C ELECTRICAL DIAGRAMS INDEX

This electrical diagram index for the RR/RD 5200/5200S, DC drive truck, lists the diagrams with portion of truck cov-
ered by each diagram.

Title Page Number Revision

Schematic, RR/RD 5200 Series, Standard Display DIA–1452–002 02 - 12/03

Schematic, RR/RD 5200 Series, Enhanced Display DIA–1452–003 02 - 12/03
Schematic, RR/RD 5200S Series, Standard Display DIA–1452–004 02 - 12/03
Schematic, RR/RD 5200S Series, Enhanced Display DIA–1452–005 02 - 12/03

Distribution Panel, RR/RD 5200/5200S Series DIA–1452–006 02 - 12/03

Access 3, RR/RD 5200/5200S Series DIA–1452–007 01 - 1/03

Access 2, RR/RD 5200/5200S Series DIA–1452–008

Mast, Hydraulic Components, RR/RD 5200 Series DIA–1452–009 01 - 12/03

Mast, Hydraulic Components, RR/RD 5200S Series DIA–1452–010 01 - 12/03

Display, Standard Access 1, RR/RD 5200/5200S Series DIA–1452–011 01 - 12/03

Display, Enhanced Access 1, RR/RD 5200/5200S Series DIA–1452–012 01 - 12/03

Fan, Lights, Contactor Panel, RR/RD 5200 Series DIA–1452–013

Fan, Lights, Contactor Panel, RR/RD 5200S Series DIA–1452–014

Brakes, RR/RD 5200 Series DIA–1452–015

Brakes, RR/RD 5200S Series DIA–1452–016

Multi-Task Handle, RR/RD 5200/5200S Series DIA–1452–017

Power Cables, RR/RD 5200 Series DIA–1452–018 02 - 12/03

Power Cables, RR/RD 5200S Series DIA–1452–019 02 - 12/03

Freezer Condition, RR/RD 5200 Series DIA–1452–020 01 - 12/03

Freezer Condition, RR/RD 5200S Series DIA–1452–021 01 - 12/03

Wire Harnesses, RR/RD 5200/5200S Series † DIA–1452–022

† Includes supplemental information.

010328 6851 - EO11396

Crown 2001 PF13082-1 Rev. 12/03 Printed in U.S.A.

03 REV. 12/03
DIA–1452–001 DIA–1452–001
 C ELECTRICAL SCHEMATIC
A B C
RR/RD 5200 SERIES, STANDARD DISPLAY
FU2 K3A*
OPTIONS*
15A
FU3 K3B*
LIGHT/FAN*
15A
FU12*
F/C*
15A P2*
FU7*
M3*
250A

1 M2 1

FU8 A1
MCR2 B-
B+
SEE NOTE 5 ACCESS 2 H-COMM
FU11 H-COMM(FU11)
SVT CA404-17 CA404-5
TILT H-COMM 3/4A VCC LED+
LED- RS
SVS* CA404-16 CA405-13 OUT GND
SIDESHIFT
VCC LED+
TP2
CA405-5
SVR CA404-15 LED- FS
REACH CA405-12 OUT GND

ORS*
CA404-4
BRES1* BRES2*
CA404-20
SUPPRESSION CA404-3 FLS
CA404-9
CA404-1
SCV6* HSS* FKS*
CA404-2

P2* CA404-7
SSS
2ND LIFT PUMP CA405-11
PVH CA404-19 TBS
HOIST CA405-4
TDS
PVA CA404-18 CA405-3 TPA *
ACCESSORY POT4
CA405-14
3 5.0K
SVP
2 PILOT
CA404-14
CA405-7
ACCESSORY
POT3
2
SVL CA404-13 1.7K TPA CAN MODULE*
LOWER CA405-6
CAN DAQ MODULE
SVA CA404-12 GND V+ C_H C_L G1 P1
ACCESSORY NOTE 2
FU4 CA405-15
CA404-6 4
TRAVEL ALARM LIFT
TP4

15A CA405-16 POT2

4) THIS SCHEMATIC REPRESENTS THE TRUCK IN ITS HOME POSITION WITH NO OPERATOR PRESENT.
ALM2* 1.7K
CA404-11 CA405-8
PRECHARGE 3

B-NEG BUS BAR

CA404-10 NOTE 2 4 4
MODULE POWER

3) HGTS12 USES SAME INPUT AS ECR2 SINCE BOTH ARE NOT PRESENT AT THE SAME TIME.
CA405-10
CA405-1
T-COMM CAN COMMUNICATIONS
CAN_H 4 TWISTED PAIR

SINGLE FAN IS STANDARD FOR RR/RD5210, RR/RD5260, RR/RD5280, AND EE TRUCKS.

ED CA404-8 CAN_L
ED CA405-9
5V
CA405-2
LGS1

M1

LGT1
FU9 A1 F1 F2 DOME LIGHT
B+ MCR1 B-
250A ACCESS 3 T-COMM

5) 250A FUSE FOR 36V TRUCK, 300A FUSE FOR 24V TRUCK.
CA402-17 TX
ED OUT CA402-10 CA601

7) DUAL FANS ARE STANDARD FOR RR/RD5220 TRUCKS.

FU6 RX 3
CA402-19 CA402-11 9 PIN D-SUB
15A FU5 CA402-18 CA402-12
T-COMM TO SERVICE TOOL
O+ RS232
15A
3 I+
CA403-10
T-COMM
3

6) ED2 IS USED ONLY ON EUROPEAN TRUCKS.

ED-A ED-B BRK1 CA403-1

2) DENOTES CONNECTION TO TRUCK FRAME

I- CAN_H 4
CA402-9
CA402-8 CAN_L
O- CA402-7
CA403-9
5V
CA402-14 CA403-2 T-COMM
MODULE POWER FU10
CA402-15 T-COMM 3A
PRECHARGE CA402-13
ECR2*
1) * THIS FEATURE IS OPTIONAL
STATUS ALARM TP1
GND/BLK CA403-12 CA402-6
32 PULSE
BEARING
SENSOR-

+V/RED
A/WHT CA403-3 BRS1 ALM1
CA402-1
B/BLU CA403-11
DMS1
HEIGHT CA402-4
HGTS12 * CA403-12 ENS
CA402-5
INTERNAL FAN(S) HGTRS*
CA403-3
NOTES:

NOTE 7 NOTE 3 ACCESS 1

CA403-4 STANDARD DISPLAY
ECR1
CA403-14 CA407-6
GND/BLK CA403-15 T-COMM 3
TRACTION CA407-9
CAN_H
32 PULSE
SENSOR-
BEARING

+V/RED
RBD1 CA403-5 CA403-7 POT1 CA407-8
A/WHT 1.7K CAN_L
CA403-6
B/BLU CA403-8
CA403-13 CA407-4
T-COMM
TRACTION CA402-16 NOTE 2
DPS3
ED IN CA407-3
ED2 DPS2
KYS
SB20 MODULE CA407-2
4 START CR4 NOTE 6 POWER
CA407-7 DPS1 4
ACC K1 CA407-1
TP5

EDS
T-COMM
K3*
TP7

TP6

TP9

IGN K1 K2 HNS
OFF TR40
+t
SB21 H-COMM(FU11)
TP8

FU1 K2 ED2-A
TP3
15A HN ED2-B
24V/36V

010328
A B C 6851 - EO11396 129333 D Sht 1

Crown 2001 PF13082-2 Rev. 12/03 Printed in U.S.A.

02 REV. 12/03
DIA–1452–002 DIA–1452–002
 C ELECTRICAL SCHEMATIC
A B C

FU2 K3A*
RR/RD 5200 SERIES, ENHANCED DISPLAY
OPTIONS*
15A
FU3 K3B*
LIGHT/FAN*
15A
FU12*
F/C*
15A P2*
FU7*
M3*
250A

1 M2 1
FU8 A1
MCR2
B+ ACCESS 2 B-
SEE NOTE 5 H-COMM
FU11 H-COMM(FU11)
SVT CA404-17 CA404-5
TILT H-COMM 3/4A
VCC LED+
LED- RS
SVS* CA404-16 CA405-13 OUT GND
SIDESHIFT
TP2
CA405-5 VCC LED+
SVR CA404-15 LED- FS
REACH CA405-12 OUT GND
ORS*
CA404-4
BRES2*
BRES1*
CA404-20 CA404-3 FLS
SUPPRESSION
CA404-9
CA404-1
SCV6* HSS* FKS*
CA404-2
P2* CA404-7
2ND LIFT PUMP SSS TPA *
CA405-11 POT4
PVH CA404-19 TBS 3 5.0K
HOIST CA405-4
PVA CA404-18 TDS
ACCESSORY CA405-3
CA405-14 TPA CAN MODULE *
SVP CA404-14 ACCESSORY CAN DAQ MODULE
PILOT
2 SVL CA404-13
CA405-7 POT3
1.7K GND V+ C_H C_L G1 P1 2
LOWER CA405-6
4
SVA CA404-12
ACCESSORY NOTE 2
FU4
CA404-6 CA405-15
TRAVEL ALARM LIFT
TP4

15A 3
CA405-16 POT2
ALM2* 4 4
CA404-11
1.7K
PRECHARGE CA405-8

CA404-10
MODULE POWER NOTE 2

B-NEG BUS BAR

CA405-10
T-COMM
CA405-1 4
CAN_H
ED CA404-8
ED CA405-9 CAN COMMUNICATIONS
CAN_L TWISTED PAIR
CA405-2
5V LGS1

M1

LGT1
FU9 A1 F1 F2 DOME LIGHT
B+ MCR1 B-
250A ACCESS 3 T-COMM CHS*
FU6 CA402-17
15A ED OUT CA402-10
3 CA601
TX
CA402-19 CA402-11 9 PIN D-SUB
RX TO SERVICE TOOL
CA402-18 CA402-12 RS232
3 FU5
15A
O+
CA403-10
T-COMM 3
I+ T-COMM
ED-A ED-B BRK1 CA403-1
4
I- CA402-9
CAN_H
CA402-8
O- CA403-9
CA402-7 CAN_L T-COMM ACCESS 1
CA402-14 CA403-2
MODULE POWER 5V FU10 ENCHANCED DISPLAY
CA402-15 T-COMM 3A CA407-6
PRECHARGE CA402-13 T-COMM 3
ECR2* TP1 CA407-9
STATUS ALARM CAN_H
CA407-8
GND/BLK CA403-12 CA402-6 CAN_L BWS1*
SENSOR-

32 PULSE
BEARING

+V/RED CA408-10
ALM1 BWS1 AND THS1
A/WHT CA403-3 BRS1 CA408-11
CA402-1 CA408-15 LOCATED IN M1
B/BLU CA403-11 THS1 *
DMS1 BWS2*
HEIGHT CA402-4 CA408-9
BWS2 AND THS2
HGTS12* CA403-12 ENS LOCAT4ED IN M2
CA408-14
CA402-5 THS2 *
INTERNAL FAN(S) HGTRS* BWS3*
CA408-8
CA403-3 BWS3 AND THS3
NOTE 7 NOTE 3
CA403-4 CA408-13 LOCATED IN M3
ECR1 THS3*
T-COMM(FU10)
CA403-14 T-COMM
GND/BLK CA403-15 CA408-7
TRACTION FKS*
32 PULSE
SENSOR-

+V/RED
BEARING

CA403-5 CA403-7 POT1 DSP4 T-COMM(FU10)

A/WHT CA408-6
CA403-6 1.7K DSP5
RBD1 B/BLU CA403-8
CA403-13 CA408-5
CA408-1
TRACTION DPS6
CA402-16 SIG CA408-4
ED IN LS* CA407-4
T-COMM
NOTE 2 CA408-3
4 KYS
SB20 12V CA407-3
DPS3
4
START CR4 DPS2
CA407-7 CA407-2
K1 MODULE POWER DPS1
ACC
TP5

EDS CA407-1
T-COMM
IGN K3*
TP7

TP6

TP9

K1 K2 HNS
OFF TR40
ED2 +t
SB21 H-COMM(FU11)
TP8

NOTE 6 ED2-A
FU1 TP3 K2
15A HN ED2-B
24V/36V

010328
A B C 6851 - EO11396 129333 D Sht 2

Crown 2001 PF13082-3 Rev. 12/03 Printed in U.S.A.

