
4 1
1
29110 BREAK OPTION 4
CA331
1 29111
CHB7 CHB8
A B C
142682 E
Crown 2013 PF25841-11 DIA-7335-115
73
SCHEMATIC DIAGRAMS
Platform Modules ACCESS 1 & 4 Forks First SAA
Platform Modules ACCESS 1 & 4 Forks First SAA
142697 C
DIA-7335-116 Crown 2013 PF25841-12
74
SCHEMATIC DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
A B C
5912 CA303-6 HGTRS 1 1
HGTRS
521 CA107-4 DISTRIBUTION BNEG 1
PC306
205 CA103-1 +BV FU1 A POWER FOR
1 2940 CA103-2 +BV ED1 FU7 B CUSTOMER ACCESSORIES 1
512 CA107-12 DISTRIBUTION BNEG C
CA308 CA305
203 CA301-6 FU2 1 204 1 2903 1 START
2924 CA103-8 IGN 2 EDS
2904 2 BATT ACC
2923 CA103-7 START 3 2905 3
2925 CA103-11 +BV KYS FROM DIST 4 2906 4 IGN
2926 CA304-9 FS 5 2907 OFF
2927 CA304-8 RS 6 2908
2928 CA303-17 LOS1 7 2909 FS KYS
2929 CA303-18 LOS2 8 2910 1 2938
2930 CA303-16 RAS1 9 2911 RS 2915
2932 CA103-3 RAS1 10 2912 1 BATT ACC
2935 CA103-4 RAS2 11 2913 LOS1 CA324
2936 (CA321) HNS 12 2914 2917 1
1 START
LOS2 GND
2918 IGN
1
2 RAS1 BACK VIEW OF KYS 2
1 2919
RAS2 2921
1
HNS
1 2922
CA309
101 CA303-1 POT1 WIPER 7 1 GRN POT1
701 CA303-4 POT1 +5V 7 2 ORG
506 CA303-19 POT1 NEG 7 3 VIO
5901 CA302-13 ORS1 4 5905 ORS1
5902 CA302-1 DMS1 5 5906 1
5903 CA302-14 GUS 6 5907 DMS1
514 CA107-7 DIST BNEG 7 527 1 529
8 5939
GUS 528
1
CHS1 CHS2
1 5918 1
3 5911 CA304-11 CHS1 3
520 CA107-3 DIST BNEG
CA332 ZSS
59136 CA303-23 ZSSA 1 BRN
CA333
59137 CA304-13 ZSSB 1 WHT
CA334
59138 CA304-14 ZSSC 1 BLU
CA335
550 CA107-6 BNEG 1 BLK
GRN
(CA321)
(FOR REFERENCE ONLY) HN1
2936 CA308-12 HNS 1
522 CA107-11 DIST BNEG
5904 CA103-5 BRS 1 BRS
4 4
524 CA107-10 DIST BNEG
5916 CA304-10 GTS2
CA322 GTS1 GTS2
530 CA107-2 DIST BNEG 1 582 1 5919 1
A B C
142683 D
Crown 2013 PF25841-13 DIA-7335-117
75
SCHEMATIC DIAGRAMS
Overhead Guard Lights/Fans
Overhead Guard Lights/Fans
A B C
LGT2
503 1
301
LEFT SIDE ASSEMBLY LEFT WORKLIGHT
PS1
POWER SUPPLY
CA501
1 12V OUT
1 535 1 504 2 1
536 2 505 3 BATT COMM
2950 3 2990 4 BV INPUT
303 4 302
2951 5 2931
305 6 310
2948 7 51062998
TO PLATFORM WALL 5105 8
9 PS2
POWER SUPPLY
309 1 12V OUT
TO MODULE
HSG 2
3 BATT COMM
CAP1 4 BV INPUT
541
OPTION
LGT3
1 BLK
542 LGT4
RED BLK 1
-
LEFT DOME LIGHT
531 1234 5 LEFT SPOTLIGHT
2 532 TB502 2
PC102 LGS1 1 PC338
2942 1 MAST MOUNTED
1
2 2943 LGS2 SPOTLIGHTS
3 534 533 1
4 2944 WHEN MAST MOUNTED SPOTLIGHTS
5 1 2952 ARE PRESENT, THE MAST CABLE
COPIED FROM LGS3 PLUGS INTO PC338
DISTRIBUTION
BOARD PAGE 29451
FNS1
3 3
LGT7
BLK RED 1
FAN1 RIGHT SPOTLIGHT
CA503 507
533 1 508 1 FAN SUPPRESSOR
534 2 510
303 3 307 1
2947 4 2992 2
305 5 308 3 V CXX
2946 6 2916 2933 4
2949 7 2920 5
TO PLATFORM WALL 5107 8 5108 RES1
9 1 2934
SB30
TO MODULE CAP2
RIGHT SIDE ASSEMBLY HSG
4 4
LGT6
1 BLK LGT5
RIGHT DOME LIGHT 1
509 RIGHT WORKLIGHT
A B C
142687 E 1 of 2
DIA-7335-118 Crown 2013 PF25841-14
76
SCHEMATIC DIAGRAMS
Overhead Guard Spotlights (Optional)
Overhead Guard Spotlights (Optional)
A B C
1 1
LEFT
LGT4
2 2
PC102
1
2 RED
3 BLK
4 BLK
5 WHT
WHT
RIGHT
3 3
LGT7
4 4
A B C
142687 E 2 of 2
Crown 2013 PF25841-15 DIA-7335-119
77
SCHEMATIC DIAGRAMS
Traction Control Module ACCESS 3
Traction Control Module ACCESS 3
A B C
FAN2
1
29122 CA201-8 +BV K3 FU3 FROM DIST 5908
1 1
579 CA411-2 M1 TEMP SENSOR CA401
2953 CA201-5 +BV K2 FU3 FROM DIST 1 MODULE POWER
5920 (CA412) ED2 COIL - 2 GPD 1 ACCESS 3
315 CA411-3 +12V TO ECR3 8 3 +12V
549 CA411-6 LOGIC NEG TO ECR3 8 4 LOGIC NEG
029 CA411-4 TRACTION ENCODER CHB 8 5 ECR1 A U
028 CA411-5 TRACTION ENCODER CHA 8 6 ECR1 B U M1
122 CA201-12 BRUSH WEAR 7 AN2 V V
8 GPD 5 W 3
9 POT CMD W
2971 (CA412) MOTOR 3 THERMAL INPUT 10 DI8/ECR2 B
2973 PC414-1 POWER UNIT CHS3 11 DI7/ECR2 A
12 DI5/ID1
2975 (CA412) MOTOR 4 THERMAL INPUT 13 DI3
9 14 DI2
018 CA204-7 CAN L 8 15 CAN L
105 CA411-1 TRACTION MOTOR TEMP 16 TEMP (+)
17 DI4/ID0
5923 (CA412) P1 COIL LOW SIDE DRIVER 18 GPD 2 CA401
19 DI1
2974 CA416-1 CHB4 20 DI6/AN1 1 8
5924 (CA412) P2 COIL LOW SIDE DRIVER 21GPD 3 9 15
5925 (CA412) SVL COIL LOW SIDE DRIVER 22 GPD 4 B+ + B- 16 23
2 017 CA204-1 CAN H 9 23 CAN H 2
543 (CA412) ED1 COIL FU10
544 (CA412) STROBE LIGHT LGT1
547 (CA403) BATTERY RESTRAINT SWITCHES 1
548 (CA403) RAIL GUIDE SWITCHES 1
551 CA403-26 BATTERY SENSE ACCESS 5 2
552 CA601-2 B- BB TO ACCESS 6 BNEG ED2
585 CA418-C BRAKE RESISTOR
579 CA411-1 M1 TEMP SENSOR 3
553 CA808-1 FREEZER CONDITIONING
554 CA808-2 FREEZER CONDITIONING 4
563 (CA809) MAST SPOT LIGHTS
502 CA206-6 B- BB POWER TO DIST +
501 CA206-5 B- BB POWER TO DIST
201 CA206-1 +BV POWER TO DIST
202 CA206-2 +BV POWER TO DIST 1
3 ED1 3
2901 CA206-3 +BV ED1 POWER TO DIST
2977 CA808-3 +BV ED1 FREEZER CONDITIONING
2978 CA808-4 +BV ED1 FREEZER CONDITIONING
2979 CA808-5 +BV ED1 FREEZER CONDITIONING
2902 CA206-4 +BV ED2 POWER TO DIST
CHS3
CA414
2973 CA401-11 CHAIN SLACK SWITCHES TO ACCESS3 1 BLK
CA415 CHB4
2954 CA201-7 DIST +BV K2 FU3 1 BLK
CA416
2974 CA401-20 CHAIN BREAK SWITCHES TO ACCESS3 1 RED CHS4
2955 CA201-8 DIST +BV K2 FU3 1 RED
CHB5
4 CA417 4
WHT GRN
A B C
142684 B
DIA-7335-120 Crown 2013 PF25841-16
78
SCHEMATIC DIAGRAMS
Steering Control Module ACCESS 5
Steering Control Module ACCESS 5
A B C
CA402
1 ACCESS 5
2
3 (SCM)
019 CA204-2 CAN_H 15 4 CAN1_H
020 CA204-8 CAN_L 15 5 CAN1_L CA402
1
CA403 5
1 1 BNEG 1
5926 (CA412) PVL COIL DRIVER 2 MH_LO
3 ECR1 A
4 ECR1 B
5927 (CA403) BRES INPUT 5 SW SPARE A1
5928 CA407-3 INNER BRAKE COIL DRIVER 6 INNER BRAKE DRIVER
2956 CA202-2 DIST+BV ED2 FU6 INNER BRAKE DRIVER FEED 7 B+ INNER BRAKE FEED B+
5929 CA407-4 OUTER BRAKE COIL DRIVER 8 OUTER BRAKE DRIVER
2957 CA202-1 DIST+BV ED2 FU5 OUTER BRAKE DRIVER FEED 9 B+ OUTER BRAKE FEED
2966 CA201-6 +BV K2 FU3 FROM DIST BOARD 10 B+ A2
2958 (CA412) PVL COIL 11 DRIVER B+
540 CA410-2 LOGIC NEG ECR2 12 12 LOGIC NEG
12 B-
025 CA410-1 CHA ECR2 13 ECR2 A
026 CA410-3 CHB ECR2 12 14 ECR2 B
15 TRAV OR
5931 (CA403) RAIL GUIDANCE SWITCHES 16 RGS
5932 CA407-6 BRAKE DISCONNECT 17 DTS
2967 CA202-8 ED DRIVER FEED CR9 DIST BOARD 18 ED +BV
2965 (CA412) ED2 COIL 12
19 ED SOURCING DRIVER
706 CA410-4 +5V ECR2 20 +5V
21 +5V
22 LOGIC NEG
027 CA410-5 INDEX ECR2 12 23 ECR INDEX
104 CA406-2 SIGNAL CS1 13 24 BDI CURRENT SENSE
2 206 CA202-3 BATTERY SENSE 25 BDI POS SENSE CA403 2
551 (CA401) BNEG BB 26 BDI NEG SENSE 9 1
705 CA406-1 +5V CS1 13 27 +5V 19 10
545 CA406-3 LOGIC NEG CS1 13 28 LOGIC NEG 28 20
OPTIONAL RAIL GUIDE AND
BATTERY RESTRAINT
5927 CA403-5 BRES TO ACCESS 5 1 BRES15933 1 BRES2
547 (CA401) BNEG BB
5931 CA403-16 RGSL 1 RGSL 5934 1 RGSR
M2
548 (CA401) BNEG BB
CA406
705 CA403-27 +5V FROM ACCESS 5 13 A VIO +
104 CA403-24 CURRENT SIGNAL TO ACCESS 5 13 B BRN 0 I CS1
545 CA403-28 LOGIC NEG FROM ACCESS 5 13 C GRN
CA407
1 WHT 0+
2968 CA202-1 +BV ED2 FU5 TO OUTER BRAKE COIL
2969 CA202-2 +BV ED2 FU6 TO INNER BRAKE COIL 2 BLU I+ BRK
5928 CA403-6 INNER BRAKE DRIVER 3 YEL I-
3 5929 CA403-8 OUTER BRAKE DRIVER 4 ORG 0- 3
5930 CA201-11 BRAKE SWITCH FROM DIST 5 5971
5932 CA403-17 BRAKE SWITCH TO ACCESS 5 6
JC413
29108 CA418-A BRAKE RESISTOR 1
29125 CA418-B BRAKE RESISTOR 2
578 CA201-1 BRAKE/TOW BNEG 3 DRIVE/TOW
29107 CA201-2 BRAKE/TOW FU4 POWER 4
5
(1) SENSOR BEARING 64 PULSE/REV 6
TRACTION MOTOR
(2) SENSOR BEARING 32 PULSE/REV
CA411 T+
105 CA401-16 TEMPERATURE ACCESS 3 105 11 1 BRN
579 (CA401) BNEG 2 579 11 2 R/W
315 CA401-3 +12V ACCESS 3 315 11 3 RED +12V
029 CA401-5 ECR3 CHB TO ACCESS 3 029 11 4 BLU CHB
028 11 ECR3
028 CA401-6 ECR3 CHA TO ACCESS 3 11 5 WHT CHA
(1)
549 CA401-4 LOGIC NEG ACCESS 3 549 6 BLK NEG
4 4
CA410
025 CA403-13 CHA TO ACCESS 5 12 1 BLU CHA STEERING
540 CA403-12 LOGIC NEG FROM ACCESS 5 12 2 BLK NEG FEEDBACK
026 CA403-14 CHB TO ACCESS 5 12 3 ORG CHA ECR2
706 CA403-20 FROM ACCESS 5 12 4 RED +5V (2)
027 CA403-23 INDEX TO ACCESS 5 12 5 YEL INDEX
6
A B C
142685 C
Crown 2013 PF25841-17 DIA-7335-121
79
SCHEMATIC DIAGRAMS
Hydraulics & Optional MMS
Hydraulics & Optional MMS
A B C
(CA412)
FOR REFERENCE ONLY
1
1 2960 CA201-9 DIST +BV K2 FU3 TO PVL COIL
2958 CA403-11 PVL COIL SUPPRESION
PVL 1
5926 CA403-2 PVL COIL DRIVER
5925 CA401-22 SVL COIL DRIVER 1 SVL
2959 CA201-10 DIST +BV K2 FU3 TO SVL COIL
PVL
SVL
HYDRAULIC BLOCK
1
2961 CA202-6 DIST TO P1 COIL P1
5923 CA401-18 ACCES 3 TO P1 COIL
2 1 2
2962 CA202-7 DIST TO P2 COIL P2
5924 CA401-21 ACCES 3 TO P2 COIL
1
2963 CA202-5 ED1 COIL ED1
543 (CA401) B- BB
1
5920 CA401-2 ACCESS 3 TO ED2 COIL - ED2
2965 CA403-19 ACCESS 5 TO ED2 COIL
2964 CA202-4 DIST BV ED1 LGT1
544 (CA401) B- BB LGT1
1 2 3 4 5
FIL1
+
3 3
2971 CA401-10 M3 THERMAL SWITCH TO ACCESS 3 THS-P1
2970 CA201-6 +BV K2 TO THS-P1 1 PUMP 1 MOTOR
2976 1
108 CA201-15 POSITIVE BRUSHWEAR BW-P1
121 CA201-16 NEGATIVEBRUSH WEAR
2975 CA401-13 M4 THERMAL SWITCH TO ACCESS 3 THS-P2
1 PUMP 2 MOTOR
M4
1
106 CA201-13 POSITIVE BRUSHWEAR
107 CA201-14 NEGATIVE BRUSHWEAR BW-P2
MOTOR MANGEMENT OPTION
4 4
A B C
142686 A
DIA-7335-122 Crown 2013 PF25841-18
80
SCHEMATIC DIAGRAMS
Guidance Control Module ACCESS 6 (Optional)
Guidance Control Module ACCESS 6 (Optional)
A B C
CA601
2972 CA201-6 DIST +BV K2 FU3 1 MODULE POWER
552 (CA401) B- BB 2 B- ACCESS 6
14 3 CAN COM
021 CA204-3 DIST CAN H 14 4 CAN H
022 CA204-9 DIST CAN L 5 CAN L
CA602
1 B1 A1 314 26 1 EAC SENSORS 12V
1
5 5 CA608 575 26 2 EAC SENSORS B NEG
901 27 3 EAC A1 TEST CA601
1 314 109 27 4 EAC A1 ANALOG
2 575 052 27 5 EAC A1 DIGITAL
1
5
902 27 6 EAC A2 TEST
CA607 27
1 901 110 27 7 EAC A2 ANALOG
053 8 EAC A2 DIGITAL CA602
EAC 2 109 28 9 1
3 052 903 28 9 EAC B1 TEST 19 10
4 902 111 28
10 EAC B1 ANALOG 28 20
5 110 054 28
11 EAC B1 DIGITAL
6 053 904 12 EAC B2 TEST
112 28 13 EAC B2 ANALOG
7 903 055 28 14 EAC B2 DIGITAL
8 111 717 24 15 STR WHL GUIDE BAR 5V
9 054 576 24 16 STR WHL GUIDE BAR B NEG
10 904 24
11 112 113 17 STR WHL GUIDE BAR COIL 4
114 24 18 STR WHL GUIDE BAR COIL 3
12 055 115 24 19 STR WHL GUIDE BAR COIL 2
EAC 5 5 EAC 116 24 20 STR WHL GUIDE BAR COIL 1
905 24 21 STR WHL GUIDE BAR COIL TEST
SENSOR B2 A2 SENSOR 25
718 22 LD WHL GUIDE BAR 5V
577 25 23 LD WHL GUIDE BAR B NEG
GS1 25
117 24 LD WHL GUIDE BAR COIL 4
118 25 25 LD WHL GUIDE BAR COIL 3
CA603 25
119 26 LD WHL GUIDE BAR COIL 2
2 COIL 4 1 116 120 25 27 LD WHL GUIDE BAR COIL 1 2
COIL 3 2 115 906 25 28 LD WHL GUIDE BAR COIL TEST
B NEG 3 576
STEER WHEEL 4
SENSOR BAR +5V 5 717
SLF TST 6 905
COIL 2 7 114
COIL 1 8 113
9
GS2
CA604
COIL 1 1 120
COIL 2 2 119
B NEG 3 577
LOAD WHEEL 4
SENSOR BAR +5V 5 718
SLF TST 6 906
COIL 3 7 118
COIL 4 8 117
9
3 3
LOAD WHEEL BAR
C1 C2 C3 C4
EAC SENSORS
B2 A2 A1 B1
4 4
C1 C2 C3 C4
STEER WHEEL BAR
A B C
142688 A
Crown 2013 PF25841-19 DIA-7335-123
81
SCHEMATIC DIAGRAMS
Travel Alarm & Freezer Conditioning (Optional)
Travel Alarm & Freezer Conditioning (Optional)
A B C
CA807 2980 2985 1 RED/WHT RES5
1 2981 1 RED/WHT RGSR
CA808 K12A 2 555 1 RED/WHT RES6
553 BNEG BB 1 3 556 558
554 BNEG BB 2 FU11 4 1 RED/WHT
5 2982 RGSL
2977 ED1 3 K12B
2978 ED1 4 6 557 559
1 RED/WHT
7 29153 RES7
1 2979 ED1 5 FU12
8 598 1 RED/WHT BRES1 1
9 2983 1 RED/WHT
K11 K11A 10 2984 2986 RES8
11 29152 1 RED/WHT BRES2
LIFTING FORKS OPTION 12
K12 29151
29154
29151
29153
SV1 5937
29130 THS2
THS-2
29152
598
K15 PVLF 5938
29129
5981
1 WHT 1 RED/WHT
RES9
CA809 1 2 3 4 5 6 7 8 1 BLK 1
RED/WHT CHS3/CHB4
WHT/BLK
RED
ORG
BLK
HN2 WHT 1 RED/WHT
RED/BLK
208 CA202-3 BV KYS RES10
K15 BLK 1
WHT
RED/WHT CHS4/CHB5
GRN
5109 CA201-1
BLU
POWER UNIT
PLATFORM
WHT/BLK
RED/BLK
2 2
ORG
WHT
GRN
RED
BLU
BLK
CA701
CA701
1 2345 67 8
JC330
29128 CA330-1 BV KYS 1 29145 564 1 RED/WHT
RES19
5915 CA336-1 BNEG 1 5980 2991 1 RED/WHT
565 CHS1/CHB7
JC336 THS3 2993 1 RED/WHT
RES20
29131 29132 1 RED/WHT
566 CHS2/CHB8
LIFTING FORKS OPTION 2994 1 RED/WHT
RES25
1 RED/WHT
5936 CA325 OPTION SUBHARNESS PVLF COIL DRIVER 560 HGTRS
29106 1 RED/WHT
5935 CA326 OPTION SUBHARNESS SV1 COIL DRIVER RES21
1 RED/WHT
511 GTS5
29112 CA327 LMS1 LIFTING FORK OPTION 2987 1 RED/WHT
RES22
RAS3 RAS4 LMS1 1 RED/WHT
29114 CA103-13 RAS3 LIFTING FORK OPTION 570 GTS6
29116 29118 2999 1 RED/WHT
29115 RES18
LOS3 LOS4 1 RED/WHT
BRS
3 29117
29100 571
3
29113 CA328 LOS4 LIFTING FORK OPTION
CA702 1 2
29121 572
RES17
29101 RS 573
RES16
29102 FS 574
RES15
HNS1
29103 583
RES14
LIFTING FORKS OPTION RAS/LOS
29104 584
RES13
5115 5114 5113 5112
EDS 587
29119
4 1 1 1 1 1 RED/WHT
RES12
4
1 RED/WHT
588 GTS2
RES35 RES36 RES33 RES34 29120 1 RED/WHT
RES11
1 RED/WHT
1 1 1 1 CA704 523 GTS1
1 589 2988 1 RED/WHT
RES111
1 1 RED/WHT
29174 2989 DMS1
29177 29176 29175 CA703
A B C
142689 G 1 of 2
DIA-7335-124 Crown 2013 PF25841-20
82
SCHEMATIC DIAGRAMS
Travel Alarm & Pallet Grab
Travel Alarm & Pallet Grab
A B C
29169 CA205-5
FU19
29170 CA205-6
FU18
5123 CA203-6
FU17
5124 CA203-7
FU16
1 1
29168
5122
29154
K15
PALLET GRAB
29167
5121
5981
TRAVEL ALARM
CA809
1234567 8
HN2
208 CA202-3 BV KYS
WHT/BLK
K15
RED
ORG
BLK
RED/BLK
5109 CA201-1
WHT
GRN
BLU
POWER UNIT
PLATFORM
WHT/BLK
ORG
RED
BLK
RED/BLK
GRN
WHT
BLU
2 TRAVEL ALARM 2
CA701
1234567 8
JC330
29173
29128 CA330-1 BV KYS 1 29145
5126
29172
5915 CA336-1 BNEG 1 5980
JC336
5125
911 1
29171 2
5127 914 3
915 DB1
PGS1
6 7 8 9 10
6
PGS1
1 2 3 4 5
4
3 913 3
912
916
4 3 2 1
PALLET GRAB
4 3 2 1 PALLET GRAB
917 COM
CLOSE
NO JAWS
919 NC
921
923
4 4
SB1
920 COM M5
OPEN
NO JAWS
918 NC 924
922
A B C
142689 G 2 of 2
Crown 2013 PF25841-21 DIA-7335-125
83
SCHEMATIC DIAGRAMS
Forks First Option w/Heaters
Forks First Option w/Heaters
A B C
RED/WHT
CA807 1
2980 2985 RES5
1 2981 1 RED/WHT
RGSR
CA808 K12A 2 555 1 RED/WHT
553 B- BB 1 3 556 558 RES6
FU11 4 2982 1 RED/WHT
554 B- BB 2 K12B 5 RGSL
2977 ED1 3 6 557 1 RED/WHT
1 2978 ED1 4 7 29153
559 RES7 1
2979 ED1 5 FU12 1 RED/WHT
8 598 BRES1
RED/WHT
K11A
9 2983 2986 1
K11 K11A
10 2983 RES8
11 29152 1 RED/WHT
BRES2
LIFTING FORKS OPTION 12 29153
OPTION K12
29154 THS-2
SV1 5937
29130
K15
PVLF 5938
29129 RED/WHT
WHT
1 1
5981 BLK RES9
1 1 RED/WHT
29151
29152
29153
598 CHS3
WHT RED/WHT
CA809 1
BLK RES10
K15
K15 1 234 567 8 1 RED/WHT
CHS4
208 CA202-3 +BV KYS
ORG
WHT/BLK
RED
BLK
2 2
RED/BLK
RED/BLK
5109 CA201-1
HN2
WHT
BLU
GRN
POWER UNIT
PLATFORM
WHT/BLK
RED
ORG
RED/BLK
BLK
BLU
WHT
GRN
CA701
1 234 567 8
RED/WHT
29128 CA304-2 +BV KYS 29145 564 1
RES19
2991 1 RED/WHT
CHS1/CHB7
5915 CA304-7 BV- 5980 565 RED/WHT
2993 1
29131 29132 RES20
1 RED/WHT
CHS2/CHB8
THS-3 2994
566 1 RED/WHT
LIFTING FORKS OPTION RES25
1 RED/WHT
5936 CA325 OPTIONS SUBHARNESS HGTRS
3 PVLF COIL DRIVER 29106 560 1 RED/WHT 3
RES21
5935 CA326 OPTIONS SUBHARNESS 1 RED/WHT
GTS5 LIFTING FORKS
SV1 COIL DRIVER 511 1 RED/WHT OPTION
2987
29113 CA303-10 LIMIT SWITCH RES22
1 RED/WHT LIFTING FORKS
GTS6 OPTION
570 1 RED/WHT
29112 CA303-9 AUX HYD SWITCH 2999 RES18
AUX 1 RED/WHT
BRS
29114 CA103-13 +BV ED2 29100 571
29115 LMS1
CA702 1 2
29121
572
29120
588
589 2989
DMS
4 573 29101 4
AUX
574 29102
583 RS
29103
584 FS 29104
587 RAS/LOS
29119
EDS
A B C
142700 E
DIA-7335-126 Crown 2013 PF25841-22
84
SCHEMATIC DIAGRAMS
Power Cables
Power Cables
A B C
BATT + ITEM 14
BNEG ITEM 15
1 1
FU15
FU10
FU14
FU13
ED2 ED1
ITEM 12
W V U
ACCESS 3 ITEM 7 ITEM 10 A1
(TCM) ITEM 11 A2
U V W P1
B+ + B-
ITEM 2
ITEM 8 ITEM 6
2 ITEM 5 2
ITEM 9 ITEM 3
ITEM 4
M3 M4
(PUMP 1) (PUMP 2)
ACCESS 5 B- P2
(SCM) M1 ITEM 1
M2 (TRACTION)
(STEERING)
ITEM 13
ACCESS 6
(GCM)
3 3
ITEM SP 3520/SP 3550 SP 3505 SP 3510 SP 3511/SP 3512 SP 3521/SP 3522
1 084571-230 PC#1 NOT USED NOT USED NOT USED 084571-230 PC#1
2 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1
3 084571-231 PC#1 NOT USED NOT USED NOT USED 084571-231 PC#1
4 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1
5 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1
6 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1
7 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1
8 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0
9 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0
4 10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 4
11 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10
12 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10
13 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10
14 084573-250 PC2/0 084571-313 PC#1 084573-250 PC2/0 084573-257 PC2/0 084573-257 PC2/0
15 084573-251 PC2/0 084571-314 PC#1 084573-251 PC2/0 084573-258 PC2/0 084573-258 PC2/0
A B C
142690 D
Crown 2013 PF25841-23 DIA-7335-127
85
SCHEMATIC DIAGRAMS
Wire Harnesses
Wire Harnesses
Harness P/N Connected By:
Power Unit
140333(a, c) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
140334(a, c) Wire Guidance Harness: JC602, PC603, PC604
140335(a) End Aisle Harness (EAC): JC602, PC607, PC608
141028(a) Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, PVL, RGSL, RGSR, SV1, THS2
142216-001 Wire Guide Harness Extension
142670(a, d) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
142671(a, d) Wire Guidance Harness: JC602, PC603, PC604
143590 CA201, CA202, K15, PC809, HN2
145255 Pallet Grab Harness W/Travel Alarm (power unit) CA201, CA202, CA203, CA205, PC809, HN2,
K15
146557 Power Harness: PC206, B-, B+, ED1, ED2
146764 ACCESS 5 to Steer Motor
149532 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC419, PF420, PC421, PC601, BNEG,
BRES1, BRES2, BW-P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1,
THS-P2, FAN, ECR6, Mast Spotlight
Platform
134322(a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331, CA332,
PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140108 Overhead Guard Left Wire Harness JC310, JC311, PC314, PC315, PC316, PC501, LGS1,
LGS2
140109 Overhead Guard Right Wire Harness JC312, JC313,JC314, JC315, JC316, PC338, PC503,
FNS, LGS3
140170(b) CHB7, CHB8, JC331,PC331 (CA331)
140290-001(a) InfoLink® Harness: Alarm, CAN, CURRENT, Load, Module, PROG, PROX, RS232, SHOCK
141029(b) Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141214(a) InfoLink Harness: CAN, PROX, SHOCK
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
DIA-7335-128 Crown 2013 PF25841-24
86
SCHEMATIC DIAGRAMS
Wire Harnesses
Harness P/N Connected By:
Platform (Continued)
142218 Forks Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
First PC306, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335, PC501,
PC503, PC701, JC705, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1,
GSI, GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1,
RAS1, RAS2, RS, LMS1, FS, RS, LOS3, GUIDANCE
143589(a) Travel Alarm JC330, JC336, PC701
145166 Pallet grab harness (platform) JC339, M5, PGS2, PGS3, SB1
145254 Pallet Grab Harness W/Travel Alarm (platform) JC 330. JC336, PC339, PC701, DB1, PGS1
147135-001 Mast Height Encoder Harness PC422
through
147135-004
149374 Lights/Fan Harness: PC102, PC338, PC501, PC503, LGS1, LGS3, FNS
149375 Work Lights Harness: PC102, LGS3
149720 InfoLink®/Intermec Cable Assembly
149721 InfoLink/Intermec Harness: PROX, RS232
149722 PROX Extender Harness: PROX
150354(a) Windows® InfoLink CAN Breakout Harness: ALARM, CAN, CURRENT, LOAD, PROG, PROX,
MODULE, RS232, SHOCK
(a) Optional
Crown 2013 PF25841-25 DIA-7335-129
87
SCHEMATIC DIAGRAMS
Index
Index
This electrical diagram index lists wiring diagrams with
the area or component(s) of the truck covered by each
diagram. Exceptions indicated are listed below.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Power Unit w/Options DIA-7335-106
Schematic - Platform w/Options DIA-7335-107
Schematic - Power Unit w/Pallet Grab DIA-7335-108
Schematic - Platform w/Pallet Grab DIA-7335-109
Schematic - Power Unit DIA-7335-110
Schematic - Platform DIA-7335-111
Platform Distribution Panel DIA-7335-112
Platform Distribution Panel Forks First SAA DIA-7335-113
Power Unit Distribution Panel DIA-7335-114
Platform Modules ACCESS 1 & 4 DIA-7335-115
Platform Modules ACCESS 1 & 4 Forks First SAA DIA-7335-116
Control Pod And Light Switches DIA-7335-117
Overhead Guard Lights/Fans DIA-7335-118
Overhead Guard Spotlights (Optional) DIA-7335-119
Traction Control Module ACCESS 3 DIA-7335-120
Steering Control Module ACCESS 5 DIA-7335-121
Hydraulics & Optional MMS DIA-7335-122
Guidance Control Module ACCESS 6 (Optional) DIA-7335-123
Travel Alarm & Freezer Conditioning (Optional) DIA-7335-124
Travel Alarm & Pallet Grab DIA-7335-125
Forks First Option w/Heaters DIA-7335-126
Power Cables DIA-7335-127
Wire Harnesses DIA-7335-128
Crown 2013 PF25841-1 Rev. 11/11 DIA-7335-105
63
SCHEMATIC DIAGRAMS
Schematic - Power Unit w/Options
Schematic - Power Unit w/Options
A B C
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-3 M3-4 M3-5 M3-6 M3-7 M3-8 M2-1 M2-2 M2-3 M2-4 M2-6 M2-8
MAST SPOT
1 2 3 4
BNEG
BNEG
+BV (ED1) FU9
TRAVEL ALARM
+BV (ED1) FU8
+BV (ED1) FU7
BRAKE DISCONNECT
SHOCK SENSOR
CAN_H
BV AK
BNEG
BNEG
BNEG
CAN_L
+BV FU2
B+
+BV FU1
RAS1
RAS2
+BV C/C
14 PVLF
C/C THS-3
C/C THS-3
+BV C/C
SV1
1
1 SV1 1
K15
FU8
9
PVLF
POWER UNIT
MAST 3 C/C 4
FU7 FU9
SPOTLIGHTS
7 M4
FU14 P2
LGT1 M3
FIL1 + FU13 P1
NOTE:
TRUCK SHOWN WITH PLATFORM
LOWERED, GATES DOWN, 1 LIFTING FORKS OPTION.
AND UNATTENDED.
FU15 ACCESS 3 2 GUIDANCE OPTION.
+ B- 3 MAST MOUNTED
12 CA401
CHB5 CHB4 B+ U U ECR6 SPOTLIGHTS OPTION.
20 V V M1 MAST 4 COLD CONDITION OPTION.
CHS4 CHS3 W W3 HEIGHT 5 PLATFORM LIGHTS/FANS
17 10 CHB FEEDBACK
OPTION.
1 11 CHA 6 BATTERY RESTRAINT
SVL 22 2 ED COIL ED2 OPTION.
2 7 DRIVER (-) 7 DUAL PUMP OPTION. 2
P2 21 TS1 TRACTION
16 TEMP 8 MOTOR MANAGEMENT
+t° TEMP
P1 18 15 14 3 +12V SYSTEM OPTION.
5 6 CHB
FAN2 8 23 7 13 4 CHA 9 TRAVEL ALARM OPTION.
ECR3
CAN_L
CAN_H
NEG TRACTION 10 SAA GATE OPTION.
8
11 EU DEADMAN SWITCH.
MMS
12 EU CHAIN BREAK SWITCHES.
M2 13 ZONE SELECT OPTION.
ED1
ACCESS 5 14 INFOLINK OPTION.
STEER A2
A1 STEER A1 A2 15 PALLET GRAB OPTION.
FU10
B+ CA403 B-
FU5 21
0+ 9 3
FU6
4
22 CR10
0+ I+ 7 19 ED COIL DRIVER (+)
I+ CA407 18 ED IN CS1
BRK I- 27 +5V
SIG CURRENT CR9
I- 0- 8 6 24 NEG SENSE
28 ECR2
0- BRK REL 17 20 13 CHA +5V STEERING
23 INDEX FEEDBACK 6 K2
PVL 11
12 14
CHB
CAN_H CA402-4
CA402-5
NEG
120 OHM
PVL 2 BRES1 BRES2
5
+BV LOGIC 10 RGSR 2 RGSL
3 B+ SENSE 25 16 3
26 BNEG SENSE
CAN_L
JC413 RES2
RES3
DTS1
9 HN2
K15
LOAD WHEEL
SENSOR BAR 2 ACCESS 6 EAC DIST PNL
DIG 1
B1
GS2 1 +12V CA608-1 2 1 BNEG 2
1 COIL 1 24 2
3
BNEG CA608-2
4 3 ANATST 34 EAC
CA604
A1 TST 1 2
2 COIL 2 25 4 A1 ANA 5 +12V 5
3 BNEG 23 5 A1 DIG 3 CA605
5 +5V 22 CA602 DIG 1
A1
6 STEST 28 6 A2 TST 4 2 1 BNEG 2
26
CA607
TR2 7 8 COIL 3 7 A2 ANA 5 3 TST 3 EAC
COIL 4 27 8 A2 DIG 6 4 5 ANA 4
+t° TR3 2 9 B1 TST 7 +12V 5
GS1 10 B1 ANA 8 CA606
FU2
+t° CR11 11 B1 DIG A2
1
COIL 4 17 9 1 BNEG
DIG 1
12 B2 TST 10 2 2
CA603
2COIL 3 18 11 3 TST 3 EAC
3 16 13 B2 ANA
CA601-2
CAN_L CA601-5
4 5 ANA
CA601-1
CA601-4
BNEG 4
FU3 2 5 15 14 B2 DIG 12 +12V 5
4 +5V
6
STEST 21 CA609 B2 4
FU1
7 8
COIL 2 19 1 DIG 1
COIL 1 20 2 BNEG 2
STEER WHEEL CA610 4 3 ANATST 34 EAC
SENSOR BAR 5 +12V 5
CAN_H
ED1 ED2
FU4
K2 24V BATT
+
A B C
149646 A 4 of 9
DIA-7335-106 Crown 2013 PF25841-2
64
SCHEMATIC DIAGRAMS
Schematic - Platform w/Options
Schematic - Platform w/Options
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS TRUCK SHOWN WITH PLATFORM LOWERED
1 GATES DOWN AND UNATTENDED.
1 1
RAS4 ACCESS 4
RAS3 CA304-2
CA303-9 CA304-7
LOS3 LMS1 CA303-1 SIG POT1
CA303-10 TRACTON
+12V CA303-4 +5V
LOS4 CA304-21 CA303-19 NEG
ECR5 CHA CA304-22
STEER CHB CA304-23 CA303-20
COMMAND NEG CA304-20 CA303-21
ECR1
+12V CA304-18
STEER CHA CA304-16 CHS2 CHS1
COMMAND
CHB CA304-17 CA304-11
NEG CA304-19 GTS2 GTS1 GTS5 GTS6
ECR4 +5V CA303-12 CA304-10
HEIGHT CHA CA303-13 10
ENCODER CHB CA303-14 CA303-6
NEG CA303-15 CA303-23 ZSSA HGTRS NOTE:
FS
CA304-9 1 LIFTING FORKS OPTION.
RS CA304-13 ZSSB
CA304-8 ZSS 13 2 GUIDANCE OPTION.
CA304-1
CAN_H CA303-7
CAN_L CA303-8
CA304-3
CA303-16 CA304-14 ZSSC
LOS1 3 MAST MOUNTED SPOTLIGHTS
CA303-17 CA304-5 OPTION.
LOS2 CA303-3
CA304-4
CA303-18 4 COLD CONDITION OPTION.
12 CHB7 CHB8
5 PLATFORM LIGHTS/FANS OPTION.
RAS1 6 BATTERY RESTRAINT OPTION.
2 2
7 RAS2 ACCESS 1
7 DUAL PUMP OPTION.
CA302-3 CA302-4 8 MOTOR MANAGEMENT SYSTEM
OPTION.
9 TRAVEL ALARM OPTION.
2
120 OHM
10 SAA GATE OPTION.
ALM1 GUS
CR12 CA302-14
11 EU DEADMAN SWITCH.
CAN_H CA302-8
CAN_L CA302-9
CA302-2 ORS1
CA302-13 12 EU CHAIN BREAK SWITCHES.
CA302-1 DMS1 13 ZONE SELECT OPTION.
11 14 INFOLINK® OPTION.
15 PALLET GRAB OPTION.
STEER POSITION INDICATOR
CA323-3
CA323-4
CA323-2
CA323-1
R1 R2
CAN_L
CAN_H
VR1
3 + C1 3
BRS
CA301 PROG CA301
CAN_H K1
CAN_L
CR1 CR2
KYS CR3
START TR1
ACC -T°
CR4
+BV (ED1) FU7 (CUSTOMER OPTIONS)
EDS IGN K1
OFF
+BV FU1 (CUSTOMER OPTIONS)
PLATFORM
LIGTHS/FAN
5
LIFTING FORK COILS
BRAKE DISCONNECT
4 5 13 251524
(FAN/SPOT LIGHTS)
MAST SPOT LIGHT
4 4
(POWER SUPPLY)
INFOLINK 14 PLATFORM
+BV (ED1) FU8
+BV (ED1) FU9
TRAVEL ALARM
6 7 8 9 C/C 4
+BV AK
CAN_H
CAN_L
+BV FU2
C/C THS-3
C/C THS-3
BNEG
BNEG
BNEG
BNEG
BNEG
1
+BV C/C
+BV C/C
RAS1
RAS2
1
PVLF
SV1
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-1 M2-3 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-2 M2-4 M2-6 M2-8
A B C
149646 A 3 of 9
Crown 2013 PF25841-3 DIA-7335-107
65
SCHEMATIC DIAGRAMS
Schematic - Power Unit w/Pallet Grab
Schematic - Power Unit w/Pallet Grab
A B C
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-4 M2-6 M2-8
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-1 M2-2 M2-3 M2-5 M2-7
MAST SPOT
1 2 3 4 15
BNEG
BNEG
TRAVEL ALARM
+BV (ED1) FU9
BNEG
BNEG
BNEG
CAN_H
+BV AK
+BV (ED1) FU8
+BV (ED1) FU7
CAN_L
PALLET
PALLET
PALLET
PALLET
B+ PVLF
BRAKE DISCONNECT
POWER UNIT
+BV FU1
+BV FU2 SHOCK SENSOR
GRAB
GRAB
GRAB
GRAB
SV1
RAS1
RAS2
14
1 1 1
SV1
K15 9
FU8
FU19 FU16
PVLF FU18 FU17
MAST
FU7 FU9 SPOTLIGHTS
3
7 M4
FU14 P2
LGT1 M3
FIL1 + FU13 P1
FU15 ACCESS 3
+ B-
12 CA401
CHB5 CHB4 B+ U U ECR6
20 V V M1 MAST NOTE:
CHS4 CHS3 W W3 HEIGHT 1 LIFTING FORKS OPTION.
17 10 CHB ENCODER
1 11 CHA 2 GUIDANCE OPTION.
SVL 22 2 ED COIL DRIVER (-) ED2 3 MAST MOUNTED
2 7
P2 21 TS1TRACTION SPOTLIGHTS OPTION. 2
16 TEMP 4 COLD CONDITION OPTION.
3 +t° TEMP
P1 18 15 10 +12V
5 6 CHA 5 PLATFORM LIGHTS/FANS
8 23 7 13 4 CHB
FAN2 ECR3 OPTION.
CAN_H
CAN_L
NEG TRACTION 6 BATTERY RESTRAINT OPTION.
8 7 DUAL PUMP OPTION.
MMS
8 MOTOR MANAGEMENT
M2 SYSTEM OPTION.
ED1 9 TRAVEL ALARM OPTION.
ACCESS 5 10 SAA GATE OPTION.
STEER A2
A1 STEER A1 A2
FU10 11 EU DEADMAN SWITCH.
B+ B-
0+ FU5 9 21
3
12 EU CHAIN BREAK SWITCHES.
4
22
ED COIL DRIVER (+) CR10 13 ZONE SELECT OPTION.
FU6 I+ 19
7 14 INFOLINK® OPTION.
0+ CA407 CA403 18 +5V ED IN
I+ 27 SIG CS1 CR9 15 PALLET GRAB OPTION.
BRK I- I- 6 24 28 NEG CURRENT
SENSE ECR2
0- 0- 8 20 13 CHA +5V
BRK REL 17 STEERING K2
23 INDEX FEEDBACK
11 12 14
PVL CHB 6
CAN_H CA402-4
CAN_L CA402-5
NEG BRES1
120 OHM
PVL 2 5
+BV LOGIC 10 RGSR 2 RGSL BRES2
3 +B SENSE 25 16
26
3
BNEG SENSE
JC413 RES2
RES3
DTS1
9 HN2
K15
LOAD WHEEL 2 EAC DIST PNL
SENSOR BAR 2 ACCESS 6 DIG 1
B1
GS2 +12V CA608-1 2 1
2 1
BNEG 2
COIL 1 24 BNEG CA608-2 3 TST 3 EAC
1 3 A1 TST 1 2 4 5 ANA 4
CA604
2 COIL 2 25 +12V 5
3 BNEG 23
4 A1 ANA
3 CA605
5 +5V 22 CA602 6 5 A1 DIG
DIG
A1
4 2 1
A2 TST 1
6 STEST 28 BNEG
CA607
2
TR2 7 8 COIL 3 26 7 A2 ANA 5 3 TST 3 EAC
COIL 4 27 8 A2 DIG 6 4 5 ANA 4
+t° TR3 9 B1 TST 7 +12V 5
GS1 2 10 B1 ANA 8 CA606 A2
+t° CR11 11 B1 DIG 9 1 DIG 1
1 COIL 4 17 12 B2 TST 10 2 BNEG 2
EAC
3
CA603
3
2 COIL 3 18 13 B2 ANA 11 4 5 ANA
TST
4
CA601-4
CA601-2
CA601-1
3 BNEG 16
CA601-5
FU3 B2 DIG 12 +12V 5
4 5 +5V
6 STEST 21
15 14
CA609 B2
4
FU1
FU2
COIL 2
7 8 COIL 19 1 DIG 1
1 20 2 BNEG 2
EAC
STEER WHEEL
CA610 4 3 ANA
TST 3
4
SENSOR BAR 5 +12V 5
CAN_L
CAN_H
ED1 ED2
FU4
K2 24V BATT
+
A B C
149646 A 6 of 9
DIA-7335-108 Crown 2013 PF25841-4
66
SCHEMATIC DIAGRAMS
Schematic - Platform w/Pallet Grab
Schematic - Platform w/Pallet Grab
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS TRUCK SHOWN WITH PLATFORM LOWERED
1 1 GATES DOWN AND UNATTENDED. 1
RAS4 ACCESS 4
RAS3 CA304-2
CA303-9 CA304-7
LOS3 LMS1 CA303-1 SIG POT1
CA303-10 CA303-4 +5V TRACTON
LOS4 +12V CA304-21
ECR5 CHA CA304-22 CA303-19 NEG
STEER CHB CA304-23 CA303-20
COMMAND NEG CA304-20 CA303-21
ECR1 +12V CA304-18
STEER CHA CA304-16 CHS2 CHS1
COMMAND CHB CA304-17 CA304-11 NOTE:
NEG CA304-19 GTS2 GTS1 GTS5 GTS6 1 LIFTING FORKS OPTION.
ECR4 +5V CA303-12 CA304-10
HEIGHT CHA CA303-13 HGTRS 10 2 GUIDANCE OPTION.
ENCODER CHB CA303-14 CA303-6
NEG CA303-15 CA303-23 ZSSA 3 MAST MOUNTED
FS SPOTLIGHTS OPTION.
CA304-9
RS CA304-13 ZSSB 4 COLD CONDITION OPTION.
CA304-8 ZSS 13 CLAMP 16
CA303-16 CA304-14 ZSSC 5 PLATFORM LIGHTS/FANS OPTION.
CAN_H CA303-7
CAN_L CA303-8
CA304-3
CA304-1
LOS1 CA303-22
CA303-17 6 BATTERY RESTRAINT OPTION.
LOS2 CA303-3 CA304-5 DETECT
CA303-18 7 DUAL PUMP OPTION.
12 CHB7 CHB8 CA304-4
8 MOTOR MANAGEMENT
SYSTEM OPTION.
2 RAS1 9 TRAVEL ALARM OPTION. 2
7 RAS2 ACCESS 1
10 SAA GATE OPTION.
CA302-3 11 EU DEADMAN SWITCH.
CA302-4
12 EU CHAIN BREAK SWITCHES.
2
13 ZONE SELECT OPTION.
120 OHM
ALM1 GUS 14 INFOLINK® OPTION.
CA302-14
ORS1
CAN_H CA302-8
CAN_L CA302-9
CA302-2 15 PALLET GRAB OPTION.
CR12 CA302-13
DMS1 16 PALLET CLAMP
CA302-1 & DETECT OPTION.
11
STEER POSITION INDICATOR
CA323-3
CAN_L CA323-4
CA323-2
CA323-1
R2
R1
CAN_H
VR1
3 + C1 3
BRS
CA301 PROG CA301 CAN_H K1
CAN_L
CR1 CR2
KYS CR3
START TR1
-T°
ACC
EDS CR4
IGN K1
OFF
PLATFORM
LIGTHS/FAN
5
(CUSTOMER OPTIONS)
(CUSTOMER OPTIONS)
LIFTING FORK COILS
BRAKE DISCONNECT
(FAN/SPOT LIGHTS)
4 5 13 251524
4 4
+BV (ED1) FU7
(POWER SUPPLY)
+BV (ED1) FU8
INFOLINK 14
TRAVEL ALARM
+BV (ED1) FU9
+BV (FU1)
PALLET GRAB
6 7 8 9
MAST SPOT
CAN_H
15
CAN_L
+BV FU2
1
+BV AK
BNEG
BNEG
BNEG
BNEG
BNEG
RAS1
RAS2
PVLF 1
B-
B-
B-
B-
SV1
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-1 M2-2 M2-3 M2-4 M2-6 M2-8
A B C
149646 A 5 of 9
Crown 2013 PF25841-5 DIA-7335-109
67
SCHEMATIC DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
A B C
M1-6 M1-4 M1-8 M1-1 M2-2 M2-4 M2-6 M2-8
M1-2 M1-5 M1-7 M1-3 M2-1 M2-3 M2-5 M2-7
+BV (ED1) FU9
BNEG
BNEG
+BV (ED1) FU7
BNEG
BNEG
BNEG
+BV (ED1) FU8
BRAKE DISCONNECT
+BV AK
+BV FU2
RAS1
+BV FU1
CAN_H
CAN_L
RAS2
TRUCK SHOWN WITH PLATFORM
1 LOWERED GATES DOWN 1
AND UNATTENDED.
FU7 FU9
FU8
LGT1 P1
M3
FIL1 + FU13
ACCESS 3
+ B-
FU15 B+ U U
CA401-20 V V M1 ECR6
CHS4 CHS3 W3 MAST HEIGHT
W ENCODER
CA401-17 CA401-10 CHB
CA401-1 CA401-11 CHA
SVL CA401-22 CA401-2 ED COIL DRIVER (-) ED2
2 TS1 2
CAN_H CA401-23
CA401-15
CA401-16 TRACTION TEMP
CA401-3 +12V +t•‹
P1 CA401-18
CA401-5 CHB
CA401-8 CA401-6 CHA
CA401-4 NEG
CAN_L
ECR3
TRACTION
FAN2
M2
ED1
ACCESS 5
STEER A2
A1 STEER A1 A2
FU10
B+ B-
FU5 CA403-21
0+ CA403-9 CA403-3
CA403-4
FU6 CA403-22
I+ CA403-7 CA403-19 ED COIL DRIVER (+)
0+ CA407 CA403-18 ED IN CR10
I+ CA403-27 +5V CS1 CR9
BRK CA403-24 SIG CURRENT
I- I- 0- CA403-6
CA403-8 CA403-28 NEG SENSE
0- BRK REL CA403-17
CA403-20
CA403-13 CHA
+5V ECR2
K2
CA403-23 INDEX STEERING
CA403-11 FEEDBACK
CA403-14 CHB
120 OHM
CAN_H CA402-4
PVL CA403-2 CA403-12 NEG
CAN_L CA402-5
CA403-5
3 B+ SENSE
+BV LOGIC CA403-10
CA403-25
CA403-16 3
CA403-26 BNEG SENSE
JC413 RES3
DTS1 RES2
TR2
+t° TR3
FU1
+t° CR11
FU3
4 4
FU2
FU4
ED1 ED2
K2 24V BATT
+
A B C
149646 A 2 of 9
DIA-7335-110 Crown 2013 PF25841-6
68
SCHEMATIC DIAGRAMS
Schematic - Platform
Schematic - Platform
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS
1 TRUCK SHOWN WITH PLATFORM LOWERED 1
ACCESS 4 GATES DOWN AND UNATTENDED.
+12V CA304-21
ECR5 CHA CA304-22
STEER CHB CA304-23 CA303-1 SIG POT1
COMMAND NEG CA304-20 TRACTON
CA303-4 +5V
+12V CA304-18 CA303-19 NEG
ECR1 CHA CA304-16
STEER CHB CA304-17
COMMAND NEG CA304-19
+5V CA303-12 CHS2 CHS1
ECR4 CA304-11
HEIGHT CHA CA303-13
ENCODER CHB CA303-14 GTS2 GTS1
NEG CA303-15 CA304-10
FS
CA304-9
RS CA303-6
CA304-8 HGTRS
RAS1
CA304-1
CA303-7
CA303-8
CA304-3
CA303-16
LOS1
CA303-17
LOS2 CA303-18
2 2
CAN_H
CAN_L
ACCESS 1
CA302-3 CA302-4
ALM1
120 OHM
CAN_H CA302-8
CAN_L CA302-9
CA302-2
CR12 CA302-13
ORS1
STEER POSITION INDICATOR
CA323-3
CA323-4
CA323-2
CA323-1
R2
R1
3 3
CAN_L
CAN_H
VR1
+ C1
BRS
CA301 CAN_H K1
CR1 CR2
CAN_L
KYS CR3
START TR1
-t°
ACC
BRAKE DISCONNECT
EDS IGN CR4
(CUSTOMER OPTIONS)
K1
OFF
(FAN/SPOT LIGHTS)
+BV (ED1) FU7
(POWER SUPPLY)
+BV (ED1) FU8
+BV (ED1) FU9
4 4
+BV (FU1)
CAN_H
CAN_L
+BV AK
+BV FU2
RAS2
BNEG
BNEG
BNEG
BNEG
BNEG
RAS1
M1-6 M1-4 M1-8 M1-1 M2-1 M2-3 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M2-2 M2-4 M2-6 M2-8
A B C
149646 A 1 of 9
Crown 2013 PF25841-7 DIA-7335-111
69
70
DIA-7335-112
Platform Distribution Panel
Platform Distribution Panel
SCHEMATIC DIAGRAMS
4
1
TP16 B NEG
TP14 CAN L
TP13 CAN H
TP12 K1
TP11 K1 COIL
TP10 ED1 FU8
TP9 ED1 FU9
TP8 ALM1
TP7 MODULE POWER
TP6 B+ FU2
TP5 RAS2
TP4 RAS1
TP3 ED1 FU7
TP2 B+ FU1
TP1 BRAKE
A
A
CA101
K1A
16 151413 12 11 10 9 8 7 6 5 4 3 2 1
CA102
CA107 1 2 3 4 5 6 7 8 9 10111213
1
2
3
4
5
5917 CA302-2 ALARM 1 NEG
1
2
3
4
5
6
7
8
TP8
R2
CR12
TP16
R1
ALM1
TP7
VR1
29124 JC331-1 CHAIN BREAK SWITCHES
515 PC301-3 B- CAN ACCESS 29114 (RAS3) LIFTING FORK OPTION
TP12 K1A
530 CA322-1 B- GTS1 CR4 2937 CA304-1 +BV KYS ACCESS 4
C1
521 (CA309) B- CHS1 2925 CA308-4 +BV KYS CONTROL POD
TP11 CR2
TP10
520 CA320-2 B- HGTRS 2941 CA302-3 +BV KYS ACCESS 1
TP2
TP1
K1
TP6
TP9
580 CA323-2 B- ACCESS 1 STR POS INDICATOR
TR1
29105 CA323-1 +BV KYS STR POS IND
+t
TP5
550 CA335-1 B- ZSS CR3 CR1 2924 CA308-2 IGN
514 CA309-7 B- ORS1 2923 CA308-3 START
513 CA302-4 B- ACCESS 1 207 PC301-4 +BV FU2 CAN ACCESS
TP4
525 CA304-3 B- ACCESS 4 5904 (CA321) BRAKE SWITCH
TP3
524 (CA321) B- BRS 2932 CA308-11 RAS2
522 (CA321) B- HN1 2935 CA308-10 RAS1
512 PC306-3 B- CUSTOMER ACCESSORIES 2997 (CA303) LIFTING FORKS DIODE
2940 PC306-2 +BV ED1 FU7 CUSTOMER ACCY
B
B
CA103
CA106
TP13 2939 PC301-5 +BV ED1 FU7 CAN ACCESS
MC1
205 PC306-1 +BV FU1 CUSTOMER ACCY
10
11
12
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
CA105
CA104
TP14
BRAKE SWITCH BLK RED/BLK BNEG
B+ FU1 WHT WHT/BLK BNEG
B+ FU2 RED BLU BNEG
B+ ED1 FU9 GRN ORG BNEG
B+ ED1 FU8 ORG GRN BNEG
B+ ED1 FU7 BLU RED CAN L
RAS1 WHT/BLK WHT CAN H
RAS2 RED/BLK BLK +BV AK FROM KYS
MC2
2
001 CA303-7 CAN H ACCESS 4
1
003 CA302-8 CAN H ACCESS 1
6
005 PC301-1 CAN H CAN ACCESS
031 CA323-3 CAN H ACCESS 1 STR POS IND 29
2
002 CA303-7 CAN L ACCESS 4
1
004 CA302-9 CAN L ACCESS 1
6
006 PC301-2 CAN L CAN ACCESS
032 CA323-4 CAN L ACCESS 1 STR POS IND 29
C
C
Crown 2013 PF25841-8
142680 E
1
Crown 2013 PF25841-9
Platform Distribution Panel Forks First SAA
4
2 (2) TP2 B+ FU1
1
(16) TP16 B NEG
(14) TP14 CAN L
(13) TP13 CAN H
(12) TP12 K1
(11) TP11 K1 COIL
(10) TP10 ED1 FU8
(9) TP9 ED1 FU9
(8) TP8 ALM1
(7)TP7 MODULE POWER
(6) TP6 B FU2
(5) TP5 RAS2
(4) TP4 RAS1
(3) TP3 ED1 FU7
(1) TP1 BRAKE
A
A
CA101 CA102 CA103
1 2 3 4 5 6 7 8 1 2 3 4 5
R2 (8)
16 5917 CA302-2 ALM1 NEG
CR12 15
CA107 (7) R1
VR1 14 29111 (CA304) CHAIN BREAK SWITCHES
515 PC301-3 BNEG CAN ACCESS 1 ALM1 13 29114 (CA701) CABIN DOW SWITCHES
530 CA322-1 BNEG GTS1 2 CR4 (12) 12 2937 CA304-1 BV KYS ACCESS 4
520 (CA309) BNEG CHS1 3 C1 (11) 11 2925 CA308-4 BV KYS CONTROL POD
521 CA320-2 BNEG HGTRS 4 CR2 K1A 10 2941 CA302-3 BV_KYS ACCESS 1
+ K1
580 CA323-2 BNEG ACCESS 1 STR POS IND 5 (6) (9) (5) (2) (1) (10) 9 29105 CA323-1 BV KYS STR POS IND
550 CA335-1 BNEG ZSS 6 CR3 CR1 +t TR1 8 2924 CA308-2 IGN
Platform Distribution Panel Forks First SAA
514 CA309-7 BNEG ORS1 7 7 2923 CA308-3 START
513 CA302-4 BNEG ACCESS 1 8 6 207 PC301-4 BV FU1 CAN ACCESS
525 CA304-3 BNEG ACCESS 4 9 (3) (4) 5 5904 (CA321) BRAKE SWITCH
524 (CA321) BNEG BRS 10 4 2935 CA308-11 RAS2
522 (CA321) BNEG HN1 11 3 2932 CA308-10 RAS1
512 PC306-3 BNEG CUSTOMER ACCESSORIES 12 2
B
B
13 1 2940 PC306-2 BV FU7 CUST ACCY
562 CA320-2 PDS CDS (13) CA105 2939 PC301-5 BV ED1 FU7 CAN ACCESS
(14)
CA106
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 205 PC306-1 BV FU1 CUST ACCY
BRAKE SWITCH BLK CA104 RED/BLK BNEG
BV FU1 WHT WHT/BLK BNEG
BV FU2 RED BLU BNEG
BV ED1 FU9 GRN ORG BNEG
BV ED1 FU8 ORG GRN BNEG
BV ED1 FU7 BLU RED CAN L
RAS1 WHT/BLK WHT CAN H
RAS2 RED/BLK BLK BV AK FROM KYS
SCHEMATIC DIAGRAMS
MC1
2 MC2
001 CA303-7 CAN H ACCESS 4 1
003 CA302-8 CAN H ACCESS 1 6
005 PC301-1 CAN H CAN ACCESS 29
031 CA323-3 CAN H ACCESS 1 STR POS IND
002 CA303-8 CAN L ACCESS 4 2
004 CA302-9 CAN L ACCESS 1 1
006 PC301-2 CAN L CAN ACCESS 6
032 CA323-4 CAN L ACCESS 1 STR POS IND 29
C
C
DIA-7335-113
142696 B
1
71
72
DIA-7335-114
Power Unit Distribution Panel
Power Unit Distribution Panel
SCHEMATIC DIAGRAMS
4
1
121 (CA412) NEGATIVE BRUSH BRUSHWEAR M3
TP19 MMS
TP18 RAS2
TP17 RAS1
TP16 CAN_L
TP15 CAN_H
TP14 INNER BRAKE
TP13 OUTER BRAKE
TP12 BATT SENSE
TP11 K1 OUT
TP10 FU9
TP9 FU8
TP8 FU7
TP7 FU2
TP6 FU1
TP5 ED2
TP4 K2
TP3 BNEG
TP2 ED1
TP1 B+
108 (CA412) POSITIVE BRUSH BRUSHWEAR M3
POSITION 1 AND 2 ARE CLOSED.
5 AND 4 ARE CLOSED, IN THE TOP
NOTE: ON DTS1 IN THE CENTER POSITION
107 (CA412) NEGATIVE BRUSH BRUSHWEAR M4
106 (CA412) POSITIVE BRUSH BRUSHWEAR M4
122 CA401-7 BRUSHWEAR
5930 CA407-5 BRAKE SWITCH
29129 (CA808) +BV_K2 FU3 PVLF AND SV1 LIFTING FORK OPTION
A
A
2959 (CA412) +BV_K2 FU3 SVL
2960 (CA412) +BV_K2 FU3 PVL
2955 PC417-1 +BV_K2 FU3 CHB5
29122 (CA401) +BV_K2 FU3 FAN2 1 2968 CA407-1 BRAKE COIL OUTER
2970 (CA412) +BV_K2 FU3 THS P1 1 2957 CA403-9 BRAKE OUTER
2954 PC415-1 +BV_K2 FU3 CHAIN SLACK 2 2956 CA403-7 BRAKE COIL INNER
2972 CA601-1 +BV_K2 FU3 ACCESS 6 2 2969 CA407-2 BRAKE INNER
2966 CA403-10 +BV_K2 FU3 ACCESS 5 3 208 K15-7 +BV HN2
2953 CA401-1 +BV_K2 FU3 ACCESS 3 3 206 CA403-25 BATTERY SENSE ACCESS 5
29107 CA413-4 DRIVE/TOW FU4 POWER 4 2964 (CA412) +BV_ED1 LGT1
578 CA413-3 DRIVE/TOW BNEG 5 2963 (CA412) ED1 COIL
5109 +BV HN2 6 2961 (CA412) P1 COIL
7 2962 (CA412) P2 COIL
4
29108 CA413-1 BRAKE RESIST 2996 8 2967 CA403-18 CR9 SUPPRESION
29125 CA413-2 BRAKE RESIST 2995
3
585 (CA401) BNEG BB
10
12
13
14
15
16
11
1
4
4
5
8
9
1
2
2
5
7
8
3
6
7
3
6
CA201
CA202
CA418
1
4
5
2
6
3
CR7
CR8
CR6
CR5 R3
29127
R4
29123
DTS1
TP19
6 4 3 1
29124
CR9
5 2
TP12
586
FU4
TP11
TP6 TP7 TP8 TP9 TP10
FU1
R5
TP14
RES2
RES3
B
B
TP13
K2
TP1
FU2
CA206 1 2 3 4 5 6
FU5
FU7
TP2
FU6
FU8
TP18
TP17
201 (CA401) +BV
TP13
202 (CA401) +BV TR2 TP5
FU9
2901 (CA401) +BV_ED1 +t
2902 (CA401) +BV_ED2
501 (CA401) BNEG BB
TP4
FU3
TP16
502 (CA401) BNEG BB
K2
CA203
TR3 CR11
CA205
CA204
+t TP15 MAST MOUNTED
GRN SPOT LIGHTS (OPTION)
12
10
11
MC2
4
5
1
6
7
8
1
1
4
5
8
9
2
3
4
5
6
7
2
3
6
7
3
9 RED/BLK BNEG
017 CA401-23 CAN_H ACCESS 3 WHT/BLK BNEG
019 CA402-4 CAN_H ACCESS 5 15 BLU BNEG
021 CA601-4 CAN_H ACCESS 6 14 ORG BNEG
018 CA401-15 CAN_L ACCESS 3 9 GRN BNEG
020 CA402-5 CAN_L ACCESS 5 15 RED CAN_L
14
MC1
022 CA601-5 CAN_L ACCESS 6 WHT CAN_H
BLK +BV_AK FROM KYS
RED/BLK RAS2
C
C
WHT/BLK RAS1
BLU +BV_ED1 FU7
ORG +BV_ED1 FU8
GRN +BV_ED1 FU9
Crown 2013 PF25841-10
RED +BV FU2
WHT +BV FU1
BLK BRAKE SWITCH
142681 E
1
SCHEMATIC DIAGRAMS
Platform Modules ACCESS 1 & 4
Platform Modules ACCESS 1 & 4
A B C
6 CA301 JC301
005 CA105-3 CAN_H 1 CAN 1 4 6 BLK
006 CA105-9 CAN_L 6 2 ACCESS 2 5
515 CA107-1 DISTRIBUTION BNEG 3 3 13 7 WHT MAST
CABLE
207 CA103-6 DISTRIBUTION +BV FU1 4 4 25 8 RED 4
2939 CA103-2 DISTRIBUTION +BV ED1 FU7 5 210 5 15 9 GRN
203 CA308-1 EDS 6 6 24
1 CA302 INFOLINK 1
5902 CA309-5 DMS1 1 SW AL ACCESS 1
5917 CA103-16 ALARM 1 2 GPD
2941 CA103-10 DISTRIBUTION +BV KYS 3 +BV (DCM)
513 CA107-8 DISTRIBUTION BNEG 4 BNEG
5 NEG
6 N/A
1 7 N/A SP 3500
003 CA105-2 CAN_H 1 8 CAN_H
004 CA105-8 CAN_L 9 CAN_L
10N/A CA302
11N/A 1 5
12SW AH/ANA 6 9
5901 CA309-4 ORS1 13SW AL
5903 CA309-6 GUS 14SW AL 10 14
CA323
29105 CA103-9 DISTRIBUTION +BV KYS 1 ACCESS 1
580 CA107-5 DISTRIBUTION BNEG 29 2
031 CA105-4 CAN_H 3 (DCM)
29 4
032 CA105-10 CAN_L GUIDANCE AND
(1) HEIGHT ENCODER (ECR4) 32 PULSE/REV STEER INDICATOR
(2) STEER SENSE ENCODER (ECR1) 32 PULSE/REV
(3) STEER SENSE ENCODER (ECR5) 32 PULSE/REV
CA303
7
2 101 CA309-1 POT1 SIGNAL 1 AN1
2 AN2 ACCESS 4 2
29123 PC331-1 CHAIN BREAK SWITCH 7 3 SW2 / AN1SP (VCM)
701 CA309-2 POT1 +5V 4 +5V
2997 CA103-3 LIFTING FORKS DIODE 2989 2 5 +5V
5912 CA320-1 HGTRS NO 2 6 SW7
001 CA105-1 CAN_H 2 7 CAN_H
002 CA105-7 CAN_L CA327 1 29139 8 CAN_L
29112 (CA701) LMS1 LIFTING FORK OPTION 9 SW1 / AN2SP CA303
29113 (CA701) LOS4 LIFTING FORK OPTION 1 29140 10 SW0 / AN3SP
CA328 5 11+5V 1 8
(1) CH A
WHT 1 CH A 703 5 12+5V
9 15
ECR4 CH B BLU 2 CH B 007 5 13ECR1 A
+12V 16
NEG RED 3 +5V 008 5
14ECR1 B 23
BLK 4 NEG 516 15LOGIC NEG
2930 CA308-9 RAS1 CA317 16SW8 / AN4SP
2928 CA308-7 LOS1 17SW9 / AN5SP
2929 CA308-8 LOS2 18SW10 / AN6SP
506 CA309-2 LOGIC NEG POT1 7 581 19RS-232 COM
20RS-232 TX
21RS-232 RX
22SW / INDEX
59136 CA332-1 ZSSA 23SW6
CA304
2937 CA103-12 +BV KYS CA330 1 1 MODULE POWER
29145 CA701-1 +BV 29128 2 DRIVER B+
3 525 CA107-9 DISTRIBUTION B- 3 B- 3
5936 CA701-3 OPTION PVLF COIL DRIVER SUBHARNESS CA325 1 5941 4 PWM1
5935 CA701-4 OPTION SV1 COIL DRIVER SUBHARNESS 1 5942 5 PWM2
CA326 6 PWM3
5980 CA701-2 OPTION TRAVEL ALARM HARNESS CA336 1 5915 7 PWM4 23 16
2927 CA308-6 REVERSE SWITCH 8 SW12 15 9
2926 CA308-5 FORWARD SWITCH 9 SW11 8 1
5916 (CA321) GATE SWITCHES 10SW5
5911 (CA309) CHAIN SLACK SWITCHES 11SW4
12SW3 CA304
59139 CA333-1 ZSSB 13SW15
59138 CA334-1 ZSSC 14SW14
3 15SW13
(2) CH A
WHT 1 CH A 009 3 16ECR2 A
ECR1 CH B
+12V
BLU 2 CH B 010 3 17ECR2 B
NEG RED 3 +12V 312 3 18+12V
BLK 4 NEG 517 4 19LOGIC NEG
(3) CH A
WHT 5 CH A 518 4 20LOGIC NEG
ECR5 CH B BLU 6 CH B 313 4 21+12V
+12V
NEG RED 7 +12V 011 4 22ECR3 A
BLK 8 NEG 012 23ECR3 B
CA318
29123 CA303-3 CHAIN BREAK OPTION
29124 PC103-14 B+ DISTRIBUTION BOARD EU CHAIN
4 1
1
29110 BREAK OPTION 4
CA331
1 29111
CHB7 CHB8
A B C
142682 E
Crown 2013 PF25841-11 DIA-7335-115
73
SCHEMATIC DIAGRAMS
Platform Modules ACCESS 1 & 4 Forks First SAA
Platform Modules ACCESS 1 & 4 Forks First SAA
142697 C
DIA-7335-116 Crown 2013 PF25841-12
74
SCHEMATIC DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
A B C
5912 CA303-6 HGTRS 1 1
HGTRS
521 CA107-4 DISTRIBUTION BNEG 1
PC306
205 CA103-1 +BV FU1 A POWER FOR
1 2940 CA103-2 +BV ED1 FU7 B CUSTOMER ACCESSORIES 1
512 CA107-12 DISTRIBUTION BNEG C
CA308 CA305
203 CA301-6 FU2 1 204 1 2903 1 START
2924 CA103-8 IGN 2 EDS
2904 2 BATT ACC
2923 CA103-7 START 3 2905 3
2925 CA103-11 +BV KYS FROM DIST 4 2906 4 IGN
2926 CA304-9 FS 5 2907 OFF
2927 CA304-8 RS 6 2908
2928 CA303-17 LOS1 7 2909 FS KYS
2929 CA303-18 LOS2 8 2910 1 2938
2930 CA303-16 RAS1 9 2911 RS 2915
2932 CA103-3 RAS1 10 2912 1 BATT ACC
2935 CA103-4 RAS2 11 2913 LOS1 CA324
2936 (CA321) HNS 12 2914 2917 1
1 START
LOS2 GND
2918 IGN
1
2 RAS1 BACK VIEW OF KYS 2
1 2919
RAS2 2921
1
HNS
1 2922
CA309
101 CA303-1 POT1 WIPER 7 1 GRN POT1
701 CA303-4 POT1 +5V 7 2 ORG
506 CA303-19 POT1 NEG 7 3 VIO
5901 CA302-13 ORS1 4 5905 ORS1
5902 CA302-1 DMS1 5 5906 1
5903 CA302-14 GUS 6 5907 DMS1
514 CA107-7 DIST BNEG 7 527 1 529
8 5939
GUS 528
1
CHS1 CHS2
1 5918 1
3 5911 CA304-11 CHS1 3
520 CA107-3 DIST BNEG
CA332 ZSS
59136 CA303-23 ZSSA 1 BRN
CA333
59137 CA304-13 ZSSB 1 WHT
CA334
59138 CA304-14 ZSSC 1 BLU
CA335
550 CA107-6 BNEG 1 BLK
GRN
(CA321)
(FOR REFERENCE ONLY) HN1
2936 CA308-12 HNS 1
522 CA107-11 DIST BNEG
5904 CA103-5 BRS 1 BRS
4 4
524 CA107-10 DIST BNEG
5916 CA304-10 GTS2
CA322 GTS1 GTS2
530 CA107-2 DIST BNEG 1 582 1 5919 1
A B C
142683 D
Crown 2013 PF25841-13 DIA-7335-117
75
SCHEMATIC DIAGRAMS
Overhead Guard Lights/Fans
Overhead Guard Lights/Fans
A B C
LGT2
503 1
301
LEFT SIDE ASSEMBLY LEFT WORKLIGHT
PS1
POWER SUPPLY
CA501
1 12V OUT
1 535 1 504 2 1
536 2 505 3 BATT COMM
2950 3 2990 4 BV INPUT
303 4 302
2951 5 2931
305 6 310
2948 7 51062998
TO PLATFORM WALL 5105 8
9 PS2
POWER SUPPLY
309 1 12V OUT
TO MODULE
HSG 2
3 BATT COMM
CAP1 4 BV INPUT
541
OPTION
LGT3
1 BLK
542 LGT4
RED BLK 1
-
LEFT DOME LIGHT
531 1234 5 LEFT SPOTLIGHT
2 532 TB502 2
PC102 LGS1 1 PC338
2942 1 MAST MOUNTED
1
2 2943 LGS2 SPOTLIGHTS
3 534 533 1
4 2944 WHEN MAST MOUNTED SPOTLIGHTS
5 1 2952 ARE PRESENT, THE MAST CABLE
COPIED FROM LGS3 PLUGS INTO PC338
DISTRIBUTION
BOARD PAGE 29451
FNS1
3 3
LGT7
BLK RED 1
FAN1 RIGHT SPOTLIGHT
CA503 507
533 1 508 1 FAN SUPPRESSOR
534 2 510
303 3 307 1
2947 4 2992 2
305 5 308 3 V CXX
2946 6 2916 2933 4
2949 7 2920 5
TO PLATFORM WALL 5107 8 5108 RES1
9 1 2934
SB30
TO MODULE CAP2
RIGHT SIDE ASSEMBLY HSG
4 4
LGT6
1 BLK LGT5
RIGHT DOME LIGHT 1
509 RIGHT WORKLIGHT
A B C
142687 E 1 of 2
DIA-7335-118 Crown 2013 PF25841-14
76
SCHEMATIC DIAGRAMS
Overhead Guard Spotlights (Optional)
Overhead Guard Spotlights (Optional)
A B C
1 1
LEFT
LGT4
2 2
PC102
1
2 RED
3 BLK
4 BLK
5 WHT
WHT
RIGHT
3 3
LGT7
4 4
A B C
142687 E 2 of 2
Crown 2013 PF25841-15 DIA-7335-119
77
SCHEMATIC DIAGRAMS
Traction Control Module ACCESS 3
Traction Control Module ACCESS 3
A B C
FAN2
1
29122 CA201-8 +BV K3 FU3 FROM DIST 5908
1 1
579 CA411-2 M1 TEMP SENSOR CA401
2953 CA201-5 +BV K2 FU3 FROM DIST 1 MODULE POWER
5920 (CA412) ED2 COIL - 2 GPD 1 ACCESS 3
315 CA411-3 +12V TO ECR3 8 3 +12V
549 CA411-6 LOGIC NEG TO ECR3 8 4 LOGIC NEG
029 CA411-4 TRACTION ENCODER CHB 8 5 ECR1 A U
028 CA411-5 TRACTION ENCODER CHA 8 6 ECR1 B U M1
122 CA201-12 BRUSH WEAR 7 AN2 V V
8 GPD 5 W 3
9 POT CMD W
2971 (CA412) MOTOR 3 THERMAL INPUT 10 DI8/ECR2 B
2973 PC414-1 POWER UNIT CHS3 11 DI7/ECR2 A
12 DI5/ID1
2975 (CA412) MOTOR 4 THERMAL INPUT 13 DI3
9 14 DI2
018 CA204-7 CAN L 8 15 CAN L
105 CA411-1 TRACTION MOTOR TEMP 16 TEMP (+)
17 DI4/ID0
5923 (CA412) P1 COIL LOW SIDE DRIVER 18 GPD 2 CA401
19 DI1
2974 CA416-1 CHB4 20 DI6/AN1 1 8
5924 (CA412) P2 COIL LOW SIDE DRIVER 21GPD 3 9 15
5925 (CA412) SVL COIL LOW SIDE DRIVER 22 GPD 4 B+ + B- 16 23
2 017 CA204-1 CAN H 9 23 CAN H 2
543 (CA412) ED1 COIL FU10
544 (CA412) STROBE LIGHT LGT1
547 (CA403) BATTERY RESTRAINT SWITCHES 1
548 (CA403) RAIL GUIDE SWITCHES 1
551 CA403-26 BATTERY SENSE ACCESS 5 2
552 CA601-2 B- BB TO ACCESS 6 BNEG ED2
585 CA418-C BRAKE RESISTOR
579 CA411-1 M1 TEMP SENSOR 3
553 CA808-1 FREEZER CONDITIONING
554 CA808-2 FREEZER CONDITIONING 4
563 (CA809) MAST SPOT LIGHTS
502 CA206-6 B- BB POWER TO DIST +
501 CA206-5 B- BB POWER TO DIST
201 CA206-1 +BV POWER TO DIST
202 CA206-2 +BV POWER TO DIST 1
3 ED1 3
2901 CA206-3 +BV ED1 POWER TO DIST
2977 CA808-3 +BV ED1 FREEZER CONDITIONING
2978 CA808-4 +BV ED1 FREEZER CONDITIONING
2979 CA808-5 +BV ED1 FREEZER CONDITIONING
2902 CA206-4 +BV ED2 POWER TO DIST
CHS3
CA414
2973 CA401-11 CHAIN SLACK SWITCHES TO ACCESS3 1 BLK
CA415 CHB4
2954 CA201-7 DIST +BV K2 FU3 1 BLK
CA416
2974 CA401-20 CHAIN BREAK SWITCHES TO ACCESS3 1 RED CHS4
2955 CA201-8 DIST +BV K2 FU3 1 RED
CHB5
4 CA417 4
WHT GRN
A B C
142684 B
DIA-7335-120 Crown 2013 PF25841-16
78
SCHEMATIC DIAGRAMS
Steering Control Module ACCESS 5
Steering Control Module ACCESS 5
A B C
CA402
1 ACCESS 5
2
3 (SCM)
019 CA204-2 CAN_H 15 4 CAN1_H
020 CA204-8 CAN_L 15 5 CAN1_L CA402
1
CA403 5
1 1 BNEG 1
5926 (CA412) PVL COIL DRIVER 2 MH_LO
3 ECR1 A
4 ECR1 B
5927 (CA403) BRES INPUT 5 SW SPARE A1
5928 CA407-3 INNER BRAKE COIL DRIVER 6 INNER BRAKE DRIVER
2956 CA202-2 DIST+BV ED2 FU6 INNER BRAKE DRIVER FEED 7 B+ INNER BRAKE FEED B+
5929 CA407-4 OUTER BRAKE COIL DRIVER 8 OUTER BRAKE DRIVER
2957 CA202-1 DIST+BV ED2 FU5 OUTER BRAKE DRIVER FEED 9 B+ OUTER BRAKE FEED
2966 CA201-6 +BV K2 FU3 FROM DIST BOARD 10 B+ A2
2958 (CA412) PVL COIL 11 DRIVER B+
540 CA410-2 LOGIC NEG ECR2 12 12 LOGIC NEG
12 B-
025 CA410-1 CHA ECR2 13 ECR2 A
026 CA410-3 CHB ECR2 12 14 ECR2 B
15 TRAV OR
5931 (CA403) RAIL GUIDANCE SWITCHES 16 RGS
5932 CA407-6 BRAKE DISCONNECT 17 DTS
2967 CA202-8 ED DRIVER FEED CR9 DIST BOARD 18 ED +BV
2965 (CA412) ED2 COIL 12
19 ED SOURCING DRIVER
706 CA410-4 +5V ECR2 20 +5V
21 +5V
22 LOGIC NEG
027 CA410-5 INDEX ECR2 12 23 ECR INDEX
104 CA406-2 SIGNAL CS1 13 24 BDI CURRENT SENSE
2 206 CA202-3 BATTERY SENSE 25 BDI POS SENSE CA403 2
551 (CA401) BNEG BB 26 BDI NEG SENSE 9 1
705 CA406-1 +5V CS1 13 27 +5V 19 10
545 CA406-3 LOGIC NEG CS1 13 28 LOGIC NEG 28 20
OPTIONAL RAIL GUIDE AND
BATTERY RESTRAINT
5927 CA403-5 BRES TO ACCESS 5 1 BRES15933 1 BRES2
547 (CA401) BNEG BB
5931 CA403-16 RGSL 1 RGSL 5934 1 RGSR
M2
548 (CA401) BNEG BB
CA406
705 CA403-27 +5V FROM ACCESS 5 13 A VIO +
104 CA403-24 CURRENT SIGNAL TO ACCESS 5 13 B BRN 0 I CS1
545 CA403-28 LOGIC NEG FROM ACCESS 5 13 C GRN
CA407
1 WHT 0+
2968 CA202-1 +BV ED2 FU5 TO OUTER BRAKE COIL
2969 CA202-2 +BV ED2 FU6 TO INNER BRAKE COIL 2 BLU I+ BRK
5928 CA403-6 INNER BRAKE DRIVER 3 YEL I-
3 5929 CA403-8 OUTER BRAKE DRIVER 4 ORG 0- 3
5930 CA201-11 BRAKE SWITCH FROM DIST 5 5971
5932 CA403-17 BRAKE SWITCH TO ACCESS 5 6
JC413
29108 CA418-A BRAKE RESISTOR 1
29125 CA418-B BRAKE RESISTOR 2
578 CA201-1 BRAKE/TOW BNEG 3 DRIVE/TOW
29107 CA201-2 BRAKE/TOW FU4 POWER 4
5
(1) SENSOR BEARING 64 PULSE/REV 6
TRACTION MOTOR
(2) SENSOR BEARING 32 PULSE/REV
CA411 T+
105 CA401-16 TEMPERATURE ACCESS 3 105 11 1 BRN
579 (CA401) BNEG 2 579 11 2 R/W
315 CA401-3 +12V ACCESS 3 315 11 3 RED +12V
029 CA401-5 ECR3 CHB TO ACCESS 3 029 11 4 BLU CHB
028 11 ECR3
028 CA401-6 ECR3 CHA TO ACCESS 3 11 5 WHT CHA
(1)
549 CA401-4 LOGIC NEG ACCESS 3 549 6 BLK NEG
4 4
CA410
025 CA403-13 CHA TO ACCESS 5 12 1 BLU CHA STEERING
540 CA403-12 LOGIC NEG FROM ACCESS 5 12 2 BLK NEG FEEDBACK
026 CA403-14 CHB TO ACCESS 5 12 3 ORG CHA ECR2
706 CA403-20 FROM ACCESS 5 12 4 RED +5V (2)
027 CA403-23 INDEX TO ACCESS 5 12 5 YEL INDEX
6
A B C
142685 C
Crown 2013 PF25841-17 DIA-7335-121
79
SCHEMATIC DIAGRAMS
Hydraulics & Optional MMS
Hydraulics & Optional MMS
A B C
(CA412)
FOR REFERENCE ONLY
1
1 2960 CA201-9 DIST +BV K2 FU3 TO PVL COIL
2958 CA403-11 PVL COIL SUPPRESION
PVL 1
5926 CA403-2 PVL COIL DRIVER
5925 CA401-22 SVL COIL DRIVER 1 SVL
2959 CA201-10 DIST +BV K2 FU3 TO SVL COIL
PVL
SVL
HYDRAULIC BLOCK
1
2961 CA202-6 DIST TO P1 COIL P1
5923 CA401-18 ACCES 3 TO P1 COIL
2 1 2
2962 CA202-7 DIST TO P2 COIL P2
5924 CA401-21 ACCES 3 TO P2 COIL
1
2963 CA202-5 ED1 COIL ED1
543 (CA401) B- BB
1
5920 CA401-2 ACCESS 3 TO ED2 COIL - ED2
2965 CA403-19 ACCESS 5 TO ED2 COIL
2964 CA202-4 DIST BV ED1 LGT1
544 (CA401) B- BB LGT1
1 2 3 4 5
FIL1
+
3 3
2971 CA401-10 M3 THERMAL SWITCH TO ACCESS 3 THS-P1
2970 CA201-6 +BV K2 TO THS-P1 1 PUMP 1 MOTOR
2976 1
108 CA201-15 POSITIVE BRUSHWEAR BW-P1
121 CA201-16 NEGATIVEBRUSH WEAR
2975 CA401-13 M4 THERMAL SWITCH TO ACCESS 3 THS-P2
1 PUMP 2 MOTOR
M4
1
106 CA201-13 POSITIVE BRUSHWEAR
107 CA201-14 NEGATIVE BRUSHWEAR BW-P2
MOTOR MANGEMENT OPTION
4 4
A B C
142686 A
DIA-7335-122 Crown 2013 PF25841-18
80
SCHEMATIC DIAGRAMS
Guidance Control Module ACCESS 6 (Optional)
Guidance Control Module ACCESS 6 (Optional)
A B C
CA601
2972 CA201-6 DIST +BV K2 FU3 1 MODULE POWER
552 (CA401) B- BB 2 B- ACCESS 6
14 3 CAN COM
021 CA204-3 DIST CAN H 14 4 CAN H
022 CA204-9 DIST CAN L 5 CAN L
CA602
1 B1 A1 314 26 1 EAC SENSORS 12V
1
5 5 CA608 575 26 2 EAC SENSORS B NEG
901 27 3 EAC A1 TEST CA601
1 314 109 27 4 EAC A1 ANALOG
2 575 052 27 5 EAC A1 DIGITAL
1
5
902 27 6 EAC A2 TEST
CA607 27
1 901 110 27 7 EAC A2 ANALOG
053 8 EAC A2 DIGITAL CA602
EAC 2 109 28 9 1
3 052 903 28 9 EAC B1 TEST 19 10
4 902 111 28
10 EAC B1 ANALOG 28 20
5 110 054 28
11 EAC B1 DIGITAL
6 053 904 12 EAC B2 TEST
112 28 13 EAC B2 ANALOG
7 903 055 28 14 EAC B2 DIGITAL
8 111 717 24 15 STR WHL GUIDE BAR 5V
9 054 576 24 16 STR WHL GUIDE BAR B NEG
10 904 24
11 112 113 17 STR WHL GUIDE BAR COIL 4
114 24 18 STR WHL GUIDE BAR COIL 3
12 055 115 24 19 STR WHL GUIDE BAR COIL 2
EAC 5 5 EAC 116 24 20 STR WHL GUIDE BAR COIL 1
905 24 21 STR WHL GUIDE BAR COIL TEST
SENSOR B2 A2 SENSOR 25
718 22 LD WHL GUIDE BAR 5V
577 25 23 LD WHL GUIDE BAR B NEG
GS1 25
117 24 LD WHL GUIDE BAR COIL 4
118 25 25 LD WHL GUIDE BAR COIL 3
CA603 25
119 26 LD WHL GUIDE BAR COIL 2
2 COIL 4 1 116 120 25 27 LD WHL GUIDE BAR COIL 1 2
COIL 3 2 115 906 25 28 LD WHL GUIDE BAR COIL TEST
B NEG 3 576
STEER WHEEL 4
SENSOR BAR +5V 5 717
SLF TST 6 905
COIL 2 7 114
COIL 1 8 113
9
GS2
CA604
COIL 1 1 120
COIL 2 2 119
B NEG 3 577
LOAD WHEEL 4
SENSOR BAR +5V 5 718
SLF TST 6 906
COIL 3 7 118
COIL 4 8 117
9
3 3
LOAD WHEEL BAR
C1 C2 C3 C4
EAC SENSORS
B2 A2 A1 B1
4 4
C1 C2 C3 C4
STEER WHEEL BAR
A B C
142688 A
Crown 2013 PF25841-19 DIA-7335-123
81
SCHEMATIC DIAGRAMS
Travel Alarm & Freezer Conditioning (Optional)
Travel Alarm & Freezer Conditioning (Optional)
A B C
CA807 2980 2985 1 RED/WHT RES5
1 2981 1 RED/WHT RGSR
CA808 K12A 2 555 1 RED/WHT RES6
553 BNEG BB 1 3 556 558
554 BNEG BB 2 FU11 4 1 RED/WHT
5 2982 RGSL
2977 ED1 3 K12B
2978 ED1 4 6 557 559
1 RED/WHT
7 29153 RES7
1 2979 ED1 5 FU12
8 598 1 RED/WHT BRES1 1
9 2983 1 RED/WHT
K11 K11A 10 2984 2986 RES8
11 29152 1 RED/WHT BRES2
LIFTING FORKS OPTION 12
K12 29151
29154
29151
29153
SV1 5937
29130 THS2
THS-2
29152
598
K15 PVLF 5938
29129
5981
1 WHT 1 RED/WHT
RES9
CA809 1 2 3 4 5 6 7 8 1 BLK 1
RED/WHT CHS3/CHB4
WHT/BLK
RED
ORG
BLK
HN2 WHT 1 RED/WHT
RED/BLK
208 CA202-3 BV KYS RES10
K15 BLK 1
WHT
RED/WHT CHS4/CHB5
GRN
5109 CA201-1
BLU
POWER UNIT
PLATFORM
WHT/BLK
RED/BLK
2 2
ORG
WHT
GRN
RED
BLU
BLK
CA701
CA701
1 2345 67 8
JC330
29128 CA330-1 BV KYS 1 29145 564 1 RED/WHT
RES19
5915 CA336-1 BNEG 1 5980 2991 1 RED/WHT
565 CHS1/CHB7
JC336 THS3 2993 1 RED/WHT
RES20
29131 29132 1 RED/WHT
566 CHS2/CHB8
LIFTING FORKS OPTION 2994 1 RED/WHT
RES25
1 RED/WHT
5936 CA325 OPTION SUBHARNESS PVLF COIL DRIVER 560 HGTRS
29106 1 RED/WHT
5935 CA326 OPTION SUBHARNESS SV1 COIL DRIVER RES21
1 RED/WHT
511 GTS5
29112 CA327 LMS1 LIFTING FORK OPTION 2987 1 RED/WHT
RES22
RAS3 RAS4 LMS1 1 RED/WHT
29114 CA103-13 RAS3 LIFTING FORK OPTION 570 GTS6
29116 29118 2999 1 RED/WHT
29115 RES18
LOS3 LOS4 1 RED/WHT
BRS
3 29117
29100 571
3
29113 CA328 LOS4 LIFTING FORK OPTION
CA702 1 2
29121 572
RES17
29101 RS 573
RES16
29102 FS 574
RES15
HNS1
29103 583
RES14
LIFTING FORKS OPTION RAS/LOS
29104 584
RES13
5115 5114 5113 5112
EDS 587
29119
4 1 1 1 1 1 RED/WHT
RES12
4
1 RED/WHT
588 GTS2
RES35 RES36 RES33 RES34 29120 1 RED/WHT
RES11
1 RED/WHT
1 1 1 1 CA704 523 GTS1
1 589 2988 1 RED/WHT
RES111
1 1 RED/WHT
29174 2989 DMS1
29177 29176 29175 CA703
A B C
142689 G 1 of 2
DIA-7335-124 Crown 2013 PF25841-20
82
SCHEMATIC DIAGRAMS
Travel Alarm & Pallet Grab
Travel Alarm & Pallet Grab
A B C
29169 CA205-5
FU19
29170 CA205-6
FU18
5123 CA203-6
FU17
5124 CA203-7
FU16
1 1
29168
5122
29154
K15
PALLET GRAB
29167
5121
5981
TRAVEL ALARM
CA809
1234567 8
HN2
208 CA202-3 BV KYS
WHT/BLK
K15
RED
ORG
BLK
RED/BLK
5109 CA201-1
WHT
GRN
BLU
POWER UNIT
PLATFORM
WHT/BLK
ORG
RED
BLK
RED/BLK
GRN
WHT
BLU
2 TRAVEL ALARM 2
CA701
1234567 8
JC330
29173
29128 CA330-1 BV KYS 1 29145
5126
29172
5915 CA336-1 BNEG 1 5980
JC336
5125
911 1
29171 2
5127 914 3
915 DB1
PGS1
6 7 8 9 10
6
PGS1
1 2 3 4 5
4
3 913 3
912
916
4 3 2 1
PALLET GRAB
4 3 2 1 PALLET GRAB
917 COM
CLOSE
NO JAWS
919 NC
921
923
4 4
SB1
920 COM M5
OPEN
NO JAWS
918 NC 924
922
A B C
142689 G 2 of 2
Crown 2013 PF25841-21 DIA-7335-125
83
SCHEMATIC DIAGRAMS
Forks First Option w/Heaters
Forks First Option w/Heaters
A B C
RED/WHT
CA807 1
2980 2985 RES5
1 2981 1 RED/WHT
RGSR
CA808 K12A 2 555 1 RED/WHT
553 B- BB 1 3 556 558 RES6
FU11 4 2982 1 RED/WHT
554 B- BB 2 K12B 5 RGSL
2977 ED1 3 6 557 1 RED/WHT
1 2978 ED1 4 7 29153
559 RES7 1
2979 ED1 5 FU12 1 RED/WHT
8 598 BRES1
RED/WHT
K11A
9 2983 2986 1
K11 K11A
10 2983 RES8
11 29152 1 RED/WHT
BRES2
LIFTING FORKS OPTION 12 29153
OPTION K12
29154 THS-2
SV1 5937
29130
K15
PVLF 5938
29129 RED/WHT
WHT
1 1
5981 BLK RES9
1 1 RED/WHT
29151
29152
29153
598 CHS3
WHT RED/WHT
CA809 1
BLK RES10
K15
K15 1 234 567 8 1 RED/WHT
CHS4
208 CA202-3 +BV KYS
ORG
WHT/BLK
RED
BLK
2 2
RED/BLK
RED/BLK
5109 CA201-1
HN2
WHT
BLU
GRN
POWER UNIT
PLATFORM
WHT/BLK
RED
ORG
RED/BLK
BLK
BLU
WHT
GRN
CA701
1 234 567 8
RED/WHT
29128 CA304-2 +BV KYS 29145 564 1
RES19
2991 1 RED/WHT
CHS1/CHB7
5915 CA304-7 BV- 5980 565 RED/WHT
2993 1
29131 29132 RES20
1 RED/WHT
CHS2/CHB8
THS-3 2994
566 1 RED/WHT
LIFTING FORKS OPTION RES25
1 RED/WHT
5936 CA325 OPTIONS SUBHARNESS HGTRS
3 PVLF COIL DRIVER 29106 560 1 RED/WHT 3
RES21
5935 CA326 OPTIONS SUBHARNESS 1 RED/WHT
GTS5 LIFTING FORKS
SV1 COIL DRIVER 511 1 RED/WHT OPTION
2987
29113 CA303-10 LIMIT SWITCH RES22
1 RED/WHT LIFTING FORKS
GTS6 OPTION
570 1 RED/WHT
29112 CA303-9 AUX HYD SWITCH 2999 RES18
AUX 1 RED/WHT
BRS
29114 CA103-13 +BV ED2 29100 571
29115 LMS1
CA702 1 2
29121
572
29120
588
589 2989
DMS
4 573 29101 4
AUX
574 29102
583 RS
29103
584 FS 29104
587 RAS/LOS
29119
EDS
A B C
142700 E
DIA-7335-126 Crown 2013 PF25841-22
84
SCHEMATIC DIAGRAMS
Power Cables
Power Cables
A B C
BATT + ITEM 14
BNEG ITEM 15
1 1
FU15
FU10
FU14
FU13
ED2 ED1
ITEM 12
W V U
ACCESS 3 ITEM 7 ITEM 10 A1
(TCM) ITEM 11 A2
U V W P1
B+ + B-
ITEM 2
ITEM 8 ITEM 6
2 ITEM 5 2
ITEM 9 ITEM 3
ITEM 4
M3 M4
(PUMP 1) (PUMP 2)
ACCESS 5 B- P2
(SCM) M1 ITEM 1
M2 (TRACTION)
(STEERING)
ITEM 13
ACCESS 6
(GCM)
3 3
ITEM SP 3520/SP 3550 SP 3505 SP 3510 SP 3511/SP 3512 SP 3521/SP 3522
1 084571-230 PC#1 NOT USED NOT USED NOT USED 084571-230 PC#1
2 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1
3 084571-231 PC#1 NOT USED NOT USED NOT USED 084571-231 PC#1
4 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1
5 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1
6 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1
7 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1
8 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0
9 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0
4 10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 4
11 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10
12 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10
13 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10
14 084573-250 PC2/0 084571-313 PC#1 084573-250 PC2/0 084573-257 PC2/0 084573-257 PC2/0
15 084573-251 PC2/0 084571-314 PC#1 084573-251 PC2/0 084573-258 PC2/0 084573-258 PC2/0
A B C
142690 D
Crown 2013 PF25841-23 DIA-7335-127
85
SCHEMATIC DIAGRAMS
Wire Harnesses
Wire Harnesses
Harness P/N Connected By:
Power Unit
140333(a, c) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
140334(a, c) Wire Guidance Harness: JC602, PC603, PC604
140335(a) End Aisle Harness (EAC): JC602, PC607, PC608
141028(a) Freezer Condition Harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, Mast
Spot Lights, PVL, RGSL, RGSR, SV1, THS2
142216-001 Wire Guide Harness Extension
142670(a, d) Wire Guidance/EAC Harness: JC602, PC603, PC604, PC607, PC608
142671(a, d) Wire Guidance Harness: JC602, PC603, PC604
143590 CA201, CA202, K15, PC809, HN2
145255 Pallet Grab Harness W/Travel Alarm (power unit) CA201, CA202, CA203, CA205, PC809, HN2,
K15
146557 Power Harness: PC206, B-, B+, ED1, ED2
146764 ACCESS 5 to Steer Motor
149532 Power Unit Harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC419, PF420, PC421, PC601, BNEG,
BRES1, BRES2, BW-P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1,
THS-P2, FAN, ECR6, Mast Spotlight
Platform
134322(a) Positive/Negative Accessory Harness
140106 Platform Harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC308, PC309, PC317, PC318, PC322, JC 322, PC325, PC328, PC330, PC331, CA332,
PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1. GTS2, HGTRS, HN1, HN2
140108 Overhead Guard Left Wire Harness JC310, JC311, PC314, PC315, PC316, PC501, LGS1,
LGS2
140109 Overhead Guard Right Wire Harness JC312, JC313,JC314, JC315, JC316, PC338, PC503,
FNS, LGS3
140170(b) CHB7, CHB8, JC331,PC331 (CA331)
140290-001(a) InfoLink® Harness: Alarm, CAN, CURRENT, Load, Module, PROG, PROX, RS232, SHOCK
141029(b) Options Harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141214(a) InfoLink Harness: CAN, PROX, SHOCK
(a) Optional
(b) SAA/EU Trucks Only
(c) US Trucks Only
(d) EU Trucks Only
DIA-7335-128 Crown 2013 PF25841-24
86
SCHEMATIC DIAGRAMS
Wire Harnesses
Harness P/N Connected By:
Platform (Continued)
142218 Forks Steering Harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
First PC306, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335, PC501,
PC503, PC701, JC705, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1,
GSI, GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1,
RAS1, RAS2, RS, LMS1, FS, RS, LOS3, GUIDANCE
143589(a) Travel Alarm JC330, JC336, PC701
145166 Pallet grab harness (platform) JC339, M5, PGS2, PGS3, SB1
145254 Pallet Grab Harness W/Travel Alarm (platform) JC 330. JC336, PC339, PC701, DB1, PGS1
147135-001 Mast Height Encoder Harness PC422
through
147135-004
149374 Lights/Fan Harness: PC102, PC338, PC501, PC503, LGS1, LGS3, FNS
149375 Work Lights Harness: PC102, LGS3
149720 InfoLink®/Intermec Cable Assembly
149721 InfoLink/Intermec Harness: PROX, RS232
149722 PROX Extender Harness: PROX
150354(a) Windows® InfoLink CAN Breakout Harness: ALARM, CAN, CURRENT, LOAD, PROG, PROX,
MODULE, RS232, SHOCK
(a) Optional
Crown 2013 PF25841-25 DIA-7335-129
87
WIRING DIAGRAMS
Index
Index
This electrical diagram index contains the electrical
diagrams that are applicable to your lift truck. See the
ELECTRICAL / Electrical System section for wire color
codes, power cable codes, and electrical diagram
symbols.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Platform with Options DIA-7335-131
Schematic - Power Unit with Options DIA-7335-132
Schematic - Platform Unit with Pallet Grab DIA-7335-133
Schematic - Power Unit with Pallet Grab DIA-7335-134
Schematic - Platform DIA-7335-135
Schematic - Power Unit DIA-7335-136
Platform Distribution Panel DIA-7335-137
Platform Distribution Panel Forks First SAA DIA-7335-138
Power Unit Distribution Panel DIA-7335-139
Access 1 (DCM) and 4 (VCM) DIA-7335-140
Access 1 (DCM) and 4 (VCM), Forks First SAA DIA-7335-141
Control Pod and Light Switches DIA-7335-142
Overhead Guard Lights/Fans DIA-7335-143
Overhead Guard Spotlights (Optional) DIA-7335-144
Access 3™ (TCM) DIA-7335-145
Access 5 (SCM) DIA-7335-146
Hydraulics and Optional MMS DIA-7335-147
Access 6 (GCM) (Optional) DIA-7335-148
Travel Alarm and Freezer Conditioning (Optional) DIA-7335-149
Travel Alarm and Pallet Grab DIA-7335-150
Forks First Option with Heaters DIA-7335-151 01 Rev. 1/18
Power Cables DIA-7335-152
Wire Harnesses DIA-7335-153 01 Rev. 1/18
Crown 2016 PF27613 Rev. 1/18 DIA-7335-130
01 Rev. 1/18
DXLIX
WIRING DIAGRAMS
Schematic - Platform with Options
Schematic - Platform with Options
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS THE LIFT TRUCK IS SHOWN WITH THE PLATFORM
1 LOWERED, GATES DOWN, AND UNATTENDED.
1 1
RAS4 ACCESS 4
RAS3 CA304-2
CA303-9 CA304-7
LOS3 LMS1 CA303-1 SIG POT1
CA303-10 TRACTON
+12V CA303-4 +5V
LOS4 CA304-21 CA303-19 NEG
ECR5 CHA CA304-22
STEER CHB CA304-23 CA303-20
COMMAND NEG CA304-20 CA303-21
ECR1
+12V CA304-18
STEER CHA CA304-16 CHS2 CHS1
COMMAND
CHB CA304-17 CA304-11
NEG CA304-19 GTS2 GTS1 GTS5 GTS6
ECR4 +5V CA303-12 CA304-10
HEIGHT CHA CA303-13 10
ENCODER CHB CA303-14 CA303-6
NEG CA303-15 CA303-23 ZSSA HGTRS NOTE:
FS
CA304-9 1 LIFTING FORKS OPTION.
RS CA304-13 ZSSB
CA304-8 ZSS 13 2 GUIDANCE OPTION.
CA304-1
CAN_H CA303-7
CAN_L CA303-8
CA304-3
CA303-16 CA304-14 ZSSC
LOS1 3 MAST MOUNTED SPOTLIGHTS
CA303-17 CA304-5 OPTION.
LOS2 CA303-3
CA304-4
CA303-18 4 COLD CONDITION OPTION.
12 CHB7 CHB8
5 PLATFORM LIGHTS/FAN OPTION.
RAS1 6 BATTERY RESTRAINT OPTION.
2 2
7 RAS2 ACCESS 1
7 DUAL PUMP OPTION.
CA302-3 CA302-4 8 MOTOR MANAGEMENT SYSTEM
OPTION.
9 TRAVEL ALARM OPTION.
2
120 OHM
10 SAA GATE OPTION.
ALM1 GUS
CR12 CA302-14
11 EU DEADMAN SWITCH.
CAN_H CA302-8
CAN_L CA302-9
CA302-2 ORS1
CA302-13 12 EU CHAIN BREAK SWITCHES.
CA302-1 DMS1 13 ZONE SELECT OPTION.
11 14 INFOLINK® OPTION.
15 PALLET GRAB OPTION.
STEER POSITION INDICATOR
CA323-3
CA323-4
CA323-2
CA323-1
R1 R2
CAN_L
CAN_H
VR1
3 + C1 3
BRS
CA301 PROG CA301
CAN_H K1
CAN_L
CR1 CR2
KYS CR3
START TR1
ACC -T°
CR4
+BV (ED1) FU7 (CUSTOMER OPTIONS)
EDS IGN K1
OFF
+BV FU1 (CUSTOMER OPTIONS)
PLATFORM
LIGHTS/FAN
5
LIFTING FORK COILS
BRAKE DISCONNECT
4 5 13 251524
(FAN/SPOT LIGHTS)
MAST SPOT LIGHT
(POWER SUPPLY)
4 INFOLINK 14 PLATFORM 4
+BV (ED1) FU8
+BV (ED1) FU9
TRAVEL ALARM
6 7 8 9 C/C 4
+BV AK
CAN_H
CAN_L
+BV FU2
C/C THS-3
C/C THS-3
BNEG
BNEG
BNEG
BNEG
BNEG
1
+BV C/C
+BV C/C
RAS1
RAS2
1
PVLF
SV1
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-1 M2-3 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-2 M2-4 M2-6 M2-8
A B C
156642 A 3 of 6
DIA-7335-131 Crown 2016 PF27613
DL
WIRING DIAGRAMS
Schematic - Power Unit with Options
Schematic - Power Unit with Options
A B C
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-3 M3-4 M3-5 M3-6 M3-7 M3-8 M2-1 M2-2 M2-3 M2-4 M2-6 M2-8
MAST SPOT
1 2 3 4
BNEG
BNEG
+BV (ED1) FU9
TRAVEL ALARM
+BV (ED1) FU8
+BV (ED1) FU7
BRAKE DISCONNECT
SHOCK SENSOR
+BV AK
CAN_H
BNEG
BNEG
BNEG
CAN_L
+BV FU2
B+
+BV FU1
RAS1
RAS2
+BV C/C
14 PVLF
C/C THS-3
C/C THS-3
+BV C/C
SV1
1 1 1
SV1
K15
FU8
9
PVLF
POWER UNIT
MAST 3 C/C 4
FU7 FU9
SPOTLIGHTS
7 M4
FU14 P2
LGT1 M3
FIL1 + FU13 P1
NOTE:
THE LIFT TRUCK IS SHOWN WITH THE
PLATFORM LOWERED, GATES DOWN, 1 LIFTING FORKS OPTION.
AND UNATTENDED.
FU15 ACCESS 3 2 GUIDANCE OPTION.
+ B- 3 MAST MOUNTED
12 CA401
CHB5 CHB4 B+ U U ECR6 SPOTLIGHTS OPTION.
20 V V M1 MAST 4 COLD CONDITION OPTION.
CHS4 CHS3 W W3 HEIGHT 5 PLATFORM LIGHTS/FANS
17 10 CHB ENCODER
OPTION.
1 11 CHA 6 BATTERY RESTRAINT
SVL 22 2 ED COIL ED2 OPTION.
2 7 DRIVER (-) 7 DUAL PUMP OPTION. 2
P2 21 TS1 TRACTION
16 TEMP 8 MOTOR MANAGEMENT
+t° TEMP
P1 18 15 14 3 +12V SYSTEM OPTION.
5 6 CHB
FAN2 8 23 7 13 4 CHA 9 TRAVEL ALARM OPTION.
ECR3
CAN_L
CAN_H
NEG TRACTION 10 SAA GATE OPTION.
8
11 EU DEADMAN SWITCH.
MMS
12 EU CHAIN BREAK SWITCHES.
M2 13 ZONE SELECT OPTION.
ED1
ACCESS 5 14 INFOLINK OPTION.
STEER A2
A1 STEER A1 A2 15 PALLET GRAB OPTION.
FU10
B+ B-
FU5 15
0+ 35 17
FU6
11
22 CR10
I+ 33 CA403 30 ED COIL DRIVER (+)
0+ 23 ED IN CS1
I+ CA407 27 +5V CR9
BRK I- I- 0- 34 32 28 SIG CURRENT
SENSE
12 NEG ECR2
0- BRK REL 4 3 10 CHA +5V STEERING
7 INDEX FEEDBACK 6 K2
PVL 2
21 8
CHB
NEG
120 OHM
PVL 26 BRES1 BRES2
5
+BV LOGIC 1 RGSR 2 RGSL
B+ SENSE 31 6
CAN_H 13
24
9 BNEG SENSE
3 3
CAN_L
JC413 RES2
RES3
DTS1
9 HN2
K15
LOAD WHEEL
SENSOR BAR 2 ACCESS 6 EAC DIST PNL
DIG 1
B1
GS2 30 +12V CA608-1 2 1 BNEG 2
1 COIL 1 21 22 BNEG CA608-2 3 TST 3 EAC
1 4 5 ANA
CA604
A1 TST 4
2 COIL 2 932 A1 ANA
1 2 +12V 5
3 BNEG 14 CA605
5 +5V CA602 25 29
3 A1 DIG 3
DIG 1
A1
6 STEST 6 A2 TST 4 2 1 BNEG 2
8
CA607
TR2 7 8 COIL 3 33 A2 ANA 5 3 TST 3 EAC
COIL 4 7 31 A2 DIG 6 4 5 ANA 4
+t° TR3 2 2 B1 TST 7 +12V 5
GS1 34 B1 ANA 8 CA606
FU2
+t° CR11 27 B1 DIG A2
1 COIL 4 11 9 1 BNEG
DIG 1
26 B2 TST 10 2 2
CA603
2 COIL 3 10 11 3 TST 3 EAC
FU3 2 3 BNEG 18 35 B2 ANA 4 5 ANA 4
5 +5V 15 28 B2 DIG 12 +12V 5
6 STEST 5 CA609 B2
FU1
7 8 COIL 2 23 1 DIG 1
4 COIL 1 12 2 BNEG 2 4
CAN_L 24
17
13
CA610 4 3 ANATST 34 EAC
4
STEER WHEEL
SENSOR BAR 5 +12V 5
CAN_H
ED1 ED2
FU4
K2 24V BATT
+
A B C
156642 A 4 of 6
Crown 2016 PF27613 DIA-7335-132
DLI
WIRING DIAGRAMS
Schematic - Platform with Pallet Grab
Schematic - Platform with Pallet Grab
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS THE LIFT TRUCK IS SHOWN WITH THE
1 1 PLATFORM LOWERED, GATES DOWN, 1
RAS4 ACCESS 4 AND UNATTENDED.
RAS3 CA304-2
CA303-9 CA304-7
LOS3 LMS1 CA303-1 SIG POT1
CA303-10 CA303-4 +5V TRACTON
LOS4 +12V CA304-21
ECR5 CHA CA304-22 CA303-19 NEG
STEER CHB CA304-23 CA303-20
COMMAND NEG CA304-20 CA303-21
ECR1 +12V CA304-18
STEER CHA CA304-16 CHS2 CHS1
COMMAND CHB CA304-17 CA304-11 NOTE:
NEG CA304-19 GTS2 GTS1 GTS5 GTS6 1 LIFTING FORKS OPTION.
ECR4 +5V CA303-12 CA304-10
HEIGHT CHA CA303-13 HGTRS 10 2 GUIDANCE OPTION.
ENCODER CHB CA303-14 CA303-6
NEG CA303-15 CA303-23 ZSSA 3 MAST MOUNTED
FS SPOTLIGHTS OPTION.
CA304-9
RS CA304-13 ZSSB 4 COLD CONDITION OPTION.
CA304-8 ZSS 13 CLAMP 16
CA303-16 CA304-14 ZSSC 5 PLATFORM LIGHTS/FAN OPTION.
CAN_H CA303-7
CAN_L CA303-8
CA304-3
CA304-1
LOS1 CA303-22
CA303-17 6 BATTERY RESTRAINT OPTION.
LOS2 CA303-3 CA304-5 DETECT
CA303-18 7 DUAL PUMP OPTION.
12 CHB7 CHB8 CA304-4
8 MOTOR MANAGEMENT
SYSTEM OPTION.
RAS1
2 9 TRAVEL ALARM OPTION. 2
7 RAS2 ACCESS 1
10 SAA GATE OPTION.
CA302-3 11 EU DEADMAN SWITCH.
CA302-4
12 EU CHAIN BREAK SWITCHES.
2
13 ZONE SELECT OPTION.
120 OHM
ALM1 GUS 14 INFOLINK® OPTION.
CA302-14
ORS1
CAN_H CA302-8
CAN_L CA302-9
CA302-2 15 PALLET GRAB OPTION.
CR12 CA302-13
DMS1 16 PALLET CLAMP
CA302-1 AND DETECT OPTION.
11
STEER POSITION INDICATOR
CA323-3
CAN_L CA323-4
CA323-2
CA323-1
R2
R1
CAN_H
VR1
3 + C1 3
BRS
CA301 PROG CA301 CAN_H K1
CAN_L
CR1 CR2
KYS CR3
START TR1
-T°
ACC
EDS CR4
IGN K1
OFF
PLATFORM
LIGHTS/FAN
5
(CUSTOMER OPTIONS)
(CUSTOMER OPTIONS)
LIFTING FORK COILS
BRAKE DISCONNECT
(FAN/SPOT LIGHTS)
4 5 13 251524
+BV (ED1) FU7
(POWER SUPPLY)
4
+BV (ED1) FU8
INFOLINK 14 4
TRAVEL ALARM
+BV (ED1) FU9
+BV (FU1)
PALLET GRAB
6 7 8 9
MAST SPOT
CAN_H
15
CAN_L
+BV FU2
1
+BV AK
BNEG
BNEG
BNEG
BNEG
BNEG
RAS1
RAS2
PVLF 1
B-
B-
B-
B-
SV1
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-1 M2-2 M2-3 M2-4 M2-6 M2-8
A B C
156642 A 5 of 6
DIA-7335-133 Crown 2016 PF27613
DLII
WIRING DIAGRAMS
Schematic - Power Unit with Pallet Grab
Schematic - Power Unit with Pallet Grab
A B C
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-4 M2-6 M2-8
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-1 M2-2 M2-3 M2-5 M2-7
MAST SPOT
1 2 3 4 15
BNEG
BNEG
TRAVEL ALARM
+BV (ED1) FU9
BNEG
BNEG
BNEG
CAN_H
+BV AK
+BV (ED1) FU8
+BV (ED1) FU7
CAN_L
PALLET
PALLET
PALLET
PALLET
B+ PVLF
BRAKE DISCONNECT
POWER UNIT
+BV FU1
+BV FU2
SHOCK SENSOR
GRAB
GRAB
GRAB
GRAB
SV1
RAS1
RAS2
1 14 1
1
SV1
K15 9 FU19
FU8
FU16
PVLF FU18 FU17
MAST
FU7 FU9 SPOTLIGHTS
3
7 M4
FU14 P2
LGT1 M3
FIL1 + FU13 P1
FU15 ACCESS 3
+ B-
12 CA401
CHB5 CHB4 B+ U U ECR6
20 V V M1 MAST NOTE:
CHS4 CHS3 W W3 HEIGHT 1 LIFTING FORKS OPTION.
17 10 CHB ENCODER
1 11 CHA 2 GUIDANCE OPTION.
2 7
SVL 22 2 ED COIL DRIVER (-) ED2 3 MAST MOUNTED 2
P2 21 TS1TRACTION SPOTLIGHTS OPTION.
16 TEMP 4 COLD CONDITION OPTION.
3 +t° TEMP
P1 18 15 10 5 +12V 5 PLATFORM LIGHTS/FAN
FAN2 8 23 7 13 4 6 CHA CHB OPTION.
ECR3
CAN_H
CAN_L
NEG TRACTION 6 BATTERY RESTRAINT OPTION.
8 7 DUAL PUMP OPTION.
MMS
8 MOTOR MANAGEMENT
M2 SYSTEM OPTION.
ED1 9 TRAVEL ALARM OPTION.
ACCESS 5 10 SAA GATE OPTION.
STEER A2
A1 STEER A1 A2
FU10 11 EU DEADMAN SWITCH.
B+ B-
FU5 0+ 35 15
17
12 EU CHAIN BREAK SWITCHES.
11
22
ED COIL DRIVER (+) CR10 13 ZONE SELECT OPTION.
FU6 I+ 30
33 14 INFOLINK® OPTION.
0+ CA407 CA403 23 +5V ED IN
I+ 27 SIG CS1 CR9 15 PALLET GRAB OPTION.
BRK I- I- 32 28 12 NEG CURRENT
SENSE ECR2
0- 0- 34 3 10 CHA +5V
BRK REL 4 STEERING K2
7 INDEX FEEDBACK
2 21 8
PVL CHB 6
NEG BRES1
120 OHM
PVL 26 5
+BV LOGIC 1 RGSR 2 RGSL BRES2
+B SENSE 31 6
3 3
CAN_H 13
CAN_L 24
9 BNEG SENSE
JC413 RES2
RES3
DTS1
9 HN2
K15
LOAD WHEEL 2 EAC DIST PNL
SENSOR BAR 2 ACCESS 6 DIG 1
B1
GS2 +12V CA608-1 2 1
22 30
BNEG 2
BNEG CA608-2 3 TST 3 EAC
1 COIL 1
1 21 A1 TST 1 2 4 5 ANA 4
CA604
2 COIL 2 9 +12V 5
3 32 14 A1 ANA
BNEG 3 CA605
CA602 25 29 A1
A1 DIG
5 +5V 3 DIG
4 2 1
A2 TST 1
6 STEST 6 BNEG
CA607
2
TR2 7 8 COIL 3 33 8 A2 ANA 5 3 TST 3 EAC
COIL 4 31 7 A2 DIG 6 4 5 ANA 4
+t° TR3 2 2 B1 TST 7 +12V 5
GS1 34 B1 ANA 8 CA606 A2
+t° CR11 27 B1 DIG 9 1 DIG 1
1 COIL 4 11 26 B2 TST 10 2 BNEG 2
3 EAC
CA603
3
2 COIL 3 10 35 B2 ANA 11 4 5 ANA
TST
4
FU3 3 BNEG 18 28 B2 DIG 12 +12V 5
5 +5V 15 CA609
6 STEST 5 B2
FU1
FU2
7 8 COIL 2 23 1 DIG
4 COIL 1 12 2 BNEG
1
2
EAC 4
17
24
13
CA610 4 3 TST 3
4
STEER WHEEL ANA 4
SENSOR BAR 2 5 +12V 5
CAN_L
CAN_H
ED1 ED2
FU4
K2 24V BATT
+
A B C
156642 A 6 of 6
Crown 2016 PF27613 DIA-7335-134
DLIII
WIRING DIAGRAMS
Schematic - Platform
Schematic - Platform
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS
1 THE LIFT TRUCK IS SHOWN WITH THE 1
ACCESS 4 PLATFORM LOWERED, GATES DOWN,
CA304-13 AND UNATTENDED.
CA304-2
+12V CA304-21 CA304-7
ECR5 CHA CA304-22
STEER CHB CA304-23 CA303-1 SIG POT1
COMMAND NEG CA304-20 TRACTON
CA303-4 +5V
+12V CA304-18 CA303-19 NEG
ECR1 CHA CA304-16
STEER CA303-20
COMMAND
CHB CA304-17
NEG CA304-19 CA303-21
+5V CA303-12 CHS2 CHS1
ECR4 CA304-11
HEIGHT CHA CA303-13
ENCODER CHB CA303-14 GTS2 GTS1
NEG CA303-15 CA304-10
FS
CA304-9
RS CA303-6
CA304-8 HGTRS
RAS1 CA304-5
CA304-1
CA303-7
CA303-8
CA303-16 CA304-3
LOS1 CA304-4
CA303-17
LOS2 CA303-18
2 2
CAN_H
CAN_L
ACCESS 1
CA302-3 CA302-4
ALM1
120 OHM
CAN_H CA302-8
CAN_L CA302-9
CA302-2
CR12 CA302-13
CA302-1 ORS1
STEER POSITION INDICATOR
CA323-3
CA323-4
CA323-2
CA323-1
R2
R1
3 3
CAN_L
CAN_H
VR1
+ C1
BRS
CA301 CAN_H K1
CR1 CR2
CAN_L
KYS CR3
START TR1
-t°
ACC
BRAKE DISCONNECT
EDS IGN CR4
(CUSTOMER OPTIONS)
K1
OFF
(FAN/SPOT LIGHTS)
+BV (ED1) FU7
(POWER SUPPLY)
4 4
+BV (ED1) FU8
+BV (ED1) FU9
+BV (FU1)
CAN_H
CAN_L
+BV AK
+BV FU2
RAS2
BNEG
BNEG
BNEG
BNEG
BNEG
RAS1
M1-6 M1-4 M1-8 M1-1 M2-1 M2-3 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M2-2 M2-4 M2-6 M2-8
A B C
156642 A 1 of 6
DIA-7335-135 Crown 2016 PF27613
DLIV
WIRING DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
A B C
M1-6 M1-4 M1-8 M1-1 M2-2 M2-4 M2-6 M2-8
M1-2 M1-5 M1-7 M1-3 M2-1 M2-3 M2-5 M2-7
+BV (ED1) FU9
BNEG
BNEG
+BV (ED1) FU7
BNEG
BNEG
BNEG
+BV (ED1) FU8
BRAKE DISCONNECT
+BV AK
+BV FU2
RAS1
+BV FU1
CAN_H
CAN_L
RAS2
THE LIFT TRUCK IS SHOWN WITH THE
1 PLATFORM LOWERED, GATES DOWN, 1
AND UNATTENDED.
FU7 FU9
FU8
LGT1 P1
M3
FIL1 + FU13
ACCESS 3
+ B-
FU15 B+ U U
20 V V M1 ECR6
CHS4 CHS3 W3 MAST HEIGHT
W ENCODER
17 CA401 10 CHB
1 11 CHA
SVL 22 2 ED COIL DRIVER (-) ED2
2 21
16 TRACTION TEMP
TS1 2
3 +12V +t°
P1 18
5 CHB
8 6 CHA
CAN_H 23
15
4 NEG
CAN_L
ECR3
TRACTION
FAN2
M2
ED1
ACCESS 5
STEER A2
A1 STEER A1 A2
FU10
B+ B-
FU5 15
0+ 35 17
11
FU6 22
I+ 33 30
ED IN ED COIL DRIVER (+)
0+ CA407 CA403 23
CS1 CR10
I+ 27 +5V CR9
BRK 28 SIG CURRENT
I- I- 0- 32
34 12 NEG SENSE
0- BRK REL 4
3
10 CHA
+5V ECR2
K2
7 INDEX STEERING
2 FEEDBACK
8 CHB
120 OHM
PVL 26 21 NEG
5
+BV LOGIC 1
3 B+ SENSE 31
6
3
CAN_H 13
CAN_L 24
9 BNEG SENSE
JC413 RES3
DTS1 RES2
TR2
+t° TR3
FU1
+t° CR11
FU3
4 4
FU2
FU4
ED1 ED2
K2 24V BATT
+
A B C
156642 A 2 of 6
Crown 2016 PF27613 DIA-7335-136
DLV
DLVI
DIA-7335-137
Platform Distribution Panel
Platform Distribution Panel
WIRING DIAGRAMS
4
1
(15) TP15 B NEG
(14) TP14 CAN L
(13) TP13 CAN H
(12) TP12 K1
(11) TP11 K1 COIL
(10) TP10 ED1 FU8
(9) TP9 ED1 FU9
(8) TP8 ALM1
(7) TP7 MODULE POWER
(6) TP6 B FU2
(5) TP5 RAS2
(4) TP4 RAS1
(3) TP3 ED1 FU7
(2) TP2 B+ FU1
(1) TP1 BRAKE
A
A
CA101 CA102 CA103
1 2 3 4 5 6 7 8 1 2 3 4 5 (8)
16 5917 CA302-2 ALM1 NEG
R2 CR12 15
CA107 (15) (7) R1
VR1
14 29124 JC331-1 CHAIN BREAK SWITCHES
515 PC301-3 BNEG CAN ACCESS 1 ALM1 13 29114 (RAS3) LIFTING FORK OPTION
530 CA322-1 BNEG GTS1 2 CR4 (12) 12 2937 CA304-1 +BV KYS ACCESS 4
520 (CA309) BNEG CHS1 3 C1 (11) 11 2925 CA308-4 +BV KYS CONTROL POD
521 CA320-2 BNEG HGTRS 4 CR2 K1A 10 2941 CA302-3 +BV KYS ACCESS 1
+ K1
580 CA323-2 BNEG ACCESS 1 STR POS IND 5 (6) (9) (5) (2) (1) (10) +t TR1 9 29105 CA323-1 +BV KYS STR POS IND
550 CA355-1 BNEG ZSS 6 CR3 CR1 8 2924 CA308-2 IGN
514 CA309-7 BNEG ORS1 7 7 2923 CA308-3 START
513 CA302-4 BNEG ACCESS 1 8 6 207 PC301-4 +BV FU2 CAN ACCESS
B
B
525 CA304-3 BNEG ACCESS 4 9 (3) (4)
5 5904 (CA321) BRAKE SWITCH
524 (CA321) BNEG BRS 10 4 2935 CA308-11 RAS2
522 (CA321) BNEG HN1 11 3 2932 CA308-10 RAS1
512 PC306-3 BNEG CUSTOMER ACCESSORIES 12 2 2997 (CA303) LIFTING FORKS DIODE
BNEG INFOLINK/INTERMEC OPTION 13 1 2940 PC306-2 +BV FU7 CUST ACCY
(13) CA105 2939 PC301-5 +BV ED1 FU7 CAN ACCESS
CA106 (14)
B+ INFOLINK/INTERMEC OPTION 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 205 PC306-1 BV FU1 CUST ACCY
BRAKE SWITCH BLK CA104 RED/BLK BNEG
BV FU1 WHT WHT/BLK BNEG
BV FU2 RED BLU BNEG
BV ED1 FU9 GRN ORG BNEG
BV ED1 FU8 ORG GRN BNEG
BV ED1 FU7 BLU RED CAN L
RAS1 WHT/BLK WHT CAN H
RAS2 RED/BLK BLK BV AK FROM KYS
MC1
2 MC2
001 CA303-7 CAN H ACCESS 4 1
003 CA302-8 CAN H ACCESS 1 6
005 PC301-1 CAN H ACCESS 29
031 CA323-3 CAN H ACCESS 1 STEER POSITION INDICATOR
2
002 CA303-8 CAN L ACCESS 4 1
004 CA302-9 CAN L ACCESS 1
C
C
006 PC301-2 CAN L ACCESS 6
032 CA323-4 CAN L ACCESS 1 STEER POSITION INDICATOR 29
Crown 2016 PF27613
142680 E
1
WIRING DIAGRAMS
Platform Distribution Panel - Forks First SAA
Platform Distribution Panel - Forks First SAA
A B C
1 1
CA101 CA102 CA103
1 2 3 4 5 6 7 8 1 2 3 4 5
R2
16
(8) 5917 CA302-2 ALM1 NEG
CR12 15
(16) R1
CA107 (7)
14 29111 (CA304) CHAIN BREAK SWITCHES
VR1
515 PC301-3 B-CAN ACCESS 1 ALM1 13 29114 (CA701) CABIN DOW SWITCHES
530 CA322-1 B- GTS1 2 CR4 (12) 12 2937 CA304-1 +BV KYS ACCESS 4
520 (CA309) B- CHS1 3 C1 (11) 11 2925 CA308-4 +BV KYS CONTROL POD
521 CA320-2 B- HGTRS 4 CR2 K1A 10 2941 CA302-3 +BV_KYS ACCESS 1
+ K1
580 CA323-2 B- ACCESS 1 STR POS IND 5 (6) (9) (5) (2) (1) (10) 9 29105 CA323-1 +BV KYS STR POS IND
550 CA335-1 B- ZSS 6 CR3 CR1 +t TR1 8 2924 CA308-2 IGN
514 CA309-7 B- ORS1 7 7 2923 CA308-3 START
513 CA302-4 B- ACCESS 1 8 6 207 PC301-4 +BV FU1 CAN ACCESS
525 CA304-3 B- ACCESS 4 9 (3) (4) 5 5904 (CA321) BRAKE SWITCH
524 (CA321) B- BRS 10 4 2935 CA308-11 RAS2
522 (CA321) B- HN1
2 512 PC306-3 B- CUSTOMER ACCESSORIES
11
12
3
2
2932 CA308-10 RAS1 2
13 1 2940 PC306-2 +BV FU7 CUST ACCY
562 CA320-2 PDS CDS (13) CA105 2939 PC301-5 +BV ED1 FU7 CAN ACCESS
(14)
CA106
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 205 PC306-1 BV FU1 CUST ACCY
BRAKE SWITCH BLK CA104 RED/BLK B-
+BV FU1 WHT WHT/BLK B-
+BV FU2 RED BLU B-
+BV ED1 FU9 GRN ORG B-
+BV ED1 FU8 ORG GRN B-
+BV ED1 FU7 BLU RED CAN L
RAS1 WHT/BLK WHT CAN H
RAS2 RED/BLK BLK +BV AK FROM KYS
MC1
2 MC2
001 CA303-7 CAN H ACCESS 4 1
003 CA302-8 CAN H ACCESS 1 6
005 PC301-1 CAN H CAN ACCESS 29
031 CA323-3 CAN H ACCESS 1 STR POS IND (1) (8) TP8 ALM1
TP1 BRAKE
(2)
2 TP2 B+ FU2 (9)
TP9 ED1 FU9
002 CA303-8 CAN L ACCESS 4 1 (3) TP3 ED1 FU7
004 CA302-9 CAN L ACCESS 1 6
(10) TP10 ED1 FU8
006 PC301-2 CAN L CAN ACCESS 29 (4) TP4 RAS1
032 CA323-4 CAN L ACCESS 1 STR POS IND (11)
(5)
TP11 K1 COIL
TP5 RAS2 (12)
(6) TP12 K1
TP6 B+ FU1
(13)
3 (7) TP7 MODULE POWER
(14)
TP13 CAN H 3
TP14 CAN L
(16)
TP16 B NEG
4 4
A B C
142696 B
Crown 2016 PF27613 DIA-7335-138
DLVII
DLVIII
DIA-7335-139
Power Unit Distribution Panel
Power Unit Distribution Panel
WIRING DIAGRAMS
4
1
121 (CA412) NEGATIVE BRUSH BRUSHWEAR M3
TP19 MMS
TP18 RAS2
TP17 RAS1
TP16 CAN_L
TP15 CAN_H
TP14 INNER BRAKE
TP13 OUTER BRAKE
TP12 BATT SENSE
TP11 K1 OUT
TP10 FU9
TP9 FU8
TP8 FU7
TP7 FU2
TP6 FU1
TP5 ED2
TP4 K2
TP3 BNEG
TP2 ED1
TP1 B+
108 (CA412) POSITIVE BRUSH BRUSHWEAR M3
POSITION 1 AND 2 ARE CLOSED.