02 REV. 12/03
DIA–1452–003 DIA–1452–003
 C ELECTRICAL SCHEMATIC
A B C
RR/RD 5200S SERIES, STANDARD DISPLAY
FU2 K3A*
OPTIONS*
15A
FU3 K3B*
LIGHT/FAN*
15A
FU12*
F/C*
15A P2
FU7 M3
M3
250A

1 M2
M2 1
FU8 A1
MCR2
B+ B-
ACCESS 2 H-COMM
250A FU11 H-COMM(FU11)
SVT CA404-17 CA404-5
TILT H-COMM 3/4A
VCC LED+ RS
LED-
SVS* CA404-16 CA405-13 OUT GND
SIDESHIFT TP2
CA405-5 VCC LED+
SVR CA404-15 LED- FS
REACH CA405-12 OUT GND
ORS*
CA404-4
BRES1*
CA404-20 CA404-3 FLS
SUPPRESSION
CA404-9
CA404-1
HSS* FKS*
CA404-2

P2 CA404-7 SSS
2ND LIFT PUMP
CA405-11
PVH CA404-19 TBS
HOIST CA405-4
TDS TPA*
PVA CA404-18 CA405-3 POT4
ACCESSORY 5.0K
CA405-14 3
CA404-14 ACCESSORY
SVP
2 PILOT CA405-7 POT3
1.7K
2
SVL CA404-13 CA405-6 TPA CAN MODULE*
LOWER CAN DAQ MODULE
SVA CA404-12 NOTE 2 GND V+ C_H C_L G1 P1
ACCESSORY
FU4 CA405-15
CA404-6 LIFT
4
TP4

15A ALM2* TRAVEL ALARM CA405-16 POT2

1.7K
CA404-11
PRECHARGE CA405-8
3

B-NEG BUS BAR

CA404-10 4 4
MODULE POWER NOTE 2
CA405-10
T-COMM
CA405-1
CAN_H 4
ED CA404-8
ED CAN_L CAN COMMUNICATIONS
CA405-9 TWISTED PAIR
5V
CA405-2
LGS1

M1
M1

LGT1
FU9 A1 F1 F2 DOME LIGHT
T-COMM
B+ MCR1 B-
250A ACCESS 3
ED OUT CA402-17 TX
CA402-10 CA601
RX 3
C- C- CA402-11 9 PIN D-SUB
CA402-20 T-COMM RS232 TO SERVICE TOOL
BRK2 BRK2 CA402-12
FU6
3 15A
C+ C+ CA403-10
T-COMM 3
CA402-19 CA403-1
CAN_H 4
CA402-18
FU5 O+ CAN_L
CA403-9
15A 5V
I+ CA403-2
FU10
BRK1
ED-A ED-B I- 3A T-COMM
CA402-9 T-COMM
CA402-8 CA402-13
O- CA402-7
CA402-14 STATUS ALARM TP1
MODULE POWER CA402-6
CA402-15
ECR2* PRECHARGE BRS3
CA402-3 ALM1
GND/BLK CA403-12
BRS2
32 PULSE
SENSOR-
BEARING

+V/RED CA402-2
A/WHT CA403-3 BRS1
CA402-1
B/BLU CA403-11
DMS2
INTERNAL FAN(S) HEIGHT
HGTS12 * CA403-12 CA402-4
DMS1
NOTE 7
ENS
CA402-5 ACCESS 1
NOTE 3 CA403-3 HGTRS* STANDARD DISPLAY
ECR1 CA407-6
CA403-4 T-COMM 3
COMM T-COMM(FU10)
CA407-9
GND/BLK CA403-14
CA407-8
CAN_H
CA403-15
TRACTION
32 PULSE

+V/RED CAN_L
SENSOR-
BEARING

RBD1 A CA403-5 CA403-7 POT1

A/WHT
+5 1.7K
B/BLU CA403-6
B CA403-8 T-COMM
CA403-13 CA407-4
TRACTION
KYS
CA402-16 DPS3
ED IN NOTE 2
SB20 CA407-3
4 START CR4 MODULE POWER
CA407-7 CA407-2
DPS2 4
ACC K1 DPS1
K1 EDS CA407-1
TP5 T-COMM
K3*
TP6

TP9
TP7

IGN K2 HNS
OFF TR40
ED2 +t
H-COMM(FU11)
TP8

K2 NOTE 6 ED2-A
FU1 TP3 SB21
15A HN ED2-B
36V

010328
A B C 6851 - EO11396 129333 D Sht 3

Crown 2001 PF13082-4 Rev. 12/03 Printed in U.S.A.

02 REV. 12/03
DIA–1452–004 DIA–1452–004
 C ELECTRICAL SCHEMATIC
A B C
RR/RD 5200S SERIES, ENHANCED DISPLAY
FU2 K3A*
OPTIONS*
15A
FU3 K3B*
LIGHT/FAN*
15A
FU12*
F/C*
15A
FU7 P2 M3
M3
250A
1 M2
M2
1

A1
FU8 MCR2
B+ B-
ACCESS 2 H-COMM
250A FU11 H-COMM(FU11)
SVT CA404-17 CA404-5
TILT H-COMM 3/4A
VCC LED+
LED- RS
SVS* CA404-16 CA405-13 OUT GND
SIDESHIFT TP2
CA405-5 VCC LED+
SVR CA404-15 LED- FS
REACH CA405-12 OUT GND
ORS*
CA404-4
BRES1*
CA404-20 CA404-3 FLS
SUPPRESSION
CA404-9
CA404-1
HSS* FKS*
CA404-2

P2 CA404-7 SSS
2ND LIFT PUMP CA405-11
PVH CA404-19 TBS
HOIST CA405-4
TDS TPA*
PVA CA404-18 CA405-3 POT4
ACCESSORY 5.0K
CA405-14 3
ACCESSORY
2 SVP
PILOT
CA404-14
CA405-7 POT3 2
1.7K
SVL CA404-13 CA405-6 TPA CAN MODULE*
LOWER CAN DAQ MODULE
SVA CA404-12 NOTE 2 GND V+ C_H C_L G1 P1
ACCESSORY
FU4 CA405-15
CA404-6 LIFT 4
TRAVEL ALARM
TP4

15A ALM2* CA405-16 POT2

CA404-11 1.7K
PRECHARGE CA405-8
3

B-NEG BUS BAR

CA404-10 4 4
MODULE POWER NOTE 2
CA405-10
T-COMM
CA405-1
CAN_H 4
ED CA404-8
ED CAN_L CAN COMMUNICATIONS
CA405-9
5V TWISTED PAIR
CA405-2
LGS1

M1
M1
LGT1
A1 F1 F2 DOME LIGHT
FU9
B+ MCR1 B-
250A ACCESS 3 T-COMM
ED OUT CHS*
CA402-17 TX
CA402-10 CA601
RX 3
C- C- CA402-11 9 PIN D-SUB
CA402-20 T-COMM RS232 TO SERVICE
BRK2 BRK2 CA402-12
3 FU6
15A
C+ C+ CA403-10
TOOL
3
T-COMM
CA402-19 CA403-1
CAN_H 4
CA402-18
FU5 O+ CAN_L
CA403-9
15A 5V T-COMM ACCESS 1
I+ CA403-2
FU10 ENCHANCED DISPLAY
BRK1
ED-A ED-B I- CA402-9 3A
T-COMM CA407-6
CA402-8 CA402-13 T-COMM 3
O- CA402-7 CA407-9
STATUS ALARM TP1 CAN_H
CA402-14 CA407-8
MODULE POWER CA402-6 CA408-11 CAN_L BWS1*
CA402-15
PRECHARGE CA408-10 BWS1 AND THS1
ECR2* BRS3 ALM1
CA402-3 LOCATED IN M1
GND/BLK CA403-12 CA408-15
BRS2 THS1* BWS2*
32 PULSE

+V/RED CA402-2
SENSOR-
BEARING

A/WHT CA403-3 BRS1 CA408-9 BWS2 AND THS2

CA402-1
B/BLU CA403-11 LOCATED IN M2
DMS2 CA408-14
HEIGHT THS2* BWS3*
INTERNAL FAN(S) HGTS12 * CA403-12 CA402-4
DMS1 CA408-8 BWS3 AND THS3
ENS LOCATED IN M3
NOTE 7 CA408-13
CA402-5
THS3*
NOTE 3 CA403-3 HGTRS* CA408-7
ECR1 T-COMM
CA403-4
DPS4 T-COMM(FU10)
GND/BLK T-COMM(FU10)
CA403-14 CA408-6
FKS*
32 PULSE

CA403-15
SENSOR-
BEARING

+V/RED TRACTION DPS5

A/WHT POT1 CA408-5
CA403-5 CA403-7
RBD1 B/BLU 1.7K DPS6
CA403-6 CA408-4
CA403-8 CA408-1 T-COMM
TRACTION CA403-13
SIG CA407-4
CA402-16 LS* DPS3
KYS ED IN 12V
4 START
SB20
CR4 NOTE 2 CA408-3
CA407-3
DPS2 4
CA407-7 CA407-2
K1 MODULE POWER DPS1
ACC
TP5

EDS CA407-1
T-COMM
K3*
TP7

TP9

IGN
TP6

K1 K2 HNS
OFF TR40
ED2 +t
H-COMM(FU11)
TP8

FU1 K2 HN NOTE 6 ED2-A

TP3 SB21
15A ED2-B
36V

010328
A B C 6851 - EO11396 129333 D Sht 4

Crown 2001 PF13082-5 Rev. 12/03 Printed in U.S.A.

02 REV. 12/03
DIA–1452–005 DIA–1452–005
 C DISTRIBUTION PANEL
A B C
RR/RD 5200/5200S SERIES
TPA CAN MODULE
CAN DAQ MODULE NOTES:
P1 G1 C_L C_H V+ GND
1.) PLACE SHUNT BETWEEN PINS 1 & 2
C45-BLK CA207-14 T-COMM(FU10) FOR LOAD SENSE ONE OPTION
C45-RED CA207-6 +BV PLACE SHUNT BETWEEN PINS 2 & 3
C46-BLK CA655 FOR LOAD SENSE TWO OPTION
1 C43-BLK CA208-9 CAN HIGH
C46-WHT CA656 2.) CONNECT LEAD TO THE SAME CONTACTOR POST WHICH
1 C43-WHT CA208-22 CAN LOW
C44-BLK 1 CA652 HAS BATTERY NEGATIVE CABLE (EEC TRUCKS ONLY).
1 C44-WHT
C44-RED 1 CA653CA654
C22-BLK TB406-9
C22-GRN TB406-12 3.) 580 MAY BE WIRED IN CA201-1 OR CA201-2.
1
1 C22-ORG TB406-13