5 AND 4 ARE CLOSED, IN THE TOP
NOTE: ON DTS1 IN THE CENTER POSITION
107 (CA412) NEGATIVE BRUSH BRUSHWEAR M4
106 (CA412) POSITIVE BRUSH BRUSHWEAR M4
122 CA401-7 BRUSHWEAR
5930 CA407-5 BRAKE SWITCH
A
A
29129 (CA808) +BV_K2 FU3 PVLF AND SV1 LIFTING FORK OPTION
2959 (CA412) +BV_K2 FU3 SVL
2960 (CA412) +BV_K2 FU3 PVL
2955 PC417-1 +BV_K2 FU3 CHB5
29122 (CA401) +BV_K2 FU3 FAN2 1 2968 CA407-1 BRAKE COIL OUTER
2970 (CA412) +BV_K2 FU3 THS P1 1 2957 CA403-35 BRAKE OUTER
2954 PC415-1 +BV_K2 FU3 CHAIN SLACK 2 2956 CA403-33 BRAKE COIL INNER
2972 CA601-1 +BV_K2 FU3 ACCESS 6 2 2969 CA407-2 BRAKE INNER
2966 CA403-1 +BV_K2 FU3 ACCESS 5 3 208 K15-7 +BV HN2
2953 CA401-1 +BV_K2 FU3 ACCESS 3 3 206 CA403-31 BATTERY SENSE ACCESS 5
29107 CA413-4 DRIVE/TOW FU4 POWER 4 2964 (CA412) +BV_ED1 LGT1
578 CA413-3 DRIVE/TOW BNEG 5 2963 (CA412) ED1 COIL
5109 +BV HN2 6 2961 (CA412) P1 COIL
7 2962 (CA412) P2 COIL
4
29108 CA413-1 BRAKE RESIST 2996 8 2967 CA403-23 CR9 SUPPRESION
29125 CA413-2 BRAKE RESIST 2995
3
585 (CA401) BNEG BB
10
12
13
14
15
16
11
1
4
4
5
8
9
1
2
2
5
7
8
3
6
7
3
6
CA201
CA202
CA418
1
4
5
2
6
3
CR7
CR8
CR6
CR5 R3
29127
R4
29123
DTS1
TP19
6 4 3 1
29124
CR9
5 2
TP12
CR10
586
FU4
TP11
TP6 TP7 TP8 TP9 TP10
B
B
FU1
R5
TP14
RES2
RES3
TP13
K2
TP1
FU2
CA206 1 2 3 4 5 6
FU5
FU7
TP2
FU6
FU8
TP18
TP17
201 (CA401) +BV
TP13
TR2
TP5
202 (CA401) +BV FU9
2901 (CA401) +BV_ED1 +t
2902 (CA401) +BV_ED2
501 (CA401) BNEG BB
TP4
FU3
TP16
502 (CA401) BNEG BB
K2
CA203
TR3 CR11
CA205
CA204
+t TP15 MAST MOUNTED
GRN SPOT LIGHTS (OPTION)
12
10
11
MC2
4
5
1
6
7
8
1
1
4
5
8
9
2
3
4
5
6
7
2
3
6
7
3
9 RED/BLK BNEG
017 CA401-23 CAN_H ACCESS 3 WHT/BLK BNEG
019 CA403-13 CAN_H ACCESS 5 15 BLU BNEG
021 CA601-4 CAN_H ACCESS 6 14 ORG BNEG
018 CA401-15 CAN_L ACCESS 3 9 GRN BNEG
020 CA403-24 CAN_L ACCESS 5 15 RED CAN_L
14
MC1
022 CA601-4 CAN_L ACCESS 6 WHT CAN_H
BLK +BV_AK FROM KYS
RED/BLK RAS2
C
C
WHT/BLK RAS1
BLU +BV_ED1 FU7
ORG +BV_ED1 FU8
GRN +BV_ED1 FU9
Crown 2016 PF27613
RED +BV FU2
WHT +BV FU1
BLK BRAKE SWITCH
156643 A
1
WIRING DIAGRAMS
Access 1 (DCM) and 4 (VCM)
Access 1 (DCM) and 4 (VCM)
A B C
6 CA301 JC301
005 CA105-3 CAN_H 1 CAN 1 4 6 BLK
006 CA105-9 CAN_L 6 2 ACCESS 2 5
515 CA107-1 DISTRIBUTION BNEG 3 3 13 7 WHT MAST
CABLE
207 CA103-6 DISTRIBUTION +BV FU1 4 4 25 8 RED 4
2939 CA103-2 DISTRIBUTION +BV ED1 FU7 5 210 5 15 9 GRN
203 CA308-1 EDS 6 6 24
CA302 INFOLINK
1 5902 CA309-5 DMS1 1 SW AL
1
5917 CA103-16 ALARM 1 2 GPD ACCESS 1
2941 CA103-10 DISTRIBUTION +BV KYS 3 +BV (DCM)
513 CA107-8 DISTRIBUTION BNEG 4 BNEG
5 NEG
6 N/A
1 7 N/A SP 3500
003 CA105-2 CAN_H 1 8 CAN_H
004 CA105-8 CAN_L 9 CAN_L
10N/A CA302
11N/A 1 5
12SW AH/ANA 6 9
5901 CA309-4 ORS1 13SW AL
5903 CA309-6 GUS 14SW AL 10 14
CA323
29105 CA103-9 DISTRIBUTION +BV KYS 1 ACCESS 1
580 CA107-5 DISTRIBUTION BNEG 29 2
031 CA105-4 CAN_H 3 (DCM)
29 4
032 CA105-10 CAN_L GUIDANCE AND
(1) HEIGHT ENCODER (ECR4) 32 PULSE/REV STEER INDICATOR
(2) STEER SENSE ENCODER (ECR1) 32 PULSE/REV
(3) STEER SENSE ENCODER (ECR5) 32 PULSE/REV
CA303
7
2 101 CA309-1 POT1 SIGNAL 1 AN1
2 AN2 ACCESS 4 2
29123 PC331-1 CHAIN BREAK SWITCH 7 3 SW2 / AN1SP (VCM)
701 CA309-2 POT1 +5V 4 +5V
2997 CA103-3 LIFTING FORKS DIODE 2989 2 5 +5V
5912 CA320-1 HGTRS NO 2 6 SW7
001 CA105-1 CAN_H 2 7 CAN_H
002 CA105-7 CAN_L CA327 1 8 CAN_L
29112 (CA701) LMS1 LIFTING FORK OPTION 29139 9 SW1 / AN2SP CA303
29113 (CA701) LOS4 LIFTING FORK OPTION 1 29140 10SW0 / AN3SP
CA328 5 11+5V 1 8
(1) CH A
WHT 1 CH A 703 5 12+5V
9 15
ECR4 CH B BLU 2 CH B 007 5 13ECR1 A
+12V 16
NEG RED 3 +5V 008 5
14ECR1 B 23
BLK 4 NEG 516 15LOGIC NEG
2930 CA308-9 RAS1 CA317 16SW8 / AN4SP
2928 CA308-7 LOS1 17SW9 / AN5SP
2929 CA308-8 LOS2 18SW10 / AN6SP
506 CA309-2 LOGIC NEG POT1 7 581 19RS-232 COM
20RS-232 TX
21RS-232 RX
22SW / INDEX
59136 CA332-1 ZSSA 23SW6
CA304
2937 CA103-12 +BV KYS CA330 1 MODULE POWER
29145 CA701-1 +BV 1 29128 2 DRIVER B+
3 525 CA107-9 DISTRIBUTION B- 3 B- 3
5936 CA701-3 OPTION PVLF COIL DRIVER SUBHARNESS CA325 1 5941 4 PWM1
5935 CA701-4 OPTION SV1 COIL DRIVER SUBHARNESS 1 5942 5 PWM2
CA326 6 PWM3
5980 CA701-2 OPTION TRAVEL ALARM HARNESS CA336 1 5915 7 PWM4 23 16
2927 CA308-6 REVERSE SWITCH 8 SW12 15 9
2926 CA308-5 FORWARD SWITCH 9 SW11 8 1
5916 (CA321) GATE SWITCHES 10SW5
5911 (CA309) CHAIN SLACK SWITCHES 11SW4
12SW3 CA304
59139 CA333-1 ZSSB 13SW15
59138 CA334-1 ZSSC 14SW14
3 15SW13
(2) CH A
WHT 1 CH A 009 3 16ECR2 A
ECR1 CH B
+12V
BLU 2 CH B 010 3 17ECR2 B
NEG RED 3 +12V 312 3 18+12V
BLK 4 NEG 517 4 19LOGIC NEG
(3) CH A
WHT 5 CH A 518 4 20LOGIC NEG
ECR5 CH B BLU 6 CH B 313 4 21+12V
+12V
NEG RED 7 +12V 011 4 22ECR3 A
BLK 8 NEG 012 23ECR3 B
CA318
29123 CA303-3 CHAIN BREAK OPTION
29124 PC103-14 B+ DISTRIBUTION BOARD EU CHAIN
4 1 29110 BREAK OPTION 4
1
CA331
1 29111
CHB7 CHB8
A B C
142682 E
Crown 2016 PF27613 DIA-7335-140
DLIX
WIRING DIAGRAMS
Access 1 (DCM) and 4 (VCM), Forks First SAA
Access 1 (DCM) and 4 (VCM), Forks First SAA
A B C
PC301 JC301
005 CA105-3 CAN_H 6 1 CAN 1 4
006 CA105-9 CAN_L 6 6 BLK
2 ACCESS 2 5 7 WHT MAST
515 CA107-1 DISTRIBUTION BNEG 3 3 13 CABLE
207 CA103-6 DISTRIBUTION +BV FU1 4 4 25 8 RED 4
2939 CA103-2 DISTRIBUTION +BV ED1 FU7 5 210 5 15 9 GRN
203 (CA305) EDS 6 6 24
CA302 INFOLINK
1 5902 (CA309) DMS1 1 SW AL 1
5917 CA103-16 ALARM 1 2 GPD ACCESS 1
2941 CA103-10 DISTRIBUTION +BV KYS 3 +BV (DCM)
513 CA107-8 DISTRIBUTION BNEG 4 BNEG
29298 PDS ALARM 5 NEG
6 N/A
1 7 N/A SP 3500
003 CA105-2 CAN_H 1 8 CAN_H
004 CA105-8 CAN_L 9 CAN_L
10N/A CA302
11N/A 1 5
29299 PDS CREEP REQ 12SW AH/ANA 6 9
5901 CA309-4 ORS1 13SW AL
5903 CA309-6 GUS 14SW AL 10 14
CA323
29105 CA103-9 DISTRIBUTION +BV KYS 1 ACCESS 1
580 CA107-5 DISTRIBUTION BNEG 29 2
031 CA105-4 CAN_H 3 (DCM)
29 4
032 CA105-10 CAN_L GUIDANCE AND
(1) HEIGHT ENCODER (ECR4) 32 PULSE/REV STEER INDICATOR
(2) STEER SENSE ENCODER (ECR1) 32 PULSE/REV
(3) STEER SENSE ENCODER (ECR5) 32 PULSE/REV
CA303
101 CA309-1 POT1 SIGNAL 7 1 AN1
2 2 AN2 ACCESS 4 2
29110 (CA304) CHAIN BREAK SWITCH 7 3 SW2 / AN1SP (VCM)
701 CA309-2 POT1 +5V 4 +5V
5 +5V
5912 CA320-1 HGTRS NO 2 6 SW7
001 CA105-1 CAN_H 2 7 CAN_H
002 CA105-7 CAN_L 8 CAN_L
29112 (CA701) AUX HYD SWITCH 9 SW1 / AN2SP
29113 (CA701) LIMIT SWITCH 10SW0 / AN3SP
CA317 11+5V
WHT 1 CH A 703 5 12+5V
(1) CH A 5
ECR4 CH B BLU 2 CH B 007 13ECR1 A
+12V
NEG RED 3 +5V 008 5 14ECR1 B
BLK 4 NEG 516 5 15LOGIC NEG
2930 (CA305) RAS1 16SW8 / AN4SP
2928 (CA305) LOS1 17SW9 / AN5SP
2929 (CA305) LOS2 18SW10 / AN6SP
506 CA309-3 LOGIC NEG POT1 7 581 19RS-232 COM
2 1 30 20RS-232 TX
013 CA307-2 RS-232 TX 30
014 CA307-3 RS-232 RX 21RS-232 RX
519 CA307-5 RS-232 NEG 30 22SW / INDEX
59136 CA332-1 ZSSA 23SW6
CA304
2937 CA103-12 +BV KYS 1 MODULE POWER
29128 CA701-1 +BV 2 DRIVER B+
525 CA107-9 DISTRIBUTION B- 3 B-
3 5936 CA701-3 OPTION PVLF COIL DRIVER SUBHARNESS 4 PWM1 3
5935 CA701-4 OPTION SV1 COIL DRIVER SUBHARNESS 5 PWM2
5955 CA329-3 GUIDANCE STATUS IN 6 PWM3
5915 CA701-2 OPTION TRAVEL ALARM 7 PWM4
2927 (CA305) REVERSE SWITCH 8 SW12
2926 (CA305) FORWARD SWITCH 9 SW11
5916 (CA321) GATE SWITCHES 10SW5
5911 (CA309) CHAIN SLACK SWITCHES 11SW4
5956 CA329-4 PDS BRAKE REQ2 OUT 12SW3 CA303
59137 CA333-1 ZSSB 13SW15 1 8
59138 CA334-1 ZSSC 14SW14
5957 CA329-5 PDS BRAKE REQ1 OUT 15SW13 9 15
WHT 1 CH A 3 16ECR2 A 16 23
(2) CH A 3
ECR1 CH B BLU 2 CH B 3 17ECR2 B
+12V RED 3 +12V 18+12V 23 16
NEG
4 NEG 3 19LOGIC NEG 15
BLK
4 9
(3) CH A
WHT 5 CH A 4 20LOGIC NEG 8 1
ECR5 CH B BLU 6 CH B 4 21+12V
+12V
NEG RED 7 +12V 4 22ECR3 A CA304
BLK NEG 23ECR3 B
CA318
CHB7 CHB8
29110 CA303-3 CHAIN BREAK 29109
29111 PC103-13 B+ DISTRIBUTION BOARD
4 PC307 4
1
013 CA303-20 RS-232 TX 2
014 CA303-21 RS-232 RX 3
4
519 (CA303) RS-232 NEG 5
6
7
8
9
A B C
142697 D
DIA-7335-141 Crown 2016 PF27613
DLX
WIRING DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
A B C
5912 CA303-6 HGTRS 1 1
HGTRS
521 CA107-4 DISTRIBUTION BNEG 1
PC306
205 CA103-1 +BV FU1 A POWER FOR
1 2940 CA103-2 +BV ED1 FU7 B CUSTOMER ACCESSORIES 1
512 CA107-12 DISTRIBUTION BNEG C
CA308 CA305
203 CA301-6 FU2 1 204 1 2903 1 START
2924 CA103-8 IGN 2 EDS
2904 2 BATT ACC
2923 CA103-7 START 3 2905 3
2925 CA103-11 +BV KYS FROM DIST 4 2906 4 IGN
2926 CA304-9 FS 5 2907 OFF
2927 CA304-8 RS 6 2908
2928 CA303-17 LOS1 7 2909 FS KYS
2929 CA303-18 LOS2 8 2910 1 2938
2930 CA303-16 RAS1 9 2911 RS 2915
2932 CA103-3 RAS1 10 2912 1 BATT ACC
2935 CA103-4 RAS2 11 2913 LOS1 CA324
2936 (CA321) HNS 12 2914 2917 1
1 START
LOS2 GND
2918 IGN
1
2 RAS1 BACK VIEW OF KYS 2
1 2919
RAS2 2921
1
HNS
1 2922
CA309
101 CA303-1 POT1 WIPER 7 1 GRN POT1
701 CA303-4 POT1 +5V 7 2 ORG
506 CA303-19 POT1 NEG 7 3 VIO
5901 CA302-13 ORS1 4 5905 ORS1
5902 CA302-1 DMS1 5 5906 1
5903 CA302-14 GUS 6 5907 DMS1
514 CA107-7 DIST BNEG 7 527 1 529
8 5939
GUS 528
1
CHS1 CHS2
3 5911 CA304-11 CHS1 1 5918 1 3
520 CA107-3 DIST BNEG
CA332 ZSS
59136 CA303-23 ZSSA 1 BRN
CA333
59137 CA304-13 ZSSB 1 WHT
CA334
59138 CA304-14 ZSSC 1 BLU
CA335
550 CA107-6 BNEG 1 BLK
GRN
(CA321)
(FOR REFERENCE ONLY) HN1
2936 CA308-12 HNS 1
522 CA107-11 DIST BNEG
5904 CA103-5 BRS 1 BRS
4 4
524 CA107-10 DIST BNEG
5916 CA304-10 GTS2
CA322 GTS1 GTS2
530 CA107-2 DIST BNEG 1 582 1 5919 1
A B C
142683 D
Crown 2016 PF27613 DIA-7335-142
DLXI
WIRING DIAGRAMS
Overhead Guard Lights / Fans
Overhead Guard Lights / Fans
A B C
LGT2
503 1
301
LEFT SIDE ASSEMBLY LEFT WORKLIGHT
PS1
POWER SUPPLY
CA501
1 12V OUT
1 535 1 504 2 1
536 2 505 3 BATT COMM
2950 3 2990 4 BV INPUT
303 4 302
2951 5 2931
305 6 310 2998
2948 7 5106
TO PLATFORM WALL 5105 8
9 PS2
POWER SUPPLY
309 1 12V OUT
TO MODULE
HSG 2
3 BATT COMM
CAP1 4 BV INPUT
541
OPTION
LGT3
1 BLK
542 LGT4
RED BLK 1
-
LEFT DOME LIGHT
535 1234 5 LEFT SPOTLIGHT
2 536 TB502
2
PC102 LGS1 1 PC338
2942 1 MAST MOUNTED
1
2 2943 LGS2 SPOTLIGHTS
3 534 533 1
4 2944
5 1 2952
COPIED FROM LGS3 29135
DISTRIBUTION
BOARD PAGE 29451
FNS1 WHEN MAST MOUNTED SPOTLIGHTS ARE
PRESENT, THE MAST CABLE PLUGS INTO PC338
3 3
LGT7
BLK RED 1
FAN1 RIGHT SPOTLIGHT
CA503 507
533 1 508 1 FAN SUPPRESSOR
534 2 510
303 3 307 1
2947 4 2992 2
305 5 308 3 V CXX
2946 6 2916 2933 4
2949 7 2920 5
TO PLATFORM WALL 5107 8 5108 RES1
9 1 2934
SB30
TO MODULE CAP1
4 RIGHT SIDE ASSEMBLY HSG 4
LGT6
1 BLK LGT5
RIGHT DOME LIGHT 1
509 RIGHT WORKLIGHT
A B C
142687 E 1 of 2
DIA-7335-143 Crown 2016 PF27613
DLXII
WIRING DIAGRAMS
Overhead Guard Spotlights (Optional)
Overhead Guard Spotlights (Optional)
A B C
LEFT
1 1
LGT4
PC102
2 1 2
2 RED
3 BLK
4 BLK
5 WHT
WHT
RIGHT
3 3
LGT7
4 4
A B C
142687 E 2 of 2
Crown 2016 PF27613 DIA-7335-144
DLXIII
WIRING DIAGRAMS
Access 3™ (TCM)
Access 3™ (TCM)
A B C
FAN2
1
29122 CA201-8 +BV K3 FU3 FROM DIST 5908
579 CA411-2 M1 TEMP SENSOR CA401
2953 CA201-5 +BV K2 FU3 FROM DIST 1 MODULE POWER
1 5920 (CA412) ED2 COIL - 2 GPD 1 1
316 CA411-3 +12V TO ECR3 8 3 +12V ACCESS 3
549 CA411-6 LOGIC NEG TO ECR3 8 4 LOGIC NEG
029 CA411-4 TRACTION ENCODER CHB 8 5 ECR1 A U
028 CA411-5 TRACTION ENCODER CHA 8 6 ECR1 B U M1
122 CA201-12 BRUSH WEAR 7 AN2 V V
8 GPD 5 W 3
WHT
1 014 9 POT CMD W
CH A
(1) CH B
BLUE
2 013 10 DI8/ECR2 B
3 330
+12V RED
NEG 11 DI7/ECR2 A
4 581
BLK 316 DUAL HEIGHT ENCODER DETECT
12 DI5/ID1
2975 (CR412) MOTOR 4 THERMAL INPUT 13 DI3
2971 (CR412) MOTOR 3 THERMAL INPUT
9 14 DI2
018 CA204-7 CAN L 15 CAN L
103 CA408-9 TRACTION MOTOR TEMP FROM FSB1 8 16 TEMP (+)
2973 PC414-1 POWER UNIT CHS3 17 DI4/ID0
5923 (CA412) P1 COIL LOW SIDE DRIVER 18 GPD 2 CA401
29148 (CA612) PDS ACTIVE 19 DI1
2974 CA416-1 CHB4 20 DI6/AN1 1 8
5924 (CA412) P2 COIL LOW SIDE DRIVER 21GPD 3 9 15
5925 (CA412) SVL LOW SIDE DRIVER 22 GPD 4 B+ + B- 16 23
017 CA404-1 CAN H 9 23 CAN H
(1) ENCODER BEARING PULSE/REV
2 2
543 (CA412) ED1 COIL FU10
544 (CA412) STROBE LIGHT LGT1
547 (CA403) BATTERY RESTRAINT SWITCHES 1
548 (CA403) RAIL GUIDE SWITCHES 1
551 CA403-9 BATTERY SENSE ACCESS 5 2
552 CA601-2 B- BB TO ACCESS 6 BNEG ED2
585 CA418-C BRAKE RESISTOR
595 CA611-3 PDS B- 3
561 CA612-7 PDS B-
553 CA808-1 FREEZER CONDITIONING 4
554 CA808-2 FREEZER CONDITIONING
563 (CA809) MAST SPOT LIGHTS +
502 CA206-6 B- BB POWER TO DIST
501 CA206-5 B- BB POWER TO DIST
201 CA206-1 +BV POWER TO DIST
202 CA206-2 +BV POWER TO DIST 1
ED1
2901 CA206-3 +BV ED1 POWER TO DIST
2977 CA808-3 +BV ED1 FREEZER CONDITIONING
3 2978 CA808-4 +BV ED1 FREEZER CONDITIONING 3
2979 CA808-5 +BV ED1 FREEZER CONDITIONING
2902 CA206-4 +BV ED2 POWER TO DIST
CHS3
CA414
2973 CA401-11 CHAIN SLACK SWITCHES TO ACCESS3 1 BLK
CA415 CHB4
2954 CA201-7 DIST +BV K2 FU3 1 BLK
CA416
2974 CA401-20 CHAIN BREAK SWITCHES TO ACCESS3 1 RED CHS4
2955 CA201-8 DIST +BV K2 FU3 1 RED
CA417 CHB5
4 4
WHT GRN
A B C
156644 A
DIA-7335-145 Crown 2016 PF27613
DLXIV
WIRING DIAGRAMS
Access 5 (SCM)
Access 5 (SCM)
A B C
2966 CA201-6 +BV K2 FU3 FROM DIST BOARD 1 B+
2958 (CA412) PVL COIL 2 DRIVER B+ ACCESS 5
706 CA410-4 +5V ECR2 12 3 +5V
5932 CA407-6 BRAKE DISCONNECT (SCM)
4 DTS
5927 (CA403) BRES INPUT 5 SW_SPARE
5931 (CA403) RAIL GUIDANCE SWITCHES 6 RGS
027 CA410-5 INDEX ECR2 12 7 ECR INDEX
026 CA410-3 CHB ECR2 12 8 ECR2 B
1 551 (CA401) BNEG BB
025 CA410-1 CHA ECR2 12 9 BDI SENSE NEG
10 ECR2 A
1
11 ECR1 B
545 CA406-3 LOGIC NEG CS1 13 12 LOGIC NEG A1
019 CA204-2 CAN_H 15 13 CAN1 H
14 B+
15 +5V
16
17 ECR1 A A2
18
19 B-
12 20
540 CA410-2 LOGIC NEG ECR2 21 LOGIC NEG
22 LOGIC NEG
2967 CA202-8 ED DRIVER FEED CR9 DIST BOARD 23 ED_+BV
020 CA204-8 CAN_L 15 24 CAN1 L
25 B NEG
5926 (CA412) PVL COIL DRIVER 26 MH_LO
705 CA406-1 +5V CS1 13 27 +5V
104 CA406-2 SIGNAL CS1 13 28 BDI CURRENT SENSE
29 TRAVEL_OR
2965 (CA412) ED2 COIL 30 ED SOURCING DRIVER
206 CA202-3 BATTERY SENSE 31 BDI SENSE POS CA403
5928 CA407-3 INNER BRAKE COIL DRIVER 32 BRAKE INNER DRIVER
2956 CA202-2 DIST+BV ED2 FU6 INNER BRAKE DRIVER FEED 33 B+ BRAKE FEED INNER
1
5929 CA407-4 OUTER BRAKE COIL DRIVER 34 BRAKE OUTER DRIVER 35
2 2957 CA202-1 DIST+BV ED2 FU5 OUTER BRAKE DRIVER FEED 35 B+ BRAKE FEED OUTER 2
OPTIONAL RAIL GUIDE AND
BATTERY RESTRAINT
5927 CA403-5 BRES TO ACCESS 5 1 BRES15933 1 BRES2
547 (CA401) BNEG BB
5931 CA403-16 RGSL 1 RGSL 5934 1 RGSR M2
548 (CA401) BNEG BB
CA406
705 CA403-27 +5V FROM ACCESS 5 13 A VIO +
104 CA403-28 CURRENT SIGNAL TO ACCESS 5 13 B BRN 0 I CS1
545 CA403-12 LOGIC NEG FROM ACCESS 5 13 C GRN
CA407
1 WHT 0+
2968 CA202-1 +BV ED2 FU5 TO OUTER BRAKE COIL
2969 CA202-2 +BV ED2 FU6 TO INNER BRAKE COIL 2 BLU I+ BRK
5928 CA403-32 INNER BRAKE DRIVER 3 YEL I-
5929 CA403-34 OUTER BRAKE DRIVER 4 ORG 0-
5930 CA201-11 BRAKE SWITCH FROM DIST 5 5971
3 5932 CA403-4 BRAKE SWITCH TO ACCESS 5 6 3
JC413
29108 CA418-A BRAKE RESISTOR 1
29125 CA418-B BRAKE RESISTOR 2
578 CA201-1 BRAKE/TOW BNEG 3 DRIVE/TOW
29107 CA201-2 BRAKE/TOW FU4 POWER 4
5
(1) SENSOR BEARING 64 PULSE/REV 6
TRACTION MOTOR
(2) SENSOR BEARING 32 PULSE/REV
CA411 T+
105 CA401-16 TEMPERATURE ACCESS 3 105 11 1 BRN
579 (CA401) BNEG 2 579 11 2 R/W
315 CA401-3 +12V ACCESS 3 315 11 3 RED +12V
029 CA401-5 ECR3 CHB TO ACCESS 3 029 11 4 BLU CHB
028 11 5 ECR3
028 CA401-6 ECR3 CHA TO ACCESS 3 11 6 BLK WHT CHA
(1)
549 CA401-4 LOGIC NEG ACCESS 3 549 NEG
4 CA410 4
025 CA403-10 CHA TO ACCESS 5 12 1 BLU CHA STEERING
540 CA403-21 LOGIC NEG FROM ACCESS 5 12 2 BLK NEG FEEDBACK
026 CA403-8 CHB TO ACCESS 5 12 3 ORG CHA ECR2
706 CA403-3 FROM ACCESS 5 12 4 RED +5V (2)
027 CA403-7 INDEX TO ACCESS 5 12 5 YEL INDEX
6
A B C
156645 A
Crown 2016 PF27613 DIA-7335-146
DLXV
WIRING DIAGRAMS
Hydraulics and Optional MMS
Hydraulics and Optional MMS
A B C
(CA412)
FOR REFERENCE ONLY
2960 CA201-9 DIST +BV K2 FU3 TO PVL COIL 1
PVL
2958 CA403-11 PVL COIL SUPPRESION
5926 CA403-26 PVL COIL DRIVER
1 1 SVL 1
5925 CA401-22 SVL COIL DRIVER
2959 CA201-10 DIST +BV K2 FU3 TO SVL COIL
PVL
SVL
HYDRAULIC BLOCK
1
2961 CA202-6 DIST TO P1 COIL P1
5923 CA401-18 ACCES 3 TO P1 COIL
2 2962 CA202-7 DIST TO P2 COIL
1
P2
2
5924 CA401-21 ACCES 3 TO P2 COIL
1
2963 CA202-5 ED1 COIL ED1
543 (CA401) B- BB
1
5920 CA401-2 ACCESS 3 TO ED2 COIL - ED2
2965 CA403-30 ACCESS 5 TO ED2 COIL
2964 CA202-4 DIST BV ED1 LGT1 STROBE LIGHT
544 (CA401) B- BB LGT1
1 2 3 4 5
3 +
FIL1 3
2971 CA401-10 M3 THERMAL SWITCH TO ACCESS 3 THS-P1
2970 CA201-6 +BV K2 TO THS-P1 1 PUMP 1 MOTOR
M3
2976 1
108 CA201-15 POSITIVE BRUSHWEAR BW-P1
121 CA201-16 NEGATIVEBRUSH WEAR
2975 CA401-13 M4 THERMAL SWITCH TO ACCESS 3 THS-P2
1 PUMP 2 MOTOR
M4
1
106 CA201-13 POSITIVE BRUSHWEAR
107 CA201-14 NEGATIVE BRUSHWEAR BW-P2
4 MOTOR MANGEMENT OPTION 4
A B C
156646 A
DIA-7335-147 Crown 2016 PF27613
DLXVI
WIRING DIAGRAMS
Access 6 (GCM) (Optional)
Access 6 (GCM) (Optional)
A B C
CA602
901 27
EAC A1 TEST
903 28 1
BLUE 25 2 EAC B1 TEST ACCESS 6
CA601 3 LD WHL GUIDE BAR +5V
2972 CA201-6 DIST +BV K2 FU3 1 29195 MODULE POWER
ORANGE 24 4
021 CA204-3 DIST CAN H 2 5 STR WHL GUIDE BAR COIL TEST
552 (CA401) B- BB 3 ORANGE 25
6
BROWN 25 LD WHL GUIDE BAR COIL TEST
022 CA204-9 DIST CAN L 4 7 LD WHL GUIDE BAR COIL 4
1 B1 A1
RED 25
8 LD WHL GUIDE BAR COIL 3 1
EAC BLACK 25
9 LD WHL GUIDE BAR COIL 2
5 5 CA608 BLACK 24
SENSOR 314 10 STR WHL GUIDE BAR COIL 2
575 GREEN 24 11 STR WHL GUIDE BAR COIL 1
BROWN 24
12 STR WHL GUIDE BAR COIL 4
081 14 13 CAN H
CA607 YELLOW 25
1 901
109 BLUE 24
14 LD WHL GUIDE BAR B NEG
15 STR WHL GUIDE BAR +5V
2 052 16
3 902 5140 17 B-
EAC 4 110 YELLOW 24 18 STR WHL GUIDE BAR B NEG
5
6 053 19
7 903 GREEN 25
20
8 111 575 26
21 LD WHL GUIDE BAR COIL 1
9 054 RED 24
22 EAC SENSORS B NEG
10 904
23 STR WHL GUIDE BAR COIL 3
082 14 24 CAN L
11 112 902 27 25 EAC A2 TEST
12 055 904 28 26 EAC B2 TEST
EAC 5 5 054 28 27 EAC B1 DIGITAL
SENSOR B2 A2 055 28 28 EAC B2 DIGITAL
052 27 29 EAC A1 DIGITAL
314 26 30 EAC SENSORS +12V
053 27 31 EAC A2 DIGITAL
109 27 32 EAC A1 ANALOG CA602
GS1 110 27 33 EAC A2 ANALOG 1
2 CA603
111
112
28
28
34 EAC B1 ANALOG 35
2
35 EAC B2 ANALOG
1 GREEN
COIL 4
2 BLACK
COIL 3
YELLOW
B NEG 3
STEER WHEEL 4 BLUE
+5V 5
SENSOR BAR SLF TST 6 ORANGE
COIL 2 7 RED
COIL 1 8 BROWN
9
GS2
CA604
COIL 1 1 GREEN
COIL 2 2 BLACK
YELLOW
B NEG 3
LOAD WHEEL 4 BLUE
SENSOR BAR SLF+5V 5 ORANGE
TST 6
RED
3 COIL 3 7
BROWN 3
COIL 4 8
9
LOAD WHEEL BAR
C1 C2 C3 C4
EAC SENSORS
B2 A2 A1 B1
4 4
C1 C2 C3 C4
STEER WHEEL BAR
A B C
156647 A
Crown 2016 PF27613 DIA-7335-148
DLXVII
WIRING DIAGRAMS
Travel Alarm and Freezer Conditioning (Optional)
Travel Alarm and Freezer Conditioning (Optional)
A B C
CA807 2980 2985 1 RES5
1 2981 1 RGSR
CA808 K12A 2 555 1
553 BNEG BB 1 3 556 558 RES6
554 BNEG BB 2 FU11 4 1
5 2982 RGSL
2977 ED1 3 K12B
2978 ED1 4 6 557 559
1
7 29153 RES7
2979 ED1 5 FU12 1
1 8 598
9 2983 1
BRES1 1
K11 K11A 10 2986 RES8
2984 1
LIFTING FORKS OPTION 11 29152 BRES2
12 RED/WHT
K12 29151
29154
SV1 5937
29130 THS2
THS-2
29151
29153
K15 PVLF 5938
29129
5981
29152
1 WHT 1
598
RES9
1 BLK 1 CHS3
CA809
1 2345 67 8 WHT 1
HN2 RES10
208 CA202-3 BV KYS BLK 1
WHT/BLK
CHS4
RED
ORG
BLK
K15 CHS4
RED/BLK
5109 CA201-1 RED/WHT
WHT
GRN
BLU
POWER UNIT
2 2
RED/BLK
PLATFORM
PLATFORM
WHT/BLK
ORG
WHT
GRN
RED
BLU
BLK
CA701
CA701
1 2345 67 8
JC330
29128 CA330-1 BV KYS 1 29145 564 1
RES19
5915 CA336-1 BNEG 1 5980 2991 1 CHS1/CHB4
565 1
JC336 THS3 2993 RES20
29131 29132 1 CHS2/CHB5
LIFTING FORKS OPTION 566 1
2994 RES25
1 HGTRS
5936 CA325 OPTION SUBHARNESS PVLF COIL DRIVER 560 1
5935 CA326 OPTION SUBHARNESS SV1 COIL DRIVER 29106 RES21
1 GTS5
511 1
29112 CA327 LMS1 LIFTING FORK OPTION 2987 RES22
RAS3 RAS4 LMS1 1 GTS6
29114 CA103-13 RAS3 LIFTING FORK OPTION 570
29116 29118 2999 1
29115 RES18
LOS3 LOS4 1
29117 BRS
3 29100 571 RED/WHT 3
29113 CA328 LOS4 LIFTING FORK OPTION
CA702 1 2
VARIABLE PALLET GRAB OPTION
CA704 29121 572
5150 5151 RES17
1
29101 RS 573
RES40 RES41 CA703 RES16
1 29102 FS 574
29181 29180
RES15
HNS1
29103 583
RES14
LIFTING FORKS OPTION RAS/LOS
29104 584
5115 5114 5113 5112 RES13
EDS 587
29119
1 1 1 1 1
4 1
RES12 4
588 GTS2
RES35 RES36 RES33 RES34 29120 1 RES11
1 GTS1
1 1 1 1 CA704 523
1 589 2988 1 RES111
1 1
29174 2989 DMS1
29177 29176 29175 CA703 RED/WHT
A B C
142689 H 1 of 2
DIA-7335-149 Crown 2016 PF27613
DLXVIII
WIRING DIAGRAMS
Travel Alarm and Pallet Grab
Travel Alarm and Pallet Grab
A B C
29169 CA205-5
FU19
29170 CA205-6
FU18
5123 CA203-6
FU17
5124 CA203-7
FU16
1 1
29168
5122
29154
K15
PALLET GRAB
29167
5121
5981
TRAVEL ALARM
CA810
1234567 8
HN2
208 CA202-3 BV KYS
WHT/BLK
K15
RED
ORG
BLK
RED/BLK
5109 CA201-1
WHT
GRN
BLU
POWER UNIT
PLATFORM
WHT/BLK
WHT/BLK
WHT
ORG
GRN
RED
BLK
TRAVEL ALARM BLU
CA705
2 2
1234567 8
JC330
29173
5126
29128 CA330-1 BV KYS 1 29145
5915 CA336-1 BNEG 1 5980
29172
JC336
5125
911 1
29171 2
5127 914 3
915 DB1
PGS1
6 7 8 9 10
6
PGS1
1 2 3 4 5
4
3 913 3
912
916
4 3 2 1
PALLET GRAB
4 3 2 1 PALLET GRAB
917 COM
CLOSE PGLS1
NO JAWS
919 NC
921
923
4 4
SB1
920 COM M5
OPEN
NO JAWS
918 NC 924
922
A B C
142689 H 2 of 2
Crown 2016 PF27613 DIA-7335-150
DLXIX
WIRING DIAGRAMS
Forks First Option with Heaters
Forks First Option with Heaters
A B C
RED/WHT
CA807 1
2980 2985 RES5
1 2981 1 RED/WHT
RGSR
CA808 K12A 2 555 1 RED/WHT
553 B- BB 1 3 556 558 RES6
FU11 4 2982 1 RED/WHT
554 B- BB 2 K12B 5 RGSL
2977 ED1 3 6 557 1 RED/WHT
1 2978 ED1 4
FU12 7 29153
559 RES7 1
2979 ED1 5 8 598 1 RED/WHT
BRES1
RED/WHT
K11A
9 2983 2986 1
K11 K11A
10 2983 RES8
11 29152 1 RED/WHT
BRES2
LIFTING FORKS OPTION 12 29153
OPTION K12
29154 THS-2
SV1 5937
29130
K15
PVLF 5938
29129 RED/WHT
WHT
1 1
5981 BLK RES9
1 1 RED/WHT
29151
29152
29153 CHS3
598 RED/WHT
WHT
CA809 1
BLK RES10
K15
K15 1 234 567 8 1 RED/WHT
CHS4
208 CA202-3 +BV KYS
ORG
WHT/BLK
RED
BLK
RED/BLK
2 2
RED/BLK
5109 CA201-1
HN2
WHT
BLU
GRN
POWER UNIT
PLATFORM
WHT/BLK
RED
ORG
RED/BLK
BLK
BLU
WHT
GRN
CA701
1 234 567 8
RED/WHT
29128 CA304-2 +BV KYS 29145 564 1
RES19
2991 1 RED/WHT
CHS1/CHB7
5915 CA304-7 BV- 5980 565 RED/WHT
2993 1
29131 29132 RES20
1 RED/WHT
CHS2/CHB8
THS-3 2994
566 1 RED/WHT
LIFTING FORKS OPTION RES25
1 RED/WHT
5936 CA325 OPTIONS SUBHARNESS 560 RED/WHT
HGTRS
3 PVLF COIL DRIVER 29106 1
RES21
3
5935 CA326 OPTIONS SUBHARNESS 1 RED/WHT
GTS5 LIFTING FORKS
SV1 COIL DRIVER 511 1 RED/WHT OPTION
2987
29113 CA303-10 LIMIT SWITCH RES22
1 RED/WHT LIFTING FORKS
GTS6 OPTION
570 1 RED/WHT
29112 CA303-9 AUX HYD SWITCH 2999 RES18
AUX 1 RED/WHT
BRS
29114 CA103-13 +BV ED2 29100 571
29115 LMS1
CA702 1 2
29121
572
29120
588
589 2989
DMS
573 29101
4 AUX 4
574 29102
583 RS
29103
584 FS 29104
587 RAS/LOS
29119
EDS
A B C
142700 E
DIA-7335-151 Crown 2016 PF27613 Rev. 1/18
01 Rev. 1/18
DLXX
WIRING DIAGRAMS
Power Cables
Power Cables
A B C
BATT + ITEM 14
BNEG ITEM 15
1 1
FU15
FU10
FU14
FU13
ED2 ED1
ITEM 12
W V U
ACCESS 3® ITEM 7 ITEM 10 A1
(TCM) ITEM 11 A2
U V W P1
B+ + B-
ITEM 2
ITEM 8 ITEM 6
2 ITEM 9
ITEM 5
ITEM 3
2
ITEM 4
M3 M4
(PUMP 1) (PUMP 2)
ACCESS 5 B- P2
(SCM) M1 ITEM 1
M2 (TRACTION)
(STEERING)
ITEM 13
ACCESS 6
(GCM)
3 3
ITEM SP 3520/SP 3550 SP 3505 SP 3510 SP 3511/SP 3512 SP 3521/SP 3522
1 084571-230 PC#1 NOT USED NOT USED NOT USED 084571-230 PC#1
2 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1
3 084571-231 PC#1 NOT USED NOT USED NOT USED 084571-231 PC#1
4 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1
5 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1
6 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1
7 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1
8 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0
9 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0
4 10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 4
11 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10
12 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10
13 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10
14 084573-250 PC2/0 084571-313 PC#1 084573-250 PC2/0 084573-257 PC2/0 084573-257 PC2/0
15 084573-251 PC2/0 084571-314 PC#1 084573-251 PC2/0 084573-258 PC2/0 084573-258 PC2/0
A B C
142690 D
Crown 2016 PF27613 DIA-7335-152
01 Rev. 1/18
DLXXI
WIRING DIAGRAMS
Wire Harnesses
Wire Harnesses
Harness P/N Connected By:
Power unit
156271 (1) (3) Wire guidance / EAC harness: JC602, PC603, PC604, PC607, PC608
156272 (1) (3) Wire guidance harness: JC602, PC603, PC604
156273 (1) End aisle harness (EAC): JC602, PC607, PC608
141028 (1) Freezer condition harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, MAST
SPOT LIGHTS, PVL, RGSL, RGSR, SV1, THS2
142216-001 Wire guide harness extension
156278 (1) (4) Wire guidance / EAC harness: JC602, PC603, PC604, PC607, PC608
156279 (1) (4) Wire guidance harness: JC602, PC603, PC604
143590 Travel alarm harness (power unit): CA201, CA202, K15, PC809, HN2
145255 Pallet grab harness with travel alarm (power unit): CA201, CA202, CA203, CA205, PC809,
HN2, K15
146557 Power harness: PC206, B-, B+, ED1, ED2
146764 Access 5 to steer motor
156103 Power unit harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC419, PF420, PC421, PC601, BNEG,
BRES1, BRES2, BW-P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1,
THS-P2, FAN, ECR6, MAST SPOTLIGHT
Platform
134322 (1) Positive / negative accessory harness
140106 Platform harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC308, PC309, PC317, PC318, PC322, JC322, PC325, PC328, PC330, PC331, CA332,
PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1, GTS2, HGTRS, HN1, HN2
140108 Overhead guard left wire harness: JC310, JC311, PC314, PC315, PC316, PC501, LGS1, LGS2
140109 Overhead guard right wire harness: JC312, JC313, JC314, JC315, JC316, PC338, PC503,
FNS, LGS3
140170 (2) Platform chain break harness: CHB7, CHB8, JC331, PC331 (CA331)
140290-001 (1) InfoLink® harness: ALARM, CAN, CURRENT, LOAD, MODULE, PROG, PROX, RS232,
SHOCK
141029 (2) Options harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141214 (1) InfoLink® harness: CAN, PROX, SHOCK
(1) Optional
(2) SAA / EU lift trucks only
(3) US lift trucks only
(4) EU lift trucks only
DIA-7335-153 Crown 2016 PF27613 Rev. 1/18
01 Rev. 1/18
DLXXII
WIRING DIAGRAMS
Wire Harnesses
Harness P/N Connected By:
Platform (continued)
142218 Forks Steering harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
First PC306, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335, PC501,
PC503, PC701, JC705, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1,
GSI, GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1,
RAS1, RAS2, RS, LMS1, FS, RS, LOS3, GUIDANCE
143589 (1) Travel alarm harness: JC330, JC336, PC701
145166 Pallet grab harness (platform): JC339, M5, PGS2, PGS3, SB1
145254 Pallet grab harness with travel alarm (platform): JC330, JC336, PC339, PC701, DB1, PGS1
147135-001 Mast height encoder harness: PC422
through
147135-004
149720 InfoLink® / intermec cable assembly
149721 InfoLink® / intermec harness: PROX, RS232
149722 PROX extender harness: PROX
150354 (1) Windows® InfoLink® CAN breakout harness: ALARM, CAN, CURRENT, LOAD, PROG, PROX,
MODULE, RS232, SHOCK
154727 Platform PDS harness (EMEA only)
158662 InfoLink® LC filter harness
161759 Spotlight harness: PC505
161947 Mast spotlights: PC811, PC812
162190 Overhead guard left harness: PC501, PC508, JC507, PC506, JC505, FAN, WRKLGT
162191 Overhead guard right harness: PC503, PC512, JC511, PC510, JC509, FAN, WRKLGT
162192 Lights / fan modules harness: JC501, PC102, PC338, JC503, LGS1, LGS2, LGS3, FNS
(1) Optional
Crown 2016 PF27613 Rev. 1/18 DIA-7335-154
01 Rev. 1/18
DLXXIII
Notes:
DLXXIV
WIRING DIAGRAMS
Index
Index
This electrical diagram index contains the electrical
diagrams that are applicable to your lift truck. See the
ELECTRICAL / Electrical System section for wire color
codes, power cable codes, and electrical diagram
symbols.
Electrical Diagrams Index
Title Page Number Revision
Schematic - Platform with Options DIA-7335-131
Schematic - Power Unit with Options DIA-7335-132
Schematic - Platform Unit with Pallet Grab DIA-7335-133
Schematic - Power Unit with Pallet Grab DIA-7335-134
Schematic - Platform DIA-7335-135
Schematic - Power Unit DIA-7335-136
Platform Distribution Panel DIA-7335-137
Platform Distribution Panel Forks First SAA DIA-7335-138
Power Unit Distribution Panel DIA-7335-139
Access 1 (DCM) and 4 (VCM) DIA-7335-140
Access 1 (DCM) and 4 (VCM), Forks First SAA DIA-7335-141
Control Pod and Light Switches DIA-7335-142
Overhead Guard Lights/Fans DIA-7335-143
Overhead Guard Spotlights (Optional) DIA-7335-144
Access 3™ (TCM) DIA-7335-145
Access 5 (SCM) DIA-7335-146
Hydraulics and Optional MMS DIA-7335-147
Access 6 (GCM) (Optional) DIA-7335-148
Travel Alarm and Freezer Conditioning (Optional) DIA-7335-149
Travel Alarm and Pallet Grab DIA-7335-150
Forks First Option with Heaters DIA-7335-151 01 Rev. 1/18
Power Cables DIA-7335-152
Wire Harnesses DIA-7335-153 01 Rev. 1/18
Crown 2016 PF27613 Rev. 1/18 DIA-7335-130
01 Rev. 1/18
DXLIX
WIRING DIAGRAMS
Schematic - Platform with Options
Schematic - Platform with Options
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS THE LIFT TRUCK IS SHOWN WITH THE PLATFORM
1 LOWERED, GATES DOWN, AND UNATTENDED.
1 1
RAS4 ACCESS 4
RAS3 CA304-2
CA303-9 CA304-7
LOS3 LMS1 CA303-1 SIG POT1
CA303-10 TRACTON
+12V CA303-4 +5V
LOS4 CA304-21 CA303-19 NEG
ECR5 CHA CA304-22
STEER CHB CA304-23 CA303-20
COMMAND NEG CA304-20 CA303-21
ECR1
+12V CA304-18
STEER CHA CA304-16 CHS2 CHS1
COMMAND
CHB CA304-17 CA304-11
NEG CA304-19 GTS2 GTS1 GTS5 GTS6
ECR4 +5V CA303-12 CA304-10
HEIGHT CHA CA303-13 10
ENCODER CHB CA303-14 CA303-6
NEG CA303-15 CA303-23 ZSSA HGTRS NOTE:
FS
CA304-9 1 LIFTING FORKS OPTION.
RS CA304-13 ZSSB
CA304-8 ZSS 13 2 GUIDANCE OPTION.
CA304-1
CAN_H CA303-7
CAN_L CA303-8
CA304-3
CA303-16 CA304-14 ZSSC
LOS1 3 MAST MOUNTED SPOTLIGHTS
CA303-17 CA304-5 OPTION.
LOS2 CA303-3
CA304-4
CA303-18 4 COLD CONDITION OPTION.
12 CHB7 CHB8
5 PLATFORM LIGHTS/FAN OPTION.
RAS1 6 BATTERY RESTRAINT OPTION.
2 2
7 RAS2 ACCESS 1
7 DUAL PUMP OPTION.
CA302-3 CA302-4 8 MOTOR MANAGEMENT SYSTEM
OPTION.
9 TRAVEL ALARM OPTION.
2
120 OHM
10 SAA GATE OPTION.
ALM1 GUS
CR12 CA302-14
11 EU DEADMAN SWITCH.
CAN_H CA302-8
CAN_L CA302-9
CA302-2 ORS1
CA302-13 12 EU CHAIN BREAK SWITCHES.
CA302-1 DMS1 13 ZONE SELECT OPTION.
11 14 INFOLINK® OPTION.
15 PALLET GRAB OPTION.
STEER POSITION INDICATOR
CA323-3
CA323-4
CA323-2
CA323-1
R1 R2
CAN_L
CAN_H
VR1
3 + C1 3
BRS
CA301 PROG CA301
CAN_H K1
CAN_L
CR1 CR2
KYS CR3
START TR1
ACC -T°
CR4
+BV (ED1) FU7 (CUSTOMER OPTIONS)
EDS IGN K1
OFF
+BV FU1 (CUSTOMER OPTIONS)
PLATFORM
LIGHTS/FAN
5
LIFTING FORK COILS
BRAKE DISCONNECT
4 5 13 251524
(FAN/SPOT LIGHTS)
MAST SPOT LIGHT
(POWER SUPPLY)
4 INFOLINK 14 PLATFORM 4
+BV (ED1) FU8
+BV (ED1) FU9
TRAVEL ALARM
6 7 8 9 C/C 4
+BV AK
CAN_H
CAN_L
+BV FU2
C/C THS-3
C/C THS-3
BNEG
BNEG
BNEG
BNEG
BNEG
1
+BV C/C
+BV C/C
RAS1
RAS2
1
PVLF
SV1
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-1 M2-3 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-2 M2-4 M2-6 M2-8
A B C
156642 A 3 of 6
DIA-7335-131 Crown 2016 PF27613
DL
WIRING DIAGRAMS
Schematic - Power Unit with Options
Schematic - Power Unit with Options
A B C
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-3 M3-4 M3-5 M3-6 M3-7 M3-8 M2-1 M2-2 M2-3 M2-4 M2-6 M2-8
MAST SPOT
1 2 3 4
BNEG
BNEG
+BV (ED1) FU9
TRAVEL ALARM
+BV (ED1) FU8
+BV (ED1) FU7
BRAKE DISCONNECT
SHOCK SENSOR
+BV AK
CAN_H
BNEG
BNEG
BNEG
CAN_L
+BV FU2
B+
+BV FU1
RAS1
RAS2
+BV C/C
14 PVLF
C/C THS-3
C/C THS-3
+BV C/C
SV1
1 1 1
SV1
K15
FU8
9
PVLF
POWER UNIT
MAST 3 C/C 4
FU7 FU9
SPOTLIGHTS
7 M4
FU14 P2
LGT1 M3
FIL1 + FU13 P1
NOTE:
THE LIFT TRUCK IS SHOWN WITH THE
PLATFORM LOWERED, GATES DOWN, 1 LIFTING FORKS OPTION.
AND UNATTENDED.
FU15 ACCESS 3 2 GUIDANCE OPTION.
+ B- 3 MAST MOUNTED
12 CA401
CHB5 CHB4 B+ U U ECR6 SPOTLIGHTS OPTION.
20 V V M1 MAST 4 COLD CONDITION OPTION.
CHS4 CHS3 W W3 HEIGHT 5 PLATFORM LIGHTS/FANS
17 10 CHB ENCODER
OPTION.
1 11 CHA 6 BATTERY RESTRAINT
SVL 22 2 ED COIL ED2 OPTION.
2 7 DRIVER (-) 7 DUAL PUMP OPTION. 2
P2 21 TS1 TRACTION
16 TEMP 8 MOTOR MANAGEMENT
+t° TEMP
P1 18 15 14 3 +12V SYSTEM OPTION.
5 6 CHB
FAN2 8 23 7 13 4 CHA 9 TRAVEL ALARM OPTION.
ECR3
CAN_L
CAN_H
NEG TRACTION 10 SAA GATE OPTION.
8
11 EU DEADMAN SWITCH.
MMS
12 EU CHAIN BREAK SWITCHES.
M2 13 ZONE SELECT OPTION.
ED1
ACCESS 5 14 INFOLINK OPTION.
STEER A2
A1 STEER A1 A2 15 PALLET GRAB OPTION.
FU10
B+ B-
FU5 15
0+ 35 17
FU6
11
22 CR10
I+ 33 CA403 30 ED COIL DRIVER (+)
0+ 23 ED IN CS1
I+ CA407 27 +5V CR9
BRK I- I- 0- 34 32 28 SIG CURRENT
SENSE
12 NEG ECR2
0- BRK REL 4 3 10 CHA +5V STEERING
7 INDEX FEEDBACK 6 K2
PVL 2
21 8
CHB
NEG
120 OHM
PVL 26 BRES1 BRES2
5
+BV LOGIC 1 RGSR 2 RGSL
B+ SENSE 31 6
CAN_H 13
24
9 BNEG SENSE
3 3
CAN_L
JC413 RES2
RES3
DTS1
9 HN2
K15
LOAD WHEEL
SENSOR BAR 2 ACCESS 6 EAC DIST PNL
DIG 1
B1
GS2 30 +12V CA608-1 2 1 BNEG 2
1 COIL 1 21 22 BNEG CA608-2 3 TST 3 EAC
1 4 5 ANA
CA604
A1 TST 4
2 COIL 2 932 A1 ANA
1 2 +12V 5
3 BNEG 14 CA605
5 +5V CA602 25 29
3 A1 DIG 3
DIG 1
A1
6 STEST 6 A2 TST 4 2 1 BNEG 2
8
CA607
TR2 7 8 COIL 3 33 A2 ANA 5 3 TST 3 EAC
COIL 4 7 31 A2 DIG 6 4 5 ANA 4
+t° TR3 2 2 B1 TST 7 +12V 5
GS1 34 B1 ANA 8 CA606
FU2
+t° CR11 27 B1 DIG A2
1 COIL 4 11 9 1 BNEG
DIG 1
26 B2 TST 10 2 2
CA603
2 COIL 3 10 11 3 TST 3 EAC
FU3 2 3 BNEG 18 35 B2 ANA 4 5 ANA 4
5 +5V 15 28 B2 DIG 12 +12V 5
6 STEST 5 CA609 B2
FU1
7 8 COIL 2 23 1 DIG 1
4 COIL 1 12 2 BNEG 2 4
CAN_L 24
17
13
CA610 4 3 ANATST 34 EAC
4
STEER WHEEL
SENSOR BAR 5 +12V 5
CAN_H
ED1 ED2
FU4
K2 24V BATT
+
A B C
156642 A 4 of 6
Crown 2016 PF27613 DIA-7335-132
DLI
WIRING DIAGRAMS
Schematic - Platform with Pallet Grab
Schematic - Platform with Pallet Grab
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS THE LIFT TRUCK IS SHOWN WITH THE
1 1 PLATFORM LOWERED, GATES DOWN, 1
RAS4 ACCESS 4 AND UNATTENDED.
RAS3 CA304-2
CA303-9 CA304-7
LOS3 LMS1 CA303-1 SIG POT1
CA303-10 CA303-4 +5V TRACTON
LOS4 +12V CA304-21
ECR5 CHA CA304-22 CA303-19 NEG
STEER CHB CA304-23 CA303-20
COMMAND NEG CA304-20 CA303-21
ECR1 +12V CA304-18
STEER CHA CA304-16 CHS2 CHS1
COMMAND CHB CA304-17 CA304-11 NOTE:
NEG CA304-19 GTS2 GTS1 GTS5 GTS6 1 LIFTING FORKS OPTION.
ECR4 +5V CA303-12 CA304-10
HEIGHT CHA CA303-13 HGTRS 10 2 GUIDANCE OPTION.
ENCODER CHB CA303-14 CA303-6
NEG CA303-15 CA303-23 ZSSA 3 MAST MOUNTED
FS SPOTLIGHTS OPTION.
CA304-9
RS CA304-13 ZSSB 4 COLD CONDITION OPTION.
CA304-8 ZSS 13 CLAMP 16
CA303-16 CA304-14 ZSSC 5 PLATFORM LIGHTS/FAN OPTION.
CAN_H CA303-7
CAN_L CA303-8
CA304-3
CA304-1
LOS1 CA303-22
CA303-17 6 BATTERY RESTRAINT OPTION.
LOS2 CA303-3 CA304-5 DETECT
CA303-18 7 DUAL PUMP OPTION.
12 CHB7 CHB8 CA304-4
8 MOTOR MANAGEMENT
SYSTEM OPTION.
RAS1
2 9 TRAVEL ALARM OPTION. 2
7 RAS2 ACCESS 1
10 SAA GATE OPTION.
CA302-3 11 EU DEADMAN SWITCH.
CA302-4
12 EU CHAIN BREAK SWITCHES.
2
13 ZONE SELECT OPTION.
120 OHM
ALM1 GUS 14 INFOLINK® OPTION.
CA302-14
ORS1
CAN_H CA302-8
CAN_L CA302-9
CA302-2 15 PALLET GRAB OPTION.
CR12 CA302-13
DMS1 16 PALLET CLAMP
CA302-1 AND DETECT OPTION.
11
STEER POSITION INDICATOR
CA323-3
CAN_L CA323-4
CA323-2
CA323-1
R2
R1
CAN_H
VR1
3 + C1 3
BRS
CA301 PROG CA301 CAN_H K1
CAN_L
CR1 CR2
KYS CR3
START TR1
-T°
ACC
EDS CR4
IGN K1
OFF
PLATFORM
LIGHTS/FAN
5
(CUSTOMER OPTIONS)
(CUSTOMER OPTIONS)
LIFTING FORK COILS
BRAKE DISCONNECT
(FAN/SPOT LIGHTS)
4 5 13 251524
+BV (ED1) FU7
(POWER SUPPLY)
4
+BV (ED1) FU8
INFOLINK 14 4
TRAVEL ALARM
+BV (ED1) FU9
+BV (FU1)
PALLET GRAB
6 7 8 9
MAST SPOT
CAN_H
15
CAN_L
+BV FU2
1
+BV AK
BNEG
BNEG
BNEG
BNEG
BNEG
RAS1
RAS2
PVLF 1
B-
B-
B-
B-
SV1
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-1 M2-2 M2-3 M2-4 M2-6 M2-8
A B C
156642 A 5 of 6
DIA-7335-133 Crown 2016 PF27613
DLII
WIRING DIAGRAMS
Schematic - Power Unit with Pallet Grab
Schematic - Power Unit with Pallet Grab
A B C
M1-6 M1-4 M1-8 M1-1 M4-2 M4-4 M3-1 M3-3 M3-7 M2-4 M2-6 M2-8
M1-2 M1-5 M1-7 M1-3 M4-1 M4-3 M4-8 M3-2 M3-4 M3-5 M3-6 M3-8 M2-1 M2-2 M2-3 M2-5 M2-7
MAST SPOT
1 2 3 4 15
BNEG
BNEG
TRAVEL ALARM
+BV (ED1) FU9
BNEG
BNEG
BNEG
CAN_H
+BV AK
+BV (ED1) FU8
+BV (ED1) FU7
CAN_L
PALLET
PALLET
PALLET
PALLET
B+ PVLF
BRAKE DISCONNECT
POWER UNIT
+BV FU1
+BV FU2
SHOCK SENSOR
GRAB
GRAB
GRAB
GRAB
SV1
RAS1
RAS2
1 14 1
1
SV1
K15 9 FU19
FU8
FU16
PVLF FU18 FU17
MAST
FU7 FU9 SPOTLIGHTS
3
7 M4
FU14 P2
LGT1 M3
FIL1 + FU13 P1
FU15 ACCESS 3
+ B-
12 CA401
CHB5 CHB4 B+ U U ECR6
20 V V M1 MAST NOTE:
CHS4 CHS3 W W3 HEIGHT 1 LIFTING FORKS OPTION.
17 10 CHB ENCODER
1 11 CHA 2 GUIDANCE OPTION.
2 7
SVL 22 2 ED COIL DRIVER (-) ED2 3 MAST MOUNTED 2
P2 21 TS1TRACTION SPOTLIGHTS OPTION.
16 TEMP 4 COLD CONDITION OPTION.
3 +t° TEMP
P1 18 15 10 5 +12V 5 PLATFORM LIGHTS/FAN
FAN2 8 23 7 13 4 6 CHA CHB OPTION.
ECR3
CAN_H
CAN_L
NEG TRACTION 6 BATTERY RESTRAINT OPTION.
8 7 DUAL PUMP OPTION.
MMS
8 MOTOR MANAGEMENT
M2 SYSTEM OPTION.
ED1 9 TRAVEL ALARM OPTION.
ACCESS 5 10 SAA GATE OPTION.
STEER A2
A1 STEER A1 A2
FU10 11 EU DEADMAN SWITCH.
B+ B-
FU5 0+ 35 15
17
12 EU CHAIN BREAK SWITCHES.
11
22
ED COIL DRIVER (+) CR10 13 ZONE SELECT OPTION.
FU6 I+ 30
33 14 INFOLINK® OPTION.
0+ CA407 CA403 23 +5V ED IN
I+ 27 SIG CS1 CR9 15 PALLET GRAB OPTION.
BRK I- I- 32 28 12 NEG CURRENT
SENSE ECR2
0- 0- 34 3 10 CHA +5V
BRK REL 4 STEERING K2
7 INDEX FEEDBACK
2 21 8
PVL CHB 6
NEG BRES1
120 OHM
PVL 26 5
+BV LOGIC 1 RGSR 2 RGSL BRES2
+B SENSE 31 6
3 3
CAN_H 13
CAN_L 24
9 BNEG SENSE
JC413 RES2
RES3
DTS1
9 HN2
K15
LOAD WHEEL 2 EAC DIST PNL
SENSOR BAR 2 ACCESS 6 DIG 1
B1
GS2 +12V CA608-1 2 1
22 30
BNEG 2
BNEG CA608-2 3 TST 3 EAC
1 COIL 1
1 21 A1 TST 1 2 4 5 ANA 4
CA604
2 COIL 2 9 +12V 5
3 32 14 A1 ANA
BNEG 3 CA605
CA602 25 29 A1
A1 DIG
5 +5V 3 DIG
4 2 1
A2 TST 1
6 STEST 6 BNEG
CA607
2
TR2 7 8 COIL 3 33 8 A2 ANA 5 3 TST 3 EAC
COIL 4 31 7 A2 DIG 6 4 5 ANA 4
+t° TR3 2 2 B1 TST 7 +12V 5
GS1 34 B1 ANA 8 CA606 A2
+t° CR11 27 B1 DIG 9 1 DIG 1
1 COIL 4 11 26 B2 TST 10 2 BNEG 2
3 EAC
CA603
3
2 COIL 3 10 35 B2 ANA 11 4 5 ANA
TST
4
FU3 3 BNEG 18 28 B2 DIG 12 +12V 5
5 +5V 15 CA609
6 STEST 5 B2
FU1
FU2
7 8 COIL 2 23 1 DIG
4 COIL 1 12 2 BNEG
1
2
EAC 4
17
24
13
CA610 4 3 TST 3
4
STEER WHEEL ANA 4
SENSOR BAR 2 5 +12V 5
CAN_L
CAN_H
ED1 ED2
FU4
K2 24V BATT
+
A B C
156642 A 6 of 6
Crown 2016 PF27613 DIA-7335-134
DLIII
WIRING DIAGRAMS
Schematic - Platform
Schematic - Platform
A B C
CA306-A +BV CUSTOMER OPTIONS
CA306-C
CA306-B +BV(KYS)
HN1
HNS
1 THE LIFT TRUCK IS SHOWN WITH THE 1
ACCESS 4 PLATFORM LOWERED, GATES DOWN,
CA304-13 AND UNATTENDED.
CA304-2
+12V CA304-21 CA304-7
ECR5 CHA CA304-22
STEER CHB CA304-23 CA303-1 SIG POT1
COMMAND NEG CA304-20 TRACTON
CA303-4 +5V
+12V CA304-18 CA303-19 NEG
ECR1 CHA CA304-16
STEER CA303-20
COMMAND
CHB CA304-17
NEG CA304-19 CA303-21
+5V CA303-12 CHS2 CHS1
ECR4 CA304-11
HEIGHT CHA CA303-13
ENCODER CHB CA303-14 GTS2 GTS1
NEG CA303-15 CA304-10
FS
CA304-9
RS CA303-6
CA304-8 HGTRS
RAS1 CA304-5
CA304-1
CA303-7
CA303-8
CA303-16 CA304-3
LOS1 CA304-4
CA303-17
LOS2 CA303-18
2 2
CAN_H
CAN_L
ACCESS 1
CA302-3 CA302-4
ALM1
120 OHM
CAN_H CA302-8
CAN_L CA302-9
CA302-2
CR12 CA302-13
CA302-1 ORS1
STEER POSITION INDICATOR
CA323-3
CA323-4
CA323-2
CA323-1
R2
R1
3 3
CAN_L
CAN_H
VR1
+ C1
BRS
CA301 CAN_H K1
CR1 CR2
CAN_L
KYS CR3
START TR1
-t°
ACC
BRAKE DISCONNECT
EDS IGN CR4
(CUSTOMER OPTIONS)
K1
OFF
(FAN/SPOT LIGHTS)
+BV (ED1) FU7
(POWER SUPPLY)
4 4
+BV (ED1) FU8
+BV (ED1) FU9
+BV (FU1)
CAN_H
CAN_L
+BV AK
+BV FU2
RAS2
BNEG
BNEG
BNEG
BNEG
BNEG
RAS1
M1-6 M1-4 M1-8 M1-1 M2-1 M2-3 M2-5 M2-7
M1-2 M1-5 M1-7 M1-3 M2-2 M2-4 M2-6 M2-8
A B C
156642 A 1 of 6
DIA-7335-135 Crown 2016 PF27613
DLIV
WIRING DIAGRAMS
Schematic - Power Unit
Schematic - Power Unit
A B C
M1-6 M1-4 M1-8 M1-1 M2-2 M2-4 M2-6 M2-8
M1-2 M1-5 M1-7 M1-3 M2-1 M2-3 M2-5 M2-7
+BV (ED1) FU9
BNEG
BNEG
+BV (ED1) FU7
BNEG
BNEG
BNEG
+BV (ED1) FU8
BRAKE DISCONNECT
+BV AK
+BV FU2
RAS1
+BV FU1
CAN_H
CAN_L
RAS2
THE LIFT TRUCK IS SHOWN WITH THE
1 PLATFORM LOWERED, GATES DOWN, 1
AND UNATTENDED.
FU7 FU9
FU8
LGT1 P1
M3
FIL1 + FU13
ACCESS 3
+ B-
FU15 B+ U U
20 V V M1 ECR6
CHS4 CHS3 W3 MAST HEIGHT
W ENCODER
17 CA401 10 CHB
1 11 CHA
SVL 22 2 ED COIL DRIVER (-) ED2
2 21
16 TRACTION TEMP
TS1 2
3 +12V +t°
P1 18
5 CHB
8 6 CHA
CAN_H 23
15
4 NEG
CAN_L
ECR3
TRACTION
FAN2
M2
ED1
ACCESS 5
STEER A2
A1 STEER A1 A2
FU10
B+ B-
FU5 15
0+ 35 17
11
FU6 22
I+ 33 30
ED IN ED COIL DRIVER (+)
0+ CA407 CA403 23
CS1 CR10
I+ 27 +5V CR9
BRK 28 SIG CURRENT
I- I- 0- 32
34 12 NEG SENSE
0- BRK REL 4
3
10 CHA
+5V ECR2
K2
7 INDEX STEERING
2 FEEDBACK
8 CHB
120 OHM
PVL 26 21 NEG
5
+BV LOGIC 1
3 B+ SENSE 31
6
3
CAN_H 13
CAN_L 24
9 BNEG SENSE
JC413 RES3
DTS1 RES2
TR2
+t° TR3
FU1
+t° CR11
FU3
4 4
FU2
FU4
ED1 ED2
K2 24V BATT
+
A B C
156642 A 2 of 6
Crown 2016 PF27613 DIA-7335-136
DLV
DLVI
DIA-7335-137
Platform Distribution Panel
Platform Distribution Panel
WIRING DIAGRAMS
4
1
(15) TP15 B NEG
(14) TP14 CAN L
(13) TP13 CAN H
(12) TP12 K1
(11) TP11 K1 COIL
(10) TP10 ED1 FU8
(9) TP9 ED1 FU9
(8) TP8 ALM1
(7) TP7 MODULE POWER
(6) TP6 B FU2
(5) TP5 RAS2
(4) TP4 RAS1
(3) TP3 ED1 FU7
(2) TP2 B+ FU1
(1) TP1 BRAKE
A
A
CA101 CA102 CA103
1 2 3 4 5 6 7 8 1 2 3 4 5 (8)
16 5917 CA302-2 ALM1 NEG
R2 CR12 15
CA107 (15) (7) R1
VR1
14 29124 JC331-1 CHAIN BREAK SWITCHES
515 PC301-3 BNEG CAN ACCESS 1 ALM1 13 29114 (RAS3) LIFTING FORK OPTION
530 CA322-1 BNEG GTS1 2 CR4 (12) 12 2937 CA304-1 +BV KYS ACCESS 4
520 (CA309) BNEG CHS1 3 C1 (11) 11 2925 CA308-4 +BV KYS CONTROL POD
521 CA320-2 BNEG HGTRS 4 CR2 K1A 10 2941 CA302-3 +BV KYS ACCESS 1
+ K1
580 CA323-2 BNEG ACCESS 1 STR POS IND 5 (6) (9) (5) (2) (1) (10) +t TR1 9 29105 CA323-1 +BV KYS STR POS IND
550 CA355-1 BNEG ZSS 6 CR3 CR1 8 2924 CA308-2 IGN
514 CA309-7 BNEG ORS1 7 7 2923 CA308-3 START
513 CA302-4 BNEG ACCESS 1 8 6 207 PC301-4 +BV FU2 CAN ACCESS
B
B
525 CA304-3 BNEG ACCESS 4 9 (3) (4)
5 5904 (CA321) BRAKE SWITCH
524 (CA321) BNEG BRS 10 4 2935 CA308-11 RAS2
522 (CA321) BNEG HN1 11 3 2932 CA308-10 RAS1
512 PC306-3 BNEG CUSTOMER ACCESSORIES 12 2 2997 (CA303) LIFTING FORKS DIODE
BNEG INFOLINK/INTERMEC OPTION 13 1 2940 PC306-2 +BV FU7 CUST ACCY
(13) CA105 2939 PC301-5 +BV ED1 FU7 CAN ACCESS
CA106 (14)
B+ INFOLINK/INTERMEC OPTION 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 205 PC306-1 BV FU1 CUST ACCY
BRAKE SWITCH BLK CA104 RED/BLK BNEG
BV FU1 WHT WHT/BLK BNEG
BV FU2 RED BLU BNEG
BV ED1 FU9 GRN ORG BNEG
BV ED1 FU8 ORG GRN BNEG
BV ED1 FU7 BLU RED CAN L
RAS1 WHT/BLK WHT CAN H
RAS2 RED/BLK BLK BV AK FROM KYS
MC1
2 MC2
001 CA303-7 CAN H ACCESS 4 1
003 CA302-8 CAN H ACCESS 1 6
005 PC301-1 CAN H ACCESS 29
031 CA323-3 CAN H ACCESS 1 STEER POSITION INDICATOR
2
002 CA303-8 CAN L ACCESS 4 1
004 CA302-9 CAN L ACCESS 1
C
C
006 PC301-2 CAN L ACCESS 6
032 CA323-4 CAN L ACCESS 1 STEER POSITION INDICATOR 29
Crown 2016 PF27613
142680 E
1
WIRING DIAGRAMS
Platform Distribution Panel - Forks First SAA
Platform Distribution Panel - Forks First SAA
A B C
1 1
CA101 CA102 CA103
1 2 3 4 5 6 7 8 1 2 3 4 5
R2
16
(8) 5917 CA302-2 ALM1 NEG
CR12 15
(16) R1
CA107 (7)
14 29111 (CA304) CHAIN BREAK SWITCHES
VR1
515 PC301-3 B-CAN ACCESS 1 ALM1 13 29114 (CA701) CABIN DOW SWITCHES
530 CA322-1 B- GTS1 2 CR4 (12) 12 2937 CA304-1 +BV KYS ACCESS 4
520 (CA309) B- CHS1 3 C1 (11) 11 2925 CA308-4 +BV KYS CONTROL POD
521 CA320-2 B- HGTRS 4 CR2 K1A 10 2941 CA302-3 +BV_KYS ACCESS 1
+ K1
580 CA323-2 B- ACCESS 1 STR POS IND 5 (6) (9) (5) (2) (1) (10) 9 29105 CA323-1 +BV KYS STR POS IND
550 CA335-1 B- ZSS 6 CR3 CR1 +t TR1 8 2924 CA308-2 IGN
514 CA309-7 B- ORS1 7 7 2923 CA308-3 START
513 CA302-4 B- ACCESS 1 8 6 207 PC301-4 +BV FU1 CAN ACCESS
525 CA304-3 B- ACCESS 4 9 (3) (4) 5 5904 (CA321) BRAKE SWITCH
524 (CA321) B- BRS 10 4 2935 CA308-11 RAS2
522 (CA321) B- HN1
2 512 PC306-3 B- CUSTOMER ACCESSORIES
11
12
3
2
2932 CA308-10 RAS1 2
13 1 2940 PC306-2 +BV FU7 CUST ACCY
562 CA320-2 PDS CDS (13) CA105 2939 PC301-5 +BV ED1 FU7 CAN ACCESS
(14)
CA106
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 101112 1 2 3 4 5 6 7 8 205 PC306-1 BV FU1 CUST ACCY
BRAKE SWITCH BLK CA104 RED/BLK B-
+BV FU1 WHT WHT/BLK B-
+BV FU2 RED BLU B-
+BV ED1 FU9 GRN ORG B-
+BV ED1 FU8 ORG GRN B-
+BV ED1 FU7 BLU RED CAN L
RAS1 WHT/BLK WHT CAN H
RAS2 RED/BLK BLK +BV AK FROM KYS
MC1
2 MC2
001 CA303-7 CAN H ACCESS 4 1
003 CA302-8 CAN H ACCESS 1 6
005 PC301-1 CAN H CAN ACCESS 29
031 CA323-3 CAN H ACCESS 1 STR POS IND (1) (8) TP8 ALM1
TP1 BRAKE
(2)
2 TP2 B+ FU2 (9)
TP9 ED1 FU9
002 CA303-8 CAN L ACCESS 4 1 (3) TP3 ED1 FU7
004 CA302-9 CAN L ACCESS 1 6
(10) TP10 ED1 FU8
006 PC301-2 CAN L CAN ACCESS 29 (4) TP4 RAS1
032 CA323-4 CAN L ACCESS 1 STR POS IND (11)
(5)
TP11 K1 COIL
TP5 RAS2 (12)
(6) TP12 K1
TP6 B+ FU1
(13)
3 (7) TP7 MODULE POWER
(14)
TP13 CAN H 3
TP14 CAN L
(16)
TP16 B NEG
4 4
A B C
142696 B
Crown 2016 PF27613 DIA-7335-138
DLVII
DLVIII
DIA-7335-139
Power Unit Distribution Panel
Power Unit Distribution Panel
WIRING DIAGRAMS
4
1
121 (CA412) NEGATIVE BRUSH BRUSHWEAR M3
TP19 MMS
TP18 RAS2
TP17 RAS1
TP16 CAN_L
TP15 CAN_H
TP14 INNER BRAKE
TP13 OUTER BRAKE
TP12 BATT SENSE
TP11 K1 OUT
TP10 FU9
TP9 FU8
TP8 FU7
TP7 FU2
TP6 FU1
TP5 ED2
TP4 K2
TP3 BNEG
TP2 ED1
TP1 B+
108 (CA412) POSITIVE BRUSH BRUSHWEAR M3
POSITION 1 AND 2 ARE CLOSED.
5 AND 4 ARE CLOSED, IN THE TOP
NOTE: ON DTS1 IN THE CENTER POSITION
107 (CA412) NEGATIVE BRUSH BRUSHWEAR M4
106 (CA412) POSITIVE BRUSH BRUSHWEAR M4
122 CA401-7 BRUSHWEAR
5930 CA407-5 BRAKE SWITCH
A
A
29129 (CA808) +BV_K2 FU3 PVLF AND SV1 LIFTING FORK OPTION
2959 (CA412) +BV_K2 FU3 SVL
2960 (CA412) +BV_K2 FU3 PVL
2955 PC417-1 +BV_K2 FU3 CHB5
29122 (CA401) +BV_K2 FU3 FAN2 1 2968 CA407-1 BRAKE COIL OUTER
2970 (CA412) +BV_K2 FU3 THS P1 1 2957 CA403-35 BRAKE OUTER
2954 PC415-1 +BV_K2 FU3 CHAIN SLACK 2 2956 CA403-33 BRAKE COIL INNER
2972 CA601-1 +BV_K2 FU3 ACCESS 6 2 2969 CA407-2 BRAKE INNER
2966 CA403-1 +BV_K2 FU3 ACCESS 5 3 208 K15-7 +BV HN2
2953 CA401-1 +BV_K2 FU3 ACCESS 3 3 206 CA403-31 BATTERY SENSE ACCESS 5
29107 CA413-4 DRIVE/TOW FU4 POWER 4 2964 (CA412) +BV_ED1 LGT1
578 CA413-3 DRIVE/TOW BNEG 5 2963 (CA412) ED1 COIL
5109 +BV HN2 6 2961 (CA412) P1 COIL
7 2962 (CA412) P2 COIL
4
29108 CA413-1 BRAKE RESIST 2996 8 2967 CA403-23 CR9 SUPPRESION
29125 CA413-2 BRAKE RESIST 2995
3
585 (CA401) BNEG BB
10
12
13
14
15
16
11
1
4
4
5
8
9
1
2
2
5
7
8
3
6
7
3
6
CA201
CA202
CA418
1
4
5
2
6
3
CR7
CR8
CR6
CR5 R3
29127
R4
29123
DTS1
TP19
6 4 3 1
29124
CR9
5 2
TP12
CR10
586
FU4
TP11
TP6 TP7 TP8 TP9 TP10
B
B
FU1
R5
TP14
RES2
RES3
TP13
K2
TP1
FU2
CA206 1 2 3 4 5 6
FU5
FU7
TP2
FU6
FU8
TP18
TP17
201 (CA401) +BV
TP13
TR2
TP5
202 (CA401) +BV FU9
2901 (CA401) +BV_ED1 +t
2902 (CA401) +BV_ED2
501 (CA401) BNEG BB
TP4
FU3
TP16
502 (CA401) BNEG BB
K2
CA203
TR3 CR11
CA205
CA204
+t TP15 MAST MOUNTED
GRN SPOT LIGHTS (OPTION)
12
10
11
MC2
4
5
1
6
7
8
1
1
4
5
8
9
2
3
4
5
6
7
2
3
6
7
3
9 RED/BLK BNEG
017 CA401-23 CAN_H ACCESS 3 WHT/BLK BNEG
019 CA403-13 CAN_H ACCESS 5 15 BLU BNEG
021 CA601-4 CAN_H ACCESS 6 14 ORG BNEG
018 CA401-15 CAN_L ACCESS 3 9 GRN BNEG
020 CA403-24 CAN_L ACCESS 5 15 RED CAN_L
14
MC1
022 CA601-4 CAN_L ACCESS 6 WHT CAN_H
BLK +BV_AK FROM KYS
RED/BLK RAS2
C
C
WHT/BLK RAS1
BLU +BV_ED1 FU7
ORG +BV_ED1 FU8
GRN +BV_ED1 FU9
Crown 2016 PF27613
RED +BV FU2
WHT +BV FU1
BLK BRAKE SWITCH
156643 A
1
WIRING DIAGRAMS
Access 1 (DCM) and 4 (VCM)
Access 1 (DCM) and 4 (VCM)
A B C
6 CA301 JC301
005 CA105-3 CAN_H 1 CAN 1 4 6 BLK
006 CA105-9 CAN_L 6 2 ACCESS 2 5
515 CA107-1 DISTRIBUTION BNEG 3 3 13 7 WHT MAST
CABLE
207 CA103-6 DISTRIBUTION +BV FU1 4 4 25 8 RED 4
2939 CA103-2 DISTRIBUTION +BV ED1 FU7 5 210 5 15 9 GRN
203 CA308-1 EDS 6 6 24
CA302 INFOLINK
1 5902 CA309-5 DMS1 1 SW AL
1
5917 CA103-16 ALARM 1 2 GPD ACCESS 1
2941 CA103-10 DISTRIBUTION +BV KYS 3 +BV (DCM)
513 CA107-8 DISTRIBUTION BNEG 4 BNEG
5 NEG
6 N/A
1 7 N/A SP 3500
003 CA105-2 CAN_H 1 8 CAN_H
004 CA105-8 CAN_L 9 CAN_L
10N/A CA302
11N/A 1 5
12SW AH/ANA 6 9
5901 CA309-4 ORS1 13SW AL
5903 CA309-6 GUS 14SW AL 10 14
CA323
29105 CA103-9 DISTRIBUTION +BV KYS 1 ACCESS 1
580 CA107-5 DISTRIBUTION BNEG 29 2
031 CA105-4 CAN_H 3 (DCM)
29 4
032 CA105-10 CAN_L GUIDANCE AND
(1) HEIGHT ENCODER (ECR4) 32 PULSE/REV STEER INDICATOR
(2) STEER SENSE ENCODER (ECR1) 32 PULSE/REV
(3) STEER SENSE ENCODER (ECR5) 32 PULSE/REV
CA303
7
2 101 CA309-1 POT1 SIGNAL 1 AN1
2 AN2 ACCESS 4 2
29123 PC331-1 CHAIN BREAK SWITCH 7 3 SW2 / AN1SP (VCM)
701 CA309-2 POT1 +5V 4 +5V
2997 CA103-3 LIFTING FORKS DIODE 2989 2 5 +5V
5912 CA320-1 HGTRS NO 2 6 SW7
001 CA105-1 CAN_H 2 7 CAN_H
002 CA105-7 CAN_L CA327 1 8 CAN_L
29112 (CA701) LMS1 LIFTING FORK OPTION 29139 9 SW1 / AN2SP CA303
29113 (CA701) LOS4 LIFTING FORK OPTION 1 29140 10SW0 / AN3SP
CA328 5 11+5V 1 8
(1) CH A
WHT 1 CH A 703 5 12+5V
9 15
ECR4 CH B BLU 2 CH B 007 5 13ECR1 A
+12V 16
NEG RED 3 +5V 008 5
14ECR1 B 23
BLK 4 NEG 516 15LOGIC NEG
2930 CA308-9 RAS1 CA317 16SW8 / AN4SP
2928 CA308-7 LOS1 17SW9 / AN5SP
2929 CA308-8 LOS2 18SW10 / AN6SP
506 CA309-2 LOGIC NEG POT1 7 581 19RS-232 COM
20RS-232 TX
21RS-232 RX
22SW / INDEX
59136 CA332-1 ZSSA 23SW6
CA304
2937 CA103-12 +BV KYS CA330 1 MODULE POWER
29145 CA701-1 +BV 1 29128 2 DRIVER B+
3 525 CA107-9 DISTRIBUTION B- 3 B- 3
5936 CA701-3 OPTION PVLF COIL DRIVER SUBHARNESS CA325 1 5941 4 PWM1
5935 CA701-4 OPTION SV1 COIL DRIVER SUBHARNESS 1 5942 5 PWM2
CA326 6 PWM3
5980 CA701-2 OPTION TRAVEL ALARM HARNESS CA336 1 5915 7 PWM4 23 16
2927 CA308-6 REVERSE SWITCH 8 SW12 15 9
2926 CA308-5 FORWARD SWITCH 9 SW11 8 1
5916 (CA321) GATE SWITCHES 10SW5
5911 (CA309) CHAIN SLACK SWITCHES 11SW4
12SW3 CA304
59139 CA333-1 ZSSB 13SW15
59138 CA334-1 ZSSC 14SW14
3 15SW13
(2) CH A
WHT 1 CH A 009 3 16ECR2 A
ECR1 CH B
+12V
BLU 2 CH B 010 3 17ECR2 B
NEG RED 3 +12V 312 3 18+12V
BLK 4 NEG 517 4 19LOGIC NEG
(3) CH A
WHT 5 CH A 518 4 20LOGIC NEG
ECR5 CH B BLU 6 CH B 313 4 21+12V
+12V
NEG RED 7 +12V 011 4 22ECR3 A
BLK 8 NEG 012 23ECR3 B
CA318
29123 CA303-3 CHAIN BREAK OPTION
29124 PC103-14 B+ DISTRIBUTION BOARD EU CHAIN
4 1 29110 BREAK OPTION 4
1
CA331
1 29111
CHB7 CHB8
A B C
142682 E
Crown 2016 PF27613 DIA-7335-140
DLIX
WIRING DIAGRAMS
Access 1 (DCM) and 4 (VCM), Forks First SAA
Access 1 (DCM) and 4 (VCM), Forks First SAA
A B C
PC301 JC301
005 CA105-3 CAN_H 6 1 CAN 1 4
006 CA105-9 CAN_L 6 6 BLK
2 ACCESS 2 5 7 WHT MAST
515 CA107-1 DISTRIBUTION BNEG 3 3 13 CABLE
207 CA103-6 DISTRIBUTION +BV FU1 4 4 25 8 RED 4
2939 CA103-2 DISTRIBUTION +BV ED1 FU7 5 210 5 15 9 GRN
203 (CA305) EDS 6 6 24
CA302 INFOLINK
1 5902 (CA309) DMS1 1 SW AL 1
5917 CA103-16 ALARM 1 2 GPD ACCESS 1
2941 CA103-10 DISTRIBUTION +BV KYS 3 +BV (DCM)
513 CA107-8 DISTRIBUTION BNEG 4 BNEG
29298 PDS ALARM 5 NEG
6 N/A
1 7 N/A SP 3500
003 CA105-2 CAN_H 1 8 CAN_H
004 CA105-8 CAN_L 9 CAN_L
10N/A CA302
11N/A 1 5
29299 PDS CREEP REQ 12SW AH/ANA 6 9
5901 CA309-4 ORS1 13SW AL
5903 CA309-6 GUS 14SW AL 10 14
CA323
29105 CA103-9 DISTRIBUTION +BV KYS 1 ACCESS 1
580 CA107-5 DISTRIBUTION BNEG 29 2
031 CA105-4 CAN_H 3 (DCM)
29 4
032 CA105-10 CAN_L GUIDANCE AND
(1) HEIGHT ENCODER (ECR4) 32 PULSE/REV STEER INDICATOR
(2) STEER SENSE ENCODER (ECR1) 32 PULSE/REV
(3) STEER SENSE ENCODER (ECR5) 32 PULSE/REV
CA303
101 CA309-1 POT1 SIGNAL 7 1 AN1
2 2 AN2 ACCESS 4 2
29110 (CA304) CHAIN BREAK SWITCH 7 3 SW2 / AN1SP (VCM)
701 CA309-2 POT1 +5V 4 +5V
5 +5V
5912 CA320-1 HGTRS NO 2 6 SW7
001 CA105-1 CAN_H 2 7 CAN_H
002 CA105-7 CAN_L 8 CAN_L
29112 (CA701) AUX HYD SWITCH 9 SW1 / AN2SP
29113 (CA701) LIMIT SWITCH 10SW0 / AN3SP
CA317 11+5V
WHT 1 CH A 703 5 12+5V
(1) CH A 5
ECR4 CH B BLU 2 CH B 007 13ECR1 A
+12V
NEG RED 3 +5V 008 5 14ECR1 B
BLK 4 NEG 516 5 15LOGIC NEG
2930 (CA305) RAS1 16SW8 / AN4SP
2928 (CA305) LOS1 17SW9 / AN5SP
2929 (CA305) LOS2 18SW10 / AN6SP
506 CA309-3 LOGIC NEG POT1 7 581 19RS-232 COM
2 1 30 20RS-232 TX
013 CA307-2 RS-232 TX 30
014 CA307-3 RS-232 RX 21RS-232 RX
519 CA307-5 RS-232 NEG 30 22SW / INDEX
59136 CA332-1 ZSSA 23SW6
CA304
2937 CA103-12 +BV KYS 1 MODULE POWER
29128 CA701-1 +BV 2 DRIVER B+
525 CA107-9 DISTRIBUTION B- 3 B-
3 5936 CA701-3 OPTION PVLF COIL DRIVER SUBHARNESS 4 PWM1 3
5935 CA701-4 OPTION SV1 COIL DRIVER SUBHARNESS 5 PWM2
5955 CA329-3 GUIDANCE STATUS IN 6 PWM3
5915 CA701-2 OPTION TRAVEL ALARM 7 PWM4
2927 (CA305) REVERSE SWITCH 8 SW12
2926 (CA305) FORWARD SWITCH 9 SW11
5916 (CA321) GATE SWITCHES 10SW5
5911 (CA309) CHAIN SLACK SWITCHES 11SW4
5956 CA329-4 PDS BRAKE REQ2 OUT 12SW3 CA303
59137 CA333-1 ZSSB 13SW15 1 8
59138 CA334-1 ZSSC 14SW14
5957 CA329-5 PDS BRAKE REQ1 OUT 15SW13 9 15
WHT 1 CH A 3 16ECR2 A 16 23
(2) CH A 3
ECR1 CH B BLU 2 CH B 3 17ECR2 B
+12V RED 3 +12V 18+12V 23 16
NEG
4 NEG 3 19LOGIC NEG 15
BLK
4 9
(3) CH A
WHT 5 CH A 4 20LOGIC NEG 8 1
ECR5 CH B BLU 6 CH B 4 21+12V
+12V
NEG RED 7 +12V 4 22ECR3 A CA304
BLK NEG 23ECR3 B
CA318
CHB7 CHB8
29110 CA303-3 CHAIN BREAK 29109
29111 PC103-13 B+ DISTRIBUTION BOARD
4 PC307 4
1
013 CA303-20 RS-232 TX 2
014 CA303-21 RS-232 RX 3
4
519 (CA303) RS-232 NEG 5
6
7
8
9
A B C
142697 D
DIA-7335-141 Crown 2016 PF27613
DLX
WIRING DIAGRAMS
Control Pod and Light Switches
Control Pod and Light Switches
A B C
5912 CA303-6 HGTRS 1 1
HGTRS
521 CA107-4 DISTRIBUTION BNEG 1
PC306
205 CA103-1 +BV FU1 A POWER FOR
1 2940 CA103-2 +BV ED1 FU7 B CUSTOMER ACCESSORIES 1
512 CA107-12 DISTRIBUTION BNEG C
CA308 CA305
203 CA301-6 FU2 1 204 1 2903 1 START
2924 CA103-8 IGN 2 EDS
2904 2 BATT ACC
2923 CA103-7 START 3 2905 3
2925 CA103-11 +BV KYS FROM DIST 4 2906 4 IGN
2926 CA304-9 FS 5 2907 OFF
2927 CA304-8 RS 6 2908
2928 CA303-17 LOS1 7 2909 FS KYS
2929 CA303-18 LOS2 8 2910 1 2938
2930 CA303-16 RAS1 9 2911 RS 2915
2932 CA103-3 RAS1 10 2912 1 BATT ACC
2935 CA103-4 RAS2 11 2913 LOS1 CA324
2936 (CA321) HNS 12 2914 2917 1
1 START
LOS2 GND
2918 IGN
1
2 RAS1 BACK VIEW OF KYS 2
1 2919
RAS2 2921
1
HNS
1 2922
CA309
101 CA303-1 POT1 WIPER 7 1 GRN POT1
701 CA303-4 POT1 +5V 7 2 ORG
506 CA303-19 POT1 NEG 7 3 VIO
5901 CA302-13 ORS1 4 5905 ORS1
5902 CA302-1 DMS1 5 5906 1
5903 CA302-14 GUS 6 5907 DMS1
514 CA107-7 DIST BNEG 7 527 1 529
8 5939
GUS 528
1
CHS1 CHS2
3 5911 CA304-11 CHS1 1 5918 1 3
520 CA107-3 DIST BNEG
CA332 ZSS
59136 CA303-23 ZSSA 1 BRN
CA333
59137 CA304-13 ZSSB 1 WHT
CA334
59138 CA304-14 ZSSC 1 BLU
CA335
550 CA107-6 BNEG 1 BLK
GRN
(CA321)
(FOR REFERENCE ONLY) HN1
2936 CA308-12 HNS 1
522 CA107-11 DIST BNEG
5904 CA103-5 BRS 1 BRS
4 4
524 CA107-10 DIST BNEG
5916 CA304-10 GTS2
CA322 GTS1 GTS2
530 CA107-2 DIST BNEG 1 582 1 5919 1
A B C
142683 D
Crown 2016 PF27613 DIA-7335-142
DLXI
WIRING DIAGRAMS
Overhead Guard Lights / Fans
Overhead Guard Lights / Fans
A B C
LGT2
503 1
301
LEFT SIDE ASSEMBLY LEFT WORKLIGHT
PS1
POWER SUPPLY
CA501
1 12V OUT
1 535 1 504 2 1
536 2 505 3 BATT COMM
2950 3 2990 4 BV INPUT
303 4 302
2951 5 2931
305 6 310 2998
2948 7 5106
TO PLATFORM WALL 5105 8
9 PS2
POWER SUPPLY
309 1 12V OUT
TO MODULE
HSG 2
3 BATT COMM
CAP1 4 BV INPUT
541
OPTION
LGT3
1 BLK
542 LGT4
RED BLK 1
-
LEFT DOME LIGHT
535 1234 5 LEFT SPOTLIGHT
2 536 TB502
2
PC102 LGS1 1 PC338
2942 1 MAST MOUNTED
1
2 2943 LGS2 SPOTLIGHTS
3 534 533 1
4 2944
5 1 2952
COPIED FROM LGS3 29135
DISTRIBUTION
BOARD PAGE 29451
FNS1 WHEN MAST MOUNTED SPOTLIGHTS ARE
PRESENT, THE MAST CABLE PLUGS INTO PC338
3 3
LGT7
BLK RED 1
FAN1 RIGHT SPOTLIGHT
CA503 507
533 1 508 1 FAN SUPPRESSOR
534 2 510
303 3 307 1
2947 4 2992 2
305 5 308 3 V CXX
2946 6 2916 2933 4
2949 7 2920 5
TO PLATFORM WALL 5107 8 5108 RES1
9 1 2934
SB30
TO MODULE CAP1
4 RIGHT SIDE ASSEMBLY HSG 4
LGT6
1 BLK LGT5
RIGHT DOME LIGHT 1
509 RIGHT WORKLIGHT
A B C
142687 E 1 of 2
DIA-7335-143 Crown 2016 PF27613
DLXII
WIRING DIAGRAMS
Overhead Guard Spotlights (Optional)
Overhead Guard Spotlights (Optional)
A B C
LEFT
1 1
LGT4
PC102
2 1 2
2 RED
3 BLK
4 BLK
5 WHT
WHT
RIGHT
3 3
LGT7
4 4
A B C
142687 E 2 of 2
Crown 2016 PF27613 DIA-7335-144
DLXIII
WIRING DIAGRAMS
Access 3™ (TCM)
Access 3™ (TCM)
A B C
FAN2
1
29122 CA201-8 +BV K3 FU3 FROM DIST 5908
579 CA411-2 M1 TEMP SENSOR CA401
2953 CA201-5 +BV K2 FU3 FROM DIST 1 MODULE POWER
1 5920 (CA412) ED2 COIL - 2 GPD 1 1
316 CA411-3 +12V TO ECR3 8 3 +12V ACCESS 3
549 CA411-6 LOGIC NEG TO ECR3 8 4 LOGIC NEG
029 CA411-4 TRACTION ENCODER CHB 8 5 ECR1 A U
028 CA411-5 TRACTION ENCODER CHA 8 6 ECR1 B U M1
122 CA201-12 BRUSH WEAR 7 AN2 V V
8 GPD 5 W 3
WHT
1 014 9 POT CMD W
CH A
(1) CH B
BLUE
2 013 10 DI8/ECR2 B
3 330
+12V RED
NEG 11 DI7/ECR2 A
4 581
BLK 316 DUAL HEIGHT ENCODER DETECT
12 DI5/ID1
2975 (CR412) MOTOR 4 THERMAL INPUT 13 DI3
2971 (CR412) MOTOR 3 THERMAL INPUT
9 14 DI2
018 CA204-7 CAN L 15 CAN L
103 CA408-9 TRACTION MOTOR TEMP FROM FSB1 8 16 TEMP (+)
2973 PC414-1 POWER UNIT CHS3 17 DI4/ID0
5923 (CA412) P1 COIL LOW SIDE DRIVER 18 GPD 2 CA401
29148 (CA612) PDS ACTIVE 19 DI1
2974 CA416-1 CHB4 20 DI6/AN1 1 8
5924 (CA412) P2 COIL LOW SIDE DRIVER 21GPD 3 9 15
5925 (CA412) SVL LOW SIDE DRIVER 22 GPD 4 B+ + B- 16 23
017 CA404-1 CAN H 9 23 CAN H
(1) ENCODER BEARING PULSE/REV
2 2
543 (CA412) ED1 COIL FU10
544 (CA412) STROBE LIGHT LGT1
547 (CA403) BATTERY RESTRAINT SWITCHES 1
548 (CA403) RAIL GUIDE SWITCHES 1
551 CA403-9 BATTERY SENSE ACCESS 5 2
552 CA601-2 B- BB TO ACCESS 6 BNEG ED2
585 CA418-C BRAKE RESISTOR
595 CA611-3 PDS B- 3
561 CA612-7 PDS B-
553 CA808-1 FREEZER CONDITIONING 4
554 CA808-2 FREEZER CONDITIONING
563 (CA809) MAST SPOT LIGHTS +
502 CA206-6 B- BB POWER TO DIST
501 CA206-5 B- BB POWER TO DIST
201 CA206-1 +BV POWER TO DIST
202 CA206-2 +BV POWER TO DIST 1
ED1
2901 CA206-3 +BV ED1 POWER TO DIST
2977 CA808-3 +BV ED1 FREEZER CONDITIONING
3 2978 CA808-4 +BV ED1 FREEZER CONDITIONING 3
2979 CA808-5 +BV ED1 FREEZER CONDITIONING
2902 CA206-4 +BV ED2 POWER TO DIST
CHS3
CA414
2973 CA401-11 CHAIN SLACK SWITCHES TO ACCESS3 1 BLK
CA415 CHB4
2954 CA201-7 DIST +BV K2 FU3 1 BLK
CA416
2974 CA401-20 CHAIN BREAK SWITCHES TO ACCESS3 1 RED CHS4
2955 CA201-8 DIST +BV K2 FU3 1 RED
CA417 CHB5
4 4
WHT GRN
A B C
156644 A
DIA-7335-145 Crown 2016 PF27613
DLXIV
WIRING DIAGRAMS
Access 5 (SCM)
Access 5 (SCM)
A B C
2966 CA201-6 +BV K2 FU3 FROM DIST BOARD 1 B+
2958 (CA412) PVL COIL 2 DRIVER B+ ACCESS 5
706 CA410-4 +5V ECR2 12 3 +5V
5932 CA407-6 BRAKE DISCONNECT (SCM)
4 DTS
5927 (CA403) BRES INPUT 5 SW_SPARE
5931 (CA403) RAIL GUIDANCE SWITCHES 6 RGS
027 CA410-5 INDEX ECR2 12 7 ECR INDEX
026 CA410-3 CHB ECR2 12 8 ECR2 B
1 551 (CA401) BNEG BB
025 CA410-1 CHA ECR2 12 9 BDI SENSE NEG
10 ECR2 A
1
11 ECR1 B
545 CA406-3 LOGIC NEG CS1 13 12 LOGIC NEG A1
019 CA204-2 CAN_H 15 13 CAN1 H
14 B+
15 +5V
16
17 ECR1 A A2
18
19 B-
12 20
540 CA410-2 LOGIC NEG ECR2 21 LOGIC NEG
22 LOGIC NEG
2967 CA202-8 ED DRIVER FEED CR9 DIST BOARD 23 ED_+BV
020 CA204-8 CAN_L 15 24 CAN1 L
25 B NEG
5926 (CA412) PVL COIL DRIVER 26 MH_LO
705 CA406-1 +5V CS1 13 27 +5V
104 CA406-2 SIGNAL CS1 13 28 BDI CURRENT SENSE
29 TRAVEL_OR
2965 (CA412) ED2 COIL 30 ED SOURCING DRIVER
206 CA202-3 BATTERY SENSE 31 BDI SENSE POS CA403
5928 CA407-3 INNER BRAKE COIL DRIVER 32 BRAKE INNER DRIVER
2956 CA202-2 DIST+BV ED2 FU6 INNER BRAKE DRIVER FEED 33 B+ BRAKE FEED INNER
1
5929 CA407-4 OUTER BRAKE COIL DRIVER 34 BRAKE OUTER DRIVER 35
2 2957 CA202-1 DIST+BV ED2 FU5 OUTER BRAKE DRIVER FEED 35 B+ BRAKE FEED OUTER 2
OPTIONAL RAIL GUIDE AND
BATTERY RESTRAINT
5927 CA403-5 BRES TO ACCESS 5 1 BRES15933 1 BRES2
547 (CA401) BNEG BB
5931 CA403-16 RGSL 1 RGSL 5934 1 RGSR M2
548 (CA401) BNEG BB
CA406
705 CA403-27 +5V FROM ACCESS 5 13 A VIO +
104 CA403-28 CURRENT SIGNAL TO ACCESS 5 13 B BRN 0 I CS1
545 CA403-12 LOGIC NEG FROM ACCESS 5 13 C GRN
CA407
1 WHT 0+
2968 CA202-1 +BV ED2 FU5 TO OUTER BRAKE COIL
2969 CA202-2 +BV ED2 FU6 TO INNER BRAKE COIL 2 BLU I+ BRK
5928 CA403-32 INNER BRAKE DRIVER 3 YEL I-
5929 CA403-34 OUTER BRAKE DRIVER 4 ORG 0-
5930 CA201-11 BRAKE SWITCH FROM DIST 5 5971
3 5932 CA403-4 BRAKE SWITCH TO ACCESS 5 6 3
JC413
29108 CA418-A BRAKE RESISTOR 1
29125 CA418-B BRAKE RESISTOR 2
578 CA201-1 BRAKE/TOW BNEG 3 DRIVE/TOW
29107 CA201-2 BRAKE/TOW FU4 POWER 4
5
(1) SENSOR BEARING 64 PULSE/REV 6
TRACTION MOTOR
(2) SENSOR BEARING 32 PULSE/REV
CA411 T+
105 CA401-16 TEMPERATURE ACCESS 3 105 11 1 BRN
579 (CA401) BNEG 2 579 11 2 R/W
315 CA401-3 +12V ACCESS 3 315 11 3 RED +12V
029 CA401-5 ECR3 CHB TO ACCESS 3 029 11 4 BLU CHB
028 11 5 ECR3
028 CA401-6 ECR3 CHA TO ACCESS 3 11 6 BLK WHT CHA
(1)
549 CA401-4 LOGIC NEG ACCESS 3 549 NEG
4 CA410 4
025 CA403-10 CHA TO ACCESS 5 12 1 BLU CHA STEERING
540 CA403-21 LOGIC NEG FROM ACCESS 5 12 2 BLK NEG FEEDBACK
026 CA403-8 CHB TO ACCESS 5 12 3 ORG CHA ECR2
706 CA403-3 FROM ACCESS 5 12 4 RED +5V (2)
027 CA403-7 INDEX TO ACCESS 5 12 5 YEL INDEX
6
A B C
156645 A
Crown 2016 PF27613 DIA-7335-146
DLXV
WIRING DIAGRAMS
Hydraulics and Optional MMS
Hydraulics and Optional MMS
A B C
(CA412)
FOR REFERENCE ONLY
2960 CA201-9 DIST +BV K2 FU3 TO PVL COIL 1
PVL
2958 CA403-11 PVL COIL SUPPRESION
5926 CA403-26 PVL COIL DRIVER
1 1 SVL 1
5925 CA401-22 SVL COIL DRIVER
2959 CA201-10 DIST +BV K2 FU3 TO SVL COIL
PVL
SVL
HYDRAULIC BLOCK
1
2961 CA202-6 DIST TO P1 COIL P1
5923 CA401-18 ACCES 3 TO P1 COIL
2 2962 CA202-7 DIST TO P2 COIL
1
P2
2
5924 CA401-21 ACCES 3 TO P2 COIL
1
2963 CA202-5 ED1 COIL ED1
543 (CA401) B- BB
1
5920 CA401-2 ACCESS 3 TO ED2 COIL - ED2
2965 CA403-30 ACCESS 5 TO ED2 COIL
2964 CA202-4 DIST BV ED1 LGT1 STROBE LIGHT
544 (CA401) B- BB LGT1
1 2 3 4 5
3 +
FIL1 3
2971 CA401-10 M3 THERMAL SWITCH TO ACCESS 3 THS-P1
2970 CA201-6 +BV K2 TO THS-P1 1 PUMP 1 MOTOR
M3
2976 1
108 CA201-15 POSITIVE BRUSHWEAR BW-P1
121 CA201-16 NEGATIVEBRUSH WEAR
2975 CA401-13 M4 THERMAL SWITCH TO ACCESS 3 THS-P2
1 PUMP 2 MOTOR
M4
1
106 CA201-13 POSITIVE BRUSHWEAR
107 CA201-14 NEGATIVE BRUSHWEAR BW-P2
4 MOTOR MANGEMENT OPTION 4
A B C
156646 A
DIA-7335-147 Crown 2016 PF27613
DLXVI
WIRING DIAGRAMS
Access 6 (GCM) (Optional)
Access 6 (GCM) (Optional)
A B C
CA602
901 27
EAC A1 TEST
903 28 1
BLUE 25 2 EAC B1 TEST ACCESS 6
CA601 3 LD WHL GUIDE BAR +5V
2972 CA201-6 DIST +BV K2 FU3 1 29195 MODULE POWER
ORANGE 24 4
021 CA204-3 DIST CAN H 2 5 STR WHL GUIDE BAR COIL TEST
552 (CA401) B- BB 3 ORANGE 25
6
BROWN 25 LD WHL GUIDE BAR COIL TEST
022 CA204-9 DIST CAN L 4 7 LD WHL GUIDE BAR COIL 4
1 B1 A1
RED 25
8 LD WHL GUIDE BAR COIL 3 1
EAC BLACK 25
9 LD WHL GUIDE BAR COIL 2
5 5 CA608 BLACK 24
SENSOR 314 10 STR WHL GUIDE BAR COIL 2
575 GREEN 24 11 STR WHL GUIDE BAR COIL 1
BROWN 24
12 STR WHL GUIDE BAR COIL 4
081 14 13 CAN H
CA607 YELLOW 25
1 901
109 BLUE 24
14 LD WHL GUIDE BAR B NEG
15 STR WHL GUIDE BAR +5V
2 052 16
3 902 5140 17 B-
EAC 4 110 YELLOW 24 18 STR WHL GUIDE BAR B NEG
5
6 053 19
7 903 GREEN 25
20
8 111 575 26
21 LD WHL GUIDE BAR COIL 1
9 054 RED 24
22 EAC SENSORS B NEG
10 904
23 STR WHL GUIDE BAR COIL 3
082 14 24 CAN L
11 112 902 27 25 EAC A2 TEST
12 055 904 28 26 EAC B2 TEST
EAC 5 5 054 28 27 EAC B1 DIGITAL
SENSOR B2 A2 055 28 28 EAC B2 DIGITAL
052 27 29 EAC A1 DIGITAL
314 26 30 EAC SENSORS +12V
053 27 31 EAC A2 DIGITAL
109 27 32 EAC A1 ANALOG CA602
GS1 110 27 33 EAC A2 ANALOG 1
2 CA603
111
112
28
28
34 EAC B1 ANALOG 35
2
35 EAC B2 ANALOG
1 GREEN
COIL 4
2 BLACK
COIL 3
YELLOW
B NEG 3
STEER WHEEL 4 BLUE
+5V 5
SENSOR BAR SLF TST 6 ORANGE
COIL 2 7 RED
COIL 1 8 BROWN
9
GS2
CA604
COIL 1 1 GREEN
COIL 2 2 BLACK
YELLOW
B NEG 3
LOAD WHEEL 4 BLUE
SENSOR BAR SLF+5V 5 ORANGE
TST 6
RED
3 COIL 3 7
BROWN 3
COIL 4 8
9
LOAD WHEEL BAR
C1 C2 C3 C4
EAC SENSORS
B2 A2 A1 B1
4 4
C1 C2 C3 C4
STEER WHEEL BAR
A B C
156647 A
Crown 2016 PF27613 DIA-7335-148
DLXVII
WIRING DIAGRAMS
Travel Alarm and Freezer Conditioning (Optional)
Travel Alarm and Freezer Conditioning (Optional)
A B C
CA807 2980 2985 1 RES5
1 2981 1 RGSR
CA808 K12A 2 555 1
553 BNEG BB 1 3 556 558 RES6
554 BNEG BB 2 FU11 4 1
5 2982 RGSL
2977 ED1 3 K12B
2978 ED1 4 6 557 559
1
7 29153 RES7
2979 ED1 5 FU12 1
1 8 598
9 2983 1
BRES1 1
K11 K11A 10 2986 RES8
2984 1
LIFTING FORKS OPTION 11 29152 BRES2
12 RED/WHT
K12 29151
29154
SV1 5937
29130 THS2
THS-2
29151
29153
K15 PVLF 5938
29129
5981
29152
1 WHT 1
598
RES9
1 BLK 1 CHS3
CA809
1 2345 67 8 WHT 1
HN2 RES10
208 CA202-3 BV KYS BLK 1
WHT/BLK
CHS4
RED
ORG
BLK
K15 CHS4
RED/BLK
5109 CA201-1 RED/WHT
WHT
GRN
BLU
POWER UNIT
2 2
RED/BLK
PLATFORM
PLATFORM
WHT/BLK
ORG
WHT
GRN
RED
BLU
BLK
CA701
CA701
1 2345 67 8
JC330
29128 CA330-1 BV KYS 1 29145 564 1
RES19
5915 CA336-1 BNEG 1 5980 2991 1 CHS1/CHB4
565 1
JC336 THS3 2993 RES20
29131 29132 1 CHS2/CHB5
LIFTING FORKS OPTION 566 1
2994 RES25
1 HGTRS
5936 CA325 OPTION SUBHARNESS PVLF COIL DRIVER 560 1
5935 CA326 OPTION SUBHARNESS SV1 COIL DRIVER 29106 RES21
1 GTS5
511 1
29112 CA327 LMS1 LIFTING FORK OPTION 2987 RES22
RAS3 RAS4 LMS1 1 GTS6
29114 CA103-13 RAS3 LIFTING FORK OPTION 570
29116 29118 2999 1
29115 RES18
LOS3 LOS4 1
29117 BRS
3 29100 571 RED/WHT 3
29113 CA328 LOS4 LIFTING FORK OPTION
CA702 1 2
VARIABLE PALLET GRAB OPTION
CA704 29121 572
5150 5151 RES17
1
29101 RS 573
RES40 RES41 CA703 RES16
1 29102 FS 574
29181 29180
RES15
HNS1
29103 583
RES14
LIFTING FORKS OPTION RAS/LOS
29104 584
5115 5114 5113 5112 RES13
EDS 587
29119
1 1 1 1 1
4 1
RES12 4
588 GTS2
RES35 RES36 RES33 RES34 29120 1 RES11
1 GTS1
1 1 1 1 CA704 523
1 589 2988 1 RES111
1 1
29174 2989 DMS1
29177 29176 29175 CA703 RED/WHT
A B C
142689 H 1 of 2
DIA-7335-149 Crown 2016 PF27613
DLXVIII
WIRING DIAGRAMS
Travel Alarm and Pallet Grab
Travel Alarm and Pallet Grab
A B C
29169 CA205-5
FU19
29170 CA205-6
FU18
5123 CA203-6
FU17
5124 CA203-7
FU16
1 1
29168
5122
29154
K15
PALLET GRAB
29167
5121
5981
TRAVEL ALARM
CA810
1234567 8
HN2
208 CA202-3 BV KYS
WHT/BLK
K15
RED
ORG
BLK
RED/BLK
5109 CA201-1
WHT
GRN
BLU
POWER UNIT
PLATFORM
WHT/BLK
WHT/BLK
WHT
ORG
GRN
RED
BLK
TRAVEL ALARM BLU
CA705
2 2
1234567 8
JC330
29173
5126
29128 CA330-1 BV KYS 1 29145
5915 CA336-1 BNEG 1 5980
29172
JC336
5125
911 1
29171 2
5127 914 3
915 DB1
PGS1
6 7 8 9 10
6
PGS1
1 2 3 4 5
4
3 913 3
912
916
4 3 2 1
PALLET GRAB
4 3 2 1 PALLET GRAB
917 COM
CLOSE PGLS1
NO JAWS
919 NC
921
923
4 4
SB1
920 COM M5
OPEN
NO JAWS
918 NC 924
922
A B C
142689 H 2 of 2
Crown 2016 PF27613 DIA-7335-150
DLXIX
WIRING DIAGRAMS
Forks First Option with Heaters
Forks First Option with Heaters
A B C
RED/WHT
CA807 1
2980 2985 RES5
1 2981 1 RED/WHT
RGSR
CA808 K12A 2 555 1 RED/WHT
553 B- BB 1 3 556 558 RES6
FU11 4 2982 1 RED/WHT
554 B- BB 2 K12B 5 RGSL
2977 ED1 3 6 557 1 RED/WHT
1 2978 ED1 4
FU12 7 29153
559 RES7 1
2979 ED1 5 8 598 1 RED/WHT
BRES1
RED/WHT
K11A
9 2983 2986 1
K11 K11A
10 2983 RES8
11 29152 1 RED/WHT
BRES2
LIFTING FORKS OPTION 12 29153
OPTION K12
29154 THS-2
SV1 5937
29130
K15
PVLF 5938
29129 RED/WHT
WHT
1 1
5981 BLK RES9
1 1 RED/WHT
29151
29152
29153 CHS3
598 RED/WHT
WHT
CA809 1
BLK RES10
K15
K15 1 234 567 8 1 RED/WHT
CHS4
208 CA202-3 +BV KYS
ORG
WHT/BLK
RED
BLK
RED/BLK
2 2
RED/BLK
5109 CA201-1
HN2
WHT
BLU
GRN
POWER UNIT
PLATFORM
WHT/BLK
RED
ORG
RED/BLK
BLK
BLU
WHT
GRN
CA701
1 234 567 8
RED/WHT
29128 CA304-2 +BV KYS 29145 564 1
RES19
2991 1 RED/WHT
CHS1/CHB7
5915 CA304-7 BV- 5980 565 RED/WHT
2993 1
29131 29132 RES20
1 RED/WHT
CHS2/CHB8
THS-3 2994
566 1 RED/WHT
LIFTING FORKS OPTION RES25
1 RED/WHT
5936 CA325 OPTIONS SUBHARNESS 560 RED/WHT
HGTRS
3 PVLF COIL DRIVER 29106 1
RES21
3
5935 CA326 OPTIONS SUBHARNESS 1 RED/WHT
GTS5 LIFTING FORKS
SV1 COIL DRIVER 511 1 RED/WHT OPTION
2987
29113 CA303-10 LIMIT SWITCH RES22
1 RED/WHT LIFTING FORKS
GTS6 OPTION
570 1 RED/WHT
29112 CA303-9 AUX HYD SWITCH 2999 RES18
AUX 1 RED/WHT
BRS
29114 CA103-13 +BV ED2 29100 571
29115 LMS1
CA702 1 2
29121
572
29120
588
589 2989
DMS
573 29101
4 AUX 4
574 29102
583 RS
29103
584 FS 29104
587 RAS/LOS
29119
EDS
A B C
142700 E
DIA-7335-151 Crown 2016 PF27613 Rev. 1/18
01 Rev. 1/18
DLXX
WIRING DIAGRAMS
Power Cables
Power Cables
A B C
BATT + ITEM 14
BNEG ITEM 15
1 1
FU15
FU10
FU14
FU13
ED2 ED1
ITEM 12
W V U
ACCESS 3® ITEM 7 ITEM 10 A1
(TCM) ITEM 11 A2
U V W P1
B+ + B-
ITEM 2
ITEM 8 ITEM 6
2 ITEM 9
ITEM 5
ITEM 3
2
ITEM 4
M3 M4
(PUMP 1) (PUMP 2)
ACCESS 5 B- P2
(SCM) M1 ITEM 1
M2 (TRACTION)
(STEERING)
ITEM 13
ACCESS 6
(GCM)
3 3
ITEM SP 3520/SP 3550 SP 3505 SP 3510 SP 3511/SP 3512 SP 3521/SP 3522
1 084571-230 PC#1 NOT USED NOT USED NOT USED 084571-230 PC#1
2 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1 084571-230 PC#1
3 084571-231 PC#1 NOT USED NOT USED NOT USED 084571-231 PC#1
4 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1 084571-307 PC#1
5 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1 084571-309 PC#1
6 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1 084571-310 PC#1
7 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1 084571-308 PC#1
8 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0 084573-253 PC2/0
9 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0 084573-252 PC2/0
4 10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 090963-052 PC#10 4
11 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10 090963-053 PC#10
12 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10 090963-050 PC#10
13 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10 090963-051 PC#10
14 084573-250 PC2/0 084571-313 PC#1 084573-250 PC2/0 084573-257 PC2/0 084573-257 PC2/0
15 084573-251 PC2/0 084571-314 PC#1 084573-251 PC2/0 084573-258 PC2/0 084573-258 PC2/0
A B C
142690 D
Crown 2016 PF27613 DIA-7335-152
01 Rev. 1/18
DLXXI
WIRING DIAGRAMS
Wire Harnesses
Wire Harnesses
Harness P/N Connected By:
Power unit
156271 (1) (3) Wire guidance / EAC harness: JC602, PC603, PC604, PC607, PC608
156272 (1) (3) Wire guidance harness: JC602, PC603, PC604
156273 (1) End aisle harness (EAC): JC602, PC607, PC608
141028 (1) Freezer condition harness: PC807, PC808, PC809, B-BB, BRES1, BRES2, CHS, ED1, MAST
SPOT LIGHTS, PVL, RGSL, RGSR, SV1, THS2
142216-001 Wire guide harness extension
156278 (1) (4) Wire guidance / EAC harness: JC602, PC603, PC604, PC607, PC608
156279 (1) (4) Wire guidance harness: JC602, PC603, PC604
143590 Travel alarm harness (power unit): CA201, CA202, K15, PC809, HN2
145255 Pallet grab harness with travel alarm (power unit): CA201, CA202, CA203, CA205, PC809,
HN2, K15
146557 Power harness: PC206, B-, B+, ED1, ED2
146764 Access 5 to steer motor
156103 Power unit harness: PC201, PC202, PC204, PC401, PC402, JC403, PC406, JC407, JC410,
PC411, JC413, PC414, PC415, PC416, PC417, PC418, PC419, PF420, PC421, PC601, BNEG,
BRES1, BRES2, BW-P1, BW-P2, ED1, ED2, LGT1, P1, P2, PVL, RGSL, RGSR, SVL, THS-P1,
THS-P2, FAN, ECR6, MAST SPOTLIGHT
Platform
134322 (1) Positive / negative accessory harness
140106 Platform harness: PC103, PC105, PC107, JC301, PC301, PC302, PC303, PC304, PC306,
PC308, PC309, PC317, PC318, PC322, JC322, PC325, PC328, PC330, PC331, CA332,
PC333, PC334, JC335, BRS, CHS1, CHS2, GTS1, GTS2, HGTRS, HN1, HN2
140108 Overhead guard left wire harness: JC310, JC311, PC314, PC315, PC316, PC501, LGS1, LGS2
140109 Overhead guard right wire harness: JC312, JC313, JC314, JC315, JC316, PC338, PC503,
FNS, LGS3
140170 (2) Platform chain break harness: CHB7, CHB8, JC331, PC331 (CA331)
140290-001 (1) InfoLink® harness: ALARM, CAN, CURRENT, LOAD, MODULE, PROG, PROX, RS232,
SHOCK
141029 (2) Options harness: JC314, JC325, JC326, JC330, PC701, PC702, BRS, CHS3, CHS4, GTS4,
GTS5, GTS6
141214 (1) InfoLink® harness: CAN, PROX, SHOCK
(1) Optional
(2) SAA / EU lift trucks only
(3) US lift trucks only
(4) EU lift trucks only
DIA-7335-153 Crown 2016 PF27613 Rev. 1/18
01 Rev. 1/18
DLXXII
WIRING DIAGRAMS
Wire Harnesses
Harness P/N Connected By:
Platform (continued)
142218 Forks Steering harness: PC102, PC103, PC105, PC107, JC301, PC302, PC303, PC304, PC305,
First PC306, PC309, PC317, PC318, PC323, PC329, PC332, JC333, PC334, JC335, PC501,
PC503, PC701, JC705, AUX, BRS, BS1, CBS7, CBS8, CDS, SHS1, CHS2, DMS, EDS, FNS1,
GSI, GTS1, GTS2, HGTRS, HN1, HN2, HNS1, LGS1, LGS2, LGS3, LOS1, LOS2, ORS1,
RAS1, RAS2, RS, LMS1, FS, RS, LOS3, GUIDANCE
143589 (1) Travel alarm harness: JC330, JC336, PC701
145166 Pallet grab harness (platform): JC339, M5, PGS2, PGS3, SB1
145254 Pallet grab harness with travel alarm (platform): JC330, JC336, PC339, PC701, DB1, PGS1
147135-001 Mast height encoder harness: PC422
through
147135-004
149720 InfoLink® / intermec cable assembly
149721 InfoLink® / intermec harness: PROX, RS232
149722 PROX extender harness: PROX
150354 (1) Windows® InfoLink® CAN breakout harness: ALARM, CAN, CURRENT, LOAD, PROG, PROX,
MODULE, RS232, SHOCK
154727 Platform PDS harness (EMEA only)
158662 InfoLink® LC filter harness
161759 Spotlight harness: PC505
161947 Mast spotlights: PC811, PC812
162190 Overhead guard left harness: PC501, PC508, JC507, PC506, JC505, FAN, WRKLGT
162191 Overhead guard right harness: PC503, PC512, JC511, PC510, JC509, FAN, WRKLGT
162192 Lights / fan modules harness: JC501, PC102, PC338, JC503, LGS1, LGS2, LGS3, FNS
(1) Optional
Crown 2016 PF27613 Rev. 1/18 DIA-7335-154
01 Rev. 1/18
DLXXIII
Notes:
DLXXIV
SCHEMATIC DIAGRAMS
Introduction to Diagram Use
Introduction to Diagram Use of the lift truck section is necessary for the applicable
lift truck setup.
Electrical schematics The page titles show the section of the lift truck wires
Schematics are designed to provide a high-level view on each page.
of the complete lift truck electrical system. They can be Components
used to diagnose and understand the electrical path of
major components in a specific circuit. Components such as solenoids, valves, encodes, or
switches in schematics and pictorials are identified by
Pictorials symbols and reference designators. See the Electrical
Pictorials are designed to provide a detailed view of the System section for more information. Reference desig-
lift truck electrical system. The circuits are shown nators are a short form of the component name.
across multiple pages. Components, connectors, and Connectors
wire are all part of pictorials. Each circuit always begins
on the left side of the page and has its connecting page A connector can be a single connection, a plug indi-
identified also. cated by PC, a jack indicated by JC. A combination of
a plug and a jack together are indicated by CA in the
The terminal board and connector numbers on the pic-
diagrams. Connectors that have multiple connections
torials are in two groups: power unit and platform. The
are indicated by pin numbers. For example, PC120-2
power unit terminal boards and connectors are as fol-
indicates that the -2 is the pin number in connector
lows:
PC120.
• 200s
• 400s Wiring
• 600s Wiring identifies the conductor connecting the compo-
• 800s nents. Standard circuits are indicated by a solid line
representing the wire. Optional features are indicated
The platform terminal boards and connectors are as by dashed lines representing the wire. Each wire has a
follows: color, number, and arrow associated with it. Wires iden-
• 100s tified by color are from a different manufacturer.
• 300s The wire arrows indicate whether the component is re-
• 500s ceiving or sending the signal. This helps identify the
• 700s source of the signal or voltage.
• 900s
The wires start at a specified location such as the dis-
tribution board. The connection points start from the
lowest number. The next connection point from the dis-
tribution panel is with the next group of 100s and con-
tinue for each connection point away from the specified
location.
The terminal board and connector numbers are in se-
quence on each page. A wire address with a connector
number or terminal board number shows which direc-
tion to look in the electrical diagrams for the other end
of the wire. When the wire goes to a component and
not a terminal board or connector, the pictorial shows a
terminal board to refer to. This terminal board is not a
solid line and has the terminal board number in paren-
theses. This terminal board is not on the lift truck.
Each page includes a section of the lift truck. When a
feature on the lift truck is not standard, a new page in-
cludes the standard and feature wires. Only one page
Crown 1991 PF8974 Rev. 3/22 DIA-ITD-001
04 Rev. 3/22
787
Notes:
788
HYDRAULIC SCHEMATIC
Single Speed Lift
Single Speed Lift
Single Speed Lift
Lift Control
To Lift
Cylinder
(a) Accumulator, precharged to 3447.4 kPa (500 psi)
(b) Lift control manifold block for Single Speed Lift
(c) RV1 preset to 19201.9 to 19374.3 kPa (2785 to 2810 psi) for TT mast
and 16133.7 to 16306.1 kPa (2340 to 2365 psi) for TL mast
(d) Lift Pump and motor, P1 output: 25.4 l/m at 3447.4 kPa (500 psi),
17.8 l/m at 12410.6 kPa (1800 psi)
(e) Return line filter, 10 micron nominal
(f) Reservoir capacity is approximately 13 liters (3.5 gal) for trucks with
single speed lift
(g) Suction strainer, 100 mesh
Figure 15744-01
Crown 2007 PF15666-1 Rev. 1/08 HYD-7335-001
01 Rev. 1/08
491
HYDRAULIC SCHEMATIC
Two Speed Lift
Two Speed Lift
Two Speed Lift
Lift Control
To Lift
Cylinder
(a) Accumulator, precharged to 3447.4 kPa (500 psi)
(b) Lift control manifold block for Two Speed Lift
(c) RV1 preset to 19201.9 to 19374.3 kPa (2785 to 2810 psi) for TT mast
and 16133.7 to 16306.1 kPa (2340 to 2365 psi) for TL mast
(d) Lift Pump and motor, P1 & P2 output: 25.4 l/m at 3447.4 kPa (500 psi),
17.8 l/m at 12410.6 kPa (1800 psi)
(e) Return line filter, 10 micron nominal
(f) Reservoir capacity is approximately 17 liters (4.5 gal) for trucks with
two speed lift
(g) Suction strainer, 100 mesh
Figure 15745-01
HYD-7335-002 Crown 2007 PF15666-2 Rev. 1/08
01 Rev. 1/08
492
HYDRAULIC SCHEMATIC
Single Speed Lift (With Lifting Fork)
Single Speed Lift (With Lifting Fork)
Single Speed Lift
(With Lifting Fork)
To Main Lift
Cylinder
To Lifting Fork
Cylinder on
Platform
(a) Accumulator, precharged to 3447.4 kPa (500 psi)
(b) Lift control manifold block for One Speed Lift
(c) Bias pressure, 2068.4 kPa (300 psi)
(d) RV2 preset to 11721.1 kPa (1700 psi)
(e) RV1 preset to 19201.9 to 19374.3 kPa (2785 to 2810 psi) for TT mast
and 16133.7 to 16306.1 kPa (2340 to 2365 psi) for TL mast
(f) Lift Pump and motor, P1 output: 25.4 l/m at 3447.4 kPa (500 psi),
17.8 l/m at 12410.6 kPa (1800 psi)
(g) Reservoir capacity is approximately 13 liters (3.5 gal) for trucks with
single speed lift
(h) Suction strainer, 100 mesh
(i) Return line filter, 10 micron nominal
Figure 15746-01
Crown 2007 PF15666-3 Rev. 1/08 HYD-7335-003
01 Rev. 1/08
493
HYDRAULIC SCHEMATIC
Two Speed Lift (With Lifting Fork)
Two Speed Lift (With Lifting Fork)
Two Speed Lift
(With Lifting Fork)
To Main Lift
Cylinder
To Lifting Fork
Cylinder on
Platform
(a) Accumulator, precharged to 3447.4 kPa (500 psi)
(b) Lift control manifold block for Two Speed Lift
(c) Bias pressure, 2068.4 kPa (300 psi)
(d) RV2 preset to 11721.1 kPa (1700 psi)
(e) RV1 preset to 19201.9 to 19374.3 kPa (2785 to 2810 psi) for TT mast
and 16133.7 to 16306.1 kPa (2340 to 2365 psi) for TL mast
(f) Lift Pump and motor, P1 & P2 output: 25.4 l/m at 3447.4 kPa (500 psi),
17.8 l/m at 12410.6 kPa (1800 psi)
(g) Reservoir capacity is approximately 17 liters (4.5 gal) for trucks with
two speed lift
(h) Suction strainer, 100 mesh
(i) Return line filter, 10 micron nominal
Figure 15747-01
HYD-7335-004 Crown 2007 PF15666-4 Rev. 1/08
01 Rev. 1/08
494
HYDRAULIC SCHEMATIC
Mast Cylinders
Mast Cylinders
To Power Mast
Unit Cylinders
TL Mast
Cylinders
Free Lift
Cylinder
To Power
Unit
Mast Mast
Cylinder Cylinder
TT Mast
Cylinders
Figure 15748
Crown 2007 PF15666-5 Rev. 1/08 HYD-7335-005
01 Rev. 1/08
495
HYDRAULIC SCHEMATIC
Single Speed Lift
Single Speed Lift
8
ACC
CV2 C1 9
P1
SVL MVL
ORF2
4
PVL
ORF3
ORF1
3
M3
RV1 PCL T1
P2
P1
1 Accumulator is set to 34.5 bar (500 psi)
2 Lift / lower manifold
7
3 RV1 is set to 192–194 bar (2785–2810 psi)
4 Lift pump and motor
5 Return line filter
6 Reservoir
7 Suction strainer
8 Emergency disconnect, for the pressure gauge
9 To the lift cylinder
Figure 141328 D sh1 of 5
Crown 2010 PF17963 Rev. 5/18 HYD-7335-006
01 Rev. 5/18
769
HYDRAULIC SCHEMATIC
Two Speed Lift
Two Speed Lift
M3 8
ACC
CV1 CV2 C1
P1 9
P1
SVL MVL
ORF2
4
PVL
ORF3
ORF1
3
M4
RV1
P2 CV3 PCL
T1
P2
2
6
1 Accumulator is set to 34.5 bar (500 psi)
2 Lift / lower manifold
3 RV1 is set to 192–194 bar (2785–2810 psi)
7 4 Lift pump and motor
5 Return line filter
6 Reservoir
7 Suction strainer
8 Emergency disconnect, for the pressure gauge
9 To the lift cylinder
Figure 141328 D sh2 of 5
HYD-7335-007 Crown 2010 PF17963 Rev. 5/18
01 Rev. 5/18
770
HYDRAULIC SCHEMATIC
Single Speed Lift (With Lifting Fork)
Single Speed Lift (With Lifting Fork)
12
ACC
CV1
CV2 C1
P2
CV3
9
SV1 SVL
P1 F
4
CV4
PVL PVLF MVL
RV2 ORF3
8 10
ORF2 ORF1 11
M3 ORF4 ORF5
ORF6
RV1 PCL PCLF T1
P1 G
3
2
6
5
1 Accumulator is set to 34.5 bar (500 psi)
2 Lift / lower manifold
3 RV1 is set to 192–194 bar (2785–2810 psi)
4 Lift pump and motor
5 Return line filter
6 Reservoir
7 7 Suction strainer
8 Emergency disconnect, for the pressure gauge
9 Bias pressure 21 bar (300 psi)
10 RV2 is set to 145–147 bar (2100–2125 psi)
11 Lifting fork cylinder on the platform
12 To the primary lift cylinder
Figure 141328 D sh3 of 5
Crown 2010 PF17963 Rev. 5/18 HYD-7335-008
01 Rev. 5/18
771
HYDRAULIC SCHEMATIC
Two Speed Lift (With Lifting Fork)
Two Speed Lift (With Lifting Fork)
12
ACC
M4
P2 CV1 CV2 C1
CV3
P2
SV1 9 SVL
P1 F
CV4
4 PVL PVLF MVL
ORF3
8 RV2
ORF2 ORF1 11
M3
ORF6 ORF4 ORF5
RV1 10
PCL PCLF T1
P1 G
3
2
6
1 Accumulator is set to 34.5 bar (500 psi)
5
2 Lift / lower manifold
3 RV1 is set to 192–194 bar (2785–2810 psi)
4 Lift pump and motor
5 Return line filter
6 Reservoir
7 Suction strainer
8 Emergency disconnect, for the pressure gauge
7
9 Bias pressure 21 bar (300 psi)
10 RV2 is set to 145–147 bar (2100–2125 psi)
11 Lifting fork cylinder on the platform
12 To the primary lift cylinder
Figure 141328 D sh4 of 5
HYD-7335-009 Crown 2010 PF17963 Rev. 5/18
01 Rev. 5/18
772
HYDRAULIC SCHEMATIC
Mast Cylinders
Mast Cylinders
4 1
TL Mast
Cylinders
2 2
TT Mast
Cylinders
1 1
3
2 2
1 Mast cylinders
2 Velocity fuse
3 Free-lift cylinder
4 To the power unit
Figure 141328 D sh5 of 5
Crown 2010 PF17963 Rev. 5/18 HYD-7335-010
01 Rev. 5/18
773
INTRODUCTION
Introduction
Introduction Service Training
This manual is intended for the service technician who Complete Service Training is available to the lift truck
is seeking information about maintenance and service technician covering all Crown Lift Trucks, module sys-
replacement parts. It contains a section on trouble tems, wire guidance, hydraulic and electrical systems.
shooting which will enable a qualified technician to lo- To obtain more information concerning service training,
cate and solve problems which may occur. contact your Crown Dealer or under "Training" on
www.crown.com.
Operator Instructions
Replacement Parts
This manual does not contain operation instructions.
Operator Instructions in tag or booklet form are sent When ordering replacement parts from this manual, al-
with each truck. Additional copies can be ordered if re- ways specify, along with the part number, the model
quired. These booklets are for you and your personnel and serial number of the truck. This information will fur-
to insure years of safe, trouble-free operation of your ther enable us to give correct, fast and efficient service.
Crown Lift Truck. For SP 3500 Series operator instruc-
For current part number of operator manuals, service
tions, refer to Crown publication, "Operator Manual
manuals, operator training programs, truck capacities
SP 3500 Series".
and technical specifications, contact your dealer or at
www.crown.com.
Operator Training This manual is arranged according to major sections
which covers maintenance and replacement parts. The
Crown has available a complete series of operator
sectional descriptions are as follows:
training programs, available through your local Crown
dealer. A complete listing of these and other available
programs can be found under "Training" on
www.crown.com
MAINTENANCE REPLACEMENT PARTS
SECTION DESCRIPTION SECTION DESCRIPTION
MA Safety 1 Power Unit Parts
M1 Inspection & Lubrication 2 Hydraulic Parts
M1.91 Componentry 3 Drive Unit Parts
M2 Hydraulic 4 Electrical Parts
M3 Drive Unit 5 Brake Parts
M4 Electrical 6 Steering Parts
M5 Brake 7 Lifting Mechanism Parts
M6 Steering 8 Cylinder Parts
M7 Lifting Mechanism 9 Platform Parts
M8 Cylinders 10 Accessories
M9 Platform 12 Labels and Decals
M10 Glossary
Crown 2007 PF15805-1 Rev. 2/11 ITD-7335-001
02 Rev. 2/11
21
INTRODUCTION
Introduction
The data plate for the SP 3500 Series truck is located
on the lower right corner, mast side, of the platform and
includes a model number and truck data number. From
these two numbers, you can identify the truck model,
series, series up dates, determine performance, ca-
pacity and specific truck data. The following pages ex-
plain the model & truck data numbering system.
Truck Data Plate
Figure 18187
ITD-7335-002 Crown 2007 PF15805-2 Rev. 2/11
02 Rev. 2/11
22
INTRODUCTION
Introduction
Model Number Example
Series Update
Significant change(s) to the product
* Capacity
that would not merit a new series
30 = 1360 kg (3000 lb)
number (generation).
Image Generator
SP - Stockpicker SP3510-30
Performance
Series
05 Single speed raise & lower, 3.5 hp drive motor,
Major technical and design changes 10.4 kph (6.5 mph) maximum travel speed, 660
making the product a new and maximum amp. hr. capacity.
improved generation. 10 Single speed raise & lower, 3.5 hp drive motor,
11.3 kph (7.0 mph) maximum travel speed, 1085
maximum amp. hr. capacity.
20 Two speed raise & lower, 3.5 hp standard drive
motor and 9.7 kph (6.0 mph) maximum travel
speed or 4.0 hp optional drive motor and 11.3 kph
(7.0 mph) maximum travel speed, 1085 maximum
amp. hr. capacity
50 Two speed raise & lower, 4.0 hp drive motor,
12.1 kph (7.5 mph) maximum travel speed, 1085
maximum amp. hr. capacity.
The example of the model number shown
(SP 3510-30) is a SP 3500 Series truck. It's equipped
with single speed raise & lower, AC traction motor ca-
pable of 11.3 Kph (7.0 mph) maximum travel speed,
has 1085 maximum amp hour capacity and 1360 kg
(3000 lb) capacity.
*Actual rated capacity may vary, depending on special
equipment or modifications. Consult capacity plate lo-
cated on the overhead guard.
Truck Serial Number Plate
Figure 18188
The truck data number provides you and your Crown
dealer with a wealth of information to insure the selec-
tion of proper parts for your Crown truck. You may sim-
ply provide this number to your Crown dealer, or use
the following breakdown if selecting your own part
numbers or service information from this manual.
Crown 2007 PF15805-3 Rev. 2/11 ITD-7335-003
02 Rev. 2/11
23
INTRODUCTION
Introduction
Drive Tires
Wire Guidance CG = Center Groove Switch Panel
- = No Wire Guidance DS = Diagonal Siped 1 = Standard
W = Wire Guidance PP = Poly, Black 30l 2 = Lift/Lower Limit Override
40 = Poly, Cream 40 3 = Lift/Lower Limit Override, Zone
RS = Razor Siped Select
NM = Poly, Non Marking 4 = Worklight, Dome Light, Fan
Straddle Width ** = Special 5 = Lift/Lower Limit Override, Work-
42 = 1067 mm (42 in) light, Dome Light, Fan
1067 mm (42 in) thru 6 = Lift/Lower Limit Override, Zone
1830 mm (72 in) in 25 mm Select, Worklight, Dome Light, Fan
(1.0 in) increments 7 = Worklight, Dome Light, Fan,
Spotlight
Mast Type 8 = Lift/Lower Limit Override, Work-
TT = Telescopic Triple Stage light, Dome Light, Fan, Spotlight
TL = Telescopic Limited Free Lift 9 = Lift/Lower Limit Override, Zone
Select, Worklight, Dome Light, Fan,
Spotlight
- TT 240 42 ----- - F PP 42 1 C
Application
Standard/Custom/Special
- = Standard
- = Standard
1 = EAC
C = Custom
S = Special
Lift Height
136 = 3455 mm (136 in)
148 = 3760 mm (148 in) Platform Width
42 = 1065 mm (42 in)
172 = 4370 mm (172 in)
48 = 1220 mm (48 in)
194 = 4930 mm (194 in)
54 = 1370 mm (54 in)
195 = 4955 mm (195 in) 60 = 1525 mm (60 in)
210 = 5335 mm (210 in) 64 = 1625 mm (64 in)
214 = 5435 mm (214 in)
240 = 6095 mm (240 in) Cold Conditioning
276 = 7010 mm (276 in) - = No Cold Conditioning/Wire Mesh Windshield
294 = 7570 mm (294 in) C = Corrosion Conditioning/Wire Mesh Windshield
312 = 7925 mm (312 in) F = Freezer Conditioning/Wire Mesh Windshield
330 = 8380 mm (330 in)
348 = 8840 mm (348 in)
366 = 9295 mm (366 in)
Custom = Plus Custom Height Aisle Guide Wheel Width
SPC = Special Lift Height
Display Aisle Guide Wheel Width i.e.
48.75 = 48.75 in
----- = No Rail Guidance
***** = Special Aisle Guide
ITD-7335-004 Crown 2007 PF15805-4 Rev. 2/11
02 Rev. 2/11
24
INTRODUCTION
Introduction
Chart 1 - Service Specifications Models SP 3505-30, SP 3510-30, SP 3520-30 and SP 3550-30H
Capacity* 1360 kg (3000 lb)
Load Center 610 mm (24.0 in)
Voltage 24Volt
Operator Type Stand-up Rider Stockpicker
Tire Type - Load/Drive: Poly/Poly
Wheels - Load/Drive: 4/1x
Head Length** 1895/1920 mm (74.6/75.6 in)
Forks - Standard L x W x T: 915 x 100 x 50 mm (36.0 x 4.0 x 2.0 in)
760, 990, 1065, 1145, 1220, 1370, 1525, 1830, 2135 mm
(30.0, 39.0, 42.0, 45.0, 48.0, 54.0, 60.0, 72.0, 84.0 in)
Wheel Base - TL/TT: 1320/1300 mm (52.0/51.25 in)
Turning Radius - TL/TT: 1750/1730 mm (69.0/68.0 in)
* Contact Factory. Capacity may be subject to derating.
** From power unit to platform edge.
Chart 2 - SP 3505 TL and TT Travel Speeds (Power Unit First)
Steered Wheel ± 10 ° (1)
Lift Height Travel Speed kph (mph)
Empty and Loaded
mm (in) kph (mph)
0 - 610 (0.0 - 24.0) 10.4 (6.5)
635 - 1625 (25.0 - 64.0) 10.4 - 8.8 (6.5 - 5.5)
1650 - 3050 (65.0 - 120.0) 8.8 - 5.3 (5.5 - 3.3)
3075 - 4470 (121.0 - 176.0) 5.3 - 1.9 (3.3 - 1.2)
4495 - 6095 (177.0 - 240.0) 1.9 (1.2)(2)
(1) Top travel speed is reduced to 80% at a 10° steering
angle. Beyond 10° travel speeds gradually reduce down
to 50% of top travel speed. Steering angle is
automatically limited to within 10° straight travel above
4575 mm (180.0 in)
(2) SP 3505 available up to 6095 mm(240.0 in)
Crown 2007 PF15805-5 Rev. 2/11 ITD-7335-005
02 Rev. 2/11
25
INTRODUCTION
Introduction
Chart 3 - SP 3510/SP 3520 TL and TT Travel Speeds (Power Unit First)
Steered Wheel ± 10 ° (3)
Lift Height Travel Speed kph (mph)
Empty and Loaded
mm (in) kph (mph)
0 - 610 (0.0 - 24.0) 12.0 7.5
635 - 1625 (25.0 - 64.0) 12.0 - 9.6 (7.5 - 6.0)(5)
1650 - 3050 (65.0 - 120.0) 9.6 - 6.1 (6.0 - 3.8)
3075 - 4470 (121.0 - 176.0) 6.1 - 3.2 (3.8 - 2.0)
4495 - 6095 (177.0 - 240.0) 3.2 - 2.4 (2.0 - 1.5)
4875 - 7925 (192.0 - 312.0) 2.4 (1.5)(4)
(3) Top travel speed is reduced to 80% at a 10° steering angle. Beyond
10° travel speeds gradually reduce down to 50% of top travel
speed. Steering angle is automatically limited to within 10° straight
travel above 4575 mm (180.0 in)
(4) SP 3520 available up to 7925 MM (312.0 in)
(5) SP 3510 available up to 6095 mm (240.0 in)
Chart 4 - SP 3550H TL and TT Travel Speeds (Power Unit First)
Steered Wheel ± 10 ° (6)
Lift Height Travel Speed kph (mph)
Empty and Loaded
mm (in) kph (mph)
0 - 610 (0.0 - 24.0) 12.0 7.5
635 - 1625 (25.0 - 64.0) 12.0 - 9.6 (7.5 - 6.0)
1650 - 3050 (65.0 - 120.0) 9.6 - 6.1 (6.0 - 3.8)
3075 - 4470 (121.0 - 176.0) 6.1 - 3.2 (3.8 - 2.0)
4495 - 5485 (177.0 - 216.0) 3.2 - 2.4 (2.0 - 1.5)
5485 - 9295 (216.0 - 366.0) 2.4 (1.5)
(6) Top travel speed is reduced to 80% at a 10° steering angle. Beyond 10°
travel speeds gradually reduce down to 50% of top travel speed. Steering
angle is automatically limited to within 10° straight travel above 5640 mm
(222.0 in)
ITD-7335-006 Crown 2007 PF15805-6 Rev. 2/11
02 Rev. 2/11
26
INTRODUCTION
Introduction
Chart 5 - Lifting/Lowering Speed
Lifting Speed
SP 3520-30
SP 3505-30 SP 3510-30
SP 35550H
Empty Loaded Empty Loaded Empty Loaded
mpm (fpm) mpm (fpm) mpm (fpm) mpm (fpm) mpm (fpm) mpm (fpm)
8.5 (28)
13.7(7) (45)(7)
Low(7) Low(7)
TL: 13.7 (45) 8.5 (28) 13.7 (45) 8.5 (28)
14.0 (46)
24.4(7) (80)(7) High(7) High(7)
7.9 (26)
12.2 (40)
Low Low
TT 12.2 (40) 7.9 (26) 12.2 (40) 7.9 (26)
13.1 (43)
21.6 (71)
High High
Lowering Speed
12.2 (38) 12.2 (38)
12.2 (40) 12.2 (38) 12.2 (40) 12.2(7) (40)(7)
Low Low Low(7) Low(7)
TL:
22.9 (75) 22.9 (75)
24.4 (80) 22.9 (75) 24.4 (80) 24.4(7) (80)(7)
High High Low(7) High(7)
7.9 (38) 7.9 (38)
12.2 (40) 7.9 (38) 12.2 (40) 12.2 (40)
Low Low Low Low
TT:
22.9 (75) 22.9 (75)
24.4 (80) 22.9 (75) 24.4 (80) 24.4 (80)
High High High High
(7) TL option on the SP 3520-30 only.
Crown 2007 PF15805-7 Rev. 2/11 ITD-7335-007
02 Rev. 2/11
27
Notes:
28
INTRODUCTION
Introduction
Introduction • Wire guidance
• Hydraulic systems
This manual is for service technicians who are ap-
• Electrical systems.
proved and correctly trained to do troubleshooting and
maintenance procedures on the lift truck. The manual For more information on service training, consult your
contains information about maintenance, troubleshoot- Crown dealer or go to "Training" on www.crown.com.
ing, and replacement parts.
Replacement Parts
Operator Instructions
For correct and fast service, when you consult Crown
This manual does not have operator instructions. for replacement parts, always give this information:
There are operator instructions in tag or booklet form • The part number
with each truck. More copies can be ordered if it is nec-
• The truck model number
essary. The operator instructions are to make sure that
you and your personnel know how to operate your • The truck serial number
Crown lift truck safely. For operator instructions, refer • The truck data number.
to "Operator Manual SP 3500 Series".
Consult your Crown dealer or go to www.crown.com
for:
Operator Training
• The newest service manuals
Crown has operator training programs that are avail- • The newest operator manuals
able through your Crown dealer. For more information
• Training
on operator training, consult your Crown dealer or go to
"Training" on www.crown.com. • Truck capacities
• Truck specifications.
Service Training
Manual Structure
Service training is available for:
• All Crown lift trucks This manual contains sections that have maintenance
and replacement parts. The section descriptions are as
• Module systems
follows:
Service and Parts Pages Chart
Maintenance Replacement Parts
Section Description Section Description
MA Safety 1 Power Unit Parts
M1 Inspection & Lubrication 2 Hydraulic Parts
M1.91 Componentry 3 Drive Unit Parts
M2 Hydraulic 4 Electrical Parts
M3 Drive Unit 5 Brake Parts
M4 Electrical 6 Steering Parts
M5 Brake 7 Lifting Mechanism Parts
M6 Steering 8 Cylinder Parts
M7 Lifting Mechanism 9 Platform Parts
M8 Cylinders 10 Accessories
M9 Platform 12 Labels and Decals
M10 Glossary
Crown 2013 PF25912-1 ITD-7335-008
21
INTRODUCTION
Introduction
The truck data plate is on the lower corner of the plat-
form on the mast side. The truck serial number is on
the data plate. The truck data plate also includes a
model number and a truck data number. From these
two numbers, you can find this information:
• The truck model
• The series
• Series updates
• Performance
• Capacity
• Specified truck data.
Truck Data Plate
Fig. 1 (18187)
Model Number
The truck model number gives you and your Crown
dealer the information to make sure that you select the
correct parts for your Crown lift truck. Special equip-
ment or modifications can change the truck capacity.
Refer to the capacity plate on the overhead guard.
ITD-7335-009 Crown 2013 PF25912-2
22
INTRODUCTION
Introduction
Model Number Example
Series Update
Significant change(s) to the product
* Capacity
that would not merit a new series
30 = 1360 kg (3000 lb)
number (generation).
Image Generator
SP - Stockpicker SP3510-30
Performance
Series
05 Single speed raise & lower, 3.5 hp drive motor,
Major technical and design changes 10.4 kph (6.5 mph) maximum travel speed, 660
making the product a new and im- maximum amp. hr. capacity.
proved generation. 10 Single speed raise & lower, 3.5 hp drive motor,
11.3 kph (7.0 mph) maximum travel speed, 1085
maximum amp. hr. capacity.
20 Two speed raise & lower, 3.5 hp standard drive mo-
tor and 9.7 kph (6.0 mph) maximum travel speed or
4.0 hp optional drive motor and 11.3 kph (7.0 mph)
maximum travel speed, 1085 maximum amp. hr.
capacity
50 Two speed raise & lower, 4.0 hp drive motor,
12.1 kph (7.5 mph) maximum travel speed, 1085
maximum amp. hr. capacity.
The example of the model number (SP 3510-30) is an Truck Data Number
SP 3500 series truck. It has:
The truck data number gives you and your Crown
• Single speed raise and lower functions
dealer the information to make sure that you select the
• An AC traction motor capable of 11.3 km/h (7 mph) correct parts for your Crown lift truck. You can give the
maximum travel speed truck data number to your Crown dealer, or use the in-
• A 1085 maximum amp hour capacity formation below to select the correct part numbers or
• A 1360 kg (3000 lb) capacity. service information from this manual.
Truck Capacity Plate
Fig. 2 (18188-01)
Crown 2013 PF25912-3 ITD-7335-010
23
INTRODUCTION
Introduction
Wire Guidance
- = No Wire Guidance Drive Tires
W = Wire Guidance CG = Center Groove Switch Panel
R = Rail Guidance DS = Diagonal Siped 1 = Standard
PP = Poly, Black 30l 2 = Lift/Lower Limit Override
Voltage 40 = Poly, Cream 40 3 = Lift/Lower Limit Override, Zone
4 = 24 volts RS = Razor Siped Select
NM = Poly, Non Marking 4 = Worklight, Dome Light, Fan
Straddle Width ** = Special 5 = Lift/Lower Limit Override, Work-
42 = 1067 mm (42 in) light, Dome Light, Fan
1067 mm (42 in) thru 6 = Lift/Lower Limit Override, Zone
1830 mm (72 in) in 25 mm Select, Worklight, Dome Light, Fan
(1.0 in) increments 7 = Worklight, Dome Light, Fan,
Spotlight
8 = Lift/Lower Limit Override, Work-
Mast Type light, Dome Light, Fan, Spotlight
TT = Telescopic Triple Stage 9 = Lift/Lower Limit Override, Zone
TL = Telescopic Limited Free Lift Select, Worklight, Dome Light, Fan,
Spotlight
- TT 240 42 B 4 - -- - F PP 42 1 C
Application
Standard/Custom/Special
- = Standard
- = Standard
1 = EAC
C = Custom
S = Special
Platform Width
Lift Height 42 = 1065 mm (42 in)
136 = 3455 mm (136 in)
48 = 1220 mm (48 in)
54 = 1370 mm (54 in)
148 = 3760 mm (148 in)
60 = 1525 mm (60 in)
172 = 4370 mm (172 in) 64 = 1625 mm (64 in)
194 = 4930 mm (194 in)
195 = 4955 mm (195 in)
Cold Conditioning
210 = 5335 mm (210 in) - = No Cold Conditioning/Wire Mesh Windshield
214 = 5435 mm (214 in) C = Corrosion Conditioning/Wire Mesh Windshield
240 = 6095 mm (240 in) F = Freezer Conditioning/Wire Mesh Windshield
276 = 7010 mm (276 in)
294 = 7570 mm (294 in)
Pallet Grab
312 = 7925 mm (312 in)
- = No Pallet Grab
330 = 8380 mm (330 in)
E = Electric Pallet Grab
348 = 8840 mm (348 in) Battery Compartment Size
2 = Pallet Grab (38 mm [1.5 in) Clamp)
366 = 9295 mm (366 in) B = B Battery Compartment
4 = Pallet Grab (102 mm [4 in] Clam)
Custom = Plus Custom Height
6 = Pallet Grab (152 mm [6 in] Clamp)
SPC = Special Lift Height
SPC = Special Lift Height
ITD-7335-011 Crown 2013 PF25912-4
24
INTRODUCTION
Introduction
Truck Specifications and Speeds
Service Specifications Chart
Capacitya) 1360 kg (3000 lb)
Load Center 610 mm (24.0 in)
Voltage 24 Volt
Operator Type Stand-up Rider Stockpicker
Tire Type - Load/Drive: Poly/Poly
Wheels - Load/Drive: 4/1x
Head Lengthb) - TL/TT: 1895/1920 mm (74.6/75.6 in)
Forks - Standard L x W x T: 915 x 100 x 50 mm (36.0 x 4.0 x 2.0 in)
760, 990, 1065, 1145, 1220, 1370, 1525, 1830, 2135 mm
(30.0, 39.0, 42.0, 45.0, 48.0, 54.0, 60.0, 72.0, 84.0 in)
Wheel Base - TL/TT: 1320/1300 mm (52.0/51.25 in)
Turning Radius - TL/TT: 1750/1730 mm (69.0/68.0 in)
a). Consult the factory. The capacity may be subject to derating, depending upon lift height, load center, and fork
length.
b). The head length is from the power unit to the platform edge.
SP 3505 TL and TT Travel Speeds (Power Unit First) Chart
Steered Wheel ± 10° a)
Lift Height Travel Speed kph (mph)
Empty and Loaded
mm (in) kph (mph)
0–610 (0.0–24.0) 10.4 (6.5)
635–1625 (25.0–64.0) 10.4–8.8 (6.5–5.5)
1650–3050 (65.0–120.0) 8.8–5.3 (5.5–3.3)
3075–4470 (121.0–176.0) 5.3–1.9 (3.3–1.2)
4495–6095 (177.0–240.0) 1.9 (1.2)b)
a). The maximum travel speed decreases to 80% at a 10° steering angle.
More than 10°, the travel speeds decrease to 50% of top travel speed.
The steering angle is automatically within 10° straight travel more than
4575 mm (180.0 in).
b). SP 3505 is available up to 6095 mm (240.0 in).
Crown 2013 PF25912-5 ITD-7335-012
25
INTRODUCTION
Introduction
SP 3510/SP 3520 TL and TT Travel Speeds (Power Unit First) Chart
Steered Wheel ± 10° a)
Lift Height Travel Speed kph (mph)
Empty and Loaded
mm (in) kph (mph)
0–610 (0.0–24.0) 12.0 7.5
635–1625 (25.0–64.0) 12.0–9.6 (7.5–6.0)b)
1650–3050 (65.0–120.0) 9.6–6.1 (6.0–3.8)
3075–4470 (121.0–176.0) 6.1–3.2 (3.8–2.0)
4495–6095 (177.0–240.0) 3.2–2.4 (2.0–1.5)
4875–7925 (192.0–312.0) 2.4 (1.5)c)
a). The maximum travel speed decreases to 80% at a 10° steering angle. More than 10°,
the travel speeds decrease to 50% of top travel speed. The steering angle is automat-
ically within 10° straight travel more than 4575 mm (180.0 in).
b). SP 3510 is available up to 6095 mm (240.0 in).
c). SP 3520 is available up to 7925 mm (312.0 in).
SP 3550H TL and TT Travel Speeds (Power Unit First) Chart
Steered Wheel ± 10° a)
Lift Height Travel Speed kph (mph)
Empty and Loaded
mm (in) kph (mph)
0 - 610 (0.0 - 24.0) 12.0 7.5
635 - 1625 (25.0 - 64.0) 12.0 - 9.6 (7.5 - 6.0)
1650 - 3050 (65.0 - 120.0) 9.6 - 6.1 (6.0 - 3.8)
3075 - 4470 (121.0 - 176.0) 6.1 - 3.2 (3.8 - 2.0)
4495 - 5485 (177.0 - 216.0) 3.2 - 2.4 (2.0 - 1.5)
5485 - 9295 (216.0 - 366.0) 2.4 (1.5)
a). The maximum travel speed decreases to 80% at a 10° steering angle. More than 10°, the travel
speeds decrease to 50% of top travel speed. The steering angle is automatically within 10°
straight travel more than 5640 mm (222.0 in).
ITD-7335-013 Crown 2013 PF25912-6
26
INTRODUCTION
Introduction
Lifting/Lowering Speed Chart
Lifting Speed
SP 3520-30
SP 3505-30 SP 3510-30
SP 35550H
Empty Loaded Empty Loaded Empty Loaded
mpm (fpm) mpm (fpm) mpm (fpm) mpm (fpm) mpm (fpm) mpm (fpm)
8.5 (28)
13.7a) (45)a)
Lowa) Lowa)
TL 13.7 (45) 8.5 (28) 13.7 (45) 8.5 (28)
14.0 (46)
24.4a) (80)a)
Higha) Higha)
7.9 (26)
12.2 (40)
Low Low
TT 12.2 (40) 7.9 (26) 12.2 (40) 7.9 (26)
13.1 (43)
21.6 (71)
High High
Lowering Speed
12.2 (38) 12.2 (38)
12.2 (40) 12.2 (38) 12.2 (40) 12.2a) (40)a)
Low Low Lowa) Lowa)
TL
22.9 (75) 22.9 (75)
24.4 (80) 22.9 (75) 24.4 (80) 24.4a) (80)a)
High High Lowa) Higha)
7.9 (38) 7.9 (38)
12.2 (40) 7.9 (38) 12.2 (40) 12.2 (40)
Low Low Low Low
TT
22.9 (75) 22.9 (75)
24.4 (80) 22.9 (75) 24.4 (80) 24.4 (80)
High High High High
a) The TL option is only available on the SP 3520-30.
Crown 2013 PF25912-7 ITD-7335-014
27
INTRODUCTION
Introduction
Introduction • Wire guidance
• Hydraulic systems
This manual is for service technicians who are ap-
• Electrical systems
proved and correctly trained to do troubleshooting and
maintenance procedures on the lift truck. The manual For more information on service training, consult your
contains information about maintenance, troubleshoot- Crown dealer or go to "Training" on www.crown.com.
ing, and replacement parts.
Replacement parts
Operator instructions
For correct and efficient service, when you consult
This manual does not have operator instructions. Crown for replacement parts, always give this informa-
There are operator instructions in tag or booklet form tion:
with each lift truck. If necessary, order more copies. • The part number
The operator instructions are to make sure that you
• Model number of the lift truck
and your personnel know how to operate your Crown
lift truck safely. For operator instructions, see "Operator • Serial number of the lift truck
Manual SP 3500 Series". • Data number of the lift truck
Consult your Crown dealer or go to www.crown.com for:
Operator training
• Newest service manuals
Crown has operator training programs that are avail- • Newest operator manuals
able through your Crown dealer. For more information
• Training
on operator training, consult your Crown dealer or go to
"Training" on www.crown.com. • Lift truck capacities
• Lift truck specifications
Service training
Manual structure
Service training is available for:
• All Crown lift trucks This manual contains sections that have maintenance
and replacement parts. The section descriptions are as
• Module systems
follows:
Service and Parts Pages
Maintenance Replacement Parts
Section Description Section Description
MA Safety 1 Power Unit Parts
M1 Inspection and Lubrication 2 Hydraulic Parts
M1.91 Componentry 3 Drive Unit Parts
M2 Hydraulic 4 Electrical Parts
M3 Drive Unit 5 Brake Parts
M4 Electrical 6 Steering Parts
M5 Brake 7 Lifting Mechanism Parts
M6 Steering 8 Cylinder Parts
M7 Lifting Mechanism 9 Platform Parts
M8 Cylinders 10 Accessories
M9 Platform 12 Labels and Decals
M10 Glossary
Crown 2016 PF27667 ITD-7335-015
29
INTRODUCTION
Introduction
Data plate
See Figure 1. The data plate is on the lower corner of
the platform on the mast side. The serial number is on
the data plate. The data plate also includes a model
number and a data number. From these two numbers,
you can find this information:
• Lift truck model
• Series
• Series updates
• Performance
• Capacity
• Specified lift truck data
Fig. 1 (18187-01)
Model number
The model number for the lift truck gives you and your
Crown dealer the information to make sure that you se-
lect the correct parts for your Crown lift truck. Special
equipment or modifications can change the lift truck ca-
pacity. See the capacity plate on the overhead guard.
ITD-7335-016 Crown 2016 PF27667
30
INTRODUCTION
Introduction
Model Number Example
Series Update
Capacity (1)
Significant changes to the product
30 = 1,360 kg (3,000 lb)
that would not merit a new series
1.0 = 1,000 kg (2,200 lb) (Lifting fork option)
number (generation).
1.25 = 1,250 kg (2,750 lb)
Image Generator
SP - Stockpicker SP3510-30
Performance
Series
05 Single speed raise and lower, 3.9 kW drive motor,
Major technical and design changes 10.4 kph (6.5 mph) maximum travel speed, 660
making the product a new and im- maximum amp-hour capacity.
proved generation. 10 Single speed raise and lower, 3.9 kW drive motor,
12 km/h (7.5 mph) maximum travel speed, 1,085
maximum amp-hour capacity.
12 Single speed raise and lower, 3.9 kW drive motor,
12 km/h (7.5 mph) maximum travel speed, 1,085
maximum amp-hour capacity, lifting fork option.
20 Two speed raise and lower, 3.9 kW standard drive
motor and 12 km/h (7.5 mph) maximum travel
speed, 1,085 maximum amp-hour capacity.
22 Two speed raise and lower, 3.9 kW standard drive
motor and 12 km/h (7.5 mph) maximum travel
speed, 1,085 maximum amp-hour capacity, lifting
fork option.
50 Two speed raise and lower, 3.9 kW drive motor,
12 km/h (7.5 mph) maximum travel speed, 1,085
maximum amp-hour capacity.
The example of the model number (SP3510-30) is an
SP 3500 series lift truck. It has:
• Single speed raise and lower functions
• An AC traction motor capable of 12 km/h (7.5 mph)
maximum travel speed
• A 1,085 maximum amp-hour capacity
• A 1,360 kg (3,000 lb) capacity
(1) Actual rated capacity can vary, depending on special
equipment or modifications. See the capacity plate on
the overhead guard.
Fig. 2 (18188-02)
Crown 2016 PF27667 ITD-7335-017
31
INTRODUCTION
Introduction
Lift truck data number parts for your Crown lift truck. You can give the data
number to your Crown dealer, or use the information
The data number gives you and your Crown dealer the that follows to select the correct part numbers or ser-
information to make sure that you select the correct vice information from this manual.
1 2 3 4 5 6 7 8 9 10 11 12 13
- TT 240 42 B 4 - -- - F PP 42 1 C
1 Standard, Custom, Special (see the Standard, Custom, Special table)
2 Mast Type (see the Mast Type table)
3 Lift Height (see the Lift Height table)
4 Outside Straddle Width (see the Outside Straddle Width table)
5 Battery Compartment Size: B = B Battery Compartment
6 Voltage: 4 = 24 V
7 Pallet Grab (see the Pallet Grab table)
8 Wire Guidance (see the Wire Guidance table)
9 Cold Condition (see the Cold Condition table)
10 Drive Tires (see the Drive Tires table)
11 Platform Width (see the Platform Width table)
12 Switch Panel (see the Switch Panel table)
13 Application (see the Application table)
Fig. 3 (31506)
Standard, Custom, Special Mast Type
Abbreviation Description Abbreviation Description
- Standard TT Telescopic triple stage
C Custom TL Telescopic limited free lift
S Special
ITD-7335-018 Crown 2016 PF27667
32
INTRODUCTION
Introduction
Lift Height Outside Straddle Width
Abbreviation Description Abbreviation Description
136 3,455 mm (136 in) 42 1,067 mm (42 in)
148 3,760 mm (148 in) 1,067 mm (42 in) through 1,830 mm (72 in)
in 25 mm (1 in) increments
166 4,215 mm (166 in) (1)
172 4,370 mm (172 in)
178 4,520 mm (178 in) (1) Pallet Grab
194 4,930 mm (194 in)
Abbreviation Description
195 4,955 mm (195 in)
202 5,130 mm (202 in) (1) - No pallet grab
210 5,335 mm (210 in) E Electric pallet grab
214 5,435 mm (214 in) 2 Pallet grab (38 mm [1.5 in] clamp)
224 4 Pallet grab (102 mm [4 in] clamp)
5,690 mm (224 in) (1)
6 Pallet grab (152 mm [6 in] clamp)
225 5,715 mm (225 in) (1)
SPC Special lift height
240 6,095 mm (240 in)
240 6,095 mm (240 in) (1)
244 6,200 mm (244 in) (1) Wire Guidance
270 6,860 mm (270 in) (1)
Abbreviation Description
276 7,010 mm (276 in)
- No wire guidance
294 7,470 mm (294 in)
W Wire guidance
306 7,770 mm (306 in) (1)
R Rail guidance
312 7,925 mm (312 in)
324 8,230 mm (324 in) (1)
330 8,380 mm (330 in) Cold Condition
342 8,685 mm (342 in) (1)
Abbreviation Description
348 8,840 mm (348 in)
360 - No cold condition
9,145 mm (360 in) (1)
C Corrosion condition
366 9,295 mm (366 in)
F Freezer condition
378 9,600 mm (378 in) (1)
Custom Plus custom height
SPC Special lift height
(1) Lifting fork option
Crown 2016 PF27667 ITD-7335-019
33
INTRODUCTION
Introduction
Drive Tires Switch Panel
Abbreviation Description Abbreviation Description
CG Center groove 1 Standard
DS Diagonal siped 2 Lift/lower limit override
PP Poly, black 3 Lift/lower limit override, zone select
40 Poly, cream 4 Worklight, dome light, fan
RS Razor siped 5 Lift/lower limit override, worklight,
dome light, fan
NM Poly, non-marking
6 Lift/lower limit override, zone select,
** Special
worklight, dome light, fan
7 Worklight, dome light, fan, spotlight
Platform Width 8 Lift/lower limit override, worklight,
dome light, fan, spotlight
Abbreviation Description 9 Lift/lower limit override, zone select,
worklight, dome light, fan, spotlight
42 1,065 mm (42 in)
48 1,220 mm (48 in)
Application
54 1,370 mm (54 in)
60 1,525 mm (60 in)
Abbreviation Description
64 1,625 mm (64 in)
- Standard
1 EAC
ITD-7335-020 Crown 2016 PF27667
34
LUBRICATION & ADJUSTMENT
Lubrication and Adjustment
Lubrication and Adjustment Before performing maintenance to any unit, it should
be taken to an area set aside for maintenance or a sec-
To obtain maximum life of any industrial equipment, a tion where there is adequate space to perform required
well planned maintenance program (PM), performed work. This is a must to insure the safety of others and
by qualified technical personnel should be followed. In to insure that proper maintenance is performed to the
conjunction with, and an integral part of, any planned unit.
maintenance program should be daily operator input.
If desired, padded packs of this checklist (OF-3772)
Operator involvement can greatly reduce truck down
are available through your Crown dealer.
time, assist in determining planned maintenance (PM)
schedules and ultimately save money. For these rea-
sons, Crown recommends a checklist similar to the Op-
erators Daily Checklist shown below.
Figure 14990
Crown 1987 PF7886-1 Rev. 1/11 M1.0-04.0-001
19 Rev. 1/11
29
LUBRICATION & ADJUSTMENT
Lubrication and Adjustment
The following is a list of lubricants and maintenance
products recommended when doing Planned Mainte-
nance on Crown Lift Trucks.
Lubrication Identification Chart
Type of Lubricant Part Number Package Quantity
363506-001 1 Quart
A Gear Lube 80W-90 (Typical)
363506-012 (12) 1 Quart Cans
363503-001 1 Quart
AA Automatic Transmission Fluid (Multi-Purpose)
363503-012 (12) 1 Quart
363513-001 1 Quart
AAA Universal Hydraulic & Transmission Fluid
363513-012 (12) 1 Quart
363514-001 1 Quart
AAAA Synthetic Gear Oil 75W-90
363514-012 (12) 1 Quart
063002-034 14.5 oz Cartridge
B Grease (Multi-Purpose)
063002-045 (40) 14.5 oz Cartridges
063002-017 14.5 oz Cartridge
BB(1) Grease (Low Temperature)
063002-046 (40) 14.5 oz Cartridges
363002-001 14 oz Cartridge
BBB Food Grade Grease (Multi-Purpose)
363002-030 (30) 14 oz Cartridges
063002-025 14.5 oz Cartridge
BBBB Grease (Multi-Purpose) Premium
063002-026 5 Gallon
C Oil (SAE 40)
363500-001 1 Quart
CC Engine Oil (10W30)
363500-012 (12) 1 Quart
363504-101 1 Gallon
D Hydraulic Oil
363504-106 (6) 1 Gallon
363505-101 1 Gallon
DD(1) Hydraulic Oil (Low Temp)
363505-106 (6) 1 Gallon
DDD Hydraulic Oil - DTE24 063001-021 1 Gallon
063002-024 14.5 oz Cartridge
E Channel Grease
063002-022 35 lb Pail
063002-024 14.5 oz Cartridge
F Gear Grease
063002-022 35 lb Pail
363107-001 15 oz Can
Chain & Cable Lube
363107-012 (12) 15 oz Cans
G
363115-001 12 oz Can
Premium Chain & Cable Lube
363115-012 (12) 12 oz Cans
363129-001 11 oz Can
H Final Finish - Rubber & Vinyl Dressing
363129-012 (12) 11 oz Cans
(1) Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.
M1.0-04.0-002 Crown 1987 PF7886-2 Rev. 1/11
19 Rev. 1/11
30
LUBRICATION & ADJUSTMENT
Lubrication and Adjustment
Lubrication Identification Chart
Type of Lubricant Part Number Package Quantity
063002-039 1 lb
I Grease (Lift Pump Coupling)
127801S 1 oz
063004-002 12 oz
J Brake Fluid - Dot 5
063004-003 1 Gallon
063002-034 14.5 oz Cartridge
K Grease (Wheel Bearing)
063002-045 (40) 14.5 oz Cartridges
L Metal Assembly Spray 063002-021 11 oz Spray
M Silicone Grease (Clear) 063002-020 5.3 oz Tube
363102-001 14 oz Can
Brake & Parts Cleaner
363102-012 (12) 14 oz Cans
363103-001 14 oz Can
N Low VOC Brake & Parts Cleaner
363103-012 (12) 14 oz Cans
363116-001 19 oz Can
Non-Flammable Brake & Parts Cleaner
363116-012 (12) 19 oz Cans
363104-001 20 oz Can
O Penetrating Lubricant
363104-012 (12) 20 oz Cans
363108-001 11 oz Can
P Premium Formula Multi-Purpose Grease
363108-012 (12) 11 oz Cans
363110-001 11 oz Can
Q White Lithium Grease
363110-012 (12) 11 oz Cans
363109-001 15 oz Can
R Choke & Carburetor Cleaner
363109-012 (12) 16 oz Cans
363106-001 10 oz Can
Contact Cleaner - Non-Flammable
363106-012 (12) 10 oz Cans
S
363128-001 11 oz Can
Contact Cleaner
363128-012 (12) 11 oz Cans
T Electrical Connector Oxidation & Corrosion Inhibitor 127189-001 30 cc
363124-001 18 oz Can
U Battery Cleaner
363124-012 (12) 18 oz Cans
363125-001 15 oz Can
V Battery Protector
363125-012 (12) 15 oz Cans
363127-001 12 oz Can
W Food Grade Machine Lubricant
363127-012 (12) 12 oz Cans
363126-001 11 oz Can
X Food Grade Silicone Spray
363126-012 (12) 11 oz Cans
363509-101 1 Gallon
Coolant
363509-106 (6) 1 Gallon
Y
363511-101 1 Gallon
Extended Life Coolant
363511-106 (6) 1 Gallon
Crown 1987 PF7886-3 Rev. 1/11 M1.0-04.0-003
19 Rev. 1/11
31
LUBRICATION & ADJUSTMENT
Lubrication and Adjustment
Alternate Lubricants & Fluids Chart
Type of Lubricant Product Name Manufacturer/ Distributor
A Gear Lube 80W-90 (Typical) Crown Crown
Automatic Transmission Fluid
AA Crown Crown
(Multi-Purpose)
AAA Universal Hydraulic & Transmission Fluid Crown Crown
AAAA Synthetic Gear Oil 75W-90 Crown Crown
Mobilgrease XHP 222 Special Mobil
Union Unoba EP No 2 Union 76 Co.
B Grease (Multi-Purpose) Retinax A(1) Shell
LM Grease Burmah Castrol
Unirex EP-2 Exxon
Lubriplate Fiske Bros Refining Co.
BB Grease (Low Temp) (2) Alvania RA(1) Shell
Helveum O(1) Burmah Castrol
BBB Food Grade Grease (Multi-Purpose) Petro Canada Purity FG Petro Canada
Mobilux EP2 64127-4 Mobil
Retinax AM 71119 Shell
BBBB Grease (Multi-Purpose) Premium
Chevron RPM Heavy Duty LC Chevron
Grease EP
C Oil (SAE 40)
D Hydraulic Oil Crown Crown
DD Hydraulic Oil (Low Temp) (2) Crown Crown
DDD Hydraulic Oil - DTE24 (3) Mobil DTE 24 Mobil
E Channel Grease Factran #2 Standard Oil Co.
F Gear, Channel & Shaft Grease Molykote BR-2 Plus Dow Corning
Chain & Cable Lube Crown Crown
G
Premium Chain & Cable Lube Crown Crown
H Final Finish - Rubber & Vinyl Dressing Crown Crown
I Grease (Lift Pump Coupling) Nyogel 774F-MS NYE Lubricants
J Brake Fluid - Dot 5 Q2-1141 Silicon Brake Fluid Dow Corning
Mobilgrease XHP 222 Special Mobil
K Grease (Wheel Bearing) Unirex EP-2 Exxon
Lubriplate No. 1242(1) Fiske Bros. Refining Co.
(1) Denotes allowable substitutes, contact factory if unavailable.
(2) Trucks operated in below freezing temperatures must use Low Temp Hydraulic Oil & Grease.
(3) Premium antiwear hydraulic oil used in blending with low temp oil.
M1.0-04.0-004 Crown 1987 PF7886-4 Rev. 1/11
19 Rev. 1/11
32
LUBRICATION & ADJUSTMENT
Lubrication and Adjustment
Alternate Lubricants & Fluids Chart
Type of Lubricant Product Name Manufacturer/ Distributor
L Metal Assembly Spray Dow Corning Dow Corning
M Silicon Grease (Clear) Dow Corning 111 Compound Dow Corning
Brake & Parts Cleaner Crown Crown
N Low VOC Brake & Parts Cleaner Crown Crown
Non-Flammable Brake & Parts Cleaner Crown Crown
O Penetrating Lubricant Crown Crown
P Premium Formula Multi-Purpose Grease Crown Crown
Q White Lithium Grease Crown Crown
R Choke & Carburetor Cleaner Crown Crown
S Contact Cleaner Crown Crown
Electrical Connector Oxidation &
T Nye Grease NYE Lubricants
Corrosion Inhibitor
U Battery Cleaner Crown Crown
V Battery Protector Crown Crown
W Food Grade Machinery Lubricant Crown Crown
X Food Grade Silicone Spray Crown Crown
Y Extended Life Coolant
Crown 1987 PF7886-5 Rev. 1/11 M1.0-04.0-005
19 Rev. 1/11
33
Notes:
34
LUBRICATION & ADJUSTMENT
Operator’s Daily Checklist
Operator’s Daily Checklist Before you do maintenance on the truck, you must
move it to an area where there is sufficient space. This
To get the maximum life out of your equipment, ap- is to make sure that others are safe and that you do the
proved personnel must follow a planned maintenance correct maintenance on the truck.
(PM) schedule. Operator input is an important part of a
This checklist (OF3772) is available through your
planned maintenance schedule. Operator input can
Crown dealer.
decrease the time that the truck is not available, help to
schedule planned maintenances, and save money. Be-
cause of this, Crown recommends an operator's daily
checklist.
Fig. 1 (14990)
Crown 2011 PF25239-1 Rev. 8/12 M1.0-04.0-006
01 Rev. 8/12
35
Notes:
36
INSPECTION AND LUBRICATION
Lubricants, Aerosols, and Service Supplies
Lubricants, Aerosols, and
Service Supplies
See the Lubrication Identification table and the Alter-
nate Lubricants and Fluids table in this section for the
recommended list of lubricants, aerosols, and service
supplies. Use the tables when performing planned
maintenance on Crown lift trucks.
Lubricant Identification
Lubricant Description Part Package
Identifier Number Quantity
A Oil, gear, 80W-90, high performance, multi-purpose 363506-001 1 qt
AA Fluid, automatic transmission, multi-purpose 363503-001 1 qt
AAA Fluid, universal hydraulic and transmission 363513-001 1 qt
363514-001 1 qt
AAAA Oil, synthetic, 75W-90
363514-101 1 gal
B Grease, multi-purpose 063002-034 14 oz cartridge
063002-017 14.5 oz cartridge
BB Grease, multi-purpose, low temperature
063002-046 40 - 14.5 oz cartridges
363002-001 14 oz cartridge
BBB Grease, food grade, multi-purpose
363002-030 5 gal
063002-025 14.5 oz cartridge
BBBB Grease, multi-purpose, premium
063002-026 5 gal
5B Grease, NLGI 00 063002-060 16 oz can
C Oil, SAE-40
363500-001 1 qt
CC Oil, engine,10W-30
363500-101 1 gal
363504-101 1 gal
D (1) Oil, standard, hydraulic
363504-005 5 gal
Oil, hydraulic, low temperature, used with premium hy- 363505-101 1 gal
DD
draulic oil 363505-005 5 gal
DDD (2) (4) Oil, premium, hydraulic, Mobil DTE 24 063001-021 1 gal
4D (3) Oil, hydraulic, Mobil Univis HVI 13 063001-035 5 gal
063002-024 14.5 oz cartridge
E Grease - mast channel and gears
063002-022 35 lb pail
EE Lubricant - channel slide 363143-001 10.5 oz can
Crown 2011 PF25240 Rev. 1/22 M1.0-04.0-050
07 Rev. 1/22
39
INSPECTION AND LUBRICATION
Lubricants, Aerosols, and Service Supplies
Lubricant Identification
Lubricant Description Part Package
Identifier Number Quantity
063002-024 14.5 oz cartridge
F Gear grease
063002-022 35 lb pail
Lubricant - chain and cable 363107-001 15 oz can
G
Lubricant, premium - chain and cable 363115-001 12 oz can
H Protectant - rubber and vinyl 363129-001 11 oz can
063002-039 1 lb
I Grease, synthetic - motor spline connection
127801S 1 oz
063004-002 12 oz
J Fluid, brake, DOT 5
063004-003 1 gal
063002-034 14 oz cartridge
K Grease - wheel bearing
063002-045 40 - 14 oz cartridges
L Lubricant, metal spray, break-in 063002-021 16 oz spray
LL Lubricant, S00727 - freezer condition 063002-059 9 oz can
M Grease, clear - O-rings 063002-020 5.3 oz tube
Cleaner, low VOC - brakes and parts 363119-001 15 oz can
N
Cleaner, nonflammable - brake and parts 363116-001 18 oz can
O Lubricant, penetrating 363104-001 15 oz can
P Grease, premium, multi-purpose 363108-001 13 oz can
Q Grease, white, lithium 363110-001 14 oz can
R Cleaner - carburetor and choke 363109-001 14 oz can
Cleaner, contact, nonflammable 363106-001 10 oz can
S
Cleaner, contact 363128-001 13.5 oz can
127189-001 55 cc
T Contact lubricant
127189-002 2 oz. tube
U Cleaner - battery 363124-001 18 oz can
V Protector - battery 363125-001 14 oz can
W Lubricant, food grade, machine 363127-001 12 oz can
X Lubricant, food grade, silicone spray 363126-001 11 oz can
363535-101 1 gal
Y Coolant, extended lift - C-5 LP series
363535-005 6 - 1 gal bottles
Z Fluid, windshield washer, protects to -29 °C (-20 °F) 300100-101 1 gal
M1.0-04.0-051 Crown 2011 PF25240 Rev. 1/22
07 Rev. 1/22
40
INSPECTION AND LUBRICATION
Lubricants, Aerosols, and Service Supplies
Lubricant Identification
Lubricant Description Part Package
Identifier Number Quantity
Technician Tips: Lift trucks operated in below freezing temperatures must use low temperature hydraulic oil
and grease.
(1) Usual operation (temperatures of 0.6 °C [33 °F] and above)
(2) Used on TSP lift trucks. Standard temperature freezers (-18 to 4 °C [0 to 39 °F]). Do not mix with dif-
ferent oil.
(3) Used on TSP lift trucks. Low temperature freezers (-40 to -12 °C [-40 to 10 °F]). Do not mix with differ-
ent oil.
(4) Premium antiwear hydraulic oil used in mixing with low temperature oil
Crown 2011 PF25240 Rev. 1/22 M1.0-04.0-051
07 Rev. 1/22
41
INSPECTION AND LUBRICATION
Lubricants, Aerosols, and Service Supplies
Alternate Lubricants and Fluids
Type of Lubricant Product Name Manufacturer/
Distributor
Oil, 80W-90, high performance, multi- Crown Crown
A
purpose - gear
Fluid, multi-purpose - Automatic trans- Crown Crown
AA
mission
Fluid, universal - hydraulic and transmis- Crown Crown
AAA
sion
AAAA Oil, synthetic, 75W-90 - gear Crown Crown
Mobilgrease XHP 222 Special Mobil
Union Unoba EP No 2 Union 76 Co.
B Grease, multi-purpose Retinax A (1) Shell
LM Grease Burmah Castrol
Unirex EP-2 Exxon
Lubriplate Fiske Bros Refining Co.
BB Grease, low temperature Alvania RA (1) Shell
Helveum O (1) Burmah Castrol
BBB Grease, multi-purpose, food grade Petro Canada Purity FG Petro Canada
Mobilux EP2 64127-4 Mobil
Retinax AM 71119 Shell
BBBB Grease, multi-purpose, premium
Chevron RPM Heavy-Duty LC Chevron
Grease EP
5B Grease NLGI 00 Mobilgrease XHP 005 Mobil
C Oil, SAE 40
CC Oil, 10W-30 - engine Crown Crown
D (2) Oil, hydraulic Crown Crown
DD Oil, hydraulic, low temperature Crown Crown
DDD (3) (5) Oil, hydraulic - Mobil DTE24 Mobil DTE 24 Mobil
4D (4) Oil, hydraulic - Mobil Univis HVI 13 Mobil Univis AVI 13 Mobil
E Grease - channel Factran #2 Standard Oil Co.
EE Lubricant - channel slide Crown Crown
F Grease - gear channel and shaft Molykote BR-2 Plus Dow Corning
Lubricant - chain and cable Crown Crown
G
Lubricant, premium - chain and cable Crown Crown
M1.0-04.0-053 Crown 2011 PF25240 Rev. 1/22
07 Rev. 1/22
42
INSPECTION AND LUBRICATION
Lubricants, Aerosols, and Service Supplies
Alternate Lubricants and Fluids
Type of Lubricant Product Name Manufacturer/
Distributor
H Protectant, rubber and vinyl Crown Crown
I Grease - lift pump coupling Nyogel 774F-MS NYE Lubricants
J Fluid, DOT 5 - brake Q2-1141 Silicone Brake Fluid Dow Corning
Mobilgrease XHP 222 Special Mobil
K Grease - wheel bearing Unirex EP-2 Exxon
Lubriplate No. 1242 (1) Fiske Bros. Refining Co.
L Spray - metal assembly Dow Corning Dow Corning
Lubricant, spray on S00727, PTFE Spray on S00727
LL Sherwin Williams
freezer lubricant
M Grease, silicone, clear Dow Corning 111 Compound Dow Corning
Cleaner, low VOC - brake and parts Crown Crown
N
Cleaner, nonflammable - brake and parts Crown Crown
O Lubricant, penetrating Crown Crown
P Grease, premium, multi-purpose Crown Crown
Q Grease, white, lithium Crown Crown
R Cleaner - choke and carburetor Crown Crown
S Cleaner - contact Crown Crown
Inhibitor - electrical connector oxidation
T NYE Grease NYE Lubricants
and corrosion
U Cleaner - battery Crown Crown
V Protector - battery Crown Crown
W Lubricant, food grade, machine Crown Crown
X Lubricant, food grade, silicone spray Crown Crown
Mobil Delvac ELC Mobil
Y Coolant, extended life Shell Rotella Ultra ELC Shell
Zerex ELC HD Coolant Zerex
Z Fluid, windshield washer
Crown 2011 PF25240 Rev. 1/22 M1.0-04.0-054
07 Rev. 1/22
43
INSPECTION AND LUBRICATION
Lubricants, Aerosols, and Service Supplies
Alternate Lubricants and Fluids
Type of Lubricant Product Name Manufacturer/
Distributor
Technician Tips: Lift trucks operated in below freezing temperatures must use low temperature hydraulic oil and
grease.
(1) Permitted alternative, consult the factory if unavailable
(2) Usual operation (temperatures of 0.6 °C (33 °F) and above)
(3) Used on TSP lift trucks. Standard temperature freezers (-18 to 4 °C (0–39 °F). Do not mix with differ-
ent oil
(4) Used on TSP lift trucks. Low temperature freezers (-40 to -12 °C (-40 to 10 °F). Do not mix with differ-
ent oil
(5) Premium antiwear hydraulic oil used in mixing with low temperature oil
M1.0-04.0-055 Crown 2011 PF25240 Rev. 1/22
07 Rev. 1/22
44
INSPECTION AND LUBRICATION
Planned Maintenance
Planned Maintenance 9. Look for unwanted material in or around the lift
truck components.
Overview 10. Look for damaged components.
11. Look for loose or missing fasteners.
To make sure that your lift truck continues to move ma-
12. Look for damaged electrical wires or connectors.
terials safely and quickly, you must do regular mainte-
nance to your lift truck.
Planned maintenance information
• Use the applicable interval table in this section to
complete the planned maintenance procedure.
CAUTION
– 60 days / 250 hr
Injury or material damage can occur. – 90 days / 500 hr
If you operate a lift truck for which repair is necessary
or that is not safe, injury or material damage can occur. – 6 months / 1,000 hr
Do not operate the lift truck until it is safe. – 12 months / 2,000 hr
Immediately make a report of the condition to the • Change the lubrication and inspection intervals to
applicable authority. decrease corrosion and wear on parts for lift trucks
operated in the following environments:
Do not make repairs or adjustments to the lift truck
unless you are approved to do them. – Environments with low temperatures
– Environments with moisture
– Environments with other conditions that can
cause contamination or corrosion
CAUTION • Use the applicable planned maintenance inspec-
tion report (PF15610) to record maintenance.
Injury or material damage can occur.
• Consult your Crown dealer for planned mainte-
If you do not correctly prepare the lift truck for mainte-
nance inspection reports.
nance, injury or material damage can occur.
Complete all lockout/tagout procedures. See Lubrication
SAFETY / Control of Hazardous Energy.
The following information gives the correct specifica-
Obey all safety instructions. See SAFETY.
tions for lubrication. Use high-grade lubricants and flu-
ids. See the tables in this section for the applicable lu-
Visually inspect the lift truck bricants.
1. Complete the Operator's Daily Checklist. See IN- • See Figure 1. Use a 100% mixture of DTE 24 hy-
SPECTION AND LUBRICATION / Operator's Daily draulic oil (P/N 063001-021) on the following lift
Checklist. trucks:
2. Move the lift truck to a maintenance area with a – Lift trucks that operate in temperatures at or more
level floor. than 0 °C (32 °F)
3. Turn off the lift truck. – Lift trucks that operate in a cooler environment
4. Put chocks against the wheels to prevent the with intermittent freezer entry
movement of the lift truck. See SAFETY / Control – Lift trucks that are stored in temperatures more
of Hazardous Energy / Lifting and Blocking. than 0 °C (32 °F)
5. Disconnect the battery. • See Figure 1. Use a 50% / 50% mixture of low tem-
6. Lockout/Tagout the lift truck. See SAFETY / Con- perature hydraulic oil (P/N 063001-006) and stan-
trol of Hazardous Energy / Lockout/Tagout proce- dard hydraulic oil (P/N 063001-021) on the follow-
dures. ing lift trucks:
7. Release the capacitance voltage in Access 3™. – Lift trucks that are stored in temperatures less
See SAFETY / Control of Hazardous Energy / Ca- than 0 °C (32 °F)
pacitance. – Lift trucks that operate continuously in tempera-
8. Blow off the lift truck with low-pressure air. tures at or less than 12 °C (10 °F)
Crown 2007 PF15806 Rev. 1/17 M1.0-7335-001
02 Rev. 1/17
53
INSPECTION AND LUBRICATION
Planned Maintenance
• Do not use lift trucks that operate in deep freezers – Nuts
in high temperature environments – Roll pins
• Apply rust preventative (P/N 078882) to the follow- – Retaining rings
ing components to prevent corrosion:
– Washers
– Fasteners
Lift Truck Stored Temperature
0
(-23.3 C)
0 0 0 0 0 0 0 0 0 0 0 0
80 F 70 F 60 F 50 F 40 F 30 F 20 F 10 F 0 F -10 F -20 F -30 F
0 0
80 F 32 F
0
(0 C)
0
70 F
0
60 F
100% Standard Oil
Consult the
Operating Environment Temperature
0
50 F factory
0 0
40 F 40 F
0 0
0 32 F(0 C)
30 F
0
20 F
0 50 / 50% Oil Mix
10 F
0
0 F (-18 C)
0
0
-10 F 80 / 20% Oil Mix
0
-20 F
0
0 (-34.4 C)
-30 F
Consult the factory
Fig. 1 (22831-01)
M1.0-7335-002 Crown 2007 PF15806 Rev. 1/17
02 Rev. 1/17
54
INSPECTION AND LUBRICATION
Planned Maintenance
Component access
This section includes components that you must open,
remove, or access when you do maintenance on the lift
truck.
5
13
1 Platform console
2 Control module
7
3 Overhead console
4 Platform floorboard
9
5 Platform back wall
6 Mast
7 Top cover 8
8 Power unit doors
9 Platform side of the power unit 11
10 Below the power unit
11 Battery covers
12 Below the battery compartment
13 Lifting fork module
10
12
Fig. 2 (31511)
Crown 2007 PF15806 Rev. 1/17 M1.0-7335-003
02 Rev. 1/17
55
INSPECTION AND LUBRICATION
Planned Maintenance
Remove the platform console to access: • SB1
• Access 1 • THS3
• Access 4 Go to the platform back wall to access:
• ALM1 • CHS1
• DB1 • CHS2
• ECR1 • ECR4
• ECR5 • HGTRS
• GTS1 • HN1
• GTS2 • RES19
• InfoLink® control module (Windows) • RES20
• K1
Go to the mast to access:
• PGS1
• CHS3
• Platform distribution panel
• CHS4
• RES11
• ECR6
• RES12
• LGT8
Remove the control module to access: • LGT9
• EDS • RES9
• FS • RES10
• GUS1
Open the top cover to access:
• HNS
• Battery cell caps
• KYS
• Battery connector
• POT1–POT3
• FIL1
• RES13–RES22
• LGT1
• RES25
• SB21
• RS
Go to the overhead console to access:
• FAN1
• LGT2–LGT7
• PS1
• PS2
• RES1
• SB30
• TB502
Go to the platform floorboard to access:
• BRS1
• Fork pins
• M5
• Pallet grab
• PGLS1
• PGLS2
• RES18
• RES40
• RES41
M1.0-7335-004 Crown 2007 PF15806 Rev. 1/17
02 Rev. 1/17
56
INSPECTION AND LUBRICATION
Planned Maintenance
Open the power unit doors to access: • TS1
• Access 3™ Go to the platform side of the power unit to access:
• Access 5 • HN2
• Access 6 • K15
• BRES1
Go below the power unit to access:
• BRES2
• GS1
• BRK1
• GS2
• Contactor panel
Remove the left and the right battery covers to access:
• Controller panel
• Battery
• CS1
• THS2
• CV1
• CV2 Go below the battery compartment to access:
• CV3 • EACA1
• Drive unit • EACA2
• DTS1 • EACB1
• ECR2 • EACB2
• ECR3 Go to the lifting fork to access:
• ED1 • GTS5
• ED2 • GTS6
• FAN2 • K15
• FU1–FU19 • LMS1
• K2 • LOS3
• K11 • LOS4
• K12 • PVLF
• M1 • SV1
• M2 • RAS3
• M3 • RAS4
• Manifold • RES21
• MVL • RES22
• ORF1–ORF6 • RES33–RES36
• P1
• Power unit distribution panel
• RES2
• RES3
• RES7
• RES8
• Reservoir
• Return filter
• RV1
• Impact sensor
• Strainer
• SVL
• PVL
Crown 2007 PF15806 Rev. 1/17 M1.0-7335-005
02 Rev. 1/17
57
INSPECTION AND LUBRICATION
Planned Maintenance
Fig. 3 (18174)
M1.0-7335-006 Crown 2007 PF15806 Rev. 1/17
02 Rev. 1/17
58
INSPECTION AND LUBRICATION
Planned Maintenance
Lubrication
Index Component Lube Quantity 60 days 90 days 6 months 12 months
Type 250 hr 500 hr 1,000 hr 2,000 hr
L-1 Brake Pedal Guides C (1) (2)
L-2 Platform Gates C (1) (2)
L-3 Battery Cover Hinge C (1) (3)
L-4 Power Unit Door Hinges C (1) (2)
L-5 Battery Rollers B (1) (3)
L-6 Battery Restraint Threads B (1) (2)
L-7 Aisle Guide Wheels B (1) (3)
L-8 Load Wheel Axles B (1) (3)
(1) - As Required
(2) - Check
(3) - Lubricate
See the Lubrication Identification table in the Lubricants, Aerosols, and Service Supplies section for the
lube type explanation and capacity
See Figure 3 for the lubrication locations
Inspection and Adjustment
Index Component 60 days 90 days 6 months 12 months
250 hr 500 hr 1,000 hr 2,000 hr
I-1 Brake Pedal Switch (1)
I-2 Brake Pedal Mechanism (1)
I-3 Platform Gates and Switches (1)
I-4 Load Wheels (1)
I-5 Aisle Guide Wheels and Switches (1)
I-6 Skids (1)
I-7 Aisle Guide Skids (1)
(1) - Inspect, clean, or adjust. See Figure 3 for the component locations
See the appropriate section of the service manual for additional information concerning inspection or
adjustment
Crown 2007 PF15806 Rev. 1/17 M1.0-7335-007
02 Rev. 1/17
59
INSPECTION AND LUBRICATION
Planned Maintenance
I-1
L-1 I-7
I-5
L-1
I-6
I-3
L-1 I-2
I-5
I-8
L-2
I-12
I-4
M1
I-11
M3
M2 I-9
I-10
I-13
I-13
Fig. 4 (18175-01)
M1.0-7335-008 Crown 2007 PF15806 Rev. 1/17
02 Rev. 1/17
60
INSPECTION AND LUBRICATION
Planned Maintenance
Lubrication
Index Component Lube Quantity 60 days 90 days 6 months 12 months
Type 250 hr 500 hr 1,000 hr 2,000 hr
Mast, Channels, Column
L-1 E (1) (2)
Rollers
L-2 Mast Hoses H (1) (2)
(1) - As Required
(2) - Check
See the Lubrication Identification table in the Lubricants, Aerosols, and Service Supplies section for the
lube type explanation and capacity
See Figure 4 for the lubrication locations
Inspection and Adjustment
Index Component 60 days 90 days 6 months 12 months
250 hr 500 hr 1,000 hr 2,000 hr
I-1 Battery Connector (1)
I-2 Battery (1)
I-3 Strobe Light / Flashing Light (1)
I-4 Lift Cylinders and Restraints (1)
I-5 Column Rollers - Mast (1)
I-6 Column Rollers - Platform (1)
I-7 Operator Harness (1)
I-8 Forks (1)
I-9 Lift Pump Motor (M3) Cables and Brushes (1)
I-10 Steer Motor (M2) Cables and Brushes (1)
I-11 Traction Motor (M1) Cables (1)
I-12 Hydraulic Lines, Fittings, Hoses (1)
I-13 Power Unit to Mast Bolts (1)
(1) - Inspect, clean, or adjust. See Figure 4 for the component locations
See the appropriate section of the service manual for additional information concerning inspection or
adjustment
Crown 2007 PF15806 Rev. 1/17 M1.0-7335-009
02 Rev. 1/17
61
INSPECTION AND LUBRICATION
Planned Maintenance
L-1
I-1
I-4
I-2
I-3
L-2
I-5
L-1
I-1
TT I-2
mast
shown L-1
I-1
I-3
L-1
I-1
I-3 I-2
ECR4
ECR1, I-7
ECR5
I-8
HN1
I-6
Fig. 5 (18176-02)
M1.0-7335-010 Crown 2007 PF15806 Rev. 1/17
02 Rev. 1/17
62
INSPECTION AND LUBRICATION
Planned Maintenance
Lubrication
Index Component Lube Quantity 60 days 90 days 6 months 12 months
Type 250 hr 500 hr 1,000 hr 2,000 hr
L-1 Lift Chain G (1) (2)
L-2 Pallet Grab Linkage C (1) (2)
(1) - As Required
(2) - Check
See the Lubrication Identification table in the Lubricants, Aerosols, and Service Supplies section for the
lube type explanation and capacity
See Figure 5 for the lubrication locations
Inspection and Adjustment
Index Component 60 days 90 days 6 months 12 months
250 hr 500 hr 1,000 hr 2,000 hr
I-1 Lift Chains (1)
I-2 Chain Anchors and Retainers (1)
I-3 Chain Slack Linkage (1)
I-4 Brake Friction Plates and Operation (1)
I-5 Pallet Grab Linkage and Operation (1)
I-6 Horn (1)
I-7 Platform Height Sensor (1)
I-8 Steering Encoder (1)
(1) - Inspect, clean, or adjust. See Figure 5 for the component locations
See the appropriate section of the service manual for additional information concerning inspection or
adjustment
Crown 2007 PF15806 Rev. 1/17 M1.0-7335-011
02 Rev. 1/17
63
INSPECTION AND LUBRICATION
Planned Maintenance
I-3
L-1
I-3 I-4
L-2
I-2
ED2
ED1
P1
P2
I-1
I-5
Fig. 6 (18177-02)
M1.0-7335-012 Crown 2007 PF15806 Rev. 1/17
02 Rev. 1/17
64
INSPECTION AND LUBRICATION
Planned Maintenance
Lubrication
Index Component Lube Quantity 60 days 90 days 6 months 12 months
Type 250 hr 500 hr 1,000 hr 2,000 hr
L-1 Steering Gearbox Oil Level DDD (1) 1 L (1 qt) (2) (2)
L-2 Steering Gears F (3) (4)
L-3 Hydraulic Filter (4) (2) (2)
Hydraulic Reservoir - Single
L-4 D 13.2 L (14 qt) (4) (2)
Pump
Hydraulic Reservoir - Dual
D 17.5 L (18.5 qt) (4) (2)
Pump
L-5 Hydraulic Strainer (2)
L-6 Drive Unit Thrust Bearing B (3) (5)
L-7 Drive Unit Fluid Level A 0.7 L (0.75 qt) (4) (2)
(1) - Use DDD (see Lubricants, Aerosols, and Service Supplies) hydraulic oil in the steering gearbox for
both normal and low temperature applications
(2) - Change; for L-1 and L-2, change first time only as noted, thereafter check at 250 hr / 60 day intervals
and change at longer interval as noted.
(3) - As Required
(4) - Check
(5) - Lubricate
See the Lubrication Identification table in the Lubricants, Aerosols, and Service Supplies section for the
lube type explanation and capacity
See Figure 6 for the lubrication locations
Inspection and Adjustment
Index Component 60 days 90 days 6 months 12 months
250 hr 500 hr 1,000 hr 2,000 hr
I-1 Contactor Tips (1)
I-2 Steering Gears and Sprockets (1)
I-3 Chain Slack Switch (1)
I-4 Stop Blocks (1)
I-5 Drive Tire (1)
I-6 All Electrical Termination Points (1)
(1) - Inspect, clean, or adjust. See Figure 6 for the component locations
See the appropriate section of the service manual for additional information concerning inspection or
adjustment
Crown 2007 PF15806 Rev. 1/17 M1.0-7335-013
02 Rev. 1/17
65
INSPECTION AND LUBRICATION
Planned Maintenance
LGT3,
LGT6 FAN1
I-9 I-10
LGT2,
LGT5
I-9 I-5
L-1
I-6
I-8
DTS1
K2
FU1–FU9
Fig. 7 (18178-02)
M1.0-7335-014 Crown 2007 PF15806 Rev. 1/17
02 Rev. 1/17
66
INSPECTION AND LUBRICATION
Planned Maintenance
Lubrication
Index Component Lube Quantity 60 days 90 days 6 months 12 months
Type 250 hr 500 hr 1,000 hr 2,000 hr
Control Cables and Pulleys
L-1 H (1) (2)
(Plastic)
(1) - As Required
(2) - Check
See the Lubrication Identification table in the Lubricants, Aerosols, and Service Supplies section for the
lube type explanation and capacity
See Figure 7 for the lubrication locations
Inspection and Adjustment
Index Component 60 days 90 days 6 months 12 months
250 hr 500 hr 1,000 hr 2,000 hr
I-1 Travel and Lift Controls (1)
I-2 Power Disconnect (1)
I-3 Panel Indicator Lights (1)
I-4 Panel Switches (1)
I-5 Cable Tension Devices (1)
I-6 Control Cables and Guides (1)
I-7 Mast Cushion Mechanisms (1)
I-8 Tow Switch (1)
I-9 Overhead Console Lights (1)
I-10 Overhead Console Fan (1)
(1) - Inspect, clean, or adjust. See Figure 7 for the component locations
See the appropriate section of the service manual for additional information concerning inspection or
adjustment
Crown 2007 PF15806 Rev. 1/17 M1.0-7335-015
02 Rev. 1/17
67
INSPECTION AND LUBRICATION
Planned Maintenance
L-1
I-1
I-3 I-4
ECR6
I-2
Fig. 8 (31512)
M1.0-7335-016 Crown 2007 PF15806 Rev. 1/17
02 Rev. 1/17
68
INSPECTION AND LUBRICATION
Planned Maintenance
Lubrication
Index Component Lube Quantity 60 days 90 days 6 months 12 months
Type 250 hr 500 hr 1,000 hr 2,000 hr
L-1 Lifting Fork Chain G (1) (2)
(1) - As Required
(2) - Check
See the Lubrication Identification table in the Lubricants, Aerosols, and Service Supplies section for the
lube type explanation and capacity
See Figure 8 for the lubrication locations
Inspection and Adjustment
Index Component 60 days 90 days 6 months 12 months
250 hr 500 hr 1,000 hr 2,000 hr
I-1 Lift Chains (1)
I-2 Chain Anchors and Retainers (1)
I-3 Chain Slack Linkage (1)
I-4 Mast Height Sensor (1)
(1) - Inspect, clean, or adjust. See Figure 8 for the component locations
See the appropriate section of the service manual for additional information concerning inspection or
adjustment
Crown 2007 PF15806 Rev. 1/17 M1.0-7335-017
02 Rev. 1/17
69
Notes:
70
LUBRICATION & ADJUSTMENT
Componentry
Componentry
Access 1
Operator Display
Location: platform.
Purpose: pertinent truck information to operator or
service technician, (SPI) steer position indicator dis-
plays steering information (Optional).
Data: information received from truck control module Figure 18286
and sensors.
Adjustment: none required.
Diagrams: DIA-7335-003 and 005 (B-2) (B-3), Access 3 (TCM)
DIA-7335-009 (B-1) (C-1) (B-2) (C-2).
Parts Breakdown: 05.0-7335-001 (8) (21).
Access 3 (TCM)
Traction Control Module
Location: traction panel.
Figure 18287
Purpose: controls braking and traction motor (M1)
speed via operator input from BRS1 and POT1.
Data: transistor control circuitry.
Adjustment: refer to Electrical.
Diagrams: DIA-7335-002 (B-2), DIA-7335-013 (B-1)
(B-2) (C-1) (C-2).
Parts Breakdown: 04.1-7335-001 (13).
Access 4 (VCM)
Vehicle Control Module
Location: operator compartment.
Purpose: controls vehicle operations
Data: refer to Electrical.
Adjustment: none required. Figure 18288
Diagrams: DIA-7335-002 (A-3), DIA-7335-003 (B-1)
(B-2), DIA-7335-009 (B-2) (C-2), DIA-7335-010 (C-2)
(C-3) (C-4).
Parts Breakdown: 09.0-7335-001 (24).
Crown 2007 PF15807-1 M1.0-7335-050
49
LUBRICATION & ADJUSTMENT
Componentry
Access 5 (SCM)
Steering Control Module Access 5 (SCM)
Location: traction panel.
Purpose: control steering operation.
Data: refer to Electrical and Steering.
Adjustment: none required.
Diagrams: DIA-7335-004 (B-3), DIA-7335-014 (B-2) Figure 18289
(B-2) (C-1) (C-2), DIA-7335-019 (A-2).
Parts Breakdown: 04.1-7335-001 (17).
Access 6 (GCM)
Access 6 (GCM)
Guidance Control Module (Optional)
Location: below steering gearbox.
Purpose: controls automatic guidance system (wire
guidance).
Data: refer to Electrical. Figure 18290
Adjustment: refer to Electrical.
Diagrams: DIA-7335-002 (B-4), DIA-7335-016 (B-1)
(B-2) (C-1) (C-2).
Parts Breakdown: 04.1-7335-001 (25).
ACCUMULATOR
Location: front, lower right side of power unit.
Purpose: shock absorber for lift/lower hydraulic sys-
tem.
Data: pre-charge 3445 kPa (500 psi) refer to Hydraulic
for charging procedures.
Adjustment: none required.
Accumulator
Diagrams: HYD-7335-001.
Parts Breakdown: 02.07335-003 (48). Figure 18285
M1.0-7335-051 Crown 2007 PF15807-2
50
LUBRICATION & ADJUSTMENT
Componentry
ALM1
Location: distribution panel on platform.
Purpose: status alarm.
Data: audible warning when operator does incorrect
sequence.
Adjustment: none required.
Diagrams: DIA-7335-003 (A-1), DIA-7335-005 (A-2),
DIA-7335-006 and 007 (B-2).
Parts Breakdown: 04.3-7335-050 (3).
Distribution Panel
BRES1, BRES2 Figure 18291
Battery Restraint Switch
Location: power unit skirt.
Purpose: monitor presence of battery retainer/side
cover and disable travel if battery retainer is not
present.
Data: wired normally open, held closed when battery
BRES1 and
retainer/side cover is in place.
BRES2 (Shown)
Adjustment: none required.
Diagrams: DIA-7335-002 (B-3) (C-3), DIA-7335-014
(B-2).
Part of Power Unit
Parts Breakdown: 01.2-7335-001 (14) (54).
BRK1
Figure 18292
Brake
Location: traction motor.
Purpose: provide braking force to traction motor to
stop truck and prevent movement of parked vehicle.
Data: Access 3 release via operator request, spring
applied.
Adjustment: refer to Brake.
Diagrams: DIA-7335-002 and 004 (A-3),
DIA-7335-014 (B-2).
Parts Breakdown: 05.3-7335-001 (6).
Figure 18293
Crown 2007 PF15807-3 M1.0-7335-052
51
LUBRICATION & ADJUSTMENT
Componentry
BRS1
Part of Platform
Brake Switch
Floorboard
Location: platform below floorboard.
Purpose: allows operator to release or apply brake.
Data: wired normally open, held closed when operator
is depressing brake pedal.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-3), DIA-7335-011 (C-4).
Parts Breakdown: 05.1-7334-001 (11).
CHS1, CHS2
Figure 18294
Chain Slack Switches
Location: base of platform - mast side.
Part of Platform
Purpose: prohibits lowering when mast chains be-
come slack.
Data: wired normally open, held closed as chains
maintain proper tension.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-2), DIA-7335-005 (B-2),
DIA-7335-011 (B-3).
Parts Breakdown: 07.6-7334-050 (51 and 56).
CHS3, CHS4 Figure 18295
Chain Slack Switches
Location: top of mainframe.
Purpose: prohibits lowering when mast chains be-
come slack.
Data: wired normally open, held closed as chains
maintain proper tension.
Adjustment: none required.
Diagrams: DIA-7335-004 (A-2) (B-2), DIA-7335-013 Part of
(C-3) (C-4). Mainframe
Parts Breakdown: 07.6-7334-050 (2).
Figure 18296
M1.0-7335-053 Crown 2007 PF15807-4
52
LUBRICATION & ADJUSTMENT
Componentry
CV1
Check Valve Lift/Lower
Location: lift/lower manifold. Manifold
Purpose: prevent back flow into pump P1.
Data: not applicable.
Adjustment: none required.
Diagrams: HYD-7335-001.
Figure 18297
Parts Breakdown: 02.4-7335-050 (7).
CV2
Lift/Lower
Check Valve Manifold
Location: lift/lower manifold (high speed lift/lower
only).
Purpose: prevent back flow into pump P1.
Data: not applicable.
Adjustment: none required. Figure 18298
Diagrams: HYD-7335-001.
Parts Breakdown: 02.4-7335-001 (7), 02.4-7335-050
(7).
Lift/Lower
Manifold
CV3
Check Valve
Location: lift/lower manifold (high speed lift/lower
only).
Purpose: prevent back flow into pump P2.
Data: not applicable. Figure 18299
Adjustment: none required.
Diagrams: HYD-7335-001.
Parts Breakdown: 02.4-7335-050 (7).
Crown 2007 PF15807-5 M1.0-7335-054
53
LUBRICATION & ADJUSTMENT
Componentry
CYLINDER
Free Lift
Location: 3rd stage mast.
Purpose: raise platform.
Data: not applicable.
Adjustment: none required.
Diagrams: HYD-7335-001. (a) 3rd Stage Mast
Parts Breakdown: 08.3-7330-001 (1). (b) Free Lift Cylinder
Figure 18300
CYLINDER
Mast
Location: main frame.
Purpose: raise mast and platform.
Data: not applicable.
Adjustment: none required.
Diagrams: HYD-7335-005.
Parts Breakdown: 08.1-7335-001 (1).
DTS1
Drive/Tow Switch
Location: distribution panel.
(a) Mast Cylinder
Purpose: to release brake allowing truck to be towed.
Data: two position, on-on, lever handle switch. Figure 18306
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3).
Parts Breakdown: 04.3-7335-001.
Distribution
Panel
Figure 18308
M1.0-7335-055 Crown 2007 PF15807-6
54
LUBRICATION & ADJUSTMENT
Componentry
ECR1
Steering Command Encoder
Location: steering command assembly.
Purpose: provide steering command input to steering
module.
Data: 5 volts D.C., 32 pulses per revolutions.
Adjustment: none required.
Diagrams: DIA-7335-003 (A-2), DIA-7335-005 (B-2),
DIA 7335-009 and 010 (A-4).
Steering Assembly
Parts Breakdown: 06.0-7335-001 (6).
Figure 18309
ECR2
Steering Feedback Encoder
Location: in front of traction motor.
Purpose: provide steer wheel position feedback to
steering module.
Data: 5 volts D.C., 256 pulses per revolution.
Adjustment: none required.
Diagrams: DIA-7335-002 and 004 (B-3),
DIA-7335-014 (B-4).
Part of
Parts Breakdown: 04.8-7335-200 (3).
Power Unit
ECR3 Figure 18310
Traction Speed Encoder
Location: traction motor.
Purpose: provide ground speed and direction informa-
tion for control system based on motor speed and di-
rection of revolution.
Data: 5 volts D.C., 32 pulses per revolution.
Adjustment: none required.
Diagrams: DIA-7335-004 (C-2), DIA-7335-014 (C-4).
Traction Motor
Parts Breakdown: 03.1-7335-001 (16).
Figure 18311
Crown 2007 PF15807-7 M1.0-7335-056
55
LUBRICATION & ADJUSTMENT
Componentry
ECR4
Lift Height Sensor
Location: lower rear platform.
Purpose: provide measured height of forks. Platform
Data: 5 volts D.C., 32 pulses per revolution.
Adjustment: none required.
Diagrams: DIA-7335-003 and 010 (A-2),
DIA-7335-005 (B-2), DIA-7335-009 (A-4).
Parts Breakdown: 09.0-7334-200 (17).
Figure 18312
ECR5
Steering Command Encoder
Location: steering command assembly.
Purpose: provide steering command input to steering
module.
Data: 5 volts D.C., 32 pulses per revolutions.
Adjustment: none required.
Diagrams: DIA-7335-003 (A-1), DIA-7335-005 (A-1), Steering Assembly
DIA-7335-010 (A-4).
Parts Breakdown: 06.0-7335-001 (6). Figure 18313
ED1
Emergency Disconnect Main Contactor
Location: lift/power panel.
Purpose: provide ability to turn off power control cir-
cuitry.
Data: positive voltage provided through K1 relay, neg-
ative voltage controlled by SCM.
Adjustment: none required.
Diagrams: DIA-7335-002, 004 and 015 (C-2), Lift/Power Panel
DIA-7335-013 (C-3), DIA-7335-019 (B-1).
Figure 18314
Parts Breakdown: 04.3-7335-100 (1), 04.4-6540-001
(1).
M1.0-7335-057 Crown 2007 PF15807-8
56
LUBRICATION & ADJUSTMENT
Componentry
ED2
Emergency Disconnect Traction & Steering Con-
tactor
Location: lift/power panel.
Purpose: provide ability to disconnect power between
MRC1 and SCM.
Data: 24 volt contactor.
Adjustment: none required.
Diagrams: DIA-7335-002 (B-2), DIA-7335-004, 013
and 015 (C-2), DIA-7335-019 (B-1). Lift/Power Panel
Parts Breakdown: 04.3-7335-100 (1), 04.4-6540-050
(1). Figure 18315
EDS
Emergency Disconnect Switch
Location: control module.
Purpose: resets the emergency-disconnect contactor,
removing battery power from steering, lift, traction and
control circuits.
Data: wired normally closed. Pressing switch button
actuates switch.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-4), DIA-7335-005 (B-4).
Control Module
Parts Breakdown: 04.6-7334-050 (27).
Fan1 Figure 18316
Operator Fan
Location: overhead console.
Purpose: operator comfort.
Data: 24 volt.
Adjustment: none required.
Diagrams: DIA-7335-003 and 004 (A-2),
DIA-7335-012 (B-3).
Parts Breakdown: 04.9-7330-050 (55). Platform Overhead Guard
Figure 18317
Crown 2007 PF15807-9 M1.0-7335-058
57
LUBRICATION & ADJUSTMENT
Componentry
FILTER
Return
Location: near upper portion of reservoir.
Purpose: remove contaminants from hydraulic fluid.
Data: 10 micron.
Adjustment: none required.
Diagrams: HYD-7335-001.
Parts Breakdown: 02.0-7335-001 (23). Hydraulic Reservoir
Figure 18318
FNS1
Fan Switch
Location: switch panel. Switch Panel
Purpose: allows operator to turn on/off fan.
Data: three position, on/off/on, rocker switch.
Adjustment: none required.
Diagrams: DIA-7335-012 (B-3).
Parts Breakdown: 04.8-7335-100 (18).
FS
Figure 18319
Forward Switch
Location: control module.
Purpose: informs traction controller forward travel di-
rection is being requested by the operator.
Data: wired normally open. Rotating twist grip away
from operator actuates switch.
Adjustment: none required.
Diagrams: DIA-7335-011 (B-2).
Parts Breakdown: 04.6-7335-001 (60).
Control Module
Figure 18320
M1.0-7335-059 Crown 2007 PF15807-10
58
LUBRICATION & ADJUSTMENT
Componentry
FU1
Lights and Fan Fuse
Location: distribution panel on power unit.
Purpose: protect overhead guard lights, strobe light,
fan and associated wiring from over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-4), DIA-7335-004 (A-4),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (10).
Distribution Panel
FU2 Figure 18321
Control Fuse
Location: distribution panel on power unit.
Purpose: protect control circuitry from over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-4), DIA-7335-004 (A-4),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (10).
FU3
Distribution Panel
Options Fuse
Location: distribution panel on power unit. Figure 18322
Purpose: protect options and associated wiring from
over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-4), DIA-7335-004 (A-4),
DIA-7335-008 (B-3).
Parts Breakdown: 04.3-7335-001 (12).
Distribution Panel
Figure 18323
Crown 2007 PF15807-11 M1.0-7335-060
59
LUBRICATION & ADJUSTMENT
Componentry
FU4
Manual Brake Fuse
Location: distribution panel on power unit.
Purpose: protect brake and associated wiring from
over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-4), DIA-7335-004 (A-4),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (12).
Distribution Panel
FU5 Figure 18324
Outer Coil Fuse
Location: distribution panel on power unit.
Purpose: protect brake outer coil and associated wir-
ing from over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (B-3),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (12).
FU6 Distribution Panel
Inner Coil Fuse
Figure 18325
Location: distribution panel on power unit.
Purpose: protect brake inner coil and associated wir-
ing from over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (B-3),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (12).
Distribution Panel
Figure 18326
M1.0-7335-061 Crown 2007 PF15807-12
60
LUBRICATION & ADJUSTMENT
Componentry
FU7
Inner Coil Fuse
Location: distribution panel on power unit.
Purpose: protect brake inner coil and associated wir-
ing from over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-004 (B-3), DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (12).
Distribution Panel
FU8
Figure 18327
Pump Motor 1 Fuse
Location: lift/power panel on power unit.
Purpose: protect lift pump motor 1 and associated wir-
ing from over-current.
Data: 75 ALS.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (A-1),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (12).
FU9
Distribution Panel
Pump Motor 2 Fuse
Location: lift/power panel on power unit. Figure 18328
Purpose: protect lift pump motor 2 and associated wir-
ing from over-current.
Data: 175 ALS.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (A-1),
DIA-7335-008 (B-3), DIA-7335-019 (B-1).
Parts Breakdown: 04.3-7335-001 (12).
Distribution Panel
Figure 18329
Crown 2007 PF15807-13 M1.0-7335-062
61
LUBRICATION & ADJUSTMENT
Componentry
FU10
Steer Module Fuse
Location: lift/power panel on power unit.
Purpose: protect power steering module and associ-
ated wiring from over-current.
Data: 30A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (B-2),
DIA-7335-013 (C-2), DIA-7335-019 (B-1).
Parts Breakdown: 04.3-7335-100 (32). Lift/Power Panel
FU11 Figure 18330
Freezer/Condition Power Unit Fuse (Optional)
Location: freezer/condition panel on power unit.
Purpose: protect freezer condition components
equipped on power unit and associated wiring from
over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (A-3),
DIA-7335-019 (B-1).
Parts Breakdown: 04.3-7335-100 (33).
Lift/Power Panel
FU12 Figure 18341
Freezer/Condition Platform Fuse (Optional)
Location: freezer/condition panel on power unit.
Purpose: protect freezer condition components
equipped on platform and associated wiring from over-
current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 and 004 (B-2),
DIA-7335-019 (B-1).
Parts Breakdown: 04.3-7335-100 (34).
Lift/Power Panel
Figure 18342
M1.0-7335-063 Crown 2007 PF15807-14
62
LUBRICATION & ADJUSTMENT
Componentry
FU13
Traction Motor Fuse
Location: lift/power panel on power unit.
Purpose: protect traction motor and associated wiring
from over-current.
Data: 140 ACK.
Adjustment: none required.
Diagrams: DIA-7335-002 (B-1).
Parts Breakdown: 04.3-7335-100 (35).
Lift/Power Panel
GTS1, GTS2 Figure 18343
Side Gate Switches
Location: platform console.
Purpose: prevents lift/lower and traction when gates
are up.
Data: wired normally open, held closed when gates are
down. GTS1 (Shown)
GTS2
Adjustment: none required.
Diagrams: DIA-7335-003 and 005 (B-2),
DIA-7335-016 (B-4).
Parts Breakdown: 09.0-7334-150 (4) (77).
Part of Platform
GTS5, GTS6 (SAA Only - not shown) Figure 18344
Rear Gate Switches
Location: rear post. Part of
Purpose: prevents lift/lower and traction when gates Platform
are up.
Data: wired normally open, held closed when gates are
down. Australian (SAA)
Adjustment: none required.
Diagrams: DIA-7335-003 (B-2) (C-2).
Parts Breakdown: 09.1-7330-175 (30).
GTS6 (Shown)
GTS5
Figure 18345
Crown 2007 PF15807-15 M1.0-7335-064
63
LUBRICATION & ADJUSTMENT
Componentry
GTS7, GTS8 (SAA Only - not shown)
Rear Gate Switches Part of
Platform
Location: rear post.
Purpose: prevents lift/lower and traction when gates
are up.
Data: wired normally open, held closed when gates are Australian (SAA)
down.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-2) (C-2).
Parts Breakdown: 09.1-7330-177 (30).
GTS8 (Shown)
GUS GTS7
Figure 18346
Guidance Switch (Optional)
Location: control module.
Purpose: allows operator to select manual or auto-
matic steering.
GUS (Not Shown)
Data: wired normally open, held closed while in manual
steering mode.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-2), DIA-7335-011 (B-3).
Parts Breakdown: not shown (optional).
HN1
Control Module
Horn
Location: on power unit side of platform, near the bot- Figure 18347
tom.
Purpose: provide operator controlled audible warning.
Data: 24-48 volt, 0.4 amp.
Part of
Adjustment: none required. Platform
Diagrams: DIA-7335-005 (B-1), DIA-7335-011 (C-4).
Parts Breakdown: 09.0-7335-050 (10).
Figure 18348
M1.0-7335-065 Crown 2007 PF15807-16
64
LUBRICATION & ADJUSTMENT
Componentry
HN2
Back-Up or Travel Alarm (Optional)
Location: platform side of power unit near bottom.
Purpose: alert pedestrians of truck movement re-
quest.
Data: reverse and/or forward switch.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-1).
Parts Breakdown: 04.0-7335-001 (13).
HNS1 Part of
Power Unit
Horn Switch
Figure 18349
Location: control module.
Purpose: allows operator to sound horn.
Data: wired normally open. Pushing horn button actu-
ates switch.
Adjustment: none required.
Diagrams: DIA-7335-011 (A-2), DIA-7335-005 (B-1).
Parts Breakdown: 04.6-7334-050 (11).
K1 Switch Panel
Figure 18350
Power Up Relay
Location: distribution panel (Platform).
Purpose: provides control circuitry power. Distribution
Data: 24 volt D.C. coil energized upon key-switch test Panel
position closure.
Adjustment: none required.
Diagrams: DIA-7335-003 and 005 (B-3),
DIA-7335-006 and 007 (B-2).
Parts Breakdown: 04.3-7335-050 (4).
Figure 18351
Crown 2007 PF15807-17 M1.0-7335-066
65
LUBRICATION & ADJUSTMENT
Componentry
K2
Module Power
Location: distribution panel (Power Unit).
Purpose: provides power to display traction, steering
and guidance modules.
Data: 24 volt D.C. coil energized by steer module.
Adjustment: none required.
Diagrams: DIA-7335-002 and 005 (C-3),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (11). Distribution
Panel
K11 Figure 18352
Freezer/Corrosion Relay
Location: freezer/corrosion distribution panel.
Purpose: provide power to thermostat circuits.
Data: 24 volt D.C. coil energized when THS2 calls for
heat (closes) and THS3 is in temperature range.
Adjustment: none required.
Diagrams: DIA-7335-017 (B-1).
Parts Breakdown: 04.3-7334-250 (11).
K12
Freezer/Corrosion Relay (Optional)
Location: freezer/corrosion distribution panel. Freezer/Corrosion Relay
Purpose: provide power to heater circuits. Figure 18354
Data: 24 volt D.C. coil energized when THS2 calls for
heat (closes) and THS3 is in temperature range.
Adjustment: none required.
Diagrams: DIA-7335-017 (B-1). Freezer/Corrosion
Relay
Parts Breakdown: 04.3-7334-250 (3).
Figure 18355
M1.0-7335-067 Crown 2007 PF15807-18
66
LUBRICATION & ADJUSTMENT
Componentry
K15
Relay (Optional)
Location: platform side of power unit near bottom un-
der travel alarm.
Purpose: provides control circuitry power.
Data: 24 volt D.C. coil energized upon key-switch test
position closure.
Adjustment: none required.
Diagrams: DIA-7335-017 (A-1).
Parts Breakdown: 04.0-7335-001 (9).
Part of Power Unit
KYS
Figure 18356
Key Switch
Location: control module.
Purpose: allows operator to power truck up and shut
truck down.
Data: key operated selector switch. Energizes K1 with
start position and maintains K1 with on position.
Adjustment: none required.
Diagrams: DIA-7335-003 and 005 (B-4),
DIA-7335-011 (C-1).
Parts Breakdown: 04.6-7335-001 (22).
LGS1 Control Panel
Figure 18357
Dome Light Switch
Location: switch panel.
Purpose: allows operator to turn on/off dome light.
Switch
Data: two-position, on/off, rocker switch. Panel
Adjustment: none required.
Diagrams: DIA-7335-012 (B-2).
Parts Breakdown: 04.8-7335-100 (8).
Figure 18358
Crown 2007 PF15807-19 M1.0-7335-068
67
LUBRICATION & ADJUSTMENT
Componentry
LGS2
Work Light Switch Switch
Panel
Location: switch panel.
Purpose: allows operator to turn on/off work light.
Data: two-position, on/off, rocker switch.
Adjustment: none required.
Diagrams: DIA-7335-012 (B-2). Figure 18359
Parts Breakdown: 04.8-7335-100 (9).
LGS3 Switch
Panel
Spot Light Switch (Optional)
Location: switch panel.
Purpose: allows operator to turn on/off spot light.
Data: two-position, on/off, rocker switch. Figure 18360
Adjustment: none required.
Diagrams: DIA-7335-012 (B-2).
Parts Breakdown: 04.8-7335-100 (10).
LGT1
Strobe or Flashing Light
Location: power unit.
Purpose: visual warning of lift truck presence.
Data: 24 volt.
Adjustment: none required.
Diagrams: DIA-7335-002 (B-1), DIA-7335-004 (B-2), Figure 18361
DIA-7335-015 (C-3).
Parts Breakdown: 04.9-7330-001.
M1.0-7335-069 Crown 2007 PF15807-20
68
LUBRICATION & ADJUSTMENT
Componentry
LGT2, 5
Work Lights (Optional)
Location: overhead console or mast.
Purpose: provide work area light outside operator
compartment.
Data: 12 volt.
Adjustment: minimal manual directional adjustment.
Diagrams: DIA-7335-012 (C-4).
Parts Breakdown: 04.9-7330-050 (22) (75).
Figure 18362
LGT3, 6
Dome Lights (Optional)
Overhead
Location: overhead console.
Console
Purpose: provide light inside operator compartment.
Data: 12 volt.
Adjustment: none available.
Diagrams: DIA-7335-012 (B-4).
Parts Breakdown: 04.9-7330-05 (35) (80).
Figure 18363
LGT4, 7
Spot Lights
Location: overhead console (Optional).
Purpose: provide work area light outside operator
compartment.
Data: 24 volt.
Adjustment: none available.
Diagrams: DIA-7335-012 (C-2) (C-3). Figure 18364
Parts Breakdown: 04.9-7332-250 (1).
Crown 2007 PF15807-21 M1.0-7335-070
69
LUBRICATION & ADJUSTMENT
Componentry
LGT8, 9
Mast Mounted Spot Lights (Optional)
Location: mast.
Purpose: provide work area light outside operator
compartment.
Data: 24 volt.
Adjustment: none available.
Diagrams: DIA-7335-018 (B-2).
Parts Breakdown: 04.9-7332-250. Figure 18365
LOS1, 2
Low Speed Lower Switch
Location: control module.
Purpose: allows operator to lower platform.
Part of
Data: wired normally open, held closed by depressing Control Module
the lower button (partially on trucks with high speed
lower).
Adjustment: none required.
Diagrams: DIA-7335-003 and 005 (A-2),
DIA-7335-011 (B-3).
Parts Breakdown: 04.6-7334-050 (68).
Figure 18366
M1
Traction Motor
Location: drive unit.
Purpose: provide driving force for traction.
Data: provides traction control via operator input
(POT1).
Adjustment: none required.
Diagrams: DIA-7335-002, 004 and 019 (B-2).
Parts Breakdown: 03.1-7335-001 (0). Figure 18368
M1.0-7335-071 Crown 2007 PF15807-22
70
LUBRICATION & ADJUSTMENT
Componentry
M2
Power Steering Motor
Location: steering gearbox.
Purpose: provide driving force for steering.
Data: steering module provides steering control via
steering command encoder ECR1 and power unit
steered wheel encoder ECR2.
Adjustment: none required.
Diagrams: DIA-7335-002 and 019 (B-2), Figure 18369
DIA-7335-014 (C-2).
Parts Breakdown: 06.0-7330-100.
M3
Lift Pump Motor
Location: reservoir.
Purpose: provide driving force for hydraulic pump sup-
plying hydraulic oil flow for lift.
Data: energized via P1 contactor.
Figure 18370
Adjustment: none required.
Diagrams: DIA-7335-002 and 007 (B-2),
DIA-7335-019 (C-2).
Parts Breakdown: 02.2-7.3-001 (0).
M4
Lift Motor (optional)
Location: reservoir.
Purpose: provide driving force for hydraulic pump sup-
Figure 18371
plying hydraulic oil flow for high speed lift.
Data: energized via P2 contactor.
Adjustment: none required.
Diagrams: DIA-7335-002 (B-1), DIA-7335-019 (C-2).
Parts Breakdown: 02.2-7.3-001 (0).
Crown 2007 PF15807-23 M1.0-7335-072
71
LUBRICATION & ADJUSTMENT
Componentry
MLV
Manual Lowering Valve
Location: lift/lower manifold.
Purpose: provide means to lower platform without
powering up truck.
Data: not applicable.
Adjustment: none required.
Diagrams: HYD-7335-001.
Figure 18372
Parts Breakdown: 02.4-7335-001 (11).
ORS1
Switch
Override Switch Panel
Location: switch panel.
Purpose: when raise lower cutout programmed for
override is encountered, actuating switch permits con-
tinuation of function.
Data: momentary contact switch. Figure 18373
Adjustment: none required.
Diagrams: DIA-7335-003 and 011 (B-3),
DIA-7335-005 (B-2).
Contactor
Parts Breakdown: 04.8-7335-100 (12). Panel
P1
Contactor
Location: Contactor Panel.
Purpose: provide control of Electrical power.
Figure 18374
Data: not applicable.
Adjustment: none required.
Diagrams: DIA-7335-004 and 019 (B-2),
DIA-7335-015 (C-2), HYD-7335-001.
Parts Breakdown: 04.3-7335-100 (39).
M1.0-7335-073 Crown 2007 PF15807-24
72
LUBRICATION & ADJUSTMENT
Componentry
P2
Contactor (Optional) Contactor
Panel
Location: contactor panel.
Purpose: provide control of Electrical power.
Data: not applicable.
Adjustment: none required.
Diagrams: DIA-7335-004 and 019 (B-2),
DIA-7335-015 (C-2), HYD-7335-001.
Figure 18375
Parts Breakdown: 04.3-7335-100 (41).
POT1
Traction Request Potentiometer
Location: control module.
Purpose: provide traction input to controller TCM.
Data: 22 K ohms.
Adjustment: refer to Electrical Maintenance - control
module.
Diagrams: DIA-7335-003 and 005 (B-1),
DIA-7335-011 (B-2). Switch Panel
Parts Breakdown: 04.6-7335-001 (42).
Figure 18376
PS1
Light Power Supply
Location: overhead console.
Purpose: provide 12 volt for work lights.
Data: 24 volt D.C. input, 12 volt D.C. output.
Switch Panel
Adjustment: none required.
Diagrams: DIA-7335-002 (A-2), DIA-7335-012 (C-1). Figure 18377
Parts Breakdown: 04.9-7330-050 (5).
Crown 2007 PF15807-25 M1.0-7335-074
73
LUBRICATION & ADJUSTMENT
Componentry
PS2
Light Power Supply
Location: overhead console.
Purpose: provide 12 volt for dome lights.
Data: 24 volt D.C. input, 12 volt D.C. output.
Overhead Console
Adjustment: none required.
Figure 18378
Diagrams: DIA-7335-002 (A-2), DIA-7335-012 (C-1).
Parts Breakdown: 04.9-7330-050 (6).
PVL
Proportional Lowering Valve
Location: lift/lower manifold.
Purpose: provide proportional flow control of lowering
functions.
Lift/Lower Manifold
Data: 24 volt D.C.
Adjustment: none required. Figure 18379
Diagrams: DIA-7335-002 (B-2), DIA-7335-004 (B-3),
DIA-7335-015 (C-1), HYD-7335-001.
Parts Breakdown: 02.4-7335-001 (15).
PCL
Proportional Lowering Valve
Location: lift/lower manifold.
Purpose: provide proportional flow control of lowering Lift/Lower Manifold
functions.
Figure 18380
Data: 24 volt D.C.
Adjustment: none required.
Diagrams: HYD-7335-001.
Parts Breakdown: 02.4-7335-001 (15).
M1.0-7335-075 Crown 2007 PF15807-26
74
LUBRICATION & ADJUSTMENT
Componentry
RAS1
Low Speed Raise Switch
Location: control module.
Purpose: allows operator to raise platform.
Part of
Data: wired normally open, held closed by depressing Control Module
the raise button (partially on trucks with high speed
raise).
Adjustment: none required.
Diagrams: DIA-7335-011 (B-2).
Parts Breakdown: 04.6-7334-050 (68).
Figure 18381
RAS2
High Speed Raise Switch
Location: control module.
Purpose: allows operator to raise platform.
Data: wired normally open, held closed by fully de-
Part of
pressing the raise button.
Control Module
Adjustment: none required.
Diagrams: DIA-7335-003 (A-2), DIA-7335-011 (B-2).
Parts Breakdown: 04.6-7334-050 (68).
RES1 Figure 18382
Resistor (Optional)
Location: overhead console.
Purpose: reduce fan noise.
Data: 25 watt, 10 ohm.
Adjustment: none required.
Overhead
Diagrams: DIA-7335-005 (A-2), DIA-7335-012 (B-4).
Console
Parts Breakdown: 04.9-7330-050 (60).
Figure 18384
Crown 2007 PF15807-27 M1.0-7335-076
75
LUBRICATION & ADJUSTMENT
Componentry
RES2, RES3
Freezer/Corrosion Heater (Optional)
Location: aisle guide wheel brackets.
Purpose: RES2 applies heat to aisle guide switch
RGS2 and RES3 applies heat to aisle guide switch
RGS1.
Data: 50 watt, 15 ohm.
Adjustment: none required.
Distribution Panel
Diagrams: DIA-7335-002 (B-3), DIA-7335-004 (B-3),
DIA-7335-008 (A-2). Figure 18385
Parts Breakdown: 04.3-7335-001 (6).
RES4, RES5
Freezer/Corrosion Heater (Optional)
Location: battery-restraint-switch brackets.
Purpose: RES4 applies heat to battery restraint switch
BRES2 and RES5 applies heat to battery restraint
switch BRES1.
Data: 50 watt, 15 ohm.
Adjustment: none required.
Diagrams: DIA-7335-017 (C-1).
Parts Breakdown: 01.2-7335-001 (43).
RES6, RES7
Figure 18386
Freezer/Corrosion Heater (Optional)
Location: main frame.
Purpose: RES6 applies heat to chain slack switch
CHS3 and RES7 applies heat to chain slack switch
CHS4.
Data: 25 watt, 30 ohm.
Adjustment: none required.
Diagrams: DIA-7335-017 (C-1).
Parts Breakdown: 07.6-7334-050 (4).
Mainframe
Figure 18387
M1.0-7335-077 Crown 2007 PF15807-28
76
LUBRICATION & ADJUSTMENT
Componentry
RES8, RES9
RES9
Freezer/Corrosion Heater (Optional)
RES8 (Shown)
Location: platform gate.
Purpose: RES8 applies heat to gate switches GTS1
and RES9 applies heat to gate switches GTS2.
Data: 25 watt, 30 ohm.
Adjustment: none required.
Diagrams: not shown. Part of
Platform
Parts Breakdown: 09.0-7334-150 (8).
Figure 18388
RES10
Freezer/Corrosion Heater
Location: control module.
Purpose: applies heat to emergency disconnect
switch EDS.
Data: 10 watt, 70 ohm.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 04.6-7334-050 (21). Control Module
Figure 18389
RES11
Freezer/Corrosion Heater (Optional)
Location: control module.
Purpose: applies heat to rise and lower switches
LOS1, LOS2, RAS1 & RAS2.
Part of
Data: 25 watt, 30 ohm.
Control Module
Adjustment: none required.
Diagrams: DIA-7335-003 (A-1).
Parts Breakdown: 04.6-7334-050 (51).
Figure 18390
Crown 2007 PF15807-29 M1.0-7335-078
77
LUBRICATION & ADJUSTMENT
Componentry
RES12
Freezer/Corrosion Heater (Optional) Control Module
Location: control module.
Purpose: applies heat to horn switch HNS1.
Data: 25 watt, 30 ohm.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 04.6-7334-050 (21).
Figure 18391
RES13
Freezer/Corrosion Heater (Optional)
Location: control module.
Purpose: applies heat to forward switch FS.
Data: 10 watt, 70 ohm.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 04.6-7334-050 (21).
RES14 Control Module
Freezer/Corrosion Heater (Optional) Figure 18392
Location: control module.
Purpose: applies heat to reverse switch RS.
Data: 10 watt, 70 ohm.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 04.6-7334-050 (21).
Control Module
Figure 18393
M1.0-7335-079 Crown 2007 PF15807-30
78
LUBRICATION & ADJUSTMENT
Componentry
RES15, RES19
Freezer/Corrosion Heater (Optional)
Location: platform (TT).
Purpose: RES15 applies heat to chain slack switch
CHS1 and RES19 applies heat to chain slack switch
CHS2.
Data: 25 watt, 30 ohm. Part of Platform
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 07.6-7334-050 (43). Figure 18394
RES16
Freezer/Corrosion Heater (Optional)
Location: below floorboard.
Purpose: applies heat to brake switch BRS1.
Data: 25 watt, 30 ohm.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 05.1-7334-001 (20).
Figure 18395
RGS1 and RGS2 (Optional)
Rail Guide Switches RGS1 and
RGS2 (Shown)
Location: aisle guide wheel bracket mounted under
power unit.
Purpose: provide ability to turn on automatic steering.
Data: wired normally closed held open.
Adjustment: none required.
Diagrams: DIA-7335-014 (B-2). Power Unit
Parts Breakdown: 10.0-7334-001 (11). Figure 18396
Crown 2007 PF15807-31 M1.0-7335-080
79
LUBRICATION & ADJUSTMENT
Componentry
RS
Reverse Switch
Location: control module.
Purpose: informs traction controller reverse travel di-
rection is being requested by the operator.
Data: wired normally open. Rotating twist grip toward
operator actuates switch.
Adjustment: none required.
Diagrams: DIA-7335-011 (B-2).
Figure 18397
Parts Breakdown: 04.6-7335-001 (60).
RV1 Lift/Lower Manifold
Relief Valve
Location: lift/lower manifold.
Purpose: limit operating pressure for lift circuit.
Data: not applicable.
Adjustment: refer to Hydraulic Maintenance.
Diagrams: HYD-7335-001.
Figure 18398
Parts Breakdown: 02.4-7335-001 (14).
SB21
Suppressor Block
Location: below strobe light on power unit.
Purpose: suppress electrical noise from operation of
strobe light.
Data: not applicable.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 04.0-7335-001 (5). Mounted to Power Unit
Figure 18400
M1.0-7335-081 Crown 2007 PF15807-32
80
LUBRICATION & ADJUSTMENT
Componentry
SVL
Lift/Lower Manifold
Solenoid Valve
Location: lift/lower manifold.
Purpose: provide proportional flow control of lowering
functions.
Data: 24 volt D.C.
Adjustment: none required.
Diagrams: DIA-7335-015 (C-1), HYD-7335-001.
Parts Breakdown: 02.4-7335-001 (15).
Figure 18402
SENSOR BAR LOAD WHEEL
Base of Mainframe
Wire Guidance (Optional)
Location: base of mainframe.
Purpose: sense signal strength from guide wire em-
bedded in floor.
Data: refer to Electrical and Wire Guide System.
Adjustment: none required.
Diagrams: DIA-7335-016 (A-3).
Parts Breakdown: 04.3-7335-500 (10).
SENSOR BAR STEER WHEEL Sensor Bar Load Wheel
Figure 18403
Wire Guidance (Optional)
Location: front and center of power unit below skirt.
Skirt of Power Unit
Purpose: sense signal strength from guide wire em-
bedded in floor.
Data: refer to Electrical Maintenance - wire guide sys-
tem.
Adjustment: none required.
Diagrams: DIA-7335-016 (A-2).
Parts Breakdown: 04.3-7335-500 (1).
Sensor Bar Steel Wheel
Figure 18404
Crown 2007 PF15807-33 M1.0-7335-082
81
LUBRICATION & ADJUSTMENT
Componentry
THS1
Power Unit Thermostat (Optional)
Location: power unit battery wall between power unit
and mast.
Purpose: provide ability to turn on power unit heaters.
Data: wired normally closed. Contact closes at 49° C
(120° F) and opens at 68° C (140° F).
Part of Power Unit
Adjustment: none required.
Diagrams: DIA-7335-015 (C-3). Figure 18405
Parts Breakdown: 01.2-7335-003 (41).
THS2
Platform Thermostat (Optional)
Location: mounted to plate assembled to Brake
switch, BRS1, located under platform floor.
Purpose: provide ability to turn on platform heaters.
Part of Power Unit
Data: wired normally closed. Contact closes at 4° C
(40° F) and opens at 15° C (60° F). Figure 18406
Adjustment: none required.
Diagrams: DIA-7335-015 (C-3).
Parts Breakdown: 01.2-7335-003 (41). Switch Panel
ZSS
Zone Select Switch (Optional)
Location: switch panel.
Figure 18407
Purpose: allows selection of lift height cutout.
Data: three position key switch.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-2), DIA-7335-011 (B-3).
Parts Breakdown: 04.8-7330-100 (17).
M1.0-7335-083 Crown 2007 PF15807-34
82
INSPECTION AND LUBRICATION
Skid Inspection
Skid Inspection
WARNING
On trucks without aisle guide wheels, the skids (1,
Figure 1) are on the lower left and the lower right cor- A truck that falls can cause injury or death.
ners of the power unit skirt (2). If the skids are not secure, the truck could fall.
Follow the procedures below to correctly inspect
the skids.
Inspect the skids
1. Make sure that the skid bolts are secured.
2. Torque the skid bolts to 162.5 ± 13.5 Nm (120 ±
2 10 ft lb).
3. Measure the distance from the bottom of the skid
(1, Figure 3) to a level floor (2).
The maximum distance from the skid (1) to a
1 level floor (2) is 25.4 mm (1 in).
If the measurement is more than 25.4 mm (1 in),
replace the skids (1).
Fig. 1 (17019-01)
On trucks with aisle guide wheels, the skids are on the 1
bottom of the front (the power unit end) wheel supports
for the aisle guides (1, Figure 2).
2 25.4 mm
(1 in)
Fig. 3 (17021-01)
Fig. 2 (17020-01)
Crown 1994 PF10332-1 Rev. 4/13 M1.5-7330-001
03 Rev. 4/13
17
INSPECTION AND LUBRICATION
Metric Torque Values
Metric Torque Values
It is important to tighten fasteners to the correct torque
value. This section shows the standard torque values
for the screws and bolts used in Crown lift trucks and
vehicles. Special torque values in the maintenance and
parts sections of this manual override the standard
torque values in this section.
Grade
Grade Identification Bolt and Screw
Specification
(on Head) Size (mm)
5.8 Class 5.8 M5 through M36
8.8 Class 8.8 M5 through M36
10.9 Class 10.9 M5 through M36
12.9 Class 12.9 M5 through M36
NOTE: Even though a bolt head is unmarked, Crown uses nothing less than class 8.8
in all its bolted assemblies. Instances do occur when class 8.8 bolts are manufactured
unmarked. When a fastener is replaced that is unmarked, replace the fastener with a
class 8.8.
Fig. 1 (15048-01)
Crown 1989 PF8514 Rev. 2/16 M1.9-06.6-001
05 Rev. 2/16
67
INSPECTION AND LUBRICATION
Metric Torque Values
Torque Chart–Metric Hex Head Cap Screws and Nuts
Thread Diameter Torque Nm (ft lb)
and Pitch
Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 5–8 (4–6) 7–8 (5–6) 8–10 (6–7)
M6 x 1.00 8–10 (6–7) 12–14 (9–10) 15–16 (11–12)
M8 x 1.25 20–25 (15–18) 28–31 (21–23) 34–37 (25–27)
M10 x 1.50 39–43 (29–32) 56–61 (41–45) 68–75 (50–54)
M12 x 1.75 71–76 (52–56) 100–107 (73–79) 119–127 (88–94)
M14 x 2.00 113–122 (83–90) 159–171 (117–126) 190–205 (140–151)
M16 x 2.00 175–190 (129–140) 247–267 (182–197) 296–320 (218–236)
M20 x 2.50 340 357 (251–271) 479–518 (353–382) 574–621 (423–458)
M24 x 3.00 587–635 (433–468) 824–892 (608–658) 990–1071 (730–790)
M30 x 3.50 1175–1274 (867–940) 1654–1792 (1220–1322) 1985–2150 (1464–1586)
Note: Special torque values in the maintenance and parts sections of this manual override the standard
torque values in this section.
Torque Chart–Metric Hex Socket Countersink Head Screws
Thread Diameter Torque Nm (ft lb)
and Pitch
Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 4–7 (3–5) 5–8 (4–6) 7–10 (5–7)
M6 x 1.00 7–10 (5–7) 9–12 (7–9) 11–14 (8–10)
M8 x 1.25 16–19 (12–14) 23–26 (17–19) 27–30 (20–22)
M10 x 1.50 31–34 (23–25) 45–49 (33–36) 54–58 (40–43)
M12 x 1.75 56–60 (41–44) 79–84 (58–62) 94–102 (69–75)
M14 x 2.00
M16 x 2.00 124–146 (99–108) 190–206 (140–152) 228–247 (168–182)
M20 x 2.50 259–281 (191–207) 363–395 (268–291) 437–473 (322–349)
M24 x 3.00 416–451 (307–333) 586–635 (432–468) 702–762 (518–562)
M30 x 3.50
Note: Special torque values in the maintenance and parts sections of this manual override the standard
torque values in this section.
M1.9-06.6-002 Crown 1989 PF8514 Rev. 2/16
05 Rev. 2/16
68
INSPECTION AND LUBRICATION
Metric Torque Values
Torque Chart–Metric Socket Head Cap Screws
Thread Diameter Torque Nm (ft lb)
and Pitch
Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 5–8 (4–6) 7–9 (5–7) 8–11 (6–8)
M6 x 1.00 9–12 (7–9) 12–15 (9–11) 15–18 (11–13)
M8 x 1.25 22–24 (16–18) 30–33 (22–24) 35–38 (26–28)
M10 x 1.50 42–45 (31–33) 58–64 (43–47) 71–76 (52–56)
M12 x 1.75 72–77 (53–57) 102–110 (75–81) 122–132 (90–97)
M14 x 2.00 115–125 (85–92) 161–175 (119–129) 194–210 (143–155)
M16 x 2.00 179–194 (132–143) 251–273 (185–201) 301–327 (222–241)
M20 x 2.50 348–377 (257–278) 489–530 (361–391) 588–637 (434–470)
M24 x 3.00 601–651 (443–480) 846–915 (624–675) 1014–1098 (748–810)
M30 x 3.50 1196–1296 (882–956) 1681–1822 (1240–1344) 2017–2187 (1488–1613)
Note: Special torque values in the maintenance and parts sections of this manual override the standard
torque values in this section.
Torque Chart–Metric Flanged Hex Head Cap Screws and Nuts
Thread Diameter Torque Nm (ft lb)
and Pitch
Class 8.8 Class 10.9 Class 12.9
M5 x 0.80 5–8 (4–6) 8–11 (6–8) 9–12 (7–9)
M6 x 1.00 9–12 (7–9) 14–16 (10–12) 16–19 (12–14)
M8 x 1.25 22–24 (16–18) 31–34 (23–25) 38–41 (28–30)
M10 x 1.50 44–48 (33–35) 62–68 (46–50) 75–81 (55–60)
M12 x 1.75 77–83 (57–61) 108–117 (80–86) 130–141 (96–104)
M14 x 2.00 123–134 (91–98) 174–187 (128–138) 209–225 (154–166)
M16 x 2.00 193–210 (143–155) 273–294 (201–217) 327–354 (241–2610)
Note: Special torque values in the maintenance and parts sections of this manual override the standard
torque values in this section.
Crown 1989 PF8514 Rev. 2/16 M1.9-06.6-003
05 Rev. 2/16
69
Notes:
70
INSPECTION & LUBRICATION
SAE Torque Values
SAE Torque Values
It is important to tighten fasteners to the correct torque
value. This section shows the standard torque values
for the screws and bolts used in Crown lift trucks and
vehicles. Special torque values in the maintenance and
parts sections of this manual override the standard
torque values in this section.
Grade
Grade Identification Bolt and Screw
Specification
(on Head) Size (in)
SAE - Grade 2 1/4 through 1-1/2
SAE - Grade 5 1/4 through 1-1/2
SAE - Grade 8 1/4 through 1-1/2
NOTE: Even though a bolt head is unmarked, Crown uses nothing less than Grade 5 in all its bolted assem-
blies. Instances do occur when Grade 5 bolts are manufactured unmarked. When a fastener is replaced that
is unmarked, replace the fastener with a Grade 5.
Fig. 1 (14916-02)
Crown 1979 PF5067 Rev. 2/16 M1.9-14.0-001
06 Rev. 2/16
71
INSPECTION & LUBRICATION
SAE Torque Values
Torque Chart
Bolt Grade 5 Grade 8
Diameter
Dry Torque Specification Dry Torque Specification
in ft Ib kg-m Nm ft lb kg-m Nm
1/4 9±3 1.2 ± 0.4 12 ± 4 13 ± 4 1.8 ± 0.5 17.5 ± 5.5
5/16 18 ± 5 2.5 ± 0.7 24.5 ± 7 25 ± 5 3.5 ± 0.7 34 ± 7
3/8 32 ± 5 4.4 ± 0.7 43.5 ± 7 48 ± 10 6.6 ± 1.3 65 ± 13.5
7/16 50 ± 10 6.9 ± 1.4 67.5 ± 13.5 75 ± 10 10.4 ± 1.4 102 ± 13.5
1/2 75 ± 10 10.4 ± 1.4 101.5 ± 13.5 112 ± 15 15.5 ± 2.0 152 ± 20.5
9/16 110 ± 15 15.2 ± 2.0 149 ± 20.5 163 ± 20 22.5 ± 3.0 221 ± 27
5/8 150 ± 20 20.7 ± 2.8 203.5 ± 27 225 ± 30 31.1 ± 4.1 305 ± 41
3/4 265 ± 35 36.6 ± 4.8 359 ± 47.5 400 ± 50 55.2 ± 6.9 542 ± 68
7/8 420 ± 60 58.1 ± 8.3 569 ± 81 640 ± 80 88.3 ± 11.0 868 ± 108
1 640 ± 80 88.5 ± 11.1 868 ± 109 960 ± 115 132.5 ± 15.9 1300 ± 156
1 1/8 800 ± 100 110.6 ± 13.8 1085 ± 136
1 1/4 1000 ± 120 138 ± 16.6 1356 ± 163
1 3/8 1200 ± 150 166 ± 20.7 1630 ± 203
1 1/2 1500 ± 200 207 ± 27.7 2034 ± 271
Torque specifications for bolts related to
hydraulic valves.
5/16 13 ± 2 1.8 ± 0.3 17.5 ± 2.5
3/8 24 ± 2 3.3 ± 0.3 32.5 ± 2.5
7/16 39 ± 2 5.4 ± 0.3 53 ± 2.5
NOTE: Special torque values in the maintenance and parts sections of this manual over-
ride the standard torque values in this section.
M1.9-14.0-002 Crown 1979 PF5067 Rev. 2/16
06 Rev. 2/16
72
INSPECTION AND LUBRICATION
Hydraulic Fitting Torque Values
Hydraulic Fitting Torque Values • Tube and hose assemblies
• O-ring fittings with jam nuts
The information in this section contains the necessary
• O-ring face seal fittings
torque values for the following:
• Flare fittings
Torques for 37° Flare Fittings, Tube Assemblies, and Hose Assemblies
Fitting or Tube Thread Size Torque Value
Size
ft lb Nm
-2 5/16–24 6–7 8–10
-3 3/8–24 8–9 10–12
-4 7/16–20 11–12 15–16
-5 1/2–20 14–15 19–20
-6 9/16–18 18–20 24–27
-8 3/4–16 36–39 49–53
-10 7/8–14 57–63 77–85
-12 1-1/16–12 79–88 107–119
-14 1-3/16–12 94–103 127–140
-16 1-5/16–12 108–113 146–153
-20 1-5/8–12 127–133 172–180
Note: The torque values called out in the maintenance section of this manual will take precedence
over torque values found on this page.
Crown 2020 PF28389 M1.9-7335-001
73
INSPECTION AND LUBRICATION
Hydraulic Fitting Torque Values
Torques for O-ring Fittings With Jam Nuts and O-ring Fittings Installed in Aluminum Blocks
Fitting or Tube Thread Size Torque Value
Size
ft lb Nm
-2 5/16–24 5–6 7–8
-3 3/8–24 6–7 8–10
-4 7/16–20 10–11 14–15
-5 1/2–20 13–14 18–19
-6 9/16–18 17–18 23–24
-8 3/4–16 30–32 41–43
-10 7/8–14 32–36 43–49
-12 1-1/16–12 51–56 69–76
-14 1-3/16–12 68–74 92–100
-16 1-5/16–12 84–92 114–125
-20 1-5/8–12 110–120 149–163
Note: The torque values called out in the maintenance section of this manual will take precedence
over torque values found on this page.
Torques for O-ring Fittings Installed in Steel
Fitting or Tube Thread Size Torque Value
Size
ft lb Nm
-2 5/16–24 6–7 8–10
-3 3/8–24 8–9 10–12
-4 7/16–20 13–15 18–20
-5 1/2–20 17–19 23–26
-6 9/16–18 22–24 30–33
-8 3/4–16 40–43 54–58
-10 7/8–14 43–48 58–65
-12 1-1/16–12 68–75 92–102
-14 1-3/16–12 90–99 122–134
-16 1-5/16–12 112–123 152–167
-20 1-5/8–12 146–161 198–218
Note: The torque values called out in the maintenance section of this manual will take precedence
over torque values found on this page.
M1.9-7335-002 Crown 2020 PF28389
74
INSPECTION AND LUBRICATION
Hydraulic Fitting Torque Values
Torques for O-ring Face Seals
Fitting or Tube Thread Size Torque Value
Size
ft lb Nm
-4 9/16–18 10–12 14–16
-6 11/16–16 18–20 24–27
-8 13/16–16 32–35 43–47
-10 1–14 46–50 62–68
-12 1-3/16–12 65–70 88–95
-16 1-7/16–12 92–100 125–136
-20 1-11/16–12 125–140 169–190
-24 2–12 150–165 203–224
Note: The torque values called out in the maintenance section of this manual will take precedence
over torque values found on this page.
Crown 2020 PF28389 M1.9-7335-003
75
Notes:
76
COMPONENTRY
Componentry
Componentry
Access 1
Operator Display
Location: platform.
Purpose: pertinent truck information to operator or
service technician, (SPI) steer position indicator dis-
plays steering information (Optional).
Data: information received from truck control module Figure 18286
and sensors.
Adjustment: none required.
Diagrams: DIA-7335-003 and 005 (B-2) (B-3), Access 3 (TCM)
DIA-7335-009 (B-1) (C-1) (B-2) (C-2).
Parts Breakdown: 05.0-7335-001 (8) (21).
Access 3 (TCM)
Traction Control Module
Location: traction panel.
Figure 18287
Purpose: controls braking and traction motor (M1)
speed via operator input from BRS1 and POT1.
Data: transistor control circuitry.
Adjustment: refer to Electrical.
Diagrams: DIA-7335-002 (B-2), DIA-7335-013 (B-1)
(B-2) (C-1) (C-2).
Parts Breakdown: 04.1-7335-001 (13).
Access 4 (VCM)
Vehicle Control Module
Location: operator compartment.
Purpose: controls vehicle operations
Data: refer to Electrical.
Adjustment: none required. Figure 18288
Diagrams: DIA-7335-002 (A-3), DIA-7335-003 (B-1)
(B-2), DIA-7335-009 (B-2) (C-2), DIA-7335-010 (C-2)
(C-3) (C-4).
Parts Breakdown: 09.0-7335-001 (24).
Crown 2011 PF25248-1 M1.91-7335-001
101
COMPONENTRY
Componentry
Access 5 (SCM)
Steering Control Module Access 5 (SCM)
Location: traction panel.
Purpose: control steering operation.
Data: refer to Electrical and Steering.
Adjustment: none required.
Diagrams: DIA-7335-004 (B-3), DIA-7335-014 (B-2) Figure 18289
(B-2) (C-1) (C-2), DIA-7335-019 (A-2).
Parts Breakdown: 04.1-7335-001 (17).
Access 6 (GCM)
Access 6 (GCM)
Guidance Control Module (Optional)
Location: below steering gearbox.
Purpose: controls automatic guidance system (wire
guidance).
Data: refer to Electrical. Figure 18290
Adjustment: refer to Electrical.
Diagrams: DIA-7335-002 (B-4), DIA-7335-016 (B-1)
(B-2) (C-1) (C-2).
Parts Breakdown: 04.1-7335-001 (25).
ACCUMULATOR
Location: front, lower right side of power unit.
Purpose: shock absorber for lift/lower hydraulic sys-
tem.
Data: pre-charge 3445 kPa (500 psi) refer to Hydraulic
for charging procedures.
Adjustment: none required.
Accumulator
Diagrams: HYD-7335-001.
Parts Breakdown: 02.07335-003 (48). Figure 18285
M1.91-7335-002 Crown 2011 PF25248-2
102
COMPONENTRY
Componentry
ALM1
Location: distribution panel on platform.
Purpose: status alarm.
Data: audible warning when operator does incorrect
sequence.
Adjustment: none required.
Diagrams: DIA-7335-003 (A-1), DIA-7335-005 (A-2),
DIA-7335-006 and 007 (B-2).
Parts Breakdown: 04.3-7335-050 (3).
Distribution Panel
BRES1, BRES2 Figure 18291
Battery Restraint Switch
Location: power unit skirt.
Purpose: monitor presence of battery retainer/side
cover and disable travel if battery retainer is not pres-
ent.
Data: wired normally open, held closed when battery
BRES1 and
retainer/side cover is in place.
BRES2 (Shown)
Adjustment: none required.
Diagrams: DIA-7335-002 (B-3) (C-3), DIA-7335-014
(B-2).
Part of Power Unit
Parts Breakdown: 01.2-7335-001 (14) (54).
BRK1
Figure 18292
Brake
Location: traction motor.
Purpose: provide braking force to traction motor to
stop truck and prevent movement of parked vehicle.
Data: Access 3 release via operator request, spring
applied.
Adjustment: refer to Brake.
Diagrams: DIA-7335-002 and 004 (A-3),
DIA-7335-014 (B-2).
Parts Breakdown: 05.3-7335-001 (6).
Figure 18293
Crown 2011 PF25248-3 M1.91-7335-003
103
COMPONENTRY
Componentry
BRS1
Part of Platform
Brake Switch
Floorboard
Location: platform below floorboard.
Purpose: allows operator to release or apply brake.
Data: wired normally open, held closed when operator
is depressing brake pedal.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-3), DIA-7335-011 (C-4).
Parts Breakdown: 05.1-7334-001 (11).
CHS1, CHS2
Figure 18294
Chain Slack Switches
Location: base of platform - mast side.
Part of Platform
Purpose: prohibits lowering when mast chains be-
come slack.
Data: wired normally open, held closed as chains
maintain proper tension.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-2), DIA-7335-005 (B-2),
DIA-7335-011 (B-3).
Parts Breakdown: 07.6-7334-050 (51 and 56).
CHS3, CHS4 Figure 18295
Chain Slack Switches
Location: top of mainframe.
Purpose: prohibits lowering when mast chains be-
come slack.
Data: wired normally open, held closed as chains
maintain proper tension.
Adjustment: none required.
Diagrams: DIA-7335-004 (A-2) (B-2), DIA-7335-013 Part of
(C-3) (C-4). Mainframe
Parts Breakdown: 07.6-7334-050 (2).
Figure 18296
M1.91-7335-004 Crown 2011 PF25248-4
104
COMPONENTRY
Componentry
CV1
Check Valve Lift/Lower
Location: lift/lower manifold. Manifold
Purpose: prevent back flow into pump P1.
Data: not applicable.
Adjustment: none required.
Diagrams: HYD-7335-001.
Figure 18297
Parts Breakdown: 02.4-7335-050 (7).
CV2
Lift/Lower
Check Valve Manifold
Location: lift/lower manifold (high speed lift/lower
only).
Purpose: prevent back flow into pump P1.
Data: not applicable.
Adjustment: none required. Figure 18298
Diagrams: HYD-7335-001.
Parts Breakdown: 02.4-7335-001 (7), 02.4-7335-050
(7).
Lift/Lower
Manifold
CV3
Check Valve
Location: lift/lower manifold (high speed lift/lower
only).
Purpose: prevent back flow into pump P2.
Data: not applicable. Figure 18299
Adjustment: none required.
Diagrams: HYD-7335-001.
Parts Breakdown: 02.4-7335-050 (7).
Crown 2011 PF25248-5 M1.91-7335-005
105
COMPONENTRY
Componentry
CYLINDER
Free Lift
Location: 3rd stage mast.
Purpose: raise platform.
Data: not applicable.
Adjustment: none required.
Diagrams: HYD-7335-001. (a) 3rd Stage Mast
Parts Breakdown: 08.3-7330-001 (1). (b) Free Lift Cylinder
Figure 18300
CYLINDER
Mast
Location: main frame.
Purpose: raise mast and platform.
Data: not applicable.
Adjustment: none required.
Diagrams: HYD-7335-005.
Parts Breakdown: 08.1-7335-001 (1).
DTS1
Drive/Tow Switch
Location: distribution panel.
(a) Mast Cylinder
Purpose: to release brake allowing truck to be towed.
Data: two position, on-on, lever handle switch. Figure 18306
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3).
Parts Breakdown: 04.3-7335-001.
Distribution
Panel
Figure 18308
M1.91-7335-006 Crown 2011 PF25248-6
106
COMPONENTRY
Componentry
ECR1
Steering Command Encoder
Location: steering command assembly.
Purpose: provide steering command input to steering
module.
Data: 5 volts D.C., 32 pulses per revolutions.
Adjustment: none required.
Diagrams: DIA-7335-003 (A-2), DIA-7335-005 (B-2),
DIA 7335-009 and 010 (A-4).
Steering Assembly
Parts Breakdown: 06.0-7335-001 (6).
Figure 18309
ECR2
Steering Feedback Encoder
Location: in front of traction motor.
Purpose: provide steer wheel position feedback to
steering module.
Data: 5 volts D.C., 256 pulses per revolution.
Adjustment: none required.
Diagrams: DIA-7335-002 and 004 (B-3),
DIA-7335-014 (B-4).
Part of
Parts Breakdown: 04.8-7335-200 (3).
Power Unit
ECR3 Figure 18310
Traction Speed Encoder
Location: traction motor.
Purpose: provide ground speed and direction informa-
tion for control system based on motor speed and di-
rection of revolution.
Data: 5 volts D.C., 32 pulses per revolution.
Adjustment: none required.
Diagrams: DIA-7335-004 (C-2), DIA-7335-014 (C-4).
Traction Motor
Parts Breakdown: 03.1-7335-001 (16).
Figure 18311
Crown 2011 PF25248-7 M1.91-7335-007
107
COMPONENTRY
Componentry
ECR4
Lift Height Sensor
Location: lower rear platform.
Purpose: provide measured height of forks. Platform
Data: 5 volts D.C., 32 pulses per revolution.
Adjustment: none required.
Diagrams: DIA-7335-003 and 010 (A-2),
DIA-7335-005 (B-2), DIA-7335-009 (A-4).
Parts Breakdown: 09.0-7334-200 (17).
Figure 18312
ECR5
Steering Command Encoder
Location: steering command assembly.
Purpose: provide steering command input to steering
module.
Data: 5 volts D.C., 32 pulses per revolutions.
Adjustment: none required.
Diagrams: DIA-7335-003 (A-1), DIA-7335-005 (A-1), Steering Assembly
DIA-7335-010 (A-4).
Parts Breakdown: 06.0-7335-001 (6). Figure 18313
ED1
Emergency Disconnect Main Contactor
Location: lift/power panel.
Purpose: provide ability to turn off power control cir-
cuitry.
Data: positive voltage provided through K1 relay, neg-
ative voltage controlled by SCM.
Adjustment: none required.
Diagrams: DIA-7335-002, 004 and 015 (C-2), Lift/Power Panel
DIA-7335-013 (C-3), DIA-7335-019 (B-1).
Figure 18314
Parts Breakdown: 04.3-7335-100 (1), 04.4-6540-001
(1).
M1.91-7335-008 Crown 2011 PF25248-8
108
COMPONENTRY
Componentry
ED2
Emergency Disconnect Traction & Steering Con-
tactor
Location: lift/power panel.
Purpose: provide ability to disconnect power between
MRC1 and SCM.
Data: 24 volt contactor.
Adjustment: none required.
Diagrams: DIA-7335-002 (B-2), DIA-7335-004, 013
and 015 (C-2), DIA-7335-019 (B-1). Lift/Power Panel
Parts Breakdown: 04.3-7335-100 (1), 04.4-6540-050
(1). Figure 18315
EDS
Emergency Disconnect Switch
Location: control module.
Purpose: resets the emergency-disconnect contactor,
removing battery power from steering, lift, traction and
control circuits.
Data: wired normally closed. Pressing switch button
actuates switch.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-4), DIA-7335-005 (B-4).
Control Module
Parts Breakdown: 04.6-7334-050 (27).
Fan1 Figure 18316
Operator Fan
Location: overhead console.
Purpose: operator comfort.
Data: 24 volt.
Adjustment: none required.
Diagrams: DIA-7335-003 and 004 (A-2),
DIA-7335-012 (B-3).
Parts Breakdown: 04.9-7330-050 (55). Platform Overhead Guard
Figure 18317
Crown 2011 PF25248-9 M1.91-7335-009
109
COMPONENTRY
Componentry
FILTER
Return
Location: near upper portion of reservoir.
Purpose: remove contaminants from hydraulic fluid.
Data: 10 micron.
Adjustment: none required.
Diagrams: HYD-7335-001.
Parts Breakdown: 02.0-7335-001 (23). Hydraulic Reservoir
Figure 18318
FNS1
Fan Switch
Location: switch panel. Switch Panel
Purpose: allows operator to turn on/off fan.
Data: three position, on/off/on, rocker switch.
Adjustment: none required.
Diagrams: DIA-7335-012 (B-3).
Parts Breakdown: 04.8-7335-100 (18).
FS
Figure 18319
Forward Switch
Location: control module.
Purpose: informs traction controller forward travel di-
rection is being requested by the operator.
Data: wired normally open. Rotating twist grip away
from operator actuates switch.
Adjustment: none required.
Diagrams: DIA-7335-011 (B-2).
Parts Breakdown: 04.6-7335-001 (60).
Control Module
Figure 18320
M1.91-7335-010 Crown 2011 PF25248-10
110
COMPONENTRY
Componentry
FU1
Lights and Fan Fuse
Location: distribution panel on power unit.
Purpose: protect overhead guard lights, strobe light,
fan and associated wiring from over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-4), DIA-7335-004 (A-4),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (10).
Distribution Panel
FU2 Figure 18321
Control Fuse
Location: distribution panel on power unit.
Purpose: protect control circuitry from over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-4), DIA-7335-004 (A-4),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (10).
FU3
Distribution Panel
Options Fuse
Location: distribution panel on power unit. Figure 18322
Purpose: protect options and associated wiring from
over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-4), DIA-7335-004 (A-4),
DIA-7335-008 (B-3).
Parts Breakdown: 04.3-7335-001 (12).
Distribution Panel
Figure 18323
Crown 2011 PF25248-11 M1.91-7335-011
111
COMPONENTRY
Componentry
FU4
Manual Brake Fuse
Location: distribution panel on power unit.
Purpose: protect brake and associated wiring from
over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-4), DIA-7335-004 (A-4),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (12).
Distribution Panel
FU5 Figure 18324
Outer Coil Fuse
Location: distribution panel on power unit.
Purpose: protect brake outer coil and associated wir-
ing from over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (B-3),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (12).
FU6 Distribution Panel
Inner Coil Fuse
Figure 18325
Location: distribution panel on power unit.
Purpose: protect brake inner coil and associated wir-
ing from over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (B-3),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (12).
Distribution Panel
Figure 18326
M1.91-7335-012 Crown 2011 PF25248-12
112
COMPONENTRY
Componentry
FU7
Inner Coil Fuse
Location: distribution panel on power unit.
Purpose: protect brake inner coil and associated wir-
ing from over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-004 (B-3), DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (12).
Distribution Panel
FU8
Figure 18327
Pump Motor 1 Fuse
Location: lift/power panel on power unit.
Purpose: protect lift pump motor 1 and associated wir-
ing from over-current.
Data: 75 ALS.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (A-1),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (12).
FU9
Distribution Panel
Pump Motor 2 Fuse
Location: lift/power panel on power unit. Figure 18328
Purpose: protect lift pump motor 2 and associated wir-
ing from over-current.
Data: 175 ALS.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (A-1),
DIA-7335-008 (B-3), DIA-7335-019 (B-1).
Parts Breakdown: 04.3-7335-001 (12).
Distribution Panel
Figure 18329
Crown 2011 PF25248-13 M1.91-7335-013
113
COMPONENTRY
Componentry
FU10
Steer Module Fuse
Location: lift/power panel on power unit.
Purpose: protect power steering module and associ-
ated wiring from over-current.
Data: 30A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (B-2),
DIA-7335-013 (C-2), DIA-7335-019 (B-1).
Parts Breakdown: 04.3-7335-100 (32). Lift/Power Panel
FU11 Figure 18330
Freezer/Condition Power Unit Fuse (Optional)
Location: freezer/condition panel on power unit.
Purpose: protect freezer condition components
equipped on power unit and associated wiring from
over-current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 (A-3), DIA-7335-004 (A-3),
DIA-7335-019 (B-1).
Parts Breakdown: 04.3-7335-100 (33).
Lift/Power Panel
FU12 Figure 18341
Freezer/Condition Platform Fuse (Optional)
Location: freezer/condition panel on power unit.
Purpose: protect freezer condition components
equipped on platform and associated wiring from over-
current.
Data: 15A.
Adjustment: none required.
Diagrams: DIA-7335-002 and 004 (B-2),
DIA-7335-019 (B-1).
Parts Breakdown: 04.3-7335-100 (34).
Lift/Power Panel
Figure 18342
M1.91-7335-014 Crown 2011 PF25248-14
114
COMPONENTRY
Componentry
FU13
Traction Motor Fuse
Location: lift/power panel on power unit.
Purpose: protect traction motor and associated wiring
from over-current.
Data: 140 ACK.
Adjustment: none required.
Diagrams: DIA-7335-002 (B-1).
Parts Breakdown: 04.3-7335-100 (35).
Lift/Power Panel
GTS1, GTS2 Figure 18343
Side Gate Switches
Location: platform console.
Purpose: prevents lift/lower and traction when gates
are up.
Data: wired normally open, held closed when gates are
down. GTS1 (Shown)
GTS2
Adjustment: none required.
Diagrams: DIA-7335-003 and 005 (B-2),
DIA-7335-016 (B-4).
Parts Breakdown: 09.0-7334-150 (4) (77).
Part of Platform
GTS5, GTS6 (SAA Only - not shown) Figure 18344
Rear Gate Switches
Location: rear post. Part of
Purpose: prevents lift/lower and traction when gates Platform
are up.
Data: wired normally open, held closed when gates are
down. Australian (SAA)
Adjustment: none required.
Diagrams: DIA-7335-003 (B-2) (C-2).
Parts Breakdown: 09.1-7330-175 (30).
GTS6 (Shown)
GTS5
Figure 18345
Crown 2011 PF25248-15 M1.91-7335-015
115
COMPONENTRY
Componentry
GTS7, GTS8 (SAA Only - not shown)
Rear Gate Switches Part of
Platform
Location: rear post.
Purpose: prevents lift/lower and traction when gates
are up.
Data: wired normally open, held closed when gates are Australian (SAA)
down.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-2) (C-2).
Parts Breakdown: 09.1-7330-177 (30).
GTS8 (Shown)
GUS GTS7
Figure 18346
Guidance Switch (Optional)
Location: control module.
Purpose: allows operator to select manual or auto-
matic steering.
GUS (Not Shown)
Data: wired normally open, held closed while in manual
steering mode.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-2), DIA-7335-011 (B-3).
Parts Breakdown: not shown (optional).
HN1
Control Module
Horn
Location: on power unit side of platform, near the bot- Figure 18347
tom.
Purpose: provide operator controlled audible warning.
Data: 24-48 volt, 0.4 amp.
Part of
Adjustment: none required. Platform
Diagrams: DIA-7335-005 (B-1), DIA-7335-011 (C-4).
Parts Breakdown: 09.0-7335-050 (10).
Figure 18348
M1.91-7335-016 Crown 2011 PF25248-16
116
COMPONENTRY
Componentry
HN2
Back-Up or Travel Alarm (Optional)
Location: platform side of power unit near bottom.
Purpose: alert pedestrians of truck movement re-
quest.
Data: reverse and/or forward switch.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-1).
Parts Breakdown: 04.0-7335-001 (13).
HNS1 Part of
Power Unit
Horn Switch
Figure 18349
Location: control module.
Purpose: allows operator to sound horn.
Data: wired normally open. Pushing horn button actu-
ates switch.
Adjustment: none required.
Diagrams: DIA-7335-011 (A-2), DIA-7335-005 (B-1).
Parts Breakdown: 04.6-7334-050 (11).
K1 Switch Panel
Figure 18350
Power Up Relay
Location: distribution panel (Platform).
Purpose: provides control circuitry power. Distribution
Data: 24 volt D.C. coil energized upon key-switch test Panel
position closure.
Adjustment: none required.
Diagrams: DIA-7335-003 and 005 (B-3),
DIA-7335-006 and 007 (B-2).
Parts Breakdown: 04.3-7335-050 (4).
Figure 18351
Crown 2011 PF25248-17 M1.91-7335-017
117
COMPONENTRY
Componentry
K2
Module Power
Location: distribution panel (Power Unit).
Purpose: provides power to display traction, steering
and guidance modules.
Data: 24 volt D.C. coil energized by steer module.
Adjustment: none required.
Diagrams: DIA-7335-002 and 005 (C-3),
DIA-7335-008 (B-2).
Parts Breakdown: 04.3-7335-001 (11). Distribution
Panel
K11 Figure 18352
Freezer/Corrosion Relay
Location: freezer/corrosion distribution panel.
Purpose: provide power to thermostat circuits.
Data: 24 volt D.C. coil energized when THS2 calls for
heat (closes) and THS3 is in temperature range.
Adjustment: none required.
Diagrams: DIA-7335-017 (B-1).
Parts Breakdown: 04.3-7334-250 (11).
K12
Freezer/Corrosion Relay (Optional)
Location: freezer/corrosion distribution panel. Freezer/Corrosion Relay
Purpose: provide power to heater circuits. Figure 18354
Data: 24 volt D.C. coil energized when THS2 calls for
heat (closes) and THS3 is in temperature range.
Adjustment: none required.
Diagrams: DIA-7335-017 (B-1). Freezer/Corrosion
Relay
Parts Breakdown: 04.3-7334-250 (3).
Figure 18355
M1.91-7335-018 Crown 2011 PF25248-18
118
COMPONENTRY
Componentry
K15
Relay (Optional)
Location: platform side of power unit near bottom un-
der travel alarm.
Purpose: provides control circuitry power.
Data: 24 volt D.C. coil energized upon key-switch test
position closure.
Adjustment: none required.
Diagrams: DIA-7335-017 (A-1).
Parts Breakdown: 04.0-7335-001 (9).
Part of Power Unit
KYS
Figure 18356
Key Switch
Location: control module.
Purpose: allows operator to power truck up and shut
truck down.
Data: key operated selector switch. Energizes K1 with
start position and maintains K1 with on position.
Adjustment: none required.
Diagrams: DIA-7335-003 and 005 (B-4),
DIA-7335-011 (C-1).
Parts Breakdown: 04.6-7335-001 (22).
LGS1 Control Panel
Figure 18357
Dome Light Switch
Location: switch panel.
Purpose: allows operator to turn on/off dome light.
Switch
Data: two-position, on/off, rocker switch. Panel
Adjustment: none required.
Diagrams: DIA-7335-012 (B-2).
Parts Breakdown: 04.8-7335-100 (8).
Figure 18358
Crown 2011 PF25248-19 M1.91-7335-019
119
COMPONENTRY
Componentry
LGS2
Work Light Switch Switch
Panel
Location: switch panel.
Purpose: allows operator to turn on/off work light.
Data: two-position, on/off, rocker switch.
Adjustment: none required.
Diagrams: DIA-7335-012 (B-2). Figure 18359
Parts Breakdown: 04.8-7335-100 (9).
LGS3 Switch
Panel
Spot Light Switch (Optional)
Location: switch panel.
Purpose: allows operator to turn on/off spot light.
Data: two-position, on/off, rocker switch. Figure 18360
Adjustment: none required.
Diagrams: DIA-7335-012 (B-2).
Parts Breakdown: 04.8-7335-100 (10).
LGT1
Strobe or Flashing Light
Location: power unit.
Purpose: visual warning of lift truck presence.
Data: 24 volt.
Adjustment: none required.
Diagrams: DIA-7335-002 (B-1), DIA-7335-004 (B-2), Figure 18361
DIA-7335-015 (C-3).
Parts Breakdown: 04.9-7330-001.
M1.91-7335-020 Crown 2011 PF25248-20
120
COMPONENTRY
Componentry
LGT2, 5
Work Lights (Optional)
Location: overhead console or mast.
Purpose: provide work area light outside operator
compartment.
Data: 12 volt.
Adjustment: minimal manual directional adjustment.
Diagrams: DIA-7335-012 (C-4).
Parts Breakdown: 04.9-7330-050 (22) (75).
Figure 18362
LGT3, 6
Dome Lights (Optional)
Overhead
Location: overhead console.
Console
Purpose: provide light inside operator compartment.
Data: 12 volt.
Adjustment: none available.
Diagrams: DIA-7335-012 (B-4).
Parts Breakdown: 04.9-7330-05 (35) (80).
Figure 18363
LGT4, 7
Spot Lights
Location: overhead console (Optional).
Purpose: provide work area light outside operator
compartment.
Data: 24 volt.
Adjustment: none available.
Diagrams: DIA-7335-012 (C-2) (C-3). Figure 18364
Parts Breakdown: 04.9-7332-250 (1).
Crown 2011 PF25248-21 M1.91-7335-021
121
COMPONENTRY
Componentry
LGT8, 9
Mast Mounted Spot Lights (Optional)
Location: mast.
Purpose: provide work area light outside operator
compartment.
Data: 24 volt.
Adjustment: none available.
Diagrams: DIA-7335-018 (B-2).
Parts Breakdown: 04.9-7332-250. Figure 18365
LOS1, 2
Low Speed Lower Switch
Location: control module.
Purpose: allows operator to lower platform.
Part of
Data: wired normally open, held closed by depressing Control Module
the lower button (partially on trucks with high speed
lower).
Adjustment: none required.
Diagrams: DIA-7335-003 and 005 (A-2),
DIA-7335-011 (B-3).
Parts Breakdown: 04.6-7334-050 (68).
Figure 18366
M1
Traction Motor
Location: drive unit.
Purpose: provide driving force for traction.
Data: provides traction control via operator input
(POT1).
Adjustment: none required.
Diagrams: DIA-7335-002, 004 and 019 (B-2).
Parts Breakdown: 03.1-7335-001 (0). Figure 18368
M1.91-7335-022 Crown 2011 PF25248-22
122
COMPONENTRY
Componentry
M2
Power Steering Motor
Location: steering gearbox.
Purpose: provide driving force for steering.
Data: steering module provides steering control via
steering command encoder ECR1 and power unit
steered wheel encoder ECR2.
Adjustment: none required.
Diagrams: DIA-7335-002 and 019 (B-2), Figure 18369
DIA-7335-014 (C-2).
Parts Breakdown: 06.0-7330-100.
M3
Lift Pump Motor
Location: reservoir.
Purpose: provide driving force for hydraulic pump sup-
plying hydraulic oil flow for lift.
Data: energized via P1 contactor.
Figure 18370
Adjustment: none required.
Diagrams: DIA-7335-002 and 007 (B-2),
DIA-7335-019 (C-2).
Parts Breakdown: 02.2-7.3-001 (0).
M4
Lift Motor (optional)
Location: reservoir.
Purpose: provide driving force for hydraulic pump sup-
Figure 18371
plying hydraulic oil flow for high speed lift.
Data: energized via P2 contactor.
Adjustment: none required.
Diagrams: DIA-7335-002 (B-1), DIA-7335-019 (C-2).
Parts Breakdown: 02.2-7.3-001 (0).
Crown 2011 PF25248-23 M1.91-7335-023
123
COMPONENTRY
Componentry
MLV
Manual Lowering Valve
Location: lift/lower manifold.
Purpose: provide means to lower platform without
powering up truck.
Data: not applicable.
Adjustment: none required.
Diagrams: HYD-7335-001.
Figure 18372
Parts Breakdown: 02.4-7335-001 (11).
ORS1
Switch
Override Switch Panel
Location: switch panel.
Purpose: when raise lower cutout programmed for
override is encountered, actuating switch permits con-
tinuation of function.
Data: momentary contact switch. Figure 18373
Adjustment: none required.
Diagrams: DIA-7335-003 and 011 (B-3),
DIA-7335-005 (B-2).
Contactor
Parts Breakdown: 04.8-7335-100 (12). Panel
P1
Contactor
Location: Contactor Panel.
Purpose: provide control of Electrical power.
Figure 18374
Data: not applicable.
Adjustment: none required.
Diagrams: DIA-7335-004 and 019 (B-2),
DIA-7335-015 (C-2), HYD-7335-001.
Parts Breakdown: 04.3-7335-100 (39).
M1.91-7335-024 Crown 2011 PF25248-24
124
COMPONENTRY
Componentry
P2
Contactor (Optional) Contactor
Panel
Location: contactor panel.
Purpose: provide control of Electrical power.
Data: not applicable.
Adjustment: none required.
Diagrams: DIA-7335-004 and 019 (B-2),
DIA-7335-015 (C-2), HYD-7335-001.
Figure 18375
Parts Breakdown: 04.3-7335-100 (41).
POT1
Traction Request Potentiometer
Location: control module.
Purpose: provide traction input to controller TCM.
Data: 22 K ohms.
Adjustment: refer to Electrical Maintenance - control
module.
Diagrams: DIA-7335-003 and 005 (B-1),
DIA-7335-011 (B-2). Switch Panel
Parts Breakdown: 04.6-7335-001 (42).
Figure 18376
PS1
Light Power Supply
Location: overhead console.
Purpose: provide 12 volt for work lights.
Data: 24 volt D.C. input, 12 volt D.C. output.
Switch Panel
Adjustment: none required.
Diagrams: DIA-7335-002 (A-2), DIA-7335-012 (C-1). Figure 18377
Parts Breakdown: 04.9-7330-050 (5).
Crown 2011 PF25248-25 M1.91-7335-025
125
COMPONENTRY
Componentry
PS2
Light Power Supply
Location: overhead console.
Purpose: provide 12 volt for dome lights.
Data: 24 volt D.C. input, 12 volt D.C. output.
Overhead Console
Adjustment: none required.
Figure 18378
Diagrams: DIA-7335-002 (A-2), DIA-7335-012 (C-1).
Parts Breakdown: 04.9-7330-050 (6).
PVL
Proportional Lowering Valve
Location: lift/lower manifold.
Purpose: provide proportional flow control of lowering
functions.
Lift/Lower Manifold
Data: 24 volt D.C.
Adjustment: none required. Figure 18379
Diagrams: DIA-7335-002 (B-2), DIA-7335-004 (B-3),
DIA-7335-015 (C-1), HYD-7335-001.
Parts Breakdown: 02.4-7335-001 (15).
PCL
Proportional Lowering Valve
Location: lift/lower manifold.
Purpose: provide proportional flow control of lowering Lift/Lower Manifold
functions.
Figure 18380
Data: 24 volt D.C.
Adjustment: none required.
Diagrams: HYD-7335-001.
Parts Breakdown: 02.4-7335-001 (15).
M1.91-7335-026 Crown 2011 PF25248-26
126
COMPONENTRY
Componentry
RAS1
Low Speed Raise Switch
Location: control module.
Purpose: allows operator to raise platform.
Part of
Data: wired normally open, held closed by depressing Control Module
the raise button (partially on trucks with high speed
raise).
Adjustment: none required.
Diagrams: DIA-7335-011 (B-2).
Parts Breakdown: 04.6-7334-050 (68).
Figure 18381
RAS2
High Speed Raise Switch
Location: control module.
Purpose: allows operator to raise platform.
Data: wired normally open, held closed by fully de-
Part of
pressing the raise button.
Control Module
Adjustment: none required.
Diagrams: DIA-7335-003 (A-2), DIA-7335-011 (B-2).
Parts Breakdown: 04.6-7334-050 (68).
RES1 Figure 18382
Resistor (Optional)
Location: overhead console.
Purpose: reduce fan noise.
Data: 25 watt, 10 ohm.
Adjustment: none required.
Overhead
Diagrams: DIA-7335-005 (A-2), DIA-7335-012 (B-4).
Console
Parts Breakdown: 04.9-7330-050 (60).
Figure 18384
Crown 2011 PF25248-27 M1.91-7335-027
127
COMPONENTRY
Componentry
RES2, RES3
Freezer/Corrosion Heater (Optional)
Location: aisle guide wheel brackets.
Purpose: RES2 applies heat to aisle guide switch
RGS2 and RES3 applies heat to aisle guide switch
RGS1.
Data: 50 watt, 15 ohm.
Adjustment: none required.
Diagrams: DIA-7335-002 (B-3), DIA-7335-004 (B-3), Distribution Panel
DIA-7335-008 (A-2). Figure 18385
Parts Breakdown: 04.3-7335-001 (6).
RES4, RES5
Freezer/Corrosion Heater (Optional)
Location: battery-restraint-switch brackets.
Purpose: RES4 applies heat to battery restraint switch
BRES2 and RES5 applies heat to battery restraint
switch BRES1.
Data: 50 watt, 15 ohm.
Adjustment: none required.
Diagrams: DIA-7335-017 (C-1).
Parts Breakdown: 01.2-7335-001 (43).
RES6, RES7
Figure 18386
Freezer/Corrosion Heater (Optional)
Location: main frame.
Purpose: RES6 applies heat to chain slack switch
CHS3 and RES7 applies heat to chain slack switch
CHS4.
Data: 25 watt, 30 ohm.
Adjustment: none required.
Diagrams: DIA-7335-017 (C-1).
Parts Breakdown: 07.6-7334-050 (4).
Mainframe
Figure 18387
M1.91-7335-028 Crown 2011 PF25248-28
128
COMPONENTRY
Componentry
RES8, RES9
RES9
Freezer/Corrosion Heater (Optional)
RES8 (Shown)
Location: platform gate.
Purpose: RES8 applies heat to gate switches GTS1
and RES9 applies heat to gate switches GTS2.
Data: 25 watt, 30 ohm.
Adjustment: none required.
Diagrams: not shown. Part of
Platform
Parts Breakdown: 09.0-7334-150 (8).
Figure 18388
RES10
Freezer/Corrosion Heater
Location: control module.
Purpose: applies heat to emergency disconnect
switch EDS.
Data: 10 watt, 70 ohm.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 04.6-7334-050 (21). Control Module
Figure 18389
RES11
Freezer/Corrosion Heater (Optional)
Location: control module.
Purpose: applies heat to rise and lower switches
LOS1, LOS2, RAS1 & RAS2.
Part of
Data: 25 watt, 30 ohm.
Control Module
Adjustment: none required.
Diagrams: DIA-7335-003 (A-1).
Parts Breakdown: 04.6-7334-050 (51).
Figure 18390
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COMPONENTRY
Componentry
RES12
Freezer/Corrosion Heater (Optional) Control Module
Location: control module.
Purpose: applies heat to horn switch HNS1.
Data: 25 watt, 30 ohm.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 04.6-7334-050 (21).
Figure 18391
RES13
Freezer/Corrosion Heater (Optional)
Location: control module.
Purpose: applies heat to forward switch FS.
Data: 10 watt, 70 ohm.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 04.6-7334-050 (21).
RES14 Control Module
Freezer/Corrosion Heater (Optional) Figure 18392
Location: control module.
Purpose: applies heat to reverse switch RS.
Data: 10 watt, 70 ohm.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 04.6-7334-050 (21).
Control Module
Figure 18393
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COMPONENTRY
Componentry
RES15, RES19
Freezer/Corrosion Heater (Optional)
Location: platform (TT).
Purpose: RES15 applies heat to chain slack switch
CHS1 and RES19 applies heat to chain slack switch
CHS2.
Data: 25 watt, 30 ohm. Part of Platform
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 07.6-7334-050 (43). Figure 18394
RES16
Freezer/Corrosion Heater (Optional)
Location: below floorboard.
Purpose: applies heat to brake switch BRS1.
Data: 25 watt, 30 ohm.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 05.1-7334-001 (20).
Figure 18395
RGS1 and RGS2 (Optional)
Rail Guide Switches RGS1 and
RGS2 (Shown)
Location: aisle guide wheel bracket mounted under
power unit.
Purpose: provide ability to turn on automatic steering.
Data: wired normally closed held open.
Adjustment: none required.
Diagrams: DIA-7335-014 (B-2). Power Unit
Parts Breakdown: 10.0-7334-001 (11). Figure 18396
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COMPONENTRY
Componentry
RS
Reverse Switch
Location: control module.
Purpose: informs traction controller reverse travel di-
rection is being requested by the operator.
Data: wired normally open. Rotating twist grip toward
operator actuates switch.
Adjustment: none required.
Diagrams: DIA-7335-011 (B-2).
Figure 18397
Parts Breakdown: 04.6-7335-001 (60).
RV1 Lift/Lower Manifold
Relief Valve
Location: lift/lower manifold.
Purpose: limit operating pressure for lift circuit.
Data: not applicable.
Adjustment: refer to Hydraulic Maintenance.
Diagrams: HYD-7335-001.
Figure 18398
Parts Breakdown: 02.4-7335-001 (14).
SB21
Suppressor Block
Location: below strobe light on power unit.
Purpose: suppress electrical noise from operation of
strobe light.
Data: not applicable.
Adjustment: none required.
Diagrams: not shown.
Parts Breakdown: 04.0-7335-001 (5). Mounted to Power Unit
Figure 18400
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COMPONENTRY
Componentry
SVL
Lift/Lower Manifold
Solenoid Valve
Location: lift/lower manifold.
Purpose: provide proportional flow control of lowering
functions.
Data: 24 volt D.C.
Adjustment: none required.
Diagrams: DIA-7335-015 (C-1), HYD-7335-001.
Parts Breakdown: 02.4-7335-001 (15).
Figure 18402
SENSOR BAR LOAD WHEEL
Base of Mainframe
Wire Guidance (Optional)
Location: base of mainframe.
Purpose: sense signal strength from guide wire em-
bedded in floor.
Data: refer to Electrical and Wire Guide System.
Adjustment: none required.
Diagrams: DIA-7335-016 (A-3).
Parts Breakdown: 04.3-7335-500 (10).
SENSOR BAR STEER WHEEL Sensor Bar Load Wheel
Figure 18403
Wire Guidance (Optional)
Location: front and center of power unit below skirt.
Skirt of Power Unit
Purpose: sense signal strength from guide wire em-
bedded in floor.
Data: refer to Electrical Maintenance - wire guide sys-
tem.
Adjustment: none required.
Diagrams: DIA-7335-016 (A-2).
Parts Breakdown: 04.3-7335-500 (1).
Sensor Bar Steel Wheel
Figure 18404
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COMPONENTRY
Componentry
THS1
Power Unit Thermostat (Optional)
Location: power unit battery wall between power unit
and mast.
Purpose: provide ability to turn on power unit heaters.
Data: wired normally closed. Contact closes at 49° C
(120° F) and opens at 68° C (140° F).
Part of Power Unit
Adjustment: none required.
Diagrams: DIA-7335-015 (C-3). Figure 18405
Parts Breakdown: 01.2-7335-003 (41).
THS2
Platform Thermostat (Optional)
Location: mounted to plate assembled to Brake
switch, BRS1, located under platform floor.
Purpose: provide ability to turn on platform heaters.
Part of Power Unit
Data: wired normally closed. Contact closes at 4° C
(40° F) and opens at 15° C (60° F). Figure 18406
Adjustment: none required.
Diagrams: DIA-7335-015 (C-3).
Parts Breakdown: 01.2-7335-003 (41). Switch Panel
ZSS
Zone Select Switch (Optional)
Location: switch panel.
Figure 18407
Purpose: allows selection of lift height cutout.
Data: three position key switch.
Adjustment: none required.
Diagrams: DIA-7335-003 (B-2), DIA-7335-011 (B-3).
Parts Breakdown: 04.8-7330-100 (17).
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COMPONENTRY
Componentry
Componentry
Introduction
The components in this section help the technician with
the information below for each component. This
section contains:
• The reference designator (for example, ALM1) that
is on the electrical diagram and parts pages.
• The description of the component.
• The location of the component on the lift truck.
• The function of the component.
• The data of the component.
• The applicable adjustments.
• The electrical diagrams that the component is on.
Two numbers immediately follow the page number.
The first number in parentheses is the grid
coordinate and the second number in parentheses
is the manual page number (for example,
DIA-7335-003 (C-2) (475)).
• The parts page that the component is on. Two
numbers immediately follow the page number. The
first number in parentheses is the component index
number and the second number in parentheses is
the manual page number (for example,
04.0-7335-001 (1) (549)).
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COMPONENTRY
Access 1
Access 1
Display Module
Location: on the platform
Function: shows the applicable lift truck information
such as battery charge and hours of operation
Data: receives input from these components:
– Access 1 2 3® modules
– ALM1
– GUS1
– ORS1.
Adjustment: if you replace a module, calibrate the lift
truck to prevent event codes. If the replacement
module includes the newest software, do a software
update in the other modules to make sure that all
software is compatible.
Diagrams: DIA-7335-131 (B-2) (478)
DIA-7335-133 (B-2) (478)
DIA-7335-135 (B-2) (478)
DIA-7335-140 (C-1, C-2) (478)
DIA-7335-141 (C-1, C-2) (478)
DIA-7335-151 (C-1, C-2) (478)
Parts Breakdown: 09.0-7335-007 (8) (555)
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COMPONENTRY
Access 1
Access 1
Fig. 1 (31528)
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COMPONENTRY
Access 3™
Access 3™
Traction Control Module
Location: on the traction panel
Function: controls the braking and traction motor (M1)
speed by the operator input from BRS1 and POT1
Data: transistor control circuitry
Adjustment: if you replace a module, calibrate the lift
truck to prevent event codes. If the replacement
module includes the newest software, do a software
update in the other modules to make sure that all
software is compatible.
Diagrams: DIA-7335-132 (B-2) (474)
DIA-7335-134 (B-2) (480)
DIA-7335-136 (B-2) (489)
DIA-7335-145 (C-1) (489)
DIA-7335-152 (A-2) (498)
Parts Breakdown: 04.1-7335-005 (13) (563)
Access 4
Vehicle Control Module
Location: operator compartment
Function: controls the lift truck operations by checking
for the correct inputs and transmitting data to all other
Access 1 2 3® modules.
Data: see the Electrical section
Adjustment: if you replace a module, calibrate the lift
truck to prevent event codes. If the replacement
module includes the newest software, do a software
update in the other modules to make sure that all
software is compatible.
Diagrams: DIA-7335-131 (B-1) (475)
DIA-7335-133 (B-1) (478)
DIA-7335-135 (B-1) (478)
DIA-7335-140 (C-3) (478)
DIA-7335-141 (C-3) (478)
DIA-7335-151 (C-3) (478)
Parts Breakdown: 09.0-7335-007 (19) (555)
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COMPONENTRY
Access 4
Access 4
Access 3™
Fig. 2 (31529)
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COMPONENTRY
Access 5
Access 5 update in the other modules to make sure that all
software is compatible.
Steering Control Module Diagrams: DIA-7335-132 (B-4) (474)
DIA-7335-134 (B-4) (485)
Location: on the controller panel on the power unit,
DIA-7335-148 (C-1) (489)
near Access 6
DIA-7335-152 (A-3) (478)
Function: controls BRK and M2
Parts Breakdown: 04.1-7335-005 (17) (561)
Data: receives input from these components:
– Access 1 2 3® modules Accumulator
– BRES1 Location: on the front, lower right side of the power
– BRES2 unit
– CS1 Function: shock absorber for the lift/lower hydraulic
– ECR2 system
– RGSL Data: pre-charge to 34 bar (500 psi). See the Hydraulic
– RGSR. section for charging procedures
Adjustment: if you replace a module, calibrate the lift Adjustment: N/A
truck to prevent event codes. If the replacement
Diagrams: HYD-7335-006 (1) (485)
module includes the newest software, do a software
HYD-7335-007 (1) (485)
update in the other modules to make sure that all
HYD-7335-008 (1) (485)
software is compatible.
HYD-7335-009 (1) (485)
Diagrams: DIA-7335-132 (B-3) (474)
Parts Breakdown: 02.0-7335-006 (48) (561)
DIA-7335-134 (B-3) (480)
02.0-7335-502 (52) (561)
DIA-7335-136 (B-3) (489)
02.0-7535-550 (16) (561)
DIA-7335-146 (C-1) (478)
DIA-7335-152 (A-2) (498)
Parts Breakdown: 04.1-7335-005 (17) (561)
Access 6
Guidance Control Module (Optional)
Location: on the controller panel on the power unit,
near Access 5
Function: controls the wire guidance and the end aisle
control (EAC) systems
Data: receives input from these components:
– Access 1 2 3® modules
– EACA1
– EACA2
– EACB1
– EACB2
– GS1
– GS2.
Adjustment: if you replace a module, calibrate the lift
truck to prevent event codes. If the replacement
module includes the newest software, do a software
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COMPONENTRY
Accumulator
Access 5
Access 6
Accumulator
Fig. 3 (31530)
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COMPONENTRY
ALM1
ALM1 BRES1 and BRES2
Status Alarm Battery Retainer Switches (Optional)
Location: on the distribution panel on the platform Location: both sides of the power unit skirt
Function: gives an audible indication of messages for Function: monitors if the battery retainers are
the operator installed. BRES1 and BRES2 do not let the lift truck
travel if the battery retainers are not on the lift truck.
Data: K1 supplies +BV and Access 1 supplies negative
to ALM1. See the Access 1 output to ALM1 in the Data: BRES1 and BRES2 are connected normally
A4.1.1 ALM1 menu. open, held closed when the battery retainers are
installed. BRES1 and BRES2 supply a B-NEG input
Adjustment: N/A
signal to Access 5. See the BRES1 and BRES2 input
Diagrams: DIA-7335-131 (A-2) (475) in the A2.4.9 BRES1/BRES2 menu.
DIA-7335-133 (A-2) (476)
Adjustment: N/A
DIA-7335-135 (A-2) (476)
DIA-7335-137 (B-2) (476) Diagrams: DIA-7335-132 (B-3) (474)
DIA-7335-138 (B-2) (476) DIA-7335-134 (B-3) (481)
DIA-7335-146 (C-2) (476)
Parts Breakdown: 04.3-7335-050 (3) (578)
Parts Breakdown: 01.2-7335-003 (49) (473)
AUX
LFOC Lifting Forks Switch
Location: LFOC console
Function: allows the operator to select lifting fork
functions
Data: switch is wired normally open, closes when you
push the button. AUX switch supplies +BV input to
Access 4
Adjustment: N/A
Diagrams: DIA-7335-132 (A-1) (485)
Parts Breakdown: 09.3-7534-011 (128) (485)
BATT
Battery
Location: between the power unit and the platform
Function: supplies power to the lift truck and its com-
ponents
Data: 24 V
Adjustment: N/A
Diagrams: DIA-7335-132 (B-4) (474)
DIA-7335-134 (B-4) (480)
DIA-7335-136 (B-4) (481)
Parts Breakdown: N/A
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COMPONENTRY
BRES1 and BRES2
ALM1
BRES1
BRES2
(a)
(a) BRES2 is shown
BATT
AUX
Fig. 4 (31531)
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COMPONENTRY
BRK
BRK Adjustment: N/A
Diagrams: DIA-7335-131 (B-1) (475)
Brake DIA-7335-133 (B-1) (479)
DIA-7335-135 (B-2) (476)
Location: on the drive unit, on M1
DIA-7335-142 (B-3, C-3) (476)
Function: supplies braking force to M1 to stop the lift
Parts Breakdown: 07.6-7334-052 (51, 56) (673)
truck and prevents the movement of the parked lift
truck
CHS3 and CHS4
Data: ED2 supplies +BV and Access 5 supplies
negative to BRK. See the Access 5 outputs to BRK in Chain Slack Switches
the A4.4.2 BRK OUTER and the A4.4.3 BRK INNER
menus. Location: on the top of the mainframe
Adjustment: see the BRAKE SYSTEM / Brake section Function: stops the lower function when the mast
chains become slack
Diagrams: DIA-7335-132 (A-3) (474)
DIA-7335-134 (A-3) (481) Data: CHS3 and CHS4 are connected normally open,
DIA-7335-136 (A-3) (476) held closed as the mast chains keep the correct
DIA-7335-146 (C-3) (476) tension. See the CHS3 and CHS4 input in the A2.2.3
CHS3/CHS4 menu.
Parts Breakdown: 05.3-7340-001 (0) (629)
Adjustment: N/A
BRS Diagrams: DIA-7335-132 (A-2) (475)
DIA-7335-134 (A-2) (479)
Brake Switch DIA-7335-136 (A-2, B-2) (476)
DIA-7335-145 (C-3, C-4) (476)
Location: below the platform floorboard
Parts Breakdown: 07.6-7334-001 (7, 9) (485)
Function: lets you release or apply the brake
07.6-7334-050 (2, 27) (671)
Data: BRS is connected normally open, held closed
when you push the brake pedal. BRS supplies a
B-NEG input signal to Access 5. See the BRS1 input in
the A2.4.10 BRS1 menu.
Adjustment: N/A
Diagrams: DIA-7335-131 (B-3) (475)
DIA-7335-133 (B-3) (479)
DIA-7335-135 (B-3) (476)
DIA-7335-142 (C-4) (476)
Parts Breakdown: 05.1-7335-001 (17) (615)
CHS1 and CHS2
Chain Slack Switches
Location: on the mast side of the platform, near the
bottom
Function: stops the lower function when the platform
chains become slack
Data: CHS1 and CHS2 are connected normally open,
held closed as the platform chains keep the correct
tension. See the CHS1 and CHS2 input in the A2.3.8
CHS1/CHS2 menu.
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COMPONENTRY
CHS3 and CHS4
CHS4
CHS3
(a)
CHS2
CHS1
(a) CHS3 is shown
BRK BRS
Fig. 5 (31532)
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COMPONENTRY
CS1
CS1 HYD-7335-008 (495)
HYD-7335-009 (495)
Current Sensor Parts Breakdown: 02.4-7335-003 (6) (522)
02.4-7335-052 (6) (522)
Location: on the contactor panel
02.4-7535-502 (20) (522)
Function: monitors the current flow in the negative 02.4-7535-552 (20) (522)
cable and supplies an input signal to Access 5
Data: receives 5 V and B-NEG from Access 5. See the
CV3
CS1 input in the A2.4.7 CS1 menu.
Check Valve
Adjustment: N/A
Location: on the manifold
Diagrams: DIA-7335-132 (B-3) (474)
DIA-7335-134 (B-3) (481) Function: prevents the back flow of hydraulic oil into
DIA-7335-136 (B-3) (481) the lift pump P2
DIA-7335-146 (C-3)(481) Data: N/A
Parts Breakdown: 04.3-7335-100 (9) (580) Adjustment: N/A
04.3-7335-156 (13) (485)
04.3-7535-100 (14) (485) Diagrams: HYD-7335-007 (495)
HYD-7335-009 (495)
CV1 Parts Breakdown: 02.4-7335-052 (6) (522)
02.4-7535-552 (20) (485)
Check Valve
Location: on the manifold
DB1
Function: prevents the back flow of hydraulic oil into Diode Block (Optional)
the lift pump P1 (two speed lift). Prevents the back flow
of hydraulic oil into the lift pump P2 (two speed lift with Location: on the platform near PGS1
lifting forks). Function: lets the current flow in the correct direction
Data: N/A when M5 operates
Adjustment: N/A Data: N/A
Diagrams: HYD-7335-007 (495) Adjustment: N/A
HYD-7335-008 (495) Diagrams: DIA-7335-150 (C-3) (495)
HYD-7335-009 (495)
Parts Breakdown: 04.0-7340-100 (23) (522)
Parts Breakdown: 02.4-7335-052 (6) (522)
02.4-7535-552 (20) (522)
CV2
Check Valve
Location: on the manifold
Function: prevents the back flow of hydraulic oil from
the lift cylinders
Data: N/A
Adjustment: N/A
Diagrams: HYD-7335-006 (495)
HYD-7335-007 (495)
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COMPONENTRY
DB1
DB1
CS1
(a) CV1, CV2, and CV3 are on the
manifold
(a)
CV3
CV2
CV1
Fig. 6 (31533)
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COMPONENTRY
DMS1
DMS1 EACA2
Two-Hand Operation Platform Switch (LFOC) (EU End Aisle Control Sensor (Optional)
and SAA Lift Trucks Only)
Location: below the battery compartment
Location: LFOC console
Function: senses the magnets for end aisle control
Function: allows the operator to select the platform and supplies an input signal to Access 6
raise and platform lower functions
Data: Receives 12 V and B-NEG from Access 6. See
Data: switch is wired normally open, closes when you the EACA2 input to Access 6 in the A2.5.4 EACA2
push the button. Supplies a negative input to Access 1. menu.
See the A2.1.1 DMS1 inputs menu.
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-7335-132 (B-4) (474)
Diagrams: DIA-7335-131 (B-2) (495) DIA-7335-134 (B-4) (485)
DIA-7335-133 (B-2) (485) DIA-7335-148 (A-2, B-4) (477)
DIA-7335-142 (B-3) (485)
Parts Breakdown: 10.4-7335-001 (12) (725)
Parts Breakdown: 09.3-7534-011 (138) (522)
EACB1
DTS1
End Aisle Control Sensor (Optional)
Drive/Tow Switch
Location: below the battery compartment
Location: on the distribution panel on the power unit
Function: senses the magnets for end aisle control
Function: to release the brake for lift truck towing and supplies an input signal to Access 6
Data: DTS1 is a two-position, on-on, rocker handle Data: Receives 12 V and B-NEG from Access 6. See
switch the EACB1 input to Access 6 in the A2.5.5 EACB1
menu.