101 CA408-1 LOAD SENSE II PRESSURE TRANSDUCER SIGNAL

HN
303 CA408-3 LOAD SENSE II PRESSURE TRANSDUCER +12V 501 (TB212) BATT NEG NB213
2915 (CA207-12) 502 (CA409) BATT NEG K3-B
MAST
42 INCH
C1-BLK TB406-1 BV(FU4) TRUCKS ONLY
C1-WHT TB406-2 SVR
C1-RED TB406-3 SVS
C1-GRN TB406-4 SVT
C1-ORG TB406-5 H-COMM FU11
C1-BLU TB406-6 FLS CA809
SEE RDB1
C1-W/B TB406-7 FKS & HSS OR F/C 1 FREEZER
C1-R/B TB406-8 LSII +12V OR F/C 1 PACKAGE CA215
5957
CA810 PICTORIAL 1 5917 CA612-7 H-COMM(FU11) HNS N.O.
2939 CA207-7 +BV
CA209 1 2 3 4 5 6 7 8 CA210 1 2
TP9
K2 TRUCK
CA207
J1 5958
12 3 CR3 16 539
SEE NOTE 1 517 CA612-6 H-COMM(FU11) HNDL SW'S
15
C45-BLK TPA T-COMM(FU10)
TRAVEL ALARM 14 516 (CA607-6) T-COMM(FU10) FLRBRD SW'S
TP3 TP8 C22-BLU (CA212)
CA205 TP4 13 515 (TB406) T-COMM(FU10) HGTRS CA646-2
2 ALM2
5929 2
K2 CA214 2
2974 29100 29101 2915 (HN)
1 R2 12 1
POST FURTHEST FROM C2 CA401
214 SB21
MOUNTING PLATE IS +. + CR2 11 1 BATT
2913 IGN KYS
10 2
2912 NEG POS
9 1 3 ST
ACC
CR4 CA211 4
SB20 OFF
TP7 TP6 2990
HYDRAULIC CONTROL K1 8 2911 CA407-7 +BV(K1) DISPLAY POWER
MODULE 2939 (CA210) +BV RDB1
R1 7 2910 (CA409) +BV(K1) LGS1 DOME LIGHT
CA204 C1 C45-RED TPA +BV
2940 CA404-20 SUPPRESSION 13 6 2909
+ CR1 EDS SB41
5937 12 5 2908
CA404-17 SVT
5936 CA404-16 SVS 11
2994 593 (NOTE 2)
5935 CA404-15 SVR 10 ED2
211 CA404-11 +BV(FU1) PC 9
2930 CA404-10 +BV(K1) PWR 8 2968 CA808-5 +BV(K1) F/C TRUCKS ONLY
4 2907 (CA409) +BV(K1) K3 COIL
2929 CA404-9 SUPPRESSION 7 H-COMM TP2 3 2906 (TB406) MANIFOLD BLOCK SOLENOIDS
5926 CA404-6 H-COMM ALM2 6 FU11 TP5 2 2905 (CA409-7) +BV(ED-A) FU4
525 CA404-5 H-COMM INPUT 5 K1
535 CA612-5 H-COMM FS/RS 3/4A
5924 CA404-4 H-COMM(FU11) 4 1 204 (CA409-1) +BV FU1
5923 CA404-3 H-COMM(FU11) 3
5922 CA404-2 H-COMM(FU11) 2
5921 CA404-1 H-COMM(FU11) 1
TRACTION CONTROL MODULE
3 BATTERY RESTRAINT
CA206 3
5906 CA203 T-COMM 2916 CA402-16 +BV(AK) EDS N.C.
5907 5
BRES2 2 FU10
BRES1 4 215 CA402-15 +BV(FU1) TCM PRECHARGE
505 1 3 2914 CA402-14 +BV(K1) TCM MOD PWR
3A 513 CA402-13 T-COMM FROM TCM
2
OVERRIDE CA202 1 306 CA402-6 +12V ALM1 INPUT
5910 2 CA824
509 2992
1 1
ORS 2
TMM ALM1
CA201 TP1
STATUS ALARM
580 CA662-1 T-COMM (FU10)
(SEE NOTE 3) 2993
2
512 (CA408) T-COMM(FU10)THS 1 TP10 TP11
511 (CA408) T-COMM(FU10)BWS FN1 FN2 SB42
TP12
5975
CA208
PIN 1 PIN 13 5973
PIN 14 PIN 25 5974 CA402-7 INTERNAL
CA208 PINS FAN(S)
1
C6-WHT CA403-1 CAN HIGH
14
C6-BLK CA403-9 CAN LOW TEST POINT DESCRIPTIONS
C6-RED CA403-2 +5V 2
15 TP1 = T-COMM AFTER FUSE FU10
C6-BLK CA403-10 T-COMM
TP2 = H-COMM AFTER FUSE FU11
3 TP3 = +BV(AK) TO HORN RELAY K2
C7-WHT CA405-1 CAN HIGH
C7-BLK CA405-9 CAN LOW 16 TP4 = +BV(ED-A) FROM FU4
4 C7-RED
C7-BLK
CA405-2 +5V 4
17
TP5 = +BV(AK) FROM EDS N.C.
TP6 = +BV(K1) AFTER K1
4
CA405-10 T-COMM
9 TP7 = +BV(AK) BEFORE K1
C43-BLK TPA CAN HIGH TP8 = +BV(FU1) TO HORN
22
C43-WHT TPA CAN LOW TP9 = H-COMM FROM HNS N.O.
11 TP10 = CAN HIGH
C8-WHT CA407-9 CAN HIGH C1 - 8 CONDUCTOR 18 AWG CABLE
24 TP11 = + 5V
C8-BLK CA407-8 CAN LOW C6,C7,45,C46 - 4 CONDUCTOR TWISTED PAIR CABLE
C8-RED CA407-6 T-COMM 25 TP12 = CAN LOW C8,C43,C44 - 3 CONDUCTOR SHIELDED CABLE WITH
DRAIN WIRE.
C22 - 8 CONDUCTOR 18 AWG CABLE TPA AND FHS

010328
A B C 6851 - EO11396 129334 C

Crown 2001 PF13082-6 Rev. 12/03 Printed in U.S.A.

02 REV. 12/03
DIA–1452–006 DIA–1452–006
 C ACCESS 3
A B C
RR/RD 5200/5200S SERIES
(TB212)
(REFERENCE ONLY)

201 (CA409) +BV FU1

RED (CA808-3) +BV FU12 (F/C ONLY) FU9
2901 (CA409) +BV(ED) FU4
48 INCH

+
TRUCKS ONLY ED-A ED-B 250A
502 (CA409) BATT NEG K3-B
(CA207-12) BATT NEG HN BATT
501
1 506
508
(CA409) BATT NEG LGT1
CA808-1 BATT NEG (F/C ONLY)
NB213 1
532 (CA409) BATT NEG LGT4/FAN BATTERY
NEGATIVE
552 (CA409) BATT NEG LGT2 M1
554 (CA409) BATT NEG LGT3
FIELD

NOTE:
C5,C6 & C10 - 4 COND TWISTED PAIR CABLE
C9 & C11 - 3 COND SHIELDED CABLE WITH DRAIN WIRE A1 F1 B- F2 B+

9 6 5 1 8 1

20 10 16 9
CA601 CA402 CA403
SERVICE 1 5
CA402
TERMINAL 6 9
C9-RED
10 RS232 TRANSMIT
BRAKE SWITCH ONE INPUT (BRS1)
5901 CA607-1 T-COMM(FU10) 1
(0V=CLOSED, 5V=OPEN)
C9-BLK
11 RS232 RECEIVE
BRAKE SWITCH TWO INPUT (BRS2)
5902 CA608-1 T-COMM(FU10) 2 (0V=CLOSED, 5V=OPEN) (48" TRUCKS ONLY)
2 C9-WHT
12 RS232 GROUND 2
BRAKE SWITCH THREE INPUT (BRS3)
5903 CA608-2 T-COMM(FU10) 3
(0V=CLOSED, 5V=OPEN) (48" TRUCKS ONLY)

513 CA206-2 T-COMM 13 TRACTION MODULE COMMON OUTPUT (T-COMM)

DEADMAN SWITCH INPUT (DMS1 &/OR DMS2)
5904 (CA607-4) T-COMM(FU10) 4
(0V=CLOSED, 5V=OPEN)
2914 CA206-3 +BV(K1) 14 MODULE POWER INPUT +BV(K1)
ENTRY SWITCH INPUT (ENS)
5905 CA607-5 T-COMM(FU10) 5
(0V=CLOSED, 5V=OPEN)
215 CA206-4 +BV(FU1) 15 PRECHARGE INPUT +BV(FU1)

2916 CA206-5 +BV(K1) 16 EMERGENCY DISCONNECT SWITCH INPUT (EDS)

306 CA206-1 +12V TO ALM1 6 STATUS ALARM OUTPUT +12V (ALM1)

2917 (CA409-5) ED CONTACTOR 17 EMER DISC CONTACTOR DRIVER OUTPUT (ED)

5974 (CA206) 7 INTERNAL FAN(S) DRIVER OUTPUT (FN1, FN2)

2920 (CA409-8) +BV(ED-A) FU5 2918 +BV INPUT FOR BRAKE (BRK1) OUTER COIL
2921 CA609-1 BRK1 O+ 18 (BETWEEN PINS 8-18 0V=BRAKES APPLIED,
18V=RELEASED, 5.5V=FOLDBACK)
8 DRIVE BRAKE (BRK1) OUTER COIL 2/3 BRAKING
5908 CA609-4 BRK1 O- +BV INPUT FOR BRAKE (BRK1) INNER COIL
2922 CA609-2 BRK1 I+ 2919 (BETWEEN PINS 9-19 0V=BRAKES APPLIED,
2923 (CA409-9) +BV(ED-A) FU6 19 17V=RELEASED, 7V=FOLDBACK)
2938 CA610-1 BRK2 C+
3 5909 CA609-3 BRK1 I- 9 DRIVE BRAKE (BRK1) INNER COIL 1/3 BRAKING 3
5920 CA610-2 BRK2 C- 20 CASTER BRAKE (BRK2) COIL OUTPUT (48" TRUCKS ONLY)
BARREL CONNECTOR 062007-103 2X
CA403

C6-WHT CA208-1 CAN HIGH 1 CAN HIGH

C6-BLK CA208-14 CAN LOW 9 CAN LOW

C6-RED CA208-2 +5V 2 CAN +5V

C6-BLK CA208-15 T-COMM 10 CAN T-COMMON

5943 CA646-1
HEIGHT SENSE ENCODER (ECR2) CHANNEL A
C5-WHT (TB406) CA645-3 3
HEIGHT SWITCH 12" FROM TOP INPUT (HGTS12)
C5-BLK (TB406) CA645-4 11 HEIGHT SENSE ENCODER (ECR2) CHANNEL B
HEIGHT RESET SWITCH (HGTRS)
C5-BLK (TB406) CA645-2 4
(0V=BELOW STAGING, 5V=ABOVE STAGING)
C5-RED (TB406) CA645-1 HEIGHT SENSE ENCODER (ECR2) T-COMM OR
12
HEIGHT SWITCH 12" FROM TOP (HGTS12)
C10-WHT
TRACTION 5 TRACTION FEEDBACK ENCODER (ECR1) CHANNEL A
CA602
ECR1 GND/BLK C10-BLK
1 13 TRACTION FEEDBACK ENCODER (ECR1) CHANNEL B
32 PULSE
SENSOR-
BEARING

+V/RED
2
A/WHT C10-RED
3 6 TRACTION FEEDBACK ENCODER (ECR1) +5V
B/BLU
4
C10-BLK
4 062007-051
14 TRACTION FEEDBACK ENCODER (ECR1) T-COMM 4
TRACTION ACCELERATOR (POT1) COMMAND
C11-WHT CA611-2 CMD +0.4-4.6V 7
(+0.4V = FULL FWD, +4.6V = FULL RVS)
C11-RED CA611-1 +4.6V 15 TRACTION ACCELERATOR + (POT1) +4.6V

C11-BLK CA611-3 +0.4V 8 TRACTION ACCELERATOR - (POT1) +0.4V

16 SPARE (SPECIALS SPEED LIMIT SWITCH (LMS))

010328
A B C 4603 - EO9288 129335 B

Crown 2001 PF13082-7 Rev. 1/03 Printed in U.S.A.