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-7335-132 (A-3) (474)
DIA-7335-134 (A-3) (477) Diagrams: DIA-7335-132 (B-3) (474)
DIA-7335-136 (A-3) (477) DIA-7335-134 (B-3) (485)
DIA-7335-139 (B-3) (477) DIA-7335-148 (A-1, B-4) (477)
Parts Breakdown: 04.3-7335-001 (8) (574) Parts Breakdown: 10.4-7335-001 (11) (725)
EACA1
End Aisle Control Sensor (Optional)
Location: below the battery compartment
Function: senses the magnets for end aisle control
and supplies an input signal to Access 6
Data: Receives 12 V and B-NEG from Access 6. See
the EACA1 input to Access 6 in the A2.5.3 EACA1
menu.
Adjustment: N/A
Diagrams: DIA-7335-132 (B-4) (474)
DIA-7335-134 (B-4) (485)
DIA-7335-148 (A-1, B-4) (477)
Parts Breakdown: 10.4-7335-001 (12) (725)
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COMPONENTRY
EACB1
DTS1
DMS1
EACA2
EACB1
EACA1
Fig. 7 (31534)
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COMPONENTRY
EACB2
EACB2 Diagrams: DIA-7335-132 (B-3) (485)
DIA-7335-134 (B-3) (485)
DIA-7335-136 (B-3) (485)
End Aisle Control Sensor (Optional)
DIA-7335-146 (C-4) (475)
Location: below the battery compartment
Parts Breakdown: 04.8-7335-200 (3) (555)
Function: senses the magnets for end aisle control
and supplies an input signal to Access 6 ECR3
Data: Receives 12 V and B-NEG from Access 6. See
the EACB2 input to Access 6 in the A2.5.6 EACB2 Travel Speed Encoder
menu. Location: the traction motor on BRK1
Adjustment: N/A Function: supplies speed and direction input to
Diagrams: DIA-7335-132 (B-4) (474) Access 3™
DIA-7335-134 (B-4) (485) Data: receives 12 V and negative from Access 3™.
DIA-7335-148 (A-2, B-4) (477) 64 pulses per revolution. See the ECR3 input in the
Parts Breakdown: 10.4-7335-001 (11) (725) A2.2.1 ECR3 menu.
Adjustment: N/A
ECR1
Diagrams: DIA-7335-146 (C-4) (474)
DIA-7335-132 (B-2) (485)
Steering Command Encoder
DIA-7335-134 (B-2) (485)
Location: the tiller knob DIA-7335-136 (C-2) (485)
Function: supplies steering command input to Parts Breakdown: 05.3-7340-001 (22) (629)
Access 4
Data: receives 12 V and negative from Access 4.
32 pulses per revolution. See the ECR1 input in the
A2.3.2 ECR1/ECR5 menu.
Adjustment: N/A
Diagrams: DIA-7335-131 (A-1) (485)
DIA-7335-133 (A-1) (485)
DIA-7335-135 (A-1) (485)
DIA-7335-140 (A-4) (478)
DIA-7335-141 (A-3) (478)
DIA-7335-151 (A-3) (478)
Parts Breakdown: 06.0-7335-001 (7) (636)
ECR2
Steering Feedback Encoder
Location: in front of M1
Function: supplies feedback to indicate the position of
the steering wheel to Access 5
Data: receives 5 V and negative from Access 5.
32 pulses per revolution. See the ECR2 input in the
A2.4.1 ECR2 menu.
Adjustment: see the ELECTRICAL SYSTEM /
Access 1 2 3® Menus / CALIBRATION Menus / C4
STEER ENCODER section
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COMPONENTRY
ECR3
ECR1
ECR3
EACB2
ECR2
Fig. 8 (31535)
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COMPONENTRY
ECR4
ECR4 Adjustment: N/A
Diagrams: DIA-7335-132 (B-2) (474)
Height Encoder DIA-7335-134 (B-2) (480)
DIA-7335-136 (C-2) (480)
Location: on the bottom corner of the platform
DIA-7335-145 (A-1) (485)
Function: supplies the measured height of the forks
Parts Breakdown: 09.0-7340-400 (2) (721)
with the mast below staging
Data: receives 5 V and negative from Access 4.
32 pulses per revolution. See the ECR4 input in the
A2.3.1 ECR4 menu.
Adjustment: N/A
Diagrams: DIA-7335-131 (A-2) (485)
DIA-7335-133 (A-2) (485)
DIA-7335-135 (A-2) (485)
DIA-7335-140 (A-2) (475)
DIA-7335-141 (A-2) (478)
DIA-7335-151 (A-2) (485)
Parts Breakdown: 09.0-7340-400 (2) (721)
ECR5
Steering Command Encoder
Location: the tiller knob
Function: supplies steering command input to
Access 4
Data: receives 12 V and negative from Access 4.
32 pulses per revolution. See the ECR5 input in the
A2.3.2 ECR1/ECR5 menu.
Adjustment: N/A
Diagrams: DIA-7335-131 (A-1) (485)
DIA-7335-133 (A-1) (485)
DIA-7335-135 (A-1) (485)
DIA-7335-140 (A-4) (475)
DIA-7335-141 (A-4) (478)
DIA-7335-151 (A-4) (485)
Parts Breakdown: 06.0-7335-001 (7) (636)
ECR6
Mast Height Encoder
Location: on the top of the mast
Function: supplies the measured height of the forks
with the mast above staging
Data: receives 12 V and negative from Access 3™.
32 pulses per revolution. See the ECR6 input in the
A2.2.8 ECR6 menu.
M1.91-7335-052 Crown 2017 PF27668
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COMPONENTRY
ECR6
ECR5
ECR6
ECR4
Fig. 9 (31536)
Crown 2017 PF27668 M1.91-7335-053
93
COMPONENTRY
ED1
ED1 EDS
Main Contactor Emergency Disconnect Switch
Location: the contactor panel Location: on the control module
Function: supplies power to M3, M4, and the platform Function: disconnects +BV to KYS
accessories
Data: EDS is closed. When you push EDS, the switch
Data: receives +BV through the K1 tips and B-NEG contacts open.
from the negative bus bar
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-7335-131 (B-3) (475)
Diagrams - Coil: DIA-7335-132 (C-2) (474) DIA-7335-133 (B-3) (479)
DIA-7335-134 (C-2) (474) DIA-7335-135 (B-4) (479)
DIA-7335-136 (C-2) (474) DIA-7335-142 (B-1) (479)
DIA-7335-147 (C-2) (482)
Parts Breakdown: 04.6-7335-052 (76) (575)
DIA-7335-152 (B-1) (489)
Diagrams - Contacts: DIA-7335-132 (A-4) (474) FAN1
DIA-7335-134 (A-4) (474)
DIA-7335-136 (A-4) (474) Operator Fan (Optional)
DIA-7335-145 (C-3) (480)
Location: on the overhead console
Parts Breakdown: 04.3-7335-100 (1) (580)
04.3-7335-156 (1) (485) Function: supplies cooling for operator comfort
04.3-7535-100 (1) (580) Data: receives +BV from FNS and B-NEG from the
negative bus bar
ED2
Adjustment: N/A
Steer and Traction Contactor Diagrams: DIA-7335-143 (B-3) (483)
Location: on the contactor panel Parts Breakdown: 04.9-7335-054 (54) (614)
Function: supplies power to Access 3™, Access 5,
and the BRK coils
Data: receives positive from Access 5 and negative
from Access 3™. See the Access 3™ outputs to ED2
in the A4.2.5 ED2 menu. See the Access 5 outputs to
ED2 in the A4.4.1 ED2 menu.
Adjustment: N/A
Diagrams - Coil: DIA-7335-132 (B-2) (474)
DIA-7335-134 (B-2) (474)
DIA-7335-136 (C-2) (474)
DIA-7335-147 (C-2) (482)
DIA-7335-152 (B-1) (489)
Diagrams - Contacts: DIA-7335-132 (A-4) (474)
DIA-7335-134 (A-4) (474)
DIA-7335-136 (A-4) (474)
DIA-7335-145 (C-2) (480)
Parts Breakdown: 04.3-7335-100 (1) (580)
04.3-7335-156 (1) (580)
04.3-7535-100 (1) (485)
M1.91-7335-054 Crown 2017 PF27668
94
COMPONENTRY
FAN1
ED1
FAN1
ED2
EDS
Fig. 10 (31537)
Crown 2017 PF27668 M1.91-7335-055
95
COMPONENTRY
FAN2
FAN2 FNS1
Power Unit Fan Fan Switch
Location: on the power unit, near and Access 3™ Location: on the switch panel
Function: supplies cooling for Access 3™ Function: lets you turn on FAN1 and turn off FAN1
Data: receives +BV from K2 and B-NEG from Data: FNS1 is a three-position, on-off-on, rocker
Access 3™. See the Access 3™ output to FAN2 and switch. FNS1 supplies +BV to FAN1
the A4.2.4 FAN2 menus.
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-7335-143 (B-3) (483)
Diagrams: DIA-7335-132 (A-2) (474)
Parts Breakdown: 04.8-7335-102 (7) (295)
DIA-7335-134 (A-2) (480)
DIA-7335-136 (A-2) (485)
DIA-7335-145 (B-1) (485)
Parts Breakdown: 04.1-7335-005 (7) (563)
FIL1
Flashing Light Filter
Location: below the flashing light on the support
bracket
Function: prevents excessive voltage
Data: N/A
Adjustment: N/A
Diagrams: DIA-7335-132 (B-2) (474)
DIA-7335-134 (B-2) (482)
DIA-7335-136 (B-1) (482)
DIA-7335-147 (C-3) (482)
Parts Breakdown: 04.9-7330-001 (3) (608)
FILTER
Return Line Filter
Location: the hydraulic reservoir
Function: removes contamination from the hydraulic
oil
Data: 10 microns
Adjustment: N/A
Diagrams: HYD-7335-006 (5) (495)
HYD-7335-007 (5) (495)
HYD-7335-008 (5) (495)
HYD-7335-009 (5) (495)
Parts Breakdown: 02.0-7335-004 (18) (516)
02.0-7335-054 (20) (516)
02.0-7535-550 (7) (485)
M1.91-7335-056 Crown 2017 PF27668
96
COMPONENTRY
FNS1
FIL1
FAN2
(a)
(a) Filter
FNS1
Fig. 11 (31538)
Crown 2017 PF27668 M1.91-7335-057
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COMPONENTRY
FS
FS Parts Breakdown: 04.3-7335-001 (10) (574)
Forward Switch
FU3
Location: on the control module Options Fuse
Function: supplies the input signal for power unit first Location: on the distribution panel on the power unit
(forward) travel to Access 4
Function: prevents these components from receiving
Data: FS is connected normally open. When the twist too much current:
grip is in the power unit first (forward) direction, FS
– The Access 3™ control circuit
closes. FS supplies a +BV input to Access 4. See the
FS input in the A2.3.7 FS menu. – The Access 5 control circuit
– The Access 6 control circuit
Adjustment: see the ELECTRICAL / Control Module /
Adjustments / Directional Switches (FS and RS) – CHS3
– CHS4
Diagrams: DIA-7335-131 (A-2) (475)
DIA-7335-133 (A-2) (479) – FAN2
DIA-7335-135 (A-2) (495) – The SVL coil
DIA-7335-142 (B-2) (495) – The PVL coil
Parts Breakdown: 04.6-7335-007 (60) (583) – The wires related to these components.
Data: 15 A
FU1
Adjustment: N/A
Customer Accessories Fuse Diagrams: DIA-7335-132 (A-4) (474)
Location: on the distribution panel on the power unit DIA-7335-134 (A-4) (477)
DIA-7335-136 (A-4) (495)
Function: prevents the customer accessories and the DIA-7335-139 (B-3) (495)
related wires from receiving too much current
Parts Breakdown: 04.3-7335-001 (10) (574)
Data: 15 A
Adjustment: N/A
Diagrams: DIA-7335-132 (A-4) (474)
DIA-7335-134 (A-4) (477)
DIA-7335-136 (A-4) (495)
DIA-7335-139 (B-3) (495)
Parts Breakdown: 04.3-7335-001 (10) (574)
FU2
Control Circuit Fuse
Location: on the distribution panel on the power unit
Function: prevents the control circuit from receiving
too much current
Data: 15 A
Adjustment: N/A
Diagrams: DIA-7335-132 (A-4) (474)
DIA-7335-134 (A-4) (477)
DIA-7335-136 (A-4) (495)
DIA-7335-139 (B-3) (495)
M1.91-7335-058 Crown 2017 PF27668
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COMPONENTRY
FU3
FU1 FU2 FU3
FS
Fig. 12 (31539)
Crown 2017 PF27668 M1.91-7335-059
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COMPONENTRY
FU4
FU4 FU7
Manual Brake Fuse Customer Accessories Fuse
Location: on the distribution panel on the power unit Location: on the distribution panel on the power unit
Function: prevents DTS1 and the related wires from Function: prevents the customer accessories and the
receiving too much current related wires from receiving too much current
Data: 15 A Data: 15 A
Adjustment: N/A Adjustment: N/A
Diagrams: DIA-7335-132 (A-4) (474) Diagrams: DIA-7335-132 (A-1) (474)
DIA-7335-134 (A-4) (477) DIA-7335-134 (A-1) (477)
DIA-7335-136 (A-4) (495) DIA-7335-136 (A-1) (495)
DIA-7335-139 (B-3) (495) DIA-7335-139 (B-3) (495)
Parts Breakdown: 04.3-7335-001 (10) (574) Parts Breakdown: 04.3-7335-001 (10) (574)
FU5 FU8
Outer Brake Coil Fuse Spotlights and Operator Fan Fuse
Location: on the distribution panel on the power unit Location: on the distribution panel on the power unit
Function: prevents the BRK outer coil and the related Function: prevents these components from receiving
wires from receiving too much current too much current:
Data: 15 A – FAN1
– LGT4
Adjustment: N/A
– LGT7
Diagrams: DIA-7335-132 (A-3) (474)
– The wires related to these components.
DIA-7335-134 (A-3) (477)
DIA-7335-136 (B-3) (495) Data: 15 A
DIA-7335-139 (B-2) (495)
Adjustment: N/A
Parts Breakdown: 04.3-7335-001 (10) (574)
Diagrams: DIA-7335-132 (A-1) (474)
DIA-7335-134 (A-1) (477)
FU6 DIA-7335-136 (A-1) (477)
DIA-7335-139 (B-3) (477)
Inner Brake Coil Fuse
Parts Breakdown: 04.3-7335-001 (10) (574)
Location: the distribution panel on the power unit
Function: prevents the BRK inner coil and the related
wires from receiving too much current
Data: 15 A
Adjustment: N/A
Diagrams: DIA-7335-132 (A-3) (474)
DIA-7335-134 (A-3) (477)
DIA-7335-136 (B-3) (495)
DIA-7335-139 (B-2) (495)
Parts Breakdown: 04.3-7335-001 (10) (574)
M1.91-7335-060 Crown 2017 PF27668
100
COMPONENTRY
FU8
FU8
FU4 FU5 FU6 FU7
Fig. 13 (31540)
Crown 2017 PF27668 M1.91-7335-061
101
COMPONENTRY
FU9
FU9 Adjustment: N/A
Diagrams: DIA-7335-149 (B-1) (474)
Power Supply Fuse
Parts Breakdown: 04.3-7334-250 (3) (576)
Location: on the distribution panel on the power unit
Function: prevents these components from receiving
FU12
too much current:
Freezer Condition Platform Fuse (Optional)
– LGT2
– LGT3 Location: on the freezer condition distribution panel
– LGT5 Function: prevents the freezer condition components
– LGT6 on the platform and the related wires from receiving too
much current
– The wires related to these components.
Data: 15 A
Data: 15 A
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-7335-149 (B-1) (486)
Diagrams: DIA-7335-132 (A-1) (474)
DIA-7335-134 (A-1) (477) Parts Breakdown: 04.3-7334-250 (3) (576)
DIA-7335-136 (A-1) (477)
DIA-7335-139 (B-3) (477) FU13
Parts Breakdown: 04.3-7335-001 (10) (574)
Pump Motor M3 Fuse
FU10 Location: on the contactor panel
Function: prevents M3 and the related wires from
Access 5 Fuse
receiving too much current
Location: on the contactor panel
Data: 300 A
Function: prevents Access 5 and the related wires
Adjustment: N/A
from receiving too much current
Diagrams: DIA-7335-132 (B-2) (474)
Data: 50 A
DIA-7335-134 (B-2) (481)
Adjustment: N/A DIA-7335-136 (B-1) (489)
DIA-7335-152 (B-1) (489)
Diagrams: DIA-7335-132 (A-3) (474)
DIA-7335-134 (A-3) (477) Parts Breakdown: 04.3-7335-102 (24) (580)
DIA-7335-136 (A-3) (477) 04.3-7335-160 (56) (580)
DIA-7335-145 (C-2) (477)
DIA-7335-152 (B-1) (477)
Parts Breakdown: 04.3-7335-160 (68) (580)
04.3-7335-200 (17) (580)
FU11
Freezer Condition Power Unit Fuse (Optional)
Location: on the freezer condition distribution panel
Function: prevents the freezer condition components
on the power unit and the related wires from receiving
too much current
Data: 15 A
M1.91-7335-062 Crown 2017 PF27668
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COMPONENTRY
FU13
FU10 FU13
FU9
(a) On the controller panel below Access 6
(a)
FU11
FU12
Fig. 14 (31541)
Crown 2017 PF27668 M1.91-7335-063
103
COMPONENTRY
FU14
FU14 FU17
Pump Motor M4 Fuse Electric Pallet Grab Fuse (Optional)
Location: on the contactor panel Location: above the distribution panel on the power
unit
Function: prevents M4 and the related wires from
receiving too much current Function: prevents M5 and PGS1 from receiving too
much current
Data: 300 A
Data: 4 A
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-7335-132 (B-1) (474)
DIA-7335-134 (B-1) (481) Diagrams: DIA-7335-134 (B-1) (487)
DIA-7335-152 (B-1) (489) DIA-7335-150 (B-1) (488)
Parts Breakdown: 04.3-7335-102 (24) (580) Parts Breakdown: 04.3-7335-001 (20) (553)
FU15
Access 3™ Fuse
Location: on the contactor panel
Function: prevents Access 3™ and the related wires
from receiving too much current
Data: 400 A
Adjustment: N/A
Diagrams: DIA-7335-132 (B-2) (474)
DIA-7335-134 (B-2) (489)
DIA-7335-136 (B-2) (489)
DIA-7335-152 (B-1) (489)
Parts Breakdown: 04.3-7335-102 (22) (580)
FU16
Electric Pallet Grab Fuse (Optional)
Location: above the distribution panel on the power
unit
Function: prevents M5 and PGS1 from receiving too
much current
Data: 4 A
Adjustment: N/A
Diagrams: DIA-7335-134 (B-1) (474)
DIA-7335-150 (C-1) (489)
Parts Breakdown: 04.3-7335-001 (20) (553)
M1.91-7335-064 Crown 2017 PF27668
104
COMPONENTRY
FU17
FU16 FU15 FU14
FU17
Fig. 15 (31542)
Crown 2017 PF27668 M1.91-7335-065
105
COMPONENTRY
GS1
GS1 Diagrams: DIA-7335-131 (B-2) (475)
DIA-7335-133 (B-2) (479)
DIA-7335-135 (B-2) (479)
Steering Wheel Wire Guidance Sensor
DIA-7335-142 (B-4, C-4) (479)
Location: on the front inner part of the power unit skirt
Parts Breakdown: 09.0-7334-150 (4) (705)
Function: senses the floor signal for the guide wire 09.0-7334-154 (77) (709)
Data: There are four sensor coils in GS1. GS1 receives
5 V and B-NEG from Access 6. See the GS1 input in
GTS5 and GTS6
the A2.5.1 GS1 menu.
Rear Gate Switches (SAA Lift Trucks)
Adjustment: see the ELECTRICAL SYSTEM /
Access 1 2 3® Menus / CALIBRATION Menus / C5 Location: on the rear platform posts
WIRE GUIDANCE section Function: prevents the raise function, the lower
Diagrams: DIA-7335-132 (A-4) (474) function, and travel when the gates are up
DIA-7335-134 (A-4) (485) Data: GTS5 and GTS6 are connected normally open,
DIA-7335-148 (A-2) (485) held closed when the gates are down. GTS5 and GTS6
Parts Breakdown: 04.3-7335-500 (1) (572) supply a B-NEG input signal to Access 4
Adjustment: N/A
GS2
Diagrams: DIA-7335-131 (B-2) (475)
DIA-7335-133 (B-2) (479)
Load Wheel Wire Guidance Sensor
Parts Breakdown: 09.1-7330-177 (30) (723)
Location: on the bottom of the mainframe
Function: senses the floor signal for the guide wire
Data: There are four sensor coils in GS2. GS2 receives
5 V and B-NEG from Access 6. See the GS2 input in
the A2.5.2 GS2 menu.
Adjustment: see the ELECTRICAL SYSTEM /
Access 1 2 3® Menus / CALIBRATION Menus / C5
WIRE GUIDANCE section
Diagrams: DIA-7335-132 (A-3) (474)
DIA-7335-134 (A-3) (485)
DIA-7335-148 (A-3) (485)
Parts Breakdown: 04.3-7335-500 (10) (572)
GTS1 and GTS2
Side Gate Switches
Location: on the platform console
Function: prevents the raise function, the lower
function, and travel when the gates are up
Data: GTS1 and GTS2 are connected normally open,
held closed when the gates are down. GTS1 and GTS2
supply a B-NEG input signal to Access 4. See the
GTS1 and GTS2 input in the A2.3.9 GTS1/GTS2
menus.
Adjustment: N/A
M1.91-7335-066 Crown 2017 PF27668
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COMPONENTRY
GTS5 and GTS6
(b)
GTS6
GTS5
GTS1
GTS2
(a)
(a) GTS1 is shown
(b) GTS5 is shown. Rear gates are
only available on Australian lift
trucks
GS2 GS1
Fig. 16 (31543)
Crown 2017 PF27668 M1.91-7335-067
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COMPONENTRY
GUS
GUS Data: receives +BV from HNS (K1) and B-NEG from
the negative bus bar
Guidance Switch (Optional) Adjustment: N/A
Location: on the control module Diagrams: DIA-7335-131 (B-1) (475)
DIA-7335-133 (B-1) (479)
Function: lets you select manual steering or automatic
DIA-7335-135 (B-1) (479)
steering
DIA-7335-142 (C-4) (479)
Data: GUS1 is connected normally open. GUS1
Parts Breakdown: 09.0-7335-050 (10) (557)
supplies a B-NEG input signal to Access 1. See the
09.0-7335-102 (18) (557)
GUS1 input in the A2.1.2 GUS1 menu.
Adjustment: N/A HN2
Diagrams: DIA-7335-131 (B-2) (475)
DIA-7335-133 (B-2) (479) Horn
DIA-7335-142 (B-3) (479) Location: on the power unit
Parts Breakdown: 04.6-7335-007 (41) (581) Function: audible alert to pedestrians of the lift truck
movement (travel alarm)
HGTRS
Data: receives +BV from K15 and B-NEG from the
negative bus bar
Height Reset Switch
Adjustment: N/A
Location: on the mast side of the platform, near the
bottom Diagrams: DIA-7335-132 (B-3) (475)
DIA-7335-134 (B-3) (479)
Function: resets ECR4 and ECR6 at approximately
DIA-7335-149 (B-2) (479)
300 mm (15 in)
DIA-7335-150 (B-2) (479)
Data: HGTRS is connected normally open, held
Parts Breakdown: 04.0-7335-013 (13) (557)
closed. HGTRS supplies a negative input signal to
Access 4. See the HGTRS input in the A2.3.10 HGTRS
menu.
Adjustment: loosen the switch mounting screws and
adjust so the switch actuates when the roller contacts
the actuating bar and resets when the roller loses
contact.
Diagrams: DIA-7335-131 (B-2) (475)
DIA-7335-133 (B-2) (479)
DIA-7335-135 (B-2) (479)
DIA-7335-142 (C-1) (479)
Parts Breakdown: 09.0-7335-050 (15) (557)
09.0-7335-102 (13) (557)
HN1
Horn
Location: on the mast side of the platform, near the
bottom
Function: operator-controlled, audible warning to tell
others of the lift truck location
M1.91-7335-068 Crown 2017 PF27668
108
COMPONENTRY
HN2
H
HN1
HGTRS
GUS
HN2
Fig. 17 (31544)
Crown 2017 PF27668 M1.91-7335-069
109
COMPONENTRY
HNS
HNS Technical Support Representative at 419-629-6300,
options 5 for assistance.
Horn Switch Diagrams: DIA-7335-131 (A-4) (475)
DIA-7335-133 (A-4) (475)
Location: on the control module
DIA-7335-140 (C-1) (475)
Function: lets you operate HN1 DIA-7335-141 (C-1) (475)
DIA-7335-151 (C-1) (475)
Data: HNS is connected normally open. When you
push HNS, it closes. HNS supplies +BV to HN1 from Parts Breakdown: 10.0-7335-003 (1) (732)
K1.
Adjustment: N/A
InfoLink® Control Module
Diagrams: DIA-7335-131 (B-1) (475)
(HD1000) (Optional)
DIA-7335-133 (B-1) (479) Location: on the platform, near Access 4
DIA-7335-135 (B-1) (479)
DIA-7335-142 (B-2) (479) Function: monitors the lift truck functions and impacts
Parts Breakdown: 04.6-7335-050 (11) (575) Data: N/A
Adjustment: The InfoLink® control module must be
InfoLink® Control Module associated to the lift truck and configured with specific
(HD2500) (Optional) customer settings. Contact a Crown InfoLink®
Technical Support Representative at 419-629-6300,
Location: on the work assist accessory tube on the options 5 for assistance.
platform Diagrams: DIA-7335-131 (A-4) (475)
Function: monitors the lift truck functions and impacts DIA-7335-133 (A-4) (475)
DIA-7335-140 (C-1) (475)
Data: N/A DIA-7335-141 (C-1) (475)
Adjustment: The InfoLink® control module must be DIA-7335-151 (C-1) (475)
associated to the lift truck and configured with specific Parts Breakdown: 10.0-7335-003 (14) (732)
customer settings. Contact a Crown InfoLink®
Technical Support Representative at 419-629-6300,
options 5 for assistance.
K1
Diagrams: DIA-7335-131 (A-4) (475) Power Up Relay
DIA-7335-133 (A-4) (475)
DIA-7335-140 (C-1) (475) Location: on the distribution panel on the platform
DIA-7335-141 (C-1) (475) Function: supplies +BV to the platform control circuit,
DIA-7335-151 (C-1) (475) the K2 coil, and the ED1 coil
Parts Breakdown: 10.0-7335-003 (1) (732) Data: K1 is a 24 VDC coil and energizes when the key
switch is in the start position
InfoLink® Control Module Adjustment: N/A
(HD2000) (Optional) Diagrams - Coil: DIA-7335-131 (B-3) (475)
Location: on the work assist accessory tube on the DIA-7335-133 (B-3) (476)
platform DIA-7335-135 (B-3) (476)
DIA-7335-137 (B-2) (476)
Function: monitors the lift truck functions and impacts DIA-7335-138 (B-2) (476)
Data: N/A Diagrams - Contacts: DIA-7335-131 (B-3) (475)
Adjustment: The InfoLink® control module must be DIA-7335-133 (B-3) (476)
associated to the lift truck and configured with specific DIA-7335-135 (B-4) (476)
customer settings. Contact a Crown InfoLink® Parts Breakdown: 04.3-7335-050 (4) (578)
M1.91-7335-070 Crown 2017 PF27668
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COMPONENTRY
K1
(a) InfoLink® module (HD2500) (the work
assist tube is not shown)
(b) InfoLink® control module (HD1000)
(c) InfoLink® control module (HD2000)
K1
(c) (a)
(b)
Fig. 18 (31545)
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COMPONENTRY
K2
K2 K15
Module Power Travel Alarm Relay (Optional)
Location: on the distribution panel on the power unit Location: on the platform side of the power unit, near
the bottom
Function: supplies +BV to the power unit control
circuit Function: supplies +BV to HN
Data: K2 is a 24 VDC coil that is energized by K1 Data: K15 is a 24 VDC coil that receives 24 V and
negative from Access 4. See the Access 4 output to
Adjustment: N/A
the K15 coil in the A3.3.1 ALM2 menu.
Diagrams - Coil: DIA-7335-132 (C-3) (474) Note: the A3.3.1 ALM2 menu shows ALM2, not K15.
DIA-7335-134 (C-3) (477) Although ALM2 is shown, Access 4 energizes the K15
DIA-7335-136 (C-3) (476) coil. The K15 tips close and energize ALM2.
DIA-7335-139 (B-2) (476)
Adjustment: N/A
Diagrams - Contacts: DIA-7335-132 (A-4) (474)
DIA-7335-134 (A-4) (477) Diagrams - Coil: DIA-7335-132 (B-1) (474)
DIA-7335-136 (A-4) (476) DIA-7335-134 (B-1) (486)
DIA-7335-139 (B-3) (476) DIA-7335-149 (A-1) (487)
DIA-7335-150 (A-1) (487)
Parts Breakdown: 04.3-7335-001 (9) (574)
Diagrams - Contacts: DIA-7335-132 (B-3) (474)
K11 DIA-7335-134 (B-3) (486)
DIA-7335-149 (B-2) (487)
DIA-7335-150 (B-2) (487)
Freezer Condition Relay (Optional)
Parts Breakdown: 04.0-7335-013 (9) (549)
Location: on the freezer condition distribution panel
Function: supplies power to the THS2 and THS3 KYS
circuits
Data: K11 is a 24 VDC coil. K11 energizes when THS2 Key Switch
closes and THS3 is in the temperature range Location: on the control module
Adjustment: N/A Function: lets you turn on the lift truck and turn off the
Diagrams - Coil: DIA-7335-149 (B-1) (486) lift truck
Diagrams - Contacts: DIA-7335-149 (B-1) (486) Data: KYS is a key operated selector switch. KYS
energizes K1 in the start position and keeps K1
Parts Breakdown: 04.3-7334-250 (2) (576) energized in the ON position. See the KYS input in the
A2.2.7 KEY SWITCH menu.
K12 Adjustment: N/A
Freezer Condition Relay (Optional) Diagrams: DIA-7335-131 (B-3) (475)
DIA-7335-133 (B-3) (479)
Location: on the freezer condition distribution panel DIA-7335-135 (B-4) (487)
Function: supplies power to the RES circuits DIA-7335-142 (C-2) (487)
Data: K12 is a 24 VDC coil. K12 energizes when THS2 Parts Breakdown: 04.6-7335-005 (22) (579)
closes and THS3 is in the temperature range
Adjustment: N/A
Diagrams - Coil: DIA-7335-149 (B-1) (486)
Diagrams - Contacts: DIA-7335-149 (B-1) (486)
Parts Breakdown: 04.3-7334-250 (4) (576)
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COMPONENTRY
KYS
(a)
K11
(a) On the controller panel
K12
below Access 6
KYS
K2
K15
Fig. 19 (31546)
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COMPONENTRY
LGS1
LGS1 LGT1
Dome Light Switch (Optional) LED Flashing Light
Location: on the switch panel Location: on the top of the power unit
Function: lets you turn on the dome light and turn off Function: supplies a visual warning of the lift truck
the dome light location
Data: LGS1 is a two-position, on-off, rocker switch. Data: 24 V
LGS1 supplies +BV to PS2.
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-7335-132 (B-2) (474)
Diagrams: DIA-7335-143 (B-2) (483) DIA-7335-134 (B-2) (482)
DIA-7335-136 (B-1) (487)
Parts Breakdown: 04.8-7335-102 (8) (295)
DIA-7335-147 (C-3) (487)
LGS2 Parts Breakdown: 04.9-7330-001 (1) (608)
04.9-7335-550 (0) (608)
Worklight Switch (Optional)
Location: on the switch panel
Function: lets you turn on the worklight and turn off the
worklight
Data: LGS2 is a two-position, on-off, rocker switch.
LGS2 supplies +BV to PS1.
Adjustment: N/A
Diagrams: DIA-7335-143 (B-2) (483)
Parts Breakdown: 04.8-7335-102 (9) (295)
LGS3
Spotlight Switch (Optional)
Location: on the switch panel
Function: lets you turn on the spotlight and turn off the
spotlight
Data: LGS3 is a two-position, on-off, rocker switch.
LGS3 supplies +BV to:
– LGT4
– LGT7
– LGT8
– LGT9
Adjustment: N/A
Diagrams: DIA-7335-143 (B-2) (483)
Parts Breakdown: 04.8-7335-102 (10) (295)
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COMPONENTRY
LGT1
LGT1
LGS3
LGS2
LGS1
Fig. 20 (31547)
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COMPONENTRY
LGT2 and LGT5
LGT2 and LGT5 Function: supplies the work area light outside the
operator compartment
Worklights (Optional) Data: LGS3 supplies 24 V to LGT8 and LGT9
Location: on the overhead console Adjustment: N/A
Function: supplies the work area light outside the Diagrams: DIA-7335-143 (C-2, C-3) (483)
operator compartment
Parts Breakdown: 04.9-7332-250 (1) (612)
Data: PS1 supplies 12 V to LGT2 and LGT5
Adjustment: N/A
LMS1
Diagrams: DIA-7335-143 (C-1, C-4) (483) Limit Switch (Lifting Forks)
Parts Breakdown: 04.9-7335-050 (2) (610) Location: auxiliary mast
04.9-7335-054 (71) (614)
Function: shut off the pump motor before the fork
LGT3 and LGT6 carriage reaches the top of the auxiliary mast
Data: connected in series with RAS3 and RAS4, wired
Dome Lights (Optional) normally closed, opens when the fork carriage reaches
the top of the auxiliary mast
Location: on the overhead console
Adjustment: adjust so the switch opens before the
Function: supplies the light inside the operator
rubber bumper contacts the mechanical stop
compartment
Diagrams: DIA-7335-131 (A-1) (483)
Data: PS2 supplies 12 V to LGT3 and LGT6
DIA-7335-133 (A-1) (483)
Adjustment: N/A DIA-7335-149 (B-3) (483)
Diagrams: DIA-7335-143 (B-2, B-4) (483) Parts Breakdown: 09.1-7534-001 (33) (610)
Parts Breakdown: 04.9-7335-050 (7) (610)
04.9-7335-054 (59) (614)
LGT4 and LGT7
Platform Spotlights (Optional)
Location: on the overhead console
Function: supplies the work area light outside the
operator compartment
Data: LGS3 supplies 24 V to LGT4 and LGT7
Adjustment: N/A
Diagrams: DIA-7335-143 (C-2, C-3) (483)
DIA-7335-144 (C-2, C-3) (484)
Parts Breakdown: 04.9-7335-052 (38) (612)
04.9-7335-056 (88) (616)
LGT8 and LGT9
Mast Spotlights (Optional)
Location: on the mast
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COMPONENTRY
LMS1
LGT6
LMS1
LGT4 (a) LGT7 is shown
LGT7
LGT5 (a)
LGT3
LGT8
LGT9
LGT2
Fig. 21 (31548)
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COMPONENTRY
LOS1 and LOS2
LOS1 and LOS2
Lowering Switches
Location: on the control module
Function: LOS1 allows the operator to lower the
platform slowly, LOS2 allows the operator to lower the
platform faster
Data: wired normally open and is closed by pressing
the lower button
Adjustment: N/A
Diagrams: DIA-7335-131 (A-2, A-2) (483)
DIA-7335-133 (A-2, A-2) (484)
DIA-7335-135 (A-2, A-2) (484)
DIA-7335-142 (B-2, B-2) (484)
Parts Breakdown: 04.6-7335-052 (68) (612)
LOS3 and LOS4
Lowering Switches (Lifting Forks)
Location: on the control panel lifting forks
Function: allows the operator to lower the forks
Data: LOS3 and LOS4 are connected in series, wired
normally open, and is closed by pressing the lower
button
Adjustment: N/A
Diagrams: DIA-7335-131 (A-1, A-1) (483)
DIA-7335-133 (A-1, A-1) (484)
Parts Breakdown: 09.3-7534-001 (22) (612)
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COMPONENTRY
LOS3 and LOS4
LOS4
LOS3
LOS1
LOS2
Fig. 22 (31549)
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COMPONENTRY
M1
M1 DIA-7335-136 (C-1) (489)
DIA-7335-147 (C-3) (489)
Traction Motor Parts Breakdown: 02.2-07.3-001 (0) (521)
02.2-7330-050 (0) (521)
Location: on the drive unit
Function: supplies the force for lift truck traction M4
Data: Access 3™ supplies the traction control by
operator input (POT1). Access 3™ supplies Lift Motor (Optional)
three-phase AC voltage. See the Access 3™ output to Location: in the front of the reservoir
M1 in the A3.2.6 M1 menu.
Function: supplies the force for P2, which supplies the
Adjustment: N/A hydraulic oil flow for the raise function
Diagrams: DIA-7335-132 (B-2) (474) Data: receives 24 V from P2 contactor and B-NEG
DIA-7335-134 (B-2) (480) from the negative bus bar
DIA-7335-136 (B-2) (482)
DIA-7335-145 (C-1) (489) Adjustment: N/A
Parts Breakdown: 03.1-7335-003 (545) Diagrams: DIA-7335-132 (B-1) (474)
03.1-7335-052 (547) DIA-7335-134 (B-1) (481)
DIA-7335-147 (C-4) (489)
M2 Parts Breakdown: 02.2-07.3-001 (0) (521)
02.2-7330-050 (0) (521)
Steer Motor
Location: on the steering gearbox
M5
Function: supplies the force for steering Electric Pallet Grab Motor (Optional)
Data: Access 5 supplies the steering control by ECR1 Location: below the platform floorboard
and ECR5. See the Access 5 output to M2 in the
A3.4.5 M2 DUTY CYCLE menu. Function: supplies the force for the electric pallet grab
Adjustment: N/A Data: 24 VDC
Diagrams: DIA-7335-132 (B-2) (474) Adjustment: N/A
DIA-7335-134 (B-2) (480) Diagrams: DIA-7335-150 (C-4) (487)
DIA-7335-136 (B-2) (489)
DIA-7335-146 (C-2) (489) Parts Breakdown: 09.0-7340-052 (60) (619)
Parts Breakdown: 06.2-7330-003 (0) (642)
M3
Lift Pump Motor
Location: in the front of the reservoir
Function: supplies the force for P1, which supplies the
hydraulic oil flow for the raise function
Data: receives 24 V from P1 contactor and B-NEG
from the negative bus bar
Adjustment: N/A
Diagrams: DIA-7335-132 (B-2) (474)
DIA-7335-134 (B-2) (481)
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COMPONENTRY
M5
M2 M1 M3 M4
M5
Fig. 23 (31550)
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COMPONENTRY
MVL
MVL
Manual Lowering Valve
Location: on the manifold
Function: lets you lower the platform without turning
on the lift truck
Data: N/A
Adjustment: N/A
Diagrams: HYD-7335-006 (495)
HYD-7335-007 (495)
HYD-7335-008 (495)
HYD-7335-009 (495)
Parts Breakdown: 02.4-7335-003 (11) (528)
02.4-7335-052 (9) (528)
02.4-7535-502 (24) (528)
02.4-7535-552 (24) (528)
ORS1
Override Switch (Optional)
Location: on the switch panel
Function: lets you override a height cutout. Lets you
override the End of Aisle control option
Data: N/A
Adjustment: N/A
Diagrams: DIA-7335-131 (B-2) (475)
DIA-7335-133 (B-2) (479)
DIA-7335-135 (B-3) (479)
DIA-7335-142 (B-3) (479)
Parts Breakdown: 04.8-7335-102 (12) (295)
09.3-7535-009 (108) (528)
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COMPONENTRY
ORS1
ORS1
ORS1
MVL
Fig. 24 (31551)
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COMPONENTRY
P1
P1 P2
Lift Pump Contactor
Location: in the front of the reservoir below M3 Location: on the contactor panel
Function: supplies the hydraulic oil flow for the raise Function: supplies control of electrical power to M4
function
Data: 24 V coil
Data: the displacement is 5.5 cc/rev (0.33 cir)
Diagrams: DIA-7335-132 (A-2, B-1) (489)
Diagrams: HYD-7335-006 (495) DIA-7335-134 (A-2, B-1) (489)
HYD-7335-007 (495) DIA-7335-147 (C-2) (489)
HYD-7335-008 (495) DIA-7335-152 (B-2) (489)
HYD-7335-009 (495)
Parts Breakdown: 04.3-7335-102 (28) (522)
Parts Breakdown: 02.1-07.3-002 (0) (522) 04.3-7335-158 (35) (522)
04.3-7535-102 (38) (528)
P1
PCL
Contactor
Pressure Compensator Valve
Location: on the contactor panel
Location: on the manifold
Function: supplies control of electrical power to M3
Function: compensates the pressure of the flow
Data: 24 V coil
control of the platform lowering functions
Diagrams - coil: DIA-7335-132 (B-2) (489)
Data: N/A
DIA-7335-134 (B-2) (489)
DIA-7335-136 (B-1, B-2) (489) Adjustment: N/A
DIA-7335-147 (C-2) (489)
Diagrams: HYD-7335-006 (495)
DIA-7335-152 (B-2) (489)
HYD-7335-007 (495)
Diagrams - contacts: DIA-7335-132 (B-2) (489) HYD-7335-008 (495)
DIA-7335-134 (B-2) (489) HYD-7335-009 (495)
DIA-7335-136 (B-1) (489)
Parts Breakdown: 02.4-7335-003 (2) (610)
DIA-7335-147 (C-2) (489)
02.4-7335-052 (2) (610)
DIA-7335-152 (B-2) (489)
02.4-7535-502 (7) (528)
Parts Breakdown: 04.3-7335-102 (28) (522) 02.4-7535-552 (7) (528)
04.3-7335-158 (35) (522)
04.3-7535-102 (38) (522) PCLF
P2 Pressure Compensator Valve (Lifting Forks)
Location: on the manifold
Lift Pump
Function: compensates the pressure of the flow
Location: in the front of the reservoir below M4
control of the platform lowering functions
Function: supplies the hydraulic oil flow for the raise
Data: N/A
function
Adjustment: N/A
Data: the displacement is 5.5 cc/rev (0.33 cir)
Diagrams: HYD-7335-008 (495)
Diagrams: HYD-7335-007 (495)
HYD-7335-009 (495)
HYD-7335-009 (495)
Parts Breakdown: 02.4-7535-502 (7) (528)
Parts Breakdown: 02.1-07.3-002 (0) (522)
02.4-7535-552 (7) (528)
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COMPONENTRY
PCLF
P1
P2
P2
P1
PCLF
PCL
Fig. 25 (31552)
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COMPONENTRY
PGS1
PGS1
Pallet Grab Switch (Optional)
Location: on the platform below the control module
Function: lets you operate the electric pallet grab
Data: PGS1 is a two-position, on-on, rocker switch
Diagrams: DIA-7335-150 (B-3) (487)
Parts Breakdown: 04.0-7340-100 (21) (555)
PGLS1 and PGLS2
Pallet Grab Limit Switches (Optional)
Location: below the platform floorboard
Function: when the arms for electric pallet grab close,
PGLS1 stops M5 to limit the distance that the arms
close. When the arms for electric pallet grab open,
PGLS2 stops M5 to limit the distance that the arms
open.
Data: wired normally closed
Diagrams: DIA-7335-150 (B-4) (487)
DIA-7335-150 (B-4) (488)
Parts Breakdown: 09.0-7340-050 (27) (617)
POT1
Traction Accelerator Potentiometer
Location: on the control module
Function: supplies the traction input to Access 4
Data: receives 5 V and negative from Access 4. The
maximum POT1 input signal to Access 4 is 4.6 V in the
power unit first (forward) direction, 2.6 V in the neutral
position, and 0.8 V in the forks first (reverse) direction.
See the POT1 input in the A2.3.3 POT1 menu.
Adjustment: see the ELECTRICAL SYSTEM / Control
Module / Adjustments / Traction Request
Potentiometer (POT1)
Diagrams: DIA-7335-131 (B-1) (475)
DIA-7335-133 (B-1) (479)
DIA-7335-135 (B-1) (479)
DIA-7335-142 (B-2) (479)
Parts Breakdown: 04.6-7335-007 (42) (581)
09.3-7534-017 (212) (581)
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COMPONENTRY
POT1
POT1
POT1
(a)
PGLS2
PGLS1
(a) PGLS2 is shown
PGS1
Fig. 26 (31553)
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COMPONENTRY
PS1
PS1 PVLF
Light Power Supply Proportional Lowering Valve
Location: on the overhead console Location: on the manifold
Function: supplies 12 V for the worklights Function: supplies proportional flow control of the fork
lowering functions
Data: 24 VDC input and 12 VDC output
Data: 24 VDC
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-7335-143 (C-1) (483)
Diagrams: DIA-7335-132 (A-1, B-1) (483)
Parts Breakdown: 04.9-7335-050 (16) (610)
DIA-7335-134 (A-1, B-1) (483)
DIA-7335-149 (A-1, B-1) (483)
PS2 HYD-7335-008 (495)
HYD-7335-009 (495)
Light Power Supply
Parts Breakdown: 02.4-7535-502 (27) (610)
Location: on the overhead console 02.4-7535-552 (27) (610)
Function: supplies 12 V for the dome lights
RAS1
Data: 24 VDC input and 12 VDC output
Adjustment: N/A Low Speed Raise Switch
Diagrams: DIA-7335-143 (C-1) (483) Location: on the control module
Parts Breakdown: 04.9-7335-050 (16) (610) Function: allows the operator to raise the platform
Data: wired normally open, is closed by pressing the
PVL raise button
Proportional Lowering Valve Adjustment: N/A
Location: on the manifold Diagrams: DIA-7335-131 (A-2) (483)
DIA-7335-133 (A-2) (483)
Function: supplies proportional flow control of the DIA-7335-135 (A-2) (483)
platform lowering functions DIA-7335-142 (B-2) (483)
Data: 24 VDC Parts Breakdown: 04.6-7335-052 (68) (614)
Adjustment: N/A 09.3-7534-013 (158) (614)
Diagrams: DIA-7335-132 (B-3) (483) RAS2
DIA-7335-134 (B-3) (483)
DIA-7335-136 (B-3) (483)
High Speed Raise Switch
DIA-7335-147 (C-1) (483)
HYD-7335-006 (495) Location: on the control module
HYD-7335-007 (495)
Function: allows the operator to raise the platform
HYD-7335-008 (495)
HYD-7335-009 (495) Data: wired normally open, is closed by pressing the
raise button
Parts Breakdown: 02.4-7335-003 (16) (610)
02.4-7335-052 (12) (610) Adjustment: N/A
02.4-7535-502 (27) (610)
Diagrams: DIA-7335-131 (A-2) (483)
02.4-7535-552 (27) (610)
DIA-7335-133 (A-2) (483)
DIA-7335-142 (B-2) (483)
Parts Breakdown: 04.6-7335-052 (68) (614)
09.3-7534-013 (158) (614)
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COMPONENTRY
RAS2
PS2
PS1
PVLF PVL
RAS1
RAS2
Fig. 27 (31554)
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COMPONENTRY
RAS3 and RAS4
RAS3 and RAS4 RES5 and RES6
Raise Switches Lifting Forks (Optional) Freezer Condition Heaters (Optional)
Location: on the control panel lifting forks Location: on the aisle guide wheels
Function: allows the operator to raise the forks Function: RES5 applies heat to RGSR. RES6 applies
heat to RGSL.
Data: RAS3 and RAS4 are connected in series, wired
normally open, and is closed by pressing the raise Data: 50 W, 15 Ω
buttons
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-7335-149 (C-1) (486)
Diagrams: DIA-7335-131 (A-1, A-1) (483)
Parts Breakdown: 10.0-7334-001 (28) (738)
DIA-7335-133 (A-1, A-1) (483)
Parts Breakdown: 09.3-7534-001 (22) (614)
RES1
Fan Resistor (Optional)
Location: on the overhead console
Function: reduces voltage applied to FAN1
Data: 25 W, 10 Ω
Adjustment: N/A
Diagrams: DIA-7335-143 (B-4) (483)
Parts Breakdown: 04.9-7335-054 (77) (614)
RES2 and RES3
Brake Resistors
Location: on the back of the distribution panel
mounting plate on the power unit
Function: decreases the current to the BRK inner coil
and the BRK outer coil. This prevents them from
receiving too much heat after a momentary BRK
release when you use DTS1.
Note: during typical operation, RES2 and RES3 are
not necessary because Access 5 controls the current
that is applied to BRK.
Data: RES2 5 Ω, 50 W, RES3 8 Ω, 50 W
Adjustment: N/A
Diagrams: DIA-7335-132 (B-3, A-3) (474)
DIA-7335-134 (B-3, A-3) (477)
DIA-7335-136 (B-3) (477)
DIA-7335-139 (B-4, B-3) (477)
Parts Breakdown: 04.3-7335-001 (4) (574)
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COMPONENTRY
RES5 and RES6
RAS3 RAS4
RES1
RES3
RES2
(a) RES6 is shown
RES5
RES6
(a)
Fig. 28 (31555)
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COMPONENTRY
RES7 and RES8
RES7 and RES8 Diagrams: DIA-7335-149 (C-4) (486)
Parts Breakdown: 04.6-7335-052 (73) (575)
Freezer Condition Heaters (Optional)
Location: on BRES1 and BRES2
RES14
Function: RES7 applies heat to BRES1. RES8 applies Freezer Condition Heater
heat to BRES2.
Location: on the control module
Data: 50 W, 15 Ω
Function: applies heat to RAS and LOS
Adjustment: N/A
Data: 25 W, 30 Ω
Diagrams: DIA-7335-149 (C-1) (486)
Adjustment: N/A
Parts Breakdown: 01.2-7335-003 (43) (473)
Diagrams: DIA-7335-149 (C-4) (486)
RES9 and RES10 Parts Breakdown: 04.6-7335-052 (51) (575)
Freezer Condition Heaters (Optional)
Location: on the mainframe
Function: RES9 applies heat to CHS3 and RES10
applies heat to CHS4
Data: 50 W, 15 Ω
Adjustment: N/A
Diagrams: DIA-7335-149 (C-2) (486)
Parts Breakdown: 07.6-7334-001 (22) (667)
07.6-7334-050 (4) (671)
RES11 and RES12
Freezer Condition Heaters (Optional)
Location: on the platform side gates
Function: RES11 applies heat to GTS1. RES12
applies heat to GTS2.
Data: 50 W, 15 Ω
Adjustment: N/A
Diagrams: DIA-7335-149 (C-4) (486)
Parts Breakdown: 09.0-7334-150 (8) (705)
RES13
Freezer Condition Heater
Location: on the control module
Function: applies heat to EDS
Data: 10 W, 70 Ω
Adjustment: N/A
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COMPONENTRY
RES14
RES13
(d)
RES14
(c)
(a) RES8 is shown RES11
(b) RES9 is shown RES12
(c) RES12 is shown
(d) Behind LOS and RAS
(b)
RES10
RES9
(a)
RES8
RES7
Fig. 29 (31556)
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COMPONENTRY
RES15
RES15 RES19 and RES20
Freezer Condition Heater (Optional) Freezer Condition Heater (Optional)
Location: on the control module Location: on the bottom of the platform (lift trucks with
a TT mast)
Function: applies heat to HNS
Function: RES19 applies heat to CHS1. RES20
Data: 10 W, 70 Ω
applies heat to CHS2.
Adjustment: N/A
Data: 50 W, 15 Ω
Diagrams: DIA-7335-149 (C-4) (486)
Adjustment: N/A
Parts Breakdown: 04.6-7335-050 (21) (575)
Diagrams: DIA-7335-149 (C-2, C-3) (486)
RES16 Parts Breakdown: 07.6-7334-052 (43) (673)
Freezer Condition Heater (Optional)
Location: on the control module
Function: applies heat to FS
Data: 10 W, 70 Ω
Adjustment: N/A
Diagrams: DIA-7335-149 (C-3) (486)
Parts Breakdown: 04.6-7335-050 (21) (575)
RES17
Freezer Condition Heater (Optional)
Location: on the control module
Function: applies heat to RS
Data: 10 W, 70 Ω
Adjustment: N/A
Diagrams: DIA-7335-149 (C-3) (486)
Parts Breakdown: 04.6-7335-050 (21) (575)
RES18
Freezer Condition Heater (Optional)
Location: below the platform floorboard
Function: applies heat to BRS
Data: 25 W, 30 Ω
Adjustment: N/A
Diagrams: DIA-7335-149 (C-3) (486)
Parts Breakdown: 05.1-7335-001 (20) (615)
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COMPONENTRY
RES19 and RES20
RES15
RES17 RES16
(a) RES20 is shown
RES18
RES19
RES20
(a)
Fig. 30 (31557)
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COMPONENTRY
RES21 and RES22
RES21 and RES22 Function: RES40 applies heat to PGLS2 and RES41
applies heat to PGLS1
Freezer Condition Heater (Optional) (SAA Lift Data: 50 W, 15 Ω
Trucks)
Adjustment: N/A
Location: on the rear platform posts
Diagrams: DIA-7335-149 (B-3) (486)
Function: RES21 applies heat to GTS5. RES22
Parts Breakdown: 09.0-7340-050 (31) (557)
applies heat to GTS6.
Data: 10 W, 120 Ω RGSL and RGSR
Adjustment: N/A
Rail Guide Switches (Optional)
Diagrams: DIA-7335-149 (C-3) (486)
Location: on the aisle guide wheels
Parts Breakdown: 09.0-7534-250 (13) (723)
Function: turn on the automatic steering and turn off
RES25 the automatic steering
Data: RGSL and RGSR are connected normally
Freezer Condition Heater (Optional) closed, held open. RGSL and RGSR supply a B-NEG
input signal to Access 5. See the RGSL and RGSR
Location: part of the HGTRS assembly
input in the A2.4.8 RGSR/RGSL menu.
Function: applies heat to HGTRS
Adjustment: N/A
Data: 24 V, 10 W
Diagrams: DIA-7335-132 (B-3) (474)
Adjustment: N/A DIA-7335-134 (B-3) (481)
DIA-7335-146 (B-2, C-2) (481)
Diagrams: DIA-7335-149 (C-3) (486)
Parts Breakdown: 10.0-7334-001 (11) (738)
Parts Breakdown: 09.0-7335-050 (15) (557)
09.0-7335-102 (13) (557)
RS
RES33, RES34, RES35, and
Reverse Switch
RES36 (not shown) Location: on the control module
Freezer Condition Heater (Optional) (Lifting Forks) Function: supplies the input signal for reverse travel to
Access 4
Location: on the lifting forks console
Data: RS is connected normally open. When the twist
Function: RES33 applies heat to LOS3, RES34 grip is in the forks first (reverse) direction, RS closes.
applies heat to RAS3, RES35 applies heat to LOS4, RS supplies a +BV input to Access 4. See the RS input
and RES36 applies heat to RAS4 in the A2.3.6 RS menu.
Data: 10 W, 120 Ω Adjustment: see the ELECTRICAL / Control Module /
Adjustment: N/A Adjustments / Directional Switches (FS and RS)
Diagrams: DIA-7335-149 (B-4) (486) Diagrams: DIA-7335-131 (A-2) (475)
DIA-7335-133 (A-2) (479)
Parts Breakdown: 09.3-7534-001 (19) (557) DIA-7335-135 (A-2) (479)
DIA-7335-142 (B-2) (479)
RES40 and RES41 (not shown)
Parts Breakdown: 04.6-7335-007 (60) (583)
09.3-7534-017 (221) (583)
Freezer Condition Heater (Optional)
Location: on the electric pallet clamp under the
platform
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COMPONENTRY
RS
(a) RES25 is part of the
HGTRS assembly
(b) RGS2 is shown
(c) RES21 is shown
(a)
RES25
RS
RGS1
RGS2
(b)
(c)
RES22
RES21
Fig. 31 (31558)
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COMPONENTRY
RV1
RV1 SB30
Relief Valve FAN1 Suppressor Block
Location: on the manifold Location: on the overhead console
Function: limits the operation pressure for the lift Function: prevents excessive voltage
circuit
Data: N/A
Data: set to 192-194 bar (2,785-2,810 psi)
Adjustment: N/A
Adjustment: see the HYDRAULIC SYSTEM /
Diagrams: DIA-7335-143 (C-4) (483)
Manifold section
Parts Breakdown: 04.9-7335-054 (63) (614)
Diagrams: HYD-7335-006 (3) (495)
HYD-7335-007 (3) (495)
HYD-7335-008 (3) (495) Impact Sensor
HYD-7335-009 (3) (495)
InfoLink® Impact Sensor (Optional)
Parts Breakdown: 02.4-7335-003 (15) (522)
02.4-7335-052 (11) (610) Location: on the power unit skirt below Access 6
02.4-7535-502 (21) (610) Function: supplies the lift truck impact input to the
02.4-7534-552 (21) (610) InfoLink® module
RV2 Data: receives 5 V from the power supply in the
InfoLink® module
Relief Valve Diagrams: DIA-7335-132 (A-1, B-1) (474)
DIA-7335-134 (A-1, B-1) (488)
Location: on the manifold
Parts Breakdown: 10.0-7335-003 (6) (732)
Function: limits the operation pressure for the lifting
fork circuit
SVL
Data: set to 145–147 bar (2,100–2,125 psi)
Adjustment: see the HYDRAULIC SYSTEM / Solenoid Valve Lower
Manifold section Location: on the manifold
Diagrams: HYD-7335-008 (10) (495) Function: supplies the hydraulic oil flow path for the
HYD-7335-009 (10) (495) lower function
Parts Breakdown: 02.4-7535-502 (21) (610) Data: the 24 VDC coil receives +BV from K2 and
02.4-7534-552 (21) (610) negative from Access 3™. See the Access 3™ output
to SVL in the A3.2.1 SVL menu.
Adjustment: N/A
SB1
Diagrams: DIA-7335-132 (B-2) (474)
DIA-7335-134 (B-2) (482)
M5 Suppressor Block
DIA-7335-136 (B-2) (482)
Location: below the platform floorboard DIA-7335-147 (C-1) (482)
HYD-7335-006 (495)
Function: prevents excessive voltage
HYD-7335-007 (495)
Data: N/A HYD-7335-008 (495)
HYD-7335-009 (495)
Adjustment: N/A
Parts Breakdown: 02.4-7335-003 (14) (522)
Diagrams: DIA-7335-150 (C-4) (487)
02.4-7335-052 (10) (522)
Parts Breakdown: part of the electric pallet-grab 02.4-7535-502 (22) (522)
harness (P/N 145166) 02.4-7535-552 (22) (522)
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COMPONENTRY
SVL
(a) SB1 is part of the electric pallet grab
harness (P/N 145166) (a)
SB1
(b) Impact sensor
SB30
(b)
SVL
RV2 RV1
Fig. 32 (31559)
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COMPONENTRY
SV1
SV1 Adjustment: Height adjustment - see ELECTRICAL /
Wire Guidance / Sensors section. Calibration - see
Electrical System / Access 123 / Calibration Menus /
Solenoid Valve Lifting Forks
C5 Wire Guidance / C5.1.2 Sensor Coil
Location: on the manifold
Diagrams: DIA-7335-132 (A-4) (483)
Function: supplies the hydraulic oil flow path for the DIA-7335-134 (A-4) (483)
lifting forks function DIA-7335-148 (A-2) (483)
Data: the 24 VDC coil receives +BV and negative from Parts Breakdown: 04.3-7335-500 (1) (610)
Access 4. See Access 4 output to SV1 in the A3.3.3
SV1 menu. TB502
Adjustment: N/A
Terminal Block
Diagrams: DIA-7335-132 (A-1, B-1) (474)
DIA-7335-134 (A-1, B-1) (482) Location: on the left side of the overhead console
DIA-7335-149 (A-1, B-1) (482) Function: keeps the LGT3 and LGT4 wires secure
DIA-7335-151 (A-1) (482)
HYD-7335-008 (495) Data: 5 terminals
HYD-7335-009 (495) Adjustment: N/A
Parts Breakdown: 02.4-7535-502 (23) (522) Diagrams: DIA-7335-143 (B-2) (483)
02.4-7535-552 (23) (522)
Parts Breakdown: 04.9-7335-050 (14) (610)
SENSOR BAR LOAD WHEEL
THS2
Wire Guidance (Optional)
Power Unit Thermostat (Optional)
Location: base of the mainframe
Location: on the power unit wall, between the power
Function: to sense the signal strength from the guide unit and the mast
wire in the floor
Function: turns on the power unit heaters
Data: see the Electrical and Wire Guide System sec-
tion Data: THS2 is connected normally closed. The contact
closes at 49 °C (120 °F) and opens at 68 °C (140 °F).
Adjustment: Height adjustment - see ELECTRICAL /
Wire Guidance / Sensors section. Calibration - see Adjustment: N/A
Electrical System / Access 123 / Calibration Menus / Diagrams: DIA-7335-149 (C-1) (486)
C5 Wire Guidance / C5.1.2 Sensor Coil
Parts Breakdown: 01.2-7335-003 (41) (475)
Diagrams: DIA-7335-132 (A-3) (483)
DIA-7335-134 (A-3) (483)
DIA-7335-148 (A-3) (483)
Parts Breakdown: 04.3-7335-500 (10) (610)
SENSOR BAR STEER WHEEL
Wire Guidance (Optional)
Location: front and center of the power unit below the
skirt
Function: to sense the signal strength from the guide
wire in the floor
Data: see the Electrical and Wire Guide System
section
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COMPONENTRY
THS2
TB502
SV1
(a) Sensor bar load wheel
(b) Sensor bar steer wheel
THS2
(b)
(a)
Fig. 33 (31560)
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COMPONENTRY
THS3
THS3
Platform Thermostat (Optional)
Location: below the platform floorboard by BRS1
Function: turns on the platform heaters
Data: THS3 is connected normally closed. The contact
closes at 49 °C (120 °F) and opens at 60 °C (140 °F).
Adjustment: N/A
Diagrams: DIA-7335-149 (B-2) (486)
Parts Breakdown: 05.1-7335-001 (23) (475)
TS1
M1 Temperature Sensor
Location: internal to M1
Function: supplies M1 temperature data
Data: TS1 is a temperature sensitive switch, TS1
supplies a B-NEG input signal to Access 3™. See the
M1 output in the A3.2.6.2 Temperature menu
Adjustment: N/A
Diagrams: DIA-7335-132 (B-2) (486)
DIA-7335-134 (B-2) (486)
DIA-7335-136 (C-2) (486)
DIA-7335-146 (C-3) (486)
Parts Breakdown: 03.1-7335-003 (0) (475)
03.1-7335-052 (0) (475)
ZSS
Zone Select Switch
Location: on the switch panel
Function: lets you select the lift height cutouts
Data: ZSS is a three-position switch. ZSS supplies a
B-NEG input signal to Access 4. See Access 4 inputs,
A2.3.14 (ZSS A), A2.3.15 (ZSS B), and A2.3.16
(ZSS C) Analyzer menus
Adjustment: N/A
Diagrams: DIA-7335-131 (B-2) (486)
DIA-7335-133 (B-2) (486)
DIA-7335-142 (B-3) (486)
Parts Breakdown: 04.8-7335-102 (11) (475)
M1.91-7335-102 Crown 2017 PF27668
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COMPONENTRY
ZSS
ZSS
THS3
TS1
Fig. 34 (31581)
Crown 2017 PF27668 M1.91-7335-103
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Notes:
144
HYDRAULIC
Hydraulic System
Hydraulic System schematics. Refer to Componentry for pump and valve
information. Refer to Manifold section for RV1 pressure
Pumps, P1 & P2, supply oil flow for the lift function. settings procedures.
Maximum pressure is limited by an adjustable relief Figure 18196-01 shows hydraulic component location
valve, RV1. The setting for RV1 is noted on hydraulic in power unit.
One Speed Lift Two Speed Lift
Figure 18196-01
1 Quick Disconnect for Pressure Gauge 5 Reservoir
2 Lift/Lower Manifold 6 Strainer
3 Sight Gauge 7 Accumulator
4 Filter
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HYDRAULIC
Hydraulic System
Hydraulic Circuits
These pages contain a brief description of hydraulic cir-
cuits for SP trucks which are typical of current standard
units. Your unit may vary. Refer to Hydraulic Schematic
for appropriate schematic.
Lift Circuit - One Speed Lift
When the lift button is depressed, oil is drawn from the
hydraulic reservoir though a 100 mesh strainer by
pump P1. Oil flows from P1 through manifold port P1 to
relief valve RV1. Oil flows to check valve CV2, unseats
CV2 and flows through CV2, to the quick disconnect
valve, accumulator and exits the manifold through port
C1. Oil flows though the mast hoses and enters the lift
cylinders through the velocity fuse(s) located at the the
bottom of the cylinders, and extends the cylinders. Dur-
ing lift, the free lift cylinder will extend fully before the
mast cylinders begin to extend. When lift is no longer
requested and P1 stops operating, pressurized oil flow
will seat CV2 blocking oil within the lift circuit through
P1.
Relief Valve Operation
During lift function, relief valve RV1 monitors hydraulic
pressure protecting the hydraulic system from exces-
sive pressure. Oil pressure is applied to the sensing
side of RV1 through the pilot line. If oil pressure ex-
ceeds RV1's adjustable pressure setting, pilot pressure
will overcome RV1's spring force compressing the
spring and opening the valve. Oil will bypass the lift cir-
cuit, by flowing through RV1 out the manifold through
T1, through a 10 micron filter and into the reservoir.
Accumulator Operation
The accumulator is used as a shock absorber for the
lift/lower hydraulic system. If the platform is stopped
suddenly, the change in oil flow exerts pressure on the
hydraulic system. The accumulator absorbs this oil
pressure change through the use of a gas pressurized
bladder located within the accumulator. The bladder
acts as a pillow to the pressurized oil, cushioning ap-
plied pressure within the hydraulic circuit. The typical
symptom of a bad or de-pressurized accumulator is
abrupt starting and stopping of the platform during lift or
lower. To charge the accumulator, refer to the Accumu-
lator section of this manual.
M2.0-7335-002 Crown 2007 PF15808-2 Rev. 2/10
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HYDRAULIC
Hydraulic System
Supply Flow
Pilot Pressure
Suction
Figure 18197-01
1 Accumulator, precharged to 3445 kPa (500 psi) 6 Reservoir capacity is approximately 13 liters (3.5 gal)
2 Lift/Lower Manifold 7 Suction strainer, 100 mesh
3 RV1 preset to 19200 to 19375 kPa (2785 to 2810 psi) 8 Quick disconnect (for pressure gauge)
4 Lift Pump, P1 output: 25.4 l/m at 3445 kPa (500 psi), 17.8 l/m 9 Velocity Fuse
at 12410 kPa (1800 psi)
5 Return line filter, 10 micron 10 Mast Cylinder
11 Free Lift Cylinder
Crown 2007 PF15808-3 Rev. 2/10 M2.0-7335-003
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HYDRAULIC
Hydraulic System
Lift Circuit - Two Speed Lift Accumulator Operation
The accumulator is used as a shock absorber for the
Low Speed Lift lift/lower hydraulic system. If the platform is stopped
When the lift button is depressed to the first detent, oil suddenly, the change in oil flow exerts pressure on the
is drawn from the hydraulic reservoir though a 100 hydraulic system. The accumulator absorbs this oil
mesh strainer by pump P1. Oil flows from P1 through pressure change through the use of a gas pressurized
manifold port P1, unseats check valve CV1 and flows bladder located within the accumulator. The bladder
through CV1 to relief valve RV1. Oil flows to check acts as a pillow to the pressurized oil, cushioning ap-
valve CV2, unseats CV2 and flows through CV2, to the plied pressure within the hydraulic circuit. The typical
quick disconnect valve, accumulator and exits the symptom of a bad or de-pressurized accumulator is
manifold through port C1. Oil flows though the mast abrupt starting and stopping of the platform during lift or
hoses and enters the lift cylinders through the velocity lower. To charge the accumulator, refer to the Accumu-
fuse(s) located at the the bottom of the cylinders, and lator section of this manual.
extends the cylinders. During lift, the free lift cylinder
will extend fully before the mast cylinders begin to ex-
tend. When lift is no longer requested and P1 stops op-
erating, pressurized oil flow will seat CV2 blocking oil
within the lift circuit; CV1 prevents oil from back flowing
through P1.
High Speed Lift
When the lift button is completely depressed, oil is
drawn from the reservoir by both pumps P2 and P1. In
addition of low speed lift operation (see above), addi-
tional oil flows from P2 through manifold port P2
through check valve CV3 and joins P1 oil flow. When
lift is no longer requested and P2 stops operating, CV2
blocks oil within the lift circuit, and CV3 prevents pres-
surized oil from back flowing through P2.
Relief Valve Operation
During lift function, relief valve RV1 monitors hydraulic
pressure protecting the hydraulic system from exces-
sive pressure. Oil pressure is applied to the sensing
side of RV1 through the pilot line. If oil pressure ex-
ceeds RV1's adjustable pressure setting, pilot pressure
will overcome RV1's spring force compressing the
spring and opening the valve. Oil will bypass the lift cir-
cuit, by flowing through RV1 out the manifold through
T1, through a 10 micron filter and into the reservoir.
M2.0-7335-004 Crown 2007 PF15808-4 Rev. 2/10
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HYDRAULIC
Hydraulic System
Supply Flow
Pilot Pressure
Suction
Figure 18198-01
1 Accumulator, precharged to 3445 kPa (500 psi) 6 Reservoir capacity is approximately 17 liters (4.5 gal)
2 Lift/Lower Manifold 7 Suction strainer, 100 mesh
3 RV1 preset to 19200 to 19375 kPa (2785 to 2810 psi) 8 Quick disconnect (for pressure gauge)
4 Lift Pump, P1 & P2 output: 25.4 l/m at 3445 kPa (500 psi), 9 Velocity Fuse
17.8 l/m at 12410 kPa (1800 psi)
5 Return line filter, 10 micron 10 Mast Cylinder
11 Free Lift Cylinder
Crown 2007 PF15808-5 Rev. 2/10 M2.0-7335-005
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HYDRAULIC
Hydraulic System
Lower Circuit - One Speed/Two Lower
Speed Lower When the lower button is depressed, solenoid valve
SVL and proportional valve PVL coils are energized
When lower is selected, oil begins to exit the lift cylin- causing SVL and PVL's spools to move to the open po-
ders. Oil leaving the cylinders is monitored by an inter- sition permitting oil flow. If the lower button is pushed to
nal velocity fuse in each cylinder. the first detent for low speed lower, PVL is only partially
Velocity fuses are hydraulic valves designed to prevent opened permitting partial oil flow. If the lower button is
the sudden release of hydraulic oil from a cylinder un- fully pushed for high speed lower, PVL is fully opened
der a catastrophic failure condition such as a line rup- permitting full hydraulic oil flow. SVL is fully opened
ture. If a mast hose or tube ruptures, hydraulic fluid will when the lower button is depressed regardless of how
be suddenly released out of the hydraulic cylinder(s) much the button is depressed. Oil exits the lift cylinders
due to the higher pressure of the oil in the lift cylin- and enters the lift/lower manifold block through port C1.
der(s). The sudden high flow exiting through the veloc- Oil flows through the open envelopes of SVL and PVL
ity fuse valve creates a pressure differential sensed at and through orifice ORF1. Oil pressure is also sensed
the pilot side of the velocity fuse. If oil pressure ex- through the pilot lines acting on both sides of pressure
ceeds the velocity fuse's spring force, pilot pressure compensator valve PCL. The pilot line opposite PCL's
will compress the spring and close the velocity fuse. spring also includes ORF3. Lower pressure at the inlet
This will block oil from exiting cylinder. to PVL is sensed in the pilot line to PCL opposite the
PCL bias spring, and outlet pressure from PVL is also
sensed at the pilot line connected to the PCL bias
spring chamber. If flow passes through PVL, a pres-
sure differential is created. If the pressure differential is
higher than the spring bias pressure it will cause PCL
to respond and close proportional to the differential
pressure, and thus limit the flow output through PVL &
PCL. The combined pressure drop across PVL and
ORF1 results in the sensed pressure differential and
results in pressure compensated flow output. ORF3 or-
ifice provides pressure damping to the sensed pres-
sure to PCL to provide smooth controlled response to
pressure or flow changes, for smooth motion control.
Once oil exits PCL, it is directed out of the manifold
through port T1. From port T1, oil flows through the 10
micron return line filter back to the reservoir.
M2.0-7335-006 Crown 2007 PF15808-6 Rev. 2/10
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HYDRAULIC
Hydraulic System
Return Flow
Pilot Pressure
Figure 18199-01
1 Accumulator, precharged to 3445 kPa (500 psi) 6 Reservoir capacity is approximately 17 liters (4.5 gal) for trucks
with two speed raise and approximately 13 liters (3.5 gal) for
trucks with single speed raise
2 Lift/Lower Manifold 7 Suction strainer, 100 mesh
3 RV1 preset to 19200 to 19375 kPa (2785 to 2810 psi) 8 Quick disconnect (for pressure gauge)
4 Lift Pump, P1 & P2 output: 25.4 l/m at 3445 kPa (500 psi), 9 Velocity Fuse
17.8 l/m at 12410 kPa (1800 psi)
5 Return line filter, 10 micron 10 Mast Cylinder
11 Free Lift Cylinder
Crown 2007 PF15808-7 Rev. 2/10 M2.0-7335-007
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HYDRAULIC
Hydraulic System
Manual Lower Circuit C1. From port C1, oil flows through the manual lower-
ing valve MVL and through ORF2. ORF2 restricts flow
The manual lowering feature is used to lower the plat- limiting the maximum rate of oil flow. After oil passes
form during truck down situations. The manual lower- through ORF2, it exits the manifold through port T1.
ing valve MVL is located on the lift/lower manifold. From port T1, oil enters the return line filter then back
When MVL is opened, oil trapped in the cylinders is to the reservoir.
released. Oil enters the lift/lower manifold through port
Return Flow
Pilot Pressure
Figure 18201-01
1 Accumulator, precharged to 3445 kPa (500 psi) 6 Reservoir capacity is approximately 17 liters (4.5 gal) for trucks
with two speed raise and approximately 13 liters (3.5 gal) for
trucks with single speed raise
2 Lift/Lower Manifold 7 Suction strainer, 100 mesh
3 RV1 preset to 19200 to 19375 kPa (2785 to 2810 psi) 8 Quick disconnect (for pressure gauge)
4 Lift Pump, P1 & P2 output: 25.4 l/m at 3445 kPa (500 psi), 9 Velocity Fuse
17.8 l/m at 12410 kPa (1800 psi)
5 Return line filter, 10 micron 10 Mast Cylinder
11 Free Lift Cylinder
M2.0-7335-008 Crown 2007 PF15808-8 Rev. 2/10
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HYDRAULIC
Hydraulic System
Reservoir 3. All hoses and lines are to be clear of any surface or
edge which will cause damaging wear and cuts, or
With all cylinders in retracted position and after all air on which they can become caught.
has been bled from hydraulic system, fill reservoir so oil
4. All connections are to be leak free.
level is at high mark on reservoir sight gauge (Figure
17175). Total capacity of hydraulic system at this level 5. Beaded elbows in suction ports of all pumps must
should be approximately 13 litres (3.5 gallons) for be positioned such that the suction hose retains its
trucks with one speed lift, and 17 litres (4.5 gallons) for full volume flow and does not collapse.
trucks with two speed lift.
Filter
NOTE
Do not tighten filter with use of a wrench. A wrench
Reservoir Sight Gauge should only be used for removal of filter.
The spin on filter cartridge has been tightened by
Crown. When replacing filter, apply a film of oil
063001-001 to seal and hand tighten the filter.
NOTE
Figure 17175
Do not use hydraulic brake fluid.
Hydraulic Lines and Fittings Use only a good grade of hydraulic oil such as Mobil
DTE 24 (Crown No. 063001-001) or equal. On trucks
equipped to operate in below freezing temperatures,
WARNING Mobil Aero HFA or equal is recommended (Crown No.
063001-006) in a 50/50 blend with standard hydraulic
AVOID HIGH PRESSURE FLUIDS - Escaping fluid un- oil.
der pressure can penetrate the skin causing serious in-
jury. Relieve pressure before disconnecting hydraulic
lines. Tighten all connections before applying pres- Drift Test
sure. Keep hands and body away from pin holes which
eject fluids under high pressure. Use a piece of card-
board or paper to search for leaks. Do not use your CAUTION
hand.
Never stand or work under a suspended load.
Any fluid injected into the skin under high pressure
should be considered as a serious medical emergency All drift tests should be conducted with a capacity load
despite an initial normal appearance of the skin. There (refer to serial plate for rated capacity of your truck).
is a delayed onset of pain, and serious tissue damage Material used for test load must be evenly stacked
may occur. Medical attention should be sought imme- within limits of a 1200 mm x 1200 mm (4 x 4 ft) square
diately by a specialist who has had experience with this pallet and must be secured to fork carriage with forks
type of injury. spread to their maximum width.
1. Blow air through all hoses and lines to remove
loose particles before installing. Any rubber hose
with wire braid inner construction, and any steel
tube lines which have been collapsed or kinked are
permanently damaged and must be replaced even
if damage is not externally visible.
2. Flexible hose must be replaced if it collapses in
normal operating position.
Crown 2007 PF15808-9 Rev. 2/10 M2.0-7335-009
01 Rev. 2/10
101
HYDRAULIC
Hydraulic System
Lift Drift Test
SP Models
NOTE
Lift measurement is to be taken from tip of fork to floor.
Elevate test load above staging height. After five min-
utes, measure distance the platform has drifted. Drift-
ing in excess of 15 mm (0.5 in) over a five minute pe-
riod is considered unacceptable.
Occasionally, a slight creep of platform may occur due
to internal leakage in the cylinder, but it can also be
caused by leakage in the manifold valves. To seat
these valves properly when this occurs, lift and lower
the platform to flush out any foreign material from valve
seat.
A thorough check for leaks in system should be con- Figure 18203
ducted if abnormal oil losses occur.
(a) 50/50 Mix of Low Temperature (063001-006 [50%]) and
Standard Hydraulic Oil (063001-021 [50%])
Freezer Preparation (b) Standard Hydraulic Oil (063001-001 [100%])
(c) 80/20 Mix of Lower Temperature (063001-006 [80%]) and
Standard Hydraulic Oil (063001-021 [20%])
NOTE
Trucks equipped with velocity fuses may experience
staging issues if an insufficient mix of low temperature
oil has been used.
If Crown trucks are operated in cooler or freezer envi-
ronments, the hydraulic fluid may require modification
to maintain the appropriate viscosity. Crown trucks may
require a mixture of low temperature hydraulic oil,
Crown P/N 063001-006 (gallons), blended with stan-
dard hydraulic oil, Crown P/N 063001-021 (gallons)
when used in a freezer or cooler. 100% low tempera-
ture oil is too thin for most cold storage operations and
therefore could shorten life of cylinder packings and
pumps if used in higher ambient temperatures.
For truck applications operating continually in temper-
atures at or above 4° C (40° F), use 100% standard hy-
draulic oil (063001-001).
For truck applications primarily operating in a cooler
environment with intermittent freezer entry, use a 50/50
blend, 50% low temperature (063001-006) and 50%
standard hydraulic oil (063001-021).
For truck applications primarily operating in a freezer
environment, use an 80/20 blend, 80% low tempera-
ture (063001-006) and 20% standard hydraulic oil
(063001-021).
A proper mixture of freezer hydraulic oil will ensure the
best and most efficient operation of your Crown equip-
ment.
M2.0-7335-010 Crown 2007 PF15808-10 Rev. 2/10
01 Rev. 2/10
102
HYDRAULIC
Pump Maintenance
Pump Maintenance
Figure 9221-01
Pump - Gear Oil Seal Removal
Overhaul the pump only in a clean, dust-free location, The oil seal (index 11) is best removed by applying
using clean tools and equipment. Dirt or grit will dam- pressure simultaneously to the pump inlet and outlet
age the highly polished machined surfaces and will re- ports. This has the effect of pressurizing the seal cavity
sult in leakage or premature failure of the pump. and forcing out the oil seal while ensuring that the pres-
sure on each side of the lobe seals (item 3 & 4) is
Before beginning the disassembly, scribe match marks
equalized so that these seals are not displaced. If the
on the body assembly, the end cover and mounting
oil seal is distorted and leaking badly, it may not be pos-
flange to insure that the pump will be reassembled
sible to build up sufficient pressure to remove it in this
properly. This pump can be assembled for either clock-
way. In this case, disassemble the pump as far as step
wise or counter-clockwise rotation as viewed from the
5 of the "DISASSEMBLY PROCEDURE" and clamp
end of the splined drive gear assembly. Arrows are
the mounting flange securely in a soft-jawed vice. The
molded in to the body assembly and the word "ROTA-
seal can then be removed with the use of a seal remov-
TION" appears on the mounting flange to aid in deter-
ing tool. Be careful not to damage the mounting flange
mining the pumps rotation. Note which direction the ar-
seal bore or the drive shafts sealing surface.
row is pointing next to the word "ROTATION" prior to
disassembly.
Crown 1982 PF5372-1 Rev. 9/06 M2.1-10.0-001
01 Rev. 9/06
117
HYDRAULIC
Pump Maintenance
Oil Seal Replacement 7. Hold the pump body vertically with the mounting
flange end downward and with one hand under-
1. Make sure the seal housing in the pump mounting neath to prevent the bushings (index 5) from falling
flange is clean and free from burrs. out. Tap the side of the body with a rawhide mallet
to dislodge the lower bushings, and slide them
2. Pack the space between the lips of the seal with a
carefully out of the body. Keep the bushings as a
high melting point, mineral based grease.
pair and place them on or near the mounting
3. Seat the oil seal. flange.
– If the mounting flange has been removed: 8. Invert the body and lift out the drive (index 9) and
Start the oil seal squarely into the housing, with the idler (index 8) gears.
the garter spring facing inward and press home
9. Remove the remaining pair of bushings as de-
to the full depth of the recess.
scribed in step 7 and place on or near the end
– If the pump is assembled: cover.
Slide an "Assembly Sleeve" (available from
Crown [#93170]) over the shaft splines until it
comes in contact with the shaft shoulder. Parts Inspection
Lightly grease the sleeve. Slide the oil seal,
Wash all metal parts thoroughly with a good cleaning
with the garter spring facing inwards, over the
fluid. Inspect, in the order disassembled, for wear and
sleeve and start it squarely into the housing.
damage.
4. Press the seal into the full depth of the recess.
5. Remove the Assembly Sleeve. Body
To obtain high efficiency the design allows for the tips
Pump Disassembly of the gear teeth to wipe the walls of the body bores
when the pump is running. Pressure will force the
1. Remove the bolts which hold the pump to the lift gears against the inlet side of the bores a wear pattern
motor. will be visible in this area. If excessive wear of the
bushing inserts or gear journals occurs this wear pat-
2. Lightly mark or scribe the end cover (index 2), the tern will deepen to form a step in the bore. Examine the
body (index 7) and the mounting flange (index 10) body bores and if a pronounced step is felt the body
to ensure re-assembly in the correct relationship. should be rejected. It is not advisable to fit worn bush-
Also note the direction of rotation of the pump. ings into a new body. Check to make sure the two hol-
3. Loosen the bolts and lockwashers (index 1) and low dowels are not loose.
pull out the bolts.
4. Remove the end cover (index 2) and carefully lift Composite Bushings
out the two backing washers (index 3), the lobe Examine the bearing inserts for signs of wear and
seals (index 4) and the body "O" ring seals (index check the bushing faces adjacent to the gears for scor-
6). The body seal is a moulded rubber seal on early ing or pitting. Make sure the holes and slots in the
pumps but changed to an "O" ring on newer units bushings are not plugged. Light scored on the bush-
(Specify when ordering). ings faces can be polished out on a lapping plate.
5. Fit an "Assembly Sleeve" tool (available from
Crown [#93170]) over the splines on the drive shaft NOTE
before withdrawing the mounting flange. Lightly tap
If new bushings are to be used in an old body, check
the mounting flange clear of the two hollow dowels
for any burrs at the edge of the wear track. If present,
in the pump body and slide it squarely off of the
this burr must be polished out or it may hold the bush-
shaft.
ing faces away from the gears and increase the internal
6. Carefully lift out the body "O" ring seal (index 6), leakage.
the two backing washers (index 3) and the lobe
seal (index 4).
M2.1-10.0-002 Crown 1982 PF5372-2 Rev. 9/06
01 Rev. 9/06
118
HYDRAULIC
Pump Maintenance
Gears
Examine the gears for discoloration, caused by over-
heating. Check the shafts for scoring. Make sure the
contact marks on the teeth are evenly distributed
across each tooth surface and that none of the teeth
are chipped.
NOTE
Bushings and/or gears are matched for widths within
0.005 mm (0.0002 in) and can only be sold and re-
placed as a matched pair.
End Cover
Examine the cover to insure flatness and inspect for
scoring and pitting.
Mounting Flange
Check for damage and check the condition of the oil
seal. If the seal needs replacement refer to the "Oil
Seal Replacement" section.
Lobe
Seal
Backing Washers
Figure 9222-01
Crown 1982 PF5372-3 Rev. 9/06 M2.1-10.0-003
01 Rev. 9/06
119
HYDRAULIC
Pump Maintenance
Clockwise Rotation
Cover End Mounting Flange End
Flat
Bushing Lobes Bushing Lobes
Assemble Drive Gear in this Bore Assemble Drive Gear in this Bore
Cover End Mounting Flange End
Flat Bushing Flat
Lobes
Assemble Drive Gear in this Bore Assemble Drive Gear in this Bore
Counter-Clockwise Rotation
Figure 9223-01
Pump Reassembly 3. Pack the space between the lips of the oil seal (in-
dex 11) with a high melting point, mineral based
Make sure that all pump components are perfectly grease.
clean and lubricated with the hydraulic oil to be used in
4. Pick up the body and hold it with the hollow dowels
the pump, prior to assembly.
up and with the fingers of one hand inside the
1. Prepare the bushings (index 5) for mounting flange bores of the body, ready to support the bushings.
end of the body for assembly as follows:
5. Pick up the mounting flange bushing complete with
(Refer to Figure 9222-01)
lobe seal and backing washers, and slide them into
Place the bushings on the workbench with their
the body bores with the lobes facing outwards and
lobes up and the flats in contact. Lubricate the lobe
away from the flat at the intersection of the body
seal (index 4) with a mineral based grease and fit
bores. The bushings must be inserted squarely
it around the bushing lobes. Fit a backing washer
into the bores and must be kept square to each
(index 3) inside each lobe seal. When fitted cor-
other. Do not use force when installing the bush-
rectly, the backing washer must be level and flush
ings. If the bushings should cock in the bores, re-
with the top surface of the bushing lobes.
move them and examine for scored body walls.
2. Prepare the bushings for the cover end of the body Light scoring can be stoned out with a fine grit hand
for installation into the pump in the same manner. stone.
M2.1-10.0-004 Crown 1982 PF5372-4 Rev. 9/06
01 Rev. 9/06
120
HYDRAULIC
Pump Maintenance
6. Lubricate the body seals "O" ring (index 6) with a Start Up Procedure
mineral based grease and seat it in the body.
A pump that has been re-assembled with new gears,
7. Refer to Figure 9223-01to find the position of the
bushings or body must be carefully broke-in before it is
drive gear bore for the direction of rotation you re-
subjected to full load working conditions.
quire. Lay the pump body on its side and slide the
drive gear (index 9) through the drive gear bore (as When test rig facilities are not available the following
called out in Figure 9223-01) so that the shaft pro- procedure must be carried out:
trudes out of the hollow dowel end of the body.
1. Install the pump on the application.
8. Slide the "Assembly Sleeve" (#93170) over the
2. Where the pump speed is variable set the speed to
end of the splined shaft. Hold the drive gear journal
1500 rev/min; otherwise run the pump at its normal
with one hand and slide the mounting flange (index
operating speed.
10) squarely over the shaft and onto the two hollow
dowels, flush against the body. The "Assembly 3. Run the pump at this speed for a period of 10 min-
Sleeve" provides a lead-in for the oil seal. Remove utes at minimum pressure, that is, with the hydrau-
the "Sleeve" and clamp the mounting flange in a lic system unloaded.
soft jawed vice with the pump body above the
4. If the pump operating pressure can be directly con-
flange. If the sleeve is stuck on the splines it can be
trolled, ensure that the pressure is progressively
removed by tightening a 1/4"-28 bolt into the end of
increased up to full working requirements over the
the "Assembly Sleeve".
first hour of operation. In circumstances where the
9. Check that the bushings are flush against the pressure cannot be directly controlled the same ef-
mounting flange face and that the lobe seals (index fect can be obtained by progressively increasing
4) and backing washers (index 3) have not become the work load on the machine, over the same pe-
dislodged. Check to see that the arrow on the riod of time.
body, adjacent to the word "ROTATION" is point-
5. During this period make frequent checks of the
ing in the correct pump rotation.
pump casing temperature, or the oil temperature, if
10. Mesh the idler gear (index 8) with the drive gear. If a temperature gauge is included in the system.
the original gears are being replaced on a new The temperature should not exceed that experi-
shaft, make sure that the marked side of the teeth enced under normal working conditions. If the tem-
are in contact so the bedded-in position of the teeth perature does rise excessively then it is possible
is maintained. that the pump has been assembled incorrectly and
it must be dismantled to check this. If no fault is
11. Pick up the bushings for the end cover side of the
found then further period of running-in at low pres-
pump, complete with lobe seals and backing wash-
sure, as in step 3, must be carried out.
ers and slide them over the gear journals with the
lobes facing outward and away from the flats in the
bores. Again, the bushings must be installed
squarely and without force.
12. Lubricate the body seal "O" ring (index 6) and seat
it in the body.
13. Place the end cover in position, aligning the scribe
marks made earlier.
14. Insert the bolts and lockwashers into the body and
hand tighten into the tapped holes in the mounting
flange. Apply a torque load of 4.7 to 5 kgm (34 to
36 ft lbs) to each bolt head.
15. Pour a small amount of hydraulic oil into the ports
and check the pump for freeness and direction of
rotation.
Crown 1982 PF5372-5 Rev. 9/06 M2.1-10.0-005
01 Rev. 9/06
121
HYDRAULIC
Lift/Lower Manifold
Lift/Lower Manifold
Relief Valve (RV1)
Operation
The lift system is protected from excessive oil pressure
by RV1. RV1 senses pressure in the lift circuit. Oil pres-
sure is applied to the sensing side of RV1 through the
pilot line. If oil pressure exceeds RV1's adjustable pres-
sure setting, pilot pressure will overcome RV1's spring
force compressing the spring and opening the valve.
Refer to Figure 23491. Oil will bypass the lift circuit by
flowing through RV1 and into the reservoir. When pres-
sure is less than RV1's pressure setting, RV1's spring
keeps RV1 closed and oil flows to the lift cylinders.
Oil flow (lift is requested)
Pilot pressure
Figure 23491
1 Pilot pressure does not exceed RV1’s spring force, valve is
closed
2 Pilot pressure exceeds RV1’s spring force, valve is open
3 Spring
4 From pump
5 To lift cylinders
6 To reservoir
Crown 2007 PF15809-1 Rev. 2/10 M2.4-7335-001
01 Rev. 2/10
129
HYDRAULIC
Lift/Lower Manifold
Adjustment
To adjust RV1, refer to Figure 23159 and proceed as
follows:
1. A fully charged battery of correct voltage should be
installed in the truck before making a relief valve
(RV1) adjustment.
2. Connect a 0-35 MPa (0-5000 psi) pressure gauge
to the quick disconnect fitting.
3. Completely depress the raise button to insure both
pumps are running when the relief valve is being
set.
4. Operate the hydraulic system until the oil tempera-
ture is between 37° and 54° C (100° and 130° F).
5. Loosen the jam nut so RV1 can be adjusted. Raise
the platform until it contacts the stops. Hold the
raise button in completely so both lift pumps are
running and check indication of pressure gauge
when the relief valve opens. Turn the adjustment
screw to change the setting.
– Set the pressure to 19.20 to 19.37 MPa (2785
Figure 23159
to 2810 psi).
1 Quick Disconnect (for Pressure Gauge) 6. Tighten the jam nut when adjustment is correct.
2 Jam Nut
7. Lower the platform 150 - 300 mm (6 - 12 in) and
3 Adjustment Screw then raise the platform until it contacts the stops.
Re-check the relief valve setting and re-adjust it if
necessary.
M2.4-7335-002 Crown 2007 PF15809-2 Rev. 2/10
01 Rev. 2/10
130
HYDRAULIC
Lift/Lower Manifold
Chart 1 - Troubleshooting
Symptom Probable Cause Possible Solution
Oil leaks around Defective o-rings in cartridge Replace o-rings.
manifold. valve or port connector fittings.
Platform will not raise Relief valve stuck in the open Replace relief valve.
(pump[s] runs). position.
Solenoid valves or manual valve Actuate the valve(s) and try to dislodge the
stuck in the open (free flow) debris. Check to see that the valve (solenoid
position. only) is not over-tightened. If neither of the
above remedies work, replace valve.
No low speed raise; high Check valve (CV1) stuck in the Actuate lift button several times to try and
speed raise works open position. dislodge debris. If that doesn’t work, replace
properly. check valve.
Platform will not raise Relief valve not adjusted correctly. Re-adjust relief valve RV1 to the proper setting
capacity load. (see the previous page).
Platform drifts down in Defective o-rings on check valves, Replace o-rings or back-up rings. Check valve
excess of the drift test solenoid valves, manual valve or capacity at o-ring sealing area for nicks or rough
specification. relief valve. surfaces.
Debris caught in check valve Actuate the valve(s) and try to dislodge the
seats. debris. If that doesn’t work, replace valve.
Manual valve not closed properly. Close manual valve or replace.
Platform will not lower. Solenoid coil failure. Check for proper voltage input and coil resis-
tance If OK, check valve for dirt, debris or bro-
ken spring. Check for dirt, debris in the valve or
broken valve spring.
Cylinder malfunction. Refer to Cylinders.
Electrical malfunction. Refer to the Wiring Diagrams (see Table of Con-
tents).
Crown 2007 PF15809-3 Rev. 2/10 M2.4-7335-003
01 Rev. 2/10
131
HYDRAULIC
Accumulator
Accumulator Crown has available a 103623-004 Accumulator
Charging Tool, designed for charging and testing blad-
The accumulator is a device in which compressed gas der and/or diaphragm type nitrogen charged accumu-
and oil is stored for the purpose of absorbing shock. lators.
When the oil pressure in the line rises, incoming oil
The accumulator must be removed from the truck prior
compresses the gas. As the surge of oil pressure
to testing or charging.
passes, the gas expands to its original size, forcing out
oil. This reduces vibrations and shock in the system
and reduces shock when contacting stops during lift Precharging
and lower.
1. Lower platform completely.
2. Turn key switch off, disconnect battery, chock
wheels and tagout truck.
3. Open the power unit doors and locate the lift man-
ifold. Open the manual valve (MV1) to remove oil
pressure from oil side of the accumulator.
Figure 15726-01
1 Accumulator
Use an inert gas, such as Nitrogen for precharging or
topping off of accumulators. Size "T" bottle dry nitro-
gen, 8.5m3 (300 cu ft), 17.9 MPa (2600 psi) is recom-
Figure 23162
mended.
1 Manual Lowering Valve
WARNING 4. Disconnect the hose from the accumulator, loosen
mounting clamp and remove accumulator. Refer to
Never use oxygen as a charging agent for accumula-
Figure 15726-01.
tors. Use only dry nitrogen as a charging agent for ac-
cumulators.
If the gas pressure in the nitrogen bottle is higher than NOTE
the maximum operating pressure of the accumulator, a Since this procedure disconnects an oil line, care
gas pressure reducing valve must be used. should be taken to catch as much oil as possible.
5. Remove dust cap from accumulator gas valve.
Crown 2007 PF15655-1 Rev. 2/10 M2.6-7335-001
01 Rev. 2/10
117
HYDRAULIC
Accumulator
6. Use thread sealing and lubricating compound on 11. Slowly open nitrogen bottle valve to fill accumula-
pipe threads of gage. tor. Once the pointer on the gage starts to deflect
unscrew the gas chuck stem one full turn. The
7. Attach one end of charging hose to the nitrogen
charge should be over a 2 to 4 minute period to
bottle and the other end to the accumulator charg-
assure a proper charge and to prevent damage to
ing tool. Refer to Figure 15728-01. Procedure is
accumulator. Shut off when gage indicates proper
similar when using only charging hose with or with-
charge. Use the gas chuck stem to tighten gas
out other accessories.
valve in accumulator to 11 Nm (8 ft lb). The pre-
8. Back gas chuck stem all the way out before attach- charge pressure setting is 3445 kPa (500 psi).
ing assembly to accumulator gas valve.
CAUTION
Do not loop or twist hose as it will stiffen when gas
pressure is released from nitrogen bottle.
Never loosen swivel nut attached to gas valve in accu-
mulator without first backing gas chuck stem out all the
way.
Do not reduce accumulator precharge by depressing
valve core (high pressure may rupture rubber valve
seat).
12. If desired precharge pressure is exceeded, make
sure nitrogen bottle valve is closed, then open
bleeder valve slightly, but only momentarily, to re-
duce pressure.
13. Once desired accumulator charge has been
achieved, remove Accumulator charging tool.
14. With the use of sealing spray or soapy water,
check accumulator for leaks.
15. Replace dust cap on accumulator and install on
truck.
16. Reconnect battery.
17. To bleed air from the accumulator, the empty forks
Figure 15728-01
should be raised to sufficiently pressurize the lift
1 Nitrogen
cylinders.
2 Bottle Valve
NOTE
3 Bleeder Valve
4 Gage Since this procedure disconnects oil line, care should
5 Accumulator be taken to catch as much oil as possible.
18. Slowly loosen the hose connection at the accumu-
9. Use wrench to tighten gas chuck swivel nut onto
lator until all air-oil mixture is released and a steady
accumulator gas valve. Close bleeder valve.
stream of oil is evident.
10. Use gas chuck stem to loosen gas valve in accu-
mulator.
M2.6-7335-002 Crown 2007 PF15655-2 Rev. 2/10
01 Rev. 2/10
118
HYDRAULIC
Accumulator
WARNING
AVOID HIGH PRESSURE FLUIDS-Escaping fluid un-
der pressure can penetrate the skin causing serious in-
jury. Relieve pressure before disconnecting hydraulic
lines. Tighten all connections before applying pres-
sure. Keep hands and body away from pin holes which
eject fluids under high pressure. Use a piece of card-
board or paper to search for leaks. Do not use your
hand.
Any fluid injected into the skin under high pressure
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 tissue damage
may occur. Medical attention should be sought imme-
diately by a specialist who has experience with this
type of injury.
19. Tighten connector.
20. Remove wheel chocks and tagout. Return the
truck to service.
Crown 2007 PF15655-3 Rev. 2/10 M2.6-7335-003
01 Rev. 2/10
119
HYDRAULIC
Hydraulic Troubleshooting
Hydraulic Troubleshooting proceed in solving the problem grows with experience.
The following chart contains symptom, probable cause
The following Troubleshooting Chart contains general and remedy. The information is general in nature and a
information necessary to effectively solve the more remedy may simply refer you to a maintenance section
common hydraulic problems. Know the system to the that has more complete troubleshooting. Use the
best of your ability. Understand the components and chart(s) carefully and completely. Do not make the sys-
their function within the system. Develop a systematic tem more complicated than necessary. Do not overlook
pattern to locate and solve the various hydraulic prob- the simplest reason(s) for a hydraulic problem.
lems that occur. The ability to identify problems and
Hydraulic Troubleshooting Chart
Symptom Probable Cause Remedy
Hydraulic oil foaming Introduction of air into pump Check reservoir oil level.
Check for proper oil viscosity.
Check plumbing.
Water in oil Check reservoir.
Hydraulic oil overheating * Oil too thin * Change to proper viscosity oil.
Oil contaminated Change filters and fill with clean oil.
Introduction of air into pump Check plumbing.
Oil level low Fill reservoir to proper level.
Platform will not raise Mast assembly binding Inspect mast for damage or misalignment.
Lift motor or pump not operating Refer to pump troubleshooting.
Manual lowering valve open Refer to valve assembly troubleshooting M2.4.
Relief valve setting incorrect Reset relief valve.
Platform will not lower Velocity fuse actuated Check for severe oil leak.
Check for more than capacity load.
Flow control valve reset.
Raise slightly to reset velocity fuse.
Chain slack switch actuated Platform/Forks resting on obstruction.
Raise slightly to eliminate chain slack.
Solenoid valve malfunction Refer to valve assembly troubleshooting M2.4.
Binding in mast assembly Inspect mast & platform for damage, misalign-
ment, etc.
*Be sure the truck has been performing its normal duty cycle at this time. Trucks equipped to operate in
freezer require a thinner weight oil.
Crown 2002 PF13448-1 Rev. 9/06 M2.9-7332-001
01 Rev. 9/06
HYDRAULIC
Hydraulic Troubleshooting
Hydraulic Troubleshooting Chart (Continued)
Symptom Probable Cause Remedy
Lowers too slow Debris in flow control valve Cycle through lift/lower to free possible debris.
Line restriction Check plumbing.
Accumulator malfunction Check accumulator operation.
Binding in mast assembly Inspect mast & platform for damage, misalign-
ment, etc.
Lowers too fast Debris in flow control valve Cycle through lift/lower to free possible debris.
External oil leak Check plumbing for leak(s).
Accumulator malfunction Refer to accumulator maintenance section
M2.6.
No hi-speed raise HSRCS switch malfunction Check HSRCS switch operation.
RAS switch malfunction in control Refer to componentry section M1.0.
module
No hi-speed lower HSLCS switch malfunction Check HSLCS switch operation.
LOS switch malfunction in control Refer to componentry section M1.0.
module
Solenoid valve malfunction Refer to valve assembly troubleshooting M2.4.
Line restriction Check plumbing.
No cushion during raise or Accumulator malfunction Charge accumulator properly. Refer to section
lower M2.6.
Damaged cushion springs or Inspect for damage.
bumpers
Will not lift capacity load Relief valve not adjusted properly Adjust relief valve. Refer to valve assembly
section M2.4.
Mast binding Inspect mast for damage, misalignment, etc.
Hydraulic component(s) malfunc- Refer to hydraulic pump M2.1 & cylinders M8.0.
tion
Platform drifts down Debris in lift/lower valve Cycle through lift/lower to free possible debris.
(in excess of drift test)
Lift cylinder packings leaking Refer to cylinder information section M8.0.
Accumulator loses charge Accumulator valve leaking, Repair. Refer to accumulator maintenance sec-
cracked, deformed, etc. tion M2.6.
Abnormal hydraulic oil External leak Check plumbing, cylinder, other hydraulic com-
usage ponents.
M2.9-7332-002 Crown 2002 PF13448-2 Rev. 9/06
01 Rev. 9/06
HYDRAULIC
Hydraulic Troubleshooting
Hydraulic Troubleshooting Chart (Continued)
Symptom Probable Cause Remedy
Lift pump & motor over- Relief valve setting too high Reset relief valve. Refer to hydraulic mainte-
heating * nance section M2.4.
Exceeding capacity load Check load weight.
Worn or damaged pump & motor Inspect pump & motor. Repair or replace.
Fluid level low Inspect fluid level. Fill system to proper level.
Refer to section M2.0.
Failure of platform to raise Lift chains not adjusted properly Adjust chains.
and lower smoothly
Mast and/or platform binding Inspect mast & platform for damage, wear, etc.
Hydraulic component malfunction Inspect pump, motor, valve, cylinder, etc. for
damage, leaks, wear, etc.
Accumulator malfunction Refer to section M2.6.
Air trapped in cylinder Bleed.
* Be sure the truck has been performing its normal duty cycle at this time.
Crown 2002 PF13448-3 Rev. 9/06 M2.9-7332-003
01 Rev. 9/06
HYDRAULIC SYSTEM
Hydraulic Troubleshooting
Hydraulic Troubleshooting hydraulic problems. The information is general and a
solution can take you to a maintenance section that
The Hydraulic Troubleshooting table contains general has more complete troubleshooting.
information that is necessary to find a solution to typical
Hydraulic Troubleshooting
Symptom Probable Cause Remedy
The hydraulic oil has foam. There is air in the lift pump. Check the level of the hydraulic oil in
the reservoir.
Check for the correct hydraulic oil viscosity.
Check the hydraulic plumbing.
There is water in the hydraulic oil. Check the reservoir and replace hydraulic oil.
The hydraulic oil is too The hydraulic oil is too thin. (1) Change to the correct viscosity hydraulic oil.
hot. (1)
The hydraulic oil is contaminated. Change the filters and replace the hydraulic oil.
There is air in the lift pump. Check the hydraulic plumbing.
The level of the hydraulic oil is too Fill the reservoir to the correct level.
low.
The platform or lifting forks The mast assembly does not Check the mast assembly, platform, and lifting
do not raise. move freely. forks for damage. Make sure that they are
aligned correctly.
The lift pump or the lift See the HYDRAULIC SYSTEM / Lift pump
pump motor does not operate. maintenance section.
The manual lowering valve (MLV) Close the manual lowering valve.
is open.
The relief valve (RV1) setting is Reset the relief valve. See the HYDRAULIC
incorrect. SYSTEM / Lift/Lower manifold section.
There is a malfunction in the Check for the correct voltage input and the cor-
solenoid valve (SV1). (2) rect coil resistance. If the voltage input and the
coil resistance are correct, check the solenoid
valves for contamination or a broken spring. (2)
The carriage is damaged or mis- Inspect the carriage for damage or misalign-
aligned. (2) ment. (2)
The platform or lifting forks The velocity fuse operates when Check for an extreme hydraulic oil leak.
do not lower. hydraulic oil flows too quickly
Check for a load that is too heavy.
through the lift cylinder.
Raise the forks to reset the velocity fuse.
The chain slack switch operated. The platform or the forks are on an object.
Raise the forks to remove the chain slack.
(1) Make sure that the lift truck operates at its usual duty cycle at this time. Lift trucks equipped to operate
in freezer conditions require a thinner weight oil
(2) 1.0 Lifting fork lift trucks only
Crown 2010 PF17889 Rev. 1/17 M2.9-7335-001
01 Rev. 1/17
177
HYDRAULIC SYSTEM
Hydraulic Troubleshooting
Hydraulic Troubleshooting (Continued)
Symptom Probable Cause Remedy
The platform or lifting forks The solenoid valves (SVL, PVL, or Check for the correct voltage input and the cor-
do not lower. PCL) do not operate correctly. rect coil resistance. If the voltage input and the
coil resistance are correct, check the solenoid
valves for contamination or a broken spring.
The solenoid valves (PVLF or Check for the correct voltage input and the cor-
PCLF) do not operate correctly. (2) rect coil resistance. If the voltage input and the
coil resistance are correct, check the solenoid
valves for contamination or a broken spring. (2)
The mast assembly does not Check the mast and the platform for damage.
move freely. Make sure that they are aligned correctly.
The carriage assembly does not Check the carriage for damage and make sure
move freely. (2) it is aligned correctly. (2)
The lower function is too There is contamination in the Use the lift and lower functions to free the pos-
slow. valves (SVL, PVL, or PCL). sible contamination. Remove and clean the
valves. Replace the valves.
There is contamination in the Use the lift and lower functions to free the pos-
valves (PVLF or PCLF). (2) sible contamination. Remove and clean the
valves. Replace the valves. (2)
There is hydraulic plumbing block- Check the hydraulic plumbing.
age.
The mast assembly does not Check the mast and the platform for damage.
move freely. Make sure that they are aligned correctly.
The carriage assembly does not Check the carriage for damage and make sure
move freely. (2) it is aligned correctly. (2)
The lower function is too The proportional solenoid valve Check for a broken valve spring.
fast. (PVL) is not working correctly.
The proportional solenoid valve Check for a broken valve spring. (2)
(PVLF) is not working correctly. (2)
There is an external hydraulic oil Check the hydraulic plumbing for leaks.
leak.
There is no high-speed The HSRCS switch is not working Check the operation of the HSRCS switch.
raise. correctly.
The RAS switch in the control See the COMPONENTRY section.
module is not working correctly.
The pump is not working correctly. Check the operation of the pump.
There is no high-speed The HSLCS switch is not working See the COMPONENTRY section.
lower. correctly.
(2) 1.0 Lifting fork lift trucks only
M2.9-7335-002 Crown 2010 PF17889 Rev 1/17
01 Rev. 1/17
178
HYDRAULIC SYSTEM
Hydraulic Troubleshooting
Hydraulic Troubleshooting (Continued)
Symptom Probable Cause Remedy
There is no high-speed The LOS switch in the control See the COMPONENTRY section.
lower. module is not working correctly.
The proportional solenoid valve Check for the correct voltage input and the cor-
(PVL) is not working correctly. rect coil resistance. If the voltage input and the
coil resistance are correct, check the solenoid
valves for contamination or a broken spring.
There is hydraulic plumbing block- Check the hydraulic plumbing.
age.
There is no cushion during The accumulator is not working Charge the accumulator correctly. See the HY-
the raise or lower func- correctly. DRAULIC SYSTEM / Accumulator section.
tions.
The cushion springs or Check the cushion springs and the bumpers for
bumpers are damaged. damage.
The lift truck does not lift a The relief valve is not adjusted Adjust the relief valve. See HYDRAULIC SYS-
capacity load. correctly. TEM / Lift/Lower Manifold section.
The mast assembly does not Check the mast assembly and the platform for
move freely. damage. Make sure that they are aligned cor-
rectly.
The hydraulic components do not See the HYDRAULIC SYSTEM / Lift pump
operate correctly. maintenance or CYLINDERS / Mast and free-
left cylinders sections.
The carriage assembly does not Check the carriage for damage and make sure
move freely. (2) it is aligned correctly. (2)
The platform drifts down There is contamination in the Use the lift and lower functions to free the pos-
(more than allowable in valves. sible contamination.
the drift test).
The packings in the lift cylinders See the CYLINDERS / Mast and free-left cylin-
leak. ders section.
The accumulator loses its The accumulator valve is leaking, Repair the accumulator. See the HYDRAULIC
charge. cracked, or deformed. SYSTEM / Accumulator section.
The hydraulic oil There is an external leak. Check the hydraulic plumbing, cylinders, and
usage is not correct. other hydraulic components.
The lift pump and the The relief valve setting is too high. Reset the relief valve. See the HYDRAULIC
motor is overheating. (1) SYSTEM / Lift/Lower manifold section.
The load is too heavy. Check the weight of the load.
The pump and motor are worn or Check the pump and the motor. Repair or re-
damaged. place the pump or motor. See the HYDRAULIC
PARTS / Lift pump section.
(1) Make sure that the lift truck operates at its usual duty cycle at this time
(2) 1.0 Lifting fork lift trucks only
Crown 2010 PF17889 Rev. 1/17 M2.9-7335-003
01 Rev. 1/17
179
HYDRAULIC SYSTEM
Hydraulic Troubleshooting
Hydraulic Troubleshooting (Continued)
Symptom Probable Cause Remedy
The lift pump and the The hydraulic fluid level is too low. Check the fluid level. Fill system to proper level.
motor is overheating. (1) See HYDRAULIC SYSTEM section.
The platform does not The lift chains are not adjusted Adjust the lift chains. See the LIFTING MECH-
raise and lower smoothly. correctly. ANISM PARTS / Lift chain section.
The mast or the platform does not Check the mast assembly and the platform for
move freely. damage. Make sure that they are aligned cor-
rectly.
The hydraulic components are not Check the pump, motor, valves, and cylinders
working correctly. for damage, leaks, and wear.
The accumulator is not working See the HYDRAULIC SYSTEM / Accumulator
correctly. section.
There is air trapped in the cylinder. Bleed the air from the cylinder. See the CYLIN-
DERS / Mast cylinder removal and installation
section.
The carriage assembly does not Check the carriage for damage and make sure
move freely. (2) it is aligned correctly. (2)
(1) Make sure that the lift truck operates at its usual duty cycle at this time
(2) 1.0 Lifting fork lift trucks only
M2.9-7335-004 Crown 2010 PF17889 Rev 1/17
01 Rev. 1/17
180
Notes:
181
DRIVE UNIT
Drive Unit
Drive Unit Remove the drive tire
DANGER
CAUTION
If you use a hydraulic jack or jack stands that do
Incorrect or missing safety procedures and safety not have sufficient capacity, severe bodily injury or
equipment can cause death or injury. death can result.
You must use the correct protective equipment and Jacks and jack stands can collapse.
obey all safety procedures to do work on a lift truck. If Make sure that the specifications for the hydraulic
you do not, death or injury can result. jack and the jack stands meet the lift truck specifi-
Follow the instructions in the SAFETY / Control of cations.
Hazardous Energy section. See the SAFETY / Control of Hazardous Energy /
Follow all recommended safety precautions. Lifting and Blocking the Power Unit section for the
Use the correct protective items, such as safety applicable lifting and blocking procedures.
glasses, work gloves, and safety-toe shoes.
1. Raise and block the power unit until the drive tire is
off of the floor. See the SAFETY / Control of Haz-
Prepare the lift truck for maintenance
ardous Energy / Lifting and Blocking section.
1. Follow all the safety procedures. See the SAFETY
2. Remove the eight bolts from the hub.
chapter.
3. Remove the drive tire.
2. Wear the appropriate protective items.
3. Move the lift truck to your work area on a level floor. Remove the drive tire from the hub
4. Fully lower the forks. 1. Put the existing drive tire assembly on the hydrau-
lic press, directly below the ram.
5. Turn the lift truck OFF.
2. Use an applicable press tool for the hydraulic press
6. Disconnect the battery.
to touch the hub circumference.
7. Secure the work area.
3. Remove the existing drive tire from the hub.
8. Lockout/tagout the lift truck. See the SAFETY /
4. Discard the existing drive tire.
Control of Hazardous Energy section.
5. Check the hub for wear or damage.
9. Put the chocks against the wheels.
Replace the hub if it is necessary.
Drive Tire Replacement 6. Make sure that the base band of the new drive tire
has not been pressed before.
Special Tools and Equipment:
• Hydraulic press
Install the drive tire
• Hydraulic jack with a 3,620 kg (8,000 lb) capacity
• Jack stands with a 4,500 kg (10,000 lb) capacity
• Tire adapter (134169) WARNING
Lift truck accidents and injury can be caused by in-
correct tire compound or tire dimension.
An incorrect tire type can have an unwanted effect on
how the lift truck can stop or steer. It can also have an
unwanted effect on the lift truck capacity.
Use only a tire with the correct compound and di-
mension.
See the data plate on the lift truck for drive tire infor-
mation.
Crown 2007 PF15810-1 Rev. 3/15 M3.0-7335-001
01 Rev. 3/15
131
DRIVE UNIT
Drive Unit
1. Put the new drive tire on the center of the hydraulic 7. Push the hub (1) into the drive tire (2) until the hub
press, below the ram. face is flush with the drive tire band.
2. Lightly lubricate the inner top 75 mm (3 in) of the
drive tire band with hydraulic oil.
3. Put the hub (1, Figure 1) with the convex face up
directly above the drive tire (2) with the edge cham- 4
fer in the drive tire band.
4. Put the tire adapter (3, 134169) above the top of
the hub (1) to align the pins in the lug nut holes. 3
Note: The ram plate (4) must have a minimum diame-
ter of 240 mm (9.5 in).
1
5. Align the components that follow below and in the
center of the ram plate (4):
• Tire adapter (3, 134169)
• Hub (1)
• Drive tire (2) 2
WARNING
Very high pressure can cause injury.
The hydraulic press uses very high pressure to push
the hub into the drive tire. Contact with the hydraulic
press during this procedure can cause injury.
You must complete the operator training, authoriza-
tions, and certifications from your employer for this
lift truck before you do service on this lift truck.
CAUTION 3
Incorrect alignment can cause damage.
If the alignment between the hub and the drive tire is
incorrect, the drive tire band can be damaged. Fig. 1 (29102)
Monitor the alignment between the hub and the 8. If the hub (1, Figure 2) has paint on the seats (2) of
drive tire during the first 75 mm (3 in) of installation. the bolts or where the inner hub face (3) touches
the axle, remove the paint.
6. Before you use the hydraulic press to push the hub
(1) into the drive tire (2), make sure that you:
• Always push the hub (1) into the drive tire (2) for the
correct installation.
• Do not push directly on the center of the convex hub
(1).
• Monitor the alignment between the hub (1) and the
drive tire (2) during the first 75 mm (3 in) of installa-
tion.
• Monitor the force of the hydraulic press during in-
stallation. If the force of the hydraulic press is low,
the hub (1) could be worn.
M3.0-7335-002 Crown 2007 PF15810-2 Rev. 3/15
01 Rev. 3/15
132
DRIVE UNIT
Drive Unit
Change the Oil
Special Tools and Equipment:
1
• 946 ml (1 qt) of 80W90 gear oil (363506-001) or au-
tomatic transmission fluid (363503-001) (lift trucks
with freezer condition)
2 • Catch pan
3
Specifications
• Change the oil the first time at 250 hours of opera-
tion, then change the oil every 2000 hours of oper-
ation.
• The oil capacity of the drive unit is 710 ml (0.8 qt).
Fig. 2 (28491) • Fill the drive unit with 710 ml (0.8 qt) of 80W90 gear
oil (363506-001) or automatic transmission fluid
CAUTION (363503-001) (lift trucks with freezer condition).
Too high torque could cause cracks in the wheel Change the oil
studs. See Figure 4.
If the torque value applied to the bolts is too high, the
1. Put a catch pan below the drive unit (1).
wheel studs could crack.
2. Remove the drain plug (2) to drain the gear oil.
Make sure that you torque the bolts to the specifica-
tions that follow. 3. Check the seal on the drain plug (2).
If the seal is damaged, replace the drain plug
(2).
Note: The eight bolts for the hub are lubricated and no
4. After you drain the gear oil, install the drain plug
thread-locking adhesive is necessary.
(2).
9. Install the eight bolts in the hub.
5. Remove the fill plug (3) to add the gear oil.
10. Tighten the eight bolts by hand.
6. Fill the drive unit (1) with gear oil until gear oil starts
11. See Figure 3. Follow the torque sequence and to flow out of the fill plug hole.
torque the eight bolts to 135–150 Nm (100–
7. Check the seals on the fill plug (3).
110 ft lb).
If the seals are damaged, replace the fill plug
(3).
8. Install the fill plug (3).
Fig. 3 (28494)
Crown 2007 PF15810-3 Rev. 3/15 M3.0-7335-003
01 Rev. 3/15
133
DRIVE UNIT
Drive Unit
• Ball (6)
• Plug (7)
• Spring (8)
• Ball (9)
3
2
Fig. 4 (29103)
Oil Pump Disassembly and Assem-
bly
Special Tools and Equipment:
• 946 ml (1 qt) of 80W90 gear oil (363506-001) or au-
tomatic transmission fluid (363503-001) (lift trucks
with freezer condition) 4
• Thread-locking adhesive (061004-005)
Specifications 3 5
• Fully clean all the parts after you disassemble the
oil pump.
6
• Check all the parts for unwanted material and dam-
age before you assemble the oil pump. Replace the 7
parts that are damaged.
Disassemble the oil pump 8
See Figure 5. 1
1. Drain the gear oil from the drive unit (2). See 9
Change the Oil.
2. Remove the oil pump housing (1) from the drive
Fig. 5 (29104)
unit (2).
3. Remove these parts from the oil pump housing (1) Assemble the oil pump
in the sequence that follows: See Figure 5.
• O-rings (3) 1. Install the ball (9) and the spring (8) in the oil pump
• Piston (4) housing (1).
• Spring (5) 2. Install the components that follow in the piston (4):
M3.0-7335-004 Crown 2007 PF15810-4 Rev. 3/15
01 Rev. 3/15
134
DRIVE UNIT
Drive Unit
• Spring (5)
• Ball (6)
• Plug (7)
3. Make sure that the piston (4) is correctly lubricated
and install the piston in the oil pump housing (1). 5
4. Install the O-rings (3) on the oil pump housing (1).
5. Install the oil pump housing (1) in the drive unit (2).
6. If drain plug replacement is necessary, apply some
thread-locking adhesive (061004-005) to the drain
1
plug before you replace the drain plug.
7. Fill the drive unit (2) with gear oil. See Change the
Oil.
Traction Motor Removal and Instal- 2
lation
Special Tools and Equipment:
• Lift device
• Straps
4
Remove the traction motor
See Figure 6.
1. Open the power unit doors. 3
2. Disconnect the electrical cables from the traction
motor (M1) (1).
3. Disconnect CA407 (2).
Fig. 6 (29105)
4. Attach a strap to M1 (1).
5. Attach the strap to a lift device. Install the traction motor
6. Use the lift device to hold M1 (1). See Figure 6.
7. Remove the four screws (3) that hold M1 (1) on the 1. Attach a strap to M1 (1).
drive unit plate (4). 2. Attach the strap to a lift device.
8. Use the lift device to remove M1 (1) and the brake 3. Use the lift device to install M1 (1).
assembly (5) from the lift truck.
4. Install the four screws (3) that hold M1 (1) on the
drive unit plate (4).
5. Connect the electrical cables to M1 (1).
6. Connect CA407 (2).
7. Close the power unit doors.
Drive Unit Removal and Installation
Special Tools and Equipment:
• Hydraulic jack with a 3,620 kg (8,000 lb) capacity
• Jack stands with a 4,500 kg (10,000 lb) capacity
• Thread-locking adhesive (061004-005)
• Thread-locking adhesive (061004-009)
Crown 2007 PF15810-5 Rev. 3/15 M3.0-7335-005
01 Rev. 3/15
135
DRIVE UNIT
Drive Unit
Remove the drive unit 1. Raise and block the power unit until you can install
the drive unit (6).
See Figure 7.
2. Make sure that the drive unit (6) is stable.
1. Open the power unit doors.
3. Apply some thread-locking adhesive (061004-004)
2. Disconnect and remove M1 (1) and the brake as-
to the four screws (3) that hold the cup holder (4)
sembly. See Traction Motor Removal and Installa-
on the drive unit plate (5).
tion.
4. Install the drive unit (6) with the four screws (4) and
3. Remove the drain plug to drain the gear oil. See
the two dowel pins.
Change the Oil.
5. Torque the four screws (3) to 340–370 Nm (250–
4. Raise and block the power unit until the drive tire
275 ft lb).
(2) is off of the floor. See the SAFETY / Control of
Hazardous Energy / Lifting and Blocking the Power 6. Install the drive tire (2). See Drive Tire Replace-
Unit section. ment / Install the drive tire.
5. Remove the drive tire (2). See Drive Tire Replace- 7. Align the marks (7) on the drive unit (6) and the cup
ment / Remove the drive tire. holder (4) to make sure that the drive tire (2) is
straight and forward.
6. Remove the four screws (3) and the two dowel pins
that hold the cup holder (4) on the drive unit plate 8. If drain plug replacement is necessary, apply some
(5). thread-locking adhesive (061004-005) to the drain
plug before you replace the drain plug.
7. Stabilize the drive unit (6).
9. Fill the drive unit (6) with gear oil. See Change the
8. Raise and block the power unit until you can re-
Oil.
move the drive unit (6).
10. Close the power unit doors.
9. Move the drive unit (6) to a clean work area for dis-
assembly. Prepare the lift truck for operation
1. Remove the chocks from the wheels.
2. Remove the lockout/tagout device.
3. Connect the battery.
4. Turn the lift truck ON.
5. Make sure that the lift truck operates correctly.
1
6
3
2
Fig. 7 (29106)
Install the drive unit
See Figure 7.
M3.0-7335-006 Crown 2007 PF15810-6 Rev. 3/15
01 Rev. 3/15
136
ELECTRICAL SYSTEM
Encoders
Encoders
Operation
Encoders change mechanical movement into a digital 5.0 V
signal. The encoder sends digital signals (channel A
and channel B) to the applicable control module. The
digital signals change from 0 V to the supply voltage at Common 1
different times. The control module then compares the Index 2 V
digital signals to calculate which channel comes first Channel A 3
and how quickly the channels change. Finally, the con- 5V 4
trol module calculates the direction and speed of the
Channel B 5
component.
+
Wire designations -
• Supply wire: The supply wire supplies positive volt-
age input to the encoder. The voltage can be 5 V,
11.3 V, or 12 V.
• Common wire: The common wire supplies the neg-
Fig. 1 (25535-01)
ative voltage input to the encoder.
• Channel A wire: The channel A wire supplies one of The DVOM should show supply voltage. For example,
the output signals from the encoder to the control- a 5 V encoder should have 5 V between the common
ler. and the supply pins.
• Channel B wire: The channel B wire supplies one of Channel feedback overview
the output signals from the encoder to the control-
ler. The encoder sends a digital pulse of supply voltage
• Index wire: Not all encoders have an index wire. from each channel wire. A DVOM is too slow to show
The index wire supplies a center reference point in the pulse signal. The DVOM shows the average volt-
functions such as steering feedback. age as the encoder turns. This voltage is approximately
half of the signal voltage. For example, a 5 V encoder
Testing the encoders sends pulses of 5 V on each channel. The DVOM
shows approximately 2.5 V. A voltage that changes
Testing the encoders helps verify that the data and from an average of 2.5 V indicates a defective encoder.
feedback from the vehicle is accurate.
Supply voltage test
See Figure 1.
1. Connect the black (negative) probe to the common
pin on the encoder.
2. Connect the red (positive) probe to the supply pin
on the encoder.
3. Measure the supply voltage between the common
and the supply pins.
Crown 2011 PF25302 Rev. 3/16 M4.0-1152-080
02 Rev. 3/16
33
ELECTRICAL SYSTEM
Encoders
Channel A feedback test
See Figure 2.
1. Connect the black (negative) probe to the common
pin on the encoder. 2.5 V
2. Connect the red (positive) probe to the channel A
pin on the encoder.
Common 1
3. While activating the motor or component the en-
Index 2 V
coder is attached to, measure the supply voltage
between the common and the channel A pins. Channel A 3
5V 4
Channel B 5
+
2.5 V -
Common 1
Index 2 V
Channel A 3 Fig. 3 (25537-01)
5V 4 The DVOM should show half of the supply voltage. For
Channel B 5 example, a 5 V encoder should have 2.5 V between
the common and the channel B pins.
+
- Index voltage overview
The index wire supplies a signal to show the center or
index position. When the encoder is in the index posi-
tion, the supply voltage is present on the index wire.
Fig. 2 (25536-01) For example, a 5 V encoder sends a 5 V signal on the
index wire when the encoder is in the index position.
The DVOM should show half of the supply voltage. For
example, a 5 V encoder should have 2.5 V between Index voltage test
the common and the channel A pins. See Figure 4.
Channel B feedback test 1. Connect the black (negative) probe to the common
See Figure 3. pin on the encoder.
1. Connect the black (negative) probe to the common 2. Connect the red (positive) probe to the index pin on
pin on the encoder. the encoder.
2. Connect the red (positive) probe to the channel B 3. Measure the supply voltage between the common
pin on the encoder. and the index pins. If supply voltage is not present,
slowly rotate the encoder shaft 360°.
3. While activating the motor or component the en-
coder is attached to, measure the supply voltage
between the common and the channel B pins.
M4.0-1152-081 Crown 2011 PF25302 Rev. 3/16
02 Rev. 3/16
34
ELECTRICAL SYSTEM
Encoders
5.0 V
Common 1
Index 2 V
Channel A 3
5V 4
Channel B 5
+
-
Fig. 4 (25538-01)
When the encoder is in the index position, the DVOM
should show supply voltage. For example, a 5 V en-
coder should have 5 V between the common and the
index pins.
Crown 2011 PF25302 Rev. 3/16 M4.0-1152-082
02 Rev. 3/16
35
Notes:
36
ELECTRICAL
Encoders
Encoders The encoders are located in various locations depend-
ing on application. Refer to Figure 18205-03. If encoder
Encoders are used to verify direction, speed, position does not work properly, use the ACCESS 123®, Ana-
and height on Crown lift trucks. lyzer menus to check encoder inputs. For more infor-
mation, refer to ACCESS 123 section.
1 Steering Command Encoder
2 Lift Height Encoder
3 Traction Encoder (mounted in traction motor)
4 Steering Feedback Encoder
Figure 18205-03
Crown 2007 PF15811-1 Rev. 2/10 M4.0-7335-001
03 Rev. 2/10
131
ELECTRICAL SYSTEM
Electrical System
Electrical System Wire color-codes
See the Wire Color-Codes table for the applicable wire
Wire color-codes and schematic colors. The function of the circuit determines the wire
symbols color. Each wire has a three or four digit number. The
first one or two digits identify the color of the lead. The
This section includes information on wire color-codes last two digits identify the lead from one through 99. It
and schematic symbols that are standard on Crown is possible that some vendor component leads do not
electrical diagrams. have these same numbers or colors. A wire pictorial
identifies each wire by number. See the WIRING DIA-
GRAMS chapter for wire pictorials and electrical dia-
grams.
Wire Color-Codes
Number Color Function
0xx Black Digital Signal (1)
1xx Brown Analog Signal (1)
2xx Red Primary positive that has not gone through a switch (2)
3xx Orange 12 V Non-Battery Positive (3)
4xx Yellow Non-Battery Positive (3)
5xx Green Primary negative that has not gone through a switch (2)
6xx Blue Isolated Negative (4)
7xx Violet 5 V Non-Battery Positive (3)
8xx Gray Non-Battery Positive (3)
9xx White Miscellaneous
29xx Red/White Primary positive that has gone through a switch (2)
59xx Green/White Primary negative that has gone through a switch (2)
(1) Signal - A conductor that gives a variable input or output potential.
(2) Primary- A conductor that gives battery positive potential or battery negative potential.
(3) Non-Battery Positive - A conductor that gives a non-battery positive potential from the output of a regulated
DC-to-DC converter.
(4) Isolated Negative - A conductor that gives a negative potential that is electrically isolated from battery nega-
tive.
Crown 2010 PF17948 Rev. 2/20 M4.1-0000-001
02 Rev. 2/20
179
ELECTRICAL SYSTEM
Electrical System
Power cables
To identify the power cables, see the Power Cables Ab-
breviations table for all lift trucks except the WP 3000
Fig. 3 (8117-01)
Series. For example: PC #1/0-10 is P/N 084572-010.
Power Cables Abbreviations
Abbreviation Part Numbers
Fig. 4 (8118-01)
PC#1 084571
PC#2 084570 Number of terminals
• All terminals are shown even if not connected.
PC#4 084569
PC#6 084568 Momentary contact switch or maintained contact
switch
PC#8 124474
• See Figures 5 and 6 for switches with a momentary
PC#10 090963 contact. A momentary contact is shown as a
PC#1/0 084572 shaded triangle.
PC#2/0 084573
PC#3/0 086749
PC#4/0 137636 Fig. 5 (8119-01)
Switches
The switch symbols show:
• The switch type Fig. 6 (8120-01)
• The number of terminals • See Figures 7 and 8 for switches with a maintained
• If the switch is a momentary contact switch or main- contact. A maintained contact is shown as an open
tained contact switch circle (an open circle also shows the common ter-
minal).
• How the switch is connected
• How the switch operates
• How the switch functions
Fig. 7 (8115-01)
Switch type
• See Figures 1 and 2 for switches with a common
terminal.
Fig. 8 (8117-01)
Fig. 1 (8115-01)
Fig. 2 (8116-01)
• See Figures 3 and 4 for switches without a common
terminal.
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ELECTRICAL SYSTEM
Electrical System
How the switch is connected bols for these switches include the symbols on the ac-
tual switch.
To know how the switch is connected, look carefully at
the contact symbols. An open circle shows a main- Example:
tained contact, thus it is the normally closed terminal. A
shaded triangle shows a momentary contact, thus it is
the normally open terminal. 1
2
Switches that have more than one maintained contact
do not have a normally open or normally closed termi- Fig. 9 (8121-01)
nal, although they can have a common terminal. Sym-
Examples (All Momentary)
With common (Transfer) Without common (Double Break)
Connected normally
open, held open
Fig. 10 (8119-01)
Fig. 11 (8120-01)
Connected normally
open, held closed
Fig. 12 (8122)
Fig. 13 (8123)
Connected normally
closed, held open
Fig. 14 (8115-01)
Fig. 15 (8117-01)
Connected normally
closed, held closed
Fig. 16 (8124) Fig. 17 (8125)
How the switch operates
If it is necessary to include how the switch mechani-
cally operates, there is a note on the electrical diagram.
Function
A reference designator shows the switch function (for
example: FS = forward switch). See the COMPONEN-
TRY chapter for more information on the applicable ref-
erence designators for your lift truck.
Notes:
• On an electrical diagram, the condition of a circuit
includes a note (for example: the lift truck is fully
lowered with no operator on the lift truck).
• See Figure 18 for an example of a positive action
switch.
Fig. 18 (8126-02)
Crown 2010 PF17948-3 Rev. 2/20 M4.1-0000-003
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ELECTRICAL SYSTEM
Electrical System
Specialty switches
• See Figure 19 for a pressure switch.
Fig. 19 (8127)
• See Figure 20 for a reed switch.
Fig. 20 (8128)
• See Figure 21 for a temperature switch.
Fig. 21 (8129)
• See Figure 22 for a brake fluid switch.
Fig. 22 (8130)
• See Figure 23 for a three position key
switch
Start
Acc
Ign
Off
Fig. 23 (8131-01)
M4.1-0000-004 Crown 2010 PF17948 Rev. 2/20
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ELECTRICAL SYSTEM
Electrical System
Switch symbols (Switches that operate mechanically)
Switch Symbols
Actuation Description Number of Momentary Fully Maintained
Terminals
with common without with common without
common common
NO SPST 2
Fig. 24 (34385) Fig. 25 (34386)
SPDT 3
Fig. 26 (34387) Fig. 27 (34388)
SPDT 4
Fig. 28 (34389) Fig. 29 (34390)
DPDT 4
Fig. 30 (34391) Fig. 31 (34392)
DPDT 6
Fig. 32 (34393) Fig. 33 (34394)
DPDT 8
Fig. 34 (34395) Fig. 35 (34396)
NOHC SPST 2
Fig. 36 (34397) Fig. 37 (34398)
SPDT 3
Fig. 38 (34399)
SPDT 4
Fig. 39 (34400)
DPDT 4
Fig. 40 (34401) Fig. 41 (34402)
DPDT 6
Fig. 42 (34403)
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ELECTRICAL SYSTEM
Electrical System
DPDT 8
Fig. 43 (34404)
M4.1-0000-004 Crown 2010 PF17948 Rev. 2/20
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ELECTRICAL SYSTEM
Electrical System
Switch Symbols
Actuation Description No. of Momentary Fully Maintained
Terminals
w/ common without w/ common without
common common
NC SPST 2
Fig. 44 (34405) Fig. 45 (34406)
SPDT 3
Fig. 46 (34407) Fig. 47 (34408)
SPDT 4
Fig. 48 (34409) Fig. 49 (34410)
DPST 4
Fig. 50 (34411) Fig. 51 (34412)
DPDT 6
Fig. 52 (34413) Fig. 53 (34414)
DPDT 8
Fig. 54 (34415) Fig. 55 (34416)
NCHO SPST 2
Fig. 56 (34417) Fig. 57 (34418)
SPDT 3
Fig. 58 (34419)
SPDT 4
Fig. 59 (34420)
DPST 4
Fig. 60 (34421)
Fig. 61 (34422)
DPDT 6
Fig. 62 (34423)
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ELECTRICAL SYSTEM
Electrical System
Switch Symbols
Actuation Description No. of Momentary Fully Maintained
Terminals
DPDT 8
Fig. 63 (34424)
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ELECTRICAL SYSTEM
Electrical System
Other Electrical Symbols
Symbol Name Symbol Name Symbol Name
Signal Flow Cable JC Connector
One Way Unconnected Fixed/Jack
Fig. 64 (34297) Fig. 65 (34308)
Fig. 66 (34319)
Cable
Signal Flow
Unconnected
PC Connector
Simultaneous Plug
Fig. 67 (34298) Insulated
Fig. 68 (34309) Fig. 69 (34320)
CA
1
Fig. 70 (34299) Signal Flow Junction Connector
Alternate Fig. 71 (34310) Point 2 Assembly
Fig. 72 (34321)
Chassis 1 2 3 4 5 Terminal
Resistor
Ground Strip
Fig. 74 (34311)
Fig. 73 (34300) Fig. 75 (34322)
* A-Analog
B-Battery Ground
L-Logic T-Connection SIP Resistor
* Return
Fig. 77 (34312)
Fig. 76 (34301) Fig. 78 (34323)
Test Double
Pot
Point Junction
Fig. 79 (34302)
Fig. 80 (34313) Fig. 81 (34324)
Cable Mast
Rheostat
Shielded Cable
Fig. 83 (34314)
Fig. 82 (34303) Fig. 84 (34325)
Cable Power
Heater
Twisted Pair Termination
Fig. 86 (34315) Fig. 87 (34326)
Fig. 85 (34304)
Cable Mult- Female/ T Thermistor
Twisted Pairs Socket
Fig. 89 (34316) Fig. 90 (34327)
Fig. 88 (34305)
Cable Multi-
Conductor Fig. 92 (34317)
Male/Pin U Mov/Transzorb
Fig. 93 (34328)
Fig. 91 (34306)
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ELECTRICAL SYSTEM
Electrical System
Other Electrical Symbols
Symbol Name Symbol Name Symbol Name
Cable Multi- Capacitor
Socket and Pin
Conductor Fig. 95 (34318) Fig. 96 (34329) Nonpolarized
Fig. 94 (34307)
+
Capacitor N-FET With
Battery
Polarized Diode Clamp Fig. 99 (34355)
Fig. 97 (34330)
Fig. 98 (34344)
P-FET With Contactor
Current Shunt
Fig. 100 (34331) Diode Clamp Fig. 102 (34356) Normally Open
Fig. 101 (34345)
Contactor
Motor Field,
Inductor Normally
Series
Fig. 103 (34332) Fig. 104 (34346) Closed
Fig. 105 (34357)
Motor Field,
LVDT Coil
Shunt
Fig. 106 (34333) Fig. 107 (34347) Fig. 108 (34358)
Series Motor, Coil
Fig. 109 (34334) Ferrite Bead M
DC Fig. 111 (34359) Suppression
Fig. 110 (34348)
M Fuse-Band
Shunt Motor,
Diode Fig. 114 (34360) Shows Positive
DC
Fig. 112 (34335) Feed
Fig. 113 (34349)
Permanent
M
LED Magnet Tach Sensor
Fig. 115 (34336) Motor Fig. 117 (34361)
Fig. 116 (34350)
Separately TT
Zener Diode M Excited Hour Meter
Fig. 118 (34337) Motor, DC Fig. 120 (34362)
Fig. 119 (34351)
M
SCR 3
Motor, AC Lamp
Fig. 121 (34338) Fig. 122 (34352) Fig. 123 (34363)
M4.1-0000-008 Crown 2010 PF17948 Rev. 2/20
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ELECTRICAL SYSTEM
Electrical System
Other Electrical Symbols
Symbol Name Symbol Name Symbol Name
Transistor
Transformer Horn
NPN
Fig. 124 (34339) Fig. 125 (34353) Fig. 126 (34364)
DC/DC
Transistor Converter
Encoder
Fig. 127 (34340) PNP Fig. 128 (34354) Power
Supply
Fig. 129 (34365)
Darlington + –
Suppressor 077728, 085670, 091181
Suppressor
NPN 077732
Fig. 130 (34342) Fig. 131 (34366) Fig. 132 (34367)
1 2 34 5
Darlington Dual
Suppressor
PNP 085484, 086755 115487 Suppressor
Fig. 133 (34343)
Fig. 134 (34368) Fig. 135 (34369)
+ – +
Dual 1 3
82495, 086322, 093757
OR Gate
Suppressor 112533 5 Filter Block
Fig. 136 (34370) Fig. 138 (34372)
Fig. 137 (34371)
Schmitt
NOR Gate Schmitt NAND
Neutralizer
Fig. 139 (34373) Fig. 140 (34374) Fig. 141 (34375)
Schmitt
Amp/Comp AND Gate
Inverter
Fig. 142 (34376) Fig. 143 (34377) Fig. 144 (34378)
NAND Gate X-OR Gate X-NOR Gate
Fig. 145 (34379) Fig. 146 (34380) Fig. 147 (34381)
Integrated
Circuit
Fig. 148 (34382)
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Notes:
190
ELECTRICAL
Electrical System
Electrical System circuit in which it is used. Each wire is assigned a three
or four digit number. The first one or two numbers iden-
The following is an explanation of terms and symbols tify the color of the lead. The last two numerals number
which are standard on Crown wiring diagrams. the lead from one thru ninety-nine. Exceptions to this
can be component leads supplied by vendors. Each
wire is identified by a number on a wiring pictorial (refer
Wiring Color Codes to section DIA).
Wires are limited to the colors shown in the chart be-
low. The color of the wire is based on the function of the
Wiring Color Codes Chart
Number Color Function
0** Black Traction Inputs/Outputs
1** Brown Analog Inputs
2** Red Battery Positive
3** Orange Non-Battery Positive
4** Yellow Status Inputs/Outputs
5** Green Battery Negative
6** Blue Isolated Negative
7** Violet Load Position Inputs/Outputs
8** Gray Indicators and Warning Devices
9** White Miscellaneous
29** Red Stripe/White Positive that has gone thru a switch
59** Green Stripe/White Negative that has gone thru a switch or resistor
Power Cables
Except WP trucks, power cables are designated using Power Cables Abbreviations Chart
one of the following abbreviations, followed by a dash
number. Abbreviation Part Numbers
PC#1 084571
PC#2 084570
PC#4 084569
PC#6 084568
PC#10 090963
PC#1/0 084572
PC#2/0 084573
PC#3/0 086749
An example of such a cable is PC # 1/0 - 10. The part
number for this cable is 084572-010.
Crown 2000 PF11845-1 Rev. 10/06 M4.1-2720-001
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ELECTRICAL
Electrical System
Component Abbreviations and Designators
Component Abbreviations and Designators
REC Rectifier
Components
RES Resistor
1AD 1A Bypass Driver
SB Suppressor Block
ALM Alarm
SSC Safety Switch Card
ATD Anti Tie Down Module
SV Hydraulic Solenoid
BATT Battery
SVA Solenoid Valve - Accessory
BDI Battery Disch. Interrupt
SVL Solenoid Valve - Lower
BRK Brake
SVP Solenoid Valve - Pilot
CA Connector Assembly
SVR Solenoid Valve - Reach
CAP Capacitor
SVS Solenoid Valve - Sideshift
DB Diode Block
SVT Solenoid Valve - Tilt
DFR Defrost
TB Terminal Board
DMC Dual Motor Card
TD Time Delay
DR Driver Module
TDR Time Delay Relay
ECN Encoder
TMM Truck Management Module
FAN Fan
TP Test Point
FIL Filter
TT Hour Meter (Truck Time)
FLS Flasher
V Discharge or Volt Meter
FU Fuse
XC Socket for PC Board
HF Hash Filter
Contactor and Relays
HN Horn
A Speed Contactor
HR Heater
B Speed Contactor
HSC High Speed Card
C Speed Contactor
JC Fixed Part of Ca
D Dual Contactor
LGT Light
ED Emerg. Disc. Contactor
M Motor
F Forward Contactor
MCR Motor Control
FA Forward Contactor A
PC Movable Part of Ca
FB Forward Contactor B
PCVA "Pressure Compensated Valve, Acc."
FW Field Weakening
PCVH "Pressure Compensated Valve, Hoist"
K Relay
PMTD Pulse Monitor Trip Driver
P Pump Contactor
POT Potentiometer
R Reverse Contactor
PS Power Supply
RA Reverse Contactor A
PS Pressure Switch
RB Reverse Contactor B
M4.1-2720-002 Crown 2000 PF11845-2 Rev. 10/06
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132
ELECTRICAL
Electrical System
Component Abbreviations and Designators Component Abbreviations and Designators
RGB Regen. Braking Contactor DTS Drive Tow Switch
S Power Steering Contactor ECS Elevation Control Switch
1A Bypass Contactor EDS Emergency Disconnect Switch
Switches EIS Extend In Switch
1AS Traction Bypass Switch EMS Emergency Switch
ACC Accessory Switch ENS Entry Switch
ACS Accelerator Switch EOS Extend Out Switch
AHS Aux. Height Switch ERLS Emergency Raise/Lower Switch
AS Switch For A Contactor ERS Erase Switch
AxA Aux. Sw. on A Contactor EXS Extend Switch
AxB Aux. Sw. on B Contactor FHS Fork Home Switch
AxC Aux. Sw. on C Contactor FKS Fork Switch
AxF Aux. Sw. on Fwd. Contactor FLMCS Forward Left Motor Cover Sw
AxR Aux. Sw. on Rev. Contactor FLS Fork Left Switch/Free Lift Switch
AXS Aux. Function Switch FNS Fan Switch
BFS Brake Fluid Switch FRMCS Forward Right Motor Cover Sw
BLS Battery Latched Switch FRS Fork Right Switch
BMS Brake Monitor Switch FS Forward Switch
BPS Brake Pressure Switch FTS Foot Guard Switch
BRES Battery Restraint Switch GCSL Gate Closed Switch Left
BRS Brake Switch GCSR Gate Closed Switch Right
BS Switch For B Contactor GOSL Gate Open Switch Left
CHS Chain Switch GOSR Gate Open Switch Right
CHSL Chain Switch Left GTS Gate Switch
CHSR Chain Switch Right GUS Guidance Switch
CLS Clamp Switch HCS Height Cable Switch
CS Switch For C Contactor HGTS Height Switch
CTS Cable Tension Switch HNS Horn Switch
DIS Direction Switch HSS High Speed Switch
DMS Dead Man Switch HTS Heater Switch
DMSL Dead Man Switch Left HTSXX Height Switch (XX Inches)
DMSR Dead Man Switch Right KORS Key Override Switch
DPS Display Switch KYS Key Switch
DRS Door Switch LCS Lower Cutout Switch
Crown 2000 PF11845-3 Rev. 10/06 M4.1-2720-003
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ELECTRICAL
Electrical System
Component Abbreviations and Designators Component Abbreviations and Designators
LGS Light Switch SWH Operator Activated Switch
LMS Limit Switch TBS Tilt Back Switch
LOS Lower Switch TDS Tilt Down Switch
LTS Loadtray Switch TES Test Switch
MFS Multi-funciton Switch THS Thermal Switch
MVS Multi-voltage Switch TLS Traverse Left Switch
NUS Null Switch TLT Tilt Switch
ORS Override Switch TRS Traverse Right Switch
PLS Pivot Left Switch TUS Tilt Up Switch
PORS Presence Overide Switch TVS Traverse Switch
PRS Pivot Right Switch ZSS Zone Select Switch
PS Pressure Switch Terms
PTS Pivot Switch ASM Assembly
PUS Pump Switch CTRL Control
QPS Quick Pick Switch CTRLR Controller
RAS Raise Switch DESIG LIST Designation List
RES Reach Extended Switch DIST PNL Distribution Panel
RGS Rail Guide Switch DSPL Display
RGSL Rail Guidance Switch Left F/C Freezer Conditioning
RGSR Rail Guidance Switch Right HCM Hydraulic Control Module
RIS Reach In Switch HDL Handle
RLMCS Rear Left Motor Cover Switch HYD Hydraulic
ROS Reach Out Switch OHG Overhead Guard
RRMCS Rear Right Motor Cover Switch PCB Printed Circuit Board
RS Reverse Switch PICT Pictorial
RSS Sheet Retainer Switch PKT Packet
SAS Safety Switch PL Platform
SCS Sideshift Center Switch PWR Power
SES Seat Switch PWR SPLY Power Supply
SLS Sideshift Left Switch SCHEM Schematic
SQS Sequence Switch TCM Traction Control Module
SRS Sideshift Right Switch TMM Truck Management Module
SSS Sideshift Switch TRAC Traction
STS Power Steer Switch
M4.1-2720-004 Crown 2000 PF11845-4 Rev. 10/06
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ELECTRICAL
Electrical System
Switches Momentary or Maintained Contact
Switch symbols convey: • Momentary contact is a shaded triangle.