01 REV. 1/03
DIA–1452–007 DIA–1452–007
 C ACCESS 2
A B C
RR/RD 5200/5200S SERIES
FU8

P2 FU7 SEE NOTE 2

ED-A ED-B
+

BATT
VOLTMETER
0V=OFF
+BV=FULL
M3 RAISE

1 M2
1
NOTES:
C7 - 4 CONDUCTOR TWISTED PAIR CABLE
C12, C13, C14 & C18 - 3 CONDUCTOR
SHIELDED CABLE WITH DRAIN WIRE
A1 B- B+

9 6 5 1 8 1

20 10 16 9

CA404 CA405
CA404
MODULE POWER
2930 CA204-8 +BV(K1) 10 (0V=OFF, +BV=ON)

5921 FREELIFT SWITCH INPUT (FLS)

CA204-1 H-COMM(FU11) 1
(0V=CLOSED, 5V=OPEN)

211 CA204-9 +BV(FU1) 11 MODULE PRECHARGE INPUT

LOAD SENSE ONE INPUT (FKS & HSS)

5922 CA204-2 H-COMM(FU11) 2 (0V=CLOSED, 5V=OPEN)

5932 (TB406) H-COMM SVA 12 SOLENOID VALVE ACCESSORY OUTPUT (SVA)

BATT GATE SWITCH INPUT (BRES1 &/OR BRES2)

5923 CA204-3 H-COMM(FU11) 3
(0V=CLOSED, 5V=OPEN)

2 5933 (TB406) H-COMM SVL 13 SOLENOID VALVE LOWER OUTPUT (SVL) 2

LIFT CUTOUT OVERRIDE SWITCH INPUT (ORS)
5924 CA204-4 H-COMM(FU11) 4
(0V=CLOSED, 5V=OPEN)

5934 (TB406) H-COMM SVP 14 SOLENOID VALVE PILOT OUTPUT (SVP)

525 CA204-5 H-COMM(FU11) 5 H-COMM OUTPUT

5935 CA204-10 H-COMM SVR 15 SOLENOID VALVE REACH OUTPUT (SVR)

5936 CA204-11 H-COMM SVS 16 SOLENOID VALVE SIDESHIFT OUTPUT (SVS)

5926 CA204-6 H-COMM ALM2 6 TRAVEL ALARM OUTPUT (ALM2)

5937 CA204-12 H-COMM SVT 17 SOLENOID VALVE TILT OUTPUT (SVT)

DUAL LIFT PUMP CONTACTOR (P2) OR

SEE NOTE 1 7
BYPASS SOLENOID (SCV6) OUTPUT

5938 (TB406) H-COMM PVA 18 PROPORTIONAL VALVE ACCESSORIES OUTPUT (PVA)

5928 (CA409-4) ED CONTACTOR 8 EMERGENCY DISCONNECT CONTACTOR OUTPUT (ED)

5939 (TB406) H-COMM PVH 19 PROPORTIONAL VALVE HOIST OUTPUT (PVH)

2929 CA204-7 +BV(EDA) FU4 9 SUPPRESSION

2940 CA204-13 +BV(EDA) FU4 20 SUPPRESSION

3 CA405 3
C7-WHT CA208-3 CAN HIGH 1 CAN HIGH

C7-BLK CA208-16 CAN LOW 9 CAN LOW

C7-RED CA208-4 CAN +5V 2 CAN +5V

C7-BLK CA208-17 T-COMM 10 CAN T-COMM

TILT FORKS DOWN SELECT INPUT (TDS)

C14-RED CA612-9 H-COMM(FU11) 3 (0V=CLOSED, 5V=OPEN)
SIDESHIFT SELECT INPUT (SSS)
C14-BLK CA612-11 H-COMM(FU11) 11
(0V=CLOSED, 5V=OPEN)
TILT FORKS BACK SELECT INPUT (TBS)
C14-WHT CA612-10 H-COMM(FU11) 4
(0V=CLOSED, 5V=OPEN)
FORWARD SWITCH (FS) INPUT
C18-BLK CA611-9 H-COMM 12
(0V=CLOSED, 5V=OPEN)

C18-RED CA611-11 +5 VOLTS 5 OPTICAL DIRECTIONAL SWITCHES +5V

C18-WHT CA611-10 H-COMM 13 REVERSE SWITCH INPUT

(0V=CLOSED, 5V=OPEN)

C13-BLK CA612-3 POT3 H-COMM 6 ACCESSORY POT (POT3) H-COMM OUTPUT

C13-RED CA612-1 POT3 +5 VOLT 14 ACCESSORY POT (POT3) +5 VOLT OUTPUT

ACCESSORY POT (POT3) COMMAND INPUT

C13-WHT CA612-2 POT3 COMMAND 7
(B/T PINS 6&7 0V=EXTEND, 5V=RETRACT)

C12-RED CA611-5 POT2 +5 VOLT 15 RAISE/LOWER ACCEL (POT2) +5 VOLT OUTPUT

4 C12-BLK
C12-WHT
CA611-7 POT2 H-COMM 8 RAISE/LOWER ACCEL (POT2) H-COMM OUTPUT
4
RAISE/LOWER ACCEL (POT2) COMMAND INPUT
CA611-6 POT2 COMMAND 16
(B/T PINS 8&16 0V=RAISE, 5V=LOWER)

NOTES:
1. RR/RD5200 USES 5927 (TB406) SCV6 OR P2.
RR/RD5200S USES 5925 (CA409) P2
2. 250A FUSE FOR 36V TRUCKS,
300A FUSE FOR 24V TRUCKS.

010328
A B C 7019 129336 A

Crown 2001 PF13082-8 Printed in U.S.A.

DIA–1452–008 DIA–1452–008
 C MAST, HYDRAULIC COMPONENTS
A B C
RR/RD 5200 SERIES
CA622
GREEN
1 SVR
CA623 GREEN
BLACK SVT
1
CA624
TB406 C2-WHT GREEN
1 SVS
C3-WHT
C1-BLK CA209-1 +BV(EDA) FU4 1
CA625
C2-BLK BLACK
C1-WHT CA209-2 H-COMM 2 1
1 C3-BLK CA626
1
C1-RED CA209-3 H-COMM 3 BLACK
1
C3-RED
C1-GRN CA209-4 H-COMM 4
C3-GRN LOAD SENSE ONE OPTION
C4-BLK
C1-ORG CA209-5 H-COMM(FU11) 5 CA617
1 FLS C25-BLK C25-WHT
1
C4-WHT
C1-BLU CA209-6 FLS N.0. 6 2 FKS
CA618 CA619
C3-ORG GRN BLK
C1-W/B CA209-7 FKS & HSS 7 1 1
C3-GRN HSS

LOAD SENSE TWO OPTION

CA617
C25-BLK
1 C25-WHT
2 FKS
CA618 CA619
C3-ORG RED BLK
C1-R/B CA209-8 +12V LS2 8 1 LS 1
C3-BLU
C22-BLK (CA209) TPA 9 CA647 BLK
1
C3-W/B
C22-WHT (CA209) F/C W/LOAD SENSE 10 1 CA620
SEE FREEZER
C3-R/B PACKAGE PICTORIAL
C22-RED (CA209) F/C W/LOAD SENSE 11 1 CA621
C3-G/B CA649 GRN POT4
2 C22-GRN (CA209) TPA 12
C3-O/B
1 TPA 2
CA648 ORG
C22-ORG (CA209) TPA 13 1

14
MANIFOLD BLOCK ASSEMBLY
2906 CA207-3 +BV(EDA) FU4
0V=OFF
20V=RAISE
5934 CA404-14 H-COMMM SVP
0V=OFF
20V=RETRACT 2924
TILT DOWN
OR SS LEFT
5932 CA404-12 H-COMM SVA

3V=OFF
3-10V=RAISE
5939 CA404-19 H-COMM PVH
2925
2V=OFF
2926
2-10V=ACCY
5938 CA404-18 H-COMM PVA
0V=OFF CA662
20V=LOWER 2927 C49-BLK
1
5933 CA404-13 H-COMM SVL
0V=OFF C49-WHT
2
20V=RAISE CHS
5927
3 5925
CA404-7 H-COMM
(CA409-6) H-COMM TO P2
SCV6
NOTE 3
2928
3
580 CA201-2 T-COMM(FU10)
59101 CA408-11 T-COMM(FU10)
WIRED NORMALLY OPEN HELD CLOSED
C16-BLK
CA645 HGTS12 IS STANDARD ON TRUCKS
HGTS12 270 AND LESS WITH 2 LIFT PUMPS
C16-WHT
C5-RED CA403-6 1 CUTS OUT P2 WHEN <12 INCHES FROM TOP
ECR2
C5-BLK CA403-12 2 32 PULSE HEIGHT ENCODER
BEARING
SENSOR-
GND/BLK

C5-WHT CA403-3 3 ECR2 IS STANDARD ON ALL TRUCKS

+V/RED
A/WHT
B/BLU

GREATER THAN 270 AND OPTIONAL

C5-BLK CA403-11 4 FOR MASTS 270 AND LESS.

CA646
5943 RED WIRED NORMALLY OPEN HELD CLOSED
CA403-4 1
WHEN MAST IS BELOW STAGING SWITCH
BLK IS HELD CLOSED
515 CA207-13 T-COMM(FU10) 2
HGTRS USED WITH HEIGHT ENCODER ONLY
(HEIGHT RESET)
NOTES: C1 - 8 CONDUCTOR 18 AWG CABLE
FREE LIFT SWITCH (FLS) C2 - 2 CONDUCTOR 18 AWG CABLE
1
C3 - 3 CONDUCTOR 18 AWG CABLE STANDARD
WIRED NORMALLY OPEN HELD CLOSED.
- 5 CONDUCTOR 18 AWG CABLE LOAD SENSE 1 OR 2
WHEN MAST IS BELOW FREELIFT
- 8 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
4 CONTACTS ARE CLOSED AND TRUCK
OPERATION IS -NOT- INHIBITED - 10 CONDUCTOR 18 AWG CABLE TPA 4
C4 - 2 CONDUCTOR 18 AWG CABLE
2 FORK SWITCH (FKS) C5 - 4 CONDUCTOR TWISTED PAIR CABLE
WIRED NORMALLY OPEN HELD CLOSED C16 - 2 CONDUCTOR 18 AWG CABLE
C22 - 3 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
SWITCH CONTACTS ARE CLOSED ANYWHERE - 5 CONDUCTOR 18 AWG CABLE TPA
BETWEEN FULLY TILTED UP OR DOWN C25 - 2 CONDUCTOR 18 AWG CABLE LOAD SENSE
- 5 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
3 SOLENOID SCV6 IS PRESENT ONLY ON 24 VOLT TRUCKS C49 - 2 CONDUCTOR 18 AWG CABLE
- 5 CONDUCTOR 18 AWG CABLE CHS W/FC

010328
A B C 6851 - EO11396 129337 C Sht 1

Crown 2001 PF13082-9 Rev. 12/03 Printed in U.S.A.