1. Type of switch.
2. Number of terminals.
3. Momentary or maintained contact. Figure 8119-01
4. How the switch is held and wired. or
5. How the switch is activated.
6. Application.
Figure 8120-01
Type of Switch
• Maintained is an open circle (an open circle also
• With common denotes the common terminal).
Figure 8115-01 Figure 8115-01
or or
Figure 8117-01
Figure 8116-01
How the Switch is Held and Wired
• Without common To determine how the switch is held and wired, look
closely at the contact symbols. An open circle denotes
a maintained contact so therefore it is the normally
closed terminal. A shaded triangle denotes a momen-
Figure 8117-01 tary contact, therefore it is the normally open terminal.
or Switches having more than one maintained contact do
not have a normally open or normally closed terminal,
although they may have a common. Symbols for these
switches include the markings present on the actual
switch.
Figure 8118-01
Example:
Number of Terminals
• All terminals are shown even if not wired.
Figure 8121-01
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ELECTRICAL
Electrical System
Examples (All Momentary)
With Common (Transfer) Without Common (Double Break)
Wired normally
open, held open
Figure 8119-01 Figure 8120-01
Wired normally
open, held closed Figure 8122
Figure 8123
Wired normally
closed, held open
Figure 8115-01 Figure 8117-01
Wired normally
closed, held closed Figure 8124 Figure 8125
How the Switch is Activated
If it is necesary to include how the switch is mechani-
cally actuated, a note will be added to the drawing (ex-
ample: operator, lever or truck actuated, etc.)
Application
Switch application is conveyed through the abbrevia-
tion (example: HTS = Height Switch 120 in., DTS =
Drive/Tow Switch).
Notes:
• In a schematic, the condition of a circuit is defined
using a note (example: vehicle shown fully low-
ered with no operator on vehicle).
• Positive action switches are marked with the fol-
lowing symbol:
8126-02
M4.1-2720-006 Crown 2000 PF11845-6 Rev. 10/06
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136
ELECTRICAL
Electrical System
Switch Symbols (Mechanically activated switches)
No. of Momentary Fully Maintained
Actuation Description
Terminals w/common w/o common w/common w/o common
Figure 8100-01
Crown 2000 PF11845-7 Rev. 10/06 M4.1-2720-007
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137
ELECTRICAL
Electrical System
Switch Symbols (Mechanically activated switches)
Continued
No. of Momentary Fully Maintained
Actuation Description Terminals w/common w/o common w/common w/o common
Figure 8101-02
M4.1-2720-008 Crown 2000 PF11845-8 Rev. 10/06
03 Rev. 10/06
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ELECTRICAL
Electrical System
Specialty Switches
Pressure Switch
Figure 8127
Reed Switch
Figure 8128
Temperature Switch
Figure 8129
Brake Fluid Switch
Figure 8130
Three Position Key Switch
Start
Off
Figure 8131-01
Crown 2000 PF11845-9 Rev. 10/06 M4.1-2720-009
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139
ELECTRICAL
Electrical System
Other Electrical Symbols
Signal Flow Terminal
Heater
One Way Strip
Signal Flow
Simultaneous T-Connection Thermistor
Signal Flow
Double Mov/
Alternate
Junction Transzorb
Chassis
Ground Mast Cable
Capacitor
Common Power Nonpolarized
Return Termination
Capacitor
Female/ Polarized
Test Point Socket
Current
Male Shunt
Cable Pin
Shielded Inductor
Cable Socket & Pin
Twisted Pair
LVDT
Connector
Fixed/Jack
Cable Multi- Ferrite Bead
Twisted Pairs Connector
Moveable/
Plug
Diode
Cable Multi-
Conductor Connector
Assembly
LED
Cable Multi-
Conductor Resistor
Zener Diode
Cable SIP Resistor
Unconnected SCR
Cable
Unconnected Pot
Transistor
Insulated
NPN
Junction
Point Rheostat
Figure 8132-02
M4.1-2720-010 Crown 2000 PF11845-10 Rev. 10/06
03 Rev. 10/06
140
ELECTRICAL
Electrical System
Other Electrical Symbols
Transistor DC/DC
Dual
PNP Converter
Suppressor
Power Supply
Darlington Battery
NPN Dual
Contactor Suppressor
Normally
Darlington Open
PNP
Contactor Filter Block
Normally
N-FET With
Closed
Diode Clamp
Coil OR Gate
P-FET With
Diode Clamp Coil NOR Gate
Suppression
Motor Field, Fuse - Band Schmitt NAND
Series Shows Positive
Feed
Motor Field,
Shunt Tach Sensor Schmitt
Buffer
Series Motor, Hour Meter
DC Schmitt
Inverter
Lamp
Shunt Motor,
Amp/Comp
DC
Horn
Permanent AND Gate
Magnet
Encoder
Motor
NAND Gate
Suppressor
Separately
Excited Motor, DC X-OR Gate
Suppressor
Motor, AC X-NOR Gate
Suppressor
Transformer Integrated
Circuit
Figure 8133-02
Crown 2000 PF11845-11 Rev. 10/06 M4.1-2720-011
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141
ELECTRICAL
Motor Monitoring System (MMS)
Motor Monitoring System (MMS)
Seven inputs of the truck management system are
used to monitor the traction motor and both pump mo-
tors. Each motor contains one temperature sensor and
two brushwear sensors. The information is communi-
cated to the traction controller. The information is then
communicated to the display. The display will light the
appropriate LED and tell the operator which motor the
overtemperature or the brush-wear event is occurring. Figure 18234
A Motor Monitoring System (MMS) event will not inhibit
any truck functions. The traction controller will only
check the status when passing through neutral.
(a) Distribution Panel Freezer/Corrosion
(Not Shown) (Optional)
(b) Access 6 Guidance Control Module
(GCM) (Optional)
(c) Access 5 Steering Control Module (SCM)
(d) Access 3 Traction Control Module (TCM)
(e) Traction Motor
(f) Lift Pump Motor
(g) Lift Pump Motor
(h) Distribution Panel (Power Unit)
Figure 18235-01
Crown 2007 PF17137-1 Rev. 12/07 M4.2-7335-200
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135
ELECTRICAL
Motor Monitoring System (MMS)
Testing Motor Monitoring System Temperature Sensors: To test a pump motor thermal
sensor. Remove the wire harness connections from the
(MMS) motor thermal sensor, short the harness wire ends to-
General Description: Each SP3500 pump motor has 2 gether and command lift. The thermal fault shall be in-
active low brushwear outputs that connect to the distri- dicated on the display as "Lift 1" or "Lift 2" and logged
bution panel and 1 active high temperature sensor out- in the fault history. Test the traction motor thermal sen-
put that connects to Access3 (TCM) (MMS circuit). The sor by unplugging CA411 and commanding traction to
2 temperature sensors connect to CA401-10 and log to sensor fault event. Refer to Charts 1 and 2 for
CA401-13 and the 4 brushwear indicators are summed location and fault codes.
to a single signal that connects to CA401-7. The AC Brushwear Sensors: To test the pump motor brush-
traction motor active high temperature sensor con- wear sensors. Remove the harness connection to a
nects to Access3 CA401-16. Motor faults are for- brushwear sensor, jumper the wire end to - BV at the
warded to the display and can be accessed to deter- distribution panel TP3 and command lift. The brush
mine which motor is experiencing the temperature or fault shall be indicated on the display as "Lift 1" or "Lift
brush fault. MMS faults do not inhibit any truck func- 2" and logged in fault history. Refer to Charts 1 and 2
tions. for location and fault codes.
Chart 1 - Sensor Information
Sensor Location T.M.M. Terminal
Temperature M1 Traction Motor M1 CA401-16
Temperature M3 Pump Motor M3 CA401-10
Temperature M4 Pump Motor M4 CA401-13
Brushwear M3A Pump Motor M3 CA201-15
Brushwear M3B Pump Motor M3 CA201-16
Brushwear M4A Pump Motor M4 CA201-13
Brushwear M4B Pump Motor M4 CA201-14
Chart 2 - Fault Information
Character Dis-
Active Sensor Icon Fault History
play
M1 Thermal Traction (M1) Over temperature 328
M1 Thermal Traction (M1) Sensor fault 329
M3 Thermal Lift 2 (M4) Over temperature 396
M4 Thermal Lift 1 (M3) Over temperature 397
M3 Brush A Lift 1 (M3) Brushwear 398
M3 Brush B Lift 1 (M3) Brushwear 398
M4 Brush A Lift 2 (M4) Brushwear 398
M4 Brush B Lift 2 (M4) Brushwear 398
M4.2-7335-201 Crown 2007 PF17137-2 Rev. 12/07
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136
ELECTRICAL
Motor Monitoring System (MMS)
(a) M1 Thermal Switch Open Upon Event
(b) M3/M4 Thermal Switches Close Upon Event
(c) M3/M4 Brushwear Switches Short to Motor Negative or Positive Upon Event
Figure 12523-03
Crown 2007 PF17137-3 Rev. 12/07 M4.2-7335-202
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137
ELECTRICAL
Wire Guidance
Wire Guidance The Crown line driver is equipped with a current meter
which accurately displays the line current within the
conductor. This reading, however, due to floor condi-
Line Driver Output tions (wire depth, metal reinforcement material, electri-
cal conduit, etc.) may not indicate the actual field
Verify that the line driver output signal is of the correct strength. Therefore, to meet the field strength required
amplitude prior to performing an alignment on the to properly guide the vehicle, the line driver output will
truck. have to be adjusted. Refer to the Installation of Wire
Crown has designed a field strength meter for use in Guidance Line Driver Instructions, PF6669.
setting up and/or checking guide wire signal strength
(5.0 Khz to 10.0 Khz) in wire guidance installations.
Chart 1 - Field Strength Cross Reference
Frequency in kHz Field Strength Values
6.25 kHz 168-190
5.2 kHz 100-118
7.0 kHz 168-190
10.0 kHz 100-120
Figure 1550-01
The field strength meter, Crown part number 112953,
will indicate actual peak to peak voltage of the radiated
signal from the guide wire in the floor. This reading rep-
resents what the truck is seeing when the sensors are
set at the recommended height from the floor. Refer to
Chart 1 - Field Strength Cross Reference for optimum
field strength values.
Crown recommends calibration of this meter annually,
and will perform this service free. Any repairs needed
for calibration will incur a reasonable charge. Please
allow a minimum of two weeks for normal calibration.
Meters needing repair may require additional time.
Meters will be returned freight collect. For information
regarding the field strength meter, refer to Technical
Service Bulletin No. 317.
Crown 1999 PF11765-1 Rev. 7/08 M4.3-7330-702
01 Rev. 7/08
22
ELECTRICAL
Wire Guidance
Figure 17183-01
1 Line Driver
2 Storage Racks
3 Transmitted Signal
4 Floor
5 Epoxy
6 Wire Embedded in Floor (Saw Cut)
M4.3-7330-703 Crown 1999 PF11765-2 Rev. 7/08
01 Rev. 7/08
23
ELECTRICAL SYSTEM
Access 1 2 3® Menus
Access 1 2 3® Menus
1 2 3
6 5 4
1 Message display
2 Navigation arrows - up, down, left, right
3 Enter or return key
4 Wire guidance display (optional)
5 Performance level (P1, P2, P3) indicators
6 Battery discharge indicator
Fig. 1 (17869-04)
Access 1 display Operator level 1
Access 1 display messages and menus can be ac- The operator level is accessed by turning on the lift
cessed from three levels of authorization: truck. The operator may choose from the following op-
tions (provided a higher priority message is not active):
1. Operator level
• Message (for example BDI = 70%)
2. Service level 2
• Hour
3. Service level 3 • Events
Typical navigation button usage: up and down arrows • Service
scroll through menu choices, right arrow enters a menu • Performance
and left arrow exits the current menu. The enter or re-
turn button is used to select a function or choice. The following messages are displayed in order of prior-
ity (if enabled), regardless of operator selection:
1. PM Due
2. User Code
3. Static Return to OFF (SRO) or Advise Message
4. Operator selected message
If any message is more than eight characters, it scrolls
across the display from right to left.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
After turning on the lift truck, the display always shows Steer - Message mode
SP 3500 regardless of which menu was selected be-
fore turning off the lift truck. To change the message This menu allows the operator to display the approxi-
displayed after turning on the lift truck, enter the Mes- mate steer tire position on the eight character display.
sage Mode and select one of the other choices. A more If the lift truck is operating in other message modes, the
detailed Message Mode explanation follows. approximate steer tire position is displayed on the eight
character display whenever the operator is depressing
the brake pedal and remains until the lift truck is travel-
ing at a slow speed. Once the lift truck begins travel,
CAUTION the steer indicator goes away, allowing other mes-
When replacing or updating software for the sages to be displayed. If the operator prefers to have
Access 1 2 3® modules, settings and calibrations for the steer indicator present at all travel speeds, then the
those modules need to be verified to ensure correct lift operator would select Steer as the message mode. To
truck operation. select this message, turn on the lift truck. Press the
right arrow button to enter the Message Mode. Use the
up or down arrows to scroll to Steer. Press the enter or
After turning on the lift truck, SP 3500 is displayed until return button. The display exits the Message Mode and
a different message mode menu is selected. shows (Steer ^).
Message mode Model - Message mode
To enter the Message Mode, turn on the lift truck. With This menu allows the operator to display the generic lift
a Message (for example BDI = 70%) present on the truck model. It is intended to be used in locations where
display, press the right arrow to enter this menu. Press the operator has no need for the other message mode
the up or down arrows to scroll through menu choices: choices. To select this message, turn on the lift truck.
Press the right arrow button to enter the Message
1. Steer Mode. Use the up or down arrows to scroll to Model.
2. Model Press the enter or return button. The display exits the
Message Mode and shows (SP 3500).
3. Timer
Timer - Message mode
4. Trip
This menu allows the operator to display a stopwatch.
5. BDI To select this message, turn on the lift truck. Press the
6. Hours right arrow, use the up or down arrows to display Timer.
Press the right arrow to enter the Timer menu. Use the
7. Odometer up or down arrows to scroll through choices:
8. Speed • Stop
Technician Tips: Message Mode is controlled by the • Start
Features menu (F26). F26 allows one of the message • Reset
choices (in which case the operator cannot scroll
through any choices) or ALL. Timer - Start
Press the enter or return button. The display exits the
Message Mode and displays;
Stopwatch (00:00:00), and starts counting.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Timer - Stop Hours - Message mode
Use the up or down arrows to display Stopwatch. Press This menu allows the operator to display accumulated
the right arrow to enter the Message Mode. Use the up runtime hours. To select this message, turn on the lift
or down arrows to display Timer. Press the right arrow truck. Press the right arrow. Use the up or down ar-
to enter the Timer menu. Use the up or down arrows to rows, scroll to Hours. Press the enter or return button.
display Stop, press the enter or return button. The dis- The display exits the Message Mode and shows H1 or
play exits the Message Mode and shows that the Stop- H2 = XX). H1 or H2 hours can be shown depending on
watch stopped, with whatever amount time accumu- which hour meter is selected in Features menu F28
lated (for example, 01:01:32). Hour Meter. See Hour for an explanation of hour me-
ters.
Timer - Reset
Odometer - Message mode
Use the up or down arrows to display the Stopwatch.
Press the right arrow to enter the Message Mode. Use Press the right arrow. Use the up or down arrows to
the up or down arrows to display Timer. Press the right scroll to Odometer. Press the enter or return button.
arrow to enter the Timer menu. Use the up or down The display exits the Message Mode and shows the
arrows to display Reset. Press the enter or return but- distance the lift truck has traveled, in miles (mi=XX) or
ton. The display exits the Message Mode. The Stop- kilometers (km=XX).
watch is zeroed, and not counting (00:00:00).
Speed - Message mode
Trip - Message mode This menu allows the operator to display the travel
This menu allows the operator to display the distance speed. Press the right arrow button to enter the Mes-
traveled in either direction since the last reset. To se- sage Mode. Use the up or down arrows to scroll to
lect this message, turn on the lift truck. Press the right Speed. Press the enter or return button. The display
arrow to enter the Message Mode. Use the up or down exits the Message Mode and shows the travel speed in
arrows to scroll to Trip. Press the enter or return button miles per hour (X.X mph) or kilometer per hour
and the display exits the Message Mode. The display (X.X kph).
shows ft=00000 or m=00000.
Trip - Reset
Press the right arrow to enter Message Mode. Use the
up or down arrows to display Trip. Press the right arrow
to display Reset. Press the enter or return button. The
display exits Message Mode and displays distance
traveled reset ft=00000 or m=00000.
BDI - Message mode
This menu allows the operator to display the battery
percent of remaining charge. To select this message,
turn on the lift truck. Press the right arrow to enter the
Message Mode. Use the up or down arrows to scroll to
BDI. Press the enter or return button. The display exits
the Message Mode and shows (BDI = XX%).
Crown 2007 PF15813 Rev. 5/21 M4.3-7335-003
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Hour blank boxes are displayed. Use the up and down ar-
rows to enter the first digit of the password. Press the
This menu allows the operator to view one of twelve right arrow to move to the next digit, continue until the
different hour meter readings. final digit is entered. Press the enter or return button to
• H1 (key on, lift truck being used) accept the password.
• H2 (key on, lift truck being used plus delay) After the password is accepted, the following menus
• H3 (odometer) are displayed:
• H4 (lift motor on time) • Analyzer (A1, A2, and A3 submenus)
• H5 (platform on time) • Features
• H6 (traction motor on time) • Performance
• H7 (steer motor on time) • Calibration
• H8 (Access 1 on time) • Hour
• H9 (Access 3 on time) • Events
• H10 (Access 4 on time) • Utilities
• H11 (Access 5 on time) An explanation of these menus is located after the
• H12 (Access 6 on time) menu tables in this section of the service manual.
To enter this menu, turn on the lift truck. Press the
down arrow to display Hour. Press the right arrow, H1
is displayed. Use the up or down arrows to view differ-
ent hour meter readings. To stop the message from
scrolling, press the right arrow at the desired hour me-
ter. To exit Hour menu, press the left arrow until Hour
is displayed.
Events
This menu allows the operator to view stored event
codes (up to 16). To enter this menu, turn on the lift
truck. Press the down arrow until Events is displayed.
Press the right arrow, Last is briefly displayed. The last
event code stored is then displayed (EV=XXX). Use
the up or down arrows to scroll through stored event
codes (Last to Last-15). Press the left arrow button to
return to the main menu at Events.
Technician Tips: Event codes cannot be cleared from
the Operator level menu.
Service levels
This menu enters maintenance levels 2 and 3. A pass-
word is required to enter maintenance levels. Contact
the local Crown dealer to obtain this password.
Technician Tips: Once maintenance Levels 2 or 3 are
entered, the lift truck must be turned off and then on to
exit the Service menu.
Level 2
To enter Level 2, turn on the lift truck. Press the down
arrow until Service is displayed. Press the right arrow,
Level 2 is displayed. Press the right arrow and four
M4.3-7335-004 Crown 2007 PF15813 Rev. 5/21
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Level 3 Performance
The lift truck is not operational in Level 3. To enter this This menu allows the operator to choose one of three
level, without pressing the brake pedal, turn on the lift performance modes to operate the lift truck.
truck. Press the down arrow until Service is displayed.
Press the right arrow and Level 2 is displayed. Press Technician Tips: Only if Operator Performance is en-
the down arrow and Level 3 is displayed. Enter the abled in the Features menu (F20):
password using the same password and procedures • P1 (maximum achievable performance level)
as entered in Level 2. • P2 (reduced performance from maximum, similar to
The difference between level 3 and level 2 are: previous model)
• The Analyzer A3 Outputs submenu is not available • P3 (used where operational conditions require low-
in level 3 (only level 2). est lift truck performance)
• The Analyzer A4 Test Outputs submenu is avail- To enter the Performance menu, turn on the lift truck.
able in level 3 (not in level 2). Use the up or down arrows to scroll to Performance.
• The Calibration menu is not available in level 3 Press the right arrow, and P1, P2, or P3 is displayed.
(only level 2). Use the up or down arrows to display a different perfor-
mance level. Once the desired level is displayed, press
• Hour meters can be viewed in both level 2 and level
the enter or return button to select. Press the left arrow
3. However, meters can only be changed in level 3.
button to return to the main menu at Performance.
An explanation of these menus is located after the
Technician Tips: The factory standard settings for the
menu tables in this section of the service manual.
P1 performance level are set to achieve maximum per-
formance. The factory standard settings for P2 are
slower, and the factory standard settings for P3 are the
slowest. However, by customizing the settings, any
performance level, P1, P2, or P3, can be higher, lower,
or the same as any other performance level. For exam-
ple, the P1 settings could be customized to be slower
than or equal to the P3 standard settings. For more in-
formation, see the Performance menu explanations fol-
lowing the menu tables in this section of the service
manual.
Crown 2007 PF15813 Rev. 5/21 M4.3-7335-005
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Operator Level 1 - User Code and Message Mode Menus
continued from page -008
User Codes Code 1 Password
Code 2 Password
Code 25 Password
Message Mode Menus
Allows the operator to select what is displayed in mes-
sage mode, if no higher priority items are active. Also
Message Mode Steer
allows the operator to control the trip meter and timer.
Only the appropriate menus are made visible based on
features menu F26 Message Mode setting. SP 3500 is
Model
displayed until an item from the menu is chosen
Timer Stop
Trip Reset Start
Reset
BDI
Message Mode Priority
Hours
1 PM Due (if H13 PM Timer menu is not set to NONE)
2 User Code (if F21 User Codes menu is enabled)
3 SRO / Advise Message
Odometer 4 Operator Selected Message
continued on page -007
Speed
Fig. 2 (17902-03)
M4.3-7335-006 Crown 2007 PF15813 Rev. 5/21
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Operator Level 1 - Hour Menus
continued from page -006
continued on page -008
Fig. 3 (17903-02)
Crown 2007 PF15813 Rev. 5/21 M4.3-7335-007
09 Rev. 5/21
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Operator Level 1 - Event, Service, and Performance Menus
continued from page -007
Events Last EV=___ XX
Last-1 EV=___ XX
Last-2 EV=___ XX
Last-3 EV=___ XX
Last-15 EV=___ XX
Service Level 2 Password
Level 3 Password
Performance P1
P2
continued on page -006
P3
Fig. 4 (17904-03)
M4.3-7335-008 Crown 2007 PF15813 Rev. 5/21
09 Rev. 5/21
208
ELECTRICAL SYSTEM
Access 1 2 3® Menus
Service Level 2 and 3 - Analyzer Menus
continued from page -033
A1.1 Full Speed Enable/Disable
Hydraulics=__
A1.2 Lower=______ Enable/Disable
A1.3 Raise=______ Enable/Disable
A1.4 Full Traction=_ Enable/Disable
A1.5 Limp Traction=_ Enable/Disable
A1.6 Steering=___ Enable/Disable
continued on page -016
A1.7 ED=_______ Enable/Disable
A1.8 Module=____ Enable/Disable
A2.1 Access1 continued on page -010
A2.2 Access3 continued on page -010
A2.3 Access4 continued on page -010
A2.4 Access5 continued on page -011
A2.5 Access6 continued on page -012
A3.1 Access1 continued on page -012
A3.2 Access3 continued on page -013
A3.3 Access4 continued on page -013
A3.4 Access5 continued on page -014
A4.1 Access1 continued on page -015
A4.2 Access3 continued on page -015
A4.3 Access4 continued on page -015
A4.4 Access5 continued on page -015
Fig. 5 (17905-03)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Access 1 Inputs
continued 0 = switch open
0/1
from page - 1 = switch closed
009 0 = switch open
0/1 1 = switch closed
0 = switch open
0/1 1 = switch closed
Access 3™ Inputs
continued PUF = Positive
from page - FF = Negative
009 PUF = Positive
FF = Negative
0 = switch open
0/1 1 = switch closed
0 = switch open
0/1 1 = switch closed
0 = switch open
0/1 1 = switch closed
0 = switch open
0/1 1 = switch closed
approx. 10.3 Volts = New brushes
approx. 1.0 Volts = Replace brushes
Approximate battery volts
Access 4 Inputs
continued A2.3.1 ECR4 A2.3.1.1 Height=_____ ____cm (in) Fork height
from page -
009 A2.3.1.2 Speed=______ ___cmps (ips)
A2.3.1.3 Cnt=______ ____cnt Lifting = increasing
Lower = decreasing
A2.3.2 ECR1/ECR5=______ _/_ count CCW = increasing
CW = decreasing
A2.3.3 POT1 A2.3.3.1 Raw=_____ ____volt Max FF = approx 0.8 V
Neutral = approx 2.6 V
Max PUF = approx 4.6 V
A2.3.3.2 Scaled=______ ____% Max FF = approx 16%
A2.3.4 RAS3/RAS4=______ 0 = switch open Neutral = approx 50%
0/1
1 = switch closed Max PUF = approx 92%
A2.3.5 LOS3/LOS4=______ 0/1 0 = switch open
1 = switch closed
A2.3.6 RS=______ 0/1 0 = switch open
1 = switch closed
A2.3.7 FS=______ 0/1 0 = switch open
1 = switch closed
A2.3.8 CHS1/CHS2=______ 0/1 0 = switch open
1 = switch closed
continued from page -011
Fig. 6 (17907-03)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -010
Access 4 Inputs Continued
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
Access 5 Inputs
CCW = decrease
continued CW = increase
from page
-009
Battery volts
Battery volts
Brake applied = Battery volts
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
Factory Use Only
Fig. 7 (17909-03)
Crown 2007 PF15813 Rev. 5/21 M4.3-7335-011
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Access 6 Inputs
continued
from page -
009
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
0 = switch open
1 = switch closed
Access 1 Outputs
0% = alarm does not sound
continued
100% = alarm sounds
from page -
009
Fig. 8 (17910-03)
M4.3-7335-012 Crown 2007 PF15813 Rev. 5/21
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212
ELECTRICAL SYSTEM
Access 1 2 3® Menus
Service Level 2 - Analyzer Menus
Access 3 Outputs
0% = lower not selected
continued approx. 65%=lower selected
from page
-009 0% = lower not selected
approx. 800 ma = lower selected
0% = high speed raise not selected
approx. 100%=hi spd raise selected
0% = high speed raise not selected
approx. 1030 ma =hi spd raise selected
0% = raise not selected
approx. 100%=raise selected
0% = raise not selected
approx. 1030 ma =raise selected
0% = fan is not operating
approx. 100%=fan is operating
0% = always
0ma = always
approx. 0–270 amps
approx. 145°C begins over temp
Access 4 Outputs
continued 0% = alarm does not sound
from page 100% = alarm sounds
-009
Fig. 9 (17911-03)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Service Level 2 - Analyzer Menus
Access 5 Outputs
continued 100% = always
from page - 0%=brake applied and travel is not
009 selected
25%=platform fully lowered, brake
released and travel is selected.
0 amps= brake applied and travel not
selected.
1.4 amps=platform fully lowered,
brake released and travel is selected.
approx. 4 ohms = always
0%=brake applied and travel is not
selected.
20%=platform fully lowered, brake re-
leased and travel is selected.
0 amps= brake applied and travel is
not selected.
3.2 amps=platform fully lowered,
brake released and travel is selected.
approx. 1.6 ohms = always
0%=lower not selected
50%=low speed lower is selected and
not in soft stop slow down on lift trucks
equipped with high speed lower.
100%=high speed lower is selected
and not in soft stop slow down on lift
trucks equipped with high speed lower.
100%=lower is selected and not in soft
stop slow down on lift trucks equipped
with single speed lower.
40 ma = lower not selected
400 ma = low speed lower is selected
and not in soft stop slowdown on lift
trucks equipped with high speed lower.
750 ma = high speed lower is selected
and not in soft stop slowdown on lift
trucks equipped with high speed lower.
750 ma = lower is selected and not in
soft stop slowdown on lift trucks
equipped with single speed lower.
0–90%
Fig. 10 (17912-02)
M4.3-7335-014 Crown 2007 PF15813 Rev. 5/21
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Service Level 3 - Analyzer Menus
Access 1 Test Outputs
continued from
page -009
Access 3 Test Outputs
continued from
page -009
Access 4 Test Inputs
continued from
page -009
Access 5 Test Outputs
continued from
page -009
Fig. 11 (17913-03)
Crown 2007 PF15813 Rev. 5/21 M4.3-7335-015
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Service Level 2 and 3 - Features Menus
continued from page -009
continued on page -017
continued on page -021
Fig. 12 (17915-02)
M4.3-7335-016 Crown 2007 PF15813 Rev. 5/21
09 Rev. 5/21
216
ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -009
3505–30 3511–1.25
N. America Europe
3510–30 3512–1.0
N. America Europe
3520–30 3521–1.25
N. America Europe
3550–30 3522–1.0
N. America Europe
3570–30 3571–1.25
N. America Europe
3580–15 3581–1.25
N. America Australia
3510–1.35
Australia
TT 3520–1.35
Australia
TL 3522–1.0
Australia
Edit XXXX
3550–1.35
Australia
Edit XXXX
Edit XXXX
Edit XXXX
F14 Wire Guidance=__ Disable
Enable
continued on page -018
Fig. 13 (17916-04)
Crown 2007 PF15813 Rev. 5/21 M4.3-7335-017
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -017
F15 Manual Wire Sense=_______ F15.1 Sense Mode=_ Disable
Standard
Sense & Slow
Sense & Stop
(5–20 ft)
F15.2 Distance=_ Edit 1.5–6.1 m
F16 End Aisle Control=_ No EAC
North Sensing
South Sensing
F17 PDS=___ Disable
Enable
F18 Battery Retainer SW=__ Yes
No
F19 Travel Alarm F19.1 Direction=____ Off
Forward
Reverse
Both
F19.2 Height=___ _____in
F20 User Performance=_ Disable
Enable F19.3 Alarm with Lower=_ Off
continued on page -019 On
Fig. 14 (17917-04)
M4.3-7335-018 Crown 2007 PF15813 Rev. 5/21
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -018
F21 User Codes F21.1 Status=____ Disable
Enable
F21.2 Codes Code # Code=__ XXXX #
Perf Level=___ P1
F21.3 Timeout=____ Never P2
5 minutes
P3
10 minutes
15 minutes
20 minutes
30 minutes
60 minutes
90 minutes
F23 Options F23.1 Pallet Clamp=____ Disable
Enable
F24 MMS=___ Disable
Enable
F25 Zone Switch=__ No
Yes
continued on page -020
Fig. 15 (17919-03)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -019
F26 Message Mode=____ Timer
Trip
Bdi
Hours
Odometer
Speed
Model
F27 LED Steer Indicator=_ Steer
Enable
All
Disable
F28 Hour Meter Mode=____ H1
H2
F29 Reset Switch (HGTRS) Height=____ xx= mm (in)
Fig. 16 (17920-03)
M4.3-7335-020 Crown 2007 PF15813 Rev. 5/21
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Service Level 2 and 3 - Performance Menus
continued from page -016
continued from page -025
P1.1 Travel Acc=_ Edit 1–9
Save? Y/N
P1.2 Travel Speeds P1.2.1 Free Ranging
continued on page -022
P1.2.2 Guided
continued on page -022
P2.1 Travel Acc=_ Edit 1–9
P2.2 Travel Speeds P2.2.1 Free Ranging
continued on page -022
P2.2.2 Guided
continued on page -022
P3.1 Travel Acc=_ Edit 1–9
P3.2 Travel Speeds P3.2.1 Free Ranging
continued on page -022
P3.2.2 Guided
continued on page -022
Edit 1–9
Edit 1–9
continued on page -023
continued on page -026
Fig. 17 (17922-02)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from P1.2.1.1 Speed Curve=____ Edit 1–9
page -021
P1.2.1.2 Max FF=____ Edit 1.0–10.5 kph
(1.0–7.0 mph)
P1.2.1.3 Max PUF=____ Edit 1.0–12.1 kph
(1.0–7.5 mph)
continued from
P1.2.2.1 Speed Curve=____ Edit 1–9
page -021
P1.2.2.2 Max FF=____ Edit 1.0–10.5 kph
(1.0–7.0 mph)
P1.2.2.3 Max PUF=____ Edit 1.0–12.1 kph
(1.0–7.5 mph)
continued from
P2.2.1.1 Speed Curve=____ Edit 1–9
page -021
P2.2.1.2 Max FF=____ Edit 1.0–10.5 kph
(1.0–7.0 mph)
P2.2.1.3 Max PUF=____ Edit 1.0–12.1 kph
(1.0–7.5 mph)
continued from
P2.2.2.1 Speed Curve=____ Edit 1.9
page -021
P2.2.2.2 Max FF=____ Edit 1.0–10.5 kph
(1.0–7.0 mph)
P2.2.2.3 Max PUF=____ Edit 1.0–12.1 kph
(1.0–7.5 mph)
continued from P3.2.1.1 Speed Curve=____ Edit 1–9
page -021
P3.2.1.2 Max FF=____ Edit 1.0–10.5 kph
(1.0–7.0 mph)
P3.2.1.3 Max PUF=____ Edit 1.0–12.1 kph
(1.0–7.5 mph)
continued from
P3.2.2.1 Speed Curve=____ Edit 1–9
page -021
P3.2.2.2 Max FF=____ Edit 1.0–10.5 kph
(1.0–7.0 mph)
P3.2.2.3 Max PUF=____ Edit 1.0–12.1 kph
(1.0.7.5 mph)
Fig. 18 (17923-04)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -021
P6 Braking P6.1 FF Braking=__ Edit 1–9
P6.2 PUF Braking=_ Edit 1–9
(0–600 in)
P7 Free Range Speeds P7.1 1.6 kph (1 mph) Edit 0–1524 cm
Speed Limit Hght=_
(0–600 in)
P7.2 0 kph (0 mph) Edit 0–1524 cm
Speed Limit Hght=_
(0–600 in)
P8 Guided Speeds P8.1 1.6 kph (1 mph) Edit 0–1524 cm
Speed Limit Hght=_
(0–600 in)
P8.2 0 kph (0 mph) Edit 0–1524 cm
Speed Limit Hght=_
(1.5–2.5 mph)
P8.3 Acquire Speed=__ Edit 1.5–4.0 kph
P9 Bdi=________ Edit 1–9
continued on page -024
Fig. 19 (17924-03)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -023
P12 EAC Setup P12.1 Mode=___ P12.1.1 Slowdown
P12.1.2 Slowdown w/Auto Resume
P12.1.3 Slowdown w/Auto stop
P12.1.4 Stop Using Motor
P12.1.5 Stop Using Brake
P12.2 FF Direction=____ P12.2.1 Slowdown Spd Edit 1.0–6.0 kph
(1.0–6.0 mph)
P12.2.2 Decel Rate Edit 1–9
P12.2.3 Resume Dist Edit 3–18 m
(10¡V60 ft)
P12.2.4 Stop Distance Edit 0–12 m
(0–40 ft)
P12.3 PUF Direction=___ P12.3.1 Slowdown Spd Edit 1.0–6.0 kph
(1.0–6.0 mph)
P12.3.2 Decel Rate Edit 1–9
P12.3.3 Resume Dist Edit 3–18 m
(10–60 ft)
P12.3.4 Stop Distance Edit 0–12 m
(0.40 ft)
P12.4 Slowdown Dir =__ Out of Aisle Only
Into and Out of Aisle
continued on P12.5 Magnet Spread =__ Edit 6–46 m
page -025
(20–150 ft)
Fig. 20 (17925-04)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -024
P13 PDS Setup P13.1 FF Direction=___ P13.1.1 Max Speed Edit 1.0–10.5 kph
(1.0–6.5 mph)
P13.1.2 Slowdown Spd Edit 1.0–6.0 kph
(1.0–6.0 mph)
P13.1.3 Decel Edit 1–9
P13.2 PUF Direction=__ P13.2.1 Max Speed Edit 1.0–10.5 kph
(1.0–6.5 mph)
P13.2.2 Slowdown Spd Edit 1.0–6.0 kph
(1.0–6.0 mph)
P13.2.3 Decel Edit 1–9
P14 Lower Speeds = ____ P14.1 Low Speed Edit 1–9
Lower 1=__
P14.2 Low Speed Edit 1–9
Lower 2=__
P14.3 Aux Lower Edit 1–9
Speed=__
P15 Soft Stop = __ Edit 1–9
P99 Load Factory Default Sure? N
Sure? Y
continued on page -021
Fig. 21 (17926-04)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Service Level 2 - Calibration Menus
continued from page -021
Calibration C1 Handles C1.1 Traction Sure? Y PUF Direction 4.6 Volts
approx.
Sure? N FF Direction 0.8 Volts
approx.
Center 2.6 Volts
approx.
Calibration Failed
C2 Valves C2.1 Main Lower Sure? N Raise above reset, lower to begin
Sure? Y
Finding Breakout, Maintain Command ____ ma
Finding Speed 1, Maintain Command ____ ma
Steps
automatically
from menu
Finding Speed 2, Maintain Command ____ ma
to menu
continued on Paused - Raise, Lower to begin
page -030
Stop Command
continued on page
-027 Lower forks to floor, press enter
Calibration Failed
Fig. 22 (17927-04)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -026
C3 Height Cutouts C3.1 Cutout 1 C3.1.1 Set Height R/L to Cutout then Enter __=mm (in)
C3.1.2 Type=____ None
PCT
PST
NCT
C3.1.3 When=___ Always
continued on page Free Range Only
-028
C3.1.4 Zone A, B, C or ALL
C3.2 Cutout 2 C3.2.1 Set Height R/L to Cutout then Enter __=mm (in)
C3.2.2 Type=____ None
PCT
PST
NCT
C3.2.3 When=___ Always
Free Range Only
C3.2.4 Zone A, B, C or ALL
Fig. 23 (17928-04)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -027
Sure? Y
C4 Steer Encoder Rotate ECR to Index [# of Counts] Encoder at Index
Sure? N
Sure? Y
C5 Wire C5.1 Sensors C5.1.2 Sensor Switch to Manual Go To Auto When Done
Guidance Coil
Sure? N
Save? N
Wheel Angle, Forks Leading
C5.1.3 travel on wire % Complete
Forks Trailing
Change Forks Trailing
continued on page -029 Directions Forks Leading
% Complete
Come to Stop Switch to Manual GUS=Manual
Switch to Auto GUS=Auto
Truck Angle, Forks Leading
C5.1.4 % Complete
travel on wire Forks Trailing
Change Forks Trailing
Directions Forks Leading % Complete
Come to Stop Switch to Manual GUS=Manual
Switch to Auto GUS=Auto
Offset Null, Forks Leading
C5.1.5 % Complete
travel on wire Forks Trailing
Change Forks Trailing
Directions % Complete
Forks Leading
Come to Stop Switch to Manual GUS=Manual
Move load bar X.X in.
Save? N
Save? Y
Fig. 24 (17929-04)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -028
Sure? N
C5.2 X-Offset Switch to Auto GUS=Auto Travel on Wire Acquire Wire
Sure? Y
Forks Leading
Forks Trailing % Complete
Sure? N
Distance reached Travel to continue
come to stop 2.5 mm
Enter to end
Sure? Y (0.1 in)
Fig. 25 (17930-05)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Service Level 2 and 3 - Hour Menus
continued from page -026
Hour H1 Runtime1=____ Edit___HRS
H2 Runtime2=_____ H2.1 Runtime2=____ Edit____HRS
H2.2 Timeout=_____ Edit____HRS
H3 Odometer=__ Edit____Kilometers/Miles
H4 Lift Motor=__ Edit____HRS
H5 Platform Lower=__ Edit____HRS
H6 Traction Motor=__ Edit____HRS
H7 Steer Motor=__ Edit____HRS
H8 Access1=__ Edit____HRS
H9 Access3=__ Edit____HRS
H10 Access4=__ Edit____HRS
H11 Access5=__ Edit____HRS
H12 Access6=__ Edit____HRS
continued on page -031
continued on
page -032
Fig. 26 (17931-04)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -030
Fig. 27 (17932-02)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Service Level 2 and 3 - Event Menus
continued from page -030
continued on
page -033
Fig. 28 (17933-02)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Service Level 2 and 3 - Utilities Menus
continued from page -032
Utilities U1 Part Numbers U1.1 Access 1 U1.1.1 Model PN=___
U1.1.2 Software PN=_
U1.2 Access 3 U1.2.1 Model PN=___
U1.2.2 Software PN=_
U1.3 Access 4 U1.3.1 Model PN=___
U1.3.2 Software PN=_
U1.4 Access 5 U1.4.1 Model PN=___
U1.4.2 Software PN=_
U1.5 Access 6 U1.5.1 Model PN=___
continued on
page -009 U1.5.2 Software PN=_
U2 Tow Mode Sure? N Tow Mode Activated
Sure? Y
U3 Truck Operation Enable
Disable
Fig. 29 (18035-03)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Analyzer A1.1 Full Speed Hydraulics = ______
If the lift truck is equipped with full speed hydraulics
The Analyzer menu is a troubleshooting tool that allows
and the full speed hydraulics function is working prop-
the technician to check the status of various circuits,
erly, the display shows that the function is Enabled. If
check component inputs and outputs and test/driven
the function is not working, the display shows Disabled,
component outputs.
indicating the circuit requires troubleshooting. Even
The Analyzer submenus are: though full speed hydraulics is disabled, low speed
• A1 Status raise and lower may still be enabled.
• A2 Inputs Technician Tips: The full speed hydraulics circuit is
• A3 Outputs (Level 2 Only) the full speed lift and lower circuit. On lift trucks
equipped with dual lift pumps, during full speed lift, the
• A4 Test Outputs (Level 3 Only)
raise button is pressed fully actuating both raise
Analyzer access switches, RAS1 and RAS2. Both M3 and M4 pump mo-
tors are energized causing lift pumps P1 and P2 to ro-
1. Turn on the lift truck. From Service Level 2 or Level tate providing full speed raise. During full speed lower,
3, press the right arrow to enter the Service sub- the lower button is pressed fully actuating lower
menus. switches, LOS1 and LOS2. The proportional lower
2. Use the up and down arrows to navigate to the An- valve, PVL is energized with 16 volts fully opening PVL.
alyzer menu. A1.2 Lower = ______
3. Press the right arrow to enter the Analyzer menu. During lower, the lower button is pressed approxi-
Use the up and down arrows to scroll through the mately half way actuating only lower switch LOS1. The
submenus. lower proportional valve is energized with approxi-
A1 Status mately 8-battery-volts opening the valve approximately
half-way. If lower is Enabled, the function is working. If
A1 Status allows technicians to view the status of mon- lower is Disabled. the function is not working.
itored lift truck systems. This information can be used
A1.3 Raise = ______
to troubleshoot service conditions by identifying com-
mon circuits for enabled or disabled functions. The A1 During raise, the raise button is pressed approximately
Status menu includes multiple submenus. half way on lift trucks with dual lift pumps or fully de-
• For all A1 Status submenus, the display scrolls right pressed on lift trucks with a single lift pump actuating
to left indicating the function is either Enabled or raise switch RAS1. M3 pump motor is energized caus-
Disabled. ing lift pump P1 to rotate. If raise is Enabled, the func-
tion is working. If raise is Disabled, the function is not
• To stop the display from scrolling, press the right
working.
arrow and the display shows Enabled or Disabled
only. A1.4 Full Traction = ______
• If the operator presses the right arrow to display En- The display indicates if Full Traction is Enabled or Dis-
abled or Disabled only, then press the left arrow and abled.
then the down arrow to scroll to the next submenu.
A1.5 Limp Traction = ______
• If the operator does not press the left arrow and al-
lows the text to scroll, then press the down arrow to When a lift truck is in an aisle and has a service condi-
scroll to the next submenu. tion, limp travel allows the operator to move the lift
truck to a maintenance area at a reduced travel speed.
Travel is not permitted with some service conditions
and in these cases, limp travel is disabled. The display
indicates if the function is Enabled or Disabled.
A1.6 Steering = ______
The display indicates if Power Steering is Enabled or
Disabled.
A1.7 ED = ______
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
The display indicates if Emergency Disconnect is En- A2.1.1 DMS1 = ______
abled or Disabled.
Technician Tips: This switch is not used on North
A1.8 Module = ______ American SP 3500 lift trucks. If Features menu F3 is
set to North America, this menu is not displayed. DMS1
A1.8 Module is the last A1 Status menu and always
is an operator presence switch located above and to
reads Enabled. This menu is reserved for future use.
the left of the steering tiller. When in guidance mode,
• Press the left arrow until returning to the A1 Status an operator must press this switch to operate the lift
menu and then press the down arrow to navigate to truck.
the A2 Inputs
• To check input, press the right arrow and actuate
A2 Inputs DMS1. Display indicates 0 when the switch is open
and 1 when closed. Press the left to return to A2.1.1
The SP 3500 lift truck has up to 5 Access 1 2 3® mod- DMS1 submenu.
ules. Each module receives input signals from electri-
• Press the down arrow to scroll to the next A2.1 sub-
cal components like switches, sensors, and encoders.
menu.
A2 Inputs allow the technician to check to see if these
signals are received by the module. The A2 Input A2.1.2 GUS1 = ______
menus are sorted by Access 1 2 3® module. See the
Technician Tips: GUS1 switch is used only on lift
A2 Input Submenus table.
trucks equipped with optional wire guidance. This
menu only appears if the F14 Wire Guidance features
A2 Inputs Submenus menu is enabled.
Sub- Module Function GUS1 is the guidance switch that allows the operator
menu to select manual or automatic steering. This switch is
on the console switch panel.
A2.1 Access 1 Display • To check input, press the right arrow and actuate
A2.2 Access 3 Traction GUS1. Display indicates 0 when the switch is open
and 1 when closed.
A2.3 Access 4 Vehicle (1) • Press the left arrow to return to A2.1.2 GUS1 sub-
A2.4 Access 5 Steering menu.
Wire Guidance and • Press the down arrow to scroll to the next A2.1 sub-
A2.5 Access 6 menu.
End Aisle Control
(1) Access A2.1.3 ORS1 = ______
4 receives all platform inputs except the guid-
ance switch and override switch inputs. Optional switch, ORS1 allows the operator to override
a raise cutout. This switch is on the console switch
• Press the right arrow to scroll to the first A2 Input
panel.
submenu.
• To check the input, press the right arrow and actu-
A2.1 Access 1 Inputs ate ORS1. The display indicates 0 when the switch
• Press the right arrow to navigate to the first A2.1 is open and 1 when closed.
submenu. • Press the left to return to the A2.1.3 ORS1 sub-
menu.
• A2.1.3 ORS1 is the last A2.1 Access 1 Inputs sub-
menu. Press the left arrow to navigate back to A2.1
Access 1 Inputs then press the down arrow to scroll
to the A2.2 submenu.
A2.2 Access 3 Inputs
• Press the right arrow to navigate to the first A2.2
Access 3 inputs submenu.
A2.2.1 ECR3 = ______
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
ECR3 is the traction encoder and is located in the trac- A2.2.4 THS-P1 = ______
tion motor. It inputs traction speed and direction.
THS-P1 is a thermal switch located in pump motor M3.
• To check the input, press the right arrow. If there is an over-temperature condition, this thermal
A2.2.1.1 Speed = ______ switch opens, M3 quits operating, and an event is
logged.
• To check the input, press the right arrow. The speed
for ECR3 is displayed in rpms. Positive numbers • To check the input, press the right arrow. The dis-
are displayed when traveling in the power unit first play indicates 1 when the switch is closed and 0
direction and negative numbers are displayed in the when open.
forks first direction. When traveling, the numbers in- Technician Tips: Pump motor thermal switches are an
crease and decrease smoothly and do not fluctuate option. Features menu, F24 MMS must be enabled for
in large increments. If they fluctuate, the encoder submenus A2.2.4 and A2.2.5 to be displayed.
must be replaced.
• Press the left arrow and then the down arrow to
• Press the left arrow and then the down arrow to scroll to the next submenu.
scroll to the next submenu.
A2.2.5 THS-P2 = ______
A2.2.1.2 Cnt = ______
THS-P2 is a thermal switch located in pump motor M4.
• To check the input, press the right arrow. In this
If there is an over-temperature condition, this thermal
menu, the input for ECR3 is displayed in count
switch opens, M4 quits operating, and an event is
(numbers). The numbers decrease when traveling
logged.
in the power unit first direction and increase in the
forks first direction. When traveling, the numbers in- • To the check input, press the right arrow. The dis-
crease and decrease smoothly and do not fluctuate play indicates 1 when the switch is closed and 0
in large increments. If they fluctuate, the encoder when open.
must be replaced. • Press the left arrow and then the down arrow to
• Press the left arrow and then the down arrow to scroll to the next submenu.
scroll to the next submenu.
A2.2.2 CHB4/CHB5 = ______
Technician Tips: CHB4 and CHB5 are platform chain
break switches are not equipped on North American lift
trucks. This menu is not displayed on North American
lift trucks.
The switches are located near the top mainframe chain
anchors and disable all hydraulic functions if a mast lift
chain breaks.
• To check the input, press the right arrow. The dis-
play indicates 1 when the switches are closed and
0 when open.
• Press the left arrow and then the down arrow to
scroll to the next submenu.
A2.2.3 CHS3/CHS4 = ______
CHS3 and CHS4 are mast chain slack switches and
are located near the mainframe chain anchors. In the
event the chains become slack (that is, the platform is
lowered on an object), lower is prohibited.
• To check the input, press the right arrow. The dis-
play indicates 1 when the switches are closed (nor-
mal operation) and 0 when open.
• Press the left arrow and then the down arrow to
scroll to the next submenu
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
A2.2.6 BW-P1/P2 = ______ • To check the input, press the right arrow. Positive
numbers are displayed. When lifting and lowering,
BW-P1/P2 are brush wear sensors located in pump
the numbers increase and decrease smoothly and
motors M3 and M4.
do not fluctuate in large increments. If they fluctu-
• To check the input, press the right arrow. The brush ate, the encoder must be replaced.
wear value displayed on motors with new brushes
• Press the left arrow and then the down arrow to
are approximately 10.3 volts. When the value
scroll to the next submenu.
reaches 1.0 volts for pump 1 motor (M3), the
brushes require replacement. When the value A2.3.1.3 Cnt = ______
reaches 1.0–4.0 volts for pump 2 motor (M4), the
In this menu, the data input for ECR4 is displayed in
brushes require replacement.
count (numbers).
Technician Tips: Brush wear sensors are an option. • To check the input, press the right arrow. The num-
The features menu, F24 MMS must be enabled for bers increase when lifting and decrease when low-
submenu A2.2.6 to be displayed. ering. When lifting/lowering, the numbers increase
• Press the left arrow and then the down arrow to and decrease smoothly and do not fluctuate in large
scroll to the next submenu. increments. If they fluctuate, the encoder must be
replaced.
A2.2.7 Key Switch = ______
• Press the left arrow and then the down arrow to
• To check the input, press the right arrow. Volts at
scroll to the next submenu.
the key switch are displayed.
• A2.2.7 Key Switch is the last A2.2 Access 3 Inputs A2.3.2 ECR1/ECR5 = ______
submenu. Press the left arrow until navigating back ECR1 and ECR5 are operator steering command en-
to A2.2 Access 3 Inputs then press the down arrow coders and are part of the steering command assembly
to scroll to the A2.3 submenu. (includes tiller) mounted on the platform.
A2.3 Access 4 Inputs • To check the input, press the right arrow. The data
numbers for both encoders are approximately the
Press the right arrow to navigate to the first A2.3
same. The numbers decrease when turning clock-
Access 4 inputs submenu.
wise and increase when turning counterclockwise.
A2.3.1 ECR4 = ______ If the numbers fluctuate, the encoder must be re-
placed.
ECR4 is the height encoder and is mounted on the
height sensor. It inputs lift/lower speed and direction • Press the left arrow until navigating to A2.3.1 ECR4
when above free lift. submenu and then the down arrow to scroll to the
next submenu.
• Press the right arrow to scroll to the first A2.3.1
ECR4 submenu. A2.3.3 POT1
A2.3.1.1 Height = ______ POT 1 is the traction request potentiometer that pro-
vides input to Access 4.
The height for ECR4 is displayed in inches or cm (cen-
timeters) dependent on how Features menu, F2 Unit of • Press the right arrow to navigate to the first A2.3.3
Measure is set. POT1 inputs submenu.
• To check the input, press the right arrow. The height
displayed is the approximate fork height measured
from the top of the forks. When lifting and lowering,
the numbers increase and decrease smoothly and
do not fluctuate in large increments. If they fluctu-
ate, the encoder must be replaced.
• Press the left arrow and then the down arrow to
scroll to the next submenu.
A2.3.1.2 Speed = ______
The speed for ECR4 is displayed in ips (inches per sec-
ond) or cmps (centimeters per second) dependent on
how features menu, F2 Unit of Measure is set.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
A2.3.3.1 Raw = ______ • To check the input, press the right arrow and actu-
ate RAS3 and RAS4 by raising the lifting forks. The
Voltage input for POT1 is shown in this menu.
display indicates 0 when the switches are open and
• To check the input, press the right arrow. While ro- 1 when closed.
tating the twist grip, the voltage displayed will be ap-
• Press the left arrow and then the down arrow to
proximately:
scroll to the next submenu.
– 0.8 volts in the maximum forks first direction.
A2.3.5 LOS3/LOS4 = ______
– 2.6 volts in neutral position.
– 4.6 volts in the maximum power unit first direc- Technician Tips: These switches are not used on
tion. North American SP 3500 lift trucks so this menu is not
displayed on North American lift trucks.
As the operator rotates the twist grip, the numbers in-
crease and decrease smoothly and do not fluctuate in These switches are on lift trucks equipped with lifting
large increments. If they fluctuate, the potentiometer forks and are located just below the lifting forks con-
must be replaced. sole.
• Press the left arrow and then the down arrow to • To check the input, press the right arrow and actu-
scroll to the next submenu. ate LOS3 and LOS4 by lowering the lifting forks.
The display indicates 0 when the switches are open
A2.3.3.2 Scaled = ______ and 1 when closed.
The percent of voltage range (5 volts) for POT1 is • Press the left arrow and then the down arrow to
shown in this menu. scroll to the next submenu.
• To check input, press the right arrow. While rotating A2.3.6 RS = ______
the twist grip, the percent of voltage displayed are
approximately: RS is the reverse switch and is located in the traction
twist grip assembly.
– 16% in the maximum forks first direction.
• To check the input, press the right arrow and actu-
– 50% in neutral position.
ate RS by rotating the twist grip in the forks first di-
– 92% in the maximum power unit first direction. rection. The display indicates 0 when the switch is
As the operator rotates the twist grip, the numbers in- open and 1 when closed.
crease and decrease smoothly and do not fluctuate in • Press the left arrow and then the down arrow to
large increments. If they fluctuate, the potentiometer scroll to the next submenu.
must be replaced.
A2.3.7 FS = ______
• Press the left arrow until navigating to A2.3.3 POT1
submenu and then the down arrow to scroll to the FS is the forward switch and is located in the traction
next submenu. twist grip assembly.
• To check the input, press the right arrow and actu-
A2.3.4 RAS3/RAS4 = ______
ate FS by rotating the twist grip in the power unit
Technician Tips: These switches are not used on first direction. The display indicates 0 when the
North American SP 3500 lift trucks so this menu is not switch is open and 1 when closed.
displayed on North American lift trucks. • Press the left arrow and then the down arrow to
These switches are on lift trucks equipped with lifting scroll to the next submenu
forks and are located in the lifting forks console.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
A2.3.8 CHS1/CHS2 = ______ dicates 0 when the switch is open and 1 when
closed.
CHS1 and CHS2 are platform chain slack switches and
are located near the platform chain anchors on lift • Press the left arrow and then the down arrow to
trucks with TT masts. In the event the chains become scroll to the next submenu.
slack (that is, the platform is lowered on an object), A2.3.13 LOS2 = ______
lower is prohibited.
LOS2 is the platform high speed lower switch and is
• To check the input, press the right arrow. The dis-
located in the control console assembly.
play indicates 1 when the switches are closed (nor-
mal operation) and 0 when open. • To check the input, press the right arrow and actu-
ate LOS2 by pressing the platform lower button fully
Technician Tips: Features menu, F6 Mast Type must for high speed lower. The display indicates 0 when
be set to TT for submenu A2.3.8 to be displayed. the switch is open and 1 when closed.
• Press the left arrow and then the down arrow to • Press the left arrow and then the down arrow to
scroll to the next submenu. scroll to the next submenu.
A2.3.9 GTS1/GTS2 = ______ A2.3.14 ZSS A = ______
GTS1 and GTS2 are side gate switches and are on the ZSS is the zone select switch. This switch is an op-
platform and are actuated by the top, horizontal arms tional key switch on the console and operators or man-
of the gates. GTS1 is on the left side gate and GTS2 is agement can select key position/zone, A, B, or without
on the right side gate. an override is established for each zone. Once a zone
• To check input, press the right arrow. To check in- is selected, the key can be removed so only authorized
put, actuate GTS1 and GTS2 by raising and lower- personnel may change the position of the zone select
ing the side gates. The display indicates 0 when the switch.
switches are open and 1 when closed.
Technician Tips: In the features menu, F25 Zone
• Press the left arrow and then the down arrow to Switch must be set to Yes for submenu A2.3.14 to be
scroll to the next submenu. displayed.
A2.3.10 HGTRS = ______ ZSS A is position A on the zone select switch.
HGTRS is a height reset switch and is located on the • To check the input, press the right arrow and select
platform. This switch actuates by a bar welded on the position A. The display indicates 1 when position A
third stage mast. is selected and 0 when not selected.
• To check the input, press the right arrow and actu- • Press the left arrow and then the down arrow to
ate HGTRS by raising the platform so the mast be- scroll to the next submenu.
gins to stage. The display indicates 0 when the
switch is open and 1 when closed.
• Press the left arrow and then the down arrow to
scroll to the next submenu.
A2.3.11 RAS1 = ______
RAS1 is the platform raise switch and is located in the
control console assembly.
• To check the input, press the right arrow and actu-
ate RAS1 by raising the platform. The display indi-
cates 0 when the switch is open and 1 when closed.
• Press the left arrow and then the down arrow to
scroll to the next submenu.
A2.3.12 LOS1 = ______
LOS1 is the platform lower switch and is located in the
control console assembly.
• To check the input, press the right arrow and actu-
ate LOS1 by lowering the platform. The display in-
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Access 1 2 3® Menus
A2.3.15 ZSS B = ______ • To check the input, press the right arrow and rotate
the steering tiller. The numbers decrease when
ZSS B is position B on the zone select switch.
turning counterclockwise and increase when turn-
• To check input, press the right arrow and select po- ing clockwise. If the numbers fluctuate, the encoder
sition B. The display indicates 1 when position B is needs to be replaced.
selected and 0 when not selected.
• Press the left arrow and then the down arrow to
• Press the left arrow and then the down arrow to scroll to the next submenu.
scroll to the next submenu.
A2.4.3 BATTERY = ______
A2.3.16 ZSS C = ______
• To check the input, press the right arrow. The bat-
ZSS C is position C on the zone select switch. tery voltage is displayed.
• To check the input, press the right arrow and select • Press the left arrow and then the down arrow to
position C. The display indicates 1 when position C scroll to the next submenu.
is selected and 0 when not selected.
A2.4.4 Steering = ______
• Press the left arrow and then the down arrow to
• To check the input, press the right arrow. The bat-
scroll to the next submenu.
tery input voltage to the steer module, Access 5, is
A2.3.19 CHB7/CHB8 = ______ displayed in this menu.
Technician Tips: These switches are not used on • Press the left arrow and then the down arrow to
North American SP 3500 lift trucks so this menu is not scroll to the next submenu
displayed on North American lift trucks. A2.4.5 BRK Inner = ______
CHB7 and CHB8 are located beneath the top main- Technician Tips: When energized, two coils, an inner
frame chain anchors and disable all hydraulic func- and outer coil, release a three-step traction brake. The
tions, if a platform lift chain breaks. inner and outer coils can be energized and de-ener-
• To check the input, press the right arrow. The dis- gized separately to provide three different levels of
play indicates 1 when the switches are closed and brake force.
0 when open. • To check the input, press the right arrow and cycle
• A2.3.19 CHB7/CHB8 is the last A2.3 Access 4 In- the brake. The display shows battery volts.
puts submenu. Press the left arrow until navigating
Technician Tips: After a self test, but before releasing
back to A2.3 Access 4 Inputs then press the down
the brake, this menu will display a value less than bat-
arrow to scroll to the A2.4 submenu.
tery volts. A2.4.5 menu is only accurate if the ED2 con-
A2.4 Access 5 Inputs tactor tips are closed. ED2 does not close until the
• Press the right arrow to navigate to the first A2.4 brake pedal is cycled for the first time after self test.
Access 5 inputs submenu. • Press the left arrow and then the down arrow to
scroll to the next submenu.
A2.4.1 ECR2 = ______
A2.4.6 BRK Outer = ______
ECR2 is the steering feedback encoder and is mounted
on the drive unit and traction motor mounting plate near • To check the input, press the right arrow. This menu
the traction motor. It provides speed and direction feed- displays battery volts.
back to Access 5. • Press the left arrow and then the down arrow to
scroll to the next submenu.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
A2.4.7 CS1 = ______ back to A2.4 Access 5 Inputs then press the down
arrow to scroll to the A2.5 submenu.
CS1 monitors current through BDI to determine battery
status. CS1 is the current sensor and is mounted on A2.5 Access 6 Inputs
the contactor panel just behind the traction motor. CS1 • Press the right arrow to navigate to the first A2.5
inputs current value to Access 5 for BDI. Access 6 inputs submenu.
• To check the input, press the right arrow. Press the
Technician Tips: GS1 and GS2 are used on lift trucks
left arrow and then the down arrow to scroll to the
equipped with wire guidance only. In the features
next submenu.
menu, F14 Wire Guidance must be enabled for A2.5.1
A2.4.8 RGSR/RGSL = ______ and A2.5.2 submenus to be displayed.
RGSR and RGSL are rail guidance switches and are Technician Tips: A wire guided lift truck has two sen-
mounted on the aisle guide wheel brackets under the sor bar assemblies (GS1 and GS2); one mounted to
power unit. RGSR is on the right side of the power unit the bottom of the main frame (GS2) and the other
and RGSL is on the left side. These switches actuate mounted to the power unit directly in front of the drive
when entering and exiting a rail guided aisle. tire (GS1). Each sensor bar contains four coils. The fol-
• To check the input, press the right arrow. The dis- lowing GS1 and GS2 menus allow the operator to view
play indicates 0 when the switches are open and 1 the Raw and Scaled input values from the coils inside
when closed. both sensor bars. The Raw value is the amount of sig-
nal (millivolts) that each coil senses from the guide wire
• Press the left arrow and then the down arrow to
path. During wire guidance calibration, the
scroll to the next submenu.
Access 1 2 3® system computes a factor to multiply
A2.4.9 BRES1/BRES2 = ______ the Raw value by and creates the Scaled value. The
purpose of the Scaled value is to balance out the in-
BRES1/BRES2 are battery retainer switches and are
puts from all four coils of each bar. No two coils are
mounted on the power unit skirt in front of the battery
manufactured the same so the Scaled values compen-
compartment. BRES1 is on the right side and BRES2
sate for the manufacturing process allowing the coils to
is on the left side. These switches actuate when the
sense equal signal ensuring proper wire guide track-
battery side covers are removed and installed.
ing.
• To check the input, press the right arrow. The dis-
play indicates 0 when the switches are open and 1 A2.5.1 GS1
when closed. GS1 is the steer wheel sensor bar.
Technician Tips: The battery retainer switches are an • To navigate to the first A2.5.1 GS1 submenu, press
option. Features menu, F18 Battery Retainer SW must the right arrow.
be set to Yes for submenu A2.4.9 to be displayed.
• Press the left arrow and then the down arrow to
scroll to the next submenu.
A2.4.10 BRS1 = ______
BRS1 is the brake pedal switch located below the plat-
form. This switch actuates when pressing and releas-
ing the brake pedal.
• To check the input, press the right arrow. The dis-
play indicates 0 when the switch is open and 1
when closed.
• Press the left arrow and then the down arrow to
scroll to the next submenu.
A2.4.11 Brake Test Speed = ______
This menu is for factory use only.
• A2.4.11 Brake Test Speed is the last A2.4 Access 5
Inputs menu. Press the left arrow until navigating
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
A2.5.1.1 Raw = ______ A2.5.1.2 Scaled = ______
See Figure 30. This menu allows the operator to check This menu allows the operator to check the Scaled
the Raw value of all four GS1 coils. value of all four GS1 coils.
• To check the input, press the right arrow. Eight dig- • To check the input, press the right arrow. Eight dig-
its appear on the display to show the Raw values of its appear on the display to show the Scaled values
the coils. Reading from left to right: the first pair of of the coils. Reading from left to right: the first pair
numbers are for the first coil; the second pair of of numbers are for the first coil; second pair of num-
numbers are for the second coil; the third pair of bers are for the second coil; the third pair of num-
numbers are for the third coil; and the fourth pair of bers are for the third coil; and the fourth pair of num-
numbers are for the fourth coil. bers are for the fourth coil.
Move the lift truck at slowest speed possible and at Move the lift truck at slowest speed possible and at
the most shallow angle possible (5 degrees or less) the most shallow angle possible (5 degrees or less)
over an active guide wire. The peak Raw values of over an active guide wire. When each coil is directly
the two inner coils are within a 15-count spread be- over the guide wire, the Scaled value is above 95%.
tween the highest and lowest. The Raw values If it is not, the wire guidance system needs to be
range is from 70% to 80%. If the Raw value is over recalibrated.
90% when the coil is directly over the wire, check • Press the left arrow and then the down arrow to
the line driver output with a Crown Field Strength scroll to the next submenu.
Meter (see Figure 30). The average field strength is
between 168 and 190 for a 6.25 KHz system or 100 A2.5.2 GS2
and 118 for a 5.2 KHz system. Also, check the sen- GS2 is the load wheel sensor bar. The procedures for
sor bar for the correct height adjustment. For height checking the input are the same as GS1.
adjustment specification, see section M4.3 in this
• Press the left arrow and then the down arrow to
service manual.
scroll to the next submenu.
Technician Tips: EAC is an end aisle control option.
Features menu, F16 End Aisle Control must be set to
1 North Sensing or South Sensing for A2.5.3, A2.5.4,
A2.5.5 and A2.5.6 submenus to be displayed.
Technician Tips: See Figure 31. On lift trucks with
EAC, a sensor bar which includes four sensors is
mounted under the power unit battery box. The pur-
2 pose of these sensors is to detect magnets buried in
the warehouse floor near the end of an aisle and send
a signal to Access 6 to slow or stop the lift truck. A1 and
B1 are active sensors when traveling in the forks first
direction. A2 and B2 are active sensors when traveling
in the forks trailing direction.
Fig. 30 (23049-01)
1 Guide wire
2 Field strength meter, P/N 112953
• Press the left arrow and then the down arrow to
scroll to the next submenu.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
A3 Outputs
Technician Tips: A3 Output menus are available in
1
Level 3 only.
A1 B1
The Access 1 2 3® modules send output signals to
electrical components like alarms, solenoid valves, and
contactor coils. The output signals for four of these
modules can be viewed from the display. See the A3
Outputs Submenus table.
A3 Outputs Submenus
A2 B2
Sub- Module Function
2 menu
Fig. 31 (23034-01) A3.1 Access 1 Display
1 EAC sensors - forks first direction
A3.2 Access 3 Traction
2 EAC sensors - forks trailing direction
A3.3 Access 4 Vehicle
A2.5.3 EACA1 = ______ A3.4 Access 5 Steering
EACA1 is the A1 sensor for optional end aisle control.
A3.1 Access 1 Outputs
• To check the input, press the right arrow and travel
• Press the right arrow to navigate to the first A3.1
in the forks first direction over an EAC floor magnet.
Access 1 outputs submenu.
The display indicates 0 until the sensor is over the
magnet. When the sensor is over the magnet, the A3.1.1 ALM1 = ______
display shows 1. After the sensor moves past the
ALM1 is an alarm on the platform distribution panel.
magnet, the display changes to 0.
• To check the output and with the platform fully low-
• Press the left arrow and then the down arrow to
ered, raise a side gate and push the lower button.
scroll to the next submenu.
The alarm sounds and the display shows 100%.
A2.5.4 EACA2 = ______ • A3.1.1 ALM1 is the only A3.1 Access 1 Outputs
EACA2 is the A2 sensor for optional end aisle control. submenu. Press the left arrow to return to A3.1
The procedures for checking the input are the same as Access 1 menu and then press the down arrow to
EACA1 except travel in the forks trailing direction. scroll to the A3.2 menu.
• Press the left arrow and then the down arrow to A3.2 Access 3 Outputs
scroll to the next submenu. • Press the right arrow to navigate to the first A3.2
A2.5.5 EACB1 = ______ Access 3 outputs submenu.
EACB1 is the B1 sensor for optional end aisle control.
The procedures for checking the input are the same as
EACA1.
• Press the down arrow to scroll to the next submenu.
A2.5.6 EACB2 = ______
EACB2 is the B2 sensor for optional end aisle control.
The procedures for checking input are the same as EA-
CA1 except travel in the forks trailing direction.
• Press the left arrow until returning to the A2 Inputs
menu and then press the down arrow to navigate to
the A3 Outputs menu.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
A3.2.1 SVL A3.2.2.2 Current = ______
SVL is the lowering solenoid valve and is on the lift/ • To check the output, press the right arrow. When
lower manifold. It opens during lower providing a path high-speed raise is selected, approximately 1,030
for oil to flow from the lift cylinders to the reservoir. milliamps are displayed.
• To navigate to the first A3.2.1 SVL submenu, press • Press the left arrow twice and then the down arrow
the right arrow. to scroll to the next submenu.
A3.2.1.1 DC = ____% A3.2.3 P1 = ______
• To check the output, press the right arrow. When P1 is the pump 1 contactor coil. The pump 1 contactor
lower is not selected, 0% of DC battery volts are is on the contactor panel just behind the traction motor.
displayed. When lower is selected, approximately When the P1 coil is energized, P1 contacts close pro-
65% of battery volts are displayed. viding voltage to the M3 low speed lift motor.
• Press the left and then the down arrow to scroll to • To navigate to the first A3.2.3 P1 submenu, press
the next submenu. the right arrow.
A3.2.1.2 Current = ______ A3.2.3.1 DC = ____%
• To check the output, press the right arrow. When • To check the output, press the right arrow. When
lower is not selected, 0 milliamps are displayed. low speed raise is selected, approximately 100% of
When lower is selected, approximately 800 milli- DC battery volts are displayed.
amps are displayed. • Press the left and then the down arrow to scroll to
• Press the left arrow twice and then the down arrow the next submenu.
to scroll to the next submenu.
A3.2.3.2 Current = ______
A3.2.2 P2 = ______ • To check the output, press the right arrow. When
Technician Tips: This submenu is displayed on lift low speed raise is selected, approximately 1,030
trucks with dual lift pumps. milliamps are displayed.
• Press the left arrow twice and then the down arrow
P2 is the pump 2 contactor coil. The pump 2 contactor
to scroll to the next submenu.
is on the contactor panel just behind the traction motor.
When the P2 coil is energized, P2 contacts close pro- A3.2.4 FAN2 = ____%
viding voltage to the M4 two speed lift motor.
FAN2 is a fan that helps to cool the Access 1 2 3®
• To navigate to the first A3.2.2 P2 submenu, press modules and is located above Access 3™ in the power
the right arrow. unit. The fan turns on when the Access 1 2 3® mod-
A3.2.2.1 DC = ____% ules mounting plate temperature is at or above 45°C
(113°F).
• To check the output, press the right arrow. When
high-speed raise is selected, approximately 100% • To check the output, press the right arrow. When
of DC battery volts are displayed. the fan is not running, 0% of battery volts are dis-
played. When the fan is running, 100% of battery
• Press the left and then the down arrow to scroll to
volts are displayed.
the next submenu.
• Press the left and then the down arrow to scroll to
the next submenu.
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Access 1 2 3® Menus
A3.2.5 ED2 Technician Tips: This submenu is only displayed if the
lift truck is equipped with ALM2 and features menu,
ED2 is the number 2 Emergency Disconnect contactor
F19 is enabled.
coil and is on the contactor panel just behind the trac-
tion motor. The ED2 coil receives battery negative from ALM2 is an optional travel alarm and is mounted be-
Access 3™ and positive battery from Access 5 (ED2 tween the power unit and the platform on the power
submenu is in Access 3™ and Access 5 submenus). unit wall. The alarm can be set to sound when traveling
When the coil is energized, ED2 contacts close provid- forward, reverse or both directions.
ing battery positive to Access 3™ and Access 5 power • To check the output, press the right arrow. When
circuit. the alarm sounds, the display indicates 100%.
• To navigate to the first A3.2.5 ED2 submenu, press • Press the left twice and then the down arrow to
the right arrow. scroll to the next A3.4 menu.
A3.2.5.1 DC = ____% A3.4 Access 5 Outputs
• To check the output, press the right arrow. 0% of • Press the right arrow to navigate to the first A3.4
DC battery volts are displayed at all times because Access 5 outputs submenu.
Access 3™ supplies battery negative to the ED2
coil. A3.4.1 ED2 = ______
• Press the left and then the down arrow to scroll to ED2 is the number 2 Emergency Disconnect contactor
the next submenu. coil and is on the contactor panel just behind the trac-
tion motor. The ED2 coil receives battery negative from
A3.2.5.2 Current = ______
Access 3™ and battery positive from Access 5 (ED2
• To check the output, press the right arrow. Approx- submenu is in Access 3™ and Access 5 submenus).
imately 0 milliamps are displayed at all times be- When the coil is energized, ED2 contacts close provid-
cause Access 3™ supplies battery negative to ED2 ing battery positive to Access 3™ and Access 5 power
coil. circuit.
• Press the left arrow twice and then the down arrow • To check the output, press the right arrow. 100% is
to scroll to the next submenu. displayed at all times because Access 5 supplies
A3.2.6 M1 battery positive to the ED2 coil.
• Press the left and then the down arrow to scroll to
M1 is the traction motor and is mounted to the drive unit
the next submenu.
mounting plate.
• To navigate to the first A3.2.6 M1 submenu, press A3.4.2 Brake 0+/0-
the right arrow. Brake 0+/0- is the output signal for the outer brake coil.
A3.2.6.1 Current = ______ The brake has two coils, an inner and outer coil. The
coils can be energized separately or at the same time
• To check output, press the right arrow and travel.
depending on the required brake force. The brake is
The current range is approximately 0–270 amps.
energized when the operator is in the operating posi-
• Press the left and then the down arrow to scroll to tion (brake pedal depressed) and travel is selected.
the next submenu.
• To navigate to the first A3.4.2 Brake 0+/0- sub-
A3.2.6.2 Temperature = ______ menu, press the right arrow.
• To check the output, press the right arrow. Over A3.4.2.1 DC = ____%
temperature begins at 145°C (293°F).
• To check the output, press the right arrow. When
• A3.2.6 M1 is the last A3.2 Access 3™ Outputs sub- the brake pedal is not depressed and travel is not
menu. Press the left arrow until returning to A3.2 selected, 0% of DC battery volts are displayed.
Access 3™ menu. Press the down arrow to scroll to Fully lower the platform and travel, approximately
the next A3.3 menu. 25% of DC battery volts are displayed.
A3.3 Access 4 Outputs • Press the left and then the down arrow to scroll to
• Press the right arrow to navigate to the first A3.3 the next submenu.
Access 4 outputs submenu.
A3.3.1 ALM2 = ______
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Access 1 2 3® Menus
A3.4.2.2 Current = ______ A3.4.3.2 Current = ______
• To check the output, press the right arrow. When • To check the output, press the right arrow. When
the brake pedal is not depressed and travel is not the brake pedal is not depressed and travel is not
selected 0 amps are displayed. Fully lower the plat- selected 0 amps are displayed. Fully lower the plat-
form and travel; approximately 1.4 amps are dis- form and travel; approximately 3.2 amps are dis-
played. played.
• Press the left and then the down arrow to scroll to • Press the left and then the down arrow to scroll to
the next submenu. the next submenu.
A3.4.2.3 Ohm = ______ A3.4.3.3 Ohm = ______
• To check the output, press the right arrow. With the • To check the output, press the right arrow. With the
brake applied or released, approximately 4 ohms brake applied or released, approximately 1.6 ohms
are displayed. are displayed.
• Press the left arrow twice and then the down arrow • Press the left arrow twice and then the down arrow
to scroll to the next submenu. to scroll to the next submenu.
A3.4.3 Brake I+/I A3.4.4 PVL
Brake I+/I- is the output signal for the inner brake coil. PVL is the proportional solenoid valve for lowering and
• To navigate to the first A3.4.3 Brake I+/I- submenu, is on the lift/lower manifold. It opens in proportion to the
press the right arrow. applied voltage during lower providing a path for oil to
flow from the lift cylinders to the reservoir.
A3.4.3.1 DC = ____%
• To navigate to the first A3.4.4 PVL submenu, press
• To check the output, press the right arrow. When the right arrow.
the brake pedal is not depressed and travel is not
selected, 0% of DC battery volts are displayed. A3.4.4.1 DC = ____%
Fully lower the platform and travel, approximately • To check the output, press the right arrow. When
20% of DC battery volts are displayed. lower is not selected, 0% of DC battery volts are
• Press the left and then the down arrow to scroll to displayed.
the next submenu. • Lift trucks With High Speed Lower:
When low speed lower is selected and the lift truck
is not in soft stop slowdown, approximately 50% of
DC battery volts are displayed. When high speed
lower is selected, approximately 100% of DC bat-
tery volts are displayed.
• Lift trucks With Single Speed Lower:
When lower is selected and the lift truck is not in
soft stop slowdown, approximately 100% of DC bat-
tery volts are displayed.
• Press the left and then the down arrow to scroll to
the next submenu.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
A3.4.4.2 Current = ______ arrow or wait approximately five seconds and the test
• To check the output, press the right arrow. When times out.
lower is not selected, approximately 41 milliamps • Press the right arrow to enter the submenus. Use
are displayed. the up and down arrows to navigate to the desired
• Lift trucks With High Speed Lower: submenu.
When low speed lower is selected and the lift truck A4.1 Access 1 Test Outputs
is not in soft stop slowdown, approximately 400 mil-
• Press the right arrow to navigate to the first A4.1
liamps are displayed. When high speed lower is se-
Access 1 submenu.
lected, approximately 750 milliamps are displayed.
• Lift trucks With Single Speed Lower: A4.1.1 ALM1
When lower is selected and the lift truck is not in ALM1 is an alarm on the platform distribution panel.
soft stop slowdown, approximately 750 milliamps
• To test the output, push the return arrow. The alarm
are displayed.
should sound.
• Press the left arrow twice and then the down arrow
• Press the down arrow to scroll to the next submenu.
to scroll to the next submenu.
A4.1.2 Lamps
A3.4.5 M2 DC = ____%
• To check the output, press the right arrow. M2 is the The A4.1.2 Lamps submenu pertains to the lamps on
power steering motor. When turning, up to 90% of the display.
DC battery volts are displayed. • To test the output, push the return arrow. All the
• This is the last A3 Outputs menu and the last Level lamps on the display should light.
2 Analyzer menu. Press the left arrow to return to • A4.1.2 Lamps is the last A4.1 Access 1 Test Out-
A3.4.5 M2 DC submenu. Press the left arrow to re- puts submenus. Press the left arrow until returning
turn to A3.4 Access 5 submenu. Press the left ar- to A4.1 Access 1 submenu.
row to return to A3 Outputs menu. Press the left ar- • Press the down arrow to scroll to A4.2 submenu.
row to return to Analyzer menu
A4 Test Outputs
When troubleshooting, A4 Test Outputs can be used to
check to see if the Access 1 2 3® module output volt-
age is being supplied to the components without oper-
ating the lift truck. See the A4 Test Outputs Submenus
table.
A4 Test Outputs Submenus
Sub- Module Function
menu
A4.1 Access 1 Display
A4.2 Access 3 Traction
A4.3 Access 4 Vehicle
A4.4 Access 5 Steering
Technician Tips: A4 is available in Level 3 service
mode only. It is not available in Level 2. For more infor-
mation and to access Level 3, see Level 3 near the
beginning of this section.
Technician Tips: During a test, all test output sub-
menus display a message Push Return to Cancel. To
cancel the test, the operator can either push the return
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
A4.2 Access 3 Test Outputs A4.2.3 P1
Technician Tips: Before connecting and disconnect- P1 is the pump 1 contactor coil. Pump 1 contactor is on
ing a DVOM from components, make sure to turn off the contactor panel just behind the traction motor.
the lift truck, disconnect the battery, and discharge the When the P1 coil is energized, P1 contacts close pro-
capacitance voltage. To discharge capacitance volt- viding voltage to the M3 low speed lift motor.
age, see the Control of Hazardous Energy section in • To test the output, connect both DVOM leads to P1
this manual. coil terminals. Step on the brake pedal, depress the
Technician Tips: Do not disconnect the terminal leads raise button and press the return arrow. The DVOM
from components and connect them to the DVOM displays approximately 10 volts.
leads when testing output. The leads must remain con- • Press the down arrow to scroll to the next submenu.
nected to the component to complete the circuit.
A4.2.4 FAN2
• Press the right arrow to navigate to the first A4.2
Access 3 test outputs submenu. FAN2 is a fan that helps to cool the Access 1 2 3®
modules and is located above Access 3™ in the power
A4.2.1 SVL unit.
SVL is the lowering solenoid valve and is on the lift/ • To test the output, connect both DVOM leads to
lower manifold. It opens during lower providing a path FAN2 terminals. Press the return arrow. The DVOM
for oil to flow from the lift cylinders to the reservoir. displays approximately 24 volts.
• To test the output, connect both DVOM leads to • Press the down arrow to scroll to the next submenu.
SVL terminals. Press the return arrow. The DVOM
A4.2.5 ED2
displays approximately 24 volts.
• Press the down arrow to scroll to the next submenu. ED2 is the number 2 Emergency Disconnect contactor
coil. The number 2 emergency disconnect contactor is
A4.2.2 P2 on the contactor panel just behind the traction motor.
Technician Tips: This submenu is only displayed on The ED2 coil receives battery negative from
lift trucks equipped with dual speed lift. Access 3™ and positive battery from Access 5.
• Press the right arrow to navigate to the first A4.2.5
P2 is the pump 2 contactor coil. The pump 2 contactor
ED2 submenu.
is on the contactor panel just behind the traction motor.
When the P2 coil is energized, P2 contacts close pro- A4.2.5.1 Low Side
viding voltage to the M4 high speed lift motor.
Low Side is the negative signal supplied by
To test the output, connect both DVOM leads to P2 coil Access 3™.
terminals. Step on the brake pedal, fully depress the • To test the output, connect DVOM positive lead to
raise button and press the return arrow. The DVOM a good battery positive reference. Connect the neg-
displays approximately 10 volts. ative DVOM lead to the ED2 coil terminal. Press the
• Press the down arrow to scroll to the next submenu. return arrow. The DVOM displays approximately 24
volts.
• Press the down arrow to scroll to the next submenu.
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A4.2.5.2 Both A4.3 Access 4 Test Outputs
Both means the negative signal supplied by • Press the right arrow to navigate to the first A4.3
Access 3™ and positive signal supplied by Access 5. Access 4 test outputs submenu.
• To test the output, connect both DVOM leads to A4.3.1 ALM2
ED2 coil terminals. Press the return arrow. The
ALM2 is an optional travel alarm and is mounted be-
DVOM displays approximately 22 volts.
tween the power unit and the platform on the power
• Press the left arrow to scroll back to A4.2.5 ED2 unit wall.
submenu. Then press the down arrow to scroll to
the next submenu. Technician Tips: This submenu is only displayed if the
features menu, F19 is enabled.
A4.2.6 M1-U
• To test the output, connect both DVOM leads to
M1-U is the traction motor U terminal signal. ALM2 terminals. Press the return arrow. The DVOM
• To test the output, connect DVOM positive lead to displays approximately 24 volts.
a good battery positive reference such as the bat- • Press the left arrow until returning to A4.3 Access 4
tery positive terminal on Access 3™. Connect the submenu. Press the down arrow to scroll to A4.4
negative DVOM lead to M1-U terminal. Press the submenu.
return arrow. The DVOM displays approximately 12
A4.4 Access 5 Test Outputs
volts.
• Press the right arrow to navigate to the first A4.4
• Press the down arrow to scroll to the next submenu.
Access 5 test outputs submenu.
A4.2.7 M1-V
A4.4.1 ED2
M1-V is the traction motor V terminal signal.
ED2 is the number 2 Emergency Disconnect contactor
• To test the output, connect the DVOM positive lead coil. The number 2 emergency disconnect contactor is
to a good battery positive reference such as the bat- on the contactor panel just behind the traction motor.
tery positive terminal on Access 3™. Connect the The ED2 coil receives battery negative from
negative DVOM lead to M1-V terminal. Press the Access 3™ and positive battery from Access 5.
return arrow. The DVOM displays approximately 12
• Press the right arrow to navigate to the first A4.4.1
volts.
ED2 submenu.
• Press the down arrow to scroll to the next submenu.
A4.4.1.1 High Side
A4.2.8 M1-W
High Side is the positive signal supplied by Access 5.
M1-W is the traction motor W terminal signal.
• To test the output, connect DVOM negative lead to
• To test the output, connect DVOM positive lead to a good battery negative reference. Connect the
a good battery positive reference such as the bat- positive DVOM lead to ED2 coil terminal. Press the
tery positive terminal on Access 3™. Connect the return arrow. The DVOM displays approximately 24
negative DVOM lead to M1-W terminal. Press the volts.
return arrow. The DVOM displays approximately 12
• Press the down arrow to scroll to the next submenu.
volts.
• A4.2.8 M1-W is the last A4.2 Access 3 Test Outputs
submenus. Press the left arrow until returning to
A4.2 Access 3 submenu. Press the down arrow to
scroll to A4.3 submenu.
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A4.4.1.2 Both • To test the output, connect both DVOM leads to M2
terminals. Press the return arrow. The DVOM dis-
Both the positive and negative signal are supplied by
plays approximately 7 volts.
Access 5 and Access 3™.
• To test the output, connect both DVOM leads to
ED2 coil. Press the return arrow. The DVOM dis-
plays approximately 24 volts.
• Press the left and then the down arrow to scroll to
the next submenu.
A4.4.2 BRK Outer
A4.4.2 BRK Outer is the submenu for the outer brake
coil.
• To test the output, connect the DVOM positive lead
to brake connector CA407 pin 1 (wire 2968). Con-
nect the negative DVOM lead to brake connector
CA407 pin 4 (wire 5929). Press the return arrow.
The DVOM displays approximately 3 volts.
• Press the down arrow to scroll to the next submenu.
A4.4.3 BRK Inner
A4.4.3 BRK Inner is the submenu for the outer brake
coil.
• To test the output, connect the DVOM positive lead
to brake connector CA407 pin 2 (wire 2969). Con-
nect the negative DVOM lead to brake connector
CA407 pin 3 (wire 5928). Press the return arrow.
The DVOM displays approximately 1.5 volts.
• Press the down arrow to scroll to the next submenu.
A4.4.4 PVL
PVL is the proportional solenoid valve for lowering and
is on the lift/lower manifold. It opens in proportion to
applied voltage during lower providing a path for oil to
flow from the lift cylinders to the reservoir.
• To test the output, connect both DVOM leads to
PVL coil terminals. Press the return arrow. The
DVOM displays approximately 12 volts.
• Press the down arrow to scroll to the next submenu.
A4.4.5 M2
M2 is the power steering motor.
• Press the right arrow to navigate to the first A4.4.5
M2 submenu.
A4.4.5.1 Clockwise
• To test the output, connect both DVOM leads to M2
terminals. Press the return arrow. The DVOM dis-
plays approximately 7 volts.
• Press the down arrow to scroll to the next submenu.
A4.4.5.2 CCwise
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Features F11 Max Load Weight = ___; This feature prompts the
operator to enter the maximum capacity load, which is
The feature menu is shown on the following pages. The indicated on the capacity data plate on the lift truck. If
first level of the menu shows the different areas of more than one capacity is listed, then enter the heavi-
setup for the lift truck. est weight listed on the capacity data plate. The factory
setting is 1,360 kg (3,000 lb) range dependent on the
Features access lift truck model.
After turning on the lift truck, navigate to the SERVICE F14 Wire Guidance = ___; This feature adjusts wire
menu by pressing the down arrow button. At the SER- guidance setting. The factory setting is disabled.
VICE menu, press the right arrow to enter LEVEL 2.
F15 Manual Wire Sense = ___; This feature adjusts
Press the right arrow again to enter the Access pass-
manual wire sense setting. The factory setting is dis-
word. Use the up or down arrow buttons to change
abled.
numbers, press right arrow to move to the next number.
Once all numbers in the Access code have been en- F16 End Aisle Control = ___; This feature adjusts end
tered, press the enter or return button. Using the down aisle control to no EAC, north sensing or south sens-
arrow, navigate to the FEATURES menu and then ing. The factory setting is No EAC.
press the right arrow. The message displayed is F1
F17 PDS = ___; This feature adjusts PDS setting. The
Language =.
factory setting is Disable.
If changes have been made in the sub menus, pressing
F18 Battery Retainer Switch = ___; This feature ad-
the left arrow at the first level menu prompts Save? N
justs battery retainer alarm setting. The factory setting
in the settings. Use the up and down arrows to select
is No.
Save? Y then press enter or return to save settings.
F19 Travel Alarm = ___; This feature sets the alarm
F1 Language = ___; This feature displays the desired
when traveling. The factory setting is Off.
language for Access 1 display messages. Factory set-
ting is English. Press down to scroll through 11 total F20 User Performance = ___; This feature deter-
choices. mines whether the operator can select different truck
performance levels. If enabled and F21 is disabled, any
F2 Unit of Measure = ___; This feature determines the
operator can select any performance level (P1, P2,
units of measure displayed (English or Metric). Factory
P3). If disabled, the operator cannot change lift truck
setting is English. Press the down arrow to continue.
performance modes. Press the right arrow, use the up
F3 Region = ___; This feature displays desired region. and down arrows to change. Press enter or return.
Range includes North America, Europe, and Australia. Press the down arrow to continue. The factory setting
Factory setting is North America. is Disabled.
F5 Truck Model = ___; This feature must be selected F21 User Codes = ____ Use this feature to enter up to
at setup. 25 operator codes (four digits each) which can be ap-
plied to various performance levels. To modify, press
F6 Mast Type = ___; This feature displays two mast
the right arrow. Use the up and down arrows to enable
types: TT or TL. Factory setting is TT.
or disable. Press the right arrow to continue. The fac-
F7 Collapsed Height = ___; This feature displays lift tory setting is Disabled.
truck collapsed height. The factory setting is 2,718 mm
Technician Tips: If F21 is enabled, operators cannot
(107 in).
change performance levels regardless of F20 setting.
F8 Lift Height = ___; This feature prompts the opera- Lift trucks are limited to the performance level assigned
tor to enter the lift truck lift height as shown on the lift to the Operator Code.
truck data plate. The factory setting is 6,096 mm
F23 Options = ____; This feature enables or disables
(240 in).
lift truck options listed in the F23 submenus.
F10 Truck Weight = ___; This feature prompts the op-
F24 Motor Monitor System (MMS) = ___; This feature
erator to enter the lift truck weight as equipped with a
adjusts MMS setting. The factory setting is Disabled.
maximum battery, which is indicated on the capacity
data plate of the lift truck. The factory setting is F25 Zone Switch = ___; This feature adjusts zone
3,825 kg (8,500 lb). switch setting. The factory setting is No.
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F26 Message Mode = ___; This feature changes the
information displayed during operation. Press the right
arrow, use the up and down arrows to change.
Select from: BDI (battery percent of charge), Hours
(hour meter reading), Odometer (total distance lift truck
has traveled in miles), Trip (total distance lift truck has
traveled since last reset), Timer (stopwatch) or All (al-
lows operator to determine message using display but-
tons). Press the enter or return button. The menu re-
turns to F26. Press the down arrow to continue. The
factory setting is None.
F27 LED Steer Indicator = ___; This feature adjusts
setting. Set to enabled or disabled. Only available if
F14 setting is disabled. The factory setting depends on
F14 setting.
F28 Hour Meter Mode = ___; This feature determines
the hour meter that is displayed during operation. To
change the displayed hour meter, press the right arrow,
use the up and down arrows to change between H1
and H2 (see hour meter description to determine mon-
itored system item). Press the enter or return button.
The menu returns to F28, press the down arrow to con-
tinue. The factory setting is Access 1.
F29 Reset Switch (HGTRS) Height = ___; This fea-
ture resets the height encoders. The factory setting is
381 mm (15 in).
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Performance access as any other performance level. For example, the P1
settings could be customized to be slower than or
The performance menu explanations are shown on the equal to the P3 standard settings. P2 and P3 menu ex-
following pages. The explanations do not explain how planations are not included in this section since they
to navigate through the menus and submenus or how are adjusted in the same manner as P1.
to change the selection. To navigate through and
change a menu selection, see the Service Level 2 and P1.1 Travel Acc = ___
3 - Performance Menus in this section of the service The travel acceleration setting is an adjustment of how
manual. The tables show the buttons that must be quickly the lift truck accelerates from idle to top travel
pushed to navigate through and change the menus. speed. The setting can be changed from 1 to 9, with 1
The performance menu can be accessed within Level taking the longest to accelerate and 9 taking the least.
2 and Level 3 of the Access 1 2 3® system. However, The factory settings are P1 = 9, P2 = 7 and P3 = 5.
to access the performance menu, the brake pedal must P1.2 Travel Speeds
not be pressed and the brake applied. After the opera-
tor selects the performance menu, lift, lower, and travel This is where lift truck travel speeds are set. The two
are disabled. Once the operator exits the performance adjustments within this submenu are Free Ranging
menu, they must recycle the key switch for lift, lower, and Guided.
and travel to be enabled. Technician Tips: If the F2 submenu is set to English,
After changing a performance setting, the operator all speeds are shown in mph. If the F2 submenu is set
must press the enter button to keep the setting. After all to Metric, the speeds are shown in kph.
changes are made and to save the settings, the opera- P1.2.1 Free Range
tor must press the left button until the display shows
Save? N. Change the N to a Y and press the enter but- Free Ranging is the term used to describe operating an
ton to save all changes. If the key switch is turned off SP 3500 with manual steering active (the lift truck is not
without saving the settings, the settings revert to the in Wire or Rail guidance mode). The three adjustments
previous settings. within this submenu are Speed Curve, Max FF, and
Max PUF.
Turn on the lift truck, do not press the brake pedal, and
navigate to the SERVICE menu by pressing the down P1.2.1.1 Speed Curve = ___
arrow button. At the SERVICE menu, enter LEVEL 2 or This setting adjusts when the lift truck travel begins
3. Press the right arrow again to enter the Access pass- speed reduction as the platform is raised during free
word. Use the up or down arrow buttons to change range travel. A setting of 1 means that the lift truck be-
number, press the right arrow to move to the next num- gins to slow down sooner (at lower elevation) and a
ber. Once all numbers in the Access code have been setting of 9 means that the lift truck begins to slow
entered, press the enter or return button. Using the down later (at higher elevation). The factory settings
down arrow navigate to the PERFORMANCE menu, are P1 = 9, P2 = 7, P3 = 5.
and then press the right arrow. The message displayed
is P1 Setup. P1.2.1.2 Max FF = ___ (Reverse Travel)
Technician Tips: P1, P2, and P3 are the three perfor- This setting adjusts the maximum travel speed in the
mance levels that may be selected when in level 1 as forks first (FF) direction. The range is 1.0–10.5 kph
long as F20 User Performance submenu is enabled (if (1.0–7.0 mph) dependent on the lift truck model. The
F20 User Performance submenu is disabled, the oper- factory settings for P1, P2, and P3 depend on the lift
ator is going to be locked in at the P1 settings). Each of truck model.
these performance levels can be programmed for dif- P1.2.1.3 Max PUF = ___ (Forward Travel)
ferent travel speeds and travel acceleration rates. This
allows these settings to be customized somewhat to an This setting adjusts the maximum travel speed in the
operator's level of experience or warehouse conges- power unit first (PUF) direction. The range is 1.0–
tion. The factory standard settings for the P1 perfor- 12.1 kph (1.0–7.5 mph) dependent on the lift truck
mance level are set to achieve maximum performance. model. The factory settings for P1, P2, and P3 depend
The factory standard settings for P2 are slower, and the on the lift truck model.
factory standard settings for P3 are the slowest. How-
ever, by customizing the settings, any performance
level, P1, P2, or P3, can be higher, lower, or the same
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P1.2.2 Guided P6.1 FF Braking = ___ (Reverse Travel)
This submenu is the same as P1.2.1 except the set- This setting adjusts the braking effort in the forks first
tings are for when the guidance switch is set to auto. (FF) direction. Range of adjustment is 1–9 with 1 pro-
viding the least amount of braking effort and 9 the
P1.2.2.1 Speed Curve = ___
most. The factory setting is 7. Before adjusting and so
This submenu is the same as P1.2.1.1 except the set- brake effort is properly adjusted, see the Brake section
tings are for when the guidance switch is set to auto. of this service manual and read and follow the Brake
Force Adjustment information.
P1.2.2.2 Max FF = ___ (Reverse Travel)
P6.2 PUF Braking = ___ (Forward Travel)
This submenu is the same as P1.2.1.2 except the set-
tings are for when the guidance switch is set to auto. This submenu is the same as P6.1, except the settings
are for the power unit first direction.
P1.2.2.3 Max PUF = ___ (Forward Travel)
P7 Free Range Speeds
This submenu is the same as P1.2.1.3 except the set-
tings are for when the guidance switch is set to auto. The P7 submenu is used to enter speed versus height
limits when operating the lift truck with manual steering
P4 Plug = ___
active. The two adjustments within this submenu are
The P4 Plug submenu adjusts plugging force. During the platform heights when lift truck speed is limited to
plugging, the control system uses regenerative motor 1.6 kph (1.0 mph) and 0 kph (0 mph).
current to slow the rotation of the drive motor. The
P7.1 1 Mph Height = ___
range of adjustment is 1–9. A setting of 9 provides the
shortest plugging distance and a setting of 1 the lon- P7.1 is the first speed, height limit. The speed of the lift
gest. However, the plugging distance is proportional to truck is limited to 1.6 kph (1.0 mph) when the platform
how far the twist grip is rotated. The longest plugging reaches the height set in this submenu. The range of
distance occurs when the twist grip is rotated slightly adjustment is 0 cm to 1,524 cm (0 in to 600 in). The
and near the neutral position and the P4 setting is set factory setting is 1,524 cm (600 in).
to 1. The shortest plugging distance is achieved when
the twist grip is rotated fully and the P4 setting is set to
9. The factory setting is 9.
P5 Coast = ___
The P5 Coast adjustment affects the coasting effort of
the lift truck when, with the lift truck traveling, the oper-
ator returns the twist grip to neutral and remains stand-
ing on the brake pedal. Regenerative motor current is
also used for this function. The higher the setting, the
lower the amount of regenerative energy applied to the
traction motor and the further the lift truck travels or
coasts when the twist grip is returned to neutral. The
lower the setting, the higher the amount of regenerative
energy applied to the traction motor and the quicker the
lift truck will coast to a stop when the twist is returned
to neutral. The range of adjustment for Coast is 1–9.
The factory setting is 9.
P6 Braking
The P6 Braking submenu adjusts the braking effort of
the lift truck. Lift truck braking is accomplished through
the traction motor brake combined with regenerative
motor current. On the SP 3500, braking is adjusted
separately for the forks first and power unit first direc-
tions of travel.
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P7.2 0 Mph Height = ___ This submenu is the same as P7.2 except the settings
are for when the guidance switch is set to auto.
P7.2 is the second speed height limit. The speed of the
lift truck is limited to 0 kph (0 mph) when the platform P8.3 Acquire Speeds = ___
reaches the height set in this submenu. When this
P8.3 sets the travel speed when lift trucks equipped
height is reached and travel is requested, the display
with wire guidance are acquiring the wire. The adjust-
shows the message Reduce Lift Height. The range of
ment range is 1.5 kph (1.5 mph) to 4.0 kph (2.5 mph).
adjustment is 0 cm to 1,524 cm (0 in to 600 in). The
The factory setting is 4.0 kph (2.5 mph).
factory setting is 1,524 cm (600 in).
P9 BDI = ___
Technician Tips: If P7.2 is set to a lower height than
P7.1, the height set for P7.2 takes precedence and the See Figure 32 and the P9 Settings table. Changing this
lift truck is not able to use the 1.6 kph (1.0 mph) speed, value affects the lift lockout level which disables the lift
height limit (P7.1) setting. circuit when the battery is 80% discharged. The range
of adjustment for P9 is 1–9. Decreasing the P9 setting
P8 Guided Speeds
reduces the volts-per-cell monitor, allowing the battery
This submenu is the same as P7 except the settings to go into deeper discharge before lift lockout. Increas-
are for when the guidance switch is set to auto. ing the P9 setting increases the volts-per-cell monitor,
disabling the lift function earlier in the discharge cycle.
P8.1 1 Mph Height = ___
Setting P9 to a level that permits battery discharge that
This submenu is the same as P7.1 except the settings is too deep may cause Event Codes relating to low bat-
are for when the guidance switch is set to auto. tery voltage to occur. The factory setting is 5.
P8.2 0 Mph Height = ___
SOC Discharge Reading
P9 set to 1
P9 set to 5
P9 set to 9
25.50
25.00
24.50
Voltage
24.00
23.50
23.00
100.0% 80.0% 60.0% 40.0% 20.0%
Lift
Lockout
State of Charge
Fig. 32 (22572-01)
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• Slowdown with Auto Resume - See Figure 33.
P9 SettingsC When the lift truck travels and senses the floor mag-
nets, Slowdown with Auto Resume mode causes
Percent P9 set to 1 P9 set to 5 P9 set to 9 the lift truck to slow down to the speed set in
P12.2.1 and P12.3.1 Slowdown Speed submenus.
100.0% 25.44 25.44 25.44
After traveling the distance set in P12.2.3 and
20.0% 23.33 23.71 24.10 P12.3.3 Resume Distance submenus, normal
travel speed is permitted. This mode is useful in
Technician Tips: The P10 and P11 menus are re- warehouses with an intersection.
served for options that may be added in the future.
P12 EAC Setup
1
Technician Tips: When traveling in auto guided steer-
ing mode, the End Aisle Control (EAC) system reminds
the operator an intersection or the end of the aisle is
approaching. This system incorporates magnets in the
floor and sensors on the lift truck. For more information
concerning the EAC system, see End Aisle Control
section in this service manual. 4
If F16 EAC submenu is set to none, the P12 EAC
Setup submenu is not available.
P12 EAC Setup submenu is used to set up how the lift
truck reacts when the EAC system senses the magnets
near the end of an aisle or intersection.
P12.1 Mode = ___ 3
This setting determines what the EAC system does
(mode) when the magnets are sensed. The choices
are:
• Slowdown - When the lift truck travels to the end of
an aisle and senses the floor magnets, Slowdown 2
mode causes the lift truck to slow down to the
speed set in P12.2.1 and P12.3.1 Slowdown Speed
submenus. Slowdown guided travel speed is main-
tained until the lift truck exits the aisle and manual
steering is selected. If reverse direction is selected
before exiting the aisle, normal guided travel speed
is permitted. When entering the aisle and switching
to auto guided steering, and before the lift truck
sensors sensing the magnets, the operator can 1
press and hold the override button (ORS1 - see
Componentry section) to override the slowdown Fig. 33 (22574-01)
speed. After entering the aisle and switching to auto 1 Floor magnets
guided steering and after the lift truck sensors 2 Power unit first resume distance
sense the magnets, normal guided travel speed is 3 Magnet spread
permitted. 4 Forks first resume distance
If the lift truck is traveling power unit first within the
power unit first Resume Distance, the speed is limited
to the power unit first Slowdown speed. If the lift truck
is traveling power unit first beyond the Resume Dis-
tance, full guided travel speed is resumed. Operation in
the forks first direction is the same.
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Technician Tips: Resume Distance is measured from P12.2.1 Slowdown Speed = ___
the magnet sensor bar located under the lift trucks bat-
This setting adjusts the lift truck speed when traveling
tery box.
forks first in Slowdown mode. The adjustment range is
• Slowdown with Auto Stop - When the lift truck trav- 1.0 kph to 6.0 kph (1.0 mph to 6.0 mph). The factory
els and senses the floor magnets, Slowdown with setting is 3.2 kph (2.0 mph).
Auto Stop mode will cause the lift truck to slow
down to the speed set in P12.2.1 and P12.3.1 Slow- P12.2.2 Decel Rate = ___
down Speed menus and, after traveling the dis- This setting adjusts the deceleration rate that the lift
tance set in P12.2.4 and P12.3.4 Stop Distance truck uses to reach the slowdown speed set in P12.2.1.
submenus, cause the lift truck to stop. The operator The range of adjustment for this setting is 1–9 with 1
must return the traction twist grip to neutral and being the least aggressive deceleration and 9 being the
press the override button for travel to be permitted. most aggressive. The factory setting is 3.
Slowdown guided travel speed is maintained until
the lift truck exits the aisle and manual steering is Technician Tips: If Stop Using Brake mode is se-
selected. When entering the aisle and switching to lected, this submenu is not available.
guided steering and before the lift truck sensors P12.2.3 Resume Distance = ___
sensing the magnets, the operator can press and
hold the override button to override the slowdown This setting adjusts the forks first distance that the lift
speed. After entering the aisle and switching to truck must travel beyond the EAC magnets before trac-
guided steering and the lift truck sensors sense the tion speed is released from the slowdown speed. The
magnets, normal guided travel speed is permitted. adjustment range is 3–18 m (10–60 ft). The factory set-
ting is 14 m (45 ft.). This setting is used on lift trucks set
• Stop Using Motor - When the lift truck travels and
to Slowdown with Auto Resume mode (see P12.1
senses the floor magnets, Stop Using Motor mode
Mode).
causes the lift truck to stop using regenerative mo-
tor current decelerating at a rate set in P12.2.2 and Technician Tips: If Slowdown with Auto Resume
P12.3.2 Decel Rate submenus. The operator must mode is not selected, this submenu is not available.
return the traction twist grip to neutral and press the
P12.2.4 Stop Distance = ___
override button for travel to be permitted. Slowdown
guided travel speed is maintained until the lift truck This submenu adjusts the distance that the lift truck
exits the aisle. must travel beyond the EAC magnets (into the slow-
• Stop Using Brake - When the lift truck travels and down zone) before the lift truck stops. The adjustment
senses the floor magnets, Stop Using Brake mode range is 0 m to 12 m (0 ft to 40 ft). The factory setting
causes the lift truck to stop using the traction brake is 6 m (20 ft). This setting is used on lift trucks set to
and at the same decelerating rate as if the operator Slowdown with Auto Stop mode (see P12.1 mode).
released the brake pedal. The operator must return Technician Tips: If Slowdown with Auto Stop mode
the traction twist grip to neutral and press the over- is not selected, this submenu is not available.
ride button for travel to be permitted. Slowdown
guided travel speed is maintained until the lift truck P12.3 PUF Direction (Forward Travel)
exits the aisle. This submenu is the same as P12.2 except the settings
P12.2 FF Direction (Reverse Travel) are for the power unit first direction.
In this submenu, adjustments are made to the mode P12.3.1 Slowdown Speed = ___
(see P12.1 Mode) performance when traveling in the This submenu is the same as P12.2.1 except the set-
forks first (FF) direction. The adjustments are: tings are for the power unit first direction.
• P12.2.1 Slowdown Speed
P12.3.2 Decel Rate = ___
• P12.2.2 Deceleration Rate
This submenu is the same as P12.2.2 except the set-
• P12.2.3 Resume Distance
tings are for the power unit first direction.
• P12.2.4 Stop Distance
P12.3.3 Resume Distance = ___
Technician Tips: Dependent on the mode selected,
some adjustments (submenus) listed above may not This submenu is the same as P12.2.3 except the set-
be available. tings are for the power unit first direction.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
P12.4 Slowdown Direction = ___ being the least aggressive deceleration and 9 being the
most aggressive. The factory setting is 9.
This submenu programs the lift truck so it will slow-
down when traveling out of the aisle or in and out of the P13.2 PUF Direction (Forward Travel)
aisle. The choices are Out of Aisle Only, or Into and Out
This submenu is the same as P13.1 except the settings
of Aisle.
are for the power unit first direction.
The factory setting is Out of Aisle Only.
P13.2.1 Max Speed = ___
Technician Tips: If Slowdown with Auto Resume is
This submenu is the same as P13.1.1 except the set-
selected, this submenu is not available.
tings are for the power unit first direction.
P12.5 Magnet Spread = ___
P13.2.2 Slowdown Speed = ___
See Figure 33. This setting tells the lift truck the dis-
This submenu is the same as P13.1.2 except the set-
tance between the inside magnets at a cross aisle. The
tings are for the power unit first direction.
adjustment range is 6 m to 46 m (20 ft to 150 ft). This
setting is used on lift trucks set to Slowdown with Auto P13.2.3 Decel Rate = ___
Resume. The factory setting is 24 m (80 ft).
This submenu is the same as P13.1.3 except the set-
Technician Tips: If Slowdown with Auto Resume is tings are for the power unit first direction.
not selected, this submenu is not available.
P14 Low Speed Lower
P13 PDS Setup
This submenu adjusts the low speed lowering speeds.
This submenu is used to set up the operating parame- The low speed lowering speed submenus are:
ters for the optional Personnel Detection System. The • P14.1 Low Speed Lower 1
PDS uses sensors mounted on the lift truck to warn the
• P14.2 Low Speed Lower 2
operator of any obstruction or person in the aisle.
• P14.3 Aux Lower Speed
Technician Tips: If F17 is set to Disable, the P13 PDS
Setup submenu is not available.
P13.1 FF Direction (Reverse Travel)
This submenu is used to adjust PDS settings for the
forks first direction of travel. The settings are:
• P13.1.1 Max Speed
• P13.1.2 Slowdown Speed
• P13.1.3 Decel Rate
P13.1.1 Max Speed = ___
This submenu sets the maximum speed in the forks
first direction when PDS is active. The adjustment
range is 1.0 kph—10.5 kph (1.0 mph—6.5 mph). The
factory setting is 9.7 kph (6.0 mph).
P13.1.2 Slowdown Speed = ___
This submenu adjusts the lift truck speed when travel-
ing in the forks first direction and PDS senses a person
or an object. The adjustment range is 1.0 kph—6.0 kph
(1.0 mph—6.0 mph). The factory setting is 2.5 kph
(1.5 mph).
P13.1.3 Decel Rate = ___
This submenu adjusts the deceleration rate that the lift
truck uses to reach the slowdown speed set in P13.1.2.
The range of adjustment for this setting is 1-9 with 1
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
P14.1 Low Speed Lower 1 = ___
This submenu adjusts the low speed lowering when the
platform is above 380 mm (15 in) (HGRTS switch con-
tacts are open). Adjusting to a setting of 1 provides the
slowest lowering speed. Adjusting to a setting of 9 pro-
vides the fastest lowering speed. The factory setting is
5.
P14.2 Low Speed Lower 2 = ___
This submenu adjusts the lowering speed when the
platform is at or below 380 mm (15 in) (HGRTS switch
contacts are closed). Adjusting to a setting of 1 pro-
vides the slowest/softest lowering speed. Adjusting to
a setting of 9 provides the fastest/hardest lowering
speed. The factory setting is 1.
P14.3 Aux Lower Speed = ___
This submenu affects the lowering speed of the auxil-
iary mast on SP 3512 and SP 3522 lift trucks. Adjusting
to a setting of 1 decreases the auxiliary lowering
speed. Adjusting to a setting of 9 decreases the auxil-
iary lowering speed. The factory setting is 5.
Technician Tips: If F5 is not set to 3512-1.0 or 3522-
1.0, this submenu is not available.
P15 Soft Stop = ___
This setting adjusts the deceleration rate of the plat-
form lowering after the lower switch has been released.
Adjusting to a setting of 1 provides the slowest/softest
stop. Adjusting to a setting of 9 provides the fastest/
hardest stop. The factory setting is 5.
P99 Load Factory Defaults = ___
With this submenu, the operator can load the factory
settings for all Performance menu levels.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Factory Settings Factory Settings
Menu Factory Setting Menu Factory Setting
P1.1 9 P7.1 1,524 cm (600 in)
P1.2.1.1 9 P7.2 1,524 cm (600 in)
See the P1 Performance P8.1 1,524 cm (600 in)
P1.2.1.2
table
P8.2 1,524 cm (600 in)
See the P1 Performance
P1.2.1.3 P8.3 4.0 km/h (2.5 mph)
table
P9 5
P1.2.2.1 9
P12.1 Slowdown Mode
See the P1 Performance
P1.2.2.2
table P12.2.1 3.2 km/h (2.0 mph)
See the P1 Performance P12.2.2 3
P1.2.2.3
table
P12.2.3 14 m (45 ft)
P2.1 7
P12.2.4 6 m (20 ft)
P2.2.1.1 7
P12.3.1 3.2 km/h (2.0 mph)
See the P2 Performance
P2.2.1.2 P12.3.2 5
table
P12.3.3 14 m (45 ft)
See the P2 Performance
P2.2.1.3
table P12.3.4 6 m (20 ft)
P2.2.2.1 7 P12.4 Out of Aisle Only
See the P2 Performance P12.5 24 m (80 ft)
P2.2.2.2
table
P13.1.1 9.7 km/h (6.0 mph)
See the P2 Performance
P2.2.2.3 P13.1.2 2.5 km/h(1.5 mph)
table
P13.1.3 9
P3.1 5
P13.2.1 9.7 km/h (6.0 mph)
P3.2.1.1 5
P13.2.2 2.5 km/h (1.5 mph)
See the P3 Performance
P3.2.1.2
table P13.2.3 9
See the P3 Performance P14.1 5
P3.2.1.3
table
P14.2 1
P3.2.2.1 5
P14.3 5
See the P3 Performance
P3.2.2.2 P15 5
table
See the P3 Performance
P3.2.2.3
table
P4 9
P5 9
P6.1 7
P6.2 7
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
P1 Performance
Region Model P1 Default and Maximum
Free Range Guided
FF PUF FF PUF
9.7 km/h 10.5 km/h 9.7 km/h 10.5 km/h
SP 3505
(6.0 mph) (6.5 mph) (6.0 mph) (6.5 mph)
10.5 km/h 12.1 km/h 10.5 km/h 12.1 km/h
SP 3510
(6.5 mph) (7.5 mph) (6.5 mph) (7.5 mph)
10.5 km/h 12.1 km/h 10.5 km/h 12.1 km/h
SP 3520
(6.5 mph) (7.5 mph) (6.5 mph) (7.5 mph)
10.5 km/h 12.1 km/h 10.5 km/h 12.1 km/h
ANSI SP 3522
(6.5 mph) (7.5 mph) (6.5 mph) (7.5 mph)
11.3 km/h 12.1 km/h 11.3 km/h 12.1 km/h
SP 3550
(7.0 mph) (7.5 mph) (7.0 mph) (7.5 mph)
9.7 km/h 11.3 km/h 9.7 km/h 11.3 km/h
SP 3570
(6.0 mph) (7.0 mph) (6.0 mph) (7.0 mph)
9.7 km/h 11.3 km/h 9.7 km/h 11.3 km/h
SP 3580
(6.0 mph) (7.0 mph) (6.0 mph) (7.0 mph)
9.0 km/h 9.0 km/h 10.5 km/h 12.1 km/h
SP 3511
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 km/h 9.0 km/h 10.5 km/h 12.1 km/h
SP 3512
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 km/h 9.0 km/h 10.5 km/h 12.1 km/h
SP 3521
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
EMEA
9.0 km/h 9.0 km/h 10.5 km/h 12.1 km/h
SP 3522
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 km/h 9.0 km/h 9.7 km/h 11.3 km/h
SP 3571
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 km/h 9.0 km/h 9.7 km/h 11.3 km/h
SP 3781
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 km/h 9.0 km/h 10.5 km/h 12.1 km/h
SP 3510
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 km/h 9.0 km/h 10.5 km/h 12.1 km/h
SP 3520
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
9.0 km/h 9.0 km/h 10.5 km/h 12.1 km/h
SP 3522
(5.6 mph) (5.6 mph) (6.5 mph) (7.5 mph)
SAA
9.0 km/h 9.0 km/h 11.3 km/h 12.1 km/h
SP 3550
(5.6 mph) (5.6 mph) (7.0 mph) (7.5 mph)
9.0 km/h 9.0 km/h 9.7 km/h 11.3 km/h
SP 3570
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 km/h 9.0 km/h 9.7 km/h 11.3 km/h
SP 3780
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
P2 Performance
Region Model P2 Default
Free Range Guided
FF PUF FF PUF
8.9 km/h 9.7 km/h 8.9 km/h 9.7 km/h
SP 3505
(5.5 mph) (6.0 mph) (5.5 mph) (6.0 mph)
9.7 km/h 11.3 km/h 9.7 km/h 11.3 km/h
SP 3510
(6.0 mph) (7.0 mph) (6.0 mph) (7.0 mph)
9.7 km/h 11.3 km/h 9.7 km/h 11.3 km/h
SP 3520
(6.0 mph) (7.0 mph) (6.0 mph) (7.0 mph)
9.7 km/h 11.3 km/h 9.7 km/h 11.3 km/h
ANSI SP 3522
(6.0 mph) (7.0 mph) (6.0 mph) (7.0 mph)
10.5 km/h 11.3 km/h 10.5 km/h 11.3 km/h
SP 3550
(6.5 mph) (7.0 mph) (6.5 mph) (7.0 mph)
8.9 km/h 10.5 km/h 8.9 km/h 10.5 km/h
SP 3570
(5.5 mph) (6.5 mph) (5.5 mph) (6.5 mph)
8.9 km/h 10.5 km/h 8.9 km/h 10.5 km/h
SP 3580
(5.5 mph) (6.5 mph) (5.5 mph) (6.5 mph)
9.0 km/h 9.0 km/h 9.7 km/h 11.3 km/h
SP 3511
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 km/h 9.0 km/h 9.7 km/h 11.3 km/h
SP 3512
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 km/h 9.0 km/h 9.7 km/h 11.3 km/h
SP 3521
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
EMEA
9.0 km/h 9.0 km/h 9.7 km/h 11.3 km/h
SP 3522
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 km/h 9.0 km/h 8.9 km/h 10.5 km/h
SP 3571
(5.6 mph) (5.6 mph) (5.5 mph) (6.5 mph)
9.0 km/h 9.0 km/h 8.9 km/h 10.5 km/h
SP 3581
(5.6 mph) (5.6 mph) (5.5 mph) (6.5 mph)
9.0 km/h 9.0 km/h 9.7 km/h 11.3 km/h
SP 3510
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 km/h 9.0 km/h 9.7 km/h 11.3 km/h
SP 3520
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
9.0 km/h 9.0 km/h 9.7 km/h 11.3 km/h
SP 3522
(5.6 mph) (5.6 mph) (6.0 mph) (7.0 mph)
SAA
9.0 km/h 9.0 km/h 10.5 km/h 11.3 km/h
SP 3550
(5.6 mph) (5.6 mph) (6.5 mph) (7.0 mph)
9.0 km/h 9.0 km/h 8.9 km/h 10.5 km/h
SP 3570
(5.6 mph) (5.6 mph) (5.5 mph) (6.5 mph)
9.0 km/h 9.0 km/h 8.9 km/h 10.5 km/h
SP 3580
(5.6 mph) (5.6 mph) (5.5 mph) (6.5 mph)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
P3 Performance
Region Model P3 Default
Free Range Guided
FF PUF FF PUF
8.0 km/h 8.9 km/h 8.0 km/h 8.9 km/h
SP 3505
(5.0 mph) (5.5 mph) (5.0 mph) (5.5 mph)
8.9 km/h 10.5 km/h 8.9 km/h 10.5 km/h
SP 3510
(5.5 mph) (6.5 mph) (5.5 mph) (6.5 mph)
8.9 km/h 10.5 km/h 8.9 km/h 10.5 km/h
SP 3520
(5.5 mph) (6.5 mph) (5.5 mph) (6.5 mph)
8.9 km/h 10.5 km/h 8.9 km/h 10.5 km/h
ANSI SP 3522
(5.5 mph) (6.5 mph) (5.5 mph) (6.5 mph)
9.7 km/h 10.5 km/h 9.7 km/h 10.5 km/h
SP 3550
(6.0 mph) (6.5 mph) (6.0 mph) (6.5 mph)
8.0 km/h 9.7 km/h 8.0 km/h 9.7 km/h
SP 3570
(5.0 mph) (6.0 mph) (5.0 mph) (6.0 mph)
8.0 km/h 9.7 km/h 8.0 km/h 9.7 km/h
SP 3580
(5.0 mph) (6.0 mph) (5.0 mph) (6.0 mph)
8.0 km/h 8.0 km/h 8.9 km/h 10.5 km/h
SP 3511
(5.0 mph) (5.0 mph) (5.5 mph) (6.5 mph)
8.0 km/h 8.0 km/h 8.9 km/h 10.5 km/h
SP 3512
(5.0 mph) (5.0 mph) (5.5 mph) (6.5 mph)
8.0 km/h 8.0 km/h 8.9 km/h 10.5 km/h
SP 3521
(5.0 mph) (5.0 mph) (5.5 mph) (6.5 mph)
EMEA
8.0 km/h 8.0 km/h 8.9 km/h 10.5 km/h
SP 3522
(5.0 mph) (5.0 mph) (5.5 mph) (6.5 mph)
8.0 km/h 8.0 km/h 8.0 km/h 9.7 km/h
SP 3571
(5.0 mph) (5.0 mph) (5.0 mph) (6.0 mph)
8.0 km/h 8.0 km/h 8.0 km/h 9.7 km/h
SP 3581
(5.0 mph) (5.0 mph) (5.0 mph) (6.0 mph)
8.0 km/h 8.0 km/h 8.9 km/h 10.5 km/h
SP 3510
(5.0 mph) (5.0 mph) (5.5 mph) (6.5 mph)
8.0 km/h 8.0 km/h 8.9 km/h 10.5 km/h
SP 3520
(5.0 mph) (5.0 mph) (5.5 mph) (6.5 mph)
8.0 km/h 8.0 km/h 8.9 km/h 10.5 km/h
SP 3522
(5.0 mph) (5.0 mph) (5.5 mph) (6.5 mph)
SAA
8.0 km/h 8.0 km/h 9.7 km/h 10.5 km/h
SP 3550
(5.0 mph) (5.0 mph) (6.0 mph) (6.5 mph)
8.0 km/h 8.0 km/h 8.0 km/h 9.7 km/h
SP 3570
(5.0 mph) (5.0 mph) (5.0 mph) (6.0 mph)
8.0 km/h 8.0 km/h 8.0 km/h 9.7 km/h
SP 3580
(5.0 mph) (5.0 mph) (5.0 mph) (6.0 mph)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
Calibration • Press the left arrow and the display shows, Save?
N. Change the N to Y and press the enter button to
See the following explanations for the calibration save the settings.
menus. • Press the down arrow to continue calibration. C2
Calibration access Valves menu is displayed.
The calibration menu is only available in Level 2 and is C2 Valves
not available in Level 3. To view the Calibration menu, This calibration allows Access 5 to determine the
the operator must not depress the brake pedal. If the amount of current required to open the proportional
operator stands on the brake pedal, the Calibration lowering valve (PVL). This calibration must be per-
menu will not be visible. Once the operator selects the formed after replacing or adjusting PVL or an
Calibration menu, they can stand on the pedal to oper- Access 1 2 3® module.
ate the lift truck functions for calibration. • Press the right arrow and C2.1 Main Lower menu is
Turn on the lift truck, do not press the brake pedal, and displayed.
navigate to the SERVICE menu by pressing the down • Press the right arrow to enter C2.1 Main Lower
arrow button. At the SERVICE menu, enter LEVEL 2. menu and the display shows, Sure? N. Change the
Press the right arrow again to enter the Access pass- N to Y and press the enter button.
word. Use the up or down arrow buttons to change
number, press the right arrow to move to the next num- The following messages are displayed:
ber. Once all numbers in the Access code have been • Raise above reset, lower to begin - See Figure 34.
entered, press the enter or return button. Using the Raise the platform above the Height Reset Switch
down arrow navigate to the Calibration menu, and then (2). The HGTRS is on the back of the platform. The
press the right arrow. The message displayed is C1 bar that actuates the switch (1) is approximately
Handles. 380 mm (15 in) tall. Therefore, the operator needs
to raise the platform at least 380 mm (15 in), but not
Technician Tips: To prevent nuisance event codes, high enough to start staging the mast.
as a rule, if any Access 1 2 3® module is replaced,
Crown recommends performing all calibrations. Also, if
the replacement module includes updated software,
the software in the remaining modules has to be up-
dated so all module software is compatible.
C1 Handles
This calibration allows the lift truck to learn the values
of the traction potentiometer (POT1). The traction po-
tentiometer must be calibrated after replacing POT1,
FS, RS, or an Access 1 2 3® module.
• Press the right arrow and C1.1 Traction menu is
displayed.
• Press the right arrow to enter C1.1 Traction menu
and the display shows, Sure? N. Change the N to Y Fig. 34 (21957-01)
and press the enter button.
The operator is then asked to set three positions for the
twist grip. As the operator performs the following com-
mands, press the right arrow to view the percent of
POT1 voltage seen by Access 4.
• PUF Direction - Rotate the twist grip to the full
power unit first direction and press the enter button.
• FF Direction - Rotate the twist grip to the full forks
first direction and press the enter button.
• Center - Release the twist grip and press the enter
button.
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
• After raising the platform, press the enter button
and lower (maintain command) the platform. Con-
tinue to follow the instructions on the display. The
menus automatically advance as the operator per-
forms each step. As the following messages ap-
pear, press the right arrow to view the current flow-
ing through PVL (from Access 5).
• Finding Breakout, Maintain Command
• Finding Speed 1, Maintain Command
• Finding Speed 2, Maintain Command
Fig. 36 (21965)
• Paused - Raise, Lower to begin - This message ap-
pears when the operator has lowered to the reset This calibration must be performed after replacing an
switch while finding the two speeds. Raise the plat- Access 1 2 3® module.
form and lower again. Technician Tips: Although ECR4 provides platform
• Stop Command height input to Access 4, this encoder does not require
• Lower forks to floor, press enter calibration. Each time the height reset switch, HGRTS,
is actuated, Access 1 2 3® checks the height input to
• Press the left arrow and the display shows, Save?
be sure that the input is correct. This is how
N. Change the N to Y and press the enter button to
Access 1 2 3® maintains the correct height of the
save the settings.
height cutouts.
• Press the down arrow to continue calibration. C3
• Press the right arrow and the C3.1 Cutout 1 menu
Height Cutouts menu is displayed.
is displayed.
C3 Height Cutouts • Press the right arrow and the C3.1.1 Set Height is
See Figure 35. If the lift truck is equipped with an over- displayed.
ride switch, a total of six raise and lower cutouts can be • Press the right arrow and R/L to Cutout then Enter
programmed. If the lift truck is not equipped with an message is displayed.
override switch, one raise cutout can be programmed. • Raise or lower the platform to the desired height. If
See Figure 36. The cutouts can also be programmed to the operator wishes to view the height of the plat-
work all the time, only while outside of the guided aisle, form, press the right arrow.
and while in a certain zone (must be equipped with a • After positioning the platform at the desired height,
zone select switch). press enter. Pressing enter sets the height and re-
turns the operator to the C3.1.1 Set Height menu.
• Press the down arrow and the C3.1.2 Type = _____
menu is displayed.
Fig. 35 (21964)
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ELECTRICAL SYSTEM
Access 1 2 3® Menus
• Press the right arrow and then the down or up arrow • To program additional cutouts, push the down ar-
to scroll to one of the following cutout types: row. Up to six different cutouts can be programmed
– None - No cutout desired. at one time. The process to program these cutouts
is performed the same as described.
– PCT - Positive (raise) Cutout: allows override
when equipped with the required override switch. • Press the left arrow and the message, Save? N, ap-
pears.
– PST - Positive (raise) Stop: no override option.
– If the operator presses the up arrow, a Clear All
– NCT - Negative (lower) Cutout: allows override
message appears. Pushing the enter button, af-
when equipped with the required override switch.
ter this message appears, deletes all the cutouts.
• Once the operator has scrolled to the type of cutout The display then returns to C3 Height Cutouts
desired, press enter to select it. The display returns menu.
to the C3.1.2 Type = _____ menu.
– If the operator presses the down arrow, Save Y
• Press the down arrow and the menu C3.1.3 When message appears. Pushing the enter button, af-
= _____ is displayed. ter this message appears, saves all the cutouts.
• Press the right arrow and then the down or up arrow The display then returns to C3 Height Cutouts
to scroll when the cutout occurs: menu.
– Always - With this setting, the cutout occurs all • Press the down arrow to continue calibration. C4
the time. Steer Encoder menu is displayed.
– Free Range Only - With this setting, the cutout C4 Steer Encoder
occurs only when the lift truck is outside of the
guided aisle. The C4 Steer Encoder menu is where the encoder in-
dex is set to the straight-ahead steer wheel position.
• Once the operator has navigated to the desired set-
This step is important for optimal wire and rail guidance
ting, press enter to select it. The display returns to
performance. Perform C4 calibration after replacing or
the C3.1.3 When = _____ menu.
adjusting ECR2 or an Access 1 2 3® module.
• Press the down arrow. If the lift truck is equipped
• See Figure 37. Rotate the steering tiller so that the
with the optional three position zone select switch
alignment marks located on the drive unit and drive
and it is enabled in the features menu F25, C3.1.4
unit mounting bracket form a straight line.
Zone menu option appears.
• Technician Tips: If this message does not appear,
disregard this step and the next two steps, and pro-
ceed with the step: Press the left arrow to return to
C3.1 Cutout 1 menu.
• Press the right arrow and the menu allows the op-
erator to program different cutout scenarios for mul-
tiple zones:
1
– A, B, C, All
• Select the desired zone (selected by the zone se-
lect switch) and press the enter button. The display
returns to the C3.1.4 Zone menu.
• Press the left arrow to return to C3.1 Cutout 1
menu.
Fig. 37 (23050-01)
1 Alignment marks
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• Press the right arrow to enter the C4 Steer Encoder required to stop the lift truck before the lift truck comes
menu and the display shows, Sure? N. Change the off the wire and an event code is logged.)
N to Y and press the enter button.
The components that directly affect wire guidance in-
• See Figure 38. The message Encoder at Index is clude the front and rear sensor bars, the steer angle
displayed and a continuous alarm goes off. If the feedback encoder (ECR2), the floor signal strength,
display does not indicate that the encoder is at in- and the Access 1 2 3® modules. Whenever any of
dex when the operator enters the menu, remove the these components are changed or adjusted, the wire
steering feedback encoder cover. Loosen the two guidance system must be calibrated. The mechanical
steering encoder screws enough to rotate the en- items that can affect wire guidance are covered in the
coder with resistance. following Pre-Calibration Checks.
Pre-Calibration Checks
The wire guidance system operates through the exist-
ing lift truck steering mechanism. Slack, lag, or exces-
sive wear within this system prevents guidance within
specifications. Before performing the wire guidance
calibration, the lift trucks steering system must be thor-
oughly checked by verifying the following:
• See Figure 39. Check the steering gear box output
gear (1), the gear on the drive unit (2) and the steer-
ing encoder gear (3). Look for chipped or missing
1 teeth or any dirt or debris between the teeth of each
gear. The gears should have a light coat of evenly
applied grease.
Fig. 38 (23042-01)
1 Steering feedback encoder mounting screws
• Rotate the encoder until the index is reached. If the
encoder is off index, the display shows the operator
how many counts the encoder is off index. At first, 3
there is no alarm, but as the encoder is rotated
closer to index, the alarm starts to beep. If the dis- 1
2
play shows a positive count, then rotate the en-
coder clockwise. If the display shows a negative
count, rotate the encoder counterclockwise. When
the encoder is at index, a continuous alarm sounds
and the display shows encoder at index. While the
encoder is at index, tighten the two screws. After
tightening the two screws, the encoder still shows
encoder at index and the continuous alarm still
sounds. Fig. 39 (23043-01)
• Press the enter button to save the setting. • The steering feedback encoder gear (3) is a split
gear. A spring inside the gear prevents backlash.
C5 Wire Guidance Insert a screwdriver between the two halves and
The wire guidance system is calibrated so the lift truck twist to see if the halves spring back into place.
automatically travels with optimum performance over
the guide wire embedded in the floor.
To calibrate an SP3500 lift truck, the operator needs a
wire guided aisle approximately 12 m (40 ft) long. (9 m
[30 ft] for offset null calibration. Additional distance is
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• See Figure 40. Check the condition of the steer mo-
tor brushes (1) and inspect the commentator.
1
1
Fig. 42 (23046-01)
• See Figure 43. Lubricate the drive unit thrust bear-
ing. The thrust bearing lubrication fitting is shown.
Fig. 40 (23044-01)
• See Figure 41. Check the fluid level (1) of the steer-
ing gearbox.
Fig. 43 (23047-01)
• Make sure that the drive tire is not flat spotted or
chunked. Check for debris such as shrink wrap or
banding that could be wrapped around the drive
Fig. 41 (23045-01) axle.
• See Figure 42. Make sure that the drive unit stud
mounting screws (1) are secure (two mounting • Check for bent or damaged outriggers.
screws are hidden behind the pump). • Check the condition of the load wheels and bear-
ings. Remove any debris wrapped around the load
wheel.
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• See Figure 44. Check the height (a) of both the Technician Tips: For field strength specifications, see
power unit and mainframe sensor bars (b). They the Wire Guidance Line Driver section in this service
measure approximately 83 mm to 86 mm (3-1/4 in manual.
to 3-3/8 in) from the floor (c).
See Figure 46. To determine the highest average field
strength, take a reading with a field strength meter, P/
N 112953, approximately every 3 m (10 ft). Total the
readings and divide by the number of readings taken.
For example, in a warehouse that has three aisles and
each aisle is 33 m (100 ft long). Take and record 10
readings in each aisle approximately 3 m (10 ft apart).
See the Field Strength Readings table.
Field Strength Readings
Aisle 1 Aisle 2 Aisle 3
175 169 175
172 169 186
Fig. 44 (21984)
167 170 179
• See Figure 45. After calibration, make sure to
check that the lift truck is centered over the guide 174 172 180
wire when traveling. Install a cable tie (1) centered
168 171 182
on the mainframe sensor bar (2).
183 182 187
193 187 177
184 190 176
187 182 183
184 177 185
1,787 1,769 1,810
Total the readings and then divide by 10.
2 1
Aisle 1: 1,787 ÷ 10 = 179
Aisle 2: 1,769 ÷ 10 = 177
Aisle 3: 1,810 ÷ 10 = 181
Fig. 45 (23048-01)
• Make sure that the steering feedback encoder In this example, the lift truck must be calibrated in Aisle
ECR2 is set to index when the drive unit alignment 3 since it has the highest average reading of 181.
marks are aligned (C4 calibration).
For the best wire guidance performance, calibrate the
lift truck at the installation or part of the warehouse with
the highest average field strength reading (field
strength varies with the depth of the wire). If the lift
truck has been calibrated on wire at the lowest average
strength, then when the lift truck is operating on wire
with a higher strength, the system can become satu-
rated and allow the lift truck to weave.
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passes over the guide wire then turn around and
pass over the guide wire so the other sensor bar
passes over the guide wire.
1
Fig. 46 (23049-01)
1 Guide wire
2 Field meter, P/N 112953
Technician Tips: Crown recommends calibration of
the field strength meter annually, and Crown performs
this service for free. Any repairs needed for calibration
incur a reasonable charge. Allow a minimum of two (2)
weeks for normal calibration. Meters needing repair
may require additional time. Meters are returned freight
collect. For information regarding the field strength me-
ter, see the Technical Service Bulletin No. 317.
• Press the down arrow to scroll to the C5 Wire Guid-
ance menu.
Sensor Coil Calibration
• Press the right arrow and the C5.1 Sensor menu is
displayed.
• Press the right arrow and the C5.1.2 Sensor Coil
menu is displayed. During the C5.1.2 sensor coil
calibration, the wire guidance system, through the
sensor coils, determines the frequency and ampli-
tude of the floor signal. The system, then, compares
the signal returned from each sensor coil and scale
the weaker coils to make each coil signal equal so
the lift truck guides centered on the guide wire.
• Press the right arrow to enter the C5.1.2 Sensor
Coil menu and the display shows, Sure? N. Change
the N to Y and press the enter button.
• Place the lift truck in the manual steering mode.
Drive the lift truck over an active wire at a shallow
angle (5 degrees or less). Both sensor bars (all
eight coils) must completely pass over the wire at
least two times. There are different ways to do this:
1. See Figure 47. One way is to drive forward so at
least the mainframe or power unit sensor bar
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1 Do not allow the sensor bars to pass over the end of the
guide wire. This may corrupt the calibration
(1)
2 Guide wire
(2)
3 Lift truck angle to the wire must be 5 degrees or less
(3)
4 Power unit sensor bar
5 Rack
6 After the power unit sensor bar passes completely over the
guide wire, backup and turn around and travel so the main-
frame sensor bar passes completely over the guide wire
7 Mainframe sensor bar
(4)
(5) (5)
(6)
(3)
(7)
(5) (5)
Fig. 47 (23051)
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2. See Figure 48. If the aisles are wide enough, an
alternative way is to weave back and forth over the
guide wire. It does not matter how the lift truck
passes over the guide wire as long as both sensor
bars pass over the guide wire twice and at an angle
of 5 degrees or less so the maximum strength sig-
nal can be sensed by the coils.
Fig. 48 (23052)
1 During peak sensor coil search, power unit and mainframe
sensor bars must travel completely over the guide wire a
minimum of two times at an angle of 5 degrees or less.
2 Guide wire
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Technician Tips: If the operator receives Coil Satu-
rated, go to auto when done message during sensor
coil calibration perform the following checks:
1. Make sure that the field strength of the wire meets
the recommendations of Crown.
2. Make sure that the sensor bars are mounted
82 mm to 86 mm (3.25 in to 3.38 in) from the floor.
A saturated coil does not invalidate the sensor coil cal-
ibration. If a sensor bar is repositioned or the field
strength is adjusted, perform the sensor coil calibration
again.
• After each coil has traveled over the guide wire
twice, center the lift truck over the guide wire and
toggle the guidance switch to Auto. The display
message changes to C5.1.3 Wheel Angle, travel on
wire.
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Wheel Angle Calibration
Wheel Angle calibration determines the steer wheel
position that provides straight-line travel.
• See Figure 49. Drive the lift truck on an active wire
for 18 m (60 ft) in each direction. This is an accumu-
lative travel distance. Therefore, if the operator can-
not travel a full 18 m (60 ft) in one direction because
they are limited by space, then travel as far as pos-
sible, reverse direction, and travel as far as possi- The lift truck must travel the length of
ble, repeating this process until a total of 18 m the guide wire approximately two times
(60 ft) has been traveled. When the operator (18 m [60 ft]) in one direction, reverse
direction and travel another approxi-
reaches the accumulated distance of 18 m (60 ft),
mately two times (18 m [60 ft]) for a to-
they are prompted by a beep. The lift truck must tal of 36 m (120 ft).
travel the length of the guide wire approximately
two times in each direction.
(2)
(1)
Fig. 49 (23053)
1 12 m (40 ft)
2 Guide wire
3 Wall
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• If the operator wants to check the percentage of dis- • After traveling 9 m (30 ft) in both directions, the op-
tance traveled, press the right button and the dis- erator will hear a beep and the message changes to
play specifies the percentage. come to a stop. Stop the lift truck.
An audible beep is given when a direction has • After coming to a stop, the message changes to
achieved 100% of the required distance. Switch to Manual. Toggle the guidance switch to
• After traveling 18 m or 60 ft in both directions, the manual. The display message changes to C5.1.2
operator will hear a beep and the message will Sensor Coil.
change to come to a stop. Stop the lift truck. • Press the left arrow twice and the message Save?
• After the operator comes to a stop, the message N appears.
changes from Switch to Manual. Toggle the guid- • Press the down arrow and Save? Y message ap-
ance switch to manual. pears. Push the enter button after this message ap-
• Then the message changes from Switch to Auto. pears to save the C5 wire guidance calibrations.
Toggle the guidance switch to Auto. The display The display returns to the Calibration menu.
message changes to C5.1.4 Truck Angle Travel on
Technician Tips: See the previous two steps. If the
Wire.
operator presses the up arrow instead of the down ar-
Truck Angle Calibration row after Save? N message appears a Load Factory
Defaults message appears. Pushing the enter button
Truck Angle calibration electronically offsets the sen-
after this message appears loads the factory defaults
sors to compensate for the lift truck tracking at an angle
for C5 wire guidance calibration (includes sensor coil,
on the guide wire.
wheel angle, truck angle and offset null calibration).
• Drive the lift truck on an active wire for 18 m (60 ft)
in each direction. The 18 m (60 ft) does not have to Load Wheel Sensor Bar Adjustment
be a continuous run, the distance accumulates. If • Place masking tape on the load wheel sensor bar
the operator wants to check the percentage of dis- and the sensor bar mounting bracket.
tance traveled, press the right button and the dis- • Place a vertical mark on the load wheel sensor bar
play specifies the percentage. that represents the centerline of the load wheel sen-
An audible beep is given when a direction has sor bar.
achieved 100% of the required distance.
• Place a vertical mark on the sensor bar mounting
• After traveling 18 m (60 ft) in both directions, the bracket that represents the centerline of the sensor
operator will hear a beep and the message will bar mounting bracket.
change to come to a stop. Stop the lift truck.
• Perform the initial wire guidance calibration.
• After the lift truck has come to a stop, the message
• At the end of the wire guidance calibration, the lift
changes to Switch to Manual. Toggle the guidance
truck software will specify the amount and direction
switch to manual, the message changes to Switch
of the load wheel sensor bar adjustment.
to Auto. Toggle the guidance switch to Auto. The
display message changes to C5.1.5 Offset Null Technician Tips: If the recommended load wheel sen-
Travel on Wire. sor bar adjustment is 3.05 mm (0.12 in) or less, no fur-
ther adjustment is required to the load wheel sensor
Offset Null Calibration
bar.
During Offset Null, the guidance module checks to be • Adjust the load wheel sensor bar according to the
sure that the sensors are centered over the wire while reading displayed by the Access 1 menu.
traveling and makes adjustments if necessary.
• After the load wheel sensor bar is positioned ac-
• Drive the lift truck on an active wire continuously in cordingly, secure the sensor bar to the sensor
one direction for 9 m (30 ft) and then change direc- mounting bracket with the fastening hardware.
tions and travel continuously for 9 m (30 ft). The
9 m (30 ft) must be one continuous direction. An au- Technician Tips: The bottom surface of the sensor
dible beep is given when a direction has achieved bar should be approximately 82.5 mm (3.25 in) above
100% of the required distance. the floor.
If the operator wants to check the percentage of dis- • Perform the wire guidance calibration until the load
tance traveled, press the right button and the dis- wheel sensor bar adjustment is equal to or less than
play specifies the percentage. 3.05 mm (0.12 in)
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When the Calibration menu appears (see Figure 35), Level 2 Submenus
calibration is complete.
H11 Access 5 On Time
Technician Tips: C5.2 X-Offset Calibration is not ex-
plained in this section because Crown recommends H12 Access 6 On Time
that C5.2 X-Offset Calibration not be used to center the H13 PM Timer
lift truck on the guide wire. If an offset is needed, the lift
truck likely has an issue that affects wire guidance and
the issue must be corrected.
Hour
While in Level 2, the Hour menu allows the operator to
view (only) all the hour meters and the PM timer.
While in level 3, the operator can change some of the
hour meters, the time of delay for the H2 hour meter
and set the PM timer.
The following Level 2 and Level 3 hour menu explana-
tions do not explain how to navigate through the menus
and submenus or how to change the selection. To nav-
igate through and change a menu selection, see the
Service Level 2 and 3 - Hour Menus tables in this sec-
tion of the service manual. The tables show the buttons
that must be pushed to navigate through and change
the menus.
Level 2 hour access
Turn on the lift truck. From Service Level 2, press the
right arrow to enter the Service submenus. Use the up
and down arrows to navigate to the Hour menus.
Hour Submenus
Hours can be viewed in Level 2. See the Level 2 Sub-
menus table for hours monitored.
Level 2 Submenus
Submenu Hours Monitored
H1 Traction, Raise, and Lower
H2 H1 Hours Plus Delay
H3 Odometer (Miles or Kilometers)
H4 Lift Pump Motor On Time
H5 Platform Lower On Time
H6 Traction Motor On Time
H7 Steer Motor On Time
H8 Access 1 On Time
H9 Access 3 On Time
H10 Access 4 On Time
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H13 PM Timer = ______
The purpose of the planned maintenance timer is to Level 3 Submenus
alert the operator when the lift truck is due for service.
In Level 2, the H13 PM timer allows the operator to Submenu Hours Change
view whether a planned maintenance reminder is set, Monitored Permitted
what hour meter the timer monitors and the hours the
Traction, Raise, and
timer is set to activate. H1 Increase Only
Lower
H13.1 Tag = ______
H2 H1 hours plus delay (1) Increase Only
H13.1 submenu shows the meter (H1 through12 or
none) that is monitored for the PM timer. For example, Odometer
H3 Increase Only
if H13.1 Tag = H1, the timer is set to monitor H1 hours. (miles or kilometers)
Technician Tips: If H13.1 is set to none, H13.2 is not Increase/
H4 Lift motor on time
available. Decrease
H13.2 Interval = ______ Increase/
H5 Platform lower on time
Decrease
The PM timer decreases in hours as the other hour me-
ters increase. When the PM timer decreases to zero, Increase/
H6 Traction motor on time
the display shows the message Service Due for a few Decrease
seconds to prompt the operator to bring the lift truck in Increase/
for service. If the timer is not reset, each time the lift H7 Steer motor on time
Decrease
truck is turned on, the message Service Due is briefly
displayed. H8 Access 1 on time No Change
H9 Access 3™ on time No Change
Level 3 hour access
H10 Access 4 on time No Change
Turn on the lift truck. From Service Level 3, press the
right arrow to enter the Service submenus. Use the up H11 Access 5 on time No Change
and down arrows to navigate to the Hour menus. H12 Access 6 on time No Change
Hour Submenus (1) H2 hour meter can only be increased, but the delay can
The operator can also view all the hour meters in level be increased or decreased.
3. Level 3 allows the operator to change some of the
• For an example of how to change an hour meter,
meters and set the PM timer. See the Level 3 Sub-
navigate to H4 Lift Motor submenu.
menus table to determine how or if a meter can be
changed. • Press the right arrow to scroll to the submenu that
shows the lift motor hours.
• Use the right or left arrow to select a digit. Use the
up or down arrow to change the hours. After chang-
ing hours to desired setting, press return.
H2 Runtime2 = ______
The H2 Runtime2 hour meter delay is adjustable from
0 to 15 minutes in 1-minute increments. The factory de-
fault is 0. Navigate to H2.2 Timeout submenu to
change delay.
H13 PM Timer = ______
To activate the PM timer, select the hour meter that the
timer monitors, and the hours the timer is set to acti-
vate, navigate to H13.1 Tag submenu and H13.2 Inter-
val.
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H13.1 Tag = ______ • To view the remaining events, press the left arrow
until navigating back to E1.1 Last submenu. Press
H13.1 submenu displays/sets the meter (H1 through12
the down arrow to scroll to the next 15 codes.
or none) that is monitored for the PM timer.
The operator can view the total count each event oc-
After selecting the hour meter, the operator needs to
curred in Accumulated History.
set the hours that the timer will activate. Navigate to
H13.2 Interval to set the hours. • To do this, press the left arrow until navigating back
to E1 Chronological History. Then, press the down
H13.2 Interval = ______ arrow.
Use this submenu to change or set the hours the PM E2 Accumulated History
timer activates. During lift truck operation, the PM timer
• Press the right arrow to view the first event in the
counts down or decreases in hours. When the PM
Accumulated History and the number of times the
timer counts down to zero, the display momentarily
event occurred. For example, if the message dis-
shows the message Service Due. This prompts the op-
played is 133 = 7 Events. This means Event 133
erator to bring the lift truck in for service.
occurred seven times.
Events • To scroll through all the events stored in Accumu-
lated History, press the down arrow.
The last 16 event codes in the order they occurred and • Press the left arrow until scrolling back to E2 Accu-
the total count of each code can be viewed in this mulated History, then press the down arrow to scroll
menu. Codes can also be erased. to E3 Clear History.
Events access E3 Clear History
• Turn on the lift truck. From Service Level 2 or Ser- • There are two ways to clear event codes: clear
vice Level 3, press the right arrow to enter the Ser- chronological and clear all. To clear chronological,
vice menus. Use the up and down arrows to navi- press the right arrow.
gate to the Events menu. Press the right arrow to
enter the Events menu. E3.1 Clear Chronological
• After E3.1 Clear Chronological is displayed, press
E1 Chronological History the right arrow. The display shows, Sure? N. If the
In E1 Chronological History submenu, the operator can operator does not want to clear history, press the
view the last 16 event codes in the order in which they return arrow. If yes, press the up arrow to change
occurred. the N to Y and then press the return arrow.
• Press the right arrow to navigate to the first sub- Technician Tips: Accumulated history is still available
menu. if the chronological events are cleared.
E1.1 Last • To clear all the chronological and accumulated
• By pressing the right arrow, the operator can dis- events, select the E3.2 Clear All menu. To do this,
play the last event code and then find out the hour from E3.1, press the down arrow.
it occurred and the battery state of charge. Press E3.2 Clear All
the right arrow. • After E3.2 Clear All is displayed, press the right ar-
Code = ______ row. The display shows, Sure? N. If the operator
does not want to clear all, press the return arrow. If
This submenu displays the last code. yes, press the up arrow to change the N to Y and
• Press the down arrow. then press the return arrow.
Hour = ______
Hour submenu displays the H1 Runtime1 when the last
code occurred.
• Press the down arrow.
Soc = ______
Soc submenu displays the battery state of charge
when the last code occurred.
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Utilities U2 Tow Mode
With the tow mode active, the brakes are released and
The Utilities menu allows the operator to view module
are not available for stopping the lift truck. All functions
and software part numbers, activate the tow mode, and
except traction are enabled. Before making the tow
electronically disable the lift truck.
mode active, be sure to read and follow the procedures
Utilities access in the Control of Hazardous Energy section in the Ser-
vice and Parts Manual.
• Turn on the lift truck. From Service Level 2 or Ser-
vice Level 3, press the right arrow to enter the Ser- • To activate the tow mode, press the right arrow. The
vice menus. Use the up and down arrows to navi- display shows Sure? N. If the operator does not
gate to the Utilities menu. Press the right arrow to want to activate the tow mode, press the return ar-
enter the Utilities menu. row. If yes, press the up arrow to change the N to Y
and then press the return arrow.
U1 Part Numbers
• With the tow mode active, the operator cannot scroll
• This submenu allows the operator to view part num- through other menus. To deactivate tow mode, turn
bers and software numbers for all the modules. off the lift truck and then turn on the lift truck.
Press the right arrow.
• Press the left arrow, and then scroll down to truck
U1.1 Access 1 operation.
• Press the right arrow again to display part numbers U3 Truck Operation
for Access 1.
The U3 Truck Operation submenu can be used to dis-
U1.1.1 Module PN = ______ able the lift truck electronically, in the event the lift truck
This submenu shows the part number for the Access 1 is being serviced. If disabled, no message will be dis-
module. played after turning on the lift truck and an operator is
not able to operate the lift truck.
• Press the down arrow to view the Access 1 soft-
ware part number. • To enable or disable truck operation, press the right
arrow, select, enable or disable, using the up or
U1.1.2 Software PN = ______ down arrow and then press the return arrow.
The software part number includes two dash numbers.
The last dash number denotes the software version.
For example, if Access 1 software part number is
122734-001-02, the part number ends with a dash 02
indicating the software version is 2.
• To view the part numbers for the remaining mod-
ules, press the left arrow until navigating back to
U1.1 Access 1, then press the down arrow to select
other modules and repeat the above process.
• Press the left arrow until navigating to U1 Part Num-
bers and then press the down arrow.
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Wire Guidance
Wire Guidance Sensor bars mounted on centerline at both ends of
truck, near floor, contain coils which act as antennas to
The Wire Guidance System automatically steers truck receive transmitted signal. The closer a coil gets to be-
down aisle without use of guide rails. Line driver pro- ing directly over the wire, the higher the amplitude of
duces set frequency of 5.2 kHz, 6.25 kHz, 7.0 kHz, or signal received by the coil. Using coil signal amplitude
10 kHz, which is transmitted through wire embedded in comparisons, truck will "sense" signal path. With this
floor down middle of each aisle. Generated signal is data, steering is electronically controlled to follow the
transmitted through embedded wire, as shown in Fig- signal.
ure 17183-01.
The wire guidance selector switch (GUS) on the con-
sole selects manual or automatic steering. When in
manual mode, truck steering is controlled by operator.
Steering remains in operator's control when switching
to automatic until guidance signal is detected. When
guidance signal is detected, steering control is auto-
matically changed to guidance system.
To align truck to wire guide signal, turn wire guidance
switch (GUS) to on. Approach angle must be no
greater than 30° and traction speed should be below
2.4 km/h (1.5 mph). Refer to Figure 17185-01. Brakes
are automatically applied when approach angle is ex-
ceeded in automatic mode. If approach speed is
greater than 2.4 km/h (1.5 mph), truck will decelerate
to 2.4 km/h (1.5 mph). Traction speed is limited to
2.4 km/h (1.5 mph) in automatic mode until truck is
aligned with wire. When aligned, acquisition speed limit
is removed and applicable speed vs. height curve will
be in force.
Figure 17183-01
(a) Line Drive Figure 17185-01
(b) Storage Racks
(a) Embedded Wire
(c) Transmitted Signal
(b) Maximum Approach Angle Cannot Exceed 30°
(d) Floor
(e) Epoxy
(f) Wire Embedded in Floor (Saw Cut)
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ELECTRICAL
Wire Guidance
Some conditions that might cause an automatic slow Operation Modes
down while traveling on wire guidance:
• Low signal strength from wire. Manual
• Truck deviates slightly from wire. When wire guidance selector switch (GUS) is in "man-
ual" position, truck steering is in operator's control.
• End of Aisle Control (EAC) (Optional) is activated.
Automatic
• Corrupted signal due to rebar, electrical conduit
and/or drain pipes beneath the floor. When wire guidance selector switch (GUS) is placed in
"automatic" position, electronics enter Search mode.
Some conditions that might cause an automatic stop At this time guidance signal has not been detected by
while traveling on wire guidance: sensors. The "auto" and "manual" indicators are both
on and traction speed is limited to 2.4 km/h (1.5 mph).
• Signal strength from wire is lost or too low.
Steering control remains in manual mode.
• Acquiring wire at an angle greater than 30°. When either sensor bar detects guidance signal, Auto
Acquisition mode will be indicated by a display change
• Truck deviates too far from wire. and a one second audible alarm. If traction speed at
this time is greater than 2.4 km/h (1.5 mph), truck will
• End of Aisle Control (EAC) (Optional) is activated.
decelerate to 2.4 km/h (1.5 mph). If angle of truck to
• Corrupted signal due to rebar, electrical conduit wire is greater than 30°, brakes will be applied. To re-
lease brakes, guidance selector switch (GUS) must be
and/or drain pipes beneath the floor.
placed in manual position. If angle of truck is within lim-
Each sensor bar contains four coils which act as sepa- its when signal is detected, manual indicator is turned
rate antennas. When the amplitude of guidance signals off and steering is controlled by electronics. Traction
received is compared, the higher amplitude signals are speed is still limited to 2.4 km/h (1.5 mph).
from coils in closer proximity to embedded wire. Sen-
When traveling in either direction, guidance system will
sors mounted on truck electronically "sense" where the
align truck with wire when all parameters are met: truck
truck is in reference to guidance signal. When wire
less than 19 mm (0.75 in) from wire, truck angle less
guidance selector switch (GUS) is in "automatic" mode,
than 1° and steer wheel less than 6° from center. When
steering module provides correct polarity and ampli-
truck is adequately aligned, auto tracking mode is indi-
tude of voltage to steering motor to keep truck centered
cated by a 2 second operation of the alarm. In this
over guidance signal. Feedback from steering feed-
mode truck is automatically guided by electronics and
back encoder (ECR2) verifies steered wheel is turned
acquisition speed limit is removed.
in direction required.
Whenever wire guidance signal strength drops near
minimum required to guide truck, guidance module
outputs a signal to illuminate signal strength light on
display (Signal). Steering module sends signal to trac-
tion controller for 2.4 km/h (1.5 mph) maximum traction
speed. If signal strength returns, signal strength indica-
tor is turned off and traction speed limit is removed.
If there is loss of guidance signal, or if signal strength
is below minimum required to guide truck, guidance
module will output signals to operate alarm and apply
brake. It will also turn the "automatic" indicator off and
turn the "manual" indicator on. Wire guidance selector
switch (GUS) must be placed in "manual" position to
release brake.
M4.3-7335-501 Crown 2008 PF15815-2
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ELECTRICAL
Wire Guidance
3. Auto Wire Lost will occur if one or more of four sit-
uations are present:
– Guidance signal lost.
– Centerline of truck leaves signal path by more
than 38 mm (1.50 in).
– Angle of truck to guidance signal is more than
1.8°.
– Steer wheel angle is more than 12° during Auto
Tracking. The truck is allowed to deviate more
immediately following a travel direction
change.
When in Auto Wire Lost, alarm is operated continu-
ously and brake is applied. Guidance selector switch
(GUS) must be placed in "manual" position to release
brakes after this situation occurs.
Figure 17187-01 Sensors
(a) Vehicle Angle Calibration Incorrect; Truck Not Tracking in Sensor bars are fastened to adjustable brackets which
Straight Line permit adjusting distance between sensor bars and
(b) Vehicle Angle Calibration Correct; Truck Tracking in Straight floor. When line driver current output is set to 220 mA,
Line sensor bar should be level and 82 - 86 mm (3.25 to
3.38 in) from floor. Refer to Figure 17186-01. Voltage
Three variations to normal operation are encountered required by sensor bar to operate is 5 volts, between
during Auto Tracking mode: terminals 5 (positive) and 3 (negative).
1. Auto Field Strength variation is encountered when
guidance signal received by sensors decreases to
minimum required to continue Auto Tracking
Mode. When entering Auto Field Strength, alarm is
pulsating, field strength indicator is turned on and
traction speed is limited to 2.4 km/h (1.5 mph).
When guidance signal received returns to above
minimum levels, alarm stops pulsating, field
strength indicator is turned off and speed limit is
removed.
2. Auto Track Deviation is encountered if center of
truck leaves guidance signal by 19 - 38 mm (0.75 -
1.50 in), truck's angle is 1 - 1.8° or steer wheel an-
gle is 6 - 12° from center. When this happens,
alarm is sounded (pulsates), and traction speed is
Figure 17186-01
limited to 2.4 km/h (1.5 mph). When truck returns
to acceptable tracking characteristics, alarm stops (a) Sensor Bar Height Adjustment
pulsating and is sounded for 2 seconds to indicate
(b) Sensor Bar
auto tracking mode, and traction speed limit is re-
moved. (c) Floor
(d) Truck Center Line
(e) Guide Wire
(f) 83 - 86 mm (3.25 - 3.38 in)
Crown 2008 PF15815-3 M4.3-7335-502
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ELECTRICAL
Wire Guidance
Calibration (3.25 in). Sensor height is typically not correct upon
shipment, as bars are moved to prevent shipping dam-
age.
Instructions for Peak Coil Search, Wheel Angle,
and Truck Angle Calibration. 1. Key-up truck and toggle brake pedal. Once power
up sequence is complete, follow key sequences in
NOTE Chart 1 - Wire Guidance Calibration.
Before performing wire guidance calibration, verify that
both sensor bars are set to correct height of 82.55 mm
Chart 1 - Wire Guidance Calibration
Display Message Keystroke Display Message Keystroke Display Message
Enter Service Mode
SP 3500 Service
Service Level 2
Level 2 ****
**** 2***
**** *3**
**** **1*
**** ***1 Calibrate
Coil Calibration
Calibrate C1
C1 or until C5
C5 C5.1 Sensor Sensor Coil C5.1.2
Sure? N Sure? Y
Go to Auto When
Sure? Y Done
2. Perform slow criss-cross maneuver across wire
two times at a small approach angle with little or no
steer tiller motion to complete the peak coil search
calibration. Make certain both sensor bars traverse
completely over the wire each pass. Edge of bars
shall be at least 304.80 mm (12 in) from wire at far
ends of pass. Passes can be made from right-to-
left or left-to-right. Refer to Figure 18596.
M4.3-7335-503 Crown 2008 PF15815-4
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ELECTRICAL
Wire Guidance
WIRE
WIRE
Keep angle between CL and WIRE
as small as possible
Figure 18596
Crown 2008 PF15815-5 M4.3-7335-504
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ELECTRICAL
Wire Guidance
3. Once peak coil search is complete, place Guid- DISPLAY MESSAGE => Switch to Manual
ance Switch (GUS) in AUTO position to begin
18. Place GUS in MANUAL position. => Beeper will
wheel angle calibration.
sound.
4. Acquire the wire and travel the required distance
DISPLAY MESSAGE => Switch to AUTO
FF or PUF.
19. Place GUS in AUTO position to begin offset null
DISPLAY MESSAGE => Forks Leading/Trailing;
calibration. => Beeper will sound and truck ac-
Press to view % complete but not required. quires wire.
5. Continue traveling in same direction until beeper 20. Travel the required distance FF or PUF.
sounds to indicate travel complete.
DISPLAY MESSAGE => Forks Leading/Trailing;
6. Bring truck to a stop. Press to view % complete but not required.
DISPLAY MESSAGE => Change Direction
21. Continue traveling in same direction until beeper
7. Travel on wire the required distance in the opposite sounds to indicate travel complete.
direction.
22. Bring truck to a stop.
DISPLAY MESSAGE => Forks Trailing/Leading;
DISPLAY MESSAGE => Change Direction
Press to view % complete but not required.
23. Travel on wire the required distance in the opposite
8. Continue traveling in same direction until beeper direction.
sounds to indicate travel complete.
DISPLAY MESSAGE => Forks Trailing/Leading;
DISPLAY MESSAGE => Come to stop Press to view % complete but not required.
9. Bring truck to a stop.
24. Continue traveling in same direction until beeper
DISPLAY MESSAGE => Switch to Manual sounds to indicate travel complete.
10. Place GUS in MANUAL position. => Beeper will DISPLAY MESSAGE => Come to stop
sound.
25. Bring truck to a stop.
DISPLAY MESSAGE => Switch to AUTO
DISPLAY MESSAGE => Switch to Manual
11. Place GUS in AUTO position to begin truck angle
26. Place GUS in MANUAL position. => Beeper will
calibration. => Beeper will sound and truck ac-
sound.
quires wire.
DISPLAY MESSAGE => Switch to AUTO
12. Travel the required distance FF or PUF.
27. Place GUS in AUTO position to begin offset null
DISPLAY MESSAGE => Forks Leading/Trailing;
calibration. => Beeper will sound and truck ac-
Press to view % complete but not required. quires wire.
13. Continue traveling in same direction until beeper 28. Travel the required distance FF or PUF.
sounds to indicate travel complete.
DISPLAY MESSAGE => Forks Leading/Trailing;
14. Bring truck to a stop.
Press to view % complete but not required.
DISPLAY MESSAGE => Change Direction
29. Continue traveling in same direction until beeper
15. Travel on wire the required distance in the opposite sounds to indicate travel complete.
direction.
30. Bring truck to a stop.
DISPLAY MESSAGE => Forks Trailing/Leading;
DISPLAY MESSAGE => Change Direction
Press to view % complete but not required.
31. Travel on wire the required distance in the opposite
16. Continue traveling in same direction until beeper
direction.
sounds to indicate travel complete.
DISPLAY MESSAGE => Come to stop
17. Bring truck to a stop.
M4.3-7335-505 Crown 2008 PF15815-6 Rev. 4/09
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ELECTRICAL
Wire Guidance
DISPLAY MESSAGE => Forks Trailing/Leading; DISPLAY MESSAGE => Switch to Manual
Press to view % complete but not required. 34. Place GUS in MANUAL position. => Beeper will
sound.
32. Continue traveling in same direction until beeper
sounds to indicate travel complete. Follow Chart 2 - Save Wire Guidance Calibration key
sequence to save wire guidance calibration.
DISPLAY MESSAGE => Come to stop
33. Bring truck to a stop.
Chart 2 - Save Wire Guidance Calibration
Display Message Keystroke Display Message Keystroke Display Message
Save Wire Guidance Calibration
Sensor Coil C5.1.2 Sensor Coil C5.1 Save? N
Save? N Save? Y Calibrate
Re-key truck for new calibration values to take effect. NOTE
Instructions for X-Offset Calibration Entering the offset distance as right (+) or left (-) for
either direction of travel (PUF or FF) is with respect to
NOTE operator's right and left when facing forks.
Before performing wire guidance calibration, verify that NOTE
both sensor bars are set to correct height of 82.55 mm
(3.25 in). Sensor height is typically not correct upon Independent offset values can be entered for Forks
shipment as bars are moved to prevent shipping dam- First and Forks Trailing directions.
age.
NOTE
NOTE Do not use X-Offset to center the truck on guidance
X-Offset calibration can be performed in conjunction wire.
with C5.1 Peak Coil and Angle calibration, or indepen-
dently. NOTE
Exiting X-Offset calibration without saving leaves ac-
NOTE tive the last known calibration values.
X-Offset value is reset to 0 at the start of a new X-Offset 1. Key-up truck, toggle brake pedal. Once power up
calibration process. X-Offset value is cumulative sequence is complete, follow key sequences in
among any multiple passes in a given direction, within Chart 3 - X-Offset Calibration to perform X-Offset
a single calibration process. calibration.
Crown 2008 PF15815-7 Rev. 4/09 M4.3-7335-506
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ELECTRICAL
Wire Guidance
Chart 3 - X-Offset Calibration
Display Message Keystroke Display Message Keystroke Display Message
Enter Service Mode
SP 3500 Service
Service Level 2
Level 2 ****
**** 2***
**** *3**
**** **1*
**** ***1 Calibrate
X-Offset Calibration
Calibrate C1
C1 or until C5
C5 C5.1 Sensor X-Offset C5.2
X-Offset C5.2 X-Offset C5.2.1 Sure? N
Sure? N Sure? Y Travel on wire
2. Acquire the wire and travel FF / PUF the required DISPLAY MESSAGE => Travel to Continue or Enter
distance. to End
DISPLAY MESSAGE => Forks Leading/Trailing 7. By traveling to continue calibration, adjustment val-
ues can be verified by repeating the same direction
3. Continue traveling in same direction until beeper
of travel. Subsequent adjustments for a given di-
sounds to indicate travel complete. Continuous
rection can be entered and accumulate on the pre-
travel of 40 ft (480 in) in given direction is required.
vious X-Offset total for that given calibration pro-
DISPLAY MESSAGE => Distance Reached Come to cess.
stop
8. Follow key sequences of Chart 4 - Save X-Offset
4. Bring truck to a stop. Calibration to end and save X-Offset calibration
values.
DISPLAY MESSAGE => Move truck Right/Left
5. Press or to toggle between Right/Left. Press
once desired direction is displayed.
DISPLAY MESSAGE => 0.1 in
6. Measure distance from center of sensor bars to
wire. Press or until this desired offset distance
is displayed. Press to keep displayed value.
M4.3-7335-507 Crown 2008 PF15815-8 Rev. 4/09
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ELECTRICAL
Wire Guidance
Chart 4 - Save X-Offset Calibration
Display Message Keystroke Display Message Keystroke Display Message
Save X-Offset Calibration
Travel to Continue or
X-Offset C5.2 Save? N
Enter to End
Save? N Save? Y Calibrate
9. Re-key truck for new calibration values to take ef-
fect.
Refer to InfoPoint Quick Reference Guide for further
information on wire guidance calibration.
Crown 2008 PF15815-9 Rev. 4/09 M4.3-7335-508
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ELECTRICAL
End Aisle Control (EAC)
End Aisle Control (EAC) Sensors are positioned:
Standard Applications
The purpose of EAC is to remind the operator that the
end or an intersection of a warehouse aisle is ap- – "A" sensors are 200 mm (8 in) from the truck's
proaching. This system incorporates magnets in the centerline.
warehouse floor and magnetic sensors on the truck.
– "B" sensors 305 mm (12 in) from the truck's
Upon detection of magnets, when approaching end of
centerline.
aisle, sensors send a signal to the truck's computer to
apply a traction plug condition to slow the vehicle. A – Sensor bar is 20 mm (0.75 in) from the floor.
text message indicating EAC zone "entered" is dis-
Special Applications
played on ACCESS 1.
– "A" sensors can be positioned any distance
End Aisle Control is divided into two modes of opera-
more than 200 mm (8 in) from the truck's cen-
tion. Auto Guide mode is in force when the truck is in
terline provided that
wire or rail guide tracking mode. Traction speed is con-
trolled by fork height versus the speed curve. End of – "B" sensors are a minimum of 100 mm (4 in)
Aisle, Auto Guided mode is in force when a truck, in from "A" sensors.
wire or rail guide tracking mode, detects magnets while
– Sensor bar is 20 mm (0.75 in) from the floor.
traveling toward the end of an aisle. End of Aisle result
is selectable as stop or slowdown via plug or brake. Different sensors must be used for sensing north or
south magnetic poles. Sensors for sensing north mag-
A traction automatic speed resume is a selectable fea-
netic poles are standard.
ture. This feature will automatically release traction
speed limit actuated by EAC zone and once truck has
traveled its preset distance beyond the EAC magnets.
The EAC system consists of a front bumper sensor bar
which includes four sensors and a sensor distribution
board.
Figure 23374 provides a pictorial view of some compo-
nents involved with the end aisle control. A sensor
bracket containing four sensors is mounted to the main
frame of the truck, in front bumper. Sensors A1 and B1
activate during travel in forward (power unit first) direc-
tion and sensors A2 and B2 active in reverse (forks
first) direction. A text message appears on operator
display to provide an indication of when truck enters or
operates in an end of aisle control area.
Crown 2007 PF15794-1 Rev. 2/10 M4.3-7335-600
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ELECTRICAL
End Aisle Control (EAC)
Figure 23374
1 End Aisle Sensors Forward Direction (Power Unit First) • 652-659 - EAC Sensor Signal Range Fault
2 End Aisle Sensors Reverse Direction (Forks First)
• 660-663 - EAC Sensor Digital Fault
Located under the battery compartment is a distribution
module for interconnection of EAC components. Sig- • 664-667 - EAC Weak Magnet Fault
nals from the sensors and EAC distribution module are
connected to CA602, pins 1 through 14 on the wire
• 668-671 - EAC Sensor Hardware Fault
guidance module. • 672 - EAC Multiple Sensors Active Fault
Codes 566 through 572 and 652 through 672 all pertain
EAC Setup to the EAC system issues.
The display is used to setup how the truck will react While in Level 2 or 3 of ACCESS 123, the Analyzer
when the EAC system senses the magnets near the menu, A2 Inputs can be used to check any one of the
end of an aisle or intersection. To setup EAC, modify four EAC sensors (Refer to ACCESS 123 section). The
the settings or for more information on EAC, refer to state of digital input shall change as the truck passes
ACCESS 123® section, Performance menu, P12 EAC over its corresponding floor magnet.
Setup submenus.
If issues are realized, verify the height of the sensors
above the floor, distance of center line of guidance bars
Troubleshooting to EAC sensors and proper magnet positioning.
EAC components are monitored by system software
and will log a fault into memory whenever a problem
with the EAC system occurs:
EAC Event Codes:
• 566 - EAC Hardware Fault
• 567-570 - EAC Sensor Latched ON
• 571-572 - EAC Magnet Missed
M4.3-7335-601 Crown 2007 PF15794-2 Rev. 2/10
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ELECTRICAL
End Aisle Control (EAC)
Termination Point Locations
Chart 1 - Access 6 (Wire Guidance Module)
Pin Function Voltage Level Connection
1 EAC Sensor Power 12 V CA602-1
2 EAC Sensor Battery Negative CA602-2
3 EAC A1 Test 7 V in Test Mode CA602-3
4 EAC A1 Analog 0-5 V When Over Magnet CA602-4
0 V When Sensing Magnet, 5V When Not
5 EAC A1 Digital CA602-5
Sensing Magnet
6 EAC A2 Test 7 V in Test Mode CA602-6
7 EAC A2 Analog 0-5 V When Over Magnet CA602-7
0 V When Sensing Magnet, 5 V When Not
8 EAC A2 Digital CA602-8
Sensing Magnet
9 EAC A2 Analog 0-5 V When Over Magnet CA602-9
0 V When Sensing Magnet, 5 V When Not
10 EAC B1 Analog CA602-10
Sensing Magnet
0 V When Sensing Magnet, 5 V When Not
11 EAC B1 Digital CA602-11
Sensing Magnet
12 EAC B2 Test 7 V in Test Mode CA602-12
13 EAC B2 Analog 0-5 V When Over Magnet CA602-13
0 V When Sensing Magnet, 5 V When Not
14 EAC B2 Digital CA602-14
Sensing Magnet
Crown 2007 PF15794-3 Rev. 2/10 M4.3-7335-602
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ELECTRICAL
Wire Guidance
Wire Guidance
The truck steering system should be thoroughly
checked before alignment procedure is attempted. The
system operates through existing truck steering mech-
anism. Slack, lag or excessive wear within this system
will prevent guidance within specifications.
Verify the following:
• Steering feedback encoder is set when drive unit
alignment marks are aligned.
• Steering gears - condition and lubrication.
• Look for load wheel debris such as shrink wrap.
• Steering motor and brushes.
• Steering gearbox - condition and lubrication.
• Drive unit stud and mounting bolts.
• Drive unit thrust bearing and lubrication.
• Drive tire condition and type (poly only).
• Look for drive tire debris such as shrink wrap.
• Load wheel condition, including bearings.
• Look for load wheel debris such as shrink wrap.
• Steer wheel sensor condition, orientation and
height adjustment.
• Load wheel sensor condition, orientation and
height adjustment.
• Sensor bearing and condition.
Crown 2007 PF15816-1 M4.3-7335-800
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ELECTRICAL
Wire Guidance
(a) Sensor Bar Height Adjustment (j) Sensor Bearing Assembly
(b) Sensor Bar (k) Steered Wheel Sensor
(c) Truck Centerline (l) Load Wheels
(d) Floor (m) Drive Tire
(e) Guidewire (n) Drive Unit Mounting Bolts
(f) Steering Motor (o) Drive Unit Thrust Bearing
(g) Steering Gearbox (p) Drive Unit Stud
(h) Steering Gears (q) Base of Main Frame (Located Under
Platform; Rotated for Clarity)
(i) Steering Feedback Encoder (r) Load Wheel Sensor
Figure 18236
M4.3-7335-801 Crown 2007 PF15816-2
192
ELECTRICAL SYSTEM
Contactor
Contactor Maintenance
Inspection
3
5
4
Fig. 1 (10554-02) 7
General Safety 8
9
CAUTION
The use of contactors from other manufacturers
could cause damage to the truck. 10
The original contactors are made for Crown lift trucks.
Only use original Crown contactors as replace-
ments.
11
Do not change the configuration of the contactors or
the electrical connections.
Fig. 2 (28096)
Checking the contacts
Refer to Figure 28096.
1. Check the silver coating of both fixed contacts (8)
and the mobile contact (9).
If the silver layer has worn off the contact points,
replace all three contacts (8, 9).
Crown 1992 PF9313-1 Rev. 4/13 M4.4-04.2-001
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41
ELECTRICAL SYSTEM
Contactor
Note: The contacts (8, 9) wear during typical operation. 4. Remove the two screws (5) from the cover (6).
This does not have an effect on typical operation. Do 5. Remove the cover (6) from the coil (11).
not clean blackened or tarnished contacts, as that
6. Install the mobile contact (9) in the replacement
could cause them to wear faster.
coil (11).
Checking the coil 7. Install the cover (6) on the replacement coil (11)
Refer to Figure 28096. with the two screws (5).
1. Use a digital volt-ohm multimeter (DVOM) to mea- 8. Install the contactor on the contactor panel with the
sure the resistance between the connections on two screws.
the coil (11). 9. Connect all electrical connections to the contactor.
Note: If there is a diode between the connections on
the coil (11), desolder the diode on one side, then mea-
sure the resistance between the connections on the
coil. If you do not do this, the results will be incorrect.
The resistance of the coil must be 15–19 Ω.
If the resistance is not 15–19 Ω, replace the coil.
Checking the return spring
Refer to Figure 28096.
1. Check the return spring (7) for corrosion or discolor
from heat.
Replace the return spring (7) if it has corrosion
or discolor.
Torque Values
For general torque values, refer to INSPECTION AND
LUBRICATION/Metric Torque Values or INSPECTION
AND LUBRICATION/SAE Torque Values.
Component Replacement
Refer to Figure 28096.
Contact Replacement
1. Disconnect the electrical connections to the con-
tactor.
Note: It is not necessary to disconnect the coil (11) for
this procedure.
2. Remove the two screws (5) from the cover (6).
3. Remove the cover (6).
4. Remove and replace both fixed contacts (8) and
the mobile contact (9).
5. Install the cover (6) with the two screws (5).
6. Connect the electrical connections to the contac-
tor.
Coil Replacement
1. Disconnect all electrical connections to the contac-
tor.
2. Remove the two screws that secure the contactor
to the contactor panel.
3. Remove the contactor.
M4.4-04.2-002 Crown 1992 PF9313-2 Rev. 4/13
05 Rev. 4/13
42
ELECTRICAL SYSTEM
EE Contactors
EE Contactors
Chart 1 - Contactor EE Function
*118280-001 *118280-002 *118280-003 *118280-004
Model
Function Function Function Function
PE 4000 L
SP 3400 ED P
SP 3500 ED P
RC 3000 DM P
NOTE: On EV100 SCR motor control systems, contactors controlled by the control
card (eg. forward, reverse, 1A, FW), regardless of battery voltage, require 24
volt coils. Refer to applicable contactor panel page for the correct contactor part
number and function.
The purpose of this information is to instruct the user Contacts
on proper care and maintenance to obtain satisfactory
service from these devices. Crown has tested and ap- In normal operation, contacts will become blackened,
plied these contactors according to the requirements of discolored, and roughened. This will not interfere with
the truck. No modifications or changes should be made proper operation and cleaning is not necessary. Con-
in the layout, physical arrangement or electrical con- tacts should be replaced before the silver contact fac-
nections without permission from Crown. ing is completely eroded through to the backing mate-
rial. The silver contact facing may transfer to either the
moving or stationary contact and cause buildup on one
CAUTION contact. This can be expected under certain conditions
and does not require contact dressing or filing. It is rec-
Before any inspection, adjustments, servicing, parts re- ommended that contacts always be replaced in mating
placement or any other act is performed requiring pairs. Use inspection mirror to inspect contacts to rear
physical contact with the electrical working compo- of the contactor.
nents or wiring of these contactors; disconnect battery,
raise drive wheels clear of floor and place blocks under
truck frame. Coil
Remove all electrical connections. Resistance reading
of 24 volt coils should be between 16-18 ohms. Resis-
Inspection tance reading of 36 volt coils should be between 42-46
The following information is intended to assist during ohms and resistance reading of 48 volt coils should be
periods of normal maintenance and to provide checks between 69-77 ohms. If reading does not fall within the
for maintaining adjustments. As these devices are limits, replace.
tested and adjusted at the factory, they should not nor-
mally require further adjustments. However, if factory
adjustments are tampered with or otherwise changed,
the checks contained in the following information may
be made.
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ELECTRICAL SYSTEM
EE Contactors
Component Replacement Contact Replacement
Refer to Figure 12402S and Parts Section of manual Disconnect electrical wiring to contactor. Remove two
when replacing components. mounting bolts from bracket and remove contactor
from truck. Remove shroud (Index 1) by removing four
screws (Index 2). Remove two screws (Index 4) from
top of contactor and remove contact assembly from coil
assembly. Disassemble and replace contacts as nec-
essary.
Reassemble contacts. Place contact assembly on coils
and fasten securely with two screws (Index 4), replace
1 shroud & screws (Index 1 & 2). Install contactor in truck
and connect wiring.
2 Coil Replacement
Disconnect all electrical wiring from contactor. Remove
two mounting bolts from mounting bracket and remove
3 contactor from truck. Remove shroud (Index 1) by re-
5
moving four screws (Index 2). Remove two screws (In-
dex 4) and separate contact assembly from coil assem-
4
bly. Remove mounting bracket from coil.
Reconnect mounting bracket to replacement coil.
Transfer plunger (Index 9) from coil being replaced to
6
replacement coil. Reassemble contact assembly to coil
assembly and secure with two screws (Index 4), re-
place shroud & screws (Index 1 & 2). Mount contactor
7 on truck and reconnect all electrical wiring.
10
Figure 12402S
M4.4-7334-026 Crown 2005 PF13962-2 Rev. 11/07
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ELECTRICAL
Control Module
Control Module WARNING
The Control Module, located in the operator compart- When making "live" voltage checks, chock load wheels
ment, contains all operator controls within easy reach. of truck, raise drive wheel clear of floor and place hard-
A planned maintenance program should include wood blocks under truck frame.
checking these operator controls for binding, sticking
or other unusual operation. An audio check should also
be made. Press buttons or turn twist grip in both direc-
Troubleshooting
tions slowly, while listening for switch actuation-reset- If an event code is displayed, refer to the Event Code
ting (signified by a "click"). There should be a "double section of this service manual and follow the trouble-
click" for two speed lift/lower. shooting steps for the code.
If a code is not displayed, many of the switches, trac-
Access tion request potentiometer (POT1) and their circuits
can be checked through the display using
ACCESS 123® Analyzer menu. To check, enter level 2
CAUTION of the display, scroll to the Analyzer menu and navigate
to the proper submenu listed in Chart 1 on the next
Disconnect battery before performing disassembly pro-
page. Actuate the component and check the display
cedures.
message for the proper input. For more information, re-
To gain access to components in directional and speed fer to ACCESS 123 section in this service manual.
control compartment, remove five mounting screws
from console and lift console from platform wall.
Directional & Speed Control Compartment
Figure 12546-01
To access remaining switches rotate console down.
While in this position, do not apply unnecessary pres-
sure to the module which may damage the wiring har-
ness. Due to weight, some form of support is needed.
Reverse disassembly procedure for assembly.
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ELECTRICAL
Control Module
Chart 1
Polarity
Analyzer
Component Display Message of Input Note 2
Submenu
Signal
EDS See Note 1 below positive When closed, EDS provides
+BV to the key switch.
FNS1 See Note 1 below positive When closed, FNS1 provides
+BV to the operator fan FAN1.
FS A2.3.7 FS 0 = switch open, 1 = switch closed positive
GUS A2.1.2 GUS1 0 = switch open, 1 = switch closed negative
HNS See Note 1 below positive When closed, HNS provides
+BV to the key switch.
KYS A2.2.7 Key Switch 0 volts = switch open, approxi- positive
mately battery volts = switch closed
LGS1 See Note 1 below When closed, LGS1 provides
+BV to PS2 power supply.
LGS2 See Note 1 below When closed, LGS2 provides
+BV to PS1 power supply.
LGS3 See Note 1 below When closed, LGS3 provides
+BV to the spot lights.
LOS1 A2.3.12 LOS1 0 = switch open, 1 = switch closed positive
LOS2 A2.3.13 LOS2 0 = switch open, 1 = switch closed positive
ORS1 A2.1.3 ORS1 0 = switch open, 1 = switch closed negative
POT1 A2.3.3.1 Raw Max FF = approximately 0.8V. Neu- positive
tral = approximately 2.6 V, Max
PUF = approximately 4.6 V
A2.3.3.2 Scaled Max FF = approximately 16%. Neu- positive
tral = approximately 50%, Max PUF
= approximately 92%
RAS1 A2.3.11 RAS1 0 = switch open, 1 = switch closed positive
RAS2 See Note 1 below When closed, RAS2 provides
+BV to P2 pump contactor coil.
RS A2.3.6 RS 0 = switch open, 1 = switch closed positive
ZSS A2.3.14 ZSS A 0 = switch open, 1 = switch closed negative
A2.3.15 ZSS B 0 = switch open, 1 = switch closed negative
A2.3.16 ZSS C 0 = switch open, 1 = switch closed negative
Note 1: No Analyzer submenu is available for checking component input because the component doesn't provide
an input to an ACCESS 123 module.
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ELECTRICAL
Control Module
Switches Traction Request Potentiometer (POT1)
If a switch input is not correct or if no analyzer submenu If the potentiometer wiper input signal is not correct,
is available for the switch, check the switch with a then check the potentiometer with a DVOM. Refer to
DVOM. If the switch provides a positive signal (refer to Figure 23336 for connections and signals.
Chart 1) to the module or another component, then
connect the black DVOM lead to test point TP16 (refer
to Figure 23336) on the platform distribution panel or
any other good battery negative reference. If the switch
provides a negative signal (refer to Chart 1), then con-
nect the red DVOM lead to test point TP2 (refer to Fig-
ure 23336) on the platform distribution panel or any
other good battery positive reference.
Close the switch and check the voltage across the
switch. The DVOM should register battery volts on both
sides of the switch. If battery volts is not displayed,
there is an open circuit, incorrect switch connection or
a bad switch. For example, if battery volts is read on
one side of a switch, but a voltage less than battery
volts is obtained from other side of switch, the switch
contacts are making poor contact and the switch
should be replaced.
Refer to the Wiring Diagrams to trace the problem cir-
cuit(s).
Figure 23336
1 Platform Distribution Panel
When checking the wiper input signal and +5V signal
to POT1, connect the black DVOM lead to test point
TP16 (refer to Figure 23336) on the platform distribu-
tion panel or any other good battery negative refer-
ence. When checking the wiper signal, the DVOM
should display:
– approximately 0.8 V when the travel twist grip
is fully rotated in the forks first direction.
– approximately 2.6 V when the travel twist grip
is not rotated (neutral).
– approximately 4.6 V when the travel twist grip
is fully rotated in the forks first direction.
If the potentiometer wiper input is not correct and the
potentiometer is receiving +5V, check for a missing
negative signal. When checking the negative signal,
connect red DVOM lead to TP2 (refer to Figure 23336)
on the platform distribution panel or any other good
battery positive reference.
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Control Module
Adjustments – Press the left arrow and the display will ask
Save? N. Change the N to Y and press the en-
Components which are adjustable are contained within ter button to save the settings.
directional and speed control compartment.
Directional Switches (FS & RS)
Traction Request Potentiometer (POT1)
1. With twist grip in neutral position, turn adjustment
1. When installing new potentiometer, before mesh- screws slowly on both directional switches, clock-
ing gears, adjust the wiper signal to approximately wise, until switch activates.
50%. To do this:
2. Turn both screws 1/2 turn counterclockwise.
– From the display, enter Level 2 and navigate to
3. From the display, enter Level 2 and navigate to the
the Analyzer menu.
Analyzer menu.
– Navigate to A2.3.3 POT1 submenu.
4. Navigate to A2.3.3 POT1 submenu.
– Press the right arrow and then the down arrow
5. Press the right arrow and then the down arrow to
to navigate to A2.3.3.2 Scaled submenu.
navigate to A2.3.3.2 Scaled submenu.
– Rotate potentiometer shaft until the display
6. With the travel twist grip released, observe the per-
shows 50%.
cent of voltage on the display. The reading should
be 48% to 52% in the center, released position.
NOTE Record reading.
For ACCESS 123 menu navigational charts (Analyzer, 7. Slowly turn twist grip until one of the directional
Calibration, etc.) and more information, refer to switches activates (signified by a "click").
ACCESS 123 section.
8. Record voltage reading on display.
2. Mesh gear teeth, tighten screws on mounting
bracket and calibrate potentiometer. To do this: 9. Slowly turn twist grip opposite way until other direc-
tional switch activates (signified by a "click").
– Keep your foot off the brake pedal and from the
display, in Level 2, navigate to the Calibration 10. Record voltage reading on display.
menu. 11. Difference of each reading from nominal center po-
– Press the right arrow. The message displayed sition reading should be within 2% of each other
will be C1 Handles. (i.e., 3% and 4.2% is OK, 3% and 5.4% is not).
– Press the right arrow and C1.1 Traction menu
should be displayed. Component Replacement
– Press the right arrow to enter C1.1 Traction
menu and the display will ask you Sure? N. Directional Switches (FS & RS)
Change the N to Y and press the enter button.
(Refer to Figure 18222)
• You will then be asked to set three positions for the
twist grip. As you perform the following commands, 1. Remove three screws (index 56) and lockwashers
press the right arrow to view the percent of POT1 (index 54).
voltage seen by ACCESS 4. 2. Move switch and bracket assembly over top of
– PUF Direction - Rotate the twist grip to the full cams and out.
power unit first direction and press the enter 3. Remove mounting bolts (index 58) of switch to be
button. replaced.
– FF Direction - Rotate the twist grip to the full 4. Transfer wires to replacement switch and tighten
forks first direction and press the enter button. screws.
– Center - Release the twist grip and press the 5. Assemble switch, insulator and spacer.
enter button.
6. Secure in place with screws, lockwashers and
nuts.
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ELECTRICAL
Control Module
7. Move switch and bracket assembly under cam, on Potentiometer (POT1)
top of posts and secure in place.
8. Adjust both switches as described in Adjustments. (Refer to Figure 18223-01)
9. Calibrate traction request potentiometer, POT1 as 1. Loosen screws (index 45) on adjustable mounting
described in Adjustments. bracket (index 49).
2. Access to lower pivot point is through hole on left
side of directional and speed control compartment.
3. Push potentiometer back so gear teeth unmesh.
4. Slide pinion gear (index 52) off potentiometer
shaft.
5. Disconnect potentiometer pins at JC309, noting lo-
cation for proper installation.
Chart 2 - JC309 Pot Wiring
Pin Color
1 Green
2 Orange
Figure 18222
3 Violet
Actuator Arm 6. Remove insulator (index 51).
7. Pull potentiometer (index 42) from mounting
(Refer to Figure 18222) bracket and remove insulator (index 44) and
washer (index 43).
1. Remove three screws (index 56) and lockwashers
(index 54). 8. Place insulator and washer, with washer against
potentiometer, on replacement potentiometer.
2. Move switch and bracket assembly over top of
cams and out. 9. Slide potentiometer through hole in mounting
bracket and assemble insulator (index 51) so small
3. Remove speed nut (index 57) from rod (index 59)
diameter slides through hole in bracket.
and slide rod out until actuator (index 64) to be re-
placed can be removed. 10. Turn potentiometer so wires are pointing out back
of panel.
4. Remove adjusting screw (index 65) and install in
replacement actuator. 11. Slide pinion gear (index 52) on potentiometer shaft
so gear teeth will mesh completely.
5. Slide rod into switch bracket, aligning actuator over
switches so rod goes through pivot point. 12. Re-connect wires to JC309.
6. Install speed nut. 13. Adjust potentiometer as described in Adjustments.
7. Move switch and bracket assembly under cam, on 14. Make certain mounting bracket screws are tight-
top of mounting posts and secure in place. ened.
8. Adjust both switches as described in Adjustments.
9. Calibrate traction request potentiometer, POT1 as
described in Adjustments.
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ELECTRICAL
Control Module
Figure 18223-01
(a) To Control Module
Cam, Torsion Spring, Stop
(Refer to Figure 17855-01)
1. Remove two cotter pins (index 11).
2. Remove washers (index 12) on outside of housing.
3. Make note of physical arrangement of components
with respect to each other and arrows on twist grip.
4. Slowly slide twist grip with square shaft to the right.
5. Replace component in question.
6. When assembling, apply grease (Crown no.
063002-025) to inside of torsion spring (index 17).
7. Install one washer (index 12) onto square shaft (in-
dex 21).
8. Slide cam (index 13) onto shaft (index 21) so cam
lobes are toward switches when arrows on twist
grip are toward top.
9. Install spacer (index 14).
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ELECTRICAL
Control Module
Figure 17855-01
(a) Part of Platform
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ELECTRICAL
Control Module
4. Depending on operator preference, position re-
placement grip with lobe toward module or away
from module with arrows up.
5. Trucks are manufactured with lobe toward module.
6. Install grip in module.
Stop & Return Assembly
7. Align key on extension with slot in grip and assem-
Figure 18247 ble extension to grip.
10. Install Stop and Return Assembly (index 15, 16, 17 8. Slide grip onto square shaft, lining up hole in shaft
and 18) on shaft, making certain torsion spring (in- with hole in grip.
dex 17) is over tab in Control Module Housing, as 9. Assemble roll pins in each end of grip.
shown in Figure 18247 and 1347-02.
Figure 1347-02
11. Install spacer (index 19) and slide shaft through
housing making certain split bushing (index 10),
washer (index 12) and bushing (index 8) remain in
housing.
12. Install cotter pin (index 11) in shaft inside direc-
tional and speed control compartment.
13. Install washers (index 12) as required to remove
any lateral movement of twist grip when final cotter
pin is installed.
14. Perform switch and potentiometer adjustments be-
ginning with potentiometer adjustment.
Twist Grip
(Refer to Figure 17855-01)
1. Remove roll pin (index 3) from each end of twist
grip (index 2).
2. Slide twist grip to the right, out of control module
housing to access extension (index 1) on end of
twist grip.
3. Remove extension from twist grip and remove grip
from module.
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ELECTRICAL
Control Module
Figure 17855-01
(a) Part of Platform RAS1, RAS2, LOS1, LOS2, HNS,
EDS
(Refer to Figure 23339)
When replacing HNS (index 11), the key switch will
need to be removed to allow access to mounting
screws.
Switch terminals are to be tightened within 388 -
459 mNm (55 - 65 in oz).
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ELECTRICAL
Control Module
Figure 23339
(a) Located on Back of Control Module
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ELECTRICAL
Control Module
Button Return Springs Power Disconnect Button Springs
(Refer to Figure 23339) (Refer to Figure 23342)
To replace Raise, Lower and Horn button return 1. Remove screws and washers from button post
springs proceed as follows: while holding button depressed.
1. Secure control module with a wire, between top 2. Pull button and springs from module.
mounting bolt hole of control module and platform
3. Replace springs, insert button through housing
wall.
and secure in place with screws and washers.
2. Remove three mounting screws (index 4) from
After assembly, test all controls for proper operation.
spring plate (index 1).
3. Lift spring plate from assembly.
4. Raise and lower buttons require two compression
springs (index 10 and 66) and the horn button re-
quires one spring (index 10).
5. Replace spring(s) in question and assemble on re-
spective actuator lever (index 17) spring guide (in-
dex 9).
6. Position spring plate so spring guides locate
springs.
7. Start mounting screws. Mounting screw closest to
key switch also holds wiring harness clamp (index
6).
8. When screws are started and harness clamp is in
place, tighten screws.
9. Remove wire securing control module.
Figure 23342
Buttons
(Refer to Figure 23339)
1. To replace buttons, remove two screws (index 14)
from button and remove.
2. Position replacement button correctly and secure
in place with screws.
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ELECTRICAL
Steering Feedback
Steering Feedback
Gear Assembly
Whenever assembling the steering feedback gears, it
is important that all gear backlash be removed. If this is
not done, steering accuracy and response is reduced
and an event code may occur.
Refer to Figure 23365.
Place the nyliner bearing (4) onto the gear shaft (9).
Next place one end of the torsion spring (6) into the
small hole in the gear (5) as shown. Slide the gear (5)
onto the gear shaft (9) aligning the other end of the tor-
sion spring (6) with the small hole on that gear (9).
Slide the second nyliner bearing (4) onto the gear shaft
(9). Install the third nyliner bearing (4) on top of the
power unit as shown.
Turn the top gear (5) until the larger hole on both gears
(5 and 9) are aligned, approximately 2 teeth. Slide a
3 mm (1/8 in) drill bit into the holes from the bottom to
keep the gears aligned.
Slide gear shaft (9) up through the power unit. Once
the gears are meshed with the steering gearbox and
drive unit gears, install the flatwasher(s) (3) and the re-
taining ring (8) to keep the gear assembly from sliding
out.
Insert the encoder shaft into the gear shaft. Make sure
the extension spring (2) is installed. If necessary rotate
the gear shaft (9) so the set screw faces straight back
to allow for easy access for tightening. Tighten set
screw to secure encoder shaft to gear shaft.
Make certain the set screw is tightened on the flat part Figure 23365
of the encoder shaft. Remove drill bit from gear assem-
bly. 1 Cover
The steer wheel feedback encoder must be calibrated. 2 Extension Spring
To calibrate, refer to ACCESS 123 section, Calibration, 3 Flatwashers
C4 Steer Encoder. 4 Nyliner Bearing
5 Gear
6 Torsion Spring
CAUTION
7 Set Screw
The steering indicators will not represent the proper 8 Retaining Ring
steer angle. The steering feedback encoder must be
9 Gear and Shaft
calibrated to ensure the steered wheel is set to straight
ahead position. 10 Alignment Holes - Insert Drill Bit
Crown 2010 PF17882-1 M4.5-7335-100
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ELECTRICAL
Battery
Battery Safety Rules
Care and maintenance of battery is very important to 1. Wear protective clothing, such as steel-toed
obtain efficient truck operation and maximum battery shoes, rubber apron, gloves, boots, and goggles
life. when performing any maintenance on batteries.
Do not allow electrolyte to come in contact with
eyes, skin, clothing, or floor. If electrolyte comes in
CAUTION contact with eyes, flush immediately and thor-
oughly with clean water. Obtain medical attention
Gases produced by a battery can be explosive. Do not
immediately. Should electrolyte be spilled on skin,
smoke, use an open flame, or create an arc or sparks
rinse promptly with clean water and wash with
in vicinity of battery. Ventilate an enclosed area well
soap. A baking soda solution (0.5 kg [1 lb] soda to
when charging.
4 l [1 gal] of water) will neutralize acid spilled on
Batteries contain sulfuric acid which may cause severe
clothing, floor or any other surface. Apply solution
burns. Avoid contact with eyes, skin, or clothing. In
until bubbling stops and rinse with clean water.
case of contact, flush immediately and thoroughly with
clean water. Obtain medical attention when eyes are 2. Keep vent plugs firmly in place at all times except
affected. A baking soda solution (0.5 kg [1 lb] soda to when adding water or taking hydrometer readings.
4 l [1 gal] of water) applied to spilled acid until bubbling
3. Do not bring any type of flame, spark, etc., near
stops, neutralizes acid for safe handling and disposal.
battery. Gas formed while battery is charging is
Leakage voltage from battery terminals to battery case highly explosive. This gas remains in cells long af-
can cause misleading trouble symptoms with truck ter charging has stopped.
electrical system. Since components of truck electrical
4. Do not lay metallic or conductive objects on bat-
system are insulated from truck frame, leakage voltage
tery. Arcing will result.
will not normally affect truck operation unless a short
circuit or breakdown of circuit wire insulation to truck 5. Do not allow dirt, cleaning solution or other foreign
frame occurs. material to enter cells. Impurities in electrolyte has
a neutralizing effect reducing available charge.
A voltage check from battery connector terminal to bat-
tery case should indicate less than 50% battery volts. If 6. If battery repair is planned, follow battery manufac-
the voltage check for leakage voltage is greater than turer's instructions concerning repair practices and
50%, this leakage voltage will discharge battery. As procedures.
battery cleanliness deteriorates, usable charge of bat-
tery decreases due to this self discharge.
Checking
A cleaner battery will have more usable charge for
truck operation and not affect operation of electronic Battery electrolyte level should be checked before
devices on unit. each charge of battery. Level should be maintained at
13 mm (0.5 in) above the “element protector” plates. If
low, add distilled water or approved local supply (con-
sult battery manufacturer) at end of a charge cycle. Do
not overfill. For maximum battery life, specific gravity
readings should be taken daily on a pilot cell and re-
corded. A different pilot cell should be selected on a
monthly basis with readings taken on all cells at semi-
annual or annual intervals. Do not take specific gravity
readings immediately after adding water. Water and
electrolyte must be thoroughly mixed by charging be-
fore a reliable reading can be taken. Normal full
charged specific gravity should be between 1.280 and
1.320.
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ELECTRICAL
Battery
Battery Care 3. Before disconnecting or connecting batteries to
charger, make sure charger is off. If an attempt is
Your Crown truck is powered by an electrical storage made to do this while charger is on, serious injury
battery. Here are a few suggestions which will help you to you, battery, and charger could result.
give battery proper care.
4. Before charging, make sure battery cells contain
The battery on your truck is located in front of opera- correct amount of water. Charging batteries with a
tor's platform. low water level might result in damage to cells.
When checking water levels, never use a match or
lighter. Battery fumes are explosive.
5. Before connecting battery cable to truck's recepta-
cle, make sure key switch is off and all controls are
in off position and brakes are applied. Battery ca-
ble must be fully connected before truck is used. If
plug is not making good contact, heat will weld two
parts of battery connector together, making it diffi-
cult to remove and necessary to replace.
6. Battery terminals should be checked and cleaned
of corrosion regularly. Good battery terminal con-
Battery Location tact is essential not only for operation, but also for
proper charging of battery.
Figure 17191-01 7. Battery cover should be closed except when
charging.
1. Charge battery only in areas designated for that
use. 8. Charging requirements will vary depending on use
of truck. Battery should be given an equalizing
2. Make certain charger being used matches voltage charge on a weekly basis. This charge should nor-
and amperage of truck battery. This voltage is mally be an additional three hours at finish rate.
listed on truck data plate and is located on lower
portion of platform. 9. Refer to charger manufacturer's instruction for
specific charging procedures.
10. Make certain battery used meets weight, type, amp
hour, voltage, and size requirements of truck (refer
to data plate). NEVER operate truck with an under-
sized battery or incorrect voltage battery. Refer to
Chart 1 - Battery Weight, Type and Rating.
Figure 17192-02
1 Typical Data Plate
2 Lower Right Corner of Mast Side of Platform
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ELECTRICAL
Battery
Chart 1 - Battery Weight, Type and Rating
Battery Weight Battery Type Battery Rating
Minimum Maximum Voltage Hour Rate Capacity
690 kg (1520 lb) 860 kg (1900 lb) “E” 24 6 1085
Charging 5. Connect battery to truck. Make certain connectors
are mated completely.
Charging requirements will vary depending on use of
truck. A battery with a specific gravity between 1.120 to
1.160 should be recharged. In some applications, more Battery Stop Adjustment
than one battery is required to provide ample power to
To minimize side-to-side (lateral) movement of battery
unit during service period.
in truck, battery covers are equipped with adjustable
stops. First, battery must be centered in power unit,
CAUTION then adjustment screw on each battery retainer should
be adjusted until it contacts battery surface. Tighten
Never smoke or bring flame near battery. Gas formed locking screw down on adjustment screw and tighten
during charging is highly explosive and can cause seri- jam nut. Do not over tighten locking screw. Once bat-
ous injury. tery stops are adjusted, battery covers should be re-
movable without loosening battery stop adjustments.
Consult charger manufacturer's manual covering your
Any time a battery of different size is installed, this ad-
charger for hints on operation and maintenance. Basic
justment is necessary. Refer to Figure 17193-02.
rules are as follows:
Placing battery on charge:
1. Park truck at charging station with forks lowered
and key removed.
2. Make certain charger control is in off position.
3. Connect battery to charger and make certain con-
nectors are mated completely.
4. Set timer for specified time. Set for Normal (Daily
Charge, except one night a week when the Equal-
ize [Weekend] Charge should be used).
5. Check charger ammeter to make certain it shows
charge.
Removing battery from charge:
1. Make certain charger is turned off.
2. Unplug connector using both hands with a straight
pulling motion.
3. Hang up charger cable to prevent damage to ca- Figure 17193-02
ble. (Broken connectors can cause poor connec-
1 Locking Screw and Jam Nut
tions and connector failures).
2 Adjustment Screw
4. Make daily battery checks and add water as
needed.
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ELECTRICAL
Battery
Battery Removal 3. Remove battery cover (one side only).
4. Position battery roller stand next to truck. Align
stand with battery. Battery roller stand should be
CAUTION same height as truck's battery compartment roll-
Don't allow any metallic object to come in contact with ers, and as long or longer than battery.
top of battery cells. This may cause a short circuit when 5. Roll battery onto stand. Using approved spreader
removing, installing, or transporting battery. Use an in- bar, lift and move battery to charging area.
sulator (such as plywood) to cover top of battery before
and during removal and installation.
1. Turn key switch off.
Figure 17194-02
1 Off
Figure 17196-02
2 On
3 Test 1 Spreader Bar
4 Turn Key Switch Off 2 Roll onto Stand
2. Open top cover and disconnect battery.
Figure 17195-02
1 Top Cover
2 Battery Cover
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ELECTRICAL
Battery
Battery Installation
CAUTION
Don't allow any metallic object to come in contact with
top of battery cells. This may cause a short circuit when
removing, installing or transporting battery. Use an in-
sulator (such as plywood) to cover top of battery before
and during removal and installation.
Make certain same battery or battery of equal weight is
loaded into truck for truck stability. See data plate for
minimum battery weight and type.
1. Check to ensure key switch is turned off.
2. Using approved spreader bar, move battery onto
roller stand and push battery into battery compart-
ment.
Figure 17195-02
1 Top Cover
2 Battery Cover
4. Connect battery and close top cover.
5. Turn key switch on and check truck operation.
Battery Cleaning
Always keep vent plugs tightly in place when cleaning
battery. When properly watered and charged, battery
will remain clean and dry. Brush or blow off any dust or
dirt which may accumulate on them. However, if elec-
trolyte is spilled or overflows from a cell, it should be
neutralized with a solution of baking soda and water
(0.5 kg [1 lb] soda to 4 l [1 gal] of water). To do this,
remove battery from truck and clean with solution of
Figure 17197-02
soda and water, brushing soda solution beneath con-
1 Spreader Bar
nectors and removing grime from covers. Then rinse
battery with cool water from a low pressure supply to
2 Roll into Compartment
remove soda and loosened dirt. If batteries stay wet
consistently, they may be overcharged or overfilled.
WARNING This condition should be investigated and corrected.
Battery can slide out and hurt someone if side retainers
are not properly installed. Be sure both retainers are in
place and secure.
3. Remove roller stand and install battery cover.
Make sure battery retainers are properly adjusted
for battery installed.
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ELECTRICAL
Battery
Troubleshooting
CAUTION
Only qualified and experienced personnel should per-
form maintenance and repair on batteries.
Records of battery specific gravity readings, charger
used, truck used, etc. can be the most effective trouble-
shooting aid. Contact your dealer for charts designed
specifically for this purpose.
Voltage readings of each cell taken at normal charger
finish rate also indicate battery condition. New batter-
ies will have cell voltages ranging from 2.1 volts to 2.3
volts. Older batteries may range from 2.045 volts to
2.055 volts. These readings still indicate a battery in
good condition.
A variation of 0.20 volts may be normal if certain cells
are exposed to higher temperatures during discharge.
Voltage differences that cannot be attributed to battery
age or operating conditions indicate a weak cell(s) and
maintenance is required.
Even if all of the measurements are within acceptable
range, the battery still may need to be replaced. Even
though it charges fully, electrolyte levels are good and
the specific gravity readings are within the acceptable
range, the battery still may not last a full shift.
Batteries are rated for approximately 300 charging “cy-
cles” per year, which means they can be discharged
and recharged about 2000 times, depending on how
well they are taken care of. Eventually they will reach a
point were they need to be replaced. The best way to
confirm this is by testing a battery when it's “under
load”. To do this, connect a fully charged battery to a
truck and connect a DVOM across the positive and
negative terminals of the battery. Power up the truck
and perform a full demand function. For example, place
the forks under a load heavy enough so that when raise
is selected, the relief valve opens and the platform can
not raise. Select raise and read the voltage. If the volt-
age under load for the battery drops more than 0.5 volts
per cell during this test this could indicate that the bat-
tery is old and needs repaired or replaced. For exam-
ple, a 24 volt battery has 12 cells. So if the voltage
drops more than 6 volts for a 24 volt battery, the battery
probably needs replaced.
What you’re looking for is uniformity among cells. All
cells should read almost exactly the same voltage
when performing a load test. If a cell’s voltage under
load is slightly lower than the others, this may indicate
a problem with the cell.
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ELECTRICAL
Motors
Motors
Chart 1 - Traction Motor Information
Traction
021189, 021217 (EE) with Thermal Sensors
Motor Type: AC Induction
Winding Type: Delta
Bearings:
Lubricant Double Row Bearing: Chevron SRI-2
Sensor Bearing: GWB (Ansonic GHY 72)
Stator Winding Resistance:
At 20° C (68° F)
Between any Two Terminals 0.00349 ohm
Direction of Rotation: Bi-directional
Nominal Stator Diameter: 188 mm (7.4 in)
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ELECTRICAL
Motors
Chart 2 - Lift Motor Information
Lift
114330, 118838 with temperature and brush wear sensors
Brushes:
No. of Brush Holders 4
No. of Brush Assemblies 4
No. of Brush Springs 4
Brush Length - New 28 mm (1.10 in)
Spring Tension on New Brushes 1560 gm (55 oz)
Min. Brush Length - Replace 15 mm (0.60 in)
Spring Tension Before Replacement 992 gm (35 oz)
Commutator:
Max. Diameter - New 54 mm (2.12 in)
Min. Diameter - Reslotting 52 mm (2.05 in)
Min. Diameter - Replace 49 mm (1.93 in)
Bearings:
Lubricant Sealed
Cond. of Performance:
(No Load)
Volts 6
Max. Amperes 27
RPM 3000 min
Field Resistance:
(Each at 25° C [75° F])
Series Ohm .0035
Armature Resistance:
(Each at 25° C [75° F])
Ohm .0045
Measured Between Bars 1 and 8
Frame Diameter: 170 mm (6.7 in)
Wound in: Series
Direction of Rotation: CWDE
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ELECTRICAL SYSTEM
Event Codes
Event Codes To ensure the Access 1 2 3® software is up-to-date,
use Access 1 and scroll to the Utilities menu. From
Access 1 2 3® Module Listing: here, the module and software part numbers applicable
Access 1: Display Control Module (DCM) to the lift truck are viewable.
Access 3™: Traction Control Module (TCM) No Event Code?
Access 4: Vehicle Control Module (VCM) When the lift truck malfunctions and no event code is
displayed, it usually means that the malfunction is not
Access 5: Steering Control Module (SCM)
electrical.
Access 6: Guidance Control Module (GCM)
If the lift truck powers up, but a code is not displayed,
the malfunction is probably mechanical or hydraulic
rather than electrical. Information regarding
mechanical and hydraulic troubleshooting is located in
CAUTION the appropriate section in this Manual.
To Locate Malfunctioning Components
When replacing an ACCESS module or updating mod-
ule software, verify settings and recalibrate as needed Component and Wiring Location Maps are provided at
strategic locations to help quickly determine the
.
physical location of items in question.
Some Troubleshooting Basics
All components are clearly marked at the connection
points.
Test Points
WARNING Test points referenced in the event code descriptions
are on the distribution panel.
Never turn on the lift truck with any control connectors Power Cable Connections
disconnected. In addition, never remove or connect
any control connectors while the lift truck is keyed on.
Statistically most malfunctions occur in or at hardware CAUTION
components, contactors, and motors. The next
components to test are connectors, wiring, and input Due to capacitance voltage present in the traction mo-
devices such as switches, potentiometers, or tor controller and lift motor controller, whenever per-
encoders. When measuring voltage and resistance of forming maintenance which may permit contact with
these components, use a Digital Volt-Ohm Meter the bus bars and associated power cables, discharge
(DVOM). Be sure to connect all components previously the capacitors.
disconnected after completing event code steps. The
• Move the lift truck to a secure non-traffic mainte-
last component to suspect is the motor control system.
nance area with a level floor.
In all instances, begin the troubleshooting procedure at
the driven device, proceed to inputs devices, then, and • Lockout or tagout the lift truck as described in lock-
only then, move on to the control to which these out/tagout in this section.
devices attach. • Disconnecting the battery discharges the capaci-
When a Malfunction Occurs tors. Once the dash display flashes, the capacitors
are discharged. Two alternative methods of dis-
• Go to Access 1 and access the Level 2: Field Ser-
charging these capacitors are to disconnect the
vice Mode as follows.
battery and hold the key switch in the start position
Note: The monitoring system can be accessed at three for 10 seconds or disconnect the battery and con-
levels of authorization: nect a 200 Ω, 2 W resistor between the positive and
Level 1: Operator Mode negative terminals on the controller.
Level 2: Field Service Mode (Full Lift Truck Operation)
• Turn key switch to off, remove key.
Level 3: Analyzer/Test Mode (No Lift Truck Operation)
This section deals with Level 2 and Level 3. For
information on Level 1, see the Operator’s Manual.
See Electrical for Access 1 information.
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ELECTRICAL SYSTEM
Event Codes
Access 1 Display Control Module (DCM)
Fig. 1 (16722-02)
1 Display Screen
2 Battery Retainer Switch Indicator*
3 Enter or Return Key, used to navigate in and out of menus
and accept inputs.
4 Wire Guidance Display (optional)
5 Navigation Keys, up, down, left and right arrows; used to
scroll through menus.
6 Operator Improper Sequence Error Indicator*
7 Service Required Indicator*
8 Battery Discharge Indicator
* NOTE: These three indicators are viewable during initial
key-on, self test and indicator functioning.
Access 1 - Display Control Module (DCM)
Access 3™ - Traction Control Module (TCM)
Access 4 - Vehicle Control Module (VCM)
Access 5 - Steering Control Module (SCM)
Access 6 - Guidance Control Module (GCM)
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ELECTRICAL SYSTEM
Event Code 101
Event Code 101 Step 5: Check for CAN line short to the battery nega-
tive, battery positive, and lift truck frame. Turn off the lift
Access 1 CAN Initialization Error. truck and disconnect battery. Using a DVOM, check the
All lift truck functions disabled. resistance at the power unit from CAN_L to battery
negative bus bar, CAN_L to TP3 on the power unit dis-
Note: Absence of battery negative to ACCESSES on tribution panel, and CAN_L to lift truck frame. Resis-
the CAN bus loads the bus and impede CAN
tance is greater than 10,000 Ω.
communications.
• If: Less than 10,000 Ω.
Step 1: Check the Access 1 CAN wiring. Wire 003
CA302-8 to CA105-2 and wire 004 CA302-9 to – Then repair or replace wiring as necessary.
CA105-8.
• If: Wiring is correct and event code continues.
– Then proceed to Step 2.
• If: Wiring incorrect.
– Then repair or replace as necessary.
Step 2: Check power to Access 1, wire 2941
CA302-3 to CA103-10 and wire 513 CA302-4 to
CA107-8.
• If: Wiring is correct and event code continues.
– Then proceed to Step 3.
• If: Wiring incorrect.
– Then repair or replace as necessary.
Step 3: Check for battery negative to other AC-
CESSES on CAN bus by verifying that power lamps
are on.
• If: ACCESS has no power.
– Then using a DVOM, check for battery positive
and battery negative. If either be missing, check
associated wiring, connector, and fuse.
Step 4: CAN communications line test:
Turn off the lift truck and use a DVOM to check the
resistance between CAN_H and CAN_L on the
platform distribution panel TP13 and TP14, is 60 Ω.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 120 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1 and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 120 Ω.
– Then replace Access 1.
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ELECTRICAL SYSTEM
Event Code 103
Event Code 103 – Then repair or replace wiring as necessary.
Access 3™ CAN Initialization Error.
All functions disabled.
Note: Access 1 CAN bus communication with
Access 3™ has not occurred within specified time.
Step 1: Turn on the lift truck, check the status of
Access 3™ power on lamps.
• If: Access 3™ power lamps are on and event code
continues.
– Then proceed to Step 2.
• If: Access 3™ power lamps are off.
– Then check for battery voltage between CA401-1
and battery negative cable.
• If: 24 V.
– Then replace Access 3™.
• If: 0 V.
– Then check wire 2953 CA401-1 to CA201-5, fuse
FU3 power unit distribution panel.
Step 2: Check CAN communications lines. Turn off
the lift truck and, using a DVOM, check resistance be-
tween CAN_H and CAN_L is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses. Repair or replace as necessary.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 60 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1 and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 60 Ω.
– Then replace Access 1.
Step 3: Check for CAN line short to battery negative,
battery positive, and lift truck frame. Turn off the lift
truck, disconnect battery and, using a DVOM, check
resistance at the power unit from CAN_L to battery
negative bus bar, CAN_L to TP3 on the power unit dis-
tribution panel and CAN_L to lift truck frame. Resis-
tance is greater than 10,000 Ω.
• If: Less than 10,000 Ω.
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ELECTRICAL SYSTEM
Event Code Repair or replace104
Event Code Repair or re- negative bus bar, CAN_L to TP3 on the power unit dis-
tribution panel and CAN_L to the lift truck frame. Resis-
place104 tance is greater than 10,000 Ω.
• If: Less than 10,000 Ω.
Access 4 CAN Initialization Error.
– Then repair or replace wiring as necessary.
All lift truck functions disabled.
Note: Access 1 CAN bus communication with
Access 4 has not occurred within specified time.
Step 1: Turn on the lift truck, check status of
Access 4 power on lamps.
• If: Access 4 power lamps are on and event code
continues.
– Then proceed to Step 2.
• If: Access 4 power lamps are off.
– Then check for battery voltage between CA304-1
and CA304-3.
• If: 24 V.
– Then replace Access 4.
• If: 0 V.
– Then check wire 2937, CA304-1 to CA103-12;
wire 525, CA304-3 to CA107-9 and fuse FU2
power unit distribution panel. Repair or replace
as necessary.
Step 2: Check CAN Communications Lines. Turn off
the lift truck and, using a DVOM, check that the resis-
tance between CAN_H and CAN_L is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses. Repair or replace as necessary.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 60 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1 and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 60 Ω.
– Then replace Access 1.
Step 3: Check for CAN line short to battery negative,
battery positive, and lift truck frame. Turn off the lift
truck, disconnect battery and, using a DVOM, check
resistance at the power unit from CAN_L to battery
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Event Code 105
Event Code 105 • If: Less than 10,000 Ω.
– Then repair or replace wiring as necessary.
Access 5 CAN Initialization Error.
All lift truck functions disabled.
Note: Access 1 CAN bus communication with
Access 5 has not occurred within specified time.
Step 1: Turn on the lift truck, check the status of
Access 5 power on lamps.
• If: Access 5 power lamps are on and event code
continues.
– Then proceed to Step 2.
• If: Access 5 power lamps are off.
– Then check for battery voltage between
CA403-26 and CA403-10.
• If: 24 V.
– Then replace Access 5.
• If: 0 V.
– Then check wire 551 CA403-26 to CA401, wire
2966 CA403-10 to CA201-6, fuse FU3 power unit
distribution panel.
Step 2: Check CAN communications lines. Turn off
the lift truck and, using a DVOM, check that the resis-
tance between CAN_H and CAN_L is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses. Repair or replace as necessary.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 60 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 3™ and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 60 Ω.
– Then replace Access 1.
Step 3: Check for CAN line short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck, disconnect battery and, using a DVOM, check
resistance at the power unit from CAN_L to battery
negative bus bar, CAN_L to TP3 on the power unit dis-
tribution panel and CAN_L to the lift truck frame. Resis-
tance is greater than 10,000 Ω.
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ELECTRICAL SYSTEM
Event Code 106
Event Code 106 • If: Less than 10,000 Ω.
– Then repair or replace wiring as necessary.
Access 6 CAN Initialization Error.
All lift truck functions disabled.
Note: Access 1 CAN bus communication with
Access 6 has not occurred within specified time.
Step 1: Turn on the lift truck, check status of
Access 6 power on lamps.
• If: Access 6 power lamps are on and event code
continues.
– Then proceed to Step 2.
• If: Access 6 power lamps are off.
– Then check for battery voltage between CA601-1
and CA601-2.
• If: 24 V.
– Then replace Access 6.
• If: 0 V.
– Then check wire 2972 CA601-1 to CA201-6, wire
552 CA601-2 to battery negative bus bar, fuse
FU3 power unit distribution panel.
Step 2: Check CAN communications lines. Turn off
the lift truck and, using a DVOM, check resistance be-
tween CAN_H and CAN_L is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 60 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1 and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 60 Ω.
– Then replace Access 1.
Step 3: Check for CAN line short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck, disconnect battery and, using a DVOM, check
resistance at the power unit from CAN_L to battery
negative bus bar, CAN_L to TP3 on the power unit dis-
tribution panel and CAN_L to the lift truck frame. Resis-
tance is greater than 10,000 Ω.
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ELECTRICAL SYSTEM
Event Code 111
Event Code 111
Access 1 Software Parameter Error.
All lift truck functions disabled.
Step 1: Download latest software.
Event Code 113
Access 3™ Software Incompatible.
All functions disabled.
Step 1: Load Access 3™ with compatible software.
Event Code 114
Access 4 Software Incompatible.
All lift truck functions disabled.
Step 1: Load Access 4 with compatible software.
Event Code 115
Access 5 Software Incompatible.
All lift truck functions disabled.
Step 1: Load Access 5 with compatible software.
Event Code 116
Access 6 Software Incompatible.
All lift truck functions disabled.
Step 1: Load Access 6 with compatible software.
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Event Code 123
Event Code 123 – Then repair or replace wiring as necessary.
Access 3™ CAN Error.
All lift truck functions disabled.
Note: Access 1 CAN bus communication with
Access 3™ was lost.
Step 1: Turn on the lift truck, check status of
Access 3™ power on lamps.
• If: Access 3™ power lamps are on and event code
continues.
– Then proceed to Step 2.
• If: Access 3™ power lamps are off.
– Then check for battery voltage between CA401-1
and battery negative cable.
• If: 24 V.
– Then replace Access 3™.
• If: 0 V.
– Then check wire 2953 CA401-1 to CA201-5, fuse
FU3 power unit distribution panel.
Step 2: Check CAN communications lines. Turn off
the lift truck and, using a DVOM, check resistance be-
tween CAN_H and CAN_L is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 60 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1 and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 60 Ω.
– Then replace Access 1.
Step 3: Check for CAN line short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck, disconnect battery and, using a DVOM, check
resistance at the power unit from CAN_L to battery
negative bus bar, CAN_L to TP3 on the power unit dis-
tribution panel and CAN_L to the lift truck frame. Resis-
tance is greater than 10,000 Ω.
• If: Less than 10,000 Ω.
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ELECTRICAL SYSTEM
Event Code 124
Event Code 124 • If: Less than 10,000 Ω.
– Then repair or replace wiring as necessary.
Access 4 CAN Error.
All lift truck functions disabled.
Note: Access 1 CAN bus communication with
Access 4 was lost.
Step 1: Turn on the lift truck, check status of
Access 4 power on lamps.
• If: Access 4 power lamps are on and event code
continues.
– Then proceed to Step 2.
• If: Access 4 power lamps are off.
– Then check for battery voltage between CA304-1
and CA304-3.
• If: 24 V.
– Then replace Access 4.
• If: 0 V.
– Then check wire 2937 CA304-1 to CA103-12,
wire 525 CA304-3 to CA107-9, fuse FU2 power
unit distribution panel.
Step 2: Check CAN communications lines. Turn off
the lift truck and, using a DVOM, check resistance be-
tween CAN_H and CAN_L is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 60 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1. Check resis-
tance between CA302-8 and CA302-9 using a
DVOM.
• If: Greater than 60 Ω.
– Then replace Access 1.
Step 3: Check for CAN line short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck, disconnect battery and, using a DVOM, check
resistance at the power unit from CAN_L to battery
negative bus bar, CAN_L to TP3 on the power unit dis-
tribution panel and CAN_L to the lift truck frame. Resis-
tance is greater than 10,000 Ω.
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ELECTRICAL SYSTEM
Event Code 125
Event Code 125 • If: Less than 10,000 Ω.
– Then repair or replace wiring as necessary.
Access 5 CAN Error.
All lift truck functions disabled.
Note: Access 1 CAN bus communication with
Access 5 was lost.
Step 1: Turn on the lift truck, check status of
Access 5 power on lamps.
• If: Access 5 power lamps are on and event code
continues.
– Then proceed to Step 2.
• If: Access 5 power lamps are off.
– Then check for battery voltage between
CA403-26 and CA403-10.
• If: 24 V.
– Then replace Access 5.
• If: 0 V.
– Then check wire 551 CA403-26 to CA401, wire
2966 CA403-10 to CA201-6, fuse FU3 power unit
distribution panel.
Step 2: Check CAN communications lines. Turn off
the lift truck and, using a DVOM, check resistance be-
tween CAN_H and CAN_L is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 60 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 3™ and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 60 Ω.
– Then replace Access 1.
Step 3: Check for CAN line short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck, disconnect battery and, using a DVOM, check
resistance at the power unit from CAN_L to battery
negative bus bar, CAN_L to TP3 on the power unit dis-
tribution panel and CAN_L to the lift truck frame. Resis-
tance is greater than 10,000 Ω.
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Event Code 126
Event Code 126 tribution panel and CAN_L to the lift truck frame. Resis-
tance is greater than 10,000 Ω.
Access 6 CAN Error. • If: Less than 10,000 Ω.
All lift truck functions disabled. – Then repair or replace wiring as necessary.
Note: Access 1 CAN bus communication with
Access 6 was lost.
Step 1: Turn on the lift truck, check status of
Access 6 power on lamps.
• If: Access 6 power lamps are on and event code
continues.
– Then proceed to Step 2.
• If: Access 6 power lamps are off.
– Then check for battery voltage between CA601-1
and CA601-2.
• If: 24 V.
– Then replace Access 6.
• If: 0 V.
– Then check wire 2972 CA601-1 to CA201-6, wire
552 CA601-2 to battery negative BB, fuse FU3
power unit distribution panel. Repair or replace
as necessary.
Step 2: Check CAN communications lines. Turn off
the lift truck and, using a DVOM, check resistance be-
tween CAN_H and CAN_L is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 60 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1 and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 60 Ω.
– Then replace Access 1.
Step 3: Check for CAN line short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck, disconnect battery and, using a DVOM, check
resistance at the power unit from CAN_L to battery
negative bus bar, CAN_L to TP3 on the power unit dis-
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Event Code 131
Event Code 131
Access 1 Alarm 1 (ALM1) Driver Shorted.
No action taken.
Step 1: Using a DVOM check for 24 V between TP8
and TP7 on platform distribution panel. Energize output
for ALM1 in analyzer mode.
• If: 0 V.
– Then remove wire 5917 from CA302-2 and check
for 24 V between CA302-2 and TP7 on platform
distribution panel. Energize output for ALM1 in
analyzer mode.
• If: 0 V.
– Then replace Access 1.
• If: 24 V.
– Then check continuity of wire 5917.
• If: Open.
– Then repair or replace wiring.
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Event Code 133
Event Code 133
Guidance Steer Indicator (GSI) CAN Error.
No lift truck functions are disabled.
Step 1: Turn on the lift truck, check status of GSI.
• If: GSI power light is on.
– Then proceed to Step 2.
• If: GSI lights are off.
– Then check for 24 V between CA201-6 and
CA206-5.
• If: 0 V.
– Then check FU3.
• If: 24 V.
– Then check for 24 V between CA403-10 and
CA403-26.
• If: 24 V.
– Then replace GSI.
• If: 0 V.
– Then issue exists in wiring between CA403-10 or
CA403-26.
Step 2: Check connection of CAN to GSI.
• If: Correct and event code continues.
– Then turn off the lift truck and, using a DVOM,
check resistance between CAN_H and CAN_L
platform distribution panels CA105-4 and
CA105-10. Resistance is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L,
repair as necessary.
• If: Greater than 60–65 Ω with all connectors con-
nected.
– Then CAN bus-terminating resistor is missing or
damaged. CAN bus contains two terminating re-
sistors, one is located in the Access 5 the other in
Access 1.
Step 3: Check for CAN lines for short battery nega-
tive, battery positive, and the lift truck frame. Turn off
the lift truck, disconnect battery and, using a DVOM,
check resistance at power unit distribution panel be-
tween CAN_L/CAN_H and battery negative bus bar,
CAN_L/CAN_H between TP15 and TP16 and CAN_L/
CAN_H to the lift truck frame. Resistance is greater
than 10,000 Ω.
• If: Less than 10,000 Ω.
– Then repair or replace as necessary.
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Event Code 134
Event Code 134 CAN_L/CAN_H to the lift truck frame. Resistance is
greater than 10,000 Ω.
Access 4 CAN Error. • If: Less than 10,000 Ω.
Full speed traction and raise 2 disabled. – Then repair as necessary.
Step 1: Turn on the lift truck, check status of
Access 4 power on lamps.
• If: Access 4 power lamps are on.
– Then proceed to Step 2.
• If: Access 4 lamps are off.
– Then check for 24 V between CA103-12 and
CA107-9.
• If: 24 V.
– Then check for 24 V between CA304-1 and
CA304-3.
• If: 24 V.
– Then replace Access 4.
• If: 0 V.
– Then issue exists in wiring connected to CA304-1
to CA304-3.
Step 2: Check CAN communications lines. Turn off
the lift truck. Using a DVOM, check that the resistance
between CAN_H and CAN_L, platform distribution
panel TP13 and TP14 is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 120 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1 and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 120 Ω.
– Then replace Access 1.
Step 3: Check for CAN lines for short battery nega-
tive, battery positive, and the lift truck frame. Turn off
the lift truck and disconnect battery. Using a DVOM,
check the resistance at the power unit distribution
panel between CAN_L/CAN_H and battery negative
bus bar, CAN_L/CAN_H between TP15 and TP16, and
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Event Code 160
Event Code 160 – Then repair or replace the wires or connect
CA428.
Access 1 Communication Error with EPS • If: The wires and connections are good.
Step 1: Turn off the lift truck. Check the resistance – Then continue to step 3.
between CA428-1 and CA428-2. Step 3: Turn on the lift truck. Make sure that the Fea-
• If: The resistance = 60 Ω. If CA428 is opened, the tures menus are set correctly.
lift truck side resistance is 60 Ω and the battery side
• If: The menu settings are not correct.
is O/L.
– Then change the menus to the correct settings.
– Then continue to step 2.
• If: The menu settings are correct.
• If: The resistance ≠ 60 Ω or O/L.
– Then continue to step 4.
– Then follow the instructions in the V-Force® bat-
tery manufacturer manual or Event Code 123. Step 4: Turn off the battery then turn on the battery.
Turn on the lift truck.
Step 2: Check the wires between CA428-1 and
CA428-2. Make sure that the wires are connected • If: The event code clears.
properly. – Then return the lift truck to service.
• If: The wires are damaged or not connected prop- • If: The event code does not clear.
erly. – Then troubleshoot the battery by following the in-
– Then repair or replace the wires or connect structions in the V-Force® battery manufacturer
CA428. manual.
• If: The wires and connections are good.
– Then continue to step 3. Event Code 162
Step 3: Turn off the battery then turn on the battery. Access 1 Communication Lost From EPS
Turn on the lift truck.
Step 1: Turn off the lift truck. Check the resistance
• If: The event code clears. between the CA428-1 and CA428-2.
– Then return the lift truck to service. • If: The resistance = 60 Ω. If CA428 is opened, the
• If: The event code does not clear. lift truck side resistance is 60 Ω and the battery side
– Then troubleshoot the battery by following the in- is O/L.
structions in the V-Force® battery manufacturer – Then continue to step 2.
manual. • If: The resistance ≠ 60 Ω or O/L.
– Then follow the instructions in the V-Force® bat-
Event Code 161 tery manufacturer manual or Event Code 123.
Access 1 Communication Lost From EPS Step 2: Check the wires between CA428-1 and
CA428-2. Make sure that the wires are connected
Step 1: Turn off the lift truck. Check the resistance
properly.
between CA428-1 and CA428-2.
• If: The wires are damaged or not connected prop-
• If: The resistance = 60 Ω. If CA428 is opened, the
erly.
lift truck side resistance is 60 Ω and the battery side
is O/L. – Then repair or replace the wires or connect
CA428.
– Then continue to step 2.
• If: The wires and connections are good.
• If: The resistance ≠ 60 Ω or O/L.
– Then continue to step 3.
– Then follow the instructions in the V-Force® bat-
tery manufacturer manual or Event Code 123. Step 3: Turn on the lift truck. Make sure that the Fea-
tures menus are set correctly.
Step 2: Check the wires between CA428-1 and
CA428-2. Make sure that the wires are connected • If: The menu settings are not correct.
properly. – Then change the menus to the correct settings.
• If: The wires are damaged or not connected prop- • If: The menu settings are correct.
erly. – Then continue to step 4.
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Event Code 163
Step 4: Turn off the battery then turn on the battery.
Turn on the lift truck.
Event Code 164
• If: The event code clears. EPS Software is Incompatible
– Then return the lift truck to service. The lift truck software is not compatible with the
• If: The event code does not clear. V-Force® lithium-ion battery software.
Step 1: Download the latest software into the lift truck
– Then troubleshoot the battery by following the in-
and correctly set up the Features Menu.
structions in the V-Force® battery manufacturer
manual. • If: The event code is cleared.
– Then return the lift truck to service.
Event Code 163 • If: The event code is not cleared.
– Then continue to step 3.
Access 1 Communication Error with EPS
Step 2: Download the latest software into the
Step 1: Turn off the lift truck. Check the resistance
V-Force® lithium-ion battery.
between the CA428-1 and CA428-2.
• If: The event code is cleared.
• If: The resistance = 60 Ω. If CA428 is opened, the
lift truck side resistance is 60 Ω and the battery side – Then return the lift truck to service.
is O/L. • If: The event code is not cleared.
– Then continue to step 2. – Then contact the Crown Service Department.
• If: The resistance ≠ 60 Ω or O/L.
– Then follow the instructions in the V-Force® bat- Event Code 165
tery manufacturer manual or Event Code 123.
Access 1 Communication Error with EPS
Step 2: Check the wires between CA428-1 and
Step 1: Turn off the lift truck. Check the resistance
CA428-2. Make sure that the wires are connected
between CA428-1 and CA428-2.
properly.
• If: The resistance = 60 Ω. If CA428 is opened, the
• If: The wires are damaged or not connected prop-
lift truck side resistance is 60 Ω and the battery side
erly.
is O/L.
– Then repair or replace the wires or connect
– Then continue to step 2.
CA428.
• If: The resistance ≠ 60 Ω or O/L.
• If: The wires and connections are good.
– Then follow the instructions in the V-Force® bat-
– Then continue to step 3.
tery manufacturer manual or Event Code 123.
Step 3: Turn on the lift truck. Make sure that the Fea-
Step 2: Check the wires between CA428-1 and
tures menus are set correctly.
CA428-2. Make sure that the wires are connected
• If: The menu settings are not correct. properly.
– Then change the menus to the correct settings. • If: The wires are damaged or not connected prop-
• If: The menu settings are correct. erly.
– Then continue to step 4. – Then repair or replace the wires or connect
Step 4: Turn off the battery then turn on the battery. CA428.
Turn on the lift truck. • If: The wires and connections are good.
• If: The event code clears. – Then continue to step 3.
– Then return the lift truck to service. Step 3: Turn off the battery then turn on the battery.
• If: The event code does not clear. Turn on the lift truck.
– Then troubleshoot the battery by following the in- • If: The event code clears.
structions in the V-Force® battery manufacturer – Then return the lift truck to service.
manual. • If: The event code does not clear.
– Then troubleshoot the battery by following the in-
structions in the V-Force® battery manufacturer
manual.
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Event Code 166
Event Code 166 – Then charge the battery.
Step 4: Confirm that the battery and the EPS harness
Load Shed Zero are properly connected.
The EPS has requested immobilization of the lift truck. • If: The battery and harness are properly connected.
Step 1: Check to see if the charger is plugged into – Then continue to step 5.
the battery.
• If: The battery and harness are not properly con-
• If: The charger is plugged into the battery. nected.
– Then unplug the charger from the battery. Turn – Then connect the battery and the EPS harness to
the key off then back on to operate the lift truck or the lift truck and continue to step 5.
plug the charger back in to continue charging.
Step 5: Measure the voltage on CA428. Measure the
• If: The charger is not plugged into the battery. voltage between CA428-4 (+) and the battery connec-
– Then the battery has a software issue. Check and tor (-).
update the battery protocol level and Consult the • If: The voltage is 34–39 V or 46–51 V.
Crown Customer Service.
– Then continue to step 6.
• If: The voltage is not 34–39 V or 46–51 V.
Event Code 167 – Then troubleshoot the battery by following the in-
EPS Error State Logged structions in the V-Force® battery manufacturer
manual.
Note: Troubleshoot the battery by following the instruc-
tions in the V-Force® battery manufacturer manual. Step 6: Measure the voltage on CA428. Measure the
voltage between CA428-5 (+) and the battery connec-
tor (-).
Event Code 168
• If: The voltage is 34–39 V or 46–51 V.
EWS Event – Then continue to step 7.
The lift truck does not have power. • If: The voltage is not 34–39 V or 46–51 V.
Step 1: View the external display unit on the – Then replace FU25 in the EPS harness.
V-Force® lithium-ion battery.
Step 7: Disconnect the battery connector from the lift
• If: The V-Force® lithium-ion battery is on. truck. Measure the voltage on the (+) and (-) terminals
– Then continue to step 2. of the battery connector.
• If: The V-Force® lithium-ion battery is not on. • If: The voltage is 34–39 V or 46–51 V.
– Then turn on the lithium-ion battery. If the lithium- – Then continue to step 8.
ion battery turns on, continue to step 2. If the lith- • If: The voltage is not 34–39 V or 46–51 V.
ium-ion battery does not turn on, then trouble-
– Then troubleshoot the battery by following the in-
shoot the battery by following the instructions in
structions in the V-Force® battery manufacturer
the V-Force® battery manufacturer manual.
manual.
Step 2: View the fault indicator LED on the V-Force®
Step 8: Connect the battery connector to the lift truck.
lithium-ion battery.
Turn on the lift truck.
• If: The fault indicator LED is flashing.
• If: The lift truck has power.
– Then troubleshoot the battery by following the in-
– Then continue to step 9.
structions in the V-Force® battery manufacturer
manual. • If: The lift truck does not have power.
• If: The fault indicator LED is not flashing. – Then see the schematic diagram to troubleshoot
the FU4, KYS, and K1 relay startup circuit.
– Then continue to step 3.
Step 9: Check the event code history, is event code
Step 3: View the battery state of charge LEDs on the 168 logged?
V-Force® lithium-ion battery.
• If: Event Code 168 is logged.
• If: The battery state of charge is greater than 0%.
– Then continue to step 10.
– Then continue to step 4.
• If: Event Code 168 is not logged.
• If: The battery state of charge is 0%.
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Event Code 169
– Then return the lift truck to service. is cleared, return the lift truck to service. If the
Step 10: Measure the voltage on the relay connector. event code is not cleared, continue to step 2.
Measure the voltage between K20-4 (+) and the bat- Step 2: Download the latest software into the lift truck
tery connector (-). and correctly set up the Features Menu.
• If: The voltage is 34–39 V or 46–51 V. • If: The event code is cleared.
– Then continue to step 11. – Then return the lift truck to service.
• If: The voltage is not 34–39 V or 46–51 V. • If: The event code is not cleared.
– Then repair or replace the wiring between FU25 – Then continue to step 3.
and K20-4. Step 3: Download the latest software into the
Step 11: Measure the voltage on the relay connector. V-Force® lithium-ion battery.
Measure the voltage between K20-4 (+) and K20-B (-). • If: The event code is cleared.
• If: The voltage is 34–39 V or 46–51 V. – Then return the lift truck to service.
– Then continue to step 12. • If: The event code is not cleared.
• If: The voltage is not 34–39 V or 46–51 V. – Then contact the Crown Service Department.
– Then repair or replace the wiring between K20-B
and PC203-8.
Step 12: Measure the voltage on the relay connector.
Measure the voltage between K20-4 (+) and K20-7 (-).
• If: The voltage is 34–39 V or 46–51 V.
– Then continue to step 13.
• If: The voltage is not 34–39 V or 46–51 V.
– Then replace K20.
Step 13: Measure the voltage on the relay connector.
Measure the voltage between K20-4 (+) and CA411-20
(-) on Access 3™.
• If: The voltage is 34–39 V or 46–51 V.
– Then replace Access 3™.
• If: The voltage is not 34–39 V or 46–51 V.
– Then repair or replace the wiring between
CA411-20 and K20-7.
Event Code 169
EPS/BRES Configuration Mismatch
The lift truck Features are not configured correctly for
the EPS type and the level installed in the lift truck. The
lift truck software is not compatible with the V-Force®
lithium-ion battery software.
Step 1: Use the Features > F15 Electrical Power
Source > F15.1 Type and F15.2 Level menus to config-
ure the EPS type and level.
• If: The Features are configured correctly.
– Then continue to step 2.
• If: The Features are not configured correctly.
– Then configure the EPS type and level to match
the EPS installed in the lift truck. Turn off the lift
truck then turn on the lift truck. If the event code
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Event Code 301
Event Code 301
Access 1 CAN Error.
Traction and raise disabled.
Step 1: Check CAN wires and connections.
Wire 018 CA401-15 Access 3™ to power unit
distribution panel CA204-7, RED wire CA203-3 to
platform distribution panel CA104-3, wire 004 CA105-8
to Access 1 CA302-9.
Wire 017 CA401-23 Access 3™ to power unit
distribution panel CA204-1, WHITE wire CA203-2 to
platform distribution panel CA104-2, wire 003 CA105-2
to Access 1 CA302-8.
• If: Wiring or connections require repair.
– Then repair as necessary.
Step 2: Check CAN communications lines. Turn off
the lift truck and, using a DVOM, check resistance be-
tween CAN_H and CAN_L, platform distribution panel
TP13 and TP14, is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 120 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1 and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 120 Ω. Event Code 302
– Then replace Access 1.
THRU
Event Code 303
Access 3™ Internal Short.
Traction disabled.
Step 1: Turn off the lift truck. Then turn on the lift
truck.
• If: Event code continues.
– Then replace Access 3™.
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Event Code 304
Event Code 304
Access 3™ / Access 4 CAN Error.
Traction and raise disabled.
Step 1: Check CAN wires and connections.
Wire 018 CA401-15 Access 3™ to power unit
distribution panel CA204-7, wire 002 CA105-7 to
Access 4 CA303-8.
Wire 017 CA401-23 Access 3™ to power unit
distribution panel CA204-1, wire 001 CA105-1
Access 4 CA303-7.
• If: Wiring or connections require repair.
– Then repair as necessary.
Step 2: Check CAN communications lines. Turn off
the lift truck and, using a DVOM, check resistance be-
tween CAN_H and CAN_L, platform distribution panel
TP13 and TP14, is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 120 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1 and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 120 Ω.
– Then replace Access 1.
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Event Code 305
Event Code 305
Access 3™ / Access 5 CAN Error.
Traction and raise disabled.
Step 1: Check CAN wires and connections.
Wire 018 CA401-15 Access 3™ to power unit
distribution panel CA204-7, wire 020 CA204-8 to
Access 5 CA402-5.
Wire 017 CA401-23 Access 3™ to power unit
distribution panel CA204-1, wire 019 CA204-2
Access 5 CA402-4.
• If: Wiring or connections require repair.
– Then repair as necessary.
Step 2: Check CAN communications lines. Turn off
the lift truck and, using a DVOM, check resistance be-
tween CAN_H and CAN_L, platform distribution panel
TP13 and TP14, is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 120 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1 and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 120 Ω.
– Then replace Access 1.
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Event Code 306
Event Code 306
Access 3™ / Access 6 CAN Error.
Traction and raise disabled.
Step 1: Check CAN wires and connections.
Wire 018 CA401-15 Access 3™ to power unit
distribution panel CA204-7, wire 021 CA204-3 to
Access 6 CA601-4.
Wire 017 CA401-23 Access 3™ to power unit
distribution panel CA204-1, wire 001 CA204-9
Access 6 CA601-5.
• If: Wiring or connections require repair.
– Then repair as necessary.
Step 2: Check CAN communications lines. Turn off
the lift truck and, using a DVOM, check resistance be-
tween CAN_H and CAN_L, platform distribution panel
TP13 and TP14, is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Check associated wiring, connections, and
fuses.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA402 from Access 5 and, using a
DVOM, check resistance between CA402-4 and
CA402-5.
• If: Greater than 120 Ω.
– Then replace Access 5.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are open.
Remove CA302 from Access 1 and, using a
DVOM, check resistance between CA302-8 and
CA302-9.
• If: Greater than 120 Ω.
– Then replace Access 1.
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Event Code 307
Event Code 307 Event Code 312
THRU Access 3™ Short Between Terminal U and V.
Traction disabled.
Event Code 309 Step 1: Check condition of motor cables.
Access 3™ Short. • If: Cables are shorted.
Traction disabled. – Then repair as necessary.
Event Code 307: Short Between battery negative and • If: Cables correct.
Terminal V. – Then disconnect traction motor (M1) phase ca-
Event Code 308: Short Between battery positive and bling from Access 3™ and turn on the lift truck.
Terminal W. • If: Event code continues.
Event Code 309: Short between battery negative and – Then replace Access 3™.
Terminal W.
Step 1: Check condition of motor cables.
• If: Cables are shorted.
– Then repair as necessary.
• If: Cables are correct.
– Then disconnect traction motor (M1) phase ca-
bling from Access 3™ and Turn on the lift truck.
• If: Event code continues.
– Then replace Access 3™.
Event Code 310
Height Encoder (ECR4) and Height Feedback En-
coder (ECR6) Software Incompatibility
Step 1: Load the compatible software for ECR4 and
ECR6.
• If: Event code 310 continues.
– Then replace Access 3™.
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Event Code 313
Event Code 313
THRU
Event Code 315
Access 3™ Short Between Terminal W and V.
Traction disabled.
Step 1: Check condition of motor cables.
• If: Cables are shorted.
– Then repair as necessary.
• If: Cables correct.
– Then disconnect traction motor (M1) phase ca-
bling from Access 3™ and turn on the lift truck.
• If: Event code continues.
– Then replace Access 3™.
Event Code 319
THRU
Event Code 320
Access 3™ Internal Issue.
All functions disabled.
Step 1: Turn off the lift truck. Then turn on the lift
truck.
• If: Event code continues.
– Then replace Access 3™.
Event Code 316
THRU
Event Code 318
Access 3™ Short Between Terminal W and U.
Traction disabled.
Step 1: Check condition of motor cables.
• If: Cables are shorted.
– Then repair as necessary.
• If: Cables correct.
– Then disconnect traction motor (M1) phase ca-
bling from Access 3™ and turn on the lift truck.
• If: Event code continues.
– Then replace Access 3™.
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Event Code 322
Event Code 322 Event Code 324
Access 3™ Battery Voltage Low. Access 3™ Internal temperature Less than -25°C
Full traction disabled. (-13°F).
Note: If event code 322 is logged with event code 541, Full traction disabled.
then see the ED system event code 541 first. Step 1: Determine air temperature of environment.
Traction disabled. • If: Ambient temperature is below -25°C (-13°F) and
Step 1: Using a DVOM check, for 24 V between the lift truck has set idle for and extended time.
Access 3™ (+) terminal and battery negative terminal. – Then Access 3™ heat sink must be warmed to
• If: Voltage is under 24 V. operate with full traction capabilities.
– Then check for correct battery, power cable con- • If: Ambient temperature is well above -25°C (-13°F)
nections, fuse FU15, and ED2 contactor. and event continues.
• If: Battery, power cable connections, FU15 and – Then replace Access 3™.
ED2 are correct.
– Then check battery charge level. Event Code 325
• If: Battery is properly charged. Access 3™ Internal Temperature Less than -40°C
– Then check feature menu for proper battery con- (-40°F).
figuration. Traction disabled.
• If: Battery is not configured correctly. Step 1: Determine air temperature of environment.
– Then correct configuration. • If: Ambient temperature is below -40°C (-40°F) and
the lift truck has set idle for and extended time.
– Then Access 3™ heat sink must be warmed to
Access 3™ operate.
• If: Ambient temperature is well above -40°C (-40°F)
and event continues.
B+ + B–
– Then replace Access 3™.
Event Code 326
FU15 Access 3™ Internal Temperature More than 85°C
ED2
(185°F).
No effect.
Event Code 323 Step 1: Check mounting of Access 3™.
• If: Installation screws are loose.
Access 3™ Battery Voltage High.
– Then tighten the installation screws.
Note: If event code 323 is logged with event code 541,
then see the ED system event code 541 first. • If: Motor M1 is hot.
Traction disabled. – Then check power cable connections and blow
off any dirt build-up.
Step 1: Using a DVOM check for 24 V Access 3™
battery positive terminal and battery negative terminal.
• If: Voltage is over 24 V (for example, 36 V).
– Then check for correct battery.
• If: Battery is 24 V.
– Then check feature menu for proper battery con-
figuration.
• If: Battery is not configured correctly.
– Then correct configuration.
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Event Code 327
Event Code 327
Access 3™ Internal Temperature in Excess of
105°C (221°F).
Traction disabled.
Step 1: Check mounting of Access 3™.
• If: Installation screws are loose.
– Then tighten the installation screws.
• If: Motor M1 is hot.
– Then check power cable connections and blow
off any dirt build-up.
Event Code 328
Access 3™ Traction Motor (M1) Temperature Sen-
sor (TS1) Above Acceptable Operating Range of
165°C (329°F).
No effect.
Step 1: Check traction motor setups.
• If: Incorrect setups.
– Then change.
• If: Setups are correct.
– Then check TS1/M1 lead or cable connections
and clean dirt off M1.
• If: This action does not correct overheating.
– Then check battery condition.
Note: Extreme duty cycle or high ambient
temperatures could also cause 328 event code
logging.
Event Code 329
Access 3™ Traction Motor M1 Temperature Sensor
TS1 Signal Out of Range.
Traction disabled.
Step 1: Using a DVOM check TS1 wiring for a short
to the lift truck frame. Check CA411-1 and CA411-2 en-
coder wires, CA411-1 wire 579 to battery negative BB
and CA411-2 wire 105 to CA401-16 to the lift truck
frame.
• If: Wires are shorted.
– Then repair as necessary.
• If: Wires are correct.
– Then using a DVOM check TS1 wiring for an
open. Check CA411-1 and CA411-2 encoder
wires, CA411-1 wire 579 to battery negative BB
and CA411-2 wire 105 to CA401-16.
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Event Code 330
Event Code 330
Access 3™ Encoder ECR3 Count Error.
Traction disabled. One or both channels lost at
Access 3™ while the lift truck is traveling.
Step 1: Check for event codes 366, 367, 376 and
377, which indicate that ECR3 power supply or logic
ground is out of range. If these codes have been
logged, resolve them before proceeding with proce-
dure below.
• If: None of these event codes have occurred.
– Then proceed to Step 2.
Note: Use Service Mode 2 to view ECR3 operation.
Step 2: Turn off the lift truck. Then turn on the lift
truck.
• If: Event code 330 logs.
– Then check ECR3 channel A and B wiring.
WHITE and BLUE wires between ECR3 and
CA411-4, -5. Wires 028, 029 between CA411-4,
-5 and Access 3™ CA401-6, -5.
• If: Wiring is correct and event code continues.
– Then replace Access 3™.
• If: No event codes slow traction or shut downs con-
tinue.
– Then check ECR3 power wiring. RED and
BLACK wires between ECR3 and CA411-3, -6.
Wires 315 and 549 between CA411-3, -6 and
Access 3™ CA401-3 and -4.
• If: Connections are good and slow traction or shut
downs continue.
– Then replace M1.
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Event Code 332
Event Code 332 – Then check for correct battery, power cable con-
nections, fuse FU10, and ED2 contactor.
Access 3™ Drive Motor (M1) Rotation More than • If: Battery, power cable connections, FU10 and
4000 rpm. ED2 correct.
Traction disabled. – Then check battery charge level.
Step 1: Check ECR3 channel A and B wiring. WHITE • If: Battery is properly charged.
and BLUE wires between ECR3 and CA411-4 and -5.
– Then check feature menu for proper battery con-
Wires 028 and 029 between CA411-4, -5 and
figuration.
Access 3™ CA401-6, -5.
• If: Battery is not configured correctly.
• If: ECR3 channel A and B wiring is correct.
– Then correct configuration.
– Then check ECR3 power wiring. RED and
BLACK wires between ECR3 and CA411-3, -6.
Wires 315, 549 between CA411-3, -6 and
Access 3™ CA401-3, -4.
• If: ECR3 power wiring is correct.
– Then replace ECR3.
Event Code 336
Access 3™ Battery Voltage Over Range.
Full traction disabled.
Note: IF event code 336 is logged with event code 541,
then see the ED system event code 541 first.
Step 1: Using a DVOM check for 24 V on Access 3™
between battery positive terminal and battery negative
terminal.
• If: Over 24 V (for example, 36 V).
– Then check for correct battery.
• If: Battery is 24 V.
– Then check feature menu for proper battery con-
Event Code 334 figuration.
Access 3™ Battery Voltage Under Range. • If: Battery is not configured correctly.
Full traction disabled. – Then correct configuration.
Note: If event code 334 is logged with event code 541,
then see the ED system event code 541 first.
Step 1: Using a DVOM check for 24 V on Access 3™
between battery positive terminal and battery negative
terminal.
• If: Under 24 V.
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Event Code 337
Event Code 337
Access 3™ 24 V Battery Voltage Fluctuating.
Full traction disabled.
Note: Battery voltage is dropping excessively under
load.
Step 1: Check Access 3™ battery negative and bat-
tery positive power cable connections.
• If: Connections in poor condition.
– Then repair or replace.
• If: Connections in good condition.
– Then check condition of battery or install a known
good battery and monitor event code 337.
Event Code 338
Access 3™ battery positive Under Voltage.
All functions disabled.
Step 1: Check battery status.
• If: Battery has correct voltage and charged.
– Then proceed to Step 2.
• If: Battery does not have correct voltage or not
properly charged.
– Then resolve battery issue.
Step 2: Turn on the lift truck and, using a DVOM,
check for 24 V between CA401-1 and battery negative
on Access 3™.
• If: 24 V.
– Then proceed with Step 3.
• If: Voltage is above 0 V but much less than 24 V.
– Then check voltage between CA201-5 and
Access 3™ battery negative.
• If: 24 V.
– Then check wiring. Wire 2953 power unit distribu-
tion panel CA201 5 to Access 3™ CA401-1.
• If: Voltage is above 0 V but much less than 24 V.
– Then check condition of power unit distribution
panel.
Step 3: Check voltage between Access 3™ battery
positive and battery negative terminals.
• If: Voltage is below 24 V.
– Then check power cable condition and connec-
tion.
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Event Code 339
Event Code 339
Access 3™ battery positive Over Voltage.
Steering, traction, and hydraulics disabled.
Step 1: Check feature menu for proper battery con-
figuration.
• If: Configuration is correct.
– Then check for proper battery.
• If: Battery is correct.
– Then proceed to Step 2.
• If: Battery is not correct.
– Then resolve battery issue.
Step 2: Using a DVOM check for 24 V between
CA401-1 and Access 3™ battery negative.
• If: 24 V.
– Then proceed to Step 3.
• If: Voltage is above 0 V but much less than 24 V.
– Then check voltage between CA201-5 and
Access 3™ battery negative.
• If: 24 V.
– Then check wiring. Wire 2953 power unit distribu-
tion panel CA201-5 to Access 3™ CA401-1.
• If: Voltage is above 0 V but much less than 24 V. Event Code 340
– Then check condition of power unit distribution
panel. Access 3™ ED2 Contactor Coil Driver Overcurrent.
Step 3: Check voltage between Access 3™ battery Steering, traction, and hydraulics disabled.
positive and battery negative terminals. Step 1: Follow troubleshooting steps for event code
• If: Voltage is above 24 V but less than 28 V and 541.
event code continues.
– Then replace Access 3™.
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Event Code 341
Event Code 341 Step 1: Disconnect wires 2962 and 5924 from P2
contactor coil and, using a DVOM, check resistance of
Access 3™ P1 Contactor Coil Driver Overcurrent. P2 contactor coil.
Raise disabled. • If: Less than 20 Ω.
Step 1: Disconnect wires 2961 and 5923 from P1 – Then replace P2 contactor coil.
contactor coil and, using a DVOM, check resistance of • If: 20 Ω and event code continues.
P1 contactor coil.
– Then check P2 contactor coil wiring for a short.
• If: Less than 20 Ω. Wire 5924 to Access 3™ CA401-21 and wire
– Then replace P1 contactor. 2962 to power unit distribution panel CA202-7.
• If: 20 Ω and event code continues. • If: Wires are not shorted remove wire 5923 from P1
– Then check P1 contactor coil wiring for a short. contactor coil.
Wire 5923 to Access 3™ CA401-18 and wire – Then check for 24 V between wire 2962 and
2961 to power unit distribution panel CA202-6. 5924 at P2 contactor coil while depressing raise
• If: Wires are not shorted remove wire 5924 from P2 2 switch.
contactor coil. • If: 0 V.
– Then check for 24 V between wire 2961 and – Then replace Access 3™.
5923 at P1 contactor coil while depressing raise
1 switch.
• If: 0 V.
– Then replace Access 3™.
Event Code 342
Access 3™ P2 Contactor Coil Driver Overcurrent.
Raise speed 2 disabled.
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Event Code 343
Event Code 343
Access 3™ Lowering Solenoid (SVL) Driver Over-
current.
Raise and lower disabled.
Step 1: Disconnect wire 5925 from SVL coil and, us-
ing a DVOM, check resistance of SVL coil.
• If: Less than 29 Ω.
– Then replace SVL coil.
• If: 29 Ω.
– Then check for 24 V between wire 5925 and wire
2959 (opposite side of SVL coil) while depressing
lower switch.
• If: 0 V.
– Then remove wire 5925 from connector
CA401-22 and, using a DVOM, check for 24 V
between wire 2959 and CA401-22 while depress-
ing lower switch.
• If: 0 V.
– Then replace Access 3™.
• If: 24 V.
– Then turn off the lift truck reconnect wire 5925 to
SVL. Connect DVOM lead to wire 2959 and TP3
on the power unit distribution panel. Turn on the
lift truck, depress lower switch and check for
24 V.
• If: 0 V.
– Then check wiring at CA201-10 and FU3.
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Event Code 344
Event Code 344 Event Code 345
Access 3™ Fan2 Driver Overcurrent. Access 3™ ED2 Contactor Driver Open.
Full traction disabled. Steering and traction disabled.
Step 1: Disconnect wires 29122 and 5908 from Fan2 Step 1: Follow troubleshooting procedure for event
and, using a DVOM, check for 24 V between wire code 541.
29122 and wire 5908. Energize output for Fan2 in ana-
lyzer mode.
• If: 0 V.
– Then remove wire 5908 from CA401-8 and check
for 24 V between CA401-8 and TP4 on power
unit distribution panel. Energize output for Fan2
in analyzer mode.
• If: 0 V.
– Then replace Access 3™.
• If: 24 V.
– Then reconnect wire 5908 and check for 24 V be-
tween wire 29122 and TP3 on power unit distribu-
tion panel.
• If: 0 V.
– Then check connection of wire 29122 to
CA201-8.
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Event Code 346
Event Code 346
Access 3™ P1 Contactor Driver Open.
Raise 1 disabled.
Step 1: Disconnect wires 2961 and 5923 from P1
contactor coil and, using a DVOM, check resistance of
P1 contactor coil.
• If: Less than 20 Ω.
– Then replace P1 contactor coil.
• If: 20 Ω, remove wire 5924 from P2 contactor coil.
– Then check for 24 V between wires 2961 and
5923 at P1 contactor coil while depressing raise
one switch.
• If: 0 V.
– Then remove wire 5923 from CA401-18 and
check for 24 V between CA401-18 and TP4 while
depressing raise one switch.
• If: 0 V.
– Then replace Access 3™.
• If: 24 V.
– Then, using a DVOM, check for 24 V between
wire 2961 and TP3 while depressing raise one
switch.
• If: 0 V.
– Then check raise one switch and associated wir-
ing.
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Event Code 348
Event Code 348 Step 1: Using a DVOM check for 24 V between wire
29122 and 5908 at FAN2 (use analyzer mode to ener-
Access 3™ Lowering Solenoid (SVL) Driver Open. gize output).
Raise disabled. • If: 0 V.
Step 1: Disconnect wires 2959 and 5925 from SVL – Then remove wire 5908 from CA401-8 and check
coil and, using a DVOM, check resistance of SVL coil. for 24 V between CA401-8 to TP4 (use analyzer
• If: Less than 29 Ω. mode to energize output).
– Then replace SVL coil. • If: 0 V.
• If: 29 Ω. – Then replace Access 3™.
– Then check for 24 V between wires 2959 and • If: 24 V.
5925 while depressing lower switch. – Then check for 24 V between wire 29122 and
• If: 0 V. TP4.
– Then disconnect wire 5925 from CA401-22 and • If: 0 V.
check for 24 V between CA401-22 and TP4 while – Then check wiring.
depressing lower switch.
• If: 0 V.
– Then replace Access 3™.
• If: 24 V.
– Then check for 24 V between wire 2959 and TP3
while depressing lower switch.
• If: 0 V.
– Then check lower switch and associated wiring.
Event Code 350
Access 3™ ED2 Contactor Driver Shorted.
Full traction disabled.
Step 1: See the ED2 troubleshooting procedure for
event code 541.
Event Code 349
Access 3™ FAN2 Driver Open.
Full traction disabled.
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Event Code 351
Event Code 351
Access 3™ P1 Contactor Driver Shorted.
Full traction, auxiliary raise, and raise2 disabled.
Step 1: Disconnect wires 2961 and 5923 from P1
contactor coil and, using a DVOM, check resistance of
P1 contactor coil.
• If: Less than 20 Ω.
– Then replace P1 contactor coil.
• If: 20 Ω, remove wire 5924 from P2 contactor coil.
– Then check for 24 V between wire 2961 and
5923 at P1 contactor coil while depressing raise
one switch.
• If: 0 V.
– Then remove wire 5923 from CA401-18 and
check for 24 V between CA401-18 to TP4 while
depressing raise one switch.
• If: 0 V.
– Then replace Access 3™.
• If: 24 V.
– Then, using a DVOM, check for 24 V between
wire 2961 and TP3 while depressing raise one
switch.
• If: 0 V.
– Then check associated wiring.
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Event Code 352
Event Code 352
Access 3™ P2 Contactor Driver Shorted.
Full traction, auxiliary raise, and raise2 disabled.
Step 1: Disconnect wires 2962 and 5924 from P2
contactor coil and, using a DVOM, check resistance of
P2 contactor coil.
• If: Less than 20 Ω.
– Then replace P2 contactor.
• If: 20 Ω, remove wire 5923 from P1 contactor coil.
– Then check for 24 V between wire 2962 and
5924 at P2 contactor coil while depressing raise
two switch.
• If: 0 V.
– Then remove wire 5924 from CA401-21 and
check for 24 V between CA401-21 to TP4 while
depressing raise two switch.
• If: 0 V.
– Then replace Access 3™.
• If: 24 V.
– Then, using a DVOM, check for 24 V between
wire 2962 and TP3 while depressing raise two
switch.
• If: 0 V.
– Then check associated wiring.
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Event Code 353
Event Code 353
Access 3™ Lowering Solenoid (SVL) Driver
Shorted.
Raise disabled.
Step 1: Disconnect wires 2959 and 5925 from SVL
coil and, using a DVOM, check resistance of SVL coil.
• If: Less than 29 Ω.
– Then replace SVL coil.
• If: 29 Ω.
– Then check for 24 V between wires 2959 and
5925 while depressing lower switch.
• If: 0 V.
– Then disconnect wire 5925 from CA401-22 and
check for 24 V between CA401-22 and TP4 while
depressing lower switch.
• If: 0 V.
– Then replace Access 3™.
• If: 24 V.
– Then check for 24 V between wire 2959 and TP3
while depressing lower switch.
• If: 0 V.
– Then check wiring at CA201-10 and FU3.
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Event Code 354
Event Code 354
Access 3™ FAN2 Driver Shorted.
No action taken.
Step 1: Disconnect wires 29122 and 5908 from FAN2
and, using a DVOM, check for 24 V between wire
29122 and wire 5908. Energize output for FAN2 in an-
alyzer mode.
• If: 0 V.
– Then remove wire 5908 from CA401-8 and check
for 24 V between CA401-8 and TP4 on power
unit distribution panel. Energize output for Fan2
in analyzer mode.
• If: 0 V.
– Then replace Access 3™.
• If: 24 V.
– Then reconnect wire 5908 and check for 24 V be-
tween wire 29122 and TP3 on power unit distribu-
tion panel.
• If: 0 V.
– Then check wiring connection at CA201-8 and
FU4.
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Event Code 355
Event Code 355 – Then replace as necessary.
• If: Contacts correct.
Access 3™ PWM Driver Over Voltage. – Then turn off the lift truck and check ED2 load
All functions disabled. bus connections.
Step 1: Using a DVOM for 24 V between CA201-5 • If: Connections correct.
and TP3 on the power unit distribution panel.
– Then follow procedures for event code 541.
• If: 0 V.
– Then check FU3.
• If: 24 V.
– Then check for 24 V between CA401-1 and TP3.
• If: 0 V.
– Then repair connection of wire 2953.
• If: 24 V.
– Then replace Access 3™.
Event Code 356
Access 3™ Detected Open Circuit in ED2 Wiring.
All functions disabled.
Step 1: Follow the ED System Troubleshooting pro-
cedure specified for event code 541.
Event Code 357
Access 3™ ED2 Contactor Error.
All functions disabled.
Step 1: Check ED2 contact tips.
• If: Contacts are worn.
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Event Code 358
Event Code 358
Access 3™ Pre-Charge Power Limit Out of Range.
All functions disabled.
Note: Power limit of pre-charge resistor internal to
Access 3™ has been exceeded.
Step 1: Check battery.
• If: Battery is correct voltage and charged.
– Then proceed to Step 2.
• If: Battery is not correct voltage or not properly
charged.
– Then resolve battery issue.
Step 2: Turn on the lift truck and cycle pedal. Using a
DVOM check for 24 V between battery positive and
battery negative power lug on Access 3™.
• If: 24 V.
– Then proceed to Step 3.
• If: Above 0 V but much less than 24 V.
– Then check cables to Access 3™.
Step 3: Turn on the lift truck and, using a DVOM,
check for 24 V between CA401-1 and battery negative
on Access 3™.
• If: Above 0 V but much less than 24 V.
– Then check for 24 V between CA201-5 and
Access 3™ battery negative.
• If: 24 V.
– Then check wiring. Wire 2953 power unit distribu-
tion panel CA201-5 to Access 3™ CA401-1.
• If: Above 0 V but much less than 24 V.
– Then check condition of power unit distribution
panel.
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Event Code 359
Event Code 359 Event Code 360
Access 3™ Pre-Charge Time Limit Exceeded. Access 3™ Pre-Charge Electrical Error.
All functions disabled. All functions disabled.
Step 1: Check battery status. Note: Resistive load is present on the ED2 bus during
• If: Battery has correct voltage and charged. pre-charge this condition is most likely a driver shorted
issue.
– Then proceed to Step 2.
Step 1: Check battery.
• If: Battery does not have correct voltage or not
properly charged. • If: Battery is correct voltage and charged.
– Then resolve battery issue. – Then proceed to Step 2.
Step 2: Turn on the lift truck and, using a DVOM, • If: Battery is not correct voltage or not properly
check for 24 V between CA401-1 and battery negative charged.
on Access 3™. – Then resolve battery issue.
• If: 24 V. Step 2: Check other events logged along side the
– Then proceed to Step 3. 360.
• If: Above 0 V but much less than 24 V.
– Then check voltage between CA201-5 and
Event Code 361
Access 3™ battery negative. Access 3™ Error.
• If: 24 V. All functions disabled.
– Then check wiring. Wire 2953 power unit distribu- Step 1: Replace Access 3™.
tion panel CA201-5 to Access 3™ CA401-1.
• If: Above 0 V but much less than 24 V. Event Code 362
– Then check condition of power unit distribution
THRU
panel.
Event Code 363
Access 3™ Internal Issue.
No action taken.
Step 1: Turn off the lift truck. Then turn on the lift
truck.
• If: Event code continues.
– Then replace Access 3™.
Event Code 364
THRU
Event Code 365
Access 3™ Internal 5 V Supply Out of Range.
All functions disabled.
Step 1: Turn off the lift truck. Then turn on the lift
truck.
• If: Event code continues.
– Then replace Access 3™.
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Event Code 366
Event Code 366
THRU
Event Code 367
Access 3™ +12 V Power Supply for Encoder 3
(ECR3) Out of Range.
All functions disabled.
Event Code 366: Supply voltage high.
Event Code 367: Supply voltage low.
Step 1: Using a DVOM, check for 12 V between wire
315 CA401-3 and TP3 (battery negative) power unit
distribution panel. When 12 V and event code contin-
ues, then check for 12 V at CA411-3 and TP3 (battery
negative).
• If: 0 V.
– Then replace Access 3™.
• If: Less than 12 V and event code continues.
– Then remove wire 315 from CA401-3 and, using
a DVOM, check for 12 V between CA401-3 and
TP3 (battery negative). When 12 V, then replace
ECR3.When less than 12 V and event code con-
tinues, then replace Access 3™.
Event Code 368
THRU
Event Code 369
Access 3™ 15 V Power Supply Out of Range.
All functions disabled.
Step 1: Internal failure.
• If: Event code continues.
– Then replace Access 3™.
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Event Code 370
Event Code 370 • If: Short circuit exists between U, V, W cables, or
frame.
THRU – Then remove phase cabling and check for M1
winding shorts to frame.
Event Code 371 • If: Short exists in M1.
Access 3™ 5 V Power Supply Out of Range. – Then replace M1.
All functions disabled.
Step 1: Internal failure.
• If: Event code continues.
– Then replace Access 3™.
Event Code 372
THRU
Event Code 373
Access 3™ Internal 227 mV Reference Voltage Out
of Range.
All functions disabled. Event Code 379
Step 1: Internal failure.
• If: Event code continues. THRU
– Then replace Access 3™.
Event Code 380
Event Code 374 Access 3™ Internal Short.
THRU Traction disabled.
Step 1: Turn off the lift truck. Then turn on the lift
Event Code 375 truck.
• If: Event code continues.
Access 3™ Internal 2.5 V Reference Voltage Out of
– Then replace Access 3™.
Range.
All functions disabled.
Step 1: Internal failure.
• If: Event code continues.
– Then replace Access 3™.
Event Code 378
Access 3™ Over Current Condition.
Traction disabled.
Step 1: Disconnect traction motor (M1) phase ca-
bling from Access 3™ and Turn on the lift truck.
• If: Event code continues.
– Then replace Access 3™.
• If: Event code clears.
– Then using a DVOM check M1 and cabling for
phase-to-phase and phase-to-frame shorts.
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Event Code 381
Event Code 381 • If: Cables are shorted.
– Then repair as necessary.
THRU • If: Cables are correct.
– Then disconnect traction motor (M1) phase ca-
Event Code 382 bling from Access 3™ and Turn on the lift truck.
Access 3™ Short. • If: Event code continues.
Traction disabled. – Then replace Access 3™.
Event Code 381: Short between battery positive and
terminal U.
Event Code 382: Short between battery negative and
terminal U.
Step 1: Check condition of motor cables.
• If: Cables are shorted.
– Then repair as necessary.
• If: Cables are correct.
– Then disconnect traction motor (M1) phase ca-
bling from Access 3™ and Turn on the lift truck.
• If: Event code continues.
– Then replace Access 3™.
Event Code 385
THRU
Event Code 383
THRU
Event Code 384
Access 3™ Short.
Traction disabled.
Event Code 383: Short between battery positive and
terminal V.
Event Code 384: Short between battery negative and
terminal V.
Step 1: Check condition of motor cables.
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Event Code 386
Event Code 386 – Then disconnect motor cables from Access 3™
and turn on the lift truck.
Access 3™ Short. • If: Event code continues.
Traction disabled. – Then replace Access 3™.
Event Code 385: Short between battery positive and • If: Event code clears.
terminal W.
– Then repair or replace M1.
Event Code 386: Short between battery negative and
terminal W. Event Code 390
Step 1: Check condition of motor cables.
THRU
• If: Cables are shorted.
– Then repair as necessary.
Event Code 392
• If: Cables are correct.
– Then disconnect traction motor (M1) phase ca- Access 3™ Traction Motor (M1) Short.
bling from Access 3™ and Turn on the lift truck. Traction disabled.
• If: Event code continues. Event Code 390: Short V to W.
– Then replace Access 3™. Event Code 391: Short VL to WH.
Event Code 392: Short VH to WL.
Step 1: Check condition of motor cables.
• If: Cables are shorted.
– Then repair as necessary.
• If: Cables are correct.
– Then disconnect traction motor (M1) phase ca-
bling from Access 3™ and Turn on the lift truck.
• If: Event code continues.
– Then replace Access 3™.
• If: Event code clears.
– Then replace M1.
Event Code 393
THRU
Event Code 387
Event Code 395
THRU
Access 3™ Traction Motor (M1) Short.
Event Code 389 Traction disabled.
Access 3™ Short Terminal U to V. Event Code 393: Short W to U.
Traction disabled. Event Code 394: Short WL to UH.
Event Code 387: Short U to V. Event Code 395: Short WH to UL.
Event Code 388: Short UL to VH. Step 1: Check condition of motor cables.
Event Code 389: Short UH to VL. • If: Cables are shorted.
Step 1: Check motor cable connections. – Then repair as necessary.
• If: Short exists between U and V. • If: Cables are correct.
– Then repair as necessary. – Then disconnect traction motor (M1) phase ca-
bling from Access 3™ and Turn on the lift truck.
• If: No short exists.
• If: Event code continues.
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Event Code 396
– Then replace Access 3™. Step 1: Turn on the lift truck and check status of
• If: Event code clears. Access 1 lights.
– Then replace M1. • If: Access 1 lights are on.
– Then issue exists in wiring (003 and 004) be-
Event Code 396 tween Access 1 CA302-9, 8 and platform distri-
bution panel CA105-8, 2. Check connector
THRU mating, connector contact condition, proper con-
tact insertion, contact crimps, and wire condition.
Event Code 397 Check CAN_H and CAN_L wires are not re-
versed.
Pump Motor Over Temperature.
• If: Access 1 lights are off.
Pump motor has worn brushes. No action taken.
– Then check for 24 V between CA302-3 and
Event Code 396: Pump motor M3. CA302-4.
Event Code 397: Pump motor M4. • If: 24 V.
Step 1: Check appropriate pump motor for dirt build- – Then replace Access 1.
up.
• If: 0 V.
• If: Dirt is present.
– Then issue exists in the wiring connected to
– Then clean as needed. CA302-3 or CA302-4.
Step 2: Check for loose connections and corroded • If: Issue continues.
terminals.
– Then trace wiring from Access 1, CA302-8 to
• If: Loose connections and corroded terminals platform distribution panel CA105-8, -2.
found.
Step 2: Turn off the lift truck using a DVOM check re-
– Then tighten or clean as needed. sistance between CAN_H and CAN_L platform distri-
Step 3: Check pump assembly to ensure that me- bution panel TP13 and TP14. Resistance is
chanical binding does not exist. approximately 60 Ω.
• If: Mechanical issues exist. • If: 0 Ω.
– Then repair or replace pump as needed. – Then short exists between CAN_H and CAN_L.
Short is present in one of the ACCESSES. Find
Event Code 398 short by unhooking ACCESSES from the CAN
bus one at a time and check resistance between
Pump Motor Brush Wear. CAN_H and CAN_L.
Pump motor M3 or M4 has worn brushes. No action • If: Greater than 60 Ω.
taken. – Then CAN bus terminating resistors are missing
Step 1: Check brushes. CAN bus contains two terminating resistors, one
• If: Brushes are worn. located in Access 5 and the other in Access 1.
– Then replace as needed. • If: All wiring is correct and event continues.
Note: Replace the brush springs also. – Then replace Access 1 or Access 5.
Intermittent connection test.
Event Code 401 • If: Codes 104 or 106 are also displayed.
Access 4 / Access 1 CAN Error. – Then intermittent connection exists in wiring (003
and 004) between Access 1 CA302-9, -8 and
No action taken.
platform distribution panel CA105-8, -2. Locate
Note 1: If event code 401 is displayed on Access 1, and repair or replace as necessary.
issue was caused by an intermittent open wire
Step 3: Check for CAN line for short to battery nega-
condition. See the intermittent connection test at the
tive, battery positive, and the lift truck frame. Turn off
end of Step 2.
the lift truck and disconnect battery. Using a DVOM,
Note 2: If event code 401 is flashing on Access 4 but is check the resistance at the power unit from CAN_L to
not displayed on Access 1, then proceed to Step 1. BV bus bar, CAN_L to TP15 and TP16 on power unit
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Event Code 405
distribution panel and CAN_L to the lift truck frame. Re- • If: Event continues.
sistance is greater than 10,000 Ω. – Then check wiring between Access 5, CA402-4,
• If: Less than 10,000 Ω. -5 and power distribution panel CA204-8, -2.
– Then replace wiring as necessary. Step 2: Turn off the lift truck and check the resistance
between CAN_H and CAN_L at the power unit distribu-
tion panel TP15 and TP16. Resistance is approxi-
mately 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Short is present in one of the ACCESSES. Find
short by unhooking ACCESSES from the CAN
bus one at a time and check resistance between
CAN_H and CAN_L.
• If: Greater than 60 Ω.
– Then CAN bus terminating resistors are missing.
CAN bus contains two terminating resistors, one
located in Access 5 and the other in Access 1.
Step 3: Check CAN line short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck and disconnect battery. Using a DVOM, check the
resistance at the power unit CAN_L to battery negative
bus bar, CAN_L to TP15 and TP16 on power unit dis-
tribution panel and CAN_L to the lift truck frame. Resis-
tance is greater than 10,000 Ω.
• If: Less than 10,000 Ω.
– Then repair wiring as necessary.
• If: All wiring is correct.
– Then replace Access 5 or Access 4.
Event Code 405
Access 5 CAN timeout.
No action taken.
Step 1: Turn on the lift truck and check the status of
Access 5 lights.
• If: Access 5 lights are on.
– Then issue exists in wiring (019 and 020) be-
tween Access 5 CA402-4, -5 and power unit dis-
tribution panel CA204-2, -8. Check connector
mating, connector contact condition, proper con-
tact insertion, contact crimps, and wire condition.
Verify that CAN_H and CAN_L wires are not re-
versed.
• If: Access 5 lights are off.
– Then check for 24 V between CA403-10 and bat-
tery negative.
• If: 24 V.
– Then replace Access 5.
• If: 0 V.
– Then issue exists in wiring to CA403-10.
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Event Code 411
Event Code 411
Access 4 / Access 1 CAN Error.
All functions disabled.
Step 1: Turn on the lift truck and check the status of
Access 1 power light.
• If: Access 1 power light is on.
– Then proceed to Step 2.
• If: Access 1 power light is off.
– Then check for 24 V to Access 1. Place DVOM
leads battery positive on CA302-3 and battery
negative on CA302-4.
• If: 24 V.
– Then check connector terminals and wiring for
possible intermittence.
• If: 0 V.
– Then issue exists in wiring between CA302-3,
CA105-10, CA302-4 and CA107-8 on the plat-
form distribution panel.
Step 2: Check CAN communication lines.
• If: Event code continues and Access 1 is on.
– Then turn off the lift truck. Check resistance be-
tween CAN_H and CAN_L on either the power
unit or platform distribution panel. resistance is
60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Short is present in one of the ACCESSES. Find
short by unplugging ACCESSES from the CAN
bus one at a time and check resistance between
CAN_H and CAN_L.
• If: Greater than 60 Ω with all connectors connected.
– Then CAN bus-terminating resistor is missing or
damaged, or wiring to the terminating resistor is
open. CAN bus contains two terminating resis-
tors, one in the Access 5 and the other in
Access 1.
Step 3: Check CAN line for short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck and disconnect battery. Using a DVOM, check the
resistance at the power unit distribution panel CAN_L
to BV bus bar and CAN_L to TP15 and TP16 and to the
lift truck frame. Resistance is greater than 10,000 Ω.
• If: Less than 10,000 Ω.
– Then replace wiring as necessary.
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Event Code 413
Event Code 413
Access 4 / Access 3™ CAN Error.
All functions disabled.
Step 1: Turn on the lift truck. Verify status of
Access 3™ power light.
• If: Access 3™ power light is on.
– Then proceed to Step 2.
• If: Access 3™ power light is off.
– Then check for 24 V to Access 3™ connect a
DVOM between battery positive CA401-1 and
battery negative power terminal.
• If: 24 V.
– Then check connector, terminals, and wiring for
possible intermittence.
• If: 0 V.
– Then issue exists in wiring between CA401-1 and
CA201-5 on the power unit distribution panel.
Step 2: Check CAN communication lines.
• If: Event code continues - Access 1 is on.
– Then turn off the lift truck and check resistance
between CAN_H and CAN_L on either the power
unit or platform distribution panels. resistance is
60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Short is present in one of the ACCESSES. Find
short by unplugging ACCESSES from the CAN
bus one at a time and check resistance between
CAN_H and CAN_L.
• If: Greater than 60 Ω with all connectors connected.
– Then CAN bus-terminating resistor is missing or
damaged, or wiring to the terminating resistor is
open. CAN bus contains two terminating resis-
tors, one in Access 5 and the other in Access 1.
Step 3: Check CAN line for short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck and disconnect battery. Using a DVOM, check the
resistance at the power unit distribution panel CAN_L
to battery negative bus bar also CAN_L to TP15 and
TP16 and CAN_L to the lift truck frame. Resistance is
greater than 10,000 Ω.
• If: Less than 10,000 Ω.
– Then replace wiring as necessary.
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Event Code 415
Event Code 415
Access 4 / Access 5 CAN Error.
No action taken.
Step 1: Turn on the lift truck. Check status of
Access 5 power light.
• If: Access 5 power light is on.
– Then proceed to Step 2.
• If: Access 5 lights are off.
– Then check for 24 V between CA403-10 and
CA403-26.
• If: 24 V.
– Then replace Access 5.
• If: 0 V.
– Then issue exists in wiring connected between
CA403-10 or CA403-26 or FU8 on the power unit
distribution panel.
Step 2: Check CAN communication lines.
• If: Event code continues and Access 5 lights are
on.
– Then turn off the lift truck and check resistance
between CAN_H and CAN_L on either the power
unit or platform distribution panel. resistance is
60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Short is present in one of the ACCESSES. Find
short by unplugging ACCESSES from the CAN
bus one at a time and check resistance between
CAN_H and CAN_L.
• If: Greater than 60 Ω with all connectors connected.
– Then CAN bus terminating resistor is missing or
damaged, or wiring to the terminating resistor is
open. CAN bus contains two terminating resis-
tors one in Access 5 and the other in Access 1.
Step 3: Check CAN line for short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck and disconnect battery. Using a DVOM, check the
resistance at the power unit distribution panel between
CAN_L and battery negative bus bar, CAN_L to TP15
and TP16 and CAN_L to the lift truck frame. Resis-
tance is greater than 10,000 Ω.
• If: Less than 10,000 Ω.
– Then replace wiring as necessary.
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Event Code 416
Event Code 416
Access 4 / Access 6 CAN Error.
No action taken.
Step 1: Turn on the lift truck. Check status of
Access 6 power light.
• If: Access 6 power light is on.
– Then proceed to Step 2.
• If: Access 6 lights are off.
– Then check for 24 V between CA403-10 and
CA403-26.
• If: 24 V.
– Then replace Access 6.
• If: 0 V.
– Then issue exists in wiring between CA403-10 or
CA403-26 or FU8 on the power unit distribution
panel.
Step 2: Check CAN communication lines.
• If: Event code continues and Access 6 lights are
on.
– Then turn off the lift truck and check resistance
between CAN_H and CAN_L on either the power
unit or platform distribution panels. resistance is
60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Short is present in one of the ACCESSES. Find
short by unplugging ACCESSES from the CAN
bus one at a time and check resistance between
Event Code 421
CAN_H and CAN_L. Access 4 Internal Fault.
• If: Greater than 60 Ω with all connectors connected. All functions disabled.
– Then CAN bus terminating resistor is missing or Step 1: Replace Access 4.
damaged, or the wiring to the terminating resistor
is open. CAN bus contains two terminating resis-
tors one located in Access 5 and the other in
Access 1.
Step 3: Check CAN line for short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck and disconnect battery. Using a DVOM, check the
resistance at the power unit distribution panel between
CAN_L and battery negative bus bar also CAN_L to
TP15 and TP16 and CAN_L to the lift truck frame. Re-
sistance is greater than 10,000 Ω.
• If: Less than 10,000 Ω.
– Then replace wiring as necessary.
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Event Code 422
Event Code 422
Access 4 Potentiometer 1 (POT1) +5 V Power Sup-
ply Out of Range.
Full traction disabled.
Step 1: Using a DVOM, check for 5 V between wire
701 CA303-4 and TP16 power unit distribution panel.
• If: 5 V and event code continues.
– Then check for 5 V at CA309-2 and TP16.
• If: 0 V.
– Then replace Access 5.
• If: Less than 5 V and event code continues.
– Then remove wire 701 from CA303-4 and, with a
DVOM, check for 5 V between CA303-4 and
TP16.
• If: Less than 5 V.
– Then replace Access 4.
• If: 5 V.
– Then a short exists in wiring. Repair or replace
wiring as necessary.
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Event Code 423
Event Code 423
Access 4 Potentiometer 1 (POT1) is Out of Electri-
cal Limits.
Full traction disabled.
Step 1: Enter Service Mode two then Analyzer. Se-
lect POT1 A2.3.3 on display menu and view reading on
display.
• If: 5 V or greater.
– Then POT1 is either incorrectly wired, wire be-
tween POT1 and Access 4 is shorted to the lift
truck frame or an open wire exists. Check condi-
tion and correctness of wiring and connector ter-
minals between Access 4 CA303-1, -4, -19 and
POT1.
• If: Wiring and terminals are correct.
– Then replace POT1.
• If: Between 2.1 V and 2.9 V.
– Then multi-task handle in center position.
• If: Between 0.7 V and 1.5 V.
– Then multi-task handle in full forward position.
• If: Between 3.4 V and 4.3 V.
– Then multi-task handle in full reverse position.
• If: Correct POT1 readings are confirmed.
– Then an intermittent connection in POT1 circuit
exists. Inspect POT1, wiring to POT1 and termi- Event Code 424
nals in connector at Access 4 CA303-1, -4, -19.
Access 4 Potentiometer 1 (POT1) Does Not Match
• If: All check correctly.
Forward Switch (FS).
– Then replace POT1.
Full traction disabled.
• If: Below 0.7 V.
Step 1: FS/POT1 operation. Enter Service Mode 2
– Then POT1 is incorrectly wired, wires between and select handle Analyzer menu. Input status of FS,
POT1 and Access 4 are shorted together or a with handle in neutral, is opened as indicated by 0 on
wire is open. Check condition and correctness of display A2.3.7. POT1 reading on display A2.3.3 is be-
wiring and connector terminals between tween 2.1–2.9 volts. Moving the handle to full forward
Access 4 CA303-1, -4, -19 and POT1. position, the toggle switches to closed, display to 1
• If: Wiring and terminals are correct. A2.3.7. Reading for POT1 A2.3.3 is between 4.0–4.6
– Then replace POT1. volts.
• If: Readings are not as listed.
– Then check switch for damaged wiring or physi-
cal damage. Wire 2907 to FS and wire 2908 to
RS.
• If: Damaged.
– Then replace switches as needed, taking care to
properly route harness. After switch replacement,
calibrate handle.
• If: POT1 not within limits.
– Then recalibrate handle.
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Event Code 425
Event Code 425 • If: Selected switch display is 1 with handle in neu-
tral.
Access 4 Potentiometer 1 (POT1) Does Not Match – Then replace Access 4.
Reverse Switch (RS).
Full traction disabled. Event Code 427
Step 1: RS/POT1 operation enter Service Mode 2.
Access 4 Potentiometer 1 (POT1) and Reverse
Select handle Analyzer menu. Input status of RS, with
Switch (RS) Out of Range.
handle in neutral, is opened as indicated by 0 on dis-
play A2.3.6. POT1 reading on display A2.3.3 is be- Full traction disabled.
tween 2.1–2.9 volts. Moving the handle to full reverse Step 1: Using a DVOM, check for 5 V between
position, the toggle switches to closed, display to 1 CA303-19 and TP16 on the platform distribution panel.
A2.3.6. Reading for POT1 A2.3.3 is between 4.0–4.6 • If: Greater than 5 V.
volts.
– Then check wires 581 CA303-19, wire 506
• If: Readings are not as listed. CA309-3, and wire 519 CA307-5 for shorts to bat-
– Then check switch for damaged wiring or physi- tery positive or the lift truck frame.
cal damage. Wire 2907 to FS and wire 2908 to • If: 0 V.
RS.
– Then replace Access 4.
• If: Damaged.
– Then replace switches as needed, taking care to
properly route harness. After switch replacement,
calibrate handle.
• If: POT1 not within limits.
– Then recalibrate handle.
Event Code 426
Access 4 Forward Switch (FS) and Reverse Switch
(RS) Closed at Same Time.
Full traction disabled.
Step 1: Check FS and RS for damage to wiring or
switch and mounting.
• If: Damaged.
– Then replace switch and calibrate handle.
• If: Correct.
– Then proceed to Step 2.
Step 2: Enter Service Mode 2 and select Analyzer
menu for FS A2.3.7 and RS A2.3.6. Check status of FS
and RS with handle in neutral position.
• If: Either FS or RS is 1.
– Then select that switch to use in Step 3.
• If: Both FS and RS are 1.
– Then choose either switch and proceed to Step 3.
Step 3: Check switch function by disconnecting out-
put wire of selected switch, wire 2907 on FS or wire
2908 on RS.
• If: Selected switch display changes to 0 when
switch wire is disconnected.
– Then replace switch and calibrate handle.
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Event Code 429
Event Code 429
Access 4 Encoders ECR1/ECR5 Count Error.
Steering and traction disabled.
Note: If count between ECR1/ECR5 is not equal, event
code is logged. Possibly due to loss of power and or
Channel A or B of either encoder.
Step 1: Enter Service Mode 2 and select ECR1
A2.3.2 in Analyzer menu. View reading on the display.
• If: ECR1 operates.
– Then proceed to Step 2.
• If: ECR1 does not operate.
– Then proceed to Step 3.
Step 2: Enter Service Mode 2 and select ECR5
A2.3.2 in Analyzer menu. View reading on the display.
• If: ECR5 operates.
– Then the issue exists due to intermittent ECR1,
ECR5, Access 4 or wiring in between these com-
ponents. Proceed through Steps 3 and 4, repair-
ing any issues encountered.
• If: ECR5 does not operate.
– Then proceed to Step 3.
Step 3: Turn off the lift truck. Check tiller knob for slip-
page between ECR1, ECR5, and tiller knob. Also
check for damaged or broken wires between ECR1
and ECR5 to CA318.
• If: Slippage is observed or any wiring issues.
Step 5: Disconnect CA318 and turn on the lift truck.
– Then repair as necessary.
Using a DVOM, check for 12 V to ECR1 at CA318-4,
Step 4: Turn off the lift truck. Check wire and termi- -3.
nals where ECR1 and ECR5 enter Access 4,
• If: Between 11.5–12.5 V.
CA304-16, -23.
– Then reconnect CA318 and again check for 12 V.
• If: Wiring or terminals issues are found.
• If: Not between 11.5–12.5 V.
– Then repair as necessary.
– Then replace ECR1.
• If: Between 11.5–12.5 V.
– Then proceed to Step 6.
• If: Not between 11.5–12.5 V with CA318 discon-
nected and ECR1 replaced.
– Then check for 12 V at Access 4 between
CA304-18, -19.
• If: Not between 11.5–12.5 V.
– Then replace Access 4.
• If: Between 11.5–12.5 V.
– Then check continuity of the harness between
CA318-3 to CA304-18 and CA318-4 to
CA304-19.
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Event Code 429
Step 7: Reconnect CA318 and turn on the lift truck.
Step 6: Disconnect CA318 and turn on the lift truck. Check for encoder counts to ECR1 CHA. Connect
Check for 12 V to ECR5 at CA318-7, -8. DVOM between CA304-16 (-17 on "forks first steer" lift
• If: Between 11.5–12.5 V. trucks) and -19 turn the tiller knob slowly.
– Then reconnect CA318 and check for 5 V. • If: Voltage slowly changes from 0.5 V to 11.5 V.
• If: Not between 11.5–12.5 V. – Then proceed to Step 8.
– Then replace ECR5. • If: Voltage does not change back and forth from
0.5 V to 11.5 V.
• If: Between 11.5–12.5 V.
– Then check for ECR1 CHA for 0.5 V to 11.5 V be-
– Then proceed to Step 7.
tween CA318-1, -4.
• If: Not between 11.5–12.5 V with CA318 still dis-
• If: Voltage slowly changes from 0.5 V to 11.5 V.
connected.
– Then check wiring harness between CA304 and
– Then check for 12 V at Access 4 between
CA318.
CA304-20, -21.