01 REV. 12/03
DIA–1452–009 DIA–1452–009
 C MAST, HYDRAULIC COMPONENTS
A B C
RR/RD 5200S SERIES
CA622
GREEN
1 SVR
CA623 GREEN
BLACK SVT
1
CA624
TB406 C2-WHT GREEN
1 SVS
C3-WHT
C1-BLK CA209-1 +BV(EDA) FU4 1
CA625
C2-BLK BLACK
1 C1-WHT CA209-2 H-COMM 2 1
1
C3-BLK CA626
C1-RED CA209-3 H-COMM 3 BLACK
1
C1-GRN CA209-4 H-COMM C3-RED
4
C3-GRN LOAD SENSE ONE OPTION
CA209-5 H-COMM(FU11) C4-BLK CA617
C1-ORG 5
C25-BLK
1 FLS 1 C25-WHT
C4-WHT
C1-BLU CA209-6 FLS N.0. 6 2 FKS
CA618 CA619
C3-ORG GRN BLK
C1-W/B CA209-7 FKS & HSS 7 1 1
C3-GRN HSS

LOAD SENSE TWO OPTION

CA617
C25-BLK
1 C25-WHT
2 FKS
CA618 CA619
C3-ORG RED BLK
C1-R/B CA209-8 +12V LS2 8 1 LS 1
C3-BLU
C22-BLK (CA209) TPA 9 CA647 BLK
1
C3-W/B
C22-WHT (CA209) F/C W/LOAD SENSE 10 1 CA620
SEE FREEZER
C3-R/B PACKAGE PICTORIAL
C22-RED (CA209) F/C W/LOAD SENSE 11 1 CA621
C3-G/B CA649 GRN POT4
C22-GRN (CA209) TPA 12 1
2 C3-O/B CA648 ORG
TPA 2
C22-ORG (CA209) TPA 13 1

14
MANIFOLD BLOCK ASSEMBLY
CA640 2995
2906 CA207-3 +BV(EDA) FU4 1 0V=OFF
5995 20V=RAISE
5934 CA404-14 H-COMMM 2 SVP

5932 CA404-12 H-COMM 3 0V=OFF

20V=RETRACT 2924
5939 CA404-19 H-COMM 4 TILT DOWN
5994 OR SS LEFT
SVA
5938 CA404-18 H-COMM 5
3V=OFF
5933 CA404-13 H-COMM 6 3-10V=RAISE
5993
PVH
2925
2V=OFF 2926
5992 2-10V=ACCY
PVA CA662
C49-BLK
1
0V=OFF
2927 C49-WHT
20V=LOWER 2
5991 CHS
SVL

3 3
580 CA201-2 T-COMM(FU10)
59101 CA408-11 T-COMM(FU10)
WIRED NORMALLY OPEN HELD CLOSED
C16-BLK HGTS12 IS STANDARD ON TRUCKS
CA645 270 AND LESS WITH 2 LIFT PUMPS
C16-WHT HGTS12
CUTS OUT P2 WHEN <12 INCHES FROM TOP
C5-RED CA403-6 1
ECR2
C5-BLK CA403-12 2 32 PULSE
BEARING HEIGHT ENCODER
SENSOR-
ECR2 IS STANDARD ON ALL TRUCKS
GND/BLK

C5-WHT CA403-3 3
+V/RED
A/WHT

GREATER THAN 270 AND OPTIONAL

B/BLU

4 FOR MASTS 270 AND LESS.

C5-BLK CA403-11

CA646
RED
5943 CA403-4 1 WIRED NORMALLY OPEN HELD CLOSED
BLK WHEN MAST IS BELOW STAGING SWITCH
515 CA207-13 T-COMM(FU10) 2 IS HELD CLOSED
HGTRS USED WITH HEIGHT ENCODER ONLY
(HEIGHT RESET)

NOTES: C1 - 8 CONDUCTOR 18 AWG CABLE

1 FREE LIFT SWITCH (FLS)
WIRED NORMALLY OPEN HELD CLOSED.
WHEN MAST IS BELOW FREELIFT
4 CONTACTS ARE CLOSED AND TRUCK
OPERATION IS -NOT- INHIBITED
2 FORK SWITCH (FKS)
WIRED NORMALLY OPEN HELD CLOSED
SWITCH CONTACTS ARE CLOSED ANYWHERE
BETWEEN FULLY TILTED UP OR DOWN
C2 - 2 CONDUCTOR 18 AWG CABLE
C3 - 3 CONDUCTOR 18 AWG CABLE STANDARD
- 5 CONDUCTOR 18 AWG CABLE LOAD SENSE 1 OR 2
- 8 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
- 10 CONDUCTOR 18 AWG CABLE TPA 4
C4 - 2 CONDUCTOR 18 AWG CABLE
C5 - 4 CONDUCTOR TWISTED PAIR CABLE
C16 - 2 CONDUCTOR 18 AWG CABLE
C22 - 3 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
- 5 CONDUCTOR 18 AWG CABLE TPA
C25 - 2 CONDUCTOR 18 AWG CABLE LOAD SENSE
- 5 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
C49 - 2 CONDUCTOR 18 AWG CABLE
- 5 CONDUCTOR 18 AWG CABLE CHS W/FC

010328
A B C 6851 - EO11396 129337 C Sht 2

Crown 2001 PF13082-10 Rev. 12/03 Printed in U.S.A.

01 REV. 12/03
DIA–1452–010 DIA–1452–010
 C DISPLAY, STANDARD
A B C
RR/RD 5200/5200S SERIES, ACCESS 1

1 1

CA604 CA407
DPS1 5911 OPERATOR SWITCH UP ARROW (DPS1)
1 1 (0V=CLOSED, 5V=OPEN)
DPS2 5912 OPERATOR SWITCH DOWN ARROW (DPS2)
2 2 (0V=CLOSED, 5V=OPEN)
DPS3 5913 OPERATOR SWITCH ENTER (DPS3)
3 3 (0V=CLOSED, 5V=OPEN)
504
4 4 DPS1,DPS2 & DPS3 T-COMM

5 SPARE NOT USED

2 C8-RED CA208-25 T-COMM 6 T-COMM 2

2911 CA207-8 +BV(K1) 7 TRUCK BATTERY VOLTS +BV(K1)

C8-BLK CA208-24 CAN LOW 8 CAN LOW

C8-WHT CA208-11 CAN HIGH 9 CAN HIGH

C8 - 3 CONDUCTOR SHIELDED CABLE WITH DRAIN WIRE

CONNECTOR PIN NUMBERING

MATING SIDE

1 2 3
4 5 6 1 2
7 8 9 3 4

PC407 PC604

3 3

4 4

010328
A B C 6851 - EO11396 129338 B Sht 1

Crown 2001 PF13082-11 Rev. 12/03 Printed in U.S.A.

01 REV. 12/03
DIA–1452–011 DIA–1452–011
 C DISPLAY, ENHANCED
A B C
RR/RD 5200/5200S SERIES, ACCESS 1

1 1

CA604 CA407
DPS1 5911 OPERATOR SWITCH UP ARROW (DPS1)
1 1
(0V=CLOSED, 5V=OPEN)
DPS2 5912 OPERATOR SWITCH DOWN ARROW (DPS2)
2 2
(0V=CLOSED, 5V=OPEN)
DPS3 5913 OPERATOR SWITCH ENTER (DPS3)
3 3 (0V=CLOSED, 5V=OPEN)
504
4 4 DPS1,DPS2 & DPS3 T-COMM

5 NOT USED (EXT INPUT FROM PIN DEVICE)

C8-RED CA208-25 T-COMM 6 T-COMM

2911 CA207-8 +BV(K1) 7 TRUCK BATTERY VOLTS +BV(K1)

C8-BLK CA208-24 CAN LOW 8 CAN LOW

C8-WHT CA208-11 CAN HIGH 9 CAN HIGH

2 CA408
2
101 PC210-2 ANALOG SIGNAL FROM LOAD SENSE 1 PRESSURE TRANSDUCER (LS) INPUT

303 PC210-1 +12V TO LOAD SENSE 2 SPARE - NOT USED -

CA605 3 PRESSURE TRANSDUCER (LS) +12 V EXCITATION

DPS6 5944 OPERATOR SWITCH DIRECT ACCESS SERVICE CODES
1 4 (DPS6)
(0V=CLOSED, 5V=OPEN)
DPS5 5945 OPERATOR SWITCH DIRECT ACCESS TRUCK HOURS
2 5 (DPS5)
(0V=CLOSED, 5V=OPEN)
DPS4 5946 OPERATOR SWITCH DIRECT ACCESS PERFORMANCE
3 6 (DPS4)
(0V=CLOSED, 5V=OPEN)
507
4 7 DPS4, DPS5, & DPS6 T-COMM
BWS3 5948 8 PUMP MOTOR (M3) BRUSH WEAR INPUT (BW3)
522 (5V=BRUSH WEAR, 0V=OK)
M3 520 BWS2
5949 9 PUMP MOTOR (M2) BRUSH WEAR INPUT (BW2)
THS3 (5V=BRUSH WEAR, 0V=OK)
M2 BWS1 5950 TRACTION MOTOR (M1) BRUSH WEAR INPUT (BW1)
10
THS2 (5V=BRUSH WEAR, 0V=OK)
521 M1
510 CHAIN SLACK SWITCH (CHS)
11
THS1 (0V=CLOSED, 5V=OPEN)
12 SPECIAL
5953 PUMP MOTOR (M3) OVER TEMP INPUT (THS3)
13
(5V=OVERTEMP, 0V=OK)
3 5954 PUMP MOTOR (M2) OVER TEMP INPUT (THS2)
3
14
(5V=OVERTEMP, 0V=OK)
5955 TRACTION MOTOR (M1) OVER TEMP INPUT (THS1)
15
512 CA201-2 T-COMM(FU10) (5V=OVERTEMP, 0V=OK)
511 CA201-1 T-COMM(FU10)

59101 CA662-2 T-COMM(FU10)

CONNECTOR PIN NUMBERING
MATING SIDE

1 2 3 1 3 4 5
C8 - 3 CONDUCTOR SHIELDED CABLE WITH DRAIN WIRE 4 5 6 6 8 9 10 1 2

7 8 9 11 12 13 14 15 3 4

PC407 PC408 PC604 & PC605

4 4

010328
A B C 6851 - EO11396 129338 B Sht 2

Crown 2001 PF13082-12 Rev. 12/03 Printed in U.S.A.

01 REV. 12/03
DIA–1452–012 DIA–1452–012
 C FAN, LIGHTS, CONTACTOR PANEL
A B C
RR/RD 5200 SERIES

CA409
207 J2 FU1 J1
204 CA207-1 +BV(FU1) 1
208 J3 FU2
205 (CA409) K3-7 +BV(FU2) 2
1 209 J4 FU3 1
206 (CA409) K3-9 +BV(FU3) 3
5914
5928 CA404-8 H-COMM 4
SB40
2945
2917 CA402-17 +BV(K1) 5 ED P2
5956
5925 (TB406) H-COMM FROM SCV6 6
2904
2947 J5 FU4
2905 CA207-2 +BV(ED-A) FU4 7
2948 J6 FU5
2920 (CA402-18) +BV(ED-A) FU5 8
2949 J7 FU6 J8
2923 (CA402-19) +BV(ED-A) FU6 9

2901 (TB212) +BV(ED-A)

201 (TB212) +BV

BARREL CONNECTOR
062007-051
CA410
2941 RES1 2942 2943 RED
2 2910 CA207-7 +BV(K1)
LGS1
1 LGT1
(DOME)
2
506 (TB212) BATT NEG NB213
K3
A B
2907 CA207-4 +BV(K1)
NOTE:
502 (CA207-12) BATT NEG RESISTOR VALUES
RES1 24V = 10 OHM
206 CA409-3 +BV(FU3) 36V = 20 OHM
RES2 24V = NONE
205 CA409-2 +BV(FU2) 36V = 12 OHM
RES3 24V = 12 OHM
4 K3-A 7 36V = 25 OHM
WHT ACCY CABLE +BV AFTER K1
BLK ACCY CABLE NEG
6 K3-B 9 NOTE:
ON 24V TRUCKS, RES2 & 2937
2932 ARE NOT PRESENT AND 2935
RES2 2937 EXTENDS FROM FNS_HI TO CA615.
HI 2935 CA615
K3
1
7 4 1 FNS LO 2934
A RES3 2936
RELAY
MOUNTING BRACKET SB80
THIS SIDE
9 6 3
B
3 5 4 3 2 1 3
(BOTTOM OF RELAY SHOWN)
JUMPER
083019 531
OPERATOR
CA802 2946 FAN
2931 C19-BLK
1
FN
C19-WHT
532 (TB212) BATT NEG NB213 2 SB81
2933 C19-RED 553
3 5

4 4 +
LGT4 - BLK
STROBE 3
LIGHT + RED
2

CRIMP CONNECTOR
CA616 062020-002 X4
2951 C20-WHT RED
1 LGT2
2950 LGS2
C20-BLK BLK LEFT
552 (TB212) BATT NEG NB213 2
WORKLIGHTS
2953 C21-WHT RED
3
4 C21-BLK BLK
LGT3
RIGHT
4
554 (TB212) BATT NEG NB213 4

C19 - 3 CONDUCTOR 18 AWG CABLE

C20,C21 - 2 CONDUCTOR 18 AWG CABLE

010328
A B C 7019 129341 A Sht 1

Crown 2001 PF13082-13 Printed in U.S.A.

DIA–1452–013 DIA–1452–013
 C FAN, LIGHTS, CONTACTOR PANEL
A B C
RR/RD 5200S SERIES

CA409
(REFERENCE ONLY)
J2 FU1 J1
1 204 CA207-1 +BV(FU1)
J3 FU2
1
205 (CA409) K3-7 +BV(FU2)
J4 FU3
206 (CA409) K3-9 +BV(FU3)
5928 CA404-8 H-COMM
SB40
2917 CA402-17 +BV(K1) ED P2

5925 CA404-7 H-COMM

2904
J5 FU4 J8
2905 CA207-2 +BV(ED-A) FU4
J6 FU5
2920 (CA402-18) +BV(ED-A) FU5
J7 FU6
2923 (CA402-19) +BV(ED-A) FU6

2901 (TB212) +BV(ED-A)

201 (TB212) +BV

BARREL CONNECTOR
062007-051
RES1 CA410 RED
2941 2942 2943
2910 CA207-7 +BV(K1) 1
2 LGS1 2
506 (TB212) BATT NEG NB213 LGT1
K3 (DOME)
A B
2907 CA207-4 +BV(K1)

502 BATT NEG NB213 NOTE:

206 (CA409) +BV(FU3) RESISTOR VALUES
RES1 = 20 OHM
205 (CA409) +BV(FU2) RES2 = 12 OHM
RES3 = 25 OHM
K3-A
4 7
WHT ACCY CABLE +BV AFTER K1

BLK ACCY CABLE NEG

6 K3-B 9

2932
RES2 2937
K3 HI 2935 CA615

2936 1
7 4 1 FNS 2934
A LO
RELAY RES3
MOUNTING BRACKET
THIS SIDE SB80
9 6 3
B

3 (BOTTOM OF RELAY SHOWN) 5 4 3 2 1

3
JUMPER 531
083019
2946 OPERATOR
CA802 FAN
2931 C19-BLK
1 FN
C19-WHT
532 (TB212) BATT NEG NB213 2 SB81
2933 C19-RED 553
3 5

4 4
+

LGT4 -
BLK
STROBE + 3
LIGHT RED
2

CRIMP CONNECTOR
CA616 062020-002 X4
2951 C20-WHT RED
1 LGT2
LGS2 LEFT
2950 C20-BLK BLK
552 (TB212) BATT NEG NB213 2
WORKLIGHTS
2953 C21-WHT RED
3 LGT3
4 554 (TB212) BATT NEG NB213 4
C21-BLK BLK RIGHT 4
C19 - 3 CONDUCTOR 18 AWG CABLE
C20,C21 - 2 CONDUCTOR 18 AWG CABLE

010328
A B C 7019 129341 A Sht 2

Crown 2001 PF13082-14 Printed in U.S.A.

DIA–1452–014 DIA–1452–014
 C BRAKES
A B C
RR/RD 5200 SERIES

1 1

LOWER FLOORBOARD
CA607
RED BLK
5901 CA402-1 T-COMM(FU10) BRS1 1
BRS1 CONNECTOR
2 062020-002

3
RED
5904 CA402-4 T-COMM(FU10) DMS1 4 BLK
RED DMS1
5905 CA402-5 T-COMM(FU10) ENS 5 BLK
540 ENS
516 CA207-14 T-COMM(FU10) 6

2 2

CA609
TRACTION BRAKE
WHITE
2921 (CA402-18) +BV(ED-A) FU5 1
O+
BLUE O+ = OUTER COIL POSITIVE
2922 (CA402-19) +BV(ED-A) FU6 2
I+ BRK1 I+ = INNER COIL POSITIVE
YELLOW I- I- = INNER COIL NEGATIVE
5909 CA402-9 T-COMM 3
O- = OUTER COIL NEGATIVE
ORANGE O-
5908 CA402-8 T-COMM 4

(BETWEEN CA609-1 & 4 0V=BRAKES APPLIED

18V=BRAKES RELEASED, 5.5V=FOLDBACK)
(BETWEEN CA609-2 & 3 0V=BRAKES APPLIED
8V=BRAKES RELEASED, 4V=FOLDBACK)

3 3

NOTES:
BRS1 & DMS1 ARE BOTH WIRED NORMALLY CLOSED - HELD OPEN

ENS IS WIRED NORMALLY CLOSED AND IS NOT ACTUATED UNTIL

THE ENTRY BAR PEDAL IS DEPRESSED
ALL SWITCHES SHOWN WITH NO OPERATOR ON PEDALS

A LOGIC ZERO (T-COMM) RELEASES BRAKES

4 4

010328
A B C 7019 129339 A Sht 1

Crown 2001 PF13082-15 Printed in U.S.A.

DIA–1452–015 DIA–1452–015
 C BRAKES
A B C
RR/RD 5200S SERIES

1 1
CA607 LOWER FLOORBOARD
5901 RED
CA402-1 T-COMM(FU10) BRS1 1 BLK
CONNECTOR
BRS1
2 062020-002

3
5904 5942 RED
CA402-4 T-COMM(FU10) DMS1 4 BLK
5905 RED DMS1
CA402-5 T-COMM(FU10) ENS 5 BLK
516 565 540 ENS
CA207-14 T-COMM(FU10) 6

BARREL CONNECTOR
PRESENT ONLY ON 48" TRUCKS
062007-103
UPPER FLOORBOARD
CA608
5902 5967 BRS2
CA402-2 T-COMM(FU10) BRS2 1 CA606
5970 5971 BRS3
5903
CA402-3 T-COMM(FU10) BRS3 2 1
5972 5969 DMS2 550
3 545 2
549 547
551 4

2 548
5
546
2
062007-103
BARREL CONNECTOR 6

CA609 TRACTION BRAKE

2921 WHITE
(CA402-18) +BV(ED-A) FU5 1
O+ O+ = OUTER COIL POSITIVE
2922 BLUE
(CA402-19) +BV(ED-A) FU6 2 I+ = INNER COIL POSITIVE
I+
5909 YELLOW BRK1 I- = INNER COIL NEGATIVE
I-
CA402-9 T-COMM 3 O- = OUTER COIL NEGATIVE
5908 ORANGE O-
CA402-8 T-COMM 4

(BETWEEN CA609-1 & 4 0V=BRAKES APPLIED

18V=BRAKES RELEASED, 5.5V=FOLDBACK)
(BETWEEN CA609-2 & 3 0V=BRAKES APPLIED
8V=BRAKES RELEASED, 4V=FOLDBACK)

PRESENT ONLY ON 48" TRUCKS

CA643
2938 R/W RED RED
C+
BLK BLK BRK2
3 C- 3
CA610
SLIP

RING CASTER BRAKE

CAPSULE CA644
G/W RED RED C+
5920 BLK BLK BRK2
C-

NOTES:
BRS1, BRS2, DMS1 & DMS2 ARE ALL WIRED NORMALLY CLOSED - HELD OPEN

BRS3 & ENS ARE WIRED NORMALLY CLOSED AND ARE NOT ACTUATED UNTIL
THE CORRESPONDING PEDALS ARE DEPRESSED

ALL SWITCHES SHOWN WITH NO OPERATOR ON PEDALS

A LOGIC ZERO (T-COMM) RELEASES BRAKES

4 4

010328
A B C 7019 129339 A Sht 2

Crown 2001 PF13082-16 Printed in U.S.A.

DIA–1452–016 DIA–1452–016
 C MULTI-TASK HANDLE
A B C
RR/RD 5200/5200S SERIES

1 1

(SOCKET STYLE TERMINALS)

CA611
(PIN STYLE TERMINALS)
RED
C11-RED CA403-15 +5 VOLT 1
3
WHT 2 POT1
C11-WHT CA403-7 COMMAND 2 (TRACTION)
(0V=FULL FWD, 5V=FULL RVS) 1
3 BLK
C11-BLK CA403-8 T-COMM

F/C 4 F/C
RED
C12-RED CA405-15 +5 VOLT 5
1
WHT 2 POT2 FS
C12-WHT CA405-16 COMMAND 6 (RAISE/LOWER)
(0V=FULL RAISE, 5V=FULL LOWER) 3 FORWARD
BLK OPTICAL
C12-BLK CA405-8 H-COMM 7
OPTICAL SWITCH BOARD SWITCH
F/C 8 F/C
BLK RED
C18-BLK CA405-12 FS INPUT 9
WHT BLK
C18-WHT CA405-13 RS INPUT 10
GRN
VIO
C18-RED CA405-5 +5 VOLT 11
2 12
WHT 2
BLU
CABLE
DRAIN REVERSE
WIRES OPTICAL
CONNECTED TO SWITCH
TRUCK FRAME RS
(PIN STYLE TERMINALS) CA612
RED (SOCKET STYLE TERMINALS)
C13-RED CA405-14 +5 VOLT 1
1
WHT 2
C13-WHT CA405-7 COMMAND 2 POT3 (ACCESSORY)
(0V=FULL EXT, 5V=FULL RETRACT) BLK 3
C13-BLK CA405-6 H-COMM 3

F/C 4 F/C
GRN
535 CA204-5 H-COMM 5
GRN
517 CA207-15 H-COMM(FU11) 6
VIO GRN
5917 (CA207) RDB1 7
HNS
F/C 8 F/C
TERMINAL
RED GRN 062020-001
C14-RED CA405-3 H-COMM(FU11) 9
TDS
WHT GRN
3 C14-WHT CA405-4 H-COMM(FU11) 10
TBS 3
BLK GRN
C14-BLK CA405-11 H-COMM(FU11) 11
SSS
12

NOTES:
C11, C12, C13, C14 & C18 - 3 CONDUCTOR SHIELDED CABLES WITH DRAIN WIRES

CONNECTOR PIN NUMBERING

"MATING SIDE"

1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
9 10 11 12 12 11 10 9

PC611 & PC612 JC611 & JC612

4 4

010328
A B C 7019 129340 A

Crown 2001 PF13082-17 Printed in U.S.A.