• If: Voltage does not change from 0.5 V to 11.5 V.
• If: Not between 11.5–12.5 V.
– Then replace ECR1.
– Then replace Access 4.
Step 8: Turn on the lift truck. With CA318 and CA304
• If: Between 11.5–12.5 V.
connected, check ECR1 CHB encoder counts. Con-
– Then check continuity of the harness between nect a DVOM between CA304-18, -19 and slowly turn
CA318-7 and CA304-21 also from CA318-8 and the tiller knob.
CA304-20.
• If: Voltage slowly changes from 0.5 V to 11.5 V.
– Then proceed to Step 9.
• If: Voltage does not change from 0.5 V to 11.5 V.
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Event Code 429
– Then check voltage for CH B between CA318-2, nect DVOM between CA304-23 (-22 on "forks first
-4. steer" lift trucks) and -20 and slowly turn the tiller knob.
• If: Voltage slowly changes from 0.5 V to 11.5 V. • If: Voltage changes from 0.5 V to 11.5 V and event
– Then check wiring harness between CA304 to code continues.
CA318. – Then replace Access 4.
• If: Voltage does not change from 0.5 V to 11.5 V. • If: Voltage does not change from 0.5 V to 11.5 V.
– Then replace ECR1. – Then check ECR CHB voltage between
CA318-6, -8.
• If: Voltage changes from 0.5 V to 11.5 V.
– Then check wiring harness between CA304 to
CA318.
• If: Voltage does not change from 0.5 V to 11.5 V.
– Then replace ECR5.
Step 9: Turn on the lift truck. With CA318 and CA304
connected, check ECR5 CHA for encoder counts. Con-
nect a DVOM to CA304-22 (-23 on "forks first steer" lift
trucks) and -20 and slowly turn the tiller knob.
• If: Voltage changes from 0.5 V to 11.5 V.
– Then proceed to Step 10.
• If: Voltage does not change from 0.5 V to 11.5 V.
– Then check ECR5 CHA voltage between
CA318-5, -8.
• If: Voltage changes from 0.5 V to 11.5 V.
– Then check wiring harness between CA304 to
CA318.
• If: Voltage does not change from 0.5 V to 11.5 V.
– Then replace ECR5.
Step 10: Turn on the lift truck. With CA318 and CA304
connected, check ECR5 CHB encoder counts. Con-
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Event Code 430
Event Code 430
Access 4 Encoders ECR1/ECR5 Turn Rate Error.
Full traction disabled.
Note: Event is logged when rate difference between
ECR1/ECR5 occur. ECR1/ECR5 turn at the same rate
through the tiller knob cause for this event code could
be ECR slippage, failure, open or intermittent wiring
between ECR1/ECR5 and Access 4.
Step 1: Enter Service Mode 2 and select ECR1
A2.3.2 in Analyzer menu. View reading on the display.
• If: ECR1 operates.
– Then proceed to Step 2.
• If: ECR1 does not operate.
– Then proceed to Step 3.
Step 2: Enter Service Mode 2 and select ECR5
A2.3.2 in Analyzer menu. View reading on the display.
• If: ECR5 operates.
– Then the issue is due to intermittent ECR1,
ECR5, Access 4 or wiring in between these com-
ponents. Proceed through Steps 3 and 4, repair-
ing any issues encountered.
• If: ECR5 does not operate.
– Then proceed to Step 3.
Step 3: Turn off the lift truck. Check tiller knob for slip-
page between ECR1, ECR5, and tiller knob. Also
check for damaged or broken wires between ECR1
and ECR5 to CA318. Step 5: Disconnect CA318 and turn on the lift truck.
• If: Slippage is observed or any wiring issues. Using a DVOM, check for 12 V to ECR1 at CA318-4,
-3.
– Then repair as necessary.
• If: Between 11.5–12.5 V.
Step 4: Turn off the lift truck. Check wire and termi-
nals where ECR1 and ECR5 enter Access 4, – Then reconnect CA318 and again check for 12 V.
CA304-16, -23. • If: Not between 11.5–12.5 V.
• If: Wiring or terminal issues are found. – Then replace ECR1.
– Then repair as necessary. • If: Between 11.5–12.5 V.
– Then proceed to Step 6.
• If: Not between 11.5–12.5 V with CA318 discon-
nected and ECR1 replaced.
– Then check for 12 V at Access 4 between
CA304-18, -19.
• If: Not between 11.5–12.5 V.
– Then replace Access 4.
• If: Between 11.5–12.5 V.
– Then check continuity of the harness between
CA318-3 and CA304-18 also CA318-4 to
CA304-19.
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Event Code 430
Step 6: Disconnect CA318 and turn on the lift truck. • If: Voltage does not change back and forth from
to check for 12 V to ECR5 at CA318-7, -8. 0.5 V to 11.5 V.
• If: Between 11.5–12.5 V. – Then check for ECR1 CHA for 0.5–11.5 V be-
– Then reconnect CA318 and check for 5 V. tween CA318-1, -4.
• If: Not between 11.5–12.5 V. • If: Voltage slowly changes from 0.5 V to 11.5 V.
– Then replace ECR5. – Then check wiring harness between CA304 and
CA318.
• If: Between 11.5–12.5 V.
• If: Voltage does not change from 0.5 V to 11.5 V.
– Then proceed to Step 7.
– Then replace ECR1.
• If: Not between 11.5–12.5 V with CA318 still dis-
connected. Step 8: Turn on the lift truck with CA318 and CA304
connected check ECR1 CHB encoder counts. Connect
– Then check for 12 V at Access 4 between
a DVOM between CA304-18, -19 and slowly turn the
CA304-20, -21.
tiller knob.
• If: Not between 11.5–12.5 V.
• If: Voltage slowly changes from 0.5 V to 11.5 V.
– Then replace Access 4.
– Then proceed to Step 9.
• If: Between 11.5–12.5 V.
• If: Voltage does not change from 0.5 V to 11.5 V.
– Then check harness continuity between CA318-7
– Then check voltage for CHB between CA318-2,
and CA304-21, CA318-8 and CA304-20.
-4.
• If: Voltage slowly changes from 0.5 V to 11.5 V.
– Then check wiring harness between CA304 to
CA318.
• If: Voltage does not change from 0.5 V to 11.5 V.
– Then replace ECR1.
–
Step 7: Reconnect CA318 and turn on the lift truck. to
check for encoder counts to ECR1 CHA. Connect
DVOM between CA304-16 (-17 on "forks first steer" lift
trucks) and -19 and turn the tiller knob slowly.
• If: Voltage slowly changes from 0.5 V to 11.5 V.
– Then proceed to Step 8.
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Event Code 430
Step 9: Turn on the lift truck. With CA318 and CA304
)
connected, check ECR5 CHA for encoder counts. Con-
nect a DVOM to CA304-22 (-23 on "forks first steer" lift
trucks) and -20 and slowly turn the tiller knob.
• If: Voltage changes from 0.5 V to 11.5 V.
– Then proceed to Step 10.
• If: Voltage does not change from 0.5 V to 11.5 V.
– Then check ECR5 CHA voltage between
CA318-5 and -8.
• If: Voltage changes from 0.5 V to 11.5 V.
– Then check wiring harness between CA304 to
CA318.
• If: Voltage does not change from 0.5 V to 11.5 V.
– Then replace ECR5.
Step 10: Turn on the lift truck. With CA318 and CA304
connected, check ECR5 CHB encoder counts. Con-
nect DVOM between CA304-23 (-22 on "forks first
steer" lift trucks) and -20 and slowly turn the tiller knob.
• If: Voltage changes from 0.5 V to 11.5 V and event
code continues.
– Then replace Access 4.
• If: Voltage does not change from 0.5 V to 11.5 V.
– Then check ECR CHB voltage between CA318-6
and -8.
• If: Voltage changes from 0.5 V to 11.5 V.
– Then check wiring harness between CA304 and
CA318.
• If: Voltage does not change from 0.5 V to 11.5 V.
– Then replace ECR5.
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ELECTRICAL SYSTEM
Event Code 431
Event Code 431
Access 4 Encoders ECR1/ECR5 Direction Error.
Steering and traction disabled.
Note: ECR1/ECR5 turn at the same time. If a
difference in direction occurs due to a wiring error or
slippage, event code 431 is logged.
Step 1: Enter service mode 2 and select ECR1
A2.3.2 in Analyzer menu. View reading on the display.
• If: ECR1 operates.
– Then proceed to Step 2.
• If: ECR1 does not operate.
– Then proceed to Step 3.
Step 2: Enter service mode 2 select ECR5 A2.3.2 in
Analyzer menu. View reading on the display.
• If: ECR5 operates.
– Then the issue is due to intermittent ECR1,
ECR5, Access 4 or wiring in between these com-
ponents. Proceed through Steps 3 and 4, repair-
ing any issues encountered.
• If: ECR5 does not operate.
– Then proceed to Step 3.
Step 3: Turn off the lift truck. Check tiller knob for slip-
page between ECR1, ECR5, and tiller knob. Also
check for damaged or broken wires between ECR1
and ECR5 to CA318.
• If: Slippage is observed or any wiring issues.
– Then repair as necessary.
Step 4: Turn off the lift truck. Check ECR1/ECR5 wire
connections at Access 4. ECR1 CA304-18, -16, -17,
-19, and ECR5 CA304-21, -22, -23, -20.
• If: Wire issues exist. Step 5: ECR1 test. Disconnect CA318 and turn on
the lift truck. Using a DVOM check for 12 V to ECR1
– Then repair as necessary. between CA318-3, -4.
• If: Between 11.5–12. 5 V.
– Then turn off the lift truck and reconnect CA318
and again check for 12 V.
• If: Not between 11.5–12.5 V.
– Then replace ECR1.
• If: Between 11.5–12.5 V.
– Then proceed to Step 6.
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Event Code 431
Step 6: ECR5 test. Disconnect CA318 and turn on – Then check for CHA voltage between CA318-1,
the lift truck. Using a DVOM check for 12 V to ECR5 -4.
between CA318-7, -8. • If: Voltage changes from 0.5 to 11.5 V.
• If: Between 11.5–12.5 V. – Then check wiring harness from CA304 to
– Then turn off the lift truck and reconnect CA318 CA318.
and again check for 12 V. • If: Voltage does not change.
• If: Not between 11.5–12.5 V. – Then replace ECR1.
– Then replace ECR5.
• If: Between 11.5–12.5 V.
– Then proceed to Step 7.
Step 7: Connect CA318 and CA304, turn on the lift
truck. Connect a DVOM between CA304-11, -19 and
slowly turn the tiller knob.
• If: Voltage changes from 0.5 V to 11.5 V.
– Then proceed to Step 8.
• If: Voltage does not change.
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Event Code 431
Step 8: With power on and CA318/CA304 con- Step 9: With vehicle power on and CA318/CA304
nected, check for encoder counts to ECR1 CHB. Con- connected, check for encoder counts to ECR5 CHA.
nect meter between CA304-12, -19 then slowly turn the Connect meter between CA304-7, -20 then slowly turn
tiller knob. the tiller knob.
• If: Voltage changes from 0.5 V to 11.5 V. • If: Voltage from 0.5 V to 11.5 V.
– Then proceed to Step 9. – Then proceed to Step 10.
• If: Voltage does not change. • If: Voltage does not change.
– Then check for CHB voltage between CA318-2, – Then check voltage for CHA between CA318-5,
-4. -8.
• If: Voltage changes from 0.5 V to 11.5 V. • If: Voltage changes from 0.5 V to 11.5 V.
– Then check wiring harness between CA304 to – Then check wiring harness between CA304 and
CA318. CA318.
• If: Voltage does not change. • If: Voltage does not change.
– Then replace ECR1. – Then replace ECR5.
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Event Code 431
Step 10: With vehicle power on and CA318/CA304
connected, check for encoder counts to ECR5 CHB.
Connect meter between CA304-8, -20 then slowly turn
the tiller knob.
• If: Voltage changes from 0.5 V to 11.5 V and event
code continues.
– Then replace Access 4.
• If: Voltage does not change.
– Then check for voltage to CHB between
CA318-6, -8.
• If: Voltage changes from 0.5 V to 11.5 V.
– Then check wiring harness between CA304 and
CA318.
• If: Voltage does not change.
– Then replace ECR5.
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Event Code 432
Event Code 432 – Then replace Access 4.
Access 4 Height Encoder 4 (ECR4) Power Supply Event Code 435
Out of Range.
Access 4 Height Encoder 4 (ECR4) Reset Error.
Full traction and high speed raise disabled.
Full traction and raise speed 2 disabled.
Step 1: Connect DVOM leads between CA303-12
and battery negative then turn on the lift truck. Step 1: Fully lower platform then raise approximately
three feet and lower.
• If: Voltage is not between 4.75 V and 5.5 V.
• If: Event code repeats.
– Then disconnect wire from CA303-12 and check
voltage at CA303-12. – Then proceed to Step 2.
• If: Voltage is between 4.75 V and 5.5 V with wire • If: Event code does repeat.
removed. – Then resume the lift truck operation and monitor.
– Then short exists in wiring or ECR4. Check wiring Step 2: Enter service mode 2 Analyzer menu and go
between ECR4 and CA303-12 through -15. Ver- to A2.3.1.1, fully lowered raise platform and observe
ify that insulation is not cut and shorted to frame. display.
• If: Wiring is correct and event code continues. • If: Height in inches changes.
– Then replace ECR4. – Then proceed to Step 3.
• If: Voltage is not between 4.75–5.5 V with wire re- • If: Height in inches does not change.
moved. – Then proceed to Step 4.
– Then replace Access 4. Step 3: Enter service mode 2 Analyzer menu and go
to A2.3.10. A fully lowered raise platform approximately
3 ft at 18 in the height reset switch (HTGRS) state s
changes from closed to open.
• If: State does not change.
– Then check HTGRS and associated wiring.
Step 4: Disconnect CA317 and check encoder wiring
for damaged crimps. If necessary, remove wires from
connector for inspection.
• If: Wiring crimps are damaged.
– Then repair or replace ECR 4 as necessary.
Pin 1: White
Pin 2: Blue
Pin 3: Red
Pin 4: Black
Event Code 433
Access 4 5 V Power Supply Out of Range.
Traction and raise disabled.
Step 1: Turn off the lift truck. Then turn on the lift
truck.
• If: Event code continues.
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Event Code 440
Step 5: Disconnect CA317 using a DVOM check volt-
age to ECR4 between CA317-3, -4.
• If: 5 V.
– Then reconnect CA317 and proceed to Step 6.
• If: Not 5 V.
– Then remove wire 703 and 516 from CA303 and
using a DVOM check voltage between pins
CA303-12, -15.
• If: 5 V.
– Then check all wiring. Wire 703 CA303-12 to
CA317-3 and wire 516 CA303-15 to CA317-4.
• If: Not 5 V.
– Then replace Access 4.
Step 6: Check ECR4 channel wiring. Wire 007
CA317-1 to CA303-13, wire 008 CA317-2 to
CA303-14.
• If: Wiring is correct and event code continues.
– Then disconnect CA317, remove white and blue
wires from JC317-1 and JC317-2. Connect a
DVOM from white (ECR4 CHA) to battery nega-
tive, turn on the lift truck and check voltage.
Reading is 0 V or 5 V depending on position of
ECR4. Perform the same test on the blue wire
(ECR4 CH B). Event Code 440
• If: Not 0 V or 5 V.
Access 4 Zone Select (ZSS) Switch Wiring Open.
– Then replace ECR4.
Raise disabled.
• If: 0 V or 5 V.
Note: If the zone select option is enabled in the lift truck
– Then reconnect wiring. features, the lift truck requires that one of the three
• If: 0 V or 5 V and event code continues. outputs from the switch be closed. This condition
– Then replace Access 4. indicates that the feature is enabled and none of the
three outputs are closed or the wire feeding the switch
is open.
Step 1: Check zone select switch.
• If: Zone switch is broken.
– Then replace as necessary.
• If: Zone switch is enabled and the lift truck is not
equipped with zone select.
– Then access service level 2 mode and disable
zone select feature.
• If: Zone switch is enabled and is present.
– Then check wiring between zone select switch
and Access 4.
• If: Wiring is correct and event code continues.
– Then replace Access 4.
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Event Code 441
Event Code 441
Access 4 Zone Select (ZSS) Switch Wiring Shorted.
Raise disabled.
Note: If the zone select option is enabled in the lift truck
features the lift truck requires that one of the three
outputs from the switch be closed. This condition
indicates that more than one of the switch outputs are
closed simultaneously and therefore the lift truck
cannot see the requested zone.
Step 1: Check condition of wiring between switch
and CA303-23, CA304-13, -14.
• If: Wires are shorted.
– Then repair as necessary.
• If: Wires are correct.
– Then proceed to Step 2.
Step 2: Using a DVOM, check the ZSS for internal
shorts. Each individual internal switch must be isolated
from the other.
• If: Switch is shorted.
– Then replace ZSS switch.
• If: Switch is correct and event code continues.
– Then replace Access 4.
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Event Code 442
Event Code 442
Access 4 Zone Select Switch (ZSS) Detected, but
Feature Not Enabled.
Raise disabled.
Note: If the lift truck has zone select option see Step 1.
If the lift truck does not have zone select option, then
see Step 2.
Step 1: Enter service mode 2 and proceed to fea-
tures and enable zone select.
• If: Event code continues.
– Then replace Access 4.
Step 2: Enter service mode 2 go to features and zone
select.
• If: Zone select is enabled.
– Then disable.
• If: Zone select is disabled.
– Then connect a DVOM to TP7 on platform distri-
bution panel and check for 24 V between
CA303-23, CA304-13, -14.
• If: 24 V is not present at any point.
– Then replace Access 4.
• If: Any terminal is shorted to negative.
– Then repair short as necessary.
Event Code 443
Access 4 Invalid Zone Select Setup.
Raise disabled.
Step 1: Enter service mode 2 and proceed to Fea-
tures menu, enter correct cutout configuration setups.
• If: Event code continues.
– Then replace Access 4.
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Event Code 445
Event Code 445
Access 4 (lifting fork option only) PVLF Driver
Open.
Nothing disabled.
Step 1: Disconnect wires 29129, 29130 and 5938
from PVLF coil using a DVOM check resistance of
PVLF coil.
• If: Less than 29 Ω.
– Then replace PVLF coil.
• If: 29 Ω.
– Then check for 24 V between wires 29129,
29130 and 5938 while depressing lifting forks
lower switch.
• If: 0 V.
– Then disconnect wire 5941 from CA304-4 and
check for 24 V between CA304-4 and TP7 on the
platform distribution panel while depressing
lower switch.
• If: 0 V.
– Then replace Access 4.
• If: 24 V.
– Then check for 24 V between wire 29129, 29130
and TP3 on the power unit distribution panel.
• If: 0 V.
– Then check lower switch and associated wiring.
• If: 24 V.
– Then check connection of CA325, CA701, and
CA809.
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Event Code 446
Event Code 446
Access 4 (Lifting Fork Option Only) PVLF Shorted.
Nothing disabled.
Step 1: Disconnect wires 29129, 29130 and 5938
from PVLF coil using a DVOM check resistance of
PVLF coil.
• If: Less than 29 Ω.
– Then replace PVLF coil.
• If: 29 Ω.
– Then, with coil disconnected, disconnect wire
5941 from CA304-4 and check for 24 V between
PC304-4 and TP7 on the platform distribution
panel.
• If: 24 V.
– Then wire 5941, 5936, 5938, or the mast cable
red wire is shorted to battery positive repair/ re-
place.
• If: 0 V.
– Then replace Access 4.
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Event Code 447
Event Code 447 Event Code 448
Access 4 (Lifting Fork Option Only) SV1 Shorted. Access 4 Travel Alarm (ALM2) Driver Shorted.
Nothing disabled. Full traction and high speed raise disabled.
Step 1: Disconnect wires 29130 and 5937 from SV1 Step 1: Disconnect wire 5915 from CA304-7. Check
coil using a DVOM check resistance of SV1 coil. for 24 V between PC304-7 and TP7 on the platform
• If: Less than 29 Ω. distribution panel.
– Then replace SV1 coil. • If: 24 V.
• If: 29 Ω. – Then wire 5915 is shorted to battery positive re-
pair/ replace.
– Then, with coil disconnected, disconnect wire
5942 from CA304-5. Check for 24 V between • If: 0 V.
PC304-5 and TP7 on the platform distribution – Then replace Access 4.
panel.
• If: 24 V.
– Then wire 5942, 5935, 5937 or mast cable green
wire is shorted to battery positive repair/ replace.
• If: 0 V.
– Then replace Access 4.
Event Code 449
THRU
Event Code 452
Access 4 Internal Driver Shorted.
Event Code 449 and 452: Traction and raise disabled.
Event Code 450: Raise disabled.
Event Code 451: Nothing disabled.
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Event Code 453
Step 1: Replace Access 4.
Event Code 453
Access 4 Chain Break.
Hydraulics disabled.
Step 1: Check lift chain.
• If: Correct.
– Then proceed to Step 2.
• If: Broken.
– Then replace as necessary.
Step 2: Check chain break switch wiring.
• If: Correct.
– Then check wire 29123, CA303-3 to CA331 and
wire 29124, CA331 to CA103-14 and wiring har-
ness between harness and switches. Using a
DVOM, check for 24 V between CA303-3 and
TP7 on platform distribution panel.
• If: 24 V.
– Then replace Access 4.
• If: 0 V.
– Then check terminal conditions.
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ELECTRICAL SYSTEM
Event Code 460
Event Code 460 – Then repair or replace wiring as necessary.
THRU
Event Code 462
Access 5 CAN Error.
Event Code 460: Access 5 receiving packets too fast.
Event Code 461: Access 5 receiving short packets.
Event Code 462: Access 5 receiving long packets.
No action taken.
Step 1: Verify that correct ACCESSES are in place
on the lift truck.
• If: Any new ACCESSES have recently been in-
stalled.
– Then check connections and software.
Step 2: Determine if logged event code is associated
with specific lift truck functions.
• If: Event code is logged when a specific function is
started or stopped.
– Then check the functions load and suppression
(for example, if event code is logging when ED1
contactor opens or closes check ED1 contactor
coil and suppression).
Step 3: Check CAN communication lines. Turn off
the lift truck. Using a DVOM, measure the resistance
between CAN_H and CAN_L on either the power unit
or platform distribution panels, resistance is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Locate short circuit and repair. A short exists in
an ACCESS. Determine this condition by discon-
necting ACCESS from the CAN bus one at a time
and measure resistance between CAN_H and
CAN_L.
• If: Greater than 65 Ω with all connectors connected.
– Then a CAN bus-terminating resistor is open,
damaged, or wiring to terminating resistor is
open. CAN bus contains two terminating resis-
tors, one located in Access 5 and the other in
Access 1.
Step 4: Check for CAN line short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck and disconnect battery. Using a DVOM, check the
resistance at the power unit distribution panel CAN_L
to battery negative bus bar then CAN_L to TP3 on the
platform distribution panel and CAN_L to the lift truck
frame. Resistance is greater than 10,000 Ω.
• If: Less than 10,000 Ω.
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Event Code 463
Event Code 463
THRU
Event Code 465
Access 6 CAN Error.
Event Code 463: Access 6 receiving packets too fast.
Event Code 464: Access 6 receiving short packets.
Event Code 465: Access 6 receiving long packets.
No action taken.
Step 1: Verify that correct ACCESSES are in place
on the lift truck.
• If: Any new ACCESS has recently been installed.
– Then check connections and software.
Step 2: Determine if logged event code is associated
with specific lift truck functions.
• If: Event code is logged when a specific function is
started or stopped.
– Then check the functions load and suppression
(for example, if event code is logging when ED1
contactor opens or closes check ED1 contactor
coil and suppression).
Step 3: Check CAN communication lines. Turn off
the lift truck. Using a DVOM, measure the resistance
between CAN_H and CAN_L on either the power unit
or platform distribution panels. Resistance is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Locate short circuit and repair. A short exists in
an ACCESS. Determine this condition by discon-
necting the ACCESS from the CAN bus one at a
time and measure resistance between CAN_H
and CAN_L.
• If: Greater than 65 Ω with all connectors connected.
– Then a CAN bus-terminating resistor is open,
damaged, or wiring to terminating resistor is
open. CAN bus contains two terminating resis-
tors, one located in Access 5 and the other in
Access 1.
Step 4: Check for CAN line short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck and disconnect battery. Using a DVOM, check the
resistance at the power unit distribution panel CAN_L
to battery negative bus bar then CAN_L to TP3 on the
platform distribution panel and CAN_L to the lift truck
frame. Resistance is greater than 10,000 Ω.
• If: Less than 10,000 Ω.
– Then repair or replace wiring as necessary.
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Event Code 466
Event Code 466 – Then repair or replace wiring as necessary.
THRU
Event Code 469
Access 1 CAN Error.
Event Code 466: Access 1 receiving packets too fast.
Event Code 467: Access 1 receiving short packets.
Event Code 468: Access 1 receiving long packets.
Event Code 469: Access 1 receiving duplicate ID.
No action taken.
Step 1: Verify that correct ACCESSES are in place
on the lift truck.
• If: Any new ACCESS has recently been installed.
– Then check connections and software.
Step 2: Determine if logged event code is associated
with specific lift truck functions.
• If: Event code is logged when a specific function is
started or stopped.
– Then check the functions load and suppression
(for example if event code is logging when ED1
contactor opens or closes check ED1 contactor
coil and suppression).
Step 3: Check CAN communication lines. Turn off
the lift truck. Using a DVOM, measure the resistance
between CAN_H and CAN_L on either the power unit
or platform distribution panels. Resistance is 60 Ω.
• If: 0 Ω.
– Then short exists between CAN_H and CAN_L.
Locate short circuit and repair. A short exists in
an ACCESS. Determine this condition by discon-
necting ACCESS from the CAN bus one at a time
and measure resistance between CAN_H and
CAN_L.
• If: Greater than 65 Ω with all connectors connected.
– Then a CAN bus-terminating resistor is open,
damaged, or wiring to terminating resistor is
open. CAN bus contains two terminating resis-
tors, one located in Access 5 and the other in
Access 1.
Step 4: Check for CAN line short to battery negative,
battery positive, and the lift truck frame. Turn off the lift
truck and disconnect battery. Using a DVOM, check the
resistance at the power unit distribution panel CAN_L
to battery negative bus bar then CAN_L to TP3 on the
platform distribution panel and CAN_L to the lift truck
frame. Resistance is greater than 10,000 Ω.
• If: Less than 10,000 Ω.
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Event Code 470
Event Code 470 – Then repair or replace wiring as necessary.
THRU
Event Code 473
Access 4 CAN Error.
Event Code 470: Access 4 receiving packets too fast.
Event Code 471: Access 4 receiving short packets.
Event Code 472: Access 4 receiving long packets.
Event Code 473: Access 4 receiving duplicate ID.
No action taken.
Step 1: Verify that correct ACCESSES are in place
on the lift truck.
• If: Any new ACCESS has recently been installed.
– Then check connections and software.
Step 2: Determine if logged event code is associated
with specific lift truck functions.
• If: Event code is logged when a specific function is
started or stopped.
– Then check the functions load and suppression
(for example, if event code is logging when ED1
contactor opens or closes check ED1 contactor
coil and suppression).
Step 3: Check CAN communication lines. Turn off Event Code 501
the lift truck. Using a DVOM, measure the resistance
between CAN_H and CAN_L on either the power unit Access 5 Communication (CAN) with Access 1
or platform distribution panels. Resistance is 60 Ω. Timeout.
• If: 0 Ω. Traction and hydraulics disabled.
– Then short exists between CAN_H and CAN_L. Note 1: Intermittent disruption of CAN communication
Locate short circuit and repair. A short exists in between Access 5 and Access 1 logs event code 501
an ACCESS). Determine this condition by dis- (Access 5 flashes event code 501). Access 1 must
connecting the ACCESS from the CAN bus one receive event code 501 from Access 5 to illuminate the
at a time and measure resistance between service required indicator (wrench shaped light).
CAN_H and CAN_L. Illumination of the indicator shows communication
between Access 5 and Access 1 has been
• If: Greater than 65 Ω with all connectors connected.
intermittently disrupted.
– Then a CAN bus-terminating resistor is open,
Note 2: Complete loss of CAN communication
damaged, or wiring to terminating resistor is
between Access 5 and Access 1 after power-up and
open. CAN bus contains two terminating resis-
initialization logs event code 501. Access 5 flashes
tors, one located in Access 5 and the other in
event code 501. If this condition exists, CAN
Access 1.
communication between Access 5 and Access 1 is
Step 4: Check for CAN line short to battery negative, disabled, Access 1 will not log event code 501, and the
battery positive, and the lift truck frame. Turn off the lift service indicator will not illuminate.
truck and disconnect battery. Using a DVOM, check the
resistance at the power unit distribution panel CAN_L
to battery negative bus bar then CAN_L to TP3 on the
platform distribution panel and CAN_L to the lift truck
frame. Resistance is greater than 10,000 Ω.
• If: Less than 10,000 Ω.
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Event Code 501
Step 1: Determine which ACCESS is indicating the
event.
• If: Access 1 displays the wrench and event code
501 is logged.
– Then proceed to Step 2.
• If: Access 1 has no wrench. Traction, hydraulics,
and steering are disabled and Access 5 is flashing
event code 501.
– Then proceed to Step 3.
Step 2: Intermittent communication event has oc-
curred between Access 1 and Access 5. Check for
more event codes.
• If: Event codes 301 or 401 are logged.
– Then disconnect plug CA302 and, using a
DVOM, check for 24 V between wire 513
CA302-4 and wire 2941 CA302-3 on the plug.
• If: 24 V.
– Then check CAN wiring between Access 1 and
platform distribution panel. Wire 003 between
CA302-8 and CA105-2 also wire 004 between
CA302-9 and CA105-8.
• If: Event codes 305, 405 have been logged.
– Then check CAN bus wiring between power unit
distribution panel and Access 5. Wire 019
CA402-4 to CA204-2 and wire 020 CA402-5 to
CA204-8.
Step 3: Communication lost between Access 1 and
Access 5. Access 5 is flashing 501 event code. Turn off
the lift truck. Then turn on the lift truck.
• If: Access 1 does not turn on.
– Then using a DVOM check for 24 V between wire
2941 CA103-10 and wire 513 CA107-8.
• If: 0 V.
– Then check wiring and connections. Wire 2941
CA302-3 to CA103-10 and wire 513 CA302-4 to
CA107-8.
• If: 24 V and Access 1 does not turn on.
– Then replace Access 1.
• If: Access 1 turns on wrench illuminated and logs
event codes 305 and 405.
– Then issue exists in CAN wiring between power
unit distribution panel and Access 5. Check wire
019 CA402-4 to CA204-2 and wire 020 CA402-5
to CA204-8.
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Event Code 503
Event Code 503
Access 5 Communication (CAN) with Access 3™
Timeout.
Traction and hydraulics disabled.
Step 1: Check power to Access 3™.
• If: Access 3™ lights are on.
– Then issue exists in wiring between power unit
distribution panel and Access 3™, check wiring
and connections. Wire 018 CA401-15 to
CA204-7 and wire 017 CA401-23 to CA204-1.
• If: Wiring is correct.
– Then clean connections.
• If: Access 3™lights are off.
– Then issue exists in the power wiring between
power unit distribution panel and Access 3™. Us-
ing a DVOM check for 24 V between CA401-1
and Access 3™ battery negative.
• If: 24 V.
– Then replace Access 3™.
• If: 0 V.
– Then issue exists in wiring between Access 3™
and power unit distribution panel check wiring
and connections. Wire 2953 CA401-1 to
CA201-5.
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Event Code 504
Event Code 504 Note: If a reset occurs, the lift truck restores
functionality without any changes in performance.
Access 5 Communication (CAN) with Access 4 There is no need for service intervention with
Timeout. occasional occurrences. However if this event
All functions disabled. becomes an issue, then follow Step 1 below.
Step 1: Check power to Access 4. Step 1: Check CAN connections between Access 5
and power unit distribution panel. Wire 019 CA402-4 to
• If: Access 4 lights are on.
CA204-2 and wire 020 CA402-5 to CA204-8.
– Then issue exists in wiring between platform dis-
• If: Wiring is correct.
tribution panel and Access 4, check wiring and
connections. Wire 001 CA303-7 to CA105-1 and – Then clean connections.
wire 002 CA303-8 to CA105-7.
• If: Wiring is correct.
– Then clean connections.
• If: Access 4 lights are off.
– Then issue exists in power wiring between plat-
form distribution panel and Access 4, check wir-
ing and connections. Using a DVOM check for
24 V between CA304-1 and battery negative.
• If: 24 V.
– Then replace Access 4.
• If: 0 V.
– Then issue exists in wiring between Access 4
and platform distribution panel check wiring and
connections. Wire 2937 CA304-1 to CA103-12
and wire 525 CA304-3 to CA107-9.
Event Code 505
Access 5 CAN Reset.
No action taken.
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Event Code 506
Event Code 506
Access 5 / Access 6 CAN Error.
All functions disabled.
Step 1: Check power to Access 6.
• If: Access 6 lights are on.
– Then issue exists in wiring between platform dis-
tribution panel and Access 6, check wiring and
connections. Wire 021 CA601-4 to CA204-3 and
wire 022 CA601-5 to CA204-9.
• If: Wiring is correct.
– Then clean connections.
• If: Access 6 lights are off.
– Then issue exists in power wiring between plat-
form distribution panel and Access 6, check wir-
ing and connections. Using a DVOM check for
24 V between CA601-1 and CA601-2.
• If: 24 V.
– Then replace Access 6.
• If: 0 V.
– Then issue exists in wiring between Access 6
and power unit distribution panel check wiring
and connections. Wire 2972 CA601-1 to
CA201-6 and wire 552 CA601-2 to battery nega-
tive.
Event Code 511
THRU
Event Code 512
Access 5 Internal Issues.
All functions disabled.
Step 1: Replace Access 5.
Event Code 513
THRU
Event Code 514
Access 5 Internal Issues.
No action taken.
Step 1: Replace Access 5.
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Event Code 515
Event Code 515
THRU
Event Code 521
Access 5 Internal Issues.
All functions disabled.
Step 1: Replace Access 5.
Event Code 522
THRU
Event Code 523
Access 5 +5 V Power Supply Out of Range.
Steering and traction disabled. PDS/Forks First (522).
Step 1: Using a DVOM, connect the negative lead to
battery negative on Access 5 and with the positive lead
check for +5 V at CA403-20 and CA403-21.
• If: 5 V (+/- 0.1 V) and event code continues. Event Code 526
– Then replace Access 5.
THRU
• If: Less than 5 V.
– Then remove wire 706 from CA403-20 and, using Event Code 527
a DVOM, check for +5 V between CA403-20 and
battery negative. Access 5 Brake battery positive Out of Range.
• If: 5 V (+/- 0.1 V). Event Code 526: Full traction disabled. This event code
– Then issue exists in ECR2 or wiring. Reconnect is logged when either inner or outer brake coil is above
wire 706 and proceed to Step 2. range.
• If: Less than 5 V. Event Code 527: Traction disabled. This event code is
logged when both inner and outer brake coils are below
– Then remove wire 704 from CA403-21 and, using range.
a DVOM, check for +5 V between CA403-21 and
battery negative. Step 1: Check status of event codes 540, 528, 529,
530, and 531, if any of these codes have been logged
Step 2: Unplug CA410 (ECR2) and, using a DVOM, resolve them before proceeding to 526 and 527.
check for +5 V between CA403-20 and Access 5 bat-
tery negative. • If: Only event codes 526 and 527 are constantly
logged.
• If: Less than 5 V.
– Then replace Access 5.
– Then issue exists in wiring between Access 5
CA403 and CA410. Check wire 706 between
CA410-4 and CA403 20 also wire 540 between
CA410-2 and CA403-12.
• If: 5 V.
– Then replace ECR2.
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Event Code 528
Event Code 528
Access 5 Inner Brake Coil Battery Positive Out of
Range.
Note: Check for event code 540 and condition of ED2
contacts also if any other event codes have been
logged relating to these areas resolve them before
continuing.
Inner Brake battery positive above range. Full traction
disabled.
Step 1: Check battery voltage.
• If: 36 V, 48 V, 80 V.
– Then install 24 V battery.
Event Code 529
Access 5 Inner Brake Coil Battery Positive Out of
Range.
Note: Check for event code 540 and condition of ED2
contacts also if any other event codes have been
logged relating to these areas resolve them before
continuing.
Inner Brake battery positive under range. Traction
disabled.
Step 1: Check FU6.
• If: FU6 in good condition.
– Then check condition of ED2 contacts. Event Code 530
• If: ED2 contacts in good condition. Access 5 Inner Brake Coil Battery Positive Out of
– Then check for 24 V between CA403-7 and bat- Range.
tery negative. Note: Check for event code 540 and condition of ED
• If: 24 V and event code continues. contacts also if any other event codes have been
– Then replace Access 5. logged relating to these areas resolve them before
continuing.
Inner Brake battery positive above range. Full traction
disabled.
Step 1: Check battery voltage.
• If: 36 V, 48 V, 80 V.
– Then install 24 V battery.
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Event Code 531
Event Code 531 Step 1: Check for 5 V between CA403-27 and bat-
tery negative.
Access 5 Inner Brake Coil Battery Positive Out of • If: 5 V (+/- 0.1 V).
Range. – Then monitor for event codes 540 and 541.
Note: Check for event code 540 and condition of ED • If: Not 5 V.
contacts also if any other event codes have been
logged relating to these areas resolve them before – Then disconnect wire 705 from CA403-27 and
continuing. check voltage between Access 5 and battery
negative.
Inner Brake battery positive under range - traction
disabled. • If: 5 V.
Step 1: Check FU5. – Then reconnect wire 705 to CA403-27 and pro-
ceed to Step 2.
• If: FU5 in good condition.
• If: Not 5 V.
– Then check condition of ED2 contacts.
– Then replace Access 5.
• If: ED2 contacts in good condition.
Step 2: Unplug CS1 from CA406 and check for 5 V
– Then check for 24 V between CA403-9 and bat-
between CA406-A and battery negative.
tery negative.
• If: Not 5 V.
• If: 24 V and event code continues.
– Then check wire connections between Access 5
– Then replace Access 5.
and CA406.
• If: 5 V.
– Then replace CS1.
Event Code 532
Access 5 +5 V Power Supply Voltage Out of Range.
No action taken.
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Event Code 533
Event Code 533 Event Code 534
Access 5 +5 V Power Supply Voltage Out of Range. THRU
No action taken.
Step 1: Check for 5 V between CA403-27 and bat- Event Code 535
tery negative. Access 5 Battery Current Out of Range.
• If: 5 V (+/- 0.1 V). Note: Check for event codes 532, 533, 536 and 537 if
– Then monitor for event codes 540 and 541. any of these event codes have been logged resolve
• If: Not 5 V. first.
– Then disconnect wire 705 from CA403-27 and All functions disabled.
check voltage between Access 5 and battery Step 1: Check wiring between Access 5 and CS1.
negative. • If: Wiring is correct.
• If: 5 V. – Then replace CS1.
– Then reconnect wire 705 to CA403-27 and pro-
ceed to Step 2.
• If: Not 5 V.
– Then replace Access 5.
Step 2: Unplug CS1 from CA406 and check for 5 V
between CA406-A and battery negative.
• If: Not 5 V.
– Then check wire connections between Access 5
and CA406.
• If: 5 V.
– Then replace CS1.
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Event Code 536
Event Code 536 – Then replace Access 5.
• If: Voltage is above or below 2.4V/2.6V.
Access 5 Battery Current Sensor Improperly In- – Then remove wire 104 from CA403-24 and check
stalled. for 2.4V/2.6V between wire 104 and battery neg-
Note: Check for event code 537 if logged resolve it ative.
first.
• If: Voltage is between 2.4V/2.6V.
No action taken.
– Then replace the Access 5.
Step 1: Enter Service Mode 2 and view CS1 sensor
• If: Voltage is above or below 2.4V/2.6V.
input. Command full traction then plugging while view-
ing CS1 values. – Then replace CS1.
• If: Values are negative during traction acceleration.
– Then check installation of CS1 to bus bar and wir-
ing between Access 5 and CS1.
• If: CS1 installation is correct and event continues.
– Then replace CS1.
• If: CS1 installation is incorrect.
– Then correct.
Event Code 538
THRU
Event Code 537
Access 5 Current Sensor 1 (CS1) Zero Reading Out
of Range.
Note: Check for event codes 532 and 533. If either
event has been logged, then resolve first.
No action taken.
Step 1: Step off the lift truck to allow ED2 contacts to
open, wait 2 min for ED2 bus to discharge then using a
DVOM check voltage between CA403-24 and battery
negative.
• If: Voltage is between 2.4V/2.6V and the event
code continues.
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Event Code 539
Event Code 539 Step 3: Turn on the lift truck and check ED contactor
operation.
Access 5 BDI Battery Voltage Out of Range. • If: Contactor pulls in (even for only a short time-1/3
Note: Check for event code 540. If logged, then second) and the ED coil wiring and contacts appear
resolve first. to be in good condition.
Event Code 538: Traction disabled. – Then proceed to Step 4.
Event Code 539: Full traction, auxiliary raise, auxiliary • If: Contactor does not pull in and the ED bus is not
lower, and raise disabled. connecting to Access 5.
Step 1: Check FU2. Replace if open. – Then follow the procedure of event 544.
Step 2: Check for 24 V between CA202-3 and Step 4: Turn off the lift truck and remove the power
CA206-5. cable from Access 5 battery positive terminal. Connect
• If: 24 V and event continues. DVOM between the battery positive cable and battery
negative on Access 5; turn on the lift truck and check
– Then check for 24 V between CA202-3 and
for 24 V.
CA403-25.
• If: 24 V with ED pulled in (about 1/3 second).
• If: 0 V.
– Then turn off the lift truck and reinstall Access 5
– Then check wiring between CA202-3 and
battery positive power cable. Connect DVOM be-
CA403-25.
tween ACCESS battery positive and battery neg-
ative turn on the lift truck and check for 24 V.
• If: Not 24 V or 24 V and event code 540 continues.
– Then replace Access 5.
• If: Not 24 V when ED is pulled-in.
– Then issue exists in ED contact wiring follow pro-
cedure for event 541.
Event Code 540
Access 5 Battery Voltage Out of Range.
Note: Access 5 monitors battery positive steer motor
input for correct battery voltage.
All functions disabled.
Step 1: Using a DVOM check the battery voltage.
• If: 24 V and battery is known to be good.
– Then proceed to Step 2.
• If: 12 V, 36 V or 48 V.
– Then install correct 24 V battery.
Step 2: Check the status of FU1 through FU9.
• If: Correct status and the event continues.
– Then proceed to Step 3.
• If: Any fuse is open.
– Then replace it.
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Event Code 541
Event Code 541 – Then Access 3™ ED2 switch is correct, replace
ED2 contactor.
Access 5 ED2 Contactor Failed to Energize. • If: 0 V.
All functions disabled. – Then remove wire 2967 from CA403-18 and
Step 1: Turn on the lift truck. Depress brake pedal to check for 24 V between wire 2967 and battery
energize ED2 contactor. negative.
• If: ED2 fails to energize. • If: 24 V.
– Then proceed to Step 2. – Then replace Access 5.
• If: ED2 energizes. • If: 0 V.
– Then, using a DVOM, check for 24 V between – Then check wiring between battery positive bat-
battery negative and battery positive on Access 5 tery terminal and CA403-18.
also between battery negative and CA403-7, Step 4: Turn off the lift truck. Remove wire 5920 from
CA403-9. ED2 coil. Using a DVOM, check resistance of ED2 coil.
• If: Greater than 24 V. • If: 0 Ω.
– Then turn off the lift truck and check for correct – Then remove wire 5920 from ED2 battery nega-
battery. tive coil terminal. Using a DVOM, check resis-
• If: Each test point is 24 V. tance of ED2 coil.
– Then clear event codes and turn on the lift truck. • If: 29 Ω.
• If: Event code continues. – Then reconnect wire 5920 and proceed to Step 5.
– Then replace Access 5. • If: Resistance is not correct.
• If: Each test point is less than 24 V. – Then replace ED2.
– Then turn off the lift truck. Remove CA403 and Step 5: Check resistance between ED2 battery posi-
battery positive cable from Access 5, using a tive coil connection and CA403-19.
DVOM check for shorts between CA403-7 (AC- • If: 0 Ω.
CESS pin) (typical 10,000) and battery negative
– Then proceed to Step 6.
terminal, CA403-9 (ACCESS pin) (typical
10,000) and battery negative terminal also be- • If: Not 0 Ω.
tween battery positive terminal and battery nega- – Then repair wiring between ED2 battery positive
tive terminal (typical 40,000). coil connection and CA403-19.
• If: Resistance is below value shown. Step 6: Enter Service Mode 2. Select ED2 test output
– Then replace Access 5. menu to activate Access 5 / Access 3™ ED2 switches.
Connect a DVOM between ED2 battery negative coil
• If: Resistance value is correct.
connection and battery negative. Check for 24 V with
– Then issue exists in ED2 load bus wiring. no active switches.
Step 2: Turn off the lift truck and check fuses FU1 • If: 0 V.
through FU9.
– Then remove wire 5920 from CA401-2 and check
• If: Fuses not functioning correctly. for 24 V.
– Then replace as necessary. • If: 24 V.
Step 3: Turn on the lift truck. Using a DVOM check – Then Access 3™ is shorted, replace Access 3™.
for 24 V between ED2 coil battery positive terminal and
• If: Not 24 V.
battery negative.
– Then Access 5 switch open, replace Access 5.
• If: 24 V.
• If: 20 V.
– Then ED2 coil supply is correct, proceed to Step
4. – Then activate Access 5 switch and check voltage
while holding Enter Button.
• If: 20 V.
• If: 20 V.
– Then Access 3™ switch is open, replace
Access 3™. – Then Access 5 is open, replace Access 5.
• If: 3 V. • If: 24 V.
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Event Code 542
– Then activate Access 3™ switch and check volt- Step 1: Turn off the lift truck and check fuses FU5,
age while holding Enter Button. FU6, and FU11.
• If: Less than 10 V. • If: Fuses are correct.
– Then Access 5 switch is shorted (ED will pull-in), – Then proceed to Step 2.
replace Access 5. • If: Fuses are open.
• If: 24 V. – Then replace as necessary.
– Then Access 3™ switch is open, replace Step 2: Check power supply wiring from TP5 to
Access 3™. CA403-7, CA403-9 and battery positive power termi-
Step 7: Activate Access 3™ ED2 switch and check nal.
voltage while holding Enter Button.
Event Code 544
Event Code 542 Access 5 ED2 Turn On Error.
All functions disabled.
Access 5 Battery Positive Power Supply Not Pres-
ent. Step 1: Follow procedure for event code 541, ED2
system troubleshooting.
All functions disabled.
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Event Code 545
Event Code 545 • If: CHS3/CHS4 resistance is correct and event
code continues.
Access 5 ED2 Turn Off Error. – Then check CHS3/CH4 wiring. Access 3™
All functions disabled. CA401-11 wire 2973 to CA414-1, CA201-7 wire
Step 1: Follow procedure for event code 541, ED2 2954 to CA415-1, CA401-20 wire 2974 to
system troubleshooting. CA416-1, CA201-8 wire 2955 to CA417-1.
Event Code 546
THRU
Event Code 548
Access 3™ ED Load Bus Pre-charge Error.
All functions disabled.
Event Code 546: General ED pre-charge error.
Event Code 547: Access 3™ pre-charge power out of
range.
Event Code 548: Access 3™ pre-charge error.
Step 1: Using a DVOM, check resistance from ED
bus (output contact) to battery negative.
• If: Less than 25 Ω.
– Then remove bus load fuses one at a time until
the resistance increases to normal value of
1000 Ω.
• If: ED bus resistance returns to normal.
– Then note last fuse removed and replace all oth-
ers to verify that bus resistance remains the
same.
Event Code 549
Access 3™ Chain Slack.
Traction and lower disabled.
Note: Prevents issues logging check lift chain
adjustments.
Step 1: Enter Service Mode 2 and select CHS3/
CHS4. Event Code 551
• If: Switch shows closed.
Access 5 Parameter Error.
– Then status is normal, event code has occurred
No action taken.
due chain adjustments.
Step 1: Turn off the lift truck. Then turn on the lift
• If: Switch shows open.
truck.
– Then check chain adjustment (see Platform in
• If: Event code clears.
Service and Parts Manual).
– Then the lift truck is operation ready.
• If: Chain adjustment is correct and event code con-
tinues. • If: Event code continues.
– Then check CHS3/CHS4 adjustment. – Then replace Access 5.
• If: If: CHS3/CHS4 adjustment is correct.
– Then check CHS3/CHS4 resistance is 0 Ω.
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Event Code 552
Event Code 552 CA410-3, blue wire between CA410 and ECR2,
orange wire between CA410 and ECR2.
THRU • If: Wiring is correct and event code continues.
– Then replace ECR2.
Event Code 553 • If: ECR2 is correct and event code continues.
Access 5 Parameter Error. – Then replace Access 5.
No action taken. • If: ECR2 counts change smoothly but count does
Step 1: Load default parameters and configure as re- not match wheel position.
quired. – Then perform ECR2 alignment.
Event Code 554
Access 5 EAC Parameter Error.
No action taken.
Step 1: Drive the lift truck over EAC magnets to reset
data.
• If: Event code clears.
– Then the lift truck is operation ready.
• If: Event code continues.
– Then replace Access 5.
Event Code 555
THRU
Event Code 556
Access 5 Encoder 2 (ECR2) Out of Range.
Traction disabled.
Note: Check status of event codes 522 and 523 if
logged then resolve them before proceeding to 555
and 556.
Step 1: Using a DVOM check for +5 V between
CA410-2 and CA410-4.
• If: Less than 4.75 V or more than 5.25 V.
– Then follow procedures for event codes 522 and
523.
• If: 5 V.
– Then proceed to Step 2.
Step 2: Check steering wheel synchronization, enter
Service Mode 2 and select Analyzer menu to view en-
coder counts. Rotate tiller knob in both directions while
viewing counts, ECR2 counts change smoothly and
continuously as steering wheel moves. Record ECR2
counts once steering wheel is at zero position.
• If: ECR2 counts erratic change or no change.
– Then check wiring, wire 025 between CA403-13
and CA410-1, wire 026 between CA403-14 and
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Event Code 557
Event Code 557
Access 5 Encoder 2 (ECR2) Index Error.
Full traction disabled.
Note 1: ECR2 count indicates that the wheel has
passed through zero position, but index signal has not
indicated the same.
Note 2: Check status of event codes 522 and 523 if
logged resolve them before proceeding to event code
557.
Step 1: Using a DVOM check for +5 V between
CA410-2 and CA410-4.
• If: Less than 4.75 V or more than 5.25 V.
– Then follow procedures for event codes 522 and
523.
• If: 5 V.
– Then proceed to Step 2.
Step 2: Check ECR2 index wiring, wire 027 between
CA403-23 and CA410-5 and yellow wire between
ECR2 and CA410.
• If: Wiring is correct.
– Then check steering wheel synchronization, en-
ter Service Mode 2 and select Analyzer menu
view encoder counts. Rotate tiller knob in both di-
rections while viewing counts, ECR2 counts
change smoothly and continuously as steering
wheel is at zero position.
• If: ECR2 counts erratic change or no change.
– Then check wiring, wire 025 between CA403-13
and CA410-1, wire 026 between CA403-14 and
CA410-3, blue wire between CA410 and ECR2
and orange wire between CA410 and ECR2.
• If: Wiring is correct and event code continues.
– Then replace ECR2.
• If: ECR2 is correct and event code continues.
– Then replace Access 5.
• If: ECR2 counts change smoothly but count does
not match wheel position.
– Then perform ECR2 alignment.
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Event Code 558
Event Code 558
THRU
Event Code 561
Access 5 Encoder 2 (ECR2) Error.
Traction and steering disabled.
Note 1: Event occurs if there is no wheel movement
upon command.
Note 2: Check status of event codes 522 and 523 if
logged resolve them before proceeding to 558, 559,
560 and 561.
Step 1: Using a DVOM, check for +5 V between
CA410-2 and CA410-4.
• If: Less than 4.75 V or more than 5.25 V.
– Then follow procedures for event codes 522 and
523.
• If: 5 V.
– Then proceed to Step 3.
Step 2: Check wire connections between Access 5
A1 and A2 terminal and M3.
• If: Wiring is correct.
– Then proceed to Step 3.
Step 3: Check steering wheel synchronization, enter
Service Mode 2 and select Analyzer menu view en-
coder counts. Rotate tiller knob in both directions while
viewing counts, ECR2 counts change smoothly and
continuously as steering wheel moves. Record ECR2
counts once steering wheel is at zero position.
• If: ECR2 count change is erratic or not at all.
– Then check wiring, wire 025 between CA403-13
and CA410-1, wire 026 between CA403-14 and
CA410-3, blue wire between CA410 and ECR2
and orange wire between CA410 and ECR2.
• If: Wiring is correct and event code continues.
– Then replace ECR2.
• If: ECR2 is correct and event code continues.
– Then replace Access 5.
• If: ECR2 counts change smoothly but count does
not match wheel position.
– Then perform ECR2 Alignment.
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Event Code 562
Event Code 562 • If: Feature is not installed.
– Then access the Features menu and turn off
Access 5 Steering Error. guidance.
Traction and steering disabled. • If: Event continues.
Note: Check status of event codes 540, 524 and 525 if – Then see the event code 506.
logged resolve them before proceeding to 562.
Step 1: Turn off the lift truck and unplug battery, re- Event Code 564
move battery positive and battery negative cables from
Access 5. Install a jumper between battery positive and Access 5 Wire Guidance Enable Error.
battery negative using a DVOM check the following: Traction disabled.
Terminal A1 to battery positive = 15,000 Ω. Note: Access 5 received a wire guidance command
Terminal A1 to battery negative = 15,000 Ω. from the guidance switch but wire enable setup is not
Terminal A2 to battery positive = 15,000 Ω. active.
Terminal A2 to battery negative = 15,000 Ω.
Step 1: ACCESS Features menu and turn on wire
Terminal A1 to A2 = 30,000 Ω.
guidance.
• If: Any are 5000 Ω below the value shown.
– Then replace Access 5.
• If: Readings are correct.
– Then reconnect cables and check A1 and A2 ca-
bles for a short.
• If: Cables are correct and the event continues.
– Then replace Access 5.
Event Code 563
Access 5 / Access 6 Communication Error.
Traction disabled.
Note: Access 5 has received a wire guidance
command from the guidance switch but has not
received communication from Access 6.
Step 1: Verify that the lift truck has guidance feature.
• If: Feature is installed.
– Then check access wiring.
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Event Code 565
Event Code 565
Access 5 / Access 3™ Traction Encoder 3 (ECR3)
Error.
Traction disabled. One or both channels lost at
Access 5 in idle or traveling.
Note: Check status of event codes 330 and 565 (both
pertain to ECR3). If logged, then resolve them before
proceeding with 565.
Step 1: Clear event history; turn off the lift truck; turn
on the lift truck and request traction.
• If: Event 565 is logged.
– Then check wiring between FSB CA408 and
Access 5 CA403.
• If: Wiring is correct.
– Then replace FSB.
• If: Event continues.
– Then replace Access 5.
• If: Event 330 is logged.
– Then check wiring between FSB CA408 and
Access 3™ CA401.
• If: Wiring is correct.
– Then replace FSB.
• If: Event continues. Event Code 566
– Then replace Access 3™.
Access 5 EAC Enable Error.
Full traction disabled.
Note: EAC feature enabled, hardware not detected.
Step 1: Verify that the lift truck has EAC feature.
• If: The lift truck does not have EAC feature.
– Then enter Features menu and disable EAC.
• If: The lift truck has EAC feature.
– Then check for event code 105 if logged check
connections to Access 6.
• If: Connections are correct.
– Then check for event code 506 if logged see the
procedures for event code 506.
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Event Code 567
Event Code 567
Access 5 EAC Sensor Latched On Error.
Full traction disabled.
Note 1: EAC sensor event code ID: 1A.
Note 2: Check status of event codes 625 and 626. If
logged, then resolve before proceeding to 567, 568,
569 or 570.
Note 3: To perform test position the lift truck away from
EAC magnets.
Step 1: Using a DVOM check for 5 V between
Access 6 CA602-5 wire 052 and battery negative.
• If: 0 V.
– Then check for a test voltage between Access 6
CA602-3 wire 901 and battery negative.
• If: Greater than 1 V.
– Then replace Access 6.
• If: 0 V.
– Then remove wire 052 from EAC distribution
panel CA607-3, check for 5 V between wire end
and battery negative.
• If: 5 V.
– Then replace EAC distribution panel.
• If: 0 V.
– Then remove wire 052 from EAC Access 6
CA602-5, check for 5 V between CA602-5 and
battery negative.
• If: 0 V.
– Then replace Access 6.
• If: 5 V.
– Then check wiring between Access 6 CA602-5
wire 052 and EAC distribution panel CA607-3.
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Event Code 568
Event Code 568
Access 5 EAC Sensor Latched On Error.
Full traction disabled.
Note 1: EAC sensor event code ID: 1B.
Note 2: Check status of event codes 625 and 626. If
logged, then resolve before proceeding to 567, 568,
569 or 570.
Note 3: To perform test position the lift truck away from
EAC magnets.
Step 1: Using a DVOM check for 5 V between
Access 6 CA602-11 wire 054 and battery negative.
• If: 0 V.
– Then check for a test voltage between Access 6
CA602-9 wire 903 and battery negative.
• If: Greater than 1 V.
– Then replace Access 6.
• If: 0 V.
– Then remove wire 054 from EAC distribution
panel CA607-9, check for 5 V between wire end
and battery negative.
• If: 5 V.
– Then replace EAC distribution panel.
• If: 0 V.
– Then remove wire 054 from EAC Access 6
CA602-11, check for 5 V between CA602-11 and
battery negative.
• If: 0 V.
– Then replace Access 6.
• If: 5 V.
– Then check wiring between Access 6 CA602-11
wire 054 and EAC distribution panel CA607-9.
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Event Code 569
Event Code 569
Access 5 EAC Sensor Latched On Error.
Full traction disabled.
Note 1: EAC sensor event code ID: 2A.
Note 2: Check status of event codes 625 and 626. If
logged, then resolve before proceeding to 567, 568,
569 or 570.
Note 3: To perform test position the lift truck away from
EAC magnets.
Step 1: Using a DVOM check for 5 V between
Access 6 CA602-8 wire 053 and battery negative.
• If: 0 V.
– Then check for a test voltage between Access 6
CA602-6 wire 902 and battery negative.
• If: Greater than 1 V.
– Then replace Access 6.
• If: 0 V.
– Then remove wire 053 from EAC distribution
panel CA607-6, check for 5 V between wire end
and battery negative.
• If: 5 V.
– Then replace EAC distribution panel.
• If: 0 V.
– Then remove wire 053 from EAC Access 6
CA602-8, check for 5 V between CA602-8 and
battery negative.
• If: 0 V.
– Then replace Access 6.
• If: 5 V.
– Then check wiring between Access 6 CA602-8
wire 053 and EAC distribution panel CA607-6.
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Event Code 570
Event Code 570
Access 5 EAC Sensor Latched On Error.
Full traction Disabled.
Note 1: EAC sensor event code ID: 2B.
Note 2: Check status of event codes 625 and 626. If
logged, then resolve before proceeding to 567, 568,
569 or 570.
Note 3: To perform test position the lift truck away from
EAC magnets.
Step 1: Using a DVOM check for 5 V between
Access 6 CA602-14 wire 055 and battery negative.
• If: 0 V.
– Then check for a test voltage between Access 6
CA602-12 wire 904 and battery negative.
• If: Greater than 1 V.
– Then replace Access 6.
• If: 0 V.
– Then remove wire 055 from EAC distribution
panel CA607-12, check for 5 V between wire end
and battery negative.
• If: 5 V.
– Then replace EAC distribution panel.
• If: 0 V.
– Then remove wire 055 from EAC Access 6
CA602-14, check for 5 V between CA602-14 and
battery negative.
• If: 0 V.
– Then replace Access 6.
• If: 5 V.
– Then check wiring between Access 6 CA602-14
wire 055 and EAC distribution panel CA607-12.
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Event Code 571
Event Code 571 Event Code 573
THRU THRU
Event Code 572 Event Code 574
Access 5 EAC Magnet Error. Access 4 Height Encoder 4 (ECR4) or Encoder 6
Full traction disabled. (ECR6) Count Error.
Event Code 571: Inner magnet error event code. Full traction and raise 2 disabled.
Event Code 572: Outer magnet error event code. Event Code 573: Event code will log if the platform fails
to lower within an allotted time after operator
Step 1: Drive the lift truck out of guided aisle then re-
command. This event occurs during a lower command
enter.
and chain slack condition.
• If: Event clears.
Event Code 574: Event code will log if the platform fails
– Then monitor. to raise within an allotted time after operator command.
• If: Event repeats. Step 1: Disconnect CA317, check encoder side wir-
– Then proceed to Step 2. ing. Make sure that there are not broken crimps on the
Step 2: Enter Service Mode 2 and select View EAC encoder wiring into connector.
Sensor Status in EAC monitor menu A2.5.4 and • If: Wiring crimp broken or damaged.
A2.5.5. Acquire wire or rail position the lift truck in EAC – Then replace ECR4.
zone, display state of corresponding sensors. Slowly
Step 2: Disconnect CA317, using a DVOM check for
drive over EAC magnets while viewing sensor state on
5 V between CA317-3 and CA317-4.
display. State is closed if not detected, open if detected.
• If: 5 V.
• If: Any magnet fails detection.
– Then reconnect CA317 and proceed to Step 3.
– Then check wiring of corresponding sensor.
• If: Less than 5 V.
• If: Wiring is correct.
– Then remove wire 703 and 516 from CA303 and,
– Then perform the same test over another magnet
using a DVOM, check for 5 V between pins
in the aisle.
CA303-12 and CA303-15.
• If: Test passes.
• If: 5 V.
– Then check the magnet in the floor. Using a piece
– Then check wiring. Wire 703 CA303-12 to
of metal, pass it over the magnet, the attraction is
CA317-3, wire 516 CA303-15 to CA317-4.
strong. Compare it to another magnet and if there
is a dramatic different in the magnetic attraction • If: Less than 5 V.
replace the magnet. – Then replace Access 4.
• If: All four magnets are detected. Step 3: Check ECR4 channel wiring. Wire 007
– Then proceed to Step 3. CA317-1 to CA303-13, wire 008 CA317-2 to
CA303-14.
Step 3: Rekey the lift truck in normal mode. Acquire
wire or rail and stop the lift truck outside the EAC • If: Wiring is correct and event code continues.
zones, remain idle with foot on brake. Wait 20 seconds – Then disconnect CA317, remove white and blue
for diagnostics to execute. wires from JC317-1 and JC317-2. Connect a
• If: Sensors fail. DVOM from white (CH A) to battery negative, turn
on the lift truck and check voltage. Reading is 0 V
– Then a 500 or 600 event code is logged. Follow
or 5 V depending on position of ECR4 disc. Per-
procedures for that event code.
form the same test on the blue wire (CH B).
• If: Time elapses and no event occurs.
• If: Not 0 V or 5 V.
– Then system is correct; continue to monitor.
– Then replace ECR4.
• If: 0 V or 5 V.
– Then reconnect wiring.
• If: 0 V or 5 V and event code continues.
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Event Code 576
– Then replace Access 4. • If: Not 0 V or 12 V.
– Then replace ECR6.
• If: 0 V or 12 V.
– Then reconnect wiring.
• If: 0 V or 12 V and event code continues.
– Then replace Access 3™.
Step 4: Disconnect CA421, check encoder side wir-
Event Code 576
ing. Make sure that there are not broken crimps on the THRU
encoder wiring into connector.
• If: Wiring crimp broken or damaged. Event Code 581
– Then replace ECR6.
Access 5 Brake Current or Resistance Error.
Step 5: Disconnect CA421, using a DVOM check for
Event Code 576: Traction disabled. Inner brake low
12 V between CA421-3 and CA421-4.
current.
• If: 12 V.
Event Code 577: Traction disabled. Inner brake hot.
– Then reconnect CA421 and proceed to Step 6.
Event Code 578: Full speed traction disabled only.
• If: Less than 12 V. Inner brake resistance high.
– Then remove wire 316 and 549 from CA401 and, Event Code 579: Traction disabled. Outer brake low
using a DVOM, check for 12 V between pins current.
CA401-3 and CA401-4.
Event Code 580: Traction disabled. Outer brake hot.
• If: 12 V.
Event Code 581: Full speed traction disabled only.
– Then check wiring. Wire 316 CA401-3 to Outer brake resistance high.
CA421-3, wire 549 CA401-4 to CA421-4.
Step 1: Allow brake assembly to cool then remove
• If: Less than 12 V. brake from traction motor and disassemble to the level
– Then replace Access 3™. that coils can be inspected.
Step 6: Check ECR6 channel wiring. Wire 014 Step 2: Inspect coils for heat damage.
CA421-1 to CA401-11, wire 013 CA421-2 to • If: Lamination material has broken down.
CA401-10.
– Then replace brake coils.
• If: Wiring is correct and event code continues.
• If: Coils do not appear to be damaged.
– Then disconnect CA421, remove white and blue
– Then, with coils at room temperature, use a
wires from JC421-1 and JC421-2. Connect a
DVOM and check resistance, typical resistance
DVOM from white (CH A) to battery negative, turn
of inner coil is 3.5 Ω outer coil 1.5 Ω.
on the lift truck and check voltage. Reading is 0 V
or 12 V depending on position of ECR6 disc. Per- • If: Either coil is significantly above value.
form the same test on the blue wire (CH B). – Then replace coil.
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Event Code 582
Event Code 582 Event Code 587
THRU Access 5 Brake Load Error.
Traction disabled.
Event Code 585 Note: Outer coil error.
Access 5 Brake Current Out of Range. Step 1: Turn off the lift truck and, using a DVOM,
Traction disabled. check resistance of outer coil. Unplug CA407 place
DVOM leads between CA407-1 and CA407-4 on the
Event Code 582 and 583: Inner brake resistance low. brake side typical resistance at room temperature is
Event Code 584 and 585: Outer brake resistance low. 1.5 Ω.
Step 1: Turn off the lift truck and, using a DVOM, • If: Resistance is less than 1.5 Ω.
check resistance of inner coil. Unplug CA407, place – Then replace outer brake coil.
DVOM leads between CA407-2 and CA407-3 on the
brake coil side, typical resistance at room temperature • If: Resistance is close to 1.5 Ω and event contin-
is 3.5 Ω. ues.
• If: Resistance is less than 3.5 Ω. – Then replace Access 5.
– Then replace inner brake coil.
• If: Resistance is close to 3.5 Ω and event contin-
ues.
– Then replace Access 5.
Event Code 586
Access 5 Brake Load Error.
Traction disabled.
Note: Inner coil error.
Step 1: Turn off the lift truck and, using a DVOM,
check resistance of inner coil. Unplug CA407, place
DVOM leads between CA407-2 and CA407-3 on the
brake coil side, typical resistance at room temperature
is 3.5 Ω.
• If: Resistance is close to 3.5 Ω and event contin-
ues.
– Then replace Access 5.
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Event Code 588
Event Code 588 Note 2: Fuse 5 circuit.
Step 1: Event code 589 check fuse 5.
Access 5 Brake Supply Voltage Error. • If: Open.
Traction disabled. – Then replace fuse 5.
Note 1: Brake power supply voltage error could result • If: Correct.
from a failure of ED2 contact close.
– Then using a DVOM check for 24 V between
Note 2: Fuse 6 circuit.
CA403-9 and battery negative.
Step 1: Check fuse 6.
• If: Less than 24 V.
• If: Open.
– Then check wiring. Wire 2902 CA206-4 to ED2
– Then replace fuse 6. contactor, wire 2957 CA202-1 to CA403-9.
• If: Correct.
– Then using a DVOM check for 24 V between
CA403-7 and battery negative.
• If: Less than 24 V.
– Then check wiring. Wire 2902 CA206-4 to ED2
contactor, wire 2956 CA202-2 to CA403-7.
Event Code 589
Access 5 Brake Supply Voltage Error.
Traction disabled.
Note 1: Brake power supply voltage error could result
from a failure of ED2 contact close.
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Event Code 590
Event Code 590 • If: 0 Ω.
– Then replace PVL.
THRU • If: 25–35 Ω.
– Then check wire 5926 CA403-2 to PVL coil, wire
Event Code 591 2958 CA403-11 to PVL coil, wire 2960 CA201-9
Access 5 Brake Driver Error. to PVL coil.
Steering and traction disabled.
Event Code 590: Inner brake driver error.
Event Code 591: Outer brake driver error.
Step 1: See the procedure for event 588 and 589.
Use event code that corresponds to the specific driver
(inner or outer brake coil).
Step 2: See the procedure for event 586 and 587.
Use event that code corresponds to the specific driver
(inner or outer brake coil).
• If: Results of Steps 1 and 2 do not indicate a brake
voltage error or shorted brake load.
– Then replace Access 5.
Event Code 592
THRU
Event Code 593
Access 5 Brake Driver Error.
Traction disabled.
Event Code 592: Inner brake driver error.
Event Code 593: Outer brake driver error.
Step 1: See the procedure for event 582, 583, 584,
585. Use event code that corresponds to the specific
driver (inner or outer brake coil).
• If: Results of Steps 1 and 2 do not indicate a brake
low resistance.
– Then replace Access 5.
Event Code 594
Access 5 Proportional Flow Valve (PVL) Load Er-
ror.
Hydraulics disabled.
Step 1: Turn off the lift truck and remove connector
CA403 from Access 5, using a DVOM check resistance
between wire 2958 and 5926.
• If: Resistance is 25–35 Ω.
– Then replace Access 5.
• If: Resistance is 0 Ω.
– Then disconnect wires from PVL coil and check
resistance at coil.
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Event Code 595
Event Code 595 • If: Wiring is correct and event code continues.
– Then replace Access 5.
Access 5 Proportional Flow Valve (PVL) Driver Er-
ror.
Raise disabled.
Step 1: Enter Service Mode 2 and select PVL moni-
tor menu A3.4.10. Raise platform then lower the dis-
play indicates percentage of PVL (lower valve) duty
cycle.
• If: Display indicates a duty cycle but the platform
does not lower.
– Then check wiring. Wire 5926 CA403-2 to PVL
coil, wire 2958 CA403-11 to PVL coil and wire
2960 CA201-9 to PVL coil.
• If: Wiring is correct and event code continues.
– Then replace Access 5.
Event Code 596
Access 5 Proportional Flow Valve (PVL) Load Er-
ror.
Raise disabled.
Step 1: Turn off the lift truck and remove connector
CA403 from Access 5, using a DVOM check resistance
between wire CA403-11 and CA403-2.
• If: 25–35 Ω.
– Then check wire 5926 CA403-2 to PVL coil, wire
2958 CA403-11 to PVL coil, wire 2960 CA201-9
to PVL coil.
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Event Code 597
Event Code 597 – Then issue exists in CAN wiring between
Access 6 and power unit distribution panel.
Access 5 Proportional Flow Valve (PVL) Driver Er- Check connectors CA601, CA204, and wiring.
ror. Wire 021 CA601-4 to CA204-3 and wire 022
Hydraulics disabled. CA601-5 to CA204-9.
Note: Shorted driver event could be due to outside • If: Access 1 displays event code 601.
short, CA403-2 to battery negative or internal short in – Then check Access 1 power on light.
Access 5. • If: Access 1 power on light is illuminated.
Step 1: Turn on the lift truck and, using a DVOM, – Then issue exists in CAN wiring between
check for 24 V between wire 5926 at PVL coil and bat- Access 1 andCA105, andCA105 and wiring. Wire
tery negative. 003 CA302-8 to CA105-2 and wire 004 CA302-9
• If: Not 24 V. to CA105-8.
– Then remove wire 2958 from CA403-11, turn on • If: Access 1 power on light is off.
the lift truck using a DVOM check for 24 V be- – Then issue exists in wiring between platform dis-
tween wire 5926 and battery positive. tribution panel and Access 1. Check wire 2941
• If: 24 V. CA302-3 to CA103-10.
– Then replace Access 5.
• If: Not 24 V.
– Then check wiring. Wire 2960 PVL to CA201-9,
wire 2958 PVL to CA403-11.
Event Code 601
Access 6 CAN Error.
Traction disabled.
Step 1: Verify source of event code.
• If: Access 6 flashes code but is not displayed by
Access 1.
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Event Code 603
Event Code 603
Access 6 CAN Error.
Traction disabled.
Step 1: Verify source of event code.
• If: Access 6 flashes code but is not displayed by
Access 1.
– Then issue exists in CAN wiring between
Access 6 and power unit distribution panel.
Check connectors CA601, CA204, and wiring.
Wire 021 CA601-4 to CA204-3 and wire 022
CA601-5 to CA204-9.
• If: Access 1 displays event code 603.
– Then check Access 3™ power on light.
• If: Access 3™ power on light is illuminated.
– Then issue exists in CAN wiring between
Access 3™ and power unit distribution panel.
Check connectors CA401, CA204, and wiring.
Wire 017 CA401-23 to CA204-1 and wire 018
CA401-15 to CA204-7.
• If: Access 3™ power on light is off.
– Then issue exists in wiring between power unit
distribution panel and Access 3™. Check wire
2953 CA401-1 to CA201-5.
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Event Code 604
Event Code 604
Access 6 CAN Error.
Traction disabled.
Step 1: Verify source of event code.
• If: Access 6 flashes code but is not displayed by
Access 1.
– Then issue exists in CAN wiring between
Access 6 and power unit distribution panel.
Check connectors CA601, CA204, and wiring.
Wire 021 CA601-4 to CA204-3 and wire 022
CA601-5 to CA204-9.
• If: Access 1 displays event code 604.
– Then check Access 4 power on light.
• If: Access 4 power on light is illuminated.
– Then issue exists in CAN wiring between
Access 4 and platform distribution panel. Check
connectors CA303, CA105, and wiring. Wire 002
CA303-08 to CA105-7 and wire 001 CA303-07 to
CA105-1.
• If: Access 3™ power on light is off.
– Then issue exists in wiring between power unit
distribution panel and Access 4. Check wire 2937
CA304-1 to CA103-12.
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Event Code 605
Event Code 605
Access 6 CAN Error.
Traction disabled.
Step 1: Verify source of event code.
• If: Access 6 flashes code but is not displayed by
Access 1.
– Then issue exists in CAN wiring between
Access 6 and power unit distribution panel.
Check connectors CA601, CA204, and wiring.
Wire 021 CA601-4 to CA204-3 and wire 022
CA601-5 to CA204-9.
• If: Access 1 displays event code 605.
– Then check Access 5 power on light.
• If: Access 5 power on light is illuminated.
– Then issue exists in CAN wiring between
Access 5 and power unit distribution panel.
Check connectors CA402, CA204, and wiring.
Wire 019 CA402-4 to CA204-2 and wire 020
CA402-5 to CA204-8.
• If: Access 5 power on light is off.
– Then issue exists in wiring between power unit
distribution panel and Access 5. Check wire 2966
CA403-10 to CA201-6.
Event Code 611
THRU
Event Code 612
Access 6 Internal Error.
All functions disabled.
Step 1: Replace Access 6.
Event Code 621
THRU
Event Code 628
Access 6 Internal Error.
Traction disabled.
Step 1: Replace Access 6.
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Event Code 631
Event Code 631 – Then replace Access 6.
Access 6 Wire Guidance Sensor Amplifier Self-
Test Error.
Traction disabled.
Step 1: Replace Access 6.
Event Code 632
Access 6 Load Wheel Sensor Bar GS2 Guidance Is-
sue.
Traction disabled.
Note: Event code 632 will also log if wire guidance
feature is enabled and sensor bars are not present.
Step 1: Check sensor bar 5 V supply. Connect
DVOM positive lead to CA602-22 and negative to bat-
tery negative and turn on the lift truck.
• If: 5 V.
– Then sensor bar power supply is correct, pro-
ceed to Step 2.
• If: 0 V.
– Then remove wire 717 from CA602-15 (steering
wheel sensor bar GS1), check for 5 V between
CA602-22 and battery negative.
• If: 5 V.
– Then issue exists in GS1 bar or the wiring from
Access 6 to GS1. Repair or replace as neces-
sary.
• If: 0 V.
– Then remove wire 718 from CA602-22 (load
wheel sensor bar GS2), check for 5 V between
CA602-22 and battery negative at Access 6.
• If: 0 V.
– Then replace Access 6.
• If: 5 V.
– Then issue exists in GS2 or the wiring from
Access 6 to GS2. Repair or replace as neces-
sary.
Step 2: Enter Service Mode 2 and view GS2 sensor
values (A2.5.3) drive slowly over the wire, values in-
crease and decrease while traversing the wire.
• If: Any of the four coil signals fail to indicate the
presence of the wire.
– Then check the wiring corresponding to that coil
for a short or an open issue per the diagrams.
• If: Wiring is correct.
– Then replace GS2.
• If: Event code continues.
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Event Code 633
Event Code 633
Access 6 Steering Wheel Sensor Bar (GS1) Guid-
ance Error.
Traction disabled.
Note: Event code 633 will also log if wire guidance
feature is enabled and sensor bars are not present.
Step 1: Check sensor bar 5 V supply. Connect
DVOM positive lead to CA602-15 and negative to bat-
tery negative and turn on the lift truck.
• If: 5 V.
– Then sensor bar power supply is correct, pro-
ceed to Step 2.
• If: 0 V.
– Then remove wire 717 from CA602-15 (steering
wheel sensor bar GS1), check for 5 V between
CA602-22 and battery negative.
• If: 5 V.
– Then issue exists in GS1 or the wiring from
Access 6 to GS1. Repair or replace as neces-
sary.
• If: 0 V.
– Then remove wire 718 from CA602-22 (load
wheel sensor bar GS2), check for 5 V between
CA602-22 and battery negative at Access 6.
• If: 0 V.
– Then replace Access 6.
• If: 5 V.
– Then issue exists in GS2 or the wiring from
Access 6 to GS2. Repair or replace as neces-
sary.
Step 2: Enter Service Mode 2 and view the GS1 sen-
sor values (A2.5.1) driving slowly over the wire, values
increase and decrease while traversing the wire.
• If: Any one of the four coil signals fail to indicate the
presence of the wire.
– Then check the wiring corresponding to that coil
for a short or an open issue per the diagrams.
• If: Wiring is correct.
– Then replace GS1.
• If: Event code continues.
– Then replace Access 6.
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Event Code 636
Event Code 636
Access 6 Guide Angle Beyond Acceptable Angle.
Traction disabled.
Note 1: Event code 636 could log if the lift truck is
driven beyond end of wire in auto guide.
Step 1: Event code 636 is logged by driving beyond
the end of the wire in auto guide system operation is
correct.
• If: Event code 632/633 was also logged.
– Then follow procedures for these event codes
before continuing.
• If: Event code 636 was logged while in aisle.
– Then check alignment of ECR2, condition of sen-
sor bars and wire guidance calibration.
• If: ECR2 requires realignment.
– Then calibrate the lift truck.
• If: Event code was not due to alignment or calibra-
tion.
– Then using the Crown field strength meter (Part
Number 112953) check wire guide field strength
(6.25 kHz, 168 ma to 190 ma, 5.2 kHz 100 ma -
118 ma).
• If: Field strength is correct and event code contin-
ues.
– Then check floor surface.
Note 2: Floor surface irregularities, corrupted signal
due to rebar, metal pipes, underground electrical wiring
in metal or plastic conduit. Any of these issues can
affect wire guidance performance, which could be
localized (for example, section in one aisle) or wide
spread.
Event Code 637
Access 6 Wire Guidance Signal Loss at Both Sen-
sor Bars.
Traction Disabled.
Step 1: Check for event codes 632/633.
• If: Event code 632 or 633 has been logged.
– Then resolve these event codes before continu-
ing.
• If: Event code 632 or 633 has not been logged.
– Then check line driver power.
• If: Line driver correct.
– Then check guide wire condition breaks are pres-
ent.
Crown 2007 PF15819 Rev. 7/20 M4.8-7335-113
08 Rev. 7/20
491
ELECTRICAL SYSTEM
Event Code 638
Event Code 638
THRU
Event Code 639
Access 6 Loss of Wire Guidance Signal from One
Sensor Bar.
Traction disabled.
Step 1: Check for event codes 632/633.
• If: Event code 632 or 633 has been logged.
– Then resolve event code 632/633 before continu-
ing.
• If: Event code 638 (load wheel sensor bar GS2)
continues.
– Then check wiring. Wire 120 CA604-1 to
CA602-27, wire 119 CA604-2 to CA602-26, wire
118 CA604-7 to CA602-25 and wire 117
CA604-8 to CA602-24.
• If: Event code 639 (steering wheel sensor bar GS1)
continues.
– Then check wiring. Wire 116 CA603-1 to
CA602-20, wire 115 CA603-2 to CA602-19, wire
114 CA603-7 to CA602-18 and wire 113
CA603-8 to CA602-17.
• If: Event code 638 or 639 continues.
– Then replace corresponding sensor bar.
• If: Event code continues after replacement of sen-
sor bar.
– Then replace Access 6.
M4.8-7335-114 Crown 2007 PF15819 Rev. 7/20
08 Rev. 7/20
492
ELECTRICAL SYSTEM
Event Code 652
Event Code 652 Event Code 660: Sensor A1 digital signal error.
Event Code 661: Sensor B1 digital signal error.
THRU Event Code 662: Sensor A2 digital signal error.
Event Code 663: Sensor B2 digital signal error.
Event Code 659
Step 1: Enter Analyzer Mode select view EAC digital
Access 6 EAC Sensor Out of Range. signal state (A2.5.3 - A2.5.6). Digital state indicates
Full traction disabled. opened if the magnet is not sensed and closed if it is
sensed. Acquire the wire and slowly drive over the
Event Code 652 and 653: Sensor A1 over or under
magnet in the position of failed sensor while viewing
range.
sensor digital state.
Event Code 654 and 655: Sensor B1 over or under
• If: Digital state switches from opened to closed
range.
back to opened as sensor passes over the magnet.
Event Code 656 and 657: Sensor A2 over or under
– Then digital sense is working properly, enter But-
range.
ton Mode select view EAC signal level corre-
Event Code 658 and 659: Sensor B2 over or under sponding to event code.
range.
• If: Signal is close to 40%.
Step 1: Enter Analyzer Mode and select view EAC
– Then strength is close to lower range threshold,
signal levels (A2.5.3 - A2.5.6). The signal value dis-
check sensor wiring per diagram and inspect
played represents the signal strength in percentage of
magnet location and floor conditions around the
full scale for the activated sensor. Display will hold the
magnet.
peak sensed value until next magnet detection cycle
occurs. • If: Correct and event code continues.
Acquire wire and slowly drive over the magnet in the – Then replace EAC sensor that corresponds with
position of failed sensor while viewing sensor signal event code.
strength. Signal strengths tend towards the lower • If: Digital state shows opened and does not change
range value, rather than the upper. when sensor passes over the magnet.
• If: Signal is close to 100% and event continues. – Then check magnet is present and the sensor
– Then check sensor wiring per diagram. wiring is correct per the diagram.
• If: Wiring is correct. • If: Correct.
– Then replace EAC sensor that corresponds with – Then replace EAC sensor that corresponds with
event code. event code.
• If: Signal is close to 40%. • If: Event code continues.
– Then strength is close to lower range threshold. – Then replace Access 6.
Check sensor wiring per diagram and inspect
magnet location and floor conditions around the
magnet.
• If: Correct.
– Then replace EAC sensor that corresponds with
event code.
• If: Event code continues.
– Then replace Access 6.
Event Code 660
THRU
Event Code 663
Access 6 EAC Sensor Digital Signal Error.
Full traction disabled.
Crown 2007 PF15819 Rev. 7/20 M4.8-7335-115
08 Rev. 7/20
493
ELECTRICAL SYSTEM
Event Code 664
Event Code 664 CA602 where the digital signal wire was re-
moved.
THRU • If: Less than 1 V.
– Then replace Access 6.
Event Code 667 • If: Greater than 3.5 V.
Access 6 EAC Magnet Field Strength Out of Range. – Then check voltage at the corresponding test sig-
Full traction disabled. nal at CA602.
Step 1: Check magnet locations for improper installa- • If: CA602 pin 0 V.
tion or damage (for example, wrong pole, positional – Then replace the corresponding EAC sensor.
alignment, floor crack through magnet, and so on). • If: If: CA602 pin greater than 5 V.
– Then replace Access 6.
Event Code 668
THRU
Event Code 671
Access 6 EAC Sensor Self-Test Error.
Full traction disabled.
Event Code 668: Sensor A1.
Event Code 669: Sensor B1.
Event Code 670: Sensor A2.
Event Code 671: Sensor B2.
Step 1: Check sensors wiring and connections as it
applies to event codes.
• If: Wiring or connections incorrect.
– Then repair as necessary.
• If: Wiring is correct and event code continues.
– Then replace EAC sensor that corresponds with
event code.
• If: Event code continues.
– Then replace Access 6.
Event Code 672
Access 6 Multiple EAC Sensors Active.
Full traction disabled.
Step 1: Check EAC sensors for damage.
• If: Sensors are damaged.
– Then repair or replace as necessary.
• If: Sensors are not damaged.
– Then move the lift truck away from EAC zone
where all sensors are inactive. Check digital sig-
nal voltage from CA602-5, -8, -11 and -14 to bat-
tery negative.
• If: Digital signal is less than 1 V.
– Then remove the corresponding digital signal
wire from CA602. Check the voltage at Access 6
M4.8-7335-116 Crown 2007 PF15819 Rev. 7/20
08 Rev. 7/20
494
ELECTRICAL SYSTEM
Event Code Introduction
Event Code Introduction Software
To make sure that the lift truck has the newest
Access 1 2 3® software, perform the following steps:
CAUTION
1. Turn on the lift truck.
If you connect the control connectors when the lift 2. Use Access 1 to enter Level 2: Field service mode.
truck is on, the lift truck could be damaged.
3. Push the up or down arrows to enter the Utilities
The truck electrical system could be damaged.
menu. This menu displays the control module and
• Do not turn the lift truck on with the control connec- software part numbers that are applicable to the lift
tors disconnected. truck.
• Do not remove or connect the control connectors
while the lift truck is on. No event code
If the lift truck malfunctions and no event code shows,
the malfunction is usually not electrical. If the lift truck
is on, but an event code does not show, the malfunction
CAUTION is usually mechanical or hydraulic, but not electrical.
When replacing a control module and doing an up- The mechanical and hydraulic data is in the applicable
date to the module software, make sure that the ad- section in this manual.
justments are correct.
Component locations
The lift truck will not operate correctly.
• Calibrate the lift truck. See the ELECTRICAL ► The component and wire location maps are at locations
Access 1 2 3® ► Calibration section. on the lift truck to help find the location of the compo-
nents. All components are clearly identified at the con-
nection points. See the COMPONENTRY section for
Troubleshooting steps more data on each component.
Most malfunctions occur in or at the output devices (re- Power cable connections
lays, contactors, and motors). The next components to
examine are connectors, wires, and input devices
(switches, potentiometers, and encoders). The last
components to examine are the control modules. Per- WARNING
form a test of the output devices, then the input de- A charged capacitor could be dangerous.
vices, and then the control module to which these de-
vices are attached. When measuring the voltage and Because of capacitance voltage in some control mod-
resistance of these components, use a digital volt-ohm ules, an injury or damage to the lift truck could occur.
multimeter (DVOM). Make sure that all components • When you do the lift truck maintenance around the
are connected after completing the event code steps. bus bars and related power cables, discharge the
capacitors.
Malfunctions
• See the SAFETY ► Control of Hazardous Energy
When a malfunction occurs, use Access 1 to go into ► Capacitance section for procedures to discharge
Level 2: Field service mode. the capacitors
Technician Tips: The monitor system has three user
levels:
Level 1: Operator mode
Level 2: Field service mode (full lift truck operation)
Level 3: Analyzer / test mode (no lift truck operation)
This section includes Level 2 and Level 3 data. For
Level 1 data, see the Operator Manual and the ELEC-
TRICAL SYSTEM / Access 1 2 3® section. For menu
data, see the ELECTRICAL SYSTEM / Access 1 2 3®
section.
Crown 2010 PF25130 Rev. 11/21 M4.8-ITD-001
02 Rev. 11/21
405
Notes:
406
BRAKE
Brake
Brake Braking Force
There are two sources of drive wheel braking, a 3 step, When a brake request is made by releasing the brake
spring applied, electromagnetically released, friction pedal, switch BRS1, located below the platform floor is
disc brake on the drive motor armature shaft, and mo- activated. The ACCESS 123 system determines the
tor braking, typically called regenerative braking. amount of braking force to be applied. The braking
force is split between the motor regenerative braking
When a brake request is made the operator releases and the 3-step disc brake. The forward and reverse
the brake pedal, which activates a switch (BRS1). The brake force can be independently adjusted through the
ACCESS 123® system then determines the amount of display Module (ACCESS 1), (performance menu P6,
braking force to be applied based on the programmed Braking, submenus P6.1 FF Braking and P6.2 PUF
truck weight (includes battery and maximum allowable Braking).
fork load) and the maximum allowable speed for the
particular travel direction and fork height. The braking
force is split between the motor regenerative braking
and the 3 step friction brake. The motor regenerative
portion is made as large as practical in order to reduce
wear on the 3 step friction brake. The forward and re-
verse brake force can be further electronically adjusted
through the display in order to address tire slide for the
particular floor condition in the application.
Figure 23367
Crown 2007 PF15820-1 Rev. 2/10 M5.0-7335-001
03 Rev. 2/10
409
BRAKE
Brake
Brake Force Adjustment 7. To adjust brake force use the display module
(ACCESS 1), proceed to performance menu mode
1. Braking force should be checked under the follow- P6 braking. To adjust braking in FF direction select
ing conditions: P6.1 for PUF select P6.2. Adjusting to a higher
number will increase braking force (reduce stop-
– Forks lowered.
ping distance). Adjusting to a lower number will de-
– On a floor surface typical of application. crease braking force (increase stopping distance).
– Both forward and reverse travel directions.
– With and without a load. Brake Adjustment
2. Brake force should be adjusted to produce the
shortest possible stopping distance without caus- Air Gap Adjustment
ing the braking wheel to slide or the load to become The "air gap", referred to on this truck, is the distance
unstable. Setting the ACCESS 123 Braking Perfor- between the brake armature and the electromagnet
mance menus (P6.1 and P6.2) to 6 or 7 is typical body with brakes applied. Refer to Figure 18184-01. As
for a properly functioning brake system on smooth the brake pads and rotor wear normally, the air gap will
dry concrete floors. For reference, a typical stop- increase and should be readjusted, or parts checked
ping distance when traveling at 8 km/h (5 mph) in and replaced, when it exceeds 1.0 mm (0.040 in).
the power unit first direction, with no load is approx-
imately 2.1 meters (7.0 feet).
NOTE
3. If floor conditions are such that tire slide occurs or
If the air gap measures more than 1.0 mm (0.040 in),
a more/less aggressive stop is desired, braking
the brake may not release properly. If the brake pad
force can be increased or decreased with a corre-
thickness is less than 2.8 mm (0.110 in), the brake
sponding increase or decrease in stopping dis-
pads and rotor should be replaced.
tance.
The customer shall verify that the stopping dis- 1. Chock load wheels. Open power unit doors to ac-
tance in any part of the application doesn't prevent cess brake assembly.
the operator from performing a specific task safely,
2. Release brake, using drive/tow switch. Refer to
or result in braking characteristics that are signifi-
Control of Hazardous Energy section of this man-
cantly different from other similar vehicles being
ual.
used in the facility. An alternative is for the cus-
tomer to train the operator to reduce travel speed 3. Using low pressure air, remove any dirt between
and/or allow for longer stopping distances. armatures and magnet body.
4. If brake force adjustments are necessary, verify 4. With a 0.875 (7/8 in) open end wrench, loosen the
the settings in steps 5 and 6 before proceeding to top nut.
step 7.
5. Using a 1.125 (1 1/8 in) open end wrench, turn the
5. Through the display module (ACCESS 1), proceed 1.125 (1 1/8 in) hex nut down until the air gap is
to features mode starting at F5 and continue 0.13 mm (0.005 in) at its tightest location. One
through F11 to verify truck specifications. Informa- complete turn of the nut will change the gap
tion for these settings can be found on truck data 1.4 mm (0.056 in) or 1/6 (60 degrees) turn will
plate and capacity plate. change gap 0.235 mm (0.009 in).
6. Verify the drive brake torque gap setting is correct 6. Torque 0.875 (7/8 in) hex nut to 122 Nm (90 ft lb).
(refer to Brake Torque Gap for GVW chart).
7. Apply brake, using drive/tow switch.
8. Remove chocks and check operation.
M5.0-7335-002 Crown 2007 PF15820-2 Rev. 2/10
03 Rev. 2/10
410
BRAKE
Brake
Figure 18184-01
1 Drive Motor 7 Rotor
2 Torque Adjuster Plate 8 Brake Parts
3 Adjuster Disc 9 Armature
4 Electromagnet 10 Torque Adjuster Cap
5 Air Gap 11 1 1/8 in Hex Nut
6 Motor Shaft 12 7/8 in Hex Nut
Torque Gap Adjustment NOTE
The "torque gap", referred to on this truck, is the dis- Refer to the capacity plate for truck GVW as equipped
tance between the torque adjuster plate and the elec- with maximum battery and capacity load.
tromagnet. Refer to Figure 18184-01. The torque plate
is factory preset and no adjustment is required, how-
ever, through routine maintenance it may be necessary
to replace components and the gap may need to be
reset to factory specifications. The torque gap will vary
with each trucks Gross Vehicle Weight (GVW).
Crown 2007 PF15820-3 Rev. 2/10 M5.0-7335-003
03 Rev. 2/10
411
BRAKE
Brake
Chart 1 - Brake Torque Gap for GVW
Torque Gap GVW (capacity load and
maximum battery)
mm (in) kg (lb)
0.00 (0.00) greater than 6509 (greater than 14350)
0.51 (0.02) 6214 - 6508 (13700 - 14349)
1.02 (0.04) 5919 - 6213 (13050 - 13699)
1.52 (0.06) 5625 - 5918 (12400 - 13049)
2.03 (0.08) 5330 - 5624 (11750 - 12399)
2.54 (0.10) 5035 - 5329 (11100 - 11749)
3.05 (0.12) 4740 - 5034 (10450 - 11099)
3.56 (0.14) 4445 - 4739 (9800 - 10449)
4.06 (0.16) 4150 - 4444 (9150 - 9799)
4.57 (0.18) 3856 - 4149 (8500 - 9149)
5.08 (0.20) less than 3855 (less than 8500
M5.0-7335-004 Crown 2007 PF15820-4 Rev. 2/10
03 Rev. 2/10
412
BRAKE
Brake
Rotor and Brake Pad Replacement Brake Assembly
Tools are available from Crown to permit replacement Before assembling brake, inspect all components for
of the pads on the brake pad assembly. When used wear, grooves, nicks or other damage. If any abnormal
with a press, these tools allow the correct positioning of wear or damage appears that may affect brake opera-
the pads and correct setting of the rivets. A press is tion, replace with new parts. Assemble brake as fol-
required to insure the rivets provide the compression lows:
strength needed to keep brake pads stationary.
1. Turn torque adjuster plate down as far as possible
to reduce spring force. Place adjuster disc on
torque adjuster plate.
2. Apply a light coat of multipurpose grease
(063002-024) to the motor end cap threads and on
top of the torque adjuster plate.
3. Position magnet body on the motor so the coil
wires jack (JC407) can be connected to plug
PC407. Apply blue thread locking adhesive
(061004-026) to the three 0.312 in. (5/16 in)
screws and secure magnet to motor with screws.
4. Assemble springs, inner and outer armatures to
Figure 18186-02 magnet body. Apply a light coat of multipurpose
grease (063002-024) to entire bottom of brake pad
1 119343 Riveter Base plate assembly. Be careful not to contaminate
2 114518 Riveter brake pads with grease.
5. Install compression spring over armature shaft.
To disassemble rotor and brake pad assembly:
6. Slip rotor on motor shaft, hub first. Thread 1.125 in.
1. Block load wheels, disconnect battery and open
(1 1/8 in) hex nut onto motor shaft. Turn nut down
power unit doors.
until the rotor moves down and almost touches the
2. Disconnect brake connector CA407. brake pads. Proper air gap adjustment will be
made later.
3. Remove retaining ring, washers and two hex nuts.
7. Thread the 0.875 in. (7/8 in) hex nut onto motor
4. Remove rotor and brake pad assembly.
shaft. Add flatwasher(s) and install retaining ring
5. Follow Brake Assembly procedure when reassem- on motor shaft.
bling the brake.
8. Set torque adjuster gap to its original factory set-
ting. See torque gap adjustment procedures.
9. Connect wire harness to brake assembly (JC407
to PC407).
10. Adjust air gap. See air gap adjustment procedures.
11. Check brake operation and stopping distance. See
adjustment procedures in truck settings section of
this manual.
Crown 2007 PF15820-5 Rev. 2/10 M5.0-7335-005
03 Rev. 2/10
413
BRAKE
Brake
Figure 18189-01
1 Drive Motor 11 Brake Pad Assembly
2 Spring 12 1 1/8 in Hex Nut
3 5/16 in Screw 13 Flatwasher
4 Inner Armature 14 Retaining Ring
5 24 Volt Wire Position 15 7/8 in Hex Nut
6 Magnet Body 16 Rotor
7 Adjuster Disc 17 Brake Pad
8 Torque Adjuster Plate 18 Rivet
9 Screw 19 Outer Armature
10 Compression Spring
M5.0-7335-006 Crown 2007 PF15820-6 Rev. 2/10
03 Rev. 2/10
414
BRAKE
Brake
Chart 2 - Troubleshooting
Problem Probable Cause Remedy
Brakes will not release Air gap greater than 1.0 mm (0.040 in) Adjust
Open circuit in brake circuitry or wiring Inspect floorboard switches
and all associated wiring
Armatures movement restricted by dirt or Clean with low pressure air
foreign material
Brake drag Air gap less than 0.25 mm (0.010 in) Adjust
Brake pad mounting plate or rotor distorted Replace
Armatures movement restricted by dirt or Clean with low pressure air
foreign material
Brakes grab Incorrect stopping distance adjustment Adjust (Refer to performance
menu PUF brake and FF
brake)
Brake pad mounting plate or rotor distorted Replace
Brake dust or foreign material restricting Clean with low pressure air
movement
Stopping distance too long Incorrect stopping distance adjustment Adjust (Refer to performance
menu PUF brake and FF
brake)
Brake pads loose or soiled with grease Replace
Abnormal noise and chatter Brake pad mounting plate or rotor distorted Replace
when brakes applied
Brake pads worn out, loose, soiled with Replace
grease or foreign material embedded
Abnormal braking force for lift Rotor thin, cracked or spline worn Replace
height or brakes applied without
Wire Guide Trucks: Guide wire lost power or Troubleshoot wire guidance
request
truck off guide wire system
Open circuit in brake circuitry or wiring Check all switches and
associated wiring
Crown 2007 PF15820-7 Rev. 2/10 M5.0-7335-007
03 Rev. 2/10
415
STEERING
Steering
Steering
Steering Indicator
Lights Enhanced
with Optional LED
Access 1
Access 5
Figure 18207
The electronic power steering utilizes a servo motor to Steering Direction
steer the drive wheel. Movement of the steering wheel
turns the steering command encoder (ECR1) anc The truck will turn in the direction the steering wheel is
ECR5 which sends data to the platform Access 1 dis- rotated when traveling forward or power unit first direc-
play module (DCM). This information is converted to a tion. If your truck is equipped with wire guidance, the
direction, rate and position signal. This information is truck will be automatically steered once the guide wire
compared with the position and direction information is acquired. Refer to Electrical Maintenance for wire
that is received from the power unit steering feedback guidance operation.
encoder (ECR2). A composite signal representing the
difference is calculated in the power unit Access 5
steer control module (SCM) and is then applied to the
steering motor (M2). Travel speed and lift height may
be limited in relation to steer wheel position.
Crown 2007 PF15821-1 M6.0-7335-001
227
STEERING
Steering
Steering Wheel Direction Indicator The second and third indicator on either side being
glowing indicates a steer angle between 35 and 60 de-
Optional five indicator lights around the power unit end grees in the indicated direction. When the third indica-
of the truck image on the display panel provide a visual tor on either side of the center indicator is the only indi-
indication of approximate steer wheel turn angle. When cator "ON", the steer angle is between 60 and 90
the center indicator only is glowing green, the angle of degrees.
the steered wheel from straight ahead is within ± 1 de-
Steering will be limited to no more than 10 degrees of
gree. If the center indicator and first indicator to either
straight ahead if the forks are raised 4570 mm (180 in)
side of the center are glowing, the steered wheel angle
or more. An alarm will sound and a message will be
is between 1 and 9 degrees in the indicated direction.
displayed (on the display panel) informing you that
The first indicator next to the center indicator being the
steering is limited.
only indicator "ON" indicates steered wheel position
between 10 and 34 degrees in the indicated direction. If steering is positioned beyond 10 degrees of straight
ahead and raise is selected, an alarm will sound notify-
ing you that raise is limited to 4570 mm (180 in). A
message will be displayed (on the display panel) in-
forming you that lift is limited to 4570 mm (180 in). To
raise the forks higher, you must steer the truck no more
than 10 degrees from straight ahead travel.
CAUTION
If the drive tire is physically turned while the truck is
"OFF", on power up, the steering indicators will not rep-
resent the proper steer angle. The steering wheel must
be rotated so drive unit and encoder pass through in-
dex to reset the electronics.
Steer Angle Indicator
Figure 3303-02
M6.0-7335-002 Crown 2007 PF15821-2
228
STEERING
Steering
Steering Wheel Adjustment ment to this friction block. If the steering wheel rotates
after the operator removes his hand, then the friction
To prevent the steering wheel from rotating "Free block needs to be replaced. This is located behind the
Wheeling", after the operator's hand has been re- steering wheel. To gain access, you must first remove
moved, a friction block is used to keep the steering the six screws securing the console cover on. With the
wheel from rotating. The friction block is tightened cover removed, the steering command assembly will
against the steering wheel shaft. There is no adjust- be visible. Refer to Figure 17865.
Part of
Platform
Figure 17865
Crown 2007 PF15821-3 M6.0-7335-003
229
STEERING
Steering
Steering Motor Gearbox
The steering motor gearbox should be filled to the level
indicator plug on the end of the gearbox with DTE 24
lubricant. Capacity of the gearbox is 0.95 liter (2 pints).
Refer to Figure 3246-01.
Fill Plug
Level Indicator Plug
Figure 3246-01
M6.0-7335-004 Crown 2007 PF15821-4
230
LIFTING MECHANISM
Mast
Mast Shim Basics
Your truck has a TL or TT mast assembly. Refer to the The mast is made to be at its tightest point when it fully
applicable mast type below for more description. extends and loosest when it fully lowers. This allows
the mast column rollers to move freely as the mast ex-
TL Mast tends and supplies better stability. Each mast is wider
at the bottom than the top. If the installed mast shims
(The TL Mast is not available on SP3570/80/71/81) cause the mast to be tight when it is fully lowered, it will
The TL mast is a two-stage mast assembly and uses not fully extend because of mast channel to column
two lift cylinders. The cylinders attach to the bottom of roller binding at approximately 75% of lift height. This
the mainframe and the top of the 2nd stage mast. The will cause damage to the mast channel. Only check the
lift chain is secured to a chain anchor at the top of the mast for tightness when near full extension.
mainframe, routed over the 2nd stage mast, and se- Shims are usually 0.8 mm (0.031 in) thick.
cured to a second chain anchor at the bottom of the
platform. Refer to LIFTING MECHANISM PARTS/Mast It is best to have an equal number of shims on each
- TL for lift chain routing. column roller stud. This is not possible all the time. If
the number of shims is not equal, it is very important to
The control cables are routed from the distribution have an equal distribution of shims for each side. Refer
panel in the power unit, to the top of the mainframe and to Figure 1. For example, two shims on each roller stud
over the top of the 2nd stage mast through a series of of the left column rollers and one each on the right side
pulleys, and secured on the platform. The control ca- column roller studs. If the shims are not equally distrib-
bles connect to CA104 and CA106 on the platform. Re- uted for each side, the mast will tilt. Refer to Figure 2.
fer to ELECTRICAL PARTS/Control Cable - TL Mast
for control cable routing.
TT Mast
The TT mast is a three-stage mast assembly and uses
two lift cylinders. The cylinders attach to the bottom of
the mainframe and to the top of the 2nd stage mast.
The free lift cylinder mounts to the bottom of the 3rd
stage mast. The lift chain is secured to a chain anchor
at the top of the mainframe, routed over the 2nd stage
mast, and secured to a second chain anchor at the bot-
tom of the 3rd stage mast. A second lift chain is se-
cured in the middle of the 3rd stage mast, routed over
the free lift cylinder yoke, and secured by a second
chain anchor at the bottom of the platform. Refer to
LIFTING MECHANISM PARTS/Mast - TT for the lift
chain routing.
The control cables are routed from the distribution
panel in the power unit, to the top of the mainframe and
over the top of the 2nd stage mast. Control cables are
then routed through a series of pulleys attached to the
bottom of the 3rd stage mast and routed over the yoke
of the free lift cylinder to the platform. The control ca-
bles connect to CA104 and CA106 on the platform. Re-
fer to ELECTRICAL PARTS/Control Cable - TT Mast
section for control cable routing.
A hydraulic hose connects to a T-fitting at the bottom of
the left lift cylinder and is routed over the top of the 2nd
stage mast, down to the bottom of the free lift cylinder
on the 3rd stage mast. Refer HYDRAULIC PARTS for
hydraulic hose routing.
Crown 2007 PF15797-1 Rev. 4/13 M7.0-7335-001
01 Rev. 4/13
39
LIFTING MECHANISM
Mast
1 1
2 3
2
3 4
3 2
4 5
5 6
5
4
Fig. 1 (17001-01)
1 Part of Platform Fig. 2 (17002-02)
1 Part of Platform
2 Not Adjustable
2 2 Shims (Platform)
3 1 Shim (Platform)
3 1 Shim (Platform)
4 2 Shim (Platform)
4 2 Shims (Mast)
5 2 Shim (Mast)
5 1 Shim (Mast)
6 1 Shim (Mast)
M7.0-7335-002 Crown 2007 PF15797-2 Rev. 4/13
01 Rev. 4/13
40
LIFTING MECHANISM
Mast
General Repair and Safety Instruc- move the grease and dry it with a clean cloth, then
spray the channel with a thin layer of paint.
tions This will let you see where the column rollers
travel.
4. Operate the mast.
WARNING 5. Inspect the mast channel again.
Incorrect or missing safety procedures or equip- 6. Repeat as required.
ment can cause death or injury.
You must use the correct protective equipment and
obey all safety procedures to do work on a truck. If you
do not, injury can result.
Refer to and obey all recommended safety precau-
tions in the applicable Crown Service Manual.
Use the correct protective items, such as safety
glasses, work gloves, and steel-toed shoes.
WARNING
Stay clear of all moving parts.
Moving parts can cut or crush hands, feet, arms, or
legs.
Keep your hands and feet away from all moving
parts such as masts, chains, forks, or wheels. 1
Make sure that the overhead guard and load back-
rest are in position. Fig. 3 (28023)
1 Channel should only show wear here
7. When the mast is within the tolerance require-
Mast Testing (Assembled) ments, apply a thin layer of grease to the mast
Use the tests that follow to check the mast when it is channels.
fully assembled. Checking the Mast Vertically
Checking the Column Roller Tracks 1. Extend the mast to near full extension.
1. Clean the mast channels. It is to be level and straight and not tilt to the left
or right. If the mast tilts to the left or right, the
2. Inspect the roller path wear in each mast channel. shimming is too loose or not balanced and it will
The only area that should show wear is the rear be necessary to adjust it. Refer to MAST/Mast
part of the I-beam where the column roller travels. Testing (Assembled)/Shim Measurements (Tol-
Refer to Figure 3. The I-beam should not have erances).
nicks or grooves. Nicks or grooves will usually oc-
cur at the side of the column roller, 10 mm
(0.375 in) from the channel face.
If you find incorrect wear, remove shims to make
the necessary adjustments. Refer to MAST/
Shim Removal (Mast Assembled), then con-
tinue with step 3.
If there is no incorrect wear, then continue to
step 7.
3. Check the mast channel again. To see the new
wear path, clean the channel with a solvent to re-
Crown 2007 PF15797-3 Rev. 4/13 M7.0-7335-003
01 Rev. 4/13
41
LIFTING MECHANISM
Mast
Shim Measurements (Tolerances) MAST/Mast Column Rollers and Shims/Shim
Installation in this chapter.
Check the travel and clearance of the mast column roll- If the dimension is 0.000 and it does not appear
ers with the mast assembled. to be too tight, continue to check the remaining
column rollers.
Note: Refer to MAST/Mast Testing (Assembled)/
WARNING Checking the Column Roller Tracks to determine if it is
necessary to remove shims from the column rollers
Stay clear of all moving parts.
with a 0.000 clearance.
Moving parts can cut or crush hands, feet, arms, or
legs.
Keep your hands and feet away from all moving
parts such as masts, chains, forks, or wheels.
Make sure that the overhead guard and load back-
rest are in position.
1. Fully extend the mast.
The reason the mast must be raised is to bring
it to its tightest point. When fully lowered, the
mast is at its loosest point.
2. Lower the mast so the column rollers are 25.4 mm
(1.0 in) away from the stops.
This will ensure that the mast does not twist.
1 2
CAUTION
Falls can cause injury or death.
Make sure that the platform the technician rides on Fig. 4 (17007-02)
is secure and that the technician uses an operator 1 Pry-bar
harness. 2 Feeler Gauge
7. Check the platform column roller measurements.
3. Use a man-up vehicle to check all the mast column Refer to PLATFORM.
rollers (four on TL masts and eight on TT masts).
4. Use a pry-bar to move and hold the mast channels Flaking
to one side. It is not unusual for a new mast to look as if it is flaking
This will force the opposite side tight against the or peeling. This shows that the column rollers are seat-
mast channel. ing to the softer mast channels. This condition is nor-
Note: This is necessary to seat each column roller mal and will go away. Grease applied to the mast chan-
against the roller stud shoulder to allow for an accurate nel will hold these particles. You can clean the mast to
clearance measurement of the column roller to the remove the particles.
channel.
5. Keep pressure on the pry-bar to keep the mast to
one side.
6. Refer to Figure 4. Use a feeler gauge to measure
the distance between the channel and the column
roller, 10 mm (0.375 in) from the channel face. Al-
ways measure from the side to which the column
rollers are tilted.
If the dimension is more than 0.8 mm (0.031 in),
add a shim behind the column roller. Refer to
M7.0-7335-004 Crown 2007 PF15797-4 Rev. 4/13
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LIFTING MECHANISM
Mast
Mast Column Rollers and Shims
Removing the Mast Column Rollers - TL
Mast
(The TL Mast is not available on SP3570/80/71/81)
Before you start the removal of the mast column rollers
to add shims, read the Shim Basics and Mast Testing
sections of this chapter. To determine where shims are
necessary on the mast, you must fully extend the mast
and check each column roller for correct tolerance. Re-
fer to MAST/Mast Testing (Assembled)/Shim Measure-
ments (Tolerances) in this chapter.
Prepare the truck
1. Move the truck to a maintenance area with a level
floor and sufficient overhead clearance to fully ex-
tend the mast.
2. Turn the truck OFF.
3. Attach a lift device to the truck. Make sure that the
lift device capacity is sufficient. Refer to Chart 1 for
the weights.
Chart 1
Component(s) Weight 1 2 1 3
kg lb Fig. 5 (10066-03)
TL Mast Assembly 800–1100 1750–2350 5. Lockout/tagout the truck. Refer to SAFETY/Control
of Hazardous Energy/Lockout/Tagout in the Ser-
Platform with Forks 500–750 1100–1650
vice and Parts Manual.
Power Unit with Battery 1650–1900 3640–4130 6. Disconnect the battery.
4. Refer to Figure 5. Raise the truck 150 mm (6.0 in). Get access to the column rollers
Put a block (1) below each outrigger (3) and below 7. Remove the screws that secure the top of the lift
the power unit (2). Do not put blocks below the wire cylinders (2, Figure 6) to the 2nd stage mast (1).
guidance sensors if they are on the truck.
Crown 2007 PF15797-5 Rev. 4/13 M7.0-7335-005
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LIFTING MECHANISM
Mast
14. Put blocks (2, Figure 8) below the platform (1).
Fig. 6 (17003-02)
1 Top of 2nd Stage Mast
2 Lift Cylinders
2
8. Loosen the screws that secure the bottom of the lift
cylinders to the mainframe.
Fig. 8 (10064-03)
9. Attach a lift device to the 2nd stage mast.
10. Raise the 2nd stage mast approximately 40 mm 15. Attach a lift device to the 2nd stage mast.
(1.5 in). 16. Lower the 2nd stage mast to get access to the col-
11. When the top of the mast is above the lift cylinders, umn rollers at the bottom of the 2nd stage mast
tilt the lift cylinders (1, Figure 7) in towards the mid- and the column rollers at the top of the mainframe.
dle of the truck. Note: Column rollers at the bottom of the 2nd stage
mast have a larger diameter. Make sure that these col-
umn rollers are only installed on the bottom of the 2nd
stage mast.
Remove the column rollers
1 1
17. Carefully remove the column rollers and record the
number of shims on each roller stud.
Note: Shims can cling to the back of the column rollers
and fall off after removal.
18. Refer to MAST/Mast Columns Rollers and Shims/
Shim Installation for the correct shim installation
procedures.
Fig. 7 (28022)
12. Attach a lift device to the platform.
13. Raise the platform 75–130 mm (3.0–5.0 in).
M7.0-7335-006 Crown 2007 PF15797-6 Rev. 4/13
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LIFTING MECHANISM
Mast
Removing the Mast Column Rollers - TT
Mast
Before you start the removal of the mast column rollers
to add shims, read the Shim Basics and Mast Testing
sections of this chapter. To determine where shims are
necessary on the mast, you must fully extend the mast
and check each column roller for correct tolerance. Re-
fer to MAST/Mast Testing (Assembled)/Shim Measure-
ments (Tolerances) in this chapter.
Prepare the truck
1. Move the truck to a maintenance area with a level
floor and sufficient overhead clearance to fully ex-
tend the mast.
2. Turn the truck OFF.
3. Attach a lift device to the truck. Make sure that the
lift device can lift the weights involved. Refer to
Chart 2 for the weights.
Chart 2
Component(s) Weight
kg lb
TT Mast Assembly 1050–1850 2350–4100 1 2 1 3
Platform with Forks 500–750 1100–1650
Fig. 9 (10066-03)
Power Unit with Battery 1650–1900 3640–4130
5. Lockout/tagout the truck. Refer to SAFETY/Control
4. Refer to Figure 9. Raise the truck 150 mm (6.0 in) of Hazardous Energy/Lockout/Tagout in the Ser-
and put a block (1) below each outrigger (3) and vice and Parts Manual.
below the power unit (2). Do not put blocks below 6. Disconnect the battery.
the wire guidance sensors if they are on the truck.
Get access to the column rollers
7. Attach a lift device to the 3rd stage mast.
8. Raise the 3rd stage mast to loosen the lift chain
attached to the chain anchors on the 3rd stage
mast.
9. Remove the nuts from the chain anchors (2,
Figure 10) at the top of the mainframe (1).
Crown 2007 PF15797-7 Rev. 4/13 M7.0-7335-007
01 Rev. 4/13
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LIFTING MECHANISM
Mast
1
2
1
2
Fig. 11 (17006-02)
Fig. 10 (17005-02) 1 Top of 2nd Stage Mast
2 Lift Cylinders
10. Remove the chain anchors (2) and secure them to
one side. 3 Hydraulic Hose Guide (TT Only)
11. Remove the control cable pulleys and free lift hose 15. Remove the hydraulic hose guide (3) on the left lift
pulley on the 2nd stage mast and secure them to cylinder and secure it to one side.
one side. 16. Loosen the screws that secure the bottom of the lift
cylinders to the mainframe.
17. Attach a lift device to the 3rd stage mast.
WARNING 18. Raise the 3rd stage mast 75–130 mm (3.0–5.0 in).
Keep your hands and feet clear of the platform 19. Put blocks (2, Figure 12) below the 3rd stage mast
when you lower the platform. (1).
When the platform is fully lowered, it will be on top of Note: The 3rd stage mast and platform are connected.
the outriggers When you raise the 3rd stage mast, the platform will
also raise.
12. Lower the 3rd stage mast to get access to the col-
umn rollers on the bottom of the 3rd stage mast
and the top of the 2nd stage mast.
13. Carefully remove the column rollers and record the
number of shims on each roller stud.
Note: Shims can cling to the back of the column rollers
and fall off after removal.
14. Remove the screws that secure the top of the lift
cylinders (2, Figure 11) to the 2nd stage mast (1).
M7.0-7335-008 Crown 2007 PF15797-8 Rev. 4/13
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LIFTING MECHANISM
Mast
1 2
3
1 Fig. 14 (17004-02)
2 1 Bottom of 2nd Stage Mast
2 Shims 0.80 mm (0.03 in) AR
Fig. 12 (10067-03)
3 Column Rollers, 115 mm (4.5 in) in Diameter
20. Attach a lift device to the 2nd stage mast.
Note: Column rollers at the bottom of the 2nd stage
21. Raise the mast approximately 40 mm (1.5 in). mast have a larger diameter. Make sure that these col-
22. When the top of the mast is above the lift cylinders, umn rollers are only installed on the bottom of the 2nd
tilt the lift cylinders (1, Figure 13) in towards the stage mast.
middle of the truck.
Remove the column rollers
24. Carefully remove the column rollers and record the
number of shims on each roller stud.
Note: Shims can cling to the back of the column rollers
1 1 and fall off after removal.
25. Refer to MAST/Mast Columns Rollers and Shims/
Shim Installation for the correct shim installation
procedures.
Shim Installation
1. To add shims, you must remove the column roller
(3, Figure 15) and add the necessary shims (2) be-
hind the column roller on the roller stud (1). Refer
to MAST/Mast Column Rollers and Shims/Remov-
ing the Mast Column Rollers.
Fig. 13 (28022)
23. Lower the 2nd stage mast to get access to the col-
umn rollers at the bottom of the 2nd stage mast
and the column rollers at the top of the mainframe.
Crown 2007 PF15797-9 Rev. 4/13 M7.0-7335-009
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LIFTING MECHANISM
Mast
6. Remove the shim from the roller stud.
1
2
Fig. 15 (17000-02)
1 Top of Mainframe
2 Shims 0.80 mm (0.03 in) AR
1
3 Column Roller, 100 mm (4 in) Diameter
Fig. 16 (3329-02)
Shim Removal (Mast Assembled)
It can be necessary to remove shims after the mast is Mast Removal
assembled. When it is necessary to remove shims, re- You can remove the mast assembly and platform from
fer to the procedures that follow. the truck as one unit. If you have to remove the platform
Removing Shims from the Top Column first, refer to the Platform chapter and Control of Haz-
ardous Energy Lockout/Tagout for platform removal
Rollers procedures.
Refer to Figure 16 Prepare the truck
1. Fully lower the mast. 1. Move the truck to a maintenance area with a level
2. Use a pry bar to push the column roller out. floor.
3. Push the shim (1) away from the remaining shims. 2. Raise the platform and remove the forks.
4. Use a hammer and small chisel to break the shim. 3. Fully lower the platform.
5. Remove the shim from the roller stud. 4. Turn the truck OFF.
Removing Shims from the Bottom Column 5. Lockout/tagout the truck. Refer to SAFETY ►Con-
trol of Hazardous Energy/Lockout/Tagout in the
Rollers
Service and Parts Manual.
Refer to Figure 16 6. Put a chock against the drive tire to prevent the
1. Attach a lift device to the mast. movement of the truck.
2. Raise the mast so you have access to the applica- 7. Remove the battery from the truck. Refer to
ble column roller. SAFETY/Control of Hazardous Energy/Battery Re-
3. While you support the mast, put blocks below the moval in the Service and Parts Manual.
mast to keep it at the correct height. Refer to 8. Use a lift device to raise the truck.
SAFETY/Control of Hazardous Energy/Lifting and
Blocking.
4. Push the shim (1) away from the remaining shims.
5. Use a hammer and small chisel to break the shim.
M7.0-7335-010 Crown 2007 PF15797-10 Rev. 4/13
01 Rev. 4/13
48
LIFTING MECHANISM
Mast
CAUTION
Incorrect blocking can cause damage to the power
unit.
The power unit, if not blocked correctly, will fall to the 1
floor when you remove the mast assembly.
Put blocks below the power unit so that it remains
parallel with the floor.
9. Put blocks below the power unit and the main-
frame, on both sides of the truck, so the load
wheels are just off the floor.
Fig. 18 (10587-02)
11. Attach a lift device to the strap or chain and apply
tension to the strap or chain.
Disconnect the hydraulics and electrical connec-
tions
1 2 12. Disconnect hydraulic hoses to the lift cylinders and
be prepared to catch hydraulic oil left in the hoses.
Fig. 17 (17008-02) 13. Secure the hydraulic hoses out of the way.
1 Wheel chock 14. Disconnect the control cables connected to the
2 Hardwood blocks power unit. Record the location and routing of the
cables.
10. Refer to Figure 18. Attach a strap or chain (1) to all
of the crossbraces to lift all the mast sections at the 15. Disconnect the limit switches from the distribution
same time. panel, if applicable.
16. Secure the limit switches out of the way.
Remove the mast and platform
Note: There could be shims between the power unit
and the mainframe.
Crown 2007 PF15797-11 Rev. 4/13 M7.0-7335-011
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49
LIFTING MECHANISM
Mast
17. Record the number of shims and their locations. Prepare the truck for operation
You will have to install the shims in the same loca- 9. Lift the truck and remove the blocks below the
tion when you install the mast assembly. power unit and the mainframe.
18. Remove the six screws, related lockwashers, and 10. Install the battery in the truck.
the four nuts that secure the mainframe to the
11. Disconnect the lift device from the truck.
power unit. Keep the shims in groups and record
their locations. 12. Remove the strap or chain from the mast cross-
braces.
19. Lift and remove the mast assembly and platform.
13. Remove the chock from the drive tire.
Mast Installation 14. Turn the truck ON.
Install the mast and platform 15. Raise the platform.
1. Refer to Figure 19. Move the mast assembly and 16. Install the forks.
platform into position near the power unit and align 17. Lower the platform.
the applicable holes in the mainframe (1) to the 18. Bleed the hydraulic system. Refer to Mast Cylinder
power unit (2). Installation and Free Lift Cylinder Installation in the
Service and Parts Manual for the correct proce-
dures.
6
3
2
4 3
Fig. 19 (28024)
2. Apply thread-locking adhesive to the screw (3)
threads.
3. Install the six screws (3), related lockwashers (4),
and the four nuts (5) that secure the mainframe (1)
to the power unit (2).
4. Install the shims (6) that you removed during the
mast removal procedure. Make sure that you in-
stall the shims in the correct locations.
5. Torque the screws to 325–353 Nm (240–260 ft lb).
Connect the electrical connections and hydraulics
6. Connect the limit switches that you disconnected
during the mast removal procedure.
7. Connect the control cables. Make sure the routing
is correct.
8. Connect the hydraulic hoses to the lift cylinders.
M7.0-7335-012 Crown 2007 PF15797-12 Rev. 4/13
01 Rev. 4/13
50
LIFTING MECHANISM
Lift Chain
Lift Chain Cleaning and lubricating the lift
Correct lift chain maintenance is necessary for the safe
chain
operation of the lift truck. It is necessary to do intermit- See the INSPECTION AND LUBRICATION section for
tent maintenance on the lift chains for the maximum the applicable lubricant and planned maintenance in-
service life. Incorrect maintenance intervals can cause tervals for the lift truck.
unsatisfactory lift chain performance.
Note: The frequency of lubrication changes with the
conditions of operation and environment.
WARNING Cleaning the lift chains
Note: The initial factory lubricant on the lift chains pre-
Falling loads can cause injury.
vents corrosion. Do not clean or remove the lubricant
Lift chains, chain anchors, chain pins, and their attach-
from the new lift chains.
ments are safety components. Their failure can cause
the load to fall, causing serious injury or death. Lubricating the lift chain
Replace damaged lift chains and their components Lubricate the lift chains at the specified maintenance
with original spare parts before returning the lift intervals for maximum service life. A layer of lubricant
truck to operation. between the chain components and on all lift chain sur-
Always replace lift chains in pairs. faces is necessary to:
– Decrease the wear on the joint
– Prevent corrosion
WARNING
– Decrease the frequency of turned pins
Cracks in the lift chains can cause injury – Decrease tight joints in the roller chain
Incorrect cleaning can cause cracks in the lift chain and – Cause smooth lift chain movement
can result in serious injury or death.
– Decrease the lift chain tension
Do not clean lift chains with steam, cold cleaning
agents, or agents that cause corrosion. This can Special tools and equipment:
damage the lift chains. – Crown chain and cable lubricant,
Clean the lift chains only with Crown chain and ca- P/N 363107-001
ble lubricant or Crown Premium chain and cable lu- – Crown premium chain and cable lubricant,
bricant. P/N 363115-001
1. Spray the lubricant onto the lift chain.
2. See Figure 1. The oil must go into the lift chain
joints (1).
WARNING – Lubrication on the lift chain and in the joints pre-
Incorrect or missing safety procedures and safety vents wear and provides maximum service life.
equipment can cause death or injury.
Use the correct protective equipment and obey all
safety procedures to do work on a lift truck.
Obey all recommended safety precautions in the
applicable Crown Service Manual.
Use the correct protective items, such as eye pro-
tection, work gloves, and safety-toe shoes.
Crown 2020 PF5856 Rev. 2/20 M7.5-18.0-001
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147
LIFTING MECHANISM
Lift Chain
Fig. 1 (33490)
Inspecting the lift chain
See the INSPECTION AND LUBRICATION section for
the applicable lubricant and planned maintenance in-
tervals for the lift truck.
Checking the lift chains for wear Fig. 2 (33491)
Special tools and equipment: 4. Replace the lift chain if the elongation is more than
3% or will be more than 3% before the next main-
– Chain wear scale, P/N 106440, or steel tape
tenance interval.
measure
– Do not repair a chain link by removing a worn
As the lift chain bends on and off the pulleys, the joints section of a lift chain and installing a new piece.
gradually wear. Material wears off the outside diameter
– If the lift truck has two lift chains, replace both lift
of the pin and the inside diameter of the holes for the
chains at the same time.
pins on the inner plates. This wear causes the lift chain
to elongate. – If a part of the lift chain is worn, replace both lift
chains at the same time.
Measuring the lift chains for wear with a chain wear
scale
1. Raise the forks 152 mm (6 in).
2. Select a section of the lift chain that moves over a
pulley during operation.
3. See Figure 2. Measure the lift chain with a chain
wear scale (1).
– Use Scale A for lift chains with a pitch of 19 mm
(0.75 in) or 25 mm (1.0 in)
– Use Scale B for lift chains with a pitch of 16 mm
(0.625 in)
Note: The pitch is the distance between the pins.
M7.5-18.0-002 Crown 2020 PF5856 Rev. 2/20
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148
LIFTING MECHANISM
Lift Chain
Measuring the lift chains for wear with a steel tape Checking the lift chain elongation
measure 1. Using the chain link number found in the Lift Chain
1. Raise the forks 152 mm (6 in). Wear table, count the chain links on the lift truck.
2. Select a section of the lift chain that moves over a 2. See Figure 3. Measure the length (2) from the cen-
pulley during operation. ter of the first chain pin to the center of the last
3. See Figure 3. Measure the lift chain pitch (1) from chain pin.
the center to the center of two chain pins of an Note: The pitch is the distance between the pins.
outer plate. 3. Calculate the percent of lift chain elongation (x).
Percent of the lift chain elongation = [measured
length /(new length/100)]-100
Example: The lift chain pitch is 25 mm (1.0 in). The Lift
Chain Wear table shows that the new length for this lift
chain pitch is 305 mm (12.0 in). The measured length
with the steel tape measure is 309 mm (12.2 in).
x = [309 / (305 / 100)] - 100
x = 309 / 3.05 - 100
x = 101.3 - 100
x = 1.3
In this example, the lift chain elongation is 1.3%.
4. Replace the lift chain if the elongation is more than
3% or if it will be more than 3% before the next
maintenance interval. See the Lift Chain Wear ta-
ble.
– Do not repair lift chains by removing a worn sec-
tion of a lift chain and installing a new piece.
– If the lift truck has two lift chains, replace both lift
chains at the same time.
– If a part of the lift chain is worn, replace both lift
chains.
Fig. 3 (33492)
4. See the pitch value in the Lift Chain Wear table to
find the number of chain links that are necessary
for the measurement.
Lift Chain Wear
New
Pitch Wear Limit
Chain Length
Links
mm in mm in mm in
25.4 1.0 12 305 12.0 314 12.375
19.05 0.75 16 305 12.0 314 12.375
15.88 0.625 20 318 12.5 327 12.875
Crown 2020 PF5856 Rev. 2/20 M7.5-18.0-003
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LIFTING MECHANISM
Lift Chain
Checking the lift chains for damage
Lift Chain Inspection
Damage Example Damage and Symptom Cause Solution
Noise • Insufficient lubrication in 1. Check the lift chain
• Mild squeaking or loud the lift chain joints elongation.
creaking during opera- • When the lift chain goes • If the lift chain is within
tion over the pulley the move- the tolerance level,
ment in the joints causes clean and lubricate the
friction. lift chain.
• If the lift chain elonga-
tion is out of the toler-
ance level, replace the
lift chain.
Joint corrosion • Insufficient lubrication 1. Replace the lift chain.
• Red or brown color (1) • Grease or oils that do not 2. Lubricate the lift chain.
in the joint area go into the joint 3. Increase the frequency
of the planned mainte-
nance intervals.
1
Surface corrosion • Insufficient lubrication or 1. Remove the corrosion
• Red or brown color (2) anti-corrosion from the lift chain with
on the connecting the correct cleaning
plates agent.
• If it is not possible to re-
2
move the corrosion, re-
place the lift chain.
2. Check the lift chain for
pitting and other corro-
sion.
• If other pitting is found
or corrosion, replace the
lift chain.
3. Increased frequency
for planned mainte-
nance intervals is nec-
essary because of the
conditions in the oper-
ating environment.
Images and technical information provided with the permission of Rexnord Kette GmbH • www.rexnord.com
Figures 28009, 28010, 28011, 28012, 28013, 28014, 28015, 28016, 28017, 28018, 28019, and 28020 are used in this table.
M7.5-18.0-004 Crown 2020 PF5856 Rev. 2/20
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LIFTING MECHANISM
Lift Chain
Lift Chain Inspection
Damage Example Damage and Symptom Cause Solution
Rigid joints • Insufficient lubrication 1. Replace the lift chain.
• The lift chain joints do 2. Increase the frequency
not return to the ex- of the planned mainte-
3 tended position easily. nance intervals.
Turned lift chain pins • Insufficient lubrication 1. Replace the lift chain.
4 • One or more chain Note: Turned chain pins are 2. Increase the frequency
pins (4) turned. a result of rigid joints. of the planned mainte-
nance intervals.
Loose lift chain pins • Insufficient lubrication 1. Replace the lift chain.
• One or more chain Note: Loose chain pins are a 2. Increase the frequency
pins (5) are protruding. result of rigid joints. of the planned mainte-
5 nance intervals.
Too much outer wear • The lift chain is not 1. Measure the width of
• The outer plates (6) aligned correctly and is the wear zone and cal-
are worn down. operating against mast culate the percentage
sections or at the side of of wear in relation to
6 the pulley. the overall width of the
• The lift chains tension is plate.
not equal. • If the wear is greater
than or equal to 5% of
the full width, replace
the lift chain. Correct the
alignment of the lift
components and pul-
leys after replacing.
• If the wear is less than
5% of the full width, cor-
rect the alignment of the
lift components and the
pulleys.
Nicks or distortion • The lift chain hits against 1. Remove the cause of
• Parts of the lift chain parts of the mast. the nicks or distortion.
have nicks (7) or are 2. Replace the lift chain.
distorted.
Images and technical information provided with the permission of Rexnord Kette GmbH • www.rexnord.com
Figures 28009, 28010, 28011, 28012, 28013, 28014, 28015, 28016, 28017, 28018, 28019, and 28020 are used in this table.
Crown 2020 PF5856 Rev. 2/20 M7.5-18.0-005
10 Rev. 2/20
151
LIFTING MECHANISM
Lift Chain
Lift Chain Inspection
Damage Example Damage and Symptom Cause Solution
Broken plates • Fatigue crack because of 1. Find and correct the
• The head section of overload cause of the overload.
the plate is missing or • Corrosion 2. Replace the lift chain.
8 the crack is protruding.
Broken pins • Pitting on the pins be- 1. Replace the lift chain.
• The outer plate (9) is cause of corrosion. Pit- 2. Increase the frequency
9 ting permanently
lifted out a small dis- of the planned mainte-
tance damages the pin. nance intervals.
Note: These defects are
not easy to see in the ini-
tial stages of inspection.
Contamination • Incorrect lubricant used. 1. Clean the lift chain and
10 • A thick layer of dirt • The lift chain was not check for damage.
mixed with oil or cleaned before lubrica- • If the lift chain is not
grease (10) is on the tion. damaged, lubricate it
lift chain. with the correct lubri-
cant.
• Replace the lift chain if it
is damaged.
2. Increase the frequency
of the planned mainte-
nance intervals.
Hydrogen absorption • The lift chain came into 1. Replace the lift chain.
11 • Non-distorting brittle contact with hydrogen. 2. Check the operating
fracture (11), only on Note: Electrolysis always conditions for sources
the outer plate makes hydrogen. Solvents of hydrogen.
made with chlorine also emit 3. See the cleaning the lift
hydrogen. chains for instructions.
Lift chain elongation • Wear caused by move- 1. Replace the lift chain.
• The lift chain elonga- ment in the joints. Note: Check if increasing
tion check found the lift Note: This type of wear is the frequency of the
chain to be out of the typical. planned maintenance inter-
tolerance level. vals can increase the life of
the lift chain.
Images and technical information provided with the permission of Rexnord Kette GmbH • www.rexnord.com
Figures 28009, 28010, 28011, 28012, 28013, 28014, 28015, 28016, 28017, 28018, 28019, and 28020 are used in this table.
M7.5-18.0-006 Crown 2020 PF5856 Rev. 2/20
10 Rev. 2/20
152
LIFTING MECHANISM
Lift Chain
Replacing the lift chain 1. Use the grinding wheel to remove the top head of
the pin (4) flush with the pin link plate (1). Be care-
1. Find the part number for the lift chain in the service ful not to damage the pin link plate.
and parts manual. Make sure that the replacement
2. Put the flat washer (2) above the opening of the
lift chain is applicable to the lift truck.
work surface.
Note: The lift chains must be replaced as a pair. Equal
– The flat washer holds the bottom pin link plate (1)
lift chain tension cannot easily be kept between the
new lift chain and the existing lift chain. and prevents damage to the lift chain compo-
nents while pushing the pin through the lift chain.
2. If the lubricant dried or there is no lubricant, soak
the new lift chains in heavy engine oil for a mini- 3. Put the lift chain on its side and seat the pin in the
mum of 30 min before installing. flat washer (2).
3. After removing the existing lift chains from the 4. Remove the pin from the lift chain through the top
mast, carefully examine the chain anchors and pul- pin link plate (1).
leys.
4. Replace the chain anchors that are broken,
cracked, or are worn. 3
5. Replace the pulleys that are worn and examine the
pulley bearings for wear. 1
4
6. Do not paint the new lift chains.
7. Install the new lift chains with new pins. Do not use
the existing pins.
8. After connecting the new lift chains to the chain an-
chors, adjust the lift chain tension for the correct
fork or platform height.
– The correct lift chain installation and mast adjust- 2
ment increase the service life.
Fig. 4 (33505)
Disconnecting a chain leaf
See Figure 4.
Special tools and equipment:
– A stable work surface with an opening that is
larger than the pin diameter. The work surface
must be of sufficient thickness to let the pin (4)
extend below the work surface to push it through
the pin link plate (1) on the bottom.
– A flat washer (2) with an inside diameter more
than the pin diameter and a height that is equal to
the head height of the pin.
– A grinding wheel (3).
– A punch with a diameter that is less than the pin
diameter.
– A hammer or press.
Crown 2020 PF5856 Rev. 2/20 M7.5-18.0-007
10 Rev. 2/20
153
Notes:
154
LIFTING MECHANISM
Fork
Fork Blade Measurement
Fork wear calipers have two measuring points or jaws.
The inside jaws measure 10 percent less than the out-
Fork Inspection side jaws. Refer to Figure 9237-01
The following causes of fork failure may mean loss of
equipment, damaged materials, bodily injury or loss of
life. At each planned maintenance interval an inspec-
tion and measurement of the forks must be made to
check for wear, overload, fatigue, bends, etc. Outside Jaws Inside Jaws
100% 90%
WARNING
Use the proper fork for how it was designed to be used.
Avoid using fork extensions. Figure 9237-01
Do not modify forks. Only qualified personnel should
make such repairs. To set the outside jaws, use a measuring instrument
Inspect forks visually each work day. such as a vernier or machinist 152 mm (6.0 in) scale
and set outside jaws at 51 mm (2.0 in). Refer to Figure
9238-01.
Abrasion
Care should be taken when using the calipers to hold
Abrasion gradually reduces the thickness of the fork.
them square across the shank or an incorrect reading
Be sure fork thickness is up to standard. Do not allow
will result.
forks to rub the floor during normal operation (if forks
do rub floor, check lift chain adjustment). Fork wear at
the heel must not exceed 10 percent of the original
thickness. At this point forks are adequate for approxi-
mately 80 percent of rated capacity (refer to Chart 2).
Crown has a fork wear calipers (part no.107330) avail-
Set at 51 mm (2.0 in)
able for use or a measuring instrument such as a ver-
nier or machinist 152 mm (6.0 in) scale may be used.
For allowable fork wear thickness refer to Chart 1.
Figure 9238-01
Chart 1 Fork Thickness Once the outside jaws are set, check to see if the inside
jaws of the calipers pass over the fork flanks between
Standard Fork Allowable 10% Wear the two ends of taper or between the end of taper and
Thickness Fork Thickness end of fork depending on how your fork was manufac-
tured (check thickest part of fork). If the inside jaws
mm in mm in
pass over the fork flanks, replace fork. Refer to Figures
32.0 1.25 28.5 1.12 9239-01 and 9240-01.
38.0 1.50 35.0 1.38
44.5 1.75 40.0 1.56
51.0 2.00 46.0 1.81
57.0 2.25 51.0 2.00
63.5 2.50 57.0 2.25
If using the fork wear calipers refer to the following:
Crown 1988 PF7392-1 Rev. 8/06 M7.8-07.2-001
01 Rev. 8/06
251
LIFTING MECHANISM
Fork
calipers square across the bore or an incorrect reading
will result.
Check Fork Rotate
Wear Here Calipers 180°
Mounting
Support
Check Fork
Wear Here
Figure 9239-01
Figure 9242-01
After the jaws are set, remove caliper and using a mea-
suring instrument such as a verniers or machinist
152 mm (6.0 in) scale, measure across the outside
jaws. The maximum allowable measurement for the
Fork mounting support bore is 43.7 mm (1.72 in) and
Cross Section 42.7 mm (1.68 in) for the platform bore.
Figure 9240-01
Mounting Support And Platform Bore Mea-
surement
To check for elongation (wear) of the mounting support
and platform bore, the outside jaws of the fork wear
calipers are used by rotating the legs of the calipers so
that the jaws are on the outside.
Use Outside Jaws
for Bore Measurement
Figure 9241-01
Check the mounting support and platform bore by plac-
ing the outside jaws into the bore and locate the largest
diameter of the bore by rotating the calipers 180 de-
grees. Set the jaws to the feel of the bore by lightly tap-
ping on them with a metal object. Be careful to hold the
M7.8-07.2-002 Crown 1988 PF7392-2 Rev. 8/06
01 Rev. 8/06
252
LIFTING MECHANISM
Fork
Percentage Reduction in Fork Thickness Wear vs. Capacity
Percentage Remaining of Specified Fork Capacity
Figure 9243-01
Overloading Fatigue
Know the capacity of the forks and truck. Fork capacity The entire fork should be visually inspected for fatigue
and load center is stamped on the fork (refer to Figure cracks each work day. Normally, a fatigue crack will
9244-01). Overloading can cause permanent deforma- start in an area about the mounting support of the fork.
tion or serious fatigue conditions. Pay particular attention for cracks that transverse the
fork in an area up to 130 mm (5.0 in) either side of the
mounting support. Fatigue cracks are a sign that an
area of the fork has weakened and the fork needs to be
replaced. If a more accurate inspection is necessary,
dye penetrants can be used or magnaflux fork. Refer to
Figure 9245-01
Location of
Capacity and
Load Center
Rating
Figure 9244-01
Figure 9245-01
Crown 1988 PF7392-3 Rev. 8/06 M7.8-07.2-003
01 Rev. 8/06
253
LIFTING MECHANISM
Fork
Bent or Twisted Forks
Overloading, glancing blows against solid objects or
picking up loads unevenly can bend or twist a fork,
making fork replacement necessary. The maximum al-
lowable difference in fork tip elevation from one fork to
another is 3% of the fork length. Cord
The maximum deformation from fork straightness shall String
be less than 183 degrees. Any angle greater will re-
quire fork repair or replacement. The fork manufacturer
or technicians with the expertise of equal competence
Cord String
are the only parties that should attempt to make such
repairs. Refer to Figure 9246-01.
Figure 9247-01
Hanger
183 Degrees Check for cracks or damage in the area of fork attach-
Max. ment. Check platform and fork rod for excessive wear
or cracks. Repair or replace parts if necessary.
Figure 9246-01 Bottom View
of Platform
To check the fork for straightness, a cord string, car-
penters chalk line or a straight edge 1220 mm (48.0 in)
or longer can be used. For an example of checking fork
straightness, a cord string will be used here (refer to
Figure 9247-01).
Figure 9248-01
CAUTION
When performing any type of inspection, adjustment,
maintenance, etc. beneath the platform, blocks should
be positioned under each side of the platform. Refer to
Control Of Hazardous Energy Lockout/Tagout and
chapter M9.0 for lifting and blocking procedures.
Measure 610 mm (24.0 in) from both sides of the cen-
ter of the mounting support and mark edge of fork. Hold
cord string taunt between these two points being sure
the string at both points is even with the top of fork.
Measure the maximum perpendicular distance from
the cord string to top of fork. If this measurement is
greater than 32 mm (1.25 in), the fork is deformed
more than 183 degrees and should be replaced. Refer
to Figure 9247-01.
M7.8-07.2-004 Crown 1988 PF7392-4 Rev. 8/06
01 Rev. 8/06
254
CYLINDERS
Mast and Free Lift Cylinders
Mast and Free Lift Cylinders
Lift Cylinder Operation
Refer to Figure 1.
The mast cylinders (1) and free lift cylinder (2, TT only)
are single acting ram type cylinders. When the operator
selects the lift function, pressurized hydraulic oil goes
into the bottom of the cylinders and extends the ram.
When the operator selects the lower function, the
weight of the mast assembly, platform, and load
pushes the hydraulic oil out to retract the cylinders.
Fig. 1 (17013-03)
1 Mast Cylinders
2 Free Lift Cylinder (TT Only)
Crown 1994 PF10326-1 Rev. 3/13 M8.0-7330-001
05 Rev. 3/13
55
CYLINDERS
Mast and Free Lift Cylinders
2 2
19 19
18
18
17 16
16 22
15
15
14
1
14 20
21
5
13
1 6 11
7
10
8
9
13
5
12
11 6
10 7
9 8
Fig. 2 (18211-02)
M8.0-7330-002 Crown 1994 PF10326-2 Rev. 3/13
05 Rev. 3/13
56
CYLINDERS
Mast and Free Lift Cylinders
1 Cylinder 12 Retaining Ring TL Mast Only
2 Ram 13 Poppet
3 Compression Spring TL Only 14 Seal
4 Shutoff Piston TL Only 15 Screw
5 Bushing 16 Collar
6 Retaining Ring 17 Packing Rod
7 O-ring 18 Cap
8 O-ring 19 Wiper Ring
9 Screw 20 Compression Spring
10 Cylinder Cap 21 Shut Off Piston
11 Compression Spring 22 Packing Rod
General Repair and Safety Instruc- Disassembling the Cylinders
tions • Use precaution when you disassemble hydraulic
cylinders.
• Clean all surfaces of contamination and oil before
you start the disassembly procedures.
WARNING
• Be sure to clean seal installation areas.
Avoid high pressure fluids. • Remove seals, O-rings, and wipers from cylinder
High pressure fluids can go through the skin and cause components.
severe injury. High pressure fluid that goes into the skin
• Fully clean all metal parts in a good grade solvent
can become a severe medical emergency even when
and dry with low pressure air.
the skin looks normal. There is a delayed start of pain
and severe tissue damage may occur. • As you repair the cylinder, be aware of component
part condition:
Release the pressure before you disconnect the hy-
draulic plumbing. – Replace worn or damaged parts.
Tighten all connections before you apply hydraulic – Replace parts that may be causing other unusual
pressure. wear.
Keep your hands away from pin-holes which eject – Replace components with heavy scores.
high pressure fluids. – If you find light scores on the tube or ram, sand
Use a piece of cardboard or paper to examine for with aluminum oxide cloth or a honing tool until
leaks. Do not use your hand. you remove the scores.
High pressure fluid that goes into the skin can be- Assembling the Cylinders
come a severe medical emergency even when the
• When you assemble a cylinder, apply clean hydrau-
skin looks normal.
lic oil to all seals, the ram, and the cylinder tube.
You must immediately get medical aid from a spe-
• When you install the ram into the cylinder tube, do
cialist who has experience with this type of injury.
not allow the ram to touch any sharp edges
• Use precaution to prevent damage to the seals or
the surfaces on which they operate.
WARNING
• Apply thread-locking adhesive to the screws.
High pressure compressed air.
There is a risk of injury from high pressure compressed
air.
Wear eye and face protection when you use com-
pressed air to clean components.
Crown 1994 PF10326-3 Rev. 3/13 M8.0-7330-003
05 Rev. 3/13
57
CYLINDERS
Mast and Free Lift Cylinders
Inspection
Inspection of the lift cylinders is necessary during
planned maintenance. Refer to INSPECTION AND LU-
BRICATION for the planned maintenance intervals for
your truck. You must also inspect the lift cylinders be-
fore you start lift cylinder maintenance.
• Inspect the cylinder assembly during a full lift and
lower sequence.
• Check the yoke area for signs of unusual wear or
damage.
• Check the rams for nicks, scratches, or surface
damage that allow unusual leakage. Incorrect cylin-
der operation can cause seal damage.
• Check the wiper rings and cap area for wear or un-
usual leakage.
Note: Too much hydraulic oil on the top of the cylinder
where the ram exits from the cap is an indication that
the rod packing is bad. You must replace the rod pack-
ing. It is not necessary to remove the cylinder to re-
place the rod packing. Refer to the applicable proce-
dures in this section.
M8.0-7330-004 Crown 1994 PF10326-4 Rev. 3/13
05 Rev. 3/13
58
CYLINDERS
Cylinder Repair Tools
Cylinder Repair Tools
You must make the tools that follow for cylinder repair.
Two extractors are necessary to remove the rod pack-
ing.
CAUTION
You can cause damage to cylinder surfaces by us-
ing incorrect tools.
Do not use a screwdriver or equivalent tools.
Use plastic or soft metal (brass, aluminum) tools
without burrs or sharp edges.
Making an extractor
Special tools and equipment:
• A screwdriver with a minimum shank length of
152 mm (6.0 in) and a maximum shank diameter of
4.0 mm (0.15 in).
• A 4 mm (No. 8) self-tapping screw.
• Welding equipment
• Grinder
• Electrical tape
1. Remove the head of the screw.
2. Weld or braze the self-tapping screw (1) to the end
of the screwdriver (2).
3. Grind the weld (4) to a maximum diameter of
4.0 mm (0.15 in).
4. Apply electrical tape to the shank of the screw-
driver (2) from the tip of the screw (1) to the screw-
driver handle (5).
This prevents damage to the cylinder tube or
ram from scratches.
5
1
Fig. 3 (18214-02)
Crown 1994 PF10326-5 Rev. 3/13 M8.0-7330-005
05 Rev. 3/13
59
CYLINDERS
Rod Packing Access and Replacement
Rod Packing Access and Re- Accessing the Rod Packing in the
placement Free Lift Cylinder
1. Move the truck to a maintenance area with a level
Accessing the Rod Packing in the floor.
Mast Cylinder 2. Raise the platform approximately 76 mm (3.0 in).
3. Put blocks below both sides of the platform. Refer
Refer to Figure 4 to SAFETY ► Control of Hazardous Energy ► Lift-
1. Move the truck to a maintenance area with a level ing and Blocking in the Service and Parts Manual.
floor. 4. Turn the truck OFF.
2. Turn the truck OFF. 5. Put chocks against the load wheels to prevent
3. Put chocks against the load wheels to prevent the movement of the truck.
movement of the truck. 6. Lockout/tagout the truck. Refer to SAFETY ►
4. Lockout/tagout the truck. Refer to SAFETY ► Control of Hazardous Energy ► Lockout/Tagout in
Control of Hazardous Energy ► Lockout/Tagout in the Service and Parts Manual.
the Service and Parts Manual. 7. Disconnect the battery.
5. Disconnect the battery. 8. Disconnect the lift chains from the free lift cylinder.
6. Remove the screw (1), nut (2), and lockwasher (3)
at the top of the mast cylinder ram.
CAUTION
Be careful not to allow kinks in the control cables
or hydraulic hoses during removal and installation.
9. Remove the screw that secures the yoke to free lift
cylinder.
10. Remove the yoke from the ram of the free lift cylin-
der and set it to the side.
Rod Packing Replacement
Special tools and equipment:
• 2 extractors - Refer to CYLINDERS ► Cylinder Re-
1 2 3 pair Tools to make these tools.
• Hydraulic sealant (061004-023)
• Poly-Pak seal tool - Refer to the applicable cylinder
parts page for the correct Poly-Pak seal tool.
Note: It is not necessary to remove the cylinder to re-
place the rod packing.
Fig. 4 (13834-02) Prepare the cylinder
7. Attach a lift device to the top crossbrace of the 2nd 1. Refer to Figure 5. Remove the bleed screw (4) and
stage mast and raise the mast to access to the cyl- seal (3).
inder cap. 2. Remove the cylinder cap (2) from the cylinder (1).
8. Put blocks below the mast to correctly support it.
Refer to SAFETY ► Control of Hazardous Energy
► Lifting and Blocking in the Service and Parts
Manual.
M8.0-7330-006 Crown 1994 PF10326-6 Rev. 3/13
05 Rev. 3/13
60
CYLINDERS
Rod Packing Access and Replacement
Note: Crown recommends that you always replace the
wiper ring when you replace the rod packing.
7. Fully clean the area where the seals seat. You
must remove any burrs, contamination, or seal
2
pieces before you install new seals.
Install the new rod packing
Refer to Figure 7.
3 8. Apply clean hydraulic oil to the new seals and the
seal contact areas of the cylinder and installation
1 tools.
4
CAUTION
You can cause damage to the cylinder surfaces by
using unsuitable tools.
Do not use a screwdriver or equivalent tools.
Use plastic or soft metal (brass, aluminum) tools
Fig. 5 (18213-02) without burrs or sharp edges.
Remove the rod packing
Refer to Figure 6. Note: Use a sleeve (Poly-Pak Seal tool) to prevent
damage to the rod packing when you push the seal
3. Put the extractors (2) between the ram (3) and the
over the threads and shoulders.
cylinder walls (1), 180° apart.
9. Install the rod packing, with the sealing lip first, into
4. Screw the extractors into the face of the rod pack-
the cylinder.
ing (4).
Fig. 6 (18215-02)
Note: Use precaution to prevent damage to the cylin-
der wall and ram.
5. Lightly and equally, pull on the screwdriver handles
(5) to remove the rod packing (4).
6. Remove the wiper ring from the cylinder cap.
Crown 1994 PF10326-7 Rev. 3/13 M8.0-7330-007
05 Rev. 3/13
61
CYLINDERS
Rod Packing Access and Replacement
2
1
7
3
6
5
Fig. 7 (18216-02)
1 Cylinder Tube
2 Sleeve (Poly-Pak Seal tool)
3 Forging Tool
4 Seal
5 Sealing lip
6 Collar
7 Inner Thread
10. Install the wiper ring.
11. Install the cylinder cap on the cylinder.
12. Inspect the bleed screw seal. Replace if neces-
sary.
13. Apply hydraulic sealant to the threads on the bleed
screw.
14. Install the seal and bleed screw.
Prepare the truck for service
15. Install the yoke.
16. Connect the lift chains.
17. Operate the cylinder(s) to check operation and for
leakage.
18. Bleed the air from the cylinder(s) before you put the
truck into service.
M8.0-7330-008 Crown 1994 PF10326-8 Rev. 3/13
05 Rev. 3/13
62
CYLINDERS
Mast Cylinder Removal and Installation
Mast Cylinder Removal and In- Remove the mast cylinder
9. Refer to Figure 9. Be prepared to catch hydraulic
stallation oil.
10. Disconnect the hydraulic hoses (2) and cylinder
Mast Cylinder Removal screws (3) at the bottom of the cylinder.
Prepare the truck for maintenance
1. Move the truck to a maintenance area with a level
floor. 1
2. Turn the truck OFF.
3. Put chocks against the load wheels to prevent
movement of the truck.
4. Lockout/tagout the truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lockout/Tagout in
the Service and Parts Manual. 2
5. Disconnect the battery.
6. Refer to Figure 8. Remove the screw (1), nut (2),
and lockwasher (3) at the top of the mast cylinder
ram.
Fig. 9 (18217-02)
1 Part of mainframe
2 Hoses and fittings
3 Screws
11. Attach a lift device to the cylinder to secure the cyl-
inder.
12. Remove the hose guides.
13. Remove the cylinder from the truck.
Mast Cylinder Installation
1 2 3 Install the mast cylinder
1. Install the mast cylinder on the truck.
2. Install the hose guides.
3. Refer to Figure 9. Install the cylinder screws (3) at
the bottom of the cylinder.
4. Connect the hydraulic hoses (2) at the bottom of
Fig. 8 (13834-02) the cylinder.
7. Attach a lift device to the top crossbrace of the 2nd 5. Refer to Figure 8. Install the screw (1), lockwasher
stage mast and raise the mast approximately (3), and nut (2) at the top of the mast cylinder ram.
1524 mm (60.0 in). 6. Remove the blocks from the mast and lower the
8. Put blocks below the mast to correctly support it. mast.
Refer to SAFETY ► Control of Hazardous Energy 7. Connect the battery.
► Lifting and Blocking in the Service and Parts
Manual.
Crown 1994 PF10326-9 Rev. 3/13 M8.0-7330-009
05 Rev. 3/13
63
CYLINDERS
Mast Cylinder Removal and Installation
Bleed air from the hydraulic system
8. With no load on the forks, raise the platform ap-
proximately 150 to 305 mm (6.0 to 12 in) to pres-
surize the cylinder.
9. Loosen the bleed screw at the top of the cylinder
until all the air is released and a solid stream of oil
flows from the screw.
10. Tighten the bleed screw.
11. Remove the blocks from below the platform.
12. Fully lower the mast and platform to release all
pressure in the cylinder.
13. Loosen the bleed screw 2–3 revolutions.
14. Remove oil from the screw threads with degreaser.
15. Dry the screw threads with low pressure air.
16. Apply hydraulic sealant to the threads and tighten
the screw.
Prepare the truck for operation
17. Check the hydraulic oil level in the reservoir and
add oil as necessary.
18. Remove the chocks from the load wheels.
19. Turn the truck ON.
20. Make sure that the truck operates correctly.
M8.0-7330-010 Crown 1994 PF10326-10 Rev. 3/13
05 Rev. 3/13
64
CYLINDERS
Free Lift Cylinder Removal and Installation
Free Lift Cylinder Removal and
Installation
Free Lift Cylinder Removal
Refer to Figure 10
Prepare the truck for maintenance
1. Move the truck to a maintenance area with a level
floor.
2. Raise the platform approximately 76 mm (3.0 in).
3. Put blocks below both sides of the platform. Refer
to SAFETY ► Control of Hazardous Energy ► Lift-
ing and Blocking in the Service and Parts Manual.
4. Turn the truck OFF.
5. Put chocks against the load wheels to prevent
movement of the truck.
6. Lockout/tagout the truck. Refer to SAFETY ►
Control of Hazardous Energy ► Lockout/Tagout in
the Service and Parts Manual.
7. Disconnect the battery.
2
Remove the free lift cylinder
8. Disconnect the lift chains from the free lift cylinder.
CAUTION
Be careful not to allow kinks in the control cables
or hydraulic hoses during removal and installation.
9. Remove the screw (3) that secures the yoke (2) to
3
the free lift cylinder (1).
10. Remove the yoke (2) from the ram of the free lift
cylinder (1) and set it aside.
4 5
11. Attach a lift device to the free lift cylinder (1) to se-
cure the cylinder.
12. Disconnect the hydraulic hoses at the bottom of
the cylinder. 1
13. Remove the nuts (4) and clamp (5) that secure the
free lift cylinder (1) to the 3rd stage mast.
14. Remove the free lift cylinder (1).
Fig. 10 (18218-02)
Crown 1994 PF10326-11 Rev. 3/13 M8.0-7330-011
05 Rev. 3/13
65
CYLINDERS
Free Lift Cylinder Removal and Installation
Free Lift Cylinder Installation
Refer to Figure 10
Install the free lift cylinder
1. Install the free lift cylinder on the truck.
2. Install the clamp (5) and nuts (4) that hold the free
lift cylinder on the 3rd stage mast.
CAUTION
Be careful not to allow kinks in the control cables
or hydraulic hoses during removal and installation.
3. Connect the hydraulic hoses at the bottom of the
cylinder.
4. Install the yoke (2) on the ram of the free lift cylin-
der (1).
5. Install the screw (3) to secure the yoke to the free
lift cylinder (1).
6. Install the chain anchors and chains that you re-
moved from the free lift cylinder.
7. Connect the battery.
Bleed air from the hydraulic system
8. With no load on the forks, raise the platform ap-
proximately 150 to 305 mm (6.0 to 12 in) to pres-
surize the cylinder.
9. Loosen the bleed screw at the top of the cylinder
until all the air is released and a solid stream of oil
flows from the screw.
10. Tighten the bleed screw.
11. Remove the blocks from below the platform.
12. Fully lower the mast and platform to release all
pressure in the cylinder.
13. Loosen the bleed screw 2-3 revolutions.
14. Remove oil from the screw threads with degreaser.
15. Dry the screw threads with low pressure air.
16. Apply hydraulic sealant to the threads and tighten
the screw.
Prepare the truck for operation
17. Check the hydraulic oil level in the reservoir and
add oil as necessary.
18. Remove the chocks from the load wheels.
19. Turn the truck ON.
20. Make sure that the truck operates correctly.
M8.0-7330-012 Crown 1994 PF10326-12 Rev. 3/13
05 Rev. 3/13
66
CYLINDERS
Mast and Free Lift Cylinders
Mast and Free Lift Cylinders
Lift cylinder operation
See Figure 1
The mast cylinders (1) and free-lift cylinder (2, TT mast
only) are single-acting, ram-type cylinders. When the
operator selects the lift function, pressurized hydraulic
oil goes into the bottom of the cylinders and extends
the ram. When the operator selects the lower function,
the weight of the mast assembly, platform, and load
pushes out the hydraulic oil to retract the cylinders.
Fig. 1 (17013-03)
See Figure 2
Velocity fuses are located in the bottom of the mast and
the free-lift cylinders. These devices monitor the flow of
hydraulic oil. If a break occurs in a hydraulic line, ex-
cess hydraulic oil flow from the cylinder forces the ve-
locity fuse poppet down, blocking oil flow, thereby lock-
ing the ram in place. A flow control valve is located in
the bottom of the lifting fork cylinder.
Crown 2017 PF27775 M8.0-7330-013
55
CYLINDERS
Mast and Free Lift Cylinders
2 2
19 19
18
18
17 16
16 22
15
15
14
1
14 20
21
5
13
1 6 11
7
10
8
9
Free-lift cylinder
13
5
12
11 6
10 7
9 8
Mast lift cylinder
Fig. 2 (18211-02)
M8.0-7330-014 Crown 2017 PF27775
56
CYLINDERS
Mast and Free Lift Cylinders
1 Cylinder 12 Retaining ring, TL mast only
2 Ram 13 Popper
3 Compression spring, TL mast only 14 Seal
4 Shut-off piston, TL mast only 15 Screw
5 Bushing 16 Collar
6 Retaining ring 17 Packing rod
7 O-ring 18 Cap
8 O-ring 19 Wiper ring
9 Screw 20 Compression spring
10 Cylinder cap 21 Shut-off piston
11 Compression spring 22 Packing rod
General repair and • Clean all the surfaces of contamination and oil be-
fore you start the disassembly procedures.
safety instructions
• Be sure to clean the seal installation areas.
• Remove the seals, O-rings, and wipers from the cyl-
inder components.
WARNING
• Fully clean all the metal parts with a good grade sol-
Avoid high-pressure fluids. vent and dry with low-pressure air.
High-pressure fluids can go through the skin and cause • As you repair the cylinder, be aware of condition of
severe injury. High-pressure fluid that goes into the the components:
skin can become a severe medical emergency even – Replace the worn or damaged parts.
when the skin looks normal. There is a delayed start of
– Replace the parts that may be causing other un-
pain and severe tissue damage occurs.
usual wear.
Release the pressure before you disconnect the hy-
– Replace the components with heavy scores.
draulic plumbing.
– If you find light scores on the tube or the ram,
Tighten all connections before you apply hydraulic
sand the tube or the ram with an aluminum oxide
pressure.
cloth or a honing tool until you remove the scores.
Keep your hands away from pin-holes which eject
high-pressure fluids. Assembling the cylinders
To examine for leaks, use a piece of cardboard or • When assembling a cylinder, apply clean hydraulic
paper. Do not use your hand. oil to all the seals, the ram, and the cylinder tube.
You must immediately get medical aid from a spe- • When installing the ram into the cylinder tube, do
cialist who has experience with this type of injury. not allow the ram to touch any sharp edges.
• Use caution to prevent damage to the seals or the
surfaces on which they operate.
• Apply thread-locking adhesive to the screws.
WARNING
High-pressure compressed air.
There is a risk of injury from high-pressure compressed
air.
Wear eye and face protection when you use com-
pressed air to clean parts.
Disassembling the cylinders
• Use caution when disassembling the hydraulic cyl-
inders.
Crown 2017 PF27775 M8.0-7330-015
57
CYLINDERS
Mast and Free Lift Cylinders
Inspection 2. Weld or braze the self-tapping screw (1) to the end
of the screwdriver (2).
Inspection of the lift cylinders is necessary during
3. Grind the weld (4) to a maximum diameter of 4.0
planned maintenance. See the Inspection and Lubrica-
mm (0.15 in).
tion section for the planned maintenance intervals for
your lift truck. You must also inspect the lift cylinders 4. Apply electrical tape (3) to the shank of the screw-
before you start lift cylinder maintenance. driver (2) from the tip of the screw (1) to the screw-
driver handle (5).
• Inspect the cylinder assembly during a full lift and
lower sequence. Note: This prevents damage to the cylinder tube or
scratches on the ram.
• Check the yoke area for signs of unusual wear or
damage.
• Check the rams for nicks, scratches, or surface
damage that allow unusual leakage. Incorrect cylin-
der operation can cause seal damage. 2
• Check the wiper rings and the cap area for wear or
unusual leakage.
Note: Too much hydraulic oil on the top of the cylinder 5
where the ram exits from the cap is an indication that 1
the rod packing is bad. You must replace the rod pack-
ing. It is not necessary to remove the cylinder to re- 3
place the rod packing. See the applicable procedures
4
in this section.
Cylinder Repair Tools Fig. 3 (18214-02)
You must make the tools that follow for cylinder repair. Rod Packing Access
Two extractors are necessary to remove the rod pack- and Replacement
ing.
Preparing the lift truck for maintenance
1. Follow all the safety procedures. See the SAFETY
CAUTION chapter in the service and parts manual.
2. Wear the appropriate items for personal safety.
Use the correct tools when working on cylinders.
You can damage the cylinder surfaces by using unsuit- 3. Move the lift truck to your work area on a level floor.
able tools. 4. Fully lower the forks.
Do not use a screwdriver or equivalent tools. 5. Turn off the lift truck.
Use plastic or soft metal (brass, aluminum) tools 6. Disconnect the battery.
without burrs or sharp edges. 7. Secure the work area.
8. Lockout/tagout the lift truck. See the SAFETY /
Making an extractor Control of Hazardous Energy in the service and
parts manual.
Special tools and equipment:
9. Put the chocks against the wheels.
• A screwdriver with a minimum shank length of
152 mm (6.0 in) and a maximum shank diameter of
4.0 mm (0.15 in).
CAUTION
• A 4.0 mm (0.15 in) self-tapping screw.
• Welding equipment Kinks in the control cables or hydraulic hoses.
• Grinder The electrical or hydraulic system could be damaged.
• Electrical tape Be careful not to allow kinks in the control cables or
hydraulic hoses during removal and installation.
1. See Figure 3. Remove the head of the self-tapping
screw (1).
M8.0-7330-016 Crown 2017 PF27775
58
CYLINDERS
Mast and Free Lift Cylinders
Accessing the rod packing in the mast cylinder 5. Remove the yoke from the ram of the free-lift cylin-
der and set it aside for later assembly.
See Figure 4.
1. Remove the screw (1), nut (2), and lockwasher (3) Accessing the rod packing in the lifting fork cylin-
at the top of the mast cylinder ram. der
2. Attach a lifting device to the top cross brace of the 1. Remove the forks from the lift truck.
second stage mast. Raise the mast approximately 2. Raise the platform approximately 915 mm (36 in).
305 mm (12 in) to access the cylinder cap. 3. Put blocks under each side of the platform.
3. Put blocks below the mast to correctly support the 4. Attach a lifting device to the fork carriage.
mast. See SAFETY/Control of Hazardous Energy/
5. Remove the chains from the front of the fork car-
Lifting and Blocking in the service and parts man-
riage assembly.
ual.
6. Slide the fork carriage down and out of the carriage
4. Attach a lifting device to the top cross brace of the
slot.
third stage mast. Raise the mast approximately
152 mm (6 in). 7. Remove the screw from the top of the cylinder.
5. Put blocks below the mast to correctly support the 8. Lift the yoke assembly from the cylinder and set it
mast. aside for later assembly.
6. Open the manual lowering valve to slacken the lift
chains and collapse the mast cylinder. Close the
Replacing the rod packing
manual lowering valve. Special tools and equipment:
7. Disconnect the lift chain from the mainframe. • Two extractors. See the Cylinders/Cylinder Repair
Tools section for instructions on making these tools.
• Cylinder seal tool kit. See the applicable cylinder
parts page for the correct Poly-Pak seal tool, Poly-
Pak driver tool, and cap socket.
Note: It is not necessary to remove the cylinder to re-
place the rod packing.
1 2 3
Fig. 4 (13834-02)
1. Accessing the rod packing in the free-lift cylinder
1. Attach a lifting device to the platform and raise it
approximately 76 mm (3.0 in).
2. Put blocks under each side of the platform.
3. Disconnect the lift chains from the free-lift cylinder.
4. Remove the screw that secures the yoke to the
free-lift cylinder.
Crown 2017 PF27775 M8.0-7330-017
59
CYLINDERS
Mast and Free Lift Cylinders
Preparing the cylinder
See Figure 5.
1. Remove the bleed screw (4) and seal (3) from the 2
cylinder (1).
2. Remove the cylinder cap (2) from the cylinder (1).
2 2
3 3
1 4
Fig. 6 (18215-02)
4
CAUTION
Use the correct tools when working on cylinders.
You can cause damage to the cylinder surfaces by us-
ing unsuitable tools.
Fig. 5 (18213-02)
Removing the rod packing Do not use a screwdriver or equivalent tools.
Use plastic or soft metal (brass, aluminum) tools
See Figure 6. without burrs or sharp edges.
1. Insert the extractors (2) between the ram (3) and
the cylinder walls (1), 180° apart.
Installing the rod packing
2. Install the extractors into the face of the rod pack-
ing (4). See Figure 7.
Note: Be careful not to damage the cylinder wall and 1. Apply clean hydraulic oil to the new seals (4) and
ram. the seal contact areas of the cylinder and installa-
3. Lightly and equally pull on the extractors (2) to re- tion tools.
move the rod packing from the cylinder. Note: Use a sleeve (2) to prevent damage to the rod
4. Remove the wiper ring from the cylinder cap. packing when you push the seal over the threads (7)
and shoulders.
Note: Crown recommends that you must replace the
wiper ring when you replace the rod packing. 2. Install the rod packing, with the sealing lip (5) first,
into the cylinder (1).
5. Fully clean the area where the seals seat. Remove
any burrs, contamination, or seal pieces before 3. Install the wiper ring into the cylinder cap.
you install the new seals. 4. Install the cylinder cap on the cylinder.
5. Inspect the bleed screw seal and replace it if nec-
essary.
6. Apply thread-locking adhesive (P/N 061004-023)
to the threads of the bleed screw.
7. Install the seal and the bleed screw into the cylin-
der.
M-8.0-7330-018 Crown 2017 PF27775
60
CYLINDERS
Mast and Free Lift Cylinders
2 4
1
7
3
1 2 3
Fig. 7 (18216-02)
Preparing the mast cylinder for operation
See Figure 8.
1. Attach a lift chain to the mainframe.
Fig. 8 (13834-02)
2. Attach a lifting device to the top cross brace of the
third stage mast.
3. Raise the mast, remove the blocks, and then lower
the third stage mast.
4. Attach a lifting device to the top cross brace of the
second stage mast.
5. Raise the mast, remove the blocks, and then lower
the second stage mast.
6. Install the screw (1), nut (2), and lock washer (3) at
the top of the mast cylinder ram.
7. Operate the cylinder to check its operation and for
any leakage.
8. Bleed the air from the cylinder before you put the
lift truck into service.
9. Adjust the mast lift chains.
Crown 2017 PF27775 M8.0-7330-019
61
CYLINDERS
Mast and Free Lift Cylinders
Preparing the free-lift cylinder for operation 9. Install the forks on the lift truck.
See Figure 9. 10. Operate the cylinder to check its operation and for
any leakage.
1. Install the yoke onto the ram of the free-lift cylinder
(2). 11. Bleed the air from the cylinder before you put the
lift truck into service.
2. Secure the yoke to the cylinder with the screw.
12. Adjust the fork carriage chains.
3. Attach the lift chains to the free-lift cylinder.
4. Attach a lifting device to the platform and raise it Preparing the lift truck for operation
approximately 76 mm (3.0 in). 1. Remove the chocks from the wheels.
5. Remove the blocks. 2. Remove the lockout/tagout device.
6. Lower the platform. 3. Connect the battery.
7. Operate the cylinder to check its operation and for 4. Turn on the lift truck.
any leakage. 5. Make sure that the lift truck operates correctly.
8. Bleed the air from the cylinder before you put the
lift truck into service. Mast Cylinder Removal
9. Adjust the free-lift chains. and Installation
DANGER
Lifting devices and blocking.
A truck that falls can cause severe injury or death.
Using a lifting device or blocks that do not have suffi-
cient capacity can result in severe injury or even death.
Do not do maintenance below or around a truck that
is not correctly secured.
1
See SAFETY/Control of Hazardous Energy/Lifting
and Blocking in the service and parts manual for the
applicable lifting and blocking procedures.
Read and obey all safety procedures in SAFETY/
2 Control of Hazardous Energy/Lifting and Blocking
in the service and parts manual.
CAUTION
Kinks in the control cables or hydraulic hoses.
Fig. 9 (17013-03)
The electrical or hydraulic system could be damaged.
Preparing the lifting fork cylinder for operation
Be careful not to allow kinks in the control cables or
1. Install the yoke assembly onto the ram of the lifting hydraulic hoses during removal and installation.
fork cylinder
2. Secure the roller bar to the cylinder with the screw.
Preparing the lift truck for maintenance
3. Attach a lifting device to the fork carriage.
1. Follow all the safety procedures. See the SAFETY
4. Lift the fork carriage up into the carriage slot.
chapter in the service and parts manual.
5. Attach the lift chains to the fork carriage.
2. Wear the appropriate items for personal safety.
6. Attach a lifting device to the platform and raise it
3. Move the lift truck to your work area on a level floor.
approximately 76 mm (3.0 in).
4. Fully lower the forks.
7. Remove the blocks.
5. Turn off the lift truck.
8. Lower the platform.
M8.0-7330-020 Crown 2017 PF27775
62
CYLINDERS
Mast and Free Lift Cylinders
6. Disconnect the battery.
7. Secure the work area.
8. Lockout/tagout the lift truck. See the SAFETY /
1
Control of Hazardous Energy section in the service
and parts manual.
9. Put the chocks against the wheels.
Removing the mast cylinder
1. See Figure 10. Remove the screw (1), nut (2), and
lockwasher (3) at the top of the mast cylinder ram.
2. Attach a lifting device to the top cross brace of the 2
second stage mast and raise the mast approxi-
mately 1,524 mm (60.0 in).
3. Put blocks below the mast to correctly support it.
See SAFETY/Control of Hazardous Energy/Lifting
and Blocking section in the service and parts man- (a)
ual. 3
(a) Mainframe
Fig. 11 (18217-02)
1 2 3
Fig. 10 (13834-02)
4. See Figure 11. Be prepared to catch any hydraulic
oil.
5. Disconnect the hydraulic hoses and fittings (2) and
the cylinder screws (3) at the bottom of the cylinder
(1).
6. Attach a lifting device to the cylinder to secure the
cylinder.
7. Remove the hose guides frrom the cylinder.
8. Remove the cylinder from the lift truck.
Crown 2017 PF27775 M8.0-7330-021
63
CYLINDERS
Mast and Free Lift Cylinders
Removing the free-lift cylinder
See Figure 12.
1. Attach a lifting device to the platform, then raise the
platform approximately 1,524 mm (60.0 in).
2. Put blocks under each side of platform.
3. Disconnect the chains from the front of the cylin-
der.
4. Remove the screw (3) that secures the yoke (2) to
the free-lift cylinder (1).
5. Remove the yoke (2) from the ram of the free-lift
cylinder (1) and set it aside for later assembly.
6. Attach a lifting device to the free-lift cylinder (1) to
secure the cylinder.
7. Disconnect the hydraulic line at the bottom of the
cylinder.
8. Remove the screws (6) at the bottom of the cylin-
der.
9. Remove the nuts (4) and clamp (5) that secure the
free-lift cylinder (1) to the third stage mast.
10. Remove the free-lift cylinder (1) from the lift truck.
2
4 5
Fig. 12 (18218-02)
M8.0-7330-022 Crown 2017 PF27775
64
CYLINDERS
Mast and Free Lift Cylinders
Removing the lifting fork cylinder
1. Remove the forks from the lift truck.
2. Raise the platform approximately 915 mm (36.0
1
in). Place blocks under each side of the platform.
3. Attach a lifting device to the fork carriage.
4. Remove the chains from the front of the fork car-
riage assembly.
5. Slide the fork carriage down and out of the carriage
slot.
6. Remove the screw from the top of the cylinder. 2
7. Lift the yoke assembly from the cylinder and set it
aside for later assembly.
8. Disconnect the hose assembly from the cylinder.
Be prepared to catch any hydraulic oil.
9. Remove the two screws from bracket towards the (a)
top of the cylinder. 3
(a) Mainframe
10. Remove the cylinder from the lift truck.
Fig. 13 (18217-02)
7. See Figure 14 Install the screw (1), lock washer
CAUTION (3), and nut (2) at the top of the mast cylinder ram.
Kinks in the control cables or hydraulic hoses.
The electrical or hydraulic system could be damaged.
Be careful not to allow kinks in the control cables or
hydraulic hoses during removal and installation.
Installing the mast cylinder
1. Install the mast cylinder on the lift truck.
2. See Figure 13. Install the screws (3) at the bottom
of the cylinder.
3. Connect the hydraulic hoses (2) at the bottom of
the cylinder.
4. Install the hose guides to the cylinder.
5. Attach a lifting device to the top cross brace of the
1 2 3
second stage mast.
6. Raise the mast, remove the blocks, and then lower
the second stage mast.
Fig. 14 (13824-02)
8. Operate the cylinder to check its operation and for
leakage.
9. Bleed the air from the cylinder before you put the
lift truck into service.
Crown 2017 PF27775 M8.0-7330-023
65
CYLINDERS
Mast and Free Lift Cylinders
Installing the free-lift cylinder
See Figure 15.
1. Install the free-lift cylinder (1) on the lift truck.
2. Attach the nuts (4) and clamp (5) to secure the
free-lift cylinder to the third stage mast.
3. Put the screws (6) at the bottom of the cylinder.
4. Connect the hydraulic line at the bottom of the cyl-
inder.
5. Put the yoke (2) on the free-lift cylinder and secure
it with the screw (3)
6. Connect the chains to the front of the cylinder.
7. Attach a lifting device to the top cross brace of the
third stage mast.
8. Raise the mast, remove the blocks, and then lower
the third stage mast.
9. Lower the platform.
10. Operate the cylinder to check its operation and for
any leakage.
11. Bleed the air from the cylinder before you put the
lift truck into service.
2
12. Adjust the free-lift chains.
4 5
Fig. 15 (18218-02)
M8.0-7330-024 Crown 2017 PF27775
66
CYLINDERS
Mast and Free Lift Cylinders
Installing the lifting fork cylinder Bleeding the lifting fork cylinder
1. Install the cylinder on the lift truck. 1. With no load on the forks, raise the lifting forks ap-
2. Install the two screws to the bracket towards the proximately 150-305 mm (6-12 in) to pressurize
top of the cylinder. the cylinder.
3. Connect the hose assembly to the cylinder. 2. Loosen the bleed screw at the top of the cylinder
until all the air is released and a solid stream of
4. Install the yoke assembly to the cylinder.
hydraulic oil flows from the screw.
5. Install the screw to the top of the cylinder.
3. Tighten the bleed screw.
6. Attach a lifting device to the fork carriage.
Preparing the lift truck for operation
7. Raise the fork carriage, and then slide the fork car-
riage up and into the carriage slot. 1. Check the hydraulic oil level in the reservoir and
add hydraulic oil as needed.
8. Attach the chains to the front of the fork carriage
assembly. 2. Remove the chocks from the wheels.
9. Attach the forks to the carriage assembly. 3. Remove the lockout/tagout device.
10. Operate the cylinder to check its operation and for 4. Connect the battery.
any leakage. 5. Turn on the lift truck.
11. Bleed the air from the cylinder before you put the 6. Make sure that the lift truck operates correctly.
lift truck into service.
12. Adjust the fork carriage chains.
WARNING
Avoid high-pressure fluids.
High-pressure fluids can go through the skin and cause
severe injury. High-pressure fluid that goes into the
skin can become a severe medical emergency even
when the skin looks normal. There is a delayed start of
pain and severe tissue damage occurs.
Release the pressure before you disconnect the hy-
draulic plumbing.
Tighten all connections before you apply hydraulic
pressure.
Keep your hands away from pin-holes which eject
high-pressure fluids.
To examine for leaks, use a piece of cardboard or
paper. Do not use your hand.
You must immediately get medical aid from a spe-
cialist who has experience with this type of injury.
Bleeding the air from the hydraulic system
1. With no load on the forks, raise the platform ap-
proximately 1,220 mm (48 in) to pressurize the cyl-
inders.
2. Loosen the bleed screw at the top of the cylinder
until all the air is released and a solid stream of
hydraulic oil flows from the screw.
3. Tighten the bleed screw.
M8.0-7330-025
67
PLATFORM
Platform
Platform
Service and/or repair of the platform and components
may be necessary to keep the truck operating properly.
Use the following information as an aid in maintaining
proper platform condition and operation.
Floor Mat Replacement Safety Shield
Remove the worn floor mat and thoroughly clean the
platform floor surface. Apply a thin coat of adhesive
(061001-031) to the back side of mat and platform
floor. Do Not apply adhesive to back side of the mat if
it is a sponge type surface, rather apply a heavier coat Figure 17029
to the platform floor. Allow the adhesive to become
A special tool 103792 will aid in the installation of the
tacky (approximately 10 to 15 minutes). Place mat in
wedge locking strips. To use the tool, the strip must be
position and apply pressure to insure good contact be-
fed through the throat of the tool head (refer to Figure
tween mat and platform floor.
17030), leaving approximately 25 mm (1.0 in) of strip
exposed beneath the head. The tool should then be in-
serted into the "V" slot in the main molding body. Once
started with both the strip and body ends flush, clamp
the end with your thumb and push the tool through the
slot. If the tool seems to push relatively hard, heat can
be applied to the molding which will liquefy the film on
the molding and act as a lubricant.
Floor Mat
Figure 17028
Safety Shield
It may be necessary to remove the safety shield when
performing service to certain areas of the platform. The
safety shield is mounted in rubber molding so that it is
(1) Main Moulding Body
fully suspended. Assemble the molding and safety
shield. Refer to Figure 17030. The wedge locking strip (2) Wedge Locking Strip
must be pressed into the open groove to secure the (3) Wedge Insertion Tool
shield in place. (4) Glass
Figure 17030
Crown 2006 PF15447-1 Rev. 7/07 M9.0-7334-001
01 Rev. 7/07
115
PLATFORM
Platform
Forks Fork Replacement
Fork Inspection WARNING
Visually inspect forks for cracks, deformation, proper Wear appropriate items, such as safety glasses, when-
mounting, etc. The platform needs to be raised accord- ever performing maintenance work. Do not place fin-
ingly to inspect the portion of fork beneath the platform. gers, hands or arms through mast or position them at
Refer to Platform for additional information. pinch points.
In this section you may be required to lift and block the
truck and mast or raise and lower different components
CAUTION for removal and installation. Make sure lifting device
When performing any type of inspection, adjustment, and sling are sufficiently rated to withstand the weight
maintenance, etc. beneath the platform, hardwood being lifted. Never work under or around a truck that is
blocks should be positioned under each side of the not properly secured. Refer to truck Data Plate for truck
platform along the mast channel. Refer to Control Of weight information.
Hazardous Energy Lockout/Tagout in this manual and It will be necessary to disconnect and remove the bat-
refer to Figure 17031. tery from the truck, disconnect tilt cylinders from the
mast, disconnect electrical connections and hydraulic
lines. "Control of Hazardous Energy" section provides
information for performing the above procedures along
with some additional information on other procedures
dealing with truck maintenance. This section should be
read and reviewed prior to mast removal, installation
and maintenance as outlined in this section.
Raise platform approximately 610 mm (24.0 in) and
securely block. Refer to Control Of Hazardous Energy
Lockout/Tagout in this manual. Wrap a chain as tight as
possible around the platform floor. As the forks pins are
removed this chain will help support the heel of the
fork. Using a sling on the fork to make sure the fork
weight is balanced evenly. Remove retaining ring from
end of fork rod. Using a lifting device to assume the fork
weight, carefully remove fork pin.
NOTE
Shorter tapered fork lengths will tend to be heavier in
the heel area. Care must be taken to handle fork safely
after removal.
Fork installation requires a balance fork hook-up to the
lifting device that allows for the fork to be raised safely
into position. Install fork pin and retaining ring.
(1) Hardwood Blocks 100 mm x 100 mm
(4.0 in x 4.0 in) Shims are used in the heel area of the fork to obtain the
(2) Operator Platform proper position of the fork tip. Fork tip height should be
(3) Pallet Grab the same as fork height at the rear edge of the platform.
(4) Fork
Be sure measurement is taken on a level surface. Ap-
ply thread locking adhesive to the screws securing
shims to platform.
Figure 17031
M9.0-7334-002 Crown 2006 PF15447-2 Rev. 7/07
01 Rev. 7/07
116
PLATFORM
Platform
After forks have been inspected, replaced, etc. remove Pallet Grab
chain from platform. Raise platform and remove blocks
from under platform. Lower platform completely and (Refer to Figure 17033)
measure fork height from floor. Fork height should be
The pallet grab is located beneath the operator plat-
approximately 75 mm (3.0 in) from top of fork to floor at
form. Mechanical linkage connects the mounting plate
maximum lowered position. If fork height is not correct
beneath the platform to the operator release handle lo-
then the lift chain will have to either shortened or
cated below the control module. The pallet grab is foot
lengthened to achieve correct fork height.
applied and hand released. The platform must be
blocked before performing any service to the pallet
Fork Height Adjustment grab. Reference Control Of Hazardous Energy Lock-
out/Tagout in this manual for lifting and blocking in-
(TL Mast Not Available On SP3470/80/71/81)
structions.
Refer to Figure 17032. On trucks equipped with TL
mast, fork height is adjusted at the chain anchors lo- Release Handle Adjustment
cated both sides at the top of the main frame. On trucks
equipped with TT mast, fork height is adjusted at the The release handle is in a near horizontal position and
chain anchors located on the free lift cylinder. With the should be parallel to the cutout in the console when the
platform completely lowered, adjust the forks so the top pallet grab is not being used (foot pedal in the "up" po-
of the forks is a maximum of 75 mm (3.0 in) from the sition). To maintain this position an adjustment can be
floor. Allow for a 6.5 mm (0.25 in) clearance between made to the push rod connecting the handle to the
underside of platform and top of outrigger. latch located on the power unit side of the platform. Re-
move pin from the connecting rod and latch. Loosen
"jam" nut securing push rod end to the push rod. Turn
rod end counterclockwise to lengthen push rod and this
(1) TL Mast Chain Anchor will rotate the release handle "down". Turn the rod end
(2) TT Mast Chain Anchor
clockwise to shorten push rod and this will rotate han-
dle up.
Foot Pedal Adjustment
CAUTION
When performing any type of inspection, adjustment,
service, etc. beneath the platform, hardwood blocks
should be positioned under each side of the platform
along the mast channel. Refer to Control Of Hazardous
Energy Lockout/Tagout in this manual.
The foot pedal has spring tension applied to it con-
stantly during normal release and applied conditions.
When the pedal is "up" or released position, the back-
side of the pedal is contacting a poly stop. The poly
stop prevents metal to metal contact between the pedal
Figure 17032
and the platform. Inspect the poly stop and replace if
needed.
Crown 2006 PF15447-3 Rev. 7/07 M9.0-7334-003
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PLATFORM
Platform
Pallet Grab Removal
Should cable "E" or "F", springs, pulleys, etc., need re-
placement the pallet grab can be removed from the
platform by removing two screws near the rear of the
platform. Hold the pallet grab in position until both
screws are removed. The pallet grab can be rotated
down the "L" shaped mounting bracket located under
the platform floor. Be careful the pallet grab does not
slip from this bracket. Remove cotter pin, flatwasher
and cable from point "G". Remove pallet grab from plat-
form and place on workbench for repair.
When reassembling the pallet grab override spring, in
the pallet grab released position should measure
143 mm (5.62 in) overall length. Refer to Figure 17033.
Attach cable "F" to the first hole in the end of the re-
tainer. If the cable has stretched slightly or a replace-
(1) Horizontal
ment cable has been installed, the second or third hole
can be used to maintain the proper spring length and
(2) Release Handle
cable tension. Two cables are used with the pallet grab
(3) Release Handle Adjustment mechanism; they are referred to as cable "E" and "F".
(4) Foot Pedal Cable "E" is the shorter of the two cables (approxi-
(5) Foot Pedal Adjustment (Jam Nuts) mately 368 mm [14.5 in] overall length) and cable "F" is
(6) Cable (F) the longer cable (approximately 1346 mm [53.0 in]
(7) (G)
overall length). Refer to Figure 17033 for cable routing
and connection points.
(8) Poly Stop
(9) Cable (F) Anchor Points A poly stop is located at the rear of the right pallet grab
(10) Cable (E) Anchor Points
arm and should be inspected for wear, damage, etc.
The stop is secured in position with two screws for sim-
(11) Poly Stop
ple installation or removal as necessary. Be sure all
springs, retainers, rollers, etc. are positioned and work-
Figure 17033 ing properly before installing mounting plate with asso-
The foot pedal position, in the released position, can be ciated parts to the underside of platform.
adjusted to make sure it latches properly. During nor-
mal operation slightly lower, release pedal position
may develop that could make latching impossible. Re-
fer to Figure 17033. To adjust pedal height, loosen the
jam nuts and turn nut clockwise until pedal height and
latching are correct. The adjustment must be made
from beneath the floor of the platform. Be sure platform
is securely blocked. If correct pedal height can not be
achieved through this adjustment, then some parts
may need to be replaced to achieve correct pedal
height.
M9.0-7334-004 Crown 2006 PF15447-4 Rev. 7/07
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PLATFORM
Platform
Operator Compartment Gates Spring Replacement
The platform has operator compartment gates that can To replace a weak or broken coil spring on the bottom
rotate "up" to allow easy entry or exit when the platform pivot shaft, left or right side, the following information
is in the lowered position. The truck will not travel or must be used.
raise until both gates are in the "down" position. The Use a spanner wrench (104712) that has two 4.0 mm
sidegate upper pivot shaft activates switches as it is (5/32 in) pins, at a spread of 23.8 mm (0.937 in). Refer
rotated. When raising the sidegates, the lower pivot to Figure 17035.
shaft has a coil spring attached that aids the operator
in raising/lowering the gate. A poly stop, located on the
floor of the platform directly below each gate upright,
acts as rest when the gates are "down".
Spanner Tool
Figure 17035
With the gate in the "down" position, place spanner
wrench on the lower pivot shaft. Using a hammer and
4.8 mm (3/16 in) diameter punch, drive the roll pin par-
tially out (approximately 12.7 to 19.0 mm (0.50 to
0.75 in). Keep spanner wrench on the shaft, remove
punch and rotate gate to "up" position. Remove roll pin
from shaft making sure spanner wrench is still on shaft.
Using spanner wrench rotate shaft until all spring ten-
sion is relieved. As the roll pin is removed the spring
tension will be transferred to the spanner wrench. You
will have to assume the load when the roll pin is com-
(1) Side Gates Down Position pletely out. Remove shaft and note the position of
(2) Console
spacers and bearings for correct position at assembly.
(3) Side Gates Upright Position Refer to Figure 17036. Position coil spring with outer
(4) Console Mounting Screws flange next to small stop welded to platform wall that
keeps the coil spring from rotating when all parts are
assembled properly.
Figure 17034
To gain access to the sidegate upper pivot shaft and
switches the console must be removed from the plat-
form. Refer to Electrical.
Remove the six console mounting screws. Refer to Fig-
ure 17034. Two additional covers must be removed
that are located on both sides of the platform for trucks
with a 1370 and 1625 mm (54.0 and 64.0 in) wide plat-
forms.
Crown 2006 PF15447-5 Rev. 7/07 M9.0-7334-005
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PLATFORM
Platform
Operator Harness
The operator belt and lanyard must be inspected regu-
larly to insure they are in a safe condition. Operator
belts are available in sizes small, medium, large and
x-large to allow for comfortable fit. Be sure belt is clean
and shows no signs of tearing, stressed areas or frayed
ends. Inspect attachment rings and buckle of belt for
wear or any sign of deterioration. Replace a belt that
has any flaws or deterioration that may affect operator
safety. The lanyard must be checked on a regular basis
for the same signs of wear as the operator belt. Inspect
snap hooks and locks at each end of the lanyard. Be
sure lanyard connection to the overhead guard is se-
cure and any signs of wear in the supports of the over-
head guard area are repaired or replaced to maintain
safe operation. If there are any doubts about the lan-
yard or operator belt, replace it.
(1) Gate
(2) Apply Spring Force
(3) Release Spring Force
(4) Bushing
(5) Roll Pin
(6) Spring Stop
(7) Torsion Spring
(8) Bushing
(9) Shaft “V” Slot
(10) Shim
Operator Harness
Figure 17036
After all parts have been installed and the side gate is
held in the "up" position, use spanner wrench to turn
the pivot shaft to increase spring force until the roll pin
can be installed through the lower gate and pivot shaft. Figure 17037
The pivot shaft will need to be turned approximately 40
to 45 degrees to allow for roll pin installation with the
side gate in the "up" position.
M9.0-7334-006 Crown 2006 PF15447-6 Rev. 7/07
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120
PLATFORM
Platform
Shim Basics
(TL Platform Not Available On SP3470/80/71/81)
The mast is designed to be at its tightest point when
fully extended and at its loosest when fully lowered.
This allows the mast and platform column rollers to
move freely as the mast extends while providing maxi-
mum stability when fully extended. Each mast is de-
signed to be wider at the bottom than at the top. If the
mast were shimmed so it was tight when fully lowered,
it would not fully extend because of mast to column
roller binding causing detrimental effects to the mast
channel. The mast should only be checked for tight-
ness when near or at full extension.
Shim (060030-085) size used is 0.8 mm (0.031 in)
thick. Refer to Lifting Mechanism for mast shimming
procedures.
TT Platform
(1) Non-Adjustable Column Rollers
(2) Shim (060030-085) 0.8 mm (0.031 in) Thick AR
Figure 17038
Crown 2006 PF15447-7 Rev. 7/07 M9.0-7334-007
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PLATFORM
Platform
Platform Removal & Shimming TL 3. Measure the distance between the channel and
the column roller, 10 mm (0.375 in) from the chan-
Mast nel face. Always measure the side the column
(TL Mast or Platform Not Available On SP3470/80/ roller is canted toward. A clearance of 0 to
71/81) 0.75 mm (0 to 0.030 in) should be obtained. Check
the center and lower platform column rollers since
In order to shim the platform column rollers it is neces- the top column rollers are not adjustable. If the di-
sary to remove the platform from the mast. Refer to mension is greater than 0 to 0.75 mm (0 to
Control Of Hazardous Energy Lockout/Tagout. 0.030 in), another shim will need to be added be-
hind the column roller. It will be necessary to re-
move the platform from the mast to shim the plat-
WARNING form column rollers. If the dimension is zero and it
Wear appropriate items, such as safety glasses, when- does not appear to be tight, proceed to check the
ever performing maintenance work. Do not place fin- remaining platform column rollers.
gers, hands or arms through mast or position them at
pinch points.
In this section you may be required to lift and block the
truck and mast or raise and lower different components
for removal and installation. Make sure 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
mast, disconnect electrical connections and hydraulic
lines. "Control of Hazardous Energy" section provides
information for performing the above procedures along
with some additional information on other procedures
dealing with truck maintenance. This section should be
read and reviewed prior to mast removal, installation
and maintenance as outlined in this section.
1. Raise platform to full extension.
(1) Adjustable Column Rollers
2. Use a man-up vehicle to get into position to mea- (2) Non-Adjustable Column Rollers
sure platform column roller clearance. Use a pry
bar to shift the platform to one side; this will force
the opposite side tight against the mast channel. Figure 17039
This is necessary to seat each platform column 4. Lower the second stage mast and block both sides
roller against the roller stud shoulder to allow for an when it is a minimum of 760 mm (30.0 in) above
accurate measurement. Once the platform has the floor. Use hardwood blocks that are 50 x
shifted, retain slight pressure to hold the platform in 100 mm (2.0 x 4.0 in). Refer to Control Of Hazard-
position. ous Energy Lockout/Tagout for lifting and blocking
procedures.
M9.0-7334-008 Crown 2006 PF15447-8 Rev. 7/07
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PLATFORM
Platform
5. Disconnect battery and chock wheels.
6. Remove platform height sensor if present on truck.
Refer to Platform for height sensor removal, instal-
lation and adjustment procedures.
7. Using a lifting device raise the platform approxi-
mately 75 mm (3.0 in) to allow the mast chains to
become slack. Note that the combined weight of
the platform and forks are approximately 485 to
620 kgs (1070 to 1360 lb).
8. Disconnect mast lift chains from the platform by re-
moving the chain pins and secure with tie straps.
9. Using lifting device, lower platform to floor making
sure that cables, hoses and lift chains do not be-
come tangled with platform to prevent any damage
to them.
10. Place platform away from mast approximately
125 mm (5.0 in) to gain access to platform column
rollers.
11. Remove column rollers and note number of shims
on each roller mounting stud. Remove column roll-
ers carefully, many times the shims will stick to the
back of the column roller and fall off after removal.
12. Shim platform column rollers as needed. Please
(1) Block Both Sides of Second Stage Mast a note that it is best to shim the platform column roll-
Minimum Height of 760 mm (30 in) ers evenly. That is an equal number of shim(s) on
(2) Use 50 x 100 mm (2.0 x 4.0 in) Hardwood Blocks each column roller. However if this is not possible
follow the shim procedures. Refer to Lifting Mech-
Figure 17040 anism. Example: Two shims on both left side plat-
form column rollers and one shim on both right side
column rollers. Refer to Figure 17041.
Crown 2006 PF15447-9 Rev. 7/07 M9.0-7334-009
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PLATFORM
Platform
13. Install platform back into mast. With lifting device,
extend platform to full height and check for tight
spots. Make sure that all cables, hoses and chains
are not pinched, cut or damaged in any way while
extending the platform up the mast. If any tight
spots are found make corrections to shims as re-
quired.
14. If no tight spots are found, lower platform and reas-
semble chains, hoses etc. in reverse order of re-
moval.
15. Connect battery remove wheel chocks and verify
truck operation.
Correct Method for Uneven Shimming
(1) One Shim
(2) Two Shims
(3) Non-Adjustable Column Rollers
Incorrect Method for Uneven Shimming
(4) One Shim
(5) Two Shims
(6) One Shim
(7) Non-Adjustable Column Rollers
Figure 17041
M9.0-7334-010 Crown 2006 PF15447-10 Rev. 7/07
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PLATFORM
Platform
Platform Removal & Shimming TT 3. Measure the distance between the channel and
the column roller, 10 mm (0.375 in) from the chan-
Mast nel face. Always measure the side the column
In order to shim the platform column rollers it is neces- roller is canted toward. A clearance of 0 to
sary to remove the platform from the mast. Refer to 0.75 mm (0 to 0.030 in) should be obtained. If the
Control Of Hazardous Energy Lockout/Tagout. dimension is greater than 0 to 0.75 mm (0 to
0.030 in), another shim will need to be added be-
hind the column roller. It will be necessary to re-
WARNING move the platform from the mast to shim the plat-
form column rollers. If the dimension is zero and it
Wear appropriate items, such as safety glasses, when- does not appear to be tight, proceed to check the
ever performing maintenance work. Do not place fin- remaining platform column rollers.
gers, hands or arms through mast or position them at
pinch points. 4. Raise the mast until the third stage is a minimum of
In this section you may be required to lift and block the 760 mm (30.0 in) above the floor, the second stage
truck and mast or raise and lower different components should be approximately 380 mm (15.0 in) from
for removal and installation. Make sure lifting device the floor. Use hardwood blocks that are 100 x
and sling are sufficiently rated to withstand the weight 100 mm (4.0 x 4.0 in) to block the second stage
being lifted. Never work under or around a truck that is mast. Refer to Control Of Hazardous Energy Lock-
not properly secured. Refer to truck Data Plate for truck out/Tagout for lifting and blocking procedures.
weight information.
It will be necessary to disconnect and remove the bat-
tery from the truck, disconnect tilt cylinders from the
mast, disconnect electrical connections and hydraulic
lines. "Control of Hazardous Energy" section provides
information for performing the above procedures along
with some additional information on other procedures
dealing with truck maintenance. This section should be
read and reviewed prior to mast removal, installation
and maintenance as outlined in this section.
1. Raise carriage through free lift and stop platform
50 mm (2.0 in) short of spring loaded stops making
contact with stop bar on third stage mast.
2. Use a man-up vehicle to get into position to mea-
sure platform column roller clearance. Use a pry
bar to shift the platform to one side; this will force
the opposite side tight against the mast channel.
This is necessary to seat each platform column
roller against the roller stud shoulder to allow for an
accurate measurement. Once the platform has (1) Block Both Sides of Second Stage Mast a
shifted, retain slight pressure to hold the platform in Minimum Height of 380 mm (15 in)
position. (2) Use 100 x 100 mm (4.0 x 4.0 in) Hardwood Blocks
Figure 17042
Crown 2006 PF15447-11 Rev. 7/07 M9.0-7334-011
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PLATFORM
Platform
5. Disconnect battery and chock wheels.
6. Remove platform height sensor if present on truck.
Refer to Height Sensor for height sensor removal,
installation and adjustment procedures.
7. Using a lifting device, raise the platform approxi-
mately 75 mm (3.0 in) to allow the mast chains to
become slack. Note that the combined weight of
the platform and forks are approximately 485 to
620 kg (1070 to 1360 lb).
8. Disconnect mast lift chains from the platform by re-
moving the chain pins and secure with tie straps.
TT Platform
(1) Chain Slack Mechanism
(2) Free Lift Chains
Figure 17043
9. Using lifting device, lower platform to floor making
sure that cables, hoses and lift chains do not be-
come tangled with platform to prevent any damage
to them.
10. Place platform away from mast approximately
TT Platform
125 mm (5.0 in) to gain access to platform column
Correct Method for Uneven Shimming
rollers.
(1) One Shim
11. Remove column rollers and note number of shims (2) Two Shims
on each roller mounting stud. Remove the column
Incorrect Method for Uneven Shimming
rollers carefully, many times the shims will stick to
the back of the column roller and fall off after re- (3) One Shim
moval. (4) One Shim
(5) Two Shims
12. Shim platform column rollers as needed. Please
note that it is best to shim the platform column roll- (6) One Shim
ers evenly. That is an equal number of shim(s) on (7) Non-Adjustable Column Rollers
each column roller. However if this is not possible
follow the shim procedures, refer to Lifting Mecha-
Figure 17044
nism. Example: Two shims on both left side plat-
form column rollers and one shim on both right side
column rollers. Refer to Figure 17044.
M9.0-7334-012 Crown 2006 PF15447-12 Rev. 7/07
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PLATFORM
Platform
13. Install platform back into mast. Remove yoke from
free lift cylinder and suspend it from the third stage
mast so that it will be moved toward the power unit
a minimum of 40 mm (1.5 in) to prevent any dam-
age to the yoke assembly while raising or lowering
the platform. Using a lifting device, extend platform
to full height and check for tight spots. Make sure
that all cables, hoses and chains are not pinched,
cut or damaged in any way while raising the plat-
form up the mast. If any tight spots are found make
corrections to shims as required.
14. If no tight spots are found, lower platform and reas-
semble chains, hoses etc. in reverse order of re-
moval.
15. Connect battery remove wheel chocks and verify
truck operation.
Crown 2006 PF15447-13 Rev. 7/07 M9.0-7334-013
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PLATFORM
Platform
Platform
DANGER
Safety Notices A truck that falls can cause severe injury or death.
Using a lift device or blocks that do not have sufficient
capacity can result in severe injury or even death.
WARNING Never do maintenance below or around a truck that
is not correctly secured.
Incorrect or missing safety procedures and safety
equipment can cause death or injury. Refer to and obey the applicable lifting and blocking
You must use the correct protective equipment and procedures in SAFETY/Control of Hazardous En-
obey all safety procedures to do work on a truck. If you ergy/Lifting and Blocking.
do not, death or injury can result. Refer to and obey the instructions in SAFETY/Con-
Refer to and obey the instructions in SAFETY/Con- trol of Hazardous Energy.
trol of Hazardous Energy. Refer to and obey all recommended safety precau-
Refer to and obey all recommended safety precau- tions.
tions.
Use the correct protective items, such as safety
glasses, work gloves, and steel-toed shoes.
Mat Replacement
Refer to Figure 1.
Special Tools and Equipment:
WARNING • Clear adhesive (061001-031).
Replace the mat
A truck or mast that falls can cause severe injury or
death. 1. Make sure that you are in an area with good air-
If the capacity of the lift device, straps or chains, or flow.
hardwood blocks cannot hold the mainframe, platform, 2. Remove the worn mat (1) from the platform floor
and load handler weight, the truck could fall. surface (2).
Refer to and obey the applicable lifting and blocking 3. Fully clean the platform floor surface (2).
procedures in SAFETY/Control of Hazardous En- Note: Do not apply adhesive (061001-031) to the bot-
ergy/Lifting and Blocking. tom of the mat (1) if the mat has a sponge type surface.
Never put fingers, hands, arms, or feet through the Apply a heavier layer to the platform floor surface (2) as
mast. an alternative.
Never put fingers, hands, arms, or feet at pinch 4. Apply a thin layer of adhesive (061001-031) to the
points. bottom of the mat (1) and the platform floor surface
Make sure that the lift device is sufficiently rated to (2).
lift the necessary parts of the mast. 5. Let the adhesive (061001-031) become tacky (10–
Make sure that the blocking material is sufficiently 15 minutes).
rated to support the necessary truck weight. 6. Put the replacement mat (1) in the correct position
Never work under or near a truck that without suffi- on the platform floor surface (2).
cient and secure blocks. 7. Apply pressure to the replacement mat (1) to make
sure that there is sufficient contact between the re-
placement mat and the platform floor surface (2).
Crown 2010 PF17884 Rev. 9/16 M9.0-7335-001
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PLATFORM
Platform
340020-002
2 340020-001
1
Fig. 2 (28373)
1. Pull the shield/screen installation tool
(340020-001, 340020-002, Figure 3) or a flat blade
screwdriver along the seam of the rubber molding
(1) to loosen the rubber molding tabs (both sides
and the bottom) (2).
2. Carefully pull one top corner of the shield away
from the rubber molding (1).
Fig. 1 (28372-01) 3. Carefully pull the side of the shield until you fully
remove the side of the shield from the guard.
Shield Removal and Installation 4. After you fully remove one side of the shield from
the rubber molding (1), tightly hold the shield and
Special Tools and Equipment: pull the remaining shield from the guard and the
• Final Step cleaner (363129-001) support.
• Shield/screen installation tools (340020-001,
340020-002) or a flat blade screwdriver.
Remove the shield 340020-001
Note: You can remove the shield without the shield/
screen installation tools (340020-001, 340020-002,
Figure 2), but it is easier to remove the shield with the
shield/screen installation tools. 1
Fig. 3 (28374-01)
M9.0-7335-002 Crown 2010 PF17884 Rev. 9/16
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546
PLATFORM
Platform
Install the shield 3. Wind a chain tightly around the platform floor (1).
1. Apply the cleaner (363129-001) to the rubber This chain helps support the fork heel.
molding (1, Figure 4). 4. Attach a sling to the fork (2) to make sure that the
The cleaner (363129-001) lets the shield/screen fork weight is balanced equally.
installation tool (340020-001, 340020-002) or 5. Remove the two retaining rings (3) from the fork
the flat blade screwdriver slide easily on the rub- rod (4).
ber molding (1).
6. Attach a lift device to the fork (2) to support the
2. Install the shield in the rubber molding (1). fork.
3. Pull the shield/screen installation tool 7. Remove the fork rod (4) from the fork (2).
(340020-001, 340020-002) or the flat blade screw-
driver along the seam of the rubber molding (1) to Install the forks
secure the rubber molding tabs (2). 1. Attach a sling to the fork (2) to make sure that the
fork weight is balanced equally.
2. Attach a lift device to the fork (2) to support the
fork.
3. Use the lift device to raise the fork (2) to the correct
position.
1 4. Install the fork rod (4) in the fork (2).
5. Install the two retaining rings (3) on the fork rod (4).
Note: Shims (5) are in the heel area of the fork (2) to
make sure that the fork tip is in the correct position. The
fork tip height must be equal to the fork height along the
2 full length of the fork. With the platform fully lowered,
the fork height must be 75 mm (3 in) from the top of the
fork to the floor.
6. Apply some thread-locking adhesive (061004-012)
to the screws (6) that hold the shims (5) to the plat-
340020-001 form.
Fig. 4 (28375-01)
Fork Removal and Installation
Refer to Figure 5.
Special Tools and Equipment:
• Balance fork hookup
• Chain
• Lift device
• Removable blue thread-locking adhesive
(061004-012)
• Sling.
Remove the forks
1. Raise the platform 610 mm (24 in).
2. Make sure that the mast and the platform are cor-
rectly blocked. Refer to and obey the applicable lift-
ing and blocking procedures in SAFETY/Control of
Hazardous Energy/Lifting and Blocking/Blocking
the Mast.
Crown 2010 PF17884 Rev. 9/16 M9.0-7335-003
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PLATFORM
Platform
Adjust the fork height on trucks with a TL mast
Refer to Figure 6.
1. Remove the cotter pin (1) from the chain anchor (2)
on the top of the mainframe (3).
2. Loosen the jam nut (4).
3. To move the chain anchor (2), turn the adjustment
nut (5) as it is necessary.
Moving the chain anchor (2) adjusts the fork
height.
1
4. When the fork height is correct, tighten the jam nut
(4).
5. Install the cotter pin (1) in the chain anchor (2).
3
3
4
2
3
5
1
Fig. 5 (28376-01) 4
Fork Height Adjustment
Specifications 2
• With the platform fully lowered, the fork height must
Fig. 6 (28377-01)
be 75 mm (3 in) from the top of the fork to the floor.
If the fork height is not 75 mm (3 in) from the top of Adjust the fork height on trucks with a TT mast
the fork to the floor, adjust the fork height.
Refer to Figure 7.
• There must be a 6.5 mm (0.25 in) clearance be-
1. Remove the cotter pin (1) from the chain anchor (2)
tween the bottom of the platform and the top of the
on the free lift cylinder (3).
outrigger.
2. Loosen the jam nut (4).
M9.0-7335-004 Crown 2010 PF17884 Rev. 9/16
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548
PLATFORM
Platform
3. To move the chain anchor (2), turn the adjustment Note: The release handle (1) must be parallel to the
nut (5) as it is necessary. cutout in the console when the pallet grab is not in op-
Moving the chain anchor (2) adjusts the fork eration (the foot pedal is in the up position).
height.
Adjust the release handle
4. When the fork height is correct, tighten the jam nut
1. Remove the cotter pin (2) and the clevis pin (3)
(4).
from the pushrod (4).
5. Install the cotter pin (1) in the chain anchor (2).
2. Loosen the nut (5) on the pushrod (4).
3. Turn the pushrod (4) clockwise (to increase the
length of the pushrod and raise the release handle)
or counterclockwise (to decrease the length of the
pushrod and lower the release handle).
4. Tighten the nut (5) on the pushrod (4).
5. Install the clevis pin (3) and the cotter pin (2) in the
pushrod (4).
1
4
5
Fig. 7 (28378-01)
Pallet Grab
The pallet grab is below the platform. Mechanical link-
age connects the mounting plate below the platform to Fig. 8 (28379-01)
the release handle below the control module. You ap-
ply the pallet grab with your foot and release the pallet
grab with your hand.
Release Handle Adjustment
Refer to Figure 8.
Crown 2010 PF17884 Rev. 9/16 M9.0-7335-005
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PLATFORM
Platform
Foot Pedal Adjustment
Refer to Figure 9.
The foot pedal (1) has spring tension applied to it con-
stantly during normal release and applied conditions.
When the foot pedal (1) is in the up (released) position,
4
the back of the foot pedal touches a bumper (2). The
bumper (2) prevents metal to metal contact between
the foot pedal (1) and the platform (3). Adjust the foot
pedal from below the platform floor.
Adjust the foot pedal
1. Make sure that the mast and the platform are cor- 5
rectly blocked. Refer to and obey the applicable lift-
ing and blocking procedures in SAFETY/Control of
Hazardous Energy/Lifting and Blocking/Blocking
the Mast.
2. Inspect the bumper (2).
Replace the bumper (2) if the bumper is dam-
aged or worn.
3. Loosen the jam nut (4). 1
4. To adjust the foot pedal (1) height, turn the adjust-
ment nut (5) clockwise.
5. When the foot pedal (1) height is satisfactory,
tighten the adjustment nut (5). 2 3
6. Tighten the jam nut (4).
Fig. 9 (28380-01)
Pallet Grab Removal and Installation
Remove the pallet grab
1. Hold the pallet grab (1, Figure 10) in position while
you remove the two screws (2) and the two lock-
washers (3) from the pallet grab.
Note: The pallet grab (1) must stay on the bracket (4)
below the platform floor (5).
2. Turn the pallet grab (1) down the bracket (4) below
the platform floor (5).
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PLATFORM
Platform
1
2
4 3
Fig. 11 (28382-01)
4 Install the pallet grab
1. Install these components on the arm (1,
Figure 11):
• 1346 mm (53 in) cable (4)
• Flatwasher (3)
• Cotter pin (2).
2. Install the pallet grab (1, Figure 11) below the plat-
form floor (5) with the two lockwashers (3) and the
1 two screws (2).
3
Pallet Grab Component Replacement
2
Specifications
Fig. 10 (28381-01) • When you replace the pallet grab components, re-
move the pallet grab from the platform floor. Refer
3. Remove these components from the arm (1, to Pallet Grab Removal and Installation/Remove
Figure 11): the pallet grab.
• Cotter pin (2)
Replace the arm springs
• Flatwasher (3)
• 1346 mm (53 in) cable (4). Refer to Figure 12.
4. Remove the pallet grab (1) from the platform. 1. Remove the existing arm springs (1) from the arm
(2) and the bracket (3).
2. Install the replacement arm springs (1) on the arm
(2) and the bracket (3).
When the pallet grab is in the released position,
the arm springs (1) must measure 143 mm
(5.62 in) in length.
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PLATFORM
Platform
2 3
2
3
1
Fig. 12 (28383-01)
4 1
Replace the 1346 mm (53 in) cable
Refer to Figure 13.
1. Remove these components from the arm (1):
• Cotter pin (2)
• Flatwasher (3)
• The existing 1346 mm (53 in) cable (4).
2. Remove these components from the retainer (5):
• Nut (6)
• Lockwasher (7)
• Screw (8)
• Two flatwashers (9)
8
• Spacer (10)
• The existing 1346 mm (53 in) cable (4).
6 5
3. Install these components on the arm (1):
• The replacement 1346 mm (53 in) cable (4) 7
• Flatwasher (3) 10
• Cotter pin (2). 4
Note: To keep the correct spring length and cable ten- 9
sion, install the components in step 4 in the second
hole or the third hole of the retainer (5) if the 1346 mm Fig. 13 (28384-01)
(53 in) cable (4) is stretched or replaced. Replace the arm bumper
4. Install these components on the retainer (5):
Refer to Figure 14.
• The replacement 1346 mm (53 in) cable (4)
1. Remove these components from the arm (1):
• Spacer (10)
• Screw (2)
• Two flatwashers (9)
• Lockwasher (3)
• Screw (8)
• Flatwasher (4)
• Lockwasher (7)
• Stop bushing (5)
• Nut (6).
• The existing arm bumper (6).
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PLATFORM
Platform
2. Install these components on the arm (1):
• The replacement arm bumper (6).
• Stop bushing (5)
• Flatwasher (4)
• Lockwasher (3)
• Screw (2). 1
1 2
2
6
3
5
Fig. 15 (28386-01)
4
Return Spring Removal and Installation
2 Refer to Figure 16.
Fig. 14 (28385-01) Special Tools and Equipment:
• Spanner wrench (104712).
Side Gates
Remove the return spring
The platform (1, Figure 15) has side gates that move
into the up position (2) and the down position (3). When 1. With the side gate in the down position, put the
the platform (1) is in the lowered position, move the spanner wrench (104712) on the lower pivot shaft
side gates into the up position (2) to go into or exit the (1).
platform. When the side gates are in the up position (2), 2. Use a hammer and a 4–5 mm (3/16 in) diameter
the truck cannot travel and the platform (1) cannot punch to push the roll pin (2) out 15–19 mm (0.50–
raise. 0.75 in).
3. Keep the spanner wrench (104712) on the lower
pivot shaft (1).
4. Remove the 4–5 mm (3/16 in) diameter punch.
5. Move the side gate (3) into the up position.
6. With the spanner wrench (104712) on the lower
pivot shaft (1), remove the roll pin (2) from the side
gate (3) and the lower pivot shaft (1).
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PLATFORM
Platform
7. Use the spanner wrench (104712) to turn the lower Full Body Harness and Lanyard
pivot shaft (1) counterclockwise to release the ten-
sion in the return spring (4). Inspect the full body harness
When you release the tension in the return 1. Inspect the full body harness for damage (for ex-
spring (4), the tension moves to the spanner ample, tearing) and wear (for example, stressed
wrench (104712). areas and frayed ends).
8. Remove these components from the side gate (3): 2. Replace the full body harness if the full body har-
• Lower pivot shaft (1) ness is damaged or worn.
• Collar (5) Inspect the lanyard
• Two nyliner bearings (6). 1. Inspect the lanyard for damage (for example, tear-
9. Record the position of the collar (5) and the two ing) and wear (for example, stressed areas and
nyliner bearings (6) to refer to during the installa- frayed ends).
tion of the lower pivot shaft (1). 2. Inspect the snap hooks and the locks on each end
10. Put the return spring flange (7) adjacent to the stop of the lanyard for damage that has an effect on op-
(8) that is welded to the platform wall (9). erator safety.
The stop (8) prevents the return spring (4) from 3. Make sure that the lanyard connection to the over-
turning when all side gate (3) parts are installed head guard is secure.
correctly.
4. Replace the lanyard if the lanyard is damaged or
worn.
9
8
4
2
7 6
5 3
Fig. 16 (28387-01)
Install the return spring
1. Install these components in the side gate (3):
• Two nyliner bearings (6).
• Collar (5)
• Lower pivot shaft (1).
2. With the side gate (3) in the up position, use the
spanner wrench (104712) to turn the lower pivot
shaft (1) clockwise 40–45° to increase the tension
in the return spring (4).
3. Install the roll pin (2) in the side gate (3) and the
lower pivot shaft (1).
M9.0-7335-010 Crown 2010 PF17884 Rev. 9/16
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PLATFORM
Platform
Shim Installation on TL Masts, Plat-
form Removal, and Platform Installa-
tion 2
Special Tools and Equipment:
• Lift device
• Straps
• Two 50 x 100 mm (2 x 4 in) hardwood blocks
• Wave®, Stockpicker, or an equivalent man-up
truck.
Prepare the truck for maintenance
1. Fully raise the platform.
2. Use a Wave®, Stockpicker, or an equivalent man- 1
up truck to be in the correct position to measure the
distance between the mast channel and the plat-
form column roller.
3. Use a pry bar to move the platform to one side.
Fig. 17 (28389-01)
This pushes the opposite side of the platform
against the mast channel. This is necessary to Remove the lift chains
push each platform column roller against the
Refer to Figure 18.
roller stud shoulder for an accurate measure-
ment. 1. Lower the second stage mast (1) to a minimum of
760 mm (30 in) above the floor.
4. Hold the platform in position.
2. Use two 50 x 100 mm (2 x 4 in) hardwood blocks
Measure the distance between the mast channel (2) to block both sides of the second stage mast
and the platform column roller (1). Refer to SAFETY/Control of Hazardous En-
Refer to Figure 17. ergy/Blocking the Mast/Block the mast and the
platform.
Note: Always measure the side that the platform col-
umn roller tilts toward.
1. Measure the distance between the mast channel
and the center and lower platform column rollers
(1).
The top platform column rollers (2) are not ad-
justable.
The clearance between the mast channel and
the center and lower platform column rollers (1)
must be 0–75 mm (0–0.030 in).
2. If the clearance between the mast channel and the
center and lower platform column rollers (1) is
more than 0–75 mm (0–0.030 in), do these steps:
• Remove the platform from the mast. Refer to Re-
move the platform.
• Add a shim behind the platform column rollers (1,
2).
3. If the clearance between the mast channel and the
center and lower platform column rollers (1) is
0 mm (0 in), make sure that the top platform rollers
(2) are tight.
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PLATFORM
Platform
Install the shims
1. Remove the platform column rollers.
2. Record the number of shims on the platform col-
umn roller studs.
3. If it is necessary, install more shims on the platform
column roller studs. Refer to LIFTING MECHA-
NISM/Mast/Shim Basics.
Install the platform
Refer to Figure 17.
1. Install the platform onto the mast.
2. Use a lift device to extend the platform to full
height.
Make sure that the cables, the hoses, and the lift
1 chains are not damaged by the platform.
3. Make sure that the clearance between the mast
channel and the center and lower platform column
rollers (1) is 0–75 mm (0–0.030 in).
If the clearance between the mast channel and
the center and lower platform column rollers (1)
is 0 mm (0 in), make sure that the top platform
1
rollers (2) are tight.
4. Lower the platform.
5. Install the lift chains on the platform with the chain
2 anchor pins.
Fig. 18 (28390-01) Prepare the truck for operation
1. Remove the straps from the lift chains.
3. Disconnect the battery.
2. Remove the lift device from the platform.
4. Put chocks against the wheels to prevent the
movement of the truck. Refer to SAFETY/Control 3. Remove the chocks from the wheels.
of Hazardous Energy/Lifting and Blocking. 4. Connect the battery.
5. Remove the platform height encoder (ECR4). Re-
fer to PLATFORM/Dual Height Encoder/ECR4 Re- Shim Installation on TT Masts, Plat-
moval and Disassembly. form Removal, and Platform Installa-
6. Attach a lift device to the platform. tion
Note: The combined weight of the platform and the
forks is 485–620 kg (1070–1360 lb). Special Tools and Equipment:
7. Use a lift device to raise the platform 75 mm (3 in) • Lift device
to let the lift chains become slack. • Straps
8. Secure the lift chains with straps. • Two 100 x 100 mm (4 x 4 in) hardwood blocks
9. Remove the chain anchor pins to disconnect the lift • Wave®, Stockpicker, or an equivalent man-up
chains from the platform. truck.
Remove the platform Prepare the truck for maintenance
1. Use a lift device to lower the platform to the floor. 1. Raise the platform through free-lift and stop the
Make sure that the cables, the hoses, and the lift platform 50 mm (2 in) before the stops that touch
chains are not damaged by the platform. the stop bar on the third stage mast.
2. Move the platform 125 mm (5 in) away from the 2. Use a Wave®, Stockpicker, or an equivalent man-
mast to get access to the platform column rollers. up truck to be in the correct position to measure the
M9.0-7335-013 Crown 2010 PF17884 Rev. 9/16
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PLATFORM
Platform
distance between the mast channel and the plat- Remove the lift chains
form column roller. 1. Raise the third stage mast (1) to a minimum of
3. Use a pry bar to move the platform to one side. 760 mm (30 in) above the floor.
This pushes the opposite side of the platform The second stage mast (2) must be 380 mm
against the mast channel. This is necessary to (15 in) above the floor.
push each platform column roller against the 2. Use two 100 x 100 mm (4 x 4 in) hardwood blocks
roller stud shoulder for an accurate measure- (3) to block both sides of the second stage mast
ment. (2). Refer to SAFETY/Control of Hazardous En-
4. Hold the platform in position. ergy/Blocking the Mast/Block the mast and the
platform.
Measure the distance between the mast channel
and the platform column roller 3. Disconnect the battery.
4. Put chocks against the wheels to prevent the
Refer to Figure 19.
movement of the truck. Refer to SAFETY/Control
Note: Always measure the side that the platform col- of Hazardous Energy/Lifting and Blocking.
umn roller tilts toward.
5. Remove ECR4. Refer to PLATFORM/Dual Height
1. Measure the distance between the mast channel Encoder/ECR4 Removal and Disassembly.
and the platform column rollers (1).
6. Attach a lift device to the platform.
The clearance between the mast channel and
the platform column rollers (1) must be 0– Note: The combined weight of the platform and the
75 mm (0–0.030 in). forks is 485–620 kg (1070–1360 lb).
2. If the clearance between the mast channel and the 7. Use a lift device to raise the platform 75 mm (3 in)
platform column rollers (1) is more than 0–75 mm to let the lift chains become slack.
(0–0.030 in), do these steps: 8. Secure the lift chains with straps.
• Remove the platform from the mast. Refer to Re- 9. Remove the chain anchor pins to disconnect the lift
move the platform. chains from the platform.
• Add a shim behind the platform column rollers (1). Remove the platform
3. If the clearance between the mast channel and the 1. Use a lift device to lower the platform to the floor.
platform column rollers (1) is 0 mm (0 in), make Make sure that the cables, the hoses, and the lift
sure that the remaining platform rollers are tight. chains are not damaged by the platform.
2. Move the platform 125 mm (5 in) away from the
mast to get access to the platform column rollers.
Install the shims
1 1. Remove the platform column rollers.
2. Record the number of shims on the platform col-
umn roller studs.
3. If it is necessary, install more shims on the platform
column roller studs. Refer to LIFTING MECHA-
NISM/Mast/Shim Basics.
Install the platform
Refer to Figure 19.
1 1. Install the platform onto the mast.
2. Remove the yoke from the free lift cylinder.
3. Hang the yoke from the third stage mast to prevent
damage to the yoke when you raise or lower the
platform.
Fig. 19 (28391-01)
Crown 2010 PF17884 Rev. 9/16 M9.0-7335-014
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PLATFORM
Platform
4. Use a lift device to extend the platform to full
height.
Make sure that the cables, the hoses, and the lift
chains are not damaged by the platform.
5. Make sure that the clearance between the mast
channel and the platform column rollers (1) is 0–
75 mm (0–0.030 in).
If the clearance between the mast channel and
the platform column rollers (1) is 0 mm (0 in),
make sure that the remaining platform rollers
are tight.
6. Lower the platform.
7. Install the lift chains on the platform with the chain
anchor pins.
8. Install the yoke on the free lift cylinder.
Prepare the truck for operation
1. Remove the straps from the lift chains.
2. Remove the lift device from the platform.
3. Remove the chocks from the wheels.
4. Connect the battery.
M9.0-7335-014 Crown 2010 PF17884 Rev. 9/16
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PLATFORM
Platform Height Sensor
Platform Height Sensor Height Sensor Encoder Replace-
ment (ECR4)
WARNING Block truck wheels.
Wear appropriate items, such as safety glasses and Raise platform high enough to expose height sensor
steel-toe shoes whenever performing maintenance assembly (ECR4) mounted on bottom of the platform to
work. Do not place fingers, hands or arms through allow removal. Refer to Figure 17711.
mast or position them at pinch points.
Disconnect battery and securely block platform. Refer
In this section you may be required to lift and block the
to Control of Hazardous Energy Lockout/Tagout and
truck and mast or raise and lower different components
Platform for proper procedures to securely block the
for removal and installation. Make sure lifting device
platform. Refer to Figure 17711.
and sling are sufficiently rated to withstand the weight
being lifted. Never work under or around a truck that is Disconnect height sensor (ECR4) wires from PC317 on
not properly secured. Refer to truck Data Plate for truck bottom of platform.
weight information.
It will be necessary to disconnect and remove the bat-
tery from the truck, disconnect tilt cylinders from the
mast, disconnect electrical connections and hydraulic
lines. "Control of Hazardous Energy" section provides
information for performing the above procedures along
with some additional information on other procedures
dealing with truck maintenance. This section should be
read and reviewed prior to mast removal, installation
and maintenance as outlined in this section.
WARNING
Make sure blocking material is strong enough to with-
stand the weight. Never work under or around a truck
that is not properly blocked. Truck must be in an area
with enough clearance to safely raise the platform. Re-
fer to Control of Hazardous Energy Lockout/Tagout
and Platform for proper procedures to securely block
the platform.
(a) Raise Platform to Allow Access to Height Sensor (ECR4)
(b) Block Platform per Control of Hazardous Energy
Figure 17711
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PLATFORM
Platform Height Sensor
Disconnect height encoder cable from bottom of main Hold the cable and allow it to slowly rewind onto the
frame. DO NOT release the cable to be quickly re- cable reel until the sleeve makes contact with the outer
tracted into height sensor as the cable could cross housing. Refer to Figure 17713-01.
thread and cause binding of height sensor. Refer to
Remove mounting screws that secure height encoder
Figure 17712.
(ECR4) assembly to platform.
Move height sensor assembly to work bench and place
face down on bench to allow access to ECR4's mount-
ing screws.
Disconnect Height Sensor
(a) Make Sure Cable Does Not Cross Thread
Cable from Mainframe
on Cable Reel
(b) ECR4 Mounting Screw
Figure 17712
(c) Install 3/8 - 16 bolt, 31.75 mm (1.25 in)
Long to Lock Cable Reel
(d) Remove Bearing Block Mounting Screw
(e) Cable Sleeve in Contact with Outer Housing
Figure 17713-01
Install a 3/8-16 bolt, 31.75 mm (1.25 in) long into exist-
ing hole in housing to lock the cable reel. Refer to Fig-
ure 17713-01.
Remove screw that mounts ECR4 to bearing block
shaft. Refer to Figure 17713-01.
Remove two mounting screws that secures ECR4
bearing block to housing. Refer to Figure 17713-01.
M9.0-7335-051 Crown 2007 PF15822-2
268
PLATFORM
Platform Height Sensor
Remove ECR4 bearing block by using the two screws Tighten ECR4 mounting screw and make sure it is
in opposite holes on the bearing block. Refer to Figure properly seated in the bearing block.
17714-01.
After ECR4 and bearing block are securely mounted on
outer housing, remove reel stop bolt.
Use Bearing Block Mounting Mount height encoder assembly on platform using ex-
Screws to Remove Encoder isting screws.
from Bearing Block
Connect cable from height encoder to bottom of mast.
Verify cable on the reel did not get cross threaded.
Reconnect height sensor harness PC317 to truck.
Remove platform blocking material.
Connect battery and lower platform.
Verify height sensor (ECR4) is functional.
WARNING
Wear appropriate items, such as safety glasses and
steel-toe shoes whenever performing maintenance
Figure 17714-01 work. Do not place fingers, hands or arms through
Remove ECR4 from bearing block. mast or position them at pinch points.
In this section you may be required to lift and block the
Install replacement ECR4 in bearing block with wire truck and mast or raise and lower different components
harness pointing up towards top of height encoder as- for removal and installation. Make sure lifting device
sembly. and sling are sufficiently rated to withstand the weight
being lifted. Never work under or around a truck that is
NOTE not properly secured. Refer to truck Data Plate for truck
weight information.
Make sure replacement ECR4 is evenly pressed into It will be necessary to disconnect and remove the bat-
the bearing block. tery from the truck, disconnect tilt cylinders from the
Mount bearing block and ECR4 on housing using exist- mast, disconnect electrical connections and hydraulic
ing screws. lines. "Control of Hazardous Energy" section provides
information for performing the above procedures along
NOTE with some additional information on other procedures
dealing with truck maintenance. This section should be
When tightening mounting screw for ECR4 the cable read and reviewed prior to mast removal, installation
reel will start to unwind. Make sure bolt has been in- and maintenance as outlined in this section.
stalled into housing prior to tightening the mounting
screw. Truck must be in area with enough clearance to safely
raise the platform. Refer to Control of Hazardous En-
ergy Lockout/Tagout and Platform for proper proce-
dures to securely block the platform.
Disconnect height sensor (ECR4) wires from PC317 on
bottom of platform.
Block truck wheels.
Crown 2007 PF15822-3 M9.0-7335-052
269
PLATFORM
Platform Height Sensor
Raise platform high enough to expose height sensor
assembly (ECR4) mounted on bottom of the platform to WARNING
allow removal. Refer to Figure 17711. Make sure blocking material used is strong enough to
withstand the weight of the platform. Never work under
or around a truck that is not properly blocked.
Disconnect battery and securely block platform. Refer
to Control of Hazardous Energy Lockout/Tagout and
Platform for proper procedures to securely block the
platform.
Disconnect height encoder cable from bottom of main
frame. DO NOT release the cable to be quickly re-
tracted into height sensor as the cable could cross over
and cause binding of height sensor. Refer to Figure
17712.
(a) Raise Platform to Allow Access to Height Sensor (ECR4)
(b) Block Platform per Control of Hazardous Energy
Figure 17711
Disconnect Height Sensor
Cable from Mainframe
Figure 17712
M9.0-7335-053 Crown 2007 PF15822-4
270
PLATFORM
Platform Height Sensor
Hold the cable and allow it to slowly rewind onto the Remove ECR4 bearing block by using the two screws
cable reel until the sleeve makes contact with the outer in opposite holes on the bearing block. Refer to Figure
housing. Refer to Figure 17718-01. 17719-01.
Remove mounting screws that secure height encoder
assembly to platform.
Move height sensor assembly to work bench and place
face down on bench to allow access to ECR4's mount-
ing screws.
Remove screw that mounts ECR4 to bearing block
shaft. Refer to Figure 17718-01.
Remove two mounting screws that secures ECR4
bearing block to housing. Refer to Figure 17718-01.
(a) Remove Height Sensor Mounting
Bracket Screws
(b) Height Sensor Mounting Bracket
(c) Use Bearing Block Screws to Remove
Bearing Block from Housing
Figure 17719-01
Remove mounting bracket from height sensor.
Turn height sensor over to expose front cover.
(a) Make Sure Cable Does Not Cross Thread
on Cable Reel
(b) ECR4 Mounting Screw
(c) Remove Bearing Block Mounting Screws
(d) Cable Sleeve in Contact with Outer Housing
Figure 17718-01
Crown 2007 PF15822-5 M9.0-7335-054
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PLATFORM
Platform Height Sensor
CAUTION WARNING
When last screw is removed in the following step, DO NOT remove spring mounted inside of cable reel.
spring tension will be released through cover rotation. Spring is reverse wound and if not kept restrained, will
unwind completely in the opposite direction. Secure
Remove screws, cover and spacer. Refer to figures
spring in cable reel to prevent spring from coming out
17720 and 17721.
of reel. Cable can be rewound on reel with spring in-
stalled inside of reel. Personal injury is possible if ex-
treme caution is not exercised when working in this
area of the height sensor.
Turn height sensor so cable reel is face down on a flat
surface.
Unwind cable from reel and leave cable lay flat so it
does not twist or kink.
Place thumbs on shaft and remove outer housing from
Remove Cover Screws cable reel.
Remove bearing from outer housing.
Figure 17720
Install replacement bearing into outer case. Make sure
bearing is evenly pressed into the outer housing.
Inspect cable reel and cable.
Replace as needed.
(a) Cover
(b) Spacer
(c) Reel
(d) Spring
(e) ARbor
Figure 17721
M9.0-7335-055 Crown 2007 PF15822-6
272
PLATFORM
Platform Height Sensor
Cable Replacement NOTE
To replace cable you will need cable 094422-002 15 m It is easier to wind cable onto reel with cable reel in
(50 ft), two sleeves 107208, swagging tool 107416 and outer housing.
chain and steel cable lubricant, 063001-009. Make sure cable is evenly wound on reel and cable is
not cross threaded on reel. Refer to Figure 17722.
WARNING
DO NOT remove spring mounted inside of cable reel.
Spring is reverse wound and if not kept restrained, will
unwind completely in the opposite direction. Secure
spring in cable reel to prevent spring from coming out
of reel. Cable can be rewound on reel with spring in-
stalled inside of reel. Personal injury is possible if ex-
treme caution is not exercised when working in this
area of the height sensor.
Remove existing cable from reel by cutting cable where
sleeve attaches cable to reel.
Install one end of replacement cable in hole on cable
reel. Refer to Figure 17722.
Attach sleeve (107208) and crimp using swagging tool
(107416). Refer to Figure 17722. (a) Wrap Clockwise
Install cable reel into outer housing. (b) Sleeve
(c) Cable (094422-002)
Install bearing block on outer housing. Make sure wires
are pointing up. (d) Cable Should be in Reel Grooves
and Not Cross Threaded
Place height sensor in a vise.
Turn cable reel and feed cable onto reel. Refer to Fig- Figure 17722
ure 17722.
Leave last groove on outside of reel empty.
Secure cable and install outer housing over cable reel.
Lubricate cable and cable reel with 063001-009.
Crown 2007 PF15822-7 M9.0-7335-056
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PLATFORM
Platform Height Sensor
Clean and install spacer over cable reel. Refer to Fig- NOTE
ure 17723-01.
Sleeve needs to be placed so it does not go into height
Lubricate spacer with 063001-009. sensor during operation.
Mark one of the mounting holes on height sensor as a Connect cable from height encoder to bottom of mast.
reference point. Refer to Figure 17723-01.
Verify cable on reel did not get cross threaded.
Clean, lubricate (063001-009) and install cover.
Reconnect height sensor harness PC317 to truck.
Rotate cover nine complete turns clockwise to preload
spring. Using mark placed on the cover as a starting Remove platform blocking material.
point. Refer to Figure 17723-01. Connect battery and lower platform.
After spring has been pre-loaded, secure cover with Verify height sensor (ECR4) is functional.
existing screws. Refer to Figure 17723-01.
Figure 17724
(a) Part of Mast
(b) Sleeve Should be 75 mm (3.0 in) Above Bracket
(c) 75 mm (3.0 in)
Figure 17723-01
(a) Place Mark on Cover, Using Mark as Starting Point, Rotate
Cover Nine Times Clockwise to Pre-load Spring
(b) Install Spacer
(c) Install Cover
(d) Use Existing Screws to Secure Cover
Install mounting bracket onto height sensor using exist-
ing bracket and mounting hardware.
Mount height encoder assembly on platform using ex-
isting screws.
Crimp remaining sleeve (107208) approximately
75 mm (3.0 in) above bracket that secures cable to
main frame. Refer to Figure 17724.
M9.0-7335-057 Crown 2007 PF15822-8 Rev. 2/10
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274
GLOSSARY
Glossary
Glossary on the truck such as on platform or in power unit. The
Function column then explains the function or circuit of
Components have been listed in chart form to assist that device. The Diagram column gives the page num-
the service technician in locating these components on ber of the diagram on which the component can be
the Electrical Diagrams and Parts Breakdown forms. found. The callout in parenthesis following the page
number corresponds to the grid callouts on that dia-
The chart is in columns: Component; Location; Func-
gram, locating that component. The Parts Breakdown
tion; Diagram; Parts Breakdown. The Component
column includes the parts breakdown page number on
column contains the abbreviation of the component as
which the component is located along with the index
it appears on the Diagrams in the Maintenance Sec-
number, in parenthesis, if applicable.
tion. The Location column gives the general location
BATTERY
Location Function Diagram Parts Breakdown
Battery Power Unit Battery Power Supply DIA-7335-002 (B-4)
Compartment DIA-7335-004 (B-4)
CONNECTIONS
Location Function Diagram Parts Breakdown
CA101 Distribution Panel - Module Power B+ DIA-7335-006 (B-2) 04.3-7335-050
Platform
CA102 Distribution Panel - Overhead Guard Light/Fan DIA-7335-006 (B-2) 04.3-7335-050
Platform Assemblies
CA103 Distribution Panel - Module Power & Controls DIA-7335-006 (B-2) 04.3-7335-050
Platform
CA104 Distribution Panel - Mast Cable 2 DIA-7335-006 (B-2) 04.3-7335-050
Platform
CA105 Distribution Panel - CAN DIA-7335-006 (B-2) 04.3-7335-050
Platform
CA106 Distribution Panel - Mast Cable 1 DIA-7335-006 (B-2) 04.3-7335-050
Platform
CA107 Distribution Panel - Module & Control Power B- DIA-7335-006 (B-2) 04.3-7335-050
Platform
CA201 Distribution Panel - Controls Power B+ & MMS DIA-7335-008 (A-2) 04.3-7335-001
Power Unit
CA202 Distribution Panel - Lift Power Panel & Brake DIA-7335-008 (B-2) 04.3-7335-001
Power Unit Power
CA203 Distribution Panel - Mast Cable #2 DIA-7335-008 (B-3) 04.3-7335-001
Power Unit
CA204 Distribution Panel - CAN Communication DIA-7335-008 (B-3) 04.3-7335-001
Power Unit
CA205 Distribution Panel - Mast Cable #1 DIA-7335-008 (B-3) 04.3-7335-001
Power Unit
CA206 Distribution Panel - Battery Voltage B+ DIA-7335-008 (A-3) 04.3-7335-001
Power Unit
Crown 2007 PF15823-1 M10-7335-001
461
GLOSSARY
Glossary
CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA301 Platform CAN Access, DIA-7335-003 (A-3),
Programming, InfoLink DIA-7335-005 (B-3),
DIA-7335-009 (B-1)
CA302 Platform I/O DIA-7335-009 (B-1)
CA303 Vehicle Control Module Power & I/O DIA-7335-009 (B-2) 04.0-7335-100
(VCM)
CA304 Vehicle Control Module Power & I/O DIA-7335-009 (B-3) 04.0-7335-100
(VCM)
CA305 Platform Key Switch (KYS) DIA-7335-011 (B-1) 04.6-7335-001 (22)
CA308 Platform Switches - Travel, Lift, DIA-7335-011 (A-1) 04.6-7334-050 (11);
Lower, Horn 04.6-7334-052 (68)
CA309 Platform Throttle & Switches - DIA-7335-011 (A-2) 04.6-7335-001
Guidance, Two Hand (EU),
Override
CA310 Platform Lights & Fan DIA-7335-012 (B-1) 04.8-7330-100
(18-21)
CA311 Platform Lights & Fan DIA-7335-012 (B-1) 04.8-7330-100
(18-21)
CA312 Platform Lights & Fan DIA-7335-012 (B-3) 04.8-7330-100
(18-21)
CA313 Platform Lights & Fan DIA-7335-012 (B-3) 04.8-7330-100
(18-21)
CA315 Platform Lights & Fan DIA-7335-012 (B-3) 04.8-7330-100
(18-21)
CA316 Platform Lights & Fan DIA-7335-012 (B-3) 04.8-7330-100
(18-21)
CA317 Platform Height Encoder DIA-7335-009 (A-2) 09.0-7334-200 (17)
CA318 Platform Steer Sense DIA-7335-009 (A-4) 04.6-7335-003 (41)
CA322 Platform Gate Switches DIA-7335-011 (B-4) 09.0-7334-150 (4)
CA323 Platform Display Control Module DIA-7335-009 (B-2) 04.6-7335-003 (41)
(DCM) Steer Indicator
CA324 Platform Switches - Travel, Lift, DIA-7335-011 (B-2) 04.6-7334-050 (11);
Lower, Horn 04.6-7334-052 (68)
CA325 Platform PVLF Driver DIA-7335-009 (B-3)
CA326 Platform SV1 Driver DIA-7335-009 (B-3)
CA327 Platform Lifting Forks Option DIA-7335-009 (B-2)
CA328 Platform Lifting Forks Option DIA-7335-009 (B-2)
CA330 Platform Travel Alarm, Lifting Forks DIA-7335-009 (B-3)
B-
M10-7335-002 Crown 2007 PF15823-2
462
GLOSSARY
Glossary
CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA331 Platform EU Chain Break DIA-7335-009 (B-4)
CA332 Platform Zone Select Switch DIA-7335-011 (B-3) 04.8-7330-100 (17)
CA333 Platform Zone Select Switch DIA-7335-011 (B-3) 04.8-7330-100 (17)
CA334 Platform Zone Select Switch DIA-7335-011 (B-3) 04.8-7330-100 (17)
CA335 Platform Zone Select Switch DIA-7335-011 (B-3) 04.8-7330-100 (17)
CA401 Traction Control Module I/O DIA-7335-013 (B-1, 04.1-7335-001 (13)
(TCM) C-2)
CA402 Steering Control Module Communications DIA-7335-014 (B-1, 04.1-7335-001 (17)
C-1)
CA403 Steering Control Module I/O DIA-7335-014 (B-1, 04.1-7335-001 (17)
C-2)
CA406 Power Unit Current Sensor DIA-7335-014 (B-2)
CA407 Power Unit Brake DIA-7335-002 (B-3), 05.3-7335-001
DIA-7335-004 (B-3),
DIA-7335-014 (B-3)
CA410 Power Unit Steering Feedback DIA-7335-014 (B-4) 04.8-7335-200 (3)
CA411 Power Unit Traction Feedback Encoder DIA-7335-014 (B-3) 03.1-7335-001 (16)
CA414 Power Unit Chain Slack, Chain Break DIA-7335-013 (B-3)
(EU)
CA415 Power Unit Chain Slack, Chain Break DIA-7335-013 (B-4)
(EU)
CA416 Power Unit Chain Slack, Chain Break DIA-7335-013 (B-4)
(EU)
CA417 Power Unit Chain Slack, Chain Break DIA-7335-013 (B-4)
(EU)
CA418 Power Unit Brake/Tow DIA-7335-008 (A-2)
CA501 Overhead Guard Lights DIA-7335-012 (B-1) 04.9-7330-052 (16,
22, 27);
04.9-7330-054 (69,
75, 80)
CA503 Overhead Guard Lights & Fan DIA-7335-012 (B-3) 04.9-7330-052 (16,
22, 27);
04.9-7330-054 (55,
69, 75, 80)
CA601 Guidance Control Communications DIA-7335-016 (B-1, 04.1-7335-001 (25)
Module (Optional) C-1)
CA602 Guidance Control I/O DIA-7335-016 (B-1, 04.1-7335-001 (25)
Module (Optional) C-2)
CA603 Guidance Control I/O DIA-7335-016 (B-2) 04.1-7335-001 (25)
Module (Optional)
Crown 2007 PF15823-3 M10-7335-003
463
GLOSSARY
Glossary
CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA604 Guidance Control I/O DIA-7335-016 (B-3) 04.1-7335-001 (25)
Module (Optional)
CA607 Guidance Control Mast Cable #3 DIA-7335-016 (B-1) 04.1-7335-001 (25)
Module (Optional)
CA608 EAC Sensor Sensor Power DIA-7335-016 (A-1) 10.0-7334-001
CA701 Platform Heaters, Lifting Forks, DIA-7335-017 (B-2),
(Freezer/Corrosion) Travel Alarm DIA-7335-018 (B-2)
(Optional)
CA702 Platform Heaters DIA-7335-017 (B-3)
(Freezer/Corrosion)
(Optional)
CA807 C/C Distribution Board Heaters & Thermostat DIA-7335-017 (B-1)
CA808 C/C Distribution Board Input Power DIA-7335-017 (A-1)
CA809 Power Unit Mast Cable #3 DIA-7335-017 (B-2),
(Freezer/Corrosion) DIA-7335-018 (C-2)
(Optional)
JC413 Power Unit Drive/Tow DIA-7335-002 (A-3), 04.3-7335-001
DIA-7335-004 (A-3),
DIA-7335-014 (B-3)
PC102 Distribution Panel Lights & Fan DIA-7335-012 (A-2)
PC306 Platform Customer Accessories DIA-7335-011 (B-1)
PC307 Platform PC Serial Port DIA-7335-009 (B-4)
PC314 Platform Spot Lights DIA-7335-012 (B-2) 04.0-7335-100 (1)
M10-7335-004 Crown 2007 PF15823-4
464
GLOSSARY
Glossary
Glossary on the truck such as on platform or in power unit. The
Function column then explains the function or circuit of
The battery, connectors and terminal boards have that device. The Diagram column gives the page num-
been listed in chart form to assist the service technician ber of the diagram on which the component can be
in locating these components on the Electrical Dia- found. The callout in parenthesis following the page
grams and Parts Breakdown forms. number corresponds to the grid callouts on that dia-
gram, locating that component. The Parts Breakdown
The chart is in columns: Component; Location; Func-
column includes the parts breakdown page number on
tion; Diagram; Parts Breakdown. The Component
which the component is located along with the index
column contains the abbreviation of the component as
number, in parenthesis, if applicable.
it appears on the Diagrams in the Maintenance Sec-
tion. The Location column gives the general location
BATTERY
Location Function Diagram Parts Breakdown
Battery Power Unit Battery Power Supply DIA-7335-047 (B-4)
Compartment DIA-7335-049 (B-4)
DIA-7335-051 (B-4)
CONNECTIONS
Location Function Diagram Parts Breakdown
CA101 Distribution Panel - Not Used DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform DIA-7335-054 (B-2)
CA102 Distribution Panel - Not Used DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform DIA-7335-054 (B-2)
CA103 Distribution Panel - +BV to Platform Modules & DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform Control Circuit; BNEG from DIA-7335-054 (B-2)
Alarm 1
CA104 Distribution Panel - Mast Cable 2 DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform DIA-7335-054 (B-2)
CA105 Distribution Panel - CAN Communication DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform DIA-7335-054 (B-2)
CA106 Distribution Panel - Mast Cable 1 DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform DIA-7335-054 (B-2)
CA107 Distribution Panel - BNEG Platform Modules & DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform Control Circuit DIA-7335-054 (B-2)
CA201 Distribution Panel - +BV to Power Unit Modules DIA-7335-055 (B-3) 04.3-7335-001 (10)
Power Unit & Control Circuit; +BV &
BNEG from Brushwear Sen-
sors
CA202 Distribution Panel - Lift Power Panel & Brake DIA-7335-055 (B-2) 04.3-7335-001 (10)
Power Unit Power
CA203 Distribution Panel - Mast Cable #2 DIA-7335-055 (B-1) 04.3-7335-001 (10)
Power Unit
CA204 Distribution Panel - CAN Communication DIA-7335-055 (B-2) 04.3-7335-001 (10)
Power Unit
Crown 2010 PF17973-1 M10-7335-010
479
GLOSSARY
Glossary
CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA205 Distribution Panel - Mast Cable #1 DIA-7335-055 (B-3) 04.3-7335-001 (10)
Power Unit
CA206 Distribution Panel - +BV & BNEG to Power Unit DIA-7335-055 (B-3) 04.3-7335-001 (10)
Power Unit & Platform Circuits
CA301 Platform CAN Access, DIA-7335-048 (A-3) Not Shown; located
Programming, InfoLink DIA-7335-050 (A-3) near ACCESS 4
DIA-7335-052 (B-3)
DIA-7335-056 (B-1)
DIA-7335-057 (B-1)
CA302 ACCESS 1 ACCESS 1 I/O DIA-7335-056 (B-1) 09.0-7335-001 (8)
DIA-7335-057 (B-1)
CA303 ACCESS 4 ACCESS 4 I/O DIA-7335-056 (B-2) 09.0-7335-001 (19)
DIA-7335-057 (B-2)
CA304 ACCESS 4 ACCESS 4 Power & I/O DIA-7335-056 (B-3) 09.0-7335-001 (19)
DIA-7335-057 (B-3)
CA305 Platform Key Switch (KYS) DIA-7335-058 (B-1) 04.6-7335-005 (22)
CA308 Platform Switches - Travel, Lift, DIA-7335-058 (B-1) 04.6-7335-005 (60)
Lower, Horn & Key 04.6-7335-050 (11, 68)
CA309 Platform Traction Potentiometer & DIA-7335-058 (B-2) 04.6-7335-005 (41)
Switches - Guidance, Two 04.8-7335-102 (12
Hand (EU), Override
CA310 Platform BNEG Left Work Light DIA-7335-059 (B-1) 04.8-7335-102 (7-10)
CA311 Platform BNEG Left Spot Light, Dome DIA-7335-059 (A-1) 04.8-7335-102 (7-10)
Light & Optional Fan
CA312 Platform BNEG Right Work Light & DIA-7335-059 (B-3) 04.8-7335-102 (7-10)
Dome Light
CA313 Platform BNEG Right Spot Light & DIA-7335-059 (A-3) 04.8-7335-102 (7-10)
Operator Fan
CA314 Platform +BV Mast Mounted Spot DIA-7335-059 (B-2) 04.9-7332-250 (1)
Lights & Left Spot Light
CA315 Platform +12 V Right Work Light DIA-7335-059 (B-3) 04.8-7335-102 (7-10)
CA316 Platform +12 V Right Dome Light DIA-7335-059 (B-3) 04.8-7335-102 (7-10)
CA317 Platform Height Encoder DIA-7335-056 (A-2) 09.0-7335-200 (21)
DIA-7335-057 (A-2)
CA318 Platform Steer Command Encoders DIA-7335-056 (A-4) 06.0-7335-001 (6)
DIA-7335-057 (A-4)
CA322 Platform Gate Switches DIA-7335-058 (B-4) 09.0-7334-150 (4)
CA323 Platform Display Control Module DIA-7335-056 (B-2) 09.0-7335-001 (16)
Steer Indicator DIA-7335-057 (B-2)
M10-7335-011 Crown 2010 PF17973-2
480
GLOSSARY
Glossary
CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA324 Platform Switches - Travel, Lift, DIA-7335-058 (C-2) 04.6-7335-005 (60)
Lower, Horn 04.6-7335-050 (11-68)
CA325 Platform BNEG PVLF DIA-7335-056 (B-3)
CA326 Platform BNEG SV1 DIA-7335-056 (B-3)
CA327 Platform +BV AUX Hyd Switch Input DIA-7335-056 (B-2)
to ACCESS 4
CA328 Platform +BV Limit Switch Input to DIA-7335-056 (B-2)
ACCESS 4
CA330 Platform +BV Travel Alarm Relay Coil DIA-7335-056 (B-3)
CA331 Platform EU Chain Break DIA-7335-056 (B-4)
CA332 Platform Zone Select Switch DIA-7335-058 (B-3) 04.8-7335-102 (11)
CA333 Platform Zone Select Switch DIA-7335-058 (B-3) 04.8-7335-102 (11)
CA334 Platform Zone Select Switch DIA-7335-058 (B-3) 04.8-7335-102 (11)
CA335 Platform Zone Select Switch DIA-7335-058 (B-3) 04.8-7335-102 (11)
CA336 Platform BNEG to K15 Coil DIA-7335-056 (B-3)
CA401 ACCESS 3 Module ACCESS 3 I/O DIA-7335-061 (B-1, 04.1-7335-001 (13)
C-2)
CA402 ACCESS 5 Module Communications DIA-7335-062 (B-1, 04.1-7335-001 (17)
C-1)
CA403 ACCESS 5 Module ACCESS 5 I/O DIA-7335-062 (B-1, 04.1-7335-001 (17)
C-2)
CA406 Power Unit Current Sensor DIA-7335-062 (B-3)
CA407 Power Unit Brake DIA-7335-047 (B-3) 05.3-7335-001 (4)
DIA-7335-049 (B-3)
DIA-7335-051 (A-3)
DIA-7335-062 (B-3)
CA410 Power Unit Steering Feedback Encoder DIA-7335-062 (B-4) 04.8-7335-200 (3)
CA411 Power Unit Traction Feedback Encoder DIA-7335-062 (B-4) 03.1-7335-001 (16)
03.1-7335-050 (17)
CA414 Power Unit Chain Slack, Chain Break DIA-7335-061 (B-4)
(EU)
CA415 Power Unit Chain Slack, Chain Break DIA-7335-061 (B-4)
(EU)
CA416 Power Unit Chain Slack, Chain Break DIA-7335-061 (B-4)
(EU)
CA417 Power Unit Chain Slack, Chain Break DIA-7335-061 (B-4)
(EU)
CA418 Power Unit Brake/Drive-Tow Switch DIA-7335-055 (B-4)
Crown 2010 PF17973-3 M10-7335-012
481
GLOSSARY
Glossary
CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA501 Overhead Guard Lights DIA-7335-059 (B-1) 04.9-7335-050 (16)
CA503 Overhead Guard Lights & Fan DIA-7335-059 (B-3) 04.9-7335-050 (63)
CA601 ACCESS 6 (Optional) Communications, +BV & DIA-7335-064 (B-1, 04.1-7335-001 (25)
BNEG C-1)
CA602 ACCESS 6 (Optional) I/O DIA-7335-064 (B-1, 04.1-7335-001 (25)
C-2)
CA603 Steer Wheel Sensor Bar I/O DIA-7335-064 (A-2) 04.3-7335-500 (1)
(Optional)
CA604 Load Wheel Sensor Bar I/O DIA-7335-064 (A-3) 04.3-7335-500 (10)
(Optional)
CA607 EAC Sensors I/O DIA-7335-064 (A-1) 10.4-7335-001 (18)
CA608 EAC Sensor Sensor Power DIA-7335-064 (A-1) 10.4-7335-001 (18)
CA701 Platform Heaters, Lifting Forks, DIA-7335-065 (B-2), Not shown; located
(Freezer/Condition) Travel Alarm DIA-7335-066 (B-2) near the Platform
(Optional)
CA702 Platform Heaters DIA-7335-065 (B-3) Not shown; located
(Freezer/Condition) behind the Control
Module
CA807 Distribution Board Battery Restraint Switches & DIA-7335-065 (B-1) 04.3-7334-250 (1)
(Freezer/Condition) Rail Guide Switches Heaters
CA808 Distribution Board Input Power DIA-7335-065 (B-1) 04.3-7334-250 (1)
(Freezer/Condition)
CA809 Power Unit Travel Alarm Relay & Other DIA-7335-065 (B-2), Not shown; located
(Freezer/Condition) Options DIA-7335-066 (B-2) near the Power Unit
Distribution Panel
JC330 Platform BNEG Travel Alarm Relay DIA-7335-065 (A-2)
(K15) Coil DIA-7335-066 (A-2)
JC336 Platform +BV Travel Alarm Relay DIA-7335-065 (A-2)
(K15) Coil, SV1 & PVLF DIA-7335-066 (A-2)
JC413 Power Unit Drive/Tow DIA-7335-047 (A-3) Not shown; located
DIA-7335-049 (A-3) near the Power Unit
DIA-7335-051 (A-3) Distribution Panel
DIA-7335-062 (B-3)
PC102 Distribution Panel Lights & Fan DIA-7335-059 (A-2)
DIA-7335-060 (A-2)
PC306 Platform Customer Accessories DIA-7335-058 (B-1)
PC338 Mast Spot Lights DIA-7335-059 (B-2) 04.9-7332-250 (1)
TB502 Overhead Guard Left Dome Light, Left Spot DIA-7335-059 (B-2) 04.9-7335-050 (14)
Light & Operator Fan
M10-7335-013 Crown 2010 PF17973-4
482
GLOSSARY
Glossary
Glossary on the truck such as on platform or in power unit. The
Function column then explains the function or circuit of
The battery, connectors and terminal boards have that device. The Diagram column gives the page num-
been listed in chart form to assist the service technician ber of the diagram on which the component can be
in locating these components on the Electrical Dia- found. The callout in parenthesis following the page
grams and Parts Breakdown forms. number corresponds to the grid callouts on that dia-
gram, locating that component. The Parts Breakdown
The chart is in columns: Component; Location; Func-
column includes the parts breakdown page number on
tion; Diagram; Parts Breakdown. The Component
which the component is located along with the index
column contains the abbreviation of the component as
number, in parenthesis, if applicable.
it appears on the Diagrams in the Maintenance Sec-
tion. The Location column gives the general location
BATTERY
Location Function Diagram Parts Breakdown
Battery Power Unit Battery Power Supply DIA-7335-047 (B-4)
Compartment DIA-7335-049 (B-4)
DIA-7335-051 (B-4)
CONNECTIONS
Location Function Diagram Parts Breakdown
CA101 Distribution Panel - Not Used DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform DIA-7335-054 (B-2)
CA102 Distribution Panel - Not Used DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform DIA-7335-054 (B-2)
CA103 Distribution Panel - +BV to Platform Modules & DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform Control Circuit; BNEG from DIA-7335-054 (B-2)
Alarm 1
CA104 Distribution Panel - Mast Cable 2 DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform DIA-7335-054 (B-2)
CA105 Distribution Panel - CAN Communication DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform DIA-7335-054 (B-2)
CA106 Distribution Panel - Mast Cable 1 DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform DIA-7335-054 (B-2)
CA107 Distribution Panel - BNEG Platform Modules & DIA-7335-053 (B-2) 04.3-7335-050 (3)
Platform Control Circuit DIA-7335-054 (B-2)
CA201 Distribution Panel - +BV to Power Unit Modules DIA-7335-055 (B-3) 04.3-7335-001 (10)
Power Unit & Control Circuit; +BV &
BNEG from Brushwear Sen-
sors
CA202 Distribution Panel - Lift Power Panel & Brake DIA-7335-055 (B-2) 04.3-7335-001 (10)
Power Unit Power
CA203 Distribution Panel - Mast Cable #2 DIA-7335-055 (B-1) 04.3-7335-001 (10)
Power Unit
CA204 Distribution Panel - CAN Communication DIA-7335-055 (B-2) 04.3-7335-001 (10)
Power Unit
Crown 2011 PF25079-1 M10-7335-015
515
GLOSSARY
Glossary
CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA205 Distribution Panel - Mast Cable #1 DIA-7335-055 (B-3) 04.3-7335-001 (10)
Power Unit
CA206 Distribution Panel - +BV & BNEG to Power Unit DIA-7335-055 (B-3) 04.3-7335-001 (10)
Power Unit & Platform Circuits
CA301 Platform CAN Access, DIA-7335-048 (A-3) Not Shown; located
Programming, InfoLink DIA-7335-050 (A-3) near ACCESS 4
DIA-7335-052 (B-3)
DIA-7335-056 (B-1)
DIA-7335-057 (B-1)
CA302 ACCESS 1 ACCESS 1 I/O DIA-7335-056 (B-1) 09.0-7335-001 (8)
DIA-7335-057 (B-1)
CA303 ACCESS 4 ACCESS 4 I/O DIA-7335-056 (B-2) 09.0-7335-001 (19)
DIA-7335-057 (B-2)
CA304 ACCESS 4 ACCESS 4 Power & I/O DIA-7335-056 (B-3) 09.0-7335-001 (19)
DIA-7335-057 (B-3)
CA305 Platform Key Switch (KYS) DIA-7335-058 (B-1) 04.6-7335-005 (22)
CA308 Platform Switches - Travel, Lift, DIA-7335-058 (B-1) 04.6-7335-005 (60)
Lower, Horn & Key 04.6-7335-050 (11, 68)
CA309 Platform Traction Potentiometer & DIA-7335-058 (B-2) 04.6-7335-005 (41)
Switches - Guidance, Two 04.8-7335-102 (12
Hand (EU), Override
CA317 Platform Height Encoder DIA-7335-056 (A-2) 09.0-7335-200 (21)
DIA-7335-057 (A-2)
CA318 Platform Steer Command Encoders DIA-7335-056 (A-4) 06.0-7335-001 (6)
DIA-7335-057 (A-4)
CA322 Platform Gate Switches DIA-7335-058 (B-4) 09.0-7334-150 (4)
CA323 Platform Display Control Module DIA-7335-056 (B-2) 09.0-7335-001 (16)
Steer Indicator DIA-7335-057 (B-2)
CA324 Platform Switches - Travel, Lift, DIA-7335-058 (C-2) 04.6-7335-005 (60)
Lower, Horn 04.6-7335-050 (11-68)
CA325 Platform BNEG PVLF DIA-7335-056 (B-3)
CA326 Platform BNEG SV1 DIA-7335-056 (B-3)
CA327 Platform +BV AUX Hyd Switch Input DIA-7335-056 (B-2)
to ACCESS 4
CA328 Platform +BV Limit Switch Input to DIA-7335-056 (B-2)
ACCESS 4
CA330 Platform +BV Travel Alarm Relay Coil DIA-7335-056 (B-3)
CA331 Platform EU Chain Break DIA-7335-056 (B-4)
CA332 Platform Zone Select Switch DIA-7335-058 (B-3) 04.8-7335-102 (11)
CA333 Platform Zone Select Switch DIA-7335-058 (B-3) 04.8-7335-102 (11)
M10-7335-016 Crown 2011 PF25079-2
516
GLOSSARY
Glossary
CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA334 Platform Zone Select Switch DIA-7335-058 (B-3) 04.8-7335-102 (11)
CA335 Platform Zone Select Switch DIA-7335-058 (B-3) 04.8-7335-102 (11)
CA336 Platform BNEG to K15 Coil DIA-7335-056 (B-3)
CA401 ACCESS 3 Module ACCESS 3 I/O DIA-7335-061 (B-1, 04.1-7335-001 (13)
C-2)
CA402 ACCESS 5 Module Communications DIA-7335-062 (B-1, 04.1-7335-001 (17)
C-1)
CA403 ACCESS 5 Module ACCESS 5 I/O DIA-7335-062 (B-1, 04.1-7335-001 (17)
C-2)
CA406 Power Unit Current Sensor DIA-7335-062 (B-3)
CA407 Power Unit Brake DIA-7335-047 (B-3) 05.3-7335-001 (4)
DIA-7335-049 (B-3)
DIA-7335-051 (A-3)
DIA-7335-062 (B-3)
CA410 Power Unit Steering Feedback Encoder DIA-7335-062 (B-4) 04.8-7335-200 (3)
CA411 Power Unit Traction Feedback Encoder DIA-7335-062 (B-4) 03.1-7335-001 (16)
03.1-7335-050 (17)
CA414 Power Unit Chain Slack, Chain Break DIA-7335-061 (B-4)
(EU)
CA415 Power Unit Chain Slack, Chain Break DIA-7335-061 (B-4)
(EU)
CA416 Power Unit Chain Slack, Chain Break DIA-7335-061 (B-4)
(EU)
CA417 Power Unit Chain Slack, Chain Break DIA-7335-061 (B-4)
(EU)
CA418 Power Unit Brake/Drive-Tow Switch DIA-7335-055 (B-4)
CA501 Overhead Guard Lights DIA-7335-059 (B-1) 04.9-7335-050 (16)
CA503 Overhead Guard Lights & Fan DIA-7335-059 (B-3) 04.9-7335-050 (63)
CA601 ACCESS 6 (Optional) Communications, +BV & DIA-7335-064 (B-1, 04.1-7335-001 (25)
BNEG C-1)
CA602 ACCESS 6 (Optional) I/O DIA-7335-064 (B-1, 04.1-7335-001 (25)
C-2)
CA603 Steer Wheel Sensor Bar I/O DIA-7335-064 (A-2) 04.3-7335-500 (1)
(Optional)
CA604 Load Wheel Sensor Bar I/O DIA-7335-064 (A-3) 04.3-7335-500 (10)
(Optional)
CA607 EAC Sensors I/O DIA-7335-064 (A-1) 10.4-7335-001 (18)
CA608 EAC Sensor Sensor Power DIA-7335-064 (A-1) 10.4-7335-001 (18)
Crown 2011 PF25079-3 M10-7335-017
517
GLOSSARY
Glossary
CONNECTIONS (Continued)
Location Function Diagram Parts Breakdown
CA701 Platform Heaters, Lifting Forks, DIA-7335-065 (B-2), Not shown; located
(Freezer/Condition) Travel Alarm DIA-7335-066 (B-2) near the Platform
(Optional)
CA702 Platform Heaters DIA-7335-065 (B-3) Not shown; located
(Freezer/Condition) behind the Control
Module
CA807 Distribution Board Battery Restraint Switches & DIA-7335-065 (B-1) 04.3-7334-250 (1)
(Freezer/Condition) Rail Guide Switches Heaters
CA808 Distribution Board Input Power DIA-7335-065 (B-1) 04.3-7334-250 (1)
(Freezer/Condition)
CA809 Power Unit Travel Alarm Relay & Other DIA-7335-065 (B-2), Not shown; located
(Freezer/Condition) Options DIA-7335-066 (B-2) near the Power Unit
Distribution Panel
JC330 Platform BNEG Travel Alarm Relay DIA-7335-065 (A-2)
(K15) Coil DIA-7335-066 (A-2)
JC336 Platform +BV Travel Alarm Relay DIA-7335-065 (A-2)
(K15) Coil, SV1 & PVLF DIA-7335-066 (A-2)
JC413 Power Unit Drive/Tow DIA-7335-047 (A-3) Not shown; located
DIA-7335-049 (A-3) near the Power Unit
DIA-7335-051 (A-3) Distribution Panel
DIA-7335-062 (B-3)
PC102 Distribution Panel Lights & Fan DIA-7335-059 (A-2)
DIA-7335-060 (A-2)
PC306 Platform Customer Accessories DIA-7335-058 (B-1)
PC338 Mast Spot Lights DIA-7335-059 (B-2) 04.9-7332-250 (1)
TB502 Overhead Guard Left Dome Light, Left Spot DIA-7335-059 (B-2) 04.9-7335-050 (14)
Light & Operator Fan
M10-7335-018 Crown 2011 PF25079-4
518
SAFETY
General Maintenance Instructions
General Maintenance Instruc- • Make sure to check the functions of the lift systems,
directional control, speed control, steering, warning
tions devices, brakes, and attachments, if any are used.
5. Avoid fire hazards and have fire protection equip-
ment present. Do not use an open flame to check
WARNING level, or for leakage of electrolyte and fluids or oil.
Do not use open pans of fuel or flammable clean-
An injury could occur. ing fluids for cleaning parts.
TO PREVENT SERIOUS RISK OF INJURY TO
YOURSELF AND OTHERS OBSERVE THE FOL- 6. Keep the maintenance area well-ventilated, clean,
LOWING SAFETY INSTRUCTIONS and dry.
7. A tip-over can occur with the improper use of this
Power industrial lift trucks may become hazardous if lift truck, even when the forks are unloaded. In the
adequate maintenance is not performed. Adequate event of a tip-over, do not jump from the lift truck.
maintenance facilities, trained personnel, and proce- Hold the steering wheel tightly and brace your feet.
dures must be provided.
8. The brakes, steering mechanisms, control mecha-
Maintenance and inspection must be performed in con- nisms, lift overload devices, guards, and safety de-
formance with the following practices: vices must be inspected regularly and maintained
in a safe operating condition.
1. A scheduled planned maintenance, lubrication,
and inspection system should be followed. • All guards must be installed to the factory configu-
ration and condition before operating the lift truck.
2. Only qualified and authorized personnel shall be Do not operate the lift truck if any guards or fasten-
permitted to maintain, repair, adjust and inspect ers are damaged, improperly installed, or missing.
the lift truck.
9. The capacity, operation, and maintenance instruc-
3. Before performing maintenance on the lift truck: tion plates or decals must be maintained in legible
• Bring the lift truck to a complete stop. condition.
• Fully lower the load engaging means. 10. All the parts of the lifting mechanisms must be in-
• Put the directional control in neutral. spected to maintain them in safe operating condi-
• Apply the parking brake. tion.
• Turn off the lift truck. 11. All hydraulic systems must be regularly inspected
• Remove the key. and maintained in conformance with good practice.
The cylinders, valves, and other similar parts must
• Chock the wheels of the lift truck.
be checked to make sure that drift has not devel-
• Raise the drive wheel off the floor or disconnect oped to the extent that it would create a hazard.
power sources.
12. Batteries, motors, controllers, limit switches, pro-
• Use chocks or other positive positioning devices.
tective devices, electrical conductors, and connec-
• Block the load engaging means, inner masts, or tions must be maintained in conformance with
chassis before working under them. When working good practice. Provide close attention to the condi-
in these areas keep hands, arms, feet, and legs tion of electrical insulation.
clear to prevent pinching or injury.
13. Keep the lift truck clean to minimize fire hazard and
• To check the performance of the lift truck and at- facilitate detection of loose or defective parts.
tachments, move the lift truck to a secure non-traffic
maintenance area with a level floor and adequate 14. Modifications and additions that affect capacity
clearance. and safe lift truck operation must not be performed
by the customer or user without the manufacturer’s
4. Before operating the lift truck: prior written approval. The capacity, operation and
• Be in the proper operating position. maintenance plates or decals are to be changed
• Apply the brake. accordingly.
• Put the directional control in neutral. • Adding electrical devices (radio, terminal, lights,
etc.) or changing existing components or wiring can
Crown 1976 PF2821 Rev. 6/22 MA-04.0-001
07 Rev. 6/22
3
SAFETY
General Maintenance Instructions
affect the lift truck operation and could cause an ac-
cident. Contact an authorized Crown personnel be-
fore adding to or changing the electrical system.
Technician Tips: In North America, for EE-rated lift
trucks, adding electrical devices could cause a fire or
explosion, as well as void the EE rating. Written ap-
proval must be obtained from Crown prior to adding
electrical device(s). Prior to use, inspection of installed
device(s) must be performed by an appropriate nation-
ally recognized testing laboratory (i.e. Underwriters
Laboratories Inc) or the Authority Having Jurisdiction
(see NFPA 505).
15. Make sure that all replacement parts are inter-
changeable with the original parts and of equal
quality to the original equipment.
16. Make sure that any equipment added to the lift
truck (terminal, fan, clipboard, etc.) is positioned so
that it does not block your vision or interfere with
safe and efficient operation of the truck.
Technician Tips: For more information about opera-
tion and maintenance procedures:
• For all lift trucks, except, Series B and tow tractors,
see ASME B56.1.
• For Series B lift trucks, see ASME B56.10.
• For tow tractors, see ASME B56.9.
Technician Tips: For European lift trucks, for more in-
formation about operation and maintenance proce-
dures, see the F.E.M. safety code - Power Industrial
Truck (section 4).
For copies send to:
F.E.M 10 Avenue Hoche
75382 Paris Cedex 08 France
MA-04.0-002 Crown 1976 PF 2821 Rev. 6/22
07 Rev. 6/22
4
SAFETY
Cleaning of Material Handling Equipment
Cleaning of Material Handling Make sure that these components are safe and cor-
rectly lubricated after cleaning.
Equipment • Be careful when using a power washer on metal
surfaces.
Cleaning procedures When using a power washer, remove the paint and
Using dry, pressurized air and solvent protective cover from components (hydraulic lines,
terminal strips, and linkages) in a freezer condition
• Clean the contamination from the material handling
environment.
equipment with dry, pressurized air.
Apply paint or protective cover to these areas to
• Remove the grease from the material handling
decrease the risk of corrosion.
equipment with the applicable solvent.
• Before installing the removed components, or lubri-
Using a power washer cating, or operating the equipment, make sure that
the equipment does not contain solvent and is dry.
See the Crown Cleaning Products table for items used
CAUTION to clean the material handling equipment.
Material damage can occur.
If the above procedures are not satisfactory and you
must use a power washer, be careful that you do not do
damage to the lift truck.
The electrical components (connectors, terminal
boards, and wires) can be permanently damaged
from water or solvents.
Contamination on or in these components after you
use a power washer can cause corrosion:
• The circuit boards
• The contactors
• The encoders
• The switches
• The potentiometers
• Event codes and irregular lift truck operation can
occur if using a power washer.
• Make sure that all the electronic components are
safe from the power washer.
Removing the components is the best procedure to
decrease the risk of damage.
• When a power washer is used, remove the lubri-
cants in or on the surface of the following compo-
nents:
– Shafts
– Bearings
– Hinges
– Gears
– Bushings
– Chains
– Linkages
Crown 2000 PF11969 Rev. 9/21 MA-1140-050
05 Rev. 9/21
5
SAFETY
Cleaning of Material Handling Equipment
Crown Cleaning Products
Cleaner Type Part Number Package Quantity
Degreaser and cleaner 363105-001 19 oz can
363105-012 (12) 19 oz cans
All-purpose cleaner 363114-001 19 oz can
363114-012 (12) 20 oz cans
Glass cleaner 363101-001 19 oz can
363101-012 (12) 19 oz cans
Waterless hand cleaner 363111-001 15 oz tube
363111-012 (12) 15 oz tubes
Pumiced and smooth hand cleaner 363112-001 1 gal jug
363112-004 (4) 1 gal jugs
Wall-mounted deluxe soap dispenser 363122 Use with P/N 363112-001
Tough on grease 063009-005 1 gal jug
Citrus degreaser spray 363156-001 32 oz spray bottle
363156-012 (12) 32 oz spray bottles
Citrus degreaser spray 363157-101 1 gal refill (use with P/N 363134-001)
363158-101 1 gal concentrated (use with P/N 363134-001)
Citra-sol degreaser 363146-001 19 oz can
363146-012 (12) 19 oz cans
Battery cleaner 363124-001 18 oz can
363124-012 (12) 18 oz cans
MA-1140-051 Crown 2000 PF11969 Rev. 9/21
05 Rev. 9/21
6
SAFETY
Control of Hazardous Energy
Control of Hazardous Energy • Do not allow dirt, cleaning solution, or other foreign
material to enter the cells. Impurities in the electro-
lyte have a neutralizing effect reducing available
Lockout/tagout charge.
In the interest of safety and to ensure compliance with • If battery repair is planned, follow the battery man-
OSHA Regulations, (Standards - 29 CFR), control of ufacturer's instructions on repair practices and pro-
hazardous energy (lockout/tagout) - 1910.147, Crown cedures.
has developed guidelines for proper energy control
when performing service and maintenance on the lift Battery care
truck. Before performing any service or maintenance,
review the appropriate sections in this service manual
for additional procedures to be followed. CAUTION
In addition, Crown recommends that all technicians Only qualified and experienced personnel should per-
wear appropriate protective items, such as eye protec- form maintenance and repair on batteries.
tion, work gloves, and safety-toe shoes, whenever per-
forming service or maintenance work on Crown equip-
ment. • Make certain the battery charger being used
matches the voltage and amperage of the lift truck
Battery battery. This voltage is listed on the lift truck serial
plate.
Safety rules • Before disconnecting or connecting batteries to a
• Wear protective clothing such as a rubber apron, battery charger, make sure that the battery charger
gloves, boots, and full-face shield when performing is off. If an attempt is made to do this while the bat-
any maintenance on batteries. Do not allow electro- tery charger is on, serious injury to you, the battery
lyte to come in contact with eyes, skin, clothing, or and battery charger could result.
the floor. If electrolyte comes in contact with eyes, • Never use a match or lighter. Battery fumes are ex-
flush immediately and thoroughly with clean water. plosive.
Obtain medical attention immediately. If electrolytes • Make certain battery used meets weight, size, and
are spilled on the skin, rinse promptly with clean voltage requirements of lift truck (see the serial
water and wash with soap. A baking soda solution plate). Never operate the lift truck with an under-
(1 lb to 1 gal of water) neutralizes acid spilled on sized battery.
clothing, floor, or any other surface. Apply solution
until bubbling stops and rinse with clean water. Charging
• Always keep the vent plugs firmly in place except
when adding water or taking hydrometer readings.
• Do not bring any type of flame or spark near the CAUTION
battery. Gas formed while the battery is charging, is
highly explosive. This gas remains in the cells long Never smoke or bring flame near the battery. Gas
after charging has stopped. formed during charging is highly explosive and can
cause serious injury.
• Do not lay metallic or conductive objects on battery.
Arcing will result.
See the battery charger manufacturer's manual for op-
eration and maintenance procedures.
Crown 2007 PF15654 Rev. 3/22 MA-7335-100
03 Rev. 3/22
5
SAFETY
Control of Hazardous Energy
Removing the battery
CAUTION
When removing the battery, move the lift truck to an
area intended for battery care. Floor must be level.
Turn key switch or toggle switch to OFF position and
remove key. Disconnect battery and lockout or tagout
lift truck as described in the Lockout/tagout section.
Never move battery partially from truck without roller
stand in place. Lower load engaging means com-
pletely. If battery is removed with load engaging means
raised, use hoist attached to mast to provide tip over
protection. Do not allow any metallic object to come in
contact with the top of the battery cells. This may cause
Fig. 1 (8251)
a short circuit when removing, transporting the battery.
Use an insulator (such as plywood) to cover the top of Lockout/tagout
the battery before and during removal. See Figure 2.
1. Turn off the key switch.
Installing the battery 2. Remove the key.
See Figure 1. 3. Install a tag on the steering wheel or travel twist
grip with a cable tie to warn others that the lift truck
is being serviced.
CAUTION
When installing the battery, move truck to area in-
tended for battery care. Floor must be level. Turn key
switch or toggle switch to OFF position and remove
key. Lockout or tagout truck as described in Lockout -
Tagout in this section. If battery was removed with load
engaging means raised, use hoist attached to mast to
provide tip over protection. Do not allow any metallic
object to come in contact with the top of the battery
cells. This may cause a short circuit when transporting
or installing the battery. Use an insulator (such as ply-
wood) to cover the top of the battery before and during Fig. 2 (8262)
installation.
When maintenance is performed with the battery in the
lift truck, disconnect the battery, remove the main
power fuses, and install a commercially available lock-
CAUTION out device on the battery connector.
Make certain battery used meets weight, size and volt- When maintenance is performed with the battery re-
age requirements of truck (refer to serial plate). moved from the lift truck, perform the following steps:
NEVER operate truck with an undersized battery. 1. Remove the main power fuses.
2. Install a lockout device on the lift truck battery con-
nector.
3. Install a tag with a cable tie on the lift truck battery
connector. Make sure that the tag cannot be re-
moved easily. The tag is a warning that the lift truck
is not available for operation.
MA-7335-101 Crown 2007 PF15654 Rev. 3/22
03 Rev. 3/22
6
SAFETY
Control of Hazardous Energy
Brake
See Figure 3. The brakes can be released using the
drive / tow switch (DTS1) during a maintenance situa-
tion. When using this method to release the brakes, the
lift truck does not have brakes available for stopping.
The lift truck does not have traction control and the
power steering system does not operate.
WARNING
Extreme care must be taken when using the Drive/Tow
switch to release the brakes. The truck will be free-
wheeling and the brake pedal in the operator compart-
ment will have no effect on braking. Brakes will only be
applied when DTS1 is moved from the Tow to the Drive
position.
• Lockout or tagout the lift truck as described in the
Lockout/tagout section.
• Put the chocks against the wheels.
• When towing the lift truck, make sure that all oper-
ators are informed of the lift trucks lack of braking.
Distribution Panel
• See Figure 4. Disconnect PC407 from JC407 and
connect PC407 to JC413 on harness.
• Move DTS1 from the drive position to the tow posi-
tion.
• Move the lift truck to an area intended for mainte- Fig. 3 (16317)
nance.
• Move DTS1 from the tow position to the drive posi-
tion.
• Disconnect the battery.
• Disconnect PC407 from JC413.
• Connect PC407 to JC407.
Technician Tips: If electrical power is provided to the
Access 1 2 3® modules and the brake and the electri-
cal system is functioning properly, the brakes can be
released through the Utilities menu (U2 Tow Mode) in
Level 2 of the Access 1 2 3® system. All functions ex-
cept traction are enabled. For more information, see
the Access 1 2 3® section.
Fig. 4 (23488)
Crown 2007 PF15654 Rev. 3/22 MA-7335-102
03 Rev. 3/22
7
SAFETY
Control of Hazardous Energy
Capacitance
See Figure 5. Due to capacitance voltage present in
Access 3™, discharge the capacitors as follows:
1. Move the lift truck to a secure non-traffic mainte-
nance area with a level floor.
2. Lockout or tagout the lift truck as described in the
Lockout/tagout section.
3. Put a minimum 100-Ω, 2-W resistor between the
positive and negative terminals of Access 3™ for
15 s or more.
Fig. 5 (16318-01)
a Battery positive
b Battery negative
MA-7335-103 Crown 2007 PF15654 Rev. 3/22
03 Rev. 3/22
8
SAFETY
Control of Hazardous Energy
Hydraulic
WARNING
AVOID HIGH PRESSURE FLUIDS – Escaping fluid
under pressure can penetrate the skin causing serious
injury. Relieve pressure before disconnecting hydraulic
lines. Tighten all connections before applying pres-
sure. Keep hands and body away from pin holes which
eject fluids under high pressure. Use a piece of card-
board or paper to search for leaks. Do not use your
hand.
Any fluid injected into the skin under high pressure
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 tissue damage
may occur. Medical attention should be sought imme- Manual Lower Valve
diately by a specialist who has had experience with this
type of injury. Fig. 6 (15658)
See Figure 6. When maintenance is performed on the
hydraulic system, perform the following steps:
1. Move the lift truck to a secure non-traffic mainte-
nance area with a level floor.
2. Make sure that there is no load on the forks.
3. Fully lower the load engaging means (mast) or, if
necessary for maintenance, block the mast sec-
tions at the appropriate height as described in the
Mast section.
4. Lockout or tagout the lift truck as described in the
Lockout/tagout section.
5. Open the power unit doors and locate the lift man-
ifold.
6. Open the manual lower valve to remove the hy-
draulic pressure.
Crown 2007 PF15654 Rev. 3/22 MA-7335-104
03 Rev. 3/22
9
SAFETY
Control of Hazardous Energy
Accumulator
See Figure 7 and Figure 8. The accumulator (hydraulic
system shock absorber) contains a charge of inert gas
such as dry nitrogen. Do not tamper with the gas valve
on the accumulator in an attempt to reduce the amount
of this charge. Use accumulator charging equipment
and procedures as described in the Accumulator - Hy-
draulic Maintenance section.
Accumulator
Fig. 7 (15726)
Fig. 8 (16830-01)
a Accumulator
b Gas valve
c Hydraulic line connection
MA-7335-105 Crown 2007 PF15654 Rev. 3/22
03 Rev. 3/22
10
SAFETY
Control of Hazardous Energy
Towing the lift truck • See Figure 9. When attaching the towing device to
the lift truck being towed, install eyelets in the holes
See the following guidelines when towing the lift truck: in the skirt. Then attach tow strap or chains that are
long enough to provide safe distance for the towed
Towing by pulling in the power unit first di- lift truck, to coast to a stop and also are capable of
rection the pull force requirements.
Do not use this procedure if the lift truck has the prox-
imity system option.
WARNING
• Towed truck must always maintain all wheels in
contact with floor.
• Maximum travel speed while towing truck is 1.6 km/
h (1 mph).
• Do not make sharp turns when towing this lift truck.
• Floor is to be level and flat without trash or debris in
towing path.
• Towed vehicle forks should be empty and no more
than 305 mm (12.0 in) off floor.
• Excessive acceleration by towing vehicle, or drag
Holes in Skirt for Eyelets
caused by towed vehicle (i.e., brake drag, drive unit
drag, wheel drag, etc.) will greatly increase require- Fig. 9 (17698)
ments to pull or push a vehicle.
Towing guidelines:
• The maximum travel speed while towing the lift
Preparing the lift truck for towing: truck is 1.6 km/h (1 mph).
• The power should be on if steering is not inhibited • Steering towed vehicle: If steering is operational, a
and the operator can be on the towed vehicle if second operator must be on the towed vehicle to
steering is not inhibited. steer the lift truck. If steering is inhibited, tow the
• If the standard brake release pedal does not func- vehicle in a straight line out of the aisle with no op-
tion, then release the brakes with the brake tow erator on the towed lift truck. Once outside of the
switch. See the Brake section. aisle, make the necessary repairs to regain steering
operation, then tow the vehicle in a straight line out
Towing device requirements: of the aisle with no operator on the towed lift truck.
• The gross vehicle weight of the towed vehicle must • The towed lift truck must always maintain all wheels
not exceed 4,535 kg (10,000 lb). See the data plate in contact with floor.
for gross vehicle weight including the battery weight
if it is in the vehicle during towing. • Allow sufficient distance for the lift truck to coast to
a stop at the final destination.
• The towing device or vehicle must have a pulling
and braking capacity greater than 3,175 kg
(7,000 lb).
Crown 2007 PF15654 Rev. 3/22 MA-7335-106
03 Rev. 3/22
11
SAFETY
Control of Hazardous Energy
Towing by pushing in the forks first direc- Pushing a disabled lift truck:
tion • See Figure 10. Using another vehicle, push against
the skirt of the disabled vehicle in the forks first di-
Do not use this procedure if the lift truck has the prox- rection.
imity system option.
Technician Tips: This procedure can be followed if the
aisle layout or position of the lift truck in the aisle does
not allow for pulling the lift truck by the power unit skirt.
Once the lift truck is outside of the aisle, follow the pre-
vious procedure for pulling the lift truck in the power
unit first direction.
WARNING
• Towed truck must always maintain all wheels in
contact with floor.
• Maximum travel speed while towing truck is 1.6 km/
h (1 mph). Skirt
• Do not make sharp turns when towing this lift truck.
• Floor is to be level and flat without trash or debris in Fig. 10 (17699)
towing path.
• Towed vehicle forks should be empty and no more WARNING
than 305 mm (12.0 in) off floor.
Braking force is not applicable if brakes are to be re-
leased with brake tow switch.
Preparing the lift truck for towing:
• The power must be on if the steering is not inhibited
and the operator can be on the towed vehicle if Towing guidelines:
steering is not inhibited. • The maximum travel speed while towing a lift truck
• If the standard brake release pedal does not func- is 1.6 km/h (1 mph).
tion, then release brakes with the brake tow switch. • Steering pushed vehicle: If steering is operational,
See the Brake section. a second operator must be on a towed vehicle to
Pushing vehicle minimum requirements: steer the lift truck in a straight line to get out of the
aisle. Once outside of aisle, follow previous proce-
• The gross vehicle weight of the towed vehicle must dure for towing the lift truck by pulling in power unit
not exceed 4,535 kg (10,000 lb). See the data plate first direction. If steering is inhibited, push the vehi-
for gross vehicle weight including the battery weight cle in a straight line out of aisle with no operator on
if it is in the vehicle during towing. the towed lift truck. Once outside of the aisle, make
• The towing vehicle must have pushing and braking the necessary repairs to regain the steering opera-
capacity greater than 3,175 kg (7,000 lb). tion, then follow previous procedure for towing the
lift truck by pulling in power unit first direction.
• Allow sufficient distance for the lift truck to coast to
a stop at the final destination.
MA-7335-107 Crown 2007 PF15654 Rev. 3/22
03 Rev. 3/22
12
SAFETY
Control of Hazardous Energy
Towing by lifting and pulling in the power Towing guidelines:
unit first direction
Use this procedure for standard lift trucks and for lift
trucks with the proximity system option.
WARNING
Do not lift towed truck higher than 51 mm (2.0 in) off
floor.
WARNING
• Make sure that there is no operator on the towed
• Towed truck must always maintain two contact vehicle.
points with floor.
• For standard lift trucks, see Figure 11. Lift and tow
• Maximum travel speed while towing truck is 1.6 km/ from the center of the power unit skirt.
h (1 mph).
• For lift trucks with the proximity system option, see
• Do not make sharp turns when towing this lift truck. Figure 12. Lift and tow from the towing point on the
• Floor is to be level and flat without trash or debris in power unit.
towing path. • Make sure that the towed vehicle does not uncou-
• Towed vehicle forks should be empty and no more ple from the towing vehicle and that the towing point
than 305 mm (12.0 in) off floor. remains at the center of the skirt.
Preparing the lift truck for towing:
• The gross vehicle weight must not exceed 4,535 kg
(10,000 lb). See the data plate for gross vehicle
weight including the battery weight if it is in the ve-
hicle during towing.
• Avoid damaging the underside of the towed vehicle
with a towing device. For example, remove the wire
guidance sensor before towing.
• Make sure that there is no operator on the towed
vehicle.
Lifting vehicle requirements:
• The lift truck must be capable of traveling and brak-
ing when towing a lift truck weighing 4,535 kg
Skirt
(10,000 lb).
• The towing device must be capable of safely lifting
Fig. 11 (17699)
2,720 kg (6,000 lb) at the skirt of the towed vehicle.
Crown 2007 PF15654 Rev. 3/22 MA-7335-108
03 Rev. 3/22
13
SAFETY
Control of Hazardous Energy
Lifting and blocking
See Figure 13 for standard lift trucks and for lift trucks
with the proximity system option.
See Figure 14 for standard lift trucks.
See Figure 15 for lift trucks with the proximity system
option.
1. Move the lift truck to a secure non-traffic mainte-
nance area with a level floor.
2. Make sure that there is no load on the forks.
3. Lockout or tagout truck as described in the Lock-
out/tagout section.
NOTES:
• Hydraulic jack capacity: 3,620 kg (8,000 lb)
• Crown P/N: 122599
Towing point • Collapsed height - minimum: 60 mm (2.25 in)
• Raised height - maximum: 400 mm (16 in)
Fig. 12 (35783) • Jack stand capacity: 4,500 kg (10,000 lb)
Towing by lifting and pulling in the forks • Commercially Available.
first direction
WARNING
WARNING Lift truck stability decreases dramatically if load wheels
are raised more than 60 mm (2.5 in). Attach sling and
Towing by lifting truck and pulling in the forks first overhead lifting device to all cross members of the
direction is not recommended. mast to prevent lift truck from tipping over when raising
the side of the lift truck.
MA-7335-109 Crown 2007 PF15654 Rev. 3/22
03 Rev. 3/22
14
SAFETY
Control of Hazardous Energy
SIDE STEER
WHEEL
Fig. 13 (16831-01)
a Load wheels
b Hardwood block
Fig. 14 (16832-01)
a Raise the platform 70–150 mm (3–6 in) from the floor
b Put the chocks against the wheels
c Set jack stand height as required - not to exceed 400 mm
(16 in). Locate the jack stands and jack on the lift truck skirt.
Crown 2007 PF15654 Rev. 3/22 MA-7335-110
03 Rev. 3/22
15
SAFETY
Control of Hazardous Energy
8. Use the manual lowering valve to lower the plat-
form and position the appropriate length blocks un-
der the platform frame in the mast channels.
9. Use clamps to secure the blocks to the mast chan-
nel or first stage block.
10. Continue lowering the platform until the platform
a frame rests on the blocks.
11. Lockout or tagout the lift truck as described in
Lockout/tagout section.
Fig. 15 (35790)
a Raise the platform 70–150 mm (3–6 in) from the floor
b Put the chocks against the wheels
c Set jack stand height as required - not to exceed 400 mm
(16 in). Locate the jack stands under the power unit skirt and
the jack on the sensor guard lift point
Mast
Blocking the masts
See Figure 16. See the following steps for blocking the Fig. 16 (16833-01)
masts: a Clamps
b Set under the platform
Technician Tips: Use 100 x 100 mm (4.0 x 4.0 in) or
c Set under the first stage
larger hardwood blocks of the appropriate length for
supporting the mast channels. Block both mast chan-
nels of each stage to maintain lift truck stability.
1. Remove any carriage-mounted accessories, such
as the roll loader, before blocking the masts.
2. Move the lift truck to a secure non-traffic mainte-
nance area with a level floor.
3. Put the chocks against the wheels. See the Lifting
and blocking section.
4. Connect the battery.
5. Raise the forks and position the appropriate length
blocks under the first stage mast. Do not block the
first stage mast when working at the mainframe
base.
6. Set the blocks under the platform only, as de-
scribed in the following steps:
7. Use clamps to secure the blocks to the mast chan-
nel.
MA-7335-111 Crown 2007 PF15654 Rev. 3/22
03 Rev. 3/22
16
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