DIA–1452–017 DIA–1452–017
 C POWER CABLES
A B C
RR/RD 5200 SERIES

ITEM 18
B+
ITEM 9
A1
F2
1 MCR2
MCR1 1
ACCESS 2 B- NEGATIVE BUS B-
ACCESS 3

B+ F1

A1

NOTE: ITEM 2 OR 19 CABLE CONNECTS TO HCM

B- POST ON TRUCKS WITH SINGLE LIFT PUMP
ITEM 10 ITEM 11

A
M2 ITEM 7 ITEM 6
LIFT
PUMP
MOTOR

D ITEM 8
ITEM 12

NOTE 1
P2 FU7 FU8 FU9
2 M3
SECOND CONTACTOR 250 250 2
LIFT AMP AMP
PUMP
MOTOR
D ITEM 19
ITEM 4
ITEM 17 ITEM 5
ITEM 3
ITEM 13

ITEM 14
EMERGENCY A B A B
DISCONNECT
F1 F2 ITEM 15 CONTACTOR
M1 (ED)
A1 TRAC A2 ITEM 16
MOTOR EMERGENCY
DISCONNECT
CONTACTOR
(ED2)
NUMBER OF LIFT PUMPS

NON ITEM 1 ITEM 2

ITEM CABLE NO. EUROPEAN
EUROPEAN TRUCK
VOLTAGE NOTE 2
1 2 1 2 BATTERY
CONNECTOR
1. PC 2/0-183 X X 24/36V
3 PC 2/0-190 X X 24/36V POS NEG
3
2. PC 2/0-182 X 36V 24/36V
TRUCK
PC 2/0-188 X 24V
BATTERY
PC 2/0-190 X X 24/36V

3. 123086 X X X X 36V
4. 123083 X X X X 24/36V
5. 123088 X X X X 24/36V POWER CABLE CROWN
6. X X X X 24/36V ABBREVIATION PART NO.
PC 1/0-218
PC#6 084568-
7. PC 1/0-217 X X X X 24/36V PC#4 084569-
8. 123087 X X 36V PC#2 084570-
PC#1 084571-
9. 123287 X X X X 24/36V PC1/0 084572-
10. X X X X 24/36V PC2/0 084573-
PC 1/0-215
PC3/0 086749-
11. PC 1/0-216 X X X X 24/36V
12. PC 1/0-220 X X 36V
13. PC 1/0-213 X X X X 24/36V
NOTES:
14. PC #6-041 X X X X 24/36V 1.) 250A FUSE FOR 36V TRUCK,
15. PC #6-042 X X X X 24/36V 300A FUSE FOR 24V TRUCK.
2.) ITEM 2 IS CONNECTED TO ED2
4 16. PC 1/0-214 X X X X 24/36V
WHICH IS CONNECTED TO M3 OR 4
17. PC 1/0-219 X X 36V B- POST ON ACCESS 2 BY
18. ITEM 19 ON EUROPEAN
123893 X X X X 24/36V
TRUCKS ONLY.
19. PC 2/0-192 X 24V
PC 2/0-193 X 36V

X IN THE COLUMN INDICATES THAT THE CABLE IS REQUIRED.

010328
A B C 6851 - EO11396 129342 B Sht 1

Crown 2001 PF13082-18 Rev. 12/03 Printed in U.S.A.

02 REV. 12/03
DIA–1452–018 DIA–1452–018
 C POWER CABLES
A B C
RR/RD 5200S SERIES

MCR2
ACCESS 2 EMERGENCY
DISCONNECT
CONTACTOR
POS NEG
1 B+ B- A1
(ED2)
1
36V
A TRUCK BATTERY

NEGATIVE
BATTERY CONNECTOR

BUS
ITEM 19 B
ITEM 3

ITEM 2

NOTE 2
ITEM 7 ITEM 4

ITEM 8 ITEM 5
ITEM 6

FU7 FU8 FU9

P2 250 250 250
CONTACTOR AMP AMP AMP

ITEM 14
ITEM 16
ITEM 15
2 2
EMERGENCY A B
DISCONNECT
CONTACTOR
(ED) ITEM 1

ITEM 9

ITEM 10
ITEM 17 ITEM 18
ITEM 12

M3 F1 F2 ITEM 13
M2 M1
LIFT SECOND
D A D LIFT A A1 TRAC A2 ITEM 11
PUMP MOTOR
PUMP
MOTOR MOTOR

NON
EUROPEAN EUROPEAN
ITEM CABLE NO.
"C" "E" "C" "E"
3 BATTERY BATTERY BATTERY BATTERY 3
COMPARTMENT COMPARTMENT COMPARTMENT COMPARTMENT
1. PC 2/0-181 X X
F1 F2
A1 B- B+
PC 2/0-189 X X
2. PC 2/0-183 X X
PC 2/0-190 X X
MCR1
3. 126020 X X X X ACCESS 3
4. PC 1/0-204 X X X X
5. PC 1/0-205 X X X X
6. PC 1/0-206 X X X X
7. PC 1/0-207 X X X X
8. PC 1/0-208 X X X X
9. PC 1/0-209 X X X X
10. PC 1/0-210 X X X X
11. PC 1/0-211 X X X X
12. PC #6-039 X X X X
13. PC #6-040 X X X X
X X X POWER CABLE CROWN
14. 123083 X
ABBREVIATION PART NO.
15. 121532 X X X X PC#6 084568-
4 16. 121533 X X X X PC#4 084569- 4
PC#2 084570-
17. PC 1/0-207 X X PC#1 084571-
X PC1/0 084572-
PC 1/0-221 X
PC2/0 084573-
18. PC 1/0-208 X X PC3/0 086749-
PC 1/0-222 X X
19. PC 2/0-191 X X

X IN THE COLUMN INDICATES THAT THE CABLE IS REQUIRED.

010328
A B C 6851 - EO11396 129342 B Sht 2

Crown 2001 PF13082-19 Rev. 12/03 Printed in U.S.A.

02 REV. 12/03
DIA–1452–019 DIA–1452–019
 C FREEZER CONDITION
A B C
RR/RD 5200 SERIES
2962 CA803
1 R/W
HEATER FOR HEIGHT 2963 RES4
ENCODER ASSEMBLY 514 CA804 *BRES2
1 GRN

CA819
C26-WHT CA805
1 R/W
1 RES19
2954 1
RES5
1
PATCH 524 CA806 *BRES1
HEATER 555 1 GRN
CA820
C26-BLK
1 TB406
CA809
2955 C23-WHT
CA663 1 7
RED-WHT C49-RED 29122 C1-W/B RES6
1 1 CA810 FLS
CA840 CA664 523 C23-BLK
RES26 C49-GREEN 544 1 8
1 1 C1-R/B
*CHS
CA841
*LOAD SENSE PACKAGE
F/C DIST BRD 062020-001 C22 TB406
GREEN CA807 C3-BLU
2X 9
FU13 1 BLK
RES6
K12-B 2 C23-BLK FLS
CA808 2955 CA809 C22 CA620
3 C3-W/B
523 1 10 1
508 (TB212) BATT NEG NB213 1 4
2962 WHT RES7
2 FU14
RED 213 2965 C25-GRN *FKS
RED (TB212)+BV 1 3 5
FU12 514 CA810 C22 CA621
4 K12-A C3-R/B
CA823 519 1 11 1 C25-RED
6 C23-WHT
2959 RED
7 062020-001
2968 CA207-4 +BV(K1) 5
536 RES11
8 CA611 RES23 POT1
2973 2964 4 2902 WHT WHT
9 CA812 CA813
2952 5 NOTE 5 RES22
10 2965 2999 599 518
2 K11 NOTE
4 11
2956
2957
1
RES8
1 6
7
2903
RES24
WHT
POT2
WHT 2
12 529
EDS 519 8
R1
K11 RES9 RES10
CA612 NOTE 5 POT3
2966
K12 4 2967 WHT
5
6
7
528
8 WHT
CA814
1

CA815
1
2973

2952
RR5200 THS4

FREEZER CONDITION SCHEMATIC (THS4 - TOP OF POWER UNIT DECK)

FU13 K12-B CA816 RES13

15A *(BRES2) 2954 2958 DMS1
1 2969 558
RES4 555 559
FU12 2
3 15A
FU14 K12-A
2956
2957
3
2960
2961
RES14
BRS1 3
4 2970 557
15A *(BRES1)
RES5 THS5 RES15
ENS

42 INCH
(DROPPING) (POT3) (BRS1)
LOWER
RES9 RES10 RES13
FLOORBOARD
(DMS1,BRS1,ENS,THS5)

(DROPPING) (POT1) (DMS1)

RES23 RES11 RES14
C1 - 8 CONDUCTOR 18 AWG CABLE
C3 - 3 CONDUCTOR 18 AWG CABLE STANDARD
(DROPPING) (POT2) (ENS) - 5 CONDUCTOR 18 AWG CABLE LOAD SENSE 1 OR 2
RES24 RES22 RES15 - 8 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
- 10 CONDUCTOR 18 AWG CABLE TPA
FU1 KYS K1 EDS C22 - 3 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
15A (EDS) *(ECR2) - 5 CONDUCTOR 18 AWG CABLE TPA
RES8 RES19 C23,C24,C26 - 2 CONDUCTOR 18 AWG CABLE
C25 - 2 CONDUCTOR 18 AWG CABLE LOAD SENSE
- 5 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
THS4 *(CHS) C49 - 5 CONDUCTOR 18 AWG CABLE CHS W/FC
K11 RES26
NOTES:
24/36V * MEANS OPTIONAL FEATURE
1. DASHED BOXES AND ASTRIX INDICATE
(FLS)
OPTIONAL FEATURES.
RES6
4 2. THS4 SHOWN AT AMBIENT OF 70 F 4
THS5 <40 F = CLOSED
>60 F = OPEN
*(FKS)
3. THS5 SHOWN AT AMBIENT OF 70 F
RES7
<140 F = CLOSED
>160 F = OPEN
4. 24V BOARDS HAVE JUMPER WIRE
K11 K12 36V BOARDS HAVE RESISTOR
5. VOLTAGE DROPPING RESISTORS
24V RESISTOR VALUE 82 OHM 10 W
36V RESISTOR VALUE 140 OHM 10 W

010328
A B C 6851 - EO11396 129343 C Sht 1

Crown 2001 PF13082-20 Rev. 12/03 Printed in U.S.A.

01 REV. 12/03
DIA–1452–020 DIA–1452–020
 C FREEZER CONDITION
A B C
RR/RD 5200S SERIES
HEATER FOR HEIGHT
ENCODER ASSEMBLY
2962 CA803
CA819 R/W
WHT C26-WHT 2954 1
1
RES5
RES19 514 CA804 *BRES1
PATCH GRN
555 1
1 HEATER
CA820
1
WHT C26-BLK
1 CA809 TB406
CA663 2955 C23-WHT
RED-WHT C49-RED 29122 1 7
1 1 C1-W/B RES6
CA840 CA664 CA810 FLS
RES26 C49-GREEN 544 523 C23-BLK
1 1 1 8
*CHS
CA841 C1-R/B

GREEN *LOAD SENSE PACKAGE

F/C DIST BRD CA807 062020-001 C22 TB406
1 2X 9 C3-BLU
FU13
BLK
K12-B 2 RES6
CA808 2955 CA809 C22 C23-BLK CA620 FLS
3 C3-W/B
508 (TB212) BATT NEG NB213 1 4 523 1 10 1
2 2962 WHT RES7
RED 213 FU14 2965 C25-GRN
RED (TB212)+BV 1 3 5 *FKS
FU12 K12-A 514 CA810 C22 CA621
4 C3-R/B C25-RED
CA823 519 1 11 1
6 C23-WHT
2959 RED
7 062020-001
2968 CA207-4 +BV(K1) 5 2976
536 RES11
8 537 CA611 RES23 POT1
2964 4 2902 WHT WHT
9 2973
CA812 CA813 5 NOTE 5
2952 2999 518 RES22
10 599 6 RES24
K11 NOTE 2956 1 1 POT2
11 2965 2903 WHT WHT
4 2957 RES8 7
12 EDS 519 529
8
2 K11 R1
RES9 RES10
2
CA612 NOTE 5 POT3
2966 WHT
K12 4 2967
5
6
7
528
8 WHT
CA814
1
CA815
1
2973
(THS4 - TOP OF POWER UNIT DECK)
2952
THS4
RR5200S CA816 RES13
2954 2958 DMS1 48 INCH
FREEZER CONDITION SCHEMATIC 1 2969 LOWER
555 559 558
2 FLOORBOARD
2956 2960 RES14
3 BRS1
2957 4 2961 (THS5,DMS1,)
FU13 K12-B 2970 557 (BRS1 & ENS)
15A *(BRES1) RES15
RES5 THS5
ENS
FU12
15A
RES17
FU14 K12-A 062007-103 2X
15A CA817 CA818
3 537 567
2991
1
526
2985
1
503
2986 BRS3 3
2 2 48 INCH
2976 2978 2979
3 UPPER
568 534 RES16
(DROPPING) (POT3) (BRS1) 4 FLOORBOARD
BRS2
RES9 RES10 RES13 2996 (BRS3,BRS2,)
566 (& DMS2)
RES18
DMS2
(DROPPING) (POT1) (DMS1)
RES23 RES11 RES14
C1 - 8 CONDUCTOR 18 AWG CABLE
C3 - 3 CONDUCTOR 18 AWG CABLE STANDARD
(DROPPING) (POT2) (ENS) - 5 CONDUCTOR 18 AWG CABLE LOAD SENSE 1 OR 2
RES24 RES22 RES15
- 8 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
- 10 CONDUCTOR 18 AWG CABLE TPA
FU1 KYS EDS C22 - 3 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
K1 (EDS) *(ECR2)
15A - 5 CONDUCTOR 18 AWG CABLE TPA
RES8 RES19
C23,C24,C26 - 2 CONDUCTOR 18 AWG CABLE
C25 - 2 CONDUCTOR 18 AWG CABLE LOAD SENSE
- 5 CONDUCTOR 18 AWG CABLE LOAD SENSE W/FC
THS4 *(CHS) C49 - 5 CONDUCTOR 18 AWG CABLE CHS W/FC
K11 (BRS2) RES26
RES16
36V NOTES:
* MEANS OPTIONAL FEATURE
(BRS3)
RES17 (FLS) 1. DASHED BOXES AND ASTRIX INDICATE
RES6 OPTIONAL FEATURES.
THS5 2. THS4 SHOWN AT AMBIENT OF 70 F
4 (DMS2)
<40 F = CLOSED 4
RES18 *(FKS) >60 F = OPEN
RES7 3. THS5 SHOWN AT AMBIENT OF 70 F
<140 F = CLOSED
>160 F = OPEN
K11 K12 4. 36V BOARDS HAVE RESISTOR
5. VOLTAGE DROPPING RESISTORS
36V RESISTOR VALUE 140 OHM 10 W

010328
A B C 6851 - EO11396 129343 C Sht 2

Crown 2001 PF13082-21 Rev. 12/03 Printed in U.S.A.

01 REV. 12/03
DIA–1452–021 DIA–1452–021
 C WIRE HARNESSES

Below are the wire harness numbers for the RR/RD 5200/5200S Series. The list also indicates the components of the truck
connected by each wire harness.

Harness No. Components Connected By:

128943 RR/RD 5200 Main Truck Wire Harness, JC601, JC655, PC204, PC206, PC207, PC208, PC211,
PC215, PC401, PC402, PC403, PC404, PC405, PC407, PC409, PC410, PC602, PC603, PC604,
PC607, PC609, PC611, PC612, PC645, PC646, PC656, PC824
129253 RR/RD 5200S Main Truck Wire Harness, JC601, JC610, JC655, PC204, PC206, PC207, PC208,
PC211, PC215, PC401, PC402, PC403, PC404, PC405, PC407, PC602, PC604, PC607, JC608,
PC609, PC611, PC612, PC640, PC645, PC646, PC656, PC824
127748 RR/RD 5200 Main Freezer Condition Wire Harness, PC803, PC804, PC805, PC806, PC807,
PC808, PC809, PC810, PC812, PC813, PC814, PC815
128232 RR/RD 5200S Main Freezer Condition Wire Harness, PC803, PC804, PC807, PC808, PC809,
PC810, PC812, PC813, PC814, PC815, PC816, PC817
123311 RR/RD 5200 Contactor Panel, JC409
121857 RR/RD 5200/5200S Enhanced Display, PC408, PC605
127716 RR/RD 5200/5200S Floorboard, JC607
127749-001 RR/RD 5200/5200S 36 Volt Floorboard Freezer Condition, JC816
127749-002 RR/RD 5200/5200S 24 Volt Floorboard Freezer Condition, JC816
125793 RR/RD 5200S Upper Floorboard, JC606
125815 RR/RD 5200S Freezer Condition Upper Floorboard, JC818, JC606, RES17
123313 RR/RD 5200 Fan and Lights, JC615, PC616, PC802
123975 RR/RD 5200S Fan and Lights, JC615, PC616, PC802
123967 RR/RD 5200/5200S Fan and/or Strobe Option JC802
127690 RR/RD 5200 36 Volt Internal Fans, JC824
128896 RR/RD 5200 24 Volt Internal Fans, JC824
128296 RR/RD 5200S Internal Fans, JC824
123972 RR/RD 5200 Battery Restraint, PC203
123973 RR/RD 5200S Battery Restraint, PC203
123314-002 RR/RD 5200/5200S, Over Ride Switch, PC202
122176-001 RR 5200/5200S Tilt & Sideshift Cable, JC624, PC625, PC626
122176-002 RD 5200/5200S Tilt & Sideshift Cable, JC624, PC625, PC626
124000-001 RR 5200/5200S Tilt/Sideshift/Load Sense, JC624, PC617, PC618, PC625, PC626
124000-002 RD 5200/5200S Tilt/Sideshift/Load Sense, JC624, PC617, PC618, PC625, PC626
124001-001 RR 5200/5200S Tilt/Sideshift/Load Sense w/Freezer Condition, JC624, PC617, PC618, PC620,
PC621, PC625, PC626
124001-002 RD 5200/5200S Tilt/Sideshift/Load Sense w/Freezer Condition, JC624, PC617, PC618, PC620,
PC621, PC625, PC626
129324-001 RR 5200/5200S Tilt/Sideshift/Load Sense w/Freezer Condition, Tilt Position Assist, JC624, JC648,
JC649, PC617, PC618, PC620, PC621, PC625, PC626, PC647
129324-002 RD 5200/5200S Tilt/Sideshift/Load Sense w/Freezer Condition, Tilt Position Assist, JC624, JC648,
JC649, PC617, PC618, PC620, PC621, PC625, PC626, PC647
124002-001 RR/RD 5200/5200S 24 Volt Fork Tilted Switch, FKS Freezer Condition, JC617, JC619, JC620, JC621
124002-002 RR/RD 5200/5200S 36 Volt Fork Tilted Switch, FKS Freezer Condition, JC617, JC619, JC620, JC621
125275 RR/RD 5200/5200S Load Sense II, PC210
123343 RR/RD 5200/5200S Keyless Key Switch, JC401
123971 RR/RD 5200 Motor Sensors, PC201
123974 RR/RD 5200S Motor Sensors, PC201
123976 RR/RD 5200/5200S Travel Alarm, PC205
087245-062 RR/RD 5200/5200S Pos/Neg Cable
126222 RR/RD 5200 EEC Control Panel
126224 RR/RD 5200S EEC Control Panel

010328 7019

Crown 2001 PF13082-22 Printed in U.S.A.

DIA–1452–022 DIA–1452–022
 C WIRE HARNESSES
8815

RR/RD 5200

128943
MAIN WIRE HARNESS

2
2 V
T R

H
C
B P
S
V
P
1
C
A
S
V
A
1
T

P
V P
1
A L
V
M

2
P

R
V
1

S
V
L
3
s C
es V
6
cc
A

2
s
es
cc
A

7019

Crown 2001 PF13082-23 Printed in U.S.A.

DIA–1452–022-SUP-1 DIA–1452–022-SUP-1
 C WIRE HARNESSES
8816

RR/RD 5200

HEIGHT SENSOR 087245-018

087245-021
HGTS 12
087245-057 2 CONDUCTOR
TO WORKLIGHT CABLE
2 CONDUCTOR
CABLE
087245-057
TO WORKLIGHT
2 CONDUCTOR
CABLE
123313
FAN/STROBE
121857
LIGHT ENHANCED DISPLAY
087245-058
FORK TILTED SWITCH
123343
087245-010 KEYLESS KEY SWITCH
FREE LIFT SWITCH S
V
T
2

B
R
V
2

P
C
H

P
1
C
A
S
V
A
1
T

P
V P
1
A L
V
M

2
P

TILT, SIDESHIFT
R
V
1

S
V
L
3
s C
es V
6
cc

122176-001, 122176-002 A

TILT, SIDESHIFT, 123314-002

LOAD SENSE cc
es
s
2 OVER RIDE
A

124000-001, 124000-002 SWITCH

123976
123311
TRAVEL ALARM
CONTACTOR
PANEL

123972
BATTERY RETAINER
SWITCH 127716
FLOORBOARD
123971
MOTOR SENSORS

7019

Crown 2001 PF13082-24 Printed in U.S.A.

DIA–1452–022-SUP-2 DIA–1452–022-SUP-2
 C WIRE HARNESSES
8817

RR/RD 5200
FREEZER/CORROSION

TO THERMOSTAT

087245-060
2 CONDUCTOR CABLE

124002-001
124002-002
TO BATTERY
FORK TILTED
RETAINER SWITCH
SWITCH

122378-003
122378-004 127748
HEATERS ON T
2
R
V
2

P
C
H
FREEZER
B

CONDITION
S
V
P
1

FREE LIFT SWITCH

C
A
S
V
A
1
T

P
V 1

HARNESS
A P L
V
M

2
P

R
V
1

S
V
L
3
s
es
C
V
6
cc
A

124001-001
124001-002
TILT, SIDESHIFT, A
cc
es
s
2

LOAD SENSE

FREEZER CONDITION
DISTRIBUTION PANEL

127749-001 36V
127749-002 24V
LOWER FLOORBOARD

7019

Crown 2001 PF13082-25 Printed in U.S.A.

DIA–1452–022-SUP-3 DIA–1452–022-SUP-3
 C WIRE HARNESSES
8818

RR/RD 5200S

126139
TO MANIFOLD
129253 BLOCK
MAIN WIRE HARNESS

2
ss
ec
cA

127716
LOWER FLOORBOARD

125793
UPPER FLOORBOARD

7019

Crown 2001 PF13082-26 Printed in U.S.A.

DIA–1452–022-SUP-4 DIA–1452–022-SUP-4
 C WIRE HARNESSES
8819

RR/RD 5200S
087245-018
123967 087245-021
HEIGHT SENSOR 128305-001 HGTS 12
128305-002 FAN/STROBE
LIGHT 2 CONDUCTOR
128305-003 CABLE
HEIGHT RESET
087245-057 SWITCH 087245-057
TO WORKLIGHT TO WORKLIGHT
2 CONDUCTOR 2 CONDUCTOR
CABLE CABLE

123343
087245-058 KEYLESS KEY
FORK TILTED SWITCH SWITCH
123314-002
OVER RIDE
SWITCH
TILT, SIDESHIFT
122176-001, 122176-002
TILT, SIDESHIFT,
LOAD SENSE
124000-001, 124000-002 121857
ENHANCED
DISPLAY

125793
2
ss
ec
cA
UPPER
FLOORBOARD

123974
MOTOR SENSORS

123973
BATTERY RETAINER 127716
SWITCH LOWER
123976
TRAVEL ALARM FLOORBOARD

7019

Crown 2001 PF13082-27 Printed in U.S.A.

DIA–1452–022-SUP-5 DIA–1452–022-SUP-5
 C WIRE HARNESSES
8820

RR/RD 5200S
FREEZER/CORROSION

087245-062
2 CONDUCTOR CABLE

122378-003
122378-004
HEATERS ON TO THERMOSTAT
FREELIFT SWITCH

126139
TO MANIFOLD
124002-001 BLOCK
124002-002
FORK TILTED SWITCH

124001-001
124001-002
TILT, SIDESHIFT,
LOAD SENSE

2
ss
ec
cA

FREEZER CONDITION
DISTRIBUTION PANEL

128232
FREEZER CONDITION
HARNESS

127749-001
LOWER FLOORBOARD

125815 UPPER FLOORBOARD

7019

Crown 2001 PF13082-28 Printed in U.S.A.

DIA–1452–022-SUP-6 DIA–1452–022-SUP-